CERTAIN AUTOCAR WX AND WXR MODEL VEHICLES BUILT BETWEEN 12/21/2004 AND 8/15/2005, VIN RANGE TO

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1 ATTENTION: SUBJECT: VEHICLES AFFECTED: SERVICE MANAGERS / PARTS MANAGERS REPLACE FAULTY GATEWAY MODULES CERTAIN AUTOCAR WX AND WXR MODEL VEHICLES BUILT BETWEEN 12/21/2004 AND 8/15/2005, VIN RANGE TO Service Bulletin Information Service Programs are product modifications that Autocar has determined should be performed proactively on all vehicles affected. It is preferred that the modification takes place prior to a failure. The expense related to this Service Program will be eligible for warranty recovery based on the published program standard labor time and required parts. Service Programs do expire. Reimbursement will not be available for claims submitted after the expiration date published on the Service Program. Number of Vehicles Affected There are 170 vehicles with serial numbers in the range to Please see Page 4 for a listing of the trucks affected by this Service Program. NOTE: To verify or determine if a particular vehicle is affected by this Service Program, you should consult the Service/Warranty screen. By entering the Vehicle Identification Number into the VIN Profile, the screen will display any outstanding Service Program(s) and/or outstanding Recall(s). If the Service Program number does not appear in the VIN Profile then the vehicle is not affected by this program. If the vehicle is on the program and has already been fixed, the Service Program number will have COMPLETED after it. Inspection A green label is attached to all replacement Gateway modules. Before replacing a Gateway module, inspect the module to see if it has a green label installed (see Figure 1 on the following page). If the green label is present, the unit is good and does not require replacement. No further action is needed. Repair Torque all fasteners to the proper torque value. Please see Repair Procedure information starting on Page 5 for further details. Time Allowance 0.5 hours per vehicle. Parts A or, A of 11

2 Figure 1 GREEN LABEL 2 of 11

3 Tools Required 15/16 socket and ratchet 15/16 combination box/open wrench Torque wrench, capable of +/-5% accuracy at 200 ft.-lbs. of torque 7/16 socket and ratchet 7/16 combination box/open wrench Torque wrench, capable of +/-15% accuracy at 76 in.-lbs. of torque DANGER The 5/8 bolts and nuts must be accurately torqued. These fasteners secure a structural crossmember on the truck frame. By not properly securing the fasteners, there is a risk of failure of the crossmember that might result in further structural failure, resulting in personal injury or death. Claims for Credit Expenses associated with the performance of this Service Program will be reimbursed based on the guidelines identified in this Bulletin, and by submitting a claim following published Instructions in the claim preparation section of the Service Operations Manual. Claim Coding Information Authorization Number: SP Repair: Expiration Date: September 30, 2006 Dealer Responsibility Dealers are to perform the Service Program on all vehicles subject to the Service Program at no charge to the owner regardless of mileage, age of vehicle, or ownership as long as the repair is carried out before the expiration date of the program unless stated otherwise in this bulletin. Whenever a vehicle subject to this Service Program is taken into or is in your vehicle inventory or dealership for service, we strongly recommend you make every effort to perform the Service Program correction before the vehicle is sold or released to the owner. 3 of 11

4 Trucks Involved in This Service Program 5VCDC6MEX5H VCDC6MF45H VCDC6MF95H VCDC6MF05H VCDC6MF25H VCDC6BE75H VCDC6BE95H VCDC6BE05H VCDC6BE25H VCDC6MF15H VCDC6MF35H VCDC6MF55H VCDC6MF75H VCDC6MF95H VCDC6MF05H VCDC6MF75H VCDC6MF95H VCDC6BE85H VCDC6BEX5H VCDC6BE15H VCDC6MFX5H VCDC6BE75H VCDC6BE95H VCDC6ME65H VCDC6MF75H VCDC6MF95H VCDC6MF05H VCDC6MF25H VCDC6MF45H VCDC6MF65H VCDC6MF25H VCDC6ME55H VCD36MF55H VCDC6MF75H VCEC6MF95H VCDC6MF05H VCDC6BE75H VCDC6MF45H VCDC6MF65H VCDC6MF85H VCDC6MFX5H VCDC6MF95H VCDC6MF55H VCDC6MF75H VCDC6MF95H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6MF06H VCDC6MF26H VCDC6MF46H VCDC6MF66H VCDC6MF86H VCDC6MFX6H VCDC6MF66H VCDC6MF86H VCDC6MFX6H VCDC6MF35H VCDC6MF55H VCDC6MF75H VCDC6MF05H VCDC6MF25H VCDC6MF66H VCDC6MF86H VCDC6MFX6H VCDC6MF16H VCDC6MF36H VCDC6MF56H VCDC6MF16H VCDC6MF36H VCDC6MF16H VCDC6MF36H VCDC6MF56H VCDC6MF06H VCDC6MF26H VCDC6BEX6H VCDC6RE16H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6MF56H VCDC6MF96H VCDC6MF06H VCDC6MF26H VCDC6MF46H VCDC6MF06H VCDC6MF26H VCDC6MF46H VCDC6MF16H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6BE26H VCD36MF76H VCDC6BEX6H VCDC6ME56H VCDC6ME76H VCDC6MF86H VCDC6BE76H VCDC6BE96H VCDC6BE56H VCDC6BE76H VCDC6MF36H VCDC6MF76H VCDC6PE76H VCDC6ME76H VCDC6MF36H VCDC6MF56H VCDC6BE36H VCDC6BE36H VCDC6BE56H VCDC6BE76H VCD36FE16H VCDC6BEX6H VCEC6MF16H VCDC6BE66H VCDC6BE86H VCDC6BEX6H VCE36MF26H VCE36MF96H VCDC6BE36H VCDC6MF06H VCEC6MF36H VCD36FE56H VCDC6BEX6H VCDC6BE16H VCEC6MF76H VCDC6MF16H VCDC6BF06H VCD36FE96H VCE36PE46H VCDC6BG26H VCDC6BE46H VCDC6MF26H VCDC6BE26H VCDC6MF06H VCDC6MF36H VCDC6MF76H VCDC6MF96H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6MF16H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MFX6H VCDC6MF16H VCDC6MF36H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6MF06H VCDC6MF26H VCDC6MF46H VCDC6MF66H VCDC6MF26H VCDC6MF46H VCDC6MF56H VCDC6MF76H VCDC6MF96H VCDC6MF96H VCDC6ME16H VCDC6ME36H of 11

5 Repair Procedure WARNING To prevent eye injury, always wear eye protection when performing vehicle maintenance, service or inspection. DANGER Before working on a vehicle, set the parking brake, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. 1. Follow safety instructions above and ensure the engine is switched off. 2. Disconnect the battery to prevent damage to the electrical system when plugging and unplugging electrical harness connectors. 3. Drain all air pressure in the system to prevent personal injury from unexpected or sudden air pressure release. Air pressure must be released before disconnecting any air lines from the Gateway module. 5 of 11

6 4. Remove the gateway module bracket by removing the 5/8 bolts and nuts labeled (1) in Figure 2. Use a 15/16 combination wrench and 15/16 socket. 1 Figure 2 6 of 11

7 5. Remove the gateway module from the bracket by removing the 1/4 stainless bolts and nuts labeled (2) in Figure 3. GATEWAY MODULE BRACKET 2 Figure 3 7 of 11

8 6. Disconnect the electrical connectors and 1/4 air lines from the gateway module. See the engineering layout for gateway module drawing, part number A (Figure 4). Note that some trucks may be equipped with an alternate gateway module, part number A , depending on the truck s configuration. The alternate gateway module includes two additional air line connections (see Figure 5 on the following page). Figure 4 8 of 11

9 Figure 5 9 of 11

10 7. Remove the gateway module from the bracket and return the module to the manufacturer. The gateway module must be packaged and shipped to the following address: Mike Frewin Account Executive Pacific Insight Electronics Corp Insight Drive Nelson, BC V1L 5P5 Phone: ext. 266 Fax: (PIH: TSX) For shipping costs, use FedEx shipping account # Connect the plumbing and wiring to the new gateway module as shown in Figure 6. NOTE: All unused connector cavities, such as the one shown in Figure 6, must be plugged with the dummy connectors installed on the existing unit to prevent corrosion of the connector terminals and subsequent failure of the gateway module. UN-USED CONNECTOR CAVITY Figure 6 1/4 AIR LINES GATEWAY MODULE GATEWAY MODULE BRACKET 10 of 11

11 9. Secure the gateway module to the gateway bracket with 1/4 stainless bolts and nuts labeled (3) as shown in Figure 7. Torque the 1/4 bolts to 76 in.-lbs., +/-11 in.-lbs. 10. Secure the bracket in the truck with 5/8 fasteners, labeled (1), as shown in Figure 2. Use a 15/16 combination wrench and socket and torque to 200 ft.-lbs., +/-10 ft.-lbs. 3 Figure 7 11 of 11

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