Jeep Cherokee (XJ): Disassembly and assembly

POWER DISTRIBUTION CENTER

The Power Distribution Center (PDC) cover, the PDC housing lower cover, the PDC relay wedges, the PDC relay cassettes and the PDC B(+) terminal stud cover are available for service replacement (Fig. 10).

The PDC cover and B(+) terminal stud cover can be simply unlatched and removed from the PDC housing without the PDC being removed or disassembled.

Service of the remaining PDC components requires that the PDC be removed from its mounting and disassembled.

Refer to Wiring Repair in the index of this service manual for the location of the wiring repair procedures.

DISASSEMBLY

PDC HOUSING LOWER COVER

(1) Disconnect and isolate the battery negative cable.

(2) Unlatch and remove the cover from the PDC.

(3) Unlatch and remove the B(+) terminal stud cover from the PDC.

(4) Remove the nut that secures the two battery wire harness PDC take out eyelets to the B(+) terminal stud of the PDC.

(5) Remove the battery wire harness PDC take out eyelets from the PDC B(+) terminal stud.

(6) Disengage the latches on the PDC mounting bracket from the tabs on the PDC housing, and pull the PDC housing upward to disengage the mounting slots from the stanchions of the mounting bracket.

(7) Using a trim stick or another suitable wide flat-bladed tool, gently pry the latches on each side and one end of the PDC housing that secure the housing lower cover to the PDC and remove the housing lower cover (Fig. 11).

PDC RELAY WEDGE

(1) Remove the PDC housing lower cover.

(2) Remove each of the relays from the PDC relay wedge to be removed.

Fig. 10 Power Distribution Center Components

1 - LATCH
2 - COVER
3 - LATCH
4 - B(+) TERMINAL STUD COVER
5 - PDC HOUSING
6 - HOUSING LOWER COVER (TYPICAL)
7 - WIRE HARNESS
8 - RELAY CASSETTE (TYPICAL)
9 - RELAY WEDGE (TYPICAL)
10 - HINGE TABS

(3) From the bottom of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches (yellow) that secure the relay wedge to the PDC relay cassette.

(4) From the top of the PDC housing, remove the relay wedge from the PDC relay cassette (Fig. 12).

PDC RELAY CASSETTE

(1) Remove the relay wedge from the PDC relay cassette to be removed.

NOTE: It may be necessary to remove relay cassettes that are not being serviced from the PDC housing in order to obtain sufficient clearance to service the faulty relay cassette. The same service procedure is repeated as necessary to remove each of the interfering relay wedges and relay cassettes from the PDC housing.

(2) From the top of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches that secure the relay cassette in the PDC (Fig. 13).

Fig. 11 PDC Housing Lower Cover Remove/Install

1 - PDC HOUSING
2 - TAB
3 - PDC HOUSING LOWER COVER
4 - LATCH

БЮ Fig. 12 PDC Relay Wedge Remove/Install

1 - RELAY WEDGE (TYPICAL)
2 - PDC HOUSING

(3) Gently and evenly press the relay cassette down through the PDC housing.

Fig. 13 PDC Relay Cassette Latches

1 - LATCHES
2 - FROM SPECIAL TOOL KIT 6680
3 - PDC RELAY CASSETTES (TYPICAL)

(4) From the bottom of the PDC housing, remove the relay cassette from the PDC (Fig. 14).

Fig. 14 PDC Relay Cassette Remove/Install

1 - PDC HOUSING
2 - PDC RELAY CASSETTE (TYPICAL)
3 - LATCHES

CAUTION: Do not remove the wiring and terminals from the terminal cavities of the faulty PDC relay cassette at this time. Refer to the Assembly procedure that follows for the proper procedures for transferring the wiring and terminals to the replacement PDC relay cassette.

ASSEMBLY

PDC RELAY CASSETTE

(1) Move the faulty PDC relay cassette with its wiring away from the bottom of the PDC housing far enough to allow the replacement relay cassette to be installed into the PDC.

(2) Using the faulty relay cassette as a guide, be certain that the replacement relay cassette is correctly oriented before installing it into the PDC housing.

(3) From the bottom of the PDC housing, align and insert the replacement relay cassette into the PDC.

Press the relay cassette up into the PDC until both of the latches are fully engaged.

CAUTION: Proper care must be taken to be certain that the wiring and terminals from the faulty PDC relay cassette are installed in the correct terminal cavities of the replacement relay cassette. To prevent mistakes it is recommended that the wiring and terminals be removed from the faulty relay cassette one cavity at a time, repaired or spliced as necessary, then installed securely into the correct cavity of the replacement relay cassette. If you are not absolutely certain into which cavity a terminal should be installed, refer to Power Distribution in the index of this service manual for the location of complete circuit diagrams covering the PDC.

(4) While pulling gently on the wire from the bottom of the faulty PDC relay cassette, use a terminal pick tool (Special Tool Kit 6680) from the top of the relay cassette to release the latch that secures the terminal in the relay cassette terminal cavity (Fig.

15).

(5) From the bottom of the faulty PDC relay cassette, remove the wire and terminal from the relay cassette terminal cavity.

(6) Make all necessary repairs and splices to the wire for the removed terminal. Refer to Wiring Repair in the index of this service manual for the location of the wiring repair procedures.

(7) From the bottom of the PDC housing, align and insert the removed wire and terminal into the correct terminal cavity of the replacement relay cassette.

Push the wire and terminal up into the relay cassette terminal cavity until it is fully engaged by the latch.

(8) Repeat Step 4, Step 5, Step 6 and Step 7 one wire and terminal at a time until each of the wires and terminals have been transferred from the faulty PDC relay cassette into the replacement relay cassette.

(9) Install the PDC relay wedge into the replacement PDC relay cassette.

Fig. 15 PDC Relay Cassette Terminal Remove/Install

1 - TERMINAL CAVITIES (TYPICAL)
2 - PDC RELAY CASSETTE (TYPICAL)
3 - TERMINAL LATCHES (TYPICAL)
4 - FROM SPECIAL TOOL KIT 6680

PDC RELAY WEDGE

(1) From the top of the PDC housing, align and insert the PDC relay wedge latch arms into the correct cavities in the relay cassette.

(2) Gently and evenly press the PDC relay wedge down into the relay cassette until both of the latches are fully engaged.

(3) Install each of the removed relays into the proper cavities of the PDC relay wedge.

(4) Install the PDC housing lower cover.

PDC HOUSING LOWER COVER

(1) Align the PDC housing lower cover to the bottom of the PDC.

(2) Press the PDC housing lower cover gently and evenly onto the PDC until each of the latches that secure the cover to the PDC is fully engaged.

(3) Engage the mounting slots on the PDC housing with the stanchions of the PDC mounting bracket and push the unit downward until the mounting bracket latches fully engage the mounting tabs on the PDC housing.

(4) Install the battery wire harness PDC take out eyelets over the PDC B(+) terminal stud.

(5) Install and tighten the nut that secures the eyelets of the battery wire harness PDC take outs to the B(+) terminal stud. Tighten the nut to 10.8 N·m (95 in. lbs.).

(6) Install the B(+) terminal stud cover onto the PDC.

(7) Install the cover onto the PDC.

(8) Reconnect the battery negative cable.