January 2005

Dealer Service Instructions for:

Emissions Recall D46

Reprogram PCM – OBD Fuel System Monitor
Models

2005 (DR) Dodge Ram Pick Up Truck

(KJ) Jeep® Liberty
(ND) Dodge Dakota
NOTE: This recall applies only to the above vehicles equipped with a 3.7L engine and built
through September 24, 2004 (MDH 092421).

2005 (PT) PT Cruiser

NOTE: This recall applies only to the above vehicles equipped with a 2.4L engine and built
through September 22, 2004 (MDH 092216).

2005 (WK) Jeep Grand Cherokee

NOTE: This recall applies only to the above vehicles equipped with a 3.7L engine and built
through September 22, 2004 (MDH 092206).

2005 (TJ) Jeep Wrangler

NOTE: This recall applies only to the above vehicles equipped with a 4.0L engine, manual transmission
and built through September 24, 2004 (MDH 092406).

2005 (PL) Neon SRT4

NOTE: This recall applies only to the above vehicles built through September 23, 2004
(MDH 092306).

IMPORTANT: Many of the vehicles within the above build periods have already
been inspected or repaired and, therefore, have been excluded from this recall.

IMPORTANT: Some of the involved vehicles may be in dealer new 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.

 Copyright 2005, DaimlerChrysler Corporation, All Rights Reserved

Emissions Recall D46 Page 2
Reprogram PCM – OBD Fuel System Monitor

Subject

The Powertrain Control Module (PCM) on about 61,000 of the above vehicles was
inadvertently programmed with incorrect software. This can cause the On Board
Diagnostic (OBD) fuel system monitor to malfunction.

Repair

The PCM must be reprogrammed (flashed).

Parts Information

Due to the likelihood that the required labels are already in your parts inventory, no
labels will be distributed initially. The following label may be ordered as needed.
Each vehicle requires application of the following label:
Part Number Description
04275086AB Authorized Modifications Label

Special Tools

The following existing special tools may be required to perform this repair:

CH9401* StarSCAN Tool

CH9404* StarSCAN Vehicle Cable

CH9409* StarSCAN Documentation Kit

CH9410* StarSCAN Ethernet Cable 12 ft.

CH9412* StarSCAN Software Update Device Kit

NPN TechCONNECT PC

NPN StarSCAN Software Update CD

NPN DRB III Scan Tool

CH7000A Flash Cable

CH7035B Data Cable
* Part of CH9400 kit.
Emissions Recall D46 Page 3
Reprogram PCM – OBD Fuel System Monitor

Service Procedure

A. Reprogram the PCM (DR / KJ / PT / TJ / PL Models):

The DealerCONNECT System, DRBIII (Diagnostic Readout Box scan
tool), CH7000A flash cable and CH7035B data cable are required to
perform this repair. Do not attempt to perform the flash procedure using an
outdated CH7000/CH7001 flash cable.
NOTE: Whenever a controller is reprogrammed, the software in the
DRBIII scan tool must be programmed with the latest revision level
available.
NOTE: If the flash process is interrupted or aborted, the flash should be
restarted and then follow the directions on the DRBIII scan tool.
1. Open the hood, install a battery charger and verify that the charging rate provides
approximately 13.5 volts.

2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data
link connector located inside the vehicle under the steering column.

3. Connect the CH7035B data cable from the DealerCONNECT machine to the
MDS port on the DRBIII scan tool.

4. Place the vehicle’s ignition key in the “RUN” position.

5. From the DealerCONNECT “WELCOME” screen, enter your “User I.D.,”

“Password” and “Dealer Code”.

6. From the DealerCONNECT “HOME PAGE” select the “SERVICE” tab.

7. From the “SERVICE” tab screen select “TechTOOLS”.

8. If the DRBIII scan tool does not “Auto Connect” select #2 on the DRBIII key
pad “Connect to TechCONNECT”.

9. After the “Auto Connect” process is complete, select “READ PART

NUMBER(S) FROM VEHICLE” on the TechCONNECT screen.
Emissions Recall D46 Page 4
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

10. Continue following the TechCONNECT on-screen instructions.

11. Select the applicable update calibration.

12. Select the “DRBIII” button located at the bottom of the TechCONNECT
monitor screen.

13. Select the “DOWNLOAD / UPDATE” button located next to the “DRBIII” button.
NOTE: The system software will automatically download to the DRBIII
scan tool.

14. After the software download to the DRBIII scan tool is complete, close the
“FLASH DOWNLOAD / UPDATE PROGRESS” window.

15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable.

16. Select #1 “RETURN TO NORMAL MODE” on the DRBIII scan tool.

17. Use the following procedure to download the flash from the DRBIII scan tool
to the vehicle.
a. Select #7 “VEHICLE FLASH” on the DRBIII scan tool.
b. Follow the directions displayed on the DRBIII scan tool screen.
c. After the reprogramming is complete, record the new module part number
displayed on the DRBIII scan tool screen.
d. Press the “PAGE BACK” button on the DRBIII scan tool.
e. Follow the directions displayed on the DRBIII scan tool screen.
Emissions Recall D46 Page 5
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

18. Due to the PCM flash procedure, Diagnostic Trouble Codes (DTC’s) may be set
in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if
so equipped). Some DTC’s may cause the Malfunction Indicator Light (MIL) to
illuminate. All of the DTC’s relate to a loss of communications with the module
that is being flashed. Check all modules, record the trouble codes, and erase the
trouble codes using the following procedure:
a. Turn the vehicle’s ignition key to the “RUN” position
b. From the DRBIII scan tool Main Menu select #1 “DRBIII Stand-Alone”.
c. From the DRBIII scan tool Stand-Alone menu select #3 “Vehicle Module Scan”.
d. From the DRBIII scan tool Vehicle Module Scan menu select #1
“1998 - 2005 Module Scan”.
e. Select “YES” on the DRBIII scan tool key pad to scan for DTC’s.
f. Follow the instructions on the DRBIII scan tool screen.
g. Once the scanning process is complete, the DRBIII scan tool will display a
list of all the modules. Modules on the list that have an asterisk next to
them have DTC’s that need to be cleared.
h. Select the module that needs to have the DTC’s cleared and follow the
instructions on the DRBIII scan tool screen to clear the DTC’s.
NOTE: Erase any DTC’s in the PCM only after all other modules have
had their DTC’s erased.
i. Turn the vehicle’s ignition key to the “OFF” position.

19. Disconnect the DRBIII scan tool from the vehicle.

20. Turn off the battery charger, disconnect it from the vehicle and then continue
with Section C – Install the Authorized Modifications Label.
 Emissions Recall D46 Page 6
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

B. Reprogram the PCM (ND and WK Models)

There are two methods which can be used to retrieve the flash file required to reprogram
the PCM. The flash file can be accessed using the internet (accessed through the
DealerCONNECT portal) or by using the StarSCAN Software Update Compact Disc
(CD). Either method is acceptable to complete this notification.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

Method I. Reprogram the PCM Using the DealerCONNECT Internet

System to Retrieve the Flash File:

NOTE: The DealerCONNECT System, StarSCAN Tool (CH9401), StarSCAN

Vehicle Cable (CH9404) and StarSCAN Ethernet Cable (CH9410) are required
to use this programming method.
CAUTION: The StarSCAN must be at version 4.06 or higher before this
procedure can be performed.
NOTE: The StarSCAN diagnostic scan tool fully supports DealerCONNECT
Internet connectivity. However, in order to take advantage of this feature you
must first configure the StarSCAN for your dealership’s network. For
instructions on setting up your StarSCAN for the dealer’s network; refer to the
StarSCAN Quick Start Networking Guide available on the www.dcctools.com
website under the “download center” link.

1. Use the following procedure to determine the PCM part number:

a. Connect the StarSCAN to the vehicle data link connector located under the
steering column.
b. Power ON the StarSCAN.
c. From the StarSCAN Home Screen, select “ECU View”.
d. From the StarSCAN ECU View Screen, select “PCM/NGC Engine”.
e. Record the PCM part number shown on the StarSCAN screen.
IMPORTANT: The PCM part number recorded will be used to select the
correct software. Be sure to record the part number exactly as it is shown.
Emissions Recall D46 Page 7
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer’s
network drop.
3. Download the flash file from the internet to the StarSCAN. Starting at the
StarSCAN “Home” screen:
a. Select “Flash Download”.
b. On the flash update text box, select “Enter Information Manually”.
c. Press the “Next” button.
d. Select “By Part Number” and then press next.
e. Press the “Show Keyboard” button and then enter the PCM part number
recorded in Step 1e of this procedure.
f. Press next and then follow the screen instructions.
g. Select the file shown on the screen.
h. Press the “Download to Scan Tool” button on the StarSCAN.

4. Install a battery charger and verify that the charging rate provides approximately
13.5 volts.
5. Press the “Show Shortcuts” key and then press the “Home” key to return to the
“Home” screen.
6. Download the file from StarSCAN to the vehicle. Starting at the StarSCAN
“Home” screen:
a. Select “ECU View”.
b. Browse the list of controllers using the scroll arrows. Highlight “PCM/NGC III.”
c. Select “More Options”.
d. Select “ECU Flash”.
e. Highlight the calibration shown on the screen.
f. Select “Update Controller”.
g. Follow the on-screen instructions and perform prompts as required.
h. When update is completed, select “OK”.
 Emissions Recall D46 Page 8
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

7. Check all modules for Diagnostic Trouble Codes (DTC’s).

NOTE: Due to the PCM programming procedure, a DTC may be set in
other modules (TCM, FCM, CCN, WCM, etc.) within the vehicle, if so
equipped. Some DTC’s may cause the MIL to illuminate. Check all modules
using “ECU View” from the ”Home” screen, record the DTC’s, and erase
these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s
in the PCM only after all other modules have had their DTC’s erased.

8. Continue with Section “C”- Install the Authorized Modifications Label.

Method II. Reprogram the PCM Using StarSCAN Update CD (ND and
WK Models):

NOTE: The software update CD being used must be at level 4.07 or higher.
1. Use the following procedure to determine the PCM part number:
a. Connect the StarSCAN to the vehicle data link connector located under the
steering column.
b. Power ON the StarSCAN.
c. From the StarSCAN Home Screen,
select “ECU View”.
d. From the StarSCAN ECU View
Screen, select “PCM/NGC Engine”.
e. Record the PCM part number shown
on the StarSCAN screen.
IMPORTANT: The PCM part
number recorded will be used to
select the correct software. Be
sure to record the part number
exactly as it is shown.
2. Insert the USB key into the USB port
on the TechCONNECT PC (Figure 1). Figure 1
 Emissions Recall D46 Page 9
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

3. Press the button located below the

CD/DVD ROM drive to open the
drive. Insert the StarSCAN
Software Update CD into the
TechCONNECT PC and press the
button again to close the ROM
drive. The StarSCAN Software
Update CD will start automatically.

4. Select “Controller Flash”.

5. Select “Enter Part Number”.

6. Enter PCM part number recorded in

Step 1e of this procedure and then
press next. Figure 2

7. Select the update shown on the screen and press next.

8. Follow the on-screen instructions. Select “Next” after each step. Select “Finish”
after completing the last step.

9. With the StarSCAN powered OFF, connect the USB Key and adapter to the
StarSCAN USB port (Figure 2).

10. Install a battery charger and verify that the charging rate provides approximately
13.5 volts.

11. Connect the StarSCAN to the data link connector located below the steering column.

12. Turn the ignition key to the “RUN” position.

13. Power ON the StarSCAN.

 Emissions Recall D46 Page 10
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

14. Download the file from the USB key to the StarSCAN. Starting at the StarSCAN
“Home” screen:
a. Select “Flash Download”.
b. Select “Use USB Device”.
c. Follow the on-screen instructions. Select “Next” after each step. Select
“Finish” after completing the last step.
d. At the “Flash File List” screen, highlight the PCM calibration.
e. Select “Download to Scantool”.
f. When download is complete, select “Close”.

15. Return to the “Home” screen.

16. Select “Show Shortcuts”.

17. Select “Home”.

18. Down load the file from the StarSCAN to the vehicle. Starting at the StarSCAN
“Home” screen:
a. Select “ECU View”.
b. Browse the list of controllers using the scroll arrows. Highlight “PCM/NGC III.”
c. Select “More Options”.
d. Select “ECU Flash”.
e. Highlight the PCM calibration shown on the screen.
f. Select “Update Controller”.
g. Follow the on-screen instructions and perform prompts as required.
h. When update is completed, select “OK”.
 Emissions Recall D46 Page 11
Reprogram PCM – OBD Fuel System Monitor

Service Procedure (Continued)

19. Check all modules for Diagnostic Trouble Codes (DTC’s).

NOTE: Due to the PCM programming procedure, a DTC may be set in
other modules (TCM, FCM, CCN, WCM, etc.) within the vehicle, if so
equipped. Some DTC’s may cause the MIL to illuminate. Check all
modules using “ECU View” from the ”Home” screen, record the DTC’s, and
erase these DTC’s prior to returning the vehicle to the customer. Erase any
DTC’s in the PCM only after all other modules have had their DTC’s
erased.

20. Continue with Section “C”- Install the Authorized Modifications Label.

C. Install the Authorized Modifications Label:

1. Type or print (with a ballpoint pen)
the recall number, dealer code and
date on the Authorized Modifications
Label (Figure 3). Reprogram Powertrain Control Module

2. Attach the label near the VECI label RECALL D46

and then close the hood.
Figure 3

D. 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.
Emissions Recall D46 Page 12
Reprogram PCM – OBD Fuel System Monitor

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
DaimlerChrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
PCM Update Previously Performed 08-D4-61-81 0.2 hours
Reprogram Powertrain Control Module 08-D4-61-82 0.8 hours

Add the cost of the label plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section,
for complete recall claim processing instructions.

Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by mail. Two
additional copies will be sent through the DCMMS. To view this recall on
DealerCONNECT, select TechCONNECT on the Service tab, click on “Search for
Service Bulletins”, enter the recall code and then click on the “Search” button.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler 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.
Emissions Recall D46 Page 13
Reprogram PCM – OBD Fuel System Monitor

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.
Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer
recall notification letter.
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.

Additional Information

If you have any questions or need assistance in completing this action, please contact
your Service and Parts District Manager.

Customer Services Field Operations

DaimlerChrysler Corporation
 EMISSIONS RECALL – REPROGRAM PCM
Dear: (Name)
DaimlerChrysler has determined that your vehicle may be equipped with an improperly functioning on-board
emission-related diagnostic system that violates California and Federal standards and regulations. These
regulations were established to protect the public health or welfare from the dangers of air pollution.
The problem is... The Powertrain Control Module (PCM) on your vehicle (VIN: xxxxxxxxxxxxxxxxx)
was inadvertently programmed with incorrect software. This can cause the On-Board
Diagnostic (OBD) fuel system monitor to malfunction.

What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do
will do... this, your dealer will reprogram your vehicle’s PCM with new software. The work
will take about an hour to complete. However, additional time may be necessary
depending on how dealer appointments are scheduled and processed.
What you must Simply contact your dealer right away to schedule a service appointment. Ask the
do... dealer to hold the part for your vehicle or to order it before your appointment.

If you need help... If you have questions or concerns which your dealer is unable to resolve, please
contact DaimlerChrysler at 1-800-853-1403.
Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed
on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN
(VVVVVVVV) and notification code D46 on the postcard.
If you have already experienced this condition and have paid to have it repaired, you may send your original
receipts and/or other adequate proof of payment to the following address for reimbursement:
DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement. Eligibility for
this remedial action may not be denied solely on the basis that you used parts not manufactured by
DaimlerChrysler Corporation, or had repairs performed by outlets other than DaimlerChrysler franchised
dealers.
In order to assure your full protection under the emission warranty provisions, it is recommended that you
have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper
maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission
inspection test.
We are sorry for any inconvenience but trust that you understand our interest in clean air. Thank you for
your attention to this important matter.
Customer Services Field Operations
DaimlerChrysler Corporation
Notification Code D46
Additional Information on Reverse Side for California Residents
If you live in The State of California requires the completion of emission recall repairs
California and don't prior to vehicle registration renewal. In addition, the State requires that every
have this recall vehicle must pass a vehicle inspection or SMOG check every two years and
performed... before it is sold. Without the free service we are providing, your vehicle may be
more likely to fail this test and require that you make costly repairs.

How the state knows State of California regulations require DaimlerChrysler to provide the
that the recall has not Department of Motor Vehicles with a record of all vehicles that have not had the
been performed... recall service performed.

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.
 NUMBER: 23-022-04

GROUP: Body

DATE: June 15, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
Rear Window Lift Glass Seal/Carrier Replacement

OVERVIEW:
This bulletin provides information to allow replacement of the rear window lift glass
seal/carrier instead of replacement of the rear window lift glass assembly.

MODELS:

1997 - 2005 (TJ) Wrangler

NOTE: This bulletin applies to vehicles equipped with a hard top (Sales Code VK0).

SYMPTOM/CONDITION:
The rear window lift glass seal/carrier requires replacement.

PARTS REQUIRED:

Qty. Part No. Description

1 05140675AA Seal/Carrier, Lift Glass
AR (1) NPN Clear Primer (3M #08691 or equivalent)
AR (1) NPN Black Primer (3M #08692 or equivalent)
AR (1) NPN Urethane Adhesive (3M #08690 or equivalent)

REPAIR PROCEDURE:
1. Open the swing gate and raise the rear window lift glass.
2. Close the swing gate.
3. Support the rear window lift glass. Disconnect both lift gate strut rods at the rear
window lift glass.
4. Lower the rear window lift glass onto the spare tire. Protect the glass at point of
contact. This will allow for a convenient work position.
5. Remove the old seal/carrier from the bottom edge of the rear window lift glass. To
assist with removal of the carrier, first peel the weatherstrip from the plastic carrier.
Using a die grinder, split the carrier along the bottom length of the carrier so that the
carrier channel is in two parts (outer and inner). Use a urethane cutting blade to free
the carrier parts from the rear window lift glass urethane.
6. Scrape all existing old urethane from the rear window lift glass.
7. Prime the entire length of the internal groove of the new seal/carrier, p/n 05140675AA,
with clear primer, 3M p/n 08691 or equivalent (Fig. 1).
23-022-04 -2-

8. Pre-prime the bottom 12.7 mm (.5 in.) of the glass on both sides with clear primer, 3M
p/n 08691 or equivalent.
9. Prime the bottom 12.7 mm (.5 in.) of the glass on both sides with black primer, 3M p/n
08692 or equivalent.
10. Place a 6.35 mm (0.25 in) bead of urethane adhesive, 3M p/n 08690 or equivalent, in
the entire length of the groove in the seal/carrier.

Fig. 1 SEAL CARRIER (END VIEW)

1 - SEAL CARRIER GROOVE

2 - WEATHERSTRIP

11. Push the seal/carrier onto the edge of the rear window rear window lift glass. Apply
temporary holding tape and let set for one hour (until the adhesive reaches green
strength).
12. Install both lift gate strut rods.
POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount

23-51-28-91 Carrier, Rear Window Weatherstrip/Seal - 0.5 Hrs.
Replace

FAILURE CODE:

P8 New Part
 NUMBER: 09-013-04

GROUP: Engine

DATE: August 6, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
Gasoline Engine Oil Quality And Viscosity Grades

MODELS:

2005 (ND) Dakota

2005 (CS) Pacifica
2005 (DR) Ram Truck
2005 (HB) Durango
2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2005 (KJ) Liberty
2005 (LX) 300/Magnum
2005 (PL) Neon
2005 (PT) PT Cruiser
2005 (RS) Town & Country/ Caravan/Voyager
2005 (TJ) Wrangler
2005 (WK) Grand Cherokee

NOTE: This information applies to U.S. and Canada markets only.

NOTE: For additional information and vehicles not covered by this Service Bulletin
refer to the service information or the Owner Manual.
09-013-04 -2-

DISCUSSION:
This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines.
This symbol, found on the front of the container, means that the oil quality has been
certified by the American Petroleum Institute (API) (Fig. 1).

Fig. 1 API SYMBOL

Only use API Certified engine oils that meet the requirements of Chrysler's Material
Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification,
that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline
engines, irrespective of model year, should be serviced with API Certified engine oils
meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine
oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the
correct viscosity grade engine oil. The following table contains the correct viscosity grades
for the 2005 model year.

Engine Oil Type

2.0L SOHC 5W-20
2.0L DOHC 5W-30
2.4L DOHC 5W-30
2.4L Turbo 5W-30
2.7L 5W-20 or 5W-30 Check Oil Cap for proper usage
3.3L 5W-20
3.5L 10W-30
3.7L 5W-30
3.8L 5W-20
4.0L 10W-30
4.7L 5W-30
5.7L 5W-20

POLICY:
Information Only.
 NUMBER: 02-006-04

GROUP: Suspension

DATE: August 20, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-02, DATED

JUNE 10, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL
YEARS AND A CHANGE TO THE TJ CROSS-CASTER AND CROSS-CAMBER
SPECIFICATION.

SUBJECT:
Special Offset Ball Joint - Allows Adjustment To Caster And Camber Angles

OVERVIEW:
This bulletin involves the replacement of one or both front upper ball joints when front end
alignment specifications can not be obtained using normal alignment practices.

MODELS:

**2001 - 2005** (TJ) Wrangler

**2001 - 2004** (WG) Grand Cherokee
**2001 - 2004** (WJ) Grand Cherokee
2001 (XJ) Cherokee

SYMPTOM/CONDITION:
The customer may experience a slight lead or drift to either side of the road. This condition
may occur when there is no driver input to the steering system, or when the driver must
maintain a constant input to the steering system in order to maintain a straight ahead
direction of the vehicle.

NOTE: THIS BULLETIN WILL NOT EFFECT SITUATIONS WHERE A LEAD OR DRIFT
CONDITION IS PRESENT ONLY WHEN BRAKING.

DIAGNOSIS:
The front end caster and/or camber angles on certain Jeep vehicles are fixed. For Grand
Cherokee vehicles both the caster and camber angles are non-adjustable (fixed). For
Wrangler and Cherokee vehicles only the camber angle is non-adjustable (fixed). The
offset ball joints listed in this bulletin allow for the adjustment of these “fixed” front end
alignment angles by an amount of up to 1.5 degrees. The offset ball joint should be used
only as required.

It is very important that the following steps are performed in order and prior to any
consideration being given towards the use of an offset ball joint(s).
02-006-04 -2-

1. Verify matching original equipment tires and wheels.

2. Verify correct tire inflation pressures.
3. Inspect for tire condition and abnormal wear. Refer to the appropriate Service Manual,
Section 22 - Tires, for additional diagnostic assistance.
4. Inspect for and correct any worn or damaged steering and front suspension
components.
5. Inspect for and correct any worn or damaged wheel bearings/hubs.
6. Verify that no brake drag is present (front or rear).
7. Road test the vehicle to determine if the slight lead or drift is present and not crown
sensitive. While road testing, verify that the condition is present even when the
transmission is in neutral.
8. If the condition is present, cross switch the front tires. If the condition follows the tires
address the condition with the tire manufacturer.
If a slight lead or drift condition is still present after the above steps have been performed,
perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description

AR 05014876AC Ball Joint - 0.5 degree
AR 05014877AC Ball Joint - 1.0 degree
AR 05016972AC Ball Joint - 1.5 degree

EQUIPMENT REQUIRED:

6289 Kit, Ball Joint Installation and Removal

Four Wheel Alignment Machine

REPAIR PROCEDURE:
WJ / WG Alignment Specifications (See Service Manual for Up-Country Specs.):

ANGLE TARGET RANGE MAX LT. TO RT. DIFF.

CASTER + 6.75° + 6.00° to + 7.50° 0.50°
CAMBER - 0.37° - 0.75° to 0.50° 0.50°
TOE (IN) + 0.20° + 0.14° to + 0.26° 0.06°

TJ Alignment Specifications:

ANGLE TARGET RANGE MAX. LT TO RT DIFF.

CASTER + 7.00° + 6.00° to + 8.00° **0.65°**
CAMBER - 0.25° - 0.88° to + 0.38° **1.0°**
TOE (IN) +0.30° +0.24° to +0.36° 0.06°
 -3- 02-006-04

XJ Alignment Specifications:

ANGLE TARGET RANGE MAX. LT to RT DIFF

CASTER + 7.00° + 5.25° to + 8.50° 0.50°
CAMBER - 0.25° -0.75° to + 0.50° 0.50°
TOE (IN) + 0.20° +0.14° to + 0.26° 0.05°

CAMBER ADJUSTMENT:
**If cross camber (angle/degree difference between sides) is greater than 1.0 degree,
select the wheel furthest from the preferred camber target value and replace that ball joint
with the appropriate offset ball joint listed above. The camber target value of the adjusted
side should equal the unadjusted side, providing a preferred cross camber value of 0.0
degrees. A cross camber of no more than 1.0 degree is allowed but both left and right
camber values must remain within the allowable camber range. Never compensate for drift
with additional cross camber. This could compromise vehicle handling.**

CASTER ADJUSTMENT:
If cross caster is greater than the specifications shown above, utilize the offset ball joint to
reduce the cross caster. If individual caster is above the specifications, utilize the cam or
shim adjustment where possible. Use the offset ball joints if the caster cannot be adjusted
using the other methods. Target caster is shown above if two offset ball joints are used.
Offset ball joints will not effect drive line (front propeller shaft) angles. If caster angles are
changed using shims and cams, always road test the vehicle to verify that no drive line
disturbance has been created. Verify that the steering wheel is centered. Never
compensate for drift with additional cross caster. This could compromise vehicle handling.

NOTE: TO PREVENT ERROR, RE-COMPENSATE THE ALIGNER HEADS EACH TIME

A CHANGE IS MADE TO A SETTING ON THE BALL JOINT.
BALL JOINT INSTALLATION:
1. Support the vehicle and front axle in a manner that will allow for the safe removal and
installation of the respective upper ball joint(s).
2. Remove the tire and wheel assembly.
3. Remove the cotter pin, retainer, and nut used to secure the axle shaft to the wheel
hub/bearing.
4. Mark the brake rotor to the axle hub/bearing for later assembly. This step will help to
minimize brake rotor lateral runout.
5. Remove the two brake caliper slide pins. Remove the brake caliper, pads, and rotor.
6. Properly support the brake caliper. Do not use the brake line to support the caliper.
7. Remove the tie rod from the steering knuckle. Do not damage the boot.
8. Mark the wheel hub/bearing to the steering knuckle for later assembly. This step will
help to minimize brake rotor lateral runout.
9. Remove the wheel hub/bearing and brake rotor shield. Carefully remove axle shaft.
10. Remove the upper and lower ball joint cotter pins and nuts.
11. Strike the steering knuckle with a brass hammer to loosen the steering knuckle from
the ball joint. Lower the steering knuckle from the ball joints studs.
12. Remove the upper ball joint using the appropriate special tools from the #6289 - Ball
Joint Installation and Removal Kit.
02-006-04 -4-

Fig. 1 BALL JOINT INDEX MARK

1 - Ball Joint Index Mark

Fig. 2 BALL JOINT POSITIONING TEMPLATE

1 - Arrow Points To Front Of Vehicle

 -5- 02-006-04

13. A ball joint positioning template is supplied in the new offset ball joint package. In
addition, an index mark is located on the side of the new offset ball joint (Fig. 1). The
ball joint index mark will be aligned to the respective mark on the template to obtain
the desired angle.
14. Make sure the template is oriented correctly (Fig. 2). Position the template on top of
the axle yoke.
15. By hand, temporarily friction fit the offset ball joint to the axle yoke. Position the ball
joint index mark to the template to obtain the desired angle. Remove the template.
16. Press the ball joint into the axle yoke bore.
17. Verify that the ball joint is fully seated and is correctly positioned relative to the
template.
18. Install the ball joint dust boot and grease fitting.
19. Install the steering knuckle. Tighten the lower ball joint nut to 109 Nm (80 ft. lbs.) and
install a new cotter pin. Tighten the upper ball joint nut to 102 Nm (75 ft. lbs.) and
install a new cotter pin.
20. Install the tie rod to the steering knuckle. Tighten the tie rod to knuckle attaching nut to
47 Nm (35 ft. lbs.) and install a new cotter pin.
21. Install the axle. Be careful not to damage the axle seal during installation.
22. Align the wheel hub/bearing and steering knuckle marks made during disassembly.
Install the brake dust shield and the wheel hub/bearing. Tighten the wheel hub/bearing
attaching bolts to 102 Nm (75 ft. lbs.).
23. Install the axle shaft washer and nut. Tighten the axle nut to 237 Nm (175 ft. lbs.).
Install axle nut retainer and a new cotter pin.
24. Align the brake rotor mark to its corresponding mark on the wheel hub/bearing and
install the brake rotor.
25. Install the brake caliper and brake pads to the steering knuckle. For Grand Cherokee
tighten the caliper slide bolts to 35 Nm (26 ft. lbs.). For Wrangler and Cherokee tighten
the caliper slide bolts to 15 Nm (11 ft. lbs.).
26. Grease the ball joint.
27. Install the tire and wheel assembly. Tighten lug nuts to 136 Nm (100 ft. lbs.).
28. If required, perform similar repair procedures to other side top ball joint.
29. Verify front wheel alignment.
NOTE: TO PREVENT ERROR, RE-COMPENSATE THE ALIGNER HEADS EACH TIME
A CHANGE IS MADE TO A SETTING ON THE BALL JOINT.

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
02-10-60-90 Ball Joint, Upper - Install One Side 3.5 Hrs.
02-10-60-91 Ball Joint, Upper - Install Both Sides 4.2 Hrs.
Note: Labor Operations Above Include All
Necessary Pre and Post Alignments.

FAILURE CODE:

P8 New Part
 NUMBER: 21-010-04

GROUP: Transmission

DATE: August 26, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
NSG-370 Manual Transmission - Lubricant Level

OVERVIEW:
This bulletin involves an acceptable “factory fill” lubricant level for the new NSG-370
manual transmission.

MODELS:

2005 (KJ) Liberty / Cherokee

2005 (TJ) Wrangler

NOTE: This bulletin applies to vehicles equipped with a NSG-370 six speed manual
transmission (sales code: DEH).

DISCUSSION:
When received from the factory, the vehicle's new NSG-370 six speed manual
transmission is correctly filled with 1.5 liters (1.6 qts.) of manual transmission lubricant (oil).
When “factory filled” with 1.5L (1.6 qts.) of lubricant, the top of the lubricant will be at the
bottom of the oil fill hole or slightly below the oil fill hole by no more than 4 mm (0.158 in.).

NOTE: Additional manual transmission lubricant should NOT be added to “top off”
the “factory fill” lubricant level if the top of the lubricant is within 4mm (0.158
in.) of the bottom of the oil fill hole.
If the NSG-370 is serviced due to repair or regular maintenance, and the transmission
lubricant has been drained, then the NSG-370 manual transmission can be refilled until the
the lubricant level is at the bottom of the oil fill hole (service fill).

The lubricant used in the new NSG-370 manual transmission is p/n 04874464 - Manual
Transmission Lubricant (MS-9224). The vehicle needs to be positioned on a level surface
when the manual transmission lubricant level is checked to ensure an accurate
measurement.

POLICY:
Information Only
 NUMBER: 09-010-04 REV. A

GROUP: Engine

DATE: October 01, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-010-04, DATED

MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION
OF THE 2005 MODEL YEAR.

SUBJECT:
4.0L Engine - Dirt And Debris Accumulation At Rear Main Seal

OVERVIEW:
This bulletin involves the application of a small amount of sealer where the top of the
transmission bellhousing mates to the engine.

MODELS:

**1997 - 2005** (TJ) Wrangler

NOTE: **This bulletin applies to vehicles equipped with a 4.0L engine (sales code
ERH) and a manual transmission (sales code DDQ, DDD, or DEH) that were
built prior to September 02, 2004 (MDH 0902XX).**

SYMPTOM/CONDITION:
The customer may experience engine oil seepage from the area of the rear main bearing
seal. Closer inspection may reveal that the cause of the engine oil seepage past the rear
main bearing seal is due to the accumulation of dirt and debris around the outside of the
rear main seal. This condition may occur more frequently if the vehicle is used in off road
conditions.

A spacer plate is used to mate the transmission bellhousing to the back of the engine. The
spacer plate has a slot machined into it at the 12 o'clock position. A small opening may
occur as a result of the spacer slot when the spacer is mated between the engine and
transmission bellhousing. The narrow spacer opening at the top of the transmission
bellhousing may allow small size debris to enter the bellhousing and accumulate around
the outside of the rear main engine seal. If debris accumulation becomes significant,
damage to the rear main seal may occur.

DIAGNOSIS:
If a vehicle is in for service perform the Repair Procedure if the repair has not previously
performed.
If engine oil seepage from the engine rear main oil seal is present, then diagnosis and
repair not addressed by this Bulletin may be required.
09-010-04 REV. A -2-

PARTS REQUIRED:

Qty. Part No. Description

AR (1) 04883971 RTV, Engine Sealant
Note: There is sufficient quantity of RTV to perform
numerous repairs.
AR (1) 04897156AA Cleaner, Throttle Body
Note: There is sufficient quantity of Cleaner to perform
numerous repairs.

REPAIR PROCEDURE:

Fig. 1 LOCATION OF ADAPTER OPENING

1 - BACK OF ENGINE
2 - LOCATION OF NARROW OPENING DUE TO SLOT IN ADAPTER PLATE
3 - TOP OF BELLHOUSING - MANUAL TRANSMISSION

1. With the ignition switch in the off position, raise the vehicle hood and make sure the
engine and exhaust manifold are not hot to the touch (Fig. 1).
2. Locate the narrow opening created by the spacer plate. The spacer opening can be
viewed when looking towards the rear of the engine and top of the transmission
bellhousing from the drivers side of the engine (Fig. 2).
3. Thoroughly clean the immediate area around the spacer opening with throttle body
cleaner, p/n 04897156AA. Allow cleaner to dry.
4. Apply a sufficient amount of RTV over the spacer opening. Verify that the spacer
opening is completely sealed off by the RTV.
5. Lower and secure vehicle hood.
 -3- 09-010-04 REV. A

Fig. 2 ADAPTER OPENING DETAIL

1 - BACK OF ENGINE
2 - ADAPTER PLATE
3- BELLHOUSING - MANUAL TRANSMISSION
4 - ADAPTER PLATE OPENING - APPLY SEALER HERE

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
06-10-01-90 Bellhousing, Apply Sealer 0.3 Hrs.

FAILURE CODE:

AM Authorized Modification
 NUMBER: 23-041-04

GROUP: Body

DATE: October 15, 2004

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
Seam Sealing Tape May Not Have Fully Fused To Soft Top

OVERVIEW:
This bulletin involves heating and affixing any loose portions of the seam sealing tape to
the soft top.

MODELS:

2005 (TJ) Wrangler

SYMPTOM/CONDITION:
The customer may notice that a small section or two of the seam sealing tape may appear
to be loose from the soft top material. The seam tape is used to seal the soft top seams at
the rear bow and “C” pillar areas of the soft top. The seam sealing tape may not have been
fully fused to the soft top when the soft top was manufactured.

DIAGNOSIS:
If the seam sealing tape is loose from the soft top perform the Repair Procedure.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

Heat Gun - capable of low heat tempertures (93°C / 200° F)

Hard Roller to roll out tape

REPAIR PROCEDURE:
1. Unzip both side windows and the rear window.
2. Remove the soft top from the vehicle.
NOTE: Do not over heat the tape or the soft top material. Make certain that the soft
top inner surface and sealing tape are clean of dust and debris. Make certain
that the clean surface that the soft top will be resting on will not transfer or
absorb any material when the soft top and sealing tape is heated. Placing a
clean white cotton towel between the soft top and the clean surface is
acceptable.
3. Lay the soft top on a clean surface so that the inner seam sealing tape is face up. Fully
inspect the rear bow and both “C” pillar areas for any loose seam sealing tape (Fig. 1).
4. Carefully heat the tape to 93° C (200° F) with a heat gun in the areas where the
sealing tape has not fused with the soft top. Hold the heat gun about 50 - 76 mm (2 to
3 in.) from the tape. Do not overheat the tape or top.
23-041-04 -2-

Fig. 1 SEAM SEALING TAPE - TJ SOFT TOP

1 - Soft Top - Third Bow and "C" Pillar Areas

2 - Seam Sealing Tape

5. With a hard roller, roll the tape on to the soft top until the sealing tape is completely
fused to the soft top material.
6. Allow the seam sealing tape and soft top to cool (approximately one minute).
7. Verify that the strips of seam sealing tape are fully fused to the soft top along the rear
bow and both “C” pillar areas.
8. Install the soft top to the vehicle.
9. Install the soft top windows.
POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
23-05-01-94 Perform Repair Procedure - Fuse Soft Top 0.7 Hrs.
Sealing Tape

FAILURE CODE:

01 Adhesive Bond
 NUMBER: 03-001-05

GROUP: Differential &

Driveline

DATE: January 13, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
FLASH: Off-Roading In 4WD Low Range - Axle Lockers May Unlock When Ignition Key Is
Cycled

OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) with new software.

MODELS:

2005 (TJ) Wrangler

NOTE: This bulletin applies to Wrangler Rubicon vehicles equipped with the Tru-Lok
axle differential lockers (sales code DSE) and built prior to January 31, 2005
(MDH 0131XX).

SYMPTOM/CONDITION:
The front and rear axle differential locker may electrically disengage so that each locker
may unlock if the ignition key (switch) is cycled from the ON to the OFF position and then
cycled back to the ON position. The vehicle operator may prefer that the differential lockers
remain in the “LOCKED” mode even when the ignition key is cycled. This may be a
preferred feature when the vehicle is being used for off-road purposes.

The new software will now maintain the front and rear axle differential locker in the
“LOCKED” mode (will not disengage electrically) if the ignition key (switch) is cycled.

DIAGNOSIS:
Using a Scan Tool (DRBIII®) with the appropriate Diagnostic Procedures Manual, verify all
engine systems are functioning as designed. If DTCs are present record them on the
repair order and repair as necessary before proceeding further with this bulletin.

If the vehicle operator describes or experiences the Symptom/Condition, perform the

Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description

1 04275086AB Label, Authorized Modification
03-001-05 -2-

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger

CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan Tool (DRBIII®)
CH7000A/7001A J1962 Cable with red DRBIII® connector
TechCONNECT Workstation

NOTE: An updated J1962 cable has been released. This cable has a red colored
connector at the DRBIII® connection. Use this cable whenever a flash is
being performed.

REPAIR PROCEDURE:
NOTE: Whenever a controller is programmed, the software in the DRBIII®; must be
programmed with the latest revision level available.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted and
then follow the directions on the DRBIII®.
1. Before beginning the reprogramming procedure, remove any old flash reprogramming
files from the DRBIII® memory. To clear the memory from the DRBIII® MAIN MENU:
a. Simultaneously press the “MORE” and “YES” keys.
b. A screen will appear requesting a “COLD BOOT”.
c. Follow the on screen instructions by selecting the “F4” key.
d. When the DRBIII® reboots to the MAIN MENU, proceed to Step #2.
2. With the ignition switch in the “RUN” position, determine the original part number of the
PCM currently in the vehicle. Using the DRBIII® select:
a. "DRBIII® Standalone".
b. "1998 - 2005 Diagnostics".
c. "All (Except Below)".
d. “Engine”.
e. “Module Display”.
f. Record the “PCM part #” on the repair order for later reference.
3. Connect the DRBIII® to TechCONNECT. Open TechTOOLS and verify that the
"DRBIII® Status: Connected" message is in the upper right corner of the TechTOOLS
screen.
4. Enter the “PCM part #” recorded in Step #2 in the “Parts Criteria” area and select
“Show Updates”. TechTOOLS will populate the available updates.
5. Select the calibration.
6. Select the “DRBIII” radio button which is next to the “Download/Update” button.
7. Select the “Download/Update” button.
8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and
follow the instructions on TechCONNECT. When the flash process is complete,
proceed to Step #9.
9. Disconnect the DRBIII® from TechCONNECT.
10. Open the hood, install a battery charger and verify that the charging rate provides
approximately 13.5 volts.
 -3- 03-001-05

11. Connect the DRBIII® to the vehicle.

12. Turn the ignition to the “Run” position (engine not running).
13. Download the flash from the DRBIII® to the vehicle. Using the DRBIII® select:
a. “Vehicle Flash”.
b. Follow the directions on the DRBIII® screen to complete the download.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules
(TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's
may cause the MIL to illuminate. Check all modules using “Module Scan”,
record the DTC's, and erase these DTC's prior to returning the vehicle to the
customer. Erase any DTC's in the PCM only after all other modules have had
their DTC's erased.

NOTE: The following step is required by law.

14. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED

2 - CHANGE AUTHORITY: TSB XX-XXX-XX
3 - DEALER CODE: XXXXX
4 - DATE: XX-XX-XX

TIME ALLOWANCE:

Labor Operation No: Description Amount

08-19-40-91 Reprogram Powertrain Control Module 0.8 Hrs.

FAILURE CODE:

FM Flash Module
 NUMBER: 23-008-05

GROUP: Body

DATE: February 04, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
Soft Top - Seam Sealer Tape Repair

OVERVIEW:
This bulletin involves making repairs to the seam(s) in the rear section of the soft top.

MODELS:

2003 - 2005 (TJ) Wrangler

NOTE: This bulletin applies to vehicles built after January 01, 2003 (MDH 0101XX).

SYMPTOM/CONDITION:
The customer may experience a water leak from one or more of the sealed seams that are
located in the rear section of the soft top. The cause of the water leak may be due to the
sealer tape used to seal the seams of the soft top. The tape may exhibit cracking, wear
through, or loss of adhesion.

DIAGNOSIS:
If the customer experiences the above condition and the cause is due to the seam sealer
tape, then perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description

1 05174166AA Kit, Seam Sealer Soft Top Repair - Black (for
Black, Medium Gray, or Green Color Soft
Tops)
1 05174665AA Kit, Seam Sealer Soft Top Repair - White (for
Khaki Color Soft Tops)
23-008-05 -2-

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Heat Gun - capable of low heat temperatures around (93°C /

200°F)
NPN Hand Held Hard Roller - suitable for rolling out 30mm (1.125
in.) wide sealer tape at temperature

REPAIR PROCEDURE:
1. Unzip both side and rear windows.
2. Remove the soft top from the vehicle.
NOTE: Make certain that the clean surface that the soft top will be resting on will not
transfer or absorb any material when the soft top and sealing tape is heated.
Placing a clean white cotton towel between the soft top and the clean surface
is acceptable.
3. Lay the soft top on a clean surface so that the inner seam sealing tape is face up.
4. Inspect seam sealer tape used in the rear bow and both “C” pillar areas of the soft top
for cracking, wear through, and/or for being loose (Fig. 1).

Fig. 1 SEAM SEALER TAPE - TJ SOFT TOP

1 - Soft Top - Rear Area

2 - Soft Top Seams With Sealer Tape

5. The repair kit includes new sealer tape which is thicker and will overlay the current/old
sealer tape. The soft top seams and old tape must be prepped to accept the new
sealer tape. In the areas where the old sealer tape is cracked, worn through, and/or
loose, use a sharp knife or razor blade to carefully cut away any bad sealer tape
areas. Do not cut the soft top material. Do not remove any old sealer tape that is
properly affixed to the soft top seam and is not cracked or worn through.
 -3- 23-008-05

6. With water and a mild detergent, clean the entire bow seam and the seams in both “C”
pillar areas. Allow top to dry thoroughly before proceeding.
NOTE: The overlay tape is to be installed on ALL of the previously sealed soft top
seams. Make certain that ALL of the old sealer tape is properly prepped.
Make certain that the soft top inner surface and any remaining old sealer tape
is clean and dry prior to installing the new overlay sealer tape.

NOTE: The two shorter seams that are located on each side of the soft top rear
window opening are repaired first. The long seam that runs from the bottom
of one “C” pillar, across the top, and all the way to the bottom of the other
“C” pillar is repaired last.
7. At one of the two (short) seams that are next to the soft top rear window opening, cut a
section of the new overlay sealer tape that is long enough to cover the entire length of
the seam.
8. Lay the new sealer tape over top of the entire seam and carefully heat the tape and
seam to around 93°C (200°F) with a heat gun. Hold the heat gun about 50 - 76 mm (2
to 3 in.) from the tape or top. Do not overheat the new tape or soft top.
9. With a suitable hard hand roller, install the new sealer tape to the seam.
NOTE: Set the hot air gun to its lowest setting and blow hot air between the sealer
tape adhesive and the seam. Gently heat the adhesive until it softens (this
may require a careful increase in the gun temperature until a change is
noticed in the new tape adhesive gloss, transparency, or color). Once the
adhesive is soft use a hand roller to squeeze the tape adhesive to the seam.
If a small amount of adhesive squeezes out from underneath the seam sealer
tape, then a good bond has been achieved. If a large amount of adhesive
squeezes out, then too much roller pressure is being applied.
10. Cut to size and install the new sealer tape to the other (short) seam that is on the other
side of the soft top rear window opening.
11. Install the remaining new sealer tape to the (long) seam that runs from the bottom of
one “C” pillar, across the top, and to the bottom of the other “C” pillar section of the
soft top. Trim off any excess tape.
12. Allow the new sealer tape to cool.
13. Verify proper sealer tape adhesion to the soft top seams.
14. Install the soft top to the vehicle.
15. Install the side and rear windows to the soft top.
POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
23-05-01-95 Folding Soft Top - Seam Sealer Tape Repair 1.2 Hrs.

FAILURE CODE:

4X Water Leak
 NUMBER: 24-003-05

GROUP: Heating & A/C

DATE: February 04, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-007-03, DATED

AUGUST 15, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO
THE TJ MODEL YEARS AND TO THE PART REQUIRED.
SUBJECT:
HVAC Drain Water Leaks Inside Vehicle And Under Passenger Side Front Carpet

OVERVIEW:
This bulletin involves installing a HVAC drain hose.

MODELS:

2002 (KJ) Liberty (Domestic Market)

2002 (KJ) Cherokee (International Market)
1997 - **2005** (TJ) Wrangler

NOTE: This bulletin applies to LHD Liberty vehicles built prior to August 10, 2001
(MDH 0810XX), and to Wrangler vehicles built prior to March 01, 2005 (MDH
0301XX).

SYMPTOM/CONDITION:
The customer may experience a wet front passenger floor or floor carpet. This condition
may occur due to water (A/C condensate) from the HVAC assembly drain tube. As A/C
condensate leaves the HVAC drain tube, it may run back along the outside of the HVAC
drain tube, enter the passenger compartment, and run under the front floor carpet on the
passenger side. This condition may occur most often while the vehicle is being driven.

DIAGNOSIS:
Inspect for the source of the water leak. Determine if the passenger side of the front floor
carpet is wet because of air conditioning condensate from the HVAC drain tube. Inspect
the HVAC assembly drain tube for the presence of a drain hose. If a HVAC assembly drain
hose is not present, and the A/C condensate from the drain tube is the cause of the water
leak, then perform the Repair Procedure.
24-003-05 -2-

PARTS REQUIRED:

Qty. Part No. Description

1 55037651AA **Hose, HVAC Drain (KJ)**
1 56000724AB **Hose, HVAC Drain (TJ)**
1 NPN Strap, Tie

REPAIR PROCEDURE:
1. Inspect the HVAC drain tube. Clean out any debris or other restrictions in the drain.
2. Install a HVAC drain hose onto the HVAC drain tube. Once assembled to the HVAC
drain tube, make sure the open end of the drain hose is facing towards the ground.
3. Install a tie strap around the drain hose to secure the hose to the HVAC drain tube.
NOTE: Inform the customer to regularly inspect the new HVAC drain hose for debris,
especially when off-road driving is performed.

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
24-65-03-97 Replace Condensate Drain Tube 0.2 Hrs.

FAILURE CODE:

P8 New Part
 NUMBER: 23-009-05

GROUP: Body

DATE: February 15, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

SUBJECT:
Sunrider Soft Top - Side Rail Pivot Link And Sleeve Repair

OVERVIEW:
This bulletin involves repair to the side bar (pivot link and/or sleeve) rather than a complete
assembly replacement.

MODELS:

2004 - 2005 (TJ) Wrangler

NOTE: This bulletin applies to Wrangler Unlimited (LWB) vehicles that are equipped
with a soft top (sales code VJ0).

SYMPTOM/CONDITION:
The vehicle owner may notice that a pivot link or sleeve in one of the soft top side bars is
broken. The soft top side bar is located above each door opening.

The Sunrider soft top has a feature that allows the front portion of the soft top, above the
driver, to be folded back without lowering the complete soft top. The pivot link and sleeve
allow each front side bar of the Sunrider soft top to fold.

DIAGNOSIS:
If a pivot link or sleeve is broken perform the Repair Procedure.

NOTE: Do not replace the full frame assembly or complete soft top assembly for a
broken side bar pivot link or sleeve.

PARTS REQUIRED:

Qty. Part No. Description

(AR) 1 05166017AA Pivot Link, Side Bar
(AR)1 05166016AA Sleeve, Side Bar Pivot Link
23-009-05 -2-

REPAIR PROCEDURE:

Fig. 1 SUNRIDER SOFT TOP PIVOT LINK

1 - Plastic Sleeve
2 - Side Bar Sleeve Detent Pin
3 - Pivot Link Screws
4 - Side Bar
5 - Pivot Link
6 - Rotate Sleeve To Clear Detent

1. Open each door and release soft top drip rail retainers.
2. Fold front section of Sunrider top back by releasing the two front header latches and
by sliding both pivot link sleeves forward.
3. Unzip both soft top side windows and let hang still attached at the bottom.
4. Remove both plastic door frames by removing thumb screws and release pin.
5. Finish sliding both side bar plastic sleeves forward/upward, past their normal stop, to
fully expose the pivot links and both attaching screws. The sleeve rotates around the
side bar. Sleeve may need to be rotated while forward/upward pressure is applied in
order to completely clear the pivot link screw and sleeve detent in the side bar (Fig. 1).
6. If only a sleeve requires replacement:
a. Remove the pivot link attaching screw closest to the sleeve.
b. Separate the side bar tube from the pivot link.
c. Remove the old sleeve.
d. Slide on the new sleeve over the side bar.
e. Connect the pivot link to the side bar tube.
f. Install the pivot link screw. Tighten the screw to 2.5 Nm (22 in. lbs.).
7. If a pivot link requires replacement:
a. Remove both pivot link screws. Note the orientation of the old pivot link for
reassembly purposes. The pivot link mechanism pivots in only one direction.
 -3- 23-009-05

b. Separate the side bar tubes from both ends of the pivot link. A broken pivot link end
may remain in the side bar tube. If necessary, drill a small hole, thread a screw into
the drilled hole, and remove the end by pulling on the screw.
c. If required, replace the old sleeve. Slide the new sleeve over the side bar.
d. Install the new pivot link into the side bar tubes.
e. Install both pivot link screws. Tighten screws to 2.5 Nm (22 in. lbs.).
8. Slide both sleeves down and over the sleeve detents.
9. Verify that the Sunrider front section operates correctly.
10. Install both door frames.
11. Finish installing the soft top to the vehicle.
POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount

No:
23-44-03-90 Link, Folding Top Side Bar Pivot - Replace - One 0.4 Hrs.
Side - Right or Left
23-44-03-91 Link, Folding Top Side Bar Pivot - Replace - Both 0.6 Hrs.
Sides - Right and Left

FAILURE CODE:

11 Broken or Cracked
 NUMBER: 21-006-05

GROUP: Transmission

DATE: February 24, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR

PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MARCH 07, 2005.

SUBJECT:
NSG370 6-Spd Transmission - May Not Remain In Reverse Gear When Selected

OVERVIEW:
This bulletin involves replacing both the internal shift subassembly and the mainshaft
reverse gear components.

MODELS:

2005 (KJ) Liberty / Cherokee

2005 (TJ) Wrangler

NOTE: This bulletin applies to vehicles equipped with a NSG-370 6-speed manual
transmission (sales code DEH).

SYMPTOM/CONDITION:
Upon shifting the 6-speed manual transmission into Reverse, the customer may notice that
reverse gear may not remain engaged.

This condition may follow/develop shortly after an accidental mis-shift into reverse has
occurred. While the vehicle is moving forward and already in a forward gear, instead of
shifting into another forward gear the reverse gear is incorrectly selected. Though reverse
can not be obtained during the mis-shift attempt, damage to the internal shift subassembly
and reverse gear may occur which may later prevent full reverse gear engagement when
reverse is selected properly. The customer should be made aware of proper shift
procedures.

This condition may also occur if the center floor console and/or shifter boot are not
positioned properly.

DIAGNOSIS:
1. Verify that the center floor console and shifter boot are not preventing the transmission
shifter from fully engaging reverse. Verify that the console is centered properly to the
shifter. Verify that the shifter boot is installed properly.
2. If the center console and shifter boot are properly installed, and the transmission fails
to remain in reverse as designed, perform the Repair Procedure.
21-006-05 -2-

PARTS REQUIRED:

Qty. Part No. Description

1 05175903AA Kit, Reverse Gear - 4x4 or 4x2 (inc. internal
shift subassembly, reverse gear, reverse
syncrho sleeve, reverse blocker ring,
retaining snap rings, oil seals, and counter
shaft seal plug )
1 04318083 Mopar® Gasket Maker
2 04874464 Lubricant, Mopar® Manual Transmission
(MS-9224)

SPECIAL TOOLS/EQUIPMENT REQUIRED:

9648 Mainshaft Build Fixture

9633 Build Fixture
NPN 3-Jaw Puller
W-262 Hub Installer
NPN Hydraulic Press
9638 Seal Installer
9635 Seal Installer
9636 Shaft Remover and Installer
7829-A Plug Installer
C-4171 Handle
6448A Bearing Installer - Tube

REPAIR PROCEDURE:
Replace the manual transmission internal shift subassembly and reverse gear
components. Refer to detailed disassembly and assembly repair procedures in
TechCONNECT which are available in Group 21 - Transmission and Transfer Case /
Manual Transmission - NSG370.

POLICY:
Reimbursable within the provisions of the warranty.
 -3- 21-006-05

TIME ALLOWANCE:

Labor Operation Description Amount

No:
21-00-03-98 Replace Manual Transmission Internal Shift 3.9 Hrs.
Assembly And Reverse Gear Components - TJ
21-00-03-98 Replace Manual Transmission Internal Shift 3.6 Hrs.
Assembly And Reverse Gear Components - KJ
21-00-06-60 Optional Equipment: 0.8 Hrs.
4x4 Equipped - KJ

FAILURE CODE:

J1 Jumps Out Of Gear