Brakes - ABS DTCs 34/35/27/28, When Driving in the Rain
BULLETIN NO.: 96-T-17AISSUE DATE: May, 1997
GROUP/SEQ. NO.: Chassis-02
CORPORATION NO.: 685004R
SUBJECT:
ABS DTCs 34 or 35 (Possibly with ABS DTCs 27 or 28) Set When Driving in the Rain or Through Standing Water (Replace Affected Rear Wheel Speed Sensor Connector)
This bulletin is being revised to change a service part number for the ABS rear wheel speed sensor connector kit and revise service procedures, and supercedes bulletin 96-T-17, which should be discarded.
MODELS AFFECTED:
1996 Saturns equipped with ABS brakes built up to and including:
^ VIN TZ265458-Sedans and Coupes
^ VIN TZ2935OO-Wagons
CONDITION:
Some customers may comment on an intermittent ABS light. Diagnostic trouble codes (DTCs) 34 (left rear wheel speed sensor circuit fault) or 35 (right rear wheel speed sensor fault) may be set. Also DTC 27 may be set with DTC 34 or DTC 28 may be set with DTC 35. These DTCs may only set while driving in the rain or driving through standing water.
CAUSE:
Insulation on wires to rear wheel speed sensor(s) may have been chafed or cut when harnesses were built, causing an intermittent short to ground in circuits 884 or 885 for DTC 34, or 882 or 883 for DTC 35. The chafe or cut can be located between 38 to 191 mm (1.5 to 7.5 in.) from the back of the rear wheel speed sensor connector.
CORRECTION:
Refer to procedures to verify chafe or cut in wiring insulation. If a chafe or cut is found, replace corresponding rear wheel speed sensor connector with connector ABS rear wheel speed sensor kit (P/N 21024043).
PROCEDURES
1. If the DTC is:
a. 34 - Disconnect left rear wheel speed sensor connector.
b. 35 - Disconnect right wheel speed sensor connector.
2. Carefully remove conduit from the conduit clamp.
3. Carefully remove the first conduit/harness retainer installed in the lateral link. (It can be removed by compressing the tangs, located under the retainer head.)
4. Open connector strain relief clip located at back of connector.
5. Carefully pull wires from the conduit and inspect for chafed and/or cut wires. (Chafing and/or cuts may be found anywhere between 38 to 191 mm [1.5 to 7.5 in.] from the back of the wheel speed sensor connector.)
IMPORTANT:
Inspect opposite wheel speed sensor circuit at the same location for chafed and/or cut insulation, prior to releasing vehicle to customer, and repair if necessary
6. If chafed and/or cut wires are evident, refer to next step. If there is no sign of chafed or cut wires, refer to "1996 Brakes Service Manual" for proper diagnosis.
IMPORTANT:
If corrosion is evident on the conductors, trim in 304 mm (12 in.) increments until no corrosion is found in wiring. The ABS wheel speed sensor connector kit is 2300 mm (90 in.) long and should be of sufficient length to perform this repair anywhere in the rear compartment area.
7. Using the ABS rear wheel speed sensor connector kit (P/N 21024043):
^ On Sedan and Coupe
a. Open rear compartment lid.
b. Pull back the left rear wheel house carpet to gain access to the ABS wheel speed sensor harness.
c. Cut the wheel speed sensor harness in the area just behind the wheel house and go to step 8.
^ On Wagon
a. Open rear liftgate.
b. Remove left rear wheel house trim panel assembly to gain access to the ABS wheel speed sensor harness.
c. Cut the wheel speed sensor harness in the area just behind the wheel house and go to step 8
8. From outside the vehicle, thread the wire from the ABS rear wheel speed sensor connector kit through the grommet into the rear compartment area.
9. Splice the wires using the Saturn approved Packard crimp and seal splices. Use the Salmon/pink color, OTC P/N 217670, found in the Saturn Wire Repair Kit, and stagger the two splices. (Staggering the splices allows the wiring to fit back into the conduit.)
10. Install left rear wheel house carpet (Sedan or Coupe), or left rear wheel house trim panel assembly (Wagon).
11. Carefully install wiring back into conduit.
NOTICE:
Conduit/wiring harness must be routed exactly as it was before removal and repair. Failure to correctly route conduit may cause damage to the conduit and/or wiring harness.
12. Install conduit/harness retainer into lateral link.
13. Secure connector strain relief clip and connect wheel speed sensor connector to wheel speed sensor.
14. Clear diagnostic trouble codes and verify that condition has been repaired.
PARTS REQUIREMENTS:
21024043 Connector Kit-ABS Rear Wheel Speed Sensor
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code H2534-Right Rear and/or H2535-Left Side.