4700, 5700, 4900, 6900 Maintenance Manual

4700 5700 4900 6900 MAINTENANCE MANUAL
Models: 4700 Models

4800 Models
4900 Models
5700 Models
5900 Models
6900 Models
STI-445-7 (06/30/2021)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Foreword
When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of obtaining safe and
reliable vehicle operation. Added benefits and savings occur when you check that the engine, undercarriage, and
noise emission control parts are in good working order during lubrication.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instructions.
Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or hours
of operation. Perform daily, pretrip inspection and maintenance as outlined in the Western Star Driver’s Manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Western
Star Trucks reserves the right to discontinue models and to change specifications or design at any time
without notice and without incurring obligation. Descriptions and specifications contained in this
publication provide no warranty, expressed or implied, and are subject to revision and editions without
notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.WesternStarTrucks.com for more information, or
contact Daimler Trucks North America LLC at the address below.
Environmental and Safety Concerns and Recommendations

Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them.
To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.
Servicing vehicles may result in contact with items known to the state of California to cause harm.
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause can-
cer and birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area. If in an enclosed are, vent the exhaust to the
outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and Reproductive Harm www.P65warnings.ca.gov/diesel.
NOTICE: Parts Replacement Considerations

Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used
parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage.
© 2002–2021 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval
system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a
Daimler company.
Daimler Trucks North America LLC

Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849
Introduction
Descriptions of Service Publications
Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
formats. Refer to www.DTNAConnect.com.
Workshop/Service Workshop/service manuals contain service and repair information for all vehicle
Manual systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifica-
tions, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Driver’s/Operator’s Driver’s/operator’s manuals contain information needed to enhance the driver’s
Manual understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
ments, and related information. Some service bulletins are updates to informa-
tion in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
www.DTNAConnect.com website.
DTNAConnect DTNAConnect provides Web-based access to the most up-to-date versions of
the publications listed above. In addition, the Service Solutions feature provides
diagnostic assistance with Symptoms Search, by connecting to a large knowl-
edge base gathered from technicians and service personnel. Search results for
both documents and service solutions can be narrowed by initially entering ve-
hicle identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™ makes Western Star, Freightliner, Freightliner Custom Chassis Cor-
poration, Sterling, and Thomas Built Buses products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.
4700 5700 4900 6900 Maintenance Manual, July 2018 I–1

Introduction
Descriptions of Service Publications
Warranty-related service information available on the www.DTNAConnect.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.
I–2 4700 5700 4900 6900 Maintenance Manual, July 2018

Introduction
Page Description
For an example of a Western Star Maintenance Manual page, see Fig. 1.
A B C
Rear Axle 35
35−01 Drive Axle Lubricant

Level Check
NOTICE
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in 2
rear axle damage.
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. If the vehicle has just been driven, allow a few
minutes for the lubricant to settle. A
3. Clean the oil fill hole plug (located in the carrier
or the side of the axle housing) and the area sur− 1
rounding it, then remove the plug. For Freight−
liner axles, see Fig. 1 ; for Meritor axles, see Fig.
2 ; for Dana Spicer axles, see Fig. 3.
NOTE: Some Freightliner and Meritor axles
have a small tapped and plugged hole located
below the housing oil fill hole. This smaller hole
is for the lubricant temperature sensor only and 2
must not be used as a fill or level hole.
IMPORTANT: A lubricant level close enough to
be seen or touched is not sufficient. It must be
level with the bottom of the fill hole.
4. Check the level of the lubricant. The lubricant
must be level with the bottom of the oil fill hole 4
(see Fig. 4). If low, add lubricant. 3
B
For Freightliner axles, see Table 1 for approved
axle lubricants and lubricant capacities. 12/07/2010 f350509a
For Meritor axles, see Table 2 for approved axle A. Front View
lubricants, and Table 3 and Table 4 for axle ca− B. Rear View
pacities. 1. Axle Breather
2. Breather Hose
For Dana Spicer axles, see Table 5 for approved 3. Temperature Sensor Port
axle lubricants, and Table 6 for axle capacities. 4. Oil Fill Plug
5. Install the oil fill hole plug and tighten it per the
Fig. 1, Freightliner Tandem Axle (forward axle shown)
following:
For Freightliner axles: 37 lbf·ft (50 N·m). the possibility of dirt and road grime entering the
assembly. Remove the plug, and check the oil
For Meritor axles: 35 lbf·ft (47 N·m). level. If low, add fluid using the same lubricant
For Dana Spicer axles: 50 lbf·ft (68 N·m). recommended for the drive axle.
6. On non−drive axles using oil−lubricated wheel
bearings, clean the hub cap and plug to minimize
Western Star Maintenance Manual, November 2011 35/1
D E
09/13/2011 f020178
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example Page
4700 5700 4900 6900 Maintenance Manual, July 2018 I–3

Introduction
Maintenance Manual Contents
Group No. Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
31 . . . . . . . . . . . . . Frame and Frame Components
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders
I–4 4700 5700 4900 6900 Maintenance Manual, July 2018

General Information 00
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
Lubrication and Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06
M1 Maintenance Interval Operations Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07
Maintenance Operation Sets Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
Maintenance Service Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11
Vehicle Maintenance Schedule Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12
4700 5700 4900 6900 Maintenance Manual, October 2020

Determining Scheduled Maintenance Intervals: 00–01
Determining Scheduled km) annually with minimal city or stop-and-go opera-

tion. Examples of Service Schedule II usage are:
Maintenance Intervals • regional delivery that is mostly freeway miles
Performing regular maintenance will help ensure that • interstate transport
your Western Star vehicle delivers safe, reliable ser- • any highway operation with high annual mileage
vice and optimum performance for years to come.
Failure to follow a regular maintenance program can NOTE: Maintenance instructions in this manual
result in inefficient operation and unscheduled down- are based on average vehicle use and normal
time. operating conditions. Unusual vehicle operating
To determine the correct maintenance intervals for conditions may require service at more frequent
your vehicle, you must first determine the type of ser- intervals.
vice or conditions in which the vehicle will be operat-
ing. Generally, most vehicles operate under condi-
tions that fall within one of the two types of service
described. Before placing your new vehicle in ser-
vice, determine the type of service (Service Schedule
I or II) that applies to the intended use of the vehicle.
After determining the vehicle’s type of service, refer
to the Maintenance Service Table (00–02) or the Ve-
hicle Maintenance Schedule Tables (00–03) to deter-
mine how often maintenance should be performed.
When the vehicle reaches the distance given for a
maintenance interval, see the applicable Mainte-
nance Interval Operations Table for a list of the main-
tenance operations to be performed at that mainte-
nance interval. Use the maintenance operation
numbers to find detailed instructions in the manual
on each operation.
Types of Service
Service Schedule I (severe service) applies to ve-
hicles that travel less than 60,000 miles (100 000
km) annually or that operate under severe conditions.
Examples of Service Schedule I usage are:
• operation on extremely poor roads or where
there is heavy dust accumulation
• constant exposure to extreme hot, cold, salt air,
or other extreme climates
• frequent short-distance travel
• construction-site operation
• city operation such as fire truck or garbage
truck
• logging
• farm operation
Service Schedule II (long-haul transport) applies to
vehicles that travel more than 60,000 miles (100 000
4700 5700 4900 6900 Maintenance Manual, October 2020 00/1

00 General Information
Maintenance Service Table: 00–02
Maintenance Service Schedule Table

Maintenance Intervals
Service Schedule Maintenance Interval Operation
Frequency Miles km Hours
Initial Maintenance (IM) first 1000 1600 100
Service Schedule I* — Maintenance 1 (M1) every 1000 1600 100
(severe service)
Maintenance 2 (M2) every 5000 8000 500
vehicles that travel up to 60,000
miles (100 000 km) annually Maintenance 3 (M3) every 10,000 16 000 1000
Maintenance 4 (M4) every 20,000 32 000 2000
Initial Maintenance (IM) first 12,500 20 000
Service Schedule II† — Maintenance 1 (M1) every 12,500 20 000
(long-haul transport)
Maintenance 2 (M2) every 50,000 80 000 —
vehicles that travel over 60,000
miles (100 000 km) annually Maintenance 3 (M3) every 100,000 160 000
Maintenance 4 (M4) every 300,000 480 000
* For Service Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance
traveled.
† Use Service Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust
accumulation, extreme climate, frequent short distance travel, construction-site operation, logging, city operation, or farm operation.
Table 1, Maintenance Service Schedule Table
00/2 4700 5700 4900 6900 Maintenance Manual, October 2020

Vehicle Maintenance Schedule Tables: 00–03
1st through 34th Maintenance for Service Schedule I Vehicles

Maint. Required Maintenance Operation Service I
Service Date
No. Interval Miles km Hours
1st Initial Maintenance (IM)/M1 1000 1600 100
2nd M1 2000 3200 200
3rd M1 3000 4800 300
4th M1 4000 6400 400
5th M1 and M2 5000 8000 500
6th M1 6000 9600 600
7th M1 7000 11 200 700
8th M1 8000 12 800 800
9th M1 9000 14 400 900
10th M1, M2, and M3 10,000 16 000 1000
11th M1 11,000 17 600 1100
12th M1 12,000 19 200 1200
13th M1 13,000 20 800 1300
14th M1 14,000 22 400 1400
15th M1 and M2 15,000 24 000 1500
16th M1 16,000 25 600 1600
17th M1 17,000 27 200 1700
18th M1 18,000 28 800 1800
19th M1 19,000 30 400 1900
20th M1, M2, M3, and M4 20,000 32 000 2000
21st M1 21,000 33 600 2100
22nd M1 22,000 35 200 2200
23rd M1 23,000 36 800 2300
24th M1 24,000 38 400 2400
25th M1 and M2 25,000 40 000 2500
26th M1 26,000 41 600 2600
27th M1 27,000 43 200 2700
28th M1 28,000 44 800 2800
29th M1 29,000 46 400 2900
30th M1, M2, and M3 30,000 48 000 3000
31st M1 31,000 49 600 3100
32nd M1 32,000 51 200 3200
33rd M1 33,000 52 800 3300
34th M1 34,000 54 400 3400
Table 2, 1st through 34th Maintenance for Service Schedule I Vehicles

35th through 68th Maintenance for Service Schedule I Vehicles

Service Date
35th M1 and M2 35,000 56 000 3500
36th M1 36,000 57 600 3600
37th M1 37,000 59 200 3700
38th M1 38,000 60 800 3800
39th M1 39,000 62 400 3900
40th M1, M2, M3, and M4 40,000 64 000 4000
41st M1 41,000 65 600 4100
42nd M1 42,000 67 200 4200
43rd M1 43,000 68 800 4300
44th M1 44,000 70 400 4400
45th M1 and M2 45,000 72 000 4500
46th M1 46,000 73 600 4600
47th M1 47,000 75 200 4700
48th M1 48,000 76 800 4800
49th M1 49,000 78 400 4900
50th M1, M2, and M3 50,000 80 000 5000
51st M1 51,000 82 000 5100
52nd M1 52,000 83 700 5200
53rd M1 53,000 85 300 5300
54th M1 54,000 86 900 5400
55th M1 and M2 55,000 88 500 5500
56th M1 56,000 90 100 5600
57th M1 57,000 91 700 5700
58th M1 58,000 93 300 5800
59th M1 59,000 94 900 5900
60th M1, M2, M3, and M4 60,000 96 500 6000
61st M1 61,000 98 200 6100
62nd M1 62,000 99 800 6200
63rd M1 63,000 101 400 6300
64th M1 64,000 103 000 6400
65th M1 and M2 65,000 104 600 6500
66th M1 66,000 106 200 6600
67th M1 67,000 107 800 6700
68th M1 68,000 109 400 6800
Table 3, 35th through 68th Maintenance for Service Schedule I Vehicles

69th through 100th Maintenance for Service Schedule I Vehicles

Service Date
69th M1 69,000 111 000 6900
70th M1, M2, and M3 70,000 112 700 7000
71st M1 71,000 114 300 7100
72nd M1 72,000 115 900 7200
73rd M1 73,000 117 500 7300
74th M1 74,000 119 100 7400
75th M1 and M2 75,000 120 700 7500
76th M1 76,000 122 300 7600
77th M1 77,000 123 900 7700
78th M1 78,000 125 500 7800
79th M1 79,000 127 100 7900
80th M1, M2, M3, and M4 80,000 128 700 8000
81st M1 81,000 130 400 8100
82nd M1 82,000 132 000 8200
83rd M1 83,000 134 000 8300
84th M1 84,000 135 200 8400
85th M1 and M2 85,000 137 000 8500
86th M1 86,000 138 400 8600
87th M1 87,000 140 000 8700
88th M1 88,000 141 600 8800
89th M1 89,000 143 200 8900
90th M1, M2, and M3 90,000 144 800 9000
91st M1 91,000 146 500 9100
92nd M1 92,000 148 100 9200
93rd M1 93,000 150 000 9300
94th M1 94,000 151 300 9400
95th M1 and M2 95,000 153 000 9500
96th M1 96,000 155 000 9600
97th M1 97,000 156 100 9700
98th M1 98,000 157 700 9800
99th M1 99,000 159 300 9900
100th M1, M2, M3, and M4 100,000 160 900 10,000
Table 4, 69th through 100th Maintenance for Service Schedule I Vehicles

1st through 24th Maintenance for Service Schedule II Vehicles

Maint.
Required Maintenance Operation Interval Service Date Miles km
No.
1st Initial Maintenance (IM)/M1 12,500 20 000
2nd M1 25,000 40 000
3rd M1 37,000 60 000
4th M1 and M2 50,000 80 000
5th M1 62,000 100 000
6th M1 75,000 120 000
7th M1 87,000 140 000
8th M1, M2, and M3 100,000 160 000
9th M1 112,000 180 000
10th M1 125,000 200 000
11th M1 137,000 220 000
12th M1 and M2 150,000 240 000
13th M1 162,000 260 000
14th M1 175,000 280 000
15th M1 187,000 300 000
16th M1, M2, and M3 200,000 320 000
17th M1 212,000 340 000
18th M1 225,000 360 000
19th M1 237,000 380 000
20th M1 and M2 250,000 400 000
21st M1 262,000 420 000
22nd M1 275,000 440 000
23rd M1 287,000 460 000
24th M1, M2, M3, and M4 300,000 480 000
Table 5, 1st through 24th Maintenance for Service Schedule II Vehicles

Maintenance Operation Sets Table: 00–04
IMPORTANT: At each Maintenance Operation Set, in NOTE: Maintenance operations appearing in italics in
addition to the maintenance operations listed here, this table are for noise emission control components.
perform all daily, weekly, and monthly maintenance Numbers in this table are reference numbers match-
operations listed in the "Pretrip and Post-Trip Inspec- ing those in the text of this manual.
tion and Maintenance" chapter of the Western Star
Driver’s Manual.
Maintenance Operation Sets for Groups 00 through 88

Maint. Oper. Maintenance Interval
Operation Description
No. IM M1 M2 M3 M4
01–01 Engine Noise Panel Inspection • •
01–02 Engine Belt Inspection • •
01–03 Packbrake® Inspection and Maintenance • • •
01–04 Engine-Support Fasteners Check • •
09–01 Intake Piping Inspection • •
09–02 Air Cleaner Element Inspection and Replacement* • •
09–03 Charge Air Cooler Inspection • •
13–01 Air Compressor Inspection • • • • •
15–01 Alternator and Starter Check • • •
15–02 Battery Check • • •
20–01 Coolant Inspection • • • • •
20–02 Cooling System Inspection • • •
20–03 Pressure/Filler Cap Test • • •
20–04 Cooling System Pressure-Flush •
25–01 Clutch Release Bearing Lubrication† • • • • •
25–02 Clutch Release Cross-Shaft Lubrication • • • • •
25–03 Sleeve Assembly Bronze Bushing Lubrication • • • • •
25–04 Fluid Level Check, Hydraulic Clutch Control • • • •
25–05 Fluid Change, Hydraulic Clutch Control •
26–01 Transmission Fluid Level Inspection • • • • •
26–02 Manual Transmission Fluid Change • • • •
26–03 Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement • • • •
26–04 ESS Transmission Filter and Boot Inspection •
26–05 Transmission Inspection •
26–06 Allison and Eaton Fuller Transmission Breather Check • • • •
26–07 Allison Transmission Fluid and Filter Change‡ • • •
26–08 Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning •
26–09 Detroit™ Automated Transmission Fluid Level Inspection • •
31–01 Fifth Wheel Inspection • • • • •
31–02 Fifth Wheel Lubrication • • • • •


No. IM M1 M2 M3 M4
31–03 Holland Fifth Wheel Sliding Mechanism Inspection • • •
31–04 Frame Fastener Torque Check • • •
31–05 Trailer Electrical Connector Lubrication • • • • •
31–06 Premier 690 Coupling Inspection • •
32–01 Suspension Inspection • • • • •
32–02 Suspension Lubrication • • • • •
32–03 Suspension U-Bolt Torque Check • • •
33–01 Knuckle Pin Lubrication§ • • • • •
33–02 Tie Rod Lubrication§ • • • • •
33–03 Tie Rod Inspection • • • • •
33–04 Front Axle Wheel Bearing Lubrication • • • • •
33–05 Front Drive Axle Lubricant Level Check • • • • •
33–06 Front Drive Axle Lubricant Change • • •
33–07 Wheel Alignment Check •
33–08 Steer Axle Hub Cap Vent Plug Inspection • • • •
35–01 Drive Axle Lubricant Level Check • • • • •
35–02 Two-Speed-Axle Shift Unit Lubricant Level Check • •
35–03 Drive Axle Breather Check • • • • •
35–04 Drive Axle Lubricant Change • • •
40–01 Wheel Nut and Rim Nut Torque Check • • • • •
40–02 Tire Check • • • • •
41–01 Driveline Inspection • • • • •
41–02 Driveline Lubrication • • • • •
42–02 Air Dryer Inspection • • • • •
42–03 Air Dryer Desiccant Replacement¶ • • • •
42–04 Alcohol Evaporator Cleaning and Inspection • •
42–05 Camshaft Bracket Lubrication • • • • •
42–06 Slack Adjuster Lubrication • • • • •
42–07 Brake Inspection • • • • •
42–08 Versajust Slack Adjuster Inspection and Lubrication** • • • •
42–09 Bendix Automatic Drain Valve Operating and Leakage Tests†† • •
46–01 Drag Link Inspection • • • • •
46–02 Drag Link Lubrication • • • • •
46–03 Power Steering Fluid and Filter Changing •
46–04 Steering Shaft Lubrication • • • • •


No. IM M1 M2 M3 M4
46–05 Power Steering Gear Lubrication • • • • •
47–01 Fuel Filter Replacement • • • • •
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement • • •
47–03 Fuel Tank Band Nut Tightening • • • • •
49–01 Exhaust System Inspection • • • • •
49–02 CAT CGI Bellows Replacement •
60–01 Cab Suspension Inspection • • •
60–02 Mirror Folding Check • •
60–03 Aerodynamic Component Inspection • • • •
72–01 Door Seal, Door Latch, and Door Hinge Lubrication • • • • •
83–01 Air Conditioner Inspection • • •
83–02 HVAC Air Filter Cleaning and Replacement • • • • •
88–01 Hood Rear Support Lubrication • • • •
* For 5700 models, complete this procedure every 300,000 miles (485 000 km).
† For Eaton Easy Pedal Advantage clutches, the interval is 50,000 miles (161 000 km) for linehaul applications.
‡ Intervals vary by transmission model, application, lubricant, and use. Contact Allison to determine the precise interval(s) for the transmission model and lubri-
cant used on the vehicle.
§ For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule
I vehicles; or every 100,000 miles (161 000 km) for Schedule II vehicles.
¶ If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M4 maintenance interval.
** Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
†† The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
Table 6, Maintenance Operation Sets for Groups 00 through 88

Initial Maintenance (IM) Operations: 00–05
IMPORTANT: After performing all operations listed in NOTE: Numbers in this table are reference numbers
this table, perform all daily and weekly maintenance matching those in the text of this manual.
operations listed in the "Pretrip Inspection and Daily
Maintenance" chapter of the Western Star Driver’s
Manual.
Initial Maintenance (IM) Operations

Maintenance
Operation Description Check
Operation Number
00–07 MI Maintenance Interval Operations Table
15–01 Alternator and Starter Check
15–02 Battery Check
26–02 Manual Transmission Fluid Change
26–03 Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement
31–04 Frame Fastener Torque Check
31–06 Premier 690 Coupling Inspection
32–03 Suspension U-Bolt Torque Check
33–06 Front Drive Axle Lubricant Change
33–07 Wheel Alignment Check
35–04 Drive Axle Lubricant Change
42–09 Bendix Automatic Drain Valve Operating and Leakage Tests*
* The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
Table 7, Initial Maintenance (IM) Operations for all Service Schedules

Lubrication and Fluid Level Check: 00–06
Table 8 summarizes all operations that must be per- Maintenance operation numbers given in the table
formed to complete Lubrication and Fluid Level are reference numbers used to help you find detailed
Check Operation 00–06 called for as an M1 mainte- instructions in the manual on the lubrication or fluid
nance interval for Service Schedule I and II vehicles. checking.
Lubrication and Fluid Level Check for Service Schedules I and II

Maintenance
Operation No.
25–01 Clutch Release Bearing Lubrication*
25–02 Clutch Release Cross-Shaft Lubrication
25–03 Sleeve Assembly Bronze Bushing Lubrication
25–04 Fluid Level Check, Hydraulic Clutch Control
26–01 Transmission Fluid Level Inspection
31–02 Fifth Wheel Lubrication
31–05 Trailer Electrical Connector Lubrication
32–02 Suspension Lubrication
33–01 Knuckle Pin Lubrication†
33–02 Tie Rod Lubrication†
33–04 Front Axle Wheel Bearing Lubrication
33–05 Front Drive Axle Lubricant Level Check
35–01 Drive Axle Lubricant Level Check
41–02 Driveline Lubrication
42–05 Camshaft Bracket Lubrication
42–06 Slack Adjuster Lubrication
46–02 Drag Link Lubrication
46–04 Steering Shaft Lubrication
46–05 Power Steering Gear Lubrication
72–01 Door Seal, Door Latch, and Door Hinge Lubrication
88–01 Hood Rear Support Lubrication
* For Eaton Easy Pedal Advantage clutches, the interval is 50,000 miles (161 000 km) for linehaul applications.
† For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule
I vehicles; or every 100,000 miles (161 000 km) for Schedule II vehicles.
Table 8, Lubrication and Fluid Level Check for Service Schedules I and II

M1 Maintenance Interval Operations Table: 00–07
The M1 Maintenance Interval Operations table lists IMPORTANT: After performing all operations listed in
all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly
at the M1 maintenance interval. Maintenance opera- maintenance operations listed in the "Pretrip and
tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance" chapter of
you find detailed instructions in this manual on the the Western Star® Driver’s Manual.
maintenance operations to be performed.
M1 Maintenance Interval Operations for Service Schedules I and II

Maintenance
Operation Number
00–06 Lubrication and Fluid Level Check
13–01 Air Compressor Inspection
20–01 Coolant Inspection
26–06 Allison and Eaton Fuller Transmission Breather Check
31–01 Fifth Wheel Inspection
31–06 Premier 690 Coupling Inspection
32–01 Suspension Inspection
33–03 Tie Rod Inspection
33–08 Steer Axle Hub Cap Vent Plug Inspection
35–03 Drive Axle Breather Check
40–01 Wheel Nut and Rim Nut Torque Check
40–02 Tire Check
41–01 Driveline Inspection
42–02 Air Dryer Inspection
42–03 Air Dryer Desiccant Replacement (with an oil-coalescing desiccant cartridge)*
42–07 Brake Inspection
42–08 Versajust Slack Adjuster Inspection and Lubrication†
42–09 Bendix Automatic Drain Valve Operating and Leakage Tests‡
46–01 Drag Link Inspection
47–01 Fuel Filter Replacement
47–02 Fuel Tank Band Nut Tightening
49–01 Exhaust System Inspection
60–03 Aerodynamic Component Inspection
83–02 HVAC Air Filter Cleaning and Replacement
* If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M4 maintenance interval.
† Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
Table 9, M1 Maintenance Interval Operations for Service Schedules I and II

The M2 Maintenance Interval Operations table lists M1 maintenance interval operations at the M2 main-
all maintenance operations that are to be performed tenance interval.
at the M2 maintenance interval. Maintenance opera-
NOTE: Maintenance operations appearing in italics in
tion numbers are reference numbers used to help this table are for noise emission control components.
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all

Maintenance
Operation Number
00–07 M1 Maintenance Interval Operations Table
01–03 Pacbrake® Inspection and Maintenance
20–02 Cooling System Inspection
20–03 Pressure/Filler Cap Test
26–02 Manual Transmission Fluid Change
26–03 Manual Transmission Air Filter/Regulator Check, and Cleaning or Replacement
26–07 Allison Transmission Fluid and Filter Change*
31–03 Holland Fifth Wheel Sliding Mechanism Inspection
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement
60–01 Cab Suspension Inspection
83–01 Air Conditioner Inspection
* Intervals vary by transmission model, application, lubricant, and use. Contact Allison to determine the precise interval(s) for the transmission model and lubri-
cant used on the vehicle.

The M3 Maintenance Interval Operations table lists maintenance interval operations in M1 and M2 when
all maintenance operations that are to be performed performing M3 maintenance interval operations.
at the M3 maintenance interval. Maintenance opera-
NOTE: Maintenance operations appearing in italics in
tion numbers are reference numbers used to help this table are for noise emission control components.
maintenance operations to be performed. Perform all

Maintenance
Operation Number
01–01 Engine Noise Panel Inspection
01–02 Engine Belt Inspection
01–04 Engine Support Fasteners Check
09–01 Intake Piping Inspection
09–02 Air Cleaner Element Inspection and Replacement*
09–03 Charge Air Cooler Inspection
15–01 Alternator and Starter Check
15–02 Battery Check
26–08 Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning
26–09 Detroit™ Automated Transmission Fluid Level Inspection
31–04 Frame Fastener Torque Check
32–03 Suspension U-Bolt Torque Check
33–06 Front Drive Axle Lubricant Change
35–02 Two-Speed-Axle Shift Unit Lubricant Level Check
35–04 Drive Axle Lubricant Change
42–04 Alcohol Evaporator Cleaning and Inspection
60–02 Mirror Folding Check
* For 5700 models, complete this procedure every 300,000 miles (485 000 km).

The M4 Maintenance Interval Operations table lists maintenance operations to be performed. Perform all
all maintenance operations that are to be performed maintenance interval operations in M1, M2, and M3
at the M4 maintenance interval. Maintenance opera- when performing M4 maintenance interval opera-
tion numbers are reference numbers used to help tions.

Maintenance
Operation Number
20–04 Cooling System Pressure Flush
25–05 Fluid Change, Hydraulic Clutch Control
26–04 ESS Transmission Filter and Boot Inspection
26–05 Transmission Inspection
42–03 Air Dryer Desiccant Replacement
46–03 Power Steering Fluid and Filter Changing
49–02 CAT CGI Bellows Replacement

Noise Emission Controls Maintenance: 00–11
General Information sale or delivery to the ultimate purchaser or while

the vehicle is in use.
2. The use of the vehicle after such a device or ele-
Federal Law, Part 205: ment of design for the purpose of noise control
Transportation Equipment Noise has been removed or rendered inoperative by
any person.
Emission Controls
Among those acts presumed to constitute tam-
Part 205, Transportation Equipment Noise Emission pering are the acts listed below:
Controls, requires the vehicle manufacturer to furnish
with each new vehicle, such written instructions for 1. The removal of engine sound-suppression
the proper maintenance, use, and repair of the ve- panels.
hicle by the ultimate purchaser to provide reasonable
2. The removal of cab tunnel or hood sound-
assurance of the elimination or minimization of noise
suppression panels.
emission control degradation throughout the life of
the vehicle. In compliance with the law, the noise 3. The removal of, or rendering inoperative, the
emission controls maintenance information in each engine speed governor so as to allow the
applicable group of this manual, in conjunction with engine speed to exceed the manufacturer’s
the vehicle service manual, provides these instruc- specifications.
tions to owners.
4. The removal of, or rendering inoperative, the
Recommendations for engine fan clutch, including bypassing the
control on any thermostatic fan drive to
Replacement Parts cause it to operate continuously.
Replacement parts, used for the maintenance or re- 5. The removal of the fan shroud.
pair of noise emission controls, should be genuine
Western Star parts. If other than genuine Western 6. The removal of, or rendering inoperative, en-
Star parts are used, for replacement or repair of gine exhaust components, including the ex-
components affecting noise emission control, the haust pipe clamping.
owner should be sure that such parts are warranted 7. The removal of air intake components.
by their manufacturer or to be equivalent to the
genuine Western Star parts in performance and du-
rability. Maintenance Instructions
Scheduled intervals are in the maintenance tables in
Western Star Noise Emission this group. A "Verification of Inspections Log (Groups
Controls Warranty 01, 20, and 49)" follows. These logs should be filled
in each time the noise emission controls on the ve-
Refer to the vehicle owner’s warranty information hicle are maintained, repaired, or replaced.
book for warranty information concerning noise emis-
sion controls.
Tampering With Noise Controls is

Prohibited
Federal law prohibits the following acts or the caus-
ing thereof:
1. The removal or rendering inoperative, by any
person (other than for the purposes of mainte-
nance, repair, or replacement) of any device or
element of design incorporated into any new ve-
hicle for the purpose of noise control prior to its

Verification of Inspections Log: 00–12
Verification of Inspections Log

Verification of Inspections Log (Group 01) Engine Rear Supports and Engine Noise Panels
Date Mileage Item Cost Maintenance Facility
Table 13, Verification of Inspections Log (Group 01) Engine Rear Supports and Engine Noise Panels
Verification of Inspections Log (Group 20) Fan Drive

Table 14, Verification of Inspections Log (Group 20) Fan Drive

Verification of Inspections Log: 00–12
Verification of Inspections Log (Group 49) Exhaust System Components

Table 15, Verification of Inspections Log (Group 49) Exhaust System Components

Engine 01
Index, Alphabetical

Engine Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02
Engine Noise Panel Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01
Engine-Support Fasteners Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–04
Pacbrake® Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–03
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–00
4700 5700 4900 6900 Maintenance Manual, September 2015

Engine 01
01–00 Safety Precautions 01–02 Engine Belt Inspection

Safety Precautions in this section apply to all Belt and Pulley Inspection
procedures within this group.
Worn or loose drive belts may cause engine over-
DANGER heating or loss of alternator power. Replace the drive
belt if any conditions described in Fig. 2 are found.
When working on the vehicle, shut down the en- To inspect a belt, gently twist it to view the belt side-
gine or motor, set the parking brake, and chock walls and bottom.
the tires. Before working under the vehicle, always 1. Inspect the belt contact surfaces for chips, flak-
place jack stands under the frame rails to ensure ing, cracks, discoloration, and other damage.
the vehicle cannot drop. Failure to follow these See Fig. 2.
steps could result in serious personal injury or
death. IMPORTANT: For EPDM rubber drive belts, do
not rely on cracking as an indicator of belt wear.
EPDM rubber drive belts resist cracking better
01–01 Engine Noise Panel than neoprene belts. A better indicator of wear
Inspection (Noise on EPDM belts is material loss.
Emission Control) 2. For EPDM belts, check the belt for material loss,
which causes the belt to seat further down in the
If equipped, inspect for torn engine panels. See pulley and to ride directly on the pulley tips. See
Fig. 1 for Caterpillar noise panel locations. If the Fig. 3.
panels are torn, contact your Western Star dealer to 3. Inspect the pulleys for excessive play or wobble.
have them replaced. Cummins M11, N14, ISC, and Excessive play or wobble indicates a failure of
ISL engines, and Detroit Diesel Series 60 and DD13 the pulley bearing. Check for belt squealing or
engines do not have engine noise panels. squeaking. Replace the bearings as necessary.
NOTE: If it is difficult to distinguish the location
of a supposed bearing noise, place a stetho-
2 scope on the component being checked, not the
pulley, to isolate the area from outside interfer-
ence.
4. Inspect all pulleys for foreign objects, oil, or
grease in the grooves.
Belt Tension Inspection

Some V-belts use a threaded adjustment, and the
ONLY accurate way to check belt tension is to use a
belt tension gauge. See your Western Star dealer for
this type of adjustment.
1 Serpentine belts are tensioned by spring-loaded idler
pulleys that are usually maintenace free. Uneven belt
11/29/95 f011040 wear can indicate a loose, worn out, or bad bearing
1. Oil Pan Noise Panel (C10 engine only) on the auto tensioner. A build up of dirt or grime
2. Left-Side Noise Panel (3406 engines only) around the front bearing surface of the wheel can
indicate a future bearing failure due to inadequate
Fig. 1, Caterpillar Engine Noise Panels
lubrication.
4700 5700 4900 6900 Maintenance Manual, September 2015 01/1

01 Engine
Caterpillar 01–03 Pacbrake® Inspection

On Caterpillar engines, there is a red and green and Maintenance
decal on the side of the idler arm mount. See Fig. 4.
A properly tensioned belt is indicated by the shoulder With frequent use, the Pacbrake exhaust brake will
of the idler arm aligned with the green zone of the operate maintenance-free. If the vehicle is used in-
decal. As the belt stretches, the shoulder will drift into consistently or seasonally, it will be necessary to per-
the red zone. If the idler arm shoulder moves into the form preventative maintenance. If the vehicle is ex-
red zone, the belt needs to be replaced. posed to excess moisture, or is used only for
periodical or seasonal use, perform the following
Cummins steps.
On Cummins engines, a properly tensioned belt is 1. With the engine off, using any oil-free or non-
indicated by the stop bar being in the center between petroleum-based high-heat lubricant, spray or
the idler arm stops. See Fig. 5. As the belt stretches, coat a sufficient amount on the restricter valve
the idler arm stop will rotate to the stop bar. If the shaft and the attaching locations at each end of
idler arm stop has rotated to contact the stop bar, the the actuation cylinder.
belt needs to be replaced.
2. With your hands or a pair of pliers, motion the
Detroit Diesel Series 60 valve several times to distribute the lubricant
down the shaft and the attaching locations.
The idler arm pivot on Detroit Diesel Series 60 en-
gines has a pointer cast into the arm. See Fig. 6. NOTE: Operation of the Pacbrake could be af-
This pointer should align with the V-groove mark at fected by starting the engine and idling for short
the rear of the mount, when belt tension is correct. periods of time. During a cold engine start-up,
As the belt stretches, the pointer will drift to the left moisture occurs in the engine and exhaust sys-
of the V-groove. If the pointer is moved past the end tem that creates a corrosion hazard. The brake
of the V-groove, the belt needs to be replaced. housing may trap water in the valve shaft bore,
causing a corrosion hazard. The brake housing
Belt Routing may trap water in the valve shaft bore, causing
corrosion resulting in an improper or non-
Refer to the following diagrams for belt routings on
the various engines. functioning brake. If it is necessary to periodi-
cally start the engine, attain normal operating
• Caterpillar: temperatures before shutting the engine down.
See Fig. 7 for CAT 3126B model.
See Fig. 8 for CAT C10 and C12 models. 01–04 Engine-Support
See Fig. 9 for CAT C15 and C16 models. Fasteners Check (Noise
• Cummins: Emission Control)
See Fig. 10 for Cummins ISX Signature 600
model, pre-2007. Front and rear engine supports for vehicles built from
January 2007 require no periodic maintenance.
See Fig. 11 for Cummins ISM model.
Mounts should be inspected when the engine is re-
See Fig. 12 for Cummins N14 model. moved for service. For vehicles manufactured prior to
See Fig. 13 for Cummins ISX models, 2007 or January 2007, perform the following check.
later. Check the rear engine-support fasteners (see
Fig. 17, Ref. 3) for tightness. Tighten the 5/8-inch
See Fig. 14 for Cummins ISC and ISL models.
fasteners 150 to 180 lbf·ft (203 to 244 N·m).
• Detroit Diesel:
Check the front engine-support fasteners for tight-
See Fig. 15 for DD Series 60 model. ness. Tighten the 3/4-inch fasteners 260 to 310 lbf·ft
See Fig. 16 for DD 13/15/16 models. (350 to 420 N·m).
01/2 4700 5700 4900 6900 Maintenance Manual, September 2015

Engine 01
1 2 3
4 5 6
7 8
01/18/2010 f151148
1. Abrasion 4. Cracking 7. Misalignment

2. Chunk-out 5. Pilling 8. Gravel Penetration
3. Improper Install 6. Uneven Rib Wear
Fig. 2, Damaged Belts
NOTE: At engine overhaul, and whenever the

engine has been removed, inspect the lower
and upper isolators (Refs. 6 and 7), and replace
them if they are worn.

01 Engine
C
09/21/2009 f012181
A. New Belt
B. Worn Belt
C. Material loss results in belt riding directly on pulley tips.
Fig. 3, EPDM Belt Wear
1
1
A
04/05/2001 f011983
1. Stop Bar
04/11/2001 2 f011982 2. Idler Arm Stops
A. Shoulder
Fig. 5, Cummins Self-Tensioner
1. Spring-Loaded Tensioner
2. Label Green Zone
Fig. 4, Caterpillar Self-Tensioner

Engine 01
1
1
2
2
04/05/2001 f011984
04/30/2001 f011976
1. V-Groove
2. Pointer 1. Fan Clutch
2. Air Conditioning Compressor
Fig. 6, Detroit Diesel Self-Tensioner 3. Alternator
3 Fig. 8, Caterpillar C10 and C12
1
2 1
04/30/2001 f011975
1. Fan Clutch
3. Alternator
4. Spring-Loaded Tensioner 04/30/2001 f011977
Fig. 7, Caterpillar 3126B 1. Fan Clutch

3. Alternator
Fig. 9, Caterpillar C15 and C16

01 Engine
2 2
3
1
4 4
04/30/2001 f011979
1. Fan Clutch
3. Alternator
Fig. 11, Cummins ISM
04/30/2001 f011978
1. Fan Clutch
2. Air Conditioning Compressor 3
3. Alternator
Fig. 10, Cummins ISX Signature 600 (pre-2007) 1
04/30/2001 f011980
1. Fan Clutch
3. Alternator
Fig. 12, Cummins N14

Engine 01
4
3
3 5
2 2
1
6
01/24/2011 f012192
1. Spring Tensioner 4. Fan Clutch
2. Alternator Pulley 5. Drive Belt
3. AC Compressor 6. Crank Shaft Pulley
Fig. 14, Cummins ISC/ISL
01/19/2012 f012182a
1. Fan Belt 4. AC Drive Belt
2. Alternator 5. Fan Clutch
3. AC Compressor
Fig. 13, Cummins ISX (2007 or later)

01 Engine
3
5
4
2
6
4
6
2
1
5
1
6
01/19/2012 f012189
1. Front Belt
2. Rear Belt
3. AC Compressor
5. Fan Clutch
6. Water Pump
Fig. 16, DD 13/15/16
01/07/2011 f012191
1. Alternator
2. AC Belt
4. Fan Clutch
5. Fan Belt
Fig. 15, Detroit Diesel Series 60

Engine 01
1 2 3
7
6
5 4
08/22/2001 f011992
1. Transmission Housing
2. Transmission Nodal Mount Bracket
3. Bolt, 5/8–18 x 4
4. Frame Bracket
5. Nut, 5/8–18
6. Lower Isolator
7. Upper Isolator
Fig. 17, Rear Engine-Support

Air Intake 09
Index, Alphabetical

Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–02
Charge Air Cooler Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–03
Intake Piping Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01
4700 5700 4900 6900 Maintenance Manual, January 2015

Air Intake 09
09–01 Intake Piping Inspection

9
Engine-Mounted Air Cleaner,

5700 Models
1. Ensure that the mounting fasteners for the air
cleaner housing are tight. See Fig. 1.
2. Check the tightness and condition of the clamp-
ing hardware. The hose clamps should be tight- 1
ened 40 lbf·in (4.5 N·m). 10
3. Ensure that the clamps are properly indexed.

9
4. Check the intake ducting for abrasions, cracks,
and holes. Replace as needed.
Frontwall-Mounted Air Cleaner,

4700 Models 3
1. Ensure that the fasteners for the air cleaner ele- 8

ment and air cleaner housing are tight. See 7
Fig. 2. 2
2. Check the tightness and condition of the clamp- 6
ing hardware. The molded-duct-to-air-cleaner 4
and molded-duct-to-elbow clamps should be
11/19/2014 5 f090512
tightened 40 lbf·in (4.5 N·m). The elbow-duct-to-
turbo clamp should be tightened 90 lbf·in (10.2 1. Air Cleaner Housing
N·m). 2. Air Cleaner Outlet Hose Clamp
3. Air Intake Duct
3. Ensure that the molded-duct-to-air-cleaner clamp 4. Air Intake Duct-to-Elbow Hose Clamp
is properly indexed. 5. Elbow
6. Elbow-to-Turbocharger Hose Clamp
4. Check the intake ducting for abrasions, cracks,
7. Mounting Bolt
and holes. Replace as needed. 8. Mounting Bracket
9. Mounting Nut
Cowl-Mounted Air Cleaner
Fig. 1, Engine-Mounted Air Cleaner and Ducting, 5700
1. Check the connections between the plastic or Models
aluminum piping and the rubber elbows. See
Fig. 3. 4. After disassembly of the plastic pipe from the
rubber connection elbow, inspect the ends of the
2. Check the tightness and condition of the clamp- pipe for evidence of the rubber elbow rubbing on
ing hardware. Clamps at rubber-to-plastic duct it. If chaffing marks are visible replace the worn
connections should be tightened 39 to 41 lbf·in pipe. Wipe any dust from the inside of the pipe.
(440 to 460 N·cm), and clamps at rubber-to-
metal duct connections should be tightened 90 to 5. Check the inside of the rubber elbow for wear
100 lbf·in (1015 to 1130 N·cm). and contamination. If the rubber elbow is reus-
able, clean it internally with a shop towel, or
3. Inspect the mating surfaces of the plastic or alu- soap and water. Blow-dry the elbow as needed,
minum pipes. If it appears that the rubber elbow and install it.
has moved on the plastic pipe, or if the hose
clamps were loose, disassemble for further in- 6. Check the condition of the gear clamp. If wear is
spection. evident, replace the gear clamp with a constant-
torque clamp. Constant-torque clamps should be
4700 5700 4900 6900 Maintenance Manual, January 2015 09/1

09 Air Intake
used if a vehicle is routinely exposed to rough

road conditions or off-road applications.
1
7. Check the two band clamps that hold the air
cleaner in place on the cowl. Ensure the canister
has not slipped downwards. If this condition is
present, loosen the two band clamp bolts and
2 slide the canister upward until the outlet pipe is
properly aligned with the opening in the cowl.
8. Inspect the alignment and fit of the rubber elbow
that passes through the cowl and attaches the
5 4 intake duct to the canister outlet pipe. Adjust as
3 necessary to ensure a proper connection and
tighten the clamps as follows: clamps at rubber-
to-plastic duct connections should be tightened
39 to 41 lbf·in (440 to 460 N·cm), and clamps at
rubber-to-metal duct connections should be tight-
ened 90 to 100 lbf·in (1015 to 1130 N·cm). Do
not over-tighten the clamps.
07/18/2011 f090491
1. Mounting Bolt, Air Cleaner Element Non–4700 Models
2. Capscrew, Air Cleaner Housing
This style of air intake system has the air cleaner
3. Clamp, Molded Duct to Air Cleaner
4. Clamp, Molded Duct to Elbow element mounted horizontally across the left side of
5. Clamp, Elbow Duct to Turbo the firewall. The air intake is through ducting built
into the hood and routed into the top of the air
Fig. 2, Frontwall-Mounted Air Cleaner, 4700 Models cleaner canister. See Fig. 4.
1. Check that the bolts on the canister mounting
brackets are tight.
2. Check the mounting angle of the air cleaner can-
ister inlet boot. It must be rotated forward slightly
to ensure a correct seal to the hood intake duct.
Inspect the hood and boot contact points for
proper contact as evident by the polished area
1 on the hood where the boot contacts it.
2 3. Check the connection points of the entire intake
system to ensure the alignment of the rubber
5 hoses to the charge air cooler pipe connections
4 are correct. Check the piping for evidence of
7 movement at the joint connections.
3
4. Check the tightness and condition of the clamp-
ing hardware. Clamps at rubber-to-plastic duct
6 connections should be tightened 39 to 41 lbf·in
08/22/2001 f090418
(440 to 460 N·cm), and clamps at rubber-to-
1. Rubber Elbow 4. Turbocharger metal duct connections should be tightened 90 to
2. Gear Clamp 5. Plastic Pipe 100 lbf·in (1015 to 1130 N·cm). Replace any
3. Constant-Torque 6. Flex Hose
clamps that are corroded or fail to operate
Clamp 7. Air Cleaner
smoothly when tightened.
Fig. 3, Air Intake, Cowl-Mounted Air Cleaner
09/2 4700 5700 4900 6900 Maintenance Manual, January 2015

Air Intake 09
2
1
3
2 4
1
10 5
3 11
7 6
5
8
08/24/2001 f090419
1. Restriction Indicator
2. Air Intake Boot
3. Canister Mounting Clamp
4. Spring Clamp
5. Charge Air Cooler Hose 07/30/2009 f090470
Fig. 4, Frontwall-Mounted Air Cleaner, Non–4700 1. Air Cleaner Housing

Models 2. Front Isolator Top Nut (2)
3. Air Restriction Indicator
09–02 Air Cleaner Element 4.
5.
Air Cleaner Outlet Hose Clamp
Air Intake Duct
Inspection and 6. Front Isolator (2)
7. Mounting Bracket
Replacement 8. Rear Mounting Bracket Capscrew (2)
9. Rear Isolator
10. Rear Isolator Mounting Capscrew (2)
NOTICE 11. Rear Isolator Nut
Do not use aftermarket air-cleaner elements. After- Fig. 5, Air Cleaner Assembly and Mounting
market air-cleaner elements may not seal the Components, 5700 Models
housing correctly, which can lead to engine dam- the cab if the vehicle is equipped with a dash-
age and potentially the loss of warranty. When re- mounted restriction gauge.
placing an air-cleaner element, use only the part
listed in PartsPro for the serial number of the Vehicles may be equipped with either a manual-reset
vehicle. restriction indicator with graduations (Fig. 6), or a
go/no-go restriction indicator without graduations
Engine-Mounted Air Cleaner, (Fig. 7).
5700 Models 1. Inspect the air restriction indicator to see if air
restriction equals or exceeds the maximum al-
For an installation diagram of the engine-mounted air lowable restriction. For instructions, see Group
cleaner used on 5700 models, see Fig. 5. 09 of the Western Star Workshop Manual.
Restriction of air flow through the air cleaner element 2. Inspect the air cleaner housing for cracks, leaks,
is measured at the tap in the air cleaner outlet. and any other damage. If the air cleaner housing
Check the restriction indicator at the air cleaner or in or element is damaged, replace it.

09 Air Intake
5
1
08/07/2007 f090452 5
4
Fig. 6, Manual-Reset Air Restriction Indicator,
Graduated
4
11/07/2014 f090471a
1. Air Cleaner Element Housing
2. Air Cleaner Element
3. Housing Cover
4. Screws
5. Inserts
Fig. 8, Air-Cleaner Assembly, 5700 Models
If a mounting isolator is damaged, replace it. For

isolator replacement instructions, see Section
09.05 of the Western Star Workshop Manual.
04/08/2005 f090431
5. If necessary, replace the air cleaner element. For
Fig. 7, Manual-Reset Air Restriction Indicator, Go/ air cleaner element replacement instructions, see
No-Go Section 09.05 of the Western Star Workshop
Manual.
IMPORTANT: Each time the air cleaner housing
6. Reset the air restriction indicator.
is replaced, perform the procedures in MOP
13–01.
3. Check the inserts at all four assembly fastener
locations (see Fig. 8). Each insert should pro- 4700 Models
trude from the housing as shown in Fig. 9. Restriction of air flow through the air cleaner element
If the head/flange of any of the threaded inserts is measured at the tap near the air cleaner outlet.
is flush with or countersunk into the housing, re- Check the restriction indicator at the air cleaner or in
place the air cleaner assembly. See Section the cab if the vehicle is equipped with a dash-
09.05 of the Western Star Workshop Manual for mounted restriction gauge.
replacement instructions. Vehicles may be equipped with either a manual-reset
4. Inspect the forward and rear mounting isolators restriction indicator with graduations (Fig. 11), or a
(see Fig. 5) for damage. Ensure the bonds be- go/no-go restriction indicator without graduations
tween the rubber and the steel plates are com- (Fig. 12).
pletely intact. See Fig. 10. 1. Inspect the air restriction indicator to see if air
restriction equals or exceeds the maximum al-
lowable restriction. For instructions, see the
Western Star Driver’s Manual.

Air Intake 09
2
1
1
01/17/2012 f090496
1. Steel Plate 2. Rubber
Fig. 10, Mounting Isolator
2. If necessary, replace the air cleaner element. For

air cleaner element replacement instructions, see
OK Group 09 of the Western Star Workshop
Manual.
3. Inspect the air cleaner housing for cracks, leaks,
or any other damage. If the air cleaner housing
B
or element is damaged, replace it.
4. Reset the air restriction indicator.
5. Each time the air cleaner housing is replaced,
perform the procedures in MOP 13–01.
OK
11/19/2014 f090513
08/07/2007 f090452
NOTE: Each insert should protrude from the housing as
shown in item A. Fig. 11, Manual-Reset Air Restriction Indicator,
A. Proper Fastener Installation Graduated
B. Damaged Insert, Flush
C. Damaged Insert, Countersunk Cowl-Mounted Air Cleaner
1. Insert
2. Screw The standard cowl-mounted air cleaner system used
on Western Star trucks is a reverse air flow design.
Fig. 9, Air-Cleaner-Housing Fasteners, 5700 Models The air flow in this system flows from the inside of

09 Air Intake
1
2
04/08/2005 f090431
5
Fig. 12, Manual-Reset Air Restriction Indicator, Go/
No-Go
the element, outward through the filter element into

the canister, then into the air intake piping on route
6
to the turbocharger. It is highly recommended that
only original equipment filter elements are used to
service the air cleaner assemblies. Aftermarket re-
placement elements may vary in size to the original
equipment, or may use a different type of seal at the
top and bottom of the element. A variance in the size 08/22/2001 f090417
of the element, or the thickness and type of seal ma- 1. Cap Nut 4. Filter Element
terial, can affect the crush of the gasket seal and 2. Service Cover 5. Mounting Band
could result in a poor seal on one of the mating sur- 3. Service Cover Gasket 6. Canister
faces. Elements that do not fit properly may allow the
Fig. 13, Cowl-Mounted Air Cleaner
element to bounce in the canister and allow dirt to
pass over the upper seal and into the canister and If unable to remove all debris, use a vacuum
intake piping. cleaner to remove all remaining dirt, dust, and
If the vehicle is equipped with dual air cleaners, re- contamination.
place both elements at the same interval. 5. Clean the gasket sealing surfaces of the canister.
1. Remove the cap nuts that secure the service Properly fitted gaskets are crucial to prevent dirt
cover to the canister. See Fig. 13. Take note of from entering the canister. Use a damp cloth to
the orientation of the air intake screen so the wipe clean and remove any hard ridges of dirt
service cover can be reinstalled in the correct built up around the old gasket sealing area on
position. the top cover and the bottom of the canister.
2. After removing the canister cap, carefully pull the 6. Apply pressure to the new gasket with your fin-
element straight up out of the canister, ensuring gers to test for resilience. When you release
no dust or debris is dropped into the canister. pressure, the gasket should instantly spring back
to its original shape.
3. Inspect the clean side of the element and canis-
ter for evidence of contamination. The clean side 7. Slide in the new element, ensuring that the bot-
of the element is the area outside the gaskets on tom gasket seats firmly.
either end of the element, including the top NOTE: The element will be sitting higher than
cover. If debris is present, find the leak, deter- normal until the cover bolts compress the gas-
mine the cause, and correct the problem area kets.
immediately.
4. Clean the inside of the canister thoroughly. Use
a clean damp cloth to wipe every surface clean.

Air Intake 09
Install a new cover gasket, making sure the seal- 5. If equipped with a dash-mounted restriction
ing area around the studs is clean and free of gauge, inspect the tube and mounting fittings on
any old gasket material. the air cleaner canister outlet pipe for tightness
and correct routing of the line to the dash-
8. Inspect the threaded area of the studs. They
mounted gauge.
should be clean and free of corrosion and foreign
material. Apply a light coating of oil. 6. If no restriction indicator of any kind is present,
check that the plugs in the canister are torqued
Inspect the cap nuts. If wear is apparent replace
to specifications.
them with new ones.
Torque the cap nuts in sequence 96 lbf·in (1080
N·cm). Do not over-tighten the cap nuts. Be cer- 09–03 Charge Air Cooler
tain that the cover has pulled down evenly
around the canister, because both element gas-
Inspection
kets and the cover gasket are being compressed 1. Check the condition of the charge air cooler pip-
as the cap nuts are tightened. ing and clamping hardware. If damaged, replace
9. Recheck the torque of the canister band mount- components and carefully reassemble it to en-
ing clamps and be certain the blank portion of sure proper penetration and alignment. Tighten
the top cap screen area is facing forward. the constant-torque clamps 98 lbf·in (11 N·m),
and the turbo-out-elbow clamp 62 lbf·in (7 N·m).
10. Press the reset button on the bottom of the air See Fig. 14.
restriction indicator to reset to zero. If the indica-
tor fails to reset to zero, replace it with a new 2. Check the connections at the charge air cooler
one. If the truck is not equipped with a restriction and all pipe-to-hose penetrations. If acceptable,
indicator or a dash-mounted restriction gauge, tighten the constant-torque clamps 98 lbf·in (11
check that the pipe plugs located in the canister, N·m) and the turbo-out-elbow clamp 62 lbf·in (7
or in the aluminum piping just before the turbo- N·m). Angle the clamps downward to prevent
charger, are tight and correctly torqued. interference with the hood.
3. Check the mounting and condition of the cooler
Frontwall-Mounted Air Cleaner, core.
Non–4700 Models
1. Release the spring clamp fasteners located at
the left end of the air cleaner canister. See
Fig. 4, Ref. 4. Use caution when removing the
element from the canister as some maneuvering
may be necessary to avoid the radiator stay rod
or brackets mounted in that area.
2. Inspect the interior of the canister. The under-
hood air intake system has the air flow directed
from the outside of the element to the inside.
Therefore, all dirt will be accumulated inside the
canister housing, and it must be cleaned thor-
oughly before reinstalling a replacement element.
3. Use caution when installing the new element to
prevent damage to the paper pleats. Be certain
the element is properly seated in the canister,
then fasten the four spring clamp fasteners.
4. Inspect the air restriction indicator mounted at
the outlet end pipe of the canister, and reset it.

09 Air Intake
2
2
07/18/2011 f090492
1. Charge Air Cooler Core
2. Constant-Torque Clamps
3. Turbo Out Elbow
4. Clamp, Turbo Out Elbow
Fig. 14, Charge Air Cooler and Piping

Air Compressor 13
Index, Alphabetical

Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01

Air Compressor 13
13–00 Safety Precautions

Safety Precautions in this section apply to all
DANGER
When working on the vehicle, shut down the en-
gine or motor, 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
death.
13–01 Air Compressor

Inspection
1. Inspect the air compressor intake hoses and
connections at the air intake and air compressor
for physical damage. If needed, change the
hoses, and/or tighten or replace the connections.
2. Inspect the coolant supply and return lines for
tight connections. Tighten the connections and
replace the lines and fasteners if needed.
3. For the air governor, inspect the piping and con-
nections for leaks. Replace gaskets and faulty
components as needed.

Alternators and Starters 15
Index, Alphabetical

Alternator and Starter Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01
Battery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–02

Alternators and Starters 15
15–00 Safety Precautions the battery compartment has been completely

vented before disconnecting or connecting the
battery cables.
procedures within this group. Battery acid is extremely harmful if splashed in
the eyes or on the skin. Always wear a face shield
and protective clothing when working around
DANGER batteries.
gine or motor, set the parking brake, and chock CAUTION
place jack stands under the frame rails to ensure The vehicle is equipped with an alternator charg-
the vehicle cannot drop. Failure to follow these ing system. Make sure the polarity (+ and –) is
steps could result in serious personal injury or correct when connecting battery cables. Revers-
death. ing the polarity will damage the alternator.
1. Make sure the batteries are disconnected.
15–01 Alternator and Starter 2. Inspect the battery cables for wear and replace
as needed. Clean cable connector terminals with
Check a wire brush. Consult your Western Star Dealer
for troubleshooting, adjustment, and battery re-
1. Disconnect the batteries. placement.
2. Check the tightness of the alternator bracket fas- 2.1 Clean and tighten the battery cables, ter-
teners; tighten the fasteners as needed. See minals, and clamps.
Group 00 for torque specifications.
2.2 Inspect the battery hold-down assembly
3. Check the tension of the alternator belt. See and the battery box. Replace worn or
Group 01 for belt tension instructions. damaged parts. Remove any corrosion
Some engines are equipped with dual alternator with a wire brush, and wash with a weak
belts. Always check both belts for correct ten- solution of baking soda and water. Rinse
sion. Engines equipped with a serpentine or with clean water, and dry. If needed, paint
poly-V belt have automatic belt tensioners and the retainer assembly to prevent corro-
do not require belt tension inspection. sion.
4. Check that all electrical connections at the alter- 2.3 Check that foreign objects, such as
nator and starter are clean. Clean and tighten all stones, bolts, and nuts are removed from
charging system electrical connections as the battery box.
needed. 2.4 After cleaning, connect the cables to the
5. Check the alternator wiring for missing insulation, batteries, and tighten them to the specifi-
kinks, and heat damage. Replace or repair as cation listed on the battery. If no specifi-
needed. cations are found, then use 10 to 15 lbf·ft
(14 to 20 N·m).
15–02 Battery Check 2.5 Coat the battery terminals with dielectric
grease.
3. Check the terminals on the battery shut-off
WARNING switch and the magnetic switch. Make sure the
terminal connections are clean and tight. Coat
Batteries generate explosive gas as a by-product the terminal connections with dielectric red
of their chemical process. Do not smoke when enamel after cleaning.
working around batteries. Put out all flames and
remove any source of sparks or intense heat in
the vicinity of the battery compartment. Make sure

Engine Cooling/Radiator 20
Index, Alphabetical

Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01
Cooling System Inspection (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02
Cooling System Pressure-Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–04
Pressure/Filler Cap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03
4700 5700 4900 6900 Maintenance Manual, 03/01/2020

20–00 Safety Precautions distilled or de-ionized water to reduce the potential

and severity of silica dropouts.
Safety Precautions in this section apply to all Keep the cooling system filled. On vehicles equipped
procedures within this group. with a frontwall-mounted translucent surge tank (see
Fig. 1), keep the coolant level between the FULL
and LOW marks. On vehicles equipped with a
DANGER frontwall-mounted steel surge tank (see Fig. 2), keep
When working on the vehicle, shut down the en- the cooling system filled so that coolant can be seen
gine or motor, set the parking brake, and chock in the sight glass in the surge tank. On vehicles
the tires. Before working under the vehicle, always equipped with a radiator-mounted translucent surge
place jack stands under the frame rails to ensure tank (see Fig. 3), keep the coolant level between the
the vehicle cannot drop. Failure to follow these FULL and LOW marks. If the coolant is low, add the
steps could result in serious personal injury or antifreeze solution mixture specified for the vehicle in
death. PartsPro (Group 01).
20–01 Coolant Inspection 2
General Information
The engine produces large quantities of heat during
its operation. Too high or low an engine operating
temperature will damage the engine. The purpose of
the cooling system is to keep the engine at its opti-
mum operating temperature. The optimum operating 1
temperature results in the most efficient use of fuel
and allows the engine oil to do its job properly.
The cooling system on Western Star vehicles is a
closed or pressure type system, with a mixture of
antifreeze and water. By pressurizing the system and
using an antifreeze/water mixture, the boiling tem-
perature of the coolant is raised, permitting more effi-
cient, higher operating temperatures.
The coolant supplied with a Western Star vehicle is a 09/07/2011 f200745
50/50 mix of antifreeze and water giving protection 1. Surge Tank 2. Fill Cap
down to –35°F (–37°C). It is recommended that this
be the minimum antifreeze mixture strength used. Fig. 1, Frontwall-Mounted Translucent Surge Tank
The maximum coolant mixture of 60 percent anti-
freeze to 40 percent water gives freeze protection to Inspection
–62°F (–52°C).
Over-concentration of antifreeze or coolant condi- WARNING
tioner can cause silicate to settle out of the coolant,
forming a silica-gel on cooling system inner surfaces, Do not remove or loosen the radiator cap until the
resulting in overheating. engine and cooling system have completely
cooled. Use extreme care when removing the cap.
In addition, the tendency for silica-gel to form in- A sudden release of pressure from removing the
creases with water hardness. Hard water (with high cap prior to the system cooling can result in a
levels of calcium and magnesium ions) increases surge of scalding coolant that could cause seri-
likelihood of the formation of silica-gel. Do not use ous personal injury.
softened water. The salt used to artificially soften it is
corrosive. Most engine manufacturers prefer use of
4700 5700 4900 6900 Maintenance Manual, 03/01/2020 20/1

20 Engine Cooling/Radiator
Every six months have the coolant mixture checked

1 2 3 4
to ensure it is at the proper concentration to protect
the cooling system from damage. Refer to the engine
manufacturer’s service literature for specific coolant
information.
NOTE: Checking the engine coolant level is part
of the Pre-trip Inspection. For more information,
see the Western Star Driver’s Manual.
1. Park the vehicle on a level surface, set the park-
ing brake, and chock the wheels. Open the hood.
2. The level of coolant should be between the FULL
and LOW marks in a translucent surge tank (see
Fig. 1 and Fig. 3) or visible through the sight
glass on a steel surge tank (see Fig. 2). If the
coolant is low or not visible in the sight glass,
05/22/2001 f200643 check the system for leaks.
1. Steel Surge Tank
2. SAE Pressure/Filler Cap WARNING
3. Sight Glass
4. Low Coolant Sensor Do not remove or loosen the radiator cap until the
Fig. 2, Steel Surge Tank, High Flow Radiators
engine and cooling system have completely
A sudden release of pressure from removing the
2 cap prior to the system cooling can result in a
surge of scalding coolant that could cause seri-
ous personal injury.
3. Slowly turn the SAE pressure/filler cap until it
3 stops, to allow the coolant pressure to bleed off.
4 Press down on the cap and turn it at the same
time, then lift off the cap.
4. While the SAE pressure/filler cap is OFF, smell
1 5 the coolant for strong odors (i.e., diesel fuel). A
strong diesel smell indicates that fuel is contami-
4
nating the coolant, and the vehicle must be taken
to a Western Star dealer to have the source
02/05/2013 f500390
found and the cooling system chemically flushed.
5. Check the condition of the coolant. If the coolant
1. Surge Tank Pressure Relief Cap
2. Surge Tank Filler Cap
shows scale, rust, silica-gel, oil, or has a frothy
3. Cold Maximum Coolant Level scum, the vehicle must be taken to a Western
4. Cold Minimum Coolant Level Star dealer to have the contaminate source
5. Coolant Level Sensor found and fixed, and the cooling system chemi-
cally flushed.
Fig. 3, Radiator-Mounted Translucent Surge Tank
NOTE: Due to environmental concerns, it is rec-
ommended that coolant flushing and the re-
NOTICE placement of coolant conditioners and coolant
Never add cold water into the system when the filters be performed by your Western Star
engine is hot as damage to the engine may result. dealer.
20/2 4700 5700 4900 6900 Maintenance Manual, 03/01/2020

20–02 Cooling System B

A 1
Inspection (Noise
Emission Control)
ing brake, and chock the wheels. Open the hood.
WARNING
10/05/2016 f200286
Do not remove or loosen the radiator cap until the
engine and cooling system have completely A. Screw tip must extend about 1/4 inch (6 mm).
cooled. Use extreme care when removing the cap. B. Washer stack must be compressed almost flat.
A sudden release of pressure from removing the 1. Adjusting Screw Hex
cap prior to the system cooling can result in a Fig. 4, Breeze Constant-Torque Hose Clamp
ous personal injury. 6. If the coolant is low, check the engine oil for pos-
2. Inspect the SAE pressure/filler cap gaskets. Re- sible coolant contamination. If the oil is discol-
place the cap if the gasket shows any signs of ored, there may be an internal engine leak, and
deterioration or damage. Install the cap and the unit should be taken to your Western Star
check to ensure that it seals properly on the dealer to be repaired before the engine is dam-
surge tank filler neck. Replace the cap if it ap- aged.
pears not to seat properly. 7. Check to see if the front of the radiator, charge
3. There is a valve on the bottom of the SAE air cooler, and oil cooler fins are clogged. Mate-
pressure/filler cap that opens under vacuum. rial in the fins will cause the cooling system to
This prevents components in the cooling/heating overheat. Pressure-wash the radiator to wash out
systems from collapsing. Inspect the vacuum- radiator clogging material.
relief valve to be sure it is not stuck. Replace the 8. Check the fan belts for wear and tightness. For
cap if the vacuum-relief valve is stuck. more information on fan belts, see Group 01. If
4. Check the hoses for possible leaks. Replace any belts are damaged, replace them. If belts are
worn, soft, or perforated hoses. loose, have the proper belt tension set by your
Western Star dealer.
5. Western Star uses Breeze Constant-Torque hose
clamps on the radiator hoses. Check the hose 9. Check the fan and fan shroud for damage. A
clamps to ensure that they are properly torqued. damaged fan or shroud will affect the air flow
See Fig. 4. The tip of the screw must extend and can cause heating problems. Have the dam-
about 1/4 inch (6 mm) from the clamp housing, aged fan or shroud replaced by your Western
and the washer stacks must be compressed al- Star dealer.
most flat. Hose clamps lose torque after installa- If all the previous steps are correct and the engine is
tion due to "compression set." Breeze Constant- overheating, there may be a problem with the fan not
Torque hose clamps will hold enough torque to operating properly, or the thermostat may be stuck
automatically keep consistent sealing pressure. closed. Take your vehicle to a Western Star dealer to
Due to temperature changes, the screw tip ex- have the problem repaired.
tension may change. The clamp screw may need
If there is a tendency for the engine to run cool, the
to be adjusted for individual applications.
fan may be running continously, or the thermostat
NOTE: Due to environmental concerns, it is rec- may be stuck open. Take the vehicle to a Western
ommended that coolant flushing and the re- Star dealer to have the problem repaired.
placement of coolant conditioners and coolant
filters be performed by your Western Star
dealer.

20 Engine Cooling/Radiator
20–03 Pressure/Filler Cap Test 5. There is a valve on the bottom of the

pressure/filler cap that opens under vacuum.
This prevents components in the cooling/heating
WARNING systems from collapsing. Inspect the vacuum-
relief valve to be sure it is not stuck. Replace the
Do not remove or loosen the radiator cap until the cap if the vacuum-relief valve is stuck.
engine and cooling system have completely
A sudden release of pressure from removing the 20–04 Cooling System
cap prior to the system cooling can result in a Pressure-Flush
ous personal injury. NOTE: See the engine manufacturer’s operation
and maintenance manual for cooling system
NOTICE maintenance. The engine manufacturer’s
manual is provided with each new vehicle at the
The radiator cap currently installed may not be the time of delivery.
same one installed when the vehicle was built. If
the radiator cap must be replaced, make sure that 1. Park the vehicle on a level surface, set the park-
it is the correct cap for the cooling system of the ing brake, and chock the wheels. Open the hood.
vehicle. Because the radiator cap pressure rating 2. Place a suitable container under the lower elbow
affects the operating temperature of the engine, of the radiator outlet pipe and under the radiator.
installing an improperly rated radiator cap may The container should be capable of holding 60
have adverse effects on the cooling system, and quarts (57 L) of fluid.
engine operating temperatures. This could cause
premature engine wear or damage.
WARNING
ing brake, and chock the wheels. Open the hood. Do not remove or loosen the radiator cap until the
2. After the coolant has cooled, loosen the engine and cooling system have completely
pressure/filler cap to relieve system pressure. cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
3. Remove the pressure/filler cap. Using the cap prior to the system cooling can result in a
Snap-On tool radiator-cap tester shown in surge of scalding coolant that could cause seri-
Table 1, check the pressure relief cap to see if it ous personal injury.
maintains pressure to within 10% of the pressure
rating marked on the cap. If it does not, replace 3. Remove the surge tank pressure/filler cap.
the cap. Make sure that the replacement radiator 4. Remove the drain plug located at the elbow of
cap is correctly rated for the cooling system of the lower radiator outlet pipe. Allow the coolant
the vehicle. Use the recommended tool in to drain.
Table 1
NOTE: Coolant, conditioners, and coolant filters
Tool Part Number must be sent to proper recyclers.
Radiator-Cap Tester TA53 5. Disconnect the radiator upper and lower hoses.
Attach the flushing gun nozzle to the radiator at
Table 1, Snap-On Tool For Pressure Relief Cap Test
the lower radiator hose opening. Run the water
4. Inspect the pressure/filler cap gaskets. Replace until the radiator is full.
the cap if the gasket shows any signs of deterio- NOTE: When flushing the radiator, do not apply
ration or damage. Install the cap and check that
the cap seals properly on the surge tank filler
more than 10 psi (103 kPa) air pressure. Exces-
neck. Replace the cap if it appears not to seat sive pressure can damage the radiator.
properly. 6. Gradually, apply air pressure to help dislodge
sediment build up in the radiator core.

IMPORTANT: All liquid that is flushed out of the

radiator must be collected and disposed of prop-
erly. Pouring contaminated water down the drain
is illegal.
7. Shut off the air at the pressure gun nozzle and
allow the radiator to refill with water, then repeat
the previous two steps until clean water flows
from the radiator.
8. Detach the gun nozzle from the lower radiator
hose opening. Connect the hoses.
9. Place a pan under the coolant filter to catch en-
gine coolant.
10. Remove the coolant filter. Install and tighten a
new filter.
11. Fill the cooling system with new coolant.
12. Install the pressure/filler cap.
13. Start the engine and turn on the cab heater.
Allow the engine to warm to normal operating
temperature. Check the radiator and hoses for
leaks. Repair as required.
14. Shut off the engine and check the coolant level.
See "Coolant Inspection" 20–01.

Clutch 25
Index, Alphabetical

Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01
Clutch Release Cross-Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02
Fluid Change, Hydraulic Clutch Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–05
Fluid Level Check, Hydraulic Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–04
Sleeve Assembly Bronze Bushing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03

Clutch 25

DANGER
death.
25–01 Clutch Release Bearing

Lubrication
Lubricate the release bearing as follows:
05/27/93 f250081a
1. With the vehicle parked on a level surface, apply NOTE: Some clutch release bearings are equipped with
the parking brakes and chock the rear tires. a lubrication extension that extends outside of the clutch
2. Remove the clutch inspection plate. housing. It is not necessary to remove the clutch in-
spection plate when the lubrication extension is used.
NOTE: For lubricating the release bearing,
Fig. 1, Release Bearing Grease Fitting
Eaton Fuller recommends a lithium-base grease
that can operate up to at least 325°F (163·C)
and meets the NLGI Grade 2 or 3 specification. 1
Meritor recommends a lithium-base high-

temperature grease that meets the NLGI Grade
3 specification.
3. Wipe away any dirt from the grease fitting. See
Fig. 1. Using a pressure-type grease gun
equipped with the recommended grease, lubri-
cate the bearing until excess grease purges from 2
the rear of the release bearing (toward the 08/10/2009 f250444
transmission). 1. Sleeve Bushing Contact Point
2. Yoke Finger Contact Points
NOTICE Fig. 2, Grease Contact Points
Do not over-lubricate the clutch release bearing.
5. Install the clutch inspection plate.
Over-lubrication could contaminate the clutch in-
ternally, causing clutch slippage and premature
failure. Do not use chassis grease or multipurpose 25–02 Clutch Release Cross-
lubricants.
4. Wipe off excess grease and apply it to both the
Shaft Lubrication
yoke finger and sleeve bushing contact points. The clutch release cross-shaft is equipped with two
See Fig. 2. grease fittings in the transmission clutch housing.

25 Clutch
See Fig. 3 and Fig. 4. Wipe the dirt from the grease Using a pressure-type grease gun equipped with
fittings and lubricate with multipurpose chassis high-temperature grease only, lubricate until grease
grease. flows from the release bearing housing.
Depress the clutch pedal a couple of times before
starting the engine.
25–04 Fluid Level Check,

Hydraulic Clutch Control
1
WARNING
2 Use only approved fluid (DOT 4 brake fluid) in the
hydraulic clutch control system. Do not mix differ-
ent types of brake fluid. The wrong fluid will dam-
age the rubber parts of the system, causing loss
of clutch function and the risk of serious personal
injury.
10/19/93 f250048a
1. Clutch Release Cross-Shaft
2. Grease Fitting NOTICE
Fig. 3, Cross-Shaft Grease Fitting, Left-Side Do not allow the fluid level in the reservoir to go
below the MIN line. If air enters the system, the
hydraulic system will not operate correctly, and
the clutch could be damaged.
If the fluid level is below the MIN line, fill the reser-
voir with new DOT 4 brake fluid from a tightly sealed
container until the level reaches the MAX line. See
Fig. 5.
25–05 Fluid Change, Hydraulic

Clutch Control
Replace the hydraulic clutch control fluid to ensure
clutch function is reliable and correct. It can be
05/27/93 f260146a changed by pressure bleeding or manual bleeding.
Pressure bleeding can be done by one person and
Fig. 4, Cross-Shaft Grease Fitting, Right-Side manual bleeding requires two.
25–03 Sleeve Assembly Bronze WARNING

Bushing Lubrication Hydraulic clutch control fluid (DOT 4 brake fluid)
Vehicles equipped with the sealed clutch-release is hazardous. It may be a skin irritant and can
bearing have a lubrication extension outside of the cause blindness if it gets in your eyes. Always
clutch housing. This extension is needed to provide wear safety glasses when handling it or bleeding
lubrication to the bronze bushing located between hydraulic lines. If you get it on your skin, wash it
the clutch bearing housing and the transmission input off as soon as possible.
shaft.

Clutch 25
4
1
3
A
05/24/2011 f250684
A. On vehicles where the pressure line slopes upward,

unclamp the hose before bleeding the system; when
finished, fasten the hose as removed.
1. Master Cylinder
2. Hydraulic Hose
3. Bracket and P-Clamp Assembly
4. Frontwall
Fig. 6, Hydraulic Hose, Upward Slope Installation
dure. To order these parts, call Kent-Moore at

1-800-328-6657.
10/25/2011 f250691 1. Park the vehicle on a level surface, shut down
Fig. 5, Reservoir, Hydraulic Clutch Control
tires and raise the hood.
2. Prepare the pressure bleeding equipment ac-
NOTICE cording to the manufacturer’s instructions. Use
Do not spill hydraulic clutch control fluid on the new DOT 4 brake fluid from a tightly sealed con-
cab paint. Clean it off immediately if any is spilled. tainer. Pressurize the bleeder system to 15 psi
Brake fluid can damage paint. (103 kPa).
3. Remove the reservoir lid (see Fig. 5) and install
IMPORTANT: The pressure line must slope con- the pressure bleed adaptor on the reservoir.
tinuously downward between the master and
slave cylinders. On some vehicles, the securing 4. Bleed the hydraulic system as follows.
clamps may need to be removed to achieve this 4.1 Open the bleed valve on the bleed tank
and allow the air to be purged. See Fig. 6. to pressurize the reservoir.
4.2 Remove the cap from the bleed valve of
Pressure Bleeding the slave cylinder. See Fig. 7. On the
NOTE: A bleeder system (J-29532) and a bleed valve, install a transparent drain hose
connected to a catch bottle. The hose
adaptor (J-35798) for the fluid reservoir are needs to fit the bleed valve tight enough
available through SPX Kent-Moore Tools and so it does not fall off when fluid is
may be used to complete the following proce- pumped out.

25 Clutch
4.3 Open the bleed valve on the slave cylin- bottle. The hose needs to fit the bleed valve tight
der. enough so it does not fall off when fluid is
pumped out.
4.4 When the draining fluid is clear and free
of air bubbles, close the bleed valve. NOTE: The following steps require two people—
one in the cab to work the clutch pedal, and one
to open and close the bleed valve and watch
the fluid.
1
4. Bleed the system, as follows.
4.1 Open the bleed valve.
4.2 Depress the clutch pedal until it stops.
4.3 Close the bleed valve.
2
4.4 Return the pedal to the upper position.
4.5 Repeat the previous steps until the fluid is
clear and free of air bubbles.
11/30/2010 f250682
4.6 Depress the clutch pedal. There should
be resistance over the full pedal stroke.
1. Bleed Valve 2. Slave Cylinder
5. Check the fluid level in the reservoir. If neces-
Fig. 7, Slave Cylinder, Hydraulic Clutch Control sary, add or drain fluid to bring the fluid level to
between the MIN and MAX lines marked on the
5. Check the fluid level in the reservoir. If neces-
side of the reservoir. Install the reservoir lid.
sary, add or drain fluid to bring the fluid level to
between the MIN and MAX lines marked on the 6. Disconnect the transparent hose. Tighten the
side of the reservoir. bleed valve 88 lbf·in (1000 N·cm) and install the
cap on the slave cylinder bleed valve.
6. Install the reservoir lid.
7. Disconnect the transparent hose. Tighten the
bleed screw 88 lbf·in (1000 N·cm) and install the
cap on the slave cylinder bleed valve.
8. Depress the clutch pedal a few times. There
should be resistance over the full pedal stroke.
Manual Bleeding
tires and open the hood.
NOTE: The hydraulic system holds approxi-
mately 0.5 quart (0.5 liter) of fluid. It may need
to be refilled during the bleeding process to pre-
vent air from re-entering the system.
2. Remove the reservoir lid and fill the reservoir
(see Fig. 5) with new DOT 4 brake fluid from a
tightly sealed container.
3. Remove the cap from the bleed valve of the
slave cylinder. See Fig. 7. On the valve, install a
transparent drain hose connected to a catch

Transmission 26
Index, Alphabetical

Allison Transmission Fluid and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–07
Allison and Eaton Fuller Transmission Breather Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–06
Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . 26–08
Detroit™ Automated Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–09
ESS Transmission Filter and Boot Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04
Manual Transmission Air Filter/Regulator Check, and Clean or Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03
Manual Transmission Fluid Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02
Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01
Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–05
4700 5700 4900 6900 Maintenance Manual, October 2020

Transmission 26
26–00 Safety Precautions 4. Shift from DRIVE to NEUTRAL, and then shift to
REVERSE to fill the hydraulic system.
Safety Precautions in this section apply to all 5. Shift to NEUTRAL and allow the engine to idle at
procedures within this group. 500 to 800 rpm.
6. Open the hood, and with the engine running at
DANGER idle, remove the dipstick from the tube and wipe
it clean.
7. Insert the dipstick into the tube completely, then
remove the dipstick.
place jack stands under the frame rails to ensure 8. Check the fluid level mark and repeat the check
the vehicle cannot drop. Failure to follow these procedure to verify the reading.
steps could result in serious personal injury or If the fluid level is within the COLD RUN band,
death. the transmission may be operated until the fluid
is hot enough to perform a hot check.
26–01 Transmission Fluid If the fluid level is not within the COLD RUN
Level Inspection band, add or drain fluid as needed to adjust the
fluid level to the middle of the COLD RUN band.
See Fig. 5.
Allison Transmission
B
NOTICE
Operating a transmission with the fluid level
higher or lower than recommended can result in A
transmission damage. Do not overfill the transmis-
sion.
Do not mix types and brands of fluid, because of
possible incompatibility. Do not use fluid addi- 12/01/97 f270002a
tives, friction modifiers, extreme-pressure gear A. Cold Run Band B. Hot Run Band
fluids, or multiviscosity lubricants.
Fig. 1, Dipstick Markings
Cold Check
Clean all dirt from around the end of the fluid fill tube NOTICE
before removing the dipstick. Do not allow foreign
matter to enter the transmission. Dirt or foreign mat- As the fluid temperature increases, so does the
ter in the hydraulic system may cause undue wear of fluid level. Do not fill above the COLD RUN band if
transmission parts, make valves stick, and clog pas- the transmission fluid is below normal operating
sages. temperature.
It is important to check the fluid level cold to deter- NOTE: Perform a hot check at the first opportu-
mine if the transmission has a sufficient amount of nity after the normal operating temperature, 160
fluid to be safely operated until a hot check can be to 200°F (71 to 93°C), has been reached.
performed.
1. Park the vehicle on a flat, level surface. Hot Check
2. Apply the parking brake and chock the tires. 1. Park the vehicle on a flat, level surface. Apply
the parking brake and chock the tires.
3. Run the engine for at least one minute.
2. Shift the transmission to NEUTRAL.

26 Transmission
3. Operate the engine at idle (500 to 800 rpm) until

normal operating temperature is reached. Check
that the sump temperature is 160 to 200°F (71 to
93°C). Check that the converter-out temperature
is 180 to 220°F (82 to 104°C).
4. Open the hood, and with the engine idling, re-
move the dipstick from the tube and wipe it
clean. A B
05/27/93 f260006a
5. Insert the dipstick completely into the tube, and
A. Full B. Low
remove the dipstick.
6. Check the fluid level mark and repeat the check Fig. 2, Checking Transmission Fluid Level
procedure to verify the reading. Safe operating 4. If needed, add the recommended fluid, until it is
level is within the HOT RUN band on the dip- level with the lower edge of the fill opening. See
stick. The HOT RUN band is between the HOT Table 1 for approved transmission lubricants.
FULL and HOT ADD marks.
5. Clean the fill plug, install it in the transmission,
If the fluid level is not within the HOT RUN band, then tighten it 50 lbf·ft (68 N·m).
add or drain fluid as needed to bring the fluid
level within the HOT RUN band. See Fig. 5. Checking at the Sight Glass
Eaton/Fuller Transmission If the transmission is equipped with a sight glass,
check the fluid level as follows:
1. Clean the oil level sight glass. See Fig. 3.
NOTICE
higher or lower than recommended can result in
sion. Overfilling will force fluid out of the case
through the main shaft openings.
possible incompatibility. Do not use fluid addi-
tives, friction modifiers, extreme-pressure gear
With the transmission at operating temperature, and
the vehicle on a level surface, check the fluid level in
the transmission.
Some transmissions are equipped with a sight glass
for checking the fluid level. For transmissions not so
equipped, check the fluid level at the fill plug.
Checking at the Fill Plug

1. Clean the area around the fill plug, and remove it
from the side of the case.
2. Using your finger or a bent pipe cleaner, see if 1. Drain Plug 3. Sight Glass
the fluid is level with the fill opening. See Fig. 2. 2. Fill Plug
3. If the transmission fluid level is low, check the Fig. 3, Eaton Fuller Transmission With a Sight Glass
transmission for leaks, and correct as needed.

Transmission 26
2. Check the fluid level in the sight glass. When the 5. If needed, add the recommended fluid, until it is
fluid level is at or above 3/4 of the sight glass, level with the lower edge of the fill opening. See
then it is at or above the minimum fill level. See Table 1 for approved transmission lubricants.
Fig. 4.
For more information and a complete listing of
Eaton approved lubricants, refer to the Eaton
website, www.roadranger.com. For more infor-
mation and a complete listing of Meritor ap-
proved lubricants, refer to the ZF Meritor web-
site, www.zf.com.
Eaton and Meritor Approved Transmission Lubricants

A B Transmission Temp. SAE
02/23/2015 f261461
Lubricant Type*
Model Range Viscosity
A. Full B. Low Synthetic transmission
lubricant meeting Eaton
Fig. 4, Transmission Fluid Level Sight Glass Eaton Fuller All —
PS-386 lubricant
specification
3. If the fluid level is low, check the transmission for
leaks, and correct as needed. Synthetic engine oil
meeting Meritor
4. If needed, add the recommended fluid, until it is Meritor All 50W
specification 0–81, or
at or above 3/4 of the sight glass. See Table 1 MIL–L–2104D or E
for approved transmission lubricants. * Do not mix types or brands of fluid. Multiweight and extreme-pressure
gear fluids are not recommended.
Meritor Transmission Table 1, Eaton and Meritor Approved Transmission
Lubricants
NOTICE 6. Clean the fill plug, install it in the transmission,
then tighten it 50 lbf·ft (68 N·m).
transmission damage. Do not overfill the transmis- 26–02 Manual Transmission
sion. Fluid Change
tives, friction modifiers, extreme-pressure gear NOTICE
1. Remove the fill plug from the transmission. higher or lower than recommended can result in
2. Insert a finger or pipe cleaner into the transmis- transmission damage. Do not overfill the transmis-
sion. sion. Overfilling will force fluid out of the case
3. Check that the fluid level is even with the base of
the fill plug. Do not mix types and brands of fluid, because of
The correct fluid capacity is established by the fill tives, friction modifiers, extreme-pressure gear
opening. If the transmission has two fill plugs, fluids, or multiviscosity lubricants.
check that the fluid level is consistent at both fill
plugs. NOTE: Fluid change intervals are extended to
4. If the transmission fluid level is low, check the
500,000 miles (800 000 km) on vehicles
transmission for leaks, and correct as needed. equipped with a Meritor RM10–115A or
RM10–145A transmission or any vehicle

26 Transmission
equipped with an Eaton/Fuller transmission filled

with synthetic transmission fluid. CAUTION
1. Park the vehicle on level ground, apply the park- To prevent skin burns from hot transmission fluid,
ing brakes, and chock the tires. Place a large wear protective gloves when removing the drain
drain pan under the transmission. plugs.
4.2 Place a strap or chain wrench around the
CAUTION filter canister, and rotate in a counter-
clockwise motion to separate the filter
To prevent skin burns from hot transmission fluid, from the mounting. Carefully spin the filter
wear protective gloves when removing the drain off the mount and remove it.
plugs.
4.3 Apply a light coat of transmission fluid to
2. Clean the area around the fill plug, and remove it the O-ring gasket on the new filter. Fill the
from the side of the case. Remove each drain filter with the specified transmission fluid,
plug from the bottom of the transmission case. and spin the filter on the mount.
Drain the fluid while the transmission is warm.
NOTE: The filter fills slowly, so be patient to
3. Clean the fill and drain plugs.
ensure the proper fluid level has been
For magnetic plugs, use a piece of key stock or reached.
any other convenient steel slug to short the two
magnetic poles and divert the magnetic field. 4.4 Once the filter has made contact with the
Clean the material that may have been attracted mount, use a strap or chain wrench to
to the magnet. The amount of material on the rotate the filter canister an additional 180
magnetic plug shows the condition and wear in to 270 degrees to firmly tighten the filter.
the transmission; excessive material may indi- Wipe the filter clean of any fluid after it is
cate that the transmission should be looked at. tightened.
Remove the key stock or steel slug from the 5. Add fluid until it is level with the lower edge of
magnetic drain plug. the fill opening. See Fig. 5. If the transmission
Install and tighten each drain plug 50 lbf·ft (68 has two fill openings, add fluid to the level of
N·m). both openings. See Table 2 for approved trans-
mission lubricants, and Table 3 for lubricant ca-
NOTE: Eaton/Fuller transmissions are available pacities. The correct capacity is established by
with an optional transmission fluid filter. The fil- the location of the fill opening.
ter is a remote-mount, spin-on type, and is lo- For more information and a complete listing of
cated between the transmission and the fluid Eaton approved lubricants, refer to the Eaton
cooler. The filter bracket is attached to the frame website, www.roadranger.com. For more infor-
rail. The filter is mounted in a vertical position, mation and a complete listing of Meritor ap-
and should be filled with fluid before installation proved lubricants, refer to the ZF Meritor web-
to ensure the proper fluid level in the transmis- site, www.zf.com.
sion case. For optimum transmission perfor-
mance, change the filter each time the fluid is Eaton and Meritor Approved Transmission Lubricants
changed. Transmission Temp. SAE
Lubricant Type*
4. For an Eaton/Fuller transmission with a transmis-
sion fluid filter(s), replace the filter(s), as follows. Synthetic transmission
lubricant meeting Eaton
4.1 Place a drain pan under the transmission Eaton Fuller All —
PS-386 lubricant
fluid filter. specification

Transmission 26
Eaton and Meritor Approved Transmission Lubricants Transmission Lubricant Capacities

Transmission Temp. SAE Transmission Make and Model* Capacity: pt (L)
Lubricant Type*
RT–12710B 26 (12.3)
Synthetic engine oil
RTX–12710B/C 26 (12.3)
meeting Meritor
Meritor All 50W
specification 0–81, or RTL0–13610B 28 (13.2)
MIL–L–2104D or E
RT–13710B 26 (12.3)
* Do not mix types or brands of fluid. Multiweight and extreme-pressure
RTX–13710B/C 26 (12.3)
gear fluids are not recommended.
Table 2, Eaton and Meritor Approved Transmission RTLO–14610B 28 (13.2)
Lubricants RTO/RTX–14708LL 29 (13.7)
RT–14710B 26 (12.3)
Transmission Lubricant Capacities RTX–14710B/C 26 (12.3)
Transmission Make and Model* Capacity: pt (L) RTLO–15610B 28 (13.2)
Eaton/Fuller 7-Speed RTX–15710B/C 26 (12.3)
T–14607A/B 37 (17.5) RTO–16210C 22 (10.4)
TX–14607B 37 (17.5) RTLO–16610B 28 (13.2)
Eaton/Fuller 9-Speed RTX–16710B 26 (12.3)
RT–11609A 27 (12.8) Eaton/Fuller 13-Speed
RTX–11609B/R 27 (12.8) RTLO–12713A 28 (13.2)
RT/RTX–11709H 27 (12.8) RTLO–14713A 28 (13.2)
RT–12609A 27 (12.8) RTLO–16713A 28 (13.2)
RTX–12609B/R 27 (12.8) Eaton/Fuller 15-Speed
RT/RTX–12709H 27 (12.8) RT/RTO/RTX–14715 28 (13.2)
RT–13609A 27 (12.8) RT/RTO/RTX–15715 28 (13.2)
RTX–13609B/R 27 (12.8) Eaton/Fuller 18-Speed
RT/RTX–13709H 27 (12.8) RTLO–14718B 28 (31.2)
RT–14609A 27 (12.8) RTLO–16718B 28 (13.2)
RTX–14609B/R 27 (12.8) RTLO–18718B 28 (13.2)
RT/RTX–14709H 27 (12.8) Meritor 9-Speed
RTX–16709B/H 27 (12.8) RM9–115A 20 (9.5)
Eaton/Fuller 10-Speed RMO9–115B 20 (9.5)
FR–11210B 23.5 (11) RMX9–115B/R 20 (9.5)
FR–14210B 23.5 (11) RM9–125A 20 (9.5)
FR–15210B 23.5 (11) RMO9–125A/B 20 (9.5)
RTO/RTX–11708LL 28 (13.2) RMX9–125A/B/R 20 (9.5)
RT–11710B 26 (12.3) RM9–135A 20.5 (9.7)
RTX–11710B/C 26 (12.3) RMO9–135A/B 20.5 (9.7)
RTO–11908LL 29 (13.7) RMX9–135A/B/R 20.5 (9.7)
RTLO–12610B 26 (12.3) RM9–145A 20.5 (9.7)

26 Transmission
Transmission Lubricant Capacities

WARNING
Transmission Make and Model* Capacity: pt (L)
RMO9–145A/B 20.5 (9.7) Drain the air supply; if the air supply is not
drained before the air filter/regulator is serviced,
RMX9–145A/B/R 20.5 (9.7) serious injury and component damage could re-
RM9–155A 20.5 (9.7) sult.
RMX9–155B 20.5 (9.7) 2. Clean the outside of the air filter/regulator with
Meritor 10-Speed cleaning solvent. See Fig. 6.
RM10–115A 20 (9.5)
RMX10–115A 20 (9.5)
RM10–125A 20 (9.5)
RMX10–125A 20 (9.5)
RM10–135A 20.5 (9.7)
RMX10–135A 20.5 (9.7)
RM10–145A 20.5 (9.7)
RMX10–145A 20.5 (9.7)
RMX10–155A 20.5 (9.7)
RMX10–165A 20.5 (9.7)
Meritor 13-Speed
RMO13–145A 22 (10.4)
* For models not listed in this table see the Eaton website, www.roadrang-
er.com.
Table 3, Transmission Lubricant Capacities
6. For a transmission equipped with a fluid pump or

10/05/2016 f260037a
a fluid cooler, operate the engine for five minutes
after filling the transmission, then check the fluid Fig. 6, Air Filter/Regulator Location (Eaton/Fuller
level again. transmission shown)
7. Install the fill plug, then tighten it 50 lbf·ft (68
N·m). 3. Remove the end cap, large O-ring, and filter ele-
ment from the filter housing. See Fig. 7. Remove
8. Operate the vehicle to check for correct opera- the small O-ring from the end cap.
tion.
NOTE: Do not remove, disassemble, or adjust
the air regulator. If the air regulator is not keep-
26–03 Manual Transmission Air ing the air pressure between 58 and 63 psi (400
Filter/Regulator Check, to 435 kPa), replace the air filter/regulator,
which is not serviceable.
and Clean or Replace
WARNING
Eaton/Fuller
Wear safety goggles when using compressed air
1. Apply the parking brakes and chock the tires. to clean parts, as permanent harm to eyes could
Drain the air reservoirs. result from flying debris.

Transmission 26
element for fluid contamination. If fluid is present,

6 7 replace the element. Inspect the air supply sys-
5
4 tem for the source of the fluid, and service it as
2 3 needed.
3. Install the element in the filter/regulator assem-
bly.
4. Apply a light coat of silicone grease, or an
equivalent grease to the O-rings in the end cap.
Install and tighten the end cap 10 to 15 lbf·ft (14
1 to 20 N·m).
10/17/2001 f260052a
5. Build air pressure in the system, check for leaks,
1. Air Regulator 5. Large O-Ring
and make any needed repairs.
2. Housing 6. End Cap
3. Small O-Ring 7. Plug
4. Filter Element
26–04 ESS Transmission Filter
Fig. 7, Eaton/Fuller Transmission Air Filter/Regulator
Components
and Boot Inspection
4. Clean the filter element by dipping it in alcohol or On ESS transmissions only, inspect the filter and
other cleaning solvent. Blow compressed air protective boots.
through the filter element (inside to outside) to 1. Remove the filter from its location on the top
loosen surface dirt and to dry the element. If it is right-hand side of the transmission.
not damaged, the sintered metallic filter element
will last the life of the vehicle. 2. Clean the filter with solvent.
Wipe out the filter housing with a clean, dry, lint- 3. Install the filter, as removed.
free rag. Clean and inspect the O-rings and the 4. Inspect the protective boots, both right and left,
end cap. Replace any parts that are damaged. for tears or signs of cracking. Replace if needed.
5. Install the large O-ring, then the filter element
(small end first) into the filter housing. 26–05 Transmission Inspection
6. Install the small O-ring in the end cap, then in-
stall the end cap and tighten it 8 to 12 lbf·ft (11 Check the transmission for oil leaks, as follows.
to 16 N·m). 1. Check at the transmission output shaft for oil
leaks. A small amount of oil and dirt accumula-
NOTICE tion is normal, as a small amount of oil is al-
lowed past the seal to lubricate it. If the rear of
A leaking air filter or air lines can cause slow or the transmission is wet with oil, the rear seal
hard shifting of the transmission, and eventual may need replacing.
transmission damage.
2. Check for oil leaks around the speedometer
7. Start the engine, and build pressure in the air pickup.
system. Check for air leaks at the filter housing
and air line connections; repair any leaks. 3. Check the transmission case joints for oil leaks.
4. Check transmission oil line fittings for oil leaks.
Meritor 5. Check the bottom of the flywheel housing for oil
1. Park the vehicle on a level surface. Apply the accumulation. Oil along the bottom seam or
parking brakes and chock the tires. around the inspection cover of the flywheel hous-
ing may be an indication of a transmission input
2. Remove the element from the air filter/regulator seal leak. Not replacing a leaking input oil seal
assembly. Inspect the O-rings in the end cap; will cause clutch slippage.
replace worn or damaged O-rings. Inspect the

26 Transmission
6. If leaks are found, take the vehicle to your West-

ern Star dealer to have the problem corrected.
26–07 Allison Transmission
Fluid and Filter Change
26–06 Allison and Eaton Fuller
Allison 3000 Family and 4000
Transmission Breather
Family Transmissions
Check
NOTE: When the optional prognostics feature is
If the transmission is equipped with a housing enabled on an Allison transmission, the system
breather (see Fig. 8), it must remain clear. A plugged monitors oil life and filter life. To reset the indica-
breather could result in pressure build-up, which tor, press the Mode button (on the electronic
could cause oil leakage. shift control) for 10 seconds with the ignition on
IMPORTANT: Do not spray water, steam, or but the engine not running. For more informa-
cleaning solution directly at the breather. These tion, see the Allison Transmission website,
actions can force water or cleaning solution into www.allisontransmission.com.
the transmission and contaminate the transmis- 1. Park the vehicle on a level surface and apply the
sion fluid. parking brakes.
If the breather is plugged, clean or replace it. If re- 2. Operate the vehicle until the transmission
placing it, use a correct-size wrench (pliers or a pipe reaches normal operating temperature: 160 to
wrench can crush or damage the breather stem and 200°F (71 to 93°C).
produce metal particles that could enter the transmis-
sion). NOTICE
Check more often if the vehicle is operating under
very dusty conditions. To prevent dirt from entering the transmission,
use only clean containers and fillers for the trans-
mission fluid. Do not use fillers or containers that
have been used for water or antifreeze. Dirt, water,
or antifreeze could damage the transmission.
2
Engine coolant in the transmission hydraulic sys-
tem requires immediate action to prevent malfunc-
tion and possible serious transmission damage.
For more information, see the Allison Transmis-
1 sion website, www.allisontransmission.com.
IMPORTANT: When draining transmission fluid,
check for evidence of dirt or water contamina-
tion. A small amount of condensation could ap-
pear in the fluid during operation.
Water contamination is normally characterized
as a milky discoloration of the transmission fluid.
11/30/2010 f260007b
Obvious contamination of the transmission fluid
could indicate a leak between the water and
NOTE: Location of the transmission breather will vary
depending on transmission model.
fluid areas of the transmission cooler. Inspect
and pressure-test the cooler to confirm the leak.
1. Breather 2. Shift Tower
If the transmission cooler is leaking and the oil
Fig. 8, Transmission Breather (Eaton Fuller shown) has been contaminated, replace the transmis-
sion cooler and overhaul the transmission.

Transmission 26
NOTE: If only the filters are being changed, do

not drain the fluid.
3. Clean the area around the drain plug and the 2
transmission fluid pan. Place a drain pan under
the transmission and remove the drain plug. Ex-
amine the fluid as it drains.
2
4. Remove the 12 mounting capscrews (six each)
from the two filter covers. See Fig. 9.
NOTE: A lot of fluid will drain when the filter
covers are removed.
5. Remove the filter covers, gaskets, O-rings, and
filters from the transmission.
6. Lubricate the new O-rings with transmission fluid,
and install them on the covers.
7. Install the filter over the gaskets.
8. Install the fluid filters on the cover assemblies.
7
9. Install the filter and cover assemblies into the
filter compartment. Align each cover assembly
with the holes in the channel plate sump, and
push the cover assemblies in by hand to seat the
seals.
6 6
NOTICE
5 5
Do not use the capscrews to draw the filter covers
to the sump. This can damage the covers, seals, 4 4
or sump.
10. Install six capscrews in each cover, and torque 3 3
the bolts 38 to 44 lbf·ft (51 to 61 N·m).
11. Install a new drain plug O-ring, and install the 2 2
drain plug. Tighten the drain plug 18 to 24 lbf·ft 1 1
(25 to 32 N·m).
09/12/2011 f261435
NOTE: Fluids meeting specification TES 295 are
preferred over TES 389 fluids for use in Allison NOTE: Allison 4000 Family transmission shown. Com-
ponents and location are similar for Allison 3000 Family
3000 and 4000 family transmissions. See the transmissions.
Allison Transmission website (www.allison-
1. Capscrew 5. Filter Element O-Ring
transmission.com) for a list of approved trans- 2. Filter Cover 6. Filter Element
mission fluids and usage recommendations. 3. Gasket 7. Drain Plug
4. O-Ring
12. Refill the transmission with fresh transmission
fluid. Use only a fluid that meets Allison Trans- Fig. 9, Allison Transmission Filter Locations and
mission specification TES 295 or TES 389. Cas- Components
trol TranSynd® is a TES 295 fluid available
through Allison distributors and dealerships. See
Table 4 for lubricant refill capacities.

26 Transmission
Lubricant Refill Capacities, Allison 3000 and 4000

Family Transmissions* 2
Family Sump Size Capacity : qt (L)

4 Inch 19 (18)
3000
2 Inch 17 (16)
4 Inch 39 (37)†
4000
2 Inch 31 (30)†
* Quantities listed are approximate. Add listed amount of fluid, then perform
a "hot check" and add fluid as needed. Do not overfill.
† Add 3 qt (2.8 L) for transmissions with PTO.
1
Table 4, Lubricant Refill Capacities, Allison 3000 and
4000 Family Transmissions
13. Check and adjust the fluid level using the appro-
priate Allison Transmission procedures in MOP 03/31/2014 f270167
26–01.
1. Drain Plug 2. Fill Plug
26–08 Detroit™ Automated Fig. 10, Drain and Fill Plugs, Detroit Automated
Transmissions
Transmission Fluid 3. Clean the fill plug and the drain plug.
Change and Magnetic 4. Install a new seal on the drain plug, then install
Plug Cleaning the plug and tighten it 45 lbf·ft (60 N·m).
NOTICE NOTICE
Detroit transmissions use synthetic lubricant that
Operating a transmission with the fluid level meets specific requirements. To see a list of ap-
higher or lower than recommended can result in proved lubricants and information to identify
transmission damage. Do not overfill the transmis- which transmissions they can be used with, see
the Transmission Fluid Service Information bro-
through the main shaft openings. chure at http://dtna.info/DT12FluidsManual.
Do not mix types or brands of fluid, because of 5. Add fluid until it is level with the lower edge of
possible incompatibility. Do not use fluid addi- the fill opening; see Fig. 12. See the Detroit
tives, friction modifiers, or extreme-pressure gear Transmission Fluid Service Information brochure
fluids. at http://dtna.info/DT12FluidsManual, for identi-
IMPORTANT: Drain the transmission when the fying the transmission type, estimated transmis-
fluid is warm. If not already warm, run the en- sion fluid capacities, and applicable fluid specifi-
gine until the transmission fluid reaches operat- cations.
ing temperature. Shift the transmission to neu- NOTE: In all cases, the correct fluid level is es-
tral (N) and shut down the engine. tablished by checking at the fill opening.
1. Apply the parking brakes, and chock the rear 6. Operate the engine for five minutes after filling
tires. Place a large drain pan under the transmis- the transmission, then check the fluid level again.
sion.
7. Install a new seal on the fill plug, then install the
2. Clean the area around the fill plug, then remove plug and tighten it 45 lbf·ft (60 N·m).
it from the side of the gear case. Remove the
8. Operate the vehicle to check for correct
drain plug from the bottom of the case. See
Fig. 10. operation.

Transmission 26
4. If needed, add the recommended fluid until it is

level with the lower edge of the fill opening. See
chure at http://dtna.info/DT12FluidsManual for
approved transmission lubricants.
5. Clean the fill plug and install a new seal on it.
Install the plug in the side of the gear case, then
tighten it 45 lbf·ft (60 N·m).
A. Full B. Low
Fig. 11, Checking Transmission Fluid Level
26–09 Detroit™ Automated

Transmission Fluid
Level Inspection
NOTICE
Do not mix types or brands of fluid, because of
tives, friction modifiers, or extreme-pressure gear
fluids.
With the transmission at operating temperature, and
the vehicle on a level surface, check the fluid level in
the transmission.
1. Clean the area around the fill plug, then remove
it from the side of the gear case.
2. Using your finger or a bent pipe cleaner, see if
the fluid is level with the fill opening. See
Fig. 12.
3. If the fluid level is low, check the transmission for
leaks, and correct as needed.
NOTICE
Detroit transmissions use synthetic lubricant that
meets specific requirements. To see a list of ap-
proved lubricants and information to identify
which transmissions they can be used with, see
chure at http://dtna.info/DT12FluidsManual.

Frame and Frame Components 31
Index, Alphabetical

Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01
Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02
Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–04
Holland Fifth Wheel Sliding Mechanism Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–03
Premier 690 Coupling Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–06
Trailer Electrical Connector Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–05

31–00 Safety Precautions 6. Check the jaw and stationary jaw for mushroom-
ing, and check that the serrations at the jaw and
wedge are in good condition.
procedures within this group. 7. Test the secondary safety lock latch for ease of
operation.
DANGER 8. Check for loose nuts or bolts on the fifth wheel
and the mounting. Set a torque wrench to the
When working on the vehicle, shut down the en- maximum torque value for the bolt being
gine or motor, set the parking brake, and chock checked, and confirm that the torque is to speci-
the tires. Before working under the vehicle, always fication. Do not loosen the bolt to check the
place jack stands under the frame rails to ensure torque. See Group 00 for bolt torque specifica-
the vehicle cannot drop. Failure to follow these tions.
9. Check all springs to see if they are securely fas-
death.
tened, and are not deformed.
31–01 Fifth Wheel Inspection WARNING

Do not disassemble the fifth wheel to inspect the
WARNING springs. The springs are under extreme pressure,
and could cause serious injury.
All fifth wheel maintenance, adjustment, and re-
building must be done only by a qualified me- 10. Check the wedge adjustment.
chanic. Improper or incomplete procedures could 10.1 Close the fifth wheel on a standard 2-inch
result in a possible disengagement of the trailer (50-mm) kingpin or similar 2-inch (50-mm)
from the tractor, which could result in personal diameter shaft so that it locks.
injury or property damage.
10.2 Push on the wedge stop rod with hand
Parts are under spring compression. Wear safety pressure. It should move in 1/4 inch (6
goggles while servicing the fifth wheel. Failure to mm) and spring back out on release.
do so can result in personal injury, due to parts
ejecting with force. If the free travel is not 1/4 inch (6 mm),
adjust the distance to 1/4 inch (6 mm) by
Fontaine turning the wedge stop rod, on the right
side of the top plate, clockwise to reduce
1. Disconnect the tractor from the trailer. For in- the gap and counter-clockwise to in-
structions, see the Western Star Driver’s Manual. crease it.
2. Thoroughly steam clean the fifth wheel. 11. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
3. Check for cracks in the fifth wheel assembly,
5/8–11 SAE grade 8 bolts, grade C locknuts, and
mounting brackets, and mounting parts.
hardened washers. Do not re-use bolts, nuts,
4. Ensure that both bracket pins are in place and and washers on fifth wheel mountings.
secured by retainer pins and cotter pins. See
12. After inspecting the fifth wheel, lubricate all mov-
Fig. 1.
ing parts with a chassis or multipurpose grease.
5. For fifth wheels equipped with bracket liners, Apply a generous coating of grease to the top
rock the fifth wheel. If it does not rock freely, re- plate to fill the grooves, or depressions, on the
move the top plate and inspect the bracket lin- top plate. See MOP 31–02 for lubrication instruc-
ers. Replace liners that are broken or less than tions.
0.125 inch (3 mm) thick at the top of the liners.
For the liner replacement procedure, see the
Fontaine website, www.fifthwheel.com.

31 Frame and Frame Components
16
13
12
8
8
7
15 14
12 5 17
12
12 18
11 12
10 19
6
5 15
20
9
21
8 5 22
27
5
26
7 6
8
25
1 15 12
2 12
24 23
4 3
12/02/2010
2 f311134
NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts.
1. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Bumper
2. Flat Washer, 5/8" 12. Flat Washer 20. Timer Spring
3. Wedge Stop Rod Spring 13. Secondary Safety Lock 21. Timer
4. Wedge Stop Rod 14. Bushing, Secondary Safety 22. Operating Handle
5. Grease Fitting Lock 23. Bolt, Operating Handle
6. Bracket Pin 15. Hex Locknut 24. Bushing, Operating Handle
7. Bracket Retainer Pin 16. Pull Handle 25. Hair Pin Cotter
8. Cotter Pin, 3/16" x 1" 17. Bolt, Bumper 26. Wedge
9. Bumper Spring 18. Bushing 27. Step Jaw
10. Handle Spring
Fig. 1, Fontaine Fifth Wheel

Holland FWS1
1. Disconnect the tractor from the trailer. For in-
structions, see the Western Star Driver’s Manual.
2. Thoroughly steam clean the fifth wheel.
3. Check the fifth wheel plate for cracks. Check for
sharp edges on top; the chamfer should be 1/8
to 1/4 inch (3 to 6 mm).
4. When the wheel is locked, the safety latch must
swing free and fall freely into position. See Fig.
2.
1
1. Release Handle 2. Lever Bar
Fig. 3, Lever Bar and Release Handle Alignment
2 9. After inspecting the fifth wheel, lubricate all mov-

3 See MOP 31–02 for lubrication instructions.
Holland FW35
4 1. Disconnect the tractor from the trailer. For in-
structions, see the Western Star Driver’s Manual.
2. Thoroughly steam clean all fifth wheel compo-
10/29/2007 f311052 nents before inspection.
1. Lubricant Grooves 3. Release Handle 3. Check for cracks in the fifth wheel assembly,
2. Safety Latch 4. Mount mounting brackets, and mounting parts.
Fig. 2, Holland FWS1 Fifth Wheel 4. Check the fastener torques on the fifth wheel
assembly and fifth wheel mounting. Tighten bolts
5. The lever bar and release handle must be in and nuts as needed. Replace missing or dam-
proper alignment. See Fig. 3. Compare the lever aged bolts.
bar and release handle alignment to a new, or a
properly operating lever bar and release handle. 5. Inspect the fifth wheel for bent, worn, damaged,
Replace any bent or misaligned lever bar or re- and missing parts; replace them as needed with
lease handle. genuine Holland parts.
6. Check all cotter pins for cracking or damage. Re- 6. Using a Holland Kingpin Lock Tester (Holland
place any cotter pin that shows any signs of tool number TF-TLN-5001, available through the
damage. PDCs as HLD TFTLN5001), check the operation
of the locking mechanism by opening and closing
7. Check all mounting bolts for signs of fatigue, and the locks. See Fig. 4.
tighten them to the proper torque. For torque
specifications, see Group 00. Inspect all angles, 7. After inspecting the fifth wheel, lubricate all mov-
plates, and brackets for cracks or other damage. ing parts with a chassis or multipurpose grease.
See MOP 31–02 for lubrication instructions.
8. Replace cracked, worn, or damaged parts with
hardened washers. Do not re-use bolts, nuts,
and washers on fifth wheel mountings.

1
2
3
A
10/26/2010 f310353b
1. Lubricant Grooves 3. Lock Control Handle

2. Safety Latch 4. Mount
04/11/2011 B f310887 Fig. 5, Simplex Series Fifth Wheel
A. The nut and washer should be snug against the fifth
wheel.
B. The locks should be completely closed around the 1
kingpin.
Fig. 4, Holland Fifth Wheel Properly Closed
Castloc II and Simplex Series

1. Disconnect the tractor from the trailer. For in-
structions, see Chapter 10 of the Western Star
Driver’s Manual.
2. Thoroughly steam clean the fifth wheel.
3. Check the fifth wheel plate for cracks. Check for
sharp edges on top; the chamfer should be 1/8 2
to 1/4 inch (3 to 6 mm).
4. When the wheel is locked, the safety latch must
swing free and fall freely into position. See Fig.
04/11/2011 f310470
5.
1. Operating Handle 2. Lever Bar
5. The lever bar and operating handle must be in
proper alignment. See Fig. 6. Compare the lever Fig. 6, Lever Bar and Operating Handle Alignment
bar and operating handle alignment to a new, or
a properly operating lever bar and operating 1). Pry up on the fifth wheel plate (item 4) below
handle. Replace any bent or misaligned lever bar the pin boss, and measure the vertical move-
or operating rod. ment (item 5). The bracket connection provides a
9/32 inch (7 mm) vertical clearance to provide
6. Check all cotter pins for cracking or damage. Re- cushioning and to avoid downward pin-loading
place any cotter pin that shows any signs of while retaining minimum plate lift. If the plate lift
damage. (Ref. A) exceeds 5/16 inch (8 mm) as a result of
7. Level the fifth wheel plate to a horizontal posi- wear or rubber deterioration, install new bracket-
tion. Measure the height from a stationary shoe rubber pads.
mounting point (see Fig. 7, item 3), such as the NOTE: Do not measure plate lift immediately
frame rail to the top of the fifth wheel plate (item after a trailer has been uncoupled from the fifth

4. Inspect the bracket pin bolts. Make sure the lock-

A
ing tabs are properly securing the bolts in place.
See Fig. 8.
2
3
4
04/11/2011 f310475
A. Extended Top Plate Lift Height
1. Fifth Wheel Top Plate 09/01/2009 f311101
2. Fifth Wheel Frame Mount
3. Frame Rail Fig. 8, Bracket Pin Bolt Locking Tabs
4. Lifting Point
5. Static Top Plate Height 5. Check the fifth wheel for bent, worn, or broken
parts. Replace as needed.
Fig. 7, Measuring Fifth Wheel Top Plate Lift
6. If the fifth wheel is equipped with low-lube plates,
wheel. The rubber may have taken a temporary check the plates and replace if damaged or worn
set, which will normally recover after being un- down to the securing bolts. It is normal for out-
coupled for a short period of time. side edges of the plate to pucker slightly; this
does not affect performance.
8. Check all mounting bolts for signs of fatigue, and
tighten them to the proper torque. For torque 7. Check the fifth wheel adjustment. Using a lock
specifications, see Group 00. Inspect all angles, tester, lock and unlock the fifth wheel several
plates, and brackets for cracks or other damage. times. Make sure that the locking mechanism
works properly.
new parts. Replace all loose mounting bolts with The lock is properly adjusted if: the wheel locks
5/8–11 Grade 8 bolts, Grade C locknuts, and and unlocks easily each time and the lock tester
hardened washers. Do not re-use bolts, nuts, rotates freely.
and washers on fifth wheel mountings. The lock is too loose if: you feel fore-aft play
10. After inspecting the fifth wheel, lubricate all mov- when pulling and pushing on the lock tester
ing parts with a chassis or multipurpose grease. handle. See Fig. 9, Ref. A.
See Maintenance Operation 31–02 for lubrica- The lock is too tight if: the lock tester does not
tion instructions. rotate freely in the lock. See Fig. 9, Ref. B.
8. If the lock is improperly adjusted, correct as fol-
Jost lows.
1. Disconnect the tractor from the trailer. For in- If the lock is too tight, loosen the jam nut, turn
structions, see the Western Star Driver’s Manual. the adjustment bolt clockwise one full turn, then
2. Thoroughly steam clean the fifth wheel. reset the jam nut. Lock and unlock the mecha-
nism several times to test. Repeat if necessary.
3. Check the mounting for missing or damaged fas- See Fig. 10.
teners, and broken components. Replace or re-
pair as needed. If the lock is too loose, loosen the jam nut, turn
the adjustment bolt counterclockwise one full
turn, then reset the jam nut. Lock and unlock the

C
1
2
D
09/02/2009 f311100
1. Jam Nut 3. Grease Zerk
2. Adjustment Bolt
H Fig. 10, Jost Fifth Wheel

G
9.1 Check the bracket for any cracks or miss-
ing and damaged parts.
9.2 Inspect the locking plungers for full en-
B gagement.
09/01/2009 f311099 9.3 Check the locking mechanism for proper
A. Checking for fore/aft play. operation.
B. Rotating tester in lock. If the plungers will not release, check the
C. Engage hook.
air cylinder or plunger adjustment.
D. Pull/push handle fore/aft.
E. Check for movement of kingpin in lock. If the plungers are loose, check the
F. Disengage hook. plunger adjustment and the plunger
G. Push/pull handle inboard/outboard. springs for proper compression. Replace
H. Rotate lock tester. if needed.
Fig. 9, Jost Fifth Wheel Adjustment 9.4 The outboard slider assembly requires no
adjustment. If the plungers are loose, in-
mechanism several times to test. Repeat if nec- spect and replace locking mechanism
essary. See Fig. 10. parts as needed.
9. If the fifth wheel is equipped with a sliding
9.5 The inboard slider is adjustable for frame
mechanism, inspect and adjust it as follows. width and plunger engagement. For ad-

justment, refer to the fifth wheel installa- Tilt the fifth wheel ramps down (the rear of the
tion instructions. fifth wheel is down) and repeat the greasing pro-
cedure. Rock the top plate back and forth sev-
eral times to spread the grease over the bearing
surface.
hardened washers. Do not re-use bolts, nuts, 2. Inspect the trailer kingpin plate and top surface
and washers on fifth wheel mountings. of the fifth wheel to make sure each is properly
greased. A liberal coating of grease should be
11. After inspecting the fifth wheel, lubricate all mov-
applied to the complete surfaces of both the
trailer kingpin plate and the top surface of the
Apply a generous coating of grease to the top
fifth wheel.
plate to fill the grooves, or depressions, on the
top plate. See MOP 31–02 for lubrication instruc- NOTE: Do not use a lube plate (high density
tions. polyethylene) on top of the fifth wheel or on the
kingpin instead of grease without prior approval
31–02 Fifth Wheel Lubrication by Fontaine Fifth Wheel. The additional thick-
ness of this material can prevent the proper op-
To maintain proper fifth wheel operation, always lubri- eration of the fifth wheel and may cause a dan-
cate the fifth wheel after an inspection has been gerous condition.
performed.
NOTE: Fontaine suggests the use of a Moly
IMPORTANT: Lubricate the fifth wheel: based lubricant such as Mobilgrease XHP 320
• After power washing or steam cleaning. or equivalent when applying lubricant to the
locking jaw and wedge.
• If the vehicle operates in harsh conditions such
as salt spray from road surfaces, or in ex- 3. Lubricate the fifth wheel prior to opening and
tremely dusty environments. closing it. Separate the jaw and wedge with a
screwdriver, and grease the full length of their
• After any service that requires removal of lubri- mating surfaces. Lubricate the top and bottom
cation from the fifth wheel head or components. contact surfaces of the jaw and wedge. See Fig.
1. Open and close the fifth wheel several times
WARNING to further distribute the grease.
Lightly oil other moving parts in the fifth wheel.
Failure to properly lubricate the fifth wheel could
result in a possible disengagement of the trailer 4. Apply grease to the top plate. Spread grease all
from the tractor, which could result in personal over the mating surface of the top plate. Be sure
injury or property damage. the grease pockets built into the top plates are
full of grease.
Fontaine
1. Tilt the top plate forward (the front of the fifth
Holland FWS1
wheel is down) and apply grease to each bearing Apply a heavy coat of grease to the top plate, either
area through the zerk fittings located on each through the grease fittings located on the underside
side of the top plate just to the front of the of the top plate, or by direct application.
bracket pins. Continue to apply grease until it is
coming out of the back of the bearing. It may be Holland FW35
necessary to raise the rear of the fifth wheel with
a pry bar to open up the pocket slightly and 1. Using a water-resistant lithium-base grease,
allow the grease to flow through. A substantial grease the top plate.
amount of grease may be required initially to fill 2. Using a light oil (such as SAE 10W or 20W
the reservoir. motor oil), lubricate the cam track and pivot. See
Fig. 11.

3. Grease the yoke tips, locks, and the release

handle and spring; see Fig. 12. Grease the 1
mounting bracket supports through the grease 2
fittings. A “low temp” grade grease rated for 2
-30°F (-34°C) or lower such as Cato Oil and
Grease #5213, Craftsman Chemical Co. #LTF 2,
Mystic LP-200, or equivalent is recommended.
3
3
12/03/2010 f311135
1. Release Handle and 3. Yoke Tip

Spring 4. Locks
2. Grease Fitting
Fig. 12, Holland FW35 Fifth Wheel, Grease Lubrication
Jost
12/03/2010 f311136
Lubricate the kingpin lock using a hand pump grease
Use a light oil (such as SAE 10W or 20W motor oil) to
lubricate the cam track and pivot.
gun through the grease zerk on the skirt of the fifth
wheel; see Fig. 10. Apply a light oil to all moving
1. Cam Plate parts. For sliding fifth wheels spray diesel fuel on the
slide path of the base plate.
Fig. 11, Holland FW35 Fifth Wheel, Oil Lubrication
Castloc II and Simplex Series NOTICE

Use a chassis or multipurpose grease to lubricate the Do not use a power grease gun. The pressure will
two grease fittings located on either side of the fifth damage the lube line.
wheel top plate. Lubricate the two grease fittings lo-
If the fifth wheel is not equipped with low-lube plates,
cated in the grease grooves on the fifth wheel top
apply a lithium-based grease with extreme pressure
plate. Lubricate the two grease fittings located below
(EP) additive to the trailer contact surface of the fifth
the top plate mounting pins. Lubricate the lock
wheel.
mechanism.
NOTE: If the fifth wheel is equipped with low-lube
Once the fifth wheel’s moving parts are lubricated,
plates, the top plate only requires lubrication at the
apply a heavy coat of grease to the top plate, either
new product break-in stage. The low-lube plates re-
through the grease fittings located on the underside
quire no further lubrication.
of the top plate, or by direct application. On slide-
mount applications, lubricate the slider lock pockets
and the slider bracket.

31–03 Holland Fifth Wheel wrench clicks. Do not loosen the fastener to check
the torque. See Group 00 in the vehicle workshop
Sliding Mechanism manual for torque specifications.
Inspection
NOTICE
1. Loosen the locking plunger jam nut and turn the
adjusting bolt out (counterclockwise). See Make sure frame fasteners are properly tightened.
Fig. 13. Continued vehicle operation with loose fasteners
could result in bracket or frame damage.
NOTE: Engine supports on vehicles built from
January 2007 do not require checking.
Inspect and check the fasteners at the following
locations:
• air tank mounting brackets
• axle stops
4 • cab mount brackets
3
2 • deck plates
• battery and tool box brackets
1
• engine supports
11/21/95 f310371 • equalizer brackets
1. Rack 3. Pocket
2. Plunger 4. Plunger Adjusting Bolt
• exhaust brackets
• fifth wheel legs
Fig. 13, Holland Fifth Wheel Sliding Mechanism
• fifth wheel mounting
2. Disengage and engage the locking plungers.
Check that the plungers are securely seated • frame crossmembers and gussets
without binding. If the locking plungers do no op- • front frame brackets
erate properly see Group 31 of the Western Star
• front suspension spring brackets
Workshop Manual for adjustment procedures.
• fuel tank brackets
3. Turn the adjusting bolt clockwise until it contacts
the rack. Turn the adjusting bolt an additional 1/2 • radius rods
turn, then securely tighten the locking nut. • rear engine supports
• rear suspension spring brackets
31–04 Frame Fastener Torque • shock absorbers
Check • all other suspension fasteners
Frame brackets and components are to be checked • all other axle fasteners
at initial maintenance (IM). Check the torque of frame • all other frame fasteners
fasteners to offset the effects of "bedding in" (or seat-
ing). When possible, always check the torque of the Any component that shows signs of cracking or other
nut, not the bolt head. This will give a true torque damage must be repaired or replaced. Refer to the
reading by eliminating bolt body friction. When vehicle workshop manual for repair or replacement
checking the torque of frame fasteners, inspect the information.
frame for cracks and other damage. Set a click-type
torque wrench to the maximum torque of the fastener
you are checking. Apply pressure until the torque

31–05 Trailer Electrical • Remove the 294 bolt. Using dye penetrate or
magnetic particle testing along the length of the
Connector Lubrication bolt, inspect for fractures.
• If the 294 bolt has no damage, install it and
In some cases, failure of trailer cables occurs due to
continue to use for another 6 months.
intrusion of chloride-based road deicing chemicals
into the trailer connector. Once inside the connector, • If the 294 bolt is fractured, DO NOT USE. Con-
the chloride-based chemicals corrode the brass ter- tact Premier Mfg. Co.
minals and create bridging between positive and 1 year after installation date:
ground terminals.
• Regardless of service duty, replace the 294 bolt
NOTE: The use of soap is not recommended for with a new one.
cleaning the electrical connector, as some
soaps may increase the corrosion process. 1 2
1. Wash out any existing grease, dirt, and corrosion
on the trailer connectors with electrical contact
cleaner spray.
2. Grease the trailer connector with a lithium-based
dielectric grease.
3
31–06 Premier 690 Coupling
Inspection 4
07/13/2010 f310313a
IMPORTANT: Before servicing the Premier cou-
pling, refer to the Premier web site at 1. Linch Pin 3. Pintle Hook
2. Handle 4. 294 Bolt
www.premier-mfg.com for complete safety,
operation, and maintenance instructions. Fig. 14, Premier 690 Trailer Coupling
WARNING
If at any time the 690 coupling is bound up (jack-
knifed), the 294 bolt MUST be replaced immedi-
ately! Do not use the coupling until the bolt has
been replaced. In addition, carefully inspect the
690 coupling, drawbar, drawbar eye, front end as-
sembly, and tail board for damage. Failure to do
so may result in trailer separation from the truck
while in use, resulting in serious personal injury
or property damage.
The time-in-service of the 294 bolt located in the 690
coupling must be monitored, and maintenance per-
formed as follows. See Fig. 14.
For a new or replaced 294 bolt:
• Record the date of installation.
6 months after installation date:

Suspension 32
Index, Alphabetical

Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01
Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02
Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03
4700 5700 4900 6900 Maintenance Manual, December 2020

Suspension 32
32–00 Safety Precautions there is any indication of the rubber bushing being
cracked or damaged, replace the bushing. Refer to
Group 32 of the Western Star Workshop Manual for
Safety Precautions in this section apply to all instructions.
Front and Rear Suspension
DANGER
Shock Absorber Check
Regularly checking shock absorbers and having
weak shock absorbers replaced will help avoid un-
scheduled down time and reduce overall mainte-
nance costs.
steps could result in serious personal injury or The role of a shock has changed dramatically. Not so
death. many years ago, most suspensions had heavy multi-
leaf springs with limited travel and a great deal of
inherent friction. These suspensions quickly self
32–01 Suspension Inspection dampened and therefore limited the amount of work
the shock needed to perform.
Front Suspension Check Low-friction suspensions, such as air and taper leaf,
have dramatically changed the shock’s role. Shocks
WARNING now play a critical role in dampening suspension
oscillation.
Do not replace individual leaves of a damaged leaf Properly functioning shocks can help to reduce the
spring assembly; replace the complete spring as- wear of more expensive suspension components,
sembly. Visible damage (cracks or breaks) to one such as air bags, while assisting in the reduction of
leaf causes hidden damage to other leaves. Re- tire wear. Worn shocks simply cannot assist in pro-
placement of only the visibly damaged part(s) is viding control over today’s sophisticated suspension
no assurance that the spring is safe. On front systems.
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could Quick Test
occur. Failure to replace a damaged spring assem-
bly could cause an accident resulting in property Shock absorbers function at temperatures ranging
damage, serious personal injury, or death. from air temperature to 350°F (177°C). A shock’s
function is to slow the bounce of the vehicle’s
Inspect the front spring assemblies for cracked, bro- springs. It does this by transforming the energy pro-
ken, or abnormally bent leaves. If any of these condi- duced by the spring to heat and dissipating it. As a
tions exist, replace the spring assembly. See your result the shock should be slightly warm to hot to the
Western Star dealer for replacement. touch after normal use.
Inspect the spring pin bushings. If there is any indi- If ride deterioration is experienced and there is a
cation of the outer bushing casing moving within the suspicion that a shock has failed internally, which is
spring eye, the complete spring assembly must be visually undetectable, perform the following checks
replaced. Refer to Group 32 of the Western Star within a few minutes of operating the vehicle.
Workshop Manual for instructions.
1. Drive the vehicle at moderate speeds for at least
For threaded and bronze bushings, ensure the center 15 minutes.
pin is free to rotate within the outer bushing. If the
pin is seized, replace the complete spring assembly. 2. Within a few minutes of driving, touch each
Refer to Group 32 of the Western Star Workshop shock absorber carefully on its body below the
Manual for instructions. dust cover or tube. First touch a part close to the
shock absorber (spring, frame) to establish a ref-
For maintenance free rubber bushings, inspect the erence temperature of metal.
bushings at the forward spring eye and shackle. If
4700 5700 4900 6900 Maintenance Manual, December 2020 32/1

32 Suspension
3. All shock absorbers should be warmer than any 6. Broken or torn air springs. Shocks will only affect
part near the shock absorber (spring, frame). this if they are broken or missing.
Suspect a failure in any shock absorber that is 7. Upper or lower mount eye broken and dust tube
noticeably cooler than the shock absorber on the broken. See Fig. 2.
other end of the axle. Different temperatures
from axle to axle do not indicate failures, but
cooler temperatures on any one axle does war-
rant removal and examination of the cooler
shock absorber. See Fig. 1.
06/18/2001 f320892
Fig. 2, Shock With Broken Eye and Tube
8. Upper or lower bushing cracked or deformed

06/18/2001 f320896
(when not under load). See Fig. 3.
Fig. 1, Temperature Touch Test
4. To inspect for an internal failure, remove and

shake the suspected shock. Listen for the sound
of metal rattling inside. Rattling of metal parts
can indicate that the shock has an internal
failure.
Shock Absorber Inspection

There are many conditions that indicate it may be
time to replace shocks. Check for the following con-
ditions.
1. Uneven tire wear (check wheel balance first).
2. Ride deterioration.
3. Excess vibration.
4. Sagging taper leaf springs (this is not caused by
weak shocks).
06/18/2001 f320893
5. Premature wear on cab, electrical, and cooling
system components. Fig. 3, Shock With Cracked Bushing
32/2 4700 5700 4900 6900 Maintenance Manual, December 2020

Suspension 32
9. Bent or dented body. See Fig. 4.
06/18/2001 f320895
06/18/2001 f320891 Fig. 5, Misting Shock

Fig. 4, Bent and Dented Shock
Misting shocks are often misdiagnosed as failures.

Misting is the process whereby very small amounts
of shock fluid evaporate at high operating tempera-
tures. The mist passes through the upper seal of the
shock. When the mist reaches the cooler outside air
it condenses and forms a film on the outside of the
shock body. When mixed with road debris and dust,
a grime will often coat the body of the shock. Misting
is perfectly normal and a necessary function of the
shock. The fluid which evaporates through the upper
seal area helps to lubricate and prolong the life of
the seal.
Many technicians find it difficult to differentiate be-
tween a misting shock and a true leaker, which
needs replacing. A leaker will show clear signs of
fluid leaking in streams from the upper seal. These
streams can most easily be seen when the shock is 06/18/2001 f320894
fully extended and one inspects as far up the main
body of the shock (underneath the dust cover or Fig. 6, Leaking Shock
tube) as possible. See Fig. 5 and Fig. 6.
WARNING
Rear Suspension Check
Do not replace individual leaves of a damaged leaf
TufTrac Suspension spring assembly; replace the complete spring as-
1. Inspect the suspension spring assemblies for sembly. Visible damage (cracks or breaks) to one
pitted, cracked, broken, or abnormally bent leaf causes hidden damage to other leaves. Re-
leaves, and extreme rust. If any of these condi- placement of only the visibly damaged part(s) is
tions exist, replace the spring assembly. no assurance that the spring is safe. On front

32 Suspension
spring assemblies, if cracks or breaks exist in the no assurance that the spring is safe. On front
two top leaves, a loss of vehicle control could spring assemblies, if cracks or breaks exist in the
occur. Failure to replace a damaged spring assem- two top leaves, a loss of vehicle control could
bly could cause an accident resulting in property occur. Failure to replace a damaged spring assem-
damage, serious personal injury, or death. bly could cause an accident resulting in property
damage, serious personal injury, or death.
IMPORTANT: On multi-leaf suspensions, closely
inspect each component of the leaf spring as- IMPORTANT: To prevent voiding the warranty
semblies, including the brackets, U-bolts, and on Barksdale height-control valves, note the fol-
related parts. lowing:
2. Inspect the brackets for cracks in the castings. • Do not overtighten the bolts in the Barksdale
Inspect the V-rod tower welds for cracking or height-control valve housing. The bolts should
other signs of damage. Also check for contact not be loose, and should not require tightening.
between the frame rail and the upper axle clamp Only if necessary, tighten the valve housing
brackets. If contact exists, check the V-rod bush- bolts 45 lbf·in (500 N·cm). Any damage to the
ing for wear. Check the V-rod fastener torques. valve housing will void the warranty.
3. Inspect the rubber center bearing and spring tip • Do not attempt to disassemble the Barksdale
pads for excessive wear, including de-lamination valve body or the control lever. There are no
of the rubber-to-metal shim interface, and distor- serviceable parts in the valve, and any disas-
tion and degradation of rubber. sembly will void the warranty.
4. Inspect the V-rods and lower control rods for
wear and looseness. NOTICE
4.1 Without disconnecting the control rods, When removing or loosening a Barksdale height-
use your hand to attempt to move each of control valve from a mounting bracket, always
the control rod ends up, down, in, and hold the valve-side mounting studs in place with
out. If there is any movement, examine an Allen wrench while loosening or tightening the
the control rods for wear or damage. Re- nuts that attach the valve to the bracket. Because
place if necessary. the mounting studs are threaded into the valve
4.2 Inspect the rubber bushings for cracks or body, loosening the nuts without holding the
cuts. studs can tighten the studs, which can crush the
valve body and damage the valve. Conversely,
4.3 Check for any shifting of the barpin. tightening the nuts without holding the studs can
4.4 Check for cracks in the metal compo- back the studs out, causing a separation of the
nents and welds. two halves of the valve body, and possibly a leak.
5. Check all fasteners for looseness. 1. Inspect the fasteners that attach the suspension
brackets to the frame for proper torque. See
6. Inspect the shock absorbers for oil leaks and Group 00 for bolt torque specifications.
worn rubber bushings. Replace the shock ab-
sorbers and/or rubber bushings if wear or dam-
age is noted. WARNING
AirLiner Suspension Be sure that the fasteners are torqued correctly.
Fasteners that are not tight can cause separation
of components or premature failure of compo-
WARNING nents, loss of vehicle control and possible per-
sonal injury or property damage.
spring assembly; replace the complete spring as- 2. Inspect the forward and rear spring brackets for
sembly. Visible damage (cracks or breaks) to one wear, cracks, and other damage. If any of these
leaf causes hidden damage to other leaves. Re- conditions exist, replace the damaged bracket(s).
placement of only the visibly damaged part(s) is

Suspension 32
WARNING
1
Replace worn, cracked, or damaged spring
brackets. Failure to do so could result in bracket
breakage, possibly leading to loss of vehicle con-
trol and resulting in personal injury or property
damage.
3. Inspect the crossmember(s) and gussets for
wear, cracks, and other damage. If any of these A
conditions exist, replace the damaged parts.
4. Visually check the air spring piston for cracks,
chips, and broken areas. Check the air bag for
rips, tears, and holes. Verify that the air spring
assembly does not leak.
WARNING
If damaged air bags are found, do not continue to
use the vehicle, take the vehicle to your Western
Star dealer to have the air bags replaced because
the sudden loss of air bag pressure can cause
loss of vehicle control resulting in serious per-
sonal injury and property damage. 08/16/96 f320453
IMPORTANT: Before checking the AirLiner sus- A. Measure height here.

pension height, make sure there is no load on 1. Left Forwardmost Axle Stop
the chassis, and the trailer is unhitched. Fig. 7, AirLiner Axle Stop Measurement
5. Park the vehicle on a level surface, using a light
application of the brakes. Do not apply the park- 9. Check the shock absorbers. For instructions, see
ing brakes. Shift the transmission into neutral, Maintenance Operation 32-01, "Suspension
and build the secondary air pressure to at least Inspection."
100 psi (690 kPa). Shut down the engine.
Chalmers Suspension
6. Mark the location of the front and rear tires on
the floor, and chock the tires on one axle only.
WARNING
7. On single-drive rear axle configurations, measure
the distance from the bottom of the left axle stop Before making any inspections, always make sure
to the top of the U-bolt pad. On dual-drive rear that the vehicle’s park brake is set and that the
axle configurations, measure the distance from wheels are chocked to prevent accidental vehicle
the bottom of the forwardmost left axle stop to movement to prevent serious injury.
the top of the axle U-bolt pad. See Fig. 7, Ref. 1. Inspect the fasteners that attach the suspension
A. The correct distance for single and dual-drive brackets to the frame for proper torque. See
rear axles is from 2-3/8 to 2-7/8 inches (60 to 73 Group 00 for bolt torque specifications.
mm).
8. If the axle stop measurement is not correct, con- WARNING
tact your Western Star dealer to adjust the level-
ing valves. Be sure that the fasteners are torqued correctly.

32 Suspension
nents, loss of vehicle control and possible per-

sonal injury or property damage. WARNING
2. Chock the front tires to prevent the vehicle from Be sure that the fasteners are torqued correctly.
moving. Place the transmission in neutral, and Fasteners that are not tight can cause separation
release the parking brakes before inspecting the of components or premature failure of compo-
Chalmers rear suspension. nents, loss of vehicle control and possible per-
3. Power-wash the Chalmers rear suspension, or sonal injury or property damage.
clean it with a hard-bristle brush before perform- 2. Visually inspect each frame hanger for any evi-
ing a visual inspection. dence of cracks and rust streaks coming out
4. Visually inspect the rubber bushings for cracks or from between the frame rail and the bracket.
other damage. 3. Visually inspect the load cushions for cuts and
Try to move the torque rod ends using your swelling. Cushions cut by the retaining lips of the
hands only, and check for any free-play. If free- saddles of frame hangers indicate the cushions
play is felt, replace the torque rod end bushing. may not be the correct hardness or configuration
Do not use a pry bar to check for free-play. Use for the use of the vehicle.
of a pry bar may lead to premature bushing re- 4. Check the shock absorbers. For instructions, see
placement. Maintenance Operation 32-01, "Suspension
5. Visually inspect the walking beam for cracks or Inspection."
other damage. If damage is found, replace the
walking beam. Hendrickson RT Series
6. Visually inspect the restrictor cans for cracks,
severe corrosion, and distortion. If any of these WARNING
conditions are present, or the restrictor can is
Before making any inspections, always make sure
missing, replace it.
that the vehicle’s park brake is set and that the
wheels are chocked to prevent accidental vehicle
WARNING movement to prevent serious injury.
Replace all cracked or missing restrictor cans. 1. Inspect the fasteners that attach the suspension
Failure to do so could lead to loss of vehicle con- brackets to the frame. See Fig. 8. See Group 00
trol, which could result in property damage, seri- for bolt torque specifications.
ous personal injury, or death.
7. Check the shock absorbers. For instructions, see WARNING
Maintenance Operation 32-01, "Suspension
Be sure that the fasteners are torqued correctly.
Inspection."
Hendrickson RS Series of components or premature failure of compo-
WARNING 2. Check that the torque on the number one spring
Before making any inspections, always make sure bracket lock bolts is 45 to 63 lbf·ft (62 to 85
that the vehicle’s park brake is set and that the N·m). See Fig. 8.
wheels are chocked to prevent accidental vehicle 3. Inspect the leaf springs for worn or broken spring
movement to prevent serious injury. leaves.
1. Inspect the fasteners that attach the suspension
brackets to the frame for proper torque. See WARNING
Group 00 for bolt torque specifications.
spring assembly; replace the complete spring as-

Suspension 32
1 Hendrickson HAS
2
WARNING
3 Before making any inspections, always make sure
that the vehicle’s park brake is set and that the
4
wheels are chocked to prevent accidental vehicle
movement to prevent serious injury.
1. Inspect the fasteners that attach the suspension
brackets to the frame for proper torque. See
WARNING
07/05/2001 f320906
1. Front Axle Stop
2. Number 1 Spring Bracket 2. Check the torque of the suspension U-bolts
3. Number 2 Spring Bracket every 24,000 miles (40,000 kilometers). For in-
4. Number 3 Spring Bracket structions, see Maintenance Operation 32-03,
"Suspension U-Bolt Torque Check."
Fig. 8, Hendrickson RT Series Suspension
3. Visually inspect each suspension bracket for any
sembly. Visible damage (cracks or breaks) to one evidence of cracks and rust streaks coming out
leaf causes hidden damage to other leaves. Re- from between the frame rail and the bracket.
placement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front 4. Check shock absorbers every 18,000 miles
spring assemblies, if cracks or breaks exist in the (30,000 kilometers). For instructions, see Mainte-
two top leaves, a loss of vehicle control could nance Operation 32-01, "Suspension Inspec-
occur. Failure to replace a damaged spring assem- tion."
bly could cause an accident resulting in property 5. Inspect the air bags for sufficient and equal pres-
damage, serious personal injury, or death. sure. Examine the air bags for wear and cuts.
4. Inspect the cam surfaces of the number two
spring bracket and number three spring bracket WARNING
for wear due to high mileage. See Fig. 8. Also
check the inner side edges of the hanger legs for If damaged air bags are found, do not continue to
wear. Excessive wear on the sides of the legs is use the vehicle, take the vehicle to your Western
an indicator there my be problems with the Star dealer to have the air bags replaced because
spring eye bushing. Excessive wear at either the sudden loss of air bag pressure can cause
point requires that the spring hanger be re- loss of vehicle control resulting in serious per-
placed. sonal injury and property damage.
5. Check the shock absorbers. For instructions, see 6. Park the vehicle on a level surface, using a light
Maintenance Operation 32-01, "Suspension application of the brakes. Do not apply the park-
Inspection." ing brakes. Shift the transmission into neutral,
and build the secondary air pressure to at least
7. Mark the location of the front and rear tires on
the floor, and chock the tires on one axle only.

32 Suspension
8. Check the ride height by measuring, directly 6. Mark the location of the front and rear tires on
above the axle, the distance from the bottom of the floor, and chock the tires on one axle only.
the frame rail to the bottom of the main support 7. Check the ride height by measuring the distance
member. The correct ride height is 4-1/4 inches from the bottom of the frame rail to the center of
(108 mm). the axle. The correct ride height is from 9-3/4 to
If any problem is found, take the vehicle to your 10-1/4 inches (248 to 260 mm).
Western Star dealer to have the problem corrected.
Reyco Suspension
Neway Suspension
WARNING
WARNING
Before making any inspections, always make sure
Before making any inspections, always make sure that the vehicle’s park brake is set and that the
that the vehicle’s park brake is set and that the wheels are chocked to prevent accidental vehicle
wheels are chocked to prevent accidental vehicle movement to prevent serious injury.
movement to prevent serious injury. 1. Inspect the fasteners that attach the suspension
1. Inspect the fasteners that attach the suspension brackets to the frame for proper torque. See
brackets to the frame for proper torque. See Group 00 for bolt torque specifications.
WARNING
WARNING
Be sure that the fasteners are torqued correctly. Fasteners that are not tight can cause separation
Fasteners that are not tight can cause separation of components or premature failure of compo-
of components or premature failure of components, loss of vehicle control and possible per-
nents, loss of vehicle control and possible personal injury or property damage.
sonal injury or property damage. 2. Check the torque of the suspension U-bolts. For
2. Visually inspect each suspension bracket for any instructions, see Maintenance Operation 32-03,
evidence of cracks and rust streaks coming out "Suspension U-Bolt Torque Check."
from between the frame rail and the bracket. 3. Check the shock absorbers. For instructions, see
3. Check the shock absorbers. For instructions, see Maintenance Operation 32-01, "Suspension In-
Maintenance Operation 32-01, "Suspension In- spection."
spection." 4. Inspect the leaf springs for worn or broken spring
4. Inspect the air bags for sufficient and equal pres- leaves.
sure. Examine the air bags for wear and cuts.
WARNING
WARNING
If damaged air bags are found, do not continue to spring assembly; replace the complete spring as-
use the vehicle, take the vehicle to your Western sembly. Visible damage (cracks or breaks) to one
Star dealer to have the air bags replaced because leaf causes hidden damage to other leaves. Re-
the sudden loss of air bag pressure can cause placement of only the visibly damaged part(s) is
loss of vehicle control resulting in serious per- no assurance that the spring is safe. On front
sonal injury and property damage. spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could
5. Park the vehicle on a level surface, using a light
occur. Failure to replace a damaged spring assem-
application of the brakes. Do not apply the park-
bly could cause an accident resulting in property
ing brakes. Shift the transmission into neutral,
damage, serious personal injury, or death.
and build the secondary air pressure to at least

Suspension 32
5. Inspect each frame hanger for any evidence of Chalmers

cracks and rust streaks coming out from between
the frame rail and the bracket. No lubrication is required on a Chalmers rear sus-
pension.
32–02 Suspension Lubrication Hendrickson

The Hendrickson RS Series suspension does not
Front Suspension require lubrication.
Weekly, grease the front spring pins and rear shackle For Hendrickson RT2 and RTE2 Series, lubricate the
pins. Wipe all dirt away from grease fittings (if bronze, ball-indented bushings in the spring eye, as
equipped) on the spring-eye bushings. Apply multi- follows.
purpose extreme pressure (EP) chassis grease with 1. Park the vehicle on a level surface, apply the
a pressurized grease gun until old grease is forced parking brakes, and chock the front tires.
out. For some applications, like twin steer, the grease
fitting is toward the inside, for clearance. When 2. Raise the rear of the vehicle until the rear wheels
greasing the spring pins, always raise the vehicle to are suspended in the air, then support the ve-
remove vehicle weight from the springs. hicle with safety stands. This relieves the load on
the bushings and pins to allow the proper flow of
Rear Suspension lubricant around them.
3. Use a multipurpose chassis grease, and lubricate
Freightliner the bronze, ball-indented bushings in the spring
eyes at the grease fitting. See Fig. 10. Continue
Single Axle to lubricate until grease exits both ends of the
No lubrication is required on a Freightliner single-axle bushing. If the pin will not accept lubricant, re-
rear suspension. move the pin and clean the lubrication channels
where lubricant may have hardened.
Tandem Axle
Lubricate the equalizer cap-and-tube assembly bush- 4
ings by applying multipurpose chassis grease at the
grease fitting until the old grease is forced out from 2 3
the cap-and-tube assembly. See Fig. 9.
2
4 1
09/15/95 f320424
1 1. Bronze Bushing 3. Grease Fitting
05/27/93 320020a 2. Lubrication Hole 4. Lubrication Groove
A. Lubricate here. Fig. 10, Hendrickson RT2 and RTE2 Series Bushing
1. Cap-and-Tube Assembly Bushing Lubrication
Fig. 9, Equalizer Assembly Lubrication

32 Suspension
Neway
No lubrication is required on a Neway rear suspen-
sion.
Reyco
No lubrication is required on a Reyco rear suspen-
sion.
32–03 Suspension U-Bolt

Torque Check
CAUTION
Failure to retorque the U-bolt nuts could result in
spring breakage and abnormal tire wear.
1. Park the vehicle on a flat surface and apply the
parking brakes. Chock the tires.
2. Check U-bolt torque in a diagonal pattern. Set a
click-type torque wrench to the highest torque
value for the fastener being checked. See Group
00 for torque specifications. Turn the wrench in a
clockwise motion (looking up) until the torque
wrench clicks. See Fig. 11.
3. Remove the chocks.
4 1
2 3
07/13/2001 f320910
Fig. 11, Tightening Pattern for U-Bolt Nuts

Front Axle 33
Index, Alphabetical

Front Axle Wheel Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04
Front Drive Axle Lubricant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–06
Front Drive Axle Lubricant Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–05
Knuckle Pin Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01
Steer Axle Hub Cap Vent Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–08
Tie Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03
Tie Rod Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02
Wheel Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–07
4700 5700 4900 6900 Maintenance Manual, May 2017

Front Axle 33

1
DANGER
steps could result in serious personal injury or A
death.
33–01 Knuckle Pin Lubrication
NOTICE
Use regulated pressure when lubricating the
knuckle assemblies, otherwise damage could re-
sult to the knuckle caps.
B
Detroit™ Axles 1
06/07/2012 f330272
the engine, and set the parking brake. Chock the A Upper View, LH Side B Lower View, LH Side
tires. When lubricating upper and lower knuckle 1. Grease Fitting
assemblies, do not raise the front axle. Fig. 1, Grease Fittings, Detroit Axles
2. Wipe the fittings clean.
3. Apply multipurpose chassis grease, NLGI Grade
1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease), until new grease is seen at the junctions
of the axle beam and knuckles. For locations of
grease fittings, see Fig. 1; for grease exit points,
see Fig. 2.
Dana Spicer Axles

Park the vehicle on a level surface, apply the parking 09/13/2012 f330275
brakes, and chock the tires. When lubricating upper
and lower knuckle assemblies, do not raise the front Fig. 2, Knuckle Pin Grease Exit Points, Detroit Axles
axle. Wipe the fittings clean, then apply multipurpose
chassis grease, NLGI Grade 1 (6% 12-hydroxy Meritor Axles
lithium stearate grease) or NLGI Grade 2 (8% 12-
hydroxy lithium stearate grease), until new grease is Park the vehicle on a level surface, apply the parking
seen at the junctions of the axle beam and knuckles. brakes, and chock the tires. When lubricating knuckle
See Fig. 3. Knuckle pins without grease fittings are pin bushings, do not raise the front axle. Wipe the
permanently lubricated. lube fittings clean, and apply multipurpose chassis
4700 5700 4900 6900 Maintenance Manual, May 2017 33/1

33 Front Axle
1
1
1
11/21/95 f330129
A. Grease exits
1. Grease Fitting 1
09/06/96 f320032a
Fig. 3, Dana Spicer Knuckle Pin Lubrication A. Grease exits
1. Grease Fitting
grease, NLGI Grade 2 (8% 12-hydroxy lithium stear-
ate grease), until new grease is seen at the bushing Fig. 4, Knuckle Pin Lubrication, Meritor Axles
grease seal opposite the fittings. The grease seal will
accept grease pressure without damage, and is de-
signed to have grease pumped out through it during
lubrication. Even if grease leaks out around the top,
or bottom-plate gasket, continue pumping until new
grease is seen at the bushing seal opposite the
grease fitting; see Fig. 4.
2
NOTE: For operation in very cold climates, use
grease).
33–02 Tie Rod Lubrication 06/12/2012

1
f330273
NOTE: Some axles require lubrication of the tie NOTE: No grease should emit from the tie-rod boot. If
grease emits from the tie-rod boot, the boot is dam-
rod ends. aged.
1. Wipe the tie rod end grease fittings clean. 1. Grease Fitting 2. Boot
2. Pump multipurpose chassis grease, NLGI Grade Fig. 5, Grease Fitting and Boot (Detroit axle shown)
1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate 1. Shut off the engine, apply the brakes, and chock
grease), into the tie rod ends until all used the rear tires.
grease is forced out and fresh grease is seen at
2. Check the tie rod boot for cracks, tears, or other
the ball stud neck. See Fig. 5.
damage. If the tie rod boot is damaged, replace
the entire tie rod end.
33–03 Tie Rod Inspection 3. Grasp by hand (or use a pipe wrench with jaw
protectors to avoid gouging the cross tube) and
IMPORTANT: If the tie rod end boot is torn or slightly rotate the cross tube toward the front of
missing, replace the entire tie rod end. Do not the vehicle and then slightly toward the rear.
replace the boot only. Then center the cross tube between the stop po-
33/2 4700 5700 4900 6900 Maintenance Manual, May 2017

Front Axle 33
sitions. If the cross tube does not rotate in either rod ends are threaded in the cross tube past the
direction, replace both tie rod ends. clamps and the slots at the cross tube ends.
4. Position yourself directly below the ball stud 8. Check the zerk fittings for damage. If a zerk fit-
socket. Using both hands, grab the end as close ting is damaged, replace it.
to the socket as possible, no more than 6 inches Some tie rod ends have no zerk fittings because
(15.2 cm) from the end. Firmly apply about 100 they are not greaseable. Do not install a zerk
pounds of hand pressure in an up and down mo- fitting on a nongreaseable tie rod end.
tion several times. When moving the assembly,
check for any movement at both tie rod ends. 9. Check that the cotter pin is in place. If it is not,
See Fig. 6. tighten the tie rod end nut to one of the following
specs depending on the axle manufacturer.
If any movement is detected at one tie rod end,
replace both tie rod ends. Always replace tie rod For Detroit axles, tighten the castle nut to 120 to
ends in pairs, even if only one tie rod end is 170 lbf·ft (163 to 230 N·m). To align the cotter
damaged. pin hole with the castle nut slot, turn the nut up
to 1/6 turn (maximum).
For Meritor axles, tighten the tie rod end nut per
the size of the stud:
• 7/8–14, 160 to 300 lbf·ft (217 to 406 N·m)
• 1–14, 250 to 450 lbf·ft (339 to 610 N·m)
• 1-1/8–12, 350 to 650 lbf·ft (475 to 881
N·m)
• 1-1/4–12, 500 to 675 lbf·ft (678 to 915
N·m)
10. Check the steering arm bolts for a minimum
torque of 300 lbf·ft (406 N·m). If the steering arm
bolt torque has fallen below this specification,
10/10/2001 f330195 remove the bolt, clean all the threads, and apply
new Loctite® 680. Tighten the bolt 300 to 450
Fig. 6, Check Movement of Tie Rod End lbf·ft (406 to 610 N·m).
NOTICE 33–04 Front Axle Wheel

Do not attempt to straighten a bent cross tube. Bearing Lubrication
Doing so could result in damage to the axle. Be
sure to replace the cross tube with an original Stemco front axle hub caps have a transparent in-
equipment cross tube with the same length, diam- spection window with lubrication level marks for
eter, and thread size as the existing cross tube. checking the amount of lubricant available for the
front wheel bearings. See Fig. 7. If the lubricant level
5. Check the cross tube for cracks or other dam- is low, remove the center fill plug and add lubricant
age. If the cross tube is bent or damaged, re- until the level reaches the ’full’ mark. Fill the hub with
place the cross tube. Hypoid Gear Oil API-GL-5 with Military Specification
6. Check the clamps for damage. If a clamp is MIL-L-2105C, SAE viscosity 75W-90.
damaged, replace the clamp. Replace the entire
cross tube assembly if either clamp is welded to
the cross tube.
7. Check for proper installation of the tie rod end
clamp to the cross tube. Make sure that the tie

33 Front Axle
1
2
07/18/2001 f350408
1. Temperature Sensor Plug
07/17/2001 f330179 2. Fill Plug
1. Correct Lubrication Level 3. Drive Axle Breather
Fig. 7, Front Hubcap Inspection Window Fig. 8, Drive Axle Housing
leaks, and have any leaks corrected. Add lubri-

33–05 Front Drive Axle cant as required. See Table 1 and Table 2 for
Lubricant Level Check recommended drive axle lubricants.
NOTICE A
Failure to keep drive axle lubricant filled to the

proper level with the recommended axle lubricant
can result in axle damage.
NOTE: Follow the recommended maintenance
schedule for draining and flushing the drive B
axles. See Group 00 for time or mileage inter-
vals.
10/05/2016 f350061a
1. With the vehicle parked on level ground, apply
the parking brakes and chock the tires. A. Correct (lubricant level at bottom of fill hole)
B. Wrong (lubricant level below fill hole)
minutes for the lubricant to settle. Fig. 9, Drive Axle Lubrication Level
3. Clean the oil fill plug and the area surrounding it. 5. Apply a small amount of thread sealant (Loctite®
Remove the fill plug. See Fig. 8. or equivalent), to the threads of the filler plug.
NOTE: A lubricant level close enough to be Install and tighten the fill plug 40 to 60 lbf·ft (54
to 81 N·m).
seen or touched is not sufficient. It must be level
with the bottom of the fill hole.
4. Lubricant should be level with the bottom of the
fill hole. See Fig. 9. If low, check the axle for

Front Axle 33
Eaton Drive Axle Recommended Lubricants

Lubricant Type Conditions SAE Viscosity
Eaton® Roadranger® Synthetic Drive Axle Lubricants, Over-the-Road Service 75W-90
or Equivalent with Military Specification MIL-L-2105D Off-Highway, or Under Extra-Heavy Loads 80W-140
Table 1, Eaton Drive Axle Recommended Lubricants
Meritor Drive Axle Recommended Lubricants

Lubricant Type Outside Air Temperature SAE Viscosity
+10°F (-12°C) & Up* 85W-140
Hypoid Gear Oil API-GL-5 with Military Specification
-40°F (-40°C) & Up* 75W-90
MIL-L-2105C
-40°F (-40°C) & Up* 75W-140
-40°F (-40°C) & Up* 75W-90
Synthetic Gear Oil
-40°F (-40°C) & Up* 75W-140
* There is no upper limit on these outside air temperatures, but axle sump temperature must never exceed 250°F (121°C).
Table 2, Meritor Drive Axle Recommended Lubricants
33–06 Front Drive Axle IMPORTANT: The axle should not be flushed
with any solvent, such as kerosene.
Lubricant Change
6. Clean the fill and drain plugs. A piece of keystock
or other convenient steel bar may be used
NOTICE across the magnetic poles to divert the magnetic
field. Clean the metallic particles from the plug.
Failure to change the axle lubricant at more fre-
NOTE: The magnetic plug should have a mini-
quent intervals, when adverse operating condi-
tions require, could result in axle damage. mum pickup capacity of 1-1/2 lb (0.7 kg) of low-
carbon steel, in bar or plate form. Magnets will
Refer to Table 1 and Table 2 for recommended rapidly loose effectiveness as collected material
drive axle lubricants. bridges the gap between the two poles. Clean
1. With the vehicle parked on level ground, apply or change the plugs before this occurs. It may
the parking brakes and chock the tires. be necessary to clean or change the plugs one
or more times between lubricant change inter-
2. Clean the area around the fill plug. Remove the
fill plug. vals.
3. Place a drain pan under the axle. Remove the 7. Install and tighten the drain plug to 35 lbf·ft (47
drain plug from the bottom of the housing and N·m).
completely drain the lubricant, while the unit is 8. Fill the axle housing to the bottom of the fill hole,
warm. (Fig. 9) using the specified lubricant. See
4. The drained oil should be stored appropriately for Table 1 and Table 2 for recommended drive axle
recycling. lubricants.
5. It is necessary to flush the axle the first time 9. Install and tighten the fill plug to 35 lbf·ft (47
(ONLY) that the axle lubricant is changed. Flush N·m).
the axle with clean flushing oil, then drain it thor- 10. Remove the chocks. Then drive the vehicle, un-
oughly. The drained oil should be stored appro- loaded, for 1 to 2 miles (2 to 3 km) at speeds not
priately for recycling.

33 Front Axle
to exceed 25 mph (40 km/h), to thoroughly circu- on the road contact surfaces of the tread. Also, a
late lubricant throughout the carrier and housing rapid wear on the steering axle could occur usu-
assembly. ally in a feathered-edge pattern. See Fig. 11.
Feathered-edging more often affects the front tire
33–07 Wheel Alignment Check on the passenger’s side of the vehicle, and is
usually more apparent on the outside groves of
the tire.
General Information If any of these listed conditions occur, the vehicle
The axles and wheels are aligned at Western Star could need a front end alignment.
using Hunter laser alignment equipment. Correct
front axle alignment is needed to ensure long tire life, A
ease of handling, and steering stability.
1. Camber is the vertical tilt of the wheel as viewed
from the front of the vehicle. Camber angle is
measured in degrees, and is not adjustable.
Negative camber is the top of the wheels tilted
inwards. Front tires wearing on the inboard side
may be due to excessive negative camber. See
Fig. 10.
A 10/21/2016 f400094a
A. Feathered-Edges.
Fig. 11, Tire Wear Due to Excessive Toe-In
Toe-In Inspection
For vehicle alignment to be accurate, the shop floor
must be level in every direction. The turn plates for
the front wheels must rotate freely without friction,
and the alignment equipment must be calibrated
10/21/2016 f400097a
every three months by a qualified technician from the
equipment manufacturer. Western Star dealers must
A. One side of tread is worn excessively. have proof of this calibration history.
Fig. 10, Tire Wear Due to Excessive Camber 1. Apply the parking brakes and chock the rear
tires.
2. Caster is the tilt of the knuckle pin (or king-pin),
as viewed from the side. Caster angle is mea- 2. Raise the front of the vehicle until the tires clear
sured in degrees and is adjustable. An incorrect the ground. Check that the safety stands will
caster angle does not cause tire wear. However, support the combined weight of the cab, axle,
a positive caster angle that exceeds specifica- and frame. Place safety stands under the axle.
tions could cause vehicle shimmy and an in- 3. Using spray paint or a piece of chalk, mark the
creased steering effort. Excessive negative entire center rib of each front tire.
caster angle could cause unstable steering, and
the vehicle may wander and weave. 4. Place a scribe or pointed instrument against the
marked center rib of each tire, and turn the tires.
3. Wheel toe-in is the distance that the front of the The scribe must be held firmly in place so that a
wheels are closer together than the rear of the single straight line is scribed all the way around
wheels. Wheel toe-in is adjustable. If toe-in is not each front tire.
correct, the vehicle could pull to one side while
driving. Wheel shimmy and excessive tire wear 5. Place a turn-plate or turntable under each front
could occur. The tires would display indentations tire. Remove the safety stands from under the

Front Axle 33
axle, then lower the vehicle. Remove the lock-

pins from the gauges; make sure the tires are
exactly straight ahead.
NOTE: If turn-plates or turntables are not avail-
able, lower the vehicle. Remove the chocks
from the rear tires and release the parking
brakes. Move the vehicle backward and then
forward about six feet (two meters).
6. Place a trammel bar at the rear of the front tires;
locate the trammel pointers at spindle height,
10/05/2016 f330014a
and adjust the pointers to line up with the scribe
lines on the center ribs of the front tires. See Fig. 13, Trammel Bar Positioning
Fig. 12. Lock the pointers in place. Check that
the scale is set on zero.
B
10/05/2016 f330082a
NOTE: B minus A equals toe-in.
A. Distance at front of tires.
B. Distance at rear of tires.
Fig. 12, Wheel Toe-In (overhead view)
7. Place the trammel bar at the front of the tires, 10/05/2016 f400100a
see Fig. 13, and adjust the scale end so that the
pointers line up with the scribe lines. See Fig. 14, Setting Trammel Bar Pointers
Fig. 14.
8. Read the toe-in from the scale. Toe-in should be
33–08 Steer Axle Hub Cap Vent
in the range of -1/32 to +3/32 inch. If corrections Plug Inspection
are needed, take the vehicle to your Western
Star Dealer to adjust the toe-in. The Toe-in
should be set as close as possible to +1/32 inch.
General Information
As a function of their design, hubcap vent plugs will
on occasion exhibit signs of hub oil on their exterior
surface. Depending on environmental conditions
and/or age of the plug, the amount of oil present can
vary. This is a normal result of the venting process

33 Front Axle
due to pressure increase within the hub cavity. For

an example of normal vent plug appearance, see
Fig. 15.
09/01/2016 f330299
09/01/2016 f330298 Fig. 16, Excessive Leakage
Fig. 15, Normal Oil Venting
A vent plug can wear or be damaged and cause ex-

cessive leakage, or allow water to enter the hub and
contaminate the oil. For examples of a leaking vent
plug, see Fig. 16 and Fig. 17. Evidence of a leaking
vent plug may appear as;
• Oil splatter around the wheel
• Gooey/gummy oil around the vent plug purge
point
• Hub/plug area is dirty, and water contaminated
oil in the hub.
• Hub/plug area is clean, but there is water con-
taminated oil in the hub. (pressure washing is
the most likely cause)
Inspection 09/01/2016 f330300
Fig. 17, Water in Oil

NOTICE
Only remove vent plugs by hand. They can be the engine and set the parking brakes. Chock
damaged if a tool is used. Wipe the hub/plug area the tires.
clean before checking the oil. Do not use a pres-
sure washer to clean the hub/plug area. The plug 2. Inspect the axle hub cap and vent plug for evi-
has a vent and this can contaminate the oil with dence of excessive leakage.
water. 3. Wipe the hub cap and vent plug clean with a rag.

Front Axle 33
4. Remove the vent plug and check the oil for evi-
dence of water contamination.
If there is evidence of water contaminated oil in
the hub, disassemble the effected axle end,
clean, inspect, and reassemble the axle end. For
instructions, refer to Group 33 of the vehicle’s
Workshop Manual.
If there is evidence of excessive leakage, re-
move the damaged part and replace it with a
new part.
5. Check the oil level in the hub, and fill the hub
with new approved oil as needed.

Rear Axle 35
Index, Alphabetical

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning and Check . . . . . . . . . . . . . . . . . . . . . 35–04
Drive Axle Breather Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–03
Drive Axle Lubricant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01
Two-Speed-Axle Shift Unit Lubricant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02

Rear Axle 35

DANGER
When working on the vehicle, shut down the en- 2
death.
A
35–01 Drive Axle Lubricant 1

Level Check
NOTICE
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage. 2
tires.
minutes for the lubricant to settle.
3. Clean the oil fill hole plug (located in the carrier 4
or the side of the axle housing) and the area sur- 3
rounding it, then remove the plug. For Detroit B
axles, see Fig. 1; for Meritor axles, see Fig. 2; 12/07/2010 f350509a
for Dana Spicer axles, see Fig. 3.
A. Front View
NOTE: Some Detroit and Meritor axles have a B. Rear View
small tapped and plugged hole located below 1. Axle Breather
the housing oil fill hole. This smaller hole is for 2. Breather Hose
the lubricant temperature sensor only and must 3. Temperature Sensor Port
not be used as a fill or level hole. 4. Oil Fill Plug
IMPORTANT: A lubricant level close enough to Fig. 1, Detroit Tandem Axle (forward axle shown)
be seen or touched is not sufficient. It must be For Detroit axles, see Table 1 for approved axle
level with the bottom of the fill hole. lubricants and Table 2 for lubricant capacities.
4. Check the level of the lubricant. The lubricant For Meritor axles, see Table 3 for approved axle
must be level with the bottom of the oil fill hole lubricants, and Table 4 and Table 5 for axle ca-
(see Fig. 4). If low, check for oil leaks (and make pacities.
corrections as needed), and add oil to the level
of the fill plug.

35 Rear Axle
4
A
B
1
2
3 10/05/2016 f350061a
07/21/2011 f350539
A. Correct (lube level at bottom of fill hole)
1. Oil Fill Plug
B. Incorrect (lube level below fill hole)
2. Temperature Indicator Plug
3. Oil Drain Plug Fig. 4, Axle Lubricant Level Check
4. Breather Hose
6. On non-drive axles using oil-lubricated wheel
Fig. 2, Plug and Breather Locations, Meritor Axles
bearings, clean the hub cap and plug to minimize
the possibility of dirt and road grime entering the
3 assembly. Remove the plug, and check the oil
level. If low, add fluid using the same lubricant
recommended for the drive axle.
Detroit Drive Axle Lubricants*
IMPORTANT: Lubricant used in Detroit rear axles must

meet Mercedes-Benz specification 235.20 (mineral) or
235.8 (synthetic). Mobil Delvac™ Gear Oil A 80W-90 and
Mobilube™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
75W-90 meet specification 235.8. For more product
1
information, see http://bevo.mercedes-benz.com.
SAE
Type Ambient Temperature Viscosity
Grade
2
Mineral Oil –15°F (–26.1°C) and up† 80W–90
02/21/2017 f350531 Synthetic Oil –40°F (–40°C) and up† 75W–90
1. Oil Fill Plug * Detroit rear axles do not require the use of friction modifiers.
2. Oil Drain Plug † There is no upper limit on the ambient temperature, but axle sump tem-
3. Axle Breather perature must never exceed 250°F (121°C).
Fig. 3, Plug and Breather Locations, Dana Spicer Axles Table 1, Detroit Drive Axle Lubricants
For Dana Spicer axles, see Table 6 for approved

axle lubricants, and Table 7 for axle capacities. Detroit Rear Axle Lubricant Capacity (Hubs Full)
5. Install the oil fill hole plug and tighten it per the Oil Capacity:
Axle
Quarts (liters)
following:
Forward-Rear, Model 4 14.3 (13.5)*
• For Detroit axles: 30 lbf·ft (41 N·m).
Single and Rearmost Tandem,
• For Meritor axles: 35 lbf·ft (47 N·m). Model 4
10.6 (10.0)*
• For Dana Spicer axles: 50 lbf·ft (68 N·m).

Rear Axle 35
Detroit Rear Axle Lubricant Capacity (Hubs Full)

Oil Capacity:
Axle
Quarts (liters)
Single, Model 2 5.8 (5.5)*
* These values assume the wheel ends are properly lubricated. Actual oil
capacity might vary slightly depending on gear ratio.
Table 2, Detroit Rear Axle Lubricant Capacity
Meritor Drive Axle Recommended Lubricant

Lubricant Type Ambient Temperature Viscosity Grade Meritor Specification
10°F (–12.2°C) and up* 85W–140 0–76–A
–15°F (–26.1°C) and up* 80W–140 0–76–B
Non-Extended Drain –15°F (–26.1°C) and up* 80W–90 0–76–D
Lubricants –40°F (–40°C) and up* 75W–90 0–76–E
–40°F (–40°C) to 35°F (2°C) 75W 0–76–J
–40°F (–40°C) and up* 75W–140 0–76–L
–40°F (–40°C) and up* 75W–90 0–76–N
Extended Drain Lubricants
–40°F (–40°C) and up* 75W–140 0–76–M
* There is no upper limit on the ambient temperature, but axle sump temperature must never exceed 250° (121°C).
Table 3, Meritor Drive Axle Recommended Lubricant
Meritor Drive Axle Lubricant Capacities for Single Meritor Drive Axle Lubricant Capacities for Tandem
Axles Axles
Capacity*: Capacity*
Axle Model Axle Model Axle Position
Pints (liters) Pints (liters)
RS–23–160 39.5 (18.7) Forward 30 (14.2)
MT–40–14X
RS–23–161 37.2 (17.6) Rear 32 (15.14)
RS–23–186 47.3 (22.4) Forward 30.2 (14.3)
RT–40–145
RS–25–160 37 (17) Rear 25.8 (12.2)
RS–26–185 46.0 (22.0) Forward 30.2 (14.3)
RT–40–145P
RS–30–185 46.0 (22.0) Rear 25.8 (12.2)
RS–30–380 58.2 (27.5) Forward 39.1 (18.5)
RT–40–160
RS–38–380 53.1 (25.1) Rear 34.4 (16.3)
* Quantities listed are approximate and include 1 pint (0.5 liter) for each RT–44–145 Forward 29.3 (13.9)
wheel end and with the drive pinion at 3 degrees. RT–44–145P Rear 25.1 (11.9)
Table 4, Meritor Drive Axle Lubricant Capacities for
Single Axles Forward 39.1 (18.5)
RT–46–160
Rear 34.4 (16.3)
Forward 38.0 (18.0)
RT–46–164EH/P
Rear 33.0 (15.0)

35 Rear Axle
Meritor Drive Axle Lubricant Capacities for Tandem

Axles
Capacity*
Axle Model Axle Position
Pints (liters)
Forward 38.0 (18.0)
RT–50–160
Rear 33.0 (15.0) A
Forward 56.1 (26.5)
RT–52–185
Rear 36.1 (17.1)
Forward 56.1 (26.5)
RT–58–185
Rear 36.1 (17.1)
* Quantities listed are approximate and include 1 pint (0.5 liter) for each 07/18/2001 f350407
wheel end and with the drive pinion at 3 degrees.:
A. Lubricant level.
Table 5, Meritor Drive Axle Lubricant Capacities for
Tandem Axles Fig. 5, Drive Axle Wheel Bearing Lubrication
Dana Spicer Drive Axle Recommended Lubricant

35–02 Two-Speed-Axle Shift
Lubricant SAE Unit Lubricant Level
Lubricant Type Condition Viscosity
Grade
Check
Dana Spicer Over-the-Road
75W–90
Roadranger® Service CAUTION
Synthetic Drive Axle
Lubricants, or Off-Highway Failure to keep the two-speed-axle shift unit filled
Equivalent with Equipment, or to the proper level with the recommended lubri-
80W–140
Military Specification Under Extra cant can result in shift unit damage.
MIL–L–2105D Heavy Loads
1. Clean the oil fill plug and the area surrounding it.
Table 6, Dana Spicer Drive Axle Recommended
Remove the fill plug. See Fig. 6.
Lubricant
2. Lubricant should be level with the bottom of the
fill hole. If lubricant level is low, check for leaks
Dana Spicer Drive Axle Lubricant Capacities and have them corrected. Add lubricant as re-
Capacity*: quired. Use the same lubricant as the drive axle.
Axle Model
Pints (liters)
DD405 31 (14.7)† 35–03 Drive Axle Breather
DP463P 40 (18.9)†
Check
* Quantities listed are approximate. Fill axle until lubricant is level with bot-
tom of fill hole with vehicle on level ground. Axle breathers must NOT be clogged. Whenever the
† Add 2 pints (1 L) of additional lubricant to the power divider.
axle lubricant level is checked, be sure the axle
Table 7, Dana Spicer Drive Axle Lubricant Capacities breather is also checked. If operating under adverse
conditions, check the breathers more often. If the
NOTE: The same lubricant that is used for the
breather is damaged or plugged, have it cleaned or
drive axle lubricates the rear axle wheel bear- replaced. For the location of the breather on Detroit
ings. See Fig. 5. axles, see Fig. 1; for Meritor axles, see Fig. 2; and
for Dana Spicer axles, see Fig. 3.

Rear Axle 35
2. Clean the fill plug and the area around it. In the
axle housing rear cover, remove the plug from
the oil fill hole. See Fig. 1.
CAUTION
1
Be careful when draining the axle oil. It may be
very hot, and could cause personal injury if it con-
tacts the skin.
3. Place a drain pan under the rear axle drain plug.
Drain the oil when it is warm. At this tempera-
ture, the oil will run more freely and ensure that
the axle is flushed.
3
2 4. Clean the fill and drain plugs. Change them if
08/06/93 f350021a necessary.
1. Gasket 4.1 For magnetic plugs, use a piece of key
2. Fill Plug stock or any other convenient steel slug
3. Shift Unit Housing Cover to short the two magnetic poles and divert
Fig. 6, Two-Speed-Axle Shift Unit
the magnetic field.
4.2 Clean away the collected material depos-
35–04 Axle Lubricant and Filter ited on each pole. Magnets will rapidly
lose their effectiveness as collected mate-
Change, and Magnetic rial bridges the gap between the two
Strainer Cleaning and poles.
Check 4.3 After the first oil is changed, inspect the
drain plug each time for large quantities
of metal particles.
NOTICE 4.4 After cleaning, install the drain plug(s)
and tighten to 30 lbf·ft (41 N·m).
When operating under adverse conditions, it may
be necessary to change the axle lubricant at more 5. Fill the axle with the recommended lubricant.
frequent intervals than listed in the scheduled See Table 1 for recommended drive axle lubri-
maintenance tables. Failure to do so could result cants and Table 2 for lubricant capacities.
in axle damage.
NOTE: Some Detroit axles have a small
Detroit™ tapped and plugged hole near and below the
housing oil fill hole. This smaller hole is for a
IMPORTANT: On Detroit axles, the oil change lubricant temperature indicator only, and
interval for long haul vehicles can be extended should not be used as a fill or level hole.
to 500,000 miles (800 000 km) for axles with
5.1 Fill the axle through the oil fill hole. Lubri-
weight ratings of 34,000 to 40,000 lb (15 000 to cant should be level with the bottom of
18 000 kg) using synthetic lubricant if a lubricant the oil fill hole. To check fluid level, see
analysis shows adequate quality. Oil must be Fig. 4.
changed at least every four years, and more
5.2 Install and tighten the fill plug 30 lbf·ft (41
often if the axle is exposed to high temperatures
N·m).
and steep grades.
tires.

35 Rear Axle
Detroit™ New Final Drive CAUTION

the engine, and set the parking brake. Chock the Be careful when draining the axle oil. It may be
tires. very hot, and could cause personal injury if it con-
tacts the skin.
2. Clean the fill plug and the area around it. In the
carrier housing, remove the plug from the oil fill 3. Place a drain pan under the rear axle drain plug.
hole. See Fig. 7 for the forward axle, and Fig. 8 Drain the oil when it is warm. At this tempera-
for the rear axle . ture, the oil will run more freely and ensure that
the axle is flushed.
4. Clean the fill and drain plugs. Change them if
necessary.
4.1 For magnetic plugs, use a piece of key
stock or any other convenient steel slug
to short the two magnetic poles and divert
the magnetic field.
ited on each pole. Magnets will rapidly
rial bridges the gap between the two
poles.
11/07/2016 f350604 4.3 After the first oil is changed, inspect the
drain plug each time for large quantities
Fig. 7, Detroit™ New Final Drive Forward Axle, Oil Fill
of metal particles.
Location 5. Fill the axle with the recommended lubricant.
See Table 8 for recommended drive axle lubri-
cants and Table 9 for lubricant capacities.
5.1 Fill the axle through the oil fill hole. Lubri-
cant should be level with the bottom of
the oil fill hole.
N·m).
Detroit Drive Axle Lubricant, New Final Drive*

Ambient
Lubricant Type
Temperature
Must meet Detroit
–40°F (–40°C) and
Fluids Specification Synthetic
up†
(DFS) 93K219.03
* Detroit rear axles do not require the use of friction modifiers.
† There is no upper limit on the ambient temperature, but axle sump tem-
11/07/2016 f350605 perature must never exceed 250°F (121°C).
Table 8, Detroit Drive Axle Lubricants, New Final
Fig. 8, Detroit™ New Final Drive Rear Axle, Oil Fill Drive
Location

Rear Axle 35
New Final Drive Oil Capacity, New Final Drive

Axle Type Oil in Hubs (2) Oil in Axle
NFD Model 4 Forward Axle TP 1.8 L 9L
NFD Model 4 Rear Rear Axle TP 1.8 L 7.5 L
NFD Model 4 Forward Axle SP 1.8 L 14 L
NFD Model 4 Rear Rear Axle SP 1.8 L 11 L
NFD Model 6 TP 1.8 L 9.5 L
NFD Model 6 SP 1.8 L 11 L
Table 9, New Final Drive Oil Capacity, New Final Drive
ing. Completely drain the lubricant while the unit

is warm, to allow the lubricant to drain faster.
A
On tandem-drive axles, it is also necessary to
remove the plug at the bottom of the interaxle
differential housing to drain that lubricant.
4. If equipped with an oil pump, replace the filter.
B NOTE: There may be about one pint (0.5 L)
of lubricant remaining in the filter.
4.1 Remove the axle oil filter using a suitable
10/05/2016 f350061a filter strap wrench (see Fig. 10) and dis-
A. Correct (lube level at bottom of fill hole) card it.
B. Incorrect (lube level below fill hole) 4.2 Using recommended drive axle lubricant
Fig. 9, Axle Lubricant Level Inspection (see Table 3), coat the face of the gasket
on the new oil filter.
Meritor Axles 4.3 Install the filter over the adapter, and
tighten the filter one full turn after the
IMPORTANT: If using synthetic lubricant, the gasket contacts the base; do not
lubricant change interval is extended to 100,000 overtighten.
miles (160 000 km). On axles with a pump and
5. Clean the fill and drain plugs as follows. Change
filter system, the filter change interval is 100,000
them if necessary.
miles (160 000 km).
1. Park the vehicle on level ground, apply the park- stock or any other convenient steel slug
ing brakes, and chock the front tires. to short the two magnetic poles and divert
NOTE: Some Meritor axles have a small tapped the magnetic field.
and plugged hole near and below the housing 5.2 Check the drain plug for metal particles
lubricant fill hole. This smaller hole is for a lubri- every 100,000 miles (160 000 km). Clean
cant temperature indicator only, and should not away the collected material deposited on
be used as a fill or level hole. each pole. Magnets will rapidly lose their
effectiveness as collected material
2. Clean the area around the fill plug, then remove
bridges the gap between the two poles.
the fill plug.
5.3 Meritor recommends plugs with elements
3. Place a drain pan under the drain plug, then re-
having a minimum pickup capacity of 1.5
move the drain plug from the bottom of the hous-
pounds (0.7 kg) of low-carbon steel. Each
time the oil is changed, replace any mag-

35 Rear Axle
Dana Spicer Axles

NOTE: If using a Roadranger synthetic drive
axle lubricant, the lubricant change interval is
extended to 180,000 miles (288 000 km).
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires.
NOTE: Some Dana Spicer axles have a small
tapped and plugged hole near and below the
housing oil fill hole. This smaller hole is for a
lubricant temperature indicator only, and should
not be used as a fill or level hole.
2. Clean the oil fill plug and the area around it (see
Fig. 3), then remove it from the oil fill hole.
10/05/2016 f350119a
3. Place a drain pan under the rear axle drain plug;
Fig. 10, Meritor Axle Oil Filter Removal see Fig. 3. Drain the oil at normal operating tem-
perature, 150°F to 200°F (65°C to 93°C). At this
netic drain plug that does not meet the temperature, the oil will run more freely and en-
minimum pickup capacity. sure that the axle is flushed.
5.4 Install the drain plug(s) and tighten to 35 NOTE: Some tandem-drive axles are equipped
lbf·ft (47 N·m). with a cylindrical magnetic strainer, located
6. Fill the axle with recommended lubricant as fol- below the lube pump on the front of the power
lows. For lubricant capacities, see Table 4 divider cover. All rear axles are fitted with mag-
(single axles) or Table 5 (tandem axles). See netic drain and fill plugs.
Table 3 for recommended lubricant. 4. At each axle oil change, remove and clean the
6.1 With the vehicle on a level surface, fill the magnetic strainer, if equipped, as follows.
axle through the oil fill hole. Allow a few 4.1 Remove the magnetic strainer from the
minutes for the oil to flow into the axle. power divider cover. See Fig. 11.
Lubricant should be level with the bottom
of the oil fill hole.
WARNING
6.2 Check the fluid level; see Fig. 4.
6.3 Install and tighten the fill plug 35 lbf·ft (47 Always wear eye protection when using com-
N·m). pressed air to clean parts, as flying debris could
cause permanent damage to unprotected eyes. Do
7. Whenever the interaxle differential housing has not point the air stream in the direction of other
been drained, add an additional 2 pints (0.9 L) of persons.
the recommended lubricant directly into the inter-
axle differential housing. 4.2 Wash the strainer in solvent, and blow it
dry with compressed air to remove oil and
8. Remove the chocks, then drive the vehicle, un- metal particles.
loaded, for 1 or 2 miles (2 or 3 km) at speeds
not to exceed 25 mph (40 km/h), to thoroughly 4.3 Install and tighten the magnetic strainer
circulate lubricant throughout the carrier and 40 to 60 lbf·ft (54 to 81 N·m).
housing assemblies. 5. Clean the fill and drain plugs as follows. Change
them if necessary.
stock or any other convenient steel slug

Rear Axle 35

N·m).
10/05/2016 f350017a
1. Magnetic Strainer
2. Power Divider
Fig. 11, Dana Spicer Tandem-Drive Axle Magnetic
Strainer
to short the two magnetic poles and divert

the magnetic field.
ited on each pole. Magnets will rapidly
rial bridges the gap between the two
poles.
5.3 Inspect the drain plug for large quantities
of metal particles.
5.4 After cleaning, install the drain plug(s)
and tighten to 40 to 60 lbf·ft (54 to 81
N·m).
IMPORTANT: The use of friction modifiers is not
approved in Dana drive axles.
6. Fill the axle with the recommended lubricant as
follows. See Table 6 for recommended lubri-
cants, and Table 7 for drive axle lubricant ca-
pacities.
6.1 With the vehicle on a level surface, fill the
axle through the oil fill hole. Lubricant
should be level with the bottom of the oil
fill hole.
6.2 Check the fluid level; see Fig. 4.

Wheels and Tires 40
Index, Alphabetical

Tire Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02
Wheel Nut and Rim Nut Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01

Wheels and Tires 40
40–01 Wheel Nut and Rim Nut

Torque Check
CAUTION
Insufficient wheel nut (rim nut) torque can cause
wheel shimmy, resulting in wheel damage, stud
breakage, and extreme tire tread wear. Excessive
wheel nut torque can break studs and clamps (if
so equipped), damage threads, and crack discs in
the stud hole area. Use the recommended torque
values, and follow the tightening sequence shown
in Fig. 1.
After an 8- or 10-stud wheel has been installed, the
wheel or rim nut torque must be rechecked after 50
to 100 miles (80 to 161 km) of operation.
See Table 1 for wheel nut torque specifications, and
see Fig. 1 for the wheel nut tightening sequence.
When checking wheel nuts on a dual disc assembly,
remove one outer nut at a time, tighten the inner nut,
then reinstall the outer nut. Repeat this procedure for
all wheel nuts, using the tightening sequence shown
in Fig 1.
After a 12-stud wheel rim has been installed, the
wheel or rim nut torque must be rechecked as fol-
lows:
• after the first load;
• every four hours of operation for a minimum of
five days;
• every 8 to 10 hours of operation.
When checking wheel or rim nut torque on 12-stud
wheel rims, use the tightening sequence shown in
Fig. 1 for each of the three stages of tightening as
follows:
1. Tighten each nut 50 lbf·ft (68 N·m).

40 Wheels and Tires
1 1 1
1 2 10 8
3 6
7 4 3 6 3 4
5 4
5 6
5 4
7 9 5 2
3 8 2
2
A 1 B 1 C D
8 5 8 5
10 11 10 11
10 1 8
3 6
4 3 4 3
5 4
7 2 9
6 9 6 9
12 7 12 7
2 2
E F
03/16/2012 f400057
A. 8-Stud Disc Wheel C. 6-Spoke Wheel E. 12-Stud Wheel Rim
B. 10-Stud Disc Wheel D. 5-Spoke Wheel F. 12-Stud Wheel Rim Adaptor
Fig. 1, Wheel Nut and Rim Nut Tightening Sequence
Wheel Fastener Torque

Application Nut Size Wheel Manufacturer Torque (dry threads): lbf·ft (N·m)
8-Stud Disc Wheel With Two-Piece Flanged Locknuts
Front and Rear Wheel Nut — All 450–500 (610–680)*
10-Stud Disc Wheel With Two-Piece Flanged Nuts
Front and Rear Wheel Nut M22 x 1.5 All 450–500 (610–680)*
10-Stud Disc Wheel With Inner and Outer Locknuts
Alcoa 400–500 (540–680)
Front Wheel Nut 1-1/8–16
All Others 450–500 (610–680)
Alcoa 400–500 (540–680)
Rear Wheel Inner Nut 3/4–16
All Others 450–500 (610–680)
Alcoa 400–500 (540–680)
Rear Wheel Outer Nut 1-1/8–16
All Others 450–500 (610–680)
Wheel Stud Retainer Nut 3/4–16 All 175–200 (235–270)
12-Stud Wheel Rim Clamp and Nuts
Adaptor Wheel Nut on Inside Bolt
M22 x 1.5 OTR 450–500 (610–680)
Circle
50 (68)†
Adaptor Wheel Nut on Outside Bolt
3/4–10 OTR 100 (136)
Circle
150 (203)

Wheels and Tires 40
Wheel Fastener Torque

Application Nut Size Wheel Manufacturer Torque (dry threads): lbf·ft (N·m)
50 (68)†
Rear Wheel Nut 3/4–10 OTR 100 (136)
150 (203)
Spoke Wheel Rim Nuts
Front Wheel Nut, 5- and 6-Spoke 3/4–10 Gunite 200–225 (271–305)‡
Rear Wheel Nut, 5- and 6-Spoke With
3/4–10 Gunite 200–225 (271–305)
Non-Corrugated Channel Spacer
Rear Wheel Nut, 5- and 6-Spoke With
3/4–10 Gunite 240–260 (325–350)
Corrugated Channel Spacer
* Torque values given for these fasteners are for lubricated threads.
† Use the tightening sequence shown in Fig. 1 for each of the three stages of tightening.
‡ On front axles with over 12,000 lb (5448 kg) capacity, tighten the wheel nuts 240 to 265 lbf·ft (325 to 359 N·m). Gunite part number W–854 nut with a
phosphate-and-oil coating must be used.
Table 1, Wheel Fastener Torque
For additional information on 12-stud wheel rims, see

Section 40.00, Subject 220 of the Western Star
Workshop Manual.
40–02 Tire Check

Tires should be inspected closely during the first
3000 to 10,000 miles (5000 to 16 000 km) for abnor-
mal wear.
Maintain the proper pressures for carried loads, per
the tire manufacturers’ recommendations, or the tire
pressure label on the driver’s door.
Have the wheel alignment checked after the first
10,000 miles (16 000 km), then every 40,000 miles
(60 000 km) thereafter.
Do not continue to drive the vehicle if tires develop
any of the following:
• blisters;
• cuts or punctures that reach to the cord;
• a nail, screw, rock, or other puncturing object;
• flat spots or irregular wear;
• tread worn to a minimum depth;
• inability to maintain proper tire pressure.

Driveline 41
Index, Alphabetical

Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01
Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02

Driveline 41
bly replaced.
1
DANGER
2
R I T OR
the vehicle cannot drop. Failure to follow these ME
death.
41–01 Driveline Inspection 1 1
1. Park the vehicle on a flat, level surface, apply 10/06/2016 f410155a

the parking brakes, and chock the tires. 1. Self-Locking Capscrew
2. Adhesive Band
CAUTION Fig. 1, Meritor U-Joint Fasteners for Bearing Caps
Due to the extreme load occurring at high-speed
rotation, a loose or broken capscrew at any point
in the driveline will weaken the driveline connec-
tion, which could eventually result in serious ve-
hicle damage. Do not over-tighten bearing-cap
capscrews or yoke-strap capscrews.
2. For driveline universal joints with bearing caps,
tighten bearing-cap capscrews 43 lbf·ft (49 N·m).
See Fig. 1, item 1.
For RPL series universal joints, tighten bearing-
cap capscrews 125 lbf·ft (169 N·m). See Fig. 2.
For driveline universal joints with yoke straps, 10/06/2016 f410182
tighten yoke-strap capscrews 125 lbf·ft (169
N·m). See Fig. 3. Fig. 2, Meritor RPL Series U-Joint
3. Check the driveline yokes for cracks, and check 5. Check if the midship bearing and mounting are
end-yokes for looseness. See Fig. 3. loose or have deteriorated, by attempting to
Have any cracked yokes replaced by an autho- move the driveshaft up and down, and from side
rized Western Star dealer. to side. If the bearing is loose on its shaft, or
rattles, have it replaced. If the bearing mount is
If any end-yoke can be moved in or out on its loose on the frame, have your Western Star
shaft, or can be rocked on its shaft, take it to an dealer tighten the mounting fasteners to the
authorized Western Star dealer for service. proper torque value. Have the midship bearing
4. Check U-joint assemblies for wear by moving the assembly replaced if the rubber cushion is dete-
driveshaft up and down, and from side to side. If riorated or oil-soaked.
any movement of the U-joint cross in the bear- 6. Check slip joints for spline wear by moving the
ings can be felt or seen, have the U-joint assem- sleeve-yoke and splined shaft back and forth.

41 Driveline
15
14
13
16
3
8 9
7 12
11
1
2
10
6
5
4
10/06/2016 f410067b
NOTE: Not all fasteners are shown.
1. Transmission 6. U-Joint Cross 12. Splined Stub Shaft
2. Transmission Output-Shaft 7. Bearing Cup (for yoke strap) 13. Driveshaft Tube
End-Yoke (yoke-strap type) 8. Yoke Strap and Capscrew 14. Tube-Yoke (bearing-cap type)
3. U-Joint Assembly 9. Slip-Joint Assembly 15. Axle Input-Shaft End-Yoke
4. Bearing Cap Self-Locking 10. Sleeve-Yoke (bearing-cap type) (yoke-strap type)
Capscrew 11. Dust Cap 16. Rear Axle
5. Bearing Cap
Fig. 3, Components of a Basic Driveline
See Fig. 4. If the slip joint can be twisted in a any evidence that balance weights are missing,
clockwise or counterclockwise movement greater have the driveshaft removed and balanced.
than 0.007 inch (0.18 mm), have both the 9. For driveshafts with slip joints, check to be sure
sleeve-yoke and the splined shaft replaced.
the yoke plug is not loose or missing. See Fig. 5,
7. Visually examine the driveshaft tubes for dents, item 2. Have your Western Star dealer repair or
bends, twists, or other damage. If any tube ap- replace the yoke plug as needed. If the yoke
pears to be damaged, have it repaired or re- plug is missing, the splined shaft may be hitting
placed by an authorized Western Star dealer. the plug and knocking it out; have your Western
Star dealer determine the correct driveshaft
8. Examine the driveshaft for evidence of missing
length.
balance weights, and for build-up of foreign ma-
terial. Remove any foreign material. If there is

Driveline 41
1
3
4
7
2 3
6
10/06/2016 f410012a
Attempt to move the sleeve-yoke and splined shaft back
and forth. 8
Fig. 4, Slip Joint Spline Wear Checking 3 1
41–02 Driveline Lubrication A
Universal Joint Lubrication 10/07/2016 f410050a

A. After grease appears, cover the pressure-relief hole
NOTE: Vehicles equipped with Meritor RPL Se- while continuing to lubricate.
ries drivelines do not require periodic lubrication. 1. Slip Joint Grease Fitting (with grease gun attached)
1. Park the vehicle on a flat surface, apply the park- 2. Yoke Plug
ing brakes, and chock the tires. 3. Grease
4. Half-Round Yoke
2. Wipe all old grease and dirt from each U-joint 5. Yoke Plug Pressure-Relief Hole
grease fitting. See Fig. 5, Ref. 8. 6. Slip Joint Seal
7. Full-Round Yoke
3. Use a hand-type grease gun, or a high-pressure 8. U-Joint Grease Fitting
gun with a low-pressure adapter, to lubricate
U-joints. If a low-pressure adapter is not used, Fig. 5, Slip Joint and U-Joint Lubrication
U-joints may not receive enough grease.
5. If grease does not appear at one seal, use a pry-
Using lithium 12-Hydroxy stearate grease (NLGI ing tool to pry the U-joint trunnion away from the
Grade 1 or Grade 2, with EP additives), lubricate non-purging seal, or tap the driveshaft or yoke
until new grease can be seen at all four U-joint with a plastic or rawhide mallet on the side oppo-
seals. Fresh grease must be seen escaping from site the dry seal, while continuing to lubricate. If
all four bearing-cap seals of each U-joint. On grease still does not appear, loosen the cap-
yokes equipped with a yoke-bearing cap, if most screws at the bearing with the dry seal, to relieve
of the grease being added to a U-joint can be seal tension. Lubricate the U-joint until new
seen escaping from just one of the U-joint seals, grease is seen at the seal, then tighten the cap-
check the torque on the capscrews at that seal. screws to the correct torque specifications. If the
4. Tighten the bearing-cap capscrews 43 lbf·ft (49 bearing will not take grease, have the U-joint re-
N·m). If the capscrews were already tight, or all placed.
of the U-joint seals still do not purge, remove the 6. Check the purged grease. If it appears rusty,
bearing cap at that seal, and examine the seal gritty, or burned, have the U-joint replaced.
for damage. If the seal is damaged, replace the
complete U-joint. 7. Wipe the purged grease from the seals, and any
excess grease from the grease fitting.

41 Driveline
Slip Joint Spline Lubrication

NOTE: Vehicles equipped with Meritor RPL Se-
ries drivelines do not require periodic lubrication.
1. If equipped with a grease fitting, wipe all old
grease and dirt from the slip joint grease fitting.
See Fig. 5, Ref. 1.
2. Use a hand-type grease gun or a high-pressure
gun with a low-pressure adapter, to lubricate the
slip joint. Add multipurpose chassis grease
(lithium 12-hydroxy stearate, NLGI Grade 1 or
Grade 2, with EP additives) until it appears at the
pressure-relief hole in the yoke plug. Then cover
the relief hole with your finger, while continuing
to apply gun pressure until new grease appears
at the slip joint seal. See Fig. 5. This ensures
complete lubrication of the splines.
3. Wipe the purged grease from the pressure-relief
hole and slip joint seal, and any excess grease
from the grease fitting.

Brakes 42
Index, Alphabetical

Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01
Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03
Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02
Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04
Bendix Automatic Drain Valve Operating and Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09
Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–07
Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05
Slack Adjuster Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06
Versajust Slack Adjuster Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–08

Brakes 42
42–00 Safety Precautions 5. Place your hand under the air dryer purge valve,
located at the base of the dryer; see Fig. 1. You
should feel a light air flow that will continue until
the air compressor unloads.
DANGER
death.
42–01 Air Brake System Valve

Inspection
NOTE: There is no scheduled air valve mainte-
nance on vehicles equipped with Bendix air
valves and a Bendix air dryer if the air dryer
desiccant is replaced at 350,000 miles (563 000
km). If the desiccant is not changed at 350,000 07/10/2001 f422259
miles (563 000 km), or if the vehicle is equipped
with another air dryer, maintenance will have to Fig. 1, Air Dryer Inspection
be performed on the air brake valves.
6. On the System Saver Twin only, if the compres-
IMPORTANT: For vehicles equipped with an oil- sor continues to run, after 50 to 60 seconds you
coalescing air dryer desiccant cartridge, replace will feel a "mini-purge", or exhaust of air, as the
the cartridge once a year, regardless of mileage. dryer switches cartridges. This is normal and will
recur every 50 to 60 seconds as long as the
compressor is running.
42–02 Air Dryer Inspection 7. When the air system reaches "cut-out" pressure,
the dryer will purge completely. After this, the
1. Park the vehicle on a level surface and apply the
dryer will not exhaust any air until the compres-
parking brakes. Shut down the engine. Chock
sor starts up again.
the tires.
8. Shut off the engine and apply a soap solution to
2. Completely drain all air reservoirs. Air pressure
each connection that contains pressurized air.
gauges should read 0 psi (0 kPa).
If soap bubbles do not appear, connections are
3. Close the drain cocks on all reservoirs.
sealed properly.
4. Start the vehicle and allow the air system pres-
If soap bubbles appear, drain all reservoirs and
sure to build while the engine idles.
remove the leaking connection. Inspect it for
Note: Some compressors may need to run damaged threads or cracks, and replace as nec-
above idle to build system air pressure in a rea- essary. Apply pipe sealant or teflon tape to the
sonable time. If air pressure build-up is ex- connection before re-installing it. Repeat the pro-
tremely slow after two to three minutes, raise cess until all connections are properly sealed.
the engine speed to 1000 to 2000 rpm.

42 Brakes
42–03 Air Dryer Desiccant NOTE: A substantial torque, up to 50 lbf·ft (68

N·m), may be necessary to remove the desic-
Replacement cant cartridge.
IMPORTANT: For vehicles equipped with an oil- 11. Inspect the condition of the O-ring seals. If they
coalescing air dryer desiccant cartridge, replace are cracked, crimped, or otherwise damaged,
replace them to ensure an airtight seal. Clean
the cartridge once a year, regardless of mileage.
the O-ring grooves of any dirt or obstruction.
Bendix AD-9 Air Dryers NOTICE
the engine, and set the parking brake. Chock the Dirt or obstructions in the O-ring grooves can
tires. cause an O-ring failure that will result in an air
leak.
2. Completely drain all air reservoirs. Air pressure
gauges should read 0 psi (0 kPa). 12. Lubricate the O-rings with silicone or lithium
grease, and install them in the end cover.
IMPORTANT: The compressor discharge line
may still contain residual air pressure. 13. Install the desiccant cartridge on the end cover.
Turn the cartridge clockwise until the desiccant
3. Identify, tag, and disconnect the three air lines cartridge makes contact with the end cover.
from the end cover.
14. Place the desiccant cartridge in a vise, and turn
4. Disconnect the harness connector from the the end cover clockwise an additional 180 to 225
heater and thermostat assembly. degrees to fully tighten the desiccant cartridge to
5. Loosen the capscrew that secures the upper the end cover.
mounting bracket strap. NOTE: Desiccant cartridge torque should not
6. Remove the two capscrews that secure the air exceed 50 lbf·ft (68 N·m).
dryer to the lower mounting bracket. Mark the 15. Place the housing over the desiccant cartridge
position of the mounting bracket to the end cover and align the mounting holes with the end cover.
and mark the capscrews to ease installation.
IMPORTANT: Replace, do not reuse the Nylok
7. Remove the upper mounting bracket strap cap-
screw, and remove the air dryer from the vehicle.
nuts on the air dryer cover.
8. Place the air dryer on a bench and remove the 16. Install the 6 capscrews, 12 washers, and 6 new
remaining 6 capscrews, 12 washers, 6 Nylok® Nylok nuts. Torque the capscrews in a star pat-
nuts, and the air dryer housing; see Fig. 2. Dis- tern 270 to 385 lbf·in (3050 to 4350 N·cm); see
card the Nylok nuts. Remove the end-cover-to- Fig. 3.
housing O-ring. 17. Install the air dryer on the lower mounting
9. Clamp the desiccant cartridge in a vise. bracket. Install the two previously marked cap-
screws, four washers, and two new Nylok nuts.
Torque the two remaining capscrews 270 to 385
WARNING lbf·in (3050 to 4350 N·cm). Install the capscrew,
two washers, and a new Nylok nut in the upper
Clamping the end cover or housing in a vise could mounting bracket strap. Torque the upper mount-
seriously compromise the air dryer’s ability to ing bracket strap capscrew 80 to 120 lbf·in (904
hold air pressure, which could cause a failure in to 1356 N·cm).
the brake system, resulting in property damage,
personal injury, or death. 18. Connect and tighten the three air lines. Connect
the harness connector to the heater and thermo-
10. Twist the end cover counterclockwise to release stat assembly until the lock tab snaps in place.
the cartridge from the end cover. Rotate the end
cover until it completely separates from the des- 19. Start the engine, build air pressure, and check
iccant cartridge. the air brake system for leaks.

Brakes 42
2
11
3 9
4 25
5 12 10 8
14 10
24
10
10 10
8 10
6
23
13
10 15 22
7
8 21
20
18 19
17
16
08/09/95 f421383
1. 5/16" x 4-1/2" Upper Mounting 9. Desiccant Cartridge 18. Purge Valve
Bracket Capscrew 10. O-Ring 19. 1/4" Tapping Screw
2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing
3. 5/16" i.d. Lockwasher 12. Lower Mounting Bracket 21. Heater and Thermostat
4. 5/16" Nylok Nut 13. 3/8" Capscrew (long) Housing
5. Upper Mounting Bracket 14. Check Valve Assembly 22. Return Spring
6. Housing 15. Purge Valve Assembly 23. Purge Piston
7. Nylok Nut 16. Purge Valve Bolt 24. 3/8" Capscrew
8. 3/8" i.d. Special Washer 17. Exhaust Diaphragm 25. End Cover
Fig. 2, AD-9 Air Dryer (exploded view)
Bendix AD–IP Air Dryers WARNING

the engine, and set the parking brake. Chock the Do not attempt to disassemble the desiccant car-
tires. tridge assembly. Parts for the assembly are not
available and the cartridge contains a 150 lb
2. Using a wrench or a socket, loosen the desiccant spring that cannot be mechanically caged. Disas-
cartridge bolt. Then separate the desiccant car- sembly could release the spring, resulting in per-
tridge from the end cover. sonal injury.
3. Pull the cartridge bolt out of the cover and re-
move the cartridge.

42 Brakes
properly aligned and allow the cartridge to rest

6 2
flush against the end cover.
11. Using a wrench or socket, tighten the desiccant
cartridge bolt 70 lbf·ft (95 N·m). Do not over-
tighten.
4 5
12. Before placing the vehicle in service, perform the
test below.
12.1 Close all reservoir drain cocks.
12.2 Build system pressure to governor cut-
out, and note that the AD-IP air dryer
1&9 3 purges with an audible escape of air.
12.3 Fan the service brakes to reduce system
air pressure to governor cut-in. Note that
the system once again builds to full pres-
7 8 sure and is followed by a purge at the
AD-IP air dryer exhaust.
09/20/94 f420544a
12.4 Check for excessive leakage around the
head of the desiccant cartridge where it
Fig. 3, End Cover to Housing Torque Pattern
contacts the end cover. With the com-
4. Remove and discard both O-rings from the car- pressor in loaded mode (compressing
tridge bolt. air), apply a soapy solution to these
areas, and observe that any leakage
5. Using a clean rag, wipe clean the inside of the does not exceed a 1-inch bubble in 1
end cover. Clean the cartridge bolt bore in the second. If leakage exceeds this measure,
end cover, and the sealing surfaces for the large- remove and re-install the desiccant
and small-diameter desiccant cartridge sealing cartridge.
rings.
6. Inspect the end cover for physical damage, then Bendix AD-9si, AD-IS and CR
inspect all air line fittings for corrosion; replace
as necessary. Turbo 2000 Air Dryers
7. Clean and inspect the bolt, paying attention to 1. Park the vehicle on a level surface, shut down
the threads and O-ring grooves. the engine, and set the parking brake. Chock the
tires.
IMPORTANT: Use only the grease supplied with
Bendix replacement kits. 2. Drain the air reservoirs.
8. Lubricate the O-rings, bolt O-ring grooves, seal- 3. Using a strap wrench or equivalent, loosen the
ing rings, and cartridge grooves. Lubricate the desiccant cartridge. See Fig. 4. Spin the car-
tridge off by hand and discard it.
end cover bore for the bolt.
4. On the new desiccant cartridge, lubricate the
9. Install both O-rings on the cartridge bolt, then,
sealing rings with silicone grease.
using a twisting motion, insert the assembled
desiccant cartridge bolt in the end cover. IMPORTANT: Only use the silicone grease sup-
10. Install the desiccant cartridge on the end cover, plied with Bendix replacement kits.
making sure the cartridge is properly seated and 5. Screw the desiccant cartridge onto the body by
flush on the end cover. hand until the seal makes contact with the body.
NOTE: It may be necessary to rotate the car- Rotate the cartridge clockwise about one full
tridge slightly until the anti-rotation lugs are turn. Tighten the cartridge firmly.

Brakes 42
1 2
3
2
3 1
10/07/2016 f421910
1. Desiccant Cartridge
2. Cartridge Sealing Ring
3. Threaded Base Post
10/07/2016 f421292
Fig. 4, Desiccant Cartridge Replacement 1. Seal 3. Air Dryer Base
2. O-Ring
WABCO System Saver 1200, Fig. 5, Desiccant Cartridge Replacement, WABCO Air
1200 Plus, and Twin Air Dryers Dryers
IMPORTANT: If the air dryer base is damaged,

NOTICE preventing a tight seal, replace the air dryer.
The WABCO System Saver air dryers can use ei- 5. Using a multipurpose, high-temperature grease
ther a standard or oil coalescing desiccant car- that resists water, steam, and alkali, lightly coat
tridge. When replacing the desiccant cartridge, it the surfaces of the new O-ring and the dryer
is very important to use the same type of car- base. Install the O-ring.
tridge that was originally installed on the dryer. Oil 6. Thread the desiccant cartridge onto the dryer
coalescing cartridges can be used in any applica- base (turn clockwise). When the seal contacts
tion, but require more frequent service intervals the base, tighten the cartridge one complete turn
(every 1 to 2 years instead of every 2 to 3 years more. Do not overtighten.
for a standard cartridge). Do not replace an oil co-
alescing cartridge with a standard cartridge, as
this may result in contamination and malfunction- 42–04 Alcohol Evaporator
ing of downstream air system components.
Cleaning and Inspection
Refer to Fig. 5 for cartridge replacement.
1. Drain the air system. Midland
2. Using a strap wrench, turn the desiccant car- Maintenance is required during both the freeze sea-
tridge counterclockwise and remove it. son and the off season to keep the alcohol evapora-
3. Remove and discard the O-ring. tor in good working order.
4. Clean the top surface of the dryer base with a Off Season
commercial cleaning solvent.
During the off season, drain the unit of alcohol. At
regular engine service intervals, open the drain cock

42 Brakes
to remove moisture from the alcohol evaporator. Be- For camshaft brackets with grease fittings, use an
fore reactivating the evaporator for the next freeze NLGI Grade 1 or Grade 2 multipurpose chassis
season, drain, disassemble, inspect, and steam- grease.
clean the unit of any sludge that may have accumu- Lubricate the camshaft bushings through the grease
lated. It is advisable to replace any rubber parts
fitting on the camshaft bracket or the spider until new
when assembling the alcohol evaporator. Perform grease flows from the inboard seal. See Fig. 6.
this service just before the freeze season.
Freeze Season Reactivation

1. Park the vehicle on a level surface and apply the
parking brakes. Shut down the engine. Chock 1
the tires.
2. Remove the filler cap, and check the cap tet-
raseal. 3
3. Remove the capscrews and reservoir from the
cover.
4. Remove the cover tetraseal. 2
5. Drain the air tank, and disconnect the line from

the evaporator outlet. Remove the check-valve A
retainer, spring, and disc. 10/07/2016 f420011a
6. Install the disc, spring, and check-valve retainer, A. Grease Exit
and connect the line to the evaporator outlet. 1. Brake Chamber 3. Non-Pressure-Relief
7. Install the cover tetraseal. 2. Slack Adjuster Grease Fitting
8. Install the reservoir on the cover and tighten the Fig. 6, Camshaft Bracket Lubrication
capscrews.
9. Fill the reservoir with 40 ounces (1183 mL) of WARNING
methyl alcohol, then install the filler cap.
If grease leaks out under the camhead, the cam-
10. Remove the chocks from the tires. shaft bracket grease seal is worn or damaged and
should be replaced. If this seal is not replaced, the
42–05 Camshaft Bracket brake linings could become contaminated with
grease. The stopping distance of the vehicle will
Lubrication be increased, which could result in personal injury
or property damage.
IMPORTANT: Perform MOP 42–07 before lubri-
cating the camshaft brackets.
42–06 Slack Adjuster
NOTE: If equipped with a Meritor extended- Lubrication
maintenance Q Plus™ brake system, the cam-
shaft bracket will not have a grease fitting. IMPORTANT: Perform MOP 42–07 before lubri-
These camshafts use a special NLGI Grade cating the slack adjusters.
synthetic polyurea grease, and do not require
lubrication for 3 years or 500,000 miles (800 Slack adjusters that have a grease fitting must be
000 km), whichever comes first. The extended lubricated periodically to ensure proper brake opera-
maintenance camshaft bushings are lubricated tion.
during the brake reline service interval.

Brakes 42
For operating temperatures between –20°F (–29°C)

WARNING and –40°F (–40°C), use Lubriplate Aero grease.
Failure to lubricate slack adjusters could lead to Lubricate a Gunite slack adjuster at the grease fitting
dragging brakes or a brake failure, resulting in until grease appears on the camshaft, or flows from
property damage, personal injury, or death. the grease relief. See Fig. 8.
Dana Spicer and Haldex

CAUTION 4
5
Do not use moly-disulfide-loaded grease or oil.
Both the life and reliability of the slack adjuster 6
will be reduced if this type of grease is used.
Lubricate the slack adjuster at the grease fitting. See 7
Fig. 7. Use standard chassis lubricant for Haldex 3
slack adjusters. Dana Spicer Low Lube slack adjust- 8
ers should be lubricated with SHC 460 synthetic
lubricant.
2 9
1 1
10
10/27/93 f420653a
1. 7/16" Adjusting Nut 6. Clevis
2. Grease Fitting 7. 1/2" Clevis Pin
2 3. Boot 8. 1/4" Clevis Pin
4. Link 9. Grease Relief
5. Brake Chamber Piston Opening
Rod 10. Slack Adjuster Spline
Fig. 8, Gunite Slack Adjuster
The newest Gunite slack adjusters are produced

without a grease relief. During lubrication with a
02/01/2001 f421649a grease gun, the lubricant is forced through the drilled
1. Grease Fitting 2. Slack Adjuster worm wheel onto the camshaft. Lubricate the slack
adjuster at the grease fitting until grease appears on
Fig. 7, Dana Spicer Slack Adjuster the camshaft. See Fig. 8.
Gunite Meritor
For operating temperatures of –20°F (–29°C) and
higher, use Texaco Multifak EP-2 or Mobil Grease
NOTE: If equipped with an extended-
No. 77. maintenance Q Plus™ brake system, the slack
adjuster will not have a grease fitting. These

42 Brakes
slack adjusters use a special NLGI Grade syn- 42–07 Brake Inspection
thetic polyurea grease, and do not require lubri-
cation for 3 years or 500,000 miles (800 000 IMPORTANT: This procedure should be per-
km), whichever comes first. The extended- formed prior to lubrication of the brake compo-
maintenance slack adjusters are lubricated dur- nents.
ing the brake reline service interval.
For slack adjusters with grease fittings and for oper- Parking Brake Operational Check
ating temperatures above –40°F (–40°C), use a
NLGI Grade 1 clay-base grease or a NLGI Grade 1
and 2 lithium-base grease.
CAUTION
For slack adjusters with grease fittings and for oper- Perform the following check in a clear safe area. If
ating temperatures below –40°F (–40°C) and above the parking brakes fail to hold the vehicle, per-
–65°F (–54°C), use a NLGI Grade 2 synthetic oil, sonal injury or property damage may result.
clay-base grease. 1. With the engine running, and air pressure at cut-
Lubricate the slack adjuster at the grease fitting until out pressure, set the parking brake.
grease is forced past the pressure-relief capscrew or 2. Put the vehicle in the lowest gear and gently at-
past the gear splines around the inboard snap ring. tempt to move it forward. The vehicle should not
See Fig. 9. move. If the vehicle moves, the parking brakes
are not operating correctly and must be repaired
before the vehicle is returned to service. See
1
Group 42 of the Western Star Workshop Manual
for repair procedures.
2
Brake Component Inspection
Air Disc Brakes
3
IMPORTANT: The following step to inspect the
4 caliper mounting bolts should only be performed
at the initial maintenance (IM) interval.
5 Vehicles may have both axial and radial
mounted calipers. Follow the instructions based
7 on the type of calipers installed on the vehicle.
6 f420012a Axial Mounted Brakes
10/20/93
1. Brake Chamber
2. Clevis IMPORTANT: The following information applies
3. Actuator Rod to all types of axial mounted brake applications.
4. Boot
5. Pressure-Relief Capscrew, Gasket, Pawl Spring,
and Pawl the engine, and set the parking brake. Chock the
6. Manual Adjusting Nut tires.
7. Grease Fitting (or plug) 2. Raise the vehicle and support it on jack stands.
Fig. 9, Meritor Slack Adjuster 3. Remove all of the wheel assemblies. For instruc-
tions, see Group 40 of the Western Star Work-
shop Manual.
NOTE: In all steps that require a torque wrench,
use a Snap On torque wrench ATECH4RS600,

Brakes 42
or an equivalent, with a center to handle length DSNCHA018005 referenced in tool letter

of 47 inches (119 cm). 18TL18. See Fig. 11. If the tool is needed, see
Table 1 for torque specifications for a 47 in (119
4. Set a torque wrench to 350 lbf·ft (475 N·m) and cm) long wrench.
tighten the caliper mounting bolts following the
tightening pattern shown in Fig. 10. If they do 5. Install the wheel assemblies. For instructions,
not turn, no further work is needed. If they turn, see Group 40 of the Western Star Workshop
take the vehicle to an authorized Freightliner Manual.
dealer to have all of the caliper bolts on that 6. Remove the jack stands and lower the vehicle.
wheel end replaced. Due to limited caliper bolt
access, it may be necessary to use tool DDC
Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Extension Angle Target Torque Tool Setting
Angle View
(degrees) [lbf·ft (N·m)] [lbf·ft (N·m)]
0°
0 296 (401)
11/28/2016 f422613
45 310 (420)
45°
11/28/2016 f422614
60 320 (434)
60°
11/06/2018 f422668
350 (475)
90 350 (475)
90°
11/28/2016 f422615
120 386 (523)

120°
11/06/2018 f422669
135 402 (545)

135°
11/28/2016 f422616
Table 1, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005

42 Brakes
2. Raise the vehicle and support it on jack stands.

2 1 4 5
3. Remove all of the wheel assemblies. For instruc-
3 6 tions, see Group 40 of the Western Star Work-
shop Manual.
03/26/2020 f422665
4. Set a torque wrench to 350 lbf·ft (475 N·m) and
tighten the caliper mounting bolts following the
Fig. 10, Axial Bolt Tightening Pattern
tightening pattern shown in Fig. 13. If they do
not turn, no further work is needed. If they turn,
take the vehicle to an authorized Freightliner
dealer to have all of the caliper bolts on that
wheel end replaced.
5. Install the wheel assemblies. For instructions,
see Group 40 of the Western Star Workshop
Manual.
6. Remove the jack stands and lower the vehicle.
WABCO Maxxus Calipers

09/28/2018 f580518
Fig. 11, DDC DSNCHA018005 30mm Air Disc Brake the engine, and set the parking brake. Chock the
Caliper Brake Bolt Torque Adaptor tires.
2. Raise the vehicle and support it on jack stands.
Radial Mounted Brakes
3. Remove all of the wheel assemblies. For instruc-
Bendix Calipers tions, see Group 40 of the Western Star Work-
shop Manual.
the engine, and set the parking brake. Chock the 4. Set a torque wrench to 273 lbf·ft (370 N·m) and
tires. tighten the caliper mounting bolts following the
tightening pattern shown in Fig. 14. If they do
2. Raise the vehicle and support it on jack stands. not turn, no further work is needed. If they turn,
3. Remove all of the wheel assemblies. For instruc- take the vehicle to an authorized Freightliner
tions, see Group 40 of the Western Star Work- dealer to have all of the caliper bolts on that
shop Manual. wheel end replaced.
4. Set a torque wrench to 200 lbf·ft (271 N·m) and 5. Install the wheel assemblies. For instructions,
tighten the caliper mounting bolts following the see Group 40 of the Western Star Workshop
tightening pattern shown in Fig. 12. If they do Manual.
not turn, no further work is needed. If they turn, 6. Remove the jack stands and lower the vehicle.
take the vehicle to an authorized Freightliner
dealer to have all of the caliper bolts on that Drum Brakes
wheel end replaced.
5. Install the wheel assemblies. For instructions, the engine, and set the parking brake. Chock the
see Group 40 of the Western Star Workshop tires. Once the tires are chocked, release the
Manual. parking brake.
6. Remove the jack stands and lower the vehicle.
WARNING
Meritor Calipers
1. Park the vehicle on a level surface, shut down Manually adjusting an automatic slack adjuster to
the engine, and set the parking brake. Chock the bring the pushrod stroke within legal limits is
tires. likely masking a mechanical problem. Adjustment

Brakes 42
D D
C C
B
A
5 6 4 4 6 5
1 2 3 3 2 1
10/31/2018 f422663a
A. Right-hand brake (viewed from below). C. Sheer sleeve above in this location.
B. Left-hand brake (viewed from below). D. Shelf above in this location.
Fig. 12, Bendix Radial Mounted Caliper Tightening Pattern (viewed from below)
is not repairing. Before adjusting an automatic for improper operation or adjustment of the auto-
slack adjuster, troubleshoot the foundation brake matic slack adjuster. See Group 42 of the West-
system and inspect it for worn or damaged com- ern Star Workshop Manual for inspection,
ponents. Improperly maintaining the vehicle brak- troubleshooting, and repair procedures.
ing system may lead to brake failure, resulting in 5. Check all of the foundation brake components for
property damage, personal injury, or death. damage, wear, and loose or missing parts. Re-
2. With the engine off, and 100 psi (690 kPa) of air pair as needed. See Group 42 of the Western
tank pressure, have an assistant apply and hold Star Workshop Manual for inspection, trouble-
an 80 to 90 psi (552 to 621 kPa) brake applica- shooting, and repair procedures.
tion.
3. Check to see if the colored over-stroke band on
each brake chamber pushrod is exposed.
If a band shows, the stroke is too long. Check
the foundation brake components for wear or
damage, and repair as needed. See Group 42 of
the Western Star Workshop Manual for inspec-
tion, troubleshooting, and repair procedures.
4. Measure the applied chamber stroke. See
Table 2 for the proper stroke for the type of
chamber being used. If the stroke is too short,
the brakes may drag or will not fully apply. Check

42 Brakes
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. 13, Meritor Radial Mounted Caliper Tightening Pattern

Brakes 42
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. 14, Wabco Maxxus Radial Mounted Caliper Tightening Pattern

42 Brakes
Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
9
1-3/8 (35)
12
16
Standard Stroke 20 1-3/4 (45)
24
30 2 (51)
Gunite
36‡ 2-1/4 (57)
16
20 2 (51)
Long Stroke 24
24
2-1/2 (64)
30
12 1-3/8 (35)
16
Standard Stroke
20 1-3/4 (44)
24
Haldex
2-1/2-Inch Extended Stroke 24 2 (51)
3-Inch Extended Stroke 24 2-1/2 (64)
Standard Stroke 30 2 (51)
Long Stroke 30 2-1/2 (64)
9
Less than 1-1/2 (38)
12
Standard Stroke 16
Less than 1-3/4 (44)
Meritor 20
24 Less than 1-7/8 (48)
Long Stroke 24
Less than 2 (51)
Standard Stroke 30
* Long stroke design is indicated by a tag, or embossing, on the brake chamber.
† Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.
‡ If type 36 chamber is used, slack length should be less than 6 inches.
Table 2, Brake Chamber Stroke Specifications

Brakes 42
42–08 Versajust Slack Adjuster Actuator Stroke–Standard Stroke
Inspection and Brake Actuator Size

Recommended Maximum
Operating Stroke (Inches)
Lubrication 20 1-3/4
IMPORTANT: Perform the Brake Inspection 16 1-3/4

maintenance operation before lubricating the 12 1-3/8
slack adjusters. Table 3, Actuator Stroke–Standard Stroke
1. Visually check for physical damage, such as bro-
ken air lines and broken or missing parts. Actuator Stroke–Long Stroke
2. Using a quality multipurpose chassis lubricant, Recommended Maximum
NLGI Grade 2, lubricate the slack adjuster Brake Actuator Size
through the grease fitting until clean lubricant
flows from the grease relief opening in the boot. 30 Long Stroke 2-1/2
24 Long 2
3. Perform the "In Service Inspection."
24 Long Stroke 2-1/2
In Service Inspection 20 Long 2
1. Apply and release the brakes several times while 16 Long 2
observing the slack adjuster. The slack adjuster Table 4, Actuator Stroke–Long Stroke
and brake actuator should move freely, without
binding or interference, and should return to the
full released position. Observe the looseness that 42–09 Bendix Automatic Drain
exists between the clevis and adapter bushing
and the yoke and link pins and their mating parts Valve Operating and
(clevis, body, link). Replace these parts if loose- Leakage Tests
ness appears excessive. Make certain the brake
actuator pushrod jam nut is tightened securely.
2. Inspect the slack adjuster for physical damage,
Operating Test
paying attention to the link, boot, and clevis. If With the system charged, apply the brakes several
any components are damaged, repair or replace times. Each time the brakes are applied, an exhaust
them as necessary. of air should occur from the exhaust port of the drain
valve. If no air comes out, push the wire stem lo-
3. Measure the brake actuator pushrod stroke while
cated inside the exhaust port. If no air comes out
making an 80 to 90 psi (552 to 621 kPa) brake
after pushing the wire stem, there may be a plugged
application. Actuator pushrod strokes should not
filter in the adapter which should be replaced.
exceed the values shown in Table 3 and
Table 4. To achieve the correct pressure for this If the drain valve does not function properly, repair or
test, build the system pressure up to a 100 psi replace it. See Section 42.12 of the Western Star
(690 kPa). Shut down the engine. Fan the Workshop Manual.
brakes to attain a 90 to 95 psi (621 to 655 kPa)
reading. Make and hold a full brake application Leakage Test
while the strokes are checked.
With the system charged and pressure stabilized in
Actuator Stroke–Standard Stroke the system, there should be no leaks at the drain
valve exhaust port. A constant slight exhaust of air at
Recommended Maximum the drain valve exhaust port could be caused by ex-
Brake Actuator Size
cessive leakage in the air brake system.
30 2
24 1-3/4

42 Brakes
If the drain valve is leaking excessively, repair or re-

place it. See Section 42.12 of the Western Star
Workshop Manual.

Steering 46
Index, Alphabetical

Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01
Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02
Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03
Power Steering Gear Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05
Steering Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04

Steering 46

DANGER
When working on the vehicle, shut down the en- 1 2
gine or motor, set the parking brake, and chock 10/07/2016 f461072
the tires. Before working under the vehicle, always 1. Grease Fitting at Pitman Arm
place jack stands under the frame rails to ensure 2. Grease Fitting at Axle Steering Arm
steps could result in serious personal injury or Fig. 1, Drag Link
death.
the socket. Use multipurpose chassis grease
46–01 Drag Link Inspection grease) or NLGI Grade 1 (6% 12-hydroxy lithium
stearate grease); Grade 2 is preferred.
WARNING
46–03 Power Steering Fluid
All steering system components are critical for
safe operation of the vehicle. Failure to maintain
and Filter Changing
the steering system as specified may result in
loss of steering control, which could lead to per- WARNING
sonal injury and property damage.
Have someone turn the steering wheel from left to Fill only with approved clean fluid. Failure to use
right. Check for movement between the ball stud end the proper fluid could cause seal deterioration and
at both the pitman arm and the steering arm. Also leaks. Fluid leaks could eventually cause loss of
check if the ball stud nut is loose. power steering assist. This could lead to an acci-
dent resulting in personal injury or property dam-
If the ball stud end is loose, replace the drag link. If age. Wear eye protection when changing the fluid
the ball stud nut is loose, replace the nut and cotter and filter.
key. See Group 00 for proper torque specifications.
Inspect the boot of the drag link at both the pitman Cylindrical Reservoir, Bottom
arm and the steering arm end for cracks, splits, or Return Port (Fig. 2)
other damage. Replace the boot as needed.
Grasp the drag link near the pitman arm end, then 1. Set the parking brake and chock the rear tires.
push and pull laterally to check for axial movement in 2. Raise the front of the vehicle and support it with
the ball stud end. If it is loose, replace the drag link. jack stands.
If there is 1/8-inch (3-mm) movement or more, do not
3. Put the vehicle in neutral.
drive the vehicle until the drag link has been re-
placed. 4. Open the hood.
5. Wipe down the area around the steering gear
46–02 Drag Link Lubrication and related hydraulic lines.
6. Place a drain pan under the steering gear and
1. Using a clean rag, wipe all dirt from both drag power steering reservoir.
link grease fittings. See Fig. 1.
7. Remove the pressure line and return hose (see
2. Using a pressure gun, apply clean grease at the Fig. 3) from the steering gear and allow the oil to
grease fittings until old grease is forced out of drain.

46 Steering
9. Remove the filter. It may be necessary to wiggle

the filter to remove it from its base.
10. Turn the steering wheel from full left to full right
three times to purge oil from the gear.
11. Connect the pressure line and return hose to the
steering gear.
12. Install a new filter into the reservoir. Position the
new filter with the larger opening up.
13. Clean the reservoir cover and gasket. Inspect the
O-ring and the cover for cracks, deformities, or
damage. Replace the gasket seal or cover as
1 needed.
14. Install the reservoir cover along with the spring
and the top plate. Make sure the center of the
top plate fits into the opening at the top of the
2 filter.
15. Place the clamp over the flanges of the cover
and shell assembly, then tighten 25 to 30 lbf·ft
(35 to 40 N·m).
16. Fill the reservoir with an approved power steer-
02/10/2015 f462251
ing fluid. See Table 1 for approved power steer-
1. Pressure Line ing fluids.
2. Return Hose
Fig. 2, Power Steering Reservoir, Side View Approved Power Steering Fluids
Fluid Type Approved Fluid
Dexron® III
Automatic Transmission Fluid Super ATF
TES-389
Table 1, Approved Power Steering Fluids
1
17. With the engine off, turn the steering wheel from
full left to full right three times. Add more power
steering fluid as needed.
18. Start the engine and operate the engine at idle.
Check the power steering fluid and add more
2
fluid if needed.
02/10/2015 f462251a
1. Pressure Line
2. Return Hose several times. Add fluid to the reservoir as
needed to maintain the fluid level.
Fig. 3, Power Steering Reservoir, Top View
20. Shut down the engine.
8. Loosen the clamp, and remove the cover along 21. Raise the vehicle, remove the jack stands, and
with the filter spring and the filter top plate. lower the vehicle.
Do not use pliers to aid in removal of the filter;
pliers could cause metal chips to enter the Flat Reservoir, Top Return Port
steering system. 1. Set the parking brake and chock the rear tires.

Steering 46
MAX HOT lines. See Fig. 4. See Table 1 for ap-

2 proved power steering fluids.
1
12. Apply a thin film of power steering fluid on the
gasket of the new filter, then attach the filter to
the filter cap and install the cap on the reservoir.
• For filter caps with a separate retaining
ring, hand-tighten the filter, then turn it an
additional 1/4 turn.
3
• For one-piece filter caps, the filter is not
threaded.
13. With the engine off, turn the steering wheel from
4 full left to full right three times. Add more power
steering fluid as needed.
14. Start the engine and operate the engine at idle.
02/17/2017 f462253a
Check that the power steering fluid level is be-
1. Reservoir 3. Pressure Line tween the MIN COLD and MAX HOT lines. Add
2. Filter Cap 4. Return Hose more power steering fluid if needed.
Fig. 4, Power Steering Reservoir 15. Turn the steering wheel from full left to full right
several times. Add fluid to the reservoir as
2. Raise the front of the vehicle and support it with needed to maintain the fluid level between the
jack stands. MIN COLD and MAX HOT lines.
3. Put the vehicle in neutral. 16. Shut down the engine.
4. Open the hood. 17. Raise the vehicle, remove the jack stands, and
5. Wipe down the area around the steering gear lower the vehicle.
and related hydraulic lines.
6. Place a drain pan under the steering gear and 46–04 Steering Shaft
power steering reservoir.
Lubrication
7. Remove the pressure line and return hose (see
Fig. 4) from the steering gear and allow the oil to IMPORTANT: Only steering shafts with zerk fit-
drain. tings should be lubricated. Shafts without zerk
8. Remove the filter cap from the reservoir, then fittings come with grease sealed inside and
remove and discard the filter. should not be greased.
• Filter caps with a separate retaining ring IMPORTANT: Some vehicles may have addi-
have a threaded connection with the filter. tional U-joints on the steering column or stub-
Unscrew the filter and discard it.
shaft. These should also be lubricated at this
• One-piece filter caps do not have a interval.
threaded fit with the filter. Pull off the filter
and discard it. 1. Open the hood and locate the lower steering
shaft U-joint grease fitting.
three times to purge oil from the gear. 2. Using a clean rag, wipe all dirt from the grease
fitting.
10. Connect the pressure line and return hose to the
steering gear. 3. Using a pressure gun, apply clean grease at the
grease fitting until old grease is forced out of the
11. Fill the reservoir with an approved power steer- seals. Use multipurpose chassis grease NLGI
ing fluid to the line between the MIN COLD and Grade 2 (8% 12-hydroxy lithium stearate grease)

46 Steering
or NLGI Grade 1 (6% 12-hydroxy lithium stearate

grease); Grade 2 is preferred. See Fig. 5.
4. Locate the upper steering shaft slip joint and
U-joint grease fittings.
5. Using a clean rag, wipe all dirt from the grease
fittings.
6. Using a pressure gun, apply clean grease at
1
both grease fittings until old grease is forced out
of the seals. Use multipurpose chassis grease
grease) or NLGI Grade 1 (6% 12-hydroxy lithium
stearate grease); Grade 2 is preferred. See 2
Fig. 6.
2 08/16/2001 f461912
1. Slip Joint Grease Fitting

2. U-Joint Grease Fitting
1 Fig. 6, Steering Shaft, Inside the Cab
Using a hand-type grease gun, apply NLGI Grade 2

or 3 multipurpose chassis grease until it starts to
come out past the sector shaft seal.
1
08/16/2001 f461913
1. Steering Gear
2. U-Joint Grease Fitting
3. Steering Shaft
Fig. 5, Steering Shaft, Under-Hood
46–05 Power Steering Gear

Lubrication
TRW TAS Series
CAUTION 10/07/2016 f461071
Apply grease to the sector shaft only with a hand- 1. Sector Shaft Grease Fitting
type grease gun. See Fig. 7. Use of a high-
pressure power grease gun will supply grease too Fig. 7, TRW TAS Series Sector Shaft Lubrication
quickly and could affect the high pressure seal,
contaminating the hydraulic fluid.

Fuel 47
Index, Alphabetical

Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01
Fuel Separator Sight Bowl Cleaning and Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02
Fuel Tank Band Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03
4700 5700 4900 6900 Maintenance Manual, April 2018

Fuel 47
47–00 Safety Precautions WARNING

Safety Precautions in this section apply to all Diesel fuel is flammable and can ignite if exposed
procedures within this group. to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
DANGER vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, pos-
When working on the vehicle, shut down the en- sibly resulting in personal injury or property dam-
gine or motor, set the parking brake, and chock age. When working on a fuel system, have a fire
the tires. Before working under the vehicle, always extinguisher within easy reach.
place jack stands under the frame rails to ensure 5. Disconnect the wiring harnesses from the water-
the vehicle cannot drop. Failure to follow these in-fuel sensor and, if equipped, the heater. See
steps could result in serious personal injury or Fig. 1.
death.
6. Spin off the sight bowl and the filter element as a
unit. Remove the O-ring from the top of the filter
47–01 Fuel Filter Replacement element.
7. Remove the sight bowl from the filter element.
Refer to the engine manufacturer’s service manual
Clean the O-ring seating surface.
for removal and installation procedures.
8. Apply a thin coating of clean diesel fuel or en-
gine oil to the O-rings.
47–02 Fuel Separator Sight 9. Spin the sight bowl onto the new filter element
Bowl Cleaning and and then fill the filter element and sight bowl as-
Element Replacement sembly with clean diesel fuel.
10. Spin the entire assembly onto the mounting head
and tighten by hand until snug.
Alliance/Racor
11. Connect the wiring harnesses for the water-in-
The only maintenance necessary on an Alliance or fuel sensor and, if equipped, the heater.
Racor fuel/water separator is to replace the filter
element. 12. Prime the fuel/water separator, as follows.
1. Park the vehicle on a level surface, shut down If equipped with a primer pump, operate the
the engine, and set the parking brake. Chock the primer pump until fuel comes out at the drain.
tires and open the hood. If not equipped with a primer pump, fill the filter
2. Place a suitable container under the fuel/water element and sight bowl with clean fuel and crank
separator. the engine until it starts.
IMPORTANT: When draining fluid from a 13. Start the engine and check for leaks.
fuel/water separator, drain the fluid into an ap- 14. Shut down the engine and repair any leaks.
propriate container, and dispose of it properly.
Many jurisdictions now issue fines for draining DAVCO Fuel Pro® 382 and 482,
fuel/water separators onto the ground. and Diesel Pro® 243
3. Turn the drain plug counterclockwise to open it.
NOTE: In the event of an emergency, when the
4. When the fuel/water separator is completely filter needs replacement but a DAVCO filter is
drained, turn the drain plug clockwise to close it. not available, a temporary filter can be used;
see Chapter 21 of the Western Star Driver’s
Manual for instructions.
4700 5700 4900 6900 Maintenance Manual, April 2018 47/1

47 Fuel
WARNING
1 Fluid circulated through the fuel/water separator
to heat the fuel may be diesel fuel returned from
the engine, or engine coolant. Drain the fuel/water
2
separator only when the engine and fluids have
cooled. Draining it when the engine is hot could
cause severe personal injury due to scalding.
If returning fuel is released into the atmosphere,
its vapors can ignite in the presence of any igni-
tion source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
heat. To do so could cause fire, possibly resulting
in serious personal injury or property damage.
3 The filter element should be changed only when the
fuel level has reached the top of the filter element.
There is no significant restriction to fuel flow until the
element is completely clogged.
4 tires and open the hood.
2. Check the fuel level in the fuel filter. Replace the
fuel/water separator element only when the filter
element is completely covered. If the fuel level
has reached the top of the filter element, follow
the procedure below to replace the element.
3. Put a clean receptacle under the fuel/water sepa-
3 rator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
5 The drain valve has a 1/2-inch (12.7-mm) pipe;
use a hose with a 1/2-inch pipe thread to fit cor-
rectly.
6 4. Remove the vent cap (Fig. 2, Item 4) and open
9
8 7 the drain valve (Fig. 2, Item 1) to drain the fuel
completely, then close the drain valve.
5. Using a DAVCO Collar Wrench (Fig. 3), remove
01/27/2011 f470566 the clear cover and collar.
1. Primer Pump 7. Wiring Harness, NOTE: Broken vent cap and collar warranty
2. Mounting Head Water-in-Fuel Sensor claims will not be accepted if any tool other than
3. O-Ring 8. Wiring Harness,
a DAVCO Collar Wrench is used for removal.
4. Filter Element Heater
5. Sight Bowl 9. Drain Plug During installation, the vent cap is to be hand-
6. Water-in-Fuel Sensor tightened only, not tightened with a wrench.
Use part number 482017 on Fuel Pro 482 units;
Fig. 1, Fuel/Water Separator Assembly, Alliance/Racor
part number 380134 on Fuel Pro 382 units.
47/2 4700 5700 4900 6900 Maintenance Manual, April 2018

Fuel 47
10. Install the clear cover and the collar. Simultane-

4 ously apply downward pressure to the top of the
clear cover until it is seated on the body of the
lower housing and hand tighten the collar until it
3 no longer spins freely. Using the collar wrench,
tighten the cover 18 lbf·ft (24 N·m). This is
equivalent to rotating the collar clockwise two or
5 three additional ribs, depending on the specific
filter model.
2 11. Prime the system.
11.1 Ensure that the drain valve is closed.
6 11.2 Fill the housing to the top of the filter ele-
ment with clean diesel fuel.
11.3 Install and hand-tighten the vent cap
1 O-ring and vent cap.
05/05/2009 f470506b
11.4 Start the engine. When the lubricating oil
1. Drain Valve 4. Vent Cap
2. Lower Housing 5. Collar reaches its normal operating pressure,
3. Clear Cover 6. Inlet Port/Check Valve increase engine speed to high idle for
one to two minutes to purge air from the
Fig. 2, DAVCO Fuel/Water Separator (Fuel Pro 382 system.
Shown)
11.5 While the engine is running, and after the
air is purged from the system, loosen the
vent cap until the fuel level falls to about
VENT CAP
FOR REMOVAL OF TOP COLLAR ONLY

one inch (2.5 cm) above the collar, then
hand-tighten the vent cap.
11.6 Check for leaks and shut down the
engine.
DAVCO Fuel Pro® 487
02/16/2009 f470277
WARNING
Fluid circulated through the fuel/water separator
Fig. 3, DAVCO Collar Wrench
6. Remove the filter, cover O-ring, and vent cap the engine, or engine coolant. Drain the fuel/water
O-ring. Dispose of them in an environmentally separator only when the engine and fluids have
acceptable manner. See Fig. 4, Fig. 5, or Fig. 6. cooled. Draining it when the engine is hot could
7. Clean all threads and sealing surfaces very thor-
oughly. Even a small amount of dirt will prevent If returning fuel is released into the atmosphere,
the fuel/water separator from sealing, and an air its vapors can ignite in the presence of any igni-
leak may result. tion source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
8. On Fuel Pro 382 units, install the grommet on heat. To do so could cause fire, possibly resulting
the bottom of the new filter. in serious personal injury or property damage.
9. Install the new filter and grommet assembly and 1. Shut down the engine, apply the parking brake,
cover O-ring on the housing. and chock the tires.

47 Fuel
10
11
9
10
8
9
8 7
6
7
5
6
4
12
11
5 3
12
2
4
13
3
14
2
1 13
1 05/05/2009 f470530
12/13/2010 f470531a
1. Inlet Port/Check Valve 8. Vent Cap O-Ring
2. Lower Housing 9. Vent Cap
1. Drain Valve 8. Clear Cover 3. Bypass Valve 10. Lower Housing Collar
2. Bottom Plate 9. Vent Cap O-Ring 4. Filter Element 11. 120VAC Pre-Heater
Assembly 10. Vent Cap 5. Spring 12. 12VDC Pre-Heater
3. Bottom Plate O-Ring 11. Collar 6. Clear Cover O-Ring 13. Drain Valve
4. Lower Housing 12. Grommet 7. Clear Cover
5. Cover O-Ring 13. Inlet Port/Check Valve
6. Filter Element 14. Heat Exchanger Fig. 5, DAVCO Fuel Pro 482
7. Spring
Fig. 4, DAVCO Fuel Pro 382

Fuel 47
2. Check the fuel level in the fuel filter. Replace the

fuel/water separator element only when the filter
6 element is completely covered. If the fuel level
has reached the top of the filter element, follow
the procedure below to replace the element.
5
3. Put a clean receptacle under the fuel/water sepa-
4 rator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
On older models, the drain valve has a 1/2-inch
(12.7-mm) pipe with threads. Use a hose with a
7 1/2-inch pipe thread to fit correctly and open the
drain valve by turning it one-quarter revolution.
On new models, the drain valve has a 3/4-inch
(19-mm) slip-on hose connection; pipe threads
3
are no longer used. Open the drain valve by
8 turning it one to one-and-a-half revolutions.
4. Remove the vent cap, shown in Fig. 7, to drain
the fuel completely, then close the drain valve.
9 5. Using a DAVCO Collar Wrench, shown in Fig. 3,
remove the clear cover and collar.
NOTE: Broken vent cap and collar warranty
claims will not be accepted if any tool other than
10 a DAVCO Collar Wrench (part number 482017)
is used for removal. During installation, the vent
cap is to be hand-tightened only, not tightened
with a wrench.
2 6. Remove the filter, cover O-ring, and vent cap
11 O-ring. Dispose of them in an environmentally
acceptable manner. See Fig. 7.
7. Clean all threads and sealing surfaces very thor-
oughly. Even a small amount of dirt will prevent
the fuel/water separator from sealing, and an air
12 leak may result.
13
1
8. Install the new filter and grommet assembly and
14 cover O-ring on the housing.
Position the filter element so the key is lined up
02/09/2011 f470568
with the keyway on the separator plate of the
housing. Use the arrow on the top of the end-
1. Drain Valve 8. Spring plate to align the filter. See Fig. 8. Ensure the
2. Lower Housing 9. Filter Element filter element is fully seated by firmly pushing on
3. Cover O-Ring 10. Check Valve Assembly the endplate. The filter should not rotate freely.
4. Vent Cap O-Ring 11. Fuel Inlet Port
5. Vent Cap 12. Pre-Heater 9. Install the clear cover and the collar. Simultane-
6. Collar 13. Fuel Outlet Port ously apply downward pressure to the top of the
7. Clear Cover 14. Water-In-Fuel Sensor clear cover until it is seated on the body of the
lower housing and hand tighten the collar until it
Fig. 6, DAVCO Diesel Pro 243
no longer spins freely. Using the collar wrench,
tighten the cover 18 lbf·ft (24 N·m). This is

47 Fuel
1. Arrow (on the 3. Separator Plate

endplate) 4. Key
2. Keyway 5. Endplate
Fig. 8, Positioning the Filter Element
equivalent to rotating the collar clockwise two or

three additional ribs, depending on the specific
filter model.
10. Prime the system
10.1 Ensure that the drain valve is closed.
10.2 Fill the housing to the top of the filter ele-
ment with clean diesel fuel.
10.3 Install and hand-tighten the vent cap
O-ring and vent cap.
10.4 Start the engine. When the lubricating oil
reaches its normal operating pressure,
increase engine speed to high idle for
one to two minutes to purge air from the
system.
10.5 While the engine is running, and after the
air is purged from the system, loosen the
vent cap until the fuel level falls to just
above the collar, then hand-tighten the
vent cap.
1. Drain Valve 8. Filter Element 10.6 Check for leaks and shut down the en-
2. Drain Valve Cap 9. Spring gine.
3. 120VAC Pre-Heater 10. Cover O-Ring
4. Inlet Port/Check Valve 11. Clear Cover
5. Lower Housing 12. Vent Cap O-Ring
6. Bypass Valve 13. Vent Cap
7. 12VDC Pre-Heater 14. Collar
Fig. 7, DAVCO Fuel Pro 487

Fuel 47
ConMet Fuel Separator Sight 1

Bowl Cleaning 2
The only maintenance necessary on ConMet fuel
separators is to clean the sight bowl, if equipped.
See Fig. 9. 3
WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to 3
open flame or intense heat could start a fire, pos-
sibly resulting in personal injury or property dam-
age. When working on a fuel system, have a fire 4
extinguisher within easy reach.
5
tires and open the hood.
6
IMPORTANT: When draining fluid from a
fuel/water separator, drain the fluid into an ap-
propriate container, and dispose of it properly.
Many jurisdictions now issue fines for draining
fuel/water separators onto the ground.
2. Drain the fuel separator. 7
3. Unscrew the sight bowl from the fuel separator. 8

4. Wipe the sight bowl clean using a soft cloth.
5. Lubricate the gasket with a film of oil, and rein-
stall it on the sight bowl. If the gasket appears 9
dry-rotted or damaged, replace the gasket.
6. Lightly lubricate the threads on the sight bowl 10
with oil, then thread the sight bowl into the bot-
08/25/95 f470146
tom of the fuel separator.
1. Vacuum Breaker/Drain Valve
7. Hand-tighten until the gasket is in full contact 2. Reducer Bushing
with the fuel separator, then tighten an additional 3. Mounting Brackets
1/4 to 1/3 turn. 4. O-ring (when equipped with heater)
5. Stainless Steel V-Clamp (when equipped with
8. Check that the drain valve is tightened and heater)
closed. 6. Heater Assembly
9. To prime the fuel separator, remove the vacuum 7. Gasket
breaker fitting and fill the unit with diesel fuel, 8. Sight Bowl Heater Rod
then install and close the fitting when the unit is 9. Sight Bowl Assembly
10. Vacuum Breaker/Drain Valve
full.
Fig. 9, ConMet Fuel Separator
IMPORTANT: The fitting must be air-tight and
the valve closed.

47 Fuel
Detroit 3. Remove the bowl by turning counterclockwise.

4. Remove the element, bowl O-ring, and element
The only maintenance necessary on an Detroit o-ring. Dispose of them in an environmentally
fuel/water separator is to replace the filter element. acceptable manner.
See Fig. 10.
5. Thoroughly clean all of the threads and sealing
surfaces. Even a small amount of dirt will prevent
the fuel/water separator from sealing, and an air
leak may result.
6. Apply a coating of clean fuel or motor oil to the
new O-ring and to the new element o-ring.
1
7. Insert the new element into the upper housing.
IMPORTANT: Do not use tools to tighten the
bowl and element.
8. Spin the bowl onto the onto the upper housing
by hand only.
9. Connect the water sensor and heater connectors
if equipped.
10. If equipped with a primer pump, prime the
fuel/water separator as follows.
2
10.1 Loosen the vent plug. Then operate the
primer pump until the fuel purges at the
vent plug.
06/09/2016 f470689
10.2 Close the vent plug.
1. Mounting Head 2. Sight Bowl 11. Start the engine and check for fuel leaks.
Fig. 10, Detroit Fuel/Water Separator 12. Shut down the engine and correct any fuel leaks.
WARNING 47–03 Fuel Tank Band Nut

Fluid circulated through the fuel/water separator Tightening
the engine, or engine coolant. Drain the fuel/water IMPORTANT: Do not overtighten the nuts.
separator only when the engine and fluids have
cooled. Draining it when the engine is hot could Rectangular Fuel Tank
Hold the retention nut on the fuel tank band with a
If returning fuel is released into the atmosphere, wrench while backing off the jam nut. Then tighten
its vapors can ignite in the presence of any igni- the retention nut 13 to 17 lbf·ft (18 to 23 N·m). After
tion source. Do not expose the fuel to, or work the retention nut has been tightened, hold the reten-
with the fuel system near, open flame or intense tion nut with a wrench while tightening the jam nut 13
heat. To do so could cause fire, possibly resulting to 17 lbf·ft (18 to 23 N·m).
in serious personal injury or property damage.
1. Drain off some fuel by loosening the vent plug Cylindrical Fuel Tank
and opening the drain valve. Hold the retention nut on the fuel tank band with a
2. Disconnect the water sensor and heater connec- wrench while backing off the jam nut. Then tighten
tions if equipped. the retention nut 30 to 35 lbf·ft (41 to 46 N·m). After

Fuel 47
the retention nut has been tightened, hold the reten-

tion nut with a wrench while tightening the jam nut 30
to 35 lbf·ft (41 to 46 N·m).

Exhaust 49
Index, Alphabetical

CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–02
Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01
4700 5700 4900 6900 Maintenance Manual, November 2020

Exhaust 49
49–00 Safety Precautions EPA10 and Newer Exhaust

System
procedures within this group. Definitions of Aftertreatment (ATS)
Terms
DANGER Refer to the following list of definitions of ATS terms
When working on the vehicle, shut down the en- and components.
gine or motor, set the parking brake, and chock • Aftertreatment System (ATS)—the entire ex-
the tires. Before working under the vehicle, always haust system from the turbocharger to the ex-
place jack stands under the frame rails to ensure haust stack or tail pipe.
steps could result in serious personal injury or • Aftertreatment Device (ATD)—a housing that
death. contains the DOC and DPF (also the SCR and
the mixing tube in one-box systems).
• BlueTec®—Daimler’s proprietary SCR technol-
49–01 Exhaust System ogy.
Inspection (Noise • Diesel Oxidation Catalyst (DOC)—a flow-
Emission Control) through device that oxidizes soot in the ATD.
• Diesel Particulate Filter (DPF)—a component in
In addition to inspecting the exhaust system at the the ATD that traps soot from the exhaust gas.
scheduled maintenance interval, inspect the exhaust
system if the noise level of the vehicle has in- • Diesel Exhaust Fluid (DEF)—the chemical agent
creased. Western Star Trucks recommends replacing that reacts with the exhaust gases in the SCR
parts that show leakage, wear, or damage, with to reduce NOx.
genuine Western Star parts. • DEF Pump—filters and supplies DEF to the
The exhaust system must be free of leaks, binding, DEF metering unit.
grounding, and excessive vibrations. These condi- • DEF Tank—holds DEF and regulates its tem-
tions are usually caused by loose, broken, or mis- perature.
aligned clamps, brackets, or pipes. If any of these
conditions exist, check the exhaust system compo- • DEF Metering Unit—mixes DEF with com-
nents and alignment. Align or replace as necessary; pressed air, and meters this mixture into the
see Group 49 of the Western Star Workshop exhaust flow via an injection nozzle.
Manual, or take the vehicle to an authorized Freight- • SCR Catalyst—the housing containing a treated
liner dealer. ceramic flow-through block where the DEF and
It is a violation of US federal law to alter exhaust exhaust gases undergo selective catalytic re-
plumbing or aftertreatment in any way that would duction (SCR).
bring the engine out of compliance with certification • Selective Catalytic Reduction (SCR)—a process
requirements. (Ref: 42 U.S.C. S7522(a) (3).) It is the used to reduce NOx emissions.
owner’s responsibility to maintain the vehicle so that
it conforms to EPA regulations. Inspection
IMPORTANT: Depending upon local jurisdic-
tional emissions guidelines, vehicles that are
domiciled outside of the U.S. and Canada may
not have engines and/or emissions aftertreat-
ment systems that are compliant with EPA10 or
GHG21 regulations.
4700 5700 4900 6900 Maintenance Manual, November 2020 49/1

49 Exhaust
IMPORTANT: The aftertreatment device (ATD), 8. Check the SCR catalyst for dents and other
which is part of the aftertreatment system (ATS), damage.
requires special attention during regularly 9. Check for heat discoloration on the surface of
scheduled maintenance inspections. No leaks the ATD. Heat discoloration may indicate internal
are allowed anywhere in the system. If any dis- damage; especially around the DPF.
crepancies are discovered, refer to the engine NOTE: Diesel exhaust fluid creeps, causing
manufacturer’s service literature for repair in- white crystals to form around the line fittings.
structions. The presence of crystals does not mean the
1. Check for leakage at the clamp that attaches the system has a leak. Replacing fittings or trouble-
exhaust pipe to the turbocharger exhaust outlet. shooting components is not necessary unless
If leakage exists, tighten the nut on the clamp to there is a system failure or a fault code.
the required torque. If leakage persists, install a
new clamp. 10. Check the DEF tank, pump, metering unit, and
lines for leaks. See Section 49.02 of the West-
2. Check the exhaust pipe, bellows, and each ex- ern Star Workshop Manual for repair procedures.
haust seal clamp for leakage, wear, cracks, or
damage. Replace damaged components as 11. Check any wires, lines, or hoses within 4 inches
needed. If leakage exists at a clamp, tighten the (10 cm) of the exhaust system for heat damage.
nuts to the required torque. If leakage persists, Repair or reroute as needed.
install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or Diesel Exhaust Fluid (DEF) Filter
removed, it must be replaced. Replacement
3. If present, check the condition of the insulation The Environmental Protection Agency’s 2010 regula-
material around the exhaust pipe between the tions require lower nitrogen oxide (NOx) exhaust
turbocharger and the ATD. emissions. Selective catalytic reduction (SCR) uses
4. Check the ATD mounting bands for tightness. diesel exhaust fluid (DEF) to lower NOx emissions in
Tighten to 30 lbf·ft (41 N·m) if needed. Do not the vehicle exhaust. A filter in the DEF pump pre-
overtighten. vents clogging of the DEF metering unit injection
nozzle.
5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that See the engine manufacturer’s maintenance manual
retain the DPF in the ATD. for filter replacement instructions and maintenance
intervals.
6. Check all sensors attached to the ATS for leaks
or damaged wires. No leaks are allowed. See EPA07 Exhaust System
Fig. 1, Fig. 2, or Fig. 3 for Detroit Diesel ATS
sensor locations. Definitions of ATS Components
7. Check the DPF exterior surface for dents or Refer to the following list of definitions of ATS com-
other damage. A dent over 3 inches (76 mm) in ponents.
diameter and 1/4-inch (6-mm) deep could cause
internal damage to the DPF, causing it to • Aftertreatment System (ATS)—the entire ex-
malfunction. haust system from the turbocharger to the ex-
haust stack or tail pipe.
• Aftertreatment Device (ATD)—a muffler-like can-
ister that houses a DPF, DOC, and sensors.
• Diesel Particulate Filter (DPF)—a filter that col-
lects and holds particulate matter (soot and
ash).
• Diesel Oxidation Catalyst (DOC)—oxidizes hy-
drocarbons and reduces NOx.
49/2 4700 5700 4900 6900 Maintenance Manual, November 2020

Exhaust 49
14 13 12
9 1
9 2
3
8
7
11
10
15 5
08/20/2009 f490355
NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the
DOC inlet pressure sensor.
1. DOC Outlet Temperature 6. Exhaust Outlet 11. SCR Outlet NOx Sensor Port
Sensor 7. DEF Metering Unit 12. SCR Inlet NOx Sensor Port
2. DOC Inlet Pressure Sensor 8. Sensor Box (see note above) 13. 14-Pin Connectors
Port 9. Exhaust Inlet 14. DPF Outlet Pressure Sensor
3. DOC Inlet Temperature Sensor 10. SCR Outlet Temperature Port
4. Front Heat Shield Sensor 15. SCR Inlet Temperature Sensor
5. DEF Nozzle
Fig. 1, One-Box ATS Sensor Locations
• Sensors—detect temperatures and pressures in engine manufacturer’s service literature for re-
the ATS. pair instructions.
Inspection 1. Check for leakage at the clamp that attaches the
exhaust pipe to the turbocharger exhaust outlet.
To meet EPA07 emissions regulations for vehicles If leakage exists, tighten the nut on the clamp to
domiciled in the USA or Canada, engines manufac- the required torque. If leakage persists, install a
tured after December 31, 2006 are equipped with an new clamp.
emission aftertreatment system. Vehicles domiciled
outside of the USA and Canada may not have after- 2. Check the exhaust pipe, bellows, and each ex-
treatment equipment, depending upon local statutory haust seal clamp for leakage, wear, cracks, or
emissions guidelines. damage. Replace damaged components as
needed. If leakage exists at a clamp, tighten the
IMPORTANT: The aftertreatment device (ATD), nuts to the required torque. If leakage persists,
which is part of the aftertreatment system (ATS), install a new exhaust seal clamp. Do not reuse
requires special attention during regularly seal clamps. Once a seal clamp is loosened or
scheduled maintenance inspections; see Fig. 4. removed, it must be replaced.
No leaks are allowed anywhere in the system. If
any discrepancies are discovered, refer to the

49 Exhaust
1
2
11 3
10
9 4
8
10
8 9
7
6
5
09/16/2009 f490353
1. DEF Metering Unit 5. DOC Inlet Temperature Sensor 9. DPF Outlet Temperature
2. DEF Nozzle 6. DOC Inlet Pressure Sensor Sensor
3. SCR Outlet Temperature 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor
Sensor 8. DPF Outlet Pressure Sensor 11. SCR Outlet NOx Sensor
4. SCR Inlet Temperature Sensor
Fig. 2, 2V2 Two-Box ATS Sensor Locations
or leaking, replace it. See 49–02 for the replace-

NOTICE ment procedure.
A leak in the CGI piping, including the bellows, 4. If present, check the condition of the insulation
will allow unfiltered air and contaminants into the material around the exhaust pipe between the
engine intake, and can cause serious engine dam- turbocharger and the ATD.
age. 5. Check the ATD mounting bands for tightness.
NOTE: Because the CGI bellows is covered Tighten to 30 lbf·ft (41 N·m) if needed. Do not
with a metal mesh, it is difficult to see cracks or overtighten.
damage that may cause a leak. 6. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that
3. On vehicles with CAT engines, inspect the CGI
retain the DPF in the ATD.
bellows and piping for evidence of damage or
leakage. See Fig. 5. If the bellows is damaged 7. Check all sensors attached to the ATD for leaks
or damaged wires. No leaks are allowed.

Exhaust 49
1
11
10
9 3
4
8
5
6
09/16/2009 f490354
1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 9. SCR Outlet Temperature
2. DOC Inlet Temperature Sensor Sensor Sensor
3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 10. SCR Sensor Box
4. DPF Sensor Box 8. SCR Inlet Temperature Sensor 11. SCR Outlet NOx Sensor
5. DPF Outlet Pressure Sensor
Fig. 3, 2HV Two-Box ATS Sensor Locations
8. Check the DPF exterior surface for dents or

other damage. See Item A of Fig. 4. A dent over
3 inches (76 mm) in diameter and 1/4-inch (6-
mm) deep could cause internal damage to the
DPF, causing it to malfunction.
9. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
10. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
Pre-EPA07 Exhaust System

Inspection
1. On all vehicles, check the condition of the muffler
body and the top stack. Check the inlet/outlet
tubes for leakage, dents, and corrosion, and

49 Exhaust
6
5 7
3 4 2 5
1 2
10/20/2006 A f490283
A. Inspect this area of the canister for dents.
1. Marmon Fitting at Inlet from Turbocharger 6. Sensor Housing
2. DOC Temperature Sensor 7. DPF Outlet Temperature Sensor
3. ATD Mounting Band 8. Exhaust Outlet Marmon Fitting
4. DPF Intake Pressure Sensor 9. DPF Outlet Pressure Sensor
5. DPF V-Band Mounting Clamps
Fig. 4, Typical EPA07 Aftertreatment Device
2 3 4 5 6 5 3 7 8 9 3 10 1
02/24/2011 f490456
1. Clamp 5. Slip Clamp 8. Center Pipe
2. Inlet Pipe 6. CGI Bellows 9. Clamp
3. U-Clamp 7. Center Pipe-Support Brace 10. Outlet Pipe
4. Forward Pipe-Support Brace
Fig. 5, CAT EPA07 Exhaust Installation with CGI Bellows
check for holes in the muffler. Replace parts as required. Use new parts, equivalent to parts
originally installed on the vehicle.

Exhaust 49
2. Inspect the exhaust flex hose (see Fig. 6) for

leakage, wear, or damage. Replace with new
parts if replacement is needed.
3. Check for leakage at the V-band coupling, which
attaches the exhaust pipe to the turbocharger
exhaust outlet. See Fig. 6.
1
2
3 06/28/2001 f490241
4
1. Exhaust Elbow 2. Exhaust Isolator
Fig. 7, Exhaust Isolator
06/01/93 f490024a
1. Flex Hose 4. Turbocharger Exhaust

2. V-Band Coupling Outlet
3. Exhaust Pipe
Fig. 6, V-Band Coupling and Flex Hose
4. If leakage exists, tighten the nut on the V-band

coupling 85 lbf·in (940 N·cm). If leakage persists,
install a new V-band coupling.
5. Inspect the turbocharger outlet pipe, and replace
it as needed.
6. Check the U-bolt clamps for tightness, and
tighten as needed. 05/28/93 f490025a
7. Check the isolator at the base and the top of the Fig. 8, Donaldson SealClamp Wide-Band Exhaust
exhaust stack (see Fig. 7) for cracking, damage, Clamp
and dry rot. Replace as needed.
8. Check for leakage at all wide-band exhaust 49–02 CAT CGI Bellows
clamps. See Fig. 8.
Replacement
If leakage exists, tighten the nuts 40 to 60 lbf·ft
(54 to 81 N·m). If leakage persists, inspect the On vehicles with CAT EPA07 compliant engines, re-
wide-band exhaust clamps. Install a new Donald- place the CGI bellows at the M4 maintenance inter-
son SealClamp™ if necessary. val to prevent a later failure.
NOTICE
A leak in the CGI piping, including the bellows,
will allow unfiltered air and contaminants into the
engine intake, and can cause serious engine
damage.

49 Exhaust
1. Park the vehicle, set the parking brake, chock the bellows could result in an exhaust leak, which
the wheels. in this case may allow ingestion of contaminants
into the engine causing engine damage.
2. Open the hood.
6.3 Use a straightedge to align the pipes so
3. Remove the right side inner fender/splash shield
that the pipe ends that attach to the bel-
as needed.
lows are parallel and concentric.
4. Remove the CGI piping between the engine and
aftertreatment device (ATD).
NOTICE
See Fig. 9.
When shortening the CGI pipe(s), it is critical to
5. On the workbench, remove the CGI bellows from leave a minimum of 1 inch (25.4 mm) of straight
the exhaust piping. Do not damage the piping.
2 3 4 5 6 5 3 7 8 9 3 10 1
02/24/2011 f490456
1. Clamp 5. Slip Clamp 8. Center Pipe
2. Inlet Pipe 6. CGI Bellows 9. Clamp
3. U-Clamp 7. Center Pipe-Support Brace 10. Outlet Pipe
4. Forward Pipe-Support Brace
Fig. 9, CAT EPA07 Exhaust Installation with CGI Bellows
NOTE: The following step, and its substeps, is pipe on the end of each CGI pipe to allow for pipe
to be done without the bellows installed. This insertion and clamp clearance. Failure to do this
will align the pipes so that the bellows can be could result in an exhaust leak, which in this case
installed correctly. may allow ingestion of contaminants into the en-
gine causing engine damage.
6. Install the CGI piping (without CGI bellows) and
align piping. 7. Once the pipes are aligned, measure the pipe
gap between the CGI pipes and record the dis-
6.1 Attach the aft CGI pipe to the ATD. tance. See Fig. 10, Ref. A.
6.2 Attach the forward CGI pipe to the en- The existing pipe gap is designed at 10 inches
gine. (254 mm). A 10.75 inches (273 mm) pipe gap is
required for the replacement CGI bellows and
NOTICE clamps. This requires one or both of the CGI
pipes to be shortened.
When the CGI pipes and bellows are installed, 8. Using a yellow paint pen, mark the pipes 1.5
there should be approximately 3/4 inch (19 mm) inches (38 mm) in from the end of each pipe.
clearance from the main bellows. Contact between

Exhaust 49
1 12. Slide the new bellows onto the aft CGI pipe as
far as it will go. See Fig. 12, Ref. A. Measure-
2
ment A should be at least 7/16 inch (10 mm)
past the face of the flange.
A
A A
1 2 3
02/23/2011 f490458
02/23/2011 f490457
A. At least 7/16 inch (10 mm)
A. Measure the pipe gap.
1. Forward CGI Pipe 3. Aft CGI Pipe
1. CGI Aft Pipe 2. CGI Forward Pipe 2. CGI Bellows
Fig. 10, Measuring the Pipe Gap (typical) Fig. 12, CGI Bellows Installation
These two marks will be used to center the bel- 13. Install the slip clamp with the retaining ring and
lows between the two pipes. graphite gasket ring onto the forward CGI pipe.
9. Once the pipes are correctly aligned and sepa- See Fig. 13 for proper installation.
rated at the correct distance, secure the aft CGI
pipe to the ATD and to any CGI pipe support
brackets. 2 3 4
1 5
10. Remove the forward CGI pipe from the truck.
11. Slide the slip clamp, with the retaining ring and
graphite gasket ring, on the aft CGI pipe. See
Fig. 11 for proper installation.
2 3 4
1 5
02/08/2010 f490417
1. CGI Bellows 4. Graphite Gasket

2. Slip Clamp 5. Forward CGI Pipe
3. Retaining Ring
Fig. 13, Forward Facing Slip Clamp Installation
14. Slide the end of the forward CGI pipe into the
bellows, and properly align the pipe.
01/29/2010 f490415
1. Aft CGI Pipe 4. Slip Clamp 15. Secure the forward CGI pipe to the engine and
2. Retaining Ring 5. CGI Bellows any CGI pipe support brackets.
3. Graphite Gasket 16. Using the yellow marks, center the bellows be-
Fig. 11, Aft Facing Slip Clamp Installation tween the exhaust pipes. Verify that the pipe is
inserted at least 7/16 inch (10 mm) past the face
of the flange. See Fig. 12, Ref. A.

49 Exhaust
17. Install the slip clamps on the bellows. Tighten the

slip clamps 11 lbf·ft (15 N·m).
18. Start the engine and check for exhaust leaks.
Tighten any clamps as needed.

Cab 60
Index, Alphabetical

Aerodynamic Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–03
Cab Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–01
Mirror Folding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–02

Cab 60

1
5 1/2"
DANGER
2
death.
60–01 Cab Suspension 07/05/2001 f310872

Inspection 1. Air Spring 2. Shock Absorber
1. On single and dual air spring systems, inspect Fig. 1, Single Air Spring Cab Suspension (typical)
the air spring(s) at the rear of the cab. Check for
wear, air leaks, and damage. See Fig. 1 for typi-
cal single air spring suspension, Fig. 2 for a typi-
cal dual air spring suspension. Replace damaged
components if necessary.
A
On combined air spring/shock absorber suspen- 1
sion, check for wear, air leaks, fluid leaks, and
damage. See Fig. 3 for air spring/shock absorber 2 1 2
suspension. Replace damaged components if
necessary.
2. On single or dual air spring suspensions, check 02/16/2015 f602538
the distance between the top and bottom air
A. 5-1/2 inches (140 mm)
spring mounting brackets. the air spring(s)
should be inflated so that the distance between 1. Shock Absorber 2. Air Spring
the top and bottom brackets measures 5-1/2 Fig. 2, Dual Air Spring Cab Suspension (typical)
inches (140 mm). See Fig. 1 for typical single air
spring suspension, Fig. 2 for a typical dual air
spring suspension.
3. Inspect the cab suspension shock absorbers for
wear, damage, or leaking fluid. See Fig. 1 for
single air spring suspension, Fig. 2 for dual air
spring suspension or, Fig. 3 for air spring/shock
absorber suspension. Replace if necessary.

60 Cab
02/13/2015 f602539
Ride height is not adjustable.

1. Combined Air Spring/Shock Absorber
Fig. 3, Air Spring/Shock Absorber Suspension
60–02 Mirror Folding Check

For vehicles with folding cab-mounted main mirrors,
make sure that the mirrors fold freely on the pivot
points. Pivot each mirror fully forward and backward
two times to break loose any debris that may affect
the fold-away feature of the mirror.
60–03 Aerodynamic
Component Inspection
Inspect aerodynamic components, if equipped, for
structural damage, cracks, or wear. These may
include:
• Cab side extenders
• Roof fairing/deflector
• Bumper
• Hood
• Side fairings
Replace or repair damaged or missing components
as needed.

Doors 72
Index, Alphabetical

Door Seal, Door Latch, Door Hinge, and Door Check Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72–01
4700 5700 4900 6900 Maintenance Manual, June 2010

Doors 72
72–01 Door Seal, Door Latch,

Door Hinge, and Door
Check Lubrication
NOTE: Light penetrating oils, such as WD–40,
should not be used because they wash out ben-
eficial factory-installed grease, and they evapo-
rate.
Door Seals
Lightly coat the door seals with a lubricant that’s safe
for rubber.
Door Latches
Wipe old grease and dirt from all door latch assem-
blies, then apply liberal amounts of an approved
grease to each moving joint; see Table 1. Use an
appropriate applicator that will not leave material
behind.
Door Hinges
Lubricate external hinges every six months. Wipe old
grease and dirt from the hinge, then force an ap-
proved grease into the hinge components; see Table
1. Use an appropriate applicator that will not leave
material behind. Wipe off any excess grease.
Door Checks
Wipe old grease and dirt from door checks. Lubricate
each moving joint of the door checks at installation
and every six months thereafter, with an approved
grease; see Table 1. Use an appropriate applicator
that will not leave material behind.
Approved Grease
NLGI
Application Lubricant
Grade
Door Latches ConocoPhillips Triton® 460 1.5
Door Checks ConocoPhillips Megaplex® XD3 2
Table 1, Approved Grease
4700 5700 4900 6900 Maintenance Manual, June 2010 72/1

Heater and Air Conditioner 83
Index, Alphabetical

Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01
HVAC Air Filter Cleaning and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02

83–00 Safety Precautions For a Climate Control compressor, if the clear-

ance is 0.035 inch (0.89 mm) or greater, replace
the clutch. For instructions, see Section 83.00,
Safety Precautions in this section apply to all Subject 140 of the Western Star Workshop
procedures within this group. Manual.
4. Check the overall condition of the air conditioning
DANGER hoses. Look for cracks, cuts, and abrasions on
When working on the vehicle, shut down the en- the hoses. Replace damaged hoses. Also check
gine or motor, set the parking brake, and chock for signs of loose fittings on all of the air condi-
the tires. Before working under the vehicle, always tioning components.
the vehicle cannot drop. Failure to follow these 1
death.
2
83–01 Air Conditioner A
Inspection
WARNING
Wear eye protection, gloves, and protective cloth-
ing when working on the air conditioning system.
Leaking refrigerant from a damaged hose or line 01/13/2010 f831825
could cause blindness or serious skin burns.
See Table 1 for acceptable clearances.
1. Park the vehicle on a level surface, apply the A. Clearance
parking brake, and chock the tires.
1. Hub
2. Inspect the A/C compressor hub. A torn or 2. Rotor Magnetic Clutch
melted rubber dampener (center section) indi-
Fig. 1, Hub/Rotor Clearance
cates internal damage has occurred within the
compressor. Inspect friction surfaces for wear,
Acceptable Compressor Clutch Clearances
oil-soaked conditions, or discoloration due to ex-
cessive heat. Acceptable Clearance:
Compressor
inch (mm)
3. With the belt removed, check to make sure that
the rotor (pulley) spins freely. It should not Denso 0.014 to 0.024 (0.35 to 0.6)
wobble or contact the hub when it is spinning. Sanden 0.016 to 0.031 (0.40 to 0.78)
Using a feeler gauge, check the clearance be- Climate Control 0.020 to 0.030 (0.50 to 0.76)
tween the rotor and hub at several locations, and
average the results. See Fig. 1. See Table 1 for Table 1, Acceptable Compressor Clutch Clearances
acceptable clearances.
For a Denso compressor, if the clearance is 83–02 HVAC Air Filter Cleaning
greater than 0.024 inch (0.6 mm), replace the
clutch. For instructions, see Section 83.04, Sub- and Replacement
ject 140 of the Western Star Workshop Manual.
The cab HVAC assembly has either two pleated,
For a Sanden compressor, if the drive plate dust/odor air filters that are not cleanable and must
clutch needs adjustment, see Section 83.01, be replaced every three months, or two foam air fil-
Subject 130 of the Western Star Workshop ters with aluminum screens that can be cleaned
Manual. every three months and replaced once a year.

83 Heater and Air Conditioner
Additionally, some vehicles are equipped with an

HVAC pre-filter that should be cleaned every three
months and replaced once a year.
On sleeper cabs, the sleeper HVAC assembly has
either two pleated, dust/odor air filters that are not
cleanable and must be replaced every three months,
or two foam air filters with aluminum screens that
can be cleaned every three months and replaced
once a year.
Cab Fresh-Air Filter

1
Replacement
1. Shut down the engine, set the parking brake,
and chock the tires.
2. From inside the cab, remove the fasteners that
attach the HVAC cover, if equipped, to the HVAC
assembly. Remove the HVAC cover. See Fig. 2.
05/19/2003 f831576
1. Air Filters
Fig. 3, Cab Fresh-Air Filters
1
5. Install two new air filters in the air intake plenum.
Make sure the arrow on the air filter is pointing in
the direction shown in Fig. 3.
6. Using screws, attach the air filter cover to the
HVAC assembly.
7. Attach the HVAC cover, if equipped, to the HVAC
05/19/2003 f831577 assembly.
1. HVAC Cover
Cab Fresh-Air Filter Cleaning,
Fig. 2, HVAC Cover
Foam Filters
3. To access the air filters, remove the screws that
attach the air filter cover to the HVAC assembly. 1. Shut down the engine, set the parking brake,
Remove the air filter cover. and chock the tires.
4. Remove the two air filters from the air intake ple- 2. From inside the cab, remove the fasteners that
num. See Fig. 3. attach the HVAC cover, if equipped, to the HVAC
assembly. Remove the HVAC cover. See Fig. 2.

3. To access the air filters, remove the screws that

attach the air filter cover to the air intake plenum.
Remove the air filter cover.
4. Remove the two air filters from the air intake ple-
num. See Fig. 3.
5. Clean the air filters, as follows.
5.1 Wash the air filters by flushing soapy
water from the air-outlet side of the filter
to the air-intake side of the filter.
5.2 Rinse the air filters by flushing clear water
from the air-outlet side of the filter to the
air-intake side of the filter.
5.3 Allow the air filters to air dry.
6. Install the air filters in the air intake plenum.
Make sure the arrow on the air filter is pointing in 1
the direction shown in Fig. 3.
7. Using screws, attach the air filter cover to the
HVAC assembly.
8. Attach the HVAC cover, if equipped, to the HVAC
assembly.
09/09/2011 f831898
HVAC Pre-Filter Cleaning NOTE: On vehicles equipped with an HVAC pre-filter,
NOTE: On vehicles equipped with an HVAC pre- the pre-filter is held in place by friction and a small
clamping force; it has no fasteners.
filter, the pre-filter should be cleaned every three
months and replaced yearly. 1. Pre-Filter
1. Shut down the engine and set the parking brake. Fig. 4, HVAC Pre-Filter
Chock the tires.
2. Open the hood.
Sleeper Fresh-Air Filter
3. Remove the pre-filter mounted at the HVAC in-
Replacement
take. See Fig. 4. 1. Shut down the engine, set the parking brake,
4. Clean the pre-filter, as follows. and chock the tires.
4.1 Wash the pre-filter by flushing soapy 2. To access the sleeper HVAC assembly, enter the
water from the air-outlet side of the filter sleeper and remove the bottom drawer from the
to the air-intake side of the filter. left-side cabinet.
4.2 Rinse the pre-filter by flushing clear water 3. Remove the air filters from the sleeper HVAC
from the air-outlet side of the filter to the assembly. See Fig. 5.
air-intake side of the filter. 4. Install new air filters in the sleeper HVAC assem-
4.3 Allow the pre-filter to air dry. bly. Make sure the arrow on the air filter is point-
ing toward the sleeper HVAC assembly; see
5. Install the pre-filter, as removed. Fig. 5.
5. Install the drawer in the cabinet.

83 Heater and Air Conditioner
05/21/2003 f831578
Fig. 5, Orientation of Sleeper Fresh-Air Filters
Sleeper Fresh-Air Filter Cleaning,

Foam Filters
1. Shut down the engine, set the parking brake,
and chock the tires.
2. To access the sleeper HVAC assembly, enter the
sleeper and remove the bottom drawer from the
left-side cabinet.
3. Remove the air filters from the sleeper HVAC
assembly. See Fig. 5.
4. Clean the air filters, as follows.
4.1 Wash the air filters by flushing soapy
water from the air-outlet side of the filter
to the air-intake side of the filter.
4.2 Rinse the air filters by flushing clear water
from the air-outlet side of the filter to the
air-intake side of the filter.
4.3 Allow the air filters to air dry.
5. Install the air filters in the sleeper HVAC assem-
bly. Make sure the arrow on the air filter is point-
ing toward the sleeper HVAC assembly; see
Fig. 5.
6. Install the drawer in the cabinet.

Hood, Grille, and Cab Fenders 88
Index, Alphabetical

Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88–01
4700 5700 4900 6900 Maintenance Manual, June 2010

Hood, Grille, and Cab Fenders 88
88–01 Hood Rear Support

Lubrication
1. Apply the parking brakes and chock the tires.
2. Open the hood.
3. Clean both the hood- and cab-mounted hood
rear support components with a soapy water so-
lution.
4. Cover all contact surfaces of the hood rear sup-
port brackets and isolators with an approved
multi-purpose, lithium-complex, soap-based
grease; see Table 1.
5. Close the hood.
Approved Suppliers of Multi-Purpose Lithium Grease

Supplier Grease
Chevron Delo Heavy Duty EP
Exxon Unirex EP2
Mobil Mobil Grease XHP 222
Shell Retinax LC Grease
Texaco Starplex 2
Table 1, Approved Suppliers of Multi-Purpose Lithium
Grease
4700 5700 4900 6900 Maintenance Manual, June 2010 88/1

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4700 5700 4900 6900 MAINTENANCE MANUAL

Models: 4700 Models

Environmental and Safety Concerns and Recommendations

NOTICE: Parts Replacement Considerations

Daimler Trucks North America LLC

4700 5700 4900 6900 Maintenance Manual, July 2018 I–1

I–2 4700 5700 4900 6900 Maintenance Manual, July 2018

For an example of a Western Star Maintenance Manual page, see Fig. 1.

35−01 Drive Axle Lubricant

Western Star Maintenance Manual, November 2011 35/1

4700 5700 4900 6900 Maintenance Manual, July 2018 I–3

Group No. Group Title

I–4 4700 5700 4900 6900 Maintenance Manual, July 2018

Title of Maintenance Operation (MOP) MOP Number

4700 5700 4900 6900 Maintenance Manual, October 2020

Determining Scheduled km) annually with minimal city or stop-and-go opera-

4700 5700 4900 6900 Maintenance Manual, October 2020 00/1

Maintenance Service Schedule Table

00/2 4700 5700 4900 6900 Maintenance Manual, October 2020

1st through 34th Maintenance for Service Schedule I Vehicles

4700 5700 4900 6900 Maintenance Manual, October 2020 00/3

35th through 68th Maintenance for Service Schedule I Vehicles

00/4 4700 5700 4900 6900 Maintenance Manual, October 2020

69th through 100th Maintenance for Service Schedule I Vehicles

4700 5700 4900 6900 Maintenance Manual, October 2020 00/5

1st through 24th Maintenance for Service Schedule II Vehicles

00/6 4700 5700 4900 6900 Maintenance Manual, October 2020

Maintenance Operation Sets for Groups 00 through 88

4700 5700 4900 6900 Maintenance Manual, October 2020 00/7

Maintenance Operation Sets for Groups 00 through 88

00/8 4700 5700 4900 6900 Maintenance Manual, October 2020

Maintenance Operation Sets for Groups 00 through 88

Table 6, Maintenance Operation Sets for Groups 00 through 88

4700 5700 4900 6900 Maintenance Manual, October 2020 00/9

Initial Maintenance (IM) Operations

Table 7, Initial Maintenance (IM) Operations for all Service Schedules

00/10 4700 5700 4900 6900 Maintenance Manual, October 2020

Lubrication and Fluid Level Check for Service Schedules I and II

4700 5700 4900 6900 Maintenance Manual, October 2020 00/11

M1 Maintenance Interval Operations for Service Schedules I and II

Table 9, M1 Maintenance Interval Operations for Service Schedules I and II

00/12 4700 5700 4900 6900 Maintenance Manual, October 2020

M2 Maintenance Interval Operations for Service Schedules I and II

4700 5700 4900 6900 Maintenance Manual, October 2020 00/13

M3 Maintenance Interval Operations for Service Schedules I and II

Table 11, M3 Maintenance Interval Operations for Service Schedules I and II

00/14 4700 5700 4900 6900 Maintenance Manual, October 2020

M4 Maintenance Interval Operations for Service Schedules I and II

4700 5700 4900 6900 Maintenance Manual, October 2020 00/15

General Information sale or delivery to the ultimate purchaser or while

Tampering With Noise Controls is

00/16 4700 5700 4900 6900 Maintenance Manual, October 2020

Verification of Inspections Log

Verification of Inspections Log (Group 20) Fan Drive

Table 14, Verification of Inspections Log (Group 20) Fan Drive

4700 5700 4900 6900 Maintenance Manual, October 2020 00/17

Verification of Inspections Log (Group 49) Exhaust System Components

00/18 4700 5700 4900 6900 Maintenance Manual, October 2020

Title of Maintenance Operation (MOP) MOP Number

4700 5700 4900 6900 Maintenance Manual, September 2015