Power Distribution Center - Loss of Battery Power
NO: 08-41-95
GROUP: Electrical
DATE: Sep. 22, 1995
SUBJECT: Loss Of Battery Feed to the Power Distribution Center
MODELS: 1996 (XJ) Cherokee
1996 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
Erratic operation of any electrical circuit fed through the Power Distribution circuit (PDC). This could include lights flickering on and off, vehicle will not crank, inoperative accessories etc.
DIAGNOSIS:
NOTE:
This inspection should be performed and repairs made if required, on all in stock vehicles and any customer owned vehicles you encounter.
Remove the small cover located at the end of the PDC and inspect for the presence of the Mega Fuse (125 amp on XJ or 175 amp on ZJ). If the Mega fuse is present, perform the repair procedure.
PARTS REQUIRED:
1 4874209 Fusible Link - 12 gauge (XJ)
1 4874208 Fusible Link - 10 gauge (ZJ)
AR 56018899 PDC Terminal Adapter Plate
REPAIR PROCEDURE:
This bulletin involves replacing the main fuse feeding the Power Distribution Center (Mega Fuse) with a fusible link.
1. Disconnect negative terminal from battery.
2. Remove the small cover and tether from the end of the PDC. Cut the tether from the cover.
3. Remove the two (2) nuts which retain the battery and alternator feeds to the PDC. Use caution to avoid damage to either stud. Removed the Mega Fuse from the PDC studs. Discard the fuse.
4. Inspect the studs and their mounting areas for any signs of damage. If this stud or boss is damaged, the plastic alternator terminal mounting plate (part number 56018899) must be replaced. To replace the plate, remove the PDC from the mounting bracket. Remove the PDC bottom cover. Unsnap the plate from the bottom of the PDC. Install the new plate, P/N 56018899, and install the bottom PDC cover.
5. Install the PDC onto the mounting bracket.
6. Remove the plastic mega-fuse retaining finger from the base of the PDC. Remove the finger using side cutters (See Figure 2). The cut should not go past the rectangular opening. Removing the finger will create a larger opening to route the fusible link and allow for cover installation.
7. Place the battery and alternator terminals onto their respective studs making sure that the terminals are completely seated on the studs.
8. Install the fuse link jumper P/N 4874208, 10 ga. for ZJ or P/N 4874209, 12 ga. for XJ over the two studs.
CAUTION:
Tightening of the nuts on the two terminal studs is critical. Over tightening the nuts can damage the PDC or the mounting plate and under tightening can lead to a poor electrical connection. Do not use any type of automatic ratchet or screw driver.
9. Hand start the nut on the battery side (the side that is integral to the metal buss bar). With the crimp area of the fuse link jumper terminal facing the alternator stud and resting against the front of the box, tighten the nut to 8.5 Nm (75 in.lb.). Repeat the procedure for the alternator side with the fuse link terminal on the alternator stud located so that the crimp area faces the battery stud and is parallel to the front of the box. Tighten the nut to 8.5 Nm (75 in.lb.).
NOTE:
Extra care must be taken when tightening the nut on the alternator stud, to prevent breakage.
The fuse link jumper should be looped downward resting in the cavity left by the removal of the mega-fuse retaining finger (See Figure 2).
10. Install the PDC end cover.
11. Install the battery negative terminal and tighten the nut to 8.5 Nm (75 in.lb.).
12. Check for proper operation of the electrical systems.
13. Clear any stored fault codes using the MDS or DRB III.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Replace PDC Mega Fuse With Fusible Link
08-90-01-90 0.3 Hrs.
Replace Alternator Terminal Mounting Plate
08-90-01-91 0.1 Hrs.
FAILURE CODE: P8 - New Part