SERVICE PROGRAM - Autocar, LLC

SERVICE PROGRAM 

SP 3-144-001 

SEPTEMBER, 2005 

ATTENTION: 

SUBJECT: 

VEHICLES 

AFFECTED: 

SERVICE MANAGERS / PARTS MANAGERS 

REPLACE FAULTY GATEWAY MODULES 

CERTAIN AUTOCAR WX AND WXR MODEL VEHICLES BUILT 

BETWEEN 12/21/2004 AND 8/15/2005, VIN RANGE 201563 TO 202538 

Service Bulletin Information 

Service Programs are product modifications that Autocar has determined should be performed proactively on all 

vehicles affected. It is preferred that the modification takes place prior to a failure. The expense related to this 

Service Program will be eligible for warranty recovery based on the published program standard labor time and 

required parts. Service Programs do expire. Reimbursement will not be available for claims submitted after the 

expiration date published on the Service Program. 

Number of Vehicles Affected 

There are 170 vehicles with serial numbers in the range 201563 to 202538. Please see Page 4 for a listing of the 

trucks affected by this Service Program. 

NOTE: To verify or determine if a particular vehicle is affected by this Service Program, you should consult the 

Service/Warranty screen. By entering the Vehicle Identification Number into the VIN Profile, the screen will 

display any outstanding Service Program(s) and/or outstanding Recall(s). If the Service Program number does 

not appear in the VIN Profile then the vehicle is not affected by this program. If the vehicle is on the program and 

has already been fixed, the Service Program number will have “COMPLETED” after it. 

Inspection 

A green label is attached to all replacement Gateway modules. Before replacing a Gateway module, inspect the 

module to see if it has a green label installed (see Figure 1 on the following page). If the green label is present, 

the unit is good and does not require replacement. No further action is needed. 

Repair 

Torque all fasteners to the proper torque value. Please see “Repair Procedure” information starting on Page 5 for 

further details. 

Time Allowance 

0.5 hours per vehicle. 

Parts 

A1440002-001 or, 

A1440002-002 

Autocar, LLC 

551 South Washington Street 

P. O. Box 190 

Hagerstown, IN 47346-0190 

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Figure 1 

GREEN 

LABEL 



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Tools Required 

15/16” socket and ratchet 

15/16” combination box/open wrench 

Torque wrench, capable of +/-5% accuracy at 200 ft.-lbs. of torque 

7/16” socket and ratchet 

7/16” combination box/open wrench 

Torque wrench, capable of +/-15% accuracy at 76 in.-lbs. of torque 

DANGER 

The 5/8” bolts and nuts must be accurately 

torqued. These fasteners secure a 

structural crossmember on the truck frame. 

By not properly securing the fasteners, 

there is a risk of failure of the crossmember 

that might result in further structural failure, 

resulting in personal injury or death. 

Claims for Credit 

Expenses associated with the performance of this Service Program will be reimbursed based on the guidelines 

identified in this Bulletin, and by submitting a claim following published Instructions in the claim preparation 

section of the “Service Operations Manual.” 

Claim Coding Information 

Authorization Number: SP-3-144-001 

Repair: 39521-2-01 

Expiration Date: September 30, 2006 

Dealer Responsibility 

Dealers are to perform the Service Program on all vehicles subject to the Service Program at no charge to the 

owner regardless of mileage, age of vehicle, or ownership as long as the repair is carried out before the expiration 

date of the program unless stated otherwise in this bulletin. Whenever a vehicle subject to this Service Program 

is taken into or is in your vehicle inventory or dealership for service, we strongly recommend you make every 

effort to perform the Service Program correction before the vehicle is sold or released to the owner. 



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Trucks Involved in This Service Program 

5VCDC6MEX5H201563 

5VCDC6MF45H201650 

5VCDC6MF95H201787 

5VCDC6MF05H201788 

5VCDC6MF25H201789 

5VCDC6BE75H201846 

5VCDC6BE95H201847 

5VCDC6BE05H201848 

5VCDC6BE25H201849 

5VCDC6MF15H201864 

5VCDC6MF35H201865 

5VCDC6MF55H201866 

5VCDC6MF75H201867 

5VCDC6MF95H201868 

5VCDC6MF05H201869 

5VCDC6MF75H201870 

5VCDC6MF95H201871 

5VCDC6BE85H201872 

5VCDC6BEX5H201873 

5VCDC6BE15H201874 

5VCDC6MFX5H201877 

5VCDC6BE75H201880 

5VCDC6BE95H201881 

5VCDC6ME65H201883 

5VCDC6MF75H201884 

5VCDC6MF95H201885 

5VCDC6MF05H201886 

5VCDC6MF25H201890 

5VCDC6MF45H201891 

5VCDC6MF65H201892 

5VCDC6MF25H201971 

5VCDC6ME55H201972 

5VCD36MF55H201995 

5VCDC6MF75H201996 

5VCEC6MF95H202006 

5VCDC6MF05H202018 

5VCDC6BE75H202060 

5VCDC6MF45H202071 

5VCDC6MF65H202072 

5VCDC6MF85H202073 


5VCDC6MF95H202079 

5VCDC6MF55H202080 

5VCDC6MF75H202081 

5VCDC6MF95H202082 

5VCDC6MF56H202131 

5VCDC6MF76H202132 

5VCDC6MF96H202133 

5VCDC6MF06H202134 

5VCDC6MF26H202135 

5VCDC6MF46H202136 

5VCDC6MF66H202137 

5VCDC6MF86H202138 


5VCDC6MF66H202140 

5VCDC6MF86H202141 


5VCDC6MF35H202143 

5VCDC6MF55H202144 

5VCDC6MF75H202145 

5VCDC6MF05H202147 

5VCDC6MF25H202148 

5VCDC6MF66H202154 

5VCDC6MF86H202155 


5VCDC6MF16H202157 

5VCDC6MF36H202158 

5VCDC6MF56H202159 

5VCDC6MF16H202160 

5VCDC6MF36H202161 

5VCDC6MF16H202207 

5VCDC6MF36H202208 

5VCDC6MF56H202209 

5VCDC6MF06H202246 

5VCDC6MF26H202247 


5VCDC6RE16H202255 

5VCDC6MF36H202256 

5VCDC6MF56H202257 

5VCDC6MF76H202258 

5VCDC6MF96H202259 

5VCDC6MF56H202260 

5VCDC6MF96H202276 

5VCDC6MF06H202277 

5VCDC6MF26H202278 

5VCDC6MF46H202279 

5VCDC6MF06H202280 

5VCDC6MF26H202281 

5VCDC6MF46H202282 

5VCDC6MF16H202286 

5VCDC6MF36H202287 

5VCDC6MF56H202288 

5VCDC6MF76H202289 

5VCDC6MF36H202290 

5VCDC6MF56H202291 

5VCDC6MF76H202292 

5VCDC6MF96H202293 

5VCDC6BE26H202307 

5VCD36MF76H202308 


5VCDC6ME56H202315 

5VCDC6ME76H202316 

5VCDC6MF86H202317 

5VCDC6BE76H202318 

5VCDC6BE96H202319 

5VCDC6BE56H202320 

5VCDC6BE76H202321 

5VCDC6MF36H202323 

5VCDC6MF76H202325 

5VCDC6PE76H202327 

5VCDC6ME76H202333 

5VCDC6MF36H202340 

5VCDC6MF56H202341 

5VCDC6BE36H202347 

5VCDC6BE36H202350 

5VCDC6BE56H202351 

5VCDC6BE76H202352 

5VCD36FE16H202356 


5VCEC6MF16H202373 

5VCDC6BE66H202374 

5VCDC6BE86H202375 


5VCE36MF26H202379 

5VCE36MF96H202380 

5VCDC6BE36H202381 

5VCDC6MF06H202389 

5VCEC6MF36H202391 

5VCD36FE56H202392 


5VCDC6BE16H202394 

5VCEC6MF76H202409 

5VCDC6MF16H202420 

5VCDC6BF06H202427 

5VCD36FE96H202430 

5VCE36PE46H202435 

5VCDC6BG26H202437 

5VCDC6BE46H202440 

5VCDC6MF26H202443 

5VCDC6BE26H202453 

5VCDC6MF06H202456 

5VCDC6MF36H202466 

5VCDC6MF76H202468 

5VCDC6MF96H202469 

5VCDC6MF36H202483 

5VCDC6MF56H202484 

5VCDC6MF76H202485 

5VCDC6MF96H202486 

5VCDC6MF16H202496 

5VCDC6MF36H202497 

5VCDC6MF56H202498 

5VCDC6MF76H202499 


5VCDC6MF16H202501 

5VCDC6MF36H202502 

5VCDC6MF56H202503 

5VCDC6MF76H202504 

5VCDC6MF96H202505 

5VCDC6MF06H202506 

5VCDC6MF26H202507 

5VCDC6MF46H202508 

5VCDC6MF66H202509 

5VCDC6MF26H202510 

5VCDC6MF46H202511 

5VCDC6MF56H202517 

5VCDC6MF76H202518 

5VCDC6MF96H202519 

5VCDC6MF96H202522 

5VCDC6ME16H202537 

5VCDC6ME36H202538 



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Repair Procedure 

WARNING 

To prevent eye injury, always wear eye 

protection when performing vehicle 

maintenance, service or inspection. 

DANGER 

Before working on a vehicle, set the parking 

brake, place the transmission in neutral 

and block the wheels. Failure to do so can 

result in unexpected vehicle movement and 

can cause serious personal injury or death. 

1. Follow safety instructions above and ensure the engine is switched off. 

2. Disconnect the battery to prevent damage to the electrical system when plugging and unplugging electrical 

harness connectors. 

3. Drain all air pressure in the system to prevent personal injury from unexpected or sudden air pressure 

release. Air pressure must be released before disconnecting any air lines from the Gateway module. 



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4. Remove the gateway module bracket by removing the 5/8” bolts and nuts labeled (1) in Figure 2. Use a 

15/16” combination wrench and 15/16” socket. 

1 

Figure 2 



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5. Remove the gateway module from the bracket by removing the 1/4” stainless bolts and nuts labeled (2) in 

Figure 3. 

GATEWAY 

MODULE 

BRACKET 

2 

Figure 3 



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6. Disconnect the electrical connectors and 1/4” air lines from the gateway module. See the engineering layout 

for gateway module drawing, part number A1440002-001 (Figure 4). 

Note that some trucks may be equipped with an alternate gateway module, part number A1440002-002, 

depending on the truck’s configuration. The alternate gateway module includes two additional air line connections 

(see Figure 5 on the following page). 

Figure 4 



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Figure 5 



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7. Remove the gateway module from the bracket and return the module to the manufacturer. The gateway 

module must be packaged and shipped to the following address: 

Mike Frewin 

Account Executive 

Pacific Insight Electronics Corp. 

1155 Insight Drive 

Nelson, BC V1L 5P5 

Phone: 250-354-1155 ext. 266 

Fax: 250-354-1166 

www.pacificinsight.com (PIH: TSX) 

For shipping costs, use FedEx shipping account # 13676986-3. 

8. Connect the plumbing and wiring to the new gateway module as shown in Figure 6. 

NOTE: All unused connector cavities, such as the one shown in Figure 6, must be plugged with the 

dummy connectors installed on the existing unit to prevent corrosion of the connector terminals and 

subsequent failure of the gateway module. 

UN-USED 

CONNECTOR 

CAVITY 

Figure 6 

1/4” AIR 

LINES 

GATEWAY 

MODULE 

GATEWAY 

MODULE 

BRACKET 



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9. Secure the gateway module to the gateway bracket with 1/4” stainless bolts and nuts labeled (3) as shown in 

Figure 7. Torque the 1/4” bolts to 76 in.-lbs., +/-11 in.-lbs. 

10. Secure the bracket in the truck with 5/8” fasteners, labeled (1), as shown in Figure 2. Use a 15/16” 

combination wrench and socket and torque to 200 ft.-lbs., +/-10 ft.-lbs. 

3 

Figure 7 



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SERVICE PROGRAM - Autocar, LLC

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