SFN-20240105C Relocate power and ground studs

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TICO Document #: SFN-20240105C (formerly TES 177)

Description of Procedure: Excessive corrosion on cab power studs on 2017-III cab dues to location on driver side cab floor. Relocate power and ground studs to a drier location not in the path of tire spray.

Units Affected: N/A

Parts Required: N/A

Planned Labor: 3 hour

Note: Current operation of a truck. Mainly verify if headlights operate with the key switch in the on or off position.

Instructions:

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

  2. Remove the front cab access covers and set them aside.

  1. At chassis PDC, disconnect the cab battery and cab ignition cables that run to the front of the truck. Secure cable ends to ensure there will be no contact.

  1. Use a meter at the front corner studs to verify there is No Power at the battery and ignition studs.

  2. Raise the cab and remove the battery, ignition, and ground cables from the bottom side of the studs. A total of four cables were removed from that area.

  3. The studs may now be removed and discarded.

  4. Plastic hole plugs may now be installed in the holes using silicone. Replace screws that were removed back into holes.

  1. At the front corner studs, use a meter to verify there is No Power at the battery and ignition studs.

  2. Raise the cab and remove the battery, ignition, and ground cables from the bottom side of the studs. A total of four cables were removed from that area.

  3. The studs may now be removed and discarded.

  4. Plastic hole plugs may now be installed in the holes using silicone. Replace screws that were removed back into holes.

  1. Re-route cables removed towards the center PDC box.

  2. The bracket currently attached to the radiator shroud needs to be removed. Reinstall the screw in shroud and tighten.

  3. The bracket removed will be used in another location.

  1. New location of bracket. An additional P-clamp was added to route and secure battery cables.

  1. Drill pass-through holes in the center PDC box per the attached drawing.

  2. De-bur holes and vacuum drill shavings.

  3. Install power and ground studs using the newly supplied hardware.

  1. The current LH center PDC pass-thru stud is also being replaced. The 2 gauge cable and the stud may be removed and discarded.

  1. Replace with new pass-thru stud. The power cable from the relay/fuse box may be connected to the stud and the nut tightened. Cover stud with red protective cover.

  1. Continue with the connections on the LH panel.

  2. The dash power wires can be installed.

  1. There will be a new 2 gauge power cable that connects to this stud. This replaces the cables that was discarded on the inside of the box.

  2. Install the cable and the nut. Cover with red protective cover.

  1. This picture shows the other end of the cable. It must be connected to the upper stud.

  1. A p-clamp was added to ensure the power cable does not touch a ground cable.

  • 26A Power cable connection inside of box with nuts tightened and red covers installed. There will be no other connection to this side of the stud.

  1. The (2) ground cables will be connected to the frame weld stud at the entrance of the PDC box. Install the ground cable that routes to the new black stud at the upper RH corner. The connection is inside the box. Tighten nut

  1. Connect the (2) dash ground cables to the ground stud. Tighten the nut. Also, ensure the ground cable is not touching the power cable.

  • 28A These pictures show the VEC mounted on the lower shelf.

  • 28B Battery supply must connect to the bottom stud.

  • 28C The ignition supply must connect to the upper stud.

  • 28D These pictures show the cable connections for the upper VEC.

  • 28E If you truck lighting is set up as an off-road (headlights on w/ignition switch on) ** The (2) cables from the upper VEC connect to the ignition post.

  • 28F If your truck lighting is set up as on-road (headlights on w/battery), The upper cable connects to the ignition post of the lower VEC. The lower cable connects to the battery post of the lower VEC.

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

  1. Return vehicle to service.