SB-10054664-5203

Western Star 4700 Radiator Mounting, Update—EPA10
Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

5900 Models
6900 Models

20-20
Western Star
Service Bulletin

Description of Revisions: This bulletin replaces the version dated
November 2013. Parts table heading have been clarified, and the
SRT times have been updated.

General Information
This procedure is for replacing the original standard mount radiator with an isolated mount radiator in Western
Star 4700 vehicles equipped with Detroit engines only. Vehicles with Cummins engines are not covered.

IMPORTANT: The required parts for this procedure will vary depending on the type of engine installed
and the front frame and crossmember configuration. See Fig. 1, Fig. 2, and Fig. 3 for different
configurations. Before scheduling a vehicle for this procedure, determining the vehicle configuration,
then refer to Table 1 under "Parts" to locate the correct table listing the required parts for that vehicle.

11/07/2013

f311171

Fig. 1, Bolt-On Front Frame and Crossmember

11/07/2013

f311172

Fig. 2, Drop-Cast Front Frame and Crossmember

Radiator Mount Replacement
1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2. Remove the hood. For instructions, see Section 88.00, Subject 100 in the Western Star Workshop Manual.
3. Remove the bumper. For instructions, refer to Group 31 of the Western Star Workshop Manual.
4. Drain the coolant from the radiator and engine block.
5. Disconnect the charge air cooler (CAC) plumbing at the CAC and engine. See Fig. 4 and Fig. 5.
6. Remove the upper radiator hose. See Fig. 6.
7. Remove the surge tank vent line from the radiator. See Fig. 7.
8. Loosen the A/C condenser and move it out of the way as follows.
8.1

Remove the receiver-drier and upper A/C hose mounting nuts, then free the receiver-drier. See Fig.
8.

8.2

Remove the radiator baffle from the right side of the radiator.

Western Star Service Bulletin, December 2013

Page 1

20-20

Western Star 4700 Radiator Mounting, Update—EPA10

Western Star
Service Bulletin

Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

11/07/2013

5900 Models
6900 Models

f311173

Fig. 3, Splayed Front Frame and Crossmember

4

3

2

1

1
3

2
6
5
10/16/2012

1.
2.
3.
4.

6

2

CAC Inlet
Hose
Tube
Hose

5. Turbocharger Inlet
Pipe
6. Clamp

10/16/2012

f200768

1. CAC Outlet
2. Clamp

Fig. 4, CAC Plumbing, Turbocharger-to-CAC

8.3

4

f200767

3. Hose
4. Engine Inlet

Fig. 5, CAC Plumbing, CAC-to-Engine Inlet

Unbolt the A/C condenser from the CAC. See Fig. 9.

NOTE: Wrap the condenser in cardboard to protect it while it is moved.
8.4

Carefully move the condenser around and set it on the right front tire. Secure it as needed. See Fig.
10.

9. Remove the three radiator strut rods and discard them.
10. Remove the upper and left-side radiator baffles.

Page 2

Western Star Service Bulletin, December 2013

20-20

Western Star 4700 Radiator Mounting, Update—EPA10
Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

Western Star
Service Bulletin

5900 Models
6900 Models

3

1

4

1

1
2
1
5
6
8
7
11/12/2013

1.
2.
3.
4.

f200831

Clamp
Hose
Tube
Hose

5. Clamp
6. Bolt
7. Nut

Fig. 6, Upper Radiator Hose Installation

3
2
1
1

2
10/16/2012

1. Clamp
2. Line

f200769

3. P-Clamp

05/24/2012

1. Upper Condenser
Line Mounting Nuts

f200759

2. Receiver-Drier
Mounting Nuts

Fig. 7, Surge Tank Vent Line
Fig. 8, Receiver-Drier Installation (typical)

11. Remove the upper fan shroud. See Fig. 11.

Western Star Service Bulletin, December 2013

Page 3

20-20

Western Star 4700 Radiator Mounting, Update—EPA10

Western Star
Service Bulletin

Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

5900 Models
6900 Models

2

3
4

1
05/24/2012

f200757

1. A/C Condenser
2. Isolator

3. Washer
4. Nut
Fig. 9, A/C Condenser Installation

12. Remove the fan. For instructions, refer to Group 20 of the Western Star Workshop Manual.
13. Remove the CAC from the radiator.
14. Remove the lower radiator hose. See Fig. 12, Fig. 13, Fig. 14, Fig. 15, or Fig. 16.
15. Disconnect the transmission cooler lines from the radiator. Cap and/or plug the fittings to prevent spills.
16. Unbolt the radiator from the lower mounts.
17. Using an appropriate lifting device, remove the radiator assembly from vehicle. See Fig. 17.
18. Remove the lower fan shroud from the radiator. See Fig. 11.
19. Remove the lower radiator mounting brackets from the engine.
20. Install the new lower radiator mounting brackets. See Fig. 18. Tighten 191 to 234 lbf·ft (260 to 317 N·m).
21. Install the lower radiator isolators on the mounting brackets. See Fig. 19.
22. Install the CAC on the radiator.
23. Install the radiator baffles.
24. Install the fan shroud. See Fig. 11.
25. Apply sealant (48-00094-141) to the threads of the fasteners, then install the fan. Tighten 30 lbf·ft (41 N·m).
26. Using an appropriate lifting device, position the new radiator assembly in the vehicle. Install the mounting
nuts, but do not tighten them at this time. See Fig. 19.
27. Install the new upper radiator hose. See Fig. 6.

Page 4

Western Star Service Bulletin, December 2013

20-20

Western Star 4700 Radiator Mounting, Update—EPA10
Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

Western Star
Service Bulletin

5900 Models
6900 Models

1

2
2

3
4
5

05/24/2012

f200760

1. Bungee Cord

2. Condenser

Fig. 10, Securing the A/C Condenser

1

10/04/2012

f200756a

1. Lower Fan Shroud
2. Upper Fan Shroud
3. Push Fastener

4. Washer
5. Screw

Fig. 11, Fan Shroud Installation

28. Connect the transmission cooler lines.
29. Install the new lower radiator hose assembly. See Fig. 12, Fig. 13, Fig. 14, Fig. 15, or Fig. 16.
30. Install the surge tank vent line on the radiator. See Fig. 7.
31. Install the new radiator strut rods. See Fig. 20. Tighten the radiator strut rod fasteners at the radiator 55 to
65 lbf·ft (75 to 90 N·m), and at the engine block 125 to 139 lbf·ft (171 to 188 N·m).
32. Tighten the radiator mounting nuts 140 to 170 lbf·ft (190 to 230 N·m).

Western Star Service Bulletin, December 2013

Page 5

20-20

Western Star 4700 Radiator Mounting, Update—EPA10

Western Star
Service Bulletin

Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

5900 Models
6900 Models

1
4
1

3

1
1

2

11/12/2013

1.
2.
3.
4.

f200836

Hose
Clamp
Tube
Hose, Elbow
Fig. 12, Lower Radiator Hose Installation

2

4
1

3

2

2
2

1

1
11/12/2013

11/12/2013

1. Hose
2. Clamp

f200832

3. Tube
4. Hose, Elbow

1. Clamp

f200833

2. Hose

Fig. 14, Lower Radiator Hose Installation

Fig. 13, Lower Radiator Hose Installation

Page 6

Western Star Service Bulletin, December 2013

20-20

Western Star 4700 Radiator Mounting, Update—EPA10
Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

Western Star
Service Bulletin

5900 Models
6900 Models

1
4
1
3

1

1
2

2

1
11/12/2013

1. Clamp

f200834

2. Hose

11/12/2013

1. Clamp
2. Hose

f200835

3. Tube
4. Hose

Fig. 15, Lower Radiator Hose Installation
Fig. 16, Lower Radiator Hose Installation

33. Install the CAC plumbing at the the CAC and the engine. See Fig. 4 and Fig. 5.
34. Install the A/C condenser as follows.
34.1

Move the condenser into position and secure it temporarily. See Fig. 9.

34.2

Position the receiver-drier and upper A/C line on their respective brackets and install the mounting
nuts. See Fig. 8. Tighten the nuts 14 to 16 lbf·ft (19 to 22 N·m).

34.3

Tighten the condenser mounting bolts 112 to 144 lbf·in (1266 to 1627 N·cm).

35. Fill the cooling system following the procedures in the engine manufacturer’s service literature.
36. Install the hood. For instructions, see Subject 88.00, Subject 100 in the Western Star Workshop Manual.
37. Install the bumper. For instructions, refer to Group 31 of the Western Star Workshop Manual.
38. Pressure check for coolant leaks. Repair as needed.
39. Drive the vehicle to get it up to operating temperature.
40. Check the transmission fluid level, and add fluid as needed.

Western Star Service Bulletin, December 2013

Page 7

20-20

Western Star 4700 Radiator Mounting, Update—EPA10

Western Star
Service Bulletin

Constellation
Heritage
> 4700 Models

4800 Models
4900 Models

1

5900 Models
6900 Models

2

1
2
3
4
4
5

3