Freightliner Business Class M2 Workshop Manual

Freightliner Business Class M2 Workshop Manual
Freightliner Truck Business Class M2 Workshop Manual PDF

The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual.

Freightliner Truck Workshop/Service Manual
Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting.

Freightliner Truck Maintenance Manual
Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.

Freightliner Truck Driver’s/Operator’s Manual
Driver’s/operator’s manuals contain information needed to enhance the driver’s 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. Driver’s/operator’s manuals do not contain detailed repair or service information.

Freightliner Truck Service Bulletins
Service bulletins provide the latest service tips, field repairs, product improvements, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject.

PFreightliner Truck arts Technical Bulletins
Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures.

Freightliner Truck 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.

Freightliner Truck Field Service Campaigns
Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers customers receive notices that apply to their vehicles.

Freightliner Truck Vehicle Receipt
Prior to signing for vehicle delivery from a transporter company, the dealer is responsible for checking for transporter-related shortages or damages, and noting these discrepancies on the transporter’s delivery receipt. The dealer is also responsible for ensuring that the vehicle was built according to the Truck Sales Order/Invoice. Refer to Section 3 of the Freightliner LLC Warranty Manual for details.

Freightliner Truck Vehicle Storage
There may be times when a vehicle is stored for long periods before customer delivery. To protect all vehicles from deterioration and weather, they must be properly maintained. Adequate protection and storage of new vehicles is the responsibility of the dealer.

Freightliner Truck Threaded Fastener Types
The majority of threaded fasteners used throughout the vehicle have U.S. customary threads (diameter and pitch are measured in inches). See Fig. 1. However, the engine and some items attached to the cab use metric fasteners (diameter and pitch are measured in millimeters).

Most threaded fasteners used on the vehicle that are 1/2-inch diameter or larger are plain hex-type fasteners (non-flanged) all metric fasteners are nonflanged. Special hardened flatwashers are used under the bolt head, and between the part being attached and the hexnut, to distribute the load, and to prevent localized overstressing of the parts. The washers are cadmium- or zinc-plated, and have a hardness rating of 38 to 45 HRC. Some fasteners smaller than 1/2-inch diameter are flanged fasteners, which have integral flanges that fit against the parts being fastened. The flanges eliminate the need for washers.

Freightliner Truck Frame Fasteners
The standard fasteners used to assemble the vehicle frame and to attach most components to the vehicle frame are threaded lockbolts (Spin Hucks). These fasteners are covered in Section 31.00.

For some other components attached to the frame, grade 8 and 8.2 phosphate-and oil-coated hexhead bolts and grade C cadmium-plated and wax-coated prevailing torque locknuts are used. The prevailing torque locknuts have distorted sections of threads to provide torque retention. For attachments where clearance is minimal, low-profile hexhead bolts and grade C prevailing torque locknuts are used. See Fig. 6.

Freightliner Truck Tightening Fasteners
When a capscrew is tightened to its torque value in a threaded hole, or a nut is tightened to its torque value on a bolt, the shank of the capscrew or bolt is stretched slightly. This stretching (tensioning) results in a preload that reduces fatigue of the fasteners. The torque values given in the tables in Specifications, 400 have been calculated to provide enough clamping force on the parts being fastened, and the correct tensioning of the bolt to maintain the clamping force.

Use of a torque wrench to tighten fasteners will help prevent overtensioning them. Overtensioning causes permanent stretching of the fasteners, which can result in breakage of the parts or fasteners.

When torquing a fastener, typically 80 to 90 percent of the turning force is used to overcome friction only 10 to 20 percent is used to stretch the capscrew or bolt. About 40 to 50 percent of the turning force is needed to overcome the friction between the underside of the capscrew head or nut and the washer. Another 30 to 40 percent is needed to overcome the friction between the threads of the capscrew and the threaded hole, or the friction between the threads of the nut and bolt.

The amount of torque required to tighten a fastener is reduced when the amount of friction is reduced. If a fastener is dry (unlubricated) and plain (unplated), the amount of friction is high. If a fastener is wax coated or oiled, or has a zinc phosphate coating or cadmium plating, the amount of friction is reduced. Each of these coatings and combinations of coatings has a different effect. Using zinc-plated hardened flatwashers under the bolt (capscrew) head and nut reduces the amount of friction. Dirt or other foreign material on the threads or clamping surfaces of the fastener or clamped part also changes the amount of friction.

Even though each different condition affects the amount of friction, a different torque value cannot be given for each different condition. To ensure they are always torqued accurately, Freightliner recommends that all fasteners be lubricated with oil (unless specifically instructed to install them dry), then torqued to the values for lubricated- and plated-thread fasteners. When locking compound or anti-seize compound is recommended for a fastener, the compound acts as a lubricant, and oil is not needed.

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