03/31/2021
CAL FTL 42-003

Subject: Inspection and Correction of the Clearance between the Drive Axle
Disc Brake Chamber and the Airliner Leaf Spring
Models Affected: Model year 2021 and 2022 Freightliner New Cascadia vehicles built from January
13, 2020 through February 16, 2021
Our records indicate that you are the owner of certain vehicles, and therefore DTNA has decided to share the
following documentation with you.
Please see the attached communication in this email. We hope you find this information helpful.

Daimler Trucks
North America LLC

Customer Advisory Letter

03/31/2021
CAL FTL 42-003

Subject: Inspection and Correction of the Clearance between the Drive Axle
Disc Brake Chamber and the Airliner Leaf Spring
Models Affected: Model year 2021 and 2022 Freightliner New Cascadia vehicles built from January
13, 2020 through February 16, 2021

Work Instructions
1. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
2. Measure the clearance between the bottom of the disc brake air chamber and the top of the Airliner leaf
spring as shown in Fig. 1. The minimum clearance is .19 inches (5 mm).
If the clearance is equal to or more than 5 mm, no further work is needed.
If the clearance is less than 5 mm, continue to step 3.

Fig. 1, Clearance between the Bottom of the Disc Brake Air Chamber and the Top of the Airliner Leaf Spring

3. If the clearance is less than 5 mm, remove the caliper/carrier assembly and hub and rotor assembly to
replace the disc brake anchor plate.
Use the 423 bill of materials in Parts Pro to get the correct anchor plate part number for the vehicle.
3.1.
Place jack stands under the frame rails.
3.2.
Following all shop procedures, remove the wheel and tire assemblies.
3.3.
Following all shop procedures, remove the air pressure from the air brake system and cage
the drive axle brakes.
3.4.
Remove the air lines at the chambers for each brake assembly.
NOTE: See subject 35.01.100 of the New Cascadia Workshop Manual for specific instructions on
preparing the hub for removal.
3.5.
Remove the bolts holding the carrier/caliper assembly onto the drive spindle.
3.6.
Remove the caliper/carrier assembly and set it aside to allow for the removal of the hub and
rotor assembly.
If needed, instructions on how to remove the WABCO caliper slack adjuster assembly can be
found in MAXXUS 22 Mechanical Sliding Disc Brake Caliper service literature on the WABCO
website.
3.7.
Remove the hub and rotor assembly.
NOTE: Always use new fasteners when installing an anchor plate.
3.8.
Remove the existing anchor plate assembly and install the new anchor plate assembly.
If needed, instructions on how to replace the anchor plate assembly can be found in Subject
42.20.120 of the New Cascadia Workshop Manual.
4. Install the hub and rotor assembly. If needed, instructions can be found in Subject 35.01.100 of the New
Cascadia Workshop Manual.
NOTE: Always use new fasteners when installing the carrier/caliper assembly.
5. Install the caliper/carrier assembly. See Fig. 2.

Fig. 2, Axial Mount Disc Brake Caliper/Carrier and Chamber
6. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque
plate.
NOTE: Where instructions call for a torque wrench, use a Snap-On torque wrench ATECH4RS600, or
equivalent, with a center-to-handle length of 47 inches (119 cm). Due to limited caliper bolt access on the
drive axles when combined with Airliner suspensions, use tool DDE DSNCHA018005 shown in Fig. 3.

Fig. 3, Special Tool, DDE DSNCHA018005

When using tool DDE DSNCHA018005, use the torque conversion values shown in Table 1.

Table 1, Torque Check with Special Tool DDE DSNCHA018005
7. Install the caliper/carrier assembly using new caliper mounting bolts. Tighten the caliper/carrier mounting
bolts in two steps as follows:
7.1. 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.

See Fig. 4 for the left-side caliper sequence and Fig. 5 for the right-side caliper sequence.

Fig. 4, Left-Side Caliper Tightening Sequence

Fig. 5, Right-Side Caliper Tightening Sequence

7.2. Repeat the tightening sequence, increasing the torque value to 375±25 lbf·ft (508±34 N·m).
8. Charge the air system and check for leaks.

9. Check the brakes for proper operation.
10. Document any vehicles found with inadequate clearance caused by incorrect anchor plates. Send this
documentation to your DTNA service representative.