North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

Inspect Rear Brake Calipers
1. Check the base label (Form WAR259) for a completion sticker for FL705 (Form WAR260) indicating this work
has been completed. The base label is usually located on the passenger-side door, about 12 inches (30 cm)
below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is not present,
proceed to the next step.
2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
3. Inspect the rear disc brake calipers for proper installation. Correctly installed calipers will have the fixed pin
positioned at the bottom of the caliper. See Fig. 1.
If the calipers are not installed correctly, go to "Caliper Orientation Procedure" on page 10.
If the calipers are installed correctly, no further work is needed. Clean a spot on the base label (Form WAR259).
Write the campaign number, FL705, on a blank red completion sticker (Form WAR260), to indicate the work has
been completed, and attach it to the base label.

A

B
05/11/2016

A. Incorrect

f422591

B. Correct
Fig. 1, Inspecting the Caliper Installation

Page 8

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

4. On each axle end, inspect the spring and caliper for evidence of contact. See Fig. 2, Fig. 3, and Fig. 4, then
go to "Caliper Orientation Procedure" on page 10.

05/13/2016

f422593

Look for contact here.
Fig. 2, Contact Area
05/13/2016

f422594

Look for contact here.
Fig. 3, Contact Area

Page 9

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

05/13/2016

f422595

Look for contact here.
Fig. 4, Contact Area

Caliper Orientation Procedure
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. Drain all the air pressure from the air brake system.
2. Raise the back of the vehicle and support it with jack stands.
3. Remove the wheels.
Page 10

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

WARNING
When work is being done on the spring chamber, carefully follow the service instructions of the chamber manufacturer. The sudden release of a compressed spring can cause serious personal injury or
death.
4. Cage the rear brake chambers so that the springs cannot actuate during disassembly.
5. Disconnect the supply and return air lines from the brake chamber.
6. Back off the manual brake adjuster 1/4 turn.
7. Remove the brake pads.
8. With the caliper/carrier assembly securely supported, remove and discard the six bolts attaching the carrier to
the anchor plate. Remove the caliper/carrier assembly.
9. If contact between the caliper and spring was noted during the inspection procedure, and the caliper shows
evidence of contact similar to that shown in Fig. 5 and Fig. 6, replace both sets of brake calipers, rotors, and
brake pads on both ends of the affected axle. Follow the procedure in "Caliper and Rotor Replacement" on page
14. Refer to PartsPro for the appropriate part numbers.

06/17/2016

f422598

Fig. 6, Caliper Damage

06/17/2016

f422597

Fig. 5, Caliper Damage

Page 11

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE
NOTE: The brake assemblies are left and right handed. See Fig. 1 on page 8.
10. Switch the brake caliper assemblies from one side of the vehicle to the other. Hand tighten the six new bolts.
11. Slide the caliper inboard and outboard. If the caliper does not slide with the mounting bolts loose, replace the
brake calipers, rotors, and brake pads on both ends of the affected axle. Go to "Caliper and Rotor Replacement"
on page 14. Refer to PartsPro for the appropriate part numbers.
If the caliper slides freely continue with the next step.
12. Align each caliper with the rotor by pushing the fixed pin side of the caliper against the shelf on the torque plate.
See Fig. 7.
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the
sheer sleeve.
13. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 7. Initially tighten all six bolts
40 to 50 lbf·ft (54 to 68 N·m). Perform the final torque spec of 180 to 200 lbf·ft (244 to 271 N·m).

B

4
A
5

6

3
1
05/13/2016

2
f422596

Tighten the fasteners in the order indicated.
A. Guide Sleeve
B. Alignment Shoulder
Fig. 7, Tightening Pattern

14. 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 caliper assembly does not move, or requires more than 40 pounds of
force to move, the caliper has a binding issue. Replace the brake calipers, rotors, and brake pads on both ends
of the affected axle. Follow the procedure in "Caliper and Rotor Replacement" on page 14. Use the part
. found in PartsPro.
numbers previously

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.

Page 12

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE
15. Install the brake pads.
15.1

Using a 0.047 inch (1.2 mm) feeler gauge, adjust the clearance. See the arrow in Fig. 8. Insert the feeler
gauge between the brake pad of the rim side and the brake caliper.
1

2

10/27/2014

f430573

1. Inboard Brake Pad
2. Feeler Gauge
Fig. 8, Adjusting the Clearance

15.2

Tighten the manual brake adjuster nut until both brake pads bear on the brake disc and there is some
resistance on the feeler gauge.

15.3

Remove the feeler gauge.

16. Install the air lines on the brake chambers. Make certain the brake hoses are not twisted and do not rub against
other components.
17. Uncage the brake chambers.
18. Install the wheels. For instructions, refer to Group 40 of the vehicle’s workshop manual.
19. Lower the vehicle.
20. 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.
21. In a safe area, check for proper brake operation, as follows, before you put the vehicle in service.
21.1

Apply and release the brakes several times to check for air leaks and proper operation.

21.2

Perform six low-speed stops to ensure proper parts replacement and full vehicle control.

21.3

Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly
cooler than others show a lack of braking effort on those wheels.

22. Clean a spot on the base label (Form WAR259). Write the campaign number, FL705, on a blank red completion
sticker (Form WAR260) to indicate the work has been completed and attach it to the base label.
Page 13

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

Caliper and Rotor Replacement
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.
NOTE: Some steps may already be completed.
1. Drain all the air pressure from the air brake system.
2. Raise the back of the vehicle and support it with jack stands.
3. Remove the wheels. For instructions, refer to Group 40 of the vehicle’s workshop manual.

WARNING
When work is being done on the spring chamber, carefully follow the service instructions of the chamber manufacturer. The sudden release of a compressed spring can cause serious personal injury or
death.
4. Cage the rear brake chambers so that the springs cannot actuate during disassembly.
5. Disconnect the supply and return air lines from the brake chamber.
6. Remove the nuts, and remove the brake chamber from the caliper/carrier assembly.
7. Back off the manual brake adjuster 1/4 turn.
8. Remove and discard the brake pads.
9. With the caliper/carrier assembly securely supported, remove and discard the six bolts attaching the carrier to
the anchor plate. Remove the caliper/carrier assembly.
10. Remove the brake rotors. For instructions, refer to Group 42 of the vehicle’s workshop manual.
11. Install the new brake rotors. For instructions, refer to Group 42 of the vehicle’s workshop manual.
12. Position the new carrier/caliper assembly, and attach it to the anchor plate with new bolts. Hand tighten the
bolts.
NOTE: The brake assemblies are left and right handed. See Fig. 1 on page 8.
13. Confirm each caliper is installed on the correct side.
14. Slide the caliper inboard and outboard. If the caliper does not slide with the mounting bolts loose, replace both
sets of brake calipers, rotors, and brake pads on both end of the affected axle. Use PartsPro to find the part
numbers.
If the caliper slides freely continue with the next step.

Page 14

Daimler Trucks
North America LLC

Recall Campaign

July 2016
FL705A
NHTSA #16V-206
Transport Canada #16-176
REVISED NOTICE

15. Align each caliper with the rotor by pushing the fixed pin side of the caliper against the shelf on the torque plate.
See Fig. 7 on page 12.
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the
sheer sleeve.
16. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 7. Initially tighten all six bolts
40 to 50 lbf·ft (54 to 68 N·m). Perform the final torque spec of 180 to 200 lbf·ft (244 to 271 N·m).
17. 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 caliper assembly does not move, or requires more than 40 pounds of
force to move, the caliper has a binding issue. Replace the brake calipers, rotors, and brake pads on both ends
of the affected axle. Use the part numbers previously found in PartsPro.

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.
18. Install new brake pads.
18.1

Using a 0.047 inch (1.2 mm) feeler gauge, adjust the clearance. See the arrow in Fig. 8 on page 13.
Insert the feeler gauge between the brake pad of the rim side and the brake caliper.

18.2

Tighten the manual brake adjuster nut until both brake pads bear on the brake disc and there is some
resistance on the feeler gauge.

18.3

Remove the feeler gauge.

19. Using new nuts, attach the brake chamber to the caliper/carrier assembly. Tighten 127 to 137 lbf· ft (172 to
186 N·m).
20. Install the air lines on the brake chambers. Make certain the brake hoses are not twisted and do not rub against
other components.
21. Uncage the brake chambers.
22. Install the wheels. For instructions, refer to Group 40 of the vehicle’s workshop manual.
23. Lower the vehicle.
24. 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.
25. In a safe area, check for proper brake operation, as follows, before you put the vehicle in service.
25.1

Apply and release the brakes several times to check for air leaks and proper operation.

25.2

Perform six low-speed stops to ensure proper parts replacement and full vehicle control.

25.3

Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly
cooler than others show a lack of braking effort on those wheels.

26. Clean a spot on the base label (Form WAR259). Write the campaign number, FL705, on a blank red completion
sticker (Form WAR260) to indicate the work has been completed and attach it to the base label.
Page 15