Safety Recall P06 Automatic Transaxle Gear Shift Module (RC-CP06-14)

Publication date: 2014-04-08
Reference number: RC-CP06-14

SAFETY RECALL P06 AUTOMATIC TRANSAXLE GEAR SHIFT MODULE

SERVICE CAMPAIGN BULLETIN

Reference Number(s): RC-CP06-14, Date of Issue: March 8, 2014

CHRYSLER:

2014 (BF) Fiat 500L

MODELS

2014 (BF) Fiat 500L

NOTE: This recall applies only to the above vehicles equipped with a six-speed Dual Dry Clutch automatic transaxle (sales code DA1) built from April 03, 2013 through February 14, 2014 (MDH 040300 through 021400) .

IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair 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 process.

SUBJECT

The Gear Shift Module (GSM) on about 1392 of the above vehicles may experience a loss of communication with the transaxle. This may result in an inability to shift the vehicle out of the "Park" position and/or be able to control the transaxle gear selection. Failure to be able to shift the transaxle as requested could cause unintended directional movement and causes a crash without warning.

REPAIR

The software level in the GSM must be interrogated. Depending on the software level found in the GSM, the GSM must be either reprogrammed or replaced.

CAUTION: The GSM assembly must be at or above 60 F. (15.5 C.) before the GSM software can be interrogated or reprogrammed. Attempting to interrogate or reprogram the GSM software below 60 F. (15.5 C.) may cause permanent GSM damage.

PARTS INFORMATION

Part Number	Description
68237769AA	Module, Gear Shift

Due to the small number of involved vehicles expected to require a gear shift module, no parts will be distributed initially. Gear shift modules should be ordered only after interrogation determines that replacement is required.

Very few vehicles are expected to require gear shift module replacement.

Special Tools

The following special tools are required to perform this repair:

NPN wiTECH VCI Pod Kit
NPN Laptop Computer
NPN wiTECH Software

SERVICE PROCEDURE

A. Interrogate Gear Shift Module (GSM) Software

CAUTION: The GSM assembly must be at or above 60 F. (15.5 C.) before the GSM software can be interrogated. Attempting to interrogate the GSM software below 60 F. (15.5 C.) may cause permanent GSM damage.

NOTE: wiTECH must be used to perform this recall. This procedure must be performed with software release level 14.01 or higher.

Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.
NOTE: Use an accurate stand-alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.
Connect the wiTECH VCI pod to the vehicle data link connector located to the right of the hood release lever.
Place the ignition in the "RUN" position.
Open the wiTECH Diagnostic application.
Starting at the "Select Tool" screen, highlight the row/tool for the wiPOD device you are using. Then select "Next" at bottom right side of the screen.
Enter your "User id" and "Password", then select "Finish" at the bottom of the screen.
From the "Vehicle View" screen, click on the "ESM" icon.
From the "ESM View" screen select "ECU Details" tab.
Select the "Configuration" button in the upper right hand corner of the screen.
Read the "ECUSwVerNumber":
- If the ECU value is 120, replace the gear shift module. Continue with Section C. Replace the Gear Shift Module (GSM).
- If the ECU value is 124 or 125, reprogram the gear shift module. Continue with Section B. Reprogram the Gear Shift Module (GSM).
- If the ECU value is 126, no further action is required. Return the vehicle to the customer.

B. Reprogram the Gear Shift Module (GSM)

NOTE: The following procedure is required if the GSM software level is at "version 124 or 125" as determined per the inspection in Section "A."

CAUTION: The GSM assembly must be at or above 60 F. (15.5 C.) before the GSM software can be reprogrammed. Attempting to reprogram the GSM software below 60 F. (15.5 C.) may cause permanent GSM damage.

From the "ESM View" screen select the "Flash" tab.
With the cursor over the desired flash file, click the small green arrow button on the right side of the screen.
From the "Flash Tab" screen follow the wiTECH screen instructions to complete the software reprogramming process.
Verify that all Diagnostic Trouble Codes (DTC's) have been cleared.
If "active" DTC "U0415-00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module" is present, perform the following procedure:
NOTE: The Transmission Control Module (TCM) may set the U0415 Diagnostic Trouble Code (DTC) when the scan tool is connected to the vehicle and the ABS module is being accessed. The DTC sets when the ABS module sends invalid messages to the TCM during tool operation in the ABS module. This only happens when a service tool is connected and accessing ABS diagnostics.
1. Clear the DTC if in the "Stored" status with the wiTECH scan tool.
2. To get the DTC to a "Stored" status use wiTECH scan tool and go into TCM, then "cycle" the ignition key. The DTC will go into the "Stored" status.
3. From the TCM, perform the clear stored DTC's process.
4. Disconnect the wiTECH scan tool to complete the process.
Turn the ignition to the "OFF" position and remove the wiTECH VCI pod and battery charger from the vehicle. Return the vehicle to the customer.

C. Replace the Gear Shift Module

NOTE: The following procedure is required if the GSM software level is at "version 120" as determined per the GSM interrogation in Section "A."

Very few vehicles are expected to require gear shift module replacement.

NOTE: The new GSM assembly doesn't require reprogramming. The new GSM has the latest version of software required (version 126).

Position the vehicle on a suitable hoist.
Disconnect and isolate the negative battery cable at the battery.
Release the snap at the top of the gear shift boot (Figure 1).
Detach the hook-and-loop strip holding the gear shift boot together (Figure 1).
Using a plastic trim stick, separate the gear shift boot bezel from the floor console (Figure 2).
Disconnect the electrical connector from the gear shift boot bezel and remove as an assembly (Figure 2).
Raise the vehicle on the hoist.
Remove and save the engine under body plastic splash shield.
Remove and save the exhaust manifold flange retaining nuts (Figure 3).
Disconnect the downstream oxygen sensor electrical connector (Figure 3).
Disconnect the exhaust system engine bracket from the engine (Figure 3).
Remove and save the front suspension crossmember brace (Figure 3).
Disconnect all of the rubber exhaust hangers and lower the exhaust system to gain access to the gear shift module (Figure 4).
Disconnect the gear shift cable end from the transaxle gear shift lever.
Unsnap the gear shift cable from the transaxle bracket (Figure 5).
Unlatch the shift cable from the shift cable plastic routing clip.
Remove and save the rear exhaust heat shield retainer clips and exhaust hanger bracket. Carefully remove and save the rear exhaust heat shield (Figure 6 and 7).
Remove and save the main exhaust heat shield retaining clips (Figure 7).
Remove and save the four gear shift module retaining bolts (Figure 7).
Remove and save the main exhaust heat shield (Figure 7).
Carefully lower the gear shift module and disconnect the electrical connector. Then remove the gear shift module from the vehicle (Figure 8).
Use the following procedure to transfer the gear shift knob:
CAUTION: Do not attempt to pull the gear shift knob from the gear shift lever without first removing the gear shift button. Gear shift knob button damage may occur.
1. Using a trim stick, carefully remove the gear shift knob button (Figure 9).
2. Remove and save the gear shift knob retaining screw (Figure 10).
3. Remove the gear shift knob from the original gear shift module lever.
4. Slide the gear shift knob onto the new gear shift module lever (Figure 10).
5. Insert the gear shift knob retaining screw and tighten securely (Figure 10).
6. While pulling out on the bottom of the gear shift knob button, insert the gear shift knob button into the gear shift knob (Figure 11).
Install the new gear shift module, main heat shield, and four retaining bolts to the vehicle. Tighten the four gear shift module retaining bolts to 18 ft.lbs. (25 N.m).
Install the rear heat shield and exhaust hanger.
Attach the gear shift cable anchor to the transaxle gear shift cable bracket.
Connect the gear shift cable end to the transaxle shift lever.
Secure the gear shift cable to the shift cable plastic routing clip.
Use the following procedure to adjust the gear shift cable:
1. Verify that the transaxle is in the "Park" position.
2. Verify that the gear shifter is in the "Park" position.
3. Lock the shift cable adjustment button by pushing it inward (Figure 12).
4. Turn the shift cable adjustment button lock clockwise to lock the shift cable adjustment button (Figure 12).
Install the exhaust system.
Connect the downstream oxygen sensor electrical connector (Figure 13).
Install the under body plastic splash shield.
Lower the vehicle from the hoist.
Place the gear shift boot bezel into position and connect the electrical connector to the gear shift boot bezel.
Snap the gear shift boot bezel to the floor console.
Secure the hook-and-loop fasteners together and snap the gear shift boot snap together.
Connect the negative battery cable to the negative battery post.

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 Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments.

Parts listed on any campaign are required for the repair but may not always be eligible for reimbursement. As stated in the Service Administration Manual; Normal shop supplies, such as general-purpose cleaners, solvents, lubricants, etc. submitted on claims are subject to non-payment or chargeback.

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

COMPLETION REPORTING AND REIMBURSEMENT

	Labour Operation Number	Time Allowance
Interrogate GSM software level, no update required	21-P0-61-81	0.2 hours
Interrogate GSM software level and reprogram GSM with new software	21-P0-61-82	0.2 hours
Inspect GSM software level and replace GSM assembly	21-P0-61-83	1.2 hours

OWNER NOTIFICATION AND SERVICE SCHEDULING

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

Enclosed with each owner letter is a Service Authorization Card to allow owners to update our records if applicable.

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 studio 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 studio'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, Postal Code, or VIN sequence.

Dealers should 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.

VIN lists may contain confidential, restricted owner name and address information. Use of this information is permitted for this notification 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.

Chrysler Canada Inc.

J.D. Kiritsis

National Service and Parts Manager

SAFETY RECALL P06 AUTOMATIC TRANSAXLE GEAR SHIFT MODULE

Dear Chrysler Canada Vehicle Owner:

This notice is sent to you in accordance with the Canada Motor Vehicle Safety Act.

Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2014 model year Fiat 500L vehicles equipped with a six-speed Dual Dry Clutch automatic transaxle.

The problem is: The Gear Shift Module may experience a loss or delay of communication with the transmission. This may result in an inability to shift the vehicle out of the "Park" position and/or be able to control the transmission gear selection. Failure to be able to shift the transmission could cause unintended directional movement and causes a crash without warning.

What your dealer will do: Fiat will repair your vehicle free of charge (parts and labor). To do this, your studio will interrogate the Gear Shift Module and reprogram or replace it as required.

What you must do to ensure your safety: Contact your Fiat Studio to schedule a service appointment and provide them with your VIN number, (shown on the enclosed Service Authorization Card).

If you need help: If you require additional assistance or information, please contact the Fiat Customer Care at 1-800-465-2001 (English) or 1-800-387-9983 (French) or by email:

www.chryslercanada.ca/en/contact_us.php (English) or

www.chryslercanada.ca/fr/contact_us.php (French).

If you have already experienced this condition and have paid to have it repaired, you will still be required to have the campaign performed by an authorized Chrysler dealer at no charge to you. Once completed, please send your original receipts and/or adequate proof of payment along with the campaign invoice to the following address for further review of possible reimbursement: Chrysler Canada Customer Care, P.O. Box 1621, Windsor, ON, N9A 4H6.

If your name and address shown on the enclosed Service Authorization Card is incorrect or if you no longer own the vehicle, please contact us at the above phone number, email address or fill in the prepaid post card.

We apologize for any inconvenience and thank you for your attention to this important matter.

Yours very truly,

Chrysler Canada Inc.

National Service and Parts Manager