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freightliner BUSINESS CLASS M2 Series Workshop Manual

freightliner BUSINESS CLASS M2 Series Workshop Manual

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BUSINESS CLASS M2 WORKSHOP MANUAL

Models: M2 100

M2 106

M2 106V

M2 112

M2 112V

STI-457, S18 (9/10P)

Daimler Trucks North America LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

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Page 1 BUSINESS CLASS M2 WORKSHOP MANUAL Models: M2 100 M2 106 M2 106V M2 112 M2 112V STI-457, S18 (9/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
Page 2 Manual. 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 3 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 4 Introduction Descriptions of Service Publications Warranty-related service information available on the AccessFreightliner.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 5 Introduction Page Description For an example of a Business Class M2 Workshop Manual page, see Fig. 00.04 Threaded Fasteners General Instructions Fastener Replacement Fastener Tightening Fastener Selection and Installation Thread Locking Compound Application Business Class M2, Workshop Manual, Supplement 0, January 2002 12/21/2001 f020132 A.
Page 6 Introduction Workshop Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .
Page 7 List of Abbreviations List of Abbreviations The following is a list of deﬁnitions for abbreviations and symbols used in Freightliner publications. A ..amperes BBC ..bumper-to-back-of-cab CWS .
Page 8 HEST ..high exhaust system LCOE ..low cab over engine FAS ..Freightliner air suspension temperature LED ..light-emitting diode FCCC .
Page 9 00.01 List of Abbreviations List of Abbreviations MID ..message identiﬁer O.D..overdrive R–134a ..refrigerant-134a (HFC) MIL ..malfunction indicator lamp OEM .
Page 10 00.01 List of Abbreviations List of Abbreviations SPN ..suspect parameter number VIW ..vehicle interface wiring (connector) sq in ..square inches VOC .
Page 11 00.02 Metric/U.S. Customary Conversion Chart General Information U.S. Customary to Metric Metric to U.S. Customary Multiply Multiply When You Know To Get When You Know To Get Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft)
Page 12 The dealer is also responsible for ensuring that the vehicle was built according to the Truck Sales Order/ Invoice. Refer to Section 3 of the Freightliner LLC Warranty Manual for details. Vehicle Storage There may be times when a vehicle is stored for long periods before customer delivery.
Page 13 00.04 Threaded Fasteners General Information Threaded Fastener Types The majority of threaded fasteners used throughout the vehicle have U.S. customary threads (diameter and pitch are measured in inches). See Fig. 1. How- ever, the engine and some items attached to the cab use metric fasteners (diameter and pitch are mea- sured in millimeters).
Page 14 NOTE: Grade 2 bolts have no grade marking; grade 2 threaded hole, or the friction between the threads of bolts are rarely used by Freightliner.These grade mark- the nut and bolt. ings are used on plain hex-type and ﬂanged bolts (capscrews).
Page 15 00.04 Threaded Fasteners General Information 07/27/95 f310466 NOTE: Grade 2 (S.A.E.) and grade A (I.F.I.) nuts have no identiﬁcation marks or notches; they are rarely used by Freight- liner. Grade B (I.F.I.) nuts have three identiﬁcation marks at 120 degrees, or 6 notches. Grade C (I.F.I.) nuts have three identiﬁcation marks at 60 degrees, or 12 notches.
Page 16 00.04 Threaded Fasteners General Information 10/19/93 f310006a 1. Grade 8 Hexhead Bolt 2. Grade 8 Low-Proﬁle Hexhead Bolt 3. Grade C Prevailing Torque Locknut Fig. 6, Frame Fastener Identiﬁcation 050/4 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 17 Use stainless steel fasteners against chrome plating, strength, and ﬁnish as originally speciﬁed. See the unpainted aluminum, or stainless steel. Freightliner Service Parts Catalog for fastener speci- ﬁcations. Fastener Tightening When replacing graded (or metric class) bolts and...
Page 18 00.04 Threaded Fasteners General Instructions NOTE: Follow the safety precautions given on the locking compound container. 1. Clean the male and female threads of the fasten- ers, removing all dirt, oil, and other foreign mate- rial. If parts are contaminated, use Stoddard sol- vent for cleaning;...
Page 19 652 (884) — — Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † 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...
Page 20 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 TORQUE VALUES FOR METRIC THREAD FASTENERS WITH LUBRICATED †...
Page 21 M30 x 2 792 (1074) 1096 (1486) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).
Page 22 See Table 1 for the character 16 characters. These weighted values are processed positions of a typical Freightliner VIN, through a series of equations designed to check va- 1FUPABAV11PA12345. lidity of the VIN and to detect VIN alteration.
Page 23 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Position 4 (Chassis Conﬁguration) VIN Position 4 (Chassis Conﬁguration) Code Chassis Code Chassis 10 x 4 Truck-Tractor 8 x 2 Truck 10 x 6 Truck 14 x 4 Truck 10 x 6 Truck-Tractor 12 x 6 Truck 12 x 4 Truck Table 3, VIN Position 4 (Chassis Conﬁguration)
Page 24 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model GVWR Columbia 120 Conventional Class 8 Columbia 120 Glider Conventional Glider CST112 Conventional Class 7 CST112 Conventional Class 8 CST112 Glider Conventional Glider CST120 Conventional Class 7...
Page 25 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model GVWR Sport Chassis Conventional Class 6 Sport Chassis Conventional Class 7 FL106 Glider Conventional Glider FL60 Glider Conventional Glider FL70 Glider Conventional Glider FL80 Glider Conventional Glider...
Page 26 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model GVWR Sport Chassis 112 Conventional Class 7 Coronado CC132 Conventional Class 7 Classic 120 Conventional Class 7 Classic 120 Conventional Class 8 Condor Glider Conventional Glider M2 106 Medium Glider...
Page 27 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model GVWR Coronado 122 RHD Glider Conventional Glider Coronado 132 Conventional Class 7 Coronado SD 122 Conventional Class 7 Coronado 122 Conventional Class 7 M2 112 Glider Conventional Glider...
Page 28 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 7 and 8 (Engine, Brakes) Code Engine Fuel Displacement Conﬁguration Brakes Caterpillar C10 Diesel 10.3 Liter Air/Hydraulic Caterpillar C12 Diesel 12.0 Liter Caterpillar C12 Diesel 12.0 Liter Hydraulic Caterpillar C12 Diesel 12.0 Liter Air/Hydraulic 14.6 Liter pre...
Page 29 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 7 and 8 (Engine, Brakes) Code Engine Fuel Displacement Conﬁguration Brakes Cummins ISC Diesel 8.3 Liter Cummins ISC Diesel 8.3 Liter Hydraulic Cummins ISC Diesel 8.3 Liter Air/Hydraulic Cummins ISB Diesel 5.9 Liter Cummins ISB Diesel...
Page 30 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 7 and 8 (Engine, Brakes) Code Engine Fuel Displacement Conﬁguration Brakes Mercedes-Benz MBE4000 Diesel 12.8 Liter Hydraulic Mercedes-Benz MBE4000 Diesel 12.8 Liter Air/Hydraulic Cummins ISL Diesel 8.9 Liter Cummins ISL Diesel 8.9 Liter Hydraulic Cummins ISL...
Page 31 00.05 Vehicle Identiﬁcation Numbering System VIN Information VIN Positions 7 and 8 (Engine, Brakes) Code Engine Fuel Displacement Conﬁguration Brakes MDEG 7.7 Diesel 7.7 Liter MDEG 7.7 Diesel 7.7 Liter Hydraulic Cummins ISX12 Diesel 11.9 Liter Detroit DD15 EV Diesel 14.8 Liter Detroit DD15 STD Diesel...
Page 32 01.01 Engine Mounts General Information General Description Three mounts support the engine and transmission, holding a total of almost 1800 lb (816 kg). Two of the engine mounts support the rear of the engine and transmission assembly. The third supports the front of the engine/transmission assembly.
Page 33 01.01 Engine Mounts Rear Engine Mount Replacement Replacement For MBE4000 engines: tighten the bolts 175 lbf·ft (237 N·m). 1. Apply the parking brakes, chock the tires, and (if 6. Inspect the engine mount rubber isolators for applicable) drain the air brake system. wear or damage and replace them if necessary.
Page 34 01.01 Engine Mounts Rear Engine Mount Replacement Place a jack under the rear of the engine, WARNING and raise the jack until it’s braced against the engine. The jack used to lower the engine must be ca- Remove the bolt from the left rear engine pable of safely lifting and supporting two metric mount.
Page 35 01.01 Engine Mounts Front Engine Mount Replacement Replacement 6. Install the upper isolator(s) in the engine mount. If applicable, place the snubber(s) on the isola- tor(s). 1. Apply the parking brakes, chock the tires, and (if applicable) drain the air brake system. WARNING WARNING The lifting device and chain used to lower the...
Page 36 01.01 Engine Mounts Rear Engine Mount Isolator Replacement Replacement 5. Disconnect the engine from the right rear engine mount. 1. Apply the parking brakes, chock the tires, and (if If not in place, set a jack under the rear applicable) drain the air brake system. of the engine and raise the jack until it is braced against the engine.
Page 37 01.01 Engine Mounts Rear Engine Mount Isolator Replacement 8. Install the new upper isolator in the engine mount. If applicable, place the snubber on the isolator. WARNING The jack used to lower the engine must be ca- pable of safely lifting and supporting two metric tons.
Page 38 01.01 Engine Mounts Front Engine Mount Isolator Replacement Replacement moved from the engine stands, do not get under the engine until it is securely installed on the en- gine mount. An unsecured engine may fall, caus- 1. Apply the parking brakes, chock the tires, and (if ing personal injury or death, and component applicable) drain the air brake system.
Page 39 01.01 Engine Mounts Rear Engine Mount Replacement, EPA07 Engines Replacement DANGER NOTE: The rear engine mounts for EPA07 en- Aftertreatment Device (ATD) internal tempera- gines are designed to last for the life of the ve- tures can remain hot enough to cause personal hicle, and should not normally need replacing.
Page 40 01.01 Engine Mounts Rear Engine Mount Replacement, EPA07 Engines under spring tension, and can cause eye injury WARNING or other personal harm if they spring out of con- trol. Never work around or under a vehicle that is sup- ported only by a jack. Always support the vehicle 13.3 Remove the Marmon clamps from each with safety stands.
Page 41 01.01 Engine Mounts Rear Engine Mount Replacement, EPA07 Engines the frame-rail engine mount. See Fig. 2. If needed, repeat the procedure on the other side of the vehicle. 06/26/2006 f012134 NOTE: The engine mount is not visible in this view. 1.
Page 42 01.01 Engine Mounts Rear Engine Mount Replacement, EPA07 Engines 42. Connect the exhaust tubing to the turbocharger. 43. Install the cab skirts to the bottom of the cab. 44. Install the ATD to the exhaust tubing. As previ- ously marked, connect the wiring to the sensors on the ATD.
Page 43 01.01 Engine Mounts Speciﬁcations Engine Mount Torque Values, Pre-EPA07 Engines Torque: Description Grade/Class Size lbf·ft (N·m) Rear Engine-Mount to Support-Bracket: All Engines 3/4–10 241 (327) Rear Engine-Mount to Frame Rail Bolts: Caterpillar Engines 1/2–13 45 (61) Engine Leg-to-Flywheel Bolts: Caterpillar 3126 and C-7 Engines 10.9 M14 x 2 x 45 100 (136)
Page 44 01.02 EPA07/10 Engine Information General Information Principles of Operation Over time, ash collects in the ATS and needs to be removed through cleaning at speciﬁc intervals. For ATS maintenance and repair information, see the EPA 2007 engine manufacturer’s service literature. The Environmental Protection Agency (EPA) man- EPA 2010 dated that all engines built after December 31, 2006...
Page 45 01.02 EPA07/10 Engine Information General Information 03/26/2009 f040783 1. Exhaust Gas Recirculation 4. Charge Air Cooler (CAC) 7. Aftertreatment Device (ATD) (EGR) Cooler 5. Turbocharger 8. Diesel Particulate Filter (DPF) 2. EGR Valve 6. Hydrocarbon Doser 9. Diesel Oxidation Catalyst (DOC) 3.
Page 46 01.02 EPA07/10 Engine Information General Information 10/15/2009 f040787 1. Exhaust Gas Recirculation 5. Turbocharger 10. DEF Tank (EGR) Cooler 6. Hydrocarbon Doser 11. DEF Injector 2. EGR Valve 7. Diesel Oxidation Catalyst (DOC) 12. Mixing Tube 3. Intake Throttle Valve 8.
Page 47 01.02 EPA07/10 Engine Information General Information EPA10-compliant DTNA vehicles are equipped with Aftertreatment System (ATS) The entire exhaust an additional tank to carry the DEF necessary for the system from the turbocharger to the exhaust stack or SCR process. DEF is colorless, non-toxic, and biode- tail pipe.
Page 48 01.03 Drive Belts Drive Belt Inspection NOTE: For diagnostic procedures and engine component replacement, refer to the engine manufacturer’s service literature. See Detroit Diesel www.detroitdiesel.com or Cummins Engine www.cummins.com. Inspection 1. Inspect the belt contact surfaces for chips, ﬂak- ing, cracks, discoloration, and other damage. Fig.
Page 49 01.03 Drive Belts Drive Belt Inspection 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 100/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 50 01.03 Drive Belts Drive Belt Inspection 01/19/2010 f151149 Fig. 2, Damaged Pulley 01/22/2010 f151150 A. Incorrect Belt-Alignment Area B. Correct Belt-Alignment Area Fig. 3, Idler-Pulley Belt Alignment 100/3 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 51 01.03 Drive Belts Drive Belt Replacement, Detroit Diesel Engines Detroit Diesel engines are equipped with two serpen- 3. Raise the hood. tine poly-V drive belts. The rear belt (closest to the 4. Locate the automatic belt tensioner assembly, on engine block surface) drives the alternator, the A/C the left (passenger) side of the engine, as you compressor, and the water pump.
Page 52 01.03 Drive Belts Drive Belt Replacement, Detroit Diesel Engines the entire assembly. Never use more force than 66 to 73 lbf (90 to 100 N). IMPORTANT: Always release the front tensioner and belt (fan drive) ﬁrst, then the rear tensioner and belt (alternator, A/C compressor, and water pump).
Page 53 01.03 Drive Belts Drive Belt Replacement, Detroit Diesel Engines 11. In the same manner as the previous step, re- move the locking bolt from the front tensioner. 12. Do a ﬁnal check to make sure both drive belts are conﬁgured correctly, and correctly installed on all the pulleys.
Page 54 01.03 Drive Belts Drive Belt Replacement, Cummins Engines Cummins ISC/ISL and ISB engines are equipped with one poly-V drive belt. The drive belt is kept at the correct tension by a system of pulleys and an automatic belt tensioner. See Fig.
Page 55 01.03 Drive Belts Drive Belt Replacement, Cummins Engines 01/26/2011 f012193 A. Pivot Point for Belt Tensioner B. Push Downward Fig. 3, Releasing the Tensioner 120/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 56 01.04 Engine, Caterpillar 3126 Engine Removal and Installation Removal Disconnect the hoses, drain them, then cover the hose ends to keep out dirt. NOTE: This procedure involves removing and 8. Mark, disconnect and remove the charge air installing the engine and the transmission as a cooler hoses.
Page 57 01.04 Engine, Caterpillar 3126 Engine Removal and Installation 14. Using a suitable breaker bar in the belt tensioner, rotate the tensioner counterclockwise. Remove the serpentine drive belt from the engine. 15. Mark and disconnect the wiring from the refriger- ant compressor. 16.
Page 58 01.04 Engine, Caterpillar 3126 Engine Removal and Installation 03/28/95 f010920 04/14/95 f200302 Fig. 2, Lifting Chain Installed Fig. 3, Front Engine Mount Fasteners 32.3 With the engine lifting eyes connected by chain to the crane, raise the crane enough to tighten the chains, but not WARNING enough to lift the front of the vehicle.
Page 59 01.04 Engine, Caterpillar 3126 Engine Removal and Installation gine mount with nuts and washers. 14. Install the serpentine drive belt onto the engine. Tighten the nuts 136 lbf·ft (184 N·m). 15. Install the radiator. Once the engine and transmission are 15.1 Set the radiator shroud back against the securely installed in the vehicle, remove...
Page 60 01.04 Engine, Caterpillar 3126 Engine Removal and Installation 22. If equipped with a transmission oil cooler, check the ﬂuid level in the transmission and add auto- matic transmission ﬂuid as needed. Refer to Group 26 of the Business Class M2 Maintenance Manual for approved automatic transmission ﬂu- ids.
Page 61 09.00 Air Intake Ducting Air Intake Ducting Replacement Replacement 1. Turn off the engine, apply the brakes, and chock the tires. 2. Open the hood. WARNING Do not operate the engine with any component of the air intake system removed. Serious physical injury can occur if the turbocharger impeller is touched when it is rotating.
Page 62 09.00 Air Intake Ducting Air Intake Ducting Replacement 03/26/2009 f090437 1. Duct 3. Seal 2. Clamp 4. Air Cleaner Housing 06/19/2006 f090435 Fig. 3, Cross-Section of Air Intake Ducting 1. Air Cleaner-to-Elbow Seal 2. Elbow 3. Elbow-to-Turbocharger Seal Fig. 2, Typical Elbow-to-Turbocharger Conﬁguration (CAT C7 engine shown) Check the installed assembly for any inter- ference or contact with adjacent compo-...
Page 63 09.01 Air Cleaner Element Replacement Replacement IMPORTANT: Do not modify, or use modiﬁed air cleaners or duct components. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. 2. Chock the tires and open the hood. NOTICE All air intake components and connections must be air- and water-tight.
Page 64 09.01 Air Cleaner Housing Removal and Installation Removal Installation IMPORTANT: Do not modify, or use modiﬁed air 1. Check the air cleaner housing for damage, and check all ducts and connections for leakage. Ad- cleaners or duct components. just or replace parts as necessary. 1.
Page 65 09.01 Air Cleaner Air Cleaner Restriction Checking Restriction Checking For vehicles equipped with a go/no-go restriction indicator without graduations, check the indicator with the engine off to see if the colored bar Restriction of air ﬂow through the air cleaner element shows through the clear window.
Page 66 09.02 Charge Air Cooler General Information General Information The charge air cooler (CAC) is attached to the front of the radiator. The function of the CAC is to cool the hot, compressed air that exits the turbocharger. The CAC reduces the temperature of this air to the en- gine manufacturers’...
Page 67 09.02 Charge Air Cooler CAC Removal and Installation Removal 5. Connect the batteries. NOTE: This procedure covers vehicles that have the charge air cooler (CAC) mounted above the condenser. 1. Apply the parking brakes and chock the tires. 2. Disconnect the batteries. ®...
Page 68 09.02 Charge Air Cooler CAC Inspection and Leakage Test Inspection The CAC core leakage test should be performed using a CAC test kit, part number 5039, which can be purchased from SPX Kent-Moore at 1-800-328- 1. Apply the parking brakes and chock the tires. 6657.
Page 69 09.02 Charge Air Cooler CAC Inspection and Leakage Test 09/12/2001 f090277a 1. Safety Chain 5. Safety Ring 8. Test Plug with Adapter 2. Test Plug 6. CAC Air Inlet 9. Test Valve/Gauge Assembly 3. Constant Tension Hose Clamp 7. CAC Air Outlet 10.
Page 70 09.02 Charge Air Cooler CAC Flushing Flushing If the charge air cooler (CAC) is suspected of being contaminated, ﬂush the CAC. 1. Apply the brakes and chock the tires. 2. Remove the CAC. For instructions, see Sub- ject 100. 3. Set the CAC in a horizontal position with the inlet and outlet ports facing up.
Page 71 09.02 Charge Air Cooler CAC Restriction Test Restriction Test After ﬂushing the charge air cooler (CAC) because of turbocharger or engine damage, test the pressure drop across the CAC and air piping as follows: 1. Remove the pipe plug from the tapped hole in the turbocharger air outlet elbow.
Page 72 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 General Information General Information The Tu-Flo 550 and 750 air compressors are two- cylinder, single stage, reciprocating compressors. The Tu-Flo 550 air compressor has a rated displace- ment of 13.2 cubic feet (4 cubic meters) per minute at 1250 rpm.
Page 73 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 General Information 01/30/2002 f130115 1. Governor Mounting Pad 02/05/2002 f130117 2. Water Inlet Port 3. Air Discharge 1. Crankshaft 4. Cylinder Head 2. Connecting Rod 5. Water Outlet Port 3. Piston Ring 6.
Page 74 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Air Compressor Replacement Replacement 1. Apply the parking brakes, chock the tires, and open the hood. 2. Drain the air system. 3. Clean all the ﬁttings and hose connections on the air compressor, power steering pump, and the supply and pressure lines on the power steering gear until they are free of dirt.
Page 75 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Air Compressor Replacement NOTE: On Caterpillar engines, apply thread lock compound 9S-3263 to the mounting capscrews. 18. Attach the air compressor to the front of the en- gine. Be sure that the drive gear engages cor- rectly with the gear in the front of the engine.
Page 76 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Troubleshooting Troubleshooting Tables Problem—Excessive Oil Passage Problem—Excessive Oil Passage Possible Cause Remedy Restricted air intake. Check engine or compressor air cleaner and replace if necessary. Check compressor air inlet for kinks, excessive bends, and be certain inlet lines have the minimum speciﬁed inside diameter.
Page 77 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Troubleshooting Problem—Excessive Oil Passage Possible Cause Remedy Excessive engine crankcase pressure. Test for excessive engine crankcase pressure and repair or replace ventilation components as necessary. NOTE: An indication of crankcase pressure is a loose or partially lifted dipstick.
Page 78 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Troubleshooting Problem—Excessive Buildup and Recovery Time Possible Cause Remedy Restricted induction line. Inspect the compressor air induction line for kinks and restrictions and replace as necessary. Restricted discharge line or compressor Inspect the compressor discharge port and line for restrictions and carbon discharge cavity.
Page 79 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Troubleshooting Problem—Compressor Leaks Oil Possible Cause Remedy Loose end cover. Check the capscrew torques and tighten as necessary. Replace gaskets or O-rings. Loose oil supply or return line ﬁttings. Check the torque of external oil line ﬁttings and tighten as necessary. Porous compressor casting.
Page 80 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Troubleshooting 01/30/2002 f130116 A. Coolant In B. Coolant Out Fig. 1, Coolant Flow Options 300/5 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 81 13.00 Air Compressor, Bendix Tu-Flo 550 and Tu-Flo 750 Speciﬁcations • Minimum Coolant Flow (water cooled) at: Tu-Flo 550 and 750 Speciﬁcations • Displacement at 1250 rpm: • Maximum rpm: 2.5 gpm (9.5 L/min) • Tu-Flo 550: 13.2 cfm • Minimum rpm: 5 gpm (19 L/min) •...
Page 82 13.01 Air Compressor, WABCO Air Compressor Removal, Inspection, and Installation Special Tools A special tool is needed to replace the drive gear on the WABCO 15.5 cfm and 28.1 cfm air compressors. Table Special Tool Tool Description Manufacturer Part Number Air Compressor Locking Device SPX Kent-Moore KM 904 589 03 63 00...
Page 83 13.01 Air Compressor, WABCO Air Compressor Removal, Inspection, and Installation IMPORTANT: Do not remove the power steering lines. Secure the lines and the pump so they are out of the way. 13. Remove the cross plate between the compressor and the power steering pump. See Fig.
Page 84 13.01 Air Compressor, WABCO Air Compressor Removal, Inspection, and Installation 02/06/2002 f130105 1. Capscrew 2. Power Steering Pump 3. O-Ring, Power Steering Pump 4. Cross Plate 5. Air Compressor 6. Hydraulic Lines Fig. 3, Power Steering Pump Installation 10. Fill the cooling system. For instructions, see Sec- tion 20.01, Subject 100.
Page 85 13.02 Air Compressor, Bendix BA-921 General Information General Information The BA-921 air compressor is a single-cylinder recip- rocating compressor with a rated displacement of 15.8 cubic feet per minute at 1250 rpm. The com- pressor consists of a water-cooled cylinder head, a valve plate assembly, and an air-cooled integral crankcase and cylinder block.
Page 86 13.02 Air Compressor, Bendix BA-921 Air Compressor Replacement Replacement 16. Turn on the engine and check for leaks. 17. Remove the chocks from the tires and lower the 1. Shut down the engine, apply the parking brakes, hood. chock the tires, and open the hood. 2.
Page 87 13.02 Air Compressor, Bendix BA-921 Troubleshooting Troubleshooting Tables Problem—Noisy Compressor Operation Problem—Noisy Compressor Operation Possible Cause Remedy Loose drive gear or components. Inspect the ﬁt of the drive gear on the compressor crankshaft. The gear or coupling must be completely seated and the crankshaft nut must be tight. If the compressor crankshaft surface is damaged, it is an indication of loose drive components.
Page 88 13.02 Air Compressor, Bendix BA-921 Troubleshooting Problem—Compressor Leaks Oil Possible Cause Remedy Cracked crankcase or end cover. Inspect the compressor exterior for cracked or broken components. Cracked or broken crankcases or mounting ﬂanges can be caused by loose mounting bolts. The end cover can be cracked by overtorquing ﬁttings or plugs installed in the end cover.
Page 89 13.02 Air Compressor, Bendix BA-921 Troubleshooting Problem—Compressor Head Gasket Malfunction Problem—Compressor Head Gasket Malfunction Possible Cause Remedy Restricted discharge line. Clear restriction or replace line. Loose cylinder head capscrews. Tighten evenly to a torque of 265 to 292 lbf·in (2990 to 3300 N·cm). Malfunctioning compressor or head Check for rough or poorly machined head or block surfaces.
Page 90 13.02 Air Compressor, Bendix BA-921 Troubleshooting Problem—Excessive Oil Passage Possible Cause Remedy Compressor runs loaded an excessive Vehicle system leakage should not exceed 1 psi (7 kPa) pressure drop per amount of time. minute without brakes applied and 3 psi (21 kPa) pressure drop per minute with brakes applied.
Page 91 13.02 Air Compressor, Bendix BA-921 Troubleshooting Problem—Excessive Buildup and Recover Time Possible Cause Remedy Malfunctioning compressor. Repair or replace the compressor after determining none of the preceding conditions exist. Compressor should be capable of building air system pressure from 85 to 100 psi (586 to 689 kPa) in 40 seconds with engine at full governed rpm. Mini- mum compressor performance is certiﬁed to meet Federal requirements by the vehicle manufacturer.
Page 92 13.02 Air Compressor, Bendix BA-921 Speciﬁcations • Maximum inlet air temperature: 250°F (121°C) BA-921 Speciﬁcations: • Flow capacity at 1800 rpm and 120 psi (827 • Maximum discharge air temperature: 400°F kPa): 11.8 cfm (204°C) • Flow capacity at 3000 rpm and 120 psi (827 •...
Page 93 General Information General Information Both Leece-Neville and Delco Remy alternators are available as original equipment on Freightliner ve- hicles. Installation and removal are the same for all alternators on a given engine design. Many alternators are equipped with a remote-sense...
Page 94 15.00 Alternator Removal and Installation Removal Hold the rotor shaft with the Allen wrench, and turn the pulley nut counterclockwise to remove it. See Fig. 1. Remove the nut, 1. Apply the parking brake, shut down the engine, washer, and pulley. and chock the rear tires.
Page 95 15.00 Alternator Removal and Installation Hold the rotor shaft with the Allen wrench, output-terminal hexnut 100 lbf·in (1140 N·cm). and turn the pulley nut clockwise to Tighten the ground-terminal hexnut 65 lbf·in (730 tighten. N·cm). Tighten the other terminal hexnuts 20 lbf·in (225 N·cm).
Page 96 15.00 Alternator Troubleshooting Troubleshooting 1. Using the Intelli-Check 2, perform a voltage drop test on the alternator cables. See Fig. IMPORTANT: Before testing, make sure: • All belts are tensioned and are not cracked, worn, or glazed; • The wiring and terminals are free of corro- sion, properly torqued, and protected with dielectric enamel.
Page 97 15.00 Alternator Troubleshooting and press Enter. Press ESC to bypass the 12.35. If the batteries will start the vehicle, vehicle ID screen. proceed with the alternator test. 3. Start the engine using onboard batteries only. If Remove the small leads from the battery, the batteries will not start the engine, they must leaving the large leads connected as they be charged.
Page 98 15.00 Alternator Troubleshooting 09/10/99 f150983 1. Red Alligator Clip 3. Hand-Held Alternator Analyzer 2. Black Alligator Clip Fig. 2, Intelli-Check Alternator Analyzer (original) 300/3 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 99 15.00 Alternator Speciﬁcations Delco Remy Alternator, Terminal Fastener Torque Description Size Torque: lbf·in (N·cm) Output ("BAT") Terminal Hexnut 5/16–18 100 (1140) 1/4–20 50 to 60 (565 to 675) Ground ("GND") Terminal Hexnut 5/16–18 60 to 90 (675 to 1016) Terminal Hexnuts 10–24 20 (220) Table 1, Delco Remy Alternator, Terminal Fastener Torque...
Page 100 15.01 Starter General Information General Information The bulkhead module monitors engine RPM, calcu- lates the starter temperature, and analyzes the spe- ciﬁc neutral conditions for the type of transmission. The starter is mounted on the forward face of the Cranking is not allowed if the engine is running, the ﬂywheel housing.
Page 101 15.01 Starter General Information Frontwall Main PDM 52 Pink 5 Amp Fuse W/Eaton Auto Trans Eaton Transmission ECU PTPDM A5 A3 A1 B2 B3 472S 01/21/2011 f151155 Fig. 1, Starter Control Circuitry with Integrated Magnetic Switch 050/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 102 15.01 Starter General Information Frontwall Keyswitch Main PDM 52 Pink 5 Amp Fuse Manual and AutoShift w/ Clutch Overcrank Protection Switch Option Some Allison Systems Allison Trans NSBU Switch Eaton Trans Some Eaton Systems Remote Magnetic Eaton Switch Trans A5 A3 A1 B2 B3 Starter Components in dotted boxes are optional and vary with vehicle content.
Page 103 15.01 Starter Starter Removal and Installation Removal Before replacing the starter, perform the checks in Troubleshooting 300. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Disconnect the negative battery cables at the batteries.
Page 104 15.01 Starter Troubleshooting Starter System sition to close the switch between pins 10 and 11. The NSBU is located on the drivers side of the trans- Troubleshooting mission case. If the NSBU requires adjustment, use the procedure in the Allison service manual. Use troubleshooting tables 1 through 5 for system If the vehicle is equipped with an automated or auto- diagnosis to reduce the likelihood of replacing a...
Page 105 15.01 Starter Troubleshooting Slow Cranking or Repeated Clicking Sound but the Engine Does Not Start This symptom often indicates low voltage at the starter, or worn and binding starter components. Step Test Procedure Test Result Action Check the ambient temperature. Slow cranking due to extreme cold is a normal condition.
Page 106 15.01 Starter Troubleshooting Starter Does Nothing or Makes Only a Single Click—Vehicles with an Integrated Magnetic Switch This symptom often indicates a problem with the magnetic switch or starter solenoid circuit. Worn components in the starter or engine can also create binding and result in this symptom. Step Test Procedure Test Result...
Page 107 15.01 Starter Troubleshooting Starter Does Nothing or Makes Only a Single Click—Vehicles with a Remote Mounted Magnetic Switch This symptom often indicates a problem with the magnetic switch or starter solenoid circuit. Worn components in the starter or engine can also create binding and result in this symptom. Step Test Procedure Test Result...
Page 108 15.01 Starter Troubleshooting Starter Makes Spinning or Grinding Sounds but the Engine Does Not Crank. This symptom often indicates a mechanical problem with the starter or the ring gear. Step Test Procedure Test Result Action With the keyswitch in the START (crank) Low or No Go to step 2.
Page 109 15.01 Starter Speciﬁcations Torque Values, Starter-Motor to Flywheel-Housing Bolts Fastener Description Size Torque Value: lbf·ft (N·m) MBE 400, DD 13/15/16 M10 x 1.5 38±5 (51±7) Cummins ISB M10 x 1.5 38±5 (51±7) Cummins ISC/ISL M12 x 1.5 58±5 (78±7) CAT 3176, 3406, 10/12, 5/8–11 100±48/-0 (+65) Cummins ISX...
Page 110 20.00 Cooling System Troubleshooting General Information General Information The main function of a cooling system is to keep the engine at its optimum operating temperature. This results in the most efficient use of fuel and allows the engine oil to provide a good lubricating ﬁlm. For the typical coolant plumbing, see Fig.
Page 111 20.00 Cooling System Troubleshooting General Information 11/02/2001 f011997 1. Heater Supply Hose 2. Heater Return Hose Fig. 1, Coolant Plumbing (typical) 050/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 112 20.00 Cooling System Troubleshooting Troubleshooting Troubleshooting sections of this manual or the engine and component manufacturer’s service publications. Possible causes of abnormally high or low coolant temperatures are listed below. For repairs, see other Problem—Coolant Temperature Above Normal Problem—Coolant Temperature Above Normal Possible Cause Remedy Coolant leakage (see possible sources...
Page 113 20.00 Cooling System Troubleshooting Troubleshooting Problem—Coolant Temperature Above Normal Possible Cause Remedy Internally plugged or damaged radiator To check for blockages, warm the engine to normal operating temperature. core Turn off the engine, and run your hand over the ﬁnned surface of the radiator. If there is a blockage in the radiator, it should cause an obvious temperature difference from one area of the core to another.
Page 114 20.01 Radiator Assembly General Information General Information The main function of a cooling system is to keep the engine at its optimum operating temperature. This results in the most efficient use of fuel and allows the engine oil to provide a good lubricating ﬁlm. The central component of the cooling system, the radiator assembly, includes the surge tank (remote mounted on the ﬁrewall), the radiator, and the surge...
Page 115 20.01 Radiator Assembly Radiator Removal and Installation Removal Place a clean container under the hose connections. The 870-square-inch radiator is held in place by a Disconnect the transmission oil cooler support bracket that is attached to the front of the hoses from the radiator, or the transmis- radiator, and to the closing crossmember.
Page 116 20.01 Radiator Assembly Radiator Removal and Installation 03/28/2003 f500360 1. Radiator 7. Hexbolt 12. Left Inner Strut Rod 2. Isolator 8. Flatwasher 13. Left Outer Strut Rod 3. Front Crossmember 9. Hexnut 14. Hexbolt 4. Support Bracket 10. Right Upper Strut Rod 15.
Page 117 20.01 Radiator Assembly Radiator Removal and Installation 4. For 870- and 1000-square-inch radiators, install the 1/2–13 hexnuts and washers onto the studs on the radiator lower brackets. Tighten 68 lbf·ft (92 N·m). For 805-square-inch radiators, install the nuts and washers on the studs on the isolators at the sides of the radiator.
Page 118 20.01 Radiator Assembly Radiator Removal and Installation 03/28/2003 f500359 1. Hexnut 6. Radiator Support Bracket 11. Left Inner Strut Rod 2. Washer 7. Isolator 12. Left Outer Strut Rod 3. Closing Crossmember 8. Washer 13. Hexbolt 4. Washer 9. Radiator 14.
Page 119 20.01 Radiator Assembly Radiator Removal and Installation 12/22/2003 f200590 Fig. 6, ABA Radial Worm-Drive Hose Clamp (typical) f200326 02/28/96 Fig. 4, T-Bolt Type Hose Clamp 08/15/94 f200286 Fig. 5, Breeze Constant-Torque Hose Clamp Installation 15. Attach the hood-stop cables to the top of the ra- diator.
Page 120 20.01 Radiator Assembly Radiator Removal and Installation Hose Clamp Torque Values Clamp Type Size Torque: lbf·in (N·cm) T-Bolt 55 (620) Breeze Constant-Torque 5/16-inch tightening screw hex 90 (1020) 3/8-inch tightening screw hex 90 (1020) 1.26-inch Diameter 31 (360) 1.50-inch Diameter 35 (400) 1.73-inch Diameter 35 (400)
Page 121 20.01 Radiator Assembly Radiator Pressure Testing Pressure Testing 1. Remove the radiator from the vehicle. For in- structions, refer to Subject 100. 2. Pressure-test the radiator. Plug the inlet, outlet, and all other ports on the radiator assembly. CAUTION Don’t apply a higher amount of air pressure than speciﬁed below;...
Page 122 20.01 Radiator Assembly Radiator Disassembly and Assembly IMPORTANT: Disassembling and assembling Slip the side channels off the radiator core and tank assembly. See Fig. radiators with nylon tanks requires the special tools listed in Table 3. Leak test the radiator core and tank assembly. Securely plug all tank ports.
Page 123 20.01 Radiator Assembly Radiator Disassembly and Assembly 05/23/95 f500184a A. Dimple Wave Lock Crimp B. See Detail 1. Channel Mounting Pin 6. Side Channel (top) 11. Nut 2. Bolt 7. End Tank 12. Radiator Brace Rod 3. 3/8-Inch Flatwasher 8. End Tank Gasket 13.
Page 124 20.01 Radiator Assembly Radiator Disassembly and Assembly 03/25/93 f500172a 1. Spring Clip Fig. 2, Remove the Spring Clip 03/25/93 f500174a 1. Side Channel 2. Radiator Core Fig. 4, Remove the Side Channels with a screwdriver. When using a screwdriver, use care not to crack or gouge the nylon tank. Place the T-bar into the T-bar groove in the disassembly/assembly ﬁxture.
Page 125 20.01 Radiator Assembly Radiator Disassembly and Assembly 03/25/93 f500180a Fig. 5, Clamp the Radiator in the Disassembly/Assembly Fixture Repeat the preceding steps to remove CAUTION the opposite tank. IMPORTANT: Check the tubes of the radia- If needed, use a rubber mallet or the heel of your hand and tap the side of the tank to loosen it.
Page 126 20.01 Radiator Assembly Radiator Disassembly and Assembly 02/17/94 f500181a 1. Sealing Surface 2. Gasket 02/17/94 f500177a Fig. Fig. 6, Place the T-Bar 8, Remove the Gasket header sealing surface is free of any dents, tool marks, or foreign particles. Lubricate a new sealing gasket with a soap and water solution, and position the gasket on the header sealing surface.
Page 127 20.01 Radiator Assembly Radiator Disassembly and Assembly not press against breakable ﬁttings, such as vent tube ports. See Fig. CAUTION Apply only enough pressure to compress the sealing gasket. Too much pressure will crack the nylon tank. Apply pressure evenly across the top of the tank until the tank-to-core sealing gasket is compressed enough to show a small gap between the bottom of the...
Page 128 20.01 Radiator Assembly Radiator Disassembly and Assembly 03/25/93 f500176a 1. Spring Clip Fig. 11, Install the Spring Clips 02/17/94 f500175a 1. Pin Fig. 10, Install the Mounting Pins 120/7 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 129 20.01 Radiator Assembly Surge Tank Removal and Installation Removal 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires. 2. Tilt the hood. WARNING Drain the coolant only when the coolant and en- 2, 3, 4 gine are cool.
Page 130 20.01 Radiator Assembly Surge Tank Removal and Installation 9. Lower the hood and remove the chocks from the tires. 130/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 131 20.01 Radiator Assembly Speciﬁcations Fastener Torques Torque Description Grade Size lbf·ft (N·m) lbf·in (N·cm) Radiator Lower-Bracket Stud Hexnuts 1/2–13 68 (92) — Fan Shroud Mounting Screws — 1/4–20 x 3/4 Inch — 108 (1220) Radiator Strut Nuts 1/2–13 68 (92) —...
Page 132 20.03 Engine Block Heater, Phillips 1000W General Information General Information To turn on the heater, connect the heater cord to a power source. The element has no thermostat. Heat dissipating from the engine block prevents coolant An engine block heater keeps the engine coolant overheating.
Page 133 20.03 Engine Block Heater, Phillips 1000W Block Heater Element Replacement Removal Installation 1. Position the heater element in the engine block. Coat the threads of the element with a small amount of sealant. For the approved sealants, refer to Speciﬁcations, 400.
Page 134 20.03 Engine Block Heater, Phillips 1000W Troubleshooting Troubleshooting 3. Drain the radiator. For instructions, refer to Sec- tion 20.01. Use the following procedures to check for the most 4. Unscrew the threaded cover that secures the common engine block heater problems. cord to the element.
Page 135 20.03 Engine Block Heater, Phillips 1000W Speciﬁcations APPROVED SEALANTS • Loctite 567 • Henkel 790 Pipegrip • Perma-Loc LH-150 400/1 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 136 20.04 Fan Clutch, Viscous General Information General Information The fan clutch senses the air temperature behind the radiator core, and engages or disengages the fan depending on that temperature. It spins the fan when more cooling airﬂow is needed, and disengages it when the radiator is sufficiently cooled.
Page 137 20.04 Fan Clutch, Viscous General Information 12/16/94 f200177a 1. Heat Sensor 4. Concentric Grooves 6. Output Plate 2. Input Plate 5. Drive Chamber 7. Fan 3. Input Shaft Fig. 1, Eaton 690 Viscous Fan Clutch 050/2 Business Class M2 Workshop Manual, Supplement 7, March 2005...
Page 138 20.04 Fan Clutch, Viscous Inspection and Operation Check Inspection (10°C). Ideally, a temperature probe placed about 1/2 inch (13 mm) from the fan clutch sen- sor is needed to see if the fan clutch engages at CAUTION the right temperature. 3.
Page 139 20.04 Fan Clutch, Viscous Inspection and Operation Check fan should be fully engaged when the air at the fan clutch sensor rises to about 155 to 165°F (68 to 74°C). With the clutch engaged, the coolant temperature will keep rising, at a slower rate, as long as the radiator is blocked with cardboard.
Page 140 20.04 Fan Clutch, Viscous Removal and Installation Removal 1. Park the vehicle on a level surface and set the parking brake. Shut down the engine. Chock the rear tires. 2. Disconnect the batteries or, if the vehicle is equipped with a battery shutoff switch, turn off the switch.
Page 141 20.04 Fan Clutch, Viscous Removal and Installation 3. Install the fan clutch assembly onto the fan hub. Tighten the 3/8–16 locknuts 28 lbf·ft (38 N·m). 4. Install the serpentine drive belt. 5. Connect the left-side charge air cooler hose to the charge air cooler.
Page 142 20.04 Fan Clutch, Viscous Speciﬁcations Fastener Torques Torque: lbf·ft Description Grade Size (N·m) Fan Clutch-to-Fan Hub Locknuts 3/8—16 28 (38) Fan Hub-to-Engine Hexbolts 10.9 15 (20) Fan Clutch-to-Fan Locknuts 5/16—18 21 (28) Table 1, Fastener Torques 400/1 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 143 20.05 Fan Clutch, Horton DriveMaster General Information General Information ® The Horton DriveMaster fan clutch is a temperature- controlled, air-operated clutch for the engine cooling fan. It is spring engaged, and controls the engine temperature by engaging or disengaging the fan. When the coolant temperature is below a speciﬁed range, air pressure keeps the fan disengaged to save engine power.
Page 144 20.05 Fan Clutch, Horton DriveMaster General Information +12V +12V 08/11/2005 f544122 A. To Indicators and Gauges C. Normally Closed B. To Electronic Injectors and Other Actuators D. Normally Open 1. Fan Override Switch 6. Foot Throttle 9. Solenoid Valve 2. Air Temperature Sensor 7.
Page 145 20.05 Fan Clutch, Horton DriveMaster Removal and Installation Removal If equipped with a metal fan ring, remove the two top fasteners holding the upper mounting bracket for the fan ring. 1. Park the vehicle on a level surface, shut down the engine, set the parking brakes, and chock Remove the fasteners holding the fan the tires.
Page 146 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild Disassembly 4. Apply 80 to 120 psi (552 to 827 kPa) to the fan clutch to lift the fan mounting disc off the spring housing/piston assembly. NOTE: This procedure involves a major rebuild of the Horton DriveMaster ®...
Page 147 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild WARNING Do not disassemble the spring housing from the piston. The interior springs are very strong, and if released could eject the housing with consider- able force, possibly resulting in serious injury. Always use the cage nut to hold the spring hous- ing and the piston together.
Page 148 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild 06/05/2002 f200571 1. Spring Housing/Piston Assembly 2. Cage Nut 3. Friction Lining 4. Torx-Head Screws Fig. 4, Friction Lining Removal and Installation 06/05/2002 f200573 1. Air Chamber Seal 4. Air Chamber Cap 2.
Page 149 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild 05/29/2002 f200574 1. Bearing Nut 2. Mounting Bracket Fig. 7, Bearing Nut Removal and Installation 07/13/94 f200029a Fig. 9, Retaining Ring Removal and Installation 05/29/2002 f200575 05/29/2002 f200578 1. Sheave 2. Mounting Bracket 1.
Page 150 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild Fig. 11. It doesn’t matter which way the 3. Apply O-ring lubricant from the kit to the outside arrow faces when the bearings are in- O-rings of the new air cartridge assembly. See stalled.
Page 151 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Major Rebuild 19. Remove the cage nut from the spring housing/ piston assembly. 20. Install the new fan mounting disc from kit. CAUTION Use care when placing the pry bar onto the fan mounting disc.
Page 152 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Minor Rebuild Disassembly NOTE: This procedure involves a minor rebuild of the Horton DriveMaster ® fan clutch, using parts from the manufacturer’s Seal Kit. If a ma- jor rebuild of the fan clutch is needed, see Sub- ject 110.
Page 153 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Minor Rebuild WARNING Release the air pressure from the fan clutch be- fore removing the friction lining Torx-head screws. Failure to release the air pressure could result in the spring housing/piston assembly be- ing ejected with force, which could result in per- sonal injury.
Page 154 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Minor Rebuild 07/13/94 f200029a Fig. 6, Retaining Ring Removal and Installation (sheave not shown) 06/05/2002 f200573 1. Air Chamber Seal 4. Air Chamber Cap 2. Retaining Ring 5. Face Seal 3. O-Ring Seal Fig.
Page 155 20.05 Fan Clutch, Horton DriveMaster Fan Clutch Minor Rebuild 13. Carefully set the new spring housing/piston as- sembly into position. See Fig. 4. Note that the new assembly has a cage nut installed on it. 14. Rotate the new spring housing/piston assembly to align the mounting holes with those of the sheave.
Page 156 20.05 Fan Clutch, Horton DriveMaster Troubleshooting Troubleshooting Tables Problem—Air Is Leaking from the Fan Clutch Problem—Air Is Leaking from the Fan Clutch Possible Cause Remedy The face seal or air cartridge is damaged Install a new seal kit. or worn. The O-ring seals are damaged or worn.
Page 157 20.05 Fan Clutch, Horton DriveMaster Troubleshooting Problem—The Fan Clutch Cycles Frequently Possible Cause Remedy The fan cycling switch at the receiver- Check the switch at the receiver-dryer, and if needed, replace the switch with dryer is set too low. a switch with a higher setting. Check the ACPU switch and unit. There is an air restriction in front of the fan Check for incorrect radiator shutter operation, winterfronts, or any other air clutch.
Page 158 20.05 Fan Clutch, Horton DriveMaster Speciﬁcations Horton DriveMaster ® Repair Kits Kit Description Part When Used Number Super Kit HOR994347 Fan Clutch Major Rebuild Seal Kit HOR994346 Replacing Seals and Air Cartridge Friction Disc Kit HOR994348 Replacing Fan Mounting Disc and Friction Lining Friction Liner Kit HOR994349 Replacing Friction Lining Only All kits are available from the PDCs.
Page 159 20.05 Fan Clutch, Horton DriveMaster Speciﬁcations +12V +12V 08/11/2005 f544122 A. To Indicators and Gauges C. Normally Closed B. To Electronic Injectors and Other Actuators D. Normally Open 1. Fan Override Switch 6. Foot Throttle 9. Solenoid Valve 2. Air Temperature Sensor 7.
Page 160 20.06 Fan Clutch, Kysor K26RA General Information General Information The fan clutch is a temperature-controlled, air- operated clutch for the engine cooling fan. It is spring engaged, and controls the engine temperature by engaging or disengaging the fan. When the coolant temperature is below a speciﬁed range, air pressure keeps the fan disengaged to save engine power.
Page 161 20.06 Fan Clutch, Kysor K26RA Fan Clutch Removal and Installation Removal 1. Park the vehicle, apply the parking brakes, and chock the tires. 2. Tilt the hood. WARNING Wear safety goggles when draining the air sys- tem or disconnecting an air line because dirt and sludge could ﬂy out at high speeds.
Page 162 20.06 Fan Clutch, Kysor K26RA Fan Clutch Removal and Installation 5. Connect the left-side hose to the charge air cooler. 100/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 163 20.06 Fan Clutch, Kysor K26RA Fan Clutch Minor Rebuild Special Tools sembly, install two 3-1/2-inch (89-mm) long carriage bolts and suitable washers on opposite sides of the clutch assembly. IMPORTANT: Special tools are are recom- mended, but not required for this procedure. On the shaft assembly side, install about a 1/2-inch (13-mm) thickness of washers Table 1...
Page 164 20.06 Fan Clutch, Kysor K26RA Fan Clutch Minor Rebuild 15 16 17 08/11/2005 f200325 A. If a lip seal is used, install it so that it faces away from the fan studs. 1. Cylinder Nut 9. Engagement Spring Carrier 17. Flatwasher 2.
Page 165 20.06 Fan Clutch, Kysor K26RA Fan Clutch Minor Rebuild 7. If you ﬁnd cracking or scoring on any surface, or if the bearings are rough, loose, or missing, re- place the fan clutch. NOTE: If you ﬁnd metal particles in the existing grease, replace the fan clutch or contact Kysor for the training needed to perform a major fan clutch rebuild.
Page 166 20.06 Fan Clutch, Kysor K26RA Fan Clutch Relining Relining 9. Remove the air pressure from the fan clutch, and allow the fan to engage. IMPORTANT: Premature wearing of the fan 10. Disconnect the shop air, and connect the air line to the fan drive.
Page 167 20.06 Fan Clutch, Kysor K26RA Fan Clutch Relining 15 16 17 08/11/2005 f200325 A. If a lip seal is used, install it so that it faces away from the fan studs. 1. Cylinder Nut 9. Engagement Spring Carrier 17. Flatwasher 2.
Page 168 20.06 Fan Clutch, Kysor K26RA Speciﬁcations • Chevron SR12 If the lubricant that comes with the rebuild kit for the Kysor K26RA fan clutch is unavailable, use one of • Amoco Rykon Premium #2EP the following approved lubricants: • Texaco RB Premium •...
Page 169 25.00 Eaton Fuller Solo Clutches General Information General Description In the dual-disc versions of these clutches, the inter- mediate plate separating the driven discs is mounted directly to the ﬂywheel. Four separator pins ensure ™ Eaton Fuller Solo clutches are 14-inch (350-mm) an equal gap on all sides of the intermediate plate single- or dual-disc assemblies used in medium-duty and increase the life of the clutch.
Page 170 25.00 Eaton Fuller Solo Clutches General Information 06/23/97 f250424 1. Clutch Cover 3. Intermediate Plate 2. Rear Driven Disc 4. Front Driven Disc Fig. 2, Solo Heavy Duty Clutches 06/04/97 f250428 1. Clutch Cover 2. Wear Indicating Tab Fig. 3, Wear Indicator 050/2 Business Class M2 Workshop Manual, Supplement 18, September 2010...
Page 171 25.00 Eaton Fuller Solo Clutches Clutch Removal Use the following procedure if you need to tempo- rarily remove and then reinstall an Eaton Fuller Solo clutch. Failure to follow these steps could cause the Solo clutch to drag or not release upon installation. IMPORTANT: Check the position of the wear indicating tab on the clutch cover.
Page 172 25.00 Eaton Fuller Solo Clutches Clutch Removal Fig. 3. An old transmission input shaft may be used for this purpose. 03/02/2010 f250676 10/10/95 f250311 Fig. 3, Installing a Spline Aligning Tool Fig. 4, Installed Shipping Bolts NOTE: Shipping bolts are installed on the clutch cover prior to removal to prevent the clutch ad- justment mechanism from unloading.
Page 173 25.00 Eaton Fuller Solo Clutches Clutch Removal 10/10/95 f250313 07/30/2009 f250671 Fig. 6, Installing Guide Studs NOTE: For a 14-inch clutch , the pressure plate will be NOTE: Mark the positions of the clutch compo- reset when it is 0.50 inch (12.7 mm) below the mounting surface of the clutch cover.
Page 174 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures Inspection The total runout will be the difference be- tween the highest plus and lowest minus readings. To calculate the runout, see NOTICE Fig. Example: The highest reading is +0.004 at Misalignment of any parts described in these pro- 12 o’clock.
Page 175 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures Calculate the runout as before. NOTE: Only if you have to reposition the ﬂywheel housing is it necessary to mark the high and low runout readings in clock posi- tions. The SAE maximum total runout for the ﬂywheel-housing bore is 0.008 inch (0.20 mm).
Page 176 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures (0.20 mm) for a 15.5-inch clutch. If the readings are higher, replace the housing. For instructions, see the engine manufac- turer’s manual. NOTE: Use a case-bore plug and shaft set to measure the bell-housing face and pilot.
Page 177 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures 06/04/97 f250428 1. Clutch Cover 2. Wear Indicating Tab Fig. 9, Resetting the Wear Indicating Tab screws into the four clutch cover holes, and tighten them ﬁnger-tight plus one full turn. For 15.5-inch clutches , install four 7/16–14 x 03/02/2010 f250676...
Page 178 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures 07/30/2009 f250671 A. 0.50 inch (12.7 mm) for 14-inch clutches; 1.75 to 03/01/94 f250017a 1.78 inches (44.4 to 45.2 mm) for 15.5-inch clutches 1. Mating Surfaces 1. Mounting Surface 2. Pressure Plate 2.
Page 179 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures 08/20/2009 f250672 1. Release Fork Finger 3. Release Fork 2. Release Bearing 4. Input Shaft 05/01/2003 f250612 Fig. 13, Input Shaft, Release Bearing, and Release Fork A. Length of Input Shaft, from the Splined End to the Bearing Cap Check the ﬁt of the splined hubs of the 1.
Page 180 25.00 Eaton Fuller Solo Clutches Clutch Inspection and Pre-Installation Procedures 08/05/2010 f250678 A. Cross section of clutch brake C. Install shallow side toward the transmission B. Install deep side toward release bearing 1. Clutch Brake 2. Input Shaft Fig. 15, Installing the Clutch Brake 110/7 Business Class M2 Workshop Manual, Supplement 18, September 2010...
Page 181 25.00 Eaton Fuller Solo Clutches 14-Inch Dual Disc Clutch Installation Installation 1. Do the clutch pre-installation procedures in Sub- ject 110. 2. If not already in place, install two 3/8–16 x 3 guide studs in the two upper mounting holes of the ﬂywheel.
Page 182 25.00 Eaton Fuller Solo Clutches 14-Inch Dual Disc Clutch Installation 06/16/97 f250442a Fig. 5, Tightening Sequence 13. Follow a crisscross pattern to remove the four 06/12/97 f250436 shipping bolts from the clutch cover. See Fig. Fig. 3, Position the Rear Disc, Solo 06/12/97 f250439 1.
Page 183 25.00 Eaton Fuller Solo Clutches 14-Inch Dual Disc Clutch Installation WARNING Wear safety goggles when tapping the pins. If any of the metal parts were to chip, ﬂying pieces of metal could cause eye injury. NOTE: Only a small portion of each separator pin is visible through the access hole.
Page 184 25.00 Eaton Fuller Solo Clutches 14-Inch Dual Disc Clutch Installation 08/20/2009 f250672 1. Release Fork Finger 3. Release Fork 2. Release Bearing 4. Input Shaft Fig. 10, Release Fork NOTICE Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and then make any necessary changes.
Page 185 25.00 Eaton Fuller Solo Clutches 15.5-Inch Clutch Installation Installation 1. Do the clutch pre-installation procedures in Sub- ject 110 before installing the clutch. 2. If not already installed, insert two 7/16–14 x 5 guide studs in the upper mounting holes of the ﬂywheel.
Page 186 25.00 Eaton Fuller Solo Clutches 15.5-Inch Clutch Installation WARNING The clutch assembly is heavy. It should be re- moved and installed only with a lifting device. If the assembly is lifted incorrectly or dropped, it could cause serious personal injury. 7.
Page 187 25.00 Eaton Fuller Solo Clutches 15.5-Inch Clutch Installation • causing permanent damage to the clutch cover. 10. Following a crisscross pattern, remove and retain the four shipping bolts from the clutch cover. See Fig. 06/02/97 f250423 Fig. 7, Tap Aligning Tool 03/02/2010 f250676 Fig.
Page 188 25.00 Eaton Fuller Solo Clutches 15.5-Inch Clutch Installation NOTE: For lubrication of the release fork ﬁn- gers, Eaton Fuller recommends a lithium-base grease that can operate up to at least 325°F (163°C) and meets the NLGI Grade 1 or 2 speciﬁcation.
Page 189 25.00 Eaton Fuller Solo Clutches Resetting the Clutch When there is excessive free pedal, try resetting the a hand tool to tighten them until the gap is re- clutch. moved and the bolts are snug. For a 15.5-inch clutch , install four 7/16–14 x Resetting 1-3/4 shipping bolts (if available) or hexhead ma- chine screws into the four clutch cover holes,...
Page 190 25.00 Eaton Fuller Solo Clutches Resetting the Clutch 08/02/2006 f250655 NOTE: The bell housing is shown transparent to provide a clear view of clutch components. A. Gap Between the Sleeve and the Pin 1. Bolt 3. Pin 4. Access Panel 2.
Page 191 25.00 Eaton Fuller Solo Clutches Resetting the Clutch 08/02/2006 f250656 1. Clutch Reset Tool 3. Access Panel 2. Threaded Bolt Fig. 4, Resetting the Clutch with the Clutch Reset Tool Clutch Reset Tool Tool Description Eaton Tool Part Code Clutch Reset Tool CLPI-SOLOTOOL f580427 Table 1, Clutch Reset Tool...
Page 192 25.00 Eaton Fuller Solo Clutches Troubleshooting Troubleshooting Tables Problem—The Clutch Does Not Release Completely Problem—The Clutch Does Not Release Completely Possible Cause Remedy The clutch pedal height is incorrect. Make adjustments to obtain the following settings: • 1/2 to 9/16 inch (12.7 to 14.3 mm) release bearing travel; •...
Page 193 25.00 Eaton Fuller Solo Clutches Troubleshooting Problem—The Clutch Does Not Release Completely Possible Cause Remedy The separator pins are bent, damaged or Be sure to use the proper tool when setting the separator pins. Also, take incorrectly set. great care when handling the intermediate plate. For procedures, see the appropriate clutch installation subject.
Page 194 25.00 Eaton Fuller Solo Clutches Troubleshooting Problem—The Clutch Vibrates Problem—The Clutch Vibrates Possible Cause Remedy The ﬂywheel is loose. Retighten the ﬂywheel mounting bolts to the proper speciﬁcations. The universal joints are worn. Replace the worn parts. The driveshaft is not properly phased. Investigate and correct the phasing of the driveshaft.
Page 195 25.00 Eaton Fuller Solo Clutches Troubleshooting Problem—The Clutch Grabs or Chatters Problem—The Clutch Grabs or Chatters Possible Cause Remedy The clutch is worn out. Replace the clutch and all worn components. The linkage system is not operating freely. Check the clutch linkage for binding or excessive wear. Replace all worn parts.
Page 196 25.00 Eaton Fuller Solo Clutches Speciﬁcations Clutch Torque Values Description Size Grade Torque: lbf·ft (N·m) Mounting Bolts, Clutch Cover to Flywheel on 14-inch clutch 3/8–16 x 1-1/4 30–35 (40–47) Mounting Bolts, Clutch Cover to Flywheel on 15.5-inch clutch 7/16–14 x 2-1/4 40–50 (54–68) Table 1, Clutch Torque Values Minimum Flywheel Bores...
Page 197 25.01 Clutch Linkage General Information General Information The clutch linkage transfers the motion of the clutch pedal to the clutch release bearing. Free play in the clutch pedal is required to ensure that the ﬁngers of the release bearing do not run against the release bearing.
Page 198 25.01 Clutch Linkage Clutch Linkage Adjustment Adjustment If this measurement is 0.125 to 0.145 inch (3.2 to 3.8 mm), no further work is needed. See Fig. If the measurement is incorrect, do all of the re- 1. Observe the following points before beginning maining steps.
Page 199 25.01 Clutch Linkage Clutch Linkage Adjustment 09/12/2002 f250596 1. Clutch Pedal 6. Jam Nut 2. Return Spring 7. Clutch Rod 3. Spring Bracket 8. Lower Lever Arm Nut 4. Upper Lever Arm 9. Lower Lever Arm 5. Upper Lever Arm Nut Fig.
Page 200 25.01 Clutch Linkage Speciﬁcations Description Torque in lbf·ft (N·m) Jam Nut 12 to 15 (16 to 20) Upper Lever Arm Nut 23 to 29 (31 to 39) Table 1, Torque Values, Clutch Linkage Adjustment 400/1 Business Class M2 Workshop Manual, Supplement 4, March 2003...
Page 201 25.02 Clutch Hydraulic System General Information General Information The hydraulic clutch control system consists of a pedal unit and a slave cylinder, connected by a hy- draulic hose that is fastened with quick-disconnect clips. See Fig. 1. The hydraulic system is self- adjusting, and it uses DOT 4 brake ﬂuid.
Page 202 25.02 Clutch Hydraulic System Pedal Unit Removal and Installation Removal Using a drain pan or other suitable con- tainer, collect the ﬂuid that drains from the pedal unit, not more than 0.5 quarts (0.5 WARNING liters). Allow the open end of the drain hose to Clutch hydraulic ﬂuid (DOT 4 brake ﬂuid) is haz- remain over the drain pan.
Page 203 25.02 Clutch Hydraulic System Pedal Unit Removal and Installation Snap the hydraulic hose into place. Tug on the hose to make sure it is in- stalled correctly. The hose should not pull out easily. NOTE: Don’t force the hose into the master cylinder.
Page 204 25.02 Clutch Hydraulic System Hydraulic Subassembly Replacement Replacement 1. Place a suitable container under the master cyl- inder to collect the ﬂuid that will drain as the hose is removed from the master cylinder. 2. Use a ﬂat-tip screwdriver to remove the quick- disconnect clip that locks the hydraulic hose into the master cylinder.
Page 205 25.02 Clutch Hydraulic System Hydraulic Subassembly Replacement 13. Fill the reservoir with approved DOT 4 hydraulic brake ﬂuid and bleed the system as instructed in Subject 130. 14. Check the function of the clutch actuation system as instructed in Subject 300.
Page 206 25.02 Clutch Hydraulic System Slave Cylinder Replacement Replacement 8. Mount the slave cylinder on the gear case, as removed. Make sure that the pushrod is attached to WARNING the clutch fork and inserted into the push- rod bore in the slave cylinder. Clutch hydraulic ﬂuid (DOT 4 brake ﬂuid) is haz- ardous.
Page 207 25.02 Clutch Hydraulic System Slave Cylinder Replacement 12/11/2001 f250582 Mount the slave cylinder with the bleed valve on top of the unit and horizontal to the ground. 1. Clamp Mounting Bolt, 1/4–20 6. Hydraulic Hose 2. Steel-Plated Washer 7. Slave Cylinder 3.
Page 208 25.02 Clutch Hydraulic System SACHS 365 mm Clutch Removal and Installation Special Tools A special tool is used for this procedure. See Table Special Tool Tool Description Manufacturer Part Number Clutch Centering Pin Kent-Moore J-45719 f580335 Table 1, Special Tool NOTE: To check tool availability, and to order NOTE: Do not grease the guide of the release tools, call SPX Kent-Moore at 1-800-328-6657.
Page 209 25.02 Clutch Hydraulic System SACHS 365 mm Clutch Removal and Installation 09/23/2005 f250626 1. Disc Assembly 4. Clutch Capscrews, 3/8–16 x 5. Input Shaft 2. Cover Assembly 13/16 6. Release Bearing 3. Washer Fig. 1, Clutch Assembly and not overlapping it. Use a ﬂashlight to more tension on one side of the clutch help verify the positioning if needed.
Page 210 25.02 Clutch Hydraulic System SACHS 365 mm Clutch Removal and Installation 11/02/2005 f250625 1. Centering Pin 2. Guide Pin 08/20/2008 f250668 Fig. 4, Capscrew Tightening Sequence Fig. 2, Centering the Clutch 08/20/2008 f250669 1. Flywheel 2. Flywheel Rim Fig. 3, Flywheel Rim 130/3 Business Class M2 Workshop Manual, Supplement 15, March 2009...
Page 211 25.02 Clutch Hydraulic System Fluid Filling and Bleeding 5. Pressurize the reservoir to ﬁll the system. Open WARNING the bleed valve on the bleed tank of the adaptor. Hydraulic clutch control ﬂuid (DOT 4 brake ﬂuid) NOTE: The hydraulic system holds approxi- is hazardous.
Page 212 25.02 Clutch Hydraulic System Fluid Filling and Bleeding 12/11/2001 f250582 1. Clamp Mounting Bolt, 1/4–20 6. Hydraulic Hose 2. Steel-Plated Washer 7. Slave Cylinder 3. Locknut, 1/4–20 8. Bleed Valve 4. Bell Housing Standoff Bracket 9. Bell Housing 5. Slave Cylinder Standoff Bracket 10.
Page 213 25.02 Clutch Hydraulic System Fluid Filling and Bleeding 7. Disconnect the transparent hose. Tighten the bleed valve 88 lbf·in (1000 N·cm) and install the cap on the slave cylinder bleed valve. 8. Check the ﬂuid level in the reservoir. If neces- sary, add or drain ﬂuid to bring the ﬂuid level to between the MIN and MAX lines marked on the side of the reservoir.
Page 214 25.02 Clutch Hydraulic System Release Bearing and Yoke Assembly Replacement Replacement 5. Install the bearing onto the release yoke. NOTE: Do not grease the guide of the release 1. Remove the transmission from the engine. bearing. It is made from an advanced composite •...
Page 215 25.02 Clutch Hydraulic System Hydraulic Hose Replacement Replacement parts of the system, causing loss of clutch func- tion and the risk of serious personal injury. 1. Park the vehicle on a level surface, shut down 8. Fill the reservoir with approved DOT 4 hydraulic the engine, and set the parking brake.
Page 216 25.02 Clutch Hydraulic System Hydraulic Hose Replacement 05/07/2007 f250661 1. Hydraulic Hose 2. Quick-Disconnect Clip 3. Master Cylinder Fig. 2, Quick-Disconnect Clip at the Master Cylinder 160/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 217 25.02 Clutch Hydraulic System Clutch Switch Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Open the hood. 3. Disconnect the clutch control switch located under the dash and above the clutch pedal, as follows.
Page 218 25.02 Clutch Hydraulic System SACHS 395 XTend Clutch Removal and Installation Special Tools A special tool is used for this procedure. See Table Special Tool Tool Description Manufacturer Part Number Clutch Centering Pin Kent-Moore J-45719 f580335 Table 1, Special Tool NOTE: To check tool availability, and to order tools, call SPX Kent-Moore at 1-800-328-6657.
Page 219 25.02 Clutch Hydraulic System SACHS 395 XTend Clutch Removal and Installation 09/26/2005 f250627 1. Disc Assembly 3. Washer 5. Input Shaft 2. Cover Assembly 4. Clutch Capscrews, M10 x 80 6. Release Bearing Fig. 2, Clutch Assembly 1. Grease the splines of the input shaft and the hub IMPORTANT: Do not remove the centering pin of the disc assembly.
Page 220 25.02 Clutch Hydraulic System SACHS 395 XTend Clutch Removal and Installation IMPORTANT: Never allow the diaphragm spring to rest on the centering pin. Slide the clutch cover assembly onto the guide pins, and position it inside the raised rim of the ﬂywheel. See Fig.
Page 221 25.02 Clutch Hydraulic System SACHS 395 XTend Clutch Removal and Installation 08/20/2008 f250668 Fig. 5, Capscrew Tightening Sequence 180/4 Business Class M2 Workshop Manual, Supplement 15, March 2009...
Page 222 25.02 Clutch Hydraulic System Hydraulic Clutch Adjustment General Information If the blue 0.56-inch (14.3-mm) end can’t be in- serted in the gap, then try to insert the green 0.50-inch (12.7-mm) end. Most hydraulically actuated clutches are auto- adjusting and require no manual adjustment under If the green end of the tool can’t be inserted in normal operating conditions.
Page 223 25.02 Clutch Hydraulic System Hydraulic Clutch Adjustment 03/26/96 f580133 A. Green End (0.50 inch or 12.7 mm) B. Blue End (0.56 inch or 14.3 mm) Fig. 2, Release Bearing Travel Tool A02-12419-000 09/15/95 f250309 Fig. 4, Adjustment with Kwik-Adjust (bell housing shown removed) release bearing moves toward the trans- mission).
Page 224 25.02 Clutch Hydraulic System Troubleshooting Diagnostic Checks IMPORTANT: If any problems are noticed during these diagnostic checks, take corrective action using the information under the heading "Troubleshooting Tables." When repairing any components, bleed the clutch hydraulic system before restoring the vehicle to ser- vice.
Page 225 25.02 Clutch Hydraulic System Troubleshooting NOTE: This step requires two persons. 5. With both the brake and the clutch pedals pressed down, start the engine. 3. Have one person press down on the clutch pedal If the engine does not start, take correc- while the other person checks the clutch hydrau- tive action using the information under the lic system for signs of leakage.
Page 226 25.02 Clutch Hydraulic System Troubleshooting Problem–The Clutch Pedal Is Unusually Hard To Operate Possible Cause Remedy The return or assist spring is broken. Replace the pedal unit. See Subject 100 for instructions. WARNING Do not attempt to disassemble the preloaded assist spring. Sudden release of the assist spring could cause property damage and serious personal injury.
Page 227 25.02 Clutch Hydraulic System Troubleshooting Problem–The Clutch Pedal Does Not Return Problem–The Clutch Pedal Does Not Return Possible Cause Remedy The return or assist spring is broken. Replace the pedal unit. See Subject 100 for instructions. WARNING Do not attempt to disassemble the preloaded assist spring. Sudden release of the assist spring could cause property damage and serious personal injury.
Page 228 25.02 Clutch Hydraulic System Speciﬁcations For fastener torque values, see the tables below. Description Size Grade/Class Torque: lbf·ft (N·m) Torque: lbf·in (N·cm) Bleed Screw — — 88 (1000) Clutch Capscrews 3/8–16 37 (50) — Clutch Switch Mounting Screw — — 23 (260) Hydraulic Sub-Assembly Retainer —...
Page 229 25.02 Clutch Hydraulic System Special Tools Special Tools Tool Description Manufacturer Part Number Clutch Centering Pin Kent-Moore J-45719 f580335 Clutch Release Bearing Travel Tool A02-12419-000 f580133a Table 1, Special Tools 500/1 Business Class M2 Workshop Manual, Supplement 9, March 2006...
Page 230 26.00 Eaton Fuller Manual Transmission Removal and Installation Removal Remove the midship bearing bracket. See Fig. 1. Park the vehicle on a level surface. Shut down Support the disconnected driveshaft and the engine, set the parking brake, and chock the chain it out of the way.
Page 231 26.00 Eaton Fuller Manual Transmission Removal and Installation 08/26/2003 f261269 1. Shift Knob 5. Boot 10. Shift Linkage Adaptor 2. Retaining Ring Screw, M6 (4 6. Floor Covering 11. Shift Linkage Flange Screw, M10 qty.) 7. Cover Plate Screw, M6 (8 qty.) (2 qty.) 3.
Page 232 26.00 Eaton Fuller Manual Transmission Removal and Installation 06/05/2001 f261005 1. Transmission 2. Output Yoke 3. Driveline 08/15/2003 f261270 Fig. 3, Output Yoke 1. Shift Tower Mounting Capscrew, 3/8–16 (4 qty.) 2. Shift Tower 3. Shift Linkage Adaptor 4. Shift Lever Fig.
Page 233 26.00 Eaton Fuller Manual Transmission Removal and Installation 08/21/2003 f261271 01/28/99 f261007 1. Socket Wrench 2. Transmission Top Cover Fig. 5, Support the Driveline 3. Gear Case 4. Bracket Fig. 7, Fuel Line Standoff Bracket Align the jack and the transmission behind the engine.
Page 234 26.00 Eaton Fuller Manual Transmission Removal and Installation 08/19/2003 f261275 1. Gear Case 2. Hanger Bracket Fig. 10, Exhaust Pipe Hanger Bracket 11/11/2003 f261273 1. Hydraulic Line 3. Mounting Screw 2. Slave Cylinder 4. Bell Housing Fig. 8, Hydraulic Clutch Slave Cylinder 08/15/2003 f261274 08/25/2003...
Page 235 26.00 Eaton Fuller Manual Transmission Removal and Installation 08/14/2003 f261279 Make sure the ﬁngers of the release yoke are rotated to clear the release bearing. 1. Bell Housing 2. Release Yoke 3. Input Shaft 4. Input Shaft Splines 01/29/99 f261013 Fig.
Page 236 26.00 Eaton Fuller Manual Transmission Removal and Installation spacer points inboard as shown in Fig. Tighten the four mounting bolts 15 lbf·ft (20 N·m). 09/02/2003 f261278 The tab on the spacer must face inboard. 08/14/2003 f261277 The ﬁnger of the release yoke must ﬁt as shown into 1.
Page 237 26.00 Eaton Fuller Manual Transmission Removal and Installation • 25 to 35 lbf·ft (34 to 48 N·m) for Eaton Fuller transmissions with 3/4-inch pipe threads. • 60 to 75 lbf·ft (81 to 102 N·m) for Eaton Fuller transmissions with 1-1/4-inch pipe threads.
Page 238 26.00 Eaton Fuller Manual Transmission Speciﬁcations Torque Values, Eaton Fuller Transmissions Torque: Torque: Description Size Grade lbf·ft (N·m) lbf·in (N·cm) Bell Housing-to-Timing Case Capscrews M10 x 1.5 33 (45) — Clutch Slave Cylinder Bracket Mounting Bolts 15 (20) — Fuel Cross-Over Line Mounting Bolts —...
Page 239 26.01 Allison Automatic Transmission Removal and Installation Removal bracket so the driveshaft can be moved far enough back. 1. Park the vehicle on a level surface, shut down Support the disconnected driveshaft and the engine, apply the parking brake, and chock tie it to the frame rail.
Page 240 26.01 Allison Automatic Transmission Removal and Installation Remove the capscrews that attach the ring gear access cover, then remove the cover. See Fig. 08/04/94 f260111a 09/27/2001 f261137 Fig. 3, Ring Gear Access NOTE: Rear-mounted hoses shown, but hoses may be attached at the front of the transmission.
Page 241 26.01 Allison Automatic Transmission Removal and Installation transmission is securely chained to the trans- mission jack. 1. Raise the vehicle frame with a hydraulic jack to obtain adequate clearance for installing the transmission. Place jack stands under the front of the vehicle. 2.
Page 242 26.01 Allison Automatic Transmission Removal and Installation 7. Tighten the 12 M10 transmission-ﬂange bolts 38 15.2 Install the ﬁll/dipstick tube and clamp. to 45 lbf·ft (51 to 61 N·m) in a star pattern. See Tighten the self-tapping screw until it is Fig.
Page 243 26.01 Allison Automatic Transmission ATF Cooler Replacment (stand-alone unit) NOTE: If the vehicle is equipped with the inte- gral radiator/cooler, see Section 20.01 for re- placement instructions. Replacement 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake, and chock the tires.
Page 244 26.01 Allison Automatic Transmission ATF Cooler Replacment (stand-alone unit) CAUTION DO NOT reuse the retaining clips. Use a new re- taining clip each time the hoses are removed. Failure to do so could result in the cooler hoses coming out of the cooler during vehicle opera- tion, leaking ATF and causing permanent damage to the transmission.
Page 245 26.01 Allison Automatic Transmission ATF Cooler Replacment (stand-alone unit) 12. Check the coolant level and add as needed. 13. Remove the tire chocks. 110/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 246 26.01 Allison Automatic Transmission Transmission ECU Replacement A new transmission control module (TCM) was intro- 6. Place the new TCM over the mounting posts, duced by Allison Transmissions in mid-2006. This and install the washers and nuts. Tighten the control — known as "fourth generation" — replaced nuts 24 lbf·in (271 N·cm).
Page 247 26.01 Allison Automatic Transmission Transmission ECU Replacement 6. Connect the blue, black, and gray electrical har- nesses to the appropriate ports on the ECU. 7. Remove the chocks from the tires. 120/2 Business Class M2 Workshop Manual, Supplement 10, September 2006...
Page 248 26.02 Transmission Shift Control, Freightliner SmartShift General Information General Information ™ The SmartShift transmission shift control is an elec- tronic transmission control device. It is applicable to automated mechanical transmissions and is required with the Mercedes-Benz AGS Automated Gear Shift ®...
Page 249 26.02 Transmission Shift Control, Freightliner SmartShift General Information 01/29/2003 f270121 1. Upshift (in manual mode, pull upward) 2. Steering Wheel 3. Downshift (in manual mode, push downward) 4. Steering Column Fig. 3, SmartShift Control Operation • For AGS, the selector switch has three posi- tions (R, N, D).
Page 250 26.02 Transmission Shift Control, Freightliner SmartShift Replacement Replacement 1. Shut down the engine, set the parking brakes, and chock the rear tires. 2. Remove the steering column covers. For detailed procedures, see Section 46.02, Subject 110. 3. Disconnect the electrical connector from the SmartShift module.
Page 251 Transmission Shift Control, Freightliner SmartShift Troubleshooting General Information The following information is provided to help deter- mine whether a potential transmission problem is ac- tually the transmission or possibly the Freightliner ® SmartShift Transmission Shift Control. Resistance checks at the SmartShift connector can help determine connection problems.
Page 252 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting 2. Remove the screws that secure the steering col- umn trim panels, and separate the forward and rear panels to access the shift control. See Fig. 3. Disconnect the electrical connector from the plug on the shift control unit.
Page 253 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting Resistance on SmartShift Controls at B and C (Except Meritor SureShift) Selector Switch Position Reading: kOhm 2.947–3.067 0.347–0.361 0.606–0.630 1.65–1.72 Applies to four-position (R-N-D-L) controls only. Table 2, Resistance on SmartShift Controls at B and...
Page 254 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting ™ SureShift , click on SmartShift with Meritor SureShift. NOTE: The DLM template for the SureShift transmission will not work with the ZF Meritor FreedomLine transmission. For further diagnos- tic assistance on FreedomLine transmissions, use Meritor’s TransSoft software.
Page 255 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting DataLink Monitor Range Gear Battery Voltage Software Selected Attained Version: (Lever): (Trans.): Gear Actuator Up−Shift Req. Ign. Switch Switched Batt. (Ign.) Shaft Speeds [rpm] Input Main Output 3000 Rail Actuator Ign. Interrupted Down−Shift Req.
Page 256 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting SmartShift Control Testing for ZF NOTE: The DLM template for the SureShift transmission will not work with the FreedomLine Meritor SureShift and transmission. For further diagnostic assistance FreedomLine on FreedomLine transmissions, use Meritor’s TransSoft software.
Page 257 26.02 Transmission Shift Control, Freightliner SmartShift Troubleshooting Make sure all tires are chocked and the parking brake is set before performing the following tests. These tests require the vehicle to be started, and precautions need to be taken to en- sure the vehicle will not move.
Page 258 M2 vehicles for years. In 2010, the clutch and the shift mechanism. It receives requests 3 ™ name changed to Freightliner AMT Automated- from the shift lever to change drive modes and Manual Transmission, and new model numbers were gears.
Page 259 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions General Information Principles of Operation A shift can be requested either manually, by pushing or pulling the SmartShift lever, or automatically. The AGS judges when to shift automatically through infor- mation provided by rotational speed (rpm) sensors.
Page 260 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions General Information 03/17/2004 f270125 1. X-Y Actuator 2. Reservoir 3. Accumulator 4. Central Unit Fig. 1, AGS Unit Components 06/02/2004 f580377 NOTE: The tool with the large opening (top) is used to disconnect the low-pressure hoses. The tool with the small opening (bottom) is used to disconnect the high- pressure lines.
Page 261 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Removal and Installation Removal mounting bolts from the bell housing except for the top two. See Fig. 1. Park the vehicle on a level surface. Shut down 7. Remove the two screws attaching the splash the engine, set the parking brake, and chock the guard to the TCU.
Page 262 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Removal and Installation 01/30/2004 f261297 1. Cover Plate 4. Washer 6. Cab Floor 2. Mounting Bolt, Cover Plate 5. Floor Plate 7. Spring Clip 3. Mounting Bolt, Floor Plate Fig. 2, Floor Access...
Page 263 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Removal and Installation 02/17/2004 f544407 1. X3 Connector 2. Electric Motor Harness Fig. 5, Harness Connector that the transmission is securely chained to the support plates on the transmission jack. 1. Align the input shaft so that its splines engage f261299 the clutch.
Page 264 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Removal and Installation 03/17/2004 f261318 Fill the reservoir to the level indicated by the arrow. Fig. 8, Hydraulic Fluid Fill Level edge of the ﬁll opening. See Fig. 9 for the loca- tion of the ﬁll plug and...
Page 265 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Removal and Installation f260006b 10/05/94 A. Full B. Low Fig. 10, Transmission Fluid Level Checking 100/5 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 266 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Control Unit Replacement IMPORTANT: To successfully replace the trans- mission control unit (TCU) on the vehicle, there must be at least 2-3/4 inches (70 mm) clear- ance between the TCU and the frame rail.
Page 267 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Control Unit Replacement 03/03/2004 f544403 When installing the new TCU, be sure to align the guide pins (arrows). 1. TCU 2. Seal Ring Fig. 3, TCU Seal Ring Check that the seal ring does not get pinched along the line where the TCU meets the hydraulic body.
Page 268 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Sensor Replacement Replacement Shift Position Sensors The shift position sensors, shown in Fig. 2, are inte- IMPORTANT: Depressurize the hydraulic system gral to the x-y actuator and cannot be replaced with- before replacing any of the hydraulic out replacing the x-y actuator.
Page 269 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Sensor Replacement 5. Insert a new cap with probe into the hydraulic reservoir. 6. Attach the electrical connector to the new cap and make sure the new cap is tightly fastened.
Page 270 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Sensor Replacement f261308 02/19/2004 1. Output Shaft Speed Sensor #2 2. Connector, Sensor #2 3. Connector, Sensor #1 4. Output Shaft Speed Sensor #1 Fig. 5, Output Shaft Speed Sensors 120/3...
Page 271 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Bleeding and Recalibration Bleeding NOTE: As the hydraulic pump builds pres- sure, you may hear it humming. IMPORTANT: Bleed the hydraulic system after Turn on the ignition, and wait one minute.
Page 272 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Bleeding and Recalibration displays "N", proceed to the next step. If it ﬂashes "SM-N", turn off the ignition, wait two minutes or until the display clears, and proceed to the next step.
Page 273 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Accumulator Replacement Special Tool A special tool is required for this procedure. See Table Special Tool for Accumulator Replacement Tool Description Manufacturer Part Number Accumulator Torque Adaptor Kent-Moore J-47291 f580381 Table 1, Special Tool for Accumulator Replacement Replacement 1.
Page 274 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Accumulator Replacement Using the torque wrench and adaptor as- sembly, tighten the M30 ﬁtting 55 lbf·ft (75 N·m). 6. Check the hydraulic ﬂuid level and add more Pentosin if needed. For detailed procedures, see Subject 150.
Page 275 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Hydraulic Fluid Reservoir Replacement Special Tool A special tool is required for this procedure. See Table Special Tool for Hydraulic Fluid Reservoir Replacement Tool Description Manufacturer Part Number Low-Pressure Hose Disconnect Tool Kent-Moore...
Page 276 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Hydraulic Fluid Reservoir Replacement 5. Remove the electrical connector from the reser- 7. Remove the reservoir from the transmission. voir cap. See Fig. 8. Position the new reservoir in the transmission. Install the two M6 fasteners that fasten it to the gear box and tighten them 71 lbf·in (800 N·cm).
Page 277 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Hydraulic Fluid Reservoir Replacement 13. Start the engine and allow the system to pressur- ize. Shift back and forth a few times from drive to reverse and back to neutral. NOTE: The ﬁrst few shifts after draining and re- ﬁlling the hydraulic system will take longer than...
Page 278 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Hydraulic System Depressurization IMPORTANT: Depressurize the hydraulic system before removing the transmission or replacing any hydraulic components. Depressurization Normal Procedure 1. Shut down the engine and set the parking brake. 2. Connect ServiceLink to the vehicle. Start the "AGS Procedures"...
Page 279 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Hydraulic System Depressurization File Help Note: You first must start communication with the AGS ECU before Start communication with entering into diagnostic mode. The Transmission AGS ECU will kick you out of diagnostic mode without first establishing this contact.
Page 280 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions X-Y Actuator Replacement Special Tool A special tool is required for this procedure. See Table Special Tool for X-Y Actuator Replacement Tool Description Manufacturer Part Number High-Pressure Line Disconnect Tool Kent-Moore J-47201 f580379...
Page 281 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions X-Y Actuator Replacement NOTE: Make sure the actuator is seated ﬁrmly The lines snap into place with an audible click. When the installation is correct, the on the mounting ﬂange. Do not use the mount- outermost O-ring is no longer visible.
Page 282 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions X-Y Actuator Replacement 02/18/2004 f261304 The outermost O-ring (arrow) is not visible when the line is installed correctly. Fig. 3, Snap the Lines Into Place 12. Start the engine and allow the system to pressur- ize.
Page 283 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Harness Replacement Replacement Remove the connector from the plug on the reservoir cap. NOTE: This procedure can be done with the 6. Unscrew the electrical connectors from the gear and rail position sensors on the x-y actuator.
Page 284 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Transmission Harness Replacement 02/10/2004 f261298 1. Clutch Position Sensor 4. Fluid Level Sensor 6. Output Shaft Speed Sensor #2 2. Gear Position Sensor 5. Output Shaft Speed Sensor #1 7. Input Shaft Speed Sensor 3.
Page 285 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Central Unit Replacement Special Tool A special tool is required for this procedure. See Table Special Tool for X-Y Actuator Replacement Tool Description Manufacturer Part Number High-Pressure Line Disconnect Tool Kent-Moore J-47201...
Page 286 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Central Unit Replacement 01/13/2005 f544421 03/10/2004 f261317 1. TCU 3. X-Y Actuator 2. Hydraulic Body 4. Hydraulic Line 1. High-Pressure Line Disconnect Tool 2. Metal Ring 3. High-Pressure Hydraulic Line Fig. 2, Hydraulic Lines on the Central Unit Fig.
Page 287 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Central Unit Replacement 14. Check the hydraulic ﬂuid level and add more Pentosin as needed. For detailed procedures, Subject 150. IMPORTANT: Use only Pentosin in the hydraulic reservoir. No other ﬂuid can be substituted.
Page 288 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Assembly Removal and Installation Special Tools Special tools are required for this procedure. See Table Special Tools for AGS Assembly Installation Tool Description Manufacturer Part Number Shift Finger Alignment Fork Kent-Moore J-47204...
Page 289 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Assembly Removal and Installation 12.2 Remove the sheet metal shift cover at the end of the shift cover housing. See Fig. Tap the shift cover with a drift to dislodge it, and then pull it out of the shift cover housing with pliers.
Page 290 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Assembly Removal and Installation 02/18/2004 f261307 06/03/2004 f261325 1. Shift Finger 3. Shift Rod 1. End Guide 3. Setscrew 2. Alignment Fork 4. Removal Cord 2. Shift Cover Housing Fig. 4, Align the Shift Finger Fig.
Page 291 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions AGS Assembly Removal and Installation Press a new shift cover onto the shift cover housing. 3. Install the hydraulic ﬂuid reservoir. For detailed procedures, see Subject 150. 4. Install the accumulator. For detailed procedures, Subject 140.
Page 292 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Actuator Replacement Replacement 4. Loosen the clutch actuator mounting capscrews, but do not remove them yet. NOTE: Replacement of the clutch actuator re- 5. Lift up the spring clip from the hydraulic line and...
Page 293 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Actuator Replacement 02/23/2004 f261312 1. Mounting Plate Capscrew 2. Connector Plug 3. 30-mm Hexhead Hydraulic Bleed Fitting 03/17/2004 f261313 4. Bleed Screw 1. Lip of Bell Housing 5. Spring Clip 2. Input Shaft 6.
Page 294 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions General Troubleshooting IMPORTANT: Always use ServiceLink when at- But in most cases, the J1587 fault code is the start- ing point for the troubleshooting procedures. See tempting to diagnose problems with the AGS Table 1 to ﬁnd information for SID fault codes.
Page 295 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions General Troubleshooting Fault Code Guide (MID 130 SIDs) Text Message Failure Reason Procedure Controller Short Lo The TCU is shorted to ground. Subject 309. Controller OPEN The TCU has an open circuit. Subject 309.
Page 296 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions General Troubleshooting Fault Code Guide (MID 130 PIDs) Text Message Failure Reason Procedure RANGE Selected Erratic The transmission is not properly calibrated. Subject 316. RANGE Attained Erratic The gears do not shift properly.
Page 297 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes IMPORTANT: Always use ServiceLink when at- Use the electrical pre-test instructions given in Table 1 as a baseline for troubleshooting when there tempting to diagnose problems with the auto- is no deﬁnite problem, the malfunction is erratic or...
Page 298 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes Electrical Pre-Test Procedure Result Action Check for resistance between pin 2 Resistance is greater than 0.3 ohms. Repair or replace the wiring as (ground) of the X3 connector and the needed.
Page 299 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes Electrical Pre-Test Procedure Result Action Turn off the ignition switch. Check the ignition ground circuit. 07/21/2004 f544483d With the ignition switch off, check for Resistance is greater than 0.3 ohms.
Page 300 Resistance is less than 55 or greater Troubleshoot the J1939 datalink. See connector from the TCU and check for than 65 ohms. Freightliner Service Bulletin 54-133. resistance between pins 7 and 13 (J1939 Resistance is between 55 and 65 The vehicle has passed the electrical datalink).
Page 301 Fig. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Engine Will Not Crank No J1587 Fault Code—"FL" on Current Gear Indicator; CHECK TRANS Light Illuminates Problem...
Page 302 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Even though the CHECK TRANS light illuminates, it is normal to see no active fault code. Table 3, Low Fluid Level Indication 301/6...
Page 303 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes No J1587 Fault Code—Transmission Fully Functional; No Information on Current Gear Indicator Problem Procedure Result Action The wiring from the X1 Power up the transmission. The current gear indicator...
Page 304 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes AGS Messages on the Current Gear Indicator Code Error Undeﬁned Gear Position Incomplete Calibration Gear or Rail Position Sensor Error "––" No J1587 Communication No Power to Gear Display "(blank screen)"...
Page 305 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Troubleshooting Without Fault Codes Date: VIN: Mileage: Serial Numbers X−Y Actuator: TCU: AGS: SID/PID SID/PID Codes: Codes: (136) (128) Full Below Above Gear Pentosin Gear seam seam level: display display power (with show system "N":...
Page 306 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions SmartShift Fault (SID 18) • To check resistance on the SmartShift up/ SmartShift Fault downshift circuit, see Table • To check resistance on the SmartShift gear There is one SmartShift fault covered in these proce- dures.
Page 307 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Shift Lever Does Not Shift Gears Resistance Check for the Up/Downshift Circuit (Pin A Resistance Check for the Gear Selection Circuit (Pin...
Page 308 3. With the results, contact Mercedes- Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Pressure Sensor Is Shorted or Open 303/1 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 309 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Hydraulic Pump Faults (SID 52) • For SID 52, FMI 05 and FMI 07, see Hydraulic Pump Faults Table 1 for procedures. • For SID 52, FMI 11, see There are three hydraulic pump faults covered in...
Page 310 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Hydraulic Pump Pressure Does Not Increase SID 52, FMI 11—The Hydraulic Pump Temperature Is Too High Failure Reason: •...
Page 311 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Hydraulic Pump Temperature Is Too High 304/3 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 312 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Actuator Faults (SID 55) • For SID 55, FMI 00, see Clutch Actuator Faults Table 1 for proce- dures. • For SID 55, FMI 07, see There are three clutch actuator faults covered in...
Page 313 Subject 301. 3. With the results, contact Mercedes- Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Complete a learning procedure using No fault codes. ServiceLink. Table 2, The Clutch Does Not Operate Properly...
Page 314 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Actuator Faults (SID 55) SID 55, FMI 13—The Clutch Needs To Be Calibrated Failure Reason: • The clutch is not calibrated properly. • There is a mechanical defect in the clutch system.
Page 315 Troubleshoot the J1939 are not plausible. other systems, particularly the engine with the J1939 datalink. datalink. See Freightliner (MID 128), the antilock brakes (MID 136) Service Bulletin 54-133. and the bulkhead module (MID 164). Table 1, The J1939 Datalink Is Not Communicating Properly SID 231, FMI 09—The J1939 Datalink Message Has Timed Out...
Page 316 The resistance is less than Troubleshoot the J1939 datalink. defective. removed, check for 54 or more than 66 ohms. See Freightliner Service Bulletin resistance between pin 7 54-133. and pin 13. The resistance is between 54 Go to the next step in the table.
Page 317 SID 231, FMI 12 is active for Troubleshoot the J1939 datalink for failure in the TCU. removed, check whether other systems (MIDs). the other systems. See Freightliner other systems have the Service Bulletin 54-133. identical fault code active This fault is not active for Contact Mercedes-Benz (SID 231, FMI 12).
Page 318 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Battery Power Supply Faults (SID 251) • For SID 251, FMI 01, see Battery Power Supply Faults Table 2 for proce- dures and pin identiﬁcation. • For SID 251, FMI 05, see There are four battery power supply faults covered in...
Page 319 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Battery Voltage Is Too High 307/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 320 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Battery Power Supply Faults (SID 251) SID 251, FMI 01—The Battery Voltage Is Too Low Failure Reason: • There is a failure of the vehicle charging sys- tem. • The power circuits lack continuity to ground.
Page 321 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Battery Voltage Is Too Low 307/4 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 322 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Battery Power Supply Faults (SID 251) SID 251, FMI 05—There Is No Power to the Transmission With the Engine Running Failure Reason: • A fuse is blown. • There is a defect in the wiring.
Page 323 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 3, There Is No Power to the Transmission With the Engine Running 307/6 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 324 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Battery Power Supply Faults (SID 251) SID 251, FMI 14—The Power Supply Is Not Properly Grounded Failure Reason: • There is a defect in the wiring. • There is a defect in the TCU.
Page 325 10 seconds of audible alert. When the (503.961.8435), email gear display clears, this procedure is complete. (MBTServiceSupport@ Freightliner.com), or phone NOTE: If during this procedure an ’SM’ or ’X’ (after the (503.745.4965 or 503.745.4988). warm up procedure) appears in the gear display, stop, turn off the ignition, and wait for the gear display to go dark.
Page 326 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The TCU Is Shorted to Ground or Open 309/1 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 327 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Control Unit Faults (SID 254) SID 254, FMI 11—The TCU AUTO Mode Software Module Has an Error Failure Reason: • The engine ECU is not providing valid data. • There is faulty data in programmable memory (EEPROM).
Page 328 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Control Unit Faults (SID 254) SID 254, FMI 11—The TCU AUTO Mode Software Module Has an Error Failure Reason: • The engine ECU is not providing valid data. • There is faulty data in programmable memory (EEPROM).
Page 329 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 3, The TCU Has a Hardware Problem 309/4 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 330 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 4, The TCU Has a Software Memory Problem 309/5 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 331 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Position Sensor Faults (PID 33) • For PID 33, FMI 04, see Clutch Position Sensor Faults Table 3 for proce- dures and pin identiﬁcation. • For PID 33, FMI 05, see There are ﬁve clutch position sensor faults covered...
Page 332 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Clutch Position Sensor Is Providing Invalid Data 310/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 333 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Position Sensor Faults (PID 33) PID 33, FMI 03—The Clutch Position Sensor Circuit Is Shorted to Power Failure Reason: • There is a defect in the wiring. • There is a defect in the TCU.
Page 334 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Position Sensor Faults (PID 33) PID 33, FMI 04—The Clutch Position Sensor Circuit Is Shorted to Ground Failure Reason: • There is a defect in the wiring. • There is a defect in the clutch position sensor.
Page 335 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 3, The Clutch Position Sensor Circuit Is Shorted to Ground 310/5 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 336 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Position Sensor Faults (PID 33) PID 33, FMI 05—The Clutch Position Sensor Circuit Is Open Failure Reason: • There is a defect in the wiring. • There is a defect in the clutch position sensor.
Page 337 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 4, The Clutch Position Sensor Circuit Is Open 310/7 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 338 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 5, The Clutch Position Sensor Gives Incorrect Resistance Readings 310/8 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 339 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Clutch Position Sensor Faults (PID 33) Harness Visual Check, Clutch Position Sensor 1. Remove the X2 female connector from the TCU. Check the plugs on the connector. If any plug(s) in the connector is damaged, soiled, worn, bro- ken, or corroded, replace the connector.
Page 340 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) • For PID 59, FMI 04, see Gear Position Sensor Faults Table 3 for proce- dures and pin identiﬁcation. • For PID 59, FMI 05, see There are ﬁve gear position sensor faults covered in...
Page 341 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). The resistance is between 34 The sensor is OK. Go to the and 122 ohms. next row in the table.
Page 342 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) PID 59, FMI 02—The Gear Position Sensor Is Providing Invalid Data Failure Reason: • There is a defect in the wiring. • There is a defect in the gear position sensor.
Page 343 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Gear Position Sensor Is Providing Invalid Data 311/4 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 344 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) PID 59, FMI 03—The Gear Position Sensor Circuit Is Shorted to Power Failure Reason: • There is a defect in the wiring. • There is a defect in the TCU.
Page 345 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Gear Position Sensor Circuit Is Shorted to Power 311/6 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 346 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) PID 59, FMI 04—The Gear Position Sensor Circuit Is Shorted to Ground Failure Reason: • There is a defect in the wiring. • There is a defect in the gear position sensor.
Page 347 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 3, The Gear Position Sensor Circuit Is Shorted to Ground 311/8 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 348 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) PID 59, FMI 05—The Gear Position Sensor Circuit Is Open Failure Reason: • There is a defect in the wiring. • There is a defect in the gear position sensor.
Page 349 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 4, The Gear Position Sensor Circuit Is Open 311/10 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 350 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 5, The Gear Position Sensor Gives Incorrect Resistance Readings Harness Visual Check, Gear transmission wiring harness. See Subject 180 for procedures.
Page 351 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Gear Position Sensor Faults (PID 59) damaged, soiled, worn, broken, or corroded, re- place the connector. If no female connectors are available, replace the transmission wiring har- ness. See Subject 180 for procedures.
Page 352 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Rail Position Sensor Faults (PID 60) • For PID 60, FMI 04, see Rail Position Sensor Faults Table 3 for proce- dures and pin identiﬁcation. • For PID 60, FMI 05, see There are ﬁve rail position sensor faults covered in...
Page 353 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Rail Position Sensor Is Providing Invalid Data 312/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 354 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Rail Position Sensor Faults (PID 60) PID 60, FMI 03—The Rail Position Sensor Circuit Is Shorted to Power Failure Reason: • There is a defect in the wiring. • There is a defect in the TCU.
Page 355 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Rail Position Sensor Circuit Is Shorted to Power 312/4 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 356 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). The resistance is between 34 Go to the next row in the table. and 122 ohms. 312/5 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 357 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 3, The Rail Position Sensor Circuit Is Shorted to Ground 312/6 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 358 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). The resistance is between 34 Go to the next row in the table. and 122 ohms. 312/7 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 359 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 4, The Rail Position Sensor Circuit Is Open 312/8 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 360 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 5, The Rail Position Sensor Gives Incorrect Resistance Readings Harness Visual Check, Rail 3. Remove the female connector from the rail posi- tion sensor.
Page 361 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Vehicle Direction Signal Faults (PID 64) • For PID 64, FMI 09, see Vehicle Direction Signal Faults Table 1 for proce- dures. • For PID 64, FMI 11, see There are two vehicle direction signal faults covered...
Page 362 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Vehicle Direction Signal Faults (PID 64) PID 64, FMI 09, 11—The Output Shaft Speed Sensor Is Not Providing Accurate Data Failure Reason: • There is a defect in one or both of the output shaft speed sensors.
Page 363 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Vehicle Direction Signal Faults (PID 64) PID 64, FMI 09, 11—The Output Shaft Speed Sensor Is Not Providing Accurate Data Failure Reason: • There is a defect in one or both of the output shaft speed sensors.
Page 364 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Output Shaft Speed Sensor Is Not Providing Accurate Data 313/4 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 365 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Voltage in the Ignition Power Circuit Is Too High 314/1 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 366 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Voltage in the Ignition Power Circuit Is Too Low 314/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 367 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Input Shaft Speed Sensor Faults (PID 161) • For PID 161, FMI 02, 03, 04, and 05, see Input Shaft Speed Sensor Table 1 for procedures. Faults • For PID 161, FMI 08, see...
Page 368 Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Input Shaft Speed Sensor Circuit Gives Invalid Data, Is Shorted, or Open 315/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 369 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Input Shaft Speed Sensor Faults (PID 161) PID 161, FMI 08—The Input Shaft Speed Sensor Is Broadcasting an Abnormal Frequency Failure Reason • There is a defect in the input shaft speed sensor.
Page 370 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Transmission Range Faults (PID 162 and 163) Transmission Range Faults Transmission Range-Attained Faults (PID 163) Transmission Range-Selected There is one transmission range-attained fault cov- Faults (PID 162) ered in these procedures. • For PID 163, FMI 02, see...
Page 371 Subject 301. 3. With the results, contact Mercedes-Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 2, The Gears Do Not Shift Properly 316/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 372 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Output Shaft Speed Sensor Faults (PID 191) • For PID 191, FMI 02, 05, and 08 see Output Shaft Speed Sensor Table 1 for procedures and pin identiﬁcation. Faults (PID 191) • For PID 191, FMI 14, see...
Page 373 Benz Transmissions Service Support by fax (503.961.8435), email (MBTServiceSupport@ Freightliner.com), or phone (503.745.4965 or 503.745.4988). Table 1, The Output Shaft Speed Sensor Circuit Gives Invalid Data, Is Open, or Not Broadcasting a Signal PID 191, FMI 14—The Output Shaft Speed Sensor Is Providing Invalid Data Failure Reason •...
Page 374 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Output Shaft Speed Sensor Faults (PID 191) PID 191, FMI 14—The Output Shaft Speed Sensor Is Providing Invalid Data Failure Reason • The antilock brake system (ABS) is not broadcasting wheel speed data.
Page 375 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations For a schematic of the AGS transmission wiring be- For a list of special tools, see Table hind the X2 (transmission) connector, see Fig. 1. For a schematic of the AGS transmission wiring behind the X1 (main vehicle) and X3 (electric motor) con- nectors, see drawing G06-49466.
Page 376 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations Special Tools for AGS Transmission Tool Description Manufacturer Part Number High-Pressure Line Disconnect Tool Kent-Moore J-47201 f580379 Shift Finger Alignment Fork Kent-Moore J-47204 f580380 Shift Mechanism End Guide Kent-Moore J-47203 f580382 Table 1, Special Tools for AGS Transmission...
Page 377 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations AGS Assembly Torque Values Description Size Torque: lbf·ft (N·m) Torque: lbf·in (N·cm) AGS Central Unit Mounting Capscrews 17 (23) — Clutch Actuator Hydraulic Fittings 37 (50) — Clutch Actuator Mounting Capscrews 17 (23) —...
Page 378 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations AGS Proprietary Fault Codes (J1708) Fault Code Description 3000113 High voltage ignition key line—external (connector X1/9) 3000209 Low voltage supply voltage—external (connector X1/12 and X1/15) 3000213 Low voltage ignition key line—external (connector X1/9) 3001210 EEPROM parameter values error—internal...
Page 379 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations AGS Proprietary Fault Codes (J1708) Fault Code Description 3009910 Test bench mode activated—internal 3010390 Automatic module: signal group cruise control / retarder—internal 3010690 Automatic module: signal output speed—internal 3010790 Automatic module: signal group MR—internal 3010890 Automatic module: signal group gear ratio—internal...
Page 380 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations AGS Proprietary Fault Codes (J1708) Fault Code Description 3018681 Plausibility error clutch open request while inlet valves are closed—internal 3018781 Plausibility error clutch open request while outlet valves are closed—internal 3019480 Plausibility error driving direction—internal 3019621 SmartShift lever data invalid—external (connector X1/8, X1/11, X1/14)
Page 381 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations AGS Proprietary Fault Codes (J1708) Fault Code Description 3022141 Short circuit GND distance sensor (gear)—internal 3022142 Short circuit GND distance sensor (selection)—internal 3022144 Short circuit GND distance sensor (clutch)—internal 3022160 Short circuit GND power stage pump motor—internal 3022215 Short circuit VCC pressure sensor signal—internal...
Page 382 Freightliner AMT and Mercedes-Benz Automated-Manual 26.03 Transmissions Speciﬁcations Learning Procedure Errors Error Description Offset of pressure modulation valve out of range Gear position "neutral" out of range Low gear position out of range High gear position out of range Low select position out of range...
Page 383 26.04 Mercedes-Benz Manual Transmission General Information • Slave cylinder; General Information • Hydraulic lines connecting the various parts of The Mercedes-Benz transmission (MBT) is offered in the system. two 6-speed models: The MBT transmission removal and installation pro- • MBT520S-6D, direct drive, 520 lb·ft torque rat- cedures have been moved to Subject 100 from their...
Page 384 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation Removal 1. Park the vehicle on a level surface. Shut down the engine, set the parking brake, and chock the rear tires. 2. Drain the transmission ﬂuid. See Fig. 1 for the location of the drain plug.
Page 385 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 01/28/99 f261007 Fig. 4, Supporting the Driveshaft 06/06/2001 f261108 1. Shift Lever 2. Shift Lever Mounting Bolt 3. Thick Washer 4. Head of Shift Lever Fig. 6, Shift Lever Connection 6. Disconnect the electrical connectors for the re- verse gear switch and the optional starter lock switch (if installed).
Page 386 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 06/05/2001 f261009 05/14/2001 f261105 1. Speedometer Sensor 3. Standoff Bracket 2. Fuel Line Bend back the nut retainer (arrow). Fig. 9, Power Take-Off Unit (PTO) Nut Retainers Fig. 7, Fuel Line Standoff Bracket and Speedometer Sensor 05/24/2001 f261107...
Page 387 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 01/29/99 f261011 Fig. 12, Capscrews Left in the Timing Case ﬂywheel. Taking these precautions will prevent damage to the input shaft, ﬂywheel, and clutch. 15. After making sure that the transmission is ﬁrmly secured and well supported, remove the trans- mission from the vehicle.
Page 388 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 15.1 Pull the transmission and jack straight back until the transmission input shaft is clear of the clutch. 15.2 Turn the left-hand front wheel to allow room for the transmission to pass. If nec- essary, lower the jack supporting the transmission.
Page 389 26.04 Mercedes-Benz Manual Transmission Transmission Removal and Installation 6. Install the fuel line standoff bracket and connect the fuel lines to the bracket. 7. Connect the electrical connectors. Connect the electrical cable to the speedometer sensor. Con- nect the electrical connector(s) on the shift lever. 8.
Page 390 26.04 Mercedes-Benz Manual Transmission Shift Mechanism Removal and Installation NOTE: These procedures are for the manual Installation transmission with shift lever only. For the auto- mated AGS transmission, see Sec- NOTE: See the installation procedure in Sec- tion 26.03, Subject 200.
Page 391 26.04 Mercedes-Benz Manual Transmission Shift Mechanism Removal and Installation 08/23/2002 f261179 Indent must face aft as shift rod is installed. Fig. 2, Shift Rod End 08/23/2002 f261180 Dimple must be at the 9 o’clock position. Fig. 3, Shift Mechanism Setscrew 110/2 Business Class M2 Workshop Manual, Supplement 8, September 2005...
Page 392 26.04 Mercedes-Benz Manual Transmission Input Shaft Removal and Installation Special Tools A special tool is required for this procedure. See Table Special Tool for Input Shaft Replacement Tool Description Manufacturer Part Number Snap Ring Removal Tool Kent-Moore J-46730 f580393 Table 1, Special Tool for Input Shaft Replacement Removal 1.
Page 393 26.04 Mercedes-Benz Manual Transmission Input Shaft Removal and Installation 02/07/2005 f261332 1. Snap Ring Removal Tool 2. Half-Round Snap Ring Fig. 2, Half-Round Snap Ring Removal snap ring. This measurement should not be more than 0.0003 inch (0.007 mm). 4. Heat the deep-groove ball bearing 176°F (80°C). 5.
Page 394 26.04 Mercedes-Benz Manual Transmission Input Shaft Radial Seal Replacement Special Tools A special tool is required for this procedure. See Table Special Tool for Input Shaft Radial Seal Replacement Tool Description Manufacturer Part Number Input Shaft Seal Installer Kent-Moore J-47901 f580401 Table 1, Special Tool for Input Shaft Radial Seal Replacement Replacement...
Page 395 26.04 Mercedes-Benz Manual Transmission Input Shaft Radial Seal Replacement 7. Install the guide tube on the transmission case. Use new M8 x 18 low-proﬁle guide tube mount- ing capscrews. Tighten the capscrews 17 lbf·ft (23 N·m). 8. Install the release fork and release bearing. Tighten the release fork mounting capscrews 26 lbf·ft (36 N·m).
Page 396 26.04 Mercedes-Benz Manual Transmission Output Shaft Radial Seal Replacement Special Tools Special tools are required for this procedure. See Table Special Tools for Output Shaft Radial Seal Installation Tool Description Manufacturer Part Number Output Shaft Seal Installer Kent-Moore J-47863 f580398 Universal Handle Kent-Moore J-8901...
Page 397 26.04 Mercedes-Benz Manual Transmission Output Shaft Radial Seal Replacement 02/17/2005 f261335 1. Universal Handle 3. Radial Seal 2. Seal Installer 4. Output Shaft Fig. 2, Output Shaft Radial Seal Ready to Install 140/2 Business Class M2 Workshop Manual, Supplement 7, March 2005...
Page 398 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation Special Tools To prevent premature tool wear, use extreme pres- sure lubricant such as Kent-Moore J 23444-A or equivalent on tool threads and at all friction and con- Special tools are required for these procedures. See tact points.
Page 399 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation Removal NOTE: J 23444-A extreme pressure lubricant can be ordered from SPX Kent-Moore at 1-800- 345-2233. 1. With the transmission removed from the vehicle and secured to keep it from moving, remove the 8.
Page 400 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation 13. On model 660 only, pull out the two shift fork guide pins, one located on the left-hand side in the ﬂanged mating surface of the shift rod hous- ing and the other on the right-hand side of the front gear case next to the shift cover (this pin has a T60 Torx ®...
Page 401 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation Fig. 9 for the installation and Table 1 for more information about the special tool. 20. Remove the countershaft ball bearing from the front gear case. 21. Remove the pilot bearing from the main shaft. 08/23/2002 f261184 1.
Page 402 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation Installation NOTE: If either gear case half, the main shaft bearings, or the input shaft was replaced, check the main shaft end play. For detailed proce- dures, see Subject 250. 1.
Page 403 26.04 Mercedes-Benz Manual Transmission Front Gear Case Removal and Installation 10. Using the countershaft seal cover installer as- 17. Coat the mating surface of the rear countershaft sembly, carefully press the front countershaft cover with Loctite 509 or equivalent sealing com- seal cover onto the countershaft.
Page 404 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation Special Tools 2. Remove the front gear case. For instructions, Subject 150. Special tools are required for these procedures. See 3. Install the main shaft/countershaft stand on the Table exposed gear shafts. For more information about the main shaft/countershaft stand, see Table 1 To prevent premature tool wear, use extreme pres-...
Page 405 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation Special Tools for Rear Gear Case Removal and Installation Tool Description Manufacturer Part Number Countershaft Retainer Kent-Moore J-46733 f580396 Table 1, Special Tools for Rear Gear Case Removal and Installation 5.
Page 406 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation IMPORTANT: On AGS transmissions, there are three speed sensors on the rear gear case: the input shaft speed sensor on the lower left-hand side, and the two output shaft speed sensors on the rear output ﬂange.
Page 407 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation 9. Carefully lift the rear gear case off the gear 2. Install the shift rails and forward shift forks on the shafts. See Fig. 6. Leave the puller/installer/ gear shafts. stand installed.
Page 408 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation 09/16/2002 f261193 Use two hammers: a metal-faced one to strike with, and a dead-blow hammer to transmit the force of the blow. 1. Metal-Faced Hammer 03/02/2005 f261194 2. Dead-Blow Hammer 1.
Page 409 26.04 Mercedes-Benz Manual Transmission Rear Gear Case Removal and Installation 03/02/2005 f261195 1. All-Thread Rod 4. Bolt Hole 2. Puller/Installer/Stand 5. Detent (in shift rail) 3. Rear Gear Case Fig. 11, Shift Rail Detents 160/6 Business Class M2 Workshop Manual, Supplement 9, March 2006...
Page 410 26.04 Mercedes-Benz Manual Transmission Reverse, First, and Second Gear Disassembly Special Tools A special tool is required for these procedures. See Table Special Tool for Reverse, First, and Second Gear Disassembly Tool Description Manufacturer Part Number Main Shaft/Countershaft Stand Kent-Moore J-46732 f580395 Table 1, Special Tool for Reverse, First, and Second Gear Disassembly...
Page 411 26.04 Mercedes-Benz Manual Transmission Reverse, First, and Second Gear Disassembly 2. Remove the inner gear wheel. 3. Remove the 1st gear wheel and the needle bear- ing. See Fig. 09/18/2002 f261201 NOTE: The mounts of the 2nd gear outer synchro cup must engage in the large recesses in the synchro body.
Page 412 26.04 Mercedes-Benz Manual Transmission Reverse, First, and Second Gear Disassembly 09/17/2002 f261203 1. Short Teeth 3. Needle Bearing 2. 2nd Gear Wheel Fig. 5, 2nd Gear Wheel and Needle Bearing 170/3 Business Class M2 Workshop Manual, Supplement 8, September 2005...
Page 413 26.04 Mercedes-Benz Manual Transmission Countershaft Removal and Installation Special Tools Special tools are required for this procedure. See Table Special Tools for Countershaft Removal and Installation Tool Description Manufacturer Part Number Main Shaft/Countershaft Lifting Device Kent-Moore J-46729 f580392 Main Shaft/Countershaft Stand Kent-Moore J-46732 f580395...
Page 414 26.04 Mercedes-Benz Manual Transmission Countershaft Removal and Installation f261213 03/02/2005 1. Lifting Device 2. Countershaft Fig. 2, Countershaft Separated From Main Shaft f261212 03/02/2005 1. Bolt 2. Lifting Device 3. Countershaft 4. Stand 5. Clamp 6. Third Gear Wheel 7. Main Shaft (stripped area) Fig.
Page 415 26.04 Mercedes-Benz Manual Transmission Fifth and Sixth Gear Disassembly Fifth Gear 1. Remove the front gear case. For instructions, Subject 150. 2. Remove the rear gear case. For instructions, see Subject 160. 3. Remove the reverse gear and the 1st gear from the main shaft.
Page 416 26.04 Mercedes-Benz Manual Transmission Fourth and Third Gear Disassembly Fourth Gear 1. Remove the front gear case. For instructions, Subject 150. 2. Remove the rear gear case. For instructions, see Subject 160. 3. Remove the reverse gear and the 1st gear from the main shaft.
Page 417 26.04 Mercedes-Benz Manual Transmission Fourth and Third Gear Disassembly Third Gear 1. Carefully remove the 3rd/4th gear synchro slide collar from the synchro body. Take care to extract the compression springs and spring holders from the synchro body. See Fig. 09/23/2002 f261208 1.
Page 418 26.04 Mercedes-Benz Manual Transmission Third and Fourth Gear Assembly Third Gear 1. Apply a coating of MobilTrans SHC ® DC (the ap- proved transmission oil) to the needle bearing. For an exploded view of this assembly, see Fig. 10/11/2002 f261223 1.
Page 419 26.04 Mercedes-Benz Manual Transmission Third and Fourth Gear Assembly 2. Fit the needle bearing onto the main shaft. Mount the 3rd gear wheel over the needle bear- ing with the short splines facing up. IMPORTANT: When installing the gear wheel, spin it and let it drop.
Page 420 26.04 Mercedes-Benz Manual Transmission Third and Fourth Gear Assembly 2. Apply a coating of approved transmission oil to 7. Heat the thrust washer to 176°F (80°C). When the 4th gear synchro ring. Mount the synchro heated, press it into the main shaft. ring on the outer cup with the stop lugs facing NOTE: Before installing, test the thickness of the snap ring by inserting it into the gap be-...
Page 421 26.04 Mercedes-Benz Manual Transmission Third and Fourth Gear Assembly 12. Install the reverse gear and the 1st gear on the main shaft. For instructions, see Subject 230. 13. Install the rear gear case. For instructions, see Subject 160. 14. Install the front gear case. For instructions, see Subject 150.
Page 422 26.04 Mercedes-Benz Manual Transmission Sixth and Fifth Gear Assembly Sixth Gear 1. Apply a coating of approved transmission oil to the needle bearing. Fit the needle bearing onto the main shaft. For an exploded view of this assembly, see Fig. 10/10/2002 f261220 1.
Page 423 26.04 Mercedes-Benz Manual Transmission Sixth and Fifth Gear Assembly 2. Mount the 6th gear wheel over the needle bear- ing with the undercut teeth facing up. 3. Install the 6th gear synchro cone. The oil grooves on the synchro cone must align with the oil grooves on the 6th gear wheel.
Page 424 26.04 Mercedes-Benz Manual Transmission Second, First, and Reverse Gear Assembly Second Gear 2. Apply a coating of approved transmission oil to the synchro ring. Install the ring with the stop lugs facing up. Install the inner cone with the For an exploded view of this assembly, see Fig.
Page 425 26.04 Mercedes-Benz Manual Transmission Second, First, and Reverse Gear Assembly 10/11/2002 f261219 1. 1st Gear Snap Ring 8. 1st Gear Outer Synchro Cup 14. 2nd Gear Outer Synchro Cup 2. Inner Gear Wheel 9. 1st/2nd Gear Synchro Slide 15. 2nd Gear Synchro Ring 3.
Page 426 26.04 Mercedes-Benz Manual Transmission Second, First, and Reverse Gear Assembly 09/23/2002 f261205 Press in the compression spring until the spring holder engages the tooth of the synchro slide collar. 1. Synchro Body 2. Synchro Slide Collar 09/20/2002 f261204 3. Compression Spring 1.
Page 427 26.04 Mercedes-Benz Manual Transmission Synchro Ring Wear Limit Inspection Special Tools A special tool is required for this procedure. See Table Special Tool for Reverse, First, and Second Gear Disassembly Tool Description Manufacturer Part Number Main Shaft/Countershaft Stand Kent-Moore J-46732 f580395 Table 1, Special Tool for Reverse, First, and Second Gear Disassembly Fifth/Sixth Gear Inspection...
Page 428 26.04 Mercedes-Benz Manual Transmission Synchro Ring Wear Limit Inspection Using the synchro slide collar, press the Calculate the average value of the syn- 6th gear synchro ring down against the chromesh reserve. 6th gear wheel. If the average value of the synchromesh While pressing the synchro slide collar reserve is below the minimum dimension, down, turn the 6th gear wheel.
Page 429 26.04 Mercedes-Benz Manual Transmission Synchro Ring Wear Limit Inspection NOTE: This step requires two persons. 8. Install the front gear case. For instructions, see Subject 150. 3. While one person holds the outer synchro cup and gear wheel in place, the other person, using a feeler gauge, measures the synchromesh re- serve of the 2nd gear.
Page 430 26.04 Mercedes-Benz Manual Transmission Main Shaft End Play Measurement Special Tools Special tools are required for this procedure. See Table Special Tools for End Play Measurement Tool Description Manufacturer Part Number Puller/Installer/Stand Kent-Moore J-46739 f580397 Main Shaft End Play Measuring Fixture Kent-Moore J-47903 f580402...
Page 431 26.04 Mercedes-Benz Manual Transmission Main Shaft End Play Measurement 02/18/2005 f261349 1. Measuring Fixture End Cap 2. Measuring Fixture Center Shaft 3. Measuring Fixture Crossbar 4. Input Shaft Gear Wheel 5. Leg of Measuring Fixture Fig. 1, Taking the First Measurement Main Shaft End Play Limits 02/21/2005 f261350...
Page 432 26.04 Mercedes-Benz Manual Transmission Main Shaft End Play Measurement f261351 02/21/2005 Using a feeler gauge,measure the gap (arrow) between the center shaft and the end cap. 1. Feeler Gauge 2. Lower Thumbscrew 3. Upper Thumbscrew 4. Measuring Fixture Center Shaft Fig.
Page 433 26.04 Mercedes-Benz Manual Transmission Speciﬁcations Torque Values, MBT Transmission Removal and Installation Fastener Size Class Torque: lbf·ft (N·m) Bell Housing-to-Timing Case Capscrews M10 x 1.5 33 (45) Clutch Slave Cylinder Bracket Mounting Bolts 15 (20) Fuel Cross-Over Line Mounting Bolts —...
Page 434 26.04 Mercedes-Benz Manual Transmission Speciﬁcations Gear Ratios Model Gear Ratio 9.201 5.230 3.145 MBT520S-6D 2.034 1.374 1.000 8.649 6.700 3.810 2.290 MBT660S-6O 1.480 1.000 0.730 6.290 Table 3, Gear Ratios Synchromesh Reserve, MBT Gear Minimum Dimension: inch (mm) Speciﬁed Dimension: inch (mm) 0.03 (0.7) 0.
Page 435 26.04 Mercedes-Benz Manual Transmission Speciﬁcations Special Tools for MBT Transmissions Tool Description Manufacturer Part Number Synchro Retainer Clips Kent-Moore J-46726 f580389 Front Gear Case Bridge Kent-Moore J-46727 f580390 Countershaft Guide Kent-Moore J-46728 f580391 Main Shaft/Countershaft Lifting Device Kent-Moore J-46729 f580392 Snap Ring Removal Tool Kent-Moore J-46730...
Page 436 26.04 Mercedes-Benz Manual Transmission Speciﬁcations Special Tools for MBT Transmissions Tool Description Manufacturer Part Number Countershaft Retainer Kent-Moore J-46733 f580396 Rear Case Puller/Installer/Stand Kent-Moore J-46739 f580397 Input Shaft Seal Installer Kent-Moore J-47901 f580401 Output Shaft Seal Installer Kent-Moore J-47863 f580398 Countershaft Seal Cap Installer Kent-Moore J-47901...
Page 437 26.04 Mercedes-Benz Manual Transmission Speciﬁcations Special Tools for MBT Transmissions Tool Description Manufacturer Part Number Main Shaft End Play Measuring Fixture Kent-Moore J-47903 f580402 Table 6, Special Tools for MBT Transmissions Standard Shop Tools for MBT Transmission Tool Description Remarks ®...
Page 438 Safety Precautions Eaton Corporation developed and supplies the hybrid The HEV has high-voltage components, including electric system for Freightliner Trucks. The primary 340-volt DC batteries and a 500-volt AC motor. system components are the hybrid drive unit (or Never cut high-voltage cables or connectors. Do not "HDU", which includes the electric generator/motor...
Page 439 26.05 Hybrid Electric Vehicle General Information 04/03/2009 f261407 A. Direction of ﬂow. B. Installed on vehicles December 2008 and later. 1. Hybrid Drive Unit (HDU) 5. DC/DC Converter (ePTO vehicles only) 2. Coolant Reservoir 6. Coolant Pump 3. Inverter 7. Hybrid Cooler and Fan 4.
Page 440 26.05 Hybrid Electric Vehicle Speciﬁcations Torque Values, Hybrid Electric Vehicle Description Torque: lbf·ft (N·m) Capscrews, Bell Housing to Flywheel Housing 35–45 (47–61) Table 1, Torque Values, Hybrid Electric Vehicle NOTE: Torque values for components of the hy- brid electric system are available from Eaton. For more information, see Eaton’s website, www.roadranger.com.
Page 441 Pedal Position Sensor Freightliner uses various pedal position sensors, de- pending on the engine. The pedal position sensor is mounted to the side of the pedal assembly. The sen- sor and the pedal assembly are both separately re- placeable.
Page 442 30.00 Electronic Throttle Control Accelerator Pedal Removal and Installation Removal 5. Connect the batteries. 6. Test the pedal operation using the diagnostic 1. Apply the parking brakes and chock the tires. software tool speciﬁed in Table 2. Disconnect the batteries. Diagnostic Software Tools 3.
Page 443 30.00 Electronic Throttle Control Pedal Position Sensor Replacement Replacement 5. Install the sensor mounting fasteners and tighten them 25 to 30 lbf·in (280 to 340 N·cm). NOTE: Vehicles manufactured on or after April 6. Install the pedal assembly and test its operation as instructed in Subject 100.
Page 444 30.00 Electronic Throttle Control Troubleshooting Complete the following procedures to diagnose ac- Diagnostic Software Tools celerator pedal assembly and pedal position sensor Engine problems. Software Tool Manufacturer Common Problems and Caterpillar Electronic Technician (CAT Caterpillar Indications Cummins INSITE Mercedes-Benz Detroit Diesel Diagnostic Link The accelerator pedal assembly was designed so Table 1, Diagnostic Software Tools that the pedal position sensor will not reach the inter-...
Page 445 30.00 Electronic Throttle Control Troubleshooting ™ Use EZWiring in ServicePro or PartsPro 9. Inspect and ensure that all connector pins at the to identify the circuit(s) that supply voltage pedal position sensor, frontwall, and the engine to the pedal position sensor. controller are free of corrosion and are not bent or damaged.
Page 446 30.00 Electronic Throttle Control Troubleshooting Diagnostic Software Values † Engine Signal Pedal Position Desired Value Idle Accelerator Pedal Position Full throttle 100% Between idle/full throttle Varies smoothly between 0% and 100% Idle 0.5 volts Accelerator Pedal Sensor Full throttle 4.5 volts Cummins, pre- Between idle/full throttle Varies smoothly between 0.5 and 4.5 volts...
Page 447 30.00 Electronic Throttle Control Troubleshooting Diagnostic Software Values † Engine Signal Pedal Position Desired Value Idle Accelerator Pedal Raw Full throttle Sensor Between idle/full throttle Varies smoothly between 15% and 75% Idle Accelerator Pedal Position Full throttle 100% Between idle/full throttle Varies smoothly between 0% and 100% Mercedes-Benz, Idle...
Page 448 2500, then that component the Freightliner LLC Engineering Department. is installed on the frame rail 98-7/16 inches (2500 The main body of the frame consists of two frame mm) aft of station zero.
Page 449 (ECUs) installed on the vehicle. Electric currents produced during electric welding can damage various electrical components on the ve- hicle, such as alternator diodes and ECUs. Freightliner LLC vehicle components that typi- 08/14/95 f310013a cally use ECUs include electronic engine, elec- A.
Page 450 31.00 Frame Assembly Frame Rail Repair 08/15/95 f310016a 08/14/95 f310014a A. Frame Rail Thickness A. Frame Rail Thickness B. Grind the weld ﬂush with the frame rail. 1. V-Groove (full depth) 1. Crack Fig. 3, Full Depth Groove Fig. 5, Weld Ground Flush 08/15/95 f310017a f310015a...
Page 451 31.00 Frame Assembly Frame Rail Repair 2. If the diameter of a hole is less than 3/8 inch (9.5 mm), enlarge it to 3/8 inch (9.5 mm), and ﬁll it with the applicable nut, washer, and bolt combi- nation. 3. Tighten the fasteners to the applicable torque value.
Page 452 31.00 Frame Assembly Frame Rail Repair 08/14/95 f310020a A. 1-11/32 inches (34 mm) Fig. 9, Minimum Distance for Drilling Holes 100/4 Business Class M2 Workshop Manual, Supplement 6, September 2004...
Page 453 31.00 Frame Assembly Welding Frame Rails Safety Precautions 1. Do not weld attachments to the frame rail. For guidelines on the attachment of equipment on the frame rails, refer elsewhere in this group. CAUTION 2. Use only the applicable welding method under "Welding Methods."...
Page 454 31.00 Frame Assembly Welding Frame Rails NOTE: AWS-E-11018 is the recommended type of weld rod. However, on 1/4-inch thick frame rails only, weld rod of type AWS-E-9018 can be used. 2. For the amperage and voltage settings for each weld position, see Speciﬁcations, 400.
Page 455 Or else disconnect the main connection at the ECU. CAUTION Freightliner vehicle components that typically use ECUs include the electronic engine, electronic auto- Do not "hollow grind" the weld. Small depres- matic transmission, and the antilock braking system sions from improper grinding of the weld will re- (ABS).
Page 456 31.00 Frame Assembly Extending Frame Rails 30° 45° 30° NOTE: Left rail shown; right rail will be opposite dimensions. DIMENSION FRAME RAIL SIZE inches inches (mm) inches (mm) inches (mm) inches (mm) 10.06 0.69 (17.5) 5.00 (127.0) 8.75 (222.2) 18.75 (476.2) 10.12 0.69 (17.5) 5.00 (127.0)
Page 457 31.00 Frame Assembly Extending Frame Rails 60° 1/16" to 1/8" 0" to 1/16" (1.6 to 3.2 mm) (0 to 1.6 mm) 10/12/94 f310025a A. Frame Rail Thickness B. Extension Thickness Fig. 2, Grinding Dimensions 10/12/94 f310026a A. Frame Rail Thickness B.
Page 458 31.00 Frame Assembly Frame Crossmember Removal and Installation 4. Remove the three mounting bolts on the midship CAUTION bracket. See Fig. 2. Lower the driveshaft slightly. The placement of crossmembers affects the over- all stability of the frame and prevents damage to the vehicle.
Page 459 31.00 Frame Assembly Frame Crossmember Removal and Installation f310876 07/23/2001 1. Web Bolt, 5/8–11 2. Hardened Flatwasher 3. Midship Crossmember 4. Frame Rail 5. Locknut, 5/8–11 Fig. 3, Midship Crossmember Fasteners 3. Install the web bolts, washers, and nuts fastening 07/18/2001 f310878 the crossmember to the frame rail.
Page 460 31.00 Frame Assembly Frame Crossmember Removal and Installation 07/19/2001 f310881 1. Frame Rail 4. Midship Bracket 2. Crossmember 5. Web Bolt, 5/8–11 3. Driveshaft 6. Midship Bearing 07/18/2001 f310879 Fig. 5, Crossmember Installation Make sure the lip of the jack stand is clear of the frame rail.
Page 461 31.00 Frame Assembly Frame Crossmember Removal and Installation NOTE: Using the axle jack, raise the axle to lower the springs and allow enough clearance to install the lower rear bolt. 4. Adjust the hanger bracket position as necessary. Tighten all of the 5/8–11 hanger locknuts 128 lbf·ft (173 N·m).
Page 462 31.00 Frame Assembly Frame Crossmember Removal and Installation f350411 07/19/2001 1. Jack Stand 2. Rear Axle 3. Axle Jack Fig. 9, Place Jack Stands on the Axle 2. Place the crossmember channel and gusset in 5. Using a rubber mallet, tap the crossmember into the frame rails with the channel opening facing place.
Page 463 31.00 Frame Assembly Frame Crossmember Removal and Installation 07/19/2001 f320911 07/19/2001 f310880 5. Hanger Bracket 1. Hardened Washer 1. Bolt, 1/2–13 2. Hanger Bolt (head 6. Frame Rail 2. Washer end) 7. Double Splayed 3. Frame Rail 3. Hanger Bolt Crossmember 4.
Page 464 31.00 Frame Assembly Frame Crossmember Removal and Installation If so equipped, remove the backup alarm from the crossmember. If any air brake valve is attached to the crossmember, drain the air reservoirs, then remove the valve(s) from the cross- member. Remove any clamps that attach air lines or wiring to the crossmember.
Page 465 31.00 Frame Assembly Frame Crossmember Removal and Installation 08/05/94 f310243a 1. Upper Gusset 4. Hardened Steel Flatwasher 7. 5/8–11 Locknut 2. 1/2–13 Button-Head Capscrew 5. 1/2–13 Locknut 8. Lower Gusset 3. 1/2–13 Grade 8 Hexbolt 6. Crossmember Channel 9. 5/8–11 Grade 8 Hexbolt Fig.
Page 466 31.00 Frame Assembly Frame Crossmember Removal and Installation 11/27/2001 f310892 1. Right Mounting Bracket 2. Overslung Crossmember 3. Right Frame Rail 4. Left Mounting Bracket 5. Mounting Bolt, 5/8-inch 6. Hexnut and Washer, 5/8-inch 7. Left Frame Rail Fig. 15, Overslung Crossmember 130/9 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 467 31.00 Frame Assembly Frame Crossmember Removal and Installation 08/08/94 f310245a 1. Rear-Closing Crossmember 3. Hardened Steel Flatwasher 5. Rear Angle Bracket 2. 5/8–11 Grade 8 Bolt 4. 5/8–11 Locknut 6. Front Angle Bracket Fig. 16, Rear-Closing Crossmember Installation 130/10 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 468 31.00 Frame Assembly Frame Rail Alignment Frame Rail Alignment 2. Locate an aft set of points. The aft points also must be at identical locations on both frame rails. Frame rail alignment is checked by measuring the Measuring back along each frame rail, distances from two sets of points on the upper ﬁnd a set of bolt holes at least six feet ﬂanges of the frame rails.
Page 469 31.00 Frame Assembly Frame Rail Alignment 33−5/8" 33−5/8" (854 mm) (854 mm) 11/28/95 f310509 A. Right Forward Point or Bolt Hole C. Left Forward Point or Bolt Hole B. Right Rear Point or Hole D. Left Rear Point or Hole 1.
Page 470 31.00 Frame Assembly Frame Shaping Frame Shaping IMPORTANT: Obtain approval from your re- gional service representative before doing any cutting or frame shaping. If the ﬂange of a frame rail is cut (for relief cuts or notches), shape the edges of the ﬂange to form a smooth-ground edge radius of 0.06 to 0.12 inch (1.5 to 3.0 mm) over the entire length of the cut.
Page 471 1. Replace hexhead bolts with identical fasteners. tached to it, so that the nut and bolt surfaces are See the Freightliner LLC Parts Book for fastener ﬂush against the frame and the part. speciﬁcations.
Page 472 31.00 Frame Assembly Frame Fastener Replacement threads and no more than 5/8-inch (16- 4. Replace Huck fasteners with standard Grade 8 mm) bolt length extend through the self- threaded fasteners if the repair location does not locking nut after it has been tightened. have the equipment to properly install replace- ment Huck fasteners.
Page 473 31.00 Frame Assembly Speciﬁcations Fig. 1 for frame rail and extension cutting di- mensions. Machine Settings for Gas-Metal Arc Welding Wire Extension Wire Diameter Current (amperes) Optimum Maximum inches (mm) Minimum Maximum inches (mm) inches (mm) 0.045 (1.14) 1/2 (13) 3/4 (19) 1/16 (1.6) 3/4 (19)
Page 474 31.00 Frame Assembly Speciﬁcations 30° 45° f310507 f310507 f310507 30° NOTE: Left rail shown; right rail will be opposite dimensions. DIMENSION FRAME RAIL SIZE inches inches (mm) inches (mm) inches (mm) inches (mm) 10.06 0.69 (17.5) 5.00 (127.0) 8.75 (222.2) 18.75 (476.2) 10.12 0.69 (17.5)
Page 475 31.01 Bumper, Non-Aerodynamic Bumper Removal and Installation Removal 1. Chock the front tires. 2. Raise the hood. 3. On the right-hand side of the vehicle, remove the lower end of the damper from the ball stud. Lift the steel spring clip with a small screwdriver and pop the end of the damper off.
Page 476 31.01 Bumper, Non-Aerodynamic Bumper Removal and Installation 09/13/2001 f880546 The right-hand side is shown; the left-hand side is similar. 1. Hood Pivot 2. Upper Bumper Mounting Bolt, 1/2–13 3. Bumper 4. Hood 5. Bumper End Cap Fig. 3, Upper Bumper Mounting Bolt Attach the M8 ball stud fastener to the ball stud.
Page 477 31.01 Bumper, Non-Aerodynamic Bumper End Cap Removal and Installation Removal Remove the lower end cap mounting bolt and washer attaching the end cap to the bumper center section. 1. Chock the front tires. Remove the upper end cap mounting bolt 2.
Page 478 31.01 Bumper, Non-Aerodynamic Bumper End Cap Removal and Installation f880547a 02/01/2002 1. End Cap 5. End Cap Mounting Bolt, 3/8–16 2. Bumper Center Section 6. Washer 3. Reinforcement 7. Weld Nut on Center Reinforcement 4. Flange Fig. 2, Bumper End Caps 110/2 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 479 31.01 Bumper, Non-Aerodynamic Three-Piece Bumper Removal and Installation, Models with Bolt-On Front Frame Brackets Removal 8. With the center piece securely grasped, remove the upper bolts that are supporting it, then re- move the center piece from the vehicle. 1. Chock the front tires. 2.
Page 480 31.01 Bumper, Non-Aerodynamic Three-Piece Bumper Removal and Installation, Models with Bolt-On Front Frame Brackets If the bolts are 1/2-inch, grade 8, phosphate and oil, tighten them 68 lbf·ft (92 N·m). 6. Tighten the fasteners that attach the end pieces to the center piece 23 lbf·ft (31 N·m). 7.
Page 481 31.01 Bumper, Non-Aerodynamic Speciﬁcations Bumper Torque Values Description Size Grade Torque in lbf·ft (N·m) Ball Stud Fastener, Hood Damper 13 (18) Bumper Mounting Bolts 1/2–13 68 (92) Bumper End Cap Mounting Bolts 3/8–16 26 (36) Table 1, Bumper Torque Values 400/1 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 482 31.02 Fifth Wheel, Fontaine 6A36 General Information General Information The Fontaine 6000 series ﬁfth wheel couples to trail- ers having the standard kingpin. When installed with an A36 angle mount, the ﬁfth wheel is bracket- mounted to the tractor frame in a position that best distributes the trailer load over the tractor axles.
Page 483 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Removal and Disassembly Removal 4. Unbolt the operating handle from the pivot mount and remove the operating handle. See Fig. 5. Remove the timer spring and timer. See Fig. WARNING 6. Remove the jaw and wedge. See Fig.
Page 484 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Removal and Disassembly 10/28/99 f310822 1. Wedge Stop Rod Nut 10. Bushing, 5/16-Inch 19. Pull Handle 2. Flatwasher, 5/8-Inch 11. Timer Spring 20. Secondary Lock 3. Wedge Stop Rod Spring 12. Jaw 21. Hexhead Bolt, 1/2–13 x 1.75 4.
Page 485 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Removal and Disassembly 08/11/2000 f310848 08/11/2000 f310850 1. Bumper Spring 3. Secondary Lock 1. Bumper 2. Handle Spring 4. Pull Handle 2. Operating Handle 3. Locknut, 1/2–13 Fig. 2, Pull Handle Removal 4. Hexhead Bolt, 1/2–13 x 1.75 Fig.
Page 486 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Removal and Disassembly 08/11/2000 f310852 1. Timer Spring 2. Timer Fig. 6, Timer Spring and Timer Removal 08/11/2000 f310847 1. Jaw 2. Wedge Fig. 7, Jaw and Wedge Removal 100/4 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 487 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Assembly and Installation Assembly 2. Close the ﬁfth wheel several times with a stan- dard 2-inch kingpin tool. With the lock closed, adjust the wedge stop rod so the end is 1/4-inch WARNING from the wedge.
Page 488 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Assembly and Installation 10/28/99 f310822 1. Wedge Stop Rod Nut 10. Bushing, 5/16-Inch 19. Pull Handle 2. Flatwasher, 5/8-Inch 11. Timer Spring 20. Secondary Lock 3. Wedge Stop Rod Spring 12. Jaw 21. Hexhead Bolt, 1/2–13 x 1.75 4.
Page 489 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Assembly and Installation 08/11/2000 f310847 01/25/2002 f310851a 1. Jaw 2. Wedge 1. Hexhead Bolt, 1/2–13 x 2.25 2. Flatwasher Fig. 2, Wedge and Jaw Installation 3. Locknut, 1/2–13 4. Operating Handle 5. Pivot Mount Fig.
Page 490 31.02 Fifth Wheel, Fontaine 6A36 Fifth Wheel Assembly and Installation 01/25/2002 f310849a 1. Hexhead Bolt, 1/2–13 x 1.5 2. Locknut, 1/2–13 3. Secondary Lock 4. Operating Handle Fig. 6, Secondary Lock Installation 08/11/2000 f310848 1. Bumper Spring 3. Secondary Lock 2.
Page 491 31.02 Fifth Wheel, Fontaine 6A36 Troubleshooting Troubleshooting Tables Problem—Difficult Coupling Problem—Difficult Coupling Possible Cause Remedy The kingpin is too high to trip the latch. Lower the landing gear. The trailer plate or kingpin is damaged. Check the trailer plate for ﬂatness. Check the kingpin for squareness with the trailer plate.
Page 492 31.06 Fifth Wheel, Fontaine 6000 and 7000 No-Slack II Series General Information General Information kingpin and unlocks the ﬁfth wheel. See Fig. 2 for an illustration of the jaw and wedge in the unlocked pos- tition. Fontaine 6000 and 7000 series ﬁfth wheels couple to trailers having the standard 2 inch kingpin.
Page 493 31.06 Fifth Wheel, Fontaine 6000 and 7000 No-Slack II Series Removal and Disassembly Fifth Wheel Removal and result in disengagement of the trailer from the tractor, leading to personal injury or property Disassembly damage. Parts are under spring compression. Wear safety Fig.
Page 494 31.06 Fifth Wheel, Fontaine 6000 and 7000 No-Slack II Series Removal and Disassembly 2. Using an overhead hoist, lift the ﬁfth wheel off the sliding mount and tractor frame. 3. Turn the ﬁfth wheel upside down. NOTE: While disassembling the ﬁfth wheel, check it for cracks and for missing or damaged parts.
Page 495 31.06 Fifth Wheel, Fontaine 6000 and 7000 No-Slack II Series Removal and Disassembly 11/12/2002 f310923 11/12/2002 f310925 1. Operating Handle 1. Jaw 2. Bolt 2. Wedge Fig. Fig. 5, Operating Handle 7, Jaw and Wedge 11/12/2002 f310924 1. Timer Spring 2.
Page 496 31.06 ® Fifth Wheel, Fontaine No-Slack II 6000 and 7000 Series Assembly and Installation Assembly and Installation 6. Install the pull handle. See Fig. 7. Use the exist- ing washer and cotter pin (inspect for wear be- fore using and replace if necessary). Attach the WARNING new secondary lock/bumper spring that is sup- plied in the repair kit.
Page 497 31.06 ® Fifth Wheel, Fontaine No-Slack II 6000 and 7000 Series Assembly and Installation 11/12/2002 f310927 1. Wedge Stop Rod Nut 11. Timer Spring 19. Pull Handle 2. Flatwasher, 5/8", Plain 12. Step Jaw and Wedge Set 20. Secondary Lock 3.
Page 498 31.06 ® Fifth Wheel, Fontaine No-Slack II 6000 and 7000 Series Assembly and Installation 11/12/2002 f310925 11/12/2002 f310923 1. Jaw 1. Operating Handle 2. Wedge 2. Bolt Fig. 2, Jaw and Wedge Fig. 4, Operating Handle 11/12/2002 f310924 11/12/2002 f310922 1.
Page 499 31.06 ® Fifth Wheel, Fontaine No-Slack II 6000 and 7000 Series Assembly and Installation 11/12/2002 f310926 A. 1/4 inch (6 mm) 1. Stop Rod 2. Wedge 11/12/2002 f310921 Fig. 8, Wedge Stop Rod Adjustment 1. Bolt 2. Secondary Lock Fig. 6, Secondary Lock 11/12/2002 f310920 1.
Page 500 31.06 Fifth Wheel, Fontaine 6000 and 7000 No-Slack II Series Troubleshooting Troubleshooting Tables Problem—Difficulty Coupling Possible Cause Remedy The kingpin is too high to trip the latch Lower the landing gear. The trailer plate or kingpin is damaged Check the trailer plate for ﬂatness. Check the kingpin for squareness with the trailer plate.
Page 501 31.10 Fifth Wheel, Fontaine H5092 Series General Information General Information Fontaine H5092 series ﬁfth wheels couple to trailers having the standard 2-inch kingpin. When installed as a stationary mount, the ﬁfth wheel is bracket- mounted to the tractor frame in a position that best distributes the trailer load over the tractor axles.
Page 502 31.10 Fifth Wheel, Fontaine H5092 Series General Information 09/06/95 f310477 Fig. 1, Fontaine H5092 Series Air Slide Fifth Wheel 11/15/2002 f310930 11/15/2002 f310929 1. Jaw 1. Jaw 2. Wedge 2. Wedge Fig. Fig. 2, Locked Position 3, Unlocked Position 050/2 Business Class M2 Workshop Manual, Supplement 4, March 2003...
Page 503 31.10 Fifth Wheel, Fontaine H5092 Series Removal and Disassembly Fifth Wheel Removal and result in disengagement of the trailer from the tractor, leading to personal injury or property Disassembly damage. Parts are under spring compression. Wear safety Fig. 1 for an exploded view of the Fontaine ®...
Page 504 31.10 Fifth Wheel, Fontaine H5092 Series Removal and Disassembly 2. Using an overhead hoist, lift the ﬁfth wheel off the sliding mount and tractor frame. 3. Turn the ﬁfth wheel upside down. NOTE: While disassembling the ﬁfth wheel, check it for cracks and for missing or damaged parts.
Page 505 31.10 Fifth Wheel, Fontaine H5092 Series Removal and Disassembly 09/14/95 f310483 1. Operating Handle 09/13/95 f310485 Fig. 5, Operating Handle Positioning Fig. 7, Operating Handle Removal 09/14/95 f310484 1. Timer 09/14/95 f310486 1. Bumper Fig. 6, Timer Removal Fig. 8, Bumper Removal 10.
Page 506 31.10 Fifth Wheel, Fontaine H5092 Series Removal and Disassembly 09/13/95 f310487 Fig. 9, Spring Removal 09/13/95 f310488 Fig. 10, Jaw and Wedge Removal 100/4 Business Class M2 Workshop Manual, Supplement 4, March 2003...
Page 507 31.10 Fifth Wheel, Fontaine H5092 Series Fifth Wheel Assembly and Installation Assembly and Installation from the tractor, leading to personal injury and property damage. ® Fig. 1 for an exploded view of a Fontaine Parts are under spring compression. Wear safety H5092 ﬁfth wheel.
Page 508 31.10 Fifth Wheel, Fontaine H5092 Series Fifth Wheel Assembly and Installation 1. Clean all moving parts with no. 2 diesel fuel be- fore assembly. 2. Always assemble the parts around a 2-inch king- pin or a shaft with a 2-inch diameter. Insert the jaw ﬁrst and then the new wedge below it.
Page 509 31.10 Fifth Wheel, Fontaine H5092 Series Fifth Wheel Assembly and Installation 09/14/95 f310483 1. Operating Handle 09/13/95 f310485 Fig. 7, Operating Handle Positioning Fig. 5, Operating Handle Installation 09/13/95 f310482 09/14/95 f310484 Fig. 8, Pull Handle Installation 1. Timer Apply grease to the bolt parts and where there is Fig.
Page 510 31.10 Fifth Wheel, Fontaine H5092 Series Fifth Wheel Assembly and Installation WARNING If the ﬁfth wheel does not operate properly, do not use it. The ﬁfth wheel could malfunction, re- sulting in personal injury or property damage due to possible disengagement of the trailer from the tractor.
Page 511 31.10 Fifth Wheel, Fontaine H5092 Series Troubleshooting Troubleshooting Tables Problem—Difficulty Coupling Problem—Difficulty Coupling Possible Cause Remedy The kingpin is too high to trip the latch Lower the landing gear. The trailer plate or kingpin is damaged Check the trailer plate for ﬂatness. Check the kingpin for squareness with the trailer plate.
Page 512 32.00 Front Suspension General Information General Information Freightliner Business Class M2 front suspensions use either a tapered leaf or a ﬂat leaf assembly. The tapered leaf suspensions are available in varying ca- pacities from 6,000-pound (2 722 kg) to 18,000- pound (8 165 kg).
Page 513 32.00 Front Suspension General Information 19, 20, 21 12/20/2001 f320943 1. U-Bolt High Nut 10. Flatwasher 17. Spring Center-Bolt and Nut 2. Bearing Washer 11. Hexnut, 3/4–10 18. Leaf Spring (leaf-and-a-half) 3. Axle 12. Shock Absorber 19. Carriage Bolt, 1/2–13 4.
Page 514 32.00 Front Suspension General Information 12/19/2001 f320938 1. U-Bolt High Nut 14. Inboard Spring Spacer 25. Leaf Spring 2. Bearing Washer 15. Front Suspension Bracket 26. Shackle Bracket 3. Axle 16. Locknut, 3/4–10 27. Frame Rail 4. Dowel 17. Shock Absorber 28.
Page 515 32.00 Front Suspension Leaf Spring and Components Removal, Cleaning and Inspection, and Installation Removal 1. Park the vehicle on a level surface. Shut down the engine, set the parking brakes, and chock the rear tires. 2. Tilt the hood. 3. Remove the front bumper end cap. For instruc- tions, see Group 4.
Page 516 32.00 Front Suspension Leaf Spring and Components Removal, Cleaning and Inspection, and Installation wear, and other damage. Replace any damaged parts. Inspect the leaf spring assembly for cracks or corrosion. If any leaves are cracked or broken, replace the entire spring assembly.
Page 517 32.00 Front Suspension Leaf Spring and Components Removal, Cleaning and Inspection, and Installation 12/19/2001 f320944 Fig. 3, Spring Removal/Installation (typical) 3. Install the spring assembly. Install the spring pin retainers. Tighten the fasteners 250 lbf·ft (339 N·m). NOTE: Leaf spring assemblies on vehicles Install the fasteners into the rear spring with suspensions manufactured at 14,600- eye.
Page 518 32.00 Front Suspension Leaf Spring and Components Removal, Cleaning and Inspection, and Installation ® Apply Alumilastic or a similar compound to the top and bottom of the spring spacer and any caster adjustment shims. CAUTION Failure to apply Alumilastic compound, or an equivalent, to areas where aluminum and steel parts contact each other, could lead to corrosion of the metals, resulting in damage to suspension...
Page 519 32.00 Front Suspension Bushing Replacement Shackle Bracket Bushing 9. Install the shackle bracket. Install the fasteners and tighten them 135 lbf·ft (183 N·m). Replacement 10. Connect the leaf spring. 1. Park the vehicle on a level surface, shut down 10.1 Install the spring shackle and the shackle the engine, set the parking brakes, and chock upper bolt.
Page 520 32.00 Front Suspension Shock Absorber Replacement Replacement 1. Apply the parking brake, chock the rear tires, and tilt the hood. 2. Remove the shock absorber. Remove the locknut from the shock ab- sorber upper mount; then, remove the 3/4–10 hexbolt and washers. Remove the locknut from the shock ab- sorber lower mount;...
Page 521 32.00 Front Suspension Troubleshooting Vehicle Lean Inspection IMPORTANT: Chassis lean can be caused by several factors such as uneven vehicle weight distribution, mismatched springs, or improper spacer installation. The following instructions detail inspecting for and correcting chassis lean due to improper spring or spacer installation. Additional troubleshooting procedures may also be found at the Hendrickson...
Page 522 32.00 Front Suspension Troubleshooting spacer adjustments will have minimal effect on Figure 3 represents a checklist for weak or sag- lean and other actions are required. If the end of ging springs. frame to ground measurements are less than 3/8 Use this checklist as the information may be re- inch (9.53 mm) difference, correct the lean by quested when ﬁling a warranty claim.
Page 523 32.00 Front Suspension Troubleshooting Problem—Frequent Spring Breakage Possible Cause Remedy A loose center bolt is allowing the spring Check the spring leaves for damage. If damaged, replace the spring leaves to slip. assembly. If not, tighten the center-bolt nut to the value listed in torque table Speciﬁcations, 400.
Page 524 32.00 Front Suspension Troubleshooting 09/23/2009 f040801 Fig. 3, Checklist for Weak or Sagging Springs 300/4 Business Class M2 Workshop Manual, Supplement 18, September 2010...
Page 525 32.00 Front Suspension Speciﬁcations Front Suspension Fastener Torque Values Description Size Torque: lbf·ft (N·m) Shackle Bracket-to-Frame Locknut 3/4–10 240 (325) Aluminum Shackles: 45 (61) Spring Shackle Pinch-Bolt Locknuts 1/2–13 Steel Shackles: 70 (95) Spring Pin Retainer Hexbolts 1/2–13 60–76 (81–103) Forward Spring-Eye Bolt 3/4–10 240 (325)
Page 526 32.01 Rear Leaf-Spring Suspension, Single Axle General Information General Information The rear leaf-spring suspension for Business Class M2 vehicles uses either 60-inch taper-leaf or 52-inch multi-leaf springs with varying capacities. See Fig. Fig. Fig. 3 Fig. Taper-leaf springs have shackles and pins to secure the rear spring end, while multi-leaf spring applica- tions use a slip spring design in which the rear spring end rides in a cast iron bracket mounted on the...
Page 527 32.01 Rear Leaf-Spring Suspension, Single Axle General Information 17, 18 12/17/2001 f320931 1. U-Bolt High Nut (4 qty.) 8. Flatwasher 15. Shock Absorber 2. Flatwashers 9. Leaf Spring Assembly 16. U-Bolt 3. U-Bolt Retainer 10. Forward Spring-Eye Bolt 17. Hexnut, 5/8–18 4.
Page 528 32.01 Rear Leaf-Spring Suspension, Single Axle General Information 14, 15, 16 f320927 08/29/2001 NOTE: Shock absorbers (standard with this suspension) not shown. 1. U-Bolt High Nuts 9. Forward Spring Hanger 16. Flatwasher 2. Flatwashers 10. Left Frame Rail 17. U-Bolts 3.
Page 529 32.01 Rear Leaf-Spring Suspension, Single Axle General Information 12/17/2001 f320928 1. U-Bolt High Nut (8 qty.) 7. Leaf Spring (with helper) 12. Spring Stop 2. Flatwashers 8. Forward Spring Hanger 13. U-Bolt Pad 3. U-Bolt Retainer 9. Forward Spring-Eye Bolt 14.
Page 530 32.01 Rear Leaf-Spring Suspension, Single Axle General Information 15, 16, 17 21, 22, 23 25, 26, 27 12/17/2001 f320929 1. U-Bolt High Nuts 12. U-Bolt Pad 23. Flatwasher 2. Flatwashers 13. Rubber Helper 24. Stabilizer Bar Link 3. U-Bolt Retainer 14.
Page 531 32.01 Rear Leaf-Spring Suspension, Single Axle Spring Assembly Replacement Replacement Install the foward spring-eye bolt, nut and washers. Make sure the bolt is inboard. Tighten 240 lbf·ft (325 N·m). 1. Park the vehicle on a level surface, shut down the engine, set the parking brakes and chock the If equipped with the optional helper leaf front tires.
Page 532 32.01 Rear Leaf-Spring Suspension, Single Axle Shock Absorber Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, set the parking brakes, and chock the tires. 2. Remove the locknut, retainers, and bushings (if applicable) from the shock absorber lower mount.
Page 533 32.01 Rear Leaf-Spring Suspension, Single Axle Wear Pad Replacement Replacement NOTE: Wear pads, used only on 52-inch multi- leaf suspensions, can be replaced without re- moving the leaf spring assemblies. They are located on the rear spring hangers. 1. Park the vehicle on a level surface, shut down the engine, set the parking brakes, and chock the front tires.
Page 534 32.01 Rear Leaf-Spring Suspension, Single Axle Speciﬁcations Torque Values Torque Description Size Grade lbf·ft (N·m) Forward Spring Bolt 3/4–10 — 240 (325) Rear Spring Shackle Bolts 3/4–10 — 240 (325) Stage 1: Hand tighten 5/8–18 Stage 2: 60 (81) (10 to 16,000-lb. ratings) Stage 3: 200 (271) Stage 4: 180 to 230 (245 to 313) †...
Page 535 32.02 Rear Leaf-Spring Suspension, Tandem-Axle General Information General Information The tandem-axle rear spring suspension uses a six- point equalizing leaf spring design, which compen- sates for axle articulation, from side-to-side, and front-to-rear. See Fig. 1. Four semi-elliptical spring assemblies are attached to the axles with U-bolts. On both sides of the vehicle, the forward end of the forward spring and the rear end of the rear spring ride in aluminum brackets that are mounted on the...
Page 536 32.02 Rear Leaf-Spring Suspension, Tandem-Axle General Information 06/09/94 f320001a NOTE: Huck fasteners may be used to attach brackets to frame rails. 1. Suspension Bracket Hexbolt 12. Spring Liner 2. Hardened Washer 13. Leaf Spring Assembly 3. Forward Spring Bracket 14. Spring Seat 4.
Page 537 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Radius Rod Removal and Installation Removal Installation NOTE: See Fig. 1 for this procedure. IMPORTANT: At all points where steel parts (in- cluding bolts, washers, and nuts) contact alumi- 1. Park the vehicle on a level surface and set the ®...
Page 538 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Radius Rod Removal and Installation 1. If installing a forward radius rod, place the radius rod front pin on the front side of the forward spring bracket, and place the radius rod rear pin in front of the axle seat. If installing a rear radius rod, place the radius rod pins between the rear side of the equalizer bracket and the front side of the axle seat.
Page 539 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Equalizer Removal, Inspection, and Installation Removal axles and frame. To allow access to the equal- izer, remove the wheel assemblies on that side, using the instructions found in Group NOTE: See Fig. 1 for this procedure. 3.
Page 540 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Equalizer Removal, Inspection, and Installation Installation 3. Apply Loctite 680 to both interior surfaces of the equalizer bracket, where the cap and tube as- sembly is inserted. Apply multipurpose chassis 1. Apply a thin ﬁlm of multipurpose chassis grease grease to the cap and tube assembly, except the to the outside of the equalizer bushings.
Page 541 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Equalizer Removal, Inspection, and Installation CAUTION Failure to apply Alumilastic compound, or an equivalent, to areas where aluminum and steel contact each other, could lead to corrosion of the metals, resulting in suspension damage. 9. Install the wheel assemblies, using the instruc- tions found in Group 40.
Page 542 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Assembly Replacement Replacement 7. Place the new spring assembly in the spring bracket and on the axle seat. Make sure the spring center-bolt head seats in the axle seat NOTE: See Fig. 1 for this procedure. hole.
Page 543 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Assembly Replacement 06/09/94 f320001a NOTE: Huck fasteners may be used to attach brackets to frame rails. 1. Suspension Bracket Hexbolt 12. Spring Liner 2. Hardened Washer 13. Leaf Spring Assembly 3. Forward Spring Bracket 14.
Page 544 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Assembly Replacement 13. Install the wheel assembly, using the instructions found in Group 40. Remove the safety stands from under the frame and axle, and lower the vehicle. 14. Check the rear axle alignment. For instructions, Group 35.
Page 545 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Bracket and Equalizer Bracket Replacement Replacement NOTE: If installing the forward spring bracket, install the nuts for the top two bolts on the out- board side of the frame rail, and install the nuts NOTE: See Fig.
Page 546 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Bracket and Equalizer Bracket Replacement 06/09/94 f320001a NOTE: Huck fasteners may be used to attach brackets to frame rails. 1. Suspension Bracket Hexbolt 12. Spring Liner 2. Hardened Washer 13. Leaf Spring Assembly 3. Forward Spring Bracket 14.
Page 547 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Bracket and Equalizer Bracket Replacement 05/09/95 f320004a A. Forward Spring Bracket B. Equalizer Bracket C. Rear Spring Bracket 1. Nut (outboard) 2. Bolt Heads (outboard) Fig. 2, Frame Brackets 12. Check the rear axle alignment. For instructions, Group 35.
Page 548 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Spring Bracket and Equalizer Bracket Replacement 1 2 3 4 10 2 2 11 12 2 1 1 2 3 10 2 2 11 12 2 1 04/11/95 f320002a A. Forward Right-Side Radius Rod C. Forward Left-Side Radius Rod B.
Page 549 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Rear Axle Alignment Adjustment Adjustment 3. On both sides of the forward-rear axle, loosen the axle U-bolts enough to allow the springs to shift on the axle seats. 1. Using a straightedge and a tape measure, deter- mine the amount of adjustment needed to align 4.
Page 550 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Rear Axle Alignment Adjustment from between the radius rod and the forward- distance that the leading end of the rearmost axle will have to be adjusted rearward, or that rear axle seat on the trailing end. the trailing end will have to be adjusted forward, NOTE: Whenever possible, alignment washers to align it at a right angle to the frame, and to...
Page 551 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Rear Axle Alignment Adjustment 21. Remove the chocks from the front tires. 22. Using the center-point bar, check the rearmost axle alignment. If alignment is within speciﬁca- tions, center the spring in the rear spring bracket, if needed.
Page 552 32.02 Rear Leaf-Spring Suspension, Tandem-Axle Speciﬁcations Torque Values Description Size IFI Grade Torque: lbf·ft (N·m) Equalizer Bracket-to-Frame Rail Locknut 3/4–10 240 (325) Forward Spring Bracket-to-Frame Rail Locknut 3/4–10 240 ( 325) Rear Spring Bracket-to-Frame Rail Locknut 5/8–11 135 (180) Stage 1: Hand-Tighten Stage 2: 60 (81) Axle U-Bolt High Nuts (Tighten in a diagonal pattern as shown 7/8–14...
Page 553 32.03 Rough Ride Diagnosis General Information General Description There are two terms used to describe rough ride conditions: harmonic and harsh. Harmonic ride prob- lems are those in which the once-per-revolution en- ergy input from such things as bent or imbalanced wheels match the natural frequency of the frame ﬂex- ing.
Page 554 32.03 Rough Ride Diagnosis Harmonic and Harsh Ride Checks Harmonic Ride Checks WARNING 1. Visually check the vehicle for signs of damaged Use safety stands to securely support all of the or missing suspension components. Repair or wheel and frame weight during suspension re- replace the components using the instructions in pairs.
Page 555 32.03 Rough Ride Diagnosis Troubleshooting Troubleshooting Tables Problem—Harmonic Ride, Tires Off the Ground Problem—Harmonic Ride, Tires Off the Ground Possible Cause Remedy Bent, distorted, or out-of-round wheels or Inspect and repair the assemblies using the instructions in Group rims are causing a rough ride. Bent, distorted, or out-of-round brake Replace damaged components using the instructions in Group 33...
Page 556 Adjust the air spring height using the instructions in the applicable suspension section in this group. The vehicle normal loaded weight is Contact the Freightliner Service Operations Regional Office for the correct markedly below the spring load capacity. application of a lower rated spring. Replace the spring assembly using the instructions in the applicable suspension section in this group.
Page 557 Freightliner AirLiner Suspension General Information General Information The Freightliner AirLiner Suspension is a single axle or tandem axle suspension that uses a combination of air and leaf springs. The suspension is manufac- tured at numerous weight ratings up to 46,000 pounds (20 865 kg).
Page 558 32.04 Freightliner AirLiner Suspension General Information 11/05/97 f320562 1. Valve Mounting Bracket 2. Height-Control Valve 3. Stud Bolt 4. Vertical Linkage Rod 5. Axle Fig. 2, Barksdale Height-Control Valve Installation, Side View 050/2 Business Class M2 Workshop Manual, Supplement 16, September 2009...
Page 559 32.04 Freightliner AirLiner Suspension General Guidelines General Guidelines To keep the air suspension system operating reliably, the air system must be kept free of any oil, moisture, or foreign material. Inspect and maintain the air sys- tem components regularly. Refer to Group 42 of the Business Class ®...
Page 560 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment Ride Height Adjustment NOTICE Failure to adjust the suspension ride height could adversely affect driveline angles. Also, if the air springs are set too high, the driver may have difficulty (or be prevented from) backing the vehicle under a trailer.
Page 561 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment the top of the U-bolt or U-bolt pad is the target If the distance is not within the acceptable range, measurement from the applicable Suspension repeat the adjustment procedure. Ride Height Measurement table.
Page 562 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment 09/28/2005 f321046a Suspension Height Measurement (A) Measure Point Target A = Measure Here 2-3/4 inch (70 mm) 3 inch (76 mm) 3-1/4 inch (83 mm) Table 2, Suspension Ride Height Measurement, Dual-Leaf Spring, 23k/46k/69k High Ride...
Page 563 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment 09/27/2005 f320933a Suspension Height Measurement (A or B) Measure Point Target A = Measure Here if Built Before August 24, 2001 2-3/8 inch (60 mm) 2-5/8 inch (67 mm) 2-7/8 inch (73 mm)
Page 564 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment 09/27/2005 f320934a Suspension Height Measurement (A or B) Measure Point Target A = Measure Here if Built Before August 24, 2001 2-3/8 inch (60 mm) 2-1/2 inch (64 mm) 2-7/8 inch (73 mm)
Page 565 32.04 Freightliner AirLiner Suspension Suspension Ride Height Adjustment 11/11/2005 f320932a Suspension Height Measurement (A or B) Measure Point Target A = Measure Here if Built Before August 24, 2001 2-1/8 inch (54 mm) 2-9/32 inch (58 mm) 2-5/8 inch (67 mm)
Page 566 32.04 Freightliner AirLiner Suspension Height-Control Valve Checking Height-Control Valve Checking tightening the nuts without holding the studs can back the studs out, causing a separation of the two halves of the valve body, and possibly a leak. It is normal to hear air escaping from the height-...
Page 567 32.04 Freightliner AirLiner Suspension Height-Control Valve Checking settle. Any air leakage during this time is consid- 6. Return the control lever to the neutral position. Air should stop ﬂowing. If so, that section of the ered normal, and does not indicate a defective valve is working.
Page 568 32.04 Freightliner AirLiner Suspension Height-Control Valve Checking 10/08/2007 f321105 A. Fill B. Exhaust 1. Air Spring Port 4. Exhaust Port Test Fitting 6. Reset Button 2. Parker Plug 5. Air Line 7. Test Gauge Assembly 3. Air Intake Port Fig. 3, Test Connections 9.
Page 569 32.04 Freightliner AirLiner Suspension Height-Control Valve Checking INLET PRESSURE 06/22/2007 f321039a Fig. 4, Inlet Pressure vs. Exhaust Pressure Change in 30 Seconds exhaust pressure change versus inlet pressure. The valve is not working correctly if the gauge pressure reading exceeds the maximum allowable within 30 seconds.
Page 570 32.04 Freightliner AirLiner Suspension Height-Control Valve Replacement Barksdale Height-Control Valve Replacement The Barksdale valve does not use an adjustable linkage rod. To adjust the Barksdale valve, see Subject 110. 1. Apply the parking brakes and chock the tires. WARNING Keep your hands and all objects away from the...
Page 571 32.04 Freightliner AirLiner Suspension Height-Control Valve Replacement tighten the nuts 95 lbf·in (1100 N·cm). Do not overtighten. 8. Remove the tape from the air lines and ﬁttings, and connect the air lines to the height-control valve as marked earlier. Tighten nylon tube air ﬁttings until only two threads show on the ﬁtting.
Page 572 32.04 Freightliner AirLiner Suspension Shock Absorber Replacement Shock Absorber Replacement 1. Chock the tires. 2. Remove the locknut, bolt, and spacer from the shock absorber lower mounting bracket. See Fig. 3. Remove the nut, upper retainer, and upper bush- ing from the top of the shock absorber.
Page 573 32.04 Freightliner AirLiner Suspension Air Spring Replacement Air Spring Replacement crossbar) in place. See Fig. 4. Tighten the lock- nut 55 lbf·ft (75 N·m). IMPORTANT: Effective March 2011, the steel 6. For bracket-mounted air springs: Attach the air spring to the upper mounting bracket, using the bead on the inside of the air bag where it at- 1/2–13 locknut on the outside of the frame rail...
Page 574 32.04 Freightliner AirLiner Suspension Air Spring Replacement 03/15/2011 f321160 A. Caution: Do Not Re-Assemble Rubber Bellow to Piston Fig. 1, Air-Spring and Piston Assembly 150/2 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 575 32.04 Freightliner AirLiner Suspension Air Spring Replacement 06/08/94 f320133 A. Air line connects here. 1. Right Frame Rail Flange 06/08/94 f320134 2. Locknut and Washer 3. Upper Mounting Bracket Fig. 4, Capscrew Connecting Leaf Spring and Air Spring Fig. 2, Bracket-Mounted Air Spring...
Page 576 32.04 Freightliner AirLiner Suspension Leaf Spring Replacement Leaf Spring Replacement NOTE: See Fig. 1 for this procedure. WARNING Do not replace individual leaves of a damaged leaf spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves.
Page 577 32.04 Freightliner AirLiner Suspension Leaf Spring Replacement 11/17/95 f320462 1. Frame Rail 11. U-Bolt Pad 19. Shock Absorber 2. Spring Hanger 12. U-Bolt 20. Nylon Locknut 3. Washer 13. Axle 21. Washer 4. Hexnut 14. Axle Seat 22. Air Spring 5.
Page 578 32.04 Freightliner AirLiner Suspension Leaf Spring Replacement 08/02/94 f320139a A. Axle Bump Stop 08/28/95 f320138a A. Arrow on U-Bolt Pad Fig. 4, Axle Bump Stop Positioning 16. Check the rear axle alignment. For instructions, Fig. 3, U-Bolt Pad Arrow Positioning refer to the rear axle section in this manual.
Page 579 32.04 Freightliner AirLiner Suspension Rear Axle Alignment Rear Axle Alignment Adjusting 3. When the axle is in alignment, install alignment shim(s) to take up the slack between the spring hanger and the spring pin. NOTE: See Fig. IMPORTANT: Make sure the same number of...
Page 580 32.04 Freightliner AirLiner Suspension Rear Axle Alignment Rear Axle Tracking Adjustment Single Axle 1. At the forward edge of the right rear tire, mea- sure the distance from the inner side of the tire to the outer side of the right frame rail. See Fig.
Page 581 32.04 Freightliner AirLiner Suspension Rear Axle Alignment 5. For bar-pin style torque rods, tighten the fasten- ers 136 lbf·ft (184 N·m). For taper-pin style torque rods, tighten the fasteners 165 lbf·ft (224 N·m). See Fig. 180/3 Business Class M2 Workshop Manual, Supplement 5, September 2003...
Page 582 32.04 Freightliner AirLiner Suspension Control Rod Replacement Replacement 1. Park the vehicle. Shut down the engine, and ap- ply the parking brakes. 2. Chock the tires. Raise the vehicle. Support the frame rails with jack stands. 3. Remove the fasteners holding the control rod to the frame rail bracket.
Page 583 32.04 Freightliner AirLiner Suspension Spring Eye Bushing Replacement Replacement the press bed for safety and to avoid bending the spring assembly. Center the bushing tool on the outer WARNING metal of the bushing and push the bush- ing from the spring eye.
Page 584 32.04 Freightliner AirLiner Suspension Speciﬁcations Torque Speciﬁcations For fastener torque values, see Table Torque Values for AirLiner Suspension Torque Description Size lbf·ft (N·m) lbf·in (N·cm) Height-Control Valve Housing Bolts 1/4–20 — 45 (500) Height-Control Valve Mounting Locknuts 1/4–20 — 95 (1100) Shock Absorber Mounting Locknuts 3/4–10...
Page 585 32.04 Freightliner AirLiner Suspension Speciﬁcations valve body and damage the valve. Conversely, tightening the nuts without holding the studs can back the studs out, causing a separation of the two halves of the valve body, and possibly a leak. 01/05/99 f320783 Fig.
Page 586 32.04 Freightliner AirLiner Suspension Speciﬁcations 06/05/2000 f320852 NOTE: Parts for cab suspension valve testing included. 1. Test Gauge Assembly with Reset Button 2. Exhaust Port Test Connector for Cab Suspension Valve (used for cab suspension valve testing) 3. Parker Plugs 4.
Page 587 32.05 ™ Freightliner TufTrac Suspension General Information General Information The TufTrac Suspension is heavy-duty "six rod" tandem-axle suspension option for trucks built for severe on/off highway work. See Fig. 1. The TufTrac design allows a truck to maneuver over bumps,...
Page 588 32.05 ™ Freightliner TufTrac Suspension General Information 07/01/99 f310804 1. Axle Clamps 4. Lower Control Rods 2. Leaf Springs 5. Rebound Stop 3. Center Bearing Fig. 1, TufTrac Suspension (46,000-pound [20 865-kilogram] version shown) 050/2 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 589 32.05 ™ Freightliner TufTrac Suspension Shock Absorber Replacement Replacement NOTE: See Fig. 1 for this procedure. 1. Park the vehicle on a level surface, shut down the engine and apply the parking brakes. Chock the tires. 2. Remove the lower shock mounting nut and washer.
Page 590 32.05 ™ Freightliner TufTrac Suspension Center Bearing Replacement Replacement 6. Remove the lower center bearing bolts attached to the spring assembly casting. Discard the bolts. 1. Park the vehicle on a level surface, shut down 7. Remove the center bearing. See Fig.
Page 591 32.05 ™ Freightliner TufTrac Suspension Center Bearing Replacement 05/06/99 f310807 1. Jack 3. Frame Rail 2. Jack Stand 4. Rear Axle Fig. 2, Jack and Jack Stand Placement 04/16/99 f310805 Fig. 3, Center Bearing Removal 12. Return the vehicle to its normal operating posi- tion.
Page 592 32.05 ™ Freightliner TufTrac Suspension Spring Assembly Removal, Assembly and Installation IMPORTANT: The spring pack assembly is not WARNING available as an assembled unit in the aftermar- ket. If the spring pack assembly is to be re- Do not attempt to remove the spring assembly by placed with a new assembly, the springs, center hand.
Page 593 32.05 ™ Freightliner TufTrac Suspension Spring Assembly Removal, Assembly and Installation 05/17/99 f350388 1. Springs 2. Lift (hoist) 3. Frame Rail Fig. 2, Leaf Spring Replacement Installation 3. Install the tip pad and bolts on each axle clamp. Tighten the bolts 37 lbf·ft (50 N·m). See Fig.
Page 594 32.05 ™ Freightliner TufTrac Suspension Lower Control Rod and V-Rod Replacement Lower Control Rod Forward axle rods are marked "FDA" and rear axle rods "RDA." Replacement 7. Fasten the new control rod to the axle clamp. Tighten the nut 136 lbf·ft (184 N·m).
Page 595 32.05 ™ Freightliner TufTrac Suspension Lower Control Rod and V-Rod Replacement 04/15/99 f310802 1. Mounting Bolt 3. Spacer 2. V-Rod Fig. 4, V-Rod Installation Place the new rod in position between the frame rails. 05/06/99 f310807 1. Jack 3. Frame Rail Install the bolts and spacers and loosely 2.
Page 596 32.05 ™ Freightliner TufTrac Suspension Axle Clamp and Retainer Replacement Replacement 6. Remove the brake cam tube support bracket from the left rear axle. Fig. 1 for this procedure. f310812 07/07/99 1. Upper Axle Clamp 5. Brake Cam Tube Support Bracket 2.
Page 597 32.05 ™ Freightliner TufTrac Suspension Axle Clamp and Retainer Replacement 07/02/99 f320810 07/07/99 f350392 Fig. 2, Jack the Vehicle Here A. Centerline of Spring 1. Tighten First 3. Tighten Third 12. Install the new upper axle clamps onto the left 2.
Page 598 32.05 ™ Freightliner TufTrac Suspension Speciﬁcations Torque Speciﬁcations Torque: Description lbf·ft (N·m) Shock Absorber Mounting Bolt 241 (327) Center Bearing Upper Mounting Bolts 68 (92) Center Bearing Lower Mounting Bolts 155 (210) Tip Pad Bolts 37 (50) Rebound Stop Mounting Bolt...
Page 599 32.06 Chalmers 800 Series Suspension General Information General Description there are no lubrication ﬁttings since grease and oil are never needed. The Chalmers 854 rear suspension (Fig. 1 The 854 rear suspension is available in three differ- Fig. 2) is a walking beam-type tandem axle suspen- ent maximum load capacities: 40,000 lb.
Page 600 32.06 Chalmers 800 Series Suspension General Information 03/26/2002 f320960 1. Restrictor Can 11. Lower Torque Rod (adjustable) 2. Upper Torque Rod Frame Bracket (LH forward) 12. Torque Rod Bushing (lower) 3. Spigot Cap (upper) 13. Lower Torque Rod Axle Housing Bracket (LH rear) 4.
Page 601 32.06 Chalmers 800 Series Suspension Restrictor Can Removal, Inspection, and Installation Removal 1. If necessary, power wash the spring restrictor can area to remove road dirt accumulation. NOTE: See Fig. 1 for this procedure. 03/26/2002 f320960 1. Restrictor Can 11. Lower Torque Rod (adjustable) 2.
Page 602 32.06 Chalmers 800 Series Suspension Restrictor Can Removal, Inspection, and Installation 2. Chock the front tires to prevent vehicle move- and in the walking beam are free of rust and de- ment. bris. See Fig. 3. Raise the rear of the vehicle just enough to re- move all weight from the rear axles, and place safety stands under the frame to support the ve- hicle in its raised position.
Page 603 32.06 Chalmers 800 Series Suspension Restrictor Can Removal, Inspection, and Installation 4. Slide, as one assembly, the spring plate, spring, and restrictor cap, into position on the walking beam. 5. Install and tighten the spring plate fasteners 35 lbf·ft (47 N·m). 6.
Page 604 32.06 Chalmers 800 Series Suspension Rubber Spring Replacement Removal 1. If necessary, power wash the spring restrictor can area to remove road dirt accumulation. NOTE: See Fig. 1 for this procedure. 03/26/2002 f320960 1. Restrictor Can 11. Lower Torque Rod (adjustable) 2.
Page 605 32.06 Chalmers 800 Series Suspension Rubber Spring Replacement 2. Chock the front tires to prevent vehicle move- ment. 3. Raise the rear of the vehicle just enough to re- move all weight from the rear axles, and place safety stands under the frame to support the ve- hicle in its raised position.
Page 606 32.06 Chalmers 800 Series Suspension Shock Absorber Replacement Replacement Extend or compress the shock absorber as nec- essary to install the mounting bolts. Install the locknuts and tighten the fasteners 170 lbf·ft (230 The Chalmers 854 rear suspension is ﬁtted with N·m).
Page 607 32.06 Chalmers 800 Series Suspension Walking Beam Removal, Inspection, and Installation Removal 1. If necessary, power wash the walking beams and axle housing ends to remove road dirt accumula- tion. NOTE: See Fig. 1 for this procedure. 03/26/2002 f320960 1. Restrictor Can 11.
Page 608 32.06 Chalmers 800 Series Suspension Walking Beam Removal, Inspection, and Installation 2. Chock the front tires to prevent vehicle move- ment. 3. Relieve all drive axle brake or wind-up loads by placing the transmission in neutral and releasing the spring or driveline brakes. 4.
Page 609 32.06 Chalmers 800 Series Suspension Walking Beam Removal, Inspection, and Installation 01/11/96 f320442 1. Front Axle Housing, Beam Saddle Bracket 2. Walking Beam 3. Beam Stop 09/27/95 f320432 Fig. 4, Beam/Saddle Bracket Alignment A. Flange thickness measurement taken at unworn area for reference.
Page 610 32.06 Chalmers 800 Series Suspension Walking Beam Repair Repair NOTE: This subject addresses only instances where excessive beam ﬂange wear occurs, but cracks in the web or ﬂange are not present. Cracked webs and/or ﬂanges require walking beam replacement. Walking beams with excessive ﬂange wear, however, can be repaired by welding a Chalm- ers Wear Plate over the worn areas as de- scribed below.
Page 611 32.06 Chalmers 800 Series Suspension Walking Beam Repair 10/19/95 f320443 A. Limit weld to this area only. 1. Walking Beam 2. Wear Plate Fig. 2, Chalmers Wear Plate Welding 140/2 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 612 32.06 Chalmers 800 Series Suspension Torque Rod Removal and Installation The torque rods hold the rear axles in place, main- 1. If necessary, power wash the rear suspension to taining both axle alignment and pinion nose angle. remove road dirt accumulation. When servicing the torque rods, it is good practice to 2.
Page 613 32.06 Chalmers 800 Series Suspension Torque Rod Removal and Installation 01/11/96 f320447 Fig. 2, Torque Rod Arrangement, 46,000- and 52,000-Pound Capacity Suspensions 6. Replace worn or damaged bushings following the instructions in Subject 160. 7. Inspect the spigots for extensive wear. See Fig.
Page 614 32.06 Chalmers 800 Series Suspension Torque Rod Removal and Installation 3. Push the torque rod into position on its spigots. After the torque rod is partially installed, use a heavy soft-faced mallet to drive the torque rod into position until the bushing contacts the spigot bottom face.
Page 615 32.06 Chalmers 800 Series Suspension Torque Rod Bushing Inspection and Replacement Inspection ous amount of rubber lubricant, such as Rimslip ® or equivalent. 1. If necessary, power wash the upper and lower 6. Place the torque rod on a solid level ﬂoor with an torque rods to remove road dirt accumulation.
Page 616 32.06 Chalmers 800 Series Suspension Torque Rod Bushing Inspection and Replacement 10/26/95 f320449 A. The amount of rubber protruding from each side of the torque rod eye must be equal. 1. Torque Rod Bushing 2. Torque Rod Eye Fig. 2, Torque Rod Bushing Protrusion 160/2 Business Class M2 Workshop Manual, Supplement 1, April 2002...
Page 617 32.06 Chalmers 800 Series Suspension Rear Axle Alignment Adjustment Adjustment have to be brought forward, or the leading end will have to be moved back to align it at a right angle to the frame. See Fig. On the Chalmers 854 Rear Suspension, the lower torque rods provide the only means for If the forward-rear axle alignment is within speci- ﬁcations, go to the step that begins "Using a...
Page 618 32.06 Chalmers 800 Series Suspension Rear Axle Alignment Adjustment 8. Using a center-point bar, determine the differ- ence between the forward-rear and the rearmost axles’ center-to-center measurements on each side of the vehicle. For instructions, see Group 35 of this manual. This difference is the approximate distance that the leading end of the rearmost axle will have to be adjusted rearward, or that the trailing end will have to be adjusted...
Page 619 32.06 Chalmers 800 Series Suspension Speciﬁcations Torque: Description Bolt Size IFI Grade lbf·ft (N·m) Beam Spring Plate Bolt 3/8 UNC 35 (47) Torque Rod End Through Bolts 5/8 UNC 135 (183) Shock Absorber Bolt 170 (230) Torque Rod End Pinch Bolts 5/8 UNC 135 (183) Table 1, Fastener Torques, 854 Suspension...
Page 620 32.07 Hendrickson RT Series Suspension General Information General Description The Hendrickson RT series suspension (see Fig. uses leaf springs to lessen road shocks. The forward and rear ends of the spring assembly ride in hang- ers. At the forward end, the springs are attached to the hanger with pins.
Page 621 32.07 Hendrickson RT Series Suspension General Information 12/27/94 f320359a A. Gap 1. No. 1 Spring Hanger 2. No. 2 Spring Hanger 3. No. 3 Spring Hanger Fig. 4, Loaded RTE Spring The axles are attached to beam hangers at the ends of the equalizer beams, allowing an articulating ac- tion between the axles to lessen road shock.
Page 622 32.07 Hendrickson RT Series Suspension Suspension Removal and Installation Removal Installation NOTE: See Fig. 1 for this procedure. NOTE: See Fig. 1 for this procedure. 1. Chock the front tires. 1. Roll the axles under the vehicle frame. Align the center bushing of each equalizer beam with the 2.
Page 623 32.07 Hendrickson RT Series Suspension Suspension Removal and Installation 9 11 09/07/94 f320141a 31. Grease Fitting (bronze bushing) 1. Forward (no. 1) Spring Hanger 16. Spring Alignment Clip 2. Locknut 17. Rear (no.2) Spring Hanger 32. Saddle Cap 3. Washer 18.
Page 624 32.07 Hendrickson RT Series Suspension Suspension Removal and Installation 08/02/94 f320181a A. Maintain an even gap. 1. Saddle 2. Saddle Cap Fig. 2, Side View 100/3 Business Class M2 Workshop Manual, Supplement 2, June 2002...
Page 625 32.07 Hendrickson RT Series Suspension Spring and Saddle Removal and Installation Removal Installation 1. Remove the suspension. For instructions, see 1. Seat the leaf spring assembly on the saddle. Subject 100. 2. Position the top pad on the spring assembly. 2.
Page 626 32.07 Hendrickson RT Series Suspension Spring and Saddle Removal and Installation 7. Coat the spring pin and the inside diameter of the spring eye bushing with multipurpose chassis grease. 8. Align the spring pin with the spring eye bushing in the forward spring hanger. 9.
Page 627 32.07 Hendrickson RT Series Suspension Spring Leaf, Spring Pin, and Spring Eye Bushing Replacement Replacement center bolt nut and tighten to the value in the table under Speciﬁcations 400. 1. Remove the spring and saddle assembly. For 8. Install the spring and saddle assembly. For in- instructions, see Subject 110.
Page 628 32.07 Hendrickson RT Series Suspension Equalizer Beam Adapter- and Tube-Type End Support Removal and Installation Removal IMPORTANT: To ensure that the required tools are available, see the applicable table under Speciﬁcations 400 before beginning these pro- cedures. Special tools are available from the Owatonna Tool Company, Owatonna, Minne- sota, or an affiliated dealer.
Page 629 32.07 Hendrickson RT Series Suspension Equalizer Beam Adapter- and Tube-Type End Support Removal and Installation 08/03/94 f320160a 1. Pulling Screw 4. Beam Hanger 7. Tube-Type Hanger Pin 2. Ram 5. Equalizer Beam 8. Speed Nut 3. Receiving Tube 6. Removing Adapter Fig.
Page 630 32.07 Hendrickson RT Series Suspension Equalizer Beam Adapter- and Tube-Type End Support Removal and Installation use a hacksaw and saw the tube along the inside surface of both axle beam hanger legs. WARNING Don’t use a cutting torch to remove the equalizer beams from the beam hangers.
Page 631 32.07 Hendrickson RT Series Suspension Equalizer Beam Adapter- and Tube-Type End Support Removal and Installation 12. Lower the equalizer beams and the crosstube to end bushings. Hand-tighten both nuts on the the ground. Remove the thrustwashers and pull beam end tubes. the beams from the crosstube.
Page 632 32.07 Hendrickson RT Series Suspension Equalizer Beam End Bushing Removal and Installation Removal WARNING Don’t use a cutting torch to remove the beam end bushing. Equalizer beams are heat-treated by the manufacturer. Using a cutting torch could weaken the beams, and may result in a loss of vehicle control.
Page 633 32.07 Hendrickson RT Series Suspension Equalizer Beam End Bushing Removal and Installation Remove the equalizer beams. For instruc- tions, see Subject 130. Position the equalizer beam on a 50-ton vertical hydraulic press. Center the shop-made adapter (refer to the applicable table under Speciﬁca- tions 400) on the trimmed end of the...
Page 634 32.07 Hendrickson RT Series Suspension Equalizer Beam End Bushing Removal and Installation Position the shop-made adapter (refer to the table under Speciﬁcations 400) against the jaws of the sheave puller. Press the new bushing into the beam eye. Install the equalizer beam. For instruc- tions, see Subject 130.
Page 635 32.07 Hendrickson RT Series Suspension Equalizer Beam Bar Pin/Bushing Assembly Removal, Installation, and Alignment Removal Center the shop-made tool, and press the bar pin/bushing assembly from the beam end eye. NOTE: Most Hendrickson suspensions are manufactured with a bar pin-type bushing as- Installation sembly that connects the equalizer beam to the axle.
Page 636 32.07 Hendrickson RT Series Suspension Equalizer Beam Bar Pin/Bushing Assembly Removal, Installation, and Alignment 04/23/96 f320522 The material used to make the tool is: 0.50" (13 mm) wall x 5.0" (127 mm) o.d. x 5.0" (127 mm) long steel tubing. NOTE: The assembly tool must be split in half as shown.
Page 637 32.07 Hendrickson RT Series Suspension Equalizer Beam Rubber Center Bushing Removal and Installation Removal IMPORTANT: Align the receiving tube so that the bushing will clear the edges of the tube when force is exerted against the NOTE: If using Owatonna tools, it is not neces- beam.
Page 638 32.07 Hendrickson RT Series Suspension Equalizer Beam Rubber Center Bushing Removal and Installation Install spacers between the ram cylinder Center the hydraulic ram and slide the and the speed nut. Tighten the speed nut pulling screw through the beam eye. and remove any slack in the assembly.
Page 639 32.07 Hendrickson RT Series Suspension Equalizer Beam Rubber Center Bushing Removal and Installation reading reaches the operating limit of 10,000 psi (68 950 kPa) and the bushing is not go- ing into the beam, check the alignment of the bushing, tooling, and hydraulic equip- ment.
Page 640 32.07 Hendrickson RT Series Suspension Equalizer Beam Bronze Center Bushing Removal and Installation Removal Install the hexnut on the pulling screw. Full thread engagement is needed. NOTE: If using Owatonna tools, you can re- move or install the bronze center bushing with- out removing the equalizer beam.
Page 641 32.07 Hendrickson RT Series Suspension Equalizer Beam Bronze Center Bushing Removal and Installation 7. If using shop-made adapters, remove the equal- izer beams. For instructions, refer to Sub- ject 130. Position the equalizer beam on a 50-ton vertical hydraulic press. Center the shop-made adapter (refer to the applicable table under Speciﬁca-...
Page 642 32.07 Hendrickson RT Series Suspension Equalizer Beam Bronze Center Bushing Removal and Installation Install the new grease seals (with the seal lips facing out). NOTE: Check that the new seals are 1/6 inch (4 mm) inside the beam hub surface to ensure clearance and protection of the seals when the saddle cap is installed.
Page 643 32.07 Hendrickson RT Series Suspension Torque Rod and Bushing Removal and Installation Removal torque rod stud. Apply lubricating oil (see Fig. then press the stud out of the bushing. IMPORTANT: To ensure that the required tools 5. Position the bushing remover/replacer tool (using are available, see the applicable table in Speci- the end with the larger outside diameter) on the...
Page 644 32.07 Hendrickson RT Series Suspension Torque Rod and Bushing Removal and Installation 08/04/94 f320172a 1. Left-Hand Frame Rail 9. Forward-Rear Axle 2. Flanged Hexnut 10. Fore-and-Aft Torque Rod 3. Spacer 11. Capscrew 4. Transverse Torque Rod Mounting Bracket 12. Mounting Bracket 5.
Page 645 32.07 Hendrickson RT Series Suspension Torque Rod and Bushing Removal and Installation 08/04/94 f320175a Fig. 4, Positioning the Pin Remover 02/04/2000 f320173b Fig. 2, Separating the Halves 08/04/94 f320075a 1. Bushing 2. Clamping Tool Fig. 5, Installing the New Bushing bracket.
Page 646 32.07 Hendrickson RT Series Suspension Torque Rod and Bushing Removal and Installation 08/04/94 f320363a Fig. 8, Correct Bushing Pin Position 11.2 Install the tapered stud in the axle bracket. Install a washer and nut. Tighten the nut 175 to 225 lbf·ft (235 to 305 N·m). 11.3 Align the straddle mount end, the mount- ing bracket, and the spacer against the...
Page 647 32.07 Hendrickson RT Series Suspension Speciﬁcations Part Tool Usage Number 1745 Adapter Puller Set Adapter-Type End Support Removal 1761 Torque Rod Set Torque Rod Bushing Removal and Installation 28536 Installing Adapter (5-3/4" o.d.) Bronze Center Bushing and Seal Removal and Installation 44119 Receiving Tube Center and End Bushing Removal and Installation...
Page 648 32.07 Hendrickson RT Series Suspension Speciﬁcations Description Size Torque: lbf·ft (N·m) Spring Center Bolt 7/16–20 50–60 (70–80) 1/2–20 65–75 (90–100) Rebound Spacer Locknut 1/2–13 38–45 (51–61) Spring Alignment Clip — 15 (20) Fore and Aft Torque Rod Mount Nut — 95 (130) Table 3, Torque Values 400/2...
Page 649 33.00 Front Axle General Information General Description NOTE: For front axle troubleshooting proce- dures, refer to Section 33.01. The front axle requires periodic servicing to maintain accurate wheel alignment. If the front axle is dam- aged enough to affect the camber angle it must be replaced.
Page 650 33.00 Front Axle General Information f330082a 08/29/94 NOTE: B minus A equals toe-in. Fig. 4, Wheel Toe-In (overhead view) 08/29/94 f400094a A. Feathered Edges Fig. 5, Tire Damage Due to Excessive Toe-In or Incorrect Drive Axle Alignment 12/20/94 f400096a 1. Knuckle Pin (King Pin) A.
Page 651 33.00 Front Axle Preliminary Checks Preliminary Checks weight distribution. Anything that changes the ratio of weight on the springs affects the align- ment angles and also the tire tread contact area. IMPORTANT: When aligning the front axle, it is Replace damaged springs as instructed in essential that the rear axle(s) be checked for Group 32 of this manual.
Page 652 If necessary, loosen the stopscrew locknut; ad- ment manufacturer. Freightliner dealers must just the stopscrew to contact the axle when the have proof of this calibration history. maximum turning angle of the wheels is deter- 1.
Page 653 33.00 Front Axle Steering Angle Checking and Adjusting 5. Repeat the step above with the steering wheel turned counterclockwise. Adjust the axle stop, as needed. 6. If equipped with power steering, adjust the steer- ing gear so that pressure is released ahead of the axle stop.
Page 654 10° 10° equipment must be calibrated every three months by a qualiﬁed technician from the equip- ment manufacturer. Freightliner dealers must have proof of this calibration history. 10° 10° Precision instruments and equipment are needed for accurately measuring and adjusting wheel alignment.
Page 655 7. Remove the chocks from the tires. ment manufacturer. Freightliner dealers must have proof of this calibration history. 1. Apply the parking brakes, and chock the rear tires.
Page 656 Caster angle is the tilt of the knuckle pin (or kingpin) months by a qualiﬁed technician from the equip- as viewed from the side. See Fig. ment manufacturer. Freightliner dealers must have proof of this calibration history. Using the alignment equipment manufacturer’s oper- ating instructions, measure the front wheel caster.
Page 657 33.00 Front Axle Caster Angle Checking and Adjusting bushings, can cause extreme deviations to caster angles. Replace damaged parts before doing caster adjustments. 1. Apply the parking brakes, and chock the front and rear tires. 2. Back off the U-bolt nuts from the U-bolts on one side of the front axle.
Page 658 Lock in place. Make sure that the ment manufacturer. Freightliner dealers must scale is set on zero. have proof of this calibration history.
Page 659 33.00 Front Axle Wheel Toe-In Checking and Adjusting 08/30/94 f330014a Fig. 2, Trammel Bar Positioning 08/30/94 f400100a Fig. 3, Calculating Wheel Toe-In 150/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 660 33.00 Front Axle Front Axle Removal and Installation Removal NOTE: This procedure involves removing the axle from underneath the front of the vehicle. If you cannot support the vehicle high enough for the axle to clear the bumper, then you will need to remove the bumper.
Page 661 33.00 Front Axle Front Axle Removal and Installation 3. Slowly raise the axle up to the bottom of the leaf 16. Lower the hood. springs, making sure the dowels on top of the 17. Remove the chocks from the rear tires. axle beam line up with the holes in the axle spacers.
Page 662 Manufacturer degrees degrees degrees degrees degrees Meritor, Freightliner, and +3 to +6-1/2 +3 to +6-1/2 +2-1/4 to +4-3/4 2 to 5 3.5 ± 1.5 Dana/Eaton IMPORTANT: Caster settings for the left and right sides must be within 1/2 degree of each other. It is necessary for only one side to be within the speciﬁcations given in this table.
Page 663 33.00 Front Axle Speciﬁcations Miscellaneous Torque Values Description Torque: lbf·ft (N·m) Meritor Stopscrew Locknut 50–65 (68–88) Dana/Eaton Stopscrew Locknut 90–120 (122–163) Table 4, Miscellaneous Torque Values 400/2 Business Class M2 Workshop Manual, Supplement 15, March 2009...
Page 664 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings General Information General Information These vehicles are equipped with one of four differ- ent wheel end assemblies: • The Con Met PreSet ® This wheel end has the bearings and oil seal pre-installed in a hub.
Page 665 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings General Information 03/22/94 f350056a 1. Cup 3. Cone 2. Tapered Roller 4. Roller Cage Fig. 2, Tapered Wheel Bearing Assembly Both the inner and outer wheel bearing cups and the wheel studs are press-ﬁt in the hub.
Page 666 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings General Information 9 10 11 08/29/2001 f330180 NOTE: On Meritor FF-981 Easy Steer Plus axles, the hub, wheel bearings, studs, and oil seal are assembled at Meritor and installed as an assembly. A.
Page 667 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings General Information 08/26/94 f330018a Fig. 4, Front Axle Wheel Hub 02/22/94 f350055a 1. Serrations 2. Clipped Head Fig. 5, Typical Wheel Studs 050/4 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 668 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Hub Assembly Removal and Installation Removal NOTICE 1. Chock the rear tires. Be careful not to let the outer wheel bearing drop from the axle spindle. Dropping the bearing can 2.
Page 669 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Hub Assembly Removal and Installation 9 10 11 08/29/2001 f330180 NOTE: On some axles, the hub, wheel bearings, studs, and oil seal are installed as a unitized wheel-end assembly. These wheel ends must be replaced as a unit. A.
Page 670 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Hub Assembly Removal and Installation 4. Wipe a ﬁlm of axle oil on the axle spindle to pre- above exist could result in the loss of a wheel or vent rust from forming behind the inner wheel loss of vehicle control, and possible personal in- bearing.
Page 671 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Axle Components Cleaning and Inspection Wheel Hub Assembly Inspection 1. Inspect the wheel hub mounting ﬂange. A loose wheel assembly will cause the ﬂange to be worn, jagged, or warped. See Fig.
Page 672 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Axle Components Cleaning and Inspection ers worn sharp. These are indications of advanced wear. See Fig. f230017a 04/14/94 Fig. 4, Damaged Wheel Stud Nut 5. Inspect the wheel or rim studs. Replace studs that are stripped, broken, bent, or otherwise damaged.
Page 673 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Axle Components Cleaning and Inspection friction surface must be removed with a solvent, prior to drum installation, then rinsed with a hot water wash. Use a clean rag to remove any oily residue or metal chips from the friction surface.
Page 674 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Axle Components Cleaning and Inspection 1. Inspect the inner friction surface. If a veneered to unacceptable limits. Remachine or replace the (highly glossed) or glazed surface exists, renew same-axle drums. the drum by using 80-grit emery cloth or by turn- 6.
Page 675 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Wheel Bearing Cup Removal and Installation, Ferrous Hubs Removal Wheel bearing cups on ferrous hubs are removed and installed by driving them out and pressing them in without heating the hub. 1.
Page 676 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Dual-Nut Wheel Bearing Lock System Installation and Adjustment Installation and Adjustment 1. Carefully mount the hub and inner wheel bearing assembly on the axle spindle. Be careful not to unseat the inner wheel bearing or seal. 2.
Page 677 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Dual-Nut Wheel Bearing Lock System Installation and Adjustment Attach a dial indicator to the hub and set End play should be between 0.001 and the point of the indicator in line with the 0.005 inch (0.03 to 0.13 mm).
Page 678 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Meritor Easy Steer Plus Hub Installation and Adjustment Installation and Adjustment 1. With the hub mounted on the axle spindle, install the inner (adjusting) nut and tighten it 600 lbf·ft (815 N·m).
Page 679 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings ConMet PreSet ® Hub Installation and Adjustment General Information ConMet PreSet steer axle hubs are equipped with a special tubular spacer inside the hub, between the inner and outer bearings. See Fig.
Page 680 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings ® ConMet PreSet Hub Installation and Adjustment 09/09/98 f330156 A. This retainer tab must engage the keyway of the 06/20/95 f330126 axle spindle. A. The ﬂat side of the retainer must engage the ﬂat side of the axle spindle.
Page 681 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings ConMet PreSet ® Hub Installation and Adjustment 4. Install the Axilok retaining nut onto the axle spindle. See Fig. 3 Fig. 5. Tighten the retaining nut 250 lbf·ft (339 N·m). Do not back off the retaining nut.
Page 682 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings ® ConMet PreSet Hub Installation and Adjustment brake drum onto the hub to provide a NOTICE steel base for the magnet of the dial indi- cator. Mount the drum on the hub’s drum Do not remove the outer wheel bearing once the pilot.
Page 683 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Outboard-Mounted Drum Removal and Installation starting with removal of the wheels and continu- WARNING ing through assembly. When replacing brake pads, shoes, rotors, or 4. Remove the wheel and tire assembly. See drums, always replace components as an axle Group 40 for instructions.
Page 684 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Outboard-Mounted Drum Removal and Installation 9 10 11 08/29/2001 f330180 NOTE: On Meritor FF-981 Easy Steer Plus axles, the hub, wheel bearings, studs, and oil seal are assembled at Meritor and installed as an assembly.
Page 685 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Outboard-Mounted Drum Removal and Installation 05/03/94 f350125 NOTE: Pilot pad at 12 o’clock position 1. Drum Pilot 2. Wheel Pilot Fig. 2, Hub Pilot Pads 160/3 Business Class M2 Workshop Manual, Supplement 18, September 2010...
Page 686 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Wheel Bearing Cup Removal and Installation, Aluminum Hubs Removal the hub that could cause loss of a wheel and loss of vehicle control, leading to personal injury or property damage. To insure a tight ﬁt, wheel bearing cups are pur- posely larger than the wheel hub bores they occupy.
Page 687 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Wheel Bearing Cup Removal and Installation, Aluminum Hubs will also cause permanent damage to the wheel hub. If the sides of the bearing cup bore are damaged during installation, replace the wheel hub assembly.
Page 688 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Wheel Stud Replacement Replacement necessary to ensure the least amount of metal removal from the wheel stud bore. Concentrated heat will damage the hub. If the hub is damaged WARNING during wheel stud removal or installation, replace If a wheel stud breaks, the remaining studs are 4.
Page 689 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Wheel Stud Replacement 08/26/94 f350053a A. "Right" Fig. 2, Thread Stamp Location of a wheel or loss of steering control, possibly resulting in personal injury. 9. Wipe off any grease on the wheel studs and wheel hub.
Page 690 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Troubleshooting Tables Problem — Noisy Bearings or Excessive Bearing Replacement Intervals Problem — Noisy Bearings or Excessive Bearing Replacement Intervals Possible Cause Remedy Not enough oil was used on the bearings, Clean, then inspect the bearings for wear.
Page 691 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Loss of Lubricant from the Wheel Hubs Problem — Loss of Lubricant from the Wheel Hubs Possible Cause Remedy The seals or gaskets are worn or Replace worn or damaged parts. damaged.
Page 692 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Brake Shoes on the Same Brake Are Wearing Unequally Problem — Brake Shoes on the Same Brake Are Wearing Unequally Possible Cause Remedy The brake linings are not a matched set. Install a new matched set of brake linings on both sets of axle brake shoes.
Page 693 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Brake Linings Are Loose Problem — Brake Linings Are Loose Possible Cause Remedy The rivet holes in the brake shoes are to Replace the brake shoes. large. Incorrectly crimped rivets are working Replace the rivets.
Page 694 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Brake Drums Are Heavily Scored Problem — Brake Drums Are Heavily Scored Possible Cause Remedy The brake linings are damaged. Install new brake linings on both sets of axle brake shoes. Clean, turn, or replace the drums.
Page 695 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Erratic Steering When the Brakes are Applied Possible Cause Remedy The front axle wheel bearings are worn or Check the bearings for wear or damage; replace as needed. were incorrectly adjusted.
Page 696 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Front Wheel Shimmy Possible Cause Remedy The axle spindle is bent. Replace the spindle. One or more of the alignment Check all alignment measurements and correct as needed. measurements are incorrect.
Page 697 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Troubleshooting Problem — Steering Wheel Spokes Do Not Point at the 3 and 9 O’clock Positions Problem — Steering Wheel Spokes Do Not Point at the 3 and 9 O’clock Positions Possible Cause Remedy The steering gear is not centered.
Page 698 Front Axle Wheel Hubs, Brake Drums, and Wheel 33.01 Bearings Speciﬁcations Dual-Nut Wheel Bearing Lock Torque Values Application Size Torque: lbf·ft (N·m) Stage 1: Tighten to 100 (135). Stage 2: Back Off Completely. Adjusting Nut — Stage 3: Tighten to 20 (25) While Rotating Hub. Stage 4: Back Off 1/3 Turn (two ﬂats of the adjusting nut).
Page 699 33.02 Front Axle Oil Seals General Information General Information tightly enough to prevent oil escaping between the outer edge of the seal and the hub bore. Wheel oil seals (also called "oil bath seals" or "hub The inside edge is usually metal or rubber with a seals") work as a dam to keep oil in the hub cavity metal ring within it to prevent the sealing element so that it constantly "bathes"...
Page 700 33.02 Front Axle Oil Seals General Information 05/19/95 f330011a A. Detail A B. Oil Seal (See detail A) ® 1. Bore-Tite Coating 4. Outer Cup 7. Bumper Lip Primary Sealing Lip 5. Inner Cup 8. Hub 3. Dirt Lip 6. Sealing Element (Packing) 9.
Page 701 33.02 Front Axle Oil Seals General Information 03/27/95 f330117a 1. Dana Spicer Outrunner Installation Tool 2. Dana Spicer Outrunner Seal Fig. 3, Dana Spicer Outrunner Seal 050/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 702 33.02 Front Axle Oil Seals Seal Replacement, Chicago Rawhide Replacement NOTE: This procedure applies to the Chicago Rawhide Scotseal ® 1. Remove the wheel, drum, and hub from the axle. For instructions, see Section 33.01, Subject 100. 2. Remove the oil seal from the hub. 3.
Page 703 33.02 Front Axle Oil Seals Seal Replacement, Chicago Rawhide 09/27/2005 f330023a f330022a 11/30/94 NOTE: Rear hub shown. NOTE: Rear hub shown. Fig. 4, Insert the Tool in the Hub Bore Fig. 3, Place the Seal on the Installation Tool 16. Spin the wheel and check the oil level. out.
Page 704 33.02 Front Axle Oil Seals Seal Replacement, Chicago Rawhide 02/09/93 f330025a 1. Filler Plug Fig. 6, Fill the Hub with Oil 09/27/2005 f330024a NOTE: Rear hub shown. Fig. 5, Strike the Tool 100/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 705 33.02 Front Axle Oil Seals Seal Replacement, Dana Spicer Replacement NOTE: This procedure applies to the Dana Spicer Outrunner ™ seal. 1. Remove the wheel, drum, and hub from the axle. For instructions, see Section 33.01, Subject 100. 2. Remove the oil seal from the hub. 3.
Page 706 33.02 Front Axle Oil Seals Seal Replacement, Dana Spicer Inspect the bearings and hub components for wear or damage. Replace any worn or damaged components as necessary. Coat the wheel bearing cones with oil. 5. Install the inner wheel bearing cone in the inner wheel bearing cup.
Page 707 33.02 Front Axle Oil Seals Seal Replacement, Dana Spicer Hit the handle of the installation tool gen- 8. Place the hubcap and a new gasket in position, tly . See Fig. then install the capscrews. Tighten the cap- screws 15 lbf·ft (20 N·m). Because of the rubber outer circumfer- ence, the Outrunner seal is easier to in- 9.
Page 708 33.02 Front Axle Oil Seals Seal Replacement, National Replacement 9. Put the oil seal on the adapter plate, making sure the words "Air Side" on the oil seal are fac- ing the adapter plate surface. ® NOTE: This procedure applies to the National oil seal.
Page 709 33.02 Front Axle Oil Seals Seal Replacement, National 02/18/2004 f330214 1. Installation Handle 6. Inner Bearing 2. Adapter Plate 7. Hub 3. Oil Seal 8. Outer Bearing 4. Bearing Pilot 9. Centering Fixture 5. Hexnut, 3/4–10 Fig. 2, Installing the Oil Seal Into the Hub (cross- sectional view) 120/2 Business Class M2 Workshop Manual, Supplement 7, March 2005...
Page 710 Subject 110 to disassemble and assemble the steering knuckle. There are three basic models for the Freightliner front axle: Model 2, Model 3, and Model 5. The basic model is indicated by the numbers on the axle’s identiﬁcation tag.
Page 711 33.03 Freightliner Front Axles Axle Removal and Installation Removal 17. Remove the axle from the vehicle. 18. If you are replacing the steering knuckles, put 1. Park the vehicle on a level surface, shut down the axle on a suitable stand and secure it to pre- the engine, set the parking brake, and chock the vent it from moving.
Page 712 33.03 Freightliner Front Axles Axle Removal and Installation 15. If equipped with a front air suspension, check that the suspension air bags are inﬂating cor- rectly. 16. Remove the chocks from the rear tires. 100/2 Business Class M2 Workshop Manual, Supplement 7, March 2005...
Page 713 33.03 Freightliner Front Axles Steering Knuckle Disassembly and Assembly Disassembly Remove the upper and lower snap rings that hold the cover plates in place. See Fig. NOTE: The following procedures can be done with the axle installed on the vehicle or with the Remove the upper and lower cover plates from the steering knuckle.
Page 714 33.03 Freightliner Front Axles Steering Knuckle Disassembly and Assembly 06/08/2011 f330211a NOTE: The number of upper and lower needle bearing sets may vary, depending on the axle model. 1. Tie-Rod Ball Joint 9. Lower Draw Key Nut 18. Shim 2. Castle Nut 10.
Page 715 33.03 Freightliner Front Axles Steering Knuckle Disassembly and Assembly 2. Install the grease seal — with the grooved side 6. Install the kingpin fully into the steering knuckle down (toward the road) — into the top of the bores, making sure the ﬂats on the kingpin are upper steering knuckle bore.
Page 716 33.03 Freightliner Front Axles Steering Knuckle Disassembly and Assembly 15. Install the brake anchor plates on the axle ends. For instructions, see the applicable section in Group 16. Install the brake air chambers and slack adjust- ers on the axle. For instructions, see the appli-...
Page 717 33.03 Freightliner Front Axles Speciﬁcations Torque Values Application Size Class Torque: lbf·ft (N·m) Air Bag-to-Leaf Spring Nuts — — 220 (298) Draw-Key Nuts — — 30–55 (40–75) Steering Arm Capscrews M20 x 1.5 10.9 480 (650) Sway Bar Fasteners —...
Page 718 35.00 Rear Axle Alignment General Information General Information Rear axle alignment should be checked whenever rear axle or suspension components are replaced. It should also be checked when there is excessive front and rear tire wear, or hard or erratic steering. Manufacturers of axle alignment equipment offer a variety of systems to precisely measure and correct rear axle alignment.
Page 719 35.00 Rear Axle Alignment Preliminary Checks The following preliminary checks should be com- Group 32 in this manual or the suspension pleted before checking any alignment measurements. manufacturer’s service literature. Sagging, fa- tigued, or broken suspension springs create a lopsided vehicle appearance and an unbalanced Preliminary Checks weight distribution.
Page 720 3. The straightedge months by a qualiﬁed technician from the equip- must line up exactly with the points. ment manufacturer. Freightliner dealers must 5. Measuring from the outside edge of each frame have proof of this calibration history. rail, mark the straightedge on both sides of the frame.
Page 721 35.00 Rear Axle Alignment Alignment Checking, Single Axle f350110b 03/25/94 For items A and D, see Speciﬁcations 400. A. Distance from Rear Axle to Target (using Bee Line Alignment Tools) B. Maximum Allowable Difference if Aligned Manually = ±1/4 inch (6 mm) C.
Page 722 2. Using a center point bar, set the two points into ment manufacturer. Freightliner dealers must the axle cap holes as shown in Fig. 2. Lock have proof of this calibration history.
Page 723 35.00 Rear Axle Alignment Alignment Checking, Tandem Axle of 1/8 inch (3 mm) or less between the spacing on one side of the vehicle compared to the other, no further action is necessary. If the difference is more than 1/8 inch (3 mm), adjust the forward- rear axle alignment.
Page 724 35.00 Rear Axle Alignment Center Point Bar Construction Materials Required NOTE: To obtain metric conversions (millime- ters), multiply the number of inches by 25.4. The following materials are required: • 62" of square steel tube (1" x 1", measured outside) •...
Page 725 35.00 Rear Axle Alignment Speciﬁcations Method Maximum Tolerance ± from Perpendicular Manual 1/4-inch (6 mm) Table 1, Maximum Tolerance from Perpendicular, Manual Method Method Maximum Tolerance ± from Perpendicular Hunter ±0.18 degree To use Hunter alignment equipment, refer to the applicable Hunter service literature.
Page 726 35.00 Rear Axle Alignment Speciﬁcations f350111b 08/29/94 NOTE: See Table 4 for values corresponding to callouts A, B, and C. Fig. 1, Tandem Axle Measurements 400/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 727 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings General Information General Information These vehicles are equipped with one of two differ- ent wheel end assemblies: • The Con Met PreSet ® This wheel end has the bearings and oil seal pre-installed in a hub.
Page 728 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings General Information volve cutting off a portion of a damaged spindle and welding on a replacement part. The heat of welding can reduce the strength of spindles made with heat-treated materials and lead to spindle failure.
Page 729 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings General Information absorption and dissipation. Lining performance and life largely depend on the condition of the drum and whether it can adequately absorb and dissipate heat generated by braking action. The brake drum is mounted on the outboard face of the hub and ﬁts over the wheel studs.
Page 730 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Hub Assembly Removal and Installation Removal If the axle is equipped with a dual-nut wheel bearing lock system, see Subject 140. 1. Park the vehicle, shut down the engine, and 11.
Page 731 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Hub Assembly Removal and Installation 07/07/95 f350135 ® A. Dual-nut wheel bearing lock system shown; an Axi-Lok locking nut could be used. 1. Inner Wheel Bearing Cup 9. Nut-Lock 14. Brake Drum Nut 2.
Page 732 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Hub Assembly Removal and Installation nuts. Using the sequence shown in Fig. tighten the nuts 150 to 170 lbf·ft (203 to 230 N·m). 06/07/94 f350011a 1. Center Portion of Drive Axle Flange 2.
Page 733 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Hub Assembly Removal and Installation On Meritor axles, tighten the oil ﬁller plug 35 lbf·ft (47 N·m). 12. Tilt the axle to the left and right, by jacking the opposite side. Hold the tilted position for one minute on each side, to allow oil to run into the wheel end.
Page 734 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Axle Components Cleaning and Inspection Wheel Hub Assembly Inspection 1. Inspect the wheel hub mounting ﬂange. A loose wheel assembly will cause the ﬂange to be worn, jagged, or warped. See Fig.
Page 735 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Axle Components Cleaning and Inspection rollers worn sharp. These are indications of advanced wear. See Fig. f230017a 04/14/94 Fig. 4, Damaged Wheel Stud Nut 5. Inspect the wheel or rim studs. Replace studs that are stripped, broken, bent, or otherwise damaged.
Page 736 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Axle Components Cleaning and Inspection to drum installation, then rinsed with a hot water wash. Use a clean rag to remove any oily residue or metal chips from the friction surface. If a drum must be turned or replaced, the other same-axle drum must be similarly turned or replaced to provide the same braking power on both wheels.
Page 737 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Axle Components Cleaning and Inspection 1. Inspect the inner friction surface. If a veneered to unacceptable limits. Remachine or replace the (highly glossed) or glazed surface exists, renew same-axle drums. the drum by using 80-grit emery cloth or by turn- 6.
Page 738 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Wheel Bearing Cup Removal and Installation, Ferrous Hubs Removal Wheel bearing cups on ferrous hubs are removed and installed by driving them out and pressing them in without heating the hub. 1.
Page 739 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Drive Axle Stud Replacement Replacement 7. If the hub was removed from the axle, see Sub- ject 100 for installation instructions. 1. Remove the wheel hub from the axle. For in- structions, see Subject 100.
Page 740 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Dual-Nut Wheel Bearing System Installation and Adjustment Installation and Adjustment 1. Carefully mount the hub and inner wheel bearing assembly on the axle spindle. Be careful not to unseat the inner wheel bearing or seal. 2.
Page 741 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Dual-Nut Wheel Bearing System Installation and Adjustment 5. With the jam nut installed and tightened, adjust and 0.005 inch (0.03 and 0.13 mm), turn the bearings. the adjusting nut again. IMPORTANT: Do not adjust the wheel bear- Once the end play is correct, bend two tabs of the nut-lock over opposing ﬂats on...
Page 742 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings ConMet PreSet ® Hub Installation and Adjustment General Information ® ConMet PreSet drive axle hubs are equipped with a special tubular spacer inside the hub, between the inner and outer bearings. See Fig.
Page 743 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings ® ConMet PreSet Hub Installation and Adjustment engage the nut’s locking clips, allowing it to spin freely by hand. See Fig. 4. Use an accu- rately calibrated torque wrench to tighten the nut to its ﬁnal torque value.
Page 744 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings ConMet PreSet ® Hub Installation and Adjustment 3. Coat both bearing assemblies with fresh oil. In- stall the inner wheel bearing and oil seal in the hub. See Section 35.02 for instructions on in- stalling the various types of oil seals.
Page 745 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings ® ConMet PreSet Hub Installation and Adjustment WARNING Add oil to the axle housing bowl or the wheel hub after the drive axle shaft and wheel hub have been serviced. Failure to add oil will damage the wheel bearings and cause them to seize during vehicle operation.
Page 746 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Outboard-Mounted Drum Removal and Installation Then, using a rag soaked in water and wrung WARNING until nearly dry, remove any remaining dust. Don’t use compressed air or dry brushing to When replacing brake pads, shoes, rotors, or clean the brake assembly.
Page 747 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Outboard-Mounted Drum Removal and Installation 07/07/95 f350135 A. Four-piece bearing system shown; an Axi-Lok locking nut could be used. 1. Inner Wheel Bearing Cup 9. Nut-Lock 14. Brake Drum Nut 2.
Page 748 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Outboard-Mounted Drum Removal and Installation 05/03/94 f350125 NOTE: Pilot pad at 12 o’clock position 1. Drum Pilot 2. Wheel Pilot Fig. 2, Hub Pilot Pads 160/3 Business Class M2 Workshop Manual, Supplement 18, September 2010...
Page 749 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Wheel Bearing Cup Removal and Installation, Aluminum Hubs Removal surfaces of the wheel hub assembly, including the bearing cup bores. To ensure a tight ﬁt, wheel bearing cups are pur- 2.
Page 750 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Wheel Bearing Cup Removal and Installation, Aluminum Hubs WARNING To prevent skin irritation, wear chemical-resistant gloves when using kerosene or diesel fuel. Also, do not expose these ﬂuids to ﬂames or heat ex- ceeding 100°F (38°C);...
Page 751 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Wheel Stud Replacement Replacement Constant, smooth movement of the wheel stud is necessary to ensure the least amount of metal removal from the wheel stud bore. Concentrated WARNING heat will damage the hub. If the hub is damaged during wheel stud removal or installation, replace If a wheel stud breaks, the remaining studs are subjected to undue strain and could fail due to...
Page 752 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Wheel Stud Replacement 08/26/94 f350053a A. "Right" Fig. 2, Thread Stamp Location Weakness in the wheel hub can result in the loss of a wheel or loss of steering control, possibly resulting in personal injury.
Page 753 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Troubleshooting Troubleshooting Tables Problem — Noisy Bearings or Excessive Bearing Replacement Intervals Problem — Noisy Bearings or Excessive Bearing Replacement Intervals Possible Cause Remedy Not enough oil was used on the bearings, Clean, then inspect the bearings for wear.
Page 754 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Troubleshooting Problem — Loss of Lubricant From the Wheel Hubs Problem — Loss of Lubricant From the Wheel Hubs Possible Cause Remedy The drive axle studs are loose. Tighten the nuts to the torque values in Speciﬁcations 400.
Page 755 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Troubleshooting Problem — Brake Linings Are Tapered Across the Width Problem — Brake Linings Are Tapered Across the Width Possible Cause Remedy The inside surface of the brake drum is Install new brake linings on both sets of axle brake shoes.
Page 756 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Troubleshooting Problem — Brake Linings Are Loose Problem — Brake Linings Are Loose Possible Cause Remedy The rivet holes in the brake shoes are too Replace the brake shoes. large. Improperly crimped rivets are working Replace the rivets.
Page 757 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Troubleshooting Problem — Brake Drums Are Heavily Scored Problem — Brake Drums Are Heavily Scored Possible Cause Remedy The brake linings are damaged. Install new brake linings on both sets of axle brake shoes. Turn or replace the drums.
Page 758 Rear Axle Wheel Hubs, Brake Drums, and Wheel 35.01 Bearings Speciﬁcations Torque Values Application Size (grade 8) Torque: lbf·ft (N·m) 1/2–13 70 (95) Drive Axle Studs (to hub) 5/8–11 135 (185) Drive Axle Stud Nuts 5/8–18 150–170 (203–230) Axilok ® Wheel Bearing Nuts Axilok Nut, ConMet Preset ®...
Page 759 On spindle-mounted seals, the spring runs around the inside of the sealing element to press the element outward against the sealing sur- face. Freightliner uses two brands of axle oil seals: • Chicago Rawhide (Scotseal ® and Scotseal Plus ®...
Page 760 35.02 Rear Axle Oil Seals General Information 05/19/95 f330011a A. Detail A B. Oil Seal (See detail A) ® 1. Bore-Tite Coating 4. Outer Cup 7. Bumper Lip Primary Sealing Lip 5. Inner Cup 8. Hub 3. Dirt Lip 6. Sealing Element (Packing) 9.
Page 761 35.02 Rear Axle Oil Seals General Information 03/27/95 f330117a 1. Dana Spicer Outrunner Installation Tool 2. Dana Spicer Outrunner Seal Fig. 2, Dana Spicer Outrunner Seal 050/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 762 35.02 Rear Axle Oil Seals Seal Replacement, Chicago Rawhide Replacement NOTE: This procedure applies to the Chicago Rawhide Scotseal ® 1. Remove the wheel, drum, and hub from the axle. For instructions, see Section 35.01, Subject 100. 2. Remove the oil seal from the hub. 3.
Page 763 35.02 Rear Axle Oil Seals Seal Replacement, Chicago Rawhide 09/27/2005 f330023a f330022a 11/30/94 NOTE: Rear hub shown. NOTE: Rear hub shown. Fig. 4, Insert the Tool in the Hub Bore Fig. 3, Place the Seal on the Installation Tool 16. Spin the wheel and check the oil level. out.
Page 764 35.02 Rear Axle Oil Seals Seal Replacement, Chicago Rawhide 02/09/93 f330025a 1. Filler Plug Fig. 6, Fill the Hub with Oil 09/27/2005 f330024a NOTE: Rear hub shown. Fig. 5, Strike the Tool 100/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 765 35.02 Rear Axle Oil Seals Seal Replacement, Dana Spicer Replacement NOTE: This procedure applies to the Dana Spicer Outrunner ™ seal. 1. Remove the wheel, drum, and hub from the axle. For instructions, see Section 35.01, Subject 100. 2. Remove the oil seal from the hub. 3.
Page 766 35.02 Rear Axle Oil Seals Seal Replacement, Dana Spicer Inspect the bearings and hub components for wear or damage. Replace any worn or damaged components as necessary. Coat the wheel bearing cones with oil. 5. Install the inner wheel bearing cone in the inner wheel bearing cup.
Page 767 35.02 Rear Axle Oil Seals Seal Replacement, Dana Spicer Hit the handle of the installation tool gen- 8. Place the hubcap and a new gasket in position, tly . See Fig. then install the capscrews. Tighten the cap- screws 15 lbf·ft (20 N·m). Because of the rubber outer circumfer- ence, the Outrunner seal is easier to in- 9.
Page 768 Freightliner rear axles are compatible with industry- standard brakes, hubs, and wheel bearings. The following explains an example of the number found on a Freightliner rear axle identiﬁcation tag, which is located on the carrier. See Fig. Typical Model Number: ART-40.0-4 •...
Page 769 35.03 Freightliner Rear Axles Single or Rearmost Axle Removal and Installation Removal 12. Place a basin under the axle shaft ﬂanges to catch any oil, then remove the axle shafts. For instructions, see Subject 120. For rear axle components, see Fig.
Page 770 35.03 Freightliner Rear Axles Single or Rearmost Axle Removal and Installation 05/23/2005 f350459 1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing 2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft 3. Yoke Nut Fig. 1, Single or Rearmost Axle Components...
Page 771 35.03 Freightliner Rear Axles Single or Rearmost Axle Removal and Installation 7. Connect the air lines to the brake air chambers. tilted position for three minutes to allow oil to run into the wheel end. 8. Install the brake shoes, as removed. For instruc-...
Page 772 35.03 Freightliner Rear Axles Single or Rearmost Axle Differential Carrier Removal and Installation Do not disassemble the differential carrier. There are Axle Removed from Vehicle no serviceable parts in the differential assembly; it must be replaced as a unit. However, it is possible to...
Page 773 35.03 Freightliner Rear Axles Single or Rearmost Axle Differential Carrier Removal and Installation 05/23/2005 f350459 1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing 2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft 3. Yoke Nut Fig. 1, Single or Rearmost Axle Components 5.
Page 774 35.03 Freightliner Rear Axles Single or Rearmost Axle Differential Carrier Removal and Installation NOTICE Make sure the hubs are ﬁlled. Driving with the hubs dry will cause bearing damage. 14. Turn the wheels, wait one minute, and check the lubricant level.
Page 775 35.03 Freightliner Rear Axles Axle Shaft Removal and Installation Removal 1. Chock the front tires. 2. If DCDL is installed on the vehicle, use the DCDL switch in the cab to engage the lock. An indicator light comes on when the differential lock is engaged.
Page 776 35.03 Freightliner Rear Axles Single or Rearmost Axle Yoke and Seal Replacement, Model 4 Axles Special Tools Special tools are required for this procedure. See Table Special Tools Tool Description Manufacturer Part Number Universal Handle Kent-Moore J-8092 f580400 Rear Pinion Seal Installer...
Page 777 35.03 Freightliner Rear Axles Single or Rearmost Axle Yoke and Seal Replacement, Model 4 Axles 6. Install the carrier yoke on the input shaft. If the yoke is damaged or worn, install a new yoke. NOTE: It is not necessary to replace the yoke when replacing the seal.
Page 778 35.03 Freightliner Rear Axles Forward-Rear Axle Removal and Installation Removal 3. At both ends of the axle, loosen all the wheel nuts. For forward-rear axle components of a tandem instal- 4. Using a suitable jack, continue to raise the ve- lation, see Fig.
Page 779 35.03 Freightliner Rear Axles Forward-Rear Axle Removal and Installation 18. Remove the brake shoes. For instructions, see WARNING the applicable service brake section in Group Never work around or under a vehicle that is sup- 19. Remove the ABS sensors and wiring, and the ported only by a jack.
Page 780 35.03 Freightliner Rear Axles Forward-Rear Axle Removal and Installation On vehicles without U-bolts, install the 16. Install the tire and wheel assemblies. For instruc- walking beams. tions, see Group 17. Adjust the brakes. For instructions, see the appli- If applicable, tighten the new U-bolt nuts...
Page 781 35.03 Freightliner Rear Axles Forward-Rear Axle Differential Carrier Removal and Installation For forward-rear axle components of a tandem instal- 8. Using a suitable jack, support the differential car- lation, see Fig. rier. Chain the differential carrier to the jack. Do not disassemble either differential carrier. There NOTICE are no serviceable parts in the differential assembly;...
Page 782 35.03 Freightliner Rear Axles Forward-Rear Axle Differential Carrier Removal and Installation 05/05/2005 f350456 1. Axle Shaft 5. Carrier Yoke 2. Forward-Rear Axle Housing 6. Input Yoke Nut 3. Carrier Capscrew 7. Forward Differential Carrier 4. Input Seal Fig. 1, Forward-Rear Axle Components...
Page 783 35.03 Freightliner Rear Axles Forward-Rear Axle Differential Carrier Removal and Installation 5. Position the forward differential carrier in front of 8. Connect the driveshaft to the forward input yoke. the axle housing, using an axle jack or other suit- For instructions, see Section 41.00, Sub-...
Page 784 35.03 Freightliner Rear Axles Thru-Shaft Repair Repair 9. Insert the thru-shaft into its bore. 10. Install the outer bearing race onto the thru-shaft 1. Remove the output yoke nut, washer, and output and bore. yoke; see Subject 170. 11. Install the snap ring and spacer. Use the next 2.
Page 785 35.03 Freightliner Rear Axles Forward-Rear Axle Yoke and Seal Replacement Special Tools Special tools are required for this procedure. See Table Special Tools for Forward-Rear Axle Yoke and Seal Replacement Tool Description Manufacturer Part Number Universal Handle Kent-Moore J-8092 f580400...
Page 786 35.03 Freightliner Rear Axles Forward-Rear Axle Yoke and Seal Replacement 5. If there is a leak between the bearing cage and the carrier housing, remove the bearing cage, as follows. See Fig. 04/01/2005 f350447 01/21/2008 f350452a 1. Universal Handle 3. Carrier Housing 1.
Page 787 35.03 Freightliner Rear Axles Forward-Rear Axle Yoke and Seal Replacement 12. Connect the main driveshaft; see Sec- tion 41.00, Subject 120. Output Yoke and Seal 1. Disconnect the interaxle driveshaft from the out- put yoke; see Section 41.00, Subject 120.
Page 788 35.03 Freightliner Rear Axles Forward-Rear Axle Yoke and Seal Replacement Assemble the output seal installer onto the threaded end of the universal handle. See Table Using the output seal installer assembly, press the seal into the bore until the seal surface is ﬂush with the thru-shaft recep-...
Page 789 35.03 Freightliner Rear Axles Main Differential Lock Disassembly and Assembly, Model 2 Axles General Information 4. Remove the DCDL control switch. 5. Remove the differential lock cover (including the Commonly known as DCDL (Driver-Controlled Differ- air interface connection). ential Lock), a main differential lock is available on 6.
Page 790 35.03 Freightliner Rear Axles Main Differential Lock Disassembly and Assembly, Model 2 Axles 7. Place the differential lock cover over the cap- screw bores in the carrier housing, and install the DCDL control switch. Tighten the nut 21 lbf·ft (28 N·m).
Page 791 35.03 Freightliner Rear Axles Main Differential Lock Disassembly and Assembly, Model 4 Axles Special Tool A special tool is required for this procedure. See Table Special Tool for Main Differential Lock Disassembly and Assembly Tool Description Manufacturer Part Number Spring Compression Tool...
Page 792 35.03 Freightliner Rear Axles Main Differential Lock Disassembly and Assembly, Model 4 Axles Assembly 1. Install the spring in the carrier housing, and, using the spring compression tool, compress it to install the shift fork in the housing. Ensure that the spring is centered in the bore.
Page 793 35.03 Freightliner Rear Axles Interaxle Differential Lock Adjustment Adjustment The Interaxle Differential (IAD) has an adjustment screw that can become loose or even fall out, caus- ing an oil leak, and malfunction of the IAD. To ensure the adjustment screw is properly tightened and se- cured, follow the steps below.
Page 794 35.03 Freightliner Rear Axles Threaded Ring Repair Special Tools Special tools are required for this procedure. See Table Special Tools for Threaded Ring Repair Tool Description Manufacturer Part Number Universal Handle Kent-Moore J-8092 f580400 Input Seal Installer Kent-Moore J-47369 f580410 To order Kent-Moore tools call 1-800-328-6657.
Page 795 35.03 Freightliner Rear Axles Threaded Ring Repair 9. Install the old yoke nut on the input shaft to pro- tect the threads, then strike the nut sharply with a brass mallet to unseat the bearing. 10. Adjust the initial bearing preload to 0.002 inch (0.05 mm), as follows:...
Page 796 35.03 Freightliner Rear Axles Threaded Ring Repair 09/14/2006 f350471 09/14/2006 f350469 A. Measure preload at this point. At ﬁnal tightening, Fig. 5, Marking the Tooth and Bearing Cage this mark should be opposite the center of the next tooth, but no further.
Page 797 35.03 Freightliner Rear Axles Threaded Ring Repair 14.5 Using the input shaft seal installer assem- bly, press the seal into the bore until the seal surface is ﬂush with the threaded ring. 15. Apply Loctite 242 to the threads of the new yoke nut, then using it and a new washer, install the existing yoke on the input shaft.
Page 798 35.03 Freightliner Rear Axles Interaxle Differential Replacement The following on-vehicle procedure replaces the in- teraxle differential (IAD) assembly and accomplishes a minor carrier rebuild by replacing the bearing races and, as needed, the shift shaft bushing. The front cover is resealed and the input shaft seal is re- placed.
Page 799 35.03 Freightliner Rear Axles Interaxle Differential Replacement Special Tools for Interaxle Differential Replacement Tool Description Manufacturer Part Number Output Bearing Remover and Axle Alliance Special Tool MBA 420589003300 Installer f580478 Shift Shaft Bushing Remover Axle Alliance Special Tool MBA 420589013300...
Page 800 35.03 Freightliner Rear Axles Interaxle Differential Replacement Special Tools for Interaxle Differential Replacement Tool Description Manufacturer Part Number Shift Shaft Piston Installer Axle Alliance Special Tool MBA 420589023300 f580481 Table 1, Special Tools for Interaxle Differential Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the front tires.
Page 801 35.03 Freightliner Rear Axles Interaxle Differential Replacement 13. Using a brass or plastic mallet, squarely tap the shift shaft piston to unseat it, and then remove it from the carrier housing. 14. Remove the piston spring, clutch collar, and shift fork.
Page 802 35.03 Freightliner Rear Axles Interaxle Differential Replacement block. The race must be square in the stalled, slight jerks can be felt and heard. housing or damage will occur when it is Fig. pressed. See Fig. 22. Lubricate the output gear and bearing of the new IAD assembly with white grease.
Page 803 35.03 Freightliner Rear Axles Interaxle Differential Replacement 27.4 Once the piston is seated, remove the shift shaft piston installer and the half- moon device. 28. Remove the input bearing race from the bearing cage. Place the new race into the cage so that it is more forward than in the ﬁnal position.
Page 804 35.03 Freightliner Rear Axles Interaxle Differential Replacement 07/16/2010 f350523 07/21/2010 f350524 Fig. 12, Push-Pull Device, Installed Fig. 13, Dial Indicator and Push-Pull Device 33.1 Set up a dial indicator as shown in Fig. 33.2 Turn the input shaft three revolutions and tighten the threaded ring until there is be- tween 0.002 and 0.003 inch (0.05 and...
Page 805 35.03 Freightliner Rear Axles Interaxle Differential Replacement 34. Install a new input shaft seal and the yoke, nut, and washer; see Subject 170 for instructions. 35. Clean, install, and adjust the IAD adjustment screw and locknut as follows. 35.1 Clean the IAD adjustment screw and lock- nut with a suitable solvent (such as brake cleaner).
Page 806 Model 2 5.8 (5.5) 7.4 (7.0) 80W-90 75W-90 Model 4 10.6 (10.0) 12.2 (11.5) Table 2, Single Rear Axle Oil Type and Capacity Special Tools for Freightliner Rear Axles Tool Description Manufacturer Part Number Universal Handle Kent-Moore J-8092 f580400 Rear Pinion Seal Installer...
Page 807 35.03 Freightliner Rear Axles Speciﬁcations Special Tools for Freightliner Rear Axles Tool Description Manufacturer Part Number Input Seal Installer Kent-Moore J-47369 f580410 Output Seal Installer Kent-Moore J-47368 f580408 † Yoke Nut Socket Axle Alliance Special Tool MBA 742589020700 f580450 Output Bearing Remover and...
Page 808 † The yoke nut socket is needed to remove the round, slotted yoke nut installed on some vehicles. It can be ordered through Paragon. Table 3, Special Tools for Freightliner Rear Axles 400/3 Business Class M2 Workshop Manual, Supplement 20, September 2011...
Page 809 40.00 Wheels and Tires General Information General Information The tires support the weight of the vehicle, and are integral parts of the transmission and braking sys- tems. The wheels serve as load carrying members between the tires and the axle. Only hub-piloted disc wheels are used on Business Class M2 vehicles.
Page 810 40.00 Wheels and Tires General Information rims of the minimum capacity can be installed with- out changing the load limitations. If tires and rims are installed that have a lower load capacity than that shown on the tire and rim label, then the tires and rims determine the load limitations (the GAWRs and GVWR will be lower).
Page 811 40.00 Wheels and Tires General Information CAUTION Mixing radial and bias ply tires should be done as an emergency measure only. Some loss of steering control and premature tire wear could occur when driving under such conditions. Better tire and vehicle performance is usually ob- tained by using tires of the same size and construc- tion.
Page 812 40.00 Wheels and Tires Disc Wheel Removal and Installation Removal 2. Apply a few drops of light engine oil to the wheel studs and the area between the body and the ﬂange of each two-piece ﬂange nut. See Fig. 1. Park the vehicle on a level surface. Shut down Wipe off any excess oil.
Page 813 40.00 Wheels and Tires Disc Wheel Removal and Installation 4. Make sure the hub-pilot pad is still centered at the top. IMPORTANT: Install the wheel assembly so that the balance weight(s) on the wheels are 180 degrees opposite the balance weight(s) on the brake drum.
Page 814 40.00 Wheels and Tires Disc Wheel Removal and Installation IMPORTANT: The two-piece ﬂange nuts seat during vehicle operation. It is necessary to peri- odically tighten the wheel nuts to the speciﬁed torque. Tighten the two-piece ﬂange nuts to the speciﬁed torque 50 to 100 miles (80 to 160 km) after service work and check the torque every 10,000 miles (16 000 km).
Page 815 40.00 Wheels and Tires Wheel and Components Inspection Inspection WARNING Inspect the tires and wheels, and correct any problems. Failure to do so could cause tire or rim damage while servicing or while in use. An incor- rectly mounted tire can burst causing personal injury and equipment damage.
Page 816 40.00 Wheels and Tires Wheel and Components Inspection Remove all foreign matter, such as grease and dirt, from the wheel mounting surface. Smooth any pro- jections on the mounting surface to ensure even pressure when tightening the wheel nuts. 110/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 817 40.00 Wheels and Tires Tire and Components Inspection Inspection on the same size rim as the one from which it was removed. Michelin Tire Corporation recommends us- ing only new tubes, ﬂaps, valve cores, caps, and WARNING O-rings in a new mounting. Inspect the tires and wheels, and correct any problems.
Page 818 40.00 Wheels and Tires Tire Inﬂation Tire Inﬂation 1. Check all parts to make sure they are correctly seated prior to inﬂation. NOTE: Inﬂate tires in a safety cage (Fig. 1) or an approved portable restraining device. Always use a clip-on chuck with an inline valve and gauge.
Page 819 40.00 Wheels and Tires Tire Inﬂation ger of cuts, snags, and punctures. Overinﬂation will overstress and damage the rims. Driving on underinﬂated tires will generate excessive heat. This weakens the tire body, and reduces tire strength. WARNING Inﬂate tires to the speciﬁed pressure. Tire under- 05/16/94 f400074a inﬂation or overinﬂation will damage wheels and...
Page 820 40.00 Wheels and Tires Tire Demounting and Mounting Service Precautions Service Precautions These tools must be smooth, and used with care, to avoid gouging the rim. • Loosening tire beads may be difficult, since WARNING considerable force may be needed. The use of a machine designed for loosening tire beads is Read the following information.
Page 821 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires WARNING Read the information in Subject 140. Failure to follow the precautions, before and during tire de- mounting and mounting, could cause tire or rim damage while servicing or in use. An incorrectly mounted tire can burst causing personal injury and equipment damage.
Page 822 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires 3. Lay the tire on the rim. If there is a balance mark on the tire, line up this mark with the valve stem. Push the lower bead over the ﬂange and into the rim well.
Page 823 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires 05/13/94 f400008a Fig. 6, Working the Upper Bead into the Rim 150/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 824 40.00 Wheels and Tires Troubleshooting Troubleshooting Tables Problem—Abnormal Tire Wear Problem—Abnormal Tire Wear Possible Cause Remedy Tires are not inﬂated to the correct Operate the tires at the recommended inﬂation pressure and use the proper pressure size tires, wheels, and rims for the load to be carried. See Speciﬁcations, 400.
Page 825 40.00 Wheels and Tires Troubleshooting Problem—Excessive On-the-Road Tire Failures Possible Cause Remedy Water or foreign material is inside the Clean and dry the tires and tubes prior to mounting. Make sure excess casing. lubricant does not ﬂow down into the tire. Store unmounted tires indoors, or under cover, to prevent moisture from collecting inside.
Page 826 40.00 Wheels and Tires Speciﬁcations Tire Pressure wheel manufacturer for the correct tire inﬂation pressure for the vehicle load. If the load ex- ceeds the maximum rim or wheel capacity, the Do not reduce the pressure of a hot tire if it exceeds load must be adjusted or reduced.
Page 827 41.00 Driveline Components General Information General Information Driveline Conﬁgurations The speciﬁc type and number of drivelines used on The simplest driveline consists of a transmission each vehicle depends on its number of transmis- output-shaft end-yoke, an axle input-shaft end-yoke, sions, its number of drive axles, and its wheelbase. and a single slip-jointed driveshaft connecting the Fig.
Page 828 41.00 Driveline Components General Information line. See Fig. 2, examples B and C. A driveline con- A long driveshaft, supported only at its ends, will sag necting a main transmission to an auxiliary transmis- in the middle from its own weight. When turning at sion is always referred to as a No.
Page 829 41.00 Driveline Components General Information use a midship bearing, mounted on a frame cross- member, for additional support. See Fig. 2, example D. This allows the No. 2 driveline to be separated into two, shorter shafts (a coupling shaft and a No. 2 driveshaft), thus improving balance and stability.
Page 830 41.00 Driveline Components General Information 05/01/95 f410068b NOTE: Not all fasteners are shown. 1. Transmission 7. Coupling Shaft End-Yoke (half- 12. Axle Input-Shaft End-Yoke (half- 2. Transmission Output-Shaft End- round) round) Yoke (half-round) 8. Intermediate Coupling Shaft 13. Forward-Rear Axle 3.
Page 831 41.00 Driveline Components General Information 05/02/95 f410072b 1. Bearing-Strap 4. U-Joint Cross Capscrew 5. Half-Round Yoke 2. Bearing Strap 6. Yoke Cross-Hole Tab 3. Bearing Cup 08/11/95 f410154 1. Bearing-Plate Self-Locking Capscrew Fig. 5, Coupling of a U-Joint With a Half-Round End- 2.
Page 832 41.00 Driveline Components General Information 11/28/94 f410073a 1. Transmission 4. Rear Axle 2. No. 2 Driveshaft 5. Extended Centerlines 3. U-Joint Working Angles Fig. 8, U-Joint Working Angles pling shaft is checked for out-of-roundness, straight- ened as necessary, then dynamically balanced. Avoiding Driveline Problems To ensure that U-joints turn in phase, sleeve-yokes, splined shafts, coupling shaft end-yokes, and cou-...
Page 833 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Half-Round End-Yoke U-Joint Uncoupling CAUTION NOTE: It is easier to check driveline parts, and Do not expose the U-joint trunnions or bearing- to replace a U-joint or midship bearing assembly cup needles to dirt or grit. The smallest bits of dirt or grit can cause rapid wear and serious if the driveshaft is removed from the vehicle.
Page 834 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Half-Round End-Yoke 08/11/95 f410074b NOTE: Not all fasteners are shown. A. End-yoke cross-hole centerline is horizontal. C. Install a half-round bearing-cup retaining wire (or B. Before uncoupling/coupling the U-joint, turn the end- safety wire) before removing the bearing straps.
Page 835 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Half-Round End-Yoke 10/21/98 f410180 NOTE: Not all fasteners are shown. A. End-yoke cross-hole centerline is horizontal. B. Before uncoupling/coupling the U-joint, turn the end- yoke until its cross-hole centerline is horizontal. 1.
Page 836 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Half-Round End-Yoke 11/28/94 f410077a A. Use ﬁne emery cloth on this surface. Fig. 5, Smooth a Half-Round End-Yoke U-Joint Bearing 11/28/94 f410075a Fig. 3, Remove Burrs from a Half-Round End-Yoke Cross-Hole 11/28/94 f410078a A.
Page 837 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Half-Round End-Yoke 05/02/95 f410124a 1. Retaining Tab Fig. 7, Seat a U-Joint in a Half-Round End-Yoke 100/5 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 838 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Full-Round End-Yoke U-Joint Uncoupling dirt or grit can cause rapid wear and serious damage to the U-joint. NOTE: It is easier to check driveline parts, and U-Joint Coupling to replace a U-joint or midship bearing assembly if the driveshaft is removed from the vehicle.
Page 839 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Full-Round End-Yoke 05/02/95 f410148 NOTE: Not all fasteners are shown. A. End-yoke cross-hole centerline is vertical. Fig. 1, U-Joint Uncoupling/Coupling of a Driveline With Full-Round End-Yokes Move one end of the cross until a trun- tight, with no gaps;...
Page 840 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Full-Round End-Yoke 05/03/95 f410102b NOTE: Sleeve-yoke shown. Fig. 4, Remove Burrs from the Machined Surface of a Full-Round Yoke Lug 05/03/95 f410143 Fig. 2, Remove a Bearing Cup from a Full-Round End- Yoke f410103b 05/03/95...
Page 841 41.00 Driveline Components U-Joint Uncoupling and Coupling With a Full-Round End-Yoke f410115b 05/03/95 08/02/96 f410145a NOTE: Sleeve-yoke shown. A. Lubricate seal lips here. Fig. 9, Seat a U-Joint Bearing Cup in a Full-Round 1. Bearing Needle 3. Bearing-Cup Seal Yoke 2.
Page 842 41.00 Driveline Components Driveshaft Removal and Installation NOTE: Many service operations do not require 2. Uncouple the No. 2 driveshaft from the transmis- sion or coupling shaft. See Fig. 3 Fig. 4 . If driveshaft removal from the vehicle: end-yoke the No.
Page 843 41.00 Driveline Components Driveshaft Removal and Installation 05/04/95 f410096b NOTE: Not all fasteners are shown. A. No. 3 Driveshaft Coupled to Half-Round End-Yokes C. Uncouple this end ﬁrst; couple this end last. B. Uncouple this end last; couple this end ﬁrst. D.
Page 844 41.00 Driveline Components Driveshaft Removal and Installation 10/21/98 f410181 NOTE: Not all fasteners are shown. A. Uncouple this end last; couple this end ﬁrst. B. Uncouple this end ﬁrst; couple this end last. 1. Forward-Rear Axle Output-Shaft Half-Round End- 2. No. 3 Driveshaft Yoke 3.
Page 845 41.00 Driveline Components Driveshaft Removal and Installation 05/05/95 f410080b NOTE: Not all fasteners are shown. A. No. 2 Driveshaft Coupled to Half-Round End-Yokes C. Uncouple this end ﬁrst; couple this end last. B. Uncouple this end last; couple this end ﬁrst. D.
Page 846 41.00 Driveline Components Driveshaft Removal and Installation 10/21/98 f410183 NOTE: Not all fasteners are shown. A. Uncouple this end last; couple this end ﬁrst. B. Uncouple this end ﬁrst; couple this end last. 1. Transmission Output-Shaft Half-Round End-Yoke 4. Single Axle or Forward-Rear Axle Input-Shaft Half- 2.
Page 847 41.00 Driveline Components Driveshaft Removal and Installation 05/04/95 f410084b NOTE: Not all fasteners are shown. A. No. 2 Driveline With Half-Round End-Yokes C. Uncouple this end ﬁrst; couple this end last. B. Uncouple this end last; couple this end ﬁrst. D.
Page 848 41.00 Driveline Components Driveshaft Removal and Installation 10/21/98 f410184 NOTE: Not all fasteners are shown. A. Uncouple this end last; couple this end ﬁrst. B. Uncouple this end ﬁrst; couple this end last. 1. Primary Coupling Shaft 4. Intermediate Coupling Shaft 2.
Page 849 41.00 Driveline Components Driveshaft Removal and Installation 08/29/96 f410086b NOTE: Not all fasteners are shown. A. No. 2 Driveline With Half-Round End-Yokes C. Uncouple this end ﬁrst; couple this end last. B. Uncouple this end last; couple this end ﬁrst. D.
Page 850 41.00 Driveline Components Driveshaft Removal and Installation 10/21/98 f410185 NOTE: Not all fasteners are shown. A. Uncouple this end last; couple this end ﬁrst. B. Uncouple this end ﬁrst; couple this end last. 1. Half-Round End-Yoke 4. No. 2 Driveshaft 2.
Page 851 41.00 Driveline Components Driveshaft Removal and Installation 5. Couple the No. 2 driveshaft to the axle input- shaft end-yoke. If the No. 2 driveshaft was coupled to half-round end-yokes, follow the cou- pling procedure in Subject 100. If the No. 2 driveshaft was coupled to full-round end-yokes, follow the coupling procedure in Subject...
Page 852 41.00 Driveline Components Driveline Component Removal/Disassembly U-Joint Removal Full-Round Yokes 1. Remove the driveshaft from the vehicle. See Subject 120. 2. Place the driveshaft in V-blocks or a soft-jawed vise; do not distort the tube with excessive grip. 3. Remove and discard all four bearing-plate self- locking capscrews.
Page 853 41.00 Driveline Components Driveline Component Removal/Disassembly 12/09/97 f410179 1. Snap Ring 4. Bearing Cups (RPL 2. Bearing Cups Joint) 05/15/98 f410187 3. Full Round Yoke 1. Press 3. Bearing Cup 2. Bridge Receiver Fig. 4, RPL U-Joint Components Fig. 7, Removing Bearing Cups from an RPL U-Joint Slip-Joint Disassembly Except RPL Drivelines 1.
Page 854 41.00 Driveline Components Driveline Component Removal/Disassembly 05/08/95 f410089b A. Use a marking stick or paint to add alignment marks. Fig. 9, Slip-Joint Alignment Marks 05/21/2008 f410525 A. In Phase (parallel phased) B. In Phase (cross phased) C. Out of Phase 11/28/94 f410090a 1.
Page 855 41.00 Driveline Components Driveline Component Removal/Disassembly 12/09/97 f410191 Fig. 11, Shroud Removal a full-round yoke), or remove the driveshaft from the vehicle (Subject 120). 2. Remove the end-yoke locknut. See Fig. 3. Using a yoke puller, remove the end-yoke. See Fig.
Page 856 41.00 Driveline Components Driveline Component Removal/Disassembly 11/28/94 f410099a A. Use a marking stick or paint to mark the end-yoke and coupling shaft with alignment marks. 1. Half-Round End- 2. End-Yoke Locknut Yoke Fig. 16, Alignment Marks on a Coupling Shaft With an End-Yoke 05/08/95 f410147...
Page 858 41.00 Driveline Components Driveline Component Cleaning and Inspection Driveshaft Tube, Slip-Joint, Sleeve-Yoke, and Tube-Yoke Cleaning and Inspection 1. With the driveshaft removed, scrape or soak away any foreign material. 2. Examine the driveshaft tube for dents, bends, twists, splitting weld-seams, and signs of missing balance weights.
Page 859 41.00 Driveline Components Driveline Component Cleaning and Inspection End-Yoke Cleaning and Inspection 1. With the transmission output-shaft and axle shaft end-yokes installed, check them for cracks and looseness. Replace cracked yokes. If the end-yoke can be moved in or out on its shaft, or can be rocked on its shaft, uncouple the driveshaft from the end- yoke.
Page 860 41.00 Driveline Components Driveline Component Cleaning and Inspection 4. Smooth and clean the entire surface of all end- dry with compressed air. Check for minute par- yoke cross-holes, using ﬁne emery cloth. See ticles of dirt or grit, and clean again if necessary. Fig.
Page 861 41.00 Driveline Components Driveline Component Cleaning and Inspection 11/28/94 f410107a 1. Spalling 3. Brinelling 5. Slinger 2. End Galling 4. Pitting Fig. 8, Damaged U-Joint Crosses 11/28/94 f410106a Fig. 9, Forcing Out Old Lubricant From a U-Joint Cross 08/02/96 f410145a A.
Page 862 41.00 Driveline Components Driveline Component Cleaning and Inspection 11/29/94 f410108a A. Use ﬁne emery cloth on this surface. B. Use a mill ﬁle on this surface. Fig. 12, Smoothing a Full-Round Yoke U-Joint Bearing 11/28/94 f410077a A. Use ﬁne emery cloth on this surface. Fig.
Page 863 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly Driveshaft Tube, Stub Shaft (Slip-Joint), and Tube-Yoke Replacement IMPORTANT: Parts for different series drivelines must not be intermixed. Incorrectly assembled or worn components can affect the entire drive- line, resulting in too much vibration or driveline f410110b 06/13/96 damage.
Page 864 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly 3. Insert the splined shaft in the sleeve-yoke, so that the alignment marks are aligned, and the U-joints at each end of the driveshaft will be in phase. See Fig. 4 Fig.
Page 865 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly Midship Bearing and Coupling the nut off slightly, and tighten it to the same torque. Shaft End-Yoke Replacement or Assembly U-Joint Replacement or Installation IMPORTANT: Parts for different series drivelines must not be intermixed. Incorrectly assembled IMPORTANT: Parts for different series drivelines or worn components can affect the entire drive- must not be intermixed.
Page 866 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly IMPORTANT: A Spicer trunnion (journal) lo- the driveshaft, and aligns with the grease ﬁtting on the sleeve-yoke (if so equipped). cator should be used to prevent damage to Fig. the U-joint trunnions and slingers. By hand, press the bearing-cup-plate ﬂush with the face of the yoke.
Page 867 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly each end of the coupling shaft will be in phase. Fig. IMPORTANT: Misaligned driveshaft yokes will cause the U-joints to be out of phase, which will cause vibration in the driveline. 3.
Page 868 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly lug. Using the above procedure, install the opposite bearing cup assembly. NOTE: The U-joint should ﬂex, and be free of excessive bind. A slight drag is the most desirable condition for new U-joints. Exces- sive looseness is not desirable, and may result in an unbalanced driveshaft.
Page 869 41.00 Driveline Components Driveline Component Replacement or Installation/ Assembly 05/10/95 f410092b Fig. 16, Axle End-Yoke Locknut 150/7 Business Class M2 Workshop Manual, Supplement 14, September 2008...
Page 870 41.00 Driveline Components Troubleshooting Troubleshooting CAUTION Noise or vibration associated with the driveline can Do not overtighten the bearing-cup-plate or be caused by non-driveline parts. To ﬁnd the cause bearing-strap capscrews. A loose or broken fas- of noise or vibration, ﬁrst road test the loaded ve- tener at any point in the driveline weakens the hicle.
Page 871 41.00 Driveline Components Troubleshooting NOTE: To disassemble the slip-joint, un- If damaged, jack up the rear axle, support it on jackstands, place the transmission in neutral, and couple the U-joint at one end of the drive- turn the driveshaft by hand to check runout. shaft, unscrew the slip-joint seal from the sleeve-yoke, then pull the sleeve-yoke and The driveshaft must be straight within 0.015 inch...
Page 872 41.00 Driveline Components Troubleshooting 11.3 Have the No. 3 driveshaft balanced to a maximum tolerance of 1 inch-ounce per 10 pounds weight per end, at 3000 rpm. 11.4 Have the No. 2 driveshaft balanced to a maximum tolerance of 1 inch-ounce per 10 pounds weight per end, at 3000 rpm.
Page 873 41.00 Driveline Components Speciﬁcations Fastener Torques Description Size Torque: lbf·ft (N·m) End-Yoke Nut RT 8609 1-1/2–18 400–450 (542–610) T/X 14607 RT 8608 /7608LL RTO 11909MLL /14909MLL /11908LL RTX 16709 /15710 /16710 Fuller RT/X 11609 /11709 /12609 /12709 /13609 /13709 2–16 450–500 (610–678) /14609 /14709 /11710 /12710 /13710 /14710 Transmission...
Page 874 41.00 Driveline Components Speciﬁcations Fastener Torques Description Size Torque: lbf·ft (N·m) Bearing Mount to Bracket 1/2–13 91 (123) Table 1, Fastener Torques 400/2 Business Class M2 Workshop Manual, Supplement 19, March 2011...
Page 875 41.01 Driveline Angularity and Balance General Information Driveline Angularity Driveline angularity may be adversely affected if rear suspension U-bolts are loose or broken; rear springs are broken, shifted, or mismatched; spring seats are The most important consideration of driveline angu- broken;...
Page 876 41.01 Driveline Angularity and Balance General Information NOTE: Some driveshafts are designed and shaft is checked for out-of-roundness, and straight- ened as necessary; then each shaft is dynamically phased with their end yokes clocked 90 degrees balanced. from each other. This is referred to as cross phasing.
Page 877 41.01 Driveline Angularity and Balance General Information 05/08/95 f410054a A. Parallel Centerlines C. Working Angles Unequal by 1/2 B. 1/2 to 1 Degree to 1 Degree 1. Main Transmission 3. Midship Bearing 5. Rear Axle 2. Coupling Shaft 4. No. 2 Driveshaft Fig.
Page 878 41.01 Driveline Angularity and Balance General Information axle pinion shaft’s extended centerline intersects the shaft unsatisfactory. For those drivetrain conﬁgura- forward-rear axle thru-shaft’s extended centerline ap- tions, it is necessary to use a modiﬁed parallel or proximately midway between the U-joints, when all of modiﬁed-intersecting arrangement for the no.
Page 879 41.01 Driveline Angularity and Balance General Information f410053a 09/14/95 A. Parallel Centerlines B. Equal U-Joint Working Angles 1. Transmission 3. Forward-Rear Axle 5. Rearmost Axle 2. No. 2 Driveshaft 4. No. 3 Driveshaft Fig. 6, Parallel Arrangement for Dual-Drive Vehicles 07/24/95 f410056a A.
Page 880 41.01 Driveline Angularity and Balance Engine and Pinion Angle Measurement Engine and Pinion Angle Section 41.00 for full-round end-yoke bear- ing cup removal. Measurement 5. Turn the end-yoke until the machined surface of the yoke lug is horizontal. See Fig. Before checking the pinion angles or engine angle, check that the engine and transmission mounts are tight and in good condition.
Page 881 41.01 Driveline Angularity and Balance Engine and Pinion Angle Measurement 10/15/2001 f410487 NOTE: Full-round end-yoke is shown. 1. Digital Angle Analyzer 2. End-Yoke 3. Transmission Fig. 3, Measuring Pinion Angles 100/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 882 Fig. 3. Compare this reading with the measured engine angle. If a vehicle is equipped with a Freightliner spring sus- pension, the axle pinion angles are factory-set using If the driveline angles are out of speciﬁcation, alignment shims at the rear springs. These shims contact your district service manager for midship have notches on the thick end of the shim.
Page 883 41.01 Driveline Angularity and Balance Driveline Angle Checking 10/03/2001 f410489 A. Tranmission C. Second Driveshaft E. Inter-Axle Driveshaft B. First Driveshaft D. Rear Drive Axle F. Rear Drive Axle (rear-most) Fig. 1, Driveline Angle Analysis (measuring locations) 10/03/2001 f410488 1. Transmission 3.
Page 884 13.1 Measure suspension height at the forward drive-axle stop on the driver’s side; see Section 32.04 for complete instructions. Table 1, Freightliner AirLiner Suspensions With Meritor RT-40/-44/-46 Axles Freightliner Spring Suspensions (with Meritor RT–40/–44/–46 Axles) Forward-Rear Axle Rearmost Axle Pinion...
Page 885 41.01 Driveline Angularity and Balance Speciﬁcations 07/19/2006 f320426 Shim Angle A (degrees) Notches (N) at X Notches (N) at Y (total at x plus y) none Three none Four (total at x plus y) Five (total at x plus y) (total at x plus y) Zero Zero...
Page 886 41.01 Driveline Angularity and Balance Speciﬁcations Hendrickson Suspensions With 52-Inch Axle Spacing Planing Angle (degrees) Suspension Control Rod Saddle Unladen Laden Forward Axle Rear Axle Suspension Axle Model Height Model Spacer Spacer (inches) Front Rear Front Rear Length Thickness Length Thickness (inches) (inches)
Page 887 41.01 Driveline Angularity and Balance Speciﬁcations Hendrickson Suspensions With 56-Inch Axle Spacing Planing Angle (degrees) Suspension Control Rod Saddle Unladen Laden Forward Axle Rear Axle Suspension Axle Model Height Model Spacer Spacer (inches) Front Rear Front Rear Length Thickness Length Thickness (inches) (inches)
Page 888 41.01 Driveline Angularity and Balance Speciﬁcations Hendrickson Suspensions With 72.5-Inch Axle Spacing Planing Angle (degrees) Suspension Control Rod Saddle Unladen Laden Forward Axle Rear Axle Suspension Axle Model Height Model Spacer Spacer (inches) Front Rear Front Rear Length Thickness Length Thickness (inches) (inches)
Page 889 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information General Description wheel speed information from the sensors. During emergency brake applications, the control unit regu- lates the braking force applied to each wheel by CAUTION sending control signals to the modulator valves. The major components of the Meritor WABCO pneu- The size of the tires installed at the factory is matic ABS system include the following:...
Page 890 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information 05/02/2001 f422186a 1. Tone Wheel and Sensor 3. Electronic Control Unit (ECU) 2. Front Modulator Valve Assembly 4. Rear Modulator Valve Assembly Fig. 1, ABS Component Location (4-channel, 4S/4M system shown) lockup, the appropriate control circuit signals the The ECU constantly monitors the wheel sensors, modulator valve(s) to release, hold, or reapply brak-...
Page 891 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information 05/12/2000 f421591 1. Tone Wheel 3. Sensor Spring Clip 10/12/2000 f610454 2. Lubricant 4. Sensor 1. Tractor ABS Warning 3. Trailer ABS Warning Fig. 2, Wheel Speed Sensor Components Light Light 2.
Page 892 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information • Increased air pressure entering the supply port Modulator Valves unseats the supply diaphragm by increasing Modulator valves control the air pressure in each af- the pressure under the diaphragm. This opens fected brake chamber during an ABS operation.
Page 893 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information 02/27/2004 f420856b NOTE: Both solenoid valves are closed. The modulator 02/17/2004 f422056 valve is shown in the braking conﬁguration with in- NOTE: Both solenoid valves are open. creased air pressure at the supply port (supply dia- A.
Page 894 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information Automatic Traction Control If the vehicle is equipped with Automatic Traction Control (ATC), the ABS/ATC system automatically reduces wheel spin during low-traction startup or acceleration. If a drive wheel starts to spin faster than the steer- axle wheels, the ATC system applies air pressure to brake that drive wheel.
Page 895 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information An ATC function switch on the dash allows the driver the self-test, and whenever a malfunction occurs, the to select from two levels of drive-axle traction control ECU completes the ground path and the ABS indica- (see Fig.
Page 896 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information allowing the PLC messages to pass from the trailer by the tractor ABS. The tractor ABS turns on the power line to the tractor ABS power line. It does this trailer ABS lamp on the dash.
Page 897 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) General Information +12V to Tractor ABS ECU Trailer ABS Warning Lamp 7−way trailer connector (pin 7) Tractor ABS Trailer ABS power Tractor ABS ECU power and PLC and PLC Trailer ABS ECU (and PLC (and PLC Filter...
Page 898 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions: • Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires before working under the vehicle.
Page 899 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Wheel Speed Sensor Replacement Replacement 5. Remove the clamping bushing from the steering knuckle. IMPORTANT: Do not attempt to repair the wheel 6. Connect the new sensor cable to the chassis sensor wire (the wire that comes with the sen- harness.
Page 900 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Wheel Speed Sensor Replacement hand, push the sensor into the clamping bushing until it is stopped by the tone wheel. 14. Install the brake drum on the wheel hub. For in- structions, refer to Group 15.
Page 901 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Wheel Speed Sensor Adjustment, Rear Axle Adjustment NOTE: The following adjustment procedure re- quires the use of special tool T11-17556-000. Use of this tool, available through the PDCs, eliminates the time-consuming task of removing the wheel and tire assembly, and the brake drum.
Page 902 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Modulator Valve Removal and Installation Removal 4. Mark the air lines for ease of installation. Discon- nect the air lines. NOTE: Wire repairs may require the use of spe- 5. Remove the fasteners attaching the front modu- cial tools for certain connectors and terminals.
Page 903 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Modulator Valve Removal and Installation 6. Test drive the vehicle to verify that the ABS warning light is functioning correctly. 130/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 904 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Modulator Valve Disassembly and Assembly Disassembly NOTE: On vehicles equipped with Automatic Traction Control (ATC), the ATC valve can be replaced without removing the modular valve assembly if there is enough room to work. 1.
Page 905 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Modulator Valve Disassembly and Assembly Lubricate the large replacement O-ring and install it in the groove in the supply port (lower port) of the service relay valve. Using two new M6 Allen-head capscrews, install the adaptor on the service relay valve.
Page 906 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Tone Ring Installation on Service Hubs Installation IMPORTANT: Some ABS service hubs do not have a tone (tooth) ring installed on the hub. The tone ring must be ordered separately and installed on the hub before installation of the hub onto the axle.
Page 907 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Tone Ring Installation on Service Hubs 02/27/98 f421667 A. Rotate the hub. 1. Tone Ring 3. Axle 2. Dial Indicator Fig. 4, Check Tone-Ring Runout 150/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 908 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Dynamometer Testing Vehicles with ATC WARNING Do not test a vehicle equipped with Automatic Traction Control (ATC) on a dynamometer unless the ATC system is disabled. Activation of the ATC on a dynamometer will cause unequal drive- wheel torque that can result in loss of vehicle control and personal injury or death.
Page 909 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing General Information nected to test the wheel speed sensors, modulator valves, or ATC valve. To disconnect the electrical connectors from the ABS ECU, remove the cap- WARNING screws and lift the covers. See Fig.
Page 910 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing Wheel Speed Sensor Tests 6. Turn the ignition switch off. 7. If the voltage at the ECU is not within the speci- Wheel Speed Sensor and Circuit ﬁed range, check the battery voltage and test the wiring to the ECU and to ground.
Page 911 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing ABS/ATC Circuit Pin and Wire Numbers Wire Circuit Description Connector Number Number 377LR+ Left Rear Sensor, High 377LR– Left Rear Sensor, Low 377RR+ Right Rear Sensor, High 377RR– Right Rear Sensor, Low 378T+ ATC Valve, High 378T–...
Page 912 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing 4. Set a digital multimeter to the AC voltmeter mode. Connect the probes to the cable connec- tor terminals for the sensor being tested. 5. Rotate the wheel by hand at a speed of 30 rpm (one-half revolution per second) and read the voltage output.
Page 913 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing • If the resistance in each solenoid coil is 4 4. The resistance in each solenoid coil and cable circuit must be 4 to 8 ohms. to 8 ohms but the resistance noted in the previous test, "Modulator Valve and Cable •...
Page 914 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) Testing 2. Disconnect the cable connector from the ATC valve. See Table 3. Connect ohmmeter probes to the ATC valve ter- minals and read the resistance. See Fig. 08/30/99 f430144 1. ATC Valve 2.
Page 915 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Troubleshooting Tables J1587 Fault Code Cross-Reference Troubleshooting MID-SID Description Using the following tables, troubleshoot the ABS sys- Table tem by MID-SID. 136-014 Ground Faults Table 10 136-015 Table 11 J1587 Fault Code Cross-Reference 136-018 ATC Valve (if equipped)
Page 916 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) Problem Test Test Result Action Short to ground 3. Measure the resistance Resistance Repair the short to ground in between pin 7 of the X2 between either pin circuit(s) 377LF+ and 377LF–...
Page 917 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) Problem Test Test Result Action Intermittent signal 7. Adjust the sensor. Using Signal output OK Adjustment solved the problem. the wheel sensor output Make sure brake chatter is not screen in Meritor PC causing the problem.
Page 918 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) Problem Test Test Result Action Short to ground 3. Measure the resistance Resistance Repair the short to ground in between pin 5 of the X2 between either pin circuit(s) 377RF+ and 377RF–...
Page 919 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) Problem Test Test Result Action Intermittent signal 7. Adjust the sensor. Using Signal output OK Adjustment solved the problem. the wheel sensor output Make sure brake chatter is not screen in Meritor PC causing the problem.
Page 920 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Left Rear Wheel Sensor Troubleshooting (SID 003) Problem Test Test Result Action Short to ground 3. Measure the resistance Resistance Repair the short to ground in between pin 1 of the X3 between either pin circuit(s) 377LR+ and 377LR–...
Page 921 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Left Rear Wheel Sensor Troubleshooting (SID 003) Problem Test Test Result Action Intermittent signal 7. Adjust the sensor. Using Signal output OK Adjustment solved the problem. the wheel sensor output Make sure brake chatter is not screen in Meritor PC causing the problem.
Page 922 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) Problem Test Test Result Action Short to ground 3. Measure the resistance Resistance Repair the short to ground in between pin 3 of the X3 between either pin circuit(s) 377RR+ and 377RR–...
Page 923 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) Problem Test Test Result Action Intermittent signal 7. Adjust the sensor. Using Signal output OK Adjustment solved the problem. the wheel sensor output Make sure brake chatter is not screen in Meritor PC causing the problem.
Page 924 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Right Front Modulator Valve Troubleshooting (SID 008) Problem Test Test Result Action Short to power 1. Measure the voltage No voltage at Repeat test. Check circuits between pins 3, 4, and 9 either pin 378RFO, 378RFI, and 378RF–...
Page 925 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Left Rear Modulator Valve Troubleshooting (SID 009) Problem Test Test Result Action Short to ground 3. Check the modulator Resistance in both Check harness wiring circuits valve inlet and outlet circuits is within 4 378LRI, 378LRO, and 378LR–...
Page 926 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Ground Faults Troubleshooting (SID 014) Problem Test Test Result Action Low voltage or 1. Disconnect the X1 Voltage is 9.5 to 14 System voltage is acceptable. open circuit (gray) connector at the volts.
Page 927 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Ground Faults Troubleshooting (SID 015) Problem Test Test Result Action Internal relay fault If fault repeats, replace the ABS ECU. Table 11, Ground Faults Troubleshooting (SID 015) ATC Valve Troubleshooting (SID 018) Problem Test Test Result...
Page 928 J1939 open/short Check the driveline Repair J1939 datalink as retarder ECU and wires. necessary. Code 13s231 05 Check the J1939 Datalink. may be active as well. Freightliner SB 54-133 300/14 Business Class M2 Workshop Manual, Supplement 2, June 2002...
Page 929 Check the driveline Check J1939 datalink and retarder ECU and wires. driveline retarder ECU. Repair as NOTE: Fault necessary. occurs if engine Freightliner SB 54-133 retarder sends message incorrectly. J1939 time out Check engine ECU and Check J1939 datalink and engine wires.
Page 930 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Conﬁguration Errors Troubleshooting (SID 253) Problem Test Test Result Action ATC conﬁguration Check J1939 for proper wiring. error Check engine ECU for communication. Repair as NOTE: ATC valve necessary, then reconﬁgure ECU. is detected without engine datalink (J1939).
Page 931 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Miscellaneous Faults Troubleshooting (SID 254) Problem Test Test Result Action ECU Mounting Check ECU mounting. Replace the ECU if fault persists. Extreme banked No correction required. This fault road (measured is for reporting only.
Page 932 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting 3. At the PLC ﬁlter, connect one lead of the DMM that has the two blue wires) and connect the to the green wire (at the 2-pin connector with the other lead to the ground where the white wire green and yellow wires) and the other lead to terminates.
Page 933 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS System Troubleshooting Trailer ABS Warning Lamp Troubleshooting Symptom Possible Cause Action Trailer ABS lamp There is no trailer connected or the trailer is not The trailer ABS lamp will not illuminate at start-up does not come on equipped with PLC.
Page 934 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Lamp Troubleshooting ABS Warning Lamp Function off, while ground at the instrument cluster pin B11 = lamp on). It also ensures that the lamp will be on if the ABS ECU is disconnected from The ABS warning lamp in the instrument cluster the vehicle harness.
Page 935 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Lamp Troubleshooting Ref. Dia. G06−42022 01/18/2002 f544040 Fig. 1, ABS Warning Lamp Wiring 310/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 936 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Lamp Troubleshooting J1587 Fault Codes (MID 136 SID 023): ABS Warning Lamp Circuit Fault Description Test Test Result Action Open Circuit Test 1: 12V (approx.) Go to Test 3. Disconnect the gray X1 connector at the ABS ECU.
Page 937 Meritor WABCO Pneumatic Antilock Braking System 42.00 (ABS) ABS Lamp Troubleshooting Diagnosing an ABS Lamp that Remains On Symptom Test Test Result Action Warning Lamp Stays On Test 1: Go to Test 2. Use Servicelink or Meritor Toolbox to check for J1587 fault codes (MID 136).
Page 938 42.01 Meritor Cam-Master Q Plus Brakes General Information General Information Principles of Operation Meritor Q Plus brakes are standard for both front and When the brake pedal is depressed, compressed air ® rear axles. These Cam-Master brakes are air- enters the brake chamber, causing the diaphragm to actuated, cam-operated, foundation brakes.
Page 939 42.01 Meritor Cam-Master Q Plus Brakes General Information 12/11/97 f421684 1. Anchor Pin 9. Capscrew, Dust Shield 17. Camshaft-and-Chamber Bracket 2. Anchor Pin Bushing 10. Dust Shield 18. Grease Fitting 3. Retaining Spring 11. Camshaft Snap Ring 19. Chamber Bracket Seal 20.
Page 940 42.01 Meritor Cam-Master Q Plus Brakes General Information 07/19/95 f420156a A. Oversized Hole (10 or 2 o’clock position) for ABS bushing. Fig. 2, Hole for ABS Wheel Speed Sensor Bushing 050/3 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 941 42.01 Meritor Cam-Master Q Plus Brakes Safety Precautions General Safety Precautions the correct tools and observe all precautions pertaining to use of those tools. • Replacement hardware, tubing, hose, ﬁttings, WARNING etc. should be the equivalent size, type, length, and strength of the original equipment. When replacing brake pads, shoes, rotors, or •...
Page 942 42.01 Meritor Cam-Master Q Plus Brakes Safety Precautions OSHA recommends that enclosed cylinders equipped with vacuums and high-efficiency (HEPA) ﬁlters be used during brake repairs. Under this system, the entire brake assembly is placed within the cylinder and the mechanic works on the brake through sleeves attached to the cylinder.
Page 943 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Removal and Installation WARNING CAUTION For a Meritor automatic slack adjuster, disengage Before starting the procedure below, read the the pull-pawl before turning the manual adjusting safety precaution information in Safety Precau- nut.
Page 944 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Removal and Installation the brake shoes are fully retracted and the drum clears the lining. See Subject 130 for instruc- tions. • On Meritor adjustors, turn the square ad- justing nut clockwise (as if tightening a right-hand threaded fastener).
Page 945 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Removal and Installation Installation Rotate the lower brake shoe forward around the hub and install a new brake shoe return spring. Install the open end of IMPORTANT: For best brake performance, do the spring hooks toward the camshaft.
Page 946 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Removal and Installation Immediately after doing the above stops, check the drum temperatures. Any drums that are signiﬁcantly cooler than others shows a lack of braking effort on those wheels. 08/09/94 f420689a A.
Page 947 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe and Lining Inspection WARNING Before starting the procedure below, read the safety precaution information in Safety Precau- tions 100. Failure to be aware of the dangers of brake lining dust exposure could result in seri- ous and permanent health damage.
Page 948 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe and Lining Inspection rial and do not exceed 1/16 inch (1.6 mm) in width or 1-1/2 inches (38 mm) in length. See Fig. 12/23/97 f421692 A. Cracks extending from hole to hole. Fig.
Page 949 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment Pre-Adjustment Checks and The speciﬁc procedure for adjusting the brake cham- ber stroke at the slack adjuster’s manual adjusting General Adjustment nut may vary, depending on which slack adjuster is installed, but there are three basic steps in complet- Information ing a manual brake chamber stroke adjustment: Before adjusting the brakes, check and adjust the...
Page 950 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment Brake Chamber Stroke Speciﬁcations Maximum Applied Stroke Chamber Type (Size) Free-Stroke: inch (mm) inch (mm) Standard Stroke 16, 20, and 24 1-3/4 (44) 2 (51) 2-1/4 (57) 5/8 to 3/4 (16 to 19) †...
Page 951 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment 10/20/93 f420182a 09/27/94 f420693a NOTE: For either free-stroke or applied chamber stroke, A. Insert screwdriver here. subtract measurement A from B. A. Measurement with the brakes released. Fig. 1, Disengage the Pull-Pawl B.
Page 952 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment 3. Fully release the brakes (the air chamber push- CAUTION rod must be fully retracted). The adjusted applied chamber stroke should be CAUTION as short as possible but not so short that the free-stroke is too short and the linings drag.
Page 953 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment f420699a 10/17/95 1. Adjusting Hexnut 07/05/1995 f420757b A. Brakes Released B. Brakes Applied Fig. 5, Adjusting Hexnut Fig. 6, Measure the Stroke Then, turn the adjusting nut counterclock- wise 1/2 turn. You will hear a ratcheting Fully apply the brakes.
Page 954 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment WARNING Do not operate the vehicle until the brakes have been checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
Page 955 42.01 Meritor Cam-Master Q Plus Brakes Brake Adjustment 8. Lower the vehicle, remove the safety stands, and remove the chocks from the tires. WARNING Do not operate the vehicle until the brakes have been checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
Page 956 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Lining Replacement WARNING Before starting this procedure, read the informa- tion in Safety Precautions 100. Failure to be aware of the dangers of brake lining dust expo- sure could result in serious and permanent health damage.
Page 957 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Lining Replacement CAUTION Drilling out rivets or cutting off rivet heads with a chisel can cause the rivet hole to become out-of- round, which could damage the brake shoe. If the lining blocks are riveted, use a suit- able riveting mandrel to push out the old rivets.
Page 958 42.01 Meritor Cam-Master Q Plus Brakes Brake Shoe Lining Replacement 09/27/94 f420164a A. The clearance between the brake lining and shoe table must be less than 0.010 inch (0.25 mm). Fig. 4, Check Clearance Along Edge 09/27/94 f420717a A. The clearance between the shoe table and the ends of the brake lining can be up to 0.025 inch (0.64 mm).
Page 959 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly Disassembly and Inspection 1. Remove the brake shoes. For instructions see Subject 110. IMPORTANT: Meritor recommends that the WARNING brake drum not be turned or rebored (resur- faced).
Page 960 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 12/12/97 f421685 NOTE: 16-1/2 inch Q Plus MX500 brake with cast spider shown. 1. Anchor Pin 11. Washer (spacer) 20. Pipe Plug 2. Anchor Pin Bushing 12. Washer (thin spacer) 21.
Page 961 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 12/12/97 f421686 NOTE: 16-1/2 inch drive axle Q Plus MX500 brake with stamped spider shown. 1. Anchor Pin 11. Capscrew, Dust Shield 20. Camshaft Bushing, 1-1/2 in. ID 2.
Page 962 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 06/23/94 f420690a A. Check for diameter and out-of-round. B. Check for cracks, heat checks, glazing, and grooves. Fig. 4, Brake Drum Inspection From the slack adjuster side of the camshaft-and-chamber bracket, remove the snap ring and any washers, spacers, 10/27/93...
Page 963 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 09/27/94 f420693a 12/10/97 f421675 A. Insert a screwdriver here to pry the pull-pawl out Fig. 8, Remove the Camshaft about 1/32 inch (0.8 mm). inspect the camshaft grease seals. If a grease Fig.
Page 964 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 17. If equipped, remove the four capscrews that at- CAUTION tach the dust shield to the brake spider; remove the dust shield. A thick layer of oxidation and dirt on the outside 18.
Page 965 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly after they have been cleaned, dried, and Place the brake spider on the axle ﬂange. Install inspected to protect them from corrosion. the mounting fasteners with hardened washers under the bolt head and nut.
Page 966 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly NOTE: If replacing a brake chamber, make sure that the new chamber is the same size and make as the brake chamber on the other side of the axle.
Page 967 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 12/10/97 f421672 Fig. 12, Install the Camshaft Brake Chamber Torque Speciﬁcations: lbf·ft (N·m) Chamber Type (Size) Midland Anchorlok 35 to 50 (48 to 68) 35 to 40 (48 to 54) Not Available With hexnut, 110 to 115 (149 to 203) 70 to 100 (95 to 136)
Page 968 42.01 Meritor Cam-Master Q Plus Brakes Brake Components Disassembly, Inspection, Cleaning, and Assembly 8. For all Cam-Master Q Plus brakes except MX500, pressure lube the camshaft-and- chamber bracket bushings. NOTE: Use meter-type ﬁttings with a maxi- mum 40 psi (276 kPa) pressure relief at the shutoff.
Page 969 42.01 Meritor Cam-Master Q Plus Brakes Troubleshooting Troubleshooting Tables Problem—No Adjustment, or Adjusted Stroke is Too Long Problem—No Adjustment, or Adjusted Stroke is Too Long Possible Cause Remedy The wrong slack adjuster is installed. Replace the slack adjuster with the correct one. The clevis is not installed correctly.
Page 970 42.01 Meritor Cam-Master Q Plus Brakes Speciﬁcations Q Plus Brake Torque Speciﬁcations Fastener Size Grade lbf·ft N·m Brake Shoe Lining Nuts 1/4 in 80 to 100 lbf·in 900 to 1120 N·cm 3/8 in 18 to 23 24 to 31 Dust Shield Fasteners 5/16–18 15 to 20 20 to 27...
Page 971 42.01 Meritor Cam-Master Q Plus Brakes Speciﬁcations Meritor Grease Speciﬁcation Speciﬁcation Number NLGI Grade Grease Type Outside Temperature, °F (°C) O-637 1 and 2 Calcium Base See Manufacturer’s Speciﬁcation O-641 — Anti-Seize See Manufacturer’s Speciﬁcation O-695 Synthetic Polyurea –40 (–40) Table 3, Meritor Grease Speciﬁcation Component Lubrication Meritor Grease Speciﬁcation...
Page 972 42.03 Dryer Reservoir Module (DRM) General Information General Information sembly, ready to be expelled at the next purge cycle. Fig. The function of the dryer reservoir module (DRM) The air then ﬂows into the desiccant cartridge. Once (Fig. 1) is to provide the vehicle with an integrated in the desiccant cartridge, air ﬂows through an oil air dryer, secondary reservoir, purge volume, and separator that removes oil and solid contaminants.
Page 973 42.03 Dryer Reservoir Module (DRM) General Information volume, through the desiccant drying bed, and out through the open purge valve. See Fig. The purge cycle lasts only a few seconds and is de- tected by an audible burst of air at the air dryer exhaust.
Page 974 42.03 Dryer Reservoir Module (DRM) General Information f422262 08/28/2001 A. Class 8 vehicles have an integrated primary reservoir. 1. Compressor 12. Integrated Reservoir (Purge Volume) 2. Engine Turbo 13. Integrated Reservoir (Secondary Volume) 3. Inlet Port 14. Purge Volume Drain Cock 4.
Page 975 42.03 Dryer Reservoir Module (DRM) General Information f422263 08/28/2001 A. Class 8 vehicles have an integrated primary reservoir. 1. Compressor 12. Integrated Reservoir (Purge Volume) 2. Engine Turbo 13. Integrated Reservoir (Secondary Volume) 3. Inlet Port 14. Purge Volume Drain Cock 4.
Page 976 42.03 Dryer Reservoir Module (DRM) Safety Precautions • To avoid injury, keep clear of the air chamber Safety Precautions pushrod when brakes are applied or when air is exhausted from the system. Before attempting to work on the air brake system, observe the following precautions: •...
Page 977 42.03 Dryer Reservoir Module (DRM) Air Dryer Replacement Replacement 8. Remove the desiccant cartridge. For instructions, Subject 120. WARNING Installation Before working on or around air brake systems 1. Install the delivery check valve and governor and components, see Safety Precautions 100.
Page 978 42.03 Dryer Reservoir Module (DRM) Desiccant Cartridge Replacement Replacement Rotate the cartridge clockwise about one full turn. If necessary, use a strap wrench to tighten the cartridge. WARNING 6. Remove the chocks from the tires. Before working on or around air brake systems and components, see Safety Precautions 100.
Page 979 42.03 Dryer Reservoir Module (DRM) Delivery Check Valve and Governor Replacement Replacement 10. Perform the operational tests in Subject 170. 11. Remove the chocks WARNING Before working on or around air brake systems and components, see Safety Precautions 100. Failure to do so may result in personal injury. 1.
Page 980 42.03 Dryer Reservoir Module (DRM) Delivery Check Valve and Governor Replacement 04/09/98 f430116 1. Air Dryer Base 4. Capscrews 7. Spring 2. Gasket 5. Adaptor 8. Check Valve Body 3. Governor 6. O-Ring 9. O-Ring Fig. 1, Delivery Check Valve Replacement 130/2 Business Class M2 Workshop Manual, Supplement 0, January 2002...
Page 981 42.03 Dryer Reservoir Module (DRM) Purge Valve Replacement Replacement 6. Install the two new O-rings on the purge valve housing cover and the new quad-ring on the purge piston. WARNING 7. Install the new purge valve assembly in the end cover while making sure the purge valve housing Before working on or around air brake systems is fully seated against the end cover.
Page 982 42.03 Dryer Reservoir Module (DRM) Heater and Thermostat Replacement Replacement IMPORTANT: Do not lubricate the heater stick or thermostat. WARNING 7. Install the O-ring on the heater/thermostat as- sembly. Then, slide the assembly into the air dryer body, making sure not to scrape insulation Before working on or around air brake systems from the wires.
Page 983 42.03 Dryer Reservoir Module (DRM) Air Reservoir Replacement Replacement NOTE: The air reservoirs are mounted in vari- ous locations, depending on the vehicle conﬁgu- ration. The reservoirs are typically mounted under the driver’s-side steps or along the frame rail, behind the cab. 1.
Page 984 42.03 Dryer Reservoir Module (DRM) Operational Tests Operational Tests leaking through the center of the threaded boss by applying a soap solution to the boss. WARNING Replace the delivery check valve if there is excessive leakage (exceeding a 1 inch Before working on or around air brake systems bubble in 5 seconds).
Page 985 42.03 Dryer Reservoir Module (DRM) Operational Tests the resistance between the electrical pins in the air dryer connector half. The resis- tance should be 1.5 to 3.0 ohms for the 12-volt heater assembly and 6 to 9 ohms for the 24-volt heater assembly. Warm the thermostat and heater assem- bly to about 90°F (32°C) and check the resistance again.
Page 986 42.03 Dryer Reservoir Module (DRM) Troubleshooting Troubleshooting Tables Problem—Air Dryer is Constantly Purging (Cycling) or Purging Excessively Problem—Air Dryer is Constantly Purging (Cycling) or Purging Excessively Possible Cause Remedy There is excessive system leakage. Using a soap-and-water solution, test for leakage at the air line ﬁttings, drain cock (or valve), and system valves.
Page 987 42.03 Dryer Reservoir Module (DRM) Troubleshooting Problem—Constant Exhaust of Air at the Air Dryer Purge Valve Problem—Constant Exhaust of Air at the Air Dryer Purge Valve Possible Cause Remedy The air dryer purge valve is leaking Test for leakage. With the compressor loaded, apply soap solution on the excessively.
Page 988 42.03 Dryer Reservoir Module (DRM) Troubleshooting Problem—The Air Dryer Does Not Purge or Exhaust Air Possible Cause Remedy The purge valve control piston is leaking. Repair or replace the purge valve. For instructions, see Subject 140. Problem—Desiccant Material is Being Expelled from the Air Dryer Purge Valve Exhaust Problem—Desiccant Material is Being Expelled from the Air Dryer Purge Valve Exhaust Possible Cause Remedy...
Page 989 42.04 Air Dryer, Bendix AD–9 General Information General Information The purge valve housing assembly, which includes the heater and thermostat assembly, and the dis- charge check valve assembly, can be serviced with- The function of the Bendix AD-9 air dryer (Fig.
Page 990 42.04 Air Dryer, Bendix AD–9 General Information The standard air dryer (Fig. 2) uses a metal seat After exiting the end cover, air ﬂows into the desic- turbo cutoff valve. The function of the metal seat is to cant cartridge. Once in the cartridge, air ﬁrst ﬂows prevent turbocharger boost pressure loss through the through an oil separator, which removes water, oil, oil vapor, and solid contaminants.
Page 991 42.04 Air Dryer, Bendix AD–9 General Information 05/26/95 f420541a 1. Desiccant Cartridge 7. Sump 13. Reservoir 2. Check Valve 8. Heater Element 14. Governor 3. Oriﬁce 9. Exhaust 15. Compressor 4. Purge Volume 10. Purge Valve 16. Control Port 5. Check Valve Assembly 11.
Page 992 42.04 Air Dryer, Bendix AD–9 General Information 05/09/95 f420542a 1. Desiccant Cartridge 8. Heater Element 14. Reservoir 2. Check Valve 9. Exhaust 15. Governor 3. Oriﬁce 10. Purge Valve 16. Compressor 4. Purge Volume 11. Turbocharger Cutoff Piston 17. Control Port 5.
Page 993 42.04 Air Dryer, Bendix AD–9 General Information The purge valve will remain open after the purge At the beginning of the purge cycle, the downward cycle is complete, and will not close until air brake travel of the purge piston is stopped when the turbo system pressure is reduced and the governor signals cutoff valve (tapered portion of the purge piston) con- the compressor to charge.
Page 994 42.04 Air Dryer, Bendix AD–9 Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions: 1. Chock the tires and shut down the engine before working under a vehicle. Depleting air system pressure may cause the vehicle to roll.
Page 995 42.04 Air Dryer, Bendix AD–9 Removal and Installation Removal Position the air dryer into the upper mounting bracket and strap. Align the two unused holes in the end cover with the WARNING bottom mounting bracket so that the bot- tom bracket supports the air dryer. The Before working on or around air brake systems end cover should rest on the bracket.
Page 996 42.04 Air Dryer, Bendix AD–9 Removal and Installation 08/09/95 f421383 1. 5/16-Inch x 4-1/2-Inch Upper Bracket Capscrew 14. Check Valve Assembly 2. Upper Bracket Strap 15. Purge Valve Assembly 3. 5/16-Inch Lockwasher 16. Purge Valve Bolt 4. 5/16-Inch Locknut 17. Exhaust Diaphragm 5.
Page 997 42.04 Air Dryer, Bendix AD–9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly NOTE: As a convenience when rebuilding the Gently rotate the electrical connector to the left until the thermostat clears the air dryer, several replacement parts and mainte- purge valve housing.
Page 998 42.04 Air Dryer, Bendix AD–9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly 08/09/95 f421383 1. 5/16-Inch x 4-1/2 Inch Upper Bracket Capscrew 14. Check Valve Assembly 2. Upper Bracket Strap 15. Purge Valve Assembly 3. 5/16-Inch Lockwasher 16. Purge Valve Bolt 4.
Page 999 42.04 Air Dryer, Bendix AD–9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly Cleaning and Inspection IMPORTANT: When installing the heater and thermostat assembly, make sure that the seal ring under the electrical connector is not twisted. WARNING 2. Install the heater and thermostat assembly. Before working on or around air brake systems Insert the heater element into the slot in and components, read...
Page 1000 42.04 Air Dryer, Bendix AD–9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly Secure the purge-valve housing to the 8. Test the air dryer for proper operation. For in- end cover using the three self-tapping structions, see Subject 130. screws. Start all three screws by hand, then torque them 85 to 125 lbf·in (960 to 1400 N·cm).
Page 1001 42.04 Air Dryer, Bendix AD–9 Air Dryer Thermostat Testing Testing 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 on each of the pins of the male connector.

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