Jeep Wrangler TJ. Manual — part 419
POWER DISTRIBUTION
CENTER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-
ment Power Distribution Center (PDC) (Fig. 7). The
molded plastic PDC housing is located on the right
side of the engine compartment, forward of the bat-
tery on the top of the right front inner fender shield.
The PDC houses up to fifteen maxi-type cartridge
fuses, which replace all in-line fusible links. The PDC
also houses up to thirteen blade-type mini fuses, and
up to twelve International Standards Organization
(ISO) relays (four standard-type and eight micro-
type).
The PDC housing is secured in the engine compart-
ment at four points. Integral mounts on both sides of
the PDC housing engage and latch to stanchions that
are integral to the stamped steel PDC bracket. The
PDC bracket is secured to the top of the right front
inner fender shield with three screws, two at the
front of the bracket and one at the rear. The PDC is
integral to the dash wire harness, which exits from
the bottom of the PDC housing. The PDC housing
has a molded plastic cover that includes two integral
latches at the rear and pivot hooks at the front that
snap over a hinge pin on the front of the PDC hous-
ing. The PDC cover is easily opened or removed for
service access and has a convenient fuse and relay
layout map integral to the inside surface of the cover
to ensure proper component identification.
The PDC cover, the PDC housing lower cover, the
PDC relay wedges, the PDC relay cassettes and the
PDC B(+) terminal stud module are available for ser-
vice replacement. The PDC main housing unit, the
fuse wedges and the bus bars cannot be repaired and
are only serviced as a unit with the dash wire har-
ness. If the PDC main housing unit, fuse wedges or
the bus bars are faulty or damaged, the dash wire
harness unit must be replaced.
OPERATION
All of the current from the battery and the gener-
ator output enters the PDC through two cables and a
single two-holed eyelet that is secured with nuts to
the two PDC B(+) terminal studs near the back of
the PDC housing. The molded plastic PDC cover is
unlatched and opened to access the battery and gen-
erator output connection B(+) terminal studs. Inter-
nal
connection
of
all
of
the
PDC
circuits
is
accomplished by an intricate combination of hard
wiring and bus bars. Refer to theWiring section of
this service manual for wiring diagrams.
REMOVAL
The Power Distribution Center (PDC) main hous-
ing unit, the PDC fuse wedges and the PDC bus bars
cannot be repaired and are only serviced as a unit
with the dash wire harness. If the PDC main housing
unit, the fuse wedges or the bus bars are faulty or
damaged, the entire PDC and dash wire harness unit
must be replaced.
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect each of the dash wire harness con-
nectors. Refer to Connector Locations in the Wir-
ing section of this service manual for the location of
the dash wire harness connector locations.
(3) Remove all of the fasteners that secure each of
the dash wire harness ground eyelets to the vehicle
body and chassis components. Refer to Connector
Locations in the Wiring section of this service man-
ual for the location of the ground eyelet locations.
(4) Disengage each of the retainers that secure the
dash wire harness to the vehicle body and chassis
components. Refer to Connector Locations in the
Wiring section of this service manual for the location
of the dash wire harness retainer locations.
Fig. 7 Power Distribution Center Location
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
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8W-97 POWER DISTRIBUTION
8W - 97 - 7
(5) Unlatch and open the PDC cover (Fig. 8).
(6) Remove the two nuts that secure the eyelet ter-
minal of the battery positive cable take out and the
engine wire harness generator output take out to the
PDC B(+) terminal studs.
(7) Remove the battery positive cable take out and
the engine wire harness generator output take out
eyelet terminal from the B(+) terminal studs.
(8) Disengage the latches on the PDC housing
mounts from the tabs on the PDC bracket stan-
chions, and pull the PDC housing upward to disen-
gage the mounts from the stanchions of the bracket.
(9) Remove the PDC and the dash wire harness
from the engine compartment as a unit.
DISASSEMBLY
POWER DISTRIBUTION CENTER DISASSEMBLY
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
module are available for service replacement. The
PDC 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 proper wiring repair procedures.
PDC HOUSING LOWER COVER REMOVAL
(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 two nuts that secure the eyelet ter-
minal to the two B(+) terminal studs of the PDC.
(5) Remove the eyelet terminal from the PDC B(+)
terminal studs.
(6) Disengage the latches on the PDC mounts from
the tabs on the PDC bracket stanchions, and pull the
PDC housing upward to disengage the mounts from
the stanchions of the 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. 9).
Fig. 8 Power Distribution Center
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
Fig. 9 PDC Housing Lower Cover Remove/Install -
Typical
1 - THROUGH FORMATION
2 - LATCHES (5)
3 - PDC HOUSING LOWER COVER
4 - WIRE HARNESS
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8W-97 POWER DISTRIBUTION
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POWER DISTRIBUTION CENTER (Continued)
PDC B(+) TERMINAL MODULE REMOVAL
(1) Remove the PDC housing lower cover.
(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 B(+)
terminal module in the PDC (Fig. 10).
(3) Gently and evenly press the two B(+) terminal
studs down through the bus bar in the PDC.
(4) From the bottom of the PDC housing, remove
the B(+) terminal module from the PDC (Fig. 11).
PDC RELAY WEDGE REMOVAL
(1) Remove the PDC housing lower cover.
(2) Remove each of the relays from the PDC relay
wedge to be removed.
(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 REMOVAL
(1) Remove the relay wedge from the PDC relay
cassette to be removed.
Fig. 10 PDC B(+) Terminal Module Latches
1 - FROM SPECIAL TOOL KIT 6680
2 - PDC HOUSING
3 - LATCHES
4 - BUS BAR
5 - B+ TERMINAL STUDS
Fig. 11 PDC B(+) Terminal Module Remove/Install
1 - PDC HOUSING
2 - LATCHES
3 - B+ TERMINAL MODULE
4 - BUS BAR
Fig. 12 PDC Relay Wedge Remove/Install - Typical
1 - RELAY WEDGE
2 - PDC HOUSING
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8W-97 POWER DISTRIBUTION
8W - 97 - 9
POWER DISTRIBUTION CENTER (Continued)
NOTE: It may be necessary to remove relay cas-
settes 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).
(3) Gently and evenly press the relay cassette
down through the PDC housing.
(4) From the bottom of the PDC housing, remove
the relay cassette from the PDC (Fig. 14).
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 proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
ASSEMBLY
POWER DISTRIBUTION CENTER ASSEMBLY
PDC HOUSING LOWER COVER INSTALLATION
(1) Align the PDC housing lower cover to the bot-
tom 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 mounts on the PDC housing with
the stanchions of the PDC bracket and push the unit
downward until the mount latches fully engage the
mounting tabs on the PDC bracket.
(4) Install the eyelet terminal over the two PDC
B(+) terminal studs.
(5) Install and tighten the two nuts that secure
the eyelet terminal to the B(+) terminal studs.
Tighten the nuts to 11.3 N·m (100 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.
PDC B+ TERMINAL MODULE INSTALLATION
(1) From the bottom of the PDC housing, align and
insert the B(+) terminal module into the PDC.
(2) From the bottom of the PDC housing, align and
insert the two studs of the PDC B(+) terminal mod-
ule through the bus bar in the PDC.
(3) From the bottom of the PDC housing, press the
B(+) terminal module gently and evenly into the PDC
until both of the latches are fully engaged.
(4) Install the PDC housing lower cover.
PDC RELAY WEDGE INSTALLATION
(1) From the top of the PDC housing, align and
insert the PDC relay wedge latch arms into the cor-
rect cavities in the relay cassette.
Fig. 13 PDC Relay Cassette Latches - Typical
1 - LATCHES
2 - FROM SPECIAL TOOL KIT 6680
3 - PDC RELAY CASSETTES
Fig. 14 PDC Relay Cassette Remove/Install - Typical
1 - PDC HOUSING
2 - PDC RELAY CASSETTE
3 - LATCHES
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8W-97 POWER DISTRIBUTION
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POWER DISTRIBUTION CENTER (Continued)
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