Park the vehicle on an even surface with the transmission on neutral.

1.2.

Set the master control switch to the

1.3.

Set the battery disconnect switch in the battery compartment to the

position and apply the parking brake.
position.

INSPECTION
1.4.

Open the rear engine panel and locate the transmission harness (see Figure 1).

Rear engine
panel

Transmission
harness

Figure 1 - Rear Engine Panel and Transmission Harness Locations

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1.5.

LI4771E

Remove the P-clamp near the transmission connector (the P-clamp can be missing and will need to be
reinstalled later) and disconnect the connector. Do not remove the double P-clamp (see Figure 2).

Double P-clamp

P-clamp

Transmission
harness
connector

Figure 2 - Double P-clamp, P-Clamp and Transmission Harness Connector Locations

1.6.

Remove the convoluted tubing (4 feet total) starting from the connector to the double p-clamp (see Figure 3).

Figure 3 - Convoluted Tubing Removed

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1.7.

LI4771E

Remove the PVC electrical tape for 1 foot starting from the transmission connector and inspect the wires.
Then inspect the rest of the convoluted tubing for signs of chafing. If there are other signs if chafing, remove
the PVC electrical tape further and inspect the underlying wires (see Figure 4).

Figure 4 - Chafed Wires and Chafed Convoluted Tubing

1.8.

At this point, refer to the table below for the next steps.

INSPECTION RESULTS

ACTION REQUIRED

No damage detected or only superficial damage on
convoluted tubing and/or wires insulation.

Continue level 1 procedure steps 1.9 to 1.16.

Wiring copper strands conductors are visible (1 to 5
wires).
Wiring severely damaged (more than 5 wires damaged
with the conductor copper strands exposed and/or
corroded).

Go to repair procedure at step 2.1.

Go to repair procedure at step 2.2.

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IMPROVE PROTECTION
1.9.

Apply Coroplast tape (N74787) for 1 foot starting from the harness connector and over any further length of
exposed wires where PVC electrical tape was removed at step 1.7 (see Figure 5).

Coroplast tape
(1 foot or more)

Figure 5 - Coroplast Tape Applied

1.10.

Install spiral sleeving (N99985) over the full extents of the sires bundle now protected with the coroplast tape
(see Figure 6).

Figure 6 - Spiral Sleeving Installation

1.11.

Replace the convoluted tubing if damaged (N28083-07) and reinsert the taped wire bundle into it. Apply
Coroplast tape (N74787) over the convoluted tubing to tighten the loom. Do not overlap (see Figure 7).

Figure 7 - Convoluted Tubing and Coroplast Tape

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SECURE EXCESS LENGTH
1.12.

Reconnect the transmission harness and reinstall the P-clamp (N84090-07) with screw (N40492) and nut
(N38593). If P-clamp was missing, install new a one.

1.13.

Secure harness excess length with two dual clamp ties (N37749) (see Figure 8).

Dual clamp
ties (N37749)

P-clamp
N84090-07

Figure 8 - Final Routing

1.14.

Close the rear engine panel.

1.15.

Set the battery disconnect switch to the ON position.

1.16.

The vehicle can return in service.

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LEVEL 2 – TRANSMISSION HARNESS REPAIR
2.1.

WIRES REPAIR

This repair procedure is only recommended for a N40216 transmission harness having 1 to 5 damaged
wires. In case of more wires being damaged, the recommendation is to replace the harness (see step 2.2).
2.1.1. Identify all wires with visible conductor copper strands (see Figure 9) and execute step 2.1.2 to step
2.1.5 for each wire.

Figure 9 - Wire Conductor Copper Strands Visible

2.1.2. Cut out the damaged section of the wire (see Figure 10).

Figure 10 - Cut Wire Damaged Section

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2.1.3. Replace the damaged wire section with the grey wire (N25831-23). Adjust length by adding 1 inch for
soldering purpose: (grey wire length = damaged section length + 1 inch) (see Figure 11).

1 in (25,4 mm)
Figure 11 - Cut Grey Wire

2.1.4. On each harness wires insert 2 in. of heat shrink tubing (N82227-03) (see Figure 12).

Figure 12 - Insert Heat Shrink Tubing

2.1.5. Prepare grey and harness wires by stripping 0.313 in. (7,5 mm) of insulation at each wire end (see
Figure 13).

0.313 in. (7,5 mm)

Figure 13 - Wires Insulation Removed

2.1.6. Using a crimp tool AD-1522 (see Figure 14) install butt splices (N8910917) at each connection between
grey wires and harness wires. Follow the steps illustrated at Figure 15 for crimping. See Figure 16
for repair result.

Figure 14 - Crimp Tool AD-1522 (For Reference Only)

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1 - Take the butt splice

2 - Insert the harness wire into
the crimp barrel of the butt splice

4 - On the other side of the splice
insert grey wire into the crimp barrel

LI4771E

3 - Crimp first wire using
AD-1522 crimp tool

5 - Crimp second wire
using AD-1522 crimp tool

Figure 15 - Butt Splice Crimping Step by Step

Figure 16 - Exemple of Repaired Wires

2.1.7. Heat splices with the heat gun until their tubing recovers and adhesive flows (see Figure 17).

Figure 17 - Butt Splice Appearance after Being Heat

2.1.8. Cover each butt splice with the piece of heat shrink tubing inserted at step 2.1.4 and heat with a heat
gun until tubing recovers and adhesive flows (see Figure18).

Figure 18 - Butt Splice Covered with Heat Shrink Tubing

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2.1.9. When all damaged wires are repaired, continue with level 1 steps 1.9 to 1.16.

2.2.

N40216 TRANSMISSION HARNESS REPLACEMENT
2.2.1. Remove the P-clamps (there should be 8) and the cable ties to free the damaged N40216 harness
and replace it with N99235 harness (see Figure 19).

Figure 19 - N40216 Transmission Harness and P-clamps Locations

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2.2.2. Start the routing of the new N99235 harness at the interior back panel connector. Using the orange
tape as reference, attach the harness to the first P-clamp (see Figure 20).

Harness
N99235
P-clamp and
orange tape

Figure 20 - Attach the Harness to the First P-clamp at the Orange Tape (Some Components Removed For Clarity)

2.2.3. Follow the original routing and secure the harness with the removed P-Clamps and new cable ties (use
as needed). Before installing the last P-clamp connect the harness connector on transmission. Then
secure the harness N99235 using one cable tie and the orange tape as reference (see Figure 21).

1.18 in.
(30 mm)

Orange
tape

Figure 21 - At the Orange Tape attach the Harness at the Shown Location with a Cable Tie (Side and Top View)

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2.2.4. Close the rear engine panel.
2.2.5. Set the battery disconnect switch to the ON position.
2.2.6. The vehicle can return in service.

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