Recall Abs Modulator Plate Reinforcement (RB148)

Publication date: 2005-04-25
Reference number: RB148

RECALL ABS MODULATOR PLATE REINFORCEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): RB148, Date of Issue: April 25, 2005

LAND ROVER:	Discovery Series II (LT)
ISSUE:	2
SECTION:	Recall Bulletins
AFFECTED VEHICLES:	Discovery Series II (LT) XA200253 to 4A846247, XA900000 to XA907213, Build Date 01 May 1998 to 10 December 2003

SITUATION:

INCREASED STOPPING DISTANCE

ABS Modulator valve cover retaining bolts can crack due to stresses transmitted by the flexing valve covers. This is a result of significant operation of traction or hill descent control, primarily associated with extensive off-road use. This failure can produce an unexpected increase in stopping distance, with the potential for total loss of service braking function.

RESOLUTION:

NOTE: It is important that the DDW "Vehicle Inquiry" screen be consulted prior to any vehicle inspection or repair.

INSTALL REINFORCING MODULATOR PLATES AND NEW SCREWS

Discovery vehicles in the affected VIN range are to have the existing ABS Modulator screws replaced and the covers reinforced with components of an improved design.

PARTS INFORMATION:

NOTE: It is anticipated that less than 0.1% of vehicles will require a replacement Modulator Valve Assembly (SRB101203). Do not order a modulator until you have determined that one is genuinely required.

CAUTION: Early stock of recall repair kit SWO500010K can contain an incorrectly machined modulator cover plate. The incorrect plate is drilled through at the center. The through-drilled hole is NOT the correct configuration for the repair application and must not be used for the Recall repair. Refer to Parts Alert PA04GI-07 and follow standard PAF practice.

SWO500010K Modulator Top Plate Kit 1

Part of kit Modulator cover 2
Part of kit Cover retaining screws 4

SRB101203 Valve Assembly - Modulator 1 If required because of frozen screws

NOTE: Campaign labels are no longer required for Safety Recall Action activities. Retailers should maintain a modest supply of labels for future use with Emissions Recall activities.

DDW WARRANTY CLAIMS:

Warranty claims should be submitted quoting the program code and option from the table in place of the normal warranty complaint code. This will result in payment of the stated time including Drive-in and Drive-out time and, where applicable parts/miscellaneous expense. The SRO is provided for information and should not be used as part of the claim process.

DDW WARRANTY CLAIM SHEET

Program Code	Option	Job Description	SRO	Time (Hours)	Part Number	Part Description Description	QTY
B148	A	Inspect ABS Modulator Number	70.65.89/39	0.1
B148	K	Inspect ABS Modulator Number with DI/DO included	70.65.89/39 02.02.02	0.1 0.2
B148	B	Install New ABS Modulator Valve Covers	70.65.89/38	0.3	SWO500010K	Modulator Top Plate Kit	1
B148	C	Install New ABS Modulator Valve	70.65.49	1.4	SRB101203	ABS Modulator Valve	1

Normal warranty policy and procedures apply.

Material allowance is included in labor operation.

REPAIR PROCEDURE

INSPECT ABS MODULATOR

Turn off ignition, open the hood and install fender protection covers.
Thoroughly clean the area around the ABS modulator pressure reduction valve reaction plates.
NOTE: The Recall Action is not required if a new specification modulator has been previously installed.
Note and record the service part number on top of the modulator. (Fig 1 )

Fig 1: Identifying Service Part Number On Top Of Modulator

If the component part number observed on the tag is SRB101203 or SRB500051 , claim Option A. No further action is required.
If the component part number observed is different from SRB101203 or SRB500051 go to the following section "INSTALLATION OF MODULATOR PLATES AND SCREWS ."

INSTALLATION OF MODULATOR PLATES AND SCREWS

NOTE: Use of an Allen "socket" wrench can facilitate screw removal. If the Allen screw is difficult to remove, a tap on the socket may "unlock" corrosion bonds and permit easy removal of the screw.

Remove and discard the four Allen screws securing the two pressure reduction valve reaction plates. (Fig 2 )
CAUTION: The plates provided in Recall parts kit SWO500010K are intended to be installed over the top of the original plates using the new longer screws to secure both plates in position.

Fig 2: Removing Pressure Reduction Valve Reaction Plate Screws

If the Allen screws were removed successfully, install the Recall kit components as follows:
- Position the new reinforcing caps with the recess facing downwards over the top of the existing plates.
- Verify that the recess in the cap clears the plastic clip. (Fig 3 )
- Install the new Allen screws (Fig 4 ) and tighten to 6 Nm (4 lb.ft).
- Claim Option B.
If any Allen screw cannot be removed, perform the following:
- Refer RAVE or GTR section 70.65.49 and replace the ABS modulator (SRB101203) following WSM procedures.
- Claim Option C.
NOTE: Campaign labels are no longer required for Safety Recall Action activities. Retailers should maintain a modest supply of labels for future use with Emissions Recall activities.