NHTSA ID Number: 10115437
Manufacturer Communication Number: IK0800516
TSB/Document Date: 2017-08-16
Summary
ISB Starter Software & Hardware Update
IK0800516 - ISB Starter Software & Hardware Update
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Countries:
CANADA, UNITED STATES,
MEXICO
Document ID: IK0800516
Availability:
ISIS
Revision:
8
Major System:
ELECTRICAL SYSTEM
Created:
4/30/2015
English
Last
Modified:
6/23/2016
Author:
Andrew
Boyd
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Title : ISB
Starter Software & Hardware Update
Applies To : DuraStar, WorkStar, CE Bus equipped with ISB and Allison transmission built prior to
06/01/2015
CHANGE LOG
06/23/2016 - Updated Applies to section of the iKnow.
04/28/2016 - Fixed Typo
04/22/2016 Updated Coding
04/06/2016 - Updated Note, and coding
11/11/2015 - Added warranty reminder to description section.
DESCRIPTION
Note : Prior to starting this repair, be sure IK0800503 was followed.
The following steps will guide technician through starter motor control software and hardware update. The update will enhance
the existing circuit design by utilizing Body Control Module to monitor the Transmission Engine Crank Enable message
broadcasted on the J1939 Public Datalink from the Transmission Control Module (TCM), while still allowing the hard
wired Transmission Engine Crank Enable signal to be captured from the (TCM).
Wiring schematic below (Figure 1) shows an example of how the new hardware and software will be added to existing starter
relay/TCM neutral relay coil side circuit. The rectifier diode and wire make up the new hardware and the new software will be
programmed in the BC as a feature code
Figure 1: Example of new circuit
SPECIAL TOOLS / SOFTWARE
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IK0800516 - ISB Starter Software & Hardware Update
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Tool Description
EZ Tech
SERVICE PARTS INFORMATION
Durastar/Workstar Part List
Kit Description
Part Number
Harness, I/P Overlay, DuraStar
2515087C91
QTY Model
1
Durastar/Workstar
CE Bus Parts List
Kit Description
Part Number
QTY Model
Harness, I/P Overlay, CE Bus
2515129C91
1
CE Bus
GROMMET 3/8" X 27/32" X 5/16
128157
1
CE Bus
LOOM, CONVOLUTED ELECTRICAL WIRE 1/4" I.D.
X .390" O.D. 1' LONG
2644094R1
2
CE Bus
SEALANT, RTV SILICONE BLACK 3 OUNCES
PTX81158
1
CE Bus
DURASTAR/WORKSTAR INSTALL PROCEDURE
1. Shift transmission into Park or Neutral, set parking brake, and install wheel chocks
2. Remove fuse panel cover, center trim ring, storage compartment, instrument cluster, and driver side panel, to access BC
3. Route pre terminated BC terminal end of new service kit wire from the fuse/relay block along existing main harness behind
storage compartment, instrument cluster to BC. Securing the harness along the way with electric tape
4. Remove Terminal Position Assurance Mechanism (TPA) from blue connector 1601 on BC, (Refer to Figure 2) populate cavity
F3 (Durastar) or F1 (Workstar) with pre terminated end (3522073C1) {from the kit}, re-insert TPA, plug connector back into BC
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IK0800516 - ISB Starter Software & Hardware Update
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Figure 2: 1601 (ESC J4) Mating View
5. Use instructions located in IK2600028 to apply new feature code 595BXH (F3 for Durastar) or 595BXK (F1 for Workstar)
6. Remove starter relay and orange terminal lock (Figure 3) by using a pick tool by prying up on the corner (if terminal lock
breaks upon removal, replace with lock from unused area in fuse/relay block)
Figure 3: Relay and terminal lock
7. Remove wire from B4 (Figure 4) and insert wire from kit coming from cavity 2 of the rectifier diode connector, to the TCM
Neutral Relay/Starter Relay Terminal block cavity B4
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IK0800516 - ISB Starter Software & Hardware Update
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Figure 4: Relay Block B4
8. Install previously removed orange terminal lock and relay(s) and secure rectifier diode with electric tape to existing
harness (Figure 5)
Figure 5: Relays installed, rectifier diode secured
9. Test new software and hardware- Crank engine 5 times using ONLY the new Body Controller circuit to validate software and
hardware were installed and are functioning correctly
NOTE: If the engine does NOT crank, validate previous steps were followed correctly, and then contact Tech Service
10. Cut existing terminal off wire removed from B4 in step 7 and then follow butt splice procedure in IK0800269 to connect
with the pre-butt spliced circuit end supplied from kit
11. Test step to validate existing software and hardware- Unplug connector 1601 from the BC, crank engine 5 times using TCM
hardwire circuit
NOTE: If the engine does NOT crank, validate previous steps were followed correctly, and then contact Tech Service
12. Clear fault codes that were generated from the testing steps, install fuse panel cover, console, trim panel, cluster, and driver
side kick panel
13. Remove wheel chocks
CE BUS INSTALL PROCEDURE
You may compare original electrical diagram of starter circuit to the circuit overlay diagram that is being installed in the steps
below
INSTALLATION PROCEDURE:
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IK0800516 - ISB Starter Software & Hardware Update
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1. Shift transmission into Park or Neutral, set parking brake, and install wheel chocks
2. Remove Terminal Position Assurance Mechanism (TPA) from blue connector 1601 on BC, populate F2 (Figure 6) with pre
terminated end (3522073C1) {from the kit}, reinsert TPA, plug connector back into BC
Figure 6: BCM Connector 1601
3. Use instructions located in IK2600028 to apply new feature code 595BXJ (F2 Bus)
4. Locate and remove steel plug (Figure 7) from cowl/firewall, clean area around the hole, and then insert GROMMET 3/8" X
27/32" X 5/16 {from kit}
Figure 7: Engine Side view of firewall/cowl
5. Route the harness from BC to gromment installed in step 4, secure with tie straps along the way
6. Locate TCM Neutral Switch Relay on underhood cowl bracket and remove circuit K92 #141 from the relay connector cavity
number 86
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NOTE: Verify circuit K92 #141 has 12v in Neutral/Park and not 12v when in gear
7. Pass wires encased in split loom through grommet into the engine compartment to the TCM Neutral Switch Relay, secure
harness along the way with tie straps
8. Seal wire pass through at grommet with Adhesive silicone sealant #81158 or equivalant
8. Populate TCM Neutral Switch Relay # 86 with seal and pre terminated end (2039343C1) {from the kit}
9. Test new software and hardware- Crank engine 5 times using ONLY the new Body Controller circuit to validate software and
hardware were installed and are functioning correctly
NOTE: If the engine does NOT crank, validate previous steps were followed correctly, and then contact Tech Service
10. Cut terminal off circuit K92 #141 that was removed from the TCM Neutral Switch Relay cavity #86 and then follow butt splice
insructions (IK0800269) to properly attach the pre terminated butt splice circuit {from the kit} to circuit K92 #141
NOTE: Connection must be crimp, solder, heat shrink since it is underhood
11. Test step to validate existing software and hardware- Unplug connector 1601 from the BC, crank engine 5 times using TCM
hardwire circuit
NOTE: If the engine does not crank validate previous steps were followed correctly then contact Tech Service
12. Clear DTC's generated by last step, remove wheel chocks
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 08540 - Cranking System
Noun: 202 - Motor, Starter
Standard Repair Times:
Description
Chassis
ISB STARTER SOFTWARE
Durastar
& HARDWARE UPDATE
ISB STARTER SOFTWARE
Workstar
& HARDWARE UPDATE
ISB STARTER SOFTWARE
CE Bus
& HARDWARE UPDATE
Engine
SRT
SRT Link
KL08-1013SB
ISB
KL08-1013SB
ISB
GY08-1013SB
ISB Starter Soft/Hardware
update SRT Times
OTHER RESOURCES
Master Service Information Site
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Copyright © 2016 Navistar, Inc.
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TSB/Document ID: IK0800516
Replacement Service Bulletin Number:
MFR Communication Date: 2016-06-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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