Repair as follows:
Note : This repair requires TIG welding and should be done by an experienced welding technician.
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. Remove the Aftertreatment Control Module (ACM).
7. Note the location of the nylon straps securing the ATS wiring to the ATS.
8. Remove the nylon straps securing the ATS wiring to the outlet side of the ATS.
9. Reposition all ATS wiring off the outlet side of the ATS to avoid damage.
10. Remove the bolts securing the ACM mounting bracket to the ATS.
11. Using an appropriately sized drill bit, drill-stop the crack. Ensure the drill bit only penetrates the heat shield.
See graphic below.
12. Clean and prep the surface area of the crack. See graphic below.
13. Using Arcos 409 TIG welding rod part number 23539448, weld the crack. Ensure each drill-stop hole has
been welded. See graphic below.
14. Allow the weld time to cool.
15. Install the ACM mounting bracket to the ATS. Torque the bolts to 25 N·m (19 lb·ft).
16. Install the ACM.
17. Reposition all ATS wiring to its original location.
18. Install all nylon straps into their original location.
19. Install the aftertreatment to the vehicle.
20. Install the right side fairing. Refer to OEM procedures.
21. Connect the batteries.
22. Start the engine.
23. 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.