1

94

9

103

95
96

104
05/24/2021

f547534a

Fig. 10, Chassis-Side Cavity Locations (Front)

05/24/2021

f547530a

Fig. 11, Chassis-Side Cavity Locations (Rear)

2. Cut off the wire or terminal being replaced. The cut point should be within the length of the new pigtail wire
length, and allow for staggered location of butt splices when multiple pigtails are being installed, in order to
reduce overall harness bundle size.
3. Select the appropriate butt splice size based on the wire sizes being connected. See Table 2 and Fig. 12.
Crimp and Solder Connector Parts
Description
STA-DRY™ Yellow splice
STA-DRY™ Blue splice
STA-DRY™ Red splice
STA-DRY™ Yellow/Blue step-down splice
STA-DRY™ Blue/Red step-down splice
DTNA Butt Splice Kit

Part Number

Gauge

PHM 1 1861
PHM 1 1862
PHM 1 1863
PHM 1 1727
PHM 1 1728
ESY ES66 404

10–12
14–16
18–22
10/12-14/16
14/16-18/22
14–16

Package
Quantity
25
25
25
10
10
50

Table 2, Crimp and Solder Connector Parts

Page 6

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

05/18/2021

f547531

Fig. 12, STA-DRY™ Butt splices

4. Two repair procedures are outlined below. One is for wire repair using kit ESY ES66 404. The other is for
repairs using Phillips STA-DRY® Crimp and Solder Connectors. Choose and follow a procedure appropriate
for the type of crimp or solder butt connector used. During the heat-shrink process, fully shrink both sides of
the tubing to the wire, in order to completely seal the connection from moisture and corrosion. For external
wire repairs on the chassis-side connector, always apply two layers of shrink tube for added moisture and
corrosion protection.
Failure to properly crimp, solder, heat-shrink, or seal the pigtail butt connector could result in poor wiring
connections and sealing. This will cause inadequate electrical continuity, or moisture and corrosion, which
will degrade the quality of the wiring connection. See Fig. 13 and Fig. 14 for examples of improper seals.

05/05/2021

Fig. 13, Incorrectly Sealed Solder Sleeve

f547497

05/05/2021

f547501

Fig. 14, Incorrectly Sealed Splice Connector

Wiring Repair Using Daimler Trucks North America (DTNA) Kit ESY
ES66 404
1. Prepare the wires to be spliced by stripping the insulation to expose 1/4 inch of copper, as shown in Fig.
15. Slide a piece of the shrink tubing onto one of the wires.

Western Star Service Bulletin, 07/19/2021

Page 7

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

f547490

Fig. 15, Tube Sleeve, Solder Sleeve, Barrel Connector,
and Prepared Wires

2. Slide a shrinkable solder sleeve onto one of the wires.
3. Place the wires that will be spliced into each end of the barrel connector.
4. Crimp each end of the barrel using a dimple-type crimp tool DKI0CHA17003-3 or a similar tool, to secure
the wires. See Fig. 16.

05/05/2021

f547491

Fig. 16, Crimping With DKI0CHA17003-3 or Similar Tool

5. Pull test the wires by hand to ensure the crimp is mechanically solid.
6. Slide the shrinkable solder sleeve onto the barrel connector, so the solder band is at the center of the barrel
connector.
7. Heat the splice using a heat gun rated at 250°F (121°C), as shown in Fig. 17, until the sleeve has
completely shrunk against the wire and the solder flows into the barrel connector. A small fillet of adhesive
may be visible at the ends of the connector. See Fig. 18.

Page 8

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

05/05/2021
05/05/2021

f547493

f547492

Fig. 18, Correctly Heated Solder Sleeve
Fig. 17, Heating the Solder Sleeve

8. Slide the shrinkable tubing over the splice and apply heat with a heat gun rated at 250°F (121°C), as shown
in Fig. 19, until it has completely shrunk against the wire insulation, as shown in Fig. 20. A small fillet of
adhesive should be visible at the ends of the shrinkable tubing. See Fig. 21.

05/05/2021

f547494

Fig. 19, Heating the Tube Sleeve

Western Star Service Bulletin, 07/19/2021

05/05/2021

f547495

Fig. 20, Sealed Tube Sleeve

Page 9

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

f547496

Fig. 21, Tube Sleeve with Adhesive

Wiring Repair Using Phillips STA-DRY® Crimp and Solder
Connectors
1. Prepare the wires to be spliced by stripping the insulation to expose 1/4 inch of copper. See Fig. 22. Slide a
3-inch section of adhesive coated shrink tubing onto one of the wires.

05/05/2021

f547498

Fig. 22, Sta-DRY Connector, Prepared Wires, and
Crimping Tool

2. Crimp the splice connector onto the wires. Use a dimple-type crimp tool DKI0CHA17003-3 or a similar tool
to crimp the connector, as shown in Fig. 23. The dimple must be at least 3/16 inch wide or there will be too
much space inside the connector and the solder will not flow into the wire. This crimp provides the
mechanical retention needed.

Page 10

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

05/06/2021

f547491a

Fig. 23, Crimping With DKI0CHA17003-3 or a Similar
Tool

3. Pull test the wires by hand to ensure the crimp is mechanically solid.

NOTE: A crimp tool that is too narrow will leave excessive air gaps in the crimp. The connection will
not have the required amount of mechanical strength and the solder will not bond the wire to the
connector.
4. Heat the properly crimped splice connector with a heat gun rated at 250°F (121°C) while slowly rotating the
wire. The solder will take longer to flow than it will for the shrinkable insulation to contract. Heat until the
solder band has completely melted into the connector. See Fig. 24. If the shrinkable insulation ruptures and
a small amount of solder bubbles out, gently shake the splice to remove the solder.

05/05/2021

f547499

Fig. 24, Sealed Splice Connector

Western Star Service Bulletin, 07/19/2021

Page 11

54-079

Replacing 104-Way Terminal Wiring Using a Pigtail Kit

Western Star
Service Bulletin

Constellation
Heritage
4700
4800
4900

> 49X
5700
5900
6900

5. When the connector has cooled, center the shrinkable tubing over the splice and heat the tubing, as shown
in Fig. 25, until it has completely sealed the splice and a small fillet of adhesive is visible at the ends of the
shrink tube. See Fig. 26.

05/05/2021

f547494a

05/05/2021

Fig. 25, Heating the Tube Sleeve

f547495a

Fig. 26, Sealed Tube Sleeve

Cavity Plug Seals
To ensure that no moisture or debris enters the connector, all empty cavities (cavities that do not contain a
sealed wire) must be plugged. Use cavity plugs to fill all empty cavities. See Table 3 for a list of cavity seal part
numbers.

Location
Chassis

Cavity Plug Seals
Cavity Position
Plug Size
1–94
1.2S–small
98–102
1.5S, 2.5S–medium
95, 96, 103, 104
2.8S–large

Part Number
23-13218-070
23-13218-100
23-13218-102

Table 3, Cavity Plug Seals

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

Page 12

Western Star Service Bulletin, 07/19/2021