5

111MO58

Bezel

5

87AX66

Grommet

10

77AM11

Screws

In addition to the above parts, one Rivnut (part number 335AM3) will be required. This Rivnut is included in the
hardware kit (part number 204SX405).
For easier access to the area behind the cab for servicing the glad hands and trailer cord, a wider deck plate is
available. The wider deck plate covers the gap between the frame rail and the fuel tank on the left-hand side of the
vehicle, and allows access to the area behind the cab by way of the fuel tank steps. Installation of the deck plate
requires two rubber mounting strips and two rubber pads. Part numbers for these components are as follows:
Qty.

Part number

Description

1

39QL4157M

Deck plate

2

12AX147F

Rubber strips

2

39QL2541M

Rubber pads

Sleeper Box Removal

1. Secure the chassis for service, apply the parking brakes and block the rear wheels to prevent the vehicle from
moving.
2. Disconnect the batteries by disconnecting the negative cable first, then the positive cable.
3. Evacuate and recover the air conditioning refrigerant.
4. Drain the engine coolant into a suitable container, and retain for refilling the cooling system after the day cab
conversion has been completed.
Note: Draining the entire cooling system is not necessary. It is only necessary to drain the system low enough
so that the heater hoses can be disconnected.
5. Disconnect the sleeper main power wire from the electronic control power module (ECPM). The ECPM is
located inside the engine compartment, on the left-hand side of the cab mounted on the bulkhead.
Sleeper Main Power Wire

6. Disconnect the sleeper main ground wire, located on the left-hand side of the cab below the windshield wiper
motor, secured to the bulkhead.
Main Ground Wire Connection

7. Disconnect the sleeper main harness connector which is located on the left-hand side of the cab.
Sleeper Main Harness Connector

8. Disconnect the air conditioner supply and return hoses that supply the sleeper. These lines are connecting to
the main air conditioning system by T-fittings located at the rear of the engine.
Locating Air Conditioner Hose T-Fittings

9. After disconnecting the lines, install the two plugs (part Nos. 3198–1010064335 [#6] and 3198- 1010064336
[#10], supplied with O-rings) into the T-fittings. These fittings are included in the hardware parts kit.
Plugs Installed in Air Conditioner T-Fittings

10. Cut the heater hoses that supply the sleeper heater core near the heater hose T-fittings located on the engine.
Locating Sleeper Heater Hoses

11. Eliminate the heater hose T-fittings (sleeper coolant supply) by replacing the existing two heater hoses on the
engine with a length of new heater hose between the heater shut-off valve (if so equipped) and the port (or
valve, if so equipped) at the front of the engine, and a length of new hose between the heater core and the port
(or valve, if so equipped) located at the center of the engine.
12. Disconnect the air conditioner and heater hoses located under the sleeper floor from the climate control unit on
the sleeper, then remove the hoses from the chassis.
13. Remove the cab entry grab handles from both sides of the cab.
14. Remove the sleeper-to-cab transition panels, the lower rear sleeper extension panels and the lower side skirt
panels. After the sleeper-to-cab transition panels have been removed, reinstall the grab handles.
Sleeper Panels

1. Sleeper-to-cab transition panel

3. Lower side skirt

2. Grab handle

4. Lower rear sleeper extension

15. Remove the muffler and exhaust stack.
16. Remove the Huck® fasteners that secure the exhaust stanchion to the frame, then remove the stanchion.
Note: For information concerning removal of Huck® frame fasteners, refer to the Frame, Axle and Suspension
Service, and Total Vehicle Alignment Manual, 14–103.
17. Remove the exhaust pipe U-clamp from the frame bracket, and the band clamp from the exhaust pipe-to-flex
pipe connection, then remove the exhaust pipe from the chassis. Remove the exhaust pipe U-clamp from the
frame bracket, and the band clamp from the exhaust pipe-to-flex pipe connection, then remove the exhaust
pipe from the chassis.
Note: Do not discard the exhaust pipe. The pipe will be cut to length and reused.
18. Remove the trailer hose coupling plate and glad hand storage bracket, and the pogo stick or towel bar.
19. Remove the fasteners that secure the sleeper to the cab subframe.
20. Clamp the seat air lines to seal, then disconnect the lines from the air seat.
21. Remove the seats and seat base assemblies from both the left- and right-hand sides of the cab for access to
the sleeper retaining bolts.
22. Remove the seat belt retractors and the shoulder belt retainers from both the left- and right-hand sides of the
chassis.
23. Remove the B-post trim panel, and the sleeper-to-cab header trim.
24. Remove the cab headliner.
25. From the inside of the cab, remove the sixteen 8 mm bolts that secure the cab to the sleeper, and from the
inside of the sleeper, remove the four 10 mm bolts that secure the sleeper to the cab.
Note: For high-rise sleepers only, an air deflector panel may be installed on the forward edge of the cab roof,
below the sleeper shelf floor. This panel must be removed prior to removing the sleeper from the chassis. The
mounting bolt holes in the cab roof for the air deflector must be sealed with silastic sealant. Refer to service
bulletin SB-610-005 for additional information.
26. Slide the sleeper box rearward, away from the cab approximately 2 inches (far enough that the sleeper
disengages the guide pins that protrude from the cab). The sleeper box can now be removed from the chassis
by using two forklifts, or by using hydraulic jacks to raise the sleeper high enough so that straps can be slid
underneath, for removal with either a hoist or overhead crane.

Sleeper Box subframe Removal
1. Using a hydraulic jack and wooden blocks as needed, support the rear of the cab.
Supporting Rear of Cab

2. Remove the sleeper box-to-cab subframes, along with all sleeper box suspension components.
3. Remove the Huck® fasteners that secure the sleeper suspension brackets to the frame, then remove the
brackets.

Cab Suspension Installation

Warning
The fuel tanks must be removed for access to the frame. The fuel tanks can be removed without draining the
fuel if a jack or dolly with a suitable cradle is used to support the tanks. Fuel tanks filled with fuel are heavy.
Use care if the tanks are removed without draining the fuel.

1. Drain the fuel from the fuel tanks, if necessary
2. Disconnect the fuel lines from the fuel tanks, and disconnect the harness connectors from the fuel tank sending
units on both sides of the vehicle.
3. Place a suitable jack or dolly under the fuel tank to be removed.
4. Remove the nuts from the fuel tank strap T-bolts, then remove the tanks from the support brackets. Move the
tanks away from the frame on both sides of the chassis.
5. Remove the Huck® fasteners that secure the forward fuel tank J-bracket, exhaust stanchion and exhaust tie
rod frame-mounted bracket. These components must be removed so that the cab suspension frame brackets
can be installed.
6. Install the left- and right-hand cab suspension support brackets (part number 30QS4224M3) to the frame.
Installing Cab Suspension Support Brackets

Note: Chassis having single frame rails without an inside frame liner will require spacers between the inside of
the frame rail and the cab suspension support bracket. These spacers (part number 71RU21613M) are
included in the suspension kit.
7. Use Huck® pins (part number 4AM10M2) and collars (part number 159AM2) to secure the cab suspension
support brackets in place.
8. To provide adequate clearance between the cab and muffler, the exhaust stanchion and frame mounted tie rod
bracket must be relocated as follows:
Locate the center line of the exhaust stanchion 67″ (1701.8 mm) from the center line of the front cab-tochassis isolator mount.
Locate the center line of the exhaust stanchion tie rod mounting bracket 59.5″ (1511.3 mm) from the
center line of the front cab-to-chassis isolator mount.
Relocating Exhaust Stanchion and Tie Rod Mounting Bracket

9. Using Huck® frame fasteners of proper length, reinstall the crossmembers to the frame where the sleeper
suspension frame brackets were attached.

Note: A variety of Huck®-Fit frame fasteners of different lengths and diameters are available through the MACK
Parts System. Lengths of the fasteners required are determined by the thickness of the frame and brackets to
be secured.
Clean grease and dirt from all mating surfaces of the components to be secured prior to assembling the
components and installing the Huck®-Fit fasteners.
Installation of certain mounting brackets to the frame will require shims to properly align the brackets where on
the original installation, the mounting bracket was mounted on top of another bracket that has now been
eliminated with the removal of the sleeper.
10. Install the cab suspension crossmember to the frame, then install the cab airbag mounting bracket to the
underside of the cab.
11. Install the cab airbag and cab shock absorbers.
12. Install the cab leveling valve (part No. 20QE2373) and linkage rod (90AX20), both included in the suspension
kit. When installing the linkage rod, use the threaded rod ends and jam nuts from the original levelling valve
linkage rod.
Cab Suspension Exploded View

13. Shorten and connect the supply air line to the cab levelling valve. Connect the delivery line from the levelling
valve to the airbag.
Cab Leveling Valve Air Lines

14. Remove the hydraulic jack and wooden blocks from underneath the cab.
15. Charge the air system, then adjust cab ride height to 7.671 ± 0.05″ (194.84 ±1.27 mm) as outlined in service
bulletin SB-668-008.
Note: If the air system has been drained, the system can be refilled with clean, dry shop air.
16. Reinstall the fuel tanks and reconnect the fuel lines and fuel level sending unit harness connectors.
Note: Do not install the muffler and exhaust pipe at this time.

Wider Deck Plate Installation (Optional)
1. Remove the existing deck plate.
2. Remove the existing frame insulating rubber mounting strips.
3. Cut two pieces of rubber insulating strips (part number 12AX147F), long enough for both the wide deck plate
and the original deck plate, then install the strips on the flange of the frame rail. Using two rubber pads (part
number 39QL2541M), install the new wide deck plate (part number 39QL4157M) to the frame rails directly
behind the cab. Install the original deck plate to the rear of the wide deck plate.
Deck Plate Installation

Preparing Closure Panel for Painting
1. Using a commercial grade automotive sealer, seal the entire seam around the perimeter of the closure panel
where the rolled edge of the sheet metal wraps around the inboard side and butts against the return flange of
the back sheet metal panel.
Seal Perimeter of Closure Panel

2. Seal all seams along the outside corners of the closure panel.
Seal Seams on Outside Corners of Closure Panel

3. Seal seams on the gasket mating surface of the closure panel.

Seal Seams on Gasket Mating Surface

4. Paint the closure panel to match the color of the cab.
Note: The cab paint color code can be found on the paint code label located on the cab door edge.
Cab Paint Code Label

Paint the entire panel, inside and out, making sure to apply enough paint to the gasket mating surface and on
the inside of the window pinch weld opening. Allow sufficient time for the paint to cure before handling the
panel.
Note: The four reinforcement brackets may also be painted if so desired.

Closure Panel Installation

1. Mark the locations in the rear face of the lower sill panel where two 17/32″ (13.5 mm) closure panel mounting
bolt holes must be drilled as follows:
Closure Panel Mounting Bolt Hole Locations in Lower Sill Panel

Note: If the sheet metal at the two existing outer sleeper mounting holes in the lower sill panel is deformed and
“pulled-out” due to the sleeper mounting bolts, straighten the sheet metal by holding a sledge hammer against
the front side of the lower sill panel and using a light hammer to gently tap the sheet metal flat.
a. Place a straightedge along the horizontal center line of the two outer sleeper box mounting bolt holes
in the lower sill.
b. Mark the location for the first hole that is to be drilled in the lower sill 19-15/16″ (506 mm) from the
center of the existing mounting bolt hole on the left-hand side of the cab.
c. Mark the location for the second hole that is to be drilled in the lower sill 18-13/16″ (478 mm) from the
center of the marked location for the first hole.
d. Center punch the two marked locations.
e. Drill two 17/32″ (13.5 mm) holes at the marked locations in the rear face of the lower sill panel.
2. Position the closure panel face down on a padded surface to prevent marring the paint (sturdy saw horses
covered with carpet are recommended).
3. Using RTV silicone sealer (part number 342SX32), apply a bead of sealant along the seam edges and
mounting bolt hole recesses. Sealant is being applied to these areas to provide a smooth transition for the
closure panel upper and lower gaskets.
Seal Closure Panel Surfaces as Indicated

4. Peel the protective paper from the closure panel gaskets (part Nos. 23QS525M for the lower gasket, and
23QS526M for the upper gasket) to expose the adhesive.
5. Apply the upper and lower gaskets to the gasket mating surface of the closure panel.
Closure Panel Gasket Surfaces

1. Upper gasket (part number 23QS526M)

2. Lower gasket (part number 23QS525M)

6. Install flat washers (part number 271AM8) onto fourteen 8 mm by 30 mm long closure panel mounting bolts
(part number 26AM14) and four 8 mm by 25 mm long mounting bolts (part number 29AM10).
7. Install flat washers (part number 271AM10) on four 10 mm by 70 mm long mounting bolts (part number
27AM9).
8. Apply a 1/8″ (6.35 mm) bead of RTV silicone sealer (part number 342SX32) to the surface of the closure panel
seals as indicated in the following illustration. Apply the silicone sealer to the seal around the entire panel.
Apply RTV Silicone Sealer to Closure Panel Gasket

9. Apply a 1/8″ (6.35 mm) bead of RTV silicone sealer to the closure panel mating surface on the back of the cab
at the areas indicated in the following illustrations.
Apply RTV Silicone Sealer to Indicated Surfaces of Cab

10. Apply RTV silicone sealer to the shanks and Loctite® 242 to the threads of the four 10 mm closure panel
mounting bolts (part number 27AM9).
11. Find the two locating pins on the back of the cab, and the corresponding locating holes in the closure panel.
12. Lift the closure panel into place at the back of the cab and align the locating pins on the cab with the mating
locating holes in the closure panel. Once aligned, push the panel forward until the gasket contacts the cab.
13. Install the four 10 mm bolts (part number 27AM9) and washers (part number 271AM10) through the closure
panel mounting holes and into the cab. Tighten the bolts until snug.

Closure Panel Mounting Bolts — Outside Cab

Key

Qty.

Part number

Description

1

4

27AM9

Bolt, M10 x 1.50 x 70 mm long

2

4

271AM10

Washer, M10

14. Apply Loctite® 242 to the threads of the closure panel mounting bolts. Install mounting bolts and flat washers,
and tighten each until snug.
Closure Panel Mounting Bolts — Inside Cab

Key

Qty.

Part number

Description

1

4

29AM10

Cab sill-to-closure panel mounting bolt,
M8 x 1.25 x 25 mm long

2

18

271AM8

Flat washer, 8 mm

3

14

26AM14

Cab-to-closure panel mounting bolt, M8 x
1.25 x 30 mm long, with conical point

15. Using a random criss-cross pattern, tighten each of the closure panel mounting bolts to the following torque
specification:

8 mm bolts inside cab (29AM10 and 26AM14) — 15 lb-ft (20 N·m)
10 mm bolts back of cab (27AM9) — 40 lb-ft (54 N·m)
16. Clean any silicone sealant from the painted surfaces that may have oozed from the joint between the closure
panel and cab. Also clean any sealant from around the four bolts installed in the back of the closure panel.
Note: Although the four 10 mm outer mounting bolts and washers are plated, they must be painted to prevent
oxidation.
17. Temporarily install the four cab-to-closure panel reinforcement brackets (two brackets are installed at the
bottom of the closure panel and two brackets are installed on the the left- and right-hand sides of the closure
panel). Use eight 8 mm bolts (part No. 26AM14).
18. At the two bottom reinforcement brackets, use a center punch to mark the locations where the bracket
mounting holes must be drilled in the cab sill.
Marking Cab Sill for Reinforcement Bracket Mounting Hole Locations

19. At the two corner reinforcement brackets, use a center punch to mark the locations where the bracket mounting
holes must be drilled in the B-post.
Marking the B-Post for Reinforcement Bracket Mounting Hole Locations

20. Remove the four reinforcement brackets
21. Drill a pilot hole at each of the eight mounting bolt hole locations, then use a 17/32″ drill bit to enlarge the holes.
22. Using the AVK installation tool, install AVK nuts at the locations as follows:
Install four AVK nuts (part No. 335AM14) into the holes drilled in the cab sill.

Install two AVK nuts (part No. 335AM14) into the lower mounting holes in the B-post on both sides of the
cab.
Install two AVK nuts (part No. 545-2C2239342) and two spacers (545-2PH265209) into the upper
mounting holes in the B-post on both sides of the cab.
AVK Nut and Spacer Locations

Key

Qty.

Part number

Description

1

2

545-2C2239342 AVK nut

2

2

5452PH265209

Spacer

3

6

335AM14

AVK nut

23. Apply Loctite® 242 to the threads of the reinforcement bracket mounting bolts (part No. 26AM14). Place
washers (part No. 271AM8) on the mounting bolts, then install the four reinforcement brackets and tighten the
mounting bolts to 15 lb-ft (20 N·m).

Antenna Mounting Hole Patch and Clearance/Marker Lamps
Installation — Chassis Originally Equipped with High-Rise Sleeper
On cabs originally equipped with a high-rise sleeper, it will be necessary to install clearance and marker lamps.
Additionally, relocation of the antenna and closing the original antenna mounting hole will be necessary. Part numbers
for the clearance lamp assemblies and associated hardware are as follows:
Qty.

Part No.

Description

5

38MO4105M

Clearance/marker lamp assembly

5

111MO58

Bezel

5

87AX66

Grommet

10

77AM11

Screws

1

335AM3

Rivnut (included in hardware kit part No. 204SX405)

1. Cut a 2″ x 2″ (50.8 x 50.8 mm) piece of sheet metal, same gauge as the sheet metal used on the cab roof.
2. Drill two 1/8″ holes at opposite sides of the sheet metal patch, 1/4″ (6.35 mm) from the edge.

Antenna Mounting Hole Patch

3. On the inside of the cab, center the patch over the antenna mounting hole in the cab roof, then mark and drill
the two 1/8″ holes in the roof.
4. Mix a two-part epoxy adhesive and apply to the cab roof around the antenna mounting hole on the inside of the
cab.
5. Position the patch over the antenna mounting hole.
6. With an assistant inside the cab to hold the antenna patch in place, secure the patch with pop rivets. Install the
pop rivets from the outside of the cab.
Except for the patch installed over the antenna mounting hole, the cab roof is already drilled for the clearance
and marker lamp mounting holes and wire harness holes. When installing the marker lamp in the center of the
cab roof, it will be necessary to install a Rivnut into the antenna patch for securing the lamp to the cab roof.
Procedures are as follows:
1. Position the marker lamp assembly (part No. 38MO4105M) and bezel (part No. 111MO58) in the center
of the cab roof and temporarily secure with one mounting screw (part No. 77AM11) in the rear mounting
hole.
2. Align the lamp assembly, then mark the location where the front mounting screw hole must be drilled in
the cab roof.
3. Remove the lamp and bezel assembly.
4. Drill a 19/64″ (7.5 mm) hole at the marked location, then install a Rivnut (part No. 335AM3).
5. Install grommets (part No. 87AX66) into the holes for the lamp wire harness holes at each of the
locations in the cab roof.
6. Mount each lamp assembly (part No. 38MO4105M) to the cab roof with a bezel (part No. 111MO58) and
mounting screws (part No. 77AM11). Apply RTV silicone sealant (342SX32) to the screws prior to
installation, and also apply silicone sealant to the grommets and around the wires inside the cab.
7. Connect the lamp connectors to the existing wire harnesses.

Interior Trim Installation
Note: The interior trim kit (part No. 204SX404) is only available in the color medium warm gray.
Note: If a hook-up lamp is to be installed on the rear of the cab, the lamp should be mounted and wire harness run to
the lamp prior to installing the lower rear interior trim panel. Power to the hook-up lamp is supplied by wire No. 26-B
located in cavity H of the sleeper harness connector (the sleeper harness connector is located on the bulkhead). The
hook-up lamp harness should be routed along the same path as the original sleeper harness (across the cab rear sill,
then up to the lamp). The size of the pass-through hole in the cab is determined by the size of the wire loom and the
rubber grommet.
1. Locate the templates supplied in the interior trim kit (part No. 204SX404).
2. Position the headliner cutting template on the headliner, then secure the template in place with masking tape.
The holes in the template align with the holes in the headliner.

Positioning and Securing Template on Headliner

3. Using a pen, pencil or felt-tip marker, mark the headliner along the edge of the template.
Marking Trim Line on Headliner

4. Using a sharp utility knife, carefully cut the headliner along the trim line.
Cutting Headliner

5. Place the B-post cutting template on the back side of the B-post trim panel with the edge of the template
aligned against the edge of the cardboard as shown in the figure below.
Placing Template on B-Post Trim Panel

6. Secure the template in place with strips of masking tape, then use a pen, pencil or felt-tip marker to mark the
three sides of the square on the trim panel.
Marking B-Post Trim Panel

7. Remove the template, then carefully cut along the lines marked on the trim panel with a sharp knife. Cut
through the cardboard ONLY. Do not cut through the vinyl. Remove and discard the piece of cardboard.
Cutting B-Post Trim Panel

8. Again, position the template on the back of the trim panel with the edge of the template aligned against the
edge of the cardboard, and secure the template in place with strips of masking tape. Using a pen, pencil or felttip marker, mark the three lines on the trim panel material through the slits in the template.
Marking Trim Panel

9. Remove the template. Using a sharp utility knife, cut the three slits through the foam and vinyl trim material.
Marking Trim Panel

10. Repeat steps 5 through 9 above for the opposite B-post trim panel. Use the same template for the opposite
side, simply turn the template over.
11. Position the trim panels onto the B-posts on both sides of the cab.
12. Install the trim panel onto the rear sill and secure with push fasteners.
13. Install the headliner into the cab and secure with push fasteners.

Note: If so desired, the sleeper dome light switch can be removed from the headliner and covered with a
suitable cover.
14. If the optional map pocket is to be installed, install the U-clips (part No. 228AM3) onto the map pocket mounting
brackets on the cab back (closure) panel.
Note: The map pocket must be ordered separately.
U-Clips Installed on Map Pocket Mounting Brackets

15. If the map pocket is being installed, cut or punch the vinyl trim on the lower rear trim panel for the map pocket
fasteners. The trim panel backing board is already punched for the fasteners; it is only necessary to punch the
vinyl trim.
Punch Map Pocket Fastener Holes in Trim Panel

16. Install the map pocket to the trim panel using the three screws (part No. 400AX35) and three washers (part No.
271AM5006). The fasteners are installed from the rear of the panel as shown in the illustration below.
Installing Map Pocket Lower Fasteners Through Back of Trim Panel

17. Install the push fasteners into the holes in the back of the upper and lower rear trim panels.
Installing Push Fasteners in Back of Trim Panel

18. Install the trim panels by aligning the push fasteners on the back of the trim panels with the mounting holes in
the back of the cab. Push the trim panels into place to secure.
19. Install the map pocket upper screws (part No. 127AM5002), then install the two screw covers (part No.
39QR435M2) over the upper map pocket fasteners.
20. Install the cab rear window and rubber seal (refer to service bulletin SB-631-001 for installation instructions). Be
sure to use the required windshield glass sealer.

Completing Installation
1. Install the driver's and rider's seats. Tighten the seat mounting hardware to 48 lb-ft (65 N·m)
2. Using the four 20 mm spacers (part No. 35AX236) and four bolts (part No. 27AM5008), install the seat belt
tethers. The spacers must be installed between the floor and the tethers. Tighten the seat belt tether mounting
bolts to 48 lb-ft (65 N·m).
3. Install the shoulder harnesses to the cab B-posts and tighten the mounting bolts to 48 lb-ft (65 N·m).
4. Install the seat belt retractors to the floor and tighten the mounting bolts to 48 lb-ft (65 N·m).
5. Reconnect the air lines to the seat(s).
6. If the exhaust flex pipe from the turbocharger outlet to the exhaust pipe is damaged or split, install a new flex
pipe (part No. 4ME299P17), or the optional pipe (part No. 4ME22039P4).
7. Reinstall the muffler assembly.
8. Mark and cut the exhaust pipe to the dimensions as follows:
From the center line of the short elbow section, measure forward 33″ (838.2 mm) and cut the pipe at that
point.
Cut 2″ (50.8 mm) from the height of the short elbow section.
Cut Exhaust Pipe to Dimensions

9. Connect the modified exhaust pipe to the flex pipe and muffler. Tighten all muffler and exhaust pipe clamps.
Note: The exhaust stack can be cut to a shorter height for day cab application.
10. Install the exhaust stanchion tie rod.
11. Department of Transportation regulations require reflective devices on the back of the cab. Install the four
reflectors (part No. 56MO327) on the back of the cab at the locations shown in the following illustration.
Locations of Back-of-Cab Reflectors

12. Refill the cooling system with the proper coolant.
13. Evacuate and recharge the air conditioning system with 3.0 lb (1.36 kg) of 134a refrigerant (refer to the
refrigerant label affixed to receiver/dryer mounting bracket).
14. Start the engine and check for air, coolant and exhaust leaks.
15. Turn the air conditioning system ON to ensure proper operation.
16. Road test the vehicle.

Issued by
Technical Service