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TSB 08-040-04 (Tehnical Service Bulletin)


NUMBER: 08-040-04
GROUP: Electrical
DATE: December 9, 2004

THE DRBIII® FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON
DealerCONNECT.
FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH
FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS
DVD FEBRUARY, 2005.

SUBJECT:
Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the
Liftgate Triggers The Theft Alarm

OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Body Control Module
(BCM) with new software.

MODELS:
2004 - 2005 (RG) Chrysler Voyager (International Markets)
2004 - 2005 (RS) Town & Country/Caravan

NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales
code JPB) and 2004 - 2005 vehicles equipped with Power Locks, Power
Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively).

SYMPTOM/CONDITION:
The vehicle operator may describe:
· The alarm sounds erroneously when opening the power liftgate using the key fob
while the Vehicle Theft Alarm (VTA) is armed.
· The driver's and/or passenger's door lock switches are inoperative.
The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure "
Diagnostic Trouble Codes (DTC's) in the BCM.

NUMBER: 08-040-04
GROUP: Electrical
DATE: December 9, 2004
DIAGNOSIS:
1. Using a Scan Tool (DRBIII®) with the appropriate Diagnostic Procedures Manual,
verify all systems are functioning as designed. If DTCs are present, other than those
listed above, record them on the repair order and repair as necessary before
proceeding further with this bulletin.
2. With the ignition switch in the "RUN" position, determine the original part number of the
BCM currently in the vehicle. Using the DRBIII® select:
a. "DRBIII® Standalone"
b. "1998 - 2005 Diagnostics"
c. "All (Except Below)"
d. "Body Interior"
e. "Body Computer"
f. "Module Display"
g. Record the "Software part #" on the repair order for later reference.
h. Check DTC's

3. If the vehicle operator describes or experiences the Symptom/Condition, use the
following table to determine the appropriate action.
Year Model BCM Software P/N Action Required

2004 RG/RS 04836966AG or earlier Perform Repair Procedure
2005 RG 04840935AC or earlier or 04843198AA
: Perform Repair Procedure
2005 RS 04839664AE or earlier or 04841954AA
: Perform Repair Procedure
2004 RG/RS 04844016AA or higher Further diagnosis is necessary.

[b]This bulletin does not apply[/b]
2005 RG 04843198AB or higher
2005 RS 04844017AA or higher or
04841954AB or higher or
04843752AA or higher

SPECIAL TOOLS/EQUIPMENT REQUIRED:
NPN Battery Charger
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan Tool (DRBIII®)
CH7000A/7001A J1962 Cable with red DRBIII® connector
TechCONNECT Workstation
NOTE: An updated J1962 cable has been released. This cable has a red colored
connector at the DRBIII® connection. Use this cable whenever a flash is
being performed.

REPAIR PROCEDURE:
NOTE: Whenever a controller is programmed, the software in the DRBIII®; must be
programmed with the latest revision level available.
08-040-04 -2-
NOTE: If this flash process is interrupted/aborted, the flash should be restarted and
then follow the directions on the DRBIII®.
1. Before beginning the reprogramming procedure, remove any old flash reprogramming
files from the DRBIII® memory. To clear the memory from the MAIN MENU:
a. Simultaneously press the "MORE" and "YES" keys.
b. A screen will appear requesting a "COLD BOOT".
c. Follow the on screen instructions by selecting the "F4" key.
d. When the DRBIII® reboots to the MAIN MENU, proceed to Step #2
2. Connect the DRBIII® to TechCONNECT. Open TechTOOLS and verify that the
"DRBIII® Status: Connected" message is in the upper right corner of the TechTOOLS
screen.
3. Enter the "Software part #" recorded during "Diagnosis" in the "Parts Criteria" area and
select "Show Updates". TechTOOLS will populate the available updates.
4. Select the calibration.
5. Select the "DRBIII" radio button which is next to the "Download/Update" button.
6. Select the "Download/Update" button.
7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and
follow the instructions on TechCONNECT. When the flash process is complete,
proceed to Step #8.
8. Disconnect the DRBIII® from TechCONNECT.
9. Open the hood, install a battery charger and verify that the charging rate provides
approximately 13.5 volts.
10. Connect the DRBIII® to the vehicle.
11. Turn the ignition to the "Run" position (engine not running).
12. Download the flash from the DRBIII® to the vehicle. Using the DRBIII® select:
a. "Vehicle Flash"
b. Follow the directions on the DRBIII® screen.
13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and
actuating both door lock switches a few times. If any door lock failure still persists then
further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new
software p/n using Diagnosis Step #2.

NOTE: Due to the BCM programming procedure, a DTC may be set in other modules
(TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's
may cause the MIL to illuminate. Check all modules using "Module Scan",
record the DTC's, and erase these DTC's prior to returning the vehicle to the
customer. Erase any DTC's in the PCM only after all other modules have had
their DTC's erased.

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: Description Amount
08-19-02-96 Reprogram Body Control Module 0.5 Hrs.

FAILURE CODE:
FM Flash Module
-3- 08-040-04