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Safety Recall R60 Occupant Restraint Control Module (RC-R60-16)

WARNING: This page is about the Grand Cherokee Freedom, 4.0 S, 4WD, which is a different variant/trim than selected.
Publication date: 2016-09-28
Reference number: RC-R60-16
Supersedes refnos: RC-CR60-15, RC-R60-15

SAFETY RECALL R60 OCCUPANT RESTRAINT CONTROL MODULE

SAFETY RECALL R60 OCCUPANT RESTRAINT CONTROL MODULE

SERVICE CAMPAIGN BULLETIN

Reference Number(s): RC-R60-16, Date of Issue:  May 6, 2016
CHRYSLER: 2003 (KJ) Jeep® Liberty; 2004 (WJ) Jeep® Grand Cherokee; 2003 - 2004 (WG) Jeep® Grand Cherokee

SERVICE INFORMATION

NOTE: WG model vehicles were added to the recall.

MODELS

2003 (KJ) Jeep® Liberty 

2004 (WJ) Jeep® Grand Cherokee 

2003 - 2004 (WG) Jeep® Grand Cherokee 

NOTE: This recall applies only to the above vehicles built from March 29, 2003 through December 09, 2004 (MDH 032900 through 120917).
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery.  Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry.

SUBJECT

The airbag system Occupant Restraint Control (ORC) module on about 48,000 of the above vehicles may experience a front airbag and/or seatbelt pretensioner inadvertent deployment. An inadvertent deployment while driving could distract the driver and cause a crash without warning.

REPAIR

The ORC module must be replaced on all involved vehicles.

Also, vehicles that had Safety Recall M35 - Occupant Restraint Control Module Filter Circuit  completed must also have the ORC module filter circuit removed.

PARTS INFORMATION

ORC Module Packages with Impact Sensors 

PARTS INFORMATION

Part Number Description
CBSZR064AA Module, ORC (KJ models)
CBSZR067AA Module, ORC (WJ/WG models with  Supplemental Side Airbags/with sales code CGS)
NOTE: To better manage required inventory for this recall, only approximately 10% of involved vehicles are expected to require impact sensor replacement.

ORC Module Packages without Impact Sensors 

PARTS INFORMATION

Part Number Description
CBSZR065AA Module, ORC (WJ/WG models without  Supplemental Side Airbags/without sales code CGS)
CBSZR066AA Module, ORC (WJ/WG models with  Supplemental Side Airbags/sales code CGS)
CBSZR063AA Module, ORC (KJ models)
NOTE: The ORC module packages (without impact sensors) above are only compatible with the impact sensors that originally came on the vehicle.

SPECIAL NOTE: For all (WJ/WG) Jeep Grand Cherokee models, the new ORC modules provided in this recall do not require front impact sensors to operate correctly. The front impact sensors are permanently disabled. Do not order or replace the front impact sensors on WJ/WG models. 

PARTS INFORMATION

Part Number Description
CBXTM352AA Switch, Transfer Case
PARTS INFORMATION

Part Number Description
68065586AA Tape, Abrasion (one roll of abrasion tape will repair 10 vehicles)
NOTE: The abrasion tape is only required for repairing WJ/WG models.

PARTS RETURN

No parts return required for this campaign.

SPECIAL TOOLS

The following special tools are required to perform this repair: 

SERVICE PROCEDURE

A. Determine ORC Module Package Required (All Models)

  1. Connect the wiPOD to the vehicle data link connector.
    CAUTION: Do not use a MicroPOD II while using the wiTECH DRBIII emulator. A VCI pod should be used to connect to the vehicle.
  2. Start a wiTECH session.
  3. Select (1) "DRB III Standalone". 
  4. Select (1) "1998-2007 Diagnostics". 
  5. Select (1) "All (Except Below)". 
  6. Select (6) "Passive Restraints" 
  7. Select (1) "Airbags". 
  8. Select (2) "Read DTC's". 
  9. Select (1) "Active". 
  10. Select "Page Back"  and then select (2) "Stored". 
  11. Record active and stored Diagnostic Trouble Codes (DTC's) for right and left front impact sensors on KJ models and right and left side impact sensors on WJ/WG models:
    • If there are no Impact Sensor DTC's, replace the Occupant Restraint Control (ORC) module.
      NOTE: Install a new ORC module package that does not contain impact sensors.
    • If there are Impact Sensor DTC's, replace the Occupant Restraint Control (ORC) module and both impact sensors.
      NOTE: Install a new ORC module package that contains new impact sensors.
    CAUTION: If only the ORC module requires replacement at this time and at some point in the future an impact sensor(s) requires replacement, the ORC module and both impact sensors will require replacement. The ORC module packages (without impact sensors) in this recall contain an ORC module that is not compatible new impact sensors.

    SPECIAL NOTE: If after completing this recall the airbag warning light is still illuminated, the cost to make additional repairs to other airbag system components is the responsibility of the vehicle owner. 

B. Replace ORC Module (KJ Models)

WARNING: TO AVOID SERIOUS OR FATAL INJURY ON VEHICLES WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) BEFORE ATTEMPTING THIS REPAIR PROCEDURE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE  , THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SRS. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
G10398209
  1. Open the hood and disconnect the negative battery cable from the battery.
  2. Remove and save the gear shift lever center console bezel (Figure 1).
  3. Apply the park brake and place gear shift lever in the neutral position.
  4. For vehicles equipped with four wheel drive  , place the four wheel drive selector handle in the "four wheel low" position.
  5. For vehicles equipped with four wheel drive  , remove and save the four wheel drive lever shift handle boot (Figure 1).
  6. For vehicles with power windows  , remove and save the front window switch assembly (Figure 2).
    G10398210
  7. Remove and save the rear window switch assembly from the center console (Figure 3).
  8. Remove and save the four center console retaining screws.
  9. Carefully remove and save the center console assembly.
  10. For vehicles that had Safety Recall M35 performed  , remove and discard the foil mastic patch from the ORC module rubber cover (Figure 4).
  11. Remove and save the ORC module rubber cover (Figure 4).
    G10398211
    G10398212
  12. For vehicles that had Safety Recall M35 performed  , disconnect the ORC module jumper harness electrical connector from the body wire harness (Figure 5).
  13. Remove and save the three ORC module mounting bolts.
  14. Carefully pull the ORC module out of the vehicle and disconnect filter circuit jumper harness electrical connector (Figure 6).
  15. Discard the original filter circuit jumper harness  (Figure 6).
    G10398213
    G10398214
  16. Disconnect the small ORC module electrical connector (Figure 7).
  17. Destroy and discard the original ORC module.
  18. Connect the large and small body harness electrical connectors to the new ORC module and place the module into position (Figure 7).
  19. Install the three retaining bolts. Tighten the two large retaining bolts to 26 ft. lbs. (36 N.m). Tighten the small retaining bolt to 105 in. lbs. (12 N.m) (Figure 8).
    G10398215
    G10398216
  20. Clean off any residual glue on the ORC module rubber cover left behind by the foil mastic patch.
  21. Place the ORC module rubber cover into position over the ORC module (Figure 9).
  22. Install the center console assembly into position.
    G10398217
  23. Install the four center console retaining screws.
  24. Install the rear window switch assembly (Figure 3).
  25. Install the front window switch assembly (Figure 2).
  26. For vehicles equipped with four wheel drive  , install the four wheel drive lever shift handle boot (Figure 1).
  27. Install the gear shift lever center console bezel (Figure 1).
  28. For vehicles that require front impact sensors  , continue with Section C. Front Impact Sensor Replacement .
  29. For vehicles that do not require front impact sensors  , continue with Step 30 of this procedure.
  30. Turn the ignition key to the "RUN" position, with no one inside the vehicle, connect the negative battery cable to the battery.
  31. Reset the clock on the radio.
  32. Start the vehicle.
  33. Connect the wiTECH scan tool and check for impact sensor and/or ORC module DTC's:
    • If there are no impact sensor and/or ORC module DTC's, continue with Step 34 of this procedure.
    • If there are impact sensor and/or ORC module DTC's, make repairs to sensor and/or ORC module as required, then continue with Step 34 of this procedure.
    NOTE: All replacement ORC Modules for this recall are configured for the optional side curtain airbag feature.
    If a new ORC module is installed in a vehicle that is not equipped with the optional side curtain airbags, the airbag indicator lamp will illuminate and "No Right SIACM" and "No Left SIACM" DTC's will be registered.
    The new ORC module must be configured to disable the side curtain airbag feature using a DRBIII® scan tool or wiTECH DRBIII emulator. Continue with Step 34 of this procedure.
  34. For vehicles without side curtain airbags  , use the following procedure to configure ORC Module:
    NOTE: This procedure should only be performed on vehicles with active DTC's "No Right SIACM and No Left SIACM".
    1. From the "SELECT FUNCTION"  Screen on the DRBIII select (9) "Miscellaneous"  button.
    2. Select (1) "Configure for Side Airbag" 
    3. Screen Prompt: "Do you want to continue?" Select "Enter" 
    4. Verify Current Status is set to: "ACM with Side Airbags" 
    5. Select (2) "ACM without Side Airbags"  then "Enter" 
    6. Verify Current Status a second time, should now read: "ACM without Side Airbags" 
    7. Select BACK PAGE  to exit.
    8. Select (2) Read DTC's.
    9. Select (1) Active.
    10. Verify No DTC's are Detected.

      SPECIAL NOTE: If after completing this recall the airbag warning light is still illuminated, the cost to make additional repairs to other airbag system components is the responsibility of the vehicle owner. 

  35. For vehicles equipped with four wheel drive  , place the four wheel drive lever shift handle into the "2 Hi" position.
  36. For vehicles equipped with four wheel drive  , check to insure that the four wheel drive indicator light is not illuminated.
  37. Remove the wiTECH scan tool and return the vehicle to the customer.

C. Front Impact Sensor Replacement (KJ Models)

  1. Locate the front impact sensors.
    NOTE: The front impact sensors are located to the right and left of the radiator on the radiator support vertical member (Figure 10).
  2. Remove and save the two mounting bolts on the front impact sensor.
  3. Disconnect the electrical connector from the front impact sensor.
  4. Remove and discard the original front impact sensor.
    G10398218
  5. Connect the vehicle wire harness connector to the new front impact sensor.
  6. Place the new front impact sensor into position and install the mounting bolts. Tighten the mounting bolts to 65 in. lbs. (7 N.m).
  7. Repeat Steps  1 through 6 to replace the second front impact sensor.
  8. Turn the ignition key to the "RUN" position, with no one inside the vehicle, connect the negative battery cable to the battery.
  9. Reset the clock on the radio.
  10. Connect the wiTECH scan tool and check for impact sensor and/or ORC module DTC's:
    • If there are no impact sensor and/or ORC module DTC's, continue with Step 11 of this procedure.
    • If there are impact sensor and/or ORC module DTC's, make repairs to sensor and/or ORC module as required, then continue with Step 11 of this procedure.

    SPECIAL NOTE: If after completing this recall the airbag warning light is still illuminated, the cost to make additional repairs to other airbag system components is the responsibility of the vehicle owner. 

  11. For vehicles equipped with four wheel drive  , place the four wheel drive lever shift handle into the "2 Hi" position.
  12. For vehicles equipped with four wheel drive  , check to insure that the four wheel drive indicator light is not illuminated.
  13. Remove the wiTECH scan tool and return the vehicle to the customer.

D. Replace ORC Module (WJ/WG Models)

WARNING: TO AVOID SERIOUS OR FATAL INJURY ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) BEFORE ATTEMPTING THIS REPAIR PROCEDURE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE  , THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SRS. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
G10398219
  1. Disconnect the negative battery cable.
  2. Remove and save the center console using the following procedure:
    1. Remove and save the two retaining screws in the console storage bin (Figure 11).
    2. Remove and save the cup holder insert from the console (Figure 11).
    3. Remove and save the two screws under the cup holder insert (Figure 12).
      G10398220
    4. Open the center console and remove and save the two screws at the bottom of the console storage bin (Figure 13).
    5. Remove and save the center console assembly (Figure 14).
      G10398221
      G10398222
      G10398223
  3. For all vehicles that had Safety Recall M35 previously performed  , remove and discard the ORC module filter circuit jumper harness (Figure 15).
    NOTE: Only vehicles that had Safety Recall M35 completed will have an ORC module filter circuit jumper harness.
  4. Remove, destroy, and discard the original ORC module (Figure 16).
    G10398224
  5. Using Mopar glass cleaner or equivalent, clean the ORC module mounting surface (Figure 17).
  6. Place the new ORC module into position and install the mounting bolts (Figure 18). Tighten the bolts to 95 in. lbs. (11 N.m).
    G10398225
    G10398226
  7. Using the supplied tape, wrap the wire harness with tape to protect the wires (Figure 19).
  8. Connect the yellow ORC module wire harness electrical connectors to the ORC module (Figure 20).
  9. Route the wires as shown in Figure 20 and secure them with two plastic tie straps.
    CAUTION: Make sure that all wire harnesses are routed to prevent chafing and/or wire harness damage.
    G10398227
    G10398228
  10. Install the center console.
  11. For vehicles that require side impact sensor replacement  , perform the following steps:
    1. Remove and save the seat belt anchor bolt (Figure 21).
    2. Remove and save the "B" pillar trim panel (Figure 21).
    3. Remove and discard the original side impact sensor (Figure 22).
    4. Install the new side impact sensor. Tighten the retaining bolts to 105 in. lbs. (12 N.m).
      G10398229
      G10398230
    5. Install the "B" pillar trim panel.
    6. Install the seat belt anchor bolt (Figure 21).
    7. Repeat Steps  a. through f. on the opposite side of the vehicle to replace the second side impact sensor.

      SPECIAL NOTE: On all (WJ/WG) Grand Cherokee models, all of the new ORC modules provided in this recall do not require front impact sensors to operate correctly. The front impact sensors are permanently disabled. 

  12. Turn the ignition key to the "RUN" position, with no one inside the vehicle, connect the negative battery cable to the battery.
  13. Reset the clock on the radio.
  14. Connect the wiTECH scan tool to the vehicle and check for impact sensor and/or ORC module DTC's:
    • If there are no impact sensor and/or ORC module DTC's, continue with Step 15 of this procedure.
    • If there are impact sensor and/or ORC module DTC's, make repairs to sensor and/or ORC module as required, then continue with Step 15 of this procedure.

    SPECIAL NOTE: If after completing this recall the airbag warning light is still illuminated, the cost to make additional repairs to other airbag system components is the responsibility of the vehicle owner. 

  15. Remove the wiTECH scan tool from the vehicle.
  16. Return the vehicle to the customer.

E. Replace the Four Wheel Drive Indicator Light Switch

  1. Carefully lift the vehicle on an appropriate hoist.
  2. Disconnect the transfer case shift cable at the transfer case lever on the transfer case.
  3. Remove and save the three transfer case shift cable bracket mounting bolts on the side of the transfer case.
  4. Relocate the transfer case shift cable bracket and shift cable to gain access to the transfer case four wheel drive indicator light switch (Figure 23).
    G10398231
  5. Using a 1 1/2 inch socket, remove and discard the original transfer case four wheel drive indicator light switch (Figure 24).
  6. Install the new transfer case four wheel drive indicator light switch. Tighten the switch to 20 ft. lbs. (27 N.m).
  7. Place the transfer case shift cable bracket and shift cable into position.
  8. Install the three transfer case shift cable bracket mounting bolts. Tighten the bolts securely.
  9. Connect the transfer case shift cable to the transfer case lever on the transfer case.
    G10398232
  10. Lower the vehicle from the hoist.

COMPLETION REPORTING AND REIMBURSEMENT

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by FCA to record recall service completions and provide dealer payments.

Use one  of the following labor operation numbers and time allowances:

LABOR OPERATION NUMBER AND TIME ALLOWANCE

  Labor Operation Number Time Allowance
Replace ORC module (KJ models) 08-R6-01-82 0.9 hours
Replace ORC module (WJ/WG models) 08-R6-01-83 0.5 hours
Related Operation (KJ Only) 
Replace 4x4 transfer case switch 08-R6-01-50 0.4 hours
Replace front impact sensors 08-R6-01-51 0.2 hours
Optional Equipment (WJ/WG Only) 
Replace side airbag sensors 08-R6-01-60 0.5 hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE: See the FCA International Warranty Policy and Procedure Manual, Claim Entry Section - Recall Claims for claim processing instructions.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners should be notified of the service requirement by their Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is attached.

VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP AND DEALER FOLLOW UP

All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Dealer inquiry as needed.

GRS provides involved Dealers with an updated  VIN list of their incomplete  vehicles. Completed vehicles are removed from GRS within several days of repair claim submission.

Dealers must perform this repair on all unsold vehicles before retail delivery.  Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

ADDITIONAL INFORMATION

If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager.

Global Service and Parts - International

Fiat Chrysler Automobiles

IMPORTANT SAFETY RECALL

R60 

This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).

Dear Jeep Vehicle Owner: (Name)

FCA US LLC has decided that a defect, which relates to motor vehicle safety, exists in certain 2003 model year Jeep Liberty vehicles and 2004 model year Jeep Grand Cherokee vehicles. 

The problem is... The airbag system Occupant Restraint Control (ORC) module on your vehicle may experience a front airbag and/or seatbelt pretensioner inadvertent deployment. An inadvertent deployment while driving could distract the driver and cause a crash without warning. 

What your dealer will do... FCA will repair your vehicle free of charge.  To do this, your dealer will replace the Occupant Restraint Control module. The work will take about two hours to complete. However, additional time may be necessary depending on service schedules.

What you must do to ensure your safety...  Simply contact your Chrysler, Jeep, Dodge or RAM dealer  right away to schedule a service appointment. Please bring this letter with you to your dealer. 

If you need help...  If you have trouble getting your vehicle serviced, please contact the Dealer  nearest your location. A representative will assist you in getting your vehicle serviced. This information can be found in the Customer Assistance section of your Owner's Manual.

We apologize for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter.

Global Service & Parts - International

Fiat Chrysler Automobiles

Notification Code R60

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