CALWS15-001

Daimler Trucks
North America LLC
Customer Advisory Letter
9/20/2019
CAL WS 15-001
Subject: Alison Flex Plate Mounting Bolts
Models Affected: Western Star 4700 and 4900 Model Year 2020
Our records indicate that you are the owner of certain vehicles, and DTNA has decided to share the following
documentation with you.
Please see the attached communication in this email. We hope you find this information helpful.
Page 1
Daimler Trucks
North America LLC
Customer Advisory Letter
9/2/2019
CAL WS 15-001
Work Instructions
Subject: Alison Flex Plate Mounting Bolts
Models Affected: Western Star 4700 and 4900 Model Year 2020
Bolt Replacement
1.
Park the vehicle, shut down the engine, and apply the parking brakes. Chock the tires.
2.
Disconnect the batteries.
3.
Remove the passenger-side fender, if installed, to gain access to the starter.
4.
Remove the starter cable brackets. See Fig. 1.
09/20/2019
f151223
Fig. 1, Starter Cable Brackets
5.
Remove the starter, with the battery cables attached, from the flywheel housing to gain access to the flex
plate access plug. See Fig. 2.
Page 2
Daimler Trucks
North America LLC
Customer Advisory Letter
9/2/2019
CAL WS 15-001
09/20/2019
f151221
Fig. 2, Removing the Starter
6.
Remove the flex plate access plug. See Fig. 3.
Page 3
Daimler Trucks
North America LLC
Customer Advisory Letter
9/2/2019
CAL WS 15-001
1
2
A
09/20/2019
f151222
A. The starter is removed before removing the flex
plate plug.
1. Access Plug Location
2. Flex Plate Mounting Bolt Location
Fig. 3, Removing the Flex Plate Access Plug
7.
Manually rotate the engine to align the flex plate bolt for removal through access plug location.
NOTE: Use a magnetic 8-mm socket to ensure that the bolts do not fall into the flywheel housing during removal of the existing fastener and installation of the new bolt (ALI29557752).
8.
Torque the bolt to 27 lbf·ft (36 N·m). Repeat this step for all 12 flex plate mounting bolts, one at a time.
9.
Install the flex plate access plug.
10.
Place the starter into the mounting hole in the flywheel housing.
11.
Hand start the three mounting bolts, then hand tighten them until snug. Using a torque wrench, and tighten
them as follows:
• Aluminum flywheel housing, 100 +/- 48 lbf·ft (135 +/- 65 N·m)
• Steel flywheel housing, 137 to 147 lbf·ft (186 to 199 N·m)
12.
Install the starter cable brackets. Torque cable bracket fasteners as follows:
• M8 fasteners, 11 lbf·ft (15 N·m)
• M10 fasteners, 22 lbf·ft (30 N·m)
13.
Install the passenger-side fender, if installed. Torque fender fasteners to 15 lbf·ft (20 N·m).
14.
Connect the batteries.
Page 4