NHTSA ID Number: 10185456
Manufacturer Communication Number: TSB-14-025
TSB/Document Date: 2021-01-11
Summary
Subject vehicles may exhibit electrical symptoms which can include, but are not limited to erratic operation of the exterior lamps, warning lamps illuminated in the instrument cluster, or erroneous DTC?s (Diagnostic Trouble Codes) setting in various modules. If the subject vehicle exhibits symptoms of this nature, inspect for corroded wire terminals within the electrical junction box on the passenger side of the bulkhead. An enhanced junction box cover and wire harness support are available to reduce the chance of water intrusion into the junction box.
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
2011MY-14MY JUNCTION BOX CORROSION DUE TO WATER INTRUSION
OVERVIEW
Subject vehicles may exhibit electrical symptoms which can include, but are not limited to erratic operation of the
exterior lamps, warning lamps illuminated in the instrument cluster, or erroneous DTC’s (Diagnostic Trouble Codes)
setting in various modules. If the subject vehicle exhibits symptoms of this nature, inspect for corroded wire terminals
within the electrical junction box on the passenger side of the bulkhead. An enhanced junction box cover and wire
harness support are available to reduce the chance of water intrusion into the junction box.
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
SUBJECT VEHICLES
2011MY – 2014MY Hino Conventional NE8J, NJ8J, and NV8J vehicles
BEFORE YOU BEGIN:
- Read and understand all instructions and procedures before you begin the work.
- Read and follow all WARNINGS and NOTICES set forth in this publication. These alerts help to avoid damage
to components, serious personal injury, or both.
- Park the vehicle on a flat, level and solid surface.
- Place the gear shift lever in "Neutral" or "Park".
- Apply the parking brake firmly and confirm parking brake activation.
- Turn off the engine and remove the key from the ignition switch.
- Always wear safety glasses or goggles to protect your eyes.
Place wheel chocks in front of and behind all the wheels to prevent the vehicle from moving.
PARTS
PART NUMBER
82069E0010
82998E0050
See Parts Catalog
Page 1 of 13
PART DESCRIPTION
Junction Box Repair Kit
Repair Terminal Kit
Wire Harness
QUANTITY
1
As Needed
As Needed
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
VEHICLE PREPARATION:
1. Park the vehicle on level ground.
2. Confirm the engine is stopped, the
ignition switch in the off (LOCK) position
and the key is removed.
3. Apply the parking brake.
Page 2 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
4. Chock the front wheels.
INSPECTION PROCEDURE
1. Release the hood latches and raise the
hood.
2. Remove the battery cover.
Remove the nut from the front
negative battery terminal. Remove
the chassis ground cable from the
front battery. Tape the end of the
battery cable to prevent contact
with the battery terminal.
NOTICE: Do not discard the battery
terminal nut. It will be reused
during the assembly procedure.
Page 3 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
3. Release the 5 clips on the
junction box cover, remove the
cover.
4. Release the lever locks on
connectors BE1, BE2, and BE3.
Remove the connectors for
inspection of the wire terminals for
corrosion.
Page 4 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
5. See the photographs for
examples of corroded wire
terminals. It will be at the
dealers’ discretion to
determine if the corrosion
damage is severe enough to
warrant replacement of the
effected wire harness, or to
repair the terminals on the
existing wire harness. If the
wire harness is deemed to be
repairable, proceed to the
Wire Terminal Repair
Procedure, below.
If the corrosion damage is
severe, replace the effected
wire harness as needed.
After replacement of the
harness, proceed to the
Junction Box Cover Repair
Procedure, below.
WIRE TERMINAL REPAIR PROCEDURE
1. Use a flat blade screwdriver
to release the black locking tabs
on the lower harness support in
the junction box. Remove the
lower wire harness from the
junction box.
Page 5 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
2. To replace corroded wire terminals,
use a suitable terminal tool or small
screw driver to release the locking tab
on the effected wire connector. Refer
to the photographs. Insert the tool into
the circled area of the connector. Apply
upward force using the tool to lift the
locking tab up on both sides of the
connector. Ensure the locking tab is
raised up as shown in the photograph
on the right.
3. Refer to the table to
select the appropriate
terminal release tool
that corresponds to the
effected connector cavity
for removal of wire
terminals.
NOTICE: A Bosch
(SPX)
Terminal Release Tool Kit
(HDT-650589) is required
to perform the following
repair procedure. Use
the following wire
terminal tools to remove
the wire terminals from
their respective cavity.
Page 6 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
4. Use the appropriate
terminal release tool to
release the individual
locking tab from the front
of the effected wire
terminal connector cavity.
Once the locking tab is
released, gently pull the
wire terminal out from the
back of the connector
cavity. Refer to the
photographs for reference.
5. Cut the old wire lead off between the
connector and the wire harness
grommet. A wire length of about 6
inches (150mm) is recommended.
Select a new repair terminal with wire
lead to match the corroded terminal
that was removed. Be certain to select
the appropriate terminal for the cavity
as the terminal assortment
(82998E0050) will include 3 different
sized terminals with a variety of
different colored leads.
NOTICE: If repairing multiple circuits, it
is recommended to stagger the repair
areas of each circuit so that the repair
areas do not stack up upon each other.
This can be achieved by cutting the
wires at various different lengths
(greater than or less than 6 inches). It
may be necessary to remove the wire
harness support and slide the harness
grommet back to allow enough room to
evenly space the solder joints.
Page 7 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
6. Trim the new wire lead to
an appropriate length. It is
necessary to solder the new
wire lead onto the existing
wire harness using shrink tube
to insulate the solder joint. In
preparation for soldering, strip
the wire insulation off of the
harness end and off of the wire
lead end. Install a piece of heat
shrink tube over one of the
wire ends. Refer to the images
below for the recommended
soldering procedure. Once the
joint is soldered, use a heat
gun to shrink the shrink tube.
7. Insert the new wire terminal into the
connector shell. The terminal should
engage with a positive “click” when
locked into position. Lightly pull back on
the wire to ensure that it is locked in
place.
8. Repeat steps 1 through 6, above to
repair any additional corroded wire
terminals on connectors BE1, BE2, or BE3.
Page 8 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
9. Snap the locking tab back in place that
was released during step 1, above on
connectors BE1, BE2, or BE3.
10. Insert the lower wire harness
back into the junction box. Ensure
that the harness support fully
engages into the clips on the
junction box. Make certain that
the harness grommet is flush with
the sealing surface of the junction
box when fully inserted.
NOTICE: Apply silicone lubricant
to the outer edge of the harness
grommet when inserting it back
into the junction box.
11. Install connectors BE1, BE2, and BE3
back into the original location from which
they were removed. Ensure that the lever
locks are fully engaged to the locked
position. Proceed to the Junction Box
Cover Repair Procedure, below.
Page 9 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
JUNCTION BOX COVER REPAIR PROCEDURE
1. Inspect the upper wire harness
support inside of the rubber
grommet. If the upper harness
support is white in color, it will
need to be replaced with the
enhanced gray wire harness
support.
2. If a white harness support is
present, release the black clips
on the junction box using a flat
blade screwdriver. Remove the
harness support from the
grommet, unlock the harness
support, and remove it from
the harness.
3. Install the gray harness
support onto the harness.
Install the harness support
into the grommet. Apply
silicone lubricant to the
rounded portion of the
grommet that contacts the
junction box.
Page 10 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
4. Insert the wire harness
back into the junction box.
Ensure that the harness
support fully engages into
the clips on the junction
box.
5. Verify that both upper and lower
harness grommets are flush with the
sealing surface of the junction box. If
the harness grommet is sticking up,
remove and reposition the harness
grommet to ensure the grommet will
be flush with the sealing surface.
6. Inspect the junction box cover
seal for a slit near the bottom
corner. If a slit is present in the
seal, replace the junction box
cover with the enhanced junction
box cover which has no slit in the
seal.
Page 11 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
7. Install the junction box cover to the
junction box. Ensure all 5 clips on the
junction box cover are fully engaged to
the junction box.
8. Lower the hood and engage the
hood latches.
9. Position the ground cable onto the
negative battery terminal. Install the
negative battery terminal nut. Tighten
the nut to the specified torque. Install the
battery cover. Proceed to the final
inspection procedure, below.
Specified Torque: 8.1 lb-ft (11.0 Nm)
Page 12 of 13
Vendor Ref.: HMM-140711-J1
Group:
Bulletin No.:
Issue Date:
TECHNICAL
27-Electrical System
SB-14-025
02-05-2014
SERVICE BULLETIN
FINAL INSPECTION PROCEDURE:
1. To complete this technical service bulletin, review the bulletin and confirm the following:
All corroded wire terminals have been replaced.
The connector lever locks were fully engaged.
The updated harness support and junction box cover are installed.
Any nuts or bolts that were removed during this procedure have been tightened to
their specified torque.
The vehicle functions normally with no warning indicator lamps illuminated.
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
CLAIM APPLICATION:
* Reimbursable in accordance within the terms and policies of the Hino Truck limited warranties.
a) Labor charge: Straight Time (To reflect actual working time)
b) Warranty code: 26000
c) Trouble code: 99
d) Operation code: 82250AOT
e) Original Part Number: 82672E0031
Page 13 of 13
Vendor Ref.: HMM-140711-J1
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TSB/Document ID: TSB-14-025
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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