Manufacturer: Chrysler (FCA US LLC)
An intermittent loss of power to electrical components could cause a vehicle to stall without warning, increasing the risk of a crash.
The recall began on October 21, 2015.
Owners may contact Chrysler customer service at 1-800-853-1403.
Chrysler’s number for this recall is R24.
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Revised May 2016
Dealer Service Instructions for:
Safety Recall R24 / NHTSA 15V-470 Power Distribution Center Electrical Connector
NOTE: This recall applies only to the above vehicles built from January 01, 2014 through September 23, 2014 (MDH 010100 through 092323).
|IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.|
The Power Distribution Center (PDC) electrical connector on about 77,700 of the above vehicles may have spread electrical terminal(s). A spread electrical terminal(s) could cause intermittent electrical connection(s) to certain electrical components. This may result in an engine stall or a shift to neutral event. Either of these conditions may cause a crash without warning.
The PDC electrical connector must be replaced.
|CBJ0R242AA||Electrical Connector Package (3.6 liter engine)|
|Each package contains the following components:|
|8||Splice Band and Heat Shrink Tube (small)|
|4||Splice Band and Heat Shrink Tube (medium)|
|1||Splice Band and Heat Shrink Tube (large)|
|Each dealer to whom vehicles in the recall were assigned will receive enough Electrical Connector Packages to service about 20% of those vehicles.|
|CBJ0R241AA||Harness, Electrical Wiring (2.4 liter engine) (without Start/Stop)|
|CBJ0R243AA||Harness, Electrical Wiring (2.4 liter engine) (with Start/Stop) (sales code XBU)|
|Each dealer to whom vehicles in the recall were assigned will receive enough Electrical Wiring Harnesses to service about 20% of those vehicles.|
|06016076||Strap, Plastic Tie|
Part return may be requested by FCA. Please ensure that wiring and connector is not probed or altered and check “Return Material Utility” in DealerCONNECT for part return instructions.
The following special tools are required to perform this repair:
- Open the hood.
- Remove and save the battery (Figure 1).
Figure 1 – Battery
- Remove and save the Z-case fuse array retaining nut (Figure 2).
Figure 2 – Z-Case Fuse Array Retaining Nut
- Disengage the Z-case fuse array retaining clips and separate the Z-case fuse array assembly from the PDC (Figure 3).
Figure 3 – Z-Case Fuse Array Assembly
- Disconnect the white electrical connector from the PDC (Figure 4).
- Loosen the three PDC retaining bolts (Figure 5).
Figure 5 – PDC Retaining Bolts
Figure 6 – PDC Top Cover
- Carefully disconnect the three PDC electrical connectors from the bottoms side of the PDC top cover.
- Locate the correct PDC electrical connector that is being replaced (Figure 7).
- Remove and discard the PDC electrical connector white plastic back cover (Figure 8).
- Remove the wire harness tape all the way back to the main wire harness (Figure 9).
Figure 9 – Wire Harness Tape
- For All Wheel Drive vehicles, there are two additional wires for the All Wheel Drive (AWD) system (red wire with a dark green trace and pink wire with a light green trace).
One of the additional wires for AWD is the same color and has the same trace strip (pink with green trace) as two other wires in the PDC electrical connector (Figure 10). Cut and splice the AWD pink with green trace wire first to prevent splicing the wrong wires together (Figure 10).
NOTE: The other two wires that have same color and have the same tracer strip (pink with green trace) are interchangeable with each other (Figure 10). Only the AWD pink with green trace wire has a dedicated cavity in the PDC electrical connector.
CAUTION: Only cut and splice one wire at a time.
SPECIAL NOTE: All repair kits will identify the pink with green trace AWD wire with a paper tag (“AWD ONLY”) and some of the repair kits will identify both of the AWD wires with a paper tags (depending on repair kit build date).
- For Vehicles not equipped with AWD, there are two additional wires for the All Wheel Drive (AWD) system (red with a dark green trace wire and pink with a light green trace wire) that will not be used (Figure 11).
The two wires used on AWD vehicles on the new electrical connector will not be connected and must be taped back to the wire harness after all other wire splices are complete.
NOTE: There are two wires that have same color and have the same tracer strip (pink with green trace) (Figure 11). They are interchangeable when being spliced to the original wire harness. As long as the wire colors on the new connector match the wire colors on the original wire harness, orientation of these two wires to the original wire harness is not connector cavity specific.
NOTE: The new wire harness connector will have a tag identifying the AWD wire (pink with green trace).
SPECIAL NOTE: Some repair kits contain a new wire harness connector that only has the pink with green trace wire identified with a tag.
CAUTION: Only cut and splice one wire at a time.
Figure 11 – AWD Wires Not Being Used and Must Be Taped Back to the Wire Harness
- Use the following procedure to splice the wires together:
NOTE: Stagger the wire splices to prevent having a large “ball” of wire splices in one location on the wire harness.
a. Strip approximately 10 – 15mm of insulation from the end of the wires.
b. Place the black shrink tube provided in the repair kit over the cut wires (Figure 12).
c. Using the supplied splice band clamps and crimp tool 10042, crimp the wires that had the insulation stripped on the wire harness side to the matching color wire (Figure 12).
d. Solder the crimps with rosin core solder (Figure 13).
Figure 14 – Shrink Tube
f. Repeat Step 6a through 6e on each wire that requires splicing (Figure 15).
CAUTION: Be sure to stagger the splice joints to prevent a large “ball” of wire splices in one location on the wire harness.
Figure 16 – Wrap Wire Harness Splices with Tape
- Place the new connector into position in the PDC tray.
- Snap the PDC top cover into position.
- Hand start the three PDC cover retaining bolts and tighten securely.
- Connect the white electrical connector to the PDC.
- Install the Z-case fuse array retaining nut. Tighten the nut securely.
- Verify the routing of the repaired wire harness. Be sure that wire harness is not in contact with any hot or moving parts that could cause chaffing of the wires and/or other underhood components.
- Install the positive battery cable clamp to the positive battery post. Tighten the positive battery cable clamp to 80 in. lbs. (9 N·m).
- Install the negative battery cable clamp to the negative battery post. Tighten the negative battery cable clamp to 80 in. lbs. (9 N·m).
- Install a plastic tie strap as shown in Figure 17 to prevent the wire harness from sagging onto the transaxle.
- Cut off plastic tie strap tail (Figure 18)
Figure 18 – Cut off Tie Strap Tail
- Continue with Section C. Electronic Power Steering Verification
NOTE: Study the wire harness routing before removing the original wire harness. The new harness must be routed in the same locations as the original wire harness.
- Place the vehicle in position to be lifted by an appropriate hoist.
- Disconnect and isolate the negative battery cable (Figure 19).
- Remove and save the Power Distribution Cover (PDC) (Figure 19).
- Remove and save the plastic engine cover (Figure 19).
- Remove and save the number one stud wire terminal retaining nut on the Z-case fuse array (Figure 20).
- Remove and save the Z-case fuse array retaining nut (Figure 20).
- Disengage the Z-case fuse array retaining clips and separate the Z-case fuse array assembly from the PDC (Figure 20).
- Disconnect the white electrical connector from the PDC (Figure 20).
- Loosen the three PDC retaining bolts (Figure 20).
- Detach the wire harness push pins from the retaining bracket.
- Disconnect the wire harness ground terminal from the transaxle case (Figure 21).
- Remove and save the wiring harness bracket (Figure 21).
- Disconnect the wiring harness push pins at the transaxle bellhousing.
- Disconnect the coolant tube bracket.
- Disconnect the transaxle control module connector.
- Lift the vehicle on the hoist.
- Remove and save the underbody splash shield (Figure 22).
Figure 22 – Underbody Splash Shield
- Disconnect the starter motor electrical connectors.
- Lower the vehicle from the hoist.
- Carefully remove and discard the original wire harness assembly from the vehicle.
- Place the original wire harness next to the new wire harness and verify that all the electrical connectors are the same (Figure 23).
- Place the new wire harness into position.
- Raise the vehicle on the hoist.
- Connect the starter motor electrical connectors.
- Connect the power steering electrical connectors at the steering gear.
- Install the underbody splash shield.
- Connect the transaxle control module connector.
- Connect the coolant tube bracket.
- Connect the wiring harness push pins at the transaxle bellhousing.
- Install the wiring harness bracket.
- Connect the wire harness ground terminal from the transaxle case.
- Connect the wire harness push pins to the retaining bracket.
- Snap the Power Distribution tray into position and install the three retaining bolts and tighten securely.
- Disconnect the white electrical connector from the PDC.
- Place the Z-case fuse array into position.
- Install the Z-case fuse array retaining nut and tighten securely.
- Place the B+ terminal on the number one stud.
- Install the number one stud wire terminal retaining nut and tighten securely.
- Install the Power Distribution Cover (PDC).
- Verify the new wire harness routing to ensure that it is routed correctly.
- Install the plastic engine cover.
- Continue with Section C. Electronic Power Steering Verification
C. Electronic Power Steering Verification Test
- Verify all accessories are turned off, the battery is fully charged and the charging system has a status of “charged”.
- Verify that the ignition is “ON”.
- Connect the wiTECH scan tool and start a session.
- Using the wiTECH scan tool, record and then erase all Diagnostic Trouble Codes (DTCs) from all modules.
- Start the engine and allow it to run for two minutes.
- Turn the steering wheel from stop-to-stop twice, holding at each stop position for one second. Then return the steering wheel to the straight ahead position.
- Turn the ignition “OFF” and wait five minutes.
- Turn the ignition on and using the scan tool, read DTCs from all modules.
- If there are no DTCs present after turning ignition “ON”, road test the vehicle for at least five minutes.
- Again, with the scan tool read If there are no DTCs present after the road test, the repair is complete.
- Remove the wiTECH scan tool from the vehicle.
- Return the vehicle to the customer.
Complete Proof of Correction Form for California Residents
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by FCA to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
|Replace PDC electrical connector (3.6L engine)||08-R2-41-82||1.5 hours|
|Replace transaxle wire harness with electrical connector (2.4L engine)||08-R2-41-83||1.9 hours|
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to FCA are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.
To use this system, click on the “Service” tab and then click on “Global Recall System.” Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC
POWER DISTRIBUTION CENTER ELECTRICAL CONNECTOR
IMPORTANT SAFETY RECALL
R24 / NHTSA 15V-470
This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Dear: (Name)
FCA has decided that a defect, which relates to motor vehicle safety, exists in certain 2015 model year Chrysler 200 vehicles.
|The problem is…||The Power Distribution Center (PDC) electrical connector on your vehicle may have spread electrical terminal(s). A spread electrical terminal(s) could cause intermittent electrical connection(s) to certain electrical components. This may result in an engine stall or a shift to neutral event. Either of these conditions may cause a crash without warning.|
|What your dealer will do…||FCA will repair your vehicle free of charge. To do this, your dealer will replace the PDC electrical connector. The work will take about two hours to complete. However, additional time may be necessary depending on service schedules.|
|What you must do to ensure your safety…||Simply contact your Chrysler, Jeep, Dodge or RAM dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Please bring this letter with you to your dealer.|
|If you need help…
|If you have questions or concerns which your dealer is unable to resolve, please contact the FCA Group Recall Assistance Center at either fcarecalls.com or 1-800-853-1403.
The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the recall has been performed.
Please help us update our records by filling out the attached prepaid postcard if any of the conditions listed on the card apply to you or your vehicle. If you have further questions go to fcarecalls.com.
If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online or you can mail your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you’ve had previous repairs and/or reimbursement you may still need to have the recall repair performed on your vehicle.
If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov.
We’re sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter.
Customer Services / Field Operations
FCA US LLC
Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.