NHTSA ID Number: 10141786
Manufacturer Communication Number: sbw5464
TSB/Document Date: 2018-06-18
Summary
sbw5464 Fuel Level Sending Unit Retrofit
54-64
Fuel Level Sending Unit Retrofit
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
Western Star
Service Bulletin
> 5900 Models
> 6900 Models
Description of Revisions: This bulletin replaces the version dated
May 2017. Instructions for removing the fuel level sender float
have been updated.
General Information
A new improved fuel-level sending unit, manufactured by KUS, is available for retrofitting the fuel-level sending
unit on all Western Star vehicles. No parameter changes are required. A new connector is required for the
retrofit. See Fig. 1.
Refer to Fig. 2 for this procedure.
1
2
10/27/2016
1
f470692
3
UP
4
6
5
7
8
08/23/2016
f470690
The orientation arrow on the unit must point outboard.
1. Zip Tie Anchor Point
2. Receptacle, Chassis-Harness Connector
3. Orientation Arrow
4. Gasket Spacer (5)
5. Gasket Alignment Notch
6. Gasket
7. Float
8. Sensor Tube
Fig. 2, Fuel-Level Sending Unit
Western Star Service Bulletin, 6/20/2017
Page 1
54-64
Western Star
Service Bulletin
Fuel Level Sending Unit Retrofit
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
> 5900 Models
> 6900 Models
Replacement Procedure
1. Park the vehicle on a level surface, shut down the engine, and set the parking brakes. Chock the tires.
2. If needed, remove the side fairing.
3. Disconnect the fuel-level sending unit harness connector.
4. Remove the five fasteners from the flange of the fuel-level sending unit and discard them.
5. Remove and discard the P-clamp from the chassis harness.
6. Lift the fuel-level sending unit out of the hole in the tank.
7. Install the gasket on the new KUS fuel-level sending unit, making sure the "UP" side of the gasket is
against the unit head, and the alignment notch on the sender aligns with notch on the gasket. See Fig. 3.
B
2
A
1
11/09/2016
f470690a
A. Alignment Notch
B. Alignment Tab
Fig. 3, Installing the Gasket
NOTICE
There is only one correct way to install the fuel-level sending unit. The orientation arrow on the top of
the sending unit must point outboard. See Fig. 2, item 3. Incorrect installation will damage the unit, and
possibly the fuel tank, leading to inaccurate fuel-level readings and fuel leaks.
NOTE: If it is necessary to remove the KUS unit once it is in the tank, it may be necessary to lift the
float to the top of the shaft in order to achieve sufficient clearance to remove the unit. A coat hanger
or aluminum welding rod shaped into a hook can be used for this purpose and is the preferred
method. Bend a coat hanger or aluminum welding rod 90 degrees and form a hook at the end 1-inch
Page 2
Western Star Service Bulletin, 6/20/2017
54-64
Fuel Level Sending Unit Retrofit
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
> 5900 Models
> 6900 Models
Western Star
Service Bulletin
long and 1-inch wide as shown in Fig. 4. See Fig. 5 for an example of the hook around the float. A
magnetic retrieval tool can also be used. See Fig. 6 for an example. It may take several attempts to
attach the magnet to the float. Also, if there is limited access, it may be necessary to adjust the cab
height to its maximum.
8. Position the fuel-level sending unit and gasket in the hole in the tank, making sure that the orientation arrow
on the top of the sending unit is pointing outboard. See Fig. 7.
B
A
A
B
06/19/2017
06/19/2017
f470702
A. Bend the coat hanger or welding rod 90 degrees.
B. Form a hook at the end 1-inch long and 1-inch
wide.
f470700
A. Positioning the hook to lift the float.
Fig. 5, Lifting the Float
Fig. 4, Making the Hook Tool
Western Star Service Bulletin, 6/20/2017
Page 3
54-64
Western Star
Service Bulletin
Fuel Level Sending Unit Retrofit
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
> 5900 Models
> 6900 Models
2
1
05/10/2017
1. Magnetic Tool
f546728
2. Float
Fig. 6, Using a Magnetic Tool to Lift the Float
NOTICE
Tapping the screw holes in a new tank requires more torque than the recommended final tightening
torque. The self-tapping fasteners will completely tap the tank wall before they are seated. Failure to
follow the proper procedure will damage the tank and cause leaks.
9. Install new fasteners.
If installing the fuel-level sending unit in a new tank, start all five of the self tapping fasteners through the
tank wall before applying the final tightening torque.
If installing the fuel-level sending unit in a used tank, start all five self tapping screws until contact is made
with the top plate of the fuel-level sending unit. Do not tighten the screws at this time.
NOTICE
Do not over tighten the fasteners. Exceeding the recommended torque specification can strip out the
holes in the tank, requiring tank repair or replacement.
10. Using the tightening sequence shown in Fig. 8, and even progression to distribute the torque evenly around
the fuel-level sending unit, sequentially tighten the screws 15 to 25 lbf·in (160 to 212 N·cm).
NOTE: When attaching the new pigtail, each wire can be connected to either wire of the chassis
harness.
11. Cut the old connector from the fuel-level sending unit harness, and splice the new pigtail to the chassis
harness and the sender receptacle. See Fig. 9.
Page 4
Western Star Service Bulletin, 6/20/2017
54-64
Fuel Level Sending Unit Retrofit
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
Western Star
Service Bulletin
> 5900 Models
> 6900 Models
4
2
1
1
11/02/2016
f470696
The orientation arrow on the unit must point outboard.
1. Orientation Arrow
Fig. 7, Sending Unit Orientation
3
5
11/17/2016
f470697
Tighten the screws in this order.
Fig. 8, Tightening Sequence
12. Connect the harness to the fuel-level sending unit.
13. Secure the harnesses to the sender with a zip-tie. See Fig. 10. Do not use a P-Clamp.
1
10/27/2016
f470693
Fig. 9, New Pigtail Installation
Western Star Service Bulletin, 6/20/2017
11/02/2016
f470695
1. Zip-Tie
Fig. 10, Harness Connected and Secured
Page 5
54-64
Fuel Level Sending Unit Retrofit
Western Star
Service Bulletin
> Constellation
> Heritage
> 4700 Models
> 4800 Models
> 4900 Models
> 5700 Models
> 5900 Models
> 6900 Models
Parts
Parts are available through the PDC.
Tank
22-inch Cylindrical
23-inch Cylindrical
25-inch Cylindrical
Fuel Tanks with Associated Senders and Gaskets
Medallion
SSI Sender (focus
Old Gasket
KUS Gasket *
Angular Sender
tube)
A22-68359-003
N/A
06-95042-000
A22-68419-023
A22-68359-000
(A22-68428-023)
06-94788-000
22-27156-000
A22-68419-025
A22-68359-001
(A22-68428-025)
A22-68359-002
N/A
06-95042-000
26-inch Cylindrical
312 mm
A22-68359-010
N/A
Rectangular
378 mm
A22-68359-011
N/A
Rectangular
C1TF 9276 C
462 mm
A22-68359-012
N/A
Rectangular
407 mm BetweenA22-66426-002
N/A
Rail Steel
Adaptor Harness, Service Only. Converts Medallion to KUS on trucks in the field.
KUS Linear
Sender
66-00939-022
66-00939-023
66-00939-025
66-00939-026
66-00939-312
66-00939-378
06-95042-000
66-00939-462
66-00939-407
A66-06600-000
* Reference only. KUS sensors include gaskets.
Table 1, Fuel Tanks with Associated Senders and Gaskets
Warranty
This bulletin is informational only. Warranty does not apply.
Page 6
Western Star Service Bulletin, 6/20/2017
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: sbw5464
Replacement Service Bulletin Number:
MFR Communication Date: 2018-02-26
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:DELIVERY
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU coding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Programming): Allows for Ford, for Lincoln, and for Mazda ECU programming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- Cost-effective ECU Coding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 3 Years Software Update, Value for Money: With 3 years of software updates and 22+ languages(no IP restrictions), XTOOL D7S auto scanner code scanner ensures ongoing compatibility for the latest car models and improved diagnostic functions. This all system vehicle diagnostic scanner comes with a 30-day return policy and a 24-month repair for dependable performance. XTOOL are dedicated to your satisfaction, so enjoy seamless support and lifetime expert assistance. Should you encounter any issues or concerns, don’t hesitate to reach out XTOOL. D7S with newest update with 22 languages freely transfer without authorization, check details from setting-language or from XTOOL
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.