XJ Refurb

[calvynandhobbs]

Sounds like you're making good progress. I'm making a run to autozone at lunch to have them test my battery. For the past 3-4 days it has turned really, really slow and then picked up speed to start. It's either the battery or my starter is getting weak and it takes a few cranks for it to pick up speed and turn the XJ over.

For some reason my sub isn't getting power all of a sudden. I have it wired with the blue wire with the radio directly to the ignition so it comes on anytime the key is turned on. I need to pull the radio out and see if that wire came loose. The green power light blinks on every now and then so I'm guess the wire came loose behind the radio somehow without interupting the power to the radio.

[reptile610]

kirk why don't you just put on those rear end caps that i gave you off of my jeep?

[BlacXJeep]

While at Walmart I picked up a fire extinquisher, after seeing Roger's friends ZJ burn down I thought it was a good idea.  I need to find a good place to mount it, but like Roger I am thinking about screwing it into my Sub Box.  I am also looking into how to make the cubby in the right rear usefull.  On the Liberty they used a bungy net and I am thinking of doing the same to my XJ.

mount the fire extinguisher in there!


or better yet shove the extinguisher under your drivers seat and do the subwoofer in there

[PaulW]

i mounted the fire extinguishers right to the c pillars in mine.  easy access you just have to open the back doors and it's right there, better yet when you have the windows open you can reach right in.

[kirksjeep]

kirk why don't you just put on those rear end caps that i gave you off of my jeep?

I am, but I am going to pull my rear bumper, beat the dents out, piant/ clear/ and buff it, and then put the new caps on.

[kirksjeep]

I made a cargo-bungie net thing for the little cubbie on the passenger side, similair to the KJ.  My fire extingquisher wouldn't fit in there, it was just a little too big.  I ended up zip tying the mount under the spare tire, so it is easy to get to, and out of the way. 

The gauges are acting up again and I think I am going to have to go to the dealer and buy new plug that was made after all of the 97-01's were having problems.  The TSB says how to do it, and that it should take a dealer .6 hours for the work.  It sounds like a little soidering and and that is it. 

Here is the TSB- R.J. you may want to print this- it will happen to YOU

NO: 08-15-99
SUBJECT: Erratic, Intermittent Cluster Operation/Intermittent Air Bag Warning light.
DATE: May 21, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-20-98 REV. A, DATED OCTOBER 2, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE BOUND TECHNICAL SERVICE BULLETIN BOOK, PUBLICATION NUMBER 81-699-99003. THIS IS A COMPLETE REVISION TO THE PROCEDURE.

OVERVIEW:
This bulletin involves installing a repair harness containing a revised instrument cluster connector.

SYMPTOM/CONDITION:
Some vehicles may exhibit an intermittent illumination of the air bag warning light or an intermittent tachometer or speedometer drop out. An Airbag Electronic Control Module (AECM) fault code -"No Cluster CCD BUS " message will be present.

DIAGNOSIS:
Using the DRB III®, read and record all active and stored fault codes in the AECM. This condition is caused by minor oxidation of the BUS circuit terminals at the instrument cluster connector. Electrical terminals will show signs of oxidation, which will appear as darkened lines or marks on the cluster male terminals. These often appear as gray or black marks rather than the appearance of oxidation or corrosion usually associated with higher current carrying circuits. This condition will set a "NO CLUSTER CCD BUS" message. The fault code will usually be stored and not active. THIS TECHNICAL SERVICE BULLETIN WILL NOT ADDRESS FUEL OR OIL PRESSURE GAUGE ISSUES. If this fault code is present, either active or stored perform the Repair Procedure.

PARTS REQUIRED:
Qty Part No. Description
1 05016261AA Cluster Connector Patch Harness
1 04856975 Electric Contact Cleaner
2 04778570 Heat Shrink Tubing


REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.


Disconnect the negative battery cable.
Remove the instrument cluster using the procedures outlined in the appropriate servicemanual.
Inspect the male terminals of pins 1 & 2 on the instrument cluster connector labeled CNB (See Figure 1). The oxidation will appear as gray or black lines or marks on the terminals. If any signs of oxidation are present, remove them by gently scraping the terminals with a small flat bladed screw driver until the oxidation is gone. Use of a magnifying glass may be helpful (See Figure 2). Use caution when performing this operation. Do not apply excessive force to the terminals to avoid bending them or damaging the cluster or terminals. Do not use a sharp tool, knife or sand paper, which could remove the protective plating from the terminals. Do not use any cleaner other than p/n 04856975. Other chemical cleaners could damage the instrument cluster.
Clean the male terminals with Electrical Contact cleaner, p/n 04856975. Apply the cleaner sparingly holding the cluster with the connector facing down to avoid excessive amount of cleaner from entering the cluster.
Remove the green cluster connector from the bracket.
Using wire cutters, remove the instrument cluster harness connector from the harness. Remove only the connector containing the BUS circuit (See Figure 1). This connector is labeled CBA on the cluster. Cut the wires as close to the insulator as possible.
The new connector must be soldered onto the harness. This operation requires a technician who is skilled at soldering to avoid a cold solder joint. Position the harness and align the wires with the patch harness, matching the color codes match the main wire colors.
NOTE: THE XJ INSTRUMENT PANEL CONTAINS ONE MORE CIRCUIT IN THIS CONNECTOR THAN THE TJ. CUT THE UNUSED WIRE CLOSE TO THE CONNECTOR ON TJ MODELS.

Stagger cut the main harness and patch harness wires so that the solder joints will be 1/2 inch apart. Remove 1/2 inch of insulation from the wires. The new harness will have a dark blue with no tracer. This will mate with a dark blue wire with a green tracer on TJ and with a dark blue wire with a white tracer on XJ.
Slide a piece of heat shrink tubing over the wires and twist the wires together for each respective circuit.
Solder each circuit using rosin core solder. Be sure to heat the wire enough to allow the solder to melt when it comes in contact with wire. Do not use acid core solder.
Position the heat shrink tubing over the solder joints and shrink the tubing using a heat gun.
Install the connector to the bracket.
Install the instrument cluster.
Connect the battery cable.
Verify correct operation of the cluster.
POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Op. No. Time
08-90-90-91 0.6 Hrs.

[reptile610]

haha i'll print it out when i get access to a printer. so your gonna do it yourself vs having the dealer do it?

[kirksjeep]

haha i'll print it out when i get access to a printer. so your gonna do it yourself vs having the dealer do it?

Of course, it's just wires.  My YJ has only been to a shop for the front end allignement after I lifted it, thats it.  The KJ has only been in a shop for warranty work, thats it.  It will most likely take me more then .6 hours, but I would doubt it would take me much more then 1 hr. 

[reptile610]

so this is the thing i start to follow when my gauges start to take a dump correct? i shouldn't do it now just over the airbag light right? btw read in the fender flare section kirk, you might be able to offer advice there.

[kirksjeep]

There are several good rightups on Jeep Forum and NAXJA about the airbag light.  Sounds like most of the time it is the clock spring, and depending on the location of the clock spring, it may be covered under a recall.  Do a google search for 2000 Cherokee Recalls and see what comes up.

[PaulW]

There are several good rightups on Jeep Forum and NAXJA about the airbag light.  Sounds like most of the time it is the clock spring, and depending on the location of the clock spring, it may be covered under a recall.  Do a google search for 2000 Cherokee Recalls and see what comes up.

clock spring is mounted under the steering wheel.  it's a wound cable system, like a "clockspring" that allows electricity to flow to the air bag and steering wheel for the horn and other buttons on the steering wheel to have a path of electricity where you can still turn the wheel.


doug, just pull the air bag fuse anyway.  if your wheeling and you hit something hard enough, it may blow off.  i've had it happen before and air bags hurt when you land on your bumper backing down a rock face to get a better line.  just disable the air bag system all together.

[reptile610]

would that clockspring also be a reason my horn doesn't work?

[PaulW]

would that clockspring also be a reason my horn doesn't work?

yes

[reptile610]

hm.... might b onto something haha.

[PaulW]

hm.... might b onto something haha.

might b