COLUMBIA MAINTENANCE MANUAL

Models: CL112
CL120

STI-409-2 (2/10P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
 Foreword
Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper
maintenance program also helps to minimize downtime and to safeguard warranties. This
maintenance manual provides information necessary for years of safe, reliable, and cost-efficient
vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also
refer to other component and body manufacturers instructions for specific inspection
and maintenance instructions.
Perform the 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.

20012010 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 (POC-SSD)
P.O. Box 3849
Portland, OR 972083849
 Introduction
Descriptions of Service Publications

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro) formats.
Workshop/Service Workshop/service manuals contain service and repair information for all vehicle
Manual systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifica-
tions, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Drivers/Operators Drivers/operators manuals contain information needed to enhance the drivers
Manual 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 improve-
ments, and related information. Some service bulletins are updates to informa-
tion in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.

Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro ServicePro provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides di-
agnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro is an electronic parts catalog system, showing the specified 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 ac-
cessed from within PartsPro.

Columbia Maintenance Manual, February 2010 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; cus-
tomers receive notices that apply to their vehicles.

I2 Columbia Maintenance Manual, February 2010

 Introduction
Page Description

For an example of a Columbia Maintenance Manual page, see Fig. 1.

A B C

Cooling 20

2001 Coolant Replacement

2002 Cooling Fan Inspection

Columbia Maintenance Manual, December 2001

D E
11/28/2001 f020127
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number

Fig. 1, Example of a Columbia Maintenance Manual Page

Columbia Maintenance Manual, February 2010 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
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner

I4 Columbia Maintenance Manual, February 2010

General Information 00
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001
Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005
Lubrication and Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004
M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006
M2 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007
M3 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008
Maintenance Operation Sets Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009
Metric/U.S. Customary Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012
Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010
Service Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002
Torque Specifications Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013
Vehicle Maintenance Schedule Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011

Columbia Maintenance Manual, February 2010

General Information 00
Determining Scheduled Maintenance Intervals: 0001

Determining Scheduled (100 000 kilometers) with minimal city or stop-and-go

operation. Examples of Schedule III usage are: re-
Maintenance Intervals gional delivery that is mostly freeway miles; interstate
transport; or any road operation with high annual
Performing regular maintenance on your Freightliner mileage.
will help ensure that your Freightliner delivers safe
Service Schedule IV (long haul transport for Opti-
reliable service and optimum performance for years
mized Vehicle Configuration) is for vehicles that an-
to come. Failure to follow a regular maintenance pro-
nually travel over 60,000 miles (100 000 km) and
gram can result in inefficient operation and unsched-
meet the following qualifications:
uled down time.
Meritor 15-1/2 inch dampened/ceramic Lite
To determine the correct maintenance intervals for
Pedal LTD clutch with sealed release bearing.
your vehicle you must first determine the type of ser-
vice or conditions the vehicle will be operating in. Synthetic transmission fluid used in transmis-
Generally, most vehicles operate under conditions sion.
that fall within one of the four types of service de- Meritor FF961 or FF981 front axle (12,000 lb.
scribed. Before placing your new vehicle in service, capacity) with synthetic lubricant.
determine the type of service (Service Schedule I, II,
III, or IV) that applies to the intended use of the ve- Front suspension with maintenance-free rubber
hicle. After determining the vehicles type of service, bushings for 12,000 lb. capacity suspension.
refer to the service schedule table or the vehicle Meritor RPL series, or Dana Spicer SPL series
maintenance schedule table, to determine how often driveline U-joints.
maintenance should be performed.
Synthetic lubricant used in rear axle.
When the vehicle reaches the distance given for a
maintenance interval, see the Maintenance Interval Equipped with any Freightliner AirLiner suspen-
Operation Table for a list of the maintenance opera- sion.
tions to be performed at that maintenance interval. Equipped with Meritor Q-Plus extended-lube
Use the maintenance operation reference numbers to cam brakes and automatic slack adjusters, front
find detailed instructions in the manual on each op- and rear.
eration.
Standard brake system package including Ben-
dix AD-9 air dryermounted on the right-hand
Types of Service frame rail, located directly behind the front
Service Schedule I (severe service) applies to ve- bumperwith heater, and a Bendix air com-
hicles that annually travel less than 6000 miles (10 pressor.
000 kilometers) or that operate under severe condi- TRW TAS65 power steering.
tions. Examples of severe service, Schedule I usage
include: operation on extremely poor roads or where NOTE: Maintenance instructions in this manual
there is heavy dust accumulation; constant exposure are based on average vehicle use and normal
to extreme hot, cold, salt-air, or other extreme cli- operating conditions. Unusual vehicle operating
mates; frequent short-distance travel; construction- conditions may require service at more frequent
site operation; city operation (fire truck); or farm intervals.
operation.
Service Schedule II (short-haul transport) applies to
vehicles that annually travel less than 60,000 miles
(100 000 kilometers) and operate under normal con-
ditions. Examples of Schedule II usage are: opera-
tion primarily in cities and densely populated areas;
local transport with infrequent freeway travel; or high
percentage of stop-and-go travel.
Service Schedule III (long-haul transport) is for ve-
hicles that annually travel more than 60,000 miles

Columbia Maintenance Manual, February 2010 00/1

00 General Information
Service Schedule Table: 0002

Maintenance Interval
Service Schedule Maintenance Interval Operation
Frequency Miles km Hours
Initial Maintenance (IM) first 1000 1600 50
Schedule I*
(Severe Service) Maintenance 1 (M1) every 1000 1600 50
vehicles that annually travel less Maintenance 2 (M2) every 5000 8000 500
than 6000 miles (10 000 km)
Maintenance 3 (M3) every 15,000 24 000 1500
Initial Maintenance (IM) first 10,000 16 000
Schedule II
(Short-Haul Transport) Maintenance 1 (M1) every 10,000 16 000

vehicles that annually travel less Maintenance 2 (M2) every 50,000 80 000
than 60,000 miles (100 000 km)
Maintenance 3 (M3) every 150,000 240 000
Initial Maintenance (IM) first 25,000 40 000
Schedule III
(Long-Haul Transport) Maintenance 1 (M1) every 25,000 40 000

vehicles that annually travel over Maintenance 2 (M2) every 100,000 161 000
60,000 miles (100 000 km)
Maintenance 3 (M3) every 300,000 483 000
Schedule IV Initial Maintenance (IM) first 25,000 40 000
(Long-Haul Transport for Maintenance 1 (M1) every 25,000 40 000
Optimized Vehicle Configuration)
vehicles that annually travel over Maintenance 2 (M2) every 100,000 161 000
60,000 miles (100 000 km) Maintenance 3 (M3) every 300,000 483 000
* For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled.
Use Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumu-
lation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation.
Table 1, Service Schedule

00/2 Columbia Maintenance Manual, February 2010

General Information 00
Vehicle Maintenance Schedule Tables: 0003

1st through 30th Maintenance for Service Schedules I and II

Maintenance Service Service Schedule I Service Schedule II
Maint. No.
Interval Date Miles km Hours Miles km
1st IM and M1 1000 1600 100 10,000 16 000
2nd M1 2000 3200 200 20,000 32 000
3rd M1 3000 4800 300 30,000 48 000
4th M1 4000 6400 400 40,000 64 000
5th M1 and M2 5000 8000 500 50,000 80 000
6th M1 6000 9600 600 60,000 96 000
7th M1 7000 11 200 700 70,000 112 000
8th M1 8000 12 800 800 80,000 128 000
9th M1 9000 14 400 900 90,000 144 000
10th M1 and M2 10,000 16 000 1000 100,000 160 000
11th M1 11,000 17 600 1100 110,000 176 000
12th M1 12,000 19 200 1200 120,000 192 000
13th M1 13,000 20 800 1300 130,000 208 000
14th M1 14,000 22 400 1400 140,000 224 000
15th M1, M2, and M3 15,000 24 000 1500 150,000 240 000
16th M1 16,000 25 600 1600 160,000 256 000
17th M1 17,000 27 200 1700 170,000 272 000
18th M1 18,000 28 800 1800 180,000 288 000
19th M1 19,000 30 400 1900 190,000 304 000
20th M1 and M2 20,000 32 000 2000 200,000 320 000
21st M1 21,000 33 600 2100 210,000 336 000
22nd M1 22,000 35 200 2200 220,000 352 000
23rd M1 23,000 36 800 2300 230,000 368 000
24th M1 24,000 38 400 2400 240,000 384 000
25th M1 and M2 25,000 40 000 2500 250,000 400 000
26th M1 26,000 41 600 2600 260,000 416 000
27th M1 27,000 43 200 2700 270,000 432 000
28th M1 28,000 44 800 2800 280,000 448 000
29th M1 29,000 46 400 2900 290,000 464 000
30th M1, M2, and M3 30,000 48 000 3000 300,000 480 000
Table 2, 1st through 30th Maintenance for Service Schedules I and II

Columbia Maintenance Manual, February 2010 00/3

00 General Information
Vehicle Maintenance Schedule Tables: 0003

31st through 60th Maintenance for Service Schedules I and II

Maintenance Service Service Schedule I Service Schedule II
Maint. No.
Interval Date Miles km Hours Miles km
31st M1 31,000 49 600 3100 310,000 496 000
32nd M1 32,000 51 200 3200 320,000 512 000
33rd M1 33,000 52 800 3300 330,000 528 000
34th M1 34,000 54 400 3400 340,000 544 000
35th M1 and M2 35,000 56 000 3500 350,000 560 000
36th M1 36,000 57 600 3600 360,000 576 000
37th M1 37,000 59 200 3700 370,000 592 000
38th M1 38,000 60 800 3800 380,000 608 000
39th M1 39,000 62 400 3900 390,000 624 000
40th M1 and M2 40,000 64 000 4000 400,000 640 000
41st M1 41,000 65 600 4100 410,000 656 000
42nd M1 42,000 67 200 4200 420,000 672 000
43rd M1 43,000 68 800 4300 430,000 688 000
44th M1 44,000 70 400 4400 440,000 704 000
45th M1, M2, and M3 45,000 72 000 4500 450,000 720 000
46th M1 46,000 73 600 4600 460,000 736 000
47th M1 47,000 75 200 4700 470,000 752 000
48th M1 48,000 76 800 4800 480,000 768 000
49th M1 49,000 78 400 4900 490,000 784 000
50th M1 and M2 50,000 80 000 5000 500,000 800 000
51st M1 51,000 82 000 5100 510,000 820 000
52nd M1 52,000 83 700 5200 520,000 837 000
53rd M1 53,000 85 300 5300 530,000 853 000
54th M1 54,000 86 900 5400 540,000 869 000
55th M1 and M2 55,000 88 500 5500 550,000 885 000
56th M1 56,000 90 100 5600 560,000 901 000
57th M1 57,000 91 700 5700 570,000 917 000
58th M1 58,000 93 300 5800 580,000 933 000
59th M1 59,000 94 900 5900 590,000 949 000
60th M1, M2, and M3 60,000 96 500 6000 600,000 965 000
Table 3, 31st through 60th Maintenance for Service Schedules I and II

00/4 Columbia Maintenance Manual, February 2010

General Information 00
Vehicle Maintenance Schedule Tables: 0003

61st through 90th Maintenance for Service Schedules I and II

Maintenance Service Service Schedule I Service Schedule II
Maint. No.
Interval Date Miles km Hours Miles km
61st M1 61,000 98 200 6100 610,000 982 000
62nd M1 62,000 99 800 6200 620,000 998 000
63rd M1 63,000 101 400 6300 630,000 1 014 000
64th M1 64,000 103 000 6400 640,000 1 030 000
65th M1 and M2 65,000 104 600 6500 650,000 1 046 000
66th M1 66,000 106 200 6600 660,000 1 062 000
67th M1 67,000 107 800 6700 670,000 1 078 000
68th M1 68,000 109 400 6800 680,000 1 094 000
69th M1 69,000 111 000 6900 690,000 1 110 000
70th M1 and M2 70,000 112 700 7000 700,000 1 127 000
71st M1 71,000 114 300 7100 710,000 1 143 000
72nd M1 72,000 115 900 7200 720,000 1 159 000
73rd M1 73,000 117 500 7300 730,000 1 175 000
74th M1 74,000 119 100 7400 740,000 1 191 000
75th M1, M2, and M3 75,000 120 700 7500 750,000 1 207 000
76th M1 76,000 122 300 7600 760,000 1 223 000
77th M1 77,000 123 900 7700 770,000 1 239 000
78th M1 78,000 125 500 7800 780,000 1 255 000
79th M1 79,000 127 100 7900 790,000 1 271 000
80th M1 and M2 80,000 128 700 8000 800,000 1 287 000
81st M1 81,000 130 400 8100 810,000 1 304 000
82nd M1 82,000 132 000 8200 820,000 1 320 000
83rd M1 83,000 134 000 8300 830,000 1 340 000
84th M1 84,000 135 200 8400 840,000 1 352 000
85th M1 and M2 85,000 137 000 8500 850,000 1 370 000
86th M1 86,000 138 400 8600 860,000 1 384 000
87th M1 87,000 140 000 8700 870,000 1 400 000
88th M1 88,000 141 600 8800 880,000 1 416 000
89th M1 89,000 143 200 8900 890,000 1 432 000
90th M1, M2, and M3 90,000 144 800 9000 900,000 1 448 000
Table 4, 61st through 90th Maintenance for Service Schedules I and II

Columbia Maintenance Manual, February 2010 00/5

00 General Information
Vehicle Maintenance Schedule Tables: 0003

91st through 100th Maintenance for Service Schedules I and II

Maintenance Service Service Schedule I Service Schedule II
Maint. No.
Interval Date Miles km Hours Miles km
91st M1 91,000 146 500 9100 910,000 1 465 000
92nd M1 92,000 148 100 9200 920,000 1 481 000
93rd M1 93,000 150 000 9300 930,000 1 500 000
94th M1 94,000 151 300 9400 940,000 1 513 000
95th M1 and M2 95,000 153 000 9500 950,000 1 530 000
96th M1 96,000 155 000 9600 960,000 1 550 000
97th M1 97,000 156 100 9700 970,000 1 561 000
98th M1 98,000 157 700 9800 980,000 1 577 000
99th M1 99,000 159 300 9900 990,000 1 593 000
100th M1 and M2 100,000 160 900 10,000 1,000,000 1 609 000
Table 5, 91st through 100th Maintenance for Service Schedules I and II

1st through 20th Maintenance for Service Schedules III and IV

Service Service Schedules III and IV
Maint. No. Maintenance Interval
Date Miles km
1 IM and M1 25,000 40 000
2 M1 50,000 80 000
3 M1 75,000 121 000
4 M1 and M2 100,000 161 000
5 M1 125,000 201 000
6 M1 150,000 241 000
7 M1 175,000 281 000
8 M1 and M2 200,000 322 000
9 M1 225,000 362 000
10 M1 250,000 402 000
11 M1 275,000 443 000
12 M1, M2, and M3 300,000 483 000
13 M1 325,000 523 000
14 M1 350,000 563 000
15 M1 375,000 604 000
16 M1 and M2 400,000 644 000
17 M1 425,000 684 000
18 M1 450,000 724 000
19 M1 475,000 764 000

00/6 Columbia Maintenance Manual, February 2010

General Information 00
Vehicle Maintenance Schedule Tables: 0003

1st through 20th Maintenance for Service Schedules III and IV

Service Service Schedules III and IV
Maint. No. Maintenance Interval
Date Miles km
20 M1 and M2 500,000 805 000
Table 6, 1st through 20th Maintenance for Service Schedules III and IV

21st through 40th Maintenance for Service Schedules III and IV

Service Service Schedules III and IV
Maint. No. Maintenance Interval
Date Miles km
21 M1 525,000 845 000
22 M1 550,000 885 000
23 M1 575,000 925 000
24 M1, M2, and M3 600,000 966 000
25 M1 625,000 1 005 800
26 M1 650,000 1 046 000
27 M1 675,000 1 086 000
28 M1 and M2 700,000 1 127 000
29 M1 725,000 1 167 000
30 M1 750,000 1 207 000
31 M1 775,000 1 248 000
32 M1 and M2 800,000 1 287 000
33 M1 825,000 1 328 000
34 M1 850,000 1 368 000
35 M1 875,000 1 408 000
36 M1, M2, and M3 900,000 1 448 000
37 M1 925,000 1 490 000
38 M1 950,000 1 529 000
39 M1 975,000 1 569 000
40 M1 and M2 1,000,000 1 609 000
Table 7, 21st through 40th Maintenance for Service Schedules III and IV

Columbia Maintenance Manual, February 2010 00/7

00 General Information
Lubrication and Fluid Level Check: 0004

Maintenance Operation 0004, Lubrication and Fluid Maintenance operation numbers given in the table
Level Check Operation Table 8 summarizes all op- are reference numbers used to help you find detailed
erations that must be performed to complete the Lu- instructions in the manual on the lubrication or fluid
brication and Fluid Level Check operation 0004 check.
called for as an M1 maintenance interval for Service
Schedule I, II, and III vehicles, and as an M2 mainte-
nance interval for Service Schedule IV vehicles.

Maintenance Operation 0004

Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Maint. Service Service
Operation Operation Description Schedules I, II, Schedule IV Check
Number and III (at M1) (at M2)
2501 Eaton Fuller Clutch Release Bearing Lubrication
2502 Clutch Release Cross-Shaft Lubrication
2503 Sleeve Assembly Bronze Bushing Lubrication
2602 Transmission Fluid Level Inspection
3102 Fifth Wheel Lubrication
3104 Trailer Electrical Connector Lubrication
3202 Suspension Lubrication
3301 Knuckle Pin Lubrication, Meritor Axles
3303 Tie Rod Lubrication, Meritor Axles
3305 Knuckle Pin Lubrication, Dana Spicer Axles
3306 Tie Rod Lubrication, Dana Spicer Axles
3502 Axle Breather and Axle Lubricant Level Inspection
4102 Driveline Lubrication
4205 Dana Spicer Camshaft Bracket Lubrication
4206 Dana Spicer, Haldex, and Gunite Slack Adjuster
Lubrication
4603 Power Steering Fluid Level Inspection
4604 Power Steering Gear Lubrication
4605 Drag Link Lubrication
4606 Rack and Pinion Inspection
7201 Door Seal, Door Latch, and Door Hinge Lubrication
Table 8, Maintenance Operation 00-04, Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV

00/8 Columbia Maintenance Manual, February 2010

General Information 00
Initial Maintenance (IM) Operations: 0005

The Initial Maintenance table lists all maintenance tenance operations to be performed. All operations
operations that are to be performed at the initial listed in the table, along with the operations listed in
maintenance (IM) interval. Maintenance operation the applicable M1 maintenance interval table, must
numbers are reference numbers used to help you be performed to complete the initial maintenance
find detailed instructions in this manual on the main- (IM).

Maintenance
Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV Check
Operation Number
0006 Perform all M1 Operations
3103 Frame Fastener Torque Check
3203 Suspension U-Bolt Torque Check
3304 All-Axle Alignment Check
4001 Wheel Nut Check
4703 Fuel Tank Band-Nut Tightening
Table 9, Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV

Columbia Maintenance Manual, February 2010 00/9

00 General Information
M1 Maintenance Interval Operations: 0006

The M1 Maintenance Interval Operations tables list IMPORTANT: After performing all operations listed in
all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly
at the M1 maintenance interval. Maintenance opera- maintenance operations listed in the "Pretrip and
tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance" chapter of
you find detailed instructions in this manual on the the Columbia Drivers Manual.
maintenance operations to be performed.

Maintenance
M1 Maintenance Interval Operations for Service Schedules I, II, and III Check
Operation Number
0004 Lubrication and Fluid Level Check (includes the following)
Eaton Fuller Clutch Release Bearing Lubrication
Fifth Wheel Lubrication
Trailer Electrical Connector Lubrication
Suspension Lubrication
Knuckle Pin Lubrication, Dana Spicer Axles
Tie Rod Lubrication, Dana Spicer Axles
Driveline Lubrication
Dana Spicer Camshaft Bracket Lubrication
Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
Door Seal, Door Latch, and Door Hinge Lubrication
1301 Bendix Air Compressor Inspection
2003 Fan Clutch Check (noise emission control)
3101 Fifth Wheel Inspection
4101 Driveline Inspection
4211 Brake Inspection
4901 Exhaust System Inspection (noise emission control)
Table 10, M1 Maintenance Interval Operations for Service Schedules I, II, and III

Maintenance
M1 Maintenance Interval Operations for Service Schedule IV Check
Operation Number
1301 Bendix Air Compressor Inspection
2003 Fan Clutch Check (noise emission control)
3101 Fifth Wheel Inspection
3102 Fifth Wheel Lubrication
3104 Trailer Electrical Connector Lubrication
4211 Brake Inspection
4901 Exhaust System Inspection (noise emission control)
7201 Door Seal, Door Latch, and Door Hinge Lubrication
Table 11, M1 Maintenance Interval Operations for Service Schedule IV

00/10 Columbia Maintenance Manual, February 2010

General Information 00
M2 Maintenance Interval Operations: 0007

The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the
all maintenance operations that are to be performed maintenance operations to be performed. Perform all
at the M2 maintenance interval. Maintenance opera- M1 maintenance interval operations at the M2 main-
tion numbers are reference numbers used to help tenance interval.

Maintenance
M2 Maintenance Interval Operations for Service Schedules I, II, and III Check
Operation Number
0006 Perform All M1 Operations
0101 Engine Support Fasteners Check (noise emission control)
0102 Engine Drive Belt Inspection
1501 Alternator, Battery, and Starter Check
2001 Pressure Relief Cap Check
2502 Clutch Release Cross-Shaft Lubrication
2503 Sleeve Assembly Bronze Bushing Lubrication
2504 Meritor Clutch Release Bearing Lubrication
2602 Transmission Fluid Level Inspection
2603 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
3201 Suspension Inspection
3203 Suspension U-Bolt Torque Check
3301 Knuckle Pin Lubrication, Meritor Axles
3302 Tie Rod Inspection
3303 Tie Rod Lubrication, Meritor Axles
3307 Basic Inspection, Meritor Unitized Wheel Ends
3308 End-Play Check, Meritor Unitized Wheel Ends
3502 Axle Breather and Axle Lubricant Level Inspection
4001 Wheel Nut Check
4201 Air Brake System Valve Inspection
4203 Air Dryer Inspection
4204 Alcohol Evaporator Cleaning and Inspection
4207 Meritor Camshaft Bracket Lubrication
4208 Meritor Slack Adjuster Lubrication
4601 Drag Link Inspection
4603 Power Steering Fluid Level Inspection
4604 Power Steering Gear Lubrication
4605 Drag Link Lubrication
4606 Rack and Pinion Steering Inspection
4701 Fuel Filter Replacement
4702 Fuel Separator Sight Bowl Cleaning and Element Replacement
8301 Air Conditioner Inspection

Columbia Maintenance Manual, February 2010 00/11

00 General Information
M2 Maintenance Interval Operations: 0007

Maintenance
M2 Maintenance Interval Operations for Service Schedules I, II, and III Check
Operation Number
8302 Air Filter Replacement*
* Replace the HVAC filters every 6 months regardless of mileage.

Table 12, M2 Maintenance Interval Operations for Service Schedules I, II, and III

Maintenance
M2 Maintenance Interval Operations for Service Schedule IV Check
Operation Number
0004 Lubrication and Fluid Level Check (includes the following)
Clutch Release Cross-Shaft Lubrication
Sleeve Assembly Bronze Bushing Lubrication
Transmission Fluid Level Inspection
Knuckle Pin Lubrication, Meritor Axles
Tie Rod Lubrication, Meritor Axles
Axle Breather and Axle Lubricant Level Inspection
Driveline Lubrication
Power Steering Fluid Level Inspection
Power Steering Gear Lubrication
Drag Link Lubrication
0006 Perform All M1 Operations
0101 Engine Support Fasteners Check (noise emission control)
0102 Engine Drive Belt Inspection
1501 Alternator, Battery, and Starter Check
2001 Pressure Relief Cap Check
2603 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
3201 Suspension Inspection
3203 Suspension U-Bolt Torque Check
3302 Tie Rod Inspection
3307 Basic Inspection, Meritor Unitized Wheel Ends
3308 End-Play Check, Meritor Unitized Wheel Ends
4001 Wheel Nut Check
4101 Driveline Inspection
4201 Air Brake System Valve Inspection
4203 Air Dryer Inspection
4204 Alcohol Evaporator Cleaning and Inspection
4601 Drag Link Inspection
4606 Rack and Pinion Steering Inspection
4701 Fuel Filter Replacement
4702 Fuel Separator Sight Bowl Cleaning and Element Replacement

00/12 Columbia Maintenance Manual, February 2010

General Information 00
M2 Maintenance Interval Operations: 0007

Maintenance
M2 Maintenance Interval Operations for Service Schedule IV Check
Operation Number
8301 Air Conditioner Inspection
8302 Air Filter Replacement*
* Replace the HVAC filters every 6 months regardless of mileage.

Table 13, M2 Maintenance Interval Operations for Service Schedule IV

Columbia Maintenance Manual, February 2010 00/13

00 General Information
M3 Maintenance Interval Operations: 0008

The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the
all maintenance operations that are to be performed maintenance operations to be performed. Perform all
at the M3 maintenance interval. Maintenance opera- M1 and M2 maintenance interval operations at the
tion numbers are reference numbers used to help M3 maintenance interval.

Maintenance
M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV Check
Operation Number
0006 Perform All M1 Operations
0007 Perform All M2 Operations
0901 Air Cleaner Element Inspection and Replacement
2002 Radiator Pressure-Flushing and Coolant Change
2601 Manual Transmission Fluid Change, and Magnetic Plug Cleaning (synthetic lubricant)
3501 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant)
4202 Bendix AD9 Air Dryer Desiccant Replacement
4209 Bendix ADIS Air Dryer Desiccant Replacement
4210 Bendix E6 Foot Control Valve Inspection and Lubrication
4602 Power Steering Fluid and Filter Change
Table 14, M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV

00/14 Columbia Maintenance Manual, February 2010

General Information 00
Maintenance Operation Sets Table: 0009

Maintenance Operation Sets for Groups 00 through 83

Maint. Service Schedules Service Schedule
Operation Description
No. I, II, and III IV
IM M1 M2 M3 IM M1 M2 M3
0004 Lubrication and Fluid Level Check
0101 Engine Support Fasteners Check (noise emission control)
0102 Engine Drive Belt Inspection
0103 Pacbrake Inspection and Lubrication*
0901 Air Cleaner Element Inspection and Replacement
1301 Bendix Air Compressor Inspection
1501 Alternator, Battery, and Starter Check
2001 Pressure Relief Cap Check
2002 Radiator Pressure-Flushing and Coolant Change
2003 Fan Clutch Check (noise emission control)
2501 Eaton Fuller Clutch Release Bearing Lubrication
2502 Clutch Release Cross-Shaft Lubrication
2503 Sleeve Assembly Bronze Bushing Lubrication
2504 Meritor Clutch Release Bearing Lubrication
2601 Manual Transmission Fluid Change, and Magnetic Plug Cleaning

(Synthetic Lubricant)
2602 Transmission Fluid Level Inspection
2603 Manual Transmission Air Filter/Regulator Check, Cleaning, or

Replacement
3101 Fifth Wheel Inspection
3102 Fifth Wheel Lubrication
3103 Frame Fastener Torque Check
3104 Trailer Electrical Connector Lubrication
3201 Suspension Inspection
3202 Suspension Lubrication
3203 Suspension U-Bolt Torque Check
3301 Knuckle Pin Lubrication, Meritor Axles
3302 Tie Rod Inspection
3303 Tie Rod Lubrication, Meritor Axles
3304 All-Axle Alignment Check
3305 Knuckle Pin Lubrication, Dana Spicer Axles
3306 Tie Rod Lubrication, Dana Spicer Axles
3307 Basic Inspection, Meritor Unitized Wheel Ends
3308 End-Play Check, Meritor Unitized Wheel Ends

Columbia Maintenance Manual, February 2010 00/15

00 General Information
Maintenance Operation Sets Table: 0009

Maintenance Operation Sets for Groups 00 through 83

Maint. Service Schedules Service Schedule
Operation Description
No. I, II, and III IV
IM M1 M2 M3 IM M1 M2 M3
3501 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning

(synthetic lubricant)
3502 Axle Breather and Axle Lubricant Level Inspection
4001 Wheel Nut Check
4101 Driveline Inspection
4102 Driveline Lubrication
4201 Air Brake System Valve Inspection
4202 Bendix AD9 Air Dryer Desiccant Replacement
4203 Air Dryer Inspection
4204 Alcohol Evaporator Cleaning and Inspection
4205 Dana Spicer Camshaft Bracket Lubrication
4206 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
4207 Meritor Camshaft Bracket Lubrication
4208 Meritor Slack Adjuster Lubrication
4209 Bendix ADIS Air Dryer Desiccant Replacement
4210 Bendix E6 Foot Control Valve Inspection and Lubrication
4211 Brake Inspection
4601 Drag Link Inspection
4602 Power Steering Fluid and Filter Change
4603 Power Steering Fluid Level Inspection
4604 Power Steering Gear Lubrication
4605 Drag Link Lubrication
4606 Rack and Pinion Steering Inspection
4701 Fuel Filter Replacement
4702 Fuel Separator Sight Bowl Cleaning and Element Replacement
4703 Fuel Tank Band-Nut Tightening
4901 Exhaust System Inspection (noise emission control)
7201 Door Seal, Door Latch, and Door Hinge Lubrication
8301 Air Conditioner Inspection
8302 Air Filter Replacement
* No specific lubrication interval. See MOP 0103 for more information.
Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 869 km), and then every 50,000 miles (80 467 km).
Check the end play at 200,000 miles (321 869 km), and then every subsequent 200,000 miles (321 869 km).
Replace the HVAC filters every 6 months regardless of mileage.

Table 15, Maintenance Operation Sets for Groups 00 through 83

00/16 Columbia Maintenance Manual, February 2010

General Information 00
Noise Emission Controls Maintenance: 0010

Noise Emission Control the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser, or while it is in
Maintenance use.
2. The use of the vehicle after such device or ele-
Federal Law, Part 205: ment of design has been removed or rendered
inoperative by any person.
Transportation Equipment Noise
Among those acts presumed to constitute tam-
Emission Controls pering are the acts listed below:
Part 205, Transportation Equipment Noise Emission A. Removal of engine noise-deadening panels.
Controls, requires the vehicle manufacturer to fur-
nish, with each new vehicle, such written instructions B. Removal of cab-tunnel or hood noise-
for the proper maintenance, use, and repair of the deadening panels.
vehicle by the ultimate purchaser to provide reason-
able assurance of the elimination or minimization of C. Removal of, or rendering inoperative, the en-
noise-emission-control degradation throughout the gine speed governor so as to allow engine
life of the vehicle. In compliance with the law, the speed to exceed manufacturers specifica-
noise emission controls maintenance information in tions.
each applicable group of this manual, in conjunction D. Removal of, or rendering inoperative, the fan
with the vehicle workshop manual, provides these clutch, including bypassing the control on
instructions to owners. any thermostatic fan drive to cause it to op-
erate continuously.
Recommendations for E. Removal of the fan shroud.
Replacement Parts
F. Removal of, or rendering inoperative, ex-
Replacement parts used for maintenance or repair of haust components, including exhaust pipe
noise emission controls should be genuine Freight- clamping.
liner parts. If other than genuine Freightliner parts
are used for replacement or repair of components G. Removal of air intake components.
affecting noise emission control, the owner should be
sure that such parts are warranted by their manufac- Maintenance Instructions
turer to be equivalent to genuine Freightliner parts in
performance and durability. Scheduled intervals are in the maintenance tables in
this group. A "Verification of Inspections Log (Groups
Freightliner Noise Emission 01, 20, and 49)" follows, and should be filled in each
time noise emission controls on the vehicle are main-
Controls Warranty tained or repaired.
Refer to the vehicle owners warranty information
book for warranty information concerning noise emis-
sion controls.

Tampering with Noise Controls is

Prohibited
Federal law prohibits the following acts or the caus-
ing thereof:
1. The removal or rendering inoperative by any per-
son (other than for purposes of maintenance,
repair, or replacement) of any device or element
of design incorporated into any new vehicle for

Columbia Maintenance Manual, February 2010 00/17

00 General Information
Verification of Inspections Log: 0011

Verification of Inspections Log

Verification of Inspections Log, Group 01
Verification of Inspections Log Group 01 Engine Mounts
Date Mileage Item Cost Maintenance Facility

Verification of Inspections Log, Group 20

Verification of Inspections Log Group 20 Fan Clutch
Date Mileage Item Cost Maintenance Facility

00/18 Columbia Maintenance Manual, February 2010

General Information 00
Verification of Inspections Log: 0011

Verification of Inspections Log, Group 49

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

Columbia Maintenance Manual, February 2010 00/19

00 General Information
Metric/U.S. Customary Conversion Tables: 0012

When You Know U.S. Multiply When You Multiply

To Get Metric To Get U.S. Customary
Customary By Know Metric By
Length
inches (in) 25.4 millimeters (mm) 0.03937 inches (in)
inches (in) 2.54 centimeters (cm) 0.3937 inches (in)
feet (ft) 0.3048 meters (m) 3.281 feet (ft)
yards (yd) 0.9144 meters (m) 1.094 yards (yd)
miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)
Area
square inches (in2) 645.16 square millimeters (mm2) 0.00155 square inches (in2)
square inches (in2) 6.452 square centimeters (cm2) 0.155 square inches (in2)
square feet (ft2) 0.0929 square meters (m2) 10.764 square feet (ft2)
Volume
cubic inches (in3) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)
cubic inches (in3) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)
cubic inches (in3) 0.01639 liters (L) 61.024 cubic inches (in3)
fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)
pints (pt) 0.47318 liters (L) 2.1134 pints (pt)
quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)
gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)
cubic feet (ft3) 28.317 liters (L) 0.03531 cubic feet (ft3)
cubic feet (ft3) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)
Weight/Force
ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)
pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)
U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)
U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)
Torque/Work Force
inchpounds (lbfin) 11.298 Newtoncentimeters (Ncm) 0.08851 inchpounds (lbfin)
footpounds (lbfft) 1.3558 Newtonmeters (Nm) 0.7376 footpounds (lbfft)
Pressure/Vacuum
inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)
pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)
Table 16, Metric/U.S. Customary Conversion

Then When You Multiply Then

When You Know Subtract To Get To Get
Divide By Know By Add
degrees Fahrenheit (F) 32 1.8 degrees Celcius (C) 1.8 32 degrees Fahrenheit (F)
Table 17, Temperature Conversion

00/20 Columbia Maintenance Manual, February 2010

General Information 00
Torque Specifications Tables: 0013

Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads
Regular Hex Flanged
Thread
Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G
Diameter
Bolt B Nut 8.2 Bolt C Nut Bolt Nut 8.2 Bolt Nut
Pitch
Torque: lbfft (Nm) Torque: lbfft (Nm) Torque: lbfft (Nm) Torque: lbfft (Nm)

f230002 f230003 f230004 f230005 f230006 f230007 f230008 f230009

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

Columbia Maintenance Manual, February 2010 00/21

00 General Information
Torque Specifications Tables: 0013

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads
Regular Hex Flanged
Thread
Grade 5 or B Grade 8 or 8.2 Grade 8 or C Grade 8 or 8.2
Diameter Grade 5 Bolt Grade G Nut
Nut Bolt Nut Bolt
Pitch
Torque: lbfft (Nm) Torque: lbfft (Nm) Torque: lbfft (Nm)

f230002 f230003 f230004 f230005 f230008 f230009

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 18. Freightliner recommends that
all plated and unplated fasteners be coated with oil before installation.
Table 19, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

00/22 Columbia Maintenance Manual, February 2010

General Information 00
Torque Specifications Tables: 0013

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads
Thread Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut
DiameterPitch Torque: lbfft (Nm) Torque: lbfft (Nm)

8.8 8 10.9 10

f230010 f230011 f230012 f230013

M6 5 (7) 7 (9)
M8 12 (16) 17 (23)
M8 x 1 13 (18) 18 (24)
M10 24 (33) 34 (46)
M10 x 1.25 27 (37) 38 (52)
M12 42 (57) 60 (81)
M12 x 1.5 43 (58) 62 (84)
M14 66 (89) 95 (129)
M14 x 1.5 72 (98) 103 (140)
M16 103 (140) 148 (201)
M16 x 1.5 110 (149) 157 (213)
M18 147 (199) 203 (275)
M18 x 1.5 165 (224) 229 (310)
M20 208 (282) 288 (390)
M20 x 1.5 213 (313) 320 (434)
M22 283 (384) 392 (531)
M22 x 1.5 315 (427) 431 (584)
M24 360 (488) 498 (675)
M24 x 2 392 (531) 542 (735)
M27 527 (715) 729 (988)
M27 x 2 569 (771) 788 (1068)
M30 715 (969) 990 (1342)
M30 x 2 792 (1074) 1096 (1486)
* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.
Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,
cadmium-plated, or waxed).
Table 20, Torque Values for Metric Thread Fasteners With Lubricated or Plated
Threads

Columbia Maintenance Manual, February 2010 00/23

Engine 01
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Engine Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102
Engine Support Fasteners Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101
Pacbrake Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103

Columbia Maintenance Manual, January 2007

Engine 01

0101 Engine Support sion, or too little tension on the belt may result in ex-
cessive and premature belt wear. Poly-V belts, or
Fasteners Check serpentine belts, are retained by a belt tensioner that
requires no tension adjustment. Replace the drive
Front and rear engine supports for vehicles built from belt if any conditions described in "Visual Inspection"
January 2007 require no periodic maintenance. are found. V-belts are installed as individual belts,
Mounts should be inspected when the engine is re- and as matched sets. When replacing matched sets
moved for service. For vehicles manufactured prior to of belts, always replace both belts at the same time.
January 2007, perform the following check. Matched belts must be from the same manufacturer.
Check the rear engine support fasteners (see Fig. 1, To inspect a belt, gently twist it to view the belt side-
Ref. 4) for tightness. Tighten the 3/4-inch fasteners walls and bottom. Inspect all belts for the following
215 to 265 lbfft (292 to 359 Nm). conditions, then perform the "Belt Tension Inspec-
tion."
Check the front engine support fasteners for tight-
ness. Tighten the 5/8-inch fasteners 125 lbfft (170
Nm).
Visual Inspection
1. Inspect the belt for glazing. See Fig. 2 , Ref. A.
NOTE: At engine overhaul, and whenever the Glazing is represented by shiny sidewalls, and is
engine has been removed, inspect the lower caused by friction created when a loose belt slips
and upper isolators (Refs. 1 and 6), and replace in the pulleys. It can also be caused by oil or
them if they are worn. See Group 01 of the grease on the pulleys.
Columbia Workshop Manual for procedures.
2. Check the belt for ply separation. See Fig. 2,
Ref. B. Oil, grease, or belt dressing can cause
the belt to fall apart in layers. Repair any oil or
2 coolant leaks that are affecting the belts before
replacing the drive belts. Do not use belt dress-
6 ing on any belt.
3. Check the belt for a jagged or streaked sidewall.
See Fig. 2, Ref. C. Jagged or streaked sidewalls
are the result of foreign objects, such as sand or
1 gravel in the pulley, or a rough pulley surface.
4. Check for tensile breaks (breaks in the cord
2 body). See Fig. 2, Ref. D. Cuts in a belt are usu-
5 4 3 ally caused by foreign objects in the pulley, or by
prying or forcing the belt during removal or instal-
lation.
10/05/94 f220047a 5. Check for uneven ribs on serpentine (poly-V)
1. Lower Isolator belts. See Fig. 2, Ref. E. Foreign objects in the
2. Engine Support Washer pulley will erode the undercord ribs, causing the
3. 3/410 Capscrew belt to lose its gripping power.
4. 3/410 Hexnut
5. Engine Mount 6. Check the drive belts for cracks. See Fig. 2, Ref.
6. Upper Isolator F. Small irregular cracks are usually signs of an
old belt.
Fig. 1, Engine Rear Mount
7. Inspect the pulleys for excessive play or wobble.
Excessive play or wobble indicates a failure of
0102 Engine Drive Belt the pulley bearing. Check for belt squealing or
Inspection squeaking. Replace the bearings as necessary.
NOTE: If it is difficult to distinguish the location
Worn or loose drive belts may cause premature
of a supposed bearing noise, place a stetho-
bearing failure or engine overheating. Excessive ten-

Columbia Maintenance Manual, January 2007 01/1

01 Engine

A D

B E

C F
11/21/94 f150010a
A. Glazing C. Streaked Sidewalls E. Uneven Ribs
B. Separating Layers D. Tensile Break F. Cracks
Fig. 2, Drive Belt Replacement Conditions

scope on the component being checked, not the 2. Install a belt tension gauge at the center of the
pulley, to isolate the area from outside interfer- belts longest free-span. Check belt tension. See
ence. Table 1 for belt tension specifications.
8. Inspect all pulleys for foreign objects, oil, or 3. If belt tension is not correct, see Group 01 of the
grease in the grooves. Columbia Workshop Manual to adjust belt ten-
sion.
Belt Tension Inspection
Threaded-Adjustment Type
1. Apply the parking brakes and chock the tires.

Drive Belt Tensions

Engine Component Belt Tension: lbf (kg)
Cummins ISB, ISC, ISM Refrigerant Compressor 100 (45)
Fan and Alternator 29.5 (27.9)
Mercedes-Benz MBE900
Refrigerant Compressor 30.0 (28.4)
Table 1, Drive Belt Tensions

01/2 Columbia Maintenance Manual, January 2007

Engine 01

Spring-Tension Type
On belts equipped with a spring tensioner, belt ten-
sion is automatically adjusted. Check that the ten-
sioner is holding tension on the belt by inserting the
end of a breaker bar in the 1/2-inch square hole on
the forward face of the tensioner, and rotating the
tensioner away from the belt. When the breaker bar
is slowly released, the tensioner should return to its
original position. The tensioner should rotate
smoothly with no binding. If not, see Group 01 of the
Columbia Workshop Manual for replacement in-
structions.
NOTE: The following engines, which appear in
Table 1, are provided with automatic tensioners
for the fan and alternator belts.

0103 Pacbrake Inspection and

Lubrication
With frequent use, the Pacbrake Exhaust Brake will
operate maintenance-free. If the vehicle is used in-
consistently or seasonally, it will be necessary to per-
form preventative maintenance. If the vehicle is ex-
posed to excess moisture, or is used only for
periodic or seasonal use, perform the following steps:
1. With the engine off, use any oil-free or non-
petroleum-based high-heat lubricant, and spray
or coat a sufficient amount on the restrictor valve
shaft and the attaching locations at each end of
the actuation cylinder.
2. With your hands or a pair of pliers, motion the
valve several times to distribute the lubricant
down the shaft and the attaching locations.
NOTE: Operation of the Pacbrake could be af-
fected by starting the engine and idling for short
periods of time. During a cold engine start-up,
moisture occurs in the engine and the exhaust
system that creates a corrosion hazard. The
brake housing may trap water in the valve shaft
bore causing corrosion, resulting in an improp-
erly functioning or non-functioning brake. If it is
necessary to periodically start the engine, attain
normal operating temperatures before shutting
down the engine.

Columbia Maintenance Manual, January 2007 01/3

Air Intake 09
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

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

Columbia Maintenance Manual, February 2004

Air Intake 09

0901 Air Cleaner Element

Inspection and
Replacement
Method 1
Replace the air cleaner element at the recommended
interval or when the air restriction indicator reaches
20 inH2O on a vehicle with a Detroit Diesel engine,
22 inH2O on a vehicle with an MBE engine, or 25
inH2O on a vehicle with a Caterpillar or Cummins
engine. For replacement instructions, see Group 09
of the Columbia Workshop Manual. Reset the air
restriction indicator.
Each time the air cleaner is replaced, perform the
procedures in MOP 1301.
If the maximum restriction is not reached, record the
air restriction value. If the value is higher than the
previous recording, reset the air restriction indicator.
If the value is lower than the previous recording, in-
spect the air cleaner and air cleaner element of
cracks, leaks, or any other damage.
If the air cleaner or air cleaner element is damaged,
replace it and reset the air restriction indicator.

Method 2
Replace the air cleaner element at the recommended
interval or when the air restriction indicator reaches
20 inH2O on a vehicle with a Detroit Diesel engine,
22 inH2O on a vehicle with an MBE engine, or 25
inH2O on a vehicle with a Caterpillar or Cummins
engine. For replacement instructions, see Group 09
of the Columbia Workshop Manual. Reset the air
restriction indicator.
Each time the air cleaner is replaced, perform the
procedures in MOP 1301.
If the maximum restriction is not reached, inspect the
air cleaner and air cleaner element for cracks, leaks,
or any other damage. If the air cleaner or air cleaner
element is damaged, replace it and reset the air re-
striction indicator.

Columbia Maintenance Manual, February 2004 09/1

Air Compressor 13
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Bendix Air Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301

Columbia Maintenance Manual, May 2002

Air Compressor 13

1301 Bendix Air Compressor

Inspection
Inspect the air intake line, oil supply and return lines,
and coolant supply and return hoses for tight connec-
tions and general condition. Tighten the connections
and replace the lines and hoses as needed. If the
compressor intake-air adapter is loose, remove the
adapter, replace the adapter gaskets, and securely
install the adapter.
Check the cooling fins on the compressor crankcase.
Clean the fins if they are clogged with dirt or grease.

Columbia Maintenance Manual, May 2002 13/1

Alternators and Starters 15
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1501

Columbia Maintenance Manual, October 2008

Alternators and Starters 15

1501 Alternator, Battery, and 4.2 Inspect the retainer assembly or battery
hold-downs, and the battery box. Replace
Starter Connections worn or damaged parts. Remove any cor-
rosion with a wire brush, and wash with a
Check weak solution of baking soda and water.
Flush with clean water, and dry. Paint the
WARNING retainer assembly if needed, to prevent
rusting.
Batteries generate explosive gas as a by-product 4.3 Check that foreign objects such as
of their chemical process. Do not smoke when stones, bolts, and nuts are removed from
working around batteries. Put out all flames and the battery box.
remove any source of sparks or intense heat in
the vicinity of the battery compartment. Make sure 4.4 After cleaning, connect the cables to the
the battery compartment has been completely batteries and tighten them to the torque
vented before disconnecting or connecting the specifications listed on the battery, gener-
battery cables. ally 10 to 15 lbfft (14 to 20 Nm).
Battery acid is extremely harmful if splashed in 4.5 Coat the battery terminals with dielectric
the eyes or on the skin. Always wear a face shield grease.
and protective clothing when working around 5. Check the alternator wiring for missing insulation,
batteries. kinks, and heat damage. Replace or repair as
1. Check the tightness of the alternator bracket fas- needed.
teners; tighten the fasteners as needed. For 6. Check the terminals on the battery shut-off
torque values, see Group 15 of the Columbia switch and the magnetic switch. Make sure the
Workshop Manual. terminal connections are clean and tight. Coat
2. Check the belt tension of the alternator drive the terminal connections with dielectric red
belt. Place a tension gauge at the belts widest enamel after cleaning.
span, and adjust the belt tension to specification.
See Group 01 for belt tension specifications.
Some engines are equipped with dual alternator
belts; always check both belts for correct tension.
Check that the tensioner operates smoothly with-
out binding. Engines equipped with a serpentine,
or poly-V belt have automatic belt tensioners and
do not require belt tension inspection.
3. Check that all electrical connections at the alter-
nator 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 charg-
ing cable terminates.
4. Inspect the battery cables for wear, and replace
them if they are damaged. Clean the cable con-
nector terminals with a wire brush. See Group
54 of the Columbia Workshop Manual for
troubleshooting instructions, and for adjustment,
repair, or replacement instructions.
4.1 Clean and tighten the battery ground
cable, terminal, and clamps.

Columbia Maintenance Manual, October 2008 15/1

Engine Cooling/Radiator 20
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fan Clutch Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2003
Pressure Relief Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
Radiator Pressure-Flushing and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002

Columbia Maintenance Manual, January 2007

Engine Cooling/Radiator 20

2001 Pressure Relief Cap 3. There is a second valve in the radiator cap that
opens under vacuum. This prevents the collapse
Check 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.
WARNING 4. Make sure that the cap seals properly on the
Do not remove or loosen the surge tank cap until coolant filler neck seat, and that the radiator cap
the engine and cooling system have completely gasket is not damaged. On vehicles with
cooled. Use extreme care when removing the cap. screw-on caps with O-rings, make sure that the
A sudden release of pressure from removing the O-ring is not cracked or deteriorated. Replace
cap prior to the system cooling can result in a the cap if the gasket shows deterioration or dam-
surge of scalding coolant that could cause seri- age.
ous personal injury.
1. Remove the fill cap, first, to relieve the cooling 2002 Radiator Pressure-
system pressure, then remove the SAE cap.
Flushing and Coolant
2. Using a radiator-cap tester, check the pressure
cap to see if it maintains pressure to within 10% Change
of the pressure rating marked on the cap. If it
doesnt, replace the cap. See Fig. 1. Make sure NOTE: For additional instructions on cleaning
that the replacement radiator cap is correctly and flushing the engine cooling system, see the
rated for the cooling system of the vehicle.

1 2

06/08/95 f500244

1. Low-Coolant-Level Sensor
2. SAE Cap (for coolant overflow pressure relief only)
3. Fill Cap

Fig. 1, Surge Tank

Columbia Maintenance Manual, January 2007 20/1

20 Engine Cooling/Radiator

applicable engine manufacturers maintenance

and operation manual.
1. Park the vehicle and apply the parking brakes.
Tilt the hood.
2. Place a suitable container under the elbow of the
radiator outlet pipe and the radiator. The con-
tainer should hold at least 60 quarts (59 liters) of
fluid.
1
WARNING
Do not remove or loosen the surge tank 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 1
cap prior to the system cooling can result in a 06/29/95 f011008
surge of scalding coolant that could cause seri-
NOTE: Cummins engine shown.
ous personal injury.
1. Coolant Drain Plug
3. Remove the surge tank cap.
Fig. 2, Coolant Drain Plug Location
WARNING 8. Repeat the previous two steps until clean water
flows from the radiator.
Do not attempt to drain the cooling system until
the coolant and engine are cool. Draining the 9. Remove the radiator side-tank drain plug and
cooling system prior to the system cooling could allow the radiator to drain. Install and tighten the
cause severe personal injury due to scalding. side-tank drain plug and the radiator outlet pipe
drain plug after the radiator has been drained.
4. Remove the drain plugs at the radiator side tank
Do not overtighten the plugs.
and at the lower radiator outlet pipe elbow. See
Fig. 2. Allow the coolant to drain. 10. Connect the hoses. Your hose clamps can be
either T-bolt clamps (see Fig. 3) or Breeze
5. Disconnect the radiator upper and lower hoses,
Constant-Torque clamps (see Fig. 4).
and install the surge tank cap. Attach the flushing
gun nozzle to the radiator at the lower radiator When working with T-bolt hose clamps, tighten
hose opening. Run the water until the radiator is the clamps 55 lbfin (620 Ncm). These clamps
full. are now standard on hoses with an inside diam-
eter greater than 2 inches (51 mm).
CAUTION When installing Breeze Constant-Torque hose
clamps, the clamps must be tightened to the cor-
When flushing the radiator, do not apply more rect torque. The screw tip of the clamp must ex-
than 15 psi (100 kPa) air pressure. Excessive pres- tend about 1/4 inch (6 mm) from the clamp hous-
sure can damage the radiator. ing, and the Belleville washer stacks must be
6. Gradually, apply air pressure to help dislodge collapsed almost flat. Use a torque wrench to
sediment built up in the radiator core. Do not install these clamps correctly. The correct instal-
apply more than 15 psi (100 kPa) air pressure to lation torque is as follows:
the radiator. Pressures exceeding 15 psi (100 For Breeze Constant-Torque clamps with a 5/16-
kPa) could damage the radiator core. inch tightening screw hex: 55 lbfin (620 Ncm).
7. Shut off the air at the pressure gun nozzle and For Breeze Constant-Torque clamps with a 3/8-
allow the radiator to refill with water. inch tightening screw hex: 90 lbfin (1020 Ncm).

20/2 Columbia Maintenance Manual, January 2007

Engine Cooling/Radiator 20

IMPORTANT: On vehicles with EPA07 compliant

engines, the coolant capacity varies depending
on the engine and accessory installation. After
servicing the cooling system, always verify that
the coolant level is between the MIN and MAX
lines on the surge tank.
13. Fill the cooling system with new coolant. See
Table 1 for the vehicles coolant capacity. Certain
equipment such as fuel heaters, water filters, and
auxiliary heaters may increase the coolant ca-
pacity and require additional coolant. The cooling
system is filled when the coolant level reaches
the MAX line on the surge tank. Freightliner rec-
02/28/96 f200326
ommends the use of a precharged and premixed
antifreeze when refilling the cooling system. See
Fig. 3, T-Bolt Type Hose Clamp Table 2 for a list of some of the precharged anti-
freeze available. Use of an equivalent antifreeze
to those listed in the table is also acceptable.
B Always check that the antifreeze meets Freight-
A 1 liners specifications and is at the proper concen-
tration for protection in the vehicle operating
area. See Table 3 for antifreeze protection infor-
mation. Freightliner specifies that antifreeze must
be an ethylene glycol solution that meets GM
6038 M Engineering Standards or a ethylene gly-
col solution that has less than 0.1% anhydrous
sodium metasilicate, and meets either GM 1825
08/15/94 f200286 M or GM 1899 M Engineering Standards. If
A. The screw tip must extend about 1/4 inch (6 mm). supplemental coolant additives are being used,
B. Belleville washers must collapse almost flat. add the supplements to the coolant as neces-
1. Tightening Screw Hex sary. See the coolant additive manufacturers
instructions for the correct amount of additive
Fig. 4, Breeze Constant-Torque Hose Clamp Installation required. Dont forget to consider the volume of
the supplemental coolant additive being added to
NOTE: All hose clamps will lose torque after the system when determining the amount of
installation due to "compression set." However, coolant required to refill the system.
when correctly installed, Breeze Constant-
Torque clamps will hold enough torque to auto- Engine Coolant Capacity (pre-EPA07 engines)
matically adjust and keep consistent sealing Capacity with 1000 Capacity with 1200
pressure. During vehicle operation and shut- Engine
sq. inch Radiator: sq. inch Radiator:
down, the screw tip may adjust according to CAT C10/C12 39.5 qt (37.4 L) 40.6 qt (38.5 L)
temperature and pressure changes. The torque
CAT 53.2 qt (50.4 L) 54.1 qt (51.5 L)
may need to be adjusted for individual applica-
tions. Cummins 39.0 qt (37.0 L) 40.2 qt (38.1 L)

11. Place a pan under the coolant filter to catch en- DDE S60 54.8 qt (51.9 L) 56.0 qt (53.0 L)
gine coolant. Table 1, Engine Coolant Capacity (pre-EPA07
engines)
12. Remove the coolant filter with a strap or chain
wrench. Install a new coolant filter and tighten.

Columbia Maintenance Manual, January 2007 20/3

20 Engine Cooling/Radiator

Manufacturer Antifreeze Type

Contains supplement additives. Available as a
Caterpillar Caterpillar Diesel Engine Antifreeze/Coolant
premixed solution.
Cummins Fleetguard Compleat Premix Premixed solution with supplement additives
Detroit Diesel Detroit Diesel Power Cool Premixed solution with supplement additives
Old World Industries Fleet Charge With supplement additives
Table 2, Approved Antifreeze

Maximum Coolant Protection in F (C) at Various Antifreeze ConcentrationS

Cooling ETHYLENE-GLYCOL-BASE ANTIFREEZE REQUIRED
System gallons (liters)
Capacity 10 11 12
gal (L)* 2 (8) 3 (11) 4 (15) 5 (19) 6 (23) 7 (26) 8 (30) 9 (34)
(38) (42) (45)
10 (38) 16 (9) 4 (16) 12 (24) 34 (37) 62 (52)
11 (42) 18 (8) 8 (13) 6 (21) 23 (31) 47 (44) 62 (52)
12 (45) 19 (7) 10 (12) 0 (18) 15 (26) 34 (37) 57 (49)
13 (49) 21 (6) 13 (11) 3 (16) 9 (23) 25 (31) 45 (43) 62 (52)
14 (53) 15 (9) 6 (14) 5 (19) 18 (28) 34 (37) 54 (48)
62
15 (57) 16 (9) 8 (13) 0 (18) 12 (24) 26 (32) 43 (42)
(52)
52 62
16 (61) 17 (8) 10 (12) 2 (17) 8 (22) 19 (28) 34 (37)
(47) (52)
42 58
17 (64) 18 (8) 12 (11) 5 (15) 4 (20) 14 (26) 27 (33)
(41) (50)
34 50 62
18 (68) 19 (7) 14 (10) 7 (14) 0 (18) 10 (23) 21 (29)
(37) (46) (52)
28 42 56
19 (72) 20 (7) 15 (9) 9 (13) 2 (17) 7 (22) 16 (27)
(33) (41) (49)
22 34 48 62
20 (76) 16 (9) 10 (12) 4 (16) 3 (19) 12 (24)
(30) (37) (44) (52)
* For cooling system capacities not shown, the required amount of antifreeze can be calculated, using the following: Ethylene-glycol-base antifreeze in a 25%
solution protects to 10F (12C), 33% to 0F (18C), 40% to 12F (24C), 50% to 34F (37C), and 60% to 62F (52C).
60% ethylene-glycol-base antifreeze and 40% water by volume gives maximum coolant protection (62F [52C]). Exceeding 60% antifreeze diminishes
coolant protection; concentrated ethylene-glycol-base antifreeze will freeze at approximately 0F (18C).
Table 3, Maximum Coolant Protection in F (C) at Various Antifreeze Concentrations

NOTE: You can mix purple-pink coolant (pre- temperature. Check the radiator and hoses for
charged with a borate/nitrate-based additive) leaks. Repair as needed.
with the common green coolant, although some 17. Shut off the engine, then check the coolant level
color change will be apparent. in the surge tank. Add coolant if the level isnt
14. Replace the surge tank cap(s). between MIN and MAX lines on the surge tank.

15. Return the hood to the operating position.

16. Start the engine and turn on the cab heater.
Allow the engine to warm up to normal operating

20/4 Columbia Maintenance Manual, January 2007

Engine Cooling/Radiator 20

2003 Fan Clutch Check (Noise 3 4

Emission Control) 5
2
Horton Advantage 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 Columbia 1
Workshop Manual.
1. Disconnect the batteries at the negative termi- 08/08/94 f200290
nals. Drain all air from the air system. If
1. System Sentry Fuse 4. Piston Friction Disc
equipped with an air starter, drain the air starter
2. Safeguard Hole 5. Air Chamber
reservoir. 3. Friction Facing

WARNING Fig. 5, Horton Advantage Fan Clutch

down the engine. Separate the halves of the fan

If the engine starts during this procedure, the fan
solenoid connector. The fan clutch should en-
could cause personal injury. If the vehicle is
gage.
equipped with an air starter, be sure that the air
starter reservoir is drained. If the fan does not operate correctly, see Group
20 of the Columbia Workshop Manual for
2. Inspect the electrical connections and wires to
troubleshooting and repair procedures.
the fan clutch solenoid. Secure the connection if
loose; replace wires and connectors if damaged. 8. With the air system charged to 120 psi (827
kPa), and with the fan solenoid connector halves
3. Clean the fan clutch air solenoid valve filter, if
separated, check the fan clutch for audible air
equipped.
leaks, using a suitable listening device.
3.1 Unscrew the fan clutch solenoid valve air
9. If a leak is detected, remove the fan blade. Using
filter and remove its element.
a soapy water solution, check the fan clutch at
3.2 Clean the filter element with cleaning sol- the following locations to find the source of the
vent. leak. Install a new seal kit. See Group 20 of the
3.3 Reassemble the clutch valve solenoid air Columbia Workshop Manual for repair proce-
filter, then install it. dures.

4. Check the fan for bent, cracked, or damaged 9.1 Check for a leak at the bleed hole on the
blades. Replace if damaged. Check for adequate fan pilot. Air leakage means the cartridge
clearance between the fan and other compo- assembly (Fig. 6, Ref. 16) or face seal
nents. (Ref. 17) is damaged.

5. Check the fan belt for wear, tension, and align- 9.2 Check for air leaks between the air cham-
ment. Correct as needed. ber and the piston friction disc. Air leak-
age means the large O-ring (Ref. 14) is
6. Check for wear on the friction facing. See Fig. 5. damaged.
Replace the friction facing if it is worn to a 1/16-
inch (1.6-mm) thickness or less. Also check the 9.3 Check for air leaks around the safeguard
facing for signs of oil contamination or burn hole on the piston friction disc. Air leak-
marks. If evidence of oil or burn marks are age means the small O-ring (Ref. 18) is
found, replace the friction facing. damaged.

7. Connect the battery cables. Start the engine, and 9.4 Check for air leaking from the System
charge the air system to 120 psi (827 kPa). Shut Sentry fuse. Leaking air means the
clutch has gotten so hot the lead alloy in

Columbia Maintenance Manual, January 2007 20/5

20 Engine Cooling/Radiator

8
7
6

19 20
5
18
23
4 22
17 21
3
1 14 15
2
13
16
12
11

10
9

24

03/30/95 f200194a
1. Mounting Bracket 9. Rear Hub Bearing 17. Face Seal
2. Rear Sheave Bearing 10. Bearing Spacer 18. Small O-Ring
3. Inner and Outer Bearing 11. Splined Hub 19. Air Chamber
Spacers 12. Forward Hub Bearing 20. Socket-Head Capscrew
4. Forward Sheave Bearing 13. Piston Friction Disc 21. Stud Bolt
5. Sheave 14. Large O-Ring 22. Lockwasher
6. Friction Facing 15. Locknut 23. Hexnut
7. Journal Spacer 16. Cartridge Assembly 24. Piston Assembly
8. Socket-Head Capscrew
Fig. 6, Horton Advantage Fan Clutch Components

the fuse melted. This released the clutch 10.4 Set the toggle switch to ON; the fan
before the heat could damage the clutch clutch should engage.
bearings. Before replacing the fuse, find
10.5 Apply the foot brake, and release the
and repair the source of the heat.
parking brakes.
10. If equipped with an override toggle switch on the
10.6 Set the toggle switch to AUTO or OFF; air
dash, check fan clutch operation as follows:
should exhaust and the fan clutch should
10.1 Connect the halves of the fan solenoid disengage. Replace the switch if neces-
connector. sary.
10.2 Turn off the air conditioner. 11. If the fan stays engaged at all times on a Detroit
Diesel engine, check the circuit breaker labeled
10.3 Start the engine and charge the air sys-
"engine fan."
tem to 120 psi (827 kPa). Tests must be
performed with the engine temperature
below 205F (96C) for Caterpillar en-
gines, and below 200F (93C) for Cum-
mins and Detroit Diesel engines.

20/6 Columbia Maintenance Manual, January 2007

Engine Cooling/Radiator 20

Kysor K22RA Fan Clutch the retaining plate to the forward-most edge of
the fan belt pulley.
1. Disconnect the batteries at the negative termi- 5. Compare the two measurements; if the difference
nals. Drain all air from the air system. If between the two measurements exceeds 0.150
equipped with an air starter, drain the air starter inches (3.8 mm), the clutch lining is worn and
reservoir. must be replaced. See Group 20 of the
Columbia Workshop Manual for clutch lining
WARNING replacement instructions.
If the engine starts during this procedure, the fan 6. Release the air pressure, then disconnect the
could cause personal injury. If the vehicle is shop hose from the air inlet of the air cylinder.
equipped with an air starter, be sure that the air Connect the vehicle air hose to the inlet.
starter reservoir is drained. 7. Connect the battery cables. Start the engine.
2. Measure the distance from the back surface of
the fan clutch retaining plate to the forward-most Horton DriveMaster Fan Clutch
edge of the fan belt pulley. See Fig. 7, Ref. A.
NOTE: If any part of the fan clutch needs to be
repaired or replaced after performing the checks
3 below, see Group 20 of the Columbia Work-
2 shop Manual.
1 1. Disconnect the batteries at the negative termi-
nals. Drain all air from the air system. If
equipped with an air starter, drain the air starter
4 reservoir.

WARNING
Make sure the batteries are disconnected before
5 checking the fan clutch. If the engine starts during
this procedure, the fan could engage, which could
result in serious personal injury.
6 A 2. Inspect the electrical connections and wires to
the fan clutch solenoid. Secure the connection if
05/27/93 f200237a
loose; replace wires and connectors if damaged.
With the fan clutch engaged, measure the distance at A;
measure it again with the fan clutch disengaged. 3. Clean the fan clutch air solenoid valve filter, if
equipped.
1. Bearing Housing 5. Air Cylinder
2. Retaining Plate 6. Fan 3.1 Unscrew the fan clutch solenoid valve air
3. Fan Pulley filter assembly and remove the filter ele-
4. Air Inlet (from solenoid ment.
valve)
3.2 Clean the filter element with cleaning sol-
Fig. 7, Kysor K22RA Fan Clutch Lining Wear Check vent.
3. Disconnect the line from the air inlet of the air 3.3 Using a clean, lint-free cloth, wipe off any
cylinder. Connect a shop air hose to the inlet. excess solvent.
4. Apply a minimum of 100 psi (690 kPa) air pres- 3.4 Reassemble the clutch valve solenoid air
sure to the air cylinderthe bearing housing will filter, then install it on the vehicle.
move backwards, disengaging the clutch. Again,
measure the distance from the back surface of

Columbia Maintenance Manual, January 2007 20/7

20 Engine Cooling/Radiator

4. Check the fan for bent, cracked, or damaged 9. If a leak is detected, remove the fan blade. In-
blades. Replace if damaged. Check for adequate stall a new seal kit. See Group 20 of the
clearance between the fan and other compo- Columbia Workshop Manual for repair proce-
nents. dures.
5. Check the fan belt for wear, tension, and align- 10. Check the fan drive for discoloration or any other
ment. Correct if necessary. signs of slipping or overheating.
6. Check for wear on the friction facing. Replace NOTE: The fan clutch may slip if the air supply
the friction facing if it is worn to a 3/16-inch (4.8- pressure is below 70 psi (483 kPa) or if there is
mm) thickness or less. Also check the facing for a leak inside the fan clutch. Any leak must be
signs of oil contamination or burn marks. If evi- remedied.
dence of oil or burn marks are found, replace the
friction facing. 11. Check the fan clutch bearings.
7. Connect the battery cables. Start the engine, and 11.1 Turn the fan in both directions and feel
charge the air system to 120 psi (827 kPa). for worn hub bearings.
Manually engage and disengage the fan clutch. 11.2 If possible, remove the drive belt and
Check the fan and fan clutch from a distance. check for worn sheave bearings by turn-
Look for vibration, fan blade contact, fan clutch ing the sheave in both directions.
slippage, and overall fan clutch operation. 11.3 If either the hub or sheave bearings are
If the fan clutch does not operate correctly, see worn, replace them, using a Horton Drive-
Group 20 of the Columbia Workshop Manual Master Super Kit.
for troubleshooting and repair procedures. For instructions and kit part number, see
8. With the air system charged to 120 psi (827 Group 20 of the Columbia Workshop
kPa), check the fan clutch for audible air leaks, Manual.
using a suitable listening device.
Check at the solenoid valve, the air filter assem-
bly, and the air hoses and fittings. See Fig. 8.
Using a wet finger or a soapy water solution,
check for a leak in the same areas.

05/30/2002 f200581

Fig. 8, Checking for Air Leaks (Horton DriveMaster)

20/8 Columbia Maintenance Manual, January 2007

Clutch 25
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Clutch Release Cross-Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2502
Eaton Fuller Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2501
Meritor Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2504
Sleeve Assembly Bronze Bushing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2503

Columbia Maintenance Manual, April 2005

Clutch 25

2501 Eaton Fuller Clutch

Release Bearing
Lubrication
The standard clutch release bearing is not sealed,
and requires lubrication. If the vehicle is not
equipped with an optional sealed clutch release bear-
ing, 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 ex-
tends outside of the clutch housing. It is not
necessary to remove the clutch inspection plate
when the lubrication extension is used.
NOTE: For lubrication of the release bearing,
Eaton Fuller recommends a lithium-base high- 05/27/93 f250081a

temperature grease that meets the NLGI grade Fig. 1, Release Bearing Grease Fitting
one or two specification.
3. Wipe any dirt away from the grease fitting. See 1
Fig. 1. Using a pressure-type grease gun
equipped with the recommended grease, lubri-
cate 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. 2
Over-lubrication could contaminate the clutch in- 08/10/2009 f250444
ternally, causing clutch slippage and premature 1. Sleeve Bushing Contact Point
failure. Do not use chassis grease or multipurpose 2. Yoke Finger Contact Points
lubricants.
Fig. 2, Grease the Contact Points
4. Wipe off excess grease and apply to both the
yoke finger and sleeve bushing contact points. See Fig. 3 and Fig. 4. Wipe any dirt from the grease
See Fig. 2. fittings, and lubricate with multipurpose chassis
grease.
5. Install the clutch inspection plate, then remove
the chocks.
2503 Sleeve Assembly Bronze
2502 Clutch Release Cross- Bushing Lubrication
Shaft Lubrication Vehicles equipped with the sealed clutch release
bearing require lubrication of the bronze bushing lo-
The clutch release cross-shaft is equipped with two
cated between the clutch bearing housing and the
grease fittings in the transmission clutch housing.
transmission input shaft. Use a pressure-type grease

Columbia Maintenance Manual, April 2005 25/1

25 Clutch

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 ex-
1 tends outside of the clutch housing. It is not
necessary to remove the clutch inspection plate
when the lubrication extension is used.
2 NOTE: For lubrication of the release bearing,
Meritor recommends a lithium-base high-
temperature grease that meets the NLGI grade
three specification.
3. Wipe any dirt from the grease fitting. See Fig. 1.
10/19/93 f250048a
Using a pressure-type grease gun equipped with
1. Clutch Release Cross-Shaft recommended grease, lubricate the bearing until
2. Grease Fitting excess grease purges from the rear of the re-
Fig. 3, Cross-Shaft Grease Fitting, Left-Side lease bearing (toward the transmission).

CAUTION
Do not over-lubricate the clutch release bearing.
Over-lubrication could contaminate the clutch in-
ternally, 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, then remove
the chocks.

05/27/93 f260146a

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

gun equipped with high-temperature grease only, and

lubricate until grease flows from the release bearing
housing. Depress the clutch pedal a couple of times
before starting the engine.

2504 Meritor Clutch Release

Bearing Lubrication
The standard clutch release bearing is not sealed,
and requires lubrication. If the vehicle is not
equipped with an optional sealed clutch release bear-
ing with a grease fitting, lubricate the bearing as
follows:

25/2 Columbia Maintenance Manual, April 2005

Transmission 26
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement . . . . . . . . . . . . . . . . . . . . . . . 2603
Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic
Lubricant)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2601
Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2602

Columbia Maintenance Manual, April 2005

Transmission 26

2601 Manual Transmission formance, change the filter each time that the
fluid is changed.
Fluid Change, and 5. For a transmission equipped with a transmission
Magnetic Plug Cleaning fluid filter(s), replace the fluid filter(s).
(Synthetic Lubricant) 5.1 Place a drain pan under the transmission
fluid filter.

CAUTION CAUTION
Operating a transmission with the fluid level
higher or lower than recommended can result in To prevent skin burns from hot transmission fluid,
transmission damage. Do not overfill the transmis- wear protective gloves when removing the filter.
sion. Overfilling will force fluid out of the case 5.2 Place a strap or chain wrench around the
through the main shaft openings. filter canister, and rotate it in a counter-
Do not mix types and brands of fluid, because of clockwise motion to separate the filter
possible incompatibility. Do not use fluid addi- from the mounting. Carefully spin the filter
tives, friction modifiers, extreme-pressure gear off the mount and remove it from the ve-
fluids, or multiviscosity lubricants. hicle.
5.3 Apply a light coat of transmission fluid to
NOTE: Fluid change intervals are extended to
the O-ring gasket on the new filter. Fill the
500,000 miles (800 000 km) on any vehicles filter with specified transmission fluid, and
filled with synthetic transmission fluid. spin the filter onto the mount.
1. Drain the transmission when the fluid is warm. If NOTE: The filter fills slowly, so be patient to
not already warm, run the engine until the trans-
mission fluid reaches operating temperature.
ensure the proper fluid level has been set.
Shift the transmission to neutral (N) and shut 5.4 Once the filter makes contact with the
down the engine. mount, use a strap wrench to rotate the
2. Park the vehicle on level ground, apply the park- canister an additional 180 to 270 degrees
ing brakes, and chock the rear tires. Place a to firmly tighten the filter. Wipe the filter
large drain pan under the transmission. clean of any fluid after it is tightened.

3. Clean the area around the fill plug, and remove it 6. Add fluid until it is level with the lower edge of
from the side of the gear case. Remove each the fill opening. See Fig. 1. If the transmission
drain plug from the bottom of the case. has two fill openings, add fluid to the level of
both openings. See Table 1 for approved trans-
4. Clean the fill and drain plugs. For magnetic mission lubricants. See Table 2 for Meritor trans-
plugs, use a piece of key stock or any other con- mission lubricant capacities and Table 3 for
venient steel slug to short the two magnetic Eaton Fuller transmission lubricant capacities.
poles and divert the magnetic field.
Install and tighten each drain plug 50 lbfft (68
Nm).
NOTE: The optional transmission fluid filter is a
remote-mount, spin-on type, and is located be-
tween the transmission and the fluid cooler. The
filter bracket is attached to the frame rail or
some other near-by location. The filter is A B
05/27/93 f260006a
mounted in a vertical position, and should be
filled with fluid before installation to assure the A. Full B. Low
proper fluid level. For optimum transmission per- Fig. 1, Checking Transmission Fluid Level

Columbia Maintenance Manual, April 2005 26/1

26 Transmission

Approved Manual Transmission Lubricants Eaton Fuller Transmission Lubricant Capacities

Transmission Temp. SAE Transmission Model Refill Capacity:* qt (L)
Lubricant Type*
Model Range Viscosity
7-Speed T Series
Eaton Fuller Transmissions
All Models 18.0 (17.0)
MobilTrans SHC 50
All 50W All 9-Speed Series
(RN 2952 E-5)
All Eaton All Models 13.5 (12.8)
Fuller Synthetic transmission
lubricant approved by All 50W All 10-Speed Manual (except deep reduction)
Eaton
FR and FRO Series 11.75 (11.0)
Meritor Transmissions
RT and RTX Series 13.0 (12.3)
MobilTrans SHC 50
FreedomLine All 50W RTLO Series 14.0 (13.2)
(RN 2952 E-5)
10-Speed Deep Reduction
Synthetic engine oil
All other meeting Meritor spec RTO14908LL
All 50W 14.0 (13.2)
Meritor 081, or MILL2104D
RTO16908LL
or 2104E
* Do not mix types or brands of fluid. Multi-weight and extreme-pressure 10-Speed Automated
gear fluids are not recommended. Lightning Top 2 (all) 13.5 (12.8)
Call 1-800-826-4357 for a complete list of Eaton approved lubricants.
10-Speed Autoshift AS2 (all) 13.0 (12.3)
Table 1, Approved Manual Transmission Lubricants
13-Speed RTLO Series
All Models 14.0 (13.2)
Meritor Transmission Lubricant Capacities
15-Speed RTO Series
Transmission Model Refill Capacity:* qt (L)
All Models 14.0 (13.2)
Meritor M/MO Series
All 18-Speed Series
M/MO (all) 10.25 (9.7)
RTLO Series
ZF Meritor FreedomLine 14.0 (13.2)
18-Speed Autoshift AS2 (all)
All 12-Speed Models 11.6 (11.0)
* Quantities listed are approximate. Fill transmission until lubricant is level
All 16-Speed Models 12.5 (11.8)
with bottom of fill hole with vehicle in normal operating position.
* Quantities listed are approximate. Fill transmission until lubricant is level Table 3, Eaton Fuller Transmission Lubricant
with bottom of fill hole with vehicle in normal operating position. Capacities
Table 2, Meritor Transmission Lubricant Capacities
44 lbfft (60 Nm) for all ZF Meritor
FreedomLine automated transmissions.
NOTE: In all cases, the correct fluid level is es- 35 to 50 lbfft (48 to 67 Nm) for all other
tablished by checking at the fill opening. Meritor transmissions.
7. Operate the engine for five minutes after filling 9. Operate the vehicle to check for correct opera-
the transmission, then check the fluid level again. tion.
8. Clean the fill plug, then install it in the transmis-
sion. 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.

26/2 Columbia Maintenance Manual, April 2005

Transmission 26

2602 Transmission Fluid 2603 Manual Transmission Air

Level Inspection Filter/Regulator Check,
Cleaning, or
CAUTION Replacement
Operating a transmission with the fluid level
higher or lower than recommended can result in Eaton Fuller
transmission damage. Do not overfill the transmis-
sion. Overfilling will force fluid out of the case 1. Apply the parking brakes, and chock the rear
through the main shaft openings. tires. Drain the air reservoirs.
Do not mix types and brands of fluid, because of
possible incompatibility. Do not use fluid addi- WARNING
tives, friction modifiers, extreme-pressure gear Drain the air supply; if the air supply is not
fluids, or multiviscosity lubricants. drained before the air filter/regulator is serviced,
With the transmission at operating temperature, and serious injury and component damage could re-
the vehicle on a level surface, check the fluid level in sult.
the transmission. 2. Clean the outside of the air filter/regulator with
1. Clean the area around the fill plug, and remove it cleaning solvent. See Fig. 2.
from the side of the gear case.
2. Using your finger or a bent pipe cleaner, see if
the fluid is level with the fill opening. See Fig. 1.
3. If the fluid level is low, check the transmission for
leaks, and correct as needed.
4. If needed, add the recommended fluid, until it is
level with the lower edge of the fill opening. See
Table 1 for approved transmission lubricants.
5. Clean the fill plug, then install it. Tighten the plug
as follows:
25 to 35 lbfft (34 to 48 Nm) for transmis-
sions with 3/4-inch pipe threads.
60 to 75 lbfft (81 to 102 Nm) for transmis-
sions with 1-1/4-inch pipe threads.
44 lbfft (60 Nm) for all ZF Meritor
FreedomLine automated transmissions.
35 to 50 lbfft (48 to 67 Nm) for all other
Meritor transmissions.
05/27/93 f260037a

Fig. 2, Air Filter/Regulator Location (Eaton Fuller

transmission shown)

3. Remove the end cap, large O-ring, and filter ele-

ment from the filter housing. See Fig. 3. Remove
the small O-ring from the end cap.

Columbia Maintenance Manual, April 2005 26/3

26 Transmission

7. Start the engine, and build pressure in the air

6 7 system. Check for air leaks at the filter housing
5
4 and air line connections; repair any leaks.
2 3
Meritor
NOTE: This procedure does not apply to
FreedomLine transmissions.
1. Park the vehicle on a level surface. Apply the
1 parking brakes, and chock the rear tires.
10/17/2001 f260052a 2. Remove the element from the air filter/regulator
1. Air Regulator 5. Small O-Ring assembly. Inspect the O-rings in the end cap;
2. Housing 6. End Cap replace worn or damaged O-rings. Inspect the
3. Large O-Ring 7. Plug element for fluid contamination. If fluid is present,
4. Filter Element replace the element. Inspect the air supply sys-
Fig. 3, Eaton Fuller Transmission Air Filter/Regulator tem for the source of the fluid, and service it as
Components needed.
3. Install the element in the filter/regulator assem-
NOTE: Do not remove, disassemble, or adjust bly.
the air regulator. If the air regulator is not keep-
ing air pressure between 58 and 63 psi (400 to 4. Apply a light coat of silicone grease, or an
435 kPa), replace the air filter/regulator. It can- equivalent grease to the O-rings in the end cap.
Install and tighten the end cap 10 to 15 lbfft (14
not be repaired. to 20 Nm).

WARNING 5. Build air pressure in the system, check for leaks,

and make any needed repairs.
Wear safety goggles when using compressed air
to clean parts, as permanent harm to eyes could
result from flying debris.
4. Clean the filter element by dipping it in alcohol or
other cleaning solvent. Blow compressed air
through the element (inside to outside) to loosen
surface dirt and to dry the element. If it is not
damaged, the sintered metallic filter element will
last the life of the vehicle.
Wipe out the filter housing with a clean, dry, lint-
free rag. Clean and inspect the O-rings and end
cap. Replace any parts that are damaged.
5. Install the large O-ring, then the filter element
(small end first) into the filter housing.
6. Install the small O-ring in the end cap, then in-
stall the end cap and tighten it until firm.

CAUTION
A leaking air filter or air lines can cause slow or
hard shifting of the transmission, and eventual
transmission damage.

26/4 Columbia Maintenance Manual, April 2005

Frame and Frame Components 31
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101
Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3102
Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103
Trailer Electrical Connector Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3104

Columbia Maintenance Manual, October 2008

Frame and Frame Components 31

3101 Fifth Wheel Inspection 8.2 Release the lock by tripping the release
latch at the bottom of the throat.
8.3 Adjust the wedge stop at the end of the
WARNING wedge to approximately 1/4-inch (6-mm)
clearance by turning the wedge stop rod
All fifth wheel maintenance, adjustment, and re- located on the right side of the top plate.
building must be done only by a qualified me-
chanic. Improper or incomplete procedures could 9. Replace cracked, worn, or damaged parts with
result in a possible disengagement of the trailer new parts. Replace all loose mounting bolts with
from the tractor, which could result in personal 5/811 SAE grade 8 bolts, grade C locknuts, and
injury or property damage. hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.
Parts are under spring compression. Wear safety
goggles while servicing the fifth wheel. Failure to 10. After inspecting the fifth wheel, lubricate all mov-
do so can result in personal injury, due to parts ing parts with a chassis or multipurpose grease.
ejecting with force. Apply a generous coating of grease to the top
plate to fill the grooves, or depressions, on the
Fontaine top plate. See Maintenance Operation 3102
for lubrication instructions.
1. Disconnect the tractor from the trailer. For in-
structions, see Chapter 10 of the Columbia
Drivers Manual.
Holland
1. Disconnect the tractor from the trailer. For in-
2. Thoroughly steam clean the fifth wheel.
structions, see the Columbia Drivers Manual.
3. Look for cracks in the fifth wheel assembly,
2. Thoroughly steam clean the fifth wheel.
mounting brackets, and mounting parts.
3. Check for loose nuts or broken bolts on the fifth
4. Check the jaw and stationary jaw for mushroom-
wheel assembly.
ing, and check that the serrations at the jaw and
wedge are in good condition. 4. Inspect for cracks or wear on the mounting bolts.
5. Test the safety lock latch for ease of operation. 5. Inspect for improper locking action and for cracks
or wear on the jaw locking mechanism.
NOTE: The safety lock latch is located at the
front of the fifth wheel on the top plate. 6. Check the depth of the grease grooves. If the
depth of the grooves is 1/8 inch or less, replace
6. Check for loose nuts or bolts on the fifth wheel the fifth wheel top plate. See Group 31 of the
and the mounting. See Fig. 1. Set a torque Columbia Workshop Manual.
wrench to the maximum torque value for the bolt
being checked, and confirm that the torque is to 7. Check the condition of the X-pattern cast into the
specification. Do not loosen the bolt to check the underside of the fifth wheel top plate. See Fig. 2.
torque. See Group 00 for bolt torque The fifth wheel top plate must be removed to
specifications. check the X-pattern.
7. Check all springs to see if they are securely fas- 7.1 Remove the roll pins from the bushing
tened, and are not deformed. pins. Remove the bushing pins from the
slide mount. Using a hoist, lift the fifth
wheel top plate off of the vehicle.
WARNING
7.2 Turn the fifth wheel top plate over with
Do not disassemble the fifth wheel to inspect the the locks open. Check the condition of
springs. The springs are under extreme pressure, the X-pattern in the pockets. If the
and could cause serious injury. X-pattern is worn away, replace the fifth
8. Check wedge adjustment. wheel top plate.

8.1 Open the kingpin lock, and vertically in- 7.3 Install the fifth wheel top plate, bushing
sert a 2-inch (50-mm) diameter shaft. pins, and roll pins.

Columbia Maintenance Manual, October 2008 31/1

31 Frame and Frame Components

13
14
10
15
1
11 12
2
3 16
9 14

4 17
18
1
1 21
19
2 22
21
3 20 23
4

25
5 21
8
6 23 26
7 24
1 6
09/18/95 f310476

1. 3/16" x 1" Cotter Pin 11. 1/420 x 3/8" Thread-Cutting 19. 1/213 x 2" Bumper Pivot Bolt
2. Lower Bracket Retainer Pin Screw 20. Bumper
3. Grease Fitting 12. Step Jaw and Wedge 21. Flatwasher
4. Lower Bracket Pin 13. Jaw Spring 22. 5/16" Bumper Pivot Bushing
5. Wedge Stop Rod 14. 1/4" x 3" Cotter Pin 23. 1/213 Locknut
6. Flatwasher 15. Timer 24. 7/16" Handle Pivot Bushing
7. Wedge Stop Rod Spring 16. Wedge Spring 25. Operating Handle (side-release
8. Wedge Stop Rod Nut 17. Pull Handle only)
9. Side Release Upper Assembly 18. Bumper Handle Spring 26. 1/213 x 2" Handle Pivot Bolt
10. Leaf Spring
Fig. 1, Fontaine H5092 Series Fifth Wheel (left-side-release shown)

8. Inspect for fatigue or cracked welds. Castloc II and Simplex Series

9. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with 1. Disconnect the tractor from the trailer. For in-
5/811 SAE grade 8 bolts, grade C locknuts, and structions, see the Columbia Drivers Manual.
hardened washers. Do not re-use bolts, nuts, 2. Thoroughly steam clean the fifth wheel.
and washers on fifth wheel mountings.
3. Check the fifth wheel plate for cracks. Check for
10. After inspecting the fifth wheel, lubricate all mov- sharp edges on top; the chamfer should be 1/8
ing parts with a chassis or multipurpose grease. to 1/4 inch (3 to 6 mm).
See Maintenance Operation 3102 for lubrica-
4. When the wheel is locked, the safety latch must
tion instructions.
swing free and fall freely into position. See
Fig. 3.

31/2 Columbia Maintenance Manual, October 2008

Frame and Frame Components 31

2
3
18
4
17
5
15
6 10

7
16
8

9
15

14
14

11 12
13 13
08/29/95 f310472
1. Locknut, 3/416 7. Torsion Spring 13. Lock Pin
2. Washer 8. Roll Pin 14. Lock Jaw
3. Rubber Washer 9. Secondary Lock, Right-Hand 15. Washer
4. Lock Adjustment Tag 10. Cam Plate 16. Right-Hand Release Handle
5. Yoke Shaft 11. Lock Guard 17. Left-Hand Release Handle
6. Yoke Sub-Assembly 12. Pin 18. Secondary Lock, Left-Hand
Fig. 2, Holland Fifth Wheel

5. The lever bar and operating handle must be in 6. Check all cotter pins for cracking or damage. Re-
proper alignment. See Fig. 4. Compare the lever place any cotter pin that shows any signs of
bar and operating handle alignment to a new, or damage.
a properly operating lever bar and operating
7. Level the fifth wheel plate to a horizontal posi-
handle. Replace any bent or misaligned lever bar tion. Measure the height from a stationary
or operating rod.
mounting point (see Fig. 5, Ref. 3), such as the

Columbia Maintenance Manual, October 2008 31/3

31 Frame and Frame Components

A
1
2

3 5

1
4
2
3

4
11/28/95 f310353b
08/31/95 f310475
1. Lubricant Grooves 3. Lock Control Handle A. Extended Top Plate Lift Height
2. Safety Latch 4. Mount
1. Fifth Wheel Top Plate
Fig. 3, Simplex Series Fifth Wheel 2. Fifth Wheel Frame Mount
3. Frame Rail
4. Lifting Point
1 5. Static Top Plate Height

Fig. 5, Measuring Fifth Wheel Top Plate Lift

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 un-
coupled for a short period of time.
8. Check all mounting bolts for signs of fatigue, and
tighten them to the proper torque. For torque
specifications, see Group 00. Inspect all angles,
2 plates, and brackets for cracks or other damage.
9. 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
09/15/95 f310470 hardened washers. Do not re-use bolts, nuts,
1. Operating Handle 2. Lever Bar and washers on fifth wheel mountings.
Fig. 4, Lever Bar and Operating Handle Alignment 10. After inspecting the fifth wheel, lubricate all mov-
ing parts with a chassis or multipurpose grease.
frame rail to the top of the fifth wheel plate (Ref. See Maintenance Operation 3102 for lubrica-
1). Pry up on the fifth wheel plate (Ref. 4) below tion instructions.
the pin boss, and measure the vertical move-
ment (Ref. 5). The bracket connection provides a
9/32-inch (7-mm) vertical clearance to provide 3102 Fifth Wheel Lubrication
cushioning and to avoid downward pin-loading
while retaining minimum plate lift. If the plate lift To maintain proper fifth wheel operation, always lubri-
(Ref. A) exceeds 5/16 inch (8 mm) as a result of cate the fifth wheel after an inspection has been
wear or rubber deterioration, install new, stan- performed.
dard or oversized bracket-shoe rubber pads; see IMPORTANT: Lubricate the fifth wheel:
Group 31 of the Columbia Workshop Manual
for replacement instructions. After power washing, or steam cleaning.

31/4 Columbia Maintenance Manual, October 2008

Frame and Frame Components 31

If the vehicle operates in harsh conditions such Once the fifth wheels moving parts are lubricated,
as salt spray from road surfaces, or in ex- apply a heavy coat of grease to the top plate, either
tremely dusty environments. through the grease fittings located on the underside
of the top plate, or by direct application. On slide-
After any service that requires removal of lubri-
mount applications, lubricate the slider lock pockets
cation from the fifth wheel head or components.
and the slider bracket.
WARNING
3103 Frame Fastener Torque
Failure to properly lubricate the fifth wheel could
result in a possible disengagement of the trailer Check
from the tractor, which could result in personal
injury or property damage. Frame brackets and components secured with Huck-
bolt fasteners do not require a torque check, how-
ever, they should be inspected for damage. Frame
Fontaine brackets and components secured with conventional
Use a multipurpose extreme pressure (EP) chassis bolts and nuts are to be checked at Initial Mainte-
grease to lubricate all moving parts on the fifth nance (IM). See Fig. 6 for pre-EPA2007 engine
wheel. When lubricating the top plate at the grease mounts. Check the torque of frame fasteners to off-
fittings for the bracket bearing area, tilt the top plate set the effects of "bedding in" (or seating). When
forward and backward to evenly distribute the checking torque, torque the nut, not the bolt head
grease. Using a pry tool, separate the jaw and whenever possible. This will give a true torque read-
wedge and lubricate the serrations using a brush to ing by eliminating bolt-body friction. When checking
distribute the grease. On slide-mount applications, the torque of frame fasteners, inspect the frame for
lubricate the slide rail and tapered wedges for cracks and other damage. Set a click-type torque
smooth operation. wrench to the maximum torque of the fastener you
are checking. Apply pressure until the torque wrench
Once the moving parts of the fifth wheel are lubri- clicks. Do not loosen the bolt to check the torque.
cated, apply a liberal coating of grease to the top See the applicable torque table in Group 00 for
plate and the trailer kingpin plate. torque specifications.

Holland CAUTION
Lubricate all moving parts with a multipurpose chas-
sis grease. Lubricate the two grease fittings located Make sure frame fasteners are properly tightened.
on either side of the top plate with a multipurpose Continued vehicle operation with loose fasteners
chassis grease. could result in bracket or frame damage.
Once the fifth wheels moving parts are lubricated, NOTE: Engine supports on vehicles built from
apply a heavy coat of grease to the top plate by di- January 2007 do not require checking.
rect application. On slide-mount applications, lubri- Check the fasteners at the following locations:
cate the baseplate rails and the plungers for smooth
operation. Axle Stops
Deck Plates
Castloc II and Simplex Series Engine Trunnion Supports
Use a chassis or multipurpose grease to lubricate the Equalizer Brackets
two grease fittings located on either side of the fifth
wheel top plate. Lubricate the two grease fittings lo- Exhaust Brackets
cated in the grease grooves on the fifth wheel top Fifth Wheel Legs
plate. Lubricate the two grease fittings located below
the top plate mounting pins. Lubricate the lock Fifth Wheel Mountings
mechanism. Frame Crossmembers and Gussets
Front Frame Brackets

Columbia Maintenance Manual, October 2008 31/5

31 Frame and Frame Components

Any component that shows signs of cracking or other

damage must be repaired or replaced. Refer to the
1 Columbia Workshop Manual for repair or replace-
4 ment information in the respective section for the
2 component in question.
5

3
3104 Trailer Electrical
Connector Lubrication
In some cases, failure of trailer cables occurs due to
6 intrusion of chloride-based road deicing chemicals
into the trailer connector. Once inside the connector,
the chloride-based chemicals corrode the brass ter-
minals and create bridging between positive and
5 ground terminals.
7 8 NOTE: The use of soap is not recommended for
cleaning the electrical connector, as some
9
soaps may increase the corrosion process.
10
1. Wash out any existing grease, dirt, and corrosion
on the trailer connectors with electrical contact
cleaner spray.
2. Grease the trailer connector with a lithium-based
11 13 dielectric grease.

2 10
12

03/30/95 f220054
1. Capscrew, 3/4 x 4.5 7. Rear Engine Mount
Inch, Grade 8 8. Nut, 5/1618
2. Washer, 3/4 Inch 9. Capscrew, 5/811 x
3. Engine Leg 2.5 Inch, Grade 8
4. Capscrew, 1/213 x 10. Washer, 5/8 Inch
1.5 Inch, Grade 8 11. Lower Isolator
5. Washer, 1/2 Inch 12. Nut, 3/410
6. Upper Isolator 13. Nut, 5/811

Fig. 6, Rear Engine Mount Assembly (pre-EPA07

engines)

Front Suspension Spring Brackets

Fuel Tank Brackets
Radius Rods
Rear Engine Supports
Rear Suspension Spring Brackets
Shock Absorbers
All Other Frame Fasteners

31/6 Columbia Maintenance Manual, October 2008

Suspension 32
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3201
Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3202
Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3203

Columbia Maintenance Manual, February 2010

Suspension 32

3201 Suspension Inspection

Front Suspension Check
WARNING A
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring as-
sembly. Visible damage (cracks or breaks) to one
leaf causes hidden damage to other leaves. Re-
placement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front B
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 assem-
bly could cause an accident resulting in property
damage, serious personal injury, or death.
Inspect the front spring assemblies for cracked, bro-
ken, or abnormally bent leaves. If any of these condi- C
tions exist, replace the spring assembly. See Group 08/14/2008 f321135
32 of the Columbia Workshop Manual for instruc-
A. Side to side crack extending beyond 3/4 of the
tions. length of the spring
B. Top to bottom crack extending beyond 3/4 of the
Composite Springs length of the spring
The Commercial Vehicle Safety Alliance (CVSA) de- C. Intersecting cracks of any length
fines a crack that causes out-of-service conditions for Fig. 1, Out-of-Service Conditions, Composite Spring
composite spring assemblies, as a separation in any
axis, which passes completely through the composite Shock Absorber Check, Front
spring material.
For additional information, refer to the CVSA, Out of
and Rear Suspensions
Service (OOS) Criteria, for composite spring assem- Make sure the shock absorber brackets are tight,
blies, Section 9, Suspension, Pages 44 to 45. and the shock absorber is not striking or rubbing the
Inspect the Liteflex spring for cracks that result in an frame or some other part of the chassis. Striking or
out-of-service condition as follows (see Fig. 1): rubbing the frame is characterized by chafe marks on
the shock absorber body and the frame rail. See Fig.
a side to side crack extending beyond 3/4 of the 2. Check the rubber mounting bushings for cracks,
length of the spring; cuts, swelling, and dry rot. Also, check the bushings
a top to bottom crack extending beyond 3/4 of for missing pieces. Replace the bushings as needed.
the length of the spring; Inspect the shock absorber for oil leakage. If the
intersecting cracks of any length. shock absorber is damaged or leaking, replace it with
a new one. See Group 32 of the Columbia Work-
The Liteflex composite spring should also be re- shop Manual for replacement instructions.
moved from service if splintering has occured to the
point where noticeable vehicle ride height loss has
occurred.

Columbia Maintenance Manual, February 2010 32/1

32 Suspension

NOTICE
Failure to replace the suspension crossmember or
gussets if they are cracked, worn, or otherwise
damaged could result in damage to the vehicle
chassis.
3. Without detaching the torque arms, attempt to
move (by hand) each radius-rod end up, down,
in, and out. If there is any movement, replace the
torque arm. If a torque arm needs to be re-
placed, see Group 32 of the Columbia Work-
shop Manual for instructions.
11/27/95 f320465
4. Inspect the weld seams between the torque arm
Fig. 2, Direct-Acting Shock Absorber (front suspension
tube and the shorter bushing tubes. If there are
shown) cracks, replace the torque arm. Do not weld the
torque arm for any reason.
Rear Suspension Check 5. Inspect the rubber bushing ends. See Fig. 3. Re-
place the torque arm for any of the following rea-
Freightliner Spring Suspension sons:
if there are gaps between the rubber bush-
WARNING ing and the pin or outer steel sleeve;
Do not replace individual leaves of a damaged leaf if either bushing end contacts a torque arm
spring assembly; replace the complete spring as- pin mounting bolt;
sembly. Visible damage (cracks or breaks) to one if there are cracks in the bushing;
leaf causes hidden damage to other leaves. Re-
placement of only visibly damaged parts is no as- if part of the rubber bushing extends be-
surance that the spring is safe. Failure to replace yond the outer circumference of the outer
a damaged spring assembly could cause an acci- bushing sleeve.
dent, resulting in serious personal injury or prop-
erty damage.
Replace worn, cracked, or damaged spring
brackets. Failure to do so could result in bracket
breakage, possibly leading to loss of vehicle con-
trol and resulting in personal injury or property
damage.
1. Inspect the forward and rear spring brackets and
equalizer brackets for wear, cracks, and other
damage. If any of these conditions exist, replace
the damaged bracket(s). See Group 32 of the
Columbia Workshop Manual for instructions.
2. Inspect the tandem-axle frame crossmember and 05/27/93 f320021a
gussets for wear, cracks, and other damage. If
any of these conditions exist, replace the dam- Fig. 3, Torque Arm Bushings
aged parts. See Group 32 of the Columbia
Workshop Manual for instructions. 6. Block up the frame enough to take chassis
weight off the springs. Attempt to move the
equalizer up and down, using a pry bar between
the top of the equalizer and top of the equalizer

32/2 Columbia Maintenance Manual, February 2010

Suspension 32

bracket; apply hand pressure only. See Fig. 4. If

movement at the center of the equalizer exceeds 2
1
1/8 inch (3 mm), replace the equalizer bushings.
See Group 32 of the Columbia Workshop A
Manual for instructions.

1 A
3
3

4
05/27/93 5 f320023a

A. 1/8" (3 mm) Clearance

1. Frame Fasteners 4. Equalizer
2. Frame Rail 5. Equalizer Bracket
2
3. Pry Bar
05/27/93 f320022a Fig. 5, Top View of the Equalizer
A. Measure the change in gap at this point.
ditions exist, replace the damaged bracket(s). See
1. Equalizer Bracket 3. Pry Bar
Group 32 of the Columbia Workshop Manual for
2. Equalizer
instructions.
Fig. 4, Side View of the Equalizer

7. With the vehicle unloaded, attempt to move the WARNING

equalizer side to side, using a pry bar between Replace worn, cracked, or damaged spring
the equalizer and frame rail. Apply hand pressure brackets. Failure to do so could result in bracket
only. See Fig. 5. If clearance between the equal- breakage, possibly leading to loss of vehicle con-
izer assembly and any frame component or fas- trol and resulting in personal injury or property
tener is less than 1/8 inch (3 mm), replace the damage.
equalizer bushings. See Group 32 of the
Columbia Workshop Manual for instructions. Inspect the crossmember(s) and gussets for wear,
cracks, and other damage. If any of these conditions
Freightliner AirLiner Suspension exist, replace the damaged parts. See Group 32 of
the Columbia Workshop Manual for instructions.
WARNING IMPORTANT: Before checking the AirLiner sus-
pension height, make sure there is no load on
Do not replace individual leaves of a damaged leaf
the chassis, and the trailer is unhitched.
spring assembly; replace the complete spring as-
sembly. Visible damage (cracks or breaks) to one IMPORTANT: To prevent voiding the warranty
leaf causes hidden damage to other leaves. Re- on Barksdale height-control valves, note the fol-
placement of only the visibly damaged part(s) is lowing:
no assurance that the spring is safe. On front
spring assemblies, if cracks or breaks exist in the Do not overtighten the bolts in the Barksdale
two top leaves, a loss of vehicle control could height-control valve housing. The bolts should
occur. Failure to replace a damaged spring assem- not be loose, and should not require tightening.
bly could cause an accident resulting in property Only if necessary, tighten the valve housing
damage, serious personal injury, or death. bolts 45 lbfin (500 Ncm). Any damage to the
valve housing will void the warranty.
Inspect the forward and rear spring brackets for
wear, cracks, and other damage. If any of these con-

Columbia Maintenance Manual, February 2010 32/3

32 Suspension

Do not attempt to disassemble the Barksdale 3.1 If the vehicle is equipped with an adjust-
valve body or the control lever. There are no able leveling valve, the length should be
serviceable parts in the valve, and any disas- 8 inches (200 mm). If the length is incor-
sembly will void the warranty. rect, see Group 32 of the Columbia
Workshop Manual for adjustment proce-
NOTICE dures.
3.2 If the vehicle is equipped with a fixed lev-
When removing or loosening a Barksdale height- eling valve, see Group 32 of the
control valve from a mounting bracket, always Columbia Workshop Manual for the
hold the valve-side mounting studs in place with overtravel lever length for the rear axle
an Allen wrench while loosening or tightening the installed in your vehicle.
nuts that attach the valve to the bracket. Because
the mounting studs are threaded into the valve 4. On single-drive rear axle configurations, measure
body, loosening the nuts without holding the the distance from the bottom of the left axle stop
studs can tighten the studs, which can crush the to the top of the U-bolt pad. On tandem (dual-
valve body and damage the valve. Conversely, drive) rear axle configurations, measure the dis-
tightening the nuts without holding the studs can tance from the bottom of the forwardmost left
back the studs out, causing a separation of the axle stop to the top of the axle U-bolt pad. See
two halves of the valve body, and possibly a leak. Fig. 7, Ref. A. The correct distance for single
and dual-drive rear axles is between 2-3/8 inches
1. Park the vehicle on a level surface, using a light and 2-7/8 inches (60 to 73 mm).
application of the brakes. Do not apply the park-
ing brakes. Shift the transmission into neutral,
and build the secondary air pressure to at least
100 psi (690 kPa). Shut down the engine. 1
2. Mark the location of the front and rear tires on
the floor, and chock the tires on one axle only.
3. Check the length of the overtravel lever between
its pivot points. See Fig. 6, Ref. A.

A A

4
1

2
3

05/15/95 f320410
A. Measure the length of the overtravel lever between
these two points.
1. V-Shaped Mark 4. Cotter Pin 08/16/96 f320453
2. Adjustment Locknut 5. Linkage Rod
A. Measure height here.
3. Overtravel Lever
1. Left Forwardmost Axle Stop
Fig. 6, AirLiner Overtravel Lever and Linkage Rod
Measurement Fig. 7, AirLiner Axle Stop Measurement

32/4 Columbia Maintenance Manual, February 2010

Suspension 32

5. If the axle stop measurement is not correct, see

Group 32 of the Columbia Workshop Manual
for adjustment procedures. 1
6. Apply the parking brakes, and remove the
chocks.

Chalmers Suspension
1. Chock the front tires, place the transmission in
neutral, and release the parking brakes.
2. Power wash the suspension, or clean it with a A
hard-bristle brush before performing a visual in-
spection.
3. Inspect the rubber bushings for cracks or other B
damage.
Try to move the torque rod ends using your
hands only, and check for any free-play. If free-
play is felt, replace the torque rod end bushing.
Do not use a pry bar to check for free-play. Use
of a pry bar may lead to premature bushing re-
placement. 09/27/95 f320432
A. Non-Wear Area B. Wear Area
4. Lift the rear of the vehicle and support the frame
on jack stands to unload the suspension compo- 1. Walking Beam
nents. The vehicle is lifted high enough when the Fig. 8, Walking Beam End Wear Thickness
beam ends are off of the saddles.
Inspect the walking beam for cracks or other WARNING
damage. If damage is found, replace the walking
beam. Replace all cracked or missing restrictor cans.
Keep the vehicle supported by the jack stands Failure to do so could lead to loss of vehicle con-
for the next operation. trol, which could result in property damage, seri-
ous personal injury, or death.
5. Manipulate the walking beam so that a microme-
ter, vernier, or dial caliper can be used to deter-
mine the wear area thickness on the bottom 3202 Suspension Lubrication
face. See Fig. 8. Measurements should be taken
a minimum of 1/2 inch from the beam flange
edges to eliminate any edge wear that may have Front Suspension
occurred. Subtract the wear area thickness (see Wipe all dirt away from the grease fittings (if
Fig. 8, Ref. B) from the thickness at the non- equipped) on the spring-eye bushings. Apply multi-
wear area (see Fig. 8, Ref. A) to determine the purpose chassis grease with a pressurized grease
amount of wear. gun until old grease is forced out.
If the beams show any wear greater than 0.062 NOTE: Service Schedule IV vehicles equipped
inch (1.5 mm), a Chalmers wear plate must be with a 12,000 lb (5452 kg) front axle are fitted
installed, or the walking beam must be replaced. with maintenance-free rubber bushings, and do
6. Rotate the restrictor cans 360 degrees and in- not require lubrication.
spect the cans for cracks, severe corrosion, and
distortion. If any of these conditions are present,
or the restrictor can is missing, replace the re-
strictor can.

Columbia Maintenance Manual, February 2010 32/5

32 Suspension

Rear Suspension the bushings and pins to allow the proper flow of
lubricant around them.
Chalmers 3. Use a multipurpose chassis grease and lubricate
No lubrication is required on the Chalmers rear the bronze, ball-indented bushings in the spring
suspension. eyes at the grease fitting. See Fig. 10. Continue
to lubricate until grease exits both ends of the
Freightliner Spring bushing. If the pin will not accept lubricant, re-
move the pin and clean the lubrication channels
Single Axle where lubricant may have hardened. Remove the
safety stands.
No lubrication is required on Freightliner single axle
rear suspensions.
4
Tandem Axle
2 3
Lubricate the equalizer cap-and-tube assembly bush-
ings by applying multipurpose chassis grease at the
grease fitting until old grease is forced out from the
cap-and-tube assembly. See Fig. 9.

A
2
4 1
09/15/95 f320424

1. Bronze Bushing 3. Grease Fitting

2. Lubrication Hole 4. Lubrication Groove
1 Fig. 10, Hendrickson RT2 and RTE2 Series Bushing
05/27/93 320020a Lubrication
A. Lubricate here.
1. Cap-and-Tube Assembly Bushing Neway
Fig. 9, Equalizer Assembly Lubrication
No lubrication is required on Neway rear suspen-
sions.
Hendrickson Reyco
The Hendrickson RS Series suspension does not
No lubrication is required on Reyco rear suspen-
require lubrication.
sions.
For Hendrickson RT2 and RTE2 Series, lubricate the
bronze, ball-indented bushings in the spring eye, as
follows: 3203 Suspension U-Bolt
1. Park the vehicle on a level surface, apply the Torque Check
parking brakes, and chock the front tires.
2. Raise the rear of the vehicle until the rear wheels CAUTION
are suspended in the air, then support the ve-
hicle with safety stands. This relieves the load on Failure to retorque the U-bolt nuts could result in
spring breakage and abnormal tire wear.

32/6 Columbia Maintenance Manual, February 2010

Suspension 32

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

parking brakes. Chock the tires.
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.
3. Remove the chocks.

Spring Assembly U-Bolt High Nut Torque Values*

Size Torque: lbfft (Nm)
Stage 1: Hand Tighten
Stage 2: 60 (81)
5/818
Stage 3: 200 (271)
Stage 4: 180 to 230 (245 to 313)
Stage 1: Hand Tighten
Stage 2: 60 (81)
3/416
Stage 3: 200 (271)
Stage 4: 270 to 330 (367 to 449)
Stage 1: Hand Tighten
Stage 2: 60 (81)
7/814
Stage 3: 200 (271)
Stage 4: 420 to 500 (571 to 680)
Stage 1: Hand tighten
Stage 2: 60 (81)
114
Stage 3: 200 (271)
Stage 4: 520 to 600 (707 to 816)
* Tighten in a diagonal pattern as shown in Fig. 11.

Table 1, Spring Assembly U-Bolt High Nut Torque

Values

4 1

01/05/99
2 3
f320783

Fig. 11, Tightening Pattern for U-Bolt High Nuts

Columbia Maintenance Manual, February 2010 32/7

Front Axle 33
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

All-Axle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3304
Basic Inspection, Meritor Unitized Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3307
End-Play Check, Meritor Unitized Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3308
Knuckle Pin Lubrication, Dana Spicer Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3305
Knuckle Pin Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301
Tie Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302
Tie Rod Lubrication, Dana Spicer Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3306
Tie Rod Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303

Columbia Maintenance Manual, October 2004

Front Axle 33

3301 Knuckle Pin Lubrication, cross-tube socket members indicates that the
tie-rod end assembly must be replaced.
Meritor Axles 2. The threaded portion of the tie-rod end assembly
must be inserted all the way into the cross-tube
CAUTION split for adequate clamping. See Fig. 2. Replace
the components if this cannot be done. For in-
Use regulated pressure when lubricating the structions, refer to Group 33 of the Columbia
knuckle assemblies, otherwise damage could re- Workshop Manual.
sult to the knuckle caps.
When lubricating knuckle pin bushings, do not raise
the front axle. Wipe the lube fittings clean, and apply
multipurpose chassis grease, NLGI Grade 1 (6% 12- OK
hydroxy lithium stearate grease) or NLGI Grade 2
(8% 12-hydroxy lithium stearate grease) until new
grease is seen at the bushing grease seal opposite
the fittings. The grease seal will accept grease pres-
sure without damage, and is designed to have
grease pumped out through it during lubrication.
Even if grease leaks out around the top, or bottom- 1
plate gasket, continue pumping until new grease is
seen at the bushing seal opposite the grease fitting.
See Fig. 1. OK

02/27/2007 f320033a
NOTE: Shown without pinch bolt to provide clarity.
A 1. Cross-Tube Split
Fig. 2, Tie-Rod End Adjustment

3303 Tie Rod Lubrication,

Meritor Axles
For any Meritor axle that requires lubrication of the
09/06/96 1 f320032a tie-rod ends, wipe the grease fittings clean, then
A. Grease Exit pump multipurpose chassis grease, NLGI Grade 1
1. Grease Fitting (6% 12-hydroxy lithium stearate grease) or NLGI
Grade 2 (8% 12-hydroxy lithium stearate grease),
Fig. 1, Meritor Knuckle Pin Lubrication into the tie-rod ends until all used grease is forced
out and fresh grease is seen at the ball stud neck.
3302 Tie Rod Inspection
Inspect the tie-rod ends as follows:
1. Shake the cross-tube. A loose fit, or movement
between the tapered shaft of the ball and the

Columbia Maintenance Manual, October 2004 33/1

33 Front Axle

3304 All-Axle Alignment

A
Check
Drive Axle Alignment Checking
Check the axle alignment, parallelism, and thrust
angle measurements for the rear drive axles. Use the
applicable procedure and specifications in Group 35
of the Columbia Workshop Manual.

Toe-In Inspection
For vehicle alignment to be accurate, the shop floor
B
must be level in every direction. The turn plates for 08/29/94 f330082a
the front wheels must rotate freely without friction,
and the alignment equipment must be calibrated NOTE: B minus A equals toe-in.
every three months by a qualified technician from the Fig. 3, Wheel Toe-In (overhead view)
equipment manufacturer. Freightliner dealers must
have proof of this calibration history. 7. Place the trammel bar at the front of the tires
(see Fig. 4) and adjust the scale end so that the
1. Apply the parking brakes and chock the rear pointers line up with the scribe lines. See Fig. 5.
tires.
2. Raise the front of the vehicle until the tires clear
the ground. Place safety stands under the axle.
3. Using spray paint or a piece of chalk, mark the
entire center rib of each front tire.
4. Place a scribe or pointed instrument against the
marked center rib of each tire, and turn the tires.
The scribe must be held firmly in place so that a
single straight line is scribed all the way around
each front tire.
5. Place a turn-plate or turntable under both front 08/30/94 f330014a
tires. Remove the safety stands and lower the
vehicle. Remove the lock-pins from the gauges; Fig. 4, Trammel Bar Positioning
make sure the tires are exactly straight ahead.
8. Read the toe-in from the scale, and compare it to
NOTE: If turn-plates or turntables are not avail- the toe-in specification in Group 33 of the
able, lower the vehicle. Remove the chocks Columbia Workshop Manual. If corrections are
from the rear tires and release the parking needed, refer to Group 33 of the Columbia
brakes. Move the vehicle backward, then for- Workshop Manual for instructions on adjusting
ward about six feet (two meters). the toe-in.
6. Place a trammel bar at the rear of the front tires;
locate the trammel pointers at spindle height,
and adjust the pointers to line up with the scribe
lines on the center ribs of the front tires. See
Fig. 3. Lock in place. Check that the scale is set
on zero.

33/2 Columbia Maintenance Manual, October 2004

Front Axle 33

1
11/21/95 f330129

A. Grease Exit
1. Grease Fitting

Fig. 6, Dana Spicer Knuckle Pin Lubrication

3306 Tie Rod Lubrication,

Dana Spicer Axles
08/30/94 f400100a For any Dana Spicer axle that requires lubrication of
the tie-rod ends, wipe the grease fittings clean, then
Fig. 5, Setting Trammel Bar Pointers pump multipurpose chassis grease, NLGI Grade 1
(6% 12-hydroxy lithium stearate grease) or NLGI
3305 Knuckle Pin Lubrication, Grade 2 (8% 12-hydroxy lithium stearate grease),
into the tie-rod ends until all used grease is forced
Dana Spicer Axles out and fresh grease is seen at the ball stud neck.

CAUTION 3307 Basic Inspection, Meritor

Use regulated pressure when lubricating the Unitized Wheel Ends
knuckle assemblies, otherwise damage could re-
sult to the knuckle caps. 1. Park the vehicle on a level surface, set the park-
ing brakes, shut down the engine, and chock the
Park the vehicle on a level surface, apply the parking
rear tires.
brakes, and chock the tires. When lubricating upper
and lower knuckle assemblies, do not raise the front 2. Raise the vehicle until the front tires are clear of
axle. Wipe the fittings clean, then apply multipurpose the ground. Support the vehicle with safety
chassis grease, NLGI Grade 1 (6% 12-hydroxy stands.
lithium stearate grease) or NLGI Grade 2 (8% 12-
hydroxy lithium stearate grease), until new grease is WARNING
seen at the junctions of the axle beam and knuckles.
See Fig. 6. Knuckle pins without grease fittings are Never work under a vehicle that is supported only
permanently lubricated. by a jack. Jacks can slip, causing the vehicle to
fall. This could result in serious injury or death.
IMPORTANT: A clicking sound while rotating the
wheel end (hub) is normal and does not indicate
a problem.

Columbia Maintenance Manual, October 2004 33/3

33 Front Axle

3. Rotate the tire and hub assembly. They should 4. Remove the tire and wheel assembly.
rotate smoothly and without noise. Grasp the
brake chamber while rotating the hub to detect
NOTE: It is normal for small amounts of grease
any hub vibration. to be visible around the inner and outer wheel
bearings.
If the hub rotates smoothly, go to the next step.
5. Remove the brake drum. If needed, back off the
If the tire and hub assembly do not rotate slack adjuster.
smoothly, or you hear noise during rotation, go to
"End-Play Check, Meritor Unitized Wheel Ends." 6. Attach the magnetic base of a dial indicator to
the end of the axle spindle.
4. Grasp the tire and hub assembly at the 3 oclock
and 9 oclock positions. Using about 50 pounds 7. Touch the dial indicator stem to the surface of
(23 kg) of force, check for vertical and horizontal the hub, making sure the stem is perpendicular
movement. to the surface of the hub.
5. If no movement or looseness is detected, raise 8. Set the dial indicator to zero.
the vehicle to remove the safety stands, lower 9. Without rotating the hub, grasp it at the 3 and 9
the vehicle, and remove the chocks from the oclock positions, and push it straight in. Note the
tires. reading on the dial indicator.
If any movement or looseness is detected, go to Pull the hub straight out. Note the reading on the
the next step. dial indicator.
6. Check the wheel-to-hub mounting. Make sure the The difference between the two measurements is
wheel and tire assembly is mounted correctly the end-play.
and that all hardware is secure.
10. If the end-play is less than 0.003 inch (0.08 mm),
7. Apply the service brakes to lock the hub and go to the step for installing the hub cap.
axle spindle together. Check again for movement
and looseness. If the end-play is 0.003 inch (0.08 mm) or
greater, go to the next step.
If movement is detected, the king pin or king pin
bushings are probably worn. 11. Remove the outer locknut and tabbed washer
from the axle spindle.
If applying the service brake eliminates the
movement, the problem is probably caused by 12. Loosen, but dont remove, the inner locknut.
incorrect wheel bearing end-play. Go to "End- 13. While rotating the hub a minimum of five rota-
Play Check, Meritor Unitized Wheel Ends." tions, tighten the inner locknut 600 lbfft (813
Nm).
3308 End-Play Check, Meritor 14. Install the tabbed washer and outer locknut.
Tighten 250 lbfft (339 Nm).
Unitized Wheel Ends
15. Repeat the procedure for checking end-play.
1. Park the vehicle on a level surface, set the park- 16. If end-play is greater than 0.003 inch (0.08 mm)
ing brakes, shut down the engine, and chock the but less than 0.006 inch (0.15 mm), record it in
rear tires. the vehicle maintenance log. Go to the next step.
2. Remove the hub cap. If end-play is 0.006 inch (0.15 mm) or greater,
3. Raise the vehicle until the front tires clear the replace the entire wheel end assembly. For in-
ground. Support the vehicle with safety stands. structions, see Group 33 of the Columbia
Workshop Manual.
WARNING 17. Check the rotation of the hub. If it doesnt rotate
smoothly and without noise, replace the entire
Never work under a vehicle that is supported only wheel end assembly. For instructions, see Group
by a jack. Jacks can slip, causing the vehicle to 33 of the Columbia Workshop Manual.
fall. This could result in serious injury or death.

33/4 Columbia Maintenance Manual, October 2004

Front Axle 33

If the hub rotates smoothly and without noise, go NOTE: If you cannot tighten the hub cap to
to the next step. the correct torque value, or if it makes a
18. Bend an opposing tab of the tabbed washer over popping sound while being tightened, re-
a flat of the outer locknut. place it with a new one.
19. Install the wheel and tire assembly. Hand-tighten 24. Remove the chocks from the tires.
the wheel nuts.
20. Raise the vehicle, remove the jackstands, then
lower the vehicle.
21. Tighten the wheel nuts 500 lbfft (678 Nm).
22. Install the hub cap.
If installing a metal hub cap, go to the next step.
If installing a plastic hub cap, do the following:
22.1 Apply a continuous 1/8-inch (3-mm) bead
of RTV silicone sealant to the outside first
thread of the hub cap. Apply the sealant
around the entire circumference.
IMPORTANT: Use only the following RTV
sealants on the hub cap:
Meritor part number 2297-Z-7098
Three Bond
Loctite Ultra Grey Adhesive Sealant 18581
22.2 Install the hub cap by hand until it is
seated.
NOTE: Disregard the torque value em-
bossed on the hub cap.
22.3 Using a torque wrench, tighten the hub
cap 75 lbfft (102 Nm).
If you cannot tighten the hub cap to the
correct torque value, or if it makes a pop-
ping sound while being tightened, replace
it with a new one.
23. If installing a metal hub cap, do the following:
23.1 Using a wire brush, clean the unitized
wheel-end inner threads and the hub cap
external threads.
23.2 Apply Loctite 17430 gasket sealant to the
external hub cap threads.
23.3 Install the hub cap by hand until it is
seated.
23.4 Using a torque wrench, tighten the hub
cap 350 lbfft (475 Nm).

Columbia Maintenance Manual, October 2004 33/5

Rear Axle 35
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Axle Breather and Axle Lubricant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3502
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (Synthetic
Lubricant)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3501

Columbia Maintenance Manual, July 2005

Rear Axle 35

3501 Axle Lubricant and Filter recommended drive axle lubricant) must be
changed at the Maintenance 2 (M2) interval,
Change, and Magnetic instead of the Maintenance 3 (M3) interval rec-
Strainer Cleaning ommended in the Maintenance Operation Chart
for axles that require only those lubricants rec-
(Synthetic Lubricant) ommended in Table 1.
1. Park the vehicle on level ground, set the parking
CAUTION brakes, and chock the front tires.
Failure to change the axle lubricant at more fre- 2. Remove the axle carrier fill plug. Then remove
quent intervals, when adverse operating condi- the drain plug from the bottom of the housing.
tions require, could result in axle damage. Completely drain the lubricant while the unit is
warm, to allow the lubricant to drain faster.
For all axles, including tandem-drive axles and two-
speed axles, do the procedures under the heading, On tandem-drive axles, it is also necessary to
"All Axle Models." For a two-speed axle with a shift remove the plug at the bottom of the interaxle
unit, also change the shift unit lubricant. See under differential housing to drain that lubricant.
the heading, "Two-Speed Axles With Shift Unit." 3. If equipped with an oil pump, remove the axle oil
filter. Use a suitable filter strap wrench. See
All Axle Models Fig. 1. Discard the old filter.
Meritor
IMPORTANT: On Meritor axles, the oil change
interval for Schedule III and IV vehicles is ex-
tended to 500,000 miles (800 000 km) for axles
using synthetic lubricant with a pump and filter
system.
On single-drive axles so equipped, the traction equal-
izer may slip or stick. When this happens, you will
hear intervals of shrill noises when the vehicle oper-
ates at low speed, or when the vehicle makes sharp
turns. Use a "limited-slip friction modifier" to correct
this slip/stick condition. Add 1.6 ounces (35 mL) of
additive for each pint (0.5 L) of lube capacity.
For all GL-5 oils, add one of the following limited-slip 05/27/93 f350119a
friction modifiers:
Fig. 1, Meritor Axle Oil Filter Removal
Lubrizol No. 6178 (Lubrizol Corporation)
DSL-178 (Guardsman Products) NOTE: There may be about one pint (0.5 L) of
lubricant remaining in the filter. Be careful not to
Equa-Torque No. 2411 (Sta-Lube Corporation)
spill it when removing the filter.
Equa-Torque No. 2414 (Sta-Lube Corporation)
4. Using the recommended drive axle lubricant,
IMPORTANT: These friction modifiers generally coat the face of the gasket on the new oil filter, if
deteriorate faster than conventional extreme- one was removed. Install the filter over the
pressure additives, so the lubricant change adapter, and tighten the filter one full turn after
schedule must be shortened when using these the gasket contacts the base; do not overtighten.
additives. The traction equalizer additive (and See Table 1 for recommended lubricants.

Columbia Maintenance Manual, July 2005 35/1

35 Rear Axle

Meritor Drive Axle Recommended Lubricant

Recommended Lubricant SAE
Ambient Temperature Meritor Specification
Lubricant Type Viscosity Grade
40F (40C) and Up* 75W90 076N
Synthetic Gear Oil
40F (40C) and Up* 75W140 076M
* There is no upper limit on these outside temperatures, but axle sump temperature must never exceed 250F (121C).

Table 1, Meritor Drive Axle Recommended Lubricant

5. Clean the fill and drain plugs. Change them if

necessary.
A
5.1 For magnetic plugs, use a piece of key
stock or any other convenient steel slug
to short the two magnetic poles and divert
the magnetic field.
5.2 Check the drain plug for metal particles
every 100,000 miles (160 000 km). Clean B
away the collected material deposited on
each pole. Magnets will rapidly lose their
effectiveness as collected material 08/17/2009 f350061a
bridges the gap between the two poles. A. Correct (lube level at bottom of fill hole)
B. Incorrect (lube level below fill hole)
5.3 Each time the oil is changed, replace any
magnetic drain plug that does not meet Fig. 2, Axle Lubricant Level Inspection
the minimum pickup capacity.
Meritor Drive Axle Lubricant Capacities
NOTE: Meritor recommends plugs with ele-
ments having a minimum pickup capacity of Axle Model Capacity:* pt (L)
1.5 pounds (0.7 kg) of low-carbon steel. Single-Drive, Single Reduction
5.4 After cleaning, install the drain plug(s) RS21160 39.5 (18.7)
and tighten to 35 lbfft (47 Nm). RS23160 39.5 (18.7)
6. Fill the axle with recommended lubricant. See RS23161 37.2 (17.6)
Table 2 for drive axle lubricant capacities.
RS23185 47.3 (22.4)
NOTE: Some Meritor axles have a small RS25160 37.2 (17.6)
tapped and plugged hole near and below the
Tandem-Drive, Single Reduction
housing lubricant fill hole. This smaller hole
is for a lubricant temperature indicator only, RT40145, RT40145A, Forward 30.2 (14.3)
and should not be used as a fill or level RT40145P Rear 25.8 (12.2)
hole. Forward 29.3 (13.9)
RT44145, RT44145P
6.1 With the vehicle on a level surface, fill the Rear 25.1 (11.9)
axle through the oil fill hole. Lubricant
Forward 39.1 (18.5)
should be level with the bottom of the oil RT46160, RT46160P
fill hole. To check fluid level, see Fig. 2. Rear 34.4 (16.3)
* Quantities listed are approximate. Fill axle until lubricant is level with bot-
tom of fill hole with vehicle on level ground.
See "Traction Equalizer Additives" in the text.

Table 2, Meritor Drive Axle Lubricant Capacities

35/2 Columbia Maintenance Manual, July 2005

Rear Axle 35

6.2 Install and tighten the fill plug 35 lbfft (47 4.4 After cleaning, install the drain plug(s)
Nm). and tighten to 41 lbfft (55 Nm).
7. Whenever the interaxle differential housing has 5. Fill the axle with the recommended lubricant.
been drained, add an additional 2 pints (0.9 L) of See Table 3 for recommended drive axle lubri-
the recommended lubricant directly into the inter- cants and drive axle lubricant capacities.
axle differential housing.
8. Remove the chocks, then drive the vehicle, un- Freightliner Rear Axle Approved Lubricant Type and
Capacity
loaded, for 1 or 2 miles (2 or 3 km) at speeds
not to exceed 25 mph (40 km/h), to thoroughly Oil Capacity:
circulate lubricant throughout the carrier and Quarts (liters)
Lubricant Type Axle
housing assemblies. Hubs Hubs
Full Dry
Freightliner 80W/90 Gear Oil
Forward 14.3 15.9
IMPORTANT: On Freightliner axles, the oil 75W/90 Synthetic Tandem (13.5) (15.0)
change interval for Schedule III and IV vehicles Gear Oil
is extended to 500,000 miles (800 000 km) for 80W/90 Gear Oil
axles with weight ratings of 34,000 to 40,000 lb Single & Rear 10.6 12.2
75W/90 Synthetic Tandem (10.0) (11.5)
(15 000 to 18 000 kg) using synthetic lubricant. Gear Oil
Oil must be changed at least every four years,
Table 3, Freightliner Rear Axle Approved Lubricant
and more often if the axle is exposed to high Type and Capacity
temperatures and steep grades.
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires.
NOTE: Some Freightliner axles have a small
tapped and plugged hole near and below the
IMPORTANT: Freightliner rear axles do not re- housing oil fill hole. This smaller hole is for a
quire the use of friction modifiers. lubricant temperature indicator only, and
2. Clean the fill plug and the area around it. In the should not be used as a fill or level hole.
axle housing rear cover, remove the plug from 5.1 With the vehicle on a level surface, fill the
the oil fill hole. axle through the oil fill hole. Lubricant
3. Place a drain pan under the rear axle drain plug. should be level with the bottom of the oil
Drain the oil when it is warm. At this tempera- fill hole. To check fluid level, see Fig. 2.
ture, the oil will run more freely and ensure that 5.2 Install and tighten the fill plug 41 lbfft (55
the axle is flushed. Nm).
4. Clean the fill and drain plugs. Change them if
necessary. Dana Spicer
4.1 For magnetic plugs, use a piece of key IMPORTANT: The use of friction modifiers is not
stock or any other convenient steel slug approved in Dana drive axles.
to short the two magnetic poles and divert
1. Park the vehicle on level ground, set the parking
the magnetic field.
brakes, and chock the tires.
4.2 Clean away the collected material depos-
2. Clean the fill plug and the area around it. In the
ited on each pole. Magnets will rapidly
axle housing rear cover, remove the plug from
lose their effectiveness as collected mate-
the oil fill hole (or standpipe, if installed in the oil
rial bridges the gap between the two
fill hole). See Fig. 3.
poles.
3. Place a drain pan under the rear axle drain plug.
4.3 After the first oil is changed, inspect the
See Fig. 3. Drain the oil at normal operating
drain plug each time for large quantities
temperature, 150F to 200F (65C to 93C). At
of metal particles.

Columbia Maintenance Manual, July 2005 35/3

35 Rear Axle

2 2

1
05/27/93 f350018a

1. Oil Fill Plug 2. Oil Drain Plug

05/27/93 f350017a
Fig. 3, Axle Housing Drain and Fill Plugs 1. Magnetic Strainer 2. Power Divider
this temperature, the oil will run more freely and Fig. 4, Dana Spicer Tandem-Drive Axle Magnetic
ensure that the axle is flushed. Strainer
NOTE: Some tandem-drive axles are equipped 5.1 For magnetic plugs, use a piece of key
with a cylindrical magnetic strainer, located stock or any other convenient steel slug
below the lube pump on the front of the power to short the two magnetic poles and divert
divider cover. All rear axles are fitted with mag- the magnetic field.
netic drain and fill plugs. 5.2 Clean away the collected material depos-
4. At each axle oil change, remove and clean the ited on each pole. Magnets will rapidly
magnetic strainer, if equipped. See Fig. 4. lose their effectiveness as collected mate-
rial bridges the gap between the two
4.1 Remove the magnetic strainer from the poles.
power divider cover.
5.3 After the first oil is changed, inspect the
drain plug each time for large quantities
WARNING of metal particles.
Always wear eye protection when using com- 5.4 After cleaning, install the drain plug(s)
pressed air to clean parts, as flying debris could and tighten to 40 to 60 lbfft (54 to 81
cause permanent damage to unprotected eyes. Do Nm).
not point the air stream in the direction of other
6. Fill the axle with the recommended lubricant.
persons.
See Table 4 for recommended drive axle lubri-
4.2 Wash the strainer in solvent, and blow it cants, and Table 5 for drive axle lubricant ca-
dry with compressed air to remove oil and pacities.
metal particles.
4.3 Install and tighten the magnetic strainer
40 to 60 lbfft (54 to 81 Nm).
5. Clean the fill and drain plugs. Change them if
necessary.

35/4 Columbia Maintenance Manual, July 2005

Rear Axle 35

Dana Spicer Drive Axle Recommended Lubricant the standpipe opening. To check fluid
level, see Fig. 2.
Lubricant SAE
Lubricant Type Condition Viscosity 6.2 Install and tighten the fill plug 40 to 60
Grade lbfft (54 to 81 Nm).
Dana Spicer Over-the-Road
Roadranger Service
75W90 Two-Speed Axles With Shift Unit
Synthetic Drive Axle
Lubricants, or Off-Highway Dana Spicer and Meritor
Equivalent with Equipment, or
80W140 1. Remove the shift unit housing cover. See Fig. 5.
Military Specification Under Extra
MILL2105D Heavy Loads Drain and discard the old lubricant. Discard the
housing cover gasket.
Table 4, Dana Spicer Drive Axle Recommended
Lubricant

Dana Spicer Drive Axle Lubricant Capacities

Capacity:*
Axle Type Axle Model
Pints (liters)
1
Single-Drive Axle Installation
Single 23080S, 23080D 40 (18.9)
Reduction 23105S, 23105D 48 (22.7)
Tandem-Drive Axle Installation
DD404, DD404P 31 (14.7)
Single
DS404, DS404P 39 (18.5) 3
Reduction
DS461P 43 (20.3) 2
08/06/93 f350021a
DT402, 402P 34 (16.1)
2-Speed (dual- 1. Housing Cover Gasket
DT451P 39 (18.5) 2. Oil Fill Plug
range)
DT461P 43 (20.3) 3. Shift Unit Housing Cover

Double DP451P 34 (16.1) Fig. 5, Two-Speed-Axle Shift Unit

Reduction DP461P 43 (20.3)
2. Thoroughly wash the axle shift parts and housing
* Quantities listed are approximate. Fill axle until lubricant is level with bot- cover, and allow them to air dry.
tom of fill hole with vehicle on level ground.
Add 2 pints (1 L) of additional lubricant to the power divider. 3. Install the housing cover and a new cover gas-
Table 5, Dana Spicer Drive Axle Lubricant Capacities
ket. Tighten the housing cover capscrews 90 to
110 lbfin (1020 to 1240 Ncm), then remove the
oil fill plug from the cover.
NOTE: Some Dana Spicer axles have a
IMPORTANT: When the ambient temperature is
small tapped and plugged hole near and above 0F (18C), use SAE 10 heavy-duty en-
below the housing oil fill hole. This smaller
gine oil, API service classification SD (sulfated
hole is for a lubricant temperature indicator
ash content must not exceed 1.85%). When the
only, and should not be used as a fill or level
ambient temperature is below 0F (18C), use
hole.
one part kerosene to three parts SAE 10 heavy-
6.1 With the vehicle on a level surface, fill the duty engine oil, API service classification SD
axle through the oil fill hole or standpipe (sulfated ash content must not exceed 1.85%).
opening. Lubricant should be level with This cold-weather mixture can be safely used
the bottom of the oil fill hole, or the top of up to 32F (0C).

Columbia Maintenance Manual, July 2005 35/5

35 Rear Axle

Commercially available automatic transmission temperature indicator only, and should not be
fluid may be used in place of SAE 10 engine oil. used as a fill or level hole.
Automatic transmission fluid can be used for all 3. Check that the lubricant is level with the bottom
temperatures; do not mix it with kerosene. To of the fill hole. See Fig. 2. If low, check for oil
prevent component damage, do not mix engine leaks, and correct as needed.
oil and automatic transmission fluid.
4. Install and tighten the fill plug 35 lbfft (47 Nm).
4. Using the recommended lubricant, fill the shift
unit housing through the oil fill hole until the lubri- IMPORTANT: Always check the axle breather
cant is level with the bottom of the opening. whenever checking lubricant level. Check the
breather more frequently under adverse operat-
5. Coat the threads of the fill plug with a small
ing conditions.
amount of Loctite 242, or equivalent sealant.
Install the fill plug finger-tight in the rear axle shift 5. Check the axle housing breather. Make sure that
unit housing. Using a wrench, tighten it an addi- it is open and unclogged. See Fig. 6. If the
tional 1-1/2 turns. breather is plugged or damaged, clean or re-
place it as needed.
3502 Axle Breather and Axle 1
Lubricant Level
Inspection
For all axles, including tandem-drive axles and two-
speed axles, do the procedures under the heading,
"All Axle Models." For a two-speed axle with a shift
unit, also change the shift unit lubricant. See under
the heading, "Two-Speed Axles With Shift Unit."

All Axle Models

Meritor
CAUTION 2 3
06/07/94 f350062a
Failure to keep the rear axle filled to the proper 1. Axle Housing 2. Carrier Oil Fill Plugs
level with the recommended lubricant can result in Breathers 3. Interaxle Differential
rear axle damage.
Fig. 6, Meritor Axle Housing Breathers
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires. 6. On non-drive axles using oil-lubricated wheel
IMPORTANT: Oil level must be checked at each bearings, check the oil level at the wheels, and
M1 interval on Meritor axles. add oil if low. Use the same lubricant recom-
mended for the drive axle.
2. Clean the fill plug and the area surrounding the
fill plug on the side of the axle carrier. Remove
NOTE: When adding to or checking the oil level,
the plug. Check lubricant level when the axle is make certain the hub cap and plug are clean
cold, or near room temperature. before removing the plug; this will minimize the
possibility of dirt and road grime entering the
NOTE: Some Meritor axles have a small tapped assembly.
and plugged hole near and below the housing
oil fill hole. This smaller hole is for a lubricant

35/6 Columbia Maintenance Manual, July 2005

Rear Axle 35

Freightliner Dana Spicer

CAUTION CAUTION
Failure to keep the rear axle filled to the proper Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in level with the recommended lubricant can result in
rear axle damage. rear axle damage.
1. Park the vehicle on level ground, set the parking 1. Park the vehicle on level ground, set the parking
brakes, and chock the tires. brakes, and chock the tires.
IMPORTANT: After 300,000 miles (500 000 km), 2. If the vehicle has just been driven, allow a few
oil level must be checked at each M1 interval on minutes for the lubricant to settle.
Freightliner axles. 3. Clean the oil fill plug and the area surrounding it.
2. Clean the fill plug and the area surrounding the See Fig. 7. Remove the plug from the fill hole (or
fill plug on the side of the axle carrier. Remove standpipe, if installed in the oil fill hole).
the plug. Check lubricant level when the axle is
cold, or near room temperature.
NOTE: Some Freightliner axles have a small
1
tapped and plugged hole near and below the
housing oil fill hole. This smaller hole is for a
lubricant temperature indicator only, and should
not be used as a fill or level hole.
3. Check that the lubricant is level with the bottom
of the fill hole. See Fig. 2. If low, check for oil
leaks, and correct as needed.
4. Install and tighten the fill plug 41 lbfft (55 Nm). 2
3
IMPORTANT: Always check the axle breather
whenever checking lubricant level. Check the
breather more frequently under adverse operat- 06/07/94 f350002a
ing conditions.
1. Axle Housing Breather
5. Check the axle housing breather. Make sure that 2. Fill Plug
it is open and unclogged. If the breather is 3. Temperature Indicator Plug
plugged or damaged, clean or replace it as
needed. Fig. 7, Dana Spicer Axle Housing Breather

6. On non-drive axles using oil-lubricated wheel IMPORTANT: A lubricant level close enough to
bearings, check the oil level at the wheels, and be seen or touched is not sufficient. It must be
add oil if low. Use the same lubricant recom- level with the bottom of the fill hole, or the top of
mended for the drive axle. the standpipe opening.
NOTE: When adding to or checking the oil level, 4. Check that the lubricant is level with the bottom
make certain the hub cap and plug are clean of the fill hole, or with the top of the standpipe
before removing the plug; this will minimize the opening. See Fig. 2. If low, check for oil leaks,
possibility of dirt and road grime entering the and correct as needed.
assembly. 5. Install and tighten the fill plug 40 to 60 lbfft (54
to 81 Nm).
IMPORTANT: Always check the axle breather
whenever checking lubricant level. Check the

Columbia Maintenance Manual, July 2005 35/7

35 Rear Axle

breather more frequently under adverse operat- unit housing. Using a wrench, tighten it an addi-
ing conditions. tional 1-1/2 turns.
6. Check the axle housing breather. Make sure that
it is unclogged and free from corrosion. See
Fig. 7. If the breather is plugged or damaged,
clean or replace it as needed.
7. Remove the chocks from the tires.

Two-Speed Axles With Shift Unit

Dana Spicer and Meritor
CAUTION
Failure to keep lubricant at the specified level
could cause damage to the axle shift unit.
1. Clean the shift unit oil fill plug, and the area sur-
rounding the plug. See Fig. 5. Turn the fill plug
counterclockwise to remove it.
2. Insert a finger or pipe cleaner into the fill plug
hole and check the fluid level. The lubricant
should be level with the bottom of the fill hole. If
low, add the recommended lubricant.

CAUTION
Before adding additional lubricant, make sure of
the type currently in the shift unit. To prevent
component damage, do not mix engine oil with
automatic transmission fluid.
IMPORTANT: When the ambient temperature is
above 0F (18C), use SAE 10 heavy-duty en-
gine oil, API service classification SD (sulfated
ash content must not exceed 1.85%). When the
ambient temperature is below 0F (18C), use
one part kerosene to three parts SAE 10 heavy-
duty engine oil, API service classification SD
(sulfated ash content must not exceed 1.85%).
This cold-weather mixture can be safely used
up to 32F (0C).
Commercially available automatic transmission
fluid may be used in place of SAE 10 engine oil.
Automatic transmission fluid can be used for all
temperatures; do not mix it with kerosene.
3. Coat the threads of the fill plug with a small
amount of Loctite 242, or equivalent sealant.
Install the fill plug finger-tight in the rear axle shift

35/8 Columbia Maintenance Manual, July 2005

Wheels and Tires 40
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Wheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Columbia Maintenance Manual, April 2005

Wheels and Tires 40

4001 Wheel Nut Check When checking wheel nuts on a dual disc assembly,
remove one outer nut at a time, tighten the inner nut,
then reinstall and tighten the outer nut. Repeat this
IMPORTANT: After a wheel has been installed, procedure for all wheel nuts, using the tightening se-
the wheel nut torque must be rechecked after quence shown in Fig. 1.
50 to 100 miles (80 to 160 km) of operation.
See Table 1 for disc wheel nut torque specifications, 1 2 1
10 8
and see Fig. 1 for the wheel nut tightening se-
quence. 7 4 3 6

CAUTION 5 6 5 4

Insufficient wheel nut (rim nut) torque can cause 7 9

3 8 2
wheel shimmy, resulting in wheel damage, stud
breakage, and extreme tire tread wear. Excessive A B
wheel nut torque can break studs, damage 09/18/2001 f400164
threads, and crack discs in the stud hole area. A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel
Use the recommended torque values, and follow
the tightening sequence shown in Fig. 1. Fig. 1, Wheel Nut Tightening Sequence

Disc Wheel Fastener Torques

Description Nut Size Wheel Manufacturer Torque: lbfft (Nm)
10-Hole and 8-Hole Hub-Piloted Disc Wheel With Two-Piece Flange Nuts*
Front and Rear Wheel Nut M22 x 1.5 All 450500 (610678)
Nuts on Double-Threaded Wheel Studs M22 x 1.5 All 390450 (529610)
Double-Threaded Wheel Stud Retainer Nut 3/416 All 175200 (235270)
10-Hole Stud-Piloted Disc Wheel With Inner and Outer Nuts
Front Wheel Nut 1-1/816 All 450500 (610678)
Rear Wheel Inner Nut 3/416 All 450500 (610678)
Rear Wheel Outer Nut 1-1/816 All 450500 (610678)
* Torque values for hub-piloted wheels are given for lubricated threads. Lubricate threads with SAE 30W engine oil. Do not apply thread lubricant to ball seats
of the nuts and wheels. Wipe it off if it is applied accidentally.
Torque values for stud-piloted wheels are given for clean, dry threads.

Table 1, Disc Wheel Fastener Torques

Columbia Maintenance Manual, April 2005 40/1

Driveline 41
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4101
Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4102

Columbia Maintenance Manual, March 2000

Driveline 41

4101 Driveline Inspection

1. Park the vehicle on a flat, level surface, apply
the parking brakes, and chock the tires.

CAUTION
Due to the extreme load occurring at high-speed
rotation, a loose or broken capscrew at any point
in the driveline will weaken the driveline connec-
tion, which could eventually result in serious ve-
hicle damage. Do not over-tighten bearing-cap
capscrews or yoke-strap capscrews.
12/09/97 f410182
2. For driveline universal joints with bearing caps,
tighten bearing-cap capscrews 43 lbfft (49 Nm). Fig. 2, Meritor RPL Series U-Joint
See Fig. 1, Ref. 1.
If any end-yoke can be moved in or out on its
For RPL series universal joints, tighten bearing- shaft, or can be rocked on its shaft, disconnect
cap capscrews 125 lbfft (169 Nm). See Fig. 2. the driveshaft and U-joint from the yoke, then
For driveline universal joints with yoke straps, check the drive components shaft seal for leak-
tighten yoke-strap capscrews 125 lbfft (169 age or other visible damage that may have been
Nm). See Fig. 3. caused by the loose yoke. Replace the seal if
needed, then tighten the yoke nut. Refer to
Group 41 of the Columbia Workshop Manual
for torque specifications. If the yoke is still loose
after tightening the yoke nut, replace the end-
yoke and yoke nut.
1
Replace the prevailing torque locknut (end-yoke
nut) if it was removed for yoke replacement, seal
2 replacement, or any other reason.
4. Check U-joint assemblies for wear by moving the
driveshaft up and down, and from side to side. If
any movement of the U-joint cross in the bear-
ME
R I T OR ings can be felt or seen, replace the U-joint as-
sembly.
5. Check if the midship bearing and mounting are
loose or have deteriorated, by attempting to
move the driveshaft up and down, and from side
1 1
to side. If the bearing is loose on its shaft, or
04/13/98 f410155a rattles, replace it. If the bearing mount is loose
on the frame, tighten the mounting fasteners to
1. Self-Locking 2. Adhesive Band
Capscrew the proper torque value. See Group 41 of the
Columbia Workshop Manual for torque specifi-
cations. Replace the midship bearing assembly if
Fig. 1, Meritor U-Joint Fasteners for Bearing Caps the rubber cushion is deteriorated or oil-soaked.
3. Check the driveline yokes for cracks, and check 6. Check slip joints for spline wear by moving the
end-yokes for looseness. See Fig. 3. sleeve-yoke and splined shaft back and forth.
Replace cracked yokes. See Fig. 4. If the slip joint can be twisted in a
clockwise, or counterclockwise movement

Columbia Maintenance Manual, March 2000 41/1

41 Driveline

15
14

13

16
3
8 9
7 12

11
1
2
10
6
5
4

3
05/01/95 f410067b
NOTE: Not all fasteners are shown.
1. Transmission 6. U-Joint Cross 12. Splined Stub Shaft
2. Transmission Output-Shaft 7. Bearing Cup (for yoke strap) 13. Driveshaft Tube
End-Yoke (yoke-strap type) 8. Yoke Strap and Capscrew 14. Tube-Yoke (bearing-cap type)
3. U-Joint Assembly 9. Slip-Joint Assembly 15. Axle Input-Shaft End-Yoke
4. Bearing Cap Self-Locking 10. Sleeve-Yoke (bearing-cap type) (yoke-strap type)
Capscrew 11. Dust Cap 16. Rear Axle
5. Bearing Cap
Fig. 3, Components of a Basic Driveline

greater than 0.007 inch (0.18 mm), replace both 9. For driveshafts with slip joints, check to be sure
the sleeve-yoke and the splined shaft. the yoke plug is not loose or missing. See Fig. 5,
Ref. 2. Repair or replace the yoke plug as
7. Visually examine the driveshaft tubes for dents,
needed. If the yoke plug is missing, the splined
bends, twists, or other damage. If any tube ap-
pears to be damaged, refer to Group 41 of the shaft may be hitting the plug and knocking it out;
contact your Regional Service Office for assis-
Columbia Workshop Manual for repair and re-
tance in determining the correct driveshaft
placement instructions.
length.
8. Examine the driveshaft for evidence of missing
balance weights, and for build-up of foreign ma-
terial. Remove any foreign material. If there is
any evidence that balance weights are missing,
remove the driveshaft and have it balanced.

41/2 Columbia Maintenance Manual, March 2000

Driveline 41

1
3
4
7
2 3

05/27/93 f410012a 6
Attempt to move the sleeve-yoke and splined shaft back
and forth.
Fig. 4, Slip Joint Spline Wear Checking 8
3 1
4102 Driveline Lubrication
A
Universal Joint Lubrication
NOTE: Vehicles equipped with Meritor RPL Se- 10/20/93 f410050a
ries drivelines do not require periodic lubrication. A. After grease appears, cover the pressure-relief hole
while continuing to lubricate.
1. Park the vehicle on a flat surface, apply the park-
1. Slip Joint Grease Fitting (with grease gun attached)
ing brakes, and chock the tires.
2. Yoke Plug
2. Wipe all old grease and dirt from each U-joint 3. Grease
grease fitting. See Fig. 5, Ref. 8. 4. Half-Round Yoke
5. Yoke Plug Pressure-Relief Hole
3. Use a hand-type grease gun, or a high-pressure 6. Slip Joint Seal
gun with a low-pressure adapter, to lubricate 7. Full-Round Yoke
U-joints. If a low-pressure adapter is not used, 8. U-Joint Grease Fitting
U-joints may not receive enough grease.
Fig. 5, Slip Joint and U-Joint Lubrication
Using lithium 12-Hydroxy stearate grease (NLGI
Grade 1 or Grade 2, with EP additives), lubricate with a plastic or rawhide mallet on the side oppo-
until new grease can be seen at all four U-joint site the dry seal, while continuing to lubricate. If
seals. Fresh grease must be seen escaping from grease still does not appear, loosen the cap-
all four bearing-cap seals of each U-joint. On screws at the bearing with the dry seal, to relieve
yokes equipped with a yoke-bearing cap, if most seal tension. Lubricate the U-joint until new
of the grease being added to a U-joint can be grease is seen at the seal, then tighten the cap-
seen escaping from just one of the U-joint seals, screws to the correct torque specifications. If the
check the torque on the capscrews at that seal. bearing will not take grease, replace the U-joint.
Refer to Group 41 of the Columbia Workshop
4. Tighten the bearing-cap capscrews 43 lbfft (49 Manual for replacement instructions.
Nm). If the capscrews were already tight, or all
of the U-joint seals still do not purge, remove the 6. Check the purged grease. If it appears rusty,
bearing cap at that seal, and examine the seal gritty, or burned, replace the U-joint.
for damage. If the seal is damaged, replace the 7. Wipe the purged grease from the seals, and any
complete U-joint. excess grease from the grease fitting.
5. If grease does not appear at one seal, use a pry-
ing tool to pry the U-joint trunnion away from the
non-purging seal, or tap the driveshaft or yoke

Columbia Maintenance Manual, March 2000 41/3

41 Driveline

Slip Joint Spline Lubrication

NOTE: Vehicles equipped with Meritor RPL Se-
ries drivelines do not require periodic lubrication.
1. If equipped with a grease fitting, wipe all old
grease and dirt from the slip joint grease fitting.
See Fig. 5, Ref. 1.
2. Use a hand-type grease gun or a high-pressure
gun with a low-pressure adapter, to lubricate the
slip joint. Add multipurpose chassis grease
(lithium 12-hydroxy stearate, NLGI Grade 1 or
Grade 2, with EP additives) until it appears at the
pressure-relief hole in the yoke plug. Then cover
the relief hole with your finger, while continuing
to apply gun pressure until new grease appears
at the slip joint seal. See Fig. 5. This ensures
complete lubrication of the splines.
3. Wipe the purged grease from the pressure-relief
hole and slip joint seal, and any excess grease
from the grease fitting.

41/4 Columbia Maintenance Manual, March 2000

Brakes 42
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4201
Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203
Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4204
Bendix AD9 Air Dryer Desiccant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4202
Bendix ADIS Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4209
Bendix E-6 Foot Control Valve Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4210
Dana Spicer Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4205
Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4206
Meritor Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4207
Meritor Slack Adjuster Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4208

Columbia Maintenance Manual, January 2008

Brakes 42

4201 Air Brake System Valve CAUTION

Inspection Clamping the end cover or housing in a vise could
NOTE: There is no scheduled air valve mainte- seriously compromise the air dryers ability to
hold air pressure, which could cause a failure in
nance on vehicles equipped with Bendix air
the brake system.
valves and a Bendix air dryer if the air dryer
desiccant is replaced at 350,000 miles (563 000 10. Twist the end cover counterclockwise to release
km). If the desiccant is not changed at 350,000 the cartridge from the end cover. Rotate the end
miles (563 000 km), or if the vehicle is equipped cover until it completely separates from the des-
iccant cartridge.
with another air dryer, maintenance will have to
be performed to the air brake valves. See NOTE: A substantial torque, up to 50 lbfft (68
Group 42 of the Columbia Workshop Manual Nm), may be necessary to remove the desic-
for procedures. cant cartridge.
11. Inspect the condition of the O-ring seals. If they
4202 Bendix AD9 Air Dryer are cracked, crimped, or otherwise damaged,
replace them to ensure an airtight seal. Clean
Desiccant Replacement the O-ring grooves of any dirt or obstruction.

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

parking brakes. Shut down the engine. Chock
CAUTION
the tires. Dirt or obstructions in the O-ring grooves can
2. Completely drain all air reservoirs. Air pressure cause an O-ring failure that will result in an air
gauges should read 0 psi (0 kPa). leak.
12. Lubricate the O-rings with silicone or lithium
CAUTION grease and install them in the end cover.

The compressor discharge line may still contain 13. Install the desiccant cartridge on the end cover.
residual air pressure. Turn the cartridge clockwise until the desiccant
cartridge makes contact with the end cover.
3. Identify, tag, and disconnect the three air lines
from the end cover. 14. Place the desiccant cartridge in a vise, and turn
the end cover clockwise an additional 180 to 225
4. Disconnect the harness connector from the degrees to fully tighten the desiccant cartridge to
heater and thermostat assembly. the end cover.
5. Loosen the capscrew that secures the upper NOTE: Desiccant cartridge torque should not
mounting bracket strap. exceed 50 lbfft (68 Nm).
6. Remove the two capscrews that secure the air 15. Place the housing over the desiccant cartridge
dryer to the lower mounting bracket. Mark the and align the mounting holes with the end cover.
position of the mounting bracket to the end cover
and mark the capscrews to ease installation. IMPORTANT: Replace, do not reuse the Nylok
7. Remove the upper mounting bracket strap cap-
nuts on the air dryer cover.
screw, and remove the air dryer from the vehicle. 16. Install the 6 capscrews, 12 washers, and 6 new
8. Place the air dryer on a bench and remove the Nylok nuts. Torque the capscrews in a star pat-
remaining 6 capscrews, 12 washers, 6 Nylok tern 270 to 385 lbfin (3060 to 4340 Ncm). See
nuts, and the air dryer housing. See Fig. 1. Dis- Fig. 2.
card the Nylok nuts. Remove the end-cover-to- 17. Install the air dryer on the lower mounting
housing O-ring. bracket. Install the two previously marked cap-
9. Clamp the desiccant cartridge in a vise. screws, four washers, and two new Nylok nuts.
Torque the two remaining capscrews 270 to 385

Columbia Maintenance Manual, January 2008 42/1

42 Brakes

2
11

3 9
4 25
5 12 10 8
14 10
24

10
10 10
8 10
6
23
13
10 15 22
7
8 21

20

18 19
17
16

08/09/95 f421383
1. 5/16 x 4-1/2-Inch Upper 9. Desiccant Cartridge 18. Purge Valve
Mounting Bracket Capscrew 10. O-Ring 19. 1/4-Inch Tapping Screw
2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing
3. 5/16-Inch Lockwasher 12. Lower Mounting Bracket 21. Heater and Thermostat
4. 5/16-Inch Nylok Nut 13. 3/8-Inch Capscrew (long) Housing
5. Upper Mounting Bracket 14. Check Valve Assembly 22. Return Spring
6. Housing 15. Purge Valve Assembly 23. Purge Piston
7. Nylok Nut 16. Purge Valve Bolt 24. 3/8-Inch Capscrew
8. 3/8-Inch Special Washer 17. Exhaust Diaphragm 25. End Cover

Fig. 1, AD-9 Air Dryer (exploded view)

lbfin (3060 to 4340 Ncm). Install the capscrew, leaks are present, see Group 42 of the
two washers, and a new Nylok nut in the upper Columbia Workshop Manual for diagnosis and
mounting bracket strap. Torque the upper mount- repair information.
ing bracket strap capscrew 80 to 120 lbfin (904
20. Remove the chocks from the tires.
to 1356 Ncm).
18. Connect and tighten the three air lines. Connect
the harness connector to the heater and thermo-
stat 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

42/2 Columbia Maintenance Manual, January 2008

Brakes 42

weeks of operation may be needed to fully

6 2 dry the system.
The temperature range in your area fluctu-
ates more than 30 degrees in one day.
Small amounts of water can accumulate in
4 5 the air brake system due to condensation.
Under these conditions, the presence of
moisture is normal and should not be con-
sidered an indication of poor air dryer per-
formance.
3. Inspect the air dryer for external damage, and
1&9 3 check that the unit is tightly mounted on the
frame. If the air dryer mounting is loose, See
Group 42 of the Columbia Workshop Manual
for mounting instructions.
7 8 4. Turn on the ignition switch, but do not start the
engine.
09/20/94 f420544a 5. Disconnect the harness connector from the air
dryer.
Fig. 2, End Cover to Housing Torque Pattern
6. Connect a voltmeter to circuit 94 on the air dry-
4203 Air Dryer Inspection ers harness connector and to a body ground
point. Check for battery voltage. If voltage is not
1. Park the vehicle on a level surface and apply the found, check and repair the open or short to
parking brakes. Shut down the engine. Chock ground in wire 94.
the tires. 7. Connect a voltmeter between the two terminals
2. Check for moisture in the air brake system by on the air dryers harness connector. If voltage is
opening the reservoir drain cocks. Examine the not found, repair the open in the ground circuit
discharge. Some trace of water in the discharge wiring.
is normal. A discharge of a milky gray liquid indi- 8. Use an ohmmeter to check resistance between
cates excessive moisture is present in the air the terminals on the end cover. See Fig. 3. The
system and the desiccant cartridge needs to be end cover contains the heater/thermostat. If the
replaced. See Group 42 of the Columbia Work- heater/thermostat is between 40 and 90F (5 and
shop Manual for troubleshooting procedures. The 32C), the heater/thermostat measured resis-
following conditions could cause small amounts tance will be infinite ohms. If the measured resis-
of moisture to be found in the air system: tance is less than infinity, replace the
An outside air source has been used to heater/thermostat.
charge the air brake system. This air did 9. Remove the heater/thermostat assembly and
not pass through the drying bed. place it in a freezer for about five minutes to cool
Air usage is unusually high and not normal. it below 40F (5C). Remove the cold
This may be due to accessory air demands heater/thermostat assembly and check resis-
or some unusual air requirement that does tance between the heater/thermostat terminals.
not allow the compressor to load and un- Resistance should be 1.5 to 3.0 ohms. As the
load in a normal fashion. Check for air sys- temperature of the heater/thermostat assembly
tem leaks. increases, the ohm reading will increase. When
the temperature goes above 45F (7C) mea-
The air dryer has been installed on a sys- sured resistance should be infinite ohms. If the
tem that had previously been operated heater/thermostat does not operate as outlined,
without an air dryer. This type of system replace it. If it does operate as outlined, install it,
will be saturated with moisture, and several then remove the chocks from the tires.

Columbia Maintenance Manual, January 2008 42/3

42 Brakes

Freeze Season Reactivation

1. Park the vehicle on a level surface and apply the
parking brakes. Shut down the engine. Chock
the tires.
2. Remove the filler cap, and check the cap tet-
raseal.
3. Remove the capscrews and reservoir from the
cover.
4. Remove the cover tetraseal.
5. Drain the air tank, and disconnect the line from
the evaporator outlet. Remove the check-valve
retainer, spring, and disc.
6. Install the disc, spring, and check-valve retainer,
1 and connect the line to the evaporator outlet.
7. Install the cover tetraseal.
8. Install the reservoir on the cover and tighten the
capscrews.
2
06/04/96 f421384 9. Fill the reservoir with 40 ounces (1183 mL) of
1. End Cover Assembly methyl alcohol, then install the filler cap.
2. Heater/Thermostat Terminals 10. Remove the chocks from the tires.
Fig. 3, End Cover Terminals Location

4204 Alcohol Evaporator 4205 Dana Spicer Camshaft

Cleaning and Inspection Bracket Lubrication
IMPORTANT: Perform MOP 4211 before lubri-
Midland cating the camshaft bracket.
Maintenance is required during both the freeze sea- Pump grease into the camshaft bracket until it ap-
son and the off season to keep the alcohol evapora- pears at the slack adjuster end of the bracket. See
tor in good working order. Fig. 4.
Use an NLGI Grade 1 or Grade 2 multipurpose chas-
Off Season sis grease. If grease leaks out under the camhead,
During the off season, drain the unit of alcohol. At the camshaft bracket grease seal is worn or dam-
regular engine service intervals, open the drain cock aged; replace it. See Group 42 of the Columbia
to remove moisture from the alcohol evaporator. Be- Workshop Manual for grease seal replacement
fore reactivating the evaporator for the next freeze instructions.
season, drain, disassemble, inspect, and steam-
clean the unit of any sludge that may have accumu-
lated. It is advisable to replace any rubber parts 4206 Dana Spicer, Haldex,
when assembling the alcohol evaporator. Perform and Gunite Slack
this service just before the freeze season.
Adjuster Lubrication
IMPORTANT: Perform MOP 4211 before lubri-
cating the slack adjusters.

42/4 Columbia Maintenance Manual, January 2008

Brakes 42

1 1

05/28/93
A f420011a 2
A. Grease Exit
1. Brake Chamber 3. Non-Pressure-Relief
2. Slack Adjuster Grease Fitting
Fig. 4, Camshaft Bracket Lubrication

Automatic slack adjusters that have a grease fitting

must be lubricated periodically to ensure proper 02/01/2001 f421649a
brake operation. 1. Grease Fitting 2. Slack Adjuster
Fig. 5, Dana Spicer Automatic Slack Adjuster
WARNING
Lubricate a Gunite automatic slack adjuster at the
Failure to lubricate slack adjusters could lead to grease fitting until grease appears on the camshaft,
dragging brakes or a brake failure, resulting in or flows from the grease relief. See Fig. 6.
property damage, personal injury, or death.
The newest Gunite automatic slack adjusters are
Dana Spicer and Haldex produced without a grease relief. During lubrication
with a grease gun, lubricant is forced through the
drilled worm wheel onto the camshaft. Lubricate the
CAUTION automatic slack adjuster at the grease fitting until
grease appears on the camshaft. See Fig. 6.
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. 4207 Meritor Camshaft
Lubricate the automatic slack adjuster at the grease Bracket Lubrication
fitting. See Fig. 5. Use standard chassis lubricant for
Haldex slack adjusters. Dana Spicer Low Lube slack IMPORTANT: Perform MOP 4211 before lubri-
adjusters should be lubricated with SHC 460 syn- cating the camshaft bracket.
thetic lubricant.
NOTE: If equipped with an extended-
Gunite maintenance Q Plus brake system, the cam-
shaft bracket will not have a grease fitting.
For operating temperatures of 20F (29C) and
These camshafts use a special NLGI grade syn-
higher, use Texaco Multifak EP-2 or Mobil Grease
No. 77. thetic polyurea grease and do not require lubri-
cation for 3 years or 500,000 miles (800 000
For operating temperatures between 20F (29C) km), whichever comes first. The extended-
and 40F (40C), use Lubriplate Aero grease. maintenance camshaft bushings are lubricated

Columbia Maintenance Manual, January 2008 42/5

42 Brakes

is not replaced, the brake linings could become

contaminated with grease. The stopping distance
of the vehicle will be increased, which could result
4
in personal injury or property damage.
5

6
4208 Meritor Slack Adjuster
Lubrication
7
3 IMPORTANT: Perform MOP 4211 before lubri-
8
cating the slack adjusters.
NOTE: If equipped with an extended-
2
maintenance Q Plus brake system, the slack
9 adjuster will not have a grease fitting. These
slack adjusters use a special NLGI grade syn-
thetic polyurea grease and do not require lubri-
1 cation for 3 years or 500,000 miles (800 000
km), whichever comes first. The extended-
10 maintenance slack adjusters are lubricated dur-
ing the brake reline service interval. For service
and lubrication instructions, see Group 42 of
the Columbia Workshop Manual.
For slack adjusters with grease fittings and for oper-
10/27/93 f420653a
ating temperatures above 40F (40C), use a
1. 7/16-Inch Adjusting 6. Clevis NLGI Grade 1 clay-base grease, or a NLGI Grade 1
Nut 7. 1/2-Inch Clevis Pin or 2 lithium-base grease.
2. Grease Fitting 8. 1/4-Inch Clevis Pin
3. Boot 9. Grease Relief For slack adjusters with grease fittings and for oper-
4. Link Opening ating temperatures below 40F (40C) and above
5. Brake Chamber Piston 10. Slack Adjuster Spline 65F (54C), use a NLGI Grade 2 synthetic oil,
Rod clay-base grease.
Fig. 6, Gunite Automatic Slack Adjuster Lubricate the slack adjuster at the grease fitting until
grease is forced past the pressure-relief capscrew or
during the brake reline service interval. For ser- past the gear splines around the inboard snap ring.
vice and lubrication instructions, see Group 42 See Fig. 7.
of the Columbia Workshop Manual.
For camshaft brackets with grease fittings, use an 4209 Bendix ADIS Air Dryer
NLGI Grade 1 or Grade 2 multipurpose chassis
grease. Desiccant Replacement
Lubricate the camshaft bushings through the grease 1. Park the vehicle on a level surface and apply the
fitting on the camshaft bracket or the spider until new parking brakes. Shut down the engine. Chock
grease flows from the inboard seal. See Fig. 4 the tires.
2. Drain the air reservoirs.
WARNING
3. Using a strap wrench or equivalent, loosen the
If grease leaks out under the camhead, the cam- desiccant cartridge. Spin the cartridge off by
shaft bracket grease seal is worn or damaged. See hand and discard it. See Fig. 8.
Group 42 in the Columbia Workshop Manual for
grease seal replacement instructions. If this seal

42/6 Columbia Maintenance Manual, January 2008

Brakes 42

IMPORTANT: Only use the silicone grease sup-

1 plied with AlliedSignal replacement kits.
5. Screw the desiccant cartridge onto the body by
2
hand until the seal makes contact with the body.
Rotate the cartridge clockwise about one full
turn. Tighten the cartridge firmly.
3 6. Remove the chocks from the tires.

4
4210 Bendix E-6 Foot Control
5
Valve Inspection and
Lubrication
7
1. Remove the brake valve from the vehicle. See
6 f420012a Section 42.10, Subject 110, of the Columbia
10/20/93
1. Brake Chamber Workshop Manual for instructions.
2. Clevis
2. Remove the roll pin from the brake pedal pivot
3. Actuator Rod
4. Boot pin. See Fig. 9.
5. Pressure-Relief Capscrew, Gasket, Pawl Spring,
and Pawl 2
6. Manual Adjusting Nut
7. Grease Fitting (or plug) 5

Fig. 7, Meritor Automatic Slack Adjuster

1 6
3
4 7
8

2 09/10/2004 f430405

3 1. E-6 Foot Control Valve 5. Roll Pin

2. Mounting Plate 6. Roller
3. Nut and Washer 7. Roller Pin
04/16/98 f421910 4. Pivot Pin 8. Pedal
1. Desiccant Cartridge Fig. 9, Brake Pedal and Valve Assembly
2. Cartridge Sealing Ring
3. Threaded Base Post 3. Remove the brake pedal pivot pin.
Fig. 8, Desiccant Cartridge Replacement 4. Remove the brake pedal.

4. On the new desiccant cartridge, lubricate the 5. Check the brake pedal mounting plate adapter
sealing rings with silicone grease. for signs of wear or cracks at the bosses (the

Columbia Maintenance Manual, January 2008 42/7

42 Brakes

area from which the pivot pin was removed). Re-

place it if necessary.
6. Check the brake pedal rollers for signs of wear
or cracks. Replace it if necessary.
7. If the rollers are replaced, replace the roller pin,
install a new cotter pin, bend it to 90 degrees
and apply Torque Seal (OPG F900 White) to the
cotter pin.
8. Remove the plunger from the valve. Using alco-
hol, clean the existing grease from the plunger.
Check the plunger for signs of wear or cracks.
Replace it if necessary.
9. Lubricate the plunger with barium grease (BW
246671).
10. Insert the plunger in the valve.
11. Install the brake pedal with the pivot pin.
12. Install a new roll pin and apply Torque Seal
(OPG F900 White) to the roll pin.
13. Install the brake valve assembly. See Section
42.10, Subject 110, of the Columbia Workshop
Manual for instructions.
14. Test the brakes before returning the vehicle to
service.

42/8 Columbia Maintenance Manual, January 2008

Steering 46
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4601
Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4605
Power Steering Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4603
Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4602
Power Steering Gear Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4604
Rack and Pinion Steering Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4606

Columbia Maintenance Manual, February 2010

Steering 46

4601 Drag Link Inspection steering fluid into the drain pan and dispose of
the fluid properly. Plug the return line fitting on
the reservoir.
WARNING 3. Loosen the clamp and remove the cover along
with the filter spring and the filter top plate.
All steering system components are critical for
safe operation of the vehicle. Failure to maintain NOTE: Always replace the power steering reser-
the steering system as specified may result in voir filter when changing the fluid.
loss of steering control, which could lead to per- 4. Remove the filter. It may be necessary to wiggle
sonal injury and property damage. the filter to remove it from its base. Do not use
Have someone turn the steering wheel from left to pliers to aid in removal of the filter; pliers could
right. Check for movement between the ball stud end cause metal chips to enter the steering system.
at both the pitman arm and the steering arm. Also Clean the inside of the reservoir, using a lint-free
check if the ball stud nut is loose. cloth.
If the ball stud end is loose, replace the drag link. If IMPORTANT: Do not start the engine while
the ball stud nut is loose, replace the nut and cotter draining the system.
key. See Group 00 for proper torque specifications.
5. Place the disconnected end of the steering gear-
Inspect the boot of the drag link at both the pitman to-reservoir hose in the drain pan. Raise the front
arm and the steering arm end for cracks, splits, or of the vehicle with a floor jack and support it with
other damage. Replace the boot as needed. See jack stands. Have someone turn the steering
Group 46 of the Columbia Workshop Manual for wheel to full lock left and right. Capture the fluid
drag link removal and installation instructions. flowing from the hose in the drain pan. Add fluid
Grasp the drag link near the pitman arm end, then to the reservoir as needed. When clean power
push and pull laterally to check for axial movement in steering fluid flows from the hose, remove the
the ball stud end. If it is loose, replace the drag link. plug from the reservoir and reconnect the hose
See Group 46 of the Columbia Workshop Manual to the reservoir. Remove the jack stands and
for replacement instructions. If there is 1/8-inch (3- lower the vehicle.
mm) movement or more, do not drive the vehicle 6. With the larger opening at the top, install a new
until the drag link is replaced. filter in the reservoir.
7. Clean the reservoir cover and gasket. Inspect the
4602 Power Steering Fluid O-ring and the cover for cracks, deformities, or
damage. Replace the gasket seal or cover as
and Filter Changing needed.
8. Install the reservoir cover along with the spring
WARNING and the top plate. Make sure the center of the
top plate fits into the opening at the top of the
Fill only with approved clean fluid. Failure to use filter.
the proper fluid could cause seal deterioration and
leaks. Fluid leaks could eventually cause loss of 9. Place the clamp over the flanges of the cover
power steering assist. This could lead to an acci- and shell assembly, then tighten 25 to 30 lbfft
dent resulting in personal injury or property dam- (35 to 40 Nm).
age. Wear eye protection when changing the fluid 10. Fill the power steering reservoir with approved
and filter. power steering fluid to the FULL COLD mark.
1. Apply the parking brakes and chock the rear See Table 1.
tires. 11. Start the engine and operate it at idle. Turn the
2. Place a drain pan under the power steering res- steering wheel to full lock left and right to adjust
ervoir, and remove the steering gear-to-reservoir the fluid level and remove any existing air from
return hose at the reservoir. Drain the power the power steering pump and gear. Recheck the
fluid level. Add fluid as needed. The system is

Columbia Maintenance Manual, February 2010 46/1

46 Steering

properly bled when the steering pump does not

labor when turning the wheel.
4604 Power Steering Gear
12. Check for leaks in the power steering system
Lubrication
and repair as needed. Top off the power steering
fluid level as needed. Sheppard
Approved Power Steering Fluids
Sheppard power steering gears manufactured with-
out grease fittings are maintenance-free. If the power
Fluid Type* Approved Fluid* steering gear has no grease fitting, then it requires
Automatic Transmission Dexron II no periodic lubrication.
Fluid Dexron III Sheppard power steering gears with grease fittings
Shell Rotella T 30W must be lubricated periodically.
Shell Rotella T SAE 30
Heavy-Duty Engine Oil Chevron 10W-40 1. Wipe off debris from the bearing cap grease fit-
Chevron Custom 10W-40 ting. See Fig. 1.
IMPORTANT: Do not use
heavy-duty engine oil on Mobil Super 10W-40
vehicles built from Texaco 10W-40
November 4, 2002. Union 10W-40
Union 15W-40
Unocal Guardol 15W-40
* Do not mix oil types. Refer to the text in this group for a detailed warning
statement.
Table 1, Approved Power Steering Fluids

4603 Power Steering Fluid

Level Inspection
1. Apply the parking brakes and chock the tires.
1
2. With the engine cool, use a shop towel or a 05/28/93 f460296a
clean rag to clean the area around the power
steering reservoir fill cap. Twist the cap counter- 1. Bearing Cap Grease Fitting
clockwise to remove it. Check the cold power
steering fluid level. The level should be between Fig. 1, Sheppard Bearing Cap Lubrication
ADD COLD and FULL COLD with the engine off. 2. Using a hand-type grease gun, apply multipur-
3. Start the engine and run it at idle until it reaches pose chassis grease until grease starts coming
operating temperature. See Table 1 for recom- out of the bearing cap dirt-and-water seal.
mended power steering fluids.
Remove the dipstick, and check that power TRW TAS Series
steering fluid is between ADD HOT and FULL
HOT. If the fluid level is low, add enough fluid to CAUTION
bring the level up to the FULL HOT mark on the
dipstick. Apply grease to the sector shaft only with a hand-
type grease gun. See Fig. 2. Use of a high-
Remove the chocks. pressure power grease gun will supply grease too
quickly and could affect the high pressure seal,
contaminating the hydraulic fluid.
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.

46/2 Columbia Maintenance Manual, February 2010

Steering 46

4606 Rack and Pinion

Steering Inspection
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 per-
sonal injury and property damage.
The rack and pinion steering system is designed to
be maintenance-free. Inspect the system as de-
scribed below, and repair or replace any components
that are worn or damaged. Figure 4 shows the com-
ponents of the rack and pinion steering system.
11/28/95 f461071 1. Park the vehicle on a level surface, and chock
1. Sector Shaft Grease Fitting the rear tires.

Fig. 2, TRW TAS Series Sector Shaft Lubrication

2. Check the steering I-Shaft U-joints for evidence
of looseness or binding. If any is found, replace
the I-Shaft.
4605 Drag Link Lubrication
3. Check the steering I-Shaft slip joint for evidence
1. Using a clean rag, wipe all dirt from both drag of lateral movement, looseness, or binding. If any
link grease fittings. See Fig. 3. is found, replace the I-Shaft.
2. Using a pressure gun, apply clean grease at the 4. Jack up one axle end at a time, and move the
grease fittings until old grease is forced out of tire in and out by hand to check the tie rod ends
the socket. Use multipurpose chassis grease for free play. No free play is allowed. If the outer
NLGI Grade 2 (8% 12-hydroxy lithium stearate tie rod ends are damaged or worn, replace them.
grease) or NLGI Grade 1 (6% 12-hydroxy lithium For repair procedures, see Group 46 of the
stearate grease). Grade 2 is preferred. Columbia Workshop Manual.
5. Check the rack and pinion gear mounting bolts
for security.
6. Check that the outer tie rod castellated nuts are
tight, and the cotter pins are properly installed.
IMPORTANT: Do not remove the rack and pin-
ion bellows unless they are damaged and must
be replaced, or there is evidence of a loose
1 2
11/27/95 f461072 inner tie rod, or there is hydraulic fluid leaking
1. Grease Fitting at Pitman Arm from the bellows.
2. Grease Fitting at Axle Steering Arm 7. Check the rack tie rod bellows for holes or tears.
Fig. 3, Drag Link If any are found, remove the bellows and check
the rack for evidence of corrosion. No corrosion
is allowed. If corrosion is found, replace the rack
and pinion unit. If there is no corrosion, replace
the damaged bellows with a new one.
8. Check the rack and pinion tie rod bellows for evi-
dence of leakage from the bellows. If hydraulic

Columbia Maintenance Manual, February 2010 46/3

46 Steering

16
11

12
15
10 13

9
8 14
7
6

17
2
3
4
5

19 21
20
8
9
22 23
18
5
1
3 4

07/24/2009 f462151

1. Steering Tie Rod Arm 10. Input Shaft Seal Cover 17. I-Shaft Slip Joint
2. Power Steering Fluid Lines 11. I-Shaft Upper Yoke 18. Transfer Lines
3. Large Bellows Clamp 12. I-Shaft Lower Yoke Boot Clamp 19. Rack and Pinion Gear
4. Bellows 13. I-Shaft Lower Yoke Boot 20. Pinch Bolt
5. Small Bellows Clamp 14. I-Shaft Lower End Yoke 21. Tie Rod Clamp
6. Driver-Side Outer Tie Rod 15. Transfer Line Tube Fittings 22. Tie Rod Clamp Nut
7. Tie Rod Jam Nut 16. Power Steering Fluid Line 23. Passenger-Side Outer Tie Rod
8. Inner Tie Rod Flat Fittings
9. Inner Tie Rod Ball Joint
Fig. 4, Rack and Pinion Steering System

fluid is found to be leaking from within the bel- hoses. Repair or replace lines, hoses, and fit-
lows, replace the rack and pinion unit. tings as necessary.
9. Check the input shaft for any leakage around the 10. Check the tube fittings on the hard transfer lines
on-center cap. If there is evidence of leakage of the gear, see Fig. 4, Item 15. If there is leak-
from inside the on-center cap, remove the on- age from either of the fittings, replace the rack
center cap and replace the input shaft seal. See and pinion unit.
Group 46 of the Columbia Workshop Manual for
instructions. IMPORTANT: Tightening the tube fittings can
cause tearing of the O-ring seal and increased
Check the steering system pressure and return fluid leakage.
lines and fittings for leaks and damaged lines or

46/4 Columbia Maintenance Manual, February 2010

Fuel 47
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4701
Fuel Separator Sight Bowl Cleaning and Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4702
Fuel Tank Band-Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4703

Columbia Maintenance Manual, March 2000

Fuel 47

4701 Fuel Filter Replacement 1

Refer to the engine manufacturers service manual 2
for removal and installation procedures.

4702 Fuel Separator Sight 3

Bowl Cleaning and

Element Replacement
ConMet Fuel Separator Sight
3
Bowl Cleaning
The only maintenance necessary on ConMet fuel
4
separators is to clean the sight bowl, if equipped.
See Fig. 1.
5

WARNING
Diesel fuel is flammable and can ignite if exposed 6
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, pos-
sibly resulting in personal injury or property dam-
age. When working on a fuel system, have a fire 7
extinguisher within easy reach.
1. Drain the fuel separator. 8

2. Unscrew the sight bowl from the fuel separator.

3. Wipe the sight bowl clean, using a soft cloth.
9
4. Lubricate the gasket with a film of oil, and rein-
stall it on the sight bowl. If the gasket appears
10
dry-rotted or damaged, replace the gasket.
5. Lightly lubricate the threads on the sight bowl 08/25/95 f470146
with oil, then thread the sight bowl into the bot- 1. Vacuum Breaker/Drain 6. Heater Assembly
tom of the fuel separator. Valve 7. Gasket
2. Reducer Bushing 8. Sight Bowl Heater
6. Hand-tighten until the gasket is in full contact 3. Mounting Brackets Rod
with the fuel separator, then tighten an additional 4. O-Ring (when 9. Sight Bowl Assembly
1/4 to 1/3 turn. equipped with heater) 10. Vacuum Breaker/Drain
5. Stainless Steel Valve
7. Check that the drain valve is tightened and V-Clamp (when
closed. equipped with heater)
8. Prime the fuel separator. Fig. 1, ConMet Fuel Separator
8.1 Remove the vacuum breaker fitting and
fill the unit with diesel fuel. IMPORTANT: The fitting must be air-tight
and the valve closed.
8.2 Install and close the vacuum breaker fit-
ting when the unit is full of fuel.

Columbia Maintenance Manual, March 2000 47/1

47 Fuel

4703 Fuel Tank Band-Nut

Tightening
Hold each fuel tank band retention nut with a wrench
while backing off its jam nut. Then tighten the reten-
tion nuts 30 to 35 lbfft (41 to 46 Nm). After the re-
tention nuts have been tightened, hold each retention
nut with a wrench while tightening its jam nut 30 lbfft
(41 Nm).
IMPORTANT: Do not overtighten.

47/2 Columbia Maintenance Manual, March 2000

Exhaust 49
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4901

Columbia Maintenance Manual, January 2007

Exhaust 49

4901 Exhaust System 4. If leakage exists, tighten the nut on the V-band
coupling 85 lbfin (940 Ncm). If leakage persists,
Inspection (Noise install a new V-band coupling.
Emission Control) 5. Inspect the turbo outlet pipe, and replace it as
needed.
In addition to inspecting the exhaust system at the 6. Check the U-bolt clamps for tightness, and
scheduled maintenance interval, inspect the exhaust tighten as needed.
system if the noise level of the vehicle has in-
creased. Replace parts that show leakage, wear, or 7. Check the isolator at the base of the exhaust
damage, with genuine Freightliner parts. stack elbow(s) (see Fig. 2), for cracking, dam-
age, and dry rot. Replace as needed.
Pre-EPA07 Exhaust System
Inspecting
1. On all vehicles, check the condition of the muffler
body and the top stack. Check the inlet/outlet
tubes for leakage, dents, and corrosion, and
check for holes in the muffler. Replace parts as
required. Use new parts, equivalent to parts
originally installed on the vehicle. See Group 49
of the Columbia Workshop Manual for replace- 1
ment procedures.
2
2. Inspect the exhaust flex hose (see Fig. 1) for
leakage, wear, or damage. Replace with new
parts if replacement is needed. 3
3. Check for leakage at the V-band coupling, which
08/25/95 f490127
attaches the exhaust pipe to the turbocharger
exhaust outlet. See Fig. 2. 1. Exhaust Pipe
2. Exhaust Elbow Isolator
3. Mounting Nut

Fig. 2, Exhaust Elbow Isolator

2 8. Check for leakage at all wide-band exhaust
clamps. See Fig. 3.
1 If leakage exists, tighten the nuts 40 to 60 lbfft
(54 to 81 Nm). If leakage persists, inspect the
sealclamps. If necessary, install a new wide-band
3 exhaust clamp.
4

EPA07 Exhaust System

Inspecting
06/01/93 f490024a

1. Flex Hose 4. Turbocharger Exhaust IMPORTANT: The Environmental Protection

2. V-Band Coupling Outlet Agencys 2007 regulations require lower ex-
3. Exhaust Pipe haust emissions, thus requiring new exhaust
system components. See Fig. 4. In particular
Fig. 1, V-Band Coupling and Flex Hose
the after-treatment device (ATD), which is part
of the after-treatment system (ATS), requires
special attention during regularly scheduled

Columbia Maintenance Manual, January 2007 49/1

49 Exhaust

maintenance inspections. If any discrepancies Definitions of ATS Components

are discovered, refer to the engine manufactur-
ers service literature for repair instructions. Refer to the following list of definitions of ATS com-
ponents.
After-Treatment System (ATS)the entire ex-
haust system from the turbocharger to the ex-
haust stack or tail pipe.
After-Treatment Device (ATD)a muffler-like
canister that houses a DPF, DOC, and sensors.
Diesel Particulate Filter (DPF)a filter that col-
lects and holds particulate matter (soot and
ash).
Diesel Oxidation Catalyst (DOC)oxidizes hy-
drocarbons and reduces NOx.
Sensorsdetect temperatures and pressures in
the ATS.

Inspection
05/28/93 f490025a
1. Check for leakage at the clamp that attaches the
Fig. 3, Donaldson Sealclamp Wide-Band Exhaust exhaust pipe to the turbocharger exhaust outlet.
Clamp If leakage exists, tighten the nut on the clamp to

6
5 7
3 4 2 5
1 2

10/20/2006 A f490283

A. Inspect this area of the canister for dents.

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

Fig. 4, Typical After-Treatment Device

49/2 Columbia Maintenance Manual, January 2007

Exhaust 49

the required torque. If leakage persists, install a

new clamp.
2. Check the exhaust pipe, bellows, and each ex-
haust seal clamp for leakage, wear, cracks, or
damage. Replace damaged components as
needed. If leakage exists at a clamp, tighten the
nuts to the required torque. If leakage persists,
install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or
removed, it must be replaced.
3. If present, check the condition of the insulation
material around the exhaust pipe between the
turbocharger and the ATD.
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. No leaks are allowed
anywhere in the system.
6. Check all sensors attached to the ATD for leaks
or damaged wires. No leaks are allowed.
7. Check the DPF exterior surface for dents or
other damage. See Item A of Fig. 4. A dent over
3 inches (76 mm) in diameter and 1/4-inch (6-
mm) deep could cause internal damage to the
DPF, causing it to malfunction.
8. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
9. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.

Columbia Maintenance Manual, January 2007 49/3

Doors 72
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Door Seal, Door Latch, Door Hinge, and Door Check Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7201

Columbia Maintenance Manual, October 2005

Doors 72

7201 Door Seal, Door Latch, Door Hinges on Vehicles Built on

Door Hinge, and Door or After 8/1/2005
Check Lubrication On vehicles built on or after 8/1/2005, the door
hinge center pin is recessed in the top loop of the
hinge bracket. There is a dimple in the top and bot-
Door Seals tom loop of the hinge bracket. See Ref. A of Fig. 1.
Lightly coat the door seals with a lubricant that is Do not lubricate this type of hinge. Lubrication could
safe for rubber. adversely affect the performance of the bushings. In
addition, some lubricants may not be compatible with
Door Latches the hinge bushings.
Approved NLGI grade 2 greases or products for lu- Door Hinges on Vehicles Built
bricating door latches are:
Before 8/1/2005
Mobilgrease Moly 52
On vehicles built before 8/1/2005, the door hinge
Chemtool Alpha 2000 center pin is flush with the top of the top loop of the
Unirex Moly H hinge bracket. There is no dimple in the top or bot-
tom loop of the hinge bracket. See Ref. B of Fig. 1.
Conoco Moly Poly
Lubricate this type of hinge with approved NLGI
Conoco Tachna 2000 grade 2 greases or products, such as:
Apply liberal amounts of an approved NLGI grade 2 Mobilgrease Moly 52
grease to each moving joint of all door latch assem-
blies. Use an appropriate applicator that will not Chemtool Alpha 2000
leave material behind. Chemtool Alpha 2000 is the Unirex Moly H
preferred product for this application because it has
superior properties and it is white, unlike the moly- Conoco Moly Poly
impregnated greases. Conoco Tachna 2000
In general, light penetrating oils, such as WD40, Lubricate external hinges every six months. Using an
should not be used because they wash out beneficial appropriate applicator, force a moly-impregnated
factory-installed grease, and they evaporate. NLGI grade 2 grease into the hinge components.
Wipe off any excess grease.
Door Hinges In general, light penetrating oils, such as WD40,
The door hinges on vehicles built before and after should not be used because they wash out beneficial
8/1/2005 have different lubrication requirements. The factory-installed grease, and they evaporate.
hinges on vehicles built before 8/1/2005 should be
lubricated, while those on vehicles built on or after Door Checks
8/1/2005 should not be lubricated.
Lubricate door checks at installation and every six
months thereafter, with moly-impregnated NLGI
CAUTION grade 2 grease.
Do not lubricate the door hinges on vehicles built
on or after 8/1/2005. Lubrication of these hinges
could adversely affect the performance of the
bushings.
To determine if the door hinges need to be lubri-
cated, first identify the hinge by checking the top loop
of the hinge bracket. See Fig. 1.

Columbia Maintenance Manual, October 2005 72/1

72 Doors

8/24/2005 f720613

A. Hinge installed on or after 8/1/2005, with dimple in the top loop of the hinge bracket. Do not lubricate.
B. Hinge installed before 8/1/2005. Lubricate according to recommendations.
Fig. 1, Door Hinge Identification

72/2 Columbia Maintenance Manual, October 2005

Heater and Air Conditioner 83
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8301
Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8302

Columbia Maintenance Manual, October 2002

Heater and Air Conditioner 83

8301 Air Conditioner

Inspection
WARNING
Wear eye protection, gloves, and protective cloth-
ing when working on the air conditioning system.
Leaking refrigerant from a damaged hose or line
could cause blindness or serious skin burns.

Preliminary Checks 08/25/94 f830641

1. Park the vehicle on a level surface, apply the
parking brakes, and chock the tires. Fig. 1, Drive Plate Clearance Inspection

2. Check the appearance of the air conditioner the hoses. Replace damaged hoses. For re-
compressor pulley assembly. If the friction sur- placement instructions, see Group 83 of the
face of the pulley shows signs of excessive Columbia Workshop Manual. Also check for
grooving due to belt slippage, replace both the loose fittings on all of the air conditioning compo-
pulley and the drive plate. Inspect the refrigerant nents.
compressor drive belt for damage and check that
7. Check for a buildup of road debris on the con-
the belt is set at the proper tension. Also check
denser fins. For cleaning instructions, see Group
the tightness of the compressor mounting fasten-
83 of the Columbia Workshop Manual.
ers. For instructions and torque values, see
Group 01 of the Columbia Workshop Manual.
Refrigerant Checking
3. Inspect the drive plate. If the friction surface of
the drive plate shows visible signs of damage Check the color of the moisture indicator on the
due to excessive heat, replace the drive plate receiver-drier. See Fig. 2.
and pulley assembly. For removal and installation If the indicator is blue, the refrigerant charge is dry.
procedures, see Group 83 of the Columbia
Workshop Manual. If the indicator is not blue, the system is contami-
nated with water. If the system is contaminated, the
4. On a Sanden A/C compressor, use a feeler refrigerant must be recovered and the receiver-drier
gauge to check that the drive plate clutch clear- must be replaced. For instructions, see Group 83 of
ance is 0.016 to 0.030 inch (0.4 to 0.8 mm). See the Columbia Workshop Manual.
Fig. 1. If the drive plate clutch requires adjust-
ment, see Group 83 of the Columbia Workshop
Manual. 8302 Air Filter Replacement
On a Climate Control A/C compressor, place a
feeler gauge between the air conditioner com- Cab Fresh Air Filter
pressor clutch and the pulley to check the com-
pressor clutch clearance. Drive plate to pulley Replacement, Blend Air
clearance is 0.020 to 0.030 inch (0.6 to 0.8 mm). If the vehicle is equipped with a cab fresh air filter, it
If the clearance is not correct, see Group 83 of must be replaced every six months regardless of
the Columbia Workshop Manual. mileage to permit proper operation of the HVAC
5. Inspect the compressor clutch coil wire. Check system.
that the connector is not damaged or loose. Re-
place the wire if it is damaged. CAUTION
6. Check the overall condition of the air conditioning
If equipped with a fresh air filter, it should be re-
hoses. Look for cracks, cuts, and abrasions on
placed every six months. If the fresh air filter is

Columbia Maintenance Manual, October 2002 83/1

83 Heater and Air Conditioner

02/26/2002 f831493

1. Air Filter Cover 2. Wire Retainer

Fig. 3, HVAC Air Intake Plenum

6. Install the air filter and air filter cover in the

HVAC air intake plenum.
7. Pull the wire retainer up and over the upper edge
of the air filter cover.
11/21/95 f830746
1. Moisture Indicator 8. Remove the chocks from the tires.

Fig. 2, Receiver-Drier Cab Recirculation Air Filter

not replaced every six months, damage to the Replacement, Blend Air
heater and air conditioner components could
occur. The cab recirculation air filter must be replaced every
six months, regardless of mileage, to permit proper
IMPORTANT: When replacing the air filter, use operation of the HVAC system.
only a Freightliner-approved air filter.
1. Park the vehicle on a level surface. Apply the CAUTION
parking brakes and chock the rear tires.
If the recirculation air filter is not replaced every
2. Lift the wire retainer on the air filter cover up and six months, damage to the heater and air condi-
over the upper edge of the cover and pull the tioner components could occur. The HVAC system
wire retainer down. See Fig. 3. should not be operated without the recirculation
3. Note the direction of the arrow on the air filter air filter installed.
cover, then remove the cover and the attached IMPORTANT: When replacing the air filter, use
filter. only a Freightliner-approved air filter.
4. Remove the air filter from the air filter cover. Dis-
1. Park the vehicle on a level surface. Apply the
card the air filter.
parking brakes and chock the rear tires.
5. Attach a new air filter to the air filter cover. Make
2. Remove the heater and air conditioner cover and
sure the arrow on the filter is pointing in the
the upper dash cover. For instructions, see Sec-
same direction as the arrow on the cover.
tion 60.08 of the Columbia Workshop Manual.

83/2 Columbia Maintenance Manual, October 2002

Heater and Air Conditioner 83

3. Remove the retainer that holds the recirculation 1. Turn off the engine, apply the brakes, and chock
air filter in place. See Fig. 4. the tires.
2. Access the sleeper HVAC assembly by raising
1 the mattress and bunk panel to the locked posi-
2 tion. If there is a baggage compartment, the
sleeper HVAC assembly may be accessed
through the baggage door on the right side of the
vehicle.
3. Slide the air filter out of the sleeper HVAC as-
sembly. See Fig. 5.

02/26/2002 f831491
1. Retainer 02/26/2002 f831492
2. Recirculation Air Filter
1. Air Filter
Fig. 4, Cab Recirculation Air Filter
Fig. 5, Sleeper HVAC Assembly
4. Remove and discard the recirculation air filter.
4. Discard the air filter.
5. Install a new recirculation air filter in the HVAC
5. Place a new air filter in the sleeper HVAC as-
assembly.
sembly. The edge of the filter should be flush
6. Install the retainer to hold the recirculation air with the HVAC assembly.
filter in place.
6. Lower the bunk panel and mattress.
7. Install the heater and air conditioner cover and
7. Remove the chocks from the tires.
the upper dash cover. For instructions, see Sec-
tion 60.08 of the Columbia Workshop Manual.

Sleeper Air Filter Replacement,

Blend Air
Replace the air filter in the sleeper HVAC unit every
six months, regardless of mileage. The filter should
not be cleaned.

CAUTION
If the sleeper air filter is not replaced every six
months, damage to the heater and air conditioner
components could occur. The HVAC system
should not be operated without the recirculation
air filter installed.

Columbia Maintenance Manual, October 2002 83/3