International Trucks Models CXT, MXT, RXT, TerraStar Repair Service Manuals
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Complete service repair manual with Electrical Wiring Diagrams for International/Navistar Trucks Models CXT, MXT, RXT, TerraStar, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
International / Navistar Trucks Models CXT, MXT, RXT, TerraStar workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,560 pages
File Format: PDF
Language: English
0000002601 - 3200, RXT, DuraStar - 4100, 4300, 4400, TranStar Natural Gas (NG), TranStar - 8500, 8600, WorkStar - 7300, 7400, 7500, 7600, 7700 Wiring Diagrams.pdf
S08322 - 3200, 4100, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, RXT March 2007 to March 2008 Electrical Wiring Diagrams.pdf
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams.pdf
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026) Service Manual.pdf
S13038 - MXT Magna MP1528 Transfer Case - Service and Electrical Troubleshooting Manual.pdf
S02013 - Carraro Axle Repair Manual and Parts Catalog (Feb 2009) Service Manual.pdf
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT, DuraStar, TranStar, WorkStar and RXT.pdf
0000002842 - 3200 DuraStar - 4100, 4300, 4400 WorkStar - 7300, 7400, 7500, 7600, 7700 TranStar - 8500, 8600 RXT Electrical Circuit Diagrams.pdf
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar Models Service Manual.pdf
S16046- HEAT VENTILATION AIR CONDITIONING (HVAC) for 2010 TerraStar, DuraStar, WorkStar, TranStar, 3200 Bus HVAC Service Manual.pdf
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models After March 01, 2007 Electrical System Troubleshooting Guide Manual.pdf
S08361 - DuraStar, TerraStar, TranStar, and WorkStar Models Built May 2010 & Later Electrical Troubleshooting Manual.pdf
0000002529 - TerraStar Electrical Circuit Diagrams (Supersedes S08362) Circuit Diagrams.pdf
S04051 - FULL POWER HYDRAULIC ABS BRAKE SYSTEM Service Manual.pdf
S09013 - Hood, Grille, Fenders, Bumper and Running Boards Service Manual.pdf
S04054 - TerraStar Truck Brake System Service Manual.pdf
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual.pdf
S04050 - Full Power Hydraulic ABS Brake System Service Manual.pdf
S04054 - Brake System Service Manual (Sept 2012) Service Manual.pdf
S12037 - Radiator _ Cooling System (July 2012) Service Manual.pdf
S12019 - Radiator, Removal and Replacement Service Manual.pdf
0000002529 - TerraStar Wiring Diagrams Manual.pdf
S09017 - Hood, Grille, Fenders and Bumper (Oct 2010) Service Manual.pdf
S16036 - CAB - MXT Service Manual.pdf
S08327 - 2007 - 2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual.pdf
S05025 - Steering Wheel and Steering Column Assembly Service Manual.pdf
S05016 - Steering Wheel Removal and Installation Service Manual.pdf
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes.pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10.pdf
TABLE OF CONTENTS
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10....1
toc....3
Summary of Changes....3
1. Description....9
1.1. Theory of Operation....15
Aftertreatment regeneration burns soot to ash when excess soot buildup occurs. For regeneration to occur, the Engine Control Module (ECM) must detect a DPF restriction by monitoring temperature and pressure sensors.....15
1.2. Switchback / Horizontal....16
1.3. Vertical / Vertical....17
1.4. In-Line....18
2. General Service Information....19
2.1. Exhaust Aftertreatment System Modifications....20
2.2. Gaskets and Fasteners....21
2.3. Diesel Particulate Filter (DPF) Indexing....21
2.4. DPF and DOC Cleaning....21
2.5. DPF General Inspection....22
DPF Inspection Points....23
2.6. DOC General Inspection....26
DOC Inspection Points....26
2.7. DPF / DOC Thread Repair....30
12 MM Thread Replacement....30
14 MM Thread Replacement....34
2.8. DOC and DPF Reuse Guidelines....38
General Information....38
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....39
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....40
Diesel Particulate Filter (DPF) Inlet / Outlet – New....41
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....42
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....43
Diesel Particulate Filter (DPF) Inlet – Clean....44
Diesel Particulate Filter (DPF) Inlet – Gouged....45
Diesel Particulate Filter (DPF) Inlet – Ash....46
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....47
Diesel Particulate Filter (DPF) Outlet – Soot Stains....48
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....49
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....50
Diesel Particulate Filter (DPF) Outlet – Face Cracked....51
Diesel Particulate Filter (DPF) Outlet – Coolant Staining....52
Diesel Particulate Filter (DPF) Outlet – Melted....53
2.9. Decomposition Reactor Tube Cleaning....54
2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....55
2.11. DEF Supply Module Filter Inspection....57
2.12. Diesel Exhaust Fluid (DEF) System Contamination....59
2.13. DEF System Decontamination Procedure....62
2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....63
Using the DEF Refractometer....63
DEF Refractometer Maintenance....65
2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....66
2.16. Diesel Exhaust Fluid (DEF) Tank Draining....69
3. Switchback / Horizontal....70
3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....70
Switchback / Horizontal – Removal....70
Switchback / Horizontal – Installation....72
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....73
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....74
Decomposition Reactor Tube – Removal....75
Decomposition Reactor Tube – Installation....76
Aftertreatment Assembly Mounting Bracket – Removal....77
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....78
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....79
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....79
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....81
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....81
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....83
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....83
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....84
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....84
(DPF) Temperature Sensors and Module – Removal....86
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....86
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....88
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....89
Diesel Particulate Filter (DPF) High Pressure Tube – Removal....90
Diesel Particulate Filter (DPF) High Pressure Tube – Installation....90
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....91
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....91
4. Vertical / Vertical ....92
4.1. Navistar® N13 Engine....92
Vertical / Vertical....92
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....93
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....93
Power Distribution Module (PDM) – Removal....94
Power Distribution Module (PDM) – Installation....94
Aftertreatment Control Module (ACM) – Removal....95
Aftertreatment Control Module (ACM) – Installation....95
5. In–Line....96
5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....96
In-Line....96
6. Diesel Exhaust Fluid (DEF) System....97
6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....97
Diesel Exhaust Fluid (DEF) Tank – Removal....97
Diesel Exhaust Fluid (DEF) Tank – Installation....100
Power Distribution Module (PDM) – Removal....101
Power Distribution Module (PDM) – Installation....101
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....102
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....105
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....106
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....108
Diesel Exhaust Fluid (DEF) Supply Module – Removal....109
Diesel Exhaust Fluid (DEF) Supply Module – Installation....110
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....111
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....111
Aftertreatment Control Module (ACM) – Removal....112
Aftertreatment Control Module (ACM) – Installation....113
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....114
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....115
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....116
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....117
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....118
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....119
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....120
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....122
Diesel Exhaust Fluid (DEF) System....123
7. Acronym List....124
tables....20
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components.....20
Table 32Acronym List.....124
Table 33Torque Chart.....125
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026) Service Manual....126
toc....128
Summary of Changes....128
1. DESCRIPTION....140
1.1. Standard Cab, Extended Cab and Crew Cab....140
1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....141
1.3. ELECTRIC WINDSHIELD WIPERS....142
1.4. WINDSHIELD WASHER....143
2. OPERATION....146
2.1. Electric Windshield Wipers....146
2.2. WINDSHIELD WASHER....146
3. MAINTENANCE....147
3.1. Windshield Washer....147
4. REMOVE....148
4.1. ONE PIECE ENCAPSULATED WINDSHIELD....148
Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and Crew Cab for all Models....148
4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....154
Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....154
4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....157
Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....157
4.4. HOOD SEAL....165
Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models....165
4.5. SUNSHADE....166
Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....166
4.6. SUN VISOR AND CLIP....166
Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....166
4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....168
Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....169
Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....171
4.8. INSTRUMENT PANEL....173
Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....173
4.9. CAB DOORS....177
Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....177
Remove Rear Cab Door on Crew Cab for All Models....181
4.10. Cab Door Hinge....186
Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....186
Remove Rear Cab Door Hinge on Crew Cab for all Models....187
4.11. CAB DOOR STRIKER PIN....189
Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for All Models....189
Remove Rear Cab Door Striker Pin on Crew Cab for all Models....190
4.12. CAB DOOR CHECK BRACKET....191
Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....191
Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models....192
4.13. CAB DOOR CHECK LINK....192
Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....192
Remove Rear Door Check Link on Crew Cab for all Models....193
4.14. CAB DOOR TRIM PANEL....195
Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....195
Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....197
Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....199
Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....201
4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....203
Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....203
Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models....205
4.16. CAB DOOR WINDOW SLIDE BLOCK....206
Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....206
Remove Rear Cab Door Window Slide Block on Crew Cab for all Models....207
4.17. CAB DOOR GLASS....209
Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....209
Remove Rear Cab Door Glass on Crew Cab for all Models....213
4.18. MODULAR DOOR HARDWARE ASSEMBLY....217
Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....217
Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....221
4.19. CAB DOOR VENT WINDOW....224
Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....224
4.20. CAB DOOR VENT WINDOW HINGE....225
Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....225
4.21. CAB DOOR VENT WINDOW SEAL....227
Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....227
4.22. CAB DOOR LOCK CYLINDER....227
Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and on Front and Rear Cab Doors of Crew Cab Models....227
4.23. CAB DOOR WINDOW ELECTRIC MOTOR....229
Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....229
Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models....230
4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....231
Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....231
Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....235
4.25. OUTER CAB DOOR HANDLE....236
Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....236
Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....240
4.26. CAB DOOR LATCH....241
Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....241
Remove Rear Cab Door Latch on Crew Cab for all Models....243
4.27. INNER CAB DOOR HANDLE....244
Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....244
Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....246
4.28. CAB DOOR WINDOW RUN CHANNELS....247
Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....247
Remove Rear Cab Door Window Run Channels on Crew Cab for all Models....250
4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....251
Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....251
Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....252
4.30. CAB DOOR ELECTRIC MIRROR SWITCH....253
Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....253
4.31. SEATS....254
Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....254
Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....256
Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....258
Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....258
Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....258
4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....260
Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....260
4.33. EXTENDED CAB BUNK/STORAGE UNIT....261
Remove Bunk/Storage Unit on Extended Cab for all Models....261
4.34. SIDE AND CORNER INTERIOR TRIM PANEL....262
Remove Side and Corner Interior Trim Panel on Standard Cab for all Models....262
Remove Side and Corner Interior Trim Panel on Extended Cab for all Models....263
Remove Side and Corner Interior Trim Panel on Crew Cab for all Models....264
4.35. Extended Cab Rear Side Window....266
Remove Rear Side Window on Extended Cab for all Models....266
Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models....268
4.36. REAR INTERIOR TRIM PANEL....269
Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....269
4.37. HEADER CONSOLE PANEL....269
Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....269
4.38. HEADLINER TRIM PANEL....273
Remove Headliner Trim Panel on Standard Cab for all Models....273
Remove Front Headliner Trim Panel on Extended Cab for all Models....274
Remove Rear Headliner Trim Panel on Extended Cab for all Models....276
Remove Front Headliner Trim Panel on Crew Cab for all Models....276
Remove Rear Headliner Trim Panel on Crew Cab for all Models....279
4.39. Crew Cab B - Pillar Trim Panel....280
Remove B - Pillar Trim Panel on Crew Cab for all Models....280
4.40. Cab Door Opening Weather Seals....280
Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....280
Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models....281
4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....282
Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....282
4.42. CAB COWL TRAY....283
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....283
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....285
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....287
4.43. WINDSHIELD WIPER ASSEMBLY....289
Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....289
4.44. ELECTRIC WINDSHIELD WIPER MOTOR....291
Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....291
4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....293
Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....293
4.46. Engine Cover And Cup Holder....297
Remove Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....297
Remove Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....297
4.47. CAB....300
General Procedures for Cab Removal....300
Remove Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....301
Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....302
Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....304
Remove Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab before January 2003....305
Remove Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models before January 2003....305
Remove Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....305
Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003....306
Cab with Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....307
Remove Low Mount Rear Cab Air Suspension for all Crew Cab Models....308
Remove Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....308
Remove Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....308
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....309
Remove Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....310
Remove Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....311
5. INSTALL....312
5.1. ONE PIECE ENCAPSULATED WINDSHIELD....312
Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and curative B) on Standard Cab, Extended Cab and Crew Cab for all Models....312
Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive on Standard Cab, Extended Cab and Crew Cab for all Models....328
5.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....333
Install Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....333
5.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....348
Install Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....348
5.4. HOOD SEAL....367
Install Hood Seal on Standard Cab, Extended Cab and Crew Cab for all Models....367
5.5. SUNSHADE....367
Install Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....367
5.6. SUN VISOR AND CLIP....368
Install Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....368
5.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....368
Install Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....368
Install Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....369
5.8. INSTRUMENT PANEL....369
Install Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....369
5.9. CAB DOORS....372
Install Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....372
Install Rear Cab Door on Crew Cab for all Models....372
5.10. CAB DOOR HINGE....374
Install Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....374
Install Rear Cab Door Hinge on Crew Cab for all Models....374
5.11. CAB DOOR STRIKER PIN....375
Install Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for all Models....375
Install Rear Cab Door Striker Pin on Crew Cab for all Models....375
5.12. CAB DOOR CHECK BRACKET....375
Install Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....375
Install Crew Cab Rear Door Check Bracket on Crew Cab for all Models....375
5.13. CAB DOOR CHECK LINK....376
Install Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....376
Install Crew Cab Rear Door Check Link on Crew Cab for all Models....376
5.14. CAB DOOR TRIM PANEL....376
Install Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....376
Install Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....377
Install Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....377
Install Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....378
5.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....379
Install Front Cab Door Inner Door Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....379
Install Rear Cab Door Inner Door Panel Water Shield on Crew Cab for all Models....379
5.16. CAB DOOR WINDOW SLIDE BLOCK....379
Install Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....379
Install Rear Cab Door Window Slide Block on Crew Cab for all Models....381
5.17. CAB DOOR GLASS....382
Install Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....382
Install Rear Cab Door Glass on Crew Cab for all Models....386
5.18. MODULAR DOOR HARDWARE ASSEMBLY....390
Install Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....390
Install Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....391
5.19. CAB DOOR VENT WINDOW....393
Install Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....393
5.20. CAB DOOR VENT WINDOW HINGE....393
Install Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....393
5.21. CAB DOOR VENT WINDOW SEAL....393
Install Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....393
5.22. CAB DOOR LOCK CYLINDER....394
Install Cab Door Lock Cylinder on Front Cab Door on Standard Cab, Extended Cab and Crew Cab Models and Rear Cab Doors on Crew Cab Models....394
5.23. CAB DOOR WINDOW ELECTRIC MOTOR....394
Install Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....394
Install Rear Cab Door Window Electric Motor on Crew Cab for all Models....395
5.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....395
Install Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....395
Install Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....397
5.25. OUTER CAB DOOR HANDLE....399
Install Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....399
Install Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....400
5.26. CAB DOOR LATCH....402
Install Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....402
Install Rear Cab Door Latch on Crew Cab for all Models....403
5.27. INNER CAB DOOR HANDLE....403
Install Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....403
Install Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....404
5.28. CAB DOOR WINDOW RUN CHANNELS....406
Install Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....406
Install Rear Cab Door Window Run Channels on Crew Cab for all Models....407
5.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....408
Install Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....408
Install Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....408
5.30. CAB DOOR ELECTRIC MIRROR SWITCH....408
Install Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....408
5.31. SEATS....409
Install Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....409
Install Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....409
Install Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....409
Install Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....410
Install Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....410
5.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....410
Install Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....410
5.33. EXTENDED CAB BUNK/STORAGE UNIT....411
Install Bunk/Storage Unit on Extended Cab for all Models....411
5.34. SIDE AND CORNER INTERIOR TRIM PANEL....411
Install Side and Corner Interior Trim Panel on Standard Cab for all Models....411
Install Side and Corner Interior Trim Panel on Extended Cab for all Models....412
Install Side and Corner Interior Trim Panel on Crew Cab for all Models....412
5.35. Extended Cab Rear Side Window....413
Install Rear Side Window Latch onto Rear Side Window on Extended Cab for all Models....413
Install Rear Side Window on Extended Cab for all Models....413
5.36. REAR INTERIOR TRIM PANEL....415
Install Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....415
5.37. HEADER CONSOLE PANEL....415
Install Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....415
5.38. HEADLINER TRIM PANEL....416
Install Headliner Trim Panel on Standard Cab for all Models....416
Install Front Headliner Trim Panel on Extended Cab for all Models....417
Install Rear Headliner Trim Panel on Extended Cab for all Models....417
Install Front Headliner Trim Panel on Crew Cab for all Models....418
Install Rear Headliner Trim Panel on Crew Cab for all Models....418
5.39. Crew Cab B - Pillar trim panel....419
Install B - Pillar Trim Panel on Crew Cab for all Models....419
5.40. Cab Door Opening Weather Seals....420
Install Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....420
Install Rear Cab Door Opening Weather Seals on Crew Cab for all Models....420
5.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....421
Install Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....421
5.42. CAB COWL TRAY....421
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....421
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....422
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....423
5.43. WINDSHIELD WIPER ASSEMBLY....423
Install Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....423
5.44. ELECTRIC WINDSHIELD WIPER MOTOR....424
Install Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....424
5.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....425
Install Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....425
5.46. Engine Cover And Cup Holder....425
Install Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....425
Install Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....426
5.47. CAB....427
Cab Squaring....427
Install Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....427
Install Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....427
Install Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....428
Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....428
Install Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....429
Install Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....429
Install Low Mount Rear Cab Air Suspension for all Crew Cab Models....429
Cab with Low Mount Front Cab Mounting for all Crew Cab Models and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....429
Install Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....430
Install Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....430
Install Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....430
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....431
General Procedures for Cab Installation....431
6. TROUBLESHOOTING....433
6.1. Electric Windshield Wiper Motor....433
6.2. WASHER PUMP MOTOR....434
7. LUBRICATION....435
7.1. 4000 Miles (6000 Km) Or Monthly....435
7.2. AS REQUIRED....435
8. ADJUSTMENTS....436
8.1. Cab Door....436
8.2. HINGE AT CAB HINGE PILLAR....436
8.3. STRIKER PIN AT LOCK PILLAR....437
8.4. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....439
8.5. CAB AIR SUSPENSION....440
9. FORMS....443
9.1. Bonded Windshield Replacement Report....443
10. Torque....445
10.1. Torque Chart....445
tables....433
Table 2Electric Windshield Wiper Motor....433
Table 3Washer Pump Motor....434
Table 4Torque Chart....445
0000002529 - TerraStar Electrical Circuit Diagrams (Supersedes S08362) Circuit Diagrams....452
0000002529 - TerraStar Wiring Diagrams Manual....691
0000002601 - 3200, RXT, DuraStar - 4100, 4300, 4400, TranStar Natural Gas (NG), TranStar - 8500, 8600, WorkStar - 7300, 7400, 7500, 7600, 7700 Wiring Diagrams....920
0000002842 - 3200 DuraStar - 4100, 4300, 4400 WorkStar - 7300, 7400, 7500, 7600, 7700 TranStar - 8500, 8600 RXT Electrical Circuit Diagrams....1640
S02013 - Carraro Axle Repair Manual and Parts Catalog (Feb 2009) Service Manual....2040
02EZM WSM_HS6.12-CA635078-CA643764_Doc270159-1ed-v02.pdf....0
Indice-Index....2046
A INFORMAZIONI GENERALI....2047
A.1 Utilizzo del manuale....2048
A.2 Proprietà delle informazioni....2049
A.3 Convenzioni e definizioni....2050
A.4 Indicazioni generali....2052
A.5 Indicazioni speciali....2053
A General information....2047
A.1 Manual use....2048
A.2 Information property....2049
A.3 Agreements and definitions....2050
A.4 General description....2052
A.5 Special recommendations....2053
B INFORMAZIONI SULLA SICUREZZA....2055
B.1 Indicazioni generali per la sicurezza....2056
B.2 Simboli di sicurezza....2057
B.3 Precauzioni generali....2058
B Safety instructions....2055
B.1 General safety recommendations....2056
B.2 Safety symbols....2057
B.3 General precautions....2058
C CARATTERISTICHE GENERALI....2060
C.1 Uso previsto....2061
C.2 Identificazione del prodotto....2061
C.3 Descrizione generale....2062
C.4 Caratteristiche Tecniche....2063
C.5 Manutenzione e cambio olio....2067
C.6 Grasso al montaggio....2070
C.7 Adesivi e coppie di serraggio....2071
C General specifications....2060
C.1 Intended use....2061
C.2 Product identification....2061
C.3 General description....2062
C.4 Technical Features....2063
C.5 Maintenance and oil change....2067
C.6 Grease in assembly....2070
C.7 Adhesives and tightening torques....2071
D SMONTAGGIO E ASSEMBLAGGIO....2075
D.1 Gruppo freno....2076
D.2 Gruppo mozzo ruota....2080
D.3 Gruppo calotta....2087
D.4 Gruppo supporto differenziale....2096
D.5 Gruppo differenziale....2104
D.6 Gruppo pignone....2108
D.7 Gruppo trave....2118
D.8 Convergenza/angolo di sterzata....2120
D.9 Interventi speciali....2123
D.10 Prove dopo montaggio....2130
D Disassembly and assembly....2075
D.1 Brake group....2076
D.2 Wheel hub group....2080
D.3 Swivel housing group....2087
D.4 Differential support group....2096
D.5 Differential group....2104
D.6 Pinion group....2108
D.7 Axle beam group....2118
D.8 Toe-in/steering angle....2120
D.9 Special repair operations....2123
D.10 Testing after assembly....2130
E RICERCA GUASTI....2131
E.1 Controllo ed esame dei guasti....2134
E.2 Diagnosi per problemi all'assale....2138
E Troubleshooting....2131
E.1 Troubleshooting....2136
E.2 Axle problem and diagnosis....2139
F ATTREZZATURE SPECIALI....2140
F.1 Attrezzature speciali....2141
F Special tools....2140
F.1 Special tools....2141
G TEMPI DI RIPARAZIONE....2147
G.1 Prontuario dei tempi di riparazione....2148
G Service operations time....2147
G.1 Service operations time schedule....2148
S04050 - Full Power Hydraulic ABS Brake System Service Manual....2161
S04051 - FULL POWER HYDRAULIC ABS BRAKE SYSTEM Service Manual....2302
S04054 - Brake System Service Manual (Sept 2012) Service Manual....2443
toc....2443
Unit Code:04087, 04GAX, 04NNH, 04JNH....2443
1. SAFETY PRECAUTIONS....2447
2. DESCRIPTION AND OPERATION....2449
2.1. BRAKE PADS....2449
2.2. BRAKE CALIPER ....2449
2.3. BRAKE ROTOR (BRAKE DISC)....2449
2.4. BRAKE BOOSTER....2450
2.5. MASTER CYLINDER....2450
2.6. HYDRAULIC CONTROL UNIT (HCU)....2450
2.7. ANTI-LOCK BRAKE SYSTEM (ABS) MODULE....2450
2.8. WHEEL SPEED SENSOR....2450
2.9. PARKING BRAKE....2450
3. REMOVAL AND INSTALLATION....2451
3.1. FRONT BRAKE CALIPER....2452
Front Brake Caliper – Removal....2452
Front Brake Caliper – Installation....2453
3.2. FRONT BRAKE PADS....2454
Front Brake Pads – Removal....2454
Front Brake Pads – Installation....2455
3.3. FRONT BRAKE CALIPER ANCHOR PLATE....2456
Front Brake Caliper Anchor Plate – Removal....2456
Front Brake Caliper Anchor Plate – Installation....2456
3.4. FRONT BRAKE ROTOR AND HUB ASSEMBLY....2457
Front Brake Rotor and Hub Assembly – Removal....2457
Front Brake Rotor and Hub Assembly – Installation....2458
3.5. REAR BRAKE CALIPER....2459
Rear Brake Caliper – Removal....2459
Rear Brake Caliper – Installation....2460
3.6. REAR BRAKE PADS....2461
Rear Brake Pads – Removal....2461
Rear Brake Pads – Installation....2462
3.7. REAR BRAKE CALIPER ANCHOR PLATE....2463
Rear Brake Caliper Anchor Plate – Removal....2463
Rear Brake Caliper Anchor Plate – Installation....2463
3.8. REAR BRAKE CALIPER SUPPORT BRACKET....2464
Rear Brake Caliper Support Bracket – Removal....2464
Rear Brake Caliper Support Bracket – Installation....2465
3.9. REAR BRAKE ROTOR....2466
Rear Brake Rotor – Removal....2466
Rear Brake Rotor – Installation....2468
3.10. PARKING BRAKE CONTROL....2469
Parking Brake Control – Removal....2469
Parking Brake Control – Installation....2470
3.11. PARKING BRAKE SHOES....2471
Parking Brake Shoes – Removal....2471
Parking Brake Shoes – Installation....2474
3.12. BOOSTER AND BACKUP PUMP ASSEMBLY....2475
Booster and Backup Pump Assembly – Removal....2475
Booster and Backup Pump Assembly – Installation....2478
3.13. BACKUP PUMP....2479
Backup Pump – Removal....2479
Backup Pump – Installation....2480
3.14. FLOW SWITCH....2481
Flow Switch – Removal....2481
Flow Switch – Installation....2481
3.15. RELAY....2482
Relay – Removal....2482
Relay – Installation....2482
3.16. MASTER CYLINDER....2483
Master Cylinder – Removal....2483
Master Cylinder – Installation....2484
3.17. PRESSURE DIFFERENTIAL SWITCH....2485
Pressure Differential Switch – Removal....2485
Pressure Differential Switch – Installation....2485
3.18. HYDRAULIC CONTROL UNIT (hCU)....2486
Hydraulic Control Unit (HCU) – Removal....2486
Hydraulic Control Unit (HCU) – Installation....2487
3.19. ANTI-LOCK BRAKE SYSTEM (ABS) MODULE....2488
Anti-Lock Brake System (ABS) Module – Removal....2488
Anti-Lock Brake System (ABS) Module – Installation....2489
3.20. REAR WHEEL SPEED SENSOR....2490
Rear Wheel Speed Sensor – Removal....2490
Rear Wheel Speed Sensor – Installation....2491
3.21. FRONT WHEEL SPEED SENSOR....2492
Front Wheel Speed Sensor – Removal....2492
Front Wheel Speed Sensor – Installation....2492
4. DIAGNOSIS AND TROUBLESHOOTING....2493
Basic Brake System Diagnostics....2493
Displaying Fault Codes....2497
Diagnostic Trouble Codes....2497
Left Wheel Speed Sensor Circuit Test....2508
Right Wheel Speed Sensor Circuit Test....2509
Rear Wheel Speed Sensor Circuit Test....2510
ABS Module Circuit Test and ABS Data Link Circuit Test....2511
Hydraulic Brake Fluid Sensor Circuit Test....2513
Flow Switch Circuit Test....2513
Hydraulic Control Unit Circuit Test....2515
BACKUP PUMP CIRCUIT TEST....2515
5. BLEEDING AND ADJUSTMENT PROCEDURES AND SPECIFICATIONS....2518
5.1. COMPONENT BLEEDING....2518
Booster and Backup Pump Assembly....2518
Hydraulic Control Unit (HCU)....2518
Caliper....2519
5.2. PARKING BRAKE CABLE ADJUSTMENT....2520
Parking Brake Cable Adjustment....2520
5.3. SPECIFICATIONS....2522
General Specifications....2522
tables....2493
Table 1Symptom Chart....2493
Table 2ABS Module Diagnostic Trouble Codes....2497
Table 3Body Controller Diagnostic Trouble Codes....2506
Table 4Left Wheel Speed Sensor Circuit Test....2508
Table 5Right Wheel Speed Sensor Circuit Test....2509
Table 6Rear Wheel Speed Sensor Circuit Test....2510
Table 7ABS Module Circuit Test....2511
Table 8ABS (J1939) Data Link Circuit Test....2512
Table 9Brake Fluid Sensor Circuit Test....2513
Table 10Flow Switch Circuit Test....2513
Table 11Hydraulic Control Unit Circuit Test....2515
Table 12Backup Pump Circuit Test....2516
Table 13General Specifications....2522
Table 14Torque Chart....2523
S04054 - TerraStar Truck Brake System Service Manual....2525
toc....2525
Unit Code:04087, 04GAX, 04NNH, 04JNH....2525
1. SAFETY PRECAUTIONS....2529
2. DESCRIPTION AND OPERATION....2531
2.1. BRAKE PADS....2531
2.2. BRAKE CALIPER ....2531
2.3. BRAKE ROTOR (BRAKE DISC)....2531
2.4. BRAKE BOOSTER....2532
2.5. MASTER CYLINDER....2532
2.6. HYDRAULIC CONTROL UNIT (HCU)....2532
2.7. ANTI-LOCK BRAKE SYSTEM (ABS) MODULE....2532
2.8. WHEEL SPEED SENSOR....2532
2.9. PARKING BRAKE....2532
3. REMOVAL AND INSTALLATION....2533
3.1. FRONT BRAKE CALIPER....2534
Front Brake Caliper – Removal....2534
Front Brake Caliper – Installation....2535
3.2. FRONT BRAKE PADS....2536
Front Brake Pads – Removal....2536
Front Brake Pads – Installation....2537
3.3. FRONT BRAKE CALIPER ANCHOR PLATE....2538
Front Brake Caliper Anchor Plate – Removal....2538
Front Brake Caliper Anchor Plate – Installation....2538
3.4. FRONT BRAKE ROTOR AND HUB ASSEMBLY....2539
Front Brake Rotor and Hub Assembly – Removal....2539
Front Brake Rotor and Hub Assembly – Installation....2540
3.5. REAR BRAKE CALIPER....2541
Rear Brake Caliper – Removal....2541
Rear Brake Caliper – Installation....2542
3.6. REAR BRAKE PADS....2543
Rear Brake Pads – Removal....2543
Rear Brake Pads – Installation....2544
3.7. REAR BRAKE CALIPER ANCHOR PLATE....2545
Rear Brake Caliper Anchor Plate – Removal....2545
Rear Brake Caliper Anchor Plate – Installation....2545
3.8. REAR BRAKE CALIPER SUPPORT BRACKET....2546
Rear Brake Caliper Support Bracket – Removal....2546
Rear Brake Caliper Support Bracket – Installation....2547
3.9. REAR BRAKE ROTOR....2548
Rear Brake Rotor – Removal....2548
Rear Brake Rotor – Installation....2550
3.10. PARKING BRAKE CONTROL....2551
Parking Brake Control – Removal....2551
Parking Brake Control – Installation....2552
3.11. PARKING BRAKE SHOES....2553
Parking Brake Shoes – Removal....2553
Parking Brake Shoes – Installation....2556
3.12. BOOSTER AND BACKUP PUMP ASSEMBLY....2557
Booster and Backup Pump Assembly – Removal....2557
Booster and Backup Pump Assembly – Installation....2560
3.13. BACKUP PUMP....2561
Backup Pump – Removal....2561
Backup Pump – Installation....2562
3.14. FLOW SWITCH....2563
Flow Switch – Removal....2563
Flow Switch – Installation....2563
3.15. RELAY....2564
Relay – Removal....2564
Relay – Installation....2564
3.16. MASTER CYLINDER....2565
Master Cylinder – Removal....2565
Master Cylinder – Installation....2566
3.17. PRESSURE DIFFERENTIAL SWITCH....2567
Pressure Differential Switch – Removal....2567
Pressure Differential Switch – Installation....2567
3.18. HYDRAULIC CONTROL UNIT (hCU)....2568
Hydraulic Control Unit (HCU) – Removal....2568
Hydraulic Control Unit (HCU) – Installation....2569
3.19. ANTI-LOCK BRAKE SYSTEM (ABS) MODULE....2570
Anti-Lock Brake System (ABS) Module – Removal....2570
Anti-Lock Brake System (ABS) Module – Installation....2571
3.20. REAR WHEEL SPEED SENSOR....2572
Rear Wheel Speed Sensor – Removal....2572
Rear Wheel Speed Sensor – Installation....2573
3.21. FRONT WHEEL SPEED SENSOR....2574
Front Wheel Speed Sensor – Removal....2574
Front Wheel Speed Sensor – Installation....2574
4. DIAGNOSIS AND TROUBLESHOOTING....2575
Basic Brake System Diagnostics....2575
Displaying Fault Codes....2579
Diagnostic Trouble Codes....2579
Left Wheel Speed Sensor Circuit Test....2590
Right Wheel Speed Sensor Circuit Test....2591
Rear Wheel Speed Sensor Circuit Test....2592
ABS Module Circuit Test and ABS Data Link Circuit Test....2593
Hydraulic Brake Fluid Sensor Circuit Test....2595
Flow Switch Circuit Test....2595
Hydraulic Control Unit Circuit Test....2597
BACKUP PUMP CIRCUIT TEST....2597
5. BLEEDING AND ADJUSTMENT PROCEDURES AND SPECIFICATIONS....2600
5.1. COMPONENT BLEEDING....2600
Booster and Backup Pump Assembly....2600
Hydraulic Control Unit (HCU)....2600
Caliper....2601
5.2. PARKING BRAKE CABLE ADJUSTMENT....2602
Parking Brake Cable Adjustment....2602
5.3. SPECIFICATIONS....2604
General Specifications....2604
tables....2575
Table 1Symptom Chart....2575
Table 2ABS Module Diagnostic Trouble Codes....2579
Table 3Body Controller Diagnostic Trouble Codes....2588
Table 4Left Wheel Speed Sensor Circuit Test....2590
Table 5Right Wheel Speed Sensor Circuit Test....2591
Table 6Rear Wheel Speed Sensor Circuit Test....2592
Table 7ABS Module Circuit Test....2593
Table 8ABS (J1939) Data Link Circuit Test....2594
Table 9Brake Fluid Sensor Circuit Test....2595
Table 10Flow Switch Circuit Test....2595
Table 11Hydraulic Control Unit Circuit Test....2597
Table 12Backup Pump Circuit Test....2598
Table 13General Specifications....2604
Table 14Torque Chart....2605
S05016 - Steering Wheel Removal and Installation Service Manual....2607
S05025 - Steering Wheel and Steering Column Assembly Service Manual....2620
toc....2622
tables....2639
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes....2640
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams....2651
S08322 - 3200, 4100, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, RXT March 2007 to March 2008 Electrical Wiring Diagrams....2940
3200 RXT 4000 7000 8000 (March 2007 to March 2008) Wiring Diagrams (S08322a).pdf (p.1-114)....2940
S08322b.pdf (p.115-222)....3054
S08322c.pdf (p.223-351)....3162
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models After March 01, 2007 Electrical System Troubleshooting Guide Manual....3291
toc....3295
SAFETY INFORMATION....3295
INTRODUCTION....3297
1. MANUAL INTRODUCTION....3299
Electronic Gauge Cluster....3301
1. Description And Operation....3303
1.1. Overview....3303
1.2. Operation....3303
1.3. EGC Diagram....3304
1.4. Data Link Communication....3304
2. Feature Codes....3304
3. Cluster Features....3305
3.1. Gauges....3305
3.2. Warning and Indicator Lamps....3311
Flashing of Diagnostic Lamps ....3311
Individual Warning Lamps....3311
In-Gauge Warning Lamps....3328
Direct Drive Warning Lamps....3328
3.3. Digital Display....3329
Display Control....3329
Display Lighting....3329
Initial Display Mode....3330
Informational Display Screens (Quadrant 1)....3330
Standard Selections....3330
Optional Selections....3330
Odometer/Trip Functions....3330
Hours Functions....3331
Fuel Economy....3331
Fuel Used (2010 and beyond Clusters)....3332
Compass/Outside Temperature (Quadrant 3)....3332
General Text and Warning Messages (Quadrant 2)....3333
HVAC Graphics....3337
Transmission Gear Displays (Quadrant 4)....3337
3.4. Audible Alarm....3338
One-time Five-short-beeps Alarm....3338
Repetitive One-short-beep Alarm....3338
One-time Ten-short-beeps Alarm ....3339
One-time Three-long-beeps Alarm....3339
Repetitive Short Duration Blips ....3339
3.5. Switches....3339
Headlight/Park Light Switch....3340
Panel Dimmer Switch....3340
Right Side Optional Switches....3340
Left Side Optional Switches....3340
3.6. Analog Inputs....3340
Pressure Sensors....3340
Outside Temperature....3341
3.7. Outputs....3341
Headlight Enable....3341
3.8. Digital Inputs....3341
3.9. Panel Dimming and Gauge Backlighting....3341
Panel Lighting....3341
3.10. Error Operation....3342
Lost Communication....3342
EGC Internal Failure....3342
Gauge Faults....3342
Digital Display....3343
3.11. Full Power, Low Power, and Standby Modes....3343
4. Cluster Programming....3345
5. User Programmable Parameters....3345
6. Caution — Handling the EGC....3346
7. Diagnostics....3346
7.1. Gauge Sweep....3346
7.2. On-Board Diagnostics....3346
7.3. Off-Board Diagnostics....3346
7.4. Diamond Logic Builder (DLB)....3347
7.5. Diagnostic Trouble Codes....3347
7.6. Displaying Fault Codes....3351
Definitions:....3352
Failure Mode Indicators (FMI):....3353
Source Addresses (SA)....3354
7.7. Clearing Fault Codes....3355
8. Troubleshooting....3355
8.1. EGC Preliminary System Check....3355
8.2. EGC Power and Data Link Voltage Checks....3357
8.3. Gauge Troubleshooting....3357
Gauge Troubleshooting Procedure....3357
Diagnostic Trouble Codes and Related Voltage Checks for the Sens....3361
8.4. Warning Lamp Troubleshooting Procedure....3374
8.5. In-Gauge Warning Lamps....3376
8.6. Direct Drive Warning Lamps....3377
Direct Drive Warning Lamp Troubleshooting:....3378
8.7. EGC Backlighting Inoperative....3378
8.8. EGC Switches....3379
Push Button Switch Troubleshooting....3379
Rocker Switch Troubleshooting....3379
8.9. Digital Display....3379
Display Control....3380
8.10. Audible Alarm....3380
8.11. Outside Temperature Display Malfunction....3381
8.12. Lost SAE J1939 Data Link Communication....3382
9. Body Controller Signals....3383
Lighting Systems....3385
1. snowplow auxiliary lighting....3389
1.1. system description....3389
Overview....3389
Operation....3389
1.2. feature codes....3389
1.3. user programmable parameters....3390
1.4. diagnostic trouble codes....3391
1.5. troubleshooting....3392
Snow plow lighting preliminary checks....3393
Auxiliary Lights Relay Tests....3394
2. back up lights....3395
2.1. system description....3395
Overview....3395
Operation....3395
2.2. feature code....3396
2.3. user programmable parameters....3396
2.4. diagnostic trouble codes....3396
2.5. troubleshooting....3397
Back Up Lights Preliminary Checks....3397
Back Up Lights Test....3398
Backup Light Relay Tests....3399
Backup Light Ball Switch Tests....3399
3. Dome and courtesy lights....3399
3.1. system description....3399
Overview....3399
Operation....3400
3.2. feature code....3400
3.3. USER PROGRAMMABLE PARAMETERS....3400
3.4. diagnostic trouble codes....3401
3.5. troubleshooting....3402
Dome and Courtesy Lights Preliminary Checks....3402
Door Switch Circuit Tests....3403
Dome Light Circuit Tests....3404
4. fog lights....3405
4.1. system description....3405
Overview....3405
Operation....3406
4.2. feature codes....3406
4.3. user programmable parameters....3406
4.4. diagnostic trouble codes....3406
4.5. troubleshooting....3407
Fog Light System Preliminary Checks....3408
Fog Light Switch Test....3408
Fog Light Open Circuit Test....3409
Fog Light Short Circuit Test....3410
5. Headlights and DTRL....3410
5.1. system description....3410
Overview....3410
Operation....3410
5.2. feature codes....3411
5.3. user programmable parameters....3411
5.4. diagnostic trouble codes....3412
5.5. troubleshooting....3413
Headlight System Preliminary Checks....3414
Headlight Switch and Headlight Dimmer Tests....3415
Headlight Open Circuit Test....3416
Headlight Short Circuit Test....3417
6. STOP, TURN, AND HAZARDS....3417
6.1. system description....3417
Overview....3417
Operation....3417
6.2. feature codes....3417
6.3. user programmable parameters....3419
6.4. diagnostic trouble codes....3419
6.5. troubleshooting....3421
Stop, Turn, and Hazards System Preliminary Checks....3421
Turn Signal Switch Test....3423
Hazard Switch Test....3423
Brake Switch Test....3424
Output Open Circuit Test....3424
Output Short Circuit Test....3425
7. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING....3425
7.1. system description....3425
Overview....3425
Operation....3426
7.2. feature codes....3426
7.3. user programmable parameters....3427
7.4. diagnostic trouble codes....3427
7.5. troubleshooting....3428
Tail, Marker, Park, and Clearance Lighting Preliminary Checks....3429
Headlight Switch Tests....3429
Interrupt Switch Tests....3430
Park Light Open Circuit Tests....3431
Park Light Short Circuit Tests....3431
8. work lights....3431
8.1. system description....3431
Overview....3431
Operation....3432
8.2. feature codes....3432
8.3. user programmable parameters....3433
8.4. diagnostic trouble codes....3433
8.5. troubleshooting....3434
Work Light System Preliminary Checks....3434
Work Light Switch Test....3435
Work Light Open Circuit Test....3435
Work Light Short Circuit Test....3436
Auxiliary Gauge Switch Pack....3437
1. Description And Operation....3439
1.1. Overview....3439
1.2. Operation....3439
1.3. AGSP Diagram....3439
1.4. Data Link Communication....3439
2. Feature Codes....3440
3. Features....3440
3.1. Gauges....3440
3.2. In-Gauge Warning Lamps....3441
3.3. Hybrid Display....3441
3.4. Switches....3442
3.5. Panel Dimming and Gauge Backlighting....3442
3.6. Error Operation....3442
Lost Communication....3443
Gauge Faults....3443
4. AGSP Programming....3444
5. User Programmable Parameters....3444
6. Caution — Handling the AGSP....3444
7. Diagnostics....3444
7.1. Gauge Sweep....3444
7.2. On-Board Diagnostics....3445
7.3. Off-Board Diagnostics....3445
7.4. Diamond Logic Builder (DLB)....3445
7.5. Diagnostic Trouble Codes....3445
8. Troubleshooting....3448
8.1. AGSP Preliminary System Check....3448
8.2. AGSP Power and Data Link Voltage Checks....3449
8.3. Gauge Troubleshooting Procedure....3449
8.4. Troubleshooting Specific Gauges....3451
8.5. In-Gauge Warning Lamps....3458
8.6. Panel Dimming and Gauge Backlighting....3459
8.7. AGSP Switches....3459
8.8. Lost SAE J1939 Data Link Communication....3459
9.1. Body Controller Signals....3459
Cab Features....3461
1. cigar lighter and power feed....3467
1.1. System description....3467
Overview....3467
Cigar Lighter Operation....3467
Cigar Lighter Power Source and Two Post Power Source Operation....3467
1.2. feature codes....3467
1.3. user programmable parameters....3467
1.4. diagnostic trouble codes....3467
1.5. diagnostics....3467
Cigar Lighter and Power Feed Preliminary Check....3467
Cigar Lighter Tests....3468
Cigar Lighter Power Source Test....3469
Two Post Power Source Test....3469
2. C.b. Power radio....3471
2.1. system description....3471
Overview....3471
Operation....3471
2.2. feature codes....3471
2.3. user programmable parameters....3471
2.4. diagnostic trouble codes....3471
2.5. diagnostics....3471
C.B. Radio Power Source Preliminary Check....3471
C.B. Power Connector Tests....3472
3. compass and temperature display....3474
3.1. system description....3474
Overview....3474
Temperature Display Operation....3474
Compass Display Operation....3474
3.2. feature codes....3474
3.3. USER PROGRAMMABLE PARAMETERS....3474
3.4. Diagnostic Trouble Codes....3474
3.5. diagnostics....3475
Compass/Temperature Display Preliminary Check....3476
Compass/Temperature Display Voltage Checks....3476
4. power windows and locks....3477
4.1. system description....3477
Overview....3477
Power Window Operation....3477
Power Door Lock Operation....3477
4.2. feature codes....3478
4.3. user programmable parameters....3480
4.4. diagnostic trouble codes....3480
4.5. Troubleshooting....3483
Power Window and Lock Preliminary Check....3484
Power Door Lock Tests....3485
Power Window Test....3486
5. cruise control....3487
5.1. system description....3487
Overview....3487
Operation....3487
5.2. feature codes....3487
5.3. user programmable parameters....3488
5.4. diagnostic trouble codes....3488
5.5. Troubleshooting....3489
Cruise Control Preliminary Check....3490
Cruise Control Switch Tests....3491
6. Theft deterrent....3493
6.1. system description....3493
Overview....3493
Operation....3493
6.2. feature codes....3494
6.3. User programmable parameters....3495
6.4. diagnostic trouble codes....3496
6.5. troubleshooting....3497
Theft Deterrent Preliminary Check....3497
Theft Deterrent System Test....3497
7. electric horn....3499
7.1. system description....3499
Overview....3499
Operation....3499
7.2. feature codes....3499
7.3. User programmable parameters....3499
7.4. diagnostic trouble codes....3500
7.5. troubleshooting....3501
Electric Horn Preliminary Check....3501
Electric Horn Test....3502
8. air horn....3504
8.1. system description....3504
Overview....3504
Operation....3504
8.2. feature codes....3504
8.3. User programmable parameters....3504
8.4. diagnostic trouble codes....3504
8.5. troubleshooting....3505
Air Horns Preliminary Check....3505
Air Horn Test....3506
9. power mirrors....3507
9.1. system description....3507
Overview....3507
Operation....3507
9.2. feature codes....3507
9.3. User programmable parameters....3507
9.4. diagnostic trouble codes....3507
9.5. troubleshooting....3507
Power Mirror Preliminary Check....3508
Power Mirror Test....3509
10. Heated Mirror....3511
10.1. system description....3511
Overview....3511
Operation....3511
10.2. feature codes....3511
10.3. User programmable parameters....3513
10.4. diagnostic trouble codes....3513
10.5. troubleshooting....3514
Heated Mirror Preliminary Check....3514
Heated Mirrors Test....3515
Left Heated Mirror Test....3515
Right Heated Mirror Test....3516
11. radio (entertainment), speakers....3517
11.1. system description....3517
Overview....3517
Operation....3517
11.2. feature codes....3517
11.3. User programmable parameters....3517
11.4. diagnostic trouble codes....3517
11.5. troubleshooting....3517
Radio Preliminary Check....3518
Radio Test....3518
12. Two-way radio....3520
12.1. system description....3520
Overview....3520
Operation....3520
12.2. feature codes....3520
12.3. User programmable parameters....3520
12.4. diagnostic trouble codes....3520
12.5. troubleshooting....3520
Two-Way Radio Circuit Tests....3520
13. Windshield wiper and washer pump....3522
13.1. system description....3522
Overview....3522
Wiper Operation....3522
Park Operation....3522
Washer Operation....3522
13.2. feature codes....3522
13.3. User programmable parameters....3523
13.4. diagnostic trouble codes....3524
NO TITLE....3526
13.5. troubleshooting....3526
Wiper and Washer Preliminary Check....3526
Washer Test....3528
Wiper Park Test....3528
Wiper Switch Test....3529
Wiper Motor Test....3530
14. Roof auxiliary load and air shield light....3532
14.1. system description....3532
Overview....3532
Roof Auxiliary Load Operation....3532
Air Shield Light Operation....3532
14.2. Feature codes....3532
14.3. User programmable parameters....3532
14.4. diagnostic trouble code....3532
Roof Auxiliary Load Feature....3532
Lighted Air Shield....3533
14.5. troubleshooting....3533
Roof Auxiliary Load Preliminary Check....3533
Roof Auxiliary Load Test....3534
IP Mounted Roof Auxiliary Load Switch Test....3534
Lighted Air Shield Preliminary Check....3535
Lighted Air Shield Test....3536
15. self contained air seat....3537
15.1. system description....3537
Overview....3537
Operation....3537
15.2. Feature codes....3537
15.3. User programmable parameters....3537
15.4. diagnostic trouble code....3537
15.5. troubleshooting....3537
Self Contained Air Seats Preliminary Check....3537
Self Contained Air Seat Test....3538
16. Heated seats....3539
16.1. system description....3539
Overview....3539
Operation....3539
16.2. Feature codes....3539
16.3. User programmable parameters....3539
16.4. diagnostic trouble code....3539
16.5. troubleshooting....3539
Heated Seats Preliminary Check....3539
Heated Seat Test....3540
17. seat belt and seat sensor....3541
17.1. system description....3541
Overview....3541
Operation....3541
17.2. feature codes....3541
17.3. User programmable parameters....3541
17.4. diagnostic trouble code....3542
17.5. troubleshooting....3542
Seat Belt Preliminary Check....3542
Seat Belt Test....3543
18. brake light switch....3544
18.1. system description....3544
Overview....3544
Operation....3544
18.2. Feature codes....3544
18.3. User programmable parameters....3544
18.4. diagnostic trouble code....3544
18.5. troubleshooting....3546
Brake Switch Preliminary Check....3546
Brake Switch Test....3547
19. Clutch switch....3548
19.1. system description....3548
Overview....3548
Operation....3548
19.2. Feature codes....3548
19.3. User programmable parameters....3548
19.4. diagnostic trouble code....3548
19.5. troubleshooting....3549
Clutch Switch Preliminary Checks....3550
No Engine Crank Clutch Switch Test....3551
Cruise Control Clutch Switch Test....3551
20. load shedding....3552
20.1. system description....3552
Overview....3552
Operation....3552
20.2. Feature codes....3552
20.3. User programmable parameters....3552
20.4. diagnostic trouble code....3552
20.5. troubleshooting....3553
Latching Relay Diagnostics....3554
Chassis Features....3555
1. trailer turn signal relays....3561
1.1. System description....3561
Overview....3561
Operation....3561
1.2. feature codes....3561
1.3. user programmable parameters....3561
1.4. diagnostic trouble codes....3561
1.5. troubleshooting....3562
Trailer Turn Signal Relay System Preliminary Checks....3563
Left Trailer Turn Signal Inop Test....3564
Right Trailer Turn Signal Inop Test....3565
2. trailer auxiliary power circuit....3566
2.1. System description....3566
Overview....3566
Operation....3566
2.2. feature codes....3566
2.3. user programmable parameters....3566
2.4. diagnostic trouble codes....3566
2.5. troubleshooting....3567
Trailer Auxiliary Power Circuit Preliminary Checks....3567
Trailer Auxiliary Circuit Tests....3567
3. Auto Neutral (Feature Code 0595AYP)....3569
3.1. Description And Operation....3569
Overview....3569
Operation....3569
3.2. Feature Codes....3570
3.3. User Programmable Parameters....3570
3.4. Diagnostics....3571
Diamond Logic Builder (DLB)....3571
Diagnostic Trouble Codes....3571
Displaying Diagnostic Trouble Codes....3572
3.5. Troubleshooting....3572
Auto Neutral Preliminary System Check....3572
Auto Neutral Does Not Engage....3573
Auto Neutral Does Not Disengage....3574
Auto Neutral Warning Lamp Inoperative....3575
3.6. Body Controller Signals....3575
3.7. Body Controller Functions....3576
Activate Auto Neutral....3576
Error Operation....3577
4. Axle Load Monitor....3578
4.1. Description And Operation....3578
Overview....3578
Operation....3578
4.2. Feature Codes....3578
4.3. User Programmable Parameters....3579
4.4. Diagnostics....3580
Diamond Logic Builder (DLB)....3580
Diagnostic Trouble Codes....3580
Displaying Diagnostic Trouble Codes....3582
4.5. Troubleshooting....3582
Axle Load Monitor Preliminary Check....3582
Axle Pressure Transducer Voltage Checks....3583
4.6. Body Controller Signals....3583
4.7. Body Controller Functions....3584
To activate the axle load monitor feature, the following conditi....3584
5. REMOTE POWER MODULE....3585
5.1. Description and Operation....3585
Overview....3585
Operation....3585
RPM Addressing....3586
5.2. Feature Codes....3586
5.3. User Programmable Parameters....3586
5.4. Diagnostics....3587
Diamond Logic Builder (DLB)....3587
Diagnostic Trouble Codes....3587
Displaying Diagnostic Trouble Codes....3590
5.5. Troubleshooting....3590
Remote Power Module Preliminary Check....3590
RPM Power, Ground and Data Link Circuits....3591
5.6. Body Controller Signals....3592
5.7. Body Controller Functions....3592
6. auxiliary power source....3593
6.1. System description....3593
Overview....3593
Operation....3593
6.2. feature codes....3593
6.3. user programmable parameters....3593
6.4. diagnostic trouble codes....3593
6.5. troubleshooting....3593
Auxiliary Power Source Preliminary Check....3594
Aux Power Source Tests....3594
7. Two-speed axle switch....3596
7.1. System description....3596
Overview....3596
Operation....3596
7.2. feature codes....3596
7.3. user programmable parameters....3596
7.4. diagnostic trouble codes....3596
7.5. troubleshooting....3597
Two-Speed Switch Preliminary Check....3597
Two-Speed Switch Test....3597
8. Air Dryer and heated drain valve....3598
8.1. System description....3598
Overview....3598
Operation....3598
8.2. feature codes....3598
8.3. user programmable parameters....3598
8.4. diagnostic trouble codes....3598
8.5. troubleshooting....3598
Air Dryer and Heated Drain Valve Preliminary Check....3598
Heated Drain Valve Test....3599
Air Dryer Test....3599
9. fuel transfer pump....3601
9.1. System description....3601
Overview....3601
Operation....3601
9.2. feature codes....3601
9.3. user programmable parameters....3601
9.4. diagnostic trouble codes....3603
9.5. troubleshooting....3603
Fuel Transfer Pump Preliminary Check....3604
Fuel Transfer Pump Won’t Run Test....3604
Fuel Transfer Pump Continuously Runs Test....3606
10. water in fuel monitor....3607
10.1. System description....3607
Overview....3607
Operation....3607
10.2. feature codes....3607
10.3. user programmable parameters....3607
10.4. diagnostic trouble codes....3607
10.5. troubleshooting....3608
Water in Fuel Preliminary Check....3608
Water Probe Test....3609
11. electric trailer brake....3610
11.1. System description....3610
Overview....3610
Operation....3610
11.2. feature codes....3610
11.3. user programmable parameters....3610
11.4. diagnostic trouble codes....3610
11.5. troubleshooting....3611
Electric Trailer Brake Preliminary Check....3611
Electric Trailer Brake Test....3612
12. air solenoid....3614
12.1. System description....3614
Overview....3614
Operation....3614
12.2. feature codes....3614
12.3. user programmable parameters....3615
12.4. diagnostic trouble codes....3616
12.5. Troubleshooting....3624
Air Solenoid Preliminary Check....3624
Air Solenoid Diagnosis....3624
13. Suspension dump....3626
13.1. System description....3626
Overview....3626
Operation....3626
13.2. feature code....3626
13.3. user programmable parameters....3626
13.4. diagnostic trouble codes....3627
13.5. Troubleshooting....3628
Suspension Dump Test....3629
14. Customer Installed Lift Gate Power Source....3631
14.1. System description....3631
Overview....3631
Operation....3631
14.2. feature code....3631
14.3. user programmable parameters....3631
14.4. diagnostic trouble codes....3632
14.5. Troubleshooting....3632
Lift Gate Test....3633
15. Fifth Wheel Slide, Air Controlled....3634
15.1. System description....3634
Overview....3634
Operation....3634
15.2. FEATURE CODE....3634
15.3. user programmable parameters....3634
15.4. diagnostic trouble codes....3635
15.5. Troubleshooting....3635
Fifth Wheel Slide Preliminary Check....3636
Fifth Wheel Slide Test....3636
16. Differential Lock Air controlled....3637
16.1. System description....3637
Overview....3637
Operation....3637
16.2. FEATURE CODE....3638
16.3. user programmable parameters....3638
16.4. diagnostic trouble codes....3639
16.5. Troubleshooting....3640
Differential Lock Preliminary Check....3641
(0595ACT) Differential Lock Test....3641
(0595ACU) Differential Lock Test....3642
17. Power Divider Lock (PDL) Air Controlled....3643
17.1. System description....3643
Overview....3643
Operation....3643
17.2. FEATURE CODE....3643
17.3. user programmable parameters....3644
17.4. diagnostic trouble codes....3645
17.5. Troubleshooting....3645
Power Divider Lock Preliminary Check....3646
Power Divider Lock Test....3646
18. Remote start/stop....3647
18.1. System Description....3647
Overview....3647
Operation....3647
18.2. FEATURE CODE....3647
18.3. user programmable parameters....3648
18.4. Diagnostic Trouble Codes....3648
18.5. Troubleshooting....3649
Remote Start/Stop Preliminary Check....3649
Remote Start/Stop System Tests....3651
19. Power Take Off (PTO)....3653
19.1. Description and Operation....3653
Overview....3653
Operation....3653
19.2. Feature Codes....3654
19.3. User Programmable Parameters....3662
19.4. Diagnostics....3663
Diamond Logic Builder (DLB)....3663
Diagnostic Trouble Codes....3663
Displaying Diagnostic Trouble Codes....3674
19.5. Troubleshooting....3674
Power Take Off (PTO) Preliminary Check....3674
19.6. Body Controller Signals....3676
19.7. Body Controller Functions....3678
20. Wheelchair Lift Interlock....3679
20.1. Description And Operation....3679
Overview....3679
Operation....3679
20.2. Feature Codes....3680
20.3. User Programmable Parameters....3680
20.4. Diagnostics....3680
Diamond Logic Builder (DLB)....3680
Diagnostic Trouble Codes....3680
Displaying Diagnostic Trouble Codes....3681
20.5. Troubleshooting....3681
Wheelchair Lift Interlock Preliminary System Check....3681
20.6. Body Controller Signals....3684
20.7. Body Controller Functions....3685
Activate Wheelchair Lift Solenoid....3685
Activate Audible Alarm....3686
TRANSMISSIONS....3687
1. Description and Operation....3689
1.1. Overview....3689
1.2. Operation....3689
2. Feature Codes....3691
2.1. Available Body Controller Configurations....3691
2.2. User Programmable Parameters....3693
3. Diagnostics....3694
3.1. Diamond Logic Builder (DLB)....3694
3.2. Diagnostic Trouble Codes....3694
3.3. Displaying Diagnostic Trouble Codes....3695
4. Troubleshooting....3696
4.1. Preliminary System Check — All Transmissions....3696
4.2. Park Position Unlock Solenoid Checks — Eaton T-Handle & All....3701
4.3. LCT Column Shifter Interlock Checks....3702
4.4. TCM Power, Ground and Data Link Circuit Checks....3702
4.5. Shift Selector Power and Ground Circuit Checks....3703
4.6. Body Controller Signals....3703
4.7. Body Controller Functions....3704
Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....3704
PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....3704
Multiplexing (Data Links)....3705
1. multiplexing (data links)....3707
1.1. Description....3707
Overview....3707
Operation....3707
1.2. troubleshooting....3709
J1939 Data Link Terminating Resistors....3709
Body Controller....3710
Electronic Engines....3711
1. REMOTE ENGINE SPEED CONTROL MODULE (RESCM)....3713
1.1. Description and Operation....3713
Overview....3713
Operation....3713
1.2. Feature Codes....3714
1.3. User Programmable Parameters....3714
1.4. Diagnostics....3714
Diamond Logic Builder (DLB)....3714
Diagnostic Trouble Codes....3714
Displaying Diagnostic Trouble Codes....3719
1.5. Troubleshooting....3719
RESCM Preliminary Check....3719
RESCM Power, Ground and Data Link Circuits....3720
1.6. Body Controller Signals....3721
1.7. Body Controller Functions....3722
2. Aftertreatment....3723
2.1. Description And Operation....3723
Overview....3723
Operation....3723
2.2. Aftertreatment Definitions....3724
2.3. Soot Accumulation Level Indications....3724
2.4. Feature Related Text Messages in the Gauge Cluster....3725
2.5. Feature Codes....3726
2.6. User Programmable Parameters....3727
2.7. Diagnostics....3727
Diamond Logic Builder (DLB)....3728
Diagnostic Trouble Codes....3728
Displaying Diagnostic Trouble Codes....3731
2.8. Troubleshooting....3731
Preliminary System Check — Aftertreatment....3731
Parked Regeneration Switch Test....3732
Parked Regeneration Switch Indicator Test....3733
Inhibit Regeneration Switch Test....3733
Inhibit Regeneration Switch Indicator Test....3734
DPF Status Warning Lamp Test....3734
HEST Warning Lamp Test....3734
Lamp Check....3735
Lost Communication and Warning Lamp Diagnostics....3735
2.9. Body Controller Signals....3735
2.10. Body Controller Functions....3737
Parked Regeneration....3737
Inhibit Regeneration....3738
Parked Regeneration Switch Indicator....3738
Inhibit Regeneration Switch Indicator....3739
DPF Status Warning Lamp....3740
HEST Warning Lamp....3740
Audible Alarm....3741
Switch Packs (J1708 Data Links)....3743
1. switch packs (j1708 data link)....3745
1.1. Description....3745
Overview....3745
Operation....3745
1.2. troubleshooting....3745
Switch Pack Preliminary Check....3746
Switch Pack Test....3746
12 Volt Power Distribution and Grounds....3747
1. 12-Volt power distribution and grounds....3749
1.1. Description....3749
Overview....3749
Operation....3749
1.2. troubleshooting....3749
Battery Power Distribution Check....3750
Accessory Power Distribution Preliminary Check....3750
Accessory Power Test....3750
Ignition Power Distribution Preliminary Check....3751
Ignition Power Test....3752
Ground Test....3753
Fans and Engine Accessories....3755
1. Engine Cooling Fan Control....3757
1.1. Description And Operation....3757
Overview....3757
Operation....3757
1.2. Feature Codes....3757
1.3. User Programmable Parameters....3758
1.4. Diagnostics....3758
Diagnostic Trouble Codes....3758
Displaying Diagnostic Trouble Codes....3759
1.5. Troubleshooting....3759
Preliminary Check — Engine Cooling Fan....3759
1.6. Body Controller Signals....3760
1.7. Body Controller Functions....3762
Fan Control — General Information....3762
ON/OFF Fan Control....3762
Low Air Pressure Engine Fan Override (0595BBB)....3763
Variable Speed Fan Control (0595AYH)....3764
2. Snow Valve (Engine Intake) (non Big Bore Engines)....3766
2.1. Description And Operation....3766
Overview....3766
Operation....3766
2.2. Feature Codes....3766
2.3. User Programmable Parameters....3766
2.4. Diagnostics....3767
Diagnostic Trouble Codes....3767
2.5. Troubleshooting....3767
Snow Valve Preliminary Check....3767
Snow Valve Mechanical Checks....3767
Snow Valve Module Checks....3768
2.6. Body Controller Signals....3768
2.7. Body Controller Functions....3768
3. Snow Valve (Engine Intake) (Big Bore Engines)....3769
3.1. Description And Operation....3769
Overview....3769
Operation....3769
3.2. Feature Codes....3770
3.3. User Programmable Parameters....3770
3.4. Diagnostics....3770
Diamond Logic Builder (DLB)....3770
Diagnostic Trouble Codes....3771
Displaying Diagnostic Trouble Codes....3771
3.5. Troubleshooting....3771
Snow Valve Preliminary Check....3771
Snow Valve Mechanical Checks....3772
Snow Valve Switch Test....3773
Snow Valve Module Checks....3773
3.6. Body Controller Signals....3775
3.7. Body Controller Functions....3775
To activate the feature, the following conditions must be true:....3775
If the conditions to activate the feature (above) are true, then....3775
If any of the following conditions occur, then the feature will ....3776
If any of the conditions to deactivate the feature (above) are t....3776
4. Exhaust Brake....3777
4.1. Description And Operation....3777
Overview....3777
Operation....3777
4.2. Feature Codes....3777
4.3. User Programmable Parameters....3778
4.4. Diagnostics....3778
Diamond Logic Builder (DLB)....3778
Diagnostic Trouble Codes....3778
Displaying Diagnostic Trouble Codes....3778
4.5. Troubleshooting....3779
Exhaust Brake Preliminary Check....3779
Exhaust Brake Switch Test....3780
4.6. Body Controller Signals....3780
4.7. Body Controller Functions....3781
To activate the exhaust brake feature, the following conditions ....3781
If the conditions to activate the feature (above) are true, then....3781
Battery, Charging, and Cranking System....3783
1. battery....3785
1.1. Description....3785
Overview....3785
Operation....3785
1.2. diagnostic trouble codes....3786
1.3. troubleshooting....3786
NO TITLE....3786
2. charging system....3787
2.1. Description....3787
Overview....3787
Operation....3787
2.2. diagnostic trouble codes....3787
2.3. troubleshooting....3788
3. ENGINE CRANKING....3788
3.1. Description....3788
Overview....3788
Operation....3788
3.2. troubleshooting....3789
4. Power pack 3....3789
4.1. Description....3789
Overview....3789
Operation....3789
4.2. troubleshooting....3790
tables....3305
Table 1Gauge Table....3305
Table 2Warning and Indicator Lamp Table – Type A....3312
Table 3Warning and Indicator Lamp Table – Type B....3320
Table 5General Text and Warning Messages requested by means of a....3333
Table 6General Text and Warning Messages Generated by the Electr....3334
Table 18Fuel Level Sensor Voltage Checks....3363
Table 20Transmission Oil Temperature Sensor Voltage Checks....3365
Table 22Axle Temperature Sensor Voltage Checks....3367
Table 24Axle Temperature Sensor Voltage Checks....3369
Table 26Air Pressure Transducer Voltage Checks....3373
Table 27Direct Drive Warning Lamp Table....3377
Table 29Ambient Air Temperature Sensor Test....3382
Table 30Ambient Air Temperature Sensor Table....3382
Table 32Feature Codes....3390
Table 33Diagnostic Trouble Codes....3391
Table 34Snow plow lighting preliminary checks....3393
Table 35Auxiliary Lights Relay Tests....3394
Table 36Diagnostic Trouble Codes....3396
Table 37Back Up Lights Preliminary Checks....3397
Table 38Back Up Lights Test....3398
Table 39Backup Light Relay Tests....3399
Table 40Backup Light Ball Switch Tests....3399
Table 41Feature Code....3400
Table 42Diagnostic Trouble Codes....3402
Table 43Dome and Courtesy Lights Preliminary Checks....3403
Table 44Door Switch Short Circuit Tests....3404
Table 45Door Switch Open Circuit Tests....3404
Table 46Dome Light Short Circuit Test....3405
Table 47Dome Light Open Circuit Test....3405
Table 48Feature Codes....3406
Table 49Diagnostic Trouble Codes....3407
Table 50Fog Light System Preliminary Checks....3408
Table 51Fog Light Switch Test....3409
Table 52Fog Light Open Circuit Test....3409
Table 53Fog Light Short Circuit Test....3410
Table 54Feature Codes....3411
Table 55Diagnostic Trouble Codes....3412
Table 56Headlight System Preliminary Checks....3414
Table 57Headlight Switch and Headlight Dimmer Test....3415
Table 58Headlight Open Circuit Test....3416
Table 59Headlight Short Circuit Test....3417
Table 60Feature Codes....3418
Table 61Diagnostic Trouble Codes....3420
Table 62Stop, Turn, and Hazards System Preliminary Checks....3422
Table 63Turn Signal Switch Test....3423
Table 64Hazard Switch Test....3423
Table 65Brake Switch Test....3424
Table 66Output Open Circuit Test....3424
Table 67Output Short Circuit Test....3425
Table 68Feature Codes....3426
Table 69Diagnostic Trouble Codes....3428
Table 70Tail, Marker, Park, and Clearance Lighting Preliminary C....3429
Table 71Headlight Switch Tests....3429
Table 72Interrupt Switch Tests....3430
Table 73Park Light Open Circuit Tests....3431
Table 74Park Light Short Circuit Tests....3431
Table 75Feature Codes....3432
Table 76Diagnostic Trouble Codes....3433
Table 77Work Light System Preliminary Checks....3434
Table 78Work Light Switch Test....3435
Table 79Work Light Open Circuit Test....3436
Table 80Work Light Short Circuit Test....3436
Table 82Gauge Table....3441
Table 88Axle Temperature Sensor Voltage Checks....3452
Table 90Axle Temperature Sensor Voltage Checks....3455
Table 93Cigar Lighter and Power Feed Preliminary Check....3468
Table 94Cigar Lighter Tests....3468
Table 95Cigar Lighter Power Source Tests....3469
Table 96Two Post Power Source Tests....3469
Table 97C.B. Radio Power Source Preliminary Check....3471
Table 98C.B. Radio Power Connector Tests....3472
Table 99Feature Codes....3474
Table 100Diagnostic Trouble Codes....3474
Table 101Compass/Temperature Display Preliminary Check....3476
Table 102Compass/Temperature Display Voltage Checks....3476
Table 103Feature Codes....3478
Table 104Diagnostic Trouble Codes....3480
Table 105Power Locks Preliminary Check....3484
Table 106Power Windows Preliminary Check....3484
Table 107One Door Lock Inop Test....3485
Table 108All Door Locks Inop Test....3485
Table 109One Power Window Inop Test....3486
Table 110All Power Windows Inop Test....3486
Table 111Feature Codes....3487
Table 112Diagnostic Trouble Codes....3488
Table 113Cruise Control Preliminary Check....3490
Table 114Steering Wheel Mounted Cruise Control Command Switch Te....3491
Table 115Steering Wheel Mounted Cruise Control Command Switch Te....3492
Table 116Feature Codes....3494
Table 117Theft Deterrent Preliminary Check....3497
Table 118Theft Deterrent System Test....3497
Table 119Feature Codes....3499
Table 120Diagnostic Trouble Codes....3501
Table 121Electric Horn Preliminary Check....3501
Table 122Electric Horn Test....3502
Table 123Feature Codes....3504
Table 124Diagnostic Trouble Codes....3505
Table 125Air Horns Preliminary Checks....3505
Table 126Air Horn Test....3506
Table 127Power Mirror Preliminary Check....3508
Table 128Power Mirror Tests....3509
Table 129Feature Codes....3511
Table 130Diagnostic Trouble codes....3513
Table 131Heated Mirror Preliminary Check....3514
Table 132Heated Mirrors Test....3515
Table 133Left Heated Mirror Test....3515
Table 134Right Heated Mirror Test....3516
Table 135Radio Preliminary Check....3518
Table 136Radio Test....3518
Table 137Two-Way Radio Circuit Tests....3520
Table 138Feature Codes....3522
Table 139Diagnostic Trouble Codes....3524
Table 140Wiper and Washer Preliminary Check....3526
Table 141Washer Test....3528
Table 142Wiper Park Test....3528
Table 143Wiper Switch Test....3529
Table 144Wiper Motor Test....3530
Table 145Feature Codes....3532
Table 146Lighted Air Shield DTC....3533
Table 147Roof Auxiliary Load Preliminary Check....3533
Table 148Roof Auxiliary Load Test....3534
Table 149IP Mounted Roof Auxiliary Load Switch Test....3534
Table 150Lighted Air Shield Preliminary Check....3535
Table 151Lighted Air Shield Test....3536
Table 152Self Contained Air Seats Preliminary Check....3537
Table 153Self Contained Air Seat Test....3538
Table 154Heated Seats Preliminary Check....3539
Table 155Heated Seat Test....3540
Table 157Seat Belt Preliminary Check....3542
Table 1580595BAG Seat Belt Test....3543
Table 159Feature Codes....3544
Table 160Diagnostic Trouble Codes....3544
Table 161Brake Switch Preliminary Check....3546
Table 162Brake Switch Test....3547
Table 163Feature Code....3548
Table 164Diagnostic Trouble Codes....3549
Table 165Clutch Switch Preliminary Checks....3550
Table 166No Engine Crank Clutch Switch Test....3551
Table 167Cruise Control Clutch Switch Test....3551
Table 168Feature Code....3552
Table 169Diagnostic Trouble Codes....3553
Table 170Feature Code....3561
Table 171Diagnostic Trouble codes....3561
Table 172Trailer Turn Signal Relay System Preliminary Checks....3563
Table 173Left Trailer Turn Signal Inop Test....3564
Table 174Right Trailer Turn Signal Inop Test....3565
Table 175Feature Codes....3566
Table 176Diagnostic Trouble Codes....3567
Table 177Trailer Auxiliary Power Circuit Preliminary Checks....3567
Table 178Trailer Auxiliary Circuit Tests....3567
Table 188Axle Pressure Transducer Voltage Checks....3583
Table 192RPM Checks....3591
Table 193Feature Codes....3593
Table 194Auxiliary Power Source Preliminary Check....3594
Table 195Aux Power Source Tests....3594
Table 197Diagnostic Trouble Codes....3596
Table 198Two-Speed Switch Preliminary Check....3597
Table 199Two-Speed Switch Test....3597
Table 200Air Dryer and Heated Drain Valve Preliminary Check....3598
Table 201Heated Drain Valve Test....3599
Table 202Air Dryer Test....3599
Table 203Feature Codes....3601
Table 204Diagnostic Trouble Codes....3603
Table 205Fuel Transfer Pump Preliminary Check....3604
Table 206Fuel Transfer Pump Won’t Run Test....3604
Table 207Fuel Transfer Pump Continuously Runs Test....3606
Table 208Feature Code....3607
Table 210Water in Fuel Preliminary Check....3608
Table 211Water Probe Test....3609
Table 212Feature Code....3610
Table 213Diagnostic Trouble Codes....3611
Table 214Electric Trailer Brake Preliminary Check....3611
Table 215Electric Trailer Brake Test....3612
Table 216Feature Code....3614
Table 217Diagnostic Trouble Codes....3616
Table 218Air Solenoid Preliminary Check....3624
Table 219Feature Code....3626
Table 220Diagnostic Trouble Codes....3627
Table 221Suspension Dump Preliminary Check....3629
Table 222Suspension Dump Test....3629
Table 223Feature Code....3631
Table 224Diagnostic Trouble Codes....3632
Table 225Lift Gate Preliminary Check....3633
Table 226Lift Gate Test....3633
Table 227Feature Code....3634
Table 228Diagnostic Trouble Codes....3635
Table 229Fifth Wheel Slide Preliminary Check....3636
Table 230Fifth Wheel Slide Test....3636
Table 231Feature Code....3638
Table 232Diagnostic Trouble Codes....3639
Table 233Differential Lock Preliminary Check....3641
Table 234(0595ACT) Differential Lock Test....3641
Table 235(0595ACU) Differential Lock Test....3642
Table 236Feature Code....3644
Table 237Diagnostic Trouble Codes....3645
Table 238Power Divider Lock Preliminary Check....3646
Table 239Power Divider Lock Test....3646
Table 240Feature Code....3648
Table 241Diagnostic Trouble Codes....3649
Table 242Remote Start/Stop Preliminary Check....3649
Table 243Remote Start/Stop System Tests....3651
Table 247PTO Hour Meter/ PTO Indicator Checks....3676
Table 249Additional Signals Used for PTO Operation....3678
Table 254Wheelchair Lift Interlock Checks....3683
Table 256Additional Signals Used for Wheelchair Lift Interlock O....3685
Table 260Park Position Unlock Solenoid Checks — Eaton T-Handle &....3701
Table 261LCT Column Shifter Interlock Checks....3702
Table 262TCM Power, Ground and Data Link Circuit Checks....3702
Table 263Shift Selector Power and Ground Circuit Checks....3703
Table 269RESCM Checks....3720
Table 276Parked Regeneration (Particulate_Trap_Regeneration_Forc....3732
Table 277Inhibit Regeneration (Particulate_Trap_Regeneration_Inh....3733
Table 279Switch Pack Preliminary Check....3746
Table 280Switch Pack Test....3746
Table 281Battery Power Distribution Check....3750
Table 282Accessory Power Distribution Check....3750
Table 283Accessory Power Test....3750
Table 284Ignition Power Distribution Check....3751
Table 285Ignition Power Test....3752
Table 286Ground Test....3753
Table 292 Snow Valve Mechanical Checks....3767
Table 293 Snow Valve Module Checks....3768
Table 298 Snow Valve Mechanical Checks....3772
Table 299 Snow Valve Switch Test....3773
Table 300 Snow Valve Module Checks....3773
Table 305 Exhaust Brake Switch Test....3780
Table 307Diagnostic Trouble codes....3786
Table 308Diagnostic Trouble codes....3787
S08327 - 2007 - 2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual....3793
S08361 - DuraStar, TerraStar, TranStar, and WorkStar Models Built May 2010 & Later Electrical Troubleshooting Manual....3926
toc....3930
SAFETY INFORMATION....3930
MANUAL INTRODUCTION....3932
1. Manual Introduction....3934
2. Vehicle Electrical System Overview....3935
3. Electrical Circuit Diagram Book....3935
3.1. CIRCUIT DIAGRAMS....3935
Circuit Diagram Instructions....3936
3.2. CONNECTOR BODY COMPOSITE....3939
4. Troubleshooting....3940
4.1. Verify The Problem....3940
4.2. Important Steps Before Performing Circuit Tests....3940
4.3. Review Feature Operation....3941
4.4. Check the Circuit Diagram....3941
4.5. Performing Circuit And System Tests....3942
4.6. Perform The Repair....3942
4.7. Verify The Repair....3942
5. Electrical Test Equipment....3942
5.1. EZ-TECH® Electronic Service Tool (EST)....3942
5.2. Body Controller Breakout Box (ZTSE4477)....3942
5.3. FLUKE 88 Digital Multimeter (DMM)....3943
5.4. MIDTRONICS EXP-1000HD....3944
5.5. Jumper Wires, Test Leads, And Test Lights....3945
Jumper Wires....3945
Test Leads....3946
Test Lights....3947
5.6. Ohm's Law Review....3947
5.7. Voltmeter....3949
Measuring Voltage....3949
5.8. Ammeter....3952
Measuring Amperage....3952
5.9. Ohmmeter....3954
Measuring Resistance....3954
Checking For Open Circuits....3956
Checking For Short Circuits....3957
6. Bench Testing Relays....3958
ELECTRONIC GAUGE CLUSTER....3962
1. Electronic Gauge Cluster....3964
1.1. System Description....3964
Overview....3964
Operation....3964
1.2. Feature Codes....3969
1.3. User Programmable Parameters....3970
1.4. Diagnostic Trouble Codes....3975
1.5. Troubleshooting....3983
Preliminary Checks....3983
Electronic Gauge Cluster Circuit Test....3985
EGC Backlight Circuit Test....3987
EGC Gauge Test....3987
Warning Lamp Test....3989
Fuel Level Gauge Circuit Test....3990
Transmission Oil Temperature Circuit Tests....3991
Front Rear and Rear Rear Axle Temperature Circuit Tests....3992
Air Pressure Transducer Circuit Tests....3993
Park Brake Switch Circuit Test....3996
Air Restriction Gauge Circuit Test....3997
Engine Coolant Level Monitor Circuit Test....3997
1.6. Electronic Gauge Cluster Programming....3998
SWITCH PACKS (J1708 DATA LINK)....4000
1. Switch Packs....4002
1.1. Description....4002
Overview....4002
Operation....4002
1.2. Diagnostic Trouble Codes....4002
1.3. Troubleshooting....4003
Switch Pack Preliminary Check....4004
Switch Pack Circuit Test....4004
J1708 Data Link Circuit Test....4005
LIGHTING SYSTEM....4006
1. Backup Lights....4010
1.1. System Description....4010
Overview....4010
Operation....4010
1.2. Feature Code....4010
1.3. user programmable parameters....4011
1.4. diagnostic trouble codes....4011
1.5. Troubleshooting....4011
Backup Lights Preliminary Checks....4012
Backup Light Circuit Test (Automatic Transmission)....4012
Backup Light Switch Test (Manual Transmission)....4014
2. Dome And Courtesy Lights....4015
2.1. System Description....4015
Overview....4015
Operation....4015
2.2. Feature Code....4016
2.3. User Programmable Parameters....4016
2.4. Diagnostic Trouble Codes....4016
2.5. Troubleshooting ....4017
Dome and Courtesy Lights Preliminary Checks....4017
Door Switch Circuit Tests....4018
Cab Dome Light Circuit Test....4019
Courtesy Lights Circuit Test....4021
3. Fog Lights....4021
3.1. System Description....4021
Overview....4021
Operation....4021
3.2. Feature Codes....4022
3.3. User Programmable Parameters ....4022
3.4. Diagnostic Trouble Codes....4022
3.5. Troubleshooting....4023
Fog Light System Preliminary Check....4023
Fog Light Switch Test....4024
Fog Light Circuit Test....4025
4. Headlights And Daytime Running Lights (DTRL)....4026
4.1. system description....4026
Overview....4027
Operation....4027
4.2. Feature Codes....4027
4.3. User Programmable Parameters....4027
4.4. Diagnostic Trouble Codes....4027
4.5. Troubleshooting....4029
Headlight System Preliminary Check....4030
Headlight Switch Test....4031
Turn Signal Switch Circuit Test....4032
Right Headlight Circuit Test....4033
Left Headlight Circuit Test....4035
5. Stop, Turn, And Hazard Lights....4035
5.1. System Description....4035
Overview....4035
Operation....4036
5.2. Feature Codes....4036
5.3. User Programmable Parameters....4036
5.4. Diagnostic Trouble Codes....4036
5.5. Troubleshooting....4039
Stop, Turn, and Hazards System Preliminary Check....4039
Turn Signal Switch Circuit Test....4040
Brake Switch Circuit Test....4042
Left Front Turn Signal Circuit Test....4044
Right Front Turn Signal Circuit Test....4044
Left Rear Turn Signal Circuit Test....4045
Right Rear Turn Signal Circuit Test....4046
6. Tail, Marker, Park, And Clearance Lighting....4046
6.1. System Description....4046
Overview....4046
Operation....4047
6.2. Feature Codes....4047
6.3. User Programmable Parameters....4047
6.4. Diagnostic Trouble Codes....4047
6.5. Troubleshooting....4048
Tail, Marker, Park, and Clearance Lighting Preliminary Check....4048
Headlight Switch Test....4048
Tail Light Circuit Test....4050
Park, Marker, Clearance, and Identification Lights Circuit Test....4050
7. Work Light....4051
7.1. System Description....4051
Overview....4051
Operation....4051
7.2. Feature Codes....4051
7.3. User Programmable Parameters....4051
7.4. Diagnostic Trouble Codes....4052
7.5. Troubleshooting....4052
Work Light System Preliminary Check....4053
Work Light Switch Test....4053
Work Light Circuit Tests....4054
8. Roof Auxiliary Load And Air Shield Light....4055
8.1. System Description....4055
Overview....4055
Roof Auxiliary Load Operation....4055
Air Shield Light Operation....4055
8.2. Feature Codes....4055
8.3. User Programmable Parameters....4056
8.4. Diagnostic Trouble CodeS....4056
Roof Auxiliary Load ....4056
Lighted Air Shield....4056
8.5. Troubleshooting....4056
Roof Auxiliary Load Preliminary Check....4056
Lighted Air Shield Preliminary Check....4057
Roof Auxiliary Load Switch Test....4058
Roof Auxiliary Load Circuit Test....4059
Lighted Air Shield Circuit Test....4059
9. Trailer Lighting....4060
9.1. System Description....4060
Overview....4060
Operation....4060
9.2. Feature Codes....4060
9.3. User Programmable Parameters....4060
9.4. Diagnostic Trouble CodeS....4060
9.5. Troubleshooting....4062
Trailer Lights Preliminary Check....4062
Trailer Socket Circuit Test....4062
Trailer Left Turn Relay Circuit Test....4064
Trailer Right Turn Relay Circuit Test....4065
Trailer Marker Light Relay Circuit Test....4066
Trailer Tail Light Relay Circuit Test....4067
Trailer Stop Light Relay Circuit Test....4068
Trailer ABS ECU Relay Circuit Test....4069
10. Auxiliary Snowplow Lighting....4069
10.1. System Description....4069
Overview....4069
Operation....4069
10.2. Feature Code....4070
10.3. user programmable parameters....4070
10.4. diagnostic trouble codes....4070
10.5. Troubleshooting....4071
Auxiliary Snowplow Lights Preliminary Checks....4071
Snowplow Switch Test....4072
Snowplow Lights Circuit Test....4072
CAB FEATURES....4074
1. Cigar Lighter And Power Feed....4080
1.1. System Description....4080
Overview....4080
Cigar Lighter Operation....4080
Cigar Lighter Power Source and Two-Post Power Source Operation....4080
1.2. Feature Codes....4080
1.3. User Programmable Parameters....4080
1.4. Diagnostic Trouble Codes....4080
1.5. Troubleshooting....4080
Cigar Lighter and Power Feed Preliminary Check....4080
Cigar Lighter Circuit Test....4081
Two-Post Power Source Circuit Test....4081
2. CB Power Radio....4082
2.1. System Description....4082
Overview....4082
Operation....4082
2.2. Feature Codes....4082
2.3. User Programmable Parameters....4082
2.4. Diagnostic Trouble Codes....4082
2.5. Troubleshooting....4082
CB Radio Power Source Preliminary Check....4083
CB Radio Circuit Test....4083
3. Compass And Temperature Display....4083
3.1. System Description....4083
Overview....4083
Temperature Display Operation....4084
Compass Display Operation....4084
3.2. Feature Codes....4084
3.3. User Programmable Parameters....4084
3.4. Diagnostic Trouble Codes....4084
3.5. Troubleshooting....4086
Compass and Temperature Display Preliminary Check....4086
Compass / Temperature Display Circuit Tests....4086
Compass Calibration....4088
Ambient Temperature Sensor Circuit Test....4089
4. Power Windows And Locks....4090
4.1. System Description....4090
Overview....4090
Power Window Operation....4090
Power Door Lock Operation....4091
4.2. Feature Codes....4091
4.3. User Programmable Parameters....4091
4.4. Diagnostic Trouble Codes....4092
4.5. Troubleshooting....4094
Power Window and Lock Preliminary Check....4095
Locks and Windows Inoperative Circuit Test....4095
Power Window Circuit Test....4096
Power Door Lock Circuit Test....4097
5. Electric Horn....4097
5.1. System Description....4097
Overview....4097
Operation....4097
5.2. Feature Codes....4097
5.3. User Programmable Parameters....4097
5.4. Diagnostic Trouble Codes....4099
5.5. Troubleshooting....4099
Electric Horn Preliminary Check....4099
Electric Horn Circuit Test....4100
6. Air Horn....4101
6.1. System Description....4101
Overview....4101
Operation....4101
6.2. Feature Codes....4101
6.3. User Programmable Parameters....4101
6.4. Diagnostic Trouble Codes....4101
6.5. Troubleshooting....4102
Air Horn Preliminary Check....4102
Air Horn Circuit Test....4103
7. Power Mirrors....4103
7.1. System Description....4103
Overview....4103
Operation....4103
7.2. Feature Codes....4104
7.3. User Programmable Parameters....4104
7.4. Diagnostic Trouble Codes....4104
7.5. Troubleshooting....4104
Power Mirror Preliminary Check....4105
Driver Power Mirror Circuit Test....4105
Passenger Power Mirror Circuit Test....4106
8. Heated Mirror....4107
8.1. System Description....4107
Overview....4107
Operation....4107
8.2. Feature Codes....4107
8.3. User Programmable Parameters....4107
8.4. Diagnostic Trouble Codes....4107
8.5. Troubleshooting....4108
Heated Mirror Preliminary Check....4108
Heated Mirror Switch Test....4109
Driver Heated Mirror Circuit Test....4109
Passenger Heated Mirror Circuit Test....4110
Heated Windshield Circuit Test....4110
9. Radio (Entertainment), Speakers....4112
9.1. System Description....4112
Overview....4112
Operation....4113
9.2. Feature Codes....4113
9.3. User Programmable Parameters....4113
9.4. Diagnostic Trouble Codes....4113
9.5. Troubleshooting....4113
Radio Preliminary Check....4113
Radio Circuit Test (16 Way Connector)....4114
Radio Circuit Test (12 Way Connector)....4114
Speaker Circuit Test (16 Way Connector)....4114
Speaker Circuit Test....4115
10. Two-Way Radio....4116
10.1. System Description....4116
Overview....4116
Operation....4116
10.2. Feature Codes....4117
10.3. User Programmable Parameters....4117
10.4. diagnostic trouble codes....4117
10.5. Troubleshooting....4117
Two-Way Radio Circuit Test....4117
11. Windshield Wiper And Washer Pump....4117
11.1. System Description....4117
Overview....4117
Wiper Operation....4118
Park Operation....4118
Washer Operation....4118
11.2. Feature Codes....4118
11.3. User Programmable Parameters....4118
11.4. Diagnostic Trouble Codes....4120
11.5. Troubleshooting....4121
Wiper and Washer Preliminary Check....4121
Washer Pump Circuit Test....4122
Wiper Switch Circuit Test....4123
Wiper Motor Circuit Test....4124
12. Park Brake And Brake Switch....4124
12.1. System Description....4124
Overview....4125
Operation....4125
12.2. Feature Codes....4125
12.3. User Programmable Parameters....4125
12.4. Diagnostic Trouble CodeS....4126
12.5. Troubleshooting....4127
Brake Switch Preliminary Check....4127
Brake Switch Test....4128
Park Brake Switch Test....4129
13. Clutch Switch....4131
13.1. System Description....4131
Overview....4131
Operation....4131
13.2. Feature Codes....4131
13.3. User Programmable Parameters....4132
13.4. Diagnostic Trouble CodeS....4132
13.5. Troubleshooting....4133
Clutch Switch Preliminary Checks....4133
Engine Crank Clutch Switch Test....4134
Cruise Control Clutch Switch Test....4136
14. Load Shedding....4136
14.1. System Description....4136
Overview....4137
Operation....4137
14.2. Feature Codes....4137
14.3. User Programmable Parameters....4137
14.4. Diagnostic Trouble CodeS....4137
14.5. Troubleshooting....4138
Latching Relay Circuit Test....4138
15. Vehicle Data Recorder....4139
15.1. System Description....4139
Overview....4139
Operation....4140
15.2. Feature Code....4140
15.3. User Programmable Parameters....4140
15.4. Diagnostic Trouble Codes....4140
15.5. Troubleshooting....4140
Vehicle Data Recorder Preliminary Check....4140
Vehicle Data Recorder Circuit Test....4141
VDR Brake Pressure Switch Circuit Test....4142
VDR Headlight Input Relay Circuit Test....4143
16. Theft Deterrent System....4144
16.1. System Description....4144
Overview....4144
Operation....4144
16.2. FEATURE CODE....4144
16.3. user programmable parameters....4144
16.4. diagnostic trouble codes....4144
16.5. Troubleshooting....4145
Theft Deterrent Preliminary Check....4146
Theft Deterrent System Test....4146
17. Seat Belt And Seat Sensor....4147
17.1. System Description....4147
Overview....4147
Operation....4148
17.2. Feature Code....4148
17.3. User Programmable Parameters....4148
17.4. Diagnostic Trouble Codes....4149
17.5. Troubleshooting....4149
Seat Belt Preliminary Check....4149
Seat Belt Indicator Circuit Test....4150
18. Self-Contained Air Seat....4151
18.1. System Description....4151
Overview....4151
Operation....4151
18.2. Feature Code....4151
18.3. User Programmable Parameters....4151
18.4. Diagnostic Trouble Codes....4151
18.5. Troubleshooting....4151
Driver and Passenger Self-Contained Air Seats Preliminary Check....4151
Driver and Passenger Self-Contained Air Seat Test....4152
19. Heated Seats....4153
19.1. System Description....4153
Overview....4153
Operation....4153
19.2. Feature Codes....4153
19.3. User Programmable Parameters....4153
19.4. Diagnostic Trouble CodeS....4153
19.5. Troubleshooting....4153
Driver and Passenger Heated Seats Preliminary Check....4153
Driver and Passenger Heated Seat Test....4153
CHASSIS FEATURES....4156
1. Heated Air Dryer and drain valve....4160
1.1. System Description....4160
Overview....4160
Operation....4160
1.2. Feature Codes....4160
1.3. User Programmable Parameters....4160
1.4. diagnostic trouble codes....4160
1.5. Troubleshooting....4160
Air Dryer and Heated Drain Valve Preliminary Check....4160
Heated Drain Valve Circuit Test....4161
Air Dryer Circuit Test....4162
2. Air Solenoid....4162
2.1. System Description....4162
Overview....4162
Operation....4162
2.2. Feature Codes....4163
2.3. User Programmable Parameters....4163
2.4. Diagnostic Trouble Codes....4163
2.5. Troubleshooting....4168
Air Solenoid Preliminary Check....4169
Air Solenoid Circuit Test....4169
3. Suspension Dump....4170
3.1. System Description....4170
Overview....4170
Operation....4170
3.2. Feature Code....4171
3.3. User Programmable Parameters....4171
3.4. Diagnostic Trouble Codes....4172
3.5. Troubleshooting....4173
Suspension Dump Preliminary Check....4173
Suspension Dump Test....4174
4. Differential Lock....4175
4.1. System description....4175
Overview....4175
Operation....4175
4.2. Feature Code....4176
4.3. User Programmable Parameters....4176
4.4. Diagnostic Trouble Codes....4177
4.5. Troubleshooting....4178
Differential Lock Preliminary Check....4179
Differential Lock Test....4179
5. Power Divider Lock....4180
5.1. System Description....4180
Overview....4180
Operation....4180
5.2. FEATURE CODE....4181
5.3. User Programmable Parameters....4181
5.4. Diagnostic Trouble Codes....4181
5.5. Troubleshooting....4182
Power Divider Lock Preliminary Check....4183
Power Divider Lock Test....4183
6. Power Take Off....4184
6.1. System Description....4184
Overview....4184
Operation....4184
6.2. Feature Code....4184
6.3. User Programmable Parameters....4184
6.4. Diagnostic Trouble Codes....4185
6.5. Troubleshooting....4186
Power Take Off Preliminary Check....4187
Power Take Off Circuit Test....4187
7. Anti-Lock Braking System ....4188
7.1. System Description....4188
Overview....4188
Operation....4188
Communication....4189
7.2. Feature Code....4189
7.3. User Programmable Parameters....4190
7.4. Diagnostic Trouble Codes....4190
7.5. Troubleshooting....4191
Anti-Lock Braking System Preliminary Check....4191
Bendix® ABS Circuit Tests....4192
Wabco® ABS Module Circuit Test....4195
8. Fifth Wheel Slide and jaw lock release....4196
8.1. System Description....4196
Overview....4196
Operation....4197
8.2. Feature Code....4197
8.3. User Programmable Parameters....4197
8.4. Diagnostic Trouble Codes....4198
8.5. Troubleshooting....4199
Fifth Wheel Slide Preliminary Check....4199
Fifth Wheel Slide Circuit Test....4199
Fifth Wheel Jaw Lock Release Circuit Test....4200
9. Fuel Heater....4200
9.1. System Description....4200
Overview....4201
Operation....4201
9.2. Feature Code....4201
9.3. User Programmable Parameters....4201
9.4. Diagnostic Trouble Codes....4201
9.5. Troubleshooting....4201
Fuel Heater Preliminary Check....4201
Fuel Heater Circuit Test ....4202
10. Remote Power Module....4202
10.1. System Description....4202
Overview....4203
Operation....4203
10.2. Feature Code....4203
10.3. User Programmable Parameters....4204
10.4. Diagnostic Trouble Codes....4204
10.5. Troubleshooting....4207
RPM Preliminary Check....4208
RPM Circuit Test....4208
11. remote start / stop....4210
11.1. System description....4210
Overview....4210
Operation....4211
11.2. FEATURE CODE....4211
11.3. user programmable parameters....4212
11.4. diagnostic trouble codes....4212
11.5. Troubleshooting....4212
Remote Start / Stop Preliminary Check....4213
Remote Start / Stop Test....4213
12. Two-speed axle ....4215
12.1. System description....4215
Overview....4215
Operation....4215
12.2. feature codes....4215
12.3. user programmable parameters....4215
12.4. diagnostic trouble codes....4215
12.5. troubleshooting....4216
Two-Speed Switch Preliminary Check....4216
Two-Speed Switch Test....4216
13. Customer installed lift gate power source....4217
13.1. System description....4217
Overview....4217
Operation....4217
13.2. FEATURE CODE....4217
13.3. user programmable parameters....4218
13.4. diagnostic trouble codes....4218
13.5. Troubleshooting....4219
Lift Gate Preliminary Check....4219
Lift Gate Circuit Test ....4220
14. Auto neutral ....4220
14.1. System description....4220
Overview....4220
Operation....4220
14.2. FEATURE CODE....4221
14.3. user programmable parameters....4221
14.4. diagnostic trouble codes....4221
14.5. Troubleshooting....4221
Auto Neutral Preliminary Check....4222
Auto Neutral Switch Test ....4222
Auto Neutral Circuit Test....4222
15. Axle Load Monitor....4224
15.1. System Description....4224
Overview....4224
Operation....4224
15.2. Feature Code....4224
15.3. User Programmable Parameters....4225
15.4. Diagnostic Trouble Codes....4226
15.5. Troubleshooting....4227
Axle Load Monitor Preliminary Check....4227
Axle Pressure Transducer Circuit Test....4227
16. water-in-fuel monitor ....4228
16.1. System Description....4228
Overview....4228
Operation....4228
16.2. Feature Code....4228
16.3. User Programmable Parameters....4228
16.4. Diagnostic Trouble Codes....4228
16.5. Troubleshooting....4229
Water-In-Fuel Monitor Preliminary Check....4229
Water Probe Circuit Test....4230
TRANSMISSIONS....4232
1. Transmission....4234
1.1. System Description....4234
Overview....4234
Operation....4234
1.2. Feature Code....4235
1.3. user programmable parameters....4235
1.4. Diagnostic Trouble Codes....4235
1.5. Troubleshooting....4237
Transmission Preliminary Check....4237
Eaton UltraShift®® TCM Circuit Test....4238
Eaton UltraShift® Selector Circuit Test....4241
Eaton T-Handle Shifter Circuit Test....4244
Eaton Hybrid TCM Circuit Test....4244
Allison TCU Circuit Test with IBB Engine....4246
Allison Shift Selector with IBB Engine ....4248
Allison TCU Circuit Test with I6/V8 Engine....4250
Allison Shifter with I6/V8 Engine....4251
Shifter Ignition Relay Circuit Test....4252
Park Position Unlock Solenoid Test....4254
1.6. Body Controller Signals....4254
Body Controller Signals....4255
MULTIPLEXING (DATA LINKS)....4256
1. Multiplexing (Data Links)....4258
1.1. Description....4258
Overview....4258
Operation....4258
1.2. Troubleshooting....4259
J1939 Data Link Terminating Resistors....4259
Body Controller....4260
J1939 Data Link Circuit Test....4260
J1708 Data Link Circuit Test....4261
12-VOLT POWER DISTRIBUTION AND GROUND....4262
1. 12-Volt Power Distribution and Grounds....4264
1.1. Description....4264
Overview....4264
Operation....4264
1.2. Troubleshooting....4264
Battery Power Distribution Check....4265
Accessory Power Distribution Preliminary Check....4265
Accessory Power Circuit Test....4266
Body Controller Accessory Feed Input Circuit Test....4267
Ignition Power Distribution Preliminary Check....4268
Ignition Power Circuit Test....4268
Ground Circuit Test....4270
FANS AND ENGINE ACCESSORIES....4272
1. Fan System....4274
1.1. System Description....4274
Overview....4274
Operation....4274
1.2. Feature Code....4274
1.3. User Programmable Parameters....4275
1.4. Diagnostic Trouble Codes....4275
1.5. Troubleshooting....4275
Fan System Preliminary Check....4276
Fan Override Switch Test....4276
2. Compression / Exhaust Brake....4277
2.1. System Description....4277
Overview....4277
Operation....4277
2.2. Feature Code....4277
2.3. User Programmable Parameters....4278
2.4. Diagnostic Trouble Codes....4278
2.5. Troubleshooting....4278
Compression / Exhaust Brake Preliminary Check....4279
Compression / Exhaust Brake Switch Test....4279
3. Aftertreatment ....4279
3.1. System Description....4279
Overview....4279
Operation....4280
3.2. Feature Code....4282
3.3. User Programmable Parameters....4282
3.4. Diagnostic Trouble Codes....4282
3.5. Troubleshooting....4283
Aftertreatment Preliminary Check....4284
Inhibit Regeneration Switch Test....4284
Parked Regeneration Switch Test....4285
Warning Lamp Test....4285
4. Cruise Control....4286
4.1. system description....4286
Overview....4286
Operation....4286
4.2. feature codes....4287
4.3. User Programmable Parameters....4287
4.4. diagnostic trouble codes....4287
4.5. Troubleshooting....4288
Cruise Control Preliminary Check....4289
Cruise Control Switch Test....4290
5. Snow Valve....4291
5.1. System Description....4291
Overview....4291
Operation....4291
5.2. Feature Code....4292
5.3. User Programmable Parameters....4292
5.4. Diagnostic Trouble Codes....4292
5.5. Troubleshooting....4292
Snow Valve Preliminary Check....4292
Snow Valve Module Circuit Test....4293
BATTERY, CHARGING, AND CRANKING SYSTEM....4294
1. Battery System....4296
1.1. Description....4296
Overview....4296
Operation....4296
1.2. Diagnostic Trouble Codes....4297
1.3. Troubleshooting....4297
Battery Test....4297
Battery Test Results....4298
Cable Drop Test....4298
Battery Pack Test....4298
Battery Pack Test Results....4298
2. Charging System....4299
2.1. Description....4299
Overview....4299
Operation....4299
2.2. Diagnostic Trouble Codes....4299
2.3. Troubleshooting....4300
Charging System Test....4300
Charging System Test Results....4300
3. Cranking System....4301
3.1. Description....4301
Overview....4301
Operation....4301
3.2. Troubleshooting....4302
Starting System Test....4302
Starting System Test Results....4302
4. Powerpack 3....4302
4.1. Description....4302
Overview....4303
Operation....4303
4.2. Troubleshooting....4303
VEHICLE AND DRIVER INFORMATION DISPLAY....4304
1. vehicle information display....4306
1.1. System description....4306
Overview....4306
Operation....4306
1.2. FEATURE CODE....4306
1.3. user programmable parameters....4307
1.4. diagnostic trouble codes....4307
1.5. Troubleshooting....4307
Vehicle Information Display Preliminary Check....4307
Vehicle Information Display Circuit Test....4307
2. Driver information display....4308
2.1. System description....4308
Overview....4308
Operation....4309
2.2. FEATURE CODE....4309
2.3. user programmable parameters....4309
2.4. diagnostic trouble codes....4309
2.5. Troubleshooting....4309
Driver Information Display Preliminary Check....4310
Driver Information Display Circuit Test....4310
tables....3947
Table 1Ohm's Law....3947
Table 2Relay Bench Test....3960
Table 3Gauges and Signal Paths....3965
Table 4Warning Lamp and Signal Path....3966
Table 5Audible Alarms....3968
Table 6Electronic Gauge Cluster Feature Codes....3969
Table 7Diagnostic Trouble Codes....3975
Table 8EGC Preliminary Checks....3983
Table 9Electronic Gauge Cluster Circuit Test....3985
Table 10EGC Backlighting Circuit Test....3987
Table 11EGC Gauge Test....3988
Table 12Warning Lamp Test....3989
Table 13Fuel Level Gauge Circuit Test....3990
Table 14Transmission Oil Temperature Circuit Test....3991
Table 15Rear Rear Axle Temperature Circuit Test....3992
Table 16Front Rear Axle Temperature Circuit Test....3993
Table 17Air Pressure Transducer Circuit Test....3994
Table 18Park Brake Switch Circuit Test....3996
Table 19 Air Restriction Gauge Circuit Test....3997
Table 20Low Coolant Sensor Circuit Test....3997
Table 21Diagnostic Trouble Codes....4002
Table 22Switch Pack Preliminary Check....4004
Table 23Switch Pack Circuit Test....4004
Table 24J1708 Data Link Circuit Test....4005
Table 25Feature Code....4010
Table 26Diagnostic Trouble Codes....4011
Table 27Backup Lights Preliminary Checks....4012
Table 28 Backup Light Circuit Test....4012
Table 29Backup Light Switch Test....4014
Table 30Feature Code....4016
Table 31Diagnostic Trouble Codes....4016
Table 32Dome and Courtesy Lights Preliminary Checks....4017
Table 33Door Switch Circuit Test....4018
Table 34Cab Dome Light Circuit Test....4019
Table 35Courtesy Lights Circuit Test....4021
Table 36Feature Codes....4022
Table 37Diagnostic Trouble Codes....4022
Table 38Fog Light System Preliminary Check....4023
Table 39Fog Light Switch Test....4024
Table 40Fog Light Circuit Test....4025
Table 41Feature Codes....4027
Table 42Diagnostic Trouble Codes....4028
Table 43Headlight System Preliminary Check....4030
Table 44Headlight Switch Test....4031
Table 45Turn Signal Switch Circuit Test....4032
Table 46Right Headlight Circuit Test....4033
Table 47Left Headlight Circuit Test....4035
Table 48Feature Codes....4036
Table 49Diagnostic Trouble Codes....4036
Table 50Stop, Turn, and Hazards System Preliminary Check....4039
Table 51Turn Signal Switch Circuit Test....4040
Table 52Brake Switch Circuit Test....4042
Table 53Left Front Turn Signal Circuit Test....4044
Table 54Right Front Turn Signal Circuit Test....4045
Table 55Left Rear Turn Signal Circuit Test....4045
Table 56Right Rear Turn Signal Circuit Test....4046
Table 57Feature Codes....4047
Table 58Diagnostic Trouble Codes....4047
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....4048
Table 60Headlight Switch Test....4049
Table 61Tail Light Circuit Test....4050
Table 62Park, Marker, Clearance, and Identification Lights Circu....4050
Table 63Feature Codes....4051
Table 64Diagnostic Trouble Codes....4052
Table 65Work Light System Preliminary Check....4053
Table 66Work Light Switch Test....4053
Table 67Work Light Circuit Test....4054
Table 68Feature Codes....4055
Table 69Lighted Air Shield DTC....4056
Table 70Roof Auxiliary Load Preliminary Check....4056
Table 71Lighted Air Shield Preliminary Check....4057
Table 72Roof Auxiliary Load Switch Test....4058
Table 73Roof Auxiliary Load Circuit Test....4059
Table 74Lighted Air Shield Circuit Test....4059
Table 75Feature Codes....4060
Table 76Diagnostic Trouble Codes....4061
Table 77Trailer Lights Preliminary Check....4062
Table 78Trailer Socket Circuit Test....4062
Table 79Trailer Left Turn Relay Circuit Test....4064
Table 80Trailer Right Turn Relay Circuit Test....4065
Table 81Trailer Marker Light Relay Circuit Test....4066
Table 82Trailer Tail Light Relay Circuit Test....4067
Table 83Trailer Stop Light Relay Circuit Test....4068
Table 84Trailer ABS ECU Relay Circuit Test....4069
Table 85Feature Code....4070
Table 86Diagnostic Trouble Codes....4070
Table 87Auxiliary Snowplow Lights Preliminary Checks....4071
Table 88 Snowplow Switch Test....4072
Table 89Snowplow Lights Circuit Test....4072
Table 90Cigar Lighter and Power Feed Preliminary Check....4081
Table 91Cigar Lighter Circuit Test....4081
Table 92Two-Post Power Source Circuit Test....4081
Table 93CB Radio Power Source Preliminary Check....4083
Table 94CB Radio Circuit Test....4083
Table 95Feature Codes....4084
Table 96Diagnostic Trouble Codes....4084
Table 97Compass and Temperature Display Preliminary Check....4086
Table 98Compass Display Circuit Test....4087
Table 99Ambient Temperature Sensor Circuit Test....4090
Table 100Feature Codes....4091
Table 101Diagnostic Trouble Codes....4092
Table 102Power Locks Preliminary Check....4095
Table 103Power Windows Preliminary Check....4095
Table 104Locks and Windows Inoperative Circuit Test....4095
Table 105Power Window Circuit Test....4096
Table 106Power Door Lock Circuit Test....4097
Table 107Feature Codes....4097
Table 108Diagnostic Trouble Codes....4099
Table 109Electric Horn Preliminary Check....4099
Table 110Electric Horn Circuit Test....4100
Table 111Feature Codes....4101
Table 112Diagnostic Trouble Codes....4102
Table 113Air Horn Preliminary Checks....4102
Table 114Air Horn Circuit Test....4103
Table 115Power Mirror Preliminary Check....4105
Table 116Driver Power Mirror Circuit Test....4105
Table 117Passenger Power Mirror Circuit Test....4106
Table 118Feature Codes....4107
Table 119Diagnostic Trouble codes....4108
Table 120Heated Mirror Preliminary Check....4108
Table 121Heated Mirror Switch Test....4109
Table 122Driver Heated Mirror Circuit Test....4109
Table 123Passenger Heated Mirror Circuit Test....4110
Table 124Heated Windshield Circuit Test....4111
Table 125Radio Preliminary Check....4113
Table 126Radio Circuit Test (16 Way Connector)....4114
Table 127Radio Circuit Test (12 Way Connector)....4114
Table 128Speaker Circuit Test (16 Way Connector)....4115
Table 129Speaker Circuit Test (12 Way Connector)....4116
Table 130Two-Way Radio Circuit Test....4117
Table 131Feature Codes....4118
Table 132Diagnostic Trouble Codes....4120
Table 133Wiper and Washer Preliminary Check....4121
Table 134Washer Pump Circuit Test....4122
Table 135Wiper Switch Circuit Test....4123
Table 136Wiper Motor Circuit Test....4124
Table 137Feature Codes....4125
Table 138Diagnostic Trouble Codes....4126
Table 139Brake Switch Preliminary Check....4127
Table 140Brake Switch Circuit Test....4128
Table 141Park Brake Switch Circuit Test....4129
Table 142Feature Code....4132
Table 143Diagnostic Trouble Codes....4132
Table 144Clutch Switch Preliminary Checks....4133
Table 145Engine Crank Clutch Switch Test....4134
Table 146Cruise Control Clutch Switch Test....4136
Table 147Feature Code....4137
Table 148Diagnostic Trouble Codes....4138
Table 149Latching Relay Circuit Test....4139
Table 150Vehicle Data Recorder Preliminary Check....4140
Table 151 Vehicle Data Recorder Circuit Test....4141
Table 152VDR Brake Pressure Switch Circuit Test....4142
Table 153VDR Headlight Input Relay Circuit Test....4143
Table 154Feature Code....4144
Table 155Diagnostic Trouble Codes....4145
Table 156Theft Deterrent Preliminary Check....4146
Table 157Theft Deterrent System Test....4146
Table 158Feature Code....4148
Table 159Seat Belt Preliminary Check....4149
Table 160Seat Belt Indicator Circuit Test....4150
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....4151
Table 162Driver and Passenger Self-Contained Air Seat Test....4152
Table 163Driver and Passenger Heated Seats Preliminary Check....4153
Table 164Driver and Passenger Heated Seat Test....4154
Table 165Air Dryer and Heated Drain Valve Preliminary Check....4160
Table 166Heated Drain Valve Circuit Test....4161
Table 167Air Dryer Circuit Test....4162
Table 168Feature Codes....4163
Table 169Diagnostic Trouble Codes....4163
Table 170Air Solenoid Preliminary Check....4169
Table 171Air Solenoid Circuit Test....4170
Table 172Feature Code....4171
Table 173Diagnostic Trouble Codes....4172
Table 174Suspension Dump Preliminary Check....4174
Table 175Suspension Dump Test....4174
Table 176Feature Codes....4176
Table 177Diagnostic Trouble Codes....4177
Table 178Differential Lock Preliminary Check....4179
Table 179Differential Lock Test....4179
Table 180Feature Code....4181
Table 181Diagnostic Trouble Codes....4182
Table 182Power Divider Lock Preliminary Check....4183
Table 183Power Divider Lock Test....4183
Table 184Feature Code....4184
Table 185Diagnostic Trouble Codes....4185
Table 186Power Take Off Preliminary Check....4187
Table 187Power Take Off Circuit Test....4187
Table 188Feature Code....4189
Table 189Diagnostic Trouble Codes....4191
Table 190Anti-Lock Braking System Preliminary Check....4191
Table 191Bendix® ABS Module Circuit Test....4192
Table 192Bendix® Steering Wheel Sensor Circuit Test....4194
Table 193Bendix® Yaw Sensor Circuit Test....4194
Table 194Wabco® ABS Module Circuit Test....4195
Table 195Feature Code....4197
Table 196Diagnostic Trouble Codes....4198
Table 197Fifth Wheel Slide Preliminary Check....4199
Table 198Fifth Wheel Slide Circuit Test....4199
Table 199Fifth Wheel Jaw Lock Release Circuit Test....4200
Table 200Fuel Heater Preliminary Check....4201
Table 201Fuel Heater Circuit Test ....4202
Table 202Diagnostic Trouble Codes....4204
Table 203RPM Preliminary Check....4208
Table 204RPM Circuit Test....4208
Table 205Feature Code....4211
Table 206Diagnostic Trouble Codes....4212
Table 207Remote Start / Stop Preliminary Check....4213
Table 208Remote Start / Stop Test....4213
Table 209Feature Codes....4215
Table 210Diagnostic Trouble Codes....4215
Table 211Two-Speed Switch Preliminary Check....4216
Table 212Two-Speed Switch Test....4216
Table 213Feature Code....4217
Table 214Diagnostic Trouble Codes....4218
Table 215Lift Gate Preliminary Check....4219
Table 216Lift Gate Test ....4220
Table 217Feature Code....4221
Table 218Diagnostic Trouble Codes....4221
Table 219Auto Neutral Preliminary Check....4222
Table 220Auto Neutral Switch Test ....4222
Table 221Auto Neutral Circuit Test ....4222
Table 222Feature Code....4224
Table 223Diagnostic Trouble Codes....4226
Table 224Axle Load Monitor Preliminary Check....4227
Table 225Axle Pressure Transducer Circuit Test....4227
Table 226Diagnostic Trouble Codes....4229
Table 227Water-In-Fuel Monitor Preliminary Check....4229
Table 228Water Probe Circuit Test....4230
Table 229Feature Code....4235
Table 230Diagnostic Trouble Codes....4236
Table 231Transmission Preliminary Check....4237
Table 232Eaton UltraShift® TCM Circuit Test....4239
Table 233Eaton UltraShift® Selector Circuit Test....4241
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....4243
Table 235Eaton T-Handle Shifter Circuit Test....4244
Table 236Eaton T-Handle Shifter Lighting Circuit Test....4244
Table 237Eaton Hybrid TCM Circuit Test....4245
Table 238Allison TCU Circuit Test with IBB Engine....4247
Table 239Allison Shift Selector Circuit Test....4248
Table 240Allison Shift Selector Lighting Circuit Test....4250
Table 241Allison TCU Circuit Test with I6/V8 Engine....4250
Table 242Allison Column Mounted Shifter ....4251
Table 243Allison T-Handle Shifter ....4252
Table 244Shifter Ignition Relay Circuit Test....4253
Table 245Park Position Unlock Solenoid Test....4254
Table 246Body Controller Signals....4255
Table 247J1939 Data Link Circuit Test....4261
Table 248J1708 Data Link Circuit Test....4261
Table 249Battery Power Distribution Preliminary Check....4265
Table 250Accessory Power Distribution Check....4265
Table 251Accessory Power Circuit Test....4266
Table 252Body Controller Accessory Feed Input Circuit Test....4267
Table 253Ignition Power Distribution Check....4268
Table 254Ignition Power Circuit Test....4268
Table 255Ground Circuit Test....4270
Table 256Feature Code....4275
Table 257Diagnostic Trouble Codes....4275
Table 258Fan System Preliminary Check....4276
Table 259Fan Override Switch Test....4276
Table 260Feature Code....4277
Table 261Diagnostic Trouble Codes....4278
Table 262Compression / Exhaust Brake Preliminary Check....4279
Table 263Compression Brake Switch Test....4279
Table 264Soot Accumulation Level Indications....4281
Table 265Feature Code....4282
Table 266Diagnostic Trouble Codes....4282
Table 267Aftertreatment Preliminary Check....4284
Table 268Inhibit Regeneration Switch Test....4284
Table 269Parked Regeneration Switch Test....4285
Table 270Warning Lamp Test....4285
Table 271Feature Code....4287
Table 272Diagnostic Trouble Codes....4288
Table 273Cruise Control Preliminary Check....4289
Table 274Cruise Control Switch Test....4290
Table 275Feature Code....4292
Table 276Snow Valve Preliminary Check....4292
Table 277Snow Valve Module Circuit Test....4293
Table 278Diagnostic Trouble Codes....4297
Table 279Diagnostic Trouble Codes....4299
Table 280Feature Code....4307
Table 281Vehicle Information Display Preliminary Check....4307
Table 282Vehicle Information Display Circuit Test....4307
Table 283Feature Code....4309
Table 284Driver Information Display Preliminary Check....4310
Table 285Driver Information Display Circuit Test....4310
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual....4314
toc....4318
SAFETY INFORMATION....4318
MANUAL INTRODUCTION....4320
1. Manual Introduction....4322
2. Vehicle Electrical System Overview....4323
3. Electrical Circuit Diagram Book....4323
3.1. CIRCUIT DIAGRAMS....4323
Circuit Diagram Instructions....4324
3.2. CONNECTOR BODY COMPOSITE....4327
4. Troubleshooting....4328
4.1. Verify The Problem....4328
4.2. Important Steps Before Performing Circuit Tests....4328
4.3. Review Feature Operation....4329
4.4. Check the Circuit Diagram....4329
4.5. Performing Circuit And System Tests....4330
4.6. Perform The Repair....4330
4.7. Verify The Repair....4330
5. Electrical Test Equipment....4330
5.1. EZ-TECH® Electronic Service Tool (EST)....4330
5.2. Body Controller Breakout Box (ZTSE4477)....4330
5.3. FLUKE 88 Digital Multimeter (DMM)....4331
5.4. MIDTRONICS EXP-1000HD....4332
5.5. Jumper Wires, Test Leads, And Test Lights....4333
Jumper Wires....4333
Test Leads....4334
Test Lights....4335
5.6. Ohm's Law Review....4335
5.7. Voltmeter....4337
Measuring Voltage....4337
5.8. Ammeter....4340
Measuring Amperage....4340
5.9. Ohmmeter....4342
Measuring Resistance....4342
Checking For Open Circuits....4344
Checking For Short Circuits....4345
6. Bench Testing Relays....4346
ELECTRONIC GAUGE CLUSTER....4350
1. Electronic Gauge Cluster....4352
1.1. System Description....4352
Overview....4352
Operation....4352
1.2. Feature Codes....4357
1.3. User Programmable Parameters....4358
1.4. Diagnostic Trouble Codes....4363
1.5. Troubleshooting....4371
Preliminary Checks....4371
Electronic Gauge Cluster Circuit Test....4373
EGC Backlight Circuit Test....4375
EGC Gauge Test....4375
Warning Lamp Test....4377
Fuel Level Gauge Circuit Test....4378
Transmission Oil Temperature Circuit Tests....4379
Front Rear and Rear Rear Axle Temperature Circuit Tests....4380
Air Pressure Transducer Circuit Tests....4381
Park Brake Switch Circuit Test....4384
Air Restriction Gauge Circuit Test....4385
Engine Coolant Level Monitor Circuit Test....4385
1.6. Electronic Gauge Cluster Programming....4386
SWITCH PACKS (J1708 DATA LINK)....4388
1. Switch Packs....4390
1.1. Description....4390
Overview....4390
Operation....4390
1.2. Diagnostic Trouble Codes....4390
1.3. Troubleshooting....4391
Switch Pack Preliminary Check....4392
Switch Pack Circuit Test....4392
J1708 Data Link Circuit Test....4393
LIGHTING SYSTEM....4394
1. Backup Lights....4398
1.1. System Description....4398
Overview....4398
Operation....4398
1.2. Feature Code....4398
1.3. user programmable parameters....4399
1.4. diagnostic trouble codes....4399
1.5. Troubleshooting....4399
Backup Lights Preliminary Checks....4400
Backup Light Circuit Test (Automatic Transmission)....4400
Backup Light Switch Test (Manual Transmission)....4402
2. Dome And Courtesy Lights....4403
2.1. System Description....4403
Overview....4403
Operation....4403
2.2. Feature Code....4404
2.3. User Programmable Parameters....4404
2.4. Diagnostic Trouble Codes....4404
2.5. Troubleshooting ....4405
Dome and Courtesy Lights Preliminary Checks....4405
Door Switch Circuit Tests....4406
Cab Dome Light Circuit Test....4407
Courtesy Lights Circuit Test....4409
3. Fog Lights....4409
3.1. System Description....4409
Overview....4409
Operation....4409
3.2. Feature Codes....4410
3.3. User Programmable Parameters ....4410
3.4. Diagnostic Trouble Codes....4410
3.5. Troubleshooting....4411
Fog Light System Preliminary Check....4411
Fog Light Switch Test....4412
Fog Light Circuit Test....4413
4. Headlights And Daytime Running Lights (DTRL)....4414
4.1. system description....4414
Overview....4415
Operation....4415
4.2. Feature Codes....4415
4.3. User Programmable Parameters....4415
4.4. Diagnostic Trouble Codes....4415
4.5. Troubleshooting....4417
Headlight System Preliminary Check....4418
Headlight Switch Test....4419
Turn Signal Switch Circuit Test....4420
Right Headlight Circuit Test....4421
Left Headlight Circuit Test....4423
5. Stop, Turn, And Hazard Lights....4423
5.1. System Description....4423
Overview....4423
Operation....4424
5.2. Feature Codes....4424
5.3. User Programmable Parameters....4424
5.4. Diagnostic Trouble Codes....4424
5.5. Troubleshooting....4427
Stop, Turn, and Hazards System Preliminary Check....4427
Turn Signal Switch Circuit Test....4428
Brake Switch Circuit Test....4430
Left Front Turn Signal Circuit Test....4432
Right Front Turn Signal Circuit Test....4432
Left Rear Turn Signal Circuit Test....4433
Right Rear Turn Signal Circuit Test....4434
6. Tail, Marker, Park, And Clearance Lighting....4434
6.1. System Description....4434
Overview....4434
Operation....4435
6.2. Feature Codes....4435
6.3. User Programmable Parameters....4435
6.4. Diagnostic Trouble Codes....4435
6.5. Troubleshooting....4436
Tail, Marker, Park, and Clearance Lighting Preliminary Check....4436
Headlight Switch Test....4436
Tail Light Circuit Test....4438
Park, Marker, Clearance, and Identification Lights Circuit Test....4438
7. Work Light....4439
7.1. System Description....4439
Overview....4439
Operation....4439
7.2. Feature Codes....4439
7.3. User Programmable Parameters....4439
7.4. Diagnostic Trouble Codes....4440
7.5. Troubleshooting....4440
Work Light System Preliminary Check....4441
Work Light Switch Test....4441
Work Light Circuit Tests....4442
8. Roof Auxiliary Load And Air Shield Light....4443
8.1. System Description....4443
Overview....4443
Roof Auxiliary Load Operation....4443
Air Shield Light Operation....4443
8.2. Feature Codes....4443
8.3. User Programmable Parameters....4444
8.4. Diagnostic Trouble CodeS....4444
Roof Auxiliary Load ....4444
Lighted Air Shield....4444
8.5. Troubleshooting....4444
Roof Auxiliary Load Preliminary Check....4444
Lighted Air Shield Preliminary Check....4445
Roof Auxiliary Load Switch Test....4446
Roof Auxiliary Load Circuit Test....4447
Lighted Air Shield Circuit Test....4447
9. Trailer Lighting....4448
9.1. System Description....4448
Overview....4448
Operation....4448
9.2. Feature Codes....4448
9.3. User Programmable Parameters....4448
9.4. Diagnostic Trouble CodeS....4448
9.5. Troubleshooting....4450
Trailer Lights Preliminary Check....4450
Trailer Socket Circuit Test....4450
Trailer Left Turn Relay Circuit Test....4452
Trailer Right Turn Relay Circuit Test....4453
Trailer Marker Light Relay Circuit Test....4454
Trailer Tail Light Relay Circuit Test....4455
Trailer Stop Light Relay Circuit Test....4456
Trailer ABS ECU Relay Circuit Test....4457
10. Auxiliary Snowplow Lighting....4457
10.1. System Description....4457
Overview....4457
Operation....4457
10.2. Feature Code....4458
10.3. user programmable parameters....4458
10.4. diagnostic trouble codes....4458
10.5. Troubleshooting....4459
Auxiliary Snowplow Lights Preliminary Checks....4459
Snowplow Switch Test....4460
Snowplow Lights Circuit Test....4460
CAB FEATURES....4462
1. Cigar Lighter And Power Feed....4468
1.1. System Description....4468
Overview....4468
Cigar Lighter Operation....4468
Cigar Lighter Power Source and Two-Post Power Source Operation....4468
1.2. Feature Codes....4468
1.3. User Programmable Parameters....4468
1.4. Diagnostic Trouble Codes....4468
1.5. Troubleshooting....4468
Cigar Lighter and Power Feed Preliminary Check....4468
Cigar Lighter Circuit Test....4469
Two-Post Power Source Circuit Test....4469
2. CB Power Radio....4470
2.1. System Description....4470
Overview....4470
Operation....4470
2.2. Feature Codes....4470
2.3. User Programmable Parameters....4470
2.4. Diagnostic Trouble Codes....4470
2.5. Troubleshooting....4470
CB Radio Power Source Preliminary Check....4471
CB Radio Circuit Test....4471
3. Compass And Temperature Display....4471
3.1. System Description....4471
Overview....4471
Temperature Display Operation....4472
Compass Display Operation....4472
3.2. Feature Codes....4472
3.3. User Programmable Parameters....4472
3.4. Diagnostic Trouble Codes....4472
3.5. Troubleshooting....4474
Compass and Temperature Display Preliminary Check....4474
Compass / Temperature Display Circuit Tests....4474
Compass Calibration....4476
Ambient Temperature Sensor Circuit Test....4477
4. Power Windows And Locks....4478
4.1. System Description....4478
Overview....4478
Power Window Operation....4478
Power Door Lock Operation....4479
4.2. Feature Codes....4479
4.3. User Programmable Parameters....4479
4.4. Diagnostic Trouble Codes....4480
4.5. Troubleshooting....4482
Power Window and Lock Preliminary Check....4483
Locks and Windows Inoperative Circuit Test....4483
Power Window Circuit Test....4484
Power Door Lock Circuit Test....4485
5. Electric Horn....4485
5.1. System Description....4485
Overview....4485
Operation....4485
5.2. Feature Codes....4485
5.3. User Programmable Parameters....4485
5.4. Diagnostic Trouble Codes....4487
5.5. Troubleshooting....4487
Electric Horn Preliminary Check....4487
Electric Horn Circuit Test....4488
6. Air Horn....4489
6.1. System Description....4489
Overview....4489
Operation....4489
6.2. Feature Codes....4489
6.3. User Programmable Parameters....4489
6.4. Diagnostic Trouble Codes....4489
6.5. Troubleshooting....4490
Air Horn Preliminary Check....4490
Air Horn Circuit Test....4491
7. Power Mirrors....4491
7.1. System Description....4491
Overview....4491
Operation....4491
7.2. Feature Codes....4492
7.3. User Programmable Parameters....4492
7.4. Diagnostic Trouble Codes....4492
7.5. Troubleshooting....4492
Power Mirror Preliminary Check....4493
Driver Power Mirror Circuit Test....4493
Passenger Power Mirror Circuit Test....4494
8. Heated Mirror....4495
8.1. System Description....4495
Overview....4495
Operation....4495
8.2. Feature Codes....4495
8.3. User Programmable Parameters....4495
8.4. Diagnostic Trouble Codes....4495
8.5. Troubleshooting....4496
Heated Mirror Preliminary Check....4496
Heated Mirror Switch Test....4497
Driver Heated Mirror Circuit Test....4497
Passenger Heated Mirror Circuit Test....4498
Heated Windshield Circuit Test....4498
9. Radio (Entertainment), Speakers....4500
9.1. System Description....4500
Overview....4500
Operation....4501
9.2. Feature Codes....4501
9.3. User Programmable Parameters....4501
9.4. Diagnostic Trouble Codes....4501
9.5. Troubleshooting....4501
Radio Preliminary Check....4501
Radio Circuit Test (16 Way Connector)....4502
Radio Circuit Test (12 Way Connector)....4502
Speaker Circuit Test (16 Way Connector)....4502
Speaker Circuit Test....4503
10. Two-Way Radio....4504
10.1. System Description....4504
Overview....4504
Operation....4504
10.2. Feature Codes....4505
10.3. User Programmable Parameters....4505
10.4. diagnostic trouble codes....4505
10.5. Troubleshooting....4505
Two-Way Radio Circuit Test....4505
11. Windshield Wiper And Washer Pump....4505
11.1. System Description....4505
Overview....4505
Wiper Operation....4506
Park Operation....4506
Washer Operation....4506
11.2. Feature Codes....4506
11.3. User Programmable Parameters....4506
11.4. Diagnostic Trouble Codes....4508
11.5. Troubleshooting....4509
Wiper and Washer Preliminary Check....4509
Washer Pump Circuit Test....4510
Wiper Switch Circuit Test....4511
Wiper Motor Circuit Test....4512
12. Park Brake And Brake Switch....4512
12.1. System Description....4512
Overview....4513
Operation....4513
12.2. Feature Codes....4513
12.3. User Programmable Parameters....4513
12.4. Diagnostic Trouble CodeS....4514
12.5. Troubleshooting....4515
Brake Switch Preliminary Check....4515
Brake Switch Test....4516
Park Brake Switch Test....4517
13. Clutch Switch....4519
13.1. System Description....4519
Overview....4519
Operation....4519
13.2. Feature Codes....4519
13.3. User Programmable Parameters....4520
13.4. Diagnostic Trouble CodeS....4520
13.5. Troubleshooting....4521
Clutch Switch Preliminary Checks....4521
Engine Crank Clutch Switch Test....4522
Cruise Control Clutch Switch Test....4524
14. Load Shedding....4524
14.1. System Description....4524
Overview....4525
Operation....4525
14.2. Feature Codes....4525
14.3. User Programmable Parameters....4525
14.4. Diagnostic Trouble CodeS....4525
14.5. Troubleshooting....4526
Latching Relay Circuit Test....4526
15. Vehicle Data Recorder....4527
15.1. System Description....4527
Overview....4527
Operation....4528
15.2. Feature Code....4528
15.3. User Programmable Parameters....4528
15.4. Diagnostic Trouble Codes....4528
15.5. Troubleshooting....4528
Vehicle Data Recorder Preliminary Check....4528
Vehicle Data Recorder Circuit Test....4529
VDR Brake Pressure Switch Circuit Test....4530
VDR Headlight Input Relay Circuit Test....4531
16. Theft Deterrent System....4532
16.1. System Description....4532
Overview....4532
Operation....4532
16.2. FEATURE CODE....4532
16.3. user programmable parameters....4532
16.4. diagnostic trouble codes....4532
16.5. Troubleshooting....4533
Theft Deterrent Preliminary Check....4534
Theft Deterrent System Test....4534
17. Seat Belt And Seat Sensor....4535
17.1. System Description....4535
Overview....4535
Operation....4536
17.2. Feature Code....4536
17.3. User Programmable Parameters....4536
17.4. Diagnostic Trouble Codes....4537
17.5. Troubleshooting....4537
Seat Belt Preliminary Check....4537
Seat Belt Indicator Circuit Test....4538
18. Self-Contained Air Seat....4539
18.1. System Description....4539
Overview....4539
Operation....4539
18.2. Feature Code....4539
18.3. User Programmable Parameters....4539
18.4. Diagnostic Trouble Codes....4539
18.5. Troubleshooting....4539
Driver and Passenger Self-Contained Air Seats Preliminary Check....4539
Driver and Passenger Self-Contained Air Seat Test....4540
19. Heated Seats....4541
19.1. System Description....4541
Overview....4541
Operation....4541
19.2. Feature Codes....4541
19.3. User Programmable Parameters....4541
19.4. Diagnostic Trouble CodeS....4541
19.5. Troubleshooting....4541
Driver and Passenger Heated Seats Preliminary Check....4541
Driver and Passenger Heated Seat Test....4541
CHASSIS FEATURES....4544
1. Heated Air Dryer and drain valve....4548
1.1. System Description....4548
Overview....4548
Operation....4548
1.2. Feature Codes....4548
1.3. User Programmable Parameters....4548
1.4. diagnostic trouble codes....4548
1.5. Troubleshooting....4548
Air Dryer and Heated Drain Valve Preliminary Check....4548
Heated Drain Valve Circuit Test....4549
Air Dryer Circuit Test....4550
2. Air Solenoid....4550
2.1. System Description....4550
Overview....4550
Operation....4550
2.2. Feature Codes....4551
2.3. User Programmable Parameters....4551
2.4. Diagnostic Trouble Codes....4551
2.5. Troubleshooting....4556
Air Solenoid Preliminary Check....4557
Air Solenoid Circuit Test....4557
3. Suspension Dump....4558
3.1. System Description....4558
Overview....4558
Operation....4558
3.2. Feature Code....4559
3.3. User Programmable Parameters....4559
3.4. Diagnostic Trouble Codes....4560
3.5. Troubleshooting....4561
Suspension Dump Preliminary Check....4561
Suspension Dump Test....4562
4. Differential Lock....4563
4.1. System description....4563
Overview....4563
Operation....4563
4.2. Feature Code....4564
4.3. User Programmable Parameters....4564
4.4. Diagnostic Trouble Codes....4565
4.5. Troubleshooting....4566
Differential Lock Preliminary Check....4567
Differential Lock Test....4567
5. Power Divider Lock....4568
5.1. System Description....4568
Overview....4568
Operation....4568
5.2. FEATURE CODE....4569
5.3. User Programmable Parameters....4569
5.4. Diagnostic Trouble Codes....4569
5.5. Troubleshooting....4570
Power Divider Lock Preliminary Check....4571
Power Divider Lock Test....4571
6. Power Take Off....4572
6.1. System Description....4572
Overview....4572
Operation....4572
6.2. Feature Code....4572
6.3. User Programmable Parameters....4572
6.4. Diagnostic Trouble Codes....4573
6.5. Troubleshooting....4574
Power Take Off Preliminary Check....4575
Power Take Off Circuit Test....4575
7. Anti-Lock Braking System ....4576
7.1. System Description....4576
Overview....4576
Operation....4576
Communication....4577
7.2. Feature Code....4577
7.3. User Programmable Parameters....4578
7.4. Diagnostic Trouble Codes....4578
7.5. Troubleshooting....4579
Anti-Lock Braking System Preliminary Check....4579
Bendix® ABS Circuit Tests....4580
Wabco® ABS Module Circuit Test....4583
8. Fifth Wheel Slide and jaw lock release....4584
8.1. System Description....4584
Overview....4584
Operation....4585
8.2. Feature Code....4585
8.3. User Programmable Parameters....4585
8.4. Diagnostic Trouble Codes....4586
8.5. Troubleshooting....4587
Fifth Wheel Slide Preliminary Check....4587
Fifth Wheel Slide Circuit Test....4587
Fifth Wheel Jaw Lock Release Circuit Test....4588
9. Fuel Heater....4588
9.1. System Description....4588
Overview....4589
Operation....4589
9.2. Feature Code....4589
9.3. User Programmable Parameters....4589
9.4. Diagnostic Trouble Codes....4589
9.5. Troubleshooting....4589
Fuel Heater Preliminary Check....4589
Fuel Heater Circuit Test ....4590
10. Remote Power Module....4590
10.1. System Description....4590
Overview....4591
Operation....4591
10.2. Feature Code....4591
10.3. User Programmable Parameters....4592
10.4. Diagnostic Trouble Codes....4592
10.5. Troubleshooting....4595
RPM Preliminary Check....4596
RPM Circuit Test....4596
11. remote start / stop....4598
11.1. System description....4598
Overview....4598
Operation....4599
11.2. FEATURE CODE....4599
11.3. user programmable parameters....4600
11.4. diagnostic trouble codes....4600
11.5. Troubleshooting....4600
Remote Start / Stop Preliminary Check....4601
Remote Start / Stop Test....4601
12. Two-speed axle ....4603
12.1. System description....4603
Overview....4603
Operation....4603
12.2. feature codes....4603
12.3. user programmable parameters....4603
12.4. diagnostic trouble codes....4603
12.5. troubleshooting....4604
Two-Speed Switch Preliminary Check....4604
Two-Speed Switch Test....4604
13. Customer installed lift gate power source....4605
13.1. System description....4605
Overview....4605
Operation....4605
13.2. FEATURE CODE....4605
13.3. user programmable parameters....4606
13.4. diagnostic trouble codes....4606
13.5. Troubleshooting....4607
Lift Gate Preliminary Check....4607
Lift Gate Circuit Test ....4608
14. Auto neutral ....4608
14.1. System description....4608
Overview....4608
Operation....4608
14.2. FEATURE CODE....4609
14.3. user programmable parameters....4609
14.4. diagnostic trouble codes....4609
14.5. Troubleshooting....4609
Auto Neutral Preliminary Check....4610
Auto Neutral Switch Test ....4610
Auto Neutral Circuit Test....4610
15. Axle Load Monitor....4612
15.1. System Description....4612
Overview....4612
Operation....4612
15.2. Feature Code....4612
15.3. User Programmable Parameters....4613
15.4. Diagnostic Trouble Codes....4614
15.5. Troubleshooting....4615
Axle Load Monitor Preliminary Check....4615
Axle Pressure Transducer Circuit Test....4615
16. water-in-fuel monitor ....4616
16.1. System Description....4616
Overview....4616
Operation....4616
16.2. Feature Code....4616
16.3. User Programmable Parameters....4616
16.4. Diagnostic Trouble Codes....4616
16.5. Troubleshooting....4617
Water-In-Fuel Monitor Preliminary Check....4617
Water Probe Circuit Test....4618
TRANSMISSIONS....4620
1. Transmission....4622
1.1. System Description....4622
Overview....4622
Operation....4622
1.2. Feature Code....4623
1.3. user programmable parameters....4623
1.4. Diagnostic Trouble Codes....4623
1.5. Troubleshooting....4625
Transmission Preliminary Check....4625
Eaton UltraShift®® TCM Circuit Test....4626
Eaton UltraShift® Selector Circuit Test....4629
Eaton T-Handle Shifter Circuit Test....4632
Eaton Hybrid TCM Circuit Test....4632
Allison TCU Circuit Test with IBB Engine....4634
Allison Shift Selector with IBB Engine ....4636
Allison TCU Circuit Test with I6/V8 Engine....4638
Allison Shifter with I6/V8 Engine....4639
Shifter Ignition Relay Circuit Test....4640
Park Position Unlock Solenoid Test....4642
1.6. Body Controller Signals....4642
Body Controller Signals....4643
MULTIPLEXING (DATA LINKS)....4644
1. Multiplexing (Data Links)....4646
1.1. Description....4646
Overview....4646
Operation....4646
1.2. Troubleshooting....4647
J1939 Data Link Terminating Resistors....4647
Body Controller....4648
J1939 Data Link Circuit Test....4648
J1708 Data Link Circuit Test....4649
12-VOLT POWER DISTRIBUTION AND GROUND....4650
1. 12-Volt Power Distribution and Grounds....4652
1.1. Description....4652
Overview....4652
Operation....4652
1.2. Troubleshooting....4652
Battery Power Distribution Check....4653
Accessory Power Distribution Preliminary Check....4653
Accessory Power Circuit Test....4654
Body Controller Accessory Feed Input Circuit Test....4655
Ignition Power Distribution Preliminary Check....4656
Ignition Power Circuit Test....4656
Ground Circuit Test....4658
FANS AND ENGINE ACCESSORIES....4660
1. Fan System....4662
1.1. System Description....4662
Overview....4662
Operation....4662
1.2. Feature Code....4662
1.3. User Programmable Parameters....4663
1.4. Diagnostic Trouble Codes....4663
1.5. Troubleshooting....4663
Fan System Preliminary Check....4664
Fan Override Switch Test....4664
2. Compression / Exhaust Brake....4665
2.1. System Description....4665
Overview....4665
Operation....4665
2.2. Feature Code....4665
2.3. User Programmable Parameters....4666
2.4. Diagnostic Trouble Codes....4666
2.5. Troubleshooting....4666
Compression / Exhaust Brake Preliminary Check....4667
Compression / Exhaust Brake Switch Test....4667
3. Aftertreatment ....4667
3.1. System Description....4667
Overview....4667
Operation....4668
3.2. Feature Code....4670
3.3. User Programmable Parameters....4670
3.4. Diagnostic Trouble Codes....4670
3.5. Troubleshooting....4671
Aftertreatment Preliminary Check....4672
Inhibit Regeneration Switch Test....4672
Parked Regeneration Switch Test....4673
Warning Lamp Test....4673
4. Cruise Control....4674
4.1. system description....4674
Overview....4674
Operation....4674
4.2. feature codes....4675
4.3. User Programmable Parameters....4675
4.4. diagnostic trouble codes....4675
4.5. Troubleshooting....4676
Cruise Control Preliminary Check....4677
Cruise Control Switch Test....4678
5. Snow Valve....4679
5.1. System Description....4679
Overview....4679
Operation....4679
5.2. Feature Code....4680
5.3. User Programmable Parameters....4680
5.4. Diagnostic Trouble Codes....4680
5.5. Troubleshooting....4680
Snow Valve Preliminary Check....4680
Snow Valve Module Circuit Test....4681
BATTERY, CHARGING, AND CRANKING SYSTEM....4682
1. Battery System....4684
1.1. Description....4684
Overview....4684
Operation....4684
1.2. Diagnostic Trouble Codes....4685
1.3. Troubleshooting....4685
Battery Test....4685
Battery Test Results....4686
Cable Drop Test....4686
Battery Pack Test....4686
Battery Pack Test Results....4686
2. Charging System....4687
2.1. Description....4687
Overview....4687
Operation....4687
2.2. Diagnostic Trouble Codes....4687
2.3. Troubleshooting....4688
Charging System Test....4688
Charging System Test Results....4688
3. Cranking System....4689
3.1. Description....4689
Overview....4689
Operation....4689
3.2. Troubleshooting....4690
Starting System Test....4690
Starting System Test Results....4690
4. Powerpack 3....4690
4.1. Description....4690
Overview....4691
Operation....4691
4.2. Troubleshooting....4691
VEHICLE AND DRIVER INFORMATION DISPLAY....4692
1. vehicle information display....4694
1.1. System description....4694
Overview....4694
Operation....4694
1.2. FEATURE CODE....4694
1.3. user programmable parameters....4695
1.4. diagnostic trouble codes....4695
1.5. Troubleshooting....4695
Vehicle Information Display Preliminary Check....4695
Vehicle Information Display Circuit Test....4695
2. Driver information display....4696
2.1. System description....4696
Overview....4696
Operation....4697
2.2. FEATURE CODE....4697
2.3. user programmable parameters....4697
2.4. diagnostic trouble codes....4697
2.5. Troubleshooting....4697
Driver Information Display Preliminary Check....4698
Driver Information Display Circuit Test....4698
tables....4335
Table 1Ohm's Law....4335
Table 2Relay Bench Test....4348
Table 3Gauges and Signal Paths....4353
Table 4Warning Lamp and Signal Path....4354
Table 5Audible Alarms....4356
Table 6Electronic Gauge Cluster Feature Codes....4357
Table 7Diagnostic Trouble Codes....4363
Table 8EGC Preliminary Checks....4371
Table 9Electronic Gauge Cluster Circuit Test....4373
Table 10EGC Backlighting Circuit Test....4375
Table 11EGC Gauge Test....4376
Table 12Warning Lamp Test....4377
Table 13Fuel Level Gauge Circuit Test....4378
Table 14Transmission Oil Temperature Circuit Test....4379
Table 15Rear Rear Axle Temperature Circuit Test....4380
Table 16Front Rear Axle Temperature Circuit Test....4381
Table 17Air Pressure Transducer Circuit Test....4382
Table 18Park Brake Switch Circuit Test....4384
Table 19 Air Restriction Gauge Circuit Test....4385
Table 20Low Coolant Sensor Circuit Test....4385
Table 21Diagnostic Trouble Codes....4390
Table 22Switch Pack Preliminary Check....4392
Table 23Switch Pack Circuit Test....4392
Table 24J1708 Data Link Circuit Test....4393
Table 25Feature Code....4398
Table 26Diagnostic Trouble Codes....4399
Table 27Backup Lights Preliminary Checks....4400
Table 28 Backup Light Circuit Test....4400
Table 29Backup Light Switch Test....4402
Table 30Feature Code....4404
Table 31Diagnostic Trouble Codes....4404
Table 32Dome and Courtesy Lights Preliminary Checks....4405
Table 33Door Switch Circuit Test....4406
Table 34Cab Dome Light Circuit Test....4407
Table 35Courtesy Lights Circuit Test....4409
Table 36Feature Codes....4410
Table 37Diagnostic Trouble Codes....4410
Table 38Fog Light System Preliminary Check....4411
Table 39Fog Light Switch Test....4412
Table 40Fog Light Circuit Test....4413
Table 41Feature Codes....4415
Table 42Diagnostic Trouble Codes....4416
Table 43Headlight System Preliminary Check....4418
Table 44Headlight Switch Test....4419
Table 45Turn Signal Switch Circuit Test....4420
Table 46Right Headlight Circuit Test....4421
Table 47Left Headlight Circuit Test....4423
Table 48Feature Codes....4424
Table 49Diagnostic Trouble Codes....4424
Table 50Stop, Turn, and Hazards System Preliminary Check....4427
Table 51Turn Signal Switch Circuit Test....4428
Table 52Brake Switch Circuit Test....4430
Table 53Left Front Turn Signal Circuit Test....4432
Table 54Right Front Turn Signal Circuit Test....4433
Table 55Left Rear Turn Signal Circuit Test....4433
Table 56Right Rear Turn Signal Circuit Test....4434
Table 57Feature Codes....4435
Table 58Diagnostic Trouble Codes....4435
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....4436
Table 60Headlight Switch Test....4437
Table 61Tail Light Circuit Test....4438
Table 62Park, Marker, Clearance, and Identification Lights Circu....4438
Table 63Feature Codes....4439
Table 64Diagnostic Trouble Codes....4440
Table 65Work Light System Preliminary Check....4441
Table 66Work Light Switch Test....4441
Table 67Work Light Circuit Test....4442
Table 68Feature Codes....4443
Table 69Lighted Air Shield DTC....4444
Table 70Roof Auxiliary Load Preliminary Check....4444
Table 71Lighted Air Shield Preliminary Check....4445
Table 72Roof Auxiliary Load Switch Test....4446
Table 73Roof Auxiliary Load Circuit Test....4447
Table 74Lighted Air Shield Circuit Test....4447
Table 75Feature Codes....4448
Table 76Diagnostic Trouble Codes....4449
Table 77Trailer Lights Preliminary Check....4450
Table 78Trailer Socket Circuit Test....4450
Table 79Trailer Left Turn Relay Circuit Test....4452
Table 80Trailer Right Turn Relay Circuit Test....4453
Table 81Trailer Marker Light Relay Circuit Test....4454
Table 82Trailer Tail Light Relay Circuit Test....4455
Table 83Trailer Stop Light Relay Circuit Test....4456
Table 84Trailer ABS ECU Relay Circuit Test....4457
Table 85Feature Code....4458
Table 86Diagnostic Trouble Codes....4458
Table 87Auxiliary Snowplow Lights Preliminary Checks....4459
Table 88 Snowplow Switch Test....4460
Table 89Snowplow Lights Circuit Test....4460
Table 90Cigar Lighter and Power Feed Preliminary Check....4469
Table 91Cigar Lighter Circuit Test....4469
Table 92Two-Post Power Source Circuit Test....4469
Table 93CB Radio Power Source Preliminary Check....4471
Table 94CB Radio Circuit Test....4471
Table 95Feature Codes....4472
Table 96Diagnostic Trouble Codes....4472
Table 97Compass and Temperature Display Preliminary Check....4474
Table 98Compass Display Circuit Test....4475
Table 99Ambient Temperature Sensor Circuit Test....4478
Table 100Feature Codes....4479
Table 101Diagnostic Trouble Codes....4480
Table 102Power Locks Preliminary Check....4483
Table 103Power Windows Preliminary Check....4483
Table 104Locks and Windows Inoperative Circuit Test....4483
Table 105Power Window Circuit Test....4484
Table 106Power Door Lock Circuit Test....4485
Table 107Feature Codes....4485
Table 108Diagnostic Trouble Codes....4487
Table 109Electric Horn Preliminary Check....4487
Table 110Electric Horn Circuit Test....4488
Table 111Feature Codes....4489
Table 112Diagnostic Trouble Codes....4490
Table 113Air Horn Preliminary Checks....4490
Table 114Air Horn Circuit Test....4491
Table 115Power Mirror Preliminary Check....4493
Table 116Driver Power Mirror Circuit Test....4493
Table 117Passenger Power Mirror Circuit Test....4494
Table 118Feature Codes....4495
Table 119Diagnostic Trouble codes....4496
Table 120Heated Mirror Preliminary Check....4496
Table 121Heated Mirror Switch Test....4497
Table 122Driver Heated Mirror Circuit Test....4497
Table 123Passenger Heated Mirror Circuit Test....4498
Table 124Heated Windshield Circuit Test....4499
Table 125Radio Preliminary Check....4501
Table 126Radio Circuit Test (16 Way Connector)....4502
Table 127Radio Circuit Test (12 Way Connector)....4502
Table 128Speaker Circuit Test (16 Way Connector)....4503
Table 129Speaker Circuit Test (12 Way Connector)....4504
Table 130Two-Way Radio Circuit Test....4505
Table 131Feature Codes....4506
Table 132Diagnostic Trouble Codes....4508
Table 133Wiper and Washer Preliminary Check....4509
Table 134Washer Pump Circuit Test....4510
Table 135Wiper Switch Circuit Test....4511
Table 136Wiper Motor Circuit Test....4512
Table 137Feature Codes....4513
Table 138Diagnostic Trouble Codes....4514
Table 139Brake Switch Preliminary Check....4515
Table 140Brake Switch Circuit Test....4516
Table 141Park Brake Switch Circuit Test....4517
Table 142Feature Code....4520
Table 143Diagnostic Trouble Codes....4520
Table 144Clutch Switch Preliminary Checks....4521
Table 145Engine Crank Clutch Switch Test....4522
Table 146Cruise Control Clutch Switch Test....4524
Table 147Feature Code....4525
Table 148Diagnostic Trouble Codes....4526
Table 149Latching Relay Circuit Test....4527
Table 150Vehicle Data Recorder Preliminary Check....4528
Table 151 Vehicle Data Recorder Circuit Test....4529
Table 152VDR Brake Pressure Switch Circuit Test....4530
Table 153VDR Headlight Input Relay Circuit Test....4531
Table 154Feature Code....4532
Table 155Diagnostic Trouble Codes....4533
Table 156Theft Deterrent Preliminary Check....4534
Table 157Theft Deterrent System Test....4534
Table 158Feature Code....4536
Table 159Seat Belt Preliminary Check....4537
Table 160Seat Belt Indicator Circuit Test....4538
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....4539
Table 162Driver and Passenger Self-Contained Air Seat Test....4540
Table 163Driver and Passenger Heated Seats Preliminary Check....4541
Table 164Driver and Passenger Heated Seat Test....4542
Table 165Air Dryer and Heated Drain Valve Preliminary Check....4548
Table 166Heated Drain Valve Circuit Test....4549
Table 167Air Dryer Circuit Test....4550
Table 168Feature Codes....4551
Table 169Diagnostic Trouble Codes....4551
Table 170Air Solenoid Preliminary Check....4557
Table 171Air Solenoid Circuit Test....4558
Table 172Feature Code....4559
Table 173Diagnostic Trouble Codes....4560
Table 174Suspension Dump Preliminary Check....4562
Table 175Suspension Dump Test....4562
Table 176Feature Codes....4564
Table 177Diagnostic Trouble Codes....4565
Table 178Differential Lock Preliminary Check....4567
Table 179Differential Lock Test....4567
Table 180Feature Code....4569
Table 181Diagnostic Trouble Codes....4570
Table 182Power Divider Lock Preliminary Check....4571
Table 183Power Divider Lock Test....4571
Table 184Feature Code....4572
Table 185Diagnostic Trouble Codes....4573
Table 186Power Take Off Preliminary Check....4575
Table 187Power Take Off Circuit Test....4575
Table 188Feature Code....4577
Table 189Diagnostic Trouble Codes....4579
Table 190Anti-Lock Braking System Preliminary Check....4579
Table 191Bendix® ABS Module Circuit Test....4580
Table 192Bendix® Steering Wheel Sensor Circuit Test....4582
Table 193Bendix® Yaw Sensor Circuit Test....4582
Table 194Wabco® ABS Module Circuit Test....4583
Table 195Feature Code....4585
Table 196Diagnostic Trouble Codes....4586
Table 197Fifth Wheel Slide Preliminary Check....4587
Table 198Fifth Wheel Slide Circuit Test....4587
Table 199Fifth Wheel Jaw Lock Release Circuit Test....4588
Table 200Fuel Heater Preliminary Check....4589
Table 201Fuel Heater Circuit Test ....4590
Table 202Diagnostic Trouble Codes....4592
Table 203RPM Preliminary Check....4596
Table 204RPM Circuit Test....4596
Table 205Feature Code....4599
Table 206Diagnostic Trouble Codes....4600
Table 207Remote Start / Stop Preliminary Check....4601
Table 208Remote Start / Stop Test....4601
Table 209Feature Codes....4603
Table 210Diagnostic Trouble Codes....4603
Table 211Two-Speed Switch Preliminary Check....4604
Table 212Two-Speed Switch Test....4604
Table 213Feature Code....4605
Table 214Diagnostic Trouble Codes....4606
Table 215Lift Gate Preliminary Check....4607
Table 216Lift Gate Test ....4608
Table 217Feature Code....4609
Table 218Diagnostic Trouble Codes....4609
Table 219Auto Neutral Preliminary Check....4610
Table 220Auto Neutral Switch Test ....4610
Table 221Auto Neutral Circuit Test ....4610
Table 222Feature Code....4612
Table 223Diagnostic Trouble Codes....4614
Table 224Axle Load Monitor Preliminary Check....4615
Table 225Axle Pressure Transducer Circuit Test....4615
Table 226Diagnostic Trouble Codes....4617
Table 227Water-In-Fuel Monitor Preliminary Check....4617
Table 228Water Probe Circuit Test....4618
Table 229Feature Code....4623
Table 230Diagnostic Trouble Codes....4624
Table 231Transmission Preliminary Check....4625
Table 232Eaton UltraShift® TCM Circuit Test....4627
Table 233Eaton UltraShift® Selector Circuit Test....4629
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....4631
Table 235Eaton T-Handle Shifter Circuit Test....4632
Table 236Eaton T-Handle Shifter Lighting Circuit Test....4632
Table 237Eaton Hybrid TCM Circuit Test....4633
Table 238Allison TCU Circuit Test with IBB Engine....4635
Table 239Allison Shift Selector Circuit Test....4636
Table 240Allison Shift Selector Lighting Circuit Test....4638
Table 241Allison TCU Circuit Test with I6/V8 Engine....4638
Table 242Allison Column Mounted Shifter ....4639
Table 243Allison T-Handle Shifter ....4640
Table 244Shifter Ignition Relay Circuit Test....4641
Table 245Park Position Unlock Solenoid Test....4642
Table 246Body Controller Signals....4643
Table 247J1939 Data Link Circuit Test....4649
Table 248J1708 Data Link Circuit Test....4649
Table 249Battery Power Distribution Preliminary Check....4653
Table 250Accessory Power Distribution Check....4653
Table 251Accessory Power Circuit Test....4654
Table 252Body Controller Accessory Feed Input Circuit Test....4655
Table 253Ignition Power Distribution Check....4656
Table 254Ignition Power Circuit Test....4656
Table 255Ground Circuit Test....4658
Table 256Feature Code....4663
Table 257Diagnostic Trouble Codes....4663
Table 258Fan System Preliminary Check....4664
Table 259Fan Override Switch Test....4664
Table 260Feature Code....4665
Table 261Diagnostic Trouble Codes....4666
Table 262Compression / Exhaust Brake Preliminary Check....4667
Table 263Compression Brake Switch Test....4667
Table 264Soot Accumulation Level Indications....4669
Table 265Feature Code....4670
Table 266Diagnostic Trouble Codes....4670
Table 267Aftertreatment Preliminary Check....4672
Table 268Inhibit Regeneration Switch Test....4672
Table 269Parked Regeneration Switch Test....4673
Table 270Warning Lamp Test....4673
Table 271Feature Code....4675
Table 272Diagnostic Trouble Codes....4676
Table 273Cruise Control Preliminary Check....4677
Table 274Cruise Control Switch Test....4678
Table 275Feature Code....4680
Table 276Snow Valve Preliminary Check....4680
Table 277Snow Valve Module Circuit Test....4681
Table 278Diagnostic Trouble Codes....4685
Table 279Diagnostic Trouble Codes....4687
Table 280Feature Code....4695
Table 281Vehicle Information Display Preliminary Check....4695
Table 282Vehicle Information Display Circuit Test....4695
Table 283Feature Code....4697
Table 284Driver Information Display Preliminary Check....4698
Table 285Driver Information Display Circuit Test....4698
S09013 - Hood, Grille, Fenders, Bumper and Running Boards Service Manual....4702
S09017 - Hood, Grille, Fenders and Bumper (Oct 2010) Service Manual....4751
S12019 - Radiator, Removal and Replacement Service Manual....4788
S12037 - Radiator _ Cooling System (July 2012) Service Manual....4815
toc....4817
Table of Contents....4817
1. Description....4819
1.1. Deaeration Tank....4820
1.2. Fan Shroud....4820
1.3. Fan Drive....4820
1.4. A/C Condenser....4820
1.5. Radiator / CAC Assembly....4820
1.6. Low Temperature Radiator (LTR)....4820
1.7. Solenoid Valve....4820
1.8. Transmission Oil Cooler....4820
2. Removal and Installation....4821
2.1. Coolant Drain, Pressure Test, and Fill Procedures....4822
Coolant Drain Procedure (Recommended)....4824
Pressure Test Procedure (Recommended)....4827
Coolant Fill Procedure (Recommended)....4828
Coolant Drain Procedure (Optional)....4830
Coolant Fill Procedure (Optional)....4831
2.2. Splash Panel....4833
Splash Panel - Removal....4833
Splash Panel - Installation....4833
2.3. Deaeration Tank....4834
Deaeration Tank - Removal....4834
Deaeration Tank - Installation....4835
2.4. A/C Condenser....4836
A/C Condenser - Removal....4836
A/C Condenser - Installation....4837
2.5. Radiator Fan and Fan Drive Assembly....4838
Fan and Fan Drive - Removal....4838
Fan and Fan Drive - Installation....4839
2.6. Fan Shroud....4840
Fan Shroud - Removal....4840
Fan Shroud - Installation....4844
2.7. Low Temperature Radiator (LTR)....4845
Low Temperature Radiator - Removal....4845
Low Temperature Radiator - Installation....4846
2.8. Radiator Hose....4847
Heat Shrink Clamp - Removal....4847
Heat Shrink Clamp - Installation....4849
Radiator Hoses - Removal....4852
Radiator Hoses - Installation....4854
2.9. Solenoid Valve....4855
Solenoid Valve – Removal....4855
Solenoid Valve – Installation....4856
2.10. Cooling Package....4857
Coolant Package - Removal....4857
Coolant Package - Installation....4861
2.11. Radiator Core / CAC Assembly....4862
Radiator Core / CAC Assembly - Removal....4862
Radiator Core / CAC Assembly - Installation....4864
tables....4865
Table 1Torque Chart....4865
S13038 - MXT Magna MP1528 Transfer Case - Service and Electrical Troubleshooting Manual....4866
S13038_07_10.pdf....0
Magna xfer case elec troubleshooting_final1.pdf....0
Table of Contents:....4915
1. General....4916
1.1. Definitions....4916
1) Actuator....4916
2) Module....4916
3) Transfer Case....4916
4) Mode Shift....4916
5) Range Shift....4916
1.2. Required Tools....4916
2. Troubleshooting....4917
2.1. From 2H to 4H....4917
2.2. From 4H to 4L....4918
2.3. From 4L to 4H....4919
2.4. From 4H to 2H....4920
2.5. From 2H to 4L....4921
2.6. From 4L to 2H....4922
2.7. Indicator Test Procedure....4923
2.8. Diagnostic Test Procedure....4924
2.9. Diagnostic Connector Test Procedure....4925
3. References....4927
3.1. Mechanization Diagram....4927
3.2. Actuator....4928
1) Mounting Position....4928
2) Interface Connector....4929
3) Actuator Position Voltages....4930
3.3. Module....4931
1) Pinout Diagram....4931
2) Module I/O Voltages....4932
3) Effects of Faults....4933
3.4. Switch....4934
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar Models Service Manual....4935
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT, DuraStar, TranStar, WorkStar and RXT....5252
S16036 - CAB - MXT Service Manual....5399
S16046- HEAT VENTILATION AIR CONDITIONING (HVAC) for 2010 TerraStar, DuraStar, WorkStar, TranStar, 3200 Bus HVAC Service Manual....5411
International Trucks Models CXT, MXT, RXT, TerraStar Repair Service Manuals
