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Installation Guide for Dorman 904-7365 Accelerator Pedal Sensor

Step-by-step installation guide for the Dorman 904-7365 Accelerator Pedal Sensor. Includes torque specifications, wiring harness routing tips, and important diagnostic warnings.

Table of contents

Quick Guide

This document provides installation instructions for the Dorman 904-7365 Accelerator Pedal Sensor. The kit includes a new 6-pin sensor and a compatible wiring harness. Important: Before replacing the sensor, verify your diagnosis using the latest Detroit Diesel instruction bulletin. Replacing the sensor will reset the system, but uncorrected underlying problems will cause the fault to return.

Before You Begin

Ensure you have the proper safety equipment and that this part is compatible with your vehicle's specific year, make, model, and configuration. If you do not have a service manual or the necessary experience, consult a qualified technician.

Installation Procedure

  1. Remove the pedal from the vehicle if necessary. Note the routing of the existing wiring harness; marking the routing is suggested as it is critical for performance.
  2. Remove the sensor screws (item 6). Disconnect the wiring harness by prying up the clip on the connector. Discard the old screws and sensor (item 29).
  3. Clean the mounting surface on the pedal. Inspect the bearing and bearing housing for wear. If the sensor shaft or bearing is damaged, replace the entire upper pedal assembly.
  4. Inspect the connector for damage, specifically the green rubber seal. If damaged, replace the wiring harness by removing the screws and cable clamps. Discard the old harness (item 13), clamps, and screws.
  5. Position the new sensor on the pedal, aligning the holes with the casting. Secure with the provided screws, torquing to 15–25 in·lbs. Do not over-tighten, as this may damage the screw holes. Connect the new wiring harness to the sensor.
  6. Secure the wiring harness to the base plate using the provided cable clamps and screws. Leave a large loop in the harness to prevent excessive wire bending. Torque these screws to 20–35 in·lbs.
  7. Reinstall the pedal in the vehicle if it was removed. Secure the wiring harness following the original routing and attach the connector(s) to the vehicle's wiring harness.

Practical help

Common problems

Sensor fault diagnosis is incorrect

Check the latest Detroit Diesel instruction bulletin before replacing the sensor. Replacing the sensor resets the system, but uncorrected problems will reoccur.

Damaged bearing or housing

If the sensor shaft or bearing shows signs of wear or damage, you must replace the entire upper pedal assembly.

Wiring harness damage

Inspect the green rubber seal on the connector. If damage is evident, replace the entire wiring harness.

Before use

  • Verify part fitment for your specific vehicle year, make, model, and configuration.
  • Consult the appropriate service manual for your vehicle.
  • Ensure you have proper safety equipment.
  • Check the latest Detroit Diesel instruction bulletin to confirm diagnosis.

Specs in practice

Sensor mounting screws torque
15–25 in·lbs
Wiring harness clamp screws torque
20–35 in·lbs
Sensor configuration
6-pin

Model compatibility

  • Includes a new 6-pin sensor and compatible wiring harness.
  • Fits existing pedal assembly.

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Manual page author

Emily Carter

User documentation editor

Prepares concise manual descriptions and highlights the most useful setup, operation, and maintenance information for readers.