AFC05911

Authorized Field Change AFC G-05911
Date: November, 2005

Subject File: ELECTRICAL
Subject: Rerouting of the Instrument Panel (IP) Harness Behind the Front Grille and Main Chassis Harness
at the Transmission and Engine Crossmember to Prevent Chafing on CF 500 and CF 600 Models Built
Between August 4, 2004 and August 7, 2005
Model: CF 500
Start Date: 08/04/2004 End Date: 08/07/2005
Model: CF 600
Start Date: 08/04/2004 End Date: 08/07/2005
DESCRIPTION
Certain CF truck models were built with electrical harnesses routed in a manner that may result in premature
wear and chafing. To remedy this, the electrical harnesses are being rerouted.
PARTS INFORMATION
Table 1 Parts Information
Part Number Description Quantity
Kit Contains the Following:

299269C91, P-Clip, Cushioned (2)
299276C91,P-Clip, Cushioned (1)
8000877R91 1
505220C1,P-Clip, Cushioned (1)
2041341C1, Saddle (3)
289862C1 Cable Strap Lock (4)
SERVICE PROCEDURE
WARNING – To avoid property damage, personal injury or death, park the vehicle on a flat
level surface, set the parking brake, chock the wheels and turn the engine off.
Rerouting the IP Harness

1. Remove grille mounting screw, and remove grille.
2. Remove cable strap lock securing the IP harness to grille mounting bracket (Figure 1).
Copyright © International Truck and Engine Corporation

1
SERVICE PROCEDURE (CONT.)
Figure 1 Remove Tie Strap from Bracket

1. Grille Mounting Bracket
2. Cable Strap Lock
3. Remove 2 cable strap locks securing the IP harness to passenger side bracket(s) (Figure 2, Item 1 and
Item 2). Remove the bracket and save fasteners for reuse during reassembly.
Figure 2 Remove Tie Straps

1. Rear Cable Strap Lock
2. Front Cable Strap Lock
3. Cable Strap Lock, Rear Driver Side Bracket
AFC–G-05911 2
4. Remove cable strap lock securing the IP harness to rear of driver side bracket (Figure 2, Item 3). Remove
the bracket and save fasteners for reuse during reassembly.
5. When necessary, remove other cable strap locks to allow movement of wire harness.
6. Use the original fasteners and a small P-clip to secure the harness at the point where the passenger side
bracket was removed. Orient the P-clip with the loop to the rear, facing up (Figure 3, Item 2).
Figure 3 Install P-Clips

1. Small P-Clip, Drivers Side Location
2. Small P-Clip, Passenger Side Location
3. Existing “L” Bracket
4. Larger P-Clip, Drivers Side Location
7. On the driver side, two P-clips (Figure 3, Item 1 and Item 4) will be installed in place of the driver side
brackets using the original fasteners. The larger clip, Figure 3, Item 4, must secure the larger harness,
and is fastened to the existing “L” bracket, Figure 3, Item 3, with the P-clip loop facing down. The small
clip, Figure 3, Item 1, must secure the small harness and should have the loop facing up (Figure 3,
Item 1, Item 2, and Item 4).
8. With the clips in place the harness should be secured so that it runs parallel with the rear of the
crossmember and clear of any interference and secure the upper leg of the harness to the cab hinge bar
with a cable strap lock (Figure 4 and Figure 5).
3 AFC–G-05911
Figure 4 Graphic Representation of Rear View of harness Routing
Figure 5 Front View of Revised Harness Routing

1. Hinge Bar
9. Re-install the grille and secure with mounting screw.
AFC–G-05911 4
Rerouting the Main Chassis Harness
10. On the driver side frame rail behind the cab, locate and remove two (2) cable strap locks from the main
chassis harness near the break out harness.
11. Remove the cable strap lock bracket near the harness break out and replace it with a cushioned P-clip.
12. Re-install the main chassis harness into the cushioned P-clip (Figure 6, Item 1), before the break out
harness (Figure 7, Item 1), and tighten the fasteners .
Figure 6 Install Cushioned P-Clip Viewed from Under Chassis

1. Cushioned P-Clip
2. Main Harness
3. Cable Strap Lock and Bracket
5 AFC–G-05911
Figure 7 Install Cushioned P-Clip Viewed from Top of Chassis

1. Breakout Harness
13. Install a cable strap lock to the main chassis harness to the rear of the cushioned P-clip as shown in
Figure 6, Item 3.
14. From under the chassis locate two (2) cable strap locks securing the main harness to the engine
crossmember.
15. Remove the cable strap locks.
16. Remove the fasteners and cable strap lock brackets. Reinstall the brackets so that the bend in the bracket
is facing downward (Figure 8, Item 5).
AFC–G-05911 6
Figure 8 Revised Harness Bracket Orientation

1. (OLD) Break Out Harness Below Bracket
2. (OLD) Bend in Bracket Upward
3. Engine Crossmember
4. (NEW) Break Out Harness Above Bracket
5. (NEW) Bend in Bracket Downward
6. (NEW) Saddle
7. Cable strap lock
17. Install a saddle to both brackets (Figure 8, Item 6) and secure the main harness with cable strap locks
(Figure 8, Item 7). When properly routed the harness should look like Figure 9.
7 AFC–G-05911
Figure 9 Under Chassis View of Properly Routed Harness
18. Follow the main harness to the passenger side to locate the third (3) cable strap lock. Note the harness,
cable strap lock and bracket will be on the passenger side of the engine crossmember (Figure 10, Item 2).
Remove the cable strap lock, install a saddle to the existing bracket and secure the harness (Figure 11).
Figure 10 Typical Harness Routing on the Passenger Side of the Engine Crossmember
1. Engine Crossmember
2. Typical Location of Harness Bracket, Saddle, and Cable Strap Lock
AFC–G-05911 8
Figure 11 Install Saddle and Cable Strap Lock to Retain Harness on Passenger Side of Engine
Crossmember
1. Bracket
2. Cable Strap Lock
3. Saddle
9 AFC–G-05911
Operation number must appear on all claims.
Table 2 Labor Information

Operation No. Description Time
Reroute Instrument Panel and Main Chassis
A40–05911–1 0.7 Hr.
Electrical Harnesses
ADMINISTRATIVE PROCEDURE
Expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to
Authorized Field Change Number G-05911.
It is important that the coding be completed properly to assist in processing the warranty claim. Complete
instructions will be found in the Warranty Manual, Section 7–1. Special attention should be given to Items
39 through 44. To assure this important improvement is made in a timely manner, all claims for G-05911
activity must be submitted by November 30, 2006 or within the normal warranty period for the vehicle, if
after November 30, 2006.
AFC–G-05911 10

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Authorized Field Change AFC G-05911

Date: November, 2005

Kit Contains the Following:

Rerouting the IP Harness

Copyright © International Truck and Engine Corporation

Figure 1 Remove Tie Strap from Bracket

Figure 2 Remove Tie Straps

Figure 3 Install P-Clips

Figure 4 Graphic Representation of Rear View of harness Routing

Figure 5 Front View of Revised Harness Routing

9. Re-install the grille and secure with mounting screw.

Figure 6 Install Cushioned P-Clip Viewed from Under Chassis

Figure 7 Install Cushioned P-Clip Viewed from Top of Chassis

15. Remove the cable strap locks.

Figure 8 Revised Harness Bracket Orientation

Figure 9 Under Chassis View of Properly Routed Harness

Table 2 Labor Information

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