sbw5464 Service Bulletin/Repair Instructions

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
Fig. 1, New Connector Pigtail
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

SaleBestseller No. 1

TOPDON Bidirectional Scan Tool, 2026 New ArtiDiag900 Lite Automotive Diagnostic Tool for Full System, Scanner for Car with Active Test, 8 Reset, Wireless OBD2 Scanner Diagnostic Tool for All Vehicles

[2026 Top-Tier Hardware and Software Upgrade]: Topdon ArtiDiag900 Lite scanner has enhanced hardware and latest features, including Android 11.0, 5x faster CPU, 10000mAh battery for 12 hours of continuous operation, stable wireless diagnosis with Bluetooth 5.0, 8-inch touchscreen. Added bi-directional control, wireless diagnosis, battery testing (optional), and DTC repair guide
[TOPDON Bidirectional Scan Tool]: This bidirectional obd2 scanner sends commands to the vehicle's ECU for active testing, enabling users to accurately and quickly locate faulty components such as injectors, coolant pumps, windows, wipers, headlights, mirrors, etc. The bidirectional control scanner is the ideal choice for workshops/automotive repair shops as it significantly reduces mechanic's diagnostic time.
[Wireless Bluetooth Diagnostic Experience]: The AD900 Lite scan tool comes with a Bluetooth 5.0 VCI, supporting a wireless diagnostic range of up to 33 feet (10 meters), allowing you to diagnose without being confined to cables or tight spaces. Stable and fast wireless diagnosis provides a comfortable repair environment. It also offers VCI cables to increase connectivity options.
[DTC Repair Guide Function]: Easily diagnose issues with your vehicle and receive guidance on repairs with the topdon scan tool's fault code definitions for all systems,maximize your diagnostic capabilities. This function is compatible with Chrysler/Dodge/Jeep/Fiat 2010-2014 and expanding with continual updates,the AritDiag 900 Lite car diagnostic scanner is the must-have tool for any technician or DIY enthusiast.
[OE-Level Full System Diagnostics]:AritDiag900 Lite full system diagnostic scanner can scan ALL available modules(Engine, Transmission, Airbag, ABS, ESP, TPMS, Gateway, Steering, Radio, Air conditioning, ect.) to✔read ECU info, ✔read/clear codes, ✔view live data stream, ✔retrieves freeze-frame, ✔perform active tests, and more. With just a simple click, it provides you with accurate and in-depth diagnostics.

SaleBestseller No. 2

TOPDON ONE Bidirectional Scan Tool, 10.1" OBD2 Scanner with J2534 Pass-Thru and ECU Coding, Over 50 Resets, Topology Mapping Car Diagnostic Tool for All Vehicles

Dual WiFi & 10.1" Touchscreen: Provides a stable, high-speed wireless link 3x faster than bluetooth, and a responsive, professional interface. Topdon ONE obd2 scanner diagnostic tool ensures smooth, non-lagging diagnostic scan, boosting mechanic efficiency
J2534 Pass-Thru Support: The included ONE VCI supports the J2534 standard, allowing it to function as a pass-thru device when paired with OEM diagnostic software.Through TOPDON’s RLink platform, technicians can perform dealer-level coding, expanding in-house capabilities without investing in multiple factory automotive scan tools
OE Topology Mapping: Visualize the vehicle’s ECU network exactly as it’s built.Zoom, pan, and highlight specific modules to pinpoint component issues with precision.Topology mapping displays real-time communication between modules
Topfix AI Assistant: Covers 5 million plus fault codes and delivers instant causes, symptoms, and repair guidance with professional wiring diagrams for each code.Slashes diagnostic time, boosts first-time fix accuracy, and increases shop revenue
50 Plus Service Functions: Covers high-demand services like ADAS calibration, DPF regen, TPMS reset, ABS bleed, and throttle adaptation.Expands your service menu, allows you to charge premium rates, and turns away zero jobs due to lack of tooling. Vehicle-specific functionality may vary.

SaleBestseller No. 3

TOPDON TopScan Lite OBD2 Scanner Bluetooth, Bi-Directional Scanner Wireless All System Diagnostic Tool for iOS & Android, 8+ Hot Reset, Repair Guides, Check Engine Car Code Reader, Performance Test

Bi-Directional Control, Quickly Locate Problems: Turn your phone into a professional diagnostic tool. You can send commands from your phone to the ECU to test injectors, cooling fans, headlights, A/C clutch, windows, wipers, and more. See which one doesn't respond. Helps you quickly locate the problem and save time. No need to tear things apart, avoid blind disassembly.
Full System Diagnostics, No Fault Hides: Unlike basic diagnostic tools that only cover 4 systems, TopScan can scan all systems. Read and clear trouble codes, view live data streams, and generate a complete vehicle health report – all issues are clear at a glance. Covers 10,000+ vehicle models and is compatible with 99.99% of vehicles.
Flexible Subscription, Choose Advanced Features as Needed: TopScan Lite provides free-for-life access to core diagnostics, including full system scan, code reading, performance tests, and repair information. After purchase, advanced features (bi-directional control, service operations, live data, code clearing, and AI functions) are free-for-the-first-year. After the first year, if you want to use advanced features, you need to subscribe on a monthly, quarterly, or yearly basis. As new models and reset functions are updated, the tool will also be continuously upgraded.
AI Assistant - TopFix: Think of TopFix as your personal AI mechanic. It leverages a repair database and OEM data to deliver clear, step-by-step repair solutions. Features include AI Q&A, one-click translation, and a full repair log, making your diagnostic process simpler and more efficient.
8+ Hot Resets, Keep Your Car in Top Shape: One-tap resets for oil, throttle, EPB, steering angle, DPF, ABS, BMS, and airbag. It enables car owners to easily perform essential maintenance, ensuring the vehicle stays in optimal condition and extends its service life.

This product presentation was made with AAWP plugin.

Last update on 2026-05-12 / Affiliate links / Images from Amazon Product Advertising API

Buffer Email Facebook Flipboard Hacker News LinkedIn Messenger Mix Pinterest Print Reddit SMS Telegram Tumblr X VK WhatsApp Line Xing Threads Bluesky Copy Mastodon Nextdoor