Repair as follows:
Note : This repair requires TIG welding and should be done by an experienced welding technician.
Note : If the Diesel Oxidation Catalyst (DOC) inlet pipe has completely separated from the Aftertreatment,
replacement of the 1-BOX is necessary.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Disconnect the batteries.
3. Remove the right side fairing. Refer to the Original Equipment Manufacturer (OEM) procedures.
4. Allow the Aftertreatment System (ATS) time to cool.
5. Remove the aftertreatment from the vehicle. .
6. If necessary, remove the bolts securing the inboard and outboard heat shield to the aftertreatment and
remove the heat shields.
7. Using an appropriately sized drill bit, drill-stop the crack.
8. Clean and prep the surface area of the crack.
9. Using Arcos 409 TIG welding rod part number 23539448, weld the crack. Ensure each drill-stop hole has
been welded.
10. Allow the weld time to cool.
11. If removed, install the inboard and outboard heat shield. Torque the bolts to 10 N·m (7 lb·ft).
12. Install the Aftertreatment to the vehicle.
13. Install the right side fairing. Refer to OEM procedures
14. Connect the batteries.
15. Start the engine.
16. Check for any exhaust leaks.
WARNING
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a
level surface, parking brake is set, and the wheels are blocked.
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well
ventilated area. Engine exhaust is toxic.