FL816 – Brake Caliper Mounting Bolts – 2019 Freightliner, Western Star & FCCC

May 14, 2019 NHTSA CAMPAIGN NUMBER: 19V367000

Insufficiently Tightened Brake Caliper Bolts

Loose brake caliper mounting bolts may reduce the brake effectiveness, increasing the risk of crash.

 

NHTSA Campaign Number: 19V367

Manufacturer Daimler TruckseBay logo North America LLC

Components SERVICE BRAKES, AIR

Potential Number of Units Affected 253

 

Summary

Daimler TruckseBay logo North America LLC (DTNA) is recalling certain 2019 FreightlinereBay logo 108SD, 114SD, Business Class M2, Cascadia, Western StareBay logo 5700, and FCCC XC Chassis vehicles equipped with air disc brakes. The brake caliper mounting bolts may have been insufficiently tightened.

 

Remedy

DTNA will notify the owners and affected vehicle manufacturers, and DTNA dealers will inspect and repair the vehicles, free of charge. The recall is expected to begin July 12, 2019. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-816.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Daimler Trucks North America Recalls

 


Recall Campaign

June 2019 FL816A-F NHTSA #19V-367 (Non-School Bus) NHTSA #19V-368 (School Bus) Transport Canada #2019-227 (Non-School Bus)  

Subject: Brake Caliper Mounting Bolts

Models Affected: Specific FreightlinereBay logo 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay logo 5700 vehicles; FreightlinereBay logo Custom Chassis B2 school bus chassis (Thomas Built Buses Saf-T-Liner C2) and X-Line chassis manufactured August 20, 2018, through September 29, 2018, and equipped with air disc brakes.  

General Information

Daimler TruckseBay logo North America LLC (DTNA), on behalf of its FreightlinereBay logo Trucks Division and wholly owned subsidiaries, Western StareBay logo Truck Sales, Inc., and FreightlinereBay logo Custom Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above. There are approximately 400 vehicles involved in this campaign. On certain vehicles, insufficiently torqued caliper mounting bolts may not provide adequate clamping force between the brake caliper and brake anchor plate, potentially resulting in reduced brake effectiveness, which could increase the risk of a crash. Caliper mounting bolts will be inspected and replaced as needed. Additional Repairs Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns before sale or delivery of a vehicle. Owners may be liable for any progressive damage that results from failure to complete campaigns within a reasonable time after receiving notification.  

Work Instructions

Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a completion sticker (Form WAR260).  

Replacement Parts

Replacement parts are now available and can be obtained by ordering the part number(s) listed below from your facing Parts Distribution Center. Letter groups include both front and rear axles and different caliper types, as noted for each group in the table below. If our records show your dealership has ordered any vehicles involved in campaign number FL816, a list of the customers and vehicle identification numbers will be available in OWL. Please refer to this list when ordering parts for this recall. Table 1 – Replacement Parts for FL816A-F
Campaign Number Vehicle Type Part Number Part Description Qty. per Caliper
FL816A Front & Rear Axle BendixeBay logo Axial Caliper Truck N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O 6 ea
23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN
FL816B Front & Rear Axle BendixeBay logo Radial Caliper School Bus 23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL816C Front & Rear Axle MeritoreBay logo Axial Caliper Truck N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O 6 ea
23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN
FL816D Front & Rear Axle Wabco Axial Caliper Truck N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O 6 ea
23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN
FL816E Rear Axle BendixeBay logo Axial Caliper Motorhome N210931 020001 SCREW-CAP,HEX,M20X60,10.9,P/O 6 ea
23-09114-004 WASHER-HRDN,0.81X1.47X.177,ZN
FL816F Front & Rear Axle BendixeBay logo Radial Caliper Truck 23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL816A-F All WAR260 BLANK COMPLETION STICKER 1 ea
  Table 1  

Removed Parts

U.S. and Canadian Dealers, please follow Warranty Failed Parts Tracking shipping instructions for the disposition of all removed parts. Export distributors, please destroy removed parts unless otherwise advised.  

Labor Allowance

Table 3 – Labor Allowance
Campaign Number/Group Procedure Time Allowed (hours) SRT Code Corrective Action
FL816A-D,F (Bus, Truck) Inspect caliper bolts, 2 axles 2.0 996-R068A 06-Inspect
FL816A,C,D,F (Truck) Inspect caliper bolts, second rear axle 1.1 996-R068B 06-Inspect
FL816E (Motorhome) Inspect caliper bolts, 2 axles, with radial runout check 2.4 996-R068F 06-Inspect
FL816A-D,F (Bus, Truck) Inspect and torque caliper bolts, 2 axles 2.0 996-R068D 12-Repair Recall/Campaign
FL816A,C,D,F (Truck) Inspect and torque caliper bolts, second rear axle 1.1 996-R068E 12-Repair Recall/Campaign
FL816E (Motorhome) Inspect and torque caliper bolts, 2 axles, with radial runout check 2.4 996-R068G 12-Repair Recall/Campaign
FL816A-F (All Vehicles) Replace caliper bolts, 1 caliper (claim this SRT once for each caliper requiring new bolts, up to 6 times) 0.5 996-R068C 12-Repair Recall/Campaign
  Table 2 IMPORTANT: When the Recall has been completed, locate the base completion label in the appropriate location on the vehicle, and attach the red completion sticker provided in the recall kit (Form WAR260). If the vehicle does not have a base completion label, clean a spot on the appropriate location of the vehicle and first attach the base completion label (Form WAR259). If a recall kit is not required or there is no completion sticker in the kit, write the recall number on a blank sticker and attach it to the base completion label.  

Claims for Credit

You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting your claim through the Warranty system within 30 days of completing this campaign. Please reference the following information in OWL:
  • Claim type is Recall Campaign.
  • In the FTL Authorization field, enter the campaign number and appropriate condition code (e.g. FL816-A, FL816-B, etc.).
  • In the Primary Failed Part Number field, enter 25-FL816-000.
  • In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table.
  • In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. Administrative time will be included automatically as SRT 939-6010A for 0.4 hours for RVs or 0.3 hours for all other vehicles. Some SRTs are optional, and if needed, must be added manually to your claim.
  • The VMRS Component Code is 013-001-129 and the Cause Code is A1 – Campaign.
  • U.S. and Canada — Reimbursement for Prior Repairs. When a customer asks about reimbursement, please do the following:
  • Accept the documentation of the previous repair.
  • Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement. (See the “Copy of Owner Letter” section of this bulletin for reimbursement guidelines.)
  • Submit an OWL Recall Pre-Approval Request for a decision.
  • Include the approved amount on your claim in the Other Charges section.
  • Attach the documentation to the pre-approval request.
  • If approved, submit a based on claim for the pre-approval.
  • Reimburse the customer the appropriate amount.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the campaign has not been previously completed. Also, check for a completion sticker prior to beginning work. U.S. and Canadian dealers: Contact the Warranty Campaigns Department via Web inquiry at DTNAConnect.com / WSC, or the Customer Assistance Center at (800) 385-4357, after normal business hours, if you have any questions or need additional information. Export distributors, submit a Web inquiry or contact your InternationaleBay logo Service Manager. U.S. and Canadian Dealers: To return excess kit inventory related to this campaign, U.S. dealers must submit a Parts Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number. Export Distributors: Excess inventory is not returnable. The letter notifying U.S. and Canadian vehicle owners is included for your reference. Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code, Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors and retail outlets within five working days.  

Copy of Notice to Owners

Subject: Brake Caliper Mounting Bolts

For the Notice to U.S. Customers: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. For the Notice to Canadian Customers: This notice is sent to you in accordance with the Canadian Motor Vehicle Safety Act. Daimler TruckseBay logo North America LLC (DTNA), on behalf of its FreightlinereBay logo Trucks Division and wholly owned subsidiaries, Western StareBay logo Truck Sales, Inc., and FreightlinereBay logo Custom Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on specific FreightlinereBay logo 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay logo 5700 vehicles; FreightlinereBay logo Custom Chassis B2 school bus chassis (Thomas Built Buses Saf-T-Liner C2) and X-Line chassis manufactured August 20, 2018, through September 29, 2018, and equipped with air disc brakes. On certain vehicles, insufficiently torqued caliper mounting bolts may not provide adequate clamping force between the brake caliper and brake anchor plate, potentially resulting in reduced brake effectiveness, which could increase the risk of a crash. Caliper mounting bolts will be inspected and replaced as needed. Please contact an authorized Daimler TruckseBay logo North America dealer to arrange to have the Recall performed and to ensure that parts are available at the dealership. To locate an authorized dealer, search online at www.Daimler-TrucksNorthAmerica.com. On the menu tab, select “Contact,” scroll down to “Find a Dealer,” and select the appropriate brand. The Recall may take up to six hours, depending on the work needed, and will be performed at no charge to you. You may be liable for any progressive damage that results from your failure to complete the Recall within a reasonable time after receiving notification. If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall Notification, please return the notification to the Warranty Campaigns Department with any information you can furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law requires that you forward this notice to your distributors and retail outlets within five working days. If you have paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement. Please see the reverse side of this notice for details. For the Notice to U.S. Customers: If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected], or the Customer Assistance Center at (800) 385-4357 after normal business hours. If you are not able to have the defect remedied without charge and within a reasonable time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236 (TTY: 800-424-9153); or to https://www.safercar.gov. For the Notice to Canadian Customers: If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected], or the Customer Assistance Center at (800) 385-4357 after normal business hours. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure

Reimbursement to Customers for Repairs Performed Prior to Recall

If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement. Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Daimler TruckseBay logo North America LLC dealer. The following documentation must be presented to your dealer for consideration for reimbursement. Please provide original or clear copies of all receipts, invoices, and repair orders that show:
  • The name and address of the person who paid for the repair
  • The Vehicle Identification Number (VIN) of the vehicle that was repaired
  • What problem occurred, what repair was done, when the repair was done
  • Who repaired the vehicle
  • The total cost of the repair expense that is being claimed
  • Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt) Reimbursement will be made by check from your Daimler TruckseBay logo North America LLC dealer.
Please speak with your Daimler TruckseBay logo North America LLC authorized dealer concerning this matter.  

Work Instructions

Subject: Caliper Mounting Bolts

Models Affected: Specific FreightlinereBay logo 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay logo 5700 vehicles; FreightlinereBay logo Custom Chassis B2 school bus chassis (Thomas Built Buses Saf-T-Liner C2) and X-Line chassis manufactured August 20, 2018, through September 29, 2018, and equipped with air disc brakes.  

General Information

IMPORTANT: Vehicles may have both axial and radial mounted calipers. Follow the work instructions based on the type of calipers on the vehicle:
  • NOTE: XC motorhome chassis have ZF independent front axles. No work is needed on ZF front axle calipers. Inspect/repair the BendixeBay logo rear axle calipers only.
Caliper Type Campaign Group Letter/Axle Position Page Number
BendixeBay logo Axial FL816A (Front/Rear) 6
BendixeBay logo Axial (with radial runout) FL816E (Rear) 18
BendixeBay logo Radial FL816B (Front/Rear) F (Front/Rear) 10
MeritoreBay logo Axial FL816C (Front/Rear) 14
Wabco Axial FL816D (Front/Rear) 16
  Table 3  

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Bendix Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL816 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm) below the door latch. If a sticker is present for FL816, no work is needed. If there is no sticker, proceed with the next step.
  2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
 DANGER
  When working on the vehicle, shut down the engine, 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 steps could result in serious personal injury or death.
  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.
NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).
  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, continue to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. See Fig. 1. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. For torque specifications, see Table 4 for a 47 in (119 cm) long wrench.
Fig. 1, DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor
Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle (degrees) Target Torque [lbf·ft (N·m)] Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613 0 350 (475) 296 (401)
11/28/2016             f422614 45 310 (420)
11/06/2018             f422668 60 320 (434)
11/28/2016             f422615 90 350 (475)
11/06/2018             f422669 120 386 (523)
11/28/2016             f422616 135 402 (545)
  Table 4, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005  
 WARNING
  When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.
  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.
Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.
  1. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is in good condition. If it is, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. Remove caliper bolts.
IMPORTANT: The caliper/carriereBay logo assemblies are left and right handed. Ensure that the correct assembly (left or right) is installed on each side of the vehicle.
  1. Align each caliper/carriereBay logo assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay logo assembly using new caliper mounting bolts. See Fig. 2.
Fig. 2, BendixeBay logo Axial Mounted Caliper  
  1. Tighten the carriereBay logo mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outer-most bolt. Then tighten the three bolts on the other side of the caliper 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outer-
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If the tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.
BendixeBay logo/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle (degrees) Target Torque [lbf·ft (N·m)] Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613 0 375 (508) 317 (430)
11/28/2016             f422614 45 332 (450)
11/06/2018             f422668 60 343 (465)
11/28/2016             f422615 90 375 (508)
11/06/2018             f422669 120 413 (560)
11/28/2016             f422616 135 431 (584)
  Table 5, BendixeBay logo/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005   Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to tighten the nut. Doing so could damage the manual brake adjuster nut.
  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. Charge the air system and check for leaks.
 WARNING
  Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL816, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.
 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Bendix Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL816 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm)below the door latch. If a sticker is present for FL816, no work is needed. If there is no sticker, proceed with the next step.
  2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
 DANGER
  When working on the vehicle, shut down the engine, 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 steps could result in serious personal injury or death.
  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.
NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center-to-handle length of 47 inches (119 cm).
  1. Set a torque wrench to 200 lbf·ft (271 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, continue to step 6.
 
 WARNING
  When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.
  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.
Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.
  1. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is in good condition. If it is, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. Remove caliper bolts.
IMPORTANT: The caliper/carriereBay logo assemblies are left and right handed. Ensure that the correct assembly (left or right) is installed on each side of the vehicle.
  1. Align each caliper/carriereBay logo assembly with the rotor by pushing the fixed pin side of the caliper against the shelf on the torque plate, then install the caliper/carriereBay logo assembly using new caliper mounting bolts. See Fig. 4.
Fig. 4, BendixeBay logo Radial Mounted Caliper NOTE: The tightening pattern will always start on the short (floating) pin side, with the bolt that passes through the sheer sleeve.
  1. Tighten the carriereBay logo mounting bolts in two steps, using the pattern shown in Fig. 5.
NOTE: A slide-ability test must be performed in the green zone (marked as ’A’), shown in Fig. 6, as the red zones are not within operational range.
  • Initially tighten all six bolts 45±5 lbf·ft (61±7 N·m). Slide the caliper inboard and outboard, through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper has a binding issue. File a WSC ticket for instructions.
  • Perform a final tightening spec of 225±22.5 lbf·ft (305±31 N·m). Slide the caliper inboard and outboard, through the center of the chamber or brake. The caliper must have a minimum of 20 mm of travel. If the brake assembly does not move, or requires more than 40 pounds of force to move, the caliper has a binding issue. File a WSC ticket for instructions.
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to tighten the nut. Doing so could damage the manual brake adjuster nut.
  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
10/31/2018
A.    Right-hand brake (viewed from below). B.    Left-hand brake (viewed from below). C.   Sheer sleeve above in this location. D.   Shelf above in this location.
  Fig. 5, Tightening Pattern (viewed from below), BendixeBay logo Radial Mounted Caliper A. The caliper must move freely in the green zone (marked as ’A’) and have a minimum of 20 mm of travel in the green zone (marked as ’A’). Fig. 6, Slide-Ability Test Area
  1. Raise the vehicle, remove the jack stands, then lower the vehicle.
  2. Charge the air system and check for leaks.
 WARNING
  Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL816, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.
 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Meritor Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL816 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm)below the door latch. If a sticker is present for FL816, no work is needed. If there is no sticker, proceed with the next step.
  2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
 DANGER
  When working on the vehicle, shut down the engine, 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 steps could result in serious personal injury or death.
  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.
NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).
  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, continue to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Table 4 for torque specifications.
 WARNING
  When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.
  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.
Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.
  1. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is in good condition. If it is, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. Remove caliper bolts.
IMPORTANT: The caliper/carriereBay logo assemblies are left and right handed. Ensure that the correct assembly (left or right) is installed on each side of the vehicle. NOTE: The MeritoreBay logo axial mounted caliper is similar to the BendixeBay logo axial mounted caliper shown in Fig. 2.
  1. Align each caliper/carriereBay logo assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay logo assembly using new caliper mounting bolts.
  2. Tighten the carriereBay logo mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all of the bolts 45±5 lbf·ft (61±7 N·m). Then tighten the bolts on the other side of the caliper 45±5 lbf·ft (61±7 N·m). See Fig. 3.
    • Repeat this process, increasing the torque value to 400±50 lbf·ft (542±68 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 6 for torque specifications.
MeritoreBay logo Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle (degrees) Target Torque [lbf·ft (N·m)] Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613 0 400 (542) 338 (458)
11/28/2016             f422614 45 354 (480)
11/06/2018             f422668 60 366 (496)
11/28/2016             f422615 90 400 (542)
11/06/2018             f422669 120 441 (598)
11/28/2016             f422616 135 460 (624)
  Table 6, MeritoreBay logo Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005 Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to tighten the nut. Doing so could damage the manual brake adjuster nut.
  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. Charge the air system and check for leaks.
 WARNING
  Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL816, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.
 

Front and/or Rear Caliper/Carrier Assembly Inspection and Installation – Wabco Maxxus Axial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL816 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm)below the door latch. If a sticker is present for FL816, no work is needed. If there is no sticker, proceed with the next step.
  2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
 DANGER
  When working on the vehicle, shut down the engine, 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 steps could result in serious personal injury or death.
  1. Raise the vehicle and support it on jack stands.
  2. Remove all of the wheel assemblies.
NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).
  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, continue to step 6. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. For torque specifications, see Table 4 for a 47 in (119 cm) long wrench.
 WARNING
  When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.
  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.
Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.
  1. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is in good condition. If it is, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. Remove caliper bolts.
IMPORTANT: The caliper/carriereBay logo assemblies are left and right handed. Ensure that the correct assembly (left or right) is installed on each side of the vehicle. NOTE: The Wabco axial mounted caliper is similar to the BendixeBay logo axial mounted caliper shown in Fig. 2.
  1. Align each caliper/carriereBay logo assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay logo assembly using new caliper mounting bolts.
  2. Tighten the carriereBay logo mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all of the bolts 45±5 lbf·ft (61±7 N·m). Then tighten the bolts on the other side of the caliper 45±5 lbf·ft (61±7 N·m). See Fig. 3.
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to tighten the nut. Doing so could damage the manual brake adjuster nut.
  1. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Install the wheel assemblies.
  4. Raise the vehicle, remove the jack stands, then lower the vehicle.
  5. Charge the air system and check for leaks.
 WARNING
  Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
  2. Clean a spot on the base label (Form WAR259). Write the recall number, FL816, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.
  BendixeBay logo Axial Caliper/CarriereBay logo Assembly Inspection and Installation – XB, XC, EFX and HDX Model Vehicles. NOTE: XC motorhome chassis have ZF independent front axle. No work is needed on ZF front axle calipers. Inspect/repair the BendixeBay logo rear axle calipers only.
  1. Check the base label (Form WAR259) for a completion sticker for FL816 (Form WAR260) indicating this work has been completed. The base label is usually located on the front wall under the dash. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step.
  2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
 DANGER
  When working on the vehicle, shut down the engine, 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 steps could result in serious personal injury or death.
  1. Raise the vehicle and place jack stands under the frame rails to ensure the vehicle cannot drop.
  2. Beginning with the right-front wheel, use a tire runout gauge to check the radial runout. See 7. Write down the measurement for later use to avoid vibration complaints.
  3. Radial Runout
Fig. 7, Radial Runout Check for Tires
  1. Mark the two studs closest to the valve stem as shown in Fig. 8, for proper wheel assembly location when reinstalling the wheel assembly on the hub.
Fig. 8, Marking Wheel Studs
  1. Remove the lug nuts, then remove the wheel assembly.
IMPORTANT: Before removing the brake pads, it is recommended to check the adjuster mechanism for proper operation. NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).
  1. Set a torque wrench to 350 lbf·ft (475 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 15. If they turn, go to step 8. Due to limited caliper bolt access, it may be necessary to use tool DDC DSNCHA018005 referenced in tool letter 18TL18. If the tool is needed, use tool DDC DSNCHA018005 only and no other tools. See Fig. 1 and Table 4 for torque specifications.
 WARNING
  When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.
  • Always reline both sets of brakes on an axle at the same time.
  • Always replace both rotors/drums on an axle at the same time.
  • Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.
Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.
  1. Remove the retainer pin, cotter pin, and brake pad retainer. Inspect the brake pad hardware to ensure it is in good condition. If it is, reuse the brake pad hardware. If the brake pad hardware is not in good condition, replace brake pad sets on both ends of the axle.
  2. Remove the brake pads.
  3. Remove the caliper bolts and washers (if installed) and discard.
IMPORTANT: The caliper/carriereBay logo assemblies are left and right handed. Ensure that the correct assembly (left or right) is installed on each side of the vehicle.
  1. Align the caliper/carriereBay logo assembly with the rotor, pushing the caliper against the shelf on the torque plate,then install the caliper/carriereBay logo assembly using new caliper mounting bolts and washers. See Table 1 for parts information. See Fig. 2 for an example of the front caliper/carriereBay logo assembly.
  2. Tighten the M20 X 2.5 carriereBay logo mounting bolts as follows. See Fig. 3.
    • Start on one side of the caliper and tighten all three bolts 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outer-most bolt. Then tighten the three bolts on the other side of the caliper 40±20 lbf·ft (54±27 N·m), beginning with the inner-most bolt and moving to the outermost bolt.
    • Repeat this process, increasing the torque value to 375±25 lbf·ft (508±34 N·m). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.
Do not use a motor driven tool to tighten the manual brake adjuster nut, or use excessive force to tighten the nut. Doing so could damage the manual brake adjuster nut.
  1. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
  2. Back off the adjuster nut three clicks.
  3. Using the two studs marked earlier as a guide, install the wheel assembly. When correctly installed, a linedrawn from the valve stem through the center of the wheel assembly should go between the two marked studs.
  4. Using a tire runout gauge, measure and record the radial runout of the tire and wheel assembly. Mark thehighest point on the tire and wheel assembly. Rotate the tire and wheel assembly until the high spot is at the 12 o’clock position (without allowing the assembly to turn). Loosen all lug nuts to let the assembly settle, then tighten the lug nuts in the proper sequence. See Group 40 of the applicable vehicle maintenance manual for the tightening sequence. The radial runout should be very close to what was recorded in step 3. If not, repeat this step. Record the “final” radial runout, note the wheel location, and include the information in the recall claim in OWL.
  5. Perform the steps above for each wheel location (as needed based on the population letter) until all wheellocations have been inspected and repaired if needed.
  6. Raise the vehicle, remove the jack stands, then lower the vehicle.
  7. Charge the air system and check for leaks.
 WARNING
  Do not operate the vehicle until the brakes have been adjusted and checked for proper operation. To do so could result in inadequate or no braking ability, which could cause personal injury or death, and property damage.
  1. In a safe area, check for proper brake operation, as follows, before putting the vehicle in service.
    • Apply and release the brakes several times to check for air leaks and proper operation.
    • Perform six low-speed stops to ensure proper parts replacement and full vehicle control.
    • Immediately after doing the above stops, check the rotor temperatures. Any rotors that are significantly cooler than others indicate a lack of braking effort on those wheels.
  2. Clean a spot on the base label (Form WAR259), write the recall number, FL816, on a red completion sticker(Form WAR260), and attach it to the base label, indicating this work has been completed.


 

9 Affected Products

Vehicles

FCCCXCL2019
FCCCXCM2019
FCCCXCR2019
FCCCXCS2019
FREIGHTLINER108SD2019
FREIGHTLINER114SD2019
FREIGHTLINERCASCADIA2019
FREIGHTLINERM2 BUSINESS CLASS2019
WESTERN STAR57002019

 


15 Associated Documents

Miscellaneous Document- Body Builder Notice

RMISC-19V367-5305.pdf 1363.997KB

 


Recall 573 Report- Amendment 3

RCLRPT-19V367-3807.PDF 214.893KB

 


Remedy Instructions and TSB

RCRIT-19V367-2464.pdf 392.55KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-19V367-4762.pdf 57.581KB

 


Miscellaneous Document- Defect Information Report

RMISC-19V367-2409.pdf 3037.81KB

 


Recall Acknowledgement

RCAK-19V367-4748.pdf 244.9KB

 


Defect Notice 573 Report

RCLRPT-19V367-6573.PDF 214.83KB

 


Recall 573 Report- Amendment 2

RCLRPT-19V367-4092.PDF 214.869KB

 


Miscellaneous Document- 573 Defect Information Report

RMISC-19V367-0155.pdf 472.33KB

 


Miscellaneous Document- 2019-4 Quarterly Report Breakdown

RMISC-19V367-2260.pdf 435.264KB

 


Recall Quarterly Report #1, 2019-2

RCLQRT-19V367-2251.PDF 211.147KB

 


Recall Quarterly Report #3, 2019-4

RCLQRT-19V367-0762.PDF 211.333KB

 


Remedy Instructions and TSB

RCRIT-19V367-7527.pdf 398.48KB

 


Remedy Instructions and TSB

RCRIT-19V367-2631.pdf 400.265KB

 


Recall Quarterly Report #2, 2019-3

RCLQRT-19V367-7721.PDF 211.247KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V367&docType=RCL

 


 

SaleBestseller No. 1
EPAuto 1/2-inch Drive Click Torque Wrench, 10-150 ft/lb, 13.6-203.5 N/m
  • Durable Ratchet Head: Made from Hardened treated Chrome Vanadium steel alloy (Cr-V) Corrosion-Retardant: Satin Finish. Made in Taiwan
  • Easy Storage: A sturdy plastic storage case is included. Non-Slip Grip: Knurled handle
  • Easy to Read: High Contrast & Dual Range Scale. Accurate: Pre-Calibrated to ± 4%
  • Accessories included: 1/2" Drive 5" long Extension Bar
  • Simple and Reliable: “Click” sound tells the preset torque value is reached. Stop applying force when you hear and feel it.
Bestseller No. 2
LEXIVON Torque Wrench 1/2-Inch Drive Click 10~150 Ft-Lb/13.6~203.5 Nm (LX-183)
35,308 Reviews
LEXIVON Torque Wrench 1/2-Inch Drive Click 10~150 Ft-Lb/13.6~203.5 Nm (LX-183)
  • PRECISE & HIGH QUALITY - Manufactured in Taiwan, our torque wrench is engineered for superior precision. It ships pre-calibrated to +/- 4% accuracy, ensuring dependable results every time. Includes a calibration certificate with a trackable serial number for your assurance.
  • DURABLE - Built to last, featuring a reinforced ratchet gear head made from hardened, heat-treated Chrome Vanadium alloy steel for maximum strength and durability.
  • LONGEVITY - Protect your investment with our proprietary Electro-Black finish, providing advanced rust and corrosion resistance for extended tool life.
  • PERFORMANCE - Easily read and set torque levels with our patent-pending dual-range scale. The high-contrast, yellow-on-black markings are designed for easy visibility, even in low-light conditions.
  • OMFORT - Equipped with a reversible ratchet head that drives in both directions and measures torque in a clockwise direction. The ergonomic, knurled handle ensures a non-slip, comfortable grip, reducing hand fatigue.
SaleBestseller No. 3
DISEN 9PCS Click Torque Wrench Set 1/4" 3/8" 1/2" Drive 20-220 In.lb, 5-45 Ft.lb, 10-170 Ft.lb with 6 Adapters, ±3% Accuracy, 72-Tooth, Dual Scale, Storage Case for Bike, Motorcycle, Car, Truck Repair
  • 【9-in-1 Torque Solution】Complete set includes 1/4", 3/8", and 1/2" drive click torque wrenches plus 6 essential adapters (extension bars, universal joint, drive adapters) securely stored in a sturdy portable case.
  • 【High Precision & Dual Scales】Factory-calibrated to ±3% accuracy with included certificate; features dual-range scales (1/4": 10-220 in.lb, 3/8": 5-45 ft.lb, 1/2": 10-170 ft.lb) for versatile application coverage.
  • 【Clear & Safe Audible Click】Upgraded loud "Click" sound provides a distinct, reliable signal (strong over 5 N.m, subtle under) when preset torque is reached, preventing overtightening and ensuring safety.
  • 【Smooth 72-Tooth Ratchet & Quick Release】Reversible 72-tooth ratchet head offers a low 5° arc swing for use in tight spaces and smooth operation in both directions. Quick-release button ensures secure socket changes.
  • 【Durable Construction & Wide Use】Hardened Cr-V steel ratchet heads and phosphated adapters resist wear; aerospace aluminum handles ensure lightweight strength and corrosion resistance. Ideal for precise torque on bikes, motorcycles, cars, trucks, wheels, and industrial applications. Backed by 24-month support.
Bestseller No. 4
LEXIVON 3/8-Inch Drive Click Torque Wrench 10~80 Ft-Lb/13.6~108.5 Nm (LX-182)
  • PRECISION - Ships pre-calibrated to +/- 4% accuracy and ready to use. Include calibration certificate with traceable serial number.
  • DURABLE - Reinforced ratchet gear head constructed from hardened, heat treated Chrome Vanadium alloy steel.
  • LONG-LASTING - Rust & corrosion protection with our unique and newly invented Electro-Black finish treatment.
  • PERFORMANCE - Features an easy-to-read, highlighted yellow print dual-range scale. Identify the markings even in low-light conditions.
  • COMFORTABLE - Comes with a reversible ratchet head that drives in both directions and measure torque in a clockwise direction.
Bestseller No. 5
Amazon Basics 3/8-inch Drive Click Torque Wrench Ratchet, 15-80 ft.-lb, 20.4-108.5 Nm
  • 3/8 inch drive torque wrench with 15-80 ft.-lb./20.4-108.5 Nm range; reminder: to prevent the ratchet from breaking, please do not overload the torque wrench
  • Durable ratchet head made from hardened treated Chrome Vanadium steel alloy (Cr-V); bright, full polish chrome finish wipes easily clean and resists rust and corrosion
  • High contrast and dual range scale pre-calibrated to ± 4%; tips: for precise scale adjustment, please use the imperial scale; the conversion formula between imperial scale and metric scale is 1 Nm = 8.86 in-lbs
  • Includes sturdy plastic case for storage and portability
  • NOTE: unlock before adjusting the torque value, lock after adjusting for stability of working torque; when finished, loosen locking ring and adjust to the lowest value for next use

Last update on 2026-06-13 / Affiliate links / Images from Amazon Product Advertising API


 

This product presentation was made with AAWP plugin.

Leave a Comment

Share to...