2017-2020 Western Star Low Max 4900 Car Hauler ATD Inlet Pipe Bellows Assembly

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Subject: ATD Inlet Pipe Bellows Assembly
Models Affected: Specific Western Star 4900 Low Max Car Hauler
Model Year 2017 through 2020 vehicles manufactured from January
1, 2016 to June 31, 2019.
Our records indicate that you are the owner of certain Western Star vehicles, and DTNA has decided to share
the following documentation with you.
Some Western Star Low Max 4900 Car Hauler applications with DD13 GHG17 engines containing bellows pipe
part number 04-32700-000, may experience high failure rates due to cracking at the ATD flange. Western Star
will be providing a modified pipe to mitigate the cracking issue. This pipe modification will be done locally under
the supervision of Transwest Truck, an authorized dealer for Western Star, and/or Western Star Management.
Please see the following documentation for the repair procedure.
Daimler Trucks
North America LLC Field Service Campaign
05/31/2019
CAL WS 49-001
Page 1
Work Instructions
Subject: ATD Inlet Pipe Bellows Assembly
Models Affected: Specific Western Star 4900 Low Max Car Hauler
Model Year 2017 through 2020 vehicles manufactured from January
1, 2016 to June 31, 2019.
ATD Inlet Pipe Bellows Assembly Replacement
IMPORTANT: Exhaust leaks are often due to improperly installed clamps. If a bellows failure is suspected, carefully
inspect the bellows for soot marks. If soot marks are not seen, carefully feel for a leaking exhaust while the
engine is idling.
1. Park the vehicle, apply the parking brakes, and shut down the engine. Chock the tires.
2. Disconnect the batteries.
WARNING
Aftertreatment Device (ATD) internal temperatures can remain hot enough to cause personal injury, or
ignite combustible materials, for hours after the engine is shut down.
To avoid potentially serious burns or material damage:
• Let the ATD cool before handling it; be especially careful when opening it to expose the DPF.
• Wear appropriate protective gear.
• Be careful not to place the ATD where flammable gases or other combustible materials may come into
contact with hot interior parts.
3. Allow the exhaust system to cool before working on it.
4. Remove the inner fender/splash shield.
5. Remove the spherical clamp at the turbocharger outlet pipe. Discard the clamp and gasket.
6. Remove the spherical clamp at the ATD inlet. Discard the clamp and gasket.
7. On DD13 engines only, remove the turbocharger outlet pipe support bracket clamp, if equipped. Save the
clamp for reuse.
8. On DD13 engines only, remove the ATD inlet pipe support bracket clamp, if equipped. Save the clamp for
reuse.
9. On DD13 engines only, if needed to make clearance, remove the ATD inlet pipe support bracket from the
frame rail.
10. Remove the bellows and ATD inlet pipe as an assembly. See Fig. 1.
Daimler Trucks
North America LLC Field Service Campaign
05/31/2019
CAL WS 49-001
Page 2
NOTE: Always use new exhaust pipe clamps and gaskets when installing exhaust system components.
11. Position the new bellows and the ATD inlet pipe assembly on the vehicle.
12. Install the new spherical clamp and gasket at the ATD inlet. Do not tighten at this time.
13. Install the new spherical clamp and gasket at the bellows-to-turbocharger outlet pipe connection. Do not
tighten at this time.
14. On DD13 engines only, install the ATD inlet pipe support bracket clamp. Do not tighten at this time.
15. Using a straight edge, align the bellows, the ATD inlet pipe, and the turbocharger outlet pipe. Check from
at least two positions about 90 degrees apart. All three components should form a straight line through the
connections.
16. Tighten the spherical clamp at the turbocharger outlet pipe connection as follows.
16.1 Tighten the nut 126 to 138 lbf·in (1425 to 1560 N·cm).
16.2 Using a plastic or rubber mallet, tap around the outside of the clamp to seat the clamp against the
pipe.
16.3 Tighten the nut a second time 126 to 138 lbf·in (1425 to 1560 N·cm).
05/30/2019 f490546
1
2 3
4
5
6
7
7
8
8
9
10
1. Clamp-5″ Spherical
2. Gasket-5″ Spherical
3. Clamp-4″ Spherical
4. Gasket-4″ Spherical
5. Tube-W/Bellows, DD13, LOWMAX
6. Bracket-ATS
7. Screw
8. Nut
9. Bracket-Support
10.Clamp, W/T-Bolt
Fig. 1, Bellows Assembly
Daimler Trucks
North America LLC Field Service Campaign
05/31/2019
CAL WS 49-001
Page 3
17. Tighten the spherical clamp at the ATD inlet connection as follows.
17.1 Tighten the nut 126 to 138 lbf·in (1424 to 1560 N·cm).
17.2 Using a plastic or rubber mallet, tap around the outside of the clamp to seat the clamp against the
pipe.
17.3 Tighten the nut a second time 126 to 138 lbf·in (1424 to 1560 N·cm).
18. On DD13 engines only, tighten the turbocharger outlet-pipe support bracket clamp 24 lbf·ft (32N·m).
19. On DD13 engines only, tighten the ATD inlet pipe support bracket clamp 24 lbf·ft (32 N·m).
20. Start the engine and check for leaks. Further tighten the clamps on any leaking connections as needed.
21. Install the inner fender/splash shield.
Parts
Parts are available at the PDCs. See Table 1 for required parts.
Required Parts
Part Number Description Qty.
TCXT130158342AB2 CTRL
ROD-TRNSV,635MM,TAPER PIN
1
TCXFMS190 BRKT,TORQUE ROD SUSP 1
TCXT130130349AB2 CLAMP-4″ SPHERICAL 1
TCXFMS191 GASKET-4″ SPHERICAL 1
04-32700-000* TUBE-W/
BELLOWS,DD13,LOWMAX
1
23-11007-100 SCREW-FLG,HEXAGON,3/
8-16,PO
2
23-13861-106 NUT-HEX,FLNG,LKG,3/8-16,ZN
AL
2
04-20164-000 CLAMP,T-BOLT,4 INCH 1
* Use the part modified by Transwest until A04-35135-000 is available
Table 1, Required Parts
Daimler Trucks
North America LLC Field Service Campaign
05/31/2019
CAL WS 49-001
Page 4

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