FL772 Brake Cali

Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A-KK K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Subject: Brake Caliper Mounting Bolts
Models Affected: Specific Freightliner Business Class M2, Cascadia, Columbia, 108SD, and 114SD vehicles; Western Star 4700,
4900, and 5700 vehicles; Freightliner Custom Chassis B2, S2C,
S2G, XB and XC Chassis; and Thomas Built Buses Saf-T Liner
C2, EFX, and HDX buses manufactured January 3, 2017, through
October 31, 2017, and equipped with air disc brakes
General Information
Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division and wholly owned
subsidiaries, Western Star Truck Sales, Inc., Freightliner Custom Chassis Corporation, and Thomas Built Buses,
has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.
There are approximately 12,202 vehicles involved in this campaign .
On certain vehicles, insufficiently torqued caliper mounting bolts may not provide adequate clamping force
between the brake caliper and brake anchor plate, potentially resulting in reduced brake effectiveness, which
could lead to a crash.
Caliper mounting bolts will be inspected, torqued, or replaced as needed.
Additional Repairs
Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a
vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns
before sale or delivery of a vehicle.
Owners may be liable for any progressive damage that results from failure to complete campaigns within a
reasonable time after receiving notification.
Work Instructions
Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a
completion sticker (Form WAR260).
Replacement Parts
Replacement parts are now available and can be obtained by ordering the part number(s) listed below from
your facing Parts Distribution Center. TBB and DTNA part numbers are interchangeable as noted in parts table.
If our records show your dealership has ordered any vehicles involved in campaign number FL772, a list of the
customers and vehicle identification numbers will be available in OWL. Please refer to this list when ordering
parts for this recall.
Table 1 - Replacement Parts for FL772A-K
Campaign
Number
FL772A
FL772B
FL772C
Part Description
Part Number
SCRW HX,SCKTHD,M16-2X110,12.9
SCREW-CAP,HEX,M20X60,10.9,P/O
WASHER-HRDN,0.81X1.47X.177,ZN
SCRW HX,SCKTHD,M16-2X110,12.9
BOLT-HEX,PC10.9,PO,M20X1.5X55
23-13315-110
N210931 020001
23-09114-004
23-13315-110
23-14285-055
Table 1, Continued on page 2
Page 1
Qty. per Caliper
6
6
6
6
6
ea
ea
ea
ea
ea
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Campaign
Number
Part Description
Part Number
FL772D
KIT-MER ADB-L, HARDWARE
TDA 41X1801
1 ea
FL772E
SCREW-CAP,SKT HD,M20X1.5X70
SCREW-CAP,HEX,M20X60,10.9,P/O
23-13843-070
N210931 020001
6 ea
WASHER-HRDN,0.81X1.47X.177,ZN
SCREW-CAP,HEX,M20,10.9,ZN,YL
23-09114-004
23-12893-060
6 ea
WASHER-HRDN,0.81X1.47X.177,ZN
23-09114-004
6 ea
FL772F
FL772G
Qty. per Caliper
6 ea
FL772H
SCRW HX,SCKTHD,M16-2X110,12.9
23-13315-110
6 ea
FL772I
SCREW-CAP,HEX,M20X60,10.9,P/O
or
SCREW-CAP,HEX,M20,10.9,ZN,YL
N210931 020001
or
23-12893-060
6 ea
FL772J
WASHER-HRDN,0.81X1.47X.177,ZN
SCRW HX,SCKTHD,M16-2X110,12.9
23-09114-004
23-13315-110
6 ea
6 ea
SCREW-CAP,HEX,M20X60,10.9,P/O
TBB 203044
or
N210931 020001
WASHER-FLAT, HARDENED,M20,ZN
TBB 61370288
or
N221822 020000
TOOL-ADAPTER, WRENCH, ADB 225
TDA 3256B1354
FL772K
FL772A-K
6 ea
1 ea
Table 1, Continued from page 1
Removed Parts
U.S. and Canadian Dealers, please follow Warranty Failed Parts Tracking shipping instructions for the
disposition of all removed parts. Export distributors, please destroy removed parts unless otherwise advised.
Labor Allowance
Table 2 - Labor Allowance
Campaign
Number
FL772A-E
(Trucks)
FL772A-E
(Trucks)
FL772F-K
(RVs and Buses)
FL772F-K
(RVs and Buses)
FL772A-K
(All Vehicles)
FL772A-K
(All Vehicles)
FL772A-K
(All Vehicles)
Procedure
Time Allowed
(hours)
SRT Code
Corrective Action
Inspect caliper bolts, 2 axles
2.0
996-R048A
06-Inspect Recall/Campaign
Inspect caliper bolts, second rear axle
1.1
996-R048B
06-Inspect Recall/Campaign
Inspect caliper bolts, 1 axle,
with radial runout check
1.2
996-R048D
06-Inspect Recall/Campaign
Inspect caliper bolts, 2 axles,
with radial runout check
2.4
996-R048E
06-Inspect Recall/Campaign
Inspect and torque caliper bolts, 2 axles
2.0
996-R048F
12-Repair Recall/Campaign
Torque caliper bolts, second rear axle
1.1
996-R048G
12-Repair Recall/Campaign
Replace caliper bolts, 1 caliper
(claim this SRT once for each caliper
requiring new bolts , up to 6 times)
0.5
996-R048C
12-Repair Recall/Campaign
Table 2
Page 2
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
IMPORTANT: When the Recall has been completed, locate the base completion label in the appropriate location on the vehicle, and attach the red completion sticker provided in the recall kit (Form WAR260). If the vehicle does not have a base completion label, clean a spot on the appropriate location of the vehicle and first
attach the base completion label (Form WAR259). If a recall kit is not required or there is no completion sticker
in the kit, write the recall number on a blank sticker and attach it to the base completion label.
Claims for Credit
You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting
your claim through the Warranty system within 30 days of completing this campaign. Please reference the
following information in OWL:
• Claim type is Recall Campaign.
• In the FTL Authorization field, enter the campaign number and appropriate condition code (e.g. FL772-A,
FL772-B, etc.).
• In the Primary Failed Part Number field, enter 25-FL772-000.
• In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table.
• In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. Administrative time will
be included automatically as SRT 939-0010A for 0.4 hours for RVs or 0.3 hours for all other vehicles.
Some SRTs are optional, and if needed, must be added manually.
• The VMRS Component Code is 013-001-129 and the Cause Code is A1 - Campaign.
• U.S. and Canada -- Reimbursement for Prior Repairs. When a customer asks about reimbursement,
please do the following:
• Accept the documentation of the previous repair.
• Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement. (See the "Copy of Owner Letter" section of this bulletin for reimbursement guidelines.)
• Submit an OWL Recall Pre-Approval Request for a decision.
• Include the approved amount on your claim in the Other Charges section.
• Attach the documentation to the pre-approval request.
• If approved, submit a based on claim for the pre-approval.
• Reimburse the customer the appropriate amount.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the
campaign has not been previously completed. Also, check for a completion sticker prior to beginning work.
U.S. and Canadian dealers, contact the Warranty Campaigns Department via Web inquiry at
DTNAConnect.com / WSC, or the Customer Assistance Center at (800) 385-4357, after normal business hours,
if you have any questions or need additional information. Export distributors, submit a Web inquiry or contact
your International Service Manager.
U.S. and Canadian Dealers: To return excess kit inventory related to this campaign, U.S. dealers must submit a
Parts Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing
PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number.
Export Distributors: Excess inventory is not returnable.
Page 3
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
The letter notifying U.S. and Canadian vehicle owners is included for your reference.
Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code,
Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to
you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie
evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day
period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the
vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in
full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless
all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the
lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors
and retail outlets within five working days.
Page 4
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Copy of Notice to Owners
Subject: Brake Caliper Mounting Bolts
For the Notice to U.S. Customers: This notice is sent to you in accordance with the National Traffic and Motor
Vehicle Safety Act. For the Notice to Canadian Customers: This notice is sent to you in accordance with the
Canadian Motor Vehicle Safety Act.
Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division and wholly owned
subsidiaries, Western Star Truck Sales, Inc., Freightliner Custom Chassis Corporation, and Thomas Built Buses,
has decided that a defect that relates to motor vehicle safety exists on specific Freightliner Business Class M2,
Cascadia, Columbia, 108SD, and 114SD vehicles; Western Star 4700, 4900, and 5700 vehicles; Freightliner
Custom Chassis B2, S2C, S2G, XB and XC chassis; and Thomas Built Buses Saf-T Liner C2, EFX, and HDX
buses manufactured January 3, 2017, through October 31, 2017, and equipped with air disc brakes.
On certain vehicles, insufficiently torqued caliper mounting bolts may not provide adequate clamping force
between the brake caliper and brake anchor plate, potentially resulting in reduced brake effectiveness, which
could lead to a vehicle crash.
Caliper mounting bolts will be inspected, torqued, or replaced as needed.
This is the second notice regarding this recall. The repair is available and you may now contact an
authorized Daimler Trucks North America dealer to arrange to have the Recall performed and to ensure that
parts are available at the dealership. To locate an authorized dealer, search on-line at
www.Daimler-TrucksNorthAmerica.com. On the menu tab, select “Contact,” scroll down to “Find a Dealer,” and
select the appropriate brand. The Recall will take up to four hours, depending on the work needed, and will be
performed at no charge to you.
You may be liable for any progressive damage that results from your failure to complete the Recall within a
reasonable time after receiving notification.
If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall
Notification, please return the notification to the Warranty Campaigns Department with any information you can
furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that
you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law
requires that you forward this notice to your distributors and retail outlets within five working days. If you have
paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement.
Please see the reverse side of this notice for details.
For the Notice to U.S. Customers: If you have questions about this Recall, please contact the Warranty
Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail
address [email protected], or the Customer Assistance Center at (800) 385-4357 after
normal business hours. If you are not able to have the defect remedied without charge and within a reasonable
time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration,
1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236
(TTY: (800) 424-9153); or to http://www.safercar.gov. For the Notice to Canadian Customers: If you have
questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m.
to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected], or
the Customer Assistance Center at (800) 385-4357 after normal business hours.
We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle
safety.
WARRANTY CAMPAIGNS DEPARTMENT
Enclosure
Page 5
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Reimbursement to Customers for Repairs
Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the
repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following
documentation must be presented to your dealer for consideration for reimbursement.
Please provide original or clear copies of all receipts, invoices, and repair orders that show:
• The name and address of the person who paid for the repair
• The Vehicle Identification Number (VIN) of the vehicle that was repaired
• What problem occurred, what repair was done, when the repair was done
• Who repaired the vehicle
• The total cost of the repair expense that is being claimed
• Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt)
Reimbursement will be made by check from your Daimler Trucks North America LLC dealer.
Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter.
Page 6
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Work Instructions
Subject: Brake Caliper Mounting Bolts
Models Affected: Specific Freightliner Business Class M2, Cascadia, Columbia, 108SD, and 114SD vehicles; Western Star 4700,
4900, and 5700 vehicles; Freightliner Custom Chassis B2, S2C,
S2G, and X-Line Chassis; and Thomas Built Buses Saf-T Liner
C2, EFX, and HDX buses manufactured January 3, 2017, through
October 31, 2017, and equipped with air disc brakes
General Procedure
IMPORTANT: Vehicles may have both axial and radial mounted calipers. Please follow the work instructions for
each calipers type - Bendix, Meritor, or Wabco and axial or radial.
1. Check the base label (Form WAR259) for a completion sticker for FL772 (Form WAR260) indicating this
work has been done. On trucks, the base label is usually located on the passenger-side door, about 12 inches
(30 cm)below the door latch, Motorhomes: on the front wall under the dash, Buses: above the driver's window.
If a sticker is present for FL772, no work is needed. If there is no sticker, proceed with the next step.
2. Park the vehicle on a level surface, shut down the engine, and set the parking brake and chock the tires.
DANGER
When working on the vehicle, shut down the engine, 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.
3. Raise the vehicle and support it on jack stands.
NOTE: FL772A-E For trucks, go to pages 8-20. Follow the appropriate procedure for each type of caliper to be
inspected (Bendix axial mounted or radial mounted on page 8 or 10, Meritor axial or radial mounted on page 12
or 13, Wabco Maxxus radial mounted on page 16). FL772F-K For motorhomes and buses, go to page 20.
Page 7
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Bendix Axial Mounted Calipers
1. Remove all of the wheel assemblies.
2. Use the Meritor extension tool TDA 3256B1354 and a torque wrench set to 375±25 lbf·ft (508±34 N·m) and
tighten the caliper mounting bolts. See Table 3. If they do not turn, go to step 10. If they turn, go to step 3.
Torque Compensation with Meritor Extension Tool TDA 3256B1354
11/11/2016
All torque settings are ±40 lbf·ft (±54 N·m)
Angle View
Extension Angle
(degrees)
1. Remove all of the wheel assemblies.
f422612
Wrench Length
Target Torque
Tool Setting
[inches (cm)]
[lbf·ft (N·m)]
[lbf·ft (N·m)]
0°
11/28/2016
0
334 (453)
45
364 (494)
f422613
45°
11/28/2016
f422614
43.5 (110.5)
400 (542)
90°
11/28/2016
90
400 (542)
135
444 (602)
f422615
135°
11/28/2016
f422616
* Compensation is calculated for a 43.5 inch (110.5 cm) nominal torque wrench using Meritor extension tool 3256B1354 at various angles.
Table 3, Torque Compensation with Meritor Extension Tool 3256B1354
Page 8
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
3. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
4. Remove the brake pads.
5. Remove caliper bolts.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
6. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque
plate, then install the caliper/carrier assembly using new caliper mounting bolts. See Fig. 1.
7. Tighten the carrier mounting bolts in two steps as follows. See Fig. 1.
1
1
07/23/2018
f422653
Tighten the carrier mounting bolts as indicated in sub-steps 10.1 and 10.2.
1. Carrier Mounting Bolts
Fig. 1, Bendix Axial Mounted Caliper
7.1
Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with
the outer-most bolt and moving to the inner-most bolt. Then tighten the three bolts on the other side
of the caliper 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outermost bolt.
7.2
Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m).
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
8. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
Page 9
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
9. Back off the adjuster nut three clicks.
10. Install the wheel assemblies.
11. Raise the vehicle, remove the jack stands, then lower the vehicle.
12. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
13. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
13.1 Apply and release the brakes several times to check for air leaks and proper operation.
13.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
13.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
14. Clean a spot on the base label (Form WAR259). Write the recall number, FL772, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Bendix Radial Mounted Calipers
1. Remove all of the wheel assemblies.
2. Set a torque wrench to 225±22.5 lbf·ft (305±31 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 10. If they turn, proceed to step 3.
3. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
4. Remove the brake pads.
5. Remove caliper bolts.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
6. Align each caliper/carrier assembly with the rotor by pushing the fixed pin side of the caliper against the
shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts. See
Fig. 2.
Page 10
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
7. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 2.
7.1
Initially tighten all six bolts 45±5 lbf·ft (61±7 N·m). Slide the caliper inboard and outboard, through the
center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If the brake
assembly does not move, or requires more than 40 pounds of force to move, the caliper has a binding issue. File a WSC ticket for instructions.
7.2
Perform a final tightening spec of 225±22.5 lbf·ft (305±31 N·m). Slide the caliper inboard and outboard, through the center of the chamber or brake. The caliper must have a minimum of 20 mm of
travel. If the brake assembly does not move, or requires more than 40 pounds of force to move, the
caliper has a binding issue. File a WSC ticket for instructions.
Tighten the fasteners in the order indicated.
Fig. 2, Bendix Radial Mounted Caliper
Page 11
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
8. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
9. Back off the adjuster nut three clicks.
10. Install the wheel assemblies.
11. Raise the vehicle, remove the jack stands, then lower the vehicle.
12. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
13. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
13.1 Apply and release the brakes several times to check for air leaks and proper operation.
13.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
13.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
14. Clean a spot on the base label (Form WAR259). Write the recall number, FL772, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Meritor Axial Mounted Calipers
1. Remove all of the wheel assemblies.
2. Use the Meritor extension tool 3256B1354 and a torque wrench set to 400±50 lbf·ft (542±68 N·m) and
tighten the caliper mounting bolts. See Table 3. If they do not turn, go to step 10. If they turn, go to step 3.
3. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
4. Remove the brake pads.
5. Remove caliper bolts.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
NOTE: The Meritor axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 1.
6. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque
plate, then install the caliper/carrier assembly using new caliper mounting bolts.
Page 12
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
7. Tighten the carrier mounting bolts in two steps as follows.
7.1
Start on one side of the caliper and tighten all of the bolts 45±5 lbf·ft (61±7 N·m). Then tighten the
bolts on the other side of the caliper 45±5 lbf·ft (61±7 N·m). See Fig. 1.
7.2
Repeat this process, increasing the torque value to 400±50 lbf·ft (542±68 N·m).
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
8. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
9. Back off the adjuster nut three clicks.
10. Install the wheel assemblies.
11. Raise the vehicle, remove the jack stands, then lower the vehicle.
12. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
13. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
13.1 Apply and release the brakes several times to check for air leaks and proper operation.
13.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
13.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
14. Clean a spot on the base label (Form WAR259). Write the recall number, FL772, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Meritor Radial Mounted Calipers
1. Remove all of the wheel assemblies.
2. Set a torque wrench to 400±50 lbf·ft (542±68 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 10. If they turn, proceed to step 3.
3. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
4. Remove the brake pads.
5. Remove caliper bolts.
Page 13
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
6. Align each caliper/carrier assembly with the rotor by pushing the fixed pin side of the caliper against the
shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts. See
Fig. 3 and Fig. 4.
1
1
07/30/2018
f422654
1. Caliper Mounting Bolts
Fig. 3, Meritor Radial Mounted Caliper
Page 14
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
7. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 4.
7.1
Initially tighten all bolts 45±5 lbf·ft (61±7 N·m). Slide the caliper inboard and outboard, through the
center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If the brake
assembly does not move, or requires more than 40 pounds of force to move, the caliper has a binding issue. File a WSC ticket for instructions.
7.2
Perform a final tightening spec of 400±50 lbf·ft (542±68 N·m). Slide the caliper inboard and outboard,
through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If
the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper
has a binding issue. File a WSC ticket for instructions.
4
4
3
3
2
2
1
1
A
B
07/30/2018
f422655
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
Fig. 4, Tightening Pattern, Meritor Caliper
Page 15
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
8. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
9. Back off the adjuster nut three clicks.
10. Install the wheel assemblies.
11. Raise the vehicle, remove the jack stands, then lower the vehicle.
12. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
13. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
13.1 Apply and release the brakes several times to check for air leaks and proper operation.
13.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
13.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
14. Clean a spot on the base label (Form WAR259). Write the recall number, FL772, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Wabco Maxxus Radial Mounted Calipers
1. Remove all of the wheel assemblies.
2. Set a torque wrench to 295±22 lbf·ft (400±30 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 10. If they turn, proceed to step 3.
3. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
4. Remove the brake pads.
5. Remove caliper bolts.
Page 16
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
6. Align each caliper/carrier assembly with the rotor by pushing the fixed pin side of the caliper against the
shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts. See
Fig. 5 and Fig. 6.
1
1
07/30/2018
f422656
1. Carrier Mounting Bolts
Fig. 5, Wabco Maxxus Radial Mounted Calipers
Page 17
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
7. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 6.
7.1
Initially tighten all bolts 45±5 lbf·ft (61±7 N·m). Slide the caliper inboard and outboard, through the
center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If the brake
assembly does not move, or requires more than 40 pounds of force to move, the caliper has a binding issue. File a WSC ticket for instructions.
7.2
Perform a final tightening spec of 295±22 lbf·ft (400±30 N·m). Slide the caliper inboard and outboard,
through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If
the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper
has a binding issue. File a WSC ticket for instructions.
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
8. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
4
4
3
3
2
2
1
1
A
B
07/30/2018
f422657
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
Fig. 6, Wabco Maxxus Radial Mounted Caliper Tightening Pattern
Page 18
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
9. Back off the adjuster nut three clicks.
10. Install the wheel assemblies.
11. Raise the vehicle, remove the jack stands, then lower the vehicle.
12. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
13. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
13.1 Apply and release the brakes several times to check for air leaks and proper operation.
13.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
13.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
14. Clean a spot on the base label (Form WAR259). Write the recall number, FL772, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Page 19
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
Bendix Axial Caliper/Carrier Assembly Inspection and Installation XB, XC, EFX and HDX model vehicles
NOTE: Vehicles in FL772G (XC chassis) have ZF independent front axle calipers and Bendix axial rear calipers
No work is require on the ZF front axle calipers. Inpsect the Bendix rear calipoers only.
DANGER
When working on the vehicle, shut down the engine, 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.
1. Remove one wheel and check radial runout before removing the next wheel.
2. Using a tire runout gauge, check the radial runout. See Fig. 7. Write down the measurement for later use to
avoid vibration complaints.
1
07/30/2018
f400373a
1. Radial Runout
Fig. 7, Radial Runout Check for Tires
Page 20
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
3. Mark the two studs closest to the valve stem as shown in Fig. 8, for proper wheel assembly location when
reinstalling the wheel assembly on the hub.
1
07/318/2018
f400390a
1. Valve Stem
Fig. 8, Marking Wheel Studs
4. Remove the lug nuts, then remove the wheel assembly.
IMPORTANT: Before removing the brake pads, it is recommended to check the adjuster mechanism for proper
operation.
5. Inspect the caliper mounting bolts by hand to see if they are loose.
5.1
If the M20 X 2.5 caliper mounting bolts are loose, proceed to step 6.
5.2
If the M20 X 2.5 caliper mounting bolts are hand tight, set a torque wrench to 375±20 lbf·ft
? . If the bolts turn, proceed
(508±27 N·m) and tighten the bolts. If the bolts do not turn, go to step X
to step 6.
6. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is
in good condition. If it is not, file a WSC ticket for instructions.
7. Remove the brake pads.
8. Remove the caliper bolts and washers (if installed) and discard.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly (left or
right) is installed on each side of the vehicle.
9. Align the caliper/carrier assembly with the rotor, pushing the fixed pin-side of the caliper against the shelf on
the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts and washers.
See Table 1 for parts information. See Fig. 1 for an example of the front caliper/carrier assembly.
10. Tighten the M20 X 2.5 carrier mounting bolts in two steps.
10.1 Initially tighten all six bolts 40 to 60 lbf·ft (54 to 81 N·m). Slide the caliper inboard and outboard,
through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If
the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper
has a binding issue. File a WSC ticket for instructions.
Page 21
Daimler Trucks
North America LLC
Recall Campaign
August 2018
FL772A- K
NHTSA #18V-353 (Non-School Bus)
NHTSA #18V-352 (School Bus)
Transport Canada #2018-285 (Non-School Bus)
Transport Canada #2018-284 (School Bus)
10.2 Perform a final tightening spec of 375±20 lbf·ft (508±27 N·m). Slide the caliper inboard and outboard,
through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If
the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper
has a binding issue. File a WSC ticket for instructions.
NOTICE
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to
tighten the nut. Doing so could damage the manual brake adjuster nut.
11. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Using the two studs marked earlier as a guide, install the wheel assembly. When correctly installed, a line
drawn from the valve stem through the center of the wheel assembly should go between the two marked
studs.
14. Using a tire runout gauge, measure and record the radial runout of the tire and wheel assembly. Mark the
highest point on the tire and wheel assembly. Rotate the tire and wheel assembly until the high spot is at
the 12 o’clock position (without allowing the assembly to turn). Loosen all lug nuts to let the assembly settle,
then tighten the lug nuts in the proper sequence. See Group 40 of the applicable vehicle maintenance
manual for the tightening sequence. The radial runout should be very close to what was recorded in step 4.
If not, repeat this step. Record the “final” radial runout, note the wheel location, and include the information
in the recall claim in OWL.
15. Perform the steps above for each wheel location (based on the population letter) until all wheel
locations have been inspected and repaired if needed.
16. Raise the vehicle, remove the jack stands, then lower the vehicle.
17. Charge the air system and check for leaks.
WARNING
Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do
so could result in inadequate or no braking ability, which could cause personal injury or death, and
property damage.
18. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
18.1 Apply and release the brakes several times to check for air leaks and proper operation.
18.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
18.3 Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
19. Clean a spot on the base label (Form WAR259), write the recall number, FL772, on a red completion sticker
(Form WAR260), and attach it to the base label, indicating this work has been completed.
Page 22