NHTSA ID Number: 10154444
Manufacturer Communication Number: FL794 REV
TSB/Document Date: 2019-03-11
Summary
FL794 Recall Campaign- Brake Caliper Mounting Bolts
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
10.2 Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If the DTNA extension tool is used, see Table 5.
Bendix
/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and DTNA Tool DSNCHA018005
Extension Angle
Target Torque
Tool Setting
Angle View
(degrees)
[lbf·ft (N·m)]
[lbf·ft (N·m)]
0°
11/28/2016
0
317 (430)
45
332 (450)
60
343 (465)
f422613
45°
11/28/2016
f422614
60°
11/06/2018
f422668
375 (508)
90°
11/28/2016
90
375 (508)
120
413 (560)
135
431 (584)
f422615
120°
11/06/2018
f422669
135°
11/28/2016
f422616
Table 5, Bendix/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and DTNA Tool
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.
11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
Page 12
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.
16. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
16.1 Apply and release the brakes several times to check for air leaks and proper operation.
16.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
16.3 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.
17. Clean a spot on the base label (Form WAR259). Write the recall number, FL794, 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 FL794 (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 FL794, 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.
3. Raise the vehicle and support it on jack stands.
4. 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).
5. Set a torque wrench to 202.5 lbf·ft (274.5 N·m) and tighten the caliper mounting bolts. If they do not turn, go
to step 13. If they turn, continue to step 6.
Page 13
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
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.
6. 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.
7. Remove the brake pads.
8. 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.
9. 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. 4.
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
10. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 5.
10.1 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. File a WSC ticket for instructions.
10.2 Perform a final tightening spec of 225±22.5 lbf·ft (305±31 N·m). If the DTNA extension tool is used,
see Table 5. 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. File a WSC ticket for instructions.
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.
11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
Page 14
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
A
1
B
2
2
1
3
3
10/31/2018
f422662a
NOTE: Washers are not used on radial mounted assemblies.
A. Right-Hand Brake
1. Short Pin (floating)
B. Left-Hand Brake
2. Shelf
Fig. 4, Bendix Radial Mounted Caliper
Page 15
3. Sheer Sleeve
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
D
D
C
C
B
A
5
1
2
6
4
4
6
5
3
3
2
10/31/2018
1
f422663a
A. Right-hand brake (viewed from below).
B. Left-hand brake (viewed from below).
C. Sheer sleeve above in this location.
D. Shelf above in this location.
Fig. 5, Tightening Pattern (viewed from below), Bendix Radial Mounted Caliper
15. 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.
16. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
16.1 Apply and release the brakes several times to check for air leaks and proper operation.
16.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
16.3 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.
17. Clean a spot on the base label (Form WAR259). Write the recall number, FL794, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Page 16
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
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 FL794 (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 FL794, 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.
3. Raise the vehicle and support it on jack stands.
4. 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).
5. 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, continue to step 6. It may be necessary to use DTNA extension tool DSNCHA018005.
See Table 4.
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.
6. 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.
7. Remove the brake pads.
8. 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.
9. 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.
Page 17
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
10. Tighten the carrier mounting bolts in two steps as follows.
10.1 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.
10.2 Repeat this process, increasing the torque value to 400±50 lbf·ft (542±68 N·m). If the DTNA extension tool is used, see Table 6.
Meritor Installation with a 47 Inch (119 cm) Torque Wrench and DTNA Tool DSNCHA018005
Target Torque
Tool Setting
Extension Angle
Angle View
(degrees)
[lbf·ft (N·m)]
[lbf·ft (N·m)]
0°
11/28/2016
0
338 (458)
45
354 (480)
60
366 (496)
f422613
45°
11/28/2016
f422614
60°
11/06/2018
f422668
400 (542)
90°
11/28/2016
90
400 (542)
120
441 (598)
135
460 (624)
f422615
120°
11/06/2018
f422669
135°
11/28/2016
f422616
Table 6, Meritor Installation with a 47 Inch (119 cm) Torque Wrench and DTNA Tool
Page 18
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
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.
11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.
16. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
16.1 Apply and release the brakes several times to check for air leaks and proper operation.
16.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
16.3 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.
17. Clean a spot on the base label (Form WAR259). Write the recall number, FL794, 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 FL794 (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 FL794, 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.
3. Raise the vehicle and support it on jack stands.
4. Remove all of the wheel assemblies.
Page 19
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL794A-V
NHTSA #18V-703 (Non-School Bus)
NHTSA #18V-702 (School Bus)
Transport Canada #2018-550 (Non-School Bus)
Transport Canada #2018-592 (School Bus)
REVISED NOTICE
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).
5. 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, continue to step 6.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: FL794 REV
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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