SB-10044783-9870

EPA07 5-Inch Flex-Tube Exhaust Bellows Replacement,
DD15
> Constellation
Heritage
4700 Models

4800 Models
4900 Models

49-9
Western Star
Service Bulletin

5900 Models
6900 Models

A new and more robust flex-tube exhaust bellows (04-29833-000) has been designed and is now available, to
replace bellows (A04-26381-000) on Western Star vehicles equipped with EPA07 DD15 engines. The new bellows requires a slip clamp assembly (TCX AMS015AM). See Fig. 1.
2
3

1

4

5

6

11/30/2011

f490415a

1. ATD Inlet Pipe
2. Slip Clamp Assembly
3. Retaining Ring

4. Graphite Gasket
5. Clamp
6. Bellows

Fig. 1, Slip Clamp Assembly

Replacement
1. Park the vehicle on a level surface, shut down the engine, and set the parking brakes. Chock the tires.
2. Allow the exhaust system time to cool before working on the vehicle.
3. Remove the passenger side fender.
4. Remove the exhaust piping between the turbocharger outlet and aftertreatment device (ATD). See Fig. 2.
4.1

Remove the U-clamp at the support brace aft of the bellows.

4.2

Remove the exhaust support brace from the frame rail aft of the bellows.

4.3

Loosen the V-clamp at the turbocharger outlet.

4.4

Remove the V-clamp at the ATD.

4.5

Remove the piping from the vehicle.

5. On the workbench, remove the exhaust bellows from the ATD inlet pipe. Do not damage the ATD inlet pipe.
6. Install the ATD inlet pipe onto the ATD.
7. Install the turbocharger outlet pipe on the turbocharger.
8. Align the ATD inlet pipe and the turbocharger outlet pipe.
9. Install the frame-mounted ATD inlet pipe support and clamp the ATD inlet pipe to it.
10. Check the alignment of the ATD inlet pipe and turbocharger outlet pipe.
11. Remove the turbocharger outlet pipe.
12. Install the slip clamp onto the ATD outlet pipe.
13. Slide the bellows onto the ATD inlet pipe.

Western Star Service Bulletin, March 2012

Page 1

EPA07 5-Inch Flex-Tube Exhaust Bellows Replacement,
DD15

49-9
Western Star
Service Bulletin

> Constellation
Heritage
4700 Models

4800 Models
4900 Models

5900 Models
6900 Models

1
2
3

4

5

9

8

10

11

7

6

11/21/2011

1.
2.
3.
4.

ATD
V-Clamp
ATD Inlet Pipe
Saddle

f490463

5.
6.
7.
8.

U-Clamp
Nut
Support Brace
Band Clamp

9. Bellows
10. V-Clamp
11. Turbocharger Outlet

Fig. 2, Original Bellows Installation

14. Install the slip clamp onto the turbocharger outlet pipe.
15. Install the turbocharger outlet pipe into the bellows and onto the turbocharger.
16. Position a new slip clamp assembly, with the retaining ring and graphite gasket, on the ATD inlet pipe. See
Fig. 3.
17. Slide the new bellows (04-29833-000) onto the ATD inlet pipe. See Fig. 4.

NOTICE
Proper alignment of the bellows and piping is critical. Improper installation may damage the parts or
cause an exhaust leak.
18. Position a new V-clamp on the turbocharger outlet end of the bellows.
19. Tighten the V-clamp at the turbocharger outlet pipe 112 lbf·in (1265 N·cm).
20. Tighten the V-clamp at the ATD inlet 112 lbf·in (1265 N·cm).
21. Tighten the slip-clamp at the ATD inlet pipe 15 lbf·ft (20 N·m).

Page 2

Western Star Service Bulletin, March 2012

EPA07 5-Inch Flex-Tube Exhaust Bellows Replacement,
DD15
> Constellation
Heritage
4700 Models

4800 Models
4900 Models

1

Western Star
Service Bulletin

5900 Models
6900 Models

2

3

4

5

01/29/2010

1. ATD Inlet Pipe
2. Retaining Ring
3. Graphite Gasket

49-9

f490415

4. Slip Clamp
5. Bellows

Fig. 3, Aft Facing Slip Clamp Installation

22. Tighten the U-clamp at the brace 64 lbf·in (723 N·cm).
23. Start the engine and run a parked regeneration.
24. Check for exhaust leaks. Fix any leaks by tightening the appropriate clamps.

Warranty
This bulletin is informational only. Warranty does not apply.

Western Star Service Bulletin, March 2012

Page 3

EPA07 5-Inch Flex-Tube Exhaust Bellows Replacement,
DD15

49-9
Western Star
Service Bulletin

> Constellation
Heritage
4700 Models

4800 Models
4900 Models

5900 Models
6900 Models

1
2
3

4

5

8

9
10

11

7

6

11/21/2011

1.
2.
3.
4.

ATD
V-Clamp
ATD Inlet Pipe
Saddle

f490464

5.
6.
7.
8.

Nut
U-Clamp
Support Brace
Slip Clamp Assembly

9. Bellows
10. V-Clamp
11. Turbocharger Outlet

Fig. 4, New Bellows Installation

Page 4

Western Star Service Bulletin, March 2012