freightliner 108SD 2021 Driver Manual
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freightliner 108SD 2021 Driver Manual

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108SD and 114SD
Driver's Manual
Maintenance Manual

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  • Page 1 108SD and 114SD Driver’s Manual Maintenance Manual...
  • Page 2 108SD AND 114SD MAINTENANCE MANUAL Models: 108SD 114SD STI-496-7 (09/20/2021) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 4 IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice.
  • Page 5 © 2011–2022 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC.
  • Page 6 EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 7 Introduction Descriptions of Service Publications Warranty-related service information available on the www.DTNAConnect.com website includes the following documentation. 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 8 Introduction Page Description For an example of a 108SD and 114SD Maintenance Manual page, see Fig. Transmission 26−01 Transmission Fluid Clean the fill plug, then install it. Tighten the plug as follows: Level Check 25 to 35 lbf·ft (34 to 48 N·m) for transmis− sions with 3/4−inch pipe threads.
  • Page 9 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 10: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number 00–01 Determining Scheduled Maintenance Intervals ........00–01 00–02 Initial Maintenance (IM) Operations.

  • Page 12: Determining Scheduled Maintenance Intervals

    General Information 00–01 Determining Scheduled Maintenance Intervals • operation primarily in cities and densely popu- Determining Scheduled lated areas Maintenance Intervals • local transport with infrequent freeway travel • high percentage of stop-and-go travel Performing regular maintenance will help ensure that your vehicle delivers safe, reliable service and opti- Schedule lll (long-haul transport) applies to vehicles mum performance.
  • Page 13 General Information 00–01 Determining Scheduled Maintenance Intervals Maintenance Schedules Maintenance Intervals Schedule Maintenance Interval Frequency Mileage Hours Initial Maintenance (IM) first 1000 1600 Maintenance 1 (M1) every 1000 1600 Schedule I (severe service) Maintenance 2 (M2) every 4000 6400 for vehicles that travel up to Maintenance 3 (M3) every 8000...

  • Page 14: Initial Maintenance (Im) Operations

    General Information 00–02 Initial Maintenance (IM) Operations Table 2 lists all maintenance operations that are to formed. All operations listed in Table 2, along with be performed at the initial maintenance (IM) interval. the operations listed in the M1 Maintenance Interval Maintenance operation numbers are reference num- Operations table (Table...

  • Page 15: M1 Maintenance Interval Operations

    General Information 00–03 M1 Maintenance Interval Operations Table 3 lists all maintenance operations that are to IMPORTANT: After performing all operations listed in be performed at the M1 maintenance interval. Main- this table, perform all daily, weekly, and monthly tenance operation numbers are reference numbers maintenance operations given in Chapter 21, "Pretrip used to help you find detailed instructions in this and Post-Trip Inspections and Maintenance", of the...
  • Page 16 General Information 00–03 M1 Maintenance Interval Operations M1 Maintenance Interval Operations Number Title 60-02 Aerodynamic Component Inspection 72-01 Door Seals Lubrication 83-01 Air Conditioner Inspection 88-01 Hood Rear Support Lubrication For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule I vehicles;...

  • Page 17: M2 Maintenance Interval Operations

    General Information 00–04 M2 Maintenance Interval Operations Table 4 lists all maintenance operations that are to manual on the maintenance operations to be per- be performed at the M2 maintenance interval. Main- formed. Perform all M1 maintenance interval opera- tenance operation numbers are reference numbers tions (see Table 3) at the M2 maintenance interval.

  • Page 18: M3 Maintenance Interval Operations

    General Information 00–05 M3 Maintenance Interval Operations Table 5 lists all maintenance operations that are to manual on the maintenance operations to be per- be performed at the M3 maintenance interval. Main- formed. Perform all M1 (Table 3) and M2 (Table tenance operation numbers are reference numbers maintenance interval operations at the M3 mainte-...

  • Page 19: M4 Maintenance Interval Operations

    General Information 00–06 M4 Maintenance Interval Operations Table 6 lists all maintenance operations that are to manual on the maintenance operations to be per- be performed at the M4 maintenance interval. Main- formed. Perform all M1 (Table 3), M2 (Table 4), and tenance operation numbers are reference numbers (Table...

  • Page 20: M5 Maintenance Interval Operations

    General Information 00–07 M5 Maintenance Interval Operations Table 7 lists all maintenance operations that are to manual on the maintenance operations to be per- be performed at the M5 maintenance interval. Main- formed. Perform all M1 (Table 3), M2 (Table 4), M3 tenance operation numbers are reference numbers (Table...

  • Page 21: Maintenance Sequence And Log

    General Information 00–08 Maintenance Sequence and Log Maintenance Sequence for Schedule I Maintenance Maintenance Interval Service Date Miles Hours Sequence IM and M1 1000 1600 2000 3200 3000 4800 M1 and M2 4000 6400 5000 8000 6000 9600 7000 11 200 M1, M2, and M3 8000 12 800...
  • Page 22 General Information 00–08 Maintenance Sequence and Log Maintenance Sequence for Schedule II Maintenance Maintenance Interval Service Date Miles Sequence IM and M1 8000 12 000 M1 and M2 16,000 24 000 24,000 36 000 M1, M2, and M3 32,000 48 000 40,000 60 000 M1 and M2...
  • Page 23 General Information 00–08 Maintenance Sequence and Log Maintenance Sequence for Schedule III Maintenance Maintenance Interval Service Date Miles Sequence IM and M1 25,000 40,200 M1 ,M2 and M3 50,000 80,400 75,000 120,600 M1, M2, M3 and M4 100,000 160,800 125,000 201,000 M1, M2 and M3 150,000...

  • Page 24: Noise Emission Controls

    Maintenance Instructions sure that such parts are warranted by their manufac- turer to be equivalent to genuine Freightliner parts in performance and durability. Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups Freightliner Noise Emission 01, 20, and 49)"...

  • Page 25: Verification Of Inspections Log

    General Information 00–10 Verification of Inspections Log Verification of Inspections Log The "Verification of Inspections Log" should be filled out each time the vehicle’s noise emission controls are maintained or repaired. Verification of Inspections Log, Group 20 Verification of Inspections Log, Group 20, Engine Cooling/Radiator Date Mileage Item...
  • Page 26 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspection............01–01 Safety Precautions .
  • Page 28 Engine 01–00 Safety Precautions 4. Check the belt for a jagged or streaked sidewall. Jagged or streaked sidewalls are the result of foreign objects, such as sand or gravel in the Safety Precautions in this section apply to all pulley, or a rough pulley surface. procedures within this group.
  • Page 29 Engine 01/18/2010 f151148 1. Abrasion 4. Cracking 7. Misalignment 2. Chunk-out 5. Pilling 8. Gravel Penetration 3. Improper Install 6. Uneven Rib Wear Fig. 1, Damaged Belts 01/2 108SD and 114SD Maintenance Manual, September 2015...
  • Page 30 Engine 09/21/2009 f012181 A. New Belt B. Worn Belt C. Material loss results in belt riding directly on pulley tips. Fig. 2, Six-Rib Serpentine Belt (cross section view) 01/24/2011 f012192 01/19/2012 f012189 1. Spring Tensioner 4. Fan Clutch 1. Front Belt 4.
  • Page 32 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 108SD and 114SD Maintenance Manual, November 2014...
  • Page 34 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash- mounted restriction gauge.
  • Page 36 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 38 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 40 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 42 Alternators and Starters 15–00 Safety Precautions 5. Check that all electrical connections at the alter- nator and starter are free of corrosion. Clean and tighten all charging system electrical connec- Safety Precautions in this section apply to all tions, including the connections at the starter B+ procedures within this group.
  • Page 44 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Drive Check (Noise Emission Control) ..........20–03 Radiator Cap Inspection .
  • Page 46 Engine Cooling/Radiator 20–00 Safety Precautions supported when the system cools. Inspect the vacuum-relief valve to be sure it is not stuck. Safety Precautions in this section apply to all 3. Make sure that the cap seals properly on the coolant filler neck seat, and that the radiator cap procedures within this group.
  • Page 47 Engine Cooling/Radiator 4. Drain the radiator, then flush the radiator until cessive wear, rebuild the hub using a hub rebuild clean water flows from it. Remove the flushing kit from Kysor. gun. 6. Any time the clutch is removed for repair or re- 5.
  • Page 48 Engine Cooling/Radiator Clean the filter element with cleaning sol- 11.1 Turn the fan in both directions and feel vent. for worn hub bearings. Using a clean, lint-free cloth, wipe off any 11.2 If possible, remove the drive belt and excess solvent. check for worn sheave bearings by turn- ing the sheave in both directions.
  • Page 50 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Adjustment, Manually Adjusted Clutches..........25–05 Eaton Fuller Clutch Release Bearing Lubrication .

  • Page 52: Eaton Fuller Clutch Release Bearing Lubrication

    Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.

  • Page 53: Eaton Fuller Clutch Release Cross-Shaft Lubrication

    Clutch 25–02 Eaton Fuller Clutch hydraulic system will not operate correctly, and the clutch could be damaged. Release Cross-Shaft If the fluid level is below the MIN line, fill the reser- Lubrication voir with new DOT 4 brake fluid from a tightly sealed container until the level reaches the MAX line.
  • Page 54 Clutch so it does not fall off when fluid is WARNING pumped out. Open the bleed valve on the slave cylin- Hydraulic clutch control fluid (DOT 4 brake fluid) der. is hazardous. It may be a skin irritant and can cause blindness if it gets in your eyes.
  • Page 55 Clutch transparent drain hose connected to a catch bottle. The hose needs to fit the bleed valve tight enough so it does not fall off when fluid is pumped out. NOTE: The following steps require two people – one in the cab to work the clutch pedal, and one to open and close the bleed valve and watch the fluid.
  • Page 56 Clutch 03/26/96 f580133 A. Green End (0.50 inch or 12.7 mm) B. Blue End (0.56 inch or 14.3 mm) 11/29/2010 f250683 Fig. 7, Release Bearing Travel Tool A02-12419-000 Fig. 9, Manual Adjustment, Easy-Pedal Clutch (shown with bell housing removed) Normal wear increases the gap between the release bearing and the transmission.
  • Page 58 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Change..........26–04 Allison and Eaton Fuller Transmission Breather Check .

  • Page 60: Safety Precautions

    Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock A. Full B. Low the tires. Before working under the vehicle, always Fig.
  • Page 61 Transmission It is important to check the fluid level cold to deter- 5. Insert the dipstick into the tube, then remove it. mine if the transmission has a sufficient amount of 6. Check the fluid level reading, then repeat the fluid to be safely operated until a hot check can be check procedure to verify the reading.
  • Page 62 Transmission 2. Park the vehicle on level ground, apply the park- Once the filter makes contact with the ing brakes, shift the transmission to neutral (N), mount, use a strap wrench to rotate the shut down the engine, and chock the tires. canister an additional 180 to 270 degrees to firmly tighten the filter.
  • Page 63 Transmission wrench can crush or damage the breather stem and Eaton Fuller Transmission Lubricant Capacities produce metal particles that could enter the transmis- Transmission Model sion). Capacity: qt (L) Prefix Number Check more often if the vehicle is operating under †...
  • Page 64 Transmission NOTICE 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. Engine coolant in the transmission hydraulic sys- tem requires immediate action to prevent malfunc- tion and possible serious transmission damage.
  • Page 65 Transmission 10. Install six capscrews in each cover, and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m). 11. Install a new drain plug O-ring, and install the drain plug. Tighten the drain plug 18 to 24 lbf·ft (25 to 32 N·m).
  • Page 66 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–02 Fifth Wheel Lubrication.
  • Page 68 Frame and Frame Components • exhaust brackets 31–00 Safety Precautions • fifth wheel legs Safety Precautions in this section apply to all • fifth wheel mountings procedures within this group. • frame crossmembers and gussets • front frame brackets DANGER •...
  • Page 69 Frame and Frame Components 4. When the wheel is locked, the safety latch must 7. Check all mounting bolts for signs of fatigue, and swing free and fall freely into position. See tighten them to the proper torque. For torque Fig.
  • Page 70 Frame and Frame Components 10.1 Close the fifth wheel on a standard 2-inch (50-mm) kingpin or similar 2-inch (50-mm) diameter shaft so that it locks. 10.2 Push on the wedge stop rod with hand pressure. It should move in 1/4 inch (6 mm) and spring back out on release.
  • Page 71 Frame and Frame Components 12/02/2010 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Bumper 2. Flat Washer, 5/8" 12. Flat Washer 20. Timer Spring 3. Wedge Stop Rod Spring 13.
  • Page 72 Frame and Frame Components 09/01/2009 f311101 Fig. 5, Bracket Pin Bolt Locking Tabs The lock is properly adjusted if: the wheel locks and unlocks easily each time and the lock tester rotates freely. The lock is too loose if: you feel fore-aft play when pulling and pushing on the lock tester handle.
  • Page 73 Frame and Frame Components plate to fill the grooves, or depressions, on the top plate. See MOP 31–03 for lubrication instruc- tions. 31–03 Fifth Wheel Lubrication To maintain proper fifth wheel operation, always lubri- cate the fifth wheel after an inspection has been performed.
  • Page 74 Frame and Frame Components NOTE: Do not use a lube plate (high density polyethylene) on top of the fifth wheel or on the kingpin instead of grease without prior approval by Fontaine Fifth Wheel. The additional thick- ness of this material can prevent the proper op- eration of the fifth wheel and may cause a dan- gerous condition.
  • Page 75 Frame and Frame Components wheel; see Fig. 7. Apply a light oil to all moving parts. For sliding fifth wheels spray diesel fuel on the slide path of the base plate. NOTICE Do not use a power grease gun. The pressure will damage the lube line.
  • Page 76 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 78: Safety Precautions

    Workshop Manual for replacement instructions. procedures within this group. Rear Suspension Check DANGER Freightliner Spring Suspension When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock WARNING the tires. Before working under the vehicle, always...
  • Page 79 2. If Fig. 3, Top View of the Equalizer movement at the center of the equalizer exceeds Freightliner AirLiner Suspension 1/8 inch (3 mm), replace the equalizer bushings. See Group 32 of the 108SD and 114SD Work- shop Manual for instructions.
  • Page 80 See Group 32 of the 108SD and 114SD Workshop Check Manual for instructions. NOTE: The Freightliner AirLiner Suspension is Freightliner AirLiner Component manufactured at numerous weight ratings. The Inspection and Operation Check control rod on the 46,000-pound-rated suspen- sion is larger, and is fastened differently than on other applications.
  • Page 81 2. Mark the location of the front and rear tires on chocks. the floor, and chock the tires on one axle only. Freightliner TufTrac 3. Check that the height-control valve vertical link- age is connected and oriented correctly. 1. Inspect the suspension spring assemblies for...

  • Page 82: Suspension Lubrication

    Chalmers Suspension 32–02 Suspension Lubrication 1. Chock the front tires, place the transmission in neutral, and release the parking brakes. Freightliner Spring Front 2. Power wash the suspension, or clean it with a hard-bristle brush before performing a visual in- Suspension spection.

  • Page 83: Suspension U-Bolt Torque Check

    2. Raise the rear of the vehicle until the rear wheels Freightliner Spring Rear are suspended in the air, then support the ve- Suspension hicle with safety stands. This relieves the load on the bushings and pins to allow the proper flow of...
  • Page 84 Suspension 10/05/2016 f320783 Fig. 8, Tightening Pattern for U-Bolt High Nuts Spring Assembly U-Bolt High Nut Torque Values Size Torque: lbf·ft (N·m) Stage 1: Hand-tighten 09/15/95 f320424 Stage 2: 60 (81) 1. Bronze Bushing 3. Grease Fitting 5/8–18 Stage 3: 200 (271) 2.
  • Page 86 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alignment Check ..............33–04 Knuckle Pin Lubrication .

  • Page 88: Knuckle Pin Lubrication

    Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.

  • Page 89: Tie Rod Inspection

    Front Axle 11/21/95 f330129 A. Grease exits 1. Grease Fitting 09/06/96 f320032a Fig. 3, Dana Spicer Knuckle Pin Lubrication A. Grease Exits 1. Grease Fitting grease, NLGI Grade 2 (8% 12-hydroxy lithium stear- ate grease), until new grease is seen at the bushing Fig.

  • Page 90: Tie Rod Lubrication

    Front Axle Then center the cross tube between the stop po- rod ends are threaded in the cross tube past the sitions. If the cross tube does not rotate in either clamps and the slots at the cross tube ends. direction, replace both tie rod ends.
  • Page 91 (see Fig. 9) and adjust the scale end so that the equipment manufacturer. Freightliner dealers must pointers line up with the scribe lines. See have proof of this calibration history. Fig.

  • Page 92: Wheel End Inspection, Front Axle

    Front Axle WARNING Never work around or under a vehicle that is sup- ported only by a jack. Always support the vehicle with safety stands. Jacks can slip, causing the vehicle to fall, which could result in serious injury or death. 2.
  • Page 93 Front Axle 114SD Workshop Manual and manufac- WARNING turer literature for procedures. Correct wheel-bearing end play is crucial to the safe and sound operation of the vehicle. If the end play is not correct, the wheel bearings could fail and cause the loss of the wheel and hub assem- bly and result in an accident causing property damage, serious injury, or death.
  • Page 94 Front Axle 33–06 Steer Axle Hub Cap Vent Plug Inspection General Information As a function of their design, hubcap vent plugs will on occasion exhibit signs of hub oil on their exterior surface. Depending on environmental conditions and/or age of the plug, the amount of oil present can vary.
  • Page 95 Front Axle clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes.
  • Page 96 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Check ............. . . 35–02 Axle Lubricant Level Check .
  • Page 98 Rear Axle 35–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 99 Rear Axle For Dana Spicer axles, see Table 6 for approved axle lubricants, and Table 7 for axle capacities. 5. Install the oil fill hole plug and tighten it per the following: • For Detroit axles: 30 lbf·ft (41 N·m). •...
  • Page 100 Rear Axle 35–02 Axle Breather Check Detroit Drive Axle Lubricants IMPORTANT: Lubricant used in Detroit rear axles must The axle housing breather must remain clean. When meet Mercedes-Benz specification 235.20 (mineral) or the axle lubricant level is checked, check that the 235.8 (synthetic).
  • Page 101 Rear Axle Meritor Drive Axle Lubricant Capacities for Single Meritor Drive Axle Lubricant Capacities for Tandem Axles Axles Capacity Capacity: Axle Model Axle Model Axle Position Pints (liters) Pints (liters) RS–23–160 39.5 (18.7) Forward 56.1 (26.5) RT–58–185 RS–23–161 37.2 (17.6) Rear 36.1 (17.1) RS–23–186...
  • Page 102 Rear Axle maintenance tables. Failure to do so could result Check the fluid level; see Fig. in axle damage. Install and tighten the fill plug 30 lbf·ft (41 N·m). Detroit Axles Meritor Axles 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake.
  • Page 103 Rear Axle 7. Whenever the interaxle differential housing has been drained, add an additional 2 pints (0.9 L) of the recommended lubricant directly into the inter- axle differential housing. 8. Remove the chocks, then drive the vehicle, un- loaded, for 1 or 2 miles (2 or 3 km) at speeds not to exceed 25 mph (40 km/h), to thoroughly circulate lubricant throughout the carrier and housing assemblies.
  • Page 104 Rear Axle 6. Fill the axle with the recommended lubricant as follows. See Table 6 for recommended lubri- cants, and Table 7 for drive axle lubricant ca- pacities. With the vehicle on a level surface, fill the axle through the oil fill hole. Lubricant should be level with the bottom of the oil fill hole.
  • Page 105 Rear Axle release the hub, an accurate measurement 9. Inspect the lubricant for discoloration. Under nor- mal conditions, the lubricant will darken; a white is not possible. or milky appearance indicates water contamina- 12.2 To seat the bearings, grip the hub at the tion.
  • Page 106 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Check.
  • Page 108 Wheels and Tires 40–01 Wheel Nut Check IMPORTANT: After a wheel has been installed, the wheel nut torque must be rechecked after 50 to 100 miles (80 to 160 km) of operation. NOTICE Insufficient wheel nut (rim nut) torque can cause 09/18/2001 f400164 wheel shimmy, resulting in wheel damage, stud...
  • Page 110 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 112 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 113 Driveline 6. Check slip joints for spline wear by moving the sleeve-yoke and splined shaft back and forth; Fig. 3. If the slip joint can be twisted in a clockwise, or counterclockwise movement greater than 0.007 inch (0.18 mm), replace both the sleeve-yoke and the splined shaft.
  • Page 114 Driveline 12/08/2010 f410067c NOTE: Not all fasteners are shown. 1. Transmission 6. U-Joint Cross 11. Dust Cap 2. Transmission Output-Shaft 7. Bearing Cup (for half-round 12. Splined Stub Shaft End-Yoke (half-round) yoke) 13. Driveshaft Tube 3. U-Joint Assembly 8. Bearing Strap and Bearing- 14.
  • Page 115 Driveline 10/06/2016 f410182 10/06/2016 f410012a Attempt to move the sleeve-yoke and splined shaft back Fig. 5, Meritor RPL Series U-Joint and forth. Fig. 3, Slip Joint Spline Wear Checking 10/06/2016 f410155a 10/07/2016 f410050a 1. Self-Locking Capscrew A. After grease appears, cover the pressure-relief hole 2.
  • Page 116 Driveline 7. Wipe the purged grease from the seals, and any excess grease from the grease fitting. Slip Joint Spline Lubrication NOTE: Vehicles equipped with Meritor RPL Se- ries drivelines do not require periodic lubrication. 1. If equipped with a grease fitting, wipe all old grease and dirt from the slip joint grease fitting;...
  • Page 118 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake Inspection and Leak Test........... . . 42–09 Air Brake System Valve Inspection .

  • Page 120: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all 5. Loosen the bolt that secures the upper mounting bracket strap. procedures within this group. 6. Remove the two bolts and Nylok® nuts that se- DANGER cure the air dryer to the lower mounting bracket.
  • Page 121 Brakes 08/09/95 f421383 1. 5/16 x 4-1/2 Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Bolt 10. O-Ring 19. 1/4-Inch Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. Lockwasher 12. Lower Mounting Bracket 21.
  • Page 122 Brakes spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury. 4. Remove and discard both O-rings from the car- tridge bolt. 5. Using a clean rag, wipe clean the inside of the end cover.
  • Page 123 Brakes 42–03 Governor Check 12.4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover. With the com- IMPORTANT: Review the warranty policy before pressor in loaded mode (compressing performing any intrusive maintenance proce- air), apply a soapy solution to these dures.

  • Page 124: Air Dryer Check

    Brakes When proper adjustment is obtained, An outside air source has been used to tighten the adjusting screw locknut, and charge the system. This air did not pass install the top cover. The pressure range through the drying bed. between cut-in and cut-out is not adjust- Air usage is exceptionally high and not able.

  • Page 125: Brake Inspection

    Brakes 4. Build system pressure to governor cutout, and 109±5 psi (751±34 kPa), then level off (or a mo- note that the dryer purges with an audible es- mentary slight fall) as the second pressure pro- cape of air. Fan the service brakes to reduce tection valve opens supplying the secondary res- system air pressure to governor cut-in.
  • Page 126 4. If they do not turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that wheel end replaced. Due to limited caliper bolt access, it may be necessary to use tool DDC DSN- CHA018005 referenced in tool letter 18TL18.
  • Page 127 If they turn, take 1. Park the vehicle on a level surface, shut down the vehicle to an authorized Freightliner dealer to the engine, and set the parking brake. Chock the have all of the caliper bolts on that wheel end tires.
  • Page 128 If they turn, take turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner dealer to the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that wheel end have all of the caliper bolts on that wheel end replaced.
  • Page 129 Brakes 07/30/2018 f422655 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 7, Meritor Radial Mounted Caliper Tightening Pattern 5. Install the wheel assemblies. For instructions, ponents. Improperly maintaining the vehicle brak- see Group 40 of the 108SD and 114SD Work- ing system may lead to brake failure, resulting in shop Manual.
  • Page 130 Brakes 07/30/2018 f422657 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 8, Wabco Maxxus Radial Mounted Caliper Tightening Pattern for improper operation or adjustment of the auto- 5. Check all of the foundation brake components for matic slack adjuster.
  • Page 131 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (45) 2 (51) Gunite ‡ 2-1/4 (57) 2 (51) Long Stroke 2-1/2 (64) 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke...
  • Page 132 Brakes 42–06 Slack Adjuster Lubrication IMPORTANT: Perform MOP 42-05 before lubri- cating the slack adjusters. Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation. WARNING Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure, resulting in property damage, personal injury, or death.

  • Page 133: Meritor Camshaft Bracket Lubrication

    Brakes 02/01/2001 f421649a 1. Grease Fitting 2. Slack Adjuster Fig. 10, Haldex Slack Adjuster Grease Fitting 10/27/93 f420653a 42–07 Meritor Camshaft 1. 7/16-Inch Adjusting Nut 2. Grease Fitting Bracket Lubrication 3. Boot 4. Link 5. Brake Chamber Piston Rod IMPORTANT: Perform MOP 42-05 before lubri- 6.
  • Page 134 Brakes 2. Remove the roll pin from the brake pedal pivot pin. See Fig. 10/07/2016 f420011a A. Grease Exit 1. Brake Chamber 2. Slack Adjuster 3. Non-Pressure-Relief Grease Fitting Fig. 12, Camshaft Bracket Lubrication 11/01/2016 f430405 1. Foot-Control Valve, 5. Roll Pin 6.
  • Page 135 Brakes 11. Install the brake pedal with the pivot pin. 11. If necessary, start the engine and charge the air system. Shut down the engine and release the 12. Install a new roll pin, then apply Torque Seal parking brakes. (OPG F900 White) to the roll pin.
  • Page 136 Brakes 42–10 WABCO System Saver pressure at which the knob automatically comes out. This pressure should be 20 to 45 psi (138 to Air Dryer Desiccant 310 kPa). Cartridge Replacement 18. Close the drain cocks, recharge the system, and completely drain the primary reservoir. On ve- hicles equipped with a DRM or AD-IS with the air NOTE: The following instructions apply to the dryer attached to the reservoir, the secondary...

  • Page 137: Versajust Slack Adjuster Inspection And Lubrication

    Brakes 2. Using a strap wrench, turn the desiccant car- any components are damaged, repair or replace tridge counterclockwise and remove it. them as necessary. 3. Remove and discard the O-ring. 3. Measure the brake actuator pushrod stroke while making an 80 to 90 psi (552 to 621 kPa) brake 4.
  • Page 138 Brakes of air should occur from the exhaust port of the drain valve. If no air comes out, push the wire stem lo- cated inside the exhaust port. If no air comes out after pushing the wire stem, there may be a plugged filter in the adapter which should be replaced.
  • Page 140 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .
  • Page 142 Steering 46–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 143 Steering NOTE: Always install a new power steering res- 3. Remove the retaining ring from the reservoir. Fig. ervoir filter when changing the fluid. 11. Disconnect the filter from the filter cover, and dis- card the filter. 12. Apply a thin film of power steering fluid on the gasket of the new filter.
  • Page 144 Steering 46–04 Power Steering Gear grease) or NLGI Grade 1 (6% 12-hydroxy lithium stearate grease). Grade 2 is preferred. Lubrication TRW TAS and THP Series Sector Shaft NOTICE Apply grease to the sector shaft with a hand-type grease gun only. Use of a high-pressure power 10/07/2016 f461072 grease gun will supply grease too quickly and...
  • Page 146 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Cylinder Inspection............47–08 CNG Fuel System Inspection .
  • Page 148 Fuel 47–00 Safety Precautions 1. Shut down the engine, apply the parking brakes, and chock the tires. Open the hood. Safety Precautions in this section apply to all 2. Place a suitable container under the fuel/water separator. procedures within this group. IMPORTANT: When draining fluid from a DANGER fuel/water separator, drain the fluid into an ap-...
  • Page 149 Fuel DAVCO Fuel Pro® 382 and 482 NOTE: In the event of an emergency, when the filter needs replacement but a DAVCO filter is not available, a temporary filter can be used; see Chapter 24 of the 108SD and 114SD Driver’s Manual for instructions.
  • Page 150 Fuel FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 3, DAVCO Collar Wrench During installation, the vent cap is to be hand- tightened only, not tightened with a wrench. Use part number 482017 on Fuel Pro 482 units; part number 380134 on Fuel Pro 382 units. 6.
  • Page 151 Fuel increase engine speed to high idle for one to two minutes to purge air from the system. 11.5 While the engine is running, and after the air is purged from the system, loosen the vent cap until the fuel level falls to about one inch (2.5 cm) above the collar, then hand-tighten the vent cap.
  • Page 152 Fuel 5. Using a DAVCO Collar Wrench, shown in Fig. remove the clear cover and collar. NOTE: Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Collar Wrench (part number 482017) is used for removal.
  • Page 153 Fuel 9. Install the clear cover and the collar. Simultane- ously apply downward pressure to the top of the clear cover until it is seated on the body of the lower housing and hand tighten the collar until it no longer spins freely. Using the collar wrench, tighten the cover 18 lbf·ft (24 N·m).
  • Page 154 Fuel 10. If equipped with a primer pump, prime the cleared of any cleaning fumes. Harsh chemicals fuel/water separator as follows. and extremely high temperatures may damage the sensor. 10.1 Loosen the vent plug. Then operate the primer pump until the fuel purges at the The following inspections must be performed by a vent plug.
  • Page 155 Fuel 3. Ensure that all rubber isolator straps are present and secure. 4. Look for signs of abrasion between the fuel tank and mounting brackets. 5. Inspect the fuel fill fitting for signs of damage or leaks. Ensure the fuel fill cap is present and in good condition, and the fitting is mounted se- curely on the tank.
  • Page 156 Fuel 4. Turn the ignition switch to the ON position and 4. Inspect all fittings for leaks. check for fuel gauge response. 5. Inspect the fuel shutoff solenoid valve for signs 5. Repair or replace any damaged fuel gauge of leaks or damage. Inspect the solenoid mount- components.
  • Page 157 Fuel Inspect the pressure gauge for damage. 3. Inspect the fuel tank for signs of frost spots or Ensure that the gauge sight glass is clear outer surface sweating. Frosting or condensation and legible. on the outer surface of the fuel tank may indicate a loss of vacuum.
  • Page 158 Fuel on the frontwall. The sensors are located in high areas, where rising gas vapors will pass by or ac- cumulate. Do not use a high-pressure washer, steam cleaner, or silicone-based chemicals on the gas detection sensors, as this may permanently disable the sensors.
  • Page 159 Fuel CYLINDERS INSPECT CYLINDERS EVERY 36 MONTHS OR 36000 MILES WHICHEVER OCCURS FIRST REGULATOR INSPECT PRESSURE NATURAL RELIEF DEVICE EVERY 2000 MILES VEHICLE 110 PSIG OPEN VALVE FILTER SLOWLY DRAIN HOUSING EVERY 1500 MILES 3600 PSIG MAX. REPLACE ELEMENT SERVICE PRESSURE EVERY 3000 MILES 04/30/2010 f470556...
  • Page 160 Fuel 05/04/2010 f470558 1. Coolant Inlet Port 9. Fuel Fill Port 2. Coolant Outlet Port 10. Filter Housing 3. Pressure Relief Valve 11. Filter Bowl 4. Pressure Regulator 12. Filter Drain Plug 5. Wiring Harness 13. Solenoid Valve 6. Manifold Bleed Valve 14.
  • Page 162 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspection (Noise Emission Control)........49–01 Safety Precautions .
  • Page 164 ATD inlet that en- system if the noise level of the vehicle has in- hances the oxidation of hydrocarbons in order creased. Freightliner Trucks recommends replacing to reduce particulate emissions. parts that show leakage, wear, or damage, with •...
  • Page 165 Exhaust shooting components is not necessary unless Inspection there is a system failure or a fault code. Model year 2007 and later diesel engines in vehicles 6. Check the DEF tank, pump, metering unit, and domiciled in the U.S. or Canada are required to meet lines for leaks.
  • Page 166 Exhaust 08/20/2009 f490355 NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the DOC inlet pressure sensor. 1. DOC Outlet Temperature 6. Exhaust Outlet 11. SCR Outlet NOx Sensor Port Sensor 7.
  • Page 167 Exhaust 09/16/2009 f490353 1. DEF Metering Unit 5. DOC Inlet Temperature Sensor 9. DPF Outlet Temperature 2. DEF Nozzle 6. DOC Inlet Pressure Sensor Sensor 3. SCR Outlet Temperature 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor Sensor 8.
  • Page 168 Exhaust 02/22/2011 f490354a 1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 10. SCR Outlet Temperature 2. DOC Inlet Temperature Sensor Sensor Sensor 3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 11. SCR Sensor Box 4. DPF Sensor Box 8.
  • Page 169 Exhaust 02/01/2011 f490449 1. ATD 5. SCR Outlet Temperature 9. DPF Inlet Temperature Sensor 2. Mixer Tube Sensor 10. DPF Inlet Pressure Sensor 3. DEF Injector 6. SCR Inlet Temperature Sensor 11. DPF Outlet Temperature 4. NOx Sensor 7. SCR Catalyst Sensor 8.
  • Page 170 Exhaust 02/01/2011 f490450 1. ATD 5. DEF Injector 9. SCR Inlet Temperature Sensor 2. DOC Inlet Temperature Sensor 6. NOx Sensor 10. Mixer Tube 3. DPF Inlet Temperature Sensor 7. SCR Outlet Temperature 11. DPF Outlet Pressure Sensor 4. DPF Outlet Temperature Sensor 12.
  • Page 171 Exhaust 02/01/2011 f490448 1. ATD 6. DEF Injector 10. DOC Inlet Temperature Sensor 2. NOx Sensor 7. Mixer Tube 11. DPF Inlet Temperature Sensor 3. SCR Catalyst 8. SCR Inlet Temperature Sensor 12. DPF Outlet Temperature 4. DPF Outlet Pressure Sensor 9.
  • Page 172 Electrical, Instruments and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Component Inspection ............54–02 Trailer Cable Inspection and Cleaning.
  • Page 174 Electrical, Instruments and Controls 54–01 Trailer Cable Inspection component failure. When it is determined that a cover has not properly prevented moisture and and Cleaning debris from entering the component, the entire component must be replaced. 1. Disconnect the trailer electrical cables from the 6.
  • Page 175 Electrical, Instruments and Controls such as CRC QD® Electronic Cleaner, inspect terminals and mating contact terminal plating. If the terminal plating exhibits signs of unrecover- able corrosion, the component and terminal will need to be replaced. 10. Inspect sealed harness connectors for presence of connector housing seals and connector pin seals designed to keep moisture and debris from entering the connector and component.
  • Page 176 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–02 Mirror Folding Check .
  • Page 178 60–01 Mirror Folding Check For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror.
  • Page 180 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seals Lubrication ............. . 72–01 108SD and 114SD Maintenance Manual, April 2011...
  • Page 182 Doors 72–01 Door Seals Lubrication NOTE: Only the door seals require lubrication. Do not lubricate the door latches or hinges. They come from the manufacturer with lifetime lubrication and require no maintenance. Lightly coat the door seals with a lubricant that is safe for rubber.
  • Page 184 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 HVAC Air Filter Replacement .
  • Page 186 Heater and Air Conditioner 83–00 Safety Precautions as necessary. For instructions, see Section 83.02, Subject 140 of the 108SD and 114SD Workshop Manual. Safety Precautions in this section apply to all 8. Check that the wiring harness connector is not procedures within this group.
  • Page 187 Heater and Air Conditioner 10/04/2001 f543921 1. Evaporator 2. Filter Fig. 1, HVAC Assembly Filter 83/2 108SD and 114SD Maintenance Manual, September 2015...
  • Page 188 Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication............88–01 108SD and 114SD Maintenance Manual, April 2011...
  • Page 190 Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 1. Apply the parking brakes and chock the tires. 2. Open the hood. 3. Clean both the hood- and cab-mounted hood rear support components with a soapy water so- lution. 4.

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