IK1600247 - Hood Gap and Alignment Tolerances

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Revision: 2

Major
System:

CAB / SLEEPER / HOOD

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5/22/2018

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Title : Hood Gap and Alignment Tolerances
Applies To : LT/ProStar/8000, Eagle/9000, HV/WorkStar/7000, HX/PayStar, MV/DuraStar/4000

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
01/25/2019 ­ Added MV/DuraStar/4000.
06/22/2018 ­ French and Spanish translation added
06/13/2018 - Initial Article Release




DESCRIPTION
This document will guide the user through what the allowable gaps should be between the hood and the surrounding body parts once the hood has
been properly installed as recieved from the factory or after being serviced in the field. The gaps are an important part of the overall vehicle
appearance and should be maintained as outlined in this article.
Reference other iKnow articles that may be helpful when verifying the hood gaps are IK1600071 for 4000 Series, IK1600108 for LoneStar, and
IK1600189 for 9000 Series.

SYMPTOM(s)
1. Hood Gaps are too big or too tight.
2. The gap is not consistant from left to right or from top to bottom.
3. Body panels on either side of the gap are not flush.
4. A misaligned hood may cause unwanted rubbing and/or wear between body parts that will lead to damage to top coat finish.
5. A misaligned hood or improper gap may cause excessive noise/clapping during vehicle operation under certain conditions.

Diagnostic Trouble Code(s) & Dashboard Indicator Light(s)
Not Applicable

Customer Observations or Concerns
Hood gap & alignment to body panels are important for overall appearance and proper performance of the vehicle.

SPECIAL TOOL(s) / SOFTWARE

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IK1600247 - Hood Gap and Alignment Tolerances

Tool Description

Tool Number

Tape Measure

obtain locally

Wood/Plastic Block
Cotton or Latex Gloves

Page 2 of 10

Comments

Instructions

obtain locally

Used to extend edges when
measuring gap.

As shown in photos

obtain locally

Use to ptotect top coat finish

SERVICE PARTS INFORMATION
Not Applicable

DIAGNOSTIC STEP(s)
Not Applicable

HOOD GAP INSPECTION STEP(s)

Wear soft gloves and take care not to scratch or damage top coat finish.

LT/ProStar/8000, MV/DuraStar/4000 - Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Comments

A

17mm - 29mm

See Figure 1, photos 1-2

B

17mm - 29mm

See Figure 1, photos 1-3

A to B Paralleism

4mm Max

Difference between A & B

Lt Side Gap vs Rt Side Gap

6mm Max

Difference between left & right sides

Measuring the hood to door gap. (Right side is shown, Left side is the same but opposite)
Measure at both Point A and Point B as shown in Figure1. Refer to Photos 2 & 3 in Figure 1 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 1: LT/ProStar/8000 and MV/DuraStar/4000
Photo 1: Overall view of right side gap showing Point A & Point B.
Photo 2: Measurement at Point A.
Photo 3: Measurement at Point B.

LT & MV Gaps Only
Cab to Hood Flushness

Requirement
0 - 5mm

Comments
See Photo 1 in Figure 2 below

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 2: LT & MV Gaps Only - Flushness & Charater Line
Photo 1: Measuring Hood Flushness to Cab Door using plastic block & Tape Measure
Photo 2: Example of a misaligned hood. (This photo depicts an unacceptable condition.)

Eagle/9000 Series with Dual DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Comments

Horizontal Gap

32mm - 42mm

Reference Figure 3 below

Vertical Gap

14mm - 24mm

Reference Figure 3 below

Measuring the hood to cab gaps. (Right side is shown, Left side is the same but opposite)
Measure both Horizonal & Verticle gaps as shown in Figure 3. Refer to Photos 2-5 in Figure 3 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 3: Eagle & 9000 Series Hood Gap & Alignment
Photo 1: Overall view of right side gap. Left side is the same but opposite.
Photo 2-3: Measurement of Horizontal Gap.
Photo 4-5: Measurement of Vertical Gap.
Drawing 1: Reference Only

9000 Series without Dual DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Vertical Gap at Hood Seam 15.08mm - 20.32mm

Comments
Reference Figure 4, photo 3

Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)
Measure both Horizonal & Verticle gaps as shown in Figure 4. Refer to Photos 2-5 in Figure 4 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 4: 9000 Series Hood Gap & Alignment
Photo 1: Overall view of left side hood to cab gap. Right side is the same but opposite.
Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.

HV/WorkStar/7000 Series- Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Comments

A

17mm - 29mm

See Figure 5, photos 1 & 2

B

17mm - 29mm

See Figure 5, photos 1 & 2

A to B Paralleism

4mm Max

Difference between A & B (both sides)

Lt Side Gap vs Rt Side Gap

6mm Max

Difference between left & right side of truck

Measuring the hood to door gap. (Right side is shown, Left side is the same but opposite)
Measure at both Point A and Point B as shown in Figure5. Refer to Photo 2 in Figure 5 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 5: HV/WorkStar/7000 Series Hood & Gap Alignment
Photo 1: Overall view of right side gap showing Point A & Point B.
Photo 2: Measurement at Point A & Point B.
Photo 3 & 4: Measurement of Characteristic Line.

Gaps

Requirement

Comments

Characteristic Line

0 +/- 5mm

See Figure 5, photo 3. Check both sides of truck

Cab to Hood Flushness

0 - 5mm Max

See FIgure 5, photo 4. Check both sides of truck

HX 515 without DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Comments

A

16mm - 26mm

See Figure 6, photos 1 & 2

B

17mm - 25mm

See Figure 6, photos 1 & 3

A to B Paralleism

5mm Max

Difference between A & B (both sides)

Flushness Cab to Hood

4mm Max

See Figure 6, Photo 4

4mm Max

Difference between the gaps from the left & right
side of truck.

Left Side Gap vs Rt Side Gap

Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)
Measure both Horizonal & Verticle gaps as shown in Figure 6. Refer to Photos 1-3 in Figure 6 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 6: HX 515 Hood Gap & Alignment
Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.
Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.
Photo 4: Gap flushness.

HX 620 with DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:
Gap Location

Requirement

Comments

A

18mm - 30mm

See Figure 7, photos 1 & 2

B

22mm - 34mm

See Figure 7, photos 1 & 3

C

17mm-29mm

See Figure 7, photo 4

A to B Paralleism

5mm Max

Lt Side Gap vs Rt
Side Gap

4mm Max

Difference between A & B
(both sides)
Difference between the
gaps from the left & right
side of truck.

Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)
Measure both Horizonal & Verticle gaps as shown in Figure 7. Refer to Photos 1-4 in Figure 7 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 7: HX 620 with DEACs Hood Gap & Alignment
Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.
Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.
Photo 4: Gap flushness.

HX 615 & 620 with Extention without DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment
Tolerances:
Gap Location

Requirement

Comments

A

18mm - 30mm

See Figure 8, photos 1 & 2

B

21mm - 33mm

See Figure 8, photos 1 & 3

Vertical Gap Paralleism

5mm Max

Difference between A & B (both sides)

Lt Side Gap vs Rt Side Gap

4mm Max

Difference between the gaps from the
left & right side of truck.

Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)
Measure both Horizonal & Verticle gaps as shown in Figure 8. Refer to Photos 1-3 in Figure 8 for measurment technique.

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IK1600247 - Hood Gap and Alignment Tolerances

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Figure 8: HX 615 & 620 with Extension without DEACs Hood Gap & Alignment
Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.
Photo 2-3: Measurement of hood to cab verticle gap & Fender seam location.

REMOVAL/ INSTALLATION PROCEDURE
Refer to appropriate service manual

WARRANTY INFORMATION
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

STANDARD REPAIR TIME
Refer to the SRT Manual for Repair Times

OTHER RESOURCES
Master Service Information Site

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