FT5409

FAST TRACK
FT5409
REFERENCE:
Nova Bus Manuals
SECTION:
16: Electrical System
RS NO:
MQR 7621-2357
EFFECTIVE IN PROD.:
N/A
SUBJECT:
Wiring Harness - Engine Compartment
A bad connection at the ZF transmission connector may cause the transmission to jerk
when shifting or show the fault code 188.
JUSTIFICATION:
LEVEL
APPLICATION DEADLINES: 2025JN01
CLAIM REFERENCE NUMBER: WB5409
DIRECT CHARGES
DESCRIPTION
LABOUR
MATERIAL
TIME
1
Inspection of the wiring harness connector +EN-MS64GA, the
connector's terminals, the p-clamp and the harness.
Nova Bus
Nova Bus
30 min
2
Replacement of the wiring harness connector.
Nova Bus
Nova Bus
20 min
MATERIAL LIST ON PAGE 2
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED
*
RETAINED
Yes
–
* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.
REVISION HISTORY
REV.
DATE
NR
2023OC17
APPROVED BY:
NQF772004 VERSION 3
CHANGE DESCRIPTION
Initial release
Signature
numérique de
Irina
Irina Negoescu
Negoescu Date : 2023.10.20
07:25:48 04'00'
WRITTEN BY
Annie St-Jacques
PAGE 1 OF 17
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FT5409
MATERIAL REQUIRED PER VEHICLE
PART NO
REV.
2
N56339
A
TIE TEFZEL CABLE TIES
1
N8951536
–
KOSTAL SLK 2.8 MALE TERMINAL (KOSTAL# 10124499150020)
1
N8951544
–
KOSTAL MLK 1.2 MALE TERMINAL (KOSTAL# 32124651823000)
QTY
DESCRIPTION
LEVEL 1
LEVEL 2 (only if required**)
1
N49091
–
CONNECTOR KOSTAL SLK
1
N49092-01
–
CLAMP CABLE FOR SLK LEFT
1
N49092-02
–
CLAMP CABLE FOR SLK RIGHT
4
N49094-02
–
TERMINAL SLK 2.8 16-14
7
N49094-03
–
TERMINAL SLK 1.2 18-16
4
N49096-02
–
SEAL WIRE SLK 2.8 16-14
5
N49096-03
–
SEAL WIRE SLK 1.2 20-16
14
2
N49098-02
N84090-05
–
–
CAVITY SEAL SLK 1.2
P-CLAMP ID 0.750"THK 0.030"M8
Materials will be available within 203 days once your order has been placed.
To order, please contact [email protected]
Or by phone for CANADA 1-800-771-6682, for USA 1-877-999-8808
Specify document number, quantity of parts required and shipping address.
**The material identified in Level 2 is to be ordered only for vehicles that meet the criteria defined in Level 1.
CLIENT
ORDER
ROAD NUMBER
VIN (2NVY/4RKY...)
FROM
TO
FROM
TO
QTY
New York City Transit - NYCT
L958
5439
5442
S92J9G9775533
S92J9G9775631
4
New York City Transit - NYCT
L959
5443
5443
S92J0H9776118
S92J0H9776118
1
New York City Transit - NYCT
LA23
5485
5530
S92J5J9776380
S92J6J9776517
46
New York City Transit - NYCT
LA73
8504
8507
L82J8J9776445
L82J8J9776476
4
New York City Transit - NYCT
LA76
8508
8633
L82J9J9776924
L82J8K9777144
125
New York City Transit - NYCT
LB29
5531
5566
S92J9J9776687
S92J6J9776873
36
New York City Transit - NYCT
LB59
5444
5484
S92J7H9776195
S92J6H9776379
41
New York City Transit - NYCT
LB78
8526
8526
L82J3K9776984
L82J3K9776984
1
New York City Transit - NYCT
LB99
5567
5602
S92J2J9776935
S92J5K9777000
36
New York City Transit - NYCT
LC32
8634
8754
L82JXK9777145
L82J5K9777277
121
New York City Transit - NYCT
LD06
8755
8758
L82J3L9777778
L82J3L9777781
4
New York City Transit - NYCT
LD08
8759
8931
L82J5M9778156
L82J8N9778508
205
PAGE 2 OF 17
NQF772004 VERSION 3
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FT5409
WARNING
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
PROCEDURE
1.1.
Park the vehicle on an even surface with the transmission on neutral.
1.2.
1.3.
Apply the parking brake and set the master control switch to the stop position.
Set the battery disconnect switch in the battery compartment to the off position.
LEVEL 1: INSPECTION
1.4.
Proceed with the steps 1 to 8 (pages 4 to 10).
1.5.
1.6.
If the connector replacement is required, proceed with the Level 2. If not, continue with step 1.6.
The vehicle can return in service.
LEVEL 2: CONNECTOR REPLACEMENT
2.1.
2.2.
Proceed with the step 9 (pages 10 to 17).
The vehicle can return in service.
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NQF772004 VERSION 3
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DESCRIPTION / WORK INSTRUCTION
Step # 1: Remove the transmission hatch on the floor inside the bus
Description: With a #3 Phillips screwdriver, remove screws securing transmission cover and remove the
transmission cover.
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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Step # 2:P-Clamp Presence
Description: Look if there is a P-Clamp around 4 inches from the Transmission Control Unit connector to
secure the transmission harness. If the P-Clamp is missing, add a P-Clamp and replace terminals and
connector
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Step # 3: Locking tab on the TCU connector
Description: Look if the locking tab on the TCU connector is broken. If it is broken, replace terminals and
connector
Step # 4: Harness test
Description: You can shake the harness, run the bus and see on Vector if there is an error frame. If it is the
case, replace terminals and connector
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Step # 5: Connector
Description:
•
•
Cut ty-raps
Remove P-Clamp
Disconnect the cable from the ZF ECU connector
•
•
Lift the connector lock (may have to pry up with tool) and raise lock up and push towards TCU
Disconnect (pull outward) the cable from the ZF ECU connector.
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Step # 6: MLK 1.2 Terminals
Description: Using a male terminal of the same size as the male connector of the ECU, check if the contact
is well made and if there is no verdigris or oxidation on the pin. If it is the case, replace terminals.
Connector’s pinout:
Used pins: SLK 2.8 terminals 8, 9, 17 & 18
Used pins: MLK 1.2 terminals 2, 5, 11, 23 & 25
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
One of the five smaller terminals to verify, MLK 1.2 terminals, pin 23
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Step # 7:SLK 2.8 terminals
Description: Using a male terminal of the same size as the male connector of the ECU, check if the contact
is well made and if there is no verdigris or oxidation on the pin. If it is the case, replace terminals.
Step # 8: ECU connector
Description: Inspect the inside of the ECU connector.
If any terminals need replaced, all terminals should be replaced, otherwise the uncut/original
length wires will put strain on onto terminations.
Step # 9: ZF terminal/connector replacement
Remove tape and loom from backshell
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Remove locking handle
Remove backshell
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Remove shroud by pulling, it will slide off
Note: Shroud locking tabs easily break
Install plugs into new connector
Cut wiring flush with connector to conserve length
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Insert seal (gasket) onto wire
Strip wire and crimp termination
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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FT5409
Insert terminated wire into connector
Install lock into connector
Once all terminations are installed into connector, lock blade is installed into side of
connector
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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Reassemble connector
Install shroud and seal onto connector
Install tie wrap wiring onto connector
Install backshell onto connector
Connect two pieces of backshell together onto cable
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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Align backshell rods into connector grooves
Push backshell toward front of connector until backshell locks into place
Service Instruction
QJ2357 : ZF Transmission Code 188
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NQF772004 VERSION 3
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•
•
•
•
•
FT5409
Install handle lock onto connector
Replace any loom and tape that was removed
Install and lock connector onto TCU module
Replace any routing anchors (cable ties and P-clamps)
Start bus and test
If the problem is still there and you have not found anything wrong in the previous
steps, you must check all the connectors related to the ZF network as well as the
front shifter.
Service Instruction
QJ2357 : ZF Transmission Code 188
PAGE 17 OF 17
NQF772004 VERSION 3