Adding Fasteners to a Cab-to-Sleeper Transition Panel,
5700 Models
Constellation
Heritage
4700 Models

4800 Models
4900 Models
> 5700 Models

60-25
Western Star
Service Bulletin

5900 Models
6900 Models

General Information
On some Western Star 5700 Model vehicles, the rear edge of the cab-to-sleeper transition panel may detach
from the sleeper. To secure the transition panels to the sleeper, add three fasteners to each panel, using the
procedure in this bulletin.

Procedure
1. Park the vehicle on a level surface, shut down the engine, and chock the tires.
2. Measure and mark three drilling locations on the transition panel, as shown in Fig. 1. Use masking tape for
marking and to protect the finish.
A

B

C

D

1
08/14/2015

A.
B.
C.
D.
1.

f602566

Measurement: 2-3/16 in (56 mm)
Measurement: 54-13/16 in (1393 mm)
Measurement: 36 in (915 mm)
Measurement: 16-7/8 in (428 mm)
Existing Fastener
Fig. 1, Drilling Locations (LH panel shown)

Western Star Service Bulletin, September 2015

Page 1

60-25

Adding Fasteners to a Cab-to-Sleeper Transition Panel,
5700 Models

Western Star
Service Bulletin

Constellation
Heritage
4700 Models

4800 Models
4900 Models
> 5700 Models

5900 Models
6900 Models

3. Using a 25/64-inch drill bit, drill through BOTH the transition panel and the sleeper skin at the marked
locations.
4. Drill 9/16-inch holes through the transition panel ONLY, as follows.
4.1

Install a stop collar 1/8 inch (3 mm) from the end of the cutting edge of a 9/16-inch drill bit. If a stop
collar is not available, make a stop using tape wrapped around the bit, 1/8 inch (3 mm) from the end
of the cutting edge. Use enough layers of tape to create an effective stop. See Fig. 2.

IMPORTANT: Do not drill the 9/16-inch hole through the sleeper skin. Drilling through the sleeper
skin will make it impossible to install the rivnuts.
4.2

At the drilling locations, drill ONLY through the transition panel, using the 9/16-inch drill bit equipped
with the stop collar or tape stop. See Fig. 3.

A

08/14/2015
08/14/2015

f602560

f602558

A. Measurement: 1/8 in (3 mm)

Fig. 3, Drilling the 9/16-inch Holes

Fig. 2, Making a Stop for the Drill Bit

4.3

Smooth the edges of the 9/16-inch hole and clean off any debris. See Fig. 4.

5. Install the rivnuts (WWS 4013-3435), as follows:
5.1

Thread a provided machine screw (23-12011-100) a couple of turns into the rivnut.

5.2

Insert the rivnut in the drilled hole.

5.3

Lightly tap in the screw and rivnut. See Fig. 5.

5.4

Remove the screw from the rivnut. Make sure the flange of the rivnut is seated against the sleeper
skin. See Fig. 6.

IMPORTANT: When installing rivnuts, the tool should not be resting on the transition panel.
Depending on the tool, it may be necessary to use washers as spacers to clear the 1/8-inch (3mm) thickness of the transition panel. For an example of a tool that requires spacers, see Fig. 7.
For an example of a tool that does not require spacers, see Fig. 8.
5.5

Using a rivnut puller tool, install the rivnuts in the sleeper skin. See Fig. 9 and Fig. 10.

6. Remove the masking tape.

IMPORTANT: Carefully hand-tighten the machine screws, making sure no dents are made in the
transition panel.

Page 2

Western Star Service Bulletin, September 2015

Adding Fasteners to a Cab-to-Sleeper Transition Panel,
5700 Models
Constellation
Heritage
4700 Models

4800 Models
4900 Models
> 5700 Models

08/14/2015

60-25
Western Star
Service Bulletin

5900 Models
6900 Models

f602561

08/14/2015

Fig. 4, Cleaning the 9/16-Inch Hole

f602562

Fig. 5, Tapping in the Rivnut

08/14/2015

f602563

Fig. 6, Rivnut Seated Against the Sleeper Skin

7. Install the machine screws (23-12011-100) and washers (23-10900-227) into the rivnuts. Hand-tighten the
machine screws.

Parts
Parts are available through the PDCs. See Table 1.
Parts
Part Number
Description
WWS 4013-3435 Rivnut, 1/4–20
23-12011-100
Machine Screw, 1/4–20
23-10900-227
Flatwasher, 1/4-Inch

Qty.
6
6
6

Table 1, Parts

Western Star Service Bulletin, September 2015

Page 3

60-25
Western Star
Service Bulletin

Adding Fasteners to a Cab-to-Sleeper Transition Panel,
5700 Models
Constellation
Heritage
4700 Models

4800 Models
4900 Models
> 5700 Models

5900 Models
6900 Models

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.

Primary Failed Part
A18-67629-XXX

OWL VMRS Codes and Labor Allowance
Component
Cause Code SRT Code
Description
Code
FAIRING, CAB TO SLEEP, ADD
004-008-001
19
792-5001A
FASTENERS (SB60-25)

Time: Hours
1.4

Table 2, OWL VMRS Codes and Labor Allowance

08/14/2015

f602564

Fig. 8, Rivnut Tool That Does Not Require Spacers
08/14/2015

f602559

Fig. 7, Rivnut Tool That Requires Spacers

Page 4

Western Star Service Bulletin, September 2015

Adding Fasteners to a Cab-to-Sleeper Transition Panel,
5700 Models
Constellation
Heritage
4700 Models

4800 Models
4900 Models
> 5700 Models

08/27/2015

5900 Models
6900 Models

f602565

Fig. 9, Installing a Rivnut (tool with spacers)

Western Star Service Bulletin, September 2015

08/14/2015

60-25
Western Star
Service Bulletin

f602567

Fig. 10, Installing a Rivnut (tool without spacers)

Page 5