S2 CHASSIS

Maintenance Manual
Part Number A24-01453-000
Publication Number STI-479-6
S2 CHASSIS MAINTENANCE MANUAL

Models: S2
S2 C
S2 G
S2 RV

STI-479-6 (2/18)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
 Foreword
Performing scheduled maintenance operations is important in obtaining safe, reliable operation of your
vehicle. A proper maintenance program will also help to minimize downtime and safeguard warranties.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instruc-
tions.
Perform the pretrip inspection and daily/weekly/monthly maintenance as outlined in the S2 Chassis Operator’s
Manual. Perform the maintenance operations in this manual at scheduled intervals based on the distance the
vehicle has traveled or hours of operation. Your Freightliner dealership has qualified technicians and
equipment to perform this maintenance.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.
Freightliner Custom Chassis Corporation (FCCC) 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.FreightlinerChassis.com for more informa-
tion, or contact Daimler Trucks North America LLC at the address below.

Environmental Concerns and Recommendations

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

NOTICE: Parts Replacement Considerations

Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with
used parts. Used parts may have been subjected to collisions or improper use and have undetected structural
damage.

© 2007–2018 Daimler Trucks North America LLC

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

Daimler Trucks North America LLC

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

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

Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides di-
agnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™ makes Freightliner Custom Chassis Corporation, Freightliner, Ster-
ling, Western Star, and Thomas Built Buses products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.

S2 Chassis Maintenance Manual, January 2011 I–1

Introduction
Descriptions of Service Publications

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

I–2 S2 Chassis Maintenance Manual, January 2011

 Introduction
Page Description

For a page example of the printed manual, see Fig. 1.

A B C

D E
02/10/2004 f020152
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, Page Example of the Printed Manual

S2 Chassis Maintenance Manual, January 2011 I–3

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
54 . . . . . . . . . . Electrical, Instruments, and Controls
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders

I–4 S2 Chassis Maintenance Manual, January 2011

General Information 00
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Maintenance Interval Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Noise Emission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
Overview of Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06

S2 Chassis Maintenance Manual, April 2017

General Information 00
Determining Scheduled Maintenance Intervals: 00–01

Determining Scheduled schedule is choosen, continue using it for the life of

the vehicle.
Maintenance Intervals
Performing regular maintenance will help ensure that
Maintenance Operations
your vehicle delivers safe, reliable service, and opti- Groups 01 through 83 in this manual have an index
mum performance. A proper maintenance program at the beginning of each Group. The index lists the
will also help to minimize downtime and safeguard Title of Maintenance Operations and the Mainte-
warranties. nance Operation (MOP) Numbers for that Group.
Follow the instructions under the MOP number to
To determine the correct maintenance intervals for
perform the required maintenance.
your vehicle, you must first determine the type of ser-
vice or conditions the vehicle will be operating in. In addition to the maintenance operations required
Most vehicles operate in conditions that fall within for the maintenance interval, perform all of the pre-
one of two schedules. Before placing your vehicle in and post-trip inspections and maintenance proce-
service, determine whether schedule I or II applies to dures in Chapter 12 and Chapter 13, "Pre- and
your vehicle. Post-Trip Checklists" and "Pre- and Post-Trip Inspec-
tions and Maintenance," in the S2 Chassis Opera-
Schedules I and II tor’s Manual.

Schedule I (urban transport) applies to vehicles that

travel up to 20,000 miles (32 000 kilometers) annu-
ally. Examples of Schedule I usage are:
• frequent short-distance travel
• operation primarily in cities and densely popu-
lated areas
• local transport with infrequent freeway travel
• high percentage of stop-and-go travel
Schedule II (rural transport) applies to vehicles that
travel over 20,000 miles (32 000 kilometers) annu-
ally. An example of Schedule II usage is:
• less frequent stop-and-go travel

Maintenance Schedules
After determining the schedule appropriate to your
vehicle, refer to the Maintenance Schedules to de-
termine when to perform the Initial Maintenance (IM)
and the frequency of performing subsequent mainte-
nance intervals for each schedule.

Maintenance Intervals
Refer to the Maintenance Interval Table to deter-
mine which maintenance interval(s) should be per-
formed when your vehicle reaches the mileage or
months of operation listed in these subjects.
Before placing your new vehicle in service, determine
the maintenance schedule (Schedule I or II) that ap-
plies to your intended use of the vehicle. Once a

S2 Chassis Maintenance Manual, April 2017 00/1

00 General Information
Maintenance Schedules: 00–02

Vehicle Maintenance Schedule Table

Vehicle Maintenance Schedule Table
Maintenance Intervals
Description Maintenance Operation Set
Frequency Miles km Months
Initial Maintenance (IM) first 2500 4000 3
Schedule I
(Urban Transport) Maintenance 1 (M1) every 2500 4000 3
vehicles that annually travel up to Maintenance 2 (M2) every 10,000 16 000 12
20,000 miles (32 000 km)
Maintenance 3 (M3) every 30,000 48 000 36
Initial Maintenance (IM) first 5000 8000 3
Schedule II
(Rural Transport) Maintenance 1 (M1) every 5000 8000 3
vehicles that annually travel over 20,000 Maintenance 2 (M2) every 20,000 32 000 12
miles (32 000 km)
Maintenance 3 (M3) every 60,000 96 500 36

00/2 S2 Chassis Maintenance Manual, April 2017

General Information 00
Maintenance Interval Table: 00–03

Maintenance Interval Table

Maintenance Interval Table
Maint. Oper. Category I Category II
Maint. No.
Set Miles km Months Miles km Months
1st IM + M1 2500 4000 3 5000 8000 3
2nd M1 5000 8000 6 10,000 16 000 6
3rd M1 7500 12 000 9 15,000 24 000 9
4th M2 10,000 16 000 12 20,000 32 000 12
5th M1 12,500 20 000 15 25,000 40 000 15
6th M1 15,000 24 000 18 30,000 48 000 18
7th M1 17,500 28 000 21 35,000 56 000 21
8th M2 20,000 32 000 24 40,000 64 000 24
9th M1 22,500 36 000 27 45,000 72 000 27
10th M1 25,000 40 000 30 50,000 80 000 30
11th M1 27,500 44 000 33 55,000 88 500 33
12th M3 30,000 48 000 36 60,000 96 500 36

S2 Chassis Maintenance Manual, April 2017 00/3

00 General Information
Overview of Maintenance Operations: 00–04

Maintenance Operation Sets

Service Schedule
Maint. No. Operation Description
Initial M1 M2 M3
01–01 Engine Drive Belt Inspecting •
01–02 Engine Support Fastener Checking •
09–01 Air Cleaner Element Inspecting and Replacing* •
13–01 Air Compressor Inspection • •
13–02 Air Compressor Filter Replacement, Propane Engine •
15–01 Alternator, Battery, and Starter Connections Check •
20–01 Radiator Cap Inspection • •
20–02 Radiator Pressure Flush and Coolant Change†
20–03 Fan Drive Inspection (Noise Emission Control) • •
20–04 Coolant Heater Check, Webasto • •
25–01 Eaton Fuller Clutch Release Bearing Lubricating • • • •
25–02 Eaton Fuller Clutch Release Cross-Shaft Lubricating • • • •
25–03 Clutch Hydraulic Fluid Level Checking • • •
25–04 Clutch Hydraulic Fluid Changing •
26–01 Manual Transmission Oil Level Checking • • •
26–02 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning‡
26–03 Allison and Eaton Fuller Transmission Breather Checking • • • •
26–04 Allison Transmission Fluid and Filter Changing§
31–01 Frame Fastener Torque Check • •
32–01 Suspension Inspecting • • • •
32–02 Suspension U-Bolt Torque Checking • •
33–01 Kingpin Lubricating, Detroit™ Axles¶ • • • •
33–02 Draw Key Nut Inspecting • •
33–03 Tie Rod End Inspecting • • • •
33–04 Tie Rod Lubricating¶ • •
35–01 Axle Lubricant Level Checking • • •
35–02 Axle Breather Checking • • • •
35–03 Axle Lubricant Changing and Magnetic Plug Cleaning** •
40–01 Wheel Nut Checking •
41–01 Driveline Inspection • • • •
41–02 Driveline Lubrication • • • •
42–01 Bendix Air Dryer AD-9 or AD-IP Desiccant Replacing†† •
42–02 Governor D-2A Checking •
42–03 Hydraulic Brake Lining Wear Checking • • • •
42–04 Slack Adjuster Lubricating‡‡ • • • •

00/4 S2 Chassis Maintenance Manual, April 2017

General Information 00
Overview of Maintenance Operations: 00–04

Service Schedule
Maint. No. Operation Description
Initial M1 M2 M3
42–05 Meritor Camshaft Bracket Lubricating‡‡ • •
42–06 Air Dryer AD-9, AD-IP Checking • •
42–07 Brake Lines and Fittings Inspecting, Hydraulic Brakes • • • •
42–08 Brake Pedal Linkage and Mounting Plate Inspecting • •
42–09 Air Brake Inspecting and Leakage Testing •
42–10 ABS Tone Rings Cleaning • • • •
42–11 Bendix Hydro-Max® Brake System Inspecting • • • •
42–12 Brake Caliper Slide Pin Lubricating, Hydraulic Brakes§§
42–13 Drum Brake Shoe Roller Lubricating • •
42–14 Foot Brake Valve Actuator Lubricating, Bendix E-6 • • •
42–15 Brake Inspecting •
42–16 WABCO System Saver Air Dryer Desiccant Cartridge Replacing†† •
46–01 Drag Link Inspecting •
46–02 Power Steering Fluid and Filter Changing •
46–03 Power Steering Fluid Level Inspecting • • •
46–04 Power Steering Gear Lubricating • • • •
46–05 Drag Link Lubricating • • • •
47–01 Fuel Tank Band Nut Tightening •
47–02 Fuel/Water Separator Element Replacing •
47–03 Inline Fuel Strainer Replacing, MBE900 Engine • •
47–04 Fuel Sender Checking • •
47–05 Fuel Tank and Line Inspecting, Propane Engine •
47–06 Fuel Rail Fitting and Injector Inspecting, Propane Engine •
47–07 Fuel Filter Replacing, Propane Engine •
49–01 Exhaust System Inspecting (Noise Emission Control) • • • •
54–01 Battery Voltage Checking • • • •
60–01 Mirror Folding Check • •
72–01 Door Seals Lubrication • • • •
83–01 Air Conditioner Inspection • • • •
83–02 HVAC Air Filter Cleaning¶¶ •

S2 Chassis Maintenance Manual, April 2017 00/5

00 General Information
Overview of Maintenance Operations: 00–04

Service Schedule
Maint. No. Operation Description
Initial M1 M2 M3
88–01 Hood Rear Support Lubrication • • •
* Inspect the air filter every 6 months. Replace the air filter every 12 months, or when filter restriction reaches 25 inH20 (if equipped with an air restriction
gauge).
† Replace the organic acid technology (OAT) coolant every 600,000 miles (965 400 km); supplemental coolant additives (SCAs) are not used with OAT coolant.
Replace nitrited organic-acid technology (NOAT) and SCA pre-charge ethylene glycol coolants every 30,000 miles (48 270 km). You must check and, if neces-
sary, recharge the SCA levels and freeze point every 25,000 miles (40 225 km) or 6 months, whichever comes first. See the applicable engine operation and
maintenance manual for further information.
‡ For oil change intervals, see the applicable Eaton Fuller Driver Manual or Service Manual.
§ For oil and filter change intervals, see the applicable Allison Operator’s Manual.
¶ For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule
I vehicles; or every 10,000 miles (16 000 km) for Schedule II vehicles.
** For Detroit rear axles with petroleum-based oil, change the lubricant every 100,000 miles (161 000 km) or every 12 months, whichever comes first; if syn-
thetic oil is used, change the lubricant every 250,000 miles (402 000 km) or every 36 months, whichever comes first. For Meritor rear axles with petroleum-
based oil, change the lubricant at 100,000 miles (161 000 km) or at 12 months of service, whichever comes first, and every 24 months thereafter; if synthetic oil
is used, change the lubricant every 250,000 miles (402 000 km) or every 36 months, whichever comes first.
†† If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage.
‡‡ Meritor Q Plus brake system slack adjusters and camshaft brackets use a special NLGI Grade synthetic polyurea grease and do not require lubrication for 3
years or 500,000 miles (800 000 km), whichever comes first.
§§ For lubricating intervals, see the Bosch Pin Slide Disc Brakes Service Manual.
¶¶ Clean the HVAC air filter every 12 months or 8000 miles (12 875 km), whichever comes first.

00/6 S2 Chassis Maintenance Manual, April 2017

General Information 00
Noise Emission Controls: 00–05

Noise Emission Controls 2. The use of the vehicle after such device or ele-
ment of design has been removed or rendered
inoperative by any person.
Federal Law, Part 205: Among those acts presumed to constitute tampering
Transportation Equipment Noise are the acts listed below:
Emission Controls 1. Removal of engine noise-deadening panels, in-
cluding cab or hood liners.
Part 205, Transportation Equipment Noise Emission
Controls, requires the vehicle manufacturer to furnish 2. Removal of or rendering inoperative the engine
each new vehicle with written instructions for the speed governor so as to allow engine speed to
proper maintenance, use, and repair of the vehicle exceed the manufacturer’s specifications.
by the ultimate purchaser to provide reasonable as- 3. Removal of or rendering inoperative the fan
surance of the elimination or minimization of noise clutch, including bypassing the control on any
emission degradation throughout the life of the ve- thermostatic fan drive to cause it to operate con-
hicle. In compliance with the law, the Noise Emission tinuously.
Control Systems maintenance located in each appli-
cable group within this manual, in conjunction with 4. Removal of the fan shroud.
the vehicle workshop manual, provides these instruc-
tions to owners. 5. Removal of or rendering inoperative exhaust sys-
tem components, including exhaust pipe clamp-
ing.
Recommendations for
6. Removal of air intake system components.
Replacement Parts
Replacement parts used for maintenance or repair of
noise emission control systems should be genuine
Freightliner parts. If other than genuine Freightliner
parts are used for replacement or repair of compo-
nents affecting noise emission control, the owner
should be sure that such parts are warranted by their
manufacturer to be equivalent to genuine Freightliner
parts in performance and durability.

Freightliner Noise Emissions

Warranty
Refer to the vehicle owner’s warranty information
book for warranty information concerning noise emis-
sion control systems.

Tampering With the Noise

Control System 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, re-
pair, or replacement, of any device or element of
design incorporated into any new vehicle for the
purpose of noise control prior to its sale or deliv-
ery to the ultimate purchaser or while it is in use.

S2 Chassis Maintenance Manual, April 2017 00/7

00 General Information
Verification of Inspections Log: 00–06

Verification of Inspections Log

The "Verification of Inspections Log" should be filled
out each time the noise emission controls on the ve-
hicle are maintained or repaired.

Verification of Inspections Log, Group 20

Verification of Inspections Log, Group 20, Engine Cooling/Radiator
Date Mileage Repair Description Cost Repair Facility

Verification of Inspections Log, Group 49

Verification of Inspections Log, Group 49, Exhaust
Date Mileage Repair Description Cost Repair Facility

00/8 S2 Chassis Maintenance Manual, April 2017

Engine 01
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Engine Drive Belt Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01
Engine Support Fastener Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–00

S2 Chassis Maintenance Manual, October 2015

Engine 01

01–00 Safety Precautions affecting the belts before replacing the drive
belts. Do not use belt dressing on any belt.
Safety Precautions in this section apply to all 4. Check for uneven ribs on serpentine (poly-V)
procedures within this group. belts. Foreign material in the pulley will erode the
undercord ribs causing the belt to lose its grip-
ping power.
DANGER
5. Check the belt for a jagged or streaked sidewall.
When working on the vehicle, shut down the en- Jagged or streaked sidewalls are the result of
gine, set the parking brake, and chock the tires. foreign material, such as sand or gravel, in the
Before working under the vehicle, always place pulley, or a rough pulley surface.
jack stands under the frame rails to ensure the
6. Check the drive belts for cracks. Small, irregular
vehicle cannot drop. Failure to follow these steps
cracks are usually an indication of an old belt.
could result in serious personal injury or death.
7. Visually inspect the pulleys for excessive play or
wobble. Excessive play or wobble indicates a
01–01 Engine Drive Belt failure of the pulley bearing. Check for belt
Inspecting squealing or squeaking. Replace the bearings as
necessary.
Worn or loose drive belts may cause premature pul- NOTE: If it is difficult to distinguish the location
ley bearing failure or engine overheating. Too much of a supposed bearing noise, obtain a stetho-
or too little tension on the belt may result in exces- scope and place it on the component being
sive or premature belt wear. Replace the engine
checked, not the pulley, to isolate the area from
drive belt if any conditions described under "Visual
Inspection" are found. outside interference.
Visually inspect all drive belts, then perform the belt 8. Inspect all pulleys for foreign material, oil, or
tension inspection. To inspect a belt, gently twist the grease in the grooves.
belt to view the belt sidewalls and the underside of If the engine drive belt needs to be replaced, see
the belt. When replacing a matched set of belts, al- Group 01 of the S2 Chassis Workshop Manual.
ways replace both belts at the same time. Matched
belts must be from the same manufacturer. Belt Tension Inspection
Visual Inspection Engine drive belts on Mercedes-Benz engines have
belt tensioners that automatically adjust the tension
For examples of drive belt conditions, see Fig. 1. on the belt. These belts do not require adjustment.

01–02 Engine Support Fastener

1. Inspect the belt for glazing. Shiny sidewalls are Checking
evidence of glazing, which is caused by friction
created when a loose belt slips in the pulleys. It NOTE: Front and rear engine supports for ve-
can also be caused by oil or grease contamina- hicles built from January 2007 require the same
tion on the pulleys. maintenance as shown below.
2. Check for tensile breaks or breaks in the cord Mounts should be inspected when the engine is re-
body. Cuts in a belt are usually caused by for- moved for service. Perform the following check.
eign material in the pulley or by prying or forcing
the belt during removal or installation. 1. Check the engine support fasteners at the rear of
the engine for tightness. Tighten the fasteners
3. Check the belt for ply separation. Oil, grease, or 241 lbf·ft (327 N·m).
belt dressing can cause the belt to fall apart in
layers. Repair any oil or coolant leaks that are

S2 Chassis Maintenance Manual, October 2015 01/1

01 Engine

1 2

3 4

5 6
07/12/2001 f150010b

1. Glazing 3. Separating Layers 5. Streaked Sidewalls

2. Tensile Break 4. Uneven Ribs 6. Cracks
Fig. 1, Drive Belt Replacement Conditions

2. Check the engine support fasteners at the front

of the engine for tightness. Tighten the fasteners
136 lbf·ft (184 N·m).
NOTE: Whenever the engine is removed, in-
spect the lower and upper isolators for wear.
Replace the isolators if necessary.

01/2 S2 Chassis Maintenance Manual, October 2015

Air Intake 09
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Cleaner Element Inspecting and Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01

S2 Chassis Maintenance Manual, October 2015

Air Intake 09

09–01 Air Cleaner Element Replacing

Inspecting and
Replacing NOTICE
Do not use aftermarket air-cleaner elements. After-
IMPORTANT: Due to the variety of possible driv- market air-cleaner elements may not seal the
ing conditions (dirt roads, paved roads, etc.), it housing correctly, which can lead to engine dam-
is critical to check the air restriction indicator, if age and potentially the loss of warranty. When re-
so equipped. If the vehicle is not equipped with placing an air-cleaner element, use only the part
an air restriction indicator, inspect all compo- listed in PartsPro for the serial number of the
nents of the air intake system and air filter every vehicle.
six months. Replace the air filter every 12 Replace the air filter every 12 months, or when filter
months, or when filter restriction reaches 25 restriction reaches 25 inH2O for diesel engines, or
inH2O for diesel engines, or when the air restric- when the air restriction indicator is completely
tion indicator is completely red for propane en- red for propane engines (if equipped with an air
gines (if equipped with an air restriction indica- restriction indicator). See Group 09 of the S2
tor). More frequent inspections and/or filter Chassis Workshop Manual for removal and in-
replacement may be needed if the vehicle is stallation instructions, or take the vehicle to an
authorized Freightliner dealer.
being operated in a dusty environment, to
avoid damaging the vehicle.

Inspecting
Remove and visually inspect the air filter for holes,
tears, cracks, or other damage at the recommended
interval. Remove loose debris, such as leaves or
pine needles, from the filter housing. If the air filter is
damaged, replace it. See Group 09 of the S2 Chas-
sis Workshop Manual for removal and installation
instructions, or take the vehicle to an authorized
Freightliner dealer.
Engine damage can occur if the air intake system is
not properly maintained. Use the air intake restriction
indicator to check for air intake system damage or
leaks. See Fig. 1 and Fig. 2. Make sure the engine
is off and note the existing reading on the indicator.
Reset the indicator by pushing it down. See Fig. 1
and Fig. 2. Start the engine and take a short test
drive. Check the indicator again and note the level of
restriction on the indicator. A decrease from the pre-
vious level of restriction or a very low air restriction
indicator reading (0 to 4 inH2O) could indicate an
air intake system problem such as a damaged
air filter, loose or disconnected air intake piping,
or a disconnected or damaged air restriction
indicator.

S2 Chassis Maintenance Manual, October 2015 09/1

09 Air Intake

H O VACUUM IN H O VACUUM H O VACUUM IN H O VACUUM

2 2 2 2
25 25
20 20
15 15
10 10
7 7

PUSH TO RESET PUSH TO RESET

A B
08/21/96 f090165
A. Partial Restriction B. Full Restriction
Fig. 1, Air Restriction Indicator, Diesel Engines

A B
12/02/2011 f090495
A. Partial Restriction B. Full Restriction
Fig. 2, Air Restriction Indicator, Propane Engines

09/2 S2 Chassis Maintenance Manual, October 2015

Air Compressor 13
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Compressor Filter Replacement, Propane Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–02
Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–00

S2 Chassis Maintenance Manual, October 2015

Air Compressor 13

13–00 Safety Precautions

Safety Precautions in this section apply to all
procedures within this group.

DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

13–01 Air Compressor

Inspection
1. Inspect the air compressor intake hoses and
connections at the air intake and air compressor
for physical damage. If needed, change the
hoses, and/or tighten or replace the connections.
2. Inspect the coolant supply and return lines for
tight connections. Tighten the connections and
replace the lines and fasteners if needed.
3. For the air governor, inspect the piping and con-
nections for leaks. Replace gaskets and faulty
components as needed.

13–02 Air Compressor Filter

Replacement, Propane
Engine
1. Loosen the spring clip from the unhinged side of
the mounting baffle and open the cover. See
Fig. 1.
2. Remove the pleated paper filter.
3. Install the new pleated paper filter and make cer-
tain it is correctly positioned.
IMPORTANT: If the entire air strainer is removed
from the compressor intake, replace the air
strainer gasket.
4. Install the cover, then tighten the spring clip.

S2 Chassis Maintenance Manual, October 2015 13/1

13 Air Compressor

6 4
5
09/20/2013 f130145

1. Air Strainer Gasket 3. Lockwashers 5. Cover

2. Spring Clip 4. Mounting Bolts 6. Filter Cannister
Fig. 1, Pleated Paper Filter Assembly

13/2 S2 Chassis Maintenance Manual, October 2015

Alternators and Starters 15
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–00

S2 Chassis Maintenance Manual, October 2015

Alternators and Starters 15

15–00 Safety Precautions Trace and inspect all wiring and cables con-
nected to:
Safety Precautions in this section apply to all • alternator
procedures within this group. • starter and depopulation studs
• batteries
DANGER
• magnetic switch
When working on the vehicle, shut down the en- • cab
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place • jump-start studs
jack stands under the frame rails to ensure the • battery isolation relays
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. • battery shutoff switches
4. Check wires and cables for wear, chafing, kinks,
discolored insulation, or loose clamps or ties.
15–01 Alternator, Battery, and Find the cause of any problems and repair, re-
Starter Connections place, and reroute wires and clamps as neces-
sary.
Check
IMPORTANT: Ensure that wires and cables are
not near any heat sources; if they are, reroute
WARNING them.
Batteries release explosive gas as a by-product of 5. Clean all circuit breakers and relays.
their chemical activity. Do not smoke when work- 6. Check the alternator wiring for missing insulation,
ing around batteries. Put out all flames and re- kinks, and heat damage. Replace or repair as
move any source of sparks or intense heat. Make needed.
sure the battery compartment is completely
vented before disconnecting or connecting the 7. On the bundled cable that runs from the batteries
battery cables. to the starter, ensure that tie straps are installed
at least every 12 inches (30 cm). Replace any
Battery acid is extremely harmful if splashed in missing tie straps, and add tie straps where
the eyes or on the skin. Always wear a face shield spacing between them exceeds 12 inches (30
and protective clothing when working around bat- cm).
teries.
8. Ensure that all cables have sufficient slack to
Damaged, chafed, or kinked wiring can cause allow for engine movement, and that there is no
electrical short-circuits and lead to fires, causing force on any wiring connectors.
property damage, injury, or death. Clean, inspect,
and maintain wiring and connections carefully. 9. If any convoluted tubing is damaged, check the
wiring inside it. Replace any damaged or missing
1. Disconnect the batteries. convoluted tubing.
2. Check the tightness of the alternator bracket fas- 10. Inspect the battery cables for wear, and replace
teners and alternator mounting fasteners; tighten as needed. Clean the cable connector terminals
the fasteners as needed. For torque values, see with a wire brush. See Group 54 of the vehicle
Group 15 of the vehicle Workshop Manual, or Workshop Manual for troubleshooting instruc-
take the vehicle to an authorized Freightliner tions, and for adjustment, repair, or replacement
dealer. instructions, or take the vehicle to an authorized
3. Check that all electrical connections at the alter- Freightliner dealer.
nator and starter are clean. Clean and tighten all 10.1 Clean and tighten the battery ground
charging system electrical connections as cable, terminal, and clamps.
needed. Spray each electrical connection at the
alternator and starter with dielectric red enamel.

S2 Chassis Maintenance Manual, October 2015 15/1

15 Alternators and Starters

10.2 Inspect the retainer assembly (or battery

hold-downs) and the battery box. Replace
worn or damaged parts. Remove any cor-
rosion with a wire brush, and wash with a
weak solution of baking soda and water.
Rinse with clean water, then dry. Paint
the retainer assembly, if needed, to pre-
vent rusting.
10.3 Check that foreign objects, such as
stones, bolts, and nuts, are removed from
the battery box.
10.4 After cleaning, connect the cables to the
batteries, and tighten them to the torque
specifications listed on the battery, gener-
ally 10 to 15 lbf·ft (14 to 20 N·m).
10.5 Coat the battery terminals with dielectric
grease.
11. Check the terminals on the battery shut-off
switch and the starter relay. Make sure that the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.

15/2 S2 Chassis Maintenance Manual, October 2015

Engine Cooling/Radiator 20
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Coolant Heater Check, Webasto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–04
Fan Drive Inspection (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03
Radiator Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01
Radiator Pressure Flush and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–00

S2 Chassis Maintenance Manual, October 2016

Engine Cooling/Radiator 20

20–00 Safety Precautions 3. Make sure that the cap seals properly on the
coolant filler neck seat, and that the radiator cap
gasket is not damaged. On vehicles with
Safety Precautions in this section apply to all screw-on caps with O-rings, make sure that the
procedures within this group. O-ring is not cracked or deteriorated. Replace
the cap if the gasket shows deterioration or dam-
DANGER age.

When working on the vehicle, shut down the en-

gine, set the parking brake, and chock the tires. 20–02 Radiator Pressure Flush
Before working under the vehicle, always place and Coolant Change
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. NOTE: For additional instructions on cleaning
and flushing the cooling system, see the engine
manufacturer’s maintenance and operation
20–01 Radiator Cap Inspection manual.
1. Place a large container under the radiator.
WARNING 2. Remove the surge tank cap.
Do not remove or loosen the radiator cap until the IMPORTANT: If the vehicle is equipped with
engine and cooling system have completely heater circuit valves, the valves should be
cooled. Use extreme care when removing the cap. closed to prevent the loss of coolant.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a 3. Open the petcock at the bottom of the radiator to
surge of scalding coolant that could cause seri- drain the engine coolant.
ous personal injury. 4. Disconnect the radiator inlet and outlet hose con-
nections.
NOTICE 5. Attach a flushing gun nozzle to the radiator out-
let.
The radiator cap currently installed may not be the
same one installed when the vehicle was built. If 6. Add water to the radiator until it is full.
the radiator cap must be replaced, make sure that
it is the correct cap for the cooling system of the NOTICE
vehicle. Because the radiator cap pressure rating
affects the operating temperature of the engine, When flushing the radiator, do not apply more
installing an improperly rated radiator cap may than 20 psi (138 kPa) air pressure. Excessive pres-
have adverse effects on the cooling system, and sure can damage the radiator or heater core.
engine operating temperatures. This could cause 7. Apply no more than 20 psi (138 kPa) air pres-
premature engine wear or damage. sure intermittently to help dislodge sediment
1. Using a radiator-cap tester, check the pressure buildup in the core.
cap to see if it maintains pressure to within 10 8. Drain the radiator, then flush the radiator until
percent of the pressure rating marked on the clean water flows from the radiator. Remove the
cap. If it doesn’t, replace the cap. Make sure that flushing gun.
the replacement radiator cap is correctly rated for
the cooling system of the vehicle. 9. Close the petcock.
2. There is a second valve in the radiator cap that 10. Using clamps, connect the hoses to the radiator.
opens under vacuum. This prevents the collapse Torque the clamps 33 to 38 lbf·in (370 to 430
of hoses and other parts that are not internally N·cm).
supported when the system cools. Inspect the
vacuum-relief valve to be sure it is not stuck.

S2 Chassis Maintenance Manual, October 2016 20/1

20 Engine Cooling/Radiator

IMPORTANT: On vehicles with EPA07 compliant 3. Check for adequate clearance between the fan
engines, the coolant capacity varies depending and the fan shroud or other engine compartment
on the engine and accessory installation. After components in both the engaged mode and the
servicing the cooling system, always verify that disengaged mode. If the clearance is not ad-
the coolant level is between the MIN and MAX equate, make the necessary adjustments.
lines on the surge tank. 4. Check the fan belt condition and the belt align-
ment. Replace or correct as necessary.
11. Fill the radiator with coolant. Use a 50/50 mixture
of antifreeze and water. Refer to the engine 5. Connect the battery cables. Start the engine, and
manufacturer’s service literature for approved charge the air system to 120 psi (827 kPa).
coolants. Manually engage and disengage the fan clutch.
See Table 1 for engine cooling system capaci- Check the fan and the fan clutch from a dis-
ties. tance. Look for vibration, fan blade contact, fan
clutch slippage, and overall fan clutch operation.
Coolant Capacities* If the fan clutch does not operate correctly, see
Coolant Volume: Group 20 of the S2 Chassis Workshop Manual
Engine Make and Model
quarts (liters) for troubleshooting and repair procedures.
Cummins ISB 30.5 (28.9)
MBE900 (6.4L) 37 (35)
Horton HT650™ Fan Drive
* The total coolant volume is dependent on the number and location of op- Check for friction facing wear condition. Replace
tional passenger heaters. when worn to 1/16-inch (1.5-mm) thick, when oil-
Table 1, Coolant Capacities spotted, or when burn marks are visible.
IMPORTANT: If the heater circuit valves were
closed earlier, open the valves now. Horton DriveMaster® Fan Clutch
NOTE: If any part of the fan clutch needs to be
repaired or replaced after performing the checks
20–03 Fan Drive Inspection below, see Group 20 of the S2 Chassis Work-
(Noise Emission shop Manual.
Control) 1. Disconnect the batteries at the negative termi-
nals. Drain all air from the air system. If
Horton Advantage® Fan Clutch equipped with an air starter, drain the air starter
reservoir.
1. Disconnect the batteries at the negative termi-
nals. Drain all air from the air system. If WARNING
equipped with an air starter, drain the air starter
reservoir. Make sure the batteries are disconnected before
checking the fan clutch. If the engine starts during
WARNING this procedure, the fan could engage, which could
result in serious personal injury.
Make sure the batteries are disconnected before 2. Inspect the electrical connections and wires to
checking the fan clutch. If the engine starts during the fan clutch solenoid. Secure the connection if
this procedure, the fan could engage, which could loose; replace wires and connectors if damaged.
result in serious personal injury.
3. If so equipped, clean the fan clutch air solenoid
2. Check the fan for loose rivets and missing valve filter as follows.
weights. Check for bent, cracked, or missing
blades. Tighten loose components. Replace the 3.1 Unscrew the fan clutch solenoid valve air
fan drive if necessary. filter assembly and remove the filter ele-
ment.

20/2 S2 Chassis Maintenance Manual, October 2016

Engine Cooling/Radiator 20

3.2 Clean the filter element with cleaning sol-

vent.
3.3 Using a clean, lint-free cloth, wipe off any
excess solvent.
3.4 Reassemble the clutch valve solenoid air
filter assembly and install it on the ve-
hicle.
4. Check the fan for bent, cracked, or damaged
blades, and replace the fan if it’s damaged.
Check for adequate clearance between the fan
and other components.
5. Check the fan belt for wear, tension, and align-
ment. Correct as necessary.
6. Check for wear on the friction facing. Replace
10/05/2016 f200581
the friction facing if it is worn to a 3/16-inch (4.8-
mm) thickness or less. Also check the facing for Fig. 1, Checking for Air Leaks (Horton DriveMaster)
signs of oil contamination or burn marks. If evi-
dence of oil or burn marks are found, replace the 11.1 Turn the fan in both directions and feel
friction facing. for worn hub bearings.
7. Connect the battery cables. Start the engine, and 11.2 If possible, remove the drive belt and
charge the air system to 120 psi (827 kPa). check for worn sheave bearings by turn-
Manually engage and disengage the fan clutch. ing the sheave in both directions.
Check the fan and the fan clutch from a dis- 11.3 If either the hub or sheave bearings are
tance. Look for vibration, fan blade contact, fan worn, replace them, using a Horton Drive-
clutch slippage, and overall fan clutch operation. Master Super Kit.
If the fan clutch does not operate correctly, see For instructions and kit part number, see
Group 20 of the S2 Chassis Workshop Manual Group 20 of the S2 Chassis Workshop
for troubleshooting and repair procedures. Manual.
8. With the air system charged to 120 psi (827
kPa), check the fan clutch for audible air leaks, Borg Warner Viscous Fan Drive
using a suitable listening device. NOTE: The Borg Warner viscous fan drive does
Check at the solenoid valve, the air filter assem- not require any maintenance. If the fan drive is
bly, and the air hoses and fittings. See Fig. 1. damaged, replace the unit. Do not attempt to
Using a wet finger or a soapy water solution, repair it.
check for a leak in the same areas.
9. If a leak is detected, remove the fan blade. In- NOTICE
stall a new seal kit. See Group 20 of the S2
Chassis Workshop Manual for repair procedures. If the fan drive assembly is damaged, replace the
10. Check the fan drive for discoloration or any other unit as soon as possible. Operating a seized or
signs of slipping or overheating. otherwise damaged clutch reduces fuel economy,
and could cause serious engine damage.
NOTE: The fan clutch may slip if the air supply
See Section 20.03 of the S2 Chassis Workshop
pressure is below 70 psi (483 kPa) or if there is Manual for replacement instructions.
a leak inside the fan clutch. Any leak must be
remedied. 1. With the engine shut down, rotate the fan at
least one full turn by hand. It should have a
11. Check the fan clutch bearings as follows.

S2 Chassis Maintenance Manual, October 2016 20/3

20 Engine Cooling/Radiator

smooth, steady drag. If it does not, replace the

fan clutch.
2. Check for physical damage to the fan or fan
shroud.
3. Check for correct drive belt alignment and ten-
sion. For specifications, see Group 01 of the S2
Chassis Workshop Manual.
4. Check for wear of the fan clutch bearings. There
should be no side-to-side or in-and-out move-
ment of the fan clutch.
5. Do all of the checks in Section 20.00 of the S2
Chassis Workshop Manual.

20–04 Coolant Heater Check,

Webasto
1. Using compressed air, clean any accumulated
debris or dust from the heater and enclosure
box. Inspect all components for wear or damage.
2. Check that the batteries are in good condition. If
the voltage is too low or too high, the heater will
automatically shut down. Check the wiring har-
nesses for damage. Replace the harnesses if
necessary.
3. Check the air intake port for obstructions. Care-
fully check the air intake tube for any restrictions
or damage, and repair or replace the tube if nec-
essary.
4. Check the exhaust system for restrictions or cor-
rosion. Replace any damaged parts.
5. Change the fuel filter, if so equipped. Inspect the
fuel line for damage, restrictions, or loose con-
nections. Repair or replace the line if it is dam-
aged.
6. Inspect all coolant lines and clamps for leakage,
restrictions, or damage. Replace the lines as
needed. Inspect the coolant circulation pump for
leakage. Repair or replace the pump if it is dam-
aged.
7. Run the heater at least once a month for 10 min-
utes.
8. Check the water and fuel connections for leak-
age. Tighten the hose clamps if needed.

20/4 S2 Chassis Maintenance Manual, October 2016

Clutch 25
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Clutch Hydraulic Fluid Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–04
Clutch Hydraulic Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03
Eaton Fuller Clutch Release Bearing Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01
Eaton Fuller Clutch Release Cross-Shaft Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–00

S2 Chassis Maintenance Manual, October 2015

Clutch 25

25–00 Safety Precautions

Safety Precautions in this section apply to all
procedures within this group.

DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

25–01 Eaton Fuller Clutch

Release Bearing
Lubricating
The standard clutch release bearing is sealed, and 05/27/93 f250081a
does not require lubrication. If the vehicle is not
equipped with a maintenance-free sealed clutch re- Fig. 1, Release Bearing Grease Fitting
lease bearing, lubricate the bearing as follows:
failure. Do not use chassis grease or multipurpose
1. Park the vehicle on a level surface. Apply the lubricants.
parking brake, and chock the rear tires.
4. Wipe off excess grease and apply to both the
2. Remove the clutch inspection plate. yoke finger and sleeve bushing contact points.
NOTE: Some clutch release bearings are See Fig. 2.
equipped with a lubrication extension that ex-
tends outside of the clutch housing. It is not 1
necessary to remove the clutch inspection plate
when the lubrication extension is used.
NOTE: For lubricating the release bearing,
Eaton Fuller recommends a lithium-base high-
temperature grease that meets the NLGI Grade
1 or 2 specification.
3. Wipe the dirt away from the grease fitting. See 2
Fig. 1. Use a low-pressure-type grease gun 08/10/2009 f250444
equipped with the recommended grease, and 1. Sleeve Bushing Contact Point
lubricate the bearing until excess grease purges 2. Yoke Finger Contact Points
from the rear of the release bearing (toward the
transmission). Fig. 2, Contact Points Requiring Grease

5. Install the clutch inspection plate.

CAUTION 6. Remove the chocks.
Do not over-lubricate the clutch release bearing.
Over-lubrication could contaminate the clutch in-
ternally, causing clutch slippage and premature

S2 Chassis Maintenance Manual, October 2015 25/1

25 Clutch

25–02 Eaton Fuller Clutch 25–03 Clutch Hydraulic Fluid

Release Cross-Shaft Level Checking
Lubricating
WARNING
IMPORTANT: This maintenance operation per-
tains only to vehicles equipped with mechanical Use only approved clutch hydraulic fluid (DOT 4
(not hydraulic) linkages. brake fluid) in the clutch hydraulic system. Do not
mix different types of brake fluid. The wrong fluid
The clutch release cross-shaft is equipped with two will damage the rubber parts of the system, caus-
grease fittings in the transmission clutch housing. ing loss of clutch function and the risk of serious
See Fig. 3 and Fig. 4. Wipe the dirt from the grease personal injury.
fittings and lubricate with multipurpose chassis
grease.
CAUTION
Do not allow the fluid level in the reservoir to go
below the MIN line. If too much air enters, the hy-
draulic system will not operate correctly, and the
clutch could be damaged.
If the fluid level is below the MIN line, fill the reser-
1 voir with DOT 4 brake fluid until the level reaches the
MAX line. See Fig. 5.

2 1 3
2

10/19/93 f250048a
1. Clutch Release Cross-Shaft 4
2. Grease Fitting
Fig. 3, Cross-Shaft Grease Fitting, Left Side

02/20/2017 f250580
1. Reservoir Cap 4. Master Cylinder
2. Reservoir 5. Hydraulic Hose
3. Pedal Unit 6. Slave Cylinder
Fig. 5, Clutch Components

05/27/93 f260146a

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

25/2 S2 Chassis Maintenance Manual, October 2015

Clutch 25

25–04 Clutch Hydraulic Fluid 6.1 Open the bleed screw on the slave cylin-
der.
Changing 6.2 Using a drain pan or other suitable con-
tainer, collect the fluid that drains from the
Replace the clutch hydraulic fluid every two years to
slave cylinder bleed valve, at least 0.5
ensure clutch function is reliable and correct. Use the
quarts (0.5 liters).
procedures below. Fluid replacement must be done
at an authorized Freightliner service facility. 6.3 When all the old fluid has passed through
the system and only new, clean fluid is
Flushing coming out, close the bleed screw.

1. Shut down the engine. 7. Check the fluid level in the reservoir and bleed
the system according to the steps under the
2. Apply the parking brakes, chock the front and heading "Bleeding the Clutch." See Fig. 7.
rear tires, and raise the hood.
Bleeding the Clutch
WARNING 1. Remove the cap from the bleed valve. Install a
Clutch hydraulic fluid (DOT 4 brake fluid) is haz- transparent drain hose on the bleed valve of the
ardous. It may be a skin irritant and can cause slave cylinder.
blindness if it gets in your eyes. Always wear 2. Open the slave cylinder bleed screw. Observe
safety glasses when handling clutch hydraulic the flow of clutch hydraulic fluid through the drain
fluid or bleeding hydraulic lines. If you get clutch hose. When no bubbles appear in the fluid, close
hydraulic fluid on your skin, wash it off as soon the slave cylinder bleed screw.
as possible.
3. Disconnect the transparent hose. Tighten the
3. Prepare the pressure bleeding equipment ac- bleed screw 88 lbf·in (1000 N·cm) and install the
cording to the manufacturer’s instructions. Use cap on the slave cylinder bleed valve.
DOT 4 brake fluid. Pressurize the bleed adaptor
to 15 psi (103 kPa). 4. Close the valve on the bleed tank of the pres-
sure bleed adaptor. Remove the pressure bleed
adaptor.
CAUTION
5. Check the fluid level in the reservoir. If neces-
Do not spill clutch hydraulic fluid (DOT 4 brake sary, add or remove clutch hydraulic fluid to bring
fluid) on the body paint. Clean it off immediately if the fluid level to the MAX line. Install the reser-
any is spilled. DOT 4 brake fluid can damage voir lid.
paint.
4. Remove the reservoir lid and install the pressure CAUTION
bleed adaptor on the reservoir.
When removing fluid from the reservoir, use a
5. Pressurize the reservoir, filling the system. Open clean tool that is used only for brake fluid. Using
the bleed valve on the bleed tank of the adaptor. a tool contaminated with oil or chemical residue
NOTE: A pressure bleeder hose (J-29532) and will destroy hydraulic system parts and cause the
a bleed adaptor (J-35798) for the fluid reservoir system to malfunction.
are available through SPX Kent-Moore Tools 6. Depress the clutch pedal a few times. There
and may be used to complete the following pro- should be resistance over the full pedal stroke.
cedure. To order these parts, call Kent-Moore at 7. Check the entire system for leaks. Tighten the
1-800-328-6657. connections between the components if neces-
6. Flush the hydraulic system, as follows. See sary. Check the fluid level in the reservoir again.
Fig. 6. 8. Make sure the reservoir lid is tight.

S2 Chassis Maintenance Manual, October 2015 25/3

25 Clutch

1
2
3

1
2
3

6
10
8

12/11/2001 f250582
1. Clamp Mounting Bolt, 1/4–20 5. Slave Cylinder Standoff 8. Bleed Valve
2. Plated Steel Washer Bracket 9. Bell Housing
3. Locknut, 1/4–20 6. Hydraulic Hose 10. Slave Cylinder Mounting
4. Bell Housing Standoff Bracket 7. Slave Cylinder Capscrew, M8

Fig. 6, Clutch Slave Cylinder

9. Lower the hood and remove the chocks from the

front and rear tires.

25/4 S2 Chassis Maintenance Manual, October 2015

Clutch 25

1
2
3

6
8
7

12/11/2001 f250581
1. M8 Capscrew and Washer 4. Pedal Unit 7. Cup Bracket
2. Pedal Unit Mounting Plate 5. Master Cylinder 8. Standoff Bracket
3. Reservoir 6. Hydraulic Hose 9. Mounting Bolt, M10
Fig. 7, Clutch Master Cylinder

S2 Chassis Maintenance Manual, October 2015 25/5

Transmission 26
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Allison Transmission Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04
Allison and Eaton Fuller Transmission Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03
Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02
Manual Transmission Oil Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–00

S2 Chassis Maintenance Manual, October 2016

Transmission 26

26–00 Safety Precautions Eaton Approved Manual and Automated

Transmission Lubricants
Safety Precautions in this section apply to all Lubricant Type* Temperature
SAE
procedures within this group. Viscosity
Synthetic transmission
DANGER lubricant meeting Eaton PS-
386 lubricant specification
All —

When working on the vehicle, shut down the en- * Do not mix types or brands of lubricant.
gine, set the parking brake, and chock the tires. Table 1, Eaton Approved Manual and Automated
Before working under the vehicle, always place Transmission Lubricants
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps CAUTION
could result in serious personal injury or death.
Operating a manual transmission with the fluid
level higher or lower than recommended can re-
26–01 Manual Transmission Oil sult in transmission damage. Do not overfill the
Level Checking transmission; overfilling will force fluid out of the
case through the main shaft openings. Fluid over-
1. Park the vehicle on a level surface. Apply the flow may also drain onto the clutch or clutch
parking brake and chock the rear tires. brake, causing additional problems.
2. Clean the area around the fill plug, then remove IMPORTANT: Do not mix types of oil, because
the plug from the side of the case. of possible incompatibility. Do not use oil addi-
3. Check that the oil is level with the lower edge of tives or friction modifiers. Do not use multivis-
the transmission fill opening. See Fig. 1. cosity oils or EP (Extreme Pressure) gear oils. If
switching from a petroleum-based lubricant to a
synthetic, all areas of each affected component
must be thoroughly drained. Switching to a syn-
thetic lubricant, when a petroleum-based lubri-
cant has been used for 50,000 miles (80 000
km) or longer may affect transmission perfor-
mance. Monitor all seal areas for the first
10/05/94 A B f260006b 10,000 miles (16 000 km) after changing to a
synthetic from a petroleum-based lubricant.
A. Full B. Low
5. Clean the fill plug, then install it in the transmis-
Fig. 1, Transmission Oil Level Checking sion. Tighten the plug as follows:
IMPORTANT: A lubricant level close enough to • 25 to 35 lbf·ft (34 to 48 N·m) for transmis-
be seen or touched is not sufficient. It must be sions with 3/4-inch pipe threads.
level with the lower edge of the fill opening. • 60 to 75 lbf·ft (81 to 102 N·m) for transmis-
4. If needed, fill the transmission with oil until level sions with 1-1/4-inch pipe threads.
with the lower edge of the fill opening. See
Table 1 for approved lubricants.
For more information and a complete listing of
approved lubricants, refer to the Eaton website,
www.roadranger.com.

S2 Chassis Maintenance Manual, October 2016 26/1

26 Transmission

26–02 Eaton Fuller Filling

Transmission Fluid
Changing and Magnetic CAUTION
Plug Cleaning Operating a manual transmission with the fluid
level higher or lower than recommended can re-
sult in transmission damage. Do not overfill the
IMPORTANT: For oil change intervals, see the
transmission; overfilling will force fluid out of the
applicable Eaton Fuller Driver Manual or Service case through the main shaft openings. Fluid over-
Manual. flow may also drain onto the clutch or clutch
Eaton Fuller has a complete listing of approved lubri- brake, causing additional problems.
cants for its transmissions on its internet website. IMPORTANT: Do not mix types of fluid, because
Refer to the Eaton website for additional information,
www.roadranger.com.
of possible incompatibility. Do not use multi-
viscosity fluids or EP (Extreme Pressure) gear
Draining fluids. Do not use fluid additives or friction modi-
fiers. If switching from a petroleum-based lubri-
IMPORTANT: Manual transmissions filled with cant to a synthetic, all areas of each affected
approved synthetic lubricants require a lubricant component must be thoroughly drained. Switch-
drain and fill, and a magnetic plug cleaning ing to a synthetic lubricant, when a petroleum-
every 500,000 miles (800 000 km), regardless based lubricant has been used for 50,000 miles
of the service or vocation of the vehicle. Manual (80 000 km) or longer may affect transmission
transmissions with petroleum-based lubricants performance. Monitor all seal areas for the first
require a lubricant drain and fill, and a magnetic 10,000 miles (16 000 km) after changing to a
plug cleaning at each Maintenance 2 (M2) inter- synthetic from a petroleum-based lubricant.
val. All transmissions, regardless of lubrication NOTE: The correct fluid level is established by
used, also require a check of the transmission checking at the fill plug opening.
breather at each Maintenance 1 (M1) interval.
1. Add fluid until it is level with the lower edge of
1. Park the vehicle on a level surface. Apply the the fill opening. See Fig. 1. If the transmission
parking brake and chock the rear tires. has two fill openings, add fluid to the level of
2. Drain the fluid while the transmission is warm. both fill openings. See Table 1 for approved
transmission lubricants, and Table 2 for lubricant
2.1 Clean the area around the drain plug(s).
capacities.
Remove the drain plug(s) from the gear
case.
Eaton Fuller Transmission Lubricant Capacities*
2.2 Clean the area around the fill plug. Re- Transmission Model Capacity: qt (L)
move the fill plug from the gear case.
5-Speed
3. Clean the magnetic plug(s) before installing it.
Use a piece of key stock, or any other conve- FS–4205A/B, FS–5205A/B 6.25 (5.9)
nient steel slug, to short the two magnetic poles FS–6305A/B 9.75 (9.2)
and divert the magnetic field.
6-Speed
4. Install and tighten the drain plug(s) 50 lbf·ft (68 FS–5406A 9.75 (9.2)
N·m).
FS–6406A, FSO–6406A 9.75 (9.2)
FO–6406A, FO-8406 10.5 (10.0)

26/2 S2 Chassis Maintenance Manual, October 2016

Transmission 26

Eaton Fuller Transmission Lubricant Capacities* 26–04 Allison Transmission

Transmission Model Capacity: qt (L) Fluid and Filter
FSO–8406A 9.75 (9.2)
Changing
* Quantities listed are approximate. Fill the transmission until the lubricant
is level with the bottom of the fill hole, with the vehicle in normal operating
position.
IMPORTANT: For oil and filter change intervals,
Table 2, Eaton Fuller Transmission Lubricant see the applicable Allison Operator’s Manual.
Capacities When draining transmission fluid, check for evidence
2. Clean the fill plug, then install it in the transmis- of dirt or water contamination. A small amount of
sion. Tighten the plug as follows: condensation will appear in the fluid during operation.
• 25 to 35 lbf·ft (34 to 48 N·m) for transmis- Water contamination is normally characterized as a
sions with 3/4-inch pipe threads. milky discoloration of the transmission fluid. Obvious
contamination of the transmission fluid indicates a
• 60 to 75 lbf·ft (81 to 102 N·m) for transmis- leak between the water and fluid areas of the trans-
sions with 1-1/4 inch pipe threads. mission cooler. Inspect and pressure-test the cooler
to confirm the leak; replace leaking transmission
26–03 Allison and Eaton Fuller coolers.

Transmission Breather 2100/2200/2500 Series

Checking 1. Park the vehicle on a level surface and apply the
parking brake.
Transmission housing breathers, if so equipped,
must remain clear. A plugged breather could result in 2. Run the engine until the transmission fluid
pressure buildup, which could cause oil leakage. reaches the operating temperature of 160 to
200°F (71 to 93°C). Shift the transmission to
If the breather is plugged, clean or replace it. See neutral (N) and shut down the engine.
Fig. 2. Check more often if the vehicle is operating
under very dusty conditions.
CAUTION
To prevent dirt from entering the transmission,
use only clean containers and fillers for the trans-
mission fluid. Do not use fillers or containers that
have been used for water or antifreeze. Dirt, water,
or antifreeze could damage the transmission.
3. Clean the area around the drain plug. Place a
drain pan under the transmission and remove the
drain plug. Examine the fluid while it drains. If
only the filter is being changed, do not drain the
fluid.
NOTE: A lot of fluid will drain when the filter is
removed.
4. Using a standard strap-type filter wrench, remove
the filter by turning it counterclockwise. See
05/27/93 f260007a
Fig. 3.
NOTE: Location of the transmission breather will vary
depending on transmission model. 5. Remove the magnet from the filter attachment
tube or from the top of the filter element.
Fig. 2, Transmission Breather (Eaton Fuller shown)
6. Clean any metal debris from the magnet. Then,
install the magnet on the filter attachment tube.

S2 Chassis Maintenance Manual, October 2016 26/3

26 Transmission

Approved Allison Transmission Lubricants*

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

2 Table 3, Approved Allison Transmission Lubricants

03/31/2000 f261061 Allison Transmission Lubricant Capacities

Fill Capacity:*
1. Magnet Transmission Model
2. External Filter qt (L)
2100/2200/2500 Series (standard 15 (14)
Fig. 3, 2100/2200/2500 Series Transmission External sump)
Filter
2100/2200/2500 Series (shallow sump) 13 (12)
7. Using transmission fluid, lubricate the gasket on 3000 Series (4 inch sump) 29 (27)
the filter.
3000 Series (2 inch sump) 26 (25)
8. Using your hand, install the filter by turning it
* Quantities listed are approximate. Add the recommended amount of fluid
clockwise until the filter gasket contacts the con-
as listed under fill capacity. Do not overfill.
verter housing or cooler manifold. Then, turn the
Table 4, Allison Transmission Lubricant Capacities
filter one more complete turn.
9. Install the drain plug and sealing washer. Tighten
the plug 22 to 30 lbf·ft (30 to 40 N·m). 3000 Series
10. Clean the area around the fill tube and remove
the dipstick. Using a clean funnel in the fill tube, CAUTION
add transmission fluid. See Table 3 for approved
transmission lubricants, and Table 4 for lubricant To prevent dirt from entering the transmission,
capacities. use only clean containers and fillers for the trans-
mission fluid. Do not use fillers or containers that
11. Check and adjust the fluid level using the proce-
have been used for water or antifreeze. Dirt, water,
dure under "Checking the Fluid Level".
or antifreeze could damage the transmission.
Approved Allison Transmission Lubricants* 1. Park the vehicle on a level surface and apply the
parking brakes.
TES-295
Product Brand
Approval Company
Name 2. Operate the vehicle until the transmission
Number reaches normal operating temperature: 160 to
ExxonMobil Lubricants 200°F (71 to 93°C).
Mobil Delvac
AN-051005 and Petroleum 3. Clean the area around the drain plug and the
Synthetic ATF
Specialties Company
transmission fluid pan. Place a drain pan under
the transmission and remove the drain plug. Ex-

26/4 S2 Chassis Maintenance Manual, October 2016

Transmission 26

amine the fluid as it drains. If only the filter is

being changed, do not drain the fluid.
4. Remove the 12 mounting bolts (6 each) from the
1
2 filter covers.
NOTE: A lot of fluid will drain when the filter
covers are removed. 1
5. Remove the filter covers, O-rings, and two
square-cut seals from the transmission. See
Fig. 4.
6. Remove the filters from the bottom of the control
module.
7. Lubricate the new O-rings with transmission fluid,
and install them on the cover assemblies.
8. Install a new square-cut seal on each cover as-
sembly, and install the fluid filter elements on the
cover assemblies.
9. Install the filter and cover assemblies into the
filter compartment.
10. Align each cover assembly with the holes in the
2
channel plate sump, and push the cover assem-
blies in by hand to seat the seals.
2
CAUTION
3
Do not use the bolts to draw the filter covers to
the sump. This can damage the covers, seals, or 4
sump. 3

11. Install six bolts in each cover, and tighten the 4 1

bolts 38 to 44 lbf·ft (51 to 61 N·m).
1
12. Install a new drain plug O-ring, and install the
drain plug. Tighten the drain plug 18 to 24 lbf·ft
(25 to 32 N·m).
13. Fill the transmission with fresh transmission fluid 08/25/95 f260317
and check the fluid level. See Table 3. See 1. Filter Cover 3. Filter Element O-Ring
Table 4 for lubricant capacities. 2. Filter Element 4. Square-Cut Seal
14. Check and adjust the fluid level using the proce- Fig. 4, Allison 3000 Series Transmission Filter Location
dures under "Checking the Fluid Level". and Components

sion. Overfilling will force fluid out of the case

Checking the Fluid Level through the main shaft openings.
Do not mix types and brands of fluid, because of
CAUTION possible incompatibility. Do not use fluid addi-
Operating a transmission with the fluid level tives, friction modifiers, extreme-pressure gear
higher or lower than recommended can result in fluids, or multiviscosity lubricants.
transmission damage. Do not overfill the transmis-

S2 Chassis Maintenance Manual, October 2016 26/5

26 Transmission

Cold Check B
Clean all dirt away from around the end of the fluid
fill tube before removing the dipstick.
A
CAUTION
Do not allow foreign matter to enter the transmis-
sion. Dirt or foreign matter in the hydraulic system
may cause undue wear of transmission parts, 12/01/97 f270002a
make valves stick, and clog passages.
A. Cold Run Band B. Hot Run Band
After replacing the transmission fluid or changing the
filter(s), it is important to check the fluid level cold to Fig. 5, Dipstick Markings
determine if the transmission has a sufficient amount Fluid foaming and aeration cause transmission
of fluid to be safely operated until a hot check can be overheating and erratic shifting.
performed.
1. Park the vehicle on a flat, level surface. NOTE: Perform a hot check at the first opportu-
nity after the normal operating temperature, 160
2. Apply the parking brake and chock the rear tires. to 200°F (71 to 93°C) has been reached.
3. Run the engine for at least one minute.
Hot Check
4. Shift from DRIVE to NEUTRAL, and then shift to
REVERSE to fill the hydraulic system. Recommended Method
5. Shift to NEUTRAL and allow the engine to idle at With the vehicle on a level surface and the transmis-
500 to 800 rpm. sion in neutral at operating temperature, perform the
6. With the engine running at idle, remove the dip- steps below.
stick from the tube, then wipe the dipstick clean. 1. On the transmission shift selector, press the up
7. Insert the dipstick into the tube and remove the and down arrow keys simultaneously. See Fig. 6.
dipstick.
8. Check the fluid level reading and repeat the 1
check procedure to verify the reading.
If the fluid level is within the COLD RUN band, S
E
L
M
O
N
I
the transmission may be operated until the fluid E
C
T
T
O
R
is hot enough to perform a HOT RUN check.
If the fluid level is not within the COLD RUN
band, add or drain fluid as needed to adjust the R MODE

fluid level to the middle of the COLD RUN band.

See Fig. 5. N

CAUTION D

Do not fill above the COLD RUN band if the trans-

mission fluid is below normal operating tempera-
ture. As fluid temperature increases, so does the
fluid level. Filling above the COLD RUN band 03/04/2008 f270159
when the transmission is below normal operating 1. Shift Selector Display Screen
temperature may result in an overfilled transmis-
sion, which causes fluid foaming and aeration. Fig. 6, Transmission Shift Selector

26/6 S2 Chassis Maintenance Manual, October 2016

Transmission 26

2. Release the arrow keys and wait for a two-

minute countdown.
3. The transmission shift selector display screen will
display one of the following messages.
• OL - OK indicates an acceptable oil level.
• OL - HI followed by a number indicates the
amount that is over-filled.
• OL - LO followed by a number indicates
the amount that is under-filled.
• OL - 70 indicates that the transmission is
not up to operating temperature.

Alternate Method
1. Park the vehicle on a flat, level surface. Apply
the parking brake and chock the rear tires.
2. Shift the transmission to NEUTRAL.
3. Operate the engine at idle (500 to 800 rpm) until
normal operating temperature is reached. Check
that the sump temperature is 160 to 200°F (71 to
93°C).
4. With the engine idling, remove the dipstick from
the tube and wipe it clean.
5. Insert the dipstick into the tube and remove it.
6. Check the fluid level reading and repeat the
check procedure to verify the reading. Safe oper-
ating level is within the HOT RUN band on the
dipstick. The HOT RUN band is between the
HOT FULL and HOT ADD marks.
If the fluid level is not within the HOT RUN band,
add or drain fluid as needed to bring the fluid
level within the HOT RUN band. See Fig. 5.

S2 Chassis Maintenance Manual, October 2016 26/7

Frame and Frame Components 31
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–00

S2 Chassis Maintenance Manual, October 2015

Frame and Frame Components 31

31–00 Safety Precautions • engine trunnion supports

• exhaust brackets
Safety Precautions in this section apply to all • frame crossmembers and gussets
procedures within this group.
• front frame brackets
DANGER • front suspension spring brackets
• fuel tank brackets
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires. • radius rods
Before working under the vehicle, always place • rear engine supports
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps • rear suspension spring brackets
could result in serious personal injury or death. • shock absorbers
• all other frame fasteners
31–01 Frame Fastener Torque Any component that shows signs of cracking or dam-
Check age must be repaired or replaced. See the applicable
group in the vehicle Workshop Manual for repair or
Frame brackets and components secured with Huck- replacement information.
bolt® fasteners do not require a torque check, how-
ever, they should be inspected for damage. Frame
brackets and components secured with conventional
bolts and nuts are to be checked at initial mainte-
nance (IM).
Check the torque of frame fasteners to offset the ef-
fects of bedding in or seating. When possible, always
check the torque of the nut, not the bolt head. This
will give a true torque reading by eliminating bolt
body friction.
When checking the torque of frame fasteners, in-
spect the frame for cracks and other damage. Set a
click-type torque wrench to the maximum torque of
the fastener you are checking. Apply pressure until
the torque wrench clicks. Do not loosen the bolt to
check the torque. For torque values, see the appli-
cable torque table in Group 00 of the vehicle Mainte-
nance Manual.

NOTICE
Make sure frame fasteners are properly tightened.
Continued vehicle operation with loose fasteners
could result in bracket or frame damage.
NOTE: Engine supports on vehicles built from
January 2007 require the same maintenance as
shown below.
Inspect the fasteners at the following locations:
• axle stops

S2 Chassis Maintenance Manual, October 2015 31/1

Suspension 32
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–00
Suspension Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01
Suspension U-Bolt Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02

S2 Chassis Maintenance Manual, October 2015

Suspension 32

32–00 Safety Precautions Freightliner Spring Shock

Safety Precautions in this section apply to all
Absorber Check
procedures within this group. Make sure that the shock absorber brackets are tight
and that the shock absorber is not striking or rubbing
DANGER on the frame or some other part of the chassis.
Check the rubber mounting bushings and replace
When working on the vehicle, shut down the en- them if worn. Inspect the shock absorber for oil leak-
gine, set the parking brake, and chock the tires. age, which is defined as being drips of oil on the
Before working under the vehicle, always place sides of the shock absorber.
jack stands under the frame rails to ensure the If the shock absorber is worn or damaged, replace it
vehicle cannot drop. Failure to follow these steps with a new one.
could result in serious personal injury or death.
Freightliner AirLiner Torque Arm
32–01 Suspension Inspecting Bushing Check
1. Without detaching the torque arms, use your
Freightliner Spring Front and hand to attempt to move each of the torque arm
Rear Suspension Spring ends up, down, in, and out. If there is any move-
ment, replace the torque arm.
Assemblies Inspection 2. Inspect the weld seams between the torque arm
NOTE: Lubrication is not required on Freight- tube and the shorter bushing tubes. If there are
liner Spring front and rear suspensions. cracks, replace the torque arm. Do not weld the
torque arm for any reason.
Inspect the front and rear suspension spring assem-
blies for pitted, cracked, broken, or abnormally bent 3. Inspect the rubber bushing ends. See Fig. 1. Re-
leaves and extreme rust. If any of these conditions place the torque arm for any of the following rea-
exist, replace the spring assembly. See Group 32 of sons.
the S2 Chassis Workshop Manual for instructions. • There are gaps between the rubber bush-
ing and the pin or the outer steel sleeve.
WARNING • Either bushing end contacts a torque arm
pin mounting bolt.
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring as- • There are cracks in the bushing.
sembly. Visible damage (cracks or breaks) to one • Part of the rubber bushing extends beyond
leaf causes hidden damage to other leaves. Re- the outside diameter of the outer bushing
placement of only the visibly damaged part(s) is sleeve.
no assurance that the spring is safe. On front
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could 52-Inch Multi-Leaf Spring
occur. Failure to replace a damaged spring assem- Component Check
bly could cause an accident resulting in property
damage, serious personal injury, or death. No lubrication is required on the 52-inch multi-leaf
spring rear suspension.
IMPORTANT: On multi-leaf suspensions, closely
inspect each component of the leaf spring as- Inspect the stabilizer bar, if present, for irregular
semblies, including the brackets, U-bolts, and bushing wear or cracks in the brackets. Check the
rubber helper spring, if present, for cracks.
related parts.

S2 Chassis Maintenance Manual, October 2015 32/1

32 Suspension

Freightliner AirLiner Component

Inspection and Operation Check
WARNING
Inspect the components and check their operation
as described below. Failure to perform these in-
spections and checks could result in separation of
worn suspension components and loss of vehicle
control, possibly causing personal injury or death,
or property damage.

05/27/93 f320021a
1. Chock the front tires and apply the parking
brake. Raise the rear of the vehicle so the tires
Fig. 1, Torque Arm Bushings just clear the ground and the suspension is fully
extended. Place safety stands under the vehicle
60-Inch Taper-Leaf Spring frame.

Component Check 2. Squeeze all air springs to check for complete

deflation.
No lubrication is required on the 60-inch taper-leaf 3. Inspect each air spring for wear at its connection
spring rear suspension. to its pedestal. Replace any worn air springs.
Inspect the rear shackle brackets for bushing wear or 4. Check the axle connection welds (beam seat to
cracks. equalizing beam) and axle adapter to axle for
Inspect the stabilizer bar, if present, for irregular cracks. If the welds are cracked, grind them out
bushing wear or cracks in the brackets. Check the and reweld the parts.
rubber helper spring, if present, for cracks. 5. Move the axle up and down while checking for
signs of looseness due to worn parts at the front
Freightliner AirLiner Component pivot connections. Replace any worn parts.
Clearance Check 6. Inspect the shock absorbers for oil leaks and
worn rubber bushings. Replace the shock ab-
Check that the air line support brackets are posi-
sorbers and/or rubber bushings if wear or dam-
tioned so the air lines do not rub against anything.
age is noted.
Reposition any configurations that could contact the
air line and result in friction and wear. There must be 7. Inspect the stabilizer bar, if so equipped, for ir-
at least 1 inch (25 mm) clearance around the rubber regular bushing wear or cracks in the brackets.
air spring when inflated. If the clearance is less than The stabilizer bar is optional on 10,000- and
1 inch (25 mm), relocate the obstructing parts. 15,000-pound AirLiner suspension systems.
8. Remove the safety stands and lower the rear of
CAUTION the vehicle to the ground. Run the engine until
air pressure of at least 100 psi (689 kPa) is
Failure to relocate obstructing parts could result maintained throughout the system.
in damage to the air spring.
9. Check that all air springs are inflated.

32–02 Suspension U-Bolt

Torque Checking
Check the U-bolt torque of both the front and rear
axles where applicable.

32/2 S2 Chassis Maintenance Manual, October 2015

Suspension 32

CAUTION 4 1

Failure to retorque the U-bolt nuts could result in

spring breakage and abnormal tire wear.
1. Park the vehicle on a flat surface and apply the
parking brake. Chock the tires.
2. Check the U-bolt torque in a diagonal pattern.
Set a click-type torque wrench to the highest 2 3
torque value for the fastener being checked. See
10/05/2016 f320783
Table 1 for U-bolt torque specifications. Turn the
wrench in a clockwise motion (looking up) until Fig. 2, Tightening Sequence for U-Bolt High Nuts
the torque wrench clicks.
Remove the chocks.

U-Bolt High Nut Torque*

Size Torque: lbf·ft (N·m)
Stage 1: Hand tighten
Stage 2: 60 (81)
5/8–18
Stage 3: 200 (271)
Stage 4: 180 to 230 (245 to 313)
Stage 1: Hand tighten
Stage 2: 60 (81)
3/4–16
Stage 3: 200 (271)
Stage 4: 270 to 330 (367 to 449)
Stage 1: Hand tighten
Stage 2: 60 (81)
7/8–14
Stage 3: 200 (271)
Stage 4: 420 to 500 (571 to 680)
Stage 1: Hand tighten
Stage 2: 60 (81)
1–14
Stage 3: 200 (271)
Stage 4: 520 to 600 (707 to 816)
* Tighten in the sequence shown in Fig. 2.

Table 1, U-Bolt High Nut Torque

S2 Chassis Maintenance Manual, October 2015 32/3

Front Axle 33
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Draw Key Nut Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02
Kingpin Lubricating, Detroit™ Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–00
Tie Rod End Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03
Tie Rod Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04

S2 Chassis Maintenance Manual, October 2015

Front Axle 33

33–00 Safety Precautions

1
Safety Precautions in this section apply to all
procedures within this group.

DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. A

33–01 Kingpin Lubricating,

Detroit™ Axles

NOTICE
Use regulated pressure when lubricating the
knuckle assemblies, otherwise damage could re-
sult to the knuckle caps.
B 1
On the front axle, grease fittings are on the top and
bottom caps of each knuckle. 06/07/2012 f330272

1. Park the vehicle on a level surface, shut down A Upper View, LH Side B Lower View, LH Side
the engine, and set the parking brake. Chock the 1. Grease Fitting
tires. When lubricating upper and lower knuckle
Fig. 1, Grease Fittings, Detroit Axles
assemblies, do not raise the front axle.
2. Wipe the grease fittings clean.
3. Apply multipurpose chassis grease, NLGI Grade
1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease), until new grease is seen at the junctions
of the axle beam and knuckles. For locations of
grease fittings, see Fig. 1; for grease exit points,
see Fig. 2.

33–02 Draw Key Nut Inspecting 09/13/2012 f330275

Axles With Unitized Wheel Ends Fig. 2, Kingpin Grease Exit Points, Detroit Axles

Check the torque of the nut that holds the draw key
on the side of the knuckle. The torque should be 30
33–03 Tie Rod End Inspecting
to 45 lbf·ft (41 to 61 N·m). See Fig. 3. IMPORTANT: If the tie rod end boot is torn or
missing, replace the entire tie rod assembly or
the tie rod end. Do not replace the boot only.

S2 Chassis Maintenance Manual, October 2015 33/1

33 Front Axle

08/31/2006 f330232

Fig. 3, Draw Key Nut 09/01/2006 f330234

1. Shut down the engine, apply the parking brake, Fig. 4, Checking Tie Rod End Movement
and chock the rear tires.
6. Check the clamps for damage. If a clamp is
2. Check the tie rod boot for cracks, tears, or other damaged, replace the clamp. Replace the entire
damage. If the tie rod boot is damaged, replace cross tube assembly if either clamp is welded to
the entire tie rod end. the cross tube.
3. Grasp by hand (or use a pipe wrench with jaw 7. Check for proper installation of the tie rod end
protectors to avoid gouging the cross tube) and clamp to the cross tube. Make sure that the tie
slightly rotate the cross tube toward the front of rod ends are threaded in the cross tube past the
the vehicle and then slightly toward the rear. clamps and the slots at the cross tube ends.
Then center the cross tube between the stop po-
sitions. If the cross tube does not rotate in either 8. Check the grease fittings for damage. If a grease
direction, replace both tie rod ends. fitting is damaged, replace it.

4. Position yourself directly below the ball stud Some tie rod ends have no grease fittings be-
socket. Using both hands, grab the end as close cause they are not greaseable. Do not install a
to the socket as possible, no more than 6 inches grease fitting on a nongreaseable tie rod end.
(15.2 cm) from the end. Firmly apply about 100 9. Check that the cotter pin is in place. If it is not,
pounds of hand pressure in an up and down mo- tighten the tie rod end nut to the applicable value
tion several times. When moving the assembly, depending on the size of the stud.
check for any movement at both tie rod ends.
• 7/8–14, 160 to 300 lbf·ft (217 to 406 N·m)
See Fig. 4.
• 1–14, 250 to 450 lbf·ft (339 to 610 N·m)
If any movement is detected at one tie rod end,
replace both tie rod ends. Always replace tie rod • 1-1/8–12, 350 to 650 lbf·ft (475 to 881
ends in pairs, even if only one tie rod end is N·m)
damaged. • 1-1/4–12, 500 to 675 lbf·ft (678 to 915
N·m)
NOTICE 10. Check the steering arm bolts for a minimum
Do not attempt to straighten a bent cross tube. torque of 300 lbf·ft (406 N·m). If the steering arm
Doing so could result in damage to the axle. Be bolt torque has fallen below this specification,
sure to replace the cross tube with an original remove the bolt, clean all the threads, and apply
equipment cross tube with the same length, diam- new Loctite® 680. Tighten the bolt 300 to 450
eter, and thread size as the existing cross tube. lbf·ft (406 to 610 N·m).
5. Check the cross tube for cracks or other dam-
age. If the cross tube is bent or damaged, re-
place the cross tube.

33/2 S2 Chassis Maintenance Manual, October 2015

Front Axle 33

33–04 Tie Rod Lubricating

For any Detroit or Meritor axle that requires lubrica-
tion of the tie-rod ends, wipe the grease fittings
clean, then pump multipurpose chassis grease, NLGI
Grade 1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease), into the tie-rod ends until all used grease is
forced out and fresh grease is seen at the ball stud
neck. See Fig. 5.

1
06/12/2012 f330273
NOTE: No grease should emit from the tie-rod boot. If
grease emits from the tie-rod boot, the boot is dam-
aged.
1. Grease Fitting 2. Boot
Fig. 5, Grease Fitting and Boot (Detroit axle shown)

S2 Chassis Maintenance Manual, October 2015 33/3

Rear Axle 35
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Axle Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02
Axle Lubricant Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–03
Axle Lubricant Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–00

S2 Chassis Maintenance Manual, October 2015

Rear Axle 35

35–00 Safety Precautions 5. Install the oil fill plug and tighten it 30 lbf·ft (41
N·m) for Detroit axles or 35 lbf·ft (47 N·m) for
Meritor axles.
Safety Precautions in this section apply to all
procedures within this group. IMPORTANT: Always check the axle breather
whenever checking the lubricant level. Check
DANGER the breather more frequently under adverse op-
erating conditions.
When working on the vehicle, shut down the en-
6. Check the axle housing breather. Make sure that
gine, set the parking brake, and chock the tires.
it is open and unclogged. If the breather is
Before working under the vehicle, always place
plugged or damaged, clean or replace it as
jack stands under the frame rails to ensure the
needed.
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.
1
35–01 Axle Lubricant Level
Checking

NOTICE A
2
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in 3
rear axle damage. 1
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. If the vehicle has just been driven, allow a few
minutes for the lubricant to settle.
B
3. Clean the fill plug and the area surrounding the 4
fill plug on the side of the axle carrier. Remove
the plug. Check lubricant level when the axle is 11/07/2012 3 f350575
cold, or near room temperature. See Fig. 1 and A. Front View
Fig. 2. B. Rear View
NOTE: Some Meritor axles have a small tapped 1. Breather Hose
and plugged hole located below the housing oil 2. Axle Housing Breather
3. Oil Drain Plug
fill hole. This smaller hole is for the lubricant 4. Oil Fill Plug
temperature sensor only and must not be used
as a fill or level hole. Fig. 1, Component Locations, Detroit Axles
4. Check that the lubricant is level with the bottom
of the fill hole. See Fig. 3. If low, check for oil
leaks, and correct as needed. Add oil to the level
of the fill plug, using the lubricant in Table 1 for
Detroit axles or Table 2 for Meritor axles.
IMPORTANT: A lubricant level close enough to
be seen or touched is not sufficient. It must be
level with the bottom of the fill hole.

S2 Chassis Maintenance Manual, October 2015 35/1

35 Rear Axle

1 Detroit Drive Axle Lubricants*

IMPORTANT: Lubricant used in Detroit rear axles must

meet Mercedes-Benz specification 235.20 (mineral) or
235.8 (synthetic). Mobil Delvac™ Gear Oil A 80W-90 and
Mobilube™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
75W-90 meet specification 235.8. For more product
information, see http://bevo.mercedes-benz.com.
SAE
Type Ambient Temperature Viscosity
Grade
Synthetic Oil –40°F (–40°C) and up† 75W–90
* Detroit rear axles do not require the use of friction modifiers.
† There is no upper limit on the ambient temperature, but axle sump tem-
2 perature must never exceed 250°F (121°C).

12/05/2003 f350436 Table 1, Detroit Drive Axle Lubricants

1. Axle Housing Breather
2. Oil Fill Plug Drive Axle Recommended Lubricant, Meritor Axles
Fig. 2, Component Locations, Meritor Axles Lubricant
Recommended SAE
Ambient Temperature
Lubricant Type Viscosity
Grade
A
10°F (–12.2°C) and up* 85W–140
Hypoid Gear Oil –15°F (–26.1°C) and up* 80W–90
API Service
–40°F (–40°C) and up* 75W–90
Classification
GL–5 –40°F (–40°C) to 35°F (2°C) 75W
B –40°F (–40°C) and up* 75W–140
Synthetic Gear –40°F (–40°C) and up* 75W–90
Oil –40°F (–40°C) and up* 75W–140
10/05/2016 f350061a
* There is no upper limit on the ambient temperature, but axle sump tem-
A. Correct (lube level at bottom of fill hole)
perature must never exceed 250°F (121°C).
B. Incorrect (lube level below fill hole)
Table 2, Drive Axle Recommended Lubricant, Meritor
Fig. 3, Axle Lubricant Level Inspection Axles

Detroit Drive Axle Lubricants*

35–02 Axle Breather Checking
IMPORTANT: Lubricant used in Detroit rear axles must
meet Mercedes-Benz specification 235.20 (mineral) or NOTE: Detroit axles have a breather hose
235.8 (synthetic). Mobil Delvac™ Gear Oil A 80W-90 and wrapped around the housing breather. The
Mobilube™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
breather hose length should not be lower than
75W-90 meet specification 235.8. For more product approximately 1 inch below the axle housing
information, see http://bevo.mercedes-benz.com. weld seam.
SAE The axle housing breather must remain clean. See
Type Ambient Temperature Viscosity Fig. 1 and Fig. 2. When the axle lubricant level is
Grade checked, check that the axle breather is open. Check
Mineral Oil –15°F (–26.1°C) and up† 80W–90 more often under poor operating conditions. If the
breather is plugged, clean it or replace it as needed.

35/2 S2 Chassis Maintenance Manual, October 2015

Rear Axle 35

35–03 Axle Lubricant Changing Allow enough time for all the old lubricant to
drain completely.
and Magnetic Plug 4. Clean the drain plug. For magnetic drain plugs, a
Cleaning piece of key stock or any other convenient steel
slug may be used to short the two magnetic
A regular schedule for changing the axle lubricant in poles and divert the magnetic field.
a particular vehicle and operation can be accurately
NOTE: Meritor recommends using magnetic
determined by analyzing oil samples taken from the
axle at specified intervals or mileages. Lubricant sup- plugs with elements having a minimum pickup
pliers frequently make their laboratory facilities avail- capacity of two pounds (one kilogram) of low-
able for determining the useful life of their product carbon steel in plate or bar form. Magnets will
under actual service conditions. The final schedule rapidly lose effectiveness as collected material
that is recommended may, for economic reasons, be bridges the gap between the two poles. Clean
related to lubricant changes that are governed by or change the plugs before this occurs. It may
climatic conditions and magnetic plug maintenance. be necessary to clean or change the plugs one
Change lubricant type and viscosity as climatic tem- or more times between lubrication change inter-
peratures demand, regardless of vehicle mileage or vals.
established change schedule.
5. After cleaning the drain plug, install and tighten
The normal operating temperature of compounded the plug 30 lbf·ft (41 N·m) for Detroit axles or 35
lubricants during the summer season is about 160 to lbf·ft (47 N·m) for Meritor axles.
220°F (71 to 104°C). The chemicals and additives
that give these lubricants increased load carrying ca-
pacity oxidize faster at temperatures above 220°F
Axle Filling
(104°C), contributing to more rapid lubricant deterio- 1. With the vehicle on a level surface, fill the axle
ration. For this reason, lubricants of this type that housings to the bottom of the oil fill hole (in the
operate continuously at high temperatures must be carrier or housing) with recommended lubricant;
changed more frequently. see Table 2. Refer to Table 3 for Detroit drive
axle lubricant capacities or Table 4 for Meritor
NOTICE drive axle lubricant capacities.
NOTE: Some Meritor axles have a small tapped
Failure to change the axle lubricant at more fre-
quent intervals, when adverse operating condi- and plugged hole located below the housing oil
tions require, could result in axle damage. fill hole. This smaller hole is for the lubricant
temperature sensor only and must not be used
Axle Draining as a fill or level hole.
2. Install the fill hole plug and tighten it 30 lbf·ft (41
1. Park the vehicle on a level surface, shut down
N·m) for Detroit axles or 35 lbf·ft (47 N·m) for
the engine, and set the parking brake. Chock the
Meritor axles.
tires.
3. After filling the carrier and housing assembly with
2. Clean the fill plug and the area around it. Re-
lubricant, drive the vehicle unloaded for one or
move the plug from the oil fill hole. See Fig. 1.
two miles (two or three kilometers) at speeds not
to exceed 25 mph (40 km/h) to thoroughly circu-
CAUTION late the lubricant throughout the assembly.
Be careful when draining the axle oil. It may be
very hot, and could cause personal injury if it con-
tacts the skin. Detroit Drive Axle Lubricant Capacities
3. Remove the plug at the bottom of the housing Axle Model* Capacity†: pints (L)
and drain the lubricant while the unit is warm. ARS–13.0–2 15 (7)

S2 Chassis Maintenance Manual, October 2015 35/3

35 Rear Axle

Detroit Drive Axle Lubricant Capacities

Axle Model* Capacity†: pints (L)
ARS–15.0–2 15 (7)
ARS–17.5–2 15 (7)
ARS–19.0–2 15 (7)
ARS–20.0–2 15 (7)
ARS–21.0–2 15 (7)
ARS–21.0–4 23 (11)
ARS–23.0–4 23 (11)
* Model code may have a "D" in the prefix (for example, DA–RS–13.0–2).
† Quantities listed are approximate and include 1 pint (0.5 liter) for each
wheel end and with the drive pinion at 3 degrees.
Table 3, Detroit Drive Axle Lubricant Capacities

Meritor Drive Axle Lubricant Capacities

Axle Model Capacity*: pints (L)
MS–10–113D 14 (6.6)
MS–12–113D 15 (7.1)
RS–13–120 18.4 (8.7)
RS–15–120 14.3 (6.8)
RS–17–145 33.6 (15.9)
RS–17–144 32.3 (15.3)
RS–19–144 32.3 (15.3)
RS–19–145 33.2 (15.7)
RS–21–145 32.3 (15.3)
RS–21–160 39.5 (18.7)
RS–21–230 38.9 (18.4)
RS–23–160 39.5 (18.7)
RS–23–161 39.5 (18.7)
RS–23–186 47.3 (22.4)
RS–23–240 37.4 (17.7)
RS–26–185 38.0 (18.0)
RS–30–185 38.0 (18.0)
* Quantities listed are approximate and include 1 pint (0.5 liter) for each
wheel end and with the drive pinion at 3 degrees.
Table 4, Meritor Drive Axle Lubricant Capacities

35/4 S2 Chassis Maintenance Manual, October 2015

Wheels and Tires 40
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Wheel Nut Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01

S2 Chassis Maintenance Manual, January 2007

Wheels and Tires 40

40–01 Wheel Nut Checking 1 2

10
1
8
IMPORTANT: In addition to the maintenance 7 4 3 6
interval in this manual, check the wheel nut
torque the first 50 to 100 miles (80 to 160 km) 5 6 5 4
of operation after a wheel has been removed
and installed. 7 9
3 8 2
When checking wheel nuts on a stud-piloted dual A B
disc assembly, remove one outer nut at a time, 09/18/2001 f400164
tighten the inner nut, then reinstall the outer nut. Re- A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel
peat this procedure for all of the inner wheel nuts in
the sequence shown in Fig. 1, then tighten all of the Fig. 1, Wheel Nut Tightening Sequence
outer wheel nuts in the same sequence.

CAUTION
Too little wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud break-
age, and extreme tire tread wear. Too much wheel
nut torque can break studs, damage threads, and
crack discs in the stud hole area.
See Table 1 for wheel nut torque specifications and
see Fig. 1 for the tightening sequence.

Wheel Nut Torque Specifications

Thread Torque (oiled)
Wheel Manufacturer
Size lbf·ft (N·m)
280 to 330 (380 to
M20 x 1.5 Accuride Corporation
447)
450 to 500 (610 to
M22 x 1.5 Accuride Corporation
678)
450 to 500 (610 to
1-1/8–16 Accuride Corporation
678)
450 to 500 (610 to
3/4–16 Accuride Corporation
678)
Table 1, Wheel Nut Torque Specifications

S2 Chassis Maintenance Manual, January 2007 40/1

Driveline 41
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01
Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–00

S2 Chassis Maintenance Manual, October 2015

Driveline 41

41–00 Safety Precautions ness exists between the slip yoke and the tube
shaft, replace the slip yoke and the tube shaft.
For instructions, see Group 41 of the vehicle
Safety Precautions in this section apply to all Workshop Manual, or take the vehicle to an au-
procedures within this group. thorized Freightliner dealer.
4. Examine the shaft for damaged or bent tubing.
DANGER Carefully remove any foreign material such as
When working on the vehicle, shut down the en- mud or dirt that has built up on the shaft.
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

41–01 Driveline Inspection

WARNING
Do not service or inspect a driveshaft with the en-
gine running. A rotating driveshaft can cause seri- 09/19/2001 f410484
ous personal injury.
Loose end yokes, excessive radial looseness, slip Fig. 1, Half-Round End Yoke
spline radial looseness, bent shaft tubing, or missing
plugs in the slip yoke can cause universal joint and
bearing defects.
See Fig. 1 for an illustration of half-round end yokes.
1. Check the output and input end yokes on both
the transmission and axle for axial looseness.
Refer to the axle or transmission manufacturer’s
service information for the correct specifications.
If loose, disconnect the driveshaft. For instruc-
tions, see Group 41 of the vehicle Workshop
Manual, or take the vehicle to an authorized
Freightliner dealer. Tighten the end yoke retain-
ing nut to the proper specification. Refer to the 09/19/2001 f410486
axle or transmission manufacturer’s service infor-
mation for the correct specifications. Fig. 2, Checking for Radial Looseness of the Slip Yoke
Spline
2. Inspect for worn universal joints. Apply a vertical
force of about 50 pounds to the driveline near 41–02 Driveline Lubrication
the universal joints. If there is any movement,
replace the universal joint. For instructions, see The Easy Service driveline requires periodic lubrica-
Group 41 of the vehicle Workshop Manual, or tion of the universal joints and slip yoke splines. See
take the vehicle to an authorized Freightliner Table 1 for approved lubricants.
dealer.
3. Examine the slip yoke spline for excessive radial
movement. See Fig. 2. If excessive radial loose-

S2 Chassis Maintenance Manual, October 2015 41/1

41 Driveline

Approved Lubricants
Lubricant and Specification Lubricant Brands
Chevron Ultra-Duty EP–2*
Phillips Petroleum Philube MW–EP2 Grease
Exxon 5160
Amalie All Purpose Grease with Moly–L1–2M
Universal joint, slip joint, and spline grease
must meet Dana Corporation specifications Shell Super Duty Special FF
(NLGI Grade No. 2, with an operating range of Marathon Maralube Molycode 529
325°F [163°C] to –10°F [–23°C])
Shell Moly Poly Grease
Kendall L424 Grease
Amoco Super Chassis Grease
Ford Specification M1C–75B or part number PN™C1AZ 19590
* Dana recommended lubricant.

Table 1, Approved Lubricants

41/2 S2 Chassis Maintenance Manual, October 2015

Brakes 42
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

ABS Tone Rings Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–10
Air Brake Inspecting and Leakage Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09
Air Dryer AD–9, AD–IP Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06
Bendix Air Dryer AD–9 or AD–IP Desiccant Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01
Bendix Hydro-Max® Brake System Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–11
Brake Caliper Slide Pin Lubricating, Bosch Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–12
Brake Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–15
Brake Lines and Fittings Inspecting, Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–07
Brake Pedal Linkage and Mounting Plate Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–08
Drum Brake Shoe Roller Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–13
Foot Brake Valve Actuator Lubricating, Bendix E–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–14
Governor D–2A Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02
Hydraulic Brake Lining Wear Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03
Meritor Camshaft Bracket Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–00
Slack Adjuster Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04
WABCO System Saver Air Dryer Desiccant Cartridge Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–16

S2 Chassis Maintenance Manual, October 2016

Brakes 42

42–00 Safety Precautions WARNING

Safety Precautions in this section apply to all Clamping the end cover or housing in a vise could
procedures within this group. seriously compromise the ability of the air dryer
to hold air pressure, which could cause a failure
DANGER in the brake system, resulting in personal injury or
property damage.
When working on the vehicle, shut down the en- 10. Twist the end cover counterclockwise to release
gine, set the parking brake, and chock the tires. the cartridge from the end cover. Rotate the end
Before working under the vehicle, always place cover until it completely separates from the des-
jack stands under the frame rails to ensure the iccant cartridge.
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. NOTE: A substantial torque, up to 50 lbf·ft (68
N·m), may be necessary to remove the desic-
cant cartridge.
42–01 Bendix Air Dryer AD–9 11. Remove and discard desiccant cartridge O-rings.
or AD–IP Desiccant
Replacing CAUTION
Dirt or obstructions in the O-ring grooves can
AD–9 Air Dryer cause an O-ring failure that will result in an air
1. Park the vehicle on a level surface and apply the leak.
parking brake. Shut down the engine. Chock the 12. Lubricate new O-rings with grease supplied in
tires. the kit and install them in the end cover.
2. Completely drain all air reservoirs. Air pressure 13. Install the desiccant cartridge on the end cover.
gauges should read 0 psi (0 kPa). Turn the cartridge clockwise until the desiccant
cartridge makes contact with the end cover.
IMPORTANT: The compressor discharge line
may contain residual air pressure. 14. Place the desiccant cartridge in a vise, and turn
the end cover clockwise an additional 180 to 225
3. Identify, tag, and disconnect the three air lines degrees to fully tighten the desiccant cartridge to
from the end cover. the end cover.
4. Disconnect the harness connector from the NOTE: Desiccant cartridge torque should not
heater and thermostat assembly. exceed 50 lbf·ft (68 N·m).
5. Loosen the bolt that secures the upper mounting
15. Place the housing over the desiccant cartridge
bracket strap.
and align the mounting holes with the end cover.
6. Remove the two bolts that secure the air dryer to
16. Install the 6 bolts, 12 washers, and 6 new nuts.
the lower mounting bracket. Mark the position of
Torque the bolts in a star pattern 270 to 385
the mounting bracket to the end cover and mark
lbf·in (3060 to 4340 N·cm). See Fig. 2.
the bolts to ease installation.
17. Install the air dryer on the lower mounting
7. Remove the upper mounting bracket strap bolt,
bracket. Install the two previously marked bolts,
and remove the air dryer from the vehicle.
four washers, and two new nuts. Torque the two
8. Place the air dryer on a bench and remove the remaining bolts 270 to 385 lbf·in (3060 to 4340
remaining 6 bolts, 12 washers, 6 nuts, and the N·cm). Install the bolt, two washers, and a new
air dryer housing. See Fig. 1. Discard the nuts. nut in the upper mounting bracket strap. Torque
Remove the end-cover-to-housing O-ring. the upper mounting bracket strap nut 80 to 120
9. Clamp the desiccant cartridge in a vise. lbf·in (904 to 1356 N·cm).

S2 Chassis Maintenance Manual, October 2016 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 Bolt 10. O-Ring 19. 1/4-Inch Screw
2. Upper Mounting Bracket Strap 11. Drain 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 Bolt (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 Capscrew 24. 3/8-Inch Bolt
8. 3/8-Inch Special Washer 17. Exhaust Diaphragm 25. End Cover

Fig. 1, AD-9 Air Dryer

18. Connect and tighten the three air lines. Connect

the harness connector to the heater and thermo-
AD–IP Air Dryer
stat assembly until the lock tab snaps in place. 1. Park the vehicle on a level surface and apply the
parking brake. Shut down the engine. Chock the
19. Start the engine, build the air pressure, and
tires.
check the air brake system for leaks. If any air
leaks are present, see Group 42 of the S2 2. Completely drain all air reservoirs. Air pressure
Chassis Workshop Manual for diagnosis and re- gauges should read 0 psi (0 kPa).
pair information.
IMPORTANT: The compressor discharge line
may contain residual air pressure.

42/2 S2 Chassis Maintenance Manual, October 2016

Brakes 42

10. Install both O-rings on the cartridge bolt and,

6 2 using a twisting motion, insert the assembled
desiccant cartridge bolt in the end cover.
11. Install the desiccant cartridge on the end cover,
making sure that the cartridge is properly seated
4 5 and flush on the end cover.
NOTE: It may be necessary to rotate the car-
tridge slightly until the anti-rotation lugs are
properly aligned and allow the cartridge to rest
flush against the end cover.
1&9 3 12. Using a wrench or socket, tighten the desiccant
cartridge bolt to 70 lbf·ft (95 N·m). Do not over-
torque.
13. Before placing the vehicle into service, perform
7 8 the testing listed below.
13.1 Close all reservoir drain cocks.
09/20/94 f420544a
13.2 Build the system pressure to governor
Fig. 2, End Cover to Housing Torque Pattern cutout and note that the AD-IP air dryer
purges with an audible escape of air.
3. Using a wrench or a socket, loosen the desiccant
13.3 Fan the service brakes to reduce system
cartridge bolt. Then separate the desiccant car-
air pressure to governor cut-in. Note that
tridge from the end cover.
the system once again builds to full pres-
4. Pull the cartridge bolt out of the end of the cover sure and is followed by a purge at the
and remove the cartridge. AD-IP air dryer exhaust.
Do not attempt to disassemble the desiccant 13.4 Check for excessive leakage around the
cartridge assembly. Parts for the assembly are head of the desiccant cartridge where it
not available and the cartridge contains a 150 lb contacts the end cover. With the com-
spring that cannot be mechanically caged. pressor in loaded mode (compressing
air), apply a soapy solution to these areas
5. Remove and discard both O-rings from the des- and observe that any leakage does not
iccant cartridge bolt. exceed a one-inch bubble in one second.
6. Using a clean rag, wipe the inside of the end If leakage exceeds this measure, remove
cover clean. Clean the cartridge bolt bore in the and re-install the desiccant cartridge.
end cover and the sealing surfaces for the large
and small diameter desiccant cartridge sealing
rings.
42–02 Governor D–2A
7. Inspect the end cover for physical damage, then
Checking
inspect all air line fittings for corrosion, and re-
place as necessary. IMPORTANT: Review the warranty policy before
performing any intrusive maintenance proce-
8. Inspect the bolt, paying attention to the threads dures. An extended warranty may be voided if
and O-ring grooves. Clean the bolt. intrusive maintenance is performed during this
IMPORTANT: Use only the grease supplied with period.
Bendix replacement kits. Every 12 months perform the operational tests as
9. Lubricate the O-rings, bolt O-ring grooves, the listed below.
sealing rings, and the cartridge grooves. Lubri-
cate the end cover bore for the bolt.

S2 Chassis Maintenance Manual, October 2016 42/3

42 Brakes

Operational Tests Cut-In Position

1. Start the engine, build air pressure in the air Apply soap solution around the cover and to the ex-
brake system, and check the pressure registered haust port. Slight bubble leakage is permitted. Exces-
by a dash or test gauge at the time the governor sive leakage indicates either a faulty inlet valve or
cuts out, stopping the compression of air by the lower piston O-ring.
compressor. The cutout pressure should be in
accordance with the pressure setting of the piece Cutout Position
number being used. Common cutout pressures Apply soap solution around the cover and to the ex-
are between 125 to 135 psi (862 to 931 kPa). haust port. Slight bubble leakage is permitted. Exces-
With the engine still running, make a series of sive leakage indicates a faulty exhaust valve seat,
brake applications to reduce the air pressure and exhaust stem O-ring, or O-ring at the top of the
observe at what pressure the governor cuts in piston.
the compressor. As in the case of the cutout If the governor does not function as described or
pressure, the cut-in pressure should be in accor- leakage is excessive, it is recommended that it be
dance with the pressure setting of the piece replaced with a new or remanufactured unit, or re-
number being used. Cut-in pressure is 105 psi paired with genuine Bendix parts.
(724 kPa).
As in the case of the cutout pressure, the cut-in
pressure should be in accordance with the pres- 42–03 Hydraulic Brake Lining
sure setting of the piece number being used. Wear Checking
Cut-in pressure is 105 psi (724 kPa).
NOTE: If the governor cover is marked nonad- Before checking lining wear with the wheel removed,
justable and the adjusting stem has been review the following brake lining exposure warning.
sheared off, this is a non-serviceable governor
and must be replaced with a new or remanufac- WARNING
tured unit. Breathing brake lining dust (asbestos or non-
2. Never condemn or adjust the governor pressure asbestos) could cause lung cancer or lung dis-
settings unless they are checked with an accu- ease. Unless exposure can be reduced below legal
rate test gauge or a dash gauge that is register- limits, wear an air purifying respirator approved
ing accurately. If the pressure settings of the D-2 by MSHA or NIOSH at all times when servicing the
governor are inaccurate or it is necessary that brakes, starting with removal of the wheels and
they be changed, the adjustment procedure fol- continuing through assembly.
lows. 1. Chock the tires on the axle that isn’t being
2.1 Remove the top cover from the governor. worked on.
2.2 Loosen the adjusting screw locknut. 2. Remove the wheel and tire assemblies from the
axle that is not chocked.
2.3 To raise the pressure settings, turn the
adjusting screw counterclockwise. To 3. To minimize the possibility of creating airborne
lower the pressure settings, turn the ad- brake lining dust, clean the dust from the brake
justing screw clockwise. Be careful not to rotor, brake caliper, and brake assembly, using
overadjust. Each 1/4 turn of the adjusting an industrial-type vacuum cleaner equipped with
screw raises or lowers the pressure set- a high-efficiency filter system. Then, using a rag
ting approximately 4 psi (28 kPa). soaked in water and wrung until nearly dry, re-
move any remaining dust. Do not use com-
2.4 When proper adjustment is obtained,
pressed air or dry brushing to clean the brake
tighten the adjusting screw locknut and
assembly.
replace the cover. The pressure range
between cut-in and cut-out is not adjust- 4. Measure the thickness of the brake pads at each
able. end of the raised axle. Replace all of the pads at

42/4 S2 Chassis Maintenance Manual, October 2016

Brakes 42

both axle ends if any of the linings is worn to

less than 3/16 inch (4.8 mm) at the thinnest
point.
5. Make sure that the brake rotor and linings are 1
free of oil and grease.
6. Install the wheel and tire assemblies, then repeat
all of the above steps on the other axle.

42–04 Slack Adjuster

Lubricating
IMPORTANT: Perform MOP 42–15 before lubri-
cating the slack adjusters. 2

Automatic slack adjusters that have a grease fitting,

must be lubricated periodically to ensure proper
brake operation.

WARNING
02/01/2001 f421649a
Failure to lubricate slack adjusters could lead to
dragging brakes or a brake failure, resulting in 1. Grease Fitting 2. Slack Adjuster
property damage, personal injury, or death.
Fig. 3, Haldex Slack Adjuster Grease Fitting
Haldex Meritor
NOTICE NOTE: If equipped with an extended mainte-
nance Q Plus™ brake system, the slack adjuster
Do not use moly-disulfide-loaded grease or oil. will not have a grease fitting. These slack ad-
Both the life and reliability of the slack adjuster justers use a special NLGI Grade synthetic
will be reduced if this type of grease is used. polyurea grease and do not require lubrication
Lubricate the automatic slack adjuster at the grease for 3 years or 500,000 miles (800 000 km),
fitting. See Fig. 3. Use standard chassis lubricant for whichever comes first. Extended maintenance
Haldex slack adjusters. slack adjusters should be lubricated during
brake reline service. For service and lubrication
Gunite instructions, see Group 42 of the S2 Chassis
Workshop Manual.
For operating temperatures of –20°F (–29°C) and
higher, use Texaco Multifak EP-2 or Mobil Grease For slack adjusters with grease fittings and for oper-
No. 77. ating temperatures above –40°F (–40°C), use an
NLGI Grade 1 clay-base grease or an NLGI Grade 1
For operating temperatures between –20°F (–29°C) and 2 lithium-base grease.
and –40°F (–40°C), use Lubriplate Aero grease.
For slack adjusters with grease fittings, and for oper-
Gunite automatic slack adjusters are produced with- ating temperatures below –40°F (–40°C) and above
out a grease relief. During lubrication with a grease –65°F (–54°C), use a NLGI Grade 2 synthetic oil or a
gun, lubricant is forced through the drilled worm clay-base grease.
wheel onto the camshaft. Lubricate the automatic
slack adjuster at the grease fitting until grease ap- Lubricate the slack adjuster at the grease fitting until
pears on the camshaft. grease is forced past the pressure-relief capscrew or

S2 Chassis Maintenance Manual, October 2016 42/5

42 Brakes

past the gear splines around the inboard snap ring. 1

See Fig. 4.

1
3
2 2
2 3

3 5

5
6
7
7
6 7
10/20/93 f420012a 06/17/2010 f430511
1. Brake Chamber 5. Pull-Pawl Seal 1. Yoke 5. Boot
2. Clevis 6. Manual Adjusting Nut 2. Yoke Pin 6. Lube Fitting
3. Actuator Rod 7. Grease Fitting (or 3. Link Pin 7. Worm Gear
4. Boot plug) 4. Link
Fig. 4, Meritor Automatic Slack Adjuster Fig. 5, Bendix Automatic Slack Adjuster

Bendix For camshaft brackets with grease fittings, use an

NLGI Grade 1 or Grade 2 multipurpose chassis
Using a quality multipurpose chassis lubricant, NLGI grease.
Grade 2, lubricate the automatic slack adjuster
through the lube fitting. See Fig. 5. Lubricate the Lubricate the camshaft bushings through the grease
slack adjuster until clean lubricant flows from the fitting on the camshaft bracket or the spider until new
grease relief opening in the boot. grease flows from the inboard seal. See Fig. 6.
If grease leaks out under the camhead, the camshaft
42–05 Meritor Camshaft bracket grease seal is worn or damaged. See Group
42 of the S2 Chassis Workshop Manual for grease
Bracket Lubricating seal replacement instructions.

IMPORTANT: Perform MOP 42–15 before lubri- WARNING

cating the camshaft brackets.
If a worn or damaged camshaft bracket grease
NOTE: If equipped with an extended mainte- seal is not replaced, the brake linings could be-
nance Q Plus™ brake system, the camshaft come contaminated with grease. The stopping dis-
bracket will not have a grease fitting. These tance of the vehicle will be increased, which could
camshafts use a special NLGI Grade synthetic result in personal injury or property damage.
polyurea grease and do not require lubrication
for 3 years or 500,000 miles (800 000 km),
whichever comes first. Extended maintenance
camshaft bushings should be lubricated during
brake reline service. For service and lubrication
instructions, see Group 42 of the S2 Chassis
Workshop Manual.

42/6 S2 Chassis Maintenance Manual, October 2016

Brakes 42

• In areas where more than a 30-degree

range of temperature occurs in one day,
small amounts of water can temporarily
1 accumulate in the air brake system due to
condensation. Under these conditions, the
presence of small amounts of moisture is
normal.
3 NOTE: A small amount of oil in the system is
normal and should not be considered as a rea-
son to replace the desiccant cartridge. Some oil
2
at the dryer exhaust is normal.
2. Visually check for physical damage, such as
A chaffed or broken air and electrical lines and bro-
10/07/2016 f420011a ken or missing parts.
A. Grease Exit 3. Check mounting bolts for tightness. Torque 30 to
1. Brake Chamber 35 lbf·ft (41 to 47 N·m).
2. Slack Adjuster
3. Non-Pressure-Relief Grease Fitting 4. Perform the operational and leakage tests listed
below.
Fig. 6, Camshaft Bracket Lubricating
Operational and Leakage Tests
42–06 Air Dryer AD–9, AD–IP 1. Check all lines and fittings leading to and from
Checking the air dryer for leakage and integrity. Repair any
leaks found.
IMPORTANT: Review the warranty policy before 2. Build system pressure to governor cutout and
performing any intrusive maintenance proce- note that the dryer purges with an audible es-
dures. An extended warranty may be voided if cape of air. Watch the system pressure and note
intrusive maintenance is performed during this the pressure fall-off for a 10-minute period. If the
period. pressure drop exceeds 1 psi/minute from either
service reservoir, inspect the vehicle air systems
Because no two vehicles operate under identical
for sources of leakage and repair them. Refer to
conditions, maintenance and maintenance intervals
troubleshooting information in Bendix service lit-
will vary. Experience is a valuable guide in determin-
erature.
ing the best maintenance interval for any one particu-
lar operation. 3. Check for excessive leakage around the purge
valve with the compressor in the loaded mode
Every 3 months:
(compressing air). Apply a soap solution to the
1. Check for moisture in the air brake system by purge valve exhaust port and observe that leak-
opening reservoir drain valves and checking for age does not exceed a 1-inch (25-mm) bubble in
presence of water. If moisture is present, the 1 second. If the leakage exceeds the maximum
desiccant cartridge may require replacement; specified, refer to troubleshooting information in
however, the following conditions can also cause the Bendix service literature.
water accumulation and should be considered
4. Build system pressure to governor cutout and
before replacing the desiccant:
note that the dryer purges with an audible es-
• An outside air source has been used to cape of air. Fan the service brakes to reduce
charge the system. This air did not pass system air pressure to governor cut-in. Note that
through the drying bed. the system once again builds to full pressure and
• Air usage is exceptionally high and not nor- is followed by a dryer purge. If the system does
mal. This may be due to high air system not follow this pattern, refer to troubleshooting
leakage. information in the Bendix service literature.

S2 Chassis Maintenance Manual, October 2016 42/7

42 Brakes

5. Check the operation of the end cover heater and

thermostat assembly during cold weather opera-
42–08 Brake Pedal Linkage and
tion as follows: Mounting Plate
5.1 Electric Power to the Dryer: With the igni- Inspecting
tion in the ON position, check for voltage
to the heater and thermostat assembly Inspect the pedal, pedal linkage, and mounting plate
using a voltmeter or testlight. Unplug the assembly for proper operation to ensure that any
electrical connector at the air dryer and problems believed to be valve-related are not actu-
place the test leads on each of the con- ally mechanism issues.
nections of the female connector on the
vehicle power lead. If there is no voltage,
look for a blown fuse, broken wires, or 42–09 Air Brake Inspecting and
corrosion in the vehicle wiring harness. Leakage Testing
Check to see if a good ground path ex-
ists. IMPORTANT: There is no scheduled (Bendix) air
5.2 Thermostat and Heater Assembly Opera- valve maintenance that requires disassembly of
tion: These tests are not possible except the valve within the warranty period. If the valve
in cold weather operation. Turn off the does not function while within the warranty pe-
ignition switch and cool the thermostat riod, do not disassemble the part as this will
and heater assembly to below 40°F void the warranty.
(4°C). Using an ohmmeter, check the re-
sistance between the electrical pins in the If any of the tests in the following procedure fail,
air dryer connector half. The resistance refer to Group 42 of the S2 Chassis Workshop
should be 1.5 to 3.0 ohms for the 12-volt Manual to test individual air brake components
heater assembly and 6.0 to 9.0 ohms for and valves.
the 24-volt heater assembly.
NOTE: Some models of the AD–9 may WARNING
have a resistance reading of 1.0 to 2.5
ohms. Some steps in this operation require the parking
Warm the thermostat and heater assem- brakes to be released. Make sure the vehicle is on
bly to approximately 90°F (32°C) and a level surface and all tires are chocked. Failure to
again check the resistance. The resis- do so could result in the vehicle rolling, causing
tance should exceed 1000 ohms. If the personal injury and/or vehicle damage.
resistance values obtained are within the 1. Park the vehicle on a level surface, shut down
stated limits, the thermostat and heater the engine, apply the parking brake, and chock
assembly is operating properly. If the re- all tires.
sistance values obtained are outside the
stated limits, replace the heater and ther- 2. Completely drain all air reservoirs.
mostat assembly. 3. Install accurate test gauges in the primary and
secondary reservoirs.
42–07 Brake Lines and Fittings 4. Start the engine and run it at a fast idle.
Inspecting, Hydraulic 5. Record reservoir pressures when the low-
pressure warning turns off.
Brakes 6. Record governor cutout pressure and air dryer
Chock the tires, release the parking brake, and make purge pressure.
a full service brake application. 7. Reduce service air pressure by applying and re-
Replace damaged or leaking components, and leasing the service brakes several times, and
tighten loose fittings. record the governor cut-in pressure.

42/8 S2 Chassis Maintenance Manual, October 2016

Brakes 42

8. Charge the air system to governor cutout, shut 22. Drain all reservoirs, then remove the gauges
down the engine, and apply the parking brake. from the service reservoirs. Close the reservoir
9. Allow pressure to stabilize for one minute. drain cocks.

10. Observe the installed service reservoir gauges. 23. Remove the chocks from the tires.
Pressure should not drop more than 10 psi (69
kPa) within five minutes. 42–10 ABS Tone Rings
11. If necessary, start the engine and charge the air
system. Shut down the engine and release the
Cleaning
parking brake.
12. Make and hold a full service brake application, CAUTION
allowing the pressure to stabilize for one minute.
Observe the installed service reservoir gauges. An accumulation of road salt, dirt, and debris on
The pressure should not drop more than 15 psi the antilock braking system (ABS) tone rings and
(103 kPa) in five minutes. sensors can cause the ABS warning light to illumi-
nate.
13. With the air system at full pressure and the en-
gine idling, operate the parking brake control IMPORTANT: During winter months in areas
valve and note that all spring brake chambers where corrosive materials are used on the high-
apply and release the parking brake promptly as ways, periodically clean the underside of the
the control valve knob is pulled out and pushed vehicle to ensure proper ABS functioning. Thor-
in. oughly clean the wheel/ABS sensor/tone ring
14. Build air system pressure to cutout, then shut areas, removing all corrosive materials.
down the engine.
15. Completely drain the secondary (front axle) res- 42–11 Bendix Hydro-Max®
ervoir. On vehicles equipped with single check
valves, where the air dryer is not attached to the Brake System Inspecting
reservoir, the primary reservoir should not lose
pressure. 1. Check the fluid level in the hydraulic brake fluid
reservoir. If needed, fill the reservoir to the ridge
16. Make a service brake application. The rear axle that surrounds the reservoir. See Fig. 7. Use
brakes should apply and release, and brake only heavy-duty brake fluid, DOT 3.
lights should illuminate.
2. Check all hydraulic lines and fittings for damage,
17. Close the drain cocks, recharge the system, and leakage, or looseness.
completely drain the primary reservoir. On ve-
hicles equipped with single check valves, where Replace damaged or leaking components, and
the air dryer is not attached to the reservoir, the tighten loose fittings.
secondary reservoir should not lose air pressure. 3. Check the brake module for leaks. If leaks are
18. Start the engine and charge the air system until found, repair or replace the brake module. See
the governor cuts out. Group 42 of the S2 Chassis Workshop Manual
for replacement instructions, or take the vehicle
19. Shut down the engine and leave the parking to an authorized Freightliner Chassis dealer.
brake released.
4. Check the electrical connections and harnesses.
20. Completely drain the primary reservoir. Make sure the connectors are fully seated and
21. Make a modulated service brake application. the harnesses are not chafed or cut. Repair or
Both front and rear brakes should modulate. At a replace any damaged harness. Disconnect any
steady full brake application, pressure should not loose connectors and inspect the terminals for
drop more than 10 psi (69 kPa) within five min- corrosion. If corrosion is present, replace the ter-
utes. minals. If corrosion is not present, reconnect the
connector.

S2 Chassis Maintenance Manual, October 2016 42/9

42 Brakes

warning indicator light is not on. This is a

B dual indicator, and indicates that the park-
ing brake is set, and warns if there is a
Hydro-Max failure condition other than
loss of back-up motor power.

A
42–12 Brake Caliper Slide Pin
Lubricating, Bosch
Hydraulic Brakes
WARNING
Breathing brake lining dust (asbestos or non-
asbestos) could cause lung cancer or lung dis-
ease. Unless exposure can be reduced below legal
limits, wear an air purifying respirator approved
by MSHA or NIOSH at all times when servicing the
brakes, starting with removal of the wheels and
continuing through assembly.
NOTE: See the Bosch Pin Slide Disc Brakes
07/31/2015 f460513b Service Manual for more information.
A. Open caps and check fluid level. Apply 1/8 oz (3.5 g) Aeroshell Grade 5 grease to
B. Fill to this level. each of the two slide pin and slide pin bore sets. See
the Bosch Pin Slide Disc Brakes Service Manual for
Fig. 7, Hydraulic Brake Fluid Reservoir additional information.
5. Check the fuse for the hydraulic brake booster With ZOH-T calipers, install the solid pin (no bush-
pump, as follows. ing) only in the anchor plate leading hole position.
5.1 Open the cover to the main power distri- Install the pin with the rubber bushing and notches
bution module (PDM). only in the anchor plate trailing hole position. Tighten
the leading-side pin first, then tighten the trailing-side
5.2 Pull the fuse in position F6 for the Hydro- pin.
Max relay.
Tighten ZOH-T bolts 93 to 107 lbf·ft (126 to 145
5.3 Inspect the relay to make sure the fuse is N·m). See Fig. 8.
not damaged. If the fuse is damaged, in-
stall a new fuse. If the fuse is not dam-
aged, install the fuse in position F6. 42–13 Drum Brake Shoe Roller
5.4 Close the PDM cover. Lubricating
6. Check the operation of the Hydro-Max brake
booster, as follows.
WARNING
6.1 With the ignition off, depress the brake
pedal and listen for the back-up motor to Breathing brake lining dust (asbestos or non-
engage. The operator should also feel the asbestos) could cause lung cancer or lung dis-
pedal force relieve and the pedal should ease. Unless exposure can be reduced below legal
depress easily. limits, wear an air purifying respirator approved
by MSHA or NIOSH at all times when servicing the
6.2 With the engine running and the parking brakes, starting with removal of the wheels and
brake released, ensure that the BRAKE continuing through assembly.

42/10 S2 Chassis Maintenance Manual, October 2016

Brakes 42

8. Apply a good-quality, multipurpose chassis

grease to the retaining clips, brake spider, and
the shoe rollers where they contact the brake
shoes.

2
9. One at a time, pull each brake shoe away from
1 the cam and install the top and the bottom shoe
4
3 rollers.
10. Install the brake drums and the wheels.

DANGER
06/20/2002 f422357
1. Flanged Bolt 3. Trailing Pin Do not operate the vehicle until the brakes have
2. Leading Pin 4. Rubber Bushing been adjusted and checked for proper operation.
To do so could result in inadequate or no braking
Fig. 8, ZOH-T Slide Pins and Bolts ability, which could cause personal injury, or
death, or property damage.
1. Park the vehicle on a level surface. Shut down
the engine, set the parking brake, and chock the IMPORTANT: See the slack adjuster manufac-
tires. turer’s service information and adjust the brakes
2. Raise the front or the rear axle and then place at the slack adjusters.
safety stands under the frame or axle. Be sure 11. Remove the safety stands, lower the vehicle, and
that the stands will support the weight of the ve- remove the chocks from the tires.
hicle.
12. In a safe area, drive the vehicle and check for
3. Remove the wheels and the brake drums. proper brake operation.

CAUTION 42–14 Foot Brake Valve

Before you back off automatic slack adjusters, see
the slack adjuster manufacturer’s service informa-
Actuator Lubricating,
tion for instructions. Failure to do so could result Bendix E–6
in damage to the slack adjusters.
1. Remove the brake valve. For instructions, see
4. Back off the slack adjusters. Group 42 of the S2 Chassis Workshop Manual.
5. Push down on the bottom brake shoe and then 2. From the outside of the cab, pull the valve away
(by pulling on the roller-retaining clip) remove the from the frontwall and remove the brake plunger.
bottom cam roller.
3. Wipe off the old grease from the plunger and the
6. Lift the top brake shoe and then (by pulling on adaptor.
the roller-retaining clip) remove the top cam
roller. 4. Inspect the bore of the adaptor and the sliding
surface of the plunger. While some discoloration
7. Thoroughly clean the rollers, retaining clips, and is permissible, there should be no pitting or
the roller pin recesses in the brake shoes. roughness of the adaptor bore or the sliding sur-
face of the plunger. If pitting or roughness exists,
CAUTION replace damaged parts with new ones.
Do not apply grease to the outer diameters of the 5. Lubricate the adaptor bore and the sliding sur-
rollers (where they contact the cam head). face of the plunger with an approved silicone-
based grease, Dow Corning 55 O-Ring Lubricant
(formerly Molykote DC–55M), or Loctite® V–755
O-Ring Lubricant.

S2 Chassis Maintenance Manual, October 2016 42/11

42 Brakes

6. Using a new gasket, install the plunger and likely masking a mechanical problem. Adjustment
brake valve following the instructions in Group is not repairing. Before adjusting an automatic
42 of the S2 Chassis Workshop Manual. slack adjuster, troubleshoot the foundation brake
system and inspect it for worn or damaged com-
ponents. Improperly maintaining the vehicle brak-
42–15 Brake Inspecting ing system may lead to brake failure, resulting in
property damage, personal injury, or death.
IMPORTANT: This procedure should be per-
2. With the engine off, and 100 psi (689 kPa) of air
formed prior to lubrication of the brake compo- tank pressure, have an assistant apply and hold
nents. an 80 to 90 psi (550 to 620 kPa) brake applica-
tion.
Parking Brake Operational Check 3. Check to see if the colored over-stroke band on
each brake chamber pushrod is exposed.
CAUTION If a band shows, the stroke is too long. Check
Perform the following check in a clear safe area. If the foundation brake components for wear or
the parking brakes fail to hold the vehicle, per- damage, and repair as needed. See Group 42 of
sonal injury or property damage may result. the S2 Chassis Workshop Manual for inspection,
troubleshooting, and repair procedures.
1. With the engine running, and air pressure at cut-
out pressure, set the parking brake. 4. Measure the applied chamber stroke. See Table
1 for the proper stroke for the type of chamber
2. Put the vehicle in the lowest gear and gently at- being used. If the stroke is too short, the brakes
tempt to move it forward. The vehicle should not may drag or will not fully apply. Check the im-
move. If the vehicle moves, the parking brakes proper operation or adjustment of the automatic
are not operating correctly and must be repaired slack adjuster. See Group 42 of the S2 Chassis
before the vehicle is returned to service. See Workshop Manual for inspection and trouble-
Group 42 of the S2 Chassis Workshop Manual shooting procedures.
for repair procedures.
5. Start the engine and build air pressure to at least
Brake Component Inspection 100 psi (689 kPa). Shut down the engine.
6. Check all foundation brake components for dam-
1. Park the vehicle on a level surface, set the park- age, wear, and loose or missing parts. Repair as
ing brake, chock the tires. Once the tires are needed. See Group 42 of the S2 Chassis Work-
chocked, release the parking brake. shop Manual for repair procedures.

WARNING
Manually adjusting an automatic slack adjuster to
bring the pushrod stroke within legal limits is

42/12 S2 Chassis Maintenance Manual, October 2016

Brakes 42

Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
9
1-3/8 (35)
12
16
Standard Stroke 20 1-3/4 (44)
24
30 2 (51)
Gunite 36‡ 2 1/4 (57)
16
20
2 (51)
24 (2-1/2 inch rated
Long Stroke stroke)
24 (3 inch rated
stroke) 2 1/2 (64)
30
12 1-3/8 (35)
16
Standard Stroke
20 1-3/4 (44)
24
Haldex
2-1/2-Inch Extended Stroke 24 2 (51)
3-Inch Extended Stroke 24 2-1/2 (64)
Standard Stroke 30 2 (51)
Long Stroke 30 2-1/2 (64)
9
Less than 1-1/2 (38)
12
Standard Stroke 16
Less than 1-3/4 (44)
Meritor 20
24 Less than 1-7/8 (48)
Long Stroke 24
Less than 2 (51)
Standard Stroke 30
* Long stroke design is indicated by a tag, or embossing, on the brake chamber.
† Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.
‡ If type 36 chamber is used, slack length should be less than 6 inches.

Table 1, Brake Chamber Stroke Specifications

S2 Chassis Maintenance Manual, October 2016 42/13

42 Brakes

42–16 WABCO System Saver 4. Clean the top surface of the dryer base with a
commercial cleaning solvent.
Air Dryer Desiccant IMPORTANT: If the air dryer base is damaged,
Cartridge Replacing preventing a tight seal, replace the air dryer.
5. Using a multipurpose, high-temperature grease
NOTICE that resists water, steam, and alkali, lightly coat
the surfaces of the new O-ring and the dryer
The WABCO System Saver air dryers can use ei- base. Install the O-ring.
ther a standard or oil coalescing desiccant car- 6. Thread the desiccant cartridge onto the dryer
tridge. When replacing the desiccant cartridge, it base (turn clockwise). When the seal contacts
is very important to use the same type of car- the base, tighten the cartridge one complete turn
tridge that was originally installed on the dryer. Oil more. Do not overtighten.
coalescing cartridges can be used in any applica-
tion, but require more frequent service intervals
(every 1 to 2 years instead of every 2 to 3 years 42–17
for a standard cartridge). Do not replace an oil co-
alescing cartridge with a standard cartridge, as
this may result in contamination and malfunction-
ing of downstream air system components.
Refer to Fig. 9 for cartridge replacement.
1. Drain the air system.

2
3

10/07/2016 f421292
1. Seal 3. Air Dryer Base
2. O-Ring
Fig. 9, Desiccant Cartridge Replacement

2. Using a strap wrench, turn the desiccant car-

tridge counterclockwise and remove it.
3. Remove and discard the O-ring.

42/14 S2 Chassis Maintenance Manual, October 2016

Steering 46
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Drag Link Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01
Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05
Power Steering Fluid Level Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03
Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02
Power Steering Gear Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–00

S2 Chassis Maintenance Manual, October 2015

Steering 46

46–00 Safety Precautions 46–02 Power Steering Fluid

Safety Precautions in this section apply to all
and Filter Changing
procedures within this group.
WARNING
DANGER
Fill only with approved clean fluid. Failure to use
When working on the vehicle, shut down the en- the proper fluid could cause seal deterioration and
gine, set the parking brake, and chock the tires. leaks. Fluid leaks could eventually cause loss of
Before working under the vehicle, always place power steering assist. This could lead to an acci-
jack stands under the frame rails to ensure the dent resulting in personal injury or property dam-
vehicle cannot drop. Failure to follow these steps age. Wear eye protection when changing the fluid
could result in serious personal injury or death. and filter.
1. Apply the parking brakes and chock the rear
46–01 Drag Link Inspecting tires.
2. Place a drain pan under the power steering res-
ervoir.
WARNING 3. Remove the retaining ring from the reservoir.
All steering system components are critical for See Fig. 1.
safe operation of the vehicle. Failure to maintain
the steering system as specified may result in 3
2
loss of steering control, which could lead to per- 4
sonal injury and property damage.
Have someone turn the steering wheel from left to
right. Check for movement between the ball stud end
at both the pitman arm and the steering arm. Also
check if the ball stud nut is loose. 1
If the ball stud end is loose, replace the drag link. If
the ball stud nut is loose, replace the nut and cotter
pin. See Group 00 for torque specifications.
Inspect the boot of the drag link at both the pitman
arm and the steering arm end for cracks, splits, or
other damage. Replace the boot as needed. See
Group 46 of the S2 Chassis Workshop Manual for
10/19/2001 f461917
drag link removal and installation instructions.
1. Power Steering 3. Filter Cover
Grasp the drag link near the pitman arm end and Reservoir 4. Return Hose
move the drag link side to side to check for axial 2. Retaining Ring
movement in the ball stud end. If it is loose, replace
the drag link. See Group 46 of the S2 Chassis Fig. 1, Power Steering Reservoir
Workshop Manual for replacement instructions. If
there is 1/8-inch (3-mm) movement or more, do not 4. Remove the filter and filter cover from the reser-
drive the vehicle until the drag link is replaced. voir. Disconnect the filter from the filter cover and
discard the filter.
5. Remove the bolts, nuts, and washers that attach
the power steering reservoir to the mounting
bracket. Drain the fluid from the reservoir, but do
not remove the supply line to the reservoir.

S2 Chassis Maintenance Manual, October 2015 46/1

46 Steering

6. Using bolts, nuts, and washers, attach the reser- 3. Add or remove fluid as necessary to bring the
voir to the mounting bracket. fluid level between the MIN COLD and MAX
HOT lines. See Table 1 for approved power
7. Fill the reservoir with an approved power steer-
ing fluid to the line between the MIN COLD and steering fluids.
MAX HOT lines. See Fig. 1. See Table 1 for ap- 4. With the engine hot, the fluid level should be at
proved power steering fluids. the MAX HOT line with the engine off.
5. Add or remove fluid as necessary to bring the
Approved Power Steering Fluids fluid level to the MAX HOT line. See Table 1 for
Fluid Type* Approved Fluid* approved power steering fluids.
Automatic Transmission Dexron® III 6. Remove the chocks from the tires.
Fluid Dexron® II
* Do not mix fluid types. Refer to the text in this group for a detailed warn-
ing statement.
46–04 Power Steering Gear
Table 1, Approved Power Steering Fluids Lubricating
8. Raise the front of the vehicle and support it with
jack stands. TRW THP Series
9. Start the engine and operate it at idle. Turn the
steering wheel from full left and full right several CAUTION
times until clean fluid starts flowing from the
power steering filter. Add fluid to the reservoir to Apply grease to the sector shaft with only a hand-
maintain the fluid level between the MIN COLD type grease gun. Use of a high-pressure power
and MAX HOT lines. grease gun will supply grease too quickly and
could affect the high pressure seal, contaminating
10. Shut down the engine. Apply a thin film of power the hydraulic fluid.
steering fluid on the gasket of a new filter. Then
attach the filter to the filter cover. Make sure that Using a hand-type grease gun, apply NLGI Grade 2
the gasket under the filter cover is not damaged. or 3 multipurpose chassis grease until it starts to
If the gasket is damaged, replace it. Install the come out past the sector shaft seal.
gasket on the reservoir. Install the filter and filter
cover in the reservoir.
46–05 Drag Link Lubricating
11. Attach the retaining ring to the reservoir to se-
cure the filter and filter cover. 1. Using a clean rag, wipe all dirt from both drag
12. Start the engine and check that the power steer- link grease fittings.
ing fluid level is between the MIN COLD and 2. Using a pressure gun, apply grease at the
MAX HOT lines. Add more fluid if needed. grease fittings until old grease is forced out of
13. Raise the vehicle, remove the jack stands, and the socket. Use multipurpose chassis grease
lower the vehicle. NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease) or NLGI Grade 1 (6% 12-hydroxy lithium
14. Remove the chocks from the tires. stearate grease).
NOTE: NLGI Grade 2 is the preferred grade.
46–03 Power Steering Fluid
Level Inspecting
1. Apply the parking brake and chock the rear tires.
2. With the engine cool, the fluid level should be
between the MIN COLD and MAX HOT lines with
the engine off.

46/2 S2 Chassis Maintenance Manual, October 2015

Fuel 47
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fuel Filter Replacing, Propane Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–07
Fuel Rail Fitting and Injector Inspecting, Propane Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–06
Fuel Sender Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–04
Fuel Tank Band Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01
Fuel Tank and Line Inspecting, Propane Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–05
Fuel/Water Separator Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02
Inline Fuel Strainer Replacing, MBE900 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–00

S2 Chassis Maintenance Manual, February 2018

Fuel 47

47–00 Safety Precautions 3. Remove the element and bowl together by turn-
ing counterclockwise.
Safety Precautions in this section apply to all 4. Remove the bowl from the element and clean
procedures within this group. the O-ring gland.
5. Apply a coating of clean fuel or motor oil to the
DANGER new O-ring and element seal.
6. Spin the bowl onto the new element, then spin
When working on the vehicle, shut down the en-
them both onto the filter head snugly by hand
gine, set the parking brake, and chock the tires.
only.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the IMPORTANT: Do not use tools to tighten the
vehicle cannot drop. Failure to follow these steps bowl and element.
could result in serious personal injury or death.
7. Connect the water sensor and heater connectors
if so equipped.
47–01 Fuel Tank Band Nut 8. If equipped with a primer pump, loosen the vent
Tightening plug. Then operate the primer pump until the fuel
purges at the vent plug. See Fig. 1.
IMPORTANT: Do not overtighten the nuts. Close the vent plug.
Hold the retention nut on the fuel tank band with a 9. Start the engine and check for fuel leaks.
wrench while backing off the jam nut. Then tighten
the retention nut 13 to 17 lbf·ft (18 to 23 N·m). After 10. Shut down the engine and correct any fuel leaks.
the retention nut has been tightened, hold the reten-
tion nut with a wrench while tightening the jam nut 13 DAVCO Diesel Pro® 245
to 17 lbf·ft (18 to 23 N·m).
WARNING
47–02 Fuel/Water Separator Fluid circulated through the fuel/water separator
Element Replacing to heat the fuel may be diesel fuel returned from
the engine, or engine coolant. Drain the fuel/water
separator only when the engine and fluids have
Alliance cooled. Draining it when the engine is hot could
The only maintenance necessary on an Alliance cause severe personal injury due to scalding.
fuel/water separator is to replace the filter element. If returning fuel is released into the atmosphere,
its vapors can ignite in the presence of any igni-
WARNING tion source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
Diesel fuel is flammable and can ignite if exposed heat. To do so could cause fire, possibly resulting
to an open flame, intense heat, or other ignition in serious personal injury or property damage.
source. Do not drain fuel near, or expose fuel 1. Shut down the engine, apply the parking brake,
vapor to open flame or intense heat. Exposure to and chock the tires.
open flame or intense heat could start a fire, pos-
sibly resulting in personal injury or property dam- 2. Check the fuel level in the fuel filter. Replace the
age. When working on a fuel system, have a fire fuel/water separator element only when the filter
extinguisher within easy reach. element is completely covered. If the fuel level
has reached the top of the filter element, follow
1. Drain off some fuel by loosening the vent plug the procedure below to replace the element.
and opening the drain valve.
3. Put a clean receptacle under the fuel/water sepa-
2. Disconnect the water sensor and heater connec- rator and attach a piece of hose to the drain
tions if so equipped. valve, to direct fuel into the receptacle.

S2 Chassis Maintenance Manual, February 2018 47/1

47 Fuel

2 the fuel/water separator from sealing, and an air

leak may result.
1 3 8. Install the new filter and grommet assembly and
cover O-ring on the housing.
Position the filter element so the key is lined up
4
with the keyway on the separator plate of the
housing. Use the arrow on the top of the end-
plate to align the filter. See Fig. 4. Ensure the
filter element is fully seated by firmly pushing on
11 the endplate. The filter should not rotate freely.
9. Install the clear cover and the collar. Simultane-
ously apply downward pressure to the top of the
5 clear cover until it is seated on the body of the
lower housing and hand tighten the collar until it
10
no longer spins freely. Using the collar wrench,
tighten the cover 18 lbf·ft (24 N·m). This is
9 6 equivalent to rotating the collar clockwise two or
three additional ribs, depending on the specific
7 filter model.
10. Prime the system
8
06/25/97 f470147 10.1 Ensure that the drain valve is closed.
1. Mounting Head 7. Water Sensor Probe 10.2 Fill the housing to the top of the filter ele-
2. Fuel Primer Pump 8. Heater Connector ment with clean diesel fuel.
3. Vent Plug 9. Drain Plug
4. Bowl O-Ring 10. Sight Bowl 10.3 Install and hand-tighten the vent cap
5. Bowl Gasket 11. Filter Element O-ring and vent cap.
6. Bowl Probe Plug
10.4 Start the engine. When the lubricating oil
Fig. 1, Alliance Fuel/Water Separator reaches its normal operating pressure,
increase engine speed to high idle for
The drain valve has a 3/4-inch (19-mm) slip-on one to two minutes to purge air from the
hose connection. Open the drain valve by turning system.
it one to one-and-a-half revolutions.
10.5 While the engine is running, and after the
4. Remove the vent cap, shown in Fig. 2, to drain air is purged from the system, loosen the
the fuel completely, then close the drain valve. vent cap until the fuel level falls to just
5. Using a DAVCO Collar Wrench, shown in Fig. 3, above the collar, then hand-tighten the
remove the clear cover and collar. vent cap.
NOTE: Broken vent cap and collar warranty 10.6 Check for leaks and shut down the en-
claims will not be accepted if any tool other than gine.
a DAVCO Collar Wrench (part number 482017)
is used for removal. During installation, the vent DAVCO Fuel Pro® 382
cap is to be hand-tightened only, not tightened
with a wrench. WARNING
6. Remove the filter, cover O-ring, and vent cap Fluid circulated through the fuel/water separator
O-ring. Dispose of them in an environmentally to heat the fuel may be diesel fuel returned from
acceptable manner. See Fig. 2. the engine, or engine coolant. Drain the fuel/water
7. Clean all threads and sealing surfaces very thor- separator only when the engine and fluids have
oughly. Even a small amount of dirt will prevent

47/2 S2 Chassis Maintenance Manual, February 2018

Fuel 47

VENT CAP
FOR REMOVAL OF TOP COLLAR ONLY

02/16/2009 f470277

Fig. 3, DAVCO Collar Wrench

1. Arrow (on the 3. Separator Plate

endplate) 4. Key
2. Keyway 5. Endplate

Fig. 4, Positioning the Filter Element

cooled. Draining it when the engine is hot could

cause severe personal injury due to scalding.
If returning fuel is released into the atmosphere,
its vapors can ignite in the presence of any igni-
tion source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
heat. To do so could cause fire, possibly resulting
in serious personal injury or property damage.
1. Drain Valve Cap 7. Spring
2. Drain Valve 8. Clear Cover The filter element should be changed only when the
3. Inlet Port/Check Valve 9. Vent Cap O-Ring fuel level has reached the top of the filter element.
4. Lower Housing 10. Vent Cap There is no significant restriction to fuel flow until the
5. Filter Element 11. Collar element is completely clogged.
6. Cover O-Ring
Fig. 2, DAVCO Diesel Pro 245

S2 Chassis Maintenance Manual, February 2018 47/3

47 Fuel

1. Shut down the engine, apply the parking brake,

and chock the tires.
2. Check the fuel level in the fuel filter. Replace the 11
fuel/water separator element only when the filter
element is completely covered. If the fuel level
has reached the top of the filter element, follow
10
the procedure below to replace the element.
3. Put a clean receptacle under the fuel/water sepa- 9
rator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
The drain valve has a 1/2-inch (12.7-mm) pipe; 8
use a hose with a 1/2-inch pipe thread to fit cor-
rectly.
4. Remove the vent cap, shown in Fig. 5, Item 10,
and open the drain valve, shown in Fig. 5, Item
1, to drain the fuel completely, then close the
drain valve. 7

5. Using a DAVCO Collar Wrench, shown in Fig. 3,

remove the clear cover and collar.
NOTE: Broken vent cap and collar warranty
claims will not be accepted if any tool other than
6
a DAVCO Collar Wrench is used for removal.
During installation, the vent cap is to be hand-
tightened only, not tightened with a wrench.
12
Use part number 380134 on Fuel Pro 382 units.
6. Remove the filter, cover O-ring, and vent cap 5
O-ring. Dispose of them in an environmentally
acceptable manner. See Fig. 5.
7. Clean all threads and sealing surfaces very thor-
oughly. Even a small amount of dirt will prevent 4
the fuel/water separator from sealing, and an air
leak may result. 13

8. Install the grommet on the bottom of the new 3

filter. 14

9. Install the new filter and grommet assembly and 2

cover O-ring on the housing.
1
10. Install the clear cover and the collar. Simultane-
ously apply downward pressure to the top of the 12/13/2010 f470531a
clear cover until it is seated on the body of the 1. Drain Valve 8. Clear Cover
lower housing and hand tighten the collar until it 2. Bottom Plate 9. Vent Cap O-Ring
no longer spins freely. Using the collar wrench, Assembly 10. Vent Cap
tighten the cover 18 lbf·ft (24 N·m). This is 3. Bottom Plate O-Ring 11. Collar
equivalent to rotating the collar clockwise two or 4. Lower Housing 12. Grommet
three additional ribs, depending on the specific 5. Cover O-Ring 13. Inlet Port/Check Valve
filter model. 6. Filter Element 14. Heat Exchanger
7. Spring
11. Prime the system.
Fig. 5, DAVCO Fuel Pro 382

47/4 S2 Chassis Maintenance Manual, February 2018

Fuel 47

11.1 Ensure that the drain valve is closed. 47–05 Fuel Tank and Line
11.2 Fill the housing to the top of the filter ele- Inspecting, Propane
ment with clean diesel fuel.
11.3 Install and hand-tighten the vent cap
Engine
O-ring and vent cap.
11.4 Start the engine. When the lubricating oil WARNING
reaches its normal operating pressure,
increase engine speed to high idle for Liquid propane can cause serious burns should it
one to two minutes to purge air from the contact the skin or eyes. When handling propane,
system. always wear approved protective gloves and eye
protection to prevent contact.
11.5 While the engine is running, and after the
air is purged from the system, loosen the Propane is extremely flammable, and can ignite if
vent cap until the fuel level falls to about an ignition source is present, causing burns and
one inch (2.5 cm) above the collar, then other serious injuries. Keep sparks and flames
hand-tighten the vent cap. away from propane. Do not smoke near propane
or when refueling the vehicle.
11.6 Check for leaks and shut down the en-
gine. See the safety precautions listed in Chapter 19 of
the S2 Chassis Operator’s Manual, or take the ve-
hicle to an authorized Freightliner dealer. Failure
47–03 Inline Fuel Strainer to observe these precautions could lead to the
Replacing, MBE900 ignition of the liquid propane, which could cause
severe bodily harm, or death, or property damage.
Engine 1. Inspect the tank and fuel lines for damage.
NOTE: Vehicles with an MBE900 engine have 2. Inspect the brackets and fasteners to make sure
an inline fuel strainer, located on the left-hand the tank is securely fastened.
frame rail under the cowl area. 3. Ensure that all service valves and/or shut-off
1. Remove the brackets on each end of the fuel vales work properly.
strainer. 4. Make certain the pressure relief valve vent is
2. Remove the P-clip. clear of any obstructions. If equipped with a dust
cap, ensure that it is securely in place.
IMPORTANT: The fuel flow arrow on the fuel 5. Check the tank fittings, connections, and fuel
strainer must be pointed toward the front of the lines for leaks.
vehicle.
6. Check the solenoid wiring and connectors, mak-
3. Remove the strainer, and install a new one. ing certain they are securely attached and
4. Install the P-clip. locked.
5. Install the brackets on each end of the fuel
strainer. 47–06 Fuel Rail Fitting and
Injector Inspecting,
47–04 Fuel Sender Checking Propane Engine
1. Check the fuel sender connections for tightness,
and tighten if needed. Apply dielectric grease to WARNING
the connections if needed.
2. Check the fuel fill hose for tightness, and tighten Liquid propane can cause serious burns should it
if needed. contact the skin or eyes. When handling propane,

S2 Chassis Maintenance Manual, February 2018 47/5

47 Fuel

always wear approved protective gloves and eye fore it enters the engine. The replacement procedure
protection to prevent contact. that follows applies to both filters. See Fig. 6 and
Propane is extremely flammable, and can ignite if Fig. 7.
an ignition source is present, causing burns and IMPORTANT: Venting the fuel supply and return
other serious injuries. Keep sparks and flames lines must be performed outside. Do not release
away from propane. Do not smoke near propane propane inside a garage or building. Once the
or when refueling the vehicle. fuel lines are vented, the vehicle can be pulled
See the safety precautions listed in Chapter 19 of into the garage.
the S2 Chassis Operator’s Manual, or take the ve-
hicle to an authorized Freightliner dealer. Failure
to observe these precautions could lead to the
ignition of the liquid propane, which could cause
severe bodily harm, or death, or property damage.
NOTE: The fuel rails and injectors do not re-
quire any adjustments.
1. Make certain that all electrical connections are
connected and locked.
2. Make certain the fuel rail is securely attached to
the engine. 1
3. Use an electronic leak detector or a liquid-leak
detection solution to check all injectors, rails, and
fittings for fuel leaks.

47–07 Fuel Filter Replacing,

Propane Engine
WARNING
10/03/2013 f470611
Liquid propane can cause serious burns should it
contact the skin or eyes. When handling propane, 1. Propane Fuel Filter
always wear approved protective gloves and eye
protection to prevent contact. Fig. 6, Fuel Filter Location (fuel going in the tank)
Propane is extremely flammable, and can ignite if
an ignition source is present, causing burns and NOTICE
other serious injuries. Keep sparks and flames
away from propane. Do not smoke near propane Damage may occur to the valve(s) if they are over-
or when refueling the vehicle. tightened.
See the safety precautions listed in Chapter 19 of 1. Turn the fuel supply and return valves clockwise
the S2 Chassis Operator’s Manual, or take the ve- to shut them off at the tank.
hicle to an authorized Freightliner dealer. Failure NOTE: Both the fuel supply and return lines
to observe these precautions could lead to the must be vented to ensure all pressure is re-
ignition of the liquid propane, which could cause
severe bodily harm, or death, or property damage.
moved from the fuel rails and lines.
The propane system is equipped with two filters— 2. To vent the system, slowly crack open the fuel
one before the fuel enters the tank, and another be- supply and return lines that are connected to the
supply and return valves until a white mist ap-

47/6 S2 Chassis Maintenance Manual, February 2018

Fuel 47

10/03/2013 f470612

1. Propane Fuel Filter

Fig. 7, Fuel Filter Location (fuel going in the engine)

pears. Continue cracking the lines open until

there is absolutely no pressure.
3. Disconnect the fuel supply and return lines from
the valves until all service work is finished.
4. Cover the open lines to prevent contaminants
from entering the system.
5. Remove and discard the filter.
6. Install the new filter, making certain the arrow on
the filter points toward the tank or engine as ap-
plicable.
7. Connect both ends of the filter to the fuel line
and tighten 28±10 lbf·ft (38±14 N·m).
8. Remove the protective cover from the fuel lines.
9. Connect the fuel lines to their designated supply
and return valve. Tighten the fuel line flare nuts
13 lbf·ft (18 N·m).

NOTICE
Damage may occur to the valve(s) if they are over-
tightened.
10. Turn the fuel supply and return valves counter-
clockwise, then start the vehicle in order to
charge the fuel lines with propane.
11. Check for leaks using an electronic leak detector
or a liquid-leak detection solution.

S2 Chassis Maintenance Manual, February 2018 47/7

Exhaust 49
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Exhaust System Inspecting (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–00

S2 Chassis Maintenance Manual, December 2015

Exhaust 49

49–00 Safety Precautions • BlueTec®—Daimler’s proprietary SCR technol-

ogy.
Safety Precautions in this section apply to all • Diesel Oxidation Catalyst (DOC)—a flow-
procedures within this group. through device that enhances the oxidation of
hydrocarbons in the ATD.
DANGER • Diesel Particulate Filter (DPF)—a component in
the ATD that traps particulate matter from the
When working on the vehicle, shut down the en- exhaust gas.
gine, set the parking brake, and chock the tires.
• Diesel Exhaust Fluid (DEF)—the chemical agent
Before working under the vehicle, always place
that reacts with the exhaust gases in the SCR
jack stands under the frame rails to ensure the
to reduce NOx.
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. • DEF Pump—filters and supplies DEF to the
DEF metering unit.
49–01 Exhaust System • DEF Tank—holds DEF and regulates its tem-
perature.
Inspecting (Noise • DEF Metering Unit—mixes DEF with com-
Emission Control) pressed air, and meters this mixture into the
exhaust flow via an injection nozzle.
The exhaust system must be free of leaks, binding,
• SCR Catalyst—the housing containing a treated
grounding, and excessive vibrations. In addition to
ceramic flow-through block where the DEF and
inspecting the exhaust system at the scheduled
exhaust gases undergo selective catalytic re-
maintenance interval, inspect the exhaust system if
duction.
the noise level of the vehicle has increased. Replace
parts that show leakage, wear, or damage, with • Selective Catalytic Reduction (SCR)—a process
genuine Freightliner parts. used to reduce NOx emissions.
These conditions are usually caused by loose, bro- Inspection
ken, or misaligned clamps, brackets, or pipes. If any
of these conditions exist, check the exhaust system IMPORTANT: The Environmental Protection
components and alignment. Align or replace as nec- Agency’s 2010 regulations mandate lowered
essary. For alignment or adjustment instructions, see exhaust emissions, thus requiring exhaust sys-
Group 49 of the S2 Chassis Workshop Manual, or tem components that reduce emissions. In par-
take the vehicle to an authorized Freightliner dealer.
ticular the aftertreatment device (ATD), which is
part of the aftertreatment system (ATS), requires
EPA10 and Newer Exhaust special attention during regularly scheduled
System maintenance inspections. See Fig. 1 for Cum-
mins ATD sensor locations. An inline ATS is
Definitions of Aftertreatment shown; actual ATS design may vary. If any dis-
System (ATS) Terms crepancies are discovered, refer to the engine
Refer to the following list of definitions of ATS terms manufacturer’s service literature for repair
and components. instructions.
• Aftertreatment System (ATS)—the entire ex- 1. Check for leakage at the clamp that attaches the
haust system from the turbocharger to the tail exhaust pipe to the turbocharger exhaust outlet.
pipe, including the Selective Catalytic Reduction If leakage exists, tighten the nut on the clamp to
(SCR) components. the required torque. If leakage persists, install a
new clamp.
• Aftertreatment Device (ATD)—a device that re-
moves pollutants from exhaust gas after the gas 2. Check the exhaust pipe, bellows, and each ex-
leaves the combustion chamber. haust seal clamp for leakage, wear, cracks, or

S2 Chassis Maintenance Manual, December 2015 49/1

49 Exhaust

10

9
7

6 8

1 3

10/20/2009 f490385

1. DOC Inlet Temperature Sensor 4. DPF Temperature Sensor 8. SCR Temperature Sensor
2. DOC Outlet Temperature Interface 9. Outlet NOx Sensor
Sensor 5. DPF Pressure Sensor Interface 10. SCR Outlet Temperature
3. DPF Outlet Temperature 6. Doser Interface Sensor
Sensor 7. SCR Inlet Temperature Sensor
Fig. 1, Cummins ATD Sensor Locations (inline ATS shown—design may vary)

damage. Replace damaged components as 3. If present, check the condition of the insulation
needed. If leakage exists at a clamp, tighten the material around the exhaust pipe between the
nuts to the required torque. If leakage persists, turbocharger and the ATD.
install a new exhaust seal clamp. Do not reuse 4. Check the ATD mounting bands for tightness.
seal clamps. Once a seal clamp is loosened or
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
removed, it must be replaced.
overtighten.

49/2 S2 Chassis Maintenance Manual, December 2015

Exhaust 49

5. Check for leaks around the clamps that attach • Aftertreatment System (ATS)—the entire ex-
the ATD in the ATS, and around the clamps that haust system from the turbocharger to the ex-
retain the DPF in the ATD. No leaks are allowed haust stack or tail pipe.
anywhere in the system. • Aftertreatment Device (ATD)—a muffler-like can-
6. Check all sensors attached to the ATD for leaks ister that houses a DPF and sensors.
or damaged wires. No leaks are allowed. • Diesel Particulate Filter (DPF)—a filter that col-
7. Check the DPF exterior surface for dents or lects and holds particulate matter (soot and
other damage. A dent over 3 inches (76 mm) in ash).
diameter and 1/4-inch (6-mm) deep could cause • Diesel Oxidation Catalyst (DOC)—oxidizes hy-
internal damage to the DPF, causing it to mal- drocarbons and reduces NOx.
function.
• Sensors—detect temperatures and pressures in
8. Check the SCR catalyst for dents and other the ATS.
damage.
9. Check for heat discoloration on the surface of IMPORTANT: The Environmental Protection
the ATD. Heat discoloration may indicate internal Agency’s 2007 regulations require lower ex-
damage; especially around the DPF. haust emissions, thus requiring new exhaust
system components. See Fig. 2. In particular
NOTE: Diesel exhaust fluid creeps, causing the aftertreatment device (ATD), which is part of
white crystals to form around the line fittings. the aftertreatment system (ATS), requires spe-
The presence of crystals does not mean the cial attention during regularly scheduled mainte-
system has a leak. Replacing fittings or trouble- nance inspections. If any discrepancies are dis-
shooting components is not necessary unless covered, refer to the engine manufacturer’s
there is a system failure or a fault code. service literature for repair instructions.
10. Check the DEF tank, pump, metering unit, and
lines for leaks. See Group 49 of the S2 Chassis Inspection
Workshop Manual for repair procedures. 1. Check for leakage at the clamp that attaches the
11. Check any wires, lines, or hoses within 4 inches exhaust pipe to the turbocharger exhaust outlet.
(10 cm) of the exhaust system for heat damage. If leakage exists, tighten the nut on the clamp to
Repair or reroute as needed. the required torque. If leakage persists, install a
new clamp.
Diesel Exhaust Fluid (DEF) Filter 2. Check the exhaust pipe, bellows, and each ex-
Replacement haust seal clamp for leakage, wear, cracks, or
The Environmental Protection Agency’s 2010 regula- damage. Replace damaged components as
tions require lower nitrogen oxide (NOx) exhaust needed. If leakage exists at a clamp, tighten the
emissions. Selective catalytic reduction (SCR) uses nuts to the required torque. If leakage persists,
diesel exhaust fluid (DEF) to lower NOx emissions in install a new exhaust seal clamp. Do not reuse
the vehicle exhaust. A filter in the DEF pump pre- seal clamps. Once a seal clamp is loosened or
vents clogging of the DEF metering unit injection removed, it must be replaced.
nozzle. 3. If present, check the condition of the insulation
See the engine manufacturer’s maintenance manual material around the exhaust pipe between the
for DEF filter replacement instructions and mainte- turbocharger and the ATD.
nance intervals. 4. Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
EPA07 Exhaust System overtighten.
5. Check for leaks around the clamps that attach
Definitions of ATS Terms the ATD in the ATS, and around the clamps that
Refer to the following list of definitions of ATS terms retain the DPF in the ATD. No leaks are allowed
and components. anywhere in the system.

S2 Chassis Maintenance Manual, December 2015 49/3

49 Exhaust

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 Junction Box
2. Temperature Sensor 7. 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. 2, Typical Aftertreatment Device

6. Check all sensors attached to the ATD for leaks

or damaged wires. No leaks are allowed.
7. Check the DPF exterior surface for dents or
other damage. See Fig. 2, item A. A dent over 3
inches (76 mm) in diameter and 1/4-inch (6mm)
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.

49/4 S2 Chassis Maintenance Manual, December 2015

Electrical, Instruments, and Controls 54
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Battery Voltage Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–01

S2 Chassis Maintenance Manual, August 2008

Electrical, Instruments, and Controls 54

54–01 Battery Voltage

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

S2 Chassis Maintenance Manual, August 2008 54/1

Cab 60
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Mirror Folding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–01

S2 Chassis Maintenance Manual, January 2011

Cab 60

60–01 Mirror Folding Check

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

S2 Chassis Maintenance Manual, January 2011 60/1

Doors 72
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Door Seals Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-01

S2 Chassis Maintenance Manual, November 2014

Doors 72

72-01 Door Seals Lubrication

NOTE: The main entry door, rear emergency
exit, and emergency hatch seals require lubrica-
tion. Do not lubricate the door latches or hinges.
They come from the manufacturer with lifetime
lubrication and do not require maintenance.
Lightly coat the door seals with a lubricant that is
safe for rubber (as recommended by the lubricant
manufacturer).

S2 Chassis Maintenance Manual, November 2014 72/1

Heater and Air Conditioner 83
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01
HVAC Air Filter Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–00

S2 Chassis Maintenance Manual, October 2015

Heater and Air Conditioner 83

83–00 Safety Precautions clutch, gently tap down at the high areas. If the
overall gap is out of spec, remove the drive plate
assembly and change the shims as necessary.
Safety Precautions in this section apply to all For instructions, see the applicable section in
procedures within this group. Group 83 of the vehicle Workshop Manual, or
take the vehicle to an authorized Freightliner
DANGER dealer.

When working on the vehicle, shut down the en- 9. Check that the wiring harness connector is not
gine, set the parking brake, and chock the tires. damaged or loose. Replace the wiring harness if
Before working under the vehicle, always place it is damaged.
jack stands under the frame rails to ensure the 10. Check the overall condition of the air conditioning
vehicle cannot drop. Failure to follow these steps hoses. Look for cracks, cuts, and abrasions on
could result in serious personal injury or death. the hoses. Replace damaged hoses.
11. Check for a buildup of road debris on the con-
83–01 Air Conditioner denser fins. Using air pressure and a whisk
broom or a soapy spray of water, carefully clean
Inspection the condenser. Be careful not to bend the fins.
1. Park the vehicle on a level surface, shut down 12. Close the hood.
the engine, and set the parking brake. Chock the
tires. 83–02 HVAC Air Filter Cleaning
2. Operate the heater and, if so equipped, the air
conditioner, to check for proper operation in all The HVAC air filter must be cleaned every 12
modes. months or 8000 miles (12 872 km), whichever comes
first, to permit proper operation of the HVAC system.
3. Open the hood.
1. Park the vehicle on a level surface, shut down
4. Check the condition of the refrigerant compres-
the engine, and set the parking brake. Chock the
sor clutch assembly for visible signs of damage
tires.
due to excessive heat. If the friction surface of
the pulley shows signs of excessive grooving 2. Disconnect the batteries.
due to belt slippage, replace both the pulley and 3. Remove the three lower HVAC cover Torx
the drive plate. screws; two at the bottom of the cover and one
5. Inspect the refrigerant compressor drive belt for on the right. Remove the cover.
damage, and replace it if necessary. 4. Disconnect the wiring harness from the evapora-
6. Check the tightness of the compressor mounting tor probe, if equipped with air conditioning.
fasteners. The torque value for the mounting fas- 5. Remove the capscrews that attach the evapora-
teners is 15 to 19 lbf·ft (20 to 26 N·m). tor service cover to the HVAC assembly. Remove
7. Inspect the drive plate. If the friction surface of the evaporator service cover. See Fig. 1.
the drive plate shows visible signs of damage 6. Pull the filter out of the HVAC assembly. See
due to excessive heat, make sure the refrigerant Fig. 2.
compressor turns freely. If the compressor does
not turn freely, the compressor should be re- 7. Clean the filter with a warm detergent solution.
placed. For instructions, see the applicable sec- Dry the filter before installing it.
tion in Group 83 of the vehicle Workshop 8. Install the filter in the HVAC assembly.
Manual, or take the vehicle to an authorized
Freightliner dealer. 9. Remove the condensate seal from the evapora-
tor service cover and install a new condensate
8. Using a feeler gauge, check that the drive plate seal on the cover.
clutch clearance is 0.016 to 0.031 inch (0.4 to
0.8 mm). If the gap is not even around the

S2 Chassis Maintenance Manual, October 2015 83/1

83 Heater and Air Conditioner

09/21/2006 f831707

Fig. 1, HVAC Cover Removal

09/22/2006 f831706

Fig. 2, HVAC Assembly Filter Removal

10. Using capscrews, attach the evaporator service

cover to the HVAC assembly.
11. Connect the wiring harness to the evaporator
probe.
12. Attach the lower HVAC cover to the dash panel.
Install the three Torx screws; two at the bottom
of the cover and one on the right.
13. Connect the batteries.

83/2 S2 Chassis Maintenance Manual, October 2015

Hood, Grille, and Cab Fenders 88
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88–01

S2 Chassis Maintenance Manual, November 2014

Hood, Grille, and Cab Fenders 88

88–01 Hood Rear Support

Lubrication
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. Open the hood.
3. Clean both the hood- and cab-mounted hood
rear support components with a soapy water so-
lution.
4. Cover all contact surfaces of the hood rear sup-
port brackets and isolators with an approved
multi-purpose, lithium-complex, soap-based
grease; see Table 1.
5. Close the hood.

Approved Suppliers of Multi-Purpose Lithium Grease

Supplier Grease
Chevron Delo Heavy Duty EP
Exxon Unirex EP2
Mobil Mobil Grease XHP 222
Shell Retinax LC Grease
Texaco Starplex 2
Table 1, Approved Suppliers of Multi-Purpose Lithium
Grease

S2 Chassis Maintenance Manual, November 2014 88/1