IK0800522 ­ Repair Information for Damaged Headlight Connector

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IK0800522
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Revision: 5
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2/15/2016

Last
10/21/2016
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Charles
Schroeder

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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:
10/21/2016 ‐ Added wire color orientation information and photo based on dealer feedback.
02/22/2016 ‐ Edited coding for models.
02/19/2016 ‐ Edited diagnostic and repair steps to include terminal damage.
02/16/2016 ‐ Article Created.





Description
The 9007 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 and is not available through the Navistar parts system. Connector or terminal
damage can be repaired using locally obtained parts instead of replacing the entire headlight assembly.

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

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IK0800522 ­ Repair Information for Damaged Headlight Connector

DTC/Light

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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
Kit Description

Dorman Light Bulb Socket 84791

Part Number

84791

Closed Barrel Butt Connector

Quantity
Required

Notes

1‐2

Must be "High Temp"
*Obtain Locally (Figure 1 below)

3‐6

*Obtain Locally

Lead Free Rosin Core Solder

*Obtain Locally

Heat Shrink Tubing

*Obtain Locally
Figure 1

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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Diagnostic Steps
The 9007 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 3 below.

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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Figure 3

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

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.

Repair Steps
Replace the damaged connector with the Dorman 84791 High Temperature Socket Pigtail. Replace the
headlight bulb if damage is present. It is recommended to replace the headlight bulb in pairs.
NOTE:

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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The wire color orientation is not the same between the OEM connector and the Dorman connector with
pigtail. To maintain the proper wire color orientation, you can de‐pin and swap the locations of the
yellow and black wires on the replacement Dorman connector. See Figure 7 below.
Figure 7

1. Replace the socket pigtail plug, with the high temperature pigtail.
◦ Use the closed barrel butt connectors to crimp and solder the wiring.
◦ Follow proper wire repair procedures as outlined in IK0800269 ‐ Proper Wire Repair.
2. To replace the headlight, if required, remove the headlight retaining bezel. See Figure 8 below.
Figure 8

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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1. Headlight Retaining Bezel
3. Remove the headlight.
Figure 9

1. Headlight
INSTALLATION PROCEDURE:
• 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

SRT Procedure

Model

Headlight Bulb, Replace

GY08‐5360A
KL08‐5360A

CE / BE Bus
DuraStar
All Models

Wiring Repairs, Perform

Engine

SRT Hours

All Engines Click Here
All Engines Click Here

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IK0800522 ­ Repair Information for Damaged Headlight Connector

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

Other Resources
Master Service Information Site
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Copyright © 2016 Navistar, Inc.

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