ELECTRONIC DASHBOARD GAUGE DROP-OUT CX, CV AND CH MODEL CHASSIS

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1 SERVICE BULLETIN (Also applies to Mack Trucks Australia) (Supersedes bulletin SB dated 12/10/02) NUMBER: SB DATE: 1/13/03 MODEL: CX, CV, CH ELECTRONIC DASHBOARD GAUGE DROP-OUT CX, CV AND CH MODEL CHASSIS On CX, CV and CH (with CX style interior) model chassis manufactured prior to March 2002, a condition may be noticed whereby the gauges intermittently drop to zero then return to normal. When this gauge drop-out occurs, the warning buzzer will also sound and the seat belt indicator lamp will turn ON as the gauge readings return to normal. This condition is experienced with the ignition switch turned ON and the engine either running or not running. Gauge drop-out is caused by an intermittent loss of the dashboard gauge cluster ground connection. To eliminate this condition, the ground wire originating at pin No. 35 of the 36- pin dash cluster connector now terminates at the 135A ground circuit breaker located on the bulkhead. This change was implemented into production during March On chassis manufactured prior to March 2002 that are experiencing gauge drop-out, it will be necessary to install a new ground wire between pin No. 35 of the 36-pin dashboard connector and the 135A circuit breaker on the bulkhead as outlined in this bulletin. Additionally, if a chassis is experiencing gauge drop-out, and the gauge cluster assembly has a date code of 1590 (159th day of the year 2000) or lower, it will also be necessary to replace the gauge cluster. The gauge cluster date code can be found on the part number label located on the top edge of the cluster assembly. 1 Figure 1 Gauge Cluster Part No. Label with Date Code SB Page 1 of 6 SERVICE PUBLICATIONS, ALLENTOWN, PA MACK TRUCKS, INC. 2003

2 The appropriate replacement gauge cluster part number can be determined from the following table. Replace the gauge cluster assembly only if the date code is 1590 or lower and the chassis is experiencing gauge drop-out. Part No. Description S Metric speedometer and standard U.S. gauges, CX and CH model chassis S Standard speedometer and standard U.S. gauges, CX and CH model chassis S Standard speedometer and standard U.S. gauges, CV model chassis with Cummins engine S Metric speedometer and standard U.S. gauges, CV model chassis with Cummins engine S Metric speedometer and standard U.S. gauges, CV model chassis with MACK engine S Standard speedometer and standard U.S. gauges, CV model chassis with MACK engine S Metric speedometer and metric gauges, CX and CH model chassis S Standard speedometer and standard U.S. gauges, CV model chassis with Allison transmission S Metric speedometer and standard U.S. gauges, CV model chassis with Allison transmission When installing a new gauge cluster assembly, take care not to touch the speedometer and tachometer pointers. Pointers can easily be depressed or pushed below the zero reading, resulting in inaccurate readings during operation (i.e., pushing the speedometer pointer 10 mph below zero will result in the speedometer registering 10 mph slower than actual vehicle speed). Damage to the speedometer or tachometer as evidenced by the pointers being pushed below zero, will void the gauge cluster warranty. The following parts are required for fabricating and connecting the ground wire: Qty. Part No. Description 1 925AM142 Terminal, female, solder type 1 86AX104 Ring terminal, 1/4 2 21AX938 Nuts, Nylok, 1/4-28UNF-3B 18-gauge wire, length as necessary Procedures for installing the dash cluster ground wire and correcting gauge drop-out are as follows: 1. Disconnect the batteries by disconnecting the negative battery cables first, then the positive cables. SB Page 2 of 6

3 2. Locate all ground connections (including cab, frame and engine grounds), then disconnect each ground wire, clean the ring terminals and the area around the terminal stud to remove dirt, corrosion, paint, etc. Reconnect the ground wires, making sure to spread the ring terminals around the stud so that the wires are not on top of each other. 2 If star washers were originally used, discard the washers. Star washers should not be used at the ground connections. 3. Remove the gauge cluster assembly from the dashboard as follows: a. Remove the six screws that secure the gauge cluster assembly to the dashboard. b. Separate the trim panel from the gauge cluster assembly, then carefully pull the cluster assembly from the dashboard. Figure 2 Removing Gauge Cluster Assembly Do not touch any of the gauge pointers, particularly the speedometer and tachometer pointers. Any evidence of impact damage to the pointers will void the warranty for the gauge cluster assembly. c. Disconnect the 36-pin connector from the back of the gauge cluster assembly. SB Page 3 of 6

4 4. Using the terminal pin extraction tool (tool No. J ), remove wire No. BK-E-0.8 from connector cavity 35 of the 36-pin connector. 3 Figure 3 Cavity 35 of 36-Pin Connector 5. Cut the terminal pin from the wire, then use electrical tape to protect and secure the wire to the harness to avoid the possibility of a short circuit. 6. Cut a length of 18-gauge wire, long enough to reach from the dashboard gauge cluster to the 135A ground circuit breaker located on the left-hand side of the bulkhead, inside the engine compartment. Using a wire thinner than 18-gauge poses a fire hazard. 4 Figure 4 Ground Circuit Breaker Location 7. Using the proper crimping tool, crimp and solder a terminal (part No. 925AM142) on one end of the 18-gauge wire. SB Page 4 of 6

5 8. Crimp and solder a 1/4 ring terminal (part No. 86AX104) on the opposite end of the wire. 9. Route the terminal pin end of the wire through the bulkhead pass-through grommet, then insert the terminal into cavity 35 of the 36-pin gauge cluster connector. 10. Reconnect the 36-pin connector to the back of the gauge cluster assembly. If the date code for the gauge cluster is 1590 or lower, replace the gauge cluster assembly. Refer to the part number chart on page 2 for the proper replacement gauge cluster assembly part number. 11. Remove and discard the nuts that secure the wires to both studs of the ground circuit breaker. 12. Attach the ring terminal for the new ground wire to the left-hand terminal (driver's side) of the ground circuit breaker. 5 Figure 5 Install Ground Wire on Terminal Stud 13. Install two stainless steel nylock nuts (part No. 21AX938) to the terminal studs (these nuts replace the existing nuts). Tighten the nuts to 65 lb-in (73 dan). 14. Install the gauge cluster assembly and dashboard trim panel. Tighten the trim panel screwsto12.5lb-in(14dan). 15. Reconnect the batteries by connecting the positive cables first, then the negative cables. SB Page 5 of 6

6 Programming is not necessary if a new gauge cluster assembly is installed or the ground wire re-routed. REV The labor code and maximum labor allowance for this operation is as follows: 732 6A hr. Time allowed to re-route ground wire. Does not include take-charge time B hr. Add time to transfer gauges from existing gauge cluster assembly to replacement assembly as required. Does not include take-charge time. When submitting a warranty claim for the repair outlined in this bulletin, note the number for this service bulletin (SB ) on the claim. SB Page 6 of 6

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