Recall - Bulkhead Wiring Connector Defect
No. 572/573July, 1993
To: All Jeep & Eagle Dealers
Subject:
Safety Recall # 572 / Customer Satisfaction Notification # 573
Bulkhead Wiring Connector
Models:
Safety Recall # 572 -- 1991 through 1993 Model Year Jeep Wrangler (YJ)
Vehicles Equipped with a Manual Transmission Built Before February 23, 1993.
Customer Satisfaction Notification # 573 -- 1991 through 1993 Model Year Jeep Wrangler (YJ) Vehicles Equipped with an Automatic Transmission Built Before February 23, 1993.
Salt tracking between the starter solenoid wire and the adjacent battery feed wire in the bulkhead connector may bypass the key control of the starter motor solenoid circuit and cause the starter to engage without ignition key initiation. This may cause vehicles equipped with a manual transmission and parked in gear to move without warning due to engine cranking. To correct the condition, the starter solenoid wiring must be relocated within the bulkhead connector.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers:
Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information.
The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
All dealers:
Each Jeep & Eagle dealer will receive a copy of this dealer recall notification letter by first class mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.
Parts
No parts are required for this service action.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
1. With the ignition key in the OFF position, disconnect the negative battery cable.
2. Disconnect the engine compartment bulkhead connector.
3. Separate the larger section of the bulkhead wiring connector from the connector.
4. Remove the blue wedge.
5. FOR 1991 - 1992 MY VEHICLES:
Remove the green wire from cavity G5 and install it in cavity A6 (Figure 1).
FOR 1993 MY VEHICLES WITHOUT
ABS: Remove the yellow wire from cavity G5 and install it in cavity A6 (Figure 1).
FOR 1993 MY VEHICLES WITH
ABS: Remove the yellow wire from cavity G5 and install it in cavity A6. Remove the existing white/tan wire from cavity A6 and install it in cavity G5 (Figure 1).
6. Reinstall the blue wedge.
7. Reunite the two sections of the bulkhead connector.
8. Remove the two fuse block/instrument panel bulkhead connector attaching screws.
9. Separate the fuse block from the bulkhead connector.
10. Separate the larger section of the bulkhead wiring connector from the connector.
11. Remove the blue wedge.
12. FOR 1991 - 1992 MY VEHICLES:
Remove the green wire from cavity G5 and install it in cavity A6 (Figure 2).
FOR 1993 MY VEHICLES:
Remove the yellow wire from cavity G5 and install it in cavity A6. Remove the existing white/tan wire from cavity A6 and install it in cavity G5 (Figure 2).
13. Reinstall the blue wedge.
14. Reunite the two sections of the bulkhead connector.
15. Reattach the fuse block to the bulkhead connector.
16. Install the fuse block/instrument panel bulkhead connector with the two attaching screws.
17. Reconnect the engine compartment bulkhead connector.
18. Connect the battery negative cable.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
NOTE:
To ensure proper payment, be sure to use the correct labor operation number for the applicable recall as shown. The recall number can also be identified from the Owner Notification Form (lower right), from the applicable dealer vehicle list or from DIAL System Function 70.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions.
Parts Return
Not applicable.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:
Chrysler Corporation 415-03-18
P.O. Box 1919
Detroit, Michigan 48231-1919
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.