NHTSA ID Number: 10130383
Manufacturer Communication Number: sbw2026
TSB/Document Date: 2018-03-13
Summary
Surge Tank Deaeration Hose Routing
20-26
Surge Tank Deaeration Hose Routing
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
5700 Models
5900 Models
6900 Models
Western Star
Service Bulletin
General Information
Interference between the hood insulation, the surge-tank deaeration hose, and the engine air-intake plenum has
been reported on some Western Star 4800 and 4900 models, with Detroit engines, built between start of
production and June 15, 2015. This interference may cause a leak or damage to the affected components.
The hose routing has been revised at the manufacturing plant to address this issue. There are no part number
changes. If a leak or rubbing issue is found, follow the instructions below to repair and reroute the hose. The
replacement hose will be longer to accommodate the new routing.
Use PartsPro by serial number to identify the hose to order, and view the installation diagram. Refer to Table 1
for the installation diagram new dash number.
Surge-Tank Deaeration Hose Configurations by Vehicle
Old Installation
New Installation
Model
Engine
Diagram
Diagram
4800 109 BBC
DD13
D05-23021-000
D05-23021-001
4800 109 AWD
DD13
D05-29340-000
D05-29340-001
4900 123 BBC
DD15
D05-30192-000
D05-30192-002
4900 123 BBC
DD15
D05-30192-001
D05-30192-003
4900 132 BBC
DD15
D05-30193-000
D05-30193-001
4800 109 BBC
DD13
D05-30194-000
D05-30194-002
4900 123 BBC
DD13
D05-30194-001
D05-30194-003
4800 109 BBC
DD13
D05-30195-000
D05-30195-002
4900 123 BBC
DD13
D05-30195-001
D05-30195-003
4900 123 BBC
DD15
D05-31184-000
D05-31184-002
4900 123 BBC
DD15
D05-31184-001
D05-31184-003
Table 1, Surge-Tank Deaeration Hose Configurations by Vehicle
Replacement
1. Park the vehicle on a level surface, shut down the engine, and set the parking brakes. Chock the tires.
2. Inspect the routing and condition of the surge-tank deaeration hose and adjacent components; check for
coolant leaks, rubbing on adjacent parts, and if the hose is routed over the engine air-intake plenum. If any
of these conditions are found, proceed to the next step.
WARNING
Do not attempt to drain the cooling system until the coolant and engine are cool. Draining the cooling
system prior to system cooling could cause severe personal injury due to scalding.
3. Drain the cooling system enough to remove any coolant from the deaeration hose.
4. Remove the original hose and discard it.
5. Install the new hose. Route the new hose under the engine air-intake plenum and to the surge tank. Use
available clipping locations as needed. Refer to Fig. 2 for typical new hose routing.
6. Inspect the intake air plenum near the deaeration hose for damage. Repair or replace as needed.
7. Inspect the hood insulation in the area of the deaeration hose for damage. Repair or replace as needed.
Western Star Service Bulletin, December 2015
Page 1
20-26
Surge Tank Deaeration Hose Routing
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
5700 Models
5900 Models
6900 Models
3
2
1
08/25/2015
1. Deaeration Hose
f200862
2. Engine Air-Intake Plenum
3. Surge Tank
Fig. 1, Old Deaeration Hose Routing (typical)
8. Add coolant to the engine cooling system as needed.
Page 2
Western Star Service Bulletin, December 2015
20-26
Surge Tank Deaeration Hose Routing
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
5700 Models
Western Star
Service Bulletin
5900 Models
6900 Models
3
2
1
08/25/2015
f200863
Route the new hose under the engine air-intake plenum.
1. Deaeration Hose
2. Engine Air-Intake Plenum
3. Surge Tank
Fig. 2, New Deaeration Hose Routing (typical)
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.
Western Star Service Bulletin, December 2015
Page 3
20-26
Surge Tank Deaeration Hose Routing
Western Star
Service Bulletin
Primary Failed Part
All
05-15440-051
Constellation
Heritage
4700 Models
> 4800 Models
> 4900 Models
5700 Models
5900 Models
6900 Models
OWL VMRS Codes and Labor Allowance
Component
Cause Code SRT Code
Description
Code
042-002-061
9
27H-5000B Deaeration Line, Surge Tank, Inspect
Time: Hours
0.1
05-15440-056
05-15440-060
05-15440-065
05-15440-069
05-15440-070
05-15440-075
05-15440-085
05-16832-049
05-16832-056
042-002-061
9
27H-5000A
Deaeration Line, Surge Tank, Replace
and Reroute
0.6
05-16832-057
05-16832-060
05-16832-061
05-16832-065
05-16832-067
05-16832-069
05-16832-070
05-16832-072
05-16832-082
Table 2, OWL VMRS Codes and Labor Allowance
Page 4
Western Star Service Bulletin, December 2015
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TSB/Document ID: sbw2026
Replacement Service Bulletin Number:
MFR Communication Date: 2015-12-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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