FL845 – Insufficiently Tightened Brake Caliper Bolts – 2019-2020 Freightliner 108SD, 114SD, Cascadia, Business Class M2, Western Star 4700 & 5700, Freightliner Custom Chassis S2, Custom Chassis XB, & Custom Chassis XC

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March 3, 2020 NHTSA CAMPAIGN NUMBER: 20V127000

Insufficiently Tightened Brake Caliper Bolts

Loose brake caliper mounting bolts can reduce brake effectiveness, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V127

Manufacturer Daimler Trucks North America LLC

Components SERVICE BRAKES, AIR

Potential Number of Units Affected 2,585

 

Summary

Daimler Trucks North America LLC (DTNA) is recalling certain 2019-2020 Freightliner 108SD, 114SD, Cascadia, Business Class M2, Western Star 4700 and 5700, Freightliner Custom Chassis S2, Custom Chassis XB, and Custom Chassis XC vehicles equipped with air disc brakes. The brake caliper mounting bolts may have been insufficiently tightened.

 

Remedy

DTNA will notify owners, and dealers will inspect and repair the vehicles, free of charge. The recall began May 1, 2020. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-845.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Daimler Trucks North America Recalls

 


Recall Campaign

April 2020
FL845A-X
NHTSA #20V-127 (Non-School Bus)
NHTSA #20V-126 (School Bus)
Transport Canada #2020-086 (Non-School Bus)
Transport Canada #2020-085 (School Bus)

Subject: Brake Caliper Mounting Bolts

Models Affected: Specific Freightliner 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-TLiner C2, EFX, and HDX buses manufactured September 4,2018, through March 29 2019, 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 3,413 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 increase the risk of a crash.

Caliper mounting bolts will be inspected and 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. Each group in the recall may include both front and rear axles and different caliper types, as noted for each group in the table below.

If our records show your dealership has ordered any vehicles involved in campaign number FL845, 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 FL845

Campaign Number Vehicle Type / Population Qty. Part Number Part Description Qty. per Caliper
FL845A Front & Rear Axle Bendix Axial Caliper Truck

1,063

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845B Front Axle Bendix Axial Caliper Truck

77

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845C Front & Rear Axle Bendix Radial Caliper Truck

7

23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL845D Front Axle Bendix Radial Caliper Truck

1

23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL845E Front Axle Bendix Radial Caliper Truck

98

23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL845E Rear Axle Bendix Axial Caliper 23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845F Front & Rear Axle Wabco Radial Caliper Truck

5

23-13843-070 SCREW-CAP,SKT HD,M20X1.5X70 6 ea
FL845G Front Axle Wabco Radial Caliper Truck

1

23-13843-070 SCREW-CAP,SKT HD,M20X1.5X70 6 ea
FL845H Front Axle Wabco Radial Caliper Truck

17

23-13843-070 SCREW-CAP,SKT HD,M20X1.5X70 6 ea
FL845H Rear Axle Wabco Axial Caliper 23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845I Front & Rear Axle Wabco Axial Caliper Truck

207

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845J Front Axle Wabco Axial Caliper Truck

15

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845K Front & Rear Axle Meritor Axial Caliper Truck

480

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845L Front Axle Meritor Axial Caliper Truck

22

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845M Front & Rear Axle Meritor H Axial Caliper Truck

105

23-14285-055 BOLT-HEX,PC10.9,PO,M20X1.5X55 6 ea
FL845N Front Axle Meritor Radial Caliper Truck

8

TDA 41X1801 CAPSCREW M20 4 ea
FL845O Front Axle Meritor Radial Caliper Truck

52

TDA 41X1801 CAPSCREW M20 4 ea
FL845O Rear Axle Meritor Axial Caliper 23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845P Front & Rear Axle Bendix Axial Caliper Shuttle Bus

17

23-09114-004 N210931 020001 WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20X60,10.9,P/O

6 ea
23-09114-004

23-12893-060

WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20,10.9,ZN,YL

FL845Q Front Axle Bendix Axial Caliper RV & Shuttle Bus

569

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845R Rear Axle Bendix Axial Caliper RV

66

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
23-12893-060 SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845S Front & Rear Axle Bendix Radial Caliper Shuttle Bus

5

23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL845T Front & Rear Axle Bendix Axial Caliper School Bus

169

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845U Front & Rear Axle Bendix Radial Caliper School Bus

416

23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL845V Front Axle Bendix Axial Caliper RV

8

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O
FL845W Front & Rear Axle Bendix Axial Caliper RV

4

23-09114-004 N210931 020001 WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20X60,10.9,P/O

6 ea
23-09114-004

23-12893-060

WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20,10.9,ZN,YL

FL845X Rear Axle Bendix Axial Caliper RV

1

23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN 6 ea
23-12893-060 SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845A-X All WAR260 BLANK COMPLETION STICKER 1 ea

 

Table 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/Group Procedure Time Allowed (hours) SRT Code Corrective Action
FL845

B,D,G,J,L & N

(Truck)

Inspect caliper bolts, front axle 1.0 996-R088A 06-Inspect
Torque caliper bolts, front axle 996-R088B 12-Repair

Recall/Campaign

FL845

A,C,E,F,H,I,K,

M,O,S & U

(Truck)

Inspect caliper bolts, front and rear axle 2.0 996-R088C 06-Inspect
Torque caliper bolts, front and rear axle 996-R088D 12-Repair

Recall/Campaign

FL845A-O

(Truck)

Inspect caliper bolts, each additional rear axle 1.1 996-R088E 06-Inspect
Torque caliper bolts, each additional rear axle 996-R088F 12-Repair

Recall/Campaign

FL845Q & V

(RV/Bus)

Inspect caliper bolts, front axle, with radial runout check 1.2 996-R088G 06-Inspect
Torque caliper bolts, front axle, with radial runout check 996-R088H 12-Repair

Recall/Campaign

FL845R & X

(RV/Bus)

Inspect caliper bolts, rear axle, with radial runout check 1.2 996-R088I 06-Inspect
Torque caliper bolts, rear axle, with radial runout check 996-R088J 12-Repair

Recall/Campaign

FL845 P, T & W

(RV/Bus)

Inspect caliper bolts, front and rear axle, with radial runout check 2.4 996-R088K 06-Inspect
Torque caliper bolts, front and rear axle, with radial runout check 996-R088L 12-Repair

Recall/Campaign

FL845A-X (Truck/RV/Bus) Replace caliper bolts, one caliper

(claim this SRT once for each caliper requiring new bolts, up to 6 times)

0.5 996-R088G 12-Repair

Recall/Campaign

 

Table 2

 

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. FL845-A, FL845-B, etc.).
  • In the Primary Failed Part Number field, enter 25-FL845-000.
  • In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table.
  • Vehicles in FL845P, Q, R, V, W, & X are required to record the “final” radial runout , note the wheel location, and include the information in the claim story of the recall claim.
  • In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. Administrative time will be included automatically as SRT 939-6010A 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 F99-999-005 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.

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.


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 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-T Liner C2, EFX, and HDX buses manufactured September 4, 2018, through March 29, 2019, 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 increase the risk of a crash.

Caliper mounting bolts will be inspected and replaced as needed.

Please 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 online 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 DTNA.Warranty.Campaigns@Daimler.com, 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 https://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 DTNA.Warranty.Campaigns@Daimler.com, 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


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.

 

Work Instructions

Subject: Brake Caliper Mounting Bolts

Models Affected: Specific Freightliner 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-TLiner C2, EFX, and HDX buses manufactured September 4,2018, through March 29 2019, and equipped with air disc brakes.

 

General Information

IMPORTANT: Vehicles may have both axial and radial mounted calipers. Follow the work instructions based on the type of calipers on the vehicle:

  • NOTE: XC motorhome chassis have ZF independent front axles. No work is needed on ZF front axle calipers. See Table 3 to determine the type of caliper installed on the vehicle and the page number for the instructions.
Caliper Type Campaign Group Letter and Axle Position Page Number
Bendix Axial FL845A (Front/Rear)

FL845B (Front)

FL845E (Rear)

9
Bendix Radial FL845C (Front/Rear)

FL845D (Front)

FL845E (Front)

FL845S (Front/Rear)

FL845U (Front/Rear)

14
Meritor Axial FL845K (Front/Rear)

FL845L (Front)

FL845M (Front/Rear) FL845O (Rear)

18
Meritor Radial FL845N (Front) FL845O (Front) 20
WABCO Maxxus Axial FL845H (Rear)

FL845I (Front/Rear)

FL845J (Front)

23
WABCO Maxxus Radial FL845F (Front & Rear)

FL845G (Front) FL845H (Front)

25
Bendix Axial (with radial runout) FL845P (Front/Rear)

FL845Q (Front)

FL845R (Rear)

FL845T (Front/Rear) FL845V (Front)

FL845W (Front/Rear)

FL845X (Rear)

28

 

Table 3, Caliper Type and Instruction Page Number

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Bendix Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Fig. 1. for a 47 in (119 cm) long wrench. see Table 4. for torque specifications.

 

Fig. 1, DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor

Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0 350 (475) 296 (401)
45°

11/28/2016             f422614

45 310 (420)
60°

11/06/2018             f422668

60 320 (434)
90°

11/28/2016             f422615

90 350 (475)
120°

11/06/2018             f422669

120 386 (523)
135°

11/28/2016             f422616

135 402 (545)

 

Table 4, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005

 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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.

  1. 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. 2.
  2. Tighten the carrier mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outer-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. See 3 for the left-front caliper and Fig. 4 for the right-front caliper.
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.

 

10/01/2018 f422664
1. Caliper/Carrier Assembly (showing service actuator)
2. Mounting Bolts and Washers (qty. 6)
3. Anchor Plate/Torque Plate

Fig. 2, Bendix Axial Mounted Caliper

 

03/26/2020 f422665

Fig. 3, Tightening Pattern, Left-Front Bendix AxialCaliper

 

03/26/2020 f422665a

Fig. 4, Tightening Pattern, Right-Front Bendix Axial Caliper

 

Bendix/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0 375 (508) 317 (430)
45°

11/28/2016             f422614

45 332 (450)
60°

11/06/2018             f422668

60 343 (465)
90°

11/28/2016             f422615

90 375 (508)
120°

11/06/2018             f422669

120 413 (560)
135°

11/28/2016             f422616

135 431 (584)

 

Table 5, Bendix/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Bendix Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center-to-handle length of 47 inches (119 cm).

  1. Set a torque wrench to 200 lbf·ft (271 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  1. 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.

  1. 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.

 

04/01/2020 f422704
NOTE: Washers are not used on radial mounted assemblies.
1. Caliper Mounting Bolts
2. Large Caliper Sliding Pin

Fig. 5, Bendix Radial Mounted Caliper

 

NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the sheer sleeve.

  1. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 6.

NOTE: A slide-ability test must be performed in the green zone (marked as ’A’), shown in Fig. 7, as the red zones are not within operational range.

  • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
  • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

04/21/2020 f422705
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
1. Large Caliper Sliding Pin

Fig. 6, Tightening Pattern, Bendix Radial Mounted Caliper

 

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.

 

05/21/2019 f422674
A. The caliper must move freely in the green zone (marked as ’A’) and have a minimum of 20 mm of travel in the green zone (marked as ’A’).

Fig. 7, Slide-Ability Test Area

 

  1. Raise the vehicle, remove the jack stands, then lower the vehicle.
  2. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Meritor Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Fig. 1. See Table 4 for torque specifications.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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. 2.

  1. 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.
  2. Tighten the carrier mounting bolts in two steps as follows.
    • 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. 3.
    • Repeat this process, increasing the torque value to 400±50 lbf·ft (542±68 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 6 for torque specifications.

 

Meritor Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0 400 (542) 338 (458)
45°

11/28/2016             f422614

45 354 (480)
60°

11/06/2018             f422668

60 366 (496)
90°

11/28/2016             f422615

90 400 (542)
120°

11/06/2018             f422669

120 441 (598)
135°

11/28/2016             f422616

135 460 (624)

 

Table 6, Meritor Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Meritor Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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.

  1. 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. 8 and Fig. 9.

 

07/30/2018 f422654
1. Caliper Mounting Bolts

Fig. 8, Meritor Radial Mounted Caliper

 

NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the sheer sleeve.

  1. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 9
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

07/30/2018 f422655
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View B. Right Hand, Bottom View

Fig. 9, Tightening Pattern, Meritor Caliper

 

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  1. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – WABCO Maxxus Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Fig. 1. for a 47 in (119 cm) long wrench. see Table 4. for torque specifications.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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 Wabco axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 2.

  1. 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.
  2. Tighten the carrier mounting bolts in two steps as follows.
    • 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. 3.
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If tool

DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service..
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – WABCO Maxxus Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 273 lbf·ft (370 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go to step 6.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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.

  1. 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. 10 and Fig. 11.

07/30/2018 f422656
1. Carrier Mounting Bolts

Fig. 10, Wabco Maxxus Radial Mounted Calipers

 

NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the sheer sleeve.

  1. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 11.
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

07/30/2018 f422657
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View

Fig. 11, Wabco Maxxus Radial Mounted Caliper Tightening Pattern

 

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.

  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  1. Raise the vehicle, remove the jack stands, then lower the vehicle.
  2. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

Bendix Axial Caliper/Carrier Assembly Inspection and Installation – XB, XC, EFX and HDX Model Vehicles

NOTE: XC motorhome chassis have ZF independent front axle. No work is needed on ZF front axle calipers.

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been completed. The base label is usually located on the front wall under the dash on RVs and over the drivers window on buses. If a sticker is present for FL845, 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. 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.

  1. Raise the vehicle and place jack stands under the frame rails to ensure the vehicle cannot drop.
  2. Beginning with the right-front wheel, use a tire runout gauge to check the radial runout. See Fig. 12. Write down the measurement for later use to avoid vibration complaints.
  3. Mark the two studs closest to the valve stem as shown in Fig. 13, for proper wheel assembly location when reinstalling the wheel assembly on the hub.

 

07/30/2018 f400373a
1. Radial Runout

Fig. 12, Radial Runout Check for Tires

 

07/318/2018 f400390a
1. Valve Stem

Fig. 13, Marking Wheel Studs

 

  1. 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.

NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).

  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 15. If they turn, go to step 8. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Fig. 1. See Table 4 for torque specifications.
 WARNING

 

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

  1. 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, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. 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.

  1. Align the caliper/carrier assembly with the rotor, pushing 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. 2 for an example of the front caliper/carrier assembly.
  2. Tighten the M20 X 2.5 carrier mounting bolts as follows. See Fig. 3.
    • Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outer-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.
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.

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.

  1. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Using the two studs marked earlier as a guide, install the wheel assembly. When correctly installed, a linedrawn from the valve stem through the center of the wheel assembly should go between the two marked studs.
  4. Using a tire runout gauge, measure and record the radial runout of the tire and wheel assembly. Mark thehighest 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 3. If not, repeat this step. Record the “final” radial runout, note the wheel location, and include the information in the recall claim in OWL.
  5. Perform the steps above for each wheel location (as needed based on the population letter) until all wheel locations have been inspected and repaired if needed.
  6. Raise the vehicle, remove the jack stands, then lower the vehicle.
  7. 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.

  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • 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.
  2. Clean a spot on the base label (Form WAR259), write the recall number, FL845, on a red completion sticker(Form WAR260), and attach it to the base label, indicating this work has been completed.

 


Daimler Trucks
North America LLC

 

July 2020
FL845
Recall Correction Notice
NHTSA #20V-127

 

IMPORTANT SAFETY RECALL

See enclosed VIN list

Subject: Brake Caliper Mounting Bolts

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

In April of this year, a letter was sent informing you that your vehicle was included in recall FL845, Brake Caliper Mounting Bolts.  Please note the letter was sent in error.

 

Upon further investigation, it was confirmed your vehicle has documentation of correct caliper torque.  Your vehicle does not require this recall.

 

We apologize for any inconvenience this may have caused. If you have questions or require further information, 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 DTNA.Warranty.Campaigns@Daimler.com.

 

WARRANTY CAMPAIGNS DEPARTMENT

 

Enclosure

 



28 Affected Products

Vehicles

MAKE MODEL YEAR
FCCC S2 2019-2020
FCCC XBP 2019-2020
FCCC XBR 2019-2020
FCCC XBS 2019-2020
FCCC XCL 2019-2020
FCCC XCM 2019-2020
FCCC XCR 2019-2020
FCCC XCS 2019-2020
FREIGHTLINER 108SD 2019-2020
FREIGHTLINER 114SD 2019-2020
FREIGHTLINER BUSINESS CLASS M2 2019-2020
FREIGHTLINER CASCADIA 2019-2020
WESTERN STAR 4700 2019-2020
WESTERN STAR 5700 2019-2020

 


13 Associated Documents

Recall Acknowledgement

RCAK-20V127-8230.pdf 244.929KB

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Miscellaneous Document- Defect Information Report

RMISC-20V127-1503.pdf 451.456KB

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Defect Notice 573 Report

RCLRPT-20V127-5835.PDF 216.417KB

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Manufacturer Notices(to Dealers,etc)

RCMN-20V127-0426.pdf 1696.798KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V127-8010.pdf 41.626KB

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Remedy Instructions and TSB

RCRIT-20V127-9857.pdf 999.035KB

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Remedy Instructions and TSB

RCRIT-20V127-3590.pdf 1002.955KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V127-1446.pdf 56.299KB

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Remedy Instructions and TSB

RCRIT-20V127-9915.pdf 1014.734KB

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Miscellaneous Document- Bodybuilder Q2 2020

RMISC-20V127-3275.pdf 522.077KB

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V127-3355.PDF 211.351KB

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V127-4505.PDF 211.156KB

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V127-6976.PDF 211.258KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V127&docType=RCL

 


 

SaleBestseller No. 1
EPAuto 1/2-inch Drive Click Torque Wrench, 10-150 ft/lb, 13.6-203.5 N/m
  • Durable Ratchet Head: Made from Hardened treated Chrome Vanadium steel alloy (Cr-V) Corrosion-Retardant: Satin Finish. Made in Taiwan
  • Easy Storage: A sturdy plastic storage case is included. Non-Slip Grip: Knurled handle
  • Easy to Read: High Contrast & Dual Range Scale. Accurate: Pre-Calibrated to ± 4%
  • Accessories included: 1/2" Drive 5" long Extension Bar and 1/2" Drive to 3/8" Drive Reducer
  • Simple and Reliable: “Click” sound tells the preset torque value is reached. Stop applying force when you hear and feel it.
SaleBestseller No. 2
LEXIVON 3/8-Inch Drive Click Torque Wrench 10~80 Ft-Lb/13.6~108.5 Nm (LX-182)
  • PRECISION - Ships pre-calibrated to +/- 4% accuracy and ready to use. Include calibration certificate with traceable serial number.
  • DURABLE - Reinforced ratchet gear head constructed from hardened, heat treated Chrome Vanadium alloy steel.
  • LONG-LASTING - Rust & corrosion protection with our unique and newly invented Electro-Black finish treatment.
  • PERFORMANCE - Features an easy-to-read, highlighted yellow print dual-range scale. Identify the markings even in low-light conditions.
  • COMFORTABLE - Comes with a reversible ratchet head that drives in both directions and measure torque in a clockwise direction.
Bestseller No. 3
Hairich 1/2 Inch Drive Click Torque Wrench, Dual-direction Torque Wrench 10-170.0ft.lb/13.60-230.5Nm, 72-tooth Torque Wrenches with Dual Range Scales, ±3% High Precision Torque Wrench For Bike
  • ±3% HIGH PRECISION AND COOL APPEARANCE: 1/2 inch drive torque wrench (10-170ft.-lb/13.6-230.5Nm)has a calibration error range of ±3%, high precision, and comes with a corresponding serial number, which is easy to trace the original data, and you can use it with confidence.Hairich torque wrench not only has superior quality but also has a superior appearance. The classic combination of black and red is fashionable and textured, allowing you to enjoy a visual feast during use.
  • PREMIUM MATERIAL AND DURABLE: Experience the ultimate durability and antiskid with the torque wrench. The main body of Hairich torque wrench set is made of chrome vanadium steel alloy, which is more strong and more durable. The head of the inch-pound torque wrench adopts a ratchet design with a reversing device to improve work efficiency. The square knurled handle is made of aluminum titanium alloy, which is ergonomic and comfortable to hold for long-time use.
  • DUAL SCALE AND QUICK SETTING: Laser Printed by dual-range(ft-lb and Nm). Our professional torque wrench is easy to read and provides direct unit conversion, When the set torque value is reached, the torque wrench will make an audible and felt click to remind you to stop applying force. Pull down the lock knob and hold it until the torque setting is completed. Release the hand, and the lock knob will automatically rebound back to lock the value.
  • ERGONOMIC DESIGN AND POWERFUL: Every design of our industrial torque wrench conforms to ergonomic, easy to handle.72-tooth ratchet, 5° ratcheting arc head, a quick-release button for easy loading and unloading, and an aluminum non-slip handle for excellent grip and control. A recent research review that, 72-tooth ratchets are very professional tooth ratchets, you just only rotate 5 degrees to finish it. Not easy to slip and wear, can be used in small spaces, and is more durable and powerful.
  • EASY OPERATION AND SAFETY: Thanks to its bidirectional drive ratchet head, our torque wrench can be measured both clockwise and counterclockwise. When the set torque value is reached, a "click" sound will remind you to stop applying force to prevent damage to the item due to excessive torque. Notice: At low Nm settings under 5 Nm the "click" sound can be too light to hear.
Bestseller No. 4
SUERCUP 3/8-Inch Drive Click Torque Wrench - 5-45 Ft-Lb/6.8-61Nm, ±3% High Accuracy Torque Wrench, Dual-Direction Adjustable 72 Tooth Click Torque Wrench for Bike, Motorcycle and Car Repair
  • 【High Precision&Quick Reading】: 3/8 torque wrench has high contrast and dual range scale( 5-45 Ft-Lb/6.8-61 Nm),making it clear and easy to read. We have professional torque wrench production technology, and after 20000 tests, the calibration error range of the torque wrench is ± 3%, making it an essential helper for you.
  • 【Safe and Reliable Operation】: Equipped with a bidirectional drive ratchet head, torque can be measured clockwise or counterclockwise. When the set torque value is reached, a "click" sound will remind you to stop applying force to prevent damage to the item due to excessive torque.
  • 【High Quality and Durable Material】: Made of hardened chromium vanadium steel alloy (Cr-V). At the same time, the bottom buckle tail plug adopts a red anodizing process to improve the product's oxidation resistance during use and enhance surface wear resistance. 72 tooth ratchet head, made of chromium molybdenum steel. High quality materials resist corrosion and are durable.
  • 【Quick Torque Setting】: Simple and fast torque setting, pull down the locking knob and hold it down to rotate to the torque you need. Release the hand and the locking knob will automatically rebound to lock the torque value. And the designer referred to the appearance of the flashlight handle and designed a non slip and labor-saving knurled handle, making it more comfortable and easy to hold when using.
  • 【Easy to Store and Widely Use】: You will receive the 3/8-inch drive click torque wrench with a sturdy plastic shell storage box, which is very delicate and durable. Torque wrench is suitable nuts and bolts on various occasions, such as bike, motorcycle, car spark, and is the best helper for you🎁. 🔔 And we provide 12 months warranty. If you have any questions, please feel free to contact us.
Bestseller No. 5
VANPO 1/4 & 3/8 & 1/2-inch Drive Click Torque Wrench, 3Pcs Torque Wrench Set 20-240in.lb, 5-45ft.lb, 20-160ft.lb, Dual-Direction Adjustable 72-Tooth Torque Wrench for Bike, Moto, Car Maintenance
  • 【3Pcs Torque Wrench Set】 The calibration error range is ±3%, each torque wrench has a calibration certificate. The 3-in-1 torque wrench set can meet your different needs. Including 1/4 inch 20-240in.lb, 3/8 inch 5-45ft.lb, 1/2 inch 20-160ft.lb.
  • 【Safe & Reliable】 When the 1/2 torque wrench reaches the preset torque value, it makes a clear "click" sound, accompanied by an obvious hand vibration that reminds you no longer to apply force, prevent damage caused. 72-tooth reversible ratchet head, it can be used both clockwise and counterclockwise directions.
  • 【Quick Release Button】 This 3/8 torque wrench has a quick release button with which accessories can easily be installed and removed, the accessories can grip and is not easy to fall down. It is more convenient to use. The torque wrench is made of CR-MO with a higher hardness.
  • 【Easy to Set】First pull down the locking knob and hold it down and then start setting the desired torque value. Release the hand and the locking knob will automatically rebound to lock the torque value. If you do not use, please set the torque key to the minimal torque value.
  • 【Widely Use】The torque wrenches can satisfy you in bicycle, motorcycle, car, truck and wheel screws, wheel nuts and in the device installation, electrical engineering, etc. We provide 12 months warranty. If you have any questions, please feel free to contact us.
SaleBestseller No. 6
CRAFTSMAN Torque Wrench, 1/2" Drive (CMMT99434)
  • PORTABILITY: Torque wrench 1/2 inch drive has a durable case for portability or storage
  • ADDED COMFORT: Bi-material handle for comfort and grip of the 1/2 torque wrench
  • HASSLE FREE USE: Locking feature adjusts quick and easily for hassle free use
  • QUICK IDENTIFICATION: Scales stamped into housing showing inch and metric torque settings
  • Meets or Exceeds ASME Specifications
Bestseller No. 7
1/2" Drive Click Torque Wrench with Deep Impact Socket (6~24mm) ,Dual-Range【10-170ft.lb/10-227Nm】±3% Precision,Dual-Direction Adjustable Torque Wrench,10"Extension Bar,Universal Joint,Drill Adapter
  • 🔧【𝐌𝐢𝐥𝐢𝐭𝐚𝐫𝐲-𝐠𝐫𝐚𝐝𝐞 𝐒𝐭𝐞𝐞𝐥】ETOOLAB torque wrench utilizes military-grade steel as its base material, coupled with professional surface rust protection methods tailored to usage habits. While ensuring user comfort, it enhances product strength, wear resistance, and rust resistance. offers a more comfortable experience and a longer lifespan!
  • 👍【𝐄𝐚𝐬𝐲-𝐭𝐨-𝐑𝐞𝐚𝐝】The scale of this 1/2 drive torque wrench is laser-engraved, using a black background with white markings. dinamometrica de 1/2 ensures clear and easy readability of the scale, even in sunlight. With a dual-scale design, users can conveniently read torque values in two different units according to their preferences, without the need for conversion!
  • ⚙️【±𝟑% 𝐏𝐫𝐞𝐜𝐢𝐬𝐢𝐨𝐧 & 𝐒𝐢𝐦𝐩𝐥𝐞 𝐋𝐨𝐜𝐤𝐢𝐧𝐠 𝐑𝐢𝐧𝐠】Our torque wrench 1/2 drive meets the high precision standard of ±3% and comes with a traceable serial certificate. You can use it with confidence! Moreover, its graduation ring is tightly locked, with smaller incremental values, ensuring precise and consistent torque output even after multiple uses. This reduces the hassle of frequent adjustments. It is undoubtedly an excellent tool for your work!
  • 🔊【𝐋𝐨𝐮𝐝 𝐂𝐥𝐢𝐜𝐤 𝐒𝐨𝐮𝐧𝐝】This torque wrenches has been upgraded to have a louder "Click" sound. We conducted over 25,000 tests to ensure that each product produces a click sound volume of no less than 45dB when the torque value exceeds 34 lbf·ft. When you hear the distinct click sound, it indicates that the preset torque has been reached, signaling you to stop applying force. You no longer need to worry about damaging your mechanical components.
  • 💯【𝐔𝐬𝐞𝐫-𝐅𝐫𝐢𝐞𝐧𝐝𝐥𝐲】Our torque wrench set features a 72-tooth dual-directional ratchet head, allowing for easy operation in both clockwise and counterclockwise directions. It is designed with an adjustable locking ring, making it effortless to adjust the preset torque value. Additionally, it includes a quick-release head design, allowing it to replace the wrench head accessories more easily!
Bestseller No. 8
TEKTON 3/8 Inch Drive Micrometer Torque Wrench (10-80 ft.-lb.) | 24330
  • Includes 1-pc. 3/8 in. drive torque wrench; Storage case; Product manual with torque conversion chart
  • Wrench emits a click that can be heard and felt when the preset value is reached
  • Permanently marked, high-contrast dual-range scale is easy to read, even in low light
  • Reversible ratchet head drives in both directions and measures torque in clockwise direction
  • Durable all-steel construction has no plastic parts to break or wear out
Bestseller No. 9
TEKTON 1/4, 3/8, 1/2 Inch Drive Micrometer Torque Wrench Set (3-Piece) | TRQ99901
  • Includes 1-pc. 1/4 in. drive micrometer torque wrench (20-200 in.-lb.) with storage case and product manual; 1-pc. 3/8 in. drive micrometer torque wrench (10-80 ft.-lb.) with storage case and product manual; 1-pc. 1/2 in. drive micrometer torque wrench (25-250 ft.-lb.) with storage case and product manual
  • Wrenches emit a click that can be heard and felt when the preset value is reached
  • Permanently marked, high-contrast dual-range scale is easy to read, even in low light
  • Reversible ratchet heads drive in both directions and measure torque in clockwise direction
  • Durable all-steel construction has no plastic parts to break or wear out
Bestseller No. 10
NEBICALS 1/4-inch Drive Click Small Bike Accurate Torque Wrench 20-200in.lb/2.26-22.6Nm for Garage Car Maintenance, Small Engine, Bolt & Nut Fastening.
  • 【PRECISION】 - Ships pre-calibrated to +/- 4% accuracy and ready to use. Include calibration certificate . Before shipping, we take 200 times calibration tests to make sure all wrenches performance well .
  • 【DURABLE】 - Reinforced ratchet gear head constructed from hardened, heat treated Chrome Vanadium alloy steel.
  • 【 RELIABLE & SAFE】: When small torque wrench set torque value is reached, the wrench will emits slight click sound to remind you to stop applying force to prevent overtorque damage to your items.
  • 【LONG-LASTING】 - Rust & corrosion protection with our unique and newly invented Chrome finish treatment.
  • 【 DUAL-DIRECTION MEASURES & WIDE USE】: The paddle of the mini torque wrench head can adjust the direction of use at any time,so that the wrench can be used both clockwise and counterclockwise directions. More widely used for Installation equipment, Electrical engineering, bicycle/motorcycle maintenance, Product assembly.With a storage box and an instruction manual.

Last update on 2024-04-11 / Affiliate links / Images from Amazon Product Advertising API

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