SB-10044605-4406

MODEL:

C2

SUBJECT:

CHASSIS PDM POWER CABLE CHAFING

DATE:

JUNE 29, 2012

INDEX: C2 12

PAGE:

1

BULLETIN: 13

OF

5

IMPORTANT: READ ENTIRE PROCEDURE BEFORE BEGINNING.
This service bulletin will address the issue of Saf-T-Liner C2 Chassis PDM Power cable chafing. The
cable can be rubbed by the PDM mounting bracket or hood / fender splash shield to the point of exposing
the copper cable strands to the atmosphere. This issue may permit corrosion in the chassis PDM power
cable eventually leading to a loss of power to the chassis systems. To resolve the issue, a nylon P-Clip
and Tie Wrap will be installed to prevent the chafing. If the power cable insulation has been worn to the
point of exposing copper, red electrical heat-shrink may be installed to environmentally seal the cable.
Target Units: C2 Units with a start date of 4/5/2004 (’04 emissions) through 4/1/2010 (’07
emissions).
Inspection: Check the unit for the presence of a P-Clip as shown in Figure 1. If P-Clip is present,
no further action is required.

P-CLIP

FIGURE 1

Product Service Bulletin

BODY

PAGE: 2 of 5

INDEX: C2 12
BULLETIN: 13

1. Make sure the ignition is in the “Off” position. Chock the tires and disconnect the batteries.
2. Inspect the Chassis PDM power cable for chafed insulation. The harness loom may need to be pulled back
for proper inspection. Check the top and bottom of the cable insulation for visible signs of copper stranding.
Figure 2

COPPER STRANDING VISIBLE

FIGURE 2

3.1 If no copper is visible and the insulation is adequately protecting the power cable, proceed to step 7.
3.2 If the insulation has been damaged with copper stranding visible, continue to step 4.
3.3 If the insulation and copper stranding have been damaged, replace the cable and proceed to step 7.
4. Protect the open copper strands by applying heat-shrink over the damaged insulation. Disconnect the
cable with damaged insulation from the Chassis PDM. Pull back the cable loom to access damaged cable
insulation.
NOTE: The heat-shrink (TBB 61201955) is 6 inches long. Normal chafing should require 3 inches
of heat shrink to repair worn area with adequate good insulation overlap. Cut the heat-shrink into
two equal lengths for this repair.
5. Slip the heat-shrink (TBB 61201955) over the cable terminal and center its length over the power cables
worn insulation. Heat the heat-shrink evenly until it fully conforms to the cable and adhesive is visible at
each end. Re-apply the loom that was pulled back.
6. Reconnect the chassis power cable(s) to the chassis PDM using the existing hardware. Torque range for
the fasteners is to be 5-10 FT-LBS.

PAGE: 3 of 5

INDEX: C2 12
BULLETIN: 13

7. Locate the unused hole in the PDM mounting plate close to the power cable. Figure 3
8. Open the P-Clip (TBB 61480924) and install around the chassis PDM power cable that is closest to the
unused hole. Figure 4

MOUNTING HOLE
MOUNTING
PUSH BARB

LOCKING PEN

FIGURE 3

FIGURE 4

9. With the locking pin still hanging loose on its tether, push the mounting barb completely into the hole in the
chassis PDM mounting plate.
10. Once the P-Clip and power cable are positioned correctly, fully install the locking pin through both tabs of
the P-Clip. The locking pin will close the P-Clip and expand the mounting barb locking it to the plate.
Figure 5

FIGURE 5

PAGE: 4 of 5

INDEX: C2 12
BULLETIN: 13

11. Use the Tie Wrap (TBB 61370022) to secure the second chassis PDM power cable to the first now retained
by the P-Clip. When the second power cable is positioned correctly, tighten the tie wrap and trim off the
excess tail. Figure 6

FIGURE 6

12. Connect the batteries and remove the tire chocks.

MATERIALS REQUIRED:
PART NUMBER
QTY.
TBB 61480924
1
TBB 61370022
1
AS REQUIRED:
TBB 61201955
1
A06-42299-152
1
A06-64216-116
1

DESCRIPTION
NYLON CABLE CLAMP, HEAVY DUTY, 3/4 I.D.
TIE WRAP, 24", BLACK
TUBE, HEAT SHRINK, RED
HARN-POS PWR, PDM (’04 EMISSIONS UNITS)
HARN-PWR, FNDR PDM, 07, B2 (’07 EMISSION

UNITS)

IMPORTANT NOTE: IF A POWER CABLE REPLACEMENT IS REQUIRED, THE ORIGINAL POWER CABLE
MUST BE RETURNED TO TBB FOR REIMBURSEMENT.
WARRANTY STATUS:
THIS PROCEDURE IS WARRANTABLE ONLY IF THE DESCRIBED CONDITION EXISTS ON A TARGET UNIT AND THE REPAIR IS PERFORMED
WITHIN THE APPLICABLE BASE WARRANTY OR EXTENDED COVERAGE WARRANTY PERIOD. IF THE PREVIOUSLY DESCRIBED
CONDITION IS NOT FOUND, THIS PROCEDURE IS CONSIDERED PREVENTIVE AND WARRANTY DOES NOT APPLY. CLAIMS MUST BE
SUBMITTED AND RECEIVED IN ACCORDANCE WITH WARRANTY COVERAGE REQUIREMENTS.

PAGE: 5 of 5

INDEX: C2 12
BULLETIN: 13

WARRANTY CODE: 7603

SRT TIME ALLOWANCES

ONE CODE ALLOWED PER CLAIM
(NOT CUMULATIVE)

CHASSIS PDM POWER CABLE CHAFING INSPECTION
SRT CODE: 52-47
OWL SRT CODE: 174-6782A SERVICE MODEL T01 (C2)

0.1

HRS.

CHASSIS PDM POWER CABLE CHAFING INSTALLATION OF P-CLIP AND TIE WRAP
SRT CODE: 52-48
OWL SRT CODE: 174-6782B SERVICE MODEL T01 (C2)

0.2

HRS.

CHASSIS PDM POWER CABLE CHAFING INSTALLATION OF HEAT SHRINK,
P-CLIP AND TIE WRAP
SRT CODE: 52-46
OWL SRT CODE: 174-6782C SERVICE MODEL T01 (C2)

0.3

HRS.

CHASSIS PDM POWER CABLE CHAFING REPLACEMENT OF THE POWER CABLE,
P-CLIP & TIE WRAP
SRT CODE: 52-49
OWL SRT CODE: 174-6782D SERVICE MODEL T01 (C2)

0.7

HRS.

PFP: A06-64216-116
QC: W09