SERVICE PROGRAM. SP November, 2008 ATTENTION: SERVICE MANAGERS/ PARTS MANAGERS

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1 ATTENTION: SERVICE MANAGERS/ PARTS MANAGERS SUBJECT: REPLACE INSTRUMENT CLUSTER LIGHT BAR VEHICLES AUTOCAR ACX MODEL AFFECTED: VEHICLES BUILT BETWEEN 30 NOVEMBER 2007 AND 22 SEPTEMBER 2008, VIN RANGE TO PROGRAM EXPIRES: 17 NOVEMBER 2009 Service Program Information: The instrument cluster light bar in certain Autocar ACX heavy duty class 8 vehicles has a software programming error which incorrectly causes the ABS trailer light to illuminate and stay illuminated. This program describes the procedure for replacing the light bar with the faulty programming. Vehicles Affected: There are 321 affected vehicles that were manufactured between 30 November 2007 and 22 September 2008, within VIN range to Refer to VIN list beginning on page 3. NOTE: To determine whether a particular vehicle is affected by this service program (or any other service program), consult the Service & Warranty link on Autocar s website: After logging into the dealer section of the website, enter the VIN into the VIN Profile; the system will display any outstanding service programs. Inspection and Repair: If the VIN is within the specified range and included in the list beginning on page 3, inspect the light bar by removing the instrument cluster from the dashboard. If the part number of the light bar is A , it does not need to be replaced. Otherwise, perform the REPAIR PROCEDURE beginning on page 5. Dealer Responsibility: Dealers must perform this service program on affected vehicles at no charge to the owner regardless of vehicle mileage, age or ownership of the vehicle. If a vehicle affected by this service program is taken into or is in your vehicle inventory or at your dealership for service, you must perform this service program before the vehicle is sold or released to the owner. Claims for Reimbursement: Submit a claim following the instructions in the Claim Preparation section of the Warranty Administration Manual. Claim Coding Information: Authorization Number: SP NOTE: Claims for reimbursement for this program will be paid by Autocar ONLY after the old light bar (identified as part number A or A ) is returned to the following address via FedEx ground account number : Pacific Insight Electronics Corp Insight Drive Nelson, BC V1L 5P5 CANADA Repair Number: For ACX LH or RH drive with tilt steering or ACX dual drive: For left hand light bar only For right hand light bar only For ACX LH or RH drive with fixed steering column: For left hand light bar only For right hand light bar only and click the Web-Link Direct icon to request emergency service assistance. Page 1 of 6

2 Expiration Date: 17 November 2009 Time Allowance: For ACX LH or RH drive with tilt steering OR ACX dual drive: Left hand light bar only: 0.5 hrs. Right hand light bar only: 0.5 hrs. For ACX LH or RH drive with fixed steering column: Left hand light bar only: 0.9 hrs. Right hand light bar only: 0.9 hrs. Tools: The following tools are required to perform this service program: Phillips Screw Driver Torque Wrench Ratchet 9/16 Socket 9/16 Wrench Phillips head bit To order parts call: Parts: Part number and description Quantity For ACX LH or RH drive: A light bar 1 For ACX dual drive: A light bar 2 and click the Web-Link Direct icon to request emergency service assistance. Page 2 of 6

3 Affected Vehicles (by VIN): Affected Vehicles, sorted by last (6) digits of VIN, in ascending order from left to right, then top to bottom: 5VCACLKH38H VCACLHE98H VCACLKF88H VCACLHE18H VCACLHE38H VCACLHE58H VCACLHE78H VCACLHE98H VCACLHE08H VCACLHE28H VCACRJFX8H VCACLKH18H VCACLJF78H VCACLJF58H VCACRJF68H VCACDJF08H VCACLKF18H VCACLKF88H VCACLKFX8H VCACLKF18H VCACLKF38H VCACLKF58H VCACLKF78H VCACLKF98H VCACLKF08H VCACLKF28H VCACLKF48H VCACLKF08H VCACLKF28H VCACLKF48H VCACLKF68H VCACLKF88H VCACLKFX8H VCACLKF18H VCACLKF38H VCACLKF58H VCACLJF38H VCACLHE38H VCACLHE58H VCACLHE78H VCACLHE98H VCACSKE08H VCACSKE28H VCACSKE98H VCACSKE08H VCACSKE28H VCACRLE98H VCACRLE08H VCACRLE28H VCACRLE48H VCACRLE68H VCACRLE28H VCACRLE48H VCACRLE68H VCACRLE88H VCACRLEX8H VCACRLE18H VCACRLE38H VCACRLE58H VCACRLE78H VCACRLE98H VCACRLE58H VCACRLE78H VCACLKE98H VCACLKE58H VCACLKE78H VCACRLE78H VCACRLE98H VCACRLE08H VCACRLE28H VCACRLE48H VCACRLE68H VCACRLE88H VCACLHE58H VCACLHE18H VCACLLE58H VCACRLE38H VCACLHE79H VCACLHE99H VCACLHE09H VCACLHE29H VCACLHE49H VCACLHE69H VCACLHE89H VCACLHEX9H VCACLHE19H VCACLJF68H VCACLJF69H VCA3LJF98H VCACLJF69H VCACLKFX9H VCACLHE79H VCACLHE39H VCACLHE59H VCACLHE79H VCACLHE99H VCACLHE09H VCACLHE29H VCACLHE49H VCACLKF38H VCACLKF58H VCACLHE79H VCACLHE99H VCACLKF79H VCACLKF99H VCACLKF09H VCACLKF29H VCACDKF19H VCACDKF39H VCACLHE49H VCACLHE69H VCACLKH79H VCACRLE38H VCACRLE58H VCACRLE78H VCACRLE98H VCACLHE19H VCACLHE29H VCACLHE49H VCACLLEX9H VCACLLE69H VCACLLE89H VCACLLEX9H VCACLLE19H VCA3LHF99H VCACLKE09H VCACLKE39H VCACLKE59H VCACLKE79H VCACLKE99H VCACLKE09H VCACLKE29H VCACLLE59H VCACLLE79H VCACLLE99H VCACLKF89H VCACLKFX9H VCACLHE39H VCACLHEX9H VCACSKF49H VCACSKF69H VCACSKF89H VCACSKFX9H VCACSKE29H VCACSKE99H VCACLJF59H VCACLHE09H VCACLKF09H VCACLKF29H VCACLKF49H VCACLKF69H VCACLKF89H VCACLJF79H VCACLJF99H VCACLJF09H VCACLJF79H VCACLJF99H VCACLJF09H VCACLJF29H VCACLJF49H VCACLJF69H VCACLJF89H VCACLJFX9H VCACDKF79H VCACLKF69H VCACLKF89H VCACLKFX9H VCACLKF19H VCACLKF39H VCACLKF59H VCACLKF79H VCACLKF99H and click the Web-Link Direct icon to request emergency service assistance. Page 3 of 6

4 5VCACLKF09H VCACLKF79H VCACLHE09H VCACLHE29H VCACLKF09H VCACLKF29H VCACLKF99H VCA3RHE08H VCACSKE89H VCACSKEX9H VCACSKE19H VCACSKE39H VCACSKEX9H VCACSKE19H VCACLKE69H VCACSJF29H VCACLJF79H VCACLJF99H VCACLJF09H VCACLJF29H VCACLKF69H VCACLHE99H VCACLHE09H VCACLHE79H VCACLHE99H VCACLHE09H VCACRLE99H VCACRJF69H VCACLJF19H VCACLJF69H VCACLJF89H VCACLHE39H VCACLHE59H VCACRJF69H VCA3RJF89H VCA3RJFX9H VCA3RJF19H VCA3RJF39H VCACRJF59H VCACRJF79H VCACRJF99H VCACRJF09H VCACLHE19H VCACLKH59H VCACLKH79H VCACLHE29H VCACLHE49H VCACLJF59H VCACLKF99H VCACLKF09H VCACLKF79H VCACRKF59H VCACRKF79H VCACRKF99H VCACRHEX9H VCACRHE19H VCACLKFX9H VCACLKF19H VCACLKF39H VCACLKF59H VCACLKF79H VCACLKF99H VCACLKF09H VCACLKF29H VCACLKF49H VCACLKF69H VCACLKF29H VCACLJF49H VCACLJF69H VCACLJF89H VCACLJFX9H VCACLJF69H VCACDKF29H VCACLJF19H VCACLJF39H VCACLJF79H VCACLJF99H VCACLJF09H VCACLJF29H VCA3RKF79H VCACLJF29H VCACLJF49H VCACLJF69H VCACLJF89H VCACLJFX9H VCACLJF19H VCACLJF39H VCACRLE69H VCACRLE89H VCACRLEX9H VCACRLE69H VCACRLE89H VCACRLEX9H VCACRLE19H VCACRLE39H VCACLJF49H VCACLHE59H VCACLHE99H VCACLHE09H VCACLHE29H VCACLHE49H VCACLHE69H VCACLHE89H VCACLHEX9H VCACRJF49H VCACRJF69H VCACLKF09H VCACLHE39H VCACLLE89H VCACLHE99H VCACLLE69H VCACLLE89H VCACRJF19H VCACLJF79H VCACLHE29H VCACLHE49H VCACLKF49H VCACLJF49H VCACLJF69H VCACLJF89H VCACLJFX9H VCACLJF19H VCACLJF39H VCACLJF59H VCACLJF79H VCACRJF59H VCACRJF19H VCACRJF39H VCACRJF59H VCACLKF19H VCACLKF39H VCACLJF69H VCACLKF29H VCACLKF49H VCACLKF69H VCACLJF19H VCACLJF39H VCACLJFX9H VCACLLE69H VCACLLE89H VCACLLEX9H VCACLJF79H VCACLHE29H VCACLHE49H VCACLHE69H VCACLHE89H VCACLHEX9H VCACLHE39H VCACLKF69H and click the Web-Link Direct icon to request emergency service assistance. Page 4 of 6

5 REPAIR PROCEDURE: WARNING To prevent eye injury, always wear eye protection when performing vehicle maintenance, service, or inspection. 1. Remove the (4) steering column bracket bolts holding the steering column in place. Use a 9/16 wrench, ratchet and 9/16 socket to remove the bolts. See Figure 1 showing steering column bracket bolt locations. WARNING Turn and lock battery disconnect switch to disconnect the battery supply from the rest of the truck to limit the risk of fire when working on the truck Figure 1 Steering Column Bolts DANGER Before working on a vehicle, turn the engine to off, set the parking brake, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement, resulting in serious personal injury or death. 2. Rotate or lower the steering column to gain access to the instrument cluster screw blocked by the turn signal collar. See Figure 2 showing the screw covered by the turn signal collar. NOTE: For ACX LH or RH drive with fixed steering column, begin at Step 1. For ACX LH or RH drive with tilt steering or ACX dual drive, begin at Step 3. Figure 2 Blocked instrument cluster screw and click the Web-Link Direct icon to request emergency service assistance. Page 5 of 6

6 3. Remove the instrument cluster from the dash by removing (8) screws with a ratchet or Phillips head screw driver (Figure 3). Figure 5 Light bar and (4) screws Remove 8 screws 4. Pull the instrument cluster from the dash. Remove the (2) white harness connectors from back of the instrument cluster light bar. See Figure 4 for the light bar connectors to be removed. Figure 4 Remove Connectors Figure 3 6. Install the A light bar to the instrument cluster with (4) screws and a Phillips screw driver. 7. Reinstall the (2) white harness connectors to the back side of the A light bar. 8. Reinstall the instrument cluster to the dash with (8) screws and a Phillips screw driver. 9. If the steering column bolts were removed, position the steering column back into the correct position and install the column bracket with (4) bolts. 10. Tighten the (4) steering column bracket bolts with a ratchet and 9/16 socket and torque the bolts to 30+/-3 Ft-lbs. with a torque wrench. 5. Remove the A or A light bar from the instrument cluster by removing the (4) screws with a ratchet or Phillips screwdriver. See Figure 5 showing the light bar screw locations. 11. For an ACX dual-drive truck, move to the opposite side of the cab, and repeat Step 3 through Step 8 for the opposite side light bar. and click the Web-Link Direct icon to request emergency service assistance. Page 6 of 6