2007 Dodge Mercedes Freightliner Sprinter Alternator Starter Y-Cable

I recently noticed the ScanGaugeII in my 2007 Sprinter was reporting a voltage below 12v.  I had replaced the main battery within the last three weeks.  So I connected my StarScan tool and confirmed the alternator output was 8.9v when I expected to see about 14v.  I had read that these trucks are famous for the "y-cable" that connects the alternator, starter and battery.  The cable runs transversely behind the oil pan and can easily be seen while looking from under the front of the truck.

The cable runs from the starter solenoid to the alternator.  In this picture it is not easy to spot anything unusual.

 This closer view shows the plastic convolute is not fully wrapping the cable.  It is deformed from heat.  The tape is also cracked from the heat.

 This is the same cable as it runs behind the oil pan.  In this picture, you can see the heat was enough to melt the convolute to the cable at the zip tie.  The bulge in the cable at the left of the image is the inline fuse.  The fuse is between the alternator and the starter solenoid lug.  The starter solenoid lug is at the middle of the cable and the second leg of the y-cable runs to the battery tray under the driver's feet.

I called Bob at Hoekstra Transportation.  They have the cable in stock and was quoted a price of $90.

This cable is reported to cause a great many engine codes.  That may be because the battery voltage gets so low since the alternator is trying to charge the battery through a corroded cable.

I will post more pictures and notes when I remove and disassemble the cable.

The removed cable:

 The end of the fuse close to the alternator got hot enough to deform the housing of the fuse.

It looks toasty.  Why was the alternator putting out so much current?

The new cable: A 906 440 16 41

 The cable did not fix any codes but I did notice that the battery voltage reported on OBD is more steady at 14.0 V +/-0.1 now.

2007 Dodge Mercedes Freightliner Sprinter Steering Lock Module (Part number: 906 462 00 30)

2008 Winnebago View based on 2007 Dodge Sprinter

Symptoms:

• I have an active code "9005 ECU Loss of communication and ECU timeout during unlocking".
• No whirring noise when I insert the key
• Most of the time no chime when I insert the key
• Can't turn key.  Key would not turn.
• The steering is unlocked but there are many failure reports of the steering being locked.

I made contact with someone from the sprinter-source.com with a Chrysler Starscan diagnostic tool.  He read the codes with the Starscan and determined that the 9005 code was still active.  We ran through the Chrysler diagnostics steps (check fuse and wire continuity) to determine the steering lock module is bad.

Schematic Ignition switch / Steering Lock Module

 The StarScan displayed 'Undefined' ELV Status.

The ELV is mounted underneath the steering column, near the driver's shins.

Part number: A 906 462 00 30

The ignition switch (EIS) communicates to the Steering Lock Module (ELV) using ISO-K.  The ELV contains a pin/bar that is driven up to the steering column to cause the steering lock.

ELV mounting location

 The security pin holding the ELV to the housing could not be removed (turned 180 deg clockwise).  It moved only about 90 deg because the lock pin/bar was partially applied.  I had to drill out two roll pins to remove the cover.

Torx security pin - turn 180 deg clockwise to unlock and remove

Hall effect sensor in the slot holding pin/bar

Magnet on pin/bar

 

Drive gear, lock bar/pin, cover, and housing.

Additional pictures: