IK0800522 - Repair Information for Damaged Headlight Connector

Page 1 of 7

BAHAMAS, BOLIVIA,
BRAZIL, BELIZE,
CANADA, CHILE,
COLOMBIA, COSTA
RICA, DOMINICAN
REPUBLIC, ECUADOR,
EL SALVADOR,
TRINIDAD AND
Document
IK0800522
Countries: TOBAGO, UNITED
ID:
STATES, URUGUAY,
VENEZUELA, MEXICO,
ARUBA, NICARAGUA,
PERU, PUERTO RICO,
Curaçao, GUATEMALA,
GUYANA, HAITI,
HONDURAS, JAMAICA,
PANAMA
ISIS, Bus ISIS, FleetISIS,
Availability:
Revision: 9
NotSIR
Major
ELECTRICAL SYSTEM Created: 2/15/2016
System:
Current
Language:

Last
11/5/2018
Modified:

English

Other
NONE
Languages:
Viewed:

Author:

Charles
Schroeder

2390
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative
Link

Bookmark

Add to
Favorites

Print

Provide
Feedback

Helpful

Not Helpful

34

11

View My
Bookmarks

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:
11/05/2018 ‐ Updated parts information based on dealer feedback.
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.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...





12/4/2018

IK0800522 - Repair Information for Damaged Headlight Connector

Page 2 of 7

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

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018

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

Terminal Butt Splc 16‐14AWG

3517502C1
3‐6
TXT126870104

Lead Free Rosin Core Solder
Heat Shrink Tubing

Sales Set Qty: 7
*Obtain Locally

2644000R1
3‐6
TXT126870142

Sales Set Qty: 50

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

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018

IK0800522 - Repair Information for Damaged Headlight Connector

Page 4 of 7

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.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018

IK0800522 - Repair Information for Damaged Headlight Connector

Page 5 of 7

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 front of the connector body.
◦ Your completed pigtail should match the OEM wiring as shown in Figure 3
below.
Figure 3

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018

IK0800522 - Repair Information for Damaged Headlight Connector

Page 6 of 7

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:

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018

IK0800522 - Repair Information for Damaged Headlight Connector

Page 7 of 7

• 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
Hide Details

Feedback Information
Viewed:

2389

Helpful:

34

Not Helpful: 11
No Feedback Found

Copyright © 2018 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

12/4/2018