NHTSA ID Number: 10119612
Manufacturer Communication Number: R61 (15V-675)
TSB/Document Date: 2017-10-21
Summary
Antilock Brake System Control Module Anti-Lock Brake System (ABS) control module on about 275,600 of the above vehicles may have a ground wire eyelet on the right front shock tower that allows water to wick through the ground wire case and into the ABS module. Moisture in the ABS module could disable the ABS and/or Electronic Stability Control (ESC) system(s). The lack of a functioning ABS and/or ESC system(s) could change the braking and/or handling characteristics of the vehicle and cause a crash without warning.
both ends of the heat shrink tube
(Figure 16).
HEAT SHRINK
TUBE
Figure 16 – Heat Shrink Tube
17. Install the two black ground terminals
from the supplied ground circuit
overlay into cavity numbers 16 and
47 of the ABS module electrical
connector (Figure 17).
ABS CONTROL MODULE
ELECTRICAL CONNECTOR
NOTE: The ground wire terminals
on the ground circuit overlay are
interchangeable and can go in
either cavity.
CAVITY 16
18. Install the ABS electrical connector
red plastic terminal lock (Figure 11).
CAVITY 47
Figure 17 – ABS Control Module Electrical
Connector
Safety Recall R61 -- Antilock Brake System Control Module
Page 18
Service Procedure (Continued)
19. Position the ABS module ground eyelet (NEW ground circuit overlay eyelet) to
the rear ground stud and the two engine ground eyelets to the forward ground
stud and install the two nuts. Tighten to 7 ft. lbs. (10 N·m) (Figure 18).
NOTE: When installing a ground ciruit overlay, the two ground wire
eyelets must be oriented as shown in Figure 18.
ABS MODULE GROUND EYELET
TWO ENGINE GROUND EYELETS
Figure 18 – Ground Eyelet Orientation
Safety Recall R61 -- Antilock Brake System Control Module
Page 19
Service Procedure (Continued)
20. Secure the ground circuit overlay to the main wire harness bundle using four
supplied tie straps (Figure 19).
21. Loop the extra ground overlay wire length and secure it with one of the
supplied tie straps to the main wire harness bundle as shown (Figure 19).
NOTE: Be sure to position the overlay wire to the rear of the main wire
harness bundle to avoid interference with the coolant bottle mounting.
TIE STRAP OVERLAY
AND HARNESS
BUNDLE TO ABS
ELECTRICAL
CONNECTOR
MAIN WIRE HARNESS BUNDLE
TIE STRAP
LOCATIONS
LOOP EXTRA OVERLAY
WIRE AND TIE STRAP
TO REAR OF HARNESS
AS SHOWN
Figure 19 – Ground Circuit Overlay
Safety Recall R61 -- Antilock Brake System Control Module
Page 20
Service Procedure (Continued)
22. Using electrical contact cleaner, clean the ABS module electrical connector.
23. Cut just the tip off the dielectric grease nozzle.
24. Apply a very light bead of dielectric grease on the face of the ABS control
module electrical connector.
CAUTION: Do not apply excess amounts of dielectric grease. ABS module
connector terminal damage and/or poor electrical connections may occur.
25. Wipe the grease evenly on the connector face.
26. Route the ABS electrical connector and position the connector to the ABS
module securing the wire harness retaining clips to the frame rail.
27. Connect the right front wheel speed sensor electrical connector.
28. Insert the ABS electrical connector into the socket of the ABS control module
and close the cover, locking the electrical connector in place.
CAUTION: Before installing the ABS control module harness electrical
connector on the ABS control module, be sure the seal is properly installed
in the electrical connector.
CAUTION: Be sure the electrical connector lock is fully engaged.
Safety Recall R61 -- Antilock Brake System Control Module
Page 21
Service Procedure (Continued)
29. Connect the negative battery cable (Figure 1).
If the ABS light is “ON” continuous after bulb check, and DTC C2200 is
present the ABS module must be replaced. Continue with Section C.
Replace ABS Control.
If the ABS light is “ON” continuous after bulb check, and DTC’s other than
C2200 are present; refer to all current, normal diagnostics published in
DealerCONNECT and repair as necessary following normal warranty repair
guidelines then continue with Step 30.
If the ABS light is not “ON” continuous after bulb check, continue with
Step 30.
30. Install the coolant reservoir and tighten the two bolts securely.
31. Install the power steering reservoir and tighten the bolt securely.
If the vehicle is equipped with a 3.6L engine, continue with Step 32.
If the vehicle is equipped with a 2.0L or a 2.4L engine, continue with
Step 39.
32. Install the plenum silencer (Figure 5).
33. Position the fresh air plenum and install the two mounting screws. Tighten the
screws securely (Figure 5).
34. Install the wheelhouse brace. Install and tighten the eight mounting bolts (four
each side) to 35 ft. lbs. (48 N·m) (Figure 4).
35. Secure the plenum silencer to the bottom of the wheelhouse brace.
36. Install the cowl screen. Install the push-pins securing the cowl screen to the
wheelhouse brace and cowl. Rotate the screw in the center of the cowl screen
90° counterclockwise to lock the screen in place (Figure 3).
Safety Recall R61 -- Antilock Brake System Control Module
Page 22
Service Procedure (Continued)
37. Install both wiper arms.
38. Install the cowl top screen. Install the seven push-pins securing the cowl top
screen at the ends. Install the remaining push-pins (Figure 2).
39. Install the engine appearance cover.
40. Close the hood and return the vehicle to the customer.
Safety Recall R61 -- Antilock Brake System Control Module
Page 23
Service Procedure (Continued)
C. Replace ABS Control Module
1. Disconnect and isolate the
negative battery cable (Figure 1).
INTEGRATED CONTROL UNIT
If the vehicle is equipped with
a 3.6L engine, continue with
Step 2.
If the vehicle is equipped with
a 2.0L or a 2.4L engine,
perform Steps 3 through 10 in
Section A. Inspect Antilock
Brake System (ABS) and then
continue with Step 2.
2. Loosen, but do not remove, the
two mounting bolts attaching the
Integrated Control Unit (ICU)
mounting bracket to the body
(Figure 20).
Figure 20 – ICU Mounting Bolts
3. Lift the ICU and mounting bracket upward to near the top of the slots in the
bracket then position the ICU on top of the frame rail to gain access to the four
ABS module attachment screws.
CAUTION: Before disassembling the ICU, the ICU must be thoroughly
cleaned. This must be done to prevent dirt particles and debris from
entering into vital areas of the ICU.
4. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent
such as Mopar
® Brake Parts Cleaner or equivalent.
Safety Recall R61 -- Antilock Brake System Control Module
Page 24
Service Procedure (Continued)
5. Remove and discard the four screws attaching the ABS control module to the
Hydraulic Control Unit (HCU) (Figure 21).
CAUTION: When removing the ABS control module from the HCU, be
sure to completely separate the two components (approximately 1.5 inches
(38 mm)) before removing the ABS control module. Otherwise, damage to
the pressure sensor or pump motor connection may result, requiring HCU
replacement. Do not to touch the sensor terminals on the HCU side or the
contact pads on the ABS side as this may result in contamination and
issues in the future.
ABS CONTROL MODULE
SCREW LOCATIONS
Figure 21 – ABS Control Module
Safety Recall R61 -- Antilock Brake System Control Module
Page 25
Service Procedure (Continued)
6. Separate the ABS control module from the HCU (Figure 21 and 22).
7. Clean any debris off the mating surfaces of the HCU and ABS control module.
CAUTION: When installing new O-rings or solenoid valve stem seals, do
not use any type of lubricant.
8. NEW solenoid valve stem seals are provided in the ABS control module kit.
Remove the twelve old and install the twelve NEW solenoid valve stem seals to
keep out moisture and debris; do not reuse solenoid valve stem seals
(Figure 22).
HCU
SOLENOID VALVE
STEM SEALS
SOLENOID VALVE
STEM SEALS
Figure 22 – Solenoid Valve Stem Seals
Safety Recall R61 -- Antilock Brake System Control Module
Page 26
Service Procedure (Continued)
9. The pump/motor O-ring is
provided with the NEW ABS
module. Be sure the O-ring is
properly seated in the mounting
groove (Figure 23).
PUMP/MOTOR O-RING
10. Align solenoid valve stems and
install the ABS module on the
HCU.
11. Install the four NEW screws
attaching the ABS control
module to the HCU. Tighten the
mounting screws to 17 in. lbs.
(2 N·m).
Figure 23 – Pump/Motor O-Ring
CAUTION: Before installing the ABS control module harness connector on
the ABS control module, be sure the seal is properly installed in the
electrical connector.
CAUTION: Be sure the electrical connector lock is fully engaged.
12. Insert the ABS control module wiring harness electrical connector into the
socket of the ABS control module and close the cover, locking the electrical
connector in place.
13. Loosen the two ICU mounting screws as necessary allowing the ICU mounting
bracket to slide down over the mounting screws and hang the assembly in place.
Tighten the two ICU mounting screws to 17 ft. lbs. (23 N·m) (Figure 19).
Safety Recall R61 -- Antilock Brake System Control Module
Page 27
Service Procedure (Continued)
14. Install the coolant reservoir and tighten the two bolts securely.
15. Install the power steering reservoir and tighten the bolt securely.
16. Install the plenum silencer (Figure 5).
17. Position the fresh air plenum and install the two mounting screws. Tighten the
screws securely (Figure 5).
18. Install the wheelhouse brace. Install and tighten the eight mounting bolts (four
each side) to 35 ft. lbs. (48 N·m) (Figure 4).
19. Secure the plenum silencer to the bottom of the wheelhouse brace.
20. Install the cowl screen. Install the five push-pins securing the cowl screen to the
wheelhouse brace and cowl. Rotate the screw in the center of the cowl screen
90° counterclockwise to lock the screen in place (Figure 3).
21. Install both wiper arms.
22. Install the cowl top screen. Install the seven push-pins securing the cowl top
screen at the ends. Install the remaining push-pins (Figure 2).
23. Install the engine appearance cover.
24. Connect the battery negative cable (Figure 1).
Safety Recall R61 -- Antilock Brake System Control Module
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Service Procedure (Continued)
25. Connect the wiTECH scan tool to initialize the ABS and perform the following:
a. Clear diagnostic trouble codes (DTC’s).
b. Perform the “ABS Verification Test” and road test the vehicle.
WARNING: To avoid possible serious or fatal injury, check the brake
function before road testing.
NOTE: The ABS Module must be initialized using the wiTECH scan tool.
If not initialized, the ABS indicator lamp will flash continuously. Because
the ABS module was replaced, there may be an active Dynamic Sensor
DTC. There will be no indication if the Steering Column Control module
(SCCM) is replaced, but the ABS initialization should be run to make sure
there are no SCCM DTCs. To initialize the ABS Module and clear offsets
have wheels pointing straight ahead and follow the directions on the
wiTECH scan tool. The drive test requires a 90° turn. If the Dynamics
Sensor was replaced, test drive the vehicle by turning the vehicle left or
right in a curving manner at vehicle speeds between 6 and 15 mph (10 and
25 km/h).
c. Turn the ignition “off”.
d. Connect all previously disconnected components and connectors.
e. Verify all accessories are turned off and the battery is fully charged.
f. Verify that the ignition is “on”, with the wiTECH scan tool, erase all
Diagnostic Trouble Codes (DTCs) from all modules. Start the engine and
allow it to run for two minutes and fully operate the system that was
indicating the failure.
g. Turn the ignition “off” and wait five seconds. Turn the ignition “on” and
using the wiTECH scan tool, read DTCs from all modules.
h. If any Diagnostic Trouble Codes (DTC’s) are present, refer to all current,
normal diagnostics published in DealerCONNECT and repair as necessary
following normal warranty repair guidelines.
Safety Recall R61 -- Antilock Brake System Control Module
Page 29
Service Procedure (Continued)
NOTE: For Sensor Signal Plausibility and Pump Motor DTC’s, the
ABS control Module must verify that the failure conditions are no
longer present in the current ignition cycle before it can turn off the
failure lamp(s). This may require the vehicle to be driven for several
minutes above 9 mph (15 km/h). Once it has been determined that the
failure condition is no longer present the lamp(s) will be turned off.
i. If there are no DTCs present after turning ignition on, road test the vehicle
for at least five minutes. Slowly turn the steering wheel from lock to lock.
Test drive the vehicle by turning the vehicle left or right in a curving manner
at a speeds between 10 and 25 km/h (6 and 15 mph). Perform several antilock braking stops.
j. Using the wiTECH scan tool verify that there are no active or stored DTC’s.
k. The repair is complete.
26. Remove the wiTECH scan tool from the vehicle.
27. Close the hood and return the vehicle to the customer.
Safety Recall R61 -- Antilock Brake System Control Module
Page 30
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:
Labor Operation
Time
Number
Allowance
Inspect and Repair: Clean and Grease ABS
Connector and Add Heat Shrink
(2.0L and 2.4L Only)
08-R6-11-82
0.6 hours
Inspect and Repair: Clean and Grease ABS
Connector and Add Heat Shrink
(3.6L Only)
08-R6-11-83
1.1 hours
Inspect and Repair: Clean and Grease ABS
Connector, Add Heat Shrink and
Install Ground Circuit Overlay
(2.0L and 2.4L Only)
08-R6-11-84
0.9 hours
Inspect and Repair: Clean and Grease ABS
Connector, Add Heat Shrink and
Install Ground Circuit Overlay
(3.6L Only)
08-R6-11-85
1.3 hours
Inspect and Repair: Clean and Grease ABS
Connector, Add Heat Shrink, Install
Ground Circuit Overlay and
Replace ABS Module (All Engines)
08-R6-11-86
1.6 hours
Safety Recall R61 -- Antilock Brake System Control Module
Page 31
Completion Reporting and Reimbursement (Continued)
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.
Dealer Notification
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.
Safety Recall R61 -- Antilock Brake System Control Module
Page 32
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.
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
FCA US LLC
ANTILOCK BRAKE SYSTEM CONTROL MODULE
______________________________________________________________________________________
IMPORTANT SAFETY RECALL
R61 / NHTSA 15V-675
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 2012 through 2015 model year
Dodge Journey vehicles.
The problem is...
Anti-Lock Brake System (ABS) control module on your vehicle may have a ground wire
eyelet on the right front shock tower that allows water to wick through the ground wire
case and into the ABS module. Moisture in the ABS module could disable the ABS and/or
Electronic Stability Control (ESC) system(s). The lack of a functioning ABS and/or ESC
system(s) could change the braking and/or handling characteristics of the vehicle and cause
a crash without warning.
What your dealer
will do...
FCA will repair your vehicle free of charge. To do this, your dealer will seal the ground eyelet
on the right shock tower to stop water migration through the ground wire case. The ABS module
and headlamp/dash wire harness must also be inspected for moisture and repaired and/or replaced
if required. The work will take about 2 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.
California
residents…
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.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
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TSB/Document ID: R61 (15V-675)
Replacement Service Bulletin Number:
MFR Communication Date: 2016-01-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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