2005-06 Jeep OPDA_CPS_Distributor Failure - Page 4 - JeepForum.com
Search  
Sign Up   Today's Posts
User: Pass: Remember?
Advertise Here
Jeep Home Jeep Forum Jeep Classifieds Jeep Registry JeepSpace Jeep Reviews Jeep Gallery Jeep Clubs Jeep Groups Jeep Videos Jeep Events Jeep Articles
Go Back JeepForum.com > Models > Jeep Wrangler Forums > TJ Wrangler Technical Forum > 2005-06 Jeep OPDA_CPS_Distributor Failure

End of Summer Sale, 20% OFF!Introducing MONSTALINER™ UV Permanent DIY Roll On Bed LineRough Country Jeep Suspension Deals at Rockridge 4WD!

Reply
Unread 12-29-2010, 10:39 AM   #46
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by ianschrd View Post
First I want to say think you Fog and Willydigger for putting in a lot of time and effort into finding a solution to this problem.

I know there was a lot of talk on the other thread about changing the gear on the OPDA. Is that still recommended? I just ordered my part today, 153 on back order.
I didn't and don't plan to. I've read somewhere that the hardness of the stock OPDA gear is the same as earlier models (I believe it is 27RC). I don't believe it is defective. There is also the issue of having to re-drill a hole in the shaft. I think the ZDDP with help the gear wear. Preventing the upper bushing from seizing should save the motor. FOG may have some more insight. He mentioned working with a NAPA gear in previous posts.

__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-29-2010, 10:43 AM   #47
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by kellyII View Post
man im totally bumed now, im not motor savvy at all. i feel i need to do this mod but I know I have no business turning a wrench. what to do, what to do... UGH

I need to get this fixed but I dont know what to do. Dam this pisses me off
I sent you a PM. I've done units for two other members and I'm willing to do the mod for you.

It is not very difficult to do, but you will need confidence to drill that first hole.
__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-29-2010, 10:56 AM   #48
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by ChaseB View Post
We're in the same boat my friend, I just picked up a 2005 X with low miles. Oil Pump Drive Gear was replaced under recall but I'm not convinced that did anything....shame there isn't an aftermarket replacement so I could just drop a new one in
The replacement is with a defective part. There will not be any lubrication of the upper bushing and it will eventually get hot and fail. The photo of the heat marks on the first page gave no warning and was modded as a preventative measure. There have been reports of the shaft completely seizing causing the housing to spin in the motor.

I don't have any images of this solution working, but based on FOG's reports (which I believe) and the complete coverage of grease using the 33MS I believe this fix will work long term.

It would be nice if there was a true Chrysler fix (opposed to parts replacement), but in lieu of that this mod seems like the way to go. Cost wise you're looking at:
1. Replacement OPDA to mod $100
2. Replacement Gasket $2
3. Tooling $50ish
4. Grease $25

2 hours of labor. Taking the time to do it right and not rush.

I would seriously consider it. I've read reports of the OPDA lasting 80K and some failures at 15K.
__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-29-2010, 01:21 PM   #49
ChaseB
Registered User
2005 TJ Wrangler 
 
Join Date: Oct 2010
Location: Lafayette, LA
Posts: 1,598
Quote:
Originally Posted by willydigger View Post
The replacement is with a defective part. There will not be any lubrication of the upper bushing and it will eventually get hot and fail. The photo of the heat marks on the first page gave no warning and was modded as a preventative measure. There have been reports of the shaft completely seizing causing the housing to spin in the motor.

I don't have any images of this solution working, but based on FOG's reports (which I believe) and the complete coverage of grease using the 33MS I believe this fix will work long term.

It would be nice if there was a true Chrysler fix (opposed to parts replacement), but in lieu of that this mod seems like the way to go. Cost wise you're looking at:
1. Replacement OPDA to mod $100
2. Replacement Gasket $2
3. Tooling $50ish
4. Grease $25

2 hours of labor. Taking the time to do it right and not rush.

I would seriously consider it. I've read reports of the OPDA lasting 80K and some failures at 15K.
The instructions provided are great and in depth. And you guys did a phenomenal job compiling all this information and doing the research. That being so, I still don't feel comfortable with tackling this job. Guess I'll just have to go for it though.....you guys should start selling modded OPDAs....I'm first in line for one!

Thanks again for the invaluable info regarding this screw up by Chrysler. It's a shame that the burden to fix this issue is left on the consumer.
ChaseB is offline   Reply With Quote
Unread 12-29-2010, 06:39 PM   #50
TJXTWO
Registered User
 
Join Date: Nov 2010
Location: San Diego, California
Posts: 123
Willydigger: I read through the thread a couple of times, and I believe you are saying the oil groove is not needed? The rest of the mod looks fairly straight forward, but the oil groove would take someone with some machining tools I suppose. Just wondering if you think the groove is worth doing or not. Thanks for the thread BTW. Great job.
__________________
03 TJ Sport, 4.5" RE SuperFlex short arm lift, Tereflfex ST swaybar, 33" MTR's, Body Armor bumpers @ sliders, 5 speed manual... 06 TJ Rubicon, 4.5" RE long arm lift, Currie Antirock front and rear , OR Fab bumpers @ sliders, K@N intake, custom exhaust, 1" BL , 1" motor mount lift, 35" MTR's on Pro Comp Alloys, 6 speed manual.
TJXTWO is offline   Reply With Quote
Unread 12-30-2010, 06:47 AM   #51
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by TJXTWO View Post
Willydigger: I read through the thread a couple of times, and I believe you are saying the oil groove is not needed? The rest of the mod looks fairly straight forward, but the oil groove would take someone with some machining tools I suppose. Just wondering if you think the groove is worth doing or not. Thanks for the thread BTW. Great job.
I've only seen one failed unit. It had score marks on the top and bottom. The heat generation at the top is the real concern. If I were you I would do the mod for the upper bushing. While it's all apart, clean the shaft with some 2000 grit sand paper. After a few thousand miles, pull it again for inspection. The score marks on the bottom should sand away, however if you notice deep scoring or any other abnormality I would look into adding the groove.

To be clear, I added the groove because it was free from a friend. There was no harm in it. My goal was to duplicate the old 2004 OPDA as much as I could. The two other OPDA's that I've modded do not have the groove. While the oil groove will not hurt things, I think the main area of concern is the upper bushing lubrication.
__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-30-2010, 10:01 AM   #52
TJXTWO
Registered User
 
Join Date: Nov 2010
Location: San Diego, California
Posts: 123
Thanks man, I really appreciate it.
__________________
03 TJ Sport, 4.5" RE SuperFlex short arm lift, Tereflfex ST swaybar, 33" MTR's, Body Armor bumpers @ sliders, 5 speed manual... 06 TJ Rubicon, 4.5" RE long arm lift, Currie Antirock front and rear , OR Fab bumpers @ sliders, K@N intake, custom exhaust, 1" BL , 1" motor mount lift, 35" MTR's on Pro Comp Alloys, 6 speed manual.
TJXTWO is offline   Reply With Quote
Unread 12-30-2010, 04:59 PM   #53
TJXTWO
Registered User
 
Join Date: Nov 2010
Location: San Diego, California
Posts: 123
One more question: What did you use to press out the roll pin (vice / press) and did you use the same roll pin to put the gear back on?
__________________
03 TJ Sport, 4.5" RE SuperFlex short arm lift, Tereflfex ST swaybar, 33" MTR's, Body Armor bumpers @ sliders, 5 speed manual... 06 TJ Rubicon, 4.5" RE long arm lift, Currie Antirock front and rear , OR Fab bumpers @ sliders, K@N intake, custom exhaust, 1" BL , 1" motor mount lift, 35" MTR's on Pro Comp Alloys, 6 speed manual.
TJXTWO is offline   Reply With Quote
Unread 12-30-2010, 09:56 PM   #54
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by TJXTWO View Post
One more question: What did you use to press out the roll pin (vice / press) and did you use the same roll pin to put the gear back on?
You'll need a 3/16 punch. It on the right in the pic below. You will hammer the roll pin out and put it back in. Make sure you are careful putting it in straight. The gear may twist on the shaft or the pin may start crooked.

__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-31-2010, 05:05 PM   #55
TJXTWO
Registered User
 
Join Date: Nov 2010
Location: San Diego, California
Posts: 123
Thanks again. I am ordering the parts next week. I found the OPDA online but not the gasket. I will have to call I guess. Have a good new year.
__________________
03 TJ Sport, 4.5" RE SuperFlex short arm lift, Tereflfex ST swaybar, 33" MTR's, Body Armor bumpers @ sliders, 5 speed manual... 06 TJ Rubicon, 4.5" RE long arm lift, Currie Antirock front and rear , OR Fab bumpers @ sliders, K@N intake, custom exhaust, 1" BL , 1" motor mount lift, 35" MTR's on Pro Comp Alloys, 6 speed manual.
TJXTWO is offline   Reply With Quote
Unread 12-31-2010, 06:37 PM   #56
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by TJXTWO View Post
Thanks again. I am ordering the parts next week. I found the OPDA online but not the gasket. I will have to call I guess. Have a good new year.
You may not need the gasket if your old one comes off. Sometimes they get fused on, but you may get lucky. You can check the dealer and even Autozone or NAPA.
__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 12-31-2010, 06:55 PM   #57
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Updated Section 2. I believe this is from a CARFAX.

Quote:
E05 MAR 2005 Campaign - Engine Oil Pump Drive Gear/Cam Replacement .

Revised June 2005

Dealer Service Instructions for:

Customer Satisfaction Notification E05
Oil Pump Drive Gear

A revised drive gear parts package has been released. The second roll pin hole must be drilled in the revised drive gear.

2005 (TJ) Jeep(R) Wrangler

NOTE : This notification applies only to the above vehicles equipped with a 4.0L eligible ("S" in the 8th VIN position) and an engine build code between 902944 (October 20, 2004) and 900325 (February 1, 2005).

IMPORTANT : Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

Subject

The oil pump drive gear on about 16,000 of the above vehicles may wear out prematurely and cause engine failure due to a loss of oil pressure.

Repair

The camshaft position sensor/oil pump drive assembly date code label must be inspected. Units within a specific date code range must have the drive gear replaced.

All unsold vehicles must have the oil pump drive gear replaced prior to retail delivery to eliminate the risk of engine failure due to premature oil pump drive gear wear. On sold vehicles, the cam/crank angle must also be checked with the DRB III scan tool. Engines found with excessive cam/crank angle must have the oil pump drive gear and the engine camshaft replaced.

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that an engine camshaft is required and the vehicle must be held overnight.

Parts Information

Special Tools

The Special Tools may be required to perform this service procedure.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments.

Use one of the labor operation numbers and time allowances shown.

Add the cost of the parts package plus applicable dealer allowance to your claim.

NOTE : See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions.

Dealer Notification

All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. This notification can be viewed on DealerCONNECT by selecting "Global Recall System" on the Service tab, then clicking on the description of this notification.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

Vehicle lists, Global Recall System, VIP and Dealer Follow UP

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers should perform this repair on all unsold vehicles before retail delivery.

Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use.

Additional Information

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services Field Operations
DaimlerChrysler Corporation
__________________
WHODEY
willydigger is offline   Reply With Quote
Unread 01-03-2011, 05:54 PM   #58
bonza
Registered User
2005 TJ Wrangler 
 
Join Date: Feb 2006
Location: Melbourne, Victoria
Posts: 342
great work willydigger and all the other contributors, have saved it for future reference

a question about engine oils. seems ACEA spec oil OK, I presume ACEA-E7 to be specific?
__________________
I like a man who grins when he fights
— Winston Churchill..
bonza is offline   Reply With Quote
Unread 01-04-2011, 11:05 AM   #59
silverhorn
Registered User
 
silverhorn's Avatar
2011 JK Wrangler 
 
Join Date: Sep 2010
Location: Houston, Texas
Posts: 23
No parts

I've burned the phone lines for three days now and cannot find the OPDA anywhere. Two dealerships have one each but will not sell. Mopar-wholesale.com says there are 182 on back order nationwide and Chrysler has given them no expected date of arrival.

Truly amazing that I cannot find a part for a 4 year old vehicle. When I spoke to Chrysler and suggested the reason for the shortage was a nationwide failure of the part on '05 and '06 Wranglers they said "there is no proof of that", and "you can't believe everything you read on the internet". Very helpful customer service.

I've been handed off to the expediting team. They said I should expect a callback in 4-5 days... how's that for expediting?
silverhorn is offline   Reply With Quote
Unread 01-04-2011, 12:27 PM   #60
willydigger
Registered User
2005 TJ Wrangler 
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 1,570
Quote:
Originally Posted by silverhorn View Post
I've burned the phone lines for three days now and cannot find the OPDA anywhere. Two dealerships have one each but will not sell. Mopar-wholesale.com says there are 182 on back order nationwide and Chrysler has given them no expected date of arrival.

Truly amazing that I cannot find a part for a 4 year old vehicle. When I spoke to Chrysler and suggested the reason for the shortage was a nationwide failure of the part on '05 and '06 Wranglers they said "there is no proof of that", and "you can't believe everything you read on the internet". Very helpful customer service.

I've been handed off to the expediting team. They said I should expect a callback in 4-5 days... how's that for expediting?
I'm going to assume you did not try dodge-wholesale.com.

I think they are different from mopar-wholesale.com.

I love this part:
Quote:
When I spoke to Chrysler and suggested the reason for the shortage was a nationwide failure of the part on '05 and '06 Wranglers they said "there is no proof of that", and "you can't believe everything you read on the internet".
I wonder why then? Are there any lawyers on the board? What about a class action or something?
__________________
WHODEY
willydigger is offline   Reply With Quote
Reply
Thread Tools


Suggested Threads





Jeep, Wrangler, Cherokee, Grand Cherokee, and other models are copyrighted and trademarked to Jeep/Chrysler Corporation. JeepForum.com is not in any way associated with Jeep or the Chrysler Corp.