NHTSA ID Number: 10045802
Manufacturer Communication Number: IK-1200788
TSB/Document Date: 2012-09-18
Summary
INTERNATIONAL
: INFORMATION PROVIDED REGARDING THE RE-ROUTING OF ALTERNATOR WIRING TO PREVENT RUB POINTS. MODELS PAYSTAR, TRANSTAR, PROSTAR. MODEL YEARS 2009-2011. *PE
IK1200788 - Alternator Wiring Re-route - 12643
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SB-10045802-9092
Countries:
CANADA,
Document
IK1200788
UNITED STATES ID:
Availability:
Internal Attachable
Revision:
0
Major
System:
ELECTRICAL
SYSTEM
Created:
7/31/2012
Current
Language:
English
Last
Modified:
8/6/2012
Other
Languages:
NONE
Author:
Lindsey
Christopher
Viewed:
96
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Title: Alternator Wiring Re-route - 12643
Applies To: PayStar®, TranStar®, and ProStar® models built 6/1/09 thru
5/31/11 with a MaxxForce® 11 or 13 engine feature code 12UXJ or 12UXH and
with alternator featurecode 08GGN, 08GGR, 08 GHG, or 08GHH.
DESCRIPTION
Alternator wiring re-route to prevent rub points.
Release Date: April 12, 2012
Supersedes: N/A
SRT: 0.5 hours
TOOLS REQUIRED
Assorted sockets
Ratchets
A wire cutter
MATERIALS REQUIRED
Sealing Compound
PARTS INFORMATION
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PART NUMBER
PART DESCRIPTION
QUANTITY
8900223R91
Kit, SR11516 Bosch alternator
routing
1
472141C2
Sealing compound, 4 ounce
tube
1
3614752C1
Dual saddle swivel guide
1
3551709C1
Cable strap 9 in. x 0.303 in.
4
Kit 8900223R91 Contains the Following Parts:
PART NUMBER
PART DESCRIPTION
QUANTITY
289862C1
Cable strap
1
3545771C1
Saddle
1
25483R1
Saddle bolt
1
120380
Saddle lock washer
1
25519R1
Saddle nut
1
922860R1
Extension bracket
1
31054R1
Fuel case bolt*
1
25708R1
Fuel case washer*
1
*There is no need to utilize the fuel case bolt and washer in this procedure.
SERVICE PROCEDURE
WARNING!
PARK VEHICLE ON HARD FLAT SURFACE, TURN THE ENGINE OFF, SET THE
PARKING BRAKE, AND BLOCK THE WHEELS TO PREVENT THE VEHICLE FROM
MOVING IN BOTH DIRECTIONS. FAILURE TO DO SO MAY RESULT IN PROPERTY
DAMAGE, PERSONAL INJURY, AND/OR DEATH.
WARNING!
IF THE VEHICLE MUST BE RAISED, DO NOT WORK UNDER THE VEHICLE SUPPORTED
ONLY BY JACKS. JACKS CAN SLIP OR FALL OVER, POTENTIALLY RESULTING IN
PROPERTY DAMAGE, PERSONAL INJURY, AND/OR DEATH.
WARNING!
ALWAYS WEAR SAFE EYE PROTECTION WHEN PERFORMING VEHICLE
MAINTENANCE. FAILURE TO DO SO MAY RESULT IN SERIOUS EYE INJURY.
WARNING!
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ALLOW COMPONENTS IN ENGINE COMPARTMENT TO COOL BEFORE SERVICING
ENGINE OR VEHICLE. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY, AND/OR DEATH.
REPAIR PROCEDURES
1. Open battery compartment, disconnect both the frame and starter negative battery cables, and the Clean
Power harness connector.
2. Inspect the fuel case area (close to the power steering pump) to see if an extension bracket, saddle, and
cable strap has already been installed as shown in Figure 1. If the extension bracket is present, remove the fuel
case bolt that secures it and cut the cable strap that is securing the alternator harness. Go to step 4 and re-use
the extension bracket.
If the extension bracket is currently installed on the fuel case, proceed to step 3.
1. Extension bracket may already be mounted to the fuel case.
3. Assemble hardware (Figure 2) to match Figure 3. Attach saddle (3545771C1) to extension bracket
(922860R1) and secure with saddle bolt (25483R1) using saddle lock washer (120380) and saddle nut
(25519R1).
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1. Fuel case bolt and washer NOT needed.
1. Alternator cables need to be strapped to the curved surface of the saddle strap.
4. Remove dipstick bracket attachment bolt (Figure 4).
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1. Dipstick bracket attachment bolt.
5. Remove the alternator harness attachment nut (Figure 5).
1. Alternator harness attachment nut.
6. Remove the alternator mounting bolt that secures the ground cable of the alternator harness (Figure 6).
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Reinstall the bolt and tighten to 19-23 ft-lb (26-31 N·m) as the ground harness will be relocated in a later Step.
1. Alternator mounting bolt.
7. Remove alternator harness ends from the alternator so the alternator cables can be re-routed (Figure 7).
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8. Use the same attachment bolt removed in Step 4 to attach the extension bracket (922860R1) to dipstick
bracket (Figure 8). Verify the extension is placed at a similar angle (Figure 9).
1. Extension bracket is underneath the P-clamps.
2. Same bolt used.
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1. Extension bracket faces in toward engine compartment.
2. Notice the angle and location of the extension bracket.
9. Reroute the alternator harness to the outside of the power steering hose and above the power steering highpressure line. Attach the alternator harness to the saddle (3545771C1) using the cable strap (289862C1).
Tighten the cable strap and cut off the excess strap (Figure 10).
1. Adjust cable strap to saddle and cut off excess cable strap.
10. Locate and remove the existing cable strap or straps that secure the alternator harness, ECM-to-sensor
harness, and chassis-to-ECM harness to the cast-in strain-relief bracket (Figure 11).
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1. ECM-to-Sensor harness
2. Chassis-to-ECM harness
3. Pump screw boss
4. Alternator harness
11. Insert a new cable strap around the strain-relief bracket and around the alternator harness and the ECM-tosensor harness and tighten the cable strap enough to lift the harnesses off of the pump screw boss (Figure 11
and Figure 12).
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1. Strain relief location.
12. Insert a second cable strap around the strain-relief bracket and around the chassis-to-ECM harness and
tighten the cable strap enough to lift the harness off the pump screw boss (Figure 13).
1. ECM-to-Sensor Harness
2. Chassis-to-ECM Harness
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3. Pump screw boss
4. Alternator Harness
13. Verify proper clearance, adjust if necessary to obtain proper clearance, and then cut off the extra cable
strap ends.
14. Remove the lower front alternator-mounting bolt, install the bolt through the ground terminal of the alternator
harness, and reinstall the bolt (Figure 14). Tighten to 19-23 ft-lb (26-31 N·m). If there is insufficient length to
reach the front bolt location of the alternator, then use the rear bolt location. Apply sealant to the bolt head after
installation.
1. Lower front alternator-mounting bolt.
15. Reinstall the power cable of the alternator harness to the positive terminal of the alternator. Tighten nut to
120 in-lb (13.5 N·m). Apply sealant to the nut after installation (Figure 15).
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1. Positive Terminal
2. NOTE: There should not be any extreme bends when the cables are mounted on
the alternator.
16. Add a dual-saddle swivel guide (3614752C1) between the power steering hose and the alternator ground
harness by using two 9 in. cable straps (3551709C1) to the area shown in Figure 16 and Figure 17.
1. Add dual swivel to this area
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17. Cut off the excess cable strap and make sure the power steering hose does not rub against the alternator
ground harness.
18. Pull the cable strap tight and cut off excess length. Inspect the re-routed alternator harness and make sure
the alternator harness does not rub on the ECM, Power Steering hose, or other objects. Adjust the extension
bracket bolt angle (Figure 9), if needed.
WARRANTY INFORMATION
Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner as Warranty Code 40, Group 12643. It is important that the coding be
completed properly to assist in processing the warranty claim. Complete instructions will be
found in the Warranty Policy Manual, Section 7.1.8. As with all claim submission, items
acquired locally must be submitted in the .Other Charges. tab. The cost of any bulk items (bag
of cable tie straps, roll of wire, barrel of oil, tube of silicone, etc.) should be prorated for the
cost of the individual pieces/amount used during each repair.
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Warranty Claim Information
Group
Noun
Cause (C)
12643
Blank
2
Warranty
Description
Code
40
Alternator wiring re-route
Standard Repair Time
Operation Number Description
A08T1
Time (hrs)
As needed by SRT below
Time (hrs)
Alternator Wiring Re-route 0.5
install kit
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Copyright © 2012 Navistar, Inc.
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TSB/Document ID: IK-1200788
Replacement Service Bulletin Number:
MFR Communication Date: 2012-08-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
MFR Component System:
MFR Component Subsystem:
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