Recall - ABS Relay Contacts Sticking
No: D380Ref:
Issue: 1
Date: 09/24/99
RECALL
ABS Relay Contacts Sticking
AFFECTED VEHICLE RANGE:
DISCOVERY Series II (LT) XA200253 to XA227447
XA900000 to XA907211
SITUATION:
ABS RELAY STICKING SYMPTOMS
The contacts of the relay which operate the ABS pump may stick and remain closed when the ABS ECU releases it from the closed position. The instrument panel ABS warning lamps will illuminate and an audible alarm will sound. ABS and Traction Control functions will be disabled.
The effect of the contacts sticking may cause brief symptoms (about 1 second) that could be interpreted as "self braking".
^ The sticking relay causes the ABS pump to run continuously; a fault which is normally detected and accommodated by closing the ABS inlet valves, thus disabling the ABS and traction control systems.
^ If the relay contacts stick immediately following legitimate ABS or traction control operation, the system may take up to one second to detect and accommodate the fault.
^ During the last 700ms of the fault detection period, pressure will build up in the brake system causing progressive application of the brakes. This results in a spontaneous application of the vehicle's brakes without illumination of the vehicle's brake lights.
^ After the one second period the fault will be detected, spontaneous braking will cease, the instrument warning lamps will illuminate and an audible alarm will sound.
RESOLUTION:
REPLACE RELAY
All Discovery Series II vehicles within the VIN range above require the ABS relay to be replaced.
All affected vehicles currently held in inventory as new or used vehicles must be repaired prior to sale.
PARTS INFORMATION:
LRN0002LABEL Campaign label
YWB101300K ABS Relay
WARRANTY CLAIMS:
D380 0.20 hrs
Remove ABS relay and replace with relay YWB101300K (Includes $0.52 allowance for Campaign Label)
Normal warranty policy and procedures apply
REPAIR PROCEDURE
REMOVE AND REPLACE RELAY R10
1. Turn off the ignition switch.
2. Lift the hood and remove the under-hood main fuse box cover
3. Locate relay R10 (Figure 1) and remove the relay.
WARNING:
The removed relay must not be used for any other application. Ensure that it is rendered useless by bending the contacts.
4. Bend the contacts of the removed relay to prevent it from being fitted to another vehicle.
5. Install new relay (YWB101300K) in position R10.
6. Install fuse box cover.
7. Turn ignition switch to the "ON" position and observe instrument warning lights.
8. Verify that all ABS warning lights extinguish.
RECALL CAMPAIGN LABEL INSTALLATION
CAUTION:
Do not touch the exposed label adhesive with your fingers. The bond will be diminished if contaminated prior to application.
NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.
1. When all specified repairs have been accomplished, prepare the Recall label (LRN0002LABEL) as follows:
a) Place the label on a hard surface.
b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Recall campaign code "D380"
^ Your retailer code
^ The date of repair
2. Clean all grease and dirt from the radiator support member.
3. Peel the completed campaign label from the backing paper and position it on the cleaned area of the cross member.
4. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the cross member surface.