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Cargo Maintenance Manual

1. Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged M ci Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque N m Torque N m Torque N m Torque N m S cdi lt ool N Doe NS gt SY SZ x 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 1618 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 60 3 8 24 30 41 32 43 25 34 42 57 76 14 42 57 45 61 35 47 60 81 76 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 7 8 14 402 545 427 579 350 475 568 770 1 8 582 789 1 12 637 863 1 14 652 884 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lu
2. If the breather is plugged clean or replace it See Fig 2 Check more often if the vehicle is operating under very dusty conditions 05 27 93 1260007a Fig 2 Transmission Breather Eaton Fuller shown 26 04 Eaton Fuller Transmission Air Filter Regulator Element Clean 1 Exhaust the air from the air reservoirs 26 2 Cargo Maintenance Manual January 2000 Transmission Exhaust the air supply before servicing the air filter regulator otherwise serious personal injury and component damage could result 2 Clean the outside of the air filter regulator with cleaning solvent Let it air dry See Fig 3 fff 05 27 93 1260037 Fig 3 Eaton Fuller Transmission Air Filter Regulator Location 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 4 Remove the small O ring from the end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing the air pressure between 57 to 62 psi 396 to 431 kPa replace the air filter regulator which is not serviceable 4 Clean the filter element 4 1 Dip the filter element in alcohol or other cleaning solvent Blow compressed air through the filter element inside to out side to loosen surface dirt and to dry the element The sintered metallic filter ele 26 10 17 2001 260052 1 Air Regulator 5 Small O Ring 2 Housing 6 End Cap
3. 1 With the ignition on check for voltage to the heater and thermostat assembly Unplug the electrical connector at the air dryer and place the test leads of a voltmeter on each of the pins of the male connector If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check that a good ground path exists 2 Check the thermostat and heater operation Turn off the ignition switch and cool the end cover as sembly to below 40 F 4 C Using an ohmmeter check the resistance between the electrical pins in the female connector The resistance should be 1 5 to 3 0 ohms for the 12 volt heater assem bly Warm the end cover assembly to over 90 F 32 C and again check the resistance It should exceed 1000 ohms If it does the thermostat and heater assembly is operating properly If it does not replace the purge valve housing assembly which includes the heater and thermostat assem bly 42 12 Air Dryer Desiccant Replacement Bendix AD 9 The desiccant change interval may vary from vehicle to vehicle Although typical desiccant cartridge life is three years many will perform adequately for a longer period of time To take maximum advantage of desiccant life and ensure that replacement occurs only when necessary disassemble clean and in spect the air dryer Replace the desiccant cartridge See Group 42 of the Cargo Workshop Manual for instructions Brakes 42 13 Air Reservoi
4. Sh Bde coat a dome 41 02 Cargo Maintenance Manual January 2000 Driveline 41 01 Driveline Inspection 41 Before lubricating the driveline U joints and slip joints make the following checks 1 Check that the yoke strap capscrews Fig 1 Ref 4 are tightened as follows e Spicer 1590 and 1610 50 to 60 Ibf ft 68 to 81 N m e Spicer 1710 125 to 135 170 to 183 N m CAUTION Do not overtighten the yoke strap capscrews due to the extreme load occurring at high speed rota tion A loose or broken capscrew at any point in the driveline weakens the driveline connection which could eventually result in serious vehicle damage 2 Check each of the output and input end yokes Fig 1 Refs 2 and 11 for cracks and loose ness Replace cracked yokes If any end yoke can be moved in or out on its shaft or can be rocked on its shaft disconnect the driveshaft and U joint from the end yoke Check the drive com ponent s shaft seal for leakage or other visible damage that may have been caused by the loose yoke Replace the seal if needed Tighten the end yoke nut to the value in Table 1 If the end yoke is still loose after tightening the yoke nut install a new yoke and yoke nut NOTE If the end yoke locknut was removed for any reason install a new one 3 Check the U joint assemblies for wear by at tempting to move the driveshaft up and down and from side to side If movement of the U joi
5. Cargo Maintenance Manual January 2004 Air Intake 09 01 Air Cleaner Element Inspecting and Replacing Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 25 inH5O if equipped with an air restriction indicator For removal and installation instructions see Group 09 of the Cargo Workshop Manual Reset the air re striction indicator If the maximum restriction is not reached record the air restriction value If the value is higher than the previous recording reset the air restriction indicator If the value is lower than the previous recording in spect the air cleaner and air cleaner element for cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air restriction indicator Method 2 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 25 inH5O if equipped with an air restriction indicator For removal and installation instructions see Group 09 of the Cargo Workshop Manual Reset the air re striction indicator If the maximum restriction is not reached inspect the air cleaner and air cleaner element for cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air re striction indicator 09 Cargo Maintenance Manual January 2004 09 1 Air Compressor 13 Index Alphabetica
6. Driveline 41 4 Cargo Maintenance Manual January 2000 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake Valve Disassembly Clean and Inspection Bendix 6 QR 1 and STSQ ciues cred CERES ESR DORN Doe OEE BEE d Ree RS CREE EES ESM Y du Puede Wee d xd 42 14 Air Brake Valve Operation 3 22 ph Ons bebe hase bia dor tup 42 03 Air Dryer Check Bendix 9 42 11 Air Dryer Desiccant Replacement Bendix 9 42 12 Air Dryer Inspection Bendix AD 9 2 osse dos pe nde eee eee aoe al pedore oe Reps 42 01 Air Reservoir Automatic Drain Valve Disassembly Clean Inspection and Lobiieation Bendix ADS ss a i dus ous 853 de e Rob Pe qoa Robo du Fal ROB Mo que e gis 42 13 Automatic Slack Adjuster Geol 34 145 Caw wheat ea dd plo feos ddd els Adare dius 42 08 Automatic Slack Adjuster Inspection 0 4 eos prm Rex Gere Rr RIPE 42 10 Automatic Slack Adjuster UDRCAUOM cape don egies ege seared debe is 42 09 Brake Chamber Inspection All Models 0 00000 eee eee 42 06 Camshaft Bracket Bushing 42 07 Foot Brake Valve Actuator 1 42 02 Quic
7. January 2000 Title of Maintenance Operation Cab Mounting Bolts Torque Gab Mounts LUbrication ee deeem Roof Vent Lubticationi i xem sea eage genase 60 Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 60 01 Cab Mounting Bolts Torque Check Check the torque of the cab mounting bolts The shock absorber to bracket mounting nut must be 50 to 65 68 to 88 N m The cab pivot lower bracket nut must be 44 to 59 Ibf ft 60 to 80 N m 60 02 Cab Mounts Lubrication Lubricate the mounts on both sides of the vehicle 60 03 Cab Roof Vent Lubrication Spray light oil on the hinges and piston shafts 60 Cargo Maintenance Manual January 2000 60 1 Doors 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Weatherstrip Door Latch and Door Hinge 72 01 Cargo Maintenance Manual January 2000 Doors 72 01 Weatherstrip Door Latch and Door Hinge Lubrication Lightly coat the door weatherstrips with a lubricant that is safe as recommended by the lubricant manu facturer on rubber Apply a few drops of light engine oil or spray a light coating of silicone lubricant such as WD 40 or equivalent on the door latch mechanism This will help reduce noise and wear Wipe off any excess oil
8. New fluid and a new filter should be installed 46 46 04 Power Steering Reservoir Fluid and Filter Change 1 Using a suction gun remove fluid from the reser voir through the filler opening or remove the re turn hose to drain the reservoir 2 Remove the cover from the reservoir by remov ing the clamp 3 Take out the spring filter cap and filter Thoroughly clean the reservoir with a lint free cloth Install the replacement filter filter cap and spring Install the gasket cover and clamp Fill the reservoir to the cold mark with Motorcraft MERCONS ATF XT 2 QDX or MERCON equiva lent Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist 8 Place the front wheels in straight ahead position and engage the parking brake Do not turn the steering wheel during the initial fill procedure 9 Fill the reservoir with fluid and allow the fluid to gravity feed the system Crack the pressure line fittings at the pump and steering gear Tighten the fittings when fluid is visible Keep adding fluid to the reservoir as required 10 Start the engine and let it idle Turn the steering wheel from lock to lock until no bubbles are seen in the reservoir Turn off the engine 11 When the fluid level in the reservoir no longer goes down start the engine Continue to add flu
9. and ST 3 46 01 Steering Driveline Lubricating 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking e fo 46 04 Power Steering Reservoir Fluid and Filter Changing e 46 05 Steering Gear Lubricating Ross TAS Series e fe 47 01 Fuel Tank Draining and Vent Checking e 49 01 Exhaust System Inspecting 54 01 Electrical System Checking 54 02 Battery Battery Box and Cable Checking and Cleaning 54 03 Ground Cables Checking and Cleaning e 6 e e 60 01 Cab Mounting Bolts Torque Checking 60 02 Cab Mounts Lubricating eo 60 03 Cab Roof Vent Lubricating eo e e oe Je e 72 01 Weatherstrip Door Hinge and Door Latch Lubricating e fe fe 83 01 Air Conditioner Checking R 134a Refrigerant Systems fe fe fe 83 02 Air Filter Replacement Replace the HVAC air filter every three months regardless of mileage 00 12 Cargo Maintenance Manual December 2004 General Information 00 Initial Maintenance IM Operations Table 00 09 IMPORTANT After performing all operations in this NOTE Numbers in this table are maintenance opera table perform all daily and weekly maintenance op tion reference numbers matching those in the text of erations listed in the Pretrip Inspection and Daily this manual The Initial
10. axle and frame Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire Front Axle 5 Place a turn plate or turntable under both front tires Raise the front of the vehicle remove the safety stands from under the axle then lower the vehicle Remove the lock pins from the gauges make sure the tires are exactly straight ahead NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brakes Move the vehicle backward and then forward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe lines on the center ribs of the front tires See Fig 3 Lock in place Check that the scale is set on zero A B gt 08 29 94 1830082 NOTE minus A equals toe in Fig 3 Wheel Toe In Overhead View 7 Move the trammel bar to the front of the tires Fig 4 and adjust the scale end so that the pointers line up with the scribe lines See Fig 5 8 Read the toe in from the scale and compare it to the toe in specification in Gr
11. or silicone lubricant Lubricate the door hinges and the door stop by spraying them with a light coating of silicone lubricant such as WD 40 or an equivalent Always lubricate new cab door hinges at installation 72 Cargo Maintenance Manual January 2000 72 1 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Check R 134a Refrigerant Systems Par Filter Replacements une d b dos enm ike S 83 Index Alphabetical MOP Number Cargo Maintenance Manual December 2004 Heater and Air Conditioner 83 01 Air Conditioner Check R 134a Refrigerant Systems Preliminary Checks 1 Apply the parking brakes and chock the tires 2 Make sure the refrigerant compressor drive belt is not damaged and is correctly tensioned Also check the tightness of the compressor mounting fasteners For instructions and torque values see Group 01 of the Cargo Workshop Manual 3 Using feeler gauge check for correct clutch clearance For instructions see Group 83 of the Cargo Workshop Manual 4 Inspect the compressor clutch coil wire Check the connector for damage or looseness Replace the wire if it is damaged 5 Check for broken burst or cut hoses Also check for loose fittings on all parts WARNING Wear eye protection when using compressed air or high pressure water to clean parts as perma nent harm to eyes could result from flying debris 6 Check for a bu
12. s suus erp ches peeve Ground Cables Check and 54 Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 Electrical Instruments and Controls 54 01 Electrical System Check Cab 1 Uncover the electrical panel on the right side of the dash by removing the fasteners 2 Check the wiring harness for movement that could strain the electrical connections Install more clamps on the harness if needed 3 Check all the wiring for chafing kinks and dis colored insulation Find the cause of any prob lems then repair replace or reroute the wires as needed 4 Check that all the relays are firmly seated in their mounting plates 5 Check the turn signal flasher if so equipped Make sure that the two male and female connec tors are firmly connected Check that the flasher fuse is firmly seated in its holder 6 Remove the instrument and control panels and check all the wiring behind them for kinks chaf ing heat damage and discolored insulation Re route repair or replace the wires as needed 7 Check the tightness of all the electrical connec tions behind the panels Make sure that all male and female connectors are firmly connected 8 Check that all the instrument and gauge light bulbs are firmly seated in their sockets 9 Check the cigarette lighter Look inside the socket for signs of overheating discoloration melting caused b
13. to 60 000 miles 100 000 km Maintenance 4 4 every 64 000 96 000 Maintenance 5 M5 every 128 000 192 000 Initial Maintenance IM first 10 000 16 000 Maintenance 1 M1 every 10 000 16 000 Schedule Ill Long Haul Transport All Maintenance 2 M2 every 20 000 32 000 s vehicles that annually travel Maintenance 3 M3 every 40 000 64 000 over 60 000 miles 100 000 km Maintenance 4 M4 every 80 000 128 000 Maintenance 5 M5 every 160 000 256 000 For Schedule severe service vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than distance traveled 00 8 Cargo Maintenance Manual December 2004 General Information 00 Maintenance Interval Tables 00 07 Maintenance Intervals for Schedule Maint No Maintenance Interval Miles km Hours 1 IM and M1 1000 1600 100 2 M1 2000 3200 200 3 M1 3000 4800 300 4 M1 and M2 4000 6400 400 5 M1 5000 8000 500 6 M1 6000 9600 600 7 M1 7000 11 200 700 8 M1 M2 and M3 8000 12 800 800 9 M1 9000 14 400 900 10 M1 10 000 16 000 1000 11 M1 11 000 17 600 1100 12 M1 and M2 12 000 19 200 1200 13 M1 13 000 20 800 1300 14 M1 14 000 22 400 1400 15 M1 15 000 24 000 1500 16 M1 M2 M3 and M4 16 000 25 600 1600 17 M1 17 000 27 200 1700 18 M1 18 000 28 800 1800 19 M1 19 000 30 400 1900 20 M1 and M2 20 000 3
14. 01 Clutch Release Bearing and Cross Shaft Lubricating 25 03 Clutch Master Cylinder Fluid Level Checking 26 01 Manual Transmission Oil Level Checking 32 02 Suspension Lubricating 33 01 Knuckle Pin Lubricating 33 03 Tie Rod End Lubricating 35 01 Axle Lubricant Level Checking 41 02 Driveline Lubricating 42 02 Foot Brake Valve Actuator Lubricating 42 09 Automatic Slack Adjuster Lubricating 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 05 Steering Gear Lubricating Ross TAS Series 60 02 Cab Mounts Lubricating 60 03 Cab Roof Vent Lubricating 72 01 Weatherstrip Door Hinge and Door Latch Lubricating Table 7 Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check for Schedules I Il and Ill Cargo Maintenance Manual December 2004 00 19 00 General Information Lubrication and Fluid Level Check M2 schedules Il and Ill 00 16 Maintenance Operation 00 16 Table 8 summarizes instructions in the manual on the lubrication or fluid all Lubrication and Fluid Level Check operations that check Lubrication and Fluid Level Check Locations must be performed at the M2 Maintenance Interval 00 17 can be used as a guide by those who do not for Schedules Il and 1 need to consult the detailed lubrication and fluid Maintenance operation numbers given in the table check instructions given elsewhere in the ma
15. 1 4 Inch Bolt 16 qty 6 First Reverse Clutch Feed Tube 3 Inch Bolt 2 qty behind Fig 7 Allison AT Series Transmission Governor Cargo Maintenance Manual January 2000 26 5 26 IMPORTANT If the governor feed and 5 sure tubes are installed wrong end first they will not align properly when the control valve is bolted in place 8 7 Lift the valve body and swing the two tubes into position to enter their holes in the transmission case Raise the valve body onto the case while engaging the rear ends of the tubes in the case and engaging the selector valve on the selec tor lever 8 8 Install fourteen valve body retaining bolts Remove the two 3 inch bolts used to hold the valve body while checking the gover nor oil screen replace them with two bolts of the correct size 8 9 Install the filter spacer and the first reverse clutch long braced feed tube use the two 3 inch bolts to retain them 8 10 Install the detent spring with its roller over the selector lever and its tab in the hole directly behind the bolt hole Install a 1 4 20 x 1 3 4 inch bolt in the detent spring and valve bogy NOTE The detent spring must be held in alignment over the selector lever while the 1 3 4 inch bolt is tightened 8 11 Tighten all of the bolts evenly 8 to 12 11 to 16 N m 9 Install a new sealring on the straighter end of the fluid intake tube Lubricate the sealring with oil soluble grease
16. 3 Large O Ring 7 Plug 4 Filter Element Fig 4 Eaton Fuller Transmission Air Filter Regulator Components ment will last the life of the vehicle pro vided it is not damaged 4 2 Wipe out the filter housing with a clean dry lint free rag 5 Clean and inspect the O rings and the end cap Replace any parts that are damaged Install the large O ring into the filter housing Install the filter element small end first into the filter housing 8 Install the small O ring into the end cap Install the end cap on the filter housing Tighten the end cap 8 to 12 11 to 16 9 Start the engine and build up pressure in the air system Check for air leaks at the filter housing and air line connections and repair any leaks CAUTION Repair any air leaks A leaking air filter or air lines can cause slow or hard shifting of the transmis sion and eventual transmission damage Cargo Maintenance Manual January 2000 26 3 26 26 05 Allison Transmission Fluid and Filter Change AT Series Fig 5 Ps 2 1 2 3 4 10 05 94 f260133a 1 Fluid Intake Tube Filter Spacer Internal Fluid Filter Washer Head Screw Governor Pressure Tube Governor Feed Tube Fig 5 Allison AT Series Transmission Filter 1 Park the vehicle on a level surface and apply the parking brakes 2 Run the engine until the transmission fluid reaches the oper
17. 5 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth Fig 2 If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 6 Check the driveshaft tubes for dents bends twists or other damage If any tube appears to be damaged remove the driveshaft and check the runout on the tube If the tube is not straight and cannot be straightened within 0 015 inch 0 38 mm on the slip joint seal surface of the splined shaft 0 020 inch 0 51 mm on the tube 3 inches 76 mm from the front and rear welds and 0 025 inch 0 635 mm at the center of the tube replace the tube See Fig 3 If the driveshaft tube requires straightening or replacement balance the repaired driveshaft be fore installing it See Group 41 of the Cargo Workshop Manual Cargo Maintenance Manual January 2000 41 1 41 Driveline 12 2 N 1 10 06 94 3 f410057a NOTE Not all fasteners are shown 1 Transmission 8 Slip Joint Assembly 13 Splined Shaft 2 Half Round End Yoke 9 Driveshaft Tube 14 Dust Seal 3 U Joint Assembly 10 Driveshaft Yoke 15 Sleeve Yoke 4 Yoke Strap and Capscrew 11 Input Shaft Half Round End 16 Full Round Yoke Lug 5 Coupling Shaft Yoke 17 U Joint Cross 6 Midship Bearing and Mount 12 Rear Axle 18 Lockplate and Capscrew 7 Bearing Cup Fig 1 Driveline Assembly With Midship Bearing for Single Axle Installation 7 C
18. Do not loosen or remove the parking brake clamp ring for any purpose at any time The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual 1 Chock the tires 2 Build the air pressure in the system to at least 100 psi 690 kPa and shut off the engine Brakes 3 Place the park control valve in the park position The brake should apply immediately Then place the park control valve in the released position The brake should release immediately If the brakes do not apply or release as required see the air brake system troubleshooting guide in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual for possible causes and corrections Do not disconnect the pressurized parking brake hose If disconnected under pressure the parking brake hose will whip as air escapes from the line and the air stream can direct dirt or sludge toward persons in the area which could result in injury 4 Check the parking brake chambers for leakage 4 1 With the park control valve released ap ply soapy water around the parking brake diaphragm clamp ring and at the drain slots and exhaust breather on the body Disconnect the service
19. Group 42 of the Cargo Workshop Manual replace any damaged parts 8 On parking brake chambers equipped with inte gral release bolts lubricate the bolt with thread anti seize compound Check the tightness of the bolt For torque values see the applicable brake chamber section in Group 42 of the Cargo Workshop Manual 42 A CAUTION If the external breather tube is missing or incor rectly installed road dirt and debris can adversely affect the operation of the brake chamber Once inside the chamber dirt and debris cause the in ternal parts to deteriorate and shorten their lives 9 On brake chambers equipped with an external breather tube make sure the flexible elbows are in place and the connector tube is inserted into each elbow 1 2 inch 13 mm 10 On all parking brake installations check for pres ence of an end cover cap or dust plug and make sure the cap or plug is securely snapped into place Service Brake Operation and Leakage Check Do not loosen or remove the parking brake clamp ring for any purpose at any time The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual 1 Apply the service brakes and check that the pi
20. Interval Operations low at the M2 Maintenance Interval NOTE Maintenance operations appearing in italics in this table are for noise emission control components M2 Maintenance Interval Operations Maint Oper No M2 Maintenance Interval Operations 00 10 00 16 20 01 Perform All M1 Operations Lubrication and Fluid Level Check includes the following Camshaft Bracket Bushing Lubricating e Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspect ing and Lubricating Bendix AD 9 Steering Driveline Lubricating Radiator Cap Checking 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 42 10 Automatic Slack Adjuster Inspecting 49 01 Exhaust System Inspecting 83 02 Air Filter Replacement Replace the HVAC air filter every three months regardless of mileage Numbers in this table are maintenance operation ref erence numbers matching those in the text of this manual The M2 Maintenance consists of all M1 In terval Operations plus the other operations listed be Cargo Maintenance Manual December 2004 00 15 00 M3 Maintenance Interval Operations Table 00 12 IMPORTANT After performing all operations in this table perform all daily and weekly maintenance op erations listed in the Pretrip Inspection and Daily Maintenance chapter of the C
21. M4 M5 Maintenance Operation Reference Number and Maintenance Operation 00 15 Lubrication and Fluid Level Check 00 16 Lubrication and Fluid Level Check 01 01 Engine Support Fasteners Checking 01 02 Engine Drive Belt Inspection 09 01 Air Cleaner Element Inspecting and Replacing 13 01 Air Compressor Inspecting Holset 15 01 Alternator and Starter Checking 20 01 Radiator Cap Checking 20 02 Radiator Pressure Flushing and Coolant Changing 25 01 Clutch Release Bearing and Release Cross Shaft Lubricating fe fe 25 02 Clutch Inspecting and Adjusting 25 03 Clutch Master Cylinder Fluid Level Checking e fe fe 26 01 Manual Transmission Oil Level Checking 26 02 Manual Transmission Oil Changing and Magnetic Plug Cleaning 26 03 Allison and Fuller Transmission Breather Checking 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 26 05 Allison Transmission Fluid and Filter Changing 31 01 Frame Fastener Torque Checking 32 01 Suspension Inspecting including cab shocks 32 02 Suspension Lubricating 32 03 U Bolt Torque Checking e e o 33 01 Knuckle Pin Lubricating J e 33 02 End Inspecting J 33 03 Tie Rod End Lubricating J o 33 04 All Axle Alignment Checking 35 01 Axle Lubricant Level Checki
22. Maintenance consists of all Maintenance chapter of the Cargo Driver s Manual M1 Operations plus the other operations listed below Also perform all M1 Maintenance Interval Operations at the Initial Maintenance IM Initial Maintenance IM Operations Maint Oper No Initial Maintenance IM Operations 00 10 Perform All M1 Operations 15 01 Alternator and Starter Checking 25 02 Clutch Inspecting and Adjusting Pedal Free Play 26 02 Manual Transmission Oil Changing and Magnetic Plug Cleaning 31 01 Frame Fastener Torque Checking 32 03 U Bolt Torque Checking 33 04 All Axle Alignment 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning Cargo Maintenance Manual December 2004 00 13 00 General Information M1 Maintenance Interval Operations Table 00 10 IMPORTANT After performing all operations in this NOTE Numbers in this table are maintenance opera table perform all daily and weekly maintenance op tion reference numbers matching those in the text of erations listed in the Pretrip Inspection and Daily this manual Maintenance chapter of the Cargo Driver s Manual M1 Maintenance Interval Operations Maint Oper No M1 Maintenance Interval Operations 00 15 Lubrication and Fluid Level Check includes the following Clutch Release Bearing and Cross Shaft Lubricating Clutch Linkage Components Lubricating Manual T
23. Run Band 270002 Hot Run Fig 11 AT MD Series Dipstick Markings EN P N 01 22 97 A Transmission Housing Oil Pan Split Line B Hot Run Band C Cold Run Band f260395 Fig 12 MT Series Dipstick Markings 5 1 Inch Depth Oil Pan temperature may result in an overfilled transmis sion which causes fluid foaming and aeration Fluid foaming and aeration cause transmission overheating and erratic shifting NOTE Perform a hot check at the first opportu nity after the normal operating temperature 160 to 200 F 71 to 93 C has been reached 26 10 Cargo Maintenance Manual January 2000 Transmission Hot Check 1 Park the vehicle on a flat level surface Apply the parking brake and chock the tires Shift the transmission to NEUTRAL Operate the engine at idle 500 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200 F 71 to 93 C Check that the converter out tempera ture is 180 to 220 F 82 to 104 C 4 With the engine idling remove the dipstick from the tube and wipe it clean Insert the dipstick into the tube and remove it Check the fluid level reading and repeat the check procedure to verify the reading Safe oper ating level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band
24. Sidewalls D Tensile Break f150010a E Uneven Ribs F Cracks Fig 2 Drive Belt Replacement Conditions 7 Visually inspect the pulleys for excessive play wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult to distinguish the locations of a supposed bearing noise place a stetho scope on the component being checked not the pulley to isolate the area from outside interfer ence 8 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tension Inspection NOTE If engine drive belts require adjustment refer to Group 01 in the Cargo Workshop Manual On belts equipped with a spring tensioner the belt tension is automatically adjusted Check that the ten sioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner down away from the belt When the breaker bar is slowly released the tensioner should return to its original position If not refer to Group 01 in the Cargo Workshop Manual for replacement in structions 01 2 Cargo Maintenance Manual January 2000 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and 09 01
25. all belts for the following conditions then per form the belt tension inspection Visual Inspection 1 Inspect the belt for glazing See Fig 2 Ref A Glazing is represented by shiny sidewalls and is caused by friction created when a loose belt slips in the pulleys It can also be caused by oil or grease contamination on the pulleys 2 Check the belt for ply separation See Fig 2 Ref B Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or cool ant leaks that are affecting the belts before re placing the drive belts Do not use belt dressing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 2 Ref C Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 4 Check for tensile breaks breaks in the cord body See Fig 2 Ref D Cuts in a belt are usu ally caused by foreign objects in the pulley or by prying or forcing the belt during removal or instal lation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 Ref E Foreign objects in the pulley will erode the undercord ribs causing the belt to lose its gripping power 6 Check the drive belts for cracks See Fig 2 Ref F Small irregular cracks are usually the signs of an old belt Cargo Maintenance Manual January 2000 01 1 01 Engine 11 21 94 A Glazing B Separating Layers C Streaked
26. are hand tight 26 14 Tighten each capscrew with a click type torque wrench 60 Ibf in 700 N cm Use the torque pat tern shown in Fig 10 to distribute the torque evenly Repeat this procedure and torque the capscrews with a click type torque wrench 15 to 20 Ibf ft 20 to 27 N m 1 4 6 10 8 13 12 17 16 19 20 15 21 18 11 14 9 7 3 5 2 09 24 96 1260396 NOTE Torque the oil pan bolts with click type torque wrench following this torque pattern Tighten the bolts 60 Ibf in 700 N cm Repeat the torque pattern with a click type torque wrench 15 to 20 Ibf ft 20 to 27 N m Fig 10 Allison MT Series Transmssion Oil Pan Torque Pattern 15 Install the oil filler tube on the oil pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 N m Install the drain plug and gasket Tighten the drain plug 15 to 20 Ibf ft 20 to 27 N m 16 Pour approximately 15 quarts 14 liters of Dexron IIE transmission fluid into the transmis sion Start the engine and allow the transmission fluid to circulate With the transmission in NEU TRAL check the fluid level Check for fluid leaks Correct any leak with the engine OFF Cargo Maintenance Manual January 2000 26 9 26 Checking the Fluid Level Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick CAUTION Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the
27. between lubrication change intervals 4 After cleaning the drain plugs install and tighten them 35 47 N m Axle Fill 1 With the vehicle on a level surface fill the axle housings to the bottom of the oil fill hole in the carrier or housing with lubricant See Table 1 for approved axle lubricants and see Table 2 for axle capacities NOTE Meritor axles have a small tapped and plugged hole located near and below the hous ing oil fill hole This smaller hole is for the lubri cant temperature sensor only and must not be used as a fill or level hole 2 Install the fill hole plug and tighten it 35 47 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for 1 or 2 miles 2 or 3 kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circulate the lubricant throughout the assembly 35 2 Cargo Maintenance Manual January 2000 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut and Rim Nut Check susc a a kx RU eee OR EEE SRR EO Dee 40 01 Cargo Maintenance Manual January 2000 Wheels and Tires 40 01 Wheel Nut and Rim Nut Check IMPORTANT In addition to the maintenance interval in this manual check the wheel nut torque the first 50 to 100 miles 80 to 160 km of operation after a wheel has been removed and installed When checking wheel nuts on a dual disc asse
28. brake hose at the service port and apply soapy water to check for piston O ring leakage Read and follow all applicable warnings and in structions in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious injury or death 4 2 If leakage is detected at either the clamp ring or the drain slots replace the parking brake section Slight leakage is permitted at the service port Any other leakage is not acceptable Using the instructions in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual replace the parking brake section do not attempt to service the parking brake section 5 Connect the air hose to the brake chamber mak ing sure that the fittings are clean and free of debris Finger tighten the nut Using a wrench further tighten the nut until you feel resistance Tighten the nut one sixth turn more 42 4 Cargo Maintenance Manual January 2000 42 Brakes 6 Repeat the above steps for each parking brake chamber 7 Apply the parking brakes Remove the chocks from the tires 42 07 Camshaft Bracket Bushing Lubrication Pump multipurpose chassis grease NLGI grade 1 or 2 into the chamber bracket until it appears at the slack adjuster end of the bracket See Fig 3 Use care that no grease enters the drum cavity If grease leaks
29. coor bed Ra ed pP Rs pd ds 46 05 Cargo Maintenance Manual January 2000 Steering 46 01 Steering Driveline Lubrication Wipe the grease fittings clean Using a pressure gun apply a lithium based grease NLGI grade 2 spar ingly to the universal joints and slip joint splines 46 02 Drag Link Lubrication 1 Using a clean rag wipe the dirt from the grease fitting on the drag link 2 Using a pressure gun apply multipurpose chas 5 5 grease at the grease fitting until old grease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 696 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease The grade 2 chassis grease is pre ferred 46 03 Power Steering Reservoir Fluid Level Check 1 Turn the engine OFF 2 Check the fluid level in the power steering reser voir e Use the COLD markings on the dipstick if the engine is at room temperature 70 F 20 e Use the HOT markings the dipstick if the engine is at normal operating tempera tures 175 F 80 C 3 The fluid level must show between the ADD and FULL markings on the dipstick If the fluid level is below the ADD mark add Motorcraft MERCON ATF XT 2 WDX MERCON equivalent NOTE After any major power steering system or component overhaul the system should be purged of old fluid and the filter discarded
30. either is plated or lubricated use Table 1 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 2 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 4 Cargo Maintenance Manual December 2004 General Information 00 Torque Specifications Tables 00 03 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m A N Ss N TOP P N uds a E 0 230010 230011 1230012 230013 6 5 7 7 9 8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 434 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated
31. lems IMPORTANT Do not mix types of oil because of possible incompatibility Do not use oil addi tives friction modifiers or synthetic lubricants 3 the fill plug Install the fill plug in the trans mission Tighten the plug 20 to 25 Ibf ft 27 to 34 N m for a 3 4 inch plug e 60 to 75 Ibf ft 81 to 102 N m for a 1 1 4 inch plug 26 02 Manual Transmission Oil Change and Magnetic Plug Clean Draining Clean the area around the fill plug 2 Remove the fill plug from the side of the case Remove the drain plug s from the bottom of the transmission case Drain the oil while the transmission is warm Clean the magnetic plug s before installing it Use a piece of key stock or any other conve nient steel slug to short the two magnetic poles and divert the magnetic field Install and tighten the drain plug s 20 27 Cargo Maintenance Manual January 2000 26 1 26 Filling 1 Add oil until it is level with the lower edge of the fill opening See Fig 1 If the transmission has two fill openings add oil to the level of both fill openings See Table 1 for approved transmission lubri cants and Table 2 for lubricant capacities Transmission Lubricant Capacities Transmission Eaton Fuller Models FS 4205A B 4 75 4 5 FS 5205A B 5 25 5 0 FS 6305A B 9 5 9 0 FS 5306A 9 0 8 5 FS 6306A 9 0 8 5 FS 8206A 10 0 9 5 RT
32. or plated zinc phosphate conversion coated cadmium plated or waxed Table 3 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Cargo Maintenance Manual December 2004 00 5 00 General Information Metric U S Customary Conversion Table 00 04 E To Get Metric Balls ede ii To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 square millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in cubic inches in 16 387 cubic centimeters cm 0 06102 cubic inches in cubic inches in 0 01639 liters L 61 024 cubic inches in3 fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft cubic feet 3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 2
33. percent water and 50 percent corrosion inhibiting antifreeze to protect the engine to 34 37 C year round See Table 1 for engine cooling system capacity and Table 2 for approved antifreezes Coolant Capacities Radiator Core Engine Make and and System Capacity Model 2 Row 3 Row quarts liters quarts liters Cummins ISB 30 5 28 9 31 0 29 3 System capacity includes all hoses fittings and the heater core Table 1 Coolant Capacities Approved Coolants Coolant Coolant Engine Manufacturer Designation Diesel Texaco JC04 Antifreeze Van Waters and Diesel Rogers Ltd Antifreeze No Canada 6038 Freightliner approved antifreeze must meet one of the following condi tions A Ethylene glycol solution that meets GM 6038 M Engineering Stan dards B Ethylene glycol solution that has less than 0 196 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards Table 2 Approved Coolants NOTE You can mix purple pink coolant pre charged with a borate nitrate based additive with the common green coolant although some color change will be apparent 20 2 Cargo Maintenance Manual August 2003 Clutch Title of Maintenance Operation MOP Clutch Inspection and Adjustment Clutch Master Cylinder Fluid Level Clutch Release Bearing and Re
34. stick condition Meritor s experience shows that the fol lowing additives perform adequately Add Elco No 2 Friction Modifier 1 ounce 30 mL of additive for each 1 pint 0 5 liter of lube capacity Lubrizol No 797 or 762 one ounce 30 mL of additive for each 1 pint 0 5 liter of lube capacity Table 2 Meritor Drive Axle Lubricant Capacities Single Axles Cargo Maintenance Manual January 2000 35 1 35 35 02 Axle Breather Check The axle housing breather must remain clean When ever the axle lubricant level is checked check that the axle breather is open Check more often under poor operating conditions If the breather is plugged clean or replace it as needed 35 03 Axle Lubricant Change and Magnetic Plug Clean A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analyzing oil samples taken from the axle at specified intervals or mileages Lubricant sup pliers frequently make their laboratory facilities avail able for determining the useful life of their product under actual service conditions The final schedule that is recommended may for economic reasons be correlated with lubricant changes that are governed by climatic conditions and magnetic plug mainte nance Change lubricant type and viscosity as cli matic temperatures demand regardless of vehicle mileage or established change schedule The normal operating temperature
35. 160 to 26 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use containers or fillers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 the area around the drain plug While the transmission fluid is warm remove the drain plug and drain the fluid IMPORTANT Examine the used transmission fluid for dirt coolant or water and metal par ticles If any of these contaminants are present a problem within the transmission system may exist 4 Remove the bolts from each filter cover at the bottom of the transmission control module Re move the filter covers O rings seals and the two cartridge type filters 5 Coat the O rings lightly with clean transmission fluid Place the O rings seals and filters on the filter covers Push each cover assembly into the bottom of the transmission to seat the seals In stall and tighten the bolts 38 to 45 Ibf ft 52 to 61 N m Install and tighten the drain plug 18 to 24 Ibf ft 24 to 33 N m 6 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid See Table 1 for approved transmission lubri cants and Table 2 for lubricant capacities 7 Check and adjust the fluid level using th
36. 19 M1 152 000 228 000 190 000 304 000 20 M1 M2 and M3 160 000 240 000 200 000 320 000 21 M1 168 000 252 000 210 000 336 000 22 M1 and M2 176 000 264 000 220 000 352 000 23 M1 184 000 276 000 230 000 368 000 24 M1 M2 M3 and M4 192 000 288 000 240 000 384 000 25 M1 200 000 300 000 250 000 400 000 26 M1 and M2 208 000 312 000 260 000 416 000 27 M1 216 000 324 000 270 000 432 000 28 M1 M2 and M3 224 000 336 000 280 000 448 000 29 M1 232 000 348 000 290 000 464 000 30 M1 and M2 240 000 360 000 300 000 480 000 31 M1 248 000 372 000 310 000 496 000 32 M1 M2 M3 M4 and M5 256 000 384 000 320 000 512 000 Table 6 Maintenance Intervals for Schedules II and Ill 00 10 Cargo Maintenance Manual December 2004 General Information 00 Maintenance Operation Sets Table 00 08 IMPORTANT At each Maintenance Operation Set in NOTE Maintenance operations appearing in italics in addition to the maintenance operations listed in this this table are for noise emission control components table perform all daily and weekly maintenance op Numbers in this table are maintenance operation ref erations listed in the Pretrip Inspection and Daily erence numbers matching those in the text of this Maintenance chapter of the Cargo Driver s Manual manual Maintenance Operation Sets Table Required Maintenance Operation Set IM M1 M2
37. 2 000 2000 21 M1 21 000 33 600 2100 22 M1 22 000 35 200 2200 23 M1 23 000 36 800 2300 24 M1 M2 and M3 24 000 38 400 2400 25 M1 25 000 40 000 2500 26 M1 26 000 41 600 2600 27 M1 27 000 43 200 2700 28 M1 and M2 28 000 44 800 2800 29 M1 29 000 46 400 2900 30 M1 30 000 48 000 3000 31 M1 31 000 49 600 3100 32 M1 M2 M3 M4 and M5 32 000 51 200 3200 Table 5 Maintenance Intervals for Schedule Cargo Maintenance Manual December 2004 00 9 00 General Information Maintenance Interval Tables 00 07 Maintenance Intervals for Schedules II and IlI n Maintenance Tote 1 IM and M1 8000 12 000 10 000 16 000 2 M1 and M2 16 000 24 000 20 000 32 000 3 M1 24 000 36 000 30 000 48 000 4 M1 M2 and M3 32 000 48 000 40 000 64 000 5 M1 40 000 60 000 50 000 80 000 6 M1 and M2 48 000 72 000 60 000 96 000 7 M1 56 000 84 000 70 000 112 000 8 M1 M2 M3 and M4 64 000 96 000 80 000 128 000 9 M1 72 000 108 000 90 000 144 000 10 M1 and M2 80 000 120 000 100 000 160 000 11 M1 88 000 132 000 110 000 176 000 12 M1 M2 and M3 96 000 144 000 120 000 192 000 13 M1 104 000 156 000 130 000 208 000 14 M1 and M2 112 000 168 000 140 000 224 000 15 M1 120 000 180 000 150 000 240 000 16 M1 M2 M3 M4 and M5 128 000 192 000 160 000 256 000 17 M1 136 000 204 000 170 000 272 000 18 M1 and M2 144 000 216 000 180 000 288 000
38. 25 03 Clutch Master Cylinder Fluid Level Check The reservoir is full when the fluid level is up to the max mark The fluid level must always be above the min mark Use only heavy duty brake fluid DOT 3 in the hydraulic clutch system Cargo Maintenance Manual January 2000 25 1 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Fluid and Filter ee 26 05 Allison and Eaton Fuller Transmission Breather 26 03 Eaton Fuller Transmission Air Filter Regulator Element 26 04 Manual Transmission Oil Change and Magnetic Plug 26 02 Manual Transmission Oil Level Check hh 26 01 Cargo Maintenance Manual January 2000 Transmission 26 01 Manual Transmission Oil Level Check NO o 1 With the transmission at operating temperature and the vehicle on a level surface check the oil level in the transmission 1 1 Clean the area around the fill plug Re move the plug from the side of the case 1 2 Using your finger or a bent pipe cleaner see if the oil is level with the lower edge of the fill opening See Fig 1 2 f needed fill the transmission with oil until level with the lower edge of the fill opening See Table 1 for approved
39. 6609A 6 0 5 7 Allison Models AT 545 16 0 15 0 MD 17 5 16 5 um Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole on Eaton Fuller transmissions with the vehicle in normal operating position On Allison transmissions add the recommended amount of fluid as listed under refill capacity Perform a hot check and add fluid as needed Do not overfill Table 2 Transmission Lubricant Capacities A CAUTION Operating a Eaton Fuller transmission with the oil level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission Overfilling the transmission will force oil out of the case through the main shaft openings Oil overflow may also drain onto the clutch or clutch brake causing additional prob lems IMPORTANT Do not mix types of oil because of possible incompatibility Do not use oil addi tives friction modifiers or synthetic lubricants Transmission NOTE The correct oil capacity is established by the fill plug opening 2 the fill plug Install the fill plug Tighten the plug 20 to 25 Ibf ft 27 to 34 N m for a 3 4 inch plug e 60 to 75 Ibf ft 81 to 102 N m for a 1 1 4 inch plug 26 03 Allison and Eaton Fuller Transmission Breather Check Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause oil leakage
40. 8 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 4 Metric U S Customary Conversion 00 6 Cargo Maintenance Manual December 2004 General Information 00 Scheduled Maintenance Intervals Description and Description Use 00 05 Use Schedule severe service applies to vehicles that annually travel up to 6000 miles 10 000 kilometers or that operate under severe conditions Examples of Schedule usage include operation on extremely poor roads or where there is heavy dust accumula tion constant exposure to extreme hot cold salt air or other extreme climates frequent short distance travel construction site operation city operation fire truck garbage truck or farm operation Schedule II short haul transport applies to vehicles that annually travel up to 60 000 miles 100 000 kilo meters and operate under normal conditions Ex amples of Schedule 11 usage are opera
41. IMPORTANT Avoid twisting the intake tube when installing the internal fluid filter intake tube and sealring the sealring could be pinched cut or deformed An air tight seal must be maintained 10 Install the intake tube and sealring Install the internal fluid filter on the intake tube making sure the grommet in the filter fits the intake tube snugly 11 Install the washer head screw to retain the fluid filter and tighten it 10 to 15 Ibf ft 14 to 20 N m Transmission 12 Submerge a new oil pan gasket in transmission fluid for five minutes Then place the oil pan gas ket on the oil pan do not use any substance as a gasket retainer IMPORTANT Do not use gasket sealing com pounds any place inside the transmission or where they might get washed into the transmis sion Also nonsoluble vegetable based cooking compounds or fibrous greases must not be used inside the transmission 13 Install the oil pan and gasket 13 1 Guide the pan and gasket carefully into place Guard against dirt or foreign mate rial entering the pan Retain the pan with four 5 16 18 washer head screws Install the screw by hand into the corners of the pan 13 2 Install the remaining seventeen washer head screws by hand carefully threading each through the gasket and into the transmission Bottom all of the screws before tightening any of them 13 3 Tighten all twenty one screws evenly 10 to 15 Ibf ft 14 to 20 Check the gas
42. If grease still does not appear bend the tabs of the lockstrap away from the heads of the bearing cup cap screws then loosen the bearing cup capscrews at the bearing with the dry seal to relieve seal Cargo Maintenance Manual January 2000 41 3 41 tension Lubricate the U joint until the old grease is purged then tighten the capscrews to the above specifications and bend the tabs of the lockstrap against a flat side of each cap screw If the bearing will not take grease re place the U joint assembly see Group 41 of the Cargo Workshop Manual 4 Check the old grease If it appears rusty gritty or burned replace the U joint assembly See Group 41 of the Cargo Workshop Manual Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubrication 1 3 Wipe all old grease and dirt from the slip joint grease fitting See Fig 4 Ref 1 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the slip joint Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to lubricate until fresh grease appears at the slip joint seal Fig 4 Ref 6 This ensures complete lubrication of the splines Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting
43. Inspection Noise Emission Controls NOTE In addition to the maintenance interval in this manual inspect the exhaust system if the vehicle has a noticeable increase in noise level at any time Replace parts that show leakage wear or damage 1 Check the muffler body muffler outlet stack muf fler shield and inlet tubes for leakage dents corrosion or holes in the muffler 2 Inspect the exhaust pipe for leakage wear or damage replace with new parts if needed Do not reuse wide band clamps Once a clamp is removed it must be replaced 3 Check for leakage at the V type clamp that at taches the exhaust pipe to the turbocharger ex haust outlet If leakage exists tighten the nut on the V type clamp 50 Ibf in 560 N cm Using a plastic hammer tap around the clamp then tighten again to 50 560 N cm If leakage persists replace the clamp 4 Check for leakage at each wide band exhaust clamp Fig 1 If leakage exists tighten the nuts on Torca Torctite exhaust clamps 40 to 60 54 to 81 N m If leakage persists install a new wide band exhaust clamp See Group 49 of the Cargo Workshop Manual for procedures 10 05 94 f490005a Fig 1 Wide Band Exhaust Clamp 49 Cargo Maintenance Manual January 2000 49 1 Electrical Instruments and Controls Title of Maintenance Operation MOP Battery Battery Box and Cable Check and Clean Electrical System Check
44. Introduction Maintenance Manual Contents Group No Group Title ee ee ord dub ind ble Ra bea ae hk Baas Engine UM aes thd eats cuc ep tas Air Intake Woe nese ete sive Alternators and Starters BY Engine Cooling Radiator BES Bhat ai ahh et do ay as ren Clutch et apse ao Transmission Ge WH Por Suspension Wo e CUR TEL TT oa eee eee RT Front Axle OD seo ace ins abide ae ace Rear Axle PE say cares dd Ge a Wheels and Tires i EES ry Driveline dra mai Eun tun dfe Brakes aO ur ihre dob qq dub Steering ded sequ e d de E mos ye Fuel HB os sub dus sodio S IUS BS Ee ele Exhaust Ea a dom Electrical Instruments and Controls cj Mp TEM RT TP Cab REA Soin CRUCE Doors zr MMC Heater and Air Conditioner I 2 Cargo Maintenance Manual May 2003 FREIGHTLINER LLC A DaimlerChrysler Company CARGO MAINTENANCE MANUAL SE Published by Freightliner LLC 4747 N Channel Ave Portland 97217 Printed in U S A Foreword When performed on a regular basis lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation Added benefits and savings occur when you chec
45. Maintenance Operation Sets 00 08 Maintenance Schedule Table 2 iie mee Rem Rm mx Rad e gom ede eee ec 00 06 Customary Conversion t pam Rosen epa Fm 00 04 Noise Emission Control Systems 00 01 Scheduled Maintenance Intervals Description and 00 05 Torque Speciicatons Tables ccc Ste Rome oh Ro qe odere eh Gad a date 00 03 Verification of INSPECHONS LOG 2 2354 ou 2 Rt Qon deg Roe eho HOD lcs dod LAGE 00 02 Cargo Maintenance Manual December 2004 General Information 00 Noise Emission Control Systems Maintenance 00 01 General Information Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission degradation throughout the life of the vehicle In compliance with the law the Noise Emis sion Control Systems maintenance located in each applicable group within this manual in
46. Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings Holland 1 Disconnect the tractor from the trailer For in structions see Chapter 11 in the Cargo Driver s Manual Thoroughly steam clean the fifth wheel Check for loose nuts or broken bolts on the fifth wheel assembly Inspect for cracks or wear on the mounting bolts 5 Inspect for improper locking action and for cracks or wear on the jaw locking mechanism 6 Inspect for gouges or wear on the fifth wheel top plate Cargo Maintenance Manual January 2000 31 1 31 Inspect for fatigue or cracked welds 8 If you observe any problems doing the previous steps correct them immediately For instructions see Group 31 of the Cargo Workshop Manual Wear safety goggles during removal installation and rebuilding Failure to do so can result in per sonal injury due to parts ejecting under spring compression 9 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 31 03 Fifth Wheel Lubrication Fontaine Oil all moving parts on the fifth wheel and grease the top plate and the two zerk fittings for the bracket
47. add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 11 for the AT and MD Series and Fig 12 for the MT Series 26 Cargo Maintenance Manual January 2000 26 11 31 Frame and Frame Components Title of Maintenance Operation MOP Fifth Wheel 1 Firth Wheel Lubrication s aene oh Pray RR HR n Frame Fastener Torque Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 Frame and Frame Components 31 01 Frame Fastener Torque Check Because of bedding in or seating the frame fas teners must be torqued at the recommended inter vals These intervals apply to new vehicles and to frame fasteners that have been removed and in stalled NOTE For off highway operations retorque the frame fasteners the first 1000 miles 1600 km then periodically depending on the operating conditions CAUTION Do not operate the vehicle with the frame fasten ers improperly tightened Continued vehicle op eration with insufficiently tightened fasteners could result in bracket or frame damage Typical frame fastener applications include front frame brackets suspension brackets fuel tank ex haust and engine supports and frame crossmembers and gussets See Group 00 of this manual for additional informa tion on fasteners and torque values 31 02 Fifth Wheel Inspection All f
48. al injury or property damage IMPORTANT On multi leaf suspensions closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts Freightliner Spring Rear Suspension Spring Brackets and Equalizer Brackets Inspection Inspect the forward and rear spring brackets equal izer brackets and the wear pads for wear cracks and other damage If any of these conditions exist replace the damaged bracket s and wear pad s See Group 32 of the Cargo Workshop Manual for instructions Failure to replace the forward spring brackets equalizer brackets or rear spring brackets if they are worn cracked or otherwise damaged could result in progressive damage to and eventual 32 breakage of the bracket This could cause a loss of vehicle control resulting in injury or property damage Freightliner Spring Shock Absorber Check Make sure that the shock absorber brackets are tight and that the shock absorber is not striking or rubbing on the frame or some other part of the chas sis Check the rubber mounting bushings and replace if worn Inspect the shock absorber for oil leakage If the shock absorber is worn or damaged replace it with a new one Freightliner AirLiner Component Clearance Check Check that the air line support brackets are posi tioned so the air lines do not rub against anything Reposition any configurations that could contact and result in friction and we
49. all four U joint seals IMPORTANT Fresh lubricant must be seen es caping from all four bearing cup seals of each U joint On full round yokes if most of the grease being added to a U joint can be seen escaping from just one of the U joint seals bend the tabs of the lockstrap away from the heads of the bear ing cup capscrews then check the torque on the bearing cup capscrews at that seal Tighten the bearing cup capscrews as follows 5 16 24 capscrews 24 Ibf ft 32 N m 3 8 24 capscrews 37 lbf ft 50 10 20 93 1410050 A After grease appears cover the pressure relief hole while continuing to lubricate Slip Joint Grease Fitting with grease gun attached Yoke Plug Grease Half Round Yoke Yoke Plug Pressure Relief Hole Slip Joint Seal Full Round Yoke U Joint Grease Fitting Fig 4 Slip Joint and U Joint Lubricating Bend the lockstrap tabs up against a flat side of each capscrew If the capscrews were already tight or all of the U joint seals still do not purge remove the bearing cup at that seal and exam ine the seal for damage If the seal is damaged replace the complete U joint assembly If grease does not appear at one of the seals use a screwdriver to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mal let on the side opposite the dry seal while continuing to apply gun pressure
50. ance Interval NOTE Maintenance operations appearing in italics in this table are for noise emission control components M4 Maintenance Interval Operations Maint Oper No M4 Maintenance Interval Operations 00 10 00 11 Perform All M1 Operations Perform All M2 Operations 00 12 Perform All M3 Operations 01 01 Engine Support Fasteners Checking 20 02 Radiator Pressure Flushing and Coolant Changing 26 02 Manual Transmission Oil Changing and Magnetic Plug Cleaning 31 01 Frame Fastener Torque Checking 33 04 All Axle Alignment Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 46 04 Power Steering Reservoir Fluid and Filter Changing Numbers in this table are maintenance operation ref erence numbers matching those in the text of this manual The M4 Maintenance consists of all M1 M2 and M3 Interval Operations plus the other operations Cargo Maintenance Manual December 2004 00 17 00 General Information M5 Maintenance Interval Operations Table 00 14 IMPORTANT After performing all operations in this NOTE Numbers in this table are maintenance opera table perform all daily and weekly maintenance op tion reference numbers matching those in the text of erations listed in the Pretrip Inspection and Daily this manual The M5 Maintenance consists of all M1 Maintenance chapter of the Cargo Driver s Manual M2 M3 an
51. ar There must be at least 1 inch 25 mm clearance around the rubber air spring when inflated If the clearance is less than 1 inch 25 mm relocate the obstructing parts A CAUTION Failure to relocate obstructing parts could result in damage to the air spring Freightliner AirLiner Component Inspection and Operation Check Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury and property damage 1 Chock the front tires Raise the rear of the ve hicle so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation If any air springs remain partially or Cargo Maintenance Manual January 2000 32 1 32 fully inflated see Group 32 of the Cargo Work shop Manual 3 Inspect each air spring for wear at its connection to its pedestal Replace any worn air springs for instructions see Group 32 of the Cargo Work shop Manual 4 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are cracked grind them out and reweld the parts 5 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts
52. argo Driver s Manual Also perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval M3 Maintenance Interval Operations General Information NOTE Numbers in this table are maintenance opera tion reference numbers matching those in the text of this manual The M3 Maintenance consists of all M1 and M2 Interval Operations plus the other operations listed below Maint Oper No M3 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 11 Perform All M2 Operations 01 02 Engine Drive Belt Inspection 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator and Starter Checking 25 02 Clutch Inspecting and Adjusting 26 05 Allison Transmission Fluid and Filter Changing 32 03 U Bolt Torque Checking 40 01 Wheel Nut and Rim Nut Checking 42 11 47 01 Air Dryer Checking Bendix AD 9 Fuel Tank Draining and Vent Checking 54 01 Electrical System Checking 00 16 Cargo Maintenance Manual December 2004 General Information IMPORTANT After performing all operations in this table perform all daily and weekly maintenance op erations listed in the Pretrip Inspection and Daily Maintenance chapter of the Cargo Driver s Manual 00 M4 Maintenance Interval Operations Table 00 13 Also perform all M1 M2 and M3 Maintenance Inter listed below val Operations at the M4 Mainten
53. ase distribution Lower the tires to the ground and regrease both top and bottom bushings until new grease is seen at the seal on the bushing opposite the fittings The grease seal will accept the grease pressure without damag ing the seal and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue 33 pumping until new grease is seen at the seal on the bushing opposite the grease fitting When lubricating knuckle pin bushings at M1 through M5 do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease until new grease is seen at the grease seal on the bush ing opposite the fittings The grease seal will accept the grease pressure without damaging the seal and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue pumping until new grease is seen at the seal on the bushing opposite the grease fitting 33 02 Tie Rod End Inspection 1 Shake the cross tube Movement or looseness between the tapered shaft of the ball and the cross tube socket members means that the tie rod end assembly must be replaced 2 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping See Fig 2 Replace the parts if this cannot be done For instructions see the axle ma
54. ating temperature of 160 to 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug While the transmission fluid is warm remove the drain plug Transmission and drain the fluid Disconnect the fill tube from the oil pan IMPORTANT Examine the used transmission fluid for dirt coolant or water and metal par ticles If any of these contaminants are present a problem may exist within the transmission system 4 Remove the modulator retainer bolt and retainer from the side of the transmission case See Fig 6 Remove the modulator Remove the seal ring from the modulator and discard the sealring 1 10 05 94 f260131a 1 Modulator 2 Modulator Sealring 3 Retainer 4 Retainer Bolt Fig 6 Allison AT Series Transmission Modulator 5 Support the oil pan Remove the twenty one washer head screws that attach the oil pan to the transmission case Remove the pan and dis card the pan gasket Clean the oil pan with mineral spirits Remove the washer head screw that attaches the internal fluid filter to the filter spacer Remove the filter and the fluid intake t
55. bearing area Holland Lubricate all moving parts with oil or a light grease Lubricate the fifth wheel top plate with a waterproof or multipurpose chassis grease Frame and Frame Components 31 2 Cargo Maintenance Manual January 2000 Suspension Title of Maintenance Operation MOP Suspension Inspection Including Cab Shocks SUSPENSION U Bolt Torque Check ess scce ciai wees 32 Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 Suspension 32 01 Suspension Inspection Including Cab Shocks Freightliner Spring Front and Rear Suspension Spring Assemblies Inspection Inspect the front and rear suspension spring assem blies for pitted cracked broken or abnormally bent leaves and extreme rust If any of these conditions exist replace the spring assembly See Group 32 of the Cargo Workshop Manual for instructions Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could oc cur Failure to replace a damaged spring assembly could cause an accident resulting in serious per son
56. bricated or plated zinc phosphate conversion coated cadmium plated waxed Table 1 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Cargo Maintenance Manual December 2004 00 3 00 Torque Specifications Tables 00 03 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged ee ee Grade 5 Bolt s odd B iac 8 2 xi or C 8 2 Grade G Nut Torque N m Torque N m Torque Ibf ft N m MZ _ n moms econ 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 17 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 7 16 14 45 61 65 88 65 88 7 16 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 8 18 155 210 215 292 3 410 240 325 340 461 340 461 3 416 270 366 380 515 7 8 9 385 522 540 732 7 814 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if
57. by following the procedures in Group 32 of the Cargo Workshop Manual 6 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted For instructions see Group 32 of the Cargo Workshop Manual 7 Remove the safety stands and lower the rear of the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system 8 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Cargo Workshop Manual for possible causes and corrections Freightliner AirLiner Control Rod Check 1 Without disconnecting the control rods attempt to move by hand each of the control rod ends up down in and out If there is any movement examine the control rods for wear or damage Replace if necessary Inspect the rubber bushings for cracks or cuts Check for any shifting of the barpin Check for cracks in the metal components and welds Cab Mount Shock Absorber Check Make sure that the shock absorber brackets are tight and that the shock absorber is not striking or rubbing on the frame or some other part of the chas Suspension sis Check the rubber mounting bushings and replace if worn Inspect the shock absorber for oil leakage If the shock absorber is worn or damaged replace it with a new one 32 02 Suspension Lubrication Freightliner Spring F
58. conjunction with the vehicle workshop manual provides these instructions to owners Normal Vehicle Use The maintenance instructions contained in this manual are based on average vehicle use and nor mal operating conditions Unusual vehicle operating conditions may require service at more frequent in tervals Recommendations for Replacement Parts Replacement parts used for maintenance or for the repair of noise emission control systems should be genuine OEM parts If other than genuine OEM parts are used for replacements or for the repair of compo nents affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine OEM parts in performance and durability Noise Emissions Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise emis sion control systems Tampering With the Noise Control System is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 the removal or rendering inoperative by any person other than for purposes of mainte nance repair or replacement of any device or ele ment of design incorporated into any new vehicle for the purpose of noise control prior to its sale or deliv ery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or ele ment of design has been removed or rendered inop erative by any perso
59. connections on the speedometer sen sor Remove the sensor and check it for mois ture See Group 54 in the Cargo Workshop Manual for removal and installation procedures 8 Check the connections on the tachometer Re move the sensor and check it for moisture See Group 54 in the Cargo Workshop Manual for removal and installation procedures 54 02 Battery Battery Box and Cable Check and Clean Batteries release a gas mixture that is explosive Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat Make sure the battery compart ment has been completely vented before discon necting or connecting battery cables Cargo Maintenance Manual January 2000 54 1 54 Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear safety glasses when working around batteries 1 Remove any corrosion from the battery box and the top of the battery Use distilled ammonia or a soda solution to neu tralize any acid present Flush off the ammonia or soda solution with clear water 2 Check the battery cases for cracks Replace a battery if its case is cracked 3 Disconnect the battery cables from the battery posts and check for corrosion If corrosion is found clean the terminals and posts using a wire brush and a solution of bak ing soda and water Use the solution sparingly Connect the cables to the batteries and tighten them 70 Ibf i
60. crew on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or damage 20 20 02 Radiator Pressure Flush and Coolant Change NOTE For additional instructions on cleaning and flushing the cooling system see the engine manufacturer s maintenance and operation manual 1 Drain the radiator 1 1 Remove the surge tank cap 1 2 Open the petcock at the bottom of the radiator to drain the engine coolant N Disconnect the radiator inlet and outlet hose con nections 3 Flush the radiator 3 1 Attach a flushing gun nozzle to the radia tor outlet 3 2 Run water in until the radiator is full 3 3 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core CAUTION When flushing the radiator do not apply more than 20 psi 138 kPa air pressure Excessive pres sure can damage the radiator or heater core 4 Drain the radiator and flush the radiator until clean water flows from the radiator Remove the flushing gun Close the petcock at the bottom of the radiator Connect the hoses The hose clamps can be ei ther T bolt clamps Fig 1 or Breeze Constant Torque clamps Fig 2 When working with T bolt type hose clamps tighten the clamps 55 Ibf in 620 N cm These clamps are now standard on hoses with an in side diameter greater than 2 inches 51 mm When installing the Bree
61. d M4 Interval Operations plus the other Also perform all M1 M2 M3 and M4 Maintenance operations listed below Interval Operations at the M5 Maintenance Interval M5 Maintenance Interval Operations Maint Oper No M5 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 11 Perform All M2 Operations 00 12 Perform All M3 Operations 00 13 Perform All M4 Operations 42 12 Air Dryer Desiccant Replacing Bendix AD 9 42 14 Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 6 QR 1 and ST 3 00 18 Cargo Maintenance Manual December 2004 General Information 00 Lubrication and Fluid Level Check M1 schedules Maintenance Operation 00 15 Table 7 summarizes all Lubrication and Fluid Level Check operations that must be performed at the M1 Maintenance Interval for Schedules II and III Maintenance operation numbers given in the table are reference numbers used to help you find detailed Il and Ill 00 15 instructions in the manual on the lubrication or fluid check Lubrication and Fluid Level Check Locations 00 17 can be used as guide by those who do not need to consult the detailed lubrication and fluid check instructions given elsewhere in the manual Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check for Schedules Il and III Maint Operation Number Operation Description 25
62. e proce dures under CHECKING THE FLUID LEVEL MT Series Fig 9 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires 2 Start the engine and check that the transmission fluid temperature is 160 200 F 71 to 93 C before draining the fluid Shift the gear selector to neutral and shut down the engine Cargo Maintenance Manual January 2000 26 7 26 Transmission 08 30 96 1 Transmission Housing 2 Transmission Oil Pan Gasket 3 5 16 18 Washer Head Capscrew 4 Plug 5 Transmission Oil Pan cs odo X 15 2 14 7 8 6 Magnet Drain Plug Gasket Drain Plug 5 16 18 x 5 8 Capscrew Flatwasher 13 10 1260369 11 Transmission Oil Filter 12 Oil Filter Spacer 13 O Ring 14 Oil Filter Tube 15 Plug Fig 9 Allison MT Series Transmission Filter Removal 26 8 Cargo Maintenance Manual January 2000 Transmission 3 Place a suitable container under the transmis sion Remove the drain plug and gasket from the transmission oil pan Allow the fluid to drain 4 Remove the nut that secures the oil filler tube to the transmission pan 5 Remove the 21 capscrews that secure the trans mission oil pan to the transmission housing Re move the transmission oil pan and gasket from the transmission Discard the gasket 6 Clean the oil pan of any debris and residual fluid in an approved cleaning tank 7 Remov
63. e the washer head capscrew that secures the filter to the transmission Remove the filter and the filter intake pipe from the transmission 8 Separate the filter intake pipe from the filter Dis card the O ring Clean the tube 9 Install the filter intake pipe on the new filter In stall a new O ring on the filter intake tube Lubri cate the O ring with a light coat of transmission fluid 10 Insert the filter intake pipe into the orifice on the bottom of the transmission Secure the filter with the 5 16 18 x 5 8 inch washer head capscrew Tighten the capscrew 10 to 15 14 to 20 N m 11 Place a new oil pan gasket on the oil pan If de sired a sealant may be used on the gasket but it must be applied carefully Sealant must be pre vented from contacting areas of the oil pan flange that are inside the raised bead of the flange NOTE Do not use gasket type sealing com pounds or cement anywhere inside the trans mission or where they might get washed into the transmission Non soluble vegetable base cooking compounds or fibrous grease must not be used inside the transmission 12 Install the oil pan and gasket onto the transmis sion Check that no dirt or debris enters the pan Secure the pan to the transmission housing with four 5 16 18 washer head capscrews installed into the corners of the oil pan but do not tighten 13 Install the remaining 17 washer head capscrews by hand Check that all of the capscrews
64. eeth on the pawl 3 4 Turn the adjusting nut one eighth turn as shown in Fig 7 Measure the stroke again and adjust until correct 7 pP 07 05 95 p 1420181 A Shorten stroke B Lengthen stroke Fig 7 Brake Stroke Adjusting A CAUTION Do not make the adjusted chamber stroke too short The free stroke must not be less than the measurements given previously If the chamber stroke is too short the linings can drag which could damage the brake 3 5 If removed install the pawl pawl spring gasket and pressure relief capscrew Tighten the capscrew 15 to 20 Ibf ft 20 to 27 N m Or remove the screwdriver from the pull pawl assembly if equipped 4 Check for correct brake chamber stroke 42 6 Cargo Maintenance Manual January 2000 Brakes 4 With the brakes fully released measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 5 Ref A 4 2 Build air pressure to 100 psi 690 kPa Shut down the engine Fully apply the brakes then measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 5 Ref B The difference between the mea surements is the brake chamber stroke 4 3 The brake chamber stroke must be less than the measurements shown in Table 1 If the brake chamber stroke is incorrect remove the pressure relief cap screw gasket pawl spring and pawl Fig 4 Ref 5 from the s
65. eners 215 to 265 292 to 359 Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 N m NOTE With Allison automatic transmissions it is necessary to remove the four fasteners hold ing the transmission oil cooler Lower the cooler out of the way to provide access to the front engine mount NOTE At engine overhaul and whenever the engine has been removed inspect the lower and upper isolators Fig 1 Refs 1 and 6 and replace them if they are worn See Group 01 of the Cargo Workshop Manual for procedures 10 05 94 1220047a 1 Lower Isolator Engine Support Washer 3 4 x 10 Capscrew 3 4 x 10 Hexnut Engine Mount Upper Isolator Fig 1 Engine Rear Mount Worn or loose drive belts may cause premature bearing failure or engine overheating Excessive ten sion or too little tension on the belt may result in ex cessive and premature belt wear Poly V belts or serpentine belts are retrained by a belt tensioner that requires no tension adjustment Replace the engine drive belt if any conditions described in the visual description are found V belts are installed as indi vidual belts and as matched sets When replacing a matched set of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist the belt to view the belt sidewalls and bottom Visually in spect
66. es of each rear Axle axle one grease fitting for each camshaft bracket 20 42 14 Air Valvest Disassemble clean and lubricate the air valves 21 60 03 Cab Roof Vent Spray light oil on hinges Lubricating and piston shafts Lubrication Table Text No Ref Components Remarks Nos 1 32 02 Front Lube on both sides of Suspension vehicle one grease fitting Spring Pinst for each spring pin two and Shackle grease fittings for each Pinst shackle 46 02 Drag Link Two grease fittings one on each end 46 03 Power Check fluid level in the 46 04 Steering reservoir 46 03 Change 46 05 fluid and filter 46 04 when required Lubricate the steering gear 46 05 46 01 Steering Three grease fittings Driveline lubricate both universal joints and the slip joint splines 42 09 Slack Lubricate both sides of Adjusters axle one grease fitting for Front Axle each slack adjuster 42 07 Camshaft Lubricate both sides of Brackets axle one grease fitting for Front Axle each camshaft bracket 33 03 Tie Rod Two grease fittings one on each end of tie rod 33 01 Knuckle Pins Two grease fittings one on top and one on bottom of knuckle pin Lubricate both sides of the axle 25 01 Clutch One grease fitting on Release bottom of the release Bearing bearing Two grease and Release fittings on the release Cross Shaft cross shaft 26 01 Tran
67. forming operations for the 33rd Maintenance Number complete the M1 opera tions only not the Initial Maintenance opera tions To determine the distance hours for the 33rd Mainte nance Number add your schedule s distance hours for the 1st Maintenance Number to the distance hours for the 32nd Maintenance Number then perform the operations listed in the applicable table in the Maintenance Operations Tables For the 34th Maintenance Number add the distance hours for the 2nd to the distance hours for the 32nd con tinue this pattern for each successive Maintenance Number Cargo Maintenance Manual December 2004 00 7 00 General Information Maintenance Schedule Table 00 06 Maintenance Schedule Table Maintenance Schedule Table Maintenance Intervals Maintenance Schedule Models peration Frequency Miles km Hours Initial Maintenance IM first 1000 1600 100 Maintenance 1 M1 every 1000 1600 100 Schedule Severe Service All Maintenance 2 M2 every 4000 6400 400 vehicles that annually travel up Maintenance 3 M3 every 8000 12 800 800 to 6000 miles 10 000 km Maintenance 4 4 every 16 000 25 600 1600 Maintenance 5 M5 every 32 000 51 200 3200 Initial Maintenance IM first 8000 12 000 Maintenance 1 M1 every 8000 12 000 Schedule Il Short Haul Transport All Maintenance 2 M2 every 16 000 24 000 vehicles that annually travel up Maintenance 3 M3 every 32 000 48 000
68. heck the driveshaft for missing balance weights and for debris build up Remove any build up If any balance weights are missing re move the driveshaft and have it balanced see Group 41 of the Cargo Workshop Manual 8 For driveshafts with slip joints check that the yoke plug is not loose or missing See Fig 4 Ref 2 Replace the yoke plug if needed If the yoke plug is missing the splined shaft may be hitting the yoke plug and knocking it out check the driveshaft for proper length 41 02 Driveline Lubrication U Joint Lubrication 1 Wipe all old grease and dirt from each U joint grease fitting See Fig 4 Ref 8 2 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the U joints NOTE If a low pressure adapter is not used with the high pressure gun the U joints may not receive enough lubricant 41 2 Cargo Maintenance Manual January 2000 Driveline 41 MY 05 27 93 Y f410012a Attempt to bend the sleeve yoke and splined shaft back and forth Fig 2 Slip Joint Spline Wear Check A A 1 A D 06 13 96 Measurement 3 76 mm Measurement 0 005 0 127 mm Measurement 0 010 0 254 mm Measurement 0 015 0 381 mm f410110b com Fig 3 Driveshaft Runout Specifications 3 Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until new grease can be seen at
69. hydraulic system may cause undue wear of transmission parts make valves stick and clog passages It is important to check the fluid level cold to deter mine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a flat surface 2 Apply the parking brake and chock the tires 3 Run the engine for at least one minute 4 Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraulic system 5 Shift to NEUTRAL and allow the engine to idle at 500 to 800 rpm 6 With the engine running at idle remove the dip stick from the tube and wipe clean 7 Insert the dipstick into the tube and remove the dipstick 8 Check the fluid level reading and repeat the check procedure to verify the reading If the fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD RUN band add or drain fluid as needed to adjust the fluid level to the middle of the COLD RUN band See Fig 11 for the AT and MD Series and Fig 12 for the MT Series CAUTION Do not fill above the COLD RUN band if the trans mission fluid is below normal operating tempera ture As fluid temperature increases so does the fluid level Filling above the COLD RUN band when the transmission is below normal operating Transmission 12 01 97 A Cold
70. i ERN dcl damit Rol eed dap opes 33 01 Tie Rod End InSpectiOri secs rex eee x OG ees 33 02 WMEZAGC End PUDNCANOM cs aras ated eod ud Ue ad tte daos Rhee ae d DAR 33 03 Cargo Maintenance Manual June 2001 Front Axle 33 01 Knuckle Pin Lubrication Hold a pressure gun on each fitting until fresh grease appears See Fig 1 This will ensure that all the old contaminated grease has been forced out It is not necessary to exceed 4000 psi 27 560 kPa The best distribution of new lubricant and the best purg ing of old lubricant occurs when about 4000 psi 27 560 kPa pressure is applied at the grease gun nozzle Using a 40 to 1 booster the air should be limited to 100 psi 689 kPa using a 50 to 1 booster the air should be limited to 80 psi 551 kPa Higher or lower pressures are not recommended 10 20 93 1320032 A Pump lubricant into each grease fitting until fresh grease comes out here 1 Grease Fitting Fig 1 Meritor Front Axle When lubricating knuckle pin bushings for initial maintenance raise the front axle until the front tires are off the ground Wipe the lube fittings clean and slowly feed multipurpose chassis grease NLGI grade 1 or 2 into each bushing area while turning the wheels from extreme right to left and back again lock to lock This will eliminate small air pockets and improve gre
71. id to the reservoir as required Do not exceed the FULL mark 12 Continue the process until the fluid level no longer changes The fluid level is correct when it is in the full range on the dipstick Cargo Maintenance Manual January 2000 46 1 46 Steering 46 05 Steering Gear Lubrication 1 Wipe off debris from the grease fitting 2 Using a hand type grease gun apply multipur pose chassis grease until the grease starts com ing out of the sector shaft dirt and water seal 46 2 Cargo Maintenance Manual January 2000 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Tank Drain and Vent Check da wes Dow uec d xd RR tae Eu 47 01 Cargo Maintenance Manual January 2000 Fuel 47 01 Fuel Tank Drain and Vent Check 1 Remove the plug or open the drain valve at the bottom of the fuel tank and allow the tank to drain until all traces of water and sediment have disappeared Install the plug or close the drain valve Remove the fuel cap and clean it with solvent Make sure the fuel cap vent is open 4 Install the cap 47 Cargo Maintenance Manual January 2000 47 1 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission 5 49 01 Cargo Maintenance Manual January 2000 Exhaust 49 01 Exhaust System
72. ifth wheel maintenance adjustment and re building must be done only by a qualified me chanic Improper or incomplete procedures could result in possible disengagement of the trailer from the tractor which could result in personal injury or property damage Fontaine 1 Disconnect the tractor from the trailer For in structions see Chapter 11 of the Cargo Driver s Manual Thoroughly steam clean the fifth wheel Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check for loose nuts or bolts on the fifth wheel and on the mounting 31 5 Check that all springs are securely fastened and not deformed WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could eject which could cause serious per sonal injury 6 Check wedge adjustment 6 1 Open the kingpin lock and vertically in sert a 2 inch 51 mm diameter shaft 6 2 Release the lock by tripping the release latch at the bottom of the throat 6 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance 7 f you observe any problems doing the previous steps correct them immediately For instructions see Group 31 of the Cargo Workshop Manual WARNING Wear safety goggles during removal installation and rebuilding Failure to do so can result in per sonal injury due to parts ejecting under spring compression 8
73. ild up of road debris on the con denser fins Using a whiskbroom and air pres sure or a spray of soapy water carefully clean off the condenser be careful not to bend the fins Cooling Check 1 Start the engine and set engine speed at 1500 rpm Close the doors and windows IMPORTANT When outside temperature and humidity are high it will take longer to cool the cab especially if fresh air vents are left open 2 Turn on the air conditioner set the controls at maximum cooling and blower speed 3 Allow the system to run for at least 10 minutes longer on hot and humid days 83 2 Check air flow from the vents If there is not enough air flow check the air intake vent for blockage and the blower motor for proper opera tion If the air flow is not cold enough see Group 83 of the Cargo Workshop Manual 5 Carefully feel the system lines The compressor discharge line should feel hot e The condenser inlet line should be notice ably warmer than the outlet line The line from the condenser should feel warm The inlet and outlet lines of the receiver drier should be about the same tempera ture The line from the receiver drier to the evaporator should feel warm The line from the evaporator to the com pressor should feel cold NOTE Oily spots on the lines or at the fittings could indicate a system leak Refrigerant Check If equipped with a moisture indicator sight glass check the color
74. ing the tightness of fasteners Maintenance manuals do not contain detailed repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers scheduled inspection and mainte nance of vehicle components Driver s operator s manuals do not contain de tailed repair or service information Freightliner LLC publishes this manual to aid in the identification of serviceable replacement vehicle parts This manual is used in conjunction with the parts book and the service parts catalog microfiche Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid These bulletins pertain to special situations that involve service work or replace ment of parts in connection with a recall no
75. k Release and Flipper Valves Check 0 0000 cece eee 42 05 Relay Valve Check aieo edere d eund ardet adde dave wade Ps 42 04 Cargo Maintenance Manual January 2000 Brakes 42 01 Air Dryer Inspection Bendix AD 9 42 42 03 Air Brake Valve Operation Check 1 Check the reservoirs for moisture A small amount teaspoon or less is normal Larger amounts may mean that the desiccant needs to be replaced Check the mounting and connecting lines 2 Tighten the fasteners attaching the air dryer to the vehicle Use the following torque values 28 38 N m for SAE grade 5 3 8 16 fasteners e 135 183 N m for SAE grade 5 5 8 11 fasteners 3 Check all air lines fittings and electrical connec tions for damage leakage or looseness 4 Replace damaged or leaking parts and tighten loose fittings or electrical connections 42 02 Foot Brake Valve Actuator Lubrication 1 Clean any dirt gravel and other foreign debris from the plunger boot and brake base bracket 2 Check the brake plunger boot for cracks holes or deterioration Replace if necessary 3 Lift up the edge of the brake plunger boot and check the plunger for existing lubrication If the plunger is dry remove it by removing the cotter pin from the clevis pin and pulling the clevis pin out Remove the piston rod and boot Lift out the plunger Lubricate the plunger and the tip of the piston rod with ba
76. k that the engine undercarriage and noise emission control parts are in good working order during lubrication This maintenance manual explains when you should lubricate parts and what to look for when checking for wear or damage For daily and weekly checks see the vehicle driver s operator s manual IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightliner LLC reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice For additional information please contact Freightliner LLC Service Systems and Documenta tion Box 3849 Portland OR 97208 3849 U S A or refer to http www Freightliner com http www Freightliner Trucks com or http www SterlingTrucks com Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to c
77. ket fit while the screws are being tight ened IMPORTANT The oil pan bolts must main tain a minimum torque of 60 Ibf in 700 N cm after the oil pan gasket has taken set 14 Install the fill tube at the side of the pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 15 Install a new sealring on the modulator then in stall the modulator and sealring in the side of the transmission case Install the modulator retainer and retainer bolt and tighten the retainer bolt 13 to 16 Ibf ft 18 to 22 N m 16 Install the drain plug and gasket and tighten the plug 15 to 20 20 to 27 N m 17 Replace the external auxiliary fluid filter 18 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid 26 6 Cargo Maintenance Manual January 2000 Transmission See Table 1 for approved transmission lubri cants and Table 2 for lubricant capacities 19 Check and adjust the fluid level using the proce dure under CHECKING THE FLUID LEVEL MD Series Fig 8 JA SE 1 2 4 3 4 5 6 7 f2 06 04 99 60130a 1 O Ring 5 Seal 2 Drain Plug 6 Filter Cover 3 Filter 7 M10 Bolt 4 O Ring Fig 8 Allison MD Series Transmission 1 Park the vehicle on a level surface and apply the parking brakes 2 Run the engine until the transmission fluid reaches the operating temperature of
78. l Title of Maintenance Operation MOP MOP Number Ar CGomptessor Inspection HO SOL x 2525 ha em Re grin c dae ee dees 13 01 Cargo Maintenance Manual January 2000 Air Compressor 13 01 Air Compressor Inspection Holset Inspect the air intake line oil supply and return lines and coolant supply and return hoses for tight connec tions and general condition Tighten the connections and replace the lines and hoses as needed If the compressor air intake adapter is loose remove the adapter replace its gaskets and securely install it Check the cooling fins on the compressor crankcase Clean the fins if they are clogged with debris 13 Cargo Maintenance Manual January 2000 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator and Starter Check cock ode ced E ue 15 01 Cargo Maintenance Manual January 2000 Alternators and Starters 15 01 Alternator and Starter Check 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Cargo Work shop Manual 2 Clean and tighten all charging system electrical connections as needed 3 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 4 Check the battery cable connections to and from the s
79. l Nut 5 and i _ 6 Spoke 3 410 Gunite 200 225 270 305 Rear Wheel Nut 5 and 6 Spoke With Channel Spacer 3 4 10 Gunite 200 225 270 305 Fig 2 Rear Wheel Nut 5 and 6 Spoke With Corrugated 3 4 10 Gunite 240 260 325 350 Channel Spacer Fig 3 On front axles with over 12 000 Ibs 5448 kg capacity tighten the wheel nuts 240 to 265 Ibf ft 325 to 359 N m Gunite part number W 854 nut with a phosphate and oil coating must be used Table 3 Spoke Type Wheel Fastener Torque Cargo Maintenance Manual January 2000 40 1 40 Wheels and Tires 1 1 1 2 o Ko Ix N 3 4 6 7 ON 3 gt 3 704 5 6 9 N J 5 ENIN 8 2 A B C D 05 27 93 1400057 A 8 Stud Disc Wheel C 6 Spoke Wheel B 10 Stud Disc Wheel D 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening Sequence NS B b SN N M c NN ps NN KO N A 4 NX 7 Ll f400033a 05 16 94 Fig 2 Non Corrugated Channel Spacer il INT 1400032 10 05 94 Fig 3 Corrugated Channel Spacer Cargo Maintenance Manual January 2000 40 2 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number E up Steere Sees ere 41 01 OKVE INS EW OMCAUOM ENS EAS aie are ded item
80. lack adjuster housing If equipped with a pull pawl as sembly Fig 6 carefully insert a screw driver and raise the relief cap about 1 8 inch 3 2 mm Maximum Allowable Brake Chamber Stroke With Meritor Automatic Slack Adjusters Chamber Size Effective sg ds wable Area squareinenes inches mm B minus A 12 Less than 1 3 8 35 16 Less than 1 3 4 44 20 Less than 1 3 4 44 24 Less than 1 3 4 44 24 Long Stroke Less than 2 51 30 Less than 2 51 Adjust the brakes whenever the applied stroke exceeds the maximum Table 1 Maximum Allowable Brake Chamber Stroke With Meritor Automatic Slack Adjusters CAUTION Before turning the adjusting nut remove the pressure relief capscrew gasket pawl spring and pawl If equipped with a pull pawl assembly raise the relief cap as instructed Failure to do so could strip the teeth on the pawl 4 4 Turn the adjusting nut one eighth turn as shown in Fig 7 Measure the stroke again and adjust until correct 42 If the stroke varies or remains greater than the specified range check the brake components including the camshafts camshaft bushings anchor pins rollers chamber brackets clevis and clevis pins For instructions see Group 42 of the Cargo Workshop Manual 4 5 If removed install the pawl pawl spring gasket and pressure relief capscrew Tighten the capscrew 15 to 20 Ibf ft 20 to 27 N m Or remove the screwdri
81. lease Cross Shaft Lubrication 25 Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 Clutch 25 01 Clutch Release Bearing and Release Cross Shaft Lubrication Clutch Release Bearing A CAUTION Do not over lubricate the release bearing Over lubricating could contaminate the clutch internally causing clutch slippage and eventual clutch failure On clutches with a grease type release bearing Fig 1 wipe the dirt from the grease fitting Using a pressure gun and high temperature grease only lu bricate the release bearing at the grease fitting until the grease starts coming out of the fitting Use only a lithium based grease that meets NLGI grade 1 or 2 specifications 05 27 93 1250081 Fig 1 Release Bearing Grease Fitting NOTE On clutches with a sealed release bear ing the release bearing is lubricated at the time of manufacture and requires no additional 25 grease for the life of the bearing This type of release bearing is not equipped with a grease fitting Clutch Release Cross Shaft The clutch release cross shaft is equipped with two grease fittings one at each side of the transmission clutch housing Wipe the dirt from the grease fittings Using a pressure gun lubricate the cross shaft with multipurpose chassis grease 25 02 Clutch Inspection and Adjustment See Group 25 of the Cargo Workshop Manual for clutch inspection and adjustment
82. lubricants Ry hg A 4 f 7 Lh 7 A s d IZ PF FB 10 05 94 f260006b A Full B Low Approved Transmission Lubricants Lubricant Type Temperature F C Vi Eaton Fuller Transmissions Heavy Duty Engine Oil API Above 10 1 2 40 or 50 Service Classification SF CD Below 10 12 30 Allison AT and MD Series Transmissionst 25 to 120 32 to 48 Allison MT Series Transmissions Dexron Il Dexron 10 to 120 23 to 48 Dexron III 10 to 120 23 to 48 Type C4 10 to 120 12 to 48 SAE 10W Type C4 32 to 120 0 to 48 SAE 30W Lubricants listed in order of preference Do not mix types of oil t Factory filled with Dexron For off highway operation or where ambient temperature is consistently above 86 F 30 or below 25 F 32 re fer to the manufacturer s fluid recommendations Table 1 Approved Transmission Lubricants CAUTION Operating an Eaton Fuller transmission with the oil level higher or lower than recommended can result in transmission damage Do not overfill the transmission Overfilling the transmission will force oil out of the case through the main shaft Fig 1 Transmission Oil Level Checking openings Oil overflow may also drain onto the clutch or clutch brake causing additional prob
83. mbly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Repeat this procedure for all of the inner wheel nuts in the sequence shown in 40 Fig 1 then tighten all of the outer wheel nuts in the same sequence CAUTION Too little wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area See Table 1 Table 2 or Table 3 for wheel nut torque specifications and see Fig 1 for the tighten ing sequence Fastener Torque for 10 Hole Disc Wheel With Inner and Outer Locknuts Description Nut Size M usos hay ads Front Wheel Nut 3 4 16 1 1 8 16 Accuride 450 500 610 680 Rear Wheel Inner Nut 3 4 16 Accuride 450 500 610 680 Rear Wheel Outer Nut 1 1 8 16 Accuride 450 500 610 680 Wheel Stud Retainer Nut 3 4 16 Accuride 175 200 235 270 Table 1 Fastener Torque for 10 Hole Disc Wheel With Inner and Outer Locknuts Fastener Torque for 8 Hole Disc Wheel With Cone Locknuts Description Nut Size Torque Mec Front and Rear Wheel Nuts M20 280 310 380 420 Table 2 Fastener Torque for 8 Hole Disc Wheel With Cone Locknuts Spoke Type Wheel Fastener Torque a Wheel Torque dry threads Description Size Manufacturer Ibf ft N m Front Whee
84. n 800 N cm Spray each connec tion with dielectric red enamel See Table 1 for approved brands Approved Dielectric Grease and Spray Sealants Material Approved Brand s Dielectric Grease Lubriplate FLP DS ES Dielectric Red Enamel 3 M 1602 Spray IVI Spray Sealer Spray On B 6 665 Table 1 Approved Dielectric Grease and Spray Sealants 4 Check the battery to starter cables Look for kinking corrosion breaks in the insulation and heat damage Check that the cable clamps are not bent damaged or stripped of insulation IMPORTANT If a battery cable is damaged re place the entire cable Never splice a battery cable 5 Check the terminals on the battery shut off Switch if so equipped Make sure they are clean and tight 6 Check the mounting fasteners for tightness The battery box must be kept in good condition to support the batteries securely and to keep them level Electrical Instruments and Controls A CAUTION Failure to keep the batteries held securely in place could result in battery damage such as loose plates or posts 54 03 Ground Cables Check and Clean Check that the ground cables are clean undamaged and tight If needed disconnect them clean the mat ing surfaces with a soda solution then connect them securely Spray the ground cable connections with dielectric red enamel See Table 1 for approved brands 54 2 Cargo Maintenance Manual
85. n Among those acts presumed to constitute tampering are the acts listed below A Removal of engine noise deadening panels B Removal of or rendering the engine speed gover nor inoperative so as to allow engine speed to exceed manufacturer s specifications C Removal of or rendering inoperative the fan clutch including by passing the control on any thermostatic fan drive to cause it to operate con tinuously Removal of the fan shroud E Removal of or rendering inoperative exhaust sys tem components including exhaust pipe clamp ing F Removal of air intake system components G Removal of hood liners noise deadening pan els Maintenance Instructions Scheduled intervals are in the maintenance tables in Group 00 of this manual A Verification of Inspec tions Log is contained in the following table and should be filled in each time the noise emission con trols on the vehicle are maintained or repaired Cargo Maintenance Manual December 2004 00 1 00 General Information Verification of Inspections Log 00 02 Verification of Inspections Log Verification of Inspections Log Groups 01 and 49 Date Mileage Repair Description Cost Repair Facility Group 01 Engine Group 49 Exhaust 00 2 Cargo Maintenance Manual December 2004 General Information 00 Torque Specifications Tables 00 03
86. n rod and slack adjuster This angle should be greater than 90 degrees in the released position and approach 90 degrees in the applied position See Fig 1 At angles less than 90 degrees brake chamber force is reduced which reduces braking efficiency 2 Check each brake chamber for correct installa tion 2 1 Check each mounting stud for the pres ence of prevailing torque locknuts and hardened flatwashers Make sure that the hardened flatwashers are installed be tween the mounting bracket and the lock nuts Do not install flatwashers touching the service non pressure chamber Brakes 07 27 94 1420009 C Greater than 90 degree angle 3 Slack Adjuster A Brakes Released B Brakes Applied 1 Brake Chamber 2 Piston Rod Fig 1 Angle Between Piston Rod and Slack Adjuster 2 2 If the locknuts are loose tighten them For correct torque values see the appli cable brake chamber section in Group 42 of the Cargo Workshop Manual Observe the piston rod engagement with the cle vis Engagement of at least 7 threads is required there should be 1 inch 25 mm clearance from the centerline of the clevis pin hole to the end of the piston rod See Fig 2 Adjust if needed Check the tightness of the piston rod nut Tighten if needed See if the chamber piston rod is in line with the slack adjuster Misalignment can cause the pis ton rod to rub on the non pressure chamber and cause a dragging brake Repo
87. ng J 35 02 Axle Breather Checking J 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 40 01 Wheel Nut and Rim Nut Checking 41 01 Driveline Inspecting 41 02 Driveline Lubricating Cargo Maintenance Manual December 2004 00 11 00 General Information Maintenance Operation Sets Table 00 08 Required Maintenance Operation Set IM M1 M2 M3 M4 M5 Maintenance Operation Reference Number and Maintenance Operation 42 01 Air Dryer Inspecting Bendix AD 9 42 02 Foot Brake Valve Actuator Lubricating 42 03 Air Brake Valve Operation Checking e oe Je 42 04 Relay Valve Checking e oe 42 05 Quick Release and Flipper Valves Checking 42 06 Brake Chamber Inspecting All Models 42 07 Camshaft Bracket Bushing Lubricating 42 08 Automatic Slack Adjuster Checking oe e e oe Je 42 09 Automatic Slack Adjuster Lubricating e e 42 10 Automatic Slack Adjuster Inspecting e fe 42 11 Air Dryer Checking Bendix AD 9 42 12 Air Dryer Desiccant Replacing Bendix 9 42 13 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix AD 9 42 14 Air Brake Valve Disassembly Cleaning and Inspecting Bendix 6 QR 1
88. not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built If the radiator cap must be replaced make sure that it is the correct cap for the cooling system of the vehicle Because the radiator cap pressure rating affects the operating temperature of the engine installing an improperly rated radiator cap may have adverse effects on the cooling system and engine operating temperatures This could cause premature engine wear or damage 1 Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 1096 of the pressure rating marked on the cap If it doesn t replace the cap Make sure that the re placement radiator cap is correctly rated for the cooling system of the vehicle 2 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 3 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On vehicles with s
89. nt trunnion in the bearings is greater than 0 006 inch 0 15 mm replace the U joint assembly 4 Check the midship bearing and bracket for loose ness and deterioration by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles re place it If the bearing bracket is loose on the frame or the bearing mount is loose on the bracket tighten the mounting bolt nuts 91 123 N m Replace the midship bearing assem bly if the rubber cushion is worn or oil soaked End Yoke Nut Torque Specifications z Torque Description Thread Size N m Transmissions Eaton Fuller FS 4205 5205 5306 6305 6306 1 1 4 18 Uum and 8206 400 450 Fuller RT 6609 1 1 2 18 540 610 100 120 Allison 545 1 2 20 140 160 600 800 Allison MD Series 2 16 815 1085 Single Axle Input Shaft Meritor RS 17 145 RS 19 145 RS 19 220 RS M32 x 1 5 21 145 5 21 230 1000 1230 Meritor 5 23 160 45 1 5 1355 1670 920 1130 Meritor RS 23 240 M39 x 1 5 1250 1530 Coupling Shaft Midship Bearings Spicer 1590 1610 and PP 475 525 1710 1 14 18 4544 712 The Allison AT 545 transmission output shaft end yoke is retained by a 1 2 20 x 1 1 2 inch bolt and a 1 1 16 inch washer Both the bolt and the washer must be replaced each time they are removed Table 1 End Yoke Nut Torque Specifications
90. nts and see Table 2 for axle capaci ties 3 Install the fill hole plug and tighten it 35 47 N m Meritor Drive Axle Recommended Lubricant Ambient Temperature eundi icd Meritor Specification Hypoid Gear Oil API 10 F 12 2 C and up 85W 140 0 76 A ene Classification 15 F 26 1 C and up 80W 140 0 76 B 15 F 26 1 C and up 80W 90 0 76 D 40 F 40 C and up 75W 90 0 76 E 40 F 40 C to 35 F 2 C 75W 0 76 J 40 F 40 C and up 75W 140 0 76 L Synthetic Gear Oil 40 F 40 C and up 75W 90 0 76 N 40 F 40 C and up 75W 140 0 76 M There is no upper limit on these ambient temperatures but axle sump temperature must never exceed 250 F 121 C Table 1 Meritor Drive Axle Recommended Lubricant Meritor Drive Axle Lubricant Capacities Single Axles Axle Type Axle Model DUE Axle Type Axle Model ane ie Single t 5 17 145 33 6 15 9 Single t RS 21 230 39 18 5 RS 17 220 31 14 7 RS 23 160 42 19 9 RS 19 145 34 4 16 3 RS 23 161 37 2 17 6 RS 19 220 31 14 7 RS 23 186 5 21 145 32 15 1 RS 23 240 45 21 3 RS 21 160 39 5 18 7 RS 26 185 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees t Single drive axles equipped with traction equalizers may require a friction modifier to correct a slip
91. nual are reference numbers used to help you find detailed M2 Lubrication and Fluid Level Check for Schedules 1 and III Maintenance Operation 00 16 Maint Operation Number Operation Description 42 07 Camshaft Bracket Bushing Lubricating 42 13 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix AD 9 46 01 Steering Driveline Lubricating Table 8 Maintenance Operation 00 16 M2 Lubrication and Fluid Level Check for Schedules Il and Ill 00 20 Cargo Maintenance Manual December 2004 General Information Lubrication Table 00 Lubrication Tables 00 17 Lubrication Table Text No Ref Components Remarks Nos 14 42 13 Air Reservoir Disassemble clean Automatic inspect and lubricate the Drain Valves automatic drain valves 15 32 02 Suspension Lubricate on both sides of Spring Pin vehicle one grease fitting for each spring pin 16 32 02 Equalizert One grease fitting on each equalizer lubricate on both sides of the vehicle 17 35 01 Rear Axle Check fluid level add 35 03 fluid if low 35 01 Change fluid when required 35 03 18 42 09 Slack Lubricate slack adjusters Adjusters on both sides of each rear Rear Axle axle one grease fitting for each slack adjuster 19 42 07 Camshaft Lubricate camshafts on Brackets Rear both sid
92. nufacturer s service manual 3 Check the tie rod end nut and clamp nut torques Tighten the tie rod end nut 100 Ibf ft 136 and tighten the clamp nut 40 to 55 Ibf ft 54 to 75 N m 33 03 Tie Rod End Lubrication Wipe the tie rod end grease fittings clean then pump multipurpose chassis grease NLGI grade 1 or 2 to the tie rod ends until all used grease is forced out and new grease appears at the ball stud neck 33 04 All Axle Alignment Checking Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the applicable procedure and specifications in Group 35 of the Cargo Workshop Manual Cargo Maintenance Manual June 2001 33 1 33 10 20 93 1320033a NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split Fig 2 Tie Rod End Adjustment Front Axle Toe in Checking For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated ev ery three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Check that the safety stands will support the combined weight of the cab
93. of compounded lubricants during the summer season is about 160 to 220 F 71 104 C The chemicals and addi tives that give these lubricants increased load carrying capacity oxidize faster at temperatures above 220 F 104 C contributing to more rapid lu bricant deterioration For this reason lubricants of this type that operate continuously at high tempera tures must be changed more frequently A CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage Axle Drain and Flush 1 Remove the plug at the bottom of the housing and drain the lubricant while the unit is warm Allow enough time for all the old lubricant to drain completely 2 Flush the unit with clean flushing oil then drain it completely Rear Axle IMPORTANT Do not flush axles with solvent such as kerosene 3 Clean the drain plugs For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of 2 pounds 1 kg of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be neces sary to clean or change the plugs one or more times
94. of the moisture indicator If the indicator is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contami nated with water recover the refrigerant replace the receiver drier evacuate the system and add a full refrigerant charge 83 02 Air Filter Replacement The air filter must be replaced every three months regardless of mileage to permit proper operation of the HVAC system A WARNING The parking brake must be fully set before open ing the front access panel Failure to do so could result in serious injury Cargo Maintenance Manual December 2004 83 1 83 1 Open the front access panel by turning the fas teners at each end of the panel one quarter turn counterclockwise 2 Prop the access panel open using the support rod 3 Open the two spring loaded clamps that secure the air filter to the HVAC assembly and remove the air filter See Fig 1 4 Install a new air filter on the HVAC assembly and secure it by closing the two spring loaded clamps over the air filter 5 Lift the access panel and release the support rod 6 Secure the support rod and press the access panel down until it locks 11 16 2004 1831671 1 Spring loaded Clamp 2 Air Filter Fig 1 Air Filter Replacement Heater and Air Conditioner 83 2 Cargo Maintenance Manual December 2004
95. ollisions or improper use and have undetected structural damage 1998 2005 Freightliner LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Freightliner LLC Freightliner LLC Service Systems and Documentation POC SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Freightliner LLC distributes the following major service publications Workshop Service Manual Maintenance Manual Driver s Operator s Manual Parts Technical Manual Service Bulletins Recall Bulletins Field Service Modifications Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation specifications and troubleshooting Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions procedures for adjustments and for check
96. oup 33 of the Cargo Workshop Manual If corrections are needed see Group 33 of the Cargo Workshop Manual for instructions on adjusting the toe in 33 2 Cargo Maintenance Manual June 2001 Front Axle 33 NS 08 30 94 f330014a Fig 4 Trammel Bar Positioning 08 30 94 1400100 Fig 5 Setting the Trammel Bar Pointers Cargo Maintenance Manual June 2001 33 3 Title of Maintenance Operation Axle Breather Axle Lubricant Change and Magnetic Plug Clean Axle Lubricant Level 35 Index Alphabetical MOP Number Cargo Maintenance Manual January 2000 35 35 01 Axle Lubricant Level Check CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Clean the oil fill hole plug located in the carrier or the side of the axle housing and the area sur rounding it Remove the plug NOTE Some Meritor axles have a small tapped and plugged hole located near and below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 With the vehicle on level ground lubricant must be level with the bottom of the oil fill hole If low add lubricant See Table 1 for approved axle lubrica
97. out under the camhead the camshaft grease seal is worn or damaged or is installed backwards NOTE The use of meter type fittings having a maximum 40 psi 275 kPa pressure relief at shutoff is recommended 05 28 93 A Grease Exit 1 Brake Chamber 2 Slack Adjuster 120011 3 Grease Fitting 10 20 93 NO oO RON 3 4 5 7 6 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or lube plug Fig 3 Camshaft Bracket Bushing Lubrication 42 08 Automatic Slack Adjuster Check 1 Check the boot for cuts tears etc Fig 4 and replace it if necessary 2 Check the brake shoe lining wear to determine the proper reline time 3 Check the free stroke If the vehicle has new brakes or brakes with new linings you must Fig 4 Meritor Automatic Slack Adjuster check the free stroke If the vehicle is in for rou tine maintenance and the brakes or linings are not new go to the next step and check the brake chamber stroke IMPORTANT Do not use installation tem plates to check the slack adjuster angles Installation templates are used only when installing a new slack adjuster or reinstalling the existing slack adjuster 3 1 With the brakes fully released measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 5 Ref A 3 2 Use a p
98. r Automatic Drain Valve Disassembly Clean Inspection and Lubrication Bendix AD 9 Disassemble the drain valve clean the parts with mineral spirits and inspect the parts Replace all rub ber parts and any worn or damaged parts use only genuine Bendix replacement parts or kits Assemble and install the valve then check for proper operation and leakage See Group 42 of the Cargo Workshop Manual for instructions 42 14 Air Brake Valve Disassembly Clean and Inspection Bendix E 6 QR 1 and ST 3 Disassemble each brake valve clean the parts with mineral spirits and inspect the parts Replace all rub ber parts and any worn or damaged parts use only genuine Bendix replacement parts or kits Assemble and install the valves then check for proper opera tion and leakage See Group 42 of the Cargo Work shop Manual for instructions 42 8 Cargo Maintenance Manual January 2000 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link ove ob eats E 46 02 Power Steering Reservoir Fluid Level 46 03 Power Steering Reservoir Fluid and Filter 46 04 Steering Driveline x um do iae Soto eee ode 46 01 Steering Gear HUDIICATION sa icu torn
99. ransmission Oil Level Checking Suspension Lubricating Knuckle Pin Lubricating Tie Rod End Lubricating Axle Lubricant Level Checking Driveline Lubricating Foot Brake Valve Actuator Lubricating Automatic Slack Adjuster Lubricating Drag Link Lubricating Power Steering Reservoir Fluid Level Checking Steering Gear Lubricating Ross TAS Series Cab Mounts Lubricating Cab Roof Vent Lubricating Weatherstrip Door Hinge and Door Latch Lubricating 32 01 Suspension Inspecting including cab shocks 33 02 Tie Rod End Inspecting 35 02 Axle Breather Checking 41 01 Driveline Inspecting 42 01 Air Dryer Inspecting Bendix AD 9 42 03 Air Brake Valve Operation Checking 42 04 Relay Valve Checking 42 05 Quick Release and Flipper Valves Checking 42 06 Brake Chamber Inspecting All Models 42 08 Automatic Slack Adjuster Checking 54 02 Battery Battery Box and Cable Checking and Cleaning 54 03 Ground Cables Checking and Cleaning 83 01 Air Conditioner Checking R 134a Refrigerant Systems 00 14 Cargo Maintenance Manual December 2004 General Information IMPORTANT After performing all operations in this table perform all daily and weekly maintenance op erations listed in the Pretrip Inspection and Daily Maintenance chapter of the Cargo Driver s Manual 00 M2 Maintenance Interval Operations Table 00 11 Also perform all M1 Maintenance
100. rence numbers and descriptions of only those maintenance operations that must be performed at that mainte nance operation set Each maintenance operation set is listed in a separate Maintenance Operations Table Before placing your new vehicle in service determine the correct maintenance intervals that apply to your intended use of the vehicle Refer to the Mainte nance Schedule Table to determine the distance or hour interval at which each Maintenance Operation Set must be performed to comply with your vehicle s schedule For Schedule vehicles equipped with an hourmeter use hours to determine maintenance in tervals rather than distance traveled When the vehicle reaches the actual distance or hours given for an interval refer to the Maintenance Interval Tables to find the Maintenance Operation Set that applies to that interval Then perform the mainte nance operations listed in the applicable Mainte nance Interval Operation Table Use the maintenance operation reference numbers to find instructions in the manual for completion of each operation Complete each Maintenance Operation Set at the required interval Then when you have completed Maintenance Operation Set M5 under the 32nd Main tenance Number listed in the Maintenance Interval Table repeat the pattern The 33rd Maintenance Number will begin at Maintenance Operation Set M1 under the 1st Maintenance Number listed in the Maintenance Interval Table NOTE When per
101. rium grease part number BW 246671 or Penzoil Adhezoplex EP 2 Install the piston rod boot clevis pin and cotter pin If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger Do not over oil Install the plunger boot Lubricate the clevis pin with light oil Check for leakage see Group 42 of the Cargo Workshop Manual for instructions Check for proper operation see Group 42 of the Cargo Workshop Manual 42 04 Relay Valve Check Chock the tires Start the engine and run it long enough to pressurize the air system to at least 80 psi 550 kPa then turn off the engine Repeat as necessary to maintain 80 psi 550 kPa pressure during this check Clean off road grime from the relay valve and any debris from the valve exhaust port Listen for air leakage around the fittings or exhaust port Tighten the fittings as necessary Use two wrenches to avoid twisting the tubing If the valve fails this check or is damaged repair or replace it see Group 42 of the Cargo Workshop Manual for instructions Remove the chocks from the tires 42 05 Quick Release and Flipper Valves Check Chock the tires Start the engine and run it long enough to pressurize the air system to at least 80 psi 550 kPa then turn off the engine Repeat as necessary to maintain 80 psi 550 kPa pressure during these checks Clean off road grime from the valve
102. ront Suspension Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins then apply multipurpose chassis grease with a pressure gun un til the old grease is forced out Freightliner Spring Rear Suspension Lubricate the spring pin by applying multipurpose chassis grease at the grease fitting See Fig 1 Lu bricate with a grease gun until grease appears at the base of the fitting 9 10 05 94 f320268a Fig 1 Forward Spring Bracket Spring Pin Grease Fitting Hendrickson Equalizer Beam End Bushings and Rubber Center Bushings No lubrication is required for the equalizer beam end bushings or equalizer beam rubber center bushings 32 2 Cargo Maintenance Manual January 2000 Suspension 32 32 03 U Bolt Torque Check Check the U bolt torque of both the front and rear axles where applicable CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear In a diagonal pattern tighten the U bolt nuts 5 8 18 205 Ibf ft 278 N m 3 4 16 300 Ibf ft 407 N m 7 8 14 460 Ibf ft 624 N m Cargo Maintenance Manual January 2000 32 3 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AlFAxle Alignment Gnecking s x dca ee debba 33 04 nr ue Aaa tae a
103. ry bar to move the slack adjuster applying the brakes Again measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 5 Ref B The difference between the two measure ments is the initial free stroke and sets the clearance between the linings and the drum The free stroke must be Cargo Maintenance Manual January 2000 42 5 42 Brakes A 4 09 27 94 1420693a 09 27 94 1420180a NOTE For a drum brake A minus B must equal 5 8 to 3 4 inch 16 to 19 mm For a disc brake A minus B must equal 7 8 to 1 1 8 inch 22 to 29 mm A With the brakes applied measure this distance B With the brakes released measure this distance A Insert screwdriver here Fig 6 Pull Pawl Assembly sectional view Fig 5 Measuring Free Stroke e drum brakes 5 8 to 3 4 inch 16 to 19 mm disc brakes 7 8 to 1 1 8 inch 22 to 29 mm 3 3 If the free stroke is incorrect remove the pressure relief capscrew gasket pawl spring and pawl Fig 4 Ref 5 from the slack adjuster housing If equipped with a pull pawl assembly Fig 6 carefully in sert a screwdriver and raise the relief cap about 1 8 inch 3 2 mm CAUTION Before turning the adjusting nut remove the pressure relief capscrew gasket pawl spring and pawl If equipped with a pull pawl assembly raise the relief cap as instructed Failure to do so could strip the t
104. s ton rods move out promptly without binding 2 Release the service brakes and check that the piston rods return to the released positions promptly without binding Read and follow all applicable warnings and in structions in Group 42 of the Cargo Workshop Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious in jury or death 3 Check the service brake chambers for leakage Cargo Maintenance Manual January 2000 42 3 42 3 1 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa A CAUTION Do not overtighten the clamp ring This can distort the flange sealing surface or the clamp ring itself 3 2 Using soapy water coat the service chamber clamp ring Leakage is exces sive if it produces a 1 inch 25 mm bubble within 5 seconds If leakage is detected tighten the clamp ring but do not exceed the maximum torque limits in Group 42 of the Cargo Workshop Manual 3 3 If leakage persists use the instructions in Group 42 of the Cargo Workshop Manual to replace the service brake diaphragm 3 4 Using soapy water coat the area around the piston rod bore No leakage is permit ted If there is leakage use the instruc tions in the applicable brake chamber section in Group 42 of the Cargo Work shop Manual and replace the service brake diaphragm Parking Brake Operation and Leakage Check
105. s and any mate rial from the valves exhaust ports Listen for air leak age around the fittings and exhaust ports Tighten the fittings as necessary Use two wrenches to avoid twisting the tubing If any valve fails this check or is damaged repair or replace it see Group 42 of the Cargo Workshop Manual for instructions Remove the chocks from the tires Cargo Maintenance Manual January 2000 42 1 42 42 06 Brake Chamber Inspection All Models Do not loosen or remove the parking brake clamp ring for any purpose at any time The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable brake chamber section in Group 42 of the Cargo Workshop Manual Do not operate the vehicle with the front brakes backed off or disconnected Backing off or discon necting the front brakes will not improve vehicle handling and may lead to loss of vehicle control resulting in property damage or personal injury NOTE Vehicles operating under severe or ad verse conditions should be checked more fre quently If the brake chamber requires disas sembly see Group 42 of the Cargo Workshop Manual for instructions 1 With the slack adjuster properly adjusted check the angle formed by the centerline of the pisto
106. sition the brake chamber on the mounting bracket if necessary Inspect the condition of the hose s to the brake chamber Check carefully for chafing restrictions such as kinking or bending and make sure the hoses are properly supported Replace a dam aged hose with the same size hose With the service brakes applied check for leaks at the hose to chamber connections Any leaks are probably caused by loose connections or by a damaged hose fitting Eliminate all leaks On chambers equipped with an external breather tube make sure that the flexible elbows are in place and that the connector tube is inserted into each elbow 1 2 inch 13 mm 42 2 Cargo Maintenance Manual January 2000 Brakes 2 3 A B Y A A 4 Y 5 08 20 93 1420225a A Minimum of 1 inch 25 mm clearance between centerline of clevis pin hole and piston rod end B Minimum of 7 threads engagement 1 Piston Rod 4 Cotter Pin 2 Piston Rod Nut 5 Pin 3 Clevis Fig 2 Piston Rod Engagement With the Clevis Read and follow all applicable warnings and in structions in Group 42 of the Cargo Workshop Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious in jury or death 7 Inspect the exterior surfaces of the chamber for damage Make sure the breather holes in the non pressure section s are open and free of de bris Using the instructions in
107. smission Check fluid level add 26 02 fluid if low 26 01 26 05 Change fluid 26 02 or 26 05 when required 41 02 Driveline One grease fitting for each U Joints and U joint One grease fitting Slip Joints for each slip joint 72 01 Door Hinges Lubricate all door hinges Latches and latches and weatherstrips Weatherstrips on the cab 13 54 02 Batteries Clean and lubricate if corrosion is present Intervals and procedures are included in the Maintenance Operations Tables and the specific groups Not shown in the illustration Air valves are located throughout the vehicle inside the cab and on the chassis Cargo Maintenance Manual December 2004 00 21 00 General Information Lubrication Tables 00 17 16 01 14 99 1000867 Fig 1 Lubrication Points 00 22 Cargo Maintenance Manual December 2004 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt InspoCcllON 5 isi irn t und e x pep 01 02 Engine Suppor Fasteners Check d ae amp pa Aa 01 01 Cargo Maintenance Manual January 2000 Engine 01 01 Engine Support Fasteners Check 01 01 02 Engine Drive Belt Inspection Check the rear engine support fasteners Fig 1 Ref 4 for tightness Tighten the 3 4 inch fast
108. tarter solenoid and cranking motor for tight ness Check the tightness of all ground straps and cable fasteners Make sure they are free of corrosion 5 Make sure that the starter mounting bolts are tight If loose tighten them 38 52 6 Check the alternator charging voltage NOTE Batteries must be fully charged in order to check alternator charging voltage 6 1 Check the charge level of the batteries for instructions see Group 54 in the Cargo Workshop Manual Charge the bat teries as needed 6 2 Turn off all vehicle loads such as the lights heater and air conditioner and connect an accurate voltmeter across the batteries Run the engine at fast idle ap proximately 1000 rpm for about two min utes to stabilize voltage output 7 Ifthe voltmeter reading rises above 15 0 volts and cannot be lowered replace the alternator If the output voltage does not rise above 12 8 volts and cannot be increased when the engine is running see Group 15 of the Cargo Workshop Manual for troubleshooting and replacement in structions 15 Cargo Maintenance Manual January 2000 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP hadiator daemon deems Be Radiator Pressure Flush and Coolant Change 20 Index Alphabetical MOP Number Cargo Maintenance Manual August 2003 Engine Cooling Radiator 20 01 Radiator Cap Check A WARNING Do
109. tice Recall bulletins pertain to mat ters of vehicle safety All bulletins are distributed to dealers customers receive notices that apply to their vehicles This publication is concerned with non safety related service work or replace ment of parts All field service modifications are distributed to dealers custom ers receive notices that apply to their vehicles Cargo Maintenance Manual May 2003 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Initial Maintenance IM Operations Table 000000 eee 00 09 Eujsriealton Tables xou etico dte tance Sas Ua bea Deas QUE dA awed aod em edness 00 17 Lubrication and Fluid Level Check M1 schedules I Il and 00 15 Lubrication and Fluid Level Check M2 schedules I Il and 00 16 M1 Maintenance Interval Operations 00 10 M2 Maintenance Interval Operations 00 11 Maintenance Interval Operations 00 12 M4 Maintenance Interval Operations 00 13 M5 Maintenance Interval Operations 00 14 Maintenance Sa Seq e 2508 8 Sees LOSERS eie Sere e Re wees LASS 00 07
110. tion primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Schedule 111 long haul transport is for vehicles that annually travel more than 60 000 miles 100 000 kilo meters with minimal city or stop and go operation Examples of Schedule Ill usage are regional delivery that is mostly freeway miles interstate transport or any road operation with high annual mileage The table under Maintenance Schedule Table shows the three different schedules of vehicle usage For each schedule the appropriate distance interval is given for performing Initial Maintenance and for repeating each maintenance operation set M1 through M5 For Schedule 1 the appropriate time interval is also given The tables under Maintenance Interval Tables show which maintenance operation set must be per formed at the actual distances miles and kilometers for each maintenance schedule or the actual hours of operation for Schedule 1 The schedule of actual distances and hours is based on the intervals given in the Maintenance Schedule Table The table under Maintenance Operation Sets Table lists in numerical order the text reference numbers and descriptions of a maintenance opera tions and indicates all maintenance operation sets at which each operation must be performed Each Maintenance Interval Operations Table IM through M5 lists the appropriate text refe
111. ube See Fig 5 Remove the sealring from the intake tube and discard the sealring 26 4 Cargo Maintenance Manual January 2000 Transmission 8 Clean or replace the governor oil screen located 8 4 in the governor feed tube bore See Fig 7 26 Remove the remaining bolts and allow the valve body to drop down Remove the governor feed tube and the governor 8 1 Remove the bolt that attaches the detent pressure tube spring to the control valve body Remove the spring 8 5 Remove the governor oil screen from the overnor feed tube bore If the screen is 8 2 Remove the two 3 inch bolts that retain replace if it is not damaged the first reverse clutch feed tube Remove clean it with mineral spirits the tube 8 6 Install the governor oil screen closed end 8 3 Remove two of the bolts near the outer first into the valve body at the governor edge of the valve body and replace them feed tube opening Install the governor with the two 3 inch bolts to hold the valve feed tube and the governor pressure body to the transmission while checking tube the governor oil screen M V wa z L gt d 1 A E 10 2 WZ a 9 3 5 7 4 6 10 05 94 1260132a 1 Fluid Intake Tube 7 First Reverse Clutch Feed Tube 2 Detent Spring 8 Governor Oil Screen in governor feed tube bore 3 Detent Spring 1 3 4 Inch Bolt 9 Governor Pressure Tube 4 Filter Spacer 10 Governor Feed Tube 5 2
112. ver from the pull pawl assembly if equipped 42 09 Automatic Slack Adjuster Lubrication Lubricate the slack adjuster using high temperature water proof grease NLGI grade 1 Texaco Thermotex EP 1 Shell Darina No 1 Marathon 528 heavy duty Sunaplex No 1 EP Amdex No 1 EP or Philube B No 1 It should be smooth textured corrosion resistant grease free of fillers and abrasives 42 10 Automatic Slack Adjuster Inspection 1 Remove the pressure relief capscrew gasket pawl spring and pawl See Fig 4 Ref 5 2 Examine the pawl for grease retention and condi tion If the grease is in good condition install the pressure relief capscrew gasket pawl spring and pawl Tighten the capscrew 15 to 20 20 to 27 Lube the slack adjuster through the grease fitting until lubricant is forced out through the pressure relief fitting or pawl slot If a hollow capscrew is used install and tighten it 15 to 20 Ibf ft 20 to 27 N m If the grease is hardened or the pawl is dry and shows extreme wear remove the slack adjuster Disassemble and clean it Inspect the internal parts Install new seals and a new boot when assembling Install and lubricate the slack ad juster See Group 42 of the Cargo Workshop Manual Cargo Maintenance Manual January 2000 42 7 42 42 11 Air Dryer Check Bendix AD 9 During cold weather operation check the operation of the end cover heater and thermostat assembly
113. y misuse of the lighter socket 10 Test the electric horn If it does not work check the wiring to it If the wiring checks out okay re place the horn 11 Check connectors Check the terminals for tight ness damage and corrosion or dirt Chassis 1 Check the main wiring harnesses Check the wir ing insulation for damage from chafing or heat Also check for kinks Reroute repair or replace the wires as needed 2 Check all the tie straps for breakage or damage Replace any broken or cracked tie straps 54 A CAUTION Do not use flat strip aluminum tie straps for hold ing electrical wiring The sharp edges on these tie straps may cause breaks in the wire insulation allowing the aluminum tie strap to make contact with the wire This could cause a short circuit and damage to the wiring 3 Check all clamps plastic connectors and grom mets Replace any that are damaged Make sure all grommets are fully seated 4 Check the magnetic switch terminals and con nections for tightness 5 Check the wires of all sensors mounted on or near the engine Make sure no wires are closer than 6 inches 15 cm to hot surfaces If any are and they cannot be rerouted make sure they are protected by heat shields Check the sensor con nectors Make sure they are tight clean and un damaged 6 Check the temperature sending units on the ax les and transmission Check for damaged wires and loose connectors 7 Check the
114. ze Constant Torque hose clamps the clamps must be tightened to the correct torque The screw tip of the clamp must extend about 1 4 inch 6 mm from the clamp housing and the Belleville washer stacks must be collapsed almost flat Use a torque Cargo Maintenance Manual August 2003 20 1 20 wrench to install these hose clamps correctly The correct installation torque for Breeze Constant Torque hose clamps is as follows For Breeze Constant Torque hose clamps with a 5 16 inch tightening screw hex 55 lbf in 620 N cm For Breeze Constant Torque hose clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm NI Lo 02 28 96 1200326 Fig 1 T Bolt Type Hose Clamp A nass 08 15 94 1200286 A The screw tip must extend about 1 4 inch 6 B The Belleville washer stacks must be collapsed almost flat 1 Tightening Screw Hex Fig 2 Breeze Constant Torque Hose Clamp Installation NOTE All hose clamps will lose torque after installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to auto matically adjust and keep consistent sealing Engine Cooling R adiator pressure During vehicle operation and shut down the screw tip may adjust according to temperature and pressure changes The torque may need to be adjusted for individual applica tions 7 Fill the radiator with coolant Use a mixture of 50

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