6MT, 2nd failed clutch interlock switch, code P083F

[Philosopheriam]

Folks,

ASE certified mechanic here. To make a long story very short:

Not long after my Jeep rolled off the lot (under 150mi on the odometer), I received the disabled/service ESS and adaptive cruise control warnings on my dash display. Using Jscan, I pulled active code P083F for "clutch switch a/b correlation". I found the live data for the clutch interlock switch and clutch position sensor and found that the interlock switch was stuck, as if the clutch pedal was always depressed. After not listening to me and erroneously replacing a battery sensor, the dealer finally replaced the clutch interlock switch and the problem was resolved.

For reference, JL models with a 6MT have a clutch position sensor at the top of the clutch pedal, which provides a variable feedback voltage based on the position of the pedal. These is also an on/off interlock switch on the side of the clutch master cylinder. This switch cycles from false to true when the clutch pedal is depressed. The PCM monitors the state of the position sensor and the interlock switch and compares the two to determine if the switches are operating correctly.

Attached are pictures of the interlock switch - it snaps in place on the side of the clutch master cylinder.

Today, with around 1600mi on the odometer, my Jeep did the same thing as before, same code, etc. The interlock switch was once again stuck on or TRUE.

So, because my time is valuable and I have no desire for another cluster F experience at the dealer, I sourced a new switch from O'Reilly's for $46 and installed it. Problem solved. Data values for the interlock switch cycle correctly as the pedal is depressed and released. A pic of the aftermarket part is attached, Standard Motor Products NS693.

I'm not sure what is the problem with these switches, however, when the next one fails, I'll just grab a replacement under O'Reilly's lifetime warranty.

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[Philosopheriam]

Folks,

I discovered the problem, now I need to determine the root cause.

Problem: interlock switch is being damaged from water intrusion (see attached photos). Evidence of corrosion (green residue) is apparent.

What I *do not* know is if the water is penetrating through the weather seal of the middle pin OR if the case halves of the switch aren't sealed properly allowing water to seep in (see photo with screwdriver pointing to switch with case halves partially separated)

For now, I added some dielectric grease to the inside of the connector. I will see what happens.

 

[bd100]

I may add dielectric grease to ours, just to be sure.

 

[gpassida]

@Philosopheriam

Thanks for figuring that out and posting the root cause with clear pics.

Did anything specific happen to cause water to get to that connector? Or just atmospheric moisture?

 

[Maverick909]

Great find. Please keep us updated if the dielectric grease works do you!

 

[Philosopheriam]

@Philosopheriam

Thanks for figuring that out and posting the root cause with clear pics.

Did anything specific happen to cause water to get to that connector? Or just atmospheric moisture?

My Jeep is a pavement princess and I have a monthly car wash subscription which allows me to get my vehicle washed up to once per day - I usually get it washed twice a week. My assumption is that the water from the car wash is going through the gaps between the hood and the body.

Like I mentioned earlier, a defective weather seal in a connector can cause this, however, of the two halves of the switch itself are not sealed properly, water will migrate through there, as well.

Only time will tell - if the dielectric grease solves this problem, it's a connector issue. If not, it's the switch itself.

 

[gpassida]

Thanks. I will look for that at seal it up on ours. You said this is located near the clutch master cylinder. Looks like that is shared with the brake fluid as well.

 

[_olllllllo_]

I wonder if this component is the same from 2018 on or if it has been revised over time. I have a 2019 JLUR that I have driven through plenty of streams and it gets the occasional hand wash (soft tops and automatic car wash air blowers do not mix). I live in Southern Arizona so I have very low humidity and that may help.

So I just researched the component and part number 68029261AA is used on Wranglers from 2007-2026. I wonder if the seal on the male side of the harness is bad.

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