108sd and 114sd maintenance manual models: 108sd 114sd and 114sd... · 108sd and 114sd maintenance...

108SD AND 114SD MAINTENANCE MANUAL

Models: 108SD114SD

STI-496-6 (6/12) Published byDaimler Trucks North America LLC

4747 N. Channel Ave.Portland, OR 97217

Printed in U.S.A.

ForewordPerforming scheduled maintenance operations is important in obtaining safe, reliable operation ofyour vehicle. A proper maintenance program will also help to minimize downtime and safeguardwarranties.

IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer toother component and body manufacturers’ instructions for specific inspection and mainte-nance instructions.Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip andpost-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle driver’smanual. Major components, such as engines, transmissions, and rear axles, are covered in their ownmaintenance and operation manuals, that are provided with the vehicle. Perform any maintenanceoperations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has thequalified technicians and equipment to perform this maintenance for you. They can also set up ascheduled maintenance program tailored specifically to your needs. Optionally, they can assist you inlearning how to perform these maintenance procedures.

IMPORTANT: Descriptions and specifications in this manual were in effect at the time ofprinting. Freightliner Trucks reserves the right to discontinue models and to changespecifications or design at any time without notice and without incurring obligation.Descriptions and specifications contained in this publication provide no warranty, expressedor implied, and are subject to revision and editions without notice.Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for moreinformation, or contact Daimler Trucks North America LLC at the address below.

Environmental Concerns and RecommendationsWhenever you see instructions in this manual to discard materials, you should attempt to reclaim andrecycle them. To preserve our environment, follow appropriate environmental rules and regulationswhen disposing of materials.

NOTICE: Parts Replacement ConsiderationsDo not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears)with used parts. Used parts may have been subjected to collisions or improper use and haveundetected structural damage.

© 2012 Daimler Trucks North America LLCAll 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 NorthAmerica LLC. Daimler Trucks North America LLC is a Daimler company.

Daimler Trucks North America LLCService Systems and Documentation (CVI-SSD)

P.O. Box 3849Portland, Oregon 97208-3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic(via ServicePro®) formats.

Workshop/ServiceManual

Workshop/service manuals contain service and repair information for all vehiclesystems and components, except for major components such as engines, trans-missions, and rear axles. Each workshop/service manual section is divided intosubjects that can include general information, principles of operation, removal,disassembly, assembly, installation, and specifications.

Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals forvehicle components and systems. They have information such as lubricationprocedures and tables, fluid replacement procedures, fluid capacities, specifica-tions, and procedures for adjustments and for checking the tightness of fasten-ers. Maintenance manuals do not contain detailed repair or service information.

Driver’s/Operator’sManual

Driver’s/operator’s manuals contain information needed to enhance the driver’sunderstanding of how to operate and care for the vehicle and its components.Each manual contains a chapter that covers pretrip and post-trip inspections,and daily, weekly, and monthly maintenance of vehicle components.Driver’s/operator’s manuals do not contain detailed repair or service information.

Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-ments, and related information. Some service bulletins are updates to informa-tion in the workshop/service manual. These bulletins take precedence overworkshop/service manual information, until the latter is updated; at that time, thebulletin is usually canceled. The service bulletins manual is available only todealers. When doing service work on a vehicle system or part, check for a validservice bulletin for the latest information on the subject.

IMPORTANT: Before using a particular service bulletin, check the currentservice bulletin validity list to be sure the bulletin is valid.

Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins containlists of parts and BOMs needed to do replacement and upgrade procedures.

Web-based repair, service, and parts documentation can be accessed using the following applications on theAccessFreightliner.com website.

ServicePro ServicePro® provides Web-based access to the most up-to-date versions of thepublications listed above. In addition, the Service Solutions feature provides di-agnostic assistance with Symptoms Search, by connecting to a large knowledgebase gathered from technicians and service personnel. Search results for bothdocuments and service solutions can be narrowed by initially entering vehicleidentification data.

PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’sbuild record.

EZWiring EZWiring™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, andFreightliner Custom Chassis Corporation products’ wiring drawings and floatingpin lists available online for viewing and printing. EZWiring can also be ac-cessed from within PartsPro.

IntroductionDescriptions of Service Publications

108SD and 114SD Maintenance Manual, January 2011 I–1

Warranty-related service information available on the AccessFreightliner.com website includes the followingdocumentation.

Recall Campaigns Recall campaigns cover situations that involve service work or replacement ofparts in connection with a recall notice. These campaigns pertain to matters ofvehicle safety. All recall campaigns are distributed to dealers; customers receivenotices that apply to their vehicles.

Field Service Campaigns Field service campaigns are concerned with non-safety-related service work orreplacement of parts. All field service campaigns are distributed to dealers; cus-tomers receive notices that apply to their vehicles.

IntroductionDescriptions of Service Publications

I–2 108SD and 114SD Maintenance Manual, January 2011

For an example of a 108SD and 114SD Maintenance Manual page, see Fig. 1.

f020176

CB

FD E

26

26/1

Transmission

A

02/04/2011

108SD and 114SD Maintenance Manual, April 2011

2. Clean the area around the fill plug, then removethe plug from the side of the gear case.

11/30/2010

A. Full

Fig. 1, Checking Transmission Fluid Level

3. Using your gloved finger or a bent pipe cleaner,check if the fluid is level with the fill opening. See

Clean all dirt from around the end of the fluid fill tubebefore removing the dipstick. Do not allow foreignmatter to enter the transmission. Dirt or foreign mat−ter in the hydraulic system may cause undue wearof transmission parts, make valves stick, and clogpassages.

Transmission Fluid

f260006c

Operating a transmission with the fluid levelhigher or lower than recommended can result intransmission damage. Do not overfill the trans−mission.Do not mix types and brands of fluid, because ofpossible incompatibility. Do not use fluid addi−tives, friction modifiers, extreme−pressure gearfluids, or multiviscosity lubricants.

Level Check26−01

NOTICE

B. Low

A B

Eaton Fuller

Allison

NOTE: Check the transmission fluid level withthe transmission at operating temperature.1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.

Fig. 1.

4. If the fluid level is low, check the transmission forleaks, and correct as needed.

5. If needed, add Eaton−approved fluid until it islevel with the lower edge of the fill opening.Eaton−approved fluid, such as the RoadrangerSAE 50 product, meets the requirements of thePS−164 Rev. 7 lubricant specification. For moreinformation about Eaton lubricant specificationsand suppliers, call 1−800−826−4357 or seew.roadranger.com.

ww−

6. Clean the fill plug, then install it. Tighten the plugas follows:

25 to 35 lbf·ft (34 to 48 N·m) for transmis−sions with 3/4−inch pipe threads.60 to 75 lbf·ft (81 to 102 N·m) for trans−missions with 3/4−inch pipe threads.

NOTE: For Allison transmissions equipped withan oil level sensor, the transmission fluid levelcan be checked electronically. For more infor−mation, refer to the Allison Transmission web−site, www.allisontransmission.com.

Cold Check

It is important to check the fluid level cold to deter−mine if the transmission has a sufficient amount offluid to be safely operated until a hot check can beperformed.1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Run the engine for at least one minute.3. Shift from DRIVE to NEUTRAL, and then shift to

REVERSE to fill the hydraulic system.4. Shift to NEUTRAL and allow the engine to idle

at 500 to 800 rpm.5. With the engine running at idle, remove the dip−

stick from the tube and wipe it clean.6. Insert the dipstick into the tube, then remove it.7. Check the fluid level reading, then repeat the

check procedure to verify the reading.If the fluid level is within the COLD RUN band,the transmission may be operated until the fluidis hot enough to perform a hot check.If the fluid level is not within the COLD RUNband, add or drain fluid as needed to adjust thefluid level to the middle of the COLD RUN band.See Fig. 2.

A. Maintenance Operation Number consists of the Group Number followed by the Sequence NumberB. Group TitleC. Group NumberD. Vehicle NameE. Release DateF. Group Number/Page Number

Fig. 1, Example of a 108SD and 114SD Maintenance Manual Page

IntroductionPage Description

108SD and 114SD Maintenance Manual, January 2011 I–3

Group No. Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor15 . . . . . . . . . . . . . . . . . . . Alternators and Starters20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission31 . . . . . . . . . . . . . Frame and Frame Components32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders

IntroductionMaintenance Manual Contents

I–4 108SD and 114SD Maintenance Manual, January 2011

Title of Maintenance Operation (MOP) MOP Number00–01 Determining Scheduled Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01

00–02 Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02

00–03 M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03





00–08 Maintenance Sequence and Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08

00–09 Noise Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

00–10 Verification of Inspections Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10

00–11 Metric/U.S. Customary Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11

00–12 Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12

General Information 00Index, Alphabetical

108SD and 114SD Maintenance Manual, June 2012

Determining ScheduledMaintenance IntervalsPerforming regular maintenance will help ensure thatyour vehicle delivers safe, reliable service and opti-mum performance. A proper maintenance programwill also help to minimize downtime and safeguardwarranties.To determine the correct maintenance intervals foryour vehicle, you must first determine the type of ser-vice or conditions the vehicle will be operating in.Most vehicles operate in conditions that fall withinone of two schedules. Before placing your vehicle inservice, determine which schedule applies to yourvehicle.

SchedulesSchedule I (severe service) applies to vehicles thattravel up to 6000 miles (10 000 kilometers) annuallyor that operate under severe conditions. Examples ofSchedule I usage are:

• operation on extremely poor roads or wherethere is heavy dust accumulation

• constant exposure to extreme hot, cold, salt air,or other extreme climates

• frequent short-distance travel• construction-site operation• city operation such as fire truck and garbage

truck.

• farm operationSchedule II (short-haul transport) applies to vehiclesthat travel 6000 miles (10 000 kilometers) or moreannually and operate under normal conditions. Ex-amples of Schedule II usage are:

• operation primarily in cities and densely popu-lated areas

• local transport with infrequent freeway travel• high percentage of stop-and-go travel

Maintenance IntervalsAfter determining the schedule appropriate to yourvehicle, refer to Table 1 to determine when to per-form the Initial Maintenance (IM) and the frequencyof performing subsequent maintenance intervals foreach schedule.

Maintenance OperationsThis manual has an index at the beginning of eachGroup that lists the title and number of each mainte-nance operation (MOP) for that Group. Follow theinstructions under the MOP number to perform therequired maintenance.In addition to the maintenance operations requiredfor the maintenance interval, perform all daily,weekly, and monthly maintenance operations listed inChapter 21, "Pretrip and Post-Trip Inspections andMaintenance", of the 108SD and 114SD Driver’sManual.

Maintenance Schedules

ScheduleMaintenance Intervals

Maintenance Interval Frequency Mileage km Hours

Schedule I*(severe service)

for vehicles that travel up to6000 miles (10 000 km) annually

Initial Maintenance (IM) first 1000 1600 100

Maintenance 1 (M1) every 1000 1600 100


Maintenance 3 (M3) every 8000 12 800 800

Maintenance 4 (M4) every 16,000 25 600 1600

Maintenance 5 (M5) every 32,000 51 200 3200

General Information 0000–01 Determining Scheduled Maintenance Intervals

108SD and 114SD Maintenance Manual, June 2012 00/1

Maintenance Schedules

ScheduleMaintenance Intervals

Maintenance Interval Frequency Mileage km Hours

Schedule II(short-haul transport)

for vehicles that travel 6000miles (10 000 km) or more

annually

Initial Maintenance (IM) first 8000 12 000

—


Maintenance 2 (M2) every 16,000 24 000



Maintenance 5 (M5) every 128,000 192 000* For Schedule I vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than mileage.

Table 1, Maintenance Schedules

General Information0000–01 Determining Scheduled Maintenance Intervals

108SD and 114SD Maintenance Manual, June 201200/2

Table 2 lists all maintenance operations that are tobe performed at the initial maintenance (IM) interval.Maintenance operation numbers are reference num-bers used to help you find detailed instructions in thismanual on the maintenance operations to be per-

formed. All operations listed in Table 2, along withthe operations listed in the M1 Maintenance IntervalOperations table (Table 3) must be performed tocomplete the initial maintenance (IM).

Initial Maintenance (IM) OperationsNumber Title

00-03 Perform All M1 Maintenance Interval Operations

31-01 Frame Fastener Torque Check

32-03 Suspension U-Bolt Torque Check

33-04 Alignment Check

47-01 Fuel Tank Band Nut Tightening

Table 2, Initial Maintenance (IM) Operations

General Information 0000–02 Initial Maintenance (IM) Operations


Table 3 lists all maintenance operations that are tobe performed at the M1 maintenance interval. Main-tenance operation numbers are reference numbersused to help you find detailed instructions in thismanual on the maintenance operations to be per-formed.

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations given in Chapter 21, "Pretripand Post-Trip Inspections and Maintenance", of the108SD and 114SD Driver’s Manual.

M1 Maintenance Interval OperationsNumber Title of Maintenance Operation

25-01 Eaton Fuller Clutch Release Bearing Lubrication

25-02 Eaton Fuller Clutch Release Cross-Shaft Lubrication

25-03 Fluid Level Check, Hydraulic Clutch Control

25-05 Clutch Adjustment, Manually Adjusted Clutches

26-01 Transmission Fluid Level Check

26-03 Allison and Eaton Fuller Transmission Breather Check

31-02 Fifth Wheel Inspection

31-03 Fifth Wheel Lubrication

31-04 Trailer Electrical Connector Protection

32-01 Suspension Inspection

32-02 Suspension Lubrication

33-01 Knuckle Pin Lubrication

33-02 Tie Rod Inspection

33-03 Tie Rod Lubrication

35-01 Axle Lubricant Level Check

35-02 Axle Breather Check

41-01 Driveline Inspection

41-02 Driveline Lubrication*

42-01 Air Brake System Valve Inspection

42-02 Bendix Air Dryer Desiccant Replacement†

42-05 Brake Inspection

42-06 Slack Adjuster Lubrication

46-03 Power Steering Fluid Level Inspection

47-04 LNG Fuel System Inspection

47-07 CNG High-Pressure Fuel Filter Element Replacement‡

60-02 Aerodynamic Component Inspection

72-01 Door Seals Lubrication

83-01 Air Conditioner Inspection

General Information0000–03 M1 Maintenance Interval Operations


M1 Maintenance Interval OperationsNumber Title of Maintenance Operation

88-01 Hood Rear Support Lubrication

* For driveline lubrication, the M1 maintenance interval is for Dana Spicer drivelines only; for Meritor drivelinessee the M2 maintenance interval.† If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage.

Otherwise use the M5 maintenance interval.‡ M1 maintenance interval should be used as a general guidelilne; the actual frequency of filter element replace-

ment will vary depending on cleanliness of the fuel station system.

Table 3, M1 Maintenance Interval Operations

General Information 0000–03 M1 Maintenance Interval Operations


Table 4 lists all maintenance operations that are tobe performed at the M2 maintenance interval. Main-tenance operation numbers are reference numbersused to help you find detailed instructions in this

manual on the maintenance operations to be per-formed. Perform all M1 maintenance interval opera-tions (see Table 3) at the M2 maintenance interval.

M2 Maintenance Interval OperationsNumber Title


13-01 Bendix Air Compressor Inspection

20-01 Radiator Cap Inspection

20-03 Fan Drive Check (Noise Emission Control)

26-02 Eaton Fuller Transmission Fluid Change, and Magnetic Plug Cleaning

41-02 Driveline Lubrication*

42-04 Air Dryer Check

42-07 Meritor Camshaft Bracket Lubrication

46-04 Power Steering Gear Lubrication

46-05 Drag Link Lubrication

47-03 Fuel Filter Replacement

47-06 CNG Fuel System Inspection

49-01 Exhaust System Inspection (Noise Emission Control)

* For driveline lubrication, the M2 maintenance interval is for Meritor drivelines only; for Dana Spicer drivelinessee the M1 maintenance interval.





manual on the maintenance operations to be per-formed. Perform all M1 (Table 3) and M2 (Table 4)maintenance interval operations at the M3 mainte-nance interval.




01-01 Engine Drive Belt Inspection

26-04 Allison Transmission Fluid and Filter Change

32-03 Suspension U-Bolt Torque Check

40-01 Wheel Nut Check

42-09 Air Brake Inspection and Leak Test

46-01 Drag Link Inspection

47-05 LNG Vacuum Integrity Test

47-08 CNG Fuel Cylinder Inspection

83-02 HVAC Air Filter Replacement*

* Replace the HVAC air filter at the recommended interval or every six months.





manual on the maintenance operations to be per-formed. Perform all M1 (Table 3), M2 (Table 4), andM3 (Table 5) maintenance interval operations at theM4 maintenance interval.





09-01 Air Cleaner Element Inspection and Replacement

15-01 Alternator, Battery, and Starter Connections Check

20-02 Radiator Pressure Flush and Coolant Change

31-01 Frame Fastener Torque Check

33-05 Wheel End Inspection, Front Axle*

35-03 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaningand Check†

35-04 Wheel End Inspection, Rear Axle*

42-03 Governor Check

46-02 Power Steering Fluid and Filter Change

47-02 Fuel/Water Separator Element Check and Replacement

60-01 Mirror Folding Check

* Complete this operation at the mileage given for the applicable maintenance schedule, or annually, whichevercomes first.† For Dana Spicer axles, if using a Roadranger synthetic drive axle lubricant, the lubricant change interval is ex-

tended to 180,000 miles (288 000 km).





manual on the maintenance operations to be per-formed. Perform all M1 (Table 3), M2 (Table 4), M3(Table 5), and M4 (Table 6) maintenance intervaloperations at the M5 maintenance interval.






25-04 Fluid Change, Hydraulic Clutch Control

42-02 Bendix Air Dryer Desiccant Replacement

42-08 Foot-Control Valve, E-6, Inspection and Lubrication




Maintenance Sequence for Schedule IMaintenance

Sequence Maintenance Interval Service Date Miles km Hours

1st IM and M1 1000 1600 100

2nd M1 2000 3200 200

3rd M1 3000 4800 300

4th M1 and M2 4000 6400 400

5th M1 5000 8000 500

6th M1 6000 9600 600

7th M1 7000 11 200 700

8th M1, M2, and M3 8000 12 800 800

9th M1 9000 14 400 900

10th M1 10,000 16 000 1000

11th M1 11,000 17 600 1100

12th M1 and M2 12,000 19 200 1200

13th M1 13,000 20 800 1300

14th M1 14,000 22 400 1400

15th M1 15,000 24 000 1500

16th M1, M2, M3, and M4 16,000 25 600 1600

17th M1 17,000 27 200 1700

18th M1 18,000 28 800 1800

19th M1 19,000 30 400 1900

20th M1 and M2 20,000 32 000 2000

21st M1 21,000 33 600 2100

22nd M1 22,000 35 200 2200

23rd M1 23,000 36 800 2300

24th M1, M2, and M3 24,000 38 400 2400

25th M1 25,000 40 000 2500

26th M1 26,000 41 600 2600

27th M1 27,000 43 200 2700

28th M1 and M2 28,000 44 800 2800

29th M1 29,000 46 400 2900

30th M1 30,000 48 000 3000

31st M1 31,000 49 600 3100

32nd M1, M2, M3, M4, and M5 32,000 51 200 3200

Table 8, Maintenance Sequence for Schedule I

General Information0000–08 Maintenance Sequence and Log


Maintenance Sequence for Schedule IIMaintenance

Sequence Maintenance Interval Service Date Miles km

1st IM and M1 8000 12 000

2nd M1 and M2 16,000 24 000

3rd M1 24,000 36 000

4th M1, M2, and M3 32,000 48 000

5th M1 40,000 60 000

6th M1 and M2 48,000 72 000

7th M1 56,000 84 000

8th M1, M2, M3, and M4 64,000 96 000

9th M1 72,000 108 000

10th M1 and M2 80,000 120 000

11th M1 88,000 132 000

12th M1, M2, and M3 96,000 144 000

13th M1 104,000 156 000

14th M1, and M2 112,000 168 000

15th M1 120,000 180 000

16th M1, M2, M3, M4, and M5 128,000 192 000

17th M1 136,000 204 000

18th M1 and M2 144,000 216 000

19th M1 152,000 228 000

20th M1, M2, and M3 160,000 240 000

21st M1 168,000 252 000

22nd M1 and M2 176,000 264 000

23rd M1 184,000 276 000

24th M1, M2, M3, and M4 192,000 288 000

25th M1 200,000 300 000

26th M1 and M2 208,000 312 000

27th M1 216,000 324 000

28th M1, M2, and M3 224,000 336,000

29th M1 232,000 348 000

30th M1 and M2 240,000 360 000

31st M1 248,000 372 000

32nd M1, M2, M3, M4, and M5 256,000 384 000

Table 9, Maintenance Sequence for Schedule II

General Information 0000–08 Maintenance Sequence and Log


Noise Emission ControlMaintenance

Federal Law, Part 205:Transportation Equipment NoiseEmission ControlsPart 205, Transportation Equipment Noise EmissionControls, requires the vehicle manufacturer to fur-nish, with each new vehicle, such written instructionsfor the proper maintenance, use, and repair of thevehicle by the ultimate purchaser to provide reason-able assurance of the elimination or minimization ofnoise-emission-control degradation throughout thelife of the vehicle. In compliance with the law, thenoise emission controls maintenance information ineach applicable group of this manual, in conjunctionwith the vehicle workshop manual, provides theseinstructions to owners.

Recommendations forReplacement PartsReplacement parts used for maintenance or repair ofnoise emission controls should be genuine Freight-liner parts. If other than genuine Freightliner partsare used for replacement or repair of componentsaffecting noise emission control, the owner should besure that such parts are warranted by their manufac-turer to be equivalent to genuine Freightliner parts inperformance and durability.

Freightliner Noise EmissionControls WarrantyRefer to the vehicle owner’s warranty informationbook for warranty information concerning noise emis-sion controls.

Tampering with Noise Controls isProhibitedFederal law prohibits the following acts or the caus-ing thereof:1. The removal or rendering inoperative by any per-

son (other than for purposes of maintenance,repair, or replacement) of any device or elementof design incorporated into any new vehicle for

the purpose of noise control, prior to its sale ordelivery to the ultimate purchaser, or while it is inuse.

2. The use of the vehicle after such device or ele-ment of design has been removed or renderedinoperative by any person.Among those acts presumed to constitute tam-pering are the acts listed below:

A. Removal of engine noise-deadening panels.

B. Removal of cab-tunnel or hood noise-deadening panels.

C. Removal of, or rendering inoperative, the en-gine speed governor so as to allow enginespeed to exceed manufacturer’s specifica-tions.

D. Removal of, or rendering inoperative, the fanclutch, including bypassing the control onany thermostatic fan drive to cause it to op-erate continuously.

E. Removal of the fan shroud.

F. Removal of, or rendering inoperative, ex-haust components, including exhaust pipeclamping.

G. Removal of air intake components.

Maintenance InstructionsScheduled intervals are in the maintenance tables inthis group. A "Verification of Inspections Log (Groups01, 20, and 49)" follows, and should be filled in eachtime noise emission controls on the vehicle are main-tained or repaired.

General Information0000–09 Noise Emission Controls


Verification of Inspections LogThe "Verification of Inspections Log" should be filledout each time the vehicle’s noise emission controlsare maintained or repaired.

Verification of Inspections Log, Group 20Verification of Inspections Log, Group 20, Engine Cooling/Radiator

Date Mileage Item Cost Maintenance Facility

Verification of Inspections Log, Group 49Verification of Inspections Log, Group 49, Exhaust

Date Mileage Item Cost Maintenance Facility

General Information 0000–10 Verification of Inspections Log


When You Know U.S.Customary

MultiplyBy To Get Metric When You

Know MetricMultiply

By To Get U.S. Customary

Lengthinches (in) 25.4 millimeters (mm) 0.03937 inches (in)

inches (in) 2.54 centimeters (cm) 0.3937 inches (in)

feet (ft) 0.3048 meters (m) 3.281 feet (ft)

yards (yd) 0.9144 meters (m) 1.094 yards (yd)

miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)

Areasquare inches (in2) 645.16 square millimeters (mm2) 0.00155 square inches (in2)

square inches (in2) 6.452 square centimeters (cm2) 0.155 square inches (in2)

square feet (ft2) 0.0929 square meters (m2) 10.764 square feet (ft2)

Volumecubic inches (in3) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)

cubic inches (in3) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)

cubic inches (in3) 0.01639 liters (L) 61.024 cubic inches (in3)

fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)

pints (pt) 0.47318 liters (L) 2.1134 pints (pt)

quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)

gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)

cubic feet (ft3) 28.317 liters (L) 0.03531 cubic feet (ft3)

cubic feet (ft3) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)

Weight/Forceounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)

pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)

U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)

U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)

Torque/Work Forceinch-pounds (lbf·in) 11.298 Newton centimeters (N·cm) 0.08851 inch pounds (lbf·in)

foot-pounds (lbf·ft) 1.3558 Newton meters (N·m) 0.7376 foot pounds (lbf·ft)

Pressure/Vacuuminches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)

pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)

Table 10, Metric/U.S. Customary Conversions

When You Know Subtract ThenDivide By To Get When You

KnowMultiply

ByThenAdd To Get

degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)

Table 11, Temperature Conversions

General Information0000–11 Metric/U.S. Customary Conversion Tables


Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads†

ThreadDiameter–

Pitch

Regular Hex FlangedGrade 5

BoltGrade 5 or

B NutGrade 8 or

8.2 BoltGrade 8 or

C NutGrade 5

BoltGrade B

NutGrade 8 or

8.2 BoltGrade G

NutTorque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

1/4–20

f230002 f230003 f230004 f230005f230006 f230007 f230008 f230009

7 (9) 8 (11) 6 (8) 10 (14)

1/4–28 8 (11) 9 (12) 7 (9) 12 (16)

5/16–18 15 (20) 16 (22) 13 (18) 21 (28)

5/16–24 16 (22) 17 (23) 14 (19) 23 (31)

3/8–16 26 (35) 28 (38) 23 (31) 37 (50)

3/8–24 30 (41) 32 (43) 25 (34) 42 (57)

7/16–14 42 (57) 45 (61) 35 (47) 60 (81)

7/16–20 47 (64) 50 (68) 40 (54) 66 (89)

1/2–13 64 (87) 68 (92) 55 (75) 91 (123)

1/2–20 72 (98) 77 (104) 65 (88) 102 (138)

9/16–12 92 (125) 98 (133) 80 (108) 130 (176)

9/16–18 103 (140) 110 (149) 90 (122) 146 (198)

5/8–11 128 (173) 136 (184) 110 (149) 180 (244)

5/8–18 145 (197) 154 (209) 130 (176) 204 (277)

3/4–10 226 (306) 241 (327) 200 (271) 320 (434)

3/4–16 253 (343) 269 (365) 220 (298) 357 (484)

7/8–9 365 (495) 388 (526) 320 (434) 515 (698)

7/8–14 402 (545) 427 (579) 350 (475) 568 (770)

1–8 — 582 (789) — —

1–12 — 637 (863) — —

1–14 — 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, Geomet 321XL coated, or waxed).

Table 12, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads

General Information 0000–12 Torque Specifications


Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads†

ThreadDiameter–

Pitch

Regular Hex Flanged

Grade 5 Bolt Grade 5 or BNut

Grade 8 or 8.2Bolt

Grade 8 or CNut

Grade 8 or 8.2Bolt Grade G Nut

Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

1/4–20

f230002 f230003 f230004 f230005 f230008 f230009

8 (11) 10 (14) —

1/4–28 9 (12) 12 (16) —

5/16–18 15 (20) 22 (30) 22 (30)

5/16–24 17 (23) 25 (34) —

3/8–16 28 (38) 40 (54) 40 (54)

3/8–24 31 (42) 45 (61) —

7/16–14 45 (61) 65 (88) 65 (88)

7/16–20 50 (68) 70 (95) —

1/2–13 70 (95) 95 (129) 95 (129)

1/2–20 75 (102) 110 (149) —

9/16–12 100 (136) 140 (190) 140 (190)

9/16–18 110 (149) 155 (210) —

5/8–11 135 (183) 190 (258) 190 (258)

5/8–18 155 (210) 215 (292) —

3/4–10 240 (325) 340 (461) 340 (461)

3/4–16 270 (366) 380 (515) —

7/8–9 385 (522) 540 (732) —

7/8–14 425 (576) 600 (813) —

1–8 580 (786) 820 (1112) —

1–12 635 (861) 900 (1220) —

1–14 650 (881) 915 (1241) —

* Threads may have residual oil, but will be dry to the touch.† Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 12. Freightliner recommends thatall plated and unplated fasteners be coated with oil before installation.

Table 13, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

General Information0000–12 Torque Specifications


Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads†

ThreadDiameter–Pitch

Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 NutTorque: lbf·ft (N·m) Torque: lbf·ft (N·m)

M6

f230010

8.8

f230011

8

f230012

10.9

f230013

10

5 (7) 7 (9)

M8 12 (16) 17 (23)

M8 x 1 13 (18) 18 (24)

M10 24 (33) 34 (46)

M10 x 1.25 27 (37) 38 (52)

M12 42 (57) 60 (81)

M12 x 1.5 43 (58) 62 (84)

M14 66 (89) 95 (129)

M14 x 1.5 72 (98) 103 (140)

M16 103 (140) 148 (201)

M16 x 1.5 110 (149) 157 (213)

M18 147 (199) 203 (275)

M18 x 1.5 165 (224) 229 (310)

M20 208 (282) 288 (390)

M20 x 1.5 213 (313) 320 (434)

M22 283 (384) 392 (531)

M22 x 1.5 315 (427) 431 (584)

M24 360 (488) 498 (675)

M24 x 2 392 (531) 542 (735)

M27 527 (715) 729 (988)

M27 x 2 569 (771) 788 (1068)

M30 715 (969) 990 (1342)

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, Geomet 321XL coated, or waxed).

Table 14, Torque Values for Metric Thread Fasteners With Lubricated or PlatedThreads

General Information 0000–12 Torque Specifications


Title of Maintenance Operation (MOP) MOP NumberEngine Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01

Engine 01Index, Alphabetical


01–01 Engine Drive BeltInspection

Worn or loose drive belts may cause engine over-heating or loss of alternator power. Excessive ten-sion, or too little tension on the belt may result in ex-cessive and premature belt wear or accessorybearing failure. Serpentine belts are retained by abelt tensioner that requires no tension adjustment.Replace the drive belt if any conditions describedbelow are found. To inspect a belt, gently twist it toview the belt sidewalls and bottom.

IMPORTANT: For EPDM rubber drive belts, donot rely on cracking as an indicator of belt wear.EPDM rubber drive belts resist cracking betterthan Neoprene belts. A better indicator of wearon EPDM belts is material loss.

Belt and Pulley Inspection1. Check the belt contact surfaces for damage. See

Fig. 1.2. Inspect the belt for glazing. Glazing is repre-

sented by shiny sidewalls, and is caused by fric-tion created when a loose belt slips in the pul-leys. It can also be caused by oil or grease onthe pulleys.

3. Check the belt for ply separation. Oil, grease, orbelt dressing can cause the belt to fall apart inlayers. Repair any oil or coolant leaks that areaffecting the belts before replacing the drivebelts. Do not use belt dressing on any belt.

4. Check the belt for a jagged or streaked sidewall.Jagged or streaked sidewalls are the result offoreign objects, such as sand or gravel in thepulley, or a rough pulley surface.

5. Check for tensile breaks (breaks in the cordbody). Cuts in a belt are usually caused by for-eign objects in the pulley, or by prying or forcingthe belt during removal or installation.

6. Check for uneven ribs on serpentine belts. For-eign objects in the pulley will erode the under-cord ribs, causing the belt to lose its grippingpower.

7. For EPDM belts, check the belt for material loss,which causes the belt to seat further down in thepulley and to ride directly on the pulley tips. SeeFig. 2.

8. For Neoprene belts, check the drive belts forcracks. Small irregular cracks are usually signsof an old belt.

9. Inspect the pulleys for excessive play or wobble.Excessive play or wobble indicates a failure ofthe pulley bearing. Check for belt squealing orsqueaking. Replace the bearings as necessary.

NOTE: If it is difficult to distinguish the locationof a supposed bearing noise, place a stetho-scope on the component being checked, not thepulley, to isolate the area from outside interfer-ence.10. Inspect all pulleys for foreign objects, oil, or

grease in the grooves.

Belt Tensioner InspectionBelt tension is automatically adjusted with a springtensioner. See Fig. 3 and Fig. 4. Check that the ten-sioner is holding tension on the belt by inserting theend of a breaker bar in the 1/2-inch square hole onthe forward face of the tensioner, and rotating thetensioner away from the belt. When the breaker baris slowly released, the tensioner should return to itsoriginal position. The tensioner should rotatesmoothly with no binding. If not, see Group 01 of the108SD and 114SD Workshop Manual for replace-ment instructions.

Engine 01

108SD and 114SD Maintenance Manual, April 2011 01/1

01/18/2010 f151148

1 2 3

4 5 6

7 8

1. Abrasion2. Chunk-out3. Improper Install

4. Cracking5. Pilling6. Uneven Rib Wear

7. Misalignment8. Gravel Penetration

Fig. 1, Damaged Belts

Engine01

108SD and 114SD Maintenance Manual, April 201101/2

09/21/2009 f012181

A

B

C

A. New BeltB. Worn BeltC. Material loss results in belt riding directly on pulley tips.

Fig. 2, Six-Rib Serpentine Belt (cross section view)

01/19/2012 f012189

1

2

6

45

3

1. Front Belt2. Rear Belt3. AC Compressor

4. Spring Tensioner5. Fan Clutch6. Water Pump

Fig. 3, DD 13/15/16 Drive Belt Routing

01/24/2011 f012192

1

2

3

4

5

6

1. Spring Tensioner2. Alternator Pulley3. AC Compressor

4. Fan Clutch5. Drive Belt6. Crank Shaft Pulley

Fig. 4, Cummins ISC/ISL Drive Belt Routing

Engine 01


Title of Maintenance Operation (MOP) MOP NumberAir Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01

Air Intake 09Index, Alphabetical


09–01 Air Cleaner ElementInspection andReplacement

Restriction of air flow through the air cleaner elementis measured at the tap in the air cleaner outlet.Check the restriction indicator at the air cleaner or inthe cab if the vehicle is equipped with a dash-mounted restriction gauge.Vehicles may be equipped with either a manual-resetrestriction indicator with graduations (Fig. 1), or ago/no-go restriction indicator without graduations(Fig. 2).1. Inspect the air restriction indicator to see if air

restriction equals or exceeds the maximum al-lowable restriction. For instructions, see Group09 of the 108SD and 114SD Workshop Manual.

2. If necessary, replace the air cleaner element. Forair cleaner element replacement instructions, seeGroup 09 of the 108SD and 114SD WorkshopManual.

3. Inspect the air cleaner housing for cracks, leaks,or any other damage. If the air cleaner housingor element is damaged, replace it.

4. Reset the air restriction indicator.5. Each time the air cleaner housing is replaced,

perform the procedures in MOP 13–01.

08/07/2007 f090452

Fig. 1, Manual-Reset Air Restriction Indicator,Graduated

04/08/2005 f090431

Fig. 2, Manual-Reset Air Restriction Indicator, Go/No-Go

Air Intake 09


Title of Maintenance Operation (MOP) MOP NumberBendix Air Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01

Air Compressor 13Index, Alphabetical


13–01 Bendix Air CompressorInspection

Inspect the air intake line, and coolant supply andreturn hoses for tight connections and general condi-tion. Tighten the connections and replace the linesand hoses as needed. See Fig. 1.If equipped with a governor adaptor attached to theair compressor, check the adaptor bolts and the gov-ernor bolts. If the bolts are loose, tighten them 14 to16 lbf·ft (19 to 22 N·m), then confirm that there areno leaks at the connection. If a leak is present, re-place the gaskets. See Fig. 2.

1

2

11/23/2010 f130135a

3

1. Air Intake 2. Coolant Supply Port 3. Coolant Return Port

Fig. 1, Bendix BA-921 Air Compressor

Air Compressor 13


09/11/2009 f130141

1 1

2 2

1. Adaptor Bolt 2. Governor Bolt

Fig. 2, Governor Adaptor

Air Compressor13


Title of Maintenance Operation (MOP) MOP NumberAlternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01

Alternators and Starters 15Index, Alphabetical


15–01 Alternator, Battery, andStarter ConnectionsCheck

WARNINGBatteries generate explosive gas as a by-productof their chemical process. Do not smoke whenworking around batteries. Put out all flames andremove any source of sparks or intense heat inthe vicinity of the battery compartment. Make surethe battery compartment has been completelyvented before disconnecting or connecting thebattery cables.Battery acid is extremely harmful if splashed inthe eyes or on the skin. Always wear a face shieldand protective clothing when working aroundbatteries.1. Check the tightness of the alternator fasteners;

tighten as needed. For torque values, see Group15 of the 108SD and 114SD Workshop Manual.

2. Inspect the alternator drive belt for cracking,glazing, and wear; see Group 01. Replace thebelt if it shows any of these symptoms.

NOTE: Engines equipped with a serpentine belthave automatic belt tensioners, and do not re-quire belt tension adjustment.3. Check the alternator wiring for missing insulation,

kinks, and heat damage. Replace or repair asneeded.

4. Check that all electrical connections at the alter-nator and starter are free of corrosion. Clean andtighten all charging system electrical connec-tions, including the connections at the starter B+terminal and ground terminals, the magneticswitch, and where the alternator charging cablesterminate. Apply red dielectric enamel to all ex-posed connections.

5. Inspect the battery retainer assembly or hold-downs, and the battery box. Replace worn ordamaged parts. Remove any corrosion with awire brush, and wash with a weak solution ofbaking soda and water. Flush with clean water,and dry. Paint the retainer assembly if needed, toprevent rusting.

6. Check that foreign material, such as road debris,is removed from the battery box.

7. Inspect and clean the battery cables, terminals,and clamps as follows. See Group 54 of the108SD and 114SD Workshop Manual for trouble-shooting instructions, and for adjustment, repair,and replacement instructions.7.1 Inspect the battery cables, and replace

any that are damaged.7.2 Clean and tighten the battery ground

cables, terminals, and clamps. Clean thecable connector terminals with a wirebrush.

7.3 Connect the cables to the batteries andtighten them to the torque specificationslisted on the battery, generally 10 to 15lbf·ft (14 to 20 N·m).

7.4 Coat the battery terminals and cable con-nections with dielectric grease.

8. Check the connections at the power net distribu-tion box. Clean and protect the power cableswith dielectric enamel as necessary.

Alternators and Starters 15


Title of Maintenance Operation (MOP) MOP NumberFan Drive Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03

Radiator Cap Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01

Radiator Pressure Flush and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02

Engine Cooling/Radiator 20Index, Alphabetical


20–01 Radiator Cap Inspection

WARNINGDo not remove or loosen the radiator cap until theengine and cooling system have completelycooled. Use extreme care when removing the cap.A sudden release of pressure from removing thecap prior to the system cooling can result in asurge of scalding coolant that could cause seri-ous personal injury.

NOTICEThe radiator cap currently installed may not be thesame one installed when the vehicle was built. Ifthe radiator cap must be replaced, make sure thatit is the correct cap for the cooling system of thevehicle. Because the radiator cap pressure ratingaffects the operating temperature of the engine,installing an improperly rated radiator cap mayhave adverse effects on the cooling system, andengine operating temperatures. This could causepremature engine wear or damage.1. Using a radiator-cap tester, check the pressure

cap to see if it maintains pressure to within 10percent of the pressure rating marked on thecap. If it doesn’t, replace the cap. Make sure thatthe replacement radiator cap is correctly rated forthe cooling system of the vehicle.

2. There is a second valve in the radiator cap thatopens under vacuum. This prevents the collapseof hoses and other parts that are not internallysupported when the system cools. Inspect thevacuum-relief valve to be sure it is not stuck.

3. Make sure that the cap seals properly on thecoolant filler neck seat, and that the radiator capgasket is not damaged. On vehicles withscrew-on caps with O-rings, make sure that theO-ring is not cracked or deteriorated. Replacethe cap if the gasket shows deterioration or dam-age.

20–02 Radiator Pressure Flushand Coolant Change

NOTE: For additional instructions on cleaningand flushing the cooling system, see the enginemaintenance and operation manual.

WARNINGDrain the coolant only when the coolant and en-gine are cool. Draining it when these are hot couldcause severe personal injury due to scalding.1. Drain the radiator, as follows.

1.1 Place a large container under the radia-tor.

1.2 Remove the surge tank cap.1.3 Open the petcock at the bottom of the

radiator to drain the engine coolant.2. Disconnect the radiator inlet and outlet hose con-

nections.3. Flush the radiator, as follows.

3.1 Attach a flushing gun nozzle to the radia-tor outlet.

3.2 Add water to the radiator until it is full.

NOTICEWhen flushing the radiator, do not apply morethan 20 psi (138 kPa) air pressure. Excessive pres-sure can damage the radiator or heater core.

3.3 Apply no more than 20 psi (138 kPa) airpressure intermittently to help dislodgesediment buildup in the core.

4. Drain the radiator, then flush the radiator untilclean water flows from it. Remove the flushinggun.

5. Close the petcock.6. Using clamps, connect the hoses to the radiator.

Tighten the clamps 33 to 38 lbf·in (370 to 430N·cm).

IMPORTANT: On vehicles with EPA10 compliantengines, the coolant capacity varies dependingon the engine and accessory installation. Afterservicing the cooling system, always verify that

Engine Cooling/Radiator 20


the coolant level is between the MIN and MAXlines on the surge tank.7. Fill the cooling system with approved coolant.

See Table 1 for some approved coolants. Referto PartsPro (module 103) for coolant system ca-pacities.

20–03 Fan Drive Check (NoiseEmission Control)

BorgWarner Kysor® K26RA andK22RA Fan Drives1. Check the fan for missing, cracked, chipped, or

damaged blades. Tighten loose components. Re-place damaged fans if necessary.

2. Check for adequate clearance around the fan.The fan should be centered in the shroud to pre-vent contact between the fan and the shroud.

3. Check the fan belt for proper alignment and con-dition. If the belt is worn or frayed, replace thebelt.

4. Verify the fan drive engagement. With the engineand ignition key switch off, apply at least 90 psi(620 kPa) to the clutch; the fan should rotatefreely. Remove air pressure from the clutch andthe fan should not rotate.

5. With the fan drive disengaged, check for airleaks at the front of the clutch and between theclutch and the drive hub. If an air leak is de-tected, the clutch seals and hub must be in-spected for wear or damage. If necessary, theseals of the clutch can be replaced with a Kysorrebuild kit. If inspection of the hub indicates ex-cessive wear, rebuild the hub using a hub rebuildkit from Kysor.

6. Any time the clutch is removed for repair or re-placement, the pulley hub and bearings shouldbe inspected for play, roughness, or damage.Hub bearing service kits are available fromKysor.

7. Check the lining with the System Alert Tool™. Ifthe lining is worn, install the appropriate lining kit.A lining that is prematurely worn is caused bycontrol air supply problems. Inspect and correctthe vehicle control system before placing the ve-hicle back in service.

8. Check the air line entry and routing at the frontor rear of the fan drive. Look for cracked, dam-aged, or improperly routed air lines. Make surethe connections are tight and that there are noair leaks.

9. Check the electrical connections at the solenoidvalve, which is typically mounted to the frontwall.Check the exhaust port for restrictions. If a re-striction is found, clear it.

Horton DriveMaster® Fan ClutchNOTE: If any part of the fan clutch needs to berepaired or replaced after performing the checksbelow, see Group 20 of the 108SD and 114SDWorkshop Manual.

WARNINGMake sure the batteries are disconnected beforechecking the fan clutch. If the engine starts duringthis procedure, the fan could engage, which couldresult in serious personal injury.1. Disconnect the batteries at the negative termi-

nals. Drain all air from the air system. Ifequipped with an air starter, drain the air starterreservoir.

2. Inspect the electrical connections and wires tothe fan clutch solenoid. Secure the connection ifloose; replace wires and connectors if damaged.

3. Clean the fan clutch air solenoid valve filter, ifequipped.3.1 Unscrew the fan clutch solenoid valve air

filter assembly, and remove the filter ele-ment.

3.2 Clean the filter element with cleaning sol-vent.

3.3 Using a clean, lint-free cloth, wipe off anyexcess solvent.

3.4 Reassemble the clutch valve solenoid airfilter assembly, and install it on the ve-hicle.

4. Visually check the fan for bent, cracked, or dam-aged blades. Replace if damaged. Check for ad-equate clearance between the fan and othercomponents.

Engine Cooling/Radiator20


5. Check the fan belt for wear, tension, and align-ment. Correct, if necessary.

6. Check for wear on the friction facing. Replacethe friction facing if it is worn to a 3/16-inch (4.8-mm) thickness or less. Also check the facing forsigns of oil contamination or burn marks. If evi-dence of oil or burn marks are found, replace thefriction facing.

7. Connect the battery cables. Start the engine, andcharge the air system to 120 psi (827 kPa).Manually engage and disengage the fan clutch.Check the fan and the fan clutch from a dis-tance. Look for vibration, fan blade contact, fanclutch slippage, and overall fan clutch operation.If the fan clutch does not operate correctly, seeGroup 20 of the 108SD and 114SD WorkshopManual for troubleshooting and repair proce-dures.

8. With the air system charged to 120 psi (827kPa), check for air leaks at the fan clutch, sole-noid valve, air hoses, and fittings from the fanclutch to the air tanks. Use a suitable listeningdevice, and, as needed, a soapy water solution.

9. If a leak is detected, remove the fan blade. In-stall a new seal kit. See Group 20 of the 108SDand 114SD Workshop Manual for repair proce-dures.

10. Check the fan drive for discoloration or any othersigns of slipping or overheating.

NOTE: The fan clutch may slip if the air supplypressure is below 70 psi (483 kPa) or if there isa leak inside the fan clutch. Any leak must beremedied.11. Check the fan clutch bearings.

11.1 Turn the fan in both directions and feelfor worn hub bearings.

11.2 If possible, remove the drive belt andcheck for worn sheave bearings by turn-ing the sheave in both directions.

11.3 If either the hub or sheave bearings areworn, replace them using a Horton Drive-Master Super Kit.For repair kit information, see Horton’swebsite, www.hortonww.com.For instructions, see Group 20 of the108SD and 114SD Workshop Manual.

Approved CoolantsManufacturer Coolant Type

Cummins Fleetguard® Compleat Premix Premixed solution with supplement additives

Detroit Diesel Detroit Diesel Power Cool Premixed solution with supplement additives

Old World Industries Fleet Charge™ With supplement additives

Table 1, Approved Coolants

Engine Cooling/Radiator 20


Title of Maintenance Operation (MOP) MOP NumberClutch Adjustment, Manually Adjusted Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–05

Eaton Fuller Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01

Eaton Fuller Clutch Release Cross-Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02

Fluid Change, Hydraulic Clutch Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–04

Fluid Level Check, Hydraulic Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03

Clutch 25Index, Alphabetical


25–01 Eaton Fuller ClutchRelease BearingLubrication

If the vehicle is not equipped with a maintenance-free sealed clutch release bearing, lubricate the bear-ing as follows:1. Park the vehicle on a level surface. Apply the

parking brakes, and chock the rear tires.2. Remove the clutch inspection plate.NOTE: For lubricating the release bearing,Eaton Fuller recommends a lithium-base greasethat can operate up to at least 325°F (163·C)and meets the NLGI grade two or three specifi-cation.3. Wipe the dirt away from the grease fitting. See

Fig. 1. Use a low-pressure-type grease gunequipped with the recommended grease, andlubricate the bearing until excess grease purgesfrom the rear of the release bearing (toward thetransmission).

NOTICEDo not over-lubricate the clutch release bearing.Over-lubrication could contaminate the clutch in-ternally, causing clutch slippage and prematurefailure. Do not use chassis grease or multipurposelubricants.4. Wipe off excess grease and apply it to both the

yoke finger and sleeve bushing contact points.See Fig. 2.

5. Install the clutch inspection plate.

25–02 Eaton Fuller ClutchRelease Cross-ShaftLubrication

IMPORTANT: This maintenance operation per-tains only to vehicles equipped with mechanical(not hydraulic) linkages.The clutch release cross-shaft is equipped with twogrease fittings in the transmission clutch housing.See Fig. 3. Wipe the dirt from the grease fittings andlubricate with multipurpose chassis grease.f250081a05/27/93

NOTE: Some clutch release bearings are equipped witha lubrication extension that protrudes from the clutchhousing.

Fig. 1, Release Bearing Grease Fitting

11/29/2010 f250680

12

3

1. Release Bearing2. Sleeve Bushing Contact Point3. Yoke Finger Contact Points

Fig. 2, Grease the Contact Points

Clutch 25


25–03 Fluid Level Check,Hydraulic Clutch Control

WARNINGUse only approved fluid (DOT 4 brake fluid) in thehydraulic clutch control system. Do not mix differ-ent types of brake fluid. The wrong fluid will dam-age the rubber parts of the system, causing lossof clutch function and the risk of serious personalinjury.

NOTICEDo not allow the fluid level in the reservoir to gobelow the MIN line. If air enters the system, thehydraulic system will not operate correctly, andthe clutch could be damaged.If the fluid level is below the MIN line, fill the reser-voir with new DOT 4 brake fluid from a tightly sealedcontainer until the level reaches the MAX line. SeeFig. 4.

25–04 Fluid Change, HydraulicClutch Control

Replace the hydraulic clutch control fluid to ensureclutch function is reliable and correct. It can bechanged by pressure bleeding or manual bleeding.

Pressure bleeding can be done by one person andmanual bleeding requires two.

IMPORTANT: The pressure line must slope con-tinuously downward between the master andslave cylinders. On some vehicles, the securingclamps may need to be removed to achieve thisand allow the air to be purged. If an air bubbleenters the system, bleed it out using the proce-dures in Section 25.01 of the 108SD and114SD Workshop Manual.

Pressure Bleeding1. Shut down the engine.

f260146a05/27/93

NOTE: There are grease fittings on both the left andright side of the housing.

Fig. 3, Cross-Shaft Grease Fitting

11/29/2010 f250681

1

2

1. Frontwall 2. Reservoir

Fig. 4, Reservoir, Hydraulic Clutch Control

Clutch25


2. Apply the parking brakes, chock the front andrear tires, and raise the hood.

WARNINGHydraulic clutch control fluid (DOT 4 brake fluid)is hazardous. It may be a skin irritant and cancause blindness if it gets in your eyes. Alwayswear safety glasses when handling it or bleedinghydraulic lines. If you get it on your skin, wash itoff as soon as possible.3. Prepare the pressure bleeding equipment ac-

cording to the manufacturer’s instructions. Usenew DOT 4 brake fluid from a tightly sealed con-tainer. Pressurize the bleed adaptor to 15 psi(103 kPa).

NOTICEDo not spill hydraulic clutch control fluid on thecab paint. Clean it off immediately if any is spilled.Brake fluid can damage paint.4. Remove the reservoir lid (see Fig. 4) and install

the pressure bleed adaptor on the reservoir.5. Pressurize the reservoir, filling the system. Open

the bleed valve on the bleed tank of the adaptor.NOTE: A pressure bleeder hose (J-29532) anda bleed adaptor (J-35798) for the fluid reservoirare available through SPX Kent-Moore Toolsand may be used to complete the following pro-cedure. To order these parts, call Kent-Moore at1-800-328-6657.6. Flush the hydraulic system as follows.

6.1 Open the bleed valve on the slave cylin-der. See Fig. 5.

6.2 Using a drain pan or other suitable con-tainer, collect the fluid that drains from theslave cylinder bleed valve, at least 0.5quarts (0.5 liters).

6.3 When all the old fluid has passed throughthe system and only new, clean fluid iscoming out, close the bleed screw.

7. Check the fluid level in the reservoir, and addfluid to the max fluid mark on the reservoir.

Manual Flushing1. Remove the cap from the bleed valve of the

slave cylinder. On the valve, install a transparentdrain hose connected to a catch bottle. The hoseneeds to fit the bleed valve tight enough so itdoesn’t fall off as fluid is pumped out.

2. Open the slave cylinder bleed screw. Observethe flow of clutch hydraulic fluid through the drainhose.

3. Remove the cap from the reservoir and pour newfluid in as the level drops. Have an assistantslowly pump the clutch pedal to help purge theold fluid.

4. When all the old fluid has passed through thesystem and only new, clean fluid is coming out,stop cycling the pedal and quickly close thebleed screw.

5. Disconnect the transparent hose. Tighten thebleed screw 88 lbf·in (1000 N·cm) and install thecap on the slave cylinder bleed valve.

6. Check the fluid level in the reservoir. If neces-sary, add or drain clutch hydraulic fluid to bringthe fluid level to the MAX line. Install the reser-voir lid.

7. Depress the clutch pedal a few times. Thereshould be resistance over the full pedal stroke.

11/30/2010 f250682

1

2

1. Bleed Valve 2. Slave Cylinder

Fig. 5, Slave Cylinder, Hydraulic Clutch Control

Clutch 25


25–05 Clutch Adjustment,Manually AdjustedClutches

NOTE: This procedure is only required for ve-hicles equipped with non-synchronized transmis-sions and manually adjusted clutches.Release bearing travel is the clearance between therear surface of the release bearing housing and theforward surface of the clutch brake disc. This dis-tance must be maintained between 1/2 and 9/16 inch(12.7 and 14.3 mm).1. Remove the clutch inspection cover from the bell

housing. See Fig. 6.

2. Slide the clutch brake tight against the transmis-sion input-shaft bearing cap.

IMPORTANT: Release bearing travel tool A02-12419-000 is available through the PDCs. Thefork at one end of the tool has green tape on it,and has two 0.50-inch (12.7-mm) diameter tips;the fork at the other end has blue tape on it,and has 0.56-inch (14.3-mm) diameter tips. SeeFig. 7.3. Measure the release bearing travel. See Fig. 8

for the correct dimension to measure. Using bothends of the release bearing travel tool, check thisgap as follows:

Position the tool so that the legs of the fork atthe blue 0.56-inch (14.3-mm) end straddle thetransmission input shaft. If the tool fits loosely,the gap is too wide and adjustment is needed.Go to the next step.If the blue 0.56-inch (14.3-mm) end can’t be in-serted in the gap, then try to insert the green0.50-inch (12.7-mm) end.If the green end of the tool can’t be inserted inthe gap, adjustment is needed. Go to the nextstep.If the green end of the tool fits — snugly orloosely — then no adjustment is needed. Nothingmore needs to be done. Install the clutch inspec-tion cover.

4. Release the clutch by depressing the pedal.Block the pedal in the released position, or have

f250002a

1

03/01/94

1. Clutch Inspection Cover

Fig. 6, Remove the Clutch Inspection Cover

f580133

A

A

B

B

03/26/96

A. Green End (0.50 inch or 12.7 mm)B. Blue End (0.56 inch or 14.3 mm)

Fig. 7, Release Bearing Travel Tool A02-12419-000

f250199a10/14/94

1 2

A

A. Clearance between release bearing housing andclutch brake must be 1/2 to 9/16 inch (12.7 to 14.3mm).

1. Release Bearing Housing2. Clutch Brake

Fig. 8, Release Bearing Travel Measurement

Clutch25


someone assist you by holding the pedal downduring the adjustment procedure.

NOTE: An open-end wrench is not recom-mended for the following step.5. Adjust the clutch, using a 5/8-inch box-end or

socket wrench on the adjustment bolt. SeeFig. 9.

5.1 Insert the 5/8-inch box-end or socketwrench through the inspection coveropening.

5.2 To begin the adjustment, release the ad-justment bolt by pressing down on thebolt head.

NOTE: On Easy-Pedal 2000 clutches, eachcomplete turn of the adjustment bolt repre-sents about 0.125 inch (3 mm) of releasebearing movement.Normal wear increases the gap between therelease bearing and the transmission.5.3 To decrease the gap: If clearance be-

tween the release bearing housing andthe clutch brake is more than 9/16 inch(14.3 mm), turn the adjustment bolt clock-wise (the release bearing moves towardthe transmission).To increase the gap: If clearance betweenthe release bearing housing and theclutch brake is less than 1/2 inch (12.7mm), turn the adjustment bolt counter-clockwise (the release bearing moves to-ward the engine).

5.4 When the adjustment is complete, makesure the adjustment bolt is locked (pulledup flush with the mounting bolts).

6. After adjusting, release the pedal and check theclearance between the release bearing housingand the clutch brake. When the adjustment iscorrect, the green end of the tool should go inand the blue should not (clearance of 1/2 to 9/16inch, or 12.7 to 14.3 mm).

7. Install the clutch inspection cover.

11/29/2010 f250683

Fig. 9, Manual Adjustment, Easy-Pedal Clutch (shownwith bell housing removed)

Clutch 25


Title of Maintenance Operation (MOP) MOP NumberAllison Transmission Fluid and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04

Allison and Eaton Fuller Transmission Breather Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03

Eaton Fuller Transmission Fluid Change, and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02

Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01

Transmission 26Index, Alphabetical


26–01 Transmission FluidLevel Check

NOTICEOperating a transmission with the fluid levelhigher or lower than recommended can result intransmission damage. Do not overfill the transmis-sion.Do not mix types and brands of fluid, because ofpossible incompatibility. Do not use fluid addi-tives, friction modifiers, extreme-pressure gearfluids, or multiviscosity lubricants.

Eaton FullerNOTE: Check the transmission fluid level withthe transmission at operating temperature.1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Clean the area around the fill plug, then remove

the plug from the side of the gear case.3. Using your gloved finger or a bent pipe cleaner,

check if the fluid is level with the fill opening. SeeFig. 1.

4. If the fluid level is low, check the transmission forleaks, and correct as needed.

5. If needed, add Eaton-approved fluid until it islevel with the lower edge of the fill opening.Eaton-approved fluid, such as the RoadrangerSAE 50 product, meets the requirements of thePS-164 Rev. 7 lubricant specification. For moreinformation about Eaton lubricant specificationsand suppliers, call 1-800-826-4357 or see ww-w.roadranger.com.

6. Clean the fill plug, then install it. Tighten the plugas follows:

• 25 to 35 lbf·ft (34 to 48 N·m) for transmis-sions with 3/4-inch pipe threads.

• 60 to 75 lbf·ft (81 to 102 N·m) for transmis-sions with 1-1/4-inch pipe threads.

AllisonNOTE: For Allison transmissions equipped withan oil level sensor, the transmission fluid levelcan be checked electronically. For more infor-mation, refer to the Allison Transmission web-site, www.allisontransmission.com.

Cold CheckClean all dirt from around the end of the fluid fill tubebefore removing the dipstick. Do not allow foreignmatter to enter the transmission. Dirt or foreign mat-ter in the hydraulic system may cause undue wear oftransmission parts, make valves stick, and clog pas-sages.It is important to check the fluid level cold to deter-mine if the transmission has a sufficient amount offluid to be safely operated until a hot check can beperformed.1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Run the engine for at least one minute.3. Shift from DRIVE to NEUTRAL, and then shift to

REVERSE to fill the hydraulic system.4. Shift to NEUTRAL and allow the engine to idle at

500 to 800 rpm.5. With the engine running at idle, remove the dip-

stick from the tube and wipe it clean.6. Insert the dipstick into the tube, then remove it.7. Check the fluid level reading, then repeat the

check procedure to verify the reading.If the fluid level is within the COLD RUN band,the transmission may be operated until the fluidis hot enough to perform a hot check.If the fluid level is not within the COLD RUNband, add or drain fluid as needed to adjust thefluid level to the middle of the COLD RUN band.See Fig. 2.

f260006c11/30/2010A B

A. Full B. Low

Fig. 1, Checking Transmission Fluid Level

Transmission 26


NOTICEAs the fluid temperature increases, so does thefluid level. Do not fill above the COLD RUN band ifthe transmission fluid is below normal operatingtemperature.NOTE: Perform a hot check at the first opportu-nity after the normal operating temperature, 160to 200°F (71 to 93°C), has been reached.

Hot Check1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Shift the transmission to NEUTRAL.3. Operate the engine at idle (500 to 800 rpm) until

normal operating temperature is reached. Checkthat the sump temperature is 160 to 200°F (71 to93°C). Check that the converter-out temperatureis 180 to 220°F (82 to 104°C).

4. With the engine idling, remove the dipstick fromthe tube and wipe it clean.

5. Insert the dipstick into the tube, then remove it.6. Check the fluid level reading, then repeat the

check procedure to verify the reading. Safe oper-ating level is within the HOT RUN band on thedipstick. The HOT RUN band is between theHOT FULL and HOT ADD marks.If the fluid level is not within the HOT RUN band,add or drain fluid as needed to bring the fluidlevel within the HOT RUN band. See Fig. 2.

26–02 Eaton FullerTransmission FluidChange, and MagneticPlug Cleaning

NOTICEOperating a transmission with the fluid levelhigher or lower than recommended can result intransmission damage. Do not overfill the transmis-sion. Overfilling will force fluid out of the casethrough the main shaft openings.Do not mix types and brands of fluid, because ofpossible incompatibility. Do not use fluid addi-tives, friction modifiers, extreme-pressure gearfluids, or multiviscosity lubricants.

NOTE: Fluid change intervals are extended to500,000 miles (800 000 km) on any vehiclesfilled with synthetic transmission fluid.1. If the transmission fluid is not at normal operat-

ing temperature, run the engine until the fluidreaches operating temperature.

2. Park the vehicle on level ground, apply the park-ing brakes, shift the transmission to neutral (N),shut down the engine, and chock the tires.

3. Place a large drain pan under the transmission.4. Clean the area around the fill plug, and remove it

from the side of the gear case. Remove eachdrain plug from the bottom of the case.

5. Clean the fill and drain plugs. For magneticplugs, use a piece of key stock or any other con-venient steel slug to short the two magneticpoles and divert the magnetic field.Install and tighten each drain plug 50 lbf·ft (68N·m).

NOTE: The optional transmission fluid filter maybe a remote-mount, spin-on type, located be-tween the transmission and the fluid cooler. Thefilter bracket is attached to the frame rail orsome other nearby location. The filter ismounted in a vertical position, and should befilled with fluid before installation to assure theproper fluid level. For optimum transmission per-

12/01/97

A

B

f270002a

A. Cold Run Band B. Hot Run Band

Fig. 2, Dipstick Markings

Transmission26


formance, change the filter each time that thefluid is changed.6. For a transmission equipped with a transmission

fluid filter(s), replace the fluid filter(s) as follows.6.1 Place a drain pan under the transmission

fluid filter.

CAUTIONTo prevent skin burns from hot transmission fluid,wear protective gloves when removing the filter.

6.2 Place a strap or chain wrench around thefilter canister, and rotate it in a counter-clockwise motion to separate the filterfrom the mounting. Carefully spin the filteroff the mount and remove it from the ve-hicle.

6.3 Apply a light coat of transmission fluid tothe O-ring gasket on the new filter. Fill thefilter with specified transmission fluid, andspin the filter onto the mount.

NOTE: The filter fills slowly, so be patient toensure the proper fluid level has beenreached.6.4 Once the filter makes contact with the

mount, use a strap wrench to rotate thecanister an additional 180 to 270 degreesto firmly tighten the filter. Wipe the filterclean of any fluid after it is tightened.

7. Add Eaton-approved fluid until it is level with thelower edge of the fill opening. See Fig. 1. If thetransmission has two fill openings, add fluid tothe level of both openings.Eaton-approved fluid, such as the RoadrangerSAE 50 product, meets the requirements of thePS-164 Rev. 7 lubricant specification. For moreinformation about Eaton lubricant specificationsand suppliers, call 1-800-826-4357 or see ww-w.roadranger.com.

See Table 1 for Eaton Fuller transmission lubri-cant capacities.

Eaton Fuller Transmission Lubricant CapacitiesTransmission Model*

Capacity: qt (L)Prefix Number

FR, FRO 112101221013210142101521016210

11.75 (11)†

RTO, RTLO 1190812910149081490914910149131491514918169081690916910169131691516918

14 (13)†

TX 14607 18 (17)†

* For models not listed in this table see the Eaton Fuller website, ww-w.roadranger.com.† Quantities listed are approximate. Capacity of transmissions equipped

with PTOs or oil coolers are greater than capacities listed. Fill transmissionuntil lubricant is level with bottom of fill hole with vehicle in normal operatingposition.

Table 1, Eaton Fuller Transmission LubricantCapacities

NOTE: In all cases, the correct fluid level is es-tablished by checking at the fill opening.8. Operate the engine for five minutes after filling

the transmission, then check the fluid level again.9. Clean the fill plug, then install it in the transmis-

sion. Tighten the plug as follows:• 25 to 35 lbf·ft (34 to 48 N·m) for Eaton

Fuller transmissions with 3/4-inch pipethreads.

• 60 to 75 lbf·ft (81 to 102 N·m) for EatonFuller transmissions with 1-1/4-inch pipethreads.

10. Operate the vehicle to check for correct opera-tion.

Transmission 26


26–03 Allison and Eaton FullerTransmission BreatherCheck

If the transmission is equipped with a housingbreather (see Fig. 3), it must remain clear. A pluggedbreather could result in pressure build-up, whichcould cause oil leakage.

IMPORTANT: Do not spray water, steam, orcleaning solution directly at the breather. Theseactions can force water or cleaning solution intothe transmission and contaminate the transmis-sion fluid.If the breather is plugged, clean or replace it. If re-placing it, use a correct-size wrench (pliers or a pipewrench can crush or damage the breather stem andproduce metal particles that could enter the transmis-sion).Check more often if the vehicle is operating undervery dusty conditions.

26–04 Allison TransmissionFluid and Filter Change

Allison 3000 Family and 4000Family TransmissionsNOTE: When the optional prognostics feature isenabled on an Allison transmission, the systemmonitors oil life and filter life. To reset the indica-tor, press the Mode button (on the electronicshift control) for 10 seconds with the ignition onbut the engine not running. For more informa-tion, see the Allison Transmission website,www.allisontransmission.com.1. Park the vehicle on a level surface and apply the

parking brakes.2. Operate the vehicle until the transmission

reaches normal operating temperature: 160 to200°F (71 to 93°C).

NOTICETo prevent dirt from entering the transmission,use only clean containers and fillers for the trans-mission fluid. Do not use fillers or containers thathave been used for water or antifreeze. Dirt, water,or antifreeze could damage the transmission.Engine coolant in the transmission hydraulic sys-tem requires immediate action to prevent malfunc-tion and possible serious transmission damage.For more information, see the Allison Transmis-sion website, www.allisontransmission.com.

IMPORTANT: When draining transmission fluid,check for evidence of dirt or water contamina-tion. A small amount of condensation will appearin the fluid during operation.Water contamination is normally characterizedas a milky discoloration of the transmission fluid.Obvious contamination of the transmission fluidindicates a leak between the water and fluidareas of the transmission cooler. Inspect andpressure-test the cooler to confirm the leak; re-place leaking transmission coolers.NOTE: If only the filter is being changed, do notdrain the fluid.

f260007b11/30/2010

1

2

NOTE: Location of the transmission breather will varydepending on transmission model.1. Breather 2. Shift Tower

Fig. 3, Transmission Breather (Eaton Fuller shown)

Transmission26


3. Clean the area around the drain plug and thetransmission fluid pan. Place a drain pan underthe transmission and remove the drain plug. Ex-amine the fluid as it drains.

4. Remove the 12 mounting capscrews (six each)from the two filter covers. See Fig. 4.

NOTE: A lot of fluid will drain when the filtercovers are removed.5. Remove the filter covers, gaskets, O-rings, and

filters from the transmission.6. Lubricate the new O-rings with transmission fluid,

and install them on the covers.7. Install the filter over the gaskets.8. Install the fluid filters on the cover assemblies.9. Install the filter and cover assemblies into the

filter compartment. Align each cover assemblywith the holes in the channel plate sump, andpush the cover assemblies in by hand to seat theseals.

NOTICEDo not use the capscrews to draw the filter coversto the sump. This can damage the covers, seals,or sump.10. Install six capscrews in each cover, and torque

the bolts 38 to 44 lbf·ft (51 to 61 N·m).11. Install a new drain plug O-ring, and install the

drain plug. Tighten the drain plug 18 to 24 lbf·ft(25 to 32 N·m).

NOTE: Fluids meeting specification TES 295 arepreferred over TES 389 fluids for use in Allison3000 and 4000 family transmissions. See theAllison Transmission website (www.allison-transmission.com) for a list of approved trans-mission fluids and usage recommendations.12. Refill the transmission with fresh transmission

fluid. Use only a fluid that meets Allison Trans-mission specification TES 295 or TES 389. Cas-trol TranSynd® is a TES 295 fluid availablethrough Allison distributors and dealerships. SeeTable 2 for lubricant refill capacities.

1

1

1

1

2

2

3

3

4

4

f260317c11/30/2010

NOTE: Allison 4000 Family transmission shown. Com-ponents and location are similar for Allison 3000 Familytransmissions.1. Filter Cover2. Filter

3. Filter Element O-Ring4. Square-Cut Seal

Fig. 4, Allison Transmission Filter Locations andComponents

Transmission 26


Lubricant Refill Capacities, Allison 3000 and 4000Family Transmissions*

Family Sump Size Capacity : qt (L)

30004 Inch 19 (18)

2 Inch 17 (16)

40004 Inch 39 (37)†

2 Inch 31 (30)†

* Quantities listed are approximate. Add listed amount of fluid, then performa "hot check" and add fluid as needed. Do not overfill.† Add 3 qt (2.8 L) for transmissions with PTO.

Table 2, Lubricant Refill Capacities, Allison 3000 and4000 Family Transmissions

13. Check and adjust the fluid level using the appro-priate Allison Transmission procedures in MOP26–01.

Transmission26


Title of Maintenance Operation (MOP) MOP NumberFifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02

Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–03

Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01

Trailer Electrical Connector Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–04

Frame and Frame Components 31Index, Alphabetical

108SD and 114SD Maintenance Manual, August 2011

31–01 Frame Fastener TorqueCheck

Frame brackets and components secured with Huck-bolt® fasteners do not require a torque check, how-ever, they should be inspected for damage. Framebrackets and components secured with conventionalbolts and nuts are to be checked at initial mainte-nance (IM).Check the torque of frame fasteners to offset the ef-fects of bedding in or seating. When possible, alwayscheck the torque of the nut, not the bolt head. Thiswill give a true torque reading by eliminating bolt-body friction.When checking the torque of frame fasteners, in-spect the frame for cracks and other damage.Set a click-type torque wrench to the maximumtorque of the fastener you are checking. Apply pres-sure until the torque wrench clicks. Do not loosen thebolt to check the torque. See the applicable torquetable in Group 00 for torque specifications.

NOTICEMake sure frame fasteners are properly tightened.Continued vehicle operation with loose fastenerscould result in bracket or frame damage.Check the fasteners at the following locations:

• axle stops• equalizer brackets• exhaust brackets• fifth wheel legs• fifth wheel mountings• frame crossmembers and gussets• front frame brackets• front suspension spring brackets• fuel tank brackets• radius rods• rear suspension spring brackets• shock absorbers• all other frame fasteners

Any component that shows signs of cracking or dam-age must be repaired or replaced. See the applicable

group in the 108SD and 114SD Workshop Manualfor repair or replacement information.

31–02 Fifth Wheel Inspection

WARNINGAll fifth wheel maintenance, adjustment, and re-building must be done only by a qualified me-chanic. Improper or incomplete procedures couldresult in a possible disengagement of the trailerfrom the tractor, which could result in personalinjury or property damage.Parts are under spring compression. Wear safetygoggles while servicing the fifth wheel. Failure todo so can result in personal injury, due to partsejecting with force.

Holland FWS11. Disconnect the tractor from the trailer. For in-

structions, see the 108SD and 114SD Driver’sManual.

2. Thoroughly steam clean the fifth wheel.3. Check the fifth wheel plate for cracks. Check for

sharp edges on top; the chamfer should be 1/8to 1/4 inch (3 to 6 mm).

4. When the wheel is locked, the safety latch mustswing free and fall freely into position. SeeFig. 1.

f31105210/29/2007

1

2

3

4

1. Lubricant Grooves2. Safety Latch

3. Release Handle4. Mount

Fig. 1, Holland FWS1 Fifth Wheel

Frame and Frame Components 31

108SD and 114SD Maintenance Manual, August 2011 31/1

5. The lever bar and release handle must be inproper alignment. See Fig. 2. Compare the leverbar and release handle alignment to a new, or aproperly operating lever bar and release handle.Replace any bent or misaligned lever bar or re-lease handle.

6. Check all cotter pins for cracking or damage. Re-place any cotter pin that shows any signs ofdamage.

7. Check all mounting bolts for signs of fatigue, andtighten them to the proper torque. For torquespecifications, see Group 00. Inspect all angles,plates, and brackets for cracks or other damage.

8. Replace cracked, worn, or damaged parts withnew parts. Replace all loose mounting bolts with5/8–11 SAE grade 8 bolts, grade C locknuts, andhardened washers. Do not re-use bolts, nuts,and washers on fifth wheel mountings.

9. After inspecting the fifth wheel, lubricate all mov-ing parts with a chassis or multipurpose grease.See MOP 31–03 for lubrication instructions.

Holland FW351. Thoroughly steam clean all fifth wheel compo-

nents before inspection.2. Check for cracks in the fifth wheel assembly,

mounting brackets, and mounting parts.3. Check the fastener torques on the fifth wheel

assembly and fifth wheel mounting. Tighten bolts

and nuts as needed. Replace missing or dam-aged bolts.

4. Inspect the fifth wheel for bent, worn, damaged,and missing parts; replace them as needed withgenuine Holland parts.

5. Using a Holland Kingpin Lock Tester (Hollandtool number TF-TLN-5001, available through thePDCs as HLD TFTLN5001), check the operationof the locking mechanism by opening and closingthe locks. See Fig. 3.

6. After inspecting the fifth wheel, lubricate all mov-ing parts with a chassis or multipurpose grease.See MOP 31–03 for lubrication instructions.

Fontaine1. Disconnect the tractor from the trailer. For in-


2. Thoroughly steam clean the fifth wheel.3. Check for cracks in the fifth wheel assembly,

mounting brackets, and mounting parts.4. Ensure that both bracket pins are in place and

secured by retainer pins and cotter pins. SeeFig. 4.

01/13/2011 f310470

1

2

1. Release Handle 2. Lever Bar

Fig. 2, Lever Bar and Release Handle Alignment

04/11/2011 f310887

A

BA. The nut and washer should be snug against the fifth

wheel.B. The locks should be completely closed around the

kingpin.

Fig. 3, Holland Fifth Wheel Properly Closed

Frame and Frame Components31

108SD and 114SD Maintenance Manual, August 201131/2

12/02/2010 f311134

12

234

5

5

67

8

8

9

1011

12

12

12

13

1415

16

87

6

5

5

8

1712

1218

15

19

2021

22

231212

24

1525

26

27

NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts.1. Wedge Stop Rod Nut2. Flat Washer, 5/8"3. Wedge Stop Rod Spring4. Wedge Stop Rod5. Grease Fitting6. Bracket Pin7. Bracket Retainer Pin8. Cotter Pin, 3/16" x 1"9. Bumper Spring10. Handle Spring

11. Bolt, Secondary Safety Lock12. Flat Washer13. Secondary Safety Lock14. Bushing, Secondary Safety

Lock15. Hex Locknut16. Pull Handle17. Bolt, Bumper18. Bushing

19. Bumper20. Timer Spring21. Timer22. Operating Handle23. Bolt, Operating Handle24. Bushing, Operating Handle25. Hair Pin Cotter26. Wedge27. Step Jaw

Fig. 4, Fontaine Fifth Wheel



5. For fifth wheels equipped with bracket liners,rock the fifth wheel. If it does not rock freely, re-move the top plate and inspect the bracket lin-ers. Replace liners that are broken or less than0.125 inch (3 mm) thick at the top of the liners.For the liner replacement procedure, see theFontaine website, www.fifthwheel.com.

6. Check the jaw and stationary jaw for mushroom-ing, and check that the serrations at the jaw andwedge are in good condition.

7. Test the secondary safety lock latch for ease ofoperation.

8. Check for loose nuts or bolts on the fifth wheeland the mounting. Set a torque wrench to themaximum torque value for the bolt beingchecked, and confirm that the torque is to speci-fication. Do not loosen the bolt to check thetorque. See Group 00 for bolt torque specifica-tions.

9. Check all springs to see if they are securely fas-tened, and are not deformed.

WARNINGDo not disassemble the fifth wheel to inspect thesprings. The springs are under extreme pressure,and could cause serious injury.10. Check wedge adjustment.

10.1 Open the kingpin lock, and vertically in-sert a 2-inch (50-mm) diameter shaft.

10.2 Release the lock by tripping the releaselatch at the bottom of the throat.

10.3 Adjust the wedge stop at the end of thewedge to approximately 1/4-inch (6-mm)clearance by turning the wedge stop rodlocated on the right side of the top plate.


12. After inspecting the fifth wheel, lubricate all mov-ing parts with a chassis or multipurpose grease.Apply a generous coating of grease to the topplate to fill the grooves, or depressions, on thetop plate. See MOP 31–03 for lubrication instruc-tions.

Jost1. Disconnect the tractor from the trailer. For in-


2. Thoroughly steam clean the fifth wheel.3. Check the mounting for missing or damaged fas-

teners, and broken components. Replace or re-pair as needed.

4. Inspect the bracket pin bolts. Make sure the lock-ing tabs are properly securing the bolts in place.See Fig. 5.

5. Check the fifth wheel for bent, worn, or brokenparts. Replace as needed.

6. If the fifth wheel is equipped with low-lube plates,check the plates and replace if damaged or worndown to the securing bolts. It is normal for out-side edges of the plate to pucker slightly; thisdoes not affect performance.

7. Check the fifth wheel adjustment. Using a locktester, lock and unlock the fifth wheel severaltimes. Make sure that the locking mechanismworks properly.The lock is properly adjusted if: the wheel locksand unlocks easily each time and the lock testerrotates freely.The lock is too loose if: you feel fore-aft playwhen pulling and pushing on the lock testerhandle. See Fig. 6, Ref. A.The lock is too tight if: the lock tester does notrotate freely in the lock. See Fig. 6, Ref. B.

09/01/2009 f311101

Fig. 5, Bracket Pin Bolt Locking Tabs



8. If the lock is improperly adjusted, correct as fol-lows.If the lock is too tight, loosen the jam nut, turnthe adjustment bolt clockwise one full turn, then

reset the jam nut. Lock and unlock the mecha-nism several times to test. Repeat if necessary.See Fig. 7.If the lock is too loose, loosen the jam nut, turnthe adjustment bolt counterclockwise one fullturn, then reset the jam nut. Lock and unlock themechanism several times to test. Repeat if nec-essary. See Fig. 7.

9. If the fifth wheel is equipped with a slidingmechanism, inspect and adjust it as follows.9.1 Check the bracket for any cracks or miss-

ing and damaged parts.9.2 Inspect the locking plungers for full en-

gagement.9.3 Check the locking mechanism for proper

operation.

09/01/2009 f311099

A

B

C

D

E

F

GH

A. Checking for fore/aft play.B. Rotating tester in lock.C. Engage hook.D. Pull/push handle fore/aft.E. Check for movement of kingpin in lock.F. Disengage hook.G. Push/pull handle inboard/outboard.H. Rotate lock tester.

Fig. 6, Jost Fifth Wheel Adjustment

09/02/2009

3

1

2

f311100

1. Jam Nut2. Adjustment Bolt3. Grease Zerk

Fig. 7, Jost Fifth Wheel



If the plungers will not release, check theair cylinder or plunger adjustment.If the plungers are loose, check theplunger adjustment and the plungersprings for proper compression. Replaceif needed.

9.4 The outboard slider assembly requires noadjustment. If the plungers are loose, in-spect and replace locking mechanismparts as needed.

9.5 The inboard slider is adjustable for framewidth and plunger engagement. For ad-justment, refer to the fifth wheel installa-tion instructions.


11. After inspecting the fifth wheel, lubricate all mov-ing parts with a chassis or multipurpose grease.Apply a generous coating of grease to the topplate to fill the grooves, or depressions, on thetop plate. See MOP 31–03 for lubrication instruc-tions.

31–03 Fifth Wheel LubricationTo maintain proper fifth wheel operation, always lubri-cate the fifth wheel after an inspection has beenperformed.

IMPORTANT: Lubricate the fifth wheel:• After power washing, or steam cleaning.• If the vehicle operates in harsh conditions such

as salt spray from road surfaces, or in ex-tremely dusty environments.

• After any service that requires removal of lubri-cation from the fifth wheel top plate or compo-nents.

WARNINGFailure to properly lubricate the fifth wheel couldresult in a possible disengagement of the trailerfrom the tractor, which could result in personalinjury or property damage.

Fontaine1. Tilt the top plate forward (the front of the fifth

wheel is down) and apply grease to each bearingarea through the zerk fittings located on eachside of the top plate just to the front of thebracket pins. Continue to apply grease until it iscoming out of the back of the bearing. It may benecessary to raise the rear of the fifth wheel witha pry bar to open up the pocket slightly andallow the grease to flow through. A substantialamount of grease may be required initially to fillthe reservoir.Tilt the fifth wheel ramps down (the rear of thefifth wheel is down) and repeat the greasing pro-cedure. Rock the top plate back and forth sev-eral times to spread the grease over the bearingsurface.

2. Inspect the trailer kingpin plate and top surfaceof the fifth wheel to make sure each is properlygreased. A liberal coating of grease should beapplied to the complete surfaces of both thetrailer kingpin plate and the top surface of thefifth wheel.

NOTE: Do not use a lube plate (high densitypolyethylene) on top of the fifth wheel or on thekingpin instead of grease without prior approvalby Fontaine Fifth Wheel. The additional thick-ness of this material can prevent the proper op-eration of the fifth wheel and may cause a dan-gerous condition.NOTE: Fontaine suggests the use of a Molybased lubricant such as Mobilgrease XHP 320or equivalent when applying lubricant to thelocking jaw and wedge.3. Lubricate the fifth wheel prior to opening and

closing it. Separate the jaw and wedge with ascrewdriver, and grease the full length of theirmating surfaces. Lubricate the top and bottomcontact surfaces of the jaw and wedge. SeeFig. 5. Open and close the fifth wheel severaltimes to further distribute the grease.Lightly oil other moving parts in the fifth wheel.

4. Apply grease to the top plate. Spread grease allover the mating surface of the top plate. Be surethe grease pockets built into the top plates arefull of grease.



Holland FWS1Apply a heavy coat of grease to the top plate, eitherthrough the grease fittings located on the undersideof the top plate, or by direct application.

Holland FW351. Using a water-resistant lithium-base grease,

grease the top plate.2. Using a light oil (such as SAE 10W or 20W

motor oil), lubricate the cam track and pivot. SeeFig. 8.

3. Grease the yoke tips, locks, and the releasehandle and spring; see Fig. 9. Grease themounting bracket supports through the greasefittings. A “low temp” grade grease rated for-30°F (-34°C) or lower such as Cato Oil andGrease #5213, Craftsman Chemical Co. #LTF 2,Mystic LP-200, or equivalent is recommended.

JostLubricate the kingpin lock using a hand pump greasegun through the grease zerk on the skirt of the fifthwheel; see Fig. 7. Apply a light oil to all moving

parts. For sliding fifth wheels spray diesel fuel on theslide path of the base plate.

NOTICEDo not use a power grease gun. The pressure willdamage the lube line.If the fifth wheel is not equipped with low-lube plates,apply a lithium-based grease with extreme pressure(EP) additive to the trailer contact surface of the fifthwheel.NOTE: If the fifth wheel is equipped with low-lubeplates, the top plate only requires lubrication at thenew product break-in stage. The low-lube plates re-quire no further lubrication.

31–04 Trailer ElectricalConnector Protection

In some cases, failure of trailer cables occurs due tointrusion of chloride-based road deicing chemicalsinto the trailer connector. Once inside the connector,the chloride-based chemicals corrode the brass ter-

12/03/2010 f311136

1

Use a light oil (such as SAE 10W or 20W motor oil) tolubricate the cam track and pivot.

1. Cam Plate

Fig. 8, Holland FW35 Fifth Wheel, Oil Lubrication

12/03/2010 f311135

1

2

2

3 3

4

1. Release Handle andSpring

2. Grease Fitting

3. Yoke Tip4. Locks

Fig. 9, Holland FW35 Fifth Wheel, Grease Lubrication



minals and create bridging between positive andground terminals.

NOTE: The use of soap is not recommended forcleaning the electrical connector, as somesoaps may increase the corrosion process.1. Wash out any existing grease, dirt, and corrosion

on the trailer connectors with electrical contactcleaner spray.

2. Grease the trailer connector with a lithium-baseddielectric grease.



Title of Maintenance Operation (MOP) MOP NumberSuspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01

Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02

Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03

Suspension 32Index, Alphabetical


32–01 Suspension Inspection

Front Suspension Check

WARNINGDo not replace individual leaves of a damaged leafspring assembly; replace the complete spring as-sembly. Visible damage (cracks or breaks) to oneleaf causes hidden damage to other leaves. Re-placement of only the visibly damaged part(s) isno assurance that the spring is safe. On frontspring assemblies, if cracks or breaks exist in thetwo top leaves, a loss of vehicle control couldoccur. Failure to replace a damaged spring assem-bly could cause an accident resulting in propertydamage, serious personal injury, or death.Inspect the front spring assemblies for cracked, bro-ken, or abnormally bent leaves. If any of these condi-tions exist, replace the spring assembly. See Group32 of the 108SD and 114SD Workshop Manual forinstructions.

Shock Absorber Check, Frontand Rear SuspensionsMake sure the shock absorber brackets are tight,and the shock absorber is not striking or rubbing theframe or some other part of the chassis. Striking orrubbing the frame is characterized by chafe marks onthe shock absorber body and the frame rail. Checkthe rubber mounting bushings for cracks, cuts, swell-ing, and dry rot. Also, check the bushings for missingpieces. Replace the bushings as needed.Inspect the shock absorber for oil leakage. If theshock absorber is damaged or leaking, replace it witha new one. See Group 32 of the 108SD and 114SDWorkshop Manual for replacement instructions.

Rear Suspension CheckFreightliner Spring Suspension

WARNINGDo not replace individual leaves of a damaged leafspring assembly; replace the complete spring as-sembly. Visible damage (cracks or breaks) to oneleaf causes hidden damage to other leaves. Re-

placement of only visibly damaged parts is no as-surance that the spring is safe. Failure to replacea damaged spring assembly could cause an acci-dent, resulting in serious personal injury or prop-erty damage.Replace worn, cracked, or damaged springbrackets. Failure to do so could result in bracketbreakage, possibly leading to loss of vehicle con-trol and resulting in personal injury or propertydamage.1. Inspect the forward and rear spring brackets and

equalizer brackets for wear, cracks, and otherdamage. If any of these conditions exist, replacethe damaged bracket(s). See Group 32 of the108SD and 114SD Workshop Manual for instruc-tions.

2. Inspect the tandem-axle frame crossmember andgussets for wear, cracks, and other damage. Ifany of these conditions exist, replace the dam-aged parts. See Group 31 of the 108SD and114SD Workshop Manual for instructions.

NOTICEFailure to replace the suspension crossmember orgussets if they are cracked, worn, or otherwisedamaged could result in damage to the vehiclechassis.3. Without detaching the torque arms, attempt to

move (by hand) each radius-rod end up, down,in, and out. If there is any movement, replace thetorque arm. If a torque arm needs to be re-placed, see Group 32 of the 108SD and 114SDWorkshop Manual for instructions.

4. Inspect the weld seams between the torque armtube and the shorter bushing tubes. If there arecracks, replace the torque arm. Do not weld thetorque arm for any reason.

5. Inspect the rubber bushing ends. See Fig. 1. Re-place the torque arm for any of the following rea-sons:

• if there are gaps between the rubber bush-ing and the pin or outer steel sleeve;

• if either bushing end contacts a torque armpin mounting bolt;

• if there are cracks in the bushing;

Suspension 32


• if part of the rubber bushing extends be-yond the outer circumference of the outerbushing sleeve.

6. Block up the frame enough to take chassisweight off the springs. Attempt to move theequalizer up and down, using a pry bar betweenthe top of the equalizer and top of the equalizerbracket; apply hand pressure only. See Fig. 2. Ifmovement at the center of the equalizer exceeds1/8 inch (3 mm), replace the equalizer bushings.See Group 32 of the 108SD and 114SD Work-shop Manual for instructions.

7. With the vehicle unloaded, attempt to move theequalizer side to side, using a pry bar between

the equalizer and frame rail. Apply hand pressureonly. See Fig. 3. If clearance between the equal-izer assembly and any frame component or fas-tener is less than 1/8 inch (3 mm), replace theequalizer bushings. See Group 32 of the 108SDand 114SD Workshop Manual for instructions.

Freightliner AirLiner Suspension

WARNINGDo not replace individual leaves of a damaged leafspring assembly; replace the complete spring as-sembly. Visible damage (cracks or breaks) to oneleaf causes hidden damage to other leaves. Re-placement of only the visibly damaged part(s) isno assurance that the spring is safe. On frontspring assemblies, if cracks or breaks exist in thetwo top leaves, a loss of vehicle control couldoccur. Failure to replace a damaged spring assem-bly could cause an accident resulting in propertydamage, serious personal injury, or death.1. Inspect the forward and rear spring brackets for

wear, cracks, and other damage. If any of theseconditions exist, replace the damaged bracket(s).See Group 32 of the 108SD and 114SD Work-shop Manual for instructions.

f320021a05/27/93

Fig. 1, Torque Arm Bushings

f320022a05/27/93

1

2

3

A

A. Measure the change in gap at this point.1. Equalizer Bracket2. Equalizer

3. Pry Bar

Fig. 2, Side View of the Equalizer

f320023a05/27/93

1 2

3

4

5

A

A. 1/8" (3 mm) Clearance1. Frame Fasteners2. Frame Rail3. Pry Bar

4. Equalizer5. Equalizer Bracket

Fig. 3, Top View of the Equalizer

Suspension32


WARNINGReplace worn, cracked, or damaged springbrackets. Failure to do so could result in bracketbreakage, possibly leading to loss of vehicle con-trol and resulting in personal injury or propertydamage.2. Inspect the crossmember(s) and gussets for

wear, cracks, and other damage. If any of theseconditions exist, replace the damaged parts. SeeGroup 31 of the 108SD and 114SD WorkshopManual for instructions.

3. Visually check the air spring piston for cracks,chips, and broken areas. Check the air bag forrips, tears, and holes. Verify that the air springassembly does not leak. If any of these condi-tions exist, replace the damaged parts. SeeGroup 32 of the 108SD and 114SD WorkshopManual for instructions.

Freightliner AirLiner ComponentInspection and Operation Check

WARNINGInspect the components and check their operationas described below. Failure to perform these in-spections and checks could result in separation ofworn suspension components and loss of vehiclecontrol, possibly causing personal injury or death,or property damage.1. Chock the front tires. Raise the rear of the ve-

hicle so the tires just clear the ground and thesuspension is fully extended. Place safety standsunder the vehicle frame.

2. Squeeze all air springs to check for completedeflation.

3. Inspect the air spring piston for cracks, chips,and broken areas. Check the air bag for rips,tears, and holes. Verify that the air spring assem-bly does not leak.

4. Check the axle connection welds (beam seat toequalizing beam) and axle adapter to axle forcracks. If welds are cracked, grind them out andreweld the parts observing the welding precau-tions given in Group 31 of the 108SD and114SD Workshop Manual.

5. Move the axle up and down while checking forsigns of looseness due to worn parts at the frontpivot connections. Replace any worn parts.

6. Inspect the shock absorbers for oil leaks andworn rubber bushings. Replace the shock ab-sorbers and/or rubber bushings if wear or dam-age is noted.

7. Inspect the stabilizer bar, if so equipped, for ir-regular bushing wear or cracks in the brackets.The stabilizer bar is optional on 10,000- and15,000-pound AirLiner suspension systems.

8. Remove the safety stands and lower the rear ofthe vehicle to the ground. Run the engine untilair pressure of at least 100 psi (689 kPa) ismaintained throughout the system.

9. Check that all air springs are inflated.

Freightliner AirLiner Control RodCheckNOTE: The Freightliner AirLiner Suspension ismanufactured at numerous weight ratings. Thecontrol rod on the 46,000-pound-rated suspen-sion is larger, and is fastened differently than onother applications.1. Without disconnecting the control rods, use your

hand to attempt to move each of the control rodends up, down, in, and out. If there is any move-ment, examine the control rods for wear or dam-age. Replace if necessary.

2. Inspect the rubber bushings for cracks or cuts.3. Check for any shifting of the barpin.4. Check for cracks in the metal components and

welds.

Ride Height Valve CheckIMPORTANT: Before checking the AirLiner sus-pension height, make sure there is no load onthe chassis, and the trailer is unhitched.

NOTICETo prevent voiding the warranty on Barksdaleheight-control valves, observe the following:

• When removing or loosening a Barksdaleheight-control valve from a mounting bracket,always hold the valve-side mounting studs in

Suspension 32


place with an Allen wrench while loosening ortightening the nuts that attach the valve to thebracket. Because the mounting studs arethreaded into the valve body, loosening the nutswithout holding the studs can tighten the studs,which can crush the valve body and damagethe valve. Conversely, tightening the nuts with-out holding the studs can back the studs out,causing a separation of the two halves of thevalve body, and possibly a leak.

• Do not overtighten the bolts in the Barksdaleheight-control valve housing. The bolts shouldnot be loose, and should not require tightening.Only if necessary, tighten the valve housingbolts 45 lbf·in (500 N·cm). Any damage to thevalve housing will void the warranty.

• Do not attempt to disassemble the Barksdalevalve body or the control lever. There are noserviceable parts in the valve, and any disas-sembly will void the warranty.

1. Park the vehicle on a level surface, using a lightapplication of the brakes. Do not apply the park-ing brakes. Shift the transmission into neutral,and build the secondary air pressure to at least100 psi (690 kPa). Shut down the engine.

2. Mark the location of the front and rear tires onthe floor, and chock the tires on one axle only.

3. Check that the height-control valve vertical link-age is connected and oriented correctly.

NOTE: The stud bolt that fastens the height-control valve horizontal lever to the vertical link-age is oriented correctly when the linkage rod isvertical, as viewed from the side of the vehicle;see Fig. 4. The rod may be on the forward oraft side of the lever to get it to be vertical.4. Measure the distance from the axle stop to the

top of the axle U-bolt pad. The correct distanceis determined by the axle and suspension con-figurations; refer to Group 32 of the 108SD and114SD Workshop Manual for details.

5. If the axle stop measurement is not correct, seeGroup 32 of the 108SD and 114SD WorkshopManual for adjustment procedures.

6. Apply the parking brakes, and remove thechocks.

Freightliner TufTrac1. Inspect the suspension spring assemblies for

pitted, cracked, broken, or abnormally bentleaves, and extreme rust. If any of these condi-tions exist, replace the spring assembly.

WARNINGDo not replace individual leaves of a damaged leafspring assembly; replace the complete spring as-sembly. Visible damage (cracks or breaks) to oneleaf causes hidden damage to other leaves. Re-placement of only the visibly damaged part(s) isno assurance that the spring is safe. On frontspring assemblies, if cracks or breaks exist in thetwo top leaves, a loss of vehicle control couldoccur. Failure to replace a damaged spring assem-bly could cause an accident resulting in propertydamage, serious personal injury, or death.

01/12/2000 f320562a

1 23

4

5

1. Valve MountingBracket

2. Height-Control Valve

3. Stud Bolt4. Linkage Rod5. Axle

Fig. 4, Typical Barksdale Height-Control ValveInstallation (side view)

Suspension32


IMPORTANT: On multi-leaf suspensions, closelyinspect each component of the leaf spring as-semblies, including the brackets, U-bolts, andrelated parts.2. Inspect the brackets for cracks in the castings.

Inspect the V-rod tower welds for cracking orother signs of damage. Also check for contactbetween the frame rail and the upper axle clampbrackets. If contact exists, check the V-rod bush-ing for wear. Check the V-rod fastener torques.

3. Inspect the rubber center bearing and spring tippads for excessive wear, including de-laminationof the rubber-to-metal shim interface, and distor-tion and degradation of rubber.

4. Inspect the V-rods and lower control rods forwear and looseness.4.1 Without disconnecting the control rods,

use your hand to attempt to move each ofthe control rod ends up, down, in, andout. If there is any movement, examinethe control rods for wear or damage. Re-place if necessary.

4.2 Inspect the rubber bushings for cracks orcuts.

4.3 Check for any shifting of the barpin.4.4 Check for cracks in the metal compo-

nents and welds.5. Check all fasteners for looseness.6. Inspect the shock absorbers for oil leaks and

worn rubber bushings. Replace the shock ab-sorbers and/or rubber bushings if wear or dam-age is noted.

Chalmers Suspension1. Chock the front tires, place the transmission in

neutral, and release the parking brakes.2. Power wash the suspension, or clean it with a

hard-bristle brush before performing a visual in-spection.

3. Inspect the rubber bushings for cracks or otherdamage.Try to move the torque rod ends using yourhands only, and check for any free-play. If free-play is felt, replace the torque rod end bushing.Do not use a pry bar to check for free-play. Use

of a pry bar may lead to premature bushing re-placement.

4. Lift the rear of the vehicle and support the frameon jack stands to unload the suspension compo-nents. The vehicle is lifted high enough when thebeam ends are off of the saddles.Inspect the walking beam for cracks or otherdamage. If damage is found, replace the walkingbeam.Keep the vehicle supported by the jack standsfor the next operation.

5. Manipulate the walking beam so that a microme-ter, vernier, or dial caliper can be used to deter-mine the wear area thickness on the bottomface. See Fig. 5. Measurements should be takena minimum of 1/2 inch from the beam flangeedges to eliminate any edge wear that may haveoccurred. Subtract the wear area thickness (seeFig. 5, Ref. B) from the thickness at the non-wear area (see Fig. 5, Ref. A) to determine theamount of wear.If the beams show any wear greater than 0.062inch (1.5 mm), a Chalmers wear plate must beinstalled, or the walking beam must be replaced.

6. Rotate the restrictor cans 360 degrees and in-spect the cans for cracks, severe corrosion, anddistortion. If any of these conditions are present,or the restrictor can is missing, replace the re-strictor can.

WARNINGReplace all cracked or missing restrictor cans.Failure to do so could lead to loss of vehicle con-trol, which could result in property damage, seri-ous personal injury, or death.

32–02 Suspension Lubrication

Freightliner Spring FrontSuspensionWipe all dirt from the grease fittings at the forwardspring pin and the spring shackle pins. Then applymultipurpose chassis grease with a pressure gununtil the old grease is forced out.

Suspension 32


Freightliner Spring RearSuspensionSingle AxleLubrication is not required on single-axle spring rearsuspensions.

Tandem Axle

NOTICEIf the equalizer cap and tube assembly isequipped with a nonrelief grease fitting, excessivelubrication can damage the bushings.Lubricate the equalizer cap and tube assembly bush-ings by applying multipurpose chassis grease at thepressure relief grease fitting. See Fig. 6. Lubricatewith a hand gun or pressure gun until grease isforced out from the base of the pressure-relief fitting.

HendricksonThe Hendrickson RS Series Haulmaax®, HN®, andPrimaax® suspensions do not require lubrication.

For Hendrickson RT® and RTE® series suspensions,lubricate the bronze, ball-indented bushings in thespring eye, as follows:1. Park the vehicle on a level surface, apply the

parking brakes, and chock the front tires.2. Raise the rear of the vehicle until the rear wheels

are suspended in the air, then support the ve-hicle with safety stands. This relieves the load onthe bushings and pins to allow the proper flow oflubricant around them.

3. Using a multipurpose chassis grease, lubricatethe bronze, ball-indented bushings in the springeyes at the grease fitting; see Fig. 7. Continue tolubricate until grease exits both ends of thebushing. If the pin will not accept lubricant, re-move the pin and clean the lubrication channelswhere lubricant may have hardened.

4. Lower the vehicle and remove the safety stands.

32–03 Suspension U-BoltTorque Check

Check the U-bolt torque of both the front and rearaxles where applicable.

NOTICEFailure to tighten the U-bolt nuts to the specifiedtorque value could result in spring breakage andabnormal tire wear.

09/27/95 f320432

1

A

B

A. Non-Wear Area B. Wear Area1. Walking Beam

Fig. 5, Walking Beam End Wear Thickness

320020a05/27/93

1

1

A

A. Lubricate here.1. Cap and Tube Assembly Bushing

Fig. 6, Equalizer Assembly Lubrication

Suspension32


1. Park the vehicle on a flat surface and apply theparking brakes. Chock the tires to prevent thevehicle from moving.

2. Check the U-bolt torque in a diagonal pattern.Set a click-type torque wrench to the highesttorque value for the fastener being checked. SeeFig. 8 for the tightening pattern. See Table 1 forU-bolt torque specifications. Turn the wrench in aclockwise motion (looking up) until the torquewrench clicks.

Spring Assembly U-Bolt High Nut Torque Values*

Size Torque: lbf·ft (N·m)

5/8–18

Stage 1: Hand-tightenStage 2: 60 (81)Stage 3: 200 (271)Stage 4: 180 to 230 (245 to 313)

3/4–16


7/8–14


1–14


* Tighten in a diagonal pattern as shown in Fig. 8.

Table 1, Spring Assembly U-Bolt High Nut TorqueValues

09/15/95 f320424

1

2

2 3

4

4

1. Bronze Bushing2. Lubrication Hole

3. Grease Fitting4. Lubrication Groove

Fig. 7, Hendrickson RT2 and RTE2 Series BushingLubrication

03/10/2011 f320783

1

2 3

4

Fig. 8, Tightening Pattern for U-Bolt High Nuts

Suspension 32


Title of Maintenance Operation (MOP) MOP NumberAlignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04

Knuckle Pin Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01

Tie Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02

Tie Rod Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03

Wheel End Inspection, Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–05

Front Axle 33Index, Alphabetical


33–01 Knuckle Pin Lubrication

NOTICEUse regulated pressure when lubricating theknuckle assemblies, otherwise damage could re-sult to the knuckle caps.

Freightliner AxlesPark the vehicle on a level surface, apply the parkingbrakes, and chock the tires. When lubricating upperand lower knuckle assemblies, do not raise the frontaxle. Wipe the fittings clean, then apply multipurposechassis grease, NLGI Grade 1 (6% 12-hydroxylithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), until new grease isseen at the junctions of the axle beam and knuckles.See Fig. 1.

Dana Spicer AxlesPark the vehicle on a level surface, apply the parkingbrakes, and chock the tires. When lubricating upperand lower knuckle assemblies, do not raise the frontaxle. Wipe the fittings clean, then apply multipurposechassis grease, NLGI Grade 1 (6% 12-hydroxylithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), until new grease isseen at the junctions of the axle beam and knuckles.See Fig. 2. Knuckle pins without grease fittings arepermanently lubricated.

Meritor AxlesPark the vehicle on a level surface, apply the parkingbrakes, and chock the tires. When lubricating knucklepin bushings, do not raise the front axle. Wipe thelube fittings clean, and apply multipurpose chassisgrease, NLGI Grade 2 (8% 12-hydroxy lithium stear-ate grease), until new grease is seen at the bushinggrease seal opposite the fittings. The grease seal willaccept grease pressure without damage, and is de-signed to have grease pumped out through it duringlubrication. Even if grease leaks out around the top,or bottom-plate gasket, continue pumping until newgrease is seen at the bushing seal opposite thegrease fitting; see Fig. 3.NOTE: For operation in very cold climates, useNLGI Grade 1 (6% 12-hydroxy lithium stearategrease).

33–02 Tie Rod InspectionIMPORTANT: If the tie rod end boot is torn ormissing, replace the entire tie rod end. Do notreplace the boot only.1. Shut off the engine, apply the brakes, and chock

the rear tires.2. Check the tie rod boot for cracks, tears, or other

damage. If the tie rod boot is damaged, replacethe entire tie rod end.

f320360a05/31/2005

1

1

A

A Grease exits1. Grease Fitting

Fig. 1, Freightliner Knuckle Pin Lubrication

11/21/95 f330129

1

1

A

A. Grease exits1. Grease Fitting

Fig. 2, Dana Spicer Knuckle Pin Lubrication

Front Axle 33


3. Grasp by hand (or use a pipe wrench with jawprotectors to avoid gouging the cross tube) andslightly rotate the cross tube toward the front ofthe vehicle and then slightly toward the rear.Then center the cross tube between the stop po-sitions. If the cross tube does not rotate in eitherdirection, replace both tie rod ends.

4. Position yourself directly below the ball studsocket. Using both hands, grab the end as closeto the socket as possible, no more than 6 inches(15.2 cm) from the end. Firmly apply about 100pounds of hand pressure in an up and down mo-tion several times. When moving the assembly,check for any movement at both tie rod ends.See Fig. 4.If any movement is detected at one tie rod end,replace both tie rod ends. Always replace tie rodends in pairs, even if only one tie rod end isdamaged.

NOTICEDo not attempt to straighten a bent cross tube.Doing so could result in damage to the axle. Besure to replace the cross tube with an originalequipment cross tube with the same length, diam-eter, and thread size as the existing cross tube.

5. Check the cross tube for cracks or other dam-age. If the cross tube is bent or damaged, re-place the cross tube.

6. Check the clamps for damage. If a clamp isdamaged, replace the clamp. Replace the entirecross tube assembly if either clamp is welded tothe cross tube.

7. Check for proper installation of the tie rod endclamp to the cross tube. Make sure that the tierod ends are threaded in the cross tube past theclamps and the slots at the cross tube ends.

8. Check the zerk fittings for damage. If a zerk fit-ting is damaged, replace it.Some tie rod ends have no zerk fittings becausethey are not greaseable. Do not install a zerkfitting on a nongreaseable tie rod end.

9. Check that the cotter pin is in place. If it is not,tighten the tie rod end nut to one of the followingspecs depending on the axle manufacturer.For Freightliner axles, tighten the castle nut to120 to 170 lbf·ft (163 to 230 N·m). To align thecotter pin hole with the castle nut slot, turn thenut up to 1/6 turn (maximum).For Meritor axles, tighten the tie rod end nut perthe size of the stud:

• 7/8–14, 160 to 300 lbf·ft (217 to 406 N·m)• 1–14, 250 to 450 lbf·ft (339 to 610 N·m)• 1-1/8–12, 350 to 650 lbf·ft (475 to 881

N·m)

09/06/96 f320032a

A

1

1

A. Grease exits1. Grease Fitting

Fig. 3, Meritor Knuckle Pin Lubrication

10/10/2001 f330195

Fig. 4, Check Movement of Tie Rod End

Front Axle33


• 1-1/4–12, 500 to 675 lbf·ft (678 to 915N·m)

10. Check the steering arm bolts for a minimumtorque of 300 lbf·ft (406 N·m). If the steering armbolt torque has fallen below this specification,remove the bolt, clean all the threads, and applynew Loctite® 680. Tighten the bolt 300 to 450lbf·ft (406 to 610 N·m).

11. Remove the chocks from the tires.

33–03 Tie Rod Lubrication

Freightliner AxlesFor any Freightliner axle that requires lubrication ofthe tie-rod ends, wipe the grease fittings clean, thenpump multipurpose chassis grease, NLGI Grade 1(6% 12-hydroxy lithium stearate grease) or NLGIGrade 2 (8% 12-hydroxy lithium stearate grease),into the tie-rod ends until all used grease is forcedout and fresh grease is seen at the ball stud neck.

Dana Spicer AxlesFor any Dana Spicer axle that requires lubrication ofthe tie-rod ends, wipe the grease fittings clean, thenpump multipurpose chassis grease, NLGI Grade 2(8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and freshgrease is seen at the ball stud neck.NOTE: For operation in very cold climates, useNLGI Grade 1 (6% 12-hydroxy lithium stearategrease).

Meritor AxlesFor any Meritor axle that requires lubrication of thetie-rod ends, wipe the grease fittings clean, thenpump multipurpose chassis grease, NLGI Grade 1(6% 12-hydroxy lithium stearate grease) or NLGIGrade 2 (8% 12-hydroxy lithium stearate grease),into the tie-rod ends until all used grease is forcedout and fresh grease is seen at the ball stud neck.

33–04 Alignment Check

Drive Axle Alignment CheckingCheck the axle alignment, parallelism, and thrustangle measurements for the rear drive axles. Forspecifications and procedures, see Group 35 of the108SD and 114SD Workshop Manual.

Toe-In InspectionFor vehicle alignment to be accurate, the shop floormust be level in every direction. The turn plates forthe front wheels must rotate freely without friction,and the alignment equipment must be calibratedevery three months by a qualified technician from theequipment manufacturer. Freightliner dealers musthave proof of this calibration history.1. Apply the parking brakes and chock the rear

tires.2. Raise the front of the vehicle until the tires clear

the ground. Place safety stands under the axle.3. Using spray paint or a piece of chalk, mark the

entire center rib of each front tire.4. Place a scribe or pointed instrument against the

marked center rib of each tire, and turn the tires.The scribe must be held firmly in place so that asingle straight line is scribed all the way aroundeach front tire.

5. Place a turn-plate or turntable under both fronttires. Remove the safety stands and lower thevehicle. Remove the lock-pins from the gauges;make sure the tires are exactly straight ahead.

NOTE: If turn-plates or turntables are not avail-able, lower the vehicle. Remove the chocksfrom the rear tires and release the parkingbrakes. Move the vehicle backward, then for-ward about six feet (two meters).6. Place a trammel bar at the rear of the front tires;

locate the trammel pointers at spindle height,and adjust the pointers to line up with the scribelines on the center ribs of the front tires. SeeFig. 5. Lock in place. Check that the scale is seton zero.

7. Place the trammel bar at the front of the tires(see Fig. 6) and adjust the scale end so that thepointers line up with the scribe lines. See Fig. 7.

Front Axle 33


8. Read the toe-in from the scale, and compare it tothe toe-in specification in Group 33 of the108SD and 114SD Workshop Manual. If correc-tions are needed, refer to Group 33 of the108SD and 114SD Workshop Manual for instruc-tions on adjusting the toe-in.

33–05 Wheel End Inspection,Front Axle

1. Park the vehicle on a level surface, shut downthe engine, set the parking brake, and chock thetires.

WARNINGNever work around or under a vehicle that is sup-ported only by a jack. Always support the vehicle

with safety stands. Jacks can slip, causing thevehicle to fall, which could result in serious injuryor death.2. Raise the front of the vehicle and support it with

safety stands.3. Remove the front wheel and tire assemblies. For

instructions, see Group 40 of the 108SD and114SD Workshop Manual.

4. Remove the brake drum. For more information,see Group 33 of the 108SD and 114SD Work-shop Manual.

5. Check for loose, damaged, or missing fastenersand hubcaps.

6. Check for lubricant around the hub cap andwheel. If lubricant is present, investigate thecause and take corrective action.

7. Check for lubricant around the hub, brake hard-ware, and brake shoes (if installed). If lubricant ispresent, check the oil seal and replace it as nec-essary. For instructions, see Section 33.02 ofthe 108SD and 114SD Workshop Manual.

8. Inspect the lubricant for discoloration. Under nor-mal conditions, the lubricant will darken; a white

A

Bf330082a08/29/94

NOTE: B minus A equals toe-in.

Fig. 5, Wheel Toe-In (overhead view)

f330014a08/30/94

Fig. 6, Trammel Bar Positioning

f400100a08/30/94

Fig. 7, Setting Trammel Bar Pointers

Front Axle33


or milky appearance indicates water contamina-tion. If the lubricant is discolored, service thewheel end. See the 108SD and 114SD Work-shop Manual and manufacturer literature for pro-cedures.

IMPORTANT: Do not mix different types of lubri-cants.9. Inspect the lubricant for the presence of foreign

matter. Use a magnet to detect any metallic ma-terials present in the lubricant. If the lubricant iscontaminated, service the hub. See the 108SDand 114SD Workshop Manual and manufacturerliterature for procedures.

10. Rotate the hub and check for free, smooth, andquiet rotation. If rotation is hampered, service thehub immediately. See the 108SD and 114SDWorkshop Manual and manufacturer literature forprocedures.

11. Using a dial indicator, measure the end play asfollows.

IMPORTANT: Do not measure the wheelbearing end play with the wheel mounted onthe hub; you cannot accurately measure oradjust bearing end play with the wheelmounted on the hub. Also, ensure that thebrakes are not applied so that that drum andhub can move freely.11.1 On vehicles equipped with aluminum

hubs, install an iron brake drum onto thehub to provide a ferrous surface for themagnetic base of the dial indicator. Withflange nuts, secure the drum to the hubusing the stud at the 12 o’clock position,followed by the studs at about the 4o’clock and 8 o’clock positions. Ensurethe nuts hold the drum securely; usewashers if needed.

11.2 Clean the spindle end; ensure it is free ofdebris and provides the smooth surfaceneeded for the ball bearing (installedlater) to seat against.

11.3 Attach the magnetic base of a dial indica-tor to the drum (or, on vehicles equippedwith iron hubs, the hub).

11.4 Dab a little grease in the center drilledhole on the end of the spindle and placean appropriate-sized ball bearing in the

hole. Center the measuring end of thedial indicator on the ball and parallel tothe spindle as shown in Fig. 8.

IMPORTANT: Maintain continual pressure onthe hub until you have taken both the in-board and outboard measurements. If yourelease the hub, an accurate measurementis not possible.11.5 To seat the bearings, grip the hub at the

three o’clock and nine o’clock positions,and push inward while oscillating it ap-proximately 45 degrees. Maintain pres-sure on the hub and note the measure-ment.

11.6 Pull the hub and drum outward while os-cillating it as before. Maintain pressure onthe hub, and note the outboard extent ofthe end play.

11.7 Find the end play by noting the differencebetween the two readings. The end playlimit for PreSet hubs is 0.006 inch (0.15mm); for non-PreSet hubs the acceptable

f330248a02/18/2011

A

A. Dab a little grease in the center drilled hole on the endof the spindle and place an appropriate-sized ball bearingin the hole.

Fig. 8, Dial Indicator Setup

Front Axle 33


range is 0.001 to 0.005 inch (0.03 to 0.13mm) inclusive.If the end play does not exceed the limitand no other problems were found in theprevious steps, no additional service isnecessary. If the end play exceeds thelimit, service the hub. See the 108SD and114SD Workshop Manual and manufac-turer literature for procedures.

Front Axle33


Title of Maintenance Operation (MOP) MOP NumberAxle Breather Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02

Axle Lubricant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check . . . . . . . . . . . . . . . . . . . . . 35–03

Wheel End Inspection, Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–04

Rear Axle 35Index, Alphabetical


35–01 Axle Lubricant LevelCheck

NOTICEFailure to keep the rear axle filled to the properlevel with the recommended lubricant can result inrear axle damage.1. Park the vehicle on level ground, apply the park-

ing brakes, and chock the tires.2. If the vehicle has just been driven, allow a few

minutes for the lubricant to settle.3. Clean the oil fill hole plug (located in the carrier

or the side of the axle housing) and the area sur-rounding it, then remove the plug. For Freigtlineraxles, see Fig. 1; for Meritor axles, see Fig. 2;for Dana Spicer axles, see Fig. 3.

NOTE: Some Freightliner and Meritor axleshave a small tapped and plugged hole locatedbelow the housing oil fill hole. This smaller holeis for the lubricant temperature sensor only andmust not be used as a fill or level hole.IMPORTANT: A lubricant level close enough tobe seen or touched is not sufficient. It must belevel with the bottom of the fill hole.4. Check the level of the lubricant. The lubricant

must be level with the bottom of the oil fill hole.See Fig. 4. If low, add lubricant.For Freightliner axles, see Table 1 for approvedaxle lubricants and lubricant capacities.For Meritor axles, see Table 2 for approved axlelubricants, and Table 3 or Table 4 for axle ca-pacities.For Dana Spicer axles, see Table 5 for approvedaxle lubricants, and Table 6 for axle capacities.

5. Install the oil fill hole plug and tighten it per thefollowing:

• For Freightliner axles: 37 lbf·ft (50 N·m).• For Meritor axles: 35 lbf·ft (47 N·m).• For Dana Spicer axles: 50 lbf·ft (68 N·m).

6. On non-drive axles using oil-lubricated wheelbearings, clean the hub cap and plug to minimizethe possibility of dirt and road grime entering the

assembly. Remove the plug, and check the oillevel. If low, add fluid using the same lubricantrecommended for the drive axle.

1

2

4 3

2

B

A

12/07/2010 f350509a

A. Front View B. Rear View1. Axle Breather2. Breather Hose3. Temperature Sensor

Port

4. Oil Fill Plug

Fig. 1, Freightliner Tandem Axle (forward axle shown)

Rear Axle 35


06/07/94 f350062a

1

2 3

1. Axle Housing Breathers2. Carrier Oil Fill Plugs3. Interaxle Differential

Fig. 2, Fill Hole Plug and Axle Housing BreatherLocations, Meritor Axles

12/09/2010 f350531

1

2

3

1. Oil Fill Plug2. Oil Drain Plug3. Axle Breather

Fig. 3, Oil Fill and Drain Plugs and Axle Breather, DanaSpicer Axles

f350061a

A

B

08/17/2009

A. Correct (lube level at bottom of fill hole)B. Incorrect (lube level below fill hole)

Fig. 4, Axle Lubricant Level Check

Rear Axle35


Freightliner Rear Axle Approved Lubricant Type and Capacity

Axle Oil Capacity: Quarts (liters)Lubricant

Synthetic Mineral

Forward-Rear 15.9 (15.0)75W–90*80W–140

85W–14080W–14080W–90*75W–90

75W75W–140

Single and Rearmost Tandem 10.6 (10.0)

* Typical lubricant.

Table 1, Freightliner Rear Axle Approved Lubricant Type and Capacity

Meritor Drive Axle Recommended LubricantLubricant Type Ambient Temperature Viscosity Grade Meritor Specification

Non-Extended DrainLubricants

10°F (–12.2°C) and up* 85W–140 0–76–A

–15°F (–26.1°C) and up* 80W–140 0–76–B

–15°F (–26.1°C) and up* 80W–90 0–76–D

–40°F (–40°C) and up* 75W–90 0–76–E

–40°F (–40°C) to 35°F (2°C) 75W 0–76–J

–40°F (–40°C) and up* 75W–140 0–76–L

Extended Drain Lubricants–40°F (–40°C) and up* 75W–90 0–76–N

–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 2, Meritor Drive Axle Recommended Lubricant

Meritor Drive Axle Lubricant Capacities for SingleAxles

Axle Model Capacity*:pt (L)

RS–23–160 39.5 (18.7)

RS–23–161 37.2 (17.6)

RS–23–186 47.3 (22.4)

RS–25–160 37 (17)

RS–26–185 46.0 (22.0)

RS–30–185 46.0 (22.0)

RS–30–380 58.2 (27.5)

RS–38–380 53.1 (25.1)

* Quantities listed are approximate and include 1 pint (0.5 liter) for eachwheel end and with the drive pinion at 3 degrees.

Table 3, Meritor Drive Axle Lubricant Capacities forSingle Axles

Meritor Drive Axle Lubricant Capacities for TandemAxles

Axle Model Axle Position Capacity*

RT–40–145Forward 30.2 (14.3)

Rear 25.8 (12.2)

RT–40–145PForward 30.2 (14.3)

Rear 25.8 (12.2)

RT–40–160Forward 39.1 (18.5)

Rear 34.4 (16.3)

RT–44–145RT–44–145P

Forward 29.3 (13.9)

Rear 25.1 (11.9)

RT–46–160Forward 39.1 (18.5)

Rear 34.4 (16.3)

RT–46–164EH/PForward 38.0 (18.0)

Rear 33.0 (15.0)

Rear Axle 35


Meritor Drive Axle Lubricant Capacities for TandemAxles

Axle Model Axle Position Capacity*

RT–50–160Forward 38.0 (18.0)

Rear 33.0 (15.0)

RT–52–185Forward 56.1 (26.5)

Rear 36.1 (17.1)

RT–58–185Forward 56.1 (26.5)

Rear 36.1 (17.1)

* Quantities listed are approximate and include 1 pint (0.5 liter) for eachwheel end and with the drive pinion at 3 degrees.

Table 4, Meritor Drive Axle Lubricant Capacities forTandem Axles

Dana Spicer Drive Axle Recommended Lubricant

Lubricant Type ConditionLubricant SAE

ViscosityGrade

Dana SpicerRoadranger®

Synthetic Drive AxleLubricants, orEquivalent withMilitary SpecificationMIL–L–2105D

Over-the-RoadService 75W–90

Off-HighwayEquipment, orUnder ExtraHeavy Loads

80W–140

Table 5, Dana Spicer Drive Axle RecommendedLubricant

Dana Spicer Drive Axle Lubricant Capacities

Axle Model Capacity*:Pints (liters)

DD405 31 (14.7)†

DP463P 40 (18.9)†

* Quantities listed are approximate. Fill axle until lubricant is level with bot-tom of fill hole with vehicle on level ground.† Add 2 pints (1 L) of additional lubricant to the power divider.

Table 6, Dana Spicer Drive Axle Lubricant Capacities

35–02 Axle Breather CheckThe axle housing breather must remain clean. Whenthe axle lubricant level is checked, check that theaxle breather is open. Check more often under ad-verse operating conditions. If the breather is plugged,clean it or replace it as needed. For the location of

the breather on Freightliner axles, see Fig. 1; forMeritor axles, see Fig. 2; and for Dana Spicer axles,see Fig. 3.

35–03 Axle Lubricant and FilterChange, and MagneticStrainer Cleaning andCheck

NOTICEWhen operating under adverse conditions, it maybe necessary to change the axle lubricant at morefrequent intervals than listed in the scheduledmaintenance tables. Failure to do so could resultin axle damage.

Freightliner Axles1. Park the vehicle on level ground, apply the park-

ing brakes, and chock the tires.NOTE: Some Freightliner axles have a smalltapped and plugged hole near and below thehousing oil fill hole. This smaller hole is for alubricant temperature indicator only, and shouldnot be used as a fill or level hole.2. Clean the oil fill plug and the area around it, then

remove the plug from the oil fill hole. See Fig. 1.3. Place a drain pan under the rear axle drain plug.

Drain the oil when it is warm. At this tempera-ture, the oil will run more freely and ensure thatthe axle is flushed.

4. Clean the fill and drain plugs as follows. Changethem if necessary.4.1 For magnetic plugs, use a piece of key

stock or any other convenient steel slugto short the two magnetic poles and divertthe magnetic field.

4.2 Clean away the collected material depos-ited on each pole. Magnets will rapidlylose their effectiveness as collected mate-rial bridges the gap between the twopoles.

4.3 Inspect the drain plug for large quantitiesof metal particles.

Rear Axle35


4.4 After cleaning, install the drain plug(s)and tighten to 37 lbf·ft (50 N·m).

IMPORTANT: The use of friction modifiers is notapproved in Freightliner drive axles.5. Fill the axle with the recommended lubricant as

follows. See Table 1 for recommended drive axlelubricants and drive axle lubricant capacities.5.1 With the vehicle on a level surface, fill the

axle through the oil fill hole. Lubricantshould be level with the bottom of the oilfill hole.

5.2 Check the fluid level; see Fig. 4.5.3 Install and tighten the fill plug 37 lbf·ft (50

N·m).

Meritor AxlesIMPORTANT: If using synthetic lubricant, thelubricant change interval is extended to 100,000miles (160 000 km). On axles with a pump andfilter system, the filter change interval is 100,000miles (160 000 km).1. Park the vehicle on level ground, apply the park-

ing brakes, and chock the front tires.NOTE: Some Meritor axles have a small tappedand plugged hole near and below the housinglubricant fill hole. This smaller hole is for a lubri-cant temperature indicator only, and should notbe used as a fill or level hole.2. Clean the area around the fill plug, then remove

the fill plug.3. Place a drain pan under the drain plug, then re-

move the drain plug from the bottom of the hous-ing. Completely drain the lubricant while the unitis warm, to allow the lubricant to drain faster.On tandem-drive axles, it is also necessary toremove the plug at the bottom of the interaxledifferential housing to drain that lubricant.

4. If equipped with an oil pump, replace the filter.

NOTE: There may be about one pint (0.5 L)of lubricant remaining in the filter.4.1 Remove the axle oil filter using a suitable

filter strap wrench (see Fig. 5) and dis-card it.

4.2 Using recommended drive axle lubricant(see Table 2), coat the face of the gasketon the new oil filter.

4.3 Install the filter over the adapter, andtighten the filter one full turn after thegasket contacts the base; do notovertighten.



5.2 Check the drain plug for metal particlesevery 100,000 miles (160 000 km). Cleanaway the collected material deposited oneach pole. Magnets will rapidly lose theireffectiveness as collected materialbridges the gap between the two poles.

5.3 Meritor recommends plugs with elementshaving a minimum pickup capacity of 1.5pounds (0.7 kg) of low-carbon steel. Eachtime the oil is changed, replace any mag-netic drain plug that does not meet theminimum pickup capacity.

5.4 Install the drain plug(s) and tighten to 35lbf·ft (47 N·m).

6. Fill the axle with recommended lubricant as fol-lows. For lubricant capacities, see Table 3

f350119a05/27/93

Fig. 5, Meritor Axle Oil Filter Removal

Rear Axle 35


(single axles) or Table 4 (tandem axles). SeeTable 2 for recommended lubricant.6.1 With the vehicle on a level surface, fill the

axle through the oil fill hole. Allow a fewminutes for the oil to flow into the axle.Lubricant should be level with the bottomof the oil fill hole.


N·m).7. Whenever the interaxle differential housing has

been drained, add an additional 2 pints (0.9 L) ofthe recommended lubricant directly into the inter-axle differential housing.

8. Remove the chocks, then drive the vehicle, un-loaded, for 1 or 2 miles (2 or 3 km) at speedsnot to exceed 25 mph (40 km/h), to thoroughlycirculate lubricant throughout the carrier andhousing assemblies.

Dana Spicer AxlesNOTE: If using a Roadranger synthetic driveaxle lubricant, the lubricant change interval isextended to 180,000 miles (288 000 km).1. Park the vehicle on level ground, set the parking

brakes, and chock the tires.NOTE: Some Dana Spicer axles have a smalltapped and plugged hole near and below thehousing oil fill hole. This smaller hole is for alubricant temperature indicator only, and shouldnot be used as a fill or level hole.2. Clean the oil fill plug and the area around it (see

Fig. 3), then remove it from the oil fill hole.3. Place a drain pan under the rear axle drain plug;

see Fig. 3. Drain the oil at normal operating tem-perature, 150°F to 200°F (65°C to 93°C). At thistemperature, the oil will run more freely and en-sure that the axle is flushed.

NOTE: Some tandem-drive axles are equippedwith a cylindrical magnetic strainer, locatedbelow the lube pump on the front of the powerdivider cover. All rear axles are fitted with mag-netic drain and fill plugs.4. At each axle oil change, remove and clean the

magnetic strainer, if equipped, as follows.

4.1 Remove the magnetic strainer from thepower divider cover. See Fig. 6.

WARNINGAlways wear eye protection when using com-pressed air to clean parts, as flying debris couldcause permanent damage to unprotected eyes. Donot point the air stream in the direction of otherpersons.

4.2 Wash the strainer in solvent, and blow itdry with compressed air to remove oil andmetal particles.

4.3 Install and tighten the magnetic strainer40 to 60 lbf·ft (54 to 81 N·m).



5.2 Clean away the collected material depos-ited on each pole. Magnets will rapidlylose their effectiveness as collected mate-rial bridges the gap between the twopoles.

f350017a

1

2

05/27/93

1. Magnetic Strainer 2. Power Divider

Fig. 6, Dana Spicer Tandem-Drive Axle MagneticStrainer

Rear Axle35


5.3 Inspect the drain plug for large quantitiesof metal particles.

5.4 After cleaning, install the drain plug(s)and tighten to 40 to 60 lbf·ft (54 to 81N·m).

IMPORTANT: The use of friction modifiers is notapproved in Dana drive axles.6. Fill the axle with the recommended lubricant as

follows. See Table 5 for recommended lubri-cants, and Table 6 for drive axle lubricant ca-pacities.6.1 With the vehicle on a level surface, fill the

axle through the oil fill hole. Lubricantshould be level with the bottom of the oilfill hole.


N·m).

35–04 Wheel End Inspection,Rear Axle

1. Park the vehicle on a level surface, shut downthe engine, set the parking brake, and chock thetires.

WARNINGNever work around or under a vehicle that is sup-ported only by a jack. Always support the vehiclewith safety stands. Jacks can slip, causing thevehicle to fall, which could result in serious injuryor death.2. Raise the rear of the vehicle until the tires clear

the ground. Then place safety stands under theaxle.

3. Remove the rear wheel and tire assemblies. Forinstructions, see Group 40 of the 108SD and114SD Workshop Manual.

4. Remove the brake drum. For more information,see Group 35 of the 108SD and 114SD Work-shop Manual.

5. Check for loose, damaged, or missing fasteners.6. Check for lubricant at the wheel seal and drive

flange gasket. If lubricant is present, investigatethe cause and take corrective action.

7. Check for lubricant around the hub, brake hard-ware, and brake shoes (if installed). If lubricant ispresent, check the oil seal and replace it as nec-essary. For instructions, see Section 35.02 ofthe 108SD and 114SD Workshop Manual.

8. Remove the axle shaft.9. Inspect the lubricant for discoloration. Under nor-

mal conditions, the lubricant will darken; a whiteor milky appearance indicates water contamina-tion. If the lubricant is discolored, service thewheel end. See the 108SD and 114SD Work-shop Manual and manufacturer literature for pro-cedures.

IMPORTANT: Do not mix different types of lubri-cants.10. Inspect the lubricant for the presence of foreign

matter. Use a magnet to detect any metallic ma-terials present in the lubricant. If the lubricant iscontaminated, service the hub. See the 108SDand 114SD Workshop Manual and manufacturerliterature for procedures.

11. Rotate the hub and check for free, smooth, andquiet rotation. If rotation is hampered or rough, orany unusual noise is heard, service the hub im-mediately. See the 108SD and 114SD WorkshopManual and manufacturer literature for proce-dures.

12. Using a dial indicator, measure the end play asfollows.

IMPORTANT: Do not measure the wheelbearing end play with the wheel mounted onthe hub; you cannot accurately measure oradjust bearing end play with the wheelmounted on the hub. Also, ensure that thebrakes are not applied so that that drum andhub can move freely.12.1 On vehicles equipped with aluminum

hubs, install an iron brake drum onto thehub to provide a ferrous surface for themagnetic base of the dial indicator. Withflange nuts, secure the drum to the hubusing the stud at the 12 o’clock position,followed by the studs at about the 4o’clock and 8 o’clock positions. Ensurethe nuts hold the drum securely; usewashers if needed.

Rear Axle 35


12.2 Clean the spindle end; ensure it is free ofdebris and provides the smooth surfaceneeded for the dial indicator to take anaccurate measurement.

12.3 Attach the magnetic base of a dial indica-tor to the drum (or, on vehicles equippedwith iron hubs, the hub). See Fig. 7.

12.4 Set the measuring end of the indicatoragainst the spindle end as shown in Fig.8. The indicator should be square withthe end of the spindle.

IMPORTANT: Maintain continual pressure onthe hub until you have taken both the in-board and outboard measurements. If yourelease the hub, an accurate measurementis not possible.12.5 To seat the bearings, grip the hub at the

three o’clock and nine o’clock positions,and push inward while oscillating it ap-proximately 45 degrees. Maintain pres-sure on the hub and note the measure-ment.

NOTE: The end play measurements must betaken at the same point to prevent an un-

even spindle end from skewing the results.As needed, mark the spot on the spindlewhere the inboard measurement was taken.12.6 Pull the hub and drum outward while os-

cillating it as before. Maintain pressure onthe hub, and note the outboard extent ofthe end play. See Fig. 9.

07/14/2009 f350501

1

2

3

451. Flange Nut2. Aluminum Hub3. Dial Indicator

4. Magnetic Base5. Iron Brake Drum

Fig. 7, Dial Indicator Setup, Aluminum Hub with IronBrake Drum

07/10/2009 f350502

1

2

The indicator should be square with the end of the spindle.1. Dial Indicator 2. Spindle End

Fig. 8, Indicator Square with the Spindle

07/14/2009 f350500

Fig. 9, Pulling the Hub Outward to Measure End Play

Rear Axle35


12.7 Find the end play by noting the differencebetween the two readings. The end playlimit for PreSet hubs is 0.006 inch (0.15mm); for non-PreSet hubs the acceptablerange is 0.001 to 0.005 inch (0.03 to 0.13mm) inclusive.If the end play does not exceed the limitand no other problems were found in theprevious steps, no additional service isnecessary. If the end play exceeds thelimit, service the hub. See the 108SD and114SD Workshop Manual and manufac-turer literature for procedures.

Rear Axle 35


Title of Maintenance Operation (MOP) MOP NumberWheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01

Wheels and Tires 40Index, Alphabetical


40–01 Wheel Nut CheckIMPORTANT: After a wheel has been installed,the wheel nut torque must be rechecked after50 to 100 miles (80 to 160 km) of operation.

NOTICEInsufficient wheel nut (rim nut) torque can causewheel shimmy, resulting in wheel damage, studbreakage, and extreme tire tread wear. Excessivewheel nut torque can break studs, damagethreads, and crack discs in the stud hole area.Follow the tightening sequence shown in Fig. 1,using the recommended torque values in Table 1.

Disc Wheel Fastener TorquesDescription Nut Size Wheel Manufacturer Torque: lbf·ft (N·m)

10-Hole and 8-Hole Hub-Piloted Disc Wheel With Two-Piece Flange Nuts*

Front and Rear Wheel Nut M22 x 1.5 All 450–500 (610–678)* Torque values for hub-piloted wheels are given for lubricated threads. Lubricate threads with SAE 30W engine oil. Do not apply thread lubricant to ball seats

of the nuts and wheels. Wipe it off if it is applied accidentally.

Table 1, Disc Wheel Fastener Torques

09/18/2001A B

f400164

110 8

63

5 4

92

7

1 2

4

6

7

5

83

A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel

Fig. 1, Wheel Nut Tightening Sequence

Wheels and Tires 40


Title of Maintenance Operation (MOP) MOP NumberDriveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01

Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02

Driveline 41Index, Alphabetical


41–01 Driveline Inspection1. Park the vehicle on a flat, level surface, apply

the parking brakes, and chock the tires.

WARNINGSelf-locking bearing-cup or bearing-strap cap-screws must not be reused; replace the cap-screws with new ones. Also, do not undertightenor overtighten any bearing-cup or bearing-strapcapscrews. A loose or broken fastener at anypoint in the driveline weakens the driveline con-nection, which could cause serious vehicle dam-age, or could result in a driveshaft separatingfrom the vehicle, possibly causing loss of vehiclecontrol that could result in serious personal injuryor death.2. Check the torque of the U-joint capscrews; see

Table 1 for installed torque values.Remove and discard any loose capscrews. Donot reuse any loosened self-locking capscrews;they are designed for one-time installation only.Replace all loosened and removed capscrewswith new ones. Tighten the new capscrews asspecified in Table 1.For half-round yokes with bearing straps , tightenthe bearing-strap capscrews following the tight-ening sequence shown in Fig. 1, in incrementsof 20 lbf·ft (25 N·m) to the torque specificationslisted in Table 1.

3. Check the driveline yokes for cracks, and checkend-yokes for looseness; see Fig. 2.Replace cracked yokes.If any end-yoke can be moved in or out on itsshaft, or can be rocked on its shaft, disconnectthe driveshaft and U-joint from the yoke, thencheck the drive component’s shaft seal for leak-age or other visible damage that may have beencaused by the loose yoke. Replace the seal ifneeded, then tighten the yoke nut. Refer to Sec-tion 41.00, Specifications 400 of the 108SDand 114SD Workshop Manual for torque specifi-cations. If the yoke is still loose after tighteningthe yoke nut, replace the end-yoke and yoke nut.Replace the prevailing torque locknut (end-yokenut) if it was removed for yoke replacement, sealreplacement, or any other reason.

4. Check U-joint assemblies for wear by moving thedriveshaft up and down, and from side to side. Ifany movement of the U-joint cross in the bear-ings can be felt or seen, replace the U-joint as-sembly.

5. Check if the midship bearing and mounting areloose or have deteriorated, by attempting tomove the driveshaft up and down, and from sideto side. If the bearing is loose on its shaft, orrattles, replace it. If the bearing mount is looseon the frame, tighten the mounting fasteners tothe proper torque value. See Section 41.00,Specifications 400 of the 108SD and 114SDWorkshop Manual for torque specifications. Re-place the midship bearing assembly if the rubbercushion is deteriorated or oil-soaked.

6. Check slip joints for spline wear by moving thesleeve-yoke and splined shaft back and forth;see Fig. 3. If the slip joint can be twisted in aclockwise, or counterclockwise movementgreater than 0.007 inch (0.18 mm), replace boththe sleeve-yoke and the splined shaft.

7. Examine the driveshaft tubes for dents, bends,twists, or other damage. If any tube appears tobe damaged, refer to Section 41.00 of the108SD and 114SD Workshop Manual for repairand replacement instructions.

8. Examine the driveshaft for evidence of missingbalance weights, and for build-up of foreign ma-terial. Remove any foreign material. If there isany evidence that balance weights are missing,remove the driveshaft and have it balanced.

12/16/2008 f410529

2

1

2

1

Tighten the capscrews in a counterclockwise sequence,starting with either number 1 position.

Fig. 1, Tightening Sequence, Half-Round Yoke BearingStrap Capscrews

Driveline 41


U-Joint Capscrew Torque SpecificationsYoke Capscrew Size Torque: lbf·ft (N·m)

Half-Round Yokes with Bearing Straps (see Fig. 2, item 8)

0.375" 45–60 (60–80)

0.5" 115–135 (155–183)

12 mm 115–135 (155–183)

Full-Round Yokes with Bearing Cups (Fig. 4) 0.375" 38–48 (52–65)

f410067c

1 2

3

3

12/08/2010

456

78 9

10

11

12

13

14 15

16

NOTE: Not all fasteners are shown.1. Transmission2. Transmission Output-Shaft

End-Yoke (half-round)3. U-Joint Assembly4. Bearing Plate Self-Locking

Capscrew5. Bearing Cup (for full-round

yoke)

6. U-Joint Cross7. Bearing Cup (for half-round

yoke)8. Bearing Strap and Bearing-

Strap Capscrew9. Slip-Joint Assembly10. Sleeve-Yoke (full-round)

11. Dust Cap12. Splined Stub Shaft13. Driveshaft Tube14. Tube-Yoke (full-round)15. Axle Input-Shaft End-Yoke

(half-round)16. Rear Axle

Fig. 2, Components of a Basic Driveline

Driveline41


U-Joint Capscrew Torque SpecificationsYoke Capscrew Size Torque: lbf·ft (N·m)

Meritor RPL Series U-Joints with Bearing Cups (Fig. 5) 0.5" 115-135 (155-183)

Table 1, U-Joint Capscrew Torque Specifications

9. For driveshafts with slip joints, check to be surethe yoke plug is not loose or missing; see Fig. 6,item 2. Repair or replace the yoke plug asneeded. If the yoke plug is missing, the splinedshaft may be hitting the plug and knocking it out;contact your Regional Service Office for assis-tance in determining the correct driveshaftlength.

41–02 Driveline Lubrication

Universal Joint LubricationNOTE: Vehicles equipped with Meritor RPL Se-ries drivelines do not require periodic lubrication.1. Park the vehicle on a flat surface, apply the park-

ing brakes, and chock the tires.2. Wipe all old grease and dirt from each U-joint

grease fitting; see Fig. 6, item 8.3. Use a hand-type grease gun, or a high-pressure

gun with a low-pressure adapter, to lubricateU-joints. If a low-pressure adapter is not used,U-joints may not receive enough grease.Using lithium 12-Hydroxy stearate grease (NLGIGrade 2, with EP additives), lubricate until newgrease can be seen at all four U-joint seals.

Fresh grease must be seen escaping from allfour bearing-cap seals of each U-joint. On full-round yokes equipped with a bearing cup, if mostof the grease being added to a U-joint can be

f410012a05/27/93

Attempt to move the sleeve-yoke and splined shaft backand forth.

Fig. 3, Slip Joint Spline Wear Checking

f410155a04/13/98

1

1 1

2

MERI TOR

1. Self-Locking Capscrew2. Adhesive Band

Fig. 4, Meritor U-Joint Fasteners for Full-Round Yokes

f41018212/09/97

Fig. 5, Meritor RPL Series U-Joint

Driveline 41


seen escaping from just one of the U-joint seals,check the torque on the capscrews at that seal.

4. Tighten the bearing-cup capscrews 38 to 48 lbf·ft(52 to 65 N·m) as needed. If the capscrews werealready tight, or all of the U-joint seals still do notpurge, remove the bearing cup at that seal, andexamine the seal for damage. If the seal is dam-aged, replace the complete U-joint.

5. If grease does not appear at one seal, use a pry-ing tool to pry the U-joint trunnion away from thenon-purging seal, or tap the driveshaft or yokewith a plastic or rawhide mallet on the side oppo-site the dry seal, while continuing to lubricate. Ifgrease still does not appear, loosen the cap-screws at the bearing with the dry seal, to relieveseal tension. Lubricate the U-joint until newgrease is seen at the seal, then tighten the cap-

screws to the correct torque specifications. If thebearing will not take grease, replace the U-joint;see Group 41 of the 108SD and 114SD Work-shop Manual.

6. Check the purged grease. If it appears rusty,gritty, or burned, replace the U-joint.

7. Wipe the purged grease from the seals, and anyexcess grease from the grease fitting.

Slip Joint Spline LubricationNOTE: Vehicles equipped with Meritor RPL Se-ries drivelines do not require periodic lubrication.1. If equipped with a grease fitting, wipe all old

grease and dirt from the slip joint grease fitting;see Fig. 6, item 1.

2. Use a hand-type grease gun or a high-pressuregun with a low-pressure adapter, to lubricate theslip joint. Add multipurpose chassis grease(lithium 12-hydroxy stearate, NLGI Grade 2, withEP additives) until it appears at the pressure-relief hole in the yoke plug. Then cover the reliefhole with your finger, while continuing to applygun pressure until new grease appears at theslip joint seal; see Fig. 6. This ensures completelubrication of the splines.

3. Wipe the purged grease from the pressure-reliefhole and slip joint seal, and any excess greasefrom the grease fitting.

f410050a10/20/93

1

1

2 3

3

34

5

6

7

8

A

A. After grease appears, cover the pressure-relief holewhile continuing to lubricate.

1. Slip Joint Grease Fitting (with grease gun attached)2. Yoke Plug3. Grease4. Half-Round Yoke5. Yoke Plug Pressure-Relief Hole6. Slip Joint Seal7. Full-Round Yoke8. U-Joint Grease Fitting

Fig. 6, Slip Joint and U-Joint Lubrication

Driveline41


Title of Maintenance Operation (MOP) MOP NumberAir Brake Inspection and Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09

Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01

Air Dryer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04

Bendix Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02

Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05

Foot-Control Valve, E-6, Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–08

Governor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03

Meritor Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–07

Slack Adjuster Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06

Brakes 42Index, Alphabetical


42–01 Air Brake System ValveInspection

IMPORTANT: There is no scheduled (Bendix) airvalve maintenance that requires disassembly ofthe valve within the warranty period. If the valvedoes not function within the warranty period, donot disassemble the part as this will void thewarranty.See the following maintenance operations forinformation about Bendix air valve maintenance.

42–02 Bendix Air DryerDesiccant Replacement

IMPORTANT: For vehicles equipped with an oil-coalescing air dryer desiccant cartridge, replacethe cartridge once a year, regardless of mileage.

AD–91. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Completely drain all air reservoirs. Air pressure

gauges should read 0 psi (0 kPa).NOTE: The compressor discharge line may stillcontain residual air pressure, open the lineslowly.3. Identify, tag, and disconnect the three air lines

from the end cover.4. Disconnect the harness connector from the

heater and thermostat assembly.5. Loosen the bolt that secures the upper mounting

bracket strap.6. Remove the two bolts and Nylok® nuts that se-

cure the air dryer to the lower mounting bracket.Mark the position of the mounting bracket to theend cover and mark the bolts to ease installation.

7. Remove the upper mounting bracket strap fas-teners, then remove the strap and the air dryer.

8. Place the air dryer on a bench and remove theremaining 6 bolts, 12 washers, 6 Nylok nuts, andthe air dryer housing. See Fig. 1. Discard theNylok nuts. Remove the end-cover-to-housingO-ring.

9. Clamp the desiccant cartridge in a vise.

WARNINGClamping the end cover or housing in a vise couldseriously compromise the air dryer’s ability tohold air pressure, which could cause a failure inthe brake system, resulting in property damage,personal injury, or death.10. Twist the end cover counterclockwise to release

the cartridge from the end cover. Rotate the endcover until it completely separates from the des-iccant cartridge.

NOTE: A substantial torque, up to 50 lbf·ft (68N·m), may be necessary to remove the desic-cant cartridge.

NOTICEDirt or obstructions in the O-ring grooves cancause an O-ring failure that will result in an airleak.11. Inspect the condition of the O-ring seals. If they

are cracked, crimped, or otherwise damaged,replace them to ensure an airtight seal. Cleanthe O-ring grooves of any dirt or obstruction.

12. Lubricate the O-rings with silicone or lithiumgrease and install them in the end cover.

13. Install the desiccant cartridge on the end cover.Turn the cartridge clockwise until the desiccantcartridge makes contact with the end cover.

14. Place the desiccant cartridge in a vise, and turnthe end cover clockwise an additional 180 to 225degrees to fully tighten the desiccant cartridge tothe end cover.

NOTE: Desiccant cartridge torque should notexceed 50 lbf·ft (68 N·m).15. Place the housing over the desiccant cartridge

and align the mounting holes with the end cover.

IMPORTANT: Replace, do not reuse the Nyloknuts on the air dryer cover.16. Install the 6 bolts, 12 washers, and 6 new Nylok

nuts. Tighten the Nylok nuts in a star pattern 17to 24 lbf·ft (370 to 520 N·m). See Fig. 2.

17. Install the air dryer on the lower mountingbracket. Install the two previously marked bolts,

Brakes 42


four washers, and two new Nylok nuts. Tightenthe two remaining Nylok nuts 17 to 24 lbf·ft (370to 520 N·m). Install the bolt, two washers, and anew Nylok nut in the upper mounting bracketstrap. Torque the upper mounting bracket strapNylok nut 80 to 120 lbf·in (900 to 1360 N·cm).

18. Connect and tighten the three air lines. Connectthe harness connector to the heater and thermo-stat assembly until the lock tab snaps in place.

19. Start the engine, build the air pressure, andcheck the air brake system for leaks. If any airleaks are present, see Group 42 of the 108SDand 114SD Workshop Manual for diagnosis andrepair information.

AD–IS1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.

08/09/95 f421383

1

2

34

5

9

10

11

12

13

14

15

1718 19

21

22

23

24

25

10

1010

1010

106

78

8

8

20

16

1. 5/16 x 4-1/2 Upper MountingBracket Bolt

2. Upper Mounting Bracket Strap3. Lockwasher4. 5/16-Inch Nylok Nut5. Upper Mounting Bracket6. Housing7. Nylok Nut8. 3/8-Inch Special Washer

9. Desiccant Cartridge10. O-Ring11. Safety Valve12. Lower Mounting Bracket13. 3/8-Inch Bolt (long)14. Check Valve Assembly15. Purge Valve Assembly16. Purge Valve Capscrew17. Exhaust Diaphragm

18. Purge Valve19. 1/4-Inch Tapping Screw20. Purge Valve Housing21. Heater and Thermostat

Housing22. Return Spring23. Purge Piston24. 3/8-Inch Bolt25. End Cover

Fig. 1, AD–9 Air Dryer (exploded view)

Brakes42


2. Drain the air reservoirs.3. Using a strap wrench or equivalent, loosen the

desiccant cartridge. Spin the cartridge off byhand and discard it. See Fig. 3.

4. On the new desiccant cartridge, lubricate thesealing rings with silicone grease.

IMPORTANT: Only use the silicone grease sup-plied with Bendix replacement kits.5. Screw the desiccant cartridge onto the body by

hand until the seal makes contact with the body.Rotate the cartridge clockwise about one fullturn. Tighten the cartridge firmly.

AD–IP1. Park the vehicle on a level surface, apply the

parking brakes, and chock the tires.2. Using a wrench or a socket, loosen the desiccant

cartridge bolt. Then separate the desiccant car-tridge from the end cover.

3. Pull the cartridge bolt out of the cover and re-move the cartridge.

WARNINGDo not attempt to disassemble the desiccant car-tridge assembly. Parts for the assembly are notavailable and the cartridge contains a 150 lbspring 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. Clean the cartridge bolt bore in theend cover, and the sealing surfaces for the large-and small-diameter desiccant cartridge sealingrings.

6. Inspect the end cover for physical damage, theninspect all air line fittings for corrosion; replaceas necessary.

7. Clean and inspect the bolt, paying attention tothe threads and O-ring grooves.

IMPORTANT: Use only the grease supplied withBendix replacement kits.8. Lubricate the O-rings, bolt O-ring grooves, seal-

ing rings, and cartridge grooves. Lubricate theend cover bore for the bolt.

9. Install both O-rings on the cartridge bolt, then,using a twisting motion, insert the assembleddesiccant cartridge bolt in the end cover.

f420544a

1 & 9

2

3

4 5

6

7 8

09/20/94

Fig. 2, AD–9 End Cover to Housing TighteningSequence

04/16/98 f421910

1

2

3

1. Desiccant Cartridge2. Cartridge Sealing Ring3. Threaded Base Post

Fig. 3, AD–IS Desiccant Cartridge Replacement

Brakes 42


10. Install the desiccant cartridge on the end cover,making sure the cartridge is properly seated andflush on the end cover.

NOTE: It may be necessary to rotate the car-tridge slightly until the anti-rotation lugs areproperly aligned and allow the cartridge to restflush against the end cover.11. Using a wrench or socket, tighten the desiccant

cartridge bolt 70 lbf·ft (95 N·m). Do not over-tighten.

12. Before placing the vehicle in service, perform thetest below.12.1 Close all reservoir drain cocks.12.2 Build system pressure to governor cut-

out, and note that the AD-IP air dryerpurges with an audible escape of air.

12.3 Fan the service brakes to reduce systemair pressure to governor cut-in. Note thatthe system once again builds to full pres-sure and is followed by a purge at theAD-IP air dryer exhaust.

12.4 Check for excessive leakage around thehead of the desiccant cartridge where itcontacts the end cover. With the com-pressor in loaded mode (compressingair), apply a soapy solution to theseareas, and observe that any leakagedoes not exceed a 1-inch bubble in 1second. If leakage exceeds this measure,remove and re-install the desiccant car-tridge.

42–03 Governor CheckIMPORTANT: Review the warranty policy beforeperforming any intrusive maintenance proce-dures. An extended warranty may be voided ifintrusive maintenance is performed during thisperiod.Every 12 months, 100,000 miles (160 900 km), or3600 operating hours, perform the operational testbelow.

Operational Test1. Start the vehicle engine, build air pressure in the

brake system, and check the pressure registered

by a dash or test gauge at the time the governorcuts-out, stopping the compression of air by thecompressor. Cut-out pressure should be in ac-cordance with the pressure setting of the piecenumber being used. Common cut-out pressuresare 125 to 135 psi (862 to 931 kPa). With theengine still running, make a series of brake appli-cations to reduce the air pressure, and observeat what pressure the governor cuts-in the com-pressor. As in the case of cut-out pressure, cut-inpressure should be in accordance with the pres-sure setting of the piece number being used.Common cut-in pressure is 105 psi (724 kPa).

NOTE: If the governor cover is marked nonad-justable, and the adjusting stem has beensheared off, this is a non-serviceable governorand it must be replaced with a new or remanu-factured unit.2. Never condemn or adjust the governor pressure

settings unless they’re checked with an accuratetest gauge or a dash gauge that’s registering ac-curately. If the pressure settings of the D-2 gov-ernor are inaccurate or it’s necessary that theybe changed, the adjustment procedure follows.2.1 Remove the top cover from the governor.2.2 Loosen the adjusting screw locknut.2.3 To raise the pressure setting, turn the ad-

justing screw counterclockwise; to lowerthe setting, turn the screw clockwise. Becareful not to overadjust. Each 1/4 turn ofthe adjusting screw raises or lowers thepressure setting approximately 4 psi (28kPa).

2.4 When proper adjustment is obtained,tighten the adjusting screw locknut, andinstall the top cover. The pressure rangebetween cut-in and cut-out is not adjust-able.

Cut-In PositionApply soap solution around the cover and to the ex-haust port. Slight bubble leakage is permitted. Exces-sive leakage indicates a faulty inlet valve or faultylower piston O-ring.

Cut-Out PositionApply soap solution around the cover and to the ex-haust port. Slight bubble leakage is permitted. Exces-

Brakes42


sive leakage indicates a faulty exhaust valve seat,exhaust stem O-ring, or O-ring at the top of thepiston.If the governor does not function as described, or ifleakage is excessive, it is recommended that it bereplaced with a new or remanufactured unit, or re-paired with genuine Bendix parts.

42–04 Air Dryer CheckThe information in this MOP applies to Bendix AD-9,AD-IP, and AD-IS/DRM air dryers.

IMPORTANT: Review the warranty policy beforeperforming any intrusive maintenance proce-dures. An extended-warranty may be voided ifintrusive maintenance is performed during thisperiod.Because no two vehicles operate under identicalconditions, maintenance and maintenance intervalswill vary. Experience is a valuable guide in determin-ing the best maintenance interval for any one particu-lar operation.Every 900 operating hours, or 25,000 miles (40 225km), or 3 months:1. Check for moisture in the air brake system by

opening reservoir drain valves and checking forthe presence of water. If moisture is present, thedesiccant cartridge may require replacement;however, the following conditions can also causewater accumulation and should be consideredbefore replacing the desiccant:1.1 An outside air source has been used to

charge the system. This air did not passthrough the drying bed.

1.2 Air usage is exceptionally high and notnormal. This may be due to high air sys-tem leakage.

1.3 In areas where more than a 30-degreerange of temperature occurs in one day,small amounts of water can temporarilyaccumulate in the air brake system due tocondensation. Under these conditions, thepresence of small amounts of moisture isnormal.

NOTE: A small amount of oil in the system isnormal and should not be considered as a rea-

son to replace the desiccant cartridge. Some oilat the dryer exhaust is normal.2. Visually check for physical damage such as

chaffed or broken air and electrical lines and bro-ken or missing parts.

3. Check mounting bolts for tightness. Tighten 30 to35 lbf·ft (41 to 47 N·m).

4. Perform the operational and leakage tests listedbelow.

Operational and Leakage Tests1. Check all lines and fittings leading to and from

the air dryer for leakage and integrity. Repair anyleaks found.

2. Build system pressure to governor cutout, andnote that the dryer purges with an audible es-cape of air. Watch the system pressure and notethe pressure fall-off for a 10-minute period. If thepressure drop exceeds 1 psi/minute from eitherservice reservoir for a single vehicle; or 3psi/minute for a tractor trailer, inspect the vehicleair systems for sources of leakage, and repairthem. Refer to troubleshooting information inBendix service literature.

3. Check for excessive leakage around the purgevalve with the compressor in the loaded mode(compressing air). Apply a soap solution to thepurge valve exhaust port and observe that leak-age does not exceed a 1-inch (25-mm) bubble in1 second. If the leakage exceeds the maximumspecified, refer to troubleshooting information inthe Bendix service literature.

4. Build system pressure to governor cutout, andnote that the dryer purges with an audible es-cape of air. Fan the service brakes to reducesystem air pressure to governor cut-in. Note thatthe system once again builds to full pressure andis followed by a dryer purge. If the system doesnot follow this pattern, refer to troubleshootinginformation in the Bendix service literature.

5. Check operation of the end cover heater andthermostat assembly during cold weather, as fol-lows:5.1 Electric Power to the Dryer: With the igni-

tion or engine kill switch in the ON posi-tion, check for voltage to the heater andthermostat assembly using a voltmeter ortestlight. Unplug the electrical connector

Brakes 42


at the air dryer and place the test leadson each of the connections of the femaleconnector on the vehicle power lead. Ifthere is no voltage, look for a blown fuse,broken wires, or corrosion in the vehiclewiring harness. Check to see if a goodground path exists.

5.2 Thermostat and Heater Assembly Opera-tion: These tests are not possible exceptin cold-weather operation. Turn off theignition switch, and cool the thermostatand heater assembly to below 40°F(4°C). Using an ohmmeter, check resis-tance between the electrical pins in theair dryer connector half. Resistanceshould be 1.5 to 3.0 ohms for the 12-voltheater assembly, and 6.0 to 9.0 ohms forthe 24-volt heater assembly.NOTE: Some models of the AD-9 mayhave a resistance reading of 1.0 to 2.5ohms.Warm the thermostat and heater assem-bly to approximately 90°F (32°C) andagain check the resistance. Resistanceshould exceed 1000 ohms. If resistancevalues obtained are within stated limits,the thermostat and heater assembly isoperating properly. If resistance valuesobtained are outside stated limits, replacethe heater and thermostat assembly.

6. On the AD-IS/dryer reservoir module (DRM) only,observe the pressure gauges of the vehicle assystem pressure builds from zero. The primarygauge should rise until it reaches approximately109±5 psi (751 ±34 kPa), then level off (or a mo-mentary slight fall) as the second pressure pro-tection valve opens supplying the secondary res-ervoir. When the secondary pressure gaugepasses through approximately 55 ±5 psi (379±34 kPa) and then 85 ±5 psi (586 ±34 kPa)there should be an associated levelling off (ormomentary slight fall) of pressure as the thirdand fourth pressure protection valves open. Fi-nally, both the primary and secondary gaugesshould reach their full pressure of approximately130 ±5 psi (896 ±34 kPa). If the AD-IS does notperform within the pressure ranges describedabove, recheck using gauges known to be accu-rate. If readings remain outside the ranges out-lined above, replace the AD-IS.

There are no kits available for servicing the pres-sure protection valves.

WARNINGDo not attempt to adjust or service the pressureprotection valves. Incorrect pressure protectionvalve settings can result in automatic applicationof the vehicle spring brakes without prior warning.This can cause personal injury or property dam-age.

42–05 Brake InspectionIMPORTANT: This procedure should be per-formed prior to lubrication of the brake compo-nents.

Parking Brake Operational Check

CAUTIONPerform the following check in a clear safe area. Ifthe parking brakes fail to hold the vehicle, per-sonal injury or property damage may result.1. With the engine running, and air pressure at cut-

out pressure, set the parking brake.2. Put the vehicle in the lowest gear and gently at-

tempt to move it forward. The vehicle should notmove. If the vehicle moves, the parking brakesare not operating correctly and must be repairedbefore the vehicle is returned to service. SeeGroup 42 of the 108SD and 114SD WorkshopManual for repair procedures.

Brake Component Inspection1. Park the vehicle on a level surface, set the park-

ing brake, and chock the tires. Once the tires arechocked, release the parking brake.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not repairing. Before adjusting an automaticslack adjuster, troubleshoot the foundation brakesystem and inspect it for worn or damaged com-ponents. Improperly maintaining the vehicle brak-

Brakes42


ing system may lead to brake failure, resulting inproperty damage, personal injury, or death.2. With the engine off, and 100 psi (689 kPa) of air

tank pressure, have an assistant apply and holdan 80 to 90 psi (550 to 620 kPa) brake applica-tion.

3. Check to see if the colored over-stroke band oneach brake chamber pushrod is exposed.If a band shows, the stroke is too long. Checkthe foundation brake components for wear ordamage, and repair as needed. See Group 42 ofthe 108SD and 114SD Workshop Manual for in-spection, troubleshooting, and repair procedures.

4. Measure the applied chamber stroke. SeeTable 1 for the proper stroke for the type of

chamber being used. If the stroke is too short,the brakes may drag or will not fully apply. Checkfor improper operation or adjustment of the auto-matic slack adjuster. See Group 42 of the108SD and 114SD Workshop Manual for inspec-tion and troubleshooting procedures.

5. Start the engine and build air pressure to at least100 psi (689 kPa). Shut down the engine.

6. Check all of the foundation brake components fordamage, wear, and loose or missing parts. Re-pair as needed. See Group 42 of the 108SD and114SD Workshop Manual for repair procedures.

Brake Chamber Stroke SpecificationsChamber

Max Applied Stroke: inch (mm)Manufacturer Type* Size†

Gunite

Standard Stroke

91-3/8 (35)

12

16

1-3/4 (45)20

24

30 2 (51)

36‡ 2-1/4 (57)

Long Stroke

16

2 (51)20

24

242-1/2 (64)

30

Haldex

Standard Stroke

12 1-3/8 (35)

16

1-3/4 (44)20

24

2-1/2-Inch Extended Stroke 24 2 (51)

3-Inch Extended Stroke 24 2-1/2 (64)

Standard Stroke 30 2 (51)

Long Stroke 30 2-1/2 (64)

Brakes 42


Brake Chamber Stroke SpecificationsChamber

Max Applied Stroke: inch (mm)Manufacturer Type* Size†

Meritor

Standard Stroke

9Less than 1-1/2 (38)

12

16Less than 1-3/4 (44)

20

24 Less than 1-7/8 (48)

Long Stroke 24Less than 2 (51)

Standard Stroke 30* Long stroke design is indicated by a tag, or embossing, on the brake chamber.† Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.‡ If type 36 chamber is used, slack length should be less than 6 inches.

Table 1, Brake Chamber Stroke Specifications

42–06 Slack AdjusterLubrication

IMPORTANT: Perform MOP 42-05 before lubri-cating the slack adjusters.Automatic slack adjusters that have a grease fittingmust be lubricated periodically to ensure properbrake operation.

WARNINGFailure to lubricate slack adjusters could lead todragging brakes or a brake failure, resulting inproperty damage, personal injury, or death.

MeritorNOTE: If equipped with an extended-maintenance Q Plus™ brake system, the slackadjuster will not have a grease fitting. Theseslack adjusters use a special NLGI grade syn-thetic polyurea grease, and do not require lubri-cation for 3 years or 500,000 miles (800 000km), whichever comes first. Extended-maintenance slack adjusters are lubricated dur-ing the brake reline service interval. For serviceand lubrication instructions, see Group 42 ofthe 108SD and 114SD Workshop Manual.For slack adjusters with grease fittings and for oper-ating temperatures above –40°F (–40°C), use an

NLGI Grade 1 clay-base grease or an NLGI Grade 1or 2 lithium-base grease.For slack adjusters with grease fittings, and for oper-ating temperatures below –40°F (–40°C) and above–65°F (–54°C), use an NLGI Grade 2 synthetic oil ora clay-base grease.Lubricate the slack adjuster at the grease fitting untilgrease is forced past the pressure-relief capscrew orpast the gear splines around the inboard snap ring.See Fig. 4.

Haldex

NOTICEDo not use moly-disulfide-loaded grease or oil.Both the life and reliability of the slack adjusterwill be reduced if this type of grease is used.Lubricate the automatic slack adjuster at the greasefitting. See Fig. 5. Use standard chassis lubricant forHaldex slack adjusters.

GuniteFor operating temperatures of –20°F (–29°C) andhigher, use Texaco Multifak EP-2 or Mobil GreaseNo. 77.For operating temperatures between –20°F (–29°C)and –40°F (–40°C), use Lubriplate Aero grease.

Brakes42


Lubricate a Gunite automatic slack adjuster at thegrease fitting until grease appears on the camshaft,or flows from the grease relief. See Fig. 6.Gunite automatic slack adjusters are produced with-out a grease relief. During lubrication with a greasegun, the lubricant is forced through the drilled wormwheel onto the camshaft. Lubricate the automaticslack adjuster at the grease fitting until grease ap-pears on the camshaft. See Fig. 7.

f420012a10/20/93

1

2

3

4

5

6

7

1. Brake Chamber2. Clevis3. Actuator Rod4. Boot5. Pull-Pawl Seal6. Manual Adjusting Nut7. Grease Fitting (or plug)

Fig. 4, Meritor Automatic Slack Adjuster

02/01/2001

1

2

f421649a

1. Grease Fitting 2. Slack Adjuster

Fig. 5, Haldex Slack Adjuster Grease Fitting

f420653a

1

2

3

45

6

7

8

10

9

10/27/93

1. 7/16-Inch Adjusting Nut2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston Rod6. Clevis7. 1/2-Inch Clevis Pin8. 1/4-Inch Clevis Pin9. Grease Relief Opening10. Slack Adjuster Spline

Fig. 6, Gunite Automatic Slack Adjuster

Brakes 42


42–07 Meritor CamshaftBracket Lubrication

IMPORTANT: Perform MOP 42-05 before lubri-cating the camshaft brackets.NOTE: If equipped with an extended-maintenance Q Plus™ brake system, the cam-shaft bracket will not have a grease fitting.These camshafts use a special NLGI grade syn-thetic polyurea grease, and do not require lubri-cation for 3 years or 500,000 miles (800 000km), whichever comes first. Extended-maintenance camshaft bushings are lubricatedduring the brake reline service interval. For ser-vice and lubrication instructions, see Group 42of the 108SD and 114SD Workshop Manual.For camshaft brackets with grease fittings, use anNLGI Grade 1 or Grade 2 multipurpose chassisgrease. Lubricate the camshaft bushings through thegrease fitting on the camshaft bracket or the spideruntil new grease flows from the inboard seal. SeeFig. 7.

WARNINGIf grease leaks out under the camhead, the cam-shaft bracket grease seal is worn or damaged. See

Group 42 of the 108SD and 114SD WorkshopManual for grease seal replacement instructions. Ifthis seal is not replaced, the brake linings couldbecome contaminated with grease. The stoppingdistance of the vehicle will be increased, whichcould result in personal injury or property dam-age.

42–08 Foot-Control Valve, E-6,Inspection andLubrication

1. Remove the brake valve from the vehicle. SeeSection 42.08, Subject 110 of the 108SD and114SD Workshop Manual for instructions.

2. Remove the roll pin from the brake pedal pivotpin. See Fig. 8.

3. Remove the brake pedal pivot pin.4. Remove the brake pedal.5. Check the brake pedal mounting plate adapter

for signs of wear or cracks at the bosses (the

f420011a05/28/93

1

2

3

A

A. Grease Exit1. Brake Chamber2. Slack Adjuster3. Non-Pressure-Relief Grease Fitting

Fig. 7, Camshaft Bracket Lubrication

09/10/2004 f430405

1

2

34

6

78

5

1. Foot-Control Valve,E-6

2. Mounting Plate3. Nut and Washer4. Pivot Pin

5. Roll Pin6. Roller7. Roller Pin8. Pedal

Fig. 8, Brake Pedal and Valve Assembly

Brakes42


area from which the pivot pin was removed). Re-place it as needed.

6. Check the brake pedal rollers for signs of wearor cracks. Replace the rollers as needed.

7. If the rollers are replaced, replace the roller pin,install a new cotter pin, bend it 90 degrees, andapply Torque Seal (OPG F900 White) to the cot-ter pin.

8. Remove the plunger from the valve. Clean theexisting grease from the plunger, using alcohol.Check the plunger for signs of wear or cracks.Replace it as needed.

9. Lubricate the plunger with synthetic grease ofNLGI Grade 1.5, such as 76 Triton synthetic EPGrease (FTL Sped 48-25432-000).

10. Insert the plunger in the valve.11. Install the brake pedal with the pivot pin.12. Install a new roll pin, then apply Torque Seal

(OPG F900 White) to the roll pin.13. Install the brake valve assembly. See Section

42.08, Subject 110 of the 108SD and 114SDWorkshop Manual for instructions.

14. Test the brakes before returning the vehicle toservice.

42–09 Air Brake Inspection andLeak Test

IMPORTANT: If any of the tests in the followingprocedure fail, refer to Group 42 of the 108SDand 114SD Workshop Manual to test individualair brake components and valves.

WARNINGSome steps in this operation require the parkingbrakes to be released. Make sure the vehicle is ona level surface and all tires are chocked. Failure todo so could result in the vehicle rolling, causingpersonal injury and/or vehicle damage.1. With the vehicle parked on a level surface, shut

down the engine, apply the parking brakes, andchock all tires.

2. Completely drain all air reservoirs.

3. Install accurate test gauges in the primary andsecondary reservoirs.

4. Start the engine and run it at a fast idle.5. Record reservoir pressures when the low-

pressure warning turns off.6. Record governor cut-out pressure and air dryer

purge pressure.7. Reduce service air pressure by applying and re-

leasing the service brakes several times, andrecord governor cut-in pressure.

8. Charge the air system to governor cut-out, shutdown the engine, and apply the parking brakes.

9. Allow pressure to stabilize for one minute.10. Observe the installed service reservoir gauges.

The pressure should not drop more than 10 psi(69 kPa) within five minutes.

11. If necessary, start the engine and charge the airsystem. Shut down the engine and release theparking brakes.

12. Make and hold a full service brake application,allowing the pressure to stabilize for one minute.Observe the installed service reservoir gauges.The pressure should not drop more than 15 psi(103 kPa) in five minutes.

13. With the air system at full pressure and the en-gine idling, perform the following:

• On trucks, operate the parking brake con-trol valve and note that the parking brakesapply and release promptly as the controlvalve knob is pulled out and pushed in onthe spring brake axles only.

• On tractors, operate the trailer supply con-trol valve knob. Note the air coming out ofthe trailer control coupling. Operate thepark control knob and note that the parkingbrakes apply and release promptly as theknob is pulled out and pushed in. Block thetrailer supply coupling, and push the trailersupply control valve and park control valveknobs in. When the park control valve knobis pulled out, the trailer supply knob shouldalso come out.

14. Build air system pressure to cut-out and shutdown the engine.

15. Completely drain the secondary (front axle) res-ervoir. On vehicles equipped with a Dryer Reser-

Brakes 42


voir Module (DRM) or AD-IS with the air dryerattached to the reservoir, the primary (rear axle)reservoir pressure should not drop below 65 psi(448 kPa). On vehicles equipped with singlecheck valves, where the air dryer is not attachedto the reservoir, the primary reservoir should notlose pressure.

16. Make a service brake application. The rear axlebrakes should apply and release and the brakelights should illuminate.On tractors, with the trailer supply knob pushedin, the trailer control coupling should deliver airduring the brake application.

17. Push the trailer air supply valve knob in. With thesecondary reservoir still completely drained,slowly drain the primary reservoir and record thepressure at which the knob automatically comesout. This pressure should be 20 to 45 psi (138 to310 kPa).

18. Close the drain cocks, recharge the system, andcompletely drain the primary reservoir. On ve-hicles equipped with a DRM or AD-IS with the airdryer attached to the reservoir, the secondaryreservoir pressure should not drop below 65 psi(448 kPa). On vehicles equipped with singlecheck valves, where the air dryer is not attachedto the reservoir, the secondary reservoir shouldnot lose air pressure.

19. On tractors only:19.1 Start the engine and build the system air

pressure to governor cut-out.19.2 Shut down the engine and leave the park-

ing brakes released.19.3 Completely drain the primary reservoir.19.4 Make a modulated service brake applica-

tion by depressing the brake pedal. Thefront brakes should apply and releaseand the brake lights should illuminate. Inaddition to the front brakes, with thetrailer supply knob pushed in, the trailercontrol coupling should deliver air duringthe brake application.

20. On trucks only:20.1 Start the engine and charge the air sys-

tem until governor cut-out.20.2 Shut down the engine and leave the park-

ing brakes released.

20.3 Completely drain the primary reservoir.20.4 Make a modulated service brake applica-

tion. Both front and rear brakes shouldmodulate. At a steady full brake applica-tion, the pressure should not drop morethan 10 psi (69 kPa) within five minutes.

21. Drain all reservoirs and remove the gauges fromthe service reservoirs. Close the reservoir draincocks.

22. Remove the chocks from the tires.

Brakes42


Title of Maintenance Operation (MOP) MOP NumberDrag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01

Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05

Power Steering Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03

Power Steering Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02

Power Steering Gear Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04

Steering 46Index, Alphabetical


46–01 Drag Link Inspection

WARNINGAll steering system components are critical forsafe operation of the vehicle. Failure to maintainthe steering system as specified may result inloss of steering control, which could lead to per-sonal injury and property damage.Have someone turn the steering wheel from left toright. As the steering wheel is turned, check forlooseness between the ball stud and the pitman arm,and between the other ball stud and the steeringarm. Check for loose ball stud castle nuts. SeeFig. 1.If there is looseness in either ball stud end, replacethe drag link. See Section 46.03 of the 108SD and114SD Workshop Manual for replacement instruc-tions. If there is 1/8-inch (3-mm) movement or more,do not drive the vehicle until the drag link is re-placed.If a ball stud nut is loose, replace the nut and cotterpin. See Section 46.03 of the 108SD and 114SDWorkshop Manual for torque specifications.Inspect the drag link boots (at both the pitman armand the steering arm ends) for cracks, splits, or otherdamage. Replace boots as needed. See Section46.03 of the 108SD and 114SD Workshop Manualfor drag link removal and installation instructions.

46–02 Power Steering Fluidand Filter Change

WARNINGFill only with approved clean fluid. Failure to usethe proper fluid could cause seal deterioration andleaks. Fluid leaks could eventually cause loss ofpower steering assist. This could lead to an acci-dent resulting in personal injury or property dam-age. Wear eye protection when changing the fluidand filter.1. Park the vehicle on a level surface, shut down

the engine, apply the parking brakes, and chockthe rear tires.

2. Place a drain pan under the power steering res-ervoir.

3. Remove the retaining ring from the reservoir.See Fig. 2.

4. Remove the filter, filter cover, and gasket fromthe reservoir. Drain the fluid from the filter intothe drain pan. Leave the filter hanging over thedrain pan.

5. Remove the nuts, bolts, and washers that attachthe power steering reservoir to the mountingbracket, but do not remove the supply line to thereservoir. Drain the power steering fluid from thereservoir.

6. Using bolts, nuts, and washers, attach the reser-voir to the mounting bracket.

12/14/2010 f462186a

1

23

4

5

5

4

6

7

7

8

8

1. Steering Gear2. Pitman Arm3. Drag Link4. Cotter Pin

5. Castle Nut6. Steering Arm7. Ball Stud8. Boot

Fig. 1, Drag Link Assembly

Steering 46


7. Using ATF fluid that meets Dexron III or TES-389specifications, fill the reservoir to the line be-tween the MIN COLD and MAX HOT lines. SeeFig. 2.

8. Raise the front of the vehicle and support it withjack stands.

9. Start the engine and operate it at idle. Turn thesteering wheel from full left to full right severaltimes until clean fluid starts flowing from thepower steering filter. Add fluid to the reservoir tomaintain the fluid level between the MIN COLDand MAX HOT lines.

10. Shut down the engine.NOTE: Always install a new power steering res-ervoir filter when changing the fluid.11. Disconnect the filter from the filter cover, and dis-

card the filter.12. Apply a thin film of power steering fluid on the

gasket of the new filter. Then attach the filter tothe filter cover. Hand-tighten the filter, then turn itan additional 1/4 turn.

13. Install the filter and filter cover in the reservoir.Make sure that the gasket under the filter coveris not damaged. If the gasket is damaged, re-place it. Install the gasket on the reservoir.

14. Attach the retaining ring to the reservoir to se-cure the filter and filter cover.

15. Start the engine and check that the power steer-ing fluid level is between the MIN COLD andMAX HOT lines. Add more power steering fluid ifneeded.

16. Raise the vehicle, remove the jack stands, andlower the vehicle.

46–03 Power Steering FluidLevel Inspection

1. Apply the parking brakes and chock the reartires.

2. With the engine cool, the fluid level should bebetween the MIN COLD and MAX HOT lines withthe engine off.

3. Add or remove fluid as necessary to bring thefluid level to the line between the MIN COLD andMAX HOT lines. Use ATF fluid that meetsDexron III or TES-389 specifications.

4. With the engine hot, the fluid level should be atthe MAX HOT ine with the engine off.

5. Add or remove fluid as necessary to bring thefluid level to the MAX HOT line. Use ATF fluidthat meets Dexron III or TES-389 specifications.

46–04 Power Steering GearLubrication

TRW TAS and THP SeriesSector Shaft

NOTICEApply grease to the sector shaft with a hand-typegrease gun only. Use of a high-pressure powergrease gun will supply grease too quickly andcould affect the high pressure seal, contaminatingthe hydraulic fluid.Using a hand-type grease gun, apply NLGI Grade 2or 3 multipurpose chassis grease until it starts tocome out past the sector shaft seal. Fig. 3.

f461917

1

2 3

4

10/19/2001

1. Power Steering Reservoir2. Retaining Ring3. Filter Cover4. Return Hose

Fig. 2, Power Steering Reservoir

Steering46


46–05 Drag Link Lubrication1. Using a clean rag, wipe all dirt from both drag

link grease fittings; see Fig. 4.2. Using a grease gun, apply clean grease at the

grease fittings until old grease is forced out ofthe socket. Use multipurpose chassis greaseNLGI Grade 2 (8% 12-hydroxy lithium stearategrease) or NLGI Grade 1 (6% 12-hydroxy lithiumstearate grease). Grade 2 is preferred.

f461071

1

11/28/95

1. Sector Shaft Grease Fitting

Fig. 3, TRW TAS Series Sector Shaft Lubrication

2 f46107211/27/951

1. Grease Fitting at Pitman Arm2. Grease Fitting at Axle Steering Arm

Fig. 4, Drag Link

Steering 46


Title of Maintenance Operation (MOP) MOP NumberCNG Fuel Cylinder Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–08

CNG Fuel System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–06

CNG High-Pressure Fuel Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–07

Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03

Fuel Tank Band Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01

Fuel/Water Separator Element Check and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02

LNG Fuel System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–04

LNG Vacuum Integrity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–05

Fuel 47Index, Alphabetical

108SD and 114SD Maintenance Manual, August 2011

47–01 Fuel Tank Band NutTightening

IMPORTANT: Do not overtighten the nuts.

Rectangular Fuel TankHold the retention nut on the fuel tank band with awrench while backing off the jam nut. Then tightenthe retention nut 13 to 17 lbf·ft (18 to 23 N·m). Afterthe retention nut has been tightened, hold the reten-tion nut with a wrench while tightening the jam nut 13to 17 lbf·ft (18 to 23 N·m).

Cylindrical Fuel TankHold the retention nut on the fuel tank band with awrench while backing off the jam nut. Then tightenthe retention nut 30 to 35 lbf·ft (41 to 46 N·m). Afterthe retention nut has been tightened, hold the reten-tion nut with a wrench while tightening the jam nut 30to 35 lbf·ft (41 to 46 N·m).

47–02 Fuel/Water SeparatorElement Check andReplacement

Alliance/RacorThe only maintenance necessary on an Alliance orRacor fuel/water separator is to replace the filterelement.1. Shut down the engine, apply the parking brakes,

and chock the tires. Open the hood.2. Place a suitable container under the fuel/water

separator.

IMPORTANT: When draining fluid from afuel/water separator, drain the fluid into an ap-propriate container, and dispose of it properly.Many states now issue fines for drainingfuel/water separators onto the ground.3. Turn the drain plug counterclockwise to open it.4. When the fuel/water separator is completely

drained, turn the drain plug clockwise to close it.

WARNINGDo not expose the fuel to open fire. Do not workwith the fuel system near open flame or intenseheat. To do so could cause fire, possibly resultingin serious personal injury or property damage.5. Disconnect the wiring harnesses from the water-

in-fuel sensor and, if equipped, the heater. SeeFig. 1.

6. Spin off the sight bowl and the filter element as aunit. Remove the O-ring from the top of the filterelement.

7. Remove the sight bowl from the filter element.Clean the O-ring seating surface.

8. Apply a thin coating of clean diesel fuel or en-gine oil to the O-rings.

9. Spin the sight bowl onto the new filter elementand then fill the filter element and sight bowl as-sembly with clean diesel fuel.

10. Spin the entire assembly onto the mounting headand tighten by hand until snug.

11. Connect the wiring harnesses for the water-in-fuel sensor and, if equipped, the heater.

12. Prime the fuel/water separator, as follows.If equipped with a primer pump, operate theprimer pump until fuel comes out at the drain.If not equipped with a primer pump, fill the filterelement and sight bowl with clean fuel and crankthe engine until it starts.

13. Start the engine and check for leaks.14. Shut down the engine and repair any leaks.

DAVCO Fuel Pro® 382 and 482NOTE: In the event of an emergency, when thefilter needs replacement but a DAVCO filter isnot available, a temporary filter can be used;see Chapter 24 of the 108SD and 114SDDriver’s Manual for instructions.

WARNINGFluid circulated through the fuel/water separatorto heat the fuel may be diesel fuel returned fromthe engine, or engine coolant. Drain the fuel/waterseparator only when the engine and fluids have

Fuel 47


cooled. Draining it when the engine is hot couldcause severe personal injury due to scalding.

If returning fuel is released into the atmosphere,its vapors can ignite in the presence of any igni-tion source. Do not expose the fuel to, or workwith the fuel system near, open flame or intenseheat. To do so could cause fire, possibly resultingin serious personal injury or property damage.The filter element should be changed only when thefuel level has reached the top of the filter element.There is no significant restriction to fuel flow until theelement is completely clogged.1. Shut down the engine, apply the parking brake,

and chock the tires.2. Check the fuel level in the fuel filter. Replace the

fuel/water separator element only when the filterelement is completely covered. If the fuel levelhas reached the top of the filter element, followthe procedure below to replace the element.

3. Put a clean receptacle under the fuel/water sepa-rator and attach a piece of hose to the drainvalve, to direct fuel into the receptacle.The drain valve has a 1/2-inch (12.7-mm) pipe;use a hose with a 1/2-inch pipe thread to fit cor-rectly.

4. Remove the vent cap (Fig. 2, Item 4) and openthe drain valve (Fig. 2, Item 1) to drain the fuelcompletely, then close the drain valve.

01/27/2011 f470566

2

3

4

3

5

6

79

8

1

1. Primer Pump2. Mounting Head3. O-Ring4. Filter Element5. Sight Bowl6. Water-in-Fuel Sensor

7. Wiring Harness,Water-in-Fuel Sensor

8. Wiring Harness,Heater

9. Drain Plug

Fig. 1, Fuel/Water Separator Assembly

f470506b05/05/2009

4

1

3

5

2

6

1. Drain Valve2. Lower Housing3. Clear Cover

4. Vent Cap5. Collar6. Inlet Port/Check Valve

Fig. 2, DAVCO Fuel/Water Separator (Fuel Pro 382Shown)

Fuel47


5. Using a DAVCO Collar Wrench (Fig. 3), removethe clear cover and collar.

NOTE: Broken vent cap and collar warrantyclaims will not be accepted if any tool other thana DAVCO Collar Wrench is used for removal.During installation, the vent cap and collar areto be hand-tightened only, not tightened with awrench. Use part number 482017 on Fuel Pro482 units; part number 380134 on Fuel Pro 382units.6. Remove the filter, cover O-ring, and vent cap

O-ring. Dispose of them in an environmentallyacceptable manner. See Fig. 4 or Fig. 5.

7. Clean all threads and sealing surfaces very thor-oughly. Even a small amount of dirt will preventthe fuel/water separator from sealing, and an airleak may result.

8. On Fuel Pro 382 units, install the grommet onthe bottom of the new filter.

9. Install the new filter and grommet assembly andcover O-ring on the housing.

10. Install the clear cover and the collar. Hand-tighten the collar.

11. Prime the system11.1 Ensure that the drain valve is closed.11.2 Fill the housing to the top with clean die-

sel fuel.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 forone to two minutes to purge air from thesystem.

11.5 While the engine is running, and after theair is purged from the system, loosen thevent cap until the fuel level falls to aboutone inch (2.5 cm) above the collar, thenhand-tighten the vent cap.

11.6 Check for leaks and shut down theengine.

47–03 Fuel Filter ReplacementFor engine-mounted fuel filter replacement, refer tothe engine manufacturer’s service manual for re-moval and installation procedures.

47–04 LNG Fuel SystemInspection

WARNINGNatural gas is highly flammable. See the safetyprecautions listed in Chapter 21 of the 108SD and114SD Driver’s Manual or Group 47 of the 108SDand 114SD Workshop Manual. Failure to observethese precautions could lead to the ignition of thenatural gas, which could cause severe bodily in-jury, death, or property damage.

NOTICEDo not use a high-pressure washer or steamcleaner on natural gas fuel system plumbing com-ponents, as this can introduce moisture and con-taminants into the threads of the fittings and dam-age the sealants.Gas detection sensors are located on the caboverhead console and in the engine compartmenton the frontwall. The sensors are located in highareas, where rising gas vapors will pass by or ac-cumulate. Do not use a high-pressure washer,steam cleaner, or silicone-based chemicals on thegas detection sensors, as this may permanentlydisable the sensors. When cleaning the vehicle,cover the sensors with a plastic covering. Keepthe sensors covered until the area has been

02/16/2009 f470277

VE

NT

CA

P

FOR REMOVAL OF TOP COLLAR ONLY

Fig. 3, DAVCO Collar Wrench

Fuel 47


12/13/2010 f470531a

3

4

5

6

7

8

9

10

11

13

14

1

2

12

1. Drain Valve2. Bottom Plate

Assembly3. Bottom Plate O-Ring4. Lower Housing5. Cover O-Ring6. Filter Element7. Spring

8. Clear Cover9. Vent Cap O-Ring10. Vent Cap11. Collar12. Grommet13. Inlet Port/Check Valve14. Heat Exchanger

Fig. 4, DAVCO Fuel Pro 382

05/05/2009 f470530

1

2

3

4

5

6

7

8

9

10

11

12

13

1. Inlet Port/Check Valve2. Lower Housing3. Bypass Valve4. Filter Element5. Spring6. Clear Cover O-Ring7. Clear Cover

8. Vent Cap O-Ring9. Vent Cap10. Lower Housing Collar11. 120VAC Pre-Heater12. 12VDC Pre-Heater13. Drain Valve

Fig. 5, DAVCO Fuel Pro 482

Fuel47


cleared of any cleaning fumes. Harsh chemicalsand extremely high temperatures may damage thesensor.The following inspections must be performed by aqualified technician, in accordance with the manufac-turer’s established inspection criteria.All tank components should be allowed to defrostbefore conducting the following inspections.

Fuel Tank and Shroud InspectingSee Fig. 6 for fuel tank and shroud componentlocations.

1. Inspect the fuel tank outer shell for dents orother signs of damage. Inspect the bottom of thetank for deep scratches, flat spots, or gouges.Replace a leaking fuel tank.

2. Ensure that the fuel tank is secured to its mount-ing brackets and that the mounting brackets aresecured to the frame. Inspect for any signs oflooseness.

3. Ensure that all rubber isolator straps are presentand secure.

4. Look for signs of abrasion between the fuel tankand mounting brackets.

5. Inspect the fuel fill fitting for signs of damage orleaks. Ensure the fuel fill cap is present and ingood condition, and the fitting is mounted se-curely on the tank.

6. Inspect the fuel outlet line and fitting for signs ofleaks or damage.

7. Inspect the primary relief vent and pipe-away linefor damage, kinks, chafing, or loose connections.

8. Inspect the fill vent fitting for signs of damage.9. Inspect the shroud cover for dents or other signs

of damage. Ensure that the shroud cover latchesare in working condition and fasten the shroudcover securely to the tank.

10. Replace leaking or damaged fuel lines. Repair orreplace leaking or damaged fittings.

Plumbing ComponentsInspectingSee Fig. 7 for plumbing component locations.Use a bubble solution to check for leaks while per-forming the following visual inspection.1. Check the following components for signs of

damage or leaks:• pressure control regulator• vapor shutoff valve• secondary relief valve• primary relief valve and threaded connec-

tions• excess flow valve• fuel shutoff valve• fill check valve

2. Inspect the fuel fill line for signs of damage,kinked or crushed piping, or chafing.

3. Ensure the red cap is present on the secondaryrelief valve.

4. Inspect the fuel tank pressure gauge for cracksin the sight glass. Ensure the indicator needle is

05/29/2009 f470534

1

2 3

4

6

5

6

1. Fuel Fill Fitting2. Fuel Outlet Line

(liquid)3. Primary Relief Vent

Line (relief valve)

4. Fill Vent Fitting (vent)5. Shroud Cover6. Shroud Cover Latches

Fig. 6, Fuel Tank Outer Shell

Fuel 47


present and in working condition. Inspect thegauge face for accuracy and legibility.

5. Inspect all vent lines for kinks, and signs of leaksor damage.

6. Replace leaking or damaged fuel lines. Repair orreplace leaking or damaged fittings.

Fuel Level Sender ComponentInspecting1. Inspect the fuel level sender wiring harness for

signs of loose connections or damage. Look forcracking or signs of moisture intrusion.

2. Inspect the fuel level sender box ( Fig. 7, Item 6)for signs of leaks or damage. Ensure that theretainer clips are installed on the mounting ears.

3. Inspect all connectors and wiring for signs ofloose connections, damage, or chafing.

4. Turn the ignition switch to the ON position andcheck for fuel gauge response.

5. Repair or replace any damaged fuel gaugecomponents.

Vaporizer InspectingSee Fig. 8 for plumbing component locations.1. Ensure that the vaporizer is secured to its

mounting brackets and that the mountingbrackets are secured to the frame. Inspect forany signs of looseness.

2. Inspect the vaporizer fuel inlet and outlet lines forsigns of chafing, damage, or leaks.

3. Inspect the vaporizer coolant hoses for signs ofchafing, damage, or leaks.

4. Inspect all fittings for leaks.5. Inspect the fuel shutoff solenoid valve for signs

of leaks or damage. Inspect the solenoid mount-ing bracket for looseness.

6. Inspect the overpressure regulator for signs ofleaks or damage.6.1 Ensure that the regulator is mounted se-

curely.6.2 Check the overpressure regulator fittings

for signs of leaks or damage.6.3 Ensure that the adjustment handle locking

nut (at the bottom of the overpressureregulator) is tightened securely.

6.4 Inspect the pressure gauge for damage.Ensure that the gauge sight glass is clearand legible.

7. Repair or replace any leaking or damaged vapor-izer components.

47–05 LNG Vacuum IntegrityTest

WARNINGNatural gas is highly flammable. See the safetyprecautions listed in Chapter 21 of the 108SD and114SD Driver’s Manual or Group 47 of the 108SDand 114SD Workshop Manual. Failure to observethese precautions could lead to the ignition of the

05/05/2010 f470533

1

2

3

4

5

67 8

10

11

12

9

1. Pressure ControlRegulator

2. Vapor Shutoff Valve3. Fuel Fill Hose4. Secondary Relief

Valve (red cap)5. Fuel Fill Fitting6. Fuel Level Sender

Box

7. Primary Relief Valve8. Tank Pressure Gauge9. Fill Vent Fitting10. Excess Flow Valve11. Fuel Shutoff Valve

(liquid)12. Fill Check Valve

Fig. 7, Fuel Tank Plumbing Components

Fuel47


natural gas, which could cause severe bodily in-jury, death, or property damage.1. Ensure the fuel tank is between 50 and 75 per-

cent full.2. Check the fuel tank pressure gauge (Fig. 7, Item

8) to ensure that pressure is within the normalrange of 120 to 150 psi (827 to 1034 kPa).

3. Inspect the fuel tank for signs of frost spots orouter surface sweating. Frosting or condensationon the outer surface of the fuel tank may indicatea loss of vacuum.

4. Check for a large variance in temperatures be-tween the fuel tank and the fuel tank shroud. A

large variance in temperatures between the fueltank and the shroud may indicate a loss ofvacuum.

5. Operate the vehicle for ten minutes. Shut downthe engine, apply the parking brakes, and notethe time.

6. Wait fifteen minutes after shutting down the en-gine, then record the fuel tank pressure and notethe time.

7. Allow the vehicle to stand for at least eighthours, then record the fuel tank pressure again.

8. Use Table 1 to determine whether the pressureincrease is within an acceptable range.

06/29/2009 f4705362

5

6

7

89

10 1112

1

34

1. Pressure Relief Device2. Fuel Inlet Line3. Check Valve4. CNG Quick-Connect Port

5. Coolant Inlet Line6. Vaporizer7. Fuel Shutoff Solenoid Valve8. Coolant Outlet Line

9. Pressure Gauge10. Overpressure Regulator11. Pressure Relief Valve12. Fuel Outlet Line

Fig. 8, LNG Vaporizer Assembly

Fuel 47


Vacuum Integrity Test ResultsPressure Increase Over Eight-

Hour Period Remedy

Less than 20 psi (138 kPa) None – Tank is normal

20 to 50 psi (138 to 345 kPa) Monitor tank and test vacuum integrity again at next maintenance date

More than 50 psi (345 kPa) Remove vehicle from service and evacuate the tank per the tank manufacturer’sinstructions

Table 1, Vacuum Integrity Test Results

47–06 CNG Fuel SystemInspection

WARNINGNatural gas is highly flammable. See the safetyprecautions listed in Chapter 21 of the 108SD and114SD Driver’s Manual or Group 47 of the 108SDand 114SD Workshop Manual. Failure to observethese precautions could lead to the ignition of thenatural gas, which could cause severe bodily in-jury, death, or property damage.The following inspections must be performed by aqualified technician, in accordance with the manufac-turer’s established inspection criteria.

NOTICEDo not use a high-pressure washer or steamcleaner on natural gas fuel system plumbing com-ponents, as this can introduce moisture and con-taminants into the threads of the fittings and dam-age the sealants.Gas detection sensors are located on the caboverhead console and in the engine compartmenton the frontwall. The sensors are located in highareas, where rising gas vapors will pass by or ac-cumulate. Do not use a high-pressure washer,steam cleaner, or silicone-based chemicals on thegas detection sensors, as this may permanentlydisable the sensors. When cleaning the vehicle,cover the sensors with a plastic covering. Keepthe sensors covered until the area has beencleared of any cleaning fumes. Harsh chemicalsand extremely high temperatures may damage thesensor.Use a bubble solution to check for leaks while per-forming the following inspection.

1. Inspect the fuel cylinders for dents or other signsof damage.Replace any leaking fuel cylinders.

2. Ensure that the fuel cylinders are secured withinthe fuel cylinder storage box.

3. Ensure that the fuel cylinder storage box is se-cured to the frame. Inspect for any signs oflooseness. If necessary, tighten the storage boxmounting bolts 160 lbf·ft (217 N·m). See Fig. 9.

NOTE: During initial pre-delivery inspection(PDI), tighten the storage box mounting bolts(shown in Fig. 9) 180 lbf·ft (244 N·m).4. Inspect the fuel fill port for signs of damage or

leaks. Ensure the port dust cover and the O-ringinside the port are both present and in good con-dition. See Fig. 10.

5. Inspect the pressure gauges on the fuel box forcracks. Ensure the indicator needles are presentand in working condition. Inspect the gaugefaces for accuracy and legibility.

6. Ensure blue caps are present on all pressurerelief devices. Each fuel cylinder is equipped withtwo caps (one on each end), which are visible onthe back of the CNG fuel cylinder storage box.One cap is located on the pressure relief valveon the inboard side of the CNG fuel box, next tothe fuel outlet line. Check the primary relief valveon the inboard side of the CNG fuel box for signsof damage or leaks.

7. Check the following components for signs ofdamage or leaks:

• manual fuel shutoff valve• fuel cylinder shutoff valves (see Fig. 11)• coolant hoses and fittings• fuel lines and fittings

Fuel47


• all fittings, connections, and joints8. Replace leaking or damaged fuel lines. Repair or

replace leaking or damaged fittings.

47–07 CNG High-Pressure FuelFilter ElementReplacement

CNG filter element replacement cycles are an impor-tant factor in maintaining the CNG fuel system integ-rity and ensuring maximum operating performance.Actual frequency of the filter element replacementcould increase or decrease depending on the cleanli-ness of the fill station fueling system.1. Shut down the engine and apply the parking

brake.

2. Close the CNG fuel cylinder shutoff valves.3. Start the engine and let it idle until the fuel lines

are empty and the engine stops. The gauges onthe fuel panel should now read at or near 0 psi.

4. Close the manual fuel shutoff valve on the fuelpanel.

5. Remove the two capscrews that secure the ac-cess cover to the fill panel, then remove the ac-cess cover. See Fig. 12. Save the capscrews forreinstallation.

6. Slowly open the bleed valve on the manifold torelieve remaining fuel pressure within the sys-tem. See Fig. 13.

IMPORTANT: Some pressure may remain in thefuel system between the solenoid valve and theengine. Use caution when loosening fittings, asa small amount of gas may leak out.7. Put a clean receptacle under the filter assembly.

Using a 1-1/4-inch wrench, unscrew the filterbowl from the filter housing.

8. Remove and discard the filter element.9. Install a new filter element in the filter housing.10. Inspect the O-ring on the filter housing for dam-

age or cracks. If necessary, replace the O-ring.

05/04/2010 f470555

1

23 3

1. Frame Rail2. CNG Fuel Cylinder Storage Box3. Mounting Bolts (qty 12 per side)

Fig. 9, Fuel Cylinder Storage Box Mounting Bracket(passenger side shown)

HIGH PRESSURE PRESSURELOWCYLINDERS

INSPECT CYLINDERSEVERY 36 MONTHS

OR 36000 MILESWHICHEVER OCCURS FIRST

NATURALGAS

VEHICLE110 PSIG

ON

MANUALSHUT

OFFVALV

E

OPEN VALVESLOWLY

3600 PSIG MAX.SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURERELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSINGEVERY 1500 MILESREPLACE ELEMENTEVERY 3000 MILES

1 2

34

04/30/2010 f470556

1. High Pressure Gauge2. Low Pressure Gauge3. Manual Fuel Shutoff Valve4. Fuel Fill Port and Dust Cap

Fig. 10, CNG Fuel Panel

Fuel 47


11. Install the filter bowl on the filter housing. Tighten90 lbf·ft (122 N·m).

12. Close the bleed valve on the manifold and openthe manual fuel shutoff valve on the fuel panel.

13. Open the fuel cylinder shutoff valves.14. Using a methane detector, leak test all fuel sys-

tem components between the fuel cylinders andthe solenoid valve. A bubble solution can beused to pinpoint the exact location of leaks.Repair or replace any leaking components.

15. Using the two capscrews removed previously,install the access cover on the fill panel.

47–08 CNG Fuel CylinderInspection

Have a qualified inspector inspect compressed natu-ral gas (CNG) fuel cylinders for damage or deteriora-tion. Note cuts, cracks, gouges, abrasions, discolora-tion, broken fibers, loose brackets, damaged gasketsor isolators, heat damage, or other problems.Refer to Compressed Gas Assocation (CGA) pam-phlet C-6.4, Methods for External Visual Inspection ofNatural Gas Fuel Containers and Their Installations,for inspection requirements and inspector qualifica-tions.For more information, go to www.cganet.com.

04/22/2010 f470554

1 2

3 4

578 6

1. Fuel Cylinder StorageBox

2. Fuel Cylinder ShutoffValves (qty 5)

3. High-Pressure Gauge4. Low-Pressure Gauge

5. Fuel Fill Port6. Dust Cap7. Manual Shutoff Valve8. Fuel Panel Access

Door

Fig. 11, CNG Fuel Cylinder Storage Box (5-cylindersystem shown)

05/04/2010 f470557

2

2

345

6

7

8

1

1. Fuel Panel AccessCover

2. Capscrews (qty 2)3. Wiring Harness4. Pressure Relief Valve

and Cap

5. Coolant Outlet Line6. Coolant Inlet Line7. Fuel Inlet Line (to fuel

cylinders)8. Fuel Outlet Line (to

engine)

Fig. 12, CNG Fuel Panel Assembly

Fuel47


After inspection, an accurate and reliable written re-port should be provided for each container inspected.Place an inspection label stating the inspection dateand inspecting agency identification on each con-tainer.

05/04/2010 f470558

6

7

8

910111213141

2

3

4

5

1. Coolant Inlet Port2. Coolant Outlet Port3. Pressure Relief Valve4. Pressure Regulator5. Wiring Harness6. Manifold Bleed Valve7. Manifold8. Manual Fuel Shutoff

Valve

9. Fuel Fill Port10. Filter Housing11. Filter Bowl12. Filter Drain Plug13. Solenoid Valve14. Fuel Line To Cylinders

Fig. 13, CNG Fuel Panel Components

Fuel 47


Title of Maintenance Operation (MOP) MOP NumberExhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01

Exhaust 49Index, Alphabetical


49–01 Exhaust SystemInspection (NoiseEmission Control)

In addition to inspecting the exhaust system at thescheduled maintenance interval, inspect the exhaustsystem if the noise level of the vehicle has in-creased. Freightliner Trucks recommends replacingparts that show leakage, wear, or damage, withgenuine Freightliner parts.The exhaust system must be free of leaks, binding,grounding, and excessive vibrations. These condi-tions are usually caused by loose, broken, or mis-aligned clamps, brackets, or pipes. If any of theseconditions exist, check the exhaust system compo-nents and alignment. Align or replace as necessary;see Group 49 of the 108SD and 114SD WorkshopManual, or take the vehicle to an authorized Freight-liner dealer.It is a violation of US federal law to alter exhaustplumbing or aftertreatment in any way that wouldbring the engine out of compliance with certificationrequirements. (Ref: 42 U.S.C. S7522(a) (3).) It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA regulations.

EPA10 Exhaust SystemDefinitions of Aftertreatment (ATS)TermsNOTE: Diagrams of ATS configurations are pro-vided later in this chapter. For Detroit Diesel,see Fig. 1, Fig. 2, and Fig. 3. For Cummins,see Fig. 4, Fig. 5, and Fig. 6.Refer to the following list of definitions of ATS termsand components.

• Aftertreatment System (ATS)—the entire ex-haust system from the turbocharger to the ex-haust stack or tail pipe.

• Aftertreatment Device (ATD)—a housing thatcontains the DOC and DPF.

• BlueTec®—Daimler’s proprietary SCR technol-ogy.

• Diesel Oxidation Catalyst (DOC)—a flowthrough device located at the ATD inlet that en-

hances the oxidation of hydrocarbons in orderto reduce particulate emissions.

• Diesel Particulate Filter (DPF)—a device in-stalled on a diesel engine system that capturesand reduces particulate matter (PM) from theexhaust gas.

• Diesel Exhaust Fluid (DEF)—the chemical agentthat reacts with the exhaust gases in the SCRto reduce NOx.

• DEF Pump—filters and supplies DEF to theDEF metering unit.

• DEF Tank—holds DEF and regulates its tem-perature.

• DEF Metering Unit—mixes DEF with com-pressed air, and meters this mixture into theexhaust flow via an injection nozzle.

• SCR Catalyst—the housing containing a treatedceramic flow-through block where the DEF andexhaust gases undergo selective catalytic re-duction (SCR).

• Selective Catalytic Reduction (SCR)—a processused to reduce NOx emissions.

InspectionTo meet EPA10 emissions regulations for vehiclesdomiciled in the USA or Canada, engines manufac-tured after December 31, 2009 are equipped with anemission aftertreatment system. Vehicles domiciledoutside of the USA and Canada may not have after-treatment equipment, depending upon local statutoryemissions guidelines.

IMPORTANT: The aftertreatment device (ATD),which is part of the aftertreatment system (ATS),requires special attention during regularlyscheduled maintenance inspections. No leaksare allowed anywhere in the system. If any dis-crepancies are discovered, refer to the enginemanufacturer’s service literature for repair in-structions. Also see the engine manufacturer’smaintenance literature for maintenance proce-dures not listed here.1. Check for leakage at the clamp that attaches the

exhaust pipe to the turbocharger exhaust outlet.If leakage exists, tighten the nut on the clamp tothe required torque. If leakage persists, install anew clamp.

Exhaust 49


2. Check the exhaust pipe, bellows, and each ex-haust seal clamp for leakage, wear, cracks, ordamage. Replace damaged components asneeded. If leakage exists at a clamp, tighten thenuts to the required torque. If leakage persists,install a new exhaust seal clamp. Do not reuseseal clamps. Once a seal clamp is loosened orremoved, it must be replaced.

3. If present, check the condition of the insulationmaterial around the exhaust pipe between theturbocharger and the ATD.

4. Check the ATD mounting bands for tightness, ifinstalled. Tighten to 30 lbf·ft (41 N·m) if needed.Do not overtighten.

5. Check for leaks around the clamps that attachthe ATD in the ATS, and around the clamps thatretain the DPF in the ATD.

NOTE: Diesel exhaust fluid creeps, causingwhite crystals to form around the line fittings.The presence of crystals does not mean thesystem has a leak. Replacing fittings or trouble-shooting components is not necessary unlessthere is a system failure or a fault code.6. Check the DEF tank, pump, metering unit, and

lines for leaks. See Section 49.01 of the 108SDand 114SD Workshop Manual for repair proce-dures.

7. Check any wires, lines, or hoses within 4 inches(10 cm) of the exhaust system for heat damage.Repair or reroute as needed.

Diesel Exhaust Fluid (DEF) FilterReplacementThe Environmental Protection Agency’s 2010 regula-tions require lower nitrogen oxide (NOx) exhaustemissions. Selective catalytic reduction (SCR) usesdiesel exhaust fluid (DEF) to lower NOx emissions inthe vehicle exhaust. A filter in the DEF pump pre-vents clogging of the DEF metering unit injectionnozzle.See the engine manufacturer’s maintenance manualfor filter replacement intervals; and see Section49.01 of the 108SD and 114SD Workshop Manualfor the filter replacement procedure.

Exhaust49


08/20/2009 f490355

12

3

4

5

6

7

8

9

1011

121314

9

15

NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and theDOC inlet pressure sensor.1. DOC Outlet Temperature

Sensor2. DOC Inlet Pressure Sensor

Port3. DOC Inlet Temperature Sensor4. Front Heat Shield5. DEF Nozzle

6. Exhaust Outlet7. DEF Metering Unit8. Sensor Box (see note above)9. Exhaust Inlet10. SCR Outlet Temperature

Sensor

11. SCR Outlet NOx Sensor Port12. SCR Inlet NOx Sensor Port13. 14-Pin Connectors14. DPF Outlet Pressure Sensor

Port15. SCR Inlet Temperature Sensor

Fig. 1, Detroit Diesel One-Box ATS (with Sensor Locations)

Exhaust 49


09/16/2009

12

3

4

5

6

7

89

1011

f490353

10

98

1. DEF Metering Unit2. DEF Nozzle3. SCR Outlet Temperature

Sensor4. SCR Inlet Temperature Sensor

5. DOC Inlet Temperature Sensor6. DOC Inlet Pressure Sensor7. DPF Inlet Temperature Sensor8. DPF Outlet Pressure Sensor

9. DPF Outlet TemperatureSensor

10. DPF Outlet NOx Sensor11. SCR Outlet NOx Sensor

Fig. 2, Detroit Diesel 2V2 Two-Box ATS (with Sensor Locations)

Exhaust49


02/22/2011 f490354a

1

2

3

4

56

7

8

10

11

12

9

1. DPF Inlet Temperature Sensor2. DOC Inlet Temperature Sensor3. DOC Inlet Pressure Sensor4. DPF Sensor Box5. DPF Outlet Pressure Sensor

6. DPF Outlet TemperatureSensor

7. DPF Outlet NOx Sensor8. SCR Inlet Temperature Sensor9. DEF Metering Unit

10. SCR Outlet TemperatureSensor

11. SCR Sensor Box12. SCR Outlet NOx Sensor

Fig. 3, Detroit Diesel 2HV Two-Box ATS (with Sensor Locations)

Exhaust 49


02/01/2011 f4904491

1

2

23

3

4

4

5

6

7

7

8

9

1011

12

1. ATD2. Mixer Tube3. DEF Injector4. NOx Sensor

5. SCR Outlet TemperatureSensor

6. SCR Inlet Temperature Sensor7. SCR Catalyst8. DOC Inlet Temperature Sensor

9. DPF Inlet Temperature Sensor10. DPF Inlet Pressure Sensor11. DPF Outlet Temperature

Sensor12. DPF Outlet Pressure Sensor

Fig. 4, Cummins Switchback Understep ATS (with Sensor Locations)

Exhaust49


02/01/2011 f490450

1

2

3 4

5

6

7

8

9

10

1112

1. ATD2. DOC Inlet Temperature Sensor3. DPF Inlet Temperature Sensor4. DPF Outlet Temperature

Sensor

5. DEF Injector6. NOx Sensor7. SCR Outlet Temperature

Sensor8. SCR Catalyst

9. SCR Inlet Temperature Sensor10. Mixer Tube11. DPF Outlet Pressure Sensor12. DPF Inlet Pressure Sensor

Fig. 5, Cummins 2HH ATS (with Sensor Locations)

Exhaust 49


02/01/2011 f490448

1 12 23

4

5

11

109

8

677

12

1. ATD2. NOx Sensor3. SCR Catalyst4. DPF Outlet Pressure Sensor5. DPF Inlet Pressure Sensor

6. DEF Injector7. Mixer Tube8. SCR Inlet Temperature Sensor9. SCR Outlet Temperature

Sensor

10. DOC Inlet Temperature Sensor11. DPF Inlet Temperature Sensor12. DPF Outlet Temperature

Sensor

Fig. 6, Cummins Switchback 2V2 ATS (with Sensor Locations)

Exhaust49


Title of Maintenance Operation (MOP) MOP NumberAerodynamic Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–02

Mirror Folding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–01

Cab 60Index, Alphabetical

108SD and 114SD Maintenance Manual, June 2012

60–01 Mirror Folding CheckFor vehicles with folding main mirrors, make surethat the mirrors fold freely on the pivot points. Pivoteach mirror fully forward and backward two times tobreak loose any debris that may affect the fold-awayfeature of the mirror.

60–02 AerodynamicComponent Inspection

Inspect aerodynamic components, if equipped, forstructural damage, cracks, or wear. These mayinclude:

• Cab side extenders• Roof fairing/deflector• Bumper• Hood

Replace or repair damaged or missing componentsas needed.

Cab 60


Title of Maintenance Operation (MOP) MOP NumberDoor Seals Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72–01

Doors 72Index, Alphabetical


72–01 Door Seals LubricationNOTE: Only the door seals require lubrication.Do not lubricate the door latches or hinges.They come from the manufacturer with lifetimelubrication and require no maintenance.Lightly coat the door seals with a lubricant that issafe for rubber.

Doors 72


Title of Maintenance Operation (MOP) MOP NumberAir Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01

HVAC Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02

Heater and Air Conditioner 83Index, Alphabetical


83–01 Air ConditionerInspection

1. With the vehicle parked on a level surface, applythe parking brakes and chock the tires.

2. Operate the heater and, if equipped with an airconditioner, the air conditioner to check forproper operation in all modes.

3. Open the hood.4. Inspect the refrigerant compressor drive belt for

damage. If needed, replace the drive belt.5. Check the tightness of the compressor mounting

fasteners. The torque value for the mounting fas-teners is 15 to 19 lbf·ft (20 to 26 N·m).

6. Inspect the drive plate. If the friction surface ofthe drive plate shows visible signs of damagedue to excessive heat, make sure the refrigerantcompressor turns freely. If the compressor doesturn freely, replace the drive plate and clutch as-sembly. For instructions, see Section 83.02,Subject 140 of the 108SD and 114SD WorkshopManual. If the compressor does not turn freely,replace the compressor. For instructions, seeSection 83.02, Subject 120 of the 108SD and114SD Workshop Manual

7. Use a feeler gauge to check that the drive plateclutch clearance is 0.016 to 0.031 inch (0.4 to0.8 mm). Check the gap at three equally spacedlocations on the drive plate, and average themeasurements to account for pulley misalign-ment. If the overall gap is out of spec, removethe drive plate assembly and change the shimsas necessary. For instructions, see Section83.02, Subject 140 of the 108SD and 114SDWorkshop Manual.

8. Check that the wiring harness connector is notdamaged or loose. Replace the wiring harness ifit is damaged.

9. Check the overall condition of the air conditioninghoses. Look for cracks, cuts, and abrasions onthe hoses. Replace damaged hoses.

10. Check for a buildup of road debris on the con-denser fins. Using air pressure and a whiskbroom or a soapy spray of water, carefully cleanoff the condenser. Be careful not to bend thefins.

83–02 HVAC Air FilterReplacement

The HVAC air filter must be replaced every sixmonths or 60,000 miles (97 000 km) to permit properoperation of the HVAC system.1. With the vehicle parked, apply the parking

brakes, and chock the tires.2. Remove the lower HVAC cover in the cab. For

instructions, see Group 60 of the 108SD and114SD Workshop Manual.

3. Disconnect the wiring harness from the evapora-tor probe.

4. Remove the capscrews that attach the evapora-tor service cover to the HVAC assembly. Removethe evaporator service cover.

5. Pull the filter out of the HVAC assembly.6. Install a new filter in the HVAC assembly. Be

sure that the arrow on the filter is pointing towardthe evaporator. See Fig. 1.

7. Remove the condensate seal from the evapora-tor service cover and install a new condensateseal on the cover.

8. Using capscrews, attach the evaporator servicecover to the HVAC assembly.

9. Connect the wiring harness to the evaporatorprobe.

10/04/2001 f543921

21

1. Evaporator 2. Filter

Fig. 1, HVAC Assembly Filter

Heater and Air Conditioner 83


10. Attach the lower HVAC cover to the dash panel.For instructions, see Group 60 of the 108SD and114SD Workshop Manual.

Heater and Air Conditioner83


Title of Maintenance Operation (MOP) MOP NumberHood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88–01

Hood, Grille, and Cab Fenders 88Index, Alphabetical


88–01 Hood Rear SupportLubrication

1. Apply the parking brakes and chock the tires.2. Open the hood.3. Clean both the hood- and cab-mounted hood

rear support components with a soapy water so-lution.

4. Cover all contact surfaces of the hood rear sup-port brackets and isolators with an approvedmulti-purpose, lithium-complex, soap-basedgrease; see Table 1.

Approved Suppliers of Multi-Purpose Lithium GreaseSupplier Grease

Chevron Delo Heavy Duty EP

Exxon Unirex EP2

Mobil Mobil Grease XHP 222

Shell Retinax LC Grease

Texaco Starplex 2

Table 1, Approved Suppliers of Multi-Purpose LithiumGrease

Hood, Grille, and Cab Fenders 88


108sd and 114sd maintenance manual models: 108sd 114sd and 114sd... · 108sd and 114sd maintenance...

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