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.
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.
Freightliner Workshop/Service Manual
Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, and speciﬁcations.
Freightliner 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 Troubleshooting Manual
Troubleshooting manuals contain diagnostic procedures for determining causes of problems in vehicle components and systems. Information on multiplexing diagnosis is included. These manuals are organized by functional systems, such as cab, chassis, and powertrain. Troubleshooting manuals do not contain repair or service information.
Freightliner 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 pre-trip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’s/ operator’s manuals do not contain detailed repair or service information.
Freightliner Service Bulletins
Service bulletins provide the latest service tips, ﬁeld repairs, product improvements, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid.
Freightliner 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.
Freightliner 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 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 Fastener Replacement
When replacing fasteners, use only identical bolts, washers, and nuts; they must be the same size, strength, and nish as originally specied. See the Freightliner Service Parts Catalog for fastener speci− fications .
When replacing graded (or metric class) bolts and capscrews, use only fasteners that have the manu− facturer’s trademark or identification on the bolt head; do not use substandard bolts. Inferior, counterfeit fas− teners are difficult to identify; buy your fasteners from a reputable supplier.
Freightliner Fastener Selection and Installation
When using nuts with bolts, use a grade (or class) of nut that matches the bolt.
When installing non−anged fasteners, use hardened steel atw ashers under the bolt (capscrew) head, and under the hexnut or locknut. For bolts 4 inches (100 mm) or less in length, make sure that at least 1−1/2threads and no more than 5/8−inch(16−mm)bolt length extends through the nut after it has been tightened. For bolts longer than 4 inches (100 mm), allow a minimum of 1−1/2threads and a maximum of 3/4−inch(19−mm)bolt length.
Never hammer or screw bolts into place. Align the holes of the parts being attached, so that the nut and bolt surfaces are ush against the washers, and the washers are ush against the parts. When installing fasteners in aluminum or plastic parts with threaded holes, start the fasteners by hand, to ensure straight starting and to prevent damaged threads.
Do not use lockwashers (split or toothed) next to alu− minum surfaces. When installing studs that do not have an interfer− ence fit, install them with thread locking compound, as instructed in this subject. When installing parts that are mounted on studs, use free−spinning(non−locking)nuts and helical−spring (split) lockwashers or internal−toothlockwashers. Do not use locknuts, because they tend to loosen the studs during removal. Do not use plain washers (at− washers)
Freightliner Fastener Tightening
Before installing fasteners, clean all fastener (and parts) threads, and all surfaces being clamped. To ensure they are always torqued accurately, Freightliner recommends that all fasteners be lubri− cated with oil (unless specifically instructed to install them dry), then torqued to the values for lubricated− and plated−thread fasteners.When locking compound or antiseize compound is recommended for a fas− tener, the compound acts as a lubricant, and oil is not needed.
Bring parts and fasteners into contact, with no gaps between them, before using a torque wrench to tighten fasteners to their final torque values. Tighten the nut, not the bolt head. This will give a truer torque reading by eliminating bolt body friction.
Always use a torque wrench to tighten fasteners, and use a slow, smooth, even pull on the wrench. Do not overtorque fasteners; overtightening causes perma− nent stretching of the fasteners, which can result in breakage of the parts or fasteners.
If specific torque values are not given for counter− sunk bolts, use the torque value for the correspond− ing size and grade of regular bolt, as given in Speci− fications 400.. Always follow the torque sequence or torque interval when provided, to ensure that clamping forces are even, and parts and fasteners are not distorted.
Freightliner Workshop Manual For Free