NAYSTAR

FIELD SERVICE CAMPAIGN -— 22127

10 January 2023

SUBJECT:

Forward Chassis Terminating Resistor

MODELS INVOLVED:
International® LoneStar® Series Truck

DEFECT DESCRIPTION:
Certain International® LoneStar® Series trucks may have been built without forward
chassis terminating resistors that could result in data communication error.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service PortalS™
with FSC 22127. Also complete any other open campaigns listed on the Service Portal

at this time.

TOOLS REQUIRED:

Description

Tool Number

Crimping Tool

Wire Stripper, 22 to 10 AWG

Diagonal Cutting Pliers

Locally Sourced

Table 1 Tools Information

PARTS REQUIRED:

Part Number Description Quantity
3572112R1 Harness, Elect, 19 Stand Twisted Pair | 1 (Thisis so as roll of 50
3549418C1 Terminal, Elect, Cable 2
3574277C1 Terminal, Cable 2
3683464C1 Terminal, Cable 4
2519455C1 Plug, Sealing, Elect Connector, Cable 4

Terminal
3683465C1 Body, Elect Connector, Male 2-Way 2
3683466C1 Lock, Connector Body, Elect, Packard 2
250759801 Lock, Connector, Body 2

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3769112C91 Resistor, 120 ohm Terminating Resistor 2

Nut, Battery Terminal 3/8 inch UNC
(One Time Use)

Source Locally Cable Tie Strap 5 (as needed)
Table 2 Parts Information

476074C1 1

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 wile 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.

1. Park vehicle on level surface.

N

Shift transmission to Park or Neutral and set parking brake.
3. Turn ignition to Key OFF position.
4. Install wheel chocks.

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

6. Obtain and cut wire harness for procedure:
e A 30-inch (762 mm) length of 19 strand twisted pair harness wire

e A 32-inch (812.8 mm) length of 19 strand twisted pair harness wire

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10.

11.

12.

13.

Using a cutting box blade, carefully remove approximately 2 in (50.8 mm) of harness
insulation at each end of the 19 strand twisted pair harness.

Using wire stripped, remove approximately % in (6.4 mm) of insulation at each end
of the precut pair harness.
/

1
0000476514

Figure 1. Connector Terminal Seal Assembly
1. Terminal seal 2519455C1
2. Terminal 3683464C1

Using the recently cut 30-inch (762 mm) length of 19 strand twisted pair harness
wire, insert electronic connector terminal seal (Figure 1, Item 1) over YELLOW wire.

Insert exposed portion of YELLOW wire into the barrel of the terminal (Figure 2, Item

1).

Using crimping tool, crimp terminal by placing the barrel of the terminal into the
appropriate crimper slot, then crimp and secure electronic connector terminal seal.

Repeat Steps 7 through 9 for GREEN wire.

Using the recently cut 32-inch (812.8 mm) length of wire, repeat Steps 7 through 9
for GREEN and YELLOW wire.

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1 2

OOO T3617

Figure 2. Connector — 2-Way
1. CavityA
2. Cavity B

NOTE: Ensure that terminals are completely inserted into the connector.

14. Populate YELLOW wire into connector Cavity A (Figure 2, Item 1) of 2-way
connector.

15. Populate GREEN wire into connector Cavity B (Figure 2, Item 2) of 2-way connector.

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0000476513

Figure 3. Connector — 2-Way
1. Connector body lock 2507598C1
2. Connector — 2-way 3683465C1
3. 120 ohm terminating resistor 3769112C91
4. Connector body lock 3683466C1

NOTE: Ensure that terminals are completely inserted into the connector.

16. Install 120 ohm terminating resistor (Figure 3, Item 3) into 2-way connector (Figure
3, Item 2).

17. Insert connector body lock (Figure 3, Item 1) into male 2-way connector (Figure 3,
Item 2).

18. Insert connector body lock (Figure 3, Item 4) into male 2-way connector (Figure 3,
Item 2).

19. Repeat Steps 15 through 18 for 32-inch (812.8 mm) length of 19 strand twisted pair
harness wire.

0000476515

Figure 4. Connector Terminal Seal Assembly
1. Terminal 3549418C1

20. At opposite end of 30-inch (762 mm) length of 19 strand twisted pair harness wire,
insert end of wire into barrel of cable terminal (Figure 4, Item 1).

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21. Using crimping tool, crimp terminal to wire end.

0000476516

Figure 5. Connector Terminal Seal Assembly
1. Terminal 3574277C1

22. At opposite end of the 32-inch (812.8 mm) length of 19 strand twisted pair harness
wire, insert end of wire into barrel of cable terminal (Figure 5, Item 1).

23. Using crimping tool, crimp terminal to wire end.

24. Unlatch and open hood.

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Moos 7 a033

Figure 6. Forward Chassis Connector
1. 1/00F forward chassis connector

25. Disconnect 1700F forward chassis connector (Figure 6, Item 1) located in the driver-
side under-hood compartment. Save fastener for reuse.

26. Remove 1700F forward chassis cover. Save cover for reuse.

2/. Remove 1700F forward chassis terminal lock. Save lock for reuse.

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0000476517

Figure 7. Forward Chassis Connector
1. Cavity 65
2. Cavity 66
3. Cavity 61
4. Cavity 62

NOTE: Ensure terminal is completely inserted into connector.

28.

29.

30.

31.

32.

33.

Populate opposite end of the pre-assembled of the 32-inch (812.8 mm) length of 19
strand wire YELLOW wire into cavity 65 (Figure 7, Item 1).

Populate GREEN wire into cavity 66 (Figure 7, Item 2).

Populate the opposite end of the pre-assembled of 19 strand twisted pair harness
30-inch length (762 mm) YELLOW wire into cavity 61 (Figure 7, Item 3).

Populate GREEN wire into cavity 62 (Figure 7, Item 4).
Insert terminal lock into 1700F forward chassis connector.

Install 1700F forward chassis connector. Using torque wrench, tighten bolt to 44 Ib-in
(5 N-m)

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CAUTION: To prevent damage to property, route and secure harness away from
any sharp objects and / or moving parts.

0000476518

Figure 8. 2-Way Connector Secured

34. Using cable tie straps, secure both — 19 Strand Twisted Pair Harness to existing
harness conduit and male 2-way connectors (Figure 8).

35. Close and latch hood.

36. Clean battery terminal with wire brush. After brushing terminal, clean with electrical
contact cleaner and dry with ship air.

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

38. Reconnect negative battery cable to negative terminal on main vehicle battery and
install new battery terminal nut.

39. Using torque wrench, tighten battery stud nut to 12 - 15 lb-ft (16 - 20 N-m).

40. Remove wheel chocks.

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LABOR INFORMATION

Operation number must appear on all claims.

Operation Number Description Time
A40-22127-1 Fabricate Overlay and Install Resistor 0.5 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 22127.

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
22127 activity must be submitted by 10 January 2023 or within the normal warranty
period for the component repaired, if after 10 January 2023.

GROUP NOUN |C] WARR. | TP | PAD

GROUP — Enter number <
NOUN — Leave blank « J

C (CAUSE) — Enter either 1, 2, 3. (See below)

1. Inspected (No repair required).
2. Inspected and repaired.
3. Defective part from parts stock.

WARRANTY — (Warranty Code) Enter 40. «
TYPE PART — Enter P for type part causing failure. <
PAD — Enter 00 <

0000047910

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