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Discussion Starter · #1 · (Edited)
Just trolling thru Dealerconnect and thought I'd do some copy/paste

SRT8


The SRT8 front suspension is very similar to the standard front suspension but some components have been modified for unique ride, handling, and steering performance. Service of all front suspension components remain the same as the standard components. When components differ, be sure to use only SRT8 components on SRT8 vehicles.

The Active Damping System (ADS) front shock assembly (1) is similar to a conventional coil over shock with the addition of a shock solenoid assembly (3) mounted on the side of its body with a three wire harness/connector (2) attached to it. Although serviced the same, the components of the SRT8 shock assembly are unique to this vehicle. The front shock absorber is manufactured by Bilstein®. Because the shock absorber is a mono-tube design, it is important to handle it with care and not support the shock by its tubular housing.

The front knuckle (8) for the SRT8 is different from the standard knuckle. Although similar in appearance, the knuckle has been modified to accept the larger tire and wheel assembly. Also, the mounting bosses for the disc brake caliper have been moved to allow for mounting of the Brembo six-piston disc brake caliper (2).

The front stabilizer bar diameter has been increased for the SRT8. It is serviced in the same manner as the standard bar.

Vehicles equipped with the ADS includes an Active Damping Control Module (ADCM) which is located beneath the LF seat where it is concealed beneath a cover panel. The ADCM receives multiple signals on the CAN bus as well as three active damping sensors. Two sensors are located on inside of the frame rail directly behind the radiator and one is mounted in the rear underside of the vehicle near the park brake cable tensioner. The sensors are 3 wire, 5V reference sensors wired directly to the ADCM.

SRT8
The SRT8 vehicles suspension system operates the same as standard suspension except the addition of the Active Damping System (ADS).

There are two operating modes of the ADS, Auto and Sport (referred to as Firm). At each ignition key on cycle, the vehicle defaults to Auto mode. The Drive Train Control Module (DTCM) communicates the request for the Firm mode to the ADCM when the terrain select switch is placed in either the Track, Sport or Snow positions. When the Firm mode is selected, the suspension has unique handling characteristics.

An Active Damping Control Module (ADCM) controls the suspension and ride for the SRT version of this vehicle by adjusting the rebound and jounce of the shock assemblies using the above information and predetermined matrix's for maximum vehicle control. The shock absorbers are unique to the Active Damping System (ADS). Each shock absorber has a valving unit that is external, but still part of the shock absorber. Inside each valving unit are two solenoids that control the damping valves to alter the ride of the vehicle. The shocks are replaced as an assembly, they cannot be disassembled for repair.

Additionally, there are three active damping sensors, two in the front of the vehicle and one in the rear. These sensors measure the plane of the vehicle.



SRT8
The SRT8 rear suspension is very similar to the standard rear suspension but some components have been modified for unique ride, handling, and steering performance. Service of all rear suspension components remain the same as the standard components. When components differ, be sure to use only SRT8 components on SRT8 vehicles.

The rear knuckle for the SRT8 is different from the standard knuckle. Although similar in appearance and in service, the mounting bosses for the disc brake caliper have been moved downward to allow mounting of the Brembo four-piston brake caliper.

The rear stabilizer bar diameter has been increased for the SRT8. It is serviced in the same manner as the standard bar.



DESCRIPTION
WARNING: All pressurized air suspension components contain high pressure air (up to 220 psig). Use extreme caution when inspecting for leaks. Wear safety goggles and adequate protective clothing when inspecting or servicing the air suspension system. A sudden release of air under this amount of pressure can cause possible serious or fatal injury.


WARNING: Support the vehicle by supplemental means before performing any work on the air suspension system to prevent the vehicle from changing height. Before any given component is to be serviced it must be deflated. Servicing the air suspension system without supplemental support, or with pressure in the specific component, can cause possible serious or fatal injury.






The air suspension system automatically or manually (operator control) lowers and lifts the vehicle using rear air suspension springs (air bag) (7) and front air suspension spring and shock assemblies (3) which replace the standard springs in the rear, and standard spring/shock in the front. The air suspension system uses multiple integrated components in various areas of the vehicle to accomplish this.

Below is a list of the components of the air suspension system. For more information on the individual components, refer to the specific components Description and Operation.

Air suspension reservoir (1)
Air Suspension Control Module (ASCM) (2)
Air suspension spring and shock assembly (3)
Air suspension compressor assembly (includes valve block) (4)
Compressor assembly valve block (part of 4, can be serviced separately)
Height sensor, front (5)
Air lines (6)
Air suspension spring (7)
Height sensor, rear (8)
Air suspension temperature sensor (not shown, connected to compressor)
Air suspension hose assembly (not shown, connected to compressor)
Air suspension reservoir bracket (not shown)
Terrain select switch (not shown, on center console)


OPERATION
Special Tools: Click to display a list of tools used in this procedure

Click here to launch the form to order any tools you need.

10247 - Tool, Air Suspension Refill

Originally Shipped In Kit Number(s) 10247.

WARNING: All pressurized air suspension components contain high pressure air (up to 220 psig). Use extreme caution when inspecting for leaks. Wear safety goggles and adequate protective clothing when inspecting or servicing the air suspension system. A sudden release of air under this amount of pressure can cause possible serious or fatal injury.


WARNING: Support the vehicle by supplemental means before performing any work on the air suspension system to prevent the vehicle from changing height. Before any given component is to be serviced it must be deflated. Servicing the air suspension system without supplemental support, or with pressure in the specific component, can cause possible serious or fatal injury.


CAUTION: When removing an air line from a component and the air line is to be reused, do not remove the 90° fitting or the brass fitting from the air line. If either is removed, the air line must be replaced. New components have air line fittings attached; however if the original air line is used the original fitting must also be used. Do not remove protective caps or plugs from air lines or components until ready to install the air line to prevent moisture or dirt intrusion. All air line fittings must be hand started to avoid cross threading.




NOTE: The air suspension system will auto-disable when lifted on a frame hoist, or when jacking one corner of the vehicle. The air suspension may attempt to change height slightly prior to switching to auto-disable. A manual disable is also available by pressing the “Up” and “Down” switches of the terrain select switch simultaneously for more that 5 seconds. The air suspension system will return to normal operation when the vehicle speed reaches 25 kph (15 mph).

NOTE: The air suspension system will not lower if any of the doors or liftgate is open (normal operation) or the engine is not running. Doors and liftgate status are ignored when using a scan tool.

NOTE: When the Air Suspension Control Module (ASCM) or any height sensor is replaced the ASCM will need to be initialized using a scan tool. Refer to the appropriate installation procedure for specific instructions.


General Information
The air suspension system is designed to raise and lower the vehicle height as required depending on driver request using the terrain select switch, or automatically with the terrain select switch in the Auto position. There is an Air Suspension Control Module (ASCM) located under the driver’s seat which contains the logic and controls for the system. Multiple modules work together to increase vehicle stability and traction along with vehicle ride height. The ASCM uses several Controller Area Network (CAN) data bus systems for inputs and outputs of the information necessary for the different systems to operate. The use of a scan tool is necessary for diagnostics, and replacement of any pressurized components. Height sensors on each corner of the vehicle monitor the vehicle height. The front of the vehicle is raised/lowered with two air suspension spring and shock assemblies, and the rear uses two air suspension springs.

The air suspension is a closed type system that does not draw in fresh air during vehicle lifting or leveling. Instead, it moves pressurized air back and forth between an air suspension reservoir and the four air springs as required to raise or lower a specific corner of the vehicle. The air suspension compressor assembly includes an air suspension valve block, controlled by the ASCM. The valve block isolates and actuates the raising and lowering of each pressurized component using individual air lines for the air springs and reservoir. The air suspension compressor does have a filtered air suspension hose assembly for adding air volume if a component of the system loses its air pressure and is replaced. The compressor is not intended to replenish the entire systems air volume. There is a procedure for complete system fill using an external source if it is necessary; however, this should only be necessary if the air suspension compressor or air compressor valve block is replaced.


Refilling the System
If the air suspension system is fully depleted of air it can be refilled using a scan tool and Air Suspension Refill Tool - 10247 which is used with a nitrogen supply tank (can be acquired at a local gas supplier). The nitrogen must be Purity Class 5 (99.999% pure). The size and volume of the nitrogen supply tank will determine how many air suspension systems can be filled.


Changing Ride Height

Using the terrain select switch, ride height can only be changed while the air suspension system is in normal operating conditions. To change the ride height using the terrain select switch. Air suspension system normal operating conditions are as follows:
Scan tool disconnected
All doors closed
Liftgate closed
Engine running
Minimum battery voltage greater than 10.5 volts

Using a scan tool, ride height can be changed regardless of the engine state (running or not), doors or liftgate state (open or closed). The only condition necessary is that battery voltage must be greater than 10.5 volts.

Ride Heights for Suspension Measurements or Adjustments
When checking or performing an alignment the air suspension system must be in the manually selected "Sport" position of the terrain select switch or the Aero mode if using a scan tool. When measuring curb height, the air suspension system must be in the manually selected "Auto" position of the terrain select switch, or the Normal Ride Height (NRH) mode if using a scan tool.


Manual Control
A terrain select switch is located on the console for driver control of the system. When the driver presses the terrain select switch to manually (two RH buttons) raise or lower the vehicle height the Electronic Vehicle Information Center (EVIC) displays a vehicle “up” or “down” icon and a LED indicator on the switch changes position. The EVIC displays the current position of the vehicle when it is achieved. When lowering the vehicle, the front is always first to move. When raising the vehicle, the rear is always the first to move. When the ASCM receives a command to change the vehicle more than one ride height position the action is performed in multiple steps. If request to change by two positions the rear will raise one position, then the front will raise one position, the rear again raises one position, then the front will raise to the final position. If requested to lower more than one position the same steps happen, EXCEPT the front moves first. This multi-step motion controls the angle the headlights are projected by controlling the pitch of the vehicle, keeping them from going above their normal projection plane.

There are five predetermined manual height settings; Normal Ride Height (NRH), two above and two below NRH. The predetermined vehicle heights (above or below NRH) are as follows:

Off-Road 2 (OR2), + 65 mm (2.6 in.) (Except if equipped with AMS + 56 mm [2.2 in.])
Off-Road 1 (OR1), + 33 mm (1.3 in.) (Except if equipped with AMS + 28 mm [1.1 in.])
Aero Mode, - 15 mm (0.59 in.)
Park Mode, - 40 mm (1.57 in.)

Automatic Control
There are five choices for automatic control using the center rotating knob of the terrain select switch. The choices are Auto, Sport, Snow, Sand/Mud, and Rock. When the driver chooses an automatic setting multiple systems are affected for the best vehicle performance. Some of the modules whose systems use these settings are:

Air Suspension Control Module (ASCM)
Antilock Brake Module (ABS)
Automatic Headlamp Leveling Module (AHLM)
Drivetrain Control Module (DTCM)
Powertrain Control Module (PCM)
Steering Control Module (SCM)
The basics of how the different automatic settings effect the systems are listed below:

Auto - When in 4WD High range the vehicle height is at NRH. The vehicle systems are set to normal performance settings. Combines optimal traction with seamless steering feel. When in 4WD Low range the vehicle height adjusts to 38 mm (1.49 in.) above NRH, the transfer case locks, and the transmission shifting adjusts to off road shifting.
Sport - When in 4WD High range the vehicle height adjusts to 15 mm (0.59 in.) below NRH. Electronic Stability Control (ESC) and traction control tuning thresholds are raised, and the Antilock Brake Control (ABS) allows less wheel slip, all to allow more driver control. Also the transmission shifting adjusts to a higher performance shifting. Not available in 4WD Low range.
Snow - When in 4WD High range the vehicle height is at NRH. Traction control is adjusted to allow less wheel slip, and initial vehicle launch will be in second gear. When in 4WD Low range the vehicle height adjusts to 33 mm (1.3 in.) above NRH, the transfer case locks, the transmission shifting and ABS adjusts to off road settings.
Sand/Mud - When in 4WD High range the vehicle height adjusts to 38 mm (1.49 in.) above NRH. Electronic Stability Control (ESC) tuning threshold is raised, and the ABS allows less wheel slip to allow more driver control. When in 4WD Low range the vehicle height adjusts to 38 mm (1.49 in.) above NRH. The transfer case and the Electronic Limited Slip Differential (ELSD) locks, the transmission shifting and ABS adjusts to off road settings.
Rock - Not available in 4WD High range. When in 4WD Low range the vehicle height adjusts to 65 mm (2.6 in.) above NRH. The transfer case and the ELSD locks, the transmission shifting and ABS adjusts to off road settings, and hill descent control is activated for steep downhill




DESCRIPTION
The MP3010 is a single speed transfer case which provides convenient full-time all-wheel-drive. No driver interaction is required. This transfer case divides engine torque almost evenly, with 47 percent of engine torque to the front axle and 53 percent of engine torque to the rear axle, resulting in a vehicle with good traction and stability








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Discussion Starter · #2 ·
Air Suspension Fill

COMPLETE SYSTEM FILL
Special Tools: Click to display a list of tools used in this procedure

Click here to launch the form to order any tools you need.

10247 - Tool, Air Suspension Refill

Originally Shipped In Kit Number(s) 10247.

WARNING: All pressurized air suspension components contain high pressure air (up to 220 psig). Use extreme caution when inspecting for leaks. Wear safety goggles and adequate protective clothing when inspecting or servicing the air suspension system. A sudden release of air under this amount of pressure can cause possible serious or fatal injury.


WARNING: Support the vehicle by supplemental means before performing any work on the air suspension system to prevent the vehicle from changing height. Before any given component is to be serviced it must be deflated. Servicing the air suspension system without supplemental support, or with pressure in the specific component, can cause possible serious or fatal injury.




NOTE: The air suspension system will auto-disable when lifted on a frame hoist, or when jacking one corner of the vehicle. The air suspension may attempt to change height slightly prior to switching to auto-disable. A manual disable is also available by pressing the “Up” and “Down” switches of the terrain select switch simultaneously for more that 5 seconds. The air suspension system will return to normal operation when the vehicle speed reaches 25 kph (15 mph).

This procedure should only be necessary when the entire system was purged of air, as in a compressor or valve block assembly replacement.





NOTE: The gauge (1) on Air Suspension Refill Tool - 10247 reads the tank pressure. The regulator limits the pressure in the line (4) to 12 bar (175 psi). When connected to the reservoir with the valves open, pressure in the reservoir can be read on the scan tool.

The Air Suspension Refill Tool - 10247 (1, 4 ,5 ,6) is used with a nitrogen supply tank (2, 3) which can be acquired at a local gas supplier. The nitrogen must be Purity Class 5 (99.999% pure).

1. Raise and support the vehicle so the suspension system is hanging (four wheels off the ground) (Refer to 04 - Vehicle Quick Reference/Hoisting - Standard Procedure) .
2. Make sure the Air Suspension Refill Tool - 10247 line on/off valve (6) is turned off and the nitrogen tank valve is turned off (2).





NOTE: With the air suspension reservoir behind the back seat, the fill fitting will always be on the drivers side of the vehicle.
3. Tilt the rear seat forward, and lift the cargo floor beauty panel (removed for clarity) to expose the reservoir (4).
4. Remove the reservoir fill connection cap (not shown).
5. With Air Suspension Refill Tool - 10247 (1, 2, 5) attached to a nitrogen tank, connect the quick coupler (2) to the air suspension reservoir fill connection (3) and open the valve (1) by turning clockwise.




6. NOTE:The regulator on Air Suspension Refill Tool - 10247 is preset to 12 bar (175 psi) (as read with a scan tool, the gauge reads tank pressure only). When connected to the reservoir and the valves open, the pressure will equalize to 12 bar (175 psi) in approximately 10-15 seconds. A hissing sound can be heard while the nitrogen is being transferred and the sound will stop when the pressures are equalized.Fill the reservoir to approximately 12 bar (175 psi) by fully opening the valve (2) on the nitrogen tank (3) and the valve (6) on Air Suspension Refill Tool - 10247 (1, 4 ,5 ,6).
7. When the pressures are equalized, close the valve (6) on the tool.
8. With a scan tool, using the routines under the Air Suspension Control Module (ASCM), perform a Short Fill on one rear air spring, verify that the air spring is seated properly, then perform a Complete Fill on that spring.
9. Repeat step 8 on the opposite rear air spring.
10. Fill the reservoir again by repeating steps 6 and 7.
11. With a scan tool, using the routines under the Air Suspension Control Module (ASCM), perform a Complete Fill on each front spring and shock assembly.
12. Verify the Air Suspension Refill Tool - 10247 line on/off valve (6) is closed and close and the nitrogen tank valve (2).




13. Remove the supports and lower the vehicle.
14. Close the valve (1) by turning counter clockwise, remove the quick coupler (2) from the air suspension reservoir fill connection (3) and install the reservoir fill connection cap (not shown).
15. With a scan tool, using the routines under the Air Suspension Control Module (ASCM), perform the following:

Command the vehicle to Normal Ride Height.
Run the Air Mass Calculation routine on the air suspension system.
If necessary, add to the system or deflate to atmosphere using the ASCM routines, then repeat the Air Mass Calculation routine again until system responds with Air Mass OK (188 - 216 bar-liters).
16. Perform the ASCM Verification Test (Refer to 28 - DTC-Based Diagnostics/MODULE, Air Suspension Control (ASCM) - Standard Procedure).
 

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Discussion Starter · #3 ·
Brake Operation

OPERATION
Battery voltage is supplied to the Antilock Brake System (ABS) module. The ABS module performs a system initialization procedure at start up along with an ABS motor check. Initialization consists of a static and dynamic self check of system electrical components.

The static and dynamic checks occurs at ignition start up. During the dynamic check, the ABS module briefly cycles solenoids to verify operation. An audible noise may be heard during this self check. This noise should be considered normal.

If an ABS component exhibits a fault during initialization, the ABS module illuminates the amber warning light and registers a fault code in the microprocessor memory.

The ABS module monitors wheel speed sensor inputs continuously while the vehicle is in motion. However, the ABS module will not activate any ABS components as long as sensor inputs indicate normal braking.

During normal braking, the master cylinder, power booster and wheel brake units all function as they would in a vehicle without ABS. The Hydraulic Control Unit (HCU) components are not activated.

The purpose of the antilock system is to prevent wheel lockup. Preventing lockup helps maintain vehicle braking action and steering control.

The ABS module activates the system whenever sensor signals indicate periods of wheel slip.

The antilock system prevents lockup during a wheel slip condition by modulating fluid apply pressure to the wheel brake units.

Brake fluid apply pressure is modulated according to wheel speed, degree of slip and rate of deceleration. Sensors at each wheel convert wheel speed into electrical signals. These signals are transmitted to the ABS module for processing and determination of wheel slip and deceleration rate.

The ABS system has four fluid pressure control channels. Each wheel brakes are controlled separately. A speed sensor input signal indicating a wheel slip condition activates the ABS module antilock program.

There are Two solenoid valves (Isolation and Dump valve) which are used in each antilock control channel. The valves are all located within the HCU valve body and work in pairs to either increase, hold, or decrease apply pressure as needed in the individual control channels.

During an ABS stop the ISO valve is energized which acts to prevent further pressure build-up to the calipers. Then the Dump valve dumps off pressure until the wheel unlocks. This will continue until the wheels quit slipping altogether.




ELECTRONIC ROLL MITIGATION (ERM)
This system anticipates the potential for wheel lift by monitoring the driver’s steering wheel input and the speed of the vehicle. When ERM determines that the rate of change of the steering wheel angle and vehicles speed are sufficient to potentially cause wheel lift, it applies the appropriate brake and may reduce engine power to lessen the chance that wheel lift will occur. ERM will only intervene during very severe or evasive driving maneuvers.

ERM can only reduce the chance of wheel lift occurring during severe or evasive driving maneuvers. It can not prevent wheel lift due to other factors such as road conditions, leaving the roadway or striking objects or other vehicles.



READY ALERT BRAKING
Ready Alert Braking is a feature that applies very low brake pressure to all calipers after a rapid accelerator pedal release is detected. This feature provides a firm confident pedal feel and optimal stopping distance in the case of rapid accelerator release.

RAIN BRAKE SUPPORT
The Rain Brake Support is a feature that removes the water film that builds up between the pads and the rotors when driving in wet conditions. When the windshield wipers are active, this feature applies a very low brake pressure to all calipers periodically. This maintains a firm, confident brake pedal feel and optimal stopping distance in wet conditions.




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Discussion Starter · #4 ·
Active Dampening

OPERATION
The Active Damping Control Module (ADCM) uses the CAN bus to communicate with multiple modules. The ADCM has the following inputs: Vehicle Speed, Steering Angle Sensor (SAS) position, Throttle Position Sensor (TPS), terrain select switch (through communication with the Drive Train Control Module (DTCM)), and three active damping sensors.

There are two operating modes of the ADS, Auto and Sport (referred to as Firm). At each ignition key on cycle, the vehicle defaults to Auto mode. The DTCM communicates the request for the Firm mode to the ADCM when the terrain select switch is placed in either the Track, Sport or Snow positions. When the Firm mode is selected, the suspension has unique handling characteristics.

The Active Damping Control Module (ADCM) controls the suspension and ride for the SRT version of this vehicle by adjusting the rebound and jounce of the shock assemblies using the above information and predetermined matrix's for maximum vehicle control. The shock absorbers are unique to the Active Damping System (ADS). Each shock absorber has a valving unit that is external, but still part of the shock absorber. Inside each valving unit are two solenoids that control the damping valves to alter the ride of the vehicle. The shocks are replaced as an assembly, they cannot be disassembled for repair.

Additionally, there are three active damping sensors, two in the front of the vehicle and one in the rear. These sensors measure the plane of the vehicle.
 

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Discussion Starter · #5 ·
Here's a tidbit


Sport - When in 4WD High range the vehicle height adjusts to 15 mm (0.59 in.) below NRH. Electronic Stability Control (ESC) and traction control tuning thresholds are raised, and the Antilock Brake Control (ABS) allows less wheel slip, all to allow more driver control. Also the transmission shifting adjusts to a higher performance shifting. Not available in 4WD Low range.

Maybe after some Can Bus sniffing we can use the track mode of the 2012 to modify the TCM to get better shifts in the 2006-2010 models

(Pure speculation by me until we can test.)
 

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Discussion Starter · #6 ·
PCM reflashing

Interesting to note the new PCM's have their own "PIN"

PCM/ECM REPROGRAMMING - GAS


PCM/TCM FLASH REPROGRAMMING
This procedure is required when one or more of the following situations are true:

1. A Powertrain Control Module (PCM) has been replaced.
2. Diagnostic Trouble Code (DTC) P1602 - PCM Not Programmed is set.
3. An updated calibration or software release is available for either the PCM or TCM.

This procedure assumes that the wiTECH™ VCI Pod and StarMOBILE® devices are properly configured to the dealership network with either a wired or wireless connection. The wiTECH™ VCI Pod and StarMOBILE® must also be running the latest operating system and software release. For help on how to network the StarMOBILE®, reference the appropriate Quick Start Networking Guide available on ‘DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > Online Documentation’ or at www.dcctools.com, under the Download Center. For help on how to network the wiTECH™ VCI Pod, use the "Help" tab at the top of the wiTECH™ Diagnostic Application.



Table of contents
1. SECTION 1 – PCM/TCM FLASH PROCEDURE
2. REQUIRED TOOLS/EQUIPMENT:
3. TECH TIPS and INFORMATION:
4. PARTS REQUIRED


SECTION 1 – PCM/TCM FLASH PROCEDURE
If using the wiTECH™ Diagnostic Application, go to REPAIR PROCEDURE – Using wiTECH™ Diagnostic Application

If using the StarMOBILE® Desktop Client, go to REPAIR PROCEDURE – Using StarMOBILE® Desktop Client



REPAIR PROCEDURE – Using wiTECH™ Diagnostic Application
1. An overview of ECU flashing is available in the wiTECH™ Diagnostic Application. This overview may be found by first selecting the "Help" tab, then "Help Contents." This will open the wiTECH™ Help System. Selecting "Flashing an ECU" under the "Using the wiTECH™ Diagnostic Application" heading will display a step-by-step instructional guide to flashing an ECU. An instructional video can also be viewed by selecting "Flash ECU" under the "Videos" heading.
2. Continue to SECTION 2 – ADDITIONAL PCM/TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced.
3. Type the necessary information on the “Authorized Modification Label" (P/N 04275086AB) and attach near the VECI label (See SECTION 3 – AUTHORIZED MODIFICATION LABEL for details).


REPAIR PROCEDURE – Using StarMOBILE® Desktop Client


NOTE: If this flash process is interrupted or aborted, the flash should be restarted.
1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 – 13.5 volts.
2. Connect the StarMOBILE® to the vehicle data link connector located under the steering column and turn the ignition key to the “RUN” position.
3. Power on the StarMOBILE®. Launch the StarMOBILE® Desktop Client and connect to the appropriate StarMOBILE® device.
4. Retrieve the old ECU P/N. From the StarMOBILE® Home screen:a. Select “ECU View"
b. Select “PCM"
c. Select “More Options"
d. Select “ECU Flash"
e. Record the P/N at the top of the Flash PCM screen for later reference.

5. Program the ECU. From the StarMOBILE® Home screen:a. Select “ECU View"
b. Select “PCM"
c. Select “More Options"
d. Select “ECU Flash"
e. Select “Browse for New File" and follow the on screen instructions.
f. Highlight the appropriate calibration based on the P/N recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If the tool is not connected to the vehicle, flash files can be searched for by selecting the “Flash Download" button from the Home screen.
g. Select “Download to Scantool"
h. Once the download is complete, select “Close" and then “Back"
i. Highlight the listed calibration, select “Update Controller" and follow the on screen instructions.
j. When the PCM update is complete, select “OK"
k. Verify that the P/N at the top of the Flash PCM screen has updated to the new part number.


NOTE: If the flash process is interrupted or aborted, the flash should be restarted.
6. Continue to SECTION 2 – ADDITIONAL PCM/TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced.
7. Type the necessary information on the “Authorized Modification Label" (P/N 04275086AB) and attach near the VECI label (See SECTION 3 – AUTHORIZED MODIFICATION LABELfor details).


SECTION 2 – ADDITIONAL PCM/TCM REPLACEMENT PROCEDURES
To continue, first determine the type of PCM/TCM in the vehicle, read and write down the required steps, and then proceed to the STEP-BY-STEP INSTRUCTIONS for additional information on completing the procedures.

If an NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines:

1. PCM Replaced (if equipped with WCM)
2. Learn ETC (if equipped with ETC)
3. Check PCM VIN (if NOT equipped with WCM)
4. Check PCM Odometer
5. Quicklearn (if equipped with EATX)


If a GPEC PCM was replaced, perform the following additional steps and/or routines:

1. If the vehicle is equipped with a CVT, verify that the TCM has the latest software calibration available.
2. PCM Replaced (if equipped with WCM)
3. Learn ETC
4. Check PCM Odometer
5. Check PCM VIN (if NOT equipped with WCM)
6. TCM Quicklearn (if equipped with EATX)


If a CVT TCM was replaced, perform the following additional steps and/or routines:

1. Initialize CVT


If an EGS TCM was replaced, perform the following additional steps and/or routines:

1. Initialize EGS


STEP-BY-STEP INSTRUCTIONS
Check PCM Odometer

From the “Home" screen, select “ECU View".

Select “PCM"
Select “Misc. Functions"
Select “Check PCM Odometer" and follow the on screen instructions.
When complete, select “Finish".
Check PCM VIN

From the “Home" screen, select “ECU View"

Select “PCM"
Select “Misc. Functions"
Select “Check PCM VIN" and follow the on screen instructions.
When complete, select “Finish"
Initialize CVT

From the “Home" screen, select “ECU View"

Select “TCM"
Select “Misc. Functions"
Select “Initialize CVT" and follow the on screen instructions.
When complete, select “Finish"
Initialize EGS

From the “Home" screen, select “ECU View"

Select “TCM"
Select “Misc. Functions"
Select “Initialize EGS" and follow the on screen instructions.
When complete, select “Finish"
Learn ETC

From the “Home" screen, select “ECU View"

Select “PCM"
Select “Misc. Functions"
Select “Learn ETC" and follow the on screen instructions.
When complete, select “Finish"
PCM Replaced

The vehicle PIN (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways:

1. The original selling invoice
2. DealerCONNECT > Parts > Key Codes
3. Contacting the District Manager.

From the “Home" screen, select “ECU View"

Select “WCM"
Select “Misc. Functions"
Select “PCM Replaced" and follow the on screen instructions.
When complete, select “Finish"
Quicklearn

From the “Home" screen, select “ECU View"

Select “PCM"
Select “Misc. Functions"
Select “Quicklearn" and follow the on screen instructions.
When complete, select “Finish"
Update CVT TCM

From the “Home" screen:

Select “ECU View"
Select “TCM"
Select “More Options"
Select “ECU Flash"
Select “Browse for New File" and follow the on screen instructions.
Highlight the appropriate calibration.
Select “Download to Scantool"
Once the download is complete, select “Close" and then “Back"
Highlight the listed calibration, select “Update Controller" and follow the on screen instructions.
When the TCM update is complete, select “OK"
Verify that the part number at the top of the “Flash TCM" screen has updated to the latest level.


SECTION 3 – AUTHORIZED MODIFICATION LABEL


NOTE: The following step is required by law when reprogramming a PCM and/or TCM.

Type the necessary information on the “Authorized Modification Label" and attach near the VECI label.



1. Powertrain Control/Transmission Control Module Part Numbers (Insert P/Ns) Used
2. Change Authority: TSB XX--XX
3. Dealer Code: XXXXX
4. Date: XX-XX-XX




REQUIRED TOOLS/EQUIPMENT:

PART NUMBER StarMOBILE® PART NUMBER wiTECH™
NPN Battery Charger NPN Battery Charger
CH9801 StarMOBILE® Tool Kit NPN wiiTECH™ Tool Kit
CH9804 StarMOBILE® Vehicle Cable NPN TechCONNECT PC or equivalent
NPN TechCONNECT PC or equivalent


TECH TIPS and INFORMATION:
The wiTECH™ Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. Training aids, including videos, are included under the "Help" tab in the wiTECH™ Diagnostic Application.
To use the StarMOBILE® in Pass-Through Mode requires that the StarMOBILE® is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode, see the StarMOBILE® training tutorials available on ‘DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > Training Aids’ link or at www.dcctools.com, under the ‘Training Aids’ link.
If the flash process is interrupted or aborted, the flash should be restarted.
Due to the PCM/TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the “Home" screen select “System View". Then select “All DTCs". Press “Clear All Stored DTCs" if there are any DTCs shown on the list.
When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations.
Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process.
The StarMOBILE® diagnostic tools fully support Internet connectivity and must be configured for the dealership network. For help on setting up the StarMOBILE® for the dealership network, refer to the StarMOBILE® Quick Start Networking Guide available on ‘DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > Online Documentation’ or at www.dcctools.com, under the download center.
The operating software in the wiTECH™ VCI Pod, wiTECH™ Diagnostic Application, and StarMOBILE® must be programmed with the latest software release. The software level is visible in the blue header at the top of the wiTECH™ Diagnostic Application and StarMOBILE® Desktop Client screens. For instructions on how to update the StarMOBILE®, refer to the StarMOBILE® Update guide available on ‘DealerCONNECT > Service > StarSCAN® and StarMOBILE® Tools > Online Documentation’ or at www.dcctools.com, under the Download Center. For instructions on how to update the wiTECH™ VCI Pod or wiTECH™ Diagnostic Application, use the "Help" tab at the top of the wiTECH™ Diagnostic Application.


PARTS REQUIRED

Qty Part Number DESCRIPTION
1 04275086AB Label, Authorized Modification
 

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Discussion Starter · #7 ·
SRT8


FRONT - SRT8
FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER - LEFT -1.60° -2.10° to +1.10°
CAMBER - RIGHT -1.60° -2.10° to +1.10°
CROSS - CAMBER (Maximum Side-To-Side Difference) 0.00° 0.50° Max
CASTER -- LEFT/RIGHT 5.20° 4.60° to 5.80°
CROSS - CASTER (Maximum Side-To-Side Difference) 0.00° -1.00° to 1.00°
TOE - TOTAL* 0.20° 0.075° to 0.325°
Positive toe (+) is toe-in and negative toe (−) is Toe-out.
* TOTAL TOE is the sum of both the left and right wheel toe settings. TOTAL TOE should be equally split between each wheel on the same axle to ensure the steering wheel is centered after setting toe.


REAR - SRT8
REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER - LEFT/RIGHT -1.30° -1.75° to -0.85°
CROSS - CAMBER (Maximum Side-To-Side Difference) 0.00° -0.60° to 0.60°
CASTER N/A N/A
TOE - INDIVIDUAL 0.10° -0.05° to 0.25°
TOE - TOTAL* 0.20° -0.10° to 0.50°
THRUST ANGLE 0.00° -0.15° to 0.15°
Positive toe (+) is toe-in and negative toe (−) is Toe-out.
* TOTAL TOE is the sum of both the left and right wheel toe settings. TOTAL TOE should be equally split between each wheel on the same axle to ensure the steering wheel is centered after setting toe.
 

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Discussion Starter · #8 ·
Air Compressor

OPERATION
WARNING: All pressurized air suspension components contain high pressure air (up to 220 psig). Use extreme caution when inspecting for leaks. Wear safety goggles and adequate protective clothing when inspecting or servicing the air suspension system. A sudden release of air under this amount of pressure can cause possible serious or fatal injury.


WARNING: Support the vehicle by supplemental means before performing any work on the air suspension system to prevent the vehicle from changing height. Before any given component is to be serviced it must be deflated. Servicing the air suspension system without supplemental support, or with pressure in the specific component, can cause possible serious or fatal injury.


The air suspension compressor assembly is made up of two primary components, the compressor and the valve block. There is a single pressurized air line between the compressor and the valve block to maintain system pressure. Control of the air compressor and valve block is from the Air Suspension Control Module (ASCM). Diagnose the air suspension system using a scan tool.


Air Compressor
The compressor runs to maintain air pressure any time the vehicle height is being changed or in the event of a small reduction in over all system pressure. Integrated reversing valves in the air compressor allow pressurized air to be moved in two directions, making this a closed system. There is a desiccant located inside the compressor for moisture protection, and an air suspension hose assembly attached to the air compressor with a discharge hose and an intake hose (including a filter) which are not pressurized, and can be replaced as an assembly. If water is visible in the filter, the air suspension hose assembly and the valve block must be replaced. An air suspension temperature sensor is attached to the air compressor bracket to monitor ambient air temperature for protection of the compressor.

Positive voltage is from a 40-amp fuse located in the PDC, and a normally open compressor relay (ASCM controlled) located in engine compartment area, and ground for the relay and compressor are through a bolted on eyelet connection.


Valve Block
The valve block controls the flow of air in the system and to maintain the pressure in the in each air spring which allows the system to move each corner of the vehicle up or down as necessary. Valves and solenoids in the valve body increase or release pressure to air lines that connect to each pressurized component. The ASCM determines pressure from an internal pressure sensor in the valve body. The air lines connected to the valve block are labeled for individual replacement.
 

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Discussion Starter · #9 · (Edited)
Just another thing added that can break

6.4L


The Exhaust Differential Pressure Sensor (2) is remotely mounted on the transmission housing. One pressure tube (3) measures back-pressure created by the valves located at the cold end of the exhaust system. The sensor monitors the pressure in the exhaust system and determines if the valves are working properly for engine performance.




6.4L ACTIVE EXHAUST VALVE


The Active Exhaust Valves (AEV) are located at the cold end of the exhaust pipe before the muffler, after the catalytic converters. The pressure created by the engine allows the valve to over come the spring tension and open for optimal engine performance. When the valve is closed. The back pressure created in the exhaust system assist in engine performance by:

Increasing the fuel economy due to the increased use of MDS
Increased use of the MDS from the AEV improvement
No loss of vehicle performance
Emissions remain the same.
The AEV is welded into the cold end of the exhaust pipe. If replacement of the valve is required. The exhaust pipe must be replaced. The AEV is non repairable.
 

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Discussion Starter · #10 ·
Rear shock ........not only a shock but has electrical outputs

SRT8


The Active Damping System (ADS) rear shock (1) is similar to a conventional shock with the addition of a damping valve canister (3) mounted on the side of the body with a three wire harness/connector (2) attached to it.
 

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Discussion Starter · #11 · (Edited)
Electrical hydraulic pump for steering?

WITH EHPS
CAUTION: There is an Electro-Hydraulic Power Steering (EHPS) pump on some vehicles requiring a different fluid. Do not mix power steering fluid types. Damage may result to the power steering pump and system if any other fluid is used. The mechanical power steering pump systems on this vehicle require the use of Power Steering Fluid +4, which meets material specification MS-9602 or equivalent. The EHPS system uses fluid which meets material specification MS-11655 or equivalent. Do not overfill.




The EHPS system consists of:

Steering column and Intermediate Shaft
Rack and pinion steering gear
EHPS pump (3.6L) (3)
Pump pressure (5) and supply/return line assembly (1, 2)
Remote power steering reservoir (The EHPS reservoir has only one hose connection)
Some early built vehicles with EHPS do not have a power steering system cooler effecting the power steering line/hose configuration.
Power assist is provided by the EHPS pump (3) mounted to the cradle in front of the engine. The EHPS pump is an electrically operated hydraulic pump which supplies variable hydraulic fluid flow and pressure to the steering gear. The EHPS pump replaces the conventional belted power steering pump. The EHPS pump has an EHPS module attached (not replaceable separately). There are two electrical connectors (6) on the EHPS pump assembly (3). One connector is a 12 volt low amperage module connector, and the other is a 12V higher amperage pump connector containing a larger gauge wire for motor operation. The power steering hoses and steering gear are substantially unchanged in function from a conventional system. However, there are unique components for this system, such as hoses for routing and the gear for valve tuning.



WITH EHPS
CAUTION: There is an Electro-Hydraulic Power Steering (EHPS) pump on some vehicles requiring a different fluid. Do not mix power steering fluid types. Damage may result to the power steering pump and system if any other fluid is used. The mechanical power steering pump systems on this vehicle require the use of Power Steering Fluid +4, which meets material specification MS-9602 or equivalent. The EHPS system uses fluid which meets material specification MS-11655 or equivalent. Do not overfill.


Multiple modules work together to improve vehicle steering assist at different rates at different speeds. At slow speeds (parking maneuvers) more assist is available and at high speeds less assist is available. The EHPS module uses the CAN - C data bus for inputs and outputs of the information necessary for operation. The use of a scan tool is necessary for diagnostics. EHPS module faults are stored in a diagnostic program memory and are accessible with the scan tool. Faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. For descriptions and procedures related to DTCs (Refer to 28 - DTC-Based Diagnostics/MODULE, Electro-Hydraulic Power Steering (EHPS) - Diagnosis and Testing).The Electro-Hydraulic Power Steering (EHPS) Pump assembly contains a control module, brushless electric motor, and hydraulic pump integrated into a single unit. The EHPS Pump draws power from the 12 volt electrical system and provides the necessary flow and pressure to the steering gear to provide normal power steering. The output flow of the EHPS Pump is varied as a function of Steering Wheel Rate (received from SAS) and Vehicle Speed (received from ABS Module) in order to provide the optimum flow of power steering fluid to the steering gear under all operating conditions. The EHPS Pump will start to provide steering assist when the Vehicle speed message greater than 5 km/h (3 mph) is received on CAN C. If the Vehicle Speed message is missing at vehicle startup, the EHPS Pump will not operate. If the Vehicle Speed message is lost during operation the EHPS pump will use a default vehicle speed of 85 km/h (59 mph) to calculate desired flow and as a result, steering effort will no longer be speed sensitive. If the Steering Wheel Position message is lost the EHPS Pump will use a default steering wheel rate of 230°/sec to calculate desired flow and as a result, steering effort may be higher on evasive steering maneuvers. The EHPS pump will resume normal operation automatically once any missing message or out of range condition noted above is restored to normal.




.
 

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Discussion Starter · #12 ·
This bottle is ahead of the spare tire.....



The air suspension reservoir (4) is located behind rear passenger seat under a folding panel and is nearly the full width of the inside of the vehicle. There is an air valve connection for initial filling or complete system filling, and an air line (1) connected to it which is part of the rear air line assembly. The reservoir is secured to the floor with two brackets (2). The brackets are hinged so that when the screw attaching the two halves together is disconnected, the top half of the bracket will flip back (open) for repositioning or removal of the air suspension reservoir.



NOTE: LHD vehicles will have the air line/fitting on the RH side of the vehicle. RHD vehicles will have the air line/fitting on the LH side of the vehicle.
 

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Discussion Starter · #13 ·
Bottom line for me is.....

Lots more stuff to go real wrong or hard to troubleshoot with the 2012 Jeep.
 

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Straight Up Beast SON!!!
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17,141 Posts
Bottom line for me is.....

Lots more stuff to go real wrong or hard to troubleshoot with the 2012 Jeep.
Thanks Jeff and would have to agree with you man!
 

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8,340 Posts
Wow! SO much info! Thanks for sharing! And i'd have to agree with you.
 

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I thought the SRT didn't have the air suspension?
 

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PWR - Boosted & Stroked
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Damn thats some info, Thanks Jeff.

So would that PIN for the PCM seem to imply that each vechile is encrypted seperately, all encryption codes are stored are stored in the dealers system & the PIN is not even given to the buyer. The only way for them to flash the car is have it hooked up reading the VIN & then enter the PIN. Is that what I'm reading?

Jim
 

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The ModMan
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Wow, awesome info. Thanks for sharing this.

Did I read correctly that the vehicle can be lowered by 40mm (when parked)? Should be nice.
 
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