2023-2025 FCA Models: Reverse Polarity, Transmission, Oil Cooler Issues

This newsletter, identified as FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER VOLUME 10, ISSUE 8, provides important service information for various FCA models, addressing several distinct issues from transmission repairs to electrical system warnings. Owners concerned about the 2024 Alfa Romeo Tonale reverse polarity issue or other service advisories should review this information carefully.

Reverse Polarity Issue in IDCM

Owners of 2023-2024 Alfa Romeo Tonale (GC), Dodge Hornet (GG), Jeep Wrangler (JL), Jeep Grand Cherokee (WL), Jeep Renegade (BV), and Jeep Compass (MV) models should be aware of a "Reverse Polarity Issue in IDCM" that can arise, particularly during jump-starting. This condition is often triggered by an incorrect connection during a 12V battery jump-start, leading to a reverse polarity situation.

If the jump-starting procedure is not followed correctly, it can result in an "IDCM failure" and necessitate an IDCM replacement. It is crucial to connect the positive (B+) terminal of the battery to the positive clamp and the ground (GND) to the negative clamp. The newsletter explicitly states: "Not following the updated service procedure will result in an IDCM failure, which will induce and IDCM replacement." While this issue can lead to significant problems, no DTCs are triggered directly by the reverse polarity protection in this IDCM. However, a drained main battery due to other issues could potentially lead to a "P2AF5" DTC, indicating a low main battery and possibly an open 150A fuse. For owners experiencing the 2024 Alfa Romeo Tonale reverse polarity issue, or similar problems in other affected models like the Dodge Hornet or various Jeeps, it's crucial to understand the cause and prevention.

Dual Battery System 150A Fuse Issue

For owners of the 2025 RAM 1500 (DT) equipped with a dual battery system, there has been a notable number of "Open 150A Underhood PDC Fuse Array" warranty claims. This issue stems from a lack of understanding regarding the interconnection of the dual batteries during service. The vehicle's dual battery system has two grounds, one from each battery.

A critical warning for technicians and owners performing any electrical repairs is: "very important to properly disconnect the battery grounds PRIOR to performing any Electrical repairs because any contact of the battery feed to ground in the vehicle will most likely blow the 150A fuse in the underhood PDC." If only one battery's ground is removed, the other battery can still supply power, creating a risk of shorting and blowing the 150A fuse. An open 150A fuse can lead to the main battery draining, the vehicle not starting, and potentially setting a "P2AF5" DTC. The 150A fuse is designed to blow at 300 amps or more to protect the wiring.

Pacifica Hybrid SI-EVT Transmission Repair

For PACIFICA HYBRID (RU-PHEV) models requiring SI-EVT transmission repair, specific one-time use fasteners must be replaced. These components include flywheel bolts, steering gear pinch bolt, shear bracket bolts, crossmember front and mid bolts, ball joint stud pinch bolt and nuts, and the drive hub to halfshaft nut. The newsletter emphasizes that these are "one-time use fasteners" and their replacement is essential to maintain full functionality and prevent future part failures.

A key instruction is: "Do not reuse fastener. If removed, a NEW fastener must be installed and tightened to specifications." Specifically, for the drive hub to halfshaft nut, "Always install a NEW drive hub to halfshaft nut. The original hub nut is one time use only and must be discarded when removed." Technicians must refer to the "Torque Specifications" for proper tightening. If the transmission or Power Inverter Module (PIM) was replaced, the transmission to PIM gasket is also a one-time use item and must be replaced with a NEW gasket.

Required Parts for Transmission Repair

The following part numbers are listed for needed components:

• 06503210 (Steering Gear Pinch Bolt)
• 06104414AA (Sheer Bracket Bolt)
• 68470042AA (Lower Ball Joint Bolt Kit)
• 06509298AA (Hub Lock Nut)
• 68382486AA (Flexplate Bolts)
• 06511823AA (Cross member front Bolt)
• 06511822AA (Cross member mid Bolt)
• 06510676AA (Control Arm Nut)

Oil Cooler Adapter Housing Repair

For vehicles equipped with 3.2L (EHK) and 3.6L (ERC) engines experiencing oil cooler leaks, a specific diagnostic step is mandatory. Before replacing the Oil Filter Adapter (OFA) or cooler, technicians "MUST be used first to determine the location of the oil leak" using oil Dye P/N CH5010042AC.

A critical warning is issued: "If oil dye has not been used, the repair will not be validated." This means that without properly identifying the leak source using the specified dye, the repair may not be covered under warranty. This procedure ensures that the correct repair is performed to resolve the oil leak.

Technician Training Updates

The newsletter also includes information regarding updates to the Learning Management System (LMS) for technician training. Various technician training message codes (MT5, MT6, NT5, NT6, TT3, TT4, TT5, TT6, TT7) are being discontinued, and new codes (MT8, TT8, TT9) will be introduced for warranty claims. While this primarily affects internal warranty processing and technician certification, it signifies ongoing efforts to ensure technicians are properly qualified for repairs.

Source: NHTSA ID: 11007087