Guidelines for Repairing or Replacing an Electrical Harness
> Recreational Vehicle
> School Bus
> Shuttle Bus

54-48

Freightliner Custom Chassis
Service Bulletin

> Walk-In Van
> S2

Description of Revisions: This bulletin replaces the version dated
October 2015. The part number for Daimler splice kits is revised.

General Information
Use the guidelines in this bulletin to determine if a damaged electrical harness should be repaired or replaced.
Refer to the wiring section in Group 54 of the applicable workshop manual for detailed wire repair instructions.
Table 1 describes general guidelines for repairing or replacing a harness. There may be cases when more than
one factor determines the course of action. For example, repairing a harness is recommended if shipping times
for the replacement harness exceed one week. However, replacement may be the only option if damage to the
harness is too extensive.

NOTE: When a harness is repaired, the source of the damage must also be identified and repaired.
Table 2 is a quick-reference for specific wire and terminal conditions.

IMPORTANT: Damaged connectors and seals can be replaced without replacing the harness. A drag
test should be performed to make sure that the terminal can retain proper tension to the mating
terminal. Refer to "Terminal Drag Test" in this bulletin for instructions. Discolored wires or melted
insulation should be replaced before any other repairs are performed on the harness.
Repairing or Replacing a Harness
Repair
Less than 20% of the harness is damaged.
If the wire damage is greater than 6 inches (15 cm), an
overlay harness can be added to replace the section of
damaged wire.
Wire is smaller than 12-gauge.
The harness is not readily available, or shipping will take
longer than one week.
Wire insulation is cracked due to excessive heat from an
external source. Repair is recommended if the damage is
isolated to one section of the wire.
There is a clean cut to the wire, corrosion is wicked no more
than 1 inch (2.5 cm) from the terminal end. If the damaged
area is over 6 inches (15 cm), the harness can be repaired
by adding overlay wiring over the damaged area.

Replace

More than 20% of the harness is damaged.

Wire is 12-gauge or larger.
The harness can be obtained in less than a week.
Wire insulation is cracked due to age, or damage is
extensive and spread throughout the wire.

The harness is proprietary, such as a datalink with sheathing
NOTE: If damage exceeds 1 inch (2.5 cm) from the terminal over a twisted pair, or a WABCO sensor and solenoid
wiring.
end, a quality repair may require adding a jumper wire to
create enough slack in the wire. If adding extra splices
stretches the wire too tightly it can degrade the integrity of
the harness.

Freightliner Custom Chassis Service Bulletin, February 2016

Page 1

54-48

Guidelines for Repairing or Replacing an Electrical Harness

Freightliner Custom Chassis
Service Bulletin

> Recreational Vehicle
> School Bus
> Shuttle Bus

> Walk-In Van
> S2

Repairing or Replacing a Harness
Repair
Replace
Two harnesses are affected. For example, M2 24 pin lever
lock connector (23-13144-010 and 23-13144-009) is
corroded on both sides. Also, if the harness has minimal
corrosion wicked up the wire, the connectors can be reExtensive damage to the harness caused by foreign material
pinned.
such as DEF fluid, diesel fuel, or road/deicer fluid.
If the damaged area is over 6 inches (15 cm), the harness
can be repaired by adding overlay wiring over the damaged
area.
Table 1, Repairing or Replacing a Harness
Wire Damage Quick Reference
Description
Remedy
Kinked Wire
Repair
Melted Insulation, Major.
Replace
Melted Insulation, Minor
Repair
Worn or Missing Insulation. See Fig. 1.
Repair
Discolored or Cracked Insulation, Major.
Replace
See Fig. 2.
Discolored or Cracked Insulation, Minor.
Repair
Datalink, Twisted Wire
NOTE: If only the terminals are damaged,
the terminals can be replaced without
replacing the twisted pair.
Corrosion in the Wire*
Corrosion in the Connector
Failed Terminal Pair Drag Test
Molded Cable†

Replace

Repair
Repair
Replace
Terminal
Replace

* Corrosion is wicked no more than 1 inch (2.5 cm) from the terminal end,
and no corrosion is wicked into the wire.
† An example is Meritor WABCO ABS sensor wiring.

Table 2, Wire Damage Quick Reference

How to Identify a Repairable Wire
See Table 3 to identify a repairable wire.

Page 2

Freightliner Custom Chassis Service Bulletin, February 2016

Guidelines for Repairing or Replacing an Electrical Harness
> Recreational Vehicle
> School Bus
> Shuttle Bus

54-48

Freightliner Custom Chassis
Service Bulletin

> Walk-In Van
> S2

12/16/2014
02/16/2015

f546121

f546138

Fig. 2, Insulation Discoloration, Major
Fig. 1, Worn Insulation, Major

Condition

Corroded Terminal

Identifying a Repairable Wire
Description

Example

If there is no further corrosion in the
wire, and it is not blackened from
corrosion, the wire can be repaired
by cutting off the corroded terminal
and stripping away the wire
insulation. A new terminal can then
be installed and inserted into the
connector.
NOTE: If the repair causes the wire
to be pulled tight, or results in
tension at the connector, a short
piece of wire and new terminal can
be added to reduce the tension.
Otherwise, all terminals must be
replaced.

A
10/29/2014

f546107

A. Corroded terminal.

Freightliner Custom Chassis Service Bulletin, February 2016

Page 3

54-48

Guidelines for Repairing or Replacing an Electrical Harness

Freightliner Custom Chassis
Service Bulletin

Condition

Corroded Wire

> Recreational Vehicle
> School Bus
> Shuttle Bus

Identifying a Repairable Wire
Description

> Walk-In Van
> S2

Example

Corroded wires can be repaired by
cutting out the damaged section.
The wire needs to be cut until only
clean wire is found for repair. It may
be necessary to add a jumper wire
to create slack and avoid wire
tension. Refer to the instructions in
this bulletin to install a jumper wire.
The example shows a small amount
of corrosion at the end of the wire.

Cut Wire (clean)
or
Worn Insulation

12/16/2014

f546117

10/29/2014

f546106

If the wire shows no sign of
corrosion, the wire can be repaired
with a splice kit.

Table 3, Identifying a Repairable Wire

Broken or Corroded Wires
Whether or not a broken or corroded wire, or cracked insulation should be repaired or replaced depends on the
extent of the damage.
A broken wire can be soldered together only if enough slack remains to avoid wire tension. If there is not
sufficient slack, a new section of wire must be soldered between the two broken ends. This technique can also
be used with small sections of corroded wire. Overlay wiring can also be used in the damaged area, however
the entire harness must be replaced if the corrosion exceeds 6 inches (15 cm).
If terminals are corroded at the connector, the terminal can be replaced. However, the entire wire must be
overlayed if corrosion exceeds 6 inches (15 cm). A jumper wire can be used in the case, if necessary.

Installing a Jumper Wire
1. Remove the terminal from the connector.
2. Cut out the damaged section of wire.

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Freightliner Custom Chassis Service Bulletin, February 2016

Guidelines for Repairing or Replacing an Electrical Harness
> Recreational Vehicle
> School Bus
> Shuttle Bus

54-48

Freightliner Custom Chassis
Service Bulletin

> Walk-In Van
> S2

3. Crimp and solder the new terminal with a new seal (if required) on to the new section of wire.

NOTE: Make sure the wire is the same gauge and quality as the wire being replaced.
4. Insert the terminal into the connector. See Fig. 3.
5. Run the wire along the harness up to the section of wire that is being replaced. See Fig. 4.
6. Splice the wires using a Daimler splice kit ESY ES66 404, or Phillips STA-DRY® Crimp and Solder
connector parts. See Fig. 5. Refer to Table 4 for a list of connector parts.
7. Inspect the harness and make sure there is enough slack. See Fig. 6.
8. Wrap the harness with convolute tubing. See Fig. 7.

12/16/2014

f546126

Fig. 4, Section of Wire to be Replaced
12/16/2014

f546120

Fig. 3, Terminal Inserted Into the Connector

Repairing a Harness Wrapped in Fiber
IMPORTANT: Do not use a hook razor blade to cut fiber wrap. Use a sewing seam ripper to cut the
fiber tape ( Fig. 8), taking care not to cut the harness wires.
1. Locate damaged area and carefully make an opening in the fiber wrap using a sewing seam ripper. See
Fig. 9.
2. Flip the tool over so the blunt end is facing wiring, then cut enough length to allow the fiber to be
unwrapped. See Fig. 10.
3. Unwrap the fiber until a sufficient area is exposed to make the repair. See Fig. 11.
4. If an overlay is necessary, remove just enough fiber to allow for a splice into the damaged wire. See Fig.
12.
5. Overlay the wire, then wrap the entire length to cover the overlay and integrate it with the harness.
6. Repair the wire as necessary. See Fig. 13.

Freightliner Custom Chassis Service Bulletin, February 2016

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54-48

Guidelines for Repairing or Replacing an Electrical Harness

Freightliner Custom Chassis
Service Bulletin

> Recreational Vehicle
> School Bus
> Shuttle Bus

> Walk-In Van
> S2

A

02/16/2015

f546135

Fig. 5, Splicing the Wires

12/16/2014

f546124

A. The wire should be slack so that there is no
tension.
Fig. 6, Slack in the Connector

02/16/2015

Fig. 7, Harness Wrapped with Convolute

f546134
02/16/2015

f546140

Fig. 8, Sewing Seam Ripper

7. Wrap the harness with fiber tape. Refer to Table 5. Make sure enough tape is used to overlap the starting
point. See Fig. 14.
8. When the harness is completely wrapped, secure both ends of the fiber wrap with electrical tape. See Fig.
15.

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Freightliner Custom Chassis Service Bulletin, February 2016

Guidelines for Repairing or Replacing an Electrical Harness
> Recreational Vehicle
> School Bus
> Shuttle Bus

54-48

Freightliner Custom Chassis
Service Bulletin

> Walk-In Van
> S2

02/16/2015

f546137

Fig. 9, Cutting an Opening into the Fiber Wrap

02/16/2015

f546139

Fig. 11, Unwrapping the Harness

02/16/2015

02/16/2015

f546141

Fig. 10, Cutting the Fiber Using the Blunt End of the
Seam Cutter

02/16/2015

f546143

Fig. 12, Overlay Added to the Damaged Area of the
Harness

f546142

Fig. 13, Wire Repaired with Shrink Tubing

Freightliner Custom Chassis Service Bulletin, February 2016

Page 7

54-48

Guidelines for Repairing or Replacing an Electrical Harness

Freightliner Custom Chassis
Service Bulletin

> Recreational Vehicle
> School Bus
> Shuttle Bus

> Walk-In Van
> S2

1

02/16/2015

f546136

1. Fiber Wrap Secured with Electrical Tape
02/16/2015

f546144

Fig. 15, Fiber Wrap Secured with Electrical Tape

Fig. 14, Wrapping the Harness with Fiber Tape

Terminal Drag Test
A drag test is performed between a single male and female terminal to determine if the engagement and
retention forces between them are sufficient. Individual terminals that fail the drag test can be replaced. If the
repair causes the wire to be pulled tight, or results in tension at the connector, a short piece of wire and new
terminal can be added to reduce the tension. Otherwise, all terminals must be replaced.
1. Perform a drag test on a known good terminal pair.
1.1

Select a mating female and male terminal pair that have the same part numbers as the affected
female and male terminal pair.

1.2

Manually insert, and then remove, the test mating male terminal into the test female terminal three
times. On the known good test terminal pair, the mating terminal will fit securely when inserted into
the terminal in the connector. There will be significant resistance (drag) when the mating terminal is
removed.

2. Compare the amount of resistance to the affected terminal pair by performing the same test on the affected
terminal pair. If the mating terminal does not have the same resistance as the good terminal pair, the
terminal pair and the seals (if required) should be replaced.

Parts
Repair wires using a Daimler splice kit ESY ES66 404, or Phillips STA-DRY Crimp and Solder Connectors
Parts.
See Table 4 for a list of STA-DRY solderless connector parts.
See Table 5 for polyester cloth tape part numbers.

Wire Size: gauge (mm)
20 to 18 (0.5 to 0.8)
16 10 14 (1 to 2)

Page 8

Phillips STA-DRY Crimp and Solder Connectors Parts
Connector Part
Shrinkable Tubing (Daimler Part Number)
Number*
PHM 1 1863
1/4 inch with internal adhesive coating (48-02461-025)
PHM 1 1862
1/4 inch with internal adhesive coating (48-02461-025)

Freightliner Custom Chassis Service Bulletin, February 2016

Guidelines for Repairing or Replacing an Electrical Harness
> Recreational Vehicle
> School Bus
> Shuttle Bus

Freightliner Custom Chassis
Service Bulletin

> Walk-In Van
> S2

Wire Size: gauge (mm)
12 to 10 (3 to 5)
8 or larger (5 or larger)

54-48

Phillips STA-DRY Crimp and Solder Connectors Parts
Connector Part
Shrinkable Tubing (Daimler Part Number)
Number*
PHM 1 1861
3/8 inch with internal adhesive coating–4 foot length (48-02461-038)
Replace the terminal or Use adhesive lined red for positive cables and black for negative
the entire cable
cables.

* Twenty-five connectors per pack.

Table 4, Phillips STA-DRY Crimp and Solder Connectors Parts
Tape—Polyester Cloth, Adhesive Backed
Roll Length
Width
82 feet (25 meters)
.75 inch (19 mm)
82 feet (25 meters)
1 inch (25 mm)
82 feet (25 meters)
2 inches (50 mm)

Part Number
48-25910-002
48-25910-003
48-25910-004

Table 5, Tape—Polyester Cloth, Adhesive Backed

Warranty
This is an informational bulletin. Warranty does not apply.

Freightliner Custom Chassis Service Bulletin, February 2016

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