NHTSA ID Number: 10181051
Manufacturer Communication Number: SBW54-076
TSB/Document Date: 2020-10-12
Summary
Western Star
Service Bulletin for Connecting the Chassis Harness Connector to the Cab Front Wall 104-Way Pass-Through Connector. This bulletin describes how the chassis harness connector functions and how to verify the four locks of the terminal stabilizer plate on the 104-way pass-through connector are in pre-stage position. The terminal stabilizer plate is the white plastic plate located inside the 104-way pass-through connector. The stabilizer plate floats up and down in the pass-through connector to protect the terminals from being damaged when the chassis harness connector is removed and connected.
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Constellation
Heritage
4700 Models
4800 Models
4900 Models
54-076
Western Star
Service Bulletin
> 49X Models
5700 Models
5900 Models
6900 Models
General Information
The chassis harness connector in the Western Star 49X (see Fig. 1) connects to a 104-way pass-through
connector (see Fig. 2) at the cab front wall.
This bulletin describes how the chassis harness connector functions and how to verify the four locks of the
terminal stabilizer plate on the 104-way pass-through connector are in pre-stage position. The terminal stabilizer
plate is the white plastic plate located inside the 104-way pass-through connector. The stabilizer plate floats up
and down in the pass-through connector to protect the terminals from being damaged when the chassis harness
connector is removed and connected.
If the locks on the terminal stabilizer plate are not in pre-stage position, they can be manually reset using tool
DK10CHA17002-12 (see Fig. 3).
The terminal stabilizer plate locks need to be in pre-stage position before engaging the chassis harness
connector.
08/10/2020
f547306
Fig. 1, Chassis Harness Connector
1
09/14/2020
f547332
1. Red Ring Clip in Locked Position
Fig. 2, 104-Way Pass-Through Connector
Western Star Service Bulletin, 10/05/2020
Page 1
54-076
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
4800 Models
4900 Models
09/23/2020
> 49X Models
5700 Models
5900 Models
6900 Models
f547338
Fig. 3, Tool for Resetting the Terminal Stabilizer Plate
Locks
How the Connectors Engage
The four terminal stabilizer plate locks located in the 104-way pass-through connector release a sliding lock
feature on the chassis harness connector that allows the chassis harness connector’s lever to move up and lock
into position. This ensures the connectors are fully engaged.
When the chassis harness connector is removed from the pass-through connector, the stabilizer plate should be
up, away from the front wall of the cab. This protects the terminals from damage when the chassis harness
connector is reconnected.
If the terminal stabilizer plate is not up, the four terminal stabilizer plate locks will not engage and release the
sliding locking feature in the chassis harness connector. This means that the lever on the chassis harness
connector will not move upward and therefore that the harness connector and the pass-through connector will
not fully engage.
Do the following to make sure the connectors fully engage.
1. Ensure none of the terminals in the 104-way pass-through connector are bent.
2. Ensure the red ring clip is in the locked position, with space between the bottom of the 104-way passthrough connector and the ring clip. See Fig. 2 and Fig. 4.
Page 2
Western Star Service Bulletin, 10/05/2020
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Constellation
Heritage
4700 Models
4800 Models
4900 Models
54-076
Western Star
Service Bulletin
> 49X Models
5700 Models
5900 Models
6900 Models
09/23/2020
f547335
Fig. 4, Ring Clip in Locked Position
3. Ensure the terminal stabilizer plate in the 104-way pass-through connector is fully lifted. Terminal exposure
should be minimal as shown in Fig. 5 and all four stabilizer plate locks should be in the pre-stage position
as shown in Fig. 6.
Western Star Service Bulletin, 10/05/2020
Page 3
54-076
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
4800 Models
4900 Models
> 49X Models
5700 Models
5900 Models
6900 Models
A
08/21/2020
f547315
Fig. 5, Minimal Terminal Exposure
08/21/2020
f547314
Fig. 6, Stabilizer Plate Lock in Pre-Stage Position
4. If the locks are not in the pre-stage position, manually lift up the terminal stabilizer plate. See Fig. 7 and
Fig. 8.
Page 4
Western Star Service Bulletin, 10/05/2020
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Constellation
Heritage
4700 Models
4800 Models
4900 Models
54-076
Western Star
Service Bulletin
> 49X Models
5700 Models
5900 Models
6900 Models
09/23/2020
f547337
Fig. 8, Using the Hook to Lift the Stabilizer Plate into
Pre-Stage Position
09/23/2020
f547336
Fig. 7, Hook on Tool DK10CHA17002-12
5. Move the chassis harness connector lever into the fully released position. The unlocked lever will fit over a
plastic tab on the plug body. See Fig. 9.
Western Star Service Bulletin, 10/05/2020
Page 5
54-076
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
4800 Models
4900 Models
> 49X Models
5700 Models
5900 Models
6900 Models
2
1
08/11/2020
f547308
1. Tab for Fully Released Lever
2. Locked Neck Cover Lock
Fig. 9, Chassis Harness Connector Lever in Fully
Released Position
6. Ensure the chassis harness connector is parallel with the 104-way pass-through connector as shown in Fig.
10 and Fig. 11. This will align the top and bottom guide tracks on the 104-way pass-through connector with
the guide covers on the chassis harness connector. See Fig. 11.
Page 6
Western Star Service Bulletin, 10/05/2020
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Constellation
Heritage
4700 Models
4800 Models
4900 Models
54-076
Western Star
Service Bulletin
> 49X Models
5700 Models
5900 Models
6900 Models
1
1
2
09/15/2020
f547309
1. Chassis Harness Connector Parallel to 104-Way
Pass-Through Connector—Top View
2. Guide Cover Aligned with Guide Track—Top View
08/11/2020
f547310
1. Chassis Harness Connector Parallel to 104-Way
Pass-Through Connector—Side View
Fig. 11, Top View of Parallel Connectors
Fig. 10, Side View of Parallel Connectors
7. Press the chassis harness connector firmly and evenly against the 104-way pass-through connector. The
pressure will release the sliding lock feature from its pre-state position, unlocking the chassis harness
connector lever.
8. Move the chassis harness lever upwards to fully engage and lock the connectors. A locked lever will snap
into place on the tab at the top of the chassis harness connector body. See Fig. 12.
Western Star Service Bulletin, 10/05/2020
Page 7
54-076
Connecting the Chassis Harness Connector to the Cab
Front Wall 104-Way Pass-Through Connector
Western Star
Service Bulletin
Constellation
Heritage
4700 Models
4800 Models
4900 Models
> 49X Models
5700 Models
5900 Models
6900 Models
A
08/11/2020
f547311
A. Move the lever upwards to fully engage the
connectors.
Fig. 12, Locked Connectors
Warranty
This is an informational bulletin only. Warranty does not apply.
Page 8
Western Star Service Bulletin, 10/05/2020
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TSB/Document ID: SBW54-076
Replacement Service Bulletin Number:
MFR Communication Date: 2020-10-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
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