IK0800522 ­ Repair Information for Damaged Headlight Connector

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IK0800522
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Title : Repair Information for Damaged Headlight Connector
Applies To : Certain DuraStar, CE / BE Bus, WorkStar, 1300, TranStar

Change Log
Please refer to the change log text box below for recent changes to this article:
07/19/2017 ‐ Updated parts information. Dealer feedback revealed the parts list was incomplete
and incorrect. Added part number for connector gasket. Updated part numbers for connector
lock and connector seal.
03/14/2017 ‐ Updated parts information. Repair can be completed with parts available in the
PDC.
10/21/2016 ‐ Added wire color orientation information and photo based on dealer feedback.

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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Description
The 3 pin headlight connector inside the headlight assembly on certain DuraStar, CE /
BE Bus, WorkStar, 1300 and TranStar models is part of the headlight assembly. This
connector is an internal part of the headlight assembly on some models. Connector or
terminal damage can be repaired parts available in the PDC instead of replacing the entire
headlight assembly.

Symptom(s)
Possible Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light

Description

SPN 2653 FMI 5

Left Low Beam Under Current

SPN 2655 FMI 5

Right Low Beam Open Circuit

SPN 4011 FMI 5

Open in Left High Beam Circuit

SPN 4012 FMI 5

Open in Right High Beam Circuit

Customer Observations or Concerns:
• Headlight is not working.

Special Tool(s) / Software
Tool Description

Tool Number

Comments

Indenter or Confined Crimp Tool for Closed
Barrel Terminals

*Obtain
Locally

Wire Stripper

*Obtain
Locally

Instructions

Service Parts Information

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IK0800522 ­ Repair Information for Damaged Headlight Connector

Kit Description

Part Number

Socket Lamp*Lamp

Quantity
Required

Page 3 of 7

Notes

3561125C1

1‐2

Sales Set Qty: 1

Lock, Connector Body*Secondary 3561139C1

1‐2

Sales Set Qty: 25

Terminal Cable (For 14GA Only)

2033816C1

3‐6

Sales Set Qty: 10

Gasket Headlight Mtg*Headlight

3561925C1

1‐2

Sales Set Qty: 1

Plug Sealing (Plug End Seal)

1671603C1

3‐6

Sales Set Qty: 42

3517502C1

3‐6

Sales Set Qty: 7

Terminal Butt Splc 16‐14AWG

Lead Free Rosin Core Solder

*Obtain Locally

Heat Shrink Tubing

*Obtain Locally

Wire 14AWG, 6", Yellow

1

*Obtain Locally

Wire 14AWG, 6", Dark Blue

1

*Obtain Locally

Wire 14AWG, 6", White

1

*Obtain Locally

Diagnostic Steps
The connector that is part of the headlight assembly may have terminal or connector
damage resulting in an inoperative headlight. The connector should be inspected as part of
normal circuit diagnostics.
REMOVAL PROCEDURE:
1. To inspect the headlight connector, unlatch hood on both sides and tilt hood forward.
2. Locate the rear side of the headlight housing.
3. Turn the socket cover and remove. See Figure 1 below.
Figure 1

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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1. Headlight Socket Cover
4. Remove light socket pigtail plug. See Figure 2 Item 2 below.
Figure 2

1.
2.
3.
4.

Headlight Socket Cover
Headlight Socket Pigtail Plug
Headlight
Headlight Retaining Bezel

5. If the headlight connector, headlight body or terminals are damaged continue to
Repair Steps.

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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Repair Steps
Replace the damaged 3 pin connector with connector 3561125C1. Replace the headlight
bulb if damage is present. It is recommended to replace the headlight bulb in pairs.
1. Use the component parts for the connector, terminals, seals and wires to pre‐
assemble a pigtail harness.
◦ Crimp the terminal and seal to each of your 6" pieces of wire.
◦ Insert the Yellow wire into cavity A of connector 3561125C1.
◦ Insert the White wire into cavity B of connector 3561125C1.
◦ Insert the Dark Blue wire into cavity C of connector 3561125C1.
◦ Insert the Lock 3561139C1 onto the back of the connector body.
◦ Install the gasket 3561925C1 onto the fron of the connector body.
◦ Your completed pigtail should match the OEM wiring as shown in Figure 3
below.
Figure 3

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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2. Replace the socket pigtail plug, with the pigtail harness you have pre‐assembled.
◦ Cut the 3 wires to remove the old connector.
◦ Use the 3 closed barrel butt connectors 3517502C1 to crimp and solder the
existing wiring to the new pigtail.
◦ Follow proper wire repair procedures as outlined in IK0800269 ‐ Proper Wire
Repair.
3. To replace the headlight, if required, remove the headlight retaining bezel. See
Figure 4 below.
Figure 4

1. Headlight Retaining Bezel
4. Remove the headlight.
Figure 5

1. Headlight
INSTALLATION PROCEDURE:

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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• The installation is performed in opposite order of the removal procedure.

Warranty Information
Warranty Claim Coding:
Group:

08810 ‐ Headlights

Noun:

388 ‐ Lamp Assembly

Standard Repair Time(s):
Description
Headlight Bulb, Replace

Wiring Repairs, Perform

SRT Procedure

Model

GY08‐5360A
KL08‐5360A
A08‐2001A (Up to 12
Minutes)
A08‐2002A (13‐24
Minutes)
A08‐2003A (25‐36
Minutes)

CE / BE Bus All
DuraStar
Engines

All Models

Engine

All
Engines

SRT
Hours
Click
Here

Click
Here

Other Resources
Master Service Information Site
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