BUSINESS CLASS M2 MAINTENANCE MANUAL

Models: M2
M2
M2
M2
M2

STI-455-4 (9/11)

100
106
106V
112
112V

Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

Foreword
Performing scheduled maintenance operations is important in obtaining safe, reliable operation
of your vehicle. A proper maintenance program will also help to minimize downtime and
safeguard warranties.

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 operations in this maintenance manual at scheduled intervals. Perform the pretrip
and post-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle
drivers manual. Major components, such as engines, transmissions, and rear axles, are covered
in their own maintenance and operation manuals, that are provided with the vehicle. Perform any
maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner
Dealership has the qualified technicians and equipment to perform this maintenance for you.
They can also set up a scheduled maintenance program tailored specifically to your needs.
Optionally, they can assist you in learning how to perform these maintenance procedures.

IMPORTANT: Descriptions and specifications in this manual were in effect at the time of
printing. Freightliner Trucks reserves the right to discontinue models and to change
specifications or design at any time without notice and without incurring obligation.
Descriptions and specifications contained in this publication provide no warranty,
expressed or implied, and are subject to revision and editions without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.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.

20012011 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 LLC is a Daimler company.

Daimler Trucks North America LLC

Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, Oregon 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
Manual

Workshop/service manuals contain service and repair information for all vehicle
systems and components, except for major components such as engines, transmissions, 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, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.

Drivers/Operators
Manual

Drivers/operators manuals contain information needed to enhance the drivers

understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pretrip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Drivers/operators manuals do not contain detailed repair or service information.

Service Bulletins

Service bulletins provide the latest service tips, field repairs, product improvements, and related information. Some service bulletins are updates to information 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 diagnostic 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 vehicles

build record.

EZWiring

EZWiring makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
Freightliner Custom Chassis Corporation products wiring drawings and floating
pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro.

Business Class M2 Maintenance Manual, May 2011

I1

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; customers receive notices that apply to their vehicles.

I2

Business Class M2 Maintenance Manual, May 2011

Introduction
Page Description
For an example of a Business Class M2 Maintenance Manual page, see Fig. 1.
A

20

Cooling

2001 Coolant Replacement

2002 Cooling Fan Inspection

Business Class M2 Maintenance Manual, December 2001

12/06/2001

A.
B.
C.
D.
E.

f020125

Maintenance Operation Number consists of the Group Number followed by the Sequence Number
Group Title
Group Number
Release Date
Group Number/Page Number
Fig. 1, Example of a Business Class M2 Maintenance Manual Page

Business Class M2 Maintenance Manual, May 2011

I3

Introduction
Maintenance Manual Contents
Group No.

Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
31 . . . . . . . . . . . . . Frame and Frame Components
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders

I4

Business Class M2 Maintenance Manual, May 2011

General Information

00
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001
Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006
M1 Lubrication and Fluid Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012
M1 Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007
M2 Lubrication and Fluid Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013
M2 Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008
M3 Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009
M4 Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010
M5 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011
Maintenance Intervals for Schedule I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003
Maintenance Intervals for Schedules II and III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002
Metric/U.S. Customary and Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017
Noise Emission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015
Overview of Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016

Business Class M2 Maintenance Manual, September 2011

00

General Information

Determining Scheduled Maintenance Intervals: 0001

any road operation with high annual mileage

Determining Scheduled
Maintenance Intervals

Maintenance Schedules

Performing regular maintenance will help ensure that

your vehicle delivers safe, reliable service and optimum performance. A proper maintenance program
will also help to minimize downtime and safeguard
warranties.

After determining the schedule appropriate to your

vehicle, refer to the Maintenance Schedules to determine when to perform the Initial Maintenance (IM)
and the frequency of performing subsequent maintenance intervals for each schedule.

To determine the correct maintenance intervals for

your vehicle, you must first determine the type of service or conditions the vehicle will be operating in.
Most vehicles operate in conditions that fall within
one of the three schedules. Before placing your vehicle in service, determine whether Schedule I, II, or
III applies to your vehicle.

Maintenance Intervals

Schedules I-III

Maintenance Operations

Schedule I (severe service) applies to vehicles that

travel up to 6000 miles (10 000 kilometers) annually
or that operate under severe conditions. Examples of
Schedule I usage are:

Groups 01 through 83 in this manual have an index

at the beginning of each Group. The index lists the
Title of Maintenance Operations and the maintenance Operation (MOP) Numbers for that Group.
Follow the instructions under the MOP number to
perform the required maintenance.

operation on extremely poor roads or where

there is heavy dust accumulation
constant exposure to extreme hot, cold, salt air,
or other extreme climates
frequent short-distance travel
construction-site operation

Refer to Maintenance Intervals for Schedule I,

Schedule II, and Schedule III to determine which
maintenance interval(s) should be performed when
your vehicle reaches the mileage or hours of operation listed in these tables.

In addition to the maintenance operations required

for the maintenance interval, perform all the daily
maintenance procedures in Chapter 11, "Pretrip Inspection and Daily Maintenance," in the Business
Class M2 Drivers Manual.

city operation such as fire truck and garbage

truck.
farm operation
Schedule II (short-haul transport) applies to vehicles
that travel up to 60,000 miles (100 000 kilometers)
annually and operate under normal conditions. Examples of Schedule II usage are:
operation primarily in cities and densely populated areas
local transport with infrequent freeway travel
high percentage of stop-and-go travel
Schedule III (long-haul transport) is for vehicles that
travel more than 60,000 miles (100 000 kilometers)
annually with minimal city or stop-and-go operation.
Examples of Schedule III usage are:
regional delivery that is mostly freeway miles
interstate transport

Business Class M2 Maintenance Manual, September 2011

00/1

00

General Information

Maintenance Schedules: 0002

Maintenance Schedules
Schedule

Schedule I*
(severe service)
for vehicles that travel up to
6000 miles (10 000 km) annually

Schedule II
(short-haul transport)
for vehicles that travel up to
60,000 miles (100 000 km)
annually

Schedule III
(long-haul transport)
for vehicles that travel over
60,000 miles (100 000 km)
annually

Maintenance Intervals
Maintenance Interval

Frequency

Mileage

km

Hours

Initial Maintenance (IM)

first

1000

1600

100

Maintenance 1 (M1)

every

1000

1600

100

Maintenance 2 (M2)

every

4000

6400

400

Maintenance 3 (M3)

every

8000

12 800

800

Maintenance 4 (M4)

every

16,000

25 600

1600
3200

Maintenance 5 (M5)

every

32,000

51 200

Initial Maintenance (IM)

first

8000

12 000

Maintenance 1 (M1)

every

8000

12 000

Maintenance 2 (M2)

every

16,000

24 000

Maintenance 3 (M3)

every

32,000

48 000

Maintenance 4 (M4)

every

64,000

96 000

Maintenance 5 (M5)

every

128,000

192 000

Initial Maintenance (IM)

first

10,000

16 000

Maintenance 1 (M1)

every

10,000

16 000

Maintenance 2 (M2)

every

20,000

32 000

Maintenance 3 (M3)

every

40,000

64 000

Maintenance 4 (M4)

every

80,000

128 000

Maintenance 5 (M5)

every

160,000

256 000

* For Schedule I vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than mileage.

Table 1, Maintenance Schedules

00/2

Business Class M2 Maintenance Manual, September 2011

00

General Information

Maintenance Intervals for Schedule I: 0003

Maintenance Intervals for Schedule I

Maintenance
Sequence

Maintenance Interval

Service Date

Miles

km

Hours

1st

IM and M1

1000

1600

100

2nd

M1

2000

3200

200

3rd

M1

3000

4800

300

4th

M1 and M2

4000

6400

400

5th

M1

5000

8000

500

6th

M1

6000

9600

600

7th

M1

7000

11 200

700

8th

M1, M2, and M3

8000

12 800

800

9th

M1

9000

14 400

900

10th

M1

10,000

16 000

1000

11th

M1

11,000

17 600

1100

12th

M1 and M2

12,000

19 200

1200

13th

M1

13,000

20 800

1300

14th

M1

14,000

22 400

1400

15th

M1

15,000

24 000

1500

16th

M1, M2, M3, and M4

16,000

25 600

1600

17th

M1

17,000

27 200

1700

18th

M1

18,000

28 800

1800

19th

M1

19,000

30 400

1900

20th

M1 and M2

20,000

32 000

2000

21st

M1

21,000

33 600

2100

22nd

M1

22,000

35 200

2200

23rd

M1

23,000

36 800

2300

24th

M1, M2, and M3

24,000

38 400

2400

25th

M1

25,000

40 000

2500

26th

M1

26,000

41 600

2600

27th

M1

27,000

43 200

2700

28th

M1 and M2

28,000

44 800

2800

29th

M1

29,000

46 400

2900

30th

M1

30,000

48 000

3000

31st

M1

31,000

49 600

3100

32nd

M1, M2, M3, M4, and M5

32,000

51 200

3200

Table 2, Maintenance Intervals for Schedule I

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00

General Information

Maintenance Intervals for Schedules II and III: 0004

Maintenance Intervals for Schedules II and III

Schedule II

Schedule III

Maintenance
Sequence

Maintenance Interval

1st

IM and M1

2nd

M1 and M2

16,000

24 000

20,000

32 000

3rd

M1

24,000

36 000

30,000

48 000

4th

M1, M2, and M3

32,000

48 000

40,000

64 000

5th

M1

40,000

60 000

50,000

80 000

6th

M1 and M2

48,000

72 000

60,000

96 000

7th

M1

56,000

84 000

70,000

112 000

8th

M1, M2, M3, and M4

64,000

96 000

80,000

128 000

9th

M1

72,000

108 000

90,000

144 000

10th

M1 and M2

80,000

120 000

100,000

160 000

11th

M1

88,000

132 000

110,000

176 000

12th

M1, M2, and M3

96,000

144 000

120,000

192 000

13th

M1

104,000

156 000

130,000

208 000

14th

M1, and M2

112,000

168 000

140,000

224 000

15th

M1

120,000

180 000

150,000

240 000

16th

M1, M2, M3, M4, and M5

128,000

192 000

160,000

256 000

17th

M1

136,000

204 000

170,000

272 000

18th

M1 and M2

144,000

216 000

180,000

288 000

19th

M1

152,000

228 000

190,000

304 000

20th

M1, M2, and M3

160,000

240 000

200,000

320 000

21st

M1

168,000

252 000

210,000

336 000

22nd

M1 and M2

176,000

264 000

220,000

352 000

23rd

M1

184,000

276 000

230,000

368 000

24th

M1, M2, M3, and M4

192,000

288 000

240,000

384 000

25th

M1

200,000

300 000

250,000

400 000

26th

M1 and M2

208,000

312 000

260,000

416 000

27th

M1

216,000

324 000

270,000

432 000

28th

M1, M2, and M3

224,000

336,000

280,000

448 000

29th

M1

232,000

348 000

290,000

464 000

30th

M1 and M2

240,000

360 000

300,000

480 000

31st

M1

248,000

372 000

310,000

496 000

32nd

M1, M2, M3, M4, and M5

256,000

384 000

320,000

512 000

Service Date

Miles

km

Miles

km

8000

12 000

10,000

16 000

Table 3, Maintenance Intervals for Schedules II and III

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Business Class M2 Maintenance Manual, September 2011

00

General Information

Overview of Maintenance Operations: 0005

Maintenance Operations for Groups 00 through 88

Maintenance
Operation No.

Title of Maintenance Operation

Maintenance Intervals
IM

M1

M2

M3

M4

M5

01-01

Engine Drive Belt Inspecting

01-02

Engine Support Fastener Checking

09-01

Air Cleaner Element Inspecting and Replacing

13-01

Air Compressor Inspecting

15-01

Alternator, Battery, and Starter Checking

20-01

Radiator Cap Inspecting

20-02

Radiator Pressure Flushing and Coolant Changing

20-03

Fan Drive Inspecting (Noise Emission Control)

20-04

Hybrid Electric System Coolant Changing

25-01

Eaton Fuller Clutch Release Bearing Lubricating

25-02

Eaton Fuller Clutch Release Cross-Shaft Lubricating

25-03

Clutch Hydraulic Fluid Level Checking

25-04

Clutch Hydraulic Fluid Changing

25-05

Clutch Adjusting, Manually Adjusted Clutches

26-01

Manual Transmission Fluid Level Checking

26-02

Eaton Fuller Transmission Fluid Changing and Magnetic Plug

Cleaning*

26-03

Allison and Eaton Fuller Transmission Breather Checking

26-04

Eaton Fuller Transmission Air Filter/Regulator Element

Cleaning

26-05

Allison Transmission Fluid and Filter Changing

26-06

Mercedes-Benz Transmission Fluid Changing and Magnetic

Plug Cleaning

26-07

Mercedes-Benz Transmission Leak Checking

31-01

Frame Fastener Torque Checking

31-02

Fifth Wheel Inspecting

31-03

Fifth Wheel Lubricating

31-04

Trailer Electrical Connector Lubricating

32-01

Suspension Inspecting

32-02

Suspension Lubricating

32-03

Suspension U-Bolt Torque Checking

33-01

Kingpin Lubricating

33-02

Tie Rod End Lubricating

33-03

Draw Key Nut Torque Checking

33-04

Tie Rod End Inspecting

Business Class M2 Maintenance Manual, September 2011

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00

General Information

Overview of Maintenance Operations: 0005

Maintenance Operations for Groups 00 through 88

Maintenance
Operation No.

00/6

Title of Maintenance Operation

Maintenance Intervals
IM

M1

M2

M3

M4

M5

33-05

Wheel End Inspection and Maintenance, 6,000-Pound and

8,000-Pound Steer Axles with Oil-Lubricated Hubs

35-01

Axle Lubricant Level Checking

35-02

Axle Breather Checking

35-03

Axle Lubricant Changing and Magnetic Plug Cleaning

40-01

Wheel Nut Checking

41-01

Driveline Inspecting

41-02

Driveline Lubricating

42-01

Air Brake System Valve Inspecting

42-02

Bendix AD9 Air Dryer Desiccant Replacing

42-03

Governor D2A Checking

42-04

Bosch Hydraulic Brake System Inspecting

42-05

Bendix ADIP Air Dryer Desiccant Replacing

42-06

Haldex and Gunite Slack Adjuster Lubricating

42-07

Meritor Camshaft Bracket Lubricating

42-08

Meritor Slack Adjuster Lubricating

42-09

Bendix ADIS Air Dryer Desiccant Replacing

42-10

Air Dryer AD9, ADIP, and ADIS/DRM Checking

42-11

Brake Lines and Fittings Inspecting, Hydraulic Brakes

42-12

Brake Pedal Linkage and Mounting Plate Inspecting

42-13

Air Brake Inspecting and Leak Testing

42-14

Foot-Control Valve, E6, Inspecting and Lubricating

42-15

Brake Inspecting
Hydro-Max

Brake System Inspecting

42-16

Bendix

46-01

Drag Link Inspecting

46-02

Power Steering Fluid Changing

46-03

Power Steering Fluid Level Inspecting

46-04

Power Steering Gear Lubricating

46-05

Drag Link Lubricating

46-06

Power Steering Filter Changing

47-01

Fuel Tank Band Nut Tightening

47-02

Fuel/Water Separator Element Replacing

47-03

LNG Fuel System Inspecting

47-04

LNG Vacuum Integrity Testing

47-05

CNG Fuel System Inspecting

Business Class M2 Maintenance Manual, September 2011

00

General Information

Overview of Maintenance Operations: 0005

Maintenance Operations for Groups 00 through 88

Maintenance
Operation No.

Title of Maintenance Operation

Maintenance Intervals
IM

M1

M2

M3

M4

M5

47-06

CNG High-Pressure Fuel Filter Element Replacing

47-07

CNG Fuel Cylinder Inspecting

49-01

Exhaust System Inspecting (Noise Emission Control)

49-02

CAT CGI Bellows and Piping Inspection

49-03

CAT CGI Bellows Replacement

60-01

Mirror Folding Check

72-01

Door Seals Lubricating

83-01

Air Conditioner Inspecting

83-02

HVAC Air Filter Replacing

88-01

Hood Rear Support Lubrication

* Change petroleum-based lubricants at M2 (including M3, M4, and M5). Change synthetic lubricants at M5 only.
Schedule II and Schedule III vehicles only.
If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M5 maintenance interval.
Replace the HVAC air filter at the recommended interval or every six months.

Table 4, Maintenance Operations for Groups 00 through 88

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General Information

Initial Maintenance (IM) Operations: 0006

NOTE: The IM Operations include the maintenance

operations in Table 5 and all of the maintenance operations in Table 6, M1 Maintenance Operations.
Initial Maintenance (IM) Operations
Maintenance
Operation No.

Title of Maintenance Operation

00-07

Perform All M1 Operations

31-01

Frame Fastener Torque Checking

32-03

Suspension U-Bolt Torque Checking

33-03

Draw Key Nut Torque Checking

47-01

Fuel Tank Band Nut Tightening

Table 5, Initial Maintenance (IM) Operations

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General Information

M1 Maintenance Operations: 0007

IMPORTANT: After performing all operations listed in

this table, perform all daily, weekly, and monthly
maintenance operations listed in the "Pretrip and

Post-Trip Inspections and Maintenance" chapter of

the Business Class M2 Drivers Manual.

M1 Maintenance Operations
Maintenance
Operation No.
00-12

Title of Maintenance Operation

Lubrication and Fluid Level Check
Eaton Fuller Clutch Release Bearing Lubricating
Eaton Fuller Clutch Release Cross-Shaft Lubricating
Clutch Hydraulic Fluid Level Checking
Manual Transmission Fluid Level Checking
Fifth Wheel Lubricating
Trailer Electrical Connector Lubricating
Suspension Lubricating
Kingpin Lubricating
Tie Rod End Lubricating
Axle Lubricant Level Checking
Driveline Lubricating
Haldex and Gunite Slack Adjuster Lubricating
Meritor Slack Adjuster Lubricating
Power Steering Fluid Level Inspecting
Power Steering Gear Lubricating
Drag Link Lubricating
Door Seals Lubricating
Hood Rear Support Lubrication

25-05

Clutch Adjusting, Manually Adjusted Clutches

26-03

Allison and Eaton Fuller Transmission Breather Checking

31-02

Fifth Wheel Inspecting

32-01

Suspension Inspecting

33-04

Tie Rod End Inspecting

33-05

Wheel End Inspection and Maintenance, 6,000-Pound and 8,000Pound Steer Axles with Oil-Lubricated Hubs*

35-02

Axle Breather Checking

41-01

Driveline Inspecting

42-01

Air Brake System Valve Inspecting

42-02

Bendix AD-9 Air Dryer Desiccant Replacing (with an oil-coalescing

desiccant cartridge)

42-04

Bosch Hydraulic Brake System Inspecting

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General Information

M1 Maintenance Operations: 0007

M1 Maintenance Operations
Maintenance
Operation No.

Title of Maintenance Operation

42-05

Bendix AD-IP Air Dryer Desiccant Replacing (with an oil-coalescing

desiccant cartridge)

42-09

Bendix AD-IS Air Dryer Desiccant Replacing (with an oil-coalescing

desiccant cartridge)

42-11

Brake Lines and Fittings Inspecting, Hydraulic Brakes

42-15

Brake Inspecting

47-03

LNG Fuel System Inspecting

47-06

CNG High-Pressure Fuel Filter Element

49-02

CAT CGI Bellows and Piping Inspection

83-01

Air Conditioner Inspecting

* Schedule III vehicles only.

If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage.

Otherwise use the M5 maintenance interval.

M1 maintenance interval should be used as a general guideline; the actual frequency of filter element replacement will vary depending on cleanliness of the fuel station system.

Table 6, M1 Maintenance Operations

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General Information

M2 Maintenance Operations: 0008

NOTE: The M2 Maintenance Operations include the

maintenance operations in Table 7 and all of the

maintenance operations in Table 9, M1 Maintenance

Operations.

M2 Maintenance Operations
Maintenance
Operation No.

Title of Maintenance Operation

00-07

Perform All M1 Maintenance Operations

00-13

Lubrication and Fluid Level Check

Eaton Fuller Transmission Fluid Changing and Magnetic Plug
Cleaning*
Meritor Camshaft Bracket Lubricating

13-01

Air Compressor Inspecting

20-01

Radiator Cap Inspecting

20-03

Fan Drive Inspecting (Noise Emission Control)

26-04

Eaton Fuller Transmission Air Filter/Regulator Element Cleaning

33-05

Wheel End Inspection and Maintenance, 6,000-Pound and 8,000Pound Steer Axles with Oil-Lubricated Hubs

42-10

Air Dryer AD9, ADIP, and ADIS/DRM Checking

42-12

Brake Pedal Linkage and Mounting Plate Inspecting

47-05

CNG Fuel System Inspecting

49-01

Exhaust System Inspecting (Noise Emission Control)

* Petroleum-based lubricants only.

Schedule II vehicles only.

Table 7, M2 Maintenance Operations

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General Information

M3 Maintenance Operations: 0009

NOTE: The M3 Maintenance Operations include the

maintenance operations in Table 8 and all of the
maintenance operations in Table 6, M1 Maintenance

Operations, and Table 7, M2 Maintenance Operations.

M3 Maintenance Operations
Maintenance
Operation No.

Title of Maintenance Operation

00-07

Perform All M1 Maintenance Operations

00-08

Perform All M2 Maintenance Operations

01-01

Engine Drive Belt Inspecting

26-05

Allison Transmission Fluid and Filter Changing

32-03

Suspension U-Bolt Torque Checking

33-03

Draw Key Nut Torque Checking

40-01

Wheel Nut Checking

42-13

Air Brake Inspecting and Leak Testing

46-01

Drag Link Inspecting

47-04

LNG Vacuum Integrity Testing

47-07

CNG Fuel Cylinder Inspecting

83-02

HVAC Air Filter Replacing*

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

Table 8, M3 Maintenance Operations

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General Information

M4 Maintenance Operations: 0010

NOTE: The M4 Maintenance Operations include the

maintenance operations in Table 9 and all of the
maintenance operations in Table 6, M1 Maintenance

Operations, Table 7, M2 Maintenance Operations,

and Table 8, M3 Maintenance Operations.

M4 Maintenance Operations
Maintenance
Operation No.

Title of Maintenance Operation

00-07

Perform All M1 Maintenance Operations

00-08

Perform All M2 Maintenance Operations

00-09

Perform All M3 Maintenance Operations

01-02

Engine Support Fastener Checking

09-01

Air Cleaner Element Inspecting and Replacing

15-01

Alternator, Battery, and Starter Checking

20-02

Radiator Pressure Flushing and Coolant Changing

20-04

Hybrid Electric System Coolant Changing

31-01

Frame Fastener Torque Checking

35-03

Axle Lubricant Changing and Magnetic Plug Cleaning

42-03

Governor D2A Checking

46-02

Power Steering Fluid Changing

47-02

Fuel/Water Separator Element Replacing

60-01

Mirror Folding Check

Table 9, M4 Maintenance Operations

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General Information

M5 Maintenance Operations: 0011

NOTE: The M5 Maintenance Operations include the

maintenance operations in Table 10 and all of the
maintenance operations in Table 6, M1 Maintenance

Operations, Table 7, M2 Maintenance Operations,

Table 8, M3 Maintenance Operations, and Table 9,
M4 Maintenance Operations.

M5 Maintenance Operations
Maintenance
Operation No.

Title of Maintenance Operation

00-07

Perform All M1 Maintenance Operations

00-08

Perform All M2 Maintenance Operations

00-09

Perform All M3 Maintenance Operations

00-10

Perform All M4 Maintenance Operations

25-04

Clutch Hydraulic Fluid Changing

26-06

Mercedes-Benz Transmission Fluid Changing and Magnetic Plug

Cleaning

26-07

Mercedes-Benz Transmission Leak Checking

42-02

Bendix AD-9 Air Dryer Desiccant Replacing

42-05

Bendix AD-IP Air Dryer Desiccant Replacing

42-09

Bendix AD-IS Air Dryer Desiccant Replacing

42-14

Foot-Control Valve, E6, Inspecting and Lubricating

46-06

Power Steering Filter Changing

49-03

CAT CGI Bellows Replacement

Table 10, M5 Maintenance Operations

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General Information

M1 Lubrication and Fluid Level Check: 0012

Table 11, MOP 00-12, lists the lubrication and fluid

level check maintenance operations that must be
performed at the M1 Maintenance Interval.
MOP 00-12, M1 Lubrication and Fluid Level Check
Maintenance
Operation No.

Title of Maintenance Operation

25-01

Eaton Fuller Clutch Release Bearing Lubricating

25-02

Eaton Fuller Clutch Release Cross-Shaft Lubricating

25-03

Clutch Hydraulic Fluid Level Checking

26-01

Manual Transmission Fluid Level Checking

31-03

Fifth Wheel Lubricating

31-04

Trailer Electrical Connector Lubricating

32-02

Suspension Lubricating

33-01

Kingpin Lubricating

33-03

Tie Rod End Lubricating

35-01

Axle Lubricant Level Checking

41-02

Driveline Lubricating

42-06

Haldex and Gunite Slack Adjuster Lubricating

42-08

Meritor Slack Adjuster Lubricating

46-03

Power Steering Fluid Level Inspecting

46-04

Power Steering Gear Lubricating

46-05

Drag Link Lubricating

72-01

Door Seals Lubricating

88-01

Hood Rear Support Lubrication

Table 11, MOP 00-12, M1 Lubrication and Fluid Level Check

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General Information

M2 Lubrication and Fluid Level Check: 0013

Table 12, MOP 00-13, lists the lubrication and fluid

level check maintenance operations that must be
performed at the M2 Maintenance Interval.
MOP 00-13, M2 Lubrication and Fluid Level Check
Maintenance
Operation No.

Title of Maintenance Operation

26-02

Eaton Fuller Transmission Fluid Changing and Magnetic Plug

Cleaning*

42-07

Meritor Camshaft Bracket Lubrication

* Petroleum-based lubricants only.

Table 12, MOP 00-13, M2 Lubrication and Fluid Level Check

00/16

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General Information

Noise Emission Controls: 0015

Noise Emission Controls

Federal Law, Part 205:
Transportation Equipment Noise
Emission Controls
Part 205, Transportation Equipment Noise Emission
Controls, requires the vehicle manufacturer to furnish
each new vehicle with written instructions for the
proper maintenance, use, and repair of the vehicle
by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of noise
emission degradation throughout the life of the vehicle. In compliance with the law, the Noise Emission
Control Systems maintenance located in each applicable group within this manual, in conjunction with
the vehicle workshop manual, provides these instructions to owners.

Recommendations for
Replacement Parts

2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts presumed to constitute tampering
are the acts listed below:
1. Removal of engine noise-deadening panels, including cab or hood liners.
2. Removal of or rendering inoperative the engine
speed governor so as to allow engine speed to
exceed the manufacturers specifications.
3. Removal of or rendering inoperative the fan
clutch, including bypassing the control on any
thermostatic fan drive to cause it to operate continuously.
4. Removal of the fan shroud.
5. Removal of or rendering inoperative exhaust system components, including exhaust pipe clamping.
6. Removal of air intake system components.

Replacement parts used for maintenance or repair of

noise emission control systems should be genuine
Freightliner parts. If other than genuine Freightliner
parts are used for replacement or repair of components affecting noise emission control, the owner
should be sure that such parts are warranted by their
manufacturer to be equivalent to genuine Freightliner
parts in performance and durability.

Freightliner Noise Emissions

Warranty
Refer to the vehicle owners warranty information
book for warranty information concerning noise emission control systems.

Tampering With the Noise

Control System is Prohibited
Federal law prohibits the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use,

Business Class M2 Maintenance Manual, September 2011

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General Information

Verification of Inspections Log: 0016

Verification of Inspections Log

The "Verification of Inspections Log" should be filled
out each time the vehicles noise emission controls
are maintained or repaired.
Verification of Inspections Log, Group 20
Verification of Inspections Log, Group 20, Engine Cooling/Radiator
Date

Mileage

Repair Description

Cost

Repair Facility

Verification of Inspections Log, Group 49

Verification of Inspections Log, Group 49, Exhaust
Date

00/18

Mileage

Repair Description

Cost

Repair Facility

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00

General Information

Metric/U.S. Customary and Temperature

Conversions: 0017
Metric/U.S. Customary Conversions
When You Know U.S.
Customary

Multiply
By

To Get Metric

When You
Know Metric

Multiply
By

To Get U.S. Customary

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)

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

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

pints (pt)

0.47318

liters (L)

2.1134

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)

0.03527

ounces (av) (oz)

pounds (av) (lb)

Area

square feet (ft2)

Volume

fluid ounces (fl oz)

pints (pt)

Weight/Force
ounces (av) (oz)

28.35

grams (g)

pounds (av) (lb)

0.454

kilograms (kg)

2.205

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 (lbfin)

11.298

Newton centimeters (Ncm)

0.08851

inch pounds (lbfin)

foot-pounds (lbfft)

1.3558

Newton meters (Nm)

0.7376

foot pounds (lbfft)

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)

Pressure/Vacuum

Table 13, Metric/U.S. Customary Conversions

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General Information

Metric/U.S. Customary and Temperature

Conversions: 0017
Temperature Conversions
When You Know

Subtract

Then
Divide By

degrees Fahrenheit (F)

32

1.8

To Get

When You
Know

degrees Celsius (C)

Multiply
By

Then
Add

To Get

1.8

32

degrees Fahrenheit (F)

Table 14, Temperature Conversions

00/20

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General Information

Torque Specifications: 0018

Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads
Regular Hex
Thread
Diameter
Pitch

Grade 5
Bolt

Grade 5 or
B Nut

Torque: lbfft (Nm)

Grade 8 or
C Nut

Torque: lbfft (Nm)

f230003

f230002

Flanged

Grade 8 or
8.2 Bolt

f230004

f230005

Grade 5
Bolt

Grade B
Nut

Torque: lbfft (Nm)

f230006

f230007

Grade 8 or
8.2 Bolt

Grade G
Nut

Torque: lbfft (Nm)

f230009

f230008

1/420

7 (9)

8 (11)

6 (8)

10 (14)

1/428

8 (11)

9 (12)

7 (9)

12 (16)

5/1618

15 (20)

16 (22)

13 (18)

21 (28)

5/1624

16 (22)

17 (23)

14 (19)

23 (31)

3/816

26 (35)

28 (38)

23 (31)

37 (50)

3/824

30 (41)

32 (43)

25 (34)

42 (57)

7/1614

42 (57)

45 (61)

35 (47)

60 (81)

7/1620

47 (64)

50 (68)

40 (54)

66 (89)

1/213

64 (87)

68 (92)

55 (75)

91 (123)

1/220

72 (98)

77 (104)

65 (88)

102 (138)

9/1612

92 (125)

98 (133)

80 (108)

130 (176)

9/1618

103 (140)

110 (149)

90 (122)

146 (198)

5/811

128 (173)

136 (184)

110 (149)

180 (244)

5/818

145 (197)

154 (209)

130 (176)

204 (277)

3/410

226 (306)

241 (327)

200 (271)

320 (434)

3/416

253 (343)

269 (365)

220 (298)

357 (484)

7/89

365 (495)

388 (526)

320 (434)

515 (698)

7/814

402 (545)

427 (579)

350 (475)

568 (770)

18

582 (789)

112

637 (863)

114

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

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00

General Information

Torque Specifications: 0018

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads
Regular Hex
Thread
Diameter
Pitch

Grade 5 Bolt

Grade 5 or B
Nut

Torque: lbfft (Nm)

Grade 8 or C
Nut

Torque: lbfft (Nm)

f230003

f230002

Flanged

Grade 8 or 8.2
Bolt

f230004

Grade 8 or 8.2
Bolt

Grade G Nut

Torque: lbfft (Nm)

f230005

f230009

f230008

1/420

8 (11)

10 (14)

1/428

9 (12)

12 (16)

5/1618

15 (20)

22 (30)

22 (30)

5/1624

17 (23)

25 (34)

3/816

28 (38)

40 (54)

40 (54)

3/824

31 (42)

45 (61)

7/1614

45 (61)

65 (88)

65 (88)

7/1620

50 (68)

70 (95)

1/213

70 (95)

95 (129)

95 (129)

1/220

75 (102)

110 (149)

9/1612

100 (136)

140 (190)

140 (190)

9/1618

110 (149)

155 (210)

5/811

135 (183)

190 (258)

190 (258)

5/818

155 (210)

215 (292)

3/410

240 (325)

340 (461)

340 (461)

3/416

270 (366)

380 (515)

7/89

385 (522)

540 (732)

7/814

425 (576)

600 (813)

18

580 (786)

820 (1112)

112

635 (861)

900 (1220)

114

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 15. Freightliner recommends that

all plated and unplated fasteners be coated with oil before installation.

Table 16, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

00/22

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General Information

Torque Specifications: 0018

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads
Class 8.8 Bolt
Class 8 Nut
Thread
DiameterPitch
Torque: lbfft (Nm)

8.8

Class 10 Nut

Torque: lbfft (Nm)

10.9

f230010

Class 10.9 Bolt

f230011

10

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 17, Torque Values for Metric Thread Fasteners With Lubricated or Plated
Threads

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Engine

01
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Engine Drive Belt Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101
Engine Support Fastener Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102

Business Class M2 Maintenance Manual, January 2007

01

Engine

0101 Engine Drive Belt

Inspecting
Worn or loose drive belts may cause premature pulley bearing failure or engine overheating. Too much
or too little tension on the belt may result in excessive or premature belt wear. Replace the engine
drive belt if any conditions described under Visual
Inspection are found.
Visually inspect all drive belts, then perform the belt
tension inspection. To inspect a belt, gently twist the
belt to view the belt sidewalls and the underside of
the belt. When replacing a matched set of belts, always replace both belts at the same time. Matched
belts must be from the same manufacturer.

Visual Inspection
For examples of drive belt conditions, see Fig. 1.

1. Inspect the belt for glazing. Shiny sidewalls are

evidence of glazing, which is caused by friction
created when a loose belt slips in the pulleys. It
can also be caused by oil or grease contamination on the pulleys.
2. Check for tensile breaks or breaks in the cord
body. Cuts in a belt are usually caused by foreign material in the pulley or by prying or forcing
the belt during removal or installation.
3. Check the belt for ply separation. Oil, grease, or
belt dressing can cause the belt to fall apart in
layers. Repair any oil or coolant leaks that are
affecting the belts before replacing the drive
belts. Do not use belt dressing on any belt.
4. Check for uneven ribs on serpentine (poly-V)
belts. Foreign material in the pulley will erode the
undercord ribs causing the belt to lose its gripping power.
5. Check the belt for a jagged or streaked sidewall.
Jagged or streaked sidewalls are the result of

07/12/2001

1. Glazing
2. Tensile Break

f150010b

3. Separating Layers
4. Uneven Ribs

5. Streaked Sidewalls
6. Cracks

Fig. 1, Drive Belt Replacement Conditions

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01

Engine

foreign material, such as sand or gravel, in the

pulley, or a rough pulley surface.
6. Check the drive belts for cracks. Small, irregular
cracks are usually indication of an old belt.
7. Visually inspect the pulleys for excessive play or
wobble. Excessive play or wobble indicates a
failure of the pulley bearing. Check for belt
squealing or squeaking. Replace the bearings as
necessary.

NOTE: If it is difficult to distinguish the location

of a supposed bearing noise, obtain a stethoscope and place it on the component being
checked, not the pulley, to isolate the area from
outside interference.
8. Inspect all pulleys for foreign material, oil, or
grease in the grooves.
If the engine drive belt needs to be replaced, see
Group 01 of the Business Class M2 Workshop
Manual.

0102 Engine Support Fastener

Checking
Front and rear engine supports for vehicles built from
January 2007 require no periodic maintenance.
Mounts should be inspected when the engine is removed for service. For vehicles manufactured prior to
January 2007, perform the following check.
1. Check the tightness of the engine support fasteners at the rear of the engine. Tighten the fasteners 241 lbfft (460 Nm).
2. Check the tightness of the engine support fasteners at the front of the engine. Tighten the fasteners 136 lbfft (327 Nm).

NOTE: When the engine is removed, inspect

the lower and upper isolators for wear. Replace
the isolators if necessary.

Belt Tension Inspection

Engine drive belts on the Mercedes-Benz and Caterpillar engines have belt tensioners that automatically
adjust the tension on the belt. These belts do not
require adjustment.

Caterpillar 3126 Engine

Inspect the belt tensioner for unusual noise and excessive looseness or shaking of the pulley bearings.
See Fig. 2. If the belt tensioner requires disassembly, refer to the engine service manual.

07/12/2001

f011990

Fig. 2, Belt Tensioner on Caterpillar 3126 Engine

01/2

Business Class M2 Maintenance Manual, January 2007

Air Intake

09
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0901

Business Class M2 Maintenance Manual, November 2009

09

Air Intake

0901 Air Cleaner Element

Inspection and
Replacement
Restriction of air flow through the air cleaner element
is measured at the tap in the air cleaner outlet.
Check the restriction indicator at the air cleaner or in
the cab if the vehicle is equipped with a dashmounted restriction gauge.
Vehicles may be equipped with either a manual-reset
restriction indicator with graduations (Fig. 1), or a
go/no-go restriction indicator without graduations
(Fig. 2).
1. Inspect the air restriction indicator to see if air
restriction equals or exceeds the maximum allowable restriction. For instructions, see the
Business Class M2 Drivers Manual.

04/08/2005

f090431

Fig. 2, Manual-Reset Air Restriction Indicator, Go/

No-Go

2. If necessary, replace the air cleaner element. For

air cleaner element replacement instructions, see
Group 09 of the Business Class M2 Workshop
Manual.
3. Inspect the air cleaner housing for cracks, leaks,
or any other damage. If the air cleaner housing
or element is damaged, replace it.
4. Reset the air restriction indicator.
5. Each time the air cleaner housing is replaced,
perform the procedures in MOP 1301.

08/07/2007

f090452

Fig. 1, Manual-Reset Air Restriction Indicator,

Graduated

Business Class M2 Maintenance Manual, November 2009

09/1

Air Compressor

13
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Air Compressor Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301

Business Class M2 Maintenance Manual, December 2001

Air Compressor

13

1301 Air Compressor

Inspecting
1. Inspect the air compressor intake adaptors at
both ends of the line for physical damage. Replace the adaptors if necessary.
2. Inspect the air intake line, oil supply and return
lines, and coolant supply and return lines for tight
connections. Tighten the connections and replace the lines if needed.
3. Check the cooling fins on the air compressor
crankcase. Clean the fins if they are clogged with
debris.

Business Class M2 Maintenance Manual, December 2001

13/1

Alternators and Starters

15
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Alternator, Battery, and Starter Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1501

Business Class M2 Maintenance Manual, January 2009

15

Alternators and Starters

Cab

1501 Alternator, Battery, and

Starter Checking

Jump-start studs
Battery isolation relays
Battery shutoff switches

WARNING
Batteries release explosive gas as a by-product of
their chemical activity. Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat. Make
sure the battery compartment is completely
vented before disconnecting or connecting the
battery cables.
Battery acid is extremely harmful if splashed in
the eyes or on the skin. Always wear a face shield
and protective clothing when working around batteries.
Damaged, chafed, or kinked wiring can cause
electrical short-circuits and lead to fires, causing
property damage, injury, or death. Clean, inspect,
and maintain wiring and connections carefully.
1. Check the tightness of the alternator bracket fasteners; tighten the fasteners as needed. For
torque values, see Group 15 of the Business
Class M2 Workshop Manual.
2. See Group 01 for belt tension specifications.
Check the alternator drive belt tension, using a
tension gauge at the belts longest span. Some
engines are equipped with more than one alternator belt; check all of them for correct tension.
Adjust the belt tension if necessary.
Engines equipped with a serpentine or poly-V
belt have automatic belt tensioners, and do not
require belt tension inspection.

4. Check wires and cables for wear, chafing, kinks,

discolored insulation, or loose clamps or ties.
Find the cause of any problems and repair, replace, and reroute wires and clamps as necessary.
5. Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.
6. On the bundled cable that runs from the batteries
to the starter, ensure that tie straps are installed
at least every 12 inches (300 mm). Replace any
missing tie straps, and add tie straps where
spacing between them exceeds 12 inches (300
mm).
7. Ensure that all cables have sufficient slack to
allow for engine movement, and that there is no
pressure on any wiring connectors.
8. If any convoluted tubing is damaged, check the
wiring inside it. Replace any damaged or missing
convoluted tubing.
9. Clean the cable connector terminals with a wire
brush. See Group 54 of the Business Class M2
Workshop Manual for troubleshooting instructions, and for adjustment, repair, or replacement
instructions.
9.1

Clean and tighten the battery ground

cable, terminal, and clamps.

9.2

Inspect the retainer assembly (or battery

hold-downs) and the battery box. Replace
worn or damaged parts. Remove any corrosion with a wire brush, and wash with a
weak solution of baking soda and water.
Rinse with clean water and dry. To prevent rusting, paint the retainer assembly.

9.3

Check for and remove any foreign objects

such as stones, bolts, or nuts, from the
battery box.

9.4

After cleaning, connect the cables to the

batteries, and tighten them to the torque
specifications listed on the battery, generally 10 to 15 lbfft (14 to 20 Nm).

3. Check that all electrical connections at the alternator and starter are clean. Clean and tighten all
charging system electrical connections including
the connections at the starter B terminal and
ground terminal, and where the alternator charging cable terminates.
Trace and inspect all wiring and cables connected to:
Alternator
Starter and depopulation studs
Batteries
Magnetic switch

Business Class M2 Maintenance Manual, January 2009

15/1

15
9.5

Alternators and Starters

Coat the battery terminals with dielectric

grease.

10. Check the terminals on the battery shut-off

switch and the magnetic switch. Make sure the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.

15/2

Business Class M2 Maintenance Manual, January 2009

Engine Cooling/Radiator

20
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Fan Drive Inspecting (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2003
Hybrid Electric System Coolant Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2004
Radiator Cap Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
Radiator Pressure Flushing and Coolant Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002

Business Class M2 Maintenance Manual, July 2009

20

Engine Cooling/Radiator

2001 Radiator Cap Inspecting

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 serious personal injury.

CAUTION

2002 Radiator Pressure

Flushing and Coolant
Changing
NOTE: For additional instructions on cleaning
and flushing the cooling system, see the engine
maintenance and operation manual.

WARNING
Drain the coolant only when the coolant and engine are cool. Draining it when these are hot could
cause severe personal injury due to scalding.

The radiator cap currently installed may not be the

same one installed when the vehicle was built. If
the radiator cap must be replaced, make sure that
it is the correct cap for the cooling system of the
vehicle. Because the radiator cap pressure rating
affects the operating temperature of the engine,
installing an improperly rated radiator cap may
have adverse effects on the cooling system, and
engine operating temperatures. This could cause
premature engine wear or damage.

1. Drain the radiator, as follows.

1. Using a radiator-cap tester, check the pressure

cap to see if it maintains pressure to within 10
percent of the pressure rating marked on the
cap. If it doesnt, replace the cap. Make sure that
the replacement radiator cap is correctly rated for
the cooling system of the vehicle.

3. Flush the radiator, as follows.

2. There is a second valve in the radiator cap that

opens under vacuum. This prevents the collapse
of hoses and other parts that are not internally
supported when the system cools. Inspect the
vacuum-relief valve to be sure it is not stuck.
3. Make sure that the cap seals properly on the
coolant filler neck seat, and that the radiator cap
gasket is not damaged. On vehicles with
screw-on caps with O-rings, make sure that the
O-ring is not cracked or deteriorated. Replace
the cap if the gasket shows deterioration or damage.

1.1

Place a large container under the radiator.

1.2

Remove the surge tank cap.

1.3

Open the petcock at the bottom of the

radiator to drain the engine coolant.

2. Disconnect the radiator inlet and outlet hose connections.

3.1

Attach a flushing gun nozzle to the radiator outlet.

3.2

Add water to the radiator until it is full.

CAUTION
When flushing the radiator, do not apply more
than 20 psi (138 kPa) air pressure. Excessive pressure can damage the radiator or heater core.
3.3

Apply no more than 20 psi (138 kPa) air

pressure intermittently to help dislodge
sediment buildup in the core.

4. Drain the radiator, then flush the radiator until

clean water flows from it. Remove the flushing
gun.
5. Close the petcock.
6. Using clamps, connect the hoses to the radiator.
Torque the clamps 33 to 38 lbfin (370 to 430
Ncm).

IMPORTANT: On vehicles with EPA07 compliant

engines, the coolant capacity varies depending
on the engine and accessory installation. After

Business Class M2 Maintenance Manual, July 2009

20/1

20

Engine Cooling/Radiator

servicing the cooling system, always verify that

the coolant level is between the MIN and MAX
lines on the surge tank.
7. Fill the radiator with coolant. Use a mixture of 50
percent water and 50 percent corrosion-inhibiting
antifreeze to protect the engine to 34F (37C)
year round.
See Table 1 for engine cooling system capacities.
See Table 2 for approved antifreezes.
Coolant Capacities (pre-EPA07 engines)
Engine Make and Model

Coolant Volume:
quarts (liters)

Caterpillar 3126

35 (33.1)

MBE904

32 (30.3)

MBE906

37 (35)

Table 1, Coolant Capacities (pre-EPA07 engines)

Approved Coolants
Coolant Manufacturer
Texaco

Coolant Designation*
JC04 Antifreeze

Van Waters and Rogers

Ltd. (Canada)

Diesel Antifreeze No. 6038

* Freightliner-approved antifreeze must meet one of the following conditions: A. Ethylene glycol solution that meets GM 6038M Engineering Standards. B. Ethylene glycol solution that has less than 0.1% anhydrous sodium metasilicate and meets either GM 1825M or GM 1899M
Engineering Standards.

Table 2, Approved Coolants

2003 Fan Drive Inspecting

(Noise Emission
Control)
Horton Advantage Fan Clutch
1. Check the fan for loose rivets and missing
weights. Check for bent, cracked, or missing
blades. Tighten loose components. Replace the
fan drive if necessary.
2. Check for adequate clearance between the fan
and the fan shroud or other engine compartment
components in both the engaged mode and the

20/2

disengaged mode. If the clearance is not adequate, make the necessary adjustments.
3. Check the fan belt condition and the belt alignment. Replace or correct as necessary.

Horton HT650 Fan Drive

Check for friction facing wear condition. Replace
when worn to 1/16-inch (1.5-mm) thick, when oil
spotted, or when burn marks are visible.

Kysor K22RA, K22FA, and

K26RA Fan Drives
1. Check the fan for missing, cracked, chipped, or
damaged blades. Tighten loose components. Replace damaged fans if necessary.
2. Check for adequate clearance around the fan.
The fan should be centered in the shroud to prevent contact between the fan and the shroud.
3. Check the fan belt for proper alignment and condition. If the belt is worn or frayed, replace the
belt.
4. Verify the fan drive engagement. With the engine
and ignition key switch off, apply at least 90 psi
(620 kPa) to the clutch; the fan should rotate
freely. Remove air pressure from the clutch and
the fan should not rotate.
5. With the fan drive disengaged, check for air
leaks at the front of the clutch and between the
clutch and the drive hub. If an air leak is detected, the clutch seals and hub must be inspected for wear or damage. If necessary, the
seals of the clutch can be replaced with a Kysor
rebuild kit. If inspection of the hub indicates excessive wear, rebuild the hub using a hub rebuild
kit from Kysor.
6. Any time the clutch is removed for repair or replacement, the pulley hub and bearings should
be inspected for play, roughness, or damage.
Hub bearing service kits are available from
Kysor.
7. Check the lining with the System Alert Tool. If
the lining is worn, install the appropriate lining kit.
A lining that is prematurely worn is caused by
control air supply problems. Inspect and correct
the vehicle control system before placing the vehicle back in service.

Business Class M2 Maintenance Manual, July 2009

20

Engine Cooling/Radiator

8. Check the air line entry and routing at the front

or rear of the fan drive. Look for cracked, damaged, or improperly routed air lines. Make sure
the connections are tight and that there are no
air leaks.
9. Check the electrical connections at the solenoid
valve. The solenoid valve is part of the air module unit (AMU), which is located on the rear
crossmember. Check the exhaust port for restrictions. If a restriction is found, clear it.

Horton DriveMaster Fan Clutch

NOTE: If any part of the fan clutch needs to be
repaired or replaced after performing the checks
below, see Group 20 of the Business Class
M2 Workshop Manual.
1. Disconnect the batteries at the negative terminals. Drain all air from the air system. If
equipped with an air starter, drain the air starter
reservoir.

WARNING
Make sure the batteries are disconnected before
checking the fan clutch. If the engine starts during
this procedure, the fan could engage, which could
result in serious personal injury.

5. Check the fan belt for wear, tension, and alignment. Correct, if necessary.
6. Check for wear on the friction facing. Replace
the friction facing if it is worn to a 3/16-inch (4.8mm) thickness or less. Also check the facing for
signs of oil contamination or burn marks. If evidence of oil or burn marks are found, replace the
friction facing.
7. Connect the battery cables. Start the engine, and
charge the air system to 120 psi (827 kPa).
Manually engage and disengage the fan clutch.
Check the fan and the fan clutch from a distance. Look for vibration, fan blade contact, fan
clutch slippage, and overall fan clutch operation.
If the fan clutch does not operate correctly, see
Group 20 of the Business Class M2 Workshop
Manual for troubleshooting and repair procedures.
8. With the air system charged to 120 psi (827
kPa), check the fan clutch for audible air leaks,
using a suitable listening device.
Check at the solenoid valve, the air filter assembly, and the air hoses and fittings. See Fig. 1.
Using a wet finger or a soapy water solution,
check for a leak in the same areas.

2. Inspect the electrical connections and wires to

the fan clutch solenoid. Secure the connection if
loose; replace wires and connectors if damaged.
3. Clean the fan clutch air solenoid valve filter, if
equipped.
3.1

Unscrew the fan clutch solenoid valve air

filter assembly, and remove the filter element.

3.2

Clean the filter element with cleaning solvent.

3.3

Using a clean, lint-free cloth, wipe off any

excess solvent.

3.4

Reassemble the clutch valve solenoid air

filter assembly, and install it on the vehicle.

4. Visually check the fan for bent, cracked, or damaged blades. Replace if damaged. Check for adequate clearance between the fan and other
components.

Business Class M2 Maintenance Manual, July 2009

05/30/2002

f200581

Fig. 1, Checking for Air Leaks (Horton DriveMaster)

9. If a leak is detected, remove the fan blade. Install a new seal kit. See Group 20 of the
Business Class M2 Workshop Manual for repair
procedures.

20/3

20

Engine Cooling/Radiator

10. Check the fan drive for discoloration or any other

signs of slipping or overheating.

NOTE: The fan clutch may slip if the air supply

pressure is below 70 psi (483 kPa) or if there is
a leak inside the fan clutch. Any leak must be
remedied.

system. Run the cooling pump until the air

bubbles stop appearing in the reservoir tank.
6. Check the coolant level, and add coolant as
needed. The system should be filled to the mid
level of the reservoir.

11. Check the fan clutch bearings.

11.1

Turn the fan in both directions and feel

for worn hub bearings.

11.2

If possible, remove the drive belt and

check for worn sheave bearings by turning the sheave in both directions.

11.3

If either the hub or sheave bearings are

worn, replace them, using a Horton DriveMaster Super Kit.
For instructions and kit part number, see
Group 20 of the Business Class M2
Workshop Manual.

2004 Hybrid Electric System

Coolant Changing
1. Disconnect the 12-volt vehicle batteries to isolate
the high voltage power source.
2. Drain the hybrid radiator, as follows.
2.1

Place a large container under the hybrid

radiator.

2.2

Remove the cap from the coolant reservoir.

2.3

If equipped with a petcock, open it at the

bottom of the hybrid radiator to drain the
coolant.

2.4

Disconnect the lower radiator hose, and

drain the remaining coolant.

2.5

Close the petcock, if equipped.

3. Install the lower radiator hose.

4. Fill the system with a coolant mixture of 50 percent ethylene glycol and 50 percent water.
5. Using ServiceRanger1, activate the HEV coolant
pump to purge any air that may be trapped in the
1 ServiceRanger is a service and diagnostic software program available from
Eaton Corporation. See the Eaton website, www.roadranger.com for more
information.

20/4

Business Class M2 Maintenance Manual, July 2009

Clutch

25
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Clutch Adjusting, Manually Adjusted Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2505
Clutch Hydraulic Fluid Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2504
Clutch Hydraulic Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2503
Eaton Fuller Clutch Release Bearing Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2501
Eaton Fuller Clutch Release Cross-Shaft Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2502

Business Class M2 Maintenance Manual, June 2006

25

Clutch

2501 Eaton Fuller Clutch

Release Bearing
Lubricating
The standard clutch release bearing is sealed, and
does not require lubrication. If the vehicle is not
equipped with a maintenance-free sealed clutch release bearing, lubricate the bearing as follows:
1. Park the vehicle on a level surface. Apply the
parking brakes, and chock the rear tires.
2. Remove the clutch inspection plate.

NOTE: Some clutch release bearings are

equipped with a lubrication extension that extends outside of the clutch housing. It is not
necessary to remove the clutch inspection plate
when the lubrication extension is used.
NOTE: For lubricating the release bearing,
Eaton Fuller recommends a lithium-base hightemperature grease that meets the NLGI grade
one or two specification.

05/27/93

f250081a

Fig. 1, Release Bearing Grease Fitting

3. Wipe the dirt away from the grease fitting. See

Fig. 1. Use a low-pressure-type grease gun
equipped with the recommended grease, and
lubricate the bearing until excess grease purges
from the rear of the release bearing (toward the
transmission).

CAUTION
Do not over-lubricate the clutch release bearing.
Over-lubrication could contaminate the clutch internally, causing clutch slippage and premature
failure. Do not use chassis grease or multipurpose
lubricants.
4. Wipe off excess grease and apply it to both the
yoke finger and sleeve bushing contact points.
See Fig. 2.
5. Install the clutch inspection plate.
6. Remove the chocks.

2
f250444

08/10/2009

1. Sleeve Bushing Contact Point

2. Yoke Finger Contact Points
Fig. 2, Grease the Contact Points

2502 Eaton Fuller Clutch

Release Cross-Shaft
Lubricating
IMPORTANT: This maintenance operation pertains only to vehicles equipped with mechanical
(not hydraulic) linkages.
The clutch release cross-shaft is equipped with two
grease fittings in the transmission clutch housing.
See Fig. 3 and Fig. 4. Wipe the dirt from the grease

Business Class M2 Maintenance Manual, June 2006

25/1

25

Clutch

ing loss of clutch function and the risk of serious

personal injury.

fittings and lubricate with multipurpose chassis

grease.

CAUTION
Do not allow the fluid level in the reservoir to go
below the MIN line. If too much air enters, the hydraulic system will not operate correctly, and the
clutch could be damaged.
1

If the fluid level is below the MIN line, fill the reservoir with DOT 4 brake fluid until the level reaches the
MAX line. See Fig. 5.

1
2

f250048a

10/19/93

1. Clutch Release Cross-Shaft

2. Grease Fitting

Fig. 3, Cross-Shaft Grease Fitting, Left Side

5
6
12/10/2001

f250580

1. Reservoir Cap
2. Reservoir
3. Pedal Unit

4. Master Cylinder
5. Hydraulic Hose
6. Slave Cylinder

Fig. 5, Clutch Components

05/27/93

f260146a

Fig. 4, Cross-Shaft Grease Fitting, Right Side

2503 Clutch Hydraulic Fluid

Level Checking
WARNING
Use only approved clutch hydraulic fluid (DOT 4
brake fluid) in the clutch hydraulic system. Do not
mix different types of brake fluid. The wrong fluid
will damage the rubber parts of the system, caus-

25/2

2504 Clutch Hydraulic Fluid

Changing
Replace the clutch hydraulic fluid every two years to
ensure clutch function is reliable and correct. Use the
procedures below. Fluid replacement must be done
at an authorized Freightliner service facility.

Flushing
1. Shut down the engine.
2. Apply the parking brakes, chock the front and
rear tires, and raise the hood.

Business Class M2 Maintenance Manual, June 2006

25

Clutch

WARNING
Clutch hydraulic fluid (DOT 4 brake fluid) is hazardous. It may be a skin irritant and can cause
blindness if it gets in your eyes. Always wear
safety glasses when handling clutch hydraulic
fluid or bleeding hydraulic lines. If you get clutch
hydraulic fluid on your skin, wash it off as soon
as possible.
3. Prepare the pressure bleeding equipment according to the manufacturers instructions. Use
DOT 4 brake fluid. Pressurize the bleed adaptor
to 15 psi (103 kPa).

CAUTION
Do not spill clutch hydraulic fluid (DOT 4 brake
fluid) on the cab paint. Clean it off immediately if
any is spilled. DOT 4 brake fluid can damage
paint.
4. Remove the reservoir lid and install the pressure
bleed adaptor on the reservoir.
5. Pressurize the reservoir, filling the system. Open
the bleed valve on the bleed tank of the adaptor.

NOTE: A pressure bleeder hose (J-29532) and

a bleed adaptor (J-35798) for the fluid reservoir
are available through SPX Kent-Moore Tools
and may be used to complete the following procedure. To order these parts, call Kent-Moore at
1-800-328-6657.
6. Flush the hydraulic system. See Fig. 6.
6.1

Open the bleed screw on the slave cylinder.

6.2

Using a drain pan or other suitable container, collect the fluid that drains from the
slave cylinder bleed valve, at least 0.5
quarts (0.5 liters).

6.3

When all the old fluid has passed through

the system and only new, clean fluid is
coming out, close the bleed screw.

7. Check the fluid level in the reservoir and bleed

the system according to the procedures under
the heading "Bleeding the Clutch." See Fig. 7.

Bleeding the Clutch

1. Remove the cap from the bleed valve. Install a
transparent drain hose on the bleed valve of the
slave cylinder.
2. Open the slave cylinder bleed screw. Observe
the flow of clutch hydraulic fluid through the drain
hose. When bubbles no longer appear in the
fluid, close the slave cylinder bleed screw.
3. Disconnect the transparent hose. Tighten the
bleed screw 88 lbfin (1000 Ncm) and install the
cap on the slave cylinder bleed valve.
4. Close the valve on the bleed tank of the pressure bleed adaptor. Remove the pressure bleed
adaptor.
5. Check the fluid level in the reservoir. If necessary, add or remove clutch hydraulic fluid to bring
the fluid level to the MAX line. Install the reservoir lid.

CAUTION
When removing fluid from the reservoir, use a
clean tool that is used only for brake fluid. Using
a tool contaminated with oil or chemical residue
will destroy hydraulic system parts and cause the
system to malfunction.
6. Depress the clutch pedal a few times. There
should be resistance over the full pedal stroke.
7. Check the entire system for leaks. Tighten the
connections between the components if necessary. Check the fluid level in the reservoir again.
8. Make sure the reservoir lid is tight.
9. Lower the hood and remove the chocks from the
front and rear tires.

2505 Clutch Adjusting,

Manually Adjusted
Clutches
NOTE: This procedure is only required for vehicles equipped with non-synchronized transmissions and manually adjusted clutches.
Release bearing travel is the clearance between the
rear surface of the release bearing housing and the
forward surface of the clutch brake disc. This dis-

Business Class M2 Maintenance Manual, June 2006

25/3

25

Clutch

1
2
3

1
2
3

6
10
8
7

f250582

12/11/2001

1.
2.
3.
4.
5.

Clamp-Mounting Bolt, 1/420

Plated Steel Washer
Locknut, 1/420
Bell Housing Standoff Bracket
Slave Cylinder Standoff Bracket

6.
7.
8.
9.
10.

Hydraulic Hose
Slave Cylinder
Bleed Valve
Bell Housing
Slave Cylinder Mounting Capscrew, M8

Fig. 6, Clutch Slave Cylinder

tance must be maintained between 1/2 and 9/16 inch

(12.7 and 14.3 mm).

25/4

1. Remove the clutch inspection cover from the bell

housing. See Fig. 8.

Business Class M2 Maintenance Manual, June 2006

25

Clutch

2
3

9
6

8
7

f250581

12/11/2001

1. M8 Capscrew and Washer

2. Pedal Unit Mounting Plate
3. Reservoir

4. Pedal Unit
5. Master Cylinder
6. Hydraulic Hose

7. Cup Bracket
8. Standoff Bracket
9. Mounting Bolt, M10

Fig. 7, Clutch Master Cylinder

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

IMPORTANT: Release bearing travel tool A0212419-000 is available through the PDCs. The
fork at one end of the tool has green tape on it,
and has two 0.50-inch (12.7-mm) diameter tips;

Business Class M2 Maintenance Manual, June 2006

the fork at the other end has blue tape on it,

and has 0.56-inch (14.3-mm) diameter tips. See
Fig. 9.
3. Measure the release bearing travel. See Fig. 10
for the correct dimension to measure. Using both
ends of the release bearing travel tool, check this
gap as follows:

25/5

25

Clutch

03/26/96

f580133

A. Green End (0.50 inch or 12.7 mm)

B. Blue End (0.56 inch or 14.3 mm)
Fig. 9, Release Bearing Travel Tool A02-12419-000

06/22/2005

f261355

1. Clutch Inspection Cover

2. Hydraulic Slave Cylinder
3. Transmission
Fig. 8, View from Underneath the Vehicle

Position the tool so that the legs of the fork at

the blue 0.56-inch (14.3-mm) end straddle the
transmission input shaft. If the tool fits loosely,
the gap is too wide and adjustment is needed.
Go to the next step.
If the blue 0.56-inch (14.3-mm) end cant be inserted in the gap, then try to insert the green
0.50-inch (12.7-mm) end.
If the green end of the tool cant be inserted in
the gap, adjustment is needed. Go to the next
step.
If the green end of the tool fits snugly or
loosely then no adjustment is needed. Nothing
more needs to be done. Install the clutch inspection cover.
4. Turn the engine flywheel until the lockstrap is
aligned with the clutch inspection-cover opening.
5. Release the clutch by depressing the pedal.
Block the pedal in the released position, or have
someone assist you by holding the pedal down
during the adjustment procedure.

25/6

10/14/94

f250199a

A. Clearance between release bearing housing and

clutch brake must be 1/2 to 9/16 inch (12.7 to 14.3
mm).
1. Release Bearing Housing
2. Clutch Brake
Fig. 10, Release Bearing Travel Measurement

NOTE: An open-end wrench is not recommended for the following step.

6. Adjust the clutch, using a 5/8-inch box-end or
socket wrench on the adjustment bolt. See
Fig. 11.
6.1

Insert the 5/8-inch box-end or socket

wrench through the inspection cover
opening.

6.2

To begin the adjustment, release the adjustment bolt by pressing down on the
bolt head.

NOTE: On Easy-Pedal 2000 clutches, each

complete turn of the adjustment bolt represents about 0.125 inch (3 mm) of release
bearing movement. On earlier Easy-Pedal
models, each complete turn of the adjust-

Business Class M2 Maintenance Manual, June 2006

25

Clutch

09/15/95

f250309

Fig. 11, Adjustment with Kwik-Adjust (shown with bell

housing removed)

ment bolt represents about 0.02 inch (0.5

mm) of release bearing movement.
Normal wear increases the gap between the
release bearing and the transmission.
6.3

To decrease the gap: If clearance between the release bearing housing and
the clutch brake is more than 9/16 inch
(14.3 mm), turn the adjustment bolt clockwise (the release bearing moves toward
the transmission).
To increase the gap: If clearance between
the release bearing housing and the
clutch brake is less than 1/2 inch (12.7
mm), turn the adjustment bolt counterclockwise (the release bearing moves toward the engine).

6.4

When the adjustment is complete, make

sure the adjustment bolt is locked (pulled
up flush with the mounting bolts).

7. After adjusting, release the pedal and check the

clearance between the release bearing housing
and the clutch brake. When the adjustment is
correct, the green end of the tool should go in
and the blue should not (clearance of 1/2 to 9/16
inch, or 12.7 to 14.3 mm).
8. Install the clutch inspection cover.

Business Class M2 Maintenance Manual, June 2006

25/7

Transmission

26
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Allison Transmission Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2605
Allison and Eaton Fuller Transmission Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2603
Eaton Fuller Transmission Air Filter/Regulator Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2604
Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 2602
Manual Transmission Oil Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2601
Mercedes-Benz Transmission Fluid Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2606
Mercedes-Benz Transmission Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2607

Business Class M2 Maintenance Manual, March 2005

26

Transmission

2601 Manual Transmission Oil

Level Checking
1. Park the vehicle on a level surface. Apply the
parking brakes and chock the rear tires.
2. Check the oil level in the transmission. See
Fig. 1.

Approved Manual Transmission Lubricants

Lubricant Type*
MobilTrans SHC DC

Temperature:
SAE
F (C)
Viscosity
All

50

* Lubricants listed in order of preference. Do not mix types of oil.

Call 1-800-826-4357 for a complete list of Eaton approved lubricants.

Table 1, Approved Manual Transmission Lubricants

CAUTION

10/05/94

A. Full

f260006b

B. Low

Fig. 1, Transmission Oil Level Checking

2.1

Clean the area around the fill plug, then

remove the plug from the side of the
case.

2.2

Using your finger or a bent pipe cleaner,

see if the oil is level with the lower edge
of the fill opening.

3. If needed, fill the transmission with oil until level

with the lower edge of the fill opening. See
Table 1 for approved lubricants.
Approved Manual Transmission Lubricants
Lubricant Type*

Temperature:
SAE
F (C)
Viscosity

Eaton Fuller Transmissions

MobilTrans SHC 50 (RN
2952 E-5)

All

50

Synthetic lubricant approved

by Eaton

All

50

Heavy-duty engine oil

Above 10 (12) 40 or 50
meeting MIL-L-2104D or
30
Caterpillar TO-4 Specification Below 10 (12)
Above 10 (12) 80 or 90
API MT-1 gear oils meeting
MIL-PRF-2105E specification Below 10 (12)
75

Operating a manual transmission with the fluid

level higher or lower than recommended can result in transmission damage. Do not overfill the
transmission; overfilling will force fluid out of the
case through the main shaft openings. Fluid overflow may also drain onto the clutch or clutch
brake, causing additional problems.

IMPORTANT: Do not mix types of oil, because

of possible incompatibility. Do not use oil additives or friction modifiers. Do not use multiviscosity oils or EP (Extreme Pressure) gear
oils. If switching from a petroleum-based lubricant to a synthetic, all areas of each affected
component must be thoroughly drained. Switching to a synthetic lubricant, when a petroleumbased lubricant has been used for 50,000 miles
(80 000 km) or longer may affect transmission
performance. Monitor all seal areas for the first
10,000 miles (16 000 km) after changing to a
synthetic from a petroleum-based lubricant.
4. Clean the fill plug, then install it in the transmission. Tighten the plug as follows:
25 to 35 lbfft (34 to 48 Nm) for Eaton
Fuller transmissions with 3/4-inch pipe
threads.
60 to 75 lbfft (81 to 102 Nm) for Eaton
Fuller transmissions with 1-1/4-inch pipe
threads.
42 lbfft (57 Nm) for all Mercedes-Benz
transmissions.

Mercedes-Benz Transmissions

Business Class M2 Maintenance Manual, March 2005

26/1

26

Transmission

2602 Eaton Fuller

Transmission Fluid
Changing and Magnetic
Plug Cleaning
Eaton Fuller has a complete listing of approved lubricants for its transmissions on its internet website.
Refer to the Eaton website for additional information,
www.roadranger.com.

Draining
IMPORTANT: Manual transmissions filled with
approved synthetic lubricants require a lubricant
drain and fill, and a magnetic plug cleaning
every 500,000 miles (800 000 km), regardless
of the service or vocation of the vehicle. Manual
transmissions with petroleum-based lubricants
require a lubricant drain and fill, and a magnetic
plug cleaning at each Maintenance 2 (M2) interval. All transmissions, regardless of lubrication
used, also require a check of the transmission
breather at each Maintenance 1 (M1) interval.
1. Park the vehicle on a level surface. Apply the
parking brakes and chock the rear tires.
2. Drain the fluid while the transmission is warm, as
follows.
2.1

Clean the area around the drain plug(s).

Remove the drain plug(s) from the gear
case.

2.2

Clean the area around the fill plug. Remove the fill plug from the gear case.

3. Clean the magnetic plug(s) before installing it.

Use a piece of key stock, or any other convenient steel slug, to short the two magnetic poles
and divert the magnetic field.
4. Install and tighten the drain plug(s) 50 lbfft (68
Nm).

Filling
CAUTION
Operating a manual transmission with the fluid
level higher or lower than recommended can result in transmission damage. Do not overfill the

26/2

transmission; overfilling will force fluid out of the

case through the main shaft openings. Fluid overflow may also drain onto the clutch or clutch
brake, causing additional problems.

IMPORTANT: Do not mix types of fluid, because

of possible incompatibility. Do not use multiviscosity fluids or EP (Extreme Pressure) gear
fluids. Do not use fluid additives or friction modifiers. If switching from a petroleum-based lubricant to a synthetic lubricant, all areas of each
affected component must be thoroughly drained.
Switching to a synthetic lubricant, when a
petroleum-based lubricant has been used for
50,000 miles (80 000 km) or longer may affect
transmission performance. Monitor all seal
areas for the first 10,000 miles (16 000 km)
after changing to a synthetic lubricant from a
petroleum-based lubricant.
NOTE: The correct fluid level is established by
checking at the fill plug opening.
1. Add fluid until it is level with the lower edge of
the fill opening. See Fig. 1. If the transmission
has two fill openings, add fluid to the level of
both fill openings. See Table 1 for approved
transmission lubricants, and Table 2 for lubricant
capacities.
2. Clean the fill plug, then install it in the transmission. Tighten the plug as follows:
25 to 35 lbfft (34 to 48 Nm) for Eaton
Fuller transmissions with 3/4-inch pipe
threads.
60 to 75 lbfft (81 to 102 Nm) for Eaton
Fuller transmissions with 1-1/4-inch pipe
threads.

2603 Allison and Eaton Fuller

Transmission Breather
Checking
Transmission housing breathers (if equipped) must
remain clear. A plugged breather could result in pressure build-up, which could cause oil leakage.
If the breather is plugged, clean or replace it. See
Fig. 2. Check more often if the vehicle is operating
under very dusty conditions.

Business Class M2 Maintenance Manual, March 2005

26

Transmission

Eaton Fuller Transmission Lubricant Capacities*

Transmission Model

Lubricant
Capacity:
qt (L)

5-Speed
FS4205A/B, FS5205A/B

6.25 (5.9)

FS6305A/B

9.75 (9.2)

6-Speed
FS5406A

9.75 (9.2)

FS6406A, FSO6406A

9.75 (9.2)

FO6406A, FO-8406

10.5 (10.0)

FSO8406A

9.75 (9.2)

7-Speed
T14607A/B

18 (17.5)

TX14607B

18 (17.5)

RT6609A

6 (5.7)

RT8709B

13.0 (12.3)
13.5 (12.7)

10-Speed
FR9210B

11.75 (11)

FRO14210C, FRO15210C

11.75 (11)

RT8908LL

14 (13.2)

RTO10910B AS2

13 (12.3)

RTO11908LL

14 (13.2)

11-Speed
RTO11909ALL

14 (13.2)

13-Speed
RTLO14913A

NOTE: Location of the transmission breather will vary

depending on transmission model.
Fig. 2, Transmission Breather (Eaton Fuller shown)

9-Speed

RT8608L

f260007a

05/27/93

14 (13.2)

18-Speed
RTLO14918B

14 (13.2)

RTLO16918B

14 (13.2)

* Quantities listed are approximate. Fill the transmission until the lubricant

is level with the bottom of the fill hole, with the vehicle in normal operating
position.

Table 2, Eaton Fuller Transmission Lubricant

Capacities

2604 Eaton Fuller

Transmission Air Filter/
Regulator Element
Cleaning
NOTE: Eaton Fuller FS/FO and T/TX transmissions do not have an air filter/regulator element
that can be serviced.

WARNING
Exhaust the air supply before servicing the air
filter/regulator; otherwise, serious personal injury
and component damage could result.
1. Exhaust the air from the air reservoirs.
2. Clean the outside of the air filter/regulator with
cleaning solvent, then let it air dry. See Fig. 3.
3. Remove the end cap, large O-ring, and filter element from the filter housing. See Fig. 4. Remove
the small O-ring from the end cap.

NOTE: Do not remove, disassemble, or adjust

the air regulator. If the air regulator is not keeping the air pressure between 57 to 62 psi (396
to 431 kPa), replace the air filter/regulator. It
cannot be repaired.
4. Clean the filter element.

Business Class M2 Maintenance Manual, March 2005

26/3

26

Transmission

ment will last the life of the vehicle, provided it is not damaged.
4.2

Wipe out the filter housing with a clean,

dry, lint-free rag.

5. Clean and inspect the O-rings and the end cap.

Replace any parts that are damaged.
6. Install the large O-ring, then the filter element
(small end first) into the filter housing.
7. Install the small O-ring in the end cap, then install the end cap on the filter housing. Tighten
the end cap until firm.
8. Start the engine, and build pressure in the air
system. Check for air leaks at the filter housing
and air line connections, and repair any leaks.

CAUTION
f260037a

05/27/93

NOTE: Location of the air filter/regulator will vary depending on transmission model.
Fig. 3, Eaton Fuller Transmission Air Filter/Regulator
Location

1
f260052a

10/17/2001

1.
2.
3.
4.

Air Regulator
Housing
Large O-Ring
Filter Element

5. Small O-Ring
6. End Cap
7. Plug

Fig. 4, Eaton Fuller Transmission Air Filter/Regulator

Components

4.1

26/4

Dip the filter element in alcohol or other

cleaning solvent. Blow compressed air
through the filter element (inside to outside) to loosen surface dirt and to dry the
element. The sintered metallic filter ele-

Repair any air leaks. A leaking air filter or air lines

can cause slow or hard shifting of the transmission, and eventual transmission damage.

2605 Allison Transmission

Fluid and Filter
Changing
When draining transmission fluid, check for evidence
of dirt or water contamination. A small amount of
condensation will appear in the fluid during operation.
Water contamination is normally characterized as a
milky discoloration of the transmission fluid. Obvious
contamination of the transmission fluid indicates a
leak between the water and fluid areas of the transmission cooler. Inspect and pressure-test the cooler
to confirm the leak; replace leaking transmission
coolers.

1000/2000/2400 Series
1. Park the vehicle on a level surface and apply the
parking brakes.
2. Run the engine until the transmission fluid
reaches the operating temperature of 160 to
200F (71 to 93C). Shift the transmission to
neutral (N) and shut down the engine.

Business Class M2 Maintenance Manual, March 2005

26

Transmission

CAUTION
To prevent dirt from entering the transmission,
use only clean containers and fillers for the transmission fluid. Do not use fillers or containers that
have been used for water or antifreeze. Dirt, water,
or antifreeze could damage the transmission.
3. Clean the area around the drain plug. Place a
drain pan under the transmission and remove the
drain plug. Examine the fluid while it drains. If
only the filter is being changed, do not drain the
fluid.

NOTE: A lot of fluid will drain when the filter is

removed.
4. Using a standard strap-type filter wrench, remove
the filter by turning it counterclockwise.
5. Remove the magnet from the filter attachment
tube or from the top of the filter element.
6. Clean any metal debris from the magnet. Then,
install the magnet on the filter attachment tube.
7. Using transmission fluid, lubricate the gasket on
the filter.
8. Using your hand, install the filter by turning it
clockwise until the filter gasket contacts the converter housing or cooler manifold. Then, turn the
filter one more complete turn.
9. Install the drain plug and sealing washer. Tighten
the plug 22 to 30 lbfft (30 to 40 Nm).
10. Clean the area around the fill tube and remove
the dipstick. Using a clean funnel in the fill tube,
add transmission fluid. See Table 3 for approved
transmission lubricants, and Table 4 for lubricant
capacities.
11. Check and adjust the fluid level using the procedure under "Checking the Fluid Level."

MD and HD Series
CAUTION
To prevent dirt from entering the transmission,
use only clean containers and fillers for the transmission fluid. Do not use fillers or containers that
have been used for water or antifreeze. Dirt, water,
or antifreeze could damage the transmission.

Business Class M2 Maintenance Manual, March 2005

Approved Allison Transmission Lubricants

Lubricant Type*

Temperature: F (C)

All Allison Transmissions

Castrol TranSynd (synthetic)

Above 22 (30)

Dexron

Above 13 (25)

III

* Lubricants listed in order of preference. Do not mix types of oil.

Table 3, Approved Allison Transmission Lubricants

Allison Transmission Lubricant Capacities
Transmission Model

Fill Capacity:*
qt (L)

On-Highway Transmissions
1000/2000/2400 Series (standard sump)

15 (14)

1000/2000/2400 Series (shallow sump)

13 (12)

HD/MD Series
HD4060/4560 (standard sump)

36 (34)

HD4060/4560 (shallow sump)

26 (25)

MD3060/3066/3560 (standard sump)

19 (18)

MD3060/3066/3560 (shallow sump)

10.5 (10)

* Quantities listed are approximate. Add the recommended amount of fluid

as listed under fill capacity, then perform a "hot check" and add fluid as
needed. Do not overfill.
Add 3 quarts (3 liters) if equipped with a PTO.

Table 4, Allison Transmission Lubricant Capacities

1. Park the vehicle on a level surface and apply the

parking brakes.
2. Operate the vehicle until the transmission
reaches normal operating temperature: 160 to
200F (71 to 93C).
3. Clean the area around the drain plug and the
transmission fluid pan. Place a drain pan under
the transmission and remove the drain plug. Examine the fluid as it drains. If only the filter is
being changed, do not drain the fluid.
4. Remove the 12 mounting bolts (six each) from
the two filter covers.

NOTE: A lot of fluid will drain when the filter

covers are removed.
5. Remove the filter covers, O-rings, and two
square-cut seals from the transmission. See
Fig. 5.

26/5

26

Transmission

9. Install the filter and cover assemblies into the

filter compartment.
1

10. Align each cover assembly with the holes in the

channel plate sump, and push the cover assemblies in by hand to seat the seals.

CAUTION
Do not use the bolts to draw the filter covers to
the sump. This can damage the covers, seals, or
sump.
11. Install six bolts in each cover, and torque the
bolts 38 to 44 lbfft (51 to 61 Nm).
12. Install a new drain plug O-ring, and install the
drain plug. Tighten the drain plug 18 to 24 lbfft
(25 to 32 Nm).
13. Refill the transmission with fresh Dexron transmission fluid (see Table 3) and check the fluid
level. See Table 4 for lubricant capacities.
14. Check and adjust the fluid level using the procedures under "Checking the Fluid Level."

Checking the Fluid Level

CAUTION

3
3
4

Operating a transmission with the fluid level

higher or lower than recommended can result in
transmission damage. Do not overfill the transmission.

4
1

Do not mix types and brands of fluid, because of

possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear
fluids, or multiviscosity lubricants.

08/25/95

1. Filter Cover
2. Filter Element

f260317

3. Filter Element O-Ring

4. Square-Cut Seal

Fig. 5, Allison MD and HD Series Transmission Filter

Locations and Components

6. Remove the filters from the bottom of the control

module.
7. Lubricate the new O-rings with transmission fluid,
and install them on the cover assemblies.
8. Install a new square-cut seal on each cover assembly, and install the fluid filter elements on the
cover assemblies.

26/6

Cold Check
Clean all dirt away from around the end of the fluid
fill tube before removing the dipstick.

CAUTION
Do not allow foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system
may cause undue wear of transmission parts,
make valves stick, and clog passages.
It is important to check the fluid level cold to determine if the transmission has a sufficient amount of

Business Class M2 Maintenance Manual, March 2005

26

Transmission

fluid to be safely operated until a hot check can be

performed.

Fluid foaming and aeration cause transmission

overheating and erratic shifting.

1. Park the vehicle on a flat, level surface.

2. Apply the parking brakes and chock the rear
tires.

NOTE: Perform a hot check at the first opportunity after the normal operating temperature, 160
to 200F (71 to 93C) has been reached.

3. Run the engine for at least one minute.

Hot Check

4. Shift from DRIVE to NEUTRAL, and then shift to

REVERSE to fill the hydraulic system.
5. Shift to NEUTRAL and allow the engine to idle at
500 to 800 rpm.

1. Park the vehicle on a flat, level surface. Apply

the parking brakes and chock the rear tires.
2. Shift the transmission to NEUTRAL.

7. Insert the dipstick into the tube, then remove the

dipstick.

3. Operate the engine at idle (500 to 800 rpm) until

normal operating temperature is reached. Check
that the sump temperature is 160 to 200F (71 to
93C). Check that the converter-out temperature
is 180 to 220F (82 to 104C).

8. Check the fluid level reading and repeat the

check procedure to verify the reading.

4. With the engine idling, remove the dipstick from

the tube and wipe it clean.

6. With the engine running at idle, remove the dipstick from the tube and wipe it clean.

If the fluid level is within the COLD RUN band,

the transmission may be operated until the fluid
is hot enough to perform a HOT RUN check.
If the fluid level is not within the COLD RUN
band, add or drain fluid as needed to adjust the
fluid level to the middle of the COLD RUN band.
See Fig. 6.
B

5. Insert the dipstick into the tube, then remove it.

6. Check the fluid level reading and repeat the
check procedure to verify the reading. Safe operating level is within the HOT RUN band on the
dipstick. The HOT RUN band is between the
HOT FULL and HOT ADD marks.
If the fluid level is not within the HOT RUN band,
add or drain fluid as needed to bring the fluid
level within the HOT RUN band. See Fig. 6.

2606 Mercedes-Benz
Transmission Fluid
Changing and Magnetic
Plug Cleaning

f270002a

12/01/97

A. Cold Run Band

B. Hot Run Band

Fig. 6, Dipstick Markings

CAUTION
Do not fill above the COLD RUN band if the transmission fluid is below normal operating temperature. As fluid temperature increases, so does the
fluid level. Filling above the COLD RUN band
when the transmission is below normal operating
temperature may result in an overfilled transmission, which causes fluid foaming and aeration.

Business Class M2 Maintenance Manual, March 2005

Draining
1. Park the vehicle on a level surface. Apply the
parking brakes and chock the rear tires.

NOTE: Drain the transmission fluid while the

transmission is warm.
2. Drain the transmission fluid, as follows. See
Fig. 7.
2.1

Remove the magnetic drain plug from the

bottom of the gear case.

2.2

Discard the aluminum gasket.

26/7

26

Transmission

sion lubricants and Table 6 for lubricant

capacities.

10/05/94

A. Full

05/22/2001

f261102

NOTE: The transmission is shown from the left-hand

side.
1. Transmission
2. Fill Plug

3. Drain Plug

Fig. 7, MBT Drain and Fill Plugs

2.3

Catch the transmission fluid in a suitable

container and dispose of it properly.

f260006b

B. Low
Fig. 8, MBT Fluid Level Checking
MB Transmission Lubricant Types

Manufacturer

Type

Mobil

Mobiltrans SHC DC

Table 5, MB Transmission Lubricant Types

MB Transmission Lubricant Capacities

3. Clean the area around the fill plug. See Fig. 7

for the location of the fill plug

Transmission Model

Refill Capacity:*
qt (L)

4. Remove the fill plug from the side of the case.

Discard the aluminum gasket.

MBT660S-6O

9.5 (9.0)

MBT520S-6D

9.5 (9.0)

NOTE: Use a piece of key stock, or any other

convenient steel slug, to short the two magnetic
poles and divert the magnetic field.

* Quantities listed are approximate. Fill the transmission until the lubricant
is level with the bottom of the fill hole, with the vehicle in normal operating
position.

Table 6, MB Transmission Lubricant Capacities

5. Clean the magnetic drain plug before installing it.

6. Install the drain plug (p/n A 124 997 01 32) and a
new aluminum gasket (p/n N 00763 024105).
Tighten the drain plug 42 lbfft (57 Nm).

Filling
CAUTION
Operating a manual transmission with the fluid
level higher or lower than recommended can result in transmission damage. Do not overfill the
transmission; overfilling will force fluid out of the
case through the main shaft openings. Fluid overflow may also drain onto the clutch or clutch
brake, causing additional problems.
1. Add transmission fluid until it is level with the
lower edge of the fill opening. See Fig. 8 for the
correct level. See Table 5 for approved transmis-

26/8

CAUTION
Use only the approved Mobiltrans SHC DC fluid.
Do not mix fluid types. Adding Mobiltrans SHC 50
RN 2952 E-5 fluid (used in Eaton and Meritor
transmissions) could damage the radial seals.
2. Clean the fill plug before installing it.
3. Install the fill plug (p/n N000908 020001) and a
new aluminum gasket (p/n N 00763 024105).
Tighten the fill plug 42 lbfft (57 Nm).

2607 Mercedes-Benz
Transmission Leak
Checking
1. Park the vehicle on a level surface. Apply the
parking brakes and chock the rear tires.

Business Class M2 Maintenance Manual, March 2005

26

Transmission

2. Check for signs of leakage at the breather. See

Fig. 9.
1

5.1

If the flat seal is damaged, replace it.

5.2

If the cover-plate bolts are too loose,

tighten them 18 lbfft (25 Nm). If the
cover-plate bolts are too tight, replace the
flat seal and tighten to 18 lbfft (25 Nm).

6. Check for signs of leakage at the transmission

fluid fill plug. If leakage is found, check the
torque on the plug and check the aluminum gasket for damage.
9

6.1

If the gasket is damaged, replace it.

6.2

If the fill plug is too loose, tighten it 42

lbfft (57 Nm). If the fill plug is too tight,
loosen it, then tighten it to 42 lbfft (57
Nm).

4
05/22/2001

f261101

NOTE: The transmission is shown from the left-hand

side.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Shift Lever Cap Seal

Breather
Output Shaft Radial Seal
Countershaft Cover Plate
Transmission Fluid Fill Plug
Transmission Fluid Drain Plug
Gear Case Seals
Clutch Slave Cylinder
Input Shaft Radial Seal
Fig. 9, MBT Leak Check

2.1

If leakage is found, check the breather for

a missing cap. Replace the cap if necessary.

2.2

Check the fluid level at the fill plug. If the

level is too high, correct the fluid level.

3. Check for signs of leakage at the cap seal on the

shift lever. If the cap seal is damaged, replace it.
4. Check for signs of leakage at the radial seal on
the output shaft. If leakage is found, remove the
output yoke (end yoke) and replace the seal. For
procedures, see Section 26.02, Subject 120 of
the Business Class M2 Workshop Manual.

NOTE: There are two cover plates on the countershaft, one at the front and one at the rear.
5. Check for signs of leakage at the rear cover
plate on the countershaft (next to the output
yoke). If leakage is found, check the torque on
the cover-plate bolts and check the flat seal for
damage.

Business Class M2 Maintenance Manual, March 2005

7. Check for signs of leakage at the transmission

fluid drain plug. If leakage is found, check the
torque on the plug and check the aluminum gasket for damage.
7.1

If the gasket is damaged, replace it.

7.2

If the drain plug is too loose, tighten it 42

lbfft (57 Nm). If the plug is too tight,
loosen it, then tighten it to 42 lbfft (57
Nm).

8. Check for fluid dripping at the gear case seals. If

substantial leakage is found at either location,
replace the transmission.

NOTE: Weeping or sweating seals are not

cause for transmission replacement.

WARNING
Clutch hydraulic fluid (DOT 4 brake fluid) is hazardous. It may be a skin irritant and can cause
blindness if it gets in your eyes. Always wear
safety glasses when handling clutch hydraulic
fluid or bleeding hydraulic lines. If you get clutch
hydraulic fluid on your skin, wash it off as soon
as possible.
9. Check for signs of leakage at the clutch slave
cylinder.

CAUTION
Do not spill clutch hydraulic fluid (DOT 4 brake
fluid) on the cab paint. Clean it off immediately if
any is spilled. DOT 4 brake fluid can damage
paint.

26/9

26

Transmission

9.1

If leakage is found on the slave cylinder

body, check the fittings and hose for damage.

9.2

If leakage is found on the piston seals,

replace the slave cylinder and bleed the
clutch hydraulic system. For detailed instructions, see Group 25 of the Business
Class M2 Workshop Manual.

9.3

If the slave cylinder fittings and/or the

hose are damaged, replace them.

9.4

Check the torque on the slave cylinder

mounting capscrews. Tighten them 13
lbfft (18 Nm).

9.5

If any leakage of clutch hydraulic fluid is

found, check the fluid level in the reservoir, and add fluid if needed. For detailed
procedures, see Group 25 of this
manual.

NOTE: There are two cover plates on the countershaft, one at the front and one at the rear.
10. Check for signs of leakage at the clutch bell
housing. If leakage is found, check the radial
seal on the input shaft, the front cover plate on
the countershaft (inside the clutch bell housing),
and the rear radial seal on the crankshaft.
10.1

If the radial seal on the input shaft is

leaking, replace the radial seal. For procedures, see Section 26.02, Subject 120
of the Business Class M2 Workshop
Manual.

10.2

If the cover plate on the countershaft is

leaking, replace the cover plate. Apply
liquid gasket (Loctite 518) to the new
cover plate when installing it.

10.3

If the rear radial seal on the engine

crankshaft is leaking, replace the rear radial seal. For procedures, see the engine
manufacturers manual.

11. Remove the chocks from the tires.

26/10

Business Class M2 Maintenance Manual, March 2005

Frame and Frame Components

31
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Fifth Wheel Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3102
Fifth Wheel Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103
Frame Fastener Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101
Trailer Electrical Connector Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3104

Business Class M2 Maintenance Manual, May 2011

31

Frame and Frame Components

3101 Frame Fastener Torque

Checking
Frame brackets and components secured with Huckbolt fasteners do not require a torque check, however, they should be inspected for damage. Frame
brackets and components secured with conventional
bolts and nuts are to be checked at initial maintenance (IM).
Check the torque of frame fasteners to offset the effects of bedding in or seating. When possible, always
check the torque of the nut, not the bolt head. This
will give a true torque reading by eliminating bolt
body friction.
When checking the torque of frame fasteners, inspect the frame for cracks and other damage. Set a
click-type torque wrench to the maximum torque of
the fastener you are checking. Apply pressure until
the torque wrench clicks. Do not loosen the bolt to
check the torque. See the applicable torque table in
Group 00 for torque specifications.

NOTICE
Make sure frame fasteners are properly tightened.
Continued vehicle operation with loose fasteners
could result in bracket or frame damage.

NOTE: Engine supports on vehicles built from

January 2007 do not require checking.
Inspect the fasteners at the following locations:
axle stops
equalizer brackets
engine trunnion supports
exhaust brackets
fifth wheel legs
fifth wheel mountings
frame crossmembers and gussets
front frame brackets
front suspension spring brackets
fuel tank brackets
radius rods
rear suspension spring brackets

shock absorbers
all other frame fasteners
Any component that shows signs of cracking or damage must be repaired or replaced. See the applicable
group in the Business Class M2 Workshop Manual
for repair or replacement information.

3102 Fifth Wheel Inspecting

WARNING
All fifth wheel maintenance, adjustment, and rebuilding must be done only by a qualified mechanic. Improper or incomplete procedures could
result in a possible disengagement of the trailer
from the tractor, which could result in personal
injury or property damage.
Parts are under spring compression. Wear safety
goggles while servicing the fifth wheel. Failure to
do so can result in personal injury, due to parts
ejecting with force.

Fontaine
1. Disconnect the tractor from the trailer. For instructions, see the Business Class M2 Drivers
Manual.
2. Thoroughly steam clean the fifth wheel.
3. Check for cracks in the fifth wheel assembly,
mounting brackets, and mounting parts.
4. Ensure that both bracket pins are in place and
secured by retainer pins and cotter pins. See
Fig. 1.
5. For fifth wheels equipped with bracket liners,
rock the fifth wheel. If it does not rock freely, remove the top plate and inspect the bracket liners. Replace liners that are broken or less than
0.125 inch (3 mm) thick at the top of the liners.
For the liner replacement procedure, see the
Fontaine website, www.fifthwheel.com.
6. Check the jaw and stationary jaw for mushrooming, and check that the serrations at the jaw and
wedge are in good condition.
7. Test the secondary safety lock latch for ease of
operation.

rear engine supports

Business Class M2 Maintenance Manual, May 2011

31/1

31

Frame and Frame Components

16
13
12
8
8

14

15

17

12

12

12

18

11

10

12

19

6
5

15
20

21

22

27
5

26

6
8
25
1

15
12

2
3

4
12/02/2010

12
24

23

f311134

NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Wedge Stop Rod Nut

Flat Washer, 5/8"
Wedge Stop Rod Spring
Wedge Stop Rod
Grease Fitting
Bracket Pin
Bracket Retainer Pin
Cotter Pin, 3/16" x 1"
Bumper Spring
Handle Spring

11.
12.
13.
14.
15.
16.
17.
18.

Bolt, Secondary Safety Lock

Flat Washer
Secondary Safety Lock
Bushing, Secondary Safety
Lock
Hex Locknut
Pull Handle
Bolt, Bumper
Bushing

19.
20.
21.
22.
23.
24.
25.
26.
27.

Bumper
Timer Spring
Timer
Operating Handle
Bolt, Operating Handle
Bushing, Operating Handle
Hair Pin Cotter
Wedge
Step Jaw

Fig. 1, Fontaine Fifth Wheel

31/2

Business Class M2 Maintenance Manual, May 2011

31

Frame and Frame Components

8. Check for loose nuts or bolts on the fifth wheel

and the mounting. Set a torque wrench to the
maximum torque value for the bolt being
checked, and confirm that the torque is to specification. Do not loosen the bolt to check the
torque. See Group 00 for bolt torque specifications.
9. Check all springs to see if they are securely fastened, and are not deformed.

2
3

WARNING
Do not disassemble the fifth wheel to inspect the
springs. The springs are under extreme pressure,
and could cause serious injury.
10. Check wedge adjustment.
10.1

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

10.2

Release the lock by tripping the release

latch at the bottom of the throat.

10.3

Adjust the wedge stop at the end of the

wedge to approximately 1/4-inch (6-mm)
clearance by turning the wedge stop rod
located on the right side of the top plate.

10/26/2010

f310353b

1. Lubricant Grooves
2. Safety Latch

3. Lock Control Handle

4. Mount

Fig. 2, Simplex Series Fifth Wheel

5. The lever bar and operating handle must be in

proper alignment. See Fig. 3. Replace any bent
or misaligned lever bar or operating rod.
1

11. Replace cracked, worn, or damaged parts with

new parts. Replace all loose mounting bolts with
5/811 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.
12. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
Apply a generous coating of grease to the top
plate to fill the grooves, or depressions, on the
top plate. See MOP 3103 for lubrication instructions.

ConMet Simplex
1. Disconnect the tractor from the trailer. For instructions, see Chapter 10 of the Business
Class M2 Drivers Manual
2. Thoroughly steam-clean the fifth wheel.
3. Check the fifth wheel plate for cracks. Check for
sharp edges on top; the chamfer should be 1/8
to 1/4 inch (3 to 6 mm).
4. When the wheel is locked, the safety latch must
swing free and fall freely into position. See Fig.
2.

Business Class M2 Maintenance Manual, May 2011

f310470

04/11/2011

1. Operating Handle

2. Lever Bar

Fig. 3, Lever Bar and Operating Handle Alignment

6. Check all clinch pins for cracking or damage.

Replace any clinch pin that shows signs of damage.
7. Measure the top plate lift. See Fig. 4.
7.1

Level the fifth wheel plate to a horizontal

position.

31/3

31

Frame and Frame Components

tions, see the Simplex Fifth Wheel Operating and

Maintenance Manual.

10. Replace cracked, worn, or damaged parts with

new parts. Replace all loose mounting bolts with
5/811 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.

1
2
3

04/11/2011

A.
1.
2.
3.
4.
5.

f310475

Extended Top Plate Lift Height

Fifth Wheel Top Plate
Fifth Wheel Frame Mount
Frame Rail
Lifting Point
Static Top Plate Height
Fig. 4, Measuring Fifth Wheel Top Plate Lift

7.2

7.3

Measure the height from a stationary

mounting point, such as the frame rail to
the top of the fifth wheel plate.
Pry up on the fifth wheel plate below the
pin boss, and measure the vertical movement.

NOTE: The bracket connection provides a

9/32-inch (7-mm) vertical clearance to provide cushioning and to avoid downward pinloading while retaining minimum plate lift.
7.4

11. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See Maintenance Operation 3103 for lubrication instructions.

Holland FWS1
1. Disconnect the tractor from the trailer. For instructions, see the Business Class M2 Drivers
Manual.
2. Thoroughly steam clean the fifth wheel.
3. Check the fifth wheel plate for cracks. Check for
sharp edges on top; the chamfer should be 1/8
to 1/4 inch (3 to 6 mm).
4. When the wheel is locked, the safety latch must
swing free and fall freely into position. See Fig.
5.
1

If the plate lift exceeds 5/16 inch (8 mm)

as a result of wear or rubber deterioration, install new, standard or oversized
bracket-shoe rubber pads; see the Simplex Fifth Wheel Operating and Maintenance Manual for replacement instructions.

NOTE: Do not measure plate lift immediately

after a trailer has been uncoupled from the fifth
wheel. The rubber may have taken a temporary
set, which will normally recover after being uncoupled for a short period of time.
8. Check the clearance between the kingpin and
the jaw of the fifth wheel. If the clearance is
greater than 1/8 inch (3 mm), dial out the slack
using the eccentric jaw pin. For detailed instruc-

31/4

9. Check all mounting bolts for signs of fatigue, and

tighten them to the proper torque. For torque
specifications, see Group 00. Inspect all angles,
plates, and brackets for cracks or other damage.

2
3

10/29/2007

f311052

1. Lubricant Grooves
2. Safety Latch

3. Release Handle
4. Mount

Fig. 5, Holland FWS1 Fifth Wheel

Business Class M2 Maintenance Manual, May 2011

31

Frame and Frame Components

5. The lever bar and release handle must be in

proper alignment. See Fig. 6. Compare the lever
bar and release handle alignment to a new, or a
properly operating lever bar and release handle.
Replace any bent or misaligned lever bar or release handle.
1

4. Check the fastener torques on the fifth wheel

assembly and fifth wheel mounting. Tighten bolts
and nuts as needed. Replace missing or damaged bolts.
5. Inspect the fifth wheel for bent, worn, damaged,
and missing parts; replace them as needed with
genuine Holland parts.
6. Using a Holland Kingpin Lock Tester (Holland
tool number TF-TLN-5001, available through the
PDCs as HLD TFTLN5001), check the operation
of the locking mechanism by opening and closing
the locks. See Fig. 7.
7. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See MOP 3103 for lubrication instructions.

2
f310470

01/13/2011

1. Release Handle

2. Lever Bar

Fig. 6, Lever Bar and Release Handle Alignment

6. Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of
damage.
7. Check all mounting bolts for signs of fatigue, and
tighten them to the proper torque. For torque
specifications, see Group 00. Inspect all angles,
plates, and brackets for cracks or other damage.
8. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
5/811 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.
9. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See MOP 3103 for lubrication instructions.

Holland FW35
1. Disconnect the tractor from the trailer. For instructions, see the Business Class M2 Drivers
Manual.
2. Thoroughly steam clean all fifth wheel components before inspection.
3. Check for cracks in the fifth wheel assembly,
mounting brackets, and mounting parts.

Business Class M2 Maintenance Manual, May 2011

04/11/2011

f310887

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

wheel.
B. The locks should be completely closed around the
kingpin.
Fig. 7, Holland Fifth Wheel Properly Closed

Jost
1. Disconnect the tractor from the trailer. For instructions, see the Business Class M2 Drivers
Manual.
2. Thoroughly steam clean the fifth wheel.
3. Check the mounting for missing or damaged fasteners, and broken components. Replace or repair as needed.

31/5

31

Frame and Frame Components

4. Inspect the bracket pin bolts. Make sure the locking tabs are properly securing the bolts in place.
See Fig. 8.

E
D

09/01/2009

f311101

Fig. 8, Bracket Pin Bolt Locking Tabs

5. Check the fifth wheel for bent, worn, or broken

parts. Replace as needed.
6. If the fifth wheel is equipped with low-lube plates,
check the plates and replace if damaged or worn
down to the securing bolts. It is normal for outside edges of the plate to pucker slightly; this
does not affect performance.

7. Check the fifth wheel adjustment. Using a lock

tester, lock and unlock the fifth wheel several
times. Make sure that the locking mechanism
works properly.

H
G

The lock is properly adjusted if: the wheel locks

and unlocks easily each time and the lock tester
rotates freely.
The lock is too loose if: you feel fore-aft play
when pulling and pushing on the lock tester
handle. See Fig. 9, Ref. A.
The lock is too tight if: the lock tester does not
rotate freely in the lock. See Fig. 9, Ref. B.
8. If the lock is improperly adjusted, correct as follows.

If the lock is too tight, loosen the jam nut, turn

the adjustment bolt clockwise one full turn, then
reset the jam nut. Lock and unlock the mechanism several times to test. Repeat if necessary.
See Fig. 10.
If the lock is too loose, loosen the jam nut, turn
the adjustment bolt counterclockwise one full
turn, then reset the jam nut. Lock and unlock the

31/6

B
f311099

09/01/2009

A.
B.
C.
D.
E.
F.
G.
H.

Checking for fore/aft play.

Rotating tester in lock.
Engage hook.
Pull/push handle fore/aft.
Check for movement of kingpin in lock.
Disengage hook.
Push/pull handle inboard/outboard.
Rotate lock tester.
Fig. 9, Jost Fifth Wheel Adjustment

mechanism several times to test. Repeat if necessary. See Fig. 10.

9. If the fifth wheel is equipped with a sliding
mechanism, inspect and adjust it as follows.

Business Class M2 Maintenance Manual, May 2011

31

Frame and Frame Components

justment, refer to the fifth wheel installation instructions.

10. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
5/811 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.

11. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
Apply a generous coating of grease to the top
plate to fill the grooves, or depressions, on the
top plate. See MOP 3103 for lubrication instructions.

3103 Fifth Wheel Lubricating

Fontaine

09/02/2009

f311100

1. Jam Nut
2. Adjustment Bolt

3. Grease Zerk

Fig. 10, Jost Fifth Wheel

9.1

Check the bracket for any cracks or missing and damaged parts.

9.2

Inspect the locking plungers for full engagement.

9.3

Check the locking mechanism for proper

operation.

If the plungers will not release, check the

air cylinder or plunger adjustment.
If the plungers are loose, check the
plunger adjustment and the plunger
springs for proper compression. Replace
if needed.
9.4

The outboard slider assembly requires no

adjustment. If the plungers are loose, inspect and replace locking mechanism
parts as needed.

9.5

The inboard slider is adjustable for frame

width and plunger engagement. For ad-

Business Class M2 Maintenance Manual, May 2011

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

wheel is down) and apply grease to each bearing
area through the zerk fittings located on each
side of the top plate just to the front of the
bracket pins. Continue to apply grease until it is
coming out of the back of the bearing. It may be
necessary to raise the rear of the fifth wheel with
a pry bar to open up the pocket slightly and
allow the grease to flow through. A substantial
amount of grease may be required initially to fill
the reservoir.
Tilt the fifth wheel rearward (the rear of the fifth
wheel is down) and repeat the greasing procedure. Rock the top plate back and forth several
times to spread the grease over the bearing surface.
2. Inspect the trailer kingpin plate and top surface
of the fifth wheel to make sure each is properly
greased. A liberal coating of grease should be
applied to the complete surfaces of both the
trailer kingpin plate and the top surface of the
fifth wheel.

NOTE: Do not use a lube plate (high density

polyethylene) on top of the fifth wheel or on the
kingpin instead of grease without prior approval
by Fontaine Fifth Wheel. The additional thickness of this material can prevent the proper operation of the fifth wheel and may cause a dangerous condition.

31/7

31

Frame and Frame Components

3. Lubricate the fifth wheel prior to opening and

closing. Grease the jaw and wedge with a screwdriver and distribute the grease along the full
length of the jaw and wedge mating surfaces.
See Fig. 11. Open and close the fifth wheel several times to further distribute the grease.
Lightly oil other moving parts in the fifth wheel.
1

2. Using a light oil (such as SAE 10W or 20W

motor oil), lubricate the cam track and pivot. See
Fig. 12.
3. Grease the yoke tips, locks, and the release
handle and spring; see Fig. 13. Grease the
mounting bracket supports through the grease
fittings. A low temp grade grease rated for
-30F (-34C) or lower such as Cato Oil and
Grease #5213, Craftsman Chemical Co. #LTF 2,
Mystic LP-200, or equivalent is recommended.
1

2
3
f310884

04/11/2011

1. Pull Handle
2. Jaw

3. Wedge
12/03/2010

Fig. 11, Fontaine Fifth Wheel

4. Apply grease to the top plate. Spread grease all

over the mating surface of the top plate. Be sure
the grease pockets built into the top plates are
full of grease.

ConMet Simplex
Apply a heavy coat of grease to the top plate, either
through the grease fittings located on the underside
of the top plate, or by direct application.
Apply grease directly to the lock mechanism.
If lubrication fittings are present, lubricate the interface of the steel bracket shoe and bracket trunnion.

Holland FW35

f311136

Use a light oil (such as SAE 10W or 20W motor oil) to

lubricate the cam track and pivot.
1. Cam Plate
Fig. 12, Holland FW35 Fifth Wheel, Oil Lubrication

Jost
Lubricate the kingpin lock using a hand pump grease
gun through the grease zerk on the skirt of the fifth
wheel; see Fig. 10. Apply a light oil to all moving
parts. For sliding fifth wheels spray diesel fuel on the
slide path of the base plate.

NOTICE
Do not use a power grease gun. The pressure will
damage the lube line.

1. Using a water-resistant lithium-base grease,

grease the top plate.

31/8

Business Class M2 Maintenance Manual, May 2011

31

Frame and Frame Components

1. Wash out any existing grease, dirt, and corrosion

on the trailer connectors with electrical contact
cleaner spray.

1
2

2. Grease the trailer connector with a lithium-based

dielectric grease.

4
12/03/2010

1. Release Handle and

Spring
2. Grease Fitting

f311135

3. Yoke Tip
4. Locks

Fig. 13, Holland FW35 Fifth Wheel, Grease Lubrication

If the fifth wheel is not equipped with low-lube plates,

apply a lithium-based grease with extreme pressure
(EP) additive to the trailer contact surface of the fifth
wheel.
NOTE: If the fifth wheel is equipped with low-lube
plates, the top plate only requires lubrication at the
new product break-in stage. The low-lube plates require no further lubrication.

3104 Trailer Electrical

Connector Lubricating
In some cases, failure of trailer cables occurs due to
intrusion of chloride-based road deicing chemicals
into the trailer connector. Once inside the connector,
the chloride-based chemicals corrode the brass terminals and create bridging between positive and
ground terminals.

NOTE: The use of soap is not recommended for

cleaning the electrical connector, as some
soaps may increase the corrosion process.

Business Class M2 Maintenance Manual, May 2011

31/9

Suspension

32
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Suspension Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3201
Suspension Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3202
Suspension U-Bolt Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3203

Business Class M2 Maintenance Manual, July 2010

32

Suspension

3201 Suspension Inspecting

Freightliner Spring Front and
Rear Suspension Spring
Assemblies Inspection
Inspect the front and rear suspension spring assemblies for pitted, cracked, broken, or abnormally bent
leaves, and extreme rust. If any of these conditions
exist, replace the spring assembly. See Group 32 of
the Business Class M2 Workshop Manual for instructions.

WARNING
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one
leaf causes hidden damage to other leaves. Replacement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could
occur. Failure to replace a damaged spring assembly could cause an accident resulting in property
damage, serious personal injury, or death.

IMPORTANT: On multi-leaf suspensions, closely

inspect each component of the leaf spring assemblies, including the brackets, U-bolts, and
related parts.

Freightliner Spring Rear

Suspension Spring Brackets and
Equalizer Brackets (Tandems)
Inspection
Inspect the forward and rear spring brackets, equalizer brackets (tandems), and the wear pads, for
wear, cracks, and other damage. If any of these conditions exist, replace the damaged bracket(s) and
wear pad(s). See Group 32 of the Business Class
M2 Workshop Manual for instructions.

WARNING
Failure to replace the forward spring brackets,
equalizer brackets, or rear spring brackets if they
are worn, cracked, or otherwise damaged could

Business Class M2 Maintenance Manual, July 2010

result in progressive damage to and eventual

breakage of the bracket. This could cause a loss
of vehicle control resulting in property damage,
serious personal injury or death.

Freightliner Spring Tandem Axle

Suspension Crossmember and
Gussets Inspection
Inspect the tandem-axle frame crossmember and
gussets for wear, cracks, and other damage. If any of
these conditions exist, replace the damaged parts.
See Section 31.00, Subject 130, of the Business
Class M2 Workshop Manual for instructions. Check
all fasteners for tightness. See Group 00 of this
manual for torque values.

CAUTION
Failure to replace the suspension crossmember or
gussets if they are cracked, worn, or otherwise
damaged could result in damage to the vehicle
chassis.

Freightliner Spring Shock

Absorber Check
NOTE: Shock absorbers are optional on spring
suspensions.
Make sure that the shock absorber brackets are tight
and that the shock absorber is not striking or rubbing
on the frame or some other part of the chassis.
Check the rubber mounting bushings and replace if
worn. Inspect the shock absorber for oil leakage,
which is defined as being drips of oil on the sides of
the shock absorber.
If the shock absorber is worn or damaged, replace it
with a new one.

Freightliner 23K, 26K, 30K

Spring Single and Tandem
Radius Rod Bushing Check
1. Without detaching the torque arms, use your
hand to attempt to move each of the radius rod
ends up, down, in, and out. If there is any movement, replace the torque arm.

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Suspension

2. Inspect the weld seams between the torque arm

tube and the shorter bushing tubes. If there are
cracks, replace the torque arm. Do not weld the
torque arm for any reason.

A
3

3. Inspect the rubber bushing ends. See Fig. 1. Replace the torque arm for any of the following reasons:
There are gaps between the rubber bushing and the pin or the outer steel sleeve.
Either bushing end contacts a torque arm
pin mounting bolt.

There are cracks in the bushing.

05/27/93

Part of the rubber bushing extends beyond

the outside diameter of the outer bushing
sleeve.

A. Measure the change in gap at this point.

1. Equalizer Bracket
3. Pry Bar
2. Equalizer

f320022a

Fig. 2, Side View of the Equalizer

1
A

05/27/93

f320021a

Fig. 1, Torque Arm Bushings

Freightliner Spring Tandem

Suspension Equalizer Bushing
Check
1. Block the frame up enough to take the weight of
the chassis off of the springs. Attempt to move
the equalizer up and down, by using a pry bar
between the top of the equalizer and the top of
the equalizer bracket. Apply hand-pressure only.
See Fig. 2. If movement at the center of the
equalizer exceeds 1/8 inch (3 mm), replace the
equalizer bushings.
2. With the vehicle unloaded, attempt to move the
equalizer side to side using a pry bar between
the equalizer and frame rail. Apply hand-pressure
only. See Fig. 3. If clearance between the equal-

32/2

4
05/27/93

A.
1.
2.
3.

f320023a

1/8 inch (3 mm) Clearance

Frame Fasteners
4. Equalizer
Frame Rail
5. Equalizer Bracket
Pry Bar
Fig. 3, Top View of the Equalizer

izer assembly and any frame component or fastener is less than 1/8 inch (3 mm), replace the
equalizer bushings.

52-Inch Multi-leaf Spring

Component Check
No lubrication is required on the 52-inch multi-leaf
spring rear suspension.

Business Class M2 Maintenance Manual, July 2010

32

Suspension

Inspect the stabilizer bar, if present, for irregular

bushing wear or cracks in the brackets. Check the
rubber helper spring, if present, for cracks.

60-Inch Tapered Leaf Spring

Component Check
No lubrication is required on the 60-inch tapered leaf
spring rear suspension.
Inspect the rear shackle brackets for bushing wear or
cracks.
Inspect the stabilizer bar, if present, for irregular
bushing wear or cracks in the brackets. Check the
rubber helper spring, if present, for cracks.

Freightliner AirLiner Component

Clearance Check
Check that the air line support brackets are positioned so the air lines do not rub against anything.
Reposition any configurations that could contact and
result in friction and wear. There must be at least 1
inch (25 mm) clearance around the rubber air spring
when inflated. If the clearance is less than 1 inch (25
mm), relocate the obstructing parts.

CAUTION
Failure to relocate obstructing parts could result
in damage to the air spring.

Freightliner AirLiner Component

Inspection and Operation Check
WARNING

3. Inspect the air spring piston for cracks, chips,

and broken areas. Check the air bag for rips,
tears, and holes. Verify that the air spring assembly does not leak.
4. Check the axle connection welds (beam seat to
equalizing beam) and axle adapter to axle for
cracks. If welds are cracked, grind them out and
reweld the parts.
5. Move the axle up and down while checking for
signs of looseness due to worn parts at the front
pivot connections. Replace any worn parts.
6. Inspect the shock absorbers for oil leaks and
worn rubber bushings. Replace the shock absorbers and/or rubber bushings if wear or damage is noted.
7. Inspect the stabilizer bar, if so equipped, for irregular bushing wear or cracks in the brackets.
The stabilizer bar is optional on 10,000- and
15,000-pound AirLiner suspension systems.
8. Remove the safety stands and lower the rear of
the vehicle to the ground. Run the engine until
air pressure of at least 100 psi (689 kPa) is
maintained throughout the system.
9. Check that all air springs are inflated.

Freightliner AirLiner Control Rod

Check
1. Without disconnecting the control rods, use your
hand to attempt to move each of the control rod
ends up, down, in, and out. If there is any movement, examine the control rods for wear or damage. Replace if necessary.
2. Inspect the rubber bushings for cracks or cuts.
3. Check for any shifting of the barpin.

Inspect the components and check their operation

as described below. Failure to perform these inspections and checks could result in separation of
worn suspension components and loss of vehicle
control, possibly causing personal injury or death,
or property damage.
1. Chock the front tires. Raise the rear of the vehicle so the tires just clear the ground and the
suspension is fully extended. Place safety stands
under the vehicle frame.
2. Squeeze all air springs to check for complete
deflation.

Business Class M2 Maintenance Manual, July 2010

4. Check for cracks in the metal components and

welds.

NOTE: The Freightliner AirLiner Suspension is

manufactured at numerous weight ratings up to
46,000 pounds. The control rod on the 46,000pound-rated suspension is larger, and is fastened differently than on other applications.

Freightliner TufTrac
1. Inspect the suspension spring assemblies for
pitted, cracked, broken, or abnormally bent

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Suspension

leaves, and extreme rust. If any of these conditions exist, replace the spring assembly.

WARNING
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one
leaf causes hidden damage to other leaves. Replacement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could
occur. Failure to replace a damaged spring assembly could cause an accident resulting in property
damage, serious personal injury, or death.

IMPORTANT: On multi-leaf suspensions, closely

inspect each component of the leaf spring assemblies, including the brackets, U-bolts, and
related parts.
2. Inspect the brackets for cracks in the castings.
Inspect the V-rod tower welds for cracking or
other signs of damage. Also check for contact
between the frame rail and the upper axle clamp
brackets. If contact exists, check the V-rod bushing for wear. Check the V-rod fastener torques.

sorbers and/or rubber bushings if wear or damage is noted.

Hendrickson Suspension
Inspection
Inspect the suspension assembly for wear, cracks,
and damage to its components. Replace the component(s) if any wear, cracks, or damage exists. Check
all fasteners for tightness.
Check for distorted or frayed rubber at the beam end
bushings. If the bushings are damaged, replace
them.
Check that the ends of the equalizer beam are not
lower in the beam hanger.
If the equalizer beam ends appear lower, use a jack
to raise each beam end, then check for movement of
the inner metal of the rubber end bushing. See Fig.
4. Movement cannot be corrected by tightening the
fastener, because parts could be damaged. If there is
movement, replace the rubber end bushings and all
connecting parts.

3. Inspect the rubber center bearing and spring tip

pads for excessive wear, including de-lamination
of the rubber-to-metal shim interface, and distortion and degradation of rubber.
2

4. Inspect the V-rods and lower control rods for

wear and looseness.
4.1

Without disconnecting the control rods,

use your hand to attempt to move each of
the control rod ends up, down, in, and
out. If there is any movement, examine
the control rods for wear or damage. Replace if necessary.

4.2

Inspect the rubber bushings for cracks or

cuts.

4.3

Check for any shifting of the barpin.

4.4

Check for cracks in the metal components and welds.

5. Check all fasteners for looseness.

f320039a

05/27/93

1. Beam Hanger
2. Equalizer Beam

3. Jack

Fig. 4, Raising the Beam End

After repairs to the suspension, check the fastener

torque after the vehicle has been in service for 2500
miles (4000 km). Tighten the adapter-type beam end
connection nut 210 to 240 lbfft (285 to 325 Nm).
See Fig. 5. Do not overtorque.

6. Inspect the shock absorbers for oil leaks and

worn rubber bushings. Replace the shock ab-

32/4

Business Class M2 Maintenance Manual, July 2010

32

Suspension

1
5
A
2

05/27/93

2
4

f320110a

05/27/93

NOTE: Do not use the three-piece adapter without the

intermediate tube.
1. Nut
2. Adapter
3. Intermediate Tube

4. Inner Metal of Beam

End Bushing
5. Beam Hanger

Fig. 5, Three-Piece Adapter-Type Beam End Connection

WARNING
Insufficient beam end fastener torque could cause
the beam to separate from the axle. This will
cause loss of vehicle control resulting in property
damage, serious personal injury or death.

Hendrickson Leaf Spring

Assembly Inspection
1. Inspect the spring hangers for wear of the spring
pin holes, cams, and the spring hanger legs. See
Fig. 6.
2. If equipped with the RTE series, the gap between the rear (no. 2) spring hanger and the top
spring leaf should measure at least 3/8 inch (9.5
mm) in an unloaded condition.
If the measurement is less than 3/8 inch (9.5
mm), install new rear (no. 3) extension hangers.
Lubricate the bolt threads with SAE 20 oil.
Tighten the 1/213 locknuts with hardened
washers 85 lbfft (115 Nm).
3. Inspect the spring leaves for cracks, gouges,
wear, or abnormal bends. The main (no. 1) and
wrapper spring leaves (no. 2)the top two

Business Class M2 Maintenance Manual, July 2010

A.
1.
2.
3.
4.

f320112a

Minimum gap of 3/8 inch (9.5 mm).

Forward (no. 1) Spring Hanger
Spring Eye Pin
Rear (no. 2) Spring Hanger
Rear (no. 3) Extension
Fig. 6, Unloaded RTE Spring Suspension

spring leavesmay be individually replaced. If

equipped with the RTE series suspension, the
first, second, and third spring leaves (the top
three spring leaves) may be individually replaced. If a spring leaf is damaged below these
numbers in a pack, replace the spring assembly.
In addition, replace both spring assemblies to
ensure even spring deflection.

Hendrickson Radius Rod

Bushing Check
1. Without detaching the torque arms, use your
hand to attempt to move each of the radius-rod
ends up, down, in, and out. If there is any movement, replace the torque arm.
2. Inspect the rubber bushing ends. Replace the
torque arm if there are gaps between the rubber
bushing and the pin or the outer steel sleeve, if
either bushing end contacts a torque arm pin
mounting bolt, if there are cracks in the bushing,
or if part of the rubber bushing extends beyond
the outside diameter of the outer bushing sleeve.

Chalmers Suspension Inspection

Chock the front wheels to prevent the vehicle from
moving. Place the transmission in neutral and release the spring or driveline brakes before inspecting
the rear suspension.

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32

Suspension

Power wash the Chalmers rear suspension or clean

it with a hard-bristle brush before performing a visual
inspection.

1. Visually inspect the rubber bushings for cracks or

other damage.
Try to move the torque rod ends, using your
hands only, and check for any free-play. If freeplay is felt, replace the torque rod end bushing.
Do not use a pry bar to check for free-play. Use
of a pry bar may lead to premature bushing replacement.

2. If equipped with optional shock absorbers, check

for worn, broken, or damaged shock bushings,
heavy corrosion on the shock absorber body, or
fluid leaking from the shock absorber. Replace
the shock absorbers if any of these conditions
are found.
3. Lift the rear of the vehicle and support the frame
on jack stands to unload the suspension components. The vehicle is lifted high enough when the
beam ends are off of the saddles. All jack stands
must be of sufficient strength and rigidity to
safely support the vehicle. Do not perform any
work on or around a vehicle that is supported
solely by a lifting device.
Visually inspect the walking beam for cracks, or
other damage. If damage is found, replace the
walking beam.
Keep the vehicle supported by the jack stands
for the next operation.
4. Manipulate the walking beam so that a micrometer, vernier, or dial caliper can be used to determine the wear area thickness on the bottom
face. See Fig. 7. Measurements should be taken
a minimum of 1/2 inch (13 mm) from the beam
flange edges to eliminate any edge wear that
may have occurred. Subtract the wear area
thickness from the nonwear area to determine
the amount of wear.
If the beams show any wear greater than the
allowable 0.062-inch (1.5-mm) wear, a Chalmers
wear plate must be installed, or the walking
beam must be replaced.
5. Rotate the restrictor cans 360 degrees and visually inspect the cans for cracks, severe corrosion, and distortion. If any of these conditions are
present or the restrictor can is missing, replace
the restrictor can.

32/6

f320432

09/27/95

A. Non-wear Area
1. Walking Beam

B. Wear Area

Fig. 7, Walking Beam End Wear Thickness

WARNING
Replace all cracked or missing restrictor cans.
Failure to do so could lead to loss of vehicle control, which could result in property damage, serious personal injury, or death.
6. Remove the jack stands, then lower the vehicle.
Check that the spring or driveline brake is applied, then remove the wheel chocks.

3202 Suspension Lubricating

Freightliner Spring Front
Suspension
Wipe all dirt from the grease fittings at the forward
spring pin and the spring shackle pins. Then apply
multipurpose chassis grease with a pressure gun
until the old grease is forced out.

Business Class M2 Maintenance Manual, July 2010

32

Suspension

Freightliner Spring Rear

Suspension

Hendrickson Spring Eye Pins,

RT and RTE Series

Single Axle

Apply multipurpose chassis grease at the spring eye

pin grease fitting, located on the inboard side of the
spring eye pin, until clean grease appears at both
ends of the spring eye pin. See Fig. 6.

Lubrication is not required on single-axle spring rear

suspensions.

Tandem Axle

Freightliner TufTrac
CAUTION

If the equalizer cap and tube assembly is

equipped with a nonrelief grease fitting, excessive
lubrication can damage the bushings.
Lubricate the equalizer cap and tube assembly bushings by applying multipurpose chassis grease at the
pressure relief grease fitting. See Fig. 8. Lubricate
with a hand gun or pressure gun until grease is
forced out from the base of the pressure-relief fitting.

The TufTrac suspension is maintenance-free and designed so that lubrication is not required. There are
no provisions for lubrication, and attempting to lubricate the suspension could shorten component life.

3203 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

spring breakage and abnormal tire wear.
A

1. Park the vehicle on a flat surface and apply the

parking brakes. Chock the tires to prevent the
vehicle from moving.

1
05/27/93

320020a

A. Lubricate here.
1. Cap and Tube Assembly Bushing
Fig. 8, Equalizer Assembly Lubrication

Hendrickson Equalizer Beam

End Bushings and Rubber
Center Bushings
No lubrication is required for the equalizer beam end
bushings or equalizer beam rubber center bushings.

Business Class M2 Maintenance Manual, July 2010

2. Check the U-bolt torque in a diagonal pattern.

Set a click-type torque wrench to the highest
torque value for the fastener being checked. See
Table 1 for U-bolt torque specifications. Turn the
wrench in a clockwise motion (looking up) until
the torque wrench clicks.
Spring Assembly U-Bolt High Nut Torque Values*
Size

Torque: lbfft (Nm)

5/818

Stage
Stage
Stage
Stage

1:
2:
3:
4:

Hand-tighten
60 (81)
200 (271)
180 to 230 (245 to 313)

3/416

Stage
Stage
Stage
Stage

1:
2:
3:
4:

Hand-tighten
60 (81)
200 (271)
270 to 330 (367 to 449)

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32

Suspension

Spring Assembly U-Bolt High Nut Torque Values*

Size

Torque: lbfft (Nm)

7/814

Stage
Stage
Stage
Stage

1:
2:
3:
4:

Hand-tighten
60 (81)
200 (271)
420 to 500 (571 to 680)

114

Stage
Stage
Stage
Stage

1:
2:
3:
4:

Hand-tighten
60 (81)
200 (271)
520 to 600 (707 to 816)

* Tighten in a diagonal pattern as shown in Fig. 9.

Table 1, Spring Assembly U-Bolt High Nut Torque

Values

03/10/2011

f320783

Fig. 9, Tightening Pattern for U-Bolt High Nuts

32/8

Business Class M2 Maintenance Manual, July 2010

Front Axle

33
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Draw Key Nut Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303
Kingpin Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301
Tie Rod End Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3304
Tie Rod End Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302
Wheel End Inspection and Maintenance, 6,000-Pound and 8,000-Pound Steer
Axles with Oil-Lubricated Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3305

Business Class M2 Maintenance Manual, July 2009

33

Front Axle

3301 Kingpin Lubricating

Sealed and Easy Steer

KingpinsAxles With Unitized
Wheel Ends

NOTE: This procedure applies to 921, 931, 932,

933, 934, 941, 942, 943, 951, 961, 963, 966,
967, 971, and 975 Series Easy Steer sealed
front axles. Refer to the identification tag on the
front of the axle beam.
On sealed and Easy Steer Plus front axles, the
grease fittings are on the top and bottom kingpin
caps of the knuckle.
1. Shut off the engine, apply the brakes, and chock
the rear tires.

10/10/2001

f330185

2. Make sure the tires touch the ground. Do not

raise the vehicle.

A. Apply lubricant until new lubricant comes from these

areas.
1. Grease Fitting

3. Clean off all grease fittings prior to lubrication.

Fig. 1, Sealed, Easy Steer Kingpin Lubrication

IMPORTANT: Meritor recognizes that industry

trends are moving toward increased selection
and usage of synthetic grease in vehicle maintenance. However, some seals are known to expand when in contact with synthetic grease.
Consult your local Meritor representative for
synthetic grease application references before
using any synthetic grease when performing
axle service and maintenance.
4. Using a multipurpose grease, NLGI grade 1 or 2,
lubricate the kingpins through the grease fittings
on the top and bottom of the knuckle. See
Fig. 1.
5. Apply lubricant until new lubricant comes from
the thrust bearing seal and the upper shim pack.
6. Remove the chocks from the tires.

Easy Steer KingpinsAxles

With Unitized Wheel Ends
NOTE: This procedure applies to Easy Steer
Plus MFS 10-2015-N and MFS 12-2015-N
sealed front axles. Refer to the identification tag
on the front of the axle beam.

Business Class M2 Maintenance Manual, July 2009

On Easy Steer Plus front axles, the grease fittings

are on the top and bottom kingpin caps of the
knuckle.
1. Shut off the engine, apply the brakes, and chock
the rear tires.
2. Make sure the tires touch the ground. Do not
raise the vehicle.
3. Clean off all grease fittings prior to lubrication.

IMPORTANT: Meritor recognizes that industry

trends are moving toward increased selection
and usage of synthetic grease in vehicle maintenance. However, some seals are known to expand when in contact with synthetic grease.
Consult your local Meritor representative for
synthetic grease application references before
using any synthetic grease when performing
axle service and maintenance.
4. Using a multipurpose grease, NLGI grade 1 or 2,
lubricate the kingpins through the grease fittings
on the top and bottom of the knuckle. See
Fig. 2.
5. Force lubricant into the upper and lower kingpin
grease fitting caps until new lubricant flows from
between the upper axle beam end and the

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33

Front Axle

4.2

Inspect the threaded zerk fitting hole in

the tie rod end, and remove any obstructions.

4.3

Install a new zerk fitting.

4.4

Apply lubrication to the new zerk fitting.

1
A

5. Remove the chocks from the tires.

3303 Draw Key Nut Torque

Checking

1
10/11/2001

f330184

A. Apply lubricant until new lubricant comes from these

areas.
1. Grease Fitting
Fig. 2, Sealed, Easy Steer Plus Kingpin Lubrication

Axles With Unitized Wheel Ends

Check the torque of the nut that holds the draw key
on the side of the knuckle. The torque should be 30
to 45 lbfft (41 to 61 Nm). See Fig. 3.

knuckle, and between the lower axle beam end

and the knuckle. See Fig. 2.
6. Remove the chocks from the tires.

3302 Tie Rod End Lubricating

This procedure applies to all tie rod ends on Meritor
nondrive steering axles.
1. Park the vehicle with the wheels in the straightahead position. Turn off the engine, apply the
brakes, and chock the rear tires.
2. Wipe clean the zerk fitting and the seal or boot.

NOTE: Synthetic lubricants are not approved for

tie rod end lubrication.
3. Using a grease gun, apply a multipurpose
grease, NLGI grade 1 or 2, to the zerk fitting until
all the old grease is purged from the boot. Discolored old grease should come out of the purge
holes near the boot crimp or bellows area.
Apply grease until all the old grease is purged
from the boot.

NOTE: If using an air pressure grease gun, do

not exceed 150 psi (1035 kPa).
4. If the tie rod end is designed for lube service and
it does not accept grease, perform the following
substeps.
4.1

Remove the zerk fitting.

10/11/2001

f330186

Fig. 3, Draw Key Nut

3304 Tie Rod End Inspecting

IMPORTANT: If the tie rod end boot is torn or
missing, replace the entire tie rod end. Do not
replace the boot only.
1. Shut off the engine, apply the brakes, and chock
the rear tires.
2. Check the tie rod boot for cracks, tears, or other
damage. If the tie rod boot is damaged, replace
the entire tie rod end.
3. Grasp by hand (or use a pipe wrench with jaw
protectors to avoid gouging the cross tube) and

33/2

Business Class M2 Maintenance Manual, July 2009

33

Front Axle

slightly rotate the cross tube toward the front of

the vehicle and then slightly toward the rear.
Then center the cross tube between the stop positions. If the cross tube does not rotate in either
direction, replace both tie rod ends.
4. Position yourself directly below the ball stud
socket. Using both hands, grab the end as close
to the socket as possible, no more than 6 inches
(15.2 cm) from the end. Firmly apply about 100
pounds of hand pressure in an up and down motion several times. When moving the assembly,
check for any movement at both tie rod ends.
See Fig. 4.
If any movement is detected at one tie rod end,
replace both tie rod ends. Always replace tie rod
ends in pairs, even if only one tie rod end is
damaged.

7. Check for proper installation of the tie rod end

clamp to the cross tube. Make sure that the tie
rod ends are threaded in the cross tube past the
clamps and the slots at the cross tube ends.
8. Check the zerk fittings for damage. If a zerk fitting is damaged, replace it.
Some tie rod ends have no zerk fittings because
they are not greaseable. Do not install a zerk
fitting on a nongreaseable tie rod end.
9. Check that the cotter pin is in place. If it is not,
tighten the tie rod end nut to one of the following
specs depending on the size of the stud.
7/814, 160 to 300 lbfft (217 to 406 Nm)
114, 250 to 450 lbfft (339 to 610 Nm)
1-1/812, 350 to 650 lbfft (475 to 881
Nm)
1-1/412, 500 to 675 lbfft (678 to 915
Nm)
10. Check the steering arm bolts for a minimum
torque of 300 lbfft (406 Nm). If the steering arm
bolt torque has fallen below this specification,
remove the bolt, clean all the threads, and apply
new Loctite 680. Tighten the bolt 300 to 450
lbfft (406 to 610 Nm).
11. Remove the chocks from the tires.

10/10/2001

f330195

Fig. 4, Check Movement of Tie Rod End

CAUTION
Do not attempt to straighten a bent cross tube.
Doing so could result in damage to the axle. Be
sure to replace the cross tube with an original
equipment cross tube with the same length, diameter, and thread size as the existing cross tube.
5. Check the cross tube for cracks or other damage. If the cross tube is bent or damaged, replace the cross tube.
6. Check the clamps for damage. If a clamp is
damaged, replace the clamp. Replace the entire
cross tube assembly if either clamp is welded to
the cross tube.

Business Class M2 Maintenance Manual, July 2009

3305 Wheel End Inspection

and Maintenance, 6,000Pound and 8,000-Pound
Steer Axles with OilLubricated Hubs
Periodic inspection and maintenance of wheel ends
on 6,000-pound and 8,000-pound steer axles is essential to sound wheel bearing performance. Check
for leaks at the oil seal and hub, and inspect the lubricant per the maintenance intervals provided in
Group 00 of this manual.

Oil Seal Leak Check

Check for evidence of oil leakage at the oil seal. If a
leak is found, replace the seal. See Section 33.02 of
the Business Class M2 Workshop Manual for instructions.

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33

Front Axle

Hub Cap Leak Inspection

Check for evidence of oil leakage between the hub
cap, gasket and hub surface. If leakage is evident,
replace the gasket with a new one. See Section
33.01, Subject 100 of the Business Class M2
Workshop Manual for instructions.
Check for a missing hub cap fill plug or vent plug.
See Fig. 5. Replace any missing parts. If a vent plug
is missing, the oil quality is compromised and must
be replaced. See Section 33.01, Subject 100 of the
Business Class M2 Workshop Manual for
instructions.

If the oil is acceptable, check the oil level. If it is not

full (see Fig. 5), fill it to the bottom of the vent plug
hole with approved lubricant (see Table 1).
Lubricant Specifications, Over-the-Road Service
Applications
Lubricant Type

Lubricant SAE
Viscosity Grade

Synthetic Drive Axle Lubricants or

Equivalent with SAE Specification
J2360 or Military Specification MIL-L2105E

75W-90

Table 1, Lubricant Specifications, Over-the-Road

Service Applications

f330247a

01/05/2009

A. Hub Cavity Full

1. Vent Plug
2. Magnetic Drain/Fill Plug
Fig. 5, Stemco Hub Cap

Lubricant Inspection
Rotate the hub so that the fill plug is down, and drain
a small sample of hub oil into a plastic container that
is free of debris, especially any metallic particles.
Then use a magnet to probe the sample. Note
whether there is substantial metallic debris present,
and compare the oil color to new approved oil. Acceptable oil will have a color similar to new oil and
have no water or metal contaminants.
If the oil is not acceptable, inspect the bearings for
damage. Replace the bearings as needed, and install
the hub per Section 33.01, Subject 100 of the
Business Class M2 Workshop Manual.

33/4

Business Class M2 Maintenance Manual, July 2009

Rear Axle

35
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Axle Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3502
Axle Lubricant Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3503
Axle Lubricant Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3501

Business Class M2 Maintenance Manual, December 2001

35

Rear Axle

3501 Axle Lubricant Level

Checking

CAUTION
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage.
1. Clean the oil fill hole plug located in the carrier or
the side of the axle housing and the area surrounding it. See Fig. 1. Remove the plug.

NOTE: Some Meritor axles have a small tapped

and plugged hole located below the housing oil
fill hole. This smaller hole is for the lubricant
temperature sensor only and must not be used
as a fill or level hole.
2. When the vehicle is on level ground, the lubricant must be level with the bottom of the oil fill
hole. If low, add lubricant. See Table 1 for approved axle lubricants and see Table 2 or
Table 3 for axle capacities.

3502 Axle Breather Checking

06/07/94

f350062a

1. Axle Housing Breathers

2. Carrier Oil Fill Plugs
3. Interaxle Differential
Fig. 1, Fill Hole Plug and Axle Housing Breather
Locations

check that the axle breather is open. Check more

often under poor operating conditions. If the breather
is plugged, clean it or replace it as needed.

The axle housing breather must remain clean. See

Fig. 1. When the axle lubricant level is checked,
Meritor Drive Axle Recommended Lubricant
Lubricant Type

Hypoid Gear Oil API Service

Classification GL5

Synthetic Gear Oil

Ambient Temperature

Viscosity Grade

Meritor Specification

10F (12.2C) and up*

85W140

076A

15F (26.1C) and up*

80W90

076D

40F (40C) and up*

75W90

076E

40F (40C) to 35F (2C)

75W

076J

40F (40C) and up*

75W140

076L

40F (40C) and up*

75W90

076N

40F (40C) and up*

75W140

076M

* There is no upper limit on the ambient temperature, but axle sump temperature must never exceed 250 (121C).

Table 1, Meritor Drive Axle Recommended Lubricant

Business Class M2 Maintenance Manual, December 2001

35/1

35

Rear Axle

Meritor Drive Axle Lubricant Capacities for Single

Axles
Axle Model

Capacity*:
pt (L)

MS10113D

14 (6.6)

MS12113D

15 (7.1)

RS13120

18.4 (8.7)

RS15120

14.3 (6.8)

RS17145

33.6 (15.9)

RS17144

32.3 (15.3)

RS19144

32.3 (15.3)

RS19145

33.2 (15.7)

RS21145

32.3 (15.3)

RS21160

39.5 (18.7)

RS21230

38.9 (18.4)

RS23160

39.5 (18.7)

RS23161

39.5 (18.7)

RS23186

47.3 (22.4)

RS23240

37.4 (17.7)

RS26185

38.0 (18.0)

RS30185

38.0 (18.0)

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

Table 2, Meritor Drive Axle Lubricant Capacities for

Single Axles
Meritor Drive Axle Lubricant Capacities for Tandem
Axles
Axle Model
RT40145
RT40145P
RT40160
RT44145
RT44145P

Axle Position

Capacity*

Forward

30.2 (14.3)

Rear

25.8 (12.2)

Forward

30.2 (14.3)

Rear

25.8 (12.2)

Forward

39.1 (18.5)

Rear

34.4 (16.3)

Forward

29.3 (13.9)

Rear

25.1 (11.9)

Meritor Drive Axle Lubricant Capacities for Tandem

Axles
Axle Model
RT46160

Axle Position

Capacity*

Forward

39.1 (18.5)

Rear

34.4 (16.3)

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

Table 3, Meritor Drive Axle Lubricant Capacities for

Tandem Axles

3503 Axle Lubricant Changing

and Magnetic Plug
Cleaning
A regular schedule for changing the axle lubricant in
a particular vehicle and operation can be accurately
determined by analyzing oil samples taken from the
axle at specified intervals or mileages. Lubricant suppliers frequently make their laboratory facilities available for determining the useful life of their product
under actual service conditions. The final schedule
that is recommended may, for economic reasons, be
related to lubricant changes that are governed by
climatic conditions and magnetic plug maintenance.
Change lubricant type and viscosity as climatic temperatures demand, regardless of vehicle mileage or
established change schedule.
The normal operating temperature of compounded
lubricants during the summer season is about 160 to
220F (71 to 104C). The chemicals and additives
that give these lubricants increased load carrying capacity oxidize faster at temperatures above 220F
(104C), contributing to more rapid lubricant deterioration. For this reason lubricants of this type that operate continuously at high temperatures must be
changed more frequently.

CAUTION
Failure to change the axle lubricant at more frequent intervals, when adverse operating conditions require, could result in axle damage.

Axle Draining
1. Remove the plug at the bottom of the housing
and drain the lubricant while the unit is warm.
Allow enough time for all the old lubricant to
drain completely.

35/2

Business Class M2 Maintenance Manual, December 2001

Rear Axle

35

2. Clean the drain plugs. For magnetic drain plugs,

a piece of key stock or any other convenient
steel slug may be used to short the two magnetic
poles and divert the magnetic field.

NOTE: Meritor recommends using magnetic

plugs with elements having a minimum pickup
capacity of two pounds (one kilogram) of lowcarbon steel in plate or bar form. Magnets will
rapidly lose effectiveness as collected material
bridges the gap between the two poles. Clean
or change the plugs before this occurs. It may
be necessary to clean or change the plugs one
or more times between lubrication change intervals.
3. After cleaning the drain plugs, install and tighten
the plugs 35 lbfft (47 Nm).

Axle Filling
1. With the vehicle on a level surface, fill the axle
housings to the bottom of the oil fill hole (in the
carrier or housing) with lubricant. See Table 1 for
approved axle lubricants and see Table 2 or
Table 3 for axle capacities.

NOTE: Some Meritor axles have a small tapped

and plugged hole located below the housing oil
fill hole. This smaller hole is for the lubricant
temperature sensor only and must not be used
as a fill or level hole.
2. Install the fill hole plug and tighten it 35 lbfft (47
Nm).
3. After filling the carrier and housing assembly with
lubricant, drive the vehicle unloaded for one or
two miles (two or three kilometers) at speeds not
to exceed 25 mph (40 km/h) to thoroughly circulate the lubricant throughout the assembly.

Business Class M2 Maintenance Manual, December 2001

35/3

Wheels and Tires

40
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Wheel Nut Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Business Class M2 Maintenance Manual, December 2001

40

Wheels and Tires

4001 Wheel Nut Checking

IMPORTANT: In addition to the maintenance
interval in this manual, check the wheel nut
torque the first 50 to 100 miles (80 to 160 km)
of operation after a wheel has been removed
and installed.
When checking wheel nuts on a stud-piloted dual
disc assembly, remove one outer nut at a time,
tighten the inner nut, then reinstall the outer nut. Repeat this procedure for all of the inner wheel nuts in
the sequence shown in Fig. 1, then tighten all of the
outer wheel nuts in the same sequence.

10

1
8

8
A

2
B

09/18/2001

A. 8-Stud Disc Wheel

f400164

B. 10-Stud Disc Wheel

Fig. 1, Wheel Nut Tightening Sequence

CAUTION
Too little wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Too much wheel
nut torque can break studs, damage threads, and
crack discs in the stud hole area.
See Table 1 for wheel nut torque specifications and
see Fig. 1 for the tightening sequence.
Wheel Nut Torque Specifications
Thread
Size
M20 x 1.5
M22 x 1.5
1-1/816
3/416

Wheel Manufacturer
Accuride Corporation
Alcoa Incorporated
Accuride Corporation
Alcoa Incorporated
Accuride Corporation
Alcoa Incorporated
Accuride Corporation
Alcoa Incorporated

Torque (oiled):
lbfft (Nm)
280 to 330 (380 to
447)
450 to 500 (610 to
678)
450 to 500 (610 to
678)
450 to 500 (610 to
678)

Table 1, Wheel Nut Torque Specifications

Business Class M2 Maintenance Manual, December 2001

40/1

Driveline

41
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Driveline Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4101
Driveline Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4102

Business Class M2 Maintenance Manual, December 2001

41

Driveline

4101 Driveline Inspecting

1. Check the output and input end yokes on both

the transmission and axle for axial looseness.
Refer to the axle or transmission manufacturers
service information for the correct specifications.

Driveline Inspection
WARNING
Do not service or inspect a driveshaft with the engine running. A rotating driveshaft can cause serious personal injury.
Loose end yokes, excessive radial looseness, slip
spline radial looseness, bent shaft tubing, or missing
plugs in the slip yoke can cause universal joint and
bearing defects.
See Fig. 1 for an illustration of the ArvinMeritor
Full-Round driveline. See Fig. 2 for an illustration of
the ArvinMeritor Easy Service or 1/2 Round
driveline.

09/19/2001

If loose, disconnect the driveshaft. For instructions, see Group 41 of the Business Class M2
Workshop Manual. Tighten the end yoke retaining nut to the proper specification. Refer to the
axle or transmission manufacturers service information for the correct specifications.
2. Inspect for worn universal joints. Apply a vertical
force of about 50 pounds to the driveline near
the universal joints. If there is any movement,
replace the universal joint. For instructions, see
Group 41 of the Business Class M2 Workshop
Manual.
3. Examine the slip yoke spline for excessive radial
movement. See Fig. 3. If excessive radial looseness exists between the slip yoke and the tube
shaft, replace the slip yoke and the tube shaft.
For instructions, see Group 41 of the Business
Class M2 Workshop Manual.

f410483

Fig. 1, Full-Round Driveline

f410486

09/19/2001

Fig. 3, Examine the Slip Yoke Spline

4. Examine the shaft for damaged or bent tubing.

Carefully remove any foreign material, such as
mud or dirt on the shaft.

4102 Driveline Lubricating

Driveline Lubrication
09/19/2001

f410484

Fig. 2, Easy Service (1/2 Round) Driveline

Business Class M2 Maintenance Manual, December 2001

The Full-Round and Easy Service drivelines require

periodic lubrication of the universal joints and slip

41/1

41

Driveline

yoke splines. See Fig. 4 for the areas that need lubrication. See Table 1 for approved lubricants.
Approved Lubricants
Lubricant and Specification

Lubricant Brands
Phillips Petroleum Philube MWEP2 Grease
Exxon 5160
Amalie All Purpose Grease with MolyL12M

Universal joint, slip joint, and spline grease

must meet ArvinMeritor Specification O634B
(NLGI Grade No. 2, Lithium 12-Hydroxy
Stearate with Molybdenum Disulfide)

Shell Super Duty Special FF

Marathon Maralube Molycode 529
Shell Moly Poly Grease
Kendall L424 Grease
Amoco Super Chassis Grease
Ford Specification M1C75B or part number PNC1AZ 19590

Table 1, Approved Lubricants

09/19/2001

f410485

Fig. 4, Lubrication Areas for Full-Round and Easy

Service Drivelines

41/2

Business Class M2 Maintenance Manual, December 2001

Brakes

42
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Air Brake Inspecting and Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4213
Air Brake System Valve Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4201
Air Dryer AD9, ADIP, ADIS/DRM Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4210
Bendix AD9 Air Dryer Desiccant Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4202
Bendix ADIP Air Dryer Desiccant Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4205
Bendix ADIS Air Dryer Desiccant Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4209
Bendix Hydro-Max Brake System Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4216
Bosch Hydraulic Brake System Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4204
Brake Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4215
Brake Lines and Fittings Inspecting, Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4211
Brake Pedal Linkage and Mounting Plate Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4212
Foot-Control Valve, E-6, Inspecting and Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4214
Governor D2A Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203
Haldex and Gunite Slack Adjuster Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4206
Meritor Camshaft Bracket Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4207
Meritor Slack Adjuster Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4208

Business Class M2 Maintenance Manual, January 2010

42

Brakes

4201 Air Brake System Valve

Inspecting
IMPORTANT: There is no scheduled (Bendix) air
valve maintenance that requires disassembly of
the valve within the warranty period. If the valve
does not function within the warranty period, do
not disassemble the part as this will void the
warranty.
See the following maintenance operations for
information about Bendix air valve maintenance.

4202 Bendix AD9 Air Dryer

Desiccant Replacing
IMPORTANT: For vehicles equipped with an oilcoalescing air dryer desiccant cartridge, replace
the cartridge once a year, regardless of mileage.
1. Park the vehicle on a level surface, apply the
parking brakes, and chock the tires.
2. Completely drain all air reservoirs. Air pressure
gauges should read 0 psi (0 kPa).

IMPORTANT: The compressor discharge line

may contain residual air pressure.
3. Identify, tag, and disconnect the three air lines
from the end cover.
4. Disconnect the harness connector from the
heater and thermostat assembly.
5. Loosen the capscrew that secures the upper
mounting bracket strap.
6. Remove the two capscrews that sencure the air
dryer to the lower mounting bracket. Mark the
position of the mounting bracket to the end cover
and mark the capscrews to ease installation.
7. Remove the upper mounting bracket strap capscrew, and remove the air dryer from the vehicle.
8. Place the air dryer on a bench and remove the
remaining six capscrews, 12 washers, six nuts,
and the air dryer housing. See Fig. 1. Discard
the nuts. Remove the end-cover-to-housing
O-ring.
9. Clamp the desiccant cartridge in a vise.

Business Class M2 Maintenance Manual, January 2010

WARNING
Clamping the end cover or housing in a vise could
seriously compromise the air dryers ability to
hold air pressure, which could cause a failure in
the brake system, resulting in property damage,
personal injury, or death.
10. Twist the end cover counterclockwise to release
the cartridge from the end cover. Rotate the end
cover until it completely separates from the desiccant cartridge.

NOTE: A substantial torque, up to 50 lbfft (68

Nm), may be necessary to remove the desiccant cartridge.
11. Remove and discard desiccant cartridge O-rings.

NOTICE
Dirt or obstructions in the O-ring grooves can
cause an O-ring failure that will result in an air
leak.
12. Lubricate new O-rings with grease supplied in
the kit and install them in the end cover.
13. Install the desiccant cartridge on the end cover.
Turn the cartridge clockwise until the desiccant
cartridge makes contact with the end cover.
14. Place the desiccant cartridge in a vise, and turn
the end cover clockwise an additional 180 to 225
degrees to fully tighten the desiccant cartridge to
the end cover.

NOTE: Desiccant cartridge torque should not

exceed 50 lbfft (68 Nm).
15. Place the housing over the desiccant cartridge
and align the mounting holes with the end cover.
16. Install the six bolts, 12 washers, and six new
nuts. Torque the nuts in a star pattern 270 to 385
lbfin (3060 to 4340 Ncm). See Fig. 2.
17. Install the air dryer on the lower mounting
bracket. Install the two previously marked bolts,
four washers, and two new nuts. Torque the two
remaining nuts 270 to 385 lbfin (3060 to 4340
Ncm). Install the bolt, two washers, and a new
nut in the upper mounting bracket strap. Torque
the upper mounting bracket strap nut 80 to 120
lbfin (904 to 1356 Ncm).

42/1

42

Brakes

2
11
9

3
4

25

10

10
14

12

10
10
10
10
23

13

10

24

22

15

7
8

21
20
18
17

19
16

08/09/95

1. 5/16 x 4-1/2 Upper Mounting

Bracket Capscrew
2. Upper Mounting Bracket Strap
3. 5/16-Inch Lockwasher
4. 5/16-Inch Nylok Nut
5. Upper Mounting Bracket
6. Housing
7. Nylok Nut
8. 3/8-Inch Special Washer

f421383

9.
10.
11.
12.
13.
14.
15.
16.
17.

Desiccant Cartridge
O-Ring
Drain Valve
Lower Mounting Bracket
3/8-Inch Bolt (long)
Check Valve Assembly
Purge Valve Assembly
Purge Valve Bolt
Exhaust Diaphragm

18.
19.
20.
21.
22.
23.
24.
25.

Purge Valve
1/4-Inch Screw
Purge Valve Housing
Heater and Thermostat
Housing
Return Spring
Purge Piston
3/8-Inch Capscrew
End Cover

Fig. 1, AD-9 Air Dryer

18. Connect and tighten the three air lines. Connect

the harness connector to the heater and thermostat assembly until the lock tab snaps in place.
19. Start the engine, build the air pressure, and
check the air brake system for leaks. If any air
leaks are present, see Group 42 of the Business
Class M2 Workshop Manual for diagnosis and
repair information.

42/2

4203 Governor D2A

Checking
IMPORTANT: Review the warranty policy before
performing any intrusive maintenance procedures. An extended warranty may be voided if
intrusive maintenance is performed during this
period.

Business Class M2 Maintenance Manual, January 2010

42

Brakes

curately. If the pressure settings of the D-2 governor are inaccurate or its necessary that they
be changed, the adjustment procedure follows.

1&9

2.1

Remove the top cover from the governor.

2.2

Loosen the adjusting screw locknut.

2.3

To raise the pressure setting, turn the adjusting screw counterclockwise; to lower
the setting, turn the screw clockwise. Be
careful not to overadjust. Each 1/4 turn of
the adjusting screw raises or lowers the
pressure setting approximately 4 psi (28
kPa).

2.4

When proper adjustment is obtained,

tighten the adjusting screw locknut, and
install the top cover. The pressure range
between cut-in and cut-out is not adjustable.

09/20/94

f420544a

Fig. 2, End Cover to Housing Torque Pattern

Cut-In Position

Every 12 months, 100,000 miles (160 900 km), or

3600 operating hours, perform the operational test
below.

Apply soap solution around the cover and to the exhaust port. Slight bubble leakage is permitted. Excessive leakage indicates a faulty inlet valve or faulty
lower piston O-ring.

Operational Test

Cut-Out Position

1. Start the vehicle engine, build air pressure in the

brake system, and check the pressure registered
by a dash or test gauge at the time the governor
cuts-out, stopping the compression of air by the
compressor. Cut-out pressure should be in accordance with the pressure setting of the piece
number being used. Common cut-out pressures
are 125 to 135 psi (862 to 931 kPa). With the
engine still running, make a series of brake applications to reduce the air pressure, and observe
at what pressure the governor cuts-in the compressor. As in the case of cut-out pressure, cut-in
pressure should be in accordance with the pressure setting of the piece number being used.
Cut-in pressure is 105 psi (724 kPa).

Apply soap solution around the cover and to the exhaust port. Slight bubble leakage is permitted. Excessive leakage indicates a faulty exhaust valve seat,
exhaust stem O-ring, or O-ring at the top of the
piston.

NOTE: If the governor cover is marked nonadjustable, and the adjusting stem has been
sheared off, this is a non-serviceable governor
and it must be replaced with a new or remanufactured unit.
2. Never condemn or adjust the governor pressure
settings unless theyre checked with an accurate
test gauge or a dash gauge thats registering ac-

Business Class M2 Maintenance Manual, January 2010

If the governor does not function as described, or if

leakage is excessive, it is recommended that it be
replaced with a new or remanufactured unit, or repaired with genuine Bendix parts.

4204 Bosch Hydraulic Brake

System Inspecting
Before checking lining wear with the wheel removed,
review the following brake lining exposure warnings.

WARNING
Breathing brake lining dust (asbestos or nonasbestos) could cause lung cancer or lung disease. Unless exposure can be reduced below legal
limits, wear an air purifying respirator approved
by MSHA or NIOSH at all times when servicing the

42/3

42

Brakes

brakes, starting with removal of the wheels and

continuing through assembly.
To minimize the possibility of creating airborne 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
system. Then, using a rag soaked in water and
wrung until nearly dry, remove any remaining dust.
Do not use compressed air or dry brushing to clean
the brake assembly.
1. Check lining wear, as follows.
1.1

Apply the parking brakes. Chock the tires

to prevent vehicle movement.

1.2

Remove one or more of the lining inspection plugs, and measure brake lining
thickness.

available and the cartridge contains a 150 lb

spring that cannot be mechanically caged. Disassembly could release the spring, resulting in personal injury.
4. Remove and discard both O-rings from the cartridge bolt.
5. Using a clean rag, wipe clean the inside of the
end cover. Clean the cartridge bolt bore in the
end cover, and the sealing surfaces for the largeand small-diameter desiccant cartridge sealing
rings.
6. Inspect the end cover for physical damage, then
inspect all air line fittings for corrosion; replace
as necessary.
7. Clean and inspect the bolt, paying attention to
the threads and O-ring grooves.

1.3

On front and rear axles, replace linings

worn to less than 1/16 inch (1.6 mm).

IMPORTANT: Use only the grease supplied with

Bendix replacement kits.

1.4

Make sure that the brake rotor and linings

are free of oil and grease.

1.5

Install the inspection plug(s).

8. Lubricate the O-rings, bolt O-ring grooves, sealing rings, and cartridge grooves. Lubricate the
end cover bore for the bolt.

2. If the wheel and hub assembly is removed from

the axle, check lining wear. Replace the linings
on all brake assemblies if worn to less than 1/16
inch (1.6 mm) at the thinnest point. Check the
brake pads for wear and replace, as necessary.

9. Install both O-rings on the cartridge bolt, then,

using a twisting motion, insert the assembled
desiccant cartridge bolt in the end cover.

4205 Bendix ADIP Air Dryer

Desiccant Replacing

NOTE: It may be necessary to rotate the cartridge slightly until the anti-rotation lugs are
properly aligned and allow the cartridge to rest
flush against the end cover.

IMPORTANT: For vehicles equipped with an oilcoalescing air dryer desiccant cartridge, replace
the cartridge once a year, regardless of mileage.
1. With the vehicle parked on a level surface, apply
the parking brakes, and chock the tires.
2. Using a wrench or a socket, loosen the desiccant
cartridge bolt. Then separate the desiccant cartridge from the end cover.

10. Install the desiccant cartridge on the end cover,

making sure the cartridge is properly seated and
flush on the end cover.

11. Using a wrench or socket, tighten the desiccant

cartridge bolt 70 lbfft (95 Nm). Do not overtorque.
12. Before placing the vehicle in service, perform the
test below.
12.1

Close all reservoir drain cocks.

12.2

Build system pressure to governor cutout, and note that the AD-IP air dryer
purges with an audible escape of air.

12.3

Fan the service brakes to reduce system

air pressure to governor cut-in. Note that
the system once again builds to full pressure and is followed by a purge at the
AD-IP air dryer exhaust.

3. Pull the cartridge bolt out of the cover and remove the cartridge.

WARNING
Do not attempt to disassemble the desiccant cartridge assembly. Parts for the assembly are not

42/4

Business Class M2 Maintenance Manual, January 2010

42

Brakes

12.4

Check for excessive leakage around the

head of the desiccant cartridge where it
contacts the end cover. With the compressor in loaded mode (compressing
air), apply a soapy solution to these
areas, and observe that any leakage
does not exceed a 1-inch bubble in 1
second. If leakage exceeds this measure,
remove and re-install the desiccant cartridge.

4206 Haldex and Gunite Slack

Adjuster Lubricating

IMPORTANT: Perform MOP 42-15 before lubricating the slack adjusters.

Automatic slack adjusters that have a grease fitting
must be lubricated periodically to ensure proper
brake operation.

WARNING
Failure to lubricate slack adjusters could lead to
dragging brakes or a brake failure, resulting in
property damage, personal injury, or death.

Haldex
CAUTION
Do not use moly-disulfide-loaded grease or oil.
Both the life and reliability of the slack adjuster
will be reduced if this type of grease is used.
Lubricate the automatic slack adjuster at the grease
fitting. See Fig. 3. Use standard chassis lubricant for
Haldex slack adjusters.

Gunite
For operating temperatures of 20F (29C) and
higher, use Texaco Multifak EP-2 or Mobil Grease
No. 77.
For operating temperatures between 20F (29C)
and 40F (40C), use Lubriplate Aero grease.
Lubricate a Gunite automatic slack adjuster at the
grease fitting until grease appears on the camshaft,
or flows from the grease relief. See Fig. 4.

Business Class M2 Maintenance Manual, January 2010

02/01/2001

f421649a

1. Grease Fitting
2. Slack Adjuster
Fig. 3, Haldex Slack Adjuster Grease Fitting

The newest Gunite automatic slack adjusters are

produced without a grease relief. During lubrication
with a grease gun, the lubricant is forced through the
drilled worm wheel onto the camshaft. Lubricate the
automatic slack adjuster at the grease fitting until
grease appears on the camshaft. See Fig. 5.

4207 Meritor Camshaft

Bracket Lubricating
IMPORTANT: Perform MOP 42-15 before lubricating the camshaft brackets.
NOTE: If equipped with an extendedmaintenance Q Plus brake system, the camshaft bracket will not have a grease fitting.
These camshafts use a special NLGI grade synthetic polyurea grease, and do not require lubrication for 3 years or 500,000 miles (800 000
km), whichever comes first. Extendedmaintenance camshaft bushings are lubricated
during the brake reline service interval. For ser-

42/5

42

Brakes

5
6
3
7

05/28/93

A.
1.
2.
3.

1
10

1. 7/16-Inch Adjusting
Nut
2. Grease Fitting
3. Boot
4. Link
5. Brake Chamber Piston
Rod

6.
7.
8.
9.

Clevis
1/2-Inch Clevis Pin
1/4-Inch Clevis Pin
Grease Relief
Opening
10. Slack Adjuster Spline

Fig. 4, Gunite Automatic Slack Adjuster

vice and lubrication instructions, see Group 42

of the Business Class M2 Workshop Manual.
For camshaft brackets with grease fittings, use an
NLGI Grade 1 or Grade 2 multipurpose chassis
grease.
Lubricate the camshaft bushings through the grease
fitting on the camshaft bracket or the spider until new
grease flows from the inboard seal. See Fig. 5.

WARNING
If grease leaks out under the camhead, the camshaft bracket grease seal is worn or damaged. See
Group 42 of the Business Class M2 Workshop
Manual for grease seal replacement instructions. If
this seal is not replaced, the brake linings could

42/6

f420011a

Grease Exit
Brake Chamber
Slack Adjuster
Non-Pressure-Relief Grease Fitting
Fig. 5, Camshaft Bracket Lubrication

f420653a

10/27/93

become contaminated with grease. The stopping

distance of the vehicle will be increased, which
could result in personal injury or property damage.

4208 Meritor Slack Adjuster

Lubricating
IMPORTANT: Perform MOP 42-15 before lubricating the slack adjusters.
NOTE: If equipped with an extendedmaintenance Q Plus brake system, the slack
adjuster will not have a grease fitting. These
slack adjusters use a special NLGI grade synthetic polyurea grease, and do not require lubrication for 3 years or 500,000 miles (800 000
km), whichever comes first. Extendedmaintenance slack adjusters are lubricated during the brake reline service interval. For service
and lubrication instructions, see Group 42 of
the Business Class M2 Workshop Manual.
For slack adjusters with grease fittings and for operating temperatures above 40F (40C), use an
NLGI Grade 1 clay-base grease or an NLGI Grade 1
or 2 lithium-base grease.
For slack adjusters with grease fittings, and for operating temperatures below 40F (40C) and above

Business Class M2 Maintenance Manual, January 2010

42

Brakes

65F (54C), use an NLGI Grade 2 synthetic oil or

a clay-base grease.
Lubricate the slack adjuster at the grease fitting until
grease is forced past the pressure-relief capscrew or
past the gear splines around the inboard snap ring.
See Fig. 6.
1
1
2
2
3

3
4

1. Desiccant Cartridge
2. Cartridge Sealing Ring
3. Threaded Base Post

5
7

1.
2.
3.
4.
5.
6.
7.

Fig. 7, Desiccant Cartridge Replacement

10/20/93

f421910

04/16/98

f420012a

Brake Chamber
Clevis
Actuator Rod
Boot
Pull-Pawl Seal
Manual Adjusting Nut
Grease Fitting (or plug)
Fig. 6, Meritor Automatic Slack Adjuster

4209 Bendix ADIS Air Dryer

Desiccant Replacing
IMPORTANT: For vehicles equipped with an oilcoalescing air dryer desiccant cartridge, replace
the cartridge once a year, regardless of mileage.

IMPORTANT: Use only the silicone grease supplied with Bendix replacement kits.
5. Screw the desiccant cartridge onto the body by
hand until the seal makes contact with the body.
Rotate the cartridge clockwise about one full
turn. Tighten the cartridge firmly.
6. Before placing the vehicle in service, perform the
following tests:
6.1

Close all reservoir drain cocks.

6.2

Build system pressure to governor cutout, and note that the AD-IS air dryer
purges with an audible escape of air.

6.3

Fan the service brakes to reduce system

air pressure to governor cut-in. Note that
the system once again builds to full pressure and is followed by a purge at the
AD-IS air dryer exhaust.

6.4

It is recommended by Bendix that the following leakage tests be made to ensure

that the AD-IS air dryer will not cycle excessively:

1. With the vehicle parked on a level surface, apply

the parking brakes, and chock the tires.
2. Drain the air dryer by operating the drain valve
on the AD-IS purge reservoir located below the
dryer.
3. Using a strap wrench or equivalent, loosen the
desiccant cartridge. Spin the cartridge off by
hand and discard it.
4. On the new desiccant cartridge, lubricate the
sealing ring with silicone grease. See Fig. 7.

Business Class M2 Maintenance Manual, January 2010

Compressor unloader mechanism

Governor
Drain cock and safety valve in first
(supply) reservoir.

42/7

42

Brakes

All air connections leading to and

from the first (supply) reservoir.

4210 Air Dryer AD9, ADIP,

ADIS/DRM Checking
IMPORTANT: Review the warranty policy before
performing any intrusive maintenance procedures. An extended-warranty may be voided if
intrusive maintenance is performed during this
period.
Because no two vehicles operate under identical
conditions, maintenance and maintenance intervals
will vary. Experience is a valuable guide in determining the best maintenance interval for any one particular operation.
Every 900 operating hours, or 25,000 miles (40 225
km), or 3 months:
1. Check for moisture in the air brake system by
opening reservoir drain valves and checking for
the presence of water. If moisture is present, the
desiccant cartridge may require replacement;
however, the following conditions can also cause
water accumulation and should be considered
before replacing the desiccant:
1.1

An outside air source has been used to

charge the system. This air did not pass
through the drying bed.

1.2

Air usage is exceptionally high and not

normal. This may be due to high air system leakage.

1.3

In areas where more than a 30-degree

range of temperature occurs in one day,
small amounts of water can temporarily
accumulate in the air brake system due to
condensation. Under these conditions, the
presence of small amounts of moisture is
normal.

NOTE: A small amount of oil in the system is

normal and should not be considered as a reason to replace the desiccant cartridge. Some oil
at the dryer exhaust is normal.
2. Visually check for physical damage such as
chaffed or broken air and electrical lines and broken or missing parts.

42/8

3. Check mounting bolts for tightness. Torque 30 to

35 lbfft (41 to 47 Nm).
4. Perform the operational and leakage tests listed
below.

Operational and Leakage Tests

1. Check all lines and fittings leading to and from
the air dryer for leakage and integrity. Repair any
leaks found.
2. Build system pressure to governor cutout, and
note that the dryer purges with an audible escape of air. Watch the system pressure and note
the pressure fall-off for a 10-minute period. If the
pressure drop exceeds 1 psi/minute from either
service reservoir for a single vehicle; or 3
psi/minute for a tractor trailer, inspect the vehicle
air systems for sources of leakage, and repair
them. Refer to troubleshooting information in
Bendix service literature.
3. Check for excessive leakage around the purge
valve with the compressor in the loaded mode
(compressing air). Apply a soap solution to the
purge valve exhaust port and observe that leakage does not exceed a 1-inch (25-mm) bubble in
1 second. If the leakage exceeds the maximum
specified, refer to troubleshooting information in
the Bendix service literature.
4. Build system pressure to governor cutout, and
note that the dryer purges with an audible escape of air. Fan the service brakes to reduce
system air pressure to governor cut-in. Note that
the system once again builds to full pressure and
is followed by a dryer purge. If the system does
not follow this pattern, refer to troubleshooting
information in the Bendix service literature.
5. Check operation of the end cover heater and
thermostat assembly during cold weather, as follows:
5.1

Electric Power to the Dryer: With the ignition or engine kill switch in the ON position, check for voltage to the heater and
thermostat assembly using a voltmeter or
testlight. Unplug the electrical connector
at the air dryer and place the test leads
on each of the connections of the female
connector on the vehicle power lead. If
there is no voltage, look for a blown fuse,
broken wires, or corrosion in the vehicle

Business Class M2 Maintenance Manual, January 2010

42

Brakes

wiring harness. Check to see if a good

ground path exists.
5.2

Thermostat and Heater Assembly Operation: These tests are not possible except
in cold-weather operation. Turn off the
ignition switch, and cool the thermostat
and heater assembly to below 40F
(4C). Using an ohmmeter, check resistance between the electrical pins in the
air dryer connector half. Resistance
should be 1.5 to 3.0 ohms for the 12-volt
heater assembly, and 6.0 to 9.0 ohms for
the 24-volt heater assembly.
NOTE: Some models of the AD-9 may
have a resistance reading of 1.0 to 2.5
ohms.
Warm the thermostat and heater assembly to approximately 90F (32C) and
again check the resistance. Resistance
should exceed 1000 ohms. If resistance
values obtained are within stated limits,
the thermostat and heater assembly is
operating properly. If resistance values
obtained are outside stated limits, replace
the heater and thermostat assembly.

6. On the AD-IS/dryer reservoir module (DRM) only,

observe the pressure gauges of the vehicle as
system pressure builds from zero. The primary
gauge should rise until it reaches approximately
109 5 psi (751 34 kPa), then level off (or a
momentary slight fall) as the second pressure
protection valve opens supplying the secondary
reservoir. When the secondary pressure gauge
passes through approximately 55 5 psi (379
34 kPa) and then 85 5 psi (586 34 kPa)
there should be an associated levelling off (or
momentary slight fall) of pressure as the third
and fourth pressure protection valves open. Finally, both the primary and secondary gauges
should reach their full pressure of approximately
130 5 psi (896 34 kPa). If the AD-IS does not
perform within the pressure ranges described
above, recheck using gauges known to be accurate. If readings remain outside the ranges outlined above, replace the AD-IS.
There are no kits available for servicing the pressure protection valves.

WARNING
Do not attempt to adjust or service the pressure
protection valves. Incorrect pressure protection
valve settings can result in automatic application
of the vehicle spring brakes without prior warning.
This can cause personal injury or property damage.

4211 Brake Lines and Fittings

Inspecting, Hydraulic
Brakes
Chock the tires, release park brake, and make a fullservice brake application.
Replace damaged or leaking components, and
tighten loose fittings.

4212 Brake Pedal Linkage and

Mounting Plate
Inspecting
Inspect the pedal, pedal linkage, and mounting plate
assembly for proper operation, to ensure that any
problems believed to be valve-related are not actually mechanism issues.

4213 Air Brake Inspecting and

Leak Testing
IMPORTANT: If any of the tests in the following
procedure fail, refer to Group 42 of the
Business Class M2 Workshop Manual to test
individual air brake components and valves.

WARNING
Some steps in this operation require the parking
brakes to be released. Make sure the vehicle is on
a level surface and all tires are chocked. Failure to
do so could result in the vehicle rolling, causing
personal injury and/or vehicle damage.
1. With the vehicle parked on a level surface, shut
down the engine, apply the parking brakes, and
chock all tires.

Business Class M2 Maintenance Manual, January 2010

42/9

42

Brakes

2. Completely drain all air reservoirs.

3. Install accurate test gauges in the primary and
secondary reservoirs.
4. Start the engine and run it at a fast idle.
5. Record reservoir pressures when the lowpressure warning turns off.
6. Record governor cut-out pressure and air dryer
purge pressure.
7. Reduce service air pressure by applying and releasing the service brakes several times, and
record governor cut-in pressure.
8. Charge the air system to governor cut-out, shut
down the engine, and apply the parking brakes.
9. Allow pressure to stabilize for one minute.
10. Observe the installed service reservoir gauges.
The pressure should not drop more than 10 psi
(69 kPa) within five minutes.
11. If necessary, start the engine and charge the air
system. Shut down the engine and release the
parking brakes.
12. Make and hold a full service brake application,
allowing the pressure to stabilize for one minute.
Observe the installed service reservoir gauges.
The pressure should not drop more than 15 psi
(103 kPa) in five minutes.
13. With the air system at full pressure and the engine idling, perform the following:
On trucks, operate the parking brake control valve and note that the parking brakes
apply and release promptly as the control
valve knob is pulled out and pushed in on
the spring brake axles only.
On tractors, operate the trailer supply control valve knob. Note the air coming out of
the trailer control coupling. Operate the
park control knob and note that the parking
brakes apply and release promptly as the
knob is pulled out and pushed in. Block the
trailer supply coupling, and push the trailer
supply control valve and park control valve
knobs in. When the park control valve knob
is pulled out, the trailer supply knob should
also come out.
14. Build air system pressure to cut-out and shut
down the engine.

42/10

15. Completely drain the secondary (front axle) reservoir. On vehicles equipped with a Dryer Reservoir Module (DRM) or AD-IS with the air dryer
attached to the reservoir, the primary (rear axle)
reservoir pressure should not drop below 65 psi
(448 kPa). On vehicles equipped with single
check valves, where the air dryer is not attached
to the reservoir, the primary reservoir should not
lose pressure.
16. Make a service brake application. The rear axle
brakes should apply and release and the brake
lights should illuminate.
On tractors, with the trailer supply knob pushed
in, the trailer control coupling should deliver air
during the brake application.
17. Push the trailer air supply valve knob in. With the
secondary reservoir still completely drained,
slowly drain the primary reservoir and record the
pressure at which the knob automatically comes
out. This pressure should be 20 to 45 psi (138 to
310 kPa).
18. Close the drain cocks, recharge the system, and
completely drain the primary reservoir. On vehicles equipped with a DRM or AD-IS with the air
dryer attached to the reservoir, the secondary
reservoir pressure should not drop below 65 psi
(448 kPa). On vehicles equipped with single
check valves, where the air dryer is not attached
to the reservoir, the secondary reservoir should
not lose air pressure.
19. On tractors only:
19.1

Start the engine and build the system air

pressure to governor cut-out.

19.2

Shut down the engine and leave the parking brakes released.

19.3

Completely drain the primary reservoir.

19.4

Make a modulated service brake application by depressing the brake pedal. The
front brakes should apply and release
and the brake lights should illuminate. In
addition to the front brakes, with the
trailer supply knob pushed in, the trailer
control coupling should deliver air during
the brake application.

20. On trucks only:

20.1

Start the engine and charge the air system until governor cut-out.

Business Class M2 Maintenance Manual, January 2010

42

Brakes

20.2

Shut down the engine and leave the parking brakes released.

20.3

Completely drain the primary reservoir.

20.4

Make a modulated service brake application. Both front and rear brakes should
modulate. At a steady full brake application, the pressure should not drop more
than 10 psi (69 kPa) within five minutes.

2
5
6

1
3
4

7
8

21. Drain all reservoirs and remove the gauges from

the service reservoirs. Close the reservoir drain
cocks.
22. Remove the chocks from the tires.

4214 Foot-Control Valve, E-6,

Inspecting and
Lubricating
This procedure will be performed during M5 maintenance intervals.
Severe service = 32k
Short-haul transport = 128k
Long-haul transport = 160k
1. Remove the brake valve from the vehicle. See
Section 42.09, Subject 110 of the Business
Class M2 Workshop Manual for instructions.
2. Remove the roll pin from the brake pedal pivot
pin. See Fig. 8.
3. Remove the brake pedal pivot pin.
4. Remove the brake pedal.
5. Check the brake pedal mounting plate adapter
for signs of wear or cracks at the bosses (the
area from which the pivot pin was removed). Replace it if necessary.
6. Check the brake pedal rollers for signs of wear
or cracks. Replace the rollers if necessary.
7. If the rollers are replaced, replace the roller pin,
install a new cotter pin, bend it 90 degrees, and
apply Torque Seal (OPG F900 White) to the cotter pin.

09/10/2004

1. Foot-Control Valve,
E-6
2. Mounting Plate
3. Nut and Washer
4. Pivot Pin

f430405

5.
6.
7.
8.

Roll Pin
Roller
Roller Pin
Pedal

Fig. 8, Brake Pedal and Valve Assembly

9. Lubricate the plunger with synthetic grease of

NLGI Grade 1.5, such as 76 Triton synthetic EP
Grease (FTL Sped 48-25432-000).
10. Insert the plunger in the valve.
11. Install the brake pedal with the pivot pin.
12. Install a new roll pin, then apply Torque Seal
(OPG F900 White) to the roll pin.
13. Install the brake valve assembly. See Section
42.09, Subject 110 of the Business Class M2
Workshop Manual for instructions.
14. Test the brakes before returning the vehicle to
service.

4215 Brake Inspecting

IMPORTANT: This procedure should be performed prior to lubrication of the brake components.

8. Remove the plunger from the valve. Clean the

existing grease from the plunger, using alcohol.
Check the plunger for signs of wear or cracks.
Replace it if necessary.

Business Class M2 Maintenance Manual, January 2010

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42

Brakes

Parking Brake Operational Check

CAUTION
Perform the following check in a clear safe area. If
the parking brakes fail to hold the vehicle, personal injury or property damage may result.
1. With the engine running, and air pressure at cutout pressure, set the parking brake.
2. Put the vehicle in the lowest gear and gently attempt to move it forward. The vehicle should not
move. If the vehicle moves, the parking brakes
are not operating correctly and must be repaired
before the vehicle is returned to service. See
Group 42 of the Business Class M2 Workshop
Manual for repair procedures.

Brake Component Inspection

1. Park the vehicle on a level surface, set the parking brake, and chock the tires. Once the tires are
chocked, release the parking brake.

the brakes may drag or will not fully apply. Check

for improper operation or adjustment of the automatic slack adjuster. See Group 42 of the
Business Class M2 Workshop Manual for inspection and troubleshooting procedures.
5. Start the engine and build air pressure to at least
100 psi (689 kPa). Shut down the engine.
6. Check all of the foundation brake components for
damage, wear, and loose or missing parts. Repair as needed. See Group 42 of the Business
Class M2 Workshop Manual for repair procedures.

4216 Bendix Hydro-Max

Brake System Inspecting
1. Check the fluid level in the hydraulic brake fluid
reservoir. If needed, fill the reservoir up to the
ridge that surrounds the reservoir. See Fig. 9.
Use only heavy-duty brake fluid, DOT 6.
A

WARNING
Manually adjusting an automatic slack adjuster to
bring the pushrod stroke within legal limits is
likely masking a mechanical problem. Adjustment
is not repairing. Before adjusting an automatic
slack adjuster, troubleshoot the foundation brake
system and inspect it for worn or damaged components. Improperly maintaining the vehicle braking system may lead to brake failure, resulting in
property damage, personal injury, or death.
2. With the engine off, and 100 psi (689 kPa) of air
tank pressure, have an assistant apply and hold
an 80 to 90 psi (550 to 620 kPa) brake application.
3. Check to see if the colored over-stroke band on
each brake chamber pushrod is exposed.
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
the Business Class M2 Workshop Manual for
inspection, troubleshooting, and repair procedures.
4. Measure the applied chamber stroke. See
Table 1 for the proper stroke for the type of
chamber being used. If the stroke is too short,

42/12

f460513a

10/31/94

A. Open caps and check fluid level.

B. Fill to this level.
Fig. 9, 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.
3. Check the brake module for leaks. If leaks are
found, repair or replace the brake module. See

Business Class M2 Maintenance Manual, January 2010

42

Brakes

Group 42 of the Business Class M2 Workshop

Manual for replacement instructions, or take the
vehicle to an authorized Freightliner dealer.
4. Check the electrical connections and harnesses.
Make sure the connectors are fully seated and
the harnesses are not chafed or cut. Repair or
replace any damaged harness. Disconnect any
loose connectors and inspect the terminals for
corrosion. If corrosion is present, replace the terminals. If corrosion is not present, reconnect the
connector.
5. Check the fuse for the hydraulic brake booster
pump, as follows.
5.1

Open the cover to the main power distribution module (PDM).

5.2

Pull the fuse in position F6 for the HydroMax relay.

5.3

Inspect the relay to make sure the fuse is

not damaged. If the fuse is damaged, install a new fuse. If the fuse is not damaged, install the fuse in position F6.

5.4

Close the PDM cover.

6. Check the operation of the Hydro-Max brake

booster, as follows.
6.1

With the engine off, depress the brake

pedal; the warning light and buzzer
should come on, and the electric motor
should run.

6.2

Start the engine and allow the gauges to

sweep. Depress the brake pedal; no
warning lights, buzzer, or electric motor
should come on.

Brake Chamber Stroke Specifications

Chamber
Manufacturer

Type*

Size
9
12

Max Applied Stroke: inch (mm)

1 3/8 (35)

16
Standard Stroke

20

1 3/4 (45)

24
Gunite

30

2 (51)

36

2 1/4 (57)

16
20
Long Stroke

24
24
30
12

Standard Stroke
Haldex

2 (51)

2 1/2 (64)
1-3/8 (35)

16
20

1-3/4 (44)

24
2-1/2-Inch Extended Stroke

24

2 (51)

3-Inch Extended Stroke

24

2-1/2 (64)

Standard Stroke

30

2 (51)

Long Stroke

30

2-1/2 (64)

Business Class M2 Maintenance Manual, January 2010

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42

Brakes

Brake Chamber Stroke Specifications

Chamber
Manufacturer

Type*

Max Applied Stroke: inch (mm)

Size
9

Less than 1-1/2 (38)

12
Standard Stroke

16

Less than 1-3/4 (44)

20

Meritor

24
Long Stroke

24

Standard Stroke

30

Less than 1-7/8 (48)

Less than 2 (51)

* Long stroke design is indicated by a tag, or embossing, on the brake chamber.

Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.
If type 36 chamber is used, slack length should be less than 6 inches.

Table 1, Brake Chamber Stroke Specifications

42/14

Business Class M2 Maintenance Manual, January 2010

Steering

46
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Drag Link Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4601
Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4605
Power Steering Filter Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4606
Power Steering Fluid Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4602
Power Steering Fluid Level Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4603
Power Steering Gear Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4604

Business Class M2 Maintenance Manual, June 2002

46

Steering

4601 Drag Link Inspecting

3. Remove the retaining ring from the reservoir.

See Fig. 1.

WARNING
All steering system components are critical for
safe operation of the vehicle. Failure to maintain
the steering system as specified may result in
loss of steering control, which could lead to personal injury and property damage.
Have someone turn the steering wheel from left to
right. Check for movement between the ball stud end
at both the pitman arm and the steering arm. Also
check if the ball stud nut is loose.

3
4

If the ball stud end is loose, replace the drag link. If

the ball stud nut is loose, replace the nut and cotter
pin. See Group 00 for proper torque specifications.
Inspect the boot of the drag link at both the pitman
arm and the steering arm end for cracks, splits, or
other damage. Replace the boot as needed. See
Group 46 of the Business Class M2 Workshop
Manual for drag link removal and installation instructions.
Grasp the drag link near the pitman arm end, and
move the drag link side to side to check for axial
movement in the ball stud end. If it is loose, replace
the drag link. See Group 46 of the Business Class
M2 Workshop Manual for replacement instructions. If
there is 1/8-inch (3-mm) movement or more, do not
drive the vehicle until the drag link is replaced.

4602 Power Steering Fluid

Changing
WARNING
Fill only with approved clean fluid. Failure to use
the proper fluid could cause seal deterioration and
leaks. Fluid leaks could eventually cause loss of
power steering assist. This could lead to an accident resulting in personal injury or property damage. Wear eye protection when changing the fluid
and filter.
1. Apply the parking brakes and chock the rear
tires.
2. Place a drain pan under the power steering reservoir.

Business Class M2 Maintenance Manual, June 2002

10/19/2001

1.
2.
3.
4.

f461917

Power Steering Reservoir

Retaining Ring
Filter Cover
Return Hose
Fig. 1, Power Steering Reservoir

4. Remove the filter and filter cover from the reservoir. Drain the fluid from the filter into the drain
pan. Leave the filter hanging over the drain pan.
5. Remove the bolts, nuts, and washers that attach
the power steering reservoir to the mounting
bracket. Drain the power steering fluid from the
reservoir, but do not remove the supply line to
the reservoir.
6. Using bolts, nuts, and washers, attach the reservoir to the mounting bracket.
7. Fill the reservoir with an approved power steering fluid to the line between the MIN COLD and
MAX HOT lines. See Fig. 1. See Table 1 for approved power steering fluids.
Approved Power Steering Fluids
Fluid Type*
Automatic Transmission
Fluid

Approved Fluid*
Dexron III
Dexron II

* Do not mix fluid types. Refer to the text in this group for a detailed warning statement.

Table 1, Approved Power Steering Fluids

8. Raise the front of the vehicle and support it with

jack stands.

46/1

46
9. Start the engine and operate it at idle. Turn the
steering wheel from full left to full right several
times until clean oil starts flowing from the power
steering filter. Add fluid to the reservoir to maintain the fluid level between the MIN COLD and
MAX HOT lines.
10. Shut down the engine and install the filter and
filter cover in the reservoir. Make sure that the
gasket under the filter cover is not damaged. If
the gasket is damaged, replace it. Install the gasket on the reservoir.
11. Attach the retaining ring to the reservoir to secure the filter and filter cover.

Steering

4604 Power Steering Gear

Lubricating
TRW THP Series
CAUTION
Apply grease to the sector shaft with only a handtype grease gun. Use of a high-pressure power
grease gun will supply grease too quickly and
could affect the high pressure seal, contaminating
the hydraulic fluid.

12. Start the engine and check that the power steering fluid level is between the MIN COLD and
MAX HOT lines. Add more power steering fluid if
needed.

Using a hand-type grease gun, apply NLGI Grade 2

or 3 multipurpose chassis grease until it starts to
come out past the sector shaft seal.

13. Raise the vehicle, remove the jack stands, and

lower the vehicle.

4605 Drag Link Lubricating

14. Remove the chocks from the tires.

1. Using a clean rag, wipe all dirt from both drag

link grease fittings.

4603 Power Steering Fluid

Level Inspecting

2. Using a pressure gun, apply grease at the

grease fittings until old grease is forced out of
the socket. Use multipurpose chassis grease
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease) or NLGI Grade 1 (6% 12-hydroxy lithium
stearate grease).

1. Apply the parking brakes and chock the rear

tires.
2. With the engine cool, the fluid level should be
between the MIN COLD and MAX HOT lines with
the engine off.
3. Add or remove fluid as necessary to bring the
fluid level to the line between the MIN COLD and
MAX HOT lines. See Table 1 for approved power
steering fluids.
4. With the engine hot, the fluid level should be at
the MAX HOT line with the engine off.
5. Add or remove fluid as necessary to bring the
fluid level to the MAX HOT line. See Table 1 for
approved power steering fluids.
6. Remove the chocks from the tires.

NOTE: NLGI Grade 2 is the preferred grade.

4606 Power Steering Filter

Changing
1. Apply the parking brakes and chock the rear
tires.
2. Raise the front of the vehicle and support it with
jack stands.
3. Remove the retaining ring from the reservoir.
See Fig. 1.
4. Remove the filter, filter cover, and gasket from
the reservoir.
5. Disconnect the filter from the filter cover, and discard the filter.
6. Apply a thin film of power steering fluid on the
gasket of the new filter. Then attach the filter to
the filter cover.

46/2

Business Class M2 Maintenance Manual, June 2002

Steering

46

7. Check for damage to the gasket that was removed from the reservoir. If the gasket is damaged, replace it. Install the gasket on the reservoir.
8. Install the filter and filter cover in the reservoir.
Attach the retaining ring to the reservoir to secure the filter and filter cover.
9. Check the fluid level in the reservoir. If necessary, add fluid to the reservoir to maintain the
fluid level between the MIN COLD and MAX
HOT lines. See Table 1 for approved power
steering fluids.
10. Raise the vehicle and remove the jack stands,
then lower the vehicle.
11. Remove the chocks from the tires.

Business Class M2 Maintenance Manual, June 2002

46/3

Fuel

47
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
CNG Fuel Cylinder Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4707
CNG Fuel System Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4705
CNG High-Pressure Fuel Filter Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4706
Fuel Tank Band Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4701
Fuel/Water Separator Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4702
LNG Fuel System Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4703
LNG Vacuum Integrity Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4704

Business Class M2 Maintenance Manual, July 2011

47

Fuel

4701 Fuel Tank Band Nut

Tightening

2
3

IMPORTANT: Do not overtighten the nuts.

Rectangular Fuel Tank

Hold the retention nut on the fuel tank band with a

wrench while backing off the jam nut. Then tighten
the retention nut 13 to 17 lbfft (18 to 23 Nm). After
the retention nut has been tightened, hold the retention nut with a wrench while tightening the jam nut 13
to 17 lbfft (18 to 23 Nm).

11

Cylindrical Fuel Tank

10

Hold the retention nut on the fuel tank band with a

wrench while backing off the jam nut. Then tighten
the retention nut 30 to 35 lbfft (41 to 46 Nm). After
the retention nut has been tightened, hold the retention nut with a wrench while tightening the jam nut 30
to 35 lbfft (41 to 46 Nm).

6
7

8
06/25/97

4702 Fuel/Water Separator

Element Replacing
Alliance
The only maintenance necessary on an Alliance
fuel/water separator is to replace the filter element.

WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain off some fuel by loosening the vent plug
and opening the drain valve. See Fig. 1.
2. Disconnect the water sensor and heater connections if equipped.

1.
2.
3.
4.
5.
6.

7.
8.
9.
10.
11.

Water Sensor Probe

Heater Connector
Drain Plug
Sight Bowl
Filter Element

Fig. 1, Alliance Fuel/Water Separator

4. Remove the bowl from the element and clean

the O-ring gland.
5. Apply a coating of clean fuel or motor oil to the
new O-ring and element seal.
6. Spin the bowl onto the new element, then spin
them both onto the filter head, snugly, by hand
only.

IMPORTANT: Do not use tools to tighten the

bowl and element.
7. Connect the water sensor and heater connectors
if equipped.
8. If equipped with a primer pump, prime the
fuel/water separator.
8.1

Loosen the vent plug. Then operate the

primer pump until the fuel purges at the
vent plug.

8.2

Close the vent plug.

3. Remove the element and bowl together, by turning counterclockwise.

Business Class M2 Maintenance Manual, July 2011

f470147

Mounting Head
Fuel Primer Pump
Vent Plug
Bowl O-Ring
Bowl Gasket
Bowl Probe Plug

47/1

47

Fuel

9. Start the engine and check for fuel leaks.

10. Shut down the engine and correct any fuel leaks.

Davco Fuel Pro 232 and 233

In the event of an emergency, when the filter needs

replacement but a Davco filter is not available, a
temporary filter can be used. For instructions, see
Chapter 14 of the Business Class M2 Drivers
Manual.

Replace the fuel/water separator element (Fig. 2)

only when the filter element is completely covered.

1
2
3

8
4

10
6
11
12
7

10/16/2001

1.
2.
3.
4.
5.

Filter Vent
Vent Seal
Filter Collar
Filter Cover
Cover Seal

f470415

6.
7.
8.
9.

Filter Spring
Filter Element
Temporary Filter Stud
Fuel Outlet

10. Check Valve Fuel Inlet

11. Drain
12. Electric Filter Preheater
(optional)

Fig. 2, Davco Fuel Pro 232 and 233

47/2

Business Class M2 Maintenance Manual, July 2011

47

Fuel

WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain the fuel below the collar level.
2. Using Davco wrench 232002, remove the filter
collar. Then remove the filter cover.
3. Remove the element and dispose of it properly.

age. When working on a fuel system, have a fire

extinguisher within easy reach.
1. Drain the fuel below the collar level. See Fig. 3.
2. Using Davco wrench 380134 or 382002, remove
the filter collar. Then remove the filter cover.
3. Remove the element and dispose of it properly.
4. Install a new element. Make sure the grommet is
in place on the filter stud.
5. Install a new cover seal on the filter cover.
6. Using the collar, attach the filter cover with the
spring to the base.

IMPORTANT: Tighten the collar by hand only.

4. Install a new element. Make sure the grommet is

in place on the filter stud.

7. Remove the filter vent. Then fill the fuel/water

separator with fuel until the fuel level is 1 inch
(2.5 cm) above the collar.

5. Install a new cover seal on the filter cover.

8. Install the filter vent on the fuel/water separator.

6. Using the collar, attach the filter cover with the

spring to the base.

9. Start the engine and raise the rpm for one

minute to purge air.

IMPORTANT: Tighten the collar by hand only.

7. Remove the filter vent. Then fill the fuel/water
separator with fuel until the fuel level is 1 inch
(2.5 cm) above the collar.
8. Install the filter vent on the fuel/water separator.
9. Start the engine and raise the rpm for one
minute to purge air.

Davco Fuel Pro 382

Replace the fuel/water separator element only when
the filter element is completely covered.
In the event of an emergency, when the filter needs
replacement but a Davco filter is not available, a
temporary filter can be used. For instructions, see
Chapter 13 of the Business Class M2 Drivers
Manual.

WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, possibly resulting in personal injury or property dam-

Business Class M2 Maintenance Manual, July 2011

4703 LNG Fuel System

Inspecting
WARNING
Natural gas is highly flammable. See the safety
precautions listed in Chapter 16 of the Business
Class M2 Drivers Manual or Group 47 of the
Business Class M2 Workshop Manual. Failure to
observe these precautions could lead to the ignition of the natural gas, which could cause serious
bodily injury or death.
The following inspections must be performed by a
qualified technician, in accordance with the manufacturers established inspection criteria.
All tank components should be allowed to defrost
before conducting the following inspections.

NOTICE
Do not use a high-pressure washer or steam
cleaner on natural gas fuel system plumbing components, as this can introduce moisture and contaminants into the threads of the fittings and damage the sealants.

47/3

47

Fuel

1
8
2
3

9
4

5
6

10

13

11
7

12

10/16/2001

1.
2.
3.
4.
5.
6.

Filter Collar
Filter Vent
Vent Seal
Filter Cover
Cover Seal
Filter Spring

f470414

7.
8.
9.
10.

Filter Element
Temporary Filter Stud
Check Valve Fuel Inlet
Fluid Heater/Bottom Plate and
Seal

11. Drain
12. Bottom Plate Collar
13. Electric Heater (optional)

Fig. 3, Davco Fuel Pro 382

Gas detection sensors are located on the cab

overhead console and in the engine compartment
on the frontwall. The sensors are located in high
areas, where rising gas vapors will pass by or accumulate. Do not use a high-pressure washer,
steam cleaner, or silicone-based chemicals on the
gas detection sensors, as this may permanently
disable the sensors. When cleaning the vehicle,
cover the sensors with a plastic covering. Keep
the sensors covered until the area has been
cleared of any cleaning fumes. Harsh chemicals
and extremely high temperatures may damage the
sensor.

47/4

Fuel Tank and Shroud Inspecting

See Fig. 4 for fuel tank and shroud component
locations.
1. Inspect the fuel tank outer shell for dents or
other signs of damage. Inspect the bottom of the
tank for deep scratches, flat spots, or gouges.
Replace a leaking fuel tank.
2. Ensure that the fuel tank is secured to its mounting brackets and that the mounting brackets are

Business Class M2 Maintenance Manual, July 2011

47

Fuel

Plumbing Components
Inspecting

See Fig. 5 for plumbing component locations.

7

10

5
11
12

1
05/29/2009

4
6

1. Fuel Fill Fitting

2. Fuel Outlet Line
(liquid)
3. Primary Relief Vent
Line (relief valve)

f470534

4. Fill Vent Fitting (vent)

5. Shroud Cover
6. Shroud Cover Latches

Fig. 4, Fuel Tank Outer Shell

secured to the frame. Inspect for any signs of

looseness.
3. Ensure that all rubber isolator straps are present
and secure.
4. Look for signs of abrasion between the fuel tank
and mounting brackets.
5. Inspect the fuel fill fitting for signs of damage or
leaks. Ensure the fuel fill cap is present and in
good condition, and the fitting is mounted securely on the tank.
6. Inspect the fuel outlet line and fitting for signs of
leaks or damage.
7. Inspect the primary relief vent and pipe-away line
for damage, kinks, chafing, or loose connections.

3
2
1
05/05/2010

1. Pressure Control
Regulator
2. Vapor Shutoff Valve
3. Fuel Fill Hose
4. Secondary Relief
Valve (red cap)
5. Fuel Fill Fitting
6. Fuel Level Sender
Box

f470533

7.
8.
9.
10.
11.

Primary Relief Valve

Tank Pressure Gauge
Fill Vent Fitting
Excess Flow Valve
Fuel Shutoff Valve
(liquid)
12. Fill Check Valve

Fig. 5, Fuel Tank Plumbing Components

Use a bubble solution to check for leaks while performing the following visual inspection.
1. Check the following components for signs of
damage or leaks.
Pressure control regulator

8. Inspect the fill vent fitting for signs of damage.

Vapor shutoff valve

9. Inspect the shroud cover for dents or other signs

of damage. Ensure that the shroud cover latches
are in working condition and fasten the shroud
cover securely to the tank.

Secondary relief valve

10. Replace leaking or damaged fuel lines. Repair or

replace leaking or damaged fittings.

Business Class M2 Maintenance Manual, July 2011

Primary relief valve and threaded connections

Excess flow valve
Fuel shutoff valve

47/5

47

Fuel

Fill check valve

2. Inspect the fuel fill line for signs of damage,
kinked or crushed piping, or chafing.
3. Ensure the red cap is present on the secondary
relief valve.
4. Inspect the fuel tank pressure gauge for cracks
in the sight glass. Ensure the indicator needle is
present and in working condition. Inspect the
gauge face for accuracy and legibility.
5. Inspect all vent lines for kinks, and signs of leaks
or damage.
6. Replace leaking or damaged fuel lines. Repair or
replace leaking or damaged fittings.

Fuel Level Sender Component

Inspecting
1. Inspect the fuel level sender wiring harness for
signs of loose connections or damage. Look for
cracking or signs of moisture intrusion.
2. Inspect the fuel level sender box (Fig. 5, Item 6)
for signs of leaks or damage. Ensure that the
retainer clips are installed on the mounting ears.

6. Inspect the overpressure regulator for signs of

leaks or damage.
6.1

Ensure that the regulator is mounted securely.

6.2

Check the overpressure regulator fittings

for signs of leaks or damage.

6.3

Ensure that the adjustment handle locking

nut (at the bottom of the overpressure
regulator) is tightened securely.

6.4

Inspect the pressure gauge for damage.

Ensure that the gauge sight glass is clear
and legible.

7. Repair or replace any leaking or damaged vaporizer components.

4704 LNG Vacuum Integrity

Testing
WARNING

4. Turn the ignition switch to the ON position and

check for fuel gauge response.

Natural gas is highly flammable. See the safety

precautions listed in Chapter 16 of the Business
Class M2 Drivers Manual or Group 47 of the
Business Class M2 Workshop Manual. Failure to
observe these precautions could lead to the ignition of the natural gas, which could cause serious
bodily injury or death.

5. Repair or replace any damaged fuel gauge

components.

1. Ensure the fuel tank is between 50 and 75 percent full.

Vaporizer Inspecting
See Fig. 6 for plumbing component locations.

2. Check the fuel tank pressure gauge (Fig. 5, Item

8) to ensure that pressure is within the normal
range of 120 to 150 psi (827 to 1034 kPa).

1. Ensure that the vaporizer is secured to its

mounting brackets and that the mounting
brackets are secured to the frame. Inspect for
any signs of looseness.

3. Inspect the fuel tank for signs of frost spots or

outer surface sweating. Frosting or condensation
on the outer surface of the fuel tank may indicate
a loss of vacuum.

2. Inspect the vaporizer fuel inlet and outlet lines for

signs of chafing, damage, or leaks.

4. Check for a large variance in temperatures between the fuel tank and the fuel tank shroud. A
large variance in temperatures between the fuel
tank and the shroud may indicate a loss of
vacuum.

3. Inspect all connectors and wiring for signs of

loose connections, damage, or chafing.

3. Inspect the vaporizer coolant hoses for signs of

chafing, damage, or leaks.
4. Inspect all fittings for leaks.
5. Inspect the fuel shutoff solenoid valve for signs
of leaks or damage. Inspect the solenoid mounting bracket for looseness.

47/6

5. Operate the vehicle for ten minutes. Shut down

the engine, apply the parking brakes, and note
the time.

Business Class M2 Maintenance Manual, July 2011

47

Fuel

1
12
10

11

06/29/2009

1.
2.
3.
4.

6
f470536

Pressure Relief Device

Fuel Inlet Line
Check Valve
CNG Quick-Connect Port

5.
6.
7.
8.

Coolant Inlet Line

Vaporizer
Fuel Shutoff Solenoid Valve
Coolant Outlet Line

9.
10.
11.
12.

Pressure Gauge
Overpressure Regulator
Pressure Relief Valve
Fuel Outlet Line

Fig. 6, LNG Vaporizer Assembly

6. Wait fifteen minutes after shutting down the engine, then record the fuel tank pressure and note
the time.

8. Use Table 1 to determine whether the pressure

increase is within an acceptable range.

7. Allow the vehicle to stand for at least eight

hours, then record the fuel tank pressure again.
Vacuum Integrity Test Results
Pressure Increase Over EightHour Period

Remedy

Less than 20 psi (138 kPa)

None Tank is normal

20 to 50 psi (138 to 345 kPa)

Monitor tank and test vacuum integrity again at next maintenance date

More than 50 psi (345 kPa)

Remove vehicle from service and evacuate the tank per the tank manufacturers
instructions
Table 1, Vacuum Integrity Test Results

Business Class M2 Maintenance Manual, July 2011

47/7

47

Fuel

4705 CNG Fuel System

Inspecting
WARNING
Natural gas is highly flammable. See the safety
precautions listed in Chapter 16 of the Business
Class M2 Drivers Manual or Group 47 of the
Business Class M2 Workshop Manual. Failure to
observe these precautions could lead to the ignition of the natural gas, which could cause serious
bodily injury or death.
The following inspections must be performed by a
qualified technician, in accordance with the manufacturers established inspection criteria.

2
1

NOTICE
Do not use a high-pressure washer or steam
cleaner on natural gas fuel system plumbing components, as this can introduce moisture and contaminants into the threads of the fittings and damage the sealants.
Gas detection sensors are located on the cab
overhead console and in the engine compartment
on the frontwall. The sensors are located in high
areas, where rising gas vapors will pass by or accumulate. Do not use a high-pressure washer,
steam cleaner, or silicone-based chemicals on the
gas detection sensors, as this may permanently
disable the sensors. When cleaning the vehicle,
cover the sensors with a plastic covering. Keep
the sensors covered until the area has been
cleared of any cleaning fumes. Harsh chemicals
and extremely high temperatures may damage the
sensor.
Use a bubble solution to check for leaks while performing the following inspection.
1. Inspect the fuel cylinders for dents or other signs
of damage.
Replace any leaking fuel cylinders.
2. Ensure that the fuel cylinders are secured within
the fuel cylinder storage box.
3. Ensure that the fuel cylinder storage box is secured to the frame. Inspect for any signs of
looseness. If necessary, tighten the storage box
mounting bolts 160 lbfft (217 Nm). See Fig. 7.

47/8

05/04/2010

f470555

1. Frame Rail
2. CNG Fuel Cylinder Storage Box
3. Mounting Bolts (qty 12 per side)
Fig. 7, Fuel Cylinder Storage Box Mounting Bracket
(passenger side shown)

NOTE: During initial pre-delivery inspection

(PDI), tighten the storage box mounting bolts
(shown in Fig. 7) 180 lbfft (244 Nm).
4. Inspect the fuel fill port for signs of damage or
leaks. Ensure the port dust cover and the O-ring
inside the port are both present and in good condition. See Fig. 8.
5. Inspect the pressure gauges on the fuel box for
cracks. Ensure the indicator needles are present
and in working condition. Inspect the gauge
faces for accuracy and legibility.
6. Ensure blue caps are present on all pressure
relief devices. Each fuel cylinder is equipped with
two caps (one on each end), which are visible on
the back of the CNG fuel cylinder storage box.
One cap is located on the pressure relief valve
on the inboard side of the CNG fuel box, next to

Business Class M2 Maintenance Manual, July 2011

47

Fuel

H IG

H PRESS UR E

RE
LOW PRES S U

CYLINDERS
INSPECT CYLINDERS
EVERY 36 MONTHS
OR 36000 MILES
WHICHEVER OCCURS FIRST

REGULATOR
INSPECT PRESSURE
RELIEF DEVICE
EVERY 2000 MILES

NATURAL
GAS
VEHICLE

110 PSIG

FILTER
DRAIN HOUSING
EVERY 1500 MILES
REPLACE ELEMENT
EVERY 3000 MILES

OPEN VALVE
SLOWLY

M
SH AN
U U
VA T O AL
LV FF
E

3600 PSIG MAX.

SERVICE PRESSURE

ON

8
04/30/2010

1.
2.
3.
4.

f470556

High Pressure Gauge

Low Pressure Gauge
Manual Fuel Shutoff Valve
Fuel Fill Port and Dust Cap
Fig. 8, CNG Fuel Panel

the fuel outlet line. Check the primary relief valve

on the inboard side of the CNG fuel box for signs
of damage or leaks.
7. Check the following components for signs of
damage or leaks.
Manual fuel shutoff valve
Fuel cylinder shutoff valves (see Fig. 9)
Coolant hoses and fittings
Fuel lines and fittings
All fittings, connections, and joints

04/22/2010

1. Fuel Cylinder Storage

Box
2. Fuel Cylinder Shutoff
Valves (qty 5)
3. High-Pressure Gauge
4. Low-Pressure Gauge

f470554

5.
6.
7.
8.

Fuel Fill Port

Dust Cap
Manual Shutoff Valve
Fuel Panel Access
Door

Fig. 9, CNG Fuel Cylinder Storage Box (5-cylinder

system shown)

2. Close the CNG fuel cylinder shutoff valves.

8. Replace leaking or damaged fuel lines. Repair or

replace leaking or damaged fittings.

3. Start the engine and let it idle until the fuel lines
are empty and the engine stops. The gauges on
the fuel panel should now read at or near 0 psi.

4706 CNG High-Pressure Fuel

Filter Element Replacing

4. Close the manual fuel shutoff valve on the fuel

panel.

CNG filter element replacement cycles are an important factor in maintaining the CNG fuel system integrity and ensuring maximum operating performance.
Actual frequency of the filter element replacement
could increase or decrease depending on the cleanliness of the fill station fueling system.

5. Remove the two capscrews that secure the access cover to the fill panel, then remove the access cover. See Fig. 10. Save the capscrews for
reinstallation.
6. Slowly open the bleed valve on the manifold to
relieve remaining fuel pressure within the system. See Fig. 11.

1. Shut down the engine and apply the parking

brake.

Business Class M2 Maintenance Manual, July 2011

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47

Fuel

6
5
7

7
3
2
6
5
4

2
3

2
1

14

13

05/04/2010

1
05/04/2010

f470557

1. Fuel Panel Access

Cover
2. Capscrews (qty 2)
3. Wiring Harness
4. Pressure Relief Valve
and Cap

5. Coolant Outlet Line

6. Coolant Inlet Line
7. Fuel Inlet Line (to fuel
cylinders)
8. Fuel Outlet Line (to
engine)

Fig. 10, CNG Fuel Panel Assembly

IMPORTANT: Some pressure may remain in the

fuel system between the solenoid valve and the
engine. Use caution when loosening fittings, as
a small amount of gas may leak out.

1.
2.
3.
4.
5.
6.
7.
8.

10
12 11

f470558

Coolant Inlet Port

Coolant Outlet Port
Pressure Relief Valve
Pressure Regulator
Wiring Harness
Manifold Bleed Valve
Manifold
Manual Fuel Shutoff
Valve

9.
10.
11.
12.
13.
14.

Fuel Fill Port

Filter Housing
Filter Bowl
Filter Drain Plug
Solenoid Valve
Fuel Line To Cylinders

Fig. 11, CNG Fuel Panel Components

12. Close the bleed valve on the manifold and open

the manual fuel shutoff valve on the fuel panel.
13. Open the fuel cylinder shutoff valves.
14. Using a methane detector, leak test all fuel system components between the fuel cylinders and
the solenoid valve. A bubble solution can be
used to pinpoint the exact location of leaks.
Repair or replace any leaking components.

7. Put a clean receptacle under the filter assembly.

Using a 1-1/4-inch wrench, unscrew the filter
bowl from the filter housing.

15. Using the two capscrews removed previously,

install the access cover on the fill panel.

8. Remove and discard the filter element.

4707 CNG Fuel Cylinder

Inspecting

9. Install a new filter element in the filter housing.

10. Inspect the O-ring on the filter housing for damage or cracks. If necessary, replace the O-ring.
11. Install the filter bowl on the filter housing. Tighten
90 lbfft (122 Nm).

47/10

Have a qualified inspector inspect compressed natural gas (CNG) fuel cylinders for damage or deterioration. Note cuts, cracks, gouges, abrasions, discoloration, broken fibers, loose brackets, damaged gaskets
or isolators, heat damage, or other problems.

Business Class M2 Maintenance Manual, July 2011

Fuel

47

Refer to Compressed Gas Assocation (CGA) pamphlet C-6.4, Methods for External Visual Inspection of
Natural Gas Fuel Containers and Their Installations,
for inspection requirements and inspector qualifications.
For more information, go to www.cganet.com.
After inspection, an accurate and reliable written report should be provided for each container inspected.
Place an inspection label stating the inspection date
and inspecting agency identification on each container.

Business Class M2 Maintenance Manual, July 2011

47/11

Exhaust

49
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4903
CAT CGI Bellows and Piping Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4902
Exhaust System Inspecting (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4901

Business Class M2 Maintenance Manual, September 2011

49

Exhaust

4901 Exhaust System

Inspecting (Noise
Emission Control)

Diesel Exhaust Fluid (DEF)the chemical agent

that reacts with the exhaust gases in the SCR
to reduce NOx.

In addition to inspecting the exhaust system at the

scheduled maintenance interval, inspect the exhaust
system if the noise level of the vehicle has increased. Freightliner Trucks recommends replacing
parts that show leakage, wear, or damage, with
genuine Freightliner parts.

DEF Tankholds DEF and regulates its temperature.

The exhaust system must be free of leaks, binding,

grounding, and excessive vibrations. These conditions are usually caused by loose, broken, or misaligned clamps, brackets, or pipes. If any of these
conditions exist, check the exhaust system components and alignment. Align or replace as necessary;
see Group 49 of the Business Class M2 Workshop
Manual, or take the vehicle to an authorized Freightliner dealer.

SCR Catalystthe housing containing a treated

ceramic flow-through block where the DEF and
exhaust gases undergo selective catalytic reduction (SCR).

It is a violation of US federal law to alter exhaust

plumbing or aftertreatment in any way that would
bring the engine out of compliance with certification
requirements. (Ref: 42 U.S.C. S7522(a) (3).) It is the
owners responsibility to maintain the vehicle so that
it conforms to EPA regulations.

EPA10 Exhaust System

Definitions of Aftertreatment (ATS)
Terms
Refer to the following list of definitions of ATS terms
and components.
Aftertreatment System (ATS)the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.
Aftertreatment Device (ATD)a housing that
contains the DOC and DPF (also the SCR and
the mixing tube in one-box systems).
BlueTecDaimlers proprietary SCR technology.
Diesel Oxidation Catalyst (DOC)a flowthrough device that oxidizes soot in the ATD.
Diesel Particulate Filter (DPF)a component in
the ATD that traps soot from the exhaust gas.

Business Class M2 Maintenance Manual, September 2011

DEF Pumpfilters and supplies DEF to the

DEF metering unit.

DEF Metering Unitmixes DEF with compressed air, and meters this mixture into the
exhaust flow via an injection nozzle.

Selective Catalytic Reduction (SCR)a process

used to reduce NOx emissions.

Inspection
To meet EPA10 emissions regulations for vehicles
domiciled in the USA or Canada, engines manufactured after December 31, 2009 are equipped with an
emission aftertreatment system. Vehicles domiciled
outside of the USA and Canada may not have aftertreatment equipment, depending upon local statutory
emissions guidelines.

IMPORTANT: The aftertreatment device (ATD),

which is part of the aftertreatment system (ATS),
requires special attention during regularly
scheduled maintenance inspections. No leaks
are allowed anywhere in the system. If any discrepancies are discovered, refer to the engine
manufacturers 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 exhaust 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.

49/1

49

Exhaust

3. If present, check the condition of the insulation

material around the exhaust pipe between the
turbocharger and the ATD.

8. Check the SCR catalyst for dents and other

damage.
9. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.

4. Check the ATD mounting bands for tightness.

Tighten to 30 lbfft (41 Nm) if needed. Do not
overtighten.

NOTE: Diesel exhaust fluid creeps, causing

white crystals to form around the line fittings.
The presence of crystals does not mean the
system has a leak. Replacing fittings or troubleshooting components is not necessary unless
there is a system failure or a fault code.

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.
6. Check all sensors attached to the ATS for leaks
or damaged wires. No leaks are allowed. See
Fig. 1, Fig. 2, or Fig. 3 for Detroit Diesel ATS
sensor locations.

10. Check the DEF tank, pump, metering unit, and

lines for leaks. See Section 49.03 of the
Business Class M2 Workshop Manual for repair
procedures.

7. Check the DPF exterior surface for dents or

other damage. 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.
13

14

12

7
11
10
6

4
15

08/20/2009

f490355

NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the
DOC inlet pressure sensor.
1. DOC Outlet Temperature
Sensor
2. DOC Inlet Pressure Sensor
Port
3. DOC Inlet Temperature Sensor
4. Front Heat Shield
5. DEF Nozzle

6.
7.
8.
9.
10.

Exhaust Outlet
DEF Metering Unit
Sensor Box (see note above)
Exhaust Inlet
SCR Outlet Temperature
Sensor

11.
12.
13.
14.

SCR Outlet NOx Sensor Port

SCR Inlet NOx Sensor Port
14-Pin Connectors
DPF Outlet Pressure Sensor
Port
15. SCR Inlet Temperature Sensor

Fig. 1, One-Box ATS Sensor Locations

49/2

Business Class M2 Maintenance Manual, September 2011

49

Exhaust

11
10

9
8

10
8

6
5
09/16/2009

1. DEF Metering Unit

2. DEF Nozzle
3. SCR Outlet Temperature
Sensor
4. SCR Inlet Temperature Sensor

f490353

5.
6.
7.
8.

DOC Inlet Temperature Sensor

DOC Inlet Pressure Sensor
DPF Inlet Temperature Sensor
DPF Outlet Pressure Sensor

9. DPF Outlet Temperature

Sensor
10. DPF Outlet NOx Sensor
11. SCR Outlet NOx Sensor

Fig. 2, 2V2 Two-Box ATS Sensor Locations

11. Check any wires, lines, or hoses within 4 inches

(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.

See the engine manufacturers maintenance manual

for filter replacement instructions and maintenance
intervals.

Diesel Exhaust Fluid (DEF) Filter

Replacement

EPA07 Exhaust System

The Environmental Protection Agencys 2010 regulations require lower nitrogen oxide (NOx) exhaust
emissions. Selective catalytic reduction (SCR) uses
diesel exhaust fluid (DEF) to lower NOx emissions in
the vehicle exhaust. A filter in the DEF pump prevents clogging of the DEF metering unit injection
nozzle.

Business Class M2 Maintenance Manual, September 2011

Definitions of ATS Terms

Refer to the following list of definitions of ATS components.
Aftertreatment System (ATS)the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.

49/3

49

Exhaust

11
10

2
9

3
7

4
8
5
6
09/16/2009

1.
2.
3.
4.
5.

DPF Inlet Temperature Sensor

DOC Inlet Temperature Sensor
DOC Inlet Pressure Sensor
DPF Sensor Box
DPF Outlet Pressure Sensor

f490354

6. DPF Outlet Temperature

Sensor
7. DPF Outlet NOx Sensor
8. SCR Inlet Temperature Sensor

9. SCR Outlet Temperature

Sensor
10. SCR Sensor Box
11. SCR Outlet NOx Sensor

Fig. 3, 2HV Two-Box ATS Sensor Locations

Aftertreatment Device (ATD)a muffler-like canister that houses a DPF, DOC, and sensors.

treatment equipment, depending upon local statutory

emissions guidelines.

Diesel Particulate Filter (DPF)a filter that collects and holds particulate matter (soot and
ash).

IMPORTANT: The aftertreatment device (ATD),

which is part of the aftertreatment system (ATS),
requires special attention during regularly
scheduled maintenance inspections; see Fig. 4.
No leaks are allowed anywhere in the system. If
any discrepancies are discovered, refer to the
engine manufacturers service literature for repair instructions.

Diesel Oxidation Catalyst (DOC)oxidizes hydrocarbons and reduces NOx.

Sensorsdetect temperatures and pressures in
the ATS.

Inspection
To meet EPA07 emissions regulations for vehicles
domiciled in the USA or Canada, engines manufactured after December 31, 2006 are equipped with an
emission aftertreatment system. Vehicles domiciled
outside of the USA and Canada may not have after-

49/4

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 exhaust seal clamp for leakage, wear, cracks, or

Business Class M2 Maintenance Manual, September 2011

49

Exhaust

6
5
1

3
A

10/20/2006

A.
1.
2.
3.
4.
5.

Inspect this area of the canister for dents.

Marmon Fitting at Inlet from Turbocharger
DOC Temperature Sensor
ATD Mounting Band
DPF Intake Pressure Sensor
DPF V-Band Mounting Clamps

6.
7.
8.
9.

f490283

Sensor Housing
DPF Outlet Temperature Sensor
Exhaust Outlet Marmon Fitting
DPF Outlet Pressure Sensor

Fig. 4, Typical Aftertreatment Device

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.
4. Check the ATD mounting bands for tightness.
Tighten to 30 lbfft (41 Nm) 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.
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 Item A of Fig. 4. A dent over
3 inches (76 mm) in diameter and 1/4-inch (6mm) deep could cause internal damage to the
DPF, causing it to malfunction.

Business Class M2 Maintenance Manual, September 2011

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.

Pre-EPA07 Exhaust System

Inspection
1. Inspect the exhaust manifold at the cylinder head
and at the turbocharger for leaks. See the engine
manufacturers service literature for repair procedures.
2. Inspect the muffler body, muffler outlet stack,
muffler shield, and inlet tubes for leakage, dents,
corrosion, or holes in the muffler.
3. Inspect the exhaust pipe and each exhaust seal
clamp for leakage, wear, or damage. Replace the
exhaust pipe if needed. If leakage exists at a
clamp, tighten the nuts to the required torque. If
leakage persists, install a new exhaust seal

49/5

49

Exhaust

2. Check the CGI piping and each exhaust 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. If any of the components is
damaged or leaking, replace it. See 4903 for
the replacement procedure.

clamp. Do not reuse seal clamps. Once a seal

clamp is loosened or removed, it must be replaced.
4. 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.

4902 CAT CGI Bellows and

Piping Inspection

4903 CAT CGI Bellows

Replacement

On vehicles with CAT engines,

On vehicles with CAT EPA07 compliant engines, replace the CGI bellows at the M3 maintenance interval to prevent a later failure.

NOTICE
A leak in the CGI piping, including the bellows,
will allow unfiltered air and contaminants into the
engine intake, and can cause serious engine damage.

NOTICE
A leak in the CGI piping, including the bellows,
will allow unfiltered air and contaminants into the
engine intake, and can cause serious engine
damage.

NOTE: Because the CGI bellows is covered

with a metal mesh, it is difficult to see cracks or
damage that may cause a leak.

1. Park the vehicle, set the parking brake, chock

the wheels.

1. Inspect the CGI bellows and piping for evidence

of damage or leakage. See Fig. 5. If the bellows
is damaged or leaking, replace it. See 4903 for
the replacement procedure.

2. Open the hood.

1
2

7 8

10

02/24/2011

1.
2.
3.
4.

1
f490456

Clamp
Inlet Pipe
U-Clamp
Forward Pipe-Support Brace

5. Slip Clamp
6. CGI Bellows
7. Center Pipe-Support Brace

8. Center Pipe
9. Clamp
10. Outlet Pipe

Fig. 5, CAT EPA07 Exhaust Installation with CGI Bellows

49/6

Business Class M2 Maintenance Manual, September 2011

49

Exhaust

3. Remove the right side inner fender/splash shield

as needed.
4. Remove the CGI piping between the engine and
aftertreatment device (ATD).
See Fig. 6.
5. On the workbench, remove the CGI bellows from
the exhaust piping. Do not damage the piping.

8. Using a yellow paint pen, mark the pipes 1.5

inches (38 mm) in from the end of each pipe.
These two marks will be used to center the bellows between the two pipes.
9. Once the pipes are correctly aligned and separated at the correct distance, secure the aft CGI
pipe to the ATD and to any CGI pipe support
brackets.

NOTE: The following step, and its substeps, is

to be done without the bellows installed. This
will align the pipes so that the bellows can be
installed correctly.

10. Remove the forward CGI pipe from the truck.

6. Install the CGI piping (without CGI bellows) and

align piping.

12. Slide the new bellows onto the aft CGI pipe as
far as it will go. See Fig. 9, Ref. A. Measurement
A should be at least 7/16 inch (10 mm) past the
face of the flange.

6.1

Attach the aft CGI pipe to the ATD.

6.2

Attach the forward CGI pipe to the engine.

NOTICE
When the CGI pipes and bellows are installed,
there should be approximately 3/4 inch (19 mm)
clearance from the main bellows. Contact between
the bellows could result in an exhaust leak, which
in this case may allow ingestion of contaminants
into the engine causing engine damage.
6.3

Use a straightedge to align the pipes so

that the pipe ends that attach to the bellows are parallel and concentric.

NOTICE

11. Slide the slip clamp, with the retaining ring and
graphite gasket ring, on the aft CGI pipe. See
Fig. 8 for proper installation.

13. Install the slip clamp with the retaining ring and
graphite gasket ring onto the forward CGI pipe.
See Fig. 10 for proper installation.
14. Slide the end of the forward CGI pipe into the
bellows, and properly align the pipe.
15. Secure the forward CGI pipe to the engine and
any CGI pipe support brackets.
16. Using the yellow marks, center the bellows between the exhaust pipes. Verify that the pipe is
inserted at least 7/16 inch (10 mm) past the face
of the flange. See Fig. 9, Ref. A.
17. Install the slip clamps on the bellows. Tighten the
slip clamps 11 lbfft (15 Nm).
18. Start the engine and check for exhaust leaks.
Tighten any clamps as needed.

When shortening the CGI pipe(s), it is critical to

leave a minimum of 1 inch (25.4 mm) of straight
pipe on the end of each CGI pipe to allow for pipe
insertion and clamp clearance. Failure to do this
could result in an exhaust leak, which in this case
may allow ingestion of contaminants into the engine causing engine damage.
7. Once the pipes are aligned, measure the pipe
gap between the CGI pipes and record the distance. See Fig. 7, Ref. A.
The existing pipe gap is designed at 10 inches
(254 mm). A 10.75 inches (273 mm) pipe gap is
required for the replacement CGI bellows and
clamps. This requires one or both of the CGI
pipes to be shortened.

Business Class M2 Maintenance Manual, September 2011

49/7

49

Exhaust

1
2

7 8

10

02/24/2011

1.
2.
3.
4.

f490456

Clamp
Inlet Pipe
U-Clamp
Forward Pipe-Support Brace

5. Slip Clamp
6. CGI Bellows
7. Center Pipe-Support Brace

8. Center Pipe
9. Clamp
10. Outlet Pipe

Fig. 6, CAT EPA07 Exhaust Installation with CGI Bellows

1
2

02/23/2011

A. Measure the pipe gap.

1. CGI Aft Pipe

f490457

2. CGI Forward Pipe

Fig. 7, Measuring the Pipe Gap (typical)

49/8

01/29/2010

f490415

1. Aft CGI Pipe

2. Retaining Ring
3. Graphite Gasket

4. Slip Clamp
5. CGI Bellows

Fig. 8, Aft Facing Slip Clamp Installation

Business Class M2 Maintenance Manual, September 2011

49

Exhaust

02/23/2011

f490458

A. At least 7/16 inch (10 mm)

1. Forward CGI Pipe
3. Aft CGI Pipe
2. CGI Bellows
Fig. 9, CGI Bellows Installation

02/08/2010

1. CGI Bellows
2. Slip Clamp
3. Retaining Ring

f490417

4. Graphite Gasket
5. Forward CGI Pipe

Fig. 10, Forward Facing Slip Clamp Installation

Business Class M2 Maintenance Manual, September 2011

49/9

Cab

60
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Mirror Folding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001

Business Class M2 Maintenance Manual, July 2010

Cab

60

6001 Mirror Folding Check

For vehicles with folding main mirrors, make sure
that the mirrors fold freely on the pivot points. Pivot
each mirror fully forward and backward two times to
break loose any debris that may affect the fold-away
feature of the mirror.

Business Class M2 Maintenance Manual, July 2010

60/1

Doors

72
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Door Seals Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7201

Business Class M2 Maintenance Manual, June 2002

Doors

72

7201 Door Seals Lubricating

NOTE: Only the door seals require lubrication.
Do not lubricate the door latches or hinges.
They come from the manufacturer with lifetime
lubrication and require no maintenance.
Lightly coat the door seals with a lubricant that is
safe for rubber.

Business Class M2 Maintenance Manual, June 2002

72/1

Heater and Air Conditioner

83
Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Air Conditioner Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8301
HVAC Air Filter Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8302

Business Class M2 Maintenance Manual, December 2001

83

Heater and Air Conditioner

8301 Air Conditioner

Inspecting
Refrigerant Compressor
Inspection
1. With the vehicle parked on a level surface, apply
the parking brakes and chock the tires.
2. Operate the heater and, if equipped with an air
conditioner, the air conditioner to check for
proper operation in all modes.
3. Open the hood.
4. Check the condition of the refrigerant compressor clutch assembly. If the friction surface of the
pulley shows signs of excessive grooving due to
belt slippage, replace both the pulley and the
drive plate.

11. Check for a buildup of road debris on the condenser 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.
12. Check the moisture indicator on the receiverdrier. See Fig. 1. If the indicator is a deep cobalt
blue, the refrigerant charge is dry. If the indicator
is not blue, the system is contaminated with
water. If the system is contaminated, recover the
refrigerant, replace the receiver drier, evacuate
the system, and add a full refrigerant charge. For
instructions, see Section 83.00, Subject 220 of
the Business Class M2 Workshop Manual.
13. Close the hood and remove the chocks from the
tires.

5. Inspect the refrigerant compressor drive belt for

damage. If needed, replace the drive belt.
6. Check the tightness of the compressor mounting
fasteners. The torque value for the mounting fasteners is 15 to 19 lbfft (20 to 26 Nm).
7. Inspect the drive plate. If the friction surface of
the drive plate shows visible signs of damage
due to excessive heat, make sure the refrigerant
compressor turns freely. If the compressor does
turn freely, replace the drive plate and clutch assembly. For instructions, see Section 83.01,
Subject 140 of the Business Class M2 Workshop Manual. If the compressor does not turn
freely, replace the compressor. For instructions,
see Section 83.01, Subject 120 of the Business
Class M2 Workshop Manual
8. Use a feeler gauge to check that the drive plate
clutch clearance is 0.016 to 0.031 inch (0.4 to
0.8 mm). If the gap is not even around the
clutch, gently tap down at the high areas. If the
overall gap is out of spec, remove the drive plate
assembly and change the shims as necessary.
For instructions, see Section 83.01, Subject 140
of the Business Class M2 Workshop Manual.
9. Check that the wiring harness connector is not
damaged or loose. Replace the wiring harness if
it is damaged.
10. Check the overall condition of the air conditioning
hoses. Look for cracks, cuts, and abrasions on
the hoses. Replace damaged hoses.

Business Class M2 Maintenance Manual, December 2001

4
12/21/2001

f543878

1. Fan Cycling Switch

2. Moisture Indicator

3. Binary Switch
4. Receiver-Drier

Fig. 1, Receiver-Drier

8302 HVAC Air Filter

Replacing
The HVAC air filter must be replaced every six
months or 60,000 miles (97 000 km) to permit proper
operation of the HVAC system.
1. With the vehicle parked, apply the parking
brakes, and chock the tires.

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83

Heater and Air Conditioner

2. Remove the lower HVAC cover in the cab. For

instructions, see Group 60 of the Business
Class M2 Workshop Manual.
3. Disconnect the wiring harness from the evaporator probe.
4. Remove the capscrews that attach the evaporator service cover to the HVAC assembly. Remove
the evaporator service cover.
5. Pull the filter out of the HVAC assembly.
6. Install a new filter in the HVAC assembly. Be
sure that the arrow on the filter is pointing toward
the evaporator. See Fig. 2.

10/04/2001

f543921

1. Evaporator

2. Filter

Fig. 2, HVAC Assembly Filter

7. Remove the condensate seal from the evaporator service cover and install a new condensate
seal on the cover.
8. Using capscrews, attach the evaporator service
cover to the HVAC assembly.
9. Connect the wiring harness to the evaporator
probe.
10. Attach the lower HVAC cover to the dash panel.
For instructions, see Group 60 of the Business
Class M2 Workshop Manual.
11. Remove the chocks from the tires.

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Index, Alphabetical

Title of Maintenance Operation (MOP)

MOP Number
Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8801

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Hood, Grille, and Cab Fenders

88

8801 Hood Rear Support

Lubrication
1. Apply the parking brakes and chock the tires.
2. Open the hood.
3. Clean both the hood- and cab-mounted hood
rear support components with a soapy water solution.
4. Cover all contact surfaces of the hood rear support brackets and isolators with an approved
multi-purpose, lithium-complex, soap-based
grease; see Table 1.
5. Close the hood.
Approved Suppliers of Multi-Purpose Lithium Grease
Supplier

Grease

Chevron

Delo Heavy Duty EP

Exxon

Unirex EP2

Mobil

Mobil Grease XHP 222

Shell

Retinax LC Grease

Texaco

Starplex 2

Table 1, Approved Suppliers of Multi-Purpose Lithium

Grease

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