DTCs 53/63/65 (ABS Wheel Sensor) Set
BULLETIN NUMBER:SBOO-04-SOO1
ISSUE DATE:
JANUARY 2000
GROUP:
ELECTRICAL
1998-99 RODEO (UE) /AMIGO (UA) REAR ABS SENSOR HARNESS REPAIR
AFFECTED VEHICLES
Some 1998-99 Rodeo (UE) and Amigo(UA) models.
SERVICE INFORMATION
Condition:
The one or more of the following ABS Diagnostic Trouble Codes (DTC) have been set:
^ Rear Speed Sensor Open or Shorted [DTC 53 (Flash out) /C0235 (Serial communications)]
^ Speed Sensor Missing [DTC 63 (Flash out) / C0236, C0237 (Serial communications)]
^ Wheel Speed Input Abnormality [DTC 65 (Flash out) / C0238 (Serial communications)]
Possible Cause:
Corrosion or fraying of the wire(s) may have occurred near the rear ABS sensor harness connector H-26 at the left upper-link arm of the rear suspension.
Correction
Repair the damaged harness by installing a Rear ABS Sensor Extension Harness kit, using the procedure outlined in this bulletin.
1. Record the radio presets if any, and disconnect battery (-).
2. Lift vehicle on a hoist.
3. Remove left-rear wheel and illuminate the left-rear suspension area with a shop light to locate the ABS harness connector (H-26). (Figure 1)
4. Disconnect the ABS harness connector (H-26) at the left-side upper-link arm. (Figure 2)
5. Cut band clip (on side of frame, near the frame-side bushing of upper-link) to release attached harness. (Figure 3)
^ Pull the cut clip out and discard.
6. Partially separate the plastic wire loom from the vehicle ABS harness and cut the (3) wires to even length. (Figure 4)
NOTE
If there are any corrosion or fraying at the ends, be sure to cut off that portion.
7. Strip the ends of the (3) cut vehicle ABS harness wires so that 6-7 (1/4") of bare wire is showing. (Figure 5)
8. Crimp joint terminals to the ends of the (3) stripped vehicle ABS harness wires. (Figure 6)
NOTE:
^ Be sure to precisely crimp the area of the joint terminal intended for that end.
^ Do not pierce or damage the heat-shrink insulation of the joint terminals during crimping.
^ Use proper non-piercing type crimping tool with a 22AWG sized crimp jaw, such as Kent-Moore VA-19730. (Figures 7 and 8)
Use only non-piercing type crimping tool with a 22AWG sized crimp jaw such as above.
9. Cut the (3) un-terminated ends of the new extension ABS harness wires at a point 50 mm (2") from end of plastic wire loom. Strip the ends of the wires so that 6-7 mm (1/4") of bare wire is showing. (Figure 9)
10. While observing the color of the wire insulator RED or ORANGE, WHITE, and BLACK), insert and crimp the matching color wire of the repair ABS harness to the crimped end of the vehicle ABS harness.
NOTE
^ Do not pierce or damage the heat-shrink insulation of the joint terminals during crimping.
^ Use proper non-piercing type crimping tool with a 22AWG sized crimp jaw. (Refer to Figures 7 and 8)
11. Using a heat-gun, apply heat evenly to the joint terminals' heat-shrink cover to fuse with the wire insulator. (Figure 11)
NOTE
^ For proper connection seal, apply even heat until some "oozing" of glue occurs at the ends of the heat-shrink cover. (Figure 12)
^ Excessive localized heat will damage the heat-shrink cover or melt the wire insulator.
12. Inspect and correct any loose or exposed terminal(s) / bare wire(s) of the sealed crimp connection.
13. Cover the section of the crimped connections with the plastic wire loom of the vehicle ABS harness, and wrap the entire area with electrical tape. (Figure 13)
NOTE
This provides secondary insulation against the elements, and does not correct any loose or exposed connection(s).
14. Cover the wrapped section of the harness with an additional supplied piece of harness protector and secure by wrapping the entire section again with electrical tape.
15. Remove and discard the remaining disconnected ABS sensor harness leading to the rear ABS sensor in rear differential housing, along with (4) harness attaching clip bands from the attachment brackets.
16. Route the new crimped connected repair ABS harness along the same path of the removed ABS sensor harness. Connect the rear ABS sensor to this repair ABS harness (Figure 14), and attach all pre-installed attaching clips along the path (Figure 15), including the location on side of frame near the frame-side bushing of upper-link. (Figure 16)
17. Loop the slack portion of the harness and bundle it with the existing fixed harness at the forward location. Tuck and secure together using a band strap. (Figure 17)
18. Bundle the unsecured harness with fixed harness (attachment clipped on side of frame near the frame-side bushing of upper-link), and secure together using a band strap. (Figure 18)
19. Cut the exposed pulled tab of the (3) previously installed band straps. Do not cut any harnesses.
20. Reinstall left-rear wheel and lower the vehicle.
21. Reconnect the battery (-), and reset the clock and radio presets.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
Use the following new labor operation:
Labor Time includes administrative time allowance.