Safety Recall R06 / NHTSA 15V-046 Occupant Restraint Control Module (RC-R06-15)

ORC Module Packages with Impact Sensors

ORC Module Packages without Impact Sensors

SPECIAL NOTE: For all (WJ) 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 models. 

Dealers should determine which ORC module is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The ORC module for the vehicle to be serviced may be determined by:

• Using GRS, enter DealerCONNECT, click on the "Service"  tab, click on "Global Recall System,"  enter the recall number  in the "Recall Code:" box, and select "VIN"  in the "List By:" drop down menu.
• Using VIP, enter DealerCONNECT, click on the "Service"  tab, click on "Single VIN Inquiry,"  enter the VIN and mileage,  click "View,"  and click on the "Recall"  tab.

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 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)

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).
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).
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).
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).
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.
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.

    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. 

34. For vehicles equipped with four wheel drive,  place the four wheel drive lever shift handle into the "2 Hi" position.
35. For vehicles equipped with four wheel drive,  check to insure that the four wheel drive indicator light is not illuminated.
    • If the four wheel drive indicator light is not illuminated, no further action is required. Continue with Step 36 of this procedure.
    • If the four wheel drive indicator light remains on, continue with Section F. Replace the Four Wheel Drive Indicator Light Switch  .
36. Remove the wiTECH scan tool and return the vehicle to the customer.

C. Front Impact Sensor Replacement

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.
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.
    • If the four wheel drive indicator light is not illuminated, continue with Step 13 of this procedure.
    • If the four wheel drive indicator light remains on, continue with Section F. Replace the Four Wheel Drive Indicator Light Switch  .
13. Remove the wiTECH scan tool and return the vehicle to the customer.

D. Replace ORC Module (WJ Models)

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).
   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).
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).
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).
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.
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).
    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) 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 ORC Module (ZB Models)

1. Roll down both windows.
2. Open the rear deck lid.
3. Remove and save the battery access cover located in the trunk.
4. Disconnect and isolate the negative battery cable from the battery (Figure 23).
5. Disengage the center console top cover from the center console (Figure 24).
6. Reaching under the center console top cover, loosen the jam nut that retains the gear shift lever extension to the transmission shifter shaft (Figure 24).
7. Unscrew and save the gear shift lever extension and gear shift ball as an assembly (Figure 24).
8. Remove and save the center console top cover (Figure 24).
9. Remove and save the eight instrument panel center stack bezel retaining screws and then remove the center stack bezel and HVAC control panel as an assembly (Figure 25).
10. Carefully remove and save the radio (Figure 26).
11. Remove and save the left side knee bolster (Figure 27).
12. Remove and save the left instrument panel speaker cover (Figure 28).
13. Remove and save the four steering column nuts and carefully lower the steering column.
14. Remove and save the instrument cluster bezel (Figure 29).
15. Remove and save the instrument panel center stack white gauge cluster (Figure 30).
16. Remove and save the instrument panel black plastic frame retaining screws (Figure 30).
17. Temporarily reinstall the steering column.
18. Carefully relocate all of the disconnected instrument panel electrical connectors located near the ORC module.
19. Disengage the center console wire harness at the floor stud on the floor board (Figure 31).
20. Disconnect the ORC module yellow connectors.
21. Remove and save the ORC module mounting bolts.
22. Remove, destroy, and discard the original ORC module.
23. For vehicles that had Safety Recall N13 performed,  remove and discard the ORC module filter circuit harness and box.
24. Install the new ORC module.
25. Install the ORC module mounting bolts. Tighten the bolts to 95 in. lbs. (11 N.m).
26. Connect the yellow body wire harness to the ORC module connectors.
27. Secure the center console wire harness to the floor stud on the floor board (Figure 24).
28. Install the instrument panel black plastic frame retaining screws. Tighten the screws securely (Figure 30).
29. Install the instrument panel center stack white gauge cluster (Figure 30).
30. Install the radio assembly (Figure 26).
31. Lower the steering column.
32. Install the instrument cluster bezel (Figure 29).
33. Install the left instrument panel speaker cover (Figure 28).
34. Install the steering column. Tighten the four steering column retaining nuts to 150 in. lbs. (17 N.m).
35. Install the left side knee bolster (Figure 27).
36. Install the instrument panel center stack bezel (Figure 25).
37. Place the center console top cover partially into position (Figure 24).
38. Screw the gear shift lever extension onto the transmission shifter shaft.
39. Reaching under the center console top cover, tighten the jam nut that retains the gear shift lever extension to the transmission shifter shaft (Figure 32).
    NOTE: Be sure that the gear shift knob gear shift pattern indicator is correctly orientated before tightening the jam nut.
40. Snap the center console top cover into position.
41. Place the ignition to the run position.
42. After checking that no one is inside the vehicle, connect the negative battery cable.
43. Install the battery access panel and close the deck lid (Figure 23).
44. Connect the wiTECH scan tool to the vehicle and check for ORC module DTC's:
    • If there are no ORC module DTC's, continue with Step 45 of this procedure.
    • If there are ORC module DTC's, make repairs to the ORC module as required, then continue with Step 45 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. 

45. Remove the wiTECH scan tool from the vehicle.
46. Reset the clock on the radio.
47. Return the vehicle to the customer.

F. 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 33).
5. Using a 1 1/2 inch socket, remove and discard the original transfer case four wheel drive indicator light switch (Figure 34).
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.
10. Lower the vehicle from the hoist.