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TSB 08-21-96 Rev. A

Wiring Harness Connector Repair Packages

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Date: Oct. 18,1996

NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-21-96, DATED JUL. 26,1996, WHICH SHOULD BE REMOVED FROM YOUR FILES.

Models: 1996 (BR) Ram Truck

1996 (AB) Ram Van/Wagon
1996 (AN) Dakota
1996 (BR) Ram Truck
1996 (XJ) Cherokee
1996 (ZJ) Grand Cherokee
1997 (TJ) Wrangler

NOTE: THIS BULLETIN APPLIES TO THE 1996 VEHICLES LISTED ABOVE AND 1997 WRANGLERS BUILT PRIOR TO JULY 15TH, 1996 (MDH 0715XX).  ALSO, CHEROKEES (XJ) BUILT ON JULY 15TH, 1996 (MDH 0715XX) OR AFTER WERE BUILT WITH 1997 STYLE WIRING HARNESSES AND CONNECTORS AND ARE NOT EFFECTED BY THIS BULLETIN.

Discussion:

Intermittent electrical complaints can be caused by poor electrical connections and can be very difficult to diagnose. Once diagnosed, the repair can be anywhere from simply reconnecting an electrical connector to complete wiring harness replacement. The following drivetrain electrical connector repair components have recently been made available to aid in drivetrain electrical repairs without replacing a complete harness. If you have determined that a customer complaint could be related to a poor electrical connection, use the following diagnosis to inspect the electrical connectors.  

Diagnosis: 

This bulletin involves only electrical connections to the following components:

Inspection of the connector begins with a thorough inspection of the insulator. If the insulator's locking tab is broke, replace the insulator. If the insulators end seal or seal ring is damaged, replace the seal. Gently pull on the wires of the connector one at a time. If the wire pulls out of the insulator, remove and inspect the wedge lock. Also, inspect the locking tab inside the insulator. Replace the wedge lock if there are any signs of damage. Replace the insulator if the locking tab is damaged.

Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and both insulator seals. To verify how secure the terminal fits to the component, insert and remove the harness side connector terminal onto the mating terminal of the component. Then, rotate the terminal 900, 1800, and 270' while inserting and removing the terminal onto the pin of the component.

NOTE: YOU WILL NEED TO INDIVIDUALLY CHECK EACH TERMINAL-TO-PIN CONNECTION FOR ANY MULTI-TERMINAL CONNECTOR.

If any connection is loose, replace the harness side connector terminal after verifying a good connection with the new terminal. For information regarding service procedures of electrical connectors, refer to Section 8W of the appropriate Service Manual.

Parts: 
COMPONENT INSULATOR
PART NUMBER 		TERMINAL
PART NUMBER 		WEDGELOCK
PART NUMBER		 END SEAL
PART NUMBER 		RING SEAL
PART NUMBER
Throttle Position
and Vehicle Speed
Sensors
04405045
04625130
04450091
04450092
04450093
Manifold Absolute
pressure Sensor
04450090
04625130
04450091
04450092
04450093
Front Oxygen
Sensor
04707126
04400110
N/A
N/A
N/A
Rear Oxygen
Sensor
04707127
04400110
N/A
N/A
N/A
Crank Position
Sensor (MANUAL
TRANSMISSION)
56016982
04604597
56016987
04414474
56016985
Crank Position
Sensor (AUTO
TRANSMISSION)
56016983
04604597
56016987
04414474
56016985
Crank Position Sensor Retainer PIN 560169M
Distributor
Synchronization
Pickup
04414468
04604597
04414470
04414474
56017460
Engine Coolant
Temperature
Sensor (3.9L, 5.2L,
5..9L, and 8.0L)
56006291
04558005
N/A
N/A
N/A
Engine Coolant
Temperature
Sensor (2.5L
and 4.0L )
04331569
04331568
N/A
N/A
N/A
Engine Coolant
Temperature Gage
Sending Unit
56006431
04558005
N/A
N/A
N/A
Intake Air
Temperature
Sensor
04414270
04331568
N/A
N/A
N/A
Oil Pressure
Sensor
04414048
04625130
04414024
04414047
04414049
Fuel Injector
04604512
N/A
N/A
N/A
04604519
Ignition Coil
04481614
04625130
04414024
04414047
04414049
Idle Air Control
Motor
56018428
04331568
N/A
N/A
N/A
Purge Solenoid
04661957
04604597
04661974
N/A
N/A
Transmission
Solenoid
56017053
56017057
N/A
N/A
N/A

Notes: 

Policy:    Information only

Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004