RECREATIONAL VEHICLE CHASSIS MAINTENANCE

MANUAL

Models: XCL
XCR
XCP
XCS
MC

STI-425-3 (9/10P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
 Foreword
Scheduled maintenance provides a key element for safe operation of your vehicle. A proper
maintenance program also helps to minimize downtime and to safeguard warranties. This
maintenance manual provides information necessary for years of safe, reliable, and cost-efficient
vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also
refer to other component and body manufacturers’ instructions for specific inspection
and maintenance instructions.
Perform the pretrip inspection and daily/weekly/monthly maintenance as outlined in the vehicle
operator’s manual. Perform the operations in this maintenance manual at scheduled intervals
based upon distance traveled or months of operation. Your authorized servicing dealer has the
qualified technicians and equipment to perform this maintenance for you. Your dealership can
also set up a scheduled maintenance program tailored specifically to your needs. Optionally,
your dealership can assist you in learning how to perform the maintenance procedures in this
manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of
printing. Freightliner Custom Chassis Corporation (FCCC) reserves the right to discon-
tinue models and to change specifications or design at any time without notice and
without incurring obligation. Descriptions and specifications contained in this publication
provide no warranty, expressed or implied, and are subject to revision and editions
without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerChassis.com for
more information, or contact Daimler Trucks North America LLC at the address below.

Environmental Concerns and Recommendations

Whenever you see instructions in this manual to discard materials, you should attempt to reclaim
and recycle them. To preserve our environment, follow appropriate environmental rules and
regulations when disposing of materials.

NOTICE: Parts Replacement Considerations

Do 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
have undetected structural damage.

© 2007–2010 Daimler Trucks North America LLC

All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced,
stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks
North America LLC. Daimler Trucks North America is a Damiler company.

Daimler Trucks North America LLC

Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208-3849
 Introduction
Descriptions of Service Publications

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro®) formats.
Workshop/Service Workshop/service manuals contain service and repair information for all vehicle
Manual systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures 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’s Driver’s/operator’s manuals contain information needed to enhance the driver’s
Manual understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip 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 over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists 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 the
AccessFreightliner.com website.
ServicePro ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides di-
agnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™ makes Freightliner Custom Chassis Corporation, Freightliner, Ster-
ling, Thomas Built Buses, and Western Star products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.

Recreational Vehicle Chassis Maintenance Manual, September 2010 I–1

Introduction
Descriptions of Service Publications

Warranty-related service information available on the AccessFreightliner.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.

I–2 Recreational Vehicle Chassis Maintenance Manual, September 2010

 Introduction
Page Description

For an example of a maintenance manual page, see Fig. 1.

A B C

Front Axle 33

33−01 Knuckle Pin Lubricating (See

Fig. 1)
33−02 Tie−Rod End Lubricating and
Inspecting

33−03 Toe−In Inspection

D E
11/11/2002 f020075

A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example of a Maintenance Manual Page

Recreational Vehicle Chassis Maintenance Manual, September 2010 I–3

Introduction
Maintenance Manual Contents

Group No. Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
30 . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Control
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner

I–4 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

15,000 Mile or 12 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
30,000 Mile or 24 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
45,000 Mile or 36 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06
60,000 Mile or 48 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07
6000 Mile or 6 Month Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
General Maintenance Schedule Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Metric/U.S. Customary Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10
Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08
Torque Specifications Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11
Vehicle Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
General Maintenance Schedule Information: 00–01

General Maintenance Schedule Tear-Out Checklists

Information IMPORTANT: Additional copies of the checklists
Performing regular maintenance on your vehicle will should be made before giving this to a dealer,
help ensure that your vehicle delivers safe reliable as they may not be returned to you. The correct
service and optimum performance for years to come. number of checklists are included to cover the
Failure to follow a regular maintenance program can warranty period, however, if you want copies of
result in inefficient operation and unscheduled down the checklists for future maintenance after the
time. warranty expires, you will need to make them.
When the vehicle reaches the distance or time Freightliner Custom Chassis Corporation
(whichever comes first) given for a maintenance in- (FCCC) will not be able to send you additional
terval, see the Vehicle Maintenance Schedule Table copies.
for a list of the maintenance operations to be per- At the back of the maintenance manual, there are
formed at that maintenance interval. Use the mainte- checklists for each maintenance interval up to 60,000
nance operation reference numbers to find detailed miles (96 540 km). When a maintenance interval
instructions in the manual for each operation. needs to be performed, take the vehicle to an autho-
NOTE: Maintenance instructions in this manual rized Freightliner dealer, remove the appropriate
are based on average vehicle use and normal checklist, and give it to the dealer. These are the
operating conditions. Unusual vehicle operating items that will be inspected for maintenance.
conditions may require service at more frequent
intervals.
For specific engine maintenance information, see the
Cummins Operation and Maintenance Manual.
IMPORTANT: Maintenance operations appearing
in italics in the following tables are for emission
control components. Numbers in the table are
reference numbers matching those in the text of
this manual.

Camp Freightliner Owner

Training
Owners who want to learn more about their vehicle
can attend a two-day training class, offered at the
Freightliner Custom Chassis Service Center in
Gaffney, South Carolina. Some of the items covered
during the training include the air brake system, elec-
trical system, vehicle storage, weight distribution, and
maintenance intervals.
To learn more about the class or to register, go to
www.freightlinerchassis.com. After entering the
website, click "Motorhomes" and select "Owner Info".
A class description and the registration form are lo-
cated under the "Camp Freightliner" tab.
If needed, service work can be scheduled for your
vehicle at the service center during your stay.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/1

00 General Information
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
01–01 Engine Drive Belt Inspecting • • • • • • • • • • • • • • • • • • • •
01–02 Engine-Support Fasteners
• • • • • • • • • • • • • • • • • • • •
Checking
01–03 Pacbrake Inspecting and
• • • • • • • • • • • • • • • • • • •
Maintenance
09–01 Air Cleaner Inspecting and
• • • • • • • • • • • • • • • • • • • •
Replacing*
09–02 Charge Air Cooler
• • • • • • • • • • • • • • • • • • • •
Inspecting and Cleaning
15–01 Alternator, Battery, and
• • • • • • • • • • • • • • • • • • • •
Starter Checking
20–01 Radiator Cap Checking • • • • • • • • • • • • • • • • • • • •
20–02 Radiator Inspecting and
• • • • • • • • • • • • • • • • • • • •
Cleaning
20–03 Coolant Replacing †
26–01 Transmission Breather
• • • • • • • • • • • • • • • • • • •
Checking
26–02 Allison MD/MH Series
• • • • • • • • • • • • • • • • • • • •
Transmission Fluid Level Checking
26–03 Allison Transmission Fluid
and Filter Changing (internal/
external filter) ‡
30–01 Throttle Pedal Pivot Pin
• • • • • • • • • • • • • • • • • • • •
Lubricating
32–01 Suspension Fastener
• • • • • • • • • •
Torque Checking
32–02 Suspension Height Control
• • • • • • • • • • • • • • • • • • • •
Valve Checking
32–03 Suspension Inspecting • • • • • • • • • • • • • • • • • • • •
32–04 ZF IFS Lubricating • • • • • • • • • • • • • • • • • • • •
32–05 Suspension Inspecting • • • • • • • • • • • • • • • • • • • •
32–06 Suspension U-Bolt Torque
• • • • • • • • • • • • • • • • • • • •
Checking
33–01 Knuckle Pin Lubricating • • • • • • • • • • • • • • • • • • • •
33–02 Tie-Rod End Lubricating
• • • • • • • • • • • • • • • • • • • •
and Inspecting

00/2 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
33–03 All-Axle Alignment Checking •
33–04 Wheel Bearing Removal,
Cleaning, Checking, Repacking,
and Adjusting§
33–05 Oil-Filled Hubs Oil Level
• • • • • • • • • • • • • • • • • • • •
Checking
33–06 Oil-Filled Hubs Oil Changing • • • • • • • • • •
35–01 Axle Lubricant Checking • • • • • • • • • • • • • • • • • • • •
35–02 Axle Lubricant Changing ¶
35–03 Axle Breather Checking • • • • • • • • • • • • • • • • • • • •
35–04 Oil-Filled Hubs Oil Level
• • • • • • • • • • • • • • • • • • • •
Checking, Tag Axle
35–05 Oil-Filled Hubs Oil
• • • • • • • • • •
Changing, Tag Axle
40–01 Wheel Nut Checking • • • • • • • • • •
40–02 Wheel Cleaning and
Polishing **
41–01 Driveline Inspecting and
• • • • • • • • • • • • • • • • • • • •
Lubricating
42–01 Brake System Valves
• • • • • • • • • • • • • • • • • • • •
Inspecting
42–02 Air Dryer Inspecting • • • • • • • • • • • • • • • • • • • •
42–03 Air Dryer Desiccant and
• • • • • •
Coalescent Filter Replacing ††
42–04 Camshaft Bracket Bushing
• • • • • • • • • • • • • • • • • • •
Lubricating
42–05 Slack Adjuster Lubricating • • • • • • • • • • • • • • • • • • • •
42–06 Foot Brake Valve Actuator
• • • • • • • • • • • • • • • • • • • •
Lubricating
42–07 Bendix Hydro-Max® Brake
System Inspecting (front-engine • • • • • • • • • • • • • • • • • • • •
diesel chassis)
42–08 Brake Caliper Slide Pin
Lubricating, Bosch Brakes (front-
engine diesel chassis) ‡‡

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/3

00 General Information
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
42–09 Brake Lines Checking,
• • • • • • • • • • • • • • • • • • • •
Hydraulic Disc or Air Brakes
42–10 Brake Lining Wear
Checking, Hydraulic Disc Brakes • • • • • • • • • • • • • • • • • • • •
(front-engine diesel chassis)
42–11 Brake Inspecting • • • • • • • • • • • • • • • • • • • •
42–12 Meritor Roller Pin
• • • • • • • • • • • • • • • • • • •
Lubricating
46–01 Drag Link Lubricating • • • • • • • • • • • • • • • • • • • •
46–02 Power Steering Reservoir
• • • • • • • • • • • • • • • • • • • •
Fluid Level Checking
46–03 Power Steering Reservoir
• • • • • • • • • • • • • • • • • • •
Fluid and Filter Changing §§
46–04 Steering Driveline
• • • • • • • • • • • • • • • • • • • •
Lubricating
46–05 Steering Gear Lubricating • • • • • • • • • • • • • • • • • • • •
46–06 Hydraulic Reservoir Filter
• • • • • • • • • •
Changing (metal reservoir only)
47–01 Fuel Tank Mounts and Fuel
• • • • • • • • • •
Line Checking
47–02 Fuel/Water Separator
Element Replacing ¶¶
49–01Exhaust System Inspecting
• • • • • • • • • • • • • • • • • • • •
(Noise Emission Control)
54–01 Ground Cables Checking
• • • • • • • • • • • • • • • • • • • •
and Cleaning
54–02 Battery Voltage Checking • • • • • • • • • • • • • • • • • • • •

00/4 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
83–01 Air Conditioner Inspecting • • • • • • • • • • • • • • • • • • • •
* Inspect the air cleaner every 12 months. Replace the air cleaner element every 24 months, or when filter restriction reaches 25 inH20 (if equipped with an air
restriction gauge).
† Beginning with model-year 2002 RV chassis, the coolant replacement interval is increased to 100,000 miles (161 000 km) or 60 months. You must check and,
if necessary, recharge the SCA (supplemental coolant additive) levels and freeze point every 25,000 miles (40 000 km) or 6 months. See the Cummins Opera-
tion and Maintenance Manual for further information.
‡ For oil and filter change intervals, see the applicable Allison Operator’s Manual.
§ For Freightliner/Meritor axles, check for correct end play every 15,000 miles (24 135 km). For ZF axles, lubricate grease fittings annually, and disassemble,
inspect, and repack the bearings every 1, 000,000 miles (1 609 000 km).
¶ For Freightliner rear axles with petroleum-based oil, change the lubricant every 100,000 miles (161 000 km) or every 12 months, whichever comes first; if
synthetic oil is used, change the lubricant every 250,000 miles (402 000 km) or every 12 months, whichever comes first. For Meritor rear axles with petroleum-
based oil, change the lubricant every 100,000 miles (161 000 km) or every 12 months, whichever comes first; if synthetic oil is used, change the lubricant every
250,000 miles (402 000 km) or every 36 months, whichever comes first.
** Perform these steps each time the wheels and/or the vehicle is washed.
†† Replace the Bendix AD9 filter and the Haldex (Midland) PURest® air dryer filter kit every 36 months.
‡‡ Lubricate every 6 months OR every 18,000 miles (28 000 km), whichever comes first.
§§ Change the TRW inline power steering filter every 12 months.
¶¶ See the Cummins Operation and Maintenance Manual for fuel/water separator element replacing intervals.

Table 1, Maintenance Operation Procedures and Schedule

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/5

00 General Information
6000 Mile or 6 Month Initial Maintenance: 00–03

Procedure Performed MOP

6000 Mile (9654 km) or 6 Month Initial Maintenance*
(check off or initial) Reference
Inspect _______ Engine Drive Belt Inspecting 01–01
Check _______ Engine-Support Fasteners Checking 01–02
Change _______ Engine Oil and Filter (see the engine manufacturer’s manual) —
Inspect _______ Pacbrake Inspecting and Maintenance 01–03
Inspect _______ Air Cleaner Inspecting and Replacing 09–01
Inspect _______ Charge Air Cooler Inspecting and Cleaning (if cleaning is needed) 09–02
Check _______ Alternator, Battery, and Starter Checking 15–01
Inspect/ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for 20–01, 20–02,
_______
Check chaffing and leaks) 20–03
Change _______ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _______ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _______ Throttle Pedal Pivot Pin Lubricating 30–01
Inspect _______ Suspension 32–01, 32–06
Check _______ Suspension Height Control Valve Checking 32–02
Lubricate _______ ZF IFS Lubricating 32–04
Check _______ Suspension U-Bolt Torque Checking 32–06
Lubricate _______ Knuckle Pin Lubricating 33–01
Lubricate _______ Tie-Rod End Lubricating and Inspecting 33–02
Check _______ All-Axle Alignment Checking 33–03
Check/
_______ Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting 33–04
Lubricate
Check/ 33–05, 33–06,
_______ Oil-Filled Hubs Oil Level Checking (front and tag axle)
Change 35–04, 35–05
Check _______ Axle Seals for Leaks —
Change _______ Axle Lubricant Changing (Freightliner axle only) 35–02
Check _______ Axle Breather Checking 35–03
Check _______ Wheel Nut Checking 40–01
Check _______ Tire Pressure —
Lubricate _______ Driveline Inspecting and Lubricating 41–01
Inspect _______ Brake System Valves Inspecting 42–01
Inspect _______ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02
Lubricate _______ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _______ Slack Adjuster Lubricating 42–05
Lubricate _______ Foot Brake Valve Actuator Lubricating 42–06
Inspect _______ Bendix Hydro-Max® Brake System Inspecting (front-engine only) 42–07
Lubricate _______ Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) 42–08
Check _______ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09

00/6 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
6000 Mile or 6 Month Initial Maintenance: 00–03

Procedure Performed MOP

6000 Mile (9654 km) or 6 Month Initial Maintenance*
(check off or initial) Reference
Check _______ Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine only) 42-10
Inspect _______ Brake Inspecting (Air Brakes) 42–11
Drain _______ Air Tanks —
Lubricate _______ Drag Link Lubricating 46–01
Lubricate _______ Steering Driveline Lubricating 46–04
Lubricate _______ Steering Gear Lubricating 46–05
Change _______ Hydraulic Reservoir Filter Changing (metal reservoir only) 46–06
Inspect _______ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _______ Fuel Filters —
Inspect _______ Exhaust System Inspecting 49–01
Check _______ Ground Cables Checking and Cleaning 54–01
Inspect _______ Air Conditioner Component Inspection 83–01
Customer†___________________________________________________ Date ________________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchassis.com).
† Your signature on this form indicates that you have reviewed and agree to the service items to be performed. Any items you wish to exclude should be indi-
cated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/7

00 General Information
15,000 Mile or 12 Month Maintenance: 00–04

Procedure Performed MOP

15,000 Mile (24 135 km) or 12 Month Maintenance*
(check off or initial) Reference
Inspect _______ Engine Drive Belt Inspecting 01–01
Check _______ Engine-Support Fasteners Checking 01–02
Change _______ Engine Oil and Filter (see the engine manufacturer’s manual) —
Inspect _______ Pacbrake Inspecting and Maintenance 01–03
Change _______ Air Cleaner Inspecting and Replacing 09–01
Inspect _______ Charge Air Cooler Inspecting and Cleaning (if cleaning is needed) 09–02
Check _______ Alternator, Battery, and Starter Checking 15–01
Inspect/ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for 20–01, 20–02,
_______
Check chaffing and leaks) 20–03
Change _______ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _______ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _______ Throttle Pedal Pivot Pin Lubricating 30–01
Inspect _______ Suspension 32–01, 32–06
Check _______ Suspension Height Control Valve Checking 32–02
Lubricate _______ ZF IFS Lubricating 32–04
Check _______ Suspension U-Bolt Torque Checking 32–06
Lubricate _______ Knuckle Pin Lubricating 33–01
Lubricate _______ Tie-Rod End Lubricating and Inspecting 33–02
Check/
_______ Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting 33–04
Lubricate
Check/ 33–05, 33–06,
_______ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04, 35–05
Check _______ Axle Seals for Leaks —
Change _______ Axle Lubricant Changing (Freightliner and Meritor axles) 35–02
Check _______ Axle Breather Checking 35–03
Check _______ Tire Pressure —
Lubricate _______ Driveline Inspecting and Lubricating 41–01
Inspect _______ Brake System Valves Inspecting 42–01
Inspect _______ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02
Lubricate _______ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _______ Slack Adjuster Lubricating 42–05
Lubricate _______ Foot Brake Valve Actuator Lubricating 42–06
Inspect _______ Bendix Hydro-Max® Brake System Inspecting (front-engine only) 42–07
Lubricate _______ Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) 42–08
Check _______ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Check _______ Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine only) 42-10
Inspect _______ Brake Inspecting (Air Brakes) 42–11

00/8 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
15,000 Mile or 12 Month Maintenance: 00–04

Procedure Performed MOP

15,000 Mile (24 135 km) or 12 Month Maintenance*
(check off or initial) Reference
Lubricate _______ Meritor Roller Pin Lubricating 42–12
Drain _______ Air Tanks —
Lubricate _______ Drag Link Lubricating 46–01
Change _______ Power Steering Reservoir Fluid and Filter Changing 46–03
Lubricate _______ Steering Driveline Lubricating 46–04
Lubricate _______ Steering Gear Lubricating 46–05
Change _______ Hydraulic Reservoir Filter Changing (including TRW) 46-06
Inspect _______ Fuel Tank Mounts and Fuel Line Checking 47-01
Change _______ Fuel Filters —
Inspect _______ Exhaust System Inspecting 49–01
Check _______ Ground Cables Checking and Cleaning 54–01
Inspect _______ Air Conditioner Component Inspection 83–01
Customer†___________________________________________________ Date ________________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchassis.com).
† Your signature on this form indicates that you have reviewed and agree to the service items to be performed. Any items you wish to exclude should be indi-
cated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/9

00 General Information
30,000 Mile or 24 Month Maintenance: 00–05

Procedure Performed MOP

30,000 Mile (48 270 km) or 24 Month Maintenance*
(check off or initial) Reference
Inspect _______ Engine Drive Belt Inspecting 01–01
Check _______ Engine-Support Fasteners Checking 01–02
Change _______ Engine Oil and Filter (see the engine manufacturer’s manual) —
Inspect _______ Pacbrake Inspecting and Maintenance 01–03
Inspect _______ Air Cleaner Inspecting and Replacing 09–01
Inspect _______ Charge Air Cooler Inspecting and Cleaning (if cleaning is needed) 09–02
Check _______ Alternator, Battery, and Starter Checking 15–01
Inspect/ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for 20–01, 20–02,
_______
Check chaffing and leaks) 20–03
Change _______ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _______ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _______ Throttle Pedal Pivot Pin Lubricating 30–01
Inspect _______ Suspension 32–01, 32–06
Check _______ Suspension Height Control Valve Checking 32–02
Lubricate _______ ZF IFS Lubricating 32–04
Check _______ Suspension U-Bolt Torque Checking 32–06
Lubricate _______ Knuckle Pin Lubricating 33–01
Lubricate _______ Tie-Rod End Lubricating and Inspecting 33–02
Check/
_______ Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting 33–04
Lubricate
Check/ 33–05, 33–06,
_______ Oil-Filled Hubs Oil Level Checking (front and tag axle)
Change 35–04, 35–05
Check _______ Axle Seals for Leaks —
Change _______ Axle Lubricant Changing (Freightliner axle only) 35–02
Check _______ Axle Breather Checking 35–03
Check _______ Wheel Nut Checking 40–01
Check _______ Tire Pressure —
Lubricate _______ Driveline Inspecting and Lubricating 41–01
Inspect _______ Brake System Valves Inspecting 42–01
Inspect _______ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02
Lubricate _______ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _______ Slack Adjuster Lubricating 42–05
Lubricate _______ Foot Brake Valve Actuator Lubricating 42–06
Inspect _______ Bendix Hydro-Max® Brake System Inspecting (front-engine only) 42–07
Lubricate _______ Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) 42–08
Check _______ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Check _______ Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine only) 42-10

00/10 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
30,000 Mile or 24 Month Maintenance: 00–05

Procedure Performed MOP

30,000 Mile (48 270 km) or 24 Month Maintenance*
(check off or initial) Reference
Inspect _______ Brake Inspecting (Air Brakes) 42–11
Lubricate _______ Meritor Roller Pin Lubricating 42–12
Drain _______ Air Tanks —
Lubricate _______ Drag Link Lubricating 46–01
Power steering fluid reservoir (fluid and filter changing, inline filter changing
Change _______ 46–03, 46–06
[including TRW])
Lubricate _______ Steering Driveline Lubricating 46–04
Lubricate _______ Steering Gear Lubricating 46–05
Inspect _______ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _______ Fuel Filters —
Inspect _______ Exhaust System Inspecting 49–01
Check _______ Ground Cables Checking and Cleaning 54–01
Inspect _______ Air Conditioner Component Inspection 83–01
Customer†___________________________________________________ Date ________________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchassis.com).
† Your signature on this form indicates that you have reviewed and agree to the service items to be performed. Any items you wish to exclude should be indi-
cated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/11

00 General Information
45,000 Mile or 36 Month Maintenance: 00–06

Procedure Performed MOP

45,000 Mile (72 405 km) or 36 Month Maintenance*
(check off or initial) Reference
Inspect _______ Engine Drive Belt Inspecting 01–01
Check _______ Engine-Support Fasteners Checking 01–02
Inspect _______ Pacbrake Inspecting and Maintenance 01–03
Change _______ Engine Oil and Filter (see the engine manufacturer’s manual) —
Change _______ Air Cleaner Inspecting and Replacing 09–01
Inspect _______ Charge Air Cooler Inspecting and Cleaning (if cleaning is needed) 09–02
Check _______ Alternator, Battery, and Starter Checking 15–01
Inspect/ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for 20–01, 20–02,
_______
Check chaffing and leaks) 20–03
Change _______ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _______ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _______ Throttle Pedal Pivot Pin Lubricating 30–01
Inspect _______ Suspension 32–01, 32–06
Check _______ Suspension Height Control Valve Checking 32–02
Lubricate _______ ZF IFS Lubricating 32–04
Check _______ Suspension U-Bolt Torque Checking 32–06
Lubricate _______ Knuckle Pin Lubricating 33–01
Lubricate _______ Tie-Rod End Lubricating and Inspecting 33–02
Check/
_______ Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting 33–04
Lubricate
Check/ 33–05, 33–06,
_______ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04, 35–05
Check _______ Axle Seals for Leaks —
Change _______ Axle Lubricant Changing (Freightliner and Meritor axles) 35–02
Check _______ Axle Breather Checking 35–03
Check _______ Tire Pressure —
Lubricate _______ Driveline Inspecting and Lubricating 41–01
Inspect _______ Brake System Valves Inspecting 42–01
Inspect _______ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02
Lubricate _______ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _______ Slack Adjuster Lubricating 42–05
Lubricate _______ Foot Brake Valve Actuator Lubricating 42–06
Inspect _______ Bendix Hydro-Max® Brake System Inspecting (front-engine only) 42–07
Lubricate _______ Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) 42–08
Check _______ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Check _______ Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine only) 42-10
Inspect _______ Brake Inspecting (Air Brakes) 42–11

00/12 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
45,000 Mile or 36 Month Maintenance: 00–06

Procedure Performed MOP

45,000 Mile (72 405 km) or 36 Month Maintenance*
(check off or initial) Reference
Lubricate _______ Meritor Roller Pin Lubricating 42–12
Drain _______ Air Tanks —
Lubricate _______ Drag Link Lubricating 46–01
Inspect _______ Power Steering Reservoir Fluid and Filter Changing 46–03
Lubricate _______ Steering Driveline Lubricating 46–04
Lubricate _______ Steering Gear Lubricating 46–05
Inspect _______ Hydraulic Reservoir Filter Changing (including TRW) 46–06
Inspect _______ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _______ Fuel Filters —
Inspect _______ Exhaust System Inspecting 49–01
Check _______ Ground Cables Checking and Cleaning 54–01
Inspect _______ Air Conditioner Component Inspection 83–01
Customer†___________________________________________________ Date ________________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchassis.com).
† Your signature on this form indicates that you have reviewed and agree to the service items to be performed. Any items you wish to exclude should be indi-
cated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/13

00 General Information
60,000 Mile or 48 Month Maintenance: 00–07

Procedure Performed MOP

60,000 Mile (96 540 km) or 48 Month Maintenance*
(check off or initial) Reference
Inspect _______ Engine Drive Belt Inspecting 01–01
Check _______ Engine-Support Fasteners Checking 01–02
Change _______ Engine Oil and Filter (see the engine manufacturer’s manual) —
Inspect _______ Pacbrake Inspecting and Maintenance 01–03
Inspect _______ Air Cleaner Inspecting and Replacing 09–01
Inspect _______ Charge Air Cooler Inspecting and Cleaning (if cleaning is needed) 09–02
Check _______ Alternator, Battery, and Starter Checking 15–01
Inspect/ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for 20–01, 20–02,
_______
Check chaffing and leaks) 20–03
Change _______ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _______ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _______ Throttle Pedal Pivot Pin Lubricating 30–01
Inspect _______ Suspension 32–01, 32–06
Check _______ Suspension Height Control Valve Checking 32–02
Lubricate _______ ZF IFS Lubricating 32–04
Check _______ Suspension U-Bolt Torque Checking 32–06
Lubricate _______ Knuckle Pin Lubricating 33–01
Lubricate _______ Tie-Rod End Lubricating and Inspecting 33–02
Check/
_______ Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting 33–04
Lubricate
Check/ 33–05, 33–06,
_______ Oil-Filled Hubs Oil Level Checking (front and tag axle)
Change 35–04, 35–05
Check _______ Axle Seals for Leaks —
Change _______ Axle Lubricant Changing (Freightliner axle only) 35–02
Check _______ Axle Breather Checking 35–03
Check _______ Wheel Nut Checking 40–01
Check _______ Tire Pressure —
Lubricate _______ Driveline Inspecting and Lubricating 41–01
Inspect _______ Brake System Valves Inspecting 42–01
Inspect _______ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02
Lubricate _______ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _______ Slack Adjuster Lubricating 42–05
Lubricate _______ Foot Brake Valve Actuator Lubricating 42–06
Inspect _______ Bendix Hydro-Max® Brake System Inspecting (front-engine only) 42–07
Lubricate _______ Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) 42–08
Check _______ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Check _______ Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine only) 42–10

00/14 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
60,000 Mile or 48 Month Maintenance: 00–07

Procedure Performed MOP

60,000 Mile (96 540 km) or 48 Month Maintenance*
(check off or initial) Reference
Inspect _______ Brake Inspecting (Air Brakes) 42–11
Lubricate _______ Meritor Roller Pin Lubricating 42–12
Drain _______ Air Tanks —
Lubricate _______ Drag Link Lubricating 46–01
Change _______ Power Steering Reservoir Fluid and Filter Changing 46–03
Lubricate _______ Steering Driveline Lubricating 46–04
Lubricate _______ Steering Gear Lubricating 46–05
Change _______ Hydraulic Reservoir Filter Changing (including TRW) 46–06
Inspect _______ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _______ Fuel Filters —
Inspect _______ Exhaust System Inspecting 49–01
Check _______ Ground Cables Checking and Cleaning 54–01
Inspect _______ Air Conditioner Component Inspection 83–01
Customer†___________________________________________________ Date ________________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchassis.com).
† Your signature on this form indicates that you have reviewed and agree to the service items to be performed. Any items you wish to exclude should be indi-
cated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/15

00 General Information
Noise Emission Controls Maintenance: 00–08

Noise Emission Control of design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
Maintenance delivery to the ultimate purchaser, or while it is in
use.
Federal Law, Part 205: 2. The use of the vehicle after such device or ele-
ment of design has been removed or rendered
Transportation Equipment Noise inoperative by any person.
Emission Controls Among those acts presumed to constitute tam-
Part 205, Transportation Equipment Noise Emission pering are the acts listed below:
Controls, requires the vehicle manufacturer to fur- A. Removal of, or rendering inoperative, the en-
nish, with each new vehicle, such written instructions gine speed governor so as to allow engine
for the proper maintenance, use, and repair of the speed to exceed manufacturer’s specifica-
vehicle by the ultimate purchaser to provide reason- tions.
able assurance of the elimination or minimization of
noise-emission-control degradation throughout the B. Removal of, or rendering inoperative, the fan
life of the vehicle. In compliance with the law, the clutch, including bypassing the control on
noise emission controls maintenance information in any thermostatic fan drive to cause it to op-
each applicable group of this manual, in conjunction erate continuously.
with the chassis workshop manual, provides these
instructions to owners. C. Removal of the fan shroud.
D. Removal of, or rendering inoperative, ex-
Recommendations for haust components, including exhaust pipe
clamping.
Replacement Parts
E. Removal of air intake components.
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freight-
liner Custom Chassis Corporation (FCCC) parts. If Maintenance Instructions
other than genuine FCCC parts are used for replace-
ment or repair of components affecting noise emis- Scheduled intervals are in the maintenance table in
sion control, the owner should be sure that such this group. A "Verification of Inspections Log (Group
parts are warranted by their manufacturer to be 49)" follows, and should be filled in each time noise
equivalent to genuine FCCC parts in performance emission controls on the vehicle are maintained or
and durability. repaired.

Freightliner Noise Emission

Controls Warranty
See the vehicle owner’s warranty information book
for warranty information concerning noise emission
controls.

Tampering With Noise Controls is

Prohibited
Federal 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 element

00/16 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Verification of Inspections Log: 00–09

Verification of Inspections Log

Verification of Inspections Log, Group 49
Date Mileage Item Cost Maintenance Facility
Group 49—Exhaust System Components

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/17

00 General Information
Metric/U.S. Customary Conversion Tables: 00–10

When You Know U.S. Multiply When You Multiply

To Get Metric To Get U.S. Customary
Customary By Know Metric By
Length
inches (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)
Area
square 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)
Volume
cubic 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/Force
ounces (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 Force
inch–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/Vacuum
inches 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 2, Metric/U.S. Customary Conversion

Then When You Multiply Then

When You Know Subtract To Get To Get
Divide By Know By Add
degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)
Table 3, Temperature Conversion

00/18 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Torque Specifications Tables: 00–11

IMPORTANT: Grade 8 regular hex zinc-yellow plated scribed in Table 4. See Table 5 for torque values for
capscrews and cadmium- and wax-coated prevailing grade 8 regular hex zinc-yellow plated capscrews
torque locknuts may be tightened to a lower torque and cadmium- and wax-coated prevailing torque
value than the grade 8 regular hex fasteners de- locknuts.

Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads†
Regular Hex Flanged
Thread
Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G
Diameter–
Bolt B Nut 8.2 Bolt C Nut Bolt Nut 8.2 Bolt Nut
Pitch
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005

f230006 f230007 f230008 f230009

1/4–20 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, or waxed).

Table 4, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/19

00 General Information
Torque Specifications Tables: 00–11

Torque Values for Grade 8 Regular Hex Zinc-Yellow Plated Capscrews and
Cadmium- and Wax-Coated Prevailing Torque Locknuts*
Regular Hex
Thread Diameter-Pitch Grade 8 or 8.2 Bolt Grade 8 or C Nut
Torque: lbf·ft (N·m)

f230004 f230005

1/4–20 6 (8)
1/4–28 7 (9)
5/16–18 13 (18)
5/16–24 14 (19)
3/8–16 23 (31)
3/8–24 26 (35)
7/16–14 37 (50)
7/16–20 41 (56)
1/2–13 56 (76)
1/2–20 63 (85)
9/16–12 81 (110)
9/16–18 90 (122)
5/8–11 112 (152)
5/8–18 126 (171)
3/4–10 198 (268)
3/4–16 221 (300)
7/8–9 319 (433)
7/8–14 352 (477)
1–8 479 (649)
1–12 524 (710)
1–14 537 (728)
* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.

Table 5, Torque Values for Grade 8 Regular Hex Zinc-Yellow Plated Capscrews
and Cadmium- and Wax-Coated Prevailing Torque Locknuts

00/20 Recreational Vehicle Chassis Maintenance Manual, September 2010

General Information 00
Torque Specifications Tables: 00–11

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads†
Regular Hex Flanged
Thread Grade 5 or B Grade 8 or 8.2 Grade 8 or C Grade 8 or 8.2
Grade 5 Bolt Grade G Nut
Diameter–Pitch Nut Bolt Nut Bolt
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230008 f230009

1/4–20 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 4. Freightliner recommends that all
plated and unplated fasteners be coated with oil before installation.
Table 6, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

Recreational Vehicle Chassis Maintenance Manual, September 2010 00/21

00 General Information
Torque Specifications Tables: 00–11

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads†
Thread Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut
Diameter–Pitch Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

8.8 8 10.9 10

f230010 f230011 f230012 f230013

M6 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, or waxed).
Table 7, Torque Values for Metric Thread Fasteners With Lubricated or Plated
Threads

00/22 Recreational Vehicle Chassis Maintenance Manual, September 2010

Engine 01
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Engine Drive Belt Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01
Engine-Support Fasteners Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02
Pacbrake Inspecting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–03

Recreational Vehicle Chassis Maintenance Manual, April 2010

Engine 01

01–01 Engine Drive Belt

Inspecting 2

WARNING
3
The engine and the belt must be cool before you
check the belt. Handling a hot belt can cause per-
sonal injury.
1. Inspect the belt for damage.
Transverse (across the belt width) cracks are 1
acceptable.
Longitudinal (direction of belt length) cracks that 11/08/2005 f0120111
intersect with transverse cracks are not accept-
able. 1. Front and Rear-Engine Rear Mount Bolt
2. Engine Mount Bracket-to-Engine Bolts
2. Replace the belt if it has unacceptable cracks, is 3. Frame Mount Bracket Bolts
frayed, or has pieces of material missing.
For additional information, see the Cummins Op- Fig. 1, Front and Rear-Engine Rear Mount (ISB chassis
built after 2002)
eration and Maintenance Manual.

01–02 Engine-Support
Fasteners Checking
1. Check the rear engine-support fasteners. See
Fig. 1. Tighten the rear engine-mount bolt 157
lbf·ft (213 N·m).
Tighten the insulator-to-frame mount bracket
bolts 91 lbf·ft (123 N·m).
Tighten the engine mount bracket-to-engine bolts 1
62 lbf·ft (84 N·m).
2. Check the 3/4–10 front-engine front mount bolt. 11/08/2005 f012110
See Fig. 2. Tighten it 95 lbf·ft (128 N·m). 1. Front and Rear-Engine Front Mount Bolt
Check the 3/4–10 rear-engine front mount bolt.
Tighten it 95 lbf·ft (128 N·m). Fig. 2, Front and Rear-Engine Front Mount (ISB chassis
built after 2002)

1. With the engine turned off, use Pacbrake Syn-

01–03 Pacbrake Inspecting and thetic Lube or Synco Super Lube, and spray or
Maintenance coat a sufficient amount on the restricter air cylin-
der valve shaft and the attaching locations at
Pacbrake recommends lubricating the moving parts each end of the actuation cylinder. See Fig. 3 for
of the exhaust brake with a synthetic based lubricant the exhaust brake lubrication points.
at every oil change. Once the lubricant is applied, the 2. Using your hands or a pair of pliers, slide the
exhaust brake should be cycled a few times to en- valve several times to distribute the lubricant
sure that the lubricant penetrates into the mating down the shaft and the attaching locations.
parts.

Recreational Vehicle Chassis Maintenance Manual, April 2010 01/1

01 Engine

03/20/2003 f012035
1. Air Cylinder
2. Pacbrake
Fig. 3, Pacbrake Exhaust Brake Lube Point Locations

NOTE: Operation of the Pacbrake could be af-

fected by starting the engine and idling for short
periods of time. During a cold engine start-up,
moisture occurs in the engine and the exhaust
system that creates a corrosion hazard. The
brake housing may trap water in the valve shaft
bore causing corrosion, resulting in an improper
or non-functioning brake. If it is necessary to
periodically start the engine, reach normal oper-
ating temperatures before shutting down the en-
gine.

01/2 Recreational Vehicle Chassis Maintenance Manual, April 2010

Air Intake 09
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Cleaner Inspecting and Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01
Charge Air Cooler Inspecting and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–02

Recreational Vehicle Chassis Maintenance Manual, January 2010

Air Intake 09

09–01 Air Cleaner Inspecting air intake piping, or a disconnected or damaged air
restriction indicator.
and Replacing
NOTE: Remove and visually inspect the air
cleaner element for obvious damage such as H20 VACUUM IN H20 VACUUM
25
holes, cuts, or dents. Remove loose debris,
20
such as leaves or pine needles, from the filter 15
housing. 10
7
Inspect the air cleaner and plumbing for holes or
tears at the recommended interval. If the air cleaner PUSH TO RESET
is damaged, replace it. See Group 09 of the Recre-
ational Vehicle Chassis Workshop Manual for re-
moval and installation procedures, or take the vehicle
to an authorized Freightliner dealer. A typical air
cleaner mounting is shown in Fig. 1.

05/22/97 f090176

Fig. 2, Air Restriction Indicator

Replace the air cleaner at the recommended interval,

or when filter restriction reaches 25 inH2O. See the
Recreational Vehicle Chassis Operator’s Manual for
specific restriction values for your engine. See
Group 09 of the Recreational Vehicle Chassis Work-
shop Manual for removal and installation procedures,
or take the vehicle to an authorized Freightliner
dealer.

09–02 Charge Air Cooler

Inspecting and Cleaning
07/11/2007 f090451 Good airflow through the radiator and charge air
cooler core is essential for proper engine cooling.
Fig. 1, Air Cleaner Mounting The cores allow air passage, but form a barrier that
tends to collect insects and airborne debris.
Engine damage can occur if the air intake system is If the charge air cooler core fins are bent, use a
not properly maintained. Use the air intake restriction small pair of needle-nose pliers or a small screw-
indicator to check for air intake system damage or driver to straighten them. If the fins are clogged, use
leaks. See Fig. 2. Make sure the engine is off and compressed air or water directed from the fan side of
note the existing reading on the indicator. Reset the the radiator core to backflush any material restricting
indicator by pushing it down. See Fig. 2. Start the airflow.
engine and take a short test drive. Check the indica-
tor again and note the level of restriction on the indi- Ensure that the hoses are not chafing and that the
cator, verifying it is at the same level as seen earlier. system is closed with no air leaks.
A decrease from the previous level of restriction or a
very low air restriction indicator reading (0 to 4
inH2O) could indicate an air intake system problem
such as a damaged air filter, loose or disconnected

Recreational Vehicle Chassis Maintenance Manual, January 2010 09/1

Alternators and Starters 15
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Alternator, Battery, and Starter Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01

Recreational Vehicle Chassis Maintenance Manual, April 2010

Alternators and Starters 15

15–01 Alternator, Battery, and Find the cause of any problems and repair, re-
place, and reroute wires and clamps as neces-
Starter Checking sary.
IMPORTANT: Ensure that wires and cables are
WARNING not near any heat sources; if they are, reroute
them.
Batteries release explosive gas as a by-product of
their chemical activity. Do not smoke when work- 4. Clean all circuit breakers and relays.
ing around batteries. Put out all flames and re- 5. Check the alternator wiring for missing insulation,
move any source of sparks or intense heat. Make kinks, and heat damage. Replace or repair as
sure the battery compartment is completely needed.
vented before disconnecting or connecting the
6. On the bundled cable that runs from the batteries
battery cables.
to the starter, ensure that tie straps are installed
Battery acid is extremely harmful if splashed in at least every 12 inches (30 cm). Replace any
the eyes or on the skin. Always wear a face shield missing tie straps, and add tie straps where
and protective clothing when working around bat- spacing between them exceeds 12 inches (30
teries. cm).
Damaged, chafed, or kinked wiring can cause 7. Ensure that all cables have sufficient slack to
electrical short-circuits and lead to fires, causing allow for engine movement, and that there is no
property damage, injury, or death. Clean, inspect, force on any wiring connectors.
and maintain wiring and connections carefully.
8. If any convoluted tubing is damaged, check the
1. Check the tightness of the alternator bracket fas- wiring inside it. Replace any damaged or missing
teners and alternator mounting fasteners; tighten convoluted tubing.
the fasteners as needed. For torque values, see
9. Inspect the battery cables for wear, and replace
Group 15 of the Recreational Vehicle Chassis
as needed. Clean the cable connector terminals
Workshop Manual, or take the vehicle to an au-
with a wire brush. See Group 54 of the Recre-
thorized Freightliner dealer.
ational Vehicle Chassis Workshop Manual for
2. Check that all electrical connections at the alter- troubleshooting instructions, and for adjustment,
nator and starter are clean. Clean and tighten all repair, or replacement instructions, or take the
charging system electrical connections as vehicle to an authorized Freightliner dealer.
needed. Spray each electrical connection at the
9.1 Clean and tighten the battery ground
alternator and starter with dielectric red enamel.
cable, terminal, and clamps.
Trace and inspect all wiring and cables con-
9.2 Inspect the retainer assembly (or battery
nected to:
hold-downs) and the battery box. Replace
• alternator worn or damaged parts. Remove any cor-
• starter and depopulation studs rosion with a wire brush, and wash with a
weak solution of baking soda and water.
• batteries Rinse with clean water, then dry. Paint
• magnetic switch the retainer assembly, if needed, to pre-
vent rusting.
• cab
9.3 Check that foreign objects, such as
• jump-start studs stones, bolts, and nuts, are removed from
• battery isolation relays the battery box.
• battery shutoff switches 9.4 After cleaning, connect the cables to the
batteries, and tighten them to the torque
3. Check wires and cables for wear, chafing, kinks, specifications listed on the battery, gener-
discolored insulation, or loose clamps or ties. ally 10 to 15 lbf·ft (14 to 20 N·m).

Recreational Vehicle Chassis Maintenance Manual, April 2010 15/1

15 Alternators and Starters

9.5 Coat the battery terminals with dielectric

grease.
10. Check the terminals on the battery shut-off
switch and the starter relay. Make sure that the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.

15/2 Recreational Vehicle Chassis Maintenance Manual, April 2010

Engine Cooling/Radiator 20
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Coolant Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03
Radiator Cap Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01
Radiator Inspecting and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02

Recreational Vehicle Chassis Maintenance Manual, January 2010

Engine Cooling/Radiator 20

20–01 Radiator Cap Checking fins of the radiator. Depending on the condition of the
radiator, this process may have to be performed sev-
eral times.
WARNING
Do not remove or loosen the radiator cap until the 20–03 Coolant Replacing
engine and cooling system have completely
cooled. Use extreme care when removing the cap. At the intervals specified in the maintenance sched-
A sudden release of pressure from removing the ule, or whenever the coolant becomes dirty, flush
cap prior to the system cooling can result in a and refill the cooling system.
surge of scalding coolant that could cause seri- NOTE: The coolant replacement interval is in-
ous personal injury. creased to 100,000 miles (161 000 km) or 60
The radiator cap is the most ignored part in the cool- months, whichever comes first. For this interval
ing system. If it is suspect, replace it. An inspection to apply, you must check and, if necessary, re-
means checking the cap with a pressure tester. A charge the SCA (supplemental coolant additive)
radiator cap in good condition will not open below 9 levels and the freeze point every 25,000 miles
psi (62 kPa). A visual check is also in order: look for (40 000 km) or 6 months, whichever comes first.
signs of deterioration of the inner gasket. Also look See the Cummins Operation and Maintenance
for cracks or breaks in the spring retainer in the cap
Manual for further information.
and for corrosion or deposits on the spring itself. If
the spring is not in perfect condition, it has probably
lost tension; replace it. See Fig. 1. WARNING
Do not remove or loosen the radiator cap until the
engine and cooling system have completely
cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a
surge of scalding coolant that could cause seri-
ous personal injury.
1. Drain the cooling system, as follows.
1.1 When the engine is cool, remove the ra-
diator cap.
Turn the cap slowly counterclockwise until
it reaches a "stop." Do not press down
05/31/2007 f200705
while turning the cap. Wait until any re-
maining pressure (indicated by a hissing
sound) is relieved, then press down on
Fig. 1, Surge Tank Coolant Fill Cap
the cap and continue turning it counter-
clockwise.
20–02 Radiator Inspecting and
1.2 When the cap is removed, run the engine
Cleaning until the upper radiator hose is hot—this
shows that the thermostat is open and
Inspect the radiator for clogging or damage and the coolant is flowing through the system.
clean and/or repair it if necessary. Soak the radiator
with a non-corrosive degreaser such as Simple
Green. Let the unit sit for several minutes to work WARNING
through the radiator. Using low water pressure, rinse
Use extreme care when draining coolant that is
the radiator. Be careful not to damage or bend the
very warm. It may still be hot enough to cause se-
rious personal injury by scalding.

Recreational Vehicle Chassis Maintenance Manual, January 2010 20/1

20 Engine Cooling/Radiator

1.3 Stop the engine. Remove the lower radia- 3.1 Slowly add a 50/50 mixture of antifreeze
tor hose to drain the coolant. Drainage and water to the surge tank until the sys-
may be speeded by removing the plug in tem is filled. Install the coolant fill cap.
the bottom of the water inlet. 3.2 Start the engine and run it at low idle for
2. Flush the cooling system, as follows. 10 seconds; then at high idle for 1
minute. Return to low idle.
CAUTION 3.3 Run the engine, with the radiator cap re-
moved, until the upper radiator hose is
During filling, air must be vented from the engine hot. With the engine idling, add coolant to
coolant passages. Any air trapped in the system the radiator until it is between the MIN
can cause severe engine damage. and MAX lines on the surge tank. Install
2.1 Connect the lower radiator hose and in- the radiator cap.
stall the plug in the bottom of the water
inlet.
2.2 Open the engine venting petcock.
2.3 Add water to the surge tank until the sys-
tem is filled.
2.4 Start the engine. Run it at low idle for 10
seconds, then at high idle for 1 minute.
Return to low idle.
2.5 Close the lower petcock when a steady
stream of water is flowing from it. Don’t
let more than 1.5 quarts (1.4 L) of water
escape.
2.6 Close the upper petcock when a steady
stream of water is flowing from it. Don’t
let more than 1.5 quarts (1.4 L) of water
escape.
2.7 Repeat several times until the drained
liquid is nearly colorless.
2.8 Completely drain the system, then close
the radiator and block the drain valves.
2.9 Disconnect all hoses from the surge tank.
Remove the tank and pour out any fluid.
Scrub and clean the inside of the surge
tank with soap and water. Flush it with
clean water, then drain it. Install the surge
tank and hoses.
IMPORTANT: On vehicles with EPA07-compliant
engines, the coolant capacity varies depending
on the engine and accessory installation. After
servicing the cooling system, always verify that
the coolant level is between the MIN and MAX
lines on the surge tank.
3. Fill the cooling system, as follows.

20/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Transmission 26
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Allison MD/MH Series Transmission Fluid Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02
Allison Transmission Fluid and Filter Changing (internal/external filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03
Transmission Breather Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01

Recreational Vehicle Chassis Maintenance Manual, January 2010

Transmission 26

26–01 Transmission Breather COLD RUN (lower) band is satisfactory for oper-
ating the vehicle. See Fig. 2. If the level is not
Checking within the COLD RUN band, add or drain fluid
until it reaches the middle of the COLD RUN
Transmission housing breathers must remain clear. A band.
plugged breather could result in pressure build-up,
which could cause lubricant leakage.
If the breather is plugged, clean or replace it. See
Fig. 1. Check more often if the vehicle is operating
under very dusty conditions.

11/16/2000 f270074

Fig. 2, Transmission Dipstick

4. Perform a hot check at the first opportunity after

normal operating temperature, 160 to 200°F (71
to 93°C), is reached.

Hot Check
Recommended Method
With the vehicle on a level surface and the transmis-
05/27/93 f260007a sion in neutral at operating temperature, perform the
steps below.
Fig. 1, Transmission Breather
1. On the transmission shift selector, press the up
26–02 Allison MD/MH Series and down arrow keys simultaneously. See Fig. 3.

Transmission Fluid 2. Release the arrow keys and wait for a two-
minute countdown.
Level Checking 3. The transmission shift selector display screen will
display one of the following messages.
Cold Check • OL - OK indicates an acceptable oil level.
IMPORTANT: After replacing the transmission • OL - HI followed by a number indicates the
fluid or changing the filter(s), it is important to amount that is over-filled.
check the fluid level cold to determine if the
• OL - LO followed by a number indicates
transmission has a sufficient amount of fluid to the amount that is under-filled.
be safely operated until a hot check can be
performed. • OL - 70 indicates that the transmission is
not up to operating temperature.
1. A cold check may be made when the sump tem-
perature is 60 to 104°F (15 to 40°C). Alternate Method
2. Run the engine for at least one minute to clear 1. Operate the transmission in a Drive (D) range
the fluid system of air. until normal operating temperature, 160 to 200°F
3. With the engine running, wipe the dipstick clean (71 to 93°C), is reached.
and check the fluid level. Any level within the

Recreational Vehicle Chassis Maintenance Manual, January 2010 26/1

26 Transmission

3. Wipe the dipstick clean and check the fluid level.

1 A safe operating level is any level within the HOT
RUN (upper) band on the dipstick. See Fig. 2.
S
E
L
M
O
N
4. If the fluid is not within this range, add or drain
I
E
C
T
T
O
R
fluid as needed to bring the level to the top of
the HOT RUN band. See Table 1 for approved
transmission lubricants. See Table 2 for lubricant
R MODE capacities.

N 26–03 Allison Transmission

D
Fluid and Filter
Changing (internal/
external filter)
03/04/2008 f270159 IMPORTANT: For oil and filter change intervals,
1. Shift Selector Display Screen
see the applicable Allison Operator’s Manual. To
request a replacement Allison Operator’s
Fig. 3, Transmission Shift Selector Manual, call 1-888-666-5799.
NOTE: The fluid must be warm to ensure an Oil and filter change intervals can also be found
accurate check. The fluid level rises as tempera- at www.allisontransmission.com. Choose
ture increases. "Service", and click "Service Tips". Then, select
2. Park the vehicle. Shift to Neutral (N) and apply the appropriate transmission to view fluid and
the parking brake. Let the engine run at idle. filter change recommendations.

Approved Allison Transmission Lubricants*

TES-295 Approval
Company Product Brand Name
Number
AN-051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic ATF
AN-011001 Castrol Heavy Duty Lubricants TranSynd
AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Company Fleetrite Synthetic ATF
AN-071006 John Deere & Company HD SynTran
* To check the latest Allison approved fluids, go to www.allisontransmission.com. Lubricants listed in order of preference. Do not mix types of oil.

Table 1, Approved Allison Transmission Lubricants

Automatic Transmission Lubricant Capacities

Refill Capacity*:
Model
qt (L)
1000, 2000, and 2000 MH 16.0 (15.1)

26/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Transmission 26

Automatic Transmission Lubricant Capacities

Refill Capacity*:
Model
qt (L)
3000 MH† and 4000 MH 17.5 (16.5)
* Quantities listed are approximate. Add the recommended amount of fluid
as listed under refill capacity. Do not overfill.
† Some Allison 3000 MH transmissions have a deeper oil sump than other
models. These models require 3 additional quarts (2.8 L) of ATF.
Table 2, Automatic Transmission Lubricant
Capacities

Recreational Vehicle Chassis Maintenance Manual, January 2010 26/3

Throttle Control 30
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Throttle Pedal Pivot Pin Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–01

Recreational Vehicle Chassis Maintenance Manual, January 2010

Throttle Control 30

30–01 Throttle Pedal Pivot Pin

Lubricating
Using a silicone spray, lubricate the throttle pedal
pivot pins as shown in Fig. 1 and Fig. 2.

3
1
07/09/2009 f300408a
2
1. Throttle Pedal 2. Pivot Pins
Assembly 3. Base Plate
Fig. 1, Floor-Mounted Throttle Pedal 07/09/2009 f300409a

1. Throttle Pedal Assembly

2. Pivot Pin (not shown)
Fig. 2, Suspended Throttle Pedal

Recreational Vehicle Chassis Maintenance Manual, January 2010 30/1

Suspension 32
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Neway Suspension Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03
Suspension Fastener Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01
Suspension Height Control Valve Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02
Suspension Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–05
Suspension U-Bolt Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–06
ZF IFS Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–04

Recreational Vehicle Chassis Maintenance Manual, April 2010

Suspension 32

32–01 Suspension Fastener 32–02 Suspension Height

Torque Checking Control Valve Checking
WARNING WARNING
Inspect the suspension fasteners. Failure to per- Inspect the height control components and check
form inspections could result in separation of their operation. Failure to perform these inspec-
worn suspension components and loss of vehicle tions and checks could result in separation of
control, possibly causing personal injury or death, worn suspension components and loss of vehicle
or property damage. control, possibly causing personal injury or death,
or property damage.
1. Chock the front or the rear tires. Working at the
front of the vehicle or at the rear of the vehicle, 1. Park the vehicle on a level surface. Apply the
raise the vehicle so that the tires just clear the parking brake and chock the tires to prevent the
ground and the suspension is fully extended. vehicle from moving.
Place safety stands under the vehicle frame.
2. Inspect the front and rear suspensions for any
2. Check the suspension fasteners. See Table 1 for signs of damage, loose components, wear, or
correct fastener torques. cracks. Replace any damaged components to
prevent failure or equipment breakdown.
3. Check the torque of the rear axle U-bolts.
3. Inspect all bolts and nuts at the pivot axle con-
In a diagonal pattern, tighten all 5/8–18 U-bolt
nuts 205 lbf·ft (278 N·m); tighten all 3/4–16 nections to assure that they are properly torqued.
U-bolt nuts 300 lbf·ft (407 N·m); and tighten all Check all other nuts and bolts for proper torque.
See Group 00 of this manual for proper torque
7/8–14 U-bolt nuts 460 lbf·ft (624 N·m).
specifications.

NOTICE 4. Check the air pressure gauge to confirm that

there is in excess of 65 psi (448 kPa) in the air
Failure to retorque the U-bolt nuts could result in system, and inspect the air springs for sufficient
spring breakage and abnormal tire wear. and equal firmness.
4. Remove the safety stands and lower the vehicle
to the ground.

Suspension Torque Specifications (lubricated threads)

Description Size Torque: lbf·ft (N·m)
Shock Absorber Mount Locknut 3/4–16 110 to 150 (149 to 203)
Air Spring Upper Mounting Plate Locknut 3/4–16 31 to 42 (42 to 57)
Air Spring Upper Mounting Plate Capscrew 1/2–13 31 to 42 (42 to 57)
Air Spring Lower Mounting Plate Capscrew 1/2–13 31 to 42 (42 to 57)
Transverse Beam Bushing Locknuts 1-1/4–12 600 to 700 (814 to 949)
Equalizing Beam Center Bushing Locknut 3/4–16 150 to 200 (203 to 271)
1-1/8–12
Equalizing Beam Front Bushing Locknut 600 to 700 (814 to 949)
1-1/4–12
Control Rod Ball Stud Locknut 1-1/8–12 550 to 650 (746 to 881)
Control and Torque Rod Mounting Locknuts 5/8–18 110 to 150 (149 to 203)
Table 1, Suspension Torque Specifications (lubricated threads)

Recreational Vehicle Chassis Maintenance Manual, April 2010 32/1

32 Suspension

NOTE: Height control valves control all front and raise the vehicle so that the tires just clear the
rear suspension air springs. Check for air leaks ground and the suspension is fully extended.
by applying a soapy solution. Then, check for Place safety stands under the vehicle frame.
bubbles at all air connections and fittings. 2. Squeeze all air springs to check for complete
5. Check the ride height of the air suspension by deflation. It may take ten minutes for the pres-
measuring the distance from the center of the sure to bleed down from the air spring. See
lower shock bolt to the bottom of the frame rail. Fig. 2. If any air springs remain partially or fully
See Fig. 1. See Table 2 for height control valve inflated, see Group 32 of the Recreational Ve-
adjustment measurements. If ride height is incor- hicle Chassis Workshop Manual, or take the ve-
rect, adjust the air suspension. hicle to an authorized Freightliner dealer. Inspect
the air springs for cracks, tears, or other dam-
Height Control Valve Adjustment Measurements
age.
Measurement 3. Inspect each air spring for wear at the pedestal
Suspension connection. Inspect for leaks at the upper and
Inches ±1/4 (mm ±6)
lower pedestal connections using a soapy solu-
10 (254) or tion. Replace any worn air springs; for instruc-
AS120 (front)
10-1/2 (267)*
tions, see Group 32 of the Recreational Vehicle
AS140 (front) 11 (279) Chassis Workshop Manual, or take the vehicle to
IFS114 (front) 17-1/2 (445) an authorized Freightliner dealer.
IFS ZF (front) 15-3/4 (400) 4. Inspect the bolts and nuts at the pivot connec-
tions, the transverse beam connections, and the
ADL-RS17/19/21 10-1/4 (260)
axle connections to ensure they are tightened to
AD200-RS17/19 9-3/4 (248) the correct torque specification.
AD200-RS15 9-3/8 (238) 5. Check all of the other suspension components
ADTB280 (rear) 17-1/4 (438) for any sign of damage, looseness, wear, or
cracks. Replace worn or damaged parts. See
Airliner 15k (rear) 8-3/4 (222)
Group 32 of the Recreational Vehicle Chassis
AD123 (rear) 18 (457) Workshop Manual, or take the vehicle to an au-
* Some vehicles have a different shock location. When this is the case, the thorized Freightliner dealer.
vehicle will have a 55 degree wheel cut. Ride height for these vehicles
should be set at 10-1/2 inches (267 mm). 6. Inspect for cracked welds. If cracks are found,
Table 2, Height Control Valve Adjustment contact Neway immediately for further instruc-
Measurements tions.
7. Inspect the torque rod and track bar pivot bush-
ings for excessive wear. Replace worn or dam-
32–03 Neway Suspension aged bushings. See Group 32 of the Recre-
ational Vehicle Chassis Workshop Manual, or
Inspecting take the vehicle to an authorized Freightliner
dealer.
WARNING 8. Move the axle up and down while checking for
signs of looseness due to worn parts at the front
Inspect the components and check their operation pivot connections. Replace any worn parts by
as described below. Failure to perform these in- following the procedures in Group 32 of the Rec-
spections and checks could result in separation of reational Vehicle Chassis Workshop Manual, or
worn suspension components and loss of vehicle take the vehicle to an authorized Freightliner
control, possibly causing personal injury or death, dealer.
or property damage. 9. Check for leaks on the height control valves by
1. Chock the front or the rear tires. Working at the applying a soapy solution, then, watching for
front of the vehicle or at the rear of the vehicle, bubbles at all air connections and fittings.

32/2 Recreational Vehicle Chassis Maintenance Manual, April 2010

Suspension 32

3 2

09/28/98 f320423a
A. Measure here for suspension ride height.
1. Frame Rail 2. Axle Housing 3. Axle Centerline

Fig. 1, Ride Height Inspection (typical Neway suspension shown)

10. Inspect the shock absorbers for oil leaks and

worn rubber bushings. Replace the shock ab-
32–04 ZF IFS Lubricating
sorbers and/or rubber bushings if wear or dam-
IMPORTANT: Do not raise the vehicle by plac-
age is noted. For instructions, see Group 32 of
the Recreational Vehicle Chassis Workshop ing a jack under the control arm(s). The weight
Manual, or take the vehicle to an authorized of the vehicle could damage the control arms
Freightliner dealer. and cause alignment issues.
11. Remove the safety stands and lower the vehicle 1. Chock the rear tires and apply the parking brake.
to the ground. Run the engine until air pressure Raise the front of the vehicle with a jack so the
of at least 100 psi (689 kPa) is maintained tires just clear the ground and the suspension is
throughout the system. fully extended. Place safety stands under the
vehicle frame.
IMPORTANT: Repeat this check at both ends of
the vehicle. WARNING
12. Check that all air springs are inflated. If the air
springs do not inflate, see Group 32 of the Rec- Never work around or under a vehicle that is sup-
reational Vehicle Chassis Workshop Manual for ported only by a jack. Always support the vehicle
possible causes and corrections, or take the ve- with safety stands. Jacks can slip, causing the
hicle to an authorized Freightliner dealer. vehicle to fall, which could result in serious injury
or death.

Recreational Vehicle Chassis Maintenance Manual, April 2010 32/3

32 Suspension

02/21/2005 f321032

Fig. 2, Holland Neway ADL 120/123 Suspension

IMPORTANT: Every 50,000 miles (80 450 km), 32–05 Suspension Inspecting
ZF recommends that the wheel hub be removed
to check the wheel bearing lash, and adjust as
needed. Freightliner Spring Front and
2. Remove the wheel hub. See Group 33 of the Rear Suspension Spring
Recreational Vehicle Chassis Workshop Manual Assemblies Inspection
for wheel bearing service procedures, or take the
vehicle to an authorized Freightliner dealer. Inspect the front and rear suspension spring assem-
blies for pitted, cracked, broken, or abnormally bent
3. Lubricate the steering knuckle/control arm at indi- leaves and extreme rust. If any of these conditions
cated maintenance intervals. Use only an NLGI exist, replace the spring assembly. See Group 32 of
Grade 2 lithium-based grease, multipurpose the Recreational Vehicle Chassis Workshop Manual
grease, or mineral oil on the lubricating points. for instructions, or take the vehicle to an authorized
See Fig. 3 and Fig. 4. Freightliner dealer.

WARNING
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring as-

32/4 Recreational Vehicle Chassis Maintenance Manual, April 2010

Suspension 32

two top leaves, a loss of vehicle control could

occur. Failure to replace a damaged spring assem-
2 bly could cause an accident resulting in property
damage, serious personal injury, or death.
1 IMPORTANT: On multi-leaf suspensions, closely
inspect each component of the leaf spring as-
semblies, including the brackets, U-bolts, and
related parts.

60-Inch Taper-Leaf Spring

Component Check
3 No lubrication is required on the 60-inch taper-leaf
09/30/2004 f321018
spring front and rear suspension.
Inspect the rear shackle brackets for bushing wear or
1. Steering Knuckle Bearing Grease Fitting (upper)
2. Control Arm cracks.
3. Steering Knuckle Bearing Grease Fitting (lower) Inspect the stabilizer bar, if present, for irregular
bushing wear or cracks in the brackets. Check the
Fig. 3, Pressure Grease Fitting Positions, RL-75E
rubber helper spring, if present, for cracks.
2
1 32–06 Suspension U-Bolt
Torque Checking
Check the U-bolt torque of both the front and rear
axles where applicable.

CAUTION
Failure to retorque the U-bolt nuts could result in
4 3
09/30/2004 f321019 spring breakage and abnormal tire wear.
1. Steering Knuckle Bearing Grease Fitting (upper) 1. Park the vehicle on a flat surface, apply the park-
2. Control Arm Grease Fitting (upper) ing brake, and chock the tires.
3. Control Arm Grease Fitting (lower)
4. Steering Knuckle Bearing Grease Fitting (lower) 2. Check the U-bolt torque in a diagonal pattern.
Set a click-type torque wrench to the highest
Fig. 4, Pressure Grease Fitting Positions, RL-75EM torque value for the fastener being checked. See
Table 3 for U-bolt torque specifications. Turn the
sembly. Visible damage (cracks or breaks) to one wrench in a clockwise motion (looking up) until
leaf causes hidden damage to other leaves. Re- the torque wrench clicks.
placement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front 3. Remove the chocks.
spring assemblies, if cracks or breaks exist in the

Recreational Vehicle Chassis Maintenance Manual, April 2010 32/5

32 Suspension

U-Bolt Torque Values

Torque:
Description Size
lbf·ft (N·m)
Stage 1: Hand tighten
Stage 2: 60 (81)
5/8–18
Stage 3: 200 (271)
Stage 4: 180 to 230 (245 to 313)
Spring Assembly U-Bolt High Nuts*
Stage 1: Hand tighten
Stage 2: 60 (81)
3/4–16
Stage 3: 200 (271)
Stage 4: 270 to 330 (367 to 449)
* Tighten in the sequence shown in Fig. 5.

Table 3, U-Bolt Torque Values

4 1

01/05/99
2 3
f320783

Fig. 5, Tightening Sequence for U-Bolt High Nuts

32/6 Recreational Vehicle Chassis Maintenance Manual, April 2010

Front Axle 33
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

All-Axle Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03
Knuckle Pin Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01
Oil-Filled Hubs Oil Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–06
Oil-Filled Hubs Oil Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–05
Tie-Rod End Lubricating and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02
Wheel Bearing Removal, Cleaning, Checking, Repacking, and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 33–04

Recreational Vehicle Chassis Maintenance Manual, January 2010

Front Axle 33

33–01 Knuckle Pin Lubricating When lubricating Meritor axle knuckle pin bushings
or Alliance Brand Product (ABP) axle needle bear-
Hold a high-pressure grease gun on each fitting until ings at the initial maintenance (IM) interval, first wipe
fresh grease appears. See Fig. 1 or Fig. 2. This will the lube fittings clean. Then, slowly feed (for Meritor
ensure that all of the old contaminated grease has axles) multipurpose chassis grease (NLGI grade 1 or
been forced out. 2) into each bushing area, or (for ABP axles), lithium
12-hydroxy stearate (with molybdenum disulfide) WL
grade 2 grease into each needle bearing area, while
1 turning the wheels from extreme right to left, and
back again (lock-to-lock). This will eliminate small air
pockets and improve grease distribution.
NOTE: The grease seal will accept the grease
pressure without damaging the seal, and is de-
signed to have grease pumped out through it
A during lubrication. Even if grease leaks out
around the top or bottom plate, continue pump-
ing until new grease is seen at the seal on the
bushing or needle bearing opposite the grease
fitting.
When lubricating knuckle pin bushings or needle
bearings after the IM maintenance interval, first wipe
1 the lube fittings clean. Then, (for Meritor axles) apply
09/06/96 f320032a
multipurpose chassis grease, or (for ABP axles),
Pump lubricant into each grease fitting until fresh grease lithium 12-hydroxy stearate (with molybdenum disul-
comes out at A. fide) WL grade 2 grease, until new grease is seen at
1. Grease Fitting the grease seal on the bushing or needle bearing
opposite the fittings.
Fig. 1, Meritor Axle Grease Fittings

1 33–02 Tie-Rod End Lubricating

and Inspecting
2
IMPORTANT: DOT roadside tie-rod assembly
replacement criteria specifies that if tie-rod end-
play is 1/8 inch (3 mm) or greater, measured on
the road, the vehicle must be taken out of ser-
vice immediately. If less than 1/8 inch (3 mm),
the vehicle does not have to be taken out of
service but a major out-of-service inspection
and maintenance must be scheduled as soon
as possible.
1. Wipe the tie-rod end grease fittings clean, then
06/13/2003 1 f330213
(for Meritor axles) pump multipurpose chassis
grease (NLGI grade 1 or 2), or (for Freightliner
1. Grease Fitting axles), lithium 12-hydroxy stearate (with molyb-
2. Steering Knuckle
denum disulfide) WL grade 2 grease, to the tie-
Fig. 2, ABP Axle Grease Fittings rod ends until all used grease is forced out and
new grease appears at the ball stud neck.

Recreational Vehicle Chassis Maintenance Manual, January 2010 33/1

33 Front Axle

NOTE: Inspect the tie-rod end boots for cracks, nut torque specifications.
wear, or damage. If a boot is cracked, worn, or
damaged, replace the tie-rod assembly. Freightliner Axle Tie-Rod End Nut

2. Inspect the tie-rod ends, as follows. Thread Torque: lbf·ft (N·m)

2.1 Shake the cross-tube. Movement or 5/8–16 60 to 115 (81 to 156)

looseness between the tapered shaft of 5/8–18 60 to 115 (81 to 156)
the ball and the cross-tube socket mem- 3/4–16 90 to 170 (122 to 230)
bers means that the tie-rod end assembly
must be replaced. 7/8–14 160 to 300 (217 to 407)

2.2 The threaded portion of the tie-rod end Table 1, Freightliner Axle Tie-Rod End Nut
assembly must be inserted all the way
into the cross-tube split for adequate Freightliner Axle Tie-Rod End Clamp Nut
clamping. See Fig. 3. Replace the parts if
this cannot be done. For instructions, see Thread Torque: lbf·ft (N·m)
the axle manufacturer’s service manual. 1/2–13 35 to 45 (47 to 61)
5/8–11 40 to 60 (54 to 81)
5/8–18 50 to 64 (73 to 87)
OK 3/4–10 155 to 175 (210 to 237)
Table 2, Freightliner Axle Tie-Rod End Clamp Nut

33–03 All-Axle Alignment

Checking
1
NOTE: The final stage manufacturer is respon-
sible for setting the vehicle ride height with air
OK suspension and some vehicle alignments. On
full-railed chassis, this includes the final toe-in
setting on the front axle. For modular style
chassis, both the front axle toe-in and rear axle
thrust angle settings are included.

Drive Axle Alignment Checking

02/27/2007 f320033a
NOTE: The maximum tolerance from perpen-
IMPORTANT: The tie-rod end threads must be visible
throughout the entire length of the split.
dicular for rear axle alignment should be ±0.25
degree.
NOTE: Pinch bolt not shown to provide clarity.
Check the axle alignment, parallelism, and thrust
1. Cross-Tube Split
angle measurements for the rear axle. Use the appli-
Fig. 3, Tie-Rod End Adjustment cable procedure and specifications in Group 35 of
the Recreational Vehicle Chassis Workshop Manual,
2.3 Check the tie-rod end nut and clamp nut or take the vehicle to an authorized Freightliner
torques. For Meritor axles, tighten the tie- dealer.
rod end nut 100 lbf·ft (136 N·m), and
tighten the clamp nut 40 to 55 lbf·ft (54 to
75 N·m). For Freightliner axles, see
Toe-In Inspection
Table 1 for tie-rod end nut torque specifi- For vehicle alignment to be accurate, the shop floor
cations and Table 2 for tie-rod end clamp must be level in every direction. The turn plates for

33/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Front Axle 33

the front wheels must rotate freely without friction,

and the alignment equipment must be calibrated A
every three months by a qualified technician from the
equipment manufacturer. Freightliner dealers must
have proof of this calibration history.
NOTE: Toe-in should be within 0 to 1/32 inch
(0.8 mm).
1. Apply the parking brake, and chock the rear
tires.
2. Raise the front of the vehicle until the tires clear
the ground. Check that the safety stands will
support the combined weight of the body, axle,
and frame. Place safety stands under the axle. B
08/29/94 f330082a
3. Using spray paint or a piece of chalk, mark the
NOTE: B minus A equals toe-in.
entire center rib of each front tire.
Fig. 4, Wheel Toe-In (overhead view)
4. Place a scribe or pointed instrument against the
marked center rib of each tire, and turn the tires.
Hold the scribe firmly in place so that a single
straight line is scribed all the way around each
front tire.
5. Place a turn-plate or turntable under both front
tires. Remove the safety stands from underneath
the axle, then lower the vehicle. Remove the
lockpins from the gauges; make sure that the
tires are pointing straight ahead.
NOTE: If turn-plates or turntables are not avail-
able, lower the vehicle. Remove the chocks 08/30/94 f330014a
from the rear tires and release the parking
brake. Move the vehicle backward and then for- Fig. 5, Trammel Bar Positioning
ward about six feet (two meters).
33–04 Wheel Bearing Removal,
6. Place a trammel bar at the rear of the front tires;
locate the trammel pointers at spindle height, Cleaning, Checking,
and adjust the pointers to line up with the scribe
lines on the center ribs of the front tires. See
Repacking, and
Fig. 4. Lock the pointers in place. Check that the Adjusting
scale is set to zero.
7. Place the trammel bar at the front of the tires Freightliner/Meritor
and adjust the scale end so that the pointers line
Check for correct end play. Correct end play is be-
up with the scribe lines. See Fig. 5 and Fig. 6.
tween 1 to 0.005 inch (25.4 to 0.12 mm).
8. Read the toe-in from the scale, and compare it to
the toe-in specification in Group 33 of the Recre- ZF IFS
ational Vehicle Chassis Workshop Manual, or
take the vehicle to an authorized Freightliner ZF recommends that all grease fittings be lubricated
dealer. If corrections are needed, see Group 33 once a year, preferably before periods of inactivity.
of the Recreational Vehicle Chassis Workshop The wheel hub should be disassembled, inspected,
Manual, or take the vehicle to an authorized and the wheel bearings repacked every 300,000
Freightliner dealer. miles (482 700 km).

Recreational Vehicle Chassis Maintenance Manual, January 2010 33/3

33 Front Axle

4. Rotate the wheels, allow the oil to settle, and

check the levels again.
5. Install the filler caps securely.
6. Remove the chocks from the tires.

33–06 Oil-Filled Hubs Oil

Changing
WARNING
Be careful not to overfill the hubs. Overfilling may
cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo-
nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
1. With the vehicle on a level surface, rotate the
front wheels so that the front hub drain plugs are
positioned downward.
2. Chock the tires.
08/30/94 f400100a 3. Place suitable containers under the hubs, re-
move the filler plugs (in the ends of the hub
Fig. 6, Setting Trammel Bar Pointers
caps) and the drain plugs, and allow the hubs to
drain completely. See Fig. 7.
33–05 Oil-Filled Hubs Oil Level
Checking
2

WARNING
Be careful not to overfill the hubs. Overfilling may
cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo-
nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
1
1. With the vehicle on a level surface, rotate the
front wheels and allow the oil in the hubs to
settle. A
2. Chock the tires.
IMPORTANT: The oil level should be at, or no 07/09/2009 f330247b
more than 1/4 inch (6 mm) above the level indi-
cators on the hub caps. A. Hub Cavity Full
1. Fill Plug/Magnetic Drain
3. If necessary, remove the filler caps (in the ends 2. Drain Plug
of the hub caps) and add enough oil (80W–90
hypoid gear oil) to bring the oil to the proper Fig. 7, Oil-Filled Hub Cap
level.
4. Install the drain plugs and tighten securely.

33/4 Recreational Vehicle Chassis Maintenance Manual, January 2010

Front Axle 33

5. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L)

of oil (80W–90 hypoid gear oil) to each hub.
6. Rotate the wheels, allow the oil to settle, and
check the levels.
IMPORTANT: Fill the hubs to the level indicators
on the hub caps, or to no more than 1/4 inch (6
mm) above the indicators. See Fig. 7.
7. Install the filler plugs securely.

Recreational Vehicle Chassis Maintenance Manual, January 2010 33/5

Rear Axle 35
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Axle Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–03
Axle Lubricant Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02
Axle Lubricant Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01
Oil-Filled Hubs Oil Changing, Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–05
Oil-Filled Hubs Oil Level Checking, Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–04

Recreational Vehicle Chassis Maintenance Manual, September 2010

Rear Axle 35

35–01 Axle Lubricant Checking 3. Fill the differential with 80/90 hypoid gear oil
through the rear axle fill hole. See Table 1 for
axle lubricant capacities.
NOTE: If the vehicle is exposed to water deep
Freightliner Drive Axle Lubricant Capacity
enough to cover the hubs, disassemble and in-
spect them for water damage and/or contamina- Differential/Hubs Capacity: qt (L)
tion. See Group 35 of the Recreational Vehicle Differential Only 5.8 (5.5)
Chassis Workshop Manual for instructions, or Differential and Hubs 7.4 (7.0)
take the vehicle to an authorized Freightliner
Table 1, Freightliner Drive Axle Lubricant Capacity
dealer.
1. Clean the area around the filler plug, and remove
the plug. NOTE: A normal oil change does not include the
hubs. Drain the differential and add 5.8 qt (5.5
2. Make sure that the lubricant is level with the bot- L) of 80/90 hypoid gear oil through the rear axle
tom of the filler plug hole. See Fig. 1. fill hole. The lubricant level should be at the bot-
tom of the fill hole.
A IMPORTANT: The entire axle capacity (axle
completely dry) is 7.4 qt (7 L). Each hub con-
tains 0.80 qt (0.75 L) of lubricant. To protect the
outer bearings from oil starvation, jack up (ar-
ticulate) each side of the axle a minimum of 4
inches (10 cm) to ensure that oil flows to the
B outer bearings. Articulate the short-side arm for
45 seconds and the long-side arm for 90 sec-
onds. After articulating the axle, add 0.80 qt
08/17/2009 f350061a
(0.75 L) of lubricant through the fill hole (in addi-
A. Correct (lube level at bottom of fill hole)
B. Incorrect (lube level below fill hole)
tion to the 5.8 qt [5.5 L] of a normal oil change)
for each hub that has been removed. Check the
Fig. 1, Axle Lubricant Checking oil level again and ensure that the axle is nei-
ther under- nor over-filled.
3. Add S.A.E. 80W–90 multipurpose gear lubricant,
or an S.A.E. 75W–90 multipurpose synthetic 4. Install the fill plug and tighten it securely.
gear lubricant. Either type of lubricant must meet
Military Specification L–2105–D and be suitable Meritor Axle
for American Petroleum Institute service classifi-
cation GL–5. Install and tighten the filler plug. 1. Remove the filler plug, then the drain plug, and
allow the differential to drain completely.
4. Inspect the axle for signs of leakage. If leakage
is indicated and the lubricant level is down, have 2. Install the drain plug. Tighten it 24 lbf·ft (34 N·m).
your dealer perform any necessary maintenance. 3. Fill the differential with an SAE 80W–90 multipur-
pose gear lubricant, or an SAE 75W–90 multipur-
pose synthetic gear lubricant. See Table 2 for
35–02 Axle Lubricant Changing axle lubricant capacities. Either type of lubricant
must meet Military Specification L–2105–D and
Freightliner Axle be suitable for American Petroleum Institute ser-
vice classification GL–5. The lubricant level
1. Remove the filler plug, then the drain plug (in the within the differential must be even with the bot-
center bottom of the axle housing), and allow the tom of the fill hole.
differential to drain completely.
2. Install the drain plug and tighten it securely.

Recreational Vehicle Chassis Maintenance Manual, September 2010 35/1

35 Rear Axle

4. Install the fill plug. Tighten it 24 lbf·ft (34 N·m).

Meritor Drive Axle Lubricant Capacity

Axle Model Capacity: pt (L)*
RS-15-120 16 (7.6)
RS-17-145 33.6 (15.9)
RS-19-145 34.4 (16.3)
RS-21-145 32 (15.1) 1
2
RS-23-160 42 (19.9)
RS-23-165 42 (19.9)
* Quantities listed are approximate and include 1 pint (0.5 L) for each wheel
end and with the drive pinion at 3 degrees.
Table 2, Meritor Drive Axle Lubricant Capacity 03/28/2007 f350484

1. Axle Housing Breather 2. Breather Tube

35–03 Axle Breather Checking Fig. 3, Freightliner Axle Housing
NOTE: On Freightliner axles, the axle housing
breather is located on the carrier assembly. 35–04 Oil-Filled Hubs Oil Level
The axle housing breather must remain unob- Checking, Tag Axle
structed. Whenever the axle lubricant is checked or
changed, also make sure that the breather is open. WARNING
Check more often under poor operating conditions. If
the breather is plugged, clean or replace it as Be careful not to overfill the hubs. Overfilling may
needed. See Fig. 2 and Fig. 3. cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo-
nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
1 1. With the vehicle on a level surface, remove the
hub cap (also referred to as a beauty ring). See
Fig. 4.
2. Rotate the rear wheels and allow the oil in the
hubs to settle.
3. Chock the tires.
IMPORTANT: The oil level should be at, or no
2
more than 1/4 inch (6 mm) above the level indi-
3
cators on the hub caps.
4. If necessary, remove the filler caps (in the ends
of the hub caps) and add enough oil (80W–90
06/07/94 f350002a
hypoid gear oil) to bring the oil to the proper
1. Axle Housing Breather level.
2. Fill Plug
3. Temperature Indicator Plug 5. Rotate the wheels, allow the oil to settle, and
check the levels again.
Fig. 2, Meritor Axle Housing (typical)
6. Install the filler caps securely.

35/2 Recreational Vehicle Chassis Maintenance Manual, September 2010

Rear Axle 35

2
2
1

A
07/28/2010 f400295

1. Cap Head 07/09/2009 f330247b

2. Hub Cap (Beauty Ring)
A. Hub Cavity Full
Fig. 4, Rear Axle Hub Cap Assembly 1. Fill Plug/Magnetic Drain
2. Drain Plug
NOTICE Fig. 5, Oil-Filled Hub Cap

Do not overtighten the cap head. Too much force 5. Install the drain plugs and tighten securely.
will strip the screw. 6. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L)
7. Install the hub cap and tighten the cap head just of oil (80W–90 hypoid gear oil) to each hub.
until snug.
IMPORTANT: Fill the hubs to the level indicators
on the hub caps, or to no more than 1/4 inch (6
35–05 Oil-Filled Hubs Oil mm) above the indicators. See Fig. 5.
Changing, Tag Axle 7. Rotate the wheels, allow the oil to settle, and
check the levels.
8. Install the filler plugs securely.
WARNING
Be careful not to overfill the hubs. Overfilling may NOTICE
cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo- Do not overtighten the cap head. Too much force
nents. This could result in loss of vehicle control will strip the screw.
and lead to personal injury and property damage. 9. Install the hub cap and tighten the cap head just
1. With the vehicle on a level surface, remove the until snug.
hub cap (also referred to as a beauty ring).
2. Rotate the rear wheels so that the rear hub drain
plugs are positioned downward.
3. Chock the tires.
4. Place suitable containers under the hubs, re-
move the filler plugs (in the ends of the hub
caps) and the drain plugs, and allow the hubs to
drain completely. See Fig. 5.

Recreational Vehicle Chassis Maintenance Manual, September 2010 35/3

Wheels and Tires 40
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Wheel Cleaning and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02
Wheel Nut Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01

Recreational Vehicle Chassis Maintenance Manual, September 2007

Wheels and Tires 40

40–01 Wheel Nut Checking A B

IMPORTANT: In addition to the maintenance 2 1

interval in this manual, check the wheel nut
4 5 3 6
torque the first 50 to 100 miles (80 to 160 km)
of operation after a wheel has been removed
and installed. 6 3 5 4
1 2
NOTE: On each wheel stud, the end that faces
away from the vehicle is stamped with an "L" or 08/20/96 f400119
an "R," depending on which side of the vehicle A. Front and Inner Rear Dual
the stud is installed. Studs stamped with an "L" B. Outer Rear Dual
are left-hand threaded and are installed on the
driver’s side of the vehicle. Studs stamped with Fig. 1, Wheel Nut Tightening Sequence (6-stud hubs)
an "R" are right-hand threaded and are installed
on the passenger’s side of the vehicle. A B
When checking wheel nuts on a dual disc assembly, 2 1
remove one outer nut at a time, tighten the inner nut, 4 5 3 6
then reinstall the outer nut. Repeat this procedure for
all of the inner wheel nuts in the sequence shown in
Fig. 1, Fig. 2, or Fig. 3. Then, tighten all of the outer 8 7 7 8
wheel nuts in the same sequence.

CAUTION 6 3 5 4
1 2
Too little wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud break- 06/23/2000 f400159
age, and extreme tire tread wear. Too much wheel A. Front and Inner Rear Dual
nut torque can break studs, damage threads, and B. Outer Rear Dual
crack discs in the stud hole area.
Fig. 2, Wheel Nut Tightening Sequence (8-stud hubs)
Tighten the wheel nuts.
• On 6-stud, stud-pilot hubs, tighten the wheel A B
nuts 450 to 500 lbf·ft (610 to 678 N·m). See
Fig. 1 for the tightening sequence. 2 1
9 7 10 8
• On 8-stud or 10-stud, hub-pilot hubs with
20-mm studs, tighten the wheel nuts 280 to 310 4 5 3 6
lbf·ft (380 to 420 N·m). See Fig. 2 or Fig. 3 for
the tightening sequence.
6 3 5 4
• On 8-stud or 10-stud, hub-pilot hubs with
22-mm studs, tighten the wheel nuts 450 to 500 8 10 7 9
lbf·ft (610 to 678 N·m). See Fig. 2 or Fig. 3 for 1 2
the tightening sequence.
NOTE: Wheel nuts for 20-mm stud hubs require 09/28/98 f400142
a 1- 3/16-inch (30-mm) socket. Wheel nuts for A. Front and Inner Rear Dual
22-mm stud hubs require a 1-5/16-inch (33-mm) B. Outer Rear Dual
socket.
Fig. 3, Wheel Nut Tightening Sequence (10-stud hubs)

Recreational Vehicle Chassis Maintenance Manual, September 2007 40/1

40 Wheels and Tires

40–02 Wheel Cleaning and

Polishing
Accuride® Machined and
Polished Aluminum Wheels
IMPORTANT: Do not scrub the wheels before
rinsing off particles with high-pressure water.
Synthetic cleaning pads and wire brushes
should not be used to clean the wheels.
Do not use strong detergents, alkaline, or acidic
cleaners to clean Accuride aluminum wheels.
These solutions can etch the surface of the alu-
minum and leave dull areas. Abrasive polishes,
or polishes not recommended for aluminum,
should not be used on aluminum wheels.
1. Rinse the wheel with high-pressure water to re-
move debris.
2. Use a 100% cotton cloth dipped in a mild soap
solution to help remove built up dirt and grease.
Dish soap or automotive car wash soap are rec-
ommended.
3. Rinse the remaining soap residue from the
wheel.
4. Dry the wheel thoroughly with a 100% cotton
cloth.
5. Use a metal cleaner/polish that is compatible
with aluminum to remove spots and stains from
the surfaces of the wheel as necessary.
6. Apply carnauba wax to the visible wheel sur-
faces. Carnauba wax should be reapplied on a
regular basis to maintain the wheel luster.
NOTE: Failure to apply a protective
polish/wax/sealant will leave the polished sur-
face susceptible to water spotting and/or pitting
from environmental contaminants.

40/2 Recreational Vehicle Chassis Maintenance Manual, September 2007

Driveline 41
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Driveline Inspecting and Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01

Recreational Vehicle Chassis Maintenance Manual, January 2010

Driveline 41

41–01 Driveline Inspecting and 5

Lubricating
Inspecting
Before lubricating the driveline U-joints and slip- 1
joints, make the following checks. 3
4
1. Check that the yoke-strap capscrews are tight- 7
2 3
ened 50 to 60 lbf·ft (68 to 81 N·m).

NOTICE 6
Do not overtighten the yoke-strap capscrews, due
to the extreme load occurring at high-speed rota-
tion. A loose or broken capscrew at any point in 8
the driveline weakens the driveline connection, 3 1
which could eventually result in serious vehicle
damage. A
2. Check the slip-joints for spline wear by trying to
bend the sleeve-yoke and splined shaft back and
10/20/93 f410050a
forth. If looseness is greater than 0.007 inch
(0.18 mm), replace both the sleeve-yoke and the A. After grease appears, cover the pressure-relief hole
splined shaft. while continuing to lubricate.
3. Check the driveshaft for missing balance 1. Slip-Joint Grease 5. Yoke Plug Pressure-
weights, and for debris buildup. Remove any Fitting (with grease Relief-Hole
gun attached) 6. Slip-Joint Seal
buildup. If any balance weights are missing, re- 2. Yoke Plug 7. Full-Round Yoke
move the driveshaft and have it balanced. For 3. Grease 8. U-Joint Grease Fitting
instructions, see Group 41 of the Recreational 4. Half-Round Yoke
Vehicle Chassis Workshop Manual, or take the
vehicle to an authorized Freightliner dealer. Fig. 1, Slip-Joint and U-Joint Lubricating
4. Check that the yoke plug is not loose or missing. 3. Using lithium 12-hydroxy stearate grease (NLGI
Replace the yoke plug if needed. If the yoke plug grade 1 or 2, with EP additives), lubricate until
is missing, the splined shaft may be hitting the new grease can be seen at all four U-joint seals.
yoke plug and knocking it out; check the drive-
shaft for proper length.
NOTICE
U-Joint Lubricating Fresh lubricant must be seen escaping from all
1. Wipe all old grease and dirt from each U-joint
four of the bearing cup seals of each U-joint. If
grease fitting. not, the U-joint may fail prematurely.
4. If the bearing will not take grease, replace the
2. Use a hand-type grease gun, or a high-pressure
U-joint assembly. For instructions, see Group 41
gun with a low-pressure adaptor, to lubricate the
of the Recreational Vehicle Chassis Workshop
U-joints. See Fig. 1.
Manual, or take the vehicle to an authorized
NOTE: If a low-pressure adaptor is not used Freightliner dealer.
with the high-pressure gun, the U-joints may not 5. Check the old grease. If it appears rusty, gritty, or
receive enough lubricant. burned, replace the U-joint assembly. For instruc-
tions, see Group 41 of the Recreational Vehicle

Recreational Vehicle Chassis Maintenance Manual, January 2010 41/1

41 Driveline

Chassis Workshop Manual, or take the vehicle to

an authorized Freightliner dealer.
6. Wipe any excess grease from the seals and
grease fittings.

Slip-Joint Spline Lubricating

1. Wipe all old grease and dirt from the slip-joint
grease fitting.
2. Use a hand-type grease gun or a high-pressure
gun with a low-pressure adaptor, to lubricate the
slip-joint. Using lithium 12-hydroxy stearate
grease (NLGI grade 1 or 2, with EP additives),
lubricate until fresh grease appears at the
pressure-relief hole in the yoke plug. Then cover
the relief hole with your finger, as shown in
Fig. 1, while continuing to lubricate until fresh
grease appears at the slip-joint seal. This en-
sures complete lubrication of the splines.
3. Wipe any excess grease from the pressure-relief
hole, slip-joint seal, and grease fitting.

41/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Brakes 42
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Dryer Desiccant and Coalescent Filter Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03
Air Dryer Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02
Bendix Hydro-Max® Brake System Inspecting (front-engine diesel chassis). . . . . . . . . . . . . . . . . . . . . . . . 42–07
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) . . . . . . . . . . . . . . . . . . . . 42–08
Brake Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–11
Brake Lines Checking, Hydraulic Disc or Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine diesel
chassis)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–10
Brake System Valves Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01
Camshaft Bracket Bushing Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04
Foot Brake Valve Actuator Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06
Meritor Roller Pin Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–12
Slack Adjuster Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05

Recreational Vehicle Chassis Maintenance Manual, September 2010

Brakes 42

42–01 Brake System Valves 42–03 Air Dryer Desiccant and

Inspecting Coalescent Filter
1. Clean the valves exterior and inspect them for Replacing
corrosion and damage.
NOTE: Desiccant change intervals may vary
2. Inspect the air lines connected to the valves for from vehicle to vehicle. Typical desiccant car-
signs of wear or damage. Replace the lines as tridge life is three years. However, if experience
needed. has shown that extended or shortened life has
3. Check the valves for leakage. resulted on a particular installation, then the in-
3.1 Apply the service brakes and hold them terval can be increased or decreased accord-
on a full line pressure of at least 80 psi ingly.
(552 kPa).
3.2 Check the air line fittings for leaks; tighten
Bendix AD-9
or replace the fittings as needed. Replacement
3.3 Coat the exhaust port and body of the 1. Park the vehicle on a level surface. Apply the
valves with soapy water, and check for parking brakes and chock the tires.
leakage. Leakage is excessive if it pro-
duces a 1-inch (25-mm) bubble within 5 2. Completely drain all air reservoirs. Air pressure
seconds. gauges should read 0 psi (0 kPa).
If a brake valve does not function as de- 3. Loosen the desiccant cartridge with a strap
scribed above, or if leakage is excessive, wrench at the base of the cartridge. Spin off the
replace it with a new or remanufactured cartridge and discard it.
unit. Repeat the leakage checks before 4. Remove the O-ring from the threaded neck and
placing the vehicle in service. discard it.
5. Remove the coalescent filter and discard it.
42–02 Air Dryer Inspecting IMPORTANT: Lubricate the new O-rings prior to
1. Check the reservoirs for moisture by pulling the installation.
lanyards. A small amount (a teaspoon or less) is 6. Install the new small O-ring in the groove on the
normal. Larger amounts may mean that the des- bottom of the new coalescent filter.
iccant needs to be replaced. Check the mounting
and connecting lines. 7. Insert the coalescent filter with the O-ring end
going into the air dryer opening first. The end of
2. Tighten the fasteners that attach the air dryer to the filter with the "X" will then be facing out.
the vehicle. Use the following torque values.
8. Install the other new O-ring over the threaded
28 lbf·ft (38 N·m) for SAE grade 5, 3/8–16 fas- neck of the desiccant cartridge.
teners.
9. Screw on the desiccant cartridge until resistance
135 lbf·ft (183 N·m) for SAE grade 5, 5/8–11 fas- is detected. Then, tighten the cartridge 1/4 to 3/4
teners. of a turn by hand.
Check all air lines, fittings, and electrical connec-
tions for damage, leakage, or looseness. Operational Check
3. Replace damaged or leaking parts, and tighten 1. Start the engine and build air pressure to 120 psi
loose fittings or electrical connections. (827 kPa).
2. Listen for the purge valve to open and release
air. A large volume of air will be expelled, fol-

Recreational Vehicle Chassis Maintenance Manual, September 2010 42/1

42 Brakes

lowed by a slow flow of air lasting approximately

30 seconds.
42–04 Camshaft Bracket
3. Shut down the engine and remove the chocks
Bushing Lubricating
from the tires.
Pump grease into the camshaft bracket bushing until
4. Perform the inspections in Maintenance Opera- it appears at the slack adjuster end of the bracket.
tion 42–02. See Fig. 1.

Haldex PURest1
Replacement
1
1. Remove the four mounting bolts and discard. Lift
the canister about 1/2 inch and remove.
2. Place the assembly upside-down. Press the car-
tridge down to compress the rubber spring then 3
rotate counterclockwise 45 degrees to release
the cartridge. The cartridge itself contains no
hazardous material, but there may be a small 2
amount of oil from the the compressor.
3. Clean the inside of the canister and aluminum
housing. 05/28/93
A f420011a
4. Remove the cartridge O-ring and discard. A. Grease Exit
5. Remove the new cartridge from the kit and make 1. Brake Chamber
certain the rubber spring is attached. 2. Slack Adjuster
3. Non-Pressure-Relief Grease Fitting
6. Install the new cartridge into the canister. Align
the slots on the cartridge with the dimplets inside Fig. 1, Camshaft Bracket Bushing Lubrication
the canister. Press the cartridge into the canister
Use an NLGI Grade 1 or Grade 2 multipurpose chas-
and rotate clockwise 45 degrees to engage the
sis grease. If grease leaks out from under the cam
cartridge.
head, the camshaft bracket grease seal is worn or
7. Place a new O-ring on the aluminum housing. damaged. For grease seal replacement instructions,
8. Place the cartridge assembly on the air dryer see Group 42 of the Recreational Vehicle Chassis
housing and install four new mounting bolts. Use Workshop Manual, or take the vehicle to an autho-
an alternating diagonal pattern and tighten the rized Freightliner dealer.
bolts 35 to 40 lbf·ft (47 to 54 N·m). Camshaft brackets without grease fittings are fitted
with special seals and packed with extended-
Operational Check lubrication-interval chassis grease. Grease them only
1. Start the engine and build air pressure to 100 psi when the camshaft is disassembled for servicing.
(690 kPa) and shut-off the engine.
2. Check for air leaks at the inlet, outlet, and canis- 42–05 Slack Adjuster
ter assembly. Correct any leakage problem. Lubricating
3. Restart the engine and build-up pressure to cut-
out pressure. At cut-out pressure, the air dryer IMPORTANT: Perform Maintenance Operation
purge valve opens and immediately expels a 42–11 before lubricating the slack adjusters.
large volume of air, followed by a slow flow of air
lasting approximately 30 seconds. Automatic slack adjusters must be lubricated periodi-
cally to ensure proper brake operation.
1Information in this section is provided by Haldex and is used with permis-
sion.

42/2 Recreational Vehicle Chassis Maintenance Manual, September 2010

Brakes 42

WARNING Bendix
Using a quality multipurpose chassis lubricant, NLGI
Failure to lubricate slack adjusters could lead to Grade 2, lubricate the automatic slack adjuster
dragging brakes or a brake failure, resulting in through the lube fitting. See Fig. 3. Lubricate the
property damage, personal injury, or death. slack adjuster until clean lubricant flows from the
grease relief opening in the boot.
Haldex
1
NOTICE
Do not use moly-disulfide-loaded grease or oil.
Both the life and reliability of the slack adjuster 3
will be reduced if this type of grease is used. 2
2 3
Lubricate a Haldex automatic slack adjuster at the
grease fitting with any extreme-pressure NLGI Grade 4
1 or Grade 2 grease if the operating temperature is
–20°F (–29°C) and above. If the operating tempera- 5
ture is below –20°F (–29°C), use a low-temperature
extreme-pressure grease.

Meritor
Lubricate the slack adjuster at the grease fitting until 6
grease is forced past the pressure-relief capscrew or 7
past the gear splines around the inboard snap ring. 7
Use high-temperature, NLGI Grade 1 waterproof 06/17/2010 f430511
grease. See Fig. 2. 1. Yoke 5. Boot
2. Yoke Pin 6. Lube Fitting
3. Link Pin 7. Worm Gear
1 4. Link

2 Fig. 3, Bendix Automatic Slack Adjuster

42–06 Foot Brake Valve

3
Actuator Lubricating
4
1. Clean any dirt, gravel, and other foreign material
from the base of the brake pedal, the plunger
boot, and the brake base bracket.
5 2. Use light oil to lubricate the brake pedal roller
and pivot pin.
7
3. Check the brake plunger boot for cracks, holes,
6 f420012a or deterioration. Replace it if necessary.
10/20/93
1. Brake Chamber 5. Pull-Pawl Seal 4. Lift the edge of the brake plunger boot and
2. Clevis 6. Manual Adjusting Nut check the plunger for existing lubrication.
3. Actuator Rod 7. Grease Fitting (or
4. Boot Lube Plug) 4.1 If the plunger is dry, remove it by remov-
ing the brake pedal and brake plunger
Fig. 2, Meritor Automatic Slack Adjuster (other slack boot. Lubricate the plunger and the inside
adjustors are similar) surface of the boot with barium grease

Recreational Vehicle Chassis Maintenance Manual, September 2010 42/3

42 Brakes

(p/n BW 246671) or Pennzoil Adhezoplex 3. Check the brake module for leaks. If leaks are
EP2. Install the plunger, boot, and the found, repair or replace the brake module. See
brake pedal. Group 42 of the Recreational Vehicle Chassis
Workshop Manual for replacement instructions,
IMPORTANT: Use only these approved lubri- or take the vehicle to an authorized Freightliner
cants. Chassis dealer.
4.2 If the plunger has grease on it, lift the 4. Check the electrical connections and harnesses.
edge of the brake plunger boot enough to Make sure the connectors are fully seated and
apply 2 to 4 drops of light oil around the the harnesses are not chafed or cut. Repair or
brake plunger, where it slides into the replace any damaged harness. Disconnect any
brake base bracket. Install the plunger loose connectors and inspect the terminals for
boot around the brake base bracket. corrosion. If corrosion is present, replace the ter-
minals. If corrosion is not present, reconnect the
42–07 Bendix Hydro-Max® connector.
5. Check the fuse for the hydraulic brake booster
Brake System Inspecting pump, as follows.
(front-engine diesel 5.1 Open the cover to the main power distri-
chassis) bution module (PDM).
5.2 Pull the fuse in position F6 for the Hydro-
1. Check the fluid level in the hydraulic brake fluid Max relay.
reservoir. If needed, fill the reservoir up to the
ridge that surrounds the reservoir. See Fig. 4. 5.3 Inspect the relay to make sure the fuse is
Use only heavy-duty brake fluid, DOT 3. not damaged. If the fuse is damaged, in-
stall a new fuse. If the fuse is not dam-
aged, install the fuse in position F6.
A
5.4 Close the PDM cover.
6. Check the operation of the Hydro-Max brake
booster, as follows.
6.1 With the ignition off, depress the brake
pedal and listen for the back-up motor to
engage. Also note that the pedal force
relieves; the pedal should depress easily.
6.2 With the ignition on, engine running, park-
ing brake released, ensure that the
B BRAKE warning indicator light is not on.
This is a dual indicator and indicates that
the parking brake is set, and warns if
there is a hydro-max failure other than
loss of back-up motor power.
10/31/94 f460513a

A. Open caps and check fluid level.

B. Fill to this level.

Fig. 4, Hydraulic Brake Fluid Reservoir

2. Check all hydraulic lines and fittings for damage,

leakage, or looseness.
Replace damaged or leaking components, and
tighten loose fittings.

42/4 Recreational Vehicle Chassis Maintenance Manual, September 2010

Brakes 42

42–08 Brake Caliper Slide Pin

Lubricating, Bosch
Brakes (front-engine
diesel chassis) 1
2
4
3
NOTE: There is no set maintenance interval for
lubricating pin-slide hydraulic disc brake cali-
pers.
Apply 1/8 oz (3.5 g) Aeroshell grade 5 grease to 06/20/2002 f422357
each of the two guide pin and guide pin bore sets.
See the Bosch Pin Slide Disc Brakes Service Manual 1. Flange-Head Bolt 3. Trailing Pin
2. Leading Pin 4. Rubber Bushing
for additional information.
IMPORTANT: The later ZOH-T caliper has im- Fig. 5, ZOH-T Slide Pins and Bolts
portant differences from the early ZOPS caliper.
ZOPS calipers (since 1998) and ZOH-T calipers
(since 2002) use different slide pins and bolts.
See Fig. 5 and Fig. 6. The later trailing pin is
identified by notches and has a rubber bushing.
Flange-head instead of hexhead bolts are used 3
1 2
with the later caliper. The later bolts have a fine 3
thread rather than a coarse thread pitch, are
longer, differently colored, and are tightened to a
higher torque specification. Use only the ZOH-T
bolts to assemble a ZOH-T caliper. The ZOPS
06/20/2002 f422358
caliper bolts have a different thread pitch and
will not assemble correctly in a ZOH-T caliper 1. Hexhead Bolt 3. Slide Pin
2. Blue Patch
mounting. Also, the ZOH-T bolts will not as-
semble correctly in a ZOPS caliper. Do not in- Fig. 6, ZOPS Slide Pins and Bolts
terchange parts. It is permissible to use both
ZOH-T pins and ZOH-T bolts in a ZOPS anchor chor plate leading hole position. Install the pin
plate, but they must be replaced as sets. Both with the rubber bushing and notches only in the
the pins and the bolts must be changed. anchor plate trailing hole position. Tighten the
leading-side pin first, then tighten the trailing-
side pin.
DANGER
Tighten ZOH-T bolts 93 to 107 lbf·ft (126 to 145
The correct pins, bolts, and bolt torque must be N·m).
used. If not, brake function could be impaired and Tighten ZOPS bolts 70 to 80 lbf·ft (95 to 108 N·m).
lead to loss of control of the vehicle, which could
result in personal injury, death, or property dam-
age. 42–09 Brake Lines Checking,
IMPORTANT: The ZOH-T caliper assembly is Hydraulic Disc or Air
similar in appearance to the existing ZOPS cali-
per. The only obvious difference is that one of
Brakes
the anchor plate slide pins (trailing side) has Check all hydraulic/air lines and fittings for damage,
notches for identification. With ZOH-T calipers, leakage, or looseness.
install the solid pin (no bushing) only in the an-

Recreational Vehicle Chassis Maintenance Manual, September 2010 42/5

42 Brakes

Replace damaged or leaking components, and

tighten loose fittings.
Parking Brake Operational Check
CAUTION
42–10 Brake Lining Wear
Perform the following check in a clear safe area. If
Checking, Hydraulic the parking brakes fail to hold the vehicle, per-
Disc Brakes (front- sonal injury or property damage may result.
engine diesel chassis) 1. With the engine running, and air pressure at cut-
out pressure, set the parking brake.
Before checking lining wear with the wheel removed, 2. Put the vehicle in the lowest gear and gently at-
review the following brake lining exposure warnings. tempt to move it forward. The vehicle should not
move. If the vehicle moves, the parking brakes
WARNING are not operating correctly and must be repaired
before the vehicle is returned to service. See
Breathing brake lining dust (asbestos or non- Group 42 of the Recreational Vehicle Chassis
asbestos) could cause lung cancer or lung dis- Workshop Manual for repair procedures, or take
ease. Unless exposure can be reduced below legal the vehicle to an authorized Freightliner dealer.
limits, wear an air purifying respirator approved
by MSHA or NIOSH at all times when servicing the Brake Component Inspection
brakes, starting with removal of the wheels and
continuing through assembly. 1. Park the vehicle on a level surface, set the park-
ing brake, and chock the tires. Once the tires are
To minimize the possibility of creating airborne brake chocked, release the parking brake.
lining dust, clean the dust from the brake rotor, brake
caliper, and brake assembly, using an industrial-type
vacuum cleaner equipped with a high-efficiency filter WARNING
system. Then, using a rag soaked in water and
wrung until nearly dry, remove any remaining dust. Manually adjusting an automatic slack adjuster to
Do not use compressed air or dry brushing to clean bring the pushrod stroke within legal limits is
the brake assembly. likely masking a mechanical problem. Adjustment
is not repairing. Before adjusting an automatic
1. Apply the brake and chock the tires to prevent slack adjuster, troubleshoot the foundation brake
vehicle movement. system and inspect it for worn or damaged com-
2. Check the brake lining wear. On front and rear ponents. Improperly maintaining the vehicle brak-
axles, replace linings worn to less than 3/16 inch ing system may lead to brake failure, resulting in
(4.8 mm). property damage, personal injury, or death.
3. Make sure that the brake rotor and linings are 2. With the engine off, and 100 psi (689 kPa) of air
free of oil and grease. tank pressure, have an assistant apply and hold
an 80 to 90 psi (550 to 620 kPa) brake applica-
NOTE: To replace the brake linings, see the ap- tion.
plicable foundation brake section in Group 42 of
3. Check to see if the colored over-stroke band on
the Recreational Vehicle Chassis Workshop each brake chamber pushrod is exposed.
Manual, or take the vehicle to an authorized
Freightliner dealer. If a band shows, the stroke is too long. Check
the foundation brake components for wear or
damage, and repair as needed. See Group 42 of
42–11 Brake Inspecting the Recreational Vehicle Chassis Workshop
Manual for inspection, troubleshooting, and re-
IMPORTANT: This procedure should be per- pair procedures, or take the vehicle to an autho-
formed prior to lubrication of the brake compo- rized Freightliner dealer.
nents.

42/6 Recreational Vehicle Chassis Maintenance Manual, September 2010

Brakes 42

4. Measure the applied chamber stroke. See

Table 1 for the proper stroke for the type of
42–12 Meritor Roller Pin
chamber being used. If the stroke is too short, Lubricating
the brakes may drag or will not fully apply. Check
for improper operation or adjustment of the auto-
matic slack adjuster. See Group 42 of the Rec- WARNING
reational Vehicle Chassis Workshop Manual for
inspection and troubleshooting procedures, or Remove all grease or oil from the camshaft head,
take the vehicle to an authorized Freightliner rollers and brake linings. Always replace linings
dealer. contaminated with grease or oil, which can in-
crease stopping distances, causing component
5. Start the engine and build air pressure to at least damage and serious personal injury.
100 psi (689 kPa). Shut down the engine.
For Q and P series Meritor brakes, lube the cam an-
6. Check all of the foundation brake components for chor and cam roller pins when the brake is disas-
damage, wear, and loose or missing parts. Re- sembled, or every six months, with Meritor specifica-
pair as needed. See Group 42 of the Recre- tion grease 0-617-A or 0-617-B. See Fig. 7 for roller
ational Vehicle Chassis Workshop Manual for and anchor pin lubrication points.
repair procedures, or take the vehicle to an au-
thorized Freightliner dealer.

Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
12 1-3/8 (35)
16
Standard Stroke
20 1-3/4 (44)
24
Haldex
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)
9
Less than 1-1/2 (38)
12
Standard Stroke 16
Less than 1-3/4 (44)
Meritor 20
24 Less than 1-7/8 (48)
Long Stroke 24
Less 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.

Table 1, Brake Chamber Stroke Specifications

Recreational Vehicle Chassis Maintenance Manual, September 2010 42/7

42 Brakes

1 2 3
03/02/2004 f430370

1. Cam Roller Pin Lube Point (Q Series)

2. Cam Roller Pin Lube Points (Q, Q Plus, and P
Series)
3. Cam Anchor Pin Lube Points (Q, Q Plus, and P
Series)

Fig. 7, Cam and Anchor Roller Pin Lubrication Points

42/8 Recreational Vehicle Chassis Maintenance Manual, September 2010

Steering 46
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01
Hydraulic Reservoir Filter Changing (metal reservoir only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–06
Power Steering Reservoir Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02
Power Steering Reservoir Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03
Steering Driveline Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04
Steering Gear Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05

Recreational Vehicle Chassis Maintenance Manual, January 2010

Steering 46

46–01 Drag Link Lubricating 3. Install the dipstick (fill cap) in the power steering
reservoir.
1. Using a clean rag, wipe the dirt from both grease
fittings on the drag link. Rear-Mounted
2. Using a pressure gun, apply multipurpose chas- 1. Clean around the power steering reservoir cap
sis grease at the grease fittings until old grease with a clean rag, then remove the reservoir cap.
is forced out of the socket. See Fig. 1.
NOTE: Use multipurpose chassis grease NLGI
grade 1 (6% 12-hydroxy lithium stearate grease)
or NLGI grade 2 (8% 12-hydroxy lithium stear-
ate grease). The grade 2 chassis grease is pre-
ferred. MAX

46–02 Power Steering Min

Reservoir Fluid Level
Checking
Side-Mounted
1. Clean around the power steering reservoir dip-
stick (fill cap) with a clean rag, then remove the 04/10/97 f461177
dipstick.
Fig. 1, Steering System Hydraulic Fluid Reservoir (rear-
mounted)
WARNING
Fill only with approved clean fluid. Do not mix WARNING
fluid types. Any mixture or any unapproved fluid
could lead to seal deterioration and leaks. Fluid Fill only with approved clean fluid. Do not mix
leakage could cause loss of power steering assist, fluid types. Any mixture or any unapproved fluid
possibly resulting in personal injury and property could lead to seal deterioration and leaks. Fluid
damage. leakage could cause loss of power steering assist,
2. With the power steering fluid at operating tem- possibly resulting in personal injury and property
perature, check the fluid level on the dipstick. If damage.
below the "Add" mark, add enough fluid to bring IMPORTANT: Do not confuse coolant with hy-
the level up to the "Full" mark on the dipstick. draulic fluid. Both are pink in color.
See Table 1 for approved power steering fluid.
2. Fill the reservoir to a level between the MIN and
Approved Power Steering Fluid MAX marks. Use only Dexron VI automatic trans-
mission fluid (ATF), or an equivalent. See
Fluid Type Approved Fluid* Table 1 for approved power steering fluid.
Automatic Transmission Fluid Dexron VI
3. Replace the reservoir cap.
Hydraulic System Fluid (power
15W40
steering with side-mounted radiator)
* Use the same lubricant when assembling parts as is used in the power
steering system.
Table 1, Approved Power Steering Fluid

Recreational Vehicle Chassis Maintenance Manual, January 2010 46/1

46 Steering

46–03 Power Steering

Reservoir Fluid and
Filter Changing 2
1. Remove the dipstick, if so equipped.
2. Drain the power steering reservoir by disconnect-
ing the power steering gear-to-reservoir hose
from the reservoir. Catch the fluid from the reser-
voir in a drain bucket, then cap the reservoir 3
port.
3. Loosen the clamps on each end of the inline
power steering filter and save them for reuse. 1
Remove the old filter, if so equipped.
IMPORTANT: Do not use teflon tape on the
threads of the hose-barb fittings.
05/06/2005 f462014
4. Unscrew the hose-barb fitting and the 90-degree
hose-barb elbow fitting from the old filter and in- 1. Hose-Barb Elbow Fitting
2. Hose-Barb Fitting
spect them for any damage. If no damage is
3. 25-Micron Power Steering Filter
found, screw the two fittings into the new 25-
micron filter. If damage is found in the fittings, Fig. 2, Power Steering Filter, Typical Installation (if so
replace them with a new 1/2–14 NPT hose-barb equipped)
fitting and elbow.
it with jack stands. Have an assistant turn the
IMPORTANT: Ensure that the "TO RESERVOIR" steering wheel to full lock left and right, and cap-
arrow on the power steering filter, if so ture the fluid flowing from the hose in the drain
equipped, is pointing towards the power steering bucket. Add fluid to the reservoir as needed.
fluid reservoir and that the hose-barb 90-degree Continue turning the steering wheel until clean
elbow fitting is located on the bottom of the power steering fluid flows from the hose into the
power steering filter. See Fig. 2. drain bucket. Remove the plug from the reservoir
and reconnect the steering gear-to-reservoir
5. Place the ends of the power steering gear-to- hose to the reservoir.
reservoir hose onto the hose-barb fittings and
tighten the two hose clamps securely. 8. Tighten the hose fitting nut finger-tight, then with
a wrench, tighten until there is firm resistance.
Tighten one-sixth turn more. Do not overtighten.
WARNING
Remove the jack stands and lower the vehicle.
Fill only with approved clean fluid. Do not mix 9. Fill the reservoir with approved fluid as needed.
fluid types. Any mixture or any unapproved fluid Start the engine and let it idle for 10 seconds.
could lead to seal deterioration and leaks. Fluid Have an assistant turn the steering wheel from
leakage could cause loss of power steering assist, lock-to-lock until no bubbles are seen in the res-
possibly resulting in personal injury and property ervoir. Shut down the engine.
damage.
10. Install a new cover gasket, the cover, and the
6. Fill the reservoir with approved power steering dipstick.
fluid. See Table 1.
11. Start the engine and check the power steering
7. Place the disconnected end of the steering gear- reservoir fluid level. If the fluid level is low, add
to-reservoir hose in a drain bucket. Do not start more of the approved fluid to bring the level up
the engine while draining the system. Raise the to the full mark on the dipstick. Turn the steering
front of the vehicle with a floor jack and support

46/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Steering 46

wheel from lock-to-lock to flush out any air. Shut

down the engine.
46–06 Hydraulic Reservoir
Filter Changing (metal
46–04 Steering Driveline reservoir only)
Lubricating NOTE: On XC chassis vehicles with a side-
mounted radiator, the hydraulic reservoir sup-
Wipe the grease fittings clean. Using a pressure gun, plies both the steering and the fan circuits.
apply a lithium-based grease (NLGI grade 2) spar-
ingly to the universal joints and slip-joint splines. 1. Drain the entire steering and fan hydraulic sys-
tems.
46–05 Steering Gear 2. Remove the reservoir lid and remove the nut that
secures the filter.
Lubricating 3. Remove the old filter and install the new filter.
1. Wipe off debris from the grease fitting. 4. Install the filter nut and tighten it securely.
2. Using a hand-type grease gun, apply multipur- 5. Fill the reservoir with the approved hydraulic
pose chassis grease until the grease starts com- fluid. See Table 1.
ing out of the sector shaft dirt and water seal.
6. Start the engine, run it for five seconds, then
Figure 3 shows the location of the sector shaft
shut down the engine.
grease fitting.
7. Fill the reservoir with 15W40 hydraulic system
fluid.
8. Start the engine. Turn the steering wheel lock-to-
lock several times until the steering wheel turns
easily. Shut down the engine.
9. Fill the reservoir with 15W40 hydraulic system
fluid.
NOTE: The steering circuit is now purged. Fol-
1
low the remaining steps to purge the fan circuit.
10. Start the engine. Run the engine at half-throttle
until the fans engage (loud chirping sound). Shut
down the engine.
11. The fan circuit is now purged. Top off the reser-
voir fluid and install the reservoir lid.
04/13/93 f460515a

1. Sector Shaft Grease Fitting

Fig. 3, Sector Shaft Lubricating

Recreational Vehicle Chassis Maintenance Manual, January 2010 46/3

Fuel 47
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fuel Tank Mounts and Fuel Line Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01
Fuel/Water Separator Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02

Recreational Vehicle Chassis Maintenance Manual, January 2010

Fuel 47

47–01 Fuel Tank Mounts and

Fuel Line Checking
WARNING
Inspect the components as described below. Fail-
ure to perform these inspections could result in
the failure of the fuel tank mounting assembly and
loss of vehicle control, possibly causing personal
injury or death, or property damage.
1. Chock the tires. Working at the front of the ve-
hicle or at the rear of the vehicle, raise the ve-
hicle so that the tires just clear the ground and
so that the suspension is fully extended. Place
safety stands under the vehicle frame.
2. Check the T-bolts that attach the fuel tank
mounting straps to the mounting brackets. Check
to see that the nuts are tight.
3. Inspect the fuel tank straps for damage or wear.
Replace them if necessary.
4. Inspect the fuel tank for leaks or damage. Re-
place the tank if necessary.
IMPORTANT: Do not attempt to repair a dam-
aged fuel tank; always replace a damaged fuel
tank.
5. Inspect the fuel lines for damage or wear.
6. Remove the safety stands and lower the vehicle.
Remove the chocks from the tires.

47–02 Fuel/Water Separator

Element Replacing
1. Chock the front tires.
2. Locate the fuel/water separator.
3. See the Cummins Operation and Maintenance
Manual for fuel/water separator element replac-
ing intervals.
4. Remove the chocks from the tires.

Recreational Vehicle Chassis Maintenance Manual, January 2010 47/1

Exhaust 49
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Exhaust System Inspecting (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01

Recreational Vehicle Chassis Maintenance Manual, January 2010

Exhaust 49

49–01 Exhaust System • DEF Tank—holds DEF and regulates its tem-
perature.
Inspecting (Noise • DEF Metering Unit—mixes DEF with com-
Emission Control) pressed air, and meters this mixture into the
exhaust flow via an injection nozzle.
The exhaust system must be free of leaks, binding, • SCR Catalyst—the housing containing a treated
grounding, and excessive vibrations. In addition to ceramic flow-through block where the DEF and
inspecting the exhaust system at the scheduled exhaust gases undergo selective catalytic re-
maintenance interval, inspect the exhaust system if duction.
the noise level of the vehicle has increased. Replace
parts that show leakage, wear, or damage, with • Selective Catalytic Reduction (SCR)—a process
genuine Freightliner parts. used to reduce NOx emissions.
These conditions are usually caused by loose, bro- Inspection
ken, or misaligned clamps, brackets, or pipes. If any
of these conditions exist, check the exhaust system IMPORTANT: The Environmental Protection
components and alignment. Align or replace as nec- Agency’s 2010 regulations mandate lowered
essary. For alignment or adjustment instructions, see exhaust emissions, thus requiring exhaust sys-
Group 49 of the Recreational Vehicle Chassis Work- tem components that reduce emissions. In par-
shop Manual, or take the vehicle to an authorized ticular the aftertreatment device (ATD), which is
Freightliner dealer.
part of the aftertreatment system (ATS), requires
special attention during regularly scheduled
EPA10 Exhaust System maintenance inspections. See Fig. 1 for Cum-
Definitions of Aftertreatment mins ATD sensor locations. If any discrepancies
System (ATS) Terms are discovered, refer to the engine manufactur-
er’s service literature for repair instructions.
Refer to the following list of definitions of ATS terms
and components. 1. Check for leakage at the clamp that attaches the
exhaust pipe to the turbocharger exhaust outlet.
• Aftertreatment System (ATS)—the entire ex- If leakage exists, tighten the nut on the clamp to
haust system from the turbocharger to the tail the required torque. If leakage persists, install a
pipe, including the Selective Catalytic Reduction new clamp.
(SCR) components.
2. Check the exhaust pipe, bellows, and each ex-
• Aftertreatment Device (ATD)—a device that re- haust seal clamp for leakage, wear, cracks, or
moves pollutants from exhaust gas after the gas damage. Replace damaged components as
leaves the combustion chamber. needed. If leakage exists at a clamp, tighten the
• BlueTec®—Daimler’s proprietary SCR technol- nuts to the required torque. If leakage persists,
ogy. install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or
• Diesel Oxidation Catalyst (DOC)—a flow- removed, it must be replaced.
through device that enhances the oxidation of
hydrocarbons in the ATD. 3. If present, check the condition of the insulation
material around the exhaust pipe between the
• Diesel Particulate Filter (DPF)—a component in turbocharger and the ATD.
the ATD that traps particulate matter from the
exhaust gas. 4. Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
• Diesel Exhaust Fluid (DEF)—the chemical agent overtighten.
that reacts with the exhaust gases in the SCR
to reduce NOx. 5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that
• DEF Pump—filters and supplies DEF to the retain the DPF in the ATD. No leaks are allowed
DEF metering unit. anywhere in the system.

Recreational Vehicle Chassis Maintenance Manual, January 2010 49/1

49 Exhaust

4
10. Check the DEF tank, pump, metering unit, and
5 lines for leaks. See Group 49 of the Recre-
ational Vehicle Chassis Workshop Manual for
repair procedures.
3 11. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
6 Diesel Exhaust Fluid (DEF) Filter
Replacement
The Environmental Protection Agency’s 2010 regula-
tions require lower nitrogen oxide (NOx) exhaust
emissions. Selective catalytic reduction (SCR) uses
diesel exhaust fluid (DEF) to lower NOx emissions in
2 the vehicle exhaust. A filter in the DEF pump pre-
vents clogging of the DEF metering unit injection
nozzle.
1 7 See the engine manufacturer’s maintenance manual
for DEF filter replacement instructions and mainte-
10/20/2009 f490386
nance intervals.

1. Exhaust Outlet EPA07 Exhaust System

2. SCR Outlet NOx Sensor
3. DPF Outlet Pressure Sensor Definitions of ATS Terms
4. DPF Intake Pressure Sensor
5. DPF Inlet Temperature Sensor Refer to the following list of definitions of ATS terms
6. SCR Inlet Temperature Sensor and components.
7. SCR Outlet Temperature Sensor
• Aftertreatment System (ATS) — the entire ex-
Fig. 1, Cummins ATD Sensor Locations haust system from the turbocharger to the tail
pipe.
6. Check all sensors attached to the ATD for leaks
or damaged wires. No leaks are allowed. • Aftertreatment Device (ATD)—a muffler-like can-
ister that houses a DPF and sensors.
7. Check the DPF exterior surface for dents or
other damage. A dent over 3 inches (76 mm) in • Diesel Particulate Filter (DPF)—a filter that col-
diameter and 1/4-inch (6-mm) deep could cause lects and holds particulate matter (soot and
internal damage to the DPF, causing it to mal- ash).
function. • Diesel Oxidation Catalyst (DOC)—oxidizes hy-
8. Check the SCR catalyst for dents and other drocarbons and reduces NOx.
damage. • Sensors—detect temperatures and pressure
9. Check for heat discoloration on the surface of within the ATS.
the ATD. Heat discoloration may indicate internal • Diffuser—a device, used as a deflector, for dis-
damage; especially around the DPF. tributing, mixing, and reducing the velocity of air
NOTE: Diesel exhaust fluid creeps, causing flow.
white crystals to form around the line fittings. Inspection
The presence of crystals does not mean the
system has a leak. Replacing fittings or trouble- IMPORTANT: The Environmental Protection
shooting components is not necessary unless Agency’s 2007 regulations require lower ex-
there is a system failure or a fault code. haust emissions, thus requiring new exhaust

49/2 Recreational Vehicle Chassis Maintenance Manual, January 2010

Exhaust 49

system components. See Fig. 2. In particular

the aftertreatment device (ATD), which is part of
the aftertreatment system (ATS), requires spe-
cial attention during regularly scheduled mainte-
nance inspections. If any discrepancies are dis-
covered, refer to the engine manufacturer’s
service literature for repair instructions.
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 to
the required torque. If leakage persists, install a
new clamp.
2. Check the exhaust pipe, bellows, and each ex-
haust seal clamp for leakage, wear, cracks, or
damage. Replace damaged components as
needed. If leakage exists at a clamp, tighten the
nuts to the required torque. If leakage persists,
install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or
removed, it must be replaced.
3. If present, check the condition of the insulation
material around the exhaust pipe between the
turbocharger and the ATD, as well as the ex-
haust wrap from the ATD to the diffuser.
4. Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
overtighten.
5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that
retain the DPF in the ATD. No leaks are allowed
anywhere in the system.
6. Check all sensors attached to the ATD for leaks
or damaged wires. No leaks are allowed.
7. Check the DPF exterior surface for dents or
other damage. See Fig. 2, Item A. A dent over 3
inches (76 mm) in diameter and 1/4-inch (6-mm)
deep could cause internal damage to the DPF,
causing it to malfunction.
8. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
9. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.

Recreational Vehicle Chassis Maintenance Manual, January 2010 49/3

49 Exhaust

3
2 4
1 B
5

4
C

9
A

6
7
11/2/2006 f490284

A. Inspect this area of the canister for dents. C. DPF Area

B. DOC Area
1. Inlet Temperature Sensor 6. Exhaust Outlet to Diffuser
2. Marmon Fitting at Inlet from Turbocharger 7. Outlet Temperature Sensor
3. Sensor Housing 8. DPF Outlet Pressure Sensor
4. DPF V-Band Mounting Clamps 9. DPF Intake Pressure Sensor
5. Inlet Temperature Sensor

Fig. 2, Cummins Aftertreatment Device

49/4 Recreational Vehicle Chassis Maintenance Manual, January 2010

Electrical, Instruments, and Controls 54
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Battery Voltage Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–02
Ground Cables Checking and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–01

Recreational Vehicle Chassis Maintenance Manual, September 2007

Electrical, Instruments, and Controls 54

54–01 Ground Cables

Checking and Cleaning
Check that the ground cables are clean, undamaged,
and tight. If needed, disconnect them, clean the mat-
ing surfaces with a soda solution, then connect them
securely. Spray the ground cable connections with
dielectric red enamel.

54–02 Battery Voltage

Checking
Check the battery open circuit voltage using an accu-
rate voltmeter. If the voltmeter registers 12.5V or
below, fully charge the battery to 12.65V. A fully
charged battery will have a voltage of 12.65V with
the charger disconnected.

Recreational Vehicle Chassis Maintenance Manual, September 2007 54/1

Heater and Air Conditioner 83
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Conditioner Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01

Recreational Vehicle Chassis Maintenance Manual, Apirl 2010

Heater and Air Conditioner 83

83–01 Air Conditioner

Inspecting
WARNING
Wear eye protection, gloves, and protective cloth-
ing when working on the air conditioning system.
Leaking refrigerant from a damaged hose or line
could cause blindness or serious skin burns.
1. Park the vehicle on a level surface, shutdown the
engine, apply the parking brake, and chock the
tires.

CAUTION
To avoid the possibility of burns, make certain
that the engine and air conditioner components
are not hot.
2. Check the appearance of the air conditioner
compressor pulley assembly. If the friction sur-
face of the pulley shows signs of excessive
grooving due to belt slippage, replace both the
pulley and the drive plate. Visually inspect the
refrigerant compressor drive belt for damage,
and check that the belt is set at the proper ten-
sion. Also check the tightness of the compressor
mounting fasteners. For instructions and torque
values and for removal and installation proce-
dures, see Group 83 of the Recreational Vehicle
Chassis Workshop Manual, or take the vehicle to
an authorized Freightliner dealer.
3. Inspect the compressor clutch coil wire. Ensure
that the connector is not damaged or loose. Re-
place the wire if it is damaged.
4. Check the overall condition of the air conditioning
hoses. Look for cracks, cuts, and abrasions on
the hoses. Replace damaged hoses; see Group
83 of the Recreational Vehicle Chassis Work-
shop Manual for replacement instructions, or
take the vehicle to an authorized Freightliner
dealer. Also, visually check for loose fittings on
all air conditioning components. Do not over-
tighten the fittings.
5. Check for a buildup of road debris on the con-
denser fins. Using air pressure and a whisk
broom or a soapy spray of water, carefully clean
off the condenser. Be careful not to bend the
fins.

Recreational Vehicle Chassis Maintenance Manual, Apirl 2010 83/1