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Safety Recall G40 Reprogram Electronic Brake Control Module (G40)

Publication date: 2007-10-01
Reference number: G40

SAFETY RECALL G40 REPROGRAM ELECTRONIC BRAKE CONTROL MODULE

SAFETY RECALL G40 REPROGRAM ELECTRONIC BRAKE CONTROL MODULE

SERVICE CAMPAIGN BULLETIN

Reference Number(s): G40, Date of Issue:  October, 2007
CHRYSLER: 2006 - 2007 (WK) Jeep® Grand Cherokee, (XK) Jeep® Commander, (WK) Jeep® Grand Cherokee SRT8; 2007 (KA) Dodge Nitro (4x4), (JK) Jeep® Wrangler (4x4)

MODELS

2006 - 2007 (WK) Jeep® Grand Cherokee 

(XK) Jeep® Commander 

NOTE: This recall applies only to the above vehicles equipped with a model 245 two speed transfer case (sales code DHX)  .

2006 - 2007 (WK) Jeep® Grand Cherokee SRT8 

2007 (KA) Dodge Nitro (4x4) 

(JK) Jeep® Wrangler (4x4) 

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

SUBJECT

The software programmed into the Electronic Brake Control (EBC) module on about 296,000 of the above vehicles may allow a momentary delay in braking when coasting up a hill during certain conditions. This could increase the vehicle's stopping distance and cause a crash without warning.

REPAIR

The EBC module must be reprogrammed (flashed).

PARTS INFORMATION

No parts are required to perform this service procedure.

SPECIAL TOOLS

The following existing special tools may be required to perform this repair: 

* Part of CH9400 kit.

SERVICE PROCEDURE

A. Reprogram the Electronic Brake Control Module using StarSCAN

CAUTION: Software for the "Bootloader" is being replaced during the first 6 seconds of the reprogramming process. If the reprogramming process is interrupted during that time period (first 6 seconds), abort/recovery is not available and the EBC module will be permanently disabled and will require replacement  .
NOTE: The StarSCAN tool must be at version 8.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen.
  1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts.
  2. Use the following procedure to determine the EBC Module software part number:
    1. Connect the StarSCAN to the vehicle data link connector and turn the ignition key to the "RUN"  position.
    2. Power ON the StarSCAN.
    3. From the StarSCAN "Home" screen, select "ECU View"  .
    4. From the StarSCAN "ECU View" screen, select "ABS Antilock Brakes"  from the list of modules.
    5. Select "More Options"  .
    6. Select "ECU Flash"  .
    7. Record the old EBC module "Part Number"  displayed at the end of the "Resident flash file for" statement near the top of "Flash ABS"  screen for later reference.
  3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop.
  4. Select "Browse for New File"  and follow the on-screen instructions.
  5. If the newly downloaded flash file "Part Number" in the StarSCAN is:
    • the same  as the number recorded in Step  g, then the EBC module is up to date. No further action is required. Turn off and disconnect the battery charger. Then disconnect the StarSCAN from the vehicle.
    • different  than the number recorded in Step  g, the EBC module requires updating. Continue with Step 6 of this procedure.
  6. Highlight the calibration and then select "Download to Scantool"  .
  7. Select "Close"  after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back"  .
  8. Highlight the listed calibration.
  9. Select "Update Controller"  and follow the on-screen instructions.
  10. When the EBC module update is complete, select "OK"  .
  11. Verify the part number (resident flash file) at the top of the screen has updated to the new part number.
  12. Press the "BACK"  button four times to return to the "Home" screen.
  13. Turn the ignition key to the "OFF" position and wait 10 seconds.
  14. Turn the ignition key to the "RUN"  position (engine not running).
  15. After completing the EBC control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure:
    1. Select "System View". 
    2. Select "All DTC's"  .
    3. Select "Clear All Stored DTC's"  and follow the on-screen instructions.
    4. Select "YES"  in the pop-up box.
    5. Start the engine and verify that there are no DTC's.
  16. Disconnect and remove the StarSCAN and battery charger from the vehicle.

B. Reprogram the Electronic Brake Control Module using StarMOBILE

CAUTION: Software for the "Bootloader" is being replaced during the first 6 seconds of the reprogramming process. If the reprogramming process is interrupted during that time period (first 6 seconds), abort/recovery is not available and the EBC module will be permanently disabled and will require replacement  .
NOTE: The StarMOBILE tool must be at version 8.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen.
  1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts.
  2. Use the following procedure to determine the EBC Module software part number:
    1. Connect the StarMOBILE to the vehicle data link connector and turn the ignition key to the "RUN"  position.
    2. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop.
    3. Power ON the StarMOBILE.
    4. From the desktop, launch the "StarMOBILE Desktop Client" software.
    5. Select "NEXT"  twice.
    6. From the on-screen list, choose the StarMOBILE that is being used and then press "NEXT"  once and then press the "FINISH"  button.
    7. From the StarMOBILE "Home" Screen, select "ECU View"  .
    8. From the StarMOBILE "ECU View" Screen, select "ABS Antilock Brakes"  from the on-screen list of modules.
    9. Select "More Options". 
    10. Select "ECU Flash"  .
    11. Record the old EBC module "Part Number"  displayed at the end of the "Resident flash file for" statement near the top of "Flash ABS"  screen for later reference.
  3. Select "Browse for New File"  and follow the on-screen instructions.
  4. If the newly downloaded flash file "Part Number" in the StarSCAN is:
    • the same  as the number recorded in Step  k, then the EBC module is up to date. No further action is required. Turn off and disconnect the battery charger. Then disconnect the StarMOBILE from the vehicle.
    • different  than the number recorded in Step  k, the EBC module requires updating. Continue with Step 5 of this procedure.
  5. Highlight the calibration and then select "Download to Client"  .
  6. Select "Close"  after the download is complete and record the newly downloaded file part number.
  7. Select "Manage Files"  .
  8. Highlight the calibration recorded in Step  6.
  9. Select "Copy to SM Devise"  and follow the on-screen instructions.
  10. Close the StarMOBILE desktop application after the download to the scan tool is complete.
  11. Disconnect the ethernet cable from the StarMOBILE scan tool.
  12. From the "System Status" screen on the StarMOBILE, press the "Exit"  button.
  13. From the "Main Menu" highlight "Enter Standalone Diagnostic Mode"  and press the "Select"  button.
  14. Highlight "ECU View"  and press the "Select"  button.
  15. Highlight "ABS"  and press the "Select"  button.
  16. Select "Flash ECU"  and press the "Select"  button.
  17. Push the "Select"  button to start the reprogramming process and follow the on-screen screen instructions.
  18. When the flash is complete, press the "OK"  button.
  19. Verify the part number (resident flash file) at the top of the screen has updated to the new part number.
  20. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure:
    1. Return to the "HOME" screen (press the "BACK"  button three times).
    2. Turn the ignition key to the "OFF"  position and wait 10 seconds.
    3. Turn the ignition key to the "RUN"  position (engine not running).
    4. From the "Home" screen highlight "All DTC's"  and press the "Select"  button.
    5. Highlight the "Clear All Stored,"  press the "Select"  button, and follow the on-screen instructions.
    6. Start the vehicle and check for DTC's.
  21. Disconnect the StarMOBILE scan tool and battery charger from the vehicle.

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 DaimlerChrysler to record recall service completions and provide dealer payments.

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

LABOUR OPERATION NUMBER AND TIME ALLOWANCE

  Labor Operation Number  Time Allowance 
EBC Module Update Previously Performed 18-G4-01-81 0.2 hours
Reprogram EBC Control Module 18-G4-01-82 0.3 hours
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

DEALER NOTIFICATION

All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair.

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

All involved vehicles have been entered into the DealerCONNECT 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. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service"  tab and then click on "Global Recall System."  Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

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.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. 

ADDITIONAL INFORMATION

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

Customer Services Field Operations

Chrysler LLC

SAFETY RECALL G40 - REPROGRAM ELECTRONIC BRAKE CONTROL MODULE

Dear: (Name)

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Chrysler LLC has decided that a defect, which relates to motor vehicle safety, exists in some 2006 and 2007 model year Jeep® Grand Cherokee and Commander vehicles and 2007 model year Jeep® Wrangler and Dodge Nitro vehicles.

The problem is... The software programmed into the Electronic Brake Control (EBC) module on your vehicle  (VIN: xxxxxxxxxxxxxxxxx) may allow a momentary delay in braking when coasting up a hill during certain conditions. This could increase the vehicle's stopping distance and cause a crash without warning. 

What your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor).  To do this, your dealer will reprogram the EBC module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on service schedules.

What you must do to ensure your safety...  Simply contact your dealer  right away to schedule a service appointment. Remember to bring this letter with you to your dealer  .

If you need help...  If you have questions or concerns which your dealer is unable to resolve, please contact Chrysler at 1-800-853-1403.

Please help us update our records, by filling out the attached prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle.

If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: Chrysler P.O. Box 4639 Oak Ridge, TN 37831, Attention: Reimbursement.

If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.

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

Customer Services Field Operations

Chrysler LLC

Notification Code G40

Note to lessors receiving this recall:  Federal regulation requires that you forward this recall notice to the lessee within 10 days.

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