Electrical - 50-way Bulkhead Connector Repair

91chrysler09

NO.: 08-14-91

GROUP: ELECTRICAL

DATE: Oct. 7, 1991


SUBJECT: Repair Procedure - Cross Threaded 50-Way Connector Screw


MODELS:

1990-92 (AA) ACCLAIM/SPIRIT/LEBARON SEDAN
(AC) DYNASTY/NEW YORKER SALON
(AG) DAYTONA
(AJ) LEBARON COUPE/LEBARON CONVERTIBLE
(AQ) CHRYSLER'S TC (MASERATI COUPE)
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE


SYMPTOM/CONDITION:

The screw and bushing from the 50-way bulkhead electrical connector may be stripped or cross threaded when mating the connector halves. The screw and bushing can be replaced using the following procedure.


PARTS REQUIRED:

1 Repair Screw Package 4638407

Consisting of:

1 - 8 mm hex head screw (10 - 24 x 4.5")
1 - O-ring
1 - Flat washer
1 - 8 mm hex head nut (10-24)


REPAIR PROCEDURE:

This procedure involves the replacement of a stripped or cross threaded 50-way bulkhead electrical connector screw with a new screw.

1. Remove and discard the old screw, O-ring, and pac-nut retainer from the 50-way bulkhead electrical connector.

2. Hand mate the 50-way male and female connector halves together.

3. Using the parts from repair package listed above (PN 4638407), slide the repair O-ring onto the new screw.


4. Insert the screw into the rear (wire side) of the male 50-way connector. (It is not necessary to remove or drill out the original bushing from the 50-way female connector.)

5. From the rear (wire side) of the female 50-way connector, install the repair washer onto the new screw and secure using the new nut.

6. Torque the nut to 35 in.lbs. This screw has a low torque capability. DO NOT OVER TORQUE.


POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 08-90-90-91 . . . . . . . . . . . . . . . . . . . 0.3 Hrs.


FAILURE CODE: X8 - Stripped