2017 - 2020 HX Technician Manual (Service and Diagnostic)

North America
2017–2020 HXTM Technician Manual (Service and Diagnostic) - HX515 6x4, HX520 6x4 , HX615 6x4 , HX620 6x4
SERVICE MANUAL
SERVICE MANUAL
2017–2020 HXTM Technician Manual (Service and Diagnostic)
HX515 6x4
HX520 6x4
HX615 6x4
HX620 6x4
0000862512
Navistar, Inc.
Revision 11
July 2018
2701 Navistar Drive, Lisle, IL 60532 USA
© 2018 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
TABLE OF CONTENTS
TABLE OF CONTENTS
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
01 Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
02 Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
03 Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
04 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
05 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
06 Drivelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
07 Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
08 Electrical / Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
09 Front End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
10 Fifth Wheel and Misc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797
11 Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
12 Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819
13 Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1053
14 Rear Axle and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083
15 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1123
16 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1195
27 Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1459
28 Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1463
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TABLE OF CONTENTS
ii
Foreword
Navistar®, Inc. is committed to continuous research and development to improve products and introduce
technological advances. Procedures, specifications, and parts defined in published technical service literature
may be altered.
NOTE – Photo illustrations identify specific parts or assemblies that support text and procedures; other
areas in a photo illustration may not be exact.
This manual includes necessary information and specifications for technicians to maintain Navistar® products.
See vehicle manuals for additional information.
Technical Service Literature is revised periodically. If a technical publication is ordered, the latest revision
will be supplied.
NOTE – To order technical service literature, contact your International dealer.
1
SAFETY INFORMATION
Safety Information
This manual provides general and specific maintenance procedures essential for reliable engine operation
and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all
possible safety conditions and hazards cannot be stated.
Read safety instructions before doing any service and test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note
Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to
the engine or vehicle.
Note: A note describes actions necessary for correct, efficient engine operation.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing
engine.
2
SAFETY INFORMATION
• Clear the area before starting the engine.
Engine
• The engine should be operated or serviced only by qualified individuals.
• Provide necessary ventilation when operating engine in a closed area.
• Keep combustible material away from engine exhaust system and exhaust manifolds.
• Install all shields, guards, and access covers before operating engine.
• Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put
protective screens over all openings before servicing engine.
• Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps.
• If an engine is not safe to operate, tag the engine and ignition key.
Fire Prevention
• Make sure charged fire extinguishers are in the work area.
NOTE – Check the classification of each fire extinguisher to ensure that the following fire types can be
extinguished.
1. Type A — Wood, paper, textiles, and rubbish

2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
• Always disconnect the main negative battery cable first.
• Always connect the main negative battery cable last.
• Avoid leaning over batteries.
• Protect your eyes.
• Do not expose batteries to open flames or sparks.
• Do not smoke in workplace.
Compressed Air
• Use an OSHA approved blow gun rated at 30 psi.(207 kPa)
• Limit shop air pressure to 30 psi (207 kPa).
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
• Do not direct compressed air at body or clothing.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are grounded.
3
SAFETY INFORMATION
• Check for frayed power cords before using power tools.
Fluids Under Pressure

• Use extreme caution when working on systems under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment

• Reinstall all safety guards, shields, and covers after servicing the engine.
• Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all
work is done.
4
TABLE OF CONTENTS
Frame
Table of Contents
1. Front Bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5
TABLE OF CONTENTS
6
FRONT BUMPER
1. Front Bumper
Overview
Feature Codes Description
0001LMU HX515 - Bumper, front flat face, gull wing, steel, 15.5 in. high x 94 in.
long
0001LRB HX615 and HX620 - Bumper, front full width, aerodynamic, painted steel
0001LLW HX515 - Bumper, front heavy duty, painted steel; swept back 40 deg.
0001LMJ Bumper, front full width, heavy duty, aluminum; swept back 40 deg.
0001LMT Bumper, front flat face, gull wing, aluminum, 15.5 in. high x 94 in. long
0001LTE HX615 and HX620 - Bumper, front full width, formed stainless clad
aluminum, bright finish
The front bumper is located on the front of the vehicle. It can be steel or heavy duty aluminum, and it can be
painted or unpainted, see feature code list.
7
FRONT BUMPER
8
TABLE OF CONTENTS
Front Axle
Table of Contents
1. Front Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9
TABLE OF CONTENTS
10
FRONT AXLES
1. Front Axles
Overview
02ARW HX515 - Axle, Front Non-driving {Meritor MFS-12-143A} wide track,
I-beam type, 12,000 pound capacity
02ASG HX615 and HX620 6x4 - Axle, Front Non-driving {Meritor MFS-13-143A}
wide track, I-beam type, 13,200 pound capacity
02ARU 8x6 Tridem - Axle, Front Non-driving {Meritor MFS-16-143A} wide track,
I-beam type, 16,000 pound capacity
02ARW Axle, Front Non-driving {Meritor MFS-12-143A} wide track, I-beam type,
12000 pound capacity
02ASM Axle, Front Non-driving {Meritor MFS-14-143A} wide track, I-beam type,
14,600 pound capacity
02AEU Axle, Front Non-driving {Dana Spicer I-160W} wide track, I-beam type,
02AUR Axle, Front Non-driving {Meritor MFS-16-133A} wide track, I-beam type,
02AYL Axle, Front Non-driving {Dana Spicer D-2000W} wide track, I-beam
type, 16,000 pound capacity
02ARU Axle, Front Non-driving {Meritor MFS-16-143A} wide track, I-beam type,
02AEV Axle, Front Non-driving {Dana Spicer I-180W} wide track, I-beam type,
02ARZ Axle, Front Non-driving {Meritor MFS-18-133A} wide track, I-beam type,
02AYK Axle, Front Non-driving {Dana Spicer D-2000W} wide track, I-beam
02AEW Axle, Front Non-driving {Dana Spicer I-200W} wide track, I-beam type,
02ARY Axle, Front Non-driving {Meritor MFS-20-133A} wide track, I-beam type,
02AYJ Axle, Front Non-driving {Dana Spicer D-2000W} wide track, I-beam
02AGT HX SBA Models - Axle, Front Non-driving {Dana Spicer I-220W} wide
track, I-beam type, 22,000 pound capacity
02ATB HX SBA Models - Axle, Front Non-driving {Meritor MFS-22-133A} wide
track, I-beam type, 22,000 pound capacity
All front axles are wide track to provide better wheel cut and turning diameter.
11
FRONT AXLES
12
TABLE OF CONTENTS
Front Suspension
Table of Contents
1. Set Back Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Multi-leaf Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parabolic Taper Leaf. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Multi-leaf Slipper Type with Torque Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Set Forward Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Multi-leaf Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parabolic Taper Leaf. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13
TABLE OF CONTENTS
14
SET BACK AXLE
1. Set Back Axle

Multi-leaf Springs
Overview
Feature Codes Descriptions
03ACS Suspension, Front, Spring, multi-leaf, shackle type, single stage spring;
20,000 pound capacity; less shock absorbers
03AGR Suspension, Front, Spring, multi-leaf, shackle type, two stage spring;
20,000 pound capacity; less shock absorbers
03ACH HX615, HX620 6X4 - Suspension, Front, Spring, multi-leaf, shackle
type; 14,000 pound capacity; with shock absorbers
03ACP HX615, HX620 8X6 - Suspension, Front, Spring, multi-leaf, shackle
type; 16,000 pound capacity; less shock absorbers
03ACR Suspension, Front, Spring, multi-leaf, shackle type; 18,000 pound
capacity; less shock absorbers
03ACT Suspension, Front, Spring, multi-leaf, shackle type; 23,000 pound
capacity; less shock absorbers
03AEP Suspension, Front, Spring, multi-leaf, shackle type; 23,000 pound
capacity; less shock absorbers and with special spacer blocks for mixer
application
03ADS Suspension, Front, Spring, multi-leaf; 20,000 pound capacity; with
torque rods and less shock absorbers, includes one (1) extra leaf on
left, use with left wing snow plow
Figure 1 Multi-leaf Front Suspension
Flat leaf springs use leaves having a constant thickness along entire length of leaf.
15
SET BACK AXLE
Multi-leaf suspensions are designed for use with front axles having capacities ranging from 14,000 to 20,000
pounds. These springs include:
• Nodular iron brackets which add strength

• Grooved spring pins which provide 'lubrication reservoirs' or threaded spring pins
• Steel shackles
• Shot-peened springs for added spring strength
• Shock absorbers to improve ride quality
• Four (4) in. wide spring on all other models
16
SET BACK AXLE
Parabolic Taper Leaf

Overview
03AGD Suspension, Front, Spring, parabolic, taper leaf; 13,200 pound capacity;
with shock absorbers
03ADD Suspension, Front, Spring, parabolic, taper leaf; 14,000 pound capacity;
03ADE Suspension, Front, Spring, parabolic, taper leaf; 16,000 pound capacity;
03ADG Suspension, Front, Spring, parabolic, taper leaf; 18,000 pound capacity;
03ADJ HX515 - Suspension, Front, Spring, parabolic, taper leaf; 20,000 pound
capacity; with 18,000 pound capacity steel springs and two (2) rubber
auxiliary springs (2000 pound capacity)
03AGA Suspension, Front, Spring, parabolic, taper leaf; 20,000 pound capacity;
Figure 2 Parabolic Taper Leaf Front Suspension
Parabolic Taper Leaf Springs

Tapered leaf springs are thicker in middle than at ends. Because of this design, these suspensions are able
to use fewer spring leaves which helps to reduce leaf-to-leaf friction. Produces a smoother ride than flat
multi-leaf springs.
Parabolic type tapered spring leaf is curved in shape of a parabola. Curvature is very slight, occurring
on bottom surface of each spring leaf.
Provides even stress distribution along entire length of leaf. Springs are also light weight, which helps reduce
overall vehicle weight.
17
SET BACK AXLE
Light-duty parabolic tapered leaf springs, are included on axles with ratings of 6,000, 7,000, and 8,000 pounds,
are available on International® Low Profile and standard rail truck models.
Suspensions include following features:
• Rubber bushings which require no lubrication

• Stamped-steel and nodular iron brackets and shackles
• Bolt type spring pins 3/4 in. diameter
• Three inch wide springs
• Springs painted with iono-clad zinc-rich epoxy for corrosion protection
Increased Capacity Parabolic Taper Leaf Springs

Springs essentially same design as standard parabolic springs. They have a parabolic shape, being slightly
curved on the bottom surface of each leaf.
However, these suspensions were designed for use with axles having higher weight carrying capacities
(from 10,000 to 18,000 pounds).
These increased capacity parabolic tapered leaf springs include:
• Nodular iron and stamped steel brackets for increased strength

• Rubber bushings, which require no lubrication on most suspensions
• Springs Painted with iono-clad Zinc-Rich Epoxy Paint for added protection against corrosion
• Shock Absorbers for improved ride
• Four (4) in. wide springs
• 16,000 to 18,000 pound have one (1) in. spring pin
Front Suspension Rubber Auxiliary Springs

Standard parabolic taper leaf front suspension systems were developed to provide balance between ride and
handling characteristics. Spring stiffness and roll stability are capable of handling most demanding applications.
18
SET BACK AXLE
Multi-leaf Slipper Type with Torque Rod

Overview
03ACU Suspension, Front, Spring, multi-leaf, slipper type; 20,000 pound capacity; with
torque rods and less shock absorbers
03ADR Suspension, Front, Spring, multi-leaf, slipper type; 20,000 pound capacity; with
torque rods and less shock absorbers, includes one (1) extra leaf on right
03ACX Suspension, Front, Spring, multi-leaf, slipper type; 24,000 pound capacity; with
torque rods and less shock absorbers
Figure 3 Slipper Type with Torque Rod Front Suspension
For heavy-duty or severe service applications International® offers the multi-leaf spring front suspensions with
the slipper type design.
The slipper type spring assembly enables the slipper type spring assembly enables the spring leaves to 'slip' or
move within the rear mounting bracket in accordance with the amount of weight the springs are carrying.
This allows spring to accommodate loads and stresses encountered in severe service applications. This spring
and bracket assembly is for use with axles rated at 20,000 pounds or more.
These front springs include:
• Nodular Iron Brackets

• Threaded Pin at Front Brackets
• Slipper Cam at Rear Brackets
• Torque Rods to provide stability while operating in off-highway environments
• Four (4) in. wide springs
19
SET FORWARD AXLE
2. Set Forward Axle

Multi-leaf Spring
Overview
Feature Code Description
03AEX HX515 - Suspension, Front, Spring, two stage multi-leaf; 20,000 pound
capacity; two (2) stage steel springs and two (2) rubber auxiliary springs,
with shocks
Figure 4 Multi-leaf Front Suspension
Flat leaf springs use leaves having a constant thickness along entire length of leaf.
Multi-leaf suspensions are designed for use with front axles having capacities ranging from 14,000 to 20,000
pounds. These springs include:
• Nodular iron brackets which add strength

• Grooved spring pins which provide 'lubrication reservoirs' or threaded spring pins
• Steel shackles
• Shot-peened springs for added spring strength
• Four inch wide spring on all other models
20
SET FORWARD AXLE
Parabolic Taper Leaf

Overview
03ADC HX515 - Suspension, Front, Spring, parabolic, taper leaf; 12,000 pound
capacity; with shock absorbers
03ADD Suspension, Front, Spring, parabolic, taper leaf; 14,000 pound capacity;
03ADE Suspension, Front, Spring, parabolic, taper leaf; 16,000 pound capacity;
03ADG Suspension, Front, Spring, parabolic, taper leaf; 18,000 pound capacity;
03ADJ HX515 - Suspension, Front, Spring, parabolic, taper leaf; 20,000 pound
capacity; with 18,000 pound capacity steel springs and two (2) rubber
auxiliary springs (2000 pound capacity)
03AEB HX515 - Suspension, Front, Spring, taper leaf, shackle type; 20,000
pound capacity; 18,000 pound capacity steel springs with two (2) Aeon
rubber auxiliary springs (2000 pound capacity); includes one (1) extra
leaf and one (1) in. spacer on left
Figure 5 Parabolic Taper Leaf Front Suspension
Taper leaf springs are thicker in middle than at ends. Because of this design, these suspensions are able
to use fewer spring leaves which helps to reduce leaf-to-leaf friction. Produces a smoother ride than flat
multi-leaf springs.
Parabolic type tapered spring leaf is curved in shape of a parabola. Curvature is very slight, occurring
on bottom surface of each spring leaf.
Provides even stress distribution along entire length of leaf. Springs are also light weight, which helps reduce
overall vehicle weight.
21
SET FORWARD AXLE
Light-duty parabolic tapered leaf springs, are included on axles with ratings of 6,000, 7,000, and 8,000 pounds,
are available on International® Low Profile and standard rail truck models.
Suspensions include following features:
• Rubber bushings which require no lubrication

• Stamped-steel and nodular iron brackets and shackles
• Bolt type spring pins 3/4 in. diameter
• Three inch wide springs
• Springs painted with iono-clad zinc-rich epoxy for corrosion protection
Increased Capacity Parabolic Taper Leaf Springs

Springs essentially same design as standard parabolic springs. They have a parabolic shape, being slightly
curved on the bottom surface of each leaf.
However, these suspensions were designed for use with axles having higher weight carrying capacities
(from 10,000 to 18,000 pounds).
These increased capacity parabolic tapered leaf springs include:
• Nodular iron and stamped steel brackets for increased strength

• Rubber bushings, which require no lubrication on most suspensions
• Springs Painted with iono-clad Zinc-Rich Epoxy Paint for added protection against corrosion
• Shock Absorbers for improved ride
• Four inch wide springs
• 16,000 to 18,000 pound have one (1) in. spring pin
Front Suspension Rubber Auxiliary Springs

Standard parabolic taper leaf front suspension systems were developed to provide balance between ride and
handling characteristics. Spring stiffness and roll stability are capable of handling most demanding applications.
22
TORQUE
3. Torque
Overview Torque
Height Control Rod Mount Bolt 60 to 80 lb-in. (7 to 9 N·m)
Height Control Valve Mount Nuts 60 to 80 lb-in. (7 to 9 N·m)
Air Spring Top Mount Nut 45 to 55 lb-ft (61 to 75 N·m)
Shock Absorber Top Mount Bolt 195 to 240 lb-ft (265 to 325 N·m)
Shock Absorber Bottom Mount Bolt 250 to 300 lb-ft (339 to 407 N·m)
Sway Bar Clamp Mount Bolts 80 to 100 lb-ft (108 to 135 N·m)
Integrated Sway Bar Assembly Locknut 170 to 185 lb-ft (230 to 251 N·m)
Integrated Sway Bar Assembly Bolt 195 to 240 lb-ft (265 to 325 N·m)
Lower Torque Rod Rear Locknuts 170 to 185 lb-ft (230 to 251 N·m)
Lower Torque Rod Front Mount Bolts 195 to 240 lb-ft (265 to 325 N·m)
Upper Torque Rod Mount Bolts 300 to 370 lb-ft (407 to 502 N·m)
Transverse Torque Rod Left Side Mount Locknut 225 lb-ft (305 N·m)
Transverse Torque Rod Right Side Mount Bolts 195 to 240 lb-ft (265 to 325 N·m)
Height Control Valve Lever Screw 50 to 55 lb-in. (6 N·m)
23
TORQUE
24
TABLE OF CONTENTS
Brakes
Table of Contents
1. Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bendix® Anti-lock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bendix® EC‑80™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bendix® ESP® EC‑80™ Controller Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Bendix® EC‑80™ ABS/ATC Controller Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Modulator Valve M-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Steering Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Steering Angle Sensor w / A26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Wheel Speed Sensor WS-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Yaw Rate Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2. Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine Mounted Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Bendix® BA-921® 15.9 Cubic Feet per Minute (CFM) Single Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cummins® 18.7 Cubic Feet per Minute (CFM) Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Knorr-Bremse® LP-720™ DLU 31.8 Cubic Feet per Minute (CFM) Dual Cylinder Air Compressor. . . . . 60
Yoosung® Air Compressor 21.0 Cubic Feet per Minute (CFM) Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3. Air Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Bendix® AD-9™ Air Dryer with Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Bendix® AD-IP™ Integral Purge Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Meritor WABCO System Saver 1200 Air Dryer with Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4. Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Air Dual Brake System for Straight Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Air Dual Brake System for Tractors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
25
TABLE OF CONTENTS
26
AIR BRAKES
1. Air Brakes
Bendix® Anti-lock Brake System (ABS)
Overview
0004AZA Air Brake ABS {Bendix® Anti-lock Brake System} full vehicle wheel
control system (four (4) channel)
0004AZU Air Brake ABS {Bendix® Anti-lock Brake System} full vehicle wheel
control system (six (6) channel; six (6) sensor; six (6) modulator)
0004AZJ Air Brake ABS {Bendix® Anti-lock Brake System} full vehicle wheel
control system (four (4) channel) with automatic traction control
0004AZV Air Brake ABS {Bendix® Anti-lock Brake System} full vehicle wheel
control system (six (6) channel; six (6) sensor; six (6) module) with
automatic traction control
0004AZS Air Brake ABS {Bendix® Anti-lock Brake System} with electronic stability
program (four (4) channel) with automatic traction control
0004AZY Air Brake ABS {Bendix® Anti-lock Brake System} with electronic
stability program (six (6) channel; six (6) sensor; six (6) modulator) with
automatic traction control
27
AIR BRAKES
1 2
6 5
4 3
0000419236
Figure 6 ABS System Wheel Speed Sensor Locations

1. Front Rear Drive Axle Wheel Speed 4. Rear Rear Drive Axle Wheel Speed
Sensor Left Sensor Left
2. Front Rear Drive Axle Wheel Speed 5. Steer Axle Wheel Speed Sensor Right
Sensor Right 6. Steer Axle Wheel Speed Sensor Left
3. Rear Rear Drive Axle Wheel Speed
Sensor Right
28
AIR BRAKES
1 2
6 5
4 3
0000419242
Figure 7 ABS System Wheel Modulator Valve Locations

1. Front Rear Drive Axle Modulator Valve 4. Rear Rear Drive Axle Modulator Valve
Left Left
2. Front Rear Drive Axle Modulator Valve 5. Steer Axle Modulator Valve Right
Right 6. Steer Axle Modulator Valve Left
3. Rear Rear Drive Axle Modulator Valve
Right
Anti-lock brake systems work by automatically creating a 'pumping or pulsing' action when brake lock-up is
imminent. Four individual wheel speed sensors and modulators control front and rear wheels. When a certain
wheel is approaching lock-up, wheel speed sensors signal electronic controller which in turn regulates brake
pressure so that lock-up is avoided. This helps driver bring vehicle to a controlled and stable stop, reducing
chance of over-braking.
During a brake stop, the maximum point of deceleration occurs just before wheel lock-up. When wheels lock
up, stopping distances increase and loss of directional control may occur.
29
AIR BRAKES
To reduce wheel lock-up, the anti-lock brake system monitors the rotational speed of the wheels using sensors
mounted on the axle ends and exciter rings mounted on the wheel assemblies.
30
AIR BRAKES
Bendix® EC‑‑80™
Overview
0000419216
Figure 8 Bendix® EC‑‑80™ Location

1. Bendix® EC‑80™ Electronic Control
Unit (ECU)
Bendix® EC‑80™ ECU is a member of a family of three Bendix®-brand electronic Anti-lock Braking System
(ABS) devices used to help improve braking characteristics of air-braked heavy-and medium-duty trucks,
tractors, and buses:
• Bendix® ABS ECU uses wheel speed sensors to monitor four (4) wheel-ends to detect wheel-slip or wheel
lock‑up during braking. System intervenes when needed, using Pressure Modulator Valves (PMVs) to
adjust and pulse brake pressure, in order to optimize contact between tires and road surface.
• Bendix® Automatic Traction Control (ATC) EC‑80™ ECU provides standard ABS; improves vehicle
traction during acceleration; and aid lateral stability while driving through curves. Bendix® ATC ECU
communicates with engine’s controller to provide Engine Torque Limiting (ETL), and use Differential
Braking (DB) to make brake applications at individual wheels.
31
AIR BRAKES
• Bendix® ESP® EC‑80™ Controller provides, in addition to ABS and ATC functions described above,
advanced braking features referred to as Bendix® ESP® Electronic Stability Program. Bendix® ESP®
EC‑80™ Controller analyzes vehicle's motion compared to driver's intended path and provides Yaw Control
(YC) and Roll Stability Program (RSP) capabilities. When necessary, system will intervene to reduce
engine throttle, and apply brakes at one or more of wheel ends, to help vehicle return to intended direction.
Bendix® EC‑80™ ATC and ESP® EC‑80™ controllers also have capability to provide a Hill Start Assist (HSA)
feature. HSA interfaces between transmission and braking system to help driver prevent vehicle from rolling
backwards when moving forward from a stationary position on steep inclines. Bendix® EC‑80™ ATC and
ESP® EC‑80™ controllers have a drag torque control feature which reduces driven-axle wheel slip (due to
drive line inertia) by communicating with engine’s controller and increasing engine torque.
32
AIR BRAKES
Bendix® ESP® EC‑‑80™ Controller Service Information
Overview
Bendix® ESP® EC‑80™ Controller Service Data and Go to www.bendix.com
Troubleshooting
33
AIR BRAKES
Removal
Overview
Special Tools
Equipment Conditions
Procedure
Follow-On Procedure
34
AIR BRAKES
Installation
Overview
Special Tools
Torque Specifications
Procedure
Follow-On Procedure
35
AIR BRAKES
Bendix® EC‑‑80™ ABS/ATC Controller Service Information
Overview
For Bendix® EC‑80™ ABS/ATC Controllers Service Go to www.bendix.com
Data and Troubleshooting
36
AIR BRAKES
Modulator Valve M-40
Removal
Overview
Air modulator valve removal for replacement or repair.
Special Tools
None
1. Vehicle parked on flat level surface with parking brake set.
2. Key OFF.
3. Wheel chocks installed.
4. Battery disconnected (page 169).
5. Remove vehicle panels, cover plates, and side skirting necessary to gain access to air modulator
valve.
6. Drain air pressure from vehicle reservoirs.
WARNING
To prevent personal injury and / or death, read all safety instructions in the “Safety
Information” section of this manual.
WARNING
To prevent property damage, personal injury, and / or death, shift transmission to park or
neutral, set parking brake, and install wheel chocks before doing diagnostic or service
procedures.
37
AIR BRAKES
Procedure
Figure 11 Air Modulator Valve

1. Air hoses (2) 4. Mounting bolts and nuts (2)
2. Air modulator valve 5. Electrical connector
3. Frame
1. Identify, mark, or label air hoses to their respective connections on valve to facilitate ease of installation.
2. Disconnect two air hoses (1) from air modulator valve (2). Remove ratchet straps as necessary.
3. Remove two mounting bolts, nuts (4), and air modulator valve (2) from frame (3).
4. Disconnect electrical connector (5) from air modulator valve (2).
Follow-On Procedure
1. Install air modulator valve. See Air Modulator Valve Install.
38
AIR BRAKES
Installation
Overview
Air modulator valve installation for replacement or repair.
Special Tools
None
None
2. Key OFF.
5. Air modulator valve removed. See Air Modulator Valve Remove.
WARNING
WARNING
procedures.
39
AIR BRAKES
Procedure
Figure 12 Air Modulator Valve

1. Air hoses (2) 4. Mounting bolts and nuts (2)
2. Air modulator valve 5. Electrical connector
3. Frame
1. If different valve is used than in removal, transfer fittings to new valve.
2. Install air modulator valve (2) to frame (3) with two mounting bolts and nuts (4).
3. Connect electrical connector (5) to air modulator valve (2).
4. Connect two air hoses (1) to air modulator valve (2) as marked during removal. Replace ratchet straps as
necessary.
Follow-On Procedure
1. Battery Reconnect Procedure (page 171).
2. With aid of an assistant, press brake pedal and check for air leaks.
3. Install vehicle panels, cover plates, and side skirting removed to gain access to air modulator valve.
40
AIR BRAKES
Steering Angle Sensor
Removal
Overview
Special Tools
Procedure
Follow-On Procedure
41
AIR BRAKES
Installation
Overview
Special Tools
Procedure
Follow-On Procedure
42
AIR BRAKES
Steering Angle Sensor w / A26
Removal
Overview
Remove steering angle sensor for sensor replacement.
Figure 15 Steering Angle Sensor

1. Steering angle sensor
Special Tools
None
2. Key OFF.
4. Batteries disconnected (page 169).
43
AIR BRAKES
WARNING
WARNING
procedures.
Removal Procedure
1. Lock steering wheel in straight ahead position.
2. Mark steering shaft position.
Figure 16 Steering Shaft U-joint

1. Steering shaft U-joint mounting nut, bolt 2. Steering shaft U-joint
and washers 3. Steering column shaft
Refer to above illustration when performing following steps:
44
AIR BRAKES
3. Remove steering shaft U-joint mounting nut, bolt and washers (1) from steering shaft U-joint (2).
4. Separate steering shaft U-joint (2) from steering column shaft (3).

1. Steering angle sensor mounting screws 3. Steering angle sensor
(3) 4. Steering angle sensor electrical
2. Steering angle sensor mounting plate connector
5. Disconnect electrical harness from steering angle sensor electrical connector (4).
6. Remove three steering angle sensor mounting screws (1), and remove steering angle sensor (3) from
steering angle sensor mounting plate (2).
Follow-On Procedure
1. Install steering angle sensor. See Steering Angle Sensor Installation (page 46).
45
AIR BRAKES
Installation
Overview
Install steering angle sensor for sensor replacement.

1. Steering angle sensor
Special Tools
None
Torque Specification
Steering angle sensor mounting screws 77.0 - 94.7 lb-in. (8.7 - 10.7 N·m)
Steering shaft U-joint mounting nut and bolt 50 - 60 lb-ft (67.8 - 81.4 N·m)
1. Steering angle sensor removed. See Steering Angle Sensor Removal (page 43).
2. Steering wheel locked in straight ahead position.
46
AIR BRAKES
WARNING
WARNING
procedures.
Installation Procedure

1. Steering angle sensor mounting screws 3. Steering angle sensor
(3) 4. Steering angle sensor electrical
2. Steering angle sensor mounting plate connector
1. Install steering angle sensor (3) on steering angle sensor mounting plate (2) with three steering angle
sensor mounting screws (1). Tighten three screws to 77.0 - 94.7 lb-in. (8.7 - 10.7 N·m).
47
AIR BRAKES
2. Connect electrical harness to steering angle sensor electrical connector (4).
Figure 20 Steering Shaft U-joint

1. Steering shaft U-joint mounting nut, bolt 2. Steering shaft U-joint
and washers 3. Steering column shaft
3. Using mark made during removal, connect steering shaft U-joint (2) to steering column shaft (3).
4. Install steering shaft U-joint mounting nut, bolt and washers (1) on steering shaft U-joint (2). Tighten nut
and bolt to 50 - 60 lb-ft (67.8 - 81.4 N·m).
Follow-On Procedure
1. Connect batteries (page 171).
48
AIR BRAKES
Wheel Speed Sensor WS-24
Removal
Overview
Transmitter speed sensor removal for replacement or repair.
Special Tools
None
2. Key OFF.
5. Unlatch and open hood.
WARNING
WARNING
procedures.
49
AIR BRAKES
Procedure
Figure 21 Speed Sensor

1. Chassis harness 4. Sensor cable
2. Electrical connector 5. Sensor
3. Fasteners
1. Remove fasteners (3) securing sensor cable (4) as required. Note fastener locations to aid during
installation.
2. Disconnect electrical connector (2) from chassis harness (1).
3. Remove spring clip and sensor (5) from hub assembly. Discard spring clip.
Follow-On Procedure
1. Install transmitter speed sensor. See Transmitter Speed Sensor Installation.
50
AIR BRAKES
Installation
Overview
Transmitter speed sensor installation for replacement or repair.
Special Tools
None
None
2. Key OFF.
5. Transmitter speed sensor removed. See Transmitter Speed Sensor Removal.
WARNING
WARNING
procedures.
51
AIR BRAKES
Procedure
Figure 22 Speed Sensor

1. Chassis harness 4. Sensor cable
2. Electrical connector 5. Sensor
3. Fasteners
Bendix recommends applying high-temperature rated silicon- or lithium-based grease to sensor opening in
steering knuckle, spring clip, and sensor prior to installation.
1. Push spring clip into hub assembly and ensure flange stop is against steering knuckle.
2. Push sensor (5) completely into spring clip until it contacts tooth wheel.
• No clearance between sensor and tooth wheel is required.
3. Route sensor cable (4) to chassis harness (1). Be sure to route sensor cable in a way that prevents
pinching or chafing and allows sufficient movement for suspension travel.
4. Connect electrical connector (2) to chassis harness (1).
5. Secure sensor cable (4) using fasteners (3) as noted during removal.
Follow-On Procedure
2. Close and latch hood.
52
AIR BRAKES
Yaw Rate Sensor
Removal
Overview
Yaw rate sensor removal for replacement. Yaw rate sensor is located on right frame rail for HX.
Special Tools
None
2. Key OFF.
WARNING
WARNING
procedures.
CAUTION
To prevent damage to sensor, shut engine off and ensure system is not powered while
connecting or disconnecting yaw rate sensor.
53
AIR BRAKES
Procedure
Figure 23 Yaw Rate Sensor

1. Yaw rate sensor 3. Electrical connector
2. Frame rail 4. Bolts (2)
1. Disconnect electrical connector (3) from yaw rate sensor (1).
2. Remove two bolts (4) and yaw rate sensor (1) from frame rail (2).
Follow-On Procedure
1. Install yaw rate sensor. See Yaw Rate Sensor Installation.
54
AIR BRAKES
Installation
Overview
Yaw rate sensor installation for replacement. Yaw rate sensor is located on right frame rail for HX.
Special Tools
None
Yaw rate sensor bolt 34 lb-ft (46 N·m)
2. Key OFF.
5. Yaw rate sensor removed. See Yaw Rate Sensor Removal.
WARNING
WARNING
procedures.
CAUTION
To prevent damage to sensor, shut engine off and ensure system is not powered while
connecting or disconnecting yaw rate sensor.
55
AIR BRAKES
Procedure
Figure 24 Yaw Rate Sensor

1. Yaw rate sensor 3. Electrical connector
2. Frame rail 4. Bolts (2)
1. Install yaw rate sensor (1) to frame rail (2) with two bolts (4). Torque bolts to 34 lb-ft (46 N·m).
2. Connect electrical connector (3) to yaw rate sensor (1).
Follow-On Procedure
56
AIR COMPRESSOR
2. Air Compressor
Engine Mounted Air Compressor
Overview
Figure 25 Single Cylinder Air Compressor Location

1. Single Cylinder Air Compressor
Compressed air for brake system and other systems is supplied by an engine driven compressor. Compressor
pulls in atmospheric air, which utilizes naturally aspirated air only, compresses it and supplies air to wet tank
(supply reservoir). These compressors are reciprocating piston, single actuating (compress in one direction)
type, with rated capacities of 13.2 or 16.5 Cubic Feet per Minute (CFM), based on piston displacement when
operating at 1250 rpm. Air compressors are water cooled and lubricated by engine oil. Various mounting and
drive adaptations are used depending on design of engine. Compressed air for brake system and other
systems is supplied by an engine driven compressor. Compressor pulls in atmospheric air, which utilizes
naturally aspirated air only, compresses it and supplies air to wet tank (supply reservoir).
These compressors are reciprocating piston, single actuating (compress in one direction) type, with rated
capacities of 13.2 or 16.5 CFM, based on piston displacement when operating at 1250 rpm.
Air compressors are water cooled and lubricated by engine oil. Various mounting and drive adaptations
are used depending on design of engine.
57
AIR COMPRESSOR
Bendix® BA-921® 15.9 Cubic Feet per Minute (CFM) Single Cylinder
Overview
04SPM HX515 and HX615 - Air Compressor {Bendix® BA-921 Head Unload}
15.9 CFM capacity, single cylinder
Bendix® BA-921® compressor is a single-cylinder reciprocating compressor with a rated displacement of

15.8 CFM at 1250 RPM.
Service Information
Bendix® BA-921® Compressor Service Information Go to www.bendix.com

For Advanced Troubleshooting Guide for Air Brake Go to www.bendix.com
Compressors
58
AIR COMPRESSOR
Cummins® 18.7 Cubic Feet per Minute (CFM) Air Compressor

Overview
04SPA HX 620 - Air Compressor {Cummins®} 18.7 CFM
Service Information
Cummins® 18.7 CFM Air Compressor Service Go to

Information https://quickserve.cummins.com/info/index.html for
service information.
59
AIR COMPRESSOR
Knorr-Bremse® LP-720™ DLU 31.8 Cubic Feet per Minute (CFM) Dual Cylinder Air
Compressor
Overview
04SPB Knorr-Bremse® LP-720™ DLU 31.8 CFM dual cylinder
Service Information
Knorr-Bremse® LP-720™ DLU 31.8 CFM Dual Go to www.knorr-bremseCVS.com for service

Cylinder Air Compressor Service Information information.
60
AIR COMPRESSOR
Yoosung® Air Compressor 21.0 Cubic Feet per Minute (CFM) Air Compressor
Overview
04SPL Optional with N13 Engines - Air Compressor 21.0 CFM capacity
Service Information
Yoosung® Air Compressor 21.0 CFM Air Compressor Go to www.yoosungco.en.ec21.com for service
Service Information information.
61
AIR DRYERS
3. Air Dryers
Overview
Figure 26 Air Dryer with Heater Location
When air is compressed by an air compressor, condensation (moisture) is formed in brake system. Also,
micro-sized particles of dirt and oil can accumulate and eventually contaminate brake reservoirs, lines, and
valves. An air dryer can help alleviate both of these problems by use of a desiccating filter to remove this
excess moisture and an alloy filter to screen out oil and dirt particles. In cold weather, an integral heater
assures that accumulated moisture does not freeze. After air dryer condenses and filters moisture and
contaminants in pressurized air stream from compressor, it automatically purges accumulated contaminants
during compressor duty cycle.
62
AIR DRYERS
Bendix® AD-9™ Air Dryer with Heater

Overview
04EBS Air Dryer (Bendix® AD-9™) with heater
Function of AD-9™ air dryer is to collect and remove air system contaminants in solid, liquid, and vapor form
before they enter brake system. It provides clean, dry air to components of brake system which increases life
of the system and reduces maintenance costs. Daily manual draining of reservoirs is eliminated.
Service Information
For service information www.bendix.com
63
AIR DRYERS
Bendix® AD-IP™ Integral Purge Air Dryer

Overview
04EBT Air Dryer (Bendix® AD-IP™) with heater
Function of Bendix® AD-IP™ Integral Purge air dryer with heater is to collect and remove air system
contaminants in solid, liquid and vapor form before they enter brake system. It provides clean, dry air to
components of brake system which increases life of system and reduces maintenance costs. Daily manual
draining of reservoirs is eliminated.
Service Information
For service information www.bendix.com
64
AIR DRYERS
Meritor WABCO System Saver 1200 Air Dryer with Heater

Overview
04EBD Air Dryer (Meritor WABCO System Saver 1200) with heater
Meritor WABCO System Saver family of air dryers is a desiccant-type air dryers. These air dryers can meet
virtually any vocational requirement. They are lightweight in design at 11.1 pounds. Functions with standard
brake systems and requires no additional purge volume reservoirs. This air dryer is available with turbo cut-off
valve to prevent leakage of turbo boost pressure and use of discharge line unloading options.
Service Information
For service information Go to www.meritorwabco.com

For Technical Bulletin for System Saver 1200 Plus Go to www.meritorwabco.com
Series Air Dryers
For troubleshooting tips for System Saver Single Go to www.meritorwabco.com
Cartridge Air Dryers
To replace a Bendix® AD-9 Air Dryer with a System Go to www.meritorwabco.com
Saver 1200 plus Air Dryer
65
BRAKES
4. Brakes
Air Dual Brake System for Straight Trucks
Overview
04091 Brake System, air dual system for straight truck applications
With dual air brake system, one set of air brake lines are used to operate rear axle brakes as primary system.
A second set of air brake lines supplies front axle brakes as secondary system. Primary and secondary
systems serve parking brakes. If either primary or secondary system suffers a loss of air pressure, other
system will retain sufficient air pressure for partial braking.
66
BRAKES
Air Dual Brake System for Tractors

Overview
04092 HX615 and HX620 - Brake System, air dual system for tractor
applications
With dual air brake system, one (1) set of air brake lines are used to operate rear axle brakes as primary
system. A second set of air brake lines supplies front axle brakes as secondary system. Primary and
secondary systems serve parking brakes and in case of tractor brakes, also serve trailer brakes. If either
primary or secondary system suffers a loss of air pressure, other system will retain sufficient air pressure
for partial braking.
67
BRAKES
68
TABLE OF CONTENTS
Steering
Table of Contents
1. Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Tilting and Telescoping Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Steering Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Clock Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Steering Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2. Steering Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sheppard M-Series Integral Power Steering Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sheppard M-100/HD94 Dual Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sheppard M-100/M-80 Dual Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sheppard M-110/M-80 Dual Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sheppard M-100 Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
69
TABLE OF CONTENTS
70
STEERING COLUMN
1. Steering Column
Tilting and Telescoping Steering Column
Overview
05710 Steering Column tilting and telescoping
Steering column assembly provides vehicle operator control of steering gear from inside vehicle cab.
Operators also have capability to tilt and telescope steering column to their own driving needs.
A steering wheel is connected to upper steering shaft. Steering shaft is connected to slip shaft by a universal
joint. Lower end of slip shaft is connected to steering gear by a second universal joint. Universal joints and slip
shaft permit correct alignment and smooth rotation of steering shaft to steering gear with no binding of shafts.
Turn signal and trailer brake controls are mounted to steering column jacket tube.
Horn will not operate with ignition switch in OFF position. When ignition switch is in ON or ACCESSORY
position, current is available at horn relay. To energize relay and feed current to horn, a path to ground is
completed through horn button mechanism in steering column.
Figure 27 Steering Column Location

1. Steering Column
71
STEERING COLUMN
Figure 28 Steering Column Components

1. Steering Wheel 3. Steering Column
2. Clock Spring
Steering Wheel
Overview
05CAW Steering Wheel four (4) spoke; 18 in. diameter, black
05CBE Steering Wheel four (4) spoke; 18 in. diameter, black leather wrapped
Many commonly used controls are located on steering wheel for easy driver access. These controls are back
lit for easy visibility. An electric horn pad is located in center of steering wheel. Standard switches include
cruise control, headlight flash (USA), marker light interrupt, and air horn. Optional switches include engine
brake, radio, and automatic manual transmission.
72
STEERING COLUMN
Clock Spring
Overview
Located under the steering wheel, the clock spring provides transmission of electrical signals and power
between the fixed structure of the steering column and the rotating switches that are mounted on the steering
wheel. Functions such as horn, light interrupt, cruise control, engine brake, radio, and transmission gear
selectors are integrated into the steering wheel control system by using a clock spring.
73
STEERING COLUMN
Steering Column
Overview
Tilt and telescoping steering column assembly can be moved toward or away from driver. Adjustment lever is
located on left side of steering column. To unlock and adjust tilt and telescoping steering column position, push
lever down, move column to desired position, and then pull lever up to lock tilt and telescoping steering column
in position. Tilt and telescoping steering column features a stowaway position for easy entry and exit.
Description
Tilt and telescoping steering column assembly allows tilt and telescope functions through a common lever.
Figure 29 Tilt and Telescoping Steering Column Assembly
A steering wheel is connected to steering column assembly. Steering column assembly is connected to
steering shaft by a universal joint. Lower end of steering shaft is connected to steering gear by a second
universal joint. Universal joints permit correct alignment and smooth rotation of steering shaft to steering
gear with no binding of shafts.
Turn signal assembly and trailer hand brake controls (if installed) are mounted to main housing assembly.
74
STEERING COLUMN
Maintenance
End Yoke Pinch Bolts

Pinch bolts and nuts on lower steering column end yokes should be checked for tightness annually or
every 50,000 miles (80,000 kilometers), whichever comes first. Visually inspect that plastic collar has been
sheared off.
Lubrication
Steering shaft slip joint and universal joints should be lubricated at assembly and at intervals indicated in
Operator's Manual of vehicle being serviced. Lubricate with Fleetrite EP2 Moly Grease or equivalent NLGI#2
multi-purpose lithium grease.
Steering Wheel Alignment

Proper steering wheel-to-steering gear alignment is designed into steering assembly. Following are a few
alignment points to check at assembly or when steering wheel alignment is a problem:
1. Test drive vehicle on a straight and level (no crown) section of road for at least one-quarter mile. Determine
if or how far off center steering wheel is when vehicle is going straight.
2. If steering wheel alignment is off, return vehicle to work area for further adjustment. Stop vehicle with front
road wheels (not steering wheel) straight ahead as indicated by driving test.
3. Proper steering wheel-to-steering gear alignment can be accomplished by removing universal joint at
steering column shaft.
4. Align steering wheel and re-attach universal joint. Use a new shear-type pinch bolt in yoke. Refer to
Torque Chart (page 78) for proper torquing procedure.
5. Test drive vehicle to assure that proper alignment has been accomplished and that steering is correct.
75
STEERING COLUMN
Operation
Tilt
Same lever, mounted on left of steering column, is used to actuate both tilt and telescoping modes of column.
Adjustable six (6) position steering column assembly can be moved toward or away from driver. Tilt positions
are adjustable in seven (7) degree increments from 14 degrees above center-line of column to 21 degrees
below center-line of column.
To adjust column,
1. Push control lever down (away from steering wheel) and move steering wheel to desired position.
2. Release lever to lock column in position.
Telescope
Same lever, mounted on left of steering column, is used to actuate both tilt and telescoping modes of column.
Column will telescope a total of 2-1/4 in.
To adjust telescopic position,
1. Unlock column by pulling tilt/telescope lever up (toward steering wheel).
2. Raise or lower steering to desired position.
3. Release lever to lock column in position.
76
STEERING GEAR
2. Steering Gear
Sheppard M-Series Integral Power Steering Gear
Overview
05PSA 6x4 - Steering Gear {Sheppard M-100} power 18.9:1 ratio
8x6 Tridem - Dual steering gears are standard. Using dual gears
means maximum steering angles for best maneuverability and, equally
important, ‘dry park’ ability at maximum front axle loading with these
extreme steering forces spread over both rails.
05PTB Steering Gear (2) {Sheppard M-100/M-80} dual power 18.9:1 ratio
Steering Gear (2) {Sheppard M-100/M-80} dual power
05PUA Steering Gear (2) {Sheppard M-110/M-80} dual power 23.0:1 ratio
Sheppard M-110 is designed for heavy duty applications with 22,000
pound front axles
Sheppard M-Series Integral Power Steering Gear provides full time hydraulic steering. Only enough manual
effort to overcome torsion bar and turn rotary valve is required.
Sheppard M-100/HD94 Dual Power

Overview
05PUB Steering Gear (2) {Sheppard M100/HD94} dual power
Sheppard model M100 is designed for heavy duty line-haul trucks and heavy bus applications with a front axle
rating between 10,000 and 14,000 pounds.
Sheppard M-100/M-80 Dual Power

Overview
05PTB Steering Gear (2) {Sheppard M-100/M-80} dual power 18.9:1 ratio
Steering Gear (2) {Sheppard M-100/M-80} dual power
Sheppard M-110/M-80 Dual Power

Overview
05PUA Steering Gear (2) {Sheppard M-110/M-80} dual power 23.0:1 ratio
Sheppard M-110 is designed for heavy duty applications with 22,000
pound front axles
77
STEERING GEAR
Sheppard model M-110 are designed for heavy duty applications with 22,000 pound front axle rating.
Sheppard M-100 Power

Overview
05PSA 6x4 - Steering Gear {Sheppard M-100} power 18.9:1 ratio
8x6 Tridem - Dual steering gears are standard. Using dual gears
means maximum steering angles for best maneuverability and, equally
important, ‘dry park’ ability at maximum front axle loading with these
extreme steering forces spread over both rails.
Service Information
Sheppard Service Manual
See Sheppard service manual Go to www.rhsheppard.com

See Sheppard service manual Go to www.rhsheppard.com
Torque Chart
Location Torque
Steering Wheel Mounting Nut 75 to 80 lb-ft (102 to 108 N·m)
Steering Gear and Column End Yoke Pinch Bolts Tighten nut until non-threaded portion above
plastic collar shears off.
Steering Column Mounting Bracket Lock Nuts 34 to 38 lb-ft (46 to 52 N·m)
Steering Column Bracket Lock Nuts 21 to 27 lb-ft (28 to 37 N·m)
Telescoping Control Lever Nut 8 to 10 lb-ft (11 to 14 N·m)
78
TABLE OF CONTENTS
Drivelines
Table of Contents
1. Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Driveshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inner-Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Driveline Vibration and Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Inspect and Measure Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Troubleshooting Driveline Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
79
TABLE OF CONTENTS
80
DRIVELINE
1. Driveline
Overview
Driveline components include driveshafts, inner-axle shaft, end yokes and flanges, universal joints and center
bearings between all driveline components.
Typical 6x4 and 8x6 drivelines have two shaft types. For 6x4 driveline, driveshaft assembly connects
transmission and forward rear axle and inner-axle shaft assembly connects rear axles. For 8x6 driveline,
driveshaft assembly connects transmission and first rear axle, inner-axle shaft assembly connects first and
second rear axles and second and third rear axles.
Driveshaft
Overview
6x4 with N13 Engines {Spicer 1810 Series} transmission to rear axle
6x4 with Cummins® ISX Engines and {Spicer SPL250XL Series} transmission to first rear axle
8x6 Models
Driveshaft connects transmission to rear axle, or, in AWD models, connects transmission to transfer case,
transfer case to rear axle, and transfer case to front driving axle.
All driveshafts have nylon-coated slip joint splines which allow shaft length to vary as axle moves with
suspension.
All driveshafts include half-round end yokes which provide significant weight savings over conventional
full-round end yokes.
This design also allows complete driveshaft disassembly in less time than is required for full-round end yokes.
81
DRIVELINE
Inner-Axle Shaft
Overview
6x4 with N13 Engines {Spicer 1710 Series} forward rear axle to rear rear axle
6x4 with Cummins® ISX Engines {Spicer SPL170XL Series} forward rear axle to rear rear axle
8x6 Tridem {Spicer SPL170XL} first rear axle to second rear axle and second
rear axle to third rear axle
Inner-axle shaft connects forward rear axle and rear rear axle in a tandem axle. It also connects first rear axle
to second rear axle and second rear axle to third rear axle in a Tridem axle.
All inner-axle shafts have nylon-coated slip joint splines which allow shaft length to vary as axles move with
suspension. Also, all inner-axle shafts include half-round end yokes.
As with driveshafts, this design provides significant weight savings over conventional full-round yokes, along
with greater ease and speed of disassembly and reassembly.
Service Information
Spicer Heavy Duty Axle Manufacturer Go to www.spicerparts.com.
82
DRIVELINE
Driveline Vibration and Troubleshooting Procedures

Inspect and Measure Driveline
Overview
Properly check drive line angles and driveline run out, use that information to properly repair vehicle and bring
driveline into specification. Information is to assist in resolving a vibration complaint that may be caused
by driveline. This article does not address other possible vibration issues, such as vibrations caused by
engine. For engine vibration, cab vibration, or mirror shake issues see Engine Vibration and Troubleshooting
Procedures in section 12 Engine.
Required Tools
• Digital Protractor, ZTSE4329
Before starting maintenance procedure, be sure that following conditions are met or performed.
1. Park vehicle on a hard, flat, level surface.

2. Place transmission in neutral (or park, if automatic transmission).
3. Set parking brake.
4. Chassis air system should be within normal operating range of 100 to 120 psi.
5. Turn ignition switch to OFF.
6. Install wheel chocks to prevent motion either forward or reverse.
7. Disconnect battery ground terminal first, then battery positive cable.
8. There must not be any occupants in cab during maintenance procedures.
Troubleshooting Driveline Vibration
1. Check and record air ride height setting.
2. If air ride is not adjusted properly then readjust to proper specifications and road test to determine if
problem has been fixed.
3. Properly adjust ride height.
4. Visually inspect driveline for damage.
5. Inspect for dents or missing wights.
6. Inspect U-joints and yokes for excessive play. It is important to do this prior to re-lubricating joints.
7. Insure U-joint bearing cups are properly seated in yokes and that caps are not spinning.
83
DRIVELINE
8. Measure drive shaft run out in three (3) locations on each shaft.
9. For accurate measurements, paint should be removed first.
10. Measure three (3) inches from each end of and center of tube.
11. Inter-Axle shafts can be measured in the center only.
12. Mark ‘high’ spots at each location on tube.
13. Ends should be less than 0.020 in., ideally less than 0.010 in. and center should be less than 0.025
in., ideally less than 0.015 in.
14. If measurements exceed limits at either end, U-joint at end of shaft with high measurement should be
removed from yoke and reinstalled in yoke after rotating either yoke or shaft 180 degrees.
15. Re-measure run outs and note location of high spots.
16. If run out is still excessive, check to see if high spots moved on shaft approximately 180 degrees or if it
stayed in same spot.
17. Moving of high spot indicates yoke is out of round, not shaft.
18. If after having a driveline shop rebalance and/or straighten a shaft, if vibration remains, it is important to
again document run out and verify it is below limits mentioned in Step 13.
84
TABLE OF CONTENTS
Exhaust
Table of Contents
1. Aftertreatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Aftertreatment with Special Temperature Control For Stationary Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2. Engine Compression Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Cummins® Interbrake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Jacobs for N13 Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3. Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Aftertreatment Mounting w / A26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horizontal w / Single Vertical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horizontal w / Dual Vertical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Vertical w / Vertical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Day Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Horizontal / Single Vertical Tailpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Horizontal / Dual Vertical Tailpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Single Can. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Vertical / Single Vertical Tailpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Single Can. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Switchback Horizontal Aftertreatment and Dual Vertical Tail Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Horizontal / Horizontal Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Diesel Exhaust Fluid (DEF) Dosing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Decomposition Reactor Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Switchback Horizontal Aftertreatment and Single Vertical Tail Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Switchback Vertical Aftertreatment Device with Dual Cans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Vertical / Vertical Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield. . . . . . . . . . . . . . 125
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Power Distribution Module (PDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Aftertreatment Control Module (ACM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Horizontal Aftertreatment Device with Dual Vertical Tailpipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4. Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
85
TABLE OF CONTENTS
86
AFTERTREATMENT
1. Aftertreatment
Aftertreatment with Special Temperature Control For Stationary Applications
Overview
07BEW Aftertreatment with special temperature control, for stationary
applications
2. Engine Compression Brake

Cummins® Interbrake
Overview
07SAP Required with Cummins® ISX Engines - Engine Compression
Brake {Cummins®} interbrake for Cummins® Signature or ISX
engines; furnished with engine
This feature utilizes Jacobs dedicated cam compression release technology. Unit includes two engine brake
housings, special valve bridges, electronic interface with ECU and two dash switches. First switch is for
brake ON / OFF position. Second switch is for selecting braking power levels (low / medium / high) to meet
driving conditions.
87
ENGINE COMPRESSION BRAKE
Jacobs for N13 Engines

Overview
07SDK Optional with N13 Engines - Engine Compression Brake by Jacobs;
for N13 engines, with selector switch and ON / OFF
Figure 30 Engine Brake Control System Components

1. Upper Valve Cover 7. Engine Brake Master Piston (within
2. Injector Harness Connector Housing)
3. Engine Brake Solenoid Harness 8. Exhaust Valve Bridge
Connector Lead (2) 9. Engine Brake Slave Piston
4. Pass Through Harness 10. Valve Cover Base
5. ECM E1 Connector 11. Engine Brake Solenoid (1 each
6. Master Piston Roller Assembly (3 each Housing)
Housing) 12. Engine Brake Housing Assembly (2)
88
ENGINE COMPRESSION BRAKE
Braking system is a hydro-mechanical device that mounts under engine's valve cover. It turns power-producing
diesel engine into a power-absorbing air compressor.
Navistar® Engine Brake by Jacobs® uses exhaust back pressure to dramatically increase braking power by
restricting flow of exhaust gases and increasing back pressure inside engine.
When driver releases accelerator pedal, forward momentum of vehicle continues to turn drivetrain and engine.
Pistons continue to move up and down. Once activated, engine brake opens exhaust valves near peak of
compression stroke, releasing highly compressed air through exhaust systems. Little energy is returned to
piston, and as cycle repeats, energy of vehicle's forward motion is now directed toward motoring diesel engine,
thus reducing forward motion causing truck to slow down.
89
EXHAUST SYSTEM
3. Exhaust System
Aftertreatment Mounting w / A26
Horizontal w / Single Vertical
Overview
0007BLJ Exhaust system, single horizontal aftertreatment device, frame-mounted
right-side under cab; for single vertical tail pipe, right-side cab-mounted
Figure 31 Horizontal Exhaust with Vertical Tip Location

1. Horizontal / vertical exhaust
Single horizontal / vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), horizontal Selective Catalyst Reduction (SCR), and a single vertical tail pipe. There
are several variations of single horizontal / vertical exhaust systems on different trucks. All variations have the
same components and removal / installation procedures are similar for different variations.
90
EXHAUST SYSTEM
Horizontal w / Dual Vertical
Overview
0007BLK Exhaust system, single horizontal aftertreatment device, frame-mounted
right-side under cab; for dual vertical tail pipes, cab-mounted
Figure 32 Horizontal Exhaust with Dual Vertical Tip Location

1. Horizontal / dual vertical exhaust
Horizontal / dual vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), horizontal Selective Catalyst Reduction (SCR), and two vertical tail pipes. There are
several variations of horizontal / dual vertical exhaust systems on different trucks. All variations have the same
components and removal / installation procedures are similar for different variations.
91
EXHAUST SYSTEM
92
EXHAUST SYSTEM
Vertical w / Vertical
Overview
0007BKN Exhaust system, single vertical aftertreatment device, frame-mounted
right-side back of cab, single vertical tail pipe, for day cab
Figure 33 Vertical Exhaust Location

1. Vertical / vertical exhaust
Single vertical / vertical exhaust system consists of a vertical Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), vertical Selective Catalyst Reduction (SCR), and a single vertical tail pipe. There
are several variations of single vertical / vertical exhaust systems on different trucks. All variations have the
93
EXHAUST SYSTEM
94
EXHAUST SYSTEM
Day Cab
Horizontal / Single Vertical Tailpipe
Overview
0007BLK Exhaust system, single vertical aftertreatment device,
frame-mounted right side back of day cab, for single vertical tail pipe
Figure 34 Horizontal Exhaust with Vertical Tip Location

1. Horizontal / vertical exhaust
Single horizontal / vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), horizontal Selective Catalyst Reduction (SCR), and a single vertical tail pipe. There
are several variations of single horizontal / vertical exhaust systems on different trucks. All variations have the
95
EXHAUST SYSTEM
Horizontal / Dual Vertical Tailpipe
Overview
0007BLJ Exhaust system, single horizontal aftertreatment device, frame
mounted right side under cab; includes single vertical tail pipe and
guard, right side, cab mounted
Figure 35 Horizontal Exhaust with Dual Vertical Tip Location

1. Horizontal / dual vertical exhaust
Horizontal / dual vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), horizontal Selective Catalyst Reduction (SCR), and two vertical tail pipes. There are
several variations of horizontal / dual vertical exhaust systems on different trucks. All variations have the same
components and removal / installation procedures are similar for different variations.
96
EXHAUST SYSTEM
Single Can
Removal
Overview
Remove aftertreatment device for repair or replacement.
WARNING
WARNING
procedures.
Required Tools
• Suitable lifting device
1. Remove right side cover panel, steps, and step supports to gain access to aftertreatment device, if
necessary.
97
EXHAUST SYSTEM
Procedure
Figure 36 Single Can Aftertreatment

1. Tail pipe 6. Exhaust pipe
2. Tail pipe clamp 7. Exhaust pipe clamp
3. DEF hoses (2) 8. Support straps (2)
4. DEF doser 9. Aftertreatment device
5. Electrical connector
1. Disconnect electrical connector (5).
2. Disconnect two Diesel Exhaust Fluid (DEF) hoses (3) from DEF doser (4).
3. Remove exhaust pipe clamp (7) and move exhaust pipe (6) aside.
4. Remove tail pipe clamp (2) and move tail pipe (1) aside.
5. Using suitable lifting device, support aftertreatment device (9) from below.
6. Remove two support straps (8) from aftertreatment device (9) and remove from vehicle.
Follow-On Procedure
1. Install aftertreatment device. See Installation Single Can.
98
EXHAUST SYSTEM
Installation
Overview
Single can aftertreatment installation for replacement or repair.
WARNING
WARNING
procedures.
Required Tools
• 12 mm DPF Thread Repair Kit - 12-235-02
Support strap bolts 53 lb-in. (6 N·m)
Tail pipe clamp 89 - 133 lb-in. (10 - 15 N·m)
Exhaust pipe clamp 44 - 89 lb-in. (5 - 10 N·m)
1. Aftertreatment device removed. See Removal Single Can.
99
EXHAUST SYSTEM
Procedure

1. Tail pipe 6. Exhaust pipe
2. Tail pipe clamp 7. Exhaust pipe clamp
3. DEF hoses (2) 8. Support straps (2)
4. DEF doser 9. Aftertreatment device
1. Install ratchet straps as necessary.
2. Using suitable lifting device, support aftertreatment device (9).
3. Install aftertreatment device (9) to vehicle with support straps (8). Torque support strap bolts to 53 lb-in. (6
N·m).
4. Install tail pipe (1) to aftertreatment device (9) with tail pipe clamp (2). Torque clamp to 89 - 133 lb-in. (10
- 15 N·m).
5. Install exhaust pipe (6) to aftertreatment device (9) with exhaust pipe clamp (7). Torque clamp to 44 -
89 lb-in. (5 - 10 N·m).
6. Install two Diesel Exhaust Fluid (DEF) hoses (3) to DEF doser (4).
7. Install electrical connector (5).
Follow-On Procedure
1. Install right side cover panel, steps, and step supports if removed to gain access to aftertreatment
device.
100
EXHAUST SYSTEM
Vertical / Single Vertical Tailpipe
Overview
0007BKN Exhaust system, single vertical aftertreatment device,
frame-mounted right side back of cab, single vertical tail pipe, for
day cab
Figure 38 Vertical Exhaust Location

1. Vertical / vertical exhaust
Single vertical / vertical exhaust system consists of a vertical Diesel Particulate Filter (DPF) and Diesel
Oxidation Catalyst (DOC), vertical Selective Catalyst Reduction (SCR), and a single vertical tail pipe. There
are several variations of single vertical / vertical exhaust systems on different trucks. All variations have the
101
EXHAUST SYSTEM
Single Can
Removal
Overview
Remove aftertreatment device for repair or replacement.
WARNING
WARNING
procedures.
Required Tools
None
102
EXHAUST SYSTEM
Procedure

1. Heat shield mounting bolts and washers 5. DEF hoses (2)
(6) 6. DEF doser
2. Heat shield 7. Electrical connector
3. Aftertreatment device 8. Exhaust pipe
4. Support straps (3) 9. Exhaust pipe clamp
1. Remove six heat shield mounting bolts and washers (1) and remove heat shield (2) from aftertreatment
device (3).
3. Disconnect two Diesel Exhaust Fluid (DEF) hoses (5) from DEF doser (6).
4. Remove exhaust pipe clamp (9) and move exhaust pipe (8) aside.
5. Using suitable lifting device, support aftertreatment device (3) from above.
6. Remove three support straps (4) from aftertreatment device (3) and remove from vehicle.
103
EXHAUST SYSTEM
Follow-On Procedure
1. Install aftertreatment device. See Installation Single Can.
104
EXHAUST SYSTEM
Installation
Overview
Single can aftertreatment installation for replacement or repair.
WARNING
WARNING
procedures.
Required Tools
Support strap bolts 53 lb-in. (6 N·m)
Exhaust pipe clamp 44 - 89 lb-in. (5 - 10 N·m)
Heat shield mounting bolts and washers 21 - 24 lb-in. (29 - 32 N·m)
1. Aftertreatment device removed. See Removal Single Can.
105
EXHAUST SYSTEM
Procedure

1. Heat shield mounting bolts and washers 5. DEF hoses (2)
(6) 6. DEF doser
2. Heat shield 7. Electrical connector
3. Aftertreatment device 8. Exhaust pipe
4. Support straps (3) 9. Exhaust pipe clamp
1. Install ratchet straps as necessary.
2. Using suitable lifting device, support aftertreatment device (3).
3. Install aftertreatment device (3) to vehicle with three support straps (4). Torque support strap bolts to
53 lb-in. (6 N·m).
4. Install exhaust pipe (8) to aftertreatment device (3) with exhaust pipe clamp (9). Torque clamp to 44 -
89 lb-in. (5 - 10 N·m).
5. Install two Diesel Exhaust Fluid (DEF) hoses (5) to DEF doser (6).
6. Install electrical connector (7).
106
EXHAUST SYSTEM
7. Install heat shield (2) to aftertreatment device (3) with six heat shield mounting bolts and washers (1).
Torque mounting bolts to 21 - 24 lb-in. (29 - 32 N·m).
Follow-On Procedure
None
107
EXHAUST SYSTEM
Switchback Horizontal Aftertreatment and Dual Vertical Tail Pipes

Overview
07DXM Exhaust System Switchback Horizontal Aftertreatment Device,
frame mounted right side under cab; includes dual vertical tail pipes
and bright guards, cab mounted
10 ft. Exhaust height - based on empty chassis with standard
components (± 1 in. height)
07WBU Exhaust height 11 ft. 6 in.
07WCK Exhaust height 12 ft. 6 in.
Figure 41 Switchback Horizontal Aftertreatment with Dual Vertical Tail Pipes
Single horizontal / dual vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and
dual vertical tail pipes. There are several variations of single horizontal / dual vertical exhaust systems on
different series of trucks. All variations have same components and removal / installation procedures are
similar for different variations.
These systems are similar to single horizontal / vertical exhaust system. One main difference is that exhaust
is split into two tail pipes behind DPF.
108
EXHAUST SYSTEM
Horizontal / Horizontal Exhaust System
Removal

109
EXHAUST SYSTEM
Procedure
Figure 42 Horizontal / Horizontal Exhaust System

1. Diesel Exhaust Fluid (DEF) Dosing 5. Turbocharger Pipe V-band Clamp
Valve 6. DOC
2. DEF Tank Assembly Electrical 7. DPF
Connector 8. SCR Canister
3. Aftertreatment Assembly Mounting 9. Tailpipe V-band Clamp
Bracket Bolt (4)
4. Aftertreatment Assembly Mounting
Bracket
There are several configurations of aftertreatment system for different engines models. All variations have
similar removal / installation procedures.
While removing aftertreatment assembly from vehicle, pay special attention to how assembly is mounted.
Certain vehicle configurations may require assembly to be lifted or maneuvered to unseat mounting bolts
from frame brackets.
Depending on vehicle configuration, it may be necessary to remove side skirts and side skirt mounting brackets
prior to removing Switchback / Horizontal exhaust system assembly.
1. Loosen V-band clamp (5) securing turbocharger pipe to DOC (6) inlet.
2. Loosen V-band clamp (9) securing tailpipe to SCR canister (8) outlet.
3. Disconnect DEF tank assembly electrical connector (2) from aftertreatment assembly mounting bracket (4).
110
EXHAUST SYSTEM
Figure 43 Diesel Exhaust Fluid (DEF) Dosing Valve

1. Diesel Exhaust Fluid (DEF) Dosing 3. DEF Dosing Valve Coolant Line (2)
Valve Electrical Connector 4. DEF Dosing Valve
2. DEF Dosing Valve Pressure Line
To disconnect DEF lines from fittings, push inward on white quick-release clip.
4. Disconnect DEF pressure line (2) from DEF dosing valve (4).
5. Disconnect two DEF coolant lines (3) from DEF dosing valve.
6. Disconnect DEF dosing valve electrical connector (1) from DEF dosing valve.
7. Support DPF, DOC, SCR canister and aftertreatment assembly mounting bracket with suitable lifting
device.
8. Remove four bracket mounting bolts from aftertreatment assembly mounting bracket.
9. Lower DPF, DOC, SCR canister and aftertreatment assembly mounting bracket.
111
EXHAUST SYSTEM
Installation
V-band clamp nut 106 lb-in. (12 N·m)
Procedure
Figure 44 Horizontal / Horizontal Exhaust System

1. Diesel Exhaust Fluid (DEF) Dosing 4. Aftertreatment Assembly Mounting
Valve Bracket
2. DEF Tank Assembly Electrical 5. Turbocharger Pipe V-band Clamp
Connector 6. DOC
3. Aftertreatment Assembly Mounting 7. DPF
Bracket Bolt (4) 8. SCR Canister
9. Tailpipe V-band Clamp
1. Raise Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), and Selective Catalyst Reduction
(SCR) canister (6, 7, and 8) and aftertreatment assembly mounting bracket with suitable lifting device.
2. Align DOC inlet (6) with turbocharger pipe (5).
3. Align SCR canister (8) outlet with tailpipe (9).
4. Install four aftertreatment assembly mounting bracket bolts (3) to vehicle frame.
5. Secure turbocharger pipe to DOC (6) with V-band clamp (5). Torque V-band clamp nut to 106 lb-in. (12
N·m).
112
EXHAUST SYSTEM
6. Secure tailpipe to SCR canister (8) outlet with V-band clamp (9). Torque V-band clamp nut to 106
lb-in. (12 N·m).
7. Connect DEF dosing valve electrical connector (1) to DEF dosing valve (4).
8. Connect two DEF coolant lines (3) to DEF dosing valve.
9. Connect DEF pressure line (2) to DEF dosing valve.
10. Connect DEF tank assembly electrical connector (2) to aftertreatment assembly mounting bracket (4).
113
EXHAUST SYSTEM
Diesel Exhaust Fluid (DEF) Dosing Valve
Removal

114
EXHAUST SYSTEM
Procedure

1. Dosing Valve Pressure Line 6. Dosing Valve Thermal Isolator
2. Dosing Valve Mounting Bolt (3) 7. Dosing Valve Spray Port
3. Dosing Valve Electrical Connector 8. Dosing Valve
4. Dosing Valve Mounting Bolt Spacer (3) 9. Dosing Valve Coolant Line (2)
5. Dosing Valve Gasket
1. Disconnect pressure line (1) from dosing valve (8).
2. Disconnect two (2) coolant lines (9) from dosing valve.
3. Disconnect dosing valve electrical connector (3) from dosing valve.
4. Remove three (3) dosing valve mounting bolts (2) and spacers (4) from dosing valve.
5. Remove dosing valve and gasket (5) from dosing valve spray port (7). Discard gasket.
6. Remove dosing valve thermal isolator (6) from dosing valve spray port (7). Discard isolator.
115
EXHAUST SYSTEM
Installation
Procedure

1. Dosing Valve Pressure Line 6. Dosing Valve Thermal Isolator
2. Dosing Valve Mounting Bolt (3) 7. Dosing Valve Spray Port
3. Dosing Valve Electrical Connector 8. Dosing Valve
4. Dosing Valve Mounting Bolt Spacer (3) 9. Dosing Valve Coolant Line (2)
5. Dosing Valve Gasket
1. Install new dosing valve thermal isolator (6) into dosing valve spray port (7) with tapered end facing
dosing valve (8).
2. Install new dosing valve gasket (5) onto bottom of dosing valve with metallic side facing dosing valve.
3. Install dosing valve and gasket to dosing valve spray port using three (3) dosing valve mounting bolts (2).
4. Connect pressure line (1) to dosing valve.
5. Connect two (2) coolant lines (9) to dosing valve.
6. Connect dosing valve electrical connector (3) to dosing valve.
116
EXHAUST SYSTEM
Decomposition Reactor Tube
Removal

117
EXHAUST SYSTEM
Procedure
Figure 47 Decomposition Reactor Tube

1. V-clamp (4) 4. Diesel Oxidation Catalyst (DOC)
2. Decomposition Reactor Tube Outlet 5. Decomposition Reactor Tube
3. Selective Catalyst Reduction (SCR) 6. Diesel Particulate Filter (DPF)
Canister 7. Decomposition Reactor Tube Inlet
1. Loosen V-clamp (1) securing decomposition reactor tube outlet (2) to SCR canister (3) inlet.
2. Loosen V-clamp securing decomposition reactor tube outlet to decomposition reactor tube (5).
3. Remove decomposition reactor tube outlet.
4. Loosen V-clamp securing decomposition reactor tube to decomposition reactor tube inlet (7).
5. Remove decomposition reactor tube.
6. Loosen V-clamp securing decomposition reactor tube inlet to DPF (6) outlet.
7. Remove decomposition reactor tube inlet.
118
EXHAUST SYSTEM
Installation
V-clamps 100 lb-in. (11.3 N·m)
Procedure
Figure 48 Decomposition Reactor Tube

1. V-clamp (4) 4. Diesel Oxidation Catalyst (DOC)
2. Decomposition Reactor Tube Outlet 5. Decomposition Reactor Tube
3. Selective Catalyst Reduction (SCR) 6. Diesel Particulate Filter (DPF)
Canister 7. Decomposition Reactor Tube Inlet
1. Secure decomposition reactor tube inlet (7) to DPF (6) outlet with V-clamp (1).
2. Secure decomposition reactor tube (5) to decomposition reactor tube inlet with V-clamp.
3. Secure decomposition reactor tube outlet (2) to decomposition reactor tube with V-clamp.
4. Secure decomposition reactor tube outlet to SCR canister (3) inlet using V-clamp.
5. Tighten four (4) V-clamps to 100 lb-in. (11.3 N·m).
119
EXHAUST SYSTEM
Switchback Horizontal Aftertreatment and Single Vertical Tail Pipes

Overview
07BJU Exhaust System Switchback Horizontal Aftertreatment Device,
frame mounted right side under cab; includes single vertical tail pipe
and guard, right side, cab mounted
Figure 49 Switchback Horizontal Aftertreatment with Single Vertical Tail Pipe
Single horizontal / vertical exhaust system consists of a horizontal Diesel Particulate Filter (DPF) and a
vertical tail pipe. There are several variations of single horizontal / vertical exhaust systems on different
series of trucks. All variations have same components and removal and installation procedures are similar
for different variations.
120
EXHAUST SYSTEM
Switchback Vertical Aftertreatment Device with Dual Cans

Overview
07BJX Exhaust System Switchback Vertical Aftertreatment Device, dual
cans, frame mounted left and right; includes single vertical tail pipe
and dual guards
Figure 50 Switchback Vertical Aftertreatment Exhaust System with Dual Cans
Two-can system uses two separate cans for Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter
(DPF).
121
EXHAUST SYSTEM
Vertical / Vertical Exhaust System
Removal

Procedure
Figure 51 Vertical / Vertical Exhaust System

1. Diesel Particulate Filter (DPF) Interface 3. Decomposition Reactor Tube Inlet
Module 4. Tailpipe
2. DPF
122
EXHAUST SYSTEM
5. Selective Catalyst Reduction (SCR) 8. Diesel Exhaust Fluid (DEF) Dosing

Interface Module Valve
6. SCR Canister 9. Turbocharger Pipe
7. Decomposition Reactor Tube 10. Diesel Oxidation Catalyst (DOC)
Removal and installation procedures for Vertical / Vertical exhaust system are similar to Switchback system.
Depending on vehicle configuration, specific component location may vary. This section will provide removal
and installation procedures for components that differ from Switchback exhaust system.
1. Remove Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) heat shield (page 125).
2. Remove Power Distribution Module (PDM) (page 129).
3. Remove Aftertreatment Control Module (ACM) (page 131).
123
EXHAUST SYSTEM
Installation
None
Procedure
1. Install Aftertreatment Control Module (ACM) (page 133).
2. Install Power Distribution Module (PDM) (page 130).
3. Install Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) heat shield (page 127).
124
EXHAUST SYSTEM
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield
Removal

Procedure
Figure 52 Heat Shield

1. Heat Shield Mounting Bolt (4) 2. Heat Shield
1. Remove four (4) heat shield mounting bolts (1) from heat shield (2).
125
EXHAUST SYSTEM
2. Remove heat shield from DPF or SCR canister.
126
EXHAUST SYSTEM
Installation
None
Procedure
Figure 53 Heat Shield

1. Heat Shield Mounting Bolt (4) 2. Heat Shield
1. Install heat shield (2) to DPF or SCR canister.
2. Install four (4) heat shield mounting bolts (1) to heat shield.
127
EXHAUST SYSTEM
Power Distribution Module (PDM)
Removal

Procedure
Figure 54 PDM
1. Diesel Exhaust Fluid (DEF) Tank 3. PDM
2. PDM Mounting Bolt
Optional PDM location, depending on vehicle configuration.
128
EXHAUST SYSTEM
1. Remove PDM mounting bolt (2) from DEF tank (1).
2. Remove PDM (3) from DEF tank.
129
EXHAUST SYSTEM
Installation
PDM mounting bolt 35 lb-in. (4 N·m)
Procedure
Figure 55 PDM
1. Diesel Exhaust Fluid (DEF) Tank 3. PDM
2. PDM Mounting Bolt
1. Install PDM (3) to DEF tank (1).
2. Install PDM mounting bolt (2) to DEF tank. Torque bolts to 35 lb-in. (4 N·m).
130
EXHAUST SYSTEM
Aftertreatment Control Module (ACM)
Removal

Procedure
Figure 56 ACM
1. Left Cab 3. ACM
2. ACM Connector 4. ACM Mounting Bolt (3)
Optional ACM location, depending on vehicle configuration.
131
EXHAUST SYSTEM
1. Unplug ACM connector (2) from ACM (3).
2. Remove three (3) ACM mounting bolts (4) from ACM.
3. Remove ACM from vehicle.
132
EXHAUST SYSTEM
Installation
None
Procedure
Figure 57 ACM
1. Left Cab 3. ACM
2. ACM Connector 4. ACM Mounting Bolt (3)
1. Install ACM (3) under left cab (1).
2. Install three (3) ACM mounting bolts (4) to ACM.
3. Connect ACM connector (2) to ACM.
133
EXHAUST SYSTEM
Horizontal Aftertreatment Device with Dual Vertical Tailpipes

Overview
0007DWX Exhaust system, single horizontal aftertreatment device,
frame-mounted right side under sleeper, includes bright dual vertical
tailpipes and bright swept back design guards, cab B pillar-mounted
Figure 58 Horizontal Exhaust with Dual Vertical Tailpipes

1. Horizontal aftertreatment device
The single horizontal / vertical exhaust system consists of a Cummins® Selective Catalyst Reduction (SCR)
Aftertreatment with insulated housing and a dual vertical tailpipe.
134
TORQUE
4. Torque
Description Torque
Aftertreatment Out / tailpipe V-band Clamp Nut 106 lb-in. (12 N·m)
Aftertreatment In / Turbo Pipe V-band Clamp Nut 106 lb-in. (12 N·m)
Decomposition Reactor Tube V-clamps 100 lb-in. (11.3 N·m)
Mount Bands 97 lb-in. (11 N·m)
Aftertreatment Power Distribution Module (PDM) Mount Bolts 35 lb-in. (4 N·m)
135
TORQUE
136
TABLE OF CONTENTS
Electrical / Software
Table of Contents
1. Diagnostic Trouble Code (DTC) List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2. Electronic Service Tools (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Diamond Logic® Builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Selecting an Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Connecting to a Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Activating Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Starting a Session. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Viewing Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Clearing Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Modifying Signals Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Programming Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Input Not Recognized by Body Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Output Not Commanded by Body Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3. General Electrical Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Electrical Connector Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4. 12 Volt Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Battery Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Battery Reconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Battery Terminal Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Starting and Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
No Click No Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Click No Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Low Cranking Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
No Starter Input Signal (Automated Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . .183
No Starter Input Signal (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
No Starter Input Signal (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Battery Gauge Reading High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Battery Gauge Reading Low / Fluctuating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Low Battery Warning / Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
Repeated Jump Starts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Battery Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Cable Drop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Electrical System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Starter System Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Charging System Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Manual Engine Bar Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Parasitic Draw Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Starter Control Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
137
TABLE OF CONTENTS
Electrical System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254

Ring Gear Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
5. Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Sleeper-Mounted Radio Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6. Aftertreatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Parked Regeneration Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
HEST Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7. Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Air - Anti-Lock Brake (ABS) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Bendix® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Air - Automatic Traction Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Bendix® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Air - Electronic Stability Control (ESC) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Bendix® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8. Chassis Body Building Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Tail and Marker Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Left Turn Light Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Right Turn Light Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Back Up Light Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Accessory Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Stop Light Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Trailer Lighting Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Remote Cruise Control Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
9. Collision Avoidance Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Collision Mitigation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Bendix® Wingman® Advanced™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
Radar Sensor Electrical Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Radar Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Radar Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Radar Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
10. Data Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

CAN Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Module Communication Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332
11. Drivetrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Driver Controlled Locking Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
12. Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Cummins® Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid
But Above Normal Operating Range - Least Severe Level. . . . . . . . . . . . . . . . . . . . . . . .373
138
TABLE OF CONTENTS
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition
Exists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement -
Data Valid But Above Normal Operating Range - Most Severe Level. . . . . . . . . . . .436
Data Valid But Above Normal Operating Range - Least Severe Level. . . . . . . . . . .437
Data Valid But Above Normal Operating Range - Moderately Severe Level. . . .438
DEFTHV Coolant Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .444
13. Exterior Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Beacon Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Work Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
14. HVAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Blower Not Working Properly for One or More Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
HVAC System Air Not Cool After A/C Turned ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
HVAC System Air Not Warm After Heat Turned ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Air Not Flowing Out Correct HVAC Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Tests and Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Blower Speeds Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Static Refrigerant Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
High and Low Side Refrigerant Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
HVAC Air Flow Control Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Base A/C System Compressor Clutch Control Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
APADS A/C System Compressor Clutch Control Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
A/C Compressor Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
15. Instruments / Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

Auxiliary Gauge Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Air Application Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Air Cleaner Restriction Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Eaton Ultrashift Shifter Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Manifold Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Rear Axle Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Rear Suspension Air Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Instrument Cluster Display Readouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Air Tank Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Coolant Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Diesel Exhaust Fluid (DEF) Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
Engine Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Engine Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Fuel Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Transmission Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Park Brake Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
16. Lighting Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

Turn, Hazard, and Brake Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
139
TABLE OF CONTENTS

Turn, Hazard or Brake Lights Not Illuminating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
Turn and Hazard Lights Input Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
Fog Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Fog Lights Not Illuminating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
High Beam Headlights Not Illuminating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
High Beam Headlights Illuminate When Not Requested. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Flash-To-Pass Not Illuminating Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
Brake Switch Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
Brake Switch Input Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
Park / Marker Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Work Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
17. Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675

RollTek Supplemental Restraint System (SRS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
Operational Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
18. Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681

Allison Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
Push Button Shift Control (Allison). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
PTO Controls Dash Mounted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
19. Windshield Wiper System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689

Windshield Wiper Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
Windshield Wiper Input 0 Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Windshield Wiper Low Speed Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
Windshield Wiper High Speed Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
Windshield Washer Pump Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760
Windshield Wipers Not Working when Washer Pump Activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766
Windshield Washer Pump and Wipers Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769
140
DIAGNOSTIC TROUBLE CODE (DTC) LIST
1. Diagnostic Trouble Code (DTC) List

SPN FMI Condition Description
158 15 ECM Switched Voltage Too HIGH - Go to appropriate Engine Diagnostic Manual for
additional diagnostic information.
158 17 ECM Switched Voltage Too LOW - Go to appropriate Engine Diagnostic Manual for
additional diagnostic information.
597 0 Brake Switch Reading Above Normal Range(page 640)
597 1 Brake Switch Reading Below Normal Range(page 642)
597 7 Brake Switch Stuck Open or Closed (failed brake switch)
1761 1 Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal
Operating Range - Most severe Level (page 375)
1761 3 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal
or Shorted to High Source (page 376)
1761 4 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Voltage Below Normal or
Shorted to Low Source (page 377)
1761 9 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Abnormal Update Rate (page 378)
1761 10 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change
(page 387)
1761 11 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Root Cause Not Known (page
388)
1761 13 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration (page 389)
Operating Range - Least Severe Level (page 390)
Operating Range - Moderately Severe Level (page 391)
2368 5 Left Front Turn Lamp Undercurrent
2368 6 Left Front Turn Lamp Over Current
2370 5 Right Front Turn Lamp Undercurrent
2370 6 Right Front Turn Lamp Over Current
2372 5 Left Rear Turn Lamp Undercurrent
2372 6 Left Rear Turn Lamp Over Current
2374 5 Right Rear Turn Lamp Undercurrent
2374 6 Right Rear Turn Lamp Over Current
2376 2 Faulty Turn Switch
2378 5 Park Lights Undercurrent(page 666)
2378 6 Park Lights Overcurrent (page 671)
2387 2 Fog Light Switch Error
2388 5 Left Fog Light Open Circuit
2388 6 Left Fog Light Short to Ground
141

2636 5 Wiper ON / OFF Relay Under Current or Open Circuit(page 739)
2636 6 Wiper ON / OFF Relay Over Current(page 741)
2637 5 Wiper High / Low Relay Under Current or Open Circuit(page 743)
2637 6 Wiper High / Low Relay Over Current(page 745)
2653 5 Left Low Beam Open Circuit(page 587)
2653 6 Left Low Beam Short to Ground(page 590)
2655 5 Right Low Beam Open Circuit(page 592)
2655 6 Right Low Beam Short to Ground(page 595)
3031 2 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent,
or Incorrect (page 392)
3031 3 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal
or Shorted to High Source (page 393)
3031 4 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal
or Shorted to Low Source (page 394)
3031 9 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate (page
395)
3031 11 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known (page
404)
3031 13 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration
(page 405)
3364 2 Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect
(page 406)
3364 3 Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or
Shorted to High Source (page 407)
3364 4 Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or
Shorted to Low Source (page 409)
3364 9 Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate (page 411)
3364 10 Aftertreatment Diesel Exhaust Fluid Quality Abnormal Rate of Change (page 419)
3364 11 Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known (page 422)
3364 13 Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration (page 423)
3364 15 Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating
Range - Least Severe Level (page 424)
3364 18 Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating
Range - Moderately Severe Level (page 426)
3521 11 Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known (page 428)
3521 16 Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating
3521 18 Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating
142

3521 31 Aftertreatment 1 Diesel Exhaust Fluid Property - Condition Exists (page 433)
3695 2 Regen Inhibit Switch Error
3695 6 Open Circuit in Regen Inhibit Switch Indicator Circuit
3696 2 Parked Regen Switch Error
3696 5 Open Circuit in Regen Switch Indicator Circuit
3696 6 Over Current for Parked Regen Switch Indicator
4008 5 Right Fog Light Open Circuit
4008 6 Right Fog Light Short to Ground
4011 5 Left High Beam Open Circuit(page 625)
4011 6 Left High Beam Short to Ground(page 628)
4012 5 Right High Beam Open Circuit(page 630)
4012 6 Right High Beam Short to Ground(page 633)
4057 5 Wiper Motor Under Current(page 747)
4057 5 Wiper Motor Over Current(page 753)
4096 31 Aftertreatment Diesel Fluid Tank Empty - Condition Exist (page 435)
143
ELECTRONIC SERVICE TOOLS (EST)
2. Electronic Service Tools (EST)

Diamond Logic® Builder
Overview
Figure 59 Diamond Logic Builder
The Navistar® Diamond Logic® Builder (DLB) software provides the ability to program, diagnose and simulate
features in the Body Control Module (BCM) module. The software also allows users to read fault codes, live
vehicle data, configure switches, manipulate the gauge cluster, and modify parameters programmed in the
BCM. DLB is also used to program modules with updated or correct software.
For additional information on DLB, see the Diamond Logic® Builder Software user guide.
144
Procedures
Selecting an Interface Cable (page 146)
Connecting to a Vehicle (page 148)
Activating Diagnostic Mode (page 150)
Starting a Session (page 152)
Viewing Fault Codes (page 154)
Clearing Fault Codes (page 155)
Modifying Signals Tab (page 156)
Programming Modules (page 158)
Input Not Recognized by Body Control Module (page 163)
Output Not Commanded by Body Control Module (page 165)
145
Selecting an Interface Cable
Overview
Instructs how to choose an interface device in Diamond Logic® Builder (DLB) software. A new interface cable
selection should be made when using different interface cable.
Special Tools
• Electronic Service Tool (EST) with DLB software
• Interface Cable (RP1210B compliant supporting J1939 and J1708)
None
Selection Procedure
Figure 60 Com Link Selection Drop-Down Menu

1. Tools drop-down menu 2. Select Com Link
1. Start DLB software on EST.
2. Select Tools drop-down menu (1).
146
3. Hover over Select Com Link (2) and choose appropriate interface cable connection.
Figure 61 Com Link Activation Drop-Down Menu

1. Tools drop-down menu 2. Activate Com Link
5. Select Activate Com Link (2).
Follow-On Procedure
1. Connecting to a Vehicle (page 148).
147
Connecting to a Vehicle
Overview
Instructs how to connect Diamond Logic® Builder (DLB) software electronically to a vehicle. When connected,
the Selected Module and Detected Module information tables in the lower right corner of the DLB screen
should match.
Special Tools
1. DLB started.
2. Interface cable connected to EST and selected in DLB (page 146).
Connection Procedure
1. Connect the interface cable to the vehicle diagnostic connector with Key OFF. Cable power light will
be illuminated (if applicable).
Figure 62 Connected Icon
148
Figure 63 Disconnected Icon
2. A detection process will begin, connecting to the vehicle automatically.

a. When software connects, active signals populate startup screen, and connected icon in bottom right
corner will show.
b. When software does not connect, signals and vehicle information will not be displayed, and
disconnected icon in bottom right corner will show. Perform Interface Device Selection (page 146).
Follow-On Procedure
1. Activating Diagnostic Mode (page 150).
149
Activating Diagnostic Mode
Overview
Instructs how to activate Diamond Logic® Builder (DLB) software diagnostic mode. Diagnostic mode is
used to view live data on DLB. With the mode deactivated, live voltages and current fault codes for vehicle
will not be shown.
Special Tools
1. Connected to a vehicle (page 148).
Activation Procedure
1 2
3
0000428351
Figure 64 Diagnostic Drop-Down Menu

1. Diagnostics drop-down menu 3. Status bar
2. Diagnose
1. Select Diagnostics drop-down menu (1).
150
2. Select Diagnose (2).
3. Wait for the status bar to finish loading (3).
Follow-On Procedure
None
151
Starting a Session
Overview
Instructs how to start a session for a software feature code in Diamond Logic® Builder (DLB) software.
Special Tools
2. Diagnostic Mode activated (page 150).
Starting Procedure
Figure 65 Features Tab

1. Features tab 3. Feature row
2. Make Session button
1. Select Features tab (1).
2. Find and select desired Feature (3) to highlight the row, or hold CTRL and select multiple Features (3) to
highlight multiple rows.
Filter icon next to Feature title in table title row can be selected to activate a search function. Feature
codes or words can be used to find features.
152
3. Select Make Session (2).
Follow-On Procedure
1. Modifying Signals Tab (page 156).
153
Viewing Fault Codes
Overview
Instructs how to view diagnostic fault codes in Diamond Logic® Builder (DLB) software.
Special Tools
1. Connected to a vehicle (page 148)
2. Diagnostic Mode activated (page 150)
Viewing Procedure
Figure 66 Viewing Faults

1. Faults tab 2. Active column
1. Key ON.
2. Select Faults tab (1) and look for fault codes with check marks in the Active column (2).
Follow-On Procedure
None
154
Clearing Fault Codes
Overview
Instructs how to clear diagnostic fault codes in Diamond Logic® Builder (DLB) software.
Special Tools
Clearing Procedure
Figure 67 Clearing Faults

1. Diagnostics drop-down menu 2. Erase Faults...
1. Select Diagnostics drop-down menu (1).
2. Select Erase Faults... (2).
Follow-On Procedure
None
155
Modifying Signals Tab
Overview
Instructs how to modify the signals tab for a software feature code in Diamond Logic® Builder (DLB) software.
Special Tools
3. Session started(page 152) with appropriate feature code.
Modify Watched Signal Columns
Figure 68 Modifying Data Columns

1. Data title bar 3. Signals tab
2. Watched tab 4. Data column options
1. Select Signals tab (3).
2. Select Watched tab (2).
3. Right click in the data title bar (1).
156
4. Select desired data column options (4) to be monitored. It is recommended to monitor the following at a
minimum: Signal, Pins, Value, Unit, Status, Signal Type, Description, Lock.
Modify Watched Signals
Figure 69 Modifying Signals

1. Watched Signals tab 3. Watch / Unwatch button
2. Signals tab
5. Select Signals tab (2).
6. Select Watched tab (1).
7. Select Watch / Unwatch (3) to stop watching undesired signals. Hovering over a row generates a pop
up box that provides the full description of a signal. Clicking in a row will show a description in a box at
the bottom of the DLB screen.
Follow-On Procedure
None
157
Programming Modules
Overview
Instructs how to program modules using Diamond Logic® Builder (DLB) software. Module programming can
take up to 40 minutes to complete depending on how many modules are being programmed.
Special Tools
1. Batteries at full charge and battery charger connected.
2. EST connected to constant power so power is not lost during programming.
3. Ensure Vehicle Identification Number (VIN) is deleted from the VIN list under the Select tab.
4. Connected to a vehicle(page 148) with Key ON.
158
Programming Procedure
Figure 70 Detected Modules Tab and Kernels

1. Kernel column 4. Kernel
2. Detected Kernel column 5. Title bar
3. Detected Kernel 6. Detected Modules tab
1. Select on Detected Modules tab (6).

a. There may be as many as five multiplexed (MUX) switch packs installed on the vehicle. Ensure all
MUX switch packs are appearing as detected.
2. Right click in Detected Modules tab title bar (5).
3. Select Kernel (4) and Detected Kernel (3) to view as columns (1, 2) in Detected Modules (6) list.
159
Figure 71 Software Updating

1. Update Software 4. Update All Software
2. Edit drop-down menu 5. Kernel
3. Update Module 6. Selected Module Kernel
4. Select Edit drop-down menu (2).
5. To update single module, highlight desired module in module list, hover over Update Software (1) and
select Update Module (3).
6. To update all modules, hover mouse over Update Software (1) and select Update Module (3).
7. Kernel (5) / Selected Module Kernel (6) versions will update to a newer version if one is available.
160
Figure 72 Programming
1. Tools drop-down menu 4. Message bar
2. Program button 5. Program
3. Program Module button
9. To program single module, highlight desired module in module list, hover over Program (5) and select
Program Module (3).
10. To program all modules, hover mouse over hover over Program (5) and select Program (2).
11. Answer any prompts that appear appropriately (if applicable).
12. Messages will be displayed in the message bar (4) showing the programming status during programming.
a. Vehicle headlights can turn ON then OFF during programming if the Lighting Control Module (LCM) is
being reprogrammed.
13. Let programming complete for all modules. Pauses may occur prior to programming completing.
161
Figure 73 Completing Programming

1. Kernel 3. Selected Module Detected Kernel
2. Detected Kernel 4. Selected Module Kernel
14. Verify in Detected Modules tab that Kernel (1) and Detected Kernels (2) match when programming is
complete. The Selected Module Kernel (4) and Selected Module Detected Kernel (3) can also be verified
on the right.
Follow-On Procedure
None
162
Input Not Recognized by Body Control Module
Overview
Instructs how to troubleshoot an input to the Body Control Module (BCM) that does not activate the component
it controls using Diamond Logic® Builder (DLB) software.
Special Tools
• 180-pin Breakout Box, 00-00956-08
• Breakout Harness, 08-854-01
• Terminal Test Kit, ZTSE4435C
• Digital Multimeter (DMM)
Troubleshooting Procedure
Step 1 Force input ON to verify BCM output operation Decision
1. Go to Signals tab and select Watched tab. Yes: Hard-wired BCM input,
Go to Step 2.
2. Ensure all feature interlocks and inhibitors are met, and ensure
Lock column has inputs and outputs unlocked. Yes: J1939 BCM input, Go
to Controller Area Network
3. Force input ON by checking the check box in the Value column
(CAN) Diagnostics (page
next to the appropriate input signal, and look for output to turn
329).
ON.
Does output turn ON? No: Go to Output Not
Commanded by Body Control
Module (page 165).
Step 2 Inspect connections at appropriate input connector Decision

1. Key OFF. Disconnect appropriate input connector. Yes: Go to Step 3.
2. Check connector and connector terminals for: damaged or
pinched wires; moisture or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are connector, harness, and terminals clean and undamaged? No: Repair connector,
harness, or terminal damage.
After repairs are complete,
retest for symptom.
163
Step 3 Check input signal to BCM Decision

1. Key OFF. Disconnect appropriate BCM connector for input Yes: Perform BCM
being tested. diagnostics. After repairs
are complete, retest for
2. Connect Breakout Box to Breakout Harness and connect
symptom.
Breakout harness to appropriate BCM connector.
3. Insert proper terminal from Terminal Test Kit to appropriate
BCM connector input pin.
4. Key ON. Input ON. Use DMM to measure voltage between
appropriate input pin and either battery power or ground.
Is voltage within valid range for specific input operation? No: Repair circuit(s) between
input component and BCM.
retest for symptom.
Follow-On Procedure
None
164
Output Not Commanded by Body Control Module
Overview
Instructs how to troubleshoot outputs that are not turned on by the Body Control Module (BCM) using Diamond
Logic® Builder (DLB) software.
Special Tools
Troubleshooting Procedure
Step 1 Force output ON to verify BCM output operation Decision
1. Go to Signals tab and select Watched tab. Yes: Go to Input Not
Recognized by Body Control
2. Ensure Lock column has inputs and outputs unlocked.
Module (page 163).
3. Force output ON by checking the check box in the Value column
next to the appropriate output signal, and look for output to turn
ON.
Does output turn ON? No: J1939 BCM output, Go
to Controller Area Network
(CAN) Diagnostics (page
329).
No: Hard-wired BCM output,
Go to Step 2.
Step 2 Inspect connections at appropriate output connector Decision

1. Key OFF. Disconnect appropriate output connector. Yes: Go to Step 3.
2. Check connector and connector terminals for: damaged or
Are connector, harness, and terminals clean and undamaged? No: Repair connector,
retest for symptom.
165
Step 3 Check output signal from BCM Decision

1. Key OFF. Disconnect appropriate BCM connector for output Yes: Repair circuit(s) between
being tested. output component and BCM.
2. Connect Breakout Box to Breakout Harness and connect
retest for symptom.
Breakout harness to appropriate BCM connector.
3. Insert proper terminal from Terminal Test Kit to appropriate BCM
connector output pin.
4. Key ON. Output ON. Use DMM to measure voltage between
appropriate output pin and either battery power or ground.
Is voltage within valid range for specific output operation? No: Perform BCM
diagnostics. After repairs
symptom.
Follow-On Procedure
None
166
GENERAL ELECTRICAL REPAIR
3. General Electrical Repair

Electrical Connector Cleaning
Overview
Instructs how to properly clean corroded or dirty electrical connectors and terminals.
Special Tools
• Electrical Contact Cleaner
• Dielectric Grease
Specifications
None
2. Key OFF.
Cleaning Procedure
1. Locate connector needing cleaning.
2. Clean the outside of the connector with electrical contact cleaner.
3. Disconnect connector halves.
4. Clean the terminals on both connector halves with electrical contact cleaner.
5. Dry connector halves and terminals with compressed air.
6. Apply a small amount of dielectric grease to connector terminals.
7. Connect connector halves.
8. Remove excess dielectric grease from outside of connector.
Follow-On Procedure
1. Reconnect batteries (page 171).
167
12 VOLT ELECTRICAL SYSTEM
4. 12 Volt Electrical System

Battery Box
Overview
Feature Code Feature Description

0008VUK Battery Box Aluminum With Plastic Cover, 18" Wide, 2, 3, or 4 Battery
Capacity, Mounted Right Side Back of Cab
0008WJN Battery Box Aluminum With Plastic Cover, 30" Wide, 2, 3 or 4 Battery
Capacity, Mounted Left Side Under Cab
0008TST Battery Box Aluminum With Plastic Cover, 30" Wide, 2, 3 or 4 Battery
Capacity, Mounted Right Side Under Cab
0008VUV Battery Box Omit, Batteries to be Mounted Temporarily, Body Builder to
Supply Battery Box
0008WGU Battery Box Cover Aluminum
0008VUH Battery Box Cover Polished Aluminum
0008VUS Battery Box Cover Polished Aluminum, Universal Cover that Covers Both
Battery Box & DEF Tank
0008WWD Battery Box Stainless Steel, Bright Finish
0008RLZ Battery Disconnect Switch (Cole-Hersee) 300 Amp; Battery Box Mounted,
Disconnects Cab Power, Does Not Disconnect Charging Circuits, Locks
with Padlock
0008WXY Battery Disconnect Switch (Cole-Hersee) for Cab Power Disconnect Switch,
Lever Operated, Does Not Disconnect Charging Circuits, Cab Mounted
0008MLM Battery System (International) Maintenance-Free (3) 12-Volt 2250CCA Total
0008MKX Battery System (International) Maintenance-Free (3) 12-Volt 2775CCA Total
0008MUE Battery System (International) Maintenance-Free (4) 12-Volt 2600CCA Total
0008MHD Battery System (International) Maintenance-Free (4) 12-Volt 3700CCA Total
0008MKL Battery System (International) Maintenance-Free, (3) 12-Volt 1950CCA
Total
Figure 74 Location View

1. Possible battery box locations
There are 2 - 4 batteries located in one of several locations (see Location View ). These batteries are wired
in parallel, with multiple jumper cables connecting positive terminals on one battery to positive terminals on
the others (and ground jumpers for ground terminals). Main cables exit the battery box to power and ground
sources, providing power from all batteries to the rest of the truck. In order to interrupt electricity flow, ALL
main ground cables must be removed.
If the vehicle is equipped with an auxiliary battery box, those batteries need to be disconnected as well.
168
Battery Disconnect
Overview
1 2
4
0000418895
Figure 75 Typical Battery Wiring

1. Main positive cables 3. Ground jumpers
2. Main ground cables 4. Positive jumpers
Special Tools
None
None
2. Key OFF.
169
Disconnect Procedure
1. If vehicle is equipped with Battery Disconnect Switch, turn switch off and skip following steps. See Battery
Disconnect Switch (page 175) for more information.
2. Remove battery box cover.
3. Remove all main ground cables (main cables are typically larger, exit the battery box, and connect to frame)
4. If vehicle is equipped with auxiliary battery box, perform steps 2 and 3 for auxiliary batteries.
5. If leaving disconnect for a long period of time, fasten cables away from ground terminals, and reinstall or
safely store battery box cover.
Follow-On Procedure
None
170
Battery Reconnect
Overview
1 2
4
0000418895

Special Tools
None
Terminal Battery Nut (Non Litium-based Tribotuff) 12 to 15 lb-ft (16.3 to 20.3 N·m)
Terminal Battery Nut (Litium-based Tribotuff) 15.5 to 19 lb-ft (21 to 25.8 N·m)
2. Key OFF.
171
Reconnect Procedure
1. If vehicle is equipped with Battery Disconnect Switch, turn switch ON. See Battery Disconnect Switch
(page 175) for more information.
2. Remove battery box cover, if installed.
3. Connect ALL main ground cables and jumper cables to proper terminals. Tighten terminal battery nuts to
proper torque specification.
4. If vehicle is equipped with auxiliary battery box, perform steps 2 and 3 for auxiliary batteries.
5. Install battery box cover.
6. Verify vehicle starts properly.
Follow-On Procedure
None
172
Battery Terminal Cleaning
Overview
Instructs how to properly clean corroded or dirty battery terminals.
1 2
4
0000418895

Special Tools
• Electrical Contact Cleaner
• Electrical Sealer Paste
Terminal Battery Nut (Non Litium-based Tribotuff) 12 to 15 lb-ft (16.3 to 20.3 N·m)
Terminal Battery Nut (Litium-based Tribotuff) 15.5 to 19 lb-ft (21 to 25.8 N·m)
173
2. Key OFF.
4. Battery box cover removed.
Cleaning Procedure
1. Disconnect all power and ground battery terminals noting exact terminal connections.
2. Clean battery terminals with wire brush.
3. Clean battery terminals and battery studs with liberal amount of electrical contact cleaner.
4. Dry battery terminals and battery studs with compressed air.
5. Connect all battery terminals to proper battery studs. Tighten battery terminal nuts to proper torque in
above torque specification table.
6. Apply electrical sealer paste to battery terminals.
Follow-On Procedure
1. Install battery box cover.
174
Battery Disconnect Switch

0008RLZ BATTERY DISCONNECT SWITCH {Cole-Hersee 75920-06} 300 Amp;
Battery Box Mounted, Disconnects Cab Power, Does Not Disconnect
Charging Circuits, Locks with Padlock
0008WXY BATTERY DISCONNECT SWITCH {Cole-Hersee} for Cab Power
Disconnect Switch, Lever Operated, Does Not Disconnect Charging
Circuits, Cab Mounted
A battery disconnect switch in an optional item the will interrupt electricity flow from the batteries without
having to disconnect cables. To operate, simply move the switch into the desired position. The switch may
be located in one of several locations.
175
Starting and Charging System

For base electrical system troubleshooting, always start with the Operational Checkout Procedure (page 177).
From there you may select starting symptoms, charging symptoms, or fault codes for specific diagnostic
procedures.
Diagnostic Section
Diagnostics
Operational Checkout Procedure (page 177)
Starting System (page 178)
Charging System (page 228)
176
Operational Checkout Procedure
Step 1 Inspect electrical system for physical damage, overall condition, and Decision
component mounting.
Perform Electrical System Inspection (page 254). Yes: Repair issue
identified during
inspection. After
repairs are complete
retest for symptom.
Were any issues identified during inspection? No: Go to Step 2.
Step 2 Determine if batteries are fully charged and in good health. Decision
Break apart battery pack and perform Battery Test (page 236) on each individual Yes: Go to Step 3.
battery.
Are all batteries in charged and in good health? No: Recharge
/ replace faulty
batteries. After repairs
are complete retest for
symptom.
Step 3 Determine if starting system is operating properly. Decision

Attempt to start vehicle. Yes: Go to Step 4.
Does starter crank engine at proper speed and vehicle start? No: Select relevant
symptom from Starting
System Symptoms
(page 178).
Step 4 Determine if charging system is operating properly. Decision

1. Start vehicle. Yes: Select relevant
symptom from
2. Turn on non-cyclical loads (headlight(s), interior lights, etc).
Charging system
3. Monitor voltage gauge. Symptoms (page
229).
Does voltage gauge fluctuate or fall below nominal voltage, and / or does battery No: Go to Step 5.
warning come on?
Step 5 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST) with ServiceMaxx™ software, check Diagnostic Yes: Go to appropriate
Trouble Code (DTC) list for active fault codes. Engine Diagnostic
Manual for additional
diagnostic information.
Are any fault codes active? No: End of
diagnostics.
177
Starting System
Overview
0008WXG Starting Motor (Mitsubishi Electric Automotive America 105P) 12-Volt, with
Soft-Start
0008WTL Starting Motor (Delco Remy 39MT) 12-Volt, Gear Reduced, With Thermal
Over-Crank Protection
Battery Pack
Typically three or four 12 volt maintenance free batteries connected in parallel, with a main power cable
running to starter, and another running to power distribution.
Depending upon battery quantity and box location, some vehicles have two positive cables to the cranking
motor solenoid. The additional cable reduces voltage drop during cranking.
Starter
Typically the starter consists of the starter motor, the starter solenoid, and the integral magnetic switch (IMS).
The IMS acts as a relay to turn on the starter solenoid, which engages the starter pinion gear and delivers
power to the starter motor.
Control
The ignition switch supplies voltage to the switched side of the neutral relay, which delivers power to the IMS,
activating the starter solenoid, and cranking the engine.
The TCM provides power to the control side of the neutral start relay once proper conditions are met. If
starter is equipped with thermal overcrank, the breaker is in between the neutral start relay and the IMS
on the switched circuit.
Diagnostic Section
Symptoms
No Click No Crank (page 179)
Click No Crank (page 181)
Low Cranking Speed (page 182)
No Starter Input Signal (Automated Manual Transmission) (page 183)
No Starter Input Signal (Automatic Transmission) (page 198)
No Starter Input Signal (Manual Transmission) (page 213)
178
No Click No Crank
Overview
Determine reason starter does not click or crank when ignition key is turned to start.
Possible Causes
• Failed / discharged batteries
• Failed starter
• Failed ignition switch
• Faults with starter interlocks
• Improperly routed cube fuse
• Loose / corroded battery wiring connections
• Loose / corroded starter wiring connections
• Open / high-resistance in wiring
• Damaged flywheel ring gear
• Damaged starter pinion gear
Step 1 Perform Operational Checkout Procedure. Decision

Yes: Go to Step 2.
Did you perform the electrical system Operational Checkout Procedure? No: Go to Operational
Checkout Procedure
(page 177).
Step 2 Check for stuck starter pinion gear. Decision

Perform Manual Engine Bar Test (page 247). Yes: Go to Step 3.
Did gear disengage flywheel (audible clunk when turned)? No: Go to Step 4.
Step 3 Inspect flywheel ring gear. Decision

Perform Ring Gear Inspection (page 255). Yes: Replace
components as
necessary. After
retest for symptom.
Was any damage found? No: End of
diagnostics.
179
Step 4 Test starter input. Decision

Perform Starter Control Circuit Test (page 252). Yes: Replace starter
assembly and perform
Ring Gear Inspection
(page 255). After
retest for symptom.
Did control circuit have battery voltage? No: See Starter Input
Diagnostics .
180
Click No Crank
Overview
Determine reason starter engages flywheel (audible click) but does not crank when ignition key is turned to
start.
Possible Causes
• Failed starter
• Open / high-resistance in wiring
• Damaged flywheel ring gear
• Damaged starter pinion gear

Yes: Go to Step 2.
Checkout Procedure
(page 177).
Step 2 Check starter power and ground cables. Decision

Perform Cable Drop Test (page 239) on power and ground circuits going to starter. Yes: Go to Step 3.
Is voltage drop within acceptable limits? No: Repair / Replace
wiring. After repairs
symptom.
Step 3 Check for stuck starter pinion gear. Decision

Perform Manual Engine Bar Test (page 247). Yes: Go to Step 4.
Did gear disengage flywheel (audible clunk when turned)? No: Replace starter
assembly and perform
(page 255). After
retest for symptom.
Step 4 Inspect flywheel ring gear. Decision

Perform Ring Gear Inspection (page 255). Yes: Replace
components as
necessary. After
retest for symptom.
Was any damage found? No: End of
diagnostics.
181
Low Cranking Speed

Overview
Determine reason starter cranks engine slowly.
Possible Causes
• Failed starter
• High-resistance in wiring

Yes: Go to Step 2.
Checkout Procedure
(page 177).
Step 2 Check starter power and ground cables. Decision

Perform Cable Drop Test (page 239) on power and ground circuits going to starter. Yes: Replace
starter.After repairs
symptom.
Is voltage drop within acceptable limits? No: Repair / Replace
symptom.
182
No Starter Input Signal (Automated Manual Transmission)

Automated Manual Transmission Starter Input Diagnostics
Step 1 Check relevant fuses. Decision
Check main cube fuse, double 100A / single 150A fuse, and 25 amp fuse F11-D. Yes: Replace fuse.
After repairs are
complete retest for
symptom.
Are fuses in good condition and not blown? No: Go to step 2.
Figure 78 Start Relay Location

1. Start Relay
Step 2 Check for start relay activation. Decision

1. Key ON. Yes: Go to Step 3.
2. Transmission in PARK or Neutral.
3. Remove and reinstall start relay, and listen for audible click.
Does relay activate upon installation? No: Go to Step 8.
Step 3 Check for Open in power (PWR) input circuit to switched side of start Decision
relay.
Perform Test 1 (page 187). Remove start relay, transmission in PARK or NEUTRAL, Yes: Go to Step 4.
key in START position. Use Digital Multi Meter (DMM), measure voltage between
start relay terminal F3 and known good ground (GND).
Is voltage B+ ± 0.5 volts? No: Go to Step 5.
183
Step 4 Check for Open in circuit between start relay and starter integral Decision
magnetic switch (IMS).
Perform Test 2 (page 188). Use DMM, measure voltage between battery PWR and Yes: Replace start
start relay terminal E4. relay. After repairs
symptom.
Is voltage B+ ± 0.5 volts? No, starter equipped
with thermal
overcrank: Go to
Step 10.
No, starter NOT
equipped with thermal
overcrank: Repair
Open between start
relay terminal E4 and
IMS S terminal. After
retest for symptom.
Step 5 Check for Open in PWR input circuit to 25 amp fuse F11-D. Decision
Perform Test 3 (page 189). Remove 25 amp fuse F11-D. Use DMM, measure Yes: Go to Step 6.
voltage between fuse panel terminal G4 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open
between fuse terminal
G4 and battery PWR.
After repairs are
complete retest for
symptom.
Step 6 Check for Open in circuit between 25-amp fuse F11-D and key switch. Decision
Perform Test 4 (page 190). Reinstall 25 amp fuse F11-D and disconnect key Yes: Go to Step 7.
switch connector. Use DMM, measure voltage between key switch terminal A
and known good GND.
H4 and key switch
terminal A. After
retest for symptom.
184
Step 7 Check for failed key switch. Decision

Perform Test 5 (page 191). Key in START position, Use DMM, measure resistance Yes: Repair Open
between key switch terminal B and key switch terminal A. between key switch
terminal B and start
relay terminal F3.
After repairs are
complete retest for
symptom.
Is resistance less than 5 ohms? No: Replace key
switch. After repairs
symptom.
Step 8 Check for PWR on start relay control side circuit. Decision
Perform Test 6 (page 192). Remove start relay. Use DMM, measure voltage Yes: Go to Step 9.
between start relay terminal F4 and known good GND.
Is voltage B+ ± 0.5 volts? No: Go to step 12.
Step 9 Check for GND on start relay control side circuit. Decision
Perform Test 7 (page 193). Use DMM, measure voltage between start relay Yes: Replace relay.
terminal E3 and terminal F4. After repairs are
complete retest for
symptom.
Is voltage B+ ± 0.5 volts? No: Go to step 13
Step 10 Check for Open in circuit between start relay and thermal overcrank. Decision
Perform Test 8 (page 194). Reinstall start relay, disconnect thermal overcrank Yes: Go to step 11.
connector, key in START position. Use DMM, measure voltage between thermal
overcrank terminal B and known good GND.
between start relay
terminal E4 and
thermal overcrank
terminal B. After
retest for symptom.
185
Step 11 Check for Open in circuit between thermal overcrank and IMS. Decision
Perform Test 9 (page 195). Use DMM, measure voltage between thermal overcrank Yes: Replace thermal
terminal A and battery PWR. overcrank. After
retest for symptom.
between thermal
overcrank terminal A
and IMS S terminal.
After repairs are
complete retest for
symptom.
Step 12 Check for Open in PWR circuit between start relay and TCM. Decision
Perform Test 10 (page 196). Disconnect Eaton TCM connector. Use DMM, measure Yes: Go to Eaton
resistance between start relay terminal F4 and Eaton TCM connector terminal 6. Transmission
Diagnostics.
Is resistance less than 5 ohms? No: Repair Open
between Eaton TCM
connector terminal
4 and start relay
F4. After repairs are
complete retest for
symptom.
Step 13 Check Open in GND circuit between start relay and TCM. Decision
Perform Test 11 (page 197). Disconnect Eaton TCM connector. Use DMM, measure Yes: Go to Eaton
resistance between start relay terminal E3 and Eaton TCM connector terminal 32. Transmission
Diagnostics.
between Eaton TCM
connector terminal
32 and start relay
E3. After repairs are
complete retest for
symptom.
186
Automated Manual Transmission Starter Input Pinpoint Tests

See latest version of Navistar® N13 Engine and Aftertreatment Wiring Schematic Form 0000009301 for
additional circuit information.
Tools Required
• Engine Terminal Test Kit ZTSE4435C,
Test 1
1. Key OFF.
2. Remove start relay from dash fuse panel.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal F3.
4. Key ON, transmission in PARK.
187
Test 2
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal E4.
188
Test 3
1. Key OFF.
2. Remove 25 amp fuse F11-D from dash fuse panel.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal G4.
4. Key ON.
189
Test 4
1. Key OFF.
2. Disconnect key switch connector 40M.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into key switch connector terminal A.
4. Key ON.
190
Test 5
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into key switch terminals A and B
component side .
4. Key ON.
191
Test 6
1. Key OFF.
192
Test 7
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminals E3 and F4.
193
Test 8
1. Key OFF.
2. Disconnect thermal overcrank connector 6316M.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into thermal overcrank connector terminal
B.
194
Test 9
1. Key OFF.
A.
195
Test 10
1. Key OFF.
2. Remove start relay from dash fuse panel, and disconnect Eaton TCM connector 7105.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal F4 and Eaton
TCM connector terminal 4.
4. Key ON.
196
Test 11
1. Key OFF.
2. Remove start relay from dash fuse panel, and disconnect Eaton TCM connector 7105.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal E3 and Eaton
TCM connector terminal 32.
4. Key ON.
197
No Starter Input Signal (Automatic Transmission)

After repairs are
complete retest for
symptom.
Figure 90 Neutral Start Relay Location

1. Neutral Start Relay
Step 2 Check for neutral start relay activation. Decision

1. Key ON Yes: Go to Step 3.
2. Transmission in PARK or Neutral
3. Remove and reinstall neutral start relay, and listen for audible click.
Does relay activate upon installation? No: Go to Step 8.
Step 3 Check for Open in power (PWR) input circuit to switched side of neutral Decision
start relay.
Perform Test 1 (page 202). Remove neutral start relay, transmission in PARK or Yes: Go to Step 4.
NEUTRAL, key in START position. Use Digital Multi Meter (DMM), measure voltage
between neutral start relay terminal J3 and known good ground (GND).
198
Step 4 Check for Open in circuit between neutral start relay and starter integral Decision
Perform Test 2 (page 203). Use DMM, measure voltage between battery PWR and Yes: Replace neutral
neutral start relay terminal G4. start relay. After
retest for symptom.
with thermal
overcrank: Go to
Step 10.
No, starter NOT
overcrank: Repair
Open between neutral
start relay terminal G4
and IMS S terminal.
After repairs are
complete retest for
symptom.
Step 5 Check for Open in PWR input circuit to 25 amp fuse F11–D. Decision
G4 and battery PWR.
After repairs are
complete retest for
symptom.
Step 6 Check for Open in circuit between 25 amp fuse F11-D and key switch. Decision
and known good GND.
H4 and key switch
terminal A. After
retest for symptom.
199

Perform Test 5 (page 206). Key in START position, Use DMM, measure resistance Yes: Repair Open
between key switch terminal B and key switch terminal A. between key switch
terminal B and neutral
start relay terminal
J3. After repairs are
complete retest for
symptom.
symptom.
Step 8 Check for PWR on neutral start relay control side circuit. Decision
Perform Test 6 (page 207). Remove neutral start relay. Use DMM, measure voltage Yes: Go to Step 9.
between neutral start relay terminal J4 and known good GND.
Is voltage B+ ± 0.5 volts? No: Go to step 12.
Step 9 Check for GND on neutral start relay control side circuit. Decision
Perform Test 7 (page 208). Use DMM, measure voltage between neutral start relay Yes: Replace relay.
terminal G3 and terminal J4. After repairs are
complete retest for
symptom.
Is voltage B+ ± 0.5 volts? No: Go to step 13
Step 10 Check for Open in circuit between neutral start relay and thermal Decision
overcrank.
Perform Test 8 (page 209). Reinstall neutral start relay, disconnect thermal Yes: Go to step 11.
overcrank connector, key in START position. Use DMM, measure voltage between
thermal overcrank terminal B and known good GND.
between neutral start
relay terminal G4 and
thermal overcrank
terminal B. After
retest for symptom.
200
Perform Test 9 (page 210). Use DMM, measure voltage between thermal overcrank Yes: Replace thermal
terminal A and battery PWR. overcrank. After
retest for symptom.
between thermal
and IMS S terminal.
After repairs are
complete retest for
symptom.
Step 12 Check for Open in PWR circuit between neutral start relay and TCM. Decision
Perform Test 10 (page 211). Disconnect TCM Data Interconnection connector. Yes: Go to Allison
Use DMM, measure resistance between neutral start relay terminal J4 and TCM Transmission
Data Interconnection terminal 6. Diagnostics.
between TCM Data
Interconnection
terminal 6 and neutral
start relay J4. After
retest for symptom.
Step 13 Check Open in GND circuit between neutral start relay and TCM. Decision
Perform Test 11 (page 212). Disconnect TCM Data & Power Interconnection Yes: Go to Allison
connector. Use DMM, measure resistance between neutral start relay terminal G3 Transmission
and TCM Data & Power Interconnection terminal 24. Diagnostics.
between TCM Data &
Power Interconnection
terminal 24 and neutral
start relay G3. After
retest for symptom.
201
Automatic Transmission Starter Input Pinpoint Tests

See latest version of Navistar® N13 Engine and Aftertreatment Wiring Schematic Form 0000009301 for
additional circuit information.
Tools Required
Test 1
1. Key OFF.
2. Remove neutral start relay from dash fuse panel.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal J3.
202
Test 2
1. Key OFF.
203
Test 3
1. Key OFF.
2. Remove 25 amp fuse F11-D from dash fuse panel.
4. Key ON.
204
Test 4
1. Key OFF.
4. Key ON
205
Test 5
1. Key OFF.
component side.
4. Key ON.
206
Test 6
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal J4.
207
Test 7
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminals G3 and J4.
208
Test 8
1. Key OFF.
B.
209
Test 9
1. Key OFF.
A.
210
Test 10
1. Key OFF.
2. Remove neutral start relay from dash fuse panel, and disconnect TCM Data Interconnection
connector 3005.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal J4 and TCM
Data Interconnection connector terminal 6.
4. Key ON.
211
Test 11
1. Key OFF.
2. Remove neutral start relay from dash fuse panel, and disconnect TCM Data & Power
Interconnection connector 3010.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal G3 and TCM
Data & Power Interconnection connector terminal 24.
4. Key ON.
212
No Starter Input Signal (Manual Transmission)

After repairs are
complete retest for
symptom.
Figure 102 Start Relay Location

1. Start Relay
Step 2 Check for start relay activation circuits. Decision

Perform Test 1 (page 217). Remove start relay, depress clutch, key in START Yes: Go to Step 3.
position. Use Digital Multi Meter (DMM), measure voltage between start relay
terminal F4 and start relay terminal E3.
213
Step 3 Check for Open in power (PWR) input circuit to switched side of start Decision
relay.
Perform Test 2 (page 218). Key in START position. Use Digital Multi Meter (DMM), Yes: Go to Step 4.
measure voltage between start relay terminal F3 and known good ground (GND).
between start relay
terminal F4 and splice
SS37. After repairs
symptom.
Step 4 Check for Open in circuit between start relay and starter integral Decision
Perform Test 3 (page 219). Use DMM, measure voltage between battery PWR and Yes: Replace start
start relay terminal E4. relay. After repairs
symptom.
with thermal
overcrank: Go to
Step 10.
No, starter NOT
overcrank: Repair
Open between start
relay terminal E4 and
IMS S terminal. After
retest for symptom.
Step 5 Check for PWR on start relay control side circuit. Decision
Perform Test 4 (page 223). Depress clutch, key in START position. Use DMM, Yes: Replace start
measure voltage between start relay terminal F4 and known good GND. relay. After repairs
symptom.
Step 6 Check for Open in PWR input circuit to 25-amp fuse F11-D. Decision
G4 and battery PWR.
After repairs are
complete retest for
symptom.
214
Step 7 Check for Open in circuit between 25 amp fuse F11-D and key switch. Decision
and known good GND.
H4 and key switch
terminal A. After
retest for symptom.
Step 8 Check for Open in PWR circuit to starter interlock switch. Decision
Perform Test 7 (page 227). Disconnect starter interlock connector, reconnect key Yes: Go to Step 12.
switch connector, key in START position. Use DMM, measure voltage between
starter interlock connector terminal B and known good GND.

Perform Test 8 (page 222). Disconnect key switch connector, key in START Yes: Repair Open
position, Use DMM, measure resistance between key switch terminals A and B between key switch
component side. terminal B and starter
interlock terminal
B. After repairs are
complete retest for
symptom.
symptom.
Step 10 Check for Open in circuit between start relay and thermal overcrank. Decision
Perform Test 9 (page 225). Reinstall start relay, disconnect thermal overcrank Yes: Go to step 11.
connector, key in START position, depress clutch. Use DMM, measure voltage
between thermal overcrank connector terminal B and known good GND.
between start relay
terminal E4 and
thermal overcrank
terminal B. After
retest for symptom.
215
Perform Test 10 (page 226). Use DMM, measure voltage between thermal Yes: Replace thermal
overcrank connector terminal A and battery PWR. overcrank. After
retest for symptom.
between thermal
and IMS S terminal.
After repairs are
complete retest for
symptom.
Step 12 Check for failed starter interlock switch. Decision

Perform Test 11 . Clutch depressed. Use DMM, measure resistance between Yes: Repair Open
starter interlock terminals B and C component side. between key switch
terminal B and starter
interlock terminal
B. After repairs are
complete retest for
symptom.
Is resistance less than 5 ohms? No: Replace starter
interlock switch. After
retest for symptom.
216
Manual Transmission Starter Input Pinpoint Tests

See latest version of N13 Engine and Aftertreatment Wiring Schematic Form 0000009301 for additional
circuit information.
Tools Required
Test 1
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminals F4 and E3.
4. Key ON, clutch depressed.
217
Test 2
1. Key OFF.
4. Key ON.
218
Test 3
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into fuse panel terminal E4.
4. Key ON.
219
Test 4
1. Key OFF.
220
Test 5
1. Key OFF.
2. Remove 25 amp fuse F11-D from dash fuse panel
4. Key ON.
221
Test 6
1. Key OFF.
4. Key ON.
222
Test 7
1. Key OFF.
2. Disconnect starter interlock connector 294A.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into starter interlock connector terminal B.
4. Key ON.
223
Test 8
1. Key OFF.
component side.
4. Key ON.
224
Test 9
1. Key OFF.
B.
225
Test 10
1. Key OFF.
A.
4. Key ON.
226
Test 11
1. Key OFF.
2. Disconnect starter interlock connector 294A.
3. Using Terminal Test Kit ZTSE4435C, insert proper pin into starter interlock terminals B and
C component side.
227
Charging System
Overview
Overview
0008GGN Alternator (Bosch LH160) Brush Type, 12 Volt 160 Amp. Capacity
0008GGR Alternator (Bosch LH200) Brush Type, 12 Volt 200 Amp. Capacity
0008GHG Alternator (Bosch LIL165 Long Life) Brush Type, 12 Volt 165 Amp. Capacity,
with Remote Voltage Sensor
0008GHH Alternator (Bosch LIL200 Long Life) Brush Type, 12 Volt 200 Amp. Capacity,
0008GHU Alternator (Delco Remy 28SI) Brush Type, 12 Volt 200 Amp. Capacity,
0008GGG Alternator (Delco Remy 36SI) Brushless, 12 Volt 165 Amp. Capacity, with
Remote Voltage Sensor
0008GHJ Alternator (Delco Remy 40SI) Brushless, 12 Volt 300 Amp. Capacity, with
Remote Voltage Sensor
0008GWZ Alternator (Leece-Neville 14923PAH) Brush Type; 12 Volt 220 Amp.
Capacity, Includes 1-Gauge Protected Charging Circuit
0008GWY Alternator (Leece-Neville 14931PAH) Brush Type, 12 Volt 320 Amp.
Capacity
0008GXB Alternator (Leece-Neville AVI160P2003) Brush Type; 12 Volt 240 Amp.
Capacity, With Remote Sense
0008GXC Alternator (Leece-Neville AVI160P2007) Brush Type; 12 Volt 210 Amp.
Capacity, With Remote Sense
0008GXK Alternator (Leece-Neville BLP4006HN) Brushless, 12 Volt 325 Amp.
Capacity, with Remote Sense
Battery Pack
Typically an arrangement of three to four 12V batteries connected in parallel, with a main power cable running
to starter, and another running to power distribution.
Alternator
There are many alternator options available. Aside from the Positive and Negative output cables, an alternator
may have an indicator (I) or lamp (L) terminal, a relay (R) or phase (W) terminal, a sense (S) terminal, and /
or a field (FM) terminal.
Indicator (I) or lamp (L) terminal: Constant 1 amp current sink to indicate charging system condition. This
terminal functions as a fault indicator by providing a ground to the battery warning light when charging
output fault is present.
Relay (R) or phase (W) terminal: Alternating speed signal at 1/2 system voltage. Maximum current loading is 4
amps. May be used for tachometers, hour meters, etc.
228
Sense (S) terminal: Connection point for remote battery voltage sensing. Alternator uses this input to
determine necessary output to keep batteries at proper voltage. In the event the sense wire is open or
disconnected, sense circuit will automatically revert to internal sensing on most models.
Field (FM) terminal: Used to monitor the pulse width modulated (PWM) field voltage. With the alternator field
referenced to ground, the FM terminal is connected to the high side of the field using a 10,000 ohm resistor.
When the field switch is turned on, essentially battery voltage appears at the FM terminal, and thus the
average voltage a Terminal FM is directly proportional to field strength. When the ECU recognizes a full field
condition, it can activate fast idle to maintain required loads.
Diagnostic Section
Symptoms
Battery Gauge Reading High (page 230)
Battery Gauge Reading Low / Fluctuating (page 231)
Low Battery Warning / Alarm (page 233)
Repeated Jump Starts (page 234)
Fault Codes
SPN 158 FMI 15 - ECM Switched Voltage Too HIGH - Go to appropriate Engine Diagnostic Manual
for additional diagnostic information .
SPN 158 FMI 17 - ECM Switched Voltage Too LOW - Go to appropriate Engine Diagnostic Manual for
additional diagnostic information .
229
Battery Gauge Reading High

Overview
Determine why voltage gauge is reading higher than expected during engine operation.
Possible Causes
• Failed alternator
• Failed gauge
• Loose / corroded alternator wiring connections

Yes: Go to Step 2.
Checkout Procedure
(page 177).
Step 2 Check voltage at alternator. Decision

1. Engine Running. Yes: Go to Battery
Gauge Diagnostics .
2. Use Digital Multi Meter (DMM), measure voltage in between alternator
main power terminal and known good ground (GND).
Is voltage 14 ±1 volts? No: Go to Step 3.
Step 3 Check sense (S) terminal, if equipped. Decision

1. Verify S terminal wire IS running directly to battery pack. Yes: Perform
Electrical System
2. Use DMM, measure voltage between S terminal and known good GND.
Test (page 245). If
charging system fails,
replace alternator.
After repairs are
complete retest for
symptom.
Is proper wire installed on S terminal, and is voltage B+ ± 0.5 volts? No: Repair circuit.
After repairs are
complete retest for
symptom.
230
Battery Gauge Reading Low / Fluctuating

Overview
Determine why voltage gauge is reading lower than normal or fluctuating during engine operation
Possible Causes
• Failed gauge
• Loose / corroded alternator wiring connections

Yes: Go to Step 2.
Checkout Procedure
(page 177).

1. Engine Running. Yes: Go to Battery
Gauge Diagnostics .
Is voltage 14 ±1 volts? No: Go to Step 3.

1. Verify S terminal wire IS running directly to battery pack. Yes: Go to Step 4.
After repairs are
complete retest for
symptom.
Step 4 Test alternator. Decision

Perform Electrical System Test (page 245). Yes: Go to Step 5.
Did charging system pass tests? No: Replace
alternator. After
retest for symptom.
231
Step 5 Test alternator cables. Decision

Perform Cable Drop Test (page 239) on alternator power (PWR) and GND cables. Yes: Go to Battery
Gauge Diagnostics .
Is voltage drop within acceptable limits? No: Repair / replace
cables. After repairs
symptom.
232
Low Battery Warning / Alarm

Overview
Determine why low battery warning or alarm is present while engine is running.
Possible Causes
• Fault in alternator wiring
• Short in lamp wiring

Yes: Go to Step 2.
Checkout Procedure
(page 177).
Step 2 Check alternator ignition (IGN) terminal, if equipped Decision

1. Verify IGN terminal wire is NOT running directly to battery pack. Yes: Go to Step 3.
2. Key ON.
3. Use Digital Multi Meter (DMM), measure voltage between IGN terminal
on alternator and known good ground (GND)
Is voltage B+ ± 0.5 volts? No: Repair IGN circuit.
After repairs are
complete retest for
symptom.

1. Verify S terminal wire IS running directly to battery pack. Yes: Go to Step 4.
After repairs are
complete retest for
symptom.
Step 4 Test alternator. Decision

Perform Electrical System Test (page 245). Yes: End of
diagnostics.
Did charging system pass tests? No: Replace
alternator. After
retest for symptom.
233
Repeated Jump Starts

Overview
Determine why batteries fail to start the engine, requiring charging or jump start.
Possible Causes
• Failed batteries
• Parasitic draw
• Loose / corroded alternator connections
• High resistance in battery cables

Yes: Go to Step 2.
Checkout Procedure
(page 177).
Step 2 Verify ALL electronics are switched OFF. Decision

Go through vehicle and verify ALL electronic accessories are turned off. Yes: Go to Step 3.
Are all electronics turned off? No: Switch off
accessories. After
retest for symptom.

1. Engine Running. Yes: Go to Step 4.
Is voltage 14 ±1 volts? No: Go to Battery
Gauge Reading Low
/ Fluctuating (page
231).
Step 4 Test battery cables. Decision

Perform Cable Drop Test (page 239) on battery cables. Yes: Go to Step 5.
Is voltage drop within acceptable limits? No: Repair / replace
cables. After repairs
symptom.
234
Step 5 Test for parasitic draw. Decision

Perform Parasitic Draw Test (page 248). Yes: Diagnose and
repair suspected
components. After
retest for symptom.
Did vehicle have a parasitic draw above specification? No: End of
diagnostics.
235
Tests
Battery Test
Overview
This test determines state of health, state of charge, and condition of a single battery.
Tools Required
• Midtronics – inTELLECT EXP HD – Battery and Electrical System tester (EXP1000HD)
Equipment Condition
• Single battery disconnected from battery pack.
Test Setup
1. If battery has threaded studs, screw negative (–) stud adapter onto negative terminal, and positive
(+) adapter onto positive terminal.
2. Connect red clamp to positive (+) terminal or adapter.
3. Connect black clamp to negative (–) terminal or adapter.
4. Rock clamps back and forth. Both sides of clamp must be firmly connected before testing. If
CHECK CONNECTION message appears, clean terminals and/or reconnect clamps.
Test Procedure
1. On EXP-1000HD, highlight Battery Test icon and press SELECT.
2. At MANUFACTURER screen, press YES if testing a Navistar vehicle.
3. If testing a Navistar vehicle, enter full OR last eight digits of VIN and press NEXT. Press SKIP to move past
step without entering a VIN.
4. Select battery POST TYPE.
5. Select BATTERY TYPE.
6. Select BATTERY CHEMISTRY.
7. Select battery RATINGS UNITS. This information is usually printed on battery label. If unreadable,
contact manufacturer.
8. Enter BATTERY RATING. Scroll to correct rating and press SELECT to being test.
236
Figure 114 Measuring Ambient Battery Temperature

1. Battery case 2. IR temperature sensor
9. If prompted, measure ambient battery temperature by aiming IR temperature sensor (2) at battery case
(1). Once temperature stabilizes, press NEXT.
NOTE – REPLACE BATTERY result may be caused by poor clamp connections. Retest battery out of
vehicle.
10. If prompted, enter battery serial number. If battery does not have serial number, press SKIP.
Figure 115 Battery Test Results
11. Test results are display across multiple screens. Scroll to view each. Press EXIT to return to Main Menu,
or PRINT to print results.
Expected Outcome
Technician will have determined current condition of a single battery.
237
Follow-On Procedure
None.
238
Cable Drop Test

Overview
This test will verify integrity of power and ground circuits. The tester will send a signal through circuit being
tested to calculate voltage drop on both individual wires and circuit as a whole.
Tools Required
Equipment Condition
• Battery fully charged.
Test Setup
NOTE – This test requires a complete circuit. If you are testing a system with a remote solenoid, you
can test from battery to solenoid, but not from battery to starter.
Figure 116 Cable Drop Test Clamp Connections
1. Connect Battery Test Cable 133-000195 to positive and negative wires of component under test,
as close to component as possible. Rock clamps back and forth to ensure good connection.
2. Connect DMM Cable A028XL to positive and negative battery terminals. Rock clamps back
and forth to ensure good connection.
Test Procedure
1. On EXP-1000HD, highlight Cable Drop icon and press SELECT.
2. Select type of circuit being tested.
3. Select battery pack configuration.
239
4. Select rated amperage or output of circuit.
5. Follow displayed instructions for connecting cables.
Figure 117 Test Results
6. When finished testing the circuit, tester will display results.
Expected Outcome
Technician will have determined integrity of circuit being tested.
Follow-On Procedure
None.
240
Electrical System Test

Overview
The Electrical System Test consists of a Battery Pack Test, Starter System Test, and Charging System Test
that run consecutively. Not all tests need to be run, but must be run in order.
Tools Required
Equipment Condition
• Vehicle parked
• Key-On Engine-Off (KOEO)
Test Setup
1. Make sure all vehicle accessory loads are off, key is not in ignition, and doors are closed.
2. Connect clamps to positive (+) and negative (–) posts closest to starter wire and chassis ground
wire. If there are multiple cables, re-test for each cable connection.
Test Procedure
1. On EXP-1000HD, highlight System Test icon and press SELECT.
2. At MANUFACTURER screen, press YES if testing a Navistar vehicle.
3. Enter full OR last eight digits of VIN and press NEXT. Press SKIP to move past step without entering a VIN.
4. Select battery pack configuration.
5. Select number of batteries in pack.
6. Select BATTERY VOLTS.
7. Select BATTERY TYPE.
8. Select BATTERY CHEMISTRY.
9. Select battery RATINGS UNITS. This information is usually printed on battery label. If unreadable,
contact manufacturer.
10. Enter BATTERY RATING. Scroll to correct rating and press SELECT to being test.
241
Figure 118 Measuring Ambient Battery Temperature

1. Battery case 2. IR temperature sensor
11. If prompted, measure ambient battery temperature by aiming IR temperature sensor (2) at battery case
(1). Once temperature stabilizes, press NEXT.
Figure 119 Passed Pack Test Results
12. If results display GOOD PACK, review and press NEXT to continue. Skip steps 13 through 16.
Figure 120 Failed Pack Test Results
13. If results display CHECK BATTERY PACK, select YES when prompted to break battery pack apart.
14. Disconnect all batteries and select YES to continue.
15. Connect to and retest each battery and press NEXT to continue.
NOTE – REPLACE BATTERY result may be caused by poor clamp connections. Retest battery out of
vehicle before replacing.
242
Figure 121 Individual Battery Test Results
16. After testing last battery, scroll through results across multiple screens.
17. Continue to Starter System Test Procedure or end diagnostics.
Expected Outcome
Technician will have determined current condition of battery pack, any problematic batteries, determined
condition of starting system, and determined condition of charging system.
Follow-On Procedure
None.
243
Starter System Test Procedure

Overview
The Starter System Test consists of a Battery Pack Test, Starter System Test, and Charging System Test that
run consecutively. Not all tests need to be run, but must be run in order.
Tools Required
Equipment Condition
• Vehicle parked
Test Setup
Starter System Test Procedure

1. Connect amp clamp around negative (-) battery cable.
2. Following a successful Battery Pack Test, press NEXT to continue to Starter System Test.
3. Start engine when prompted.
Figure 122 Passed Starter System Test
4. After testing, scroll through results across multiple screens.
5. Continue to Charging System Test Procedure or end diagnostics.
Expected Outcome
Follow-On Procedure
None.
244
Charging System Test Procedure

Overview
The Charging System Test consists of a Battery Pack Test, Starter System Test, and Charging System Test
that run consecutively. Not all tests need to be run, but must be run in order.
Tools Required
Equipment Condition
• Vehicle parked
Test Setup
Charging System Test Procedure

1. Press NEXT after a successful Starter System Test
2. Connect amp clamp around negative (–) battery cable.
3. CHECKING FOR ALTERNATOR OUTPUT: The tester will immediately begin testing for alternator voltage.
4. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off vehicle loads (blowers, interior light, radio,
etc.) and idle engine. Press NEXT to continue.
NOTE – If necessary, tester will ask if you are testing a diesel engine. It will resume testing after making
selection.
5. REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Raise rpm with loads off. Gradually increase rpm
until tester tells you to HOLD rpm as bar on display moves to the right.
NOTE – Some 8 cylinder and older vehicles idle at a high level after starting, allowing tester to detect
rpm increase automatically.
6. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold rpm while tester takes system measurements.
NOTE – If rpm increase is not detected, tester displays COULD NOT DETERMINE ENGINE SPEED. HOLD
ENGINE AT 1500 RPM. Raise rpm to 1500 as directed and continue.
7. ENGINE REV DETECTED, IDLE ENGINE: Allow engine to idle and press NEXT.
8. TESTING ALTERNATOR AT IDLE, LOADS OFF: The tester will next test engine at idle, and then test
diode ripple.
245
9. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: Turn on the high-beam headlight(s) and
the blower to high. Do not use cyclical loads such as air conditioning or windshield wipers.
10. TESTING ALTERNATOR AT IDLE, LOADS ON: The tester will determine if charging system is able to
provide sufficient current for demands of vehicle’s electrical system.
11. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The tester will test charging system with loads on
and prompt you to rev the engine. Gradually increase rpm until the analyzer tells you to HOLD rpm as
the bar on display moves to the right.
12. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold rpm while tester takes system measurements.
13. ENGINE REV DETECTED, IDLE ENGINE: Tester has detected rpm increase. Press NEXT.
14. ANALYZING CHARGING SYSTEM DATA: Tester is completing final analysis of charging system data.
15. TURN OFF LOADS AND ENGINE: Turn off lights and blower motor. Turn key OFF. Press NEXT to
display results.
Figure 123 Passed Charging System Test
16. After testing, scroll through results across multiple screens. Excessive alternator diode ripple usually
means one or more diodes have failed in the alternator or there is stator damage.
Expected Outcome
Follow-On Procedure
None.
246
Manual Engine Bar Test

Overview
This procedure will manually rotate the engine to check if starter pinion gear is stuck.
Tools Required
Breaker bar with 19mm socket
Equipment Condition
• Ignition key OFF.
Test Setup
None.
Test Procedure
1. Turn accessory drive pulley clockwise so crankshaft rotates approximately 15 degrees. Listen for “clunk”
sound of stuck starter pinion disengaging.
• If an audible noise is heard from the starter area when the engine is rotated by hand, there is most
likely flywheel ring gear damage.
Expected Outcome
Engine will rotate with adequate force, and starter pinion gear will be dislodged from flywheel ring gear, if stuck.
Follow-On Procedure
None.
247
Parasitic Draw Test

Overview
This procedure will measure for excessive current while vehicle is turned off by temporarily replacing all
ground paths with an Ammeter. This will aid in diagnostics of shorts and / or faulty modules draining battery
while vehicle is off.
Tools Required
• Jumper wire
Equipment Condition
Test Setup
1. Roll windows down.
2. Switch off all electrical loads (lights, radio, auxiliary equipment, etc)
3. Turn OFF and remove ignition key.
248
Test Procedure
Figure 124 Basic Electrical System (typical)

1. Starter 4. Chassis Ground Cable
2. Starter Ground 5. Power Distribution
3. Negative Terminal Jumper Cables
1. Remove all ground paths from negative battery terminals. In the example shown, starter ground (2) and
chassis ground (4) cables must be disconnected from batteries (there may be other cables depending on
application). Negative terminal jumper cables (3) do not need to be disconnected.
249
Figure 125 Set-up for Parastic Draw Test (Jumper Installed)

1. Starter 3. Jumper wire
2. Connected grounds 4. Power distribution
2. Connect starter ground, chassis ground, and other grounds from battery (if equipped). This can be done
by simply bolting the cable eyelets together as shown (2).
3. Connect a jumper wire (3), from all connected ground cables to a negative battery terminal.
CAUTION
Do not activate any electronics or open doors.
4. Start a timer for 5 minutes. This is the time it takes for electrical devices to shut down and go into standby.
During this time, doors MUST remain closed, and jumper must remain in contact with battery and grounds.
5. Set up multimeter to measure amperage from connected ground cables to negative battery terminal,
parallel to jumper wire (3).
250
6. After 5 minute timer is up, remove jumper while ensuring meter leads do not lose contact with ground
cables and negative battery terminal. IF AT ANY TIME CURRENT FLOW IS INTERRUPTED, YOU MUST
BEGIN AGAIN WITH JUMPER AND WAIT 5 MINUTES BEFORE REMOVING.
7. Under normal conditions on a vehicle equipped with a standard electronics package, acceptable current
draw is approximately 25 milliampere PER BATTERY.
• If current draw is higher than 25 mA PER BATTERY, remove fuses one at a time until a significant
current drop is noted (do not open vehicle doors). Do not reinstall the fuses as this may wake up
modules and cause excessive current through meter. Make note of fuse locations as they are pulled
so they can be reinstalled in proper location when test is complete.
Once fuse has been identified, diagnose electrical faults downstream of that fuse.
• Another possible source of parasitic draw is failed alternator diodes. If removing fuses does not find
the problem, remove alternator power cable and watch for current drop. If a drop is noted, replace
alternator.
Expected Outcome
Current draw will be within acceptable limits.
Follow-On Procedure
None.
251
Starter Control Circuit Test

Overview
This test will check for input to starter from starter control circuit .
Tools Required
Equipment Condition
Test Setup
None.
Test Procedure
Figure 126 Starter (typical)

1. Sense (S) terminal
1. With ignition key in START position, measure voltage between starter integral magnetic switch (IMS) S
terminal and ground.
• If meter does not read battery voltage, suspect issues in control circuit, starter interlocks, or ignition
switch.
Expected Outcome
Meter will read battery voltage ± 0.5 volts.
252
Follow-On Procedure
None.
253
Inspections
Electrical System Inspection

Overview
This procedure will quickly check over important electrical system components.
Tools Required
None.
Equipment Condition
• Engine cool
• Hood open
• Battery covers removed
Inspection Procedure
1. Wiggle and inspect battery connections for looseness and corrosion.
2. Inspect cube fuse. Verify starter power cable is installed directly to positive terminal, NOT on top of
cube fuse.
3. Inspect battery wiring for fraying, insulation integrity, and proper routing.
4. Wiggle and inspect starter connections for looseness and corrosion.
5. Inspect starter wiring for fraying, insulation integrity, and proper routing.
6. Wiggle and inspect alternator connections for looseness and corrosion.
7. Inspect alternator wiring for fraying, insulation integrity, and proper routing.
8. Inspect accessory drive belt for cracks, wear, and contamination.
9. Inspect accessory drive auto tensioner for spring tension through full range of movement.
10. Inspect accessory drive pulleys for damage and looseness, and that they spin freely.
Expected Outcome
All inspected components will be free of damage and in good working order.
Follow-On Procedure
None.
254

Overview
This procedure will check all teeth on flywheel ring gear for chips, pitting, milling, or any issues.
Tools Required
Breaker bar with 19mm socket
Equipment Condition
Starter removed. See Starter Removal..
1. Mark ring gear with paint pen.
2. Bar engine over by accessory drive pulley and inspect each tooth on flywheel ring gear. Keep rotating
until back at paint pen mark.
Figure 127 DAMAGED Ring Gear
3. If teeth are milled, chipped, or damaged replace flywheel.
255
Figure 128 GOOD Ring Gear
Expected Outcome
All inspected components will be free of damage and in good working order.
Follow-On Procedure
None.
256
ACCESSORIES
5. Accessories
Sleeper-Mounted Radio Control
Overview
0008RJG Radio auxiliary controls; located in sleeper control panel; includes
display and controls for radio power, volume, mode, seek / tune, clock
and alarm
Figure 129 Sleeper Controls Location

1. Sleeper-mounted controls
The sleeper cab auxiliary radio controls module resembles a small radio face plate and includes a digital display.
Features include:
• Power (ON and OFF)

• Volume (UP and DOWN)
• Mode
• Seek / time
• Clock with alarm
257
ACCESSORIES
• Display station or time
258
AFTERTREATMENT
6. Aftertreatment
Diesel Particulate Filter (DPF)
Regeneration Inhibit Switch
Overview
0595BXR BC Program, Inhibit Regen Switch, Bistable, for Diesel Particulate Filter in
the Exhaust Aftertreatment System, for Non-Multiplexed Vehicles
Figure 130 Regeneration Inhibit Switch
The regeneration inhibit switch prevents normal or parked regenerations when operated. The switch can be
either a two position switch or a three position switch. The two position switch inhibits both parked and normal
regenerations when switched to the ON position. The three position switch inhibits normal regeneration in
the upper position and will cancel the inhibit function in the lower position, or if a parked regeneration is
activated. The regeneration inhibit switch is directly connected to the Body Controller (BC) which receives
input voltages based on switch positions.
259
AFTERTREATMENT
Figure 131 Regeneration Inhibit Switch Input Signals

1. Regen Inhibit Switch 2. Parked Regen Switch
Regen Inhibit Switch Fault Code Diagnostics

SPN FMI Description
3695 2 Regen Inhibit Switch Error
3695 6 Open Circuit in Regen Inhibit Switch Indicator Circuit
260
AFTERTREATMENT
Figure 132 Inhibit Regeneration Switch Pin Locations

1. BC Connector J3 Pin A2 6. Plug
2. BC ZVR Splice Pack 7. BC Connector J4 Pin E15
3. BC Connector J5 Pin F12 8. Ground Splice Pack
4. Plug 9. Ground Splice Pack
5. Plug 10. Panel Light Splice Adapter
261
AFTERTREATMENT
Parked Regeneration Switch
Overview
0595BXM BC Program, Parked Regen Switch, for Diesel Particulate Filter in the
Exhaust Aftertreatment System, for Non-Multiplexed Vehicles
Figure 133 Parked Regeneration Switch
The parked regeneration switch activates a parked regeneration when it is operated. The switch is a two
position switch which will activate the parked regeneration event when the appropriate conditions are met. The
parked regeneration switch is directly connected to the Body Controller (BC) which receives input voltages
based on switch position. See the HX Series Operation and Maintenance Manual for instructions on how to
activate a parked regeneration.
262
AFTERTREATMENT
Figure 134 Parked Regeneration Switch Input Signals

1. Parked Regen Switch 2. Regen Inhibit Switch
Parked Regen Switch Fault Code Diagnostics

SPN FMI Description
3696 2 Parked Regen Switch Error
3696 5 Open Circuit in Regen Switch Indicator Circuit
3696 6 Over Current for Parked Regen Switch Indicator
263
AFTERTREATMENT
Figure 135 Parked Regeneration Switch Pin Locations

1. BC Connector J3 Pin A8 6. Plug
2. BC ZVR Splice Pack 7. BC Connector J4 Pin E10
3. BC Connector J5 Pin F8 8. Ground Splice Pack
4. Plug 9. Ground Splice Pack
5. Plug 10. Panel Light Splice Adapter
264
AFTERTREATMENT
HEST Monitoring
Overview
0595KBC Exhaust High Temp Indicator for High Exhaust Temperatures
(Aftertreatment), for Non-Multiplexed Vehicles
Figure 136 EGC HEST Lamp
The Body Controller (BC) receives J1939 input from the Electronic Control Module (ECM) indicating the
exhaust system is above warning threshold temperature. The BC turns On the HEST_Warning_Lamp_Cmd
output at connector J4 pin-E2 to illuminate the High Exhaust System Temperature (HEST) lamp in the
Electronic Gauge Cluster (EGC).
265
AFTERTREATMENT
Figure 137 HEST Diamond Logic® Builder (DLB) Session

1. HEST warning lamp output 2. Exhaust system temperature input
266
AFTERTREATMENT
Figure 138 HEST Lamp Output from Body Controller Connector J4 (1601)
1. HEST lamp output
See HX Electrical Circuit Diagram Manual for additional circuit details.
267
BRAKES
7. Brakes
Bendix Air Anti-Lock Brake System
Bendix Air Automatic Traction Control System
Bendix Air Electronic Stability Control System
Meritor Wabco Air Anti-Lock Brake System
Meritor Wabco Air Automatic Traction Control System
Meritor Wabco Air Electronic Stability Control System
Air - Anti-Lock Brake (ABS) System

Bendix®
Overview
0004AZA Air Brake; Bendix® Anti-Lock Brake System (ABS), Full Vehicle Wheel
Control System (4-Channel)
0004AZU Air Brake; Bendix® Anti-Lock Brake System (ABS), Full Vehicle Wheel
Control System (6-Channel)
268
BRAKES
1 2
6 5
4 3
0000419236
Figure 139 ABS System Wheel Speed Sensor Locations

1. Front Rear Drive Axle Wheel Speed 4. Rear Rear Drive Axle Wheel Speed
Sensor Left Sensor Left
2. Front Rear Drive Axle Wheel Speed 5. Steer Axle Wheel Speed Sensor Right
Sensor Right 6. Steer Axle Wheel Speed Sensor Left
3. Rear Rear Drive Axle Wheel Speed
Sensor Right
269
BRAKES
1 2
6 5
4 3
0000419242
Figure 140 ABS System Wheel Modulator Valve Locations

1. Front Rear Drive Axle Modulator Valve 4. Rear Rear Drive Axle Modulator Valve
Left Left
2. Front Rear Drive Axle Modulator Valve 5. Steer Axle Modulator Valve Right
Right 6. Steer Axle Modulator Valve Left
3. Rear Rear Drive Axle Modulator Valve
Right
270
BRAKES
0000419216
Figure 141 ABS Module Location

1. ABS Module
ABS maximizes braking while preventing wheel lockup under hard braking and slippery conditions.
Wheel speed sensors detect the rate of rotation for each wheel and transmits information via direct connection
to the ABS module. ABS module determines the amount of air the modulator valves allow to the brake
chambers when a difference in wheel speed under braking is detected. The ABS provides output to the
Engine Control Module (ECM) and the Transmission Control Module (TCM) (If equipped) over the 500K
Powertrain J1939 communication network controlling engine braking, engine output, and transmission retarder
under ABS operation.
Inputs
• Wheel Speed Sensors
Provide wheel speed data to the ABS module as an AC signal. Voltage and frequency changes depending
on the speed of rotation of the wheels. 4 Channel ABS configurations have four wheel speed sensors
and 6 Channel ABS configurations have six wheel speed sensors.
271
BRAKES
Outputs
• ABS Indicator
Indicates if an ABS fault is present. Reference the ABS Indicator section of this manual for information
about the ABS indicator.
• Modulator Valves
Manipulate brake application air pressure to each brake chamber during ABS operation. The ABS module
electronically controls each valve using two integrated hold and release solenoids. 4 Channel ABS
configurations have four modulator valves and 6 Channel ABS configurations have six modulator valves.
Input Signals Output Signals

Wheel Speed Sensors Modulator Valves
Steer Steer
Axle Axle
Drive Drive
Axle Axle
6 Channel Only 6 Channel Only

ABS ABS
Auxiliary Auxiliary
Axle Axle
0000415306
Figure 142 ABS Signal Map
Service Information
For Bendix® ABS Service Information www.bendix.com
Diagnostics
ABS Module Loss of Communication
272
BRAKES
Service Procedures
ABS Module Removal
ABS Module Installation
Modulator Valve Removal
Modulator Valve Installation
Wheel Speed Sensor Removal
Wheel Speed Sensor Installation
273
BRAKES
Air - Automatic Traction Control System

Bendix®
Overview
0004AZJ Air Brake; Bendix® Anti-Lock Brake System (ABS), Full Vehicle Wheel
Control System (4-Channel) with Automatic Traction Control (ATC)
0004AZV Air Brake; Bendix® Anti-Lock Brake System (ABS), Full Vehicle Wheel
Control System (6-Channel) with Automatic Traction Control (ATC)
0000419218
Figure 143 Traction Control Component Location

1. Traction Control Switch 2. Drive Axle Traction Control Valve
274
BRAKES
0000419216

1. ABS Module
Reference Bendix® Anti-Lock Brake System for more information about the ABS inputs and outputs used by
the above feature codes to operate with the traction control system.
Traction control system maximizes traction under acceleration during low traction events by limiting engine
torque and modulating braking (if necessary), limiting wheel slip. The Engine Control Module (ECM) and drive
axle traction control valve work together for the traction control system.
Traction control mode is switched by the traction control switch which sends a message over the 125K Low
Speed J1939 network through the Body Control Module (BCM) and over the 500K Powertrain J1939 network to
the ABS module. Using the inputs from the ABS system wheel speed sensors, the ABS module will determine if
a low traction condition has occurred. The ABS module will provide output to the Engine Control Module (ECM)
over the 500K Powertrain J1939 network to limit engine torque. If needed, the ABS module will also manipulate
the drive axle traction control valve over a direct connection to actuate the brake chambers at the drive axle(s).
Inputs
• Traction Control Switch
A two-position momentary switch that communicates with the BCM over 125K Low Speed J1939 to change
the traction control system modes. The ABS module allows more wheel spin and engine power when
OFF ROAD on the switch is selected.
275
BRAKES
Outputs
• Drive Axle Traction Control Valve
Actuated by the ABS module to provide air pressure to the drive axle(s) brakes, bringing wheel slip or
spin under control. The ABS module electronically controls the valve using two integrated hold and
release solenoids.
• Traction Control Indicator
Indicates wheel spin or if a traction control fault is present. Reference the Traction Control Indicator
section of this manual for information about the traction control indicator.
BCM
ECM
ECM
J4 BARO
J1
J6
J1939 J1939
J2 500K Powertrain 500K Powertrain
J7 J3 ECM
J5
Traction
Drive Axle Traction
Control Switch
Control Valve
J1939 ABS ABS

125K Low Speed
0000415308
Figure 145 Traction Control Signal Map
Service Information
For Bendix® Traction Control Service Information www.bendix.com
Diagnostics
Service Procedures
ABS Module Removal
Trailer ATR-6 Valve Removal
Trailer ATR-6 Valve Installation
276
BRAKES
Air - Electronic Stability Control (ESC) System

Bendix®
Overview
0004AZS Air Brake; Bendix® Anti-Lock Brake System (ABS), with Electronic Stability
Program (ESP) (4-Channel) with Automatic Traction Control
0004AZY Air Brake; Bendix® Anti-Lock Brake System (ABS), with Electronic Stability
Program (ESP) (6-Channel) with Automatic Traction Control
7 6 5 4
0000419471
Figure 146 Electronic Stability Control Component Locations

1. Steering Angle Sensor 5. Primary Air Pressure Sensor
2. Yaw Rate Sensor 6. Secondary Air Pressure Sensor
3. Suspension Pressure Sensor 7. Steer Axle Traction Control Valve
4. Trailer Modulator Valve
277
BRAKES
0000419216

1. ABS Module
Reference Bendix® Anti-Lock Brake System and Bendix® Traction Control System for more information
about the ABS and traction control inputs and outputs used by the above feature codes to operate with
the ESC system.
ESC minimizes the possibility of a rollover during a slide or sudden change of direction by reducing engine
torque and applying the brakes. ESC works with the traction control system and ABS to stabilize the vehicle in
the line of the driver’s intended direction.
Using the inputs from the ABS system wheel speed sensors, yaw rate sensor, steering angle sensor, the ABS
module determines if a sudden lateral loss of traction occurred. The steering angle sensor and yaw rate sensor
send information to the ABS module over the ABS Private J1939 network. The ABS module manipulates the
steer axle traction control valve and trailer modulator valve with the traction control and ABS outputs to provide
braking pressure to the proper areas. Engine torque is also limited as an output of the traction control system.
Inputs
• Axle Load Sensor
Provides air pressure data from the air bags of the rear suspension to the ABS module. The data indicates
vehicle load which is a calculation the ABS module uses under ESC events.
278
BRAKES
• Primary and Secondary Delivery Air Pressure Sensors
Provides air pressure data from the primary and secondary air brake circuits to the ABS module. The data
indicates how much braking pressure is being requested by the driver.
• Steering Angle Sensor
Provides steering wheel position data to the ABS module based on driver input.
• Yaw Rate Sensor
Provides lateral acceleration and rotation data of the vehicle to the ABS module.
Outputs
• ESC Indicator
Indicates if the ESC is engaging, or if an ESC fault is present. Reference the Electronic Stability Control
Indicator section of this manual for information about the ESC indicator.
• Steer Axle Traction Control Valve
Actuated by the ABS module to provide air pressure to the steer axle brakes, bringing wheel slip or spin
under control. The ABS module electronically controls the valve using two integrated hold and release
solenoids.
• Stop Lights
The stop lights activate during an ESC event. Reference the Stop / Turn Lights section of this manual for
information about the stop light operation.
• Trailer Modulator Valve
Manipulates the brake application air pressure to the trailer brakes during ESC operation. The ABS
module electronically controls the valve using two integrated hold and release solenoids.
279
BRAKES

Steering Angle Steer Axle Traction
Sensor Control Valve
J1939
ABS Private
Yaw Rate
Sensor
J1939
ABS Private
Trailer Modulator
Valve
Primary Delivery Air
Pressure Sensor
Secondary Delivery Air

ABS ABS
Pressure Sensor
No Lift Axle Only

Axle
Load Sensor
0000415309
Figure 148 ESC Signal Map
Service Information
For Bendix® ESC / ESP Service Information www.bendix.com
Diagnostics
Service Procedures
ABS Module Removal
Steering Angle Sensor Removal
Steering Angle Sensor Installation
Yaw Rate Sensor Removal
Yaw Rate Sensor Installation
280
CHASSIS BODY BUILDING WIRING
8. Chassis Body Building Wiring

Overview
0008HAB Body BLDR Wiring BOC or U/C at HX Frame. Back of standard cab at
left frame or under extended or crew cab at left frame; includes sealed
connectors for tail/amber turn/marker/ backup/accessory power/ground
and sealed connector for stop/turn.
0008HAE Body Builder Wiring rear of frame; includes sealed connectors for
tail/amber turn/marker/ backup/accessory power/ground and sealed
connector for stop/turn.
0595BCM Trailer Lighting, for Non-Multiplexed Vehicles.
Chassis Body Builder connectors provide power and ground for lights and accessories installed with the body
builder’s assembly. This section only covers circuits included with the chassis. Refer to service and diagnostic
information provided by the body builder or trailer manufacturer for circuit and component diagnostics after the
body builder or trailer socket connectors.
Figure 149 Chassis Body Builder Connectors at Back Of Cab (Back Of Cab)
281
Figure 150 Chassis Body Builder Connectors at End Of Frame (EOF)
282
Figure 151 Body Builder and Trailer Lighting Relays and Fuses
1. 15A Fuse F1-P (Reverse Range Relay) 13. Body Marker Relay
2. 20A Fuse F5-C (Body Marker) 14. Body Stop Relay
3. 20A Fuse F5-G (Body Stop) 15. Body Right Turn Relay
4. 20A Fuse F5-H (Body Tail) 16. Body Left Turn Relay
5. 5A Fuse F4-F (Accessory) 17. Body Tail Relay
6. 20A Fuse F5-S (Left Turn) 18. Trailer Stop Relay
7. 20A Fuse F7-D (Back Up Lights) 19. Reverse Range Relay
8. 20A Fuse F7-B (Trailer Stop) 20. Body Back Up Light Relay
9. 20A Fuse F7-H (Accessory) 21. Body Accessory Relay
10. 10A Fuse F8-G (Back Up Lights)
11. Accessory Relay
12. 20A Fuse F5-R (Right Turn)
Chassis Body Builder Symptom Diagnostics

Tail and Marker Diagnostics (page 287)
Left Turn Light Diagnostics (page 290)
Right Turn Light Diagnostics (page 293)
Back Up Light Diagnostics (page 296)
Accessory Diagnostics (page 298)
Stop Light Diagnostics (page 300)
Trailer Lighting Diagnostics (page 303)
283

Overview
If chassis lights are not working properly go to appropriate chassis wiring diagnostics before diagnosing body
builder wiring. The following steps direct technicians to systematically troubleshoot chassis body builder
wiring performance to avoid unnecessary work and repairs. See Chassis Body Builder Wiring Overview
Step 1 Determine if vehicle chassis lights are working properly. Decision

Activate and observe chassis lights (turn signals, brake lights, marker lights, etc.). Yes: Go to Step 2.
Are chassis lights illuminating? No: Go to appropriate
chassis lighting
systems diagnostics in
this manual.
Step 2 Determine if body builder or trailer light(s) are burnt out or damaged. Decision
1. Key OFF. Yes: Replace burnt
out light(s) or repair
2. Disconnect body builder or trailer light(s) that do not illuminate.
damage. After repairs
3. Inspect and determine if light(s) are burnt out or damaged. are complete, retest
for symptom.
Are body builder or trailer light(s) burnt out or damaged? No: Go to Step 3.
Step 3 Trailer lights not working properly, if equipped. Decision

2. Activate park / marker lights. Move headlight switch to middle position.
3. Activate stop / brake lights.
Are trailer brake, stop and marker lights working properly? No: Go to Tailer
Lighting Diagnostics,
(page 303)
Step 4 Inspect 7-way Body Builder connector and 3-way Body Builder Decision
Turn/Stop connectors.
1. Key OFF. Yes: Go to Step 5.
2. Disconnect Body Builder connectors.
3. Check connectors and connector terminals for: damage or pinched
wires; moisture or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are Body Builder connector, harness, and terminals clean and undamaged? No: Repair connector,
harness, or terminal
are complete, retest
for symptom.
284
Step 5 Determine if chassis Body Builder connector ground circuit has high Decision
resistance.
Using a Digital Multimeter (DMM), measure resistance between chassis Body Yes: Go to Step 6.
Builder 7-way connector pin-G and battery ground.
Is resistance less than 5 ohms? No: Repair high
resistance in chassis
Body Builder ground
circuit. See Electrical
Circuit Diagram
Manual. After repairs
for symptom.
Step 6 Body builder tail and / or marker lights not working properly. Decision
2. Activate park/marker lights. Move headlight switch to the middle
position.
3. Measure voltage between chassis Body Builder 7-way connector pin-A
and ground.
4. Measure voltage between chassis Body Builder 7-way connector pin-D
and ground.
Are both voltage readings within 0.5 volts of battery voltage? No: Go to Tail and
Marker Diagnostics,
(page 287)
Step 7 Body builder left turn lights not working properly. Decision
2. Activate left turn signal lights.
3. Measure voltage between chassis Body Builder 7-way connector pin-B
and ground, and/or Measure voltage between chassis Body Builder
Turn/Stop 3-way connector pin-A and ground.
Is voltage toggling between B+ ± 0.5 volts and 0 volts? No: Go to Left Turn
Light Diagnostics
(page 290).
Step 8 Body builder right turn lights are not working properly. Decision
2. Activate right turn signal lights.
3. Measure voltage between chassis Body Builder 7-way connector pin-C
and ground, and/or Measure voltage between chassis Body Builder
Turn/Stop 3-way connector pin-B and ground.
Is voltage toggling between B+ ± 0.5 volts and 0 volts? No: Go to Right Turn
Light Diagnostics
(page 293).
285
Step 9 Body builder back up lights not working properly. Decision

2. Activate back up lights.
3. Measure voltage between chassis Body Builder 7-way connector pin-E
and ground.
Is voltage within 0.5 volts of battery voltage? No: Go to Back Up
Light Diagnostics
(page 296).
Step 10 Body builder accessories not working properly. Decision

2. Activate Body Builder accessories.
3. Measure voltage between chassis Body Builder 7-way connector pin-F
and ground.
Is voltage within 0.5 volts of battery voltage? No: Go to Accessory
Diagnostics (page
298).
Step 11 Body builder stop lights not working properly. Decision

1. Key ON. Yes, all Body Builder
connector pins have
2. Activate stop / brake lights.
proper voltage or
3. Measure voltage between chassis Body Builder Turn/Stop 3-way ground: Repair circuit
connector pin-C and ground. problem(s) in body
builder assembly.
After repairs are
complete, retest for
symptom.
Is voltage within 0.5 volts of battery voltage? No: Go to Stop Light
Diagnostics (page
300).
286
Tail and Marker Diagnostics

Overview
Body builder tail and marker lights illuminate when the Body Controller (BC) receives input from the headlight
switch and turns On the park lights output circuit at BC connector J2 pin-G.
Figure 152 Park Lights Output from Body Controller Connector J2 (1604)
1. Park lights power output
Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did you perform Operational Checkout Procedure? No: Go to Operational
Checkout Procedure
(page 284).
287
Step 2 Determine if fuses for body builder tail and marker lights circuits are Decision
blown.
Inspect fuses F5-H and F5-C. Yes: Go to Step 3.
Are fuses in good condition and not blown? No: Replace fuse(s)
and retest. If fuse
blows, test for short
between fuse and
7-way body builder
connector. After
repairs are complete,
retest for symptom.
Figure 153 Chassis Body Builder Tail and Marker Lights, Switch OFF
288
Figure 154 Chassis Body Builder Tail and Marker Lights, Switch ON
Step 3 Determine if tail and marker lights circuits have proper voltage and ground.
Determine if chassis circuits for body builder tail and marker lights circuits have proper voltage and ground,
per Chassis Body Builder Tail and Marker Lights, Switch OFF; and Chassis Body Builder Tail and Marker
Lights, Switch ON graphics. Circuits shown in red should have battery voltage at specified operator controls.
End Diagnostic Tests

After performing diagnostic steps, if fault remains, verify steps were completed correctly and proper decision
was made. Notify supervisor for further action.
289
Left Turn Light Diagnostics

Overview
Body builder left turn lights illuminate when the Body Controller (BC) received input from the multifunction
switch and turns On the Trailer Left Turn Lamp Cmd output circuit at BC connector J1 pin-B.

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Step 2 Determine if fuses for body builder left turn lights circuits are blown. Decision
Inspect fuse F5-S. Yes: Go to Step 3.
Is fuse in good condition and not blown? No: Replace fuse and
retest. If fuse blows,
test for short between
fuse and body builder
connectors. After
retest for symptom.
290
Figure 155 Chassis Body Builder Left Turn Lights, Switch OFF
291
Figure 156 Chassis Body Builder Left Turn Lights, Switch ON
Step 3 Determine if left turn circuits have proper voltage and ground.
Determine if chassis circuits for body builder left turn lights circuits have proper voltage and ground, per
Chassis Body Builder Left Turn Lights, Switch OFF; and Chassis Body Builder Left Turn Lights, Switch ON
graphics. Circuits shown in red should have battery voltage at specified operator controls.

292
Right Turn Light Diagnostics

Overview
Body builder right turn lights illuminate when the Body Controller (BC) received input from the multifunction
switch and turns On the Trailer Right Turn Lamp Cmd output circuit at BC connector J1 pin-A.

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Step 2 Determine if fuse for body builder right turn lights circuit is blown. Decision
Inspect fuse F5-R. Yes: Go to Step 3.
Is fuse in good condition and not blown? No: Replace fuse and
retest. If fuse blows,
test for short between
fuse and body builder
connectors. After
retest for symptom.
293
Figure 157 Chassis Body Builder Right Turn Lights, Switch OFF
294
Figure 158 Chassis Body Builder Right Turn Lights, Switch ON
Step 3 Determine if right turn circuits have proper voltage and ground.
Determine if chassis circuits for body builder right turn lights circuits have proper voltage and ground, per
Chassis Body Builder Right Turn Lights, Switch OFF; and Chassis Body Builder Right Turn Lights, Switch
ON graphics. Circuits shown in red should have battery voltage at specified operator controls.

295
Back Up Light Diagnostics

Overview
Body builder back up lights illuminate when the Transmission Control Module (TCM) provides a path to
ground energizing the Reverse Range Relay and Body Backup Light Relay. When the Body Back Up Light
Relay is energized fuse F7-D provides power to Pin-E of the 7-way Body Builder Connector for the body
builder back up lights.

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Step 2 Determine if fuses for body builder back up lights circuits are blown. Decision
Inspect fuses F7-D, F8-G and F1-P. Yes: Go to Step 3.
and retest. If fuse
blows, test for short.
After repairs are
symptom.
Figure 159 Chassis Body Builder Back Up Lights, Switch OFF
296
Figure 160 Chassis Body Builder Back Up Lights, Switch ON
Step 3 Determine if back up circuits have proper voltage and ground.

Determine if chassis circuits for body builder back up lights circuits have proper voltage and ground, per
Chassis Body Builder Back Up Lights, Switch OFF; and Chassis Body Builder Back Up Lights, Switch ON
graphics. Circuits shown in red should have battery voltage at specified operator controls.

297
Accessory Diagnostics
Overview
The chassis body builder accessory circuits activate when the ignition key switch provides power to energize
the Accessory Relay and Body Accessory Relay. When the Body Accessory Relay is energized fuse F7-H
provides power to pin-F of the 7-way Body Builder Connector for body builder accessories.

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Step 2 Determine if fuses for body builder accessory circuits are blown. Decision
Inspect fuses F7-H and F4-F. Yes: Go to Step 3.
and retest. If fuse
After repairs are
symptom.
Figure 161 Chassis Body Builder Accessories, Switch OFF
298
Figure 162 Chassis Body Builder Accessories, Switch ON
Step 3 Determine if chassis body builder accessory circuits have proper voltage and ground.
Determine if chassis circuits for body builder accessories have proper voltage and ground, per Chassis Body
Builder Accessories, Switch OFF; and Chassis Body Builder Accessories, Switch ON graphics. Circuits
shown in red should have battery voltage at specified operator controls.

299
Stop Light Diagnostics

Overview
Body builder stop lights illuminate when the Body Controller (BC) received input from the brake switch and
turns On the LH Trailer Brake Signal output circuit at BC connector J4 pin-F15.

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Step 2 Determine if fuses for body builder stop lights circuits are blown. Decision
Inspect fuses F5-G and F7-B. Yes: Go to Step 3.
and retest. If fuse
After repairs are
symptom.
300
Figure 163 Chassis Body Builder Stop Lights, Switch OFF
301
Figure 164 Chassis Body Builder Stop Lights, Switch ON
Step 3 Determine if stop lights circuits have proper voltage and ground.
Determine if chassis circuits for body builder stop lights circuits have proper voltage and ground, per Chassis
Body Builder Stop Lights, Switch OFF; and Chassis Body Builder Stop Lights, Switch ON graphics. Circuits

302
Trailer Lighting Diagnostics

Overview
Trailer stop lights associated with Feature Code 0595BCM illuminate when the Body Controller (BC) received
input from the brake switch and turns On the LH Trailer Brake Signal output circuit at BC connector J4 pin-F15.
Trailer marker lights and tail lights illuminate when the BC receives input from the headlight switch and turns
On the output at pin-D and pin-F. This section only covers circuits included with the vehicle chassis.
Figure 165 Trailer Lighting Diamond Logic® Builder (DLB) Session

1. Trailer brake light output 3. Trailer marker light output
2. Trailer tail light output
303
Figure 166 Trailer Marker and Tail Lights Output from BC Connector J2
1. Trailer marker light output 2. Trailer tail light output
304
Figure 167 Trailer Brake Lights Output from BC Connector J4

1. Trailer brake lights output

Yes: Go to Step 2.
Checkout Procedure
(page 284).
Figure 168 Trailer Socket Connector
305
Step 2 Inspect 6-way Trailer Socket connector. Decision

2. Disconnect trailer socket connector located on rear of sleeper or end
of frame.
3. Check connector and connector terminals for: damage or pinched
Are Trailer Socket connector, harness, and terminals clean and undamaged? No: Repair connector,
for symptom.
Step 3 Trailer tail lights not working properly. Decision

2. Activate park/marker lights. Move headlight switch to middle position.
3. Measure voltage between chassis Trailer Socket 6-way connector
pin-B and ground.
Is voltage within 0.5 volts of battery voltage? No: Repair open or
short between trailer
socket pin-B and BC
J2 pin-D. After repairs
for symptom.
Step 4 Trailer marker lights not working properly. Decision

2. Activate park/marker lights. Move headlight switch to the middle
position.
3. Measure voltage between chassis Trailer Socket 6-way connector
pin-D and ground.
Is voltage within 0.5 volts of battery voltage? No: Repair open or
short between trailer
socket pin-D and BC
J2 pin-F. After repairs
for symptom.
306
Figure 169 Chassis Body Builder Stop Lights, Switch ON
Step 4 Determine if fuses for trailer stop lights circuit is blown. Decision
Inspect fuse F7-B. Yes: Go to Step 5.
Is fuse in good condition and not blown? No: Replace fuse(s)
and retest. If fuse
After repairs are
symptom.
307
Step 5 Trailer stop lights not working properly.

Determine if chassis circuits for trailer stop lights circuits have proper voltage and ground, per Chassis Body
Builder Stop Lights, Switch ON graphics. Circuits shown in red should have battery voltage at specified
operator controls.

308
Remote Cruise Control Connection

Overview
08TSE Body Building Wiring Modifications to provide for remote cruise control
connection
309
COLLISION AVOIDANCE SYSTEMS
9. Collision Avoidance Systems

Collision Mitigation System
Bendix® Wingman® Advanced™
Overview
0008TPL Collision Mitigation System, Bendix Wingman Advanced
0000419234
Figure 170 Bendix Wingman Advanced Components

1. Radar Sensor
310
0000419216

1. ABS Module
The following features are included with Bendix Wingman Advanced:
• Adaptive Cruise Control

• Brake Overuse Alert
• Collision Mitigation Braking
• Following Distance Alert
• Impact Alert
• Stationary Object Alert
Bendix Wingman Advanced integrates collision warnings, collision avoidance, and cruise control that adapts to
movements of other vehicles. Radar sensor detects distance between the front of the vehicle and forward
moving vehicles and has a range of approximately 500 feet. Anti-Lock Brake System (ABS) module manages
Bendix Wingman Advanced and operates the ABS and Electronic Stability Control (ESC) systems. Body
Control Module (BCM) is the gateway module to relay messages between communication networks and other
modules. Engine Control Module (ECM) controls engine speed and engine braking. Electronic Gauge Cluster
(EGC) shows visual and audible alerts and data to the driver. These components communicate over the
500K Powertrain J1939 communication network.
311
Adaptive Cruise Control (ACC)

ACC maintains speed set by the driver and will adjust speed to keep a set following distance. If the detected
forward vehicle slows down below the set cruise speed as detected by the radar sensor, a message is sent
over 500K Powertrain J1939 to the ECM and ABS module to first reduce engine power, then apply the engine
retarder (if equipped), and finally apply the foundation brakes to maintain set following distance. If the detected
forward vehicle increases speed, ACC returns to the original set speed.
Alerts
• Brake Overuse Alert
Warns driver when the foundation brakes are used too often by the ACC. The alert is cancelled by
engaging the brakes, pressing the cruise cancel button, or turning off cruise control. Cruise control should
not be enabled again for 20 minutes. The braking function of the ACC will be unavailable for 20 minutes if
reactivated within the 20 minutes of the alert. The system will shut down and a fault code will set if the
driver does not cancel the alert within 15 seconds of the alert sounding and all Bendix® Wingman®
Advanced™ controlling features will be disabled until the next ignition cycle. Brake Overuse Alert is
calculated by the ABS module.
• Following Distance Alert (FDA)
FDA warns the driver when the distance between the vehicle and a moving forward vehicle is decreasing.
The feature is available when vehicle speed is above 5 mph. Following distance is measured by the radar
sensor which sends a message over 500K Powertrain J1939 resulting in the EGC activating FDA.
• Impact Alert (IA)
IA warns the driver when a collision with another forward moving vehicle is possible. The feature is
available when vehicle speed is above 15 mph. Collision Mitigation Braking typically occurs with IA. The
radar sensor detects possible collisions and sends a message over 500K Powertrain J1939 resulting in
the EGC activating IA.
• Stationary Object Alert (SOA)
SOA alerts the driver when a stationary object is in the vehicle’s line of travel up to 3 seconds prior to
collision. The feature is available when the vehicle is moving above 10 mph. When the radar sensor
detects stationary objects large enough, and radar reflective, it sends a message over 500K Powertrain
J1939 resulting in the EGC activating SOA.
Collision Mitigation Braking

Collision Mitigation functions at speeds above 15 mph and reacts when a possible collision is detected by the
radar sensor. The radar sensor sends a message over 500K Powertrain J1939 to the ABS module to apply the
foundation brakes up to two-thirds braking capacity. The driver must immediately act once Collision Mitigation
activates to avoid a collision or reduce damage in a collision. If any brake system or Bendix Wingman
Advanced fault codes are present, Collision Mitigation will not function.
312
Output Signals
ABS Module
ABS Electronic Gauge Cluster
Radar Sensor
J1939
500K Powertrain
Body Control Module

Engine Control Module
BARO
J4
J1
ECM
J6
J2
J7 J3
J5
0000418884
Figure 172 Collision Mitigation Signal Map
Service Information
For Bendix Wingman Advanced Service Information www.bendix.com
Diagnostics
Radar Sensor Loss of Communication (page 317)
Service Procedures
Radar Sensor Removal (page 320)
Radar Sensor Installation (page 322)
Radar Sensor Adjustment (page 324)
Tech Tips
• If replacing the radar sensor or mounting plate, or if the truck is equipped with the base Electronic Gauge
Cluster (EGC), the lateral adjustments (page 324) must be made to the radar sensor using method
with the Bendix® Alignment Tool Kit, 19-090-01.
313
• A lateral adjustment can be made to the radar sensor using the cluster display in the premium EGC (if
equipped) if the radar sensor or mounting plate is not being replaced.
• A radar sensor vertical adjustment (page 326) should be performed when lateral adjustments are
performed.
314

Overview
The following steps direct technicians to systematically troubleshoot Bendix® Wingman® Advanced™
performance to avoid unnecessary repairs.
Step 1 Check for proper collision mitigation system operation. Decision

1. Key ON. Press cruise control switch at least once till in ON position. Yes: Go to Step 5.
2. Start vehicle while parked. Wait approximately 20 seconds for system
self-test to complete after set of short beeps.
Is a long warning beep heard? No: Go to Step 2.
Step 2 Check for debris on radar sensor. Decision

Inspect the radar sensor for debris, or objects that may be obstructing sensor view. Yes: Go to Step 3.
Is radar sensor clean and free from obstruction? No: Clean sensor
or remove objects
from the front of radar
sensor and retest for
fault. If fault is still
present, go to Step 3.
Step 3 Check for damaged radar sensor. Decision

Inspect the radar sensor for cracks or broken pieces. Yes: Go to Step 4.
Is radar sensor undamaged? No: Replace radar
sensor (page 320).
After repairs are
fault.
Step 4 Check for damaged radar sensor mounting. Decision

Inspect the radar sensor mounting and front of vehicle for damage or misalignment. Yes: Go to Step 5.
Is radar sensor mounting and vehicle front end properly aligned and undamaged? No: Align radar sensor
(page 324). After
retest for fault. If fault
is still present, go to
Step 5.
315

™
Using Electronic Service Tool (EST) with ServiceMaxx software, check Diagnostic Yes: Go to
Trouble Code (DTC) list for active fault codes related to the collision mitigation www.bendix.com for
system. fault code diagnostics
Yes, codes related
to radar sensor
communication: Go
to Radar Sensor Loss
of Communication
(page 317) for further
diagnostics.
Are any related fault codes active? No: Go to Step 6.
Step Check radar sensor communication. Decision

6
Perform Module Communication Test (page 332) to determine modules Yes: End diagnostics.
communicating.
Is radar sensor communicating? No, radar sensor
only: Go to Radar
Sensor Loss of
Communication
(page 317) for further
diagnostics.
No, multiple modules:
Go to CAN (Controller
Area Network) System
(page 329) section for
diagnostics.

316
Radar Sensor Electrical Test

Overview
The following steps direct technicians to systematically troubleshoot radar sensor communication to avoid
unnecessary repairs.
Fault Facts
• CAN-H voltage should be approximately 2.7 volts and CAN-L voltage should be approximately 2.3 volts.
The sum of CAN-H and CAN-L voltages should be approximately 5 volts, and should not be equal. If
CAN-H and CAN-L have the same voltage suspect CAN wires shorted together.
• See CAN (Controller Area Network) System (page 329) for further information on CAN communication
and CAN faults.
Tools Required
• Terminal Test Kit ZTSE4435C
Possible Causes
• Radar sensor ground circuit Open, high resistance or short to power
• Radar sensor ignition circuit Open, high resistance or short to ground
• CAN-H circuit Open or high resistance
• CAN-L circuit Open or high resistance
• Failed Radar sensor

Yes: Go to Step 2.
Checkout Procedure
(page 315).
Step 2 Check for blown fuses. Decision

Inspect collision mitigation related fuses in the on the interior Power Distribution Yes: Replace
Module (PDM) for opens. fuse. If fuse blows
immediately, test for
short to ground. After
retest for fault.
Are any fuses blown? No: Go to Step 3.
317
Step Inspect connections at radar sensor connector 8903 Decision

3
1. Key OFF. Disconnect radar sensor connector 8903. Yes: Repair connector,
2. Check radar sensor connector and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or
for fault.
Are connector, harness, and terminals clean and undamaged? No: Go to Step 4.
Step Check radar sensor ground for Open, high resistance or short to power Decision
4
1. Key OFF. Leave radar sensor connector 8903 disconnected. Yes: Go to Step 5.
2. Insert proper terminal from Terminal Test Kit ZTSE4435C to connector
8903 pin-5.
3. Key ON. Use Digital Multimeter (DMM) to measure voltage between
pin-5 and power.
Is voltage within 0.5 volts of battery voltage? No: Repair Open, high
resistance or short to
power in radar sensor
ground circuit. After
retest for fault.
Step Check radar sensor ignition power for Open, high resistance or short to Decision
5 ground
1. Key OFF. Leave radar sensor connector 8903 disconnected. Yes: Go to Step 5.
2. Insert proper terminal from Terminal Test Kit to connector 8903 pin-8.
3. Key ON. Use DMM to measure voltage between pin-8 and ground.
Is voltage within 0.5 volts of battery voltage? No: Repair Open, high
resistance or short to
ground in radar sensor
ignition circuit. After
retest for fault.
Step 6 Check CAN-H voltage to radar sensor Decision

1. Key ON. Leave radar sensor connector 8903 disconnected. Yes: Go to Step 7.
3. Key ON. Use DMM to measure voltage between pin-1 and ground.
Is voltage approximately 2.7 volts? No: Repair Open or
high resistance on
CAN-H circuit. After
retest for fault.
318
Step 7 Check CAN-L voltage to radar sensor Decision

1. Key OFF. Leave radar sensor connector 8903 disconnected. Yes: Replace radar
sensor. After repairs
3. Key ON. Use DMM to measure voltage between pin-6 and ground. for fault.
Is voltage approximately 2.3 volts? No: Repair Open or
high resistance on
CAN-L circuit. After
retest for fault.

319
Radar Sensor Removal
0000419134
Figure 173 Radar Sensor Component View

1. Vertical adjustment screw 3. Stationary adjustment screw
2. Lateral adjustment screw 4. Radar sensor connector
Special Tools
None
None
2. Key OFF.
Removal Procedure
1. Disconnect radar sensor connector (4).
320
2. Remove vertical adjustment screw (1), lateral adjustment screw (2), and stationary adjustment screw (3),
counting number of turns out on each.
3. Remove radar sensor.
Follow-On Procedure
None
321
Radar Sensor Installation
0000419134
Figure 174 Radar Sensor Component View

1. Vertical adjustment screw 3. Stationary adjustment screw
2. Lateral adjustment screw 4. Radar sensor connector
Special Tools
None
None
2. Key OFF.
1. Install radar sensor.
322
2. Install vertical adjustment screw (1), lateral adjustment screw (2), and stationary adjustment screw (3),
turning number of turns in recorded from remove procedure.
3. Connect radar sensor connector (4).
Follow-On Procedure
2. Radar Sensor Adjustment (page 324).
323
Radar Sensor Adjustment

Special Tools
• Bendix® Wingman® ACB Alignment Tool Kit, 19-090-01
Specifications
Radar lateral measurement difference 1/8 in. max
Radar vertical measurement 0° (±0.5°)
3. Key ON.
Lateral Adjustment Procedure
0000419141
Figure 175 Bendix® Alignment Tool Lateral Measurement Installation

1. Measuring device 3. Radar sensor
2. Steel clip 4. Alignment tool
1. Install steel clip (2) from kit over radar sensor (3).
2. Install alignment tool (4) so flat surface of angled metal is facing down with magnetic feet on steel clip (2).
324
3. Switch the alignment tool laser ON so laser points left (passenger side of truck).
4. Place a tape measure or ruler (1) on fixed point of the vehicle that is symmetrical across both sides
of the truck (ex. tow hooks).
5. Measure where laser from alignment tool (4) hits on measuring device (1) and record measurement.
6. Switch the alignment tool laser ON so laser points the opposite direction (if equipped), or rotate alignment
tool (4) so laser points in opposite direction.
7. Place measuring device on fixed point of the vehicle that is symmetrical on the opposite side of the
truck from fixed point in Step 9.
8. Measure where laser from alignment tool (4) hits on measuring device (1) and record measurement.
0000419134
Figure 176 Radar Sensor Components

1. Vertical adjustment screw 4. Radar sensor
2. Lateral adjustment screw
3. Stationary adjustment screw (Do not
adjust)
9. Turn lateral adjustment screw (2) on radar sensor until two measurements are within 1/8 in of each other.
10. Go to Vertical Adjustment Procedure (page 326).
325
Vertical Adjustment Procedure
2 3 4
0000419142
Figure 177 Setting Digital Angle Gauge Zero

1. Frame rail 3. Digital angle gauge
2. ON / OFF button 4. Zero button
11. Turn ON digital angle gauge (3) from kit by pressing ON/OFF button (2).
12. Place digital angle gauge (3) on top of frame rail (1) parallel with frame rails.
13. Zero the digital angle gauge (3) by pressing the zero button (4).
326
1 2
RO
ZE
F
/OF
3
ON
0000419151
Figure 178 Bendix® Alignment Tool Vertical Measurement Installation

1. Digital angle gauge 3. Radar sensor
2. Steel clip 4. Alignment tool
14. Install steel clip (2) from kit over radar sensor (3).
15. Rotate alignment tool (4) so flat surface of angled metal is facing up with magnetic feet on steel clip (2)
(if not already done).
16. Place digital angle gauge (1) on top of flat surface of alignment tool (4), parallel with frame rails.
17. Check measurement on digital angle gauge (1).
327
0000419134
Figure 179 Radar Sensor Components

1. Vertical adjustment screw 4. Radar sensor
2. Lateral adjustment screw
3. Stationary adjustment screw (Do not
adjust)
18. Turn vertical adjustment screw (1) on radar sensor till digital angle gauge reads 0° (±0.5°).
Follow-On Procedure
None
328
DATA LINKS
10. Data Links

CAN Systems
Overview
J1939 is an industry standard for providing communications between modules over a Controller Area Network
(CAN) bus (also know as a datalink).
Trucks are equipped with multiple separate networks of varying speed (125K, 250K, 500K, etc). The Body
Control Module (BCM) is used as a gateway between these networks. This gateway allows the datalinks to
communicate with one another.
All J1939 datalinks are a twisted pair of wires with 2 terminating resistors, and though they are separate,
are diagnosed the same. Certain modules are required to communicate over the faster 500K datalink per
regulations and industry standards.
Faults
Short
Either of the CAN wires may become shorted to ground, power, or to each other. This may cause very
erratic communication, complete loss of communication. and / or many types of fault codes originating from
modules on that network. With the key ON, a healthy network will read approximately 2.7V and 2.3V DC on
CAN-H and CAN-L, respectively.
If a short to POWER occurs on CAN-H, the network MAY still function.
If a short to GROUND occurs on CAN-L, the network MAY still function.
Terminating Resistor Failure

There are two 120 ohms terminating resistors on each network, one at either end. Their purpose is to minimize
the reflection of data across the network, preventing the signal from becoming erratic.
The resistance of a healthy network, measured from CAN-H to CAN-L with batteries disconnected, should be
approximately 60ohms.
A network with one terminating resistor MAY still function.
329
DATA LINKS
Backbone Open
Figure 180 Backbone Open (example only)
If there is an open on the backbone of the network, the network is essentially divided into two separate
networks, with each side only being able to communicate with the modules on their side.
If the open results in loss of a terminating resistor, loss of communication MAY result.
Node Open
Figure 181 Node Open (example only)
If there is an open on a single node of the network, only that module’s communication will be lost. All other
modules will communicate as they should.
If the open results in loss of a terminating resistor, loss of communication MAY result.
330
DATA LINKS
Approximate CAN DC Voltage Measurements (Key ON)

Fault CAN-H (yellow) Reading CAN-L (green) Reading
Healthy network 2.7V 2.3V
CAN-H shorted to POWER 12V 11.7V
CAN-H shorted to GROUND 0V 0.5V
CAN-L shorted to POWER 11.7V 12V
CAN-L shorted to GROUND 0.5V 0V
CAN-H & CAN-L shorted together 2.5V 2.5V
CAN-H & CAN-L open between 0V 0V
connector and nearest module(s)
Approximate CAN Resistance Measurements (Batteries Disconnected)

Fault Resistance (CAN-H to CAN-L)
Healthy network 60 ohms
Loss / failure of one terminating resistor 120 ohms
Loss / failure of both terminating resistors 0 ohms
331
DATA LINKS
Tests
Module Communication Test

Overview
The purpose of this test is to determine which modules are functional and communicating with the Body
Control Module (BCM). This, along with the network map, will help tracing the location of the fault.
Tools Required
• Electronic Service Tool (EST) with NavKal™ software.
Equipment Condition
Key ON.
Test Setup
1. Determine what modules are installed on vehicle.
2. Using Electronic Service Tool (EST) with NavKal™ software, connect to vehicle and open NavKal™.
332
DATA LINKS
Test Procedure
Figure 182 NavKal Home Page

1. Sniffer Tab
1. Verify modules are communicating by viewing modules that appear in the lower right hand corner under
Sniffer tab.
Follow-On Procedure
None.
333
DRIVETRAIN
11. Drivetrain
Driver Controlled Locking Differential
Overview
0595BXL Locking Differential, Driver Controlled, for Non-Multiplexed Vehicles
0014WBN DIFF. SWITCH CONTROLS Two Independent Switches for Control
Traction Differentials on Tandem Rear Axles, Mounted on Dash
0014WCE DIFF. SWITCH CONTROLS Three Independent Switches for Control
Traction Differentials on Tridem Rear Axles, Mounted on Dash
Selectively locks drive axle differential, transmitting power to drive wheels on axles equipped with a differential
lock.
Differential Lock Control is enabled by the operator using a hardwired Master Differential Lock Control Switch
mounted on the instrument panel. The vehicle speed interlock is provided to enable and disable the Differential
Lock Control along with the switch input. Locked and Unlocked state for each axle differential is requested
by individual Differential Lock Switches.
The Body Controller (BC) accepts vehicle speed information and engine speed information from the Engine
Control Module (ECM) on the data link. The BC provides low side relay drive to Differential Lock Control relay
which implements vehicle speed interlock. System allows differential request to lock the differential when
vehicle speed is below ‘Diff_Lock_Engagement_Speed’. System allows differential request to unlock the
differential when vehicle speed reaches or exceeds ‘Max_Diff_Lock_Speed’.
334
DRIVETRAIN
Figure 183 Driver Controlled Locking Differential DLB Session

1. Differential Locking Output
335
DRIVETRAIN
Figure 184 Driver Controlled Locking Differential Output from Body Controller Connector J4 (1601)
1. Differential Locking Output
336
DRIVETRAIN
Figure 185 Driver Controlled Locking Differential Relays

1. Differential Lock Latch relay 2. Differential Lock Control relay
337
ENGINE
12. Engine
Cummins® Diagnostics
Table Of Contents
Diagnostics
Fault Code Diagnostics (page 339)
Tests and Inspections (page 439)
338
ENGINE
Fault Code Diagnostics
Fault Code List

SPN FMI Cummins Description
Fault
Code
111 1 235 Coolant Level - Data Valid But Below Normal Operating Range - Most
Severe Level
111 3 195 Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to
High Source (page 341)
111 4 196 Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to
Low Source (page 349)
111 17 2448 Coolant Level - Data Valid But Below Normal Operating Range - Least
Severe Level (page 357)
111 18 197 Coolant Level - Data Valid But Below Normal Operating Range -
Moderately Severe Level (page 365)
1569 15 6255 Engine Protection Torque Derate - Data Valid But Above Normal
1569 31 3714 Engine Protection Torque Derate - Condition Exists (page 374)
1761 1 1673 Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below
Normal Operating Range - Most severe Level (page 375)
1761 3 1669 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage
Above Normal or Shorted to High Source (page 376)
1761 4 1668 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Voltage Below
Normal or Shorted to Low Source (page 377)
1761 9 4677 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Abnormal Update Rate
(page 378)
1761 10 4769 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal
Rate of Change (page 387)
1761 11 4739 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Root Cause
Not Known (page 388)
1761 13 4732 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of
Calibration (page 389)
Normal Operating Range - Least Severe Level (page 390)
Normal Operating Range - Moderately Severe Level (page 391)
3031 2 1679 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic,
Intermittent, or Incorrect (page 392)
3031 3 1678 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage
3031 4 1677 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage
Below Normal or Shorted to Low Source (page 394)
339
ENGINE
SPN FMI Cummins Description

Fault
Code
3031 9 4572 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal
Update Rate (page 395)
3031 11 4737 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause
Not Known (page 404)
3031 13 4731 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out
of Calibration (page 405)
3364 2 3878 Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or
Incorrect (page 406)
3364 3 1686 Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage
3364 4 1685 Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage
Below Normal or Shorted to Low Source (page 409)
3364 9 3868 Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate
(page 411)
3364 10 4277 Aftertreatment Diesel Exhaust Fluid Quality Abnormal Rate of Change
(page 419)
3364 11 1715 Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known
(page 422)
3364 13 1714 Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration (page 423)
3364 15 4842 Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above
Normal Operating Range - Least Severe Level (page 424)
3364 18 3867 Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal
Operating Range - Moderately Severe Level (page 426)
3521 11 4768 Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known
(page 428)
3521 16 6765 Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above
3521 18 6766 Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below
3521 31 4235 Aftertreatment 1 Diesel Exhaust Fluid Property - Condition Exists (page
433)
4096 31 3547 Aftertreatment Diesel Fluid Tank Empty - Condition Exist (page 435)
5246 0 3712 Aftertreatment SCR Operator Inducement - Data Valid But Above Normal
Operating Range - Most Severe Level (page 436)
5246 15 4134 Aftertreatment SCR Operator Inducement - Data Valid But Above Normal
5246 16 6254 Aftertreatment SCR Operator Inducement Severity - Data Valid But Above
340
ENGINE
SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted
to High Source
Fault Overview
This fault code sets when Engine Control Module (ECM) detects Coolant Level Sensor Circuit signal voltage is
above normal or shorted to a high source.
Associated Faults
None
Fault Facts
None
Possible Causes
• Low coolant level
• Open or high resistance in VREF circuit
• Open or short in Engine Coolant Level (ECL) signal circuit
• Open or high resistance in ground circuit
• Open or short in output circuit
• Failed ECL sensor
• Failed Coolant Level Module (CLM)

Use Electronic Service Tool (EST). Key ON Engine OFF (KOEO), check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 111 FMI 3.
Is SPN 111 FMI 3 active or pending? No: Perform Procedure
019-362 Inactive or Intermittent
Fault Code Check (See
Cummins Service Information).
Step 2 Check coolant level. Decision

Inspect coolant level at deaeration tank. Yes: Refer to appropriate
engine service manual and
repair coolant leak. After
repairs are complete, retest
for fault.
Is coolant level low, is there evidence of coolant loss, or does operator No: Go to Step 3.
complain of coolant leaks or consumption?
341
ENGINE
Step 3 Inspect connections at Coolant Level Module (CLM). Decision

A. Key OFF. Disconnect CLM. CLM is located on Powertrain Yes: Go to Step 4
Harness towards front of engine.
B. Check connector terminals for: damaged or pinched wires;
moisture or corroded terminals; loose, bent, or broken pins;
or broken connector housing.
Is CLM connector, harness, and terminals clean and undamaged? No: Repair / replace
connector, harness, or
terminal. After repairs are
complete, retest for fault.
Step 4 Check for Open \ high resistance in VREF circuit. Decision

A. Key OFF. Connector CLM disconnected. Yes: Go to step 5.
B. Use Engine Terminal Test Kit ZTSE4435C, insert proper
terminal into vehicle harness pin-A.
C. Key ON. Use Digital Multimeter (DMM) to measure voltage
between Engine Terminal Test Kit ZTSE4435C pin-A and
ground.
Is voltage 5 volts ± .025? No: Repair open / high
resistance between CLM
pin-A and ECM pin-08. After
for fault.
342
ENGINE
Step 5 Check for an Open / high resistance in ground circuit. Decision

B. Insert proper terminal into vehicle harness pin-D.
C. Measure resistance between pin-D and ground.
Is resistance less than 5 ohms? No: Repair Open / high
pin-D and ECM pin-32. After
for fault.
Step 6 Inspect connections at Engine Coolant Level (ECL) sensor. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Go to Step 7.
Is ECL connector, harness, and terminals clean and undamaged? No: Repair / replace
343
ENGINE
Step 7 Check for short in ECL ground circuit. Decision

A. Key OFF. CLM and ECL disconnected. Yes: Go to Step 8.
B. Insert proper terminal into vehicle harness pin-B.
C. Measure resistance between pin-B and ground.
Is resistance greater than 1,000 ohms? No: Repair short between
ECL pin-B and CLM pin-E.
retest for fault.
344
ENGINE
Step 8 Check for short in ECL signal circuit. Decision

B. Insert proper terminal into vehicle harness ECL pin-A.
C. Measure resistance between pin-A and ground.
CLM pin-B and ECL sensor
pin-A. After repairs are
345
ENGINE
A
B
E
B A
0000433249
Step 9 Check for Open in ECL signal circuit. Decision

A. Key OFF. ECL and CLM disconnected. Yes: Go to Step 10.
B. Insert proper terminal into vehicle harness ECL pin-A and CLM
connector pin-B.
C. Measure resistance between ECL pin-A and CLM pin-B.
Is resistance less than 5 ohms? No: Repair Open between
Step 10 Inspect connections at ECM (6000) connector. Decision

A. Key OFF. Disconnect ECM. Yes: Go to Step 11.
Is ECM connector, harness, and terminals clean and undamaged? No: Repair / replace
346
ENGINE
Step 11 Check for Open or high resistance in output circuit. Decision

A. Key OFF. CLM and ECM disconnected. Yes: Go to Step 12.
B. Insert proper terminal into Coolant Module connector pin-C and
ECM connector 6000 pin-35.
C. Measure resistance between CLM connector pin-C and ECM
connector pin-35.
Is resistance less than 5 ohms? No: Repair Open or short
between CLM pin-C and
ECM pin-35. After repairs are
347
ENGINE
Step 12 Check for failed ECL. Decision

A. Drain engine coolant below ECL sensor. Yes: Replace CLM. After
B. Key OFF. Disconnect ECL sensor.
for fault.
C. Insert proper terminal into sensor pin-A and pin-B.
D. Measure resistance between pin-A and pin-B.
Is resistance 210,000 ± 10k ohms? No: Replace ECL sensor.
Torque to 9 - 11 lb-ft (12 -
15 N•m). After repairs are

was made. Retest for fault.
348
ENGINE
SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted
to Low Source
Fault Overview
This fault code sets when Engine Control Module (ECM) detects Coolant Level Sensor Circuit signal voltage is
below normal or shorted to a low source.
Associated Faults
None
Fault Facts
None
Possible Causes


for fault.
349
ENGINE


ground.
for fault.
350
ENGINE

for fault.

351
ENGINE

retest for fault.
352
ENGINE

353
ENGINE
A
B
E
B A
0000433249

connector pin-B.

354
ENGINE

connector pin-35.
355
ENGINE

for fault.

356
ENGINE
SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range
- Least Severe Level
Fault Overview
This fault code sets when Engine Control Module (ECM) has detected low engine coolant level.
Associated Faults
None
Fault Facts
None
Possible Causes


for fault.
357
ENGINE


ground.
for fault.
358
ENGINE

for fault.

359
ENGINE

retest for fault.
360
ENGINE

361
ENGINE
A
B
E
B A
0000433249

connector pin-B.

362
ENGINE

connector pin-35.
363
ENGINE

for fault.

364
ENGINE
SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range -
Moderately Severe Level
Fault Overview
This fault code sets when Engine Control Module (ECM) has detected low engine coolant level.
Associated Faults
None
Fault Facts
None
Possible Causes


for fault.
365
ENGINE


ground.
for fault.
366
ENGINE

for fault.

367
ENGINE

retest for fault.
368
ENGINE

369
ENGINE
A
B
E
B A
0000433249

connector pin-B.

370
ENGINE

connector pin-35.
371
ENGINE

for fault.

372
ENGINE
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal
Operating Range - Least Severe Level
Fault Overview
This is an information-only fault code that will only become active if other critical engine performance fault
codes are active for an extended period of time.
Associated Faults
Any Aftertreatment or
SCR related faults
Fault Facts
Troubleshoot all other active fault codes. This fault code will become inactive when all other active fault
codes are resolved.
Possible Causes
• Other Aftertreatment or SCR related codes are active
Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) Yes: Repair Associated Faults.
list for Associated Faults (page 373). After associated faults are
repaired, SPN 1569 FMI 15
will become inactive.
Are Associated Faults active or previously active? No: Test drive vehicle and
retest for SPN 1569 FMI 15. If
fault code does not return, end
diagnostics.
End Diagnostic Test

After performing diagnostic steps, if SPN 1569 FMI 15 remains, verify each step was completed correctly
and proper decision was made. Return to fault code diagnostics.
373
ENGINE
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists
Fault Overview
Associated Faults
SCR related faults
Fault Facts
codes are resolved.
Possible Causes

diagnostics.
End Diagnostic Test

374
ENGINE
SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But
Below Normal Operating Range - Most Severe Level
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level is equal to 0%.
Associated Faults
SPN 3031 FMI 9 SPN 3364 FMI 9 SPN 1761 FMI 3 SPN 1761 FMI 4
(Cummins FC 4572) (Cummins FC 3868) (Cummins FC 1669) (Cummins FC 1668)
SPN 1761 FMI 9
(Cummins FC 4677)
Fault Facts
If multiple associated faults are present, use Cummins QuickServe Online Fault Code Analyzer, or EDS to
determine what faults to diagnose first.
Fault indicates there is no DEF in DEF tank. Completely refilling DEF tank with approved DEF, will cause
fault to go inactive and tank level to rise at real time.
Possible Causes
• Low DEF tank level

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) Yes: Go to Step 2.
list for Associated Faults (page 375).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
retest for SPN 1761 FMI 1.
Step 2 Check for damaged Diesel Exhaust Fluid tank and DEF lines Decision
Inspect DEF tank and lines for damage and leaks. Yes: Turn key off for 60
seconds or until ECM powers
down. Fill DEF tank to 100%
using approved DEF. After
repairs are complete, retest for
SPN 1761 FMI 1.
Are DEF tank and lines free of damage and not leaking? No: Repair damaged or
leaking DEF tank and lines.
End Diagnostic Test

After performing diagnostic steps, if SPN 1761 FMI 1 remains, verify each step was completed correctly and
proper decision was made. Return to fault code diagnostics.
375
ENGINE
SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit -
Voltage Above Normal or Shorted to High Source
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level sensor signal
voltage is greater than expected for more than 10 seconds.
Associated Faults
None
Fault Facts
If replacing a Float / Optical DEF head unit with Ultrasonic DEF head unit, submerge DEF head unit into DEF
two or three times at a rapid pace before installing into tank to initialize flow through the boot encapsulation.
Possible Causes
• Poor electrical connections
• Failed DEF head unit

Use EST, Key On Engine Off (KOEO), check DTC list for SPN 1761 FMI 3 Yes: Go to Step 2
Is SPN 1761 FMI 3 active or pending? No: Repair Active faults. After
SPN 1761 FMI 3.
Step 2 Inspect connections at DEF head unit Decision

1. Key Off. Yes: Replace DEF head unit.
2. Disconnect DEF head unit and connector
3. Check DEF head unit and connector terminals for damage
or pinched wires; wet and corroded terminals ; loose, bent or
Are DEF head unit connector, harness, and terminal clean and undamaged? No: Repair connector,
End Diagnostic Test

376
ENGINE
SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit -
Voltage Below Normal or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level sensor signal
voltage is less than expected for more than 10 seconds.
Associated Faults
None
Fault Facts
Possible Causes

Use EST, Key On Engine Off (KOEO), check DTC list for SPN 1761 FMI 4 Yes: Go to Step 2
SPN 1761 FMI 4.

End Diagnostic Test

377
ENGINE
SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal
Update Rate
Fault Overview
Fault code sets when Engine Control Module (ECM) does not detect Diesel Exhaust Fluid (DEF) head unit
communication on private J1939 CAN bus. Engine torque will be reduced if fault is active for a limited period
of time. Engine torque will be severely reduced and vehicle speed will be limited after extended engine
operation with this fault code active.
Associated Faults
Fault Facts
If more than one of following sensor modules fail (or set a fault), suspect a common Private CAN circuit,
common power circuit, ground circuit, or switched ignition relay problem. The following components share
J1939 CAN, power and ground circuits: EGR Valve (EGRV), VGT Actuator (VGTA), AFT temperature sensor
module, NOx OUT sensor module, NOx IN sensor module, Particulate Matter (PM) sensor module and DEF
head unit. Verify batteries are fully charged and connections are clean before completing diagnostics.
Possible Cause
• SWBAT circuit Open or short to GND
• Private CAN-H circuit Open or short to GND
• Private CAN-L circuit Open or short to GND
• Private CAN-H circuit short to PWR
• Private CAN-L circuit short to PWR
• GND circuit Open or high resistance
• Private CAN-H short to Private CAN-L
378
ENGINE

Is EST DTC list clear of Associated Faults? No: Repair Private CAN circuit,
common sensor module(s)
power or ground circuit failure,
aftertreatment smart sensor
relay or aftertreatment PDM
problem. After repairs are
complete, retest for SPN 1761
FMI 9.

Step 3 Verify DEF head unit communication. Decision

Key On, verify DEF level gauge position on Electronic Gauge Cluster Yes: Go to Step 4.
(EGC).
Is DEF level gauge pointing to 6 o'clock position? No: Perform Procedure
Step 4 Inspect DEF head unit connector. Decision

1. Key Off. Yes: Go to Step 5.
2. Disconnect DEF head unit Connector.
3. Check DEF head unit connector terminals for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or
Are DEF head unit connector, harness, and terminals clean and No: Repair connector,
undamaged? harness, or terminal damage.
Step 5 Check for voltage to DEF head unit. Decision

1. Perform Test 1 (page 382) . Yes: Go to Step 7.
2. Use DMM, measure voltage between Breakout Harness
18-124-01 pin-3 and pin-4.
379
ENGINE
Step 6 Check SWBAT circuit for Open or short to Ground. Decision

1. Perform Test 2 (page 383). Yes: Repair Open or high
resistance between DEF head
unit pin-3 and Ground. After
18-124-01 pin-4 and known good Ground.
SPN 1761 FMI 9.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
unit pin-4 and switched ignition
relay pin-87. After repairs are
FMI 9.
Step 7 Check Private CAN-H circuit. Decision

1. Perform Test 3 (page 384). Yes: Go to Step 8.
Is voltage approximately 2.7 volts? No: Repair Open or short to
Ground if voltage is less than 2
volts. Repair short to Power if
voltage is greater than 3 volts.
Step 8 Check Private CAN-L circuit. Decision

Step 9 Check for Private CAN-H shorted to Private CAN-L. Decision

1. Perform Test 5 (page 386). Yes: Replace DEF head unit.
2. Use DMM, measure resistance between Breakout Harness
18-124-01 pin-1 and pin-2.
Is resistance between 55 and 65 ohms? No: Repair short between
DEF head unit pin-1 and pin-2.
380
ENGINE
End Diagnostic Test

381
ENGINE
Pin-Point Tests (SPN 1761 FMI 9)

See latest version of HX Interactive Schematics on Service Portal for additional circuit information.
Tools Required
• Breakout Harness 18-124-01
Figure 214 DEF Head Unit Circuit Check
Test 1
1. Key Off.
2. Disconnect DEF head unit.
3. Connect Breakout Harness 18-124-01 to vehicle harness and leave DEF head unit disconnected.
4. Key On Engine Off (KOEO).
382
ENGINE
Figure 215 SWBAT Circuit Check
Test 2
1. Key Off.
383
ENGINE
Figure 216 CAN-H Circuit Check
Test 3
1. Key Off.
384
ENGINE
Figure 217 CAN-L Circuit Check
Test 4
1. Key Off.
385
ENGINE
Figure 218 CAN-H to CAN-L Circuit Check
Test 5
1. Key Off.
386
ENGINE
SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor
- Abnormal Rate of Change
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level sensor signal is
invalid for an extended period of time.
Associated Faults
SPN 3363 FMI 7
(Cummins FC 3242)
Fault Facts
Possible Causes


1. Key Off. Yes: Replace DEF head unit
End Diagnostic Test

387
ENGINE
SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor -
Root Cause Not Known
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level sensor has
an internal error.
Associated Faults
SPN 1761 FMI 9 SPN 3364 FMI 9 SPN 3031 FMI 9
(Cummins FC 4677) (Cummins FC 3868) (Cummins FC 4572)
Fault Facts
Possible Causes


Use EST, Key On Engine Off (KOEO), check DTC list for SPN 1761 FMI 11. Yes: Replace DEF head unit.
SPN 1761 FMI 11.
End Diagnostic Test

and proper decision was made. Return to fault code diagnostics
388
ENGINE
SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor -
Out of Calibration
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Level sensor sensing
element is out of calibration.
Associated Faults
Fault Facts
Possible Causes


End Diagnostic Test

389
ENGINE
SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid
But Below Normal Operating Range - Least Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid (DEF) Tank Level is greater
than 2.2% and less than or equal to 5.6% of being full.
Associated Faults
Fault Facts
Fault indicates there is no DEF in DEF tank. Completely refilling DEF tank with approved DEF , will cause
Possible Causes
• Low DEF Tank Level

SPN 1761 FMI 17.
End Diagnostic Test

390
ENGINE
SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid
But Below Normal Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid (DEF) Tank Level is less
than or equal to 2.2% or greater than 0% of being full.
Associated Faults
Fault Facts
Fault indicates there is no DEF in DEF tank. Completely refilling DEF tank with approved DEF , will cause
Possible Causes
• Low DEF Tank Level

SPN 1761 FMI 18.
End Diagnostic Test

391
ENGINE
SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data
Erratic, Intermittent, or Incorrect
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Temperature Senor sensing element has detected Diesel
Exhaust Fluid Tank Temperature is too high or too low for ambient temperatures.
Associated Faults
SPN 3031 FMI 6
(Cummins FC 4736)
Fault Facts
Possible Causes
• Block heater or auxiliary coolant being used

Step 2 Check for Block Heater, Auxiliary Power Unit or other auxiliary Decision
coolant heaters being used.
Interview vehicle operator and view fault code freeze frame data. Yes: Clear fault code after
all other faults have been
diagnosed or repaired. After
SPN 3031 FMI 2.
Was fault set after using a Block Heater, Auxiliary Power Unit or other No: Replace DEF head unit.
auxiliary coolant heater over night? After repairs are complete,
End Diagnostic Test

392
ENGINE
SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor -
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Tank Temperature sensor
signal is shorted to power.
Associated Faults
SPN 1761 FMI 9
(Cummins FC 4677)
Fault Facts
Possible Causes
• Failed DEF head Unit

Is EST DTC list clear of Associated Faults? No: Repair Active faults. After
SPN 3031 FMI 3.

End Diagnostic Test

393
ENGINE
SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor -
Fault Overview
signal is shorted to ground.
Associated Faults
Fault Facts
Possible Causes

Is EST DTC list clear of Associated Faults? No: Repair Active faults. After
SPN 3031 FMI 4.
Step 2 Inspect connections at DEF head unit. Decision

End Diagnostic Test

394
ENGINE
SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature -
Abnormal Update Rate
Fault Overview
Fault code sets when Engine Control Module (ECM) does not detect Diesel Exhaust Fluid (DEF) head unit
Associated Faults
Fault Facts
Possible Cause
• Failed DEF Tank head unit
395
ENGINE

FMI 9.


(EGC).


1. Perform Test 1(page 399). Yes: Go to Step 7.
18-124-01 pin-3 and pin-4.
396
ENGINE

1. Perform Test 2(page 400). Yes: Repair Open or high
SPN 3031 FMI 9.
FMI 9.



1. Perform Test 5(page 403). Yes: Replace DEF head unit.
18-124-01 pin-1 and pin-2.
397
ENGINE
End Diagnostic Test

398
ENGINE

Tools Required
Test 1
1. Key Off.
399
ENGINE
Test 2
1. Key Off.
400
ENGINE
Test 3
1. Key Off.
401
ENGINE
Test 4
1. Key Off.
402
ENGINE
Test 5
1. Key Off.
403
ENGINE
SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature -
Root Cause Not Known
Fault Overview
has an internal error.
Associated Faults
Fault Facts
Possible Causes


SPN 3031 FMI 11.
End Diagnostic Test

404
ENGINE
SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature
Sensor - Out of Calibration
Fault Overview
sensing element is out of calibration.
Associated Faults
Fault Facts
Possible Causes


End Diagnostic Test

405
ENGINE
SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic,
Intermittent, or Incorrect
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor internal temperature is above minimum
operating temperature for greater than 10 seconds.
Associated Faults
SPN 1761 FMI 9 SPN 3364 FMI 9
(Cummins FC 4677) (Cummins FC 3868)
Fault Facts
Possible Causes


SPN 3364 FMI 2.
End Diagnostic Test

and proper decision was made. Notify supervisor for further action.
406
ENGINE
SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit -
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor sensing element voltage is too high or is
shorted to power.
Associated Faults
Fault Facts
Possible Cause
• Incorrectly routed DEF Tank Coolant Lines
• Diesel Exhaust Fluid Tank Heater Valve (DEFTHV) installed incorrectly
• Failed DEFTHV


Use EST, Key On Engine Off (KOEO), check DTC list for SPN 3364 FMI 3. Yes: Go to Step 3.
SPN 3364 FMI 3.
Step 3 Verify coolant lines are routed properly. Decision

Perform DEF Head Unit Coolant Line Routing Inspection (page 440). Yes: Go to Step 4.
Are DEF coolant lines routed correctly? No: Route coolant lines
properly to restore correct
coolant flow through DEF
system. After repairs are
FMI 3.
407
ENGINE
Step 4 Check for proper installation of DEFTHV. Decision

Review results from DEF Head Unit Coolant Line Routing Inspection Yes: Go to Step 5.
preformed in Step 3.
Is DEFTHV installed correctly? No: Reposition DEFTHV
properly. After repairs are
FMI 3.
Step 5 Check for failed DEFTHV. Decision

Perform DEFTHV Coolant Flow Test (page 444). Yes: If equipped with
Ultrasonic DEF head unit,
ONLY replace DEFTHV. If
equipped with Float / Optical
DEF head unit, replace both
DEFTHV and DEF head unit.
Is there a steady, constant stream of coolant after allowing 30 seconds No: Replace DEF head unit.
of residual coolant to exit? After repairs are complete,
End Diagnostic Test

408
ENGINE
SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit -
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor sensing element voltage is too low or is
shorted to ground.
Associated Faults
Fault Facts
Possible Cause
• Failed DEFTHV


Use EST, Key ON Engine OFF (KOEO), check DTC list for SPN 3364 FMI 4. Yes: Go to Step 3.
SPN 3364 FMI 4.

FMI 4.
409
ENGINE

FMI 4.

End Diagnostic Test

410
ENGINE
SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update
Rate
Fault Overview
Fault code sets when Engine Control Module (ECM) does not detect Diesel Exhaust Fluid (DEF) Head Unit
Associated Faults
Fault Facts
Possible Cause

FMI 9.
411
ENGINE


(EGC).


18-124-01 pin-3 and pin-4.

1. Perform Test 2(page 415). Yes: Repair Open or high
SPN 3364 FMI 9.
FMI 9.
412
ENGINE



1. Perform Test 5(page 418). Yes: Replace DEF head unit.
18-124-01 pin-1 and pin-2.
End Diagnostic Test

413
ENGINE

Tools Required
Test 1
1. Key Off.
414
ENGINE
Test 2
1. Key Off.
415
ENGINE
Test 3
1. Key Off.
416
ENGINE
Test 4
1. Key Off.
417
ENGINE
Test 5
1. Key Off.
418
ENGINE
SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate
of Change
Fault Overview
Fault code sets when Diesel Exhaust Fluid Quality sensor sensing element is reading an unexpected value.
Associated Faults
Fault Facts
Possible Causes
• Contaminated or degraded DEF
• Aerated DEF

Step 2 Check DEF quality and DEF tank for debris. Decision
Perform DEF Quality Test (page 442). Yes: Removing air bubbles
from boot has corrected fault
condition. After repairs are
FMI 10
Was there air bubbles removed from DEF head unit silicone boot? No: Go to Step 3.
419
ENGINE
Review results from DEF Quality Test performed in step 2. Yes: Go to Step 4.
Is urea concentration between 30 and 34% and free of contamination or No: Drain DEF tank, flush with
debris? distilled water, and fill with new
and / or known good DEF. After
SPN 3364 FMI 10.
Is the concentration signal displayed in the service tool matching No: Replace DEF head unit.
Refractometer reading within 3%? After repairs are complete,

FMI 10.

FMI 10.

420
ENGINE
End Diagnostic Test

421
ENGINE
SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause
Not Known
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Quality sensor has an
internal error.
Associated Faults
Fault Facts
Possible Causes


SPN 3364 FMI 11.
End Diagnostic Test

422
ENGINE
SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Quality sensor sensing
element is out of calibration.
Associated Faults
SPN 1761 FMI 9
(Cummins FC 4677)
Fault Facts
Possible Causes


2. Disconnect DEF head unit and Connector
retest for SPN 3364 FMI 13
3. Check DEF head unit and connector terminals for damage or
pinched wires; corroded terminals ; loose, bent or broken pins;
End Diagnostic Test

423
ENGINE
SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But
Above Normal Operating Range - Least Severe Level
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor sensing element is reading above critical
threshold.
Associated Faults
Fault Facts
Possible Causes
• Aerated DEF

Perform DEF Quality Test (page 442). Yes: Go to Step 3.
Is urea concentration between 30 and 34% and free of any bubbles, No: If air bubbles are present,
contamination or debris? remove them. If debris or
contamination found, drain
DEF tank, flush with distilled
water, and fill with new and / or
known good DEF. After repairs
are complete, retest for SPN
3364 FMI 15.
424
ENGINE
Review results from DEF Quality Test performed in Step 2. Yes: Go to Step 4.

FMI 15.

Review results from DEF Head Unit Coolant Line Routing Inspection Yes: Replace DEF head unit.
preformed in Step 4. After repairs are complete,
FMI 15.
End Diagnostic Test

425
ENGINE
SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But
Below Normal Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Diesel Exhaust Fluid Quality (DEF) sensor sensing element is reading below critical
threshold.
Associated Faults
Fault Facts
Possible Causes
• Aerated DEF
426
ENGINE

list for Associated Faults(page 426).
3364 FMI 18.

FMI 18.

FMI 18.
End Diagnostic Test

427
ENGINE
SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause
Not Known
Fault Overview
Fault code sets when Engine Control Module detected Diesel Exhaust Fluid (DEF) Quality sensor has
an internal error.
Associated Faults
None
Fault Facts
Possible Causes
Step 1 Check DEF quality. Decision

Perform DEF Quality Test (page 442). Yes: Replace DEF head unit.
Is urea concentration between 30 and 34%? No: Drain DEF tank, flush with
distilled water, and fill with new
and/or known good DEF. After
SPN 3521 FMI 11.
End Diagnostic Test

428
ENGINE
SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But
Above Normal Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor sensing element is in-range, but reading high.
Associated Faults
Fault Facts
Possible Causes
• Aerated DEF

list for Associated Faults(page 429).
3521 FMI 16.
429
ENGINE

FMI 16.

FMI 16.
End Diagnostic Test

430
ENGINE
SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But
Below Normal Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Quality sensor sensing element is reading below a critical
threshold.
Associated Faults
Fault Facts
Possible Causes
• Aerated DEF

3521 FMI 18.
431
ENGINE

FMI 18.

FMI 18.
End Diagnostic Test

432
ENGINE
SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists
Fault Overview
Fault code sets when Engine Control Module detects Diesel Exhaust Fluid (DEF) Quality sensor sensing
element reported an unknown error.
Associated Faults
Fault Facts
Possible Causes
• Aerated DEF

3521 FMI 31.
433
ENGINE

FMI 31.

FMI 31.
End Diagnostic Test

434
ENGINE
SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition
Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid (DEF) Tank is empty.
Associated Faults
None
Fault Facts
None
Possible Causes
• Empty DEF Tank
SPN 4096 FMI 31.
End Diagnostic Test

435
ENGINE
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above
Normal Operating Range - Most Severe Level
Fault Overview
Associated Faults
SCR related faults
Fault Facts
codes are resolved.
Possible Causes

repaired, SPN 5246 FMI 0 will
become inactive.
diagnostics.
End Diagnostic Test

436
ENGINE
Normal Operating Range - Least Severe Level
Fault Overview
Associated Faults
SCR related faults
Fault Facts
codes are resolved.
Possible Causes

diagnostics.
End Diagnostic Test

437
ENGINE
Normal Operating Range - Moderately Severe Level
Fault Overview
Associated Faults
SCR related faults
Fault Facts
codes are resolved.
Possible Causes

diagnostics.
End Diagnostic Test

438
ENGINE
Tests and Inspections
Overview
Tests
DEF Head Unit Coolant Line Routing Inspection (page 440)
DEF Quality Test (page 442)
DEFTHV Coolant Flow Test (page 444).
439
ENGINE
DEF Head Unit Coolant Line Routing Inspection

Overview
Identify proper coolant line routing for DEF Tank.
Tools Required
None
Equipment Condition
None
1 2 3
0000429485
Figure 229 DEF Tank Coolant Line Routing

1. DEF Head Unit Line to DEF Supply 3. DEF Coolant Return Line Tee Fitting
Module 4. Supply Line
2. DEF Tank Heater Valve 5. Return Line
1. Verify that DEF head unit outlet line is routed properly to DEF supply module inlet.
2. Verify that supply line is routed properly to inlet of DEF Tank Heater Valve (DEFTHV).
3. Verify that DEFTHV is installed correctly and coolant supply flow arrow is facing inlet of DEF head unit.
4. Verify that return line is routed properly to outlet of DEF supply module.
440
ENGINE
2
1
0000429484
Figure 230 DEF Tank Coolant Return Line Tee Fitting

1. Supply Line 3. Return Line
2. Plastic Coupler 4. Tee Fitting
5. Verify that supply and return lines are not crossed at Tee fitting and plastic coupler.
Expected Outcome
Technician will determine proper DEF tank coolant line routing.
441
ENGINE
DEF Quality Test

Overview
Inspect Diesel Exhaust Fluid (DEF) for contamination and proper urea concentration.
WARNING
To prevent personal injury or death, avoid contact with Diesel Exhaust Fluid (DEF) / urea.
Do not get DEF in eyes. In case of eye contact, immediately flush eyes with large amounts
of water for a minimum of 15 minutes. Do not swallow. If DEF is ingested, contact a
physician immediately.
Tools Required
• Diesel Exhaust Fluid (DEF) Refractometer 5025
Equipment Condition
• Calibrate DEF Refractometer (see 5025 DEF Refractometer Operating Instructions included in tool kit).
Test Procedure
1. Visually inspect inside of DEF tank for debris, bubbles, icing or other forms of contamination.
• If bubbles are found on sensor, remove bubbles before continuing.
442
ENGINE
Figure 231 Ultrasonic Diesel Exhaust Fluid Head Unit

1. Concentration sensor silicone boot 2. Tie straps (2)
2. Using a clean uncontaminated rod, push down on boot (Item 1) to release any trapped air bubbles.
3. Obtain sample of Diesel Exhaust Fluid (DEF) from the DEF tank.
4. Visually inspect sample for fuel, oil or other forms of contamination.
5. Use DEF Refractometer 5025 to test urea concentration of DEF.
6. Use Electronic Service Tool (EST) to view DEF concentration signal. Refractometer reading and EST
signal should be within 3% of each other.
Expected Outcome
No air bubbles on concentration sensor or inside sensor boot. Diesel Exhaust Fluid (DEF) urea concentration
should be between 30 and 34%. Refractometer reading and EST signal should be within 3% of each other.
DEF and DEF tank should be free of contamination such as debris, bubbles, icing, fuel, and oil.
443
ENGINE
DEFTHV Coolant Flow Test

Overview
This test will identify a failed Diesel Exhaust Fluid Tank Heater Valve (DEFTHV).
Tools Required
None
Equipment Condition
None
Test Setup
None
Test Procedure
1. Key Off. DEFTHV is normally closed at Key Off.
2. Verify that coolant supply flow direction arrow on DEFTHV is pointing towards DEF head unit.
3. Using hose clamp pliers, pinch off DEF head unit coolant return line to restrict back flow.
4. Disconnect the coolant return line from the DEF head unit and watch coolant flow from return port of
DEF head unit.
5. Allow 30 seconds of residual coolant to exit DEF head unit coolant return port.
Expected Outcome
Replace DEFTHV if there is a constant stream of coolant coming from DEF head unit return port.
444
ENGINE
445
EXTERIOR LIGHTING
13. Exterior Lighting

Beacon Light
Overview
0008ACJ Beacon light, wiring for one customer-installed beacon, with sleeper cab,
includes 2-way switch and 14 ft (427 cm) of wiring
0008WZC Beacon lights, two, cab mounted, includes mounting brackets, wiring,
and switch on dash
Figure 232 Beacon Light Location

1. Beacon light
Beacon lights are rotating or flashing lights affixed to the top of a vehicle to attract the attention of surrounding
vehicles and pedestrians.
This provision adds a switch and wiring for customer-installed beacon lights.
446
EXTERIOR LIGHTING
Work Light
Overview
0008XKJ Work light, two, pedestal type, mounted to top rear back of cab below
drip rail
0008WGV Accessory wiring, special wiring for two work lights that customer will
install on top rear corners of cab, with dash switch, will also activate
standard work light
Figure 233 Work Light Location

1. Work light
Work lights illuminate the area behind the cab, outside the vehicle. Work lights only work with the key switch
ON and can be activated by work light switch, key fob, or when vehicle is in reverse, depending on features
installed. Additionally, when the work light with remote option is installed, work lights can be activated remotely
using the key fob. If the work light ON in reverse feature is installed, the work lights will be activated any time
the transmission is shifted into reverse.
The work light switch is a two-position (ON / OFF) rocker type switch located in various positions on the vehicle.
When the key switch is ON and the work light switch is ON, the switch pack will communicate with the Body
Control Module (BCM) on the drivetrain 1939 data link. When the BCM receives this work light request
message on the data link, the BCM will supply voltage to the work light output circuit.
447
EXTERIOR LIGHTING
The BCM work light output circuit provides electrical current to all individual work lights using a single circuit.
The ground is supplied for each work light connector individually, from the left-side dash-mounted dual post
ground plate, and each is identified by individual circuit numbers.
448
HVAC
14. HVAC
0016WKB Heater & A/C (International Blend-Air) with Integral Heater & Defroster. Base
A/C system.
0016WJC APADS System (Index sensors and controls) Air Conditioner Protection and
Diagnostic System. Use w/ temp controlled fan.
0016VRT Heater enhanced recirculation for extreme cold control, for extreme cold
weather climates. High output heater core.
Figure 234 In Cab HVAC Components

1. HVAC Control 4. Fuse block
2. Mode door stepper motor 5. Fresh air door stepper motor
3. APADS module (Feature Code 6. HVAC vent (“Summer” or “Winter”)
0016WJC only) 7. HVAC Assembly
HVAC Control
The Heating Ventilation and Air Conditioning (HVAC) control is installed in the cab's instrument panel center.
Knobs control blower motor speed and hot / cold air flow across the blend air door, mode door, and fresh air
door. The push button Air Conditioning (A/C) switch is an input to activate the A/C compressor clutch. Setting
the mode control to MAX closes the fresh air door.
449
HVAC
Figure 235 Under Hood HVAC Components

1. Heater hoses 4. Condenser
2. A/C compressor 5. Receiver/drier
3. A/C compressor clutch 6. A/C high-pressure service port
Compressor
When the A/C compressor clutch is activated and the engine is running, the compressor draws low-pressure
refrigerant from the evaporator core, compresses and sends high-pressure refrigerant to the condenser.
To control A/C system high side and low side refrigerant pressures and evaporator core temperature, the
compressor clutch is switched On and Off by high pressure and low pressure safety switches and a thermal
switch.
Condenser
As air flows thru the A/C condenser heat is transferred to ambient air. Condenser cooling fins must be free
of contamination and restrictions to transfer heat properly. The engine cooling fan helps draw air thru the
condenser and cooling package to dissipate heat. During normal A/C system operation, the condenser outlet
line should be cooler than the inlet line.
Receiver/Drier
The receiver/drier filters particles from liquid refrigerant, removes moisture, stores a portion of liquid refrigerant,
and contains the high-pressure service port. If the compressor or other A/C components fail or require
replacement, the receiver/drier must be replaced to prevent corrosion and damage. To prevent moisture
contamination, replace the receiver/drier whenever the A/C system has been opened to the atmosphere. The
receiver/drier is not serviceable, and must be replaced if required.
450
HVAC
Figure 236 HVAC Assembly

1. Heater core 5. Resistor block
2. Blend door stepper motor 6. Thermal switch
3. Blower motor 7. HVAC filter
4. Blower motor connector 8. Evaporator core
HVAC Assembly
The heater core, A/C evaporator core, thermal switch and resistor block are in one unit under the passenger
seat. This system uses common air ducts and blower motor to blend cooled, heated and outside air; providing
heating, cooling, defrosting, dehumidifying and ventilation in whatever combination the driver chooses.
Evaporator Core
The evaporator core is a heat exchanger that absorbs heat due to the refrigerant pressure drop caused by
the expansion valve, cooling and dehumidifying the cab as air is forced across the evaporator core by the
blower motor.
Thermal Switch
The thermal switch uses a capillary tube to sense evaporator core temperature. If the evaporator core gets too
cold the thermal switch Opens turning Off the A/C compressor clutch.
451
HVAC
Figure 237 Under Cab HVAC Components

1. Low-pressure switch 3. Expansion valve
2. High-pressure switch 4. A/C low-pressure service port
Expansion Valve and Pressure Switches

The expansion valve is installed under the passenger side cab between the receiver/drier and evaporator
core. Refrigerant temperature and pressure sensing are built into the expansion valve. High-pressure liquid
refrigerant enters the expansion valve. A metering orifice causes a restriction and refrigerant changes state
to low-pressure gas, absorbing heat in the evaporator core. High-pressure and low-pressure switches are
installed in the expansion valve, to control compressor clutch On-Off cycling and A/C system pressure.
If the expansion valve is stuck closed, the evaporator core and expansion valve will be near ambient
temperature; when stuck open, both evaporator core and valve may be extremely cold with frost or ice build-up.
Because expansion valve channels are small, blockage in the HVAC system is often found here (valve is very
sensitive to contamination). Contamination is often water. When even a small amount of water reaches the
valve, the extreme cold from pressure drop freezes water, forming an ice blockage. After the HVAC system
shuts down and warms up, the valve may operate again.
452
HVAC
Figure 238 Blower Motor Control Relays and Fuses

1. Blower Motor / High Speed Relay 5. AC Relay
2. 20A Fuse F7-G 6. AC Control Relay
3. 10A Fuse F8-S 7. Main Control Relay
4. 30A Fuse F7-R 8. Med-Hi Speed Relay
453
HVAC
Air Conditioning Protection and Diagnostic Systems (APADS)

APADS is an optional system that uses an electronic module to control A/C compressor clutch cycling, and
sends a signal to turn On the engine cooling fan if high-side refrigerant pressure is 300 psi or more. The
APADS module receives input from the high-pressure and low-pressure refrigerant switches.
APADS Fault (Blink) Code Diagnostics

LED Blinks Description / Possible Causes
1 Red A/C system loss of refrigerant
2 Red A/C system overcharged, engine cooling fan failure, restricted condenser
3 Red Compressor clutch circuit Open or shorted (page 504)
4 Red Low-pressure switch or high-pressure switch Open circuit (page 504)
Rapid Green Low electrical system voltage
Slow Green No faults
A “blink” is approximately 1/4 second in duration. Once the number of blink codes has been broadcast, there is
a delay of two seconds before the fault code is repeated.
454
HVAC
HVAC Symptom Diagnostics

Blower Not Working Properly for One or More Speeds (page 459)
HVAC System Air Not Cool After A/C Turned ON (page 466)
HVAC System Air Not Warm After Heat Turned ON (page 470)
Air Not Flowing Out Correct HVAC Ducts (page 473)
455
HVAC

Overview
The following steps direct technicians to systematically troubleshoot Heating Ventilation and Air Conditioning
(HVAC) system performance to avoid unnecessary work and repairs. See HVAC system overview (page
449) for more information.
Figure 239 HVAC Control

1. Blower control switch 3. A/C switch
2. Hot/cold blend door control 4. Mode switch
Step 1 Determine if Heating Ventilation and Air Conditioning (HVAC) system Decision
and engine cooling system components are damaged or restricted.
Inspect the following components for damage, restrictions and proper mounting: Yes: Repair damage
or restrictions. After
• Condenser repairs are complete,
retest for symptom.
• Compressor belt
• A/C compressor, compressor clutch and wiring
• Heater hoses and A/C lines
• HVAC assembly air filter
• HVAC assembly vent in correct position for current season: “Summer” or
“Winter”
• Engine cooling system level and operation
Were HVAC system or engine cooling system problems found? No: Go to Step 2.
456
HVAC
Step 2 Determine if one or more blower motor speeds are not working properly. Decision
1. Turn ignition Key ON. Yes: Go to Step 3.
2. Rotate HVAC mode switch to any position other then OFF.
3. Rotate blower control switch to each of 4 positions and determine if
each blower speed works properly.
Do all 4 blower speeds work properly? No: Go to Blower Not
Working Properly for
One or More Speeds
(page 459).
Step 3 Determine if HVAC system air is not cool after A/C is turned ON. Decision
1. If equipped, verify heater shut-off valve is closed in hot temperatures. Yes: Go to Step 4.
2. Turn ignition Key On and start engine.
3. Rotate HVAC hot / cold blend control all the way counterclockwise
to cold.
4. Rotate blower control switch to position 4.
5. Rotate mode switch to blow air from center ducts, and push A/C switch
ON.
6. Determine if A/C compressor engages.
7. If compressor engages, insert a thermometer into center HVAC duct
and run engine at 1800 rpm for 5 minutes. High ambient humidity will
reduce HVAC systems ability to cool.
Does A/C compressor engage, and is center HVAC duct temperature approximately No: Go to HVAC
20°F (11°C) lower then ambient temperature, or colder? System Air Not Cool
After A/C Turned ON
(page 466).
Step 4 Determine if HVAC system air is not warm after heat is turned ON. Decision
1. If equipped, verify heater shut-off valve is opened in cold temperatures. Yes: Go to Step 5.
2. Turn ignition Key On and start engine. Run engine to operating
temperature.
3. Rotate hot / cold control all the way clockwise to hot.
5. Rotate mode switch to blow air from center ducts.
Is HVAC duct temperature warm? No: Go to HVAC
System Air Not Warm
After Heat Turned ON
(page 470).
457
HVAC
Step 5 Determine if air flows out correct HVAC ducts. Decision

1. Turn ignition Key On. Yes: If HVAC system
air is not cool after
running the system for
3. Rotate mode switch to each position and determine if air flows out 15 minutes or more,
appropriate ducts. the evaporator core
may be freezing up
due to thermal switch
or circuit problem(s).
Does air flow out correct HVAC ducts? No: Go to Air Not
Flowing Out Correct
HVAC Ducts (page
473).
458
HVAC
Blower Not Working Properly for One or More Speeds

Overview
When the ignition Key is ON, power is supplied to the HVAC Control thru Fuse F8-S. The Main Control Relay
is energized when the ignition Key is ON and the HVAC mode switch is in any position other then OFF.
When energized, the Main Control Relay supplies current from fuse F7-G to the Blower Control switch. The
Blower Control switch has four possible positions.
Blower Control position 1 (lowest volume air flow)

Current flows thru the Main Control Relay, all three resistors of the Resistor Block, Blower Motor / High
Speed Relay to the Blower Motor.
Blower Control position 2

Current flows through the Main Control Relay, Blower Control, two resistors of the Resistor Block, Blower Motor
/ High Speed Relay to the Blower Motor.
Blower Control position 3

Current flows thru the Main Control Relay, Blower Control, Med-Hi Speed Relay, 1 resistor of the Resistor
Block, Blower Motor / High Speed Relay to the Blower Motor.
Blower Control position 4 (highest volume air flow)

Power runs thru the Main Control Relay and Blower Control to energize the Blower Motor / High Speed Relay.
Current then flows from 30A Fuse F7-R, thru the Blower Motor / High Speed Relay to the Blower Motor.
Possible Causes
• Blower motor or circuits
• Blower Motor / High Speed Relay or circuits
• Med-Hi Speed Relay or circuits
• Resistor Block or circuits
• Blower Control switch or circuits
• Main Control Relay or circuits
• HVAC Control or circuits
459
HVAC
Figure 240 HVAC Control OFF, Key ON
460
HVAC
Test Procedure

Yes: Go to Step 2.
Checkout Procedure
(page 456).

2. Hot/cold blend control 4. Mode switch
Step 2 Determine which blower motor speed(s) are not working. Decision
1. Turn ignition Key On. All: Go to Step 3.
2. Rotate mode switch to any position other then OFF.
3. Rotate blower control switch to each of four positions and determine
which blower speed(s) are not works properly.
Which blower speed(s) are not working properly? Blower speed 1, 2,
3, or 4 not working
properly: Go to Blower
Speeds Tests (page
479).
461
HVAC

Step 3 Determine if fuses related to blower motor are blown. Decision

1. Remove passenger side instrument panel covering fuse block. Yes: Go to Step 4.
2. Inspect 10A fuse F8-S, and 20A Fuse F7-G.
Are fuses F8-S and F7-G in good condition and not blown? No: Replace blown
fuse(s), Test for circuit
shorts. After repairs
for symptom.
Step 4 Determine if Main Control Relay is receiving power. Decision

1. Key Off. Remove Main Control Relay. Yes: Reinstall Main
Control Relay. Go to
2. Key On. HVAC mode switch in any position other than OFF.
Step 5.
3. Measure voltage at fuse block 1002 M1 pin-D2 and pin-D1.
Is voltage within 0.5 volts of battery voltage? No: Repair power
circuit to Main Control
Relay, or HVAC
Control. After repairs
for symptom.
462
HVAC
Step 5 Determine if Blower Control switch is receiving power. Decision

2. Measure voltage at Blower Control connector pin-E.
Is voltage within 0.5 volts of battery voltage? No: Repair circuit
between Blower
Control pin-E and
fuse block 1002
M1 pin-C2, or Main
Control Relay. After
retest for symptom.

463
HVAC
Step 6 Determine if blower motor is receiving power. Decision

1. Perform Test 2 (page 465). Yes: Replace blower
motor. After repairs
2. Measure voltage between blower motor connector pin-A and pin-B.
for symptom.
Is voltage within 0.5 volts of battery voltage when blower motor speed 4 is selected? No: Repair power
or ground circuits
to blower motor,
failed Blower Motor
/ High Speed Relay,
or Blower Control
for symptom.
Pin-Point Tests - Blower Motor Control
Test 1
1. Remove lower instrument panel trim to access Blower Control connector (1056M).
2. Key Off. Disconnect Blower Control connector from back of HVAC Control.
464
HVAC
Test 2
1. Remove passenger side seat and HVAC assembly cover.
2. Key Off. Disconnect 2-pin Blower motor connector.
465
HVAC
HVAC System Air Not Cool After A/C Turned ON

Overview
To cool properly the Air Conditioning (A/C) system needs the correct amount of liquid and gas refrigerant
flow at correct pressures. Refrigerant pressure is controlled by compressor clutch cycling, a correctly
operating expansion valve, and proper air flow thru the condenser and evaporator core. The A/C compressor
pressurizes the A/C system when the compressor clutch is activated and the engine is running. The expansion
valve causes a pressure drop in the evaporator core, and heat is absorbed. The Thermal Switch uses a
temperature probe to sense evaporator core temperature. To prevent freezing, if the evaporator core gets
below approximately 30° F (-1° C) the Thermal Switch Opens interrupting power to the compressor clutch.
Fault Facts
After replacing A/C system components or discharging the system, evacuate (vacuum) the A/C system
to remove all moisture.
A/C system pressures are effected by ambient temperature, air flow thru the condenser, condenser heat
transfer, humidity, engine temperature, engine (compressor) RPM, and A/C compressor On/Off switching.
Possible Causes
• Incorrect refrigerant charge, contamination, or refrigerant leak
• Refrigerant restriction
• Low air flow thru condenser
• Failed A/C compressor
• Failed expansion valve
• Hot/cold blend door stuck / failed blend door stepper motor or circuits
• Low air flow thru evaporator core, or HVAC filter restriction
• HVAC assembly vent set to “Winter” position
• Failed compressor clutch or circuits
• Failed high or low pressure safety switch(s) or circuits
• Failed thermal switch or circuits
• Failed HVAC Control or circuits
• Failed AC Control Relay or circuits, or APADS module
• Failed AC Relay or circuits, or APADS Relay
WARNING
To prevent personal injury or death, wear safety glasses with side shields.

Yes: Go to Step 2.
Checkout Procedure
(page 456).
466
HVAC
Step 2 Determine if A/C system has proper static refrigerant Decision

pressure.
Perform Static Refrigerant Pressure Test (page 488). Yes: Leave A/C gauges connected.
Go to Step 3.
Is refrigerant static pressure at expected pressure? No, 10 psi or more low: Test for and
repair A/C system leak(s). Charge
A/C system to proper level (page
1317). After repairs are complete,
retest for symptom.
No, 10 psi or more high: Determine
and repair source of possible
contamination. Discharge,
evacuate, and recharge A/C system,
using a R-134a recovery/recycling
and charging station (page 1317).
After repairs are complete, retest for
symptom.
Step 3 Determine if A/C compressor clutch comes ON. Decision

1. Start engine. Yes: Go to Step 4.
2. Rotate hot / cold blend control to cold.
4. Rotate mode switch to blow air from center ducts, and push A/C switch
ON.
Does A/C compressor clutch come ON? No: Go to Step 6.
Step 4 Determine if A/C system has proper high-side and low-side pressures. Decision
Perform High and Low Side Refrigerant Pressure Test (page 490). Yes: Go to Step 5.
Are A/C system pressures within specification? No: Diagnose and
repair A/C refrigerant
system problem per
High and Low Side
Refrigerant Pressure
Test.
467
HVAC

468
HVAC
Step 5 Determine if air is flowing properly thru A/C Decision

evaporator core.
1. Inspect HVAC filter. Yes: Verify all HVAC ducts, seals, housing
and drains are installed properly, are in
2. Verify HVAC vent is set to “Summer”.
good condition and flowing properly. After
3. Remove passenger seat and HVAC assembly repairs are complete, retest for symptom.
cover.
No, HVAC filter restricted and/or vent set
4. Observe evaporator core for ice, or other to “Winter”: Clean or replace HVAC filter.
obstructions causing a restriction or misdirection Set vent to “Summer”. After repairs are
of air-flow. complete, retest for symptom.
5. Rotate HVAC mode switch to any position other No, evaporator core icing: Repair or
then OFF. replace thermal switch or circuit. After
repairs are complete, retest for symptom.
No, evaporator core restricted: Clean or
7. Rotate HVAC hot / cold blend door knob all the replace evaporator core. After repairs are
way counterclockwise to cold and than all the complete, retest for symptom.
way clockwise to hot while observing blend door
movement. No, blend door or linkage binding or
Is air flowing properly through the A/C evaporator core? damaged: Repair or replace blend door or
linkage. After repairs are complete, retest
for symptom.
No, blend door not moving: Diagnose
and repair blend door motor or circuit.
See HVAC Air Flow Control Testing (page
493). After repairs are complete, retest for
symptom.
Step 6 Determine which HVAC Feature Code is installed for proper compressor Decision
clutch control testing.
1. Obtain Vehicle Identification Number (VIN). See cab drivers door jam. 0016WKB: Go to
Base A/C System
2. Open International Service Portal web site.
Compressor Clutch
3. Enter last 8 of VIN in the Chassis / VIN Number field, and click View. Control Testing (page
497).
4. Click the Components tab.
Does vehicle have HVAC Feature Code 0016WKB or 0016WJC? 0016WJC: Go to
APADS A/C System
Compressor Clutch
Control Testing (page
504).
469
HVAC
HVAC System Air Not Warm After Heat Turned ON

Overview
When the engine is at operating temperature, heated engine coolant flows thru the heater core. When the
HVAC control hot/cold control is turned clockwise to hot, and the mode switch is in any position other than
“OFF”, air is directed thru the heater core and HVAC ducts, to heat the vehicle interior.
Possible Causes
• Engine not up to operating temperature (may need winter front in cold ambient temperatures)
• Low engine coolant level
• Engine thermostat stuck open
• Engine cooling fan On when not needed
• HVAC filter restriction
• HVAC assembly vent set to “Summer” position
• Heater core internal flow restriction (temp difference in heater hoses with cab heat Off) and/or air flow
restriction
• Heater shut-off valve closed, if equipped
• Hot/cold blend door stuck / failed blend door stepper motor or circuits
WARNING

Yes: Verify heater
shut-off valve is open,
if equipped. Go to
Step 2.
Checkout Procedure
(page 456).
Step 2 Determine if engine cooling system will not get up to proper operating Decision
temperature.
1. Connect Electronic Service Tool (EST) and log in. Yes: Go to Step 3.
2. Run engine to operating temperature while monitoring Engine Coolant
Temperature (ECT).
Does ECT reach 180°F (82°C) or higher? No: See Engine
Diagnostic Manual.
470
HVAC

471
HVAC
Step 3 Determine if air and coolant are flowing properly thru Decision
heater core.
1. Inspect HVAC filter. Yes: Check for restricted / pinched heater
hoses, or closed heater shut-off valve.
2. Verify HVAC vent is set to “Winter”.
If heater hoses are not restricted, flush
3. Remove passenger seat and HVAC assembly cover. or replace heater core. After repairs are
complete, retest for original problem.
4. Observe heater core for obstructions causing a
restriction or misdirection of air-flow. No, HVAC filter restricted and/or vent set
to “Summer”: Clean or replace HVAC
5. Rotate HVAC mode switch to any position other then
filter. Set vent to “Winter”. After repairs
OFF.
are complete, retest for symptom.
6. Turn ignition Key On and start engine. No, heater core restricted: Clean or
7. Rotate HVAC hot / cold blend door knob all the replace heater core. After repairs are
way counterclockwise to cold and than all the complete, retest for symptom.
way clockwise to hot while observing blend door No, blend door or linkage binding or
movement. damaged: Repair or replace blend door
Is air flowing properly thru the heater core? or linkage. After repairs are complete,
retest for symptom.
No, blend door not moving: diagnose and
repair blend door motor or circuit. See
HVAC Air Flow Control Testing (page
493). After repairs are complete, retest
for symptom.
472
HVAC
Air Not Flowing Out Correct HVAC Ducts

Overview
The HVAC control mode switch determines which HVAC ducts air flows out of. With the ignition Key ON the
Mode Door / Air Distribution Stepper Motor controls air flow thru the HVAC ducts to the windshield, center
vents, and/or floor.
Possible Causes
• HVAC Control assembly
• Mode door stepper motor or circuits
• Mode door or linkage
• Restricted or damages HVAC ducts

Yes: Go to Step 2.
Checkout Procedure
(page 456).
473
HVAC

Step 2 Determine if HVAC ducts are damaged or restricted. Decision

Inspect HVAC vents and ducts for debris, damage and restrictions. Yes: Repair damage
and clear restrictions.
After repairs are
symptom.
Are HVAC ducts damaged or restricted. No: Go to Step 3.
474
HVAC
Figure 249 Key ON, No Door Movement
Step 3 Determine if power and ground circuits to mode door stepper motor Decision
are working properly.
1. Remove drivers side lower right interior panel Yes: Go to Step 4.
2. Disconnect 3-way connector to the Mode Door stepper motor.
3. Key ON
4. Measure voltage between pin-A (A75BK) and pin-C (75GM).
Is voltage within 0.5 volts of battery voltage? No: Diagnose and
repair power or ground
circuit problem. After
retest for symptom.
475
HVAC
Figure 250 Key On, Blend Door Moving to Cold
476
HVAC
Figure 251 Key ON, Blend Door Moving to Hot
477
HVAC
Step 4 Determine if mode door stepper motor control circuit is working properly. Decision
1. Key ON Yes: Go to Step 5.
2. Measure voltage between pin-D (A75BF) and ground as the HVAC
control mode door switch is moved to each position.
• Hot: 0V
• Middle temperature: 6V
• Cold: 12V
Is voltage within 0.5 volts of expected voltage? No: Diagnose and
repair circuit A75BF.
If circuit is not open
or shorted, Replace
HVAC control. After
retest for symptom.
Step 5 Determine if mode door or linkage is binding or damaged. Decision

1. Remove mode door stepper motor. Yes: Repair linkage or
mode door damage.
2. Inspect mode door and linkage for binding or damage.
After repairs are
symptom.
Is mode door or linkage binding or damaged? No: replace mode
door stepper motor.
After repairs are
symptom.
478
HVAC
Tests and Inspections

Blower Speeds Tests
Overview
When the ignition Key is ON HVAC and mode switch is in any position other than OFF, the HVAC Control
provides power to energize the Main Control Relay, which then allows current to flow to the Blower Control
switch.

Tools Required
Equipment Condition
None
Test Setup
1. Key On. Mode switch in any position other than OFF.
479
HVAC
Test Procedure
Figure 253 HVAC Control ON, Blower Control Position 1
480
HVAC
With the Ignition Key ON, HVAC Control ON, and Blower Control in position 1; current flows thru the Main
Control Relay, three resistors in the Resistor Block, the normally closed Blower Motor / High Speed Relay, to
the Blower motor.
1. Rotate Blower Control switch to position 1. Determine if Blower Control position 1 circuits and components
are operating correctly per HVAC Control ON, Blower Control Position 1 graphic (Figure 253). Circuits
481
HVAC
482
HVAC
With the Ignition Key ON, HVAC Control ON and Blower Control in position 2, current flows thru the Main
Control Relay, Blower Control, two resistors in the Resistor Block, Blower Motor / High Speed Relay, to
the Blower motor.
483
HVAC
484
HVAC
With the Ignition Key ON, HVAC Control ON and Blower Control in position 3, power is provided thru the Main
Control Relay, Blower Control, and the Med-Hi Speed Relay is energized. When the Med-Hi Speed Relay
is energized current flows thru the Med-Hi Speed Relay, one resistor in the Resistor Block, Blower Motor /
High Speed Relay, to the Blower motor.
485
HVAC
486
HVAC
With the Ignition Key ON, HVAC Control ON and Blower Control in position 4, power is provided thru the Main
Control Relay, Blower Control, and the Blower Motor / High Speed Relay is energized. When the Blower Motor
/ High Speed Relay is energized current flows thru the High Speed Relay to the Blower motor.
4. Remove passenger side instrument panel covering fuse block.
5. Inspect 30A fuse F7-R. Replace if blown replace. Test for circuit short.
6. Rotate Blower Control switch to position 4. Evaluate Blower Control circuits and components operation
per HVAC Control ON, Blower Control Position 4 graphic (Figure 256). Circuits shown in red should
have battery voltage at specified operator controls.
Expected Outcome
Determine circuit(s) or component(s) causing one or more blower speeds to not work correctly.
487
HVAC
Static Refrigerant Pressure Test
Overview
If uncontaminated R-134a refrigerant is in the Air Conditioning (A/C) system and some liquid refrigerant is
present the below table will show expected static (Engine OFF) A/C system pressure for specific temperatures,
but does not tell us if the system is full or overcharged. Static pressure should be read when the A/C system
is at ambient temperature and after engine is OFF for five minutes or more. If static pressure is too high
refrigerant is either contaminated or hotter then expected. If static pressure is too low look for refrigerant leaks.
Tools Required
• Manifold gauge set or A/C Machine
• Thermometer
WARNING
Equipment Condition
1. Engine OFF for 5 minutes or more, and system is at ambient temperature.
2. Refrigerant type has been identified.
Test Setup
1. Remove body panel below passenger door to access A/C low-pressure service port.
2. Engine OFF. Connect A/C manifold gauge set to vehicle service ports.
488
HVAC
Test Procedure
R-134a Static Temperature / Pressure Table
Ambient Air Temperature °F (°C) R134A (psig)
40 (4) 35
45 (7) 40
50 (10) 45
55 (13) 51
60 (16) 57
65 (18) 64
70 (21) 71
75 (24) 78
80 (27) 86
85 (29) 95
90 (32) 104
95 (35) 113
100 38) 124
105 (41) 134
110 (43) 146
115 (46) 159
120 (49) 172
125 (52) 185
130 (54) 200
1. Measure ambient temperature. Engine heat will effect A/C system pressure.
2. See R-134a Static Temperature Pressure Table to help determine if A/C system is over or under charged.
Expected Outcome
Determine if static refrigerant pressure is within expected pressure listed in R-134a Static Temperature
/ Pressure Table.
489
HVAC
High and Low Side Refrigerant Pressure Test
Overview
Evaluates Air Conditioning (A/C) system high-side and low-side refrigerant pressures to help determine if:
• Refrigerant charge is correct

• Compressor, condenser, expansion valve, A/C lines, and cooling fan are flowing and working properly
• High-pressure switch, low-pressure switch, thermal switch and circuits are working properly
Look for frost on A/C lines and components, indicating a refrigerant flow restriction.
High ambient humidity and temperature will reduce A/C systems ability to cool.
Tools Required
• Thermometer
Equipment Condition
WARNING
1. A/C manifold gauge set connected to vehicle high and low pressure A/C service ports.
Test Setup

1. Blower control switch 2. Hot/cold blend control
490
HVAC
3. A/C Switch 4. Mode switch

2. Rotate HVAC hot / cold blend control all the way counterclockwise to cold.
4. Rotate mode switch to blow air from center ducts, and push A/C switch ON.
5. Insert thermometer into center HVAC duct.
6. Run engine to 1800 rpm.
Test Procedure
1. Observe manifold gauge set high and low pressure gauges.
2. If low-side pressure goes below 5 psi, or high-side pressure goes above 375 psi: compressor clutch
control problem. Go to Step 6 to determine HVAC Feature code, (page 469)
Ambient Relative Vent Air High-Side Refrigerant Low-Side Compressor

Air Humidity Temperature Pressure Refrigerant Pressure Cycling
Temperature
°F °C RH % °F °C psig kPa g psig kPa g
70 21 30-50 45-57 7-14 80-140 552-965 7-25 48-172 Yes
70 21 70-90 45-58 7-14 85-145 586-1000 7-25 48-172 Yes
80 27 30-50 46-60 8-16 105-165 724-1138 10-25 69-172 Yes
80 27 70-90 50-60 10-16 110-175 758-1207 10-25 69-172 Yes / No
90 32 30-50 53-61 12-19 130-195 896-1345 15-25 103-172 Yes / No
90 32 70 55-66 13-19 135-210 931-1442 15-30 103-207 No
100 38 30-50 60-68 16-20 160-230 1103-1586 15-30 103-207 No
100 38 70 65-78 18-26 165-260 1138-1793 20-35 138-241 No
A/C System Dynamic Temperature and Pressure Table
3. Compare observed pressures to A/C System Dynamic Temperature and Pressure Table.
Expected Outcome
Determine if low-side and high-side refrigerant pressures are within pressures listed in A/C System Dynamic
Temperature and Pressure Table, if not see Gauge Readings Indicating Possible Problems.
Gauge Readings Indicating Possible Problems

• Low-side low, high-side low: diagnose and repair low refrigerant charge or A/C Compressor Test (page
506).
• Low-side low, high-side normal: diagnose and repair refrigerant restriction, low refrigerant charge, or
expansion valve stuck closed.
• Low-side low, high-side high: diagnose and repair refrigerant restriction or expansion valve stuck closed.
• Low-side high, high-side low: diagnose and repair compressor failure or expansion valve stuck open.
491
HVAC
• Low-side high, high-side high: diagnose and repair refrigerant over charge, air or oil contamination,
condenser restriction, engine cooling fan, or expansion valve stuck open.
• Compressor not cycling properly: compressor clutch control problem. Go to HVAC System Air Not Cool
After A/C Turned ON Step 6 to determine HVAC Feature code (page 469).
492
HVAC
HVAC Air Flow Control Test
Overview
With the ignition Key ON and HVAC Control ON the Blend Door Stepper Motor controls air flow thru the
heater core and evaporator core.
With the ignition Key ON and HVAC Control ON the Recirculation / Fresh Air Door Stepper Motor controls
fresh air flow into the cab. When the Mode switch is moved to the “Max” position the fresh air door closes,
recirculating air inside the cab.

Tools Required
Equipment Condition
None
Test Setup
1. Key On. Mode switch in any position other than OFF.
493
HVAC
Test Procedure
1. Inspect HVAC vents and ducts for debris, damage and restrictions. If required, Repair damage and
clear restrictions.
Figure 259 HVAC Air Flow Control, Key ON
2. Disconnect stepper motor electrical connector.
3. Measure voltage between power and ground circuits for stepper motor to be tested. If voltage is not within
0.5 volts of battery voltage, diagnose and repair power or ground circuit problem. Circuits shown in red
should have battery voltage.
494
HVAC
Figure 260 Example: Key ON, HVAC Control ON, Blend Door Moving to Cold
495
HVAC
Figure 261 Example: Key ON, HVAC Control ON, Blend Door Moving to Hot
4. Measure voltage between stepper motor control circuit and ground as the control is moved.
• Open: 0V
• Closed: 12V
If control circuit voltage is not appropriate repair circuit high resistance or short. If control circuit voltage is
not appropriate and circuit does not have high resistance or a short, replace HVAC control.
5. Inspect door and linkage for binding or damage. If linkage is not binding or damaged, replace stepper
motor.
Expected Outcome
Determine circuit(s) or component(s) causing blend door stepper motor or recirculation / fresh air door stepper
motor to not work correctly.
496
HVAC
Base A/C System Compressor Clutch Control Test
Overview
With the ignition Key ON, A/C switch ON, and mode switch in any position other than OFF power is provided to
energize the AC Control Relay which provides power to the refrigerant Compressor Clutch thru the Thermal
Switch and AC Relay.
497
HVAC
Figure 262 A/C Compressor Clutch Controls: A/C Switch and/or HVAC Control OFF
498
HVAC
Tools Required
Equipment Condition
None
Test Setup
2. Rotate hot / cold blend control to cold.
499
HVAC
Test Procedure
Figure 263 A/C Switch and HVAC Control ON, Compressor Running
500
HVAC
In the A/C Switch and HVAC Control ON, Compressor Running graphic (Figure 263) the HVAC Control and
A/C Switch are ON which energizes the AC Control Relay. Current then flows thru the AC Control Relay,
Thermal Switch and AC Relay, energizing the refrigerant Compressor Clutch.
501
HVAC
Figure 264 A/C Switch and HVAC Control ON, Compressor Not Running (High-side Pressure Greater
than 375 psig)
502
HVAC
In the A/C Switch and HVAC Control On, Compressor Not Running graphic (Figure 264) the HVAC Control
and A/C Switch are ON which energizes the AC Control Relay. Current then flows thru the Thermal Switch
to the AC Relay. The AC Relay is energized cutting off power to the A/C compressor clutch, when one
or both pressure switches are closed.
1. Determine if A/C compressor clutch turns ON, and cycles OFF if low-side pressure is 5 psi or lower, and
cycles Off if high-side pressure is approximately 375 psi or higher. Circuits shown in red should have
battery voltage at specified operator controls, temperatures, and pressures.
Expected Outcome
Determine circuit(s) or component(s) causing compressor clutch to not engage.
503
HVAC
APADS A/C System Compressor Clutch Control Test
Overview
Air Conditioning Protection and Diagnostic Systems (APADS) is a micro-controller based system that controls
A/C compressor clutch cycling. The APADS module receives input from the high-pressure and low-pressure
refrigerant switches, and the HVAC Control thru the Thermal Switch.
Figure 265 APADS Compressor Controls: Ignition Switch ON, HVAC Control OFF
Circuits shown in red should have battery voltage at specified operator controls, temperatures, and pressures.
504
HVAC
APADS Compressor Control Rules

• A/C compressor clutch OFF for first 15 seconds after ignition switch engaged, then turned ON for 15
seconds, unless high or low pressure switches are out of bound or faults exist.
• Maximum A/C compressor On/Off cycle rate is once every 15 seconds.
• A/C compressor turned OFF when high-pressure switch exceeds maximum pressure, and / or when
low-pressure switch exceeds minimum pressure.
• If supply voltage to APADS module drops below 11.0 volts A/C compressor clutch turned OFF.
• If an Open A/C compressor clutch fault is detected compressor is turned OFF until next ignition cycle.
Tools Required
Digital Multimeter (DMM)
Equipment Condition
None
Test Setup
2. Rotate HVAC hot / cold blend control to cold.
Test Procedure
Determine if compressor control circuits and components are operating correctly per APADS Compressor
Controls: Ignition Switch ON, HVAC Control OFF graphic (Figure 265). Circuits shown in red should have
battery voltage at specified operator controls, temperatures, and pressures.
Expected Outcome
Determine circuit(s) or component(s) causing compressor clutch to not engage.
505
HVAC
A/C Compressor Compression Test
Overview
If the A/C compressor is suspected of malfunctioning, but testing has been inconclusive, perform this test. This
test can help identify if a compressor is operating correctly, but will not identify faulty component if the test fails.
Tools Required
• Cardboard
Equipment Condition
1. Body panel below passenger door removed for access.
2. Cover over expansion valve removed.
3. A/C machine connected to vehicle HVAC system. Refer to Recovery Station - Install (page 1321).
Test Procedure
1. Place a piece of cardboard in front of the A/C condenser to block airflow.
2. Run engine at 1800 rpm.
3. Set HVAC control for maximum cooling, blower switch on high.
4. Observe high-side gauge reading. Pressure should climb quickly to 275 to 300 psi.
5. If specification is not met, compressor may not be functioning correctly. If specification is met, remove
cardboard and go to the next step.
6. With HVAC system still running, spray expansion valve with an aerosol ’cooling spray’.
7. Low-side pressure should drop to 10 to 15 psi.
8. If specification is met, the compressor may be functioning correctly.
9. If specification is not met, the compressor is not be functioning correctly.
Expected Outcome
Determine if A/C compressor is operating properly.
506
INSTRUMENTS / GAUGES
15. Instruments / Gauges

Instrumentation Sections
Instrument Cluster (page 515)
Auxiliary Gauge Pack (AGP) (page 507)
Park Brake Indicator (page 528)
Auxiliary Gauge Pack

Overview
Figure 266 Auxiliary Gauge Pack (AGP) Gauge Locations
Gauge Name Possible AGP Positions

Air Application Gauge 1, 2, 3, 4
Air Cleaner Restriction Gauge 4
Eaton Ultrashift Shifter Gauge 1
Manifold Pressure Gauge 1, 2, 3, 4
Front Rear Axle Oil Temperature Gauge 1, 2, 3
Rear Rear Axle Oil Temperature Gauge 2, 3, 4
Rear Suspension Air Pressure Gauge 1, 2, 3, 4
507
Figure 267 J3 - 4 Pin Connector

1. Battery Positive 3. Local Interconnect Network (LIN)
2. Ground 4. Dimming
AGP Diagnostics
Air Application Gauge
Air Cleaner Restriction Gauge
Eaton Ultrashift Shifter Gauge
Manifold Pressure Gauge
Rear Axle Oil Temperature Gauge
Rear Suspension Air Pressure Gauge
508
Air Application Gauge
Overview
0016HGN Gauge, Air Application
The air application gauge shows the amount of service brake air pressure being applied in the primary brake
system in either pounds per square inch (PSI) or kilopascal (kPa). The gauge receives its signal from the
air application transducer which is a direct input to the instrument cluster. The instrument cluster sends
the transducer information over the Local Interconnect Network (LIN) communication interface to the air
application gauge.
509
Air Cleaner Restriction Gauge
Overview
0016HLC Gauge, Air Cleaner Restriction (Filter Minder); Mounted in Instrument Panel
Figure 268 Air Cleaner Restriction Gauge

1. Vacuum Hose Connection
The air cleaner restriction gauge shows the engine air filter capacity and how much of that capacity remains. A
vacuum hose from the air intake piping routes through the fire wall and mounts directly to the rear of the gauge.
The maximum restriction of the filter element is measured when the engine is operated under a full load, in
which the gauge will lock at that point. The maximum restriction can be read when the engine is shut down.
510
Eaton Ultrashift Shifter Gauge
Overview
0016HLD Indicator Transmission Gear Position, Display Gear Transmission
The Eaton Ultrashift shifter gauge displays the gear status of the Eaton Ultrashift automatic transmission.
The Transmission Control Module (TCM) communicates the gear status to the instrument cluster over
the J1939 communication interface. The instrument communicates the gear information over the Local
Interconnect Network (LIN) communication interface to the shifter gauge. If the shifter gauge does not receive
the appropriate message or data KEY ON, the gauge will show blank. If the condition continues after 20
seconds, the gauge will display dashes. If the data being received is corrupted or not supported, the gauge
will show asterisks.
511
Manifold Pressure Gauge
Overview
0016HKB Gauge, Manifold Pressure, Data Link Driven; Mounted in Instrument Panel,
Includes Controller Module
Figure 269 Intake Manifold Pressure Sensor Location

1. Intake Manifold Pressure Sensor
The manifold pressure gauge shows the amount of air intake pressure created by the engine in units of either
pounds per square inch (PSI) or kilopascal (kPa). The gauge receives its signal from the manifold pressure
sensor which is a direct input to the Engine Control Module (ECM). The ECM sends the manifold pressure
information to the instrument cluster over the J1939 communication interface. The instrument cluster sends
the received message over the Local Interconnect Network (LIN) communication interface to the manifold
pressure gauge.
512
Rear Axle Oil Temperature Gauge
Overview
0016HGL Gauge, Oil Temperature, Rear Axle
Figure 270 Rear Axle Oil Temperature Sensor Locations

1. Rear Axle Oil Temperature Sensors
The rear axle oil temperature gauge(s) shows the temperature of the rear axle oil where temperature is shown
in either degrees Fahrenheit (⁰F) or degrees Celsius (⁰C). The gauge receives its signal from the rear axle oil
temperature sensor, which is a direct input to the instrument cluster. The instrument cluster sends the received
signal over the Local Interconnect Network (LIN) communication interface to the rear axle oil temperature
gauge(s). If equipped with tandem axles, there will be a rear axle oil temperature gauge for each axle. The
instrument cluster checks the sensor values at KEY ON. If the sensor shows a temperature of -22°F (-30°C) or
less, a 30 minute timer will start prior to checking for an open condition to prevent a false open fault.
513
Rear Suspension Air Pressure Gauge
Overview
0016HLB Gauge, Air Pressure for Pressure in Rear Air Suspension; Mounted in
Instrument Panel
The rear suspension air pressure gauge shows the amount of air pressure load in the rear air suspension
in either pounds per square inch (PSI) or kilopascal (kPa). The gauge receives its signal from the rear air
suspension pressure transducer which is a direct input to the instrument cluster. The instrument cluster sends
the transducer information over the Local Interconnect Network (LIN) communication interface to the rear
suspension air pressure gauge. The gauge will activate at KEY ON.
514
Instrument Cluster
Overview
0016HBA Gauge Cluster English With English Electronic Speedometer
0016HBB Gauge Cluster English With Metric Electronic Speedometer
0016HBC Gauge Cluster Metric With Metric Electronic Speedometer
Figure 271 Instrument Cluster Gauge Locations

1. Engine Oil Temperature Gauge 7. Fuel Level Gauge
2. Engine Oil Pressure Gauge 8. Tachometer
3. Speedometer 9. Odometer / Function Display
4. Diesel Exhaust Fluid (DEF) Gauge 10. Engine Coolant Temperature Sensor
5. Primary Air Pressure Gauge Gauge
6. Secondary Air Pressure Gauge 11. Transmission Oil Temperature Gauge
Instrument Cluster Display Readouts
The instrument cluster displays various readouts such as vehicle speed, engine speed, engine fluid
temperatures and pressures, transmission fluid temperatures, fuel level, DEF level, air pressures, and volts
through either analog or digital readouts. Inputs to the instrument cluster can be direct or communicated
messages through the J1939 communication interface.
Instrument Cluster Bulb Check

KEY ON, the instrument cluster performs a bulb check where each warning lamp will illuminate for a certain
amount of time. All the gauges in both the instrument cluster and the Auxiliary Gauge Pack (AGP), except for
the fuel gauge and the air cleaner restriction gauge, will perform a gauge sweep with KEY ON. If a fault is
515
recognized, the gauge pointer will default to the 6 o’clock position. The instrument cluster may power down if
either the battery voltage or ignition voltage drops below 9 volts.
Instrument Cluster Self-diagnostic Mode

The instrument cluster is able to enter a self-diagnostic mode and can detect faults including: gauge, warning
lights, Odometer / Function Display, buzzer, and backlighting, in that order. If a fault is found with a gauge, the
Odometer / Function Display will show “Sensor”, “Fault”, and the gauge name. If a fault is found with a warning
lamp, a “0” (not active), or a “1” (active), and the name of the warning lamp will be displayed. The Odometer /
Function Display is tested by showing “Test” and “Display”, then driving the display segments. The buzzer test
initiates showing “Test” and “Buzzer”, then activates a beep tone once. The display indicates the backlight test
has initiated by showing “Test” and “Backlgh”. The backlight cycles through the dimming ranges. The self
diagnostic mode will start over after backlight test. Enter self diagnostic mode using the following procedure:
1. KOEO, parking brake set, press Mode / Reset button till ambient temperature screen is reached.
2. Release button, then hold Mode / Reset button until “Diag Active” appears on Odometer / Function Display
- The software version of the instrument cluster will show after approximately five seconds.
3. Press Mode / Reset starting the test sequence for each gauge - The gauges will perform a sweep from the
minimum to the maximum value and the warning lights will cycle ON and OFF.
4. To force gauge test or warning lamp test, press Mode / Reset button until desired gauge is reached.
5. Cycle ignition to exit self-diagnostic mode.
Figure 272 J1 - 14-pin Connector

1. Battery Positive 8. High Beam Indicator
2. Right Turn Signal 9. Door Switch
3. Left Turn Signal 10. Ground
4. Not Used 11. Air Filter Restriction
5. Dimmer Power Signal Output 1 12. J1939 Positive
6. Dimmer Power Signal Output 2 13. J1939 Negative
7. Switched Ignition 14. J1939 Shield
516
Figure 273 J2 - 20-pin Connector

1. Panel Dimmer Up 12. Ground
2. Brake Air One 13. Air Application Analog Input
3. Brake Air Two 14. Rear Suspension Pressure Analog Input
4. Panel Dimmer Down 15. Park Lamp Dig Input
5. Not Used 16. Forward Rear Axle Temperature Analog
6. Fuel Sender Input
7. Transmission Oil Temperature 17. Rear Rear Axle Temperature Analog
8. 5 Volt Reference Input
9. 5 Volt Reference 18. Not Used
10. Zero Volt Reference 19. Park Brake Indicator
11. Zero Volt Reference 20. Not Used
Instrument Cluster Gauge Diagnostics

Air Tank Pressure Gauges
Coolant Temperature Gauge
Diesel Exhaust Fluid (DEF) Level Gauge
Engine Oil Pressure Gauge
Engine Oil Temperature Gauge
Fuel Level Gauge
Speedometer
Tachometer
Transmission Oil Temperature Gauge
Voltmeter
517
Air Tank Pressure Gauges
Overview
Figure 274 Air Pressure Transducer / Switch Locations

1. Body Controller (BC) Park Brake Switch 5. Park Brake Switch
2. Secondary Air Pressure Transducer 6. Engine Control Module (ECM) Park
3. Primary Air Pressure Transducer Brake Switch
4. Transmission Control Module (TCM)
Park Brake Switch
The primary and secondary air tank pressure gauges display air tank pressures in either pounds per square
inch (PSI) or kilopascal (kPa). The gauge will display pressure at KEY ON or if the door is opened. If the door
is open for longer than 5 minutes the brake pressure gauges will no longer display, and the gauges will stay
active for approximately 11 seconds after the door is closed. There can be up to three pressure transducers in
the vehicle air lines, which are direct inputs to the instrument cluster.
518
Coolant Temperature Gauge
Overview
Figure 275 N13 Engine Coolant Temperature Sensor Location

1. N13 Engine Coolant Temperature
Sensor
The coolant temperature gauge shows the temperature of the engine coolant where temperature is shown in
either degrees Fahrenheit (⁰F) or degrees Celsius (⁰C). The gauge receives its signal from the engine coolant
temperature (ECT) sensor, which is a direct input to the Engine Control Module (ECM). Sensor information is
sent to the instrument cluster over the J1939 communication interface.
519
Diesel Exhaust Fluid (DEF) Level Gauge
Overview
Figure 276 DEF Tank Sensor Location

1. DEF Tank Sensor
The diesel exhaust fluid (DEF) level gauge shows the amount of DEF remaining in the DEF tank ranging from
empty (E) to full (F). The level of DEF is measured by the DEF tank sensor which sends a 250K J1939
communicated message to the ECM on the DEF level. The ECM sends a 500K J1939 communicated message
to the instrument cluster to operate the gauge. If the level reaches 15% or 100 miles till empty, an indicator
light will appear along with audible warnings. If the DEF level reaches 10%, the vehicle will derate until 5%
empty, after which the vehicle will be derated to 5 mph maximum at empty.
520
Engine Oil Pressure Gauge
Overview
Figure 277 N13 Engine Oil Pressure Sensor Location

1. N13 Engine Oil Pressure Sensor
The engine oil pressure gauge shows the pressure of the engine oil where pressures are shown in either
pounds per square inch (PSI) or kilopascal (kPa). The gauge receives its signal from the engine oil pressure
sensor, which is a direct input to the Engine Control Module (ECM). Sensor information is sent to the
instrument cluster over the J1939 communication interface.
521
Engine Oil Temperature Gauge
Overview
Figure 278 N13 Engine Oil Temperature Sensor Location

1. N13 Engine Oil Temperature Sensor
The engine oil temperature gauge shows the temperature of the engine oil where temperature is shown in
either degrees Fahrenheit (⁰F) or degrees Celsius (⁰C). The gauge receives its signal from the engine oil
temperature sensor, which is a direct input to the Engine Control Module (ECM). Sensor information is sent to
the instrument cluster over the J1939 communication interface.
522
Fuel Level Gauge
Overview
Figure 279 Fuel Level Sensor Location

1. Fuel Level Sensor
The fuel level gauge displays the amount of fuel in a fuel tank, ranging from empty (E) to full (F). KEY ON, the
fuel level will activate. The fuel level gauge receives its signal from the fuel level sensor, which is a direct
input to the instrument cluster.
523
Speedometer
Overview
Figure 280 Output Shaft Speed Sensor Location

1. Output Shaft Speed Sensor
The speedometer shows the vehicle speed in either miles per hour (mph) or kilometers per hour (km/h). Vehicle
speed is obtained from the transmission output shaft speed sensor and is either a direct input to the Engine
Control Module (ECM) (manual transmission) or Transmission Control Module (TCM) (automatic transmission).
The sensor information is then sent to the instrument cluster over the J1939 communication interface.
524
Tachometer
Overview
Figure 281 Tachometer Input Sensor Locations

1. Camshaft Position (CMP) Sensor 2. Crankshaft Position (CKP) Sensor
The tachometer shows engine speed in rotations per minute (rpm) and is obtained from the both the CMP
sensor and CKP sensor. The CKP sensor and CMP sensor are direct inputs to the Engine Control Module
(ECM) where sensor information is sent to the instrument cluster over the J1939 communication interface.
525
Transmission Oil Temperature Gauge
Overview
The transmission oil temperature gauge shows the temperature of the transmission oil where temperature
is shown in either degrees Fahrenheit (⁰F) or degrees Celsius (⁰C). The gauge receives its signal from
the transmission oil temperature sensor, which can either be a communicated message over the J1939
communication interface, or it can be a direct input to the instrument cluster. The instrument cluster will look for
a J1939 transmission oil temperature sensor CAN message, however if the message is not received, then it
will default to using a directly connected sensor. The transmission oil temperature sensor will be a direct input
to the Transmission Control Module (TCM) on vehicles that are equipped with a TCM. The TCM communicates
the sensor signal to the instrument cluster over the J1939 communication interface.
526
Voltmeter
Overview
The voltmeter displays electrical system voltage in the Odometer / Function Display. Normal operating voltage
while the engine is running will be between 12 and 15 volts. If the voltmeter displays a system voltage outside
of these limits, the instrument cluster will sound a five-short-beep alarm once. The voltmeter voltage is
determined by the Engine Control Module (ECM) which then communicates the voltage information to the
instrument cluster over the J1939 communication interface.
527
Park Brake Indicator

Overview
Software Feature Code Description
0595BUZ BC PROG, Park Brake Indicator with zero cluster configuration
Electronic Gauge Cluster (EGC) activates the park brake indicator when the Park Brake Switch is closed
completing the circuit to ZVR ground. The Body Controller (BC) determines the status of the park brake
switch for use as input for other features.
The park brake indicator should go out when the park brake is released.
Figure 282 Park Brake Indicator DLB Session

1. Park brake switch input signal
528
LIGHTING SYSTEMS
16. Lighting Systems

Turn, Hazard, and Brake Lights
Overview
0595BXS Turn Signals / Brake, for Non-Multiplexed Vehicles
0595AAD Brake Switch
The Body Controller (BC) module receives input from the multifunction (turn signal) switch, hazard switch
and brake switch; and sends power output to the turn \ hazard \ brake lights thru chassis wiring harnesses.
Right or left turn signal lights blinking is activated by pulling the multifunction switch handle up or down.
Hazard warning lights blinking is activated by pressing the two-position hazard switch. Brake lights are
activated by pressing the brake pedal
Figure 283 Turn, Hazard, Brake Lights Input and Output Circuits
529
LIGHTING SYSTEMS
Turn, Hazard and Brake Lights Symptom Diagnostics

Turn, Hazard or Brake Lights Not Illuminating (page 533)
Turn and Hazard Lights Input Diagnostics (page 543)
Turn, Hazard and Brake Lights Fault Code Diagnostics

SPN FMI Description
2368 5 Left Front Turn Lamp Undercurrent (failed bulb, high resistance in
Left_Turn_Signal_Blink or ground circuit)
2368 6 Left Front Turn Lamp Overcurrent (failed bulb, Left_Turn_Signal_Blink circuit short to
ground)
2370 5 Right Front Turn Lamp Undercurrent (failed bulb, high resistance in
Right_Turn_Signal_Blink or ground circuit)
2370 6 Right Front Turn Lamp Overcurrent (failed bulb, Right_Turn_Signal_Blink circuit
short to ground)
2372 5 Left Rear Turn Lamp Undercurrent (failed bulb, high resistance in LT_RR_Turn_Cmd
or ground circuit)
2372 6 Left Rear Turn Lamp Overcurrent (failed bulb, LT_RR_Turn_Cmd circuit short to
ground)
2374 5 Right Rear Turn Lamp Undercurrent (failed bulb, high resistance in
RT_RR_Turn_Cmd or ground circuit)
2374 6 Right Rear Turn Lamp Overcurrent (failed bulb, RT_RR_Turn_Cmd circuit short to
ground)
2376 2 Faulty Turn Switch (failed multifunction switch, short in Right_Turn Signal_Switch or
Left_Turn Signal_Switch circuits)
530
LIGHTING SYSTEMS
Overview
The following steps direct technicians to systematically troubleshoot turn, hazard and brake lights performance
using Diamond Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Turn, Hazard and Brake
lights Overview (page 529) for more information.
Step 1 Determine if turn, hazard or brake light(s) are burnt out or damaged. Decision
out light(s) or repair
2. Disconnect light(s) that do not illuminate.
3. Inspect and determine if light(s) are burnt out or damaged. are complete, retest
for symptom.
Are turn, hazard, or brake light(s) burnt out or damaged? No: Go to Step 2.
Step 2 Check for Active turn, hazard and brake lights fault codes. Decision
1. Using Electronic Service Tool (EST) with Diamond Logic® Builder Yes: Go to fault code
(DLB®) software, select Faults tab. diagnostics (page 530)
for active SPN / FMI.
2. Key ON.
3. Check Faults tab for Active fault codes.
Are turn, hazard and brake lights fault codes Active? No: Go to Step 3.
Figure 284 Hazard Switch

1. Hazard lights ON 2. OFF
531
LIGHTING SYSTEMS
Figure 285 Multifunction (Turn Signal) Switch
Step 3 Determine if turn, hazard and / or brake lights do not illuminate when Decision
requested.
Turn ON turn, hazard and brake lights. Yes: Go to Turn and
Hazard Lights Input
Diagnostics (page
543).
Do turn, hazard and brake lights illuminate? No: Go to Turn,
Hazard and Brake
Lights Not Illuminating
(page 566).
532
LIGHTING SYSTEMS
Turn, Hazard or Brake Lights Not Illuminating
Overview
Turn lights illuminate when the Body Controller (BC) receives multifunction (turn signal) switch input and turns
On the blinking right or left turn lights.
Hazard warning lights illuminate when the BC receives hazard switch input and turns On the blinking right
and left lights.
Brake lights illuminate when the BC receives input from the brake switch and turns On the rear lights.
Fault Facts
None
Possible Causes
• Burnt out or damaged turn / hazard / brake lights
• Right_Turn_Signal_Switch circuit Open or high resistance
• Left_Turn_Signal_Switch circuit Open or high resistance
• Multifunction switch ground circuit Open or high resistance
• Failed multifunction switch
• Hazard_Switch circuit Open or high resistance
• Hazard switch ground circuit Open or high resistance
• Failed hazard switch
• Brake_Switch_Digital_Input circuit Open or high resistance
• Brake switch ground circuit Open or high resistance
• Failed brake switch
• Right_Turn_Signal_Blink and/or Left_Turn_Signal_Blink output circuit(s) short to ground
• Right_Turn_Signal_Blink and/or Left_Turn_Signal_Blink circuit(s) Open or high resistance
• RT_RR_Turn_Cmd and/or LT_RR_Turn_Cmd circuit(s) short to ground
• RT_RR_Turn_Cmd and/or LT_RR_Turn_Cmd circuit(s) Open or high resistance
• Turn / hazard /brake light ground circuit(s) Open or high resistance
• Failed Body Controller (BC)
533
LIGHTING SYSTEMS
Figure 286 Turn Signals / Brake DLB Session (Turn Signals and Hazard Switch Input to Body
Controller)
1. Right_Turn_Signal_Switch 3. Hazard_Switch
2. Left_Turn_Signal_Switch
534
LIGHTING SYSTEMS
Figure 287 Brake Switch DLB Session (Input to Body Controller)

1. Brake_Switch_Digital_Input
535
LIGHTING SYSTEMS
Figure 288 Right and Left Front Turn and Hazard Lights Output from Body Controller Connector J2
(1604)
1. Right front turn and hazard signal 2. Left front turn and hazard signal
536
LIGHTING SYSTEMS
Figure 289 Right and Left Rear Turn, Hazard and Brake Lights Output from Body Controller
Connector J1 (1603)
1. Left rear turn \ hazard \ brake signal 2. Right rear turn \ hazard \ brake signal

Yes: Go to Step 2.
Checkout Procedure
(page 531).
537
LIGHTING SYSTEMS
Step 2 Determine if turn signal and hazard switch input is received by the Decision
Body Controller (BC).
1. Using Electronic Service Tool (EST) with Diamond Logic® Builder Yes: Go to Step 3.
(DLB), select the Turn Signals/Brake Feature, and click Make Session.
2. Pull multifunction switch handle up to activate right turn lights. Observe
Right_Turn_Signal_Switch Value column (Figure 286).
3. Pull multifunction switch handle down to activate left turn lights.
Observe Left_Turn_Signal_Switch Value column.
4. Push hazard switch to activate hazard lights. Observe Hazard_Switch
Value column.
Do check marks appear in the appropriate Value columns? No: Go to Turn and
Hazard Lights Input
Diagnostics (page
543).
Step 3 Determine if brake switch input is received by the Body Controller (BC). Decision
1. Using EST with DLB, select the Brake Switch Feature and click Make Yes, front lights not
Session. working: Go to Step 4.
2. Push brake pedal down to activate the brake lights. Observe the
Brake_Signal_Digital_Input Value column (Figure 287).
Does a check mark appear in the Brake_Signal_Digital_Input Value column? Yes, rear lights not
working: Go to Step
11.
No: Go to Brake
Switch Input
Diagnostics (page
637).
Step 4 Determine if right front turn / hazard light ground circuit is Open or Decision
has high resistance.
Disconnect right front turn / hazard light connector. Measure resistance between Yes: Go to Step 5.
right front turn / hazard light chassis harness connector pin-3 and ground.
Is resistance less than 5 ohms? No: Repair Open or
high resistance in right
front turn / hazard light
recheck for original
symptom.
538
LIGHTING SYSTEMS
Step 5 Inspect connections at BC connector J2 (1604). Decision

2. Remove left kick panel.
3. Disconnect BC connector J2. (Figure 288).
4. Check connector and connector terminals for: damaged or pinched
Are BC connector J2, harness, and terminals clean and undamaged? No: Repair connector,
for symptom.
Step 6 Determine if Right_Turn_Signal_Blink circuit is shorted to ground. Decision

With right front turn / hazard light connector disconnected, measure resistance Yes: Go to Step 7.
between BC connector J2 pin-K and ground.
Is resistance greater than 1000 ohms? No: Repair short
to ground in
Right_Turn_Signal_Blink
circuit. After repairs are
symptom.
Step 7 Determine if Right_Turn_Signal_Blink circuit is Open or has high Decision

resistance.
With right front turn / hazard light connector disconnected, measure resistance Yes: Go to Step 8.
between BC connector J2 pin-K and right front turn / hazard light connector pin-1.
or high resistance in
Right_Turn_Signal_Blink
symptom.
Step 8 Determine if left front turn / hazard light ground circuit is Open or Decision
has high resistance.
Disconnect left front turn / hazard light connector. Measure resistance between Yes: Leave left front
left front turn / hazard light connector pin-3 and ground. turn / hazard light
disconnected. Go to
Step 9.
Is resistance less than 5 ohms? No: Repair Open or high
resistance in left front
turn / hazard light ground
complete recheck for
original symptom.
539
LIGHTING SYSTEMS
Step 9 Determine if Left_Turn_Signal_Blink circuit is shorted to ground. Decision

Measure resistance between BC connector J2 pin-C and ground. Yes: Go to Step 10.
to ground in
Left_Turn_Signal_Blink
circuit. After repairs
for symptom.
Step 10 Determine if Left_Turn_Signal_Blink circuit is Open or has high Decision

resistance.
Measure resistance between BC connector J2 pin-C and left front turn / hazard Yes: Replace Body
light connector pin-1. Controller (BC). After
retest for symptom.
high resistance in
Left_Turn_Signal_Blink
for symptom.
Step 11 Determine if right rear turn / hazard light ground circuit is Open or has Decision
high resistance.
Disconnect right rear turn / hazard light connector. Measure resistance between Yes: Go to Step 12.
right rear turn / hazard light connector pin-1 and ground.
high resistance in right
rear turn / hazard light
symptom.

for symptom.
540
LIGHTING SYSTEMS
Step 13 Determine if RT_RR_Turn_Cmd circuit is shorted to ground. Decision

With right rear turn / hazard light connector disconnected, measure resistance Yes: Go to Step 14.
between BC connector J1 pin-M and ground.
to ground in
RT_RR_Turn_Cmd
for symptom.
Step 14 Determine if RT_RR_Turn_Cmd circuit is Open or has high resistance. Decision

Measure resistance between BC connector J1 pin-M and right rear turn / hazard Yes: Go to Step 15.
light chassis harness connector pin-3.
high resistance in
RT_RR_Turn_Cmd
for symptom.
Step 15 Determine if left rear turn / hazard light ground circuit is Open or has Decision
high resistance.
Disconnect left rear turn / hazard light connector. Measure resistance between left Yes: Leave left rear
rear turn / hazard light chassis harness connector pin-1 and ground. turn / hazard light
disconnected. Go to
Step 16.
high resistance in left
rear turn / hazard light
symptom.
Step 16 Determine if LT_RR_Turn_Cmd circuit is shorted to ground. Decision

Measure resistance between BC connector J1 pin-D and ground. Yes: Go to Step 17.
to ground in
LT_RR_Turn_Cmd
for symptom.
541
LIGHTING SYSTEMS
Step 17 Determine if LT_RR_Turn_Cmd circuit is Open or has high resistance. Decision

Measure resistance between BC connector J1 pin-D and left rear turn / hazard Yes: Replace Body
light connector pin-3. Controller (BC). After
retest for symptom.
high resistance in
LT_RR_Turn_Cmd
for symptom.

542
LIGHTING SYSTEMS
Turn and Hazard Lights Input Diagnostics
Overview
Turn lights illuminate when the Body Controller (BC) receives multifunction (turn signal) switch input and turns
On the blinking right or left turn lights.
Hazard warning lights illuminate when the Body Controller (BC) receives hazard switch input and turns On
the blinking right and left lights.
Fault Facts
None
Possible Causes
• Right_Turn_Signal_Switch circuit Open or high resistance
• Left_Turn_Signal_Switch circuit Open or high resistance
• Hazard_Switch circuit Open or high resistance
• Hazard switch ground circuit Open or high resistance
• Failed hazard switch
543
LIGHTING SYSTEMS
Figure 290 Turn Signals / Brake DLB Session (Turn Signals and Hazard Switch Input to Body
Controller)
1. Right_Turn_Signal_Switch 3. Hazard_Switch
2. Left_Turn_Signal_Switch
544
LIGHTING SYSTEMS
Figure 291 Right and Left Turn Signal Input to Body Controller Connector J3 (1600)
1. Right turn signal input 2. Left turn signal input
545
LIGHTING SYSTEMS
Figure 292 Hazard Switch Input to Body Controller Connector J7 (1606)

1. Hazard switch input
Step 1 Determine if turn signal or hazard switch input is not received by Decision
the Body Controller (BC).
1. Pull multifunction switch handle up to activate right turn lights. Yes, hazard switch input
Observe Right_Turn_Signal_Switch Value column (Figure 290). problem: Go to Step 6.
2. Pull multifunction switch handle down to activate left turn lights.
Observe Left_Turn_Signal_Switch Value column.
3. Push hazard switch to activate hazard lights. Observe
Hazard_Switch Value column
Do check marks appear in the appropriate turn signal Value columns? No, turn signal input
problem: Go to Step 2.
546
LIGHTING SYSTEMS

1. Key OFF. Yes,
Right_Turn_Signal_Switch
input problem: Go to Step
3. Disconnect BC connector J3 (Figure 291). 3.
wires; moisture or corroded terminals; loose, bent, or broken pins;
Are BC connector J3, harness, and terminals clean and undamaged? Yes,
Left_Turn_Signal_Switch
input problem: Go to Step
4.
No: Repair connector,
symptom.
Step 3 Determine if Right_Turn_Signal_Switch circuit is Open or has high Decision

resistance.
2. Connect 180-pin Breakout Box 00-00956-08 to Breakout Harness
08-854-01.
3. Connect Breakout Harness 08-854-01 to BC connector J3 and
leave BC disconnected.
4. Disconnect multifunction switch connector.
5. Using Terminal Test Kit ZTSE4435C, insert proper terminal into
multifunction switch connector pin-10.
6. Using a Digital Multimeter (DMM), measure resistance between
BC connector J3 pin-A6 and multifunction switch chassis harness
connector pin-10.
high resistance in
Right_Turn_Signal_Switch
original symptom.
547
LIGHTING SYSTEMS
Step 4 Determine if Left_Turn_Signal_Switch circuit is Open or has high Decision

resistance.
Measure resistance between BC connector J3 pin-A7 and multifunction switch Yes: Go to Step 5.
chassis harness connector pin-1.
high resistance in
Left_Turn_Signal_Switch
original symptom.
Step 5 Determine if multifunction switch ground circuit is Open or has high Decision
resistance.
Measure resistance between multifunction switch chassis harness connector and Yes: Replace
ground. multifunction switch.
After repairs are
complete recheck
for original symptom.
If symptom continues,
replace Body
Controller.
high resistance in
multifunction switch
symptom.

for symptom.
548
LIGHTING SYSTEMS
Step 7 Determine if Hazard_Switch circuit is Open or has high resistance. Decision

Measure resistance between BC connector J7 pin-A6 and hazard switch connector Yes: Go to Step 8.
pin-3.
or high resistance
in Hazard_Switch
are complete recheck
Step 8 Determine if hazard switch ground circuit is Open or has high Decision
resistance.
Measure resistance between hazard switch connector pin-2 and ground. Yes: Replace
hazard switch. After
symptom. If symptom
continues, replace
Body Controller.
high resistance in
hazard switch ground
549
LIGHTING SYSTEMS
Fog Lights
Overview
0595BYJ Fog Lights Rocker Switch, for Non-Multiplexed Vehicles
0008621 FOG LIGHTS (2) {Per-Lux 600 Series} 100 Watt Sealed Beam, Amber,
with Rectangular Lens and Louvers
0008649 FOG LIGHTS (2) {Per-Lux 600 Series} 100 Watt Sealed Beam, Clear, With
Rectangular Lens and Louvers
0008WLM FOG LIGHTS (2) {Peterson} Amber, Halogen, Rectangular
0008WLN FOG LIGHTS (2) {Peterson} Clear, Halogen, Rectangular
0008XJG FOG LIGHTS (2) Clear Lens, Halogen, Rectangular, with White Light Source
0008WMK FOG LIGHTS Prewire; Includes Switch and Wiring for Fog Lights Mounted
by Customer
The Body Control (BC) module receives input from the Fog Light switch and sends power output to the left
and right fog lights thru chassis wiring harnesses.
Figure 293 Fog Lights Input and Output Circuits
550
LIGHTING SYSTEMS
Fog Lights Symptom Diagnostics

Fog Lights Not Illuminating (page 552)
Fog Lights Fault Code Diagnostics

SPN FMI Description
2387 2 Fog Light Switch Error (Faulty Fog Light Switch or input circuit)
2388 5 Left Front Fog Lights Under Current Or Open Circuit (Left_Front_Fog_Light_Cmd
circuit, bulb, or ground fault)
2388 6 Left Front Fog Lights Overcurrent (Short to ground in Left_Front_Fog_Light_Cmd
circuit, bulb)
4008 5 Right Front Fog Light Undercurrent (Right_Front_Fog_Light_Cmd circuit, bulb, or
ground fault)
4008 6 Right Front Fog Light Overcurrent (Short to ground in Right_Front_Fog_Light_Cmd
circuit, bulb)
551
LIGHTING SYSTEMS
Fog Lights Not Illuminating
Overview
The following steps direct technicians to systematically troubleshoot fog light performance using Diamond
Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Fog Light Overview (page 550) for
more information.
Fog lights illuminate when the Body Controller (BC) receives input from the fog light switch and turns On the
fog light output at BC J1 pin-K and J1 pin-F.
Possible Causes
• Burnt out or damaged fog lights
• Fog_Light_Switch input circuit Open or high resistance
• Fog light switch ground circuit Open or high resistance
• Failed Fog Light switch
• Left_Front_Fog_Light_Cmd and/or Right_Front_Fog_Light_Cmd output circuit(s) short to ground
• Left_Front_Fog_Light_Cmd and/or Right_Front_Fog_Light_Cmd circuit(s) Open or high resistance
• Left and/or right fog light ground circuit(s) Open or high resistance
552
LIGHTING SYSTEMS
Figure 294 Fog Lights DLB Session

1. Left front fog light output 3. Fog light switch input
2. Right front fog light output
553
LIGHTING SYSTEMS
Figure 295 Fog Lights Input to Body Controller Connector J7 (1606)

1. Fog light switch input circuit
554
LIGHTING SYSTEMS
Figure 296 Fog Lights Output from Body Controller Connector J1 (1603)
1. Right front fog light output circuit 2. Left front fog light output circuit
Step 1 Determine if fog lamps are burnt out or damaged. Decision

1. Turn Fog Light switch On. Yes: Replace burnt out
fog light(s) or repair
2. Observe fog lights and determine which are not illuminating.
3. Key OFF. are complete, retest
for symptom.
4. Disconnect fog light(s) that do not illuminate.
5. Inspect and determine if fog light(s) are burnt out or damaged.
Are fog light(s) burnt out or damaged? No: Go to Step 2.
555
LIGHTING SYSTEMS
Step 2 Determine if Fog_Light_Switch input is received by the Body Controller Decision

(BC).
1. Using Electronic Service Tool (EST) with Diamond Logic® Builder Yes, and left fog light
(DLB), select the Fog Lights Feature and click Make Session. Observe not working: Go to
the Fog_Light_Switch, Value column (Figure 294). Step 6.
2. Turn Fog lights ON. Observe the Fog_Light_Switch Value column.
Does a check mark appear in the Fog_Light_Switch Value? Yes, and right fog light
not working: Go to
Step 9.
No: Go to Step 3.

3. Disconnect BC connector J7 (1606) (Figure 295).
for symptom.
Step 4 Determine if Fog_Light_Switch circuit is Open or has high resistance. Decision

2. Using a Digital Multimeter (DMM), measure resistance between BC
connector J7 pin-B5 and fog light switch connector pin-3.
or high resistance
in Fog_Light_Switch
556
LIGHTING SYSTEMS
Step 5 Determine if fog light switch ZVR (ground) circuit is Open or has high Decision
resistance.
1. Perform Test 2 (page 560). Yes: Replace fog
light switch. After
2. Using a DMM, measure resistance between fog light switch connector
and ground.
symptom. If symptom
continues, replace
Body Controller.
high resistance in
fog light switch ZVR
(ground) circuit. After
symptom.
Step 6 Determine if left fog light ground circuit is Open or has high resistance. Decision
2. Using a DMM, measure resistance between left fog light connector
and ground.
high resistance in
left fog light ground
Step 7 Determine if Left_Front_Fog_Light_Cmd circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J1 pin-F
to ground.
Is resistance greater than 1000 ohms? No: Repair short to
ground in Left_Front
_Fog_Light_Cmd
for symptom.
557
LIGHTING SYSTEMS
Step 8 Determine if Left_Front_Fog_Light_Cmd circuit is Open or has high Decision

resistance.
1. Perform Test 5 (page 561). Yes: Replace Body
Controller. After
2. Using a DMM, measure resistance between BC connector J1 pin-F
and left fog light connector.
symptom.
or high resistance
in Left_Front
_Fog_Light_Cmd
Step 9 Determine if right fog light ground circuit is Open or has high resistance. Decision
2. Using a DMM, measure resistance between right fog light connector
and ground.
high resistance in
right fog light ground
Step 10 Determine if Right_Front_Fog_Light_Cmd circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J1 pin-K
to ground.
ground in Right_Front
_Fog_Light_Cmd
for symptom.
558
LIGHTING SYSTEMS
Step 11 Determine if Right_Front_Fog_Light_Cmd circuit is Open or has high Decision

resistance.
Controller. After
2. Using a DMM, measure resistance between BC connector J1 pin-K
and right headlight connector.
symptom.
or high resistance
in Right_Front
_Fog_Light_Cmd
circuit.

559
LIGHTING SYSTEMS
Pin-Point Test - Fog lights Not illuminating

Tools Required
Test 1
1. Key OFF.
2. Disconnect Body Controller (BC) connector J7 (1606).
3. Connect 180-pin Breakout Box 00-00956-08 to Breakout Harness 08-854-01.
4. Connect Breakout Harness 08-854-01 to BC connector J7 and leave BC disconnected.
5. Disconnect fog light switch connector.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fog light switch connector pin-3.
Test 2
1. Key OFF.
2. Disconnect fog light switch connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fog light switch connector
ground.
Test 3
1. Key OFF.
2. Disconnect left fog light connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into left fog light connector ground.
Test 4
1. Key OFF.
560
LIGHTING SYSTEMS
Test 5
1. Key OFF.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into left fog light connector.
Test 6
1. Key OFF.
2. Disconnect right fog light connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into right fog light connector.
Test 7
1. Key OFF.
Test 8
1. Key OFF.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into right fog light connector.
561
LIGHTING SYSTEMS
Headlights
Overview
0595BXP Headlights W / DRL, for Non-Multiplexed Vehicles
0595AAH Lights On W / Wipers
The Body Control (BC) module receives input from the headlight switch and high beam switch, and sends
power output to the headlight(s) thru chassis wiring harnesses. The headlight switch is a three position
tri-stable rocker switch with Off, Park lights, and Low beam positions.
The high beam switch is integrated into the multifunction (turn signal) switch. High beam headlight transition
and flash-to-pass features are activated by pulling back the multifunction switch.
If programmed, the Lights ON with Wipers customer programmable feature can automatically turns ON the low
beam headlight(s) when the windshield wipers are activated.
Activation of the high beam headlight(s) also turns ON the high beam indicator inside the Electronic Gauge
Cluster (EGC).
Figure 297 Headlights Input and Output Circuits
562
LIGHTING SYSTEMS
Low Beam Headlights Symptom Diagnostics

Low Beam Headlights Not Illuminating (page 566)
Low Beam Headlights Illuminate When Not Requested (page 580)
Low Beam Headlights Fault Code Diagnostics

SPN FMI Description
2653 5 Left Low Beam Under Current (page 587)
2653 6 Left Low Beam Short to Ground (page 590)
2655 5 Right Low Beam Open Circuit (page 592)
2655 6 Right Low Beam Short to Ground (page 595)
High Beam Headlights Symptom Diagnostics

High Beam Headlights Not Illuminating (page 599)
High Beam Headlights Illuminate When Not Requested (page 613)
Flash-To-Pass Not Illuminating Headlights (page 620)
High Beam Headlights Fault Code Diagnostics

SPN FMI Description
4011 5 Left High Beam Open Circuit (page 625)
4011 6 Left High Beam Short to Ground (page 628)
4012 5 Right High Beam Open Circuit (page 630)
4012 6 Right High Beam Short to Ground (page 633)
563
LIGHTING SYSTEMS
Overview
The following steps direct technicians to systematically troubleshoot low beam headlight performance using
Diamond Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Headlight Overview (page
Figure 298 Headlight Switch Positions

1. Low beam 3. Off
2. Park lights
Step 1 Determine if low beam headlight(s) are burnt out or damaged. Decision
1. Press headlight switch to low beam position. Yes: Replace burnt
out headlight(s) or
2. Observe headlight(s) and determine which are not illuminating.
repair damage. After
3. Key OFF. repairs are complete,
retest for symptom.
4. Disconnect headlight(s) that do not illuminate.
5. Inspect and determine if headlight(s) are burnt out or damaged.
Are low beam headlight(s) burnt out or damaged? No: Go to Step 2.
Step 2 Check for Active low beam headlight(s) fault codes. Decision
2. Key ON with low beam headlight(s) ON.
Are low beam headlight(s) fault codes Active? No: Go to Step 3.
564
LIGHTING SYSTEMS
Step 3 Determine if low beam headlight(s) do not illuminate when requested. Decision
Turn ON low beam headlight(s). Yes: Go to Step 4.
Are all low beam headlight(s) illuminating? No: Go to Low
Beam Headlights
Not Illuminating (page
566).
Step 4 Determine if low beam headlight(s) illuminate when not requested. Decision
1. Turn headlight switch to the OFF position. Yes: Go to Low Beam
Headlights Illuminate
2. Observe headlight(s) and determine which are illuminating.
When Not Requested
(page 580).
Are any low beam headlight(s) illuminating? No: End diagnostics.
565
LIGHTING SYSTEMS
Low Beam Headlights Not Illuminating
Overview
Low beam headlight(s) illuminate when the Body Controller (BC) receives input from the headlight switch and
turns On the low beam headlight output at BC J2 pin-B and J2 pin-H.
Fault Facts
None
Possible Causes
• Burnt out or damaged headlight(s)
• Headlight_Switch input circuit Open or high resistance
• Headlight switch ground circuit Open or high resistance
• Failed headlight switch
• Left_Lowbeam_Cmd and/or Right_Lowbeam_Cmd output circuit(s) short to ground
• Left_Lowbeam_Cmd and/or Right_Lowbeam_Cmd circuit(s) Open or high resistance
• Left and/or right headlight ground circuit(s) Open or high resistance
Figure 299 Headlights DLB Session (Input Signals to Body Controller)

1. Flash_To_Pass_Signal 3. Highbeam_Signal (low beam to high
2. Headlight_Switch beam transition)
566
LIGHTING SYSTEMS
Figure 300 Headlight Switch Input to Body Controller Connector J7 (1606)

1. Input for low beam headlight(s)
567
LIGHTING SYSTEMS
Figure 301 Low Beam Headlights Output from Body Controller Connector J2 (1604)
1. Left_Lowbeam_Cmd 2. Right_Lowbeam_Cmd

Yes: Go to Step 2.
Checkout Procedure
(page 564).
Step 2 Determine if Headlight_Switch input is received by the Body Controller Decision

(BC).
1. Using Electronic Service Tool (EST) with Diamond Logic® Builder Yes, and left low beam
(DLB), select the Headlights Feature and click Make Session. Observe not working: Go to
the Headlight_Switch, Value column (Figure 320). Step 6.
2. Turn low beam headlight(s) ON. Observe the Headlight_Switch Value
column.
Does a check mark appear in the Headlight_Switch Value? Yes, and right low
beam not working: Go
to Step 9.
No: Go to Step 3.
568
LIGHTING SYSTEMS

for symptom.
Step 4 Determine if Headlight_Switch circuit is Open or has high resistance. Decision

connector J7 pin-B6 and headlight switch connector pin-6.
or high resistance
in Headlight_Switch
Step 5 Determine if headlight switch ground circuit is Open or has high Decision
resistance.
1. Perform Test 2 (page 573). Yes: Replace
headlight switch. After
2. Using a DMM, measure resistance between headlight switch connector
pin-5 and ground.
symptom. If symptom
continues, replace
Body Controller.
or high resistance
in headlight switch
symptom.
569
LIGHTING SYSTEMS
Step 6 Determine if left headlight ground circuit is Open or has high resistance. Decision
2. Using a DMM, measure resistance between left headlight connector
pin-3 and ground.
high resistance in
left headlight ground
Step 7 Determine if Left_Lowbeam_Cmd circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J2 pin-B
to ground.
to ground in
Left_Lowbeam_Cmd
for symptom.
Step 8 Determine if Left_Lowbeam_Cmd circuit is Open or has high resistance. Decision

Controller. After
2. Using a DMM, measure resistance between BC connector J2 pin-B
and left headlight connector pin-1.
symptom.
high resistance in
Left_Lowbeam_Cmd
Step 9 Determine if right headlight ground circuit is Open or has high Decision
resistance.
2. Using a DMM, measure resistance between right headlight connector
pin-3 and ground.
high resistance in
right headlight ground
570
LIGHTING SYSTEMS
Step 10 Determine if Right_Lowbeam_Cmd circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J2 pin-H
to ground.
to ground in
Right_Lowbeam_Cmd
for symptom.
Step 11 Determine if Right_Lowbeam_Cmd circuit is Open or has high Decision

resistance.
Controller. After
and right headlight connector pin-1.
symptom.
high resistance in
Right_Lowbeam_Cmd
circuit.

571
LIGHTING SYSTEMS
Pin-Point Test - Low Beam Headlights Not illuminating

Tools Required
• 180-pin Breakout Box 00-00956-08
Figure 302 Measuring Headlight_Switch Circuit for High Resistance
Test 1
1. Key OFF.
5. Disconnect headlight switch connector.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into headlight switch connector pin-6.
572
LIGHTING SYSTEMS
Figure 303 Measuring Headlight Switch Ground Circuit for High Resistance
Test 2
1. Key OFF.
573
LIGHTING SYSTEMS
Figure 304 Measuring Left Headlight Ground Circuit for High Resistance
Test 3
1. Key OFF.
2. Disconnect left headlight connector. Slide over red lock, press tab and pull to disconnect.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into left headlight connector pin-3.
574
LIGHTING SYSTEMS
Figure 305 Measuring Left_Lowbeam_Cmd Circuit for Short to Ground
Test 4
1. Key OFF.
575
LIGHTING SYSTEMS
Figure 306 Measuring Left_Lowbeam_Cmd Circuit for High Resistance
Test 5
1. Key OFF.
576
LIGHTING SYSTEMS
Figure 307 Measuring Right Headlight Ground Circuit for High Resistance
Test 6
1. Key OFF.
2. Disconnect right headlight connector. Slide over red lock, press tab and pull to disconnect.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into right headlight connector pin-3.
577
LIGHTING SYSTEMS
Figure 308 Measuring Right_Lowbeam_Cmd Circuit for Short to Ground
Test 7
1. Key OFF.
578
LIGHTING SYSTEMS
Figure 309 Measuring Right_Lowbeam_Cmd Circuit for High Resistance
Test 8
1. Key OFF.
579
LIGHTING SYSTEMS
Low Beam Headlights Illuminate When Not Requested
Overview
Low beam headlight(s) illuminate when the Body Controller (BC) receives input from the headlight switch and
turns On the Left_Lowbeam_Cmd and Right_Lowbeam_Cmd output circuits.
Fault Facts
None
Possible Causes
• Headlight_Switch input circuit short to ground
• Left_Lowbeam_Cmd and/or Right_Lowbeam_Cmd output circuits short to power

1. Flash_To_Pass_Signal 3. Highbeam_Signal
2. Headlight_Switch
580
LIGHTING SYSTEMS
Figure 311 Low Beam Headlights Output from Body Controller Connector J2 (1604)
1. Left_Lowbeam_Cmd 2. Right_Lowbeam_Cmd

Yes: Go to Step 2.
Checkout Procedure (page
564).
Step 2 Determine if Headlight_Switch input signal to the Body Controller Decision

(BC) is activate when commanded OFF.
(DLB) software, select the Features tab.
2. Turn low beam headlight(s) OFF.
3. Select the Headlights Feature and click Make Session. Observe
the Headlight_Switch Value column (Figure 310).
Does a check mark appear in the Headlight_Switch Value? No: Go to Step 4.
581
LIGHTING SYSTEMS
Step 3 Determine if Headlight_Switch circuit is shorted to ground. Decision

1. Perform Test 1 (page 584). Yes: Replace headlight
switch. After repairs are
headlight switch connector pin-6 and ground.
original symptom.
Is resistance greater than 1000 ohms? No: Repair short to ground
in Headlight_Switch
original symptom.
Step 4 Inspect connections at Body Controller (BC) connector J2 (1604). Decision

1. Key OFF. Yes, and left low beam
illuminated: Go to Step 5.
Yes, and right low beam
3. Disconnect BC connector J2 (Figure 311).
4. Check connector J2 and connector terminals for: damaged or
Are connector J2, harness, and terminals clean and undamaged? No: Repair connector,
symptom.
Step 5 Determine if Left_Lowbeam_Cmd output circuit is shorted to power. Decision

1. Perform Test 2 (page 585). Yes: Repair short to power
in Left_Lowbeam_Cmd
2. Using a DMM measure voltage between BC connector J2 pin-B
and ground.
symptom.
Is voltage greater than 0.5 volts? No: Replace Body
Controller (BC). After
retest for symptom.
582
LIGHTING SYSTEMS
Step 6 Determine if Right_Lowbeam_Cmd circuit is shorted to power. Decision

1. Perform Test 3 (page 586). Yes: Repair short to
power in Park_Lights
2. Using a DMM measure voltage between BC connector J2 pin-H
output circuit. After repairs
and ground.
symptom.
retest for symptom.

583
LIGHTING SYSTEMS
Pin-Point Test - Low Beam Headlights Illuminate When Not Requested

Tools Required
Figure 312 Measuring Headlight_Switch Circuit for Short to Ground
Test 1
1. Key OFF.
584
LIGHTING SYSTEMS
Figure 313 Measuring Left_Lowbeam_Cmd Circuit for Short to Power
Test 2
1. Turn headlight(s) OFF.
585
LIGHTING SYSTEMS
Figure 314 Measuring Right_Lowbeam_Cmd Circuit for Short to Power
Test 3
586
LIGHTING SYSTEMS
SPN 2653 FMI 5 - Left Low Beam Under Current
Overview
Fault code sets when the Body Controller (BC) detects an Open or high resistance in the Left_Lowbeam_Cmd
circuit.
Associated Faults
None
Fault Facts
None
Possible Causes
• Failed left low beam bulb
• Left headlight ground circuit Open or high resistance
• Left_Lowbeam_Cmd circuit Open or high resistance
Step 1 Inspect connections at left headlight. Decision

2. Disconnect left headlight connector.
3. Check left headlight connector terminals for: damaged or pinched
Are left headlight connector, harness, and terminals clean and undamaged? No: Repair connector,
for SPN 2653 FMI 5.
Step 2 Inspect left low beam headlight bulb. Decision

1. Key OFF. Yes: Replace burnt out
low beam bulb. After
2. Disconnect left low beam headlight bulb.
3. Check for burnt out left low beam headlight bulb. retest for SPN 2653
FMI 5.
Is left low beam headlight burnt out. No: Go to Step 3.
587
LIGHTING SYSTEMS
Step 3 Check for Open or high resistance in left headlight ground circuit. Decision
1. Perform Test 1 (page 589). Yes: Repair Open
or high resistance
2. Use a Digital Multimeter (DMM) to measure resistance between left
between left headlight
headlight connector pin-3 and ground.
connector pin-1 and
BC J2 pin-B. After
retest for SPN 2653
FMI 5.
or high resistance
connector pin-3 and
ground. After repairs
for SPN 2653 FMI 5.

588
LIGHTING SYSTEMS
Pin-Point Test - SPN 2653 FMI 5

Tools Required
Test 1
1. Key OFF.
589
LIGHTING SYSTEMS
SPN 2653 FMI 6 - Left Low Beam Short to Ground
Overview
Fault code sets when Body Controller (BC) detects a short to ground in the Left_Lowbeam_Cmd circuit.
Associated Faults
None
Fault Facts
Headlights may not work immediately after short to ground is removed. Turn Key OFF then ON to reset the BC.
Possible Causes
• Failed / shorted left low beam
• Left_Lowbeam_Cmd circuit short to ground

for SPN 2653 FMI 6.
Step 2 Check for short to ground in Left_Lowbeam_Cmd circuit. Decision

1. Perform Test 1 (page 591). Yes: Replace left
low beam bulb or
2. Using a Digital Multimeter (DMM) measure resistance between left
repair shorted wiring
at bulb. After repairs
for SPN 2653 FMI 6.
ground between left
headlight connector
pin-1 and BC J2
pin-B. After repairs are
SPN 2653 FMI 6.

590
LIGHTING SYSTEMS

Tools Required
Figure 316 Check for Short to Ground in Left_Lowbeam_Cmd Circuit
Test 1
1. Key OFF.
591
LIGHTING SYSTEMS
SPN 2655 FMI 5 - Right Low Beam Open Circuit
Overview
Fault code sets when the Body Controller (BC) detects an Open or high resistance in the right low beam
power circuit.
Associated Faults
None
Fault Facts
None
Possible Causes
• Failed right low beam bulb
• Right headlight ground circuit Open or high resistance
• Right_Lowbeam_Cmd circuit Open or high resistance
Step 1 Inspect connections at right headlight. Decision

2. Disconnect right headlight connector.
3. Check right headlight connector terminals for: damaged or pinched
Are right headlight connector, harness, and terminals clean and undamaged? No: Repair connector,
for SPN 2655 FMI 5.
Step 2 Inspect right low beam headlight bulb. Decision

low beam headlight
2. Disconnect right low beam headlight bulb.
bulb. After repairs are
3. Check for burnt out right low beam headlight bulb. complete, retest for
SPN 2655 FMI 5.
Is the right low beam headlight burnt out? No: Go to Step 3.
592
LIGHTING SYSTEMS
Step 3 Check for Open or high resistance in right headlight ground circuit. Decision
or high resistance
2. Use a Digital Multimeter (DMM) to measure resistance between right
between right
headlight connector
pin-1 and BC pin J2
pin-H. After repairs are
SPN 2655 FMI 5.
or high resistance
between right
headlight connector
pin-3 and ground.
After repairs are
SPN 2655 FMI 5.

593
LIGHTING SYSTEMS

Tools Required
Test 1
1. Key OFF.
594
LIGHTING SYSTEMS
SPN 2655 FMI 6 - Right Low Beam Short to Ground
Overview
Fault code sets when the Body Controller (BC) detects a short to ground in the Right_Lowbeam_Cmd circuit.
Associated Faults
None
Fault Facts
Headlights may not work immediately after a short to ground is removed. Turn Key OFF then ON to reset
the BC.
Possible Causes
• Right_Lowbeam_Cmd circuit short to ground
• Failed / shorted right low beam bulb

for SPN 2655 FMI 6.
Step 2 Check for short to ground in Right_Lowbeam_Cmd circuit. Decision

1. Perform Test 1 (page 596). Yes: Replace right
low beam bulb or
2. Using a Digital Multimeter (DMM) measure resistance between right
repair shorted bulb
for SPN 2655 FMI 6.
ground between right
headlight connector
pin-1 and BC pin J2
pin-H. After repairs are
SPN 2655 FMI 6.

595
LIGHTING SYSTEMS

Tools Required
Figure 318 Check for Short to Ground in Right_Lowbeam_Cmd Circuit
Test 1
1. Key OFF.
596
LIGHTING SYSTEMS
Overview
The following steps direct technicians to systematically troubleshoot high beam headlight performance using
Diamond Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Headlight Overview (page

1. Low beam 3. Off
2. Park lights
Step 1 Determine if high beam headlight(s) are burnt out or damaged. Decision
out headlight(s) or
2. Disconnect headlight(s) that do not illuminate.
3. Inspect and determine if headlight(s) are burnt out or damaged. repairs are complete,
retest for symptom.
Are high beam headlight(s) burnt out or damaged? No: Go to Step 2.
Step 2 Check for Active high beam headlight(s) fault codes. Decision
2. Turn Key ON with low beam headlight(s) ON.
3. Pull the multifunction (turn signal) switch back all the way and release,
to activate the high beam headlight(s).
Are high beam headlight(s) fault codes Active? No: Go to Step 3.
597
LIGHTING SYSTEMS
Step 3 Determine if high beam headlight(s) do not illuminate when requested. Decision
Turn ON high beam headlight(s). Yes: Go to Step 4.
Are high beam headlight(s) illuminating? No: Go to High
Beam Headlights
566).
Step 4 Determine if high beam headlight(s) illuminate when not requested. Decision
Pull the multifunction switch back all the way and release to turn OFF the high Yes: Go to High Beam
beam headlight(s). Headlights Illuminate
When Not Requested
(page 580).
Are high beam headlight(s) illuminating? No: Go to Step 5.
Step 5 Determine if flash-to-pass does not illuminate headlight(s) when Decision

requested.
Pull multifunction switch back half way to turn ON the headlight(s) flash-to-pass Yes, both headlight(s)
feature. illuminating: End
diagnostics.
Do headlight(s) illuminate? No: Go to
Flash-To-Pass Not
Illuminating Headlights
(page 620).
598
LIGHTING SYSTEMS
High Beam Headlights Not Illuminating
Overview
High beam headlight(s) illuminate when the Body Controller (BC) receives Headlight_Switch input from
the headlight switch and the Highbeam_Signal is activated. Pulling back the multifunction switch all the
way activates the high beam headlight(s) transition.
Fault Facts
None
Possible Causes
• Burnt out or damaged headlight(s)
• Highbeam_Signal input circuit Open or high resistance
• Left_Highbeam_Cmd and/or Right_Highbeam_Cmd output circuit(s) short to ground
• Left_Highbeam_Cmd and/or Right_Highbeam_Cmd circuit(s) Open or high resistance
• Left and/or right headlight ground circuit(s) Open or high resistance

1. Flash_To_Pass_Signal 3. Highbeam_Signal (low beam to high
2. Headlight_Switch beam transition)
599
LIGHTING SYSTEMS
Figure 321 High Beam Headlights Input to Body Controller Connector J3 (1600)
1. Highbeam_Signal 2. Flash_To_Pass_Signal
600
LIGHTING SYSTEMS
Figure 322 High Beam Headlights Output from Body Controller Connector J1 (1603)
1. Left_Highbeam_Cmd 2. Right_Highbeam_Cmd

Yes: Go to Step 2.
Checkout Procedure
(page 597).
Step 2 Determine if Highbeam_Signal input is received by the Body Controller Decision

(BC).
1. Using an Electronic Service Tool (EST) with Diamond Logic® Builder Yes, left high beam not
(DLB), select the Headlights Feature and click Make Session. Observe working: Go to Step 6.
the Highbeam_Signal, Value column (Figure 320).
2. Turn low beam headlight(s) ON. Pull the multifunction switch all the
way back and release to activate the high beam headlight(s). Observe
the Highbeam_Signal Value column.
Does a check mark appear in the Highbeam_Signal Value? Yes, right high beam
not working: Go to
Step 9.
No: Go to Step 3.
601
LIGHTING SYSTEMS

for symptom.
Step 4 Determine if Highbeam_Signal circuit is Open or has high resistance. Decision

BC connector J3 pin-A4 and multifunction switch chassis harness
connector pin-2.
or high resistance
in Highbeam_Signal
resistance.
multifunction switch.
2. Using a DMM, measure resistance between multifunction switch
After repairs are
chassis harness connector pin-9 and ground.
complete recheck
replace Body
Controller.
high resistance in
symptom.
602
LIGHTING SYSTEMS
Step 6 Determine if left headlight ground circuit is Open or has high resistance. Decision
2. Using a DMM, measure resistance between left headlight connector
pin-3 and ground.
high resistance in
left headlight ground
Step 7 Determine if Left_Highbeam_Cmd circuit is shorted to ground. Decision

to ground.
to ground in
Left_Highbeam_Cmd
for symptom.
Step 8 Determine if Left_Highbeam_Cmd circuit is Open or has high Decision

resistance.
Controller. After
and left headlight connector pin-2.
symptom.
high resistance in
Left_Highbeam_Cmd
603
LIGHTING SYSTEMS
Step 9 Determine if right headlight ground circuit is Open or has high Decision
resistance.
2. Using a DMM, measure resistance between right headlight connector
pin-3 and ground.
high resistance in
right headlight ground
Step 10 Determine if Right_Highbeam_Cmd circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J1 pin-L
to ground.
to ground in
Right_Highbeam_Cmd
for symptom.
Step 11 Determine if Right_Highbeam_Cmd circuit is Open or has high Decision

resistance.
Controller. After
2. Using a DMM, measure resistance between BC connector J1 pin-L and
right headlight connector pin-2.
symptom.
high resistance in
Right_Highbeam_Cmd
circuit.

604
LIGHTING SYSTEMS
Pin-Point Test - High Beam Headlights Not illuminating

Tools Required
Figure 323 Measuring Highbeam_Signal Circuit for High Resistance
Test 1
1. Key OFF.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into multifunction switch chassis
harness connector pin-2.
605
LIGHTING SYSTEMS
Figure 324 Measuring Multifunction Switch Ground Circuit for High Resistance
Test 2
1. Key OFF.
606
LIGHTING SYSTEMS
Test 3
1. Key OFF.
607
LIGHTING SYSTEMS
Figure 326 Measuring Left_Highbeam_Cmd Circuit for Short to Ground
Test 4
1. Key OFF.
608
LIGHTING SYSTEMS
Figure 327 Measuring Left_Highbeam_Cmd Circuit for High Resistance
Test 5
1. Key OFF.
609
LIGHTING SYSTEMS
Test 6
1. Key OFF.
610
LIGHTING SYSTEMS
Figure 329 Measuring Right_Highbeam_Cmd Circuit for Short to Ground
Test 7
1. Key OFF.
611
LIGHTING SYSTEMS
Figure 330 Measuring Right_Highbeam_Cmd Circuit for High Resistance
Test 8
1. Key OFF.
612
LIGHTING SYSTEMS
High Beam Headlights Illuminate When Not Requested
Overview
High beam headlight(s) illuminate when the Body Controller (BC) receives Headlight_Switch input and then the
Highbeam_Signal is activated, or when the Flash_To_Pass_Signal is activated. Pulling back the multifunction
(turn signal) switch half way activates the flash-to-pass feature, and pulling back all the way activates the
Highbeam_Signal transition.
Fault Facts
None
Possible Causes
• Flash_To_Pass_Signal circuit short to ground
• Left_Highbeam_Cmd output circuits short to power
• Right_Highbeam_Cmd output circuits short to power

1. Flash_To_Pass_Signal 3. Highbeam_Signal
2. Headlight_Switch
613
LIGHTING SYSTEMS
Figure 332 High Beam Headlights Output from Body Controller Connector J1 (1603)
1. Left_Highbeam_Cmd 2. Right_Highbeam_Cmd

Yes: Go to Step 2.
Checkout Procedure (page
597).
Step 2 Determine if Flash_To_Pass_Signal to the Body Controller (BC) is Decision

activate when commanded OFF.
2. Select the Headlights Feature and click Make Session. Observe
the Flash_To_Pass_Signal Value column (Figure 331).
Does a check mark appear in the Flash_To_Pass_Signal Value? No: Go to Step 4.
614
LIGHTING SYSTEMS
Step 3 Determine if Flash_To_Pass_Signal circuit is shorted to ground. Decision

1. Perform Test 1 (page 617). Yes: Replace multifunction
multifunction switch chassis harness connector pin-3 and ground.
original symptom.
Is resistance greater than 1000 ohms? No: Repair short to ground
in Flash_To_Pass_Signal
original symptom.

1. Key OFF. Yes, left high beam
Yes, right high beam
4. Check connector J1 and connector terminals for: damaged or
Are connector J1 harness, and terminals clean and undamaged? No: Repair connector,
symptom.
Step 5 Determine if Left_Highbeam_Cmd output circuit is shorted to power. Decision

in Left_Highbeam_Cmd
2. Using a DMM measure voltage between BC connector J1 pin-H
and ground.
symptom.
retest for symptom.
615
LIGHTING SYSTEMS
Step 6 Determine if Right_Highbeam_Cmd circuit is shorted to power. Decision

in Right_Highbeam_Cmd
2. Using a DMM measure voltage between BC connector J1 pin-L
and ground.
symptom.
retest for symptom.

616
LIGHTING SYSTEMS
Pin-Point Test - High Beam Headlights Illuminate When Not Requested

Tools Required
Figure 333 Measuring Flash_To_Pass_Signal for Short to Ground
Test 1
1. Key OFF.
617
LIGHTING SYSTEMS
Figure 334 Measuring Left_Highbeam_Cmd Circuit for Short to Power
Test 2
618
LIGHTING SYSTEMS
Figure 335 Measuring Right_Highbeam_Cmd Circuit for Short to Power
Test 3
619
LIGHTING SYSTEMS
Flash-To-Pass Not Illuminating Headlights
Overview
Pulling back the multifunction (turn signal) switch half way activates the high beam headlight(s), or low beam
headlight(s) if the high beams are currently active.
Fault Facts
If the flash-to-pass, high beam headlight(s), windshield wipers, and turn signals all are not working, check the
ground circuit to the multifunction switch.
Possible Causes
• Flash_To_Pass_Signal circuit Open or high resistance
Figure 336 High Beam Headlights Input to Body Controller Connector J3 (1600)
1. Highbeam_Signal 2. Flash_To_Pass_Signal
620
LIGHTING SYSTEMS

Yes: Go to Step 2.
Checkout Procedure
(page 597).

for symptom.
Step 3 Determine if Flash_To_Pass_Signal circuit is Open or has high Decision

resistance.
connector J3 pin-A14 and multifunction switch connector pin-3.
high resistance in
Flash_To_Pass_Signal
621
LIGHTING SYSTEMS
resistance.
multifunction switch.
2. Using a DMM, measure resistance between multifunction switch
After repairs are
chassis harness connector pin-9 and ground.
complete recheck
replace Body
Controller.
high resistance in
symptom.

622
LIGHTING SYSTEMS
Pin-Point Test - Flash-To-Pass Not illuminating Headlights

Tools Required
Figure 337 Measuring Flash_To_Pass_Signal Circuit for High Resistance
Test 1
1. Key OFF.
623
LIGHTING SYSTEMS
Figure 338 Measuring Multifunction Ground Circuit for High Resistance
Test 2
1. Key OFF.
624
LIGHTING SYSTEMS
SPN 4011 FMI 5 - Left High Beam Open Circuit
Overview
Fault code sets when the Body Controller (BC) detects an Open or high resistance in the Left_Highbeam_Cmd
circuit.
Associated Faults
None
Fault Facts
None
Possible Causes
• Failed left high beam bulb
• Left headlight ground circuit Open or high resistance
• Left_Highbeam_Cmd circuit Open or high resistance

for SPN 4011 FMI 5.
Step 2 Inspect left high beam headlight bulb. Decision

high beam bulb. After
2. Disconnect left high beam headlight bulb.
3. Check for burnt out left high beam headlight bulb. retest for SPN 4011
FMI 5.
Is left high beam headlight burnt out. No: Go to Step 3.
625
LIGHTING SYSTEMS
Step 3 Check for Open or high resistance in left headlight ground circuit. Decision
or high resistance
2. Use a Digital Multimeter (DMM) to measure resistance between left
connector pin-2 and
BC pin J1 pin-H. After
retest for SPN 4011
FMI 5.
or high resistance
connector pin-3 and
ground. After repairs
for SPN 4011 FMI 5.

626
LIGHTING SYSTEMS

Tools Required
Test 1
1. Key OFF.
627
LIGHTING SYSTEMS
SPN 4011 FMI 6 - Left High Beam Short to Ground
Overview
Fault code sets when Body Controller (BC) detects a short to ground in the Left_Highbeam_Cmd circuit.
Associated Faults
None
Fault Facts
Headlights may not work immediately after short to ground is removed. Turn Key OFF then ON to reset the BC.
Possible Causes
• Failed / shorted left high beam
• Left_Highbeam_Cmd circuit short to ground

for SPN 4011 FMI 6.
Step 2 Check for short to ground in Left_Highbeam_Cmd circuit. Decision

1. Perform Test 1 (page 629). Yes: Replace left
high beam bulb or
2. Using a Digital Multimeter (DMM) measure resistance between left
repair shorted wiring
at bulb. After repairs
for SPN 4011 FMI 6.
ground between left
headlight connector
pin-1 and BC pin J2
pin-B. After repairs are
SPN 4011 FMI 6.

628
LIGHTING SYSTEMS

Tools Required
Figure 340 Measuring for Short to Ground in Left_Highbeam_Cmd Circuit
Test 1
1. Key OFF.
629
LIGHTING SYSTEMS
SPN 4012 FMI 5 - Right High Beam Open Circuit
Overview
Fault code sets when the Body Controller (BC) detects an Open or high resistance in the Right_Highbeam_Cmd
circuit.
Associated Faults
None
Fault Facts
None
Possible Causes
• Failed right high beam
• Right headlight ground circuit Open or high resistance
• Right_Highbeam_Cmd circuit Open or high resistance

for SPN 4012 FMI 5.
Step 2 Inspect right high beam headlight bulb. Decision

high beam bulb. After
2. Disconnect right high beam headlight bulb.
3. Check for burnt out right high beam headlight bulb. retest for SPN 4012
FMI 5.
Is the right high beam headlight burnt out? No: Go to Step 3.
630
LIGHTING SYSTEMS
Step 3 Check for Open or high resistance in right headlight ground circuit. Decision
or high resistance
2. Use a Digital Multimeter (DMM) to measure resistance between right
between right
headlight connector
pin-2 and BC pin J1
pin-L. After repairs are
SPN 4012 FMI 5.
or high resistance
between right
headlight connector
pin-3 and ground.
After repairs are
SPN 4012 FMI 5.

631
LIGHTING SYSTEMS

Tools Required
Test 1
1. Key OFF.
632
LIGHTING SYSTEMS
SPN 4012 FMI 6 - Right High Beam Short to Ground
Overview
Fault code sets when the Body Controller (BC) detects a short to ground in the Right_Highbeam_Cmd circuit.
Associated Faults
None
Fault Facts
Headlights may not work immediately after a short to ground is removed. Turn Key OFF then ON to reset
the BC.
Possible Causes
• Right_Highbeam_Cmd circuit short to ground
• Failed / shorted right high beam

for SPN 4012 FMI 6.
Step 2 Check for short to ground in Right_Highbeam_Cmd circuit. Decision

1. Perform Test 1 (page 634). Yes: Replace right
high beam bulb or
2. Using a Digital Multimeter (DMM) measure resistance between right
repair shorted bulb
for SPN 4012 FMI 6.
ground between right
headlight connector
pin-2 and BC pin J1
pin-L. After repairs are
SPN 4012 FMI 6.

633
LIGHTING SYSTEMS

Tools Required
Figure 342 Measuring for Short to Ground in Right_Highbeam_Cmd Circuit
Test 1
1. Key OFF.
634
LIGHTING SYSTEMS
Brake Switch Input

Overview
0595AAD Brake Switch (Input)
Figure 343 Brake Switch Location

1. Brake switch
The brake lamp system has separate input and output feature codes that work together to Illuminate stop
lamps when the brake pedal is depressed.
635
LIGHTING SYSTEMS
Figure 344 Brake Switch Input and Output Circuits
Air Brakes Input Symptom Diagnostics

Brake Switch Input Diagnostics (page 637)
Air Brake Fault Code Diagnostics

SPN FMI Description
597 0 Brake Switch Reading Above Normal (page 640)
597 1 Brake Switch Reading Below Normal Range (page 642)
597 7 Brake Switch Stuck Open or Closed (failed brake switch)
636
LIGHTING SYSTEMS
Brake Switch Input Diagnostics
Brake lights illuminate when the Body Controller (BC) receives brake switch input and turns On the right and
left brake lights.
Fault Facts
None
Possible Causes
• Brake_Switch_Digital_Input circuit Open or high resistance
• Brake switch ground circuit Open or high resistance
• Failed brake switch
Figure 345 Brake Switch DLB Session (Input Signal to Body Controller)
1. Brake_Switch_Digital_Input
637
LIGHTING SYSTEMS
Figure 346 Brake Switch Input to Body Controller Connector J5 (1602)

1. Brake switch input

Yes: Go to Step 2.
Checkout Procedure
(page 531).

for symptom.
638
LIGHTING SYSTEMS
Step 3 Determine if Brake_Switch_Digital_Input circuit is Open or has Decision

high resistance.
2. Connect 180-pin Breakout Box 00-00956-08 to Breakout
Harness 08-854-01.
3. Connect Breakout Harness 08-854-01 to BC connector J5 and
leave BC disconnected.
4. Disconnect brake switch connector.
5. Using Terminal Test Kit ZTSE4435C, insert proper terminal into
brake switch connector pin-C.
6. Using a DMM, measure resistance between BC connector J5
pin-E14 and brake switch connector pin-C.
or high resistance in
Brake_Switch_Digital_Input
complete recheck for original
symptom.
Step 4 Determine if brake switch ZVR (ground) circuit is Open or has Decision
high resistance.
Measure resistance between brake switch connector pin-D and ground. Yes: Replace brake switch.
After repairs are complete
recheck for original symptom.
replace Body Controller.
Is resistance less than 5 ohms? No: Repair Open or high
resistance in brake switch
ground circuit. After repairs
are complete recheck for
original symptom.

639
LIGHTING SYSTEMS
SPN 597 FMI 0 - Brake Switch Reading Above Normal
Overview
Fault code sets when Body Controller (BC) detects brake switch input circuit voltage is greater than expected.
Associated Faults
None
Fault Facts
None
Possible Causes
• Ground (ZVR) circuit Open
• Brake Switch Input circuit Open or high resistance
• Brake Switch Input circuit short to power
• Failed Brake Switch
Step 1 Inspect connections at brake switch connector. Decision

3. Check brake switch and connector terminals for: damaged or pinched
Are brake switch connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.
Step 2 Check for Open or high resistance in ground (ZVR) circuit. Decision
Measure voltage between brake switch connector pin-D and battery power. Yes: Go to Step 3.
Is voltage B+ ± 0.5 volts? No: Repair Open or
high resistance in
brake switch ZVR
circuit.
Step 3 Check for short to power in Brake Switch Input circuit. Decision
Measure voltage between brake switch connector pin-C and ground. Yes: Repair short to
power between brake
switch connector pin-C
and BC J5 pin-E14.
Is voltage greater than 11 volts? No: Go to Step 4.
640
LIGHTING SYSTEMS
Step 4 Check for Open or high resistance in Brake Switch Input circuit Decision
1. Disconnect brake switch connector. Yes: Replace Brake
switch.
2. Short brake switch input to brake switch ground.
3. Using Electronic Service Tool (EST) with Diamond Logic® Builder
(DLB) software, select Connectors tab.
Is Brake_Analog_Switch_Signal voltage 0 volts ± 0.3 volts? No: Repair Open
or high resistance
between brake switch
connector pin-C and
BC J5 pin-E14.

641
LIGHTING SYSTEMS
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range
Overview
Fault code sets when Brake Switch Input circuit is shorted to ground.
Associated Faults
None
Fault Facts
None
Possible Causes
• Brake Switch Input circuit short to GND
Step 1 Inspect connections at brake switch connector. Decision

1. Key OFF. Yes: Check Brake
Switch Input circuit for
short to GND.
3. Check brake switch and connector terminals for: damaged or pinched
Are brake switch connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.

642
LIGHTING SYSTEMS
Park / Marker Lights

Overview
0595BXN Park / Marker Lights, for Non-Multiplexed Vehicles
0595BXT Marker Interrupt Switch, for Non-Multiplexed Vehicles
The Body Control (BC) module receives input from the headlight switch and marker interrupt switch, and
sends power output to the park lights thru chassis wiring harnesses. The headlight switch is a three position
tri-stable rocker switch with Off, Park lights, and Low beam positions. The marker interrupt switch, installed
in the right instrument panel, is a two position mono-stable switch. The top momentary position turns Off
the park lights while pushed.
Activation of the Park lights also turns On the night time illumination mechanism inside the Electronic Gauge
Cluster (EGC).
Figure 347 Park / Marker Lights Input and Output Circuits
643
LIGHTING SYSTEMS
Park / Marker Lights Symptom Diagnostics

Park Lights Not Illuminating (page 647)
Park Lights Illuminate When Not Requested (page 661)
Park / Marker Lights Fault Code Diagnostics

SPN FMI Description
2378 5 Park Lights Undercurrent (page 666)
2378 6 Park Lights Overcurrent (page 671)
644
LIGHTING SYSTEMS
Overview
The following steps direct technicians to systematically troubleshoot park / marker lights performance using
Diamond Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Park / Marker Light Overview

1. Low beam 3. Off
2. Park lights
Step 1 Determine if park light bulb(s) are burnt out or damaged. Decision
out park light bulbs,
2. Disconnect park light bulb(s) that do not illuminate.
3. Inspect and determine if bulb(s) are burnt out or damaged. repairs are complete,
retest for symptom.
Are park light bulb(s) burnt out or damaged? No: Go to Step 2.
Step 2 Check for Active park lights fault codes. Decision

2. Key ON with parking lights ON.
Are park lights fault codes Active? No: Go to Step 3.
Step 3 Determine if park lights do not illuminate when requested. Decision

Turn ON park lights. Yes: Go to Step 4.
Are park lights illuminating? No: Go to Park Lights
647).
645
LIGHTING SYSTEMS
Step 4 Determine if park lights illuminate when not requested. Decision

Turn OFF park lights. Yes: Go to Park Lights
Illuminate When Not
Requested (page
661).
Are park lights illuminating? No: End diagnostics.
646
LIGHTING SYSTEMS
Park Lights Not Illuminating
Overview
Park lights illuminate when the Body Controller (BC) receives input from the headlight switch and turns On
the park lights output circuit at BC connector J2 pin-G. If the park lights do not illuminate, verify the marker
interrupt switch is not active.
Fault Facts
None
Possible Causes
• Burnt out park light(s)
• Headlight_Enable_Signal (park lights input) circuit Open or high resistance
• Headlight_Enable_Signal circuit short to ground
• Power circuit to the headlight switch Open, high resistance, or short to ground
• Marker interrupt switch circuit short to ground
• Failed marker interrupt switch
• Park_Lights output circuit short to ground
• Park_Lights output circuit Open or high resistance
• Park light(s) ground circuit(s) Open or high resistance
Figure 349 Park / Marker Lights DLB Session (Input Signals to Body Controller)
1. Headlight_Enable_Signal (activated) 2. Marker_Interrupt_Switch (inactive)
647
LIGHTING SYSTEMS
Figure 350 Park Lights Input to Body Controller Connector J5 (1602)

1. Marker interrupt switch input 2. Headlight_Enable_Signal (park lights
input)
Figure 351 Marker Interrupt Switch Positions

1. Marker / park lights OFF 2. Interrupt not active
648
LIGHTING SYSTEMS

Yes: Go to Step 2.
Checkout Procedure
(page 645).
Step 2 Determine if Headlight_Enable_Signal (park lights input) is received by Decision

the Body Controller (BC).
(DLB), select the Park / Marker Lights Feature and click Make Session.
Observe the Headlight_Enable_Signal, Value column (Figure 349).
2. Turn park lights ON. Observe the Headlight_Enable_Signal Value
column.
Does a check mark appear in the Headlight_Enable_Signal Value? No: Go to Step 3.
649
LIGHTING SYSTEMS
Step 3 Determine if fuse for headlight switch power circuit is blown. Decision
1. Inspect fuse for the headlight switch. Yes: Replace fuse.
After repairs are
2. Measure voltage drop across fuse.
complete recheck
If fuse blows again, go
to Step 4.
Is fuse for the headlight switch blown? No: Go to Step 4.
Step 4 Determine if power circuit to the headlight switch has correct voltage. Decision
1. Perform Test 1 (page 654). Yes: Leave headlight
switch disconnected.
2. Using a DMM, measure voltage between headlight switch connector
Go to Step 5.
pin-2 and ground.
Is voltage within 0.5 volts of battery voltage? No: Repair Open or
short to ground in
power circuit to the
symptom.

for symptom.
Step 6 Determine if Headlight_Enable_Signal circuit is shorted to ground. Decision

2. Using a DMM, measure resistance between BC connector J5 pin-E11
and ground.
to ground in
Headlight_Enable
_Signal circuit. After
symptom.
650
LIGHTING SYSTEMS
Step 7 Determine if Headlight_Enable_Signal circuit is Open or has high Decision

resistance.
2. Using a DMM, measure resistance between BC connector J5 pin-E11
and headlight switch connector pin-3.
symptom.
in Headlight_Enable
symptom.
Step 8 Determine if Marker_Interrupt_Switch signal to the Body Controller Decision

(BC) is active when not commanded ON.
1. Using EST with DLB software, select the Features tab. Yes: Go to Step 9.
2. Turn Park lights OFF, and verify marker interrupt switch is released
(not active) (Figure 351).
3. Select the Park / Marker Lights Feature, and click Make Session.
Observe the Marker_Interrupt_Switch, Value column (Figure 349).
Does a check mark appear in the Marker_Interrupt_Switch, Value column? No: Go to Step 10.
Step 9 Determine if Marker_Interrupt_Switch input circuit is shorted to ground. Decision

1. Perform Test 4 (page 657). Yes: Replace marker
interrupt switch. After
Marker_Interrupt_Switch pin-3 and ground.
symptom.
to ground in
Marker_Interrupt_Switch
651
LIGHTING SYSTEMS

4. Check connector J2 and connector terminals for: damaged or pinched
for symptom.
Step 11 Determine if Park_Lights output circuit is shorted to ground. Decision

2. Using a DMM measure resistance between BC connector J2 pin-G
and ground.
ground in Park_Lights
for symptom.
Step 12 Determine if Park_Lights output circuit is Open or has high resistance. Decision
2. Using a DMM, measure resistance between BC connector J2 pin-G
and pin-2 (positive) of each park light connector not illuminating.
or high resistance
between BC J2-G and
park light(s) pin. After
retest for symptom.
652
LIGHTING SYSTEMS
Step 13 Determine if park lights ground circuit(s) are Open or have high Decision
resistance.
Controller. After
2. Using a DMM, measure resistance between park lights connector pin-3
and ground.
symptom.
high resistance in
park lights ground

653
LIGHTING SYSTEMS
Pin-Point Test - Park Lights Not Illuminating

Tools Required
Figure 353 Measuring Voltage to Headlight Switch
Test 1
1. Key OFF.
654
LIGHTING SYSTEMS
Figure 354 Measuring Headlight_Enable_Signal (Park Lights) Input Circuit for Short to Ground
Test 2
1. Key OFF.
4. Connect Breakout Harness 08-854-01 to BC connector J5 and leave BC disconnected..
655
LIGHTING SYSTEMS
Figure 355 Measuring Headlight_Enable_Signal Circuit for High Resistance
Test 3
1. Key OFF.
4. Connect Breakout Harness 08-854-01 to BC connector J5 and leave BC disconnected..
656
LIGHTING SYSTEMS
Figure 356 Measuring Marker_Interrupt_Switch Input Circuit for Short to Ground
Test 4
1. Key OFF.
2. Disconnect marker interrupt switch connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into marker interrupt switch
connector pin-3.
657
LIGHTING SYSTEMS
Figure 357 Measuring Park_Lights Output Circuit for Short to Ground
Test 5
1. Key OFF.
658
LIGHTING SYSTEMS
Figure 358 Measuring Park_Lights Output Circuit for High Resistance
Test 6
1. Key OFF.
5. Disconnect park lights connector.
6. Using Terminal Test Kit ZTSE4435C, insert proper terminal into park light connector pin-2.
659
LIGHTING SYSTEMS
Figure 359 Measuring Park Lights Ground Circuits for High Resistance
Figure 360 Measuring Park Lights Ground Circuit(s) for High Resistance
Test 7
1. Key OFF.
660
LIGHTING SYSTEMS
Park Lights Illuminate When Not Requested
Overview
Park lights illuminate when the Body Controller (BC) receives input from the headlight switch and turns On the
Park_Lights output circuit at BC connector J2 (1604) pin-G.
Fault Facts
None
Possible Causes
• Headlight_Enable_Signal (park lights input) circuit short to power
• Park_Lights output circuit short to power
Figure 361 Park / Marker Lights DLB Session (Input Signals to Body Controller)
1. Headlight_Enable_Signal (activated) 2. Marker_Interrupt_Switch (inactive)
661
LIGHTING SYSTEMS

Yes: Go to Step 2.
Checkout Procedure
(page 645).
Step 2 Determine if Headlight_Enable_Signal (park lights input) to the Decision

Body Controller (BC) is activate when commanded OFF.
2. Turn park lights OFF.
3. Select the Park / Marker Lights Feature and click Make Session.
Observe the Headlight_Enable_Signal, Value column (Figure 361).
Does a check mark appear in the Headlight_Enable_Signal Value? No: Go to Step 4.
662
LIGHTING SYSTEMS
Step 3 Determine if Headlight_Enable_Signal circuit is shorted to power. Decision

in Headlight_Enable
2. Using a Digital Multimeter (DMM), measure voltage between
headlight switch connector pin-3 and ground.
symptom.
Is voltage greater than 0.5 volts? No: Replace headlight
original symptom.

symptom.
Step 5 Determine if Park_Lights output circuit is shorted to power. Decision

2. Using a DMM measure voltage between BC connector J2 pin-G and
ground.
retest for symptom.
Is voltage 0 ± 0.5 volts? No: Repair short to
power in Park_Lights
output circuit. After
retest for symptom.

663
LIGHTING SYSTEMS
Pin-Point Test - Park Lights Illuminate When Not Requested

Tools Required
Figure 363 Measuring Headlight_Enable_Signal Circuit for Short to Power
Test 1
1. Key OFF.
664
LIGHTING SYSTEMS
Figure 364 Measuring Park_Lights Circuit for Short to Power
Test 2
1. Turn park lights OFF.
665
LIGHTING SYSTEMS
SPN 2378 FMI 5 - Park Lights Undercurrent
Overview
Fault code sets when the Body Controller (BC) detects an Open or high resistance in the Park_Lights output
circuit.
Associated Faults
None
Fault Facts
None
Possible Causes
• Failed park light bulb(s)
• Park light(s) ground circuit(s) Open or high resistance
• Park_Lights output circuit Open or high resistance
666
LIGHTING SYSTEMS
Step 1 Inspect park light connections. Decision

2. Disconnect park light connector(s).
3. Check park light connector terminals for: damaged or pinched wires;
moisture or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are park light connectors, harnesses, and terminals clean and undamaged? No: Repair connector,
for SPN 2378 FMI 5.
Step 2 Determine if park light bulb(s) are burnt out or damaged. Decision
out park light bulbs,
2. Inspect and determine if bulb(s) are burnt out or damaged.
retest for symptom.
Are park light bulb(s) burnt out or damaged? No: Go to Step 3.
Step 3 Determine if park lights ground circuit(s) are Open or have high Decision
resistance.
2. Using a DMM, measure resistance between park lights connector pin-3
and ground.
high resistance in
park lights ground

for symptom.
667
LIGHTING SYSTEMS
Step 5 Determine if Park_Lights output circuit is Open or has high resistance. Decision
connector J2 pin-G and each park light connector pin-2.
retest for symptom.
or high resistance
between BC connector
J2 pin G and park
light(s) pin. After
retest for SPN 2378
FMI 5.

668
LIGHTING SYSTEMS

Tools Required
Figure 366 Measuring Park Lights Ground Circuit(s) for High Resistance
Test 1
1. Key OFF.
669
LIGHTING SYSTEMS
Figure 367 Measuring Park_Lights Circuit for High Resistance
Test 2
1. Key OFF.
5. Disconnect park light connector.
670
LIGHTING SYSTEMS
SPN 2378 FMI 6 - Park Lights Overcurrent
Overview
Fault code sets when the Body Controller (BC) detects a short to ground in the Park_Lights output circuit.
Associated Faults
None
Fault Facts
Park lights may not work immediately after a short to ground is repaired. Turn ignition Key OFF then ON
to reset the BC.
Possible Causes
• Park lights output circuit short to ground
671
LIGHTING SYSTEMS

for symptom.
Step 2 Determine if Park_Lights output circuit is shorted to ground. Decision

2. Using a Digital Multimeter (DMM) measure resistance between BC
connector J2 pin-G and ground.
retest for symptom.
ground in park lights
output circuit. After
retest for SPN 2378
FMI 6.

672
LIGHTING SYSTEMS

Tools Required
Test 1
1. Key OFF.
673
LIGHTING SYSTEMS
Work Light
0008WLL Light, Work one (1) pedestal mounted back of cab with switch on
instrument panel
0008XGN Light, Work two (2) LED, mounted back of cab with upper corners with
switch on instrument panel
0008XGM Light, Work two (2) pedestal mounted back of cab with switch on
instrument panel
Work light(s) help illuminate the fifth-wheel trailer hook-up area. The Work light switch is a two-position rocker
switch installed in the instrument panel. Power is supplied to pin-2 of the work light switch connector from 15A
fuse F11-P (1004-M2). When the switch is activated power is provided thru the work light switch, to the work
light switch connector pin-3 and to pin-A of the work light bulb connector(s).
674
SEATS
17. Seats
RollTek Supplemental Restraint System (SRS)
Overview
The International® HXTM Series vehicle is equipped with the RollTek Rollover Protection System. When used
with seat belts, the RollTek Supplemental Restraint System (SRS) provides additional protection to the driver
in rollover crashes. Sensors in the RollTek seat base detect when the truck enters an irrecoverable rollover
and activate the system.
RollTek first tightens the lap and shoulder belts securing the driver to the seat. Second, it lowers the seat
suspension, increasing seat stability and moving the driver away from the steering wheel and ceiling. The
side-roll airbag deploys from the outboard side of the seatback as the seat is pulled down to its lowest position,
providing protection to the driver in the point of contact with the cab in a rollover.
Figure 370 RollTek Supplemental Restraint System

1. Side Roll Airbag (SRA) 3. Inter Connect Point (ICP) bar
2. RollTek SRS module cover
The RollTek SRS consists of a rollover crash sensor, seat and seat belt tensioning system, and a side rollover
airbag. Located at the base of the driver’s seat, the rollover sensor continuously monitors the truck’s angular
rate at all times after completion of an initial diagnostic check. During a life-threatening rollover event, the
sensor compares the truck’s acceleration, roll angle, and roll rate against known rollover conditions. When the
comparison indicates an irrecoverable rollover condition, the sensor deploys the side airbag.
675
SEATS
Figure 371 Side Roll Airbag Deployed
Upon receiving the signal from the rollover sensor, gas cylinders inside the seat base activate to tighten the lap
and shoulder belts around the driver and lower the seat suspension. As the gas cylinders tighten the seat belt
and lower the seat, a side-roll airbag will deploy from the outboard side of the seatback. The airbag will inflate
between the driver’s head / neck and the side wall / door of the truck. The airbag will remain inflated for several
seconds to provide added protection during multiple rollover events.
Figure 372 RollTek SRS Diagnostic Lamp
The operational readiness of the RollTek system is indicated by the side airbag graphic indicator on the
instrument panel gauge cluster. The indicator comes on for approximately 6 seconds when the engine is
started and then goes off. The indicator will go out for one second, then go back on and stay on if there is
a problem with the RollTek system. The RollTek system may or may not be operational when the warning
lamp is continuously illuminated, depending on the nature of the fault.
676
SEATS
Service Nomenclature Parts Nomenclature

RollTek SRS Module (contains seatbelt pretensioner Power Tower
device and roll sensor – located directly behind
drivers seat)
RollTek SRS Work Packages Covered

Operational Check
Symptom
Tests - RollTek Power Circuit Check
Tests - RollTek CND Circuit Check
Removal
Installation
The RollTek SRS module is provided power and ground through a five pin connector. There is can (+), can
(–), and one pin for the warning lamp on the dash.
Tools Required

• Electronic Service Tool with ServiceMaxxTM Software
WARNING
To prevent property damage, personal injury, and / or death, wait two minutes after
disconnecting RollTek SRS module chassis connector to allow components to
discharge. Failure to adhere to this warning can cause Side Roll Airbag to deploy.
See latest wiring schematic for ProStar® chassis additional circuit information.
677
SEATS
Operational Check
Check Communication
1. Connect EST with ServiceMaxxTM to DLC. Yes: Go to next step.
Can you communicate with RollTek SRS module?
No: Refer to RollTek SRS
Diagnostics on ServiceMaxxTM.
Test 1 – Power Circuit Check

2. Check for Power on RollTek chassis connector Yes: Power to connector is good.
Power circuit.
No: Go to next step.
Is there Power on RollTek chassis connector Power
circuit?
Test 2– Ground Circuit Check

3. Check for Ground on RollTek chassis connector Yes: Repair open Ground circuit.
Ground circuit.
No: Repair open Power circuit.
Is there Ground on RollTek chassis connector
Ground circuit?
678
SEATS
Symptoms
Symptom Action
RollTek SRS Diagnostic Lamp Illuminated Proceed to RollTek SRS Wiring Diagnostic steps
679
SEATS
Diagnostics
Follow these steps if RollTek SRS Diagnostic lamp stays illuminated on dash. This will determine faults with
chassis connector to RollTek SRS module.
Tools Required

• Electronic Service Tool with ServiceMaxxTM Software
WARNING
To prevent property damage, personal injury, and / or death, wait two minutes after
disconnecting RollTek SRS module chassis connector to allow components to
discharge. Failure to adhere to this warning can cause Side Roll Airbag to deploy.
See latest wiring schematic for HXTM chassis additional circuit information.
Step 1 Check power and ground to RollTek SRS connector Decision

1. Connect Electronic Service Tool With ServiceMaxxTM Software to Yes: Power
Diagnostic Connector. and Ground are
operational.
2. Can you communicate with RollTek SRS Module?
3. If yes, proceed to next step. If no, refer to RollTek SRS Diagnostic
information from IMMI.
Does meter read battery voltage? No: Go to step 3.

1. Key OFF. Yes: Power
and Ground are
2. Disconnect RollTek SRS Chassis Connector.
operational.
3. Key ON. Check for B+ between Power and Ground on RollTek chassis
connector.
Does meter read battery voltage? No: Go to step 3.

1. RollTek SRS Chassis Connector disconnected. Yes: Repair open
Ground circuit.
2. Key ON. Check for B+ between Power on RollTek chassis connector
and chassis ground.
Does meter read battery voltage? No: Repair open
Power circuit.

680
TRANSMISSION
18. Transmission
Allison Automatic Transmission
Overview
0013ATP Allison 4000 RDS P Automatic Transmission, 5th Generation Controls;
Close Ratio, 5-Speed, With Overdrive; On/Off Hwy; Includes Oil Level
Sensor, With PTO Provision, Less Retarder
0013AUV Allison 4000 RDS P Automatic Transmission, 5th Generation Controls;
Close Ratio, 5-Speed, With Overdrive; Refuse; Includes Oil Level
0013ATR Allison 4000 RDS P Automatic Transmission, 5th Generation Controls;
Close Ratio, 6-Speed, With Double Overdrive; On/Off Hwy; Includes Oil
Level Sensor, With PTO Provision, Less Retarder
0013AUY Allison 4000 RDS P Automatic Transmission, 5th Generation Controls;
Close Ratio, 6-Speed, With Double Overdrive; Refuse; Includes Oil Level
0013AUN Allison 4000 EVS P Automatic Transmission, 5th Generation Controls,
Close Ratio, 5-Speed; With Overdrive, Includes Oil Level Sensor, With
Provision for PTO, Less Retarder
0013AUR Allison 4000 EVS P Automatic Transmission, 5th Generation Controls;
Close Ratio, 6-Speed; With Double Overdrive; Includes Oil Level Sensor,
With Provision for PTO, Less Retarder
0013AUT Allison 4500 RDS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 5-Speed, With Overdrive; On/Off Hwy; Includes Oil Level
0013AUU Allison 4500 RDS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 5-Speed, With Overdrive; Refuse; Includes Oil Level Sensor,
With PTO Provision, Less Retarder
0013AUW Allison 4500 RDS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 6-Speed, With Double Overdrive; On/Off Hwy; Includes Oil
Level Sensor, With PTO Provision, Less Retarder
0013AUX Allison 4500 RDS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 6-Speed, With Double Overdrive; Refuse; Includes Oil Level
0013AUP Allison 4500 EVS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 5-Speed; With Overdrive; Includes Oil Level Sensor, With
Provision for PTO, Less Retarder
0013AUS Allison 4500 EVS P Automatic Transmission, 5th Generation Controls;
Wide Ratio, 6-Speed; With Double Overdrive; Includes Oil Level Sensor,
With Provision for PTO, Less Retarder
0013AVM Allison 4700 OFS P Automatic Transmission, 5th Generation Controls;
7 Speed, With Double Overdrive; Includes Oil Level Sensor, With PTO
Provision, Less Retarder
0013AVT Allison 4700 RDS P Automatic Transmission, 5th Generation Controls; 7
Speed, With Double Overdrive, On/Off Hwy, Includes Oil Level Sensor,
With PTO Provision, Less Retarder
681
TRANSMISSION
The Allison Automatic Transmission actuates gear shifts automatically through use of valves and actuators
internal to the transmission. The chosen gear depends on a combination of valves and actuators activated to
control clutch packs inside the transmission. The valves and actuators are controlled by the Transmission
Control Module (TCM) which receives J1939 communication interface inputs for operation from the Engine
Control Module (ECM) and instrument cluster. See Allison Automatic Transmission (page 1059) in the
Transmission Section of this manual for information on the different types of Allison Automatic Transmissions.
Service Information
For Allison Automatic Transmission Service Go to www.allisontransmission.com
Information
Figure 373 TCM Location

1. TCM
682
TRANSMISSION
Figure 374 TCM Data Interconnection Connector (3005) Pin Locations

1. PCS 1 12. Output Speed Sensor pin-A
2. PCS 2 13. Turbine Speed Sensor pin-B
3. PCS 2 14. Turbine Speed Sensor pin-A
4. Shift Solenoid 1 15. Train ID
5. HSD-3, Retarder Solenoid, Accumulator 16.
Solenoid (Allison 4000); HSD-3, 17. Plug
Retarder Solenoid (Allison 4700) 18. EOF Shifter
6. TCC 19. Plug
7. Accumulator Solenoid (4000); Pressure 20. Allison Ground Feed
Switch 2 (4700) 21. Ignition Feed Relay
8. Transmission Retarder ON/OFF Switch 22. Power Distribution Module (PDM)
9. Engine Speed Sensor pin-B 23. PDM
10. Engine Speed Sensor pin-A 24. EOF Shifter
11. Output Speed Sensor pin-B
Figure 375 TCM Data & Power Interconnection Connector (3010) Pin Locations
1. Pressure Switch 2 4. Retarder Solenoid
2. Reverse Range Relay 5. Retarder Resistance Module
3. Retarder Temperature Sensor 6. Neutral Start Relay
683
TRANSMISSION
7. Plug 17. Analog Return, Retarder Resistance

8. Allison Stop Switch C Module
9. Plug 18. Signal Return
10. TCM Park Brake Switch 19. Sump Temperature
11. TCM Signal Return 20. Pressure Switch 1
12. Transmission Shift Control 21. HSD 1
13. Engine Sensor Interface 22. PCS 4
14. J1939 + 23. Main Mod
15. J1939 - 24. HSD 2
16. Sensor Power, Retarder Resistance
Module
684
TRANSMISSION
Push Button Shift Control (Allison)

Overview
0013WBL Allison Transmission Shift Control, Push-Button Type; for Allison 3000 &
4000 Series Transmission
Figure 376 Allison Push Button Shift Control Location
The Allison Automatic Transmission push button shift control electronically selects the transmission gear range
based on input from the operator. The controls have a digital display which shows the transmission status
and buttons displaying reverse (R), neutral (N), drive (D), Mode, Up Arrow, and Down Arrow which control
the various transmission functions. The shift controller communicates desired transmission functions to
the TCM on a proprietary data interface.
Service Information
For Allison Automatic Transmission Shift Control Go to www.allisontransmission.com
Service Information
685
TRANSMISSION
Figure 377 Transmission Control Connector (101) Pin Locations

A. Direction Signal F. Battery +
B. Ignition Sense G. Ground
C. J1939 + H. Not Used
D. J1939 – I. Not Used
E. Dimmer Input J. Not Used
686
TRANSMISSION
PTO Controls Dash Mounted

Overview
0013WVD PTO control, dash mounted for customer provided PTO; includes control
valve, piping and wiring, wired for PTO
The dash mounted PTO controls are rocker switches that can be found in the center control panel of the
vehicle. These switches control the activation of the PTO when operated.
687
TRANSMISSION
688
WINDSHIELD WIPER SYSTEM
19. Windshield Wiper System

Windshield Wiper Diagnostics
Overview
Feature Codes
0595AYC Windshield Wipers Without Low Washer Fluid Indicator
Figure 378 Windshield Wiper and Washer Components

1. Wiper motor 3. Washer fluid reservoir
2. Washer pump
Wiper Operation
Windshield wipers are capable of: high, low, or intermittent operation. Both wiper relays are installed in the
fuse block. The three wiper switches are in the multifunction (turn signal) switch and are wired to the Body
Controller (BC). A Zero Volt Reference (ZVR) ground signal passes through the appropriate wiper switch to
the BC when any of these switches is closed. The windshield wipers have eight speeds: off, high, low, and
five intermittent speeds. These speeds are determined by the condition of the three wiper switches. Each
of the eight possible wiper switch settings causes a different combination of open and closed switches. The
combination of open or closed switches is used by the BC to determine wiper speed. If wipers work in the
high position, all three input wires to the BC are functioning correctly.
689
Figure 379 In Cab Wiper and Washer Components

1. Multifunction switch 3. Multifunction switch connector
2. Fuse block location 4. Body Controller (BC)
Park Operation
The Body Controller (BC) de-energizes both wiper relays when the wipers are switched OFF while the key
switch is in the IGNITION position. The BC provides battery voltage to the wiper park switch (internal to
wiper motor) while the wipers are not parked and the key switch is in the IGNITION position. Battery voltage
is provided through the park switch to the normally closed Wiper Power Relay. Current flows through the
normally closed Wiper Power Relay and through the normally closed Wiper High/Low Relay to the low speed
terminal of the wiper motor. This causes the wiper motor to operate at low speed, until the wipers are parked.
Voltage supplied to the wiper motor will be replaced by ground when the wipers reach the park position,
causing the wiper motor to stop in the parked position.
Washer Operation
The washer pump is wired to the washer switch in the multifunction switch assembly. Ignition voltage is also
provided to the washer pump. Ground is supplied to the washer pump when the washer switch closes, causing
the washer pump to activate. The ground from the washer switch is also applied to the Body Controller (BC).
The BC activates the low speed wipers for three wiper cycles when it receives the washer signal. This occurs
only if the wipers are not currently in the high speed wiper mode.
690
Figure 380 Wiper Input and Output Circuits
691
Figure 381 Washer Pump and Wiper Motor Input and Output Circuits
692
Figure 382 Windshield Wiper Connector Locator

1. Windshield Wiper Connector
693
Figure 383 Wiper Motor and Washer Pump Control Relays and Fuses
1. Wiper High/Low Relay 3. Wiper Power Relay
2. 25A Fuse F11–D
Windshield Wiper Symptom Diagnostics

Windshield Wiper Input 0 Not Working (page 701)
Windshield Wiper Low Speed Not Working (page 719)
Windshield Wiper High Speed Not Working (page 729)
Windshield Washer Pump Not Working (page 760)
Windshield Wipers Not Working when Washer Pump Activated (page 766)
Windshield Washer Pump and Wipers Not Working (page 769)
694
Windshield Wiper Fault Code Diagnostics

SPN FMI Description
2636 5 Wiper ON / OFF Relay Under Current or Open Circuit (page 739)
2636 6 Wiper ON / OFF Relay Over Current (page 741)
2637 5 Wiper High / Low Relay Under Current or Open Circuit (page 743)
2637 6 Wiper High / Low Relay Over Current (page 745)
4057 5 Wiper Motor Undercurrent (page 747)
4057 6 Wiper Motor Overcurrent (page 753)
Windshield Wiper Input Switch

Multifunction Switch Wiper Input 0 Wiper Input 1 Wiper Input 2
Wiper Position
Intermittent 1 X
Intermittent 2 X
Intermittent 3 X X
Intermittent 4 X
Intermittent 5 X X
Low X X
High X X X
695
Overview
The following steps direct technicians to systematically troubleshoot windshield wiper performance using
Diamond Logic® Builder (DLB®) to avoid unnecessary work and repairs. See Windshield Wiper Overview
(page 689) for more system information.
Figure 384 Windshield Wiper and Washer Inputs to Body Controller Connector J3 (1600)
1. Wiper_0_Signal 3. Wiper_2_Signal
2. Wiper_1_Signal 4. Washer_Pump_Signal
696
Figure 385 Windshield Wiper Outputs from Body Controller Connector J4 (1601)
1. Wiper_High_Speed_Cmd 2. Wiper_Low_Speed_Cmd
697
Figure 386 Windshield Wiper Outputs from Body Controller Connector J2 (1602)
1. Wiper_Output_from_fuse_circuit
Step 1 Check for Active windshield wiper fault codes. Decision

Using Electronic Service Tool (EST) with Diamond Logic® Builder (DLB®) software, No: Go to Step 2.
Key ON, check Faults Tab for Active Fault codes.
Are windshield wiper fault codes Active? Yes: Go to Windshield
Wiper Fault Code
Diagnostics (page
695) for active SPN /
FMI.
Step 2 Check for Hi operation from windshield wipers. Decision

Key ON, with windshield wipers switch in Hi setting. Observe windshield wiper Yes: Go to Step 4.
speed.
Are windshield wipers operating at Hi speed? No: Go to Step 3.
698
Step 3 Check for failed inputs to Body Controller. Decision

Using EST with DLB® software, Open Connectors tab J3 (1600) (page 696). Yes: Go to Windshield
Key ON with windshield wiper switch in Hi setting, verify Wiper_0_Signal, Wiper High Speed Not
Wiper_1_Signal, and Wiper_2_Signal are all activated. Working (page 729).
Do all windshield wiper inputs turn ON when Windshield wiper switch is in the Hi No: Windshield Wiper
position? Input 0 Not Working
(page 701)
No: Windshield Wiper
Input 1 Not Working
(page 707)
No: Windshield Wiper
Input 2 Not Working
(page 713)
Step 4 Check low speed windshield wiper operation. Decision

Key ON, with windshield wipers switch in Low setting. Observe windshield wiper Yes: Go to Step 5.
speed.
Are windshield wipers operating at Low speed? No: Go to Windshield
Wiper Low Speed Not
Working (page 719).
Step 5 Check for correct operation of intermittent speed positions. Decision

Check each intermittent wiper speed individually. Yes: Go to Step 7.
Do all of the intermittent speeds work correctly? No: Go to Step 6.
Step 6 Check for correct feature code selected in Body Controller. Decision
Using EST with DLB® software, Open Features tab and verify correct windshield Yes: Replace
wiper Feature Code is programmed. Multifunction Switch.
Is vehicle programed with correct feature code? No: Program with
correct feature code.
699
Step 7 Check for proper window washer pump and wiper operation. Decision
1. Verify windshield washer reservoir is full. Yes: End of
Diagnostics.
2. Activate windshield washer.
Do windshield wipers and washer work as expected? No: Windshield
washer pump does
not activate. Go to
Windshield Washer
Pump Not Working
(page 760)
No: Windshield wipers
do not activate. Go to
Windshield Wipers Not
Working when Washer
Pump Activated (page
766).
No: Windshield wipers
and washer pump do
not activate. Go to
Windshield Washer
Pump and Wipers Not
Working (page 769).
700
Windshield Wiper Input 0 Not Working
Overview
Windshield Wiper Input 0 is not activating when being selected.
Fault Fact
None
Possible Causes
• Open ZVR (ground) circuit
• Open or high resistance in WW 0 Circuit
• Short to PWR in WW 0 Circuit
• Failed Multifunction Switch
• Failed Body Controller

Yes: Go to Step 2.
Did you perform Operational Checkout Procedure. No: Go to
Operational Checkout
Procedure(page 696).
Step 2 Inspect Body Controller (BC) J3 and J5 connection. Decision

2. Disconnect BC J3 and J5 connector.
3. Check BC J3 and J5 connector terminals for: damaged or pinched
Are Body Controller J3 and J5 connector, harness, and terminals clean and No: Repair connector,
undamaged? harness, or terminal
damage.
Step 3 Check for signal to Body Controller on WW 0 Circuit. Decision

Perform Test 1 (page 703). Key ON with INT 1 ON and Body Controller Yes: Replace Body
disconnected, use Digital Multimeter (DMM) to measure voltage between Body Controller.
Controller pin J3 pin-A9 and PWR.
Is voltage 0 ± 0.5 volts? No: Go to Step 4.
701
Step 4 Check for Open in ZVR ground circuit Decision

Perform Test 2 (page 704). Key ON, use DMM to measure voltage between Yes: Go to Step 5.
Multifunction Switch connector pin-7 and PWR.
or high resistance
between Body
Controller pin
J5 pin-E5 and
Multifunction Switch
pin-7.
Step 5 Check for Open or high resistance in WW 0 Circuit Decision

Perform Test 3 (page 705). Key OFF, use DMM to measure resistance between Yes: Go to Step 6.
Multifunction Switch connector pin-8 and Body Controller pin J3 pin-A9.
between Multifunction
Switch pin-8 and
Body Controller pin J3
pin-A9.
Step 6 Check for short to PWR in WW 0 Circuit Decision

Perform Test 4 (page 706). Key ON with INT 1 ON and Body Controller Yes: Replace
disconnected, use DMM to measure voltage between Body Controller pin J3 pin-A9 Multifunction Switch.
and ground.
Is voltage less than 0.5 volts? No: Repair short
to PWR between
pin-8 and Body
Controller pin J3
pin-A9.

702
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working

Tools Required
Figure 387 Check for WW 0 Circuit Signal to Body Controller
Test 1
1. Key OFF.
2. Disconnect Body Controller connector J3 (1600).
4. Connect Breakout Harness 00-00961-01 to Body Controller connector J3 and leave Body
Controller disconnected.
5. Key ON.
703
Figure 388 Check for Open in ZVR Circuit
Test 2
1. Key OFF.
2. Disconnect Multi function switch connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into multifunction switch connector
pin-7.
4. Key ON.
704
Figure 389 Check for Open in WW 0 Circuit
Test 3
1. Key OFF.
2. Disconnect Body Controller connector J3.
pin-8.
705
Figure 390 Check for short to PWR in WW 0 Circuit
Test 4
1. Key OFF.
5. Key ON.
706
Overview
Windshield Wiper Input 1 is not activating when selected.
Fault Fact
None.
Possible Causes
• Open ZVR ground circuit

Yes: Go to Step 2.
Step 2 Inspect Body Controller J3 (1600) and J5 (1602) connection. Decision

2. Disconnect Body Controller J3 and J5 connector.
3. Check Body Controller J3 and J5 connector terminals for: damaged or
pinched wires; moisture or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
damage.
Step 3 Check for signal to Body Controller on WW 1 Circuit Decision

Perform Test 1 (page 709). Key ON with INT 2 ON with Body Controller Yes: Replace Body
707
Step 4 Check for Open in ZVR Circuit Decision

Multifunction Switch connector (1801) pin-7 and PWR.
or high resistance
between Body
Controller pin
J5 pin-E5 and
pin-7.

Perform Test 3 (page 711). Use DMM to measure resistance between Multifunction Yes: Go to Step 6.
Switch connector pin-11 and Body Controller pin J3 pin-A10.
Switch pin-11 and
pin-A10.

Perform Test 4 (page 712). Key ON with INT 2 ON with Body Controller Yes: Replace
disconnected, use DMM to measure voltage between Body Controller pin J3 Multifunction Switch.
pin-A10 and ground.
to PWR between
pin-11 and Body
Controller pin J3
pin-A10.

708
Pin-Point Test - Windshield Wiper Input 1 Not Working

Tools Required
Figure 391 Check for WW 1 Signal to Body Controller
Test 1
1. Key OFF.
5. Key ON.
709
Test 2
1. Key OFF.
2. Disconnect Multi function switch connector (1801).
pin-7.
4. Key ON.
710
Figure 393 Check for Open in WW 1 Circuit
Test 3
1. Key OFF.
pin-11.
711
Figure 394 Check for Short to PWR in WW 1 Circuit
Test 4
1. Key OFF.
5. Key ON.
712
Overview
Windshield Wiper Input 2 not activating when selected.
Fault Fact
None.
Possible Causes
• Open in ZVR ground circuit

Yes: Go to Step 2.
Step 2 Inspect Body Controller J3 (1600) and J5 (1602) connection. Decision

2. Disconnect Body Controller J3 and J5 connector.
3. Check Body Controller J3 and J5 and connector terminals for:
damaged or pinched wires; moisture or corroded terminals; loose, bent,
or broken pins; or broken connector housing.
damage.
Step 3 Check for signal to Body Controller on WW 2 Circuit Decision

Perform Test 1 (page 715). Key ON with INT 4 ON and Body Controller Yes: Replace Body
713
Step 4 Check for Open in ZVR Circuit Decision

or high resistance
between Body
Controller pin
J5 pin-E5 and
pin-7.

Perform Test 3 (page 717). Use DMM to measure resistance between Multifunction Yes: Go to Step 6.
Switch connector pin-5 and Body Controller pin J3 pin-A11.
Switch pin-5 and
pin-A11

Perform Test 4 (page 718). Key ON with INT 4 ON and Body Controller Yes: Replace
Disconnected, use DMM to measure voltage between Body Controller pin J3 Multifunction Switch.
pin-A11 and ground.
to PWR between
pin-5 and Body
Controller pin J3
pin-A11

714
Pin-Point Test - Windshield Wiper Input 2 Not Working

Tools Required
Figure 395 Check for WW 2 Signal to Body Controller
Test 1
1. Key OFF.
5. Key ON.
715
Test 2
1. Key OFF.
2. Disconnect Multifunction switch connector.
pin-7.
4. Key ON.
716
Figure 397 Check for Open in WW2 Circuit
Test 3
1. Key OFF.
pin-5.
717
Figure 398 Check for Short to PWR in WW2 Circuit
Test 4
1. Key OFF.
5. Key ON.
718
Windshield Wiper Low Speed Not Working
Overview
Low speed windshield wipers are not working or working faster than expected when Low Windshield Wipers
are commanded ON.
Fault Facts
None.
Possible Causes
• Open in Wiper_Low_Speed_Cmd circuit
• Short to ground in Wiper_High_Speed_Cmd circuit
• Open or short to ground in Wipers_Output_from_fuse_circuit
• Open or Short to ground in Wiper Low circuit
• Failed Wiper High/Low Relay
• Failed Windshield Wiper Motor

Yes: Go to Step 2.
Step 2 Inspect Wiper Power Relay connection. Decision

2. Disconnect Wiper Power Relay from fuse block.
3. Check Wiper Power Relay and connector terminals for: damaged or
Are Wiper Power Relay connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.
Step 3 Inspect Wiper High/Low Relay connections. Decision

2. Disconnect Wiper High/Low Relay from fuse block.
3. Check Wiper High/Low Relay and connector terminals for: damaged or
Are Wiper High/Low Relay connector, harness, and terminals clean and No: Repair connector,
damage.
719
Step 4 Inspect windshield wiper motor connector. Decision

2. Disconnect windshield wiper motor connector.
3. Check windshield wiper motor and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or broken
Are windshield wiper motor connector, harness, and terminals clean and No: Repair connector,
damage.
Step 5 Check windshield wiper Low speed operation. Decision

Key ON, with windshield wipers switch in Low setting. Observe windshield wiper Yes: End Diagnostics.
speed.
No, Low windshield
wipers operate at
Higher than expected
speed: Go to Step 6.
Are windshield wipers operating at Low speed? No, Low windshield
wipers do not operate:
Go to Step 8.
Step 6 Check for short to ground in Wiper_High_Speed_Cmd circuit. Decision

Perform Test 1 (page 723). Key ON with windshield wiper switch in Low setting. Yes: Go to Step 7.
Use Digital Multimeter (DMM) to measure voltage between Windshield Wiper
High/Low Relay terminal for pin-85 and PWR.
Is voltage B+ ± 0.5 volts? No: Replace Failed
Windshield Wiper High
/ Low Relay.
Step 7 Check for short to ground in Wiper_High_Speed_Cmd circuit. Decision

Perform Test 2 (page 723). Key ON with windshield wiper switch in Low setting. Yes: Replace Body
Use DMM to measure voltage between Body Controller pin J4 pin-E6 and PWR. Controller.
Is voltage B+ ± 0.5 volts? No: Repair short
to ground between
pin-E6 and fuse block.
Step 8 Check for failed Wiper Motor. Decision

Perform Test 3 (page 724). Key ON with windshield wiper switch in Low setting. Yes: Replace
Use DMM to measure voltage between Windshield Wiper Motor pin-E and ground. Windshield Wiper
Motor.
720
Step 9 Check for failed Body Controller. Decision

Use DMM to measure voltage between Body Controller pin J2 pin-A and ground.
Is voltage B+ ± 0.5 volts? No: Replace Body
Controller.
Step 10 Check for Open or short to ground in Wipers_Output_from_fuse_circuit. Decision

Use DMM to measure voltage between fuse block pin-G1 and ground.
or short to ground
between Body
Controller pin J2 pin-A
and fuse block pin-G1.

or short to ground
between Body
Step 12 Check for PWR to Wiper High / Low Relay. Decision

Use DMM to measure voltage between fuse block terminal for pin-30 of Wiper
High / Low Relay and ground.

Perform Test 8 (page 726). Key OFF. Use DMM to measure resistance between Yes: Go to Step 14.
fuse block terminal for pin-30 of Wiper High / Low Relay and fuse block terminal for
pin-30 of Wiper Power Relay.
or short to ground
between fuse block
terminals.
Step 14 Check for Open or short to PWR in Wiper_Low_Speed_Cmd circuit. Decision

Perform Test 9 (page 727). Key ON with windshield wiper switch in Low setting. Yes: Replace
Use DMM to measure voltage between fuse block pin-J2 and PWR. Windshield Power
Relay.
721
Step 15 Check for Wiper_Low_Speed_Cmd signal to Wiper Power Relay. Decision

Perform Test 10 (page 727). Key ON with windshield wiper switch in Low setting. Yes: Repair Open or
Use DMM to measure voltage between Body Controller pin J4 pin-E7 and PWR. short to PWR between
Body Controller pin
J4 pin-E7 and Wiper
Power Relay pin-J2.
Controller.
Step 16 Check for Open or short to ground in Wiper Low circuit. Decision
Perform Test 11 (page 727). Key ON with windshield wiper switch in Low setting. Yes: Replace Wiper
Use DMM to measure resistance between fuse block terminal for Wiper High/Low High / Low Relay.
Relay pin-87A and Wiper Motor pin-E.
or short to ground
between fuse block
and Wiper Motor
pin-E.

722
Pin-Point Test - Windshield Wiper Low Speed Not Functioning

Figure 399 Windshield Wiper Circuit
Tools Required
Test 1
1. Key OFF.
2. Disconnect Wiper High / Low Relay.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block terminal for Wiper
High/Low Relay pin 85.
4. Key ON. Low Windshield Wipers ON.
Figure 400 Check for Short to ground in Wiper_High_Speed_Cmd Circuit
Test 2
1. Key OFF.
3. Connect 180-pin Breakout Box 00-00956-08 to Breakout Harness 00-00961-01
4. Connect Breakout Harness 00-00961-01 to Body Controller Connector J4.
723
Figure 401 Check for Failed Wiper Motor
Test 3
1. Key OFF.
2. Disconnect Wiper Motor.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into Wiper Motor connector pin-E.
724
Figure 402 Check for Failed Body Controller
Test 4
1. Key OFF.
Figure 403 Check for Open or Short to ground in Wipers_Output_from_fuse_circuit
Test 5
1. Key OFF.
2. Disconnect Wiper Power Relay.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block pin-G1.
725
Figure 404 Check for Open or Short to ground in Wipers_Output_from_fuse_circuit
Test 6
1. Key OFF.
Test 7
1. Key OFF.
High/Low Relay pin-30.
Test 8
1. Key OFF.
4. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block terminals for Wiper
Power Relay and Wiper High/Low Relay pin-30.
726
Figure 405 Check for Open or short to PWR in Wiper_Low_Speed_Cmd Circuit
Test 9
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block pin-J2.
Figure 406 Check for Signal to Wiper Power Relay
Test 10
1. Key OFF.
727
Test 11
1. Key OFF.
3. Disconnect Wiper Motor.
High/Low Relay pin-87A.
728
Windshield Wiper High Speed Not Working
Overview
Hi speed windshield wipers not working or working slower than expected when commanded ON.
Fault Facts
None.
Possible Causes
• Open or short to PWR in Wiper_Low_Speed_Cmd circuit
• Open or high resistance in Wiper_High_Speed_Cmd Circuit
• Open or short to ground in Wipers_Output_from_fuse_circuit
• Open or Short to ground in Wiper High circuit
• Failed Wiper High/Low Relay
• Failed Windshield Wiper Motor

Yes: Go to Step 2.
Step 2 Inspect Wiper Power Relay connection Decision

3. Check Wiper Power Relay and connector terminals for: damaged or
Are Wiper Power Relay and terminals clean and undamaged? No: Repair connector,
damage.
Step 3 Inspect Wiper High / Low Relay connection. Decision

2. Disconnect High / Low Relay from fuse block.
3. Check High / Low Relay and terminals for: damaged or pinched wires;
connector housing.
Are High / Low Relay and terminals clean and undamaged? No: Repair connector,
damage.
729
Step 4 Inspect windshield wiper motor connector. Decision

2. Disconnect windshield wiper motor connector.
3. Check windshield wiper motor and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or broken
Are windshield wiper motor connector, harness, and terminals clean and No: Repair connector,
damage.
Step 5 Check windshield wiper High speed operation. Decision

Key ON, with windshield wipers switch in High setting. Observe windshield wiper Yes: End Diagnostics.
speed.
No, High speed
windshield wipers
operate at Lower than
expected speed: Go
to Step 6.
Are windshield wipers operating at High speed? No, High speed
windshield wipers
do not operate: Go to
Step 9.
Step 6 Check for Open or short to PWR in Wiper_High_Speed_Cmd circuit Decision

Perform Test 1 (page 733). Key ON with windshield wiper switch in High setting. Yes: Go to Step 8.
Use DMM to measure voltage between Wiper High / Low Relay fuse block terminal
for pin-85 and PWR.
Step 7 Check for Open or short to PWR in Wiper_High_Speed_Cmd circuit Decision

Perform Test 2 (page 733). Key ON with windshield wiper switch in High setting. Yes: Open or short
Use DMM to measure voltage between Body Controller pin J4 pin-E6 and PWR. to PWR between
fuse block and Body
Controller J4 pin-E6.
Controller.
730
Step 8 Check for Open or Short to ground in Wipers_Output_from_fuse_circuit. Decision

Perform Test 3 (page 733). Key ON with windshield wiper switch in High setting. Yes: Replace Wiper
Use DMM to measure voltage between Wiper High/ Low Relay fuse block terminal High / Low Relay.
for pin-86 and PWR.
or short to ground
between Body
and Wiper High / Low
Relay.
Step 9 Check for failed Windshield Wiper Motor. Decision

Perform Test 4 (page 734). Key ON with windshield wiper switch in High setting. Yes: Replace
Use DMM to measure voltage between Windshield Wiper Motor pin-D and ground. Windshield Wiper
Motor.
Step 10 Check for failed Body Controller. Decision

Use DMM to measure voltage between Body Controller pin J2 pin-A and ground.
Controller.
Step 11 Check for proper voltage in Wipers_Output_from_fuse_circuit. Decision

or short to ground
between Body
Controller pin J2–A
Step 12 Check for proper voltage in Wipers_Output_from_fuse_circuit. Decision

or short to ground
between Body
731
Step 13 Check for PWR to Wiper High / Low Relay. Decision

Use DMM to measure voltage between fuse block terminal for Wiper High/Low
Relay pin-30 and ground.
Step 14 Check for Open or short to ground in Wiper_Output_from_fuse_circuit. Decision

Perform Test 9 (page 736). Key OFF. Use DMM to measure resistance between Yes: Go to Step 15.
fuse block terminals for Wiper Power Relay pin-30 and Wiper High/Low Relay
pin-30.
or short to ground
between fuse block
terminals.
Step 15 Check for proper voltage on Wiper_Low_Speed_Cmd circuit. Decision

Perform Test 10 (page 737). Key ON with windshield wiper switch in High setting. Yes: Replace Wiper
Use DMM to measure voltage between fuse block pin-J2 and PWR. Power Relay.
Step 16 Check for Open or Short to PWR on Wiper_Low_Speed_Cmd circuit. Decision

Perform Test 11 (page 737). Key ON with windshield wiper switch in High setting. Yes: Repair Open or
Use DMM to measure voltage between Body Controller pin J4 pin-E7 and PWR. short to PWR between
Body Controller pin
J4 pin-E7 and Wiper
Power Relay pin-J2.
Controller.
Step 17 Check for Open or short to ground on Wiper High circuit. Decision
Perform Test 12 (page 737). Key ON with windshield wiper switch in Low setting. Yes: Replace Wiper
Use DMM to measure resistance between fuse block terminal for Wiper High/Low High / Low Relay.
Relay pin-87 and Wiper Motor pin-D.
or short to ground
between fuse block
and Wiper Motor
pin-D.

732
Pin-Point Test - Windshield Wiper High Speed Not Working

Tools Required
Test 1
1. Key OFF.
4. Key ON. High Windshield Wipers ON.
Figure 407 Check for Open or Short to PWR in Wiper_High_Speed_Cmd Circuit
Test 2
1. Key OFF.
733
Test 3
1. Key OFF.
Figure 408 Check for Failed Wiper Motor
Test 4
1. Key OFF.
2. Disconnect Wiper Motor connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into Wiper Motor connector pin-D.
734
Figure 409 Check for Failed Body Controller
Test 5
1. Key OFF.
Figure 410 Check for Proper Voltage in Wipers_Output_from_fuse_circuit
Test 6
1. Key OFF.
735
Figure 411 Check for proper Voltage in Wipers_Output_from_fuse_circuit
Test 7
1. Key OFF.
Test 8
1. Key OFF.
Test 9
1. Key OFF.
4. Using Terminal Test Kit ZTSE4435C, insert proper terminals into fuse block terminals for Wiper
High/Low Relay and Wiper Power Relay pin-30.
736
Figure 412 Check for Failed Wiper Power Relay
Test 10
1. Key OFF.
Figure 413 Check for Open or Short to PWR in Wiper Power Relay CTL Circuit
Test 11
1. Key OFF.
737
Test 12
1. Key OFF.
738
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit
Overview
Fault code sets when Body Controller (BC) detects Wiper_Low_Speed_Cmd circuit is Open or is under current.
Associated Faults
None.
Fault Facts
None
Possible Causes
• Open or high resistance in Wiper_Low_Speed_Cmd circuit
• Failed Wiper Power Relay
Step 1 Inspect connections at Wiper Power Relay. Decision

3. Check Wiper Power Relay terminals for: damaged or pinched wires;
connector housing.
for SPN 2636 FMI 5.
Step 2 Check for Open or high resistance in Wiper_Low_Speed_Cmd circuit. Decision

Perform Test 1 (page 740). Use Digital Multimeter (DMM) to measure resistance Yes: Replace Wiper
between Body Controller pin J4 pin-E7 and Wiper Power Relay pin-J2. Power Relay.
Is resistance ≤ 5 ohms? No: Repair Open
or high resistance
between Body
Controller pin J4
pin-E7 and Wiper
Power Relay pin-J2.

739

Tools Required
Figure 414 Check for Open in Wiper_Low_Speed_Cmd Circuit
Test 1
1. Key OFF.
740
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current
Overview
Fault code sets when Body Controller detects Wiper ON / OFF circuit is over current.
Associated Faults
None
Fault Facts
None
Possible Causes
• Short to PWR in Wiper_Low_Speed_Cmd Circuit

connector housing.
for SPN 2636 FMI 6.
Step 2 Check for Short to PWR in Wiper_Low_Speed_Cmd circuit. Decision

Perform Test 1 (page 742). Key ON with Wiper ON, use Digital Multimeter (DMM) Yes: Replace Wiper
to measure voltage between fuse block pin-J2 and ground. Power Relay.
to PWR between
Body Controller pin
J4 pin-E7 and Wiper
Power Relay pin-J2.

741

Tools Required
Figure 415 Check for Short to PWR in Wiper_Low_Speed_Cmd Circuit
Test 1
1. Key OFF.
4. Key ON. Wiper ON.
742
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or Open Circuit
Overview
Fault code sets when Body Controller detects Wiper_High_Speed_Cmd circuit is Open or under current
Associated Faults
None
Fault Facts
None
Possible Causes
• Open or high resistance in Wiper_High_Speed_Cmd Circuit
• Failed Wiper High / Low Relay
Step 1 Inspect connections at Wiper High / Low Relay. Decision

3. Check Wiper High / Low Relay and terminals for: damaged or pinched
Are Wiper High / Low Relay and terminals clean and undamaged? No: Repair connector,
for SPN 2637 FMI 5.
Step 2 Check for Open or high resistance in Wiper_High_Speed_Cmd circuit. Decision

Perform Test 1 (page 744). Use Digital Multimeter (DMM) to measure resistance Yes: Replace Wiper
between Body Controller pin J4 pin-E6 and fuse block terminal for Wiper High/Low High / Low Relay.
Relay pin-85.
or high resistance
between Body
Controller pin J4

743

Tools Required
Test 1
1. Key OFF.
744
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current
Overview
Fault code sets when the Body Controller (BC) detects the Wiper_High_Speed_Cmd circuit is over current.
Associated Faults
None
Fault Facts
None
Possible Causes
• Open or high resistance in Wiper_High_Speed_Cmd circuit

for SPN 2637 FMI 6.
Step 2 Check for Short to PWR in Wiper_High_Speed_Cmd circuit. Decision

Perform Test 1 (page 746). Key ON with Hi speed wipers ON, use Digital Multimeter Yes: Replace Wiper
(DMM) to measure voltage between fuse block terminal for Wiper High/Low Relay High / Low Relay.
pin-85 and ground.
Is voltage less than 0.5 volts? No: Repair short to
PWR between Body
Controller pin J4

745

Tools Required
Test 1
1. Key OFF.
4. Key ON. Wiper ON.
746
SPN 4057 FMI 5 - Wiper Motor Under Current
Overview
Fault code sets when the Body Controller (BC) detects Wiper High or Low circuit is Open or under current.
Associated Faults
None.
Fault Facts
None.
Possible Causes
• Open or high resistance in Wiper_Output_from_fuse_circuit
• Open or high resistance in Wiper Low circuit
• Open or high resistance in Wiper High circuit
Step 1 Inspect connections at Wiper Motor. Decision

3. Check Wiper Motor connector terminals for: damaged or pinched
Are Wiper Motor connector, harness, and terminals clean and undamaged? No: Repair connector,
for SPN 4057 FMI 5.

3. Check Wiper Power Relay and terminals for: damaged or pinched
for SPN 4057 FMI 5.
747

2. Disconnect Wiper High / Low Relay from fuse block.
for SPN 4057 FMI 5.
Step 4 Inspect connections at Body Controller (BC) connectors J2 (1604) and Decision
J4 (1601).
2. Disconnect BC connectors J2 and J4.
3. Check BC connectors J2 and J4 connector terminals for: damaged or
Are BC connectors J2 and J4 connector, harness, and terminals clean and No: Repair connector,
for SPN 4057 FMI 5.
Step 5 Check for correct voltage in Wiper High circuit. Decision

Perform Test 1 (page 750). Key ON with High speed wipers ON, use Digital Yes: Go to Step 7.
Multimeter (DMM) to measure voltage between Wiper Motor connector pin-D and
ground.
Step 6 Check for Open or high resistance in Wiper High circuit. Decision
Wiper Motor pin-D and fuse block terminal for Wiper High/Low Relay pin-87.
or high resistance
between Wiper Motor
pin-D and fuse block.
Step 7 Check for correct voltage in Wiper Low circuit. Decision

Perform Test 3 (page 751). Key ON with Low speed wipers ON, use DMM to Yes: Replace Wiper
measure voltage between Wiper Motor pin-E and ground. Motor.
748
Step 8 Check for Open or high resistance in Wiper Low circuit. Decision
Wiper Motor pin-E and fuse block terminal for Wiper High/Low Relay pin-87A
or high resistance
between Wiper Motor
pin-E and fuse block.
Step 9 Check for proper voltage in Wiper_Output_from_fuse_circuit. Decision

Perform Test 5 (page 752). Key ON with Low speed wipers ON, use DMM to Yes: Go to Step 10.
measure voltage between fuse block pin-G2 and ground.
or high resistance
between Body
and Wiper Power
Relay pin G2.
Step 10 Check for voltage to the Wiper High/Low Relay. Decision

Perform Test 6 (page 752). Key ON with Low speed wipers ON, use DMM to Yes: Replace Wiper
measure voltage between fuse block terminal for Wiper High/Low Relay pin-30 High / Low Relay.
and ground.
Step 11 Check for Open or high resistance between Wiper Power Relay and Decision
Wiper High/Low Relay low speed wiper circuit.
Perform Test 7 (page 752). Key OFF, Use DMM to measure resistance between Yes: Replace Wiper
fuse block pin-J1 and fuse block terminal for Wiper High/Low Relay pin-30. Power Relay.
or high resistance
between fuse block
terminals pin-J1 and
Wiper High / Low
Relay pin-30.

749

Tools Required
Figure 416 Check for Proper Voltage in Wiper High Circuit
Test 1
1. Key OFF.
4. Key ON. Wiper on High.
Test 2
1. Key OFF.
3. Disconnect Wiper High / Low Relay .
5. Using Terminal Test Kit, insert proper terminal into fuse block terminal for Wiper High/Low
Relay pin-87.
750
Figure 417 Check for Proper Voltage in Wiper Low Circuit
Test 3
1. Key OFF.
4. Key ON. Wiper on Low.
Test 4
1. Key OFF.
5. Using Terminal Test Kit, insert proper terminal into fuse block terminal for Wiper High/Low
Relay pin-87A.
751
Figure 418 Check for Proper Voltage in Wiper_Output_from_fuse_circuit
Test 5
1. Key OFF.
Test 6
1. Key OFF.
Test 7
1. Key OFF.
High/Low Relay pin-30 and Wiper Power Relay pin-30.
752
SPN 4057 FMI 6 - Wiper Motor Over Current
Overview
Fault code sets when the Body Controller (BC) detects the Wiper High or Low circuit is shorted to ground or
over current.
Associated Faults
None
Fault Facts
None
Possible Causes
• Short to ground in Wiper_Output_from_fuse_circuit
• Short to ground in Wiper Low Circuit
• Short to ground in Wiper High Circuit
Step 1 Inspect Wiper Motor connector. Decision

3. Check Wiper Motor connector terminals for: damaged or pinched
Are Wiper Motor connector, harness, and terminals clean and undamaged? No: Repair connector,
for SPN 4057 FMI 6.

connector housing.
for SPN 4057 FMI 6.
753

2. Disconnect Wiper High / Low Relay from fuse block.
3. Check Wiper High / Low Relay terminals for: damaged or pinched
for SPN 4057 FMI 6.
Step 4 Inspect connections at Body Controller Connectors J2 (1604) and J4 Decision

(1601).
2. Disconnect Body Controller Connectors J2 and J4.
3. Check Body Controller Connectors J2 and J4 connector terminals for:
damaged or pinched wires; moisture or corroded terminals; loose, bent,
or broken pins; or broken connector housing.
Are Body Controller Connectors J2 and J4 connector, harness, and terminals clean No: Repair connector,
and undamaged? harness, or terminal
for SPN 4057 FMI 6.
Step 5 Check for Key ON short to ground in Wiper High circuit. Decision
Perform Test 1 (page 756). Key ON with high wipers ON, use Digital Multimeter Yes: Go to Step 7.
(DMM) to measure voltage between wiper motor connector pin-D and ground
Step 6 Check for Key Off short to ground in Wiper High circuit. Decision
wiper motor connector pin-D and ground
Is resistance > 1000 ohms? No: Repair short
to ground between
Wiper Motor pin-D and
fuse block terminal
for Wiper High / Low
Relay pin-87
Step 7 Check for Key On short to ground in Wiper Low circuit. Decision
Perform Test 3 (page 757). Key ON with low wipers ON, use DMM to measure Yes: Replace
voltage between wiper motor connector pin-E and ground Windshield Wiper
Motor.
754
Step 8 Check for Key Off short to ground in Wiper Low circuit. Decision
wiper motor connector pin-E and ground
Is resistance > 1000 ohms? No: Repair short
to ground between
Wiper Motor connector
pin-E and fuse block
terminal for Wiper High
/ Low Relay pin-87A.
Step 9 Check for Short to ground in Wiper_Output_from_fuse_circuit. Decision

Perform Test 5 (page 758). Use DMM to measure resistance between fuse block Yes: Go to Step 10.
pin-G2 and ground.
Is resistance > 1000 ohms? No: Repair short to
ground between Body
and Wiper Power
Relay pin-G2.
Step 10 Check for Open or high resistance in Wiper_Output_from_fuse_circuit. Decision

Perform Test 6 (page 758). Use DMM to measure resistance between fuse block Yes: End Diagnostics.
terminal for Wiper High/Low Relay pin-30 and ground.
Is resistance > 1000 ohms? No: Repair short to
ground between Wiper
High / Low Relay
pin-30 and Wiper
Power Relay pin-30.

755

Tools Required
Figure 419 Check for short ground in Wiper High Circuit
Test 1
1. Key OFF.
4. Key ON. Wiper on High.
756
Figure 420 Check for short to ground in Wiper High Circuit
Test 2
1. Key OFF.
Figure 421 Check for Short to ground in Wiper Low Circuit
Test 3
1. Key OFF.
757
Figure 422 Check for Short to ground in Wiper Low Circuit
Test 4
1. Key OFF.
Figure 423 Check for Short to ground in Wiper_Output_from_fuse_circuit
Test 5
1. Key OFF.
758
Test 6
1. Key OFF.
759
Windshield Washer Pump Not Working
Overview
Windshield Washer Pump is not activating when selected. The Body Controller (BC) activates the low speed
wipers for three wiper cycles when it receives the Washer_Pump_Signal. This occurs only if the wipers are not
currently in the high speed wiper mode.
Fault Fact
None.
Possible Causes
• Open or high resistance in Washer Pump ground circuit
• Open or high resistance in Washer Pump power circuit
• Short to ground in Washed Pump power circuit
• Open or short to ground in PWR feed to washer pump fuse
• Failed Washer Pump
• Failed washer pump fuse
Step 1 Inspect Washer Pump connection and inspect for washer fluid. Decision
2. Disconnect washer pump connector.
3. Check washer pump and connector terminals for: damaged or pinched
Are washer pump connector, harness, and terminals clean and undamaged and is No: Repair connector,
there washer fluid in the tank? harness, or terminal
damage. Fill washer
tank.
Step 2 Determine if Washer Pump ground circuit is operating properly. Decision

Perform Test 1 (page 762). Key ON with washer pump ON, use Digital Multimeter Yes: Go to Step 3.
(DMM) to measure voltage between Washer Pump connector pin-B and PWR.
Step 3 Check for voltage in Washer Pump power circuit. Decision

Perform Test 2 (page 763). Key ON, use DMM to measure voltage between Washer Yes: Replace Washer
Pump pin-A and ground. Pump.
760
Step 4 Check for Open or short to ground in Washer Pump power circuit. Decision
Perform Test 3 (page 763). Key ON use DMM to measure voltage between fuse Yes: Repair Open
block 1004 (M2) pin-H4 and ground. or high resistance
between fuse block
pin-H4 and Washer
Pump pin-A
Step 5 Check for Open or short to ground in PWR Circuit. Decision

Perform Test 4 (page 763). Key ON use DMM to measure voltage between fuse Yes: Replace Washer
block 1004 (M2) pin-G4 and ground. Pump fuse and check
for shorts.
or high resistance
between fuse block
pin-G4 and PWR.
Step 6 Check for Open in ground Circuit. Decision

or high resistance
Switch pin-6 and J5
pin-E5.
Step 7 Check for Open or high resistance in Washer Pump ground Circuit Decision
Perform Test 6 (page 765). Key OFF, use DMM to measure resistance between Yes: Replace
Multifunction Switch connector pin-12 and Washer Pump pin-B. Multifunction Switch.
Switch pin-12 and
Washer Pump pin-B.

761
Pin-Point Test - Windshield Washer Pump Not Working

Tools Required
• Breakout Harness ZTSE4498
Figure 424 Check Washer Pump ground Circuit
Test 1
1. Key OFF.
2. Disconnect Washer Pump connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into Washer Pump connector pin-B.
4. Key ON. Washer Pump ON.
762
Figure 425 Check for PWR in Washer Pump Power Circuit
Test 2
1. Key OFF.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into Washer Pump connector pin-A.
4. Key ON.
Test 3
1. Key OFF.
2. Disconnect Washer Pump fuse.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block 1004 (M2) pin-H4.
4. Key ON.
Test 4
1. Key OFF.
2. Disconnect Washer Pump fuse.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into fuse block 1004 (M2) pin-G4.
4. Key ON.
763
Figure 426 Measure Voltage in Ground Circuit
Test 5
1. Key OFF.
2. Disconnect Multifunction Switch connector.
3. Using Terminal Test Kit ZTSE4435C, insert proper terminal into Multifunction Switch connector
pin-6.
4. Key ON.
764
Figure 427 Measure Resistance in Washer Pump ground Circuit
Test 6
1. Key OFF.
5. Using Terminal Test Kit, insert proper terminal into Multifunction Switch connector pin-12.
765
Windshield Wipers Not Working when Washer Pump Activated
Overview
Windshield Wiper Not Working when Washer Pump is selected. The Body Controller (BC) activates the low
speed wipers for three wiper cycles when it receives the washer signal. This occurs only if the wipers are not
currently in the high speed wiper mode.
Fault Fact
None.
Possible Causes
• Open or high resistance in Washer Pump ground Circuit
• Failed Low Wiper Circuit
Step 1 Inspect Body Controller (BC) J3 connection. Decision

2. Disconnect BC J3 (1600) connector.
3. Check BC J3 and connector terminals for: damaged or pinched wires;
connector housing.
Are J3 connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.
Step 2 Check for signal to Body Controller on Washer_Pump_Signal circuit. Decision

Key ON with washer ON, use Electronic Service Tool (EST) with Diamond Logic® Yes: Go to Windshield
Builder (DLB) check connector tab, connector J3 for check mark on pin J3 pin-A15. Wiper Low Speed Not
Working Diagnostics
(page 719).
Does check mark appear next to pin J3 pin-A15? No: Go to Step 3.
Step 3 Check for Open or high resistance in Washer_Pump_Signal circuit Decision

Perform Test 1 (page 768). Key OFF, use Digital Multimeter (DMM) to measure Yes: Replace Body
resistance between BC pin J3 pin-A15 and Multifunction Switch connector pin-12. Controller.
Is resistance < 5 ohms? No: Repair Open
or high resistance
between Body
Controller connector
pin J3 pin-A15 and
connector pin-12.
766

767
Pin-Point Test - Windshield Wipers Not Working when Washer Pump Activated
Tools Required
Figure 428 Check for Open in Washer_Pump_Signal Circuit
Test 1
1. Key OFF.
5. Connect Breakout Harness 00-00961-01 to BC connector J3.
pin-12.
768
Windshield Washer Pump and Wipers Not Working
Overview
Windshield Wiper Pump and Windshield Wipers are both not working when washer selected. The
Body Controller (BC) activates the low speed wipers for three wiper cycles when it receives the
Washer_Pump_Signal. This occurs only if the wipers are not currently in the high speed wiper mode.
Fault Fact
None.
Possible Causes
• Open or high resistance in Washer Pump ground Circuit
Step 1 Inspect Multifunction Switch connection. Decision

3. Check Multifunction Switch and connector terminals for: damaged or
Are Multifunction Switch connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.
Step 2 Inspect Body Controller (BC) J3 connection. Decision

2. Disconnect BC J3 connector.
3. Check BC J3 and connector terminals for: damaged or pinched wires;
connector housing.
Are BC J3 connector, harness, and terminals clean and undamaged? No: Repair connector,
damage.
Step 3 Check for Open or high resistance in ground circuit Decision

Perform Test 1 (page 771). Key ON, use Digital Multimeter (DMM) to measure Yes: Go to Step 4.
voltage between Multifunction Switch connector pin-6 and PWR.
Switch pin-6 and BC
J5 pin-E5.
769
Step 4 Check for signal to Body Controller (BC) on Washer Pump ground Decision
Circuit
Key ON with washer ON, use Electronic Service Tool (EST) with Diamond Logic® Yes: Replace Body
(DLB) check connector tab, connector J3 for check mark on pin J3 pin-A15. Controller.
Does check mark appear next to pin J3 pin-A15? No: Repair Open
or high resistance
Switch connector
pin-12 and Body
Controller J3 pin-A15.
Step 5 Check for Open in Washer Pump ground circuit Decision

Perform Test 2 (page 771). Key ON with washer pump ON and Body Controller Yes: End Diagnostics.
Disconnected, use DMM to measure voltage between Body Controller pin J3
pin-A15 and PWR.
or high resistance
Switch pin-12 and
pin-A15.
Step 6 Check for Open in Washer Pump ground Circuit Decision

Perform Test 3 (page 772). Key ON with washer pump ON, use DMM to measure Yes: End Diagnostics.
voltage between Washer Pump connector pin-B and PWR.
or high resistance
Switch pin-12 and
Washer Pump pin-B.

770
Pin-Point Test - Windshield Wiper and Washer Pump Not Working

Tools Required
Figure 429 Check for Open in ground Circuit
Test 1
1. Key OFF.
pin-6.
4. Key ON.
Test 2
1. Key OFF.
5. Key ON, Washer Pump ON.
771
Figure 430 Check for Open in Washer Pump ground Circuit
Test 3
1. Key OFF.
4. Key ON, Washer Pump ON.
772
TABLE OF CONTENTS
Front End
Table of Contents
1. Bug Deflector/Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
2. Fender Extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

Quarter Fenders - Rear Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776
3. Hood/Grill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
Head Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
Head Light Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .780
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781
Tilting Front End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
Hood Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
Headlight Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
773
TABLE OF CONTENTS
774
BUG DEFLECTOR/SCREEN
1. Bug Deflector/Screen
Overview
0009WAC Bug Screen front end; mounted behind grille
0009WBD HX615 and HX620 - Bug Deflector stainless steel, mounted on hood
A front end bug screen helps protect the radiator from damage or blockage caused by insects and other small
pieces of road debris.
775
FENDER EXTENSIONS
2. Fender Extensions
Overview
0009585 Fender Extensions rubber
Side mounted fender extensions help keep dirt, mud and other debris away from side of truck. These
extensions provide protection even with use of most wide base radial tires.
Quarter Fenders - Rear Wheels

Overview
0009505 HX615 and HX620 - Quarter Fenders for rear wheels, mirror-finished
stainless steel, frame mounted
Quarter Fenders reduce amount of splash and spray that gets on back of cab.
Quarter Fenders are frame mounted just ahead of rear wheels for stability and durability. A 5-1/2 inch plastic
mud flap is included with all quarter fenders.
776
HOOD/GRILL
3. Hood/Grill
Overview
0009ANC HX515 - Front End Tilting, fiberglass; with stationary grille
0009ASE HX615 and HX620 - Front End Tilting composite
0009HCP HX515 - Grille, Stationary, black vertical accent bars with black mesh
0009HCL HX615 and HX620 - Grille, black vertical accent bars with black mesh
0009HCN HX615 and HX620 - Grille, chrome vertical accent bars with black
mesh
Figure 431 Hood/Grill

1. Grill and Bug Screen 3. Fasteners (8)
2. Hood
Grille is a one-piece, chrome, injection-molded assembly that is secured to the hood using screws and insert
tabs. A front end bug screen helps protect radiator from damage or blockage caused by insects and other
small pieces of road debris. Bug screen is fitted to back side of the grille and is removed with grille.
777
HOOD/GRILL
Head Lights
Adjustment

Adjustment
Horizontal adjustment for headlight(s) is set at factory and no adjustment is needed.
1. To adjust headlight vertical direction, release hood latch and tilt hood forward.
2. Locate adjustment control stem on rear of headlight housing.
3. Rotate adjustment screw clockwise or counterclockwise to adjust vertical adjustment of headlight beam.
778
HOOD/GRILL
Bulb Replacement

Bulb Replacement
1. To remove turn signal and headlight bulbs from headlight assembly, turn counterclockwise and remove.
2. Install turn signal and headlight bulbs into proper positions in headlight assembly and turn clockwise to
lock in position.
779
HOOD/GRILL
Head Light Assembly
Removal

Procedure
2. Disconnect three connectors from rear of headlight assembly.
3. Turn marker light connector 1/4 turn counterclockwise and remove from headlight housing.
4. Remove two bolts and wire harness P-clip from hood and headlight assembly.
5. Remove two nuts from hood and headlight assembly.
6. Remove headlight assembly from hood.
780
HOOD/GRILL
Installation
Headlight assembly nuts 4 lb-ft (5 N·m)
Hood and headlight assembly P-clip bolt 4 lb-ft (5 N·m)
Procedure
1. Install headlight assembly in hood opening and secure with two nuts. Torque nuts to 4 lb-ft (5 N·m).
2. Install two bolts and wire harness P-clip through hood and secure headlight assembly. Torque bolts
to 4 lb-ft (5 N·m).
3. Install marker light connector into headlight assembly opening and turn clockwise 1/4 turn to lock in
headlight assembly.
4. Connect three electrical connectors to rear of headlight assembly.
781
HOOD/GRILL
Tilting Front End

Overview
0009ANC Front end, tilting, fiberglass, with stationary grille
0009ASE Front end, tilting composite
0009HCL Grille, black vertical accent bars with black mesh
0009HCN Grille, chrome vertical accent bars with black mesh
0009HCP Grille, stationary, black vertical accent bars with black mesh
Figure 432 Tilting Front End

1. Front end
The front end consists of the front fenders and the hood, made of high strength composite. The aerodynamic
hood is a multi-piece design with chrome trim accent pieces, which include a wind-split in the center of the
hood and louvered hood side accents. The chassis mounted front end design helps isolate ambient noise and
thus improves interior sound quality of the vehicle.
Hood height at the cowl and rear edge of hood is not adjustable. The rear hood supports are designed so
that they cannot be aligned incorrectly.
The hood adjustment is done by moving the hood hinge mounting plate located at the front cross-member.
782
HOOD/GRILL
The horizontal adjustment for the headlights is set at the factory and no adjustment is needed.
Service Procedures
Tilting Front End Removal (page 784)
Tilting Front End Installation (page 786)
Hood Alignment Procedure (page 788)
Headlight Alignment Procedure (page 795)
783
HOOD/GRILL
Removal
Overview
Remove tilting front end for front end replacement.
WARNING
To prevent property damage, personal injury, and / or death, have an assistant aid in
removal of tilting front end.
Special Tools
None
Equipment Condition
1. Hood grille removed from hood. See Hood Grille Removal .
2. Hood tilt assist spring assembly removed from radiator. See Hood Tilt Assist Spring Assembly
Removal .
Procedure
1. With the hood still supported at 45 degree angle with a floor stand, disconnect front end wire harness
connectors and ground connection between the hood and chassis. Remove wire harness from loop
clamps on the chassis, if so equipped (the harness stays with the hood).
784
HOOD/GRILL
Figure 433 Remove Tilting Front End

1. Lock nut (2) 4. Hood hinge hex bolt (2)
2. Flat washer (2) 5. Hood assembly
3. Hood mounting insulator (2) 6. Hood hinge bracket
2. Remove lock nut (1) and flat washer (2) from each hood hinge hex bolt (4).
3. Remove each hood hinge hex bolt (4) from inboard side of hood hinge bracket (6).
4. With an assistant, remove hood assembly (5) from vehicle. Place hood assembly (5) on an appropriate
padded surface to protect painted surfaces.
5. If it is necessary to remove a hood mounting insulator (3) from hood assembly (5), push hood mounting
insulator (3) out of hinge in hood assembly (5).
Follow-On Procedure
1. Install tilting front end. See Tilting Front End Installation (page 786).
785
HOOD/GRILL
Installation
Overview
Install tilting front end for front end replacement.
WARNING
installation of tilting front end.
Special Tools
None
Hood hinge lock nut 50 – 55 lb-ft (68 – 75 N·m)
Equipment Condition
1. Tilting front end removed. See Tilting Front End Removal (page 784).
Procedure
1. If required, assemble tilt assist springs, stop cables and splash panels onto hood assembly before
mounting hood assembly.
786
HOOD/GRILL
Figure 434 Install Tilting Front End

1. Lock nut (2) 4. Hood hinge hex bolt (2)
2. Flat washer (2) 5. Hood assembly
3. Hood mounting insulator (2) 6. Hood hinge bracket
2. If removed, install each hood mounting insulator (3) into hood assembly (5) by pushing hood mounting
insulator (3) into hinge of hood assembly (5).
3. Place a padded work stand in front of vehicle. With an assistant, rest the hood assembly (5) in place and
install each hood hinge hex bolt (4) in inboard side of hood hinge bracket (6).
4. Install flat washer (2) and lock nut (1) on each hood hinge hex bolt (4). Tighten to 50 – 55 lb-ft (68 – 75 N·m).
5. Connect the front end wire harness connector and ground connections between the hood and chassis.
Secure the wire harness with the loop clamps on the chassis, if so equipped.
Follow-On Procedure
1. Install hood tilt assist spring assembly from radiator to hood assembly. See Hood Tilt Assist
Spring Assembly Installation .
2. Install hood grille onto hood. See Hood Grille Installation .
787
HOOD/GRILL
Hood Alignment
Overview
Adjust hood to properly fit cab.
Figure 435 Hood Location

1. Hood
Special Tools
None
Specifications
Clearance, Hood-to-Cab (Initial) TBD (Initial)
Flushness, Hood-to-Cab (Initial) TBD (Initial)
Clearance, Hood-to-Cab (Final) TBD (Final)
Flushness, Hood-to-Cab (Final) TBD (Final)
Hood hinge bracket mounting nuts 97 - 108 lb-ft (131.5 - 146.4 N·m)
788
HOOD/GRILL
2. Key OFF.
4. Hood grille removed from hood. See Hood Grille Removal .
5. Hood unlatched and open.
Alignment Procedure
Figure 436 Hood Assist Spring Removal

1. Cotter pin 3. Hood assist spring
2. Hood assist spring mounting bracket 4. Retaining pin
1. Remove cotter pin (1) and retaining pin (4), and disconnect hood assist spring (3) from hood assist
spring mounting bracket (2).
2. Repeat Step 1 for hood assist spring (3) on other side of hood.
789
HOOD/GRILL
3. Close hood and do not latch hood.
Figure 437 Clearance Between Rear of Hood and Cab Front

1. Rear edge of hood 3. Raised edge of cab front
2. Clearance
4. Measure clearance (2) between rear edge of hood (1) and raised edge of cab front (3) on driver-side
and passenger-side of hood.
790
HOOD/GRILL
Figure 438 Flushness of Rear of Hood to Cab Front

1. Rear edge of hood 3. Raised edge of cab front
2. Flushness
5. Measure flushness (2) of rear edge of hood (1) to raised edge of cab front (3) on driver-side and
passenger-side of hood.
a. If all clearance measurements are TBD (Initial) and all flushness measurements are TBD (Initial), no
initial adjustment is necessary. Skip Steps 6 through 8, and proceed with Step 9.
b. If any clearance measurement is not TBD (Initial) or any flushness measurement is not TBD (Initial),
proceed with Step 6.
791
HOOD/GRILL
Figure 439 Hood Hinge Bracket and Mounting Nuts

1. Hood hinge bracket 2. Hood hinge bracket mounting nut (3)
6. Loosen three hood hinge bracket mounting nuts (2).
7. Move hood hinge bracket (1) until all clearances are TBD (Initial) and all flushness is TBD (Initial).
8. Tighten three hood hinge bracket mounting nuts (2) to 97 - 108 lb-ft (131.5 - 146.4 N·m).
792
HOOD/GRILL
Figure 440 Hood Assist Spring Installation

1. Cotter pin 3. Hood assist spring
2. Hood assist spring mounting bracket 4. Retaining pin
9. Raise hood.
10. Install hood assist spring (3) on hood assist spring mounting bracket (2), and secure with retaining pin
(4) and cotter pin (1).
11. Repeat Step 10 for hood assist spring (3) on other side of hood.
12. Close hood and do not latch hood.
13. Repeat clearance measurements and flushness measurements.

a. If all clearance measurements are TBD (Final) and all flushness measurements are TBD (Final), no
final adjustment is necessary. Skip Steps 14 through 16.
b. If any clearance measurement is not TBD (Final) or any flushness measurement is not TBD (Final),
proceed with Step 14.
793
HOOD/GRILL
Figure 441 Hood Hinge Bracket and Mounting Nuts

1. Hood hinge bracket 2. Hood hinge bracket mounting nut (3)
14. Loosen three hood hinge bracket mounting nuts (2).
15. Move hood hinge bracket (1) until all clearances are TBD (Final) and all flushness is TBD (Final).
16. Tighten three hood hinge bracket mounting nuts (2) to 97 - 108 lb-ft (131.5 - 146.4 N·m).
Follow-On Procedure
1. Install hood grille onto hood. See Hood Grille Installation .
2. Latch hood.
794
HOOD/GRILL
Headlight Alignment Procedure
Overview
Adjust headlights to properly illuminate road.
Figure 442 Headlight Location

1. Headlight (2)
Special Tools
None
795
HOOD/GRILL
WARNING
To prevent personal injury or death, read all safety instructions in Safety Precautions
section.
WARNING
procedures.

2. Key OFF.
4. Batteries disconnected(page 169).
Procedure
1. To adjust the headlight vertical direction, release hood latch and tilt hood forward.
2. Locate adjustment control stem on rear of headlight housing.
3. Rotate the adjustment screw clockwise or counterclockwise to adjust the vertical position of the headlight
beam.
Follow-On Maintenance
Repeat procedure for opposite headlight.
796
TABLE OF CONTENTS
Fifth Wheel and Misc.

Table of Contents
1. Fifth Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
Air Slide ON / OFF Toggle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
Air Slide Fifth Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Stationary Fifth Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
2. Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Door Lock and Ignition Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
797
TABLE OF CONTENTS
798
FIFTH WHEEL
1. Fifth Wheel
Air Slide ON / OFF Toggle Switch
Overview
0010WDC Fifth Wheel release effects with in cab ON/OFF toggle type air slide
release switch for customer installed air slide fifth wheel
Air Slide Fifth Wheels are available with in cab toggle type air slide release switch for aftermarket air slide
fifth wheel.
799
FIFTH WHEEL
Air Slide Fifth Wheel

Overview
0010EPM Fifth Wheel, Air Slide {Fontaine BLHAWB-D375-1/BLHAWB875024}
24 in. slide, 8.75 in. above top of frame, left hand roadside release;
includes non-tilt
0010GKJ Fifth Wheel, Air Slide {Holland FW-2555} extra capacity, 24.5 in.
slide, 8.5 in. above top of frame, 62,500 pound maximum vertical
load, 150,000 pound maximum draw bar pull, with outboard angle
mount, left hand release
0010HHW Fifth Wheel, Air Slide {Fontaine SL7LWB675012} 12 in. slide, cast
top plate, 6.75 in. above top of frame, left hand release
0010HHY Fifth Wheel, Air Slide {Fontaine SL7LWB725012} 12 in. slide, cast
top plate, 7.25 in. above top of frame, left side release
0010HHZ Fifth Wheel, Air Slide {Fontaine SL7LWB825012} 12 in. slide, cast
top plate, 8.25 in. above top of frame, left side release
0010HJA Fifth Wheel, Air Slide {Fontaine SL7LWB675024} 24 in. slide, cast
top plate, 6.75 in. above top of frame; left side release
0010HJB Fifth Wheel, Air Slide {Fontaine SL7LWB725024} 24 in. slide, cast
0010HJC Fifth Wheel, Air Slide {Fontaine SL7LWB825024} 24 in. slide, cast
0010HKJ Fifth Wheel, Air Slide {Jost JSK37USL-A8PX24} 24 in. slide, cast
0010HKK Fifth Wheel, Air Slide {Jost JSK37USL-A9PX24} 24 in. slide, heavy
duty top plate, 8.75 in. above top of frame; left side release
0010HYX Fifth Wheel, Air Slide {Fontaine SL7LWB675036} 36 in. slide, cast
0010KKM Fifth Wheel, Air Slide {Holland FW35J712XL00} 12 in. slide, 7 in.
above top of frame, left side release
0010KKN Fifth Wheel, Air Slide {Holland FW35J812XL00} 12 in. slide, 8 in.
0010KKP Fifth Wheel, Air Slide {Holland FW35J912XL00} 12 in. slide, 9 in.
0010KKR Fifth Wheel, Air Slide {Holland FW35J724XL00} 24 in. slide, 7 in.
0010KKS Fifth Wheel, Air Slide {Holland FW35J824XL00} 24 in. slide, 8 in.
0010KKT Fifth Wheel, Air Slide {Holland FW35J924XL00} 24 in. slide, 9 in.
0010KKU Fifth Wheel, Air Slide {Holland FW35J736XL00} 36 in. slide, 7 in.
0010KKV Fifth Wheel, Air Slide {Holland FW35J836XL00} 36 in. slide, 8 in.
800
FIFTH WHEEL
Air Slide Fifth Wheels are available with various slide travel lengths. This type of fifth wheel permits fine tuning
of load distribution or adjustment of overall tractor/trailer length to meet federal governmental regulations and
minimization of trailer gap to help maximize fuel economy.
801
FIFTH WHEEL
Stationary Fifth Wheel

Overview
0010EYC Fifth Wheel, Stationary {Fontaine SL7FMA-D69-3} cast top plate;
8.69 in. above top of frame; left hand release
0010EYD Fifth Wheel, Stationary {Fontaine SL7FMA-D69-2} cast top plate;
7.69 in. above top of frame; left hand release
0010GWY Fifth Wheel, Stationary {Holland FW-0070-S09619-2} 8 in. above
top of frame, extra capacity, left hand release
0010GWZ Fifth Wheel, Stationary {Holland FW-0070-S09619-3} 7 in. above
0010GYZ Fifth Wheel, Stationary {Holland FW35-S10504-1L} 8.62 in. above
top of frame; left hand release
0010HCA Fifth Wheel, Stationary {Holland FW-0070-S09619-1} 9 in. above
0010HKE Fifth Wheel, Stationary {Jost JSK37USL-PM-004} 8.69 in. above
0010HKG Fifth Wheel, Stationary {Holland FW35-S801XL} 8.69 in. above
0010HKH Fifth Wheel, Stationary {Jost JSK37USL-PM-003} 7.69 in. above
0010HKT Fifth Wheel, Stationary {Holland FW35-S10687-19} Kompensator,
11.86 in. above top of frame; left hand release with lock out feature
0010HYR Fifth Wheel, Stationary {Holland FW35-S10504-2L} 7.75 in. above
0010HYU Fifth Wheel, Stationary {Holland FW35-S10504-3L} 6.75 in. above
0010HYV Fifth Wheel, Stationary {Holland FW35-S10504-4L} 5.75 in. above
A stationary fifth wheel is an economical alternative to a sliding fifth wheel. This option is for customers who
have standardized their trailer loading or tractor/trailer combinations.
If load distribution or tractor/trailer combinations change, customer can move stationary fifth wheel backward
or forward in two inch increments as necessary to meet new requirement. This adjustment requires loosening
mounting bolts, repositioning fifth wheel and retightening bolts.
802
KEYS
2. Keys
Door Lock and Ignition Keys
Overview
0010943 Optional All Alike Fleet - includes ignition and cab door keys
0010WBE ID Z-001
0010WGN ID Z-003
0010WGM ID Z-026
0010WBG ID Z-053
0010WBD ID Z-100
0010WGP ID Z-122
0010WBC ID Z-150
0010WBB ID Z-200
0010WBA ID Z-250
Figure 443 Door Lock Location

1. Door Lock Location
Fleet owners may prefer a common key to every truck door lock and ignition switch to simplify day-to-day
operations.
803
KEYS
804
TABLE OF CONTENTS
Clutch
Table of Contents
1. Clutch System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Clutch Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Hydraulic Clutch Actuation System with Air Assist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Clutch Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Air Assist Servo and Slave Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Bleeder Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
Push Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Eaton® Fuller Solo Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
Eaton® Fuller Soft-Rate 7 Spring Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
Eaton® Fuller Vibration Control Technology (VCT) Plus Soft-Rate Damper. . . . . . . . . . . . . . . . . . . . . . 816
Eaton® Fuller VCT Plus Soft-Rate Damper with Pre-Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
805
TABLE OF CONTENTS
806
CLUTCH SYSTEM
1. Clutch System
Clutch Brake
Overview
0011WAG Clutch Brake two piece
Figure 444 Clutch Brake Location
A torque limiting clutch brake is standard with all non-synchronized transmissions. Torque limiting brake is
designed to slip if excessive torque is encountered. This increases clutch brake life and reduces drive tang
breakage. Clutch brake is used with non-synchronized transmissions to prevent gear clash when shifting
into first or reverse.
807
CLUTCH SYSTEM
Hydraulic Clutch Actuation System with Air Assist

Overview
0011WAK Clutch Effects hydraulic clutch actuation system, with air assist
Figure 445 Hydraulic Clutch Actuation Location
Hydraulic clutch system is a group of components that utilizes hydraulic fluid to interrupt power flow between
engine and driveline at clutch assembly. Driver depresses clutch pedal to disengage clutch and interrupt power
transfer to transmission, driveline, and drive wheels, but allows engine to continue turning. Driver releasing
clutch pedal reengages clutch and transfers power from engine to transmission input shaft and driveline.
Clutch and clutch actuation system are designed to provide smooth engagement of engine power, allowing
driver to control vehicle speed through gear selection.
Clutch Pedal
When clutch pedal is depressed, fluid pressure is built up in master cylinder, forcing fluid into air assist servo or
slave cylinder (depending on which is equipped), which causes clutch release fork to move. Release fork
and release bearing compress pressure springs of clutch to disengage clutch disc. When clutch pedal is
released, fluid pressure is released from air assist servo, and release fork and release bearing decompress
clutch pressure springs which engage clutch disc.
Clutch free-play is travel clutch pedal makes before any action takes place. Hydraulic clutch utilizes no
free-play.
808
CLUTCH SYSTEM
Master Cylinder
Clutch master cylinder provides pressure for system operation. When pedal force is applied to clutch master
cylinder, piston displaces hydraulic fluid in chamber of master cylinder. Further piston travel allows fluid to be
forced through hydraulic hose to air assist servo located at transmission. When pedal force is released, clutch
master cylinder is returned to its initial position by a spring.
Reservoir
Reservoir is remotely mounted from master cylinder in a location accessible for service. Reservoir supply
hose should maintain a downward slope from reservoir to allow trapped gases and trapped bubbles to be
released from clutch master cylinder. Reservoir includes a fluid level indicator where MIN/MAX is indicated
on a printed label. Fill cap includes a vent to allow trapped air to escape and has Use Only DOT 3 or DOT
4 Brake Fluid printed on top of fill cap.
Air Assist Servo and Slave Cylinder
Slave cylinder is rigidly attached to clutch housing. When master cylinder directs fluid to slave cylinder, piston
in slave cylinder moves push rod out against release fork. Since release bearing is connected to release fork,
force is transmitted to pressure spring of clutch, and clutch is then disengaged.
If equipped, air assist servo is used in place of slave cylinder to reduce pedal effort needed to actuate clutch.
Air Assist Servo has a hydraulic inlet, air inlet, and air exhaust valve. Air assisted servo requires a regulated air
supply at 65 ± 10 psi (4.5 ± 0.7 bar) with an air supply between 90 to 130 psi (6.2 to 9 bar) from vehicle air
supply reservoir. Air assist servo should be rigidly attached to clutch housing. When clutch master cylinder
directs fluid to air assist servo, piston in air assist servo moves push rod out against release fork. Since clutch
release bearing is connected to clutch release fork, force is transmitted to pressure spring of clutch, and
clutch is then disengaged. Air assist shall be able to actuate (disengage) clutch with increased pedal effort
when loss of air pressure is experienced.
Hydraulic Hose
Hydraulic hose materials are compatible with DOT 3 and DOT 4 brake fluid. Inspect hydraulic hoses regularly
to ensure hydraulic hoses show no signs of wear or leaks. If hydraulic hoses have leaks present or are
unserviceable, replace hydraulic hose.
Bleeder Valve
Bleeder valve is located on air assist servo/slave cylinder and is utilized to release trapped air that is in
hydraulic clutch system. Hydraulic clutch system must be bled whenever a component in hydraulic clutch
system has been replaced, or has been opened, allowing air to enter system.
Service Information
Eaton Solo Advantage self-adjusting clutch service and Go to www.Eaton.com

troubleshooting
Eaton Solo Advantage Clutch Reset Tool Users Guide Go to www.Eaton.com
Heavy-Duty Clutch Service Manual Go to www.Eaton.com
Eaton Medium-Duty Clutch Service Manual Go to www.Eaton.com
Solo Heavy-Duty Clutch Service Information Go to www.Eaton.com
809
CLUTCH SYSTEM
Master Cylinder
Adjustment should not be necessary if installing new master cylinder.
This may require two people to perform this operation.
CAUTION
To prevent vehicle damage, push rod must NOT preload master cylinder internal spring
after clevis pin is inserted.

810
CLUTCH SYSTEM
Push Rod Adjustment
Adjustment nut 6 to 9 lb-ft (8 to 12 N·m)
1. Pull rubber boot down, uncovering adjustment nut on push rod.
2. Loosen adjustment nut and gently rotate push rod out until clevis pin can be inserted in bell crank yoke
without force. Push rod must NOT preload master cylinder internal spring after clevis pin is inserted.
3. Connect clutch master cylinder clevis to clutch pedal and secure with clevis pin. Secure clevis pin with
hairpin.
4. Tighten adjustment nut. Torque nut to 6 to 9 lb-ft (8 to 12 N·m).
5. Depress clutch pedal and pull rubber boot up over push rod and adjustment nut.
811
CLUTCH SYSTEM
Clutch
Overview
0011MGR Clutch {Eaton Fuller Solo Advantage} self-adjusting, two-plate,
cast angle spring; ceramic, 15.5 inch diameter, soft clutch 7 spring
damper, mechanical pull-type control, 1,700 lbf-ft torque capacity
0011MGP Clutch {Eaton Fuller ECA-1850} two-plate, ceramic, 7 spring with
pre-damper, 15.5 in. diameter, with adjustment-free Feature, 1,850
lbf-ft torque capacity
0011MGS Clutch {Eaton Fuller Solo Advantage} self-adjusting, two-plate, cast
angle spring; ceramic, 15.5 in. diameter, 7 spring coaxial VCT Plus
damper (soft rate) mechanical pull-type control, 6 button disc, 1,860
0011MGU Clutch {Eaton Fuller Solo Advantage} self-adjusting, two-plate, cast
damper (soft rate) mechanical pull-type control, 6 button disc, 2,050
0011MGV Clutch {Eaton Fuller Solo Advantage} self-adjusting, two-plate, cast
PD damper (soft rate) mechanical pull-type control, 6 button disc,
1,860 lbf-ft torque capacity
0011MGW Clutch {Eaton Fuller Solo Advantage} self-adjusting, two-plate, cast
PD damper (soft rate) mechanical pull-type control, 4 button disc,
1,750 lbf-ft torque capacity
0011MHG Cummins® ISX - Clutch {Eaton Fuller ECA-2250} two-plate, ceramic,
7 spring with pre-damper, 15.5 in. diameter, with adjustment-free
feature, 2,250 lbf-ft torque capacity
0011MHL Cummins® ISX - Clutch {Eaton® Fuller Solo Advantage}
self-adjusting, two-plate, cast angle spring; ceramic, 15.5 in.
diameter, 7 spring coaxial VCT Plus PD damper (soft rate)
mechanical pull-type control, 6 button disc, 2,050 lbf-ft torque
capacity
812
CLUTCH SYSTEM
Figure 446 Clutch Location
813
CLUTCH SYSTEM
Eaton® Fuller Solo Clutch
Eaton® Fuller Solo clutches are 'adjustment free' after initial clutch installation and have improved heat/wear
resistant facing material. Key to minimizing clutch wear is proper adjustment. Solo clutch stays in constant
adjustment after installation, greatly extending clutch life. There is a visual clutch wear indicator that provides
easy visual reference for amount of wear incurred. While clutch itself does not require adjustment, linkage still
needs periodic lubrication and maintenance due to wear.
Standard Solo Features Exclusive Solo technology maintains proper clutch adjustment at all
times to maximize clutch service life.
Wear indicator tab provides convenient visual indication of remaining
clutch life.
Proper adjustment maintains clutch brake squeeze or smoother
shifts in first and reverse gears.
Solo XL Features Roller yoke, provides smoother operation and educed bushing and
bearing wear.
Sealed premium lubed-for-life release bearing.
Improved steel-backed bushings resist wear for increased service
life.
Solo Advantage© Features Lube interval increased to 50,000 miles for line haul applications to
minimize maintenance and reduce cost of ownership.
New increased warranty up to 3 years or 350,000 miles for Solo
Advantage© line haul applications.
New patented release bearing provides increased lubrication and
improved strength to extend the life of the clutch.
A full-round contamination baffle protects against debris
Stainless steel cam spring delivers increased durability and long life.
Eliminates 13 manual adjustments for every truck, on average.
814
CLUTCH SYSTEM
Eaton® Fuller Soft-Rate 7 Spring Damper
Damper's durability and dampening capabilities have been increased by fine tuning spring rates and improving
component robustness. Eaton® Fuller Soft-Rate 7 spring damper offers a soft torsional-rate while providing
increased torque capacities.
Proven design offers these benefits

Unique Internal Dampening System Fine-tuned spring rates and hysteresis levels reduce torsional
vibrations.
Premium Ceramic Facing Material Provides longer life and a reduction in flywheel wear.
Increased Torque Capacity Up to 1700 lbf-ft
More durable design.
High Tensile Strength Spring Wire For added durability.
815
CLUTCH SYSTEM
Eaton® Fuller Vibration Control Technology (VCT) Plus Soft-Rate Damper
VCT Plus Soft-Rate Damper can significantly reduce severe vibration, cutting down on maintenance costs and
downtime, and extending drivetrain component life.
VCT Plus offers these benefits

Unique Internal Dampening System Employs fine-tuned spring rates and hysteresis levels to reduce
torsional vibrations.
Increased Torque Capacity Up to 2050 lbf-ft
Premium Ceramic Facing Material Provides longer life and less flywheel wear.
Six (6) Paddle Design Offers longer life
816
CLUTCH SYSTEM
Eaton® Fuller VCT Plus Soft-Rate Damper with Pre-Damper
VCTplusPD is built off existing VCTplus platform, VCTplusPD incorporates a Pre-Damper feature designed
to eliminate transmission idle gear rattle in applications with today's high torque engines. VCTplusPD has
same soft-rate dampening characteristics as standard VCTplus damper, and also same six (6) paddle design
with premium ceramic facings for longer life. VCTplusPD is available in Solo and Easy-Pedal models for
torque ratings up to 2250 lbf-ft.
817
CLUTCH SYSTEM
Description Torque
Clutch Reservoir Mount Bolts and Nuts 7 to 8 lb-ft (9 to 11 N·m)
Master Cylinder Mount Bolts and Nuts 15 to 18 lb-ft (20 to 25 N·m)
Hydraulic Hose Connection to Clutch Master Cylinder 15 to 18 lb-ft (20 to 25 N·m)
Clutch Master Cylinder Push Rod Adjustment Nut 6 to 9 lb-ft (8 to 12 N·m)
Air Assist Servo / Slave Cylinder Bolts 11 to 15 lb-ft (15 to 21 N·m)
Air Assist Servo / Slave Cylinder Bleeder Valve 4 lb-ft (5.4 N·m)
818
TABLE OF CONTENTS
Engines
Table of Contents
1. Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823
2. Block Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825
3. Cold Start Assist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826

Either Cold Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826
4. Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828

Radiator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
Coolant System Drain, Fill, and Pressure Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
Coolant System Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
Deaeration Cap Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 833
N13 Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837
Cummins® ISX Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .839
Deaeration Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
Relocate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845
Power Steering Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846
Relocate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846
Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848
HVAC Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849
Relocate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .851
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .853
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .855
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .856
Fan Shroud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
Navistar® Upper (N13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .857
Navistar® Lower (N13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .860
(Cummins® ISX) Two and Three Piece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .864
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 868
Navistar® Upper (N13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .868
Navistar® Lower (N13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .869
Fan Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .871
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 874
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .874
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .875
Radiator Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876
Heat Shrink Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .876
Radiator Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .878
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 879
819
TABLE OF CONTENTS
Heat Shrink Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879

Radiator Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .882
Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 883
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 883
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .883
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .885
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .888
Radiator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 889
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 889
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .892
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 898
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899
Recirculation Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .905
Radiator Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .906
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .908
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Navistar® N13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
Power Steering Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
Cummins® ISX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
Cooling Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
5. Cooling System with Navistar® A26 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919

Cooling Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919
Cooling System External Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921
Deaeration Tank Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 924
Check Coolant Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930
Coolant Pressure Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 933
Cooling Package Flush Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937
Coolant Drain Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945
Deaeration Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .949
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .952
Power Steering Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955
Relocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955
Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .957
Radiator Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .962
Cooling Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 968
820
TABLE OF CONTENTS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .968
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 982
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .982
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .990
Coolant Fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 999
HVAC Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006
Relocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1010
Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1015
Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1026
Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1031
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036
Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1041
6. Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048

Horton Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
Fan Drive with Override Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1049
7. Power Take Off (PTO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050

Front Engine PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050
Rear Engine PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051
821
TABLE OF CONTENTS
822
AIR CLEANER
1. Air Cleaner
Overview
0012VBB Air Cleaner Dual Element
0012VGB Air Cleaner Dual Element, with integral pre-cleaner
0012VBA Air Cleaner Dual; polished stainless steel; mounted one on each
side of cowl ahead of doors. Available with Cummins® ISX engines.
0012VBC Air Cleaner Single Element with vacuator (a device that discharges
accumulated dirt and water from the system)
0012VBH Air Cleaner Single Element, with integral pre-cleaner
Figure 447 Air Cleaner Location - Left
823
AIR CLEANER
Figure 448 Air Cleaner Location - Right
824
BLOCK HEATER
2. Block Heater
Overview
0012WCT Block Heater, Engine {Phillips} 120 volts 1500 watts with Y-cord for
fuel heater; cord to operate both heaters
0012WYW Block Heater, Engine {Phillips} 120 volts 1500 watts block and 120
volts 300 watts oil pan heater with Y-cord from socket to operate
both heaters; socket mounted in standard location
0012864 Block Heater, Engine {Phillips} 120 volts 1500 watts
Block heaters are optional for engines. Block heaters are for maintaining engine warm, block heaters may also
include fuel heaters and oil pan heaters.
825
COLD START ASSIST
3. Cold Start Assist

Either Cold Start
Overview
0012WEG N13 Engines: Cold Starting Equipment Automatic; with Engine
ECM Control
0012991 Cummins® ISX Engines: Cold Starting Equipment Automatic Ether;
with Engine ECM Control
826
COLD START ASSIST
HX515 and HX615
Integrated starting aid consists of an air intake heater operated by International® Diamond Logic® control
module. System automatically monitors ambient conditions and determines when heater is required.
Benefits include fast, dependable starts at lower temperatures which reduce stress on starting system. It also
eliminates need for volatile starting fuels, preventing harmful emissions of these fluids, thus avoiding potentially
damaging effects to mechanical components of engine. System is completely contained within vehicle. It is not
necessary to plug vehicle in for system to operate.
HX620
This temperature controlled automatically activated system injects a metered amount of ether prior to engine
cranking which will make vehicle easier to start.
827
COOLING SYSTEM
4. Cooling System
Radiator System
Overview
0012UBV HX515 - Radiator Aluminum: Welded, front to back down flow
system, 1177 in², 825 in² CAC, 949 in² 3 Core LTR
0012UBE HX615 - Radiator Aluminum; single row, down flow system, 1429
in², front to back, 764.1 in² CAC, 1123.3 in² LTR
0012UCU HX620 - Radiator Aluminum; front to back, down flow system,
1564.8 in², 556.8 in² CAC
0012WGA Hose Clamps, Radiator Hoses, Mechanical Type; with
constant-tension functionality
0012WCX Hose Clamps, Radiator Hoses {Gates} shrink band type
Navistar® vehicles are equipped with a coolant package that combines all coolant components into one
forward-mounted area. This design makes service of coolant package components easier and eliminates long
periods of downtime, waiting for radiator and cooling component repair.
Shrink band clamps maintain a consistent, dynamic tension so they never need retightening. Heat-sensitive
material shrinks to conform to any shape of hose and housing when heat is applied and automatically readjusts
every time engine comes to operating temperature. After engine is shut down, temperatures decrease. When
ambient temperatures drop below freezing, clamping force will increase by using band's increased thermal
contraction. Shrink band hose clamps feature a smooth surface that won't rust or corrode.
828
COOLING SYSTEM
Coolant System Drain, Fill, and Pressure Test Procedures

Coolant System Drain
Required Tools
• Flush-face Quick Connect Coupler, KL5007NAV-282
• 20 Gallon Tank and Cart Assembly, KL5003NAV
• Pressure Fitting, 44277
• Cap Adapter, KL5004NAV
• Pressure Module, KL5006NAV
• Coolant Cap Pressure Tester Tool, 09-040-01
• Vacuum Module, KL5005NAV
• Quick Connect Extension for Cap Adapter, KL5008NAV
829
COOLING SYSTEM
WARNING
To prevent personal injury or death, wear safety glasses with side shields to protect eyes.
Limit compressed air to 30 psi (207 kPa).
WARNING
To prevent personal injury or death from hot coolant or steam scalding, allow engine to
cool sufficiently or remove cap per cap removal procedure (page 834).
WARNING
To prevent property damage, personal injury, or death, take care when performing any
maintenance or making any check or repair. Some materials in this vehicle may also be
hazardous if used, serviced, or handled improperly. If there are any questions pertaining
to service, have work done by a skilled technician.
CAUTION
To prevent engine or equipment damage, if vehicle is equipped with optional surge tank,
plug hose leading from surge tank to deaeration tank, prior to performing coolant fill
procedure. This will isolate surge tank.
CAUTION
To prevent engine or equipment damage, coolant may be Hot. Filling Coolant

Management Tool tank with Hot Coolant may reduce tank life.
IMPORTANT – If system has been drained, fill with an Extended Life Coolant (pre-diluted 50/50 or concentrated
mixed 50/50) meeting Navistar® B-1 Type III or IIIA specifications. If system has been flushed with water, a
significant amount of freshwater flush will remain in system. In this case, refilling with a mixture containing a
higher percentage (75%) of coolant concentrate is advised in order to achieve a final mixture close to 50/50.
IMPORTANT – If a known leak exists, do not pressurize cooling system. A gravity drain must be used. After
necessary repairs have been made, proceed to Pressure Test Procedure.
IMPORTANT – Screen in tank valve strainer must periodically be checked for debris.
Use following procedure to remove pressure from cooling system:
1. Allow engine to cool.

2. Wrap a thick cloth around cap.
3. Partially unscrew pressure cap slowly while firmly holding cap down, then pause to allow pressure
to release.
4. When system pressure is released, fully unscrew pressure cap while continuing to hold cap down.
Slowly release downward pressure from cap.
5. Remove cap.
830
COOLING SYSTEM
1. Park vehicle on a flat, level surface.

2. Place transmission in neutral (or park if automatic transmission).
4. Turn off ignition.
5. Install wheel chocks to prevent forward or backward movement.
6. Disconnect battery, always disconnect ground battery terminal first, then positive cable..
Any vehicle not previously equipped with a quick-connect fitting, rather than a typical drain valve / pet cock
in radiator drain port, must have a quick-disconnect fitting installed to use Navistar® Coolant Management
Tool (KL5007NAV).
Coolant level of deaeration tank must be checked to make sure cooling system is full before draining cooling
system. Performing this check will confirm cooling system is filled to proper level when refilling cooling system.
To function properly, cooling system must be completely filled with coolant and all air must be expelled. To
accomplish this, one of following procedures should be carefully completed:
1. Vac-and-Fill Coolant Fill Method using Navistar® Coolant Management Tool (KL5007NAV): This
method first places cooling system under a vacuum, and then fills cooling system through a fitting
at bottom of radiator. This method avoids need for running engine to purge trapped air and need to
temporarily defeat operation of EGR valve during initial coolant deaeration period.
2. Gravity-Fill Coolant Fill Method: This is a traditional gravity-fill-only method that involves pouring
or pumping coolant into deaeration tank of cooling system and using a combination of gravity
and engine operation to purge system of air.
• One disadvantage of this method is a requirement to temporarily disconnect wiring harness

from EGR-motor, to protect EGR cooler from heat damage prior to being completely deaerated
(freed of trapped air).
• This method creates a fault code that must be removed with a computerized Electronic
Service Tool (EST).
• It may be necessary to run engine at various speeds for up to an hour after filling, followed by
a 10 to 12 hour cool-down and top-off, to avoid releasing a vehicle that can be approximately
one gallon low on coolant.
Before using KL5007NAV Coolant Management Tool, read, understand, and follow safety precautions and
general operating instructions supplied with tool. This equipment must be operated by qualified personnel.
Operator must be familiar with vehicle cooling systems, coolants, and dangers they present.
Before using KL5007NAV Coolant Management Tool, vehicle must be equipped with a special male
quick-connect fitting (3688493C2) in place of typical coolant drain pet cock. Vehicles not built with this fitting
are easily retrofitted. Make sure that this fitting is installed on vehicle before performing following procedure.
Coolant Drain
1. Attach tank hose to quick-connect fitting on bottom of cooling system.
831
COOLING SYSTEM
Figure 449 Tank Valve

1. Drain 3. Fill
2. Closed
2. Turn tank valve to DRAIN.
WARNING
To prevent personal injury or death, use caution when removing deaeration tank cap.
Deaeration tank cap may be under pressure.
3. Remove deaeration tank cap and install cap adapter (KL5004NAV).
IMPORTANT – Limit air pressure to 15 psi (103 kPa).
4. Attach pressure module.
5. Connect source of clean, dry compressed air to pressure module and open air valve.
6. Drain cooling system. If system is not draining, make sure tank valve is set to DRAIN.
7. When finished draining cooling system, close air valve and make necessary repairs.
832
COOLING SYSTEM
Deaeration Cap Pressure Test
Required Tools
• Flush-face Quick Connect Coupler, KL5007NAV-282
• 20 Gallon Tank and Cart Assembly, KL5003NAV
• Pressure Fitting, 44277
• Cap Adapter, KL5004NAV
• Pressure Module, KL5006NAV
• Coolant Cap Pressure Tester Tool, 09-040-01
• Vacuum Module, KL5005NAV
• Quick Connect Extension for Cap Adapter, KL5008NAV
833
COOLING SYSTEM
WARNING
WARNING
WARNING
CAUTION
To prevent engine or equipment damage, if vehicle is equipped with optional surge tank,
plug hose leading from surge tank to deaeration tank, prior to performing coolant fill
procedure. This will isolate surge tank.
CAUTION
To prevent engine or equipment damage, coolant may be Hot. Filling Coolant

Management Tool tank with Hot Coolant may reduce tank life.
IMPORTANT – If system has been drained, fill with an Extended Life Coolant (pre-diluted 50/50 or concentrated
mixed 50/50) meeting Navistar® B-1 Type III or IIIA specifications. If system has been flushed with water, a
significant amount of freshwater flush will remain in system. In this case, refilling with a mixture containing a
higher percentage (75%) of coolant concentrate is advised in order to achieve a final mixture close to 50/50.
IMPORTANT – If a known leak exists, do not pressurize cooling system. A gravity drain must be used. After
necessary repairs have been made, proceed to Pressure Test Procedure.
IMPORTANT – Screen in tank valve strainer must periodically be checked for debris.
Use following procedure to remove pressure from cooling system:

2. Wrap a thick cloth around cap.
to release.
5. Remove cap.
834
COOLING SYSTEM

6. Disconnect battery, always disconnect ground battery terminal first, then positive cable..
Any vehicle not previously equipped with a quick-connect fitting, rather than a typical drain valve / pet cock
in radiator drain port, must have a quick-disconnect fitting installed to use Navistar® Coolant Management
Tool (KL5007NAV).
Coolant level of deaeration tank must be checked to make sure cooling system is full before draining cooling
system. Performing this check will confirm cooling system is filled to proper level when refilling cooling system.
To function properly, cooling system must be completely filled with coolant and all air must be expelled. To
accomplish this, one of following procedures should be carefully completed:
1. Vac-and-Fill Coolant Fill Method using Navistar® Coolant Management Tool (KL5007NAV): This
method first places cooling system under a vacuum, and then fills cooling system through a fitting
at bottom of radiator. This method avoids need for running engine to purge trapped air and need to
temporarily defeat operation of EGR valve during initial coolant deaeration period.
2. Gravity-Fill Coolant Fill Method: This is a traditional gravity-fill-only method that involves pouring
or pumping coolant into deaeration tank of cooling system and using a combination of gravity
and engine operation to purge system of air.
• One disadvantage of this method is a requirement to temporarily disconnect wiring harness

from EGR-motor, to protect EGR cooler from heat damage prior to being completely deaerated
(freed of trapped air).
• This method creates a fault code that must be removed with a computerized Electronic
Service Tool (EST).
• It may be necessary to run engine at various speeds for up to an hour after filling, followed by
a 10 to 12 hour cool-down and top-off, to avoid releasing a vehicle that can be approximately
one gallon low on coolant.
Before using KL5007NAV Coolant Management Tool, read, understand, and follow safety precautions and
general operating instructions supplied with tool. This equipment must be operated by qualified personnel.
Operator must be familiar with vehicle cooling systems, coolants, and dangers they present.
Before using KL5007NAV Coolant Management Tool, vehicle must be equipped with a special male
quick-connect fitting (3688493C2) in place of typical coolant drain pet cock. Vehicles not built with this fitting
are easily retrofitted. Make sure that this fitting is installed on vehicle before performing following procedure.
Pressure Test
1. Determine rated pressure of deaeration cap. Test deaeration cap using 09-040-01 Coolant Cap Pressure
Tester.
2. Replace cap if not within specification.
835
COOLING SYSTEM
3. Attach tank hose to quick-connect fitting on bottom of cooling system.

1. Drain 3. Fill
2. Closed
4. Turn tank valve to CLOSED.
WARNING
To prevent personal injury of death, DO NOT exceed pressure rating on deaeration tank
cap.
5. Open air valve on pressure module. Do not exceed pressure rating on deaeration tank cap.
6. Close air valve. System is now pressurized with air. Note gauge reading and check for pressure decay. If
no decay is detected, continue to Coolant Fill Procedure. If decay is evident, check cooling system
for leak(s).
7. Turn tank valve to DRAIN to vent air.
8. Disconnect compressed air and remove pressure module.
836
COOLING SYSTEM
Coolant System Fill
N13 Fill
Fill Procedure
1. Open any shutoff valve in heater circuit, in-transit heat circuit, or Auxiliary Power Unit (APU) circuit (not
shown).
IMPORTANT – If vehicle cooling system has been flushed with water prior to filling, use a portion of undiluted
coolant concentrate to assist in achieving a 50/50 mixture after filling, or use a 75/25 mixture for the fill process.
IMPORTANT – Any vehicle not previously equipped with a quick-connect fitting, rather than a typical drain
valve / pet cock in radiator drain port, must have a quick-connect fitting installed to use Navistar® Coolant
Management Tool (KL5007NAV).
IMPORTANT – Before filling cooling system, make sure coolant supply tank is filled with proper type and
concentration of coolant specified for particular engine being serviced.
IMPORTANT – Use an Extended Life Coolant (pre-diluted) 50/50 or concentrated mixed 50/50) meeting
Navistar® B-1 Type III or IIIA specifications. Do not mix with conventional coolants, hybrid coolants, or
Supplemental Coolant Additives (SCAs). Heavy-duty, extended life coolants meeting all specifications of ASTM
D6210 (current year revision), are allowed provided Navistar® Inc. approved radiator conditioner is used.
2. Set tank valve on Navistar® Coolant Management Tool (KL5007NAV) to CLOSED.
3. Connect tank hose to quick-connect fitting, located on driver side of radiator. Ensure coolant supply tank
contains at least as much coolant as vehicle’s coolant capacity, to prevent pulling air into system.
4. Replace deaeration tank cap with cap adapter (KL5004NAV).
5. Connect vacuum module to cap adapter (KL5004NAV) and verify that blue valve and air valve on vacuum
module are closed.
6. Connect air hose on vacuum module to a source of clean, dry shop air.
IMPORTANT – Clear exhaust hose must be directed to an appropriate location because air and coolant
mist will exit hose.
7. Open air valve on vacuum module.
8. Allow 20 to 25 in Hg (68 to 85 kPa) (green zone) vacuum to be drawn on cooling system.
9. Once vacuum module reaches green zone as indicated by vacuum gauge, set tank valve to FILL.
IMPORTANT – Before system fills to top with coolant, air valve will need to be closed to prevent coolant
from being expelled by vacuum module.
IMPORTANT – Never allow storage tank to completely empty and thereby allow air to enter cooling system.
837
COOLING SYSTEM
Figure 451 Coolant Level

1. Deaeration Tank 2. Low Coolant Sensor
10. Watch coolant level in deaeration tank.
11. When coolant level reaches low coolant sensor on deaeration tank, close air valve on vacuum module
12. Allow existing vacuum to remove most of remaining air from deaeration tank.
13. Open blue vent valve to release vacuum.
• When blue vent valve is opened, hoses expand to their normal size and coolant level goes down in
deaeration tank.
14. Close blue vent valve, and then partially open air valve to slowly draw in coolant until deaeration tank is full.
15. Disconnect shop air from vacuum module.
16. Disconnect vacuum module from cap adapter (KL5004NAV), remove cap adapter (KL5004NAV), and
tightly install deaeration tank pressure cap.
17. Disconnect tank hose from quick-connect radiator drain fitting.
18. Run engine and check coolant freeze point with refractometer, tool number 5025.
19. Ensure coolant level is at top of sight glass or at MAX level on deaeration tank.
20. Close any shutoff valves in heater circuit or in-transit heat circuit.
21. Instruct operator to inspect and adjust coolant level as necessary, prior to daily operation.
838
COOLING SYSTEM
Cummins® ISX Fill

Fill Procedure
IMPORTANT – For Cummins® ISX, do not disconnect Exhaust Gas Recirculation (EGR) valve electrical
connector.
Figure 452 Typical Deaeration Tank Cummins® ISX

1. Deaeration Tank 3. COLD MIN Line
2. COLD MAX Line
IMPORTANT – To function properly, coolant system must be completely filled with coolant and all air must
be expelled.
1. Turn on ignition without starting vehicle (Key On Engine OFF). This opens electrically actuated coolant
flow valve.
2. If so equipped, fully open cab heater coolant shutoff valves and coolant system vent valve.
3. Remove fill cap and pour a 50/50 mixture (75/25 if system has been flushed with water) of proper coolant
concentrate (refer to Lubricant and Sealer Specifications in Maintenance Intervals and Specifications
section of Operator’s Manual) and demineralized or distilled water into deaeration tank. First pour should
reach to top of reservoir fill neck.
839
COOLING SYSTEM
A 50/50 coolant mixture will achieve a -34 °F (-37 °C) freeze point. A 53/47 coolant mixture will achieve
a -40 °F (-40 °C) freeze point.
4. Close vent in upper radiator pipe when air is purged.
5. Open lower radiator pipe vent until coolant comes out, and then close vent.
6. Start engine (Key ON Engine Running), and continue to add enough coolant to keep coolant level between
COLD MIN and COLD MAX levels marked on deaeration tank.
7. Replace deaeration tank cap tightly after adding make-up coolant for two minutes.
8. Run engine at governed speed until engine temperature reaches 185 °F (85 °C).
9. Let engine completely cool. Recheck coolant level and concentration / freeze point with a refractometer
and top off as needed to achieve a coolant level at COLD MAX line when cold.
840
COOLING SYSTEM
Deaeration Tank
Relocate
WARNING
WARNING
To prevent vehicle damage, personal injury or death, use care when removing or
installing cooling system components with hood OPEN. With hood assembly OPEN,
available space to maneuver components such as charge air cooler, HVAC condenser,
external transmission cooler (if applicable) and radiator frame and core assembly is
limited, making handling of components difficult.
CAUTION
To prevent damage to vehicle or HVAC system, when connections are broken, all exposed
openings must be covered to prevent dirt from entering system.
IMPORTANT – Locations of coolant package system components throughout this manual are typical locations.
Some component locations will vary depending on vehicle application.

9. Drain coolant (page 831) if any coolant components are to be removed.
Procedure
2. Disconnect electrical connector (not shown) from low coolant sensor.
3. Remove two deaeration tank bracket bolts from deaeration tank bracket.
841
COOLING SYSTEM
4. Remove four mount nuts from top of deaeration tank.
5. Move deaeration tank with deaeration tank bracket away from cooling package.
842
COOLING SYSTEM
Removal
WARNING
WARNING
CAUTION

9. Drain coolant (page 831) if any coolant components are to be removed.
2. Disconnect electrical connector (not shown) from low coolant sensor.
3. Remove three deaeration hoses from deaeration tank.
4. Remove two coolant hoses from deaeration tank.
5. Remove two deaeration tank bracket bolts from deaeration tank bracket.
843
COOLING SYSTEM
6. Remove four mount nuts from top of deaeration tank.
7. Remove deaeration tank with deaeration tank bracket from cooling package.
8. To remove deaeration tank from deaeration tank bracket, remove four deaeration tank bolts securing
it to deaeration tank bracket.
844
COOLING SYSTEM
Installation
Deaeration tank bolts 17 to 21 lb-ft (23 to 29 N·m)
Deaeration tank mount nuts 17 to 21 lb-ft (23 to 29 N·m)
Deaeration tank bracket bolts 17 to 21 lb-ft (23 to 29 N·m)
1. If a different deaeration tank is being installed than one removed, transfer low coolant sensor to
replacement deaeration tank.
2. Secure deaeration tank to deaeration tank bracket with four deaeration tank bolts. Torque deaeration tank
bolts to 17 to 21 lb-ft (23 to 29 N·m).
3. Position deaeration tank with deaeration tank bracket on cooling package.
4. Install four mount nuts on top of deaeration tank. Torque mount nuts to 17 to 21 lb-ft (23 to 29 N·m).
5. Install two deaeration tank bracket bolts on deaeration tank bracket. Torque deaeration tank bracket
bolts to 17 to 21 lb-ft (23 to 29 N·m).
6. Install three deaeration hoses to deaeration tank if removed.
7. Install two coolant hoses to deaeration tank if removed.
8. Connect electrical connector (not shown) to low coolant sensor.
9. Fill coolant system (page 837) to proper level and leak-test coolant system (page 835) if system was
drained for replacement.
845
COOLING SYSTEM
Power Steering Reservoir

Relocate
WARNING
WARNING
CAUTION

846
COOLING SYSTEM
Procedure
Figure 453 Typical Power Steering Reservoir

1. Mount Bolts 4. Steering Hose Mount Bracket
2. Power Steering Reservoir 5. Mount Bracket Nut
3. Left Radiator Frame
1. Remove mount bracket nut securing power steering hoses on left radiator frame.
2. Remove two (2) bolts from power steering reservoir bracket and move and secure power steering reservoir
out of way.
847
COOLING SYSTEM
Reinstallation
None
1. Move power steering reservoir and bracket to proper location, install two (2) bolts in power steering
reservoir bracket.
2. Install mount bracket nut securing power steering hoses on left radiator frame.
848
COOLING SYSTEM
HVAC Condenser
Relocate
WARNING
WARNING
WARNING
CAUTION

2. Turn front tires full left.
10. If coolant system components are to be removed, drain coolant system (page 831).
849
COOLING SYSTEM
Procedure
CAUTION
To prevent damage to HVAC condenser and HVAC condenser lines when repositioning
HVAC condenser, watch for kinking or severe bending of HVAC condenser lines or hose.
Damage from kinking or severe bending may require replacement of HVAC condenser
lines or hose.
CAUTION
To prevent damage perform this procedure to relocate HVAC condenser out of the way
of cooling package and perform HVAC Condenser - Install procedure to position HVAC
condenser on cooling package.
2. Remove five (5) bolts on upper left quarter fender splash panel. Remove left panel.
3. Remove five (5) bolts on upper right quarter fender splash panel. Remove right panel.
4. Remove nut securing P-clamps and HVAC lines to side frame bracket.
5. Slice an line in passenger recirculation seal adjacent to P-clamp to remove HVAC condenser.
6. Remove fasteners holding HVAC condenser to front charge air cooler. Remove two (2) bolts and washers
on left first. Remove two (2) nuts and washers on right.
7. Carefully remove HVAC condenser by moving HVAC condenser around right side of cooling package.
Rest HVAC condenser (1) on passenger-side front tire (4) and secure HVAC lines to air intake duct.
850
COOLING SYSTEM
Removal
Navistar® N13
WARNING
Refrigerant must be recovered from air conditioning system before any components of
system are removed or replaced. Removing components while pressure is in HVAC
system will cause personal injury or death.
WARNING
Serious injury or blindness will result from refrigerant contacting eyes. Safety goggles or
other adequate eye protection must be worn when working with refrigerant. Temperature
of liquid refrigerant is -20 °F (-29 °C). If refrigerant should contact eyes, Do Not Rub them.
Splash eyes with cold water for at least 15 minutes to gradually get temperature above
freezing point. See a doctor immediately.
WARNING
Wear nonporous gloves (Nitril is recommended material). Should liquid refrigerant come
into contact with skin, remove any contaminated clothing, including shoes; then treat
injury as though skin had been frostbitten or frozen. See a doctor immediately.
WARNING
Federal and state laws require that refrigerant be recovered and recycled to help protect
environment. Always use approved refrigerant recycling equipment when working
with R-134a to prevent accidental discharge. If released into atmosphere, refrigerant
evaporates very quickly and may displace oxygen surrounding work area, especially in
small or enclosed areas. This situation creates hazard of suffocation, brain damage, or
death for anyone in work area. If a leak should occur, avoid breathing refrigerant and
lubricant vapor. Thoroughly ventilate area before continuing with service.
WARNING
To prevent personal injury or death, while International® Servicing System -

RHS980C-NAV is connected to both HVAC system and refrigerant supply cylinder, never
open high side hand valve of RHS980C-NAV while HVAC system is operating. If hot,
high pressure refrigerant is forced through gauge to refrigerant supply cylinder; it could
cause cylinder to rupture.
WARNING
To prevent personal injury or death, during system diagnostic tests, Do Not Turn
either hand valve on International® Servicing System - RHS980C-NAV for any reason.
Equipment can be damaged. When connected to HVAC system, gauges will indicate
system pressures with valves closed (fully Clockwise). These valves are used only
while servicing HVAC system.
851
COOLING SYSTEM
WARNING
When installing and removing any service hose or fitting, a small amount of refrigerant
may escape. Always follow all safety precautions to avoid personal injury or death.
CAUTION
To prevent damage to HVAC condenser and HVAC condenser lines, watch for kinking
or severe bending of HVAC condenser lines or hose. Damage from kinking or severe
bending may require replacement of HVAC condenser lines or hose.
CAUTION
Procedure
2. Remove five (5) bolts on upper left quarter fender splash panel. Remove left panel.
3. Remove five (5) bolts on upper right quarter fender splash panel. Remove right panel.
4. Remove four (4) bolts on panel assembly under passenger door. Remove panel.
5. Remove Freon from HVAC system (page 1317).
6. Remove two (2) nuts securing P-clamps and HVAC lines to side frame bracket.
7. Disconnect HVAC lines to HVAC condenser.
8. Remove fasteners holding HVAC condenser to front charge air cooler. Remove two (2) bolts and washers
on left first. Remove two (2) nuts and washers on right.
9. Carefully remove HVAC condenser and move to safe padded work bench, and covered to prevent damage
to HVAC condenser fins.
852
COOLING SYSTEM
Cummins® ISX
CAUTION
To prevent damage to HVAC condenser and HVAC condenser lines when repositioning
HVAC condenser, watch for kinking or severe bending of HVAC condenser lines or hose.
Damage from kinking or severe bending may require replacement of HVAC condenser
lines or hose.
CAUTION
To prevent damage perform this HVAC Condenser - Remove procedure to reposition

HVAC condenser out of the way of cooling package and perform HVAC Condenser - Install
procedure to position HVAC condenser on cooling package.
CAUTION
Procedure
2. Remove four (4) HVAC P-clamp nuts from frame bracket.
3. Remove eight (8) nuts and washers securing HVAC condenser brackets to cooling package frame.
853
COOLING SYSTEM
Figure 454 Cummins® ISX HVAC Condenser Repositioning

1. HVAC Condenser 3. HVAC Condenser Lines
2. Air Intake Duct 4. Right Front Tire
4. Carefully remove HVAC condenser by moving HVAC condenser around right side of cooling package.
Rest HVAC condenser (1) on passenger-side front tire (4) and secure HVAC lines to air intake duct.
5. If HVAC condenser is to be removed, drain coolant system (page 831).
6. Disconnect HVAC lines and secure to air intake duct.
7. Carefully remove HVAC condenser and move to safe padded work bench, and covered to prevent damage
to HVAC condenser fins.
854
COOLING SYSTEM
Installation
Navistar® N13
HVAC condenser bolts 13 to 14 lb-ft (18 to 19 N·m)
IMPORTANT – Prior to installing HVAC condenser, inspect insulators for damage or wear and replace as
necessary.
Procedure
1. If HVAC condenser was removed, carefully position HVAC condenser on front charge air cooler.
2. Secure HVAC condenser to front charge air cooler with four bolts and washers. Torque bolts to 13 to
14 lb-ft (18 to 19 N·m).
3. Install HVAC lines to HVAC condenser (if removed).
4. Install two nuts to secure P-clamps and HVAC lines to side frame bracket. DO NOT overtighten.
855
COOLING SYSTEM
Cummins® ISX
None
Procedure
1. If HVAC condenser was removed, carefully position HVAC condenser on cooling package by aligning
bracket holes with studs on frame.
2. Install HVAC condenser brackets to cooling package with eight (8) washers and nuts.
3. Install HVAC lines to HVAC condenser (if removed).
4. Install nuts fastening P-clamps and HVAC lines to side frame bracket.
856
COOLING SYSTEM
Fan Shroud
Removal
Navistar® Upper (N13)

WARNING
WARNING
installing cooling system components with hood in OPEN. With hood assembly in
OPEN, available space to maneuver components such as charge air cooler, HVAC
condenser, external transmission cooler (if applicable) and radiator frame and core
assembly is limited, making handling of components difficult.
CAUTION

Procedure
2. Drain coolant system (page 831).
3. Remove deaeration tank (page 843) from cooling package.
857
COOLING SYSTEM
4. Remove upper radiator hoses and pipe.
Figure 455 N13 Fan Ring

1. Fan Shroud Ring 5. Bottom Fan Shroud Ring Bracket
2. Passenger Side Fan Shroud Ring 6. Mount Bolt
Bracket 7. Bold
3. Driver Side Fan Shroud Ring Bracket 8. Mount Bolt and Washer
4. Engine
5. Remove three (3) bolts (7) securing fan shroud ring (1) to fan shroud ring brackets.
6. Remove two (2) mount bolts (6) and passenger side fan shroud ring bracket (2) from engine.
7. Remove two (2) mount bolts, washers, and driver side fan shroud ring bracket (3) from engine.
8. Remove fan shroud ring.
858
COOLING SYSTEM
Figure 456 N13 Upper Fan Shroud

1. Bolt 4. P-clamp
2. Upper Fan Shroud 5. Upper Coolant Hose
3. Fastener 6. Radiator
9. Remove fastener (3) and P-clamp (4) securing upper coolant hose (5) to radiator (6).
10. Remove 12 bolts (1) securing upper fan shroud (2) to radiator.
11. Carefully remove upper fan shroud from radiator.
859
COOLING SYSTEM
Navistar® Lower (N13)

Procedure
3. Disconnect deaeration tank electrical connector from low coolant sensor.
4. Remove four (4) bolts from deaeration tank.
5. Remove four (4) nuts from top of deaeration tank.
6. Reposition deaeration tank and secure out of way.
7. Loosen two (2) spring clamps from radiator inlet hose.
8. Remove radiator inlet hose from radiator inlet connection and engine outlet connection.
9. Remove spring clamps and disconnect charge air cooler hoses from charge air cooler.
Figure 457 Radiator Fan

1. Radiator Fan 2. Fan Drive
860
COOLING SYSTEM
3. Flat Washers (6) 5. Fan Mount Nuts (6)

4. Lock Washers (6)
10. Remove six (6) fan mount nuts (5), lock washers (4), and flat washers (3) securing radiator fan (1)
to fan drive (2).
11. Remove radiator fan from fan drive.
Figure 458 N13 Fan Ring

1. Fan Shroud Ring 5. Bottom Fan Shroud Ring Bracket
2. Passenger Side Fan Shroud Ring 6. Mount Bolt
Bracket 7. Bold
3. Driver Side Fan Shroud Ring Bracket 8. Mount Bolt and Washer
4. Engine
12. Remove bolt (7) securing fan shroud ring (1) to bottom fan shroud ring bracket (5).
13. Remove fan shroud ring from cooling package.
861
COOLING SYSTEM
Figure 459 Typical Power Steering Reservoir

1. Bolt 4. Nut
2. Power Steering Reservoir 5. Driver Side Radiator Frame
3. P-clamp
14. Remove nut (4) securing P-clamp (3) and power steering hose to driver side radiator frame (5).
15. Remove two (2) bolts securing power steering reservoir and secure power steering reservoir out of the way.
862
COOLING SYSTEM
Figure 460 N13 Lower Fan Shroud

1. Lower Fan Shroud 3. Bolt (5)
2. Cooling Package
16. Remove five (5) bolts (3) securing lower fan shroud (1) to cooling package (2).
17. Remove lower fan shroud from cooling package.
863
COOLING SYSTEM
(Cummins® ISX) Two and Three Piece

IMPORTANT – Vehicles equipped with Cummins® ISX engines come with a either a two piece or a three
piece fan shroud. Upper shrouds can be easily removed to provide increased service access to many
cooling system components.
Two piece fan shroud is described below. Three piece shroud is removed and replaced in a similar fashion.
Procedure
3. Remove HVAC Condenser (page 853).
4. Disconnect deaeration tank electrical connector from low coolant sensor.
5. Remove four (4) bolts from deaeration tank.
6. Remove four (4) nuts from top of deaeration tank.
7. Reposition deaeration tank and secure out of way.
8. Loosen two (2) spring clamps from radiator inlet hose.
9. Remove radiator inlet hose from radiator inlet connection and engine outlet connection.
10. Remove spring clamps and disconnect charge air cooler hoses from charge air cooler.
11. Remove bolts securing right side and left side fan shroud ring brackets and remove brackets from
engine and fan shroud ring.
864
COOLING SYSTEM
Figure 461 Two Piece Cummins® ISX Fan Shroud

1. Left Upper Fan Shroud 4. Right Lower Fan Shroud Joint
2. Left Upper Fan Shroud Joint 5. Lower Fan Shroud
3. Right Upper Fan Shroud
865
COOLING SYSTEM
Figure 462 Three Piece Cummins® ISX Fan Shroud

1. Left Fan Shroud Joint 4. Right Fan Shroud Joint
2. Left Upper Fan Shroud 5. Left Fan Shroud
3. Top Fan Shroud Joint 6. Lower Fan Shroud
12. Remove two (2) bolts and washers from top left of upper fan shroud from left side of lower fan shroud.
13. Remove two (2) bolts and washers from lower right of top fan shroud from right side of lower fan shroud.
14. Remove nuts securing upper fan shroud to cooling package.
15. Carefully pull back top of fan shroud ring and remove upper fan shroud by lifting up.
866
COOLING SYSTEM
Figure 463 Typical Cummins® ISX Left Radiator Stay Rod

1. Stay Rod Washer 4. Stay Rod Mount Bolts
2. Stay Rod Mount Nut 5. Stay Rod Mount Bracket
3. Left Stay Rod
16. Remove bolts (4), washers (1), and nuts (2) from Stay Rods (3) and stay rod mount brackets (5), on
both sides of Radiator.
17. Remove bolt securing fan shroud ring to bottom bracket.
18. Remove nuts securing lower fan shroud to cooling package.
19. Remove lower fan shroud from radiator.
867
COOLING SYSTEM
Installation
Navistar® Upper (N13)

Upper fan shroud bolts 35 to 89 lb-in. (4 to 10 N·m)
Driver side fan shroud ring bracket mount bolts 17 to 21 lb-ft (23 to 29 N·m)
Passenger side fan shroud ring bracket mount bolts 17 to 21 lb-ft (23 to 29 N·m)
Procedure
1. Install upper fan shroud on radiator and secure with 12 bolts. Torque bolts to 35 to 89 lb-in. (4 to 10 N·m).
2. Install upper coolant hose on radiator and secure with P-clamp and fastener.
3. Position fan shroud ring on fan shroud.
4. Install driver side fan shroud ring bracket to engine and secure with two (2) mount bolts and washers.
Torque bolts to 17 to 21 lb-ft (23 to 29 N·m).
5. Install passenger side fan shroud ring bracket to engine and secure with two (2) mount bolts and washers.
Torque bolts to 17 to 21 lb-ft (23 to 29 N·m).
6. Secure fan shroud ring to fan shroud ring brackets using three (3) bolts. Torque bolts to 21 to 24 lbf-ft
(29 to 32 N·m).
7. Install upper radiator hose and pipe.
8. Install deaeration tank (page 845) on cooling package.
9. Fill coolant system (page 837) to proper level and leak-test coolant system (page 835).
868
COOLING SYSTEM
Navistar® Lower (N13)

Lower fan shroud bolts 35 to 89 lb-in. (4 to 10 N·m)
Power steering reservoir bolts 41 to 50 lb-ft (56 to 68 N·m)
Radiator fan nuts 24 to 28 lb-ft (33 to 38 N·m)
Charge air cooler hose spring clamps 71 to 80 lb-in. (8 to 9 N·m)
Procedure
1. Install lower fan shroud on cooling package and secure with five (5) bolts. Torque bolts to 35 to 89 lb-in. (4
to 10 N·m).
2. Align power steering reservoir on driver side radiator frame and secure with two (2) bolts. Torque bolts to
41 to 50 lb-ft (56 to 68 N·m).
3. Install P-clamp to driver side radiator frame and secure with nut.
4. Install fan shroud ring and secure to bottom fan shroud ring bracket with bolt. Torque bolt to 21 to 24 lbf-ft
(29 to 32 N·m).
5. Install radiator fan on fan drive.
6. Install six flat washers, lock washers, and mount nuts on radiator fan. Torque nuts to 24 to 28 lb-ft (33
to 38 N·m).
7. Connect two charge air cooler hoses to charge air cooler and secure with spring clamps. Torque clamps to
71 to 80 lb-in. (8 to 9 N·m).
8. Connect radiator inlet hose to radiator and secure with heat shrink clamp.
9. Install deaeration tank.
869
COOLING SYSTEM
Two Piece (Cummins® ISX)

Coolant hose spring clamps 71 to 80 lb-in. (8 to 9 N·m)
Charge air cooler hose spring clamps 71 to 80 lb-in. (8 to 9 N·m)
Procedure
1. Position bottom fan shroud on radiator.
2. Secure lower fan shroud onto cooling package with washers and bolts.
3. Install bolt securing fan shroud ring to bottom bracket.
4. Install nuts, washers, and bolts in stay rods and stay rod mount brackets, on both sides of radiator.
5. Install upper fan shroud onto lower fan shroud making sure that holes and tabs line up.
6. Install upper fan shroud to cooling package with nuts.
7. Install two (2) bolts and washers on lower right side of upper fan shroud into right side of lower fan shroud.
8. Install two (2) bolts and washers on top left of upper fan shroud into top left side of lower fan shroud.
9. Install bolts securing right and left fan shroud ring brackets and install brackets on engine and fan
shroud ring.
10. Install left and right coolant hose onto inlet tubes and tighten spring clamps. Torque clamps to 71 to
80 lb-in. (8 to 9 N·m).
11. Attach charge air cooler hoses to inlet and outlet tubes and tighten spring clamps. Torque clamps to
71 to 80 lb-in. (8 to 9 N·m).
12. Reposition deaeration tank onto cooling package and tighten using four (4) fan bolts to frame.
13. Carefully reposition HVAC condenser by raising HVAC condenser over top of cooling package and then
align bracket holes with studs on frame.
870
COOLING SYSTEM
Fan Belt
Removal
Navistar® N13
WARNING
CAUTION

Procedure
871
COOLING SYSTEM
Figure 464 N13 Fan Belt (Radiator Fan not Shown for Clarity)
1. Fan Belt 3. Tensioner Release Bolt
2. Ban Drive 4. Belt Tensioner
2. Use a breaker bar and socket on tensioner release bolt (3) to relieve tension on fan belt (1) and then
remove fan belt from belt tensioner (4).
3. Remove fan belt from all pulleys.
4. Remove fan belt by working it around radiator fan.
872
COOLING SYSTEM
Cummins® ISX
Procedure
Figure 465 Typical Cummins® ISX Fan Belt

1. Fan Belt 3. Tensioner Release Hole
2. Fan Drive 4. Belt Tensioner
2. Insert breaker bar in belt tensioner release hole (3), relieve tension from fan belt (1), and remove fan
belt from belt tensioner (4).
3. Remove fan belt from all pulleys
4. Remove fan belt by working fan belt around radiator fan.
873
COOLING SYSTEM
Install
Navistar® N13
None
CAUTION
To prevent engine and vehicle damage inspect fan belt for damage and wear prior to
installation. Fan belt should be replaced if any defects are found.
Manual re-tensioning is not needed on belts equipped with a spring-loaded automatic belt tensioner.
Procedure
1. Install fan belt by working fan belt around radiator fan.
2. Position fan belt on all pulleys except belt tensioner.
3. Use breaker bar and socket on tensioner release bolt to apply tension to belt tensioner and then install fan
belt on belt tensioner.
874
COOLING SYSTEM
Cummins® ISX
None
CAUTION
To prevent engine and vehicle damage inspect fan belt for damage and wear prior to
installation. Fan belt should be replaced if any defects are found.
Manual re-tensioning is not needed on belts equipped with a spring-loaded automatic belt tensioner.
Procedure
1. Install fan belt by working fan belt around radiator fan.
2. Position fan belt on all pulleys except belt tensioner.
3. Insert breaker bar in belt tensioner release hole, relieve tension from tensioner, and install fan belt on belt
tensioner.
4. Close and latch the hood.
875
COOLING SYSTEM
Radiator Hose
Removal
Heat Shrink Clamp

Overview
There are two types of radiator clamps that are utilized for installation of radiator hoses, spring clamps and
Gates PowerGrip SB heat shrink clamps. If radiator hoses are equipped with heat shrink clamps, be sure to
follow procedures for removal and installation of heat shrink clamps. If radiator hoses are equipped with spring
clamps, follow procedures for removal and installation of radiator hoses.
Required Tools
• Heavy-duty Heat Shrink Clamp Cutting Tool, ZTSE4479
• Standard Heat Gun
Equipment Condition
WARNING
WARNING
WARNING
CAUTION

876
COOLING SYSTEM

Procedure
Figure 466 Heavy-duty Heat Shrink Clamp Cutting Tool, ZTSE4479
Figure 467 Heat Shrink Clamp - Remove

1. Heavy-duty Heat Shrink Clamp Cutting 2. Heat Shrink Clamp
Tool, ZTSE4479 3. Radiator Side Frame
IMPORTANT – Use following procedure to remove heat shrink clamps at all locations on radiator hoses.
877
COOLING SYSTEM
1. Use heat shrink clamp cutting tool, start on one side of heat shrink clamp and work across heat shrink
clamp to cut entire heat shrink clamp.
2. Move to heat shrink clamp at other end of radiator hose. Cut heat shrink clamp, use heat shrink clamp
cutting tool.
3. Remove radiator hose.
4. Slide heat shrink clamps off radiator hose.
Radiator Hose Assemblies

Equipment Condition
If radiator hoses are mounted using heat shrink clamps, refer to Heat Shrink Clamp - Remove (page 878)
before attempting to remove any radiator hoses.
Procedure
2. Perform Coolant Drain (page 831) procedure,
Upper
3. Loosen constant torque clamp securing upper radiator hose assembly to radiator inlet. Slide constant
torque clamp past fitting bead on radiator hose.
4. Loosen constant torque clamp securing upper radiator hose assembly to engine coolant outlet. Slide
constant torque clamp past fitting bead on radiator hose.
5. Remove upper radiator hose assembly from radiator inlet and engine coolant outlet.
6. Remove two radiator hoses from coolant pipe by loosening constant torque clamps and sliding radiator
hoses off coolant pipe.
Lower
7. Loosen constant torque clamp securing lower radiator hose assembly to radiator outlet. Slide constant
torque clamp past fitting bead on radiator hose.
8. Loosen constant torque clamp securing lower radiator hose assembly to engine coolant inlet. Slide
constant torque clamp past fitting bead on radiator hose.
9. Remove lower radiator hose assembly from radiator outlet and engine coolant inlet.
10. Remove two (2) radiator hoses from coolant pipe by loosening constant torque clamps and sliding radiator
hoses off coolant pipe.
878
COOLING SYSTEM
Installation
Heat Shrink Clamp

None
Figure 468 Heat Shrink Clamp
IMPORTANT – Place heat shrink clamps on radiator hose to be reconnected. Use following procedure to
install heat shrink clamps at all locations on radiator hoses.
879
COOLING SYSTEM
Figure 469 Heat Shrink Clamp - Prepare

1. Clamp Brace 2. Heat Shrink Clamp
1. Remove heat shrink clamp from clamp brace by squeezing heat shrink clamp to collapse heat shrink
clamp, then fold in half and remove heat shrink clamp from clamp brace.
2. Place heat shrink clamps on radiator hose.
3. Position radiator hose on radiator, engine, and fittings as needed.
880
COOLING SYSTEM
4. Slide heat shrink clamp over top of fitting bead. (Heat shrink clamps have a wider sealing surface than
conventional clamps and can be positioned over a wide area, including bead, without causing leaks.)
Figure 471 Cross Section Clamp and Hose

1. Hose 3. Fitting
2. Heat Shrink Clamp
CAUTION
To prevent damage to heat shrink clamps, avoid applying excessive heat, as this can
cause them to melt.
IMPORTANT – Be sure to position clamp so print on heat shrink clamp is facing up and in full view.
5. Use a standard heat gun with setting on high.
6. Do not use open flame to apply heat.
7. Follow heat gun manufacturer's safety procedures.
8. Do not apply heat to one spot too long. Move gun continuously.
9. Move heat gun continuously around as much of heat shrink clamp surface as possible, 1/3 of surface
minimum.
10. Continue until shrinking is complete (printed information on heat shrink clamp will turn gray when enough
heat has been applied).
11. Remove heat source.
12. To be sure a good seal was made, check connections by trying to turn hose. Hose and heat shrink clamp
should not turn when using reasonable torque.
881
COOLING SYSTEM
Radiator Hose Assemblies

Radiator hose constant torque clamps 53 to 62 lb-in. (6 to 7 N·m)
Equipment Condition
If radiator hoses are to be mounted using heat shrink clamps, refer to Heat Shrink Clamp - Install (page
880) before attempting to install any radiator hoses.
Inspect radiator hoses and coolant pipes for damage and wear prior to installation. Any radiator hose or
coolant pipe with defects should be replaced.
Procedure
Lower
1. Position two (2) radiator hoses on coolant pipe and secure with constant torque clamps. Torque constant
torque clamps to 53 to 62 lb-in. (6 to 7 N·m).
2. Position lower radiator hose assembly on radiator outlet and engine coolant inlet with constant torque
clamps. Torque constant torque clamps to 53 to 62 lb-in. (6 to 7 N·m).
Upper
3. Position two (2) radiator hoses on coolant pipe and secure with constant torque clamps. Torque constant
torque clamps to 53 to 62 lbf-in. (6 to 7 N·m).
4. Position upper radiator hose assembly on radiator inlet and engine coolant outlet with constant torque
clamps. Torque constant torque clamps to 53 to 62 lbf-in. (6 to 7 N·m).
5. Inspect all hose connections prior to filling cooling system by trying to turn each hose. Hose and clamp
should not turn when using reasonable torque.
882
COOLING SYSTEM
Charge Air Cooler

Removal
Navistar® N13
WARNING
WARNING
WARNING
CAUTION

883
COOLING SYSTEM
Procedure
1. Reposition HVAC condenser (page 852).
3. Remove top mount nuts and one bottom mount bolt from deaeration tank
4. Secure deaeration tank away from fan shroud.
5. Loosen constant torque clamp on each Charge Air Cooler (CAC) hose.
6. Disconnect CAC hose from each side of CAC.
7. Remove two (2) bolts and washers from top of CAC.
8. Remove two (2) bolts and washers from bottom of CAC.
9. Remove CAC from cooling package.
10. Secure CAC in a safely supported position on floor or workbench.
884
COOLING SYSTEM
Cummins® ISX
IMPORTANT – Cummins® ISX engines have a Charge Air Cooler (CAC) mounted above radiator within
cooling package frame.
Procedure
Figure 472 Typical Cummins® ISX Charge Air Cooler (CAC)

1. CAC Mount Bolts 3. Radiator Upper Frame Plate
2. CAC
2. Remove top mount nuts and one bottom mount bolt from deaeration tank
3. Secure deaeration tank away from fan shroud.
4. Remove button snaps from recirculation seals.
IMPORTANT – Button snaps may not be reusable, new button snaps will be needed for proper installation of
recirculation seals.
885
COOLING SYSTEM
5. Remove top recirculation seal.
6. Remove top mounting bolts from upper fan shroud.
Figure 473 Cummins® ISX Radiator Hoses

1. Left CAC hose 3. Right CAC Hose Assembly
2. Upper Radiator Hose 4. Lower Radiator Hose
7. Loosen two (2) spring clamps and remove right CAC hose assembly (3) with hoses.
8. Loosen two (2) spring clamps and remove left CAC hose (1).
9. Remove all bolts securing top channel plate from cooling package.
10. Remove mount bolts from CAC from cooling package frame.
11. With aid of an assistant, remove CAC from radiator upper frame plate.
12. Sling charge air cooler in a safely supported position on floor or work bench.
886
COOLING SYSTEM
Installation
Navistar® N13
CAC mounting bolts 17 to 21 lb-ft (23 to 29 N·m)
CAC hose constant torque clamps 71 to 80 lb-in. (8 to 9 N·m)
IMPORTANT – Prior to installing Charge Air Cooler (CAC) hoses and pipes, inspect them for dirt or particles.
Remove any dirt or particles.
IMPORTANT – Prior to installing CAC, inspect insulators for damage or wear and replace as necessary.
Procedure
1. Position CAC on cooling package.
2. Secure top and bottom of CAC to cooling package with four (4) bolts and washers. Torque bolts to 17 to
21 lb-ft (23 to 29 N·m).
3. Connect two (2) CAC hoses to sides of CAC and secure with constant torque clamps. Torque constant
torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
4. Install HVAC condenser (page 855).
5. Install deaeration tank (page 845) on top of fan shroud.
6. Install top mount nuts and one bottom mounting bolts into deaeration tank.
887
COOLING SYSTEM
Cummins® ISX
CAC hose spring clamps 71 to 80 lb-in. (8 to 9 N·m)
Procedure
1. With aid of an assistant, install charge air cooler on radiator upper frame plate.
2. Install mount bolts for CAC into cooling package frame.
3. Align top channel plate on CAC.
4. Install all bolts securing top channel plate into cooling package.
5. Install left CAC hose and two (2) spring clamps. Torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
6. Install right CAC hose assembly with hoses and two (2) spring clamps. Torque clamps to 71 to 80 lb-in. (8
to 9 N·m).
7. Install top bolts on upper fan shroud into cooling package.
8. Install top recirculation seal onto frame.
9. Install button snaps into recirculation seal.
10. Install deaeration tank (page 845) on top of fan shroud.
11. Install top mount nuts and one bottom mounting bolts into deaeration tank.
888
COOLING SYSTEM
Radiator Assembly
Removal
Navistar® N13
WARNING
WARNING
WARNING
CAUTION
IMPORTANT – Button snaps may not be reusable; new button snaps will be needed for proper installation of
recirculation seals.

889
COOLING SYSTEM

10. Drain coolant (page 831) system.
11. Relocate HVAC condenser .
• Remove HVAC condenser (page 852).

• Remove HVAC condenser (page 853).
12. Relocate Charge Air Cooler (CAC) .
• Remove Charge Air Cooler (N13) (page 884).

• Remove Charge Air Cooler (Cummins®) (page 885).
13. Relocate power steering reservoir (page 847).
14. Remove (page 843) or relocate (page 841) deaeration tank.
To aid with installation, note locations and positions of passenger side and driver side stay rods, bolts, and nuts.
Required Tools
WARNING
To prevent vehicle damage, personal injury or death, use care when using A-frames with
chain falls.
• Cranes or A-frames with chain falls used to remove radiator assembly.

• Padded floor stand to provide support under hood.
Procedure
1. Remove driver side radiator stay rod from radiator and lower down to rest beside engine.
2. Remove passenger side radiator stay rod from radiator and lower down to rest beside engine.
3. Remove six (6) fan mount nuts, lock washers, and flat washers securing radiator fan to fan drive.
4. Remove radiator fan from fan drive.
5. Disconnect and remove upper and lower radiator hoses (page 878).
6. Disconnect radiator vent line from radiator.
7. Remove or reposition transmission oil cooler assembly.
8. Remove or reposition fuel cooler.
9. Disconnect radiator ground connector.
10. Use A-frame with chain fall, attach to radiator. Take slight strain on chain fall, check radiator attachment.
11. Remove nut and washer from each side of radiator assembly.
12. Remove lower insulators from both brackets and save for installation.
890
COOLING SYSTEM
IMPORTANT – Upper insulators may have remained on brackets or radiator assembly. Make sure upper
insulators are saved for installation.
13. Remove radiator assembly from vehicle.
14. Secure radiator assembly in a safely supported position on floor or workbench.
15. Clean any spilled coolant from floor, engine compartment, and workbench.
16. Remove radiator core from radiator assembly (page 907).
891
COOLING SYSTEM
Cummins® ISX
CAUTION
To prevent damage to vehicle, hood or bumper, due to overextending when tilt assist
cylinder is removed. Prior to disconnecting tilt assist cylinder, position a padded support
under hood.
Procedure
1. Loosen two spring clamps and remove left charge air cooler hose.
2. Tilt hood assembly to a 45° angle and support tilted hood with floor stand to relieve tension on tilt assist
cylinder assembly.
3. Remove three (3) bolts from left torsion bar mount plate.
4. Remove left torsion bar mount plate from left torsion bar.
5. Remove three (3) bolts from right torsion bar mount plate.
6. Remove right torsion bar mount plate from right torsion bar.
7. Slide both left and right torsion bars out of hood hinge rod.
8. Temporarily tie ends of both loose torsion bars forward and out of way until it is time to reinstall torsion
bar mount plates.
9. With aid of an assistant, remove retainer pin and disconnect hood tilt assist cylinder from top channel plate.
10. Gently lower hood onto padded support.
11. Disconnect radiator ground wire.
12. Remove transmission oil cooler.
892
COOLING SYSTEM
Figure 474 Typical Cummins® ISX Left Radiator Components

1. Stay Rod Mount Bracket 6. Transmission Oil Cooler Bracket Bolt
2. Stay Rod Bolt 7. Lower Mount Bushing
3. Left Stay Rod 8. Mount Nut
4. Left Radiator Hose 9. Radiator Inlet Connection
5. Spring Clamp
13. Loosen spring clamp on left radiator hose, slide spring clamp past fitting bead on left radiator hose, and
remove left radiator hose from radiator.
14. Remove bolt, nut, and washer from left radiator stay rod and stay rod mounting bracket.
15. Remove mount nut and lower mount bushing from left radiator mount bolt.
893
COOLING SYSTEM
Figure 475 Typical Right Stay Rod

1. Radiator to Deaeration Tank Hose 3. Stay Rod Bolt
2. Stay Rod Mount Bracket 4. Stay Rod
16. Remove radiator to deaeration tank hose.
17. Remove bolt, nut, and washer from right radiator stay rod and stay rod mount bracket.
894
COOLING SYSTEM
Figure 476 Typical Cummins® ISX Right Radiator Components

1. Right Radiator Hose 5. Lower Mount Bushing
2. Spring Clamp 6. Latch Bracket Bolts
3. Radiator Outlet Connection 7. Bumper Latch Bracket
4. Mount Nut
18. Loosen spring clamp on right radiator hose, slide spring clamp past fitting bead on radiator hose, and
remove right radiator hose from radiator outlet connection.
19. Remove two (2) bolts and right bumper latch bracket from mega bracket.
895
COOLING SYSTEM
Figure 477 Typical Cummins® ISX Radiator Mount Assembly

1. Radiator Assembly 5. Lower Insulators
2. Mega Bracket 6. Upper Insulators
3. Nut 7. Radiator Ground Connector
4. Washer
20. Remove mount nut and lower mount bushing from right radiator mount bolt.
896
COOLING SYSTEM
Figure 478 Typical Cummins® ISX Radiator Assembly

1. Radiator Assembly 3. Radiator Mount Bolts
2. Upper Mount Bushings
21. With aid of an assistant, remove radiator assembly from right side of vehicle.
22. Remove radiator mount bolts and mount bushings from bottom of radiator assembly.
23. Secure radiator assembly in a safely supported position on floor or workbench.
897
COOLING SYSTEM
Installation
Navistar® N13
Radiator assembly nuts 65 to 79 lb-ft (88 to 107 N·m)
Radiator stay rod bolts and nuts 70 to 85 lb-ft (95 to 115 N·m)
IMPORTANT – Prior to installing radiator assembly, inspect insulators for wear or damage and replace as
necessary.
IMPORTANT – Make sure upper insulators are installed on mega brackets before radiator assembly is installed.
Procedure
1. With a lifting device or aid of an assistant, position radiator assembly in vehicle.
2. Install lower insulators on both mega brackets.
3. Install washer and nut to each side of radiator assembly. Torque nuts to 65 to 79 lb-ft (88 to 107 N·m).
NOTE – Place passenger side and driver side stay rods, bolts, and nuts in locations and positions noted
during removal.
4. Install passenger side and driver side stay rods to radiator and secure with two (2) bolts and nuts. Torque
bolts and nuts to 70 to 85 lb-ft (95 to 115 N·m).
5. Remove lifting device from radiator assembly.
6. Connect radiator ground connector.
7. Install radiator hoses (page 882) to radiator assembly.
8. Install CAC (page 887).
9. Install lower fan shroud (page 869).
898
COOLING SYSTEM
Cummins® ISX
Hose spring clamp 71 to 80 lb-in. (8 to 9 N·m)
Procedure
1. With aid of an assistant, install radiator assembly to right side of vehicle.
2. Install radiator mount bolts and mount bushings into radiator assembly.
3. Install mount nut and lower mount bushing into right radiator mount bolt.
4. Install bolts from radiator to frame.
5. Install right radiator hose to radiator outlet connection, slide spring clamp past fitting bead on radiator
hose. Torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
6. Install radiator stay rod bolt, nut, and washer on right radiator stay rod and stay rod mount bracket.
7. Install deaeration tank hose on radiator.
8. Install mount nut and lower mount bushing to left radiator mount bolt.
9. Install radiator stay rod bolt, nut, and washer onto left radiator stay rod and stay rod mount bracket.
10. Install left radiator hose on radiator outlet connection, slide spring clamp past fitting bead on radiator
hose. Torque clamps to 71 to 80 lbf-in. (8 to 9 N·m).
11. Connect radiator ground wire.
12. Install power steering reservoir on left side of radiator and secure with two (2) bolts.
13. Install nut on mount bracket securing power steering hoses on left radiator frame.
14. With aid of an assistant, install CAC on radiator upper frame plate.
15. Install bolts on CAC to cooling package frame.
16. Install top channel plate on CAC and secure with bolts.
17. Install two button snaps on recirculation seals.
18. Install right CAC hose assembly with hoses and secure with two (2) spring clamps. Torque clamps to
71 to 80 lbf-in. (8 to 9 N·m).
19. Install bottom fan shroud on radiator.
20. Install bottom fan shroud with washers and bolts.
21. Install radiator fan on fan drive.
22. Install six washers, lock washers, and nuts on the radiator fan.
899
COOLING SYSTEM
23. Align top fan shroud on bottom fan shroud.
24. Secure top fan shroud with washers and bolts.
25. Install left CAC hose assembly with hoses and secure with two spring clamps. Torque clamps to 71 to
80 lbf-in. (8 to 9 N·m).
26. Install deaeration tank (page 845) on cooling package and secure with nuts and bolt.
27. Slide both torsion bars into hood hinge rod.
28. Install right torsion bar mount plate on right torsion bar.
29. Install three (3) bolts in right torsion bar mount plate.
30. Install left torsion bar mount plate on left torsion bar.
31. Install three (3) bolts in left torsion bar mount plate.
32. With aid of an assistant, install hood tilt assist cylinder and secure retainer pin.
Figure 479 Typical Cummins® ISX HVAC Condenser Mount Bolts

1. Right Upper HVAC Condenser Bolts 2. Left Upper HVAC Condenser Bolts
900
COOLING SYSTEM
3. Right Lower HVAC Condenser Bolts 4. Left Lower HVAC Condenser Bolts
33. Install HVAC condenser on mount bracket and secure with four (4) bolts and washers.
34. Install nut on HVAC condenser line P-clamps securing HVAC lines to the cooling package frame and
tighten.
35. Close and latch the hood.
901
COOLING SYSTEM
Recirculation Seals
Removal
Navistar® N13
WARNING
WARNING

902
COOLING SYSTEM
Procedure
Figure 480 Recirculation Seals

1. Passenger Side Recirculation Seal 8. CAC Hose
2. Fasteners 9. Lower Recirculation Seal
3. Top Recirculation Seal 10. Bolts
4. Driver Side Recirculation Seal 11. Cooling Package
5. Radiator Hose 12. Deaeration Hose
6. Hose Clamp 13. Spring Clamp
7. Constant Torque Clamps
1. Remove 10 fasteners and top recirculation seal from cooling package.
Driver Side Recirculation Seal

2. Drain coolant (page 831).
3. Loosen two (2) constant torque clamps and disconnect driver side CAC hose.
4. Loosen hose clamp on top radiator hose and disconnect radiator hose.
5. Remove eight (8) fasteners and driver side recirculation seal from cooling package.
Passenger Side Recirculation Seal

6. Reposition HVAC condenser (page 852).
7. Loosen two (2) constant torque clamps and disconnect passenger side CAC hose.
8. Loosen hose clamp on radiator hose and disconnect radiator hose.
903
COOLING SYSTEM
9. Remove spring clamp and deaeration hose.
10. Remove eight (8) fasteners and passenger side recirculation seal from cooling package.
Lower Recirculation Seal

11. Remove six (6) bolts securing lower recirculation seal bracket (not shown) to cooling package.
12. Carefully remove lower recirculation seal bracket (not shown) with lower recirculation seal.
13. Remove seven (7) fasteners (not shown) and lower recirculation seal from cooling package.
904
COOLING SYSTEM
Installation
Navistar® N13
Hose spring clamp 71 to 80 lb-in. (8 to 9 N·m)
Procedure
Lower Recirculation Seal
1. Install lower recirculation seal on lower recirculation seal bracket (not shown) with seven (7) fasteners
(not shown).
2. Carefully position lower recirculation seal bracket (not shown) with lower recirculation seal on cooling
package.
3. Fasten lower recirculation seal bracket (not shown) to cooling package with six (6) bolts.
Passenger Side Recirculation Seal

4. Position passenger side recirculation seal on cooling package with eight (8) fasteners.
5. Install deaeration hose with spring clamp. Torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
6. Connect radiator hose and secure with hose clamp. Torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
7. Connect passenger side CAC hose and secure with two (2) constant torque clamps. Torque clamps to
71 to 80 lb-in. (8 to 9 N·m).
8. Install HVAC condenser (page 856).
Driver Side Recirculation Seal

10. Position driver side recirculation seal on cooling package with eight (8) fasteners.
11. Connect radiator hose with hose clamp. Torque clamps to 71 to 80 lbf-in. (8 to 9 N·m).
12. Connect driver side CAC hose with two (2) constant torque clamps. Torque clamps to 71 to 80 lbf-in. (8
to 9 N·m).
14. Install top recirculation seal on cooling package and secure with 10 fasteners.
905
COOLING SYSTEM
Radiator Core
Removal
Navistar® N13
Overview
Radiator core is a replaceable component only. If replacing radiator core, use only authorized International
parts and assemblies.
WARNING
CAUTION
To prevent damage to vehicle, when connections are broken, all exposed openings must
be covered to prevent dirt from entering system.
1. Radiator assembly removed (page 890) from vehicle.
IMPORTANT – Phosphate conditioner is required whenever radiator is replaced. Conditioner coats internal
components for improving cooling characteristics and corrosion resistance.
906
COOLING SYSTEM
Procedure
Figure 481 N13 Radiator Core

1. Fasteners 8. Driver Side Frame Plate
2. Upper Frame Plate 9. Lower Frame Plate
3. Top Recirculation Seal 10. Front Gusset
4. Bolts 11. Nuts
5. Passenger Side Frame Plate 12. Front of Radiator Core
6. Rear Gusset 13. Bracket
7. Radiator Core 14. Rear of Radiator Core
1. Remove four (4) fasteners securing both ends of top recirculation seal.
2. Remove seven (7) bolts securing upper frame plate to radiator core and remove upper frame plate.
3. Remove eight (8) bolts and front gusset.
4. Remove eight (8) bolts and rear gusset.
5. Remove six (6) bolts securing bracket to radiator core and remove bracket.
6. Remove 20 bolts and four (4) nuts from lower frame plate.
7. Remove lower frame plate from radiator core.
8. Transfer transmission oil cooler line fittings, ground wire, and drain valve to new replacement radiator
core (if applicable).
907
COOLING SYSTEM
Cummins® ISX
Procedure
Figure 482 Cummins® ISX Recirculation Seals

1. Recirculation Seal Mount Bolts 4. Radiator Core Mount Nuts
2. Right Recirculation Seal 5. Radiator Core Mount Bolts
3. Left Recirculation Seal
1. Remove two (2) bolts (1) and right recirculation seal (2) from right radiator frame.
2. Remove two (2) bolts and left recirculation seal (3) from left radiator frame.
3. Remove four (4) mount nuts (4) and bolts (5) securing radiator core to right radiator frame and left radiator
frame.
908
COOLING SYSTEM
Figure 483 Typical Cummins® ISX Gusset Plates

1. Radiator Inlet Connection 4. Radiator Outlet Connection
2. Gusset Plat Fan Drives 5. Left Gusset Plate
3. Right Gusset Plate
4. Remove three (3) bolts and left gusset plate (5) from radiator inlet connection (1).
5. Remove three (3) bolts and right gusset plate (3) from radiator outlet connection (4).
909
COOLING SYSTEM
Figure 484 Typical Cummins® ISX Top Frame Plate

1. Upper Frame Plate 3. Radiator Core
2. Top Frame Plate Mount Bolts
6. Remove eight (8) bolts (2) on upper frame plate (1) from both side radiator frames.
910
COOLING SYSTEM
Figure 485 Typical Bottom Frame Plate Cummins® ISX

1. Left Radiator Frame 4. Right Radiator Frame
2. Coolant Hose Fitting 5. Lower Frame Plate
3. Radiator Core 6. Frame Mount Bolts
7. Remove coolant hose fitting (2) from radiator core (3).
8. Remove 10 bolts (6) from lower frame plate (5) and both side radiator frames (1 and 4).
911
COOLING SYSTEM
Figure 486 Typical Cummins® ISX Radiator Core

1. Left Radiator Frame 4. Drain Valve
2. Radiator Core 5. Bottom Frame Plate
3. Right Radiator Frame
9. Support radiator core and spread radiator frame apart. Carefully lift and remove radiator core from bottom
frame.
10. Transfer ground wire and drain valve to new replacement core (if applicable).
912
COOLING SYSTEM
Installation
Navistar® N13
Lower frame plate, rear gusset, and front gusset to 33 to 40 lb-ft (45 to 54 N·m)
radiator core bolts and nuts
Bracket to radiator core bolts 33 to 40 lb-ft (45 to 54 N·m)
Gusset bolts 33 to 40 lb-ft (45 to 54 N·m)
Upper frame plate to radiator core bolts 33 to 40 lb-ft (45 to 54 N·m)
IMPORTANT – Prior to installing radiator core, inspect mounting insulators for damage or wear and replace as
necessary.
Procedure
1. Rest radiator core on a flat surface and install lower frame plate, rear gusset, and front gusset.
2. Install lower frame plate, rear gusset, and front gusset to radiator core with 20 bolts and four (4) nuts.
Torque bolts and nuts to 33 to 40 lb-ft (45 to 54 N·m).
3. Install bracket to radiator core with six (6) bolts. Torque bolts to 33 to 40 lb-ft (45 to 54 N·m).
4. Install eight (8) bolts in rear gusset. Torque bolts to 33 to 40 lb-ft (45 to 54 N·m).
5. Install eight (8) bolts in front gusset. Torque bolts to 33 to 40 lb-ft (45 to 54 N·m).
6. Install upper frame plate to radiator core with seven (7) bolts. Torque bolts to 33 to 40 lb-ft (45 to 54 N·m).
7. Install both ends of upper recirculation seal with four (4) fasteners.
8. Install radiator assembly (page 898) in vehicle.
913
COOLING SYSTEM
Cummins® ISX
Lower frame plate and side radiator frame bolts 33 to 40 lb-ft (45 to 54 N·m)
Coolant hose fitting clamps 71 to 80 lb-in. (8 to 9 N·m)
Radiator core on radiator frame mount nuts and bolt 33 to 40 lb-ft (45 to 54 N·m)
Procedure
1. Support radiator core and spread radiator frame apart. Carefully install radiator core.
2. Install 10 bolts on lower frame plate and both side radiator frames. Torque bolts to 33 to 40 lb-ft (45
to 54 N·m).
3. Install coolant hose fitting on radiator core. Torque clamps to 71 to 80 lb-in. (8 to 9 N·m).
4. Align radiator core on both side radiator frames with four (4) mount nuts and bolts. Torque bolts to 33 to
40 lb-ft (45 to 54 N·m).
5. Install upper frame plate on both side radiator frames and secure with eight (8) bolts. Torque bolts to
33 to 40 lbf-ft (45 to 54 N·m).
6. Install left gusset plate at radiator inlet connection with three (3) bolts. Torque bolts to 33 to 40 lb-ft
(45 to 54 N·m).
7. Install right gusset plate at radiator outlet connection with three (3) bolts. Torque bolts to 33 to 40 lb-ft
(45 to 54 N·m).
8. Install two (2) bolts and left recirculation seal on left side radiator frame. Torque bolts to 33 to 40 lb-ft
(45 to 54 N·m).
9. Install two (2) bolts and right recirculation seal on right side radiator frame. Torque bolts to 33 to 40 lb-ft
(45 to 54 N·m).
10. Install radiator assembly (page 899) into chassis.
914
COOLING SYSTEM
Power Steering Oil Cooler

Removal
Cummins® ISX
WARNING
WARNING
CAUTION

915
COOLING SYSTEM
Procedure
Figure 487 Typical Power Steering Hoses Cummins® ISX

1. Power Steering Oil Cooler 3. Power Steering Reservoir
2. Power Steering Hoses
1. Place suitable container under power steering oil cooler hoses to catch any oil from system.
2. Drain power steering reservoir (3) into container.
3. Disconnect two power steering hoses (2) at power steering oil cooler (1).
4. Cap ends of power steering hoses and power steering oil cooler.
5. Remove two (2) bolts from power steering line P-clamps from front cross member.
6. Remove power steering oil cooler from front of cooling package frame by moving to right side of vehicle.
916
COOLING SYSTEM
Installation
Cummins® ISX
None
Inspect power steering oil cooler prior to installation for damage.
Procedure
1. Install power steering oil cooler on front cross member with P-clamps and two (2) mount bolts.
2. Remove capped ends from power steering hoses and power steering oil cooler.
3. Connect two (2) power steering hoses to power steering oil cooler.
4. Fill power steering reservoir and check for leaks.
917
COOLING SYSTEM
Cooling Ring
Overview
0012WTA Fan Drive Special Effects fan cooling ring with fan shroud effects,
engine mounted
918
COOLING SYSTEM WITH NAVISTAR® A26 ENGINE
5. Cooling System with Navistar® A26 Engine

Cooling Package
Overview
0012WYZ Radiator drain & fill fitting special; to vacuum out or fill the cooling system
from the bottom of radiator, for use with quick-connect radiator drain tool or
shop coolant evacuation-fill system
0012XBC Radiator aluminum; welded, down-flow system, front to back, 1325 sq.in.,
806 sq.in. charge air cooler
0012XBN Radiator aluminum; welded, front-to-back crossflow system, 1084 sq.in.,
Figure 488 Cooling Package

1. Deaeration tank 4. Power steering cooler
2. Radiator 5. Fuel cooler
3. Charge Air Cooler (CAC)
Radiator transfers heat from liquid coolant to outside air. A thermostat controls coolant flow through radiator,
keeping engine operating in optimum temperature zone. Cooling requirements of engine and related
919
components determine radiator requirements. CAC sits in front of radiator and cools air to permissible
temperature for turbocharger.
See-through deaeration tank prevents over- or under-filling and allows for quick, accurate coolant level
inspections. Deaeration tank efficiently collects air bubbles in engine coolant to promote longer water pump
and cylinder liner life. Deaeration tank is fitted with 15-psi rated cap.
920
Cooling System External Cleaning
Special Tools
• Plastic Radiator Cleaning Wand, 4106-NAV
2. Front tires turned full left.
3. Chassis air system within normal operating range of 100 to 120 psi.
4. Key OFF.
6. Ensure cooling package components are dry before cleaning. If not, resulting mud will be
extremely difficult to clean out.
7. Install quick connect coupling with thread sealer in end of wand tool, if not already done.
WARNING
section.
WARNING
To prevent personal injury or death, wear safety glasses with side shields to protect
eyes. Limit compressed air pressure to 30 psi (207 kPa). For air pressures exceeding
this pressure use goggles or face shields.
WARNING
To prevent personal injury or death, hearing protection must be worn when using
cleaning wand.
WARNING
To prevent personal injury or death, when using cleaning wand, avoid breathing vapor
or mist. Do not breathe dust. Use with adequate ventilation and appropriate breathing
apparatus.
WARNING
To prevent property damage, personal injury, or death, never put any part of your body
beneath a raised hood unless hood is fully forward in its range of motion and is fully
settled in over center position.
921
CAUTION
To prevent property or vehicle damage, follow recommended service procedures and

maintain adequate air flow through air exchange devices. Cleaning should be performed
by a qualified technician.
CAUTION
To prevent vehicle damage, do not start cleaning process with water. Resulting mud will
be extremely difficult to clean out.
CAUTION
To prevent vehicle damage, take care that fins of radiator, CAC, and HVAC condenser are
not damaged by striking cleaning wand tip against them.
Air Deflector Removal

1. Remove five bolts and remove passenger-side upper hood splash guard.
2. Disconnect and clip tie wraps for hood position sensor, if equipped.
3. Remove five bolts and remove driver-side upper hood splash guard.
4. Remove two bolts on top of passenger-side radiator air deflector and move up and out of the way.
5. Remove two bolts on top of driver-side radiator air deflector and move up and out of the way.
6. Check ball valve shut.
7. Attach air line to wand quick connect coupling, make sure line air pressure does not exceed
125 psi (kPa).
HVAC Condenser Cleaning

1. Insert cleaning wand in front of condenser.
2. Open ball valve, and sweep right to left across face of condenser starting at top and slowly work
toward bottom.
3. Shut ball valve and remove cleaning wand from front of condenser.
Charge Air Cooler (CAC) Cleaning

1. Insert cleaning wand between radiator and CAC.
2. Open ball valve, and sweep right to left across face of radiator starting at top and slowly work
toward bottom.
3. Shut ball valve and remove cleaning wand from between radiator and CAC.
Front of Radiator Cleaning

1. Insert cleaning wand between radiator and CAC.
2. Open ball valve, and sweep right to left across face of radiator starting at top and slowly work
toward bottom.
3. Shut ball valve and remove cleaning wand from between radiator and CAC.
922
Air Deflector Installation

1. Move passenger-side radiator air deflector over radiator and install two bolts on top of
passenger-side radiator.
2. Move driver-side radiator air deflector over radiator and install two bolts on top of driver-side
radiator.
3. Install driver-side upper hood splash guard and install five bolts holding splash guard to hood.
4. Connect and install tie wraps for hood position sensor, if equipped.
5. Install passenger-side upper hood splash guard and install five bolts holding splash guard to hood.
Follow-On Procedure
None
923
Deaeration Tank Inspection
Overview
Inspect condition of deaeration tank.
Figure 489 Deaeration Tank Location

1. Deaeration tank
Special Tools
• Coolant Cap Pressure Tester, 09-040-01
Specifications
None
4. Key OFF.
924
WARNING
section.
WARNING
WARNING
Setup
Figure 490 Deaeration Tank Setup

1. Deaeration tank 2. Deaeration tank cap
925
2. Refer to above illustration when performing following steps:
Wrap a thick cloth around deaeration tank cap (2).

3. Partially unscrew deaeration tank cap (2) slowly while firmly holding deaeration tank cap (2)
down, then pause to allow pressure to release.
4. When system pressure is released, fully unscrew deaeration tank cap (2) while continuing to hold
deaeration tank cap (2) down. Slowly release downward pressure from deaeration tank cap (2).
Figure 491 Deaeration Tank Inspection

1. Remove deaeration tank cap (2) from deaeration tank (1).
2. Use coolant cap pressure tester, perform pressure test on deaeration tank cap (2).
3. If deaeration tank cap (2) does not maintain proper pressure, replace deaeration tank cap.
926
Figure 492 Deaeration Tank Cap Vacuum Relief Valve Inspection

1. Deaeration tank cap 2. Vacuum relief valve
4. Gently lift vacuum relief valve (2) and verify deaeration cap (1) is not sticking closed.
5. If debris is found, replace deaeration tank cap and retest.
927
Figure 493 Deaeration Tank Thread Inspection

1. Deaeration tank 3. Sealing surface
2. Tank threads
6. Check deaeration tank (1), tank threads (2), and sealing surface (3) for damage to threads or sealing
surface.
7. Perform System Pressure Test .
8. Pressure Test Cooling System .
9. After inspection, if damaged, replace deaeration tank. See Deaeration Tank Removal (page 949) and
Deaeration Tank Installation (page 952).
928
Figure 494 Deaeration Tank Cap Installation

10. Install deaeration tank cap (2) to deaeration tank (1).
Follow-On Procedure
1. If deaeration tank cap fails tests and inspections, replace deaeration tank cap, and retest.
2. If deaeration tank is damaged, replace deaeration tank. See Deaeration Tank Removal (page 949)
and Deaeration Tank Installation (page 952).
929
Check Coolant Condition
Overview
Check freeze protection of coolant in cooling system.
Special Tools
• Coolant and Battery Refractometer, ZTSE4796
Specifications
None
4. Key OFF.
6. Distilled water and liquid to be measured at same temperature.
WARNING
section.
WARNING
WARNING
Setup
1. Allow engine to cool. Coolant and refractometer zero liquid should be close to same temperature.
2. Wrap a thick cloth around pressure cap.
to release.
5. Remove pressure cap.
6. Clean prism completely to prevent residual impurities, which could cause error during measuring.
7. Aim the front end (prism and cover plate end) of refractometer towards a bright light.
930
8. Adjust focusing ring of diopter (knurled ring in front of eye piece) until reticle (scale in mirror
tube) can be seen clearly.
9. Set refractometer to null or zero point.
10. Null or zero point should be adjusted once every 30 minutes.
11. Open cover plate.
12. Place one or two drops of pure distilled water on surface of prism.
13. Close cover plate and press plate lightly.
14. Through eyepiece, observe where shadow line falls.
a. If required, adjust correction screw (just behind prism cover) with screw driver
(supplied in kit) to make shadow line coincide with water line.
b. Refractometer now has a null point, and is ready to begin measuring.
15. Open cover plate of refractometer and use soft cloth (provided in kit) to wipe off water on surface
of prism and cover plate.
Coolant Check Procedure

1. Allow engine to cool. Coolant and refractometer zero liquid should be close to same temperature.
2. Wrap a thick cloth around pressure cap.
to release.
4. When system pressure is released, fully unscrew pressure cap while continuing to hold cap down. Slowly
release downward pressure from cap.
5. Remove pressure cap.
6. Clean prism completely to prevent residual impurities, which could cause error during measuring.
7. Aim front end (prism and cover plate end) of refractometer towards a bright light.
8. Adjust focusing ring of diopter (knurled ring in front of eye piece) until reticle (scale in mirror tube) can
be seen clearly.
WARNING
To prevent personal injury, use plastic dropper provided when measuring liquid.
9. Place one or two drops of cooling system liquid to be measured on surface of prism.
10. Close cover plate and press plate lightly. Scale reading on shadow line is freeze point of cooling system
liquid being sampled.
11. If required, adjust correction screw (just behind prism cover) with screw driver (supplied in kit) to make
shadow line coincide with water line.
931
12. Coolant mixture of 50 / 50 will achieve a -34°F (-37°C) freeze point. Coolant mixture of 53 / 47 will achieve
a -40°F (-40°C) freeze point.
13. Open cover plate of refractometer and use soft cloth (provided in kit) to wipe off water on surface of
prism and cover plate.
Follow-On Procedure
CAUTION
To prevent damage to refractometer, do NOT use water to wash refractometer.
1. After measurements are taken, wipe liquid completely from prism surface and cover plate surface
with soft cloth and let surface dry.
2. Replace refractometer in its case, and store in a dry, clean area.
3. Install pressure cap.
932
Coolant Pressure Check Procedure
Overview
Check holding pressure of cooling system.
Special Tools
• Coolant Management Tool, KL5007NAV
• Source of Clean, Dry Compressed Air (Shop Air Regulated to 30 ± 2 psi), Obtain Locally
Specifications
Minimum Pressure Decay 0 psi (0 kPa)
4. Key OFF.
WARNING
section.
WARNING
WARNING
Setup
1. Connect coolant management tool tank hose from coolant management tank to quick-connect
fitting on bottom of cooling system (if not already done).
2. Install cap adapter from coolant management tool in place of deaeration tank cap (if not already
done).
933
Pressure Check Procedure

1. DRAIN 3. FILL
2. CLOSE
1. Turn tank valve to CLOSE (2).
WARNING
To prevent property damage, personal injury, or death, do not exceed pressure rating on
deaeration tank cap.
934
Figure 496 Cap Adapter and Pressure Module

1. Pressure module 3. Pressure monitor (with relief valve)
2. Air valve 4. Cap adapter
2. Attach pressure module to cap adapter.
3. Connect source of clean, dry compressed air to pressure module.
4. Open air valve (2) on pressure module to pressurize cooling system.
5. Close air valve (2) to lock in pressure.
6. Take note of gauge reading and check for pressure decay.
a. If no decay is detected, continue to next step.

b. If decay is evident, check cooling system for leak(s).
935

1. DRAIN 3. FILL
2. CLOSE
7. Turn tank valve to DRAIN (1) to vent air.
8. Disconnect compressed air and remove pressure module.
Follow-On Procedure
1. If decay is evident and leaks are found, repair leaks.
936
Cooling Package Flush Procedure
Overview
Remove debris from components of cooling package.

1. Cooling package
Special Tools
• Coolant Flushing Adapter Kit, 09-889-02
• Coolant Management System (Kit), KL5007NAV
• Navistar® Engine Diagnostics
• Stop Watch, Obtain Locally
• Hot Water 10 gallon, Obtain Locally
Specifications
None
937
4. Key OFF.
6. Cooling system drained of coolant. See Coolant Drain Procedure (page 945).
Understand what components are affected by a contaminated cooling system. Review following checklist to
ensure all components are accounted for:
System Flush Checklist Y / N?

Engine and Radiator
Cab and Sleeper Heater Core(s)
Diesel Exhaust Fluid (DEF) Heater Hoses
Optional Heaters
Optional Auxiliary Power Unit (APU)
Aftermarket Equipment (non-warranty)
WARNING
section.
WARNING
WARNING
WARNING
To prevent vehicle damage, personal injury, or death, engine system cleaner is a

flammable liquid. It is CRITICAL that 15 gallons of water is mixed with 2.5 gallons of
engine system cleaner (6:1 ratio) prior to usage.
938
WARNING
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be hazard to
human health and environment. Handle all fluids and other contaminated materials (e.g.
filters, rags, and etc.) in accordance with applicable regulations. Recycle or dispose
of engine fluids, filters, and other contaminated materials according to applicable
regulations.
CAUTION
To prevent damage to test equipment, when draining any contaminated fluid from cooling
system components, make sure to drain into a drain pan, NOT Coolant Management
System (CMS).
CAUTION
To prevent damage to equipment, make sure filter sock on Cleaning Management System
(CMS) is removed prior to performing this procedure.
Preparation
1. Inspect coolant hoses for swelling and softening from oil contamination.
2. Fill cooling system with water. See Coolant Fill Procedure (page 999).
3. Start and run engine, and allow coolant temperature to reach 120°F (48.8°C).
4. Drain contaminated fluid from cooling system (page 945). If viscosity of contaminated fluid is too
thick, drain from lower radiator hose.
Coolant Filter Flush, if Applicable

NOTE – Coolant filter is optional equipment.
1. Disconnect batteries, if connected.

2. Remove and discard coolant filter from housing, clean housing.
3. Disconnect inlet and outlet hoses from coolant filter, and using Coolant Flushing Adapter Kit,
09-889-02, install fitting, 09-889-02-07, into hoses.
4. Fill cooling system with 2.5 gallons of engine system cleaner and 15 gallons of water. See Coolant
Fill Procedure (page 999).
5. Connect batteries.
6. Start engine and run for approximately 30 to 45 minutes at 1,200 rpm.
7. Drain contaminated fluid from cooling system (page 945).
Flush Thermostat Housing

2. Remove thermostat housing and thermostats.
3. Install two rubber gaskets and reinstall thermostat housing and radiator hoses.
939
4. Flush section of cooling system with 2.5 gallons of engine system cleaner and 15 gallons of hot
water using Coolant Management System (CMS). Prior to flushing, water and cleaner mixture
should be heated to 115°F (46°C) minimum. If available, fill container with hot water.
5. Remove upper radiator hose and, using Coolant Flushing Adapter Kit, 09-889-02, install both
large coolant flush adapters.
6. Install CMS hoses, 12-353-01A, to adapters and flush for 15 minutes.
7. Reverse CMS hoses and flush for an additional 15 minutes.
8. Check condition of fluid. If fluid has a dark 'blackish' color, empty contents and fill with 15 gallons
of clean hot water and 2.5 gallons of engine system cleaner and repeat flush.
9. Remove CMS hoses and cap both large coolant flush adapters; use caps from EGR flushing kit,
CMS tool kit, or both.
Front Heater Core Flush

2. Loosen front heater core input hose clamp, remove front heater core input hose from front heater
core tube, and install two (2) small coolant flush adapters, 09-889-02-02.
3. Install CMS hose, 12-353-01A, on front heater core input hose flush adapter.
4. Install cap on flush adapter on front heater core tube.
5. Install CMS hose, 12-353-01A, to deaeration tank adapter, 09-889-02-03.
water using CMS for 15 minutes. Prior to flushing, water and cleaner mixture should be heated to
115°F (46°C) minimum. If available, fill container with hot water.
7. Remove CMS hose, 12-353-01A, from front heater core input hose flush adapter and remove
cap from flush adapter on front heater core tube. Install cap on front heater core input hose
flush adapter, and install CMS hose, 12-353-01A, to flush adapter on front heater core tube and
flush for 15 minutes.
8. Remove small flush adapters, hoses, and clamps.
9. Install rubber cap from adapter kit into input heater core tube and install plug into rubber
input hose and secure with clamps.
Rear Heater Core Flush, if Applicable

NOTE – Rear heater core is optional.

2. Loosen rear heater core input hose clamp, remove rear heater core input hose from rear heater
core tube, and install two (2) small coolant flush adapters, 09-889-02-02.
3. Install CMS hose, 12-353-01A, on rear heater core input hose flush adapter.
4. Install cap on flush adapter on rear heater core tube.
940
water using CMS for 15 minutes. Prior to flushing, water and cleaner mixture should be heated to
115°F (46°C) minimum. If available, fill container with hot water.
7. Remove CMS hose, 12-353-01A, from rear heater core input hose flush adapter and remove cap
from flush adapter on rear heater core tube. Install cap on rear heater core input hose flush
adapter, and install CMS hose, 12-353-01A, to flush adapter on rear heater core tube and flush
for 15 minutes.
DEF Heater Core Flush

2. Loosen DEF heater core input hose clamp, remove DEF heater core input hose from DEF heater
core tube, and install two small coolant flush adapters, 09-889-02-02.
3. Install CMS hose, 12-353-01A, on DEF heater core input hose flush adapter.
4. Install cap on flush adapter on DEF heater core tube.
6. Connect Navistar® Engine Diagnostics to vehicle diagnostics connection.
7. Open DEF tank heater valve actuator test; see appropriate Engine Diagnostic manual.
water using Coolant Management System (Kit), KL5007NAV. Prior to flushing, water and cleaner
mixture should be heated to 115°F (46°C) minimum. If available, fill container with hot water.
9. Start CMS pump and press START button in Navistar® Engine Diagnostics to energize DEFTHV
actuator.
10. After 15 minutes, Navistar® Engine Diagnostics will de-energize DEFTHV actuator. Turn off CMS
pump.
11. Remove CMS hose, 12-353-01A, from DEF heater core input hose flush adapter and remove cap
from flush adapter on DEF heater core tube. Install cap on DEF heater core input hose flush
adapter, and install CMS hose, 12-353-01A, to flush adapter on DEF heater core tube.
12. Start CMS pump and press START button in Navistar® Engine Diagnostics to energize DEFTHV
actuator.
pump.
941
Front and Rear, if Applicable, Heater Core Rinse

NOTE – Rear heater core is optional.

2. Fill CMS with 20 gallons of clean water.
3. Loosen hose clamps and remove plugs from heater core return hose.
4. Install small coolant flush adapters in rear heater core return hose and rubber cap over rear
heater core return tube, and tighten hose clamps.
5. Install cap plug on small coolant flush adapter and CMS hose to deaeration adapter and run
into drain or bucket.
6. Connect CMS hose to small coolant flush adapter.
7. Connect and open drain valve on radiator discharge hose running it into a drain or bucket.
8. Run CMS and flush with clean water.
9. When water level gets low, turn off CMS.
10. Close drain valve on radiator discharge hose.
12. Disconnect CMS hose from small coolant flush adapter.
13. Remove and install cap on small coolant flush adapter on rear heater core return hose.
14. Install CMS hose on small coolant flush adapter.
15. Open drain valve on radiator discharge hose.
17. When water level gets low, turn off CMS.
18. Close drain on radiator discharge hose.
19. Disconnect CMS hose from small coolant flush adapter.
20. Remove clamps, hoses, caps, and small flush adapters from engine.
21. Connect heater core return hose to engine hose and tighten hose clamp.
DEF Heater Rinse

3. Loosen hose clamps and remove plugs from DEF heater core return hose.
4. Install small coolant flush adapters in DEF heater core return hose and rubber cap over DEF
heater core return tube, and tighten hose clamps.
5. Install cap plug on small coolant flush adapter and CMS hose to deaeration adapter and run
into drain or bucket.
6. Connect CMS hose to small coolant flush adapter.
7. Connect and open drain valve on radiator discharge hose running it into a drain or bucket.
8. Connect Navistar® Engine Diagnostics to vehicle diagnostics connection.
942
9. Open DEF tank heater valve actuator test, see appropriate Engine Diagnostic manual.
10. Start CMS pump and press START in Navistar® Engine Diagnostics to energize DEFTHV actuator.
CAUTION
To prevent damage to vehicle or test equipment, if water level gets low in CMS,
de-energize actuator and turn off CMS.
pump.
Radiator and Engine Rinse

3. Install radiator discharge hose onto radiator drain coupler.
4. Remove cap from large coolant flush adapter on upper radiator outlet.
5. Connect CMS hose to large coolant flush adapter on upper radiator outlet.
8. When water level gets low turn of CMS.
11. Disconnect CMS hose from large coolant flush adapter on upper radiator outlet.
12. Install cap on large coolant flush adapter on upper radiator outlet.
13. Remove cap from large coolant flush adapter on thermostat housing hose.
14. Connect CMS hose to large coolant flush adapter on thermostat housing hose.
17. When water level gets low turn off CMS.
19. Disconnect CMS hose from large coolant flush adapter on thermostat housing hose.
20. Loosen V-clamp and remove large coolant flush adapter from thermostat housing hose.
21. Remove two clamps, large coolant flush adapter and hose from upper radiator outlet.
22. Connect thermostat housing hose to upper radiator outlet with V-clamp or new heat shrink clamp
as required.
Final Rinse
1. Connect batteries, if disconnected.
2. Ensure CMS is clean.
943
3. Fill CMS with clean water.
4. Ensure all hoses are connected and fill cooling system with water (page 999).
5. Start engine and run for 30 to 45 minutes at 1200 rpm.
6. Shut down engine and drain cooling system (page 945).
CAUTION
To prevent damage to vehicle, if there are still dark traces of oil left in cooling system,
replace all rubber hoses for cooling system as they may be soaked with oil and repeat
flushing procedures as necessary.
7. Perform Steps 2 through 6 three times or until clear fluid comes out.
8. Disconnect batteries.
9. Remove thermostat housing and remove two rubber gaskets.
10. Replace thermostats and seals using new parts and install thermostat housing.
11. Re-connect all loose hoses and connections.
Follow-On Procedure
Follow-On Procedure
1. Ensure all hoses are connected and fill cooling system with water (page 999).
2. Connect batteries (page 171), if disconnected.
944
Coolant Drain Procedure
Overview
Drain coolant for coolant replacement or cooling system component removal.
Special Tools
• CXI CK-500 Retrofit Kit (optional)
Specifications
None
4. Key OFF.
WARNING
Failure to observe the following warning may cause property damage, personal injury, or
death. Park the vehicle on a flat level surface. Make sure the engine ignition is off , and
the transmission is in neutral or in the park if the vehicle is equipped with an automatic
transmission. Set the parking brake, chock the wheels, and disconnect the batteries at
the negative terminal before performing any service procedures on the engine or vehicle.
WARNING
Failure to observe the following warning may cause property damage, personal injury, or
death. Use care when removing or installing cooling system components with the hood
in the open position. With the hood assembly in the open position, the available space
to maneuver components such as the charge air cooler, air conditioning condenser,
external transmission cooler (if applicable), and radiator frame and core assembly is
limited, making handling of the components difficult.
WARNING
Failure to observe the following warning may cause property damage, personal injury,
or death. To avoid personal injury or death from hot coolant or steam, use only the
following procedure to remove the pressure cap from the radiator or expansion tank.
Allow the engine to cool first. Wrap a thick, heavy cloth around the cap. Push down,
loosen cap slowly to its first notch position; then pause a moment to allow pressure to
release through the overflow tube. After the pressure has been released, the pressure
cap may be removed.
945
Coolant Drain Procedure
Figure 499 Quick-Connect Fittings

1. Male quick-connect fitting (3609890C1) 2. Female quick-connect fitting
(2594109C1)
The following tools are available through the parts group:
• The male quick-connect fitting (1) comes as standard equipment on vehicles with feature code 012WYZ,
and is located in place of the traditional radiator drain valve. This fitting has 1/4-in male national pipe
thread (NPT) and can replace most existing 1/4-in NPT drain valves.
• The female quick-connect fitting (2) has 1/4-in female NPT and can be easily connected to your coolant fill
/ extraction machine or a drain hose.
You can obtain either of these optional quick-connect fittings through your direct ship parts coordinator. Prices
and availability can be obtained directly through the parts distribution centers.
If you do not have a coolant fill / extraction machine, the CXI 2V-700 Coolant Extractor / Injector has been
evaluated in our engineering shops with favorable results and can be purchased directly from the manufacturer.
The benefits of using such a device include the following:
• Little or no mess
• The ability to change sensors without draining the coolant
946
• Quick drain / fill times
Figure 500 CXI CK-500 Retrofit Kit
NOTE – The retrofit kit shown is available from Dunn and Bybee Tool. Visit Dunn and Bybee Tool’s
website (http://www.db-toolco.com/CXI/CXI.htm) for further information, or contact Charles Sams at
931-738-3611.
Use the CXI CK-500 retrofit kit to convert conventional drain valves to the male quick-connect fitting:
1. Insert one of the rubber radiator cap plugs into the deaeration tank.
2. Use the CXI 2V-700 Coolant Extractor / Injector to create a vacuum on the vehicle’s cooling system.
3. Unscrew the drain valve and replace with the male quick-connect fitting.
Retrofit Kit Contents:
• Male-to-female adaptor hose (1)

• Radiator cap plugs (3)
• ISO16028 to Volvo-style adaptor (1)
• Plastic case (1)
947
Figure 501 Coolant Fill / Extraction Machine Connection

1. Radiator 4. Female quick-connect fitting
2. Male quick-connect fitting
3. Coolant fill / extraction machine hose or
drain hose
1. Connect female quick-connect fitting (4) to coolant fill / extraction machine hose or drain hose (3).
2. Locate male quick-connect fitting (2) at lower passenger-side of radiator (1).
3. Connect female quick-connect fitting (4) to male quick-connect fitting (2).
4. Drain coolant.
5. Disconnect female quick-connect fitting (4) from male quick-connect fitting (2).
Follow-On Procedure
1. Perform Coolant Pressure Check Procedure (page 933).
2. Perform other cooling system maintenance as required.
948
Deaeration Tank
Removal
Overview
Remove deaeration tank for repair or replacement.

1. Deaeration tank
Special Tools
None
4. Key OFF.
949
7. Hood open.
8. Cooling system drained. See Coolant Drain Procedure .
WARNING
section.
WARNING
WARNING
Procedure
Cooling package is equipped with three hoses and electrical connector attached to the deaeration tank.
950
Figure 503 Deaeration Tank

1. Deaeration hose (3) 4. Side mount bolt (3)
2. Deaeration tank 5. Electrical connector
3. Top mount nut (4)
1. Disconnect electrical connector (5) from low coolant level sensor in deaeration tank (2).
2. Remove three deaeration hoses (1) from deaeration tank (2).
3. Remove three side mount bolts (4) from side mount of deaeration tank (2).
4. Remove four top mount nuts (3) from top of deaeration tank (2).
5. Remove deaeration tank (2) from cooling package.
Follow-On Procedure
1. If replacement is needed, install low coolant level sensor in new deaeration tank by tightening
low coolant sensor hand tight and then turning two full turns.
2. Install deaeration tank. See Deaeration Tank Installation (page 952).
951
Installation
Overview
Install deaeration tank after repair or replacement.

1. Deaeration tank
Special Tools
None
Deaeration tank mounting nuts and bolts 21.4 - 23.6 lb-ft (29 - 32 N•m)
1. Deaeration tank removed. See Deaeration Tank Removal (page 949).
WARNING
section.
952
WARNING
WARNING
Procedure
Cooling package is equipped with three hoses and electrical connector attached to the deaeration tank.

1. Deaeration hose (3) 4. Side mount bolt (3)
2. Deaeration tank 5. Electrical connector
3. Top mount nut (4)
1. Install deaeration tank (2) on cooling package.
953
2. Install four top mount nuts (3) at top of deaeration tank (2).
3. Install three side mount bolts (4) at side mount of deaeration tank (2).
4. Torque four top mount nuts (3) and three side mount bolts (4) to 21.4 - 23.6 lb-ft (29 - 32 N•m).
5. Install three deaeration hoses (1) on deaeration tank (2).
6. Connect electrical connector (5) to low coolant level sensor in deaeration tank (2).
Follow-On Procedure
1. Fill cooling system. See Coolant Fill Procedure (page 999).
2. Connect batteries (page 171).
4. Remove wheel chocks.
954
Power Steering Reservoir
Relocation
Overview
Relocate power steering pump for cooling package removal.
Special Tools
None
4. Key OFF.
6. Batteries disconnected.
WARNING
section.
WARNING
WARNING
955
Procedure
Figure 506 Power Steering Reservoir

1. Power steering reservoir mount 3. Mounting bolt (2)
2. Power steering reservoir
1. Remove two mounting bolts (3) from power steering reservoir (2).
2. Relocate power steering reservoir (2) back, away from power steering reservoir mount (1), and up beside
engine out of way of cooling package. Secure in place to prevent damage.
Follow-On Procedure
1. Continue cooling package removal.
956
Reinstallation
Overview
Reinstall power steering pump after cooling package installation.
Special Tools
None
Mounting bolts 71.5 - 79.7 lb-ft (97 - 108 N·m)
4. Key OFF.
7. Cooling package installed. See Cooling Package Installation (page 975).
WARNING
section.
WARNING
WARNING
957
Procedure
Figure 507 Power Steering Reservoir

1. Power steering reservoir mount 3. Mounting bolt (2)
2. Power steering reservoir
1. Position power steering reservoir (2) on power steering reservoir mount (1) and secure with two mounting
bolts (3). Torque two bolts to 71.5 - 79.7 lb-ft (97 - 108 N·m).
Follow-On Procedure
1. Top off power steering reservoir with fluid.
2. When available, start engine and cycle steering wheel to bleed system.
958
Radiator Hose
Removal
Overview
Remove radiator hoses for replacement.
Figure 508 Radiator Hose Location

1. Heat shrink clamp (4) 3. Lower radiator hose
2. Upper radiator hose
Special Tools
• Hose Clamp Cutting Tool, ZTSE4479
4. Key OFF.
959

7. Cooling system drained. See Coolant Drain Procedure (page 945).
8. Container under radiator hoses to catch coolant from system.
9. Hood raised.
WARNING
section.
WARNING
WARNING
WARNING
To prevent property damage, personal injury, or death, if vehicle must be raised, do not
work under vehicle supported only by jacks. Jacks can slip or fall over.
960
Removal Procedure
Figure 509 Heat Shrink Clamp Removal

1. Heat shrink clamp 3. Radiator hose
2. Example cut line
1. Use hose clamp cutting tool, ZTSE4479, to cut through each heat shrink clamp (1) at each end of radiator
hose (3) from one edge of clamp to the other. See example cut line (2).
2. Remove each cut heat shrink clamp (1) from radiator hose (3), and remove radiator hose (3).
3. Repeat Steps 1 and 2 for heat shrink clamps on other radiator hose.
Follow-On Procedure
1. Install radiator hoses. See Radiator Hose Installation (page 962).
961
Installation
Overview
Install radiator hoses after replacement.
Figure 510 Radiator Hoses

1. Heat shrink clamp (4) 3. Lower radiator hose
Special Tools
• Heat Gun (obtain locally)
None
962
4. Key OFF.
7. Hood raised.
8. Radiator hoses removed. See Radiator Hose Removal (page 959).
WARNING
section.
WARNING
WARNING
WARNING
NOTE – Place heat shrink clamps on the radiator hose to be reconnected. Use the following procedure
to install heat shrink clamps at all locations on the radiator hoses.
963
Figure 511 Prepare Heat Shrink Clamps

1. Heat shrink clamp 2. Brace
1. Remove heat shrink clamps (1) from braces (2) as follows:

a. Squeeze heat shrink clamp (1) to collapse brace (2).
b. Fold brace (2) in half and remove heat shrink clamp (1) from brace (2).
964
Figure 512 Install Radiator Hose with Heat Shrink Clamps

1. Heat shrink clamps (2) 3. Engine fitting
2. Radiator hose 4. Radiator fitting
2. Place two heat shrink clamps (1) on radiator hose (2).
3. Install radiator hose (2) on engine fitting (3) and radiator fitting (4).
965
Figure 513 Cross Section Clamp and Hose

1. Radiator / engine fitting 3. Radiator hose
2. Heat shrink clamp
IMPORTANT – Position heat shrink clamp so print is facing up and in full view.
4. Slide each heat shrink clamp (2) along radiator hose (3) so that each heat shrink clamp (2) is centered
over bead in radiator / engine fitting (1).
NOTE – Heat shrink clamps have a wider sealing surface than conventional clamps and can be
positioned over a wide area, including the bead, without causing leaks.
CAUTION
To prevent damage to heat shrink clamps be aware that, although heat shrink clamps are
very durable, too much heat can melt them. Do not use open flame to apply heat. Do
not apply heat to one spot too long. Move gun continuously when applying heat. Follow
heat gun manufacturer's safety procedures.
5. Apply heat to each heat shrink clamp (2) as follows:
966
a. With standard heat gun at high setting, move heat gun around as much of the heat shrink
clamp surface as possible, 1/3 of the surface at a minimum.
b. Remove heat source when shrinking is complete and printed information on heat shrink
clamp turns gray.
6. Check connections by trying to turn each end of radiator hose (3). Radiator hose (3) and heat shrink
clamps (2) should not turn when using reasonable force.
7. Repeat Steps 1 through 6 to install the other radiator hose.
Follow-On Procedure
967
Cooling Package
Removal
Overview
Remove cooling package for repair or replacement.
WARNING
removal of cooling package.

1. Cooling package
Special Tools
• A-frame with chain fall or engine hoist, obtained locally.
968
4. Key OFF.
7. A/C system evacuated.
8. Cooling system drained. See Coolant Drain Procedure (page 945).
9. Hood and bumper removed. See Hood Grille Removal , Tilting Front End Removal (page 784),
and Front Bumper Removal .
10. Power steering reservoir relocated. See Power Steering Reservoir Relocation (page 955).
11. Relocate HVAC condenser. See HVAC Condenser Relocation (page 1010).
WARNING
section.
WARNING
WARNING
969
Removal Procedure
Figure 515 Driver-Side Upper Connections

1. Radiator 5. Clamp
2. Heat shrink clamp 6. CAC
4. Driver-side Charge Air Cooler (CAC)
pipe
1. Remove heat shrink clamp (2) and disconnect upper radiator hose (3) from radiator (1). See Radiator
Hose Removal (page 959) to remove heat shrink clamp (2).
2. Remove clamp (5) and disconnect driver-side CAC pipe (4) from CAC (6).
970
Figure 516 Driver-Side Lower Connections

1. Power steering cooler 4. Fuel cooler hose (2)
2. Clamp (2) 5. Fuel cooler
3. Power steering cooler hose (2)
3. Remove two clamps (2) and disconnect two power steering cooler hoses (3) from power steering cooler (1).
4. Disconnect two fuel cooler hoses (4) from fuel cooler (5).
971
Figure 517 Passenger-Side Connections

1. Electrical cable 6. Clamp
2. Upper deaeration tank hose 7. Passenger-side CAC pipe
3. Clamp 8. Clamp
4. Deaeration tank 9. Lower deaeration tank hose
5. CAC
5. Disconnect electrical cable (1) from deaeration tank (4).
6. Expand clamp (3) and disconnect upper deaeration tank hose (2) from deaeration tank (4).
7. Remove clamp (6) and disconnect passenger-side CAC pipe (7) from CAC (5).
8. Expand clamp (8) and disconnect lower deaeration tank hose (9) from deaeration tank (4).
972
Figure 518 Bottom Connections

1. Transmission cooler hose (2) 3. Heat shrink clamp
2. Lower radiator hose 4. Radiator
9. Disconnect two transmission cooler hoses (1) from radiator (4).
10. Remove heat shrink clamp (3) and disconnect lower radiator hose (2) from radiator (4). See Radiator Hose
Removal (page 959) to remove heat shrink clamp (3).
973
Figure 519 Mounting Hardware

1. Radiator support 3. Lower mounting nut
2. Side mounting bolt, nut, and washer
11. Connect A-frame with chain fall or engine hoist securely to cooling package.
12. Remove side mounting bolt, nut, and washer (2), and pivot radiator support (1) away from radiator.
13. Remove lower mounting nut (3).
14. Repeat Steps 12 and 13 on other side of vehicle.
15. Use A-frame with chain fall or engine hoist to lift and remove cooling package.
16. Secure cooling package in a safely-supported position on shop floor.
Follow-On Procedure
1. Install cooling package. See Cooling Package Installation (page 975).
974
Installation
Overview
Install cooling package after repair or replacement.
WARNING
installation of cooling package.

1. Cooling package
Special Tools
• A-frame with chain fall or engine hoist, obtained locally.
Charge Air Cooler (CAC) pipe clamps 7.5 - 9.4 lb-ft (10.2 - 12.8 N·m)
Power steering cooler hose clamps 7.5 - 9.4 lb-ft (10.2 - 12.8 N·m)
Radiator mounting nuts and bolts 64.9 - 79.6 lb-ft (88 - 108 N·m)
Transmission cooler hose fittings 142.3 - 174.8 lb-ft (193 - 237 N·m)
975
1. Cooling package removed. See Cooling Package Removal (page 968).
WARNING
section.
WARNING
WARNING
Figure 521 Mounting Hardware

1. Radiator support 3. Lower mounting nut
2. Side mounting bolt, nut, and washer
976
1. Use A-frame with chain fall or engine hoist to lift and install cooling package.
2. Install lower mounting nut (3).
3. Pivot radiator support (1) toward radiator, and install side mounting bolt, nut, and washer (2).
4. Repeat Steps 2 and 3 on other side of vehicle.
5. Torque two lower mounting nuts (3) and two side mounting bolts and nuts (2) to 64.9 - 79.6 lb-ft (88 -
108 N·m).
Figure 522 Bottom Connections

1. Transmission cooler hose (2) 3. Heat shrink clamp
2. Lower radiator hose 4. Radiator
6. Connect two transmission cooler hoses (1) to radiator (4). Tighten fittings to 142.3 - 174.8 lb-ft (193 -
237 N·m).
977
7. Install lower radiator hose (2) to radiator (4) with heat shrink clamp (3). See Radiator Hose Installation
(page 962) to install heat shrink clamp (3).
Figure 523 Passenger-Side Connections

1. Electrical cable 6. Clamp
2. Upper deaeration tank hose 7. Passenger-side CAC pipe
3. Clamp 8. Clamp
4. Deaeration tank 9. Lower deaeration tank hose
5. CAC
8. Connect lower deaeration tank hose (9) to deaeration tank (4), and secure with clamp (8).
9. Connect passenger-side CAC pipe (7) to CAC (5), and secure with clamp (6). Torque clamp to 7.5 - 9.4
lb-ft (10.2 - 12.8 N·m).
10. Connect upper deaeration tank hose (2) to deaeration tank (4), and secure with clamp (3).
11. Connect electrical cable (1) to deaeration tank (4).
978
Figure 524 Driver-Side Lower Connections

1. Power steering cooler 4. Fuel cooler hose (2)
2. Clamp (2) 5. Fuel cooler
3. Power steering cooler hose (2)
12. Connect two fuel cooler hoses (4) to fuel cooler (5).
13. Connect two power steering cooler hoses (3) to power steering cooler (1), and secure with two clamps (2).
Torque clamps to 7.5 - 9.4 lb-ft (10.2 - 12.8 N·m).
979
Figure 525 Driver-Side Upper Connections

1. Radiator 4. Driver-side CAC pipe
2. Heat shrink clamp 5. Clamp
3. Upper radiator hose 6. CAC
14. Install upper radiator hose (3) to radiator (1) with heat shrink clamp (2). See Radiator Hose Installation
(page 962) to install heat shrink clamp (2).
15. Connect driver-side CAC pipe (4) to CAC (6), and secure with clamp (5). Torque clamp to 7.5 - 9.4
lb-ft (10.2 - 12.8 N·m).
Follow-On Procedure
1. Reinstall HVAC condenser. See HVAC Condenser Reinstallation (page 1015).
2. Reinstall power steering reservoir. See Power Steering Reservoir Reinstallation (page 957).
3. Install hood and bumper. See Front Bumper Installation , Tilting Front End Installation (page
786), and Hood Grille Installation .
5. Charge A/C system.
980
981
Radiator
Removal
Overview
Remove radiator for repair or replacement.
Figure 526 Radiator

1. Radiator
Special Tools
None
1. Cooling package removed. See Cooling Package Removal (page 968).
WARNING
section.
982
WARNING
WARNING
Removal Procedure
Figure 527 Air Dam Removal

1. Passenger-side air dam mounting bolt 5. Driver-side air dam
(3) 6. Lower air dam mounting bolt (3)
2. Upper air dam 7. Lower air dam
3. Upper air dam mounting bolt (4) 8. Passenger-side air dam
4. Driver-side air dam mounting bolt (4)
1. Remove four upper air dam mounting bolts (3), and remove upper air dam (2).
983
2. Remove four driver-side air dam mounting bolts (4), and remove driver side air dam (5).
3. Remove three passenger-side air dam mounting bolts (1), and remove passenger-side air dam (8).
4. Remove three lower air dam mounting bolts (6), and remove lower air dam (7).
Figure 528 Deaeration Tank Removal

1. Deaeration tank 5. Deaeration tank hose
2. Upper mounting nut (4) 6. Side mounting bolt (3)
3. Radiator fitting 7. Hose mounting screw
4. Radiator frame
5. Remove hose mounting screw (7).
6. Disconnect deaeration tank hose (5) from radiator fitting (3).
7. Remove three side mounting bolts (6) and four upper mounting nuts (2).
8. Remove deaeration tank (1) from radiator frame (4).
984
Figure 529 Radiator Shroud Removal

1. Mounting bolt (8) 3. Radiator frame
2. Radiator shroud
9. Remove eight mounting bolts (1), and remove radiator shroud (2) from radiator frame (3).
985
Figure 530 Radiator Frame Support and Gusset Plate Removal

1. Support mounting bolt (4) 5. Lower gusset plate mounting bolt (3)
2. Upper gusset plate mounting bolt (3) 6. Lower gusset plate
3. Upper gusset plate 7. Frame support
4. Radiator frame
10. Remove three upper gusset plate mounting bolts (2), and remove upper gusset plate (3) from radiator
frame (4).
11. Remove three lower gusset plate mounting bolts (5), and remove lower gusset plate (6) from radiator
frame (4).
12. Remove four support mounting bolts (1), and remove frame support (7) from radiator frame (4).
986
Figure 531 CAC Removal

1. Upper passenger-side mounting bolt, 4. Lower driver-side mounting bolt
collar, and bushing 5. CAC
2. Radiator frame 6. Lower passenger-side mounting
3. Upper driver-side mounting nut bushing
13. Remove upper passenger-side mounting bolt, collar, and bushing (1).
14. Remove lower driver-side mounting bolt (4).
15. Remove upper driver-side mounting nut (3).
16. Lean CAC (5) forward slightly, lift CAC (5) off of lower passenger-side mounting bushing (6), and remove
CAC (5) from radiator frame (2).
987
Figure 532 Power Steering Cooler and Fuel Cooler Removal

1. Power steering cooler mounting bushing 4. Fuel cooler mounting nut (2)
(2) 5. Radiator frame
2. Power steering cooler 6. Fuel cooler
3. Power steering cooler mounting bolt 7. Fuel cooler mounting bushing (2)
and nut
17. Remove power steering cooler mounting bolt and nut (3).
18. Slide power steering cooler (2) away from power steering cooler mounting bushings (1), and remove
power steering cooler (2) from radiator frame (5).
19. Remove two fuel cooler mounting nuts (4).
20. Slide fuel cooler (6) away from fuel cooler mounting bushings (7), and remove fuel cooler (6) from radiator
frame (5).
988
Figure 533 Upper Radiator Frame Rail and Radiator Removal

1. Upper radiator frame rail 4. Radiator
2. Passenger-side mounting bolt (4) 5. Driver-side mounting bolt (4)
3. Radiator frame
21. Remove four driver-side mounting bolts (5).
22. Remove four passenger-side mounting bolts (2).
23. Remove upper radiator frame rail (1) from radiator frame (3).
24. Slide radiator (4) upwards and out of radiator frame (3).
Follow-On Procedure
1. Transfer two radiator mounting bushings to new radiator.
2. Install radiator. See Radiator Installation (page 990).
989
Installation
Overview
Install radiator after repair or replacement.
Figure 534 Radiator Location

1. Radiator
Special Tools
None
990
Air dam mounting bolts 21.4 - 23.6 lb-ft (29 - 32 N·m)
Deaeration tank hose mounting screw 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m)
Deaeration tank mounting bolts and nuts 21.4 - 23.6 lb-ft (29 - 32 N·m)
Driver-side Charge Air Cooler (CAC) mounting bolt 38.4 - 42.8 lb-ft (52 - 58 N·m)
and nut
Fuel cooler mounting nuts 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m)
Passenger-side CAC mounting bolt 38.4 - 42.8 lb-ft (52 - 58 N·m)
Power steering cooler mounting bolt and nut 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m)
Radiator frame gusset plate mounting bolts 38.4 - 42.8 lb-ft (52 - 58 N·m)
Radiator frame support mounting bolts 38.4 - 42.8 lb-ft (52 - 58 N·m)
Radiator shroud mounting bolts 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m)
Upper radiator frame rail mounting bolts 38.4 - 42.8 lb-ft (52 - 58 N·m)
1. Radiator removed. See Radiator Removal (page 982).
WARNING
section.
WARNING
WARNING
991
Figure 535 Radiator and Upper Radiator Frame Rail Installation

1. Upper radiator frame rail 4. Radiator
2. Passenger-side mounting bolt (4) 5. Driver-side mounting bolt (4)
3. Radiator frame
1. Slide radiator (4) into radiator frame (3).
2. Install upper radiator frame rail (1) on radiator frame (3) with eight mounting bolts (2, 5). Torque bolts to
38.4 - 42.8 lb-ft (52 - 58 N·m).
992
Figure 536 Power Steering Cooler and Fuel Cooler Installation

1. Power steering cooler mounting bushing 4. Fuel cooler mounting nut (2)
(2) 5. Radiator frame
2. Power steering cooler 6. Fuel cooler
3. Power steering cooler mounting bolt 7. Fuel cooler mounting bushing (2)
and nut
3. Slide fuel cooler (6) into two fuel cooler mounting bushings (7), and secure with two fuel cooler mounting
nuts (4). Torque nuts to 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m).
4. Slide power steering cooler (2) into two power steering cooler mounting bushings (1), and secure with
power steering cooler mounting bolt and nut. Torque bolt and nut to 9.1 - 9.8 lb-ft (12.3 - 13.3 N·m).
993
Figure 537 CAC Installation

1. Upper passenger-side mounting bolt, 4. Lower driver-side mounting bolt
collar, and bushing 5. CAC
2. Radiator frame 6. Lower passenger-side mounting
3. Upper driver-side mounting nut bushing
5. Lower CAC (5) into lower passenger side mounting bushing (6).
6. Secure CAC (5) to radiator frame (2) with upper driver-side mounting nut (3), lower driver-side mounting
bolt (4), and upper passenger-side mounting bolt, collar, and bushing (1). Torque bolts and nut to 38.4 -
42.8 lb-ft (52 - 58 N·m).
994
Figure 538 Radiator Frame Support and Gusset Plate Installation

1. Support mounting bolt (4) 5. Lower gusset plate mounting bolt (3)
2. Upper gusset plate mounting bolt (3) 6. Lower gusset plate
3. Upper gusset plate 7. Frame support
4. Radiator frame
7. Install frame support (7) onto radiator frame (4) with four support mounting bolts (1). Torque bolts to
38.4 - 42.8 lb-ft (52 - 58 N·m).
8. Install lower gusset plate (6) onto radiator frame (4) with three lower gusset plate mounting bolts (5).
Torque bolts to 38.4 - 42.8 lb-ft (52 - 58 N·m).
9. Install upper gusset plate (3) onto radiator frame (4) with three lower gusset plate mounting bolts (2).
Torque bolts to 38.4 - 42.8 lb-ft (52 - 58 N·m).
995
Figure 539 Radiator Shroud Installation

1. Mounting bolt (8) 3. Radiator frame
2. Radiator shroud
10. Install radiator shroud (2) onto radiator frame (3) with eight mounting bolts (1). Torque bolts to 9.1 - 9.8
lb-ft (12.3 - 13.3 N·m).
996
Figure 540 Deaeration Tank Installation

1. Deaeration tank 5. Deaeration tank hose
2. Upper mounting nut (4) 6. Side mounting bolt (3)
3. Radiator fitting 7. Hose mounting screw
4. Radiator frame
11. Install deaeration tank (1) onto radiator frame (4) with four upper mounting nuts (2) and three side
mounting bolts (6). Torque nuts and bolts to 21.4 - 23.6 lb-ft (29 - 32 N·m).
12. Connect deaeration tank hose (5) to radiator fitting (3), and secure with clamp.
13. Install hose mounting screw (7) through hose clamp and into radiator frame (4). Torque screw to 9.1
- 9.8 lb-ft (12.3 - 13.3 N·m).
997
Figure 541 Air Dam Installation

1. Passenger-side air dam mounting bolt 5. Driver-side air dam
(3) 6. Lower air dam mounting bolt (3)
2. Upper air dam 7. Lower air dam
3. Upper air dam mounting bolt (4) 8. Passenger-side air dam
4. Driver-side air dam mounting bolt (4)
14. Install lower air dam (7) with three lower air dam mounting bolts (6).
15. Install passenger-side air dam (8) with three passenger-side air dam mounting bolts (1).
16. Install driver-side air dam (5) with four driver-side air dam mounting bolts (4).
17. Install upper air dam (2) with four upper air dam mounting bolts (3).
18. Torque twelve air dam mounting bolts (1, 3, 4, 6) to 21.4 - 23.6 lb-ft (29 - 32 N·m).
Follow-On Procedure
1. Install cooling package. See Cooling Package Installation (page 975).
998
Coolant Fill Procedure
Overview
Fill engine cooling system for vehicle operation.
Special Tools
• Coolant Management Tool, KL5007NAV
Specifications
None
4. Key OFF.
6. Check open any shutoff valve in heater circuit, in-transit heat circuit, or Auxiliary Power Unit
(APU) circuit.
7. Connect tank hose to quick-connect fitting on vehicle’s bottom radiator connection.
8. Ensure tank contains at least as much coolant as vehicle’s coolant capacity to prevent pulling
air into system.
Fill Procedure
NOTE – Do not disconnect Exhaust Gas Recirculation (EGR) Valve electrical connector.
To function properly, the cooling system must be completely filled with coolant and all air must be expelled. To
accomplish this, the following procedures should be carefully completed:
1. Turn on ignition without starting the vehicle. This opens the electrically actuated coolant flow valve.
999

1. COLD MAX and COLD MIN lines 3. Fill cap
2. Deaeration tank
2. Remove fill cap (3) and pour a 50/50 mixture (75/25 if it has been flushed with water) of the proper coolant
concentrate (refer to Lubricant and Sealer Specifications in the Maintenance Intervals and Specifications
section of the Operator’s Manual) and demineralized or distilled water into the deaeration tank (2). A 50/50
coolant mixture will achieve a -34°F (-37°C) freeze point. A 53/47 coolant mixture will achieve a -40°F
(-40°C) freeze point. The first pour should reach to the top of the reservoir fill neck.
3. Connect vacuum module to cap adapter, and verify that both valves on vacuum module are closed.
4. If so equipped, close the vent in the upper radiator pipe when air is purged.
5. If so equipped, open the lower radiator pipe vent until coolant comes out, and then close it.
6. Start the engine, and continue to add enough coolant to keep the coolant level between the COLD MAX
and COLD MIN lines (1) marked on the deaeration tank (2). Replace the fill cap (3) tightly after adding
make-up coolant for two minutes.
7. Run engine at governed speed until engine temperature reaches 185°F (85°C).
1000
8. Let engine completely cool. Recheck coolant level and concentration / freeze point with a refractometer
and top off as needed to achieve a coolant level at the COLD MAX line when cold.
Follow-On Procedure
1. Perform Check Coolant Condition (page 930).
1001
HVAC Condenser
Removal
Overview
Remove HVAC condenser for repair or replacement.
Figure 543 HVAC Condenser

1. HVAC condenser
Special Tools
None
4. Key OFF.
1002
7. Grill and bug screen removed.

9. HVAC system discharged.
WARNING
section.
WARNING
WARNING
To prevent vehicle damage, personal injury, or death, take care when performing any
WARNING
To prevent vehicle damage, personal injury, or death, use care when removing or
power steering cooler (if applicable) and radiator frame and core assembly is limited,
making handling of components difficult. Remove hood prior to performing work on
cooling system.
WARNING
CAUTION
1003
Procedure
Figure 544 HVAC Condenser and Lines

1. HVAC inlet tube 5. Driver-side HVAC condenser mounting
2. Passenger-side HVAC condenser bolt and washer (2)
mounting bolt and washer (2) 6. HVAC outlet tube mounting nut
3. HVAC inlet tube mounting nut 7. HVAC outlet tube
4. HVAC condenser
1. Remove HVAC inlet tube mounting nut (3), disconnect HVAC inlet tube (1) from HVAC condenser (4),
and install caps.
2. Remove HVAC outlet tube mounting nut (6), disconnect HVAC outlet tube (7) from HVAC condenser (4),
and install caps.
3. Loosen two driver-side HVAC condenser mounting bolts and washers (5).
4. Remove two passenger-side HVAC condenser mounting bolts and washers (2).
5. Carefully slide HVAC condenser (3) toward passenger-side, and remove.
1004
Follow-On Procedure
1. Install HVAC condenser. See HVAC Condenser Installation (page 1006).
1005
Installation
Overview
Install HVAC condenser for repair or replacement.

1. HVAC condenser
Special Tools
None
HVAC condenser mounting bolts 13 - 14 lb-ft (18 - 19 N·m)
HVAC inlet tube mounting nut 19.1- 21.2 lb-ft (25.9 - 28.8 N·m)
HVAC outlet tube mounting nut 19.1- 21.2 lb-ft (25.9 - 28.8 N·m)
1006
4. Key OFF.
8. HVAC condenser removed. See HVAC Condenser Removal (page 1002).
WARNING
section.
WARNING
WARNING
WARNING
cooling system.
WARNING
CAUTION
1007
Procedure

1. HVAC inlet tube 5. Driver-side HVAC condenser mounting
2. Passenger-side HVAC condenser bolt and washer (2)
mounting bolt and washer (2) 6. HVAC outlet tube mounting nut
3. HVAC inlet tube mounting nut 7. HVAC outlet tube
4. HVAC condenser
1. Install two driver-side HVAC condenser mounting bolts and washers (5) loosely into driver-side of Charge
Air Cooler (CAC), if not already installed.
2. Carefully slide HVAC condenser (4) on insulators of two driver-side HVAC condenser mounting bolts
and washers (5).
3. Install two passenger-side HVAC condenser mounting bolts and washers (2).
4. Tighten two passenger-side HVAC condenser mounting bolts and washers (2) and two driver-side HVAC
condenser mounting bolts and washers (5) to 13 - 14 lb-ft (18 - 19 N·m).
5. Remove caps from HVAC outlet tube (7) and connection on HVAC condenser (4).
1008
6. Install new seal plate on HVAC outlet tube (7). Lubricate seal with lubricant, International® P-80.
7. Install HVAC outlet tube (7) on HVAC condenser (4) with HVAC outlet tube mounting nut (6). Tighten
nut to 19.1- 21.2 lb-ft (25.9 - 28.8 N·m).
8. Remove caps from HVAC inlet tube (1) and connection on HVAC condenser (4).
9. Install new seal plate on HVAC inlet tube (1). Lubricate seal with lubricant, International® ZGGR725028.
10. Install HVAC inlet tube (1) on HVAC condenser (4) with HVAC inlet tube mounting nut (3). Tighten nut to
19.1- 21.2 lb-ft (25.9 - 28.8 N·m).
Follow-On Procedure
1. Complete all required system flushes and purges.
2. Make sure oil level in compressor is at specification(page 1335).
3. Evacuate and charge A/C system using recommended procedure.
4. Install grill and bug screen.
1009
Relocation
Overview
Relocate HVAC condenser for Charge Air Cooler (CAC) or cooling package removal.

1. HVAC condenser
Special Tools
None
4. Key OFF.
1010

9. Passenger-side headlight electrical connector disconnected.
10. HVAC system discharged if HVAC system components are to be removed.
WARNING
section.
WARNING
WARNING
WARNING
cooling system.
WARNING
CAUTION
CAUTION
To prevent vehicle or HVAC system damage when relocating HVAC condenser, watch for
kinking or severe bending of HVAC condenser lines or hoses. Damage from kinking or
severe bending may require replacement of HVAC condenser lines or hoses.
1011
Procedure
Figure 548 Passenger-Side Radiator Air Dam and HVAC Line P-Clamp Nuts
1. Passenger-side radiator air dam 2. Passenger-side radiator air dam
mounting bolts (3) 3. HVAC line P-clamp nut (2)
1. Remove three passenger-side radiator air dam mounting bolts (1).
2. Remove passenger-side radiator air dam (2).
3. Remove two HVAC line P-clamp nuts (3).
4. Cut tie wraps that secure HVAC lines, as required, to allow movement of HVAC condenser.
1012

1. HVAC line (2) 3. HVAC condenser
2. Passenger-side HVAC condenser 4. Driver-side HVAC condenser mounting
mounting bolt and washer (2) bolt and washer (2)
5. Loosen two driver-side HVAC condenser mounting bolts and washers (4).
6. Remove two passenger-side HVAC condenser mounting bolts and washers (2).
CAUTION
7. Carefully slide HVAC condenser (3) toward passenger-side tire, swing around radiator, and set in vicinity
of passenger tire.
8. Secure HVAC condenser (3) with cord, tie wraps, or tape to prevent slipping and damage to lines,
hoses, or condenser.
1013
Follow-On Procedure
1. Continue Charge Air Cooler (CAC) or cooling package removal.
1014
Reinstallation
Overview
Reinstall HVAC condenser after Charge Air Cooler (CAC) or cooling package installation.

1. HVAC condenser
Special Tools
None
HVAC condenser mounting bolts 13 - 14 lb-ft (18 - 19 N·m)
HVAC inlet tube mounting nut 19.1- 21.2 lb-ft (25.9 - 28.8 N·m)
HVAC outlet tube mounting nut 19.1- 21.2 lb-ft (25.9 - 28.8 N·m)
HVAC line P-clamp nuts 19 - 21 lb-ft (26 - 29 N·m)
Radiator air dam mounting bolts 21 - 26 lb-ft (28 - 35 N·m)
1015

4. Key OFF.
7. Charge Air Cooler (CAC) or cooling package installed.
WARNING
section.
WARNING
WARNING
WARNING
cooling system.
WARNING
CAUTION
1016
CAUTION
Procedure

1. HVAC line (2) 3. HVAC condenser
2. Passenger-side HVAC condenser 4. Driver-side HVAC condenser mounting
mounting bolt and washer (2) bolt and washer (2)
1. Install two driver-side HVAC condenser mounting bolts and washers (4) loosely into driver-side of Charge
Air Cooler (CAC), if not already installed.
2. Remove cord, tie wraps, or tape holding HVAC condenser (3) on passenger-side tire area.
1017
CAUTION
To prevent vehicle or HVAC system damage when reinstalling HVAC condenser, watch
for kinking or severe bending of HVAC condenser lines or hoses. Damage from kinking
or severe bending may require replacement of HVAC condenser lines or hoses.
3. Carefully move HVAC condenser (3) from passenger-side, swing around radiator, and slide on insulators
of two driver-side HVAC condenser mounting bolts and washers (4).
4. Install two passenger-side HVAC condenser mounting bolts and washers (2).
5. Tighten two passenger-side HVAC condenser mounting bolts and washers (2) and two driver-side HVAC
condenser mounting bolts and washers (4) to 13 - 14 lb-ft (18 - 19 N·m).
6. Install tie wraps on HVAC lines (1) and hoses as required.
Figure 552 Passenger-Side Radiator Air Dam and HVAC Line P-Clamp Nuts
1. Passenger-side radiator air dam 2. Passenger-side radiator air dam
mounting bolts (3) 3. HVAC line P-clamp nut (2)
1018
7. Install HVAC lines and P-clamps with two HVAC line P-clamp nuts (3). Torque P-clamp nuts to 19 -
21 lb-ft (26 - 29 N·m).
8. Install passenger-side radiator air dam (2) with three passenger-side radiator air dam mounting bolts
(1). Tighten bolts to 21 - 26 lb-ft (28 - 35 N·m).
Follow-On Procedure
1. If HVAC system was discharged, charge HVAC system.
2. Connect passenger-side headlight electrical connector.
1019
Charge Air Cooler (CAC)

Overview
0012WYZ Radiator drain & fill fitting special; to vacuum out or fill the cooling system
from the bottom of radiator, for use with quick-connect radiator drain tool or
shop coolant evacuation-fill system
0012XBC Radiator aluminum; welded, down-flow system, front to back, 1325 sq.in.,
0012XBN Radiator aluminum; welded, front-to-back crossflow system, 1084 sq. in.,
866 sq. in. charge air cooler

1. Deaeration tank 4. Power steering cooler
2. Radiator 5. Fuel cooler
3. Charge Air Cooler (CAC)
CAC is mounted in front of radiator and cools air to permissible temperature for turbocharger. The CAC is
an air-to-air cooler that cools the air which is compressed by the turbocharger before it enters the engine’s
intake manifold and cylinders.
1020
Removal
Overview
Remove Charge Air Cooler (CAC) for replacement or repair.
Figure 554 CAC

1. CAC
Special Tools
None
4. Key OFF.
1021

9. HVAC condenser relocated or removed. See HVAC Condenser Relocation (page 1010) or HVAC
Condenser Removal (page 1002).
WARNING
section.
WARNING
WARNING
CAUTION
1022
Removal Procedure
Figure 555 CAC Piping

1. Passenger-side CAC pipe 4. CAC
2. Driver-side CAC pipe 5. Clamp
3. Clamp
1. Loosen clamp (5) on passenger-side CAC pipe (1) and disconnect passenger-side CAC pipe (1) from
CAC (4).
2. Loosen clamp (3) on driver-side CAC pipe (2) and disconnect driver-side CAC pipe (2) from CAC (4).
1023
Figure 556 CAC Driver-Side Mounting Hardware

1. Upper mounting nut 3. CAC
2. Lower mounting bolt
3. Remove lower mounting bolt (2) from driver-side of CAC (3).
4. Remove upper mounting nut (1) from driver-side of CAC (3).
1024
Figure 557 CAC Passenger-Side Mounting Hardware

1. Upper mounting bolt, washer and 2. CAC
insulator 3. Lower mounting nut
5. Loosen lower mounting nut (3) at passenger-side of CAC (2).
6. Remove upper mounting bolt, washer and insulator (1), and remove CAC (2).
Follow-On Procedure
1. Install CAC. See Charge Air Cooler (CAC) Installation (page 1026).
1025
Installation
Overview
Install Charge Air Cooler (CAC) after replacement or repair.
Figure 558 CAC

1. CAC
Special Tools
None
CAC mounting hardware 38.4 - 42.8 lb-ft (52 - 58 N•m)
CAC pipe clamps 7.5 - 9.4 lb-ft (10.2 - 12.8 N•m)
1. CAC removed. See Charge Air Cooler (CAC) Removal (page 1021).
1026
WARNING
WARNING
procedures.
WARNING
To prevent personal injury or death, avoid contact with DEF / urea. Do not get DEF in eyes.
In case of eye contact, immediately flush eyes with large amounts of water for a minimum
of 15 minutes. Do not swallow. If DEF is ingested, contact a physician immediately.
WARNING
To prevent personal injury and / or death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard
clothing and rags contaminated with engine fluids.
1027
Figure 559 CAC Passenger-Side Mounting Hardware

1. Upper mounting bolt, washer and 2. CAC
insulator 3. Lower mounting nut
1. Install CAC (2) with passenger-side upper mounting bolt, washer and insulator (1). Tighten bolt to 38.4 -
42.8 lb-ft (52 - 58 N•m).
2. Tighten passenger-side lower mounting nut (3) to 38.4 - 42.8 lb-ft (52 - 58 N•m).
1028
Figure 560 CAC Driver-Side Mounting Hardware

1. Upper mounting nut 3. CAC
2. Lower mounting bolt
3. Install upper mounting nut (1) on driver-side of CAC (3).
4. Install lower mounting bolt (2) on driver-side of CAC (3).
5. Tighten bolt and nut to 38.4 - 42.8 lb-ft (52 - 58 N•m).
1029
Figure 561 CAC Piping

1. Passenger-side CAC pipe 4. CAC
2. Driver-side CAC pipe 5. Clamp
3. Clamp
6. Connect driver-side CAC pipe (2) to CAC (4), and tighten clamp (3) to 7.5 - 9.4 lb-ft (10.2 - 12.8 N•m).
7. Connect passenger-side CAC pipe (1) to CAC (4), and tighten clamp (5) to 7.5 - 9.4 lb-ft (10.2 - 12.8 N•m).
Follow-On Procedure
1. Install or reinstall HVAC condenser. See HVAC Condenser Installation (page 1006) or HVAC
Condenser - Reinstallation (page 1015).
1030
Clean
Overview
CAC is cleaned to remove contamination for better transfer of internal heat to outside air.
CACs are not required to be leak proof. Do not test CAC for leakage by submerging it in radiator test tank.
Almost all CACs will show leakage if they are submerged.
Special Tools
• Coolant Management System (CMS), KL5007NAV
• CAC Cleaning Adapter Kit, 09-925-01
• Coolant Cap Pressure Tester (Usually Mounted on KL5007NAV), 09-040-01
• EGR Cleaning Fluid 5 Gallons (19 L), 2512460C1
2. Place transmission in NEUTRAL (or PARK, if automatic transmission).
3. Chassis air system within normal operating range of 100 - 120 psi.
5. Key OFF.
10. HVAC condenser relocated.
11. CAC removed.
WARNING
section.
WARNING
WARNING
1031
CAUTION
Off-Chassis Pressure Test

WARNING
To prevent property damage, personal injury, or death, clean all rubber collars and other
pressure test components of any oil, grease, or other lubricants. Serious injury or death
can occur if metal couplers are forced out during pressure testing.
WARNING
To prevent property damage, personal injury, or death, using appropriate fasteners,

attach safety cables to CAC mounting holes or to a stationary object. Serious injury or
death can occur if couplers blow out of coupling collars during pressure testing.
WARNING
To prevent property damage, personal injury, or death, adjust air regulator valve to
minimum setting before connecting air supply. Accidentally applying high pressure can
damage tool components or CAC resulting in flying objects, serious injury, or death.
Figure 562 Gauge and Regulator Assembly

1. Gauge 3. Air valve
2. Air regulator knob
1. Install CAC Pressure Test Kit per instructions included with ZTSE4341, using appropriate hoses
and clamps from CAC adapter Flushing Kit 09-25-1.
1032
2. Connect a filtered air supply to air valve (3) on gauge and regulator assembly.
WARNING
To prevent property damage, personal injury, or death, increase air pressure slowly to
prevent adapters from blowing off during testing. After testing, relieve pressure slowly
through bleed valve before removing test equipment.
WARNING
To prevent property damage, personal injury, or death, when applying air pressure, watch
for movement of the hoses or clamps. If any movement is noticed, stop immediately and
relieve any pressure, tighten clamps, or reposition hoses and clamps if necessary.
3. Open air valve slightly, and slowly increase air pressure until gauge reads 30 psi (205 kPa). If
required, adjust air regulator until gauge reads 30 psi as follows.
4. Pull air regulator knob (2) outward to unlock.
5. Turn air regulator knob to adjust pressure to 28 - 32 psi (193 - 221 kPa).
6. Push air regulator knob back into locked position.
7. Close air valve and monitor gauge with stop watch for 15 seconds. Note any decrease in air
pressure.
8. Repeat Steps 3 and 4 three times to verify results.
9. If air pressure drops more than 5 psi (34 kPa) in 15 seconds, replace CAC. If air pressure drop is 5
psi (34 kPa) or less in 15 seconds, perform cleaning (page 1034) procedure.
10. Slowly turn bleed-off valve on bleed-off coupler counterclockwise and release air from system.
11. Disconnect filtered air supply from air valve.
12. Remove CAC Pressure Test Kit per instructions included with ZTSE4341.
Charge Air Cooler (CAC) Cleaning Management System (CMS) Install

1. Position Pump / Heater Switch on Cleaning Management System (CMS) to OFF.
2. Make sure reservoir of CMS is clean and filter has been replaced.
3. Add 5 gallons (19 liters) of tap water to CMS reservoir first, followed by 5 gallons (19 liters) of
cleaning fluid to CMS.
1033
Figure 563 CAC Inlet and Outlet Adapters

1. CAC adapter (2) 3. 5-in. hose (2)
2. T-clamp (2 each) 4. CAC inlet and outlet
4. With CAC on a flat surface, install large hose (3) on CAC inlet and outlet with two T-clamps.
5. Install two adapter (1) in each large hose with two T-clamps (2).
6. Connect CMS flow from pump hose to outlet adapter.
7. Install flow from pump hose to CMS.
8. Connect CMS flow return hose to inlet adapter.
9. Connect flow return hose to CMS.
10. Position Pump / Heater Switch on CMS to Heater and allow temperatures to reach approximately
130°F (54°C) before flushing.
Cleaning Procedure
1. Set and start timer on CMS for 20 minutes, position Pump / Heater Switch on CMS to PUMP, and perform
20 minute forward flush.
2. Position Pump / Heater Switch to OFF.
1034
Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal

1. Disconnect flow return hose from CMS.
2. Disconnect CMS flow return hose from inlet adapter.
3. Remove flow from pump hose from CMS.
4. Disconnect CMS flow from pump hose from outlet adapter.
5. Disconnect two T-clamps on two adapter on each large hose.
6. Remove two T-clamps on each large hose on CAC inlet and outlet.
7. Blow dry CAC with compressed air.
8. Install CAC.
9. Run engine to verify proper operation, no leaks, and no fault codes.
Follow-On Procedure
None
1035
Flush
Overview
CAC is flushed internally to remove contamination due to turbocharger failure.
Special Tools
• Coolant Management System (CMS), KL5007NAV
• CAC Cleaning Adapter Kit, 09-925-01
• Coolant Cap Pressure Tester (Usually Mounted on KL5007NAV), 09-040-01
• EGR Cleaning Fluid 5 Gallons (19 L), 2512460C1
2. Place transmission in NEUTRAL (or PARK, if automatic transmission).
3. Chassis air system within normal operating range of 100 - 120 psi.
5. Key OFF.
8. Grill and bug screen removed .
10. HVAC condenser relocated (page 1010).
11. CAC removed (page 1021).
WARNING
section.
WARNING
WARNING
CAUTION
1036
Off-Chassis Pressure Test

WARNING
To prevent property damage, personal injury, or death, clean all rubber collars and other
pressure test components of any oil, grease, or other lubricants. Serious injury or death
can occur if metal couplers are forced out during pressure testing.
WARNING
To prevent property damage, personal injury, or death, using appropriate fasteners,

attach safety cables to CAC mounting holes or to a stationary object. Serious injury or
death can occur if couplers blow out of coupling collars during pressure testing.
WARNING
To prevent property damage, personal injury, or death, adjust air regulator valve to
minimum setting before connecting air supply. Accidentally applying high pressure can
damage tool components or CAC resulting in flying objects, serious injury, or death.
Figure 564 Gauge and Regulator Assembly

1. Gauge 3. Air valve
1. Install CAC Pressure Test Kit per instructions included with ZTSE4341, using appropriate hoses
and clamps from CAC adapter Flushing Kit 09-25-1.
1037
2. Connect a filtered air supply to air valve (3) on gauge and regulator assembly.
WARNING
To prevent property damage, personal injury, or death, increase air pressure slowly to
prevent adapters from blowing off during testing. After testing, relieve pressure slowly
through bleed valve before removing test equipment.
WARNING
To prevent property damage, personal injury, or death, when applying air pressure, watch
for movement of the hoses or clamps. If any movement is noticed, stop immediately and
relieve any pressure, tighten clamps, or reposition hoses and clamps if necessary.
3. Open air valve slightly, and slowly increase air pressure until gauge reads 30 psi (205 kPa). If
required, adjust air regulator until gauge reads 30 psi as follows.
4. Pull air regulator knob (2) outward to unlock.
5. Turn air regulator knob to adjust pressure to 28 - 32 psi (193 - 221 kPa).
6. Push air regulator knob back into locked position.
7. Close air valve and monitor gauge with stop watch for 15 seconds. Note any decrease in air
pressure.
8. Repeat Steps 3 and 4 three times to verify results.
9. If air pressure drops more than 5 psi (34 kPa) in 15 seconds, replace CAC. If air pressure drop is 5
psi (34 kPa) or less in 15 seconds, perform cleaning (page 1034) procedure.
10. Slowly turn bleed-off valve on bleed-off coupler counterclockwise and release air from system.
11. Disconnect filtered air supply from air valve.
12. Remove CAC Pressure Test Kit per instructions included with ZTSE4341.
Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation

1. Position Pump / Heater Switch on Cleaning Management System (CMS) to OFF.
2. Make sure reservoir of CMS is clean and filter has been replaced.
3. Add 5 gallons (19 liters) of tap water to CMS reservoir first, followed by 5 gallons (19 liters) of
cleaning fluid to CMS.
1038
Figure 565 CAC Inlet and Outlet Adapters

1. CAC adapter (2) 3. 5-in hose (2)
2. T-clamp (2 each) 4. CAC inlet and outlet
4. With CAC on a flat surface, install large hose (3) on CAC inlet and outlet with two T-clamps.
5. Install two adapter (1) in each large hose with two T-clamps (2).
6. Connect CMS flow from pump hose to outlet adapter.
7. Install flow from pump hose to CMS.
8. Connect CMS flow return hose to inlet adapter.
9. Connect flow return hose to CMS.
10. Position Pump / Heater Switch on CMS to Heater and allow temperatures to reach approximately
130°F (54°C) before flushing.
Flush Procedure
1. Fill Cleaning Management System (CMS) with 10 gallons (38 liters) of hot tap water.
2. Set and start timer on CMS for 10 minutes, position Pump / Heater Switch on CMS to PUMP, and perform
10 minute rinse with hot tap water.
3. Position Pump/Heater Switch on CMS to OFF.
1039
4. Disconnect CMS flow from pump hose from inlet adapter.
5. Disconnect CMS flow return hose from outlet adapter.
6. Tip CAC on its side and allow water to drain.
7. Drain and clean CMS.
Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal

1. Disconnect flow return hose from CMS.
2. Disconnect CMS flow return hose from inlet adapter.
3. Remove flow from pump hose from CMS.
4. Disconnect CMS flow from pump hose from outlet adapter.
5. Disconnect two T-clamps on two adapter on each large hose.
6. Remove two T-clamps on each large hose on CAC inlet and outlet.
7. Blow dry CAC with compressed air.
8. Install CAC (page 1026).
9. Run engine to verify proper operation, no leaks, and no fault codes.
Follow-On Procedure
None
1040
Pressure Test
Overview
Pressure test the Charge Air Cooler (CAC) to check for leaks
WARNING
To prevent personal injury or death, read all safety instructions in the “Safety
WARNING
To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.
WARNING
Special Tools
• CAC Pressure Test Kit ZTSE4341
• CAC Cleaning Adapter Kit 09–925–01
T-clamps 55 lb-in. (6.2 N·m)
Equipment Condition
• Inlet (hot side) CAC pipes and hoses removed from CAC.
• Outlet (cold side) CAC pipes and hoses removed from CAC.
1041
Test Setup
Figure 566 CAC Cleaning Adapter Kit 09-925-01 With CAC Pressure Test Kit ZTSE4341 Installed
1. CAC Pressure Test Kit ZTSE4341
WARNING
To prevent personal injury or death, clean all hoses and other pressure test components
of oil, grease, or other lubricants before connecting.
Figure 567 CAC Pressure Test Kit Installed on CAC Outlet

1. Gauge / regulator assembly 5. Large hose
2. Quick disconnect fitting 6. Charge Air Cooler (CAC) outlet
3. Gauge coupler 7. Safety cable
4. T-clamp (2)
1. Install large hose (5) and T-clamp (4) onto CAC outlet (6). Tighten T-clamp (4) securing large hose
to CAC outlet to 55 lb-in. (6.2 N·m).
1042
2. Install gauge coupler (3) and T-clamp (4) onto large hose. Tighten T-clamp (4) securing gauge
coupler (3) to large hose (5) to 55 lb-in (6.2 N·m).
3. Connect safety cable (7) to a known good anchor point.
4. Attach gauge / regulator assembly (1) onto quick disconnect fitting (2).
5. Install large hose and T-clamp onto CAC inlet. Tighten T-clamp securing large hose to CAC
outlet to 55 lb-in (6.2 N·m).
6. Install bleed-off coupler and T-clamp onto large hose. Tighten T-clamp securing gauge coupler
to large hose to 55 lb-in (6.2 N·m).
7. Connect safety cable to a known good anchor point.
Test Procedure
1. Visually inspect CAC for cracks, holes, and other damage. If cracked or damaged, replace CAC.
Figure 568 Gauge / Regulator Assembly Connections

1. Air valve 3. Gauge
WARNING
To prevent personal injury or death, attach safety cables to Charge Air Cooler (CAC) or
a known good anchor point.
CAUTION
Adjust air regulator valve to minimum setting before connecting shop air supply.
Accidentally applying high-pressure can damage tool components or the Charge Air
Cooler (CAC).
2. Connect filtered shop air supply to air valve (1) on gauge / regulator assembly.
1043
WARNING
To prevent personal injury or death, increase air pressure slowly to prevent coupler
blowing-out during testing.
3. Open air valve slightly, and slowly increase air pressure until gauge (3) reads 30 psi (205 kPa). If needed,
adjust air regulator knob (2) as follows until gauge reads 30 psi (205 kPa).
4. Pull air regulator knob outward to unlock.
5. Turn air regulator knob to adjust pressure to 30 psi (205 kPa).
6. Push air regulator knob inward back into locked position.
7. Close air valve and monitor gauge pressure for 15 minutes.

a. If air pressure drops more than 5 psi (34 kPa) in 15 minutes, replace CAC.
b. If air pressure drops 5 psi (34 kPa) or less in 15 minutes, perform cleaning procedure. See Charge Air
Cooler (CAC) Cleaning in Engine Service Manual.
8. Repeat steps 3 through 7 three times to verify results.
Expected Outcome
Air pressure in CAC will drop 5 psi (34 kPa) or less in 15 minutes.
1044
Follow-On Procedure
Figure 569 Bleed-Off Coupler Components

1. Bleed-off coupler 2. Bleed-off valve
WARNING
To prevent personal injury or death, relieve air pressure through bleed-off valve slowly
before removing test equipment.
1. Slowly turn bleed-off valve (2) on bleed-off coupler (1) counterclockwise, and release air from
system.
2. Disconnect filtered shop air supply from air valve on gauge / regulator assembly.
1045
Figure 570 Bleed-Off Coupler Installed on CAC Intake

1. Safety cable 4. Small hose
2. Bleed-off coupler 5. CAC intake
3. T-clamp (2)
3. Disconnect safety cable (1) from anchor point.
4. Remove bleed-off coupler (2) and T-clamp (3) from small hose (4).
5. Remove small hose (4) and T-clamp (3) from CAC intake (5).
Figure 571 CAC Pressure Test Kit Installed on CAC Outlet

1. Gauge / regulator assembly 5. Large hose
2. Quick-disconnect fitting 6. CAC outlet
3. Gauge coupler 7. Safety cable
4. T-clamp (2)
6. Remove gauge / regulator assembly (1) from quick-disconnect fitting (2).
7. Remove safety cable (7) from anchor point.
8. Remove gauge coupler (3) and T-clamp (4) from large hose (5).
1046
9. Remove large hose (5) and T-clamp (4) from CAC outlet (6).
10. Reinstall the hot and cold side CAC hoses and pipes.
1047
FAN DRIVE
6. Fan Drive
Horton Fan Drive
Overview
0012THT Fan Drive {Horton Drivemaster} direct drive type, two speed with
residual torque device for disengaged fan speed
0012WTA Fan Drive special effects fan cooling ring with fan shroud effects,
engine mounted
Cooling requirements of engine, transmission and related components determine applicable fan, fan drive and
fan drive ratio. Standard fan is nylon.
1048
FAN DRIVE
Fan Drive with Override Switch

Overview
0012WBR Fan Override Manual; with electric switch on instrument panel, (fan
ON with switch ON)
A fan override option allows cooling fan to be engaged manually before an anticipated heavy duty load cycle.
1049
POWER TAKE OFF (PTO)
7. Power Take Off (PTO)

Front Engine PTO
Overview
0012851 HX515 - PTO Effects, engine front less PTO unit, includes adapter
plate on engine front mounted.
1050
Rear Engine PTO

Overview
0012WPU PTO, engine rear for N13 engines (ratio 1.276:1)
For ease of maintenance, a REPTO hatch is provided when REPTO is ordered. Simply remove access
plate to service REPTO joint.
1051
1052
TABLE OF CONTENTS
Transmissions
Table of Contents
1. Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1055
Auxiliary Push Button Shift Control (Allison). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1055
Push Button Shift Control (Allison). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
Shift Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
2. Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059

Allison Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059
Allison Automatic Transmission Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065
Troubleshooting - Powers, Grounds, and Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065
Hydraulic Retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066
Automatic Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066
Allison Spare Input / Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067
3. Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069

Eaton® UltraShift® PLUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069
Fuller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1071
4. Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1072

Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1072
Transmission Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1072
Auxiliary Transmission Lube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1073
5. Transmission Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074

Automatic Transmission Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074
Manual Transmission Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075
Auxiliary Transmission Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076
6. Auxiliary Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077

Fuller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077
Spicer®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078
7. Power Take Off (PTO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079

Transmission Mounted PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079
Thru-shaft PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1080
PTO Controls - Dash Mounted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1081
1053
TABLE OF CONTENTS
1054
SHIFTER
1. Shifter
Auxiliary Push Button Shift Control (Allison)
Overview
0013WUW HX620 - Auxiliary Transmission Shift Control {Allison} push-button
type; for Allison 4700 OFS series transmission with secondary
shifter mounted at end of frame
Troubleshooting - Powers, Grounds, and Data Link

See section 08 - Electrical Troubleshooting for Powers, Grounds, and Data Link.
1055
SHIFTER
Push Button Shift Control (Allison)

Overview
0013WBL Transmission Shift Control {Allison} push button type; for Allison
3000 and 4000 series transmission
Figure 572 Allison Push Button Shift Control Location
Automatic push button control located on dash to shift Allison automatic transmission.
1056
SHIFTER

1057
SHIFTER
Shift Control Parameters

Overview
0013WYR Shift Control Parameters Allison 3000 or 4000 series transmissions,
fifth generation controls, with EcoCal and Dynamic Shift Sensing
(FuelSense Basic)
0013WYS Shift Control Parameters Allison 3000 or 4000 series transmissions,
fifth generation controls, with EcoCal, Dynamic Shift Sensing, and
Neutral at Stop-Premium (FuelSense Plus)
0013WYT Shift Control Parameters Allison 3000 or 4000 series transmissions,
fifth generation controls, with EcoCal, Dynamic Shift Sensing,
Neutral at Stop-Premium, and Acceleration Rate Management
(FuelSense Max)
0013WYU Shift Control Parameters Allison 3000 or 4000 series transmissions,
fifth generation controls, performance programming
All Allison transmissions require a shift control parameter.
Performance programming provides optimized shift parameters for performance biased applications with a
secondary fuel economy mode.
FuelSense Basic includes EcoCal and dynamic shift sensing. EcoCal features lower speed shift schedules
to keep engine speed optimal. Dynamic shift sensing automatically selects optimized shift schedules based
on vehicle weight and operating grade.
FuelSense Plus includes EcoCal, dynamic shift sensing and neutral at stop. Neutral at stop eliminates load on
engine while vehicle is stopped and provides locked output to help prevent roll-back.
FuelSense Max includes EcoCal, dynamic shift sensing, neutral at stop and acceleration rate management.
Acceleration rate management mitigates aggressive driving practices by automatically controlling engine
torque. Intensity of control is determined by vehicle weight and operating grade.
1058
AUTOMATIC TRANSMISSIONS
2. Automatic Transmissions
Allison Transmission
Overview
0013AUN Transmission, Automatic {Allison 4000EVS_P} fifth generation
controls, close ratio, 5 speed; with overdrive, includes oil level
sensor, with provision for PTO, less retarder
0013AUP Transmission, Automatic {Allison 4500EVS_P} fifth generation
controls; wide ratio, 5 speed; with overdrive; includes oil level
sensor, with provision for PTO, less retarder
0013AUR Transmission, Automatic {Allison 4000EVS_P} fifth generation
controls; close ratio, 6 speed; with double overdrive; includes oil
level sensor, with provision for PTO, less retarder
0013AUS Transmission, Automatic {Allison 4500EVS_P} fifth generation
controls; wide ratio, 6 speed; with double overdrive; includes oil
level sensor, with provision for PTO, less retarder
0013ATP Transmission, Automatic {Allison 4000_RDS_P} fifth generation
controls; close ratio, 5 speed, with overdrive; On/Off highway;
includes oil level sensor, with PTO provision, less retarder
0013ATR Transmission, Automatic {Allison 4000_RDS_P} fifth generation
controls; close ratio, 6 speed, with double overdrive; On/Off
highway; includes oil level sensor, with PTO provision, less retarder
0013AUT Transmission, Automatic {Allison 4500_RDS_P} fifth generation
controls; wide ratio, 5 speed, with overdrive; On/Off highway;
0013AUU Transmission, Automatic {Allison 4500_RDS_P} fifth generation
controls; wide ratio, 5 speed, with overdrive; refuse; includes oil
level sensor, with PTO provision, less retarder
0013AUV Transmission, Automatic {Allison 4000_RDS_P} fifth generation
controls; close ratio, 5 speed, with overdrive; refuse; includes oil
level sensor, with PTO provision, less retarder
0013AUW Transmission, Automatic {Allison 4500_RDS_P} fifth generation
controls; wide ratio, 6 speed, with double overdrive; On/Off
highway; includes oil level sensor, with PTO provision, less retarder
0013AUX Transmission, Automatic {Allison 4500_RDS_P} fifth generation
controls; wide ratio, 6 speed, with double overdrive; refuse; includes
oil level sensor, with PTO provision, less retarder
0013AUY Transmission, Automatic {Allison 4000_RDS_P} fifth generation
controls; close ratio, 6 speed, with double overdrive; refuse;
0013AVT Transmission, Automatic {Allison 4700_RDS_P} fifth generation
controls; 7 speed, with double overdrive, On/Off highway, includes
oil level sensor, with PTO provision, less retarder
1059

0013AVM Transmission, Automatic {Allison 4700_OFS_P} fifth generation
controls; 7 speed, with double overdrive; includes oil level sensor,
with PTO provision, less retarder
1060
Allison EVS Transmission

Emergency Vehicle Series (EVS) vehicles include Class 4 to 6 emergency vehicles and higher powered Class
8 crash vehicles. Any vehicle equipped with emergency signaling; such as siren, light bar, grill signal, portable
light, and etc. that allows vehicle to ignore general traffic laws in emergency situations, is considered as an
emergency vehicle, and must be equipped with an EVS transmission. Typical EVS transmissions include aerial
ladder/platform, airport crash/fire/rescue vehicles, ambulances, mobile command centers, pumpers, with and
without split shaft PTO, support vehicles, and tankers.
1061
Allison RDS Transmissions

Rugged Duty Series (RDS) transmissions are for construction, service, and refuse uses. Any vehicle that
operates in on/off highway and utilizes PTO operation use an RDS transmission. Typical include airport
support, concrete mixers and pumpers, dump vehicles, farm and agriculture, front/side/rear loaders, packing
recyclers, roll-on/roll-off vehicles, landscaping vehicles, liquid waste haulers, propane delivery, snow plows,
street cleaning, tow vehicles, utility vehicles, and yard tractors/spotters. RDS transmissions allow for snow
plow vehicles with 1000, 2100, 2200 and 2500 RDS transmissions. Landfill and tandem axle refuse vehicles
are acceptable with 3000 RDS transmissions. The 1000, 2100 and 2200 RDS transmission vehicles are
NOT allowed as refuse vehicles.
1062
Allison OFS Transmissions

Allison Oil Field Series (OFS) transmissions are designed specifically for oil and gas field applications.
1063
1064
Allison Automatic Transmission Flywheel
Figure 573 Torque Sequence
Production Installation Instructions for Flywheel Bolts

Flywheel bolt gage stretch is used to indirectly measure bolt tension in assembled condition. Bolt gage stretch
is used for audit. Bolt load and stretch targets are shown in table once bolts have been loaded to initial
value, they may not be reused.
Flywheel Bolt Load and Stretch Targets

Actual Bolt Loads lb (N) Bolt Gage Stretch in. (mm)
Target Minimum Maximum Target Minimum Maximum
34,000 31,422 36,046 0.0182 0.0164 0.0201
(151,240) (139,772) (160,046) (0.4623) (0.4166) (0.5105)
Service Installation Instructions for Flywheel Bolts

1. Torque flywheel bolts to 100 N·m in torque sequence.
2. Tighten flywheel bolts an additional 90 degrees in torque sequence.
3. Tighten flywheel bolts another additional 90 degrees in torque sequence.
1065
Hydraulic Retarder

0013WDM Hydraulic Retarder for Allison 4000 series transmission
Automatic Neutral

0013WUA Automatic Neutral Allison WT transmission shifts to neutral when
parking brake is engaged and remains in neutral when parking
brake is disengaged
This feature is used in refuse applications where operator is frequently exiting vehicle.
1066
Allison Spare Input / Output

Overview
0013WUC Allison Spare Input/Output for Rugged Duty Series (RDS); general
purpose trucks, construction
0013WUE Allison Spare Input/Output for Emergency Vehicle Series (EVS);
fire/pumper, tank, aerial/ladder
0013WUH Allison Spare Input/Output for Rugged Duty Series (RDS); airport
refueler, sewer evacuation
0013WUJ Allison Spare Input/Output for Rugged Duty Series (RDS); Front
Loaders, Rear Loaders, Recycling/Packer Trucks
0013WUK Allison Spare Input/Output for Rugged Duty Series (RDS); side
loaders
0013WUR Allison Spare Input/Output for dump/construction with two speed
axle or auxiliary transmission (RDS)
0013WUS Allison Spare Input/Output for Rugged Duty Series (RDS); general
purpose trucks modified for single input auto neutral
0013WUY Allison Spare Input/Output for Oil Field Series (OFS)
Pre-programmed control functions designed to meet customer needs are available as optional equipment on
Allison transmissions.
Spare inputs/outputs are circuits that can be used to activate up to four auxiliary functions programmed
into Transmission Control Module (TCM).
1067
Allison Spare Inputs/Outputs - Powers, Grounds, and Data Link

1068
MANUAL TRANSMISSIONS
3. Manual Transmissions
Eaton® UltraShift® PLUS
Overview
0013GVY Transmission, Manual {Eaton Fuller UltraShift+ FO-14E310C-LAS} 10 speed
fully automated manual; aluminum clutch housing, overdrive, electronic shift
controls, electric clutch actuation, air range shift, internal lube oil pump,
hill start aid
0013GVZ Transmission, Manual {Eaton Fuller UltraShift+ FO-16E310C-LAS} 10 speed
fully automated manual; aluminum clutch housing, overdrive, electronic shift
controls, electric clutch actuation, air range shift, internal lube oil pump,
hill start aid
0013GWB Transmission, Manual {Eaton Fuller UltraShift+ FOM-15E310C-LAS}
10 speed fully automated manual; aluminum clutch housing, overdrive,
electronic shift controls, electric clutch actuation, air range shift, internal
lube oil pump, hill start aid
0013GWC Transmission, Manual {Eaton Fuller UltraShift+ FOM-16E310C-LAS}
10 speed fully automated manual; aluminum clutch housing, overdrive,
0013GWN Transmission, Manual {Eaton Fuller UltraShift+ FO-14E308LL-VCS} 10
speed fully automated manual; with aluminum clutch housing, overdrive,
0013GWP Transmission, Manual {Eaton Fuller UltraShift+ FO-16E308LL-VCS} 10
speed fully automated Manual; with aluminum clutch housing, overdrive,
0013GWR Transmission, Manual {Eaton Fuller UltraShift+ FO-17E308LL-VCS} 10
0013GWV Transmission, Manual {Eaton Fuller UltraShift+ FO-14E309ALL-VMS} 11
speed fully automatic manual; with aluminum clutch housing, overdrive,
0013GWW Transmission, Manual {Eaton Fuller UltraShift+ FO-16E309ALL-VMS} 11
0013GWX Transmission, Manual {Eaton Fuller UltraShift+ FO-17E309ALL-VMS} 11
1069

0013GYN Transmission, Manual {Eaton Fuller UltraShift+ FO-20E313A-MHP} 13
0013GWZ Transmission, Manual {Eaton Fuller UltraShift+ FO-16E313A-MHP} 13
0013GXA Transmission, Manual {Eaton Fuller UltraShift+ FO-18E313A-MHP} 13
0013GXH Transmission, Manual {Eaton Fuller UltraShift+ FO-18E318B-VXP} 18 speed
fully automated manual; with aluminum clutch housing, overdrive, electronic
shift controls, electric clutch actuation, air range shift, internal lube oil pump,
hill start aid
1070
Fuller
Overview
0013GHJ HX515 and HX615 6x4 - Transmission, Manual {Fuller FR-14210B} 10
speed manual, with air shift
0013GHL HX615 8x6 Tridem - Transmission, Manual {Fuller FRO-14210C} 10 speed
manual, with overdrive, with air shift
0013GHS HX620 - Transmission, Manual {Fuller FRO-16210C} 10 speed manual, with
overdrive, with air shift, with internal lube oil pump
0013GHL Transmission, Manual {Fuller FRO-14210C} 10 speed manual, with
overdrive, with air shift
0013GHP Transmission, Manual {Fuller FR0-15210C} 10 speed manual, with overdrive,
with air shift, with internal lube oil pump
0013GHS Transmission, Manual {Fuller FRO-16210C} 10 speed manual, with
overdrive, with air shift, with internal lube oil pump
0013GHW Transmission, Manual {Fuller RTO(F)-14908LL} 10 speed manual; double
lo with overdrive and with air shift
0013GHX Transmission, Manual {Fuller RTO(F)-16908LL} 10 speed manual; double lo
with overdrive, internal lube pump and with air shift
0013GMZ Transmission, Manual {Fuller RTO(F)-14909ALL} 11 speed manual, with
overdrive and double lo and with air shift
0013GNA Transmission, Manual {Fuller RTO(F)-16909ALL} 11 speed manual, with
overdrive and double lo, with lube oil pump, and with air shift
0013GJS Transmission, Manual {Fuller RTLO-18913A} 13 speed manual; with double
overdrive, with air shift and internal lube oil
0013GKJ Transmission, Manual {Fuller RTLO(F)-16913A} 13 speed manual; with
double overdrive, with air shift and internal lube oil
0013GHY Transmission, Manual {Fuller RTO(F)-16915} 15 speed manual; with
overdrive with air shift and internal lube oil pump
0013GKL Transmission, Manual {Fuller RTLO(F)-16918B} 18 speed manual; with
double overdrive, with air shift and internal lube oil pump
0013GKM Transmission, Manual {Fuller RTLO(F)-18918B} 18 speed manual, with
double overdrive and double lo, internal lube oil pump and air shift
0013GYK Transmission, Manual {Fuller RTLOF-20918B} 18 speed manual, with double
overdrive, internal lube oil pump, includes air shift
1071
TRANSMISSION OIL
4. Transmission Oil
Transmission Oil
Overview
0013WLX Optional with Manual Transmission - Transmission Oil {EmGard 40W}
Synthetic; 22 through 33.99 Pints
Transmission Oil Level
Figure 574 Proper Oil Level
Check transmission oil level, remove fill plug. Make sure the oil is level with bottom of filler plug opening.
Because you can reach oil with your finger does not mean the oil is at proper level. One inch of oil level
is about one gallon of transmission oil.
• Check transmission daily for oil leaks. Repair promptly to prevent oil loss and subsequent transmission
failure.
• Check transmission oil level at every engine oil change interval. Add transmission oil as necessary.
• Drain and replace transmission oil as recommended by schedule in lubrication interval chart.
1072
TRANSMISSION OIL
Auxiliary Transmission Lube

Overview
0013WMA HX620 - Auxiliary Transmission Lube {EmGard 40W} synthetic; 1 through
21.99 pints
1073
TRANSMISSION OIL COOLER
5. Transmission Oil Cooler

Automatic Transmission Oil Cooler
Overview
0013WCU Oil Cooler, auto transmission {Modine} remote mounted; for use with
automatic transmission less retarder
0013WHL Oil Cooler, auto transmission remote mounted; for use with automatic
transmission and retarder
1074
Manual Transmission Oil Cooler

Overview
0013WGJ Oil Cooler, manual transmission water to oil type included in radiator end
tank (requires transmission lube oil pump)
Transmissions are normally cooled by oil being splashed by rotating gears. Heat is then dissipated by
convection through transmission case to atmosphere.
Transmission oil cooler should be used when conditions (any one or a combination) that are very likely to
cause transmission oil to exceed 250° F.
• Operating at low speed with high wheel demand horsepower (grades exceeding 3% with GVW at 80,000
pounds or above).
• Vehicle encounters high ambient air temperatures (areas where average summer temperatures exceed
90° F for 30% of season.
• Vehicle configurations restrict air flow around transmission, such as low front bumpers, license plate racks
below bumper, deck plates, optional fuel tanks, and similar items.
Transmission oil coolers are required for 400 Peak HP or greater.
Transmission oil coolers are recommended for 350 to 399 Peak HP.
Transmission oil coolers may be required in all severe service applications or where high ambient temperatures
are normal.
1075
Auxiliary Transmission Oil Cooler

Overview
0013702 HX620 - Oil Cooler, auxiliary transmission for Spicer auxiliary transmission,
front mounted, includes oil pump
1076
AUXILIARY TRANSMISSIONS
6. Auxiliary Transmissions
Fuller
Overview
0013607 HX620 - Transmission, Auxiliary {Fuller AT-1202} 2 speed with
air shift controls two speed Fuller AT-1202 Auxiliary Transmission
extends extreme low gear reduction required for demanding
applications
Auxiliary transmissions are used in severe service and On/Off highway applications.
1077
AUXILIARY TRANSMISSIONS
Spicer®
Overview
0013PDN HX620 - Transmission, Auxiliary {Spicer ATO-1750-4C} 4 speed;
mounted with pin center of forward flange 48 in. back of cab Includes
1241-C top mounted PTO; with output to front and lube pump
Auxiliary transmissions are used in severe service and On/Off highway applications.
1078
7. Power Take Off (PTO)

Transmission Mounted PTO
Overview
0013XAR PTO, Location, bottom of transmission
0013XAM PTO, Location, dual, left and right of transmission
0013XAT PTO, Location, dual, left and top of transmission
0013XAV PTO, Location, dual, right and bottom of transmission
0013XAJ PTO, Location, dual, right and rear of transmission
0013XAL PTO, Location, left of transmission
0013XAN PTO, Location, no PTO
0013XAS PTO, Location, rear of transmission
0013XAK PTO, Location, right of transmission
0013XAP PTO, Location, top of transmission
1079
Thru-shaft PTO
Overview
0013901 Thru-shaft PTO provision; left; with Fuller transmission
1080
PTO Controls - Dash Mounted

Overview
0013WVD PTO control, dash mounted for customer provided PTO; includes control
valve, piping and wiring, wired for PTO
0013XAZ PTO CONTROL, DASH MOUNTED For Customer Provided PTO, Includes
Switch and Wiring, for Allison Transmission
Controls for customer provided PTO for HX620 are mounted on dash for operator use.
1081
Dash Mounted Electrical Controls

See section 08 - Electrical for Dash Mounted PTO Controls.
1082
TABLE OF CONTENTS
Rear Axle and Suspension

Table of Contents
1. Axle Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085
Axle Lift Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085
Axle Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085
Axle Mounting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086
System Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086
Self-steering Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087
2. Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088

Air Suspensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088
Torque Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1090
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1090
Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1091
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1092
Transverse Torque Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1093
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1093
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1094
Cross Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1095
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1095
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1096
Leveling Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1097
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1097
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1098
Tandem Rear Suspension (Chalmers Walking Beam Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1099
Hendrickson - Walking Beam Type Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1101
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104
Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1104
Center Bushing Replacement Rubber or Bronze (On Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1105
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1107
Three-piece Beam End Adapter with Rubber Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1108
Remove (On Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1108
Install (On Vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1109
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110
Driveline Service and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111
Height Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
Driveline Angle Procedure - How to Measure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1115
Ride Height Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116
Ride Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1120
Drive Line Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1121
1083
TABLE OF CONTENTS
1084
AXLE CONTROLS
1. Axle Controls
Axle Lift Controls
Overview
0014RAA Axle, Lift, Controls for one lift axle; all controls inside cab; includes pressure
gauge, pressure regulator and lift/lower switch
0014RAR Axle, Lift, Controls for one lift axle; controls inside cab on center dash panel;
includes pressure gauge and pressure regulator outside cab
0014RAU Axle, Lift, Controls for one non-steer lift axle, customer installed, all controls
inside cab
0014RAV Axle, Lift, Controls for two lift axles, controls inside cab on center dash panel,
includes pressure gauges and regulator outside
0014RAD Axle, Lift, Controls for two lift axles; all controls inside cab; includes pressure
gauge, pressure regulator and lift/lower switch
Lift axle systems; including axle assemblies, controls and control lines. Types of lift axles covered are
self-steering axles and fixed (non-steering) axles. Lift axles covered may be configured as pusher axles
(located ahead of rear drive axles) or tag axles (located behind rear drive axles).
Axle Types
Fixed Axles
Fixed axles do not allow wheels to steer while cornering. This causes increased tire wear due to tire scrubbing
while cornering, but it allows axle design to be simple, requiring less maintenance. Fixed axle currently used
has a 20,000 pound maximum load capacity and may be used as a tag axle or a single pusher axle.
Self-Steering Axles
Self-steering axles reduce tire wear, but are more complex than fixed axles. Self-steering axles are similar to
front, non-driving, steering axles. Like a front axle, steering arms and knuckles at ends of self-steer axle are
connected by a tie rod so that both tires on axle track together. A spring-loaded self-centering mechanism
keeps tires aimed straight ahead until drag created by cornering causes tires to deflect, or steer, in direction
that creates least rolling resistance. As direction of travel straightens out self-centering mechanism returns
tires to their straight ahead position.
Self-steer axle currently used has a 13,200 pound maximum load capacity. Self-steer axle may be used in any
lift axle location and in any combination.
1085
AXLE CONTROLS
Axle Mounting Locations
Pusher Axles
Pusher axles are mounted ahead of rear drive axles. Depending on application, following things may vary
between pusher axles:
• Type of axle (self-steer or fixed)

• Maximum load capacity of lift axle assembly
• Mounting distance between drive axle and nearest pusher axle
• Mounting distance between pusher axles (when two pusher axles are used)
• Ride height of pusher axle
These items are selected before lift axle installation and are not changeable after installation.
Tag Axles
Tag axles are mounted behind rear drive axles. Depending on application, following things may vary between
tag axles:
• Type of axle (self-steer or fixed)

• Maximum load capacity of axle
• Mounting distance between drive axle and tag axle
• Ride height of tag axle
These items are selected before lift axle installation and are not changeable after installation.
Axle Spacing
Optimum spacing between drive axle(s) and lift axles (and between multiple lift axles) is determined by vehicle
application. This spacing is set when lift axle is installed. Once installed, axle spacing is not adjustable and
has no effect on maintenance of system.
System Controls
Controls
Lift axle controls are available in two configurations. Either all of controls are located inside cab, or controls are
split between inside cab and outside cab. Lift axle controls consist of following:
• Axle Enable Switch (one switch per vehicle): Activate remaining electrical controls of all lift axles on vehicle.
• Lift Axle UP / DOWN Switch (separate switch for each lift axle): Raise and lower indicated lift axle.
• Pressure Regulator Control (separate control for each axle): Adjust pressure in load air springs on
indicated lift axle.
• Pressure Gauge (one gauge per axle for in-cab controls; two gauges per axle for mixed controls): Indicate
pressure in load air springs on indicated lift axle.
1086
AXLE CONTROLS
In Cab Controls
Axle controls are located on a floor mounted pedestal next to driver’s seat. Controls accessible from driver’s
seat are Axle Enable Switch, Lift Axle UP / DOWN Switch, Pressure Regulator and Pressure Gauge.
Mixed Controls - Pressure Gauge and Switches in Cab and Pressure Gauge and Regulator Outside Cab
Axle Enable Switch, Lift Axle UP / DOWN Switch, and a Pressure Gauge are located on a floor mounted
pedestal next to driver’s seat. Pressure Regulator and a second Pressure Gauge are located on an external
panel located at rear of cab. This allows load air spring pressure to be set from outside of cab, while still
allowing control switches and Pressure Gauge to be accessible from driver’s seat.
Self-steering Axle Assemblies
Overview
Self-steering axles reduce tire wear; but are more complex than fixed axles. Self-steering axles are similar to
front, non-driving, steering axles. Like a front axle, steering arms and knuckles at ends of self-steer axle are
connected by a tie rod so that both tires on axle track together. A spring-loaded self-centering mechanism
keeps tires aimed straight ahead until drag created by cornering causes tires to deflect, or steer, in direction
that creates least rolling resistance. As direction of travel straightens out self-centering mechanism returns
tires to their straight ahead position.
Self-steer axle currently used have a 13,200 pound load capacity. Self-steer axle may be used in any lift axle
location and in any combination.
Self-centering self-steering axles can only track while moving forward. Backing up with auxiliary suspension in
down position can result in damage to steering components of axle; therefore, self-steering lift axles must
be lifted when vehicle is in reverse. Factory installed self-steering lift axles include a control system that
automatically raises all lift axle assemblies when vehicle is put into reverse.
1087
REAR SUSPENSION
2. Rear Suspension
Air Suspensions
Overview
0014UKZ Suspension, Rear, Tandem {Hendrickson HMX-460-60} walking beam type
60 in. axle spacing; 46,000 pound capacity, with rubber end bushings,
transverse torque rods, less shock absorbers
0014ULU Suspension, Rear, Tandem {Chalmers 854-46H} walking beam type, with
rubber spring, 54 in. axle spacing; 46,000 pound capacity, with standard
restrictor cans, (8) torque rods, less shocks
0014ULA Suspension, Rear, Air Tandem {Hendrickson HAS-402-60} 60 in. axle
spacing; 40,000 pound capacity, 9.5 in. ride height, with shock absorbers
mounted in standard location
0014ULV Suspension, Rear, Air Tandem {Hendrickson HAS-402-60} 60 in. axle
mounted inboard
0014ULB Suspension, Rear, Air Tandem {Hendrickson HAS-460-55} 55 in. axle
0014ULT Suspension, Rear, Air Tandem {Hendrickson HAS-460-55} 55 in axle
mounted inboard
0014ULC Suspension, Rear, Air Tandem {Hendrickson HAS-460-60} 60 in. axle
0014ULS Suspension, Rear, Air Tandem {Hendrickson HAS-460-60} 60 in. axle
mounted inboard
0014UNX Suspension, Rear, Tandem {Hendrickson HMX-400-54} walking beam type
54 in. axle spacing; 40,000 pound capacity, with rubber end bushings,
transverse torque rods, less shock absorbers
0014UPX Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 55 in. axle
0014UPV Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 55 in. axle
0014UNY Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 60 in. axle
0014UPU Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 60 in. axle
1088
REAR SUSPENSION

0014UPW Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 60 in. axle
0014UNW Suspension, Rear, Air Tandem {Hendrickson PRIMAAX EX} 72 in. axle
0014UPC Suspension, Rear, Air, Tridem {Hendrickson PAX-690-55} 55 in. axle
Rear tandem suspensions provide versatility needed for trucks and tractors which operate both on- and
off-highway. Rear axles are tied together by suspension's equalizing beams (walking beams). Equalizing
beams keep axles in set parallel, to help ensure that load being carried remains balanced. By balancing load
between rear axles, as well as inclusion of torque rods, stability is enhanced and articulation is increased
for improved on/off highway operation.
1089
REAR SUSPENSION
Torque Rods
Removal
WARNING
To prevent property damage, personal injury, or death, always use floor stands to support
vehicle before working under it. Using only a jack could allow vehicle to fall.

4. Chassis air system should be within normal operating range of 100 - 120 psi.
Procedure
1. Remove straddle mount bar pin locknuts and washers at axle end of torque rod.
2. Loosen rebound bolt locknut in frame hanger.
3. Remove straddle mount locknuts, bolts, and washers, and any alignment shims at frame hanger ends of
torque rod. Remove torque rod. Note number of shims as they must be reinstalled in same position to
avoid affecting axle alignment.
1090
REAR SUSPENSION
Reinstallation
None
Procedure
WARNING
Squarely support torque rod on hydraulic press table to remove bushings.
CAUTION
Do not use heat or a cutting torch to remove bushing from torque rod. Use of heat will
adversely affect strength of torque rod.
1. Using shop press, push out old bushing.
2. Use five in. long, two in. ID, and 1/4 in. wall steel tube tool.
3. Support torque rod end on tube tool and center bushing.
4. Push directly on bushing straddle mount bar pin until bushing clears torque rod end.
5. Clean and inspect ID of torque rod ends; remove any nicks with emery cloth.
6. Lubricate ID of torque rod ends and new rubber bushings with a vegetable base oil (cooking oil or lard) only.
WARNING
Squarely support torque rod on hydraulic press table to install bushings.
7. Press in new bushings.
8. Support torque rod end on receiving tool with end tube of torque rod centered on receiving tool.
9. Straddle mounted bar pin bushing must have flats positioned 10 degrees counterclockwise to shank of
torque rod.
10. Press directly on straddle mount bar pin bushing. Bushing must be centered within torque rod end tubes.
11. When pressing in new bushings, press past desired final position by approximately 3/16 in.
12. Press bushing again from opposite side to center bushing within torque rod end.
1091
REAR SUSPENSION
Installation
Torque Rod Bar Pin Locknut 150 - 205 lb-ft (203 - 278 N·m)
Rebound Bolt Locknut 49 - 66 lb-ft (66 - 89 N·m)
Procedure
1. Position new or re-bushed torque rod in bottom cap and install washers and locknuts. Do not torque
nuts at this time.
2. Position torque rod on forward face of frame hanger legs and assemble bolts, washers, locknuts and any
alignment shims. Tighten locknuts (page 1110).
3. Tighten locknuts at axle end of torque rod. Tighten locknuts (page 1110).
4. Tighten rebound bolt locknuts (page 1110).
1092
REAR SUSPENSION
Transverse Torque Rod
Removal
WARNING

Procedure
1. Remove locknuts and washers that connect transverse rod to frame (if rod is double straddle design,
remove axle fasteners also).
2. Remove locknuts and washers which connect tapered stud to axle bracket.
3. Remove tapered stud from axle bracket by striking axle bracket only with hammer.
4. Remove torque rod bushing.
1093
REAR SUSPENSION
Installation
Torque Rod Tapered Stud Nuts 500 - 600 lb-ft (675 - 810 N·m)
Transverse Rod Locknut 175 - 225 lb-ft (237 - 305 N·m)
Procedure
1. Clean tapered hole in axle bracket of all foreign material.
2. Install tapered stud in axle bracket.
3. Install washer and locknut on stud. Tighten locknut (page 1110).
4. After tightening, strike axle bracket only with hammer and check torque values per Step 3 above.
5. Position straddle mount end of torque rod at transverse rod frame bracket.
6. Install washers and locknuts that connect transverse rod to frame. Tighten locknuts (page 1110) (if double
straddle design, repeat for axle bracket connection).
1094
REAR SUSPENSION
Cross Tube
Removal
WARNING

Procedure
1. Dump air pressure from air springs. Raise frame of vehicle to remove load from suspension. Use frame
stands.
2. Remove locknuts and washers that connect air spring mounting brackets to both main support members.
3. Raise both air spring mounting brackets with cross tube by using jacks under each air spring mounting
bracket. Raise up high enough so that cross tube clears main support members.
4. Remove cross tube by sliding it out from air spring mounting brackets.
1095
REAR SUSPENSION
Installation
Air Spring Bracket to Main Support Member Locknut 220 - 300 lb-ft (298 - 407 N·m)
Procedure
1. Grease bore of each air spring mounting brackets.
2. Install cross tube to attached air spring mounting bracket by sliding it through bore, across into opposite air
spring mounting bracket bore.
3. Lower both air spring mounting brackets with cross tube in place; guide bolts into main support member
holes.
4. Install washers and locknuts that connect air spring mounting bracket to main support member. Tighten
locknuts (page 1110).
5. Lower vehicle and remove stands.
1096
REAR SUSPENSION
Leveling Valve
Removal
WARNING

Procedure
1. Raise vehicle and support axle with floor stands.
2. Dump air pressure from air springs.
3. Remove rebound bolt, lock nut, washers, spacer tube and rebound roller from frame hanger.
4. Raise rear of frame high enough to remove load from main support member.
5. Remove U-bolts locknuts and washers.
6. Remove U-bolts, bottom cap, and top pad.
7. Remove both locknuts and washers which connect the air spring mounting brackets to both main support
members.
8. Lift air spring mounting brackets off the main support members with jacks.
9. Remove main support member assembly.
1097
REAR SUSPENSION
Installation
Procedure
1. Install height control valve and secure with two bolts and nuts. Torque bolts and nuts (page 1110).
2. Connect height control rod to height control valve lever and secure with locknut and washer. Torque
locknut (page 1110).
3. Connect two air lines to height control valve.
4. Check ride height and adjust as needed.
1098
REAR SUSPENSION
Tandem Rear Suspension (Chalmers Walking Beam Type)

Overview
0014UZS Suspension, Rear, Tandem {Chalmers 854-40L} walking beam type, with
0014UZB Suspension, Rear, Tandem {Chalmers 854-46H-HS} walking beam type,
rubber spring, 54 in. axle spacing; 46,000 pound capacity, with High
Stability (HS) restrictor cans and (8) torque rods less shocks
0014UZT Suspension, Rear, Tandem {Chalmers 860-46H-HS} walking beam type,
with rubber spring, 60 in. axle spacing; 46,000 pound capacity, with High
Stability (HS) restrictor cans, (8) torque rods, less shocks
0014UZU Suspension, Rear, Tandem {Chalmers 854-46H} walking beam type, with
0014UZV Suspension, Rear, Tandem {Chalmers 860-46H} walking beam type, with
0014UZW Suspension, Rear, Tandem {Chalmers 872-46H-HS} walking beam type,
0014UZX Suspension, Rear, Tandem {Chalmers 854-52-H-HS} walking beam type,
Figure 575 Chalmers 800 Suspension
1099
REAR SUSPENSION
Chalmers 800 Series

Chalmers 800 Series tandem suspensions are rubber load cushion suspensions, designed for heavy tractor,
mixer, dump, logger and refuse applications.
Chalmers variable rate rubber springs, one per side, are directly loaded in compression and self-adjust to load
on impact. Metal cans fit over rubber springs to prevent excessive deformation and provide additional stability.
Each rubber spring bears on middle of a walking beam, ends of which rest on two axles. Rubber springs and
beams are sole support and cushion load and provide oscillation.
1100
REAR SUSPENSION
Hendrickson - Walking Beam Type Suspension

Overview
0014ULX HX515, HX615, HX620 6x4 - Suspension, Rear, Tandem {Hendrickson
HMX-400-54} walking beam type 54 in. axle spacing; 40,000 pound
capacity, with rubber end bushings, transverse torque rods, less shock
absorbers
0014UHD Suspension, Rear, Tandem {Hendrickson RT-403} walking beam type 54
in. axle spacing; 40,000 pound capacity with rubber center bushings
0014UHK Suspension, Rear, Tandem {Hendrickson RT-463} walking beam type 54
in. axle spacing; 46,000 pound capacity with bronze center bushings
0014UHL Suspension, Rear, Tandem {Hendrickson RT-463} walking beam type;
60 in. axle spacing, 46,000 pound capacity with transverse torque rods
and rubber center bushings
0014ULY Suspension, Rear, Tandem {Hendrickson HMX-460-54} walking beam
type 54 in. axle spacing; 46,000 pound capacity, with rubber end
bushings, transverse torque rods, less shock absorbers
0014ULZ Suspension, Rear, Tandem {Hendrickson HMX-460-60} walking beam
type 60 in. axle spacing; 46,000 pound capacity, with rubber end
0014UMC Suspension, Rear, Tandem {Hendrickson HMX-460-72.5} walking beam
type 72.5 in. axle spacing; 46,000 pound capacity, with rubber end
0014698 Suspension, Rear, Tandem {Hendrickson RT-523} walking beam Type
54 in. axle spacing; 52,000 pound capacity with bronze center bushings
0014524 Suspension, Rear, Tandem {Hendrickson RT-650} walking beam type 56
in. axle spacing; 65,000 pound capacity with rubber center bushings
0014UJE Suspension, Rear, Tandem {Hendrickson R-700} walking beam type,
solid mount 60 in. axle spacing; 80,000 pound capacity less transverse
torque rods
1101
REAR SUSPENSION
Figure 576 Hendrickson RT Series Suspension
Hendrickson RT Series
For applications that require suspensions with higher weight carrying capacities, use Hendrickson RT series.
Hendrickson RT suspensions have leaf spring design and connect forward rear and rear-rear axles together
with equalizing beams.
RT Series provides excellent durability and traction for dump, construction, refuse, cement mixer, and
fire/rescue trucks that operate in both on and on/off highway environments.
Hendrickson RT series suspensions have weight capacities ranging from 34,000 to 65,000 pounds. Axle
spacing ranges from 52 to 60 inches.
1102
REAR SUSPENSION
Figure 577 Hendrickson HMX Suspension
Hendrickson HMX Suspensions

Hendrickson HMX Series suspensions are premium rubber suspension designed for vehicle applications
where durability and driver comfort are essential. Suspensions offers an excellent ride and provides superior
roll stability. Improved ride reduces road shock and vibration to vehicle for longer service life and fewer repairs.
Light weight suspension allows for increased payload for vehicle.
These suspensions provide versatility needed for trucks and tractors which operate both on and off highway.
Rear axles are tied together by suspension's equalizing beams (walking beams). Equalizing beams keep both
axles in set parallel, to help ensure that load being carried remains balanced. By balancing load between
two rear axles, as well as inclusion of torque rods, stability is enhanced and articulation is increased for
improved on/off highway operation.
1103
REAR SUSPENSION
Maintenance
Fasteners
Beam End Tube Nut 375 - 425 lbf-ft (508 - 576 N·m)
Procedure
Check torque of beam end fasteners after 1,000 miles (1,600 km) of off-road or severe service, or 10,000
miles (16,000 km) of on-road service.
WARNING
Fasteners which do not provide a secure joint between frame and brackets can cause
premature failure of frame brackets, separation of components, loss of vehicle control
and possible personal injury or property damage.
Tighten fasteners to values found in torque chart (page 1110).
1104
REAR SUSPENSION
Center Bushing Replacement Rubber or Bronze (On Vehicle)
Removal
WARNING
CAUTION
Do not modify or substitute parts.
CAUTION
Do not use a cutting torch to remove any attaching fasteners, to remove beams from
axles or to remove bushings from beam centers or ends. All beams are heat-treated
for strength and long service life. Use of heat (cutting torch or welding) on suspension
components will shorten life of these parts. A part that is damaged in this manner may
fail in operation.
CAUTION
Aluminum components (such as beams) can be damaged with prolonged exposure

to salt or acid wash, or by contact with hard objects that gouge parts. A part that is
excessively damaged may fail during operation.

Procedure
1. Raise axles and support vehicle by frame. Use frame stands.
2. Remove wheels from forward rear axle on side being serviced.
3. Remove nuts and washers securing saddle caps, then remove caps.
4. Remove bushings.
1105
REAR SUSPENSION
5. Use hole saw to remove plug welded on outside end of inner section of rubber bushing.
6. Use 2 in. (50.8 mm) diameter hole saw for 340 Series bushings; use 2-1/2 in. (63.5 mm) diameter hole
saw for 380 through 450 Series bushings.
7. For bronze bushings, remove center sleeve by hand.
8. After plug has been cut out or center sleeve removed, remove cross tube through hole.
9. With bronze bushings, remove seal on bushing side of beam.
10. Using hydraulic press, remove center bushing from beam.
1106
REAR SUSPENSION
Installation
Saddle Nut 275 - 300 lbf-ft (373 - 407 N·m)
Saddle Cap Stud 55 - 60 lbf-ft (75 - 88 N·m)
Procedure
IMPORTANT – Do not install bronze center bushings into aluminum suspension beams.
1. After removing bushings, thoroughly inspect beam bores.
CAUTION
If torch undercutting is found from previous maintenance procedures, replace beam. Do

not take responsibility for possible road failure by re-bushing defective beam.
2. Clean beam center bores with emery cloth, removing any nicks or metal build-up.
3. Use emery cloth to remove rust-protective coating from outer metal of new bushing, then apply a thin
coat of multi-purpose grease.
4. Install new bushing into beam.
5. Lubricate both ends of cross tube and install tube.
6. Install bushing plug / center.
7. With rubber bushing, install bushing plug in same location as one removed, and arc weld in place.
8. With bronze bushing, install thrust washer / seal on center sleeve.
9. Using jack, raise beam into position. Install saddle caps and washers / nuts, then tighten to specifications.
See torque chart (page 1110). Remove jack from beam.
10. Install wheels.
11. Lower vehicle and put back into service.
1107
REAR SUSPENSION
Three-piece Beam End Adapter with Rubber Bushing
Remove (On Vehicle)

WARNING
CAUTION
Do not modify or substitute parts.
CAUTION
Do not use a cutting torch to remove any attaching fasteners, to remove beams from
axles or to remove bushings from beam centers or ends. All beams are heat-treated
for strength and long service life. Use of heat (cutting torch or welding) on suspension
components will shorten life of these parts. A part that is damaged in this manner may
fail in operation.
CAUTION
Aluminum components (such as beams) can be damaged with prolonged exposure

to salt or acid wash, or by contact with hard objects that gouge parts. A part that is
excessively damaged may fail during operation.

Procedure
1. Raise axles and support vehicle by frame. Use frame stands.
2. Remove wheels from forward rear axle on side being serviced (front or rear depending on beam end
being serviced.
1108
REAR SUSPENSION
Install (On Vehicle)

None
Procedure
1. Raise axles and support vehicle by frame if not already done. Use frame stands.
2. Install wheels on forward rear axle on side that was serviced (front or rear depending on beam end
being serviced.
3. Raise axles by frame and remove frame stands.
4. Lower axles by frame to floor.
5. Return vehicle to normal service.
1109
REAR SUSPENSION
Torque
Description Torque
U-bolt Locknut 260 - 300 lbf-ft (352 - 407 N·m)
Torque Rod Bar Pin Locknut 150 - 205 lbf-ft (203 - 278 N·m)
Rebound Bolt Locknut 49 - 66 lbf-ft (66 - 89 N·m)
Shock Absorber Locknut 50 - 70 lbf-ft (68 - 95 N·m)
Air Spring Bracket to Main Support Member Locknut 220 - 300 lbf-ft (298 - 407 N·m)
Air Spring to Frame Hanger Locknut 50 - 70 lbf-ft (68 - 95 N·m)
Air Spring to Frame Hanger Locknut 20 - 30 lbf-ft (27 - 41 N·m)
Air Spring to Mounting Bracket Locknut 20 - 30 lbf-ft (27 - 41 N·m)
Transverse Rod Locknut 175 - 225 lbf-ft (237 - 305 N·m)
Extension Arm Jam Nut 100 - 150 lbf-in. (11 - 17 N·m)
Extension Arm Locknut 100 - 150 lbf-in. (11 - 17 N·m)
Transverse Torque Rod Straddle Mount End 200 - 240 lbf-ft (271 - 320 N·m)
Air Spring Frame Hanger Nuts 110 - 120 lbf-ft (149 - 163 N·m)
Height control valve bolts and nuts (2) 111 lbf-ft (151 N·m)
Height control rod to height control valve lever locknut 142 lbf-in. (16.0 N·m)
and washer
Maintenance Torque Chart

Description Torque
Torque Rod Tapered Stud Nuts 500 - 600 lbf-ft (675 - 810 N·m)
Torque Rod Bracket Mounting Bolt Nuts 250 - 275 lbf-ft (339 - 373 N·m)
Torque Rod Mounting Bolt (1-1/8 in.) 550 - 600 lbf-ft (746 - 813 N·m)
Spring Center Bolt (7/16 - 20) 50 - 60 lbf-ft (68 - 81 N·m)
1/2 - 20 65 - 75 lbf-ft (88 - 102 N·m)
Spring Pin Draw-key Nut 75 - 100 lbf-ft (102 - 136 N·m)
Spring Pin Double Lock Bolt Nut 45 - 63 lbf-ft (61 - 85 N·m)
Rear Spring Bracket Rebound Bolt Nut 70 - 80 lbf-ft (95 - 108 N·m)
Top Pad to Spring(Spring Aligning Set Screw) 100 - 150 lbf-ft (136 - 203 N·m)
Top Pad to Saddle Bolt Nut, Leaf Spring 275 - 300 lbf-ft (373 - 407 N·m)
Saddle Nut 275 - 300 lbf-ft (373 - 407 N·m)
Saddle Cap Stud 55 - 60 lbf-ft (75 - 88 N·m)
Beam End Tube Nut 375 - 425 lbf-ft (508 - 576 N·m)
Bar Pin Beam End (All Series) 450 - 600 lbf-ft (611 - 810 N·m)
Bolt Diameter 1” Grade 8 (Not shown)
To get maximum service life from a suspension system, check torques of mounting bolts
and nuts periodically, and tighten to specified torque.
1110
REAR SUSPENSION
Driveline Service and Troubleshooting

Overview
Air ride suspension is the ultimate in smooth, shock and vibration-free ride with a preset constant frame height.
Air springs on air ride suspension take place of steel springs, which means there is no inter-leaf friction to
overcome. Thereby, minimum road shock is transferred to frame, cargo, and driver air suspension (6 x
4) and air suspension (4 x 2).
Air ride suspension adjusts to load changes automatically, providing a low rate suspension with a light or no
load condition, and a higher rate suspension with heavier loads. Major components of air suspension system,
whether used on single or tandem axles are as follows:
Figure 578 Air Suspension (6X4)

1. Air spring 8. Bushing
2. Shock absorber 9. Suspension mounting bracket
3. Upper U-bolt axle seat 10. Frame rails
4. U-bolts 11. Axle stop
5. Lower U-bolt plate 12. Reinforcement plate
6. Tapered leaf spring 13. Shock absorber frame mounting bracket
7. Axle seat 14. Air spring mounting bracket
1111
REAR SUSPENSION
Figure 579 Air Suspension (4x2)

1. Air spring 8. Bushing
2. Shock absorber 9. Suspension mounting bracket
3. U-bolt / axle seat 10. Frame rails
4. U-bolts 11. Axle stops
5. Lower U-bolt plate 12. Reinforcement plate
6. Tapered leaf spring 13. Shock absorber upper mounting bracket
7. Axle seat 14. Air spring mounting bracket
1112
REAR SUSPENSION
Height Control Valve
Overview
Height control valve is the brain of air suspension and is sensitive to height. When properly adjusted it will
provide and maintain ride height.
Figure 580 Height Control Valve System Components

1. Control valve lever 4. Height control adjustment rod
2. Height control valve 5. Torque rod mounting
3. Air spring
Height control valve is mounted forward of front axle on tandem axle assembly, drivers side frame rail. Valve
has a lever arm connected to forward axle assembly with a vertical linkage rod. This height control valve lever
is sensitive to frame height thus providing automatic filling or exhausting of air springs maintain vehicle
ride height.
Place valve arm in neutral position (on center-indent) to automatically return valve to a closed position.
Height control valve is closed in neutral position.
1113
REAR SUSPENSION
Figure 581 Height Control Valve (Mounted On Passenger Side) For Dual Ride Height Feature
1. Air line 6. Height control rod
2. Air spring 7. Height control valve
3. Pilot valve tee 8. Height control valve cross feed air line
4. Spring fill tee 9. Main feed air line supply
5. Pilot air supply line
Figure 582 Height Control Valve (Mounted On Passenger Side Rail)

1. Air spring fill line (rear) line 5. Tee
2. Dump pilot line 6. Height control rod
3. Air spring supply line (pre-formed) 7. Height control valve
4. Air spring 8. Air line main feeds (valve supply line)
1114
REAR SUSPENSION
Driveline Angle Procedure - How to Measure

Often a valve is unnecessarily replaced. There are basic steps to be performed to determine if valve is
defective or if proper adjustment has not been performed. To determine status of a valve, perform following
service checks:
1. Remove cotter pin and washer from upper link. Loosen clamp and detach vertical linkage from height
control lever arm.
2. Assure that brake air reservoir pressure is at governor cutoff pressure or about 100 psi (689.5 kPa).
3. Raise height control valve lever approximately 45 degrees above horizontal.

a. Air pressure at air springs should begin to increase within 15 seconds.
b. Truck frame will rise. Detect by feeling shock absorber extend at dust tube to shock absorber body joint.
4. Lower height control valve lever approximately 45 degrees below horizontal.

a. Air pressure at air springs will decrease.
b. Reduce air pressure until air spring height is approximately 10 inches (254 mm).
5. Raise valve lever to 45 degrees above horizontal, until air spring height is to dimension shown in Ride
Height Dimensions .
a. Refer to X dimension shown in Height Adjustment Valve and Rod .
b. Release the valve lever.
6. Check valve body and all tubing connections and air springs for air leaks with soapy water. Repair as
necessary.
7. Recheck air spring height 15 minutes after step 5 above has been completed. If air spring height has
changed, return to step 5 and repeat until correct height is obtained.
8. If no leaks are found, and height control valve functions as described above, and air spring height is at
specified dimension after 15 minutes, valve is functioning properly.
9. Refer to Ride Height Adjustment and perform adjustment .
1115
REAR SUSPENSION
Ride Height Measurement
Overview
Test to accurately measure vehicle ride height and determine if any adjustments are required for air
suspensions with single frame rail other than International Ride Optimized Suspension (IROS).
For Hadley Smartvalve Service Information, refer to www.hadleyadvantage.com.
Special Tools
• Tape Measure
Specifications
True center of axle tube to bottom of frame rail See installed Feature Code description
(±1/8 in.)
1. Vehicle parked on a hard, flat, level surface.
2. Transmission in neutral (or park, if automatic transmission).
3. Chassis air system within normal operating range 100 to 120 psi (6.9 to 8.3 bar).
4. Key OFF.
5. Wheel chocks installed. Do not apply parking brake or come to abrupt stop.
6. Vehicle unloaded.
Measurement Procedure
1. With air system pressure over 100 psi, deflate rear suspension to lowest level.
2. Re-inflate rear suspension allowing it to return to ride height with air system pressure over 100 psi.
1116
REAR SUSPENSION
1 2
3
0000432832
Figure 583 Axle Tube Front Center Line

1. Axle tube front vertical measurement 3. Axle tube
2. Axle tube center line mark
3. At wheel end of axle tube (3), closest to leveling valve, measure vertically on front of axle tube (1) and
find the center of the axle tube.
4. Mark a line on the front of the axle tube indicating the center measurement of the axle tube (2).
1117
REAR SUSPENSION
1 2
3
0000432834
Figure 584 Axle Tube Rear Center Line

1. Axle tube center line mark 3. Axle tube
2. Axle tube rear vertical measurement
5. At same wheel end of axle tube (3), measure vertically on the rear of the axle tube (2) and find the center
of the axle tube.
6. Mark a line on the rear of the axle tube indicating the center measurement of the axle tube (1).
1118
REAR SUSPENSION
4 3 2
0000432831
Figure 585 Ride Height Measurement

1. Bottom of frame rail 3. True center of axle tube
2. Marked line on front of axle tube 4. Marked line on rear of axle tube
7. Measure vertical distance from marked line on front of axle tube (2) to bottom of frame rail (1). Record
measurement.
8. Measure vertical distance from marked line on rear of axle tube (4) to bottom of frame rail (1). Record
measurement.
9. Average recorded measurements made from front and rear of axle tube. Averaged measurement will
indicate proper ride height from true center of axle tube (3) to bottom of frame rail (1).
10. Ensure measurement average reads the same as stated in the installed Feature Code description.
11. If measurements are out of specification, perform follow-on procedure to make necessary adjustments.
Follow-On Procedure
1. Perform Ride Height Adjustment (page 1120) if ride height is out of specification.
1119
REAR SUSPENSION
Ride Height Adjustment
Overview
Procedure to properly adjust ride height if out of specification.
For Hadley Smartvalve Service Information, refer to www.hadleyadvantage.com.
Special Tools
• Tape Measure
Specifications
Ride height measurement See installed Feature Code description
1. Perform Ride Height Measurement (page 1116).
Adjustment Procedure
Travel exceeds specification:
1. Do not bend height control system brackets or rods to adjust suspension height.
2. Loosen lever arm bolt that holds arm to height control valve.
3. Pivot lever arm down to exhaust air from suspension, lowering chassis to some point below
correct air spring height.
4. Final air spring height must be achieved by adding air to suspension, not exhausting.
5. Add air until axle travel reaches proper value according to specifications table.
6. When correct axle travel value has been achieved, retighten lever arm bolt.
Travel is less than specification:

1. Do not bend height control system brackets or rods to adjust suspension height.
2. Loosen lever arm bolt that holds arm to height control valve.
3. Push lever arm up to add air to suspension, raising chassis, until axle travel reaches proper
value according to specifications table.
4. When correct axle travel value has been achieved, retighten lever arm bolt.
Follow-On Procedure
None
1120
REAR SUSPENSION
Drive Line Vibration
1121
REAR SUSPENSION
1122
TABLE OF CONTENTS
Fuel System
Table of Contents
1. DEF System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125
DEF Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1127
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1128
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1130
Diesel Exhaust Fluid (DEF) Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1132
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1134
Diesel Exhaust Fluid (DEF) Head Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1137
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1137
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1139
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1141
DEF Supply Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1143
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1143
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1145
Inlet Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1147
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1147
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1149
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1151
DEF Doser Inlet Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1153
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1153
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1155
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1157
2. DEF Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160

DEF Tank (9.5 Gallon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160
DEF Tank Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164
DEF Tank (15.9 Gallon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1166
DEF Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1168
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1168
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1169
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1171
DEF Supply Module Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1173
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1173
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1175
DEF Head Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1177
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1177
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1179
DEF Tank (16 Gallon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1181
DEF Tank Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1181
3. Fuel Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1182

Fuel Cooler Without Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1182
4. Fuel Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1183

Cummins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1183
Fuel Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1183
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1183
1123
TABLE OF CONTENTS
5. Fuel Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1185

Davco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1185
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1187
Filter Change Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1188
Racor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1189
Fuel Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1189
Common Issues with Winter Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1190
Fuel Wax. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1190
Fuel Blending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191
6. Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1192

Hydraulic Reservoir (60 Gallon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1192
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1193
1124
DEF SYSTEM
1. DEF System
DEF Tank
Overview
0015WDY DEF tank, 15.9-US gal (60.1 L) capacity, frame-mounted outside left
rail, under cab
Figure 587 Diesel Exhaust Fluid (DEF) Tank Location

1. DEF lines 2. DEF tank
Vehicles with Selective Catalytic Reduction (SCR) systems are equipped with a DEF tank.
DEF
DEF is the reactant necessary for functionality of the SCR system. It is a clear, nontoxic fluid, which is used
to deliver ammonia to the SCR catalyst and is a 32.5 percent strength urea/water solution with high purity
requirements
DEF Tank
The DEF tank is filled with DEF and houses the DEF tank pickup assembly.
1125
DEF SYSTEM
DEF Supply Module

DEF fluid is provided to the SCR system by the DEF supply module. The DEF supply module controls flow
or dosing rate of DEF.
DEF Tank Pickup Assembly

The DEF tank pickup assembly is mounted in the DEF tank. The assembly includes the DEF level sensor,
urea quality sensor, pickup screen, heating loop, temperature sensor in level housing, and temperature
sensor in quality housing. These components are used to circulate coolant to heat and defrost DEF and
are serviced as a complete assembly.
DEF Lines
DEF lines supply DEF from the DEF tank to the DEF supply module and dosing valve.
DEF Coolant Lines

DEF coolant lines supply coolant to the DEF tank and dosing valve to heat or defrost DEF.
DEF Tank Heater Valve

DEF tank heater valve is an electronically controlled check valve that controls coolant flow to the DEF tank
during temperatures below 32°F (0°C). The valve is controlled by the Aftertreatment Control Module or Engine
Control Module depending on the application.
DEF Line Heater

The DEF line heater is used to heat the DEF lines when the ambient temperature is below 23°F (-5°C). The
dosing system will not prime until the DEF lines are completely defrosted.
1126
DEF SYSTEM
Inspection
Overview
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
• DEF Refractometer 5025
Equipment Condition
None
Procedure
1. Obtain sample of DEF.
2. Visually inspect for contamination
3. Use DEF Refractometer to test DEF urea concentration.
Expected Outcome
DEF should be free of contamination, and urea concentration should be 32.5% +/- 1.5%.
Follow-on Procedure
None
1127
DEF SYSTEM
Filter
Removal
Overview
Diesel Exhaust Fluid (DEF) tank filter removal for filter replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
None
1128
DEF SYSTEM
Procedure
Figure 588 DEF Tank Filter

1. DEF supply module 2. DEF filter housing
1. Remove DEF filter housing (2) from DEF supply module (1). Discard DEF filter housing (2).
2. Remove biolube pump spray from DEF supply module (1). Discard biolube spray pump.
3. Remove DEF filter from DEF supply module (1). Discard DEF filter.
Expected Outcome
None
Follow-on Procedure
1. Install DEF filter. See DEF Filter Installation.
1129
DEF SYSTEM
Installation
Overview
Install Diesel Exhaust Fluid (DEF) filter for filter replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
• System Filter Kit
None
Equipment Condition
1. DEF filter removed. See DEF Filter Removal.
1130
DEF SYSTEM
Procedure

1. Install DEF filter to DEF supply module (1).
2. Install biolube pump spray to DEF supply module (1).
3. Install DEF filter housing (2) to DEF supply module (1).
Expected Outcome
None
Follow-on Procedure
None
1131
DEF SYSTEM
Diesel Exhaust Fluid (DEF) Tank
Removal
Overview
Removal of Diesel Exhaust Fluid (DEF) tank for replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
1. Vehicle battery box, left side steps, step support, and front step bracket removed, if necessary.
2. DEF tank drained, if necessary.
1132
DEF SYSTEM
Procedure
Figure 590 DEF Tank

1. Head module 6. Support bar nuts, washers, and screws
2. DEF hoses (2) (2)
3. Coolant hoses (2) 7. DEF tank
4. Vent hose 8. Support bar
2. Disconnect two DEF hoses (2) from head module (1).
3. Disconnect two coolant hoses (3) from head module (1).
4. Disconnect vent hose (4) from head module (1).
5. Remove two support bar nuts, washers, screws (6), and support bar (8) from DEF tank support.
6. Remove DEF tank (7) from DEF tank support.
Expected Outcome
None
Follow-on Procedure
1. Install DEF tank. See DEF Tank Installation.
1133
DEF SYSTEM
Installation
Overview
Installation of Diesel Exhaust Fluid (DEF) tank after repair or replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
Support bar nuts 91 - 115 lb-in. (10.3 - 13 N·m)
Equipment Condition
1. DEF tank removed. See DEF Tank Removal.
1134
DEF SYSTEM
Procedure
Figure 591 DEF Tank

1. Head module 6. Support bar nuts, washers, and screws
2. DEF hoses (2) (2)
3. Coolant hoses (2) 7. DEF tank
1. Install DEF tank (7) to DEF tank support.
2. Install support bar (8) to DEF tank support with two support bar screws, nuts, and washers (6). Torque
nuts to 91 - 115 lb-in (10.3 - 13 N·m).
3. Connect vent hose (4) to head module (1).
4. Connect two coolant hoses (3) to head module (1).
5. Connect two DEF hoses (2) to head module (1).
6. Connect electrical connector (5).
Expected Outcome
None
1135
DEF SYSTEM
Follow-on Procedure
1. If necessary, install left side front step bracket, step support, steps, and battery box removed to
gain access to DEF tank.
2. Fill DEF tank.
1136
DEF SYSTEM
Diesel Exhaust Fluid (DEF) Head Module
Removal
Overview
Diesel Exhaust Fluid (DEF) head module removal for replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
1137
DEF SYSTEM
Procedure
Figure 592 DEF Head Module

1. DEF head module 3. DEF tank
2. Mounting screws and washers (6)
1. Remove six mounting screws and washers (2) from DEF head module (1).
2. Carefully lift DEF head module (1) to remove from DEF tank (3).
Expected Outcome
None
Follow-on Procedure
1. Install DEF head module. See DEF Head Installation.
1138
DEF SYSTEM
Cleaning
Overview
Clean debris from inside Diesel Exhaust Fluid (DEF) tank.
WARNING
WARNING
WARNING
Required Tools
• Mild detergent solution
• Soft-bristled brush
• Wet/dry vacuum
Equipment Condition
1. Remove DEF tank. See DEF Tank Removal.
2. Remove DEF head module. See DEF Head Removal.
Procedure
1. Flush inside of DEF tank with distilled water.
2. Visually inspect inside of DEF tank for debris.
3. Rinse inside of DEF tank with warm, distilled water and a mild detergent solution.
4. Clean DEF deposits inside of DEF tank with a clean rag or soft-bristled brush.
5. Drain DEF tank.
6. Flush inside of DEF tank with distilled water.
7. Visually inspect inside of DEF tank for debris from cleaning.
8. If debris is found inside DEF tank, use a wet/dry vacuum to remove debris.
1139
DEF SYSTEM
Expected Outcome
DEF tank should be free of debris.
Follow-on Procedure
1. Install DEF head module. See DEF Head Installation.
1140
DEF SYSTEM
Installation
Overview
Diesel Exhaust Fluid (DEF) head module installation for replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
Equipment Condition
1. DEF head module removed. See DEF Head Removal.
1141
DEF SYSTEM
Procedure

2. Mounting screws and washers (6)
1. Install DEF head module (1) to DEF tank (3).
2. Secure DEF head module (1) to DEF tank (3) with six mounting screws and washers (2).
Expected Outcome
None
Follow-on Procedure
1142
DEF SYSTEM
DEF Supply Module
Removal
Overview
Remove Diesel Exhaust Fluid (DEF) supply module for module replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
2. DEF supply module drained.
1143
DEF SYSTEM
Procedure
Figure 594 DEF Supply Module

1. DEF supply module 4. Mounting bolts and washers (2)
2. Electrical connector 5. Coolant hoses (2)
3. DEF hoses (2)
1. Disconnect two coolant hoses (5) from DEF supply module (1).
2. Disconnect two DEF hoses (3) from DEF supply module (1).
3. Disconnect electrical connector (2) from DEF supply module (1).
4. Using suitable lifting device, support DEF supply module (1) from below.
5. Remove two mounting bolts and washers (4) from DEF supply module (1), and remove from vehicle.
Expected Outcome
None
Follow-On Procedure
1. Install DEF supply module. See DEF Supply Module Installation.
1144
DEF SYSTEM
Installation
Overview
Install Diesel Exhaust Fluid (DEF) supply module for module replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Required Tools
None
Mounting bolts 21 - 26 lb-ft (27.8 - 34.8 N·m)
1. DEF supply module removed. See DEF Supply Module Removal.
1145
DEF SYSTEM
Procedure

1. DEF supply module 4. Mounting bolts and washers (2)
2. Electrical connector 5. Coolant hoses (2)
3. DEF hoses (2)
1. Using suitable lifting device, support DEF supply module (1).
2. Install DEF supply module (1) to vehicle with two mounting bolts and washers (4). Torque two mounting
bolts to 21 - 26 lb-ft (27.8 - 34.8 N·m).
3. Connect electrical connector (2) to DEF supply module (1).
4. Connect two DEF hoses (3) to DEF supply module (1).
5. Connect two coolant hoses (5) to DEF supply module (1).
Expected Outcome
None
Follow-On Procedure
1146
DEF SYSTEM
Inlet Screen
Removal
Overview
Remove Diesel Exhaust Fluid (DEF) supply module inlet screen for screen replacement.
WARNING
WARNING
WARNING
Required Tools
• M5 screw
1. DEF supply module removed. See DEF Supply Module Removal.
1147
DEF SYSTEM
Procedure
Figure 596 DEF Supply Module Inlet Screen

1. Inlet DEF connector 3. DEF supply module housing
2. DEF supply module inlet screen
1. Remove inlet DEF connector (1), and discard O-ring.
2. Thread M5 screw into DEF supply module inlet screen (2) one to two turns.
3. Pull M5 screw with DEF supply module inlet screen (2) out of DEF supply module housing (3).
Expected Outcome
None
Follow-On Procedure
1. Install DEF supply module inlet screen. See DEF Supply Module Inlet Screen Installation.
1148
DEF SYSTEM
Cleaning
Overview
Clean debris from Diesel Exhaust Fluid (DEF) supply module inlet screen.
WARNING
WARNING
WARNING
Required Tools
• Air compressor
1. DEF supply module inlet screen removed. See DEF Supply Module Inlet Screen Removal.
1149
DEF SYSTEM
Procedure
1. Blow compressed air through the inlet screen.
2. Soak the inlet screen in warm water with a mild detergent solution.
3. Rinse the inlet screen with warm water.
5. Inspect the inlet screen for blockages.
Expected Outcome
DEF supply module inlet screen should be free of debris.
Follow-On Procedure
1. Install DEF supply module inlet screen. See DEF Supply Module Inlet Screen Installation.
1150
DEF SYSTEM
Installation
Overview
Install Diesel Exhaust Fluid (DEF) supply module inlet screen for screen replacement.
WARNING
WARNING
WARNING
Required Tools
None
Inlet DEF connector 38 - 43 lb-ft (52 - 58 N·m)
1. DEF supply module inlet screen removed. See DEF Supply Module Inlet Screen Removal.
1151
DEF SYSTEM
Procedure
Figure 597 DEF Supply Module Inlet Screen

1. Inlet DEF connector 3. DEF supply module housing
2. DEF supply module inlet screen
1. Install DEF supply module inlet screen (2) in inlet port of DEF supply module housing (3).
2. Install new O-ring on inlet DEF connector (1).
3. Install inlet DEF connector (1) to inlet port of DEF supply module housing (3). Torque connector to 38 -
43 lb-ft (52 - 58 N·m).
Expected Outcome
None
Follow-On Procedure
1. Install DEF supply module. See DEF Supply Module Installation.
1152
DEF SYSTEM
DEF Doser Inlet Screen
Removal
Overview
Remove Diesel Exhaust Fluid (DEF) doser inlet screen for screen replacement.
WARNING
WARNING
WARNING
Required Tools
• Pick
• T-25 socket drive
1. Recirculate and depressurize DEF system after engine shutdown. This can take up to 15 minutes.
2. Remove steps, top cover panel, right side cover panel, and reinforcement panel to gain access
to DEF doser, if necessary.
3. Remove DEF hoses from DEF doser.
1153
DEF SYSTEM
Procedure
Figure 598 DEF Doser Inlet Screen

1. DEF doser connector manifold 4. DEF doser inlet screen
2. Outlet connector cylinder 5. Inlet connector cylinder
3. DEF doser 6. Capscrews (2)
1. Use a T-25 socket drive to remove two capscrews (6).
2. Remove DEF doser connector manifold (1) from DEF doser (3).
3. Remove outlet connector cylinder (2) and inlet connector cylinder (5) from DEF doser connector manifold
(1) or DEF doser (3), and discard four O-rings.
4. Use a pick to remove DEF doser inlet screen (4) from DEF doser (3).
Expected Outcome
None
Follow-On Procedure
1. Install DEF doser inlet screen. See DEF Doser Inlet Screen Installation.
1154
DEF SYSTEM
Cleaning
Overview
Clean debris from Diesel Exhaust Fluid (DEF) doser inlet screen.
WARNING
WARNING
WARNING
Required Tools
• Air compressor
1. DEF doser inlet screen removed. See DEF Doser Inlet Screen Removal.
1155
DEF SYSTEM
Procedure
2. Soak the inlet screen in warm water with a mild detergent solution.
3. Rinse the inlet screen with warm water.
5. Inspect the inlet screen for blockages.
Expected Outcome
DEF doser inlet screen should be free of debris.
Follow-On Procedure
1. Install DEF doser inlet screen. See DEF Doser Inlet Screen Installation.
1156
DEF SYSTEM
Installation
Overview
Install Diesel Exhaust Fluid (DEF) doser inlet screen for screen replacement.
WARNING
WARNING
WARNING
Required Tools
• Synthetic grease
• T-25 socket drive
DEF doser connector manifold capscrews 71 lb-in. (8 N·m)
1. DEF doser inlet screen removed. See DEF Doser Inlet Screen Removal.
1157
DEF SYSTEM
Procedure
Figure 599 DEF Doser Inlet Screen

1. DEF doser connector manifold 4. DEF doser inlet screen
2. Outlet connector cylinder 5. Inlet connector cylinder
3. DEF doser 6. Capscrews (2)
1. Install DEF doser inlet screen (4) in inlet (bottom) port of DEF doser (3).
2. Install new O-rings on outlet connector cylinder (2) and inlet connector cylinder (5), and apply synthetic
grease to O-rings.
3. Install outlet connector cylinder (2) and inlet connector cylinder (5) in ports of DEF doser connector
manifold (1) so that cylinders contact bottom of ports.
4. Install DEF doser connector manifold (1) on DEF doser (3) with two capscrews (6). Torque capscrews to
71 lb-in. (8 N·m).
Expected Outcome
None
Follow-On Procedure
1. Install DEF hoses on DEF doser.
2. Install reinforcement panel, right side cover panel, top cover panel, and steps if removed to gain
access to DEF doser.
1158
DEF SYSTEM
1159
DEF TANK
2. DEF Tank
DEF Tank (9.5 Gallon)
Overview
0015DYP DEF Tank 9.5 US gal. (36 L) capacity, frame mounted outside left rail,
under cab
0015DYR HX615 and HX620 - DEF Tank 9.5 US gal. (36 L) capacity, frame
mounted outside left rail, back of cab
Figure 600 Typical DEF Tank Location

1. Left Fender Mud Flap 3. Fuel Tank
2. DEF Tank
1160
DEF TANK
Figure 601 DEF Tank

1. DEF Tank Mounting Bracket Nut (4) (2 3. DEF Tank Assembly Electrical
not numbered) Connector
2. DEF Tank Mounting Bracket Bolt (2) 4. DEF Tank Assembly
1161
DEF TANK
Figure 602 DEF Tank Pickup Assembly

1. DEF Tank Pickup Assembly Screws (6) 5. DEF Coolant Lines (2)
(4 not shown) 6. DEF Tank Pickup Assembly Electrical
2. DEF Tank Connection
3. DEF Tank Pickup Assembly 7. DEF Return Line
4. DEF Suction Line
1162
DEF TANK

1. DEF Supply Module Suction Line 5. DEF Supply Module
2. DEF Supply Module Return Line 6. DEF Supply Module Mounting Bolt (2)
3. DEF Supply Module Pressure Line 7. DEF Supply Module Electrical
4. DEF Supply Module Bracket Connector
Actual component location may vary depending on vehicle configuration.
Oxides of nitrogen are created by high temperature and speed of combustion. Once in atmosphere, nitrogen
oxide emissions result in ground-level ozone formation and smog. Emission particulates include unburned fuel
and lube oil (liquid hydrocarbons), carbon soot from incomplete combustion (main contributor to smoke), water
from combustion, and sulfur compounds from fuel and lubrication oil.
Selective Catalytic Reduction (SCR) uses Diesel Exhaust Fluid (DEF) in order to convert nitrogen oxides
(NOx) in exhaust stream to nitrogen and water. A dosing valve is used to inject DEF into exhaust stream. DEF
mixes with exhaust gas and converts into ammonia, which neutralizes NOx. Once ammonia reacts with NOx, it
passes over SCR catalyst and produces harmless nitrogen and water vapor.
SCR system, is equipped with a DEF tank. DEF tank is filled with DEF, which is a clear, nonhazardous fluid.
DEF tank has a temperature/level sending unit to protect system. DEF will slush at approximately -11°C
(12°F), so DEF temperature is continuously monitored.
1163
DEF TANK
DEF Tank Components
Quality Sensor (DEFQ)

Diesel Exhaust Fluid Tank Level/Diesel Exhaust Fluid Tank Temperature (DEFTLT), and DEF Quality (DEFQ)
sensor is a combination sensor used to monitor DEF tank level, DEF tank temperature, and urea concentration
of DEF. DEFTL, DEFTT, DEFQ sensor is installed inside DEF tank and is a smart sensor that communicates
with Aftertreatment Control Module (ACM).
Diesel Exhaust Fluid (DEF) Pump

DEF is provided to entire SCR system by DEF supply module. DEF supply module directly controls flow
Decomposition reactor tube is section of exhaust pipe between aftertreatment diesel particulate filter and
aftertreatment SCR catalyst. Aftertreatment decomposition reactor tube is designed to help atomize and mix
DEF that is sprayed into exhaust stream for complete NOx conversion.
Coolant Control Valve (Diesel Exhaust Fluid (DEF) Tank Heater Valve)
DEF coolant lines supply coolant to DEF tank and dosing valve to heat or defrost DEF.
An electronically controlled check valve that controls coolant flow to DEF tank during temperatures below 23 °F
(-5 °C). Valve is controlled by ACM or ECM depending on application.
Diesel Exhaust Fluid (DEF) Fluid Level

DEF tank pickup assembly is mounted in DEF tank. Assembly includes DEF level sensor, urea quality sensor,
pickup screen, and heating loop used to circulate coolant to heat and defrost DEF. These components are
serviced as a complete assembly.
1164
DEF TANK
Diesel Exhaust Fluid (DEF) Supply and Return Lines
Figure 604 DEF Tank Lines

1. DEF Tank Pickup Assembly Return Line 4. DEF Supply Module Suction Line
2. DEF Tank Pickup Assembly Suction 5. DEF Supply Module Return Line
Line 6. DEF Supply Module
3. DEF Tank Pickup Assembly
DEF lines supply DEF from DEF tank to DEF supply module and dosing valve.
1165
DEF TANK
DEF Tank (15.9 Gallon)

Overview
0015WDY DEF tank, 15.9-US gal (60.1 L) capacity, frame-mounted outside left
rail, under cab
Figure 605 Diesel Exhaust Fluid Tank Location

1. DEF lines 2. DEF tank
Vehicles with Selective Catalytic Reduction (SCR) systems are equipped with a DEF tank.
DEF
DEF is the reactant necessary for functionality of the SCR system. It is a clear, nontoxic fluid, which is used
to deliver ammonia to the SCR catalyst and is a 32.5–percent strength urea/water solution with high purity
requirements
DEF Tank
The DEF tank is filled with DEF and houses the DEF tank pickup assembly.
1166
DEF TANK
DEF Supply Module

DEF fluid is provided to the SCR system by the DEF supply module. The DEF supply module controls flow
DEF Tank Pickup Assembly

The DEF tank pickup assembly is mounted in the DEF tank. The assembly includes the DEF level sensor,
urea quality sensor, pickup screen, heating loop, temperature sensor in level housing, and temperature
sensor in quality housing. These components are used to circulate coolant to heat and defrost DEF and
are serviced as a complete assembly.
DEF Lines
DEF lines supply DEF from the DEF tank to the DEF supply module and dosing valve.
DEF Coolant Lines

DEF coolant lines supply coolant to the DEF tank and dosing valve to heat or defrost DEF.
DEF Tank Heater Valve

DEF tank heater valve is an electronically controlled check valve that controls coolant flow to the DEF tank
during temperatures below 32°F (0°C). The valve is controlled by the Aftertreatment Control Module or Engine
Control Module depending on the application.
DEF Line Heater

The DEF line heater is used to heat the DEF lines when the ambient temperature is below 23°F (-5°C). The
dosing system will not prime until the DEF lines are completely defrosted.
1167
DEF TANK
DEF Tank
Inspection
Overview
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
• DEF Refractometer 5025
Equipment Condition
None
Procedure
1. Obtain sample of DEF.
2. Visually inspect for contamination
3. Use DEF Refractometer to test DEF urea concentration.
Expected Outcome
DEF should be free of contamination, and urea concentration should be 32.5% +/- 1.5%.
Follow-On Procedure
None
1168
DEF TANK
Removal
Overview
Removal of Diesel Exhaust Fluid (DEF) tank for replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
None
1. Vehicle battery box, driver-side steps, step support, and front step bracket removed, if necessary.
2. DEF tank drained, if necessary.
1169
DEF TANK
Procedure
Figure 606 DEF Tank

1. Head module 5. Electrical connector
2. DEF hose (2) 6. Support bar nut, washer, and screw (2)
3. Coolant hose (2) 7. DEF tank
4. Disconnect two DEF hoses (2) from head module (1).
5. Disconnect two coolant hoses (3) from head module (1).
6. Disconnect vent hose (4) from head module (1).
7. Remove two support bar nuts, washers, screws (6), and support bar (8) from DEF tank support.
8. Remove DEF tank (7) from DEF tank support.
Follow-On Procedure
1. Install DEF tank. See DEF Tank Installation (page 1171).
1170
DEF TANK
Installation
Overview
Installation of Diesel Exhaust Fluid (DEF) tank after repair or replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
None
DEF tank support bar nuts and screws 91 - 115 lb-in. (10.3 - 13 N·m)
1. DEF tank removed. See DEF Tank Removal (page 1169).
1171
DEF TANK
Procedure
Figure 607 DEF Tank

1. Head module 5. Electrical connector
2. DEF hose (2) 6. Support bar nut, washer, and screw (2)
3. Coolant hose (2) 7. DEF tank
1. Install DEF tank (7) to DEF tank support.
2. Install support bar (8) to DEF tank support with two support bar screws, nuts, and washers (6). Torque
nuts to 91 - 115 lb-in. (10.3 - 13 N·m).
3. Connect vent hose (4) to head module (1).
4. Connect two coolant hoses (3) to head module (1).
5. Connect two DEF hoses (2) to head module (1).
6. Connect electrical connector (5).
Follow-On Procedure
1. If necessary, install driver-side front step bracket, step support, steps, and battery box removed to
gain access to DEF tank.
2. Refill DEF tank.
1172
DEF TANK
DEF Supply Module Filter
Removal
Overview
Remove Diesel Exhaust Fluid (DEF) supply module filter for filter replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
None
None
1173
DEF TANK
Procedure

1. Remove DEF filter housing (2) from DEF supply module (1). Discard DEF filter housing (2).
2. Remove biolube pump spray from DEF supply module (1). Discard biolube spray pump.
3. Remove DEF supply module filter from DEF supply module (1). Discard DEF supply module filter.
Follow-On Procedure
1. Install DEF supply module filter. See DEF Supply Module Filter Installation (page 1175).
1174
DEF TANK
Installation
Overview
Install Diesel Exhaust Fluid (DEF) supply module filter for filter replacement.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
• System Filter Kit
None
1. DEF supply module filter removed. See DEF Supply Module Filter Removal (page 1173).
1175
DEF TANK
Procedure

1. Install DEF supply module filter to DEF supply module (1).
2. Install biolube pump spray to DEF supply module (1).
3. Install DEF filter housing (2) to DEF supply module (1).
Follow-On Procedure
None
1176
DEF TANK
DEF Head Module
Removal
Overview
Remove Diesel Exhaust Fluid (DEF) head module for replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
None
1. DEF tank removed. See DEF Tank Removal (page 1169).
1177
DEF TANK
Procedure

2. Mounting screw and washer (6)
1. Remove six mounting screws and washers (2) from DEF head module (1).
2. Carefully lift DEF head module (1) to remove from DEF tank (3).
Follow-On Procedure
1. Install DEF head module. See DEF Head Module Installation (page 1179).
1178
DEF TANK
Installation
Overview
Install Diesel Exhaust Fluid (DEF) head module after replacement or repair.
WARNING
WARNING
procedures.
WARNING
WARNING
Special Tools
None
DEF head module mounting screws and washers 2.5 ft-lb (3.4 N·m)
1. DEF head module removed. See DEF Head Module Removal (page 1177).
1179
DEF TANK
Procedure

2. Mounting screw and washer (6)
1. Install DEF head module (1) to DEF tank (3).
2. Secure DEF head module (1) to DEF tank (3) with six mounting screws and washers (2). Torque mounting
screws in star pattern to 2.5 ft-lb (3.4 N·m).
Follow-On Procedure
1. Install DEF tank. See DEF Tank Installation (page 1171).
1180
DEF TANK
DEF Tank (16 Gallon)

Overview
0015WDE DEF Tank 16 US gal (60.6 L) capacity, frame mounted outside left rail,
under cab
Actual component location may vary depending on vehicle configuration.
Selective Catalytic Reduction (SCR) system, is equipped with a diesel exhaust fluid (DEF) tank. DEF tank is
filled with DEF, which is a clear, nonhazardous fluid. DEF tank has a temperature/level sending unit to protect
the system. DEF will slush at approximately -11 °C (12 °F), so DEF temperature is continuously monitored.
DEF Tank Components
Quality Sensor (DEFQ)

Diesel Exhaust Fluid Tank Level/Diesel Exhaust Fluid Tank Temperature (DEFTLT), and DEF Quality (DEFQ)
sensor is a combination sensor used to monitor DEF tank level, DEF tank temperature, and urea concentration
of DEF. DEFTL, DEFTT, DEFQ sensor is installed inside DEF tank and is a smart sensor that communicates
with Aftertreatment Control Module (ACM).
DEF Pump
DEF fluid is provided to entire SCR system by DEF supply module. DEF supply module directly controls flow
Coolant Control Valve (DEF Heater)

An electronically controlled check valve that controls coolant flow to DEF tank during temperatures below 23°F
(-5°C). Valve is controlled by ACM or ECM depending on application.
DEF Fluid Level

DEF Supply and Return Lines
DEF lines supply DEF from DEF tank to DEF supply module and dosing valve.
1181
FUEL COOLER
3. Fuel Cooler
Fuel Cooler Without Thermostat
Overview
0015WCS Fuel Cooler without thermostat; mounted in front of cooling module
1182
FUEL HEATER
4. Fuel Heater
Cummins
Fuel Heater
Overview
0015LNA Fuel heater (Cummins), thermal recirculation valve, mounted to Cummins
ISX engines and thermostatically controlled
Figure 612 Fuel Heater Location

1. Approximate fuel heater location
Fuel heaters keep fuel warm in cold temperatures to prevent fuel from gelling.
1183
FUEL HEATER
1184
FUEL WATER SEPARATOR
5. Fuel Water Separator

Davco
0015LKW Fuel/Water Separator {Davco Fuel Pro 382} with fuel heated fuel heater,
thermostatic fuel temperature control, mounted in standard position,
includes Water-In-Fuel (WIF) light
0015LKX Fuel/Water Separator {Davco Fuel Pro 382} 12 volt DC pre-heater,
includes Water-In-Fuel (WIF) light, mounted in standard location
0015LKY Fuel/Water Separator {Davco Fuel Pro 382} 12 volt DC pre-heater
and fuel heated, thermostatic fuel temperature control, includes
Water-In-Fuel (WIF) light, mounted in standard position
0015LLA Fuel/Water Separator {Davco Fuel Pro 382} 12 volt DC pre-heater
and fuel heated, thermostatic fuel temperature control, includes
Water-In-Fuel (WIF) light, mounted in standard position
Figure 613 Fuel Water Separator Location
Fuel water separator protects precision fuel system components from damaging effects of water, extending life
of fuel filter. When a fuel heater is included, chance of fuel filter plugging in cold weather is reduced.
1. Fuel from tank enters fuel water separator (suction side of fuel system).
1185
2. Large contaminants and ‘free’ water are separated from fuel and remain in water separator body.
3. Fuel rises into clear cover.
4. Contaminants and emulsified water are captured by filter media.
5. Fuel level rises to maintain fuel path through clean filter media with low restriction.
6. Clean, water-free fuel exits fuel water separator and flows to engine fuel injection system.
1186
Preventive Maintenance
Precautions
WARNING
When diesel fuel is circulated through an operating engine, it can become very hot. To
prevent property damage, personal injury, and / or death, wear protective clothing when
draining hot oil (page 1187).
When draining hot oil, do following:
• Scalding hazard! Do not allow fuel to come in contact with eyes or unprotected skin. Allow engine and
fuel to cool to ambient temperature before replacing fuel filter or performing service operations which
could result in spillage of fuel from fuel system. If this is not possible, protective equipment (face shield,
insulated hat, gloves, and apron) must be worn.
• Fire Prevention! Heated diesel fuel can form combustible vapor mixtures in area around fuel source. To
eliminate potential for fire, keep open flames, sparks or other potential ignition sources away from work
area. Do not smoke during filter replacement or service operations.
• Inhalation Prevention! Always perform engine or vehicle fuel system maintenance in a well ventilated area
that is kept free of bystanders.
• Ignition key must be in OFF.
Weekly - Drain Water

1. Turn off engine and open vent cap.
2. Place suitable eight ounce, plastic or metal container under drain valve at base of filter and open valve.
3. Water will flow into container. When fuel begins to flow out of drain, close drain valve. Drain least amount
of fuel possible.
4. Hand tighten vent cap.
5. Start engine, raise RPM for one minute to purge air from system.
1187
Filter Change Procedure
Every Filter Change

Change cover and vent cap O-rings (included with service filter kit).
Every 12 Months
• Check all electrical connections for corrosion.
• Check all fuel fittings for leaks.
In extreme winter or salt corrosion environments may require lubrication of collar threads with anti-seize
lubricant every 180 days.
WARNING
When diesel fuel is circulated through an operating engine, it can become very hot. To
prevent property damage, personal injury, and / or death, wear protective clothing when
draining hot oil (page 1187).
1. Remove vent cap and open drain valve to drain fuel below collar level.
2. Remove collar than remove the clear cover.
3. Remove filter, cover, and vent cap seals. Dispose of filter and seals properly.
4. Use clean shop rag, clean cover, collar, and thread on the filter body.
5. Install new filter, cover seal, and vent cap seal.
6. Reinstall clear cover and collar. Hand tighten collar.
7. Prime system by filling clear cover with clean diesel fuel until it reaches to of filter.
8. Install vent cap. Hand tighten vent cap.
9. Start engine and run for one minute. Slowly open vent cap and allow fuel to drop to about one inch
above collar.
10. Close vent cap. Hand tighten vent cap. It is normal for fuel level to vary after initial start-up and during
engine operation. Filter performance is not affected.
1188
Racor
Overview
0015LKU Fuel/Water Separator {Racor} Fuel Pre-Filter and Filter Base, includes
Water-In-Fuel Sensor
Utilizes a replaceable filter element which includes a reusable clear plastic bowl and an integral contaminant
drain. A water-in-fuel sensor in clear bowl alerts driver through a dash mounted message that Fuel Water
Separator has reached maximum accumulation of water and must be drained. An integral manual fuel primer
pump and anti-drain back valve in filter head make fuel filter changes easier and more sanitary.
Modern fuel systems have been developed to reduce emissions and fuel consumption, and improve engine
performance. These high-pressure systems operate at pressures approaching 30,500 psi (2100 bar) and with
component match clearances typically from 2 to 5 microns for injectors. At these pressures, very small, hard
particles are potential sources of fuel system malfunction.
Excessive contamination of diesel fuel can cause premature clogging of diesel fuel filters or premature wear of
critical fuel injection system parts. Depending on size and nature of particles, this can lead to:
• Reduced component life

• Component malfunction
• Fuel system or engine failure
Fuel Filter Maintenance
Fuel filters must be changed periodically to prevent restriction of fuel flow from fuel tank to fuel pump. Fuel
restriction will increase over time as sediment gets collected in filter media. Sediment could possibly consist of
rust, dirt, dust, oxidation products, and biological growth.
Change fuel filters as recommended by appropriate Engine Owner's Manual or Operation and Maintenance
Manual. When operating under severe conditions, additional fuel filter changes can be required. To determine
if this is necessary, fuel filter restriction must be checked. Refer to appropriate Engine Service Manual for fuel
filter restriction checking procedures. After checking restriction a few times, a maintenance schedule for fuel
filter changes can be established for each type of operation.
1189
Common Issues with Winter Fuel
Two winter fuel handling issues, wax and ice, have annoyed diesel operators for years. There is no solution
to either of these problems that is ideal for all situations, but the better the problem is understood, the less
difficult the process of finding a solution becomes.
Determining whether a low power complaint is due to a fuel filter plugging complaint is fairly simple:
• Replace fuel filter with a new filter.

• If this allows vehicle to operate normally even for a short period of time, then obviously something in fuel is
plugging filter and causing complaint.
A simple way of determining whether filter plugging is caused by wax or ice.
1. Bring plugged filter into a warm shop.
2. Drain out liquid fuel.
3. Place filter upside down on a piece of paper or in a shallow pan.
4. Allow filter to warm to room temperature.
5. If there is ice in filter, it will melt and run out of filter and water on paper or in pan will be obvious.
Most petroleum wax, on the other hand, will not melt at room temperature. To speed analysis process,
filter can be cut open and spread out.
Once cause of low power complaint is determined, a logical solution can be chosen.
Fuel Wax
All middle (or intermediate) distillate fuels, such as diesel fuels, contain paraffin wax. Paraffin wax is a solid,
crystalline mixture of straight-chain or normal hydrocarbons melting in approximate range of 104 to 140°F
(40 to 60°C). This paraffin wax occurs naturally in the crude oil from which fuel oils are distilled. The wax
content of a distillate fuel varies greatly, depending on the crude oil from which the fuel is produced and in the
processing of the fuel. Generally, higher boiling distillate fuels, such as U.S. Number 2-D diesel fuel, have a
higher concentration of paraffin wax than lower boiling distillate fuels.
Because of strong relationship between temperature and solubility of wax, wax separation is a problem in
handling and using diesel fuel during cold weather. As fuel cools, a temperature is reached at which the
soluble paraffin wax in the fuel begins to come out of solution (Cloud Point); any further cooling will cause wax
to separate out of solution. Temperature at which a certain fuel will become saturated with wax and causes
filter plugging problems is termed Cold Filter Plugging Point (ASTM D6371). Temperature at which fuel will no
longer flow is the Pour Point (ASTM D97). At pour point, most of fuel is still liquid, although it is very thick
or viscous and trapped in a honeycomb-like network of wax crystals.
Since diesel powered equipment is frequently used at temperatures low enough to cause wax to separate,
a number of techniques have been devised to prevent the wax from causing problems by plugging fuel
screens, lines, filter, and so on, and preventing fuel flow to engine. Vehicles designed to operate at very
low temperatures have provisions for heated fuel tanks, insulated fuel lines, heated fuel filters and other
mechanisms to warm fuel so that wax does not separate. These more elaborate systems are usually not
practical in more temperate climates where they are needed only a few days a year.
1190
Fuel Blending
There are two different types of fuel blending processes. First is blending of used engine lubricating oil to
reduce fuel costs and to aid in disposing of used engine oil. Second is blending of heavier fuels with lighter
fuels to lower wax content, cloud point, and pour point, and thus improve cold weather operation.
1191
HYDRAULIC RESERVOIR
6. Hydraulic Reservoir
Hydraulic Reservoir (60 Gallon)
Overview
0015WTN Hydraulic Reservoir, 24 in. (610 mm) diameter, non-polished aluminum,
60 US gal. total capacity; with 1.25 in. supply line and 1 in. return line
mounted left side Back-of-Cab (BOC)
0015WBV Hydraulic Reservoir, 24 in. (610 mm) diameter, non-polished aluminum,
60 US gal. total capacity; with 1.25 in. supply line and 1 in. return line
mounted right side Back-of-Cab (BOC)
Hydraulic reservoir is mounted on Back-Of-Cab (BOC) on either right side or left side depending on feature
code.
1192
HYDRAULIC RESERVOIR
Torque
Description Torque
Diesel Exhaust Fluid (DEF) Tank Mount Bolts 16 lbf-ft (22 N·m)
DEF Hold Down Strap Nuts 106 lbf-in. (12 N·m)
DEF tank pickup assembly Torx® screws 27 lbf-in. (3 N·m)
DEF Tank Heater Valve Mount Bolts 62 lbf-in. (7 N·m)
1193
HYDRAULIC RESERVOIR
1194
TABLE OF CONTENTS
Cab
Table of Contents
1. Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1199
Power Door Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1199
Door Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1205
Electric Window and Door Lock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1206
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1206
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1207
Door Handle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1208
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1208
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1213
2. Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1214
Cab Interior Trim - Base Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1214
Engine Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1215
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1215
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1217
Air Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1218
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1218
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1220
Center Console Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1221
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1221
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223
Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1224
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1225
Lower Instrument Cluster Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1226
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1226
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1227
Cab Interior Trim - Upgraded Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1228
Vehicle Exterior - Paint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1229
Paint Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1229
Body and Chassis Paint Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1234
Cab Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1237
Ride Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1238
Cab Rear Suspension - Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1241
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
Cab Rear Suspension - Air Bag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1244
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1248
Cab Rear Suspension - Ride Height Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1249
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1251
Cab Rear Air Suspension - Sleeper Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1252
Cab Skirts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1253
Cab Interior Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1254
Cab Sunshade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1255
Day Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1256
1195
TABLE OF CONTENTS
Door Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1257

Sleeper Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1261
Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1262
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1262
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1264
Luggage Compartment - Release Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1266
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1268
Cab Side Fairing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1270
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1271
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1274
Cab Skirts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1278
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1279
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1281
Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1283
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1284
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1290
3. Heating Ventilation Air Conditioning (HVAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302

HVAC with Integral Heater and Defroster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302
Sleeper HVAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1305
Sleeper Blend Door Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1306
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1306
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1308
Sleeper Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310
Air Conditioner with APAds™ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1311
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1311
Air Conditioner with Bergstrom Enhanced Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1312
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1312
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313
Refrigerant Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313
Service Procedures for R-134a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317
Refrigerant Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1319
Recovery / Recycling / Charging Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1320
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1320
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1321
Discharging HVAC System (Refrigerant Recovery). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1323
Evacuating HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325
Charge HVAC System (Full Charge). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328
Adding Refrigerant to HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329
Oil Fill Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331
Leak Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336
Flush and Purge HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340
HVAC System Internal Damage Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340
Flush HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1341
Purge HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1358
HX HVAC Specific Flush Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1360
General Heat Ventilation Air Conditioning (HVAC) System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1369
Pre-Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1369
HVAC Compressor - Navistar® N13 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1371
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1371
1196
TABLE OF CONTENTS
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1373
HVAC Blend Door Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1374
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1374
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1375
HVAC Expansion Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1376
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1376
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1378
HVAC Fresh Air Door and Recirculation Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1379
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1379
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1380
HVAC High Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1381
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1381
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1382
HVAC Control Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1383
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1383
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1385
HVAC Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1386
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1386
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1387
HVAC Mode Door and Air Distribution Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1388
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1388
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1390
Vehicle HVAC Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1391
Charge Quantities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1391
Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1391
Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392
Recommended Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392
Frequently Used HVAC System Consumable Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
Refrigerant Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
4. Instrumentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402
Driver Instrumentation Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402
Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402
Air Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Air Cleaner Restriction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Air Pressure for Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Primary and Secondary Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Allison Oil Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Engine Oil Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Manual Transmission Oil Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
Rear Axle Oil Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
5. Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
National with RollTek®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
Passenger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
RollTek® Seat with Supplemental Restraint System (SRS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1408
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1408
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1413
RollTek® Side Roll Airbag (SRA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1418
1197
TABLE OF CONTENTS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1418
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1423
RollTek® Supplemental Restraint System (SRS) Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1429
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1429
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1436
6. Windshield Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1445

Windshield Wiper System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1445
Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1446
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1446
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1449
Windshield Wiper Arm and Blade Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1452
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1452
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1453
Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1454
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1454
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1455
7. Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1456
Specifications for Ride Height Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1456
Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1457
1198
ACCESSORIES
1. Accessories
Power Door Locks
Overview
16WJG Cab Door Locks, power
Figure 614 Typical Electric Window and Door Lock Switch Panel Location
Power window and power door lock switches have different configurations depending on feature supplied.
Ignition switch and door locks are coded identical so that one key operates both ignition switch and door
locks. Code number is stamped and bar-coded on plastic bag that ignition switch and door lock cylinders are
supplied. This plastic bag is to remain with vehicle. It is very important that this plastic bag be kept in a safe,
secure place, so that if a replacement key is required, key can be replaced.
Code number does not appear on ignition switch body or door lock assembly.
1199
ACCESSORIES
Door Panel
Removal
WARNING
To prevent property damage, personal injury, or death, read all safety precautions (page
1313).
WARNING
To prevent property damage, personal injury, or death, always disconnect ground battery
terminal first, then positive cable. Failure to follow this warning may result in a direct
battery short, this is a fire or explosion hazard.
WARNING
These procedures are to provide instructions and specifications for setting desired cab ride height. Before
starting adjustment procedure, be sure that following conditions are met or performed.

8. There must not be any occupants in cab and no change in cab weight during maintenance
procedures.
Procedure
This procedure if for driver door, passenger door is similar.
Door panels may be single piece or two piece, and door panels may be held in with screws or pop fasteners,
depending on features provided.
1200
ACCESSORIES
Figure 615 Door Center Panel - Remove
1. Use trim removal tool, remove door center panel (eight (8) pop fasteners).
Figure 616 Circular Cover - Remove
2. Use trim removal tool, remove door circular cover.
3. Lower window until window regulator bracket bolts are visible.
1201
ACCESSORIES
Figure 617 Window Regulator Bracket - Disconnect

1. 10 mm Hex Bolts (2)
4. Remove two (2) 10 mm bolts (1) from window regulator bracket, technical aid needed to hold window
in place until door panel is removed.
Figure 618 Door Panel Screws - Remove

1. Door Panel Torx® Screws (12)
5. Remove 12 door panel, Torx®, screws (1).
6. Disconnect inner door light.
7. Remove two (2) bolts and disconnect door hinge stop strap.
1202
ACCESSORIES
8. Disconnect manual door latch rod.
9. Remove manual door lock rod linkage from lock rod holder.
10. Disconnect window and door lock control panel.
11. Cut cable tie securing lock actuator and window regulator wire harnesses together.
12. Disconnect electrical connector from window regulator.
Figure 619 Door Lock and Window Connectors
13. Remove door actuator nut and washer.
14. Remove upper door panel.
15. When door panel (page 1203) is removed..
16. Place 1/2 in. drive long extension under window regulator bracket to keep bracket and window
approximately even with window regulator bracket and from falling into bottom of door.
17. Technical aid slowly release window, while holding extension, to rest window.
1203
ACCESSORIES
Figure 620 Door Panel

1. Door Release Connector to Door Latch 5. Safety Light and Connection
2. Power Door Lock Control 6. Power Window Motor
3. Power Window Controls 7. Power Door Lock
4. Window Frame to Inner Door Panel 8. Door Latch
Connection
1204
ACCESSORIES
Installation
Procedure
This procedure if for driver’s door, passenger’s door is similar.
1. Technical aid needed to hold window in place until door panel is replaced and window control plate is
attached to door panel (page 1205).
2. Place upper door panel in position on door, install manual door lock through door panel opening.
3. Install two (2) fasteners (one (1) bottom right and one (1) lower right) to hold door panel in place.
4. Connect electrical connector to window regulator.
5. Raise window until control plate is lined with plug opening.
6. Install two (2) bolts holding window control plate to door panel.
7. Insert manual door lock rod linkage into lock rod holder and secure holder over lock rod.
8. Install manual door lock.
9. Connect window and door lock connectors to control panel, install wind and door lock control panel in
upper door panel.
10. Install door actuator washer and nut to secure actuator to door panel frame.
11. Install cable tie to window regulator frame to secure regulator and door actuator wire harnesses.
12. Install upper door panel fasteners.
13. Connect door hinge stop strap and install two (2) bolts.
14. Install window control plug.
15. Connect inner door light, install lower door panel.
16. Install lower door panel fasteners.
1205
ACCESSORIES
Electric Window and Door Lock Switch
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
1. Remove door panel, see Door Panel - Remove (page 1200), enough to pull door panel away far enough to
disconnect and remove window and door lock connectors.
2. Pull upper door panel away from door far enough to disconnect three (3) electric window and door lock
connectors.
3. Remove electric window and door lock panel from upper door panel.
1206
ACCESSORIES
Installation
Procedure
Installation procedures show driver door; passenger door procedures are identical.
1. Pull upper door panel away from door far enough to install electric window and door lock panel through
upper door panel.
2. Connect three (3) electric window and door lock connectors.
3. Align upper right corner of door panel on door.
4. Install upper right corner of door panel once screws or pop fasteners are aligned.
1207
ACCESSORIES
Door Handle Replacement
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
1. Remove door panel, see Door Panel - Remove (page 1200).
1208
ACCESSORIES
Figure 621 Door Handle Rods - Remove

1. Door Latch Mechanism 5. Bell Crank
2. Door Handle to Latch Mechanism Rod 6. Door Lock Mechanism to Door Latch
3. Door Lock Mechanism Mechanism Rod
4. Squeeze Tabs (4)
2. Remove door handle rods (2 and 6).
Figure 622 Door Lock Rod End - Remove

1. Rod 3. Door Lock Mechanism
2. Rod Lock
3. Uncouple rod lock (2) and remove rod (1) end from door lock mechanism (3).
1209
ACCESSORIES
Figure 623 Door Latch Rod - Remove

1. Rod 2. Rod Lock
4. Uncouple rod lock (2) and remove rod (1) from door latch mechanism.
Figure 624 Bell Crank Rod - Unhook

1. Bell Crank Rod 2. Bell Crank
5. Unhook bell crank rod (1) and remove bell crank rod (1).
1210
ACCESSORIES
Figure 625 Squeeze Tabs - Remove

1. Squeeze Tabs
6. Carefully squeeze four (4) squeeze tabs (1) and push door bezel clear of door.
Figure 626 Door Bezel - Remove

1. Door Bezel
7. Slowly remove outer door bezel (1) while squeezing tabs.
1211
ACCESSORIES
Figure 627 Lock Mechanism Screws - Remove

1. Door Handle Mechanism Screws (4)
8. Remove four (4) door handle mechanism, Torx®, screws.
9. Remove door lock mechanism from door.
10. Remove door lock from door lock mechanism. Maintain key integrity, lock must be saved and reused.
11. Slide clip out of door lock mechanism.
12. Use pick to pry clip out of door lock mechanism.
13. Use needle nose pliers to finish removing keeper clip.
14. Use small flat punch and hammer to drive lock out of door lock mechanism.
1212
ACCESSORIES
Installation
None
Procedure
1. Install lock into door lock mechanism.
2. Align four (4) tabs on lock to grooves on lock mechanism.
3. Use 15/16 in. socket to gently push lock into lock mechanism
4. Align keeper clip in groove on lock.
5. Gently push keeper clip in groove fully locking lock in lock mechanism
6. Insert new door lock mechanism in door.
7. Install four (4) lock mechanism, Torx®, screws.
8. Slowly install outer door bezel while squeezing tabs.
9. Carefully squeeze four (4) tabs while them through inside door.
10. Install door handle rods.
11. Install rod end in door lock mechanism and clip on keeper lock.
12. Install rod end in door latch mechanism and clip on keeper lock.
13. Install and hook bell crank rod.
14. Install door panel, see Door Panel - Install (page 1205).
1213
CAB
2. Cab
Cab Interior Trim - Base Level
Overview
16VJZ Cab Interior Trim classic level, for day cab
International® HX™ Series utilizes an aluminum cab for corrosion resistance and weight reduction. Riveted
and adhesive-bonded construction results in increased strength and better repairability compared to cabs
which use 100% welded construction. Lap-joint strength is improved through use of adhesive sealers with
rivets. This combination produces a joint strength that is much stronger than joints without adhesives. Use of
improved assembly fixtures and techniques, improved fasteners and sealers in combination with extremely
efficient door seals, results in a 'tight' cab for consistent interior temperatures.
Doors have a flat design for easier repairability and stainless steel piano type hinges for strength, corrosion
resistance and proper door fit. Thicker door frames provide a better base for retention of fasteners. Doors
open easier as trim panels have been designed to prevent material from packing around door frame. Handle is
mounted low on door for easy accessibility from ground and is flush mounted to reduce chance of damage.
Other standard features include flush-mounted inner door latches and push-button inside and key-operated
outside door locks.
Cabs are sealed and insulated to provide low noise levels and optimal temperature control.
1214
CAB
Engine Cover
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
1. Loosen or remove driver kick panel.
2. Remove four (4) screws from middle driver’s kick panel (under and left of steering wheel column).
3. Remove three (3) pop fittings from driver’s left kick panel.
4. Remove middle kick panel and left kick panel.
5. Remove two (2) screws from right kick panel (under and right of steering wheel column).
6. Remove two (2) bolts from accelerator pedal.
7. Remove one (1) screw and pop out four (4) clips and remove left panel of center console.
1215
CAB
8. Remove right kick panel.
9. Lift upper section up and over steering wheel column.
10. Pull accelerator pedal toward driver’s seat, to have enough room for right kick panel to be removed.
11. Pull right kick panel to side and out.
12. Remove three (3) screws and remove right panel of center console.
Steps 1 and 2 need not be removed completely if not required. Loosen left and right panels of center console (
Step 1 (page 1215) and Step 5 (page 1215) to remove fasteners in Step 8 (page 1216).
13. Remove three (3) bolts from lower center console and remove lower center console.
Wiring and lines may need to be moved slightly to remove fasteners and engine cover.
14. Remove 17 bolts on center console engine cover. There are three (3) bolts across top of cover, four (4)
across bottom under floor mat, and five (5) bolts on each side. Remove engine cover.
1216
CAB
Installation
None
Procedure
Wiring and lines may need to be moved slightly to install fasteners and engine cover.
1. Install engine cover. Install 17 bolts on center console engine cover. There are three (3) bolts across top of
cover, four (4) across bottom under floor mat, and five (5) bolts on each side.
2. Install lower center console and install three (3) bolts in lower center console.
3. Install right panel of center console and install three (3) screws.
4. Install left panel of center console and install one (1) screw and install in four (4) clips.
5. Install steering column right kick panel (if removed).
6. Pull accelerator pedal toward driver’s seat, to have enough room for right kick panel to be installed.
7. Push steering column right kick panel to side and in.
8. Lift upper section up and over steering column.
9. Settle steering column right kick panel in place.
10. Install two (2) bolts in accelerator pedal.
11. Install two (2) screws in steering column right kick panel (under and right of steering wheel column).
12. If wall kick panel was disconnected from middle kick panel, reconnect two (2) clips connecting both
kick panels.
13. Install middle and wall kick panels.
14. Install four (4) screws in middle kick panel (under and left of steering wheel column).
15. Install three (3) pop fittings in wall kick panel.
1217
CAB
Air Switches
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
Air switch control panel may have one or more air switches and may have other electrical connectors mounted
in panel depending on features provided.
1. Remove three (3) bolts from lower center console top bolt row and move lower center console back to
get to allow access to air switch control panel. Loosen and move aside right and left center console
covers to allow access to center console fasteners.
2. Remove (unscrew) air switch knob(s).
3. Remove four (4) screws at bottom of air switch control panel.
4. Pry six (6) clips loose to remove air switch control panel.
1218
CAB
5. Verify connectors are labeled.
6. Disconnect lighter connector and any other connectors attached behind air switch control panel.
7. Remove air switch control panel.
Air Valve(s)
If air valve(s) must to be removed, air system must be vented, drain air tanks.
Label each air line connection prior to removal to ensure correct orientation upon reassembly.
8. Remove four (4) flat phillips head screws for each air valve.
9. Remove four (4) pan head, Torx®, screws for each set of air valves.
10. Disconnect air lines from each air valve.
11. Remove air valve(s).
1219
CAB
Installation
None
Procedure
Air Valve(s)
If air valve(s) were removed, follow next four (4) steps to replace air valve otherwise go to Step 5 (page 1220).
1. Install air valve(s).
2. Connect air lines to each air valve.
3. Install four (4) pan head, Torx®, screws for each set of air valves.
4. Install four (4) flat phillips head screws for each air valve.
5. Connect lighter connector and any other connectors attached behind air switch control panel.
6. Align and install air switch control panel.
7. Align and install six (6) clips connecting air switch control panel to center console.
8. Install four (4) screws at bottom of air switch control panel.
9. Install air switch knob(s).
10. Install lower center console and install three (3) bolts in lower center console.
1220
CAB
Center Console Switches
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
Three center modules in switch panel do not have to be removed to remove switch panel.
1. Loosen and move aside right and left center console side covers to allow access to center console
fasteners.
2. Detach six (6) clips and move switch panel away from center console.
3. Verify all switch connectors are labeled.
4. Disconnect all switch connectors.
5. If not labeled, label each connector as it is disconnected.
1221
CAB
6. Behind panel, each connector is removed from switch by prying out both metal latches and pulling
connector away from switch.
Air Vent Module (Located Above Center Console Switch Panel)

Air vent module may have gauges that may require maintenance.
7. Remove three (3) screws holding air vent module in place.
8. Remove air vent module, held in place with four (4) clips.
9. Disconnect gauge or switch connector(s).
Air Valve(s) from Switch Panel

If air valve(s), on switch panel must to be removed, air system must be vented.
10. Vent air tanks to remove air pressure on air switch on lower left switch panel.
11. Make sure all air lines and connectors are identified.
12. Disconnect air and electrical connections on each air switch.
Some air lines go from one switch to other, do not loose these air lines.
13. Remove switch panel cover.
Center Modules from Switch Panel

Follow appropriate steps below to remove each of three (3) center modules from switch panel.
14. Remove screws and remove navigational panel, disconnect navigational panel connector(s).
15. Remove screws and remove transmission control panel, disconnect transmission control panel
connector(s).
Radio may be removed without removing center console switch panel cover.
16. Use radio removal device, remove radio, and disconnect radio connector(s).
1222
CAB
Installation
None
Procedure
Air Vent Module (Located Above Center Console Switch Panel)
Air vent module may have gauges that may require maintenance.
1. Connect gauge or switch connector(s).
2. Install air vent module, install four (4) clips.
3. Install three (3) screws holding air vent module in place.
Center Modules in Switch Panel

Follow appropriate steps below to install each of three (3) center modules in switch panel.
4. Connect navigational panel connector(s), install navigational panel, and install screws.
5. Connect transmission control panel connector(s), install transmission control panel, and install screws.
Radio may be installed without removing center console switch panel cover.
6. Connect radio connector(s) and install radio.
Air Valve(s) in Switch Panel

If air valve(s), on switch panel were removed, perform following two (2) steps to replace air valves on switch
panel before replacing all other switch on switch panel.
7. Replace switch panel cover.
8. Connect air and electrical connections to air switches.
9. Connect all switch connectors to switches on switch panel.
10. Align two (2) alignment pins in alignment holes, install six (6) clips to install switch panel on center console.
11. Install right and left center console side covers.
1223
CAB
Instrument Cluster
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
1. Remove eight (8) clips and remove instrument cluster cover.
2. Remove five (5) screws lay instrument cluster down in front of steering wheel.
3. Remove one (1) 14-pin connector, one (1) 20-pin connector, and jumper feed clip from back of instrument
cluster.
4. Remove instrument cluster.
1224
CAB
Installation
None
Procedure
1. Lay instrument cluster on steering column.
2. Connect one (1) 14-pin connector, one (1) 20-pin connector, and jumper feed clip in back of instrument
cluster.
3. Install instrument cluster in dash install five (5) screws.
4. Install eight (8) clips to install instrument cluster cover.
1225
CAB
Lower Instrument Cluster Panel
Removal
WARNING
1313).
WARNING
WARNING

procedures.
Procedure
1. Remove nine (9) clips to remove lower instrument cluster cover.
2. Verify all switch connectors are labeled.
3. Disconnect all switch connectors, if not labeled, label each connector as it is disconnected.
4. Behind panel, each connector is removed from switch by prying out both metal latches and pulling
connector away from switch.
5. Remove instrument cluster lower panel.
1226
CAB
Installation
None
Procedure
1. Install instrument cluster lower panel above steering column.
2. Connect all switch connectors.
3. Install nine (9) clips to install lower instrument cluster cover.
1227
CAB
Cab Interior Trim - Upgraded Trim

Overview
0016VKA Cab Interior Trim diamond level for day cab.
Diamond interior trim features a two-tone color scheme.
1228
CAB
Vehicle Exterior - Paint

Paint Schematics
Standard Chassis and Cab Paint

Standard colors used for bumper, wheels, and chassis items including frames, suspensions, axles, and fuel
tanks, are identified as follows. If an item is available in an optional color, that is also identified:
Description Standard Optional

Grille Bars Black Stainless Steel
Grille Surround Chrome Steel
Disc Wheels White Color (Non-metallic Paint)
Bumper Painted Steel Chrome Plated Steel
Frame, Suspensions, Axles, and Black Color (Non-metallic Paint)
Other Chassis Related Items
Paint schematic 100LU must be specified for standard single color cab paint on HX515 Models.
Paint schematic 100LW must be specified for standard single color cab paint on HX615 Models.
Paint schematic 100LX must be specified for standard single color cab paint on HX620 Models.
1229
CAB
Optional Colors
Instruction Number
Item Standard Colors
Code HX Models
Frame Rails, Black 10636

Cross Members,
10631 931LU 931LW 931LX
Suspensions,
Axles, Hubs, and
associated running
gear. (Fuel tanks can
not be painted other
than standard black
color.)
Wheels (Disc and White (Hubs and 10632 932LU 932LW 932LX
Rim with Disc Wheel Drums Painted
system) but does not Chassis Color)
include Hubs and
Drums for Disc
Line 1 and 2 Items See Above 10641 941LU 941LW 941LX
10646
Locking Rings and Gray Only -
Side Rings for Tube
Type Tires
Grille Chrome -
Stainless Steel -
Aluminum Fuel Tanks, Bumpers, Hubs Will Not Be Painted.
BTR fuel tanks will be painted same color as frame rails.
Optional two-color and three-color paint schematics are available. Due to contour lines of back panel, paint
schematic does not cover back panel; it stops at first sheet metal break line.
1230
CAB
Code Description
10769 Premium Color Paint
International® four-digit number and paint chips depicting colors, are found in
CT-400 ‘Exterior Paint’ color pages (PDB-85000).
A listing of advertised four-digit codes, along with their respective color descriptions,
also appears at back of this section.
Base Coat ` Clear Coat paint is mandatory with premium colors.
10771 Custom Color
With International® four-digit number: This category includes colors that were
formerly standard and have an International® number.
Without International® four-digit number: If no International® color match can be
found for color requested by customer, must supply either: current DuPont number
and description of color, or two (2) good, clean color samples, painted on 3 in. x 5 in.
metal or other rigid, non-porous material.
• These samples will not be returned or retained by plant. New samples must
be provided with each order.
• Three weeks additional production time will be required to mix custom paint.
Base Coat / Clear coat paint is mandatory with custom colors.
10761 Special Paint Types
Base Coat / Clear Coat (with Standard Colors) - one (1) or two (2) colors.
1231
CAB
Code Description
See Charts Special Paint Chart Schematics or Placements
a. Special Paint Ordering Codes Charts (page 1233)

b. Paint specific components a color other than standard or surrounding
color: Any special paint or any modification of those shown must be
accompanied by one of 'Special Painting Instructions' forms. All paint
breaks must be dimensioned as noted:
• Horizontal breaks dimensioned from bottom of cab (not from bottom

of skirts).
• Vertical breaks dimensioned from door openings and other definite
points.
• If back of cab is to be painted as part of schematic, that information
must be identified also.
c. Paint specific components a color other than standard or surrounding
color: Special Paint Chart Schematics or Placement Restrictions
1. Multi-toned cab tops are not available.

2. Multi-toned cab roof fairings (shields) are not available.
3. Belt lines less than 1/2 in. are not available.
4. Standard bumper is powder coated and cannot be painted
(These apply to WorkStar and TranStar only).
5. Metallic paint on frame rails, cross members, suspension,
axles, hubs, and associated running gear, battery boxes,
fuel tanks, and fuel tank straps or wheels are not available.
6. Special paint schematics will not be accepted on stock
orders.
1232
CAB
HX™ Series Special Paint Ordering Codes Chart

Number Of Design Extended
Hood Cab
Colors Breaks Onto Back Panel
0 (Solid) 35107 35100 N/A

1 to 2 35207 35200 35208
2-Tone
3 to 4 35223 35216 35224
5 and Up 35255 35248 35256
0 (Solid) 35107 35100 N/A
1 to 2 35307 35300 35308
3-Tone
3 to 4 35323 35316 35324
5 and Up 35355 35348 35356
0 (Solid) 35107 35100 N/A
1 to 2 N/A N/A N/A
4-Tone
3 to 4 35423 35416 35424
5 and Up 35455 35448 35456
1233
CAB
Body and Chassis Paint Guidelines
Paint Code
Find general color of a paint code go to ‘Service Portal’. On the home page select ‘Vehicle Information’. Select
on ‘Details’ tab. Retrieve 4 digit paint code for the VIN.
Break down into actual color name, including metallic, paint code will need to be looked up using Paint Code
Maintenance tool (https://evalue.internationaldelivers.com/mfgwebapps/csdwet/).
• Select ‘Applications’ from upper right corner tabs.

• Select ‘Paint Code’ from list of applications.
• Enter 4 digit paint code, and then select ‘Search Tab’.
Description
This general field guideline applies to all product lines produced at International Truck and Bus plants.
• Common sense is to be used when applying these guidelines to painted products. Customer perception,
color and end-use must be considered prior to proceeding with warranty claims.
• Refer to most recent Warranty Policy Letter regarding prior approval requirements.
• Attempt should be made to keep original OEM paint surface for long-term durability before repainting with
after-market material.
• Buffing and polishing dirt and defects is recommended before repainting.
• When properly performed, Fusor adhesive repairs are recommended over panel replacements.
• Damage due to rock chips and other normal wear and tear should be repaired in a timely manner to
prevent formation and propagation of corrosion across rest of panel. Progressive damage due to lack of
proper maintenance is not considered warrantable.
1234
CAB
Inspection Criteria
Following vehicle surface areas should be inspected at corresponding distances. All visible sunlight exposed
surfaces must be covered by topcoat.
• ‘A’ Surface, or primary area: Should be inspected at 4 to 6 ft (1.2 to 1.8 m). This area will include both
sides of standard cab, all areas around driver’s door, transition panels, hood sides, front to middle top of
hood, and chassis skirts above steps.
• ‘B‘ Surface, or secondary area: Should be inspected at 6 to 8 ft (1.8 to 2.4 m). This area will include upper
portion of side window to drip molding, middle to back of hood, chassis skirts from top step to bottom of
skirt, and painted front bumper.
• ‘C’ Surfaces: Should be inspected at 8 to 10 ft (2.4 to 3.0 m). This area includes entire roof, back of cab,
air dam, and return flanges.
• ‘D’ Surfaces: Include underside of hood, cab, sunshades, and aero devices. There are no requirements
for these surfaces. Underside of sunshades and roof air deflectors may have paint coverage but are not
covered under warranty as these surfaces are not designed to accept paint.
General Appearance Inspection Characteristics

Vehicle should be washed prior to inspecting for following items:
• Gloss / Orange Peel: Should be a consistent level so as to not present a contrast of gloss or surface
appearance between adjacent areas / panels.
• Color Match: Cab, hood, fender extensions, and skirting should have visual color match in bright daylight.
Coverage will be complete to conceal all substrate / primer color.
• Metallic Mottling: No Machine / Zebra stripes allowed. ’Eye catching’ mottling is not allowed on ‘A’ or
‘B’ surfaces in bright daylight.
• Repairs: There can be no evidence that vehicle had paint repair. Visible over spray, shadows, tape marks
or residue are not allowed. Multiple-tone vehicles shall have clear crisp straight lines of demarcation from
color to color. Process at plant for multi-toned paint is color 1 base coat then clear, color 2 base coat then
clear, color 3 base coat then clear and so on depending on how many colors are used. This gives a step
down effect to each color. This will be felt by touch. This is process and NOT a paint defect.
• Deep scratches: Exposed substrate in any area, large dings, dongs, and paint damage are not acceptable
and must be repaired.
• Thin Areas: For long-term reliability issues, thin (primer showing) areas on sunlight-exposed areas are
not allowed.
• Dings / Dongs, Mars / Marks, Bubbles / Craters, Sags / Runs, and Light Scratches: These items should
not be repaired if they are not visible at prescribed viewing distance per definition of ‘A’, ‘B’, and ‘C’
surfaces. These items should never be repaired on ‘D’ surfaces.
• Dirt / Fisheye: These items should not be repaired unless visible and excessive at prescribed viewing
distance per definition of ‘A’, ‘B’, and ‘C’ surfaces. Excessive is defined as 5 or more particles in a
6 in. (150 mm) radius.
1235
CAB
Chassis Paint Requirements

Chassis will be inspected for runs and sags, over-spray, grind marks, poor or thin paint coverage and easy
removal of paint from substrate. Term ‘Chassis’ will include all support areas, rails, fuel tanks, painted steps,
wheels, and drive lines (when applicable).
• Coverage: All visible areas of frame must be covered. All colored frames must have adequate coverage to
provide appearance of proper color match throughout body of the frame. Steel Hubs must be covered with
paint. Aluminum hubs will be left unpainted. No paint is allowed on studs, back plate, or machined areas.
An important area is the side of the frame between trailer / box and cab.
Top flanges, lower flanges and outside of web must be totally covered. Areas directly below fifth wheel
mounting and above rear axles may have minimal coverage due to accessibility. Axles, hubs, yokes, and
U-bolts shall have uniform coverage. Prop shafts and outside of assembled yokes shall have uniform
coverage over 360 degrees of rotation (due to inner bearings, it is recommended by OEM supplier that
driveline yokes are not to be degreased prior to topcoat application). No open thin areas are allowed. Areas
behind hoses and brackets must be primed and some effort must be made to cover this area. Purchased
fifth wheels are prepared for painting at designated supplier; as a result International should not be
responsible for premature corrosion / rust marks on fifth wheels during pre-sale. Fifth wheel ramp is
welded after frame is primed. A corrosion resistant primer is applied prior to chassis topcoat application to
prevent rust marks forming from weld. Due to function of ramp and fifth wheel, continually touch-up after
delivery by customer is recommended.
• Runs / Sags: Sags on open areas of inside of frame rails shall not exceed 6 in. (150 mm) lineal and 2 in.
(50 mm) vertical in a 4 ft (1.2 m) length. On fifth wheel units, rear cross member is to be free of sags and
thin areas. Sags on open area of outside of rails shall not have sags that exceed 3 in. (75 mm) lineal and
2 in. (50 mm) vertical and have no more then 1 crest. Sags on drive lines and axles are allowed if not
excessive. Some sags may occur in hard to access areas and are allowed if not excessive. Horizontal
surfaces of all steps shall not exhibit excessive paint, bubbles, crazing or pooling.
• Over-spray: All visible areas of frame area must be free of over-spray. Over-spray inside rail and less
visible areas may be allowed if not excessive.
• Marking: All top flanges and web shall be free of hose, drag marks and excessive marring. Manufacturing
characteristics of rails in general cause scratching and some surface marks on sides of rail. These marks
will be painted over and will not be repaired by sanding or metal finishing.
1236
CAB
Cab Rear Suspension

Overview
0016WLD Cab Rear Suspension dual frame mounted cab rear air suspension;
includes special cross-member assembly
Figure 628 Cab Rear Suspension Location

1. Torsion Bar 4. Ride Height Adjustment Valve
2. Right Air Bag 5. Left Air Bag
3. Right Shock Absorber 6. Left Shock Absorber
Cab air suspension increases driver comfort and reduces fatigue while working in rigorous on and off-road
environments.
1237
CAB
Ride Height Adjustment
Ride Height Valve Mounting Bolt and Nut 60 to 80 lbf-in. (6.8 to 9.0 N·m)
Ride Height Valve Lever Bolt and 2 Nuts (aligned with Both Nuts Snug to Valve Lever
valve lever even between 2 nuts)
WARNING
1313).
WARNING
WARNING

8. Ensure that all cab mounting, hood mounting, muffler mounting components, and air cleaner
mounting components are correctly installed to ensure free (unobstructed) movement of cab.
9. There must not be any occupants in cab and no change in cab weight during adjustment
procedures.
10. Hood must be shut to prevent counteracting ride suspension.
1238
CAB
Adjustment - Set
Figure 629 Measure Cab Ride Height

1. Outside Floor of Cab 3. Top Surface of Cross Member
2. 9.21 ± 0.375 in. (233.21 ± 9.53 mm)
1. Measure cab ride height between bottom of cab and top of cross member. This measurement must be
made between two measuring points from bottom of cab to top of frame and must meet specified height (2).
Figure 630 Ride Height Adjustment Valve

1. Ride Height Linkage Clamp 4. Ride Height Valve Operator
2. Adjusting Linkage Turnbuckle 5. Ride Height Valve
3. Adjusting Linkage Operator Connecting
Bolt
1239
CAB
2. Disconnect adjusting linkage bolt (3) from ride height valve by removing nut from linkage socket and
valve lever.
It is very important that height valve be cycled completely before and after any ride height adjustments. Cycling
of height valve will help make adjustment more accurate.
3. Dump air from rear cab air suspension by rotating valve lever (4) to EXH (exhaust).
4. Refill rear cab air suspension to proper ride height of 9.21 ± 0.375 in. (233.21 ± 9.53 mm) by rotating
valve lever (4) to FILL.
5. Remove locking clamp (1) from linkage (2).
6. Turn linkage turnbuckle clockwise to lengthen linkage or turn linkage socket counterclockwise to shorten
linkage.
When at proper length, linkage should connect to valve lever without affecting ride height adjustment.
7. Attach linkage socket with nut installed on valve lever and secure with nut. Torque nut (page 1456)
while holding both nuts.
8. Re-measure cab ride height, and adjust as required. Proper ride height is 9.21 ± 0.375 in. (233.21 ±
9.53 mm).
1240
CAB
Cab Rear Suspension - Shock
Removal
WARNING
1313).
WARNING
WARNING
1. These procedures are to provide instructions and specifications for maintaining cab ride
suspension. Before starting maintenance procedure, be sure that following conditions are met or
performed.
procedures.
1241
CAB
Procedure
Figure 631 Ride Height Shock Absorber - Remove

1. Upper Shock Absorber Flange Head 4. Upper and Lower Flange Head Nuts (2)
Bolt 5. Shock Absorber
2. Upper Ride Height Cab Mount 6. Lower Shock Absorber Bushing
3. Upper Shock Absorber Mount and 7. Lower Shock Absorber Flange Head
Bushing Bolt
1. Remove upper and lower flange head bolts (1 and 7) and flange head nuts (4).
2. Slide upper and lower shock bushings (3 and 6) out of mounts.
1242
CAB
Installation
Ride Height Shock Absorber Flange Head Bolt and 80 to 100 lbf-ft (108 to 135 N·m)
Flange Head Nut
Procedure
1. Slide upper and lower shock bushings into mounts.
2. Install upper and lower flange head bolts and flange head nuts.
3. Torque flange head bolts and nuts (page 1456).
4. Perform ride height adjustment, see ride height adjustment procedure .
1243
CAB
Cab Rear Suspension - Air Bag
Removal
WARNING
1313).
WARNING
WARNING
These procedures are to provide instructions and specifications for maintaining cab ride suspension. Before
starting maintenance procedure, be sure that following conditions are met or performed.

procedures.
Procedure
1. Remove cab rear suspension shock (page 1241).
2. Remove four (4) skirt screws and remove passenger skirt panel.
3. Disconnect ride height adjustment lever.
4. Manually place ride height adjustment valve lever to FILL and raise cab to maximum height.
1244
CAB
• Hydraulic jack may be used to raise cab far enough to free upper air bag assembly frame from ride
height frame.
• Cranes or A-frames with chain falls may also be used to raise rear of cab.
IMPORTANT – Use care when using chain falls, prevent hooks from damaging cab.
5. Install wood blocks or other blocking device (floor stands) between cab bottom and frame or ground (floor).
6. Depressurize air system, vent air tanks.
7. Manually place ride height adjustment lever to EXH and depressurize ride height system.
Figure 632 Air Bag - Remove

1. Air Bag Upper Mount 4. Air Bag Lower Mount
2. Air Bag Mount Flange Head Bolts (2) 5. Cross Member
3. Air Bag 6. Air Bag Flange Head Nuts (2)
8. Remove two (2) air bag assembly flange head bolts (2) from air bag assembly upper mount (1). Flange
head nuts (6) may be tack welded to air bag assembly upper mount.
1245
CAB
Figure 633 Air Bag Air Line Fitting - Disconnect

1. Air Bag 3. Air Bag Assembly Air Line
2. Lower Air Bag Mount 4. Air Bag Assembly Air Line Fitting
9. Disconnect air bag assembly air line (3) fitting (4) from air bag (1).
It may be necessary to remove shock absorber (if not already done) from lower air bag mount (2) to get
to air line fitting.
Figure 634 Air Bag - Remove

1. Air Bag 4. Air Bag Assembly Air Line Fitting
2. Air Bag Upper Mount 5. Lower Air Bag Mount
3. Upper Ride Height Cab Mount 6. Cross Member
1246
CAB
10. Slide air bag upper mount (2) from upper air height cab mount (3), or remove air bag (1) from air bag
upper mount.
It is easier to slide air bag upper mount from upper air height cab mount to remove air bag.
11. Lift and remove air bag from lower air bag mount (5) on cross member (6).
1247
CAB
Installation
Ride Height Air Bag Upper Flange Head Bolt and 41 to 50 lbf-ft (56 to 68 N·m)
Flange Head Nut (Normally tacked in place)
Procedure
1. Install air bag in lower air bag mount.
2. Slide air bag upper mount with air bag attached on upper air height cab mount and align bolt holes, or
install air bag in air bag upper mount.
3. Install air bag on air bag lower mount and into air bag upper mount. Install two air bag flange head bolts
through air bag upper mount. Flange head nuts may be tack welded to air bag upper mount.
4. Connect air bag assembly air line fitting to air bag, connecting air bag assembly air line under lower air
bag mount.
5. Torque flange head bolts (page 1456).
6. Remove cab wood blocks or some other blocking device (floor stands) between frame and cab bottom.
7. Raise rear of cab, hydraulic jack may be used to raise cab far enough to free cab blocking device. Cranes
or A-frames with chain falls may also be used to raise rear of cab.
8. Remove cab wood blocks or other blocking device (floor stands) between cab bottom and frame or
ground (floor).
9. Start and run engine to pressurize air system.
10. Pressurize air bag assembly to maximum height.
11. Check ride height air system for leaks.
1248
CAB
Cab Rear Suspension - Ride Height Valve
Removal
WARNING
1313).
WARNING
WARNING
WARNING

procedures.
Procedure
Air bag removal is not required to perform maintenance on ride height valve, however steps to brace cab, vent
air system, and disconnect ride height valve must be performed prior to removing ride height valve.
1249
CAB
1. Remove four (4) skirt screws and remove skirt.
Figure 635 Ride Height Valve

1. Ride Height Valve 5. Valve Mounting Bolt
2. Ride Height Adjustment Lever Jam Nut 6. Valve Mounting Locknut
3. Right Height Adjustment Lever 7. Air Lines to Air Bags from Valve
4. Right Height Adjustment Lever Bolt 8. Air Line Quick Valve
2. Remove ride height adjustment lever jam nut (2) and disconnect ride height adjustment lever (3).
3. Manually place ride height adjustment lever to FILL and raise cab to maximum height.
• Hydraulic jack may be used to raise cab far enough to install blocking device.
• Cranes or A-frames with chain falls may also be used to raise rear of cab.
4. Install wood blocks or some other blocking device (floor stands) between cab bottom and frame or ground
(floor).
5. Depressurize air system, vent air tanks.
6. Manually place ride height adjustment lever to EXH and depressurize ride height system.
7. Remove ride height valve mounting bolt (5) and locknut (6).
8. Remove air supply hose and air outlet line (7) to air bags from ride height air line quick valve (8).
9. Remove ride height valve (1).
1250
CAB
Installation
Ride Height Valve Mounting Bolt and Nut 60 to 80 lbf-in. (6.8 to 9.0 N·m)
Procedure
1. Install air supply hose and air outlet line to air bags to ride height air line quick valve.
2. Install ride height valve.
3. Install ride height valve bolt and locknut.
4. Torque bolt and locknut (page 1456).
5. Remove cab wood blocks or some other blocking device (floor stands) between frame and cab bottom.
6. Raise rear of cab, hydraulic jack may be used to raise cab far enough to free cab blocking device. Cranes
or A-frames with chain falls may also be used to raise rear of cab.
7. Remove cab wood blocks or other blocking device (floor stands) between cab bottom and frame or
ground (floor).
8. Pressurize air system.
9. Start and run engine to pressurize air system.
10. Pressurize air bag assembly to maximum height.
11. Check ride height air system for leaks.
1251
CAB
Cab Rear Air Suspension - Sleeper Cab

Overview
0016VUT Cab rear air suspension, includes integrated crossmember, for sleeper
cab
Figure 636 Sleeper Cab Rear Air Suspension Location

1. Mounting bracket (2) 3. Shock absorber
2. Air bag 4. Torque rod
Cab rear air suspension increases driver comfort and reduces fatigue while working in rigorous on- and
off-road environments.
1252
CAB
Cab Skirts
Overview
0016XBZ Cab Skirts, painted body color, includes LED lights, mounted under cab
0016XBK Cab Skirts, polished stainless steel; includes LED lights, mounted under
cab
Cab skirts are painted body color or polished stainless steel depending on feature code, including LED
lights, and mounted under cab.
1253
CAB
Cab Interior Storage

Overview
0016VAW Storage, Cab Interior molded holder for thermos, maps, and CD's;
located at base of passenger seat
Interior cab storage includes molded holder for thermos or drink cups, storage for maps, and CD storage,
located adjacent to base of passenger seat, in door panels, and at base of center console.
1254
CAB
Cab Sunshade
Overview
0016XWD Sunshade, Exterior aerodynamic, painted roof color; includes integral
clearance / marker lights
0016XWE Sunshade, Exterior bright finish; includes integral clearance / marker
lights
Located on cab exterior above windshield, to shade driver, cab, and passenger for high heat from sun.
1255
CAB
Day Cab
Overview
Day cab is where the operator controls the vehicle and does not provide a sleeper for overnight usage. A
passenger has a seat in the day cab in addition to the operator.
Seat mounting bolts 23 - 27 lb-ft. (31 - 37 N·m)
Seat belt bracket to seat, bolts and nuts 25 - 35 lb-ft. (34 - 47 N·m)
Seat shoulder belt bolts 25 - 35 lb-ft. (34 - 47 N·m)
1256
CAB
Door Adjustment Procedure
Overview
Adjust driver-side and passenger-side cab doors to properly fit in cab openings.
Figure 637 Cab Doors

1. Passenger-side door 2. Driver-side door
Special Tools
None
Specifications
Clearance, rear of door to cab opening 0.24 - 0.35 in (6 - 9 mm)
Door hinge mounting bolts 17 - 20 lb-ft (23.1 - 27.1 N·m)
Door striker bolt 34 - 50 lb-ft (46 - 68 N·m)
1257
CAB
2. Key OFF.
WARNING
WARNING
procedures.
Adjustment Procedure
Figure 638 Clearance Between Rear of Door and Cab Opening

1. Rear edge of door 3. Acceptable clearance: 0.24 - 0.35 in (6
2. Raised edge of cab opening - 9 mm)
1258
CAB
1. Measure the clearance between rear edge of door (1) and raised edge of cab opening (2), taking multiple
measurements along straight edge of door.
a. If all measurements are 0.24 - 0.35 in (6 - 9 mm), no adjustment is necessary. Skip Steps 2 through 5.
b. If any measurement is not 0.24 - 0.35 in (6 - 9 mm), proceed with Step 2.
Figure 639 Shim Installation

1. Hinge mounting bolt (6) 3. Hinge
2. Door frame
NOTE – Do not loosen all six hinge mounting bolts (1) at the same time. Install or remove shims at one
end of hinge (3) and tighten three bolts at that end prior to loosening three bolts at other end of hinge
(3).
2. Loosen three hinge mounting bolts (1) at one end of hinge (3) enough to remove or install shims between
hinge (3) and door frame (2).
3. Remove or install enough shims between hinge (3) and door frame (2) to change the clearance measured
in Step 1 to 0.24 - 0.35 in (6 - 9 mm).
1259
CAB
a. If a clearance of 0.24 - 0.35 in (6 - 9 mm) cannot be achieved by removing or installing shims, contact
Navistar for further instructions.
NOTE – When tightening hinge mounting bolts (1) at bottom of hinge (3), make sure ground strap is
positioned in same orientation as it was prior to loosening bolts.
4. Tighten three hinge mounting bolts (1) to 17 - 20 lb-ft (23.1 - 27.1 N·m).
5. Repeat Steps 2 through 4 at other end of hinge.
6. Loosen and move door striker bolt as needed. Tighten bolt to 34 - 50 lb-ft (46 - 68 N·m).
Follow-On Procedure
When door is properly adjusted, door should fit cab opening with 0.24 to 0.35 in (6 to 9 mm) clearance
between edge of door and cab opening:
• A newspaper sheet should not be able to pass between weather seal and door frame (paper should tear).
• The door weather seal should make contact with slight pressure, but without damage to seal.
• The door should latch, lock, and release without undue effort.
• The door should not rattle when vehicle is moving.
1260
CAB
Sleeper Cab
Overview
0016AUB Cab conventional, low-roof sleeper cab, 51 in (129.5 cm) from seat to
inside back of cab, with 37-in. (94 cm) wide bunk
0016AUC Cab conventional, hi-rise sleeper cab, 51 in (129.5 cm) from seat to
inside back of cab, with 37-in. (94 cm) wide bunk
Figure 640 Sleeper Cab

1. Sleeper cab
The sleeper cab utilizes an aluminum riveted shell.
Features of the cab include:
• Aluminum cab
• Removable riveted inner back and corner panels
• Extruded aluminum door frames with aluminum inner and outer panels
• Tinted safety glass – all windows
1261
CAB
Vent Window
Removal
Overview
Sleeper cab vent window removal for repair or replacement.
Special Tools
None
Equipment Condition
1. Interior trim panels and accessories removed as needed.
1262
CAB
Removal Procedure
Figure 641 Vent Window

1. Vent window location
1. Locate end of window seal, and carefully pry out using window seal removal tool.
2. Remove window seal from vent window by pulling window seal out along perimeter of vent window.
3. Remove 14 nuts from threaded studs of vent window.
4. From outside vehicle, remove 14 threaded studs and vent window from vehicle, and place vent window on
padded work station.
Expected Outcome
None
Follow-On Procedure
1. Install sleeper cab vent window.
1263
CAB
Installation
Overview
Sleeper cab vent window installation following repair or replacement.
Special Tools
None
Vent window nuts 7 lb-ft (9.5 N·m)
Equipment Condition
1. Sleeper cab vent window removed.
1264
CAB
Figure 642 Vent Window

1. Vent window location
1. From outside vehicle, install vent window and 14 threaded studs to vehicle.
2. Install 14 nuts to threaded studs of vent window. Torque nuts to 7 lb-ft (9.5 N•m).
3. Locate starting point of window seal, and press seal firmly into ridge of vent window.
4. Install window seal to vent window by firmly pressing window seal into ridge along perimeter of vent window.
Expected Outcome
None
Follow-On Procedure
1. Install interior trim panels and accessories as needed.
1265
CAB
Luggage Compartment - Release Cable
Removal
Overview
Release cable removal for repair or replacement.
Special Tools
None
Equipment Condition
1. Bunk bed lifted and stored away.
1266
CAB
Removal Procedure
Figure 643 Luggage Release Cable

1. Release cable channel 2. Latch
1. Disconnect release cable (1) from latch (2).
2. Remove bracket and release cable (1) from luggage compartment.
Expected Outcome
None
Follow-On Procedure
1. Install release cable.
1267
CAB
Installation
Overview
Release cable installation following repair or replacement.
Special Tools
None
Equipment Condition
1. Release cable removed.
1268
CAB
Figure 644 Luggage Release Cable

1. Release cable channel 2. Latch
1. Install release cable (1) and bracket to luggage compartment.
2. Connect release cable (1) to latch (2).
Expected Outcome
None
Follow-On Procedure
None
1269
CAB
Cab Side Fairing
Overview
0016WYV Cab side fairings, for use on conventional sleeper cab
0016WZR Cab side fairings, includes cab side extender top extensions, for use with
conventional hi-rise sleeper cab, without aerodynamic package
Figure 645 Cab Side Fairing Location

1. Cab side fairing
Cab side fairings are helpful in directing air flow past the tractor and trailer gap. These items aerodynamically
help merge the tractor and trailer into one vehicle. It is important to remember with large trailer gaps (even
on vehicles with side extenders), the atmosphere begins to treat the tractor and trailer as two separate
vehicles. This is because turbulence begins to form in the trailer gap as the air passes over and around the
tractor and hits the nose of the trailer.
Turbulence resulting from air flow between the back of the tractor and the front of the trailer is reduced
when cab side fairings are used. The cab side fairings reduce air flow between the tractor and trailer and
are effective even with trailers that are not full height. An extended roof fairing (included with aerodynamic
packages) further improves aerodynamic efficiency when full-height trailers are used.
The 18-in. (45.7 cm) extenders further reduce the gap between the tractor and trailer.
1270
CAB
Removal
Overview
Remove cab side extenders for repair or replacement.
Special Tools
None
None
WARNING
WARNING
procedures.
1271
CAB
Removal Procedure
Figure 646 Roof Extender

1. M8 bolts and washers (4) 3. Roof extender
2. M8 bolt, washer, and locknut 4. Self-tapping screw
1. Remove self-tapping screw (4) from roof extender (3).
2. Remove four M8 bolts and washers (1) from roof extender (3).
3. Remove M8 bolt, washer, locknut (2), and roof extender (3) from cab.
1272
CAB
Figure 647 Side Extender

1. Upper mounting bracket 4. M8 bolts and washers (6)
2. M8 bolts and washers (3) 5. Self-tapping screws (3)
3. Side extender 6. Lower mounting brackets (2)
4. Remove three self-tapping screws (5) from side extender (3).
5. Remove six M8 bolts and washers (4) from side extender (3) at two lower mounting brackets (6).
6. Remove three M8 bolts, washers (2), and side extender (3) from upper mounting bracket (1).
Expected Outcome
None
Follow-On Procedure
1. Install cab side extenders. See Cab Side Extenders Installation.
1273
CAB
Installation
Overview
Install cab side extenders following repair or replacement.
Do not torque bolts and screws until all panels are adjusted properly.
Special Tools
None
Side extender self-tapping screws 3 - 13 lb-in. (0.3 - 1.5 N·m)
M8 bolt and locknut 97 - 124 lb-in. (11.0 - 14.0 N·m)
1. Cab side extenders removed. See Cab Side Extenders Removal.
1274
CAB

1. Upper mounting bracket 4. M8 bolts and washers (6)
2. M8 bolts and washers (3) 5. Self-tapping screws (3)
3. Side extender 6. Lower mounting brackets (2)
1. Position side extender (3) to upper mounting bracket (1), and secure using three M8 bolts and washers (2).
2. Install six M8 bolts and washers (4) to side extender (3) at two lower mounting brackets (6).
3. Install three self-tapping screws (5) to side extender (3). Torque screws to 3 - 13 lb-in. (0.3 - 1.5 N·m).
1275
CAB
Figure 649 Roof Extender

1. M8 bolts and washers (4) 3. Roof extender
2. M8 bolt, washer, and locknut 4. Self-tapping screw
4. Install roof extender (3), M8 bolt, washer, and locknut (2) to cab.
5. Install four M8 bolts and washers (1) to roof extender (3).
6. Install self-tapping screw (4) to roof extender (3).
7. Adjust roof extender (3) and side extender to match all body lines with cab.
8. Torque M8 bolt, washer, and locknut (2) to 97 - 124 lb-in. (11.0 - 14.0 N·m).
9. Torque four M8 bolts and washers (1) to 97 - 124 lb-in. (11.0 - 14.0 N·m).
10. Torque self-tapping screw (4) to 3 - 13 lb-in. (0.3 - 1.5 N·m).
1276
CAB

1. Upper mounting bracket 4. M8 bolts and washer (6)
2. M8 bolts and washer (3) 5. Self-tapping screws (3)
3. Side extender 6. Lower mounting bracket (2)
11. Torque nine M8 bolts and washers (2 and 4) to 97 - 124 in-lb (11.0 - 14.0 N·m).
12. Torque three self-tapping screws (5) to 3 - 13 in-lb (0.3 - 1.5 N·m).
Expected Outcome
None
Follow-On Procedure
None
1277
CAB
Cab Skirts
Overview
0016VZV Modesty panel, polished stainless steel, with Light Emitting Diode (LED)
lights, for 51 in (129.5 cm) sleeper
0016XJS Modesty panel, painted body color, with LED lights, for 51 in (129.5
cm) sleeper
Figure 651 Cab Skirts

1. Cab skirt
Cab skirts are located below the sides of the cab.
Cab skirts improve air movement along the sides of the truck. Air turbulence around the front fender
extensions, fuel tanks, battery box, frame access steps, and quarter fenders is reduced, allowing for improved
fuel efficiency.
Two configurations of cab skirts are available. One configuration is painted the same color as the cab, and the
other is polished stainless steel. Skirt strips are very flexible to reduce abrasion when in contact with pavement,
extending service life. Serviceability is made simple with only four mounting bolts to remove each skirt.
1278
CAB
Removal
Overview
Cab skirt removal for repair or replacement.
Special Tools
None
None
1279
CAB
Removal Procedure
1. Remove four bolts from cab skirt.
2. Remove cab skirt from vehicle.
Expected Outcome
None
Follow-On Procedure
1. Install cab skirt.
1280
CAB
Installation
Overview
Cab skirt installation following repair or replacement.
Special Tools
None
None
1. Cab skirt removed.
1281
CAB
1. Position cab skirt on vehicle.
2. Install four bolts to secure cab skirt to vehicle.
Expected Outcome
None
Follow-On Procedure
None
1282
CAB
Windshield
Overview
For proper windshield removal and installation, use International® Bonded Windshield Tool Kit, ZTSE4470.
This kit comes complete with toolbox and all the tools required to remove and install bonded windshields.
For additional materials, contact your International® dealer for service parts.
For windshield installation, use Windshield Replacement Kit, 2592784C91. A pneumatic or electric caulking
gun is required for application of the adhesive.
Center divider bar acorn nut 60 lb-in. (6.8 N·m)
1283
CAB
Removal
2. Place protective coverings over areas near windshield.
3. Remove windshield wiper arms and blades.
Figure 652 Mounting Brackets Tape

1. Sunshade 3. Mounting brackets
2. Tape
4. If unit is equipped with exterior sunshade (1), place tape (2) on bottom side mounting brackets (3)
to protect paint.
5. Remove sunshade.
1284
CAB
1 2
0000428169
Figure 653 Driver-side A-pillar Trim Panel

1. Driver-side A-pillar trim panel 2. Speaker
6. Beginning at header trim panel (top), remove driver side A-pillar trim panel (1) by pulling free from cab
A-pillar. When pulling trim panel free, disconnect speaker (2) connector on inside of trim panel.
1285
CAB
0000428170
Figure 654 Passenger-side A-pillar Trim Panel

1. Passenger-side A-pillar trim panel
7. Beginning at header trim panel (top), remove passenger-side A-pillar trim panel (1) by pulling free from
cab A-pillar.
1286
CAB
0000428171
Figure 655 Passenger Side A-pillar Grab Handle

1. Grab handle 2. Bolts (2)
8. Remove 2 bolts (2) from grab handle (1) and remove handle.
WARNING
To prevent vehicle damage, personal injury, and / or possible death, wear protective eye
wear and work gloves when removing windshield.
1287
CAB
Figure 656 Cut Off Rubber Trim Flange

1. Utility knife 2. Rubber trim flange
9. Lift outer flange of encapsulation rubber trim and, with a utility knife (1), cut rubber trim flange (2) entirely
off windshield.
• When using power knife to cut around windshield, use spray bottle filled with water to lubricate cutting
area. This will prevent burning of urethane and re-bonding of windshield.
1288
CAB
Figure 657 Cut Windshield Out

1. Power knife 4. Outside cutting blade
2. Short inside cutting blade 5. Long handle utility knife
3. Long inside cutting blade
10. Cut windshield out.

a. Use power knife (1) with short inside cutting blade (2), or long inside cutting blade (3) and / or outside
cutting blade (4), cut completely around windshield until it is free from cab windshield fence.
b. If windshield will not lift off, use a long-handle utility knife (5) to cut through adhesive.
11. With aid of assistant, lift windshield off cab and place it out of way.
1289
CAB
Installation
Figure 658 Windshield Replacement Kit

1. Body primer, 43532 4. Betaseal™ Express one-part urethane
2. Clear glass primer, 43518 adhesive
3. Black-out glass primer, 43520A 5. Cartridge tips
These materials must be used on or before the expiration date marked on container. Refer to individual
containers for expiration dates.
Additional materials needed include the following:

Essex® GC800 Glass Cleaner
White or Brown Paper Towels
Pneumatic or Electric Caulking Gun
Windshield must be made of laminated safety glass only (AS-1 per ANSI Z26.1, latest revision and
Navistar® TMS - 9522 SAE J1203).
1290
CAB
WARNING
To prevent vehicle damage, personal injury, and / or possible death, wear protective work
gloves when handling the windshield. Also wear appropriate protective gloves when
™ system chemicals from the Essex® windshield installation
using any of the Betaseal™
kit.
Before installing new windshield, wipe off any water remaining around windshield fence and surrounding
cab area with a lint-free cloth.
1. Dry-fit new windshield to ensure it fits properly. While windshield is in place, attach a piece of tape (as a
reference mark) across the center, top portion of windshield and cab. Use a utility knife and cut the
tape between the cab and windshield.
2. Remove windshield and place on a suitable padded work stand.
Figure 659 Remove Urethane Adhesive

1. Old adhesive 3. Gasket chisel
2. Windshield fence 4. Old adhesive
3. Use gasket chisel (3), remove old adhesive (1) from windshield fence (3).
a. Leave thin layer, 5/64 to 8/64 in. (2 to 3 mm), thick bead of old adhesive (4).
b. While removing old adhesive, try to maintain a consistent thickness on windshield fence.
4. Remove any dirt or water remaining from windshield removal with a brush or clean, lint-free cloth.
1291
CAB
Figure 660 Apply Body Primer

1. Body primer, 43532 3. Windshield fence
2. Applicator
5. Shake body primer container for at least one minute.
6. Apply body primer (1).

a. Use clean, dry applicator (2) to cover scratches and bare metal on the windshield fence (3).
b. DO NOT apply body primer over old urethane adhesive left on windshield fence.
c. Allow primer to dry for 6 to 10 minutes minimum after application.
1292
CAB
Figure 661 Remove Flash

1. Bonding surface 2. Razor blade
7. Use razor blade (2), if necessary, and plastic scrubbing pad, remove any flash from bonding surface
(1) of new windshield.
a. Clean new windshield thoroughly with Essex® glass cleaner GC800 and dry thoroughly with paper
towels.
b. Ensure windshield is completely clean and dry before proceeding.
Read and understand next step thoroughly and completely to ensure correct application and removal of
43518 clear glass primer.
1293
CAB
Figure 662 Apply Clear Glass Primer

1. Clear glass primer, 43518 4. White or brown paper towel
2. Applicator 5. Bonding surface
3. Windshield
8. Shake clear glass primer (1) container for at least one minute.
9. Apply clear glass primer with a clean, dry applicator (2) to windshield (3) bonding surface (5) only.
CAUTION
To prevent property damage, if clear glass primer is applied to clear glass surface, glass
will haze.
10. Immediately wipe clear glass primer off bonding surface by following 8 to 10 in. (20 to 25 cm) behind
applicator (2) with a white or brown paper towel (4). DO NOT use a cloth shop towel.
11. After completing first application of clear glass primer, repeat application and removal process.
1294
CAB
Figure 663 Apply Black-out Glass Primer

1. Black-out glass primer, 43520A 3. Windshield
2. Applicator 4. Bonding srface
12. Shake black-out glass primer (1) container for at least one minute.
13. Apply black-out glass primer with a clean, dry applicator (2) to the windshield bonding surface (4). Allow
primer to dry to a tack-free condition for 6 to 10 minutes minimum after application.
CAUTION
To prevent damage to vehicle, after priming the windshield, ensure there is no contact
with the bonding surface, as oil from the skin will affect bonding performance. If the
windshield is not bonded properly, the cab strength and safety would be compromised. If
contact with the bonding surface has occurred, repeat the cleaning process and reapply
43520A black-out glass primer and allow it to dry for 6 to 10 minutes before applying
Betaseal™™ Express one-part urethane adhesive.
1295
CAB
Figure 664 Adhesive Tube and Cartridge Tip

1. Trim dimensions 3. Adhesive tube
2. Cartridge tip
14. Measure, mark, and trim cartridge tip (2) to trim dimensions (1) shown for proper adhesive application.
15. Attach cartridge tip to adhesive tube (3)
1296
CAB
Figure 665 Apply Adhesive to Weld Seams

1. Pneumatic or electric caulking gun 3. Windshield fence
2. Betaseal™ one-part urethane adhesive
16. Load adhesive tube into a pneumatic or electric caulking gun (1).
17. Apply small bead of adhesive (2) to weld seams at top and bottom of windshield fence (3) on both sides.
• Apply adhesive bead 0 to 5/64 in. (0 to 2 mm) at least 5/8 to 6/8 in. (16 to 19 mm) high and 3/8 to 4/8 in.
(10 to 13 mm) wide maximum to new windshield from encapsulation edge.
1297
CAB
Figure 666 Apply Adhesive to Windshield

1. Pneumatic or electric caulking gun 4. Plastic or wood tongue depressor
2. Cartridge tip 5. Locating tab
3. Adhesive
18. Apply adhesive to windshield.

a. Hold pneumatic or electric caulking gun (1) as close to 90° angle as possible, start applying adhesive
(3) at the outer edge of locating tab (5) at the bottom of the windshield.
b. Apply a uniform bead completely around the windshield.
c. Overlap adhesive at the seam slightly, use a plastic or wood tongue depressor (4) to smooth or even
out adhesive as required before installing windshield.
1298
CAB
Figure 667 Position Windshield

1. Windshield 3. Windshield locating tab
2. Tape mark 4. Cab locator post
19. Position windshield.
Be careful not to touch windshield on cab when installing.

a. With aid of assistant, align windshield with tape marks (2) on windshield and cab.
b. Align windshield locator tabs (3) with cab locator post (4) at bottom of windshield opening.
1299
CAB
4
3
2
0000428165
Figure 668 Push Windshield into Place

1. Windshield 4. Tape on cab
2. Windshield encapsulation rubber trim 5. Tape on windshield
3. Windshield fence
20. While holding windshield locator tabs in place on cab locator posts, push windshield (1) back against
windshield fence (3).
21. Check windshield encapsulation rubber trim (2) to make sure it is positioned properly around windshield
opening.
22. With aid of assistant, gently push on windshield all around outer edges to seat it properly against
windshield fence. Tabs built into windshield prevent it from being pushed in too far.
23. Remove tape from windshield (5), and sunshade mounting brackets (if applicable).
24. If the vehicle is equipped with an exterior sunshade, install sunshade.
25. Install passenger side A-pillar trim panel by aligning trim panel retaining clips with the mounting holes
and push in to secure.
26. Install passenger side grab handle and secure with two bolts. Tighten bolts to 77 to 95 lbf-in (9 to 11 N·m).
27. Connect speaker connector on driver side A-pillar trim panel. Install driver side A-pillar trim panel by
aligning trim panel retaining clips with mounting holes and push in to secure.
1300
CAB
CAUTION
To prevent damage to vehicle, Betaseal™™ Express one-part urethane adhesive should be

allowed to cure for 60 minutes before testing windshield wipers, windshield washer, or
driving vehicle.
28. Install windshield wiper arms and blades.
29. Test operation of windshield wipers and washer.
30. Clean windshield and surrounding areas.
1301
HEATING VENTILATION AIR CONDITIONING (HVAC)
3. Heating Ventilation Air Conditioning (HVAC)

HVAC with Integral Heater and Defroster
Overview
0016WKB Air Conditioner {International® Blend-Air} with integral heater and
defroster and R-134a refrigerant

1. HVAC Control 4. Fuse Block
2. Mode Door Stepper Motor 5. Fresh Air Door Stepper Motor
3. APADS module (Feature Code 16WJC 6. HVAC Vent (‘Summer’ or ‘Winter’)
only) 7. HVAC Assembly
1302

1. Heater Core 5. Resistor Block
2. Blend Door Stepper Motor 6. Thermal Switch
3. Blower Motor 7. HVAC Filter
4. Blower Motor Connector 8. Evaporator Core

1. Heater Hoses 4. Condenser
2. HVAC Compressor 5. Receiver / drier
3. HVAC Compressor Clutch 6. HVAC High-pressure Service Port
1303

1. Low Pressure Switch 3. Expansion Valve
2. High Pressure Switch 4. Low Pressure Service Port
HVAC unit located under passenger seat, provides heating and cooling as well as window defrosters. HVAC
compressor is mounted on passenger side of engine and driven by engine serpentine belt.
1304
Sleeper HVAC
Overview
0016WDL Thermostat temperature control, for sleeper area of sleeper cab
The sleeper air conditioning (A/C) and heating system is a system of components designed to provide
conditioned air to the vehicle’s sleeper area. The sleeper system is a subsystem of the vehicle’s overall
Heating, Ventilation, and Air Conditioning (HVAC) system, and shares common components. The main
components of the sleeper HVAC system are found either on or in the rear HVAC unit under the lower sleeper
bunk, on the passenger-side of the vehicle and include evaporator core, expansion valve, heater core, blend
air door, air door actuator, blower, linear power module, rear HVAC controller, temperature sensor, and air filter.
The addition of the sleeper HVAC system does not affect the operation of the front (cab) A/C system. The
rear Thermostatic Expansion Valve (TXV) and evaporator core are connected in parallel with the TXV and
evaporator core in the front A/C system.
A/C is automatically requested by the sleeper HVAC controller whenever the temperature requested for the
sleeper system is set lower than the temperature sensed by the rear HVAC unit. Upon receiving the A/C
request, the Body Control Module (BCM) will energize the A/C compressor if all requirements are met. To
energize the A/C compressor, the engine must be running and the blower speed controls for both the front and
rear HVAC systems must be ON. Blower speed and air discharge temperature of the sleeper HVAC system
can be adjusted from either the rear control panel or the rear HVAC switches located on the center panel.
1305
Sleeper Blend Door Actuator
Removal
Overview
Sleeper blend door actuator removal for repair or replacement.
Special Tools
None
1. Bunk raised as needed for access.
1306
Removal Procedure
1. Remove ten screws, retention strap, and cover from rear HVAC assembly.
2. Disconnect electrical connector from blend door actuator. Remove wire ties as needed.
3. Remove two screws and blend door actuator from rear HVAC assembly.
Expected Outcome
None
Follow-On Procedure
1. Install sleeper blend door actuator.
1307
Installation
Overview
Sleeper blend door actuator installation following repair or replacement.
Special Tools
None
None
1. Sleeper blend door actuator removed.
1308
1. Install blend door actuator to rear HVAC assembly with two screws.
2. Connect electrical connector to blend door actuator. Secure wires with wire ties as needed.
3. Install cover and retention strap to rear HVAC assembly with ten screws.
Expected Outcome
None
Follow-On Procedure
1. Lower bunk.
1309
Sleeper Control Panel
Overview
0016WDL Thermostat temperature control, for sleeper area of sleeper cab
Figure 673 Sleeper Control Location

1. Sleeper-mounted controls
The sleeper cab includes a control panel at the head of the bunk to conveniently control various accessories,
including Heating, Ventilation, and Air Conditioning (HVAC), radio, light, and power settings.
1310
Air Conditioner with APAds™ System

Overview
0016WJC APADS System (Index Sensors and Controls) Air Conditioner Protection
and Diagnostics System, use with temperature controlled fan
Location
See Figure (Figure 669) Item 3 for location.
Troubleshooting
See section 08 - Electrical.
1311
Air Conditioner with Bergstrom Enhanced Heater

Overview
0016VRT Heater, Enhanced Circulation (Bergstrom) Control, for extreme cold
weather climates
Bergstrom, enhanced circulation control heater feature code is designed for use in extreme cold weather
climates.
Troubleshooting
1312
Safety Precautions
General Precautions
WARNING
To prevent property damage, personal injury, or death, use only genuine International®
service parts. Use of inferior parts can adversely affect quality and reliability of vehicle.
WARNING
To prevent property damage, personal injury, or death, do not make modifications to any
part, component, or system of vehicle, as that can adversely affect quality and reliability
of vehicle.
WARNING
maintenance or making any check or repair. Some materials in vehicle may also be
WARNING
WARNING
To prevent personal injury or death, read all safety instructions in this Safety Precautions
(page 1313) section.
WARNING
To prevent personal injury or death, use proper ventilation when operating an engine in
a closed area.
Refrigerant Precautions
Refrigerant R-134a is nonflammable, nonexplosive, and noncorrosive hydro-fluorocarbon refrigerant. R-134a

is heavier than air and has a slight ether-type odor. Although R-134a is classified as a safe refrigerant, following
precautions must be observed to protect HVAC system components and personnel working on HVAC system.
1313
WARNING
Carbon monoxide is a colorless, odorless, and dangerous gas that is present in vehicle
exhaust. When it is necessary to operate engine during vehicle service in a confined
area, always use proper equipment to vent exhaust gasses outside of work area.
WARNING
Serious injury or blindness will result from refrigerant contacting eyes. Safety goggles or
other adequate eye protection must be worn when working with refrigerant. Temperature
of liquid refrigerant is -20 °F (-29 °C). If refrigerant should contact eyes, Do Not Rub them.
Splash eyes with cold water for at least 15 minutes to gradually get temperature above
freezing point. See a doctor immediately.
WARNING
Wear nonporous gloves (Nitril is recommended material). Should liquid refrigerant come
into contact with skin, remove any contaminated clothing, including shoes; then treat
injury as though skin had been frostbitten or frozen. See a doctor immediately.
WARNING
Never weld, solder, steam clean, or use excessive heat on any HVAC lines or equipment
while system is charged. Heat applied to any part will cause pressure within system to
become excessive, which may result in an explosion and possible personal injury.
Inhalation can cause death or serious injury, do not smoke or allow any type of fire or
flame in immediate area while servicing HVAC system. Refrigerant is not combustible;
however, in presence of heat it changes to a poisonous gas.
WARNING
Pressurized refrigerant containers must not be exposed to open flame or temperatures

above 125 °F (51 °C). Do not discard empty refrigerant containers where they are likely
to be subjected to heat of trash burners or etc.; they may explode, resulting in personal
injury or possible death. Containers must be stored, installed, and disposed of in
accordance with all state and local ordinances.
1314
WARNING
R-134a must not be mixed with air and then pressurized. When mixed with large
quantities of air and pressurized, R-134a becomes combustible.
WARNING
Refrigerant must be recovered from air conditioning system before any components of
system are removed or replaced. Removing components while pressure is in HVAC
system will cause personal injury or death.
WARNING
To prevent serious injury or death, Do Not install or remove HVAC testing or charging
equipment while engine is running.
WARNING
Federal and state laws require that refrigerant be recovered and recycled to help protect
environment. Always use approved refrigerant recycling equipment when working
with R-134a to prevent accidental discharge. If released into atmosphere, refrigerant
evaporates very quickly and may displace oxygen surrounding work area, especially in
small or enclosed areas. This situation creates hazard of suffocation, brain damage, or
death for anyone in work area. If a leak should occur, avoid breathing refrigerant and
lubricant vapor. Thoroughly ventilate area before continuing with service.
WARNING
To prevent personal injury or death, while International® Servicing System -

RHS980C-NAV is connected to both HVAC system and refrigerant supply cylinder, never
open high side hand valve of RHS980C-NAV while HVAC system is operating. If hot,
high pressure refrigerant is forced through gauge to refrigerant supply cylinder; it could
cause cylinder to rupture.
WARNING
To prevent personal injury or death, during system diagnostic tests, Do Not Turn
either hand valve on International® Servicing System - RHS980C-NAV for any reason.
Equipment can be damaged. When connected to HVAC system, gauges will indicate
system pressures with valves closed (fully Clockwise). These valves are used only
while servicing HVAC system.
WARNING
When installing and removing any service hose or fitting, a small amount of refrigerant
may escape. Always follow all safety precautions to avoid personal injury or death.
1315
WARNING
To prevent personal injury or death, always use correct replacement refrigerant hoses.
Do not use hoses other than those specified for HVAC system being serviced. Use of
improper hoses may cause a hose rupture and a release of refrigerant.
CAUTION
Use only new or recycled R-134a refrigerant; not any of so called ‘direct replacement’
refrigerants. Use of a recovery machine dedicated for R-134a is necessary to reduce
possibility of refrigerant incompatibility concerns.
CAUTION
When charging HVAC system, refrigerant tank must be kept upright. If tank is not upright,
liquid refrigerant may enter system and cause compressor damage.
CAUTION
To prevent damage to test equipment, make sure test equipment is clear of all moving
parts in engine compartment.
CAUTION
To prevent damage HVAC components, vehicle’s standard refrigerant system uses only
specified PAG lubricant in the refrigerant system (International® ZGGR725028). PAG
oils absorb atmospheric moisture very quickly. Never leave PAG oil exposed to air for
a prolonged time. Wear nonporous gloves while handling PAG oil and tightly reseal oil
container immediately after each use.
Use only Mineral Based refrigerant oil (International® ZGGR6912) to lubricate O-rings and
fittings. Never use grease, penetrating oil, motor oil, Ester, PAG oil, or etc. to lubricate
O-rings.
IMPORTANT – Before connecting any service equipment to refrigerant system, refrigerant in system must be
identified. Failure to identify system refrigerant before connecting equipment could result in contamination of
service equipment and any refrigerant stored in equipment.
IMPORTANT – When servicing HVAC system, insure that inner gaskets are present in both service port caps;
and verify that caps are installed when service is completed. Service port caps, with functioning gaskets, are
an important part of maintaining a leak free HVAC system.
IMPORTANT – Although service equipment may appear physically different from equipment described here,
function of equipment used to perform each service procedure is basically identical. When performing these
service procedures using service equipment different from that shown, refer to manufacturer’s instructions
supplied with that equipment.
1316
Service Procedures for R-134a

Service Procedures
Standard service procedures for vehicle’s HVAC system are described in this section. Refer to Specifications
(page 1391) for correct refrigerant charge values for HVAC system.
In addition to Safety Precautions (page 1313) section, special attention to following rules during servicing, and
component removal and installation, will aid in avoiding unnecessary and time-consuming problems.
1. Perform service inside a warm, well ventilated, dry shop.
2. When working on HVAC system, keep work area and tools as clean as possible. Also, clean all
connections, ports, or fittings before disconnecting or removing components.
3. Never use hot steam to clean inside of system. Dry nitrogen cleaning is recommended for this purpose.
4. All HVAC component and refrigerant line openings should be immediately plugged during removal and
remain so until re-installation to prevent entry of dirt, moisture, and other foreign material. Even slightest
particle can cause problems if carried to a vulnerable place within system.
5. Never remove protective caps from components until moment of assembly into system.
6. Never install non-sealed components.
7. Anytime HVAC fitting is disconnected, O-ring must be replaced. New O-ring must be lubricated with
Mineral-based oil (International® PN: ZGGR6912). Never use grease, penetrating oil, motor oil, Ester,
PAG oil, or etc. to lubricate O-rings.
8. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original positions.
• Never bend a hose to a radius less than 10 times diameter of hose.

• Never route a hose any closer than four (4) in. from exhaust manifold or related piping.
• Periodically inspect hoses for leaks or brittleness. Replace hoses immediately if indication of damage
is found.
10. Tighten all fittings properly.
11. Use backup wrench when loosening or tightening fittings, when possible.
12. Refrigerant oil quickly absorbs moisture. Store oil only in moisture-free containers and keep oil containers
closed until ready to use. Close refrigerant oil container immediately after use.
13. Any system that has been discharged, or opened to replace a component, must be evacuated (and system
oil quantity must be returned to normal) before charging.
14. Use extreme care to prevent moisture from entering system. Moisture can freeze at thermostatic
expansion valve and block refrigerant flow during system operation. Always properly evacuate system
after service to remove any moisture and air from HVAC system.
15. Spare components should be sealed and stored in a warm, dry facility.
1317
Additional attention to following during component remove and install will aid in avoiding unnecessary and
time-consuming problems.
16. Note and label electrical connections during removal.
17. Note cable routing during removal. Where necessary, cables should make sweeping curves.
18. It is important that all refrigerant hose O-rings and tubing fittings be lubricated with Mineral-based oil
(International® PN: ZGGR6912). Never use grease, penetrating oil, motor oil, Ester, PAG oil, or etc. to
lubricate O-rings.
19. Tighten fittings as specified in the torque chart. Use only a torque wrench known to be accurate. Always
use a back-up wrench when loosening or tightening fittings.
20. Replace receiver / drier unit on HVAC system which is opened for more than a very short period, when
HVAC system is flushed, or when compressor is replaced because of an internal failure that contaminates
HVAC system.
21. Be certain that evaporator core temperature sensing capillary tube is properly inserted into evaporator
core. When re-installing capillary tube, Always insert it into a new location in evaporator. This will insure
that capillary tube makes contact with evaporator for correct temperature control sensing.
22. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original
positions. Never bend to a radius less than 10 times diameter of hose. Never route any closer than four
(4) inches from exhaust manifold or related piping. Periodically inspect for leaks or brittleness. Replace
lines immediately if indication of damage is found.
23. HVAC system must be flushed or purged any time compressor is replaced due to internal failure. Refer to
Purge or Flush HVAC System (page 1345).
24. Compressor oil level must be checked and replaced as specified in Oil Fill Guidelines (page 1331).
25. Use extreme care to prevent moisture from entering HVAC system. Moisture can freeze at expansion
valve metering orifice and block refrigerant flow during system operation.
26. All HVAC component and refrigerant line openings should be immediately covered or plugged during
removal and remain so until re-installation to prevent entry of dirt, moisture and other foreign material.
Even slightest particle can cause problems if carried to a vulnerable place within HVAC system.
27. Never remove protective caps from components until moment of assembly into HVAC system.
29. Spare components should be stored in a warm, dry facility.
30. Perform service inside a warm, well ventilated dry shop.
31. Never use hot steam to clean inside of HVAC system. Dry nitrogen cleaning is recommended for this
purpose. Refer to Flush and Purge HVAC System (page 1345).
1318
Refrigerant Identification
WARNING
Before doing any of following work, read Safety Precautions (page 1313). Failure to read
Safety Precautions and to be aware of dangers involved when working with refrigerant,
could lead to serious personal injury or death.
function of this equipment used to perform each service procedure is basically similar. If performing these
service procedures using service equipment different from that described, refer to manufacturer’s instructions
1. Calibrate Refrigerant Identifier per manufacturer’s instructions.
2. Connect sampling hose to low pressure service port.
3. Connect other end of sampling hose to Refrigerant Identifier.
4. Open service valve.
5. Start sampling procedure (refer to manufacturer’s instructions).
6. When sampling is complete Refrigerant Identifier will indicate a pass or fail condition, type of refrigerant,
and percentage of concentration. International recognizes only R-134a in a 98% concentration. Anything
else is considered contaminated.
7. Close service valve and disconnect sampling hose.
1319
Recovery / Recycling / Charging Station
Removal
WARNING
1313).
WARNING

procedures.
Procedure
1. Be sure valves on service ports on red and blue hoses are closed (fully CCW).
2. Verify that both valves on recovery station are set to CLOSED.
3. Remove blue and red hoses from vehicle service ports.
4. Install protection caps for both service ports on vehicle.
1320
Installation
None
Procedure
CAUTION
To prevent damage to test equipment, make sure test equipment is clear of all moving
parts in engine compartment.
IMPORTANT – Fittings on service hoses for R-134a HVAC systems are standard Metric SAE quick connect
fittings that will work only on R-134a HVAC system service ports.
IMPORTANT – Although available service equipment may appear physically different from equipment
described, function of equipment used to perform each service procedure is basically identical. If performing
these service procedures using service equipment different from that described, refer to manufacturer’s
instructions supplied with that equipment.
Locations of HVAC system high pressure and low pressure service ports vary by vehicle model and year. High
pressure service port is located on compressor’s high pressure discharge line between compressor and
expansion valve. Typical locations are on receiver / drier or on compressor. Low pressure port is located on
compressor suction line, between expansion valve and compressor.
Discharge and suction ports are usually marked on compressor head. If marking is not visible, identify suction
(low pressure) side by larger diameter hose connected to compressor.
1. Remove protection caps from both service ports on vehicle. Maintain protection caps for reuse. Protection
caps should be replaced when service ports are not in use.
2. On recovery station and hose fittings, verify that all valves are closed. Valves at recovery station must be
set to CLOSED. Valves at quick connect fittings must be set fully counter-clockwise (CCW).
3. Connect recovery station to HVAC system as follows:
4. Connect blue hose to low pressure service port.
5. Connect red hose to high pressure service port.
WARNING
To prevent equipment damage, personal injury, or death. During system diagnostic

tests, Do Not Open either hand valve on recovery station for any reason. During
service procedures, Do Not Open valves on recovery station, until instructed to do so
in procedures.
6. Once quick connect fittings are attached to service ports.
7. Turn knob clockwise (CW) pushes an internal pin down to open service port valve.
8. Turn knob counter-clockwise (CCW) raises pin, to close service port valve.
1321
9. Once closed, remove quick-disconnect fitting.
1322
Discharging HVAC System (Refrigerant Recovery)
WARNING
function of this equipment used to perform each service procedure is basically similar. If performing these
IMPORTANT – If HVAC system is being discharged because a leak is suspected, leak must be located before
discharging HVAC system. Refer to Leak Detection (page 1336).
Locations of HVAC system high pressure and low pressure service ports vary by vehicle model and year. High
pressure service port is located on compressor’s high pressure discharge line between compressor and
1. Empty ’recovered oil’ catch bottle on recovery station. This is necessary to determine amount of oil
recovered during refrigerant recovery procedure.
2. Remove protection caps from both service ports.
3. Verify that all valves are closed on recovery station and hose fittings.
4. Valves at recovery station must be set to CLOSED.
5. Valves at quick-disconnect fittings must be set fully counter-clockwise (CCW).
7. Connect blue hose to low pressure service port.
8. Connect red hose to high pressure service port.
9. Open (turn CW) valves on quick-disconnect fittings connected to service ports on vehicle.
10. Set both hand valves on recovery station to RECOVERY or VACUUM.
11. Turn recovery station main power switch ON and press RECOVER.
• Recovery station will automatically shut off when refrigerant in HVAC system has been exhausted
to storage tank.
12. During recovery process in next step, refrigerant may become trapped in receiver / drier. Heating receiver
/ drier with a heat gun will force refrigerant out of receiver / drier and ensure that all of refrigerant is
recovered from system.
1323
WARNING
Heating receiver / drier with an open flame could result in equipment damage, bodily
injury, or death. Never use an open flame torch to heat receiver / drier.
13. Close quick connect valves, and set both valves on recovery station to CLOSED.
14. When recovering refrigerant by use of a recovery station, system oil is separated from refrigerant during
recovery cycle.
15. When refrigerant recovery operation is complete, recovery station will drain oil into station’s calibrated
catch bottle.
16. Amount of oil recovered may be used to determine amount of New oil that must be added back to HVAC
system. Refer to Oil Fill Guidelines (page 1331).
17. Remove blue and red hoses from service ports on HVAC system.
18. Install protection caps for both service ports on vehicle.
19. Work may now begin on HVAC system.
1324
Evacuating HVAC System
WARNING
CAUTION
To prevent damage HVAC components, amount of oil lost during recovery process,
component replacement, or purging / flushing must be replaced with New oil. Method
for determining how much refrigerant oil must be added to HVAC system is located in
Oil Fill Guidelines (page 1331).
CAUTION
To prevent damage or contamination to International® Servicing System - RHS980C-NAV

and R-134a refrigerant, take extreme precaution to ensure that other refrigerants are not
recovered into RHS980C-NAV. A refrigerant identifier is recommended for evaluating
refrigerant in HVAC system prior to servicing. Recovering other refrigerants will
contaminate refrigerant in RHS980C-NAV charge cylinder.
CAUTION
To prevent damage HVAC components, use only refrigerant oil specified for HVAC
system being serviced (refer to Specifications (page 1391)).
CAUTION
To prevent damage to HVAC system, PAG oils absorb atmospheric moisture very quickly.
Never leave PAG oil exposed to air for a prolonged time. Tightly reseal oil container
immediately after each use.
CAUTION
To prevent damage HVAC components, do not re-use recovered oil. Be sure to dispose
of recovered oil properly to avoid an environmental hazard.
High pressure service port is located on compressor’s high pressure discharge line between compressor and
Whenever HVAC system has been discharged, HVAC system must be completely evacuated of air and
moisture before being recharged. After evacuation HVAC system vacuum should measure between 750
and 1000 microns.
1325
During following procedure, oil should not be added until HVAC system has been leak tested, and all leaks
have been repaired.
1. Determine amount of NEW refrigerant oil to be added to HVAC system. Refer to Oil Fill Guidelines (page
1331). If oil is being added directly to compressor, it must be added before starting evacuation procedure.
If oil is to be added during evacuation / charging procedure, follow instructions furnished with recovery
station, or refrigerant oil injector tool, to add oil before charging procedure.
2. Verify all valves are closed, on recovery station and hose fittings. Valves at recovery station must be set to
CLOSED. Valves (knobs) at quick-connect fittings must be set fully counter-clockwise (CCW).
3. Use a valve and T-fittings, connect electronic vacuum gauge to recovery station, at vacuum manifold.
Close valve that isolates electronic vacuum gauge from low pressure line.
CAUTION
To prevent damage to HVAC system or electronic vacuum gauge, valve for electronic
vacuum gauge must be closed until instructed to open it. If valve is open during system
charging, excess pressure may damage electronic vacuum gauge.
5. Connect blue low pressure hose to low pressure service port.
6. Connect red high pressure hose to high pressure service port.
7. Open valves on red and blue hoses, turn knobs fully clockwise.
8. Set both hand valves on recovery station to RECOVERY or VACUUM.
9. Turn on main power switch and press VACUUM on recovery station.
10. After low pressure gauge on station shows vacuum is being established in HVAC system, continue to
operate vacuum pump for 10 minutes.
11. After 10 minutes, set both valves on recovery station to CLOSED, and observe low side gauge for one
(1) minute.
12. Gauge should not indicate a rise of more than 2 inches-Hg.
13. If gauge rises more than 2 inches-Hg in one (1) minute, system has a leak which must be repaired.
Refer to Leak Detection (page 1336).
1326
14. If there are no leaks or all leaks have been repaired:
15. Set both hand valves on recovery station to RECOVERY or VACUUM and press VACUUM.
16. Open valve connecting electronic vacuum gauge to recovery station low side line.
17. Continue to operate recovery station vacuum pump until HVAC system has pulled a vacuum of 750 to
1000 microns as measured by electronic vacuum gauge.
• Operate vacuum pump for a minimum of 10 minutes even if vacuum reaches its target value sooner.
18. Close both hand valves on recovery station, and valve connecting electronic vacuum gauge to recovery
station low side line.
19. HVAC system is ready to be charged. Remember, if full amount of refrigerant oil has not yet been added to
HVAC system, it must be added before charging HVAC system with refrigerant, as explained in Charge
HVAC System (Full Charge) .
IMPORTANT – Do Not disconnect recovery / recycling / charging station from HVAC system before charging
HVAC system.
1327
Charge HVAC System (Full Charge)
WARNING
WARNING
Do not remove compressor oil fill plug to check oil level in compressor while HVAC
system is charged with refrigerant. Crankcase side of compressor is under pressure and
personal injury or death may result. It is not possible to check oil level in compressor
on HVAC system that is under system pressure.
CAUTION
Use only new or recycled R-134a refrigerant; not any of so called 'direct replacement'
refrigerants. Use of equipment dedicated for R-134a is necessary to reduce possibility
of oil and refrigerant incompatibility concerns.
CAUTION
When charging HVAC system, refrigerant tank must be kept upright. If tank is not upright,
liquid refrigerant may enter system and cause compressor damage.
function of equipment used to perform each service procedure is basically similar. If performing these
IMPORTANT – If recycled refrigerant is to be used, follow instructions supplied with recycling equipment to
purge air from refrigerant before charging system.
Perform charging procedure, using new or recycled refrigerant, only after following actions have been
completed:
• System components repaired or replaced.

• System flushed or purged (if required).
• Refrigerant oil added (only if oil was added directly to the compressor, see Oil Fill Guidelines (page 1331)).
• System completely evacuated.
1328
CAUTION
Electronic vacuum gauge used during Evacuation procedure must be isolated from
refrigerant system (valve closed) before HVAC system is charged. If gauge is connected
to HVAC system during charging, excess pressure may damage it.
CAUTION
If equipment being used adds system refrigerant oil during evacuation / charging
procedure, first determine amount of oil to be added (refer to Oil Fill Guidelines (page
1331)). Then follow instructions furnished with recovery station, or refrigerant oil
injector tool, to add correct amount of New oil to HVAC system during this procedure.
1. Recovery station blue (suction) and red (discharge) hoses should still be connected as they were during
evacuation operation.
2. Add oil to return system oil capacity to its correct level (See Oil Fill Guidelines (page 1331)). To add oil
during evacuation / charging process, follow instructions furnished with recovery station, or refrigerant
oil injector tool.
CAUTION
Due to density of R-134a, amount of refrigerant required to charge a typical HVAC system
has been reduced. Overcharging system will result in excessively high head pressures
during operation and may damage compressor. Be sure to check specifications on
vehicle being serviced. This information is often located on a label on refrigerant
compressor.
3. Determine amount of refrigerant needed to charge HVAC system. This information can be found in
Specifications (page 1391).
4. Following instructions provided with recovery station; set recovery station to charge system with specified
amount of refrigerant.
5. On recovery station, set low side valve to CLOSED, and high side valve to CHARGE.
6. Press CHARGE to start charge procedure. When system is fully charged, recovery station will turn off.
7. Complete charging procedure by setting both hand valves on recovery station to CLOSED.
8. Before disconnecting recovery station from HVAC system, perform HVAC System Operational Checkout
Procedure in Section 08 - Electrical.
9. Disconnect blue and red hose quick-disconnect fittings from vehicle service ports.
10. Install protective caps on both of vehicle service port fittings.
Adding Refrigerant to HVAC System
Do Not add refrigerant to HVAC system in hopes of improving cooling. It’s very possible that HVAC system
will be overcharged and cause component failure.
1329
If it is found, during HVAC system tests, that HVAC system needs refrigerant; it will be necessary to perform
following procedures:
1. Discharge HVAC system, refer to Discharging HVAC System (page 1323).
2. Evacuate HVAC system, refer to Evacuating HVAC System (page 1325).
3. Charge HVAC system, refer to Charging HVAC System (Full Charge) (page 1328).
1330
Oil Fill Guidelines
Overview
WARNING
To prevent personal injury or death, before doing any work, read Safety Precautions
(page 1313). Failure to read Safety Precautions, and to be aware of dangers involved
when working with refrigerant could lead to serious personal injury or death.
CAUTION

and R-134a refrigerant, do not re-use recovered oil. Be sure to dispose of recovered oil
properly, to avoid an environmental hazard.
CAUTION
Replacement compressors contain a quantity of oil when shipped. To prevent damage

to HVAC components, this oil must be drained from new compressor to verify or adjust
quantity before refilling compressor (and system) with correct amount of oil. Oil drained
from a new compressor may be used to refill compressor prior to installation.
CAUTION
During normal HVAC operation, oil is circulated through system with refrigerant, and
a small amount is retained in each component. If certain components of system are
removed, some of refrigerant oil will go with component. To prevent damage to HVAC
components and maintain original total oil charge, it is necessary to compensate for oil
lost by adding oil to system with new part.
IMPORTANT – Correct volume of refrigerant oil in HVAC system is critical for proper HVAC system operation.
Insufficient oil will result in compressor failure. Too much oil decreases cooling efficiency, resulting in poor
system cooling performance. In general, when servicing HVAC system, ensure that amount of oil (retained
or added) in repaired system (compressor and components) equals total system capacity indicated in
Specifications (page 1391). Replacement oil may be added directly into compressor before evacuation, or
injected into system at any time after recharge. Following paragraphs describe how to determine quantity
of refill oil needed under most common conditions.
Unless stated otherwise, following procedures assume that HVAC system is not being flushed and purged.
• If refrigerant was only recovered for purpose of measuring refrigerant charge, add amount of oil removed
from HVAC system during refrigerant recovery procedure.
Total replacement oil quantity equals oil from refrigerant recovery procedure.
1331
• If compressor is replaced (and HVAC system was not contaminated and had no leaks) fill new compressor
with amount of oil removed from HVAC system during refrigerant recovery procedure, plus quantity of oil
that was contained in old compressor. (Oil in new compressors must be drained before adding new oil to
HVAC system. Refer to Checking Compressor Oil Level (page 1335), for procedures to check oil level in
refrigerant compressor.) Refill HVAC system (new compressor) as follows:
Total replacement oil quantity equals oil from refrigerant recovery procedure plus oil drained from old
compressor.
• If a component other than compressor is replaced, and there is no oil leak; add amount of oil removed from
HVAC system during refrigerant recovery procedure, plus amount indicated for replaced component in
Oil Capacity by Component (page 1332) table.
Total replacement oil quantity equals oil from refrigerant recovery procedure plus oil indicated in
component table.
• If amount of oil in HVAC system is unknown (due to an oil leak, ruptured hose, or etc.); refer to Excessive
Oil Loss Due To Refrigerant Leak (page 1333).
• Whenever HVAC system has become contaminated: make necessary repairs; flush and purge HVAC
system; and replace expansion valve, receiver / drier, and compressor. Oil in new compressors must be
drained before adding new oil to HVAC system. Refer to Checking Compressor Oil Level (page 1335), for
procedures to check oil level in compressor. Refill HVAC system (compressor) as follows:
Total replacement oil quantity equals total system capacity as specified in Specifications (page 1391)
minus 0.5 fl-oz (15 cc) (oil film left in new compressor).
Oil Capacity by Component

Component Typical Oil Amount
Evaporator 2 fl-oz (60 cc)
Condenser 1 fl-oz (30 cc)
Receiver / drier 0.5 fl-oz (15 cc)
Hoses (normal length) 0.3 fl-oz (10 cc)
Pressure Switches 0 fl-oz (0 cc)
Expansion Valve 0 fl-oz (0 cc)
1332
Oil Separation During Refrigerant Recovery

Oil removed from HVAC system during refrigerant recovery process must be replaced.
Always empty recovery station oil catch bottle before recovering refrigerant.
After recovering refrigerant, check calibrated bottle to determine how much oil has been removed from HVAC
system. This quantity may be used to help determine amount of New oil that must be added to HVAC system
before or during recharging of HVAC system.
Do not use recovered refrigerant oil.
Excessive Oil Loss Due to Refrigerant Leak

When there is a refrigerant leak, an unknown amount of oil escapes from HVAC system with refrigerant. When
a major leak is detected perform following procedures to re-establish correct HVAC system oil level.
CAUTION
When installing components, use new O-rings and C-plates lubricated with
Mineral-based oil (International® PN: ZGGR6912). Never use grease, penetrating oil,
motor oil, Ester, PAG oil, or etc. to lubricate O-rings.
1. Use service equipment and observation to determine location of leak. Refer to Leak Detection (page 1336).
2. Discharge HVAC System (page 1323).
3. Make any necessary repairs.
4. If HVAC system does not appear to be contaminated, purge HVAC system. If HVAC system appears
contaminated, such as after an internal compressor failure, it must be flushed before purging. Refer to
Purging or Flushing the HVAC System (page 1345).
5. If HVAC system was not contaminated:
6. Re-establish correct system oil level as follows: (Oil in compressors must be drained before adding new
oil to HVAC system. Refer to Check Compressor Oil Level (page 1335), for procedures to check oil
level in refrigerant compressor.)
minus 0.5 fl-oz (15 cc) (oil film left in compressor after draining).
7. Install compressor. (Compressor was removed to drain oil.)
8. If HVAC system was contaminated:
9. Replace expansion valve.
10. Replace compressor and re-establish correct system oil level as follows: (Oil in compressors must be
drained before adding new oil to HVAC system. Refer to Check Compressor Oil Level (page 1335), for
procedures to check oil level in refrigerant compressor.)
1333
minus 0.5 fl-oz (15 cc) (oil film left in compressor after draining).
11. Replace receiver / drier.
12. Using new O-rings, and C-plates, lubricated with Mineral-based oil (International® PN: ZGGR6912).
Never use grease, penetrating oil, motor oil, Ester, PAG oil, or etc. to lubricate O-rings. Reconnect all
components of HVAC system. Torque all joints per Torque Chart (page 1457).
13. Evacuate HVAC system; refer to Evacuating HVAC System (page 1325).
14. Charge HVAC system; refer to Charging HVAC System (Full Charge) (page 1328).
1334
Check Compressor Oil Level
WARNING
To prevent personal injury or death, do not remove oil fill plug to check oil level
in refrigerant compressor after HVAC system has been charged with refrigerant.
Crankcase side of compressor is under pressure.
CAUTION
To prevent vehicle damage, after performing any service on HVAC system, insure that
HVAC system contains correct type and volume of refrigerant oil before operating HVAC
system.
IMPORTANT – To prevent contamination, keep compressor tightly sealed when not measuring oil level.
IMPORTANT – It is not possible to check oil level in compressor on HVAC system that is under system
pressure. If it is suspected that there is not enough oil in HVAC system, it will be necessary to remove all oil
currently in HVAC system and refill HVAC system with a full oil charge.
Compressor oil level can be accurately checked only by removing compressor from vehicle and draining oil
into a clean, calibrated container.
1. Verify that HVAC system is discharged.
2. Remove compressor.
3. Remove oil plug and drain as much oil as possible into a suitable clean, calibrated container.
4. Remove caps (if present) from suction and discharge ports.
5. Drain remaining compressor oil from suction and discharge ports, into calibrated container, while turning
shaft, clockwise (CW) only, by hand or with a socket wrench on armature retaining nut. Turn shaft one half
turn every minute for approximately three (3) minutes. Replace caps on suction and discharge ports.
6. Measure and record amount of oil drained from compressor.
7. Inspect oil for signs of contamination such as discoloration or foreign material.
8. If oil shows signs of contamination, replace compressor. Verify that new compressor contains correct
amount of oil (continue this procedure starting at Step 3).
9. If oil is not contaminated, add correct amount of oil to compressor as determined by Oil Fill Guidelines
(page 1331).
Oil drained from new compressor may be used to refill compressor. Do Not Use recovered oil or oil drained
from a used compressor.
10. Install oil fill plug taking care not to twist O-ring. Replace O-ring if damaged. Torque oil plug to 11 to 15
lbf-ft (15 to 20 N·m). Do not over-tighten plug to stop a leak. Stop leaks first by fixing any seat damage,
removing dirt and installing new O-ring, lubricate new O-ring with Mineral-based oil (International® PN:
ZGGR6912). Never use grease, penetrating oil, motor oil, Ester, PAG oil, or etc. to lubricate O-rings.
1335
Leak Detection
Sealant Detection
CAUTION

and R-134a refrigerant. Sealants and leak stop chemicals in HVAC systems may cause
serious damage to RHS980C-NAV if they are present in refrigerant intended for recovery.
Detection devices are readily available to check for presence of these chemicals and are
highly recommended to protect RHS980C-NAV.
Before any work is done on a HVAC system, refrigerant should be checked for sealants and leak stop
chemicals.
Sealants and leak stop chemicals in HVAC systems may cause serious damage to RHS980C-NAV if they are
present in refrigerant intended for recovery. Detection devices are readily available to check for presence
of these chemicals and are highly recommended to protect RHS980C-NAV. If a sealant is detected, do not
service vehicle.
Leak Detection
WARNING
To prevent personal injury or death, before doing any work, read Safety Precautions
(page 1313). Failure to read Safety Precautions, and to be aware of dangers involved
when working with refrigerant could lead to serious personal injury or death.
IMPORTANT – Although service equipment may appear physically different from equipment described,
function of equipment used to perform each service procedure is basically same. If performing these service
procedures using service equipment different from that described, refer to manufacturer’s instructions supplied
with that equipment.
Refrigerant leaks are often indicated by an oily residue at point of leak.
When servicing HVAC system, ensure that inner gaskets are present in both service port caps; and verify that
caps are installed when service is completed. Service port caps, with functioning gaskets, are an important
part of maintaining a leak free HVAC system.
There are several methods of refrigerant leak detection. Method used could depend on many factors including
equipment availability, layout of HVAC system being serviced, or even personal preference. Primary
recommended methods are electronic refrigerant leak detector and phosphor dye / ultraviolet lamp method.
In addition, brief descriptions are provided for two alternate methods (ultrasonic leak detection and soap
solution). By using described methods, either separately or in some combination, it should be possible to
locate and verify most refrigerant leaks.
1336
Electronic Refrigerant Leak Detectors

In terms of sensitivity and safety, electronic leak detector is excellent for finding both slow and major system
leaks. Ensure that detector being used is intended for use with R-134a refrigerant. Detector is also listed in
the Special Tools (page 1394) section.
Figure 674 Leak Detectors

1. D400A Leak Detector 2. D440A-NAV Leak Detector
Unit is a hand-held device having a flexible probe used to seek out refrigerant leaks. An audio leak indicator
signals a warning in presence of a leak. It is important to become familiar with leak detector instructions for
detector being used. Speed at which probe is moved over component being checked is very important in
locating larger than permissible leaks. Leak check procedure should be in accordance with SAE J1628.
Before starting to look for leaks, it is recommended to clean away all oil or grease, and blow away refrigerant
residue from fittings and HVAC components. All suspected areas should be cleaned using soap and water, not
a solvent. A detected leak should be a flow of refrigerant, not a residual condition of refrigerant that is trapped
under an oil film, etc. A detected leak rate in excess of 1.0 oz / year is unacceptable.
To take advantage of operating characteristics of HVAC system, test high pressure part of HVAC system with
system running. Low pressure part of HVAC system should be tested with HVAC system and engine OFF.
1337
Ultraviolet (UV) Lamp Leak Testing

An alternate method to electronic leak testing is ultraviolet light. Phosphor dye is added to HVAC system and
leaks are detected by use of an ultraviolet (UV) lamp. When illuminated by UV lamp, phosphor dye will
produce a bright yellow-green trace at leak. It has been discovered during use of ultraviolet light and phosphor
dye that other types of leaks may also appear as a yellow-green trace when UV light shines on them. If
phosphor dye is used for leak detection, it is recommended that an electronic leak detector also be used
to verify that a detected leak is a refrigerant leak.
Phosphor dye can be added to any system that is not already charged with it. Dye charging process should be
performed according to instructions provided by manufacturer of dye injector. Kit provides UV lamp used to
illuminate suspected leaks. Kit also contains connection hoses and a dye injector, as well as, eyeglasses used
to enhance effect of UV light on dye. After adding phosphor dye to HVAC system, compressor or receiver /
drier should be labeled indicating that HVAC system contains phosphor dye.
Ultrasonic Leak Detectors

An ultrasonic leak detector listens for distinctive ’sound’ of gas passing through an opening. To use this type of
detector effectively, refrigerant system is first discharged, and then pressurized to 300 psi using dry nitrogen
and a manifold gauge set. Refer to Refrigerant Leak Testing with Nitrogen (page 1339).
Detector is then used to scan the suspected joints or components. Depending on detector being used, a leak
may be indicated by a visual or audible signal. Suspected leaks should not be cleaned with a soap solution
prior to scanning with this tool, as any solution remaining at leak site may mask leak.
Unit is a hand-held device and may include attachments to vary directional sensitivity of unit. Because this
type of sensor does not sample gas used in HVAC system, it may be used with any refrigerant system. It
may also be used to detect leaks in vehicle air system. It is important to become familiar with leak detector
instructions for detector being used.
1338
Soap Solution with Nitrogen

Another alternative method of leak detection is soap solution method. To improve results of this method HVAC
system is first discharged, and then pressurized to 300 psi using dry nitrogen. Refer to Refrigerant Leak
Testing with Nitrogen. A solution of soap and water is then sprayed on suspected joints or components. A leak
is indicated by bubbles forming at point where pressurized nitrogen is escaping.
Refrigerant Leak Testing with Nitrogen

When checking for refrigerant leaks using an ultrasonic detector or a soap solution, refrigerant in HVAC
system must first be recovered, refer to Discharging HVAC System (page 1323); then, HVAC system must be
pressurized with dry nitrogen, as follows.
1. Connect International® Servicing System - RHS980C-NAV to HVAC system.
2. Initially keep both valves on RHS980C-NAV closed.
3. High pressure hose (red) to high pressure port on vehicle. Open quick connect valve.
4. Low pressure hose (blue) is not connected. Keep gauge valve and quick connect valve closed. Opening
low pressure valve while HVAC system is pressurized may damage RHS980C-NAV.
5. Connect pressurized nitrogen cylinder to RHS980C-NAV and pressurize HVAC system to 300 psi.
6. Connect RHS980C-NAV yellow hose to nitrogen source.
7. Set output pressure at nitrogen cylinder regulator to 300 psi.
8. Slowly open high side RHS980C-NAV valve to pressurize HVAC system (high side gauge should read
300 psi).
9. Test for leaks using ultrasonic detector or soap solution.
10. After locating leak, set nitrogen cylinder regulator to 0 psi.
WARNING
To prevent personal injury or death in following step, pressure must be released in a

manner that does not trap pressure in HVAC system.
11. Before disconnecting RHS980C-NAV, slowly release pressure from HVAC system by partially
disconnecting a fitting until pressure is released.
12. Remove RHS980C-NAV from HVAC system and repair leak.
13. Evacuate and recharge HVAC system. Refer to Charging HVAC System (Full Charge) (page 1328).
14. If leak is first detected by RHS980C-NAV during evacuation mode leak test; follow on-screen instructions
to locate leak by using High Pressure mode and D400A or D440A-NAV Leak Detector.
1339
Flush and Purge HVAC System

HVAC System Internal Damage Inspection
CAUTION
To prevent damage to vehicle or HVAC system, HVAC service should be completed with
service station that meets J2788 standards and has had all current required maintenance
procedures completed.
Drier Cutting Tool

Description Tool Number
Drier Cutting Tool TC3Q
1. Remove receiver / drier, cut it open, and inspect for metal in filter.
2. Make a mark 6-1/2 in. from bottom of receiver / drier.
3. Cut open receiver / drier at mark with drier cutting tool.
4. Carefully remove top of receiver / drier and flow tube, tube will have to be popped out of lock washer
in bottom of receiver / drier.
5. Inspect filter retainer and filter element top for evidence of metal particles.
6. Some compressors will not circulate very much metal through system; any evidence requires entire
system be flushed.
7. If metal is found, flush entire HVAC system except condenser, expansion valve, and receiver / drier.
Those items must be replaced.
1340
Flush HVAC System
Overview

1. HVAC Control 4. Fuse Block
2. Mode Door Stepper Motor 5. Fresh Air Door Stepper Motor
3. APADS module (Feature Code 16WJC 6. HVAC Vent (‘Summer’ or ‘Winter’)
only) 7. HVAC Assembly
1341

1. Heater Core 5. Resistor Block
2. Blend Door Stepper Motor 6. Thermal Switch
3. Blower Motor 7. HVAC Filter
4. Blower Motor Connector 8. Evaporator Core
1342

1. Heater Hoses 4. Condenser
2. HVAC Compressor 5. Receiver / drier
3. HVAC Compressor Clutch 6. HVAC High-pressure Service Port
1343

1. Low Pressure Switch 3. Expansion Valve
2. High Pressure Switch 4. Low Pressure Service Port
1344
WARNING
WARNING
To prevent damage to HVAC system, serious personal injury, or death, dry nitrogen gas
is recommended for flushing or purging. To prevent personal injury or death, do not use
nitrogen at pressures over 200 psi (1,378 kPa). Commercial cylinders of dry nitrogen
contain pressures in excess of 2,000 psi (13,780 kPa). This pressure must be reduced,
use a pressure regulator, to reduce outlet pressure to 200 psi (1,378 kPa).
WARNING
To prevent damage to HVAC system, serious personal injury, or death, HVAC system can
be flushed or purged only after refrigerant has been discharged (recovered).
CAUTION
To prevent damage to HVAC system, when flushing or purging components of HVAC

system use only dry nitrogen. Introduction of compressed air into HVAC system may
cause HVAC system contamination.
CAUTION
To prevent damage to HVAC system components, never flush more than one component
with one attached hose at a time.
CAUTION
To prevent damage to vehicle HVAC system, when flushing components, use only
flushing agents approved for R-134a charged HVAC systems (refer to Fleetrite HVAC
catalog for approved flush solvent). Residue left by unapproved flushing products will
destroy lubrication properties of oil used in R-134a HVAC systems.
IMPORTANT – Although available service equipment may appear physically different from equipment shown,
Flush gun is required to inject flushing agent into component being flushed. Refer to Flush Gun for complete
information on this service equipment.
Special adapters are required to connect service equipment to some HVAC system components. Refer to
Special Tools (page 1394) for complete information on these service adapters. Standard fittings and adapters
can be purchased or fabricated locally. Quick disconnect fittings can reduce time required to swap hoses,
adapters, and components.
1345
HVAC systems that have had an internal compressor failure, that have been overcharged with refrigeration oil,
or that have been left open for an extended period of time, will need to be flushed, purged or both. Normally,
HVAC system always has pressure in it. Some loss of refrigerant from one season to next is normal, and does
not mean that HVAC system is dirty. Flushing is generally necessary only after an internal compressor failure
has contaminated refrigerant system. Flushing and purging are performed on HVAC system after refrigerant
has been discharged (recovered) and before the system is reassembled and evacuated.
Flushing removes heavy contamination, such as gritty oil and large dirt buildup, which occur after an internal
compressor failure. When a part is flushed, a flushing solvent is forced through it; liquid solvent cleans
part, picks up contaminants and flushes them out.
Purging must always be performed: after flushing HVAC system; any time there is excessive refrigerant
oil found in HVAC system; or, when HVAC system has been left open for an extended period of time.
Purging removes flushing solvent, excessive refrigerant oil, damp air, and loose particles from HVAC system
components by passing a stream of inert, dry nitrogen gas through parts of HVAC system or individual
components. This assures that HVAC system components are dry and free of any contaminants. If left in
HVAC system, these contaminants would have a negative effect on life and operation of HVAC system.
1346
Tools Required
Figure 679 HVAC System Flush Tool, 19-000-01
HX Specific Flush Tools List (page 1360)

Location Description / Tool Identification Tool Number
Condenser Inlet 19-353-07
A/C Drain Tool Fitting ½ in. male
Condenser Outlet 19-353-09
A/C Fill Tool Fitting ½ in. male
Condenser Line at Compressor 19-353-06
A/C Fill Tool Fitting ½ in. female
Condenser Line Loop 19-043-01
Condenser Loop Tool
Condenser Line at Receiver / Drier 19-353-10
A/C Fill Tool Fitting 7/16 in. male
Evaporator Flush / Purge 19-094-02
Evaporator Adaptor Tool
Suction Line at Compressor 19-353-03
A/C Fill Tool Fitting ¾ in. female
Expansion Valve Isolation Fitting 19-632-02
Line Loop Tool
Evaporator Line at Receiver / Drier 19-353-11
A/C Drain Tool Fitting ⅜ in. female
1347
Figure 680 International® Servicing System - RHS980C-NAV
1348
Figure 681 Flush Tank Assembly (Part of HVAC System Flush Tool, 19-000-01)
Refrigerant Identification Procedure has been performed to prevent tool contamination.
HVAC System Internal Damage Inspection (page 1340) has been performed to determine presence of metal
contaminants in HVAC system.
Following procedures must be observed whenever a component or system is flushed and purged.
• Never flush and purge entire HVAC system. Flush and purge HVAC system in segments (never larger than
one component and one hose) to lessen chance of blowing contaminants throughout HVAC system.
• Never flush or purge compressor, receiver / drier, or expansion valve.
• Flush or purge each HVAC system section or component in opposite direction of normal refrigerant flow.
• After flushing and purging HVAC system, change oil in compressor, refer to Oil Fill Guidelines (page 1331),
and replace receiver / drier prior to evacuating and charging HVAC system.
1349
Flush Procedure
CAUTION
To prevent damage to HVAC system, assemblies to be flushed must be no larger than

one component and one attached hose.
1. Verify HVAC system is discharged.
2. Inspect all flush fittings for damage and replace any deteriorated seals.
3. Disconnect both ends of component or components to be flushed, and tightly cap rest of HVAC system.
4. Use Application Table (page 1394) and Flush Fitting Adapter Location diagrams, install flush fittings to
proper locations.
5. Use suitable container filled with solvent, submerge any small lines removed during adaptor installation
process.
Figure 682 Regulator and Pulse Valve Remove

1. Regulator and Pulse Valve Assembly 2. Flush Tank
6. Remove regulator and pulse valve assembly (1) from top of flush tank (2).
1350
Figure 683 Fill Flush Tank with Solvent

1. Flush Tank
7. Fill flush tank (1) with one (1) gallon of solvent for day cabs, or two (2) gallons of solvent for sleeper
cabs, as applicable.
8. Reinstall regulator and pulse valve assembly into flush tank.
9. With tank regulator turned off (shut), open main nitrogen tank valve, use input gauge on regulator, verify
that enough pressure is available to perform flushing procedure.
10. Connect input of flush gun to output of supply line from nitrogen tank. Some form of shutoff valve should
be installed at input of flush gun.
1351
Figure 684 Connect Discharge Hose to Flush Fitting

1. Discharge Hose 2. Flush Fitting
11. Use correct fittings or block fitting adapters, connect discharge hose (1) to flush fitting (2) on component to
be flushed. Components are flushed in opposite direction of normal refrigerant flow.
12. Use correct fittings or block fitting adapters, connect flush gun output to component to be flushed. A trigger
type air gun may also be used as flush gun output.
1352
Figure 685 Discharge Barrel

1. Discharge Hose 2. Discharge Barrel
13. Use cam-lock coupling, connect discharge hose (1) to discharge barrel (2).
WARNING
Follow procedural steps in correct order. Failure to do so could result in damage to tool
or vehicle, and may harm technician.
1353
Figure 686 Flush Tank Assembly Connection

1. Flush Gun Assembly 2. Flush Tank Assembly
14. Use quick coupling on long hose, connect flush gun assembly (1) to flush tank assembly (2).
Figure 687 Nitrogen Regulator Hose Connection

1. Flush Tank 3. Regulator and Pulse Valve Assembly
2. Nitrogen Regulator Hose
15. Connect nitrogen regulator hose (2) to regulator and pulse valve assembly (3) on flush tank (1).
1354
Figure 688 Nitrogen Regulator Assembly

1. Nitrogen Regulator Assembly
16. Use correct fittings or block fitting adapters, connect flush gun assembly to quick coupling located on
nitrogen regulator assembly (1).
• A trigger type air gun may also be used as flush gun output.
17. With nitrogen regulator assembly set to 120 psi (827 kPa), purge components by squeezing trigger
on flush gun assembly.
18. While holding flush gun assembly trigger, adjust regulator to 200 psi (1,379 kPa), then back down to
100 psi (689 kPa) working pressure.
1355
Figure 689 Discharge Hose Site Glass

1. Discharge Hose Sight Glass 2. Discharge Barrel
19. Monitor discharge hose sight glass (1). Purge until solvent is not evident and continue for an additional
five (5) seconds.
20. After appropriate amount of solvent is injected, disconnect flush gun assembly from flush tank assembly
quick coupling.
21. Reconnect flush gun assembly to flush tank assembly.
22. Move connections to each appropriate connection pair and repeat steps.
23. See vehicle specific section for appropriate connection pairs.
24. After flush, cap open ends of each component until component can be purged. Use Cap Plug, ZTSE4660
or equivalent.
1356
Refrigerant Line Flush
WARNING
Make sure discharge assembly is completely drained. Excessive amounts of Volatile

Organic Compounds (VOCs) could be released into local air if barrel is not drained. Read
MSDS thoroughly before performing any flushing work.
1. Drain entire discharge assembly of used flushing solvent to prevent a high amount of VOCs from being
released. Dispose of used solvent in accordance with local EPA regulations. Do not reinstall top of
discharge assembly.
2. Remove charcoal filter pack.
CAUTION
Set Nitrogen regulator pressure to 120 psi (827 kPa) to provide a 100 psi (689 kPa) working
pressure, or damage to equipment may occur.
Figure 690 Blow Gun
3. Use blow gun to blow any loose particles out of lines and dry solvent from lines.
4. After flushing is complete, that component must be purged before connecting it to HVAC system. Refer to
Purge Procedure (page 1359).
WARNING
Flush gun MUST be removed from equipment setup before performing purge procedures.
Flush gun is not designed to be used at pressures used for purge procedures.
1357
Purge HVAC System
Overview
WARNING
WARNING
To prevent damage to HVAC system, serious personal injury, or death, dry nitrogen gas
is recommended for flushing or purging. To prevent personal injury or death, do not use
nitrogen at pressures over 200 psi (1,378 kPa). Commercial cylinders of dry nitrogen
contain pressures in excess of 2,000 psi (13,780 kPa). This pressure must be reduced,
use a pressure regulator, to reduce outlet pressure to 200 psi (1,378 kPa).
WARNING
To prevent damage to HVAC system, serious personal injury, or death, HVAC system can
be flushed or purged only after refrigerant has been discharged (recovered).
CAUTION
To prevent damage to HVAC system, when flushing or purging components of HVAC

system use only dry nitrogen. Introduction of compressed air into HVAC system may
cause HVAC system contamination.
CAUTION
To prevent damage to HVAC system components, never flush more than one component
with one attached hose at a time.
CAUTION
To prevent damage to vehicle HVAC system, when flushing components, use only
flushing agents approved for R-134a charged HVAC systems (refer to Fleetrite HVAC
catalog for approved flush solvent). Residue left by unapproved flushing products will
destroy lubrication properties of oil used in R-134a HVAC systems.
IMPORTANT – Although available service equipment may appear physically different from equipment shown,
1358
Purge Procedure
1. Verify that HVAC system is discharged.
2. Disconnect both ends of component to be purged and ensure rest of HVAC system is tightly capped.
3. With tank regulator turned off (closed), open main nitrogen tank valve, and using input gauge on regulator,
verify that enough pressure is available to perform purging procedure.
4. Using correct fittings or block fitting adapters, connect drain line to component to be purged. Components
are purged in opposite direction of normal refrigerant flow.
5. Place outlet of drain line into a suitable waste container.
6. Use correct fittings or block fitting adapters, connect nitrogen supply line output to component to be
purged. A trigger type air gun may be hand-held for some components.
7. Set supply line regulator to 4 psi (28 kPa).
8. Slowly open supply line valve at output of tank regulator. If a trigger type air gun is being used, actuate
trigger.
9. Let dry nitrogen flow at 4 psi (28 kPa) for one to two minutes, or until there is no trace of refrigerant flushing
agent or refrigerant oil flowing from drain tube.
10. Use pressure regulator, raise pressure to 200 psi (1,378 kPa) and let dry nitrogen flow for 25 to 30 seconds.
11. Adjust pressure regulator to 0 psi. Close supply line valve.
12. Release all pressure from trigger type air gun hose. Point air gun into waste container, and actuating trigger.
13. Disconnect supply and drain lines from purged unit. Remove all fittings and adapters. Tightly cap openings
of purged unit until ready to install it into HVAC system.
IMPORTANT – When reconnecting components, always install new O-rings and C-plates on HVAC systems.
Always lubricate O-rings and threads on fittings with mineral-based lubricant (International® PN: ZGGR6912).
Never use grease, penetrating oil, motor oil, Ester, PAG oil, or etc. to lubricate O-rings..
14. Installed components into HVAC system using new O-rings and C-plates.
15. After purging HVAC system, and prior to evacuating and charging HVAC system:
16. Change oil in compressor. Refer to Oil Fill Guidelines (page 1331).
17. Replace receiver / drier.
18. Reinstall (or replace) all other components that were removed for service.
1359
HX HVAC Specific Flush Setup
HX HVAC Condenser Flush and Purge Setup

A/C Drain Tool Fitting ½ in. male 19-353-07
Condenser Inlet
A/C Fill Tool Fitting ½ in. male 19-353-09

Condenser Outlet
CAUTION
To prevent damage to vehicle and condenser, condenser must be remove from vehicle
and placed on external work surface.
CAUTION
To prevent damage to vehicle and condenser, condenser must be replaced in the event
of compressor failure.
1. Remove condenser from vehicle and place on work surface, flush tool cabinet is ideal to provide a work
space that will not damage condenser.
2. When install condenser inlet and outlet fittings on condenser with nuts, start nut and fitting at same time
wiggling them in place together until nut is tight.
1360
Figure 691 Condenser Inlet Fitting Installed
3. Install condenser inlet fitting, 19-353-07 on condenser inlet.
Figure 692 Condenser Outlet Fitting Installed
4. Install condenser outlet fitting, 19-353-09 on condenser outlet.
1361
HX HVAC Condenser Supply and Return Line Flush and Purge Setup
A/C Fill Tool Fitting ½ in. female 19-353-06
Condenser Line at Compressor
Condenser Loop Tool 19-043-01

Condenser Line Loop
A/C Fill Tool Fitting 7/16 in. male 19-353-10

Condenser Line at Receiver / drier
1362
Figure 693 Condenser Line Loop Installed
1. Install condenser line loop fitting, 19-043-01 between condenser inlet and condenser outlet.
Figure 694 Condenser Line at Compressor Fitting (Left Fitting) Installed
2. Install condenser line at compressor fitting, 19-353-06 on compressor outlet.
1363
Figure 695 Condenser Line at Receiver / Drier Fitting (Shown in Middle) Installed
3. Install condenser line at receiver / drier fitting, 19-353-10 on receiver / drier inlet.
1364
HX HVAC Evaporator Flush and Purge Setup

Evaporator Adaptor Tool 19-094-02
Figure 696 Evaporator Adapter Tool Installed
1. Install evaporator adapter tool, 19-094-02 on evaporator under cab passenger side.
1365
HVAC Compressor to Receiver / Drier Flush and Purge Setup

A/C Fill Tool Fitting ¾ in. female 19-353-03
Suction Line at Compressor
Line Loop Tool 19-632-02

Expansion Valve Isolation Fitting
A/C Drain Tool Fitting ⅜ in. female 19-353-11

Evaporator Line at Receiver / drier
1366
CAUTION
To prevent damage to vehicle and condenser, Receiver / Drier must be replaced any time
HVAC is opened for maintenance and should not be flushed or purged.
CAUTION
To prevent damage to vehicle and Expansion Valve, expansion valve must be replaced
in the event of compressor failure and should not be flushed or purged.
Figure 697 Expansion Valve Isolation Fitting Installed
1. Install expansion valve isolation fitting, 19-632-02 on expansion valve inlet and outlet under cab passenger
side.
1367
Figure 698 Suction Line at Compressor Fitting (Shown on Right) Installed
2. Install suction line at compressor fitting, 19-353-03 on compressor inlet on passenger side of engine.
Figure 699 Evaporator Line at Receiver / Drier Fitting (Shown in Middle) Installed
3. Install evaporator line at receiver / drier fitting, 19-353-11 on receiver / drier outlet passenger side of engine.
1368
General Heat Ventilation Air Conditioning (HVAC) System Maintenance

Pre-Removal Procedures
Depending on vehicle engine combination, replacement of certain components may require removal of nearby
assemblies to gain access to compressor mounting bolts and lines.
WARNING
To prevent property damage, personal injury, or death, park vehicle on a flat, level
surface. Make sure engine ignition switch is in OFF and transmission is in neutral
or park if vehicle is equipped with an automatic transmission. Set parking brake,
chock wheels, and disconnect batteries at negative terminal before doing any service
procedures on vehicle.
WARNING
1313).
Special attention to following, during component removal and installation, will aid in avoiding unnecessary
and time-consuming problems.
1. When working on HVAC system keep work area and tools as clean as possible. Also, clean all
connections, ports or fittings before disconnecting or removing components.
2. All HVAC component and refrigerant line openings should be immediately covered or plugged during
removal and remain so until re-installation to prevent entry of dirt, moisture and other foreign material.
Even slightest particle can cause problems if carried to a vulnerable place within HVAC system.
3. Never remove protective caps from components until moment of assembly into HVAC system.
5. If receiver / drier is one of multiple components being installed in HVAC system, it should be last component
installed. This reduces amount of time that receiver / drier desiccant is exposed to atmospheric moisture.
6. Anytime HVAC fitting is disconnected, O-ring and C-plate must be replaced. New O-ring must be lubricated
with Mineral-based oil. C-plate does not require lubrication. Never use grease, penetrating oil, motor oil,
Ester or PAG oil, etc. to lubricate O-rings and fittings.
Never bend a hose to a radius less than 10 times the diameter of the hose.
Never route a hose any closer than four (4) inches from exhaust manifold or related piping.
8. Whenever possible use a backup wrench when loosening or tightening fittings.
9. All fittings must be tightened as specified in Torque Chart. Use only a torque wrench known to be accurate.
1369
10. Before performing any work on this vehicle or vehicle components, be sure to perform these basic
procedures:
WARNING
terminal first, then positive cable. When reconnecting battery cables, connect positive
cables first, and then reconnect negative cables. Failure to follow this warning may result
in a direct battery short, which is a fire or explosion hazard.
18. Discharge HVAC system. Refer to Discharge HVAC System (Recycle Mode) .
1370
HVAC Compressor - Navistar® N13 Engine
Removal
WARNING
1313).
WARNING

Procedure
1. Perform pre-removal procedure (page 1369).
2. Remove or loosen serpentine belt from compressor pulley.
3. Use 16 mm socket on long breaker bar to release serpentine belt tensioner pulley.
4. Reach serpentine belt tensioner pulley from driver side of engine, or from underneath engine.
5. Serpentine belt tensioner is toward center of engine just inboard large secondary pulley on opposite side
of engine from HVAC compressor pulley.
6. Disconnect compressor clutch wiring connector and high side temperature switch wiring connector from
engine wire harness.
7. Cut zip tie and disconnect high side temperature switch wiring connector.
8. Cut zip tie and disconnect compressor clutch wiring connector.
9. Disconnect compressor clutch and HP sensor electrical connectors.
1371
10. Disconnect HP compressor line from compressor. Install cleanliness covers on pipe end and pump cavity.
11. Disconnect HP compressor line from receiver / drier. Install cleanliness covers on pipe end and receiver /
drier cavity.
12. Remove HP compressor line.
13. Remove coolant package strut lower bushing bolt and nut, loosen upper bushing bolt and nut. Swing
strut out of way of compressor access.
14. Disconnect LP compressor line from compressor. Install cleanliness covers on pipe end and pump cavity.
Move LP compressor line out of way of compressor removal.
CAUTION
When removing mounting bolts from compressors, use technical assistance to support
compressor during removal to prevent damage to mounting bolts and compressor.
15. Remove four (4) 10 mm hex flange head bolts mounting compressor on engine.
16. Remove two (2) bottom bolts, use 10 mm deep socket on 3/8 in. ratchet.
17. Remove zip tie holding heater hose adjacent to two (2) bottom compressor bolts on frame.
18. Remove two (2) bottom hex flange head bolts, move heater hose to remove both bolts from lower
compressor mount.
19. Remove two (2) upper bolts from compressor mount.
20. Remove compressor.
1372
Installation
Compressor mounting bolts 17 to 21 lb-ft (23 to 29 N·m)
Procedure
Verify that clutch is installed on compressor before performing steps in following installation procedure.
1. If system is to be flushed, perform that operation before reassembling system. Refer to Flush and Purge
HVAC System (page 1345).
2. Before installing compressor, refer to Oil Fill Guidelines (page 1331). Oil shipped in new compressors
must be drained when determining correct amount of refrigerant oil to be added to HVAC system.
3. Install compressor assembly including any brackets previously secured by four (4) compressor mounting
bolts, use 10 mm deep socket on 1/4 in. drive ratchet. Tighten to 17 to 21 lb-ft (23 to 29 N·m).
4. Install zip tie to hold heater hose adjacent to two (2) bottom compressor bolts.
CAUTION
When installing mounting bolts on compressors, use technical assistance to support

compressor during removal to prevent damage to mounting bolts and compressor.
5. Remove cleanliness covers from pipe end and pump cavity. Connect LP compressor line to compressor.
6. Swing coolant package strut into place. Install strut lower bushing bolt and nut, tighten upper bushing
bolt and nut.
7. Install HP compressor line.
8. Remove cleanliness covers from pipe end and receiver / drier cavity. Connect HP compressor line
to receiver / drier.
9. Remove cleanliness covers from pipe end and pump cavity. Connect HP compressor line to compressor.
10. Connect compressor clutch and HP sensor electrical connectors.
11. Connect high side temperature switch wiring connector and install zip tie. Connect compressor clutch
wiring connector and install zip tie.
12. Install or tighten compressor belt on compressor pulley.
13. Secondary belt tensioner is toward center of engine just inboard large serpentine pulley on opposite side
of engine from HVAC compressor pulley.
14. Reach serpentine belt tensioner pulley from driver side of engine, or from underneath engine.
15. Use 16 mm socket on long breaker bar to release serpentine belt tensioner pulley.
16. Discharge HVAC system. Refer to Discharge HVAC System (Recycle Mode) .
17. Restore vehicle to operational.
1373
HVAC Blend Door Stepper Motor
Removal
WARNING
1313).
WARNING

Procedure
1. Perform pre-removal procedure(page 1369).
2. Disconnect blend door stepper motor.
3. Remove three (3) mounting nuts from stepper motor.
4. Remove blend door stepper motor.
1374
Installation
Stepper motor mounting nuts 20 lb-in. (2.26 N·m)
Procedure
1. Install blend door stepper motor.
2. Install three (3) mounting nuts on stepper motor. Torque nuts to 20 lb-in. (2.26 N·m).
3. Connect blend door stepper motor.
4. Install interference around blend door stepper motor.
1375
HVAC Expansion Valve
Removal
WARNING
1313).
WARNING

Procedure
Depending on vehicle engine combination, replacement of certain components may require removal of nearby
assemblies to gain access to compressor mounting bolts and lines.
WARNING
To prevent property damage, personal injury, or death, park vehicle on a flat, level
surface. Make sure engine ignition switch is in OFF and transmission is in neutral
or park if vehicle is equipped with an automatic transmission. Set parking brake,
chock wheels, and disconnect batteries at negative terminal before doing any service
procedures on vehicle.
2. Remove modesty panel on passenger side of cab.
3. Discharge HVAC system (page 1323).
4. Disconnect refrigerant recovery equipment from vehicle HVAC system and store on unit.
1376
5. Remove P-clamp from high and low pressure HVAC lines closest to expansion valve.
6. Remove hex nut holding high and low pressure HVAC lines from expansion valve stud.
7. Remove high and low pressure HVAC lines from expansion valve and remove O-rings.
8. Install cleanliness caps on both HVAC lines and both openings in expansion valve.
9. High and low pressure HVAC lines held together by bracket that is closed around HP line and slotted
to accept LP line.
10. Remove three (3) screws holding expansion valve black cover box underneath passenger side of cab.
11. Disconnect sensor electrical connectors for high and low pressure HVAC switches on expansion valves.
12. Remove expansion valve.
13. Remove two (2) hex socket head bolts from expansion valve.
14. Remove expansion valve.
15. Discard two (2) O-rings.
16. Install two (2) cleanliness covers on open lines.
17. If no further work is to be done on HVAC system, repair or replace expansion valve.
1377
Installation
Socket head bolts 50 lb-in. (5.7 N∙m)
Expansion valve box cover Hand tight
Procedure
1. Install expansion valve.
2. Remove cleanliness covers from high and low pressure HVAC lines and expansion valve openings for
HVAC lines.
3. Clean area around HVAC lines and HVAC lines.
4. Install new O-rings on high and low pressure HVAC lines.
5. Install new expansion valve, install two (2) hex socket head bolts in expansion valve.
6. Torque two (2) hex socket head bolts to 50 lb-in. (5.7 N∙m).
7. Connect sensor electrical connectors for high and low pressure HVAC switches to expansion valves.
8. Install expansion valve black cover box underneath passenger side of cab.
9. Install three (3) screws holding box underneath passenger side of cab.
10. Torque three (3) screws to hand tight.
11. Remove cleanliness caps from both HVAC lines and both expansion valve openings. high and low
pressure HVAC lines from expansion valve, remove O-rings, and install cleanliness caps on both HVAC
lines and both openings in expansion valve.
High and low pressure HVAC lines are held together by bracket that is closed around HP line and slotted
to accept LP line.
1378
HVAC Fresh Air Door and Recirculation Stepper Motor
Removal
WARNING
1313).
WARNING

Procedure
2. Remove interference for fresh air door and recirculation stepper motor.
3. Disconnect fresh air door and recirculation stepper motor.
5. Remove fresh air door and recirculation stepper motor.
1379
Installation
Procedure
1. Install fresh air door/recirculation stepper motor.
3. Connect fresh air door and recirculation stepper motor.
4. Install interference around fresh air door and recirculation stepper motor.
1380
HVAC High Pressure Switch
Removal
WARNING
1313).
WARNING

Procedure
1. Remove HVAC expansion valve. See HVAC Expansion Valve - Remove (page 1376).
2. Remove high pressure switch from HVAC expansion valve.
1381
Installation
None
Procedure
1. Install new HVAC high pressure switch in HVAC expansion valve.
2. Install HVAC expansion valve. See HVAC Expansion Valve - Install (page 1378).
1382
HVAC Control Head
Removal
WARNING
1313).
WARNING

1383
Procedure
Figure 700 HVAC Control Head

2. Hot / cold blend door control 4. Mode switch
2. Remove instrument cluster panel .
3. Remove four (4) corner screws.
4. Pull HVAC control head out of center console far enough to disconnect connectors.
5. Disconnect both connectors.
6. Fully remove HVAC control head.
1384
Installation
None
Procedure
1. Install HVAC control head.
2. Connect both HVAC control head connectors.
3. Fully insert HVAC control head in center console.
4. Install four (4) corner screws.
5. Install instrument cluster panel (page 1225).
1385
HVAC Low Pressure Switch
Removal
WARNING
1313).
WARNING

Procedure
1. Remove HVAC expansion valve. See HVAC Expansion Valve - Remove (page 1376).
2. Remove low pressure switch from HVAC expansion valve.
1386
Installation
None
Procedure
1. Install new HVAC low pressure switch in HVAC expansion valve.
2. Install HVAC expansion valve. See HVAC Expansion Valve - Install (page 1378).
1387
HVAC Mode Door and Air Distribution Stepper Motor
Removal
WARNING
1313).
WARNING

Procedure
2. Dash - Remove
3. Remove four (4) mounting bolts from lower dash frame on right side.
4. Remove one (1) upper dash mounting bolt from defroster grate.
5. Remove four (4) lower dash mounting bolts from left side.
6. Remove two (2) bolts, one with P-clamp, from lower steering column.
7. Remove four (4) nuts from steering column mounting studs.
8. Reposition steering column and wheel to cab floor.
9. Reposition dash away from front of cab, requires technical assistance.
10. Disconnect mode door stepper motor.
1388
12. Remove mode door stepper motor.
1389
Installation
Steering Column Mounting Bracket Lock Nuts 34 to 38 lb-ft (46 to 52 N·m)
Steering Column Bracket Lock Nuts 21 to 27 lb-ft (28 to 37 N·m)
Procedure
1. Install mode door stepper motor.
3. Connect mode door stepper motor.
4. Dash - Install
5. Reposition dash to front of cab, requires technical assistance.
6. Reposition steering column and wheel to dash.
7. Install and torque (page 78) four (4) nuts on steering column mounting studs.
8. Install and torque (page 78) two (2) bolts, one with P-clamp, on lower steering column.
9. Install and torque four (4) lower dash mounting bolts on left side.
10. Install and torque one (1) upper dash mounting bolt on defroster grate.
11. Install and torque four (4) mounting bolts on lower dash frame on right side.
12. Restore vehicle to operational.
1390
Vehicle HVAC Specifications

Charge Quantities
HVAC System Based on Engine Charge Amount

HX w/out Integrated Receiver Drier 62 oz. (3.875 lbs.) (1.76 kg)
HX w/ Integrated Reciever Drier 44.8 oz. (2.8 lbs.) (1.27 kg)
Oil Capacity
Component Typical Oil Capacity

Compressor **Equal to amount of oil drained from original
compressor.
Evaporator 2 fl. oz. (60 cc)
Condenser 2 fl. oz. (60 cc)
Receiver / Drier 1 fl. oz. (30 cc)
Expansion Valve 0 fl. oz. (0 cc)
Suction Line 1 fl. oz. (30 cc)
Discharge Line 1 fl. oz. (30 cc)
Receiver to expansion valve line 1 fl. oz. (30 cc)
Pressure switches or other sensors 0 fl. oz. (0 cc)
Minor system leak 3 fl. oz. (90 cc)
Major system leak 0 fl. oz. (0 cc)
Two-evaporator system components (if applicable)
Liquid line to rear evaporator / expansion valve 1 fl. oz. (30 cc)
Suction line from rear evaporator 3 fl. oz. (90 cc)
Rear (auxiliary) evaporator 2 fl. oz. (60 cc)
Rear (auxiliary) expansion valve 0 fl. oz. (0 cc)
Complete system oil charge: 10.14 fl. oz. (300 cc)
Only PAG 100 oil (International® ZGGR725028) for oil matching or balancing.
1391
Service Tools
Recommended Service Tools
CAUTION
Servicing tools recommended for this system were designed specifically for use with
R-134a systems. Servicing tools designed and used for R-12 systems must not be
used when servicing R-134a systems unless they are specifically identified as being
compatible with both systems
Servicing HVAC systems efficiently and effectively requires proper tools and equipment. Recommended
tools, as well as alternate service tools are listed.
Tools listed in following tables can be ordered through International® tool suppliers. For special tools that are
obtained locally, refer to Tools Obtained Locally .
HVAC Special Service Tools

Description Number
International® Servicing System RHS980C-NAV
HVAC Oil and Dye Injection Equipment 12401-NAV
Refrigerant Leak Detector D400A
Refrigerant Leak Detector D440A-NAV
For more information on these tools, refer to Special Tools (page 1394).
Frequently Used HVAC System Consumable Items
Description ISN PN Reference RTI PN

Hose Red 15 ft. 0.5 ACME x M14-1.5 IRTI0288003505 028 80035 05
Hose Blue 15 ft. 0.5 ACME x M14-1.5 IRTI0288003605 028 80036 05
Coupling FSC High Red M14-1.5 215010 IRTI0238009500 023 80095 00
Coupling FSC Low Blue M14-1.5 215011 IRTI0238009600 023 80096 00
Kit Filter Maintenance for RHS980C-NAV IRTI3608217500 360 82175 00
Oil Vacuum Pump (Qt.) 217020 IRTI0118000400 011 80004 00
Cord Power 5-15 Plug 5-15 Recep. 120 in. IRTI0258011419 025 80114 19
Thermistor Probe 10 K 1/4 in. 2-pin 20 ft. IRTI0258040400 025 80404 00
Sealer Identifier Kit IRTI3608173300 360 81733 00
Equipment Storage Cover RHS980C-NAV IRTI0268048200 026 80482 00
Filter, In-line Micron for Machines, 10 Pk. IRTI3608161800 360 81618 00
O-ring Repair Set for R-134a Service IRTI3608067200 360 80672 00
Kit Replacement ID Sample Hose IRTI3608221900 360 82219 00
RHS980C-N
Sealant Detector Cartridge, 25 Pk. IRTI0268030900 026 80309 00
Oil, Vacuum Pump (12 Qt. Case) IRTI3608001200 360 80012 00
1392
Description ISN PN Reference RTI PN

Replacement Battery for Circuit Board IRTI3608229200 360 82292 00
CR1025
1393
Special Tools
Special Tools
HVAC System Flush Tool, 19-000-01
Figure 701 HVAC System Flush Tool - 19-000-01
HVAC system flush tool clears HVAC system of contaminants caused by compressor failure or use of incorrect
refrigerant or oil.
HVAC Flush Fitting Application

Front Evaporator Liquid 19-094-01
Front Evaporator Suction 19-353-01
Suction Line at Compressor 19-353-03
Suction Line Plug 19-353-02
Suction Line at Expansion Valve 19-353-04
Condenser Line at Compressor 19-353-06
Condenser Line Loop 19-043-01
1394

Condenser Line at Receiver / Drier 19-353-05
Sleeper Rear Suction Line (same as Suction Line at 19-353-03
Compressor)
Sleeper Rear Liquid Line (same as Condenser Line at 19-353-06
Compressor)
Sleeper Rear Lines at Rear Expansion Valve 19-632-01
Sleeper Evaporator 19-094-01
Sleeper Evaporator No-idle 19-094-02
Condenser Inlet 19-353-07
Condenser Outlet 19-353-09
International® Servicing System - RHS980C-NAV
Figure 702 International® Servicing System - RHS980C-NAV
International® Servicing System (RHS980C-NAV) is recommended HVAC service machine, meeting SAE
J2788 standards. If other recovery tools (meeting SAE J2788) are used, refer to instructions provided by tool
manufacturer (this includes current Robinair machine).
1395
RHS980C-NAV can be used to perform a fully automatic service. Technician will be prompted for entry
of data such as charge amount and given options like vacuum leak test. Once necessary data has been
entered, RHS980C-NAV will automatically perform complete service and alert technician for interaction or
that service is complete.
RHS980C-NAV can also be used to perform individual functions like recycle, vacuum, or charge. Keypad
has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM, and CHARGE) to allow technician to jump
directly to any one of these functions.
Units of measure displayed can be changed at any time by repeatedly pressing U/M key.
A setup routine can be used to select options, set default values, perform maintenance operations, and
manage fluid capacities processed.
For any additional operating instructions refer to operator’s manual supplied with RHS980C-NAV.
CAUTION
Sealants and leak stop chemicals in HVAC systems may cause serious damage to
RHS980C-NAV if they are present in refrigerant recovered intended for recovery.
Detection devices readily available to check for presence of these chemicals and are
highly recommended to protect RHS980C-NAV.
New SAE Standard J2788 dictates that filter must be changed at set intervals to ensure that recycled
refrigerant is pure.
RHS980C-NAV has one filter, which must be changed after recycling every 150 pounds of refrigerant.
Technician will be alerted when filter life is at 100 pounds (45 KG). This allows time to order a replacement
filter kit.
When filter has purified 150 pounds (68 KG) of refrigerant, RHS980C-NAV will shut down and not perform
any function.
A new filter must be installed to re-activate RHS980C-NAV controller.
1396
Refrigerant Identifier
Figure 703 Refrigerant Identifier Hose (Found on Rear of RHS980C-NAV)
There are a lot of alternative and blended refrigerants; International® only recognizes R-134a for HVAC system.
Only way to know for sure if safe recovery of refrigerant in HVAC system is through use of a refrigerant identifier.
If RHS980C-NAV has a refrigerant identifier installed, refrigerant identifier samples refrigerant, then displays
type and purity of refrigerant in HVAC system. Refrigerant identifier hose is found on rear of RHS980C-NAV
and connects to vehicle low side service port. Refrigerant identifier is supplied as part of a kit which includes
necessary hoses and fittings. Refrigerant identifier is an optional item and can be installed in field.
1397
D440A-NAV and D400A Leak Detectors
Figure 704 Leak Detectors

1. D400A Leak Detector 2. D440A-NAV Leak Detector
D400A and D440A-NAV features a long life heated sensor technology that is designed to detect more current
and difficult HFC refrigerants, such as R-134a, in addition to all HCFC and CFC refrigerants including
hydrocarbon 'blends'. D400A and D440A-NAV unique digital leak size indicator takes guesswork out of
whether or not to repair a small leak. Digital display equipped on D440A-NAV is independent of audio alarm
and sensitivity level, allowing precise pinpointing of leak source. D400A and D440A-NAV do not require
rechargeable batteries. D400A and D440A-NAV are SAE J2791 compliant.
D440A-NAV and D400A Leak Detectors are hand-held devices having a flexible probe used to seek out
refrigerant leaks. An audio leak indicator signals a warning in presence of a leak. It is important to become
familiar with leak detector instructions. The speed at which probe is moved over component being checked is
very important in locating larger than permissible leaks.
Before using this detector to look for leaks, it is recommended to clean away all oil or grease, and blow away
refrigerant residue from fittings and HVAC components. All suspected areas should be cleaned using soap
and water, not a solvent. A detected leak should be a flow of refrigerant, not a residual condition of refrigerant
that is trapped under an oil film, etc. A detected leak rate in excess of 1.0 oz. / year is unacceptable.
1398
HVAC Oil and Dye Injection Equipment - 12401-NAV
Figure 705 HVAC Oil and Dye Injection Equipment - 12401-NAV
Replacing proper amount of oil during service is critical to compressor survival and extended customer
satisfaction. During service, additional lubrication is required to replace lubricant removed during component
replacement. Traditional method of replacing lubrication has several short-falls.
With objective of making a technician’s job easier and ensuring highest quality repairs, Navistar® decided to
transition to cartridge oil injection method. At any point in service, technician could add lube to component or
system, whether under a vacuum, or charged. Tool also has check valves, which means no mess.
For additional information refer to documentation supplied with HVAC Oil and Dye Injection Equipment -
12401-NAV.
1399
Flush Tank Assembly
Figure 706 Flush Tank Assembly (Part of HVAC System Flush Tool, 19-000-01)
If refrigerant system has been contaminated, such as due to an internal compressor failure, it must be flushed
and purged before it can be repaired and recharged. A flush gun is used, along with compressed dry nitrogen,
to force flushing agent through hoses and components of refrigerant system. Flush gun and drain hose
with compression fitting / adapter is obtained locally.
1400
Refrigerant Identification
WARNING
CAUTION
To prevent damage or contamination to RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant
in HVAC system prior to servicing. Recovering other refrigerants will contaminate
refrigerant in RHS980C-NAV charge cylinder. To prevent damage or contamination
to RHS980C-NAV and R-134a refrigerant, take extreme precaution to ensure that
other refrigerants are not recovered into RHS980C-NAV. A refrigerant identifier is
recommended for evaluating refrigerant in HVAC system prior to servicing. Recovering
other refrigerants will contaminate refrigerant in RHS980C-NAV charge cylinder.
CAUTION
To prevent damage or contamination to RHS980C-NAV and R-134a refrigerant, check

refrigerant identification hose for oil or UV dye contamination before connecting.
Replace hose if necessary.
Although service equipment may appear physically different from equipment described here, function of
equipment used to perform each service procedure is basically identical. When performing these service
procedures using service equipment different from that identified, refer to manufacturer’s instructions supplied
with that equipment.
Before any work is done on an HVAC system, refrigerant should be identified.
1. Calibrate Refrigerant Identifier per manufacturer’s instructions.
2. Connect sampling hose to low pressure service port located on evaporator outlet line.
3. Connect other end of sampling hose to Refrigerant Identifier.
4. Open service valve.
5. Start sampling procedure (refer to manufacturer’s instructions).
6. When sampling is complete Refrigerant Identifier will indicate a PASS / FAIL condition, type of refrigerant,
and percentage of concentration. International® recognizes only R-134a in a 98%, or greater,
concentration. Anything else is considered contaminated.
7. Close service valve and disconnect sampling hose.
8. Verify that protective caps are installed on both vehicle service port fittings.
1401
INSTRUMENTATION
4. Instrumentation
Driver Instrumentation Display
Overview
0016HLN Electronic Vehicle Monitoring driver information display, flush mounted
style in wing Panel; with 6.5 in. color touch screen, includes GPS
navigation for North America with truck logistics and USB port
0016HLP Electronic Vehicle Monitoring driver information display, flush mounted
style in wing panel; with 6.5 in. color touch screen, includes GPS
navigation for North America with truck logistics, USB port and Wi-Fi
Gauge Cluster
Overview
0016HBA Gage Cluster English with English electronic speedometer
0016HBB Gage Cluster English with Metric electronic speedometer
0016HBC Gage Cluster Metric with Metric electronic speedometer
Cluster is a reliable, quick-disconnect package for most commonly used instruments. Should need arise,
cluster body can be quickly detached from instrument panel for quick access to any of its components. Either
complete cluster assembly or any of its components can be replaced.
Always place ignition switch in OFF (not ACC) prior to working on cluster, due to potential shorting between
ground and ignition pins, which will damage circuit board and gauges.
Gauges
Overview
0016HGN Gauge, Air Application
0016HLC Gauge, Air Cleaner Restriction {Filter-Minder} mounted in instrument panel
0016HLB Gauge, Air Pressure for pressure in rear air suspension; mounted in
instrument panel
0016HKB Gauge, Manifold Pressure data link driven; mounted in instrument panel,
includes controller module
0016HGH Gauge, Oil Temperature, Auto Transmission, for Allison transmission
0016HGG Gauge oil temperature, Engine
0016HGJ Gauge, Oil Temperature, Manual Transmission, for manual transmission
0016HGL Gauge, Oil Temperature, Rear Axle
1402
INSTRUMENTATION
All instruments are located on instrument panel in a demountable instrument cluster directly in front of driver.
Gauges and panel lights of cluster are connected to vehicle electrical system by three connectors mounted
to back side of cluster.
Facing cluster mounted in instrument panel are three vehicle harness connectors fastened to back of cluster.
Left or driver's side connector is yellow, center is green, and right or passenger's side is natural.
Each harness connector has 17 pins numbered right to left. Bottom row contains pins 1 through 9 and top
row, pins 10 through 17. There is a space between pins 13 and 14.
Air Application
Air Cleaner Restriction
Air Pressure for Rear Suspension
Primary and Secondary Air Pressure
Allison Oil Temperature
Engine Oil Temperature
Manual Transmission Oil Temperature
Rear Axle Oil Temperature
1403
SEATS
5. Seats
National with RollTek®
Drivers
Overview
0016KVL Driver seat (National Model HP), RollTek® equipped, air suspension,
high back, Mordura cloth, two arm rests, isolator, 7 in. (17.8 cm)
adjuster, 3 chamber lumbar, 6-way front adjust, 3-way rear cushion
adjust, 3 - 14 degree back angle adjustment, adjustable side bolster,
back cycler, non-swivel
0016KVM Driver seat (National Model HP), RollTek® equipped, air suspension, high
back, vinyl, two arm rests, isolator, 7 in. (17.8 cm) adjuster, 3 chamber
lumbar, 6-way front adjust, 3-way rear cushion adjust, 3 - 14 degree
back angle adjustment, adjustable side bolster, back cycler, non-swivel
0016KVN Driver seat (National Model HP), RollTek® equipped, air suspension,
high back, vinyl boxing/leather-facing, two arm rests, isolator, 7 in. (17.8
cm) adjuster, 3 chamber lumbar, 6-way front adjust, 3-way rear cushion
Figure 707 RollTek Supplemental Restraint System

1. Side Roll Airbag (SRA) 3. Interconnect Point (IPC) bar
2. RollTek Supplemental Restraint System
(SRS) module cover
RollTek equipped National seats utilize RollTek SRS to provide additional protection to operator in rollover
crashes. Sensors in RollTek seat base detect when truck enters an irrecoverable rollover and activate system.
RollTek first tightens lap and shoulder belts securing driver to seat. Second, it lowers seat suspension,
increasing seat stability and moving driver away from steering wheel and ceiling. SRA deploys from outboard
side of seat back as seat is pulled down to its lowest position, providing protection to operator in point of
contact with cab in a rollover.
1404
SEATS
The seat suspension utilizes a scissors-type suspension with a wide base and cast components. This
combination results in better lateral stability and lower levels of buzz, squeaks, and rattles.
The National air seats were developed and tuned specifically for LT™ vehicles. Seat suspension components
such as air spring, damper, and isolator were designed to provide a smooth, integrated ride.
1405
SEATS
Passenger
Overview
0016SPE Passenger seat (National Model HP), RollTek® equipped, air suspension,
high back, Mordura cloth, two arm rests, isolator, 7 in. (17.8 cm)
adjuster, 3 chamber lumbar, 6-way front adjust, 3-way rear cushion
0016SPG Passenger seat (National Model HP), RollTek® equipped, air suspension,
high back, vinyl, two arm rests, isolator, 7 in. (17.8 cm) adjuster, 3
chamber lumbar, 6-way front adjust, 3-way rear cushion adjust, 3 - 14
degree back angle adjustment, adjustable side bolster, back cycler,
non-swivel
0016SPH Passenger seat (National Model HP), RollTek® equipped, air suspension,
high back, vinyl boxing/leather-facing, two arm rests, isolator, 7 in. (17.8
cm) adjuster, 3 chamber lumbar, 6-way front adjust, 3-way rear cushion
Figure 708 RollTek® Supplemental Restraint System

1. Side Roll Airbag (SRA) 3. Interconnect Point (IPC) bar
2. RollTek Supplemental Restraint System
(SRS) module cover
RollTek equipped National seats utilize RollTek SRS to provide additional protection to operator in rollover
crashes. Sensors in RollTek seat base detect when truck enters an irrecoverable rollover and activate system.
RollTek first tightens lap and shoulder belts securing driver to seat. Second, it lowers seat suspension,
increasing seat stability and moving driver away from steering wheel and ceiling. SRA deploys from outboard
side of seat back as seat is pulled down to its lowest position, providing protection to operator in point of
contact with cab in a rollover.
The seat suspension utilizes a scissors-type suspension with a wide base and cast components. This
combination results in better lateral stability and lower levels of buzz, squeaks, and rattles.
1406
SEATS
The National air seats were developed and tuned specifically for LT™ vehicles. Seat suspension components
such as air spring, damper, and isolator were designed to provide a smooth, integrated ride.
1407
SEATS
RollTek® Seat with Supplemental Restraint System (SRS)
Removal
Overview
Remove National seat with RollTek SRS.
WARNING
section.
WARNING
WARNING
To prevent property damage, personal injury, or death, before removing National Seat
equipped with RollTek® system, disconnect batteries from vehicle. Failure to follow this
warning may result in airbag and pretensioners unintentionally deploying.
WARNING
To prevent property damage, personal injury, or death, wait two minutes after
disconnecting battery to allow internal components to discharge. Failure to allow
components to discharge could cause airbag and pretensioner to deploy.
Required Tools
None
6. Disconnect battery, always disconnect ground battery terminal first, then positive cable. Wait two
minutes after disconnecting battery to allow internal components to discharge.
7. Open air tank drain valves and lower air tanks to 0 psi (0 kPa).
Procedure
1. Raise seat cushion to highest position, and adjust to full forward position.
2. Use chugger knob, located at right side of seat, adjust seat back full forward. Raise seat back to full upright
position allowing maximum clearance for removal.
1408
SEATS
Figure 709 RollTek® SRS Module Cover

1. Top cover 3. Outboard electrical plate
3. Remove outboard electrical plate (3) on RollTek SRS module lower cover by disengaging three plastic
push clips, exposing chassis harness to RollTek SRS system connection.
Figure 710 Chassis Connector

1. RollTek SRS module chassis connector
4. Disconnect chassis connector (1) from RollTek SRS module.
5. Disconnect seat air supply quick disconnect fitting.
6. Remove plastic push clip from top cover (Figure 709) (1) on RollTek SRS module. Remove top cover.
1409
SEATS
7. Remove two plastic push clips located on outboard side of RollTek SRS module cover (Figure 709) (2).
8. Remove RollTek SRS module cover by moving it upward, tipping top of it forward, and placing it to side as
it will be reinstalled after new unit is put in place.
Figure 712 Three-point Belt System Anchorage Point

1. Three-point belt system anchor
1410
SEATS
9. Remove and discard nut and bolt that attach end fitting of three-point belt system (1) to Interconnect
Point (ICP) anchorage point.
Figure 713 ICP Bar Cartridge

1. ICP bar cartridge 2. ICP bar bolt (4)
WARNING
To prevent property damage, personal injury, or death, following airbag deployment,

tether mounting bolts at ICP bar must be replaced.
For instances other than those following an airbag deployment tether mounting bolts at ICP bar can be reused.
10. Remove and discard four bolts on rear of ICP bar. For instances other than those following an airbag
deployment, do not discard four bolts.
11. Remove rear ICP cartridge from ICP bar.
1411
SEATS
Figure 714 ICP Bar Tether Connections

1. ICP bar (seat belt) tether connection (2)
12. Remove two tether connections from ICP bar (1) that secure seat tethers to cab floor. Tethers will remain
attached to tether bracket on cab floor.
In day cab applications, rear mounts for National seat anchor plate will be studs. In sleeper cab application, all
four mounts will be bolts.
13. Remove two forward bolts and two rear nuts securing National seat anchor plate to cab floor. Lift rear
of seat anchor plate over studs (day cab application), and move National Seat assembly with RollTek
SRS unit forward.
14. With technician assistance, remove National seat with RollTek SRS module from cab of vehicle.
Expected Outcome
None
None
1412
SEATS
Installation
Overview
Install National seat with RollTek SRS.
WARNING
section.
WARNING
Required Tools
None
Seat mounting front M8 bolts and two nuts on rear 15 - 20 lb-ft (20 - 27 N·m)
studs
Seat mounting rear studs and nuts 15 - 20 lb-ft (20 - 27 N·m)
Seat belt tether M12 bolts 30 lb-ft (41 N·m)
Three-point belt anchorage 7/16-20 bolt and flange 30 ± 5 lb-ft (41 ± 7 N·m)
nut
1. Insure battery is still disconnected.
2. Insure air tanks are still drained to 0 psi (0 kPa).
Procedure
1. With technician assistance, place National seat with RollTek SRS module in cab of vehicle.
2. Raise seat cushion to highest position, and adjust seat back to full-forward and full-upright position. This
will allow maximum clearance for installation procedure.
1413
SEATS
Figure 715 RollTek® SRS module Rear Flanges

1. RollTek SRS module rear flange (2)
3. Slide seat assembly rearward to line up with mounting holes in cab floor. Be sure rear flanges (1) of
RollTek SRS module are routed into slots in floor-mounted tether bracket.
4. Secure seat to cab floor using two M8 bolts and two nuts on rear studs (day cab application). Tighten
to 15 - 20 lb-ft (20 - 27 N·m).

1. ICP bar seat belt tether connection (2)
1414
SEATS
WARNING

For instances other than those following airbag deployment tether mounting bolts at ICP bar can be reused.
5. Secure two seat belt tethers on floor up to ICP attachment points with M12 bolts. Tighten to 30 lb-ft (41
N·m).

6. Attach three-point belt anchorage (1) to ICP bar with supplied 7/16-20 bolt and flange nut. Tighten to 30
± 5 lb-ft (41 ± 7 N·m).
Perform following checklist prior to moving forward:
• Ensure National seat anchor plate to cab floor is torqued properly.

• Ensure two seat tethers to ICP bar are torqued properly.
• Ensure three-point end fitting is torqued to ICP bar properly.
1415
SEATS
7. Install RollTek SRS Module cover by tipping top of it forward and moving it downward to cover unit.

8. Install two plastic push clips located on outboard side of RollTek SRS module cover (2), three on each side.
1416
SEATS
9. Install top cover (1) on RollTek SRS module cover.
10. Install plastic push pin in top cover.
11. Connect seat air supply quick disconnect fitting. Position over back of SRS module cover.

12. Connect chassis connector (1) to RollTek SRS module.
13. Install outboard electrical plate (Figure 719) (3) on RollTek SRS module lower cover with provided plastic
push clips, three total.
14. Connect battery, connect battery positive cable first, then connect battery ground cable.
Expected Outcome
None
None
1417
SEATS
RollTek® Side Roll Airbag (SRA)
Removal
Overview
Remove RollTek® SRA.
WARNING
section.
WARNING
WARNING
To prevent property damage, personal injury, or death, before removing any component
from RollTek® system, disconnect batteries from vehicle. Failure to follow this warning
may result in airbag and pretensioners unintentionally deploying.
WARNING
WARNING
To prevent property damage, personal injury, or death, do not attempt to service or

disassemble RollTek® SRS module. RollTek® SRS module cannot be serviced.
WARNING
To prevent property damage, personal injury, or death, do not cut, drill, braze, solder,
weld, strike, or probe any part of RollTek® system.
WARNING
To prevent property damage, personal injury, or death, keep all liquids, acids, halogens,
heavy metals, and heavy salts away from RollTek® system.
WARNING
To prevent property damage, personal injury, or death, do not attempt to adapt, reuse
or install a RollTek® system in any vehicle other than specific vehicle for which it is
designed.
1418
SEATS
WARNING
To prevent property damage, personal injury, or death, keep hands and hand tools away
from scissor points under seat.
WARNING
To prevent property damage, personal injury, or death, do not cut wires or tamper with
connectors between vehicle wiring harness and RollTek® system. Cutting or removing
electrical connectors could result in unintentional deployment.
WARNING
To prevent property damage, personal injury, or death, do not expose RollTek® to

electricity. Never probe a circuit.
WARNING
To prevent property damage, personal injury, or death, do not connect electrical power
to RollTek® SRS module unless module is securely mounted to seat riser in vehicle.
After all warnings are understood, removal of system may begin.
Required Tools
None
Procedure
1419
SEATS

3. Remove outboard electrical plate (3) on RollTek SRS module lower cover by disengaging three plastic
push clips. Chassis harness to RollTek SRS system connection is visible.

5. Separate seat back cover by disengaging J-channel attachment at bottom of seat back.
6. Unzip seat back cover and tuck out of way.
1420
SEATS
Figure 723 SRA Connector

1. SRA connector 2. Seat belt buckle switch connector
7. Disconnect yellow SRA connector (1).
8. Disconnect seat belt buckle switch connector (2).
Figure 724 SRA Rivet Mount

1. SRA rivet mount
When drilling out SRA module mounting rivet, make sure entire rivet is removed from bracket.
1421
SEATS
9. Using a 3/16 in drill bit, drill out SRA rivet mount (1) located at bottom of airbag bracket. Remove entire
rivet from bracket.
Figure 725 Retention Tab

1. SRA retention tab 2. Seat retention tab
10. Carefully pull airbag module down approximately 15 - 20 mm to disengage airbag module tab (1) from
upper retention tab on seat (2).
11. Remove airbag module by carefully sliding it up and out from seat pocket. Wire harness remains attached
to bottom of airbag module.
Expected Outcome
None
None
1422
SEATS
Installation
Overview
Install RollTek® Side Roll Air Bag (SRA).
WARNING
section.
WARNING
WARNING

WARNING
WARNING
WARNING
designed.
WARNING
WARNING
1423
SEATS
WARNING

WARNING
Required Tools
None
None
Procedure
Unpacking Replacement SRA Unit
CAUTION
To prevent loss of SRA Unit, SRA parts must be returned in original packaging.
1. Remove unit from main carton. There can be two units per carton.
2. If parts need to be returned, retain original carton.
1424
SEATS
Product Identification
Figure 726 New SRA Module

1. Serial number
1. Locate product identification label. This is located on back side of unit. Verify new unit is proper
Part Number (PN) and system for vehicle configuration. Note: each SRA unit has a unique serial
number that needs to be recorded by OEM.
1425
SEATS
RollTek® Side Roll Air Bag (SRA) - Installation
Figure 727 SRA Install

1. Seat back cover zipper 3. SRA module ramped hook
2. SRA module
1. Open seat back upholstery (1) to gain access to airbag compartment located on outboard side of seat back.
2. Slide wire harness followed by module (2) through seat back foam and upholstery.
3. Slide unit down then up to engage ramped hook (3) to upper tab.
4. Tuck seat cover in around SRA module.
5. Make sure wiring harness is free and not pinched.
CAUTION
To prevent vehicle component damage, do not make wiring connection at this time.
1426
SEATS
Figure 728 SRA Module Rivet
6. Align mounting holes and install SRA using proper OEM supplied mounting hardware (3/16 in. stainless
steel rivet).

7. Connect SRA (yellow) electrical connector (1).
8. Connect seat belt buckle switch connector (2).
9. If necessary, secure two wire harness (SRA connection and Buckle Switch connection) with cable tie.
10. Close zipper on seat back upholstery carefully to ensure that no materials are caught in zipper.
11. Pull front section of seat back cover taught under seat back, and align with J-channel on rear section of
seat back cover and connect.
1427
SEATS

12. Connect RollTek SRS chassis connector (1).
13. Reattach outboard electrical plate on RollTek SRS module lower cover by installing 3 plastic push clips.
Expected Outcome
None
None
1428
SEATS
RollTek® Supplemental Restraint System (SRS) Module
Removal
Overview
Remove RollTek Supplemental Restraint System (SRS) module.
WARNING
section.
WARNING
WARNING
To prevent property damage, personal injury, or death, before removing any component
from RollTek® system, disconnect batteries from vehicle. Failure to follow this warning
may result in airbag and pretensioners unintentionally deploying.
WARNING
WARNING

WARNING
WARNING
WARNING
To prevent property damage, personal injury, or death, do not attempt to adapt, reuse,
designed.
1429
SEATS
WARNING
WARNING
WARNING

WARNING
Required Tools
None
Procedure
1430
SEATS

3. Remove outboard electrical plate (3) on RollTek SRS module lower cover by disengaging 3 plastic push
clips. Chassis harness to RollTek SRS system connection will now be visible.

5. Disconnect seat air supply quick disconnect fitting.
6. Remove plastic push clip from top cover (Figure 731) (1) on RollTek SRS module. Remove top cover.
1431
SEATS
7. Remove 2 plastic push clips located on outboard side of RollTek SRS module cover (Figure 731) (2).
Figure 733 RollTek® SRS module Cover
8. Remove cover by moving it upward and tipping top of it forward and placing it to side as it will be
re-installed after new unit is put in place.
9. Separate seat back cover by disengaging J-channel attachment at bottom of seat back.
10. Unzip seat back cover and tuck out of way.
1432
SEATS

11. Disconnect SRA connector (1), and seat belt buckle switch connector (2).
12. Carefully use snips to cut two zip ties attaching wire harnesses to seat back.

13. Remove and discard nut and bolt that attaches end fitting of three-point belt system (1) to Interconnect
Point (ICP) anchorage point.
1433
SEATS
Figure 736 ICP Bar Cartridge

1. ICP bar cartridge 2. ICP bar bolt (4)
14. Remove and discard four bolts (2) on rear of ICP bar. Remove rear ICP cartridge (1) from ICP bar.

WARNING

1434
SEATS
15. Remove and discard two tether mounting bolts from ICP bar that secure seat tethers (1) to cab floor. For
instances other than those following an airbag deployment, do not discard two bolts. Tethers will remain
attached to tether bracket on floor.
Figure 738 RollTek® SRS module Seat Mounting Bolts
16. Remove and discard four bolts that attach RollTek unit to seat base, two on each side.
17. Remove two forward bolts, and two rearward nuts, (four bolts on sleeper cab application) that bolt National
seat anchor plate to floor. Slide seat forward to access back of seat. Floor mounted tether attachment
bracket and seat tethers remain installed to cab floor.
18. Remove entire RollTek SRS ICP bar assembly from seat and out of vehicle.
Expected Outcome
None
None
1435
SEATS
Installation
Overview
Install RollTek Supplemental Restraint System (SRS) Module.
WARNING
section.
WARNING
WARNING

WARNING
WARNING
WARNING
designed.
WARNING
WARNING
1436
SEATS
WARNING

WARNING
Required Tools
None
Seat base bolts and washers 30 ± 5 lb-ft (41 ± 7 N·m)
ICP bar bolts 30 ± 5 lb-ft (41 ± 7 N·m)
Seat M8 front bolts (day cab application) 15 - 20 lb-ft (20 - 27 N·m)
Seat rear studs and nuts (day cab application) 15 - 20 lb-ft (20 - 27 N·m)
Seat belt tether M12 bolts 30 lb-ft (41 N·m)
Three-point belt anchorage 7/16-20 bolt and flange 30 ± 5 lb-ft (41 ± 7 N·m)
nut
Procedure
Seat anchor plate must be detached from cab floor and moved forward to allow access to install RollTek SRS
module to seat anchor plate.
1437
SEATS
Figure 739 RollTek® SRS Module Seat Mounting Bolts
3. Place RollTek SRS module in position behind seat. Line up four bolt holes in seat base with RollTek
SRS module, two each side.
4. Secure RollTek SRS module to seat base with four (4) supplied bolts and washers. Tighten to 30 ± 5
lb-ft (41 ± 7 N·m).
Figure 740 ICP Bar Seat Belt Webbing
5. Slide ICP bar forward of airline and into channel with buckle positioned on inboard side of seat. Ensure
seat belt webbing protruding down from center of ICP bar is not twisted.
WARNING
To prevent property damage, personal injury, or death, make sure to have cable routed
over two center bolts when installing ICP bar. Failure to do so will lead to improper
operation of RollTek® seat belt pretensioner device.
1438
SEATS
Figure 741 ICP Bar Cable Routing

1. ICP bar cable
6. Ensure cable is routed over two center bolts of ICP bar. Secure ICP bar to seat with four supplied bolts.
Tighten to 30 ± 5 lb-ft (41 ± 7 N·m).
Figure 742 RollTek® SRS Module Rear Flanges

1. RollTek SRS module rear flanges
7. Slide seat assembly rearward to line up with mounting holes and studs in cab floor. Be sure rear flanges
of RollTek SRS module are routed into slots in floor mounted tether bracket. Seat will need to be lifted
to clear rear anchor plate studs (day cab application), and to engage rear flanges into slots on floor
mounted tether bracket.
1439
SEATS
8. Secure seat to cab floor using two M8 bolts, and two nuts on rear studs (day cab application). Tighten
to 15 - 20 lb-ft (20 - 27 N·m).

WARNING

9. Secure two seat belt tethers on floor up to ICP attachment points with M12 bolts. Tighten to 30 lb-ft (41
N·m).
1440
SEATS

10. Attach three-point belt anchorage to ICP bar with supplied 7/16–20 bolt and flange nut. Tighten to 30
± 5 lb-ft (41 ± 7 N·m).
11. Perform following checklist prior to moving forward:
• Ensure two seat tethers to ICP bar are torqued properly.

• Ensure four bolts that attach RollTek SRS Module to seat anchor plate are torqued properly.
• Ensure four bolts that attach ICP bar to seat are torqued properly and ICP bar cable is routed over
center two bolts properly.
• Ensure three-point end fitting is torqued to ICP bar properly.
1441
SEATS
12. Install RollTek SRS Module cover by tipping top of it forward, and moving it downward and to cover unit.

1442
SEATS
13. Install six plastic push clips located on both inboard and outboard sides of RollTek SRS module cover
(2), three on each side.
14. Install top cover (1) on RollTek SRS Module cover.
15. Install plastic push pin to top cover.

16. Connect SRA connector (1), and seat belt buckle switch connector (2).
17. If necessary, secure two (wire harness (SRA connection and Buckle Switch connection) with cable tie.
18. Close zipper on seat back upholstery carefully to ensure that no materials are caught in zipper.
19. Pull front section of seat back cover taught under seat back, and align with J-channel on rear section of
seat back cover and connect.
20. Connect seat air supply quick disconnect fitting.
1443
SEATS

21. Connect chassis connector to RollTek SRS module (1).
22. Install outboard electrical plate (Figure 746) (3) on RollTek SRS module lower cover by installing three
plastic push clips.
23. Connect main positive battery terminal first, and then connect main battery ground terminal.
Expected Outcome
None
None
1444
WINDSHIELD WIPERS
6. Windshield Wipers
Windshield Wiper System
Overview
0016XWJ Windshield wiper blades, snow type
Figure 749 Windshield Wiper System

1. Cowl / drain 3. Wiper arm (2)
2. Wiper blade (2) 4. Electric motor
The wiper system provides a means to clear the outer windshield washer surface from rain, snow,
contaminants, or other debris. The wipers are capable of several speeds: high, low, variable, intermittent, and
off. Intermittent setting is capable of varying the amount of time between wipes.
1445
WINDSHIELD WIPERS
Windshield Wiper Motor
Removal
Overview
Remove windshield wiper motor for motor replacement.
Figure 750 Windshield Wiper Motor

1. Windshield wiper motor
Special Tools
None
1. Windshield wiper arm and blade assemblies removed. See Windshield Wiper Arm and Blade
Assemblies Removal .
2. Cowl tray removed. See Cowl Tray Removal .
3. Air inlet duct removed. See Air Inlet Duct Removal .
4. Windshield wiper motor, bracket and linkage assembly removed from engine side of cowl. See
Windshield Wiper Motor, Bracket and Linkage Assembly Removal .
1446
WINDSHIELD WIPERS
Removal Procedure
Figure 751 Windshield Wiper Motor, Bracket and Linkage Assembly

1. Windshield wiper linkage 5. Windshield wiper motor
2. Windshield wiper motor mounting screw 6. Windshield wiper motor mounting
(3) bracket
3. Windshield wiper motor, bracket and 7. Windshield wiper motor pivot arm
linkage assembly mounting bracket 8. Windshield wiper motor pivot arm
4. Windshield wiper motor mounting mounting nut
bracket mounting screw (2)
1. Place windshield wiper motor, bracket and linkage assembly on a clean, dry work surface.
2. Remove windshield wiper motor pivot arm mounting nut (8) from shaft of windshield wiper motor (5) and
windshield wiper motor pivot arm (7).
3. Remove windshield wiper motor pivot arm (7) with windshield wiper linkage (1) from shaft of windshield
wiper motor (5).
1447
WINDSHIELD WIPERS
4. Remove three windshield wiper motor mounting screws (2) from windshield wiper motor (5), windshield
wiper motor mounting bracket (6), and windshield wiper motor, bracket and linkage assembly mounting
bracket (3), and remove windshield wiper motor (5).
5. If windshield wiper motor mounting bracket (6) is damaged, remove two windshield wiper motor mounting
bracket mounting screws (4) from windshield wiper motor mounting bracket (6) and windshield wiper
motor, bracket and linkage assembly mounting bracket (3), and remove windshield wiper motor mounting
bracket (6).
Follow-On Procedure
1. Install windshield wiper motor. See Windshield Wiper Motor Installation (page 1449).
1448
WINDSHIELD WIPERS
Installation
Overview
Install windshield wiper motor for motor replacement.
Figure 752 Windshield Wiper Motor

1. Windshield wiper motor
Special Tools
None
Windshield wiper motor mounting bracket mounting 92 to 110 lb-in. (10.4 to 12.4 N·m)
screws
Windshield wiper motor mounting screws 92 to 110 lb-in. (10.4 to 12.4 N·m)
Windshield wiper motor pivot arm mounting nut 180 to 220 lb-in. (20.3 to 24.9 N·m)
1. Windshield wiper motor removed. See Windshield Wiper Motor Removal (page 1446).
1449
WINDSHIELD WIPERS
Figure 753 Windshield Wiper Motor, Bracket and Linkage Assembly

1. Windshield wiper linkage 5. Windshield wiper motor
2. Windshield wiper motor mounting screw 6. Windshield wiper motor mounting
(3) bracket
3. Windshield wiper motor, bracket and 7. Windshield wiper motor pivot arm
linkage assembly mounting bracket 8. Windshield wiper motor pivot arm
4. Windshield wiper motor mounting mounting nut
bracket mounting screw (2)
1. Before installing the windshield wiper motor (5) onto the windshield wiper motor mounting bracket (6)
make sure it is in the PARKED or OFF position.
2. Place windshield wiper motor, bracket and linkage assembly on a clean, dry work surface.
3. If windshield wiper motor mounting bracket (6) is being replaced, install new bracket on windshield wiper
motor, bracket and linkage assembly mounting bracket (3) with two windshield wiper motor mounting
bracket mounting screws (4). Tighten two screws to 92 to 110 lb-in. (10.4 to 12.4 N·m).
1450
WINDSHIELD WIPERS
4. Install windshield wiper motor (5) onto windshield wiper motor mounting bracket (6) with three windshield
wiper motor mounting screws (2). Tighten screws to 92 to 110 lb-in. (10.4 to 12.4 N·m).
5. Position windshield wiper motor pivot arm (7) with windshield wiper linkage (1) over shaft of windshield
wiper motor (5).
6. Align windshield wiper linkage (1) with windshield wiper motor pivot arm (7) so that they are in line with
each other, and press windshield wiper motor pivot arm (7) onto shaft of windshield wiper motor (5).
7. Install windshield wiper motor pivot arm mounting nut (8) onto shaft of windshield wiper motor (5) to secure
windshield wiper motor pivot arm (7). Tighten nut to 180 to 220 lb-in. (20.3 to 24.9 N·m).
Follow-On Procedure
1. Install windshield wiper motor, bracket and linkage assembly to engine side of cowl. See
Windshield Wiper Motor, Bracket and Linkage Assembly Installation .
2. Install air inlet duct. See Air Inlet Duct Installation .
3. Install cowl tray. See Cowl Tray Installation .
4. Install windshield wiper arm and blade assemblies. See Windshield Wiper Arm and Blade
Assemblies Installation .
1451
WINDSHIELD WIPERS
Windshield Wiper Arm and Blade Assembly
Removal
Overview
Before removing wiper arm and blade assembly, mark or note orientation of blade assembly to wiper pivot
post for easier installation.
Procedure
2. Disconnect washer hose from T-fitting.
3. Lift up on lock lever and remove driver wiper arm and blade assembly from wiper pivot post.
4. Lift up on lock lever and remove passenger wiper arm and blade assembly.
1452
WINDSHIELD WIPERS
Installation
None
Procedure
1. Press passenger wiper arm and blade assembly onto wiper pivot post until assembly locks in place.
2. Press driver wiper arm and blade assembly onto wiper pivot post until assembly locks in place.
3. Ensure that both lock levers are pressed down.
4. Attach washer hose to T-fitting.
6. Turn wipers on high speed, activate windshield washer, and check for proper wiper operation. If required,
adjust windshield wiper arm and blade assembly.
1453
WINDSHIELD WIPERS
Windshield Wiper Assembly
Removal
Procedure
2. Remove both driver and passenger windshield wiper arm and blade assembly.
3. Remove cab cowl tray.
4. If needed, cut wire tie securing wiring harness to windshield wiper motor.
5. Disconnect electrical connector from windshield wiper motor.
6. Remove mounting nuts (2) from mounting studs (1).
7. Disconnect electrical connector (3) on windshield wiper assembly (4).
8. Remove windshield wiper assembly (5).
1454
WINDSHIELD WIPERS
Installation
Windshield wiper assembly mounting studs and 16 lb-ft (22 N·m); DO NOT exceed 18 lb-ft (24 N·m)
nuts
Procedure
1. Install windshield wiper assembly onto mounting studs and secure with mounting nuts. Tighten nuts to 16
lbf-ft (22 N·m); DO NOT exceed 18 lbf-ft (24 N·m).
2. Connect electrical connector to windshield wiper motor.
3. If removed, secure wiring harness and connector with wire tie.
4. Install cab cowl tray.
5. Install driver and passenger windshield wiper arm and blade assembly.
7. Turn wipers on high speed, activate windshield washer, and check for proper wiper operation. If required,
adjust windshield wiper arm and blade assembly.
1455
TORQUE
7. Torque
Specifications for Ride Height Components
Ride Height Shock Absorber Flange Head Bolt and Flange 80 to 100 lb-ft (108 to 135 N·m)
Head Nut
Ride Height Air Bag Upper Flange Head Bolt and Flange 41 to 50 lb-ft (56 to 68 N·m)
Head Nut (Normally tacked in place)
Ride Height Valve Mounting Bolt and Nut 60 to 80 lb-in. (6.8 to 9.0 N·m)
Ride Height Valve Lever Bolt and 2 Nuts (aligned with valve Both Nuts Snug to Valve Lever
lever even between 2 nuts)
1456
TORQUE
Torque Chart
Torque Specifications for Thread Size
1-1/16-14 46 to 50 lb-ft (63 to 68 N·m)
1-14 40 to 44 lb-ft (54 to 60 N·m)
7/8-14 22 to 26 lb-ft (30 to 35 N·m)
3/4-16 22 to 26 lb-ft (30 to 35 N·m)
11/16-16 15 to 19 lb-ft (20 to 26 N·m)
5/8-18 15 to 19 lb-ft (20 to 26 N·m)
7/16-20 7 to 11 lb-ft (9 to 15 N·m)
3/8-24 4 to 11 lb-ft (5 to 15 N·m)
Oil Fill Plug 11 to 15 lb-ft (15 to 20 N·m)
6 mm 80 to 90 lb-in. (9 to 10 N·m)
8 mm 170 to 190 lb-in. (19 to 21 N·m)
Lubricate all O-rings and fitting threads with Mineral-based oil.
1457
TORQUE
1458
TABLE OF CONTENTS
Front Wheel
Table of Contents
1. Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
Front Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
Front Disc Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
Front Wheel Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
Front Wheel Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
Front Wheel Brand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
1459
TABLE OF CONTENTS
1460
WHEELS AND TIRES
1. Wheels and Tires

Front Wheels
Front Disc Wheels

0027DMA Wheels, Front {Accuride} Disc; 22.5 in. painted steel, two-hand hole,
10-stud (285.75 mm BC) hub piloted, flanged nut, metric mount, 8.25
DC rims; with steel hubs
Hub Piloted Wheels

'Piloting' or centering of wheel is handled totally by center hole of wheel and its precise fit on wheel hub.
Because mounting studs are not required for piloting, flanged nuts are used to provide clamping force to
secure disc wheels. This provides greater value by eliminating rim wear and stress cracking that can be
promoted by lug nut centered (ball-seated) designs.
For maintenance on Front Wheels and Tires refer to Group 28 - Rear Wheel.
Front Wheel Guards

0029WAP Wheel Guards, Front {Accuride} for metric hub piloted wheels with
flanged mounting nuts mounted between hub and wheel
Front Wheel Seals

0029598 Wheel Seals, Front {Stemco Voyager} oil lubricated wheel bearings
ILO standard oil seals
Front Wheel Brand

0029AAA Wheel Brand, Front {Alcoa} aluminum disc front wheels
0029174 Wheel Brand, Front / Rear {Alcoa} disc wheels
1461
WHEELS AND TIRES
1462
TABLE OF CONTENTS
Rear Wheel
Table of Contents
1. Wheels, Rims and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1465
Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1469
Tire Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1469
Brake Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1469
Wheel and Wheel Assemblies Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1470
Disc Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1470
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1470
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1473
OSHA Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1474
Wall Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1475
Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1476
Wheel Studs and Mounting Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1476
Installation, Tightening, and Alignment (Lateral Run-Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1479
Wheel and Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483
Static Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483
Dynamic Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483
Tire Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
Tire Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
Radial and Bias Ply Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1485
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1485
Alignment - Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1485
Alignment - Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1485
Tire Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1486
Service Load and Inflation Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1487
Tire and Rim Combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1494
Ply Rating Verses Load Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495
Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1496
1463
TABLE OF CONTENTS
1464
WHEELS, RIMS AND TIRES
1. Wheels, Rims and Tires

Wheel Components
This section covers wheel assemblies for medium and heavy duty vehicles. Various types of wheels (cast
spoke or disc) are available and vary in size, types and material (steel or aluminum).
Figure 1, Figure 2, Figure 3, Figure 4 and Figure 5 illustrate types of Disc Wheels or Rims used on
International® vehicles.
Figure 754 Steel or Aluminum or Aluminum Disc Wheel with Tubeless Tire
Figure 755 Steel Disc Wheel with Tube Type Tire
Two different locations of drum mountings are also used:
1. Inboard mounted drums are secured to hub on brake group side of hub. Inboard mounted drums
are always used with a cast spoke wheel. Also, some disc wheels use this application (Figure 6).
2. Outboard mounted drums are secured between wheel and hub, and are held in place by wheel
assembly. Outboard mounted drums will be used with disc wheels only (Figure 7).
1465
Figure 756 Inboard Mounted Drum Ball Seat (Conical) Nuts

1. Drum 4. Wheel Outer Nut
2. Wheel 5. Wheel Inner Nut
3. Wheel Bolt 6. Wheel Hub
Figure 757 Outboard Mounted Drum With Ball Seat Nuts

1. Drum 4. Wheel Outer Nut
2. Wheel 5. Wheel Inner Nut
3. Wheel Bolt 6. Wheel Hub
Figure 6 and Figure 7 also illustrate use of Ball Seat Nut Mounting System.
Figure 8 and Figure 9 illustrate use of Flange Nut Wheel Mounting System.
Refer to Installation, Tightening and Alignment for procedures.
1466
Figure 758 Flange Nut System, Front Wheel Mounting

1. Flange Nut 4. Wheel Stud (22 mm)
2. Wheel 5. Wheel Hub
3. Brake Drum
Figure 759 Flange Nut System, Rear Wheels Mounting

2. Wheels 5. Wheel Hub
3. Brake Drum
1467
Warnings
WARNING
Failure to observe following warnings may result in property damage, personal injury, or
death.
Always loosen rim clamps before complete removal of nut from stud (cast spoke wheels).
With loosened nuts on stud, strike clamps with a heavy hammer and be sure each clamp
is loose.
Always deflate tires completely before removing locks or side rings.
Always inspect and clean all parts before assembly.
Always inflate tires in a safety cage.
Always use ‘clip-on’ air chuck with remote control valve to inflate tires.
Never strike cast spokes of wheel assembly when loosening rim clamps.
Never mix rim side rings or lock rings of different types or size.
Never use cracked, bent or badly rusted parts.
Never reinflate flat tires on vehicle - use spare.
Never add air until certain each side or lock ring is fully seated.
Never hammer side or lock ring on a partially or fully inflated tire.
When installing tire and rim assembly on disc braked axles, make sure tire valve stem
clears brake caliper. Use of a valve stem retainer or a tire manufacturer's stem-forming
tool are only acceptable methods of obtaining clearance when necessary.
Use only same type and style wheels and mounting hardware to replace original parts.
Failure to do so may result in an assembly which looks fine, but does not fit together
properly which could possibly cause wheel or fastener failures which might result in
personal injury.
Do not attempt to mix ball seat wheels or fasteners with flange nut wheels or fasteners.
Do not mix foreign (not made in North America) parts with domestic (made in North
America) parts. Many foreign wheel components are similar, but not exactly same as
North American-made parts.
Do not change from aluminum wheels to steel wheels or vice versa without changing
mounting hardware where required or in some cases with flange nut mounting systems
changing hub and stud assembly.
Consult Service Parts Catalog or wheel / rim distributor before attempting any wheel or
fastener changes.
1468
Service Procedure
When servicing wheels, different procedures will be required for different types of wheels.
Tire Service
This requires removal of disc wheel and tire on vehicles with disc wheels. On vehicles with cast spoke wheel,
tire and rim assembly will be removed for tire service.
Brake Service
1. Vehicles with Hydraulic Disc Brakes will have to have Wheel or Rim Tire Assembly removed to service
Wheel / Brake Components.
2. Vehicles with cast spoke wheels or disc wheels and inboard mounted brake drums (single or dual tires):
remove wheel, hub and drum as an assembly to perform brake service.
3. Vehicles with disc wheels (single or dual tires) with outboard mounted brake drums: remove wheel or dual
wheels assembly. Then remove brake drum leaving hub assembly intact on vehicle. Wheel bearing and
seal service will not be required with this procedure.
For more detailed information on Brake Service, refer to Group 04 - Brakes in CTS-5000 Master Service
Manual.
1469
Wheel and Wheel Assemblies Removal and Installation

Disc Wheels
Removal
Refer to Figure 12 and Figure 13.
Figure 760 Disc Rear Wheel Assembly
1470
Figure 761 Disc Front Wheel Assembly
1. Set parking brake and block wheels not being serviced to prevent vehicle from moving.
2. Break all wheel nuts loose on wheel(s) being serviced.
3. Position vehicle on floor stand(s).
WARNING
A jack must never be used alone to support vehicle while under-chassis service is being
performed. Jack may lower and serious personal injury could result. Always support
vehicle with floor stands.
4. If brake service is to be performed, loosen or back off brake adjustment so that drum will move freely without
drag (not required with disc brakes). Refer to Group 04 - Brakes in CTS-5000 Master Service Manual.
5. Remove wheel nuts (outer nuts with dual wheels at rear) (Figure 14).
1471
Figure 762 Remove Outer Wheel Nuts (Ball Seat)
6. Remove wheel from wheel studs.
7. On dual wheel application, remove inner wheel nuts and wheel (Figure 15).
Figure 763 Remove Inner Wheel Nuts (Ball Seat)
1472
Installation
1. Installation of wheel and tire assembly is essentially reverse of removal procedure. Special attention must
be given to following:
a. Before mounting wheel assemblies on vehicles, be sure all parts are clean and free from foreign
matter. Excess paint on wheel stud hole perimeters can cause wheel mounting nuts to loosen with use.
b. Be certain wheel stud threads are clean to allow correct torquing of nuts. Do not apply any lubricant
on threads.
2. Install wheel assembly. Refer to Installation, Tightening and Alignment.
Refer to Torque Chart for correct torque values for wheel nuts.
1473
OSHA Standards
The Occupational Safety and Health Administration (OSHA) has established rules and regulations pertaining
to servicing Multi-Piece Rim Wheels.
The text herein refers to selected excerpts from OSHA standard. For complete details, refer to complete
OSHA standard 1910.177 to ensure compliance.
Basically, regulations state that it is up to employer to provide employee training to instruct all employees who
service multi-piece rims in safety hazards involved and safety procedures to be followed.
The employer shall see that no employee services multi-piece or single piece rim wheels unless trained, and
demonstrates and maintains ability to service multi-piece rim wheels safely.
This shall include following tasks:
1. Demounting of tires, which includes deflation.

2. Inspection of components.
3. Mounting of tires, which includes inflator with restraining device.
4. Use of restraining device.
5. Handling of wheels.
6. Inflation of tires when a wheel is mounted on vehicle.
7. An understanding of necessity of standing outside trajectory both during inflation of tire and during
inspection of rim wheel following inflation.
8. Installation and removal of wheels.
OSHA also states type of tire servicing equipment to be used.
1. Restraining device (inflation cage).

2. Clip-on-chuck with enough hose to permit employees to stand clear of potential trajectory of
wheel components. An in-line valve with gauge or pressure regulator preset to a desired value
must also be provided.
3. Current charts must be posted in service area.
4. Current rim manual containing instructions for types of rims being serviced shall be available
in service area.
5. The employer must assure that only tools recommended in rim manual are used to service
multi-piece rim wheels.
1474
Wall Charts
The National Highway Traffic Safety Administration (NHTSA) has prepared two charts which are to be
posted in rim wheel service area. These charts alert service personnel of hazards involved when working
with multi-piece wheels.
One chart is called ‘Safety Chart’ which illustrates proper safety precautions to be followed when servicing
truck and bus multi-piece wheels.
The second chart is called ‘Matching Chart’ which provides guidance of various wheel makes and components
which can be safely interchanged.
These charts are available to all persons who service multi-piece wheels as follows:
Individuals who service such wheels may obtain a single copy of each chart, without cost, by writing:
General Services Division/Distribution

National Highway Traffic Safety Admin.
400 Seventh Street, S.W.
Washington, D.C. 20590
Establishments and other organizations desiring these charts may order same in any quantity desired from:
Superintendent of Documents
Government Printing Office (GPO)
Washington, D.C. 20402
The GPO ordering numbers for charts are:
Safety Chart #050-003-0315-8

Matching Chart #050-003-00316-6
1475
Care and Maintenance

Wheel rims should be periodically inspected both on vehicle and during tire changes for cracks, loose wheel
studs, worn mounting holes or being bent.
Disc wheels have rims which are integral with wheel itself; important thing to note is that wheel stud nuts
must be kept tight. This means they should be inspected and tightened at regular intervals. When checking
mounting studs and nuts on dual disc wheels (Figure 16), outer nut should be backed off before attempting to
tighten inner nut. Try all cap nuts after first trip or any wheel change. When properly installed, they should
remain tight indefinitely.
Figure 764 Dual Disc Wheel Installation

1. Inner Wheel 4. Outer Nut
2. Outer Wheel 5. Stud
3. Inner Nut
Left-hand thread nuts can be identified by small groove machined around flats, or letter ‘L’ stamped on nut.
Left-hand studs can be identified by letter ‘L’ stamped on head. Use left-hand nuts on left side of vehicle
Whenever a tire is removed, clean off all grease and road dirt. Use a wire brush or steel wool to remove
rubber from wheel/rim bead seat.
Projections on side wall of gutter may cause uneven seating of side ring and lead to chipping of gutter.
Remove these and other projections in mounting area to assure best possible fits.
Nicks and gouges in vicinity of fixed flange may lead to rim fracture.
Do not heat or weld wheels or rims in an attempt to straighten or repair severe road damage; replace
component. The special alloy used in these components is heat-treated, and uncontrolled heating from
welding torch affects properties of material.
To avoid possible corrosive effects to aluminum wheels, use only a slight amount of water and neutral soap
(similar to Ivory Snow, etc. - no detergents) when mounting tires. Do not use commercial rubber lubricants.
Do not allow dirt to enter mounting area during installation.
Wheel Studs and Mounting Nuts
Maintaining wheel stud and mounting nut tightness does much to insure safe and satisfactory wheel operation.
Loose wheel mounting can cause vibration, shimmy, tire wear, stud breakage, worn studs, mounting nuts
(Figure 17) and worn or elongated stud holes (Figure 18). Parts with these characteristics must be replaced.
Always keep wheel stud nuts tightened to specified torque. Refer to Torque Chart for correct torque values.
1476
Figure 765 Defective Mounting Nut
Figure 766 Elongated Stud Holes
Check for uniform seating of nuts (Figure 19). It is extremely important that various nuts are not interchanged
or intermixed. Nut on top is in good condition. The one on bottom is exemplary of a scarred and galled nut
that should be replaced.
1477
Figure 767 Comparing Mounting Nuts
Rust streaks (Figure 20) from stud holes are a good indication that mounting nuts are not tightened to
specified torque.
Figure 768 Indication of Loose Mounting Nuts
Before mounting wheel assemblies on vehicle, make sure all parts are clean and free from foreign matter.
Excess paint on wheel mounting face stud hole perimeters can cause wheel mounting nuts to loosen with use.
1478
Installation, Tightening, and Alignment (Lateral Run-Out)
Disc Wheels
When installing disc wheels, be certain that threads on studs and nuts are clean to permit correct torquing of
nuts. Mounting surfaces of rims, wheels, spacer rings and clamps should be free of dirt, rust or damage. Use a
wire brush to clean mounting contact surfaces. Do not use lubricant on threads.
After rim or wheel has been properly torqued, assembly should be checked for tire lateral run-out. This can be
accomplished by attaching a tire run-out dial indicator to a steady, firm surface and placed to just barely touch
outside surface of tire curb rib (Figure 21). If this area is scuffed, cut or gouged, you will get an improper reading
on dial indicator. The lateral run-out on front steering tires should not exceed 0.125 in. For rear axles with dual
wheels, lateral run-out should not exceed 0.187 in. If lateral run-out exceeds se measurements, check for bent
or cocked rims, improperly adjusted wheel bearings, and/or improper tire bead seating. Make corrections as
needed. Loosen all lug nuts and rim clamps and re-torque to specifications. Then re-check lateral run-out.
Figure 769 Checking Total Lateral Run-out
1479
Disc Wheels with (Ball Seat) Nuts

1. Slide inner/rear or front tire and wheel in position over studs and push back as far as possible. Use care to
avoid damage to threads on studs and inspect valve stem to caliper for clearance if applicable.
2. Install wheel nut on front wheels and inner wheel nut on rear dual wheels. Run nuts on studs until nuts
start to contact wheel. Rotate wheel a half turn to allow parts to seat naturally.
3. Draw up stud nuts alternately following sequence (crisscross pattern) illustrated in Figure 24. Do not fully
tighten nuts at this time. This procedure will allow a uniform seating of nuts and insure even face-to-face
contact of wheel and hub.
Figure 770 Disc Wheel Tightening Sequence
4. Continue tightening nuts to torque value in Torque Chart, using same alternating method shown in
Figure 24.
5. Install outer rear wheel and nuts. Repeat preceding method. Be sure that both inner and outer tire valve
stems are accessible.
6. After operating vehicle approximately 50 miles (80 km), check stud nuts for tightness. Some natural seating
of parts may be encountered and torque on nuts will drop. Retighten all nuts to specified torque value.
To check and tighten inner wheel to proper torque, first loosen outer wheel nuts several turns and tighten inner
nuts, then retighten outer nuts (rear wheel only).
To prevent losing seating of outer wheel when checking inner wheel torque, it is suggested that alternate outer
nuts be loosened and tighten inner nuts, then retighten outer nuts. Then loosen remaining outer nuts, tighten
inner nuts and then retighten outer nuts.
Once each week inspect and re-torque wheel stud nuts, if necessary (Figure 23).
1480
Disc Wheels with Flange Nuts

Refer to Figure 25 and Figure 26 for cross section view of flange nut installation.
Figure 771 Flange Nut System, Front Wheel Mounting

2. Wheel 5. Wheel Hub
3. Brake Drum
Figure 772 Flange Nut System, Rear Wheel Mounting

2. Wheels 5. Wheel Hub
3. Brake Drum
1. Slide inner rear or front tire and wheel in position over studs and push back as far as possible. Use care so
that threads on studs are not damaged. Inspect valve stem to brake caliper for clearance, if applicable.
1481
2. Position outer rear tire and wheel in place over studs and push back as far as possible. Again use care so
that threads on studs are not damaged.
3. Run nuts on studs until nuts contact wheel or wheels. Rotate wheel assembly a half turn to permit parts
to seat naturally.
4. Draw up nuts alternately following (crisscross pattern) sequence illustrated in Figure 24. Do not fully
tighten nuts at this time. This procedure will allow uniform seating of nuts and assure even face-to-face
contact of wheel and hub.
5. Continue tightening nuts to values in Torque Chart use same alternating method shown in Figure 24.
Once each week inspect and re-torque wheel stud nuts, if necessary (Figure 23).
1482
Wheel and Tire Balancing

Front wheel and tire assemblies must be balanced to prevent wheel vibration and bounce. While correct
front wheel alignment is necessary for easy steering and maximum tire life, cause of unstable steering can
frequently be traced to improper balance of front wheels. When this condition exists, wheel and tire assembly
should be properly balanced.
A vulcanized or retreaded tire, or a tire that has a boot in it, Must Not be used as a front steering tire.
Static Balancing
A wheel out of balance statically has a tendency to bounce up and down, resulting in rapid tire wear in round
or oblong spots.
Static balancing is performed while wheel is stationary by attaching weights to rim flange to offset an opposite
heavy point.
Static balancing may be sufficient in some instances where vehicle is operated only at slow speeds, however,
dynamic balancing (in motion) balances wheel and tire assembly statically as well as dynamically, thereby
eliminating vibrations and wheel bounce at both low and high speeds.
A wheel may be perfectly balanced statically (not in motion) but may still vibrate and bounce at high speed
rotation because of its being out of balance dynamically.
Dynamic Balancing
Dynamic balancing is complete wheel balancing procedure of which static balancing is only a part.
Dynamic balancing (in motion) takes into consideration distribution of weight to be added to wheel. This is
accomplished by rapidly rotating (normal truck operating speed) wheel and tire assembly either on vehicle
or with wheel assembly removed and placed on a dynamic balancing machine. This determines heavy
point on wheel.
When amount of weight required to offset a heavy part in a wheel assembly is known, it is sometimes
necessary to attach one half of weight to outside rim flange and remaining half to inside rim flange.
With weight properly distributed on wheel assembly, wheel should be in balance both statically and dynamically
and should rotate free of vibration and bounce at normal truck operating speeds.
1483
Tire Care
Inspection
A regular program of tire inspection is essential for prevention of rapid air loss failures. At a minimum, tires
should be inspected at time of regular preventive maintenance checks.
In any tire inspection routine, tires should be inspected for lowing conditions. If any are found, tire should be
removed and repaired, retreaded or scrapped as condition indicates.
1. Any blister, bump or raised portion anywhere on surface of tire tread or sidewall (other than a
bump made by a repair). These indicate start of internal separation.
2. Any cut that reaches to belt or ply cords, or any cut that is large enough to grow in size and depth.
3. Any nail or puncturing object.
4. If any stone or object is held by a tread groove and is starting to drill into tread base, remove object.
5. Look for skid spots and irregular wear conditions.
Proper tire inflation, tire loads, and road speeds are important determining factors governing tire mileage,
and also affect steering ease and maneuverability. How much these factors affect tire wear is illustrated in
paragraphs which follow.
Inflation
Tire pressures should be checked at regular and frequent intervals and pressures maintained to specifications.
Use an accurate tire pressure gauge and check when tires are cool.
Over-inflated or under-inflated tires will reduce service life of tire.
Never ‘bleed’ (remove) air from hot tires. The pressure will be reduced but an increase in temperature will
result as soon as driving continues.
Loads
Loading vehicles beyond tire load capacity decreases tire life, requiring more frequent replacement of tires.
Tire Matching
Dual Tires
Dual tires should be matched using tires of equivalent size. Tires which differ more than 1/4 in. (6.35 mm) in
diameter or 3/4 in. (19.05 mm) in circumference should not be mounted on same dual wheel. The larger or
less worn tire should be mounted on outside.
Tandem Drive Axles

When mounting tires on tandem drive axles, follow same instructions as specified for dual tires. However,
never install four largest tires on one driving axle and four smallest on other. This method of tire mounting will
cause high axle lubricant temperatures which may lead to premature axle failures.
Front Wheel Drive, 4x4, 6x6 and 8x6

Replacement tires must have same rolling radius as original equipment tires to avoid damage to drive train
components and to have proper steering effort. Refer to line setting ticket for original equipment tire size.
1484
Radial and Bias Ply Tires
It is recommended for best overall performance that only bias or only radial tires be used on a vehicle.
However, different heavy truck tires may be used under following conditions:
1. If radials are mixed with bias tires, best handling will be obtained with bias tires on steer axle.
2. Bias or radial tires may be used on either axle of two-axle vehicles, providing vehicle has dual rear
wheels or is equipped with wide-base single tires.
3. Either bias or radial tires may be used on steering axle of vehicles with three or more axles. Either
all bias or all radial tires should be used on non-steering axles.
4. Never mix different tire sizes or tire constructions on same axle.
5. Never mix bias and radial tires in a tandem or multiple axle combination.
Rotation
Rotation Is Always Advisable:

1. If front (steering) axle tires become irregularly worn, move to rear drive axle or trailer position.
2. In a dual assembly, if one tire wears much faster than its mate, reverse position of tires.
Rotation May Be Advisable:

1. If tires are highway type tread design:
Front (Steering) Axle: When required, replace tire when tire tread is worn to 1/8 inch (3.17mm) or less.
Rotate worn tires to any other position. Retreaded or recapped tires are not to be used on steering axles.
Rear and Trailer Axles: Tires must be removed when tread is worn to no less than 1/16 inch (1.58mm).
However, tires identified by word "regroovable" molded on sidewall can be regrooved.
2. If rib or highway type tire is used on front axle and lug or off-road type on rear axle positions:
Front (Steering Axle) : Install new tires at front wheels when tread is worn to 1/8 inch (3.17 mm) or
less. These tires can be moved to trailer positions.
Rear and Trailer Axles: Tires must be removed when tread is worn to 1/16 inch (1.58 mm) or less. Tires
identified with word "regroovable" molded on sidewall can be regrooved.
Alignment - Front Axle
Before any alignment adjustment is performed, always check vehicle for loose king pins, worn wheel bearings
and tire rod ends, or any looseness in steering system. Attempts to correct alignment on a vehicle with worn
components are fruitless. Refer to Group 02 - Front Axles in CTS-5000 Master Service Manual for front axle
alignment information.
Alignment - Rear Axle
In recent years, importance of drive-axle alignment has become increasingly evident. Tandem-drive axles
that are not parallel to each other or axles that are not perpendicular to chassis center line have a definite
effect on steer tire wear. For rear axle alignment information, refer to Group 14 - Rear Axles in CTS-5000
Master Service Manual.
1485
Tire Wear
Radial tires can exhibit three types of normal wear patterns: 1. Even, 2. Erosion, 3. Shoulder.
Even Wear. Like a bias tire, radial tires which have an even wear pattern is a sign that they are being properly
used and maintained.
Erosion Wear has also been called rolling wear, channel or river wear and can be found in both bias or radial
tires. Erosion wear is found more often at free rolling tires. This is an indication that tire is used in a slow
wearing operation. What happens is that belt plies are held very rigid and tread is not allowed to distort
as it passes through contact area. Wear will only occur at edge of tread. The tire is not being worn fast
enough through normal driving. No corrective action required. If erosion gets to be 1/16 in. (1.588 mm) or
more, tire should be rotated.
Shoulder Wear even with tires inflated properly is a normal wear of certain radial tire designs. If both inside
and outside shoulders are wearing evenly around tire, no further action is required. Do not over-inflate tire to
correct this effect. To do so could lead to premature failure when impact of road hazard is encountered.
1486
Service Load and Inflation Charts
Service Load and Inflation Chart (not Michelin) (For Trucks, Buses and Trailers in Normal Highway
Service) (Page 1)
Tire Size Tire Load Limits (Pounds) at Various Cold Inflation Pressures (psi)
Designations
Tube Tube- 65 70 75 80 85 90 95 100
Type less
8R19.5 D 2350 2460 2570 2700 2780 2880 3000 3070
S 2410 2540 2680 2800 2930 3060 3170 3280
9R22.5 D 3120 3270 3410 3550 3690 3820 3950F 4070
S 3190 3370 3560 3730 3890 4050 4210 4350
10R22.5 D 3690 3870 4040 4200 4375 4520 4670 4875F
S 3770 4000 4210 4410 4610 4790 4970 5150F
10.00R20 11R22.5 D 4760F 4950 5120 5300 5470
S 4990 5220 5430F 5640 5840
11.00R20 12R22.5 D 5190 5390 5590 5780G 5960
S 5450 5690 5920 6140 6370
12.00R20 D 5910 6140 6360 6580 6790
S 6200 6480 6740 7010 7250
14.00R20 D 8120 8430 8740 9030 9320
S 8510 8890 9260 9610 9960
11R24.5 D 5070 5260 5450 5640 5820
S 5310 5550 5780 6000 6210
11.00R22 12R24.5 D 5520 5730 5940 6140 6330
S 5790 6040 6290 6530 6770
12.00R24 D 6650 6910 7160 7410 7640
S 6980 7280 7580 7880 8160
D = Dual Tire Usage
S = Single Tire Usage
Letters listed with loads designate maximum load range for that load range. Do not exceed rim load or
inflation limits
1487
Service) (Page 2)
Tire Size Tire Load Limits (Pounds) at Various
Designations Cold Inflation Pressures (psi)
Tube Tube- 105 110 115 120
Type less
8R19.5 D 3160 3375F
S 3400 3500F
9R22.5 D 4200
S 4500F
10R22.5 D 4970 5110 5250G
S 5320 5490 5680G
10.00R20 11R22.5 D 5750G 5800H
S 6175G 6240 6430 6610H
11.00R20 12R22.5 D 6150 6320 6500 6750H
S 6590G 6790 7010 7390H
12.00R20 D 7000 7200J
S 7500 7740 7980 8210J
14.00R20 D 9610L
S 10300 10620 10960L
11R24.5 D 6000G 6170H
S 6430G 6630 6840 7030H
11.00R22 12R24.5 D 6530 6720H
S 7000 7220 7440 7660H
12.00R24 D 7870 8100J
S 8450 8710 8970 9230J
D=Dual Tire Usage
S=Single Tire Usage
Letters listed with loads designate maximum load range for that load
range. Do not exceed rim load or inflation limits
1488
Service) (Page 3)
Designations
Tubeless 50 55 60 65 70 75 80 85 90 95 100
225/ 70R19.5 D 2150 2300 2445 2600 2720 2860 3000E 3115 3245 3415F 3490
S 2270 2445 2600 2755 2895 3040 3195E 3315 3450 3640F 3715
245/70R19.5 D 2755 2910 3070 3220 3415 3515 3655 3875F 3940 4075 4375G
S 2930 3085 3265 3425 3640 3740 3890 4080F 4190 4335 4545G
265/70R19.5 D 2755 2900 3085 3195 3430 3600 3750 3930 4095 4300 4405
S 2910 3085 3280 3415 3650 3830 3970 4180 4355 4540 4685
245/75R22.5 D 2600 2760 2930 3085 3260 3425 3640 3740 3890 4080 4190
S 2755 2935 3115 3305 3470 3645 3860 3980 4140 4300 4455
255/70R22.5 D 2835 3030 3220 3415 3585 3765 3970 4110 4275 4410 4455
S 3000 3225 3425 3640 3815 4005 4190 4370 4550 4675 4895
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that load range. Do not exceed rim load and/or
inflation limits.
Service) (Page 4)
Tire Size Tire Load Limits (Pounds) at Various
Designations Cold Inflation Pressures (psi)
Tubeless 105 110 115 120
225/ 70R19.5 D 3615 3750G
S 3845 3970G
245/70R19.5 D 4500 4625H
S 4620 4805H
265/70R19.5 D 4560 4805 4860 5070G
S 4850 5070 5170 5355G
245/75R22.5 D 4335 4410G
S 4610 4675G
255/70R22.5 D 4610 4675G 5070H
S 5065 5205G 5510H
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that
load range. Do not exceed rim load and/or inflation limits.
1489
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway
Service) (Page 5)
Tire Size Designations Tire Load Limits (Pounds) at Various Cold Inflation
Pressures (psi)
Tube Type Tube- less 65 70 75 80 85 90 95 100
9R22.5 D 3474 3671 3835 4050 4300F
S 3700 3912 4050 4307 4540F
10R22.5 D 3914 4131 4349 4566 4740F 4995
S 4255 4490 4725 4962 5150F 5600
10.00R20 11R22.5 D 4224 4450 4650 4922 5180 5750G
S 4692 4950 5215 5470 5755 6175G
11.00R20 12R22.5 D 4425 4675 4950 5200 5500 5800
S 4990 5280 5570 5870 6155 6455
12.00R20 D 4629 4815 5181 5435 5725 5966
S 5197 5512 5827 6117 6447 6725
14.00R20 D 8077 8473 8887 9232
S 8832 9287 9782 10197
11R24.5 D 3640 3993 4224 4455 4693 4923 5180 5790G
S 4390 4705 4960 5235 5513 5780 6105 6430G
11.00R22 12R24.5 D 4915 5116 5300 5520 5730 5940 6140 6330
S 5060 5303 5520 5790 6040 6290 6530 6770
12.00R24 D 5922 6167 6390 6650 6910 7160 7410 7640
S 6135 6420 6660 6980 7280 7580 7880 8160
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that load range. Do not exceed rim load
and/or inflation limits
1490
Service) (Page 6)
Tire Size Designations Tire Load Limits (Pounds) at Various
Cold Inflation Pressures (psi)
Tube Type Tube- less 105 110 115 120
9R22.5 D
S
10R22.5 D 5080G
S 5680G
10.00R20 11R22.5 D 5778 5880 5950H
S 6245 6427 6610H
11.00R20 12R22.5 D 6100 6400 6750H
S 6740 7030 7390H
12.00R20 D 6255 6500 6755 7160J
S 7055 7330 7605 8270J
14.00R20 D 9645 9900M
S 10692 11000M
11R24.5 D 5970 6150 6330H
S 6630 6830 7030H
11.00R22 12R24.5 D 6530 6720H
S 7000 7220 7440 7660H
12.00R24 D 7870 8100J
S 8450 8710 8970 9230J
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that load range. Do
not exceed rim load and/or inflation limits
1491
Service) (Page 7)
Designations
Tubeless 65 70 75 80 85 90 95 100
225/ 70R19.5 D 2920 3085 3250 3415F
S 3040 3220 3405 3640F
245/70R19.5 D 3315 3415 3515 3655 3860F 4025 4197
S 3540 3640 3740 3890 4080F 4218 4412
265/70R19.5 D 3400 3610 3820 4030 4235 4445 4655
S 3570 3795 4020 4240 4465 4690 4910
285/70R19.5 D 3620 3843 4070 4290 4518 4743 5071
S 3935 4175 4425 4665 4910 5155 5511
305/70R19.5 D 4108 4354 4600 4840 5079 5328 5583
S 4388 4658 4928 5180 5440 5705 5965
235/80R22.5 D 3813 4035 4277 4410G
S 4035 4277 4542 4675G
255/70R22.5 D 3521 3712 3905 4096 4280 4420
S 3810 4022 4235 4447 4652 4805
255/80R22.5 D 3910 4135 4355 4575 4810G
S 4235 4465 4710 4960 5205G
275/80R22.5 D 4350 4587 4832 5070 5335 5675G
S 4825 5090 5365 5625 5920 6175G
295/80R22.5 D 4375 4698 4960 5222 5483 5744
S 5065 5360 5645 5930 6215 6500
315/80R22.5 D 4798 5105 5413 5780 6055 6330
S 5850 6140 6435 6675 6995 7310
275/80R24.5 D 3833 4112 4350 4587 4832 5070 5335 5675G
S 4285 4560 4825 5090 5365 5625 5920 6175G
305/75R24.5 D 5222 5483 5744 6005 6267 6528 6789 6945H
S 5358 5645 5930 6215 6500 6788 7078 7368
Service) (Page 8)
Tire Size
Tire Load Limits (Pounds) at Various Cold Inflation Pressures (psi)
Designations
Tubeless 65 70 75 80 85 90 95 100
385/65R22.5 S 6333 6640 6940 7280 7580 7890
425/65R22.5 S 7670 8000 8400 8840 9220 9590
445/65R22.5 S 8033 8465 8850 9330 9780 10240
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that load range. Do not exceed rim load
and/or inflation limits.
1492
Service) (Page 9)
Tire Size Tire Load Limits (Pounds) at Various Cold
Designations Inflation Pressures (psi)
Tubeless 105 110 115 120 125 130
225/ 70R19.5 D
S
245/70R19.5 D 4368 4540G
S 4609 4805G
265/70R19.5 D 4860 5070G
S 5135 5355G
285/70R19.5 D 5217 5375 5675H
S 5733 5963 6175H
305/70R19.5 D 5843 6085 6395J
S 6223 6470 6780J
235/80R22.5 D
S
255/70R22.5 D 4540 4852 5070H
S 5000 5273 5510H
255/80R22.5 D
S
275/80R22.5 D
S
295/80R22.5 D 6005 6267 6780H
S 6788 7078 7390H
315/80R22.5 D 6605 6885 7160 7560 7893 8255L
S 7630 7950 8270 8485 8750 9000L
275/80R24.5 D
S
305/75R24.5 D
S 7658 7830H
Service) (Page 10)
Tire Size Tire Load Limits (Pounds) at Various Cold
Designations Inflation Pressures (psi)
Tubeless 105 110 115 120 125 130
385/65R22.5 S 8220 8530 8900 9150 9370J
425/65R22.5 S 10000 10500 10740 11110 11400L
445/65R22.5 S 10655 11070 11490 11945 12320 12800L
D = Dual Tire Usage
Letters listed with loads designate maximum load range for that load range. Do not
exceed rim load and/or inflation limits.
1493
Tire and Rim Combinations
Tire and Rim Combinations - Tires Designed for Normal Highway Service
Tube Type Tubeless
Tire Size Rim Width Tire Size Rim Width
14/80R20 10.00 225/70R19.5 6.00, 6.75
365/80R20 10.00 235/80R22.5 6.75, 7.50
245/70R19.5 6.75, 7.50
255/70R22.5 7.50, 8.25
265/70R19.5 6.75, 7.50, 8.25
275/80R22.5 7.50, 8.25
285/75R24.5 7.50, 8.25
295/75R22.5 7.50, 8.25
315/80R22.5 9.00
385/65R22.5 12.25
425/65R22.5 12.25, 13.00
445/65R22.5 13.00, 14.00
WARNING
Do not mount tube type tires on tubeless wheels or tubeless tires on tube type wheels.
To do so could result in severe personal injury.
CAUTION
Always use approved tire and rim combinations for diameters and contours. After
mounting dual tires, insure tires do not contact each other under a loaded condition.
CAUTION
Not applicable for ML (Mining and Logging) tires.
1494
Ply Rating Verses Load Range
Load Range Replaces Ply Rating

D 8
E 10
F 12
G 14
H 16
J 18
L 20
M 22
N 24
1495
Torque Chart
Disc Wheels Torque
Nut Mounting
11/16 in. Flange 350 to 400 lb-ft (475 to 543 N·m)
22 mm Flange Motor Wheel - 37.5 mm across flats or 450 to 500 lb-ft (610 to 678 N·m)
International® / Budd - 33 mm across flats
Ball Seat (Conical Nut)
¾ in. Standard Square Cap: 13/16 in. across flats or 1-½ in. 450 to 500 lb-ft (610 to 678 N·m)
across flats
1-1/8 in. Standard Hex Cap: 1-¾ in. across flats 450 to 500 lb-ft (610 to 678 N·m)
15/16 in. Heavy Duty Square Cap: 15/16 in. across flats 750 to 900 lb-ft (1017 to 1221 N·m)
1-5/16 in. Heavy Duty Cap: 1-¾ in. across flats 750 to 900 lb-ft (1017 to 1221 N·m)
Dry Threads - No Lubrication
Where excessive corrosion exists, a light coat of lubricant on first three threads of stud bolt is permitted.
Keep lubricant away from cap nut ball faces, or ball seats of disc wheels and rim clamps of cast wheels.
1496

2017 - 2020 HX Technician Manual (Service and Diagnostic)

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2017–2020 HXTM Technician Manual (Service and Diagnostic)

2701 Navistar Drive, Lisle, IL 60532 USA

08 Electrical / Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

09 Front End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773

10 Fifth Wheel and Misc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797

14 Rear Axle and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083

15 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1123

27 Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1459

28 Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1463

NOTE – To order technical service literature, contact your International dealer.

• Clear the area before starting the engine.

1. Type A — Wood, paper, textiles, and rubbish

• Check for frayed power cords before using power tools.

Fluids Under Pressure

Removal of Tools, Parts, and Equipment

2. Set Forward Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Set Back Axle

Figure 1 Multi-leaf Front Suspension

• Nodular iron brackets which add strength

Parabolic Taper Leaf

Figure 2 Parabolic Taper Leaf Front Suspension

Parabolic Taper Leaf Springs

Suspensions include following features:

• Rubber bushings which require no lubrication

Increased Capacity Parabolic Taper Leaf Springs

These increased capacity parabolic tapered leaf springs include:

• Nodular iron and stamped steel brackets for increased strength

Front Suspension Rubber Auxiliary Springs

Multi-leaf Slipper Type with Torque Rod

Figure 3 Slipper Type with Torque Rod Front Suspension

These front springs include:

• Nodular Iron Brackets

2. Set Forward Axle

Figure 4 Multi-leaf Front Suspension

• Nodular iron brackets which add strength

Parabolic Taper Leaf

Figure 5 Parabolic Taper Leaf Front Suspension

Suspensions include following features:

• Rubber bushings which require no lubrication

Increased Capacity Parabolic Taper Leaf Springs

These increased capacity parabolic tapered leaf springs include:

• Nodular iron and stamped steel brackets for increased strength

Front Suspension Rubber Auxiliary Springs

Figure 6 ABS System Wheel Speed Sensor Locations

Figure 7 ABS System Wheel Modulator Valve Locations

Figure 8 Bendix® EC‑‑80™ Location

Bendix® ESP® EC‑‑80™ Controller Service Information

Bendix® EC‑‑80™ ABS/ATC Controller Service Information

Modulator Valve M-40

Figure 11 Air Modulator Valve

4. Disconnect electrical connector (5) from air modulator valve (2).

Figure 12 Air Modulator Valve

1. If different valve is used than in removal, transfer fittings to new valve.

3. Connect electrical connector (5) to air modulator valve (2).

Steering Angle Sensor

Steering Angle Sensor w / A26

Figure 15 Steering Angle Sensor

2. Mark steering shaft position.

Figure 16 Steering Shaft U-joint

Refer to above illustration when performing following steps:

Figure 17 Steering Angle Sensor

Refer to above illustration when performing following steps:

Figure 18 Steering Angle Sensor