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Technical Service Bulletins

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#1 ·
Thought I would start a thread to link to the FAQ listing all the TSB's I can find. I'll add to them here as I can in no particular order....

A/T - ATF Usage List
NUMBER: 21-004-04
GROUP: Transmission
DATE: March 16, 2004
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-01, DATED JUNE 29, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN ADDED TO HIGHLIGHT REVISIONS.
SUBJECT:
Automatic Transmission Fluid Usage ATF+4 (Type 9602)

MODELS:
NOTE : This bulletin applies to all transmissions manufactured by Chrysler except for 1999 and earlier minivans with the 41TE/AE transmission. This Service Bulletin DOES NOT apply to all AWD transmissions, Sprinter transmissions, Crossfire transmissions and WG bodies equipped with a W5J400 or NAGI transmission (sales code DGJ).
DISCUSSION:
A new transmission fluid (ATF+4(R) - Type 9602) has been developed and is being used as factory fill for all vehicles with Chrysler automatic transmissions. It is recommended that all vehicles with Chrysler automatic transmissions EXCEPT FOR THOSE LISTED ABOVE be serviced with ATF+4(R).
NOTE :ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R).
NOTE :Service intervals do not change. The service interval currently in effect for a given vehicle should continue to be followed.
NOTE :ATF+4(R) is compatible with ATF+3 and ATF+2. ATF+4(R) can be used to top off vehicles that currently have ATF+2 or ATF+3. Do not use ATF+2 or ATF+3 to top off vehicles that have ATF+4(R) fluid.
BENEFITS
Better anti-wear properties
Improved rust/corrosion prevention
Controls oxidation
Eliminates deposits
Controls friction
Retains anti-foaming properties
Superior properties for low temperature operation
FLUID COLOR
Mopar ATF+4(R) is a World Class Fluid having exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not support a fluid change.

POLICY:
Information Only
Disclaimer :This bulletin is supplied as technical information only and is not an authorization for repair.
 
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#52 ·
Transfer Case Shifter - Creaking/Thumping Noise

NO: 21-09-98
GROUP: Transmission
DATE: Jul. 31, 1998
SUBJECT:
Transfer Case Shifter Noise
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 21-02-97 REV. A, DATED, JULY 11, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILE AND NOTE IN THE 1997 BOUND TECHNICAL SERVICE BULLETIN MANUAL, PUBLICATION NUMBER 81-699-98004. THE BULLETIN ADDS MODELS AND ADDITIONAL PARTS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1993 - **1998** (ZJ) Grand Cherokee/Grand Wagoneer
1994 - **1998** (ZG) Grand Cherokee (International Market)
**1997 - 1999 (TJ) Wrangler**
**1995 - 1999 (XJ) Cherokee**
SYMPTOM/CONDITION:
A thumping or creaking noise may be heard coming from the transmission tunnel area on acceleration or while driving over bumpy roads.
DIAGNOSIS:
Road test the vehicle, if the noise is present and there are no worn or damaged parts relating to the transfer case shift mechanism, perform the Repair Procedure.
PARTS REQUIRED:
1 04886481AA Repair Kit, Transfer Case Shifter (ZJ/ZG)
**1 05014148AA Repair Kit, Transfer Case Shifter (TJ/XJ)**
REPAIR PROCEDURE:
This bulletin involves installing a transfer case shifter repair kit.
1. Disconnect the shift rods from the torque shaft.

2. Remove the torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket. (Refer to Figure 1) Install new bushings on the torque shaft for XJ and TJ.
3. Remove the bronze bushing/retainer and rubber gasket from the body bracket.
4. Remove the green torque shaft bushing from the transmission bracket and install the new bushing supplied in the kit. Insert the new gasket into the body bracket.
5. Install the bronze bushing/retainer and tightening the screws to 5 Nm (45 in. lbs.).
**NOTE :TJ AND XJ MODELS USE THE ORIGINAL TORQUE SHAFT WITH THE NEW PARTS SUPPLIED IN THE XJ/TJ KIT. ZJ/ZG REQUIRE REPLACEMENT OF THE TORQUE SHAFT WHICH IS SUPPLIED IN THE ZJ/ZG KIT.**
6. Slide the boot on to the torque shaft and apply multipurpose grease (MOPAR p/n 04318063 or equivalent) to the area that the bronze bushing will contact.
7. Install the torque shaft and seat the boot on the bushing retainer flange.
8. Connect the transfer case shift linkage and adjust as necessary.

POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: **21-03-10-93** 0.6 Hrs.

FAILURE CODE: P8 - New Part
 

Attachments

#53 ·
A/T - Overdrive Unavailable in Cold Temperatures

NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
SUBJECT:
Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS.
MODELS:
1996 - **1998** (AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
1996 - **1998** (ZJ) Grand Cherokee
NOTE :THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION.
SYMPTOM/CONDITION:
At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy.
DIAGNOSIS:
The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures.
NOTE : THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED.

PARTS/EQUIPMENT REQUIRED:
**1 04798668 Kit, By-Pass V-10 Applications**
1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents)
AR(1) 04318044 Thread Sealant
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE : THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.
 

Attachments

#54 ·
A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Bypass Kit Installation


1. Record all radio pre-sets and disconnect the negative battery cable.
2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter.
3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation.
4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal.
5. Disconnect the pressure and return lines from the transmission housing fittings.
6. Remove and discard the fittings from the transmission housing.
7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1).
8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.).
9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF.
10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward.
11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter.
NOTE : THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER.
CAUTION :IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE.
12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting.
13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.).

14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line.
CAUTION : AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION.
15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes.
16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.).
17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your application.
18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block.
19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block.
NOTE :DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS.
NOTE : ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY.
20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it.
21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system.
22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing.
CAUTION : WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line.
24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line.
25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing.
27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly.
28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing.
CAUTION :WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line.
30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line.
31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing.
33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system.
36. If applicable, connect the wire harness to the temperature sensor.
37. Lower the vehicle.
38. Re-connect the negative battery cable and reset the radio stations recorded in step one.
39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual.
40. Raise the vehicle and check for leaks (idle in Neutral).
 

Attachments

#55 ·
A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Flash Programming (1996 Models)


NOTE : THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.
NOTE : THE FOLLOWING STEPS ARE REQUIRED BY LAW.

9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay.

10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label.
 

Attachments

#56 ·
A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Programming Cold Overdrive Feature (All Applications)


Using the DRB III, use the following procedures to program the overdrive cutoff feature.
1. Connect the DRB III (Scan Tool) to the vehicle and power it up.
2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU.
4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU.
5. The module ID screen will appear, press enter to move to next menu.
6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS.
7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE.
8. Follow the steps presented on the DRB III which will prompt you through the feature selection.
9. When the password is asked for use: 84362172.
10. Follow the remaining prompts for overdrive feature verification.
NOTE : IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED.
 
#57 ·
Engine - Coolant Recommendations

NO: 07-03-97
GROUP: Cooling
DATE: May 9, 1997
SUBJECT:
Engine Coolant Usage
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1997 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/
Power Ram/Power Ram Cab & Chassis
1989 - 1993 (AG) Daytona
1989 (AH) Lancer/LeBaron GTS
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1997 (AN) Dakota
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1997 (BR) Ram Truck
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (European Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1989 - 1992 (MJ) Comanche
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1997 (PR) Prowler
1992 - 1997 (SR) Viper/Viper Coupe
1997 (TJ) Wrangler
1989 - 1997 (XJ) Cherokee
1989 - 1995 (YJ) Wrangler
1993 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles.
NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT.
However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure.
Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant.
Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant.
The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool.
POLICY: Information Only
 
#58 ·
Evaporator/Cowl Screen - Revision

NO: 24-17-97
GROUP: Heating & A/C
DATE: Dec. 31, 1997
SUBJECT:
Evaporator service/Cowl Screen
MODELS:
1993 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
1993 - 1997 (ZG) Grand Cherokee (International Markets)
DISCUSSION:
A revised cowl plenum screen has been released which contains a fine mesh screen to minimize debris from entering the heater A/C housing. A build up of organic debris can decay and form acids which over time may contribute to evaporator corrosion/odor. When an evaporator is replace for leaks, the new screen should be installed as a precaution. Inspect the plenum area for any open holes or missing plugs which would allow leaves or other debris to enter the heater A/C housing. All of these areas should be sealed.
PARTS REQUIRED:
1 55036542 Screen, cowl plenum
REPAIR PROCEDURE:
This bulletin involves installing a revised cowl plenum screen.
1. Remove the windshield wiper arms.
2. Remove the cowl grille.
3. Remove the cowl screen.

4. Install the new screen, p/n 55036542. (See Figure 1)
5. Install the cowl grille.
6. Install the wiper arms.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-02-08-97 0.3 Hrs.

FAILURE CODE: P8 - New Part
 

Attachments

#59 ·
Door Check Roller - Worn/Broken/Missing

NO: 23-53-97
GROUP: Body
DATE: Oct. 3, 1997
SUBJECT:
Door Check Roller Repair
MODELS:
1993 - 1997 (ZJ) Grand Cherokee, Grand Wagoneer
1993 - 1997 (ZG) Grand Cherokee
SYMPTOM/CONDITION:
A new door check roller has been released which will allow for the replacement of door check rollers without replacement of the entire hinge assembly. The roller is an improved design which may also reduce noise associated with the door check rollers used previously. The roller can be used on any ZJ body vehicle including early models which were equipped with the stamped star wheel type roller.
DIAGNOSIS:
Inspect the door check roller, if the roller is worn, broken or the missing, perform the Repair Procedure.
PARTS REQUIRED:
AR 05011164AA Door Check Roller (2 required for each front door, 1
required for each rear door)
REPAIR PROCEDURE:
This bulletin involves replacement of the door check roller. The repair requires a qualified welder experienced in MIG welding.
1. Disconnect the battery negative cable.
2. Front doors require removal from the vehicle. If the repair is being performed on a rear door, proceed to step 7.
3. Disconnect the wiring harness and pull the harness boot and harness from the door to allow for door removal.
4. Scribe marks on the door hinges to facilitate later installation of the door.
5. Remove the door from the vehicle and place the door on a protected work bench to assure that the paint is not damaged during the repair.
6. Using a die grinder, grind away the rivet material from the bottom side of the roller shaft. Use care not to remove excessive material from the hinge.

7. Remove the roller by tapping it out of the hinge with a punch. If the roller shaft is difficult to remove, it may be necessary to drill the shaft out of the hinge using a 1/4 inch drill.
8. The new roller will be welded into place. To facilitate the welding process, remove the plating from the end of the new roller with sand paper. Install the new roller by pressing it into place with a 3 inch or larger C clamp, using a small socket or suitable tool to prevent any pressure from being applied to the outer bearing. Applying pressure to the outer bearing will damage the rollers and cause premature failure.
9. On front doors, repeat the roller removal and installation process for the second roller.
10. Place a wet rag around the roller bearing to minimize risk of heat damage to the bearing or dust seals. Using a MIG, wire weld process, puddle weld the bottom of the roller shaft to the hinge. This process requires a qualified welder skilled in MIG welding. The maximum weld build up cannot exceed 1.0 mm. If the weld build up is in excess of 1.0 mm, the weld must be filed to allow for clearance between the weld and the hinge when the door is closed.
11. Install the front door(s) on the vehicle. Install the harness and trim panel. Adjust the door to the opening.
12. Prime and paint the affected area.
13. Lubricate the hinge roller and torsion bar MOPAR Spray White Lube, p/n 04318066 or equivalent.
14. Connect the battery negative cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: Replace Door Check Roller - Right Front Door
23-40-20-94 1.0 Hrs.

Replace Door Check Roller - Left Front Door
23-40-20-95 1.0 Hrs.

Replace Door Check Roller - Right Rear Door
23-40-20-96 0.6 Hrs.

Replace Door Check Roller - Right Rear Door
23-40-20-97 0.6 Hrs.
FAILURE CODE: P8 - New Part
 
#60 ·
Door Trim Panel - Vinyl or Paint Peeling

NO: 23-51-97
GROUP: Body
DATE: Sep. 19, 1997
SUBJECT:
Door Trim Panel Vinyl or Paint Peeling
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 23-50-96 REV. C, DATED DEC. 20, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 BOUND TECHNICAL SERVICE BULLETIN MANUAL. THE BULLETIN ADDS PART NUMBERS TO ADDRESS LIMITED MODELS WITH WOOD GRAIN TRIM ACCENTS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1996 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
The vinyl may peel and separate from the bolster on the door trim panel near the arm rest or paint may peel from the door trim panel pull handle. A repair kit has been developed which eliminates the need to replace the door trim panel. These parts contain an improved paint formula which is less susceptible to contamination from hand creams and sun tan lotions.
DIAGNOSIS:
Inspect the door trim panel, if the vinyl is peeling or paint is peeling from the pull handle, perform the Repair Procedure.
**PARTS REQUIRED**:

Laredo Models

**Limited Models**
REPAIR PROCEDURE:
This bulletin involves installing a door trim panel repair kit.
1. Remove the door trim panel and place it on a clean, protected work bench surface.

2. Locate the heat stakes shown in Figure 1 and drill out the heat stakes on the outer perimeter of the bolster using a 23/64 in. Drill. Make sure to position the drill in the center of the heat stakes when drilling.
3. Remove the 3 door handle screws.

4. Remove any left over heat stake material with a die grinder or suitable tool to remove assure a smooth surface after drilling.
5. Insert the new bolster and wood grain trim accent into the trim panel and install the retainers onto the posts (See Figure 1). Seat the retainers fully using an 11/32 in. nut driver or socket to push them into place, making sure that the new bolster is tight against the trim panel. Install the screws in the locations shown. The front door requires two additional screws in the area of the door switch module.
6. Transfer door switch module to the new assembly.
7. Install the switch module screws.
8. Install the door handle screws.

9. Transfer the sound deadener to the new assembly using care to keep it below the upper retainers to avoid contact with them.
10. Install the trim panel replacing any damaged retainers with the new ones supplied in the kit.
TIME ALLOWANCE:
Labor Operation No:
Install Door Trim Panel Repair Kit - One Front Door
23-20-22-94 0.6 Hrs.

Install Door Trim Panel Repair Kit - Both Front Doors
23-20-22-95 1.1 Hrs.

Install Door Trim Panel Repair Kit - One Rear Door
23-20-22-97 0.5 Hrs.

Install Door Trim Panel Repair Kit - Both Rear Doors
23-20-22-98 0.9 Hrs.

FAILURE CODE: P8 - New Part
 

Attachments

#61 ·
Fuel Pump - Diagnosis

NO: 14-06-97
GROUP: Fuel
DATE: Jul. 3, 1997
SUBJECT:
Fuel Pump Diagnosis
MODELS:
1997 (TJ) Wrangler
1996 (ZJ) Grand Cherokee
1996 (ZG) Grand Cherokee - International Markets
1994 - 1996 (XJ) Cherokee
SYMPTOM/CONDITION:
Symptoms may include no start, rough idle, long crank times, driveway die outs or erratic fuel pressure. A new fuel pump has been released which delivers improved performance. This pump should be used whenever fuel pump failures are encountered.
DIAGNOSIS:
Basic fuel system diagnostics should be used as outlined in the appropriate service manual. A brief recap of the basic diagnostics follows:
Fuel pressure specification - 49 psi - plus or minus 5 psi.
High fuel pressure indicates problems with the fuel pressure regulator. Refer to the service manual for regulator diagnosis. Do not replace the fuel pump for high pressure.
Low fuel pressure - Low pressure could indicate a pump problem or it could indicate a plugged fuel filter or restricted fuel line or no fuel in the tank. Be sure to check these items before replacing the fuel pump.
Fuel System Leak down - When checking fuel pressure be sure to check the integrity of the system after shut down. With the fuel pressure gauge connected, shut the engine off and observe the pressure gauge. The system should maintain at least 24 psi for five minutes after shut down. If the pressure bleeds off quicker, it could indicate that an injector is leaking down or that the pressure regulator is leaking. This can lead to driveablity problems and require further diagnosis.
NOTE: IN RARE CASES WHERE MULTIPLE FUEL PUMP FAILURES HAVE OCCURRED ON THE SAME VEHICLE, A BUILD UP OF RESIDUE MAY HAVE ACCUMULATED ON THE INSIDE OF THE FUEL TANK. THE PRESENCE OF THIS RESIDUE IS NOT EASILY IDENTIFIABLE. THE RESIDUE CAN PASS THROUGH THE IN TANK FILTER AND CONTAMINATED THE PUMP ROTOR. IF MULTIPLE FAILURES HAVE OCCURRED WITH NO OBVIOUS INDICATION OF THE CAUSE, CONSIDERATION SHOULD BE MADE TO REPLACING THE FUEL TANK TO AVOID FUTURE PROBLEMS.
PARTS REQUIRED:
1 04762964 Pump Module - 1994-1995 XJ
1 04798941 Pump Module - 1996 XJ
1 04883261 Pump Module - 1996 ZJ
1 04897754AB Pump Module - 1997 TJ - 15 gallon tank
1 04897755AB Pump Module - 1997 TJ - 19 gallon tank
POLICY: Information Only
 
#62 ·
Heater A/C Housing - Service

NO: 24-02-98
GROUP: Air Conditioning
DATE: Mar 13, 1998
SUBJECT:
Heater A/C Housing, Service
MODELS:
1993 - 1998 (ZJ) Grand Cherokee, Grand Wagoneer
1994 - 1998 (ZG) Grand Cherokee (International Markets)
DISCUSSION:

The service manual procedures to service the heater A/C housing, evaporator or heater core have been revised, based on feedback from our training and field personnel as well as dealership technicians. The new procedure is simpler and more efficient than the current service manual procedure. The revised service manual procedure is included and should - be used starting immediately. Listed are the labor operation numbers and times that will be affected by this revision.
NOTE : THE REVISED LABOR OPERATION TIMES WILL BE EFFECTIVE ON MARCH 16, 1998.
 

Attachments

#63 ·
Heater A/C Housing - Service
Removal and Installation
Heater A/C housing
Removal


1. Disconnect battery. This must be done to prevent accidental airbag deployment.
2. Using on A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to Service Manual Procedures for A/C system evacuation and charge.
3. Remove the shift knob by pulling sharply upward.
4. Place the transfer case in low range. Pry the shift indicator bezel out of the console using a trim stick.
5. Apply the parking brake and place the transfer case in neutral. Remove the parking brake trim insert. Remove the console attaching screws. Lift the console up and disconnect the 4WD indicator lamp hamess. Remove the console.
6. Remove the passenger side knee blocker. Remove the single end screw. Remove the screws below the glove box. Remove the screw at the courtesy lamp. Remove the ash receiver and the screws behind it. Remove the instrument panel armature screw behind the ash receiver. Open the glove box and remove the screws behind it. Lower the panel and disconnect the lamp harnesses.
7. Remove the pod switch bezels on both sides of the steering column with a trim stick.
8. Remove the drive side knee blocker. Remove the end screw and screws located at the bottom of the knee blocker.
9. Remove the cowl top trim panel by prying it up with a trim stick. Remove the solar sensor if equipped.

10. Remove the "A" post trim panels.
11. Remove the remove the bolts that attach the lower instrument panel reinforcement to the instrument panel armature and remove the reinforcement.
12. Disconnect the park lamp switch.
13. Pull back the carpet at the transmission tunnel from the base of the instrument panel center bezel. Remove the nuts from the upper studs and bolts through the floor that secure the instrument panel center bracket.
14. Remove the bolts that secure the instrument panel center bracket to the drivers side of the transmission tunnel.
15. Remove the screws securing the Vehicle Information Center and remove it. Remove the screw fastening the mounting bracket.
16. Unplug the vacuum harness connector or vent tube on ATC equipped vehicles and the wire harness located under the passenger side of the instrument panel.
17. Remove the screws holding the passenger side kick panel, along with the screw from the kick panel shroud.
18. Unplug the antenna cable near the right cowl side panel.
19. Unplug the instrument panel wire harness connectors from the junction block at the right cowl side panel.
20. Remove the bolts that secure the instrument panel armature to the windshield fence.
21. Remove the nuts that secure the top if the instrument panel armature to the windshield fence.
22. Remove the bolts that secure the ends of the instrument panel to the cowl side panel.
23. Remove the nuts that secure the steering column to the brake pedal support and lower the steering column.
24. Remove the bolts that secure the instrument panel armature to the brake pedal support.
25. Place a protective cover on the seats. Lift the instrument panel off the windshield fence studs and maneuver the instrument panel out and lower it onto the seats.
26. Disconnect the refrigerant lines from the evaporator tubes. Make sure to install plugs or tape the ends of the lines and fittings to ensure that excessive amounts of moisture do not contaminate the A/C system.

27. Remove the vacuum line at the tee from the main vacuum supply harness. This line runs through the body with the upper refrigerant line.
28. Disconnect the heater hoses from the heater core and clamp the ends closed to prevent coolant loss.
29. Remove the coolant overflow bottle.
30. Remove the Powertrain Control Module with connectors intact and set aside.
31. Remove the heater A/C housing mounting nuts from the studs on the engine compartment side of the dash.
32. Remove the heater A/C housing from the vehicle.
33. To install the components, reverse the procedure stated above.
Torque Specifications:
Instrument panel center bracket to floor transmission tunnel fastener 28 Nm (250 in. Lbs.)
Instrument panel to windshield fence bolts and nuts 12 Nm (105 in. Lbs.)
Instrument panel to cowl side inner panel bolts 12 Nm (105 in. Lbs.)
Instrument panel to steering column support bolts 12 Nm (105 in. Lbs.)
 
#64 ·
Engine - High Driveability Index Fuels
NO: 14-08-97
GROUP: Fuel
DATE: Nov. 21, 1997
SUBJECT:
Poor Driveability With High DI (Driveability Index) Fuel
MODELS:
1996 - 1998 (AB) Ram Van/Wagon
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1996 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (PL) Neon
1997 (PR) Prowler
1996 - 1998 (SR) Viper Roadster/Coupe
1997 - 1998 (TJ) Wrangler
1996 - 1998 (XJ) Cherokee
1995 - 1998 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F).
DISCUSSION:
Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems.
For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance.
The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular.
Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane.
Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock.
Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline.

The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction.
If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis.
POLICY: Information Only
 
#65 ·
Liftgate Ajar Switch - Terminal Corrosion

NO: 08-28-97
GROUP: Electrical
EFFECTIVE DATE: Sept. 8, 1997
SUBJECT:
Liftgate Ajar Switch Terminal Corrosion
MODELS:
1996 - 1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (International Markets)
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 18, 1997 (MDH 06- 08-XX)
SYMPTOM/CONDITION:
Water can enter the liftgate ajar switch causing corrosion to the terminals. This condition can lead to any of the symptoms listed below:
- Vehicle Information Center displays liftgate ajar
- Rear Wiper inoperative
- Security alarm will not set
- Courtesy lamps stay on
- Ignition off draw causing dead battery
DIAGNOSIS:
If customer complaints are received indicating any of the complaints listed above, perform the Repair Procedure.
PARTS REQUIRED:
1 56005640 Switch - Liftgate Ajar
1 05011102AA Connector Repair Package
1 04778570 Heat Shrink Tubing
REPAIR PROCEDURE:
This bulletin involves replacing the liftgate ajar switch and repairing the harness connector.
1. Disconnect and isolate the battery negative cable.
2. Remove the liftgate lower trim panel.
3. Remove the liftgate latch and remove the ajar switch from the latch.
4. Install the new switch, P/N 56005640.
5. Stagger cut the liftgate ajar switch connector from the harness.
6. Strip approximately 1 inch of insulation from the wires at the harness and repair package.
7. Slide two pieces of heat shrink tubing over the wires on the connector package. Using rosin core solder, twist the wires together and solder the two wires making sure of a hot solder joint by heating the wire hot enough to melt the solder.
8. Position the heat shrink tubing over the bare wire and apply heat to the tubing with a heat gun to fully shrink the tubing and seal the wires at both ends.
9. Connect the harness to the switch.
10. Install the liftgate trim panel.
11. Connect the battery negative cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-88-94 0.5 Hrs.

FAILURE CODE: P8 - New Part
 
#66 ·
Garage Door Opener - Rolling Code Information

NO: 08-20-97
GROUP: Electrical
DATE: May, 16, 1997
SUBJECT:
Garage Door Opener
MODELS:
1996 - 1997 (FJ) Avenger/Sebring/Talon
1996 - 1997 (JA) Cirrus
1996 - 1997 (JX) Sebring Convertible
1996 - 1997 (LH) LHS
1996 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Rolling code technology (random digital code signals from the remote transmitter) is a security feature incorporated into some recently manufactured garage door openers. Garage door opener transmitters on Chrysler vehicles built before approximately March 1, 1997 will not function with a random digital code receiver. Owners who own or purchase vehicles built before March 1, 1997 and have or purchase a random digital code garage door opener have three options that will make this combination work.
Option # 1 For garage door opener's with a rolling code activation switch (or button): disengage (turn off) the rolling code feature on the garage door opener via the on/off switch (or button).
Option # 2 Replace the non-rolling code visor/garage door opener assembly with the new rolling code compatible visor/garage door opener assembly. The new assembly can be identified by the shape of the LED (LED in the shape of a house is rolling code compatible).
Option # 3 Purchase a Universal Receiver (via HomeLink(R): 1-800-355-3515) which allows the existing non-rolling code garage door opener transmitter to activate the rolling code garage door receiver, however, bypassing the rolling code security feature.
POLICY: Information Only
 
#67 ·
Speedometer - Needle Jumps/Vibrates

NO: 08-36-97
GROUP: Electrical
DATE: Oct. 3, 1997
SUBJECT:
**Speedometer Needle Jumps**
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-29-96, DATED SEPTEMBER 6, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE BOUND 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010.) THE BULLETIN REVISES THE SUBJECT/SYMPTOM TO HIGHLIGHT THE MOST COMMON SYMPTOM OF THOSE LISTED BELOW. THE REVISION IS HIGHLIGHTED WITH ASTERISKS.
MODELS:
1996 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
An short circuit in the shift interlock cable solenoid may cause a variety of symptoms including the following:
** The speedometer needle jumps or vibrates when the brakes are applied.** Blown fuse at location 5 in the fuse panel.
Brake warning light is illuminated.
DIAGNOSIS:
If fuse 5 is blown or any of the symptoms described above are present, perform the Repair Procedure.
PARTS REQUIRED:
1 52078961 Shift interlock cable
REPAIR PROCEDURE:
This bulletin involves replacing the shift interlock cable.
1. Lower the steering column. (Refer to the 1996 Grand Cherokee Service Manual, Publication No. 81-370-6147, page 19-22 for this procedure if you are not familiar with it.)

2. Remove the two screws retaining the interlock mechanism to the steering column and unsnap the mechanism from the column. (See Illustration)
3. Remove the center console and related trim.
(Refer to the 1996 Grand Cherokee Service Manual, Publication No.81-370-6147, page 23-35 for this procedure if you are not familiar with it.)
4. Disconnect the cable eyelet from the bell crank.
5. Remove the wire from the solenoid on the cable.
6. Remove the accelerator pedal. Release the cable from the accelerator pedal clip and remove the cable.
7. Install the new cable P/N 52078961 and snap the interlock mechanism into the steering column. Secure the mechanism with the two screws removed earlier.
CAUTION : THE INTERLOCK CABLE MUST BE CLIPPED TO THE RIGHT HAND STUD UNDER THE ACCELERATOR PEDAL. THIS WILL PREVENT ANY INTERFERENCE WITH THE ACCELERATOR PEDAL.
8. Install the accelerator pedal, routing the cable between the accelerator pedal mounting studs and securing it with the clip to the right hand stud.
9. Place the ignition switch in the "ACCESSORY" position.
10. Remove the shipping pin from the interlock mechanism.
11. Connect the cable eyelet to the bell crank.
12. Place the gear shift selector in park.
13. Push the spring loaded cable adjuster forward and insert the cable into the bracket.
14. Push the cable adjuster lock down to lock the adjustment.
15. Connect the solenoid wire.
16. Install the center console and related trim.
17. Verify correct operation of the interlock system.
18. Install the steering column onto the bracket.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-20-69-90 0.7 Hrs.

FAILURE CODE: P8 - New Part
 
#68 ·
Tire & Wheel - Runout

NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT:
Tire & Wheel Runout
MODELS:
1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures.

PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting).
POLICY: Information Only
 

Attachments

#69 ·
Windshield Area - Wind Noise

NO: 23-17-97
GROUP: Body
DATE: Apr. 4, 1997
SUBJECT:
Wind Noise - Windshield Area
MODELS:
1996 - 1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (Overseas Markets)
SYMPTOM/CONDITION:
Wind noise at the sides of the windshield. This noise may be a result of sealer skips/leaks in the "A" pillar area. A sealer patch is applied in the assembly process to cover an access hole in the "A" pillar. This patch may not be fully sealed to the body and may leak. This can lead to wind noise or whistles which can easily be mistaken for a windshield sealer leak.
DIAGNOSIS/REPAIR PROCEDURE:
This bulletin involves testing the "A" pillar area for sealer leaks and applying sealer to the area if leaks are found.
If wind noise is present at the "A" pillar to the sides of the windshield, perform the Repair Procedure.
1. Remove the "A" pillar interior trim.

2. Apply a solution of soapy water to the area around the sealer patch (see Figure 1).
3. From outside of the vehicle, close the door and using an approved air nozzle direct the air flow at the "A" Pillar area and watch for air bubbles.
4. If leaks are found, clean the area with a solvent such as MOPAR Super Cleen, p/n 04318015 or equivalent, and apply body seam sealer such as MOPAR 04318025 or equivalent to the affected areas.
5. Install the "A" pillar trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-94 (right side) 0.2 Hrs.

23-50-02-95 (left Side) 0.2 Hrs.

FAILURE CODE: XX - Service Adjustment
 

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