Grand Voyager L4-153 2.5L SOHC (1989)
Multiple Junction Connector: Technical Service Bulletins
A604 EATX - Wiring Repair Package
NO.: 08-16-90
GROUP:
ELECTRICAL
DATE:
Sept. 24, 1990
SUBJECT:
A604 EATX Wiring Harness/ Electronic Connector Repair Package
MODEL YEARS/BODY CODES:
1989-90
AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1990
AA - ACCLAIM/SPIRIT
AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AY - IMPERIAL/FIFTH AVENUE
DISCUSSION
When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal push-out, and spreading of terminals. These problems
have led to intermittent setting of fault codes 12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving parts.
Connector seals, covers, and shields must be present and in good shape. Terminals must be clean and fully engaged with a tight fit. The 60-way, 8-way
and other sealer connectors for the A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals.
When wiring, connectors or terminals need repair on an A604 EATX the following service parts are now available.
REQUIRED PARTS FOR REPAIRS
Repair Package - 8-Way Solenoid Connector
4419476
(Connector Assembly on Wire w/Heat Shrink)
Repair Package - 2-Way Connector (For
4419478
Output and Turbine Speed Sensors)
Repair Package - 60-Way Connector
4419479
(14 Two Terminal Leads)
Repair Package - 60-Way Insulator
4419491
60-Way Connector Outer Shield
4400980
REQUIRED PARTS FOR MAKING A GAUGE
0.045 in. Male Pin Terminal - 2-Way
4400110
0.090 in. Male Pin Terminal - 8-Way
4368163
Heat Shrink Tubing - 0.25 in. Diameter
4419644
PROCEDURE FOR MAKING A GAUGE
To properly check a terminal for spreading, a gauge is required. To make a gauge, select the correct male pins from the parts list above (pins for gauging
the 60-way connector are included in Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin into each end of
a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing shrinks tightly onto the base of both pins. The shrink tubing will now serve
as a handle while gauging terminals.
INSPECTING CONNECTORS
Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the face of the connectors. If terminals are pushed out,
carefully remove the locking wedge and push in the terminals until they snap into position. Carefully install the wedge until it is flush with the outer
surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of the way, clear the wedge cavity and reinstall the wedge.
To inspect the connector for spread terminals, take the appropriate size gauge and insert it into each of the female connector pins. The terminals should
mate snugly with the gauge.
Verify proper transaxle operation after service.
NOTE:
WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE THAT ALL TERMINALS HAVE AN
INTERFERENCE FIT.
60-WAY CONNECTOR REPAIRS
If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using repair package PN 4419491. If terminals are damaged or
