FIELD SERVICE BULLETIN

[ ] Safety Recall
[X] Field Campaign
[ ] Service Information
[ ] Product Improvement

FDOT MODELS THAT
USE NON OEM
ALTERNATORS
Battery cable routing

FSB_2012-101
Revision: 1
Issue Date: 12/11/2012
Manual Section: N/A
Author: L. Bollini & M.
Neuville
Approval: B. Sprague
Form Rev. C 06/04/09

UNITS AFFECTED: Ford and Chevy FDOT models that use an OEM and/or aftermarket
alternator.
DESCRIPTION: Cables that are routed across rigid edges can rub and chafe, exposing the
conductor material, and cause a short circuit.
CAMPAIGN EXPIRATION DATE: 90 Days
MATERIALS NEEDED: If issues are found or harness repair is necessary: loom, p-clamps,
zip-ties, and proper gauge wire.
PROCEDURE:
For any questions that arise while performing these procedures, or for help in completing the
service, please contact Ray Cullers with Transit Plus at 813-335-9052.
The goal of this procedure is to identify high-current cables that require extra scrutiny to ensure
they are not chafing or otherwise allowed to short circuit. First the method of connection
between power sources will be discussed and the cables that need attention will be identified.
Second, it will be shown where to find the cables. Lastly, a list of best practices will be
described to which the cables identified earlier must be compared.
Method of connection, what needs attention
This procedure is for all Ford and Chevy FDOT’s that utilize an OEM alternator or
aftermarket alternator. Bus models will vary significantly because of model year, option
equipment, and chassis; therefore, connections will be described in general. Figure 1
shows the overall method of connection, where the alternator connects to an under-hood
stud, the battery connects to a stud in the battery box, and heavy gauge cable runs
between them. On some models, the cable from the alternator may encounter other
connections before reaching the under-hood stud. Those connections will vary because
of the model changes and options, so be sure to examine the cable routing completely
from the alternator to the under-hood stud. Do not stop examination too early. The
cables that require examination are those pointed to with arrows in Figure 1. An image
of an under-hood stud is provided in Figure 2.

FSB 2012-101

Page 1 of 9

ALTERNATOR
-

UNDER-HOOD
POWER STUD

BATTERY BOX
POWER STUD

TO ACCESSORIES

TO ACCESSORIES

+

+

BATTERY

Figure 1: Overall method of connection

Figure 2: Example of under-hood stud.
Figures 3 and 4 show staged examples of a poorly routed power cable. The power cable
should not be rubbing against any dip sticks or brackets.
Here

Here

Figure 3: Staged example of power cable rubbing
against dip sticks

FSB 2012-101

Figure 4: Staged photo of power
cable against alternator

Page 2 of 9

Where to find the cables
First locate your alternator. On Fords, the alternator is usually low on the front of the
engine. Figures 5 and 6 show locations for alternators on Chevrolet models.
Look by the
coolant tank.

Alternator

Figure 5: Alternator location on diesel Chevy
Look by the power
steering fluid tank.

Here

Alternator

Figure 6: Alternator location on gasoline Chevy
FSB 2012-101

Page 3 of 9

Follow the alternator cables to the under-hood power studs. Ensure it is not resting or
rubbing on hot surfaces, valve covers, or dipstick tubes. Figure 7 shows the location of
the studs. Figure 8 uses a red line to show the routing between the under-hood stud and
battery box.

Figure 7: Location of under-hood studs. The left picture shows the studs covered. Under-hood
routing will vary.

UNDERHOOD
STUD
BATTERY
BOX

Figure 8: General cable routing, under-hood stud to battery box.

FSB 2012-101

Page 4 of 9

Best practices for securing cables
With the cables now identified and located, compare the cables on the bus to the cables
shown in the pictures below. These photos show best practices, so if any cables do not
reflect these practices, it is important to change the cables on your bus to match these
practices as closely as possible. Important note: Any p-clamps used MUST BE
RUBBER COATED! Also, ensure p-clamps are sized so they are snug to the cable they
hold, but not crushing them. Oversized p-clamps are not acceptable because they allow
too much movement.

Power cables loomed
for entire length.

Practice 1: Ensure all power cables are loomed for their entire length throughout the bus. Loom
must be rated for high temperatures.

FSB 2012-101

Page 5 of 9

Tape wrapped through hole
and over top edge of box
helps keep loom in place.

Edge is
protected
with loom

Practice 2: Battery box pass-through edges are protected with loom.

P-clamps keep
cables separated in
approach to switch.

Practice 3: P-clamps separate cables in approach to component.

FSB 2012-101

Page 6 of 9

Cables are protected
from corner using a
p-clamp.

Practice 4: If cables must cross a corner, use P-clamps to hold them in place.

Unavoidable
edge protected
with trim
Practice 5: Edge trim protects unavoidable edges.

FSB 2012-101

Page 7 of 9

Other
hoses/cables

Clamp

Hot object
(transmission here)
Practice 6: P-clamp to hold cables away from hot objects and other hoses/cables. Specifically
check for this under the cab of the vehicle.

Clamp

Practice 7: Where cables must run through difficult areas like this wheel well, use p-clamps to
secure them in one spot.

FSB 2012-101

Page 8 of 9

Harness must be kept away
from dipstick tube.
Example of pair
of zip-ties.

Practice 8: Keep electrical harnesses away from dipstick tubes. If re-routing the harness is not
possible, use zip-ties or P-clamps to keep the dipstick tube and electrical harness separated. In
this picture, two zip ties were used to maintain spacing. One was looped loosely around both the
dipstick and harness, and a second was looped tightly between them to form a “waist.” The first
one was then tightened.
For any questions that arise while performing these procedures, or for help in completing the
service, please contact Ray Cullers with Transit Plus at 813-335-9052.

FSB 2012-101

Page 9 of 9