SFN-20240118C Change power supplied to headlights

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TICO Document #: SFN-20240118C (formerly TES 138)

Description of Procedure: Design revision to change power supplied to the headlight hi-beam switch.​

Units Affected: N/A

Parts Required: Butt Splice, 12 gauge (1 required)​

Planned Labor: 1 hour

Instructions:

  1. Park vehicle on flat surface, apply parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

  2. Remove gauge panel by removing #10 socket head screws with 1/8” hex key wrench.  Panel is located at top of dash cover.  There are 7 screws for this panel.

  1. Gently pull gauge panel away from dash cover.

  1. Locate wire bundle coming from the turn signal switch. 

  2. Cut circuit HDLT-A (black 16 gauge) going to turn signal switch about 12” away from the connector.

  3. Fold back and seal portion of wire that remains on the harness side. 

  4. Route wire towards the headlight switch.

  1. Remove key switch panel from dash cover assembly by removing four #10 socket head screws with 1/8” hex key wrench.

  1. Pull key switch panel away from dash cover. 

  1. Locate circuit LT101-A (black , 12 gauge).

  2. Cut wire, splice with wire HDLT-A that was routed from turn switch.

  3. ​Seal connection.

  1. Reinstall dash gauge panel and headlight switch in the reverse order that it was removed in.  Ensure no wires are pinched or removed from terminals during this process.

  1. Turn on ignition switch with the headlight switch in the off position.   Wait 15 seconds for the DRL module to activate.  

  1. After DRL are on cycle the high beam switch with the turn stalk.  There should not be any buzzing from the relay.  You can watch the high beam indicator to verify the relay function has cycled.

  1. Turn on the headlight switch and verify the headlight functions.

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.