NHTSA ID Number: 10199446
Manufacturer Communication Number: SBW54-079
TSB/Document Date: 2021-07-26
Summary
Western Star
Service Bulletin for Replacing 104-Way Terminal Wiring Using a Pigtail Kit. This bulletin contains information required to replace 104-way connector wires or terminals using the properly sized pigtail, as documented in the kit listed in the repair portion of the bulletin.
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Constellation
Heritage
4700
4800
4900
54-079
Western Star
Service Bulletin
> 49X
5700
5900
6900
General Information
This bulletin contains information required to replace 104-way connector wires or terminals using the properly
sized pigtail, as documented in the kit listed in the repair portion of the bulletin. See Fig. 1 and Fig. 2 for
examples of the 104-way connector. Before replacing a terminal using pigtail kits, remove the terminals from the
connector following the guidelines in Section 54.00, Subject 140 of the 49X Workshop Manual.
05/10/2021
f547504
Fig. 1, 104-Way Connector, Locked
05/10/2021
f547505
Fig. 2, 104-Way Connector, Unlocked
06/11/2021
f547502
Fig. 3, Label 24-02065-000
NOTE: Service label part number 24-02065-000 should be installed on the chassis-side cover back
shell, as shown in Fig. 3, alerting users to service information within this service bulletin. If the label
is not installed or is unreadable, it should be replaced by ordering part 24-02065-000 through DTNA
Connect:
Western Star Service Bulletin, 07/19/2021
Page 1
54-079
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Western Star
Service Bulletin
Constellation
Heritage
4700
4800
4900
> 49X
5700
5900
6900
• Navigate to the ’DTNA Publications’ page of DTNA Connect.
• Select ’Western Star.’ See Fig. 4.
07/12/2021
f121008
Fig. 4, Western Star
• Select ’Miscellaneous Items.’ See Fig. 5.
07/12/2021
f121009
Fig. 5, Miscellaneous Items
• Locate item 24-02065-000 ’Notice Label sbw_079.’
• Select ’Place an Order.’ See Fig. 6.
Page 2
Western Star Service Bulletin, 07/19/2021
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Constellation
Heritage
4700
4800
4900
54-079
Western Star
Service Bulletin
> 49X
5700
5900
6900
07/12/2021
f121010
Fig. 6, ’Place an Order’ Button
Wiring Repair Instructions
1. Select the appropriate repair pigtail for the terminal size, wire size, seal size, and connector cavity location,
as shown in Fig. 7. Pigtail repair kit AFL DK00001 000 was created to assist with the proper repair and
installation of additional connections at the 104-way connector. Use pigtails when populating unused
cavities, or servicing damaged or defective terminals and seals within the connector. See Table 1 for a list
of parts included in kit AFL DK00001 000.
Western Star Service Bulletin, 07/19/2021
Page 3
54-079
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Western Star
Service Bulletin
Constellation
Heritage
4700
4800
4900
05/05/2021
> 49X
5700
5900
6900
f547489
Fig. 7, Crimping Tool and Kit ESY ES66 404
Location Cavity Position
Cab
Chassis
1–94
98–102
98–102
95, 96, 103, 104
1–94
98–102
98–102
95, 96, 103, 104
Gauge
16T
16T
12T
10T
16T
16T
12T
10T
Pigtail Repair Kit
Terminal Terminal Part
Size
Number
1.2
23-13214-832
2.8
23-13214-752
2.8
23-13214-752
2.8
23-13214-757
1.2
23-13214-822
2.8
23-13214-861
2.8
23-13214-865
2.8
23-13214-866
Parts
Seal Part
Number
23-12497-431
23-12497-411
23-12497-410
23-12497-413
23-12497-431
23-12497-411
23-12497-410
23-12497-413
Wire Part
Number
48-25085-109
48-25085-109
48-25085-309
48-25085-509
48-25085-109
48-25085-109
48-25085-309
48-25085-509
Length
Quantity
(inches)
16
25
8
2
8
2
8
2
16
25
8
2
8
2
8
2
Table 1, Pigtail Repair Kit Parts
1.1
When repairing a terminal/wire using the pigtail kit, select an equal or larger wire size for the repair.
Never install pigtail with a wire size smaller than the original wire being replaced. Additionally only
cavities 95, 96, 103, and 104 can be used for larger 12 and 10 gauge wires. See Fig. 8 and Fig. 9
for examples of cab-side cavity locations. See Fig. 10 and Fig. 11 for examples of chassis-side
cavity locations.
• Small 1.2 terminals are located in cavities 1 to 94, with wire sizes ranging from 22 to 16
gauge.
• Large 2.8 terminals are located in cavities 95 to 104, with wire sizes ranging from 20 to 10
gauge.
Page 4
Western Star Service Bulletin, 07/19/2021
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Constellation
Heritage
4700
4800
4900
54-079
Western Star
Service Bulletin
> 49X
5700
5900
6900
21
63
63
21
1
86
86
1
9
94
94
9
103
95
104
96
05/24/2021
f547529a
95
103
104
96
05/24/2021
Fig. 8, Cab-side Cavity Locations (Front)
Western Star Service Bulletin, 07/19/2021
f547511b
Fig. 9, Cab-Side Cavity Locations (Rear)
Page 5
54-079
Replacing 104-Way Terminal Wiring Using a Pigtail Kit
Western Star
Service Bulletin
Constellation
Heritage
4700
4800
4900
> 49X
5700
5900
6900
21
63
1
86
9
94
95
103
96
104
21
63
86
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TSB/Document ID: SBW54-079
Replacement Service Bulletin Number:
MFR Communication Date: 2021-07-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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