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Disassembly






POWER DISTRIBUTION CENTER DISASSEMBLY

PDC HOUSING LOWER COVER

REMOVAL

The Power Distribution Center (PDC) cover, the PDC housing lower cover, the PDC relay wedges, the PDC mini fuse wedge, the PDC relay cassettes and the PDC B(+) terminal stud module are available for service replacement. The PDC cover can be simply unlatched and removed from the PDC housing without the PDC being removed or disassembled. Service of the remaining PDC components requires that the PDC be removed from its mounting and disassembled. Refer to Wiring Repair in Wiring Diagrams for the location of the wiring repair procedures.




1. Unlatch and remove the cover from the PDC.

2. Remove the two nuts that secure the two-holed eyelet of the battery wire harness PDC take out to the B(+) terminal studs near the inboard end of the PDC.

3. Remove the battery wire harness PDC take out eyelet from the two PDC B(+) terminal studs.

4. Disengage the latches on the PDC housing mounts from the tabs on the PDC mounting stanchions on the battery tray, and pull the PDC housing upward to disengage the mounts from the stanchions.

5. Where the headlamp and dash wire harness exits the PDC, remove the tape that secures the wire harness to the trough formation on the PDC housing lower cover.

6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latches (2) on each side of the PDC housing that secure the housing lower cover (3) to the PDC and remove the housing lower cover.

PDC B+ TERMINAL MODULE

REMOVAL




1. Remove the PDC housing lower cover.

2. From the top of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches that secure the B(+) terminal module in the PDC.

3. Gently and evenly press the two B(+) terminal studs down through the bus bar in the PDC.

4. From the bottom of the PDC housing, remove the B(+) terminal module from the PDC.

PDC RELAY WEDGE

REMOVAL




1. Remove the PDC housing lower cover.

2. Remove each of the relays from the PDC relay wedge (1) to be removed.

3. From the bottom of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches (yellow) that secure the relay wedge (1) to the PDC relay cassette (2).

4. From the top of the PDC housing, remove the relay wedge (1) from the PDC relay cassette (2).

PDC RELAY CASSETTE

REMOVAL






CAUTION: Do not remove the wiring and terminals from the terminal cavities of the faulty PDC relay cassette at this time. Refer to the Assembly procedure that follows for the proper procedures for transferring the wiring and terminals to the replacement PDC relay cassette.

1. Remove the relay wedge from the PDC relay cassette to be removed.

NOTE: It may be necessary to remove relay cassettes that are not being serviced from the PDC housing in order to obtain sufficient clearance to access the faulty relay cassette. The same service procedure is repeated as necessary to remove each of the interfering relay wedges and relay cassettes from the PDC housing.

2. From the top of the PDC housing, use a small screwdriver or a terminal pick tool (2) (Special Tool Kit 6680) to release the two latches (1) that secure the relay cassette (3) in the PDC.

3. Gently and evenly press the relay cassette (3) down through the PDC housing.




4. From the bottom of the PDC housing (1), remove the relay cassette (2) from the PDC.
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