NHTSA ID Number: 10079600
Manufacturer Communication Number: 20-28
TSB/Document Date: 2016-09-09
Summary
SURGE TANK CRACKS AT FILLER NECK
20-28
Surge Tank Cracks at Filler Neck
Constellation
Heritage
> 4700 Models
4800 Models
4900 Models
5700 Models
Western Star
Service Bulletin
5900 Models
6900 Models
On some Western Star 4700 models, the plastic frontwall-mounted surge tank (A05-28531-001) may crack
around the filler neck. If this occurs, replace the tank with the improved design part (A05-28531-002). See
Fig. 1 for a typical installation.
0
0
0
0
0
8, 9
06/07/2012
A. To Radiator
B. To Engine Vent Port
1.
2.
3.
4.
5.
Surge Tank
Capscrew
Washer (2)
Flanged Nut
HVAC Air Plenum
1831905
C. To Engine Shunt Port
6. Frontwall
7. Coolant Level
Sensor
8. Capscrew
9. Washer
Fig. 1, Plastic Frontwall-Mounted Surge Tank
Installation
Surge Tank Replacement
1.
Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
2.
Remove the surge tank cap, and drain the coolant system enough to allow the surge tank to empty.
3.
Mark the hoses attached to the surge tank for reference, then disconnect the hoses.
4.
Disconnect the wiring harness from the low coolant sensor.
5.
Remove the fasteners attaching the old surge tank to the air cleaner bracket, the HVAC plenum, and the
frontwall.
6.
Remove the old surge tank.
7.
Remove the overflow hose from the old surge tank.
8.
Install the overflow hose on the bottom of the new surge tank.
9.
Position the new surge tank onto the air cleaner bracket, then install the fasteners. Tighten just enough to
hold the surge tank in place.
10. Attach the new surge tank to the HVAC air plenum and the frontwall.
Western Star Service Bulletin. June 2016
Page 1
20-28
Surge Tank Cracks at Filler Neck
Western Star
Service Bulletin
Constellation
Heritage
> 4700 Models
4800 Models
4900 Models
5700 Models
5900 Models
6900 Models
11. Tighten all the fasteners 18 lbf-ft (24 N-m).
12. As previously marked, connect the engine and radiator hoses to the surge tank.
13. Fill the coolant system through the surge tank.
14. Install the surge tank cap.
15. Connect the wiring harness to the low coolant sensor.
16. Start the engine and check for coolant leaks. Repair any leaks. Add coolant if needed.
Parts
Parts are available through the PDC. Refer to Table 1 for replacement part number.
Replacement Part
Original
Replacement
I
AOS-28531-001
AOS-28531-002
I
Table 1, Replacement Part
Warranty
This procedure is warrantable only if the described condition exists and the repair is performed within the
applicable base or extended coverage warranty period. If a failure is not found, this procedure is considered
preventive and warranty does not apply.
Normal warranty applies. See Table 2 for OWL VMRS codes and labor allowance information. Enter this service
bulletin number in the Service Bulletin # field.
OWL VMRS Codes and Labor Allowance
Primary Failed Part
AOS-28531-001
Component
Code
042-002-009
Cause Code
14
SRT Code
Description
267-5065A Surge Tank, R/R
Time: Hours
0.8
Table 2, OWL VMRS Codes and Labor Allowance
Page2
Western Star Service Bulletin. June 2016
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TSB/Document ID: 20-28
Replacement Service Bulletin Number:
MFR Communication Date: 2016-06-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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