DORMAN 904-7365 Accelerator Pedal Sensor Instruction Manual

DORMAN 904-7365 Accelerator Pedal Sensor

Product Information

Specifications :

• New sensor with six-pin configuration
• Includes wiring harness compatible with the new six-pin sensor
• Fits the existing pedal assembly
• Compatible with Detroit Diesel vehicles

Product Usage Instructions

Before You Begin:

If you are unsure about following the necessary procedures correctly, seek the services of a qualified technician.

Installation Steps:

1. Remove the pedal from the vehicle if necessary. Carefully observe and mark the routing of the wiring harness for reference.
2. Remove the sensor screws and disconnect the wiring harness from the sensor. Clean the mounting surface of the pedal assembly.
3. Inspect the bearing and bearing housing for wear. Replace the entire upper pedal assembly if there is damage to the sensor shaft or bearing.
4. Inspect the connector for any damage to the green rubber seal. Replace the wiring harness if damage is evident.
5. Reinstall the pedal in the vehicle if it was removed. Secure the wiring harness as originally routed and attach connectors to the vehicle wiring harness.

FAQ

• Q: What should I do if I encounter difficulties during installation?
  • A : If you face challenges during installation or have any doubts, it is recommended to consult a qualified technician for assistance.
• Q: Can I reuse the old sensor screws and wiring harness?
  • A : No, it is advised to discard the old sensor screws, wiring harnesses, clamps, and screws and use the components provided in the kit for optimal performance.

BEFORE YOU BEGIN

• Always wear proper safety equipment when performing repairs.
• Ensure this part fits your exact vehicle year, make, model, and configuration. You can verify at your point of purchase using the part number on the box, or using the part number above at DormanProducts.com.
• Reference the appropriate service manual for your vehicle. If you do not have a service manual, and do not have the training or experience to perform the necessary procedures correctly, seek the services of a qualified technician

PLEASE NOTE: Included in this kit is a new sensor with a six-pin configuration! This kit includes a wiring harness that works with the new six- pin sensor. It will fit your existing pedal assembly.
Important! Before replacing an existing sensor, check the most current instruction bulletin from Detroit Diesel to ensure that your diagnosis of a sensor fault is correct. Replacing the sensor will reset the system and any other fault will be temporarily cleared.

Uncorrected problems will reoccur!

1. Remove the pedal from the vehicle if necessary. Depending on the pedal installation, it may not be possible to replace the sensor without removing the pedal from the vehicle.
   • NOTE : Carefully observe the routing of the wiring harness. Marking the wire routing is suggested. Correct harness routing is critical to the performance of the product.
2. Remove sensor screws (item 6). Pry up clip-on connector of the wiring harness to disconnect it from the sensor. Discard screws and sensor (item 29). Clean surface where sensor mounts to pedal. Inspect bearing and bearing housing for wear. If there is damage to the sensor shaft or bearing, replace entire upper pedal assembly.
3. inspect the connector for any damage to green rubber seal. If damage is evident, replace wiring harness. To replace the wiring harness, remove screws and cable clamps, again carefully observing the routing of the wiring harness. Discard the wiring harness (item 13), clamps and screws.
4. Position new sensor on the pedal, lining up holes in the sensor with holes in the casting. Secure with screws provided in kit. Torque to 15–25 in.·lbs. Over-tightening screws may damage screw holes in casting. Connect the wiring harness provided in kit to the sensor.
5. Secure wiring harness to base plate with cable clamps and screws provided in kit. Leave a large loop in the harness assembly to eliminate excessive bending of the wires. Torque to 20–35 in.·lbs.
6. Reinstall the pedal in the vehicle if removal was necessary. Secure the wiring harness as originally routed. Attach connector(s) to vehicle wiring harness.

Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety features.

Dorman Products, Inc.

Corporate Office and Customer Service: 1-800-523-2492

• Tech Line : 1-866-933-2911
  ©2021 No reproduction in whole or in part without prior written approval.

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