Western Star 49X 2020 Maintenance Manual
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Western Star 49X 2020 Maintenance Manual

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47X AND 49X MAINTENANCE MANUAL
Models: 47X
49X
STI-507-3 (09/10/2021)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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  • Page 1 47X AND 49X MAINTENANCE MANUAL Models: 47X STI-507-3 (09/10/2021) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or hours of operation. Perform daily, pretrip inspection and maintenance as outlined in the Western Star 47X and 49X Driver’s Manual.
  • Page 4 © 2020–2022 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC.
  • Page 5 EZWiring EZWiring ™ makes Western Star, Freightliner, Freightliner Custom Chassis Cor- poration, Sterling, and Thomas Built Buses products’ wiring drawings and float- ing 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 Western Star Maintenance Manual page, see Fig. Rear Axle 35−01 Drive Axle Lubricant Level Check NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
  • Page 8 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 09 ......Air Intake 13 .

  • 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 Determining Scheduled operating conditions. Unusual vehicle operating conditions may require service at more frequent Maintenance Intervals intervals. Performing regular maintenance on your Western Star vehicle will help ensure that your vehicle deliv- ers safe reliable service and optimum performance for years to come.
  • Page 12 General Information Service Schedule Table: 00–02 Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles Initial Maintenance (IM) first 10,000 16 000 Schedule I Maintenance 1 (M1) every 10,000 16 000 (Short-Haul Transport) vehicles that annually travel less than 60,000 Maintenance 2 (M2) every 50,000...
  • Page 13 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles IM and M1 10,000 16 000 20,000 32 000 30,000 48 000 40,000 64 000 M1 and M2 50,000 80 000 60,000...
  • Page 14 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles 36th 360,000 576 000 37th 370,000 592 000 38th 380,000 608 000 39th 390,000 624 000 40th M1 and M2 400,000 640 000 41st...
  • Page 15 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles 71st 710,000 1 143 000 72nd 720,000 1 159 000 73rd 730,000 1 175 000 74th 740,000 1 191 000 75th M1, M2, and M3 750,000...
  • Page 16 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. No. Maintenance Interval Date Miles IM and M1 25,000 40 000 50,000 80 000 75,000 121 000 M1 and M2 100,000 161 000 125,000 201 000 150,000...
  • Page 17 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. No. Maintenance Interval Date Miles M1, M2, and M3 900,000 1 448 000 925,000 1 490 000 950,000 1 529 000 975,000 1 569 000 M1 and M2 1,000,000 1 609 000...

  • Page 18: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–04 The Initial Maintenance table lists all maintenance tenance operations to be performed. All operations operations that are to be performed at the initial listed in the table, along with the operations listed in maintenance (IM) interval.

  • Page 19: M1 Maintenance Interval Operations

    Trip Inspections and Maintenance chapter of the you find detailed instructions in this manual on the Western Star 47X and 49X Driver’s Manual. maintenance operations to be performed. Maintenance M1 Maintenance Interval Operations for Service Schedules I and II...

  • Page 20: M2 Maintenance Interval Operations

    General Information M2 Maintenance Interval Operations: 00–06 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M2 maintenance interval. Maintenance opera- M1 maintenance interval operations at the M2 main- tion numbers are reference numbers used to help tenance interval.
  • Page 21 General Information M3 Maintenance Interval Operations: 00–07 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M3 maintenance interval. Maintenance opera- M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval.

  • Page 22: Maintenance Operation Sets Table

    General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 09–01 Air Cleaner Inspection • 13–01 Air Compressor Inspection • • • • 15–01 Alternator, Battery, and Starter Connections Check • • 20–01 Pressure Relief Cap Check •...
  • Page 23 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 42–05 Brake Inspection • • • • 42–06 Haldex Slack Adjuster Lubrication • • • • 42–07 Meritor Camshaft Bracket Lubrication • •...

  • Page 24: Noise Emission Controls Maintenance

    Western clamping. Star parts. If other than genuine Western Star parts G. Removal of air intake components. are used for replacement or repair of components affecting noise emission control, the owner should be...

  • Page 25: Verification Of Inspections Log

    General Information Verification of Inspections Log: 00–10 Verification of Inspections Log Verification of Inspections Log, Group 20 Verification of Inspections Log — Group 20 — Fan Clutch Date Mileage Item Cost Maintenance Facility Verification of Inspections Log, Group 49 Verification of Inspections Log — Group 49 — Exhaust System Components Date Mileage Item...
  • Page 27 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection ............. . 09–01 47X and 49X Maintenance Manual, August 2020...
  • Page 29 See Fig. If a mounting isolator is damaged, replace it. For isolator replacement instructions, see Section 09.01 of the Western Star 47X and 49X Work- shop Manual. 08/07/2007 f090452 5. Check that the quick connect fitting for the air compressor supply line is fully engaged with the Fig.
  • Page 30 Air Intake 01/17/2012 f090496 1. Steel Plate 2. Rubber Fig. 4, Mounting Isolator 12/05/2019 f090528a 1. Air Cleaner Housing Rear Mounting 2. Nut Bracket 3. Forward Mounting 6. Clamp Isolator 7. Intake Duct 4, Rear Mounting Isolator 8. Clamp Fig. 3, Air Cleaner Assembly changes in the intake air restriction gauge readings, or loss of power.
  • Page 31 Air Intake 04/15/2020 f090544 1. Pre-Cleaner 2. Filter Housing Fig. 6, Pre-Cleaner Location 09/3 47X and 49X Maintenance Manual, August 2020...
  • Page 33 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 35 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 37 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 39 Batteries generate explosive gas as a by-product nector terminals with a wire brush. See Group of their chemical process. Do not smoke when 54 of the Western Star 47X and 49X Workshop working around batteries. Put out all flames and Manual for adjustment, repair, or replacement remove any source of sparks or intense heat in instructions.
  • Page 40 Alternators and Starters 6. Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed. 7. Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning.
  • Page 41 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) ..........20–03 Pressure Relief Cap Check.
  • Page 43 Engine Cooling/Radiator 20–00 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 44 Engine Cooling/Radiator surge of scalding coolant that could cause seri- ous personal injury. 3. Remove the surge tank cap. 4. Remove the drain plugs from the radiator tank. Allow the coolant to drain. 5. Disconnect the radiator upper and lower hoses, and install the surge tank cap and the radiator tank drain plug.
  • Page 45 Secure the connection if repaired or replaced after performing the checks loose; replace wires and connectors if damaged. below, see Group 20 of the Western Star 47X 3. Check the fan for bent, cracked, or damaged and 49X Workshop Manual for instructions.
  • Page 46 Engine Cooling/Radiator 4. Check the fan belt for wear, tension, and align- ment. Correct if necessary. 5. Check for wear on the friction facing. Replace the friction facing if it is worn to a 3/16-inch (4.8- mm) thickness or less. Also check the facing for signs of oil contamination or burn marks.
  • Page 47 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubrication........... . . 25–01 Fluid Change, Hydraulic Clutch Control.
  • Page 49 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 50 Clutch Hydraulic clutch control fluid is hazardous. It may be a skin irritant and can cause blindness if it gets in your eyes. Always wear safety glasses when handling it or bleeding hydraulic lines. If you get it on your skin, wash it off as soon as possible. NOTICE Do not spill hydraulic clutch control fluid on the cab paint.
  • Page 51 Clutch Manual Bleeding 3. Remove the reservoir lid (see Fig. 3) and install the pressure bleed adaptor on the reservoir. 1. Park the vehicle on a level surface, shut down 4. Bleed the hydraulic system as follows. the engine, and set the parking brake. Chock the Open the bleed valve on the bleed tank tires and open the hood.
  • Page 53 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ™ Detroit Automated Transmission Fluid Change and Magnetic Plug Cleaning..... . 26–01 ™...

  • Page 55: Detroit Automated Transmission Fluid Change And Magnetic Plug Cleaning

    Transmission 26–00 Safety Precautions 2. Clean the area around the fill plug, then remove it from the side of the gear case. Remove the drain plug from the bottom of the case. See Fig. Safety Precautions in this section apply to all procedures within this group.

  • Page 56: Detroit Automated Transmission Fluid Level Inspection

    Transmission the Transmission Fluid Service Information bro- chure at http://dtna.info/DT12FluidsManual approved transmission lubricants. 5. Clean the fill plug and install a new seal on it. Install the plug in the side of the gear case, then tighten it 45 lbf·ft (60 N·m). 26–03 Eaton Fuller A.
  • Page 57 Transmission 4. Install each drain plug and tighten them 50 lbf·ft For more information and a complete listing of (68 N·m). Eaton approved lubricants, refer to the Eaton website, www.roadranger.com. NOTE: For an Eaton Fuller transmission, the optional transmission fluid filter is a remote- Approved Manual Transmission Lubricants mount, spin-on type, and is located between the Transmission...

  • Page 58: Eaton Fuller Transmission Fluid Level Inspection

    Transmission Some transmissions are equipped with a sight glass Eaton Fuller Transmission Lubricant Capacities for checking the fluid level. For transmissions not so Transmission Model Refill Capacity: qt (L) equipped, check the fluid level at the fill plug. UltraShift PLUS Checking at the Fill Plug 13.0 (12.0) MHP and MXP...
  • Page 59 Transmission WARNING Drain the air supply; if the air supply is not drained before the air filter/regulator is serviced, serious injury and component damage could re- sult. 2. Clean the outside of the air filter/regulator with cleaning solvent. See Fig. 1.
  • Page 60 Transmission 10/17/2001 f260052a 1. Air Regulator 5. Small O-Ring 2. Housing 6. End Cap 3. Large O-Ring 7. Plug 4. Filter Element Fig. 6, Eaton Fuller Transmission Air Filter/Regulator Components through the element (inside to outside) to loosen surface dirt and to dry the element. If it is not damaged, the sintered metallic filter element will last the life of the vehicle.
  • Page 61 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 63: Safety Precautions

    Frame and Frame Components 31–00 Safety Precautions of the locking mechanism by opening and closing the locks. See Fig. 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.
  • Page 64 Frame and Frame Components 12/02/2010 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Bumper 2. Flat Washer, 5/8" 12. Flat Washer 20. Timer Spring 3. Wedge Stop Rod Spring 13.
  • Page 65 Frame and Frame Components 6. Check the jaw and stationary jaw for mushroom- top plate. Lubricate grease channels in the top ing, and check that the serrations at the jaw and plate using a lithium complex grease, suitable for wedge are in good condition and not fully worn use in high pressure applications.

  • Page 66: Fifth Wheel Lubrication

    Frame and Frame Components The lock is too loose if: you feel fore-aft play Apply a generous coating of grease to the top when pulling and pushing on the lock tester plate to fill the grooves, or depressions, on the handle.
  • Page 67 Frame and Frame Components 09/02/2009 f311100 1. Jam Nut 3. Grease Zerk 2. Adjustment Bolt Fig. 5, Jost Fifth Wheel NOTE: Do not use a lube plate (high density polyethylene) on top of the fifth wheel or on the kingpin instead of grease. The additional thick- ness of this material can prevent the fifth wheel and trailer from experiencing a proper coupling event.
  • Page 68 Frame and Frame Components Lightly oil other moving parts in the fifth wheel. 12/03/2010 f311136 Use a light oil (such as SAE 10W or 20W motor oil) to lubricate the cam track and pivot. 1. Pull Handle 3. Wedge 2. Jaw 1.

  • Page 69: Frame Fastener Torque Check

    Frame and Frame Components • equalizer brackets parts. For sliding fifth wheels spray diesel fuel on the slide path of the base plate. • exhaust brackets Lubricate the Slide Release Arm center pivot bushing • fifth wheel legs using Lithium based EP rated grease. The zerk is •...
  • Page 71 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 73: Safety Precautions

    Suspension Check Group 32 of the Western Star 47X and 49X Work- shop Manual. Components Checking Inspect the spring pin bushings. If there is any indi-...
  • Page 74 Suspension breakage, possibly leading to loss of vehicle con- and build the secondary air pressure to at least trol and resulting in personal injury or property 100 psi (690 kPa). Shut down the engine. Have damage. an assistant chock the tires on one axle only. 2.
  • Page 75 4. If the measurement is not within the acceptable range, refer to Section 32.01, Subject 100 in the Western Star 47X and 49X Workshop Manual for adjustment instructions. If the dis- tance is within the acceptable range, apply the parking brakes.
  • Page 76 Suspension 02/21/2017 f320961a Suspension Height Measurement Measure Point 02/21/2017 f321046a Target Suspension Height Measurement 2-3/8 inch 2-1/2 inch 2-7/8 inch A = Measure Here Measure Point (60 mm) (64 mm) (73 mm) Target Table 3, Suspension Ride-Height Measurement, 2-3/4 inch 3 inch 3-1/4 inch A = Measure Here...
  • Page 77 If the nut turns on the second application, the bolt is stretching and must be replaced. See Group 32 of the Western Star 47X and 49X 32/5 47X and 49X Maintenance Manual, February 2021...
  • Page 79 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Knuckle Pin Lubrication .
  • Page 81 For in- grease is seen at the bushing grease seal opposite structions, refer to Group 33 of the Western Star the fittings. The grease seal will accept grease pres- 47X and 49X Workshop Manual.
  • Page 82 Front Axle 33–03 Tie Rod Lubrication Detroit and Meritor Axles For any Detroit or Meritor axle that requires lubrica- tion of the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud...
  • Page 83 Front Axle Positive camber is the outward tilt of the wheel at the caster angle that exceeds specifications could cause top. Excessive positive camber in one wheel causes vehicle shimmy, road shock, and an increased steer- the vehicle to pull in the opposite direction, rapidly ing effort.
  • Page 84 Group 40 in this manual and Group 40 in the weight distribution. Anything that changes the Western Star 47X and 49X Workshop Manual for ratio of weight on the springs affects the align- more information. Replace any tire that is exces- ment angles and also the tire tread contact area.
  • Page 85 Refer to Section either an extreme right or left position. Although front 33.01, Subject 110 in the Western Star 47X and wheel movement can be limited by the amount of 49X Workshop Manual.
  • Page 86 Using the alignment equipment manufacturer’s oper- nents. For poppet valve adjustment instructions, ating instructions, measure the front wheel caster. refer to Group 46 in the Western Star 47X and 49X Workshop Manual. Compare the caster angles with those shown in the appropriate table in Alignment Specifications in this...
  • Page 87 Front Axle Weak or broken leaf springs, or worn shackle 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 88 Front Axle 2. Road test the vehicle. Alignment Specifications Caster IMPORTANT: Caster angle settings for the left and right sides should be a minimum of 1.0 de- gree and no more than 5.0 degrees apart from each other, while not exceeding the upper and lower limits.
  • Page 89 Front Axle Western Star 47X and 49X Front Suspension, Set Back Axle - 49-00267-101/Set Forward Axle - 49-00267-102 Description Units Target Tolerance Caster LH (degrees) ±1.5 IMPORTANT: LH and RH caster angle settings should be a minimum of 1.0 degree and no more than 5.0...
  • Page 90 Front Axle Western Star 47X and 49X Front Suspension, Set Back Axle - 49-00267-101/Set Forward Axle - 49-00267-102 Description Units Target Tolerance Tracking/Lateral Inches ±0.25 Offset 02/08/2017 f330306 Rear Suspension RDA Thrust Degrees ±0.18 Angle 02/08/2017 f330307 FDA/RDA Scrub Degrees ±0.08...
  • Page 91 Front Axle Camber Camber, Detroit and Meritor Axles Left Camber: Right Camber: Axle Model degrees degrees –1/4 ± 7/16 –1/4 ± 7/16 Table 2, Camber, Detroit and Meritor Axles Camber, Dana/Eaton Axles Left Camber: Right Camber: Axle Model degrees degrees All E Series +1/4 ±...
  • Page 92 Front Axle 33–05 Steer Axle Hub Cap Vent Plug Inspection General Information As a function of their design, hubcap vent plugs will on occasion exhibit signs of hub oil on their exterior surface. Depending on environmental conditions and/or age of the plug, the amount of oil present can vary.
  • Page 93 Front Axle clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes.
  • Page 95 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection......... . 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning.
  • Page 97 Rear Axle 35–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, 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 98 Rear Axle For magnetic plugs, use a piece of key Detroit Drive Axle Lubricant, Model 4 and Model 6 stock or any other convenient steel slug Ambient to short the two magnetic poles and divert Lubricant Type Temperature the magnetic field. Mobil Delvac 1 Gear –40°F (–40°C) and Synthetic...
  • Page 99 Rear Axle 04/28/2020 f350692 04/28/2020 f350693 ™ Fig. 3, Detroit New Final Drive Forward Axle, Oil Fill Location ™ Fig. 4, Detroit New Final Drive Rear Axle, Oil Fill Location ture, the oil will run more freely and ensure that the axle is flushed.
  • Page 100 Rear Axle New Final Drive Oil Capacity, New Final Drive Axle Type Oil in Hubs (2) Oil in Axle NFD Model 6 TP 1.8 L 9.5 L NFD Model 6 SP 1.8 L 11 L Table 4, New Final Drive Oil Capacity, New Final Drive Meritor®...
  • Page 101 Rear Axle Meritor Drive Axle Recommended Lubricant Recommended Lubricant SAE Ambient Temperature Meritor Specification Lubricant Type Viscosity Grade Synthetic Gear Oil –40°F (–40°C) and Up 75W–90 0–76–N There is no upper limit on these outside temperatures, but axle sump temperature must never exceed 250°F (121°C). Table 5, Meritor Drive Axle Recommended Lubricant 5.
  • Page 102 Rear Axle 2. Clean the fill plug and the area around it. In the axle housing rear cover, remove the plug from the oil fill hole (or standpipe, if installed in the oil fill hole). See Fig. 10/05/2016 f350017a 1. Magnetic Strainer 2.
  • Page 103 Rear Axle 6. Fill the axle with the recommended lubricant. Fill the axle through the oil fill hole or Table 7 for recommended drive axle lubri- standpipe opening. Lubricant should be cants, and Table 8 for drive axle lubricant ca- level with the bottom of the oil fill hole, or pacities.
  • Page 104 Rear Axle IMPORTANT: A lubricant level close enough to Meritor® be seen or touched is not sufficient. It must be level with the bottom of the fill hole. NOTICE 5. Install and tighten the fill plug 30 lbf·ft (41 N·m). Failure to keep the rear axle filled to the proper IMPORTANT: Always check the axle breather level with the recommended lubricant can result in...
  • Page 105 Rear Axle 10/06/2016 f350002a 1. Axle Housing Breather 2. Fill Plug 10/05/2016 f350062a 3. Temperature Indicator Plug 1. Axle Housing Breathers Fig. 9, Dana Spicer Axle Housing Breather 2. Carrier Oil Fill Plugs 3. Interaxle Differential level with the bottom of the fill hole, or the top of Fig.
  • Page 107 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Check.
  • Page 109 Truck alignment must be done at the initial mainte- NOTE: Torque values are given for lubricated nance. Refer to Group 33 of the Western Star 47X threads. Apply 2 drops of SAE 30W oil to a and 49X Workshop Manual for instructions on the point between the nuts and flanges.
  • Page 111 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 113 125 lbf·ft (169 N·m) Fig. 3 needed, then tighten the yoke nut. Refer to Group 41 of the Western Star 47X and 49X Table 1, U-Joint Torque Specifications Workshop Manual for torque specifications. If the yoke is still loose after tightening the yoke nut, 3.
  • Page 114 Driveline 10/06/2016 f410067b NOTE: Not all fasteners are shown. 1. Transmission 6. U-Joint Cross 12. Splined Stub Shaft 2. Transmission Output-Shaft 7. Bearing Cup (for yoke strap) 13. Driveshaft Tube End-Yoke (yoke-strap type) 8. Yoke Strap and Capscrew 14. Tube-Yoke (bearing-cap type) 3.
  • Page 115 Driveline Regional Service Office for assistance in deter- mining the correct driveshaft length. 06/02/2016 f410534 1. Yoke 4. Washer 2. Input Flange 5. Nut 3. Bolt 10/07/2016 f410050a Fig. 4, Meritor RPL35 Series U-Joint A. After grease appears, cover the pressure-relief hole while continuing to lubricate.
  • Page 116 Driveline U-joints. If a low-pressure adapter is not used, gun pressure until new grease appears at the U-joints may not receive enough grease. slip joint seal. See Fig. 6. This ensures complete lubrication of the splines. Using lithium 12-Hydroxy stearate grease (NLGI Grade 2, with EP additives), lubricate until new 3.
  • Page 117 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Air Dryer Inspection .

  • Page 119: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions NOTE: The compressor discharge line may still contain residual air pressure, open the line slowly. Safety Precautions in this section apply to all procedures within this group. 3. Identify, tag, and disconnect the three air lines from the end cover.
  • Page 120 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 121 Brakes WARNING Do not attempt to disassemble the desiccant car- tridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury.

  • Page 122: Air Dryer Inspection

    Brakes IMPORTANT: Only use the silicone grease sup- 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that plied with Bendix replacement kits. the system once again builds to full pres- 5. Screw the desiccant cartridge onto the body by sure and is followed by a purge at the hand until the seal makes contact with the body.

  • Page 123: Alcohol Evaporator Cleaning And Inspection

    Brakes 3. Inspect the air dryer for external damage, and check that the unit is tightly mounted on the frame. If the air dryer mounting is loose, repair it. 4. Turn on the ignition switch, but do not start the engine.
  • Page 124 The vehicle should not If the caliper mounting bolts turn at all, take the move. If the vehicle moves, the parking brakes vehicle to an authorized Western Star dealer for are not operating correctly and must be repaired repair.
  • Page 125 Brakes Torque Compensation with Meritor Extension Tool 3256B1354 11/11/2016 f422612 All torque settings are ±40 lbf·ft (±54 N·m). Compensation is calculated for a 43.5 inch (110.5 cm) nominal torque wrench using Meritor extension tool 3256B1354 at various angles. Extension Angle Wrench Length Target Torque Tool Setting...
  • Page 126 Re- the foundation brake components for wear or pair as needed. damage, and repair as needed. See Group 42 of the Western Star 47X and 49X Workshop Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) †...

  • Page 127: Haldex Slack Adjuster Lubrication

    Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44) Meritor Less than 1-7/8 (48) Long Stroke Less than 2 (51) Standard Stroke Long stroke design is indicated by a tag, or embossing, on the brake chamber. †...

  • Page 128: Meritor Slack Adjuster Lubrication

    Brakes 000 km), whichever comes first. The extended- 4. Grease the S-cam tubes. maintenance camshaft bushings are lubricated Drive Axle S-cam Tube Greasing during the brake reline service interval. For ser- vice and lubrication instructions, see Group 42 1. Park the vehicle on a level surface, shut down of the 47X and 49X Workshop Manual.
  • Page 129 10/20/93 1. Brake Chamber 1. Remove the brake valve from the vehicle; see 2. Clevis Group 42, of the Western Star 47X and 49X 3. Actuator Rod Workshop Manual. 4. Boot 5. Pressure-Relief Capscrew, Gasket, Pawl Spring, 2. Remove the roll pin from the brake pedal pivot and Pawl pin.

  • Page 130: Wabco System Saver Air Dryer Desiccant Cartridge Replacement

    Brakes 42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement NOTE: The following instructions apply to the System Saver 1200, 1200 Plus, and Twin air dryers. NOTICE The WABCO System Saver air dryers can use ei- ther a standard or oil coalescing desiccant car- tridge.
  • Page 131 filter in the adapter which should be replaced. If the drain valve does not function properly, repair or replace it. See Section 42.14 of the Western Star 47X and 49X Workshop Manual. Leakage Test...
  • Page 133 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .
  • Page 135 Steering 46–00 Safety Precautions placement instructions. 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 procedures within this group. 46–02 Power Steering Fluid DANGER and Filter Change When working on the vehicle, shut down the en-...
  • Page 136 Steering tween the MIN COLD and MAX HOT lines. Add more power steering fluid if needed. 15. Turn the steering wheel from full left to full right several times. Add fluid to the reservoir as needed to maintain the fluid level between the MIN COLD and MAX HOT lines.
  • Page 137 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement ............. 47–01 Fuel Tank Band-Nut Tightening.
  • Page 139 Fuel 47–00 Safety Precautions 2. Place a suitable container under the fuel/water separator, to collect the draining fuel. The drain valve has a 3/8 inch (9.5 mm) slip-on hose con- Safety Precautions in this section apply to all nection. procedures within this group. 3.
  • Page 140 Fuel 04/22/2020 f470759 04/21/2020 f470758 1. O-Ring, Filter Element 7. Filter Element 1. Fill Port (Optional) 5. Fuel Heater, 12V 2. O-Ring, Clear Bowl 8. Port Plug, M22 2. Return Fuel Heating 6. WIF Sensor 3. Drain Valve 9. Vent Plug Loop 7.
  • Page 141 Fuel is used for removal. During installation, the vent 3. Put a clean receptacle under the fuel/water sepa- rator and attach a piece of hose to the drain cap is to be hand-tightened only, not tightened valve, to direct fuel into the receptacle. with a wrench.
  • Page 142 Fuel three additional ribs, depending on the specific 3. Empty the filter into a suitable container, and filter model. close the drain plug. 10. Prime the system 4. If equipped, remove the wiring harness connec- tors from the water sensor probe and the heater. 10.1 Ensure that the drain valve is closed.
  • Page 143 Fuel 6. Remove the sight bowl from the filter element. Clean the O-ring seating surface. 7. Apply a thin coating of clean diesel fuel or en- gine oil to the O-ring and the new gasket, and assemble filter and bowl. 8.
  • Page 145 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Maintenance............49–01 Safety Precautions .
  • Page 147 If any of these conditions exist, check the exhaust system compo- nents and alignment. Align or replace as necessary; see Group 49 of the Western Star 47X and 49X Workshop Manual. It is a violation of US federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certification...
  • Page 149 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Component Inspection ............54–02 Trailer Cable Inspection and Cleaning.
  • Page 151 Electrical, Instruments, and Controls 54–01 Trailer Cable Inspection 5. Inspect the component protective cover for proper fit and function. Inspect cover for cracks, and Cleaning broken mounting, missing sealing surfaces, warped or bulged surfaces. The cover must pre- 1. Park the vehicle on a level surface, shut down vent moisture and debris from entering the com- the engine, and set the parking brake.
  • Page 152 Electrical, Instruments, and Controls 9. Check all electrical connectors for correct fit and that the connector locking tabs are in place and will hold the connector firmly into the component. Inspect connector terminals for signs of corro- sion, thermal distortion, warping, discoloration, high amperage heating or discoloring.
  • Page 153 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication .
  • Page 155 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 156 05/07/2012 f602471 NOTE: Baggage door latch shown. Sleeper access door latch is similar. A. Lubricate the latch jaws and the exposed length of cable. 03/31/2016 f720773 Fig. 3, Baggage Door Latch 1. Sleeper Access Door Handle 2. Baggage Door Handle Fig.
  • Page 157 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 159 fittings on all of the air conditioning the tightness of the compressor mounting fasten- components. ers. For instructions and torque values, see Group 01 of the Western Star 47X and 49X 7. Check for a buildup of road debris on the con- Workshop Manual. denser fins.
  • Page 160 Cab Fresh-Air Filter Replacement IMPORTANT: When replacing the air filter, use only a Western Star-approved air filter. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
  • Page 161 L/H side of the sleeper bunk. 5. Install the access panel. IMPORTANT: When replacing the air filter, use only a Western Star-approved air filter. Sleeper Air Filter Replacement 1. Park the vehicle on a level surface, set the park- ing brake, and shut down the engine.
  • Page 162 Heater and Air Conditioner 06/02/2020 f832187 1. Lower Cabinet Door 2. Carpet 3. Air Filter Fig. 5, Sleeper HVAC Access Panel, 72-inch Sleepers (Similar for 60-inch Sleeper) 06/03/2020 f832188 1. HVAC Cover Panel 2. Air Filter Fig. 6, Sleeper HVAC Access Panel, 48-inch Sleeper 5.
  • Page 163 Heater and Air Conditioner 06/02/2020 f832189 1. HVAC Cover Panel 2. Air Filter Fig. 7, Sleeper HVAC Access Panel, 36-inch Sleeper 05/22/2020 f832190 1. Air Filter 2. HVAC Cover Fig. 8, Removing the Dual HVAC System Filter, 72-inch Sleepers (Similar for 60-inch Sleeper) 2.
  • Page 164 Heater and Air Conditioner 04/23/2020 f832191 1. Air Filter Fig. 9, Removing the Dual HVAC System Filter, 48-inch Sleeper 06/01/2020 f832200 1. Lower Bunk 3. Front Center Bunk Partition 4. Storage Compartment Divider 2. Lower Bunk Strut Fig. 10, Lower Bunk Assembly, 48-Inch Sleeper 83/6 47X and 49X Maintenance Manual, August 2020...
  • Page 165 Heater and Air Conditioner 04/23/2020 f832192 1. Air Filter Fig. 11, Removing the Dual HVAC System Filter, 36-inch Sleeper Remove the condenser cover. Fig. 12, Condenser Cover Fasteners (compact style condenser) 83/7 47X and 49X Maintenance Manual, August 2020...

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