NAYSTAR

FIELD SERVICE CAMPAIGN — 22110
08 June 2022

SUBJECT:
DEF Tank Jumper Harness Missing Wires

MODELS INVOLVED:
International® HX® Series trucks

DEFECT DESCRIPTION:

Certain International® HX® Series trucks may have a DEF tank jumper harness with a
missing circuit. All other vehicles built during this period have either been repaired prior
to shipment or determined to not require this repair.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service PortalS™
with FSC 22110. Also complete any other open campaigns listed on the Service Portal
at this time.

TOOLS REQUIRED:

Description Tool Number
Terminal Crimping Tool 14-24 AWG
Wire Stripper, 22 to 10 AWG Locally Sourced
Diagonal Cutting Pliers

Table 1 Tools Information

PARTS REQUIRED:

Part Number Description Quantity
476074C1 Use) Terminal 3/8-inch (10mm) UNC (One Time 1
3627568C1 Terminal Cable Framatome 2.8 2

Locally Sourced 14 AWG White TXL wire 136-inch long (3454 mm) 1
Locally Sourced Cable Tie Strap As Needed

Table 2 Parts Information

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WORK INSTRUCTIONS

WARNING! To prevent personal injury and / or death, or damage to property, park
vehicle on hard flat surface, turn the engine off, set the parking brake, and install
wheel chocks to prevent the vehicle from moving in both directions.

WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.

WARNING! To prevent personal injury and / or death, or damage to property, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.

WARNING! To prevent personal injury and / or death, or damage to property,
remove the ground cable from the negative terminal of the battery before
disconnecting any electrical components. Always connect the ground cable last.

—_

. Park vehicle on level surface.

2. Shift transmission to Park of Neutral and set parking brake.
3. Turn ignition to Key OFF position.

4. Install wheel chocks.

5. Obtain and cut wire harness for procedure:

e 14 AWG WHITE TXL wire 136-inch long (3454 mm)

6. Using wire stripper, remove approximately 1/4-inch (6 mm) from both ends of wire.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 2

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0000474455

Figure 1. 14 AWG WHITE TXL 136-inch (3454 mm) wire
1. 3627568C1 cable terminal

7. Starting at one end of the 14 AWG WHITE TXL 136-inch (3454 mm) wire, insert end of wire
into barrel of cable terminal (Figure 1, Item 1)

NOTE: Ensure proper crimping is performed on all terminals.
8. Using crimping tool, crimp terminal to wire end.

9. Repeat Step 7 through Step 8 for opposite end of 14 AWG WHITE TXL 136-inch (3454 mm)
wire.

10. Disconnect and isolate negative battery cable on main vehicle battery. Discard battery
terminal nut.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 3

0000474456

Figure 2. DEF Jumper Harness Connector Location
1. Connector 280A

11. Access connector 280A (Figure 2, Item 1) located underneath the driver- side cab.

12. Disconnect connector 280A (Figure 2, Item 1).

13. Remove connector 280A terminal lock. Save terminal lock for reuse.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

Page 4

0000474457

Figure 3. Connector 280A
1. Cavity 11

14. Populate one end of preassembled 14 AWG WHITE TXL 136-inch (3454 mm) wire terminal
into cavity 11 (Figure 3, Item 1) of connector 280A.

15. Install terminal lock into connector 280A.

16. Reconnect connector 280A (Figure 2, Item 1).

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 5

0000474458

Figure 4. DEF Jumper Harness Connector
1. Connector 275B

17. Working from underneath the driver-side cab, route preassembled 14 AWG WHITE TXL
136-inch (3454 mm) wire from connector 280A (Figure 2, Item 1) towards DEF tank
connector 275B (Figure 4, Item 1).

18. Disconnect connector 275B (Figure 4, Item 1).

19. Remove connector 275B terminal lock. Save terminal lock for reuse.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 6
20.

21.

22.

0000474457

Figure 5. Connector 275B
1. Cavity 11

Populate opposite end of preassembled 14 AWG WHITE TXL 136-inch (3454 mm) length
wire terminal into cavity 11 (Figure 5, Item 1) of connector 275B.

Install terminal lock into connector 275B.

Reconnect connector 275B (Figure 4, Item 1).

NOTE: Space cable tie straps 12 to 14 inches apart.

23.

24.

25.

26.

27.

28.

29.

Using cable tie straps, secure preassembled 14 WHITE TXL 136-inch (3454 mm) wire to
existing harness.

Clean battery terminal with wire brush. Then clean with electrical contact cleaner and dry
with shop air.

Apply BLUE dielectric grease to battery terminal stud, negative battery cable ring terminal,
and threads of new battery stud nut.

Using new battery stud nut, reconnect negative battery cable to negative terminal on main
vehicle battery and install new battery terminal nut.

Using torque wrench tighten battery stud nut to 12 - 15 Ib-ft (16 - 20 Nem).
Confirm DEF level gauge functionality.

Remove wheel chocks.

© 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 7
LABOR INFORMATION

Operation number must appear on all claims.

Operation Number Description Time
A40-22110-1 Create And Install Overlay Harness 0.8 hrs
Table 3 Labor Information

WARRANTY CLAIMS

Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner, making reference to Field Service Campaign 22110.

Section 7 of the Warranty Policy and Procedures Manual contains further information
related to the submission and processing of AFC / Recall claims.

As with all claim submissions, items acquired locally must be submitted in the “Other
Charges” tab. The cost of any bulk items (Such as a bag of cable tie straps, roll of wire,
barrel of oil, or tube of silicone) should be prorated for the cost of the individual pieces /
amount used during each repair.

To make sure this important improvement is made in a timely manner, all claims for
22110 activity must be submitted by 08 June 2023 or within the normal warranty period
for the component repaired, if after 08 June 2023.

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