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Sterling Trucks Acterra MX Maintenance Manual

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ACTERRA MAINTENANCE MANUAL
Models: MX
STI-403-1 (10/08P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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  • Page 1 ACTERRA MAINTENANCE MANUAL Models: MX STI-403-1 (10/08P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 2 Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation.
  • Page 3 Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic ® (via ServicePro ) formats. Workshop/Service Workshop/service manuals contain service and repair information for all vehicle Manual systems and components, except for major components such as engines, trans- missions, and rear axles.
  • Page 4 Introduction Warranty-related service information available on the AccessSterling.com website includes the following docu- mentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety.
  • Page 5 Page Description For an example of an Acterra Maintenance Manual page, see Frame and Fifth Wheel 31−01 Frame Fastener Torque Checking CAUTION: 31−02 Fifth Wheel Inspecting and Lubricating FONTANE Acterra Trucks Maintenance Manual, April 2000 02/11/2002 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B.

  • Page 6: Table Of Contents

    Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .
  • Page 7 General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Initial Maintenance (IM) Operations Table ..........00–09 Lubrication and Fluid Level Check (M1).

  • Page 8: General Information

    General Information 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...
  • Page 9 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 Verification of Inspections Log — Group 49 Verification of Inspections Log — Group 49 — Exhaust Date Mileage 00/2...
  • Page 10 General Information Torque Values for U.S. Customary Thread Fasteners With Lubricated Regular Hex Thread Grade 5 Grade 5 or Diameter– Bolt B Nut Pitch Torque: lbf·ft (N·m) f230002 1/4–20 7 (9) 1/4–28 8 (11) 5/16–18 15 (20) 5/16–24 16 (22) 3/8–16 26 (35) 3/8–24...
  • Page 11 Torque Specifications Tables: 00–03 Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Thread Grade 5 Bolt Diameter–Pitch Torque: lbf·ft (N·m) f230002 1/4–20 8 (11) 1/4–28 9 (12) 5/16–18 15 (20) 5/16–24 17 (23) 3/8–16 28 (38) 3/8–24 31 (42) 7/16–14 45 (61) 7/16–20...
  • Page 12 General Information Torque Values for Metric Thread Fasteners With Lubricated Thread Diameter–Pitch M8 x 1 M10 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x 2 M30 x 2 Sterling recommends that all plated and unplated fasteners be coated with oil before installation.
  • Page 13 Metric/U.S. Customary Conversion Tables: 00–04 When You Know U.S. Multiply Customary Length inches (in) 25.4 inches (in) 2.54 feet (ft) 0.3048 yards (yd) 0.9144 miles (mi) 1.609 Area square inches (in 645.16 square inches (in 6.452 square feet (ft 0.0929 Volume cubic inches (in 16387.0...
  • Page 14 General Information Description 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 I usage include: operation on extremely poor roads or where there is heavy dust accumula- tion;...
  • Page 15 Maintenance Schedule Table: 00–06 Maintenance Schedule Schedule I (Severe Service) vehicles that annually travel up to 6000 miles (10 000 km) Schedule II (Short-Haul Transport) vehicles that annually travel up to 60,000 miles (100 000 km) Schedule III (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 00/8...
  • Page 16 General Information Maint. No. Maintenance Interval M1, M2, M3, M4, and M5 Acterra Maintenance Manual, October 2008 Maintenance Interval Tables: 00–07 Maintenance Intervals for Schedule I Miles IM and M1 1000 2000 3000 M1and M2 4000 5000 6000 7000 M1, M2, and M3 8000 9000 10,000...
  • Page 17 Maintenance Interval Tables: 00–07 Maintenance Intervals for Schedules II and III (all models) Maint. Maintenance Interval IM and M1 M1 and M2 M1, M2, and M3 M1 and M2 M1, M2, M3, and M4 M1 and M2 M1, M2, and M3 M1, and M2 M1, M2, M3, M4, and M5 M1 and M2...
  • Page 18 General Information IMPORTANT: At each Maintenance Operation Set, in addition to the maintenance operations listed in this table, perform all daily, weekly, and monthly mainte- nance operations listed in the "Pretrip and Post-trip Inspections and Maintenance" chapter of the Acterra ®...
  • Page 19 Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets for Groups 00 through 83 REQUIRED MAINTENANCE OPERATION SET Maintenance Operation Number and Operation Description 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 33–07 Draw Key Nut Inspecting 35–01...
  • Page 20 General Information Maintenance Operation Sets for Groups 00 through 83 REQUIRED MAINTENANCE OPERATION SET Maintenance Operation Number and Operation Description 42–23 Bosch Rail-Slide Hydraulic Brake Caliper Lubricating 42–24 Brake Inspection 46–01 Steering Driveline Lubricating 46–02 Drag Link Lubricating 46–03 Power Steering Reservoir Fluid Level Checking 46–04 Power Steering Reservoir Fluid and Filter Changing 46–05...
  • Page 21 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 vehicle driver’s manual. Also, perform all M1 Maintenance Interval Operations at the Initial Maintenance (IM).
  • Page 22 General Information IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . M1 Maintenance Interval Operations Maint.
  • Page 23 M1 Maintenance Interval Operations Table: 00–10 Maint. Oper. No. 42–09 Automatic Slack Adjuster Checking, Meritor 42–14 Air Brake Valve Leak Checking, Bendix TC–6 42–17 Brake Lining Wear Checking, Hydraulic Disc Brakes 42–18 Brake Lines Checking, Hydraulic Disc Brakes 42–19 Power Booster Checking, Bendix Hydro-Max 42–21 Automatic Slack Adjuster Inspecting, Gunite 42–24...
  • Page 24 General Information IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1 Maintenance Interval Operations at the M2 Mainte- nance Interval.
  • Page 25 M3 Maintenance Interval Operations Table: 00–12 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval.
  • Page 26 General Information IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1, M2, and M3 Maintenance Interval Operations at the M4 Maintenance Interval.
  • Page 27 M5 Maintenance Interval Operations Table: 00–14 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1, M2, M3, and M4 Maintenance Interval Operations at the M5 Maintenance Interval.
  • Page 28 General Information Maintenance Operation 00–15 (see marizes all Lubrication and Fluid Level Check opera- tions that must be performed at the M1 Maintenance Interval for Schedules I, II, and III Maint. Oper. No. 25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating 25–03 Hydraulic Fluid Level Checking 26–01...
  • Page 29 Lubrication and Fluid Level Check (M2): 00–16 Maintenance Operation 00–16 (see marizes all Lubrication and Fluid Level Check opera- tions that must be performed at the M2 Maintenance Interval for Schedules I, II, and III Maint. Oper. No. 35–04 Two-Speed-Axle Shift Unit Oil Level Checking 42–08 Camshaft Bracket Bushing Lubricating 42–15...
  • Page 30 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–02 Engine-Support Fasteners Checking .
  • Page 31 Engine 01–01 Engine-Support Fasteners Checking Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance. Mounts should be inspected when the engine is re- moved for service. For vehicles manufactured prior to January 2007, perform the following check. Check the rear engine-support fasteners (see Ref.
  • Page 32 11/21/94 A. Glazing B. Separating Layers C. Streaked Sidewalls checked, not the pulley, to isolate the area from outside interference. 8. Inspect all pulleys for foreign objects, oil, or grease in the grooves. Belt Tension Inspection NOTE: If engine drive belts require adjustment, ®...
  • Page 33 Engine Engine Cummins ISB, ISC, ISM Mercedes-Benz MBE900 01–03 Pacbrake Inspecting and Maintenance With frequent use, the Pacbrake Exhaust Brake will operate maintenance-free. If the vehicle is used in- consistently or seasonally, it will be necessary to per- form preventative maintenance. If the vehicle is ex- posed to excess moisture, or is used only for periodical or seasonal use, perform the following steps:...

  • Page 34: Air Intake

    Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting and Replacing ..........09–01 Acterra Maintenance Manual, February 2004...
  • Page 35 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 inH O on a vehicle with an MBE engine, or 25 O on a vehicle with a Caterpillar or Cummins engine, if equipped with an air restriction indicator.

  • Page 36: Air Compressor

    Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspecting, Bendix ........... . . 13–01 Air Compressor Rebuilding/Replacing, Bendix .
  • Page 37 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.

  • Page 38: Alternators And Starters

    Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Checking ........15–01 Acterra Maintenance Manual, October 2008...
  • Page 39 Alternators and Starters 15–01 Alternator, Battery, and Starter Connections Checking WARNING Batteries generate explosive gas as a by-product of their chemical process. Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment.
  • Page 40 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Checking (Noise Emission Control) ..........20–03 Radiator Cap Checking.
  • Page 41 Engine Cooling/Radiator 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.
  • Page 42 11/19/94 1. Radiator 2. Horn Fig. 2, Draining The Engine Coolant 4. Drain the radiator, and flush the radiator until clean water flows from the radiator. Remove the flushing gun. 5. Close the petcock at the bottom of the radiator. 6.

  • Page 43: Horton Advantage Fan Clutch

    Engine Cooling/Radiator the coolant level is between the MIN and MAX lines on the surge tank. 7. Fill the radiator with coolant. Use a mixture of 50 percent water and 50 per- cent corrosion-inhibiting antifreeze to protect the engine to –34°F (–37°C) year round. Table 1 for engine cooling system capaci- ties.
  • Page 44 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. Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele- ment.
  • Page 45 Engine Cooling/Radiator 03/30/95 1. Mounting Bracket 2. Rear Sheave Bearing 3. Inner and Outer Bearing Spacers 4. Forward Sheave Bearing 5. Sheave 6. Friction Facing 7. Journal Spacer 8. Socket-Head Capscrew Fig. 6, Horton Advantage Fan Clutch Components 10.6 Set the toggle switch to the AUTO or OFF position;...
  • Page 46 05/27/93 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.
  • Page 47 Engine Cooling/Radiator 05/30/2002 Fig. 8, Checking for Air Leaks (Horton DriveMaster) 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.
  • Page 48 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch (Pull-Type) Inspecting and Adjusting..........25–02 Clutch Release Bearing and Release Cross-Shaft Lubricating .
  • Page 49 Clutch 25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating Clutch Release Bearing CAUTION Do not over-lubricate the clutch release bearing. Over-lubrication could contaminate the clutch in- ternally, causing clutch slippage and premature failure. Do not use chassis grease or multipurpose lubricants.
  • Page 50 06/17/2002 1. Reservoir 5. Hydraulic Hose 2. Reservoir Cap 6. Slave Cylinder 3. Pedal Unit 7. Reservoir Hose 4. Master Cylinder Fig. 2, Clutch Components procedures below. Fluid replacement must be done at an authorized Freightliner service facility. Draining and Filling 1.
  • Page 51 Clutch Press down on the pedal several times, until no more fluid drains from the reser- voir. Cover the hose to avoid contamination of the clutch hydraulic fluid. 5. Connect the hydraulic hose to the slave cylinder. Install the clamp, as removed. 6.
  • Page 52 hose. When no bubbles appear in the fluid, close the valve on the slave cylinder. Release 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.
  • Page 53 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Breather Checking ..........26–03 Allison Transmission Fluid and Filter Changing .
  • Page 54 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, check the fluid level in the transmission. Clean the area around the fill plug, then remove the plug from the side of the case.
  • Page 55 42 lbf·ft (57 N·m) for all Mercedes-Benz transmissions. 26–02 Eaton Fuller and TTC 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 fluid while the transmission is warm. 3.
  • Page 56 Transmission fected component must be thoroughly drained. Switching 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.
  • Page 57 11. Check and adjust the fluid level using the proce- dure under "Checking the Fluid Level." Approved Allison Transmission Lubricants Lubricant Type Temperature: °F (°C) All Allison Transmissions ™ Castrol TranSynd Above –22 (–30) (synthetic) On-Highway Transmissions (1000/2000/2400 Series) ® Dexron Above –13 (–25) AT and MD Series...
  • Page 58 Transmission 10/05/94 1. Fluid Intake Tube 5. Governor Pressure 2. Filter Spacer Tube 3. Internal Fluid Filter 6. Governor Feed Tube 4. Washer-Head Screw Fig. 3, Allison AT Series Transmission Filter 11. Submerge a new oil pan gasket in transmission fluid for five minutes.
  • Page 59 10/05/94 1. Fluid Intake Tube 2. Detent Spring 3. Detent Spring 1-3/4" Bolt 4. Filter Spacer 5. 2-1/4" Bolt (16 qty.) 6. First/Reverse Clutch Feed Tube 3" Bolt (2 qty., behind) 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.
  • Page 60 Transmission 08/25/95 1. Filter Cover 3. Filter Element O-Ring 2. Filter Element 4. Square-Cut Seal Fig. 5, Allison MD Series Transmission Filter Locations and Components CAUTION Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump.
  • Page 61 08/30/96 1. Transmission Housing 2. Transmission Oil Pan Gasket 3. 5/16–18 Washer-Head Capscrew 4. Plug 5. Transmission Oil Pan Fig. 6, Allison MT Series Transmission, Filter Removal 26/8 6. Magnet 7. Drain Plug Gasket 8. Drain Plug 9. 5/16–18 x 5/8 Capscrew 10.

  • Page 62: Checking The Fluid Level

    Transmission 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.
  • Page 63 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.
  • Page 64 Transmission 26–05 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. NOTE: Drain the transmission fluid while the transmission is warm. 2. Drain the transmission fluid. See Remove the magnetic drain plug from the bottom of the gear case.
  • Page 65 CAUTION Use only the approved Mobiltrans SHC Do not mix fluid types. Adding SHC 50 RN 2952 E-5 fluid (used in Eaton and Meritor transmis- sions) could damage the radial seals. 2. Clean the fill plug before installing it. 3. Install the fill plug (p/n N000908 020001) and a new aluminum gasket (p/n N 00763 024105).
  • Page 66 Transmission 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.
  • Page 67 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting ............. . 31–02 Fifth Wheel Lubricating.
  • Page 68 Frame and Frame Components 31–01 Frame Fastener Torque Checking Because of "bedding in" (or seating), frame fasteners must be torqued at the recommended intervals. These intervals apply to new vehicles, and to frame fasteners that have been removed and installed. NOTE: For off-highway operations, retorque frame fasteners the first 1000 miles (1600 km), then periodically, depending on operating condi-...
  • Page 69 Check the drive-axle-flange fasteners (see tightness. Tighten the fasteners as follows: 05/27/93 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.
  • Page 70 Frame and Frame Components 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.
  • Page 71 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Suspension Inspecting ............. . 32–01 Suspension Lubricating.
  • Page 72 Suspension 32–01 Suspension Inspecting Sterling 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 32of ®...
  • Page 73 Either bushing end contacts a torque arm pin mounting bolt. There are cracks in the bushing. Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve. 10/05/94 1. Upper Mounting Bracket 2. Shock Absorber 3. Lower Mounting Bracket Fig.
  • Page 74 Suspension 05/27/93 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 60-Inch Taper-Leaf Spring Component Check No lubrication is required on the 60-inch taper-leaf spring rear suspension.
  • Page 75 3. Check for any shifting of the barpin. 4. Check for cracks in the metal components and welds. NOTE: The 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 fastened dif- ferently than on other applications;...
  • Page 76 Suspension 05/27/93 1. Beam Hanger 3. Jack 2. Equalizer Beam Fig. 5, Raising the Beam End 05/27/93 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.
  • Page 77 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...
  • Page 78 Suspension WARNING 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.
  • Page 79 3. Use a click-type torque wrench to check that spring hanger bolts are tightened 190 lbf·ft (258 N·m). 4. Use a click-type torque wrench to check that the 5/8-inch torque rod clamp nuts are tightened 125 to 150 lbf·ft (170 to 203 N·m). 5.
  • Page 80 Suspension Hendrickson Spring-Eye Pins, RT and RTE Series NOTE: See Fig. 7 for this procedure. 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.
  • Page 81 Suspension 01/05/99 f320783 Fig. 12, Tightening Pattern for U-Bolt High Nuts 32/10 Acterra Maintenance Manual, September 2002...

  • Page 82: Front Axle

    Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking ............33–04 All-Wheel-Drive Front Axle Oil Changing .
  • Page 83 Front Axle 33–01 Knuckle Pin Lubricating Standard Meritor Axles 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...
  • Page 84 pand when in contact with synthetic grease. Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance. 4. Using a multipurpose grease, NLGI grade 1 or 2, lubricate the kingpins through the grease fittings on the top and bottom of the knuckle.
  • Page 85 Front Axle 1. Shut off the engine, apply the brakes, and chock the rear tires. 2. Check the tie rod boot for cracks, tears, or other damage. If the tie rod boot is damaged, replace the entire tie rod end. 3.
  • Page 86 1-1/8–12, 350 to 650 lbf·ft (475 to 881 N·m) 1-1/4–12, 500 to 675 lbf·ft (678 to 915 N·m) 10. Check the steering arm bolts for a minimum torque of 300 lbf·ft (406 N·m). If the steering arm bolt torque has fallen below this specification, remove the bolt, clean all the threads, and apply new Loctite ®...
  • Page 87 Front Axle 2. On front-wheel-drive vehicles equipped with MT- 14, MT-17, and MT-22 axles, check the oil level in the hubs. The oil drain bore must be at the bottom in order to check the oil level. See 04/10/96 A. Correct Oil Level 1.
  • Page 88 Front Axle 10/11/2001 f330186 Fig. 8, Draw Key Nut 33/6 Acterra Maintenance Manual, September 2002...

  • Page 89: Rear Axle

    Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning .
  • Page 90 Rear Axle 35–01 Axle Lubricant Level Checking 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 (see Fig.
  • Page 91 Meritor Drive Axle Lubricant Capacities, Tandem Axles Axle Model Capacity Forward 29.8 (14.1) RT–34–144 Rear 34 (16.1) 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, Meritor Drive Axle Lubricant Capacities, Tandem Axles 3.
  • Page 92 Rear Axle NOTE: Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of 2 pounds (1 kg) of low-carbon steel, in plate or bar form. Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles. Clean or change the plugs before this occurs.
  • Page 93 35–05 Two-Speed-Axle Shift Unit Oil Changing 1. Remove the shift unit housing cover (see 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.

  • Page 94: Wheels And Tires

    Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut Checking..............40–01 Acterra Maintenance Manual, March 2000...
  • Page 95 Wheels and Tires 40–01 Wheel Nut Checking IMPORTANT: In addition to the maintenance interval in this manual, check the wheel nut torque the first 50 to 100 miles (80 to 160 km) of operation after a wheel has been removed and installed.
  • Page 96 05/27/93 A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel Fig. 1, Wheel Nut and Rim Nut Tightening Sequence 40/2 C. 6-Spoke Wheel D. 5-Spoke Wheel Wheels and Tires Acterra Maintenance Manual, March 2000 f400057...
  • Page 97 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting ..............41–01 Driveline Lubricating.
  • Page 98 Driveline 41–01 Driveline Inspecting Inspecting 1. Check that the yoke-strap capscrews (see Ref. 4) are tightened as follows: Dana Spicer 1590 and 1610: 50 to 60 lbf·ft (68 to 81 N·m) Dana Spicer 1710: 125 to 135 lbf·ft (170 to 183 N·m) CAUTION Do not overtighten the yoke-strap capscrews, due...
  • Page 99 10/06/94 NOTE: Not all fasteners are shown. 1. Transmission 2. Half-Round End Yoke 3. U-Joint Assembly 4. Yoke Strap and Capscrew 5. Coupling Shaft 6. Midship Bearing and Mount 7. Bearing Cup Fig. 1, Driveline Assembly With Midship Bearing for Single-Axle Installation If the driveshaft tube requires straightening or replacement, balance the repaired driveshaft be- fore installing it.
  • Page 100 Driveline 05/27/93 Attempt to bend the sleeve yoke and splined shaft back and forth. Fig. 2, Slip-Joint Spline Wear Checking 06/13/96 A. Measurement: 3" (76 mm) B. Measurement: 0.015" (0.38 mm) C. Measurement: 0.020" (0.51 mm) D. Measurement: 0.025" (0.635 mm) Fig.
  • Page 101 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.
  • Page 102 Brakes Title of Maintenance Operation (MOP) Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC ..........42–16 Air Brake Valve Inspecting and Leak Checking, Bendix BP–R1 .
  • Page 103 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 that attach the air dryer to the vehicle.
  • Page 104 3. Clean any road grime from the relay valve and any debris from the valve exhaust port. 4. Listen for air leakage around the fittings or ex- haust port. Tighten the fittings as necessary. Use two wrenches to avoid twisting the tubing. 5.
  • Page 105 Brakes 07/27/94 A. Brakes Released C. Greater than 90 B. Brakes Applied degree angle 1. Brake Chamber 3. Slack Adjuster 2. Piston Rod Fig. 2, Angle Between Piston Rod and Slack Adjuster 2. Check each brake chamber for correct installa- tion.
  • Page 106 spring which, if released, could cause serious in- jury or death. 7. Inspect the exterior surfaces of the chamber for damage. Make sure the breather holes in the non-pressure section(s) are open and free of de- bris. Using the instructions in Group 42 of the ®...
  • Page 107 Brakes If leakage persists, use the instructions in Group 42 of the Acterra Manual to replace the service brake dia- phragm. Using soapy water, coat the area around the piston-rod bore. On some Bendix ser- vice chambers loosen the boot, if neces- sary.
  • Page 108 42–08 Camshaft Bracket Bushing Lubricating IMPORTANT: Perform MOP 42–24 cating the camshaft brackets. 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 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.
  • Page 109 Brakes 42–11 Automatic Slack Adjuster Inspecting, Meritor IMPORTANT: Perform MOP 42–24 cating the slack adjusters. 1. Remove the pull-pawl assembly. See . 2. Examine the pull-pawl assembly for grease re- tention and condition. If the grease is in good condition, install the pull-pawl assembly. Lube the slack adjuster through the grease fitting until lubricant is forced out through the inboard cam- shaft splines and the pull-pawl assembly.
  • Page 110 42–16 Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC 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.
  • Page 111 Brakes adjuster at the grease fitting until grease appears on the camshaft. 10/27/93 1. 7/16-Inch Adjusting 6. Clevis Hexnut 7. 1/2-Inch Clevis Pin 2. Grease Fitting 8. 1/4-Inch Clevis Pin 3. Boot 9. Grease Relief 4. Link Opening 5. Brake Chamber Piston 10.
  • Page 112 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.
  • Page 113 Brakes 10/28/94 1. V-Ways 2. Bleeder Fitting Fig. 9, Caliper V-Ways 12. Apply two level teaspoons of Aeroshell Grade 5 (ES1246) grease on each side of the assembly. Apply it evenly along the full length of the V-way groove and anchor plate rail, and apply one level teaspoon evenly on both sides of the key and spring.
  • Page 114 the Acterra ® Workshop Manual for inspection, troubleshooting, and repair procedures. 4. Measure the applied chamber stroke. See Table 3 for the proper stroke for the type of chamber being used. If the stroke is too short, the brakes may drag or will not fully apply. Check for improper operation or adjustment of the auto- matic slack adjuster.
  • Page 115 Brakes Manufacturer Standard Stroke Meritor Long Stroke Standard Stroke Long stroke design is indicated by a tag, or embossing, on the brake chamber. † Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers. ‡...
  • Page 116 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating ............. . . 46–02 Power Steering Gear Lubricating.
  • Page 117 Steering 46–01 Steering Driveline Lubricating Wipe the grease fittings clean. See pressure gun, apply a lithium-based grease (NLGI grade 2) sparingly to the universal joints and slip-joint splines. 46–02 Drag Link Lubricating 1. Using a clean rag, wipe the dirt from both grease fittings on the drag link.
  • Page 118 10/05/94 1. Grease Fitting 2. Drag Link (pitman arm end shown) Fig. 2, Steering Drag Link 46–03 Power Steering Reservoir Fluid Level Checking Metal Ventra Reservoir 1. Turn off the engine, apply the parking brakes, and chock the tires. 2. Open the hood. 3.
  • Page 119 Steering Plastic Ventra Reservoir NOTE: If the power steering reservoir in the ve- hicle looks like the reservoir shown in use the following procedure. 1. Turn off the engine, apply the parking brakes, and chock the tires. 10/19/2001 1. Power Steering Reservoir 2.
  • Page 120 11. Fill the reservoir with ATF 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. 12. Install a new cover gasket, the cover, and nut. Tighten the nut 28 lbf·ft (38 N·m).
  • Page 121 Steering 2. Open the hood. 3. Place a drain pan under the power steering res- ervoir. 4. Remove the retaining ring from the reservoir. Fig. 5. Remove the filter and filter cover from the reser- voir. Drain the fluid from the filter into the drain pan.
  • Page 122 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Tank Draining and Vent Checking ..........47–01 Acterra Maintenance Manual, March 2000...
  • Page 123 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.
  • Page 124 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Controls)........49–01 Acterra Maintenance Manual, January 2007...
  • Page 125 Exhaust 49–01 Exhaust System Inspecting (Noise Emission Controls) NOTE: In addition to the maintenance interval in this manual, inspect the exhaust system if the vehicle has a noticeable increase in noise level at any time. Replace parts that show leakage, wear, or damage.
  • Page 126 10/20/2006 A. Inspect this area of the canister for dents. 1. Marmon Fitting at Inlet from Turbocharger 2. DOC Temperature Sensor 3. ATD Mounting Band 4. DPF Intake Pressure Sensor 5. DPF V-Band Mounting Clamps Diesel Particulate Filter (DPF)—a filter that col- lects and holds particulate matter (soot and ash).
  • Page 127 Exhaust 9. Check any wires, lines, or hoses within 4 inches (10 cm) of the exhaust system for heat damage. Repair or reroute as needed. Acterra Maintenance Manual, January 2007 49/3...

  • Page 128: Electrical, Instruments, And Controls

    Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Coolant Level Sensor Cleaning............54–02 Electrical System Checking.
  • Page 129 Electrical, Instruments, and Controls 54–01 Electrical System Checking 1. Uncover the electrical panel (see moving the fasteners. 10/05/94 1. Flasher 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.
  • Page 130 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 until the metal is exposed.
  • Page 131 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Weatherstrip, Door Latch, and Door Hinge Lubricating........72–01 Acterra Maintenance Manual, March 2000...
  • Page 132 Doors 72–01 Weatherstrip, Door Latch, and Door Hinge Lubricating Lightly coat door weatherstrips with a lubricant that is safe (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 on the door latch mecha- nism.

  • Page 133: Heater And Air Conditioner

    Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting............83–01 HVAC Air Filter Replacing.
  • Page 134 Heater and Air Conditioner 83–01 Air Conditioner Inspecting WARNING Wear eye protection, gloves, and protective cloth- ing when working on the air conditioning system. Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns. Preliminary Checks 1.
  • Page 135 Heater and Air Conditioner 7. Close the hood. 8. Remove the chocks from the tires. f831564 02/17/2003 1. Screw 2. Filter Cover Fig. 2, Air Filter Replacement 83/2 Acterra Maintenance Manual, October 2008...

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