Service Bulletin

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Customer Bulletin

Commercial Products

Vehicles #06-02

Rattle Noise from Engine Bay

Product: Workman® MD & MDX Aug 23, 2012

Affected Units:

Models:

07273

07279

07266TC

07273TC

Serial Numbers:

311000001 – 312000531

311000001 – 312000689

311000001 – 312000252

311000001 – 312000460

Situation:

A rattling noise coming from the engine bay area may be caused by the Starter / Generator

(S/G) Pulley – Drive (119-9482) not being secured by the torqued nut. It has been determined

that the hub of the Pulley can be too thin (see image below) which causes the S/G Nut (119-

9651) to bottom out on the taper of the Armature shaft of the S/G before it can secure the

Pulley. This loose Pulley can then wobble, and make a rattling noise.

Instructions:

Park the vehicle on a level surface, stop the engine, set the parking brake and remove the

ignition key. Raise the Cargo box and secure it in place with the prop rod to gain access to the

S/G. Loosen the Pivot Bolt / Flange Nut and Carriage Bolt / Lock Nut that secure the S/G, but

do not remove them. Remove the S/G Belt from the S/G Pulley. Remove the S/G Nut (119-

9651) (RH thread), S/G Washer-Lock (119-9652), and S/G Pulley – Drive (119-9482). Inspect

the Armature (119-9658) shaft and Key-Woodruff (119-9657) for damage and replace as

needed (follow the steps to replace the Armature as detailed on section 6, page 18 of the

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Customer Bulletin Vehicles #06-02 Commercial Products Rattle Noise from Engine Bay Product: Workman® MD & MDX Affected Units: Aug 23, 2012 Models: 07273 07279 07266TC 07273TC Serial Numbers: 311000001 – 312000531 311000001 – 312000689 311000001 – 312000252 311000001 – 312000460 Situation: A rattling noise coming from the engine bay area may be caused by the Starter / Generator (S/G) Pulley – Drive (119-9482) not being secured by the torqued nut.
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Customer Bulletin Commercial Products Vehicles #06-02 Rattle Noise from Engine Bay Workman MD/MDX Service Manual). Inspect the Pulley for any damage. If damage is present, replace the Pulley with Pulley – Drive (121-6277) which has a thicker hub. If in doubt about the fit of the original Pulley (119-9482), add an 11/16” I.D. Washer / Spacer (107-4293) onto the starter shaft before the S/G Pulley, and reinstall the S/G Washer-Lock (1199652) & Nut (119-9651). Torque the nut to 15 to 25 ft. – lbs.