2005 Tj Chassis

  • Upload
    art-doe

  • View
    216

  • Download
    0

Embed Size (px)

Citation preview

  • 8/14/2019 2005 Tj Chassis

    1/72

    TABLE OF CONTENTS

    1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

    1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1

    2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

    3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

    3.1 TEVES MARK 20I SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.1.1 PEDAL FEEL/VEHICLE CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . .23.1.2 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.1.3 ABS AND BRAKE WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . .23.1.4 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . .23.1.5 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.1.6 RELAYS/SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.1.7 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

    3.2 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.2.1 SYSTEM INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    3.2.2 DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.2.3 INTERMITTENT DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . .43.3 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    3.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    3.4 USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.5 DRBIII ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

    3.5.1 DRBIII DOES NOT POWER UP (BLANK SCREEN) . . . . . . . . . . . . . .53.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

    4.0 DISCLAIMERS, SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

    4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

    4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.2 VEHICLE PREPARATION FOR TESTING . . . . . . . . . . . . . . . . . . . . . . . .64.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.4 DRBIII SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

    4.3 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . .7

    4.4 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

    7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

    BRAKES (CAB)CAB POWER FEED CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10CONTROLLER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13G-SWITCH NOT PROCESSABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15LEFT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19LEFT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

    i

  • 8/14/2019 2005 Tj Chassis

    2/72

    TABLE OF CONTENTS - Continued

    RIGHT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19RIGHT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19LEFT FRONT SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22LEFT REAR SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22RIGHT FRONT SENSOR SIGNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22RIGHT REAR SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22PUMP MOTOR NOT WORKING PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

    SYSTEM OVER VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29SYSTEM UNDER VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31*ABS WARNING INDICATOR ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33*ABS WARNING INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35*BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37*FRONT AXLE LOCK INDICATOR REMAINS FLASHING . . . . . . . . . . . . . . . . . . . . . . .38*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . .40*REAR AXLE LOCK INDICATOR REMAINS FLASHING . . . . . . . . . . . . . . . . . . . . . . . .42*REAR AXLE LOCK INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

    VERIFICATION TESTSVERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

    8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

    8.1 CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.3 G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.4 FUSES & RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.5 WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.6 WHEEL SPEED SENSOR CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.7 BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

    8.7.1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518.7.2 BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

    9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

    AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY. . . . . . . . . . . . . . . . . . . . . . . .53BRAKE LAMP SWITCH - GRAY 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .53C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . . .53C115 (OFF-ROAD PACKAGE) - BLACK (FRONT FEEDBACK OVERLAY SIDE). . . . .54C116 (OFF-ROAD PACKAGE) - LT GRAY (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . .54C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR FEEDBACK OVERLAY SIDE) . . . .54CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . .54CONTROLLER ANTILOCK BRAKE - 25 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

    DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY . .56FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . .56G-SWITCH (LHD) - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56INSTRUMENT CLUSTER C1 - 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56INSTRUMENT CLUSTER C2 - 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57LEFT FRONT WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .57LEFT REAR WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58LEFT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . . . .58

    ii

  • 8/14/2019 2005 Tj Chassis

    3/72

    TABLE OF CONTENTS - Continued

    FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60FRONT LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE). . . . . . . . . . . . . . . . . . . . . .60REAR LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE) . . . . . . . . . . . . . . . . . . . . . . .60REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY. . . .61REAR LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . . .61RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .61RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . .62

    RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .62RIGHT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .62VEHICLE SPEED SENSOR - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

    10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

    10.1 TEVES MARK 20I CONTROLLER ANTILOCK BRAKE - ABS . . . . . . . . . . . . . . .6510.2 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

    iii

  • 8/14/2019 2005 Tj Chassis

    4/72

    NOTES

    iv

  • 8/14/2019 2005 Tj Chassis

    5/72

    1 .0 I N T ROD UC T I ON

    The procedures contained in this manual include

    all the specifications, instructions, and graphics

    n e ed e d t o d ia g n os e t h e 2 00 5 T J C h a s s is s ys t e m

    problems: Teves Mark 20i Antilock Braking System

    (ABS) and Axle Lock. The diagnostics in this man-

    ual are based on the failure condition or symptom

    being present at time of diagnosis.Follow the recommendations below when choos-

    ing your diagnostic path.

    1 . F i r s t m a k e s u r e t h e D R BI I I is communicating

    w i t h t h e C A B . I f t h e D R B I I I displays a No

    Response condition, you must diagnose that

    first.

    2. Read DTCs (diagnostic trouble codes) with th e

    DRBIII.

    3. If no DTCs are present, identify t he customer

    complaint.

    4. Once t he DTC or customer complaint is identi-

    fi ed , l oca t e t h e m a t c h in g t e s t i n t h e Ta b le of Contents and begin t o diagnose the symptom.

    All component location views are in Section 8.0.

    All connector pinouts are in Section 9.0. All sche-

    matics are in Section 10.0.

    An asterisk (*) placed before the symptom de-

    scription indicates a customer complaint.

    When repairs a re r equired, refer t o the a ppropri-

    a t e s er vice m a n u a l for t h e p r op er r e m ova l a n d

    repair procedure.Diagnostic procedures change every

    year. New diagnostic systems may be added; carryover

    syst em s m ay b e en h an ced . R E AD T H IS M AN U AL

    BEFORE TRYING TO DIAGNOSE A VEHICLE DI-

    AGNOSTIC TROUBLE CODE. It is recommended

    that you review the entire manual to become familiar

    with all new and changed diagnostic procedures.

    After using this book, if you have any comments

    or recommendations, please fill out the form at the

    back of the book and mail it back to us.

    1. 1 SYSTEM COVERAGE

    This diagnostic manual covers the Teves Mark

    20i Antilock Braking System (ABS) found on the

    2005 Jeep Wrangler. Diagnosis of the Axle Lock is

    covered in this manual.

    1. 2 SIX-STEP TROUBLESHOOTINGPROCEDURE

    Diagnosis of the a ntilock brak e system is done in

    six basic steps:

    verification of complaint

    verificat ion of any r elated symptoms

    symptom analysis

    problem isolation

    repair of isolated problem

    verification of proper operation

    2 . 0 I D EN T I F I C AT I ON OFSYSTEM

    Vehicles equipped with the Teves Mark 20i an-

    ti lock brake system can be identified by the pres-ence of t he hydraulic contr ol unit (HCU) located

    un der t he h ood nea r t he power bra ke booster. Vehi-

    cles equipped with Axle Lock can be identified by

    the presence of the Axle Lock Switch located on the

    lower center of the instrument panel.

    3 . 0 SYST EM D ESCR I PT I ON A N DFUNCTIONAL OPERATION

    3.1 TEVES MARK 20I SYSTEM

    DESCRIPTION

    An electronic control module is used to monitor

    wheel speeds and to modulate (control) hydraulic

    p r e s s u r e i n e a c h b r a k e c h a n n e l t o p r e v e n t w h e e l

    lock-up during braking.

    During a non-ABS stop, the system functions a s a

    standar d front/rear split configuration. The pri-

    mary hydraulic system supplies brake fluid pres-

    sure to th e front brakes, and the secondary h ydrau-

    lic system supplies the rear brakes. A conventional

    combination/proportioning valve is used.

    D u r i n g a n A B S s t o p , t h e s y s t e m s t i l l u s e s t h e

    front/rear hydraulic split; however, the brakes sys-

    t e m p r e ss u r e i s f u r t h e r s p li t i n t o t h r e e con t r o l

    chan nels. During ABS operation, the front wheels

    are controlled independently an d are on two sepa-

    r a t e con t r o l c h a n n e ls . T h e r e a r w h ee ls a r e con -

    trolled together thr ough one control chann el. By

    u s in g a s e pa r a t e con t r o l c h a n n e l f or e a ch fr on t

    wheel, m ore steering control is maintained during

    maximum braking.

    Du rin g an an tilock stop, wh eel lock-up d oes not

    n e ce s sa r i ly m e a n t h a t t h e w h e el h a s l ock e d, i t

    m e a n s o n ly t h a t t h e w h e el i s t u r n i n g s low er t h a n

    th e veh icle speed. This is called wheel s lip an d isindicated as a percentage. 0% slip means that the

    wheel is r olling free an d 100% slip means tha t the

    wheel is locked. The antilock system maintains an

    average of approximately 20% wh eel slip.

    I t i s i m p or t a n t t o r e m e m be r t h a t t h e a n t i lock

    brake system does not shorten the vehicle stopping

    distance under all driving conditions, but provides

    improved control of the vehicle while stopping.

    Vehicle stopping distance is still dependent on ve-

    hicle speed, weight, t ires, road surface, and other

    factors.

    1

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    6/72

    3. 1.1 PEDAL FEEL/VEHICLE

    CHARACTERISTICS

    There are several pedal feel/vehicle characteris-

    tics th at ar e considered norma l for a ntilock braking

    that may require further explanation.

    When stopping conditions activate the ant ilock

    b r a ke s, t h e d r iv er m a y fe el s om e vib r a t ion s /

    p u l s a t i o n s i n t h e b r a k e p e d a l a n d m a y h e a r t h esolenoid valves clicking a nd the pump motor run -

    ning. The vibrations/pulsations are caused by the

    isolating, building an d d ecaying of brake fluid pr es-

    s u r e w it h in t h e b r a ke lin e s. T h e A BS p r ev en t s

    complete wheel lock-up, but some wheel slip is

    required for t he best brak ing performa nce. This slip

    may result in some tire chirping, depending on the

    r oa d s u r fa ce . T h is ch i r p in g s h ou l d n ot b e i n t er -

    preted as total wheel lock-up. Total wheel lock-up

    leaves black tire marks on dry pavement. Antilock

    braking may leave some light m arks.

    At the end of an ABS stop, the ABS system may

    not function below 5 Km /h (3 mph). There ma y be aslight brake pedal drop anytime the ABS is deacti-

    vated.

    In case of braking on a bumpy sur face, th e ABS

    module may detect wheel locking t endencies du e to

    wheel hop and cycle ABS. In that event the brake

    pedal may pulsate with a perceived loss of deceler-

    ation. ABS braking ma y also be activated at t imes

    while on dry pavement with san d, gravel, or other

    loose debris on the road.

    It should be noted that the pulsating pedal feel

    chara cteristic will not illum inate t he bra ke warn ing

    indicators or set a diagnostic trouble code that is

    stored in the Controller Antilock Brake (CAB).

    When investigating a hard pedal feel, inspect the

    sensor and tone wheel teeth for chips/broken teeth,

    damaged sensor pole t ips, excessive ru nout of th e

    tone wheel, or excessive gap.

    3. 1.2 SYSTEM COMPONENTS

    A n t i l o c k B r a k e S y s t e m

    controller antilock brake (CAB)

    vacuum booster

    mast er cylinder (w/center valves)

    hydraulic control unit (HCU)valve block a ssembly: 6 valve solenoids (3 inlet

    valves, 3 outlet valves), 3

    accumulators

    pum p/motor a ssembly: 1 motor

    2 p u m p s

    G (acceleration) switch

    1 proportioning valve

    4 wheel speed sensor/tone wheel assemblies

    ABS warning indicator

    fuses and wiring harness

    fluid reservoir (integral part of master cylinder

    assembly)

    3. 1.3 ABS AND BRAKE WARNING

    INDICATORS

    The amber ABS warning indicator is located in

    t h e i n st r u m e n t cl u st e r. I t i s u s e d t o i n for m t h edriver tha t th e ant ilock function h as been tu rn ed off

    d u e t o a s ys t e m m a l fu n c t ion . O n a T J m od e l t h e

    warning indicator is controlled by the CAB and the

    ABS relay. The CAB controls the indicator by di-

    rectly groun ding t he ABS relay contr ol circuit. The

    ABS relay grounds the indicator circuit when it is

    de-energized.

    The red brake warning indicator is located in the

    instrument cluster. I t can be activated by applica-

    tion of the parking brake, low brake fluid level or by

    turn ing the ignition switch to th e sta rt position.

    3. 1. 4 CONTROLLER ANTILOCK BRAKE(CAB)

    T he con t r oller a n t ilock b ra k e (C AB ) is a

    microprocessor-based device tha t monitors wheel

    speeds and controls the antilock functions.

    The primary functions of the CAB are:

    monitor wheel speeds

    detect wheel locking tendencies

    control fluid pressure modulation to the brakes

    during antilock stop operation

    monitor the system for proper operation

    provide communication to the DRBIII while in

    diagnostic mode

    contr ol t he ABS relay

    store diagnostic information in non-volatile mem-

    or y

    The CAB continuously monitors the speed of each

    wheel. When a wheel locking tendency is detected,

    th e CAB will comma nd t he app ropriate valve in t he

    H C U t o m od u la t e b r a ke flu id p r es su r e t o t h a t

    wheel. Brake pedal position is maintained during

    an antilock stop by being a closed system with the

    use of three accumulators. The CAB continues to

    contr ol pressure in individual hydraulic circuitsun til a wheel locking t endency is no longer pr esent.

    T h e C A B t u r n s o n t h e p u m p / m o t o r d u r i n g a n a n -

    tilock stop.

    The a ntilock brake system is constan tly moni-

    tored by the CAB for proper operation. If the CAB

    d e t ect s a s ys t e m m a l fu n c t ion , i t ca n d is a b le t h e

    a n t ilock s ys t em a n d t u r n on t h e A BS w a r n in g

    indicator. If t he ant ilock function is disabled, the

    system will revert to standard base brake system

    operation.

    2

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    7/72

    The CAB inpu ts include th e following:

    four wheel speed sensors

    brake lamp switch

    ignition switch

    battery voltage

    diagnostic communication

    G switch (acceleration switch)

    The CAB outputs include the following:

    six valve/solenoid drivers

    pump/motor actuation

    ABS warning indicator control

    diagnostic communication

    3.1. 5 HYDRAULIC CONTROL UNIT

    The hydraulic control un it (HCU) conta ins t he

    valve block assembly, three accumulators, and the

    pump/motor assembly.

    Va l v e B l o c k A s s e m b l y : The valve block assem-

    bly contains 6 valves with three inlet valves andt h r e e ou t l et v a lv es . T h e i n le t v a lv es a r e s p r in g -

    loaded in t he open position a nd t he outlet valves are

    s p r in g l oa d e d i n t h e cl os e d p os it i on . D u r in g a n

    antilock stop, these valves are cycled to maintain

    the proper slip ratio for each channel. If a wheel

    locks, the inlet valve is closed to prevent any further

    pressure increase. Then the outlet valve is opened

    t o r e l e a s e t h e p r e s s u r e t o t h e a c c u m u l a t o r s u n t i l

    the wheel is no longer slipping. Once the wheel is no

    longer slipping, the outlet valve is closed and the

    i n le t v a lv e i s op e n ed t o r e a p pl y p r e s s u r e. I f t h e

    wheel is decelerating within its predetermined lim-

    its (proper slip ratio), both valves will close to hold

    the pressure constant.

    P u m p / M o t o r A s s e m b l y : T h e p u m p /m ot or a s -

    sembly pr ovides t he extra amount of fluid needed

    durin g ant ilock br aking. The pu mp is su pplied fluid

    tha t is released to th e accum ulators when t he outlet

    valve is opened during an antilock stop. The pump

    is also used to drain the accumulator circuits after

    the ant ilock st op is complete. The pu mp is operat ed

    by a n integral electric motor. This motor is con-

    trolled by the CAB. The CAB turns on the motor

    when an antilock stop is detected. The pump con-

    tinues to run during the an tilock stop and is tu rnedoff a p p r ox im a t e ly 3 -5 s e con d s a ft e r t h e s t op i s

    com p le t e. T h e p u m p m e ch a n i s m con s is t s of t w o

    opposing pistons operat ed by a n eccentr ic cam . One

    piston supplies the primary hydraulic circuit . The

    opposing piston supplies the secondary hydraulic

    circuit . In operation, one piston draws fluid from

    the accum ulators. Th e opposing piston pum ps fluid

    to the valve body solenoids. The CAB monitors the

    pump/motor opera tion.

    A c c u m u l a t o r s : The accumulators provide tem-

    porary fluid storage during a n a ntilock stop an d ar e

    drained by the pump/motor.

    3.1.6 RELAYS/SWITCHES

    R e l a y s : The ABS Relay is located in the power

    distribution center (PDC). When the relay is de-

    energized, it supplies a ground to turn on the ABS

    warning indicator. The ABS relay is controlled byt h e C AB . T h e C AB e n er g iz es t h e r e la y w h e n i t

    receives an ignition input signal.

    3.1. 7 SENSORS

    Wh e e l S p e e d S e n s o r s a n d To n e Wh e e l s : On e

    wheel speed sensor (WSS is located at each wheel

    a n d s en d s a s m a ll AC s ign a l t o t h e C on t r olle r

    Antilock Brake (CAB). This voltage is generated by

    m a g n et i c i n d u ct i on w h e n a t oot h e d s e n sor r i n g

    (tone wheel) passes by a st at iona ry m agnetic sensor

    (wheel speed sensor). The CAB converts the AC

    signals into digital signals for each wheel.The front wheel sensor is atta ched t o a boss in th e

    steering knu ckle. The tone wheel is an integral par t

    of t h e fr on t a x le s h a ft . T h e r e a r s p ee d s e n sor i s

    mounted in t he caliper ada pter plat e (rear disc only)

    a n d t h e r e a r t o n e w h e e l i s a n i n t e g r a l p a r t o f t h e

    rear rotor h ub. The front wheel speed sensor air gap

    is NOT adjustable. The correct front wheel speed

    sensor air gap is from 0.40mm to 1.3mm (0.016 t o

    0.051). P r e fe r r ed r e a r s e n sor a i r g a p f or d r u m

    brak e systems is 1.1mm (0.043). Acceptable a ir ga p

    range is 0.92mm to 1.275mm (0.036 to 0.050). All

    wheel speed sensors have a resistance between 900

    and 1300 ohms.Correct ant ilock system operation is dependent

    on correct wheel speed signals from the wheel speed

    sens ors. The vehicles wheels a nd t ires sh ould all be

    the sa me size an d type. In addition, the tires should

    be inflated to the recommended pressures for opti-

    mum system operation. Varia tions in wh eel and tire

    size or significant variations in inflation pressure

    can produce inaccurate wheel speed signals; how-

    ever, the system will continue to function when

    using the mini-spare. When driven over rough road

    surfaces, the rear wheel speed sensor signals may

    be erratic and cause a false trouble code.

    G ( A c c e l e r a t i o n ) S w i t c h : The CAB monitorst h e a cce le r a t ion s w it ch a t a l l t i m es . T h e s w it ch

    a s s em b ly con t a i n s t h r e e m e r cu r y s w it ch e s t h a t

    monitor vehicle deceleration rat es (G-force). Sud-

    den, rapid changes in vehicle and wheel decelera-

    tion rate trigger t he switch, sending a signal t o the

    CAB. The switch a ssembly responds to t hree decel-

    eration rates; two for forward braking and one for

    rearward braking.

    3

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    8/72

    3. 2 DIAGNOSTIC TROUBLE CODES

    The Teves Mar k 20i Ant ilock Bra ke Syst em (ABS)

    module may report any of the following diagnostic

    trouble codes:

    Controller Failure

    G Switch Not Processable

    Left Front Sensor Circuit Failure Left Front Sensor Signal Failure

    Left Rear Sensor Circuit Failure

    Left Rear Sensor Signal Failure

    CAB Power Feed Circuit

    System Over voltage

    System Under voltage

    Pump Motor Not Working Properly

    Right Front Sensor Circuit Failure

    Right Front Sensor Signal Failure

    Right Rear Sensor Circuit Failure

    Right Rear Sensor Signal Failure

    Diagnostic trouble codes are retained in memory

    u n t i l e r a s e d u s i n g t h e D R B I I I, or aut omatically

    erased after 255 key cycles.

    3.2.1 SYSTEM INITIALIZATION

    S ys t em in it ia liza t ion s t a r t s w h en t h e k ey is

    turned to RUN. At this point, the CAB performs a

    complete self-check of all electrical components in

    the antilock brake systems.

    At around 19 km/h (12 miles per hour), the pump

    motor is briefly activated to ensure operation, and

    wheel speed sensor circuitry is checked. If the brakepedal is applied when the vehicle reaches 19 km/h

    (12 mph), this check will be delayed until 40 km/h

    ( 2 5 m p h ) . I f , d u r i n g t h e d y n a m i c t e s t , t h e b r a k e

    p ed a l is a p pl ie d, t h e d r iv er m a y fe el t h e t e st

    t h r o u gh b r a k e p e d a l p u l s a t ion s . T h i s i s a n or m a l

    condition. Throughout the remainder of the drive

    cycle, ongoing tests are performed, and the CAB

    monitors ABS circuits for continuity.

    If any component causes a diagnostic trouble code

    during system initialization or dynamic check, the

    CAB will illuminate the ABS warning indicator.

    3.2.2 DIAGNOSTIC MODETo enter diagnostic mode, vehicle speed must be

    below 10 km/h (6 m ph), a no response message

    will be displayed by the DRBIII. The following a re

    chara cteristics of diagnostic m ode:

    The ABS warning indicator will f lash. If a hard

    d ia g n os t ic t r ou b le cod e i s p r e se n t , s u ch a s a

    Speed Sensor Circuit or Signal Failure t rouble

    code or CAB P ower Feed Circuit diagnostic trou-

    ble code, the indicator will be illuminated without

    blinking and limited diagnostic operations only

    will be a vailable u nt il the diagnostic tr ouble code

    condition is corrected.

    Antilock operation is disabled.

    3. 2.3 INTERMITTENT DIAGNOSTIC

    TROUBLE CODES

    If the malfunction is not present while perform-ing a test procedure, the diagnostic procedures will

    not locate the problem. In this case, the code can

    on ly s u gge st a n a r e a t o i n sp ect . C h eck for t h e

    following:

    loose or corr oded connections

    dam aged components (sensors, tone wheels espe-

    cially)

    damaged wiring

    excessive axle shaft runout

    brake system hydraulic leaks

    base brake system problems, non-ABS related.If no obvious p roblems ar e foun d, era se diagn ostic

    trouble codes and, with the key on, wiggle the wire

    ha rness an d connectors. Recheck for codes per iodi-

    cally a s you work thr ough the system. This proce-

    d u r e m a y u n c ov er a n i n t er m i t t en t or d iffi cu l t t o

    locate malfunction.

    3.3 AXLE LOCK

    3.3.1 GENERAL

    For this vehicle, the Axle Lock has no dedicated

    module controller. A manual switch located on theinstrument panel controls th e system. No DTCs

    will occur for this system.

    3.3.2 DESCRIPTION

    The a xle lock h as the ability to lock the front and

    rear axle differentials. The system components are

    the instrument cluster, axle lock switch, front and

    rear locker relays, front a nd r ear locker pu mps, an d

    locker ind icat or switches. To operat e both lockers

    three requirements need to be met:

    1. ignition in t he ON position

    2. tran sfer case ran ge sensor indicating 4 LOWr a n g e

    3. vehicle speed less tha n 16km/h (10 mph)

    The 16km/h (10 mph) engagement is for engage-

    ment only. All axles will r emain locked if vehicle

    speed does not exceed 72 km/h (45 mph).

    The instrument cluster has the control logic that

    monitors these requirements. If the requirements

    are not met the axle lock switch will be disabled.

    The axle lock switch receives the enable signals

    from the instrument cluster. Any subsequent down-

    4

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    9/72

    ward press of the axle lock switch will operate the

    front locker relay and front locker pump. The first

    downward press on the axle lock switch locks the

    r e a r a x le , t h e s e con d d ow n w a r d p r e ss l ock s t h e

    front axle (rear is still locked), th e th ird downward

    press unlocks the front axle (rear is still locked), the

    fourth downward press locks the front axle (rear

    axle is st i l l locked). An upward press on the axle

    lock switch at any time will unlock any axle that iscur rent ly locked.

    The enabled axle lock switch energizes the locker

    r e la y a n d v ol t a ge i s s e n t t o t h e l ock e r p u m p t o

    supply 5 psi of air t o the a xle allowing th e differen-

    tial to lock up. The axle lock indicator on the

    i n st r u m e n t cl u st e r fl a sh e s d u r i n g t h e t r a n s i t ion

    state. The instrument cluster is seeking lock feed-

    b a ck fr om t h e l ock i n g i n di ca t or s w it ch . Wi t h a

    successful lock requ est th e axle lock indicator will

    be illuminated and a chime will sound.

    If an a xle is engaged t he a xle lock switch r emains

    enabled until all axles are unlocked, regardless if

    the key is removed from the ignition switch. If theignition key is removed and either axle is locked the

    instrument cluster axle lock indicator to the cor-

    responding axle will flash and the chime will sound

    three t imes to alert of battery discharge. Flashing

    axle lock indicators will continue until axles are

    unlocked. Once the axles have been locked it will

    remain locked until one of the following happens:

    1. an upward press of the axle lock switch for all

    locked axles or downward press for front axle

    only

    2. tra nsfer case is shifted out of 4 LOW ran ge

    3. vehicle speed exceeds 72 km/h (45 mph)

    4. loss of batt ery power

    3.4 USING THE DRBIII

    Refer t o the DRBIII user s guide for ins tr uctions

    a n d a s s is t a n ce w it h r e a d in g d ia g n os t ic t r ou b le

    codes, erasing trouble codes and other DRBIII

    functions.

    3.5 DRBIII ERROR MESSAGES

    Under normal operation, the DRBIII will dis-

    play one of only two error messages:

    U s e r R eq u es t e d WAR M B oot or U s e r R e-

    quested COLD Boot

    This is a sa mple of such an error messa ge display:

    ver: 2.14date: 26 J ul93file: key_itf.ccdate: Jul 26 1993line: 548err: 0x1User-Requested COLD Boot

    Press MORE to switch between this displayand the application screen.Press F4 when done noting information.

    3.5.1 DRBIII DOES NOT POWER UP

    (BLANK SCREEN)

    If the LE Ds do not light or no soun d is emitt ed at

    star t up, check for loose cable conn ections or a bad

    cable. Check the vehicle battery voltage (data link

    16-way conn ector cavity 16). A min imum of 11 volts

    is required to adequately power the DRBIII. Also,

    check for a good ground at the DLC.

    I f a ll con n ect ion s a r e p r op er b et we en t h eDRBIII and the vehicle or other devices, and the

    vehicle bat tery is fully charged, an d inoperative

    DRBIII may be the result of faulty cable or vehicle

    wiring.

    3.5. 2 DISPLAY IS NOT VISIBLE

    Low temperatures will affect the visibility of the

    display. Adjust the contrast to compensate for this

    condition.

    4.0 DISCLAIMERS, SAFETYWARNINGS

    4.1 DISCLAIMERS

    All information, illustrations, and specifications

    c o n t a i n e d i n t h i s m a n u a l a r e b a s e d o n t h e l a t e s t

    5

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    10/72

    informat ion available at the t ime of publication.

    The right is reserved to make changes at any t ime

    without notice.

    4.2 SAFETY

    4. 2. 1 TECHNICIAN SAFETY INFORMATION

    WARNING: ENGINES PRODUCE CARBONMONOXIDE THAT IS ODORLESS, CAUSESSLOWER REACTION TIME, AND CAN LEADTO SERIOUS INJURY. WHEN THE ENGINE ISOPERATING, KEEP SERVICE AREAS WELLVENTILATED OR ATTACH THE VEHICLEEXHAUST SYSTEM TO THE SHOP EXHAUSTREMOVAL SYSTEM.

    Set th e park ing brake a nd block the wheels before

    t e s t in g or r e p a ir i n g t h e v eh i cl e. I t i s e sp e ci a ll y

    important to block the wheels on front-wheel drive

    vehicles; the parking brake does not hold the drivewheels.

    When servicing a vehicle always wear eye protec-

    tion and remove any metal jewelry such as watch-

    bands or bracelets th at m ight make a n inadvertent

    electrical contact.

    Additional safety procedures can be found in the

    service ma nu al. Following th ese procedures is very

    important to avoid injury.

    4. 2. 2 VEHICLE PREPARATION FOR

    TESTING

    M a k e s u r e t h e v e h i c l e b e i n g t e s t e d h a s a f u l l ych a r g ed b a t t e r y. I f i s d oe s n ot , fa l se d ia g n os t ic

    trouble codes or error messages may occur.

    4. 2.3 SERVICING SUB-ASSEMBLIES

    Some components of the antilock brake system

    are intended to be serviced in assembly only. At-

    tempting to remove or repair certain system sub-

    components may result in personal injury and/or

    improper system opera tion. On ly those component s

    with appr oved repair a nd inst allation pr ocedures in

    the service manual should be serviced.

    4.2.4 DRBIII SAFETY INFORMATION

    WARNING: EXCEEDING THE LIMITS OF THEDRBIII MULTIMETER IS DANGEROUS. ITCAN EXPOSE YOU TO SERIOUS ORPOSSIBLY FATAL INJURY. CAREFULLYREAD AND UNDERSTAND THE CAUTIONSAND THE SPECIFICATION LIMITS.

    Follow t he vehicle m an ufacturer s service speci-

    fications at all times.

    Do not use th e DRBIII if i t ha s been dam aged.

    D o n ot u s e t h e t e st le a ds if t h e in s u la t ion is

    damaged or if metal is exposed.

    To a void electrical shock, do n ot touch the test

    leads, tips or the circuit being tested.

    C h oos e t h e p r op e r r a n g e a n d fu n c t ion for t h e

    measurement. Do not try voltage or current mea-

    surements that may exceed the rated capacity. Do not exceed the limits shown in the table below:

    F U N CTION IN P U T LIMIT

    Volt s 0 - 500 pea k volt s AC

    0 - 500 volts DC

    O h m s (r e si st a n ce )* 0 - 1 .1 2 m e goh m s

    Frequency Measured

    Frequency Generated

    0 - 1 0 k H z

    Tem per a t u r e -50 - 600C

    -58 - 1100F

    * Ohms cannot be measured if voltage is present.O h m s ca n b e m e a su r e d on l y i n a n on -p ow er e d

    circuit.

    Voltage between any terminal and ground must

    not exceed 500v DC or 500v peak AC.

    Use caution when measuring voltage above 25v

    DC or 25v AC.

    Use the low current shunt to measure circuits up

    to 10A. Use the high current clamp to measure

    circuits exceeding 10A.

    When testing for the presence of voltage or cur-

    r e n t , m a k e s u r e t h e m e t e r i s f u n ct i on i n g c or -

    r e ct l y. Ta k e a r e a d in g of a k n ow n v ol t a ge orcurrent before accepting a zero reading.

    When measuring current, connect the meter in

    series with the load.

    Disconnect the live test lead before disconnecting

    the common test lead.

    Wh en u sin g t h e m et er fu n ct ion , k eep t h e

    DRBIII away from spark plug or coil wires to

    avoid m easur ing error from outside inter ference.

    4.3 WARNING

    4. 3.1 VEHICLE DAMAGE WARNINGS

    Before disconnecting any control module, make

    s u r e t h e i gn i t ion i s O F F . F a i l u r e t o d o s o c ou l d

    damage t he m odule.

    When t esting voltage or continu ity at an y control

    module, use the terminal side (not the wire end) of

    the connector. Do not pierce wire insulation; this

    will damage i t and eventually cause i t to fail be-

    cause of corrosion.

    6

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    11/72

    Be careful when performing electrical tests so as

    to prevent accidental shorting of terminals. Such

    mistakes can damage fuses or components. Also, a

    second code could be set, making diagnosis of the

    original problem more difficult.

    4.3. 2 ROAD TESTING A COMPLAINT

    VEHICLE

    Some complaints will require a test drive as part

    of th e r epair verificat ion procedure. The purp ose of

    the test drive is to try to duplicate the diagnostic

    code or symptom condition.

    NOTE: After the repair of pump or speedsignal DTCs, the vehicle must be driven at 25km/h (15 mph) to clear the DTC from the CAB.

    WARNING: BEFORE ROAD TESTING AVEHICLE, BE SURE THAT ALLCOMPONENTS ARE REASSEMBLED.

    DURING THE TEST DRIVE, DO NOT TRY TOREAD THE DRBIII SCREEN WHILE INMOTION. DO NOT HANG THE DRB FROMTHE REAR VIEW MIRROR OR OPERATE ITYOURSELF. HAVE AN ASSISTANTAVAILABLE TO OPERATE THE DRBIII.

    4.4 DIAGNOSIS

    1. Your diagnostic test pr ocedure mu st begin with a

    thorough visual inspection of the ABS for dam-

    aged components or disconnected connectors.

    T h e b r a k e l a m p s m u s t b e o p e r a t i o n a l p r i o r t ocontinuing.

    2. Connect the DRBIII to the data link connector

    located under the dash. If the DRBIII does not

    power up, check the power and ground supplies

    to t he conn ector.

    3. Select Ant ilock Br ak es. Tur n t he ign ition on. If

    t h e D RB I II disp lays No Resp onse, per form

    the proper test .

    4 . R ea d a n d r e cor d a l l A BS d ia g n os t ic t r ou b le

    codes. If t he CAB P ower Feed Circuit tr ouble

    cod e i s p r e se n t , i t m u s t b e r e p a i r ed p r ior t o

    addressing any other DTCs. If any additionalcod e s a r e p r e se n t , p r oce ed t o t h e a p p r op r ia t e

    test.

    5. If there ar e no diagnostic trouble codes present,

    s e le ct I n p u t s /O u t p u t s a n d r e a d t h e b r a k e

    switch input a s you press and release th e brake

    pedal. If the display does not m atch t he st ate of

    the pedal, perform the appr opriat e test. Read th e

    G-Switch stat us, with the vehicle on a level

    su rfa ce, both swit ches sh ould r ead CLOSE D. If

    the st atu s is not correct, perform t he appr opriate

    test. If a problem with the ABS warning indica-

    tor exists, refer to th e a ppropriate t est .

    6. If no other problem are found, i t will be neces-

    s a r y t o r o a d t e s t t h e v eh i cl e. T H E D R B I II

    MU ST N OT B E CON NE CTE D TO TH E

    D ATA L IN K C ON N E C T OR WH E N R O AD

    T E S TI N G F O R P R O P E R A N TI LO CK O P -

    E R AT IO N . T HE S YS T E M I S D I S AB L E D

    WH I LE I N D I AG N OS T I C M OD E . Performseveral antilock stops from above 50 Km/h (30

    m p h ) a n d t h e n r e p e a t s t e p s 2 , 3 , a n d 4 . I f a n y

    diagnostic trouble codes are present, proceed to

    the appropriate test .

    7. The following conditions should be considered

    NORMAL operat ion, a nd no r epair s sh ould be

    attempted to correct them.

    B r a ke p ed a l fe ed ba ck d u r in g a n AB S s t op

    (clicking, vibrat ing)

    Clicking, groaning or buzzing at 10 Km/h (6

    mph) (drive off self test)

    Groaning noise during a n ABS stop

    S li gh t b r a k e p e d a l d r op a n d p op n oi se w h e n

    ignition is initially turned on

    Brake pedal ratcheting down at the end of an

    ABS stop

    8. If the complaint is ABS cycling at t he end of a

    s t op a t low s pe ed s, it m a y b e c a us ed b y a

    marginal wheel speed sensor signal. The sensor

    a i r g a p , t on e w h e el con d it i on , a n d /or b r a k e s

    ha nging up ar e possible cau ses of this condition.

    9 . A ft e r a r oa d t e s t i n w h i ch n o p r o bl em s w er e

    found, refer to any Technical Service Bulletinsthat may a pply.

    5 . 0 R EQU I RED T OOL S A N DEQUIPMENT

    DRBIII (diagnostic read-out box)

    jumper wires

    ohmmeter

    voltmetertest lamp

    7

    GENERAL IN FORMATI ON

  • 8/14/2019 2005 Tj Chassis

    12/72

  • 8/14/2019 2005 Tj Chassis

    13/72

    7 .0

    DIAGNOSTI C I NFORM ATI ON AND

    PROCEDURES

    9

  • 8/14/2019 2005 Tj Chassis

    14/72

    S y m p t o m :

    CAB POWER FEED CIRCUIT

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    CAB POWER FEED CIRCUIT

    When Monitored: Ignition on. The CAB monitors t he F used B(+) circuit a t all times for

    proper system voltage.

    Set Condition: If the F used B(+) voltage is missing when the CAB detects th at a n intern al

    main driver is not on, the Diagnostic Trouble Code (DTC) is set.

    P O S S I B L E C A U S E S

    INTERMITTENT DTC

    B(+) CIRCUIT SHORTED TO GROUND

    BLOWN FUSE - FUSED B(+) CIRCUIT

    CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND

    FUSED B(+) CIRCUIT OPEN

    NO B+ SUP PLY TO FUSE

    CAB - FUSED B(+) CIRCUIT OPEN

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, era se DTCs.Turn the ignition off.

    Turn the ignition on.

    Drive the vehicle above 25 km/h (15 mph) for at least 10 seconds.

    Stop th e vehicle.

    With the DRBIII, read DTCs.

    Does the DRBIII display CAB Power Feed Circuit DTC present right now?

    All

    Yes G o To 2

    N o Go To 9

    2 Tu r n t h e ig ni t ion off.

    Rem ove and Ins pect F us e 12 in the P D C.

    Is the F us e blow n?

    All

    Yes G o To 3

    N o Go To 6

    10

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    15/72

    TES T ACTION AP P LICAB ILITY

    3 Tu r n t h e ig ni t ion off.

    Remove Fuse 12 from the PDC.

    Disconnect the CAB h arn ess connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .Using a test light connected to 12 volts, probe the Fused B(+) Circuit.

    Does the test light illuminate brightly?

    All

    Yes Repair the Fused B(+) Circuit Shorted to Ground.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 4

    4 Tu r n t h e ig ni t ion off.

    Remove Fuse 12 from the PDC.

    The CAB must be connected for the results of this test to be valid.

    Using a test light connected to 12 volts, probe the Fused B+ circuit at the PDC fuse

    term inal.

    Does the test light illuminate brightly?

    All

    Yes Replace t he Controller Antilock Bra ke in accordance w ith the

    Service Informa tion.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 5

    5 Tu r n t h e i gn it i on off.

    If there are no potential caus es rem aining, view repair .

    All

    Continue

    Replace the Fuse.

    Perform ABS VERIFICATION TEST - VER 1.

    6 Tu r n t h e i gn it i on off.

    Remove Fuse 12 from the PDC.

    Disconnect the CAB h arn ess connector.N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    M eas ure the res istance of the F us ed B+ circuit betw een the P D C fus e term inal and

    the CAB connector.

    Is the resistance below 5 ohms?

    All

    Yes G o To 7

    N o Repair the Fused B+ circuit for an open.

    Perform ABS VERIFICATION TEST - VER 1.

    7 R em ov e F u s e 1 2 fr om t h e P DC .

    Turn the ignition on.

    M eas ure the voltage of the F us ed B+ s upply to F us e 12 in the P D C.

    Is the voltage above 10 volts?

    All

    Yes G o To 8

    N o Repair the B+ Supply circuit for an open.

    Perform ABS VERIFICATION TEST - VER 1.

    8 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace t he Controller Antilock Brak e in accordance w ith the

    Service Informa tion.

    Perform ABS VERIFICATION TE ST - VER 1.

    11

    BRAKES (CAB)

    CAB POWER FEED CIRCUIT C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    16/72

    TES T ACTION AP P LICAB ILITY

    9 Tu r n t h e ig ni t ion off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.

    Visually inspect th e r elated wire har ness connectors. Look for broken, bent, pu shedout, or corroded t ermina ls.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were a ny pr oblems found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    12

    BRAKES (CAB)

    CAB POWER FEED CIRCUIT C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    17/72

    S y m p t o m :

    CONTROLLER FAILURE

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    CONTROLLER FAILURE

    When Monitored: Ignition on. The CAB monitors its int ern al microprocessors for correct

    operation.

    Set Condition: If the CAB detects a n interna l fault , the DTC is set .

    P O S S I B L E C A U S E S

    GROUND AND POWER CONNECTIONS

    GROUND CIRCUIT HIGH RESISTANCE

    GROUND CIRCUIT INTERFE RENCE

    CAB - INTE RNAL FAILURE

    TES T ACTION AP P LICAB ILITY

    1 Inspect for non-factory wiring tha t may interfere with CAB power or ground circuits.

    Disconnect the CAB h arn ess connector.

    Inspect the CAB wiring harness for incorrect routing and damage.

    Inspect the CAB harness and component connectors for corrosion and damage.

    Were an y concerns found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 2

    2 Tu r n t h e ig ni t ion off.

    Disconnect the CAB h arn ess connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the CAB ground circuits to body ground.

    Is the resistance below 1.0 ohm?

    All

    Yes G o To 3

    N o Repair the Ground circuit high resistance.

    Perform ABS VERIFICATION TEST - VER 1.

    3 Tu r n t h e i gn it i on off.

    Disconnect the CAB h arn ess connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Turn the ignition on.

    Turn on a ll accessories.

    Measure the voltage of the Ground circuit.

    Is the voltage below 1.0 volts?

    All

    Yes G o To 4

    N o Repair as necessary. Unsplice any accessories connected to t he

    CAB ground circuit. Reroute and shield any high voltage cables

    away from the CAB ground circuit.

    Perform ABS VERIFICATION TEST - VER 1.

    13

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    18/72

    TES T ACTION AP P LICAB ILITY

    4 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace the CAB.

    Perform ABS VERIFICATION TEST - VER 1.

    14

    BRAKES (CAB)

    CONTROLLER FAILURE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    19/72

    S y m p t o m :

    G-SWITCH NOT PROCESSABLE

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    G-SWITCH NOT PR OCESSABLE

    When M onitored: Ignition on. The CAB sends a test signal out to the G-switch and

    monitors the sense circuits #1 and #2.

    Set Condition: If the sense circuits ar e open for 2 minu tes while driving or a n otherwise

    improper signal is detected a t any time, th e Diagnostic Trouble Code (DTC) is set.

    P O S S I B L E C A U S E S

    G-SWITCH TEST SIGNAL CIRCUIT OPEN

    INTERMITTENT DTC

    G-SWITCH TEST SIGNAL OR SENSE CIRCUIT SHORT TO VOLTAGE OR GROUND

    G-SWITCH SIGNAL CIRCUIT INTERNAL OPEN

    CAB - TEST SIGNAL CIRCUIT OPEN

    G-SWITCH #1 SENSE CIRCUIT OPE N

    G-SWITCH #1 SENSE SWITCH OPEN

    CAB - #1 SENSE CIRCUIT OPEN

    G-SWITCH #2 SENSE CIRCUIT OPE N

    G-SWITCH #2 SENSE SWITCH OPEN

    CAB - #2 SENSE CIRCUIT OPEN

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, read the s tatus of the G -S w itch interna l s w itches .

    What is the status of both of the G-Switches?

    All

    Both G-Switches are closed.

    G o To 2

    Both G-Switches are open.

    G o To 3

    Only the #1 G-Switch is open.

    G o To 7

    Only the #2 G-Switch is open.

    G o To 1 0

    15

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    20/72

    TES T ACTION AP P LICAB ILITY

    2 Tu r n t h e ig ni t ion off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.

    Visually inspect th e r elated wire har ness connectors. Look for broken, bent, pu shedout, or corroded t ermina ls.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were a ny pr oblems found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    3 Tu r n t h e ig ni t ion off.

    Disconnect the CAB connector.

    C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .

    Disconnect the G-Switch Sensor Connector.

    N O TE : C h e c k c o n n e c t o r - C l e a n / re p a i r a s n e c e s s a r y.

    Measure the resistance of the G-Switch Test Signal circuit.Is the resistance below 5 ohms?

    All

    Yes G o To 4

    N o Repair the G-Switch Test Signal Circuit Open.

    Perform ABS VERIFICATION TEST - VER 1.

    4 Tu r n t h e i gn it i on off.

    Disconnect the CAB Connector.

    C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .

    Disconnect the G-Switch Sensor Connector.

    C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .

    Turn the ignition on.

    Using a 12-volt t est light connected t o ground, check th e Test Signa l an d both Sen se

    circuits.Using a 12-volt test light connected to 12-volts, check the Test Signal and both Sense

    circuits.

    C AU T IO N : T h e t e s t l i g h t s h o u l d n o t l i g h t a t a n y t e s t p o i n t .

    D oes the tes t l ight i l lum inate at any t es t point?

    All

    Yes Repair the G -S w itch Tes t S ignal or S ens e circuit for a s hort to

    voltage or ground.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 5

    5 Tu r n t h e i gn it i on off.

    Disconnect the G-Switch Connector.

    C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .

    Remove G-Switch from vehicle.While holding the G-Switch level, measure the resistance of the G-Switch Test Signal

    circuit a nd the G-Switch #1 Sense circuit in th e G-Switch connector.

    Is the resistance below 5 ohms?

    All

    Yes G o To 6

    N o Replace G-Switch.

    Perform ABS VERIFICATION TEST - VER 1.

    16

    BRAKES (CAB)

    G-SWITCH NOT PROCESSABLE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    21/72

    TES T ACTION AP P LICAB ILITY

    6 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace the CAB.

    Perform ABS VERIFICATION TEST - VER 1.

    7 Tu r n t h e ig ni t ion off.

    Disconnect the CAB Connector.

    N o t e : Ch e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y.

    Disconnect the G-Switch Sensor Connector.

    Measure the resistance of the G-Switch #1 Sense Circuit.

    Is the resistance below 5 ohms?

    All

    Yes G o To 8

    N o Repair the G-Switch #1 Sense circuit open.

    Perform ABS VERIFICATION TEST - VER 1.

    8 Tu r n t h e ig ni t ion off.

    C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .Remove G-Switch from vehicle.

    While holding the G-Switch level, measure the resistance of the G-Switch Test Signal

    circuit a nd the G-Switch #1 Sense circuit in the G-Switch connector.

    Is the resistance below 5 ohms?

    All

    Yes G o To 9

    N o Replace G-Switch Assembly.

    Perform ABS VERIFICATION TEST - VER 1.

    9 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace t he CAB.

    Perform ABS VERIFICATION TEST - VER 1.

    1 0 Tu r n t h e i gn it i on off.

    Disconnect the CAB Connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Disconnect the G-Switch Connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the G-Switch #2 Sense Circuit.

    Is the resistance below 5 ohms?

    All

    Yes G o To 11

    N o Repair the G-Switch #2 Sense Circuit Open.

    Perform ABS VERIFICATION TEST - VER 1.

    11 Tu r n t h e i gn i t ion off.Disconnect the G-Switch connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Remove the G-Switch from vehicle.

    While holding the G-Switch level, measure the resistance of the G-Switch Test Signal

    circuit a nd the G-Switch #2 Sense circuit in th e G-Switch connector.

    Is the resistance below 5 ohms?

    All

    Yes G o To 1 2

    N o Replace the G-Switch Assembly.

    Perform ABS VERIFICATION TEST - VER 1.

    17

    BRAKES (CAB)

    G-SWITCH NOT PROCESSABLE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    22/72

    TES T ACTION AP P LICAB ILITY

    12 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace the CAB.

    Perform ABS VERIFICATION TEST - VER 1.

    18

    BRAKES (CAB)

    G-SWITCH NOT PROCESSABLE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    23/72

    S y m p t o m L i s t :

    LEFT FRONT SENSOR CIRCUIT FAILURE

    LEFT REAR SEN SOR CIRCUIT FAILURE

    RIGHT FRONT S ENS OR CIRCUIT FAILURE

    RIGHT REAR S ENS OR CIRCUIT FAILURE

    Te s t N o t e : Al l s y m p t o m s l i s t e d a b o v e a r e d i a g n o s e d u s i n g t h e s a m e te s t s .

    The title for the tests will be LEFT FRONT SENSOR CIRCUIT

    FAILURE.

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    LEFT FRONT SENSOR CIRCUIT FAILURE

    When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits

    continuously.

    Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the

    Diagnostic Trouble Code (DTC) will set .

    LEFT REAR SENSOR CIRCUIT FAILURE

    When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits

    continuously.

    Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the

    Diagnostic Trouble Code (DTC) will set .

    RIGHT FRONT SENSOR CIRCUIT FAILUREWhen M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits

    continuously.

    Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the

    Diagnostic Trouble Code (DTC) will set .

    RIGHT REAR SENSOR CIRCUIT FAILURE

    When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits

    continuously.

    Set Condition: If the CAB detects an open or shorted Wheel speed sensor circuit , the

    Diagnostic Trouble Code (DTC) will set .

    P O S S I B L E C A U S E S

    SENSOR OR CONNECTOR DAMAGE

    INTERMITTENT DTC

    WHEEL SPEED SENSOR OPEN OR SHORTED TO GROUND

    WHEEL SPEED SENSOR (+) OR (-) CIRCUIT SHORTED TO VOLTAGE

    19

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    24/72

    P O S S I B L E C A U S E S

    WHEEL SPEE D SE NSOR (+) OR (-) CIRCUIT SH ORTED TO GROUND

    WHEEL SPEED SENSOR CIRCUITS SHORTED TOGETHER

    SPEED SENSOR (+) OR (-) CIRCUIT OPEN

    CAB - INTERNAL SHORT OR OPEN

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, read DTCs.

    With the DRBIII, era se DTCs.

    Turn the ignition off.

    Turn the ignition on.

    With the DRBIII, read DTCs.

    Does the DRBIII display a Wheel Speed Sensor Circuit Failure DTC?

    All

    Yes G o To 2

    N o Go To 9

    2 Tu r n t h e ig ni t ion off.

    Inspect t he a ffected Wheel Speed Sensor a nd Connector.

    Is the Sensor or Connector Damaged?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 3

    3 Tu r n t h e ig ni t ion off.

    Disconnect the affected Wheel Speed Sensor connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    M eas ure the res is tance acros s the W heel S peed S ens or (+) and (-) circuits at theSensor side of the connector.

    Measure t he resista nce between ground an d th e (+) and (-) circuits on the Sen sor side

    of the connector.

    Is the S ens or res istance 900 to 1300 ohm s and res istance to ground m ore tha n 15k

    ohms?

    All

    Yes G o To 4

    N o Repair t he short or replace the Wheel Speed Sensor, as n ecessary.

    Perform ABS VERIFICATION TEST - VER 1.

    4 Tu r n t h e i gn it i on off.

    Disconnect the affected Wheel Speed Sensor connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Disconnect the CAB connector.N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Turn the ignition on.

    Measure the voltage of the Wheel Speed Sensor (+) and (-) circuits.

    Is the voltage above 1 volt at either circuit?

    All

    Yes Repair the Wheel Speed Sensor circuit for a short to voltage.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 5

    20

    BRAKES (CAB)

    LEFT FRONT SENSOR CIRCUIT FAILURE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    25/72

    TES T ACTION AP P LICAB ILITY

    5 Tu r n t h e ig ni t ion off.

    Disconnect the affected Wheel Speed Sen sor Connector.

    Disconnect the CAB Connector.

    M eas ure the res is tance betw een the W heel S peed S ens or (+) and (-) circuits andground.

    Is t he r esistance below 15,000 ohms for either circuit?

    All

    Yes Repair the Wheel Speed Sensor circuit short to ground.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 6

    6 Tu r n t h e ig ni t ion off.

    Disconnect the CAB Connector.

    Disconnect the affected Wheel Speed Sen sor ha rness connector.

    M eas ure th e r es is tance th rough the W heel S peed S ens or (+) and (-) circuits at the

    CAB har ness connector.

    Is the resistance below 200 ohms?

    All

    Yes Repair the Wheel Speed Sensor circuits shorted together.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 7

    7 Tu r n t h e i gn it i on off.

    Disconnect the affected Wheel Speed Sen sor Connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Disconnect the CAB Connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the Wheel Speed Sensor (+) and (-) circuits.

    Is the resistance below 5 ohms for both circuits?

    All

    Yes G o To 8

    N o Repair t he Wheel Speed Sensor (+) or (-) circuit for an open.Perform ABS VERIFICATION TEST - VER 1.

    8 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace t he Controller Antilock Brak e in accordance w ith the

    Service Informa tion.

    Perform ABS VERIFICATION TE ST - VER 1.

    9 Tu r n t h e i gn it i on off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.

    Visually inspect the related wire harness component and in-line connectors. Look for

    broken, bent, pushed out, or corroded terminals.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were any problems found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    21

    BRAKES (CAB)

    LEFT FRONT SENSOR CIRCUIT FAILURE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    26/72

    S y m p t o m L i s t :

    LEFT FRONT SENSOR SIGNAL FAILURE

    LEFT REAR SEN SOR SIGNAL FAILURE

    RIGHT FRONT S ENS OR S IGNAL FAILURE

    RIGHT REAR S ENS OR S IGNAL FAILURE

    Te s t N o t e : Al l s y m p t o m s l i s t e d a b o v e a r e d i a g n o s e d u s i n g t h e s a m e te s t s .

    T he t i t l e f o r t he t e s t s w i l l be L E F T F R O N T SE N SO R SI GN A L

    FAILURE.

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    LEFT FRONT SENSOR SIGNAL FAILURE

    When M onitored: Wheel speed com parison is checked at drive off a nd continuously

    thereafter.

    Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an

    extended length of t im e, a nd does not see a corresponding wheel speed change, th e

    Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or

    erratic.

    LEFT REAR SENSOR SIGNAL FAILURE

    When M onitored: Wheel speed com parison is checked at drive off a nd continuously

    thereafter.

    Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an

    extended length of t im e, a nd does not see a corresponding wheel speed change, th eDiagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or

    erratic.

    RIGHT FRONT SENSOR SIGNAL FAILURE

    When M onitored: Wheel speed com parison is checked at drive off a nd continuously

    thereafter.

    Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an

    extended length of t im e, a nd does not see a corresponding wheel speed change, th e

    Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or

    erratic.

    RIGHT REAR SENSOR SIGNAL FAILURE

    When M onitored: Wheel speed com parison is checked at drive off a nd continuously

    thereafter.

    Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an

    extended length of t im e, a nd does not see a corresponding wheel speed change, th e

    Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or

    erratic.

    22

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    27/72

    P O S S I B L E C A U S E S

    SPEE D SE NSOR OR CONNECTOR DAMAGED

    TONE WHEEL DAMAGED

    WHEEL SP EED SENSOR AIR GAP OUT OF SPECIFICATION

    WHEEL BEARING EXCESS RUNOUT

    WHEEL SPEE D SE NSOR INOPERATIVE

    CAB - CANT READ WHE EL SP EE D SE NSOR SIGN AL

    INTERMITTENT SIGNAL DTC

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .Using the DRBIII, monitor all Wheel Speed Sensors while an assistant drives the

    vehicle.

    Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).

    Note the DRBIII Wheel Speed Sensor readings.

    Is one wheel speed signal zero or differing from others by m ore tha n 5 km/h (3 mph)?

    All

    Yes G o To 2

    N o Go To 7

    2 Tu r n t h e ig ni t ion off.

    Inspect the Wheel Speed Sensor and Connector at the affected wheel.

    Is the Sensor or Connector Damaged?

    All

    Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25

    km/h (15 m ph) before it will extinguish the ABS In dicat or.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 3

    3 Tu r n t h e ig ni t ion off.

    At the affected wheel, inspect the Tone Wheel for dama ged or missing teet h, cracks,

    or looseness.

    N o t e : T h e To n e W h e e l Te e t h s h o u l d b e p e r f e c t l y s q u a r e , n o t b e n t o r n i c k e d .

    Is the Tone Wheel OK?

    All

    Yes G o To 4

    N o Replace the Tone Wheel. The CAB must sense all four wheels at

    25 km/h (15 mph ) before it will extinguish t he ABS Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    4 Tu r n t h e i gn it i on off.

    Using a Feeler Gauge, measure the Wheel Speed Sensor Air Gap.

    N O TE : T h e Ai r G a p s h o u l d b e c h e c k e d i n a t l e a s t f o u r p l a c e s o n t h e T o n e

    Wh eel.

    Is the Air Gap between 0.42 mm - 1.71 mm (0.017 - 0.068) ?

    All

    Yes G o To 5

    N o Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25

    km/h (15 mph ) before it will extinguish the ABS In dicat or.

    Perform ABS VERIFICATION TEST - VER 1.

    23

    BRAKES (CAB)

    LEFT FRONT SENSOR SIGNAL FAILURE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    28/72

    TES T ACTION AP P LICAB ILITY

    5 Tu r n t h e ig ni t ion off.

    Inspect the wheel bearing for excessive runout or clearance.

    N o t e : R e f e r t o t h e a p p r o p r i a t e s e r v i c e i n f o r m a t i o n , i f n e c e s s a r y , f o r p r o c e -

    d u r e s o r s p e c i f i c a t i o n s .Is the bearing run out O K ?

    All

    Yes G o To 6

    N o Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25

    km/h (15 mph ) before it will extinguish the ABS In dicat or.

    Perform ABS VERIFICATION TEST - VER 1.

    6 Tu r n t h e ig ni t ion off.

    Raise the affected wheel off the ground.

    Disconnect the Wheel Speed Sensor connector a t the affected wheel.

    S et up an A C voltm eter t o read t he output of the W heel S peed S ens or.

    Q uickly rotate the w heel by s pinning the t ire by han d.

    Measure the Wheel Speed Sensor AC voltage output.

    Does the voltage go above 650 millivolts as the wheel is rotated?

    All

    Yes Replace t he Controller Antilock Bra ke in accordance w ith the

    Service Informa tion.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Replace the Wheel Speed Sensor in accordance with the Service

    Information. The CAB must sense all four wheels at 25 km/h (15

    mph) before it will extinguish the ABS In dicator.

    Perform ABS VERIFICATION TEST - VER 1.

    7 Tu r n t h e i gn it i on off.

    Visually inspect th e a ffected Wheel Speed Sensor for correct installat ion.

    Visually inspect t he Tone Wheel for looseness and correct installat ion.

    Visually inspect the wiring ha rness for loose or interm ittent connections.

    Visually inspect mechan ical brake components.Inspect for conditions that may cause lockup or drag.

    Inspect for seized caliper or wheel cylinder piston.

    Inspect all component s for a condition which ma y cause a Wheel Speed Signal DTC

    to s et.

    Is any Component Damaged?

    All

    Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25

    km/h (15 m ph) before it will extinguish the ABS In dicat or.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    24

    BRAKES (CAB)

    LEFT FRONT SENSOR SIGNAL FAILURE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    29/72

    S y m p t o m :

    PUMP MOTOR NOT WORKING PROPERLY

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    PU MP MOTOR NOT WORKING PR OPERLY

    When Monitored: Ignition on. The CAB comma nds th e pump on at 20 km/h (12 mph) to

    check its operation, if the brake switch is not applied. If the driver has their foot on the

    b r a ke , t h e t e st w ill r u n a t 4 0 k m /h (2 5 m p h ). T he C AB m on it or s p u mp volt a ge

    continuously.

    Set Condition: The DTC is stored when t he CAB detects: 1) Impr oper volta ge decay after

    the pump was turned off. 2) Pump not energized by the CAB, but voltage is present for 3.5

    seconds. 3) Pum p is t ur ned on by the CAB, but their is insufficient volta ge to operat e it.

    P O S S I B L E C A U S E S

    ABS PUMP MOTOR INTERMITTENT DTC

    FUSED B(+) CIRCUIT INTERMITTENTLY SHORTED TO GROUND

    FUSED B(+) CIRCUIT SHORTED TO GROUND

    CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND

    FUSE BLOWN - PUMP MOTOR CIRCUIT

    NO B+ SUP PLY TO FUSE

    ABS PUMP MOTOR INOPERATIVE

    FUSED B(+) CIRCUIT OPEN

    GROUND CIRCUIT OPE N

    GROUND CIRCUIT HIGH RESISTANCE

    CAB - INTERNAL FAULT

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, read DTCs.

    With the DRBIII, era se DTCs.

    Turn the ignition off.

    Turn the ignition on.

    With the DRBIII, actuate the A BS pum p m otor.D id th e P um p M otor operate w hen actuated?

    All

    N o Go To 2

    Yes G o To 1 3

    2 Tu r n t h e ig ni t ion off.

    Rem ove and ins pect the A BS P um p fus e in the P D C.

    Is the F us e blow n?

    All

    Yes G o To 3

    N o Go To 7

    25

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    30/72

    TES T ACTION AP P LICAB ILITY

    3 Tu r n t h e ig ni t ion off.

    Make sure the Pump Motor connector is secure.

    Vis ually ins pect the F us ed B(+) Circuit in t he w iring ha rnes s from the P D C to the

    CAB. Look for any sign of an Intermittent Short to Ground.Is the w iring har nes s O K ?

    All

    Yes G o To 4

    N o Repair the Fused B(+) Circuit shorted to ground. The CAB must

    sense all four wheels at 25 km/h (15 mph) before it will extinguish

    the ABS In dicat or.

    Perform ABS VERIFICATION TEST - VER 1.

    4 Tu r n t h e ig ni t ion off.

    Remove ABS PUMP Fuse 8 from the Power Distribution Center (PDC).

    Disconnect the CAB connector.

    Make sure the Pump Motor connector is secure.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Using a test light connected to 12 volts, probe the Fused B (+) Circuit.Is the t es t l ight on?

    All

    Yes Repair the F us ed B(+) circuit s hort to ground. The CA B m us t

    sense all four wheels at 25 km/h (15 mph) before it will extinguish

    the ABS Indicator.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 5

    5 Tu r n t h e i gn it i on off.

    Remove ABS PUMP Fuse 12 from the PDC.

    The CAB must be connected for the results of this test to be valid.

    Using a test light connected to 12 volts, probe the Fused B (+) circuit in the PDC.

    Is the t es t l ight on?

    All

    Yes Replace t he Controller Antilock Bra ke in accordance w ith the

    Service Informa tion.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 6

    6 Tu r n t h e i gn it i on off.

    Make sure the Pump Motor connector is secure

    If there ar e no potential caus es rem a ining, replace th e F u s e.

    If there are no possible causes remaining, view repair.

    All

    Repair

    Replace th e ABS Pu mp Motor Fuse. The CAB must sense all four

    w heels at 25 km /h (15 m ph) before it w ill extinguis h the A BS

    Indicator.Perform ABS VERIFICATION TE ST - VER 1.

    26

    BRAKES (CAB)

    PUMP MOTOR NOT WORKING PROPERLY C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    31/72

    TES T ACTION AP P LICAB ILITY

    7 Tu r n t h e ig ni t ion off.

    Remove ABS PUMP Fuse #12 from the Power Distribution Center (PDC).

    Disconnect the CAB connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .M eas ure the res istance of the F u s ed B (+) circuit betw een t he P D C F us e Term inal

    and the CAB connector.

    Is the resistance below 10 ohms?

    All

    Yes G o To 8

    N o Repair the Fused B(+) circuit for an open. The CAB must sense all

    four wheels at 25 km/h (15 mph) before it will extinguish the ABS

    Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    8 Tu r n t h e ign it ion on .

    Using a 12-volt test light connected t o ground, check t he B+ supply to Fu se 12 in th e

    PDC.

    Is the B+ s upply O K ?

    All

    Yes G o To 9

    N o Repair the B+ s upply for an open. The CAB m u s t s ens e all four

    w heels at 25 km /h (15 m ph) before it w ill extinguis h the A BS

    Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    9 Tu r n t h e i gn it i on off.

    Disconnect Pump Motor Connector.

    Connect a 10 gauge jumper wire between pump motor Fused B (+) circuit and a 40

    Amp Fused B (+) circuit.

    Connect a 10 gauge jumper wire between pump motor ground circuit and a known

    good body ground.

    Monitor Pump Motor operation.Is the pum p m otor ru nning?

    All

    Yes G o To 1 0

    N o Replace t he Controller Antilock Brake in accordance w ith the

    Service Information. The CAB must sense all four wheels at 25

    km/h (15 mph ) before it will extinguish the ABS In dicat or.

    Perform ABS VERIFICATION TEST - VER 1.

    1 0 Tu r n t h e i gn it i on off.

    Disconnect CAB Connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the CAB ground circuits.

    Is the resistance below 1.0 ohm?

    All

    Yes G o To 11

    N o Repair the ground circuit for an open. The CA B m us t s ens e all

    four wheels at 25 km/h (15 mph) before it will extinguish the ABS

    Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    27

    BRAKES (CAB)

    PUMP MOTOR NOT WORKING PROPERLY C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    32/72

    TES T ACTION AP P LICAB ILITY

    11 M a k e s u r e t h e P u m p M ot or con n e ct or is se cu r e .

    Turn the ignition on.

    With the DRBIII, enable pum p m otor actuation.

    N O TE : P u m p m o t o r w i l l n o t o p e r a t e , b u t v o l t a g e w i l l b e a p p l i e d .Measure the voltage drop across the ABS ground circuit connection, with pump motor

    actuation enabled.

    Is t he voltage below 0.1 volt?

    All

    Yes G o To 1 2

    N o Repair the G round circuit for an open. The CA B m us t s ens e all

    four wheels at 25 km/h (15 mph) before it will extinguish the ABS

    Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    12 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace the Controller Anti-Lock Brake in accordance with the

    S ervice Inform at ion. The CAB m us t s ens e all four w heels at 25

    km/h (15 m ph) before it will extinguish th e ABS In dicator.

    Perform ABS VERIFICATION TEST - VER 1.

    1 3 Tu r n t h e ig ni t ion off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.

    Make sure the Pump Motor connecter is secure.

    Visually inspect th e relat ed wire h ar ness connectors. Look for broken, bent, pu shed

    out, or corroded t ermina ls.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were a ny pr oblems found?

    All

    Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25

    km/h (15 m ph) before it will extinguish the ABS In dicat or.Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    28

    BRAKES (CAB)

    PUMP MOTOR NOT WORKING PROPERLY C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    33/72

    S y m p t o m :

    SYSTEM OVER VOLTAGE

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    SYSTEM OVER VOLTAGE

    When Monitored: Ignition on. The CAB monitors t he F used B(+) circuit a t all times for

    proper system voltage.

    Set Condition: If the volta ge is above 16.5 volts, th e Diagnostic Trouble Code (DTC) is set.

    P O S S I B L E C A U S E S

    BATTERY OVERCHARGED

    FUSED IGNITION SWITCH OUTPUT HIGH

    GROUND CIRCUIT OPE N

    CAB - INTERNAL FAULT

    INTERMITTENT DTC

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, era se DTCs.

    Turn the ignition off.

    Turn the ignition on.

    S tart the engine.

    With the DRBIII

    , read DTCs.Does the DRBIII display System Overvoltage DTC?

    All

    Yes G o To 2

    N o Go To 6

    2 Tu r n t h e ig ni t ion off.

    Inspect for battery charger connected to battery.

    Is a battery charger connected to the batt ery?

    All

    Yes Charge battery to proper level. D is connect the battery charger.

    Clear DTCs.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 3

    29

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    34/72

    TES T ACTION AP P LICAB ILITY

    3 Tu r n t h e ig ni t ion off.

    Disconnect the CAB connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    S tart the engine.Raise en gine RP Ms a bove 1,800.

    M eas ure th e batt ery voltage.

    Is t he voltage a bove 16.5 volts ?

    All

    Yes Refer to appropriate s ervice inform ation for charging s ystem

    tes ting and repair.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 4

    4 Tu r n t h e ig ni t ion off.

    Disconnect the CAB connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the ground circuits.

    Is the resistance below 1.0 ohm?

    All

    Yes G o To 5

    N o Repair the Ground circuit for an open.

    Perform ABS VERIFICATION TEST - VER 1.

    5 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace t he Contr oller Antilock Bra ke.

    Perform ABS VERIFICATION TEST - VER 1.

    6 Tu r n t h e ig ni t ion off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.

    Visually inspect th e relat ed wire h arn ess connectors. Look for broken, bent, push ed

    out, or corroded t ermina ls.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were a ny pr oblems found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    30

    BRAKES (CAB)

    SYSTEM OVER VOLTAGE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    35/72

    S y m p t o m :

    SYSTEM UNDER VOLTAGE

    W h e n M o n i t o r e d a n d S e t C o n d i t i o n :

    SYSTEM UNDER VOLTAGE

    When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output for

    proper system voltage.

    Set Condition: If the volta ge is below 9.5 volts, th e Diagnostic Trouble Code (DTC) is set.

    P O S S I B L E C A U S E S

    BATTERY VOLTAGE LOW

    INTERMITTENT DTC

    FUSED IGNITION SWITCH OUTPUT CIRCUIT H IGH RESISTANCE

    GROUND CIRCUIT OPE N

    CAB - INTERNAL FAULT

    TES T ACTION AP P LICAB ILITY

    1 Tu r n t h e ign it ion on .

    With the DRBIII, era se DTCs.

    Turn the ignition off.

    Turn the ignition on.

    S tart the engine.

    Drive the vehicle above 16 km/h (10 mph) for at least 20 seconds.Stop the vehicle

    With the DRBIII, read DTCs.

    Does the DRBIII display System Un dervoltage DTC?

    All

    Yes G o To 2

    N o Go To 6

    2 E ngin e Ru nn in g.

    M eas ure th e batt ery voltage.

    Is the battery voltage below 10 volts?

    All

    Yes Refer to appropriate s ervice inform ation for charging s ystem

    tes ting and repair.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Go To 3

    3 Tu r n t h e ig ni t ion off.

    Disconnect the CAB connector.

    N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .

    Measure the resistance of the ground circuits.

    Is the resistance below 1.0 ohm?

    All

    Yes G o To 4

    N o Repair the Ground circuit for an open.

    Perform ABS VERIFICATION TEST - VER 1.

    31

    BRAKES (CAB)

  • 8/14/2019 2005 Tj Chassis

    36/72

    TES T ACTION AP P LICAB ILITY

    4 D is con n e ct t h e C AB h a r n e s s con n e ct or .

    Turn the ignition on.

    Measure the voltage of the Fused Ignition Switch circuit.

    Is the voltage above 10 volts?

    All

    Yes G o To 5

    N o Repair the Fused Ignition Switch Output Circuit for high resis-

    tance

    Perform ABS VERIFICATION TEST - VER 1.

    5 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All

    Repair

    Replace t he Contr oller Antilock Bra ke.

    Perform ABS VERIFICATION TEST - VER 1.

    6 Tu r n t h e ig ni t ion off.

    Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or

    partially broken wires.Visually inspect th e relat ed wire h ar ness connectors. Look for broken, bent, pu shed

    out, or corroded t ermina ls.

    Refer to any Hotline letters or Technical Service Bulletins that may apply.

    Were a ny pr oblems found?

    All

    Yes Repair as necessary.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Test Complete.

    32

    BRAKES (CAB)

    SYSTEM UNDER VOLTAGE C o n t i n u e d

  • 8/14/2019 2005 Tj Chassis

    37/72

    S y m p t o m :

    *ABS WARNING INDICATOR ALWAYS ON

    P O S S I B L E C A U S E S

    ABS RELAY STUCK

    ABS RELAY FUSED B+ CIRCUIT OPEN

    ABS RELAY CONTROL CIRCUIT OPEN

    CAB INTERNAL OPEN

    ABS INDICATOR DRIVER SHORT TO GROUND

    INSTRUMENT CLUSTER CONCERN

    TES T ACTION AP P LICAB ILITY

    1 R em ov e t h e AB S r e la y fr om P D C.Perform the key-on bulb test.

    Does the ABS Indicator light and remain lit?

    All

    Yes G o To 2

    N o Go To 3

    2 D is con n e ct t h e I n s t r u m e n t C lu s t e r C 2 h a r n e s s con n e ct or .

    Remove the ABS relay from the PDC.

    Using a 12-volt test light connected to 12-volts, check the ABS Warning Indicator

    Driver circuit.

    Does the test light illuminate?

    All

    Yes Repair the ABS Indicator circuit for a short to ground. The CAB

    may have to sense all four wheels at 25 km/h (15 mph) before itwill extinguish the ABS Indicator.

    Perform ABS VERIFICATION TE ST - VER 1.

    N o Refer to symptom list for pr oblems related t o Instru ment Cluster.

    The CAB may have to sense all four wheels at 25 km/h (15 mph)

    before it will extinguish the ABS Indicator.

    Perform ABS VERIFICATION TEST - VER 1.

    3 I n s t a ll a s u bs t it u t e r el a y i n p la ce of t h e AB S r e la y.

    Perform the key-on bulb check.

    Does t he ABS Warn ing Indicator operat e OK?

    All

    Yes Replace th e A