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Business Class Trucks Maintenance Manual

1. Maintenance Schedule Models t Operation Frequency Miles Km Hours Initial Maintenance IM first 1000 1600 100 Maintenance 1 M1 every 1000 1600 100 FL50 FL60 FL70 FL80 Maintenance 2 M2 every 4000 6400 400 Eu Maintenance 3 M3 every 8000 12 800 800 Maintenance 4 M4 every 16 000 25 600 1600 SCHEDULE I Severe Service Maintenance 5 M5 every 32 000 51200 3200 vehicles that annually travel Initial Maintenance IM first 4000 6000 100 up to 6000 miles 10 000 km MB50 Maintenance 1 M1 every 4000 6000 100 MB60 Maintenance 2 M2 every 8000 12 000 200 MR Maintenance 3 M3 every 16 000 24 000 400 Maintenance 4 M4 every 32 000 48 000 800 Maintenance 5 M5 every 64 000 96 000 1600 Initial Maintenance IM first 8000 12 000 SCHEDULE Il Maintenance 1 M1 every 8000 12 000 Short Haul Transport Maintenance 2 M2 every 16 000 24 000 vehicles that annually travel All up to 60 000 miles 100 000 Maintenance 3 M3 every 32 000 48 000 km Maintenance 4 M4 every 64 000 96 000 Maintenance 5 M5 every 128 000 192 000 Initial Maintenance IM first 10 000 16 000 SCHEDULE Ill Maintenance 1 M1 every 10 000 16 000 Long Haul Transport Maintenance 2 M2 every 20 000 32 000 vehicles that annually travel All over 60 000 miles 100 000 Maintenance 3 M3 every 40 000 64 000 km Maintenance 4 M4 every 80 000 128 000 Maintenance 5 M5 every 160 000 256 000 For Schedule severe serv
2. Torque Description aag Ibf ft N m Allison AT 545 1 2 20 od ED Allison MD Series 2 16 ie Single Axle Input Shaft Meritor RS 13 120 RS 15 120 and 210 RS 17 140 and 20 740 920 RS 19 145 and 220 M32x 15 4000 1250 and RS 21 145 and 230 1000 1230 Meritor RS 23 160 M45 x 1 5 1355 1670 920 1130 Meritor RS 23 240 M39 x 1 5 1250 1530 Tandem Axle Input and Output Shafts Meritor RD and RR 17 145 T of RT 34 145 and M39 x 1 5 a RD and RR 20 145 of RT 40 145 Coupling Shaft Midship Bearings Spicer 1590 1610 475 525 and 1710 hae 644 712 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 End Yoke Nut Torque Specifications Torque Description ssa Ibf ft N m Transmissions Fuller FS 4005 5005 5106 1 1 4 18 eee 6105 and 6206 Fuller RT 6609 _ RT RTO 6610 and 1 1 2 18 ADR I RT 8609 Fuller T 8607 RT 7608LL 2 16 450 500 RT 8608L and 610 675 RT RTO 6613 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 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 m
3. 1400032a Fig 3 Corrugated Channel Spacer 40 2 Business Class Trucks Maintenance Manual January 1998 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline NSPE eonun dau pter d Est Ebbene Edad d Rupe XR bd Saeed d dad rera 41 01 Driveline LUDIC Ama ccc rr NP NAA ARALAN HA REBANN ELA RA BA RNGA RANA BARA AAG 41 02 Business Class Trucks Maintenance Manual January 1998 Driveline 41 01 Driveline Inspecting 41 Inspecting 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 Ibf ft 170 to 183 N m 4h 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 End Yoke Nut Torque Specifications
4. 08 20 93 420008a A With the brakes released measure this distance B With the brakes applied measure this distance 1 Brake Chamber 3 Adjusting Screw 2 Slack Adjuster Fig 4 Brake Adjusting Typical Manual Slack Adjuster IMPORTANT On slack adjusters equipped with an adjusting screw locking sleeve wipe clean the locking sleeve area and depress the locking sleeve when positioning the wrench or socket over the adjusting screw Do not try to turn the adjusting screw without fully depressing the locking sleeve 2 2 Turn the adjusting screw until it is tight then back off the adjustment until the drum is free Normally the adjusting screw will need to be backed off 2 or 3 clicks 2 3 To see if the drum is free strike the brake drum with a steel tool and listen for a clear ringing sound If a dull thud is heard the brake is dragging and further adjustment is needed NOTE Checking the brake adjustment when the wheel is off the ground may be unreli able Looseness or wear anywhere in the wheel bearings will cause the drum to be misaligned while the wheel is off the ground Check the brake adjustment with the wheel on the ground 42 IMPORTANT On slack adjusters equipped with an adjusting screw locking sleeve make sure that the locking sleeve is engaged around the adjusting screw hexhead after adjustment thus locking the adjusting screw in place 42 10 Camshaft Bracket Bushing Lubricating
5. 25 02 Clutch Pull Type Inspecting and Adjusting Cleaning 26 02 Eaton Fuller and Meritor Transmission Oil Changing and Magnetic Plug 26 08 Aisin Transmission Fluid and Filter Changing and Magnetic Plug Cleaning 31 01 Frame Fastener Torque Checking 32 03 U Bolt Torque Checking 33 04 All Axle Alignment Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 35 04 Two Speed Axle Shift Unit Oil Level Checking 00 16 Business Class Trucks Maintenance Manual February 2004 General Information 00 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 Business Class Trucks Driver s Manual M1 Maintenance Interval Operations Maint Oper No 00 15 Lubrication and Fluid Level Check all but FL112 includes the following Clutch Release Bearing and Cross Shaft Lubricating M1 Maintenance Interval Operations Hydraulic Fluid Level Checking Manual Transmission Oil Level Checking Fifth Wheel Lubricating Suspension Lubricating Knuckle Pin Lubricating Tie Rod End Lubricating All Wheel Drive Front Axle Oil Level Checking Axle Lubricant Level Checking Dri
6. 31 03 Fifth Wheel Lubricating Fontaine Use a multipurpose extreme pressure EP chassis grease and lubricate all moving parts on the fifth wheel When lubricating the top plate at the grease fittings for the bracket bearing area tilt the top plate forward and backward to evenly distribute the grease Using a pry tool separate the jaw and wedge and lubricate the serrations using a brush to distribute the grease On slide mount applications lubricate the slide rail and tapered wedges for smooth operation Once the fifth wheel s moving parts are lubricated apply a liberal coating of grease to the top plate and the trailer kingpin plate Holland Lubricate all moving parts with oil or a light grease Lubricate the fifth wheel top plate with a waterproof or multipurpose chassis grease Once the moving parts of the fifth wheel are lubri cated apply a heavy coat of grease to the top plate by direct application On slide mount applications lubricate the baseplate rails and the plungers for smooth operation 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 1 Loosen the locking plunger jam nut and turn the adjusting bolt out counterclockwise See Fig 3 2 Disengage and engage the locking plungers Check that the plungers are securely seated without binding If the locking plungers do not operate properly see Group 31 of the Business Class Trucks Service Manual for adjustment procedures 3 Turn the ad
7. Description Use 00 05 Use Schedule I 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 Il usage are operation primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Schedule Ill 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 three different schedules of vehicle usage For each schedule the appropriate distance interval is given for performing Initial Maintenance and for re peating each maintenance operation set M1 through M5 For Schedule the appropriate time interva
8. Repair Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust Date Mileage Repair Description Cost Repair Facility 00 2 Business Class Trucks Maintenance Manual February 2004 General Information 00 Torque SSpecifications Tables 00 03 Torque Values for U S Customary Thread Fasteners with Lubricated or Plated Threads t Regular Hex Flanged M cia 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 Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m ae lt ool N Doe NS 2 LI SI SS x 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 18 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 50 3 8 24 30 41 32 43 25 34 42 57 716 14 42 57 45 61 35 47 60 81 7 16 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 32
9. Alternator Battery and Starter Checking 20 02 Radiator Pressure Flushing and Coolant Changing 26 02 Eaton Fuller and Meritor Transmission Oil Changing and Magnetic Plug Cleaning 31 01 33 04 Frame Fastener Torque Checking All Axle Alignment Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 46 04 Power Steering Reservoir Fluid and Filter Changing 46 06 Miter Gear Lubricating Right Hand Drive Only 47 02 Gasoline In Tank Fuel Filter Replacement 00 22 Business Class Trucks Maintenance Manual February 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 Business Class Trucks 00 M5 Maintenance Interval Operations Table 00 14 Driver s Manual Also perform all M1 M2 M3 and operations listed below M4 Maintenance Interval Operations at the M5 Main tenance 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 13 02 Air Compressor Rebuilding Replacing Bendix 25 04 Hydraulic Fluid Replacing 26 09 Mercedes Benz Transmission Leak Checking 26 10 Mer
10. 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 Checking 1 If equipped with a moisture indicator sight glass check the color of the moisture indicator See Fig 1 Ref 1 If the indicator is a deep cobalt blue the refriger ant 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 2 On H 12 refrigerant systems only check the receiver drier sight glass See Fig 1 Ref 2 The presence or absence of bubbles tells whether or not the system has enough refriger ant Bubbles normally appear when the system is started then disappear after a few seconds Only an occasional bubble should be seen during nor mal operation If bubbles continue all of the time the system is running the system is merely low on not completely out of refrigerant Business Class Trucks Maintenance Manual January 1998 83 1 83 1 7 2 7 m ON 2r m ND zi N 12 16 93 f250177b 1 Moisture Indicator Sight Glass 2 Receiver Drier Sight Glass Fig 1 Receiver Drier A clear sight glass means that the system has enough refrigerant to work properly or that it is completely out of refrigerant or tha
11. apply one of the following methods 1 An enclosed cylinder vacuum system equipped with a High Efficiency Particulate Air HEPA filter 2 A solvent spray system that keeps the asbestos contaminated parts wet until they can be placed in a sealed and labelled plastic bag To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter System Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear Business Class Trucks Maintenance Manual October 1998 42 11 1 1 Apply the parking brakes Chock the tires to prevent vehicle movement 1 2 Remove one or more of the lining inspec tion plugs and measure brake lining thickness 1 3 On front and rear axles replace linings worn to less than 1 16 inch 1 6 mm 1 4 Make sure that the brake rotor and linings are free of oil and grease 1 5 Install the inspection plug s 2 If the wheel and hub assembly is removed from the axle check lining wear Replace the linings on all brake assemblies if worn to less than 1 16 inch 1 6 mm at the thinnest point NOTE To replace the brake linings see the ap plicable foundation brake section in Group 42 of the Business Class Trucks Service Manual
12. 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 Lubricating U Joint Lubricating 1 Wipe all old grease and dirt from each U joint grease fitting See Fig 4 Ref 8 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 4 Slip Joint and U Joint Lubricating 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter 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 3 Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until new grease can be seen at 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 Business Class Trucks Maintenance Manual January 1998 41 3 41 Driveline ing
13. 7 6 Remove the filters from the bottom of the control module 7 Lubricate the new O rings with transmission fluid and install them on the cover assemblies 8 Install a new square cut seal on each cover as sembly and install the fluid filter elements on the cover assemblies 9 Install the filter and cover assemblies into the filter compartment Transmission 10 Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals 4h CAUTION Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump 11 Install six bolts in each cover and torque the bolts 38 to 44 Ibf ft 51 to 61 N m 12 Replace the drain plug O ring and install the drain plug Tighten the drain plug 18 to 24 Ibf ft 25 to 32 N m 13 Refill the transmission with fresh Dexron trans mission fluid see Table 4 and check the fluid level See Table 5 for lubricant capacities 14 Check and adjust the fluid level using the proce dures under Checking the Fluid Level MT Series 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Start the engine and check that the transmission fluid temperature is 160 to 200 F 71 to 93 C before draining the fluid Shift the gear selector to neutral and shut down the engine 3 Place a suitable container under the transmis sion then remove th
14. Adjuster Inspecting Meritor 1 Remove the pressure relief capscrew gasket pawl spring and pawl See Fig 6 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 then tighten the capscrew 15 to 20 Ibf ft 20 to 27 N m Lube the slack adjuster through the grease fitting until lubricant is forced out through the pressure relief fitting or pawl slot Then 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 then install and lubricate the slack adjuster See Group 42 of the Business Class Trucks Service Manual 42 15 Air Dryer Checking Bendix AD 9 During cold weather operation check the operation of the end cover heater and thermostat assembly 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
15. C has been reached 26 12 Business Class Trucks Maintenance Manual February 2003 Transmission Hot Check 1 Park the vehicle on a flat level surface Apply the parking brakes and chock the rear 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 5 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 add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 10 for the AT MD and HD series and Fig 11 for the MT series 26 06 Chrysler Transmission Fluid and Filter Changing Replacement 1 Park the vehicle on a level surface and apply the parking brakes 4h 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
16. Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 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 Business Class Trucks Service Manual for instructions 42 42 20 Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 12 QR 1 R 14 SR 1 ST 3 TC 7 and TP 5 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 Business Class Trucks Service Manual for instructions 42 21 Brake Lining Wear Checking Hydraulic Disc Brakes Before checking lining wear with the wheel removed review the following brake lining exposure warnings A WARNING Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease Unless exposure can be reduced below legal limits wear an air purifying respirator approved by MSHA or NIOSH at all times when servicing the brakes starting with removal of the wheels and continuing through assembly To reduce asbestos exposure below legal limits
17. If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81 N m If leakage persists install a new wide band exhaust clamp See Group 49 of the Business Class Trucks Service Manual for procedures 10 05 94 NC 1490032a A Check the Tightness of These Fasteners Fig 1 Typical Exhaust Pipe to Exhaust Flange Fasteners OM 366 Engine Shown 10 05 94 f490005a Fig 2 Wide Band Exhaust Clamp Business Class Trucks Maintenance Manual October 1998 49 1 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Coclantibevel Sensor Cleaning cha dace ncs use Se Go pd end doo M Regu mt Bele et Saws eS kai eqs 54 02 Electrical System OCIO cenar kA ALAN baad emcee PANAMAN d NA eee Oui ean p Ra ate Ae 54 01 Business Class Trucks Maintenance Manual January 1998 Electrical Instruments and Controls 54 01 Electrical System Checking Cab 1 Uncover the electrical panel Fig 1 by removing the fasteners 10 05 94 1 Flasher 1540843 Fig 1 Under Dash Electrical Panel 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 thei
18. M4 Maintenance Interval Operations Table llli ees 00 13 M5 Maintenance Interval Operations Table 0c es 00 14 Maintenance Interval Tables s ua ai KANG mas er ks BOs ga VEER REAR ORC e e e RR Oa we ANG ATA mage amp 00 07 Maintenance Operation Sets Tables llli 00 08 Maintenance Schedule Table grcas t Eum cett erae dp dered PHAT eed PIGA DN IG ae E ded 00 06 Metric U S Customary Conversion Tables exco uhr pee ew REAR RE RG AUR Rp RACKS 00 04 Noise Emission Control Systems Maintenance 4 ee 00 01 Scheduled Maintenance Intervals Description and Use ce eee 00 05 Torque SSpecifications Tables ns 43e diee e pex ap ERR Pp Re Ra eR meh ER ERAEEDIHM EG 00 03 Verification of Inspections LOG 2 63 24 coc pde gp deem ines bake x mna pede Re o E pue ee oe gn E Re die 00 02 Business Class Trucks Maintenance Manual February 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 compl
19. NOTE Drain the transmission fluid while the transmission is warm 2 1 Remove the magnetic drain plug from the bottom of the gear case 2 2 Discard the aluminum gasket 2 3 Catch the transmission fluid in a suitable container and dispose of it properly 3 Clean the area around the fill plug E A 2 gt v 1 Pg y y KA 4 y j A v A A Y Be j MM sal ULL 7777777277774 10 05 94 A B 260006b A Full B Low Fig 20 Transmission Fluid Level Checking MBT Transmission Lubricant Types Manufacturer Type Mobil Mobiltrans SHC 50 RN 2952 E 2 Table 8 MBT Transmission Lubricant Types 26 20 Business Class Trucks Maintenance Manual February 2003 Transmission MBT Transmission Lubricant Capacities m Refill Capacity Transmission Model quarts liters MBT660S 60 9 5 9 0 MBT520S 6D 9 5 9 0 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating position Table 9 MBT Transmission Lubricant Capacities 4h CAUTION Use only Mobiltrans SHC 50 RN 2952 E 2 fluid Do not mix fluid types Adding RN 2952 E 5 fluid used in Eaton and Meritor transmissions could damage the radial seals 2 Clean the fill plug before installing it 3 Install the fill plug p n NO00908 020001 and a new aluminum gasket p n N 00763 024105 Tighten the fill plug 42 Ibf ft 57 N m 2
20. Replace the wire if it is damaged 5 Check for broken burst or cut hoses Also check for loose fittings on all parts 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 build 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 Checking 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 4 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 Business Class Trucks Service Manual 5 Carefully feel the system lines e 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
21. one end of the hose into an approval gasoline container See Fig 2 IMPORTANT Do not allow fuel to spill onto the engine intake or exhaust manifolds Place a shop towel under and around the pressure test port when the pressure is re leased from the fuel rail 3 4 Place a shop towel under the test port then screw the other end of the hose onto the test port Allow the fuel to flow into the gasoline container until fuel pressure is completely released Business Class Trucks Maintenance Manual January 1998 47 1 47 Fuel 10 9 f 7 2 8 NO 3 03 16 95 f010913 7 N 1 Fuel Pressure Test Port 2 Test Hose 6 3 Approved Gasoline Can 5 Fig 2 Relieving Fuel Pressure 3 5 Remove the hose from the test port and reconnect the gauge to the hose 03 17 95 1470135 Install the protective plastic cap to the 1 Fuel Filter Pressure Regulator a deu ist port on NG fuel rai s Fuel Pump Guard Bracket 3 Fuel Pump Gauge Electrical Connector 3 7 Install the filler cap on the fuel tank 4 Pressure Relief Rollover Valve 5 Clamp Ring Mounting Capscrew 4 Disconnect the fuel supply line from the 6 Hardened Flatwasher filter pressure regulator then disconnect the 7 Rollover Valve Grommet EVAP canister line from the rollover valve See 8 EVAP Canister Connection Fig 3 9 Fuel Supply Line Connection 10 Fuel Pump Mounting Clamp Ring 5 Disconnect the electrical connector 6 Remove the fuel pump module from t
22. 11 42 13 Slack Adjusters Front Axle Lubricate both sides of axle one grease fitting for each slack 42 24 42 26 adjuster 6 42 10 Camshaft Brackets Front Axle Lubricate both sides of axle one grease fitting for each camshaft bracket 7 33 05 33 06 Oil Lubricated All Wheel Drive Check oil level add oil if low 33 05 Change oil 33 06 when Front Axle t required 8 33 03 Tie Rod Two grease fittings one on each end of tie rod Business Class Trucks Maintenance Manual February 2004 00 29 00 Lubrication Tables 00 18 General Information No MOP No Components Remarks 9 33 01 Knuckle Pins Two grease fittings one on top one on bottom of knuckle pin Lubricate both sides of axle 10 25 01 Clutch Release Bearing and One grease fitting on bottom of release bearing Two grease Release Cross Shaft fittings on release cross shaft 11 26 01 26 02 Transmission Check fluid level add fluid if low 26 01 Change fluid 26 02 26 05 26 06 26 05 or 26 06 when required 12 41 02 Driveline U Joints and Slip Joints One grease fitting for each U joint One grease fitting for each slip joint 13 72 01 Door Hinges Latches and Lubricate all door hinges latches and weatherstrips on cab Weatherstrips 14 15 01 Batteries Clean and lubricate if corrosion is present 15 42 19 Air Reservoir Automatic Drain Disassemble clean inspect
23. 136 N m and tighten the clamp nut 40 to 55 Ibf ft 54 to 75 N m 33 03 Tie Rod End Lubricating 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 Business Class Trucks Service Manual Business Class Trucks Maintenance Manual June 2001 33 1 33 Front Axle 1 2 M y 2 04 15 96 N3 350149 10 20 93 1320033a NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split 1 Vent Valve 2 Oil Level Check and Fill Plug 3 Oil Drain Plug Fig 3 All Wheel Drive Front Axle Differential Fig 2 Tie Rod End Adjustment Toe In Checking Front Axle See Group 33 of the Business Class Trucks Ser vice Manual for wheel alignment procedures 33 05 All Wheel Drive Front Axle Oil Level Checking 1 On all front wheel drive vehicles check the oil level in the differential See Fig 3 1 1 Remove the oil level check and fill plug and make sure the oil level is even with the bottom of the bore 1 2 If needed add oil until the differential is filled to the bottom of the bore 1 3 Install the oil l
24. 20 03 Fan Clutch Checking Noise Emission Control Eaton Viscous Fan Clutch 4h CAUTION If the fan drive assembly is damaged replace the unit as soon as possible Operating a seized or otherwise damaged clutch reduces fuel economy and could cause serious engine damage See Group 20 of the Business Class Trucks Ser vice Manual for replacement instructions 1 With the engine off rotate the fan at least one full turn by hand It should have a smooth steady drag If it does not replace the fan clutch 2 Check for physical damage to the fan or fan shroud 3 At the fan clutch mounting 3 1 Check for correct drive belt alignment and tension For specifications see Group 01 of the Business Class Trucks Service Manual 3 2 Check for wear of the fan clutch bearings There should be no side to side or in and out movement of the fan clutch 3 3 Do all of the checks in Section 20 02 of the Business Class Trucks Service Manual Horton Advantage Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Business Class Trucks Service Manual 1 Disconnect the electrical cables from the battery Drain all air from the air system If equipped with an air starter drain the air starter reservoir If the engine starts during this procedure the fan could cause personal injury If the vehicle is Engine Cooling R adiator equipped
25. 28 Ibf ft 38 N m Install the dipstick 12 Start the engine and check the power steering reservoir fluid level If the fluid level is low add more of the approved fluid to bring the level up to the full mark on the dipstick 46 46 05 Steering Gear Lubricating 1 Wipe off debris from the grease fitting See Fig 4 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 04 13 93 1 Sector Shaft Grease Fitting f460515a Fig 4 Sector Shaft Lubricating Ross TAS Series 46 06 Miter Gear Lubricating Right Hand Drive Only NOTE The following procedure applies to right hand drive vehicles only Two miter gears con nect to a transverse shaft running underneath the dashboard 1 Inside the cab remove the under dash faceplate and expose the miter gears NOTE The miter gears may or may not be equipped with a grease fitting opposite the shaft If no grease fitting is present the unit re quires no maintenance If a grease fitting is present follow the procedure below 2 Using a hand type grease gun apply no more than one ounce 28 g of multipurpose chassis grease at the grease fitting Business Class Trucks Maintenance Manual November 2002 46 3 46 4h CAUTION Do not use a pressure gun Apply only a small amount of grease It is not necessary to fill the unit with grease Do not force
26. 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 or plated zinc phosphate conversion coated cadmium plated or waxed Table 3 Torque Values for Metric Thread Fasteners with Lubricated or Plated Threads Business Class Trucks Maintenance Manual February 2004 00 5 00 Metric U S Customary Conversion Tables 00 04 General Information a Bo POPO To Get Metric ier ME ji a 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 in2 645 16 square millimeters mm2 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 in3 cubic inches in 16 387 cubic centimeters cm3 0 06102 cubi
27. 42 22 Brake Lines Checking Hydraulic Disc Brakes Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 42 23 Power Booster Checking Bendix Hydro Max Check for proper operation see Group 42 of the Business Class Trucks Service Manual for instruc tions 42 24 Automatic Slack Adjuster Lubricating Gunite Lubricate the slack adjuster until grease flows from the grease relief opening See Fig 10 For tempera tures to 40 F 40 C use Lubriplate Aero for tem peratures to 20 F 29 C use Texaco Multifak EP 2 or Mobil Grease No 77 Brakes hs g RON 10 27 93 7 16 Inch Adjusting Hexnut Grease Fitting Boot Link Brake Chamber Piston Rod 10 f420653a Clevis 1 2 Inch Clevis Pin 1 4 Inch Clevis Pin Grease Relief Opening 10 Slack Adjuster Spline 6 7 8 9 Fig 10 Gunite Automatic Slack Adjuster 42 25 Automatic Slack Adjuster Inspecting and Adjusting Gunite Inspect the slack adjuster for structural damage Replace the slack adjuster if needed Inspect the slack adjuster boot for cuts or tears If the boot is damaged replace it see Fig 10 2 1 2 2 Remove the two clevis pins Rotate the worm shaft adjusting hexnut counterclockwise to move the link away from the clevis About 45 Ibf ft 60 N m is needed You will hear a clicking soun
28. 7 6 RTO 6610 RTO 6613 RT 11610 13 0 12 3 RTO 11613 14 5 13 7 RTO 11610 RTLO 12913A 14 0 13 2 RTX 11610 RTLO 14913A RT 11710B RTLO 16913A RTX 11710B C All 15 Speed Series RT 12610 14 0 13 2 RT 11715 14 0 13 2 RTLO 12610B 14 0 13 2 RTO 11715 RT 12710B 13 0 12 3 RTX 11715 RTX 12710B C RT 14915 14 0 13 2 RTLO 13610B 14 0 13 2 RTO 14915 RTX 13710B C 13 0 12 3 RTO 16915 RTLO 14610B 14 0 13 2 All 18 Speed Series RT 14710B 13 0 12 3 RTLO 14918B 14 0 13 2 RTL 14710B RTLO 16918B RTX 14710B C 18 Speed Autoshift AS2 all RTLO 15610B 14 0 13 2 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating RTX 15710B 13 0 12 3 position 10 Speed Deep Reduction Table 2 Eaton Fuller Transmission Lubricant Capacities RT 7608LL 9 75 9 2 Bia Iden Meritor Transmission Lubricant Capacities RT 11708LL Refill Capacity Transmission Model in Quarts liters Meritor M MO Series M MO all 10 25 9 7 Meritor 9 and 10 Speed RM RMO RMX Series Business Class Trucks Maintenance Manual February 2003 26 3 26 Meritor Transmission Lubricant Capacities Transmission Model peices 115A B C R all 10 0 9 5 125A B C R all 135A B C R all 10 25 9 7 145A B C R 10 25 9 7 155A B C R all 165A all Meritor 13 Speed RMO Series RMO13 14
29. 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 Rockwell Drive Axle Recommended Lubricant Business Class Trucks Maintenance Manual January 1998 35 1 35 Rear Axle Rockwell Drive Axle Lubricant Capacities Single Axles Axle Type Axle Model ane ie Axle Type Axle Model sine die RS 13 120 16 7 6 RS 19 220 31 14 7 RS 15 120 16 7 6 RS 21 145 32 15 1 RS 15 210 16 7 6 RS 21 160 39 5 18 7 Single t RS 17 140 81 14 7 Single t RS 21 230 39 18 5 RS 17 145 33 6 15 9 RS 23 160 42 19 9 RS 17 220 31 14 7 45 21 3 RS 23 240 RS 19 145 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each whee 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 stick condition as described in the vehicle driver s manual Rockwell s experience shows that the following additives perform adequately Add Elco No 2 Friction Modifier 1 ounce 30 ml of additive for each 1 pint 0
30. Business Class Trucks Maintenance Manual August 2003 Engine Cooling R adiator 20 01 Radiator Cap Checking WARNING Do 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 4h 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 10 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 su
31. Checking A WARNING Use only approved DOT 3 brake fluid in the clutch hydraulic system Do not mix different types of brake fluid The wrong fluid will damage the rub ber parts of the system causing loss of clutch function and the risk of serious personal injury 4h CAUTION Do not allow the fluid level in the reservoir to go below the MIN mark If too much air enters it will not be possible to bleed the system properly and the clutch could be damaged If the fluid level is below the MIN mark fill the reser voir with DOT 3 brake fluid until the level reaches the MAX mark See Fig 2 Business Class Trucks Maintenance Manual June 2002 25 1 25 Clutch 2 Apply the parking brakes chock the front and rear tires and open the hood 4h WARNING Clutch hydraulic fluid DOT 3 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling clutch hydraulic fluid or bleeding hydraulic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 3 Using a flat head screwdriver remove the quick disconnect clamp that attaches the hydraulic hose to the slave cylinder Retain the clamp for later installation See Fig 3 06 20 2002 1250592 HU 1 2 iam 3 10 7 9 8 5 6 4 NC 7 06 17 2002 1250591 1 Reservoir 6 Hydraulic Hose 2 Reservoir Cap 7 Slave Oylinder 3 Reservoir Br
32. 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 performing 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 Business Class Trucks Maintenance Manual February 2004 00 7 00 Maintenance Schedule Table 00 06 General Information Maintenance Interval Maintenance Intervals
33. Steering Driveline Lubricating e Drag Link Lubricating e Power Steering Reservoir Fluid Level Checking e Steering Gear Lubricating Ross TAS Series Weatherstrip Door Hinge and Door Latch Lubricating 26 06 Chrysler Transmission Fluid and Filter Changing 26 07 Chrysler Transmission Band Adjusting 31 02 Fifth Wheel Inspecting 32 01 Suspension Inspecting 33 02 Tie Rod End Inspecting 35 02 Axle Breather Checking 41 01 Driveline Inspecting 42 01 Air Dryer Inspecting Bendix AD 9 42 02 Air Brake Valve Inspecting and Leak Checking Bendix BP R1 42 04 Air Brake Valve Operation Checking Bendix BP R1 and E 12 42 05 Relay Valve Checking Midland 42 06 Quick Release and Flipper Valves Checking Midland 42 07 Brake Chamber Inspecting All Models 00 18 Business Class Trucks Maintenance Manual February 2004 General Information 00 M1 Maintenance Interval Operations Table 00 10 Maint Oper No M1 Maintenance Interval Operations 42 09 Brake Adjusting Manual Slack Adjusters 42 12 Automatic Slack Adjuster Checking Meritor 42 17 Air Brake Valve Operation Checking Bendix R 14 and TC 7 42 18 42 21 Air Brake Valve Leak Checking Bendix TC 7 Brake Lining Wear Checking Hydraulic Disk Brakes 42 22 Brake Lines Checking Hydraulic Disk Brakes 42 23 Power Booster Checking Bendix Hydro Max 42 25
34. Unit Oil Level Checking nh 35 04 Business Class Trucks Maintenance Manual January 1998 Rear Axle 35 01 Axle Lubricant Level Checking 4h 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 Fig 1 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 lubricants and see Table 2 or Table 3 for axle capacities 35 a P L 2 3 06 07 94 f350062a 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 1 Fill Hole Plug and Axle Housing Breather Locations 3 Install the fill hole plug and tighten it 35 Ibf ft 47 N m Rockwell Drive Axle Recommended Lubricant Recommended Lubricant Type Ambient Temperature Lubricant SAE Viscosity Grade Rockwell Specification Hypoid Gear Oil API Service Classification GL 5 410 F 12 2 C and up 85W 140 0 76 A 15 F 26 1 C and up 80W 140 0 76
35. and Flipper Valves Checking Midland 000 eee eee 42 06 Relay Valve Checking Midland e zan naan KAG NA NN kt dee eb ep dope NARRA KH ob RR ged eds 42 05 Business Class Trucks Maintenance Manual October 1998 Brakes 42 01 Air Dryer Inspecting Bendix AD 9 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 Ibf ft 38 N m for SAE grade 5 3 8 16 fas teners 135 Ibf ft 183 N m for SAE grade 5 5 8 11 fas teners Check all air lines fittings and electrical connec tions for damage leakage or looseness 3 Replace damaged or leaking parts and tighten loose fittings or electrical connections 42 02 Air Brake Valve Inspecting and Leak Checking Bendix BP R1 1 Clean the valve exterior and inspect it for corro sion and damage 2 Inspect the air lines connected to the valve for signs of wear or damage Replace the lines as needed 3 Check the valve for leakage 3 1 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa 3 2 Check the air line fittings for leaks tighten or replace the fittings as needed 3 3 Coat the exhaust port and body of the valve with soapy water and check for leakage Leakage is exce
36. 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 42 10 Business Class Trucks Maintenance Manual October 1998 Brakes heater assembly is operating properly If it does not replace the purge valve housing assembly which includes the heater and thermostat assem bly 42 16 Air Dryer Desiccant Replacing 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 Business Class Trucks Service Manual for instructions 42 17 Air Brake Valve Operation Checking Bendix R 14 and TC 7 Check the valve for proper operation see Group 42 of the Business Class Trucks Service Manual for instructions 42 18 Air Brake Valve Leak Checking Bendix TC 7 Check for leakage see Group 42 of the Business Class Trucks Service Manual for instructions 42 19 Air Reservoir Automatic
37. and lubricate the automatic drain Valves valves 16 32 02 Suspension Spring Pin t Lubricate on both sides of vehicle one grease fitting for each spring pin 17 32 02 Equalizer Freightliner One grease fitting on each equalizer lubricate on both sides of the vehicle 18 35 04 35 05 Two Speed Axle Shift Unit t Check oil level add oil if low 35 04 Change oil 35 05 when required 19 35 01 35 03 Rear Axle Check fluid level add fluid if low 35 01 Change fluid when required 35 03 20 42 11 42 13 Slack Adjusters Rear Axle Lubricate slack adjusters on both sides of each rear axle one 42 24 42 26 grease fitting for each slack adjuster 21 42 10 Camshaft Brackets Rear Axle Lubricate camshafts on both sides of each rear axle one grease fitting for each camshaft bracket 22 31 03 Fifth Wheel t Inspect the fifth wheel then lubricate the top plate and all moving parts 23 42 03 Air Valves t Disassemble clean and lubricate all air valves Intervals and procedures are included in the Maintenance Operations Tables and the specific groups t Not shown in illustration t Air valves are located throughout the vehicle inside the cab and on the chassis Table 18 Lubrication Table for FL112 Models Only 00 30 Business Class Trucks Maintenance Manual February 2004 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt InspecllORk obit meet e xe Etre Eu a
38. are under spring compression Wear safety goggles during removal installation and rebuild ing Failure to do so can result in personal injury due to parts ejecting with force FONTAINE 1 Disconnect the tractor from the trailer For instruc tions refer to the vehicle driver s manual 2 Thoroughly steam clean the fifth wheel 3 Look for cracks in the fifth wheel assembly mounting brackets and mounting parts Continued vehicle operation with loose 10 11 31 Check moving parts for wear or damage Test the safety lock latch for free operation Check for loose nuts or bolts in the fifth wheel and in the mounting Check all springs to see if they are securely fastened and not deformed Check wedge adjustment 8 1 Open the kingpin lock and vertically insert a 2 inch diameter shaft 8 2 Release the lock by tripping the release latch at the bottom of the throat 8 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance If you observe any problems when doing the above steps correct them immediately For in structions refer to the fifth wheel section in the vehicle service manual Oil all moving parts on the fifth wheel and grease the top plate and the two zerk fittings for the bracket bearing area Replace cracked worn or damaged parts with new parts Replace loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do
39. components Use only genuine Bendix replacement parts or kits Test the operation of the unloader mechanism See Group 13 of the Business Class Trucks Service Manual for rebuild or replacement instructions and test operations NOTE Bendix factory rebuilt air compressors are available from authorized Bendix distribu tors and carry a new compressor warranty 13 Business Class Trucks Maintenance Manual January 1998 13 1 Alternator and Starter 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Checking lille 15 01 Business Class Trucks Maintenance Manual January 2004 Alternator and Starter 15 01 Alternator Battery and Starter Checking 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 Battery acid is extremely harmful if splashed in eyes or on skin Always wear a face shield and protective clothing when working around batter ies 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Business Class Trucks Service Manual 2 Check the belt tension of the alternator drive belt Use a tension gauge at the belt s widest span and adj
40. cup capscrews then check the torque on joint seal Fig 4 Ref 6 This ensures complete the bearing cup capscrews at that seal Tighten lubrication of the splines the bearing cup capscrews as follows 3 Wipe any excess grease from the pressure relief 5 66 24 capscrews 24 Ibf ft 2 N m hole slip joint seal and grease fitting 3 8 24 capscrews 37 Ibf ft 50 N m 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 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 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 44 of the Business Class Trucks Service Manual 4 Che
41. excess grease out past the shaft seal Steering 46 4 Business Class Trucks Maintenance Manual November 2002 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Tank Draihing and Verit Checking urne artana payin ta edel oa x ened DR E E awww be 47 01 Gasoline In Tank Fuel Filter Replacement 0000 nh 47 02 Business Class Trucks Maintenance Manual January 1998 Fuel 47 01 Fuel Tank Draining and Vent Checking Remove the plug or open the drain valve at the bot tom 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 On earlier vehicles with a screw on fuel cap remove the fuel cap and clean it with solvent Make sure the fuel cap vent is open Install the cap On vehicles with a quarter turn fuel cap check to be sure the vent line at the inboard side of the fuel tank is clean and not plugged 47 02 Gasoline In Tank Fuel Filter Replacement The fuel pump module is located in the fuel tank on gas powered vehicles and is fitted with a fuel filter on its base The fuel pump draws fuel from the bot tom of the fuel tank to prevent cavitation on turns or inclines The in tank fuel filter prevents dirt and sedi ment that collects on the bottom of the fuel tank from entering the fuel system The in tank fuel filter must be changed periodically to ensure proper fuel system
42. filter element and position the spring on top of the filter element 7 Fill the reservoir with approved power steering fluid See Table 1 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 IMPORTANT Do not start the engine while draining the system 8 Place the disconnected end of the steering gear to reservoir hose in a drain bucket Raise the front of the vehicle with a floor jack and support it with jack stands Have someone turn the steer ing wheel to full lock left and right and capture the fluid flowing from the hose in the drain bucket Add fluid to the reservoir as needed Continue turning the steering wheel until clean power steering fluid flows from the hose into the drain bucket Remove the plug from the reservoir and reconnect the steering gear to reservoir hose to the reservoir 9 Tighten the hose fitting nut finger tight then with a wrench tighten until there is firm resistance Tighten one sixth turn more Do not overtighten Remove the jack stands and lower the vehicle 10 Fill the reservoir with approved fluid as needed Start the engine and let it idle Have someone turn the steering wheel from lock to lock until no bubbles are seen in the reservoir Turn off the engine 11 Install a new cover gasket the cover and the 3 8 16 hexnut Tighten the hexnut
43. 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 level surface 2 Apply the parking brakes and chock the rear 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 500 800 rpm 6 With the engine running at idle remove the dip stick from the tube and wipe clean 26 10 Business Class Trucks Maintenance Manual February 2003 Transmission 26 08 30 96 Transmission Housing Transmission Oil Pan Gasket 5 16 18 Washer Head Capscrew Plug Transmission Oil Pan Sh wN gt OOO 15 14 7 8 6 Magnet Drain Plug Gasket Drain Plug 5 16 18 x 5 8 Capscrew Flatwasher 13 12 11 10 1260369 11 Transmission Oil Filter 12 Oil Filter Spacer 13 O Ring 14 Oil Filter Tube 15 Plug Fig 8 Allison MT Series Transmission Filter Removal Business Class Trucks Maintenance Manual February 2003 26 11 26 Transmission B A 1 4 6 10 8 13 12 hA 16 12 01 97 f270002a K A Cold Run Band B Hot Run Band 19 20 Fig 10 AT MD and HD Series Dipstick Markings 15 21 18 S 11 5 9 7 14 3 T A 2 3 z Ta Ka 09 24 96 1260396 B NOTE Torque the oil pan bolts with a click type torque wrench fol
44. no 1 main and no 2 wrapper spring leaves the top two spring leaves may be individually replaced If equipped with the RTE or UE series suspension the nos 1 2 and 3 spring leaves the top three spring leaves may be individually replaced If a spring leaf is damaged below these numbers in a pack replace the spring assembly In addition replace both spring assemblies to ensure even spring deflection 32 Hendrickson Radius Rod Bushing Checking 1 Without detaching the torque arms attempt to move by hand each of the radius rod ends up down in and out If there is any movement re place the torque arm 2 Inspect the rubber bushing ends Replace the torque arm if there are gaps between the rubber bushing and the pin or the outer steel sleeve if either bushing end contacts a torque arm pin mounting bolt if there are cracks in the bushing or if part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve Chalmers Suspension Inspecting Chock the front wheels to prevent the vehicle from moving Place the transmission in neutral and re lease the spring or driveline brakes before inspecting the rear suspension Power wash the Chalmers rear suspension or clean it with a hard bristle brush before performing a visual inspection 1 Visually inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play I
45. not loosen or remove the parking brake clamp ring see Fig 1 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 Busi ness Class Trucks Service Manual Brakes 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 Business Class Trucks Service Manual for instructions 1 With the slack adjuster properly adjusted check the angle formed by the centerline of the piston 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 2 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 flatwa
46. oil until level with the lower edge of the fill opening See Table 1 for approved lubricants N SA AN ss KXAN Us JA CSSD PPTL IDI DILL v 10 05 94 A B A Full B Low KS Ns NS NS KSSE De 7707721177 sf f260006b Fig 1 Transmission Fluid Level Checking 4h CAUTION Operating a manual transmission with the oil level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion overfilling 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 problems IMPORTANT Do not mix types of oil because of possible incompatibility Do not use oil addi tives or friction modifiers Do not use multi viscosity oils or EP Extreme Pressure gear oils If switching from a petroleum based lubri cant to a synthetic all areas of each affected 26 component must be thoroughly drained Switch ing to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic from a petroleum based lubricant 4 Clean the fill plug then install it in the gear case Tighten the plug as follows Approved Manual Transmission Lubricants Lubricant Type Temperature SAE in F C Viscosity Eaton Fulle
47. plug 08 06 93 1 Housing Cover Gasket 2 Oil Fill Hole Plug 3 Shift Unit Housing Cover f350021a Fig 2 Two Speed Axle Shift Unit 2 The lubricant level should be maintained at the bottom of the fill hole If low add the specified lubricant 4h CAUTION Before adding additional lubricant make sure what type is currently in the axle shift unit Do not mix engine oil and automatic transmission fluid to prevent component damage IMPORTANT When the vehicle operating tem peratures are above 0 F 18 C use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 85 When the vehicle operating tempera tures are below 0 F 18 C use one part of Business Class Trucks Maintenance Manual January 1998 35 3 35 kerosene to three parts of SAE 10 heavy duty engine oil API service classification SD sul fated ash content must not exceed 1 85 This cold weather mixture can be safely used up to g2 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures Do not mix kerosene with auto matic transmission fluid 3 Apply a small amount of Loctite 242 or equiva lent sealant to the threads of the fill hole plug Install the fill hole plug finger tight then using a wrench tighten the plug 1 1 2 turns more 35 05 Two Speed Axle Shift
48. stroke exceeds the mea surements shown in Table 5 check the founda tion brakes for problems such as worn cams bushings pins and rollers or broken springs Repair or replace as needed For instructions 42 see Group 42 of the Business Class Trucks Service Manual 5 If there are no problems with the foundation brakes manually adjust the slack adjuster as follows 5 1 Turn the adjusting hexnut three quarters of a turn counterclockwise See Fig 10 a B E s lt A gt 09 27 94 1420434b A With the brakes released measure this distance B With the brakes applied measure this distance Fig 11 Brake Stroke Check Gunite Automatic Slack Adjuster Maximum Allowable Brake Chamber Stroke with Gunite Automatic Slack Adjusters Chamber Size Maximum Allowable Stroke 12 Less than 1 3 8 inches 35 mm 16 20 Less than 1 3 4 inches 44 mm 24 24 long stroke 30 Less than 2 inches 51 mm Table 5 Maximum Allowable Brake Chamber Stroke with Gunite Automatic Slack Adjusters 5 2 Keeping the wrench on the adjusting hex nut have someone apply the brakes sev eral times while you watch the hexnut It Business Class Trucks Maintenance Manual October 1998 423 42 should turn clockwise If it does not re place the slack adjuster NOTE The adjusting hexnut will turn in small steps You will not be able to see it turn very well without a wrench on it 5 3 Che
49. the end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep 10 17 2001 f260052a 1 Air Regulator 5 Small O Ring 2 Housing 6 End Cap 3 Large O Ring 7 Plug 4 Filter Element Fig 4 Eaton Fuller Transmission Air Filter Regulator Components ing the air pressure between 57 to 62 psi 396 to 431 kPa replace the air filter regulator It cannot be repaired 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 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 6 Install the large O ring then the filter element small end first into the filter housing 7 Install the small O ring into the end cap then install the end cap on the filter housing Tighten the end cap until firm 8 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 Business Class Trucks Maintenance Manual February 2003 26 5 26 4h CAUTION Repair any air leaks A leaking air filter or air lines can cause slow or hard sh
50. the orifice on the bottom of the transmission then secure the filter with the 5 16 18 x 5 8 inch washer head cap screw Tighten the capscrew 10 to 15 Ibf ft 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 are hand tight Business Class Trucks Maintenance Manual February 2003 26 9 26 NI NA VN A SF E X 4 NC NN 7 Pa NS V 2 2 3 nga 4 1 T 08 25 95 260317 1 Filter Cover 2 Filter Element 3 Filter Element O Ring 4 Square Cut Seal Fig 7 Allison MD and HD Series Transmission Filter Locations and Components 14 Tighten each capscrew with a click type torque wrenc
51. warnings and instructions in the applicable brake chamber section in Group 42 of the Busi ness Class Trucks Service 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 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 Business Class Trucks Service 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 brake hose at the service port and apply soapy water to check for piston O ring leakage Business Class Trucks Maintenance Manual October 1998 42 5 42 Read and follow all applicable warnings and in structions in the applicable brake chamber section in Group 42 of the Business Class
52. 0 324 000 270 000 432 000 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 9 Maintenance Intervals for Schedules II and Ill all models Business Class Trucks Maintenance Manual February 2004 00 11 00 General Information Maintenance Operation Sets Tables 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 Business Class Trucks manual Driver s Manual Maintenance Operation Sets for Groups 00 through 26 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 00 15 Lubrication and Fluid Level Check all models but FL112 00 16 Lubrication and Fluid Level Check all models but FL112 e 00 17 Lubrication and Fluid Level Check FL112 models only 01 01 Eng
53. 15 miles 23 km or more Fluid at temperatures of approximately 85 to 125 F 29 to 52 C is warm 4 Wipe the dipstick clean again and reinsert it until seated Check the fluid level and add or drain fluid as necessary 4 1 If the fluid is warm any level above the MIN dot see Fig 13 is satisfactory If the level is at or below the MIN dot use a funnel to add fluid until the level is above this dot At the next opportunity check the fluid when it is hot Business Class Trucks Maintenance Manual February 2003 26 13 26 Transmission 1 4 6 9 7 10 12 3 11 13 Tm 14 T eS Wir P Al a EP Oj ATN d 1 i PEE AX pd E ma lO E SAW a o AASA EO li A ER E DARE HAD E f5 WA EL VIT e es ee 7v X HH fe iiL ali ET c 15 ER D Ka ku OR Ag 16 nE 4A Y nj i MOTE Sse Dee 17 18 20 12 12 94 1260301 1 Torque Converter 8 Rear Band 15 Seal 2 Input Shaft 9 Overrunning Clutch 16 Intermediate Shaft 3 Oil Pump 10 Overdrive Clutch 17 Overdrive Overrunning Clutch 4 Front Band 11 Direct Clutch 18 Direct Clutch Spring 5 Front Clutch 12 Planetary Gear 19 Overdrive Piston Retainer 6 Rear Clutch 13 Governor 20 Filter 7 Planetaries 14 Output Shaft 21 Valve Body Fig 12 Chrysler 46RH Transmission and Overdrive Unit 1 2 3 4 os MIN OK MAX 12 12 94 1260302 1 MIN Dot Minimum Level Add Fluid 3 MAX Mark Maximum Correc
54. 2 While the transmission fluid is warm raise the vehicle remove the oil pan 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 there may be a problem within the transmission 26 3 Remove the three filter screws Remove the filter from the valve body See Fig 12 4 Install the new filter 4 1 Position the new filter on the valve body and install the filter screws finger tight 4 2 Tighten the filter screws 35 Ibf in 400 N cm 4 3 Install the oil pan bolts and tighten them 13 Ibf ft 17 N m Refilling After Fluid and Filter Change 1 Lower the vehicle and remove the dipstick Using a clean funnel in the fill tube add 2 quarts 1 9 liters of Mopar ATF Plus Type 7176 transmis sion fluid 2 Check and adjust the fluid level using the proce dures under Checking the Fluid Level Checking the Fluid Level 1 With the transmission in neutral and the parking brake applied run the engine at idle for at least one minute to clear the fluid system of air 2 Shift the transmission briefly through all the gear ranges Then shift back into neutral 3 Wipe the dipstick clean and check the fluid tem perature NOTE Fluid at the operating temperature of approximately 180 F 82 C is hot Hot fluid cannot be held comfortably between the finger tips The fluid will be hot if the vehicle has been driven
55. 2 models only Business Class Trucks Maintenance Manual February 2004 00 9 00 General Information Maintenance Interval Tables 00 07 Maintenance Intervals for Schedule MB50 60 70 80 models only Maint No Maintenance Interval Miles km Hours 1 IM and M1 4000 6000 100 2 M1 and M2 8000 12 000 200 3 M1 12 000 18 000 300 4 M1 M2 and M3 16 000 24 000 400 5 M1 20 000 30 000 500 6 M1 and M2 24 000 36 000 600 7 M1 28 000 42 000 700 8 M1 M2 M3 and M4 32 000 48 000 800 9 M1 36 000 54 000 900 10 M1 and M2 40 000 60 000 1000 11 M1 44 000 66 000 1100 12 M1 M2 and M3 48 000 72 000 1200 13 M1 52 000 78 000 1300 14 M1 and M2 56 000 84 000 1400 15 M1 60 000 90 000 1500 16 M1 M2 M3 M4 and M5 64 000 96 000 1600 17 M1 68 000 102 000 1700 18 M1 and M2 72 000 108 000 1800 19 M1 76 000 114 000 1900 20 M1 M2 and M3 80 000 120 000 2000 21 M1 84 000 126 000 2100 22 M1 and M2 88 000 132 000 2200 23 M1 92 000 138 000 2300 24 M1 M2 M3 and M4 96 000 144 000 2400 25 M1 100 000 150 000 2500 26 M1 and M2 104 000 156 000 2600 27 M1 108 000 162 000 2700 28 M1 M2 and M3 112 000 168 000 2800 29 M1 116 000 174 000 2900 30 M1 and M2 120 000 180 000 3000 31 M1 124 000 186 000 3100 32 M1 M2 M3 M4 and M5 128 000 192 000 3200 Table 8 Maintenance Intervals for Schedule MB50 60 70 80 models only 00 10 Business Cla
56. 5 75 7 16 20 50 60 70 80 Locknuts Spring Center Bolt 1 2 20 eat Sorina M ing Eve Bol 65 75 90 100 de ounting Eye Bolt 3 416 270 365 1 2 13 Rebound Spacer 1 2 13 38 45 51 61 Shock Absorber Upper Bracket 5 811 125 170 Locknut Mounting Locknuts Spring Alignment Clip 15 20 Business Class Trucks Maintenance Manual December 2002 31 1 31 Hendrickson Suspension Torque Values Na F Torque Description Size Ibf ft N m Fore and Aft Torque Rod Mount Nut Bn os Table 2 Hendrickson Suspension Torque Values All Hendrickson beam end fasteners must maintain their torque values to firmly clamp the rubber bushing inner metal tubes to the beam hanger legs Insufficient beam end fastener torque could cause the beam to separate from the axle and result in loss of vehicle control Tighten the nut see Fig 1 to the torque value in Table 2 Do not over torque 5 2 ul ZZZ LLL i a FI WIZ KN ZZ uz Z LAT H p P 77 j ILA I ng ZL PI mog mog Z TA 2 LU IEEE un Inm SE ee cea a aa a 3 n gt 4 05 27 93 f320110a NOTE Do not use the three piece adapter without the intermediate tube 1 Nut 4 2 Adapter 3 Intermediate Tube Inner Metal of Beam End Bushing 5 Beam Hanger Fig 1 Three Piece Adapter Type Beam End Connection Check the drive axle flange fasteners Fig 2 for tightness Tighten the fasteners as follows Frame and Frame Compon
57. 5 liter of lube capacity or Lubrizol No 797 or 762 1 ounce 30 mL of additive for each 1 pint 0 5 liter of lube capacity Table 2 Rockwell Drive Axle Lubricant Capacities Single Axles Rockwell Drive Axle Lubricant Capacities Tandem Axles Capacity Axle Model pints liters Tr Forward 29 8 14 1 RT 34 135 Rear 34 16 1 Tu Forward 30 4 14 4 RT 40 145 Rear 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 3 Rockwell Drive Axle Lubricant Capacities Tandem Axles 35 02 Axle Breather Checking The axle housing breather Fig 1 must remain clean Whenever 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 Changing and Magnetic Plug Cleaning 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 m
58. 5A 11 0 10 4 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating position Table 3 Meritor Transmission Lubricant Capacities 4h CAUTION Operating a manual transmission with the oil level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion overfilling 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 problems IMPORTANT Do not mix types of oil because of possible incompatibility Do not use multi viscosity oils or EP Extreme Pressure gear oils Do not use oil additives or friction modifi ers If switching from a petroleum based lubri cant to a synthetic all areas of each affected component must be thoroughly drained Switch ing to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic from a petroleum based lubricant NOTE The correct oil level is established by checking the fill plug opening 2 Clean the fill plug then install it in the gear case Tighten the plug as follows Transmission 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe thread
59. 6 Business Class Trucks Maintenance Manual February 2003 26 21 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Pl Wheel INSPECING s sx dunner KA A x e Eh oan kene PAG LNG SH LAGUNA ET PLA MGA DIY DDS 31 02 FRR VV MON LUCU na amp cnc ATON TA ARA aca ad tua et PAWA dak ae AW AA GRAN WAWA Gave am NN a Awd AA NANA 31 03 Frame Fastener Torque Checking 22 2 eee 31 01 Holland Fifth Wheel Sliding Mechanism Inspecting llis 31 04 Business Class Trucks Maintenance Manual December 2002 Frame and Frame Components 31 01 Frame Fastener Torque Checking 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 4h CAUTION Continued vehicle operation with insufficiently tightened fasteners could result in bracket or 31 Freightliner Airliner Suspension Torque Values Description Size Sea Air Spring Upper Mounting Bi Bracket 5 8 11 125 170 Spring Hanger Mounting Locknute 3 4 10 210 285 Lateral Control Rod Nut 5 8 11 185 136 Table 1 Freightliner AirLiner Suspension Torque Values Tighten Hendrickson su
60. 6 Check the driveshaft tubes for dents bends twists or other damage If any tube appears to 7 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 Business Class Trucks Service Manual Check the driveshaft for missing balance weights and for debris build up Remove any build up If any balance weights are missing re 41 2 Business Class Trucks Maintenance Manual January 1998 Driveline 41 z UU MY 05 27 93 Y f410012a Attempt to bend the sleeve yoke and splined shaft back and forth Fig 2 Slip Joint Spline Wear Checking A lt A i A C D C 06 13 96 Measurement 3 76 mm Measurement 0 015 0 38 mm Measurement 0 020 0 51 mm Measurement 0 025 0 635 mm f410110b com Fig 3 Driveshaft Runout Specifications move the driveshaft and have it balanced see Group 41 of the Business Class Trucks Service Manual 8 For driveshafts with slip joints check that the yoke plug is not loose or missing See Fig
61. 7 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 718 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 lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 1 Torque Values for U S Customary Thread Fasteners with Lubricated or Plated Threads Business Class Trucks Maintenance Manual February 2004 00 3 00 Torque SSpecifications Tables 00 03 General Information Torque Values for U S Customary Thread Fasteners with Dry Unlubricated Plain Unplated Threads t Regular Hex Flanged eee ick Grade 5 Bolt ias odd B E 8 2 xe or C a d 8 2 Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m mme pa aroos sos um zc 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 1614 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 1
62. 90 258 190 258 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 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 Business Class Trucks Maintenance Manual February 2004 General Information 00 Torque SSpecifications Tables 00 03 Torque Values for Metric Thread Fasteners with Lubricated or Plated Threads t 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 7 N Ss N TOP F P N uds a E WA 230010 230011 1230012 230013 M6 5 7 7 9 M8 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
63. ADD mark add enough fluid to bring the level up to the full mark on the dipstick See Table 1 for approved power steering fluid SON SS SY NOY 10 05 94 1 Power Steering Fluid Reservoir 2 Steering Gear 1460514a Fig 3 Power Steering Reservoir Approved Power Steering Fluids Fluid Type Approved Fluid Automatic Transmission Dexron II Fluid Type Dexron III Heavy Duty Engine Oil Union 10W 40 IMPORTANT Do notuse 200 ve heavy duty engine oil in Mobil Super 10W 40 vehicles built from Union 15W 40 November 4 2002 Shell Rotella T30W Do not mix engine oil with automatic transmission fluid ATF Use the same lubricant for parts as is used in the power steering system Table 1 Approved Power Steering Fluids 3 Install the dipstick fill cap in the power steering reservoir 46 04 Power Steering Reservoir Fluid and Filter Changing 1 Remove the dipstick 3 8 16 hexnut and cover See Fig 3 2 Drain the power steering reservoir by disconnect ing the power steering gear to reservoir hose from the reservoir Keep the hose in an upright position to prevent drainage of fluid 46 2 Business Class Trucks Maintenance Manual November 2002 Steering 3 Catch the fluid from the reservoir in a drain bucket then cap the reservoir port 4 Lift out the spring and filter element 5 Thoroughly clean the reservoir with a lint free cloth 6 Install a new
64. Automatic Slack Adjuster Inspecting and Adjusting Gunite 83 01 Air Conditioner Checking R 12 and R 134a Refrigerant Systems Business Class Trucks Maintenance Manual February 2004 00 19 00 General Information M2 Maintenance Interval Operations Table 00 11 IMPORTANT After performing all operations in this Numbers in this table are maintenance operation ref table perform all daily and weekly maintenance op erence numbers matching those in the text of this erations listed in the Pretrip Inspection and Daily manual The M2 Maintenance consists of all M1 In Maintenance chapter of the Business Class Trucks terval Operations plus the other operations listed be Driver s Manual Also perform all M1 Maintenance low Interval Operations 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 Perform All M1 Operations Lubrication and Fluid Level Check all but FL112 includes the following e Two Speed Axle Shift Unit Oil Level Checking e Camshaft Bracket Bushing Lubricating e Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspect ing and Lubricating Bendix DV 2 Steering Driveline Lubricating 13 01 Air Compressor Inspecting Bendix 20 01 Radiator Cap Checking 20 03 Fa
65. Brake Adjusting Manual Slack Adjusters Meritor 1 Check the adjustment on Meritor brakes when ever the brake chamber piston rod applied stroke exceeds the maximum allowable stroke 1 1 With the brakes released measure the distance from the face of the brake cham ber to the centerline of the clevis pin Fig 4 Ref A Record the exact dis tance as measurement A 1 2 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa Measure the distance from the face of the brake chamber to the center line of the clevis pin Fig 4 Ref B Record the exact distance measured as measurement B 1 3 Subtract measurement A from measure ment B to determine the applied stroke If the applied stroke equals or exceeds the maxi mum allowable stroke adjust the brakes See Table 3 Maximum Allowable Brake Chamber Stroke with Meritor Manual Slack Adjusters Chamber Size Effective Area ee ne E square inches B minus A 12 1 1 2 38 16 1 3 4 44 20 1 3 4 44 24 1 3 4 44 24 long stroke 2 51 30 2 51 Adjust the brakes whenever the applied stroke exceeds the maximum Table 3 Maximum Allowable Brake Chamber Stroke with Meritor Manual Slack Adjusters 2 1 Wipe clean the adjusting screw hexhead See Fig 4 Position a wrench or socket over the adjusting screw hexhead 42 6 Business Class Trucks Maintenance Manual October 1998 Brakes
66. Business Class Trucks Maintenance Manual Contents Group No Group Title OO peace ct oce deu tus General Information Ol ee PRIV ETT Engine UC Air Intake WG ioe oe iesu ne a cee me MINER Air Compressor PA PE Alternator and Starter 20 cuam Peewee Engine Cooling Radiator 2D AA ee oe cede oe ae Clutch 2O maa aah Rei th fe dnd Dub fiut ie ee E Transmission Ol coxa a ee Sateen Frame and Frame Components 32 ida ed E Ee uec exi Pr er ds Suspension DO a thar e Geka ta a attentione dd arvo Front Axle COMMERCE LOL do NAKA P Rear Axle L1 a care ae saya a AG EU BAY A Wheels and Tires m Driveline PRICE Brakes 46x ccs sue kad LI du E ics Steering d deii cb s BIBE ea tae eee tae nh tn ie en quid ud e uf Fuel 49 Be hss oe dcc tae Sav eh SUE cee YG Exhaust bdo eos huni aga Electrical Instruments and Controls p Mcr IE es es PA Doors o MC RT Heater and Air Conditioner Introduction FREIGHTLINER BUSINESS CLASS TRUCKS MAINTENANCE MANUAL Models FL50 STI 266 2 04P FL60 FL70 FL80 FL106 FL112 MB50 MB60 MB70 MB80 Published by Freightliner LLC 4747 N Channel Ave Portland OR 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 check that the engine undercarriage and noise emission control parts are in good working order during lubricat
67. Class Trucks Maintenance Manual July 1999 Suspension 2 1 Z A Y A 3 S 05 27 93 5 1320023a A 1 8 inch 3 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 4 Top View of the Equalizer when inflated If the clearance is less than 1 inch 25 mm relocate the obstructing parts 4h CAUTION Failure to relocate obstructing parts could result in damage to the air spring Freightliner AirLiner Component Inspecting and Operation Checking WARNING 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 resulting in property damage serious per sonal injury or death 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 fully inflated see Group 32 of the Business Class Trucks Service Manual 3 Inspect each air spring for wear at its connection to its pedestal Replace any worn air springs for 32 instructions see Group 32 of the Business Class Trucks Service Manual 4 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are crack
68. Fig 17 ATF Dipstick Aisin Transmission 12 Inspect the high temperature ATF level 12 14 Make sure the vehicle is in neutral and start the engine and remove the chocks Drive the vehicle for 30 minutes to raise the ATF temperature to normal working oil temperature Park the vehicle on a level service and chock the tires 12 2 With the engine idling engage the brake pedal and successively shift gear posi tions to spread ATF throughout the trans mission 12 3 Set the shift selector to neutral N 12 4 Continue engine idle and remove the dip stick Wipe it clean re insert it remove it and measure the ATF level 12 5 If the ATF temperature is between 158 to 176 F 70 to 80 C the fluid should mea sure in the HOT range See Fig 17 e f the ATF level is below the HOT range add ATF until the level is within the HOT range e f the ATF level is above the HOT range remove the drain plug Fig 16 and drain ATF until the level is lower than the required range Then install the drain plug Transmission and refill with ATF until the level is within the HOT range 13 Remove the chocks from the tires 26 09 Mercedes Benz MBT Transmission Leak Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Check for signs of leakage at the breather See Fig 18 5 05 22 2001 8 7 6 1261101 NOTE The transmission is shown from the left hand side Sh
69. Group 09 of the Business Class Trucks Service Manual Reset the air restriction 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 Business Class Trucks Maintenance Manual February 2004 09 1 Air Compressor Title of Maintenance Operation MOP Air Compressor Inspecting Bendix 20 5 Air Compressor Rebuilding Replacing Bendix 13 Index Alphabetical MOP Number Sidley Geta BBs Rod dust acta dud m navn SB dna e anaes 13 01 Business Class Trucks Maintenance Manual January 1998 Air Compressor 13 01 Air Compressor Inspecting Bendix 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 02 Air Compressor Rebuilding Replacing Bendix Disassemble clean and inspect the air compressor Replace all seals gaskets springs and all parts that are worn or damaged beyond re use Replace the air compressor unloader mechanism
70. If applicable rotate each wheel until the oil drain bore is at the bottom then re move the drain bore plugs and allow the oil to drain into a suitable container If needed use a bent piece of sheet metal to direct the draining oil so it doesn t splash on the tires 4 Fill the differential and hubs if applicable with new Oil 4 1 Install the drain bore plugs in each hub and the differential then tighten the plugs firmly 33 4 2 Remove the plug from the oil level check bore in each hub and from the fill and check bore in the differential 4 3 Fill the hubs and differential until the oil level within each is even with the bottom of the fill and check bore 4 4 Install the check bore plug in each hub and install the fill and check plug in the differential Tighten all the plugs firmly Lift the front axle off the jack stands remove the stands and lower the vehicle to the ground Then remove the chocks from the rear tires Business Class Trucks Maintenance Manual June 2001 33 3 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather Oeo NIFI xau ae meo Exod tri eue t dian eue d dte vb dE ROSE ravens IL d qu d RS d 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning lille 35 03 Axle Lubricant Level Checking 42e Roses Ra DAGAT E EE DOES kde EUER OR ede ERE d 35 01 Two Speed Axle Shift Unit Oil Changing 0000 ec nh 35 05 Two Speed Axle Shift
71. 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 5 Use care that no grease enters the drum cavity If grease leaks 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 n A Grease exit 1 Brake Chamber 2 Slack Adjuster f420011a 3 Grease Fitting Fig 5 Camshaft Bracket Bushing Lubrication 42 11 Manual Slack Adjuster Lubricating Bendix Manual Slack Adjusters Lubricate the slack adjuster with chassis grease NLGI grade 1 or 2 Apply enough grease to com pletely fill the body cavity Business Class Trucks Maintenance Manual October 1998 42 7 42 Midland Manual Slack Adjusters Midland slack adjusters are greased for life at as sembly However a grease fitting is furnished to per mit optional lubricating 42 12 Automatic Slack Adjuster Checking Meritor 1 Check the boot for cuts tears etc and replace it if necessary See Fig 6 Brakes 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
72. S 6206A 9 0 8 5 FS 6406A 9 75 9 2 FSO 6406A FS 7206A 10 0 9 5 FS 8206A 10 0 9 5 FSO 8406A 9 75 9 2 6 Speed Autoshift all 10 4 9 8 7 Speed T Series T 8607A B 18 0 17 0 T 14607A B 13 0 12 3 All 9 Speed Series except deep reduction RT 6609A 6 0 5 7 RT 8609A 6 0 5 7 RT 8709B 13 0 12 3 RT 11609A 13 5 12 8 RTO 11609A B RTX 11609A B P R RT 11709H 13 5 12 8 RTX 11709H RT 12609A 13 5 12 8 RTO 12609A B RTX 12609A B P R RT 12709H 13 5 12 8 RTX 12709H RT 13609A H 13 5 12 8 RTX 13609B H R FS 4005A B C 5 25 5 0 26 2 Business Class Trucks Maintenance Manual February 2003 Transmission 26 Eaton Fuller Transmission Lubricant Capacities Eaton Fuller Transmission Lubricant Capacities RTX 11708LL RTO 11908LL RTO 14908LL RTO 16908LL Transmission Model jon ris tero in Transmission Model a H RT 14609A H 13 5 12 8 10 Speed Automated Models RTX 14609B H R Top 2 all 14 0 13 2 RTX 16709B H 13 5 12 8 Lightning all 13 5 12 8 9 Speed Deep Reduction 10 Speed Autoshift AS2 all 13 0 12 3 RT 8608L 13 5 12 8 11 Speed RTO Series RT 11707LL 14 0 13 2 RTO 11909ALL 14 0 13 2 All 10 Speed Manual Series except deep reduction RTO 14909ALL 10 Speed FR FRO all 11 75 11 1 All 13 Speed Series R 6610 6 0 5 7 RT 6613 8 0
73. Trucks Ser vice 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 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 Business Class Trucks Service 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 Tighten the nut finger tight Using a wrench further tighten the nut until you feel re sistance Then tighten the nut one sixth turn more 6 Repeat the above steps for each parking brake chamber 7 Apply the parking brakes Remove the chocks from the tires 42 08 Air Dryer Desiccant Replacing Meritor WABCO System Saver 1000 Replace the desiccant cartridge For instructions see Group 42 of the Business Class Trucks Service Manual NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However if experience has shown that extended or shortened life has resulted on a particular installation then the in terval can be increased or decreased accord ingly Brakes 42 09 Meritor
74. Unit Oil Changing 1 Remove the shift unit housing cover Fig 2 and drain the old lubricant Discard the housing cover gasket and the old lubricant 2 Thoroughly wash the axle shift parts and housing cover and allow them to air dry 3 Install the housing cover and a new housing cover gasket Tighten the housing cover cap screws 90 to 110 Ibf in 1020 to 1240 N cm then remove the oil fill hole plug from the cover 4 Fill the shift unit housing through the oil fill hole until the specified lubricant is level with the bot tom of the opening IMPORTANT When the vehicle operating tem peratures are above 0 F 18C use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 8596 When the vehicle operating tempera tures are below 0 F 18 C use one part of kerosene to three parts of SAE 10 heavy duty engine oil API service classification SD sul fated ash content must not exceed 1 85 This cold weather mixture can be safely used up to g2 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures Do not mix kerosene with auto matic transmission fluid Rear Axle Apply a small amount of Loctite 242 or an equivalent sealant to the threads of the oil fill hole plug Install the oil fill hole plug finger tight then using a wrench tighten the plug 1 1 2
75. acket 8 Elbow Connector 4 Clutch Support Plate 9 Actuator Hose 5 Master Cylinder 10 Jam Nut Fig 2 Clutch Components 25 04 Hydraulic Fluid Replacing Replace the clutch hydraulic fluid every two years to ensure clutch function is reliable and correct Use the procedures below Fluid replacement must be done at an authorized Freightliner service facility Draining and Filling 1 Shut down the engine Timing Case Mounting Capscrew M10 Hardened Flatwasher Timing Case Standoff Bracket Cushioned Clamp Bell Housing Standoff Bracket Hydraulic Hose Washer M10 Bell Housing to Timing Case Mounting Capscrew M10 9 Flatwasher 10 Slave Cylinder Capscrew M8 Qo GY OY Re OT c 11 Slave Oylinder Fig 3 Clutch Slave Cylinder 25 2 Business Class Trucks Maintenance Manual June 2002 Clutch 3 1 Using a drain pan or other suitable con tainer collect the fluid that drains from the pedal unit not more than 0 3 quarts 0 3 liters 3 2 Allow the open end of the drain hose to remain over the drain pan 3 3 Press down on the pedal several times until no more fluid drains from the reser voir in the pedal unit 3 4 Cover the hose to avoid contamination of the clutch hydraulic fluid 4 Connect the hydraulic hose to the slave cylinder Install the clamp as removed 5 Fill the reservoir with approved DOT 3 brake fluid and bleed the system according to the proce dures under the he
76. ading Bleeding the Clutch See Fig 4 Bleeding the Clutch 1 Apply the parking brake and chock the tires 2 Prepare the pressure bleeding equipment ac cording to the manufacturer s instructions Use DOT 3 brake fluid Pressurize the bleeder unit to 15 psi 103 kPa 4h CAUTION Do not spill clutch hydraulic fluid DOT 3 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 3 brake fluid can damage paint 3 Remove the reservoir lid and install the pressure bleed adaptor on the reservoir 4 Remove the cap from the bleed valve Install a transparent drain hose on the bleed valve of the slave cylinder IMPORTANT The slave cylinder may not be mounted in a horizontal position If it isn t re move the slave cylinder and hold it in a horizon tal position to completely purge all air from the cylinder 5 Pressurize the reservoir filling the system Open the bleed valve on the bleed tank NOTE A pressure bleeder hose J 29532 and a bleeder adaptor J 35798 for the fluid reser 25 voir are available through SPX Kent Moore Tools and may be used to complete the follow ing procedure To order these parts call Kent Moore at 1 800 328 6657 6 Press the clutch pedal all the way down and keep it down 7 Open the slave cylinder bleed valve Observe the flow of clutch hydraulic fluid through the drain hose When no bubbles appear in the fluid close the valve on the slave cylinder Re
77. agnetic 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 of compounded lubricants during the summer season is about 160 to 220 F 71 to 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 4h CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage Axle Draining and Flushing 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 35 2 Business Class Trucks Maintenance Manual January 1998 Rear Axle 2 Flush the unit with clean flushing oil then drain it completely 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 poun
78. akes 7 8 to 1 1 8 inch 22 to 29 mm 42 8 Business Class Trucks Maintenance Manual October 1998 42 Brakes 3 3 If the free stroke is incorrect remove the pressure relief capscrew gasket pawl spring and pawl Fig 6 Ref 5 from the slack adjuster housing If equipped with a pull pawl assembly Fig 8 carefully in sert a screwdriver and raise the relief cap about 1 8 inch 3 2 mm 09 27 94 A Insert screwdriver here f420693a Fig 8 Pull Pawl Assembly sectional view 4h 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 3 4 Turn the adjusting nut one eighth turn as shown in Fig 9 Measure the stroke again and adjust until correct 4h 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 A a N 2 B AN Ko Sa N 07 05 95 po Fj N ae 420181a A Shorten stroke B Lengthen stroke Fig 9 Brake St
79. al 42 05 Relay Valve Checking Midland 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 Business Class Trucks Maintenance Manual October 1998 42 1 42 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 the Midland service manual for in structions Remove the chocks from the tires 42 06 Quick Release and Flipper Valves Checking Midland 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 valves 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 the Midland service manual for in structions Remove the chocks from the tires 42 07 Brake Chamber Inspecting All Models Do
80. alues 4h CAUTION Failure to replace the suspension crossmember or gussets if they are cracked worn or otherwise damaged could result in damage to the vehicle chassis Freightiner Spring Shock Absorber Checking 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 See Fig 1 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 Spring Tandem Radius Rod Bushing Checking 1 Without detaching the torque arms attempt to move by hand each of the radius rod ends up down in and out If there is any movement re place the torque arm 2 Inspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason 3 Inspect the rubber bushing ends See Fig 2 Re place the torque arm for any of the following rea sons Business Class Trucks Maintenance Manual July 1999 32 1 32 Suspension 10 05 94 1 Upper Mounting Bracket 2 Shock Absorber 3 Lower Mounting Bracket f320267a Fig 1 Shock Absorber Installation front suspension shown e There are gaps between the rubber bush ing and the pin or the outer steel sleeve e Either bushing end contacts a
81. 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 Busi ness Class Trucks Service Manual 1 Apply the service brakes and check that the pis 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 Business Class Trucks Service Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious injury or death 42 4 Business Class Trucks Maintenance Manual October 1998 Brakes 3 Check the service brake chambers for leakage 3 1 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa 4h 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 See Fig 1 On Bendix service chambers tighten the clamp ring enough to stop the leakage but do not exceed
82. ar ATF Plus Type 7176 Table 6 Approved Chrysler Transmission Lubricants Chrysler Transmission Lubricant Capacities Transmission Model Eun 46RH Full Capacity 10 9 10 3 46RH Fill Amount After Fluid 2 0 1 9 Change 46RH Fill Amount After Overhaul 6 0 5 7 Table 7 Chrysler Transmission Lubricant Capacities 26 07 Chrysler Transmission Band Adjusting Front Band Adjusting The front kickdown band adjusting screw is located on the left hand side of the transmission case above the manual lever shaft and the park neutral position switch See Fig 14 1 Raise the vehicle Fig 14 Front Band Adjusting Screw Chrysler 2 Loosen the locknut on the front band adjusting screw 3 Back off the locknut three to five turns Make sure the adjusting screw turns freely in the trans mission case If necessary apply lubricant to the screw threads 4 Set the adjusting screw To turn the adjusting screw use a 5 16 inch 8 point socket on a 0 to 100 Ibf in O to 1100 N cm torque wrench 4 1 Tighten the adjusting screw 72 Ibf in 800 N cm 4 2 Back off the adjusting screw 2 7 8 turns 5 Holding the adjusting screw in position tighten the locknut 30 Ibf ft 41 N m 6 Lower the vehicle Rear Band Adjusting The rear low reverse band adjusting screw is lo cated on the lower surface of the valve bogy It is accessible only when the oil pan and filter are re moved See Fi
83. aust System Inspecting 54 01 Electrical System Checking eje lo 54 02 Coolant Level Sensor Cleaning 72 01 Weatherstrip Door Hinge and Door Latch Lubricating 00 14 Business Class Trucks Maintenance Manual February 2004 General Information 00 Maintenance Operation Sets Tables 00 08 Maintenance Operation Sets for Groups 46 through 83 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 83 01 Air Conditioner Checking R 12 and R 134a Refrigerant Systems Table 13 Maintenance Operation Sets for Groups 46 through 83 Business Class Trucks Maintenance Manual February 2004 00 15 00 General Information Initial Maintenance IM Operations Table 00 09 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 Business Class Trucks Driver s Manual Also perform all M1 Maintenance Interval Operations at the Initial Maintenance IM NOTE Numbers in this table are maintenance opera tion reference numbers matching those in the text of this manual The Initial Maintenance consists of all M1 Operations plus the other operations listed below Initial Maintenance IM Operations Maint Oper No Initial Maintenance IM Operations 00 10 Perform All M1 Operations
84. c inches in3 cubic inches in3 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 qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft3 cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 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 lbf in 11 298 Newton centimeters N cm 0 08851 inch pounds lbf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Ibf ft 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 Then When You Multiply Then When You Know Subtract Divide By To Get Know By Add To Get degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 degrees Fahrenheit F Table 5 Temperature Conversion 00 6 Business Class Trucks Maintenance Manual February 2004 General Information 00 Scheduled Maintenance Intervals Description and
85. ce Manual July 1999 01 3 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and Replacing naaa aaa 09 01 Business Class Trucks Maintenance Manual February 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 22 inH5O on a vehicle with an MBE engine or 25 inH O on a vehicle with a Detroit Diesel Caterpillar or Cummins engine if equipped with an air restriction indicator For replacement instructions see Group 09 of the Business Class Trucks Service Manual Reset the air restriction 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 of 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 22 inH5O on a vehicle with an MBE engine or 25 inH O on a vehicle with a Detroit Diesel Caterpillar or Cummins engine if equipped with an air restriction indicator For replacement instructions see
86. cedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 42 08 Air Dryer Desiccant Replacing Meritor WABCO System Saver 1000 42 16 Air Dryer Desiccant Replacing Bendix AD 9 42 20 Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 12 QR 1 R 14 SR 1 ST 3 TC 7 and TP 5 54 02 Coolant Level Sensor Cleaning NOTE Numbers in this table are maintenance opera tion reference numbers matching those in the text of this manual The M5 Maintenance consists of all M1 M2 M3 and M4 Interval Operations plus the other Business Class Trucks Maintenance Manual February 2004 00 23 00 General Information Lubrication and Fluid Level Check M1 all models but FL112 00 15 Maintenance Operation 00 15 Table 14 summa rizes all Lubrication and Fluid Level Check opera tions that must be performed at the M1 Maintenance Interval for Schedules II and III for all models but FL112 Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check Maintenance Operation 00 18 can be used as a guide by those who do not need to consult the detailed lubrication and fluid check instructions given elsewhere in the manual Maint Oper No Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check for All Models but FL112 Operation Description 25 01 Clut
87. ch Release Bearing 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 f250081a 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 On Sachs hydraulic clutches never lubricate the release bearing The release bearing is made of plastic with a kind of embedded grease 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 Pull Type Inspecting and Adjusting See Group 25 of the Business Class Trucks Ser vice Manual for clutch pull type inspecting and ad justing 25 03 Hydraulic Fluid Level
88. ch Release Bearing and Cross Shaft Lubricating 25 03 Hydraulic Fluid Level Checking 31 03 Fifth Wheel Lubricating 26 01 Manual Transmission Oil Level Checking 32 02 Suspension Lubricating 33 01 Knuckle Pin Lubricating 33 03 Tie Rod End Lubricating 33 05 All Wheel Drive Front Axle Oil Level Checking 35 01 Axle Lubricant Level Checking 41 02 Driveline Lubricating 42 03 Foot Brake Valve Actuator Lubricating Bendix E 12 42 11 Manual Slack Adjuster Lubricating 42 13 Automatic Slack Adjuster Lubricating Meritor 42 24 Automatic Slack Adjuster Lubricating Gunite 42 26 Automatic Slack Adjuster Lubricating Haldex 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 05 Steering Gear Lubricating Ross TAS Series 72 01 Weatherstrip Door Hinge and Door Latch Lubricating Table 14 Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check for All Models but FL112 00 24 Business Class Trucks Maintenance Manual February 2004 General Information 00 Lubrication and Fluid Level Check M2 all models but FL112 00 16 Maintenance Operation 00 16 Table 15 summa instructions in the manual on the lubrication or fluid rizes all Lubrication and Fluid Level Check opera check Maintenance Operation 00 18 can be used tions that must be performed at the M2 Maintenance as a guide by those who do not need to consult
89. cing Bendix AD 9 0 000200 ee 42 16 Air Dryer Desiccant Replacing Meritor WABCO System Saver 1000 a 42 08 Air Dryer inspecting Bendix ADH9 3 0 dacs bate mt hn Doe Oe dee KAI UT Re bebe ge OX DC CUP oe ee 42 01 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bend DV s gd caer ehed Pate Ee wah pag Sura dra en OP GU EEE SS d qud d dra 42 19 Automatic Slack Adjuster Checking Meritor llli eh 42 12 Automatic Slack Adjuster Inspecting and Adjusting Gunite 2l 42 25 Automatic Slack Adjuster Inspecting Meritor llli 42 14 Automatic Slack Adjuster Lubricating Gunite llli 42 24 Automatic Slack Adjuster Lubricating Haldex lille 42 26 Automatic Slack Adjuster Lubricating Meritor iilii 42 13 Brake Chamber Inspecting All Models 0 00000 cee ete 42 07 Brake Lines Checking Hydraulic Disc Brakes 00 0000 ee 42 22 Brake Lining Wear Checking Hydraulic Disc Brakes llle 42 21 Camshaft Bracket Bushing Lubricating se e nre emnt beso ket epe debe map vob heb e ore e 42 10 Foot Brake Valve Actuator Lubricating Bendix E 12 4 42 03 Manual Slack Adjuster IUBICATING padaan a ctp 2 onc deat nita andi de RU CRUECI B ARE RA diee eee cutus 42 11 Meritor Brake Adjusting Manual Slack Adjusters 0 000 000 cee eee 42 09 Power Booster Checking Bendix Hydro Max 00 eee 42 23 Quick Release
90. ck the counterclockwise torque of the adjusting hexnut The torque should be greater than 15 Ibf ft 20 N m If it is not replace the slack adjuster 42 26 Automatic Slack Adjuster Lubricating Haldex Lubricate a Haldex automatic slack adjuster at the grease fitting with any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is 20 F 29 C and above If the operating tempera ture is below 20 F 29 C use a low temperature extreme pressure grease Brakes 42 14 Business Class Trucks Maintenance Manual October 1998 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Lk UOCI me P c FD EET 46 02 Miter Gear Lubricating Right Hand Drive Only 2 eee 46 06 Power Steering Reservoir Fluid Level Checking llli ee 46 03 Power Steering Reservoir Fluid and Filter Changing 0000 e eee ees 46 04 Steering Driveline Lubricating llla 46 01 Steering Gear bu bricaling i odds Km KGG BRP pondere ka puedes ro pe debe eu ped qe e 46 05 Business Class Trucks Maintenance Manual November 2002 Steering 46 01 Steering Driveline Lubricating Wipe the grease fittings clean See Fig 1 Using a pressure gun apply a lithium based grease NLGI grade 2 sparingly to the universal joints and slip joint splines 46 2 Using a pressure gun apply multipurpose chas sis grease at the grease fittings until old gr
91. ck the old grease If it appears rusty gritty or burned replace the U joint assembly See Group 41 of the Business Class Trucks Service Manual 5 Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubricating 1 Wipe all old grease and dirt from the slip joint grease fitting See Fig 4 Ref 1 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter 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 41 4 Business Class Trucks Maintenance Manual January 1998 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 12 QR 1 R 14 SR 1 ST 3 TC 7 and TPD 4 paanan aa KE sue dup Xe s eee DSR EROR EERE vO E EH e 42 20 Air Brake Valve Inspecting and Leak Checking Bendix BP R1 0 000 eee 42 02 Air Brake Valve Leak Checking Bendix TC 7 eee ene 42 18 Air Brake Valve Operation Checking Bendix BP R1 and E 12 0 002020 c cee 42 04 Air Brake Valve Operation Checking Bendix R 14 and TC 7 lille 42 17 Air Dryer Checking Bendix AD 9 152208 hada Rt Red E Bee eke Sek Rd oe Shee 42 15 Air Dryer Desiccant Repla
92. d 42 12 Business Class Trucks Maintenance Manual October 1998 Brakes Remove the old boot from the link 2 3 Install a new boot on the link heavy sec tion down Be careful not to damage the boot 2 4 Seat the boot so that the bottom of the boot is in the boot insert and the top is in the groove of the link 2 5 Rotate the adjusting hexnut clockwise until the 1 4 inch hole in the clevis lines up with the hole in the link Install the 1 4 inch clevis pin and the cot ter pin 2 6 Tap the clevis upward or downward until the large hole in the slack adjuster lines up with one in the clevis Install the 1 2 inch clevis and the cotter pin Make sure both clevis pins are installed Failure to do so will cause the slack adjuster to work incor rectly which could lead to loss of braking control This could result in an accident causing personal injury or property damage 3 Check for correct chamber stroke 3 1 With the brakes fully released use a ruler to measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 11 Ref A 3 2 Build air pressure to at least 85 psi 585 kPa Apply the brakes then measure the distance from the bottom of the brake chamber to the center of the large clevis pin See Fig 11 Ref B The difference between the measurements is the brake chamber stroke Compare this measurement with those shown in Table 5 4 If the brake chamber
93. d differently than on other applications see Group 32of the Business Class Trucks Service Manual for removal and installation information Business Class Trucks Maintenance Manual July 1999 32 3 32 Hendrickson Suspension Inspecting Inspect the suspension assembly for wear cracks and damage to its components Replace the compo nent s if any wear cracks or damage exists For instructions see Group 32 of the Business Class Trucks Service Manual Check all fasteners for tightness Check for distorted or frayed rubber at the beam end bushings If the bushings are damaged replace them Check that the ends of the equalizer beam are not lower in the beam hanger If the equalizer beam ends appear lower use a jack to raise each beam end and check for movement of the inner metal of the rubber end bushing see Fig 5 Movement cannot be corrected by tightening the fastener because parts could be damaged If there is movement replace the rubber end bushings and all connecting parts 05 27 93 1 Beam Hanger 2 Equalizer Beam 1320039a 3 Jack Fig 5 Raising the Beam End After repairs to the suspension check the fastener torque after the vehicle has been in service for 2500 miles 4000 km Tighten the adapter type beam end connection nut see Fig 6 210 to 240 Ibf ft 285 to 325 N m Do not over torque 4h WARNING Insufficient beam end fastener torque could cause the beam to separate
94. down away from the belt When the breaker bar is slowly released the tensioner should return to its original position If not see Group 01 of the Business Class Trucks Service Manual for re placement instructions NOTE The following engines are provided with automatic drive belt tensioners Caterpillar CFE Detroit Diesel Series 55 and Dodge Magnum The following engines which appear in Table 1 are provided with automatic tensioners for the fan and alternator belts and refrigerant com pressor for Caterpillar C10 C12 Caterpillar C10 and C12 and Cummins B and C Series Drive Belt Tensions Engine Component m k a on Cummins B and C Series Refrigerant Compressor 100 45 Alternator 105 48 Cummins M11 Fan 160 73 Refrigerant Compressor 90 41 Fan and Alternator 70 32 Detroit Diesel Series 50 Refrigerant Compressor 95 43 Fan and Alternator 160 73 Mercedes Benz OM366LA Refrigerant Compressor 100 45 or 140 64 Air Compressor 50 23 For a regular V belt tighten the belt to 100 Ib 45 kg For a Powerband V belt tighten the belt to 140 Ib 64 kg Table 1 Drive Belt Tensions 01 2 Business Class Trucks Maintenance Manual July 1999 Engine 01 11 21 94 f150010a A Glazing D Tensile Break B Separating Layers E Uneven Ribs C Streaked Sidewalls F Cracks Fig 2 Drive Belt Replacement Conditions Business Class Trucks Maintenan
95. ds 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 between lubrication change intervals 4 After cleaning the drain plugs install and tighten them 35 Ibf ft 47 N m Axle Filling 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 or Table 3 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 Ibf ft 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 35 04 Two Speed Axle Shift Unit Oil Level Checking 4h CAUTION Failure to keep lubricant at the specified level could cause damage to the axle shift unit 1 Clean the oil fill hole plug in the shift unit housing cover and the area surrounding it See Fig 2 Remove the fill hole
96. e as recommended by the lubricant manufac turer on rubber Apply a few drops of light engine oil or spray a light coating of silicone lubricant such as WD 40 or an equivalent on the door latch mechanism This will help reduce noise and wear Wipe off any excess oil or silicone lubricant Lubricate door hinges 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 Business Class Trucks Maintenance Manual January 1998 72 1 Heater and Air Conditioner 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Conditioner Checking R 12 and R 134a Refrigerant Systems 0 00000 c ee ee eee 83 01 Business Class Trucks Maintenance Manual January 1998 Heater and Air Conditioner 83 01 Air Conditioner Checking R 12 and 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 Business Class Trucks Service Manual 3 Using a feeler gauge check for correct clutch clearance For instructions see Group 83 in the Business Class Trucks Service Manual 4 nspect the compressor clutch coil wire Check the connector for damage or looseness
97. e 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 Inspecting 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 manufacturer s service manual 3 Check the tie rod end nut and clamp nut torques Tighten the tie rod end nut 100 Ibf ft
98. e side view N N N 1222722222244 ANY A EN 03 03 95 Fuel Pump Module Gasket Fuel Pump Mounting Clamp Ring Fuel Pump Guard Bracket Clamp Ring Mounting Capscrew Hardened Flatwasher Fuel Tank Fuel Pump Module 1470137 nNOoORBRON Fig 5 Fuel Pump Module cutaway view 11 Apply a light coat of silicone spray to the gasket if needed to ease installation then install the fuel pump module in the fuel tank IMPORTANT Only use grade 8 capscrews NOTE Use the holes not intended for the guard bracket 12 13 14 47 11 1 Install the fuel pump clamp ring over the fuel pump module then install three 5 16 18 grade 8 capscrews and hard ened flatwashers to hold it in place Do not tighten the capscrews yet 11 2 Install the fuel pump guard bracket over the fuel filter pressure regulator then fas ten it in place with the remaining two cap screws and hardened flatwashers 11 3 Tighten all five capscrews 15 Ibf ft 20 N m Connect the fuel lines to the fittings on the fuel filter oressure regulator and the rollover valve Reconnect the electrical connector Fill the fuel tank with clean unleaded gasoline Connect the batteries start the engine and check for fuel leaks Also check that the fuel level gauge is working properly Correct any fuel leaks with the engine OFF Business Class Trucks Maintenance Manual January 1998 47 3 Exhaust 49 Index Alphabetical Titl
99. e drain plug and gasket from the transmission oil pan Allow the fluid to drain See Fig 8 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 then remove 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 Remove the washer head capscrew that secures the filter to the transmission then remove the filter and the filter intake pipe from the transmis sion 8 Separate the filter intake pipe from the filter dis card the O ring then clean the tube 26 8 Business Class Trucks Maintenance Manual February 2003 Transmission 26 y 2s ee NG yi ND Sf x E C c A 7 gt 4 1 P EE i 9 10 4 10 05 94 f260132a 1 Fluid Intake Tube 7 First Reverse Clutch Feed Tube 2 Detent Spring 8 Governor Screen in control valve body 3 Detent Spring 1 3 4 Bolt 9 Governor Pressure Tube 4 Filter Spacer 10 Governor Feed Tube 5 2 1 4 Bolt 16 qty 6 First Reverse Clutch Feed Tube 3 Bolt 2 qty behind Fig 6 Allison AT Series Transmission Governor 9 Install the filter intake pipe on the new filter In stall a new O ring on the filter intake tube then lubricate the O ring with a light coat of transmis sion fluid 10 Insert the filter intake pipe into
100. e fan clutch operation as follows 10 1 Connect the halves of the fan solenoid connector 10 2 Turn the air conditioner off 10 3 Start the engine and charge the air sys tem to 120 psi 827 kPa Tests must be performed with the engine temperature below 205 F 96 C for Caterpillar en 20 gines and below 200 F 93 C for Cum mins and Detroit Diesel engines 10 4 Set the toggle switch to the ON position the fan clutch should engage 10 5 Apply the foot brake and release the parking brakes 10 6 Set the toggle switch to the AUTO or OFF position the air should exhaust and the fan clutch should disengage Replace the switch if necessary 11 If the fan stays engaged at all times on a Detroit Diesel engine check the circuit breaker labeled engine fan Kysor K22RA Fan Clutch 1 Disconnect the electrical cables from the battery Drain all air from the air system If equipped with an air starter drain the air starter reservoir A WARNING If the engine starts during this procedure the fan could cause personal injury If the vehicle is equipped with an air starter be sure that the air starter reservoir is drained 2 Measure the distance from the back surface of the fan clutch retaining plate to the forward most edge of the fan belt pulley See Fig 7 Ref A 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 4 Apply a minimum of 100 psi 690 kPa air
101. e of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Controls illie 49 01 Business Class Trucks Maintenance Manual October 1998 Exhaust 49 01 Exhaust System Inspecting Noise Emission Controls 49 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 2 1 On Caterpillar Cummins and Detroit Die sel engines check for leakage at the V type clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the V type clamp 85 Ibf in 940 N cm If leak age persists install a new V band cou pling 2 2 On Mercedes Benz OM 366LA and Dodge Magnum engines check the tight ness of the fasteners that attach the ex haust pipe to the exhaust flange Fig 1 If needed tighten the fasteners 33 Ibf ft 45 N m for Mercedes Benz OM 366LA engines For Dodge Magnum engines tighten the fasteners 25 Ibf ft 34 N m 3 Check for leakage at each wide band exhaust clamp Fig 2
102. each slack adjuster 21 42 10 Camshaft Brackets Rear Axle Lubricate camshafts on both sides of each rear axle one grease fitting for each camshaft bracket 22 31 03 Fifth Wheel t Inspect the fifth wheel then lubricate top plate and all moving parts 23 42 03 Air Valves t Disassemble clean and lubricate all air valves Intervals and procedures are included in the Maintenance Operations Tables and the specific groups t Not shown in illustration t Air valves are located throughout the vehicle inside the cab and on the chassis Table 17 Lubrication Table for All Models but FL112 See Fig 2 for lubrication points FL112 models only 00 28 Business Class Trucks Maintenance Manual February 2004 General Information 00 Lubrication Tables 00 18 09 15 97 f000862 Fig 2 Lubrication Points FL112 models only No MOP No Components Remarks 132 02 Front Suspension Spring Pins Lube both sides of vehicle one grease fitting for each spring pin and Shackle Pins t two grease fittings for each shackle 46 02 Drag Link Two grease fittings one on each end 46 03 46 04 Power Steering Check fluid level in reservoir 46 03 change fluid and filter 46 46 05 04 when required Lubricate steering gear 46 05 4 46 01 46 06 Steering Driveline Lubricate grease fittings at slip joint splines and both universal joints Lubricate miter gear if applicable 5 42
103. ease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 6 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease Grade 2 chassis grease is pre 6 Q g 1 5 4 3 7 ae O i 7 K CY 6 10 05 94 p 1460516a 1 Pinch Bolt 4 Boot 6 Prevailing Torque Locknut 2 Universal Joint Shaft 5 Boot Retainer 7 Grease Fitting 3 Bushing Fig 1 Steering Driveline 46 02 Drag Link Lubricating ferred 1 Using a clean rag wipe the dirt from both grease fittings on the drag link See Fig 2 Business Class Trucks Maintenance Manual November 2002 46 1 46 Steering 10 05 94 1 Grease Fitting 2 Drag Link pitman arm end shown 1460926 Fig 2 Steering Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 1 Clean around the power steering reservoir dip stick fill cap with a clean rag then remove the dipstick See Fig 3 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 Failure to keep the power steering reservoir full could result in damage to the power steering pump and improper operation of the power steer ing system 2 With the power steering fluid at operating tem perature check the fluid level on the dipstick If below the
104. ease fittings one on each end of tie rod 9 33 01 Knuckle Pins Two grease fittings one on top one on bottom of knuckle pin Lubricate both sides of axle 10 25 01 Clutch Release Bearing and One grease fitting on bottom of release bearing Two grease Release Cross Shaft fittings on release cross shaft 11 26 01 26 02 Transmission Check fluid level add fluid if low 26 01 Change fluid 26 02 26 05 26 06 26 05 26 06 26 08 or 26 10 when required 26 08 26 10 12 41 02 Driveline U Joints and Slip Joints One grease fitting for each U joint and one for each slip joint 13 72 01 Door Hinges Latches and Lubricate all door hinges latches and weatherstrips on the cab Weatherstrips 14 15 01 Batteries Clean and lubricate if corrosion is present 15 42 19 Air Reservoir Automatic Drain Disassemble clean inspect and lubricate automatic drain valves Valves 16 32 02 Suspension Spring Pin Lubricate on both sides of vehicle one grease fitting for each spring pin 17 32 02 Equalizer t One grease fitting on each equalizer lubricate both sides of vehicle 18 35 04 35 05 Two Speed Axle Shift Unit t Check oil level add oil if low 35 04 Change oil 35 05 when required 19 35 01 35 03 Rear Axle Check fluid level add fluid if low 35 01 Change fluid when required 35 03 20 42 11 42 13 Slack Adjusters Rear Axle Lubricate slack adjusters on both sides of each rear axle one 42 24 42 26 grease fitting for
105. ed 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 by following the procedures in Group 32 of the Business Class Trucks Service 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 Business Class Trucks Service 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 Busi ness Class Trucks Service Manual for possible causes and corrections Freightliner AirLiner Control Rod Checking 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 2 Inspect the rubber bushings for cracks or cuts 3 Check for any shifting of the barpin 4 Check for cracks in the metal components and welds NOTE The Freightliner AirLiner Suspension is manufactured at numerous weight ratings up to 46 000 pounds The control rod on the 46 000 pound rated suspension is larger and is fas tene
106. ed or dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and the fan clutch from a dis tance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation 20 If the fan clutch does not operate correctly see Group 20 of the Business Class Trucks Service Manual for troubleshooting and repair proce dures 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device Check at the solenoid valve the air filter assem bly and the air hoses and fittings See Fig 8 Using a wet finger or a soapy water solution check for a leak in the same areas 05 30 2002 1200581 Fig 8 Checking for Air Leaks Horton DriveMaster 9 If a leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Busi ness Class Trucks Service Manual f
107. ed had RO Bet Gis KAG AS Gm AGNO 33 02 Tie Rod End Lubricalirig 22b pee et Roo Ra doses Puedo dace pan des pons eerie po a 33 03 Business Class Trucks Maintenance Manual June 2001 Front Axle 33 01 Knuckle Pin Lubricating 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 f320032a 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 grease distribution Lower the tires to the ground and regrease both top and bottom bushings until new grease is seen at th
108. ents Tighten 1 2 inch drive axle stud nuts with or without dowels 75 to 115 Ibf ft 102 to 156 N m and tighten 5 8 inch drive axle stud nuts 150 to 230 Ibf ft 203 to 312 N m 06 09 94 NOTE Spoke wheel shown 1 Drive Axle Flange Studs and Nuts f400090b 2 Drive Axle Flange Fig 2 Drive Axle Flange 31 02 Fifth Wheel Inspecting 4h WARNING All fifth 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 causing serious damage or injury 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 Fontaine Disconnect the tractor from the trailer For instruc tions see Chapter 10 of the Business Class Trucks Driver s Manual Thoroughly steam clean the fifth wheel then make the following checks 1 Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 31 2 Business Class Trucks Maintenance Manual December 2002 Frame and Frame Components 2 Check moving parts for wear or damage Test the safety lock latch for operation 4 Check for loose nuts and bolts in the fifth wheel and in the mounting 5 Check that all springs are securely fastened and not deformed 6 Check wedge adjustment 6 1 Open the
109. evel check and fill plug and tighten it firmly 2 On front wheel drive vehicles equipped with MT 17 axles check the oil level in the hubs 2 1 The oil drain bore must be at the bottom in order to check the oil level See Fig 4 04 10 96 350148 A Correct Oil Level 1 Oil Level Checking Bore 2 Oil Drain Bore Fig 4 All Wheel Drive Front Axle Hub MT 17 Axles 2 2 Remove the plug from the oil level check ing bore and make sure the oil is level with the bottom edge of the bore 2 3 If needed add oil until each axle hub is filled to the bottom of the bore 2 4 Install the plug in each oil level checking bore and tighten it firmly 33 2 Business Class Trucks Maintenance Manual June 2001 Front Axle 33 06 All Wheel Drive Front Axle Oil Changing 1 Drive the vehicle until the axle oil is warmed then park it and chock the rear tires 2 Jack up the front axle until the wheels are off the ground then secure the axle on jack stands 3 On vehicles equipped with an MT 11 front axle drain the oil from the differential On vehicles equipped with an MT 17 front axle drain the oil from the differential and the hubs 3 1 Remove the oil drain plug from the differ ential and allow the oil to drain See Fig 5 1 A 2 04 15 96 1 3 1350149 1 Vent Valve 2 Oil Level Check and Fill Plug 3 Oil Drain Plug Fig 5 All Wheel Drive Front Axle Differential 3 2
110. f F Small irregular cracks are usually the signs of an old belt 7 Visually inspect the pulleys for excessive play or 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 location of a supposed bearing noise obtain a stetho scope and place it on the component being checked not the pulley to isolate the area from outside interference Business Class Trucks Maintenance Manual July 1999 01 1 01 8 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tension Inspection NOTE If engine drive belts require adjustment see Group 01 of the Business Class Trucks Service Manual Threaded Adjustment Type 1 Apply the parking brakes and chock the tires to prevent the vehicle from moving 2 Install a belt tension gauge at the center of the belt s longest free span Check belt tension See Table 1 for belt tension specifications 3 If belt tension is not correct see Group 01 of the Business Class Trucks Service Manual to adjust belt tension Spring Tension Type 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 Engine end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner
111. f free play is felt replace the torque rod end bushing Do not use a pry bar to check for free play Use of a pry bar may lead to premature bushing re placement See Group 32 of the Business Class Trucks Service Manual for replacement instructions 2 If equipped with optional shock absorbers check for worn broken or damaged shock bushings heavy corrosion on the shock absorber body or fluid leaking from the shock absorber Replace the shock absorbers if any of these conditions are found see Group 32 of the Business Class Trucks Service Manual 3 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends are off of the saddles All jack stands must be of sufficient strength and rigidity to safely support the vehicle Do not perform any work on or around a vehicle that is supported solely by a lifting device Business Class Trucks Maintenance Manual July 1999 32 5 32 Visually inspect the walking beam for cracks or other damage If damage is found see Group 32 of the Business Class Trucks Service Manual for replacement instructions Keep the vehicle supported by the jack stands for the next operation 4 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 8 Measurements should be taken a minimum of 1 2 inc
112. from the axle This will Suspension 5 2 Jii ZZ LAL i TE Ul bp V 7 22 eZ WILLD AA PAS Cae ZA 77 LA PA 777 g Ce JM 2 us a Aus tret D REEDE EEEE Zu 3 4 05 27 93 f320110a NOTE Do not use the three piece adapter without the intermediate tube 1 Nut 4 Inner Metal of Beam 2 Adapter End Bushing 3 Intermediate Tube 5 Beam Hanger Fig 6 Three Piece Adapter Type Beam End Connection cause loss of vehicle control resulting in property damage serious personal injury or death 32 4 Business Class Trucks Maintenance Manual July 1999 Suspension Hendrickson Leaf Spring Assembly Inspecting See Fig 7 05 27 93 f320112a A Minimum gap of 3 8 inch 9 5 mm Forward no 1 Spring Hanger Spring Eye Pin Rear no 2 Spring Hanger Rear no 3 Extension PINA Fig 7 Unloaded RTE or UE Spring Suspension 1 Inspect the spring hangers for wear of the spring pin holes cams and the spring hanger legs 2 f equipped with the RTE or UE series the gap between the rear No 2 spring hanger and the top spring leaf should measure at least 3 8 inch 9 5 mm in an unloaded condition If the measurement is less than 3 8 inch 9 5 mm install new rear No 3 extension hangers Lubricate the bolt threads with SAE 20 oil Tighten the 1 2 13 locknuts with hardened wash ers 85 lbf ft 115 N m 3 Inspect the spring leaves for cracks gouges wear or abnormal bends The
113. g 15 1 Raise the vehicle Business Class Trucks Maintenance Manual February 2003 26 15 26 Transmission t 12 13 94 1 Locknut 2 Rear Band Adjusting Screw f260304 3 Band Adjusting Lever 4 Valve Body Fig 15 Rear Band Adjusting Screw Chrysler 2 Remove the transmission oil pan and drain the fluid Remove the fluid filter 3 Loosen the locknut and back it off five to six turns Make sure the adjusting screw turns freely on the band adjusting lever 4 Setthe adjusting screw To turn the adjusting screw use a 5 16 inch 8 point socket on a 0 to 100 Ibf in 1100 N cm torque wrench 4 1 Tighten the adjusting screw 72 Ibf in 800 N cm 4 2 Back off the adjusting screw two turns 5 Holding the adjusting screw in position tighten the locknut 25 Ibf ft 34 N m 6 Install the filter and oil pan Replace the oil pan gasket Tighten the oil pan bolts 13 Ibf ft 17 N m 7 Lower the vehicle Check and adjust the fluid level using the proce dures under Checking the Fluid Level 26 08 Aisin Transmission Fluid and Filter Changing and Magnetic Plug Cleaning 1 Park the vehicle on a level surface and apply the parking brakes Chock the rear tires 26 16 Business Class Trucks Maintenance Manual February 2003 Transmission 2 Run the engine until the transmission fluid reaches the operating temperature of 160 to 200 F 71 to 93 C Shift the transmis
114. g Bendix AD 9 47 01 Fuel Tank Draining and Vent Checking 54 01 Electrical System Checking 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 Business Class Trucks Maintenance Manual February 2004 00 21 00 General Information M4 Maintenance Interval Operations Table 00 13 IMPORTANT After performing all operations in this NOTE Maintenance operations appearing in italics in table perform all daily and weekly maintenance op this table are for noise emission control components erations listed in the Pretrip Inspection and Daily Numbers in this table are maintenance operation ref Maintenance chapter of the Business Class Trucks erence numbers matching those in the text of this Driver s Manual Also perform all M1 M2 and M3 manual The M4 Maintenance consists of all M1 M2 Maintenance Interval Operations at the M4 Mainte and M3 Interval Operations plus the other operations nance Interval listed below M4 Maintenance Interval Operations Maint Oper No M4 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 11 Perform All M2 Operations 00 12 Perform All M3 Operations 01 01 Engine Support Fasteners Checking 09 01 Air Cleaner Element Inspecting and Replacing 15 01
115. g Bendix AD 9 42 17 Air Brake Valve Operation Checking Bendix R 14 and TC 7 42 18 Air Brake Valve Leak Checking Bendix TC 7 42 19 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and oala le Lubricating Bendix DV 2 for FL112s perform at M1 interval 42 20 Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 12 QR 1 R 14 SR 1 ST 3 TC 7 and TP 5 42 21 Brake Lining Wear Checking Hydraulic Disk Brakes 42 22 Brake Lines Checking Hydraulic Disk Brakes 42 23 Power Booster Checking Bendix Hydro Max 42 24 Automatic Slack Adjuster Lubricating Gunite 42 25 Automatic Slack Adjuster Inspecting and Adjusting Gunite 42 26 Automatic Slack Adjuster Lubricating Haldex REQUIRED MAINTENANCE OPERATION SET M1 Maintenance Operation Number and Operation Description 46 01 Steering Driveline Lubricating for FL112s perform at M1 interval 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 04 Power Steering Reservoir Fluid and Filter Changing e 46 05 Steering Gear Lubricating Ross TAS Series 46 06 Miter Gear Lubricating Right Hand Drive Only 47 01 Fuel Tank Draining and Vent Checking 47 02 Gasoline In Tank Fuel Filter Replacement e 49 01 Exh
116. h 13 mm from the beam flange edges to eliminate any edge wear that may have occurred Subtract the wear area thickness Fig 8 Ref B from the non wear area Fig 8 Ref A to determine the amount of wear If the beams show any wear greater than the allowable 0 062 inch 1 5 mm wear a Chalmers wear plate must be installed or the walking beam must be replaced See Group 32 of the Business Class Trucks Service Manual for re pair and replacement instructions 09 27 95 1320432 1 Walking Beam A Non Wear Area B Wear Area Fig 8 Walking Beam End Wear Thickness Suspension 5 Rotate the restrictor cans 360 degrees and visu ally inspect the cans for cracks severe corro sion and distortion If any of these conditions are present or the restrictor can is missing replace the restrictor can See Group 32 of the Business Class Trucks Service Manual for replacement instructions Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death Vehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement 6 Remove the jack stands then lower the vehicle Check that the spring or driveline brake is ap plied then remove the wheel chocks Reyco 79KB Suspension Visual Inspection The Reyco 79KB suspension requires minima
117. h 5 Ibf ft 7 N m Use the torque pattern shown in Fig 9 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 15 Install the oil filler tube on the oil pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 N m Transmission then 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 Checking the Fluid Level 4k CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multi viscosity lubricants Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick 4h CAUTION Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the 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
118. hassis grease at the pressure relief grease fitting See Fig 11 Lubricate Business Class Trucks Maintenance Manual July 1999 32 7 32 10 05 94 f320268a Fig 10 Forward Spring Bracket Spring Pin Grease Fitting with a hand gun or pressure gun until grease is forced out from the base of the pressure relief fitting 05 27 93 IL 320020a A Lubricate here 1 Cap and Tube Assembly Bushing Fig 11 Equalizer Assembly Lubrication Suspension 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 Hendrickson Spring Eye Pins RT RTE U AND UE Series Apply multipurpose chassis grease at the spring eye pin grease fitting located on the inboard side of the spring eye pin until clean grease appears at both ends of the spring eye pin 32 03 U Bolt Torque Checking Check the U bolt torque of both the front and rear axles where applicable 4h CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a flat surface and apply the parking brakes Chock the tires to prevent the vehicle from moving 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 1 for U bolt torque specifications Turn t
119. he wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove the chocks 32 8 Business Class Trucks Maintenance Manual July 1999 Suspension 32 U Bolt Torque Values Torque Description Size Ibf ft N m Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 5 8 18 3 4 16 Spring Assembly U Bolt High Nuts 7 8 14 Tighten in a diagonal pattern as shown in Fig 12 Table 1 U Bolt Torque Values 01 05 99 1320783 Fig 12 Tightening Pattern for U Bolt High Nuts Business Class Trucks Maintenance Manual July 1999 32 9 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AlFAxIG AligninentGneckingis a xxm KG GRAN GAL GARD abend obl ape qtio dC 3 dude codo gas 33 04 All Wheel Drive Front Axle Oil Changing 222 nh 33 06 All Wheel Drive Front Axle Oil Level Checking llllsleeeelle eh 33 05 isn ckle P EIU suopte at Sieh KI E pad eos Mate MALA sos qna Gee aod np dee de dieu EE ud lon ue 33 01 MEAROG EGGINSPCCING ann dri srini RR pod BO Rb ir
120. he fuel tank 6 1 Clean the top of the fuel pump module to prevent dirt from entering the fuel tank 6 2 Remove the two capscrews holding the fuel pump guard bracket in place Re move the guard bracket capscrews and hardened flatwashers 6 3 Remove the other three capscrews hold ing the fuel pump clamp ring in place Remove the capscrews and hardened flatwashers 6 4 Remove the fuel pump module from the fuel tank See Fig 4 6 5 Remove the fuel pump module gasket from the fuel tank see Fig 5 and dis card the old gasket Fig 3 Fuel Pump Module top view 7 Replace the fuel filter 7 1 Use an appropriate tool to pry back the retaining tabs See Fig 4 7 2 Remove the in tank fuel filter from the fuel pump module 7 3 Install the new filter into the retaining tabs until the filter is firmly seated 8 Check that the sensing unit electrical wires float and in tank fuel filter are properly installed 9 Install a new fuel pump module gasket in the opening of the fuel tank 10 Position the fuel pump module in the orifice on top of the fuel tank Check that the fuel filter oressure regulator is facing the frame rail See Fig 3 47 2 Business Class Trucks Maintenance Manual January 1998 F uel 03 03 95 1470136 Fuel Level Float Fuel Gauge Sending Unit Electric Fuel Pump Retaining Tab In Tank Fuel Filter Mounting Screw Electrical Wiring nOooBRom Fig 4 Fuel Pump Modul
121. heel 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 eye Torque lubricated threads Description Nut Size Ibf ft N m 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 z Wheel Torque dry threads Description Size Manufacturer Ibf ft N m Front Wheel Nut 5 and 7 E E x 6 Spoke 3 4 10 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 Business Class Trucks Maintenance Manual January 1998 40 1 40 Wheels and Tires 05 27 93 A 8 Stud Disc Wheel B 10 Stud Disc Wheel 1400057 C 6 Spoke Wheel D 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening Sequence Ll 1400033a 05 16 94 Fig 2 Non Corrugated Channel Spacer li PLACITA 10 05 94
122. iance with the law the Noise Emis sion Control Systems maintenance located in each applicable group within this manual in conjunction with the vehicle service manual provides these in structions 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 Freightliner parts If other than genuine Freightliner parts are used for replacements or for the repair of components affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in performance and dura bility Freightliner 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 u
123. ice vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than distance traveled Table 6 Maintenance Schedule Table 00 8 Business Class Trucks Maintenance Manual February 2004 General Information 00 Maintenance Interval Tables 00 07 Maintenance Intervals for Schedule FL50 60 70 80 106 112 models only 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 32 000 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 7 Maintenance Intervals for Schedule FL50 60 70 80 106 11
124. ift Lever Cap Seal Breather Output Shaft Radial Seal Countershaft Rear Cover Plate Transmission Fluid Fill Plug Transmission Fluid Drain Plug Gear Case Seals Clutch Slave Cylinder Input Shaft Radial Seal 0 00 d GO Seo ce Fig 18 MBT Transmission Leak Check 2 1 If leakage is found check the breather for a missing cap Replace the cap if neces sary 2 2 Check the fluid level at the fill plug If the level is too high correct the fluid level 3 Check for signs of leakage at the cap seal on the shift lever If the cap seal is damaged replace it 26 18 Business Class Trucks Maintenance Manual February 2003 Transmission 4 Check for signs of leakage at the radial seal on the output shaft If leakage is found remove the output yoke end yoke and replace the seal For procedures see Section 26 00 Subject 130 of the Business Class Trucks Service Manual NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 5 Check for signs of leakage at the rear cover plate on the countershaft next to the output yoke If leakage is found check the torque on the cover plate bolts and check the flat seal for damage 5 1 If the flat seal is damaged replace it 5 2 If the cover plate bolts are too loose tighten them 18 Ibf ft 25 N m If the cover plate bolts are too tight replace the flat seal and tighten to 18 Ibf ft 25 N m 6 Check for signs of leakage at
125. ifting of the transmis sion and eventual transmission damage 26 05 Allison Transmission Fluid and Filter Changing AT Series 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 160 to 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine A 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 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 Support the oil pan then 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 5 Clean the oil pan with mineral spirits 6 Remove the washer head screw that attaches the internal fluid filter to the filter spacer then remove the filter and discard it See Fig 5 Re move the fluid intake tube and then remove the seal ring from the intake tube and di
126. in Piston Rod Nut 5 Clevis Pin Clevis Fig 3 Piston Rod Engagement With the Clevis Business Class Trucks Maintenance Manual October 1998 42 3 42 Piston Rod Nut Torque Values iuc Rod Size Torque Ibf ft Description inches N m Anchorlok Tandem Chambers All 15 25 20 34 MGM Tandem Chambers All 25 35 34 47 f 1 2 20 30 27 41 Bendix Service Chambers 5 8 30 50 41 68 1 2 20 30 27 41 Midland Service Chambers 5 8 33 90 45 122 Table 1 Piston Rod Nut Torque Values 5 Seeifthe 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 Reposition the brake chamber on the mounting bracket if necessary 6 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 Read and follow all applicable warnings and in structions in Group 42 of the Bu
127. ine Support Fasteners Checking e 01 02 Engine Drive Belt Inspection 09 01 Air Cleaner Element Inspecting and Replacing e 13 01 Air Compressor Inspecting Bendix 13 02 Air Compressor Rebuilding Replacing Bendix 15 01 Alternator Battery and Starter Checking e 20 01 Radiator Cap Checking o o lo lo 20 02 Radiator Pressure Flushing and Coolant Changing e 20 03 Fan Clutch Checking o lo fe lo 25 01 Clutch Release Bearing and Release Cross Shaft Lubricating ef o fe lolo lo 25 02 Clutch Pull Type Inspecting and Adjusting je 25 03 Hydraulic Fluid Level Checking 25 04 Hydraulic Fluid Replacing 26 01 Manual Transmission Oil Level Checking 26 02 Eaton Fuller and Meritor Transmission Oil Changing and Magnetic Plug Cleaning e e 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking eje 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 26 05 Allison Transmission Fluid and Filter Changing 26 06 Chrysler Transmission Fluid and Filter Changing 26 07 Chrysler Transmission Band Adjusting 26 08 Aisin Transmission Fluid and Filter Changing and Magnetic Plug Cleaning 26 09 Mercedes Benz Transmission Leak Checking 26 10 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning Table 10 Maintenance Operation Sets for Groups 00 through 26 00 12 Business Class Trucks Maintenance Manual February 2004 Gene
128. ing brakes and chock the rear tires Drain the oil while the transmission is warm Clean the area around the fill plug and the drain plug s 4 Remove the fill plug from the side of the gear case Remove the drain plug s from the bottom of the case 5 Clean the magnetic plug s before installation Use a piece of key stock or any other conve nient steel slug to short the two magnetic poles and divert the magnetic field 6 Install and tighten the drain plug s 50 Ibf ft 68 N m for an Eaton Fuller plug and 35 to 50 Ibf ft 48 to 67 N m for a Meritor plug NOTE Meritor recommends replacing the mag netic drain plug each time the oil is changed 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 See Table 2 for lubricant capacities of Eaton Fuller transmissions See Table 3 for lubri cant capacities of Meritor transmissions Eaton Fuller Transmission Lubricant Capacities Refill Capacity in Transmission Model Quarts liters 5 Speed FS Series Transmission Model aum a n FS 4205A B 6 25 5 9 FS 5005A B C 5 25 5 0 FS 5205A B 6 25 5 9 FS 6105A B 9 5 9 0 FS 6305A B 9 75 9 2 All 6 Speed Series FS 5106A 9 0 8 5 FS 5406A 9 75 9 2 F
129. installed Breeze Constant Torque clamps will hold enough torque to auto matically adjust and keep consistent sealing pressure During vehicle operation and shut 20 2 Business Class Trucks Maintenance Manual August 2003 Engine Cooling R adiator 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 For Mercedes Benz OM 366LA engines maintain a minimum of 50 percent by volume of a corrosion inhibiting antifreeze Do not use more than 55 percent by volume of corrosion inhibiting antifreeze and do not add any other substances to the coolant For all other engines use a mixture of 50 per cent water and 50 percent corrosion inhibiting antifreeze to protect the engine to 34 F 37 C year round See Table 1 and Table 2 for engine cooling sys tem capacities See Table 3 for approved antifreezes 20 Coolant Capacities FL112 only Radiator Core Engine Make and and System Capacity Model 1000 Sq In 1200 Sq In quarts liters quarts liters Caterpillar C10 30 8 29 1 33 7 31 9 Series Caterpillar C12 EUER 30 8 29 1 33 7 81 9 Cummins M11 30 0 28 4 32 9 31 1 Detroit Diesel Series 55 35 1 33 2 38 0 36 0 Coolant Capacities all but FL112 Radiator Core Engine Make and and System Capacity Model 2 Row 3 Row quar
130. ion 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 refer to the vehicle driver 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 at any time or change specifications and design without notice and without incurring obligation For additional information please contact Freightliner LLC Service Systems and Documenta tion P O Box 3849 Portland OR 97208 3849 U S A or refer to http www Freightliner com and http www Freightliner Trucks 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 collisions or improper use and have undetected structural damage 1995 2004 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 recordi
131. ire 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 the temperature sending units on the ax les and transmission Check for damaged wires and loose connectors Business Class Trucks Maintenance Manual January 1998 54 1 54 Electrical Instruments and Controls 54 02 Coolant Level Sensor Cleaning 1 Drain enough coolant from the radiator to expose the coolant level sensor 2 Disconnect wire 173 from the sensor in the ra diator surge tank Remove the sensor from the surge tank 3 Using a fine grit sandpaper clean the sensor un til the metal is exposed Clean the tapped hole with a wire brush 4 Install the sensor do not seal the sensor threads with tape and reconnect wire 173 Fill the cool ing system to the proper level 5 Start the engine The LOW WTR light and warn ing buzzer should be off If the light and buzzer are off the sensor is okay If the light and buzzer are on replace the sensor 54 2 Business Class Trucks Maintenance Manual January 1998 Doors 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Weatherstrip Door Latch and Door Hinge Lubricating llle 72 01 Business Class Trucks Maintenance Manual January 1998 Doors 72 01 Weatherstrip Door Latch and Door Hinge Lubricating Lightly coat door weatherstrips with a lubricant that is saf
132. justing bolt in clockwise until it con tacts the rack Turn the adjusting bolt an addi tional 1 2 turn then tighten the locking nut se curely Business Class Trucks Maintenance Manual December 2002 31 3 31 Frame and Frame Components Y N 3 gt 2 o 1 11 21 95 310371 1 Rack 3 Pocket 2 Plunger 4 Plunger Adjusting Bolt Fig 3 Locking Plungers 31 4 Business Class Trucks Maintenance Manual December 2002 Suspension Title of Maintenance Operation MOP SUSPENSION INSHECHNG sac c ace544c0 R254 anda NAA GWAG SUSPENSION Lubricating aca eec rat reds U Bolt Torque Checking 0c eee eee 32 Index Alphabetical MOP Number Business Class Trucks Maintenance Manual July 1999 Suspension 32 01 Suspension Inspecting Freightliner Spring Front and Rear Suspension Spring Assemblies Inspecting 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 Business Class Trucks Service 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 crac
133. kingpin lock and insert a 2 inch 51 mm diameter shaft vertically 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 Business Class Trucks Service Manual 8 Replace cracked worn or damaged parts with new parts Replace loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C nuts and hardened washers Do not reuse bolts nuts and washers on fifth wheel mountings Holland Disconnect the tractor from the trailer For instruc tions see Chapter 10 of the Business Class Trucks Driver s Manual Thoroughly steam clean the fifth wheel then inspect for 1 Loose nuts or broken bolts on the fifth wheel as sembly 2 Cracks or wear on the mounting bolts Improper locking action cracks or wear on the jaw locking mechanism Gouges or wear on the fifth wheel top plate Fatigued or cracked welds 6 Replace cracked worn or damaged parts with new parts Replace loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C nuts and hardened washers Do not reuse bolts nuts and washers on fifth wheel mountings 7 f you observe any problems doing the previous steps correct them immediately For instructions 31 see Group 31 of the Business Class Trucks Service Manual
134. ks 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 property damage serious personal injury or death 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 Inspecting 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 Business Class Trucks Ser vice 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 breakage of the bracket This could cause a loss 32 of vehicle control resulting in property damage serious personal injury or death Freightliner Spring Tandem Axle Suspension Crossmember and Gussets Inspecting Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 31 of the Business Class Trucks Ser vice Manual for instructions Check all fasteners for tightness see Group 00 in this manual for torque v
135. l is also given The tables under Maintenance Interval Tables show which maintenance operation set must be performed at the actual distances miles and kilometers for each maintenance schedule or the actual hours of operation for Schedule The schedule of actual dis tances and hours is based on the intervals given in the Maintenance Schedule Table The tables under Maintenance Operation Sets Tables list 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 reference 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
136. l main tenance To provide trouble free operation in over the road applications do the following visual inspec tion 1 Park the vehicle on level ground Apply the park ing brakes and chock the tires 2 Check that the torque rod clamps are directed away from the spring to prevent possible interfer ence during operation See Fig 9 3 Check the fit of springs to hangers to ensure good ride characteristics 4 Check for elongated holes in the suspension components See Group 32 of the Business Class Trucks Service Manual for proper repair procedures 5 Check bushing condition Replace any bushing that is worn cracked dry rotted or otherwise damaged See Group 32 of the Business Class Trucks Service Manual for removal and installa tion instructions 6 Check tire condition If abnormal tire wear is found check and replace all worn or damaged components and check suspension alignment See Group 32 of the Business Class Trucks Service Manual for component removal and in 32 6 Business Class Trucks Maintenance Manual July 1999 Suspension 32 01 04 96 1 Torque Rod Clamp 7 DES EN PELA KAS SNNNSNN 2 Torque Rod 1320488 Fig 9 Reyco 79KB Torque Rod Clamp Position stallation procedures and for suspension align ment instructions Reyco 79KB Fastener Torque Check Check the U bolt nuts hanger mounting bolts torque rod clamp nuts and the spring retainer bolts for
137. lease the clutch pedal and then close the valve at the bleeder unit 8 Disconnect the bleeder unit and install the cap on the slave cylinder bleeder valve 9 Check the fluid level in the reservoir If neces sary add or remove clutch hydraulic fluid to bring the fluid level to the MAX line Install the reser voir cap 10 Depress the clutch pedal a few times There should be resistance over the full pedal stroke 11 Check the entire system for leaks Tighten con nections if necessary Check the fluid level in the reservoir again 12 Remove the chocks from the tires Business Class Trucks Maintenance Manual June 2002 25 3 25 Clutch 1 a 2 x f 2 T1 N 3 4 Z 17 a 16 i Y ag Pai B 137 1277 9 qu O 11 x 7 3 06 20 2002 1250593 1 Reservoir Bracket Mounting Bolt 5 16 24 10 Frontwall Standoff Bracket 2 Steel Plated Washer 5 16 11 Cushioned Clamp 3 Locknut 5 16 24 12 Locknut 1 4 20 4 Clutch Support Plate 13 Steel Plated Washer 1 4 5 Master Cylinder Capscrew M6 14 Clamp Mounting Bolt 1 4 20 6 Hardened Flatwasher M6 15 Hydraulic Hose 7 Locknut 1 2 13 16 Master Cylinder 8 Hardened Flatwasher 0 53 17 Reservoir Bracket 9 Frontwall Bracket Mounting Bolt 1 2 13 Fig 4 Clutch Master Cylinder 25 4 Business Class Trucks Maintenance Manual June 2002 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Aisin Transmissi
138. ler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers A 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 1 Park the vehicle on a level surface apply the parking brakes and chock the rear tires Approved Allison Transmission Lubricants Lubricant Type Temperature in F C Vi MS All Allison Transmissions Castrol Above 67 55 TranSynd AT and MD Series 1 Dexron II 25 to 120 32 to 48 MT Series Dexron IIE 10 to 120 23 to 48 Dexron III Above 17 27 Type C4 10 to 120 12 to 48 SAE 10W Type C4 32 to 120 0 to 48 SAE 30W HD Series Dexron Ill Above 17 27 Lubricants listed in order of preference Do not mix types of oil t Factory filled with Dexron II t For off highway operation or where ambient temperature is consistently above 86 F 30 C or below 17 F 27 C refer to the manufacturer s fluid recommendations Table 4 Approved Allison Transmission Lubricants Allison Transmission Lubricant Capacities Refill Capacity in Quarts liters Transmission Model On Highway Series 1000 2000 2400 15 0 14 2 Wate
139. lowing this torque pattern Tighten the bolts 5 Ibf ft 7 N m then repeat the torque pattern with a click type torque wrench 15 to 20 Ibf ft 20 to 27 N m Fig 9 Allison MT Series Transmission Oil Pan Torque 2h Pattern CAY 7 Insert the dipstick into the tube and remove the aiias 260095 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 10 for the AT MD and HD series and Fig 11 for the MT series A CAUTION Do not fill above the COLD RUN band if the trans mission fluid is below normal operating tempera A Transmission Housing Oil Pan Split Line B Hot Run Band C Cold Run Band Fig 11 MT Series Dipstick Markings 5 1 Inch Depth Oil Pan ture As fluid temperature increases so does the fluid level Filling above the COLD RUN band when the transmission is below normal operating 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
140. ltimate 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 person 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 Business Class Trucks Maintenance Manual February 2004 00 1 00 General Information Verification of Inspections Log 00 02 Verification of Inspections Log Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Repair Description Cost
141. n Clutch Checking 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 42 14 Automatic Slack Adjuster Inspecting Meritor 49 01 Exhaust System Inspecting 00 20 Business Class Trucks Maintenance Manual February 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 Business Class Trucks 00 M3 Maintenance Interval Operations Table 00 12 Driver s Manual Also perform all M1 and M2 Mainte listed below nance Interval Operations at the M3 Maintenance Interval M3 Maintenance Interval Operations 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 25 02 Clutch Pull Type Inspecting and Adjusting 26 05 Allison Transmission Fluid and Filter Changing 26 08 Aisin Transmission Fluid and Filter Changing and Magnetic Plug Cleaning 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 32 03 U Bolt Torque Checking 33 06 All Wheel Drive Front Axle Oil Changing 35 05 Two Speed Axle Shift Unit Oil Changing 40 01 Wheel Nut Checking 42 15 Air Dryer Checkin
142. nd gasket 12 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 in stalled by hand into the corners of the pan 12 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 12 3 Tighten all twenty one screws evenly 10 to 15 Ibf ft 14 to 20 N m Check the gas ket fit while the screws are being tight ened IMPORTANT The oil pan bolts must main tain a minimum torque of 60 Ibf in 680 N cm after the oil pan gasket has taken a set 13 Install the fill tube at the side of the pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 N m 14 Install the drain plug and gasket and tighten the plug 15 to 20 Ibf ft 20 to 27 N m 15 Replace the external auxiliary fluid filter 16 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid See Table 4 for approved transmission lubricants and Table 5 for lubricant capacities 17 Check and adjust the fluid level using the proce dure under Checking the Fluid Level MD and HD Series When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operation 26 mission coo
143. ne manufacturer s manual 11 Remove the chocks from the tires 26 10 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning Draining 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Drain the transmission fluid See Fig 19 05 22 2001 3 2 261102 NOTE The transmission is shown from the left hand side 1 Transmission 2 Fill Plug 3 Drain Plug Transmission 4 Remove the fill plug from the side of the case Discard the aluminum gasket NOTE Use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 Clean the magnetic drain plug before installing it 6 Install the drain plug p n A 124 997 01 32 and a new aluminum gasket p n N 00763 024105 Tighten the drain plug 42 Ibf ft 57 N m Filling 4h CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force transmission fluid out of the case through the main shaft open ings 1 Add transmission fluid until it is level with the lower edge of the fill opening See Fig 19 for location of the fill plug and Fig 20 for correct level See Table 8 for approved transmission lu bricants and Table 9 for lubricant capacities Fig 19 MBT Transmission Drain and Fill Plugs
144. ng 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 checking 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 pretrip in
145. ng the checks below see Group 20 of the Business Class Trucks Service Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir Make sure the batteries are disconnected and if applicable the air starter reservoir is drained be fore checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Using a clean lint free cloth wipe off any excess solvent 20 6 Business Class Trucks Maintenance Manual August 2003 Engine Cooling R adiator 05 27 93 f200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 1 Bearing Housing 5 Air Cylinder 2 Retaining Plate 6 Fan 3 Fan Pulley 4 Air Inlet from solenoid Valve Fig 7 Kysor K22RA Fan Clutch Lining Wear Checking 3 4 Reassemble the clutch valve solenoid air filter assembly and install on the vehicle 4 Visually check the fan for bent crack
146. not re use bolts nuts and washers on fifth wheel mountings HOLLAND 1 Disconnect the tractor from the trailer For instruc tions refer to the vehicle 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 Check for improper locking action and for cracks or wear on the jaw locking mechanism Heavy Trucks Maintenance Manual November 1993 A 31 1 D Group Number Page Number Maintenance Operation Number consists of the Group Number followed by the Sequence Number 1020034 Fig 1 Page Example of the Printed Manual Business Class Trucks Maintenance Manual December 2002 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Initial Maintenance IM Operations Table 00000 ccc eee 00 09 Lubrication Tables maet d d dike mamas hh one aoe d RAT oe eee A hae Ru A Gaetan ad wanes 00 18 Lubrication and Fluid Level Check M1 FL112 models only llle 00 17 Lubrication and Fluid Level Check M1 all models but FL112 llle 00 15 Lubrication and Fluid Level Check M2 all models but FL112 0 002 eee 00 16 M1 Maintenance Interval Operations Table liliis 00 10 M2 Maintenance Interval Operations Table illii eh 00 11 M3 Maintenance Interval Operations Table llllilelilell es 00 12
147. of the brake chamber to the center of the large clevis pin See Fig 7 Ref A 10 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or Lube Plug OP OM NO 09 27 94 1420180a NOTE For a drum brake A minus B must equal 5 8 to 3 4 16 to 19 mm For a disc brake A minus B must equal 7 8 to 1 1 8 22 to 29 mm A With the brakes applied measure this distance B With the brakes released measure this distance Fig 6 Meritor Automatic Slack Adjuster 2 Check the brake shoe lining wear to determine the proper reline time For instructions see Brake Lining Wear Checking Hydraulic Disc Brakes 3 Check the free stroke If the vehicle has new brakes or brakes with new linings you must 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 Fig 7 Measuring Free Stroke 3 2 Use a pry 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 7 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 e drum brakes 5 8 to 3 4 inch 16 to 19 mm e disc br
148. on Fluid and Filter Changing and Magnetic Plug Cleaning lille sess 26 08 Allison Transmission Fluid and Filter Changing l l hh 26 05 Allison Eaton Fuller and Meritor Transmission Breather Checking 0 0000s eee eee eee 26 03 Chrysler Transmission Band AdJUstifig 3 es GD c dda Wee hint a Odie Waa Male nnt 26 07 Chrysler Transmission Fluid and Filter Changing llli 26 06 Eaton Fuller Transmission Air Filter Regulator Element Cleaning llle 26 04 Eaton Fuller and Meritor Transmission Fluid Changing and Magnetic Plug IC PP PUT 26 02 Manual Transmission Fluid Level Checking 26 01 Mercedes Benz MBT Transmission Leak Checking illis 26 09 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 5 26 10 Business Class Trucks Maintenance Manual February 2003 Transmission 26 01 Manual Transmission Fluid Level Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 With the transmission at operating temperature Eaton Fuller transmissions or at room tempera ture Meritor transmissions check the oil level in the transmission 2 1 Clean the area around the fill plug then remove the plug from the side of the case 2 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 3 If needed fill the transmission with
149. operation 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires 2 Disconnect the batteries to prevent static dis charge A WARNING Release the fuel system pressure before removing the fuel pump module Otherwise fuel could spray out possibly resulting in severe personal injury and property damage including fire Always wear proper eye protection when releasing the fuel sys tem pressure Fuel squirted into the eyes can cause serious injury including blindness 3 Release the fuel system pressure and drain the fuel tank 4h WARNING Gasoline is flammable and can ignite if exposed to open flame intense heat or other ignition source 47 Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame intense heat or other ignition source could start a fire possibly resulting in personal injury or property damage When working on a fuel system have a fire extinguisher within easy reach 3 1 Remove the fuel tank cap to release the fuel tank pressure 3 2 Unscrew the protective plastic cap from the pressure test port on the fuel rail See Fig 1 Ref 3 Z NG 3 E N X N id A Mi 03 1 7 95 1010914 1 Fuel Rail 2 Fuel Supply Line 3 Fuel Pressure Test Port Protective Cap Fig 1 Fuel Pressure Test Port 3 3 Obtain a Kent Moore fuel pressure gauge tool set 5069 or equivalent tool Re move the gauge from the hose Place
150. or repair procedures 10 Check the fan drive for discoloration or any other signs of slipping or overheating NOTE The fan clutch may slip if the air supply pressure is below 70 psi 483 kPa or if there is a leak inside the fan clutch Any leak must be remedied 11 Check the fan clutch bearings 11 1 Turn the fan in both directions and feel for worn hub bearings 11 2 If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions Business Class Trucks Maintenance Manual August 2003 20 7 20 If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit For instructions and kit part number see Group 20 of the Business Class Trucks Service Manual Engine Cooling R adiator 20 8 Business Class Trucks Maintenance Manual August 2003 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Pull Type Inspecting and Adjusting sse een bem minem etm eae 25 02 Clutch Release Bearing and Release Cross Shaft Lubricating 0c cece eee 25 01 Hydraulic Fluid Level Ghecking 4 sages a Seek ERR x E WAG eee ee KEEP eRe a eee eee Ss 25 03 Hydraul Fluid TREDIACING Ys odes She aot vt qucoet u aide Jak aliud d admins NA DEL 25 04 Business Class Trucks Maintenance Manual June 2002 Clutch 25 01 Clutch Release Bearing and Release Cross Shaft Lubricating Clut
151. or until clean water flows from the radiator Remove the flushing gun 5 Close the petcock at the bottom of the radiator 6 Connect the hoses Your hose clamps can be either T bolt clamps Fig 3 or Breeze Constant Torque clamps Fig 4 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 Breeze 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 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 Ibf in 620 N cm For Breeze Constant Torque hose clamps with a 3 8 inch tightening screw hex 90 lbf in 1020 N cm N WA N Zo 02 28 96 1200326 Fig 3 T Bolt Type Hose Clamp A Boe N 4 08 15 94 200286 A The screw tip must extend about 1 4 inch 6 mm B The belleville washer stacks must be collapsed almost flat 1 Tightening Screw Hex Fig 4 Breeze Constant Torque Hose Clamp Installation NOTE All hose clamps will lose torque after installation due to compression set However when correctly
152. ove the driveshaft up and down and from side to side If movement of the U joint 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 Ibf ft Business Class Trucks Maintenance Manual January 1998 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 123 N m Replace the midship bearing assem bly if the rubber cushion is worn or oil soaked 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
153. pres sure to the air cylinder the bearing housing will move backwards disengaging the clutch Again measure the distance from the back surface of the retaining plate to the forward most edge of the fan belt pulley 5 Compare the two measurements if the difference between the two measurements exceeds 0 150 inches 3 8 mm the clutch lining is worn and must be replaced See Group 20 of the Busi ness Class Trucks Service Manual for clutch lining replacement instructions 6 Release the air pressure then disconnect the shop hose from the air inlet of the air cylinder Connect the vehicle air hose to the inlet 7 Connect the electrical cables to the battery Business Class Trucks Maintenance Manual August 2003 20 5 20 Engine Cooling R adiator 03 30 95 f200194a 1 Mounting Bracket 9 Rear Hub Bearing 17 Face Seal 2 Rear Sheave Bearing 10 Bearing Spacer 18 Small O Ring 3 Inner and Outer Bearing 11 Splined Hub 19 Air Chamber Spacers 12 Forward Hub Bearing 20 Socket Head Capscrew 4 Forward Sheave Bearing 13 Piston Friction Disc 21 Stud Bolt 5 Sheave 14 Large O Ring 22 Lockwasher 6 Friction Facing 15 Locknut 23 Hexnut 7 Journal Spacer 16 Cartridge Assembly 24 Piston Assembly 8 Socket Head Capscrew Fig 6 Horton Advantage Fan Clutch Components 8 Start the engine Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performi
154. proper fastener torque 1 Park the vehicle on level ground Apply the park ing brakes and chock the tires 2 Use a click type torque wrench to check that U bolt nuts are tightened 400 to 450 Ibf ft 540 to 610 N m 3 Usea click type torque wrench to check that spring hanger bolts are tightened 190 Ibf ft 258 N m 4 Use aclick type torque wrench to check that the 5 8 inch torque rod clamp nuts are tightened 125 to 150 Ibf ft 170 to 203 N m 5 Use a click type torque wrench to check that the two end nuts for each torque rod are tightened 400 to 450 Ibf ft 540 to 610 N m 6 Use a click type torque wrench to check that spring retainer bolts are tightened 60 to 80 Ibf ft 81 to 109 N m 32 02 Suspension Lubricating Freightliner Spring Front 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 Single Axle Lubricate the spring pin by applying multipurpose chassis grease at the grease fitting See Fig 10 Lu bricate with a grease gun until grease appears at the base of the fitting Tandem Axle 4h CAUTION If the equalizer cap and tube assembly is equipped with a nonrelief grease fitting excessive lubrication can damage the bushings Lubricate the equalizer cap and tube assembly bush ings by applying multipurpose c
155. r rosion with a wire brush and wash with a weak solution of baking soda and water Rinse with clean water and dry Paint the retainer assembly if needed to prevent rusting 7 9 Check that foreign objects such as stones bolts and nuts are removed from the battery box 7 4 After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 7 5 Spray each connection with dielectric red enamel and coat the battery terminals with dielectric grease see Table 1 Protectant Material Approved Brand Dielectric Grease Lubriplate FLP DS ES Dielectric Red Enamel 3M 1602 IVI Spray Sealer Spray Spray On B 6 665 Table 1 Approved Dielectric Protectants Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning see Table 1 Business Class Trucks Maintenance Manual January 2004 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Clutch Checking Noise Emission Control Radiator Gap Checking usu Stet ren dre ee gtr 4 ARABE Radiator Pressure Flushing and Coolant Changing 20 Index Alphabetical MOP Number
156. r mounting plates 5 Check the turn signal flasher if so equipped See Fig 1 Make sure that the two male and female connectors are firmly connected Check that the flasher fuse is firmly seated in its holder 6 Check the cigarette lighter Look inside the Socket for signs of overheating discoloration melting caused by misuse of the lighter socket 7 Test the electric horn If it does not work check the adjustment screw on the horn unit Turn the screw in or out until the horn works If the horn 54 still does not work check the wiring to it If the wiring checks out okay replace the horn 8 Check connectors on the right side of the fire wall below the radiator surge tank See Fig 2 Check the terminals for tightness damage and corrosion or dirt 10 05 94 1540844 1 Electrical Connectors 2 Magnetic Switch Fig 2 Right Side of the Firewall 9 Check the seven way trailer cable plug at the back of the cab Make sure all the pins are tight and free of dirt and grease Chassis 1 Check the main wiring harness Check the wiring 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 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 w
157. r Transmissions t MobilTrans SHC 50 RN All 50 2952 E 5 Synthetic transmission All 50 lubricant approved by Eaton Heavy duty engine oil API Above 10 12 40 or 50 service classification SF or CD Below 10 12 30 Meritor Transmissions Above 10 12 40 or 50 Heavy duty engine oil API service classification CD CE SF or SG iri 30 Mineral gear oil With rust Above 10 12 90 oo inhibitor API Above 46 80 26 Synthetic transmission All 50 lubricant meeting Meritor specification 0 81 Mercedes Benz Transmissions MobilTrans SHC 50 RN All 50 2952 E 2 Lubricants listed in order of preference Do not mix types of oil t Call 1 800 826 4357 for a complete list of Eaton approved lubricants Table 1 Approved Manual Transmission Lubricants e 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads e 35 to 50 Ibf ft 48 to 67 N m for all Meritor transmissions Business Class Trucks Maintenance Manual February 2003 26 1 26 e 42 Ibf ft 57 N m for all Mercedes Benz transmissions 26 02 Eaton Fuller and Meritor Transmission Fluid Changing and Magnetic Plug Cleaning Transmission Eaton Fuller Transmission Lubricant Capacities Draining 1 Park the vehicle on a level surface Apply the park
158. r contamination is normally characterized as a AT Series milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a AT 545 16 0 15 1 leak between the water and fluid areas of the trans MT Series Business Class Trucks Maintenance Manual February 2003 26 7 26 Allison Transmission Lubricant Capacities Transmission Model on io MT 643 15 0 14 2 MT 653 MD Series MD 3060 19 0 18 0 MD 3560 HD Series FL112 only t HD 4060 36 34 HD 4560 HD 4060P 39 37 HD 4560P Quantities listed are approximate Add the recommended amount of fluid as listed under refill capacity then perform a hot check and add fluid as needed Do not overfill t NOTE Quantities listed are for a standard size not shallow oil pan Table 5 Allison Transmission Lubricant Capacities 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains If only the filter is being changed do not drain the fluid 4 Remove the 12 mounting bolts six each from the two filter covers NOTE A lot of fluid will drain when the filter covers are removed 5 Remove the filter covers O rings and two square cut seals from the transmission See Fig
159. ral Information 00 Maintenance Operation Sets Tables 00 08 Maintenance Operation Sets for Groups 31 through 41 REQUIRED MAINTENANCE OPERATION SET M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 31 01 Frame Fastener Torque Checking 31 02 Fifth Wheel Inspecting 31 03 Fifth Wheel Lubricating 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 32 01 Suspension Inspecting 32 02 Suspension Lubricating 32 03 U Bolt Torque Checking 33 01 Knuckle Pin Lubricating 33 02 Tie Rod End Inspecting 33 03 Tie Rod End Lubricating 33 04 All Axle Alignment Checking 33 05 All Wheel Drive Front Axle Oil Level Checking 33 06 All Wheel Drive Front Axle Oil Changing 35 01 Axle Lubricant Level Checking 35 02 Axle Breather Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 35 04 Two Speed Axle Shift Unit Oil Level Checking for FL112s perform at M1 interval 35 05 Two Speed Axle Shift Unit Oil Changing 40 01 Wheel Nut Checking 41 01 Driveline Inspecting 41 02 Driveline Lubricating Table 11 Maintenance Operation Sets for Groups 31 through 41 Maintenance Operation Sets for Group 42 REQUIRED MAINTENANCE OPERATION SET M1 M2 M3 M4 M5 Maintenance Operation Number and Ope
160. ration Description 42 01 Air Dryer Inspecting Bendix AD 9 42 02 Air Brake Valve Inspecting and Leak Checking Bendix BP R1 42 03 Foot Brake Valve Actuator Lubricating Bendix E 12 42 04 Air Brake Valve Operation Checking Bendix BP R1 and E 12 42 05 42 06 Relay Valve Checking Midland Quick Release and Flipper Valves Checking Midland 42 07 Brake Chamber Inspecting All Models 42 08 Air Dryer Desiccant Replacing Meritor WABCO System Saver 1000 42 09 Brake Adjusting Manual Slack Adjusters Business Class Trucks Maintenance Manual February 2004 00 13 00 General Information Maintenance Operation Sets Tables 00 08 Table 12 Maintenance Operation Sets for Group 42 Maintenance Operation Sets for Groups 46 through 83 Maintenance Operation Sets for Group 42 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 42 10 Camshaft Bracket Bushing Lubricating for FL112s perform at M1 interval t 42 11 Manual Slack Adjuster Lubricating 42 12 Automatic Slack Adjuster Checking Meritor e e fe lolo le 42 13 Automatic Slack Adjuster Lubricating Meritor 42 14 Automatic Slack Adjuster Inspecting Meritor e B 42 15 Air Dryer Checking Bendix AD 9 s E 42 16 Air Dryer Desiccant Replacin
161. re that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On vehicles with screw 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 Flushing and Coolant Changing 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 See Fig 1 N x MON 11 19 94 v d 1 Surge Tank 1500107a Fig 1 Surge Tank and Cap 1 2 Open the petcock at the bottom of the radiator to drain the engine coolant See Fig 2 2 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 Business Class Trucks Maintenance Manual August 2003 20 1 20 Engine Cooling R adiator 11 19 94 1 Radiator f500108a 2 Horn Fig 2 Draining The Engine Coolant 4h 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 radiat
162. roke Adjusting 4 Check for correct brake chamber stroke 4 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 7 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 7 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 4 If the brake chamber stroke is incorrect remove the pressure relief cap screw gasket pawl spring and pawl Fig 6 Ref 5 from the slack adjuster housing If equipped with a pull pawl as sembly Fig 8 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 Area Maximum Allowable Stroke inches mm square inches B minus A 12 Less than 1 3 8 35 16 Less than 1 3 4 44 20 Less than 1 3 4 44 Business Class Trucks Maintenance Manual October 1998 42 9 42 Maximum Allowable Brake Chamber Stroke with Meritor Automatic Slack Adjusters Chamber Size Effective Area Maximum Allowable Stroke inches mm square inches B minus A 24 Less than 1 3 4 44 24 long
163. s 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads 35 to 50 Ibf ft 48 to 67 N m for all Meritor transmissions 42 Ibf ft 57 N m for all Mercedes Benz transmissions 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause oil leakage 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 98 1260007a Fig 2 Transmission Breather Eaton Fuller shown 26 4 Business Class Trucks Maintenance Manual February 2003 26 Transmission 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning NOTE Meritor transmissions do not have an air filter regulator element that needs servicing 1 Exhaust the air from the air reservoirs WARNING 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 then let it air dry See Fig 3 05 27 93 1260037a 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
164. scard the seal ring Transmission 10 05 94 1260133a 1 Fluid Intake Tube 5 Governor Pressure 2 Filter Spacer Tube 3 Internal Fluid Filter 6 Governor Feed Tube 4 Washer Head Screw Fig 5 Allison AT Series Transmission Filter 7 Remove clean and install the governor feed line screen located in the control valve body See Fig 6 8 Install a new seal ring into the fluid intake tube IMPORTANT Avoid twisting the intake tube when installing the internal fluid filter intake tube and seal ring the seal ring could be pinched cut or deformed An air tight seal must be maintained 9 Install the intake tube with the seal ring installed into the main housing Install the internal fluid filter on the intake tube making sure the grom met in the filter fits the intake tube snugly 10 Install the washer head screw to retain the fluid filter and tighten it 10 to 15 Ibf ft 14 to 20 N m 11 Submerge a new oil pan gasket in transmission fluid for five minutes Then place the gasket on the 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 26 6 Business Class Trucks Maintenance Manual February 2003 Transmission sion Also nonsoluble vegetable based cooking compounds or fibrous greases must not be used inside the transmission 12 Install the oil pan a
165. shers 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 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 Business Class Trucks Service 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 3 Adjust if needed 42 2 Business Class Trucks Maintenance Manual October 1998 Brakes 42 2 yf z 06 25 93 14207314 A Do not remove this clamp ring B Do not remove the factory sealed clamp ring 1 MGM E Series Brake Chamber 2 MGM TR T Series Brake Chamber Fig 1 Service Parking Brake Chambers 1 B 2 pa 3 A a ae B 1 A T A 4 07 27 94 f420009a A Brakes Released C Greater than 90 Y 5 B Brakes Applied degree angle 1 Brake Chamber 3 Slack Adjuster 2 Piston Rod 08 20 93 1420225a Fig 2 Angle Between Piston Rod and Slack Adjuster A Minimum of 1 inch 25 mm clearance between Check the tightness of the piston rod nut See Table 1 for torque values Tighten if needed B 1 2 3 centerline of clevis pin hole and piston rod end Minimum of 7 threads engagement Piston Rod 4 Cotter P
166. siness Class Trucks Service Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious injury 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 Group 42 of the Business Class Trucks Service 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 Brakes bolt For torque values see the applicable brake chamber section in Group 42 of the Business Class Trucks Service Manual 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 Checking Do not loosen or remove the parking brake clamp ring see Fig 1 for any purpose at
167. sion to neutral N and shut down the engine 4h 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 magnetic drain plug and drain the fluid See Fig 16 NOTE The transmission should drain about 7 9 quarts 7 5 L 06 17 99 A Drain Plug f261021 Fig 16 Aisin Transmission Drain Plug 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 Replace the filter It is located on the passenger side of the vehicle 4 1 Place a drain pan under the transmission fluid filter 4h CAUTION To prevent skin burns from hot transmission fluid wear protective gloves when removing the filter OOM uoo 11 26 4 2 Place a strap or chain wrench around the filter canister and rotate in a counter clockwise motion to separate the filter from the mounting Carefully spin the filter off the mount and remove it from the ve hicle 4 3 Apply a light coat of transmission fluid to the O ring gasket on the new filter Fill the filter with the specified transmission fluid and spin
168. spection and daily 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 notice 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 c
169. spension fasteners to the torque values given in Table 2 Hendrickson Suspension Torque Values frame damage Torque NM Description Size q Typical frame fastener applications include front Ibf ft N m frame brackets suspension brackets spring brack Top Pad to Spring ets fuel tank exhaust and engine supports frame Aligning Setscrew mo 100 150 135 200 crossmembers and gussets and fifth wheel mounting RT RTE brackets oe ae 275 400 375 542 See Group 00 of the Business Class Trucks Ser RT RTE vice Manual for additional information on fasteners U Bolt Locknut U UE 7 8 14 237 302 321 409 lues and torque values Spring Pin Locknut 1 2 13 45 63 61 85 Tighten all Freightliner AirLiner suspension fasteners to the torque values in Table 1 Also tighten all sus ME e Straddle 5 8 11 190 260 pension air line fittings and air lines ae ape 1 1 4 12 175 225 235 305 Freightliner Airliner Suspension Torque Values 7 814 Saddle Cap Stud 55 65 75 90 Description Size orque 3 416 mE Saddle Cap Locknut 71g 44 225 275 305 373 Leveling Valve Adjustment Nut 1 4 20 5 7 RT RTE Leveling Valve Mounting Bolt Saddle Cap Locknut E Nuts 5 16 18 14 19 U UE 3 4 16 125 145 169 197 Air Spring Upper Mounting SNe 399060 Adapter Type Beam 3 4 16 210 240 285 325 Locknuts 1 2 13 23 31 End Locknut Air Spring Lower Mounting 1 2 13 5
170. ss Class Trucks Maintenance Manual February 2004 General Information 00 Lubrication Tables 00 18 See Fig 1 for lubrication points not on FL 112 221 171 09 15 97 f000271 Fig 1 Lubrication Points all models but FL112 No MOP No Component Remarks 1 32 02 Front Suspension Spring Pins Lube both sides of vehicle one grease fitting for each spring pin and Shackle Pins t two grease fittings for each shackle 46 02 Drag Link Two grease fittings one on each end 46 03 46 04 Power Steering Check fluid level in reservoir 46 03 change fluid and filter 46 46 05 04 when required Lubricate steering gear 46 05 4 46 01 46 06 Steering Driveline Lubricate grease fittings at slip joint splines and both universal joints Lubricate miter gear if applicable 5 42 11 42 13 Slack Adjusters Front Axle Lubricate both sides of axle one grease fitting for each slack 42 24 42 26 adjuster 6 42 10 Camshaft Brackets Front Axle Lubricate both sides of axle one grease fitting for each camshaft bracket 7 33 05 33 06 Oil Lubricated All Wheel Drive Check oil level add oil if low 33 05 Change oil 33 06 when Front Axle required Business Class Trucks Maintenance Manual February 2004 00 27 00 Lubrication Tables 00 18 General Information No MOP No Component Remarks 8 33 03 Tie Rod Two gr
171. ss Trucks Maintenance Manual February 2004 General Information 00 Maintenance Interval Tables 00 07 Maintenance Intervals for Schedules II and III all models Maint Schedule Il Schedule Ill No Maintenance Interval Miles km Miles km 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 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 00
172. ssive if it pro duces a 1 inch 25 mm bubble within 5 seconds If the brake valve does not function as described above or if leakage is exces sive replace it with a new or remanufac 42 tured unit Repeat the leakage checks before placing the brake valve in service 42 03 Foot Brake Valve Actuator Lubricating Bendix E 12 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 barium 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 5 Check for leakage see Group 42 of the Busi ness Class Trucks Service Manual for instruc tions 42 04 Air Brake Valve Operation Checking Bendix BP R1 and E 12 Check for proper operation see Group 42 of the Business Class Trucks Service Manu
173. stroke Less than 2 51 30 Less than 2 51 Adjust the brakes whenever the applied stroke exceeds the maximum Table 4 Maximum Allowable Brake Chamber Stroke with Meritor Automatic Slack Adjusters A 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 9 Measure the stroke again and adjust until correct 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 Business Class Trucks Service 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 screwdriver from the pull pawl assembly if equipped 42 13 Automatic Slack Adjuster Lubricating Meritor 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 Brakes 42 14 Automatic Slack
174. t Fluid Level 2 OK Band Acceptable Fluid Level 4 Dipstick Fig 13 Dipstick Fluid Level Markings Chrysler Transmission mistaken for a pump seal leak bubbles in the A CAUTION fluid and foaming This can reduce fluid life sig Do not overfill the transmission Overfilling nificantly anc cause smiling problems causes leakage from the pump vent this can be 26 14 Business Class Trucks Maintenance Manual February 2003 Transmission 4 2 If the fluid is hot any level within the OK band see Fig 13 is satisfactory If the level is below the OK band use a funnel to add just enough fluid to bring the level up to the MAX mark Do not overfill 4 3 If fluid is above the MAX mark drain off any excess fluid at one of the cooler lines If the cooler lines are too hot use a suction gun and flexible tubing with a di ameter of 1 8 inch to 3 16 inch 3 mm to 4 75 mm NOTE See Table 6 for approved transmission lubricants and Table 7 for lubricant capacities 5 To prevent dirt and water from entering the trans mission be sure the dipstick cap is properly seated 6 When the fluid level is correct shut down the engine and release the parking brake 26 Approved Chrysler Transmission Lubricants 12 3 94 H yf 1260303 1 Front Band Adjusting Screw 2 Locknut 3 Manual Lever Shaft 4 Park Neutral Position Switch Temperature SAE Lubricant Type in F C Viscosity Mop
175. t it is over charged A cloudy sight glass means that dirt or broken down bits of desiccant are flowing through the system This is a serious condition that requires complete flushing of the system installation of a new receiver drier and if the desiccant cartridge of the receiver drier has fallen apart installation of a new refrigerant compressor and expansion Valve Oil streaks in the sight glass mean low refriger ant or too much oil in the system Heater and Air Conditioner 83 2 Business Class Trucks Maintenance Manual January 1998
176. tes HeLa d eed mue Racked 01 02 Engine Support Fasteners Checking aco ip acr ede se dca dared dieser ean de OLR RU bane RR 01 01 Business Class Trucks Maintenance Manual July 1999 Engine 01 01 Engine Support Fasteners Checking Check the rear engine support fasteners Fig 1 Ref 4 for tightness Tighten the 3 4 inch fasteners 215 to 265 Ibf ft 292 to 359 N m Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 N m NOTE At engine overhaul and whenever the engine has been removed inspect the lower and upper isolators Refs 1 and 6 and replace them if they are worn See Group 01 of the Business Class Trucks Service Manual for procedures 9200472 4 3 4 x 10 Hexnut 5 Engine Mount 6 Upper Isolator 10 05 94 1 Lower Isolator 2 Engine Support Washer 3 3 4 x 10 Capscrew Fig 1 Engine Rear Mount 01 02 Engine Drive Belt Inspection 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 retained 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 01 vidual belts and as matched sets When replacing a matched set of bel
177. the Interval for Schedules II and III for all models but detailed lubrication and fluid check instructions given FL112 elsewhere in the manual Maintenance operation numbers given in the table are reference numbers used to help you find detailed Maint Oper No M2 Lubrication and Fluid Level Check for All Models but FL112 Maintenance Operation 00 16 Operation Description 35 04 Two Speed Axle Shift Unit Oil Level Checking 42 10 Camshaft Bracket Bushing Lubricating 42 19 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 46 01 Steering Driveline Lubricating Table 15 Maintenance Operation 00 16 M2 Lubrication and Fluid Level Check for All Models but FL112 Business Class Trucks Maintenance Manual February 2004 00 25 00 General Information Lubrication and Fluid Level Check M1 FL112 models only 00 17 Maintenance Operation 00 17 Table 16 summa instructions in the manual on the lubrication or fluid rizes all Lubrication and Fluid Level Check opera check Maintenance Operation 00 18 can be used tions that must be performed at the M1 Maintenance as a guide by those who do not need to consult the Interval for Schedules II and III for FL112 models detailed lubrication and fluid check instructions given only elsewhere in the manual Maintenance operation numbers given in the table are reference numbers used
178. the filter back onto the mount NOTE The filter fills slowly so be patient to ensure the proper fluid level has been reached 4 4 Once the filter has made contact with the mount use a strap or chain wrench to rotate the filter canister an additional 180 to 270 degrees to firmly tighten the filter Wipe the filter clean of any fluid after it is tightened Clean the plug before installing it Clean drain plug threads in the tank Install the plug Tighten 32 Ibf ft 43 N m Remove the transmission fluid dipstick Prepare 11 quarts 10 L of Dexron III automatic transmission fluid ATF Through the dipstick tube fill the transmission with Dexron Ill about 7 4 quarts 7 L Inspect the low temperature ATF level 11 1 Make sure the vehicle is in neutral and start the engine 11 2 Let the engine idle and successively shift positions to spread ATF throughout the transmission 11 3 11 4 Set the shift selector to neutral N Continue engine idle and remove the dip stick Wipe it clean re insert it remove it and measure the ATF level 11 5 If the ATF temperature is between 68 and 86 F 20 and 30 C the fluid should measure in the COLD range See Fig 17 Refill the ATF until it reaches the appro priate range 11 6 Business Class Trucks Maintenance Manual February 2003 2617 26 d 1 A XV 4 i B s j 12 06 1999 1011723 A Hot Range B Cold Range 1 Dipstick
179. the maximum torque limits in Table 2 Do not overtighten On other service chamber makes if leak age is detected tighten the clamp ring but do not exceed the maximum torque limits in Group 42 of the Business Class Trucks Service Manual Clamp Ring Torque Values Bendix Chambers Description Torque Ibf in N cm 5 16 24 Nut 130 150 1460 1700 3 8 16 Nut 140 180 1580 2040 Table 2 Clamp Ring Torque Values Bendix Chambers 3 3 If leakage persists use the instructions in Group 42 of the Business Class Trucks Service Manual to replace the service brake diaphragm 3 4 Using soapy water coat the area around the piston rod bore On some Bendix ser vice chambers loosen the boot if neces sary No leakage is permitted If there is leakage use the instructions in the appli cable brake chamber section in Group 42 of the Business Class Trucks Service Manual and replace the service brake diaphragm NOTE On weatherproof Bendix chambers the leakage check can be performed at the cross drilled mounting stud 42 Parking Brake Operation and Leakage Checking Do not loosen or remove the parking brake clamp ring see Fig 1 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
180. the transmission fluid fill plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 6 1 If the gasket is damaged replace it 6 2 If the fill plug is too loose tighten it 42 Ipf ft 57 N m If the plug is too tight loosen it and tighten to 42 Ibf ft 57 N m 7 Check for signs of leakage at the transmission fluid drain plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 7 1 If the gasket is damaged replace it 7 2 If the drain plug is too loose tighten it 42 Ibf ft 57 N m If the plug is too tight loosen it and tighten to 42 Ibf ft 57 N m 8 Check for fluid dripping at the gear case seals If substantial leakage is found at either location replace the transmission NOTE Weeping or sweating seals are not cause for transmission replacement Clutch hydraulic fluid DOT 3 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling clutch hydraulic 26 fluid or bleeding hydraulic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 9 Check for signs of leakage at the clutch slave cylinder 4h CAUTION Do not spill clutch hydraulic fluid DOT 3 brake fluid on the cab paint Clean it off immediately if any is spilled Clutch hydraulic fluid can damage paint 9 1 If leakage is found on the slave c
181. to help you find detailed Maint Oper No M1 Lubrication and Fluid Level Check for FL112 Models Only Maintenance Operation 00 17 Operation Description 25 01 Clutch Release Bearing and Cross Shaft Lubricating 26 01 Manual Transmission Oil Level Checking 31 03 32 02 Fifth Wheel Lubricating Suspension Lubricating 33 01 Knuckle Pin Lubricating 33 03 Tie Rod End Lubricating 33 05 All Wheel Drive Front Axle Oil Level Checking 35 01 Axle Lubricant Level Checking 35 04 Two Speed Axle Shift Unit Oil Level Checking 41 02 Driveline Lubricating 42 03 Foot Brake Valve Actuator Lubricating Bendix E 12 42 10 Camshaft Bracket Bushing Lubricating 42 11 Manual Slack Adjuster Lubricating 42 13 42 19 Automatic Slack Adjuster Lubricating Meritor Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 42 24 Automatic Slack Adjuster Lubricating Gunite 42 26 Automatic Slack Adjuster Lubricating Haldex 46 01 46 02 Steering Driveline Lubricating Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 05 Steering Gear Lubricating Ross TAS Series 72 01 Weatherstrip Door Hinge and Door Latch Lubricating Table 16 Maintenance Operation 00 17 M1 Lubrication and Fluid Level Check for FL112 Models Only 00 26 Busine
182. torque arm pin mounting bolt e There are cracks in the bushing e Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve Freightliner Spring Tandem Equalizer Bushing Checking 1 Block the frame up enough to take the weight of the chassis off of the springs Attempt to move the equalizer up and down by using a pry bar between the top of the equalizer and the top of the equalizer bracket Apply hand pressure only See Fig 3 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings f320021a 05 27 93 Fig 2 Torque Arm Bushings 1 A IS Va 2 05 27 93 1320022a A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer Fig 3 Side View of the Equalizer 2 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 4 If clearance between the equal izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace the equalizer bushings Freightiner AirLiner Component Clearance Checking 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 wear There must be at least 1 inch 25 mm clearance around the rubber air spring 32 2 Business
183. ts 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 all drive belts for the following conditions then perform 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 coolant leaks that are affecting the belts before replacing the drive belts Do not use belt dress ing 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 Re
184. ts liters quarts liters Caterpillar CFE 28 26 5 Series Cummins B Series 30 5 28 9 31 0 29 3 Cummins C Series and M11 31 2 29 5 Detroit Diesel Series 50 31 4 29 7 m Dodge Magnum V 8 28 26 5 Dodge Magnum V 10 36 34 Mercedes Benz OM 366LA 29 5 27 9 30 0 28 4 System capacity includes all hoses fittings and the heater core Table 1 Coolant Capacities all but FL112 System capacity includes all hoses fittings and the heater core Table 2 Coolant Capacities FL112 only Approved Coolants Coolant Coolant Engine Type Manufacturer Designation Diesel Texaco JC04 Antifreeze Van Waters and Diesel Antifreeze Rogers Ltd No 6038 Canada Gasoline t Chrysler Mopar 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 1 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards t Because Dodge Magnum Engines use aluminum parts the coolant used with these engines must contain Alugard 340 2 Table 3 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 Business Class Trucks Maintenance Manual August 2003 20 3 20
185. turns more 35 4 Business Class Trucks Maintenance Manual January 1998 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel rat Ire ipio e ER xr LP EC ETT 40 01 Business Class Trucks Maintenance Manual January 1998 Wheels and Tires 40 40 01 Wheel Nut Checking A CAUTION IMPORTANT In addition to the maintenance Too little wheel nut torque can cause wheel interval in this manual check the wheel nut shimmy resulting in wheel damage stud break torque the first 50 to 100 miles 80 to 160 km age and extreme tire tread wear Too much wheel of operation after a wheel has been removed nut torque can break studs damage threads and and installed crack discs in the stud hole area When checking wheel nuts on a dual disc assembly See Table 1 Table 2 or Table 3 for wheel nut remove one outer nut at a time tighten the inner nut torque specifications and see Fig 1 for the tighten then reinstall the outer nut Repeat this procedure for Ng Sequence all of the inner wheel nuts in the sequence shown in Fig 1 then tighten all of the outer wheel nuts in the same sequence Fastener Torque for 10 Hole Disc Wheel With Inner and Outer Locknuts Description Nut Size M loud rer OU 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 W
186. ust the belt tension if needed See Group 01 in this manual for belt tension specifi cations Some Caterpillar engines are equipped with dual alternator belts Always check both belts for correct tension Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension in spection 3 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections as needed 4 On the bundled cable running from the batteries to the starter ensure that tie straps are installed at least every 12 inches 800 mm Replace any missing tie straps and add tie straps where spac ing between straps exceeds 12 inches 300 mm 5 Ensure that all cables have sufficient slack to allow for engine movement and that there is no pressure on any wiring connectors 6 Check all wiring inside of damaged convoluted tubing and replace any damaged or missing con voluted tubing 7 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals 15 with a wire brush See Group 54 of the Business Class Trucks Service Manual for troubleshoot ing instructions and for adjustment repair or replacement instructions 7 1 Clean and tighten the battery ground cable terminal and clamps 7 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any co
187. ustom ers receive notices that apply to their vehicles Business Class Trucks Maintenance Manual December 2002 I 1 Introduction For a page example of the printed manual see Fig 1 Page Description 11 28 2001 A B Group Title C Group Number D Release Date E A B Y Frame and Fifth Wheel 31 01 Frame Fastener Torque Checking Because of bedding in or seating frame fasteners must be torqued at recommended intervals When tightening fasteners check the frame for cracks and other damage CAUTION fasteners could result in bracket or frame damage Frame fasteners are used on front frame brackets axle stops equalizer stops suspension brackets fuel tank brackets exhaust and air intake brackets engine trun nion supports rear engine supports frame crossmem bers and gussets fifth wheel mounting angles and fifth wheel legs Refer to the frame section in the vehicle service manual for additional information on frame fasteners and to the general information section in the vehicle service manual for fastener information and torque values 31 02 Fifth Wheel Inspecting and Lubricating WARNING All fifth wheel maintenance adjust ment and rebuilding must be done only by a quali fied mechanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in per sonal injury or property damage Parts
188. veline Lubricating Foot Brake Valve Actuator Lubricating Bendix E 12 Manual Slack Adjuster Lubricating Automatic Slack Adjuster Lubricating Meritor Automatic Slack Adjuster Lubricating Gunite Automatic Slack Adjuster Lubricating Haldex Drag Link Lubricating Power Steering Reservoir Fluid Level Checking Steering Gear Lubricating Ross TAS Series Weatherstrip Door Hinge and Door Latch Lubricating Business Class Trucks Maintenance Manual February 2004 00 17 00 General Information M1 Maintenance Interval Operations Table 00 10 Maint Oper No 00 17 Lubrication and Fluid Level Check FL112 only includes the following Clutch Release Bearing and Cross Shaft Lubricating M1 Maintenance Interval Operations Manual Transmission Oil Level Checking e Fifth Wheel Lubricating e Suspension Lubricating e Knuckle Pin Lubricating e Tie Rod End Lubricating All Wheel Drive Front Axle Oil Level Checking e Axle Lubricant Level Checking Two Speed Axle Shift Unit Oil Level Checking Driveline Lubricating Foot Brake Valve Actuator Lubricating Bendix E 12 Camshaft Bracket Bushing Lubricating Manual Slack Adjuster Lubricating e Automatic Slack Adjuster Lubricating Meritor Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspect ing and Lubricating Bendix DV 2 e Automatic Slack Adjuster Lubricating Gunite Automatic Slack Adjuster Lubricating Haldex
189. ves of the fan solenoid connector The fan clutch should en gage If the fan does not operate correctly see Group 20 of the Business Class Trucks Service Manual for troubleshooting and repair proce dures With the air system charged to 120 psi 827 kPa and with the fan solenoid connector halves separated check the fan clutch for audible air leaks using a suitable listening device If a leak is detected remove the fan blade Using a soapy water solution check the fan clutch at the following locations to locate the source of the leak Install a new seal kit See Group 20 of the Business Class Trucks Service Manual for re pair procedures 9 1 Check for a leak at the bleed hole on the fan pilot Air leakage means that the car tridge assembly Fig 6 Ref 16 or face seal Ref 17 is damaged 9 2 Check for air leaks between the air cham ber and the piston friction disc Air leak age means that the large O ring Ref 14 is damaged 9 3 Check for air leaks around the safeguard hole on the piston friction disc Air leak age means the small O ring Ref 18 is damaged 9 4 Check for air leaking from the System Sentry fuse Leaking air means the clutch has gotten so hot the lead alloy in the fuse melted This released the clutch before the heat could damage the clutch bearings Before replacing the fuse find and repair the source of the heat If equipped with an override toggle switch on the dash check th
190. with an air starter be sure that the air starter reservoir is drained 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Reassemble the clutch valve solenoid air filter assembly and install on the vehicle 4 Visually check the fan for bent cracked or dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing See Fig 5 Replace the friction facing if it is worn to a 1 16 inch 1 6 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evidence of oil or burn marks are found replace the friction facing 08 08 94 1 System Sentry Fuse 2 Safeguard Hole 3 Friction Facing f200290 4 Piston Friction Disc 5 Air Chamber Fig 5 Horton Advantage Fan Clutch 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Shut 20 4 Business Class Trucks Maintenance Manual August 2003 Engine Cooling R adiator down the engine Separate the hal
191. ylinder body check the fittings and hose for dam age 9 2 If leakage is found on the piston seals replace the slave cylinder and bleed the clutch hydraulic system For detailed in structions on bleeding the clutch see Group 25 9 3 If the slave cylinder fittings and or the hose are damaged replace them 9 4 Check the torque on the slave cylinder mounting capscrews Tighten them 15 Ibf ft 20 N m 9 5 If any leakage of clutch hydraulic fluid is found check the fluid level in the reser voir and add fluid if needed For detailed procedures see Group 25 NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 10 Check for signs of leakage at the clutch bell housing If leakage is found check the radial seal on the input shaft the front cover plate on the countershaft inside the clutch bell housing and the rear radial seal on the crankshaft 10 1 If the radial seal on the input shaft is leaking replace the radial seal For pro cedures see Section 26 00 Subject 120 of the Business Class Trucks Service Manual 10 2 If the front cover plate on the countershaft is leaking replace the cover plate Apply liquid gasket Loctite 518 to the new cover plate when installing it Business Class Trucks Maintenance Manual February 2003 26 19 26 10 3 If the rear radial seal on the engine crankshaft is leaking replace the rear ra dial seal For procedures see the engi

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