Repairing a Harness Wrapped in Fiber
IMPORTANT: Do not use a hook razor blade to cut fiber wrap. Use a sewing seam ripper to cut the
fiber tape ( Fig. 8), taking care not to cut the harness wires.
1. Locate damaged area and carefully make an opening in the fiber wrap using a sewing seam ripper. See
Fig. 10.

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Western Star Service Bulletin, 02/04/2020

Guidelines for Repairing or Replacing an Electrical Harness
> Constellation
> Heritage
> 4700 Models
> 4800 Models

> 4900
> 5700
> 5900
> 6900

Western Star
Service Bulletin

Models
Models
Models
Models

01/21/2020

54-061

f547094

11/08/2019

Fig. 7, Harness Wrapped with TwistTube®

f547053

Fig. 8, Sewing Seam Ripper

2. Flip the tool over so the blunt end is facing wiring, then cut enough length to allow the fiber to be
unwrapped. See Fig. 9.

11/08/2019

f547054

Fig. 9, Cutting an Opening into the Fiber Wrap

11/08/2019

f547055

Fig. 10, Cutting the Fiber Using the Blunt End of the
Seam Cutter

3. Unwrap the fiber until a sufficient area is exposed to make the repair. See Fig. 11.
4. If an overlay is necessary, remove just enough fiber to allow for a splice into the damaged wire. See Fig.
12.

Western Star Service Bulletin, 02/04/2020

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54-061

Guidelines for Repairing or Replacing an Electrical Harness

Western Star
Service Bulletin

> Constellation
> Heritage
> 4700 Models
> 4800 Models

02/16/2015

f546139

Fig. 11, Unwrapping the Harness

> 4900
> 5700
> 5900
> 6900

Models
Models
Models
Models

02/16/2015

f546143

Fig. 12, Overlay Added to the Damaged Area of the
Harness

5. Overlay the wire, then wrap the entire length to cover the overlay and integrate it with the harness.
6. Repair the wire as necessary. See Fig. 13.

02/16/2015

f546142

Fig. 13, Wire Repaired with Shrink Tubing

7. Wrap the harness with fiber tape. Refer to Table 5. Make sure enough tape is used to overlap the starting
point. See Fig. 14.
8. When the harness is completely wrapped, secure both ends of the fiber wrap with electrical tape. See Fig.
15.

Page 8

Western Star Service Bulletin, 02/04/2020

Guidelines for Repairing or Replacing an Electrical Harness
> Constellation
> Heritage
> 4700 Models
> 4800 Models

> 4900
> 5700
> 5900
> 6900

54-061
Western Star
Service Bulletin

Models
Models
Models
Models

1

02/16/2015

f546136

1. Fiber Wrap Secured with Electrical Tape
02/16/2015

f546144

Fig. 15, Fiber Wrap Secured with Electrical Tape

Fig. 14, Wrapping the Harness with Fiber Tape

Terminal Drag Test
A drag test is performed between a single male and female terminal to determine if the engagement and
retention forces between them are sufficient. Individual terminals that fail the drag test can be replaced. If the
repair causes the wire to be pulled tight, or results in tension at the connector, a short piece of wire and new
terminal can be added to reduce the tension. Otherwise, all terminals must be replaced.
1. Perform a drag test on a known good terminal pair.
1.1

Select a mating female and male terminal pair that have the same part numbers as the affected
female and male terminal pair.

1.2

Manually insert, and then remove, the test mating male terminal into the test female terminal three
times. On the known good test terminal pair, the mating terminal will fit securely when inserted into
the terminal in the connector. There will be significant resistance (drag) when the mating terminal is
removed.

2. Compare the amount of resistance to the affected terminal pair by performing the same test on the affected
terminal pair. If the mating terminal does not have the same resistance as the good terminal pair, the
terminal pair and the seals (if required) should be replaced.

Parts
Repair wires using a Daimler splice kit ESY ES66 404, or Phillips STA-DRY Crimp and Solder Connectors
Parts.
See Table 4 for a list of STA-DRY solderless connector parts.
See Table 5 for polyester cloth tape part numbers.
See Table 6 for TwistTube® part list.
See Table 7 for sewing seam ripper tool part number.

Western Star Service Bulletin, 02/04/2020

Page 9

54-061

Guidelines for Repairing or Replacing an Electrical Harness

Western Star
Service Bulletin

> Constellation
> Heritage
> 4700 Models
> 4800 Models

Wire Size: gauge (mm)
20 to 18 (0.5 to 0.8)
16 10 14 (1 to 2)
12 to 10 (3 to 5)
8 or larger (5 or larger)

> 4900
> 5700
> 5900
> 6900

Models
Models
Models
Models

Phillips STA-DRY Crimp and Solder Connectors Parts
Connector Part
Shrinkable Tubing (Daimler Part Number)
Number*
PHM 1 1863
1/4 inch with internal adhesive coating (48-02461-025)
PHM 1 1862
1/4 inch with internal adhesive coating (48-02461-025)
PHM 1 1861
3/8 inch with internal adhesive coating–4 foot length (48-02461-038)
Replace the terminal or Use adhesive lined red for positive cables and black for negative
the entire cable
cables.

* Twenty-five connectors per pack.

Table 4, Phillips STA-DRY Crimp and Solder Connectors Parts
Tape—Polyester Cloth, Adhesive Backed
Roll Length
Width
82 feet (25 meters)
0.75 inch (19 mm)
82 feet (25 meters)
1 inch (25 mm)
82 feet (25 meters)
2 inches (50 mm)

Part Number
48-25910-002
48-25910-003
48-25910-004

Table 5, Tape—Polyester Cloth, Adhesive Backed
DTNA P/N

DTNA Description

48-26131-000

Tube-TwistTube®,
PES,BK,DIA5
Tube-TwistTube®,
PES,BK,DIA8
Tube-TwistTube®,
PES,BK,DIA13
Tube-TwistTube®,
PES,BK,DIA19
Tube-TwistTube®,
PES,BK,DIA25
Tube-TwistTube®,
PES,BK,DIA38
Tube-TwistTube®,
PES,BK,DIA51

48-26131-001
48-26131-002
48-26131-003
48-26131-004
48-26131-009
48-26131-011

Vendor (Bentley
Harris / Federal Mogul
Wrap Part 2420) P/N
BEN 2421000503SCM

Reference
Diameter

DTNA Recommended Bundle Size
Min
Max

5 mm

1 mm_18GA Wire

6 mm_1/4"

BEN 2421000803SCM

8 mm

6 mm_1/4"

9 mm_3/8"

BEN 2421001303SCM

13 mm

8 mm_5/16"

14 mm_9/16"

BEN 2421001903SCM

19 mm

14 mm_9/16"

22 mm_7/8"

BEN 2421002503SCM

25 mm

21 mm_13/16"

31 mm_1 1/4"

BEN 2421003803S

38 mm

31 mm_1 1/4"

45 mm_1 3/4"

BEN 2421005103S

51 mm

45 mm_1 3/4"

60 mm_2 3/8"

Table 6, TwistTube® Chart
Tool Part Number
DKI0CHA17002-13

Description
Sewing Seam Ripper Tool

Table 7, Sewing Seam Ripper Tool

NOTE: The tool part number DKI0CHA17002-13 is a part of the tool kit DDE DKI0CHA17001. For
more information refer to Tool Letter 18TL-3.

Page 10

Western Star Service Bulletin, 02/04/2020

Guidelines for Repairing or Replacing an Electrical Harness
> Constellation
> Heritage
> 4700 Models
> 4800 Models

> 4900
> 5700
> 5900
> 6900

Models
Models
Models
Models

54-061
Western Star
Service Bulletin

Warranty
This is an informational bulletin. Warranty does not apply.

Western Star Service Bulletin, 02/04/2020

Page 11