NHTSA ID Number: 10154444
Manufacturer Communication Number: FL794 REV
TSB/Document Date: 2019-03-11
Summary
FL794 Recall Campaign- Brake Caliper Mounting Bolts
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. 6 and Fig. 7.
Page 20
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
1
1
07/30/2018
f422654
1. Caliper Mounting Bolts
Fig. 6, Meritor Radial Mounted Caliper
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. 7.
10.1 Initially tighten all 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 400±50 lbf·ft (542±68 N·m). If the DTNA extension tool is used, see
Table 6. 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.
Page 21
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
4
4
3
3
2
2
1
1
A
B
07/30/2018
f422655
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
Fig. 7, Tightening Pattern, Meritor Caliper
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.
Page 22
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
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 - Wabco Maxxus 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 for a 47 in (119 cm) long wrench.
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.
Page 23
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
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 Wabco 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.
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 375±25 lbf·ft (508±34 N·m). If the DTNA extension tool is used, see Table 5 depending on the length of the torque wrench.
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 - Wabco Maxxus 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.
Page 24
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
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 273 lbf·ft (370 N·m) and tighten the caliper mounting bolts. If they do not turn, go to
step 13. If they turn, continue to step 6.
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. 8 and Fig. 9.
Page 25
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
1
1
07/30/2018
f422656
1. Carrier Mounting Bolts
Fig. 8, Wabco Maxxus Radial Mounted Calipers
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. 9.
10.1 Initially tighten all 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 295±22 lbf·ft (400±30 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.
Page 26
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
4
4
3
3
2
2
1
1
A
B
07/30/2018
f422657
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
Fig. 9, Wabco Maxxus Radial Mounted Caliper Tightening Pattern
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.
Page 27
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
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.
Bendix Axial Caliper/Carrier Assembly Inspection and
Installation - XB, XC, EFX and HDX Model Vehicles.
NOTE: XC motorhome chassis have ZF independent front axle. No work is needed on ZF front axle calipers.
Inspect/repair the Bendix rear axle calipers only.
1. Check the base label (Form WAR259) for a completion sticker for FL794 (Form WAR260) indicating this
work has been completed. The base label is usually located on the front wall under the dash. If a sticker is
present, 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 place jack stands under the frame rails to ensure the vehicle cannot drop.
4. Beginning with the right-front wheel, use a tire runout gauge to check the radial runout. See Fig. 10. Write
down the measurement for later use to avoid vibration complaints.
5. Mark the two studs closest to the valve stem as shown in Fig. 11, for proper wheel assembly location when
reinstalling the wheel assembly on the hub.
1
1
07/318/2018
f400390a
1. Valve Stem
Fig. 11, Marking Wheel Studs
07/30/2018
1. Radial Runout
Fig. 10, Radial Runout Check for Tires
Page 28
f400373a
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
6. Remove the lug nuts, then remove the wheel assembly.
IMPORTANT: Before removing the brake pads, it is recommended to check the adjuster mechanism for proper
operation.
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).
7. 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 15. If they turn, continue to step 8. It may be necessary to use DTNA extension tool DSNCHA018005.
See Fig. 1 and 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.
8. 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 both brake pad sets on both ends of the axle.
9. Remove the brake pads.
10. Remove the caliper bolts and washers (if installed) and discard.
IMPORTANT: The caliper/carrier assemblies are left- and right-handed. Ensure that the correct assembly is installed on the side being worked on.
11. Align the caliper/carrier assembly with the rotor, pushing the caliper against the shelf on the torque plate,
then install the caliper/carrier assembly using new caliper mounting bolts and washers. See Table 1 for
parts information. See Fig. 2 for an example of the front caliper/carrier assembly.
12. Tighten the M20 X 2.5 carrier mounting bolts as follows. See Fig. 3.
12.1 Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with
the inner-most bolt and moving to the outer-most bolt. Then tighten the three bolts on the other side
of the caliper 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outermost bolt.
12.2 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.
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.
13. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
14. Back off the adjuster nut three clicks.
Page 29
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
15. Using the two studs marked earlier as a guide, install the wheel assembly. When correctly installed, a line
drawn from the valve stem through the center of the wheel assembly should go between the two marked
studs.
16. Using a tire runout gauge, measure and record the radial runout of the tire and wheel assembly. Mark the
highest point on the tire and wheel assembly. Rotate the tire and wheel assembly until the high spot is at
the 12 o’clock position (without allowing the assembly to turn). Loosen all lug nuts to let the assembly settle,
then tighten the lug nuts in the proper sequence. See Group 40 of the applicable vehicle maintenance
manual for the tightening sequence. The radial runout should be very close to what was recorded in step 3.
If not, repeat this step. Record the “final” radial runout, note the wheel location, and include the information
in the recall claim in OWL.
17. Perform the steps above for each wheel location (as needed based on the population letter) until all wheel
locations have been inspected and repaired if needed.
18. Raise the vehicle, remove the jack stands, then lower the vehicle.
19. 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.
20. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
20.1 Apply and release the brakes several times to check for air leaks and proper operation.
20.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
20.3 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.
21. Clean a spot on the base label (Form WAR259), write the recall number, FL794, on a red completion sticker
(Form WAR260), and attach it to the base label, indicating this work has been completed.
Page 30
- 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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- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
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