Countries: CANADA, UNITED STATES Document ID: IK0800660

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Major System: | ELECTRICALSYSTEM Created: 8/21/2023
Current Language: English Last Modified: 10/3/2023

Knowledge Base Other Languages: NONE Author: Anthony Tondola
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Title: RH Chassis Harness Rubbing Inner Fender

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Applies To: RH built prior to 07/03/2023

CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

u 0/03/2023 - Initial Article Release

DESCRIPTION

This document will guide the user through changing the routing of the chassis harness that passes behind the left inner fender.
In some cases, the wiring harness in this area can be damaged by rubbing the inner fender. The purpose of the following
procedure is to reduce the possibility of the harness contacting the left Inner fender.

This procedure only applies to RH units built prior to 07/03/2023 with harness damage caused by the harness contacting the left
inner fender.

SYMPTOM(s)

Customer Observations or Concerns:

* Check engine light (CEL)
¢ Various circuit faults

Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):

DTC/Light Description
NIA Fault codes vary greatly due to the
lamount of circuits in this harness

SPECIAL TOOL(s) / SOFTWARE

[Tool Description Tool Number Comments Instructions

N/A N/A

Tools Resource Center

SERVICE PARTS INFORMATION

Kit Description Part Number Require Notes
IWASHER 25707R1 2
NUT 25519R1 2
BOLT 25483R1 2
SADDLE, CLAMP. 204134101 2
EXTENSION, CLIP 364084C1 2

DIAGNOSTIC STEP(s)

1. Remove the left inner fender (Refer to the appropriate service manual for removal instructions)

2. Inspect for signs of harness damage

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REPAIR STEP(s)

To prevent property damage, personal injury, and/or death, keep flames or sparks away

from the vehicle, and do not smoke while servicing the vehicle’s batteries. Batteries expel
explosive gases.

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

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

To prevent property damage, personal injury, and/or death, if the vehicle must be raised,
do not work under the vehicle supported only by jacks. Jacks can slip or fall over.

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

1. Bring the vehicle into the shop and park on a flat surface

2. Shift the transmission into park or neutral, set the parking brake, and install wheel chocks
3. Remove the left front inner fender wheel well and set it aside.

4. Remove both passthrough connectors at the cowl.

5. It may be necessary to remove the ground wire

* Follow iKNow article - |IK0800582 - Red Gel Coat Removal from Start Studs and Electrical Connections

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6. Remove all tie straps needed to gain access to the damaged wire harness.

7. Remove the conduit from the wire harness and discard. Remove the conduit to the frame rail.

8. Inspect all wires for chaffing/damage, solder, and shrink tube all damaged wires. If needed add a new length of wire to the
harness So that the harness is not shortened.

+ Follow iKNow article - |KO800269 - Proper Wire Repair

9. Install saddle clamp 2041341C1 to extension 364084C1 using washer, 25705R1 and nut 25519R1.

10. Mount extension, 364084C1 to stud behind the front cab mount using nut 25519R1 and washer 25707R1

.

11. Reroute the electrical harness to the right side of the airlines.

New routing on right
side of airlines

Original layout New layout

12. Install new tie straps in the extension.

Install tie strap new support
bracket.

13. Route cable as shown below. Install tie strap in new support bracket

14. Install tie straps along the harness as needed to support the harness and eliminate and potential for chaffing. (See
examples below).