NHTSA ID Number: 10154488
Manufacturer Communication Number: FL783-REV
TSB/Document Date: 2019-03-11
Summary
FL783 Dealer Bulletin Brake Caliper Mounting Bolts
C
f422663
A. Left-hand brake (viewed from below).
B. Right-hand brake (viewed from below).
C. Sheer sleeve above in this location.
D. Shelf above in this location.
Fig. 4, Tightening Pattern, Bendix
Radial Mounted Caliper
6.1 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.
6.2 Perform a final tightening spec of 225±22.5 lbf·ft (305±31 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.
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.
7. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
8. Back off the adjuster nut three clicks.
9. Install the wheel assemblies.
10. Raise the vehicle, remove the jack stands, then lower the vehicle.
11. 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.
12. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
12.1 Apply and release the brakes several times to check for air leaks and proper operation.
12.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
12.3 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.
13. Clean a spot on the base label (Form WAR259). Write the recall number, FL783, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Page 12
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Meritor Axial Mounted Calipers
1. Set a torque wrench to 400±50 lbf·ft (542±68 N·m) and tighten the caliper mounting bolts. If they do not
turn go to step 7. If they turn, go to step 2. It may be necessary to use Meritor extension tool TDA 3256B1354
or DTNA tool DSNCHA018005 to access the bolts. If an extension tool is used, see Table 3.
2. 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 not, file a WSC ticket for instructions.
3. Remove the brake pads.
4. Remove caliper bolts.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly is installed on the right side of the vehicle.
NOTE: The Meritor axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 1.
5. 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.
6. Tighten the carrier mounting bolts in two steps as follows.
6.1
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. 2.
6.2
Repeat this process, increasing the torque value to 400±50 lbf·ft (542±68 N·m).
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.
7. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
8. Back off the adjuster nut three clicks.
9. Install the wheel assemblies.
10. Raise the vehicle, remove the jack stands, then lower the vehicle.
11. 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.
12. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
12.1 Apply and release the brakes several times to check for air leaks and proper operation.
12.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
12.3 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.
13. Clean a spot on the base label (Form WAR259). Write the recall number, FL783, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Page 13
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Meritor Radial Mounted Calipers
1. Set a torque wrench to 400±50 lbf·ft (542±68 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 7. If they turn, go to step 2.
2. 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 not, file a WSC ticket for instructions.
3. Remove the brake pads.
4. 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.
5. 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. 5 and Fig. 6.
1
1
07/30/2018
f422654
1. Caliper Mounting Bolts
Fig. 5, Meritor Radial Mounted Caliper
Page 14
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
6. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 6.
6.1
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.
6.2
Perform a final tightening spec of 400±50 lbf·ft (542±68 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.
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. 6, 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.
7. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
8. Back off the adjuster nut three clicks.
Page 15
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
9. Install the wheel assemblies.
10. Raise the vehicle, remove the jack stands, then lower the vehicle.
11. 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.
12. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
12.1 Apply and release the brakes several times to check for air leaks and proper operation.
12.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
12.3 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.
13. Clean a spot on the base label (Form WAR259). Write the recall number, FL783, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Wabco Maxxus Axial Mounted Calipers
1. Set a torque wrench to 375±25 lbf·ft (508±34 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 7. If they turn, go to step 2. It may be necessary to use Meritor extension tool TDA 3256B1354
or DTNA tool DSNCHA018005 to access the bolts.. If an extension tool is used, see Table 3.
2. 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 not, file a WSC ticket for instructions.
3. Remove the brake pads.
4. Remove caliper bolts.
IMPORTANT: The caliper/carrier assemblies are left and right handed. Ensure that the correct assembly is installed on the right side of the vehicle.
NOTE: The Wabco axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 1.
5. 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.
6. Tighten the carrier mounting bolts in two steps as follows.
6.1
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. 2.
6.2
Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m).
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.
7. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
8. Back off the adjuster nut three clicks.
9. Install the wheel assemblies.
Page 16
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
10. Raise the vehicle, remove the jack stands, then lower the vehicle.
11. 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.
12. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
12.1 Apply and release the brakes several times to check for air leaks and proper operation.
12.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
12.3 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.
13. Clean a spot on the base label (Form WAR259). Write the recall number, FL783, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Front and Rear Caliper/Carrier Assembly Inspection and
Installation - Wabco Maxxus Radial Mounted Calipers
1. Set a torque wrench to 295±22 lbf·ft (400±30 N·m) and tighten the caliper mounting bolts. If they do not
turn, go to step 7. If they turn, go to step 2.
2. 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 not, file a WSC ticket for instructions.
3. Remove the brake pads.
4. Remove caliper bolts.
Page 17
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
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.
5. 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. 7 and Fig. 8.
1
1
07/30/2018
f422656
1. Carrier Mounting Bolts
Fig. 7, Wabco Maxxus Radial Mounted Calipers
Page 18
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through
the sheer sleeve.
6. Tighten the carrier mounting bolts in two steps, using the pattern shown in Fig. 8.
6.1
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.
6.2
Perform a final tightening spec of 295±22 lbf·ft (400±30 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.
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.
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. 8, Wabco Maxxus Radial Mounted Caliper Tightening Pattern
Page 19
Daimler Trucks
North America LLC
Recall Campaign
January 2019
FL783A-M
NHTSA #18V-525
Transport Canada #2018-418
REVISED NOTICE
7. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
8. Back off the adjuster nut three clicks.
9. Install the wheel assemblies.
10. Raise the vehicle, remove the jack stands, then lower the vehicle.
11. 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.
12. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
12.1 Apply and release the brakes several times to check for air leaks and proper operation.
12.2 Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
12.3 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.
13. Clean a spot on the base label (Form WAR259). Write the recall number, FL783, on a completion sticker
(Form WAR260), and attach it to the base label to indicate this recall has been completed.
Page 20
- 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: FL783-REV
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, AIR:DISC:CALIPER
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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