NHTSA ID Number: 10054678
Manufacturer Communication Number: SB-20-18
TSB/Document Date: 2014-02-15
Summary
WESTERN STAR
: THERE ARE RADIATOR FAILURES RESULTING IN COOLANT LEAK DUE TO A COOLANT TUBE HAVING A CRACK AND NEED AN UPDATED ISOLATED ENGINE MOUNT, IF THERE IS A CRACK IN COOLANT TUBE. *PE UPDATED 6/26/14. *PE
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
20-18
Western Star
Service Bulletin
5900 Models
6900 Models
SB-10054678-2050
Description of Revisions:This bulletin replaces the version dated
December 2013. The SRT times have been revised.
General Information
Some EPA10 compliant Western Star 4800 and 4900 vehicles manufactured March 2010 and later, with specific
combinations of engine operating parameters, may have radiator failures resulting in a coolant leak due to a
crack in the coolant tube. See Fig. 1. Leaks in other places (at the end tank, header, fittings, or any place other
than the coolant tubes) do not apply for this bulletin. If leaks occur in the coolant tubes, Western Star recommends a radiator update to an isolated engine-mounted radiator. Isolated engine-mounted radiators were production installed in 4800 and 4900 models beginning in August, 2012. This procedure is to replace a standard
engine-mounted radiator with an isolated engine-mounted radiator.
05/31/2005
f500383
Fig. 1, Crack in Coolant Tube
IMPORTANT: Before scheduling a vehicle for this procedure, determine if the vehicle to be serviced
has a set forward (SF) or set back (SB) axle configuration, then refer to Table 1 under "Parts" for a
listing of the required parts tables for each configuration.
Radiator 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 or remove the straps and open the hood while supporting it. For instructions, see Group
88 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. Remove the charge air cooler (CAC) plumbing at the turbocharger outlet and the CAC inlet, and at the CAC
outlet and the engine inlet. See Fig. 2 and Fig. 3.
Western Star Service Bulletin, April 2014
Page 1
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
20-18
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
4
3
2
> 4800 Models
> 4900 Models
5900 Models
6900 Models
1
1
3
2
6
5
6
2
10/16/2012
1.
2.
3.
4.
4
f200767
5. Turbocharger Outlet
Pipe
6. Clamp
10/16/2012
1. CAC Outlet
2. Clamp
Fig. 2, CAC Plumbing, Turbocharger-to-CAC
f200768
3. Hose
4. Engine Inlet
Fig. 3, CAC Plumbing, CAC-to-Engine Inlet
6. Remove the upper radiator hose. See Fig. 4 for DDC engines, or Fig. 18 for Cummins engines.
7. Disconnect the surge tank vent line. See Fig. 6.
8. Remove the grille from the radiator.
9. Remove the baffles and mounting brackets located on both sides of the grille. See Fig. 7.
10. Loosen the A/C condenser and move it out of the way as follows.
10.1
Remove the receiver-drier and upper condenser-line mounting nuts, then free the receiver-drier. See
Fig. 8.
10.2
Remove the radiator baffle from the right side of the radiator.
NOTE: The A/C lines run through the right-side baffle. The baffle must be moved with the
condenser.
10.3
Unbolt the A/C condenser from the CAC. See Fig. 9.
NOTE: Wrap the condenser in cardboard to protect it while it is moved.
10.4
Carefully move the condenser around and set it on the right front tire. Secure it as needed. See Fig.
10 .
11. Remove the three radiator strut rods and discard them.
12. Unbolt the city horn from the side radiator channel if applicable.
13. Remove the upper fan shroud. See Fig. 11.
14. Remove the fan. For instructions, refer to Group 20 of the Western Star Workshop Manual.
15. Disconnect the lower radiator hose assembly at the radiator. See Fig. 12 for DDC engines, or Fig. 18 for
Cummins engines.
Page 2
Western Star Service Bulletin, April 2014
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
20-18
Western Star
Service Bulletin
5900 Models
6900 Models
1
2
3
4
1
2
1
10/16/2012
1. Radiator
2. Upper Radiator Hose
3. Clamp
f200771
4. Clamp Fastener
5. Lower Radiator Hose
1
6
Fig. 4, Upper Radiator Hose Installation, DDC Engine
1
4
1
11/07/2013
1.
2.
3.
4.
5.
6.
3 1
5
f200830
Clamp
Upper Radiator Hose
Hose, Lower Radiator, Radiator to Tube
Lower Radiator Tube
Fastener
Hose, Lower Radiator Tube-to-Engine
Fig. 5, Radiator Hose Installation, Cummins Engine
16. Disconnect the transmission cooler lines from the radiator. Cap and/or plug the fittings to prevent spills.
17. Unbolt the radiator from the lower mounts.
18. Using an appropriate lifting device, remove the radiator assembly from vehicle. See Fig. 13.
19. Remove the lower fan shroud from the radiator. See Fig. 11.
20. Remove the upper radiator baffle.
21. Remove the CAC from the radiator.
22. Remove the transmission cooler fittings and the upper vent line fitting.
23. Install the transmission cooler fittings and upper vent line fitting on the new radiator.
24. Install the CAC on the new radiator.
25. Install the upper radiator baffle.
Western Star Service Bulletin, April 2014
Page 3
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
20-18
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
5900 Models
6900 Models
3
2
1
10/16/2012
f200769
1. Clamp
2. Line
3. P-Clamp
Fig. 6, Surge Tank Vent Line
1
2
1
3
2
02/01/2013
f880915
1. Baffle (one on each side of the grille)
2. Bracket (one on each side of the grille)
3. Grille
Fig. 7, Grille Assembly
11/28/2012
1. Upper Condenser
Line Mounting Nuts
f200773
2. Receiver-Drier
Mounting Nuts
Fig. 8, Receiver-Drier Installation (typical)
26. Apply sealant (48-00094-141) to the threads of the fasteners, then install the fan. Tighten 30 lbf·ft (41 N·m).
27. Install the fan shroud on the new radiator. See Fig. 11.
28. Remove the lower radiator mounting brackets from the engine.
Page 4
Western Star Service Bulletin, April 2014
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
20-18
Western Star
Service Bulletin
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
29. Install the new lower radiator mounting brackets. See Fig. 14. Tighten 191 to 234 lbf·ft (260 to 317 N·m).
30. Install the lower radiator isolators on the mounting brackets. See Fig. 15.
31. 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. 15.
32. Install the lower radiator hose.
33. Connect the transmission cooler lines.
34. Install the new upper radiator hose. See Fig. 4 for DDC engines or Fig. 18 for Cummins engines.
IMPORTANT: On DD13 engines, the left strut rod attaches to the top of the bracket on the radiator.
On DD15/16 engines, the left strut rod attaches to the bottom of the bracket on the radiator.
35. Install the new isolated radiator strut rods. See Fig. 16 for DDC engine installations, or Fig. 17 for Cummins
engine installations. 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) for DDC engines, or 55 to 65 lbf·ft (75 to 90 N·m) for
Cummins engines.
36. Tighten the radiator mounting nuts 140 to 170 lbf·ft (190 to 230 N·m).
37. Install the A/C condenser as follows.
37.1
Move the condenser into position and secure it temporarily. See Fig. 9.
37.2
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).
Western Star Service Bulletin, April 2014
Page 5
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
20-18
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
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
37.3
Tighten the condenser mounting nuts 112 to 144 lbf·in (1266 to 1627 N·cm).
37.4
Install the grille mounting brackets and baffle brackets.
38. Install the radiator baffles.
39. Install the grille.
40. Install the CAC plumbing at the turbocharger outlet and the CAC inlet and the CAC outlet and the engine
inlet. See Fig. 2 and Fig. 3.
Page 6
Western Star Service Bulletin, April 2014
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
20-18
Western Star
Service Bulletin
5900 Models
6900 Models
4
1
1
2
1
3
10/16/2012
1. Clamp
2. Radiator Hose Elbow
f200772
1
Fig. 12, Lower Radiator Hose Installation, DDC Engines
2
4
4
5
3
5
10/16/2012
1.
2.
3.
4.
5.
f500411
Radiator
Lower Radiator Mounting Bracket, Right Side
Lower Radiator Mounting Bracket, Left Side
Washer
Nut
Fig. 13, Radiator Assembly Removal
41. Fill the cooling system following the procedures in the engine manufacturer’s service literature.
42. Install the hood. For instructions, see Group 88 of the Western Star Workshop Manual.
43. Install the bumper. For instructions, refer to Group 31 of the Western Star Workshop Manual.
44. Pressure check for coolant leaks. Repair as needed.
45. Drive the vehicle to get it up to operating temperature.
46. Check the transmission fluid level, and add fluid as needed.
Western Star Service Bulletin, April 2014
Page 7
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
20-18
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
1
> 4800 Models
> 4900 Models
5900 Models
6900 Models
2
3
10/16/2012
f500412
1. Fastener
2. Lower Isolated Radiator Mounting Bracket, Right
Side
3. Lower Isolated Radiator Mounting Bracket, Left
Side
Fig. 14, Lower Isolated Radiator Mounting Bracket
Installation
Page 8
Western Star Service Bulletin, April 2014
Western Star 4800 and 4900 Radiator Mounting,
Update—EPA10
Constellation
Heritage
4700 Models
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TSB/Document ID: SB-20-18
Replacement Service Bulletin Number: SB-20-18-A
MFR Communication Date: 2014-04-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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