Adding Fog Lamps or Auxiliary High Beams to Cascadia Vehicles

General Information
NOTE: A Highline SAM Cab is required when adding auxiliary high beams (reference module 32A in PartsPro to determine if the vehicle was built with a Baseline or a Highline SAM Cab).

Fog Lamps
The fog lamp option works only when the marker or low beam lamps are on. The fog lamp control is part of the headlamp switch and is turned on by pulling the headlamp switch outward. The fog lamps turn off when the high beams are selected. Once low beam lamps are re-selected, the fog lamps will turn back on.

Auxiliary High Beams
The auxiliary high beams option works only when the high beam head lamps are on. A separate switch on the dash controls the auxiliary high beam function. If the auxiliary high beam switch is selected by pressing the top of the switch, the auxiliary lamps will remain off until the high beam head lamps are turned on. If the low beam lamps are selected, the auxiliary high beams are temporarily turned off until the high beam head lamps are re-selected.
Since both the fog lamps and the auxiliary high beams are mounted in the same location in the front bumper, only one of the two functions is used. This bulletin addresses adding either feature, or converting from one feature to the other.

Adding or Converting from Auxiliary High Beams to Fog Lamps

1. Shut down the engine and chock the tires.
2. Open the hood.
3. With the ignition off, remove the headlamp switch and replace it with the new switch called out in Table 1 .
NOTE: Refer to D22-60559-000 for an illustration of the switch mounting and location

4. Vehicles built after 8/24/2015 do not have the fog light switch circuit (27A) in the harness between the headlight switch and the MSF. To verify whether or not this circuit is present on the vehicle, see module 311 in PartsPro and look for harness part number A06-58500-XXX:

If the vehicle has harness A06-58500-000, the fog light switch circuit is present;

If the vehicle has harness A06-58500-001, the fog light switch circuit is not present (the circuit will need to be added).
NOTE: Vehicles with the following serial numbers, built from 6/8/2015 to 6/11/2015, also do not contain the fog light switch wiring: GU4930, GU4831, GU4932, GT6943, GT6944, GZ9423, GC5166, and GR0444

5. If the vehicle currently has harness A06-58500-001:

replace harness A06-58500-001 with A06-58500-000; or

run a new circuit in the existing harness between the headlight switch connector (pin 4) and the MSF 12-pin connector (pin 6) using terminal p/n 23-13208-080. Use 20 gauge wire.
6. If converting from auxiliary high beam lamps to fog lamps, use the original wiring supplied for the auxiliary high beam, wires 27L and 27R in connector 20 of the SAM Cab. Remove wire 27L form cavity 10 and install it in cavity 8, and remove wire 27R from cavity 12 and install it in cavity 17.

If adding fog lamps, install the A06- harness part numbers from Table 1 using the forward harness installation print from module 288, along with layout harness prints from module 288 and 321 listed for the vehicles serial number. A wiring diagram is also supplied in  Table 1 for reference if needed.

If adding fog lamps, the front bumper end caps may not be cut for fog lamps. The end cap is comprised of two parts, the inner reinforcement and the outer cover. See Fig 1 for the location of the end cap cut out (outer cover).

If adding fog lamps, the end cap inner reinforcement will also need to be cut and drilled. Use the template in Service Solution 3529 to cut out the inner reinforcement.  Fig2 shows the lamp before the modification, and Fig 3 shows the the lamp with the inner reinforcement added.

NOTE: The template in Service Solution 3529 is actual size, and is for the left side of the vehicle. The template can be used in reverse for the right side of the vehicle. Use measurements to validate that the template is the correct size. The center hole diameter is 4.09 inches (104 mm), and the diameter of the three mounting holes is .354 inch (9 mm). The template is to be placed on the wheel side of the bumper reinforcement and uses the top, curved side and bottom edges for alignment.
NOTE: A second option to cutting of the fascia and inner reinforcement would be to purchase pre cut piece parts. Table 3 shows optional piece parts that can be purchased if cutting is not an option.

7. If adding fog lamps, once the cut outs are complete, install the new fog lamps.

If converting from auxiliary high beam lamps to fog lamps, remove the to original Auxiliary High beam lamps and install the new fog lamps. Remove the auxiliary high beam switch from the dash and install the switch hole cover in its place. See Table 1.
NOTE: The SAM Cab can be programmed once the fog lamps are installed and the wiring is routed and hooked up.

8. Using SAM Cab Parameters for "Auxiliary Headlamps and Fog Lamps" in ServiceLink, select parameter 003 447 20 58 for fog lamps.

If converting , the MSF also needs to be programmed. Under the MSF parameters for "Auxiliary head lights," select the parameter for no content 000 447 79 23.
9. Close the hood.

Adding or Converting from Fog Lamps to Auxiliary High Beams

1. Shutdown the engine and chock the tires.
2. Open the hood.
3. If converting from fog lamps, turn the ignition off and remove the headlamp switch. Replace it with the new switch (from Table 3 ), which does not contain fog lamp control feature.

NOTE: Refer to D22-60559-000 for an illustration of the switch mounting and location.

If converting from fog lamps to auxiliary high beams, use the original wiring supplied with the fog lamps, wires 28L and 28R in the SAM Cab connector 20. First remove wire 28L form cavity 8 and install it in cavity 10. Next remove 27R to 28R from cavity 17 and install it in cavity 12.

If adding auxiliary high beams, install the A06- harness part numbers from Table 2 using the forward installation print from module 288 along with the layout harness prints from module 288 and 321 listed for the vehicles serial number.

If adding auxiliary high beams, the front bumper end caps may not be cut for lamps. The end cap is comprised of two parts, the inner reinforcement and the outer cover. See Fig 1 for the location of the end cap cut out (outer cover).

If adding auxiliary high beams, the end cap inner reinforcement also needs to be cut and drilled. Use the template in Service Solution 3529 to cut out the end cap inner cover. Fig 2 shows the reinforcement before the cut out is complete, and Fig 3 shows the assembly after the modification is complete.

NOTE: The template in Service Solution 3529 is actual size, and is for the left side of the vehicle. The template can be used in reverse for the right side of the vehicle. Use measurements to validate that the template is the correct size. The center hole diameter is 4.09 inches (104 mm), and the diameter of the three mounting holes is .354 inch (9 mm). The template is to be placed on the wheel side of the bumper reinforcement and uses the top, curved side and bottom edges for alignment.

NOTE: Pre-cut piece parts can be ordered as an alternative to cutting the fascia and inner reinforcement. Table 3 shows optional piece parts that can be purchased if cutting is not an option.

If adding auxiliary high beams once the cutouts are complete, install the new auxiliary high beam.

If converting auxiliary high beams, remove the original fog lamps and install the new auxiliary high beam lamps.
NOTE: The SAM Cab can be programmed once the auxiliary high beam lamps are installed and the wiring is routed and hooked up.

4. Using SAM Cab Parameters for "Auxiliary Headlamps and Fog Lamps" in ServiceLink, select parameter 002 447 37 58 for auxiliary high beams.
5. The MSF also needs to be programmed. Under the MSF parameters for “Auxiliary head lights” select the auxiliary head lamp parameter 000 447 78 23.
6. Close the hood.

Table 1, Parts Required to Add Fog Lamps or Convert from Auxiliary High Beams to Fog Lamps

Table 2, Parts Required to Add Auxiliary High Beams or Convert from Fog Lamps to Auxiliary High Beams