Campaign W48 – Power Transfer Unit Input Splines – Two-Speed Power Transfer Units (PTU)

June 11, 2020 NHTSA CAMPAIGN NUMBER: 20E037000

Power Transfer Input Splines May Break

A loss of drive can cause a vehicle crash without prior warning. A loss of the Park function can cause unintended vehicle rollaway which can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 20E037

Manufacturer Chrysler (FCA US LLC)

Components POWER TRAIN

Potential Number of Units Affected 2,669

 

Summary

Chrysler (FCA US LLC) is recalling certain Two-Speed Power Transfer Units (PTU) sold as replacement parts for certain Jeep Cherokee vehicles, part numbers 68090605AJ, 68090605AK, 68090605AL, 68282447AA, 68282447AB, 68282447AC, 68307403AA and 68307403AB. Relative movement in the Power Transfer Unit (PTU) between the differential input splines and the transmission output shaft may cause some input spline teeth to wear off, which may eventually cause a loss of engagement between the transmission and the differential inside the PTU. If this occurs, power cannot be transferred between the front wheels and the transmission which results in a loss of drive while the vehicle is in motion and a loss of the Park function while stationary.

 

Remedy

FCA US LLC will notify owners, and dealers will perform a software update that will maintain vehicle propulsion by engaging rear wheel drive and prevent rolling in Park by activating the electronic parking brake if a failed input spline occurs. If the subject part is not installed in a vehicle, it will be exchanged with a new part. All repairs will be conducted free of charge. This recall began July 16, 2020. Owners may contact FCA USA LLC customer service at 1-800-853-1403. FCA’s number for this recall is W48.

 

Notes

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.

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New Safety Recall Advanced Communication – W48

FCA US LLC (FCA US) has announced an equipment safety recall on some Power Transfer Units (PTUs) (part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB).

 

REASON FOR THIS SAFETY RECALL

Some Power Transfer Units (part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB) may have been built to allow movement in the PTU between the differential input splines and the transmission output shaft. This condition may result in the teeth of the input splines wearing off, which may eventually cause a loss of engagement between the transmission and the differential inside the PTU. If this occurs, torque cannot be transferred between the front wheels and the transmission, which will result in a loss of motive power while the vehicle is in motion and a loss of the PARK function while stationary. A loss of motive power or PARK function can cause a vehicle crash without prior warning and/or injury to others outside the vehicle.

 

SERVICE ACTION

FCA US will conduct a Voluntary Safety Recall to reprogram any affected vehicles with software for the Drive Train Control Module (DTCM) and the Electric Park Brake (EPB) that will maintain vehicle propulsion by engaging rear wheel drive and prevent rolling in PARK by activating the electric park brake if a failed input spline occurs. If the subject part is not installed in a vehicle, it will be exchanged with a new part. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 3rd Quarter of 2020.

 

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July 2020

Dealer Service Instructions for:

Safety Recall W48 / NHTSA 20E-037 PTU Input Spline – Equipment

 

Subject

About 2650 Power Transfer Units (part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB) may have been built to allow movement in the PTU between the differential input splines and the transmission output shaft. This condition may result in the teeth of the input splines wearing off, which may eventually cause a loss of engagement between the transmission and the differential inside the PTU. If this occurs, torque cannot be transferred between the front wheels and the transmission, which will result in a loss of motive power while the vehicle is in motion and a loss of the PARK function while stationary. A loss of motive power or PARK function can cause a vehicle crash without prior warning and/or injury to others outside the vehicle.

 

Repair

If the PTU the owner purchased has not been installed, exchange it for a new one.

If the PTU has been installed, reprogram the affected vehicle with software for the Drive Train Control Module (DTCM) and the Electric Park Brake (EPB) that will maintain vehicle propulsion by engaging rear wheel drive function and prevent rolling in the PARK selection by activating the electric park brake if a failed input spline occurs.

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that reprogramming is required and the vehicle must be held overnight.

 

Parts Information

If exchanging the part over the counter, use the following part number.

 

Recalled parts: part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB.

 

Parts Return

Core return is required for this campaign. Return the PTU to the MOPAR Core Return Center for core credit.

 

Special Tools

The following special tools are required to perform this repair:

 

 

Service Procedure

NOTE: This flash procedure is for vehicles that have had a recalled PTU installed. The flash is designed for 2014-2017 (KL) Jeep_ Cherokee.

 

NOTE:  This recall applies only to the above vehicles equipped with a Power Transfer Unit (PTU) (sales code DK4).

 

IMPORTANT:  Some of the involved vehicles may be in dealer used vehicle inventory.  Dealers should complete this recall service on these vehicles before retail delivery.  Dealers should also perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

A.  Drive Train Control Module (DTCM)

 

NOTE: The wiTECH scan tool must be used to perform this recall.  If the reprogramming flash for the DTCM or EPB is aborted or interrupted, repeat the procedure. 

 

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts.  Do not allow the charger to time out during the flash process.  Set the battery charger timer (if so equipped) to continuous charge.

 

NOTE:  Use an accurate stand-alone voltmeter.  The battery charger volt meter may not be sufficiently accurate.  Voltages outside of the specified range will cause an unsuccessful flash.  If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

 

2. Connect the wiTECH micro pod II to the vehicle data link connector.

 

3. Place the ignition in the “RUN” position.

 

4. Open the wiTECH 2.0 website.

 

5. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen.  Click “Accept”.

 

6. From the “Vehicle Selection” screen, select the vehicle to be updated.

 

7. From the “Action Items” screen, select the “Topology” tab.

 

NOTE: The DTCM must be at the latest software calibration level after completing this recall.

 

8. From the “Topology” tab, select the “DTCM” module icon.

 

9. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU) Part Number” with the “New ECU Part Number” listed.
   • If the “Current ECU part Number” is the same as the “New Part Number”, proceed to Step B. Electric Park Brake.
   • If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 10.

 

10. From the DTCM tab, select the DTCM flash part number. Read the flash special instructions page.  Select “OK” to continue.

 

11. From the flash ECU agreement page, agree to terms by checking the box.

 

12. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.

 

13. Confirm the software is at the latest available calibration level.

 

14. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click “Close”.

 

B.  Electric Park Brake (EPB)

 

1. Go back one page to the Topology screen.

 

NOTE: The EPB must be at the latest software calibration level after completing this recall.

 

2. From the “Topology” tab, select the “EPB” module icon.

 

3. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU) Part Number” with the “New ECU Part Number” listed.
   • If the “Current ECU part Number” is the same as the “New Part Number”, proceed to Step 9.
   • If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 4.

 

4. From the EPB tab, select the EPB flash part number. Read the flash special instructions page.  Select “OK” to continue.

 

5. From the flash ECU agreement page, agree to terms by checking the box.

 

6. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.

 

7. Confirm the software is at the latest available calibration level.

 

8. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click “Close”.

 

9. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.

 

10. Remove the battery charger from the vehicle.

 

11. Close the vehicle hood.

 

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1 Affected Product

Equipment

 

 

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11 Associated Documents

Owner Notification Letter(Part 577)

RCONL-20E037-1565.pdf 370.425KB

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Defect Notice 573 Report

RCLRPT-20E037-9440.PDF 220.108KB

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Recall Acknowledgement

RCAK-20E037-4926.pdf 245.059KB

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Manufacturer Notices(to Dealers,etc) – Media Release re safety recall on some Power Transfer Units (PTUs) (part numbers 68090605AJ, 68090605AK, 68090605AL, 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB)

RCMN-20E037-4502.pdf 200.702KB

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Remedy Instructions and TSB – Dealer Service Instructions re Safety Recall W48 / NHTSA 20E-037 PTU Input Spline – Equipment

RCRIT-20E037-4749.pdf 641.248KB

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Recall Quarterly Report #2, 2020-4

RCLQRT-20E037-9644.PDF 211.234KB

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Recall Quarterly Report #1, 2020-3

RCLQRT-20E037-6724.PDF 211.138KB

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Recall Quarterly Report #4, 2021-2

RCLQRT-20E037-4109.PDF 211.426KB

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Recall Quarterly Report #3, 2021-1

RCLQRT-20E037-6111.PDF 211.323KB

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Recall Quarterly Report #5, 2021-3

RCLQRT-20E037-5672.PDF 211.537KB

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Recall Quarterly Report #6, 2021-4

RCLQRT-20E037-6424.PDF 211.631KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20E037&docType=RCL

 

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