FSB 810-004 Service Bulletin/Repair Instructions

Trucks
Mack Trucks

Greensboro, NC USA
Date
Group
No.
Release
Page
7.2020
81
01
01
1(11)
Back Of Cab Crack, Repair

LR
FSB 810-004, Back of Cab Crack, Repair

(July 2020)

Certain Mack LR model trucks may experience crack on the back of cab. Mack Trucks

determine to replace the existing panel kit of engine cover with new panel kit.

Follow the instruction outlined in this FSB to repair the crack on the back of cab and to

replace the panel kit of engine cover.
Required Parts

Part Description
New part number
Quantity
Engine cover, panel kit
78586554
1
PV729-FSB810-004_M
USA152379213
Mack Trucks
Date

7.2020
Group
No.
Release
81
01
01
Procedure

You must read and understand the precautions and guidelines in Service Information,

group 8, "General Safety Practices, Brakes" before performing this procedure. If you are

not properly trained and certified in this procedure, ask your supervisor for training before

you perform it.

NOTE: Information is subject to change without notice. Illustrations are used for reference

only and can differ slightly from the actual vehicle being serviced. However, key

components addressed in this information are represented as accurately as possible.

1 Park the vehicle on a level surface with the steering wheel in the straight ahead position.

2 Apply the parking brake.

3 Place the gear lever in neutral or park.

4 Install the wheel chocks.
W7086748
Page

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Mack Trucks
Date

7.2020
Group
No.
Release
81
01
01
5 Disconnect the cable from the battery’s negative terminal.
W3086747
CAUTION

Risk of material damage.

Failure to secure loose material in the cab before tilting may result in material damage.

Secure all loose material within the cab before tilting.
CAUTION

Risk of material damage.

Damage may occur to the cab.

Make sure that there is adequate space in front of the vehicle before tilting the cab.
WARNING

Risk of serious injury.

A cab that is not tilted to the end position constitutes a safety risk.

Always tilt the cab to the end position. Never perform any work under the cab before it has

been tilted to the end position.
Page

3(11)
Mack Trucks
Date

7.2020
6 Tilt the cab forward.
T8160359
7 Remove the nuts and washers.

8 Remove the panel.
T8159766
Group
No.
Release
81
01
01
Page

4(11)
Mack Trucks
Date

7.2020
Group
No.
Release
81
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9 Drill a stop hole at the end of crack. Weld and repair the crack on the back of cab.
T8159770
10 Remove the M6 studs.

Note: Do not remove all the studs. Remove only the highlighted studs as shown in the

illustration.
T8159767
Page

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Mack Trucks
Date

7.2020
Group
No.
Release
81
01
01
11 Weld and close the stud holes.

Required part

Part Description
New part number
Quantity
Engine cover, panel kit
78586554
1
12 Position the panel.

Note: Use existing studs (remaining M6 studs) to position the panel.
T8159768
13 Mark the position of panel holes in BIW (Body In White) for the new rivet nuts.
T8160363
Page

6(11)
Mack Trucks
Date

7.2020
14 Remove the panel.

15 Drill holes in the BIW.
T8160364
16 Install the M8 rivet nuts.
T8160365
Group
No.
Release
81
01
01
Page

7(11)
Mack Trucks
Date

7.2020
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Release
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17 Position the panel.
T8160366
18 Install the screws.

Note: The screws to run through the saddlebag upright panel that is behind the outer skin

panel of rear wall.
T8159769
19 Torque tighten the screws.

Tightening

torque
25 ± 2.5 Nm (18.5 ± 1.8 ft-lb)
Page

8(11)
Mack Trucks
Date

7.2020
20 Install the washers and nuts.
T8160367
21 Torque tighten the nuts.

Tightening

torque
10.5 ± 1.5 Nm (7.75 ± 1 ft-lb)
22 Tilt back the cab.

Note: Ensure that the cab locks are engaged.
T8160360
Group
No.
Release
81
01
01
Page

9(11)
Mack Trucks
Date

7.2020
23 Connect the battery cable to the negative (ground) terminal.
W3086758
24 Remove the wheel chocks.
W7086759
Group
No.
Release
81
01
01
Page

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Mack Trucks
Date

7.2020
Group
No.
Release
81
01
01
Reimbursement

This repair may be eligible for reimbursement if a

product failure was experienced within time and

mileage limits of the applicable warranty coverage.

Reimbursement is obtained via the normal claim

handling process.
UCHP

Reimbursement
Claim type (used only when uploading from the

dealer Bus. Sys.)
01
Labour Code

Back Of Cab Crack, repair
8102-16-09-01 (5.0 hrs)
Causal Part
84169992
Mack Trucks reserves the right to make any changes in design or to make additions to or

upon its products without incurring any obligations to install the same on vehicles previously

built.
Page

11(11)

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