NHTSA ID Number: 10044244
Manufacturer Communication Number: PI0783
TSB/Document Date: 2012-05-24
Summary
MACK TRUCKS
: FRAME FLANGE CONTACTING SUSPENSION CROSSMEMBER. CERTAIN MACK MODELS MAY HAVE CONTACT ISSUES BETWEEN THE FRAME RAILS AND CROSS MEMBER. THIS CONTACT CAN CAUSE A SIDE LOADING CONDITION TO THE FRAME. *JS
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TSB/Document ID: PI0783
Replacement Service Bulletin Number:
MFR Communication Date: 2012-04-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SUSPENSION
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
Service Program
Trucks
Mack Trucks, Inc.
Greensboro, NC USA
SB-10044244-3809
Date
Group
No.
Release
Page
4.2012
711
783
01
1(13)
Frame Flange Contacting
Suspension Crossmember
GU
PI0783, Frame Flange Contacting Suspension
Crossmember
(April 2012)
Information
Certain MACK GU model chassis built from 09/15/2008 to 12/31/2011 equipped with 105
mm flange frame rails and SS52 suspension crossmember, may have contact issues
between the frame flange and cross member. This contact can cause a side loading
condition to the frame. To repair this issue complete the following procedure.
Note: Information is subject to change without notice.
Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
Required Parts
PV729-PI0783
Quantity
Part Number
Description
1
4MR3431M
1
4MR3431M4
Tranverse Torque Rod
Relief Template
Trunnion Relief Cutout Template
USA52829
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
Procedure
You must read and understand the precautions and guidelines in Service Information
Group 70, “General Safety Practices, Frame, Springs and Wheels” before performing
this procedure. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
Rear Suspension, Remove
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
2 Disconnect all cables from the negative (ground) and positive battery terminals to prevent
personal injury from electrical shock and prevent damage to electrical components.
3 Cage all four parking brake chambers.
Note: Caging the parking brakes allows the suspension and axles to roll freely.
4 Mark the center of the trunnion in relation to the frame rail.
5
W7001186
1 – Frame Rail Guide Support
2 – Air Jack Stand
DANGER
Never work under or around a vehicle unless it is supported on jack stands of adequate
rating. Failure to use adequate jack stands can result in the vehicle falling, which can
cause serious injury or death to anyone under the vehicle.
Using the proper jack raise the rear section of the frame, just ahead of the front rear axle.
Support the chassis with jackstands. The frame should be raised high enough to take the
weight off the suspension and allow the suspension to slide within the framerail.
6 Remove the drive shaft at the front differential.
7 Remove the air hoses located at each brake chamber or at the frame junctions located in
frame depending on setup.
Note: Mark and note the position of each air hose for future reference.
8 Remove the airline to the front power divider and or rear inter-axle locks.
9 Disconnect the ABS sensors located within the chassis. Cut cable ties as needed.
Page
2(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
10
W7072613
1 – Rear Crossmembers
Remove the huck fasteners from the cross-member just past the rear axle. Slide the
cross-member rearward.
Page
3(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
11
W7072615
Remove the huck fasteners from both sides of the trunnion suspension (8 on each side).
Page
4(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
12
W7072614
Remove the rear axle bump stops from the chassis on each side.
Note: Rear axle only.
13 Remove the lateral torque rods from the chassis mounting (If applicable).
14 Spread the rear of the chassis open with a porta-power or similar tool.
Note: Spread the chassis just enough to allow the suspension freedom to roll rearward.
Page
5(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
15
W7072615
Roll the suspension rearward until the proper area of frame is exposed enough to allow
the cut/s to be made.
Note: If necessary adjust the height of the jacks or remove further items along the rail
which block the path of the trunnion.
Note: Some vehicles use both templates, depending on whether the vehicle is equipped
with lateral torque rods.
Page
6(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
Frame Rail Modification (Long Cut)
1 Install the long template onto the chassis area of the lower frame flange.
2 Mark the center of the template.
3
W7072616
Align the template with the trunnion center marked in step 4 during the removal.
4 Clamp the template in place with vise grips or similar tool.
5 Cut the frame rail using a plasma cutter.
6 Remove the template and chip slag from the edge.
7 Using a grinder or portable belt sander, dress and clean the open notch in the frame rail.
Note: Grind the open notch smooth so that there are no sharp or jagged edges. Grind
horizontally (parallel) to the frame edge so as not to leave vertical marks on the flange.
Note: Dress the top and bottom edges of the cut to leave a smooth radius.
Note: Paint the exposed bare metal of the frame with approved chassis paint.
8 Perform the same task for the lower flange on the other frame rail.
Page
7(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
Frame Rail Modification (Short Cut)
Note: Perform this procedure only if the lateral torque rods are present and interfere with
the lower flange of the frame.
1 Install the short template onto the frame where the rear stabilizer rod meets the frame.
2 Mark the center of the torque rod mounting.
3 Center the template onto the area to be cut on the lower frame flange.
4
W7072616
Align the template on the frame as shown in the illustration.
5 Clamp the template in place with vise grips or similar tool.
6 Cut the frame rail using a plasma cutter.
7 Remove the template and chip slag from the edge.
8 Using a grinder or portable belt sander, dress and clean the open notch in the frame rail.
Note: Grind the open notch smooth so that there are no sharp or jagged edges. Grind
horizontally (parallel) to the frame edge so as not to leave vertical marks on the flange.
Note: Dress the top and bottom edges of the cut to leave a smooth radius.
Note: Paint the exposed bare metal of the frame with approved chassis paint.
Page
8(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
Rear Suspension, Install
1
W7072818
Roll the suspension forward until the holes in the frame are once again aligned.
Note: In order to freely roll the suspension forward in the frame, It may be necessary to
adjust the height of the jack stands.
Note: To avoid improper alignment, reposition the rear crossmember(s) before bolting
the suspension into place.
2 Secure the fasteners for the rear suspension.
3 If applicable, install the lateral torque rods. Torque fasteners to 260 Nm (192 ft-lb).
Page
9(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
4
W7072614
Install the rear axle bump stops. Torque fasteners to 260 Nm (192 ft-lb).
Note: Install for rear axle only.
Page
10(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
5
W7072613
1 – Rear Crossmembers
Secure the fasteners for the end cross member.
6 Secure the fasteners for the cross member just after the rear axle.
7 Connect the ABS sensors and secure with cable ties as needed.
8 Install the air line to the front power divider and/or rear interaxle locks.
9 Install the air hoses previously removed at the brake chambers or frame junctions.
10 Install the driveshaft.
11 Uncage all four parking brake chambers.
Page
11(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
12
W7001186
1 – Frame Rail Guide Support
2 – Air Jack Stand
Remove any jack stands or jacks used to support the frame.
Note: Any u-bolts or other devices securing the body to the truck should be reinstalled at
this time.
13 Unchock the wheels.
14 Reconnect all previously removed cables to the negative (ground) and positive battery
terminals.
Page
12(13)
Mack Trucks, Inc.
Service Program
Date
4.2012
Group
No.
Release
711
783
01
Reimbursement
This repair is covered by an authorized Service Program. Reimbursement is
obtained via the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
B
Recall Status
Vehicle repaired per instruction
1- Modified per
instruction
Labor Code
Primary Labor Code
To complete both carriers
1352G–ZZ–96
8.0 hrs.
Time to take charge and determine campaign status
101AA–0A–00
0.3 hrs.
Causal Part
3188724
Authorization Number
PI0783
Expiration Date
27 April 2013
Note: Take Charge Time is not included in the Labor Code for this operation. Take charge
may be eligible but can only be used once per repair visit. If vehicle is having other warranty
repairs performed, take charge should be charged to the warranty repair, otherwise take
charge can be charged to this service program.
Page
13(13)
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