Caps and Plugs

1/2 inch (JIG 8) plugs with caps (qty. 4) to plug hydraulic hoses

Paint Marker/Tag

Identifying hydraulic hoses and steering positions (intermediate shaft)

Lift Table/Jack

Support and lower the steering gear out of the frame

Shims/Blocks

Support the steering gear

Torque Wrench

Capable of 420 lbf-ft (570 N-m)

Punch

Staking the locknut on the pitman arm

Power Steering Fluid

Dexron Ill type ATF

Pry Bar

Removing the intermediate shaft from input on the steering gear

Torque Seal F-900

Applied to pinch bolt and locknut for intermediate shaft

Wrenches/Sockets

36 mm socket
7/16 inch (11 mm) socket/wrench
7/8 inch (22 mm) wrench
17 mm socket/wrench
1-3/16 inch (30 mm) socket/wrench
2-3/4 inch impact socket

Table 3, Tools Needed to Replace the Steering Gear

Page 8

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

Steering Gear Replacement
IMPORTANT: The removed steering gear will be returned. See the Removed Parts and Claims for Credit sections
of the bulletin for more information.
1.

Disassemble the left and right tie rods from the pitman arm. See Fig. 3.

06/01/2016

f462278

3. Tie Rod

1. Castle Nut
2. Ball

Fig. 3, Tie Rod Assembly

-----------NOTICE----------Do not use a pry bar or pickle fork to remove the tie rod end, or seal damage could occur.
1.1

Remove the cotter pin.

1.2

Loosen the castle nut on the tie rod end.

1.3

Using an air/steel hammer or two arm puller, pop the joint from the pitman arm.

1.4

Using tie straps, secure the tie rods to the frame so they are out of the way.

Page 9

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

2.

Remove the P-clip that secures the hydraulic hoses to the frame. See Fig. 4 .

06/01/2016

f462279

Fig. 4, Removing the P-Clip

AwARNING
Hydraulic fluid may leak onto the shop floor. If this should occur, make certain the spill is cleaned up to
avoid slipping when removing the steering gear.

3.

Place a drain pan under the hydraulic lines of the steering gear.

4.

Mark the hydraulic hoses and the fittings at the steering gear for identification later. See Fig. 5 . Disconnect the
hoses and remove the fittings from the steering gear. Put the fittings aside in a clean area free of dust and
debris.
4.1

Plug the connectors on the hoses and steering gear with caps to prevent fluid from bleeding out. See
Fig. 6. If caps are not available, drain the system according to shop practice.

4.2

Using tie straps, secure the hoses to the frame so they are out of the way.

Page 1O

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/01/2016

f462290

Fig. 5, Steering Gear Hydraulic Hoses
06/01/2016

f462281

Fig. 6, Hydraulic Hose Connections Capped

IMPORTANT: Ensure that the steering wheel is centered before marking the intermediate shaft and the 90-degree
miter box.
NOTE: It will help to mark the position of the intermediate shaft at the 90-degree miter box before removal.
This will make it easier to align during installation. See Fig. 7 .
5.

Disconnect the intermediate shaft. See Fig. 8.
5.1

Remove and discard the pinch bolt from the U-joint of the intermediate shaft.

5.2

Spread the joint slight using a pry bar in the slot to increase the gap.

5.3

Slide the U-joint forward and out of the way.

Page 11

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/02/2016

f462292

A. Paint marks on the intermediate shaft and miter box.
1. Miter Box
Fig. 7, 90-Degree Miter Box and Intermediate Shaft

06/01/2016

f462280

Fig. 8, Intermediate Shaft Disconnected (pinch bolt
removed)

A DANGER
The steering gear is very heavy. Two technicians are needed to safely remove and lower the steering gear.
Failure to follow these instructions could lead to severe personal injury.

6.

Remove the steering gear.
6.1

Loosen, but do not remove, the four mounting bolts.

6.2

Leaving the center-most mounting bolt assembled to prevent the steering gear from falling, remove the
other three bolts. See Fig. 9.

6.3

Position shims across the lower control arms and use a jack to support the steering gear when
disconnected. See Fig. 10

NOTE: Remove the steer box through the passenger side of the axle (by the pitman arm), while rotating the
the steering gear down onto the shims.
6.4

Page 12

Remove the center-most mounting bolt and lower the steering gear.

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/01/2016

f462275

1. Outer Mounting Bolts
2. Center-Most Mounting Bolt
Fig. 9, Steering Gear Mounting Bolts

f462282

06/01/2016

1. Shim
Fig. 10, Positioning the Shims

7.

Remove the pitman arm.

NOTE: The pitman arm-to-steer gear is a press fit, so the two-arm puller will need to be large enough so that an
impact gun can run down.
7 .1

Loosen the locknut securing the pitman arm to the box.

7.2

Using a two-arm puller, remove the pitman arm from the box. See Fig. 11 . If necessary, hit it with a steel
hammer to loosen and break free.

06/01/2016

f462283

1. Pitman Arm
Page 13

Fig. 11, Removing the Pitman Arm with a Two-Arm Puller

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

IMPORTANT: During the installation process, take care to minimize the rotation of the pitman shaft as much as
possible while removed in order to avoid changing the steering wheel alignment.
8.

Install the pitman arm on the new steering gear. Make sure the alignment marks on the shaft of the box and the
pitman arm match up. See Fig. 12 .
8.1

Line up the splines on the pitman arm with the correct steering position of the box.

8.2

Using an impact gun, tighten the locknut until the pitman arm is pressed all the way onto the shaft.
Tighten 420 lbf-ft (570 N-m).

8.3

Using a punch, stake the locknut. See Fig. 13.

06/01/2016

f462291

Fig. 12, Alignment Marks on the Shaft of the Steering
Gear and Pitman Arm

9.

06/01/2016

f462284

Fig. 13, Staking the Locknut

Install the new steering gear on the chassis.

A DANGER
The steering gear is very heavy. Two technicians are needed to safely position and install the steering gear.
Failure to follow these instructions could lead to severe personal injury.

NOTE: Install the steer box through the passenger side of the axle (pitman arm first), while rotating the steering
gear up and into position.
9.1

Using a jack and shims, position the new steering gear in the proper installation position. See Fig. 14.
and Fig. 15.

9.2

Using the four mounting bolts, secure the steering gear. Tighten the bolts 361 lbf-ft (490 N-m). See Fig. 9.

Page 14

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/01/2016

f462285

1. New Steering Gear
2. Shim
Fig. 14, New Steering Gear Installation

06/01/2016

f462289

Fig. 15, Positioning the Steering Gear (box is hidden by
the A-frame)

10. Place a drain pan under the steering gear and hydraulic hoses.
11. Using the identification marks made earlier, install the hydraulic fittings removed earlier. Orient and tighten
the hydraulic hoses to the steering gear. Tighten the hoses 60 lbf-ft (80 N-m). See
12. Using a P-clip, mount the hydraulic hoses to the frame. See Fig. 16
13. Connect the intermediate shaft onto the steering gear.
NOTE: Ensure that the intermediate shaft is properly aligned by aligning the marks on the 90-degree miter box.
See Fig. 7 .
13.1

Slide the intermediate shaft U-joint onto the steering gear input shaft. See Fig. 17.

13.2

Install a new pinch bolt in the U-joint and tighten with a new locknut. Tighten 35 lbf-ft (48 N-m).

13.3

Apply white Torque Seal F-900 on the exposed pinch bolt threads and locknut.

Page 15

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/01/2016

f462286

Fig. 16, Mounting the Hydraulic Hoses to the Frame

06/01/2016

f462276

Fig. 17, Intermediate Shaft Connected to the Steering
Gear

14. Install the tie rods.
NOTE: Coat the tie rod end ball with 15/40 oil before tightening the tie rod end fasteners.
14.1

Insert the tie rod end in the pitman arm taper. Connect the tie rod end. See Fig. 18.

14.2

Tighten the castle nuts on the left and right sides 184 lbf-ft (250 N-m).

14.3

Install the cotter pins. See Fig. 19.

Page 16

Daimler Trucks
North America LLC

Recall Campaign

June 2016
FL712AB
NHTSA #16V-366

06/01/2016

f462287

1. Ball
2. Tie Rod

3.

4.

Castle Nut
Cotter Pin

06/01/2016

f462288

Fig. 19, Installing the Cotter Pins

Fig. 18, Tie Rod Installation

15. Fill the power steering reservoir with Dexron Ill type ATF and bleed the system as follows.
IMPORTANT: Do not turn the steering wheel until instructed. Doing so can cause air to enter the system, which can
make it more difficult and time-consuming to bleed air from the system.
15.1

Fill the power steering reservoir with Dexron Ill type ATF until nearly full. Crank the starter for 10 seconds
without allowing the engine to start; if the engine does start, shut it down immediately. Check and fill the
reservoir as needed. Repeat this procedure three times, each time checking and filling the reservoir.

15.2

Start the engine and let it idle for two minutes. Shut down the engine, and check the fluid level in the
reservoir.

15.3

Start the engine again. Turn the steering wheel from full-left to full-right, several times. As necessary,
add fluid until the reservoir dipstick reads at the full line.

16. Clean a spot on the base label (Form WAR259), write the recall number, FL712, on a completion sticker (Form
WAR260), and attach it to the base label.

Page 17