IPC, Interior Lights and/or Headlamps Flicker - keywords battery courtesy electrical fluctuation generator head intermittent lamp light

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Customers may have comments of a flickering light condition in the IPC, interior lamps or headlights. This condition is most likely to be noticed when the engine RPM is low and when high electrical load requirements are in place on the generator.

Important: Review bulletin 02-06-03-008A - Low Voltage Display on IP Gauge, Lights Dim at Stop Lights, Battery Discharged, before proceeding with this PI.

1. Disconnect the negative battery cable from the battery/batteries.
2. Slide the protective boot on the generator BAT terminal aside and remove the retainer and wire cable from the BAT terminal.
3. Unplug the generator 4-cavity terminal from the top of the generator.
4. Inspect cavity D on the generator connector for a red cavity plug. If a red cavity plug is present, it is not necessary to replace the generator connector. Remove the CPA and save. Remove the red cavity plug and continue with step 9. If a red cavity plug is NOT present, continue with the next step.
5. Remove and save the orange Weatherpack seal and CPA from the 4-way connector.
6. Using the proper terminal removal tool, remove the two or three wires from the 4-way connector. On vehicles without Supplemental Brake Assist (SBA), install a red cavity plug, P/N 12059168, into cavity "A" of the new 4-way connector, P/N 12186568. On some 2003 and 2004 model year vehicles with SBA, install the dark blue (Circuit 5668) wire of the vehicle wiring harness into cavity "A" of the new 4-way connector.
7. Depending on the vehicles model and year, install the brown wire (Circuit 25) or red wire (Circuit 225) of the vehicles wiring harness into cavity "B" of the new 4-way connector.
8. Install the gray (Circuit 23) wire of the vehicle wiring harness into cavity "C" of the new 4-way connector.
9. Obtain a piece of 0.80 mm/18GA black wire, 254 mm (8 in) long.
10. Install a red terminal seal, P/N 12048086, and terminal, P/N 12048074, (crimp and solder) on one end of the new black wire.
11. Install the new black wire into cavity "D" of the new 4-way connector.
12. Reinstall the connector seal and CPA, from the original connector, to the new connector.
13. Plug the 4-way connector into the generator.
14. Route the black wire to the generator BAT terminal, sliding the wire into the small end to the output terminal boot, along side the generator output wire.
15. Obtain a ring terminal from the terminal kit (J-38125-D) that is the same diameter as the positive post of the generator. Crimp and solder the ring terminal from the terminal kit (J-38125-D) on to the open end of the new black wire.
16. Place the generator output wire and the new black wire onto the generator BAT terminal and install the retainer.
17. Connect the negative battery cable.

Note: This modification will not work if the vehicle is utilizing the new "Regulated Voltage Control" system. This is new feature on some full-size trucks and utilities for the 2005 model year. Please inspect the vehicle prior to performing this modification.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.