90007-MEL-003 Honda BOLT-WASHER (9X105)

Necessary Parts
Cab Preparation
1. Remove the rear cab cover. 2. Install 6K-7954 Bar to the right inside rear cab compartment as shown in the illustration and photo above.3. Fasten the bar with an intermittent 3.0 mm (.12 in) fillet weld, BOTH VERTICAL SIDES, at location (A) using the dimensions shown in the illustration and photo. 4. Install two 4D-7529 Bosses to the cab floor as shown in the illustration above. Weld the bosses with a 3.0 mm (.12 in) fillet weld all around at locations (B).5. The location of the ARC ON/OFF switch depends on whether the truck has factory overspeed control. Drill holes in the dash panel, as shown in the illustration below, for your truck.
Trucks without engine overspeed
Trucks with engine overspeedAir System Installation
1. 6D-1891 Connector. 2. 3J-1907 Seal. 3. 5P-4317 Connector. 4. 6D-3781 Valve Group. 5. 4H-6147 Connector. 6. 3D-7587 Elbow.1. Assemble the items to 3E-8978 Valve Group as shown in the illustration above.
7. Two 8T-8915 Bolt. 8. Four 8T-4896 Washer. 9. Two 9G-9150 Clip. 10. 4D-6880 Hose Assembly. 11. 7D-4065 Hose Assembly. 12. 6G-1799 Hose Assembly.2. Install 3E-8978 Valve Group to 6K-7954 Bar on the right sidewall with two 8T-8915 Bolts (7), two 9G-9150 Clips (9) and four 8T-4896 Washers (8). Use two hardened washers to stand off valve from bar to relieve stress on valve body.3. Install hose assemblies (10), (11) and (12) as shown in the illustration above. 4. Remove the cover under the cab. 5. Route the hoses through the tunnel to the front. Identify the hoses before running them through the tunnel. 6. Remove existing hose going from the retarder valve (handle) to the service brake check valve.7. Install 5H-4778 Elbow into the existing tee on the service brake check valve where the retarder hose was removed. Install 6G-1799 Hose Assembly (from ARC shuttle valve) into the elbow. 8. Install 7D-4065 Hose Assembly into existing connector on retarder valve where service brake hose was removed. 9. Remove existing elbow and hose from front lower port of service brake valve (pedal). Install 2D-7325 Tee as shown in illustration. Install elbow and hose that were removed into the 2D-7325 Tee. Add 4H-6147 Connector and 4D-6880 Hose Assembly into tee as shown in the illustration.10. Use tie straps as needed to secure new hoses to existing hoses.Wiring Installation (Cab)
1. Disconnect both VE connectors of the main cab harness from the cab junction plate. 2. Splice 405-GY wire into 405-GY wire in large VE connector of existing main cab harness (location 17). Solder and cover the splice with heat shrink tubing.3. There are two variations for picking up 450-YL circuit inside of cab: A. For trucks with PIN 4YC1-424, fasten 8N-1539 Socket to 450-YL wire and insert into location 20 of small VE connector of the main cab harness.B. For trucks with PIN 4YC425-Up, splice 450-YL wire into 450-YL wire in small VE connector of existing main cab harness (location 18). Solder and cover splice with heat shrink tubing.4. There are two variations for coding the ARC harness: A. For trucks without engine overspeed (PIN 4YC1-590), remove 202-BK wires from locations 17, 18, and 19 in VE connector of ARC harness. Insert one of the 202-BK wires into location 37 of same connector. Cut the sockets off of the other two 202-BK wires and tape them back to the harness.B. For trucks with engine overspeed (PIN 4YC591-Up) no rework is necessary.
Typical Example5. Remove the hose from the elbow in location #12 of the side junction plate. Install 2D-7325 Tee into the elbow. Install 107-0615 Switch Assembly into the tee as shown in the photo above. Install the hose back into the tee. Fasten the ARC retrofit harness DT connector to the switch assembly.6. Splice 892-BR wire into 892-BR wire of the EPTC-II transmission harness. Splice 893-GN wire into 893-GN wire of the EPTC-II transmission harness. Solder and cover the splices with heat shrink tubing. 7. Attach D991-OR and 202-BK wire terminals to the ARC pressure switch.8. Connect D988-WH and 202-BK sure seal breakout to ARC control solenoid (located on the rear of the valve).9. Connect D989-BU and 202-BK sure seal breakout to ARC supply solenoid (located on the top of the valve). Secure each connection in clips as shown in the illustration. 10. Attach 202-BK ground wire terminal to switched side of disconnect switch11. Route remaining ARC harness through tunnel to front of cab. 12. Disconnect 454-GN and 200-BK wires from existing manual retarder switch. Tape ends and tie back. Attach D992-PU and 202-BK wires to the switch. 13. Remove 454-GN and 200-BK wires from existing retarder lamp. Tape ends and tie back to the harness. Route 454-GN and 202-BK breakout through grommet and attach to the retarder lamp.14. Apply 106-9119 Film to dash cover plate. 15. Install 4D-1836 Switch in dash cover plate. Fasten three 7N-8419 Terminals to the switch. Assemble the wires to the switch as shown in the illustration.16. Install 308-YL Wire to switch terminal "R".17. Use tie straps as needed to secure the new ARC harness to the existing harnesses.18. Install the cover that was removed from under the cab.ARC Control Box
1. Apply 3E-9028 Film on 111-6253 ARC Control Group. 2. Install ARC control group to 109-1744 Plate Assembly (1) with four 5M-3062 Bolts (2) and 8T-4896 Washers (3). Install two 9D-3721 Switches (4) to the plate assembly with the nuts and washers furnished. 3. Connect D993-YL and 202-BK wires to service set switch (lower) and D994-BU and 202-BK wires to service clear switch (upper) as shown in the illustration.4. Install the plate assembly on the floor bosses with two 5M-3062 Bolts and 8T-4896 Washers.5. Connect the VE connector from the ARC harness to the control box. Connect the 10 pin sure seal breakout from the box to the ARC harness and secure with 3T-3046 Clip Assembly.