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freightliner BUSINESS CLASS M2 100 Maintenance Manual

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BUSINESS CLASS M2 MAINTENANCE MANUAL
Models: M2 100
M2 106
M2 106V
M2 112
M2 112V
STI-455-6 (03/01/2020)
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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  • Page 1 BUSINESS CLASS M2 MAINTENANCE MANUAL Models: M2 100 M2 106 M2 106V M2 112 M2 112V STI-455-6 (03/01/2020) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 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 4 © 2001–2020 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC.
  • Page 5 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 6 Introduction Descriptions of Service Publications Warranty-related service information available on the www.DTNAConnect.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety.
  • Page 7 Introduction Page Description For an example of a Business Class M2 Maintenance Manual page, see Fig. Cooling 20−01 Coolant Replacement 20−02 Cooling Fan Inspection Business Class M2 Maintenance Manual, December 2001 12/06/2001 f020125 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B.
  • Page 8 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 9: Table Of Contents

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

  • Page 11: Determining Scheduled Maintenance Intervals

    General Information Determining Scheduled Maintenance Intervals: 00–01 • any road operation with high annual mileage Determining Scheduled Maintenance Intervals Maintenance Schedules After determining the schedule appropriate to your Performing regular maintenance will help ensure that vehicle, refer to the Maintenance Schedules to deter- your vehicle delivers safe, reliable service and opti- mine when to perform the Initial Maintenance (IM) mum performance.
  • Page 12 General Information Maintenance Schedules: 00–02 Maintenance Schedules Maintenance Intervals Schedule Maintenance Interval Frequency Mileage Hours Initial Maintenance (IM) first 1000 1600 Maintenance 1 (M1) every 1000 1600 Schedule I Maintenance 2 (M2) every 4000 6400 (severe service) for vehicles that travel up to Maintenance 3 (M3) every 8000...
  • Page 13 General Information Maintenance Intervals for Schedule I: 00–03 Maintenance Intervals for Schedule I Maintenance Maintenance Interval Service Date Miles Hours Sequence IM and M1 1000 1600 2000 3200 3000 4800 M1 and M2 4000 6400 5000 8000 6000 9600 7000 11 200 M1, M2, and M3 8000...
  • Page 14 General Information Maintenance Intervals for Schedules II and III: 00–04 Maintenance Intervals for Schedules II and III Schedule II Schedule III Maintenance Maintenance Interval Service Date Sequence Miles Miles IM and M1 8000 12 000 10,000 16 000 M1 and M2 16,000 24 000 20,000...
  • Page 15 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. 01-01 Engine Drive Belt Inspecting • • • 01-02 Engine Support Fastener Checking • • 09-01 Air Cleaner Element Inspecting and Replacing •...
  • Page 16 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. Wheel End Inspection and Maintenance, 6,000-Pound and 33-05 • • • • • • ‡ 8,000-Pound Steer Axles with Oil-Lubricated Hubs 33-06 All-Axle Alignment Check •...
  • Page 17 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. 47-01 Fuel Tank Band Nut Tightening • 47-02 Fuel/Water Separator Element Replacing • • 47-03 LNG Fuel System Inspecting •...

  • Page 18: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–06 NOTE: The IM Operations include the maintenance operations in Table 5 and all of the maintenance op- erations in Table 6, M1 Maintenance Operations. Initial Maintenance (IM) Operations Maintenance Title of Maintenance Operation Operation No.

  • Page 19: M1 Lubrication And Fluid Level Check

    General Information M1 Maintenance Operations: 00–07 IMPORTANT: After performing all operations listed in Post-Trip Inspections and Maintenance" chapter of this table, perform all daily, weekly, and monthly the Business Class® M2 Driver’s Manual. maintenance operations listed in the "Pretrip and M1 Maintenance Operations Maintenance Title of Maintenance Operation...
  • Page 20 General Information M1 Maintenance Operations: 00–07 M1 Maintenance Operations Maintenance Title of Maintenance Operation Operation No. 42-04 Bosch Hydraulic Brake System Inspection 42-09 Brake Lines and Fittings Inspection, Hydraulic Brakes 42-13 Brake Inspection 42-14 Hydro-Max ™ Brake System Inspection † 42-15 WABCO System Saver Air Dryer Desiccant Cartridge Replacement ‡...

  • Page 21: M2 Lubrication And Fluid Level Check

    General Information M2 Maintenance Operations: 00–08 NOTE: The M2 Maintenance Operations include the maintenance operations in Table 6, M1 Maintenance maintenance operations in Table 7 and all of the Operations. M2 Maintenance Operations Maintenance Title of Maintenance Operation Operation No. 00-07 Perform All M1 Maintenance Operations 00-13...

  • Page 22: M3 Maintenance Operations

    General Information M3 Maintenance Operations: 00–09 NOTE: The M3 Maintenance Operations include the maintenance operations in Table 8 and all of the maintenance operations in Table 6, M1 Maintenance Operations, and Table 7, M2 Maintenance Opera- tions. M3 Maintenance Operations Maintenance Title of Maintenance Operation Operation No.

  • Page 23: M4 Maintenance Operations

    General Information M4 Maintenance Operations: 00–10 NOTE: The M4 Maintenance Operations include the Operations, Table 7, M2 Maintenance Operations, maintenance operations in Table 9 and all of the Table 8, M3 Maintenance Operations. maintenance operations in Table 6, M1 Maintenance M4 Maintenance Operations Maintenance Title of Maintenance Operation...

  • Page 24: M5 Maintenance Operations

    General Information M5 Maintenance Operations: 00–11 NOTE: The M5 Maintenance Operations include the Operations, Table 7, M2 Maintenance Operations, maintenance operations in Table 10 and all of the Table 8, M3 Maintenance Operations, and Table maintenance operations in Table 6, M1 Maintenance M4 Maintenance Operations.
  • Page 25 General Information M1 Lubrication and Fluid Level Check: 00–12 Table 11, MOP 00-12, lists the lubrication and fluid level check maintenance operations that must be performed at the M1 Maintenance Interval. MOP 00-12, M1 Lubrication and Fluid Level Check Maintenance Title of Maintenance Operation Operation No.
  • Page 26 General Information M2 Lubrication and Fluid Level Check: 00–13 Table 12, MOP 00-13, lists the lubrication and fluid level check maintenance operations that must be performed at the M2 Maintenance Interval. MOP 00-13, M2 Lubrication and Fluid Level Check Maintenance Title of Maintenance Operation Operation No.

  • Page 27: Noise Emission Controls

    Replacement Parts Replacement parts used for maintenance or repair of noise emission control systems should be genuine Freightliner parts. If other than genuine Freightliner parts are used for replacement or repair of compo- nents affecting noise emission control, the owner...

  • Page 28: Verification Of Inspections Log

    General Information Verification of Inspections Log: 00–16 Verification of Inspections Log The "Verification of Inspections Log" should be filled out each time the vehicle’s noise emission controls are maintained or repaired. Verification of Inspections Log, Group 20 Verification of Inspections Log, Group 20, Engine Cooling/Radiator Date Mileage Repair Description...
  • Page 29 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–01 Engine Support Fastener Checking.
  • Page 31 Engine 01–00 Safety Precautions 4. Check for uneven ribs on serpentine (poly-V) belts. Foreign material in the pulley will erode the undercord ribs causing the belt to lose its grip- Safety Precautions in this section apply to all ping power. procedures within this group.
  • Page 32 Engine 07/12/2001 f150010b 1. Glazing 3. Separating Layers 5. Streaked Sidewalls 2. Tensile Break 4. Uneven Ribs 6. Cracks Fig. 1, Drive Belt Replacement Conditions NOTE: When the engine is removed, inspect the lower and upper isolators for wear. Replace the isolators if necessary.
  • Page 33 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 Business Class M2 Maintenance Manual, November 2014...
  • Page 35 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash- mounted restriction gauge.
  • Page 37 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 39 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 41 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Checking..........15–01 Safety Precautions .
  • Page 43 Alternators and Starters 15–00 Safety Precautions Engines equipped with a serpentine or poly-V belt have automatic belt tensioners, and do not require belt tension inspection. Safety Precautions in this section apply to all 4. Check that all electrical connections at the alter- procedures within this group.
  • Page 44 Alternators and Starters 10.1 Clean and tighten the battery ground cable, terminal, and clamps. 10.2 Inspect the retainer assembly (or battery hold-downs) and the battery box. Replace worn or damaged parts. Remove any cor- rosion with a wire brush, and wash with a weak solution of baking soda and water.
  • Page 45 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Drive Inspecting (Noise Emission Control) ..........20–03 Hybrid Electric System Coolant Changing .
  • Page 47 Engine Cooling/Radiator 20–00 Safety Precautions Tool Part Number Radiator-Cap Tester TA53 Safety Precautions in this section apply to all Table 1, Snap-On Tool For Pressure Relief Cap Test procedures within this group. 2. There is a second valve in the radiator cap that opens under vacuum.
  • Page 48 Engine Cooling/Radiator Horton HT650 Fan Drive CAUTION Check for friction facing wear condition. Replace When flushing the radiator, do not apply more when worn to 1/16-inch (1.5-mm) thick, when oil than 20 psi (138 kPa) air pressure. Excessive pres- spotted, or when burn marks are visible. sure can damage the radiator or heater core.
  • Page 49 Engine Cooling/Radiator 9. Check the electrical connections at the solenoid signs of oil contamination or burn marks. If evi- valve. The solenoid valve is part of the air mod- dence of oil or burn marks are found, replace the ule unit (AMU), which is located on the rear friction facing.
  • Page 50 Engine Cooling/Radiator a leak inside the fan clutch. Any leak must be remedied. 11. Check the fan clutch bearings. 11.1 Turn the fan in both directions and feel for worn hub bearings. 11.2 If possible, remove the drive belt and check for worn sheave bearings by turn- ing the sheave in both directions.
  • Page 51 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Adjusting, Manually Adjusted Clutches ..........25–05 Clutch Hydraulic Fluid Changing .
  • Page 53 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 54 Clutch 25–02 Eaton Fuller Clutch 25–03 Clutch Hydraulic Fluid Release Cross-Shaft Level Checking Lubricating WARNING IMPORTANT: This maintenance operation per- tains only to vehicles equipped with mechanical Use only approved clutch hydraulic fluid (DOT 4 brake fluid) in the clutch hydraulic system. Do not (not hydraulic) linkages.
  • Page 55 fluid is procedures below. Fluid replacement must be done coming out, close the bleed screw. at an authorized Freightliner service facility. 7. Check the fluid level in the reservoir and bleed Flushing the system according to the procedures under the heading "Bleeding the Clutch."...
  • Page 56 Clutch 12/11/2001 f250582 1. Clamp-Mounting Bolt, 1/4–20 6. Hydraulic Hose 2. Plated Steel 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. Slave Cylinder Mounting Capscrew, M8 Fig.
  • Page 57 Clutch 12/11/2001 f250581 1. M8 Capscrew and Washer 4. Pedal Unit 7. Cup Bracket 2. Pedal Unit Mounting Plate 5. Master Cylinder 8. Standoff Bracket 3. Reservoir 6. Hydraulic Hose 9. Mounting Bolt, M10 Fig. 7, Clutch Master Cylinder 25–05 Clutch Adjusting, Release bearing travel is the clearance between the rear surface of the release bearing housing and the Manually Adjusted...
  • Page 58 Clutch If the green end of the tool can’t be inserted in the gap, adjustment is needed. Go to the next step. If the green end of the tool fits — snugly or loosely — then no adjustment is needed. Nothing more needs to be done.
  • Page 59 Clutch 6. Adjust the clutch, using a 5/8-inch box-end or mm), turn the adjustment bolt counter- socket wrench on the adjustment bolt. See clockwise (the release bearing moves to- Fig. ward the engine). When the adjustment is complete, make sure the adjustment bolt is locked (pulled up flush with the mounting bolts).
  • Page 61 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Changing ..........26–05 Allison and Eaton Fuller Transmission Breather Checking .
  • Page 63 Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER f260006b 10/05/94 When working on the vehicle, shut down the en- A. Full B. Low gine, set the parking brake, and chock the tires. Before working under the vehicle, always place Fig.
  • Page 64 Transmission areas for the first 10,000 miles (16 000 km) Allison after changing to a synthetic from a petroleum- Cold Check based lubricant. 4. Clean the fill plug, then install it in the transmis- Clean all dirt away from around the end of the fluid sion.
  • Page 65 Transmission 4. With the engine idling, remove the dipstick from the tube and wipe it clean. 5. Insert the dipstick into the tube, then remove it. 6. Check the fluid level reading and repeat the check procedure to verify the reading. Safe oper- ating level is within the HOT RUN band on the dipstick.
  • Page 66 Transmission after changing to a synthetic from a petroleum- 5. For Procision transmissions, change the lubrica- tion filter as follows: based lubricant. 4. Clean the fill plug, then install it in the transmis- NOTICE sion. Tighten the plug 42 lbf·ft (57 N·m). To prevent damage to the threads, use hand tools 26–02 Eaton Fuller to remove the lubrication filter housing.

  • Page 67: Allison And Eaton Fuller Transmission Breather Checking

    Transmission NOTE: The correct fluid level is established by Eaton Fuller Transmission Lubricant Capacities checking at the fill plug opening (manual and Lubricant automated) or the oil level dipstick (Procision). † Transmission Model Capacity: qt (L) 1. On manual and automated transmssions, add fluid until it is level with the lower edge of the fill RT–8608L 13.5 (12.7)

  • Page 68: Eaton Fuller Transmission Air Filter/Regulator Element Cleaning

    Transmission f260007a 05/27/93 NOTE: Location of the transmission breather will vary depending on transmission model. Fig. 3, Transmission Breather (Eaton Fuller shown) 26–04 Eaton Fuller 10/05/2016 f260037a Transmission Air Filter/ NOTE: Location of the air filter/regulator will vary de- pending on transmission model. Regulator Element Fig.
  • Page 69 Transmission ment will last the life of the vehicle, pro- NOTICE vided it is not damaged. Wipe out the filter housing with a clean, To prevent dirt from entering the transmission, dry, lint-free rag. use only clean containers and fillers for the trans- mission fluid.
  • Page 70 Transmission Approved Allison Transmission Lubricants Lubricant Type Temperature: °F (°C) All Allison Transmissions Castrol TranSynd ™ (synthetic) Above –22 (–30) Dexron® III Above –13 (–25) Lubricants listed in order of preference. Do not mix types of oil. Table 7, Approved Allison Transmission Lubricants Allison Transmission Lubricant Capacities Fill Capacity: Transmission Model...

  • Page 71: Mercedes-Benz Transmission Fluid Changing And Magnetic Plug Cleaning

    Transmission 9. Install the filter and cover assemblies into the filter compartment. 10. Align each cover assembly with the holes in the channel plate sump, and push the cover assem- blies in by hand to seat the seals. NOTICE Do not use the bolts to draw the filter covers to the sump.

  • Page 72: Mercedes-Benz Transmission Leak Checking

    Transmission 26–07 Mercedes-Benz Transmission Leak Checking 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. f260006b 10/05/94 2. Check for signs of leakage at the breather. See A. Full B. Low Fig. Fig.
  • Page 73 Transmission NOTE: There are two cover plates on the coun- 9. Check for signs of leakage at the clutch slave cylinder. tershaft, one at the front and one at the rear. 5. Check for signs of leakage at the rear cover NOTICE plate on the countershaft (next to the output yoke).
  • Page 74 Transmission 11. Remove the chocks from the tires. 26/12 Business Class M2 Maintenance Manual, March 2016...
  • Page 75 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting ............. . 31–02 Fifth Wheel Lubricating.

  • Page 77: Safety Precautions

    Frame and Frame Components • frame crossmembers and gussets 31–00 Safety Precautions • front frame brackets Safety Precautions in this section apply to all • front suspension spring brackets procedures within this group. • fuel tank brackets • radius rods DANGER •...
  • Page 78 Frame and Frame Components Push on the wedge stop rod with hand pressure. It should move in 1/4 inch (6 mm) and spring back out on release. If the free travel is not 1/4 inch (6 mm), adjust the distance to 1/4 inch (6 mm) by turning the wedge stop rod, on the right side of the top plate, clockwise to reduce the gap and counter-clockwise to in-...
  • Page 79 Frame and Frame Components Pry up on the fifth wheel plate below the 3. Using a Holland Kingpin Lock Tester, part num- pin boss, and measure the vertical move- ber TF-TLN-1000 or TF-TLN-5000, check the ment. operation of the locking mechanism by opening and closing the locks.
  • Page 80 Frame and Frame Components ConMet Simplex greased. A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the Apply a heavy coat of grease to the top plate, either fifth wheel.
  • Page 81 Frame and Frame Components 09/06/2001 f310885 1. Pivot 3. Cam Plate 2. Cam Track Fig. 7, Holland Fifth Wheel Cam Plate 2. Grease the trailer connector with a lithium-based dielectric grease. 31/5 Business Class M2 Maintenance Manual, July 2018...
  • Page 83 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspecting .

  • Page 85: Safety Precautions

    WARNING 32–01 Suspension Inspecting Failure to replace the forward spring brackets, equalizer brackets, or rear spring brackets if they Freightliner Spring Front and are worn, cracked, or otherwise damaged could result in progressive damage to and eventual Rear Suspension Spring breakage of the bracket.
  • Page 86 Attempt to move with a new one. the equalizer up and down, by using a pry bar between the top of the equalizer and the top of Freightliner 23K, 26K, 30K the equalizer bracket. Apply hand-pressure only. Spring Single and Tandem Fig.
  • Page 87 CAUTION 9. Check that all air springs are inflated. Failure to relocate obstructing parts could result Freightliner AirLiner Control Rod in damage to the air spring. Check 1. Without disconnecting the control rods, use your hand to attempt to move each of the control rod...
  • Page 88 4. Check for cracks in the metal components and the control rods for wear or damage. Re- welds. place if necessary. NOTE: The Freightliner AirLiner Suspension is Inspect the rubber bushings for cracks or manufactured at numerous weight ratings up to cuts.
  • Page 89 Suspension Hendrickson Leaf Spring Assembly Inspection 1. Inspect the spring hangers for wear of the spring pin holes, cams, and the spring hanger legs. See Fig. 05/27/93 f320039a 1. Beam Hanger 3. Jack 2. Equalizer Beam Fig. 4, Raising the Beam End f320112a 05/27/93 A.
  • Page 90 Suspension Hendrickson Radius Rod Keep the vehicle supported by the jack stands for the next operation. Bushing Check 4. Manipulate the walking beam so that a microm- eter, vernier, or dial caliper can be used to deter- 1. Without detaching the torque arms, use your mine the wear area thickness on the bottom hand to attempt to move each of the radius-rod face.

  • Page 91: Suspension Lubricating

    Check that the spring or driveline brake is ap- plied, then remove the wheel chocks. 32–02 Suspension Lubricating 05/27/93 320020a Freightliner Spring Front A. Lubricate here. Suspension 1. Cap and Tube Assembly Bushing Fig. 8, Equalizer Assembly Lubrication Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins.
  • Page 92 Suspension Table 1 for U-bolt torque specifications. Turn the wrench in a clockwise motion (looking up) until the torque wrench clicks. Spring Assembly U-Bolt High Nut Torque Values Size Torque: lbf·ft (N·m) Stage 1: Hand-tighten Stage 2: 60 (81) 5/8–18 Stage 3: 200 (271) Stage 4: 180 to 230 (245 to 313) Stage 1: Hand-tighten...
  • Page 93 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–06 Draw Key Nut Torque Checking .
  • Page 95 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 96 Front Axle ™ Easy Steer Kingpins—Axles 2. Make sure the tires touch the ground. Do not raise the vehicle. With Unitized Wheel Ends 3. Clean off all grease fittings prior to lubrication. NOTE: This procedure applies to Easy Steer IMPORTANT: Meritor recognizes that industry Plus ™...
  • Page 97 Front Axle 5. Force lubricant into the upper and lower kingpin 3. Using a grease gun, apply a multipurpose grease fitting caps until new lubricant flows from grease, NLGI grade 1 or 2, to the zerk fitting until between the upper axle beam end and the all the old grease is purged from the boot.
  • Page 98 Front Axle sitions. If the cross tube does not rotate in either direction, replace both tie rod ends. 5. Position yourself directly below the ball stud socket. Using both hands, grab the end as close to the socket as possible, no more than 6 inches (15.2 cm) from the end.
  • Page 99 Front Axle Hub Cap Leak Inspection rod ends are threaded in the cross tube past the clamps and the slots at the cross tube ends. Check for evidence of oil leakage between the hub 9. Check the zerk fittings for damage. If a zerk fit- cap, gasket and hub surface.
  • Page 100 Fig. 10, Wheel Toe-In (overhead view) every three months by a qualified technician from the 7. Place the trammel bar at the front of the tires equipment manufacturer. Freightliner dealers must (see Fig. 11) and adjust the scale end so that have proof of this calibration history.
  • Page 101 Front Axle 09/01/2016 f330298 Fig. 13, Normal Oil Venting plug, see Fig. 14 Fig. 15. Evidence of a leaking 10/05/2016 f400100a vent plug may appear as; • Oil splatter around the wheel Fig. 12, Setting Trammel Bar Pointers • Gooey/gummy oil around the vent plug purge 8.
  • Page 102 Front Axle If there is evidence of excessive leakage, re- move the damaged part and replace it with a new part. 5. Check the oil level in the hub, and fill the hub with new approved oil as needed. 09/01/2016 f330299 Fig.
  • Page 103 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning .
  • Page 105 Rear Axle 35–00 Safety Precautions temperature indicator only, and should not be used as a fill or level hole. Safety Precautions in this section apply to all 4. Check that the lubricant is level with the bottom procedures within this group. of the fill hole.
  • Page 106 Rear Axle 2. When the vehicle is on level ground, the lubri- Detroit Drive Axle Lubricants cant must be level with the bottom of the oil fill hole. If low, add lubricant. See Table 3 for ap- IMPORTANT: Lubricant used in Detroit rear axles must proved axle lubricants and see Table 4 Table...
  • Page 107 Rear Axle Meritor Drive Axle Recommended Lubricant Lubricant Type Ambient Temperature Viscosity Grade Meritor Specification –40°F (–40°C) and up 75W–90 0–76–N Synthetic Gear Oil –40°F (–40°C) and up 75W–140 0–76–M There is no upper limit on the ambient temperature, but axle sump temperature must never exceed 250° (121°C). Table 3, Meritor Drive Axle Recommended Lubricant Meritor Drive Axle Lubricant Capacities for Single Meritor Drive Axle Lubricant Capacities for Tandem...
  • Page 108 Rear Axle that operate continuously at high temperatures must be changed more frequently. NOTICE Failure to change the axle lubricant at more fre- quent intervals, when adverse operating condi- tions require, could result in axle damage. ™ Detroit IMPORTANT: On Detroit axles, the oil change interval for long haul vehicles can be extended to 500,000 miles (800 000 km) for axles with weight ratings of 34,000 to 40,000 lb (15 000 to...
  • Page 109 Rear Axle NOTE: Some Meritor axles have a small tapped 5. Fill the axle with the recommended lubricant. Table 1 for recommended lubricants and and plugged hole located below the housing oil Table 2 for lubricant capacities. fill hole. This smaller hole is for the lubricant temperature sensor only and must not be used NOTE: Some Detroit axles have a small as a fill or level hole.
  • Page 111 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Checking.
  • Page 113 Wheels and Tires 40–01 Wheel Nut Checking IMPORTANT: In addition to the maintenance interval in this manual, check the wheel nut torque the first 50 to 100 miles (80 to 160 km) of operation after a wheel has been removed and installed.
  • Page 115 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting ..............41–01 Driveline Lubricating.
  • Page 117 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 118 Driveline 09/19/2001 f410486 Fig. 3, Examine the Slip Yoke Spline Approved Lubricants Lubricant and Specification Lubricant Brands Phillips Petroleum Philube MW–EP2 Grease Exxon 5160 Amalie All Purpose Grease with Moly–L1–2M Universal joint, slip joint, and spline grease Shell Super Duty Special FF must meet ArvinMeritor Specification O–634–B Marathon Maralube Molycode 529 (NLGI Grade No.
  • Page 119 Driveline 09/19/2001 f410485 Fig. 4, Lubrication Areas for Full-Round and Easy Service Drivelines 41/3 Business Class M2 Maintenance Manual, August 2015...
  • Page 121 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake Inspecting and Leak Test ........... . . 42–11 Air Brake System Valve Inspection .
  • Page 123 Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all 5. Loosen the bolt that secures the upper mounting bracket strap. procedures within this group. 6. Remove the two bolts and Nylok® nuts that se- DANGER cure the air dryer to the lower mounting bracket.
  • Page 124 Brakes 08/09/95 f421383 1. 5/16 x 4-1/2 Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Bolt 10. O-Ring 19. 1/4-Inch Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. Lockwasher 12. Lower Mounting Bracket 21.
  • Page 125 Brakes spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury. 4. Remove and discard both O-rings from the car- tridge bolt. 5. Using a clean rag, wipe clean the inside of the end cover.
  • Page 126 Brakes 42–03 Governor D–2A Check 12.4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover. With the com- IMPORTANT: Review the warranty policy before pressor in loaded mode (compressing performing any intrusive maintenance proce- air), apply a soapy solution to these dures.
  • Page 127 Brakes When proper adjustment is obtained, Apply the parking brakes. Chock the tires tighten the adjusting screw locknut, and to prevent vehicle movement. install the top cover. The pressure range Remove one or more of the lining inspec- between cut-in and cut-out is not adjust- tion plugs, and measure brake lining able.
  • Page 128 Brakes for a Haldex slack adjuster. Use standard chassis lubricant for Haldex slack adjusters. 02/01/2001 f421649a 06/26/2007 f422363c 1. Grease Fitting 2. Slack Adjuster Fig. 5, Haldex Automatic Slack Adjuster Grease Fitting Fig. 4, Dana Spicer Automatic Slack Adjuster 42–06 Meritor Camshaft Gunite Bracket Lubrication For operating temperatures of –20°F (–29°C) and...
  • Page 129 Brakes 10/07/2016 f420011a A. Grease Exit 1. Brake Chamber 2. Slack Adjuster 3. Non-Pressure-Relief Grease Fitting Fig. 7, Camshaft Bracket Lubrication 42–07 Meritor Slack Adjuster Lubrication 10/27/93 f420653a IMPORTANT: Perform a brake inspection follow- 1. 7/16-Inch Adjusting 6. Clevis 7. 1/2-Inch Clevis Pin ing the instructions in this group before lubricat- 2.
  • Page 130 Brakes For slack adjusters with grease fittings and for oper- Every 900 operating hours, or 25,000 miles (40 225 ating temperatures below –40°F (–40°C) and above km), or 3 months: –65°F (–54°C), use an NLGI Grade 2 synthetic oil, 1. Check for moisture in the air brake system by clay-base grease.
  • Page 131 Brakes them. Refer to troubleshooting information in again check the resistance. Resistance Bendix service literature. should exceed 1000 ohms. If resistance values obtained are within stated limits, 3. Check for excessive leakage around the purge the thermostat and heater assembly is valve with the compressor in the loaded mode operating properly.
  • Page 132 Brakes 42–10 Brake Pedal Linkage and 11. If necessary, start the engine and charge the air system. Shut down the engine and release the Mounting Plate parking brakes. Inspection 12. Make and hold a full service brake application, allowing the pressure to stabilize for one minute. Inspect the pedal, pedal linkage, and mounting plate Observe the installed service reservoir gauges.
  • Page 133 Brakes 42–12 Bendix E-6 Foot Control pressure at which the knob automatically comes out. This pressure should be 20 to 45 psi (138 to Valve Inspection and 310 kPa). Lubrication 18. Close the drain cocks, recharge the system, and completely drain the primary reservoir. On ve- hicles equipped with a DRM or AD-IS with the air 1.
  • Page 134 IMPORTANT: This procedure should be per- not turn, no further work is needed. If they turn, formed prior to lubrication of the brake compo- take the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that nents.
  • Page 135 Brakes 09/28/2018 f580518 Fig. 11, DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor 42/13 Business Class M2 Maintenance Manual, November 2019...
  • Page 136 If they turn, 1. Park the vehicle on a level surface, shut down take the vehicle to an authorized Freightliner the engine, and set the parking brake. Chock the dealer to have all of the caliper bolts on that tires.
  • Page 137 If they turn, not turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner take the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that dealer to have all of the caliper bolts on that wheel end replaced.
  • Page 138 Brakes 07/30/2018 f422655 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 13, Meritor Radial Mounted Caliper Tightening Pattern 5. Install the wheel assemblies. For instructions, ponents. Improperly maintaining the vehicle brak- see Group 40 of the vehicle workshop manual ing system may lead to brake failure, resulting in for repair procedures.
  • Page 139 Brakes 07/30/2018 f422657 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 14, Wabco Maxxus Radial Mounted Caliper Tightening Pattern for improper operation or adjustment of the auto- 5. Check all of the foundation brake components for matic slack adjuster.
  • Page 140 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (45) 2 (51) Gunite ‡ 2-1/4 (57) 2 (51) Long Stroke 2-1/2 (64) 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke...
  • Page 141 Manual for replacement instructions, or take the tridge that was originally installed on the dryer. Oil vehicle to an authorized Freightliner dealer. coalescing cartridges can be used in any applica- 42/19...
  • Page 142 Brakes 42–16 Versajust Slack Adjuster tion, but require more frequent service intervals. Do not replace an oil coalescing cartridge with a Inspection and standard cartridge, as this may result in contami- nation and malfunctioning of downstream air sys- Lubrication tem components. Refer to Fig.
  • Page 143 Brakes With the system charged and pressure stabilized in Actuator Stroke–Standard Stroke the system, there should be no leaks at the drain Recommended Maximum valve exhaust port. A constant slight exhaust of air at Brake Actuator Size Operating Stroke (Inches) the drain valve exhaust port could be caused by ex- 1-3/4 cessive leakage in the air brake system.
  • Page 145 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .

  • Page 147: Drag Link Inspection

    Steering 46–00 Safety Precautions If there is 1/8-inch (3-mm) movement or more, do not drive the vehicle until the drag link is replaced. Safety Precautions in this section apply to all 46–02 Power Steering Fluid procedures within this group. Changing DANGER When working on the vehicle, shut down the en- WARNING...

  • Page 148: Drag Link Lubrication

    Steering 46–03 Power Steering Fluid 5. Remove the bolts, nuts, and washers that attach the power steering reservoir to the mounting Level Inspecting bracket. Drain the power steering fluid from the reservoir, but do not remove the supply line to 1.
  • Page 149 Steering 4. Remove the filter, filter cover, and gasket from the reservoir. 5. Disconnect the filter from the filter cover, and dis- card the filter. 6. Apply a thin film of power steering fluid on the gasket of the new filter. Then attach the filter to the filter cover.
  • Page 151 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Cylinder Inspecting............47–07 CNG Fuel System Inspecting .

  • Page 153: Safety Precautions

    Fuel 47–00 Safety Precautions source. Do not drain fuel near, or expose fuel vapor to open flame or intense heat. Exposure to open flame or intense heat could start a fire, pos- Safety Precautions in this section apply to all sibly resulting in personal injury or property dam- procedures within this group.
  • Page 154 Fuel 6. Spin the bowl onto the new element, then spin has reached the top of the filter element, follow them both onto the filter head, snugly, by hand the procedure below to replace the element. only. 3. Put a clean receptacle under the fuel/water sepa- rator and attach a piece of hose to the drain IMPORTANT: Do not use tools to tighten the valve, to direct fuel into the receptacle.
  • Page 155 Fuel FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 3, DAVCO Collar Wrench 11.3 Install and hand-tighten the vent cap O-ring and vent cap. 11.4 Start the engine. When the lubricating oil reaches its normal operating pressure, increase engine speed to high idle for one to two minutes to purge air from the system.
  • Page 156 Fuel element is completely covered. If the fuel level three additional ribs, depending on the specific has reached the top of the filter element, follow filter model. the procedure below to replace the element. 10. Prime the system 3. Put a clean receptacle under the fuel/water sepa- 10.1 Ensure that the drain valve is closed.
  • Page 157 Fuel 1. Arrow (on the 3. Separator Plate endplate) 4. Key 2. Keyway 5. Endplate Fig. 5, Positioning the Filter Element 06/09/2016 f470689 1. Drain Valve 8. Filter Element 1. Mounting Head 2. Sight Bowl 2. Drain Valve Cap 9. Spring 3.
  • Page 158 Fuel 4. Remove the element, bowl O-ring, and element NOTICE o-ring. Dispose of them in an environmentally acceptable manner. Do not use a high-pressure washer or steam 5. Thoroughly clean all of the threads and sealing cleaner on natural gas fuel system plumbing com- surfaces.
  • Page 159 Fuel 05/29/2009 f470534 05/05/2010 f470533 1. Fuel Fill Fitting 4. Fill Vent Fitting (vent) 2. Fuel Outlet Line 5. Shroud Cover 1. Pressure Control 7. Primary Relief Valve (liquid) 6. Shroud Cover Latches Regulator 8. Tank Pressure Gauge 3. Primary Relief Vent 2.
  • Page 160 Fuel Fuel Level Sender Component 47–04 LNG Vacuum Integrity Inspecting Testing 1. Inspect the fuel level sender wiring harness for signs of loose connections or damage. Look for WARNING cracking or signs of moisture intrusion. Natural gas is highly flammable. See the safety 2.
  • Page 161 Fuel 06/29/2009 f470536 1. Pressure Relief Device 5. Coolant Inlet Line 9. Pressure Gauge 2. Fuel Inlet Line 6. Vaporizer 10. Overpressure Regulator 3. Check Valve 7. Fuel Shutoff Solenoid Valve 11. Pressure Relief Valve 4. CNG Quick-Connect Port 8. Coolant Outlet Line 12.
  • Page 162 Fuel 47–05 CNG Fuel System Inspecting WARNING Natural gas is highly flammable. See the safety precautions listed in Chapter 16 of the Business Class® M2 Driver’s Manual or Group 47 of the Business Class® M2 Workshop Manual. Failure to observe these precautions could lead to the igni- tion of the natural gas, which could cause serious bodily injury or death.
  • Page 163 Fuel CYLINDERS INSPECT CYLINDERS EVERY 36 MONTHS OR 36000 MILES WHICHEVER OCCURS FIRST REGULATOR INSPECT PRESSURE NATURAL RELIEF DEVICE EVERY 2000 MILES VEHICLE 110 PSIG OPEN VALVE FILTER SLOWLY DRAIN HOUSING EVERY 1500 MILES 3600 PSIG MAX. REPLACE ELEMENT SERVICE PRESSURE EVERY 3000 MILES 04/30/2010 f470556...
  • Page 164 Fuel 05/04/2010 f470558 1. Coolant Inlet Port 9. Fuel Fill Port 2. Coolant Outlet Port 10. Filter Housing 3. Pressure Relief Valve 11. Filter Bowl 4. Pressure Regulator 12. Filter Drain Plug 5. Wiring Harness 13. Solenoid Valve 6. Manifold Bleed Valve 14.
  • Page 165 Fuel ation, broken fibers, loose brackets, damaged gaskets or isolators, heat damage, or other prob- lems. Refer to Compressed Gas Assocation (CGA) pam- phlet C-6.4, Methods for External Visual Inspection of Natural Gas Fuel Containers and Their Installations, for inspection requirements and inspector qualifica- tions.
  • Page 167 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement............49–03 CAT CGI Bellows and Piping Inspection .
  • Page 169 • DEF Metering Unit—mixes DEF with com- system if the noise level of the vehicle has in- creased. Freightliner Trucks recommends replacing pressed air, and meters this mixture into the exhaust flow via an injection nozzle.
  • Page 170 Exhaust 1. Check for leakage at the clamp that attaches the 11. Check any wires, lines, or hoses within 4 inches exhaust pipe to the turbocharger exhaust outlet. (10 cm) of the exhaust system for heat damage. If leakage exists, tighten the nut on the clamp to Repair or reroute as needed.
  • Page 171 Exhaust 08/20/2009 f490355 NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the DOC inlet pressure sensor. 1. DOC Outlet Temperature 6. Exhaust Outlet 11. SCR Outlet NOx Sensor Port Sensor 7.
  • Page 172 Exhaust 09/16/2009 f490353 1. DEF Metering Unit 5. DOC Inlet Temperature Sensor 9. DPF Outlet Temperature 2. DEF Nozzle 6. DOC Inlet Pressure Sensor Sensor 3. SCR Outlet Temperature 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor Sensor 8.
  • Page 173 Exhaust 09/16/2009 f490354 1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 9. SCR Outlet Temperature 2. DOC Inlet Temperature Sensor Sensor Sensor 3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 10. SCR Sensor Box 4. DPF Sensor Box 8.
  • Page 174 Exhaust 10/20/2006 f490283 A. Inspect this area of the canister for dents. 1. Marmon Fitting at Inlet from Turbocharger 6. Sensor Housing 2. DOC Temperature Sensor 7. DPF Outlet Temperature Sensor 3. ATD Mounting Band 8. Exhaust Outlet Marmon Fitting 4.
  • Page 175 Exhaust 49–03 CAT CGI Bellows NOTICE Replacement When shortening the CGI pipe(s), it is critical to leave a minimum of 1 inch (25.4 mm) of straight On vehicles with CAT EPA07 compliant engines, re- pipe on the end of each CGI pipe to allow for pipe place the CGI bellows at the M3 maintenance inter- insertion and clamp clearance.
  • Page 176 Exhaust 02/24/2011 f490456 1. Clamp 5. Slip Clamp 8. Center Pipe 2. Inlet Pipe 6. CGI Bellows 9. Clamp 3. U-Clamp 7. Center Pipe-Support Brace 10. Outlet Pipe 4. Forward Pipe-Support Brace Fig. 6, CAT EPA07 Exhaust Installation with CGI Bellows 01/29/2010 f490415 02/23/2011...
  • Page 177 Exhaust 02/23/2011 f490458 A. At least 7/16 inch (10 mm) 1. Forward CGI Pipe 3. Aft CGI Pipe 2. CGI Bellows Fig. 9, CGI Bellows Installation 02/08/2010 f490417 1. CGI Bellows 4. Graphite Gasket 2. Slip Clamp 5. Forward CGI Pipe 3.
  • Page 179 Electrical, Instruments, and Controls Trailer Cable Inspection and Cleaning 1. Disconnect the trailer electrical cables from the sockets at the cab. 2. Inspect the cables and sockets for evidence of corrosion, and clean as necessary. If a socket is too badly corroded to clean, replace it. Freight- liner recommends also replacing the socket’s harness as well, if the corrosion has gotten into the wires and connectors inside the socket.
  • Page 181 Electrical, Instruments, and Controls Electrical Component not have signs of thermal distortion, warping, dis- coloration, high amperage heating or discoloring. Inspection If needed, disconnect cables, scrub and clean as needed using a nylon brush. Clean debris with 1. Park the vehicle, apply the parking brakes, and vacuum or electrical contact cleaner such as shut down the engine.
  • Page 182 Electrical, Instruments, and Controls protective wrap must be repaired and harness must be wrapped and secured to prevent further damage. When possible, harness should be routed with drip loop. 12. Inspect fuses and relays for correct fit, and that the terminals hold the fuses and relays firmly in place.
  • Page 183 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–02 Mirror Folding Check .
  • Page 185 60–01 Mirror Folding Check For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror.
  • Page 187 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seals Lubricating ............. . 72–01 Business Class M2 Maintenance Manual, June 2002...
  • Page 189 Doors 72–01 Door Seals Lubricating NOTE: Only the door seals require lubrication. Do not lubricate the door latches or hinges. They come from the manufacturer with lifetime lubrication and require no maintenance. Lightly coat the door seals with a lubricant that is safe for rubber.
  • Page 191 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting............83–01 HVAC Air Filter Replacing.
  • Page 193 Heater and Air Conditioner 83–00 Safety Precautions 8. Use a feeler gauge to check that the drive plate clutch clearance is 0.016 to 0.031 inch (0.4 to 0.8 mm). If the gap is not even around the Safety Precautions in this section apply to all clutch, gently tap down at the high areas.
  • Page 194 Heater and Air Conditioner 8. Using capscrews, attach the evaporator service cover to the HVAC assembly. 9. Connect the wiring harness to the evaporator probe. 10. Attach the lower HVAC cover to the dash panel. For instructions, see Group 60 of the Business Class®...
  • Page 195 Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication............88–01 Business Class M2 Maintenance Manual, November 2014...
  • Page 197 Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 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. Clean both the hood- and cab-mounted hood rear support components with a soapy water so- lution.

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