2018 Newmar Mountain Aire

FL816 – Insufficiently Tightened Brake Caliper Bolts – 2019 Newmar Mountain Aire & Essex Motorhomes

by
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May 22, 2019 NHTSA CAMPAIGN NUMBER: 19V384000

Insufficiently Tightened Brake Caliper Bolts

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

 

NHTSA Campaign Number: 19V384

Manufacturer NewmareBay Corporation

Components SERVICE BRAKES

Potential Number of Units Affected 3

 

Summary

NewmareBay Corporation (NewmareBay) is recalling certain 2019 Mountain AireeBay and Essex motorhomes built on FreightlinereBay XC chassis equipped with air disc brakes. The brake caliper mounting bolts may have been insufficiently tightened.

 

Remedy

NewmareBay will notify owners, and FreightlinereBay dealers will inspect and repair the vehicles, free of charge. The recall began June 20, 2019. Owners may contact NewmareBay customer service at 1-800-731-8300. NewmareBay’s numbers for this recall are FL-816 and 19V-367.

 

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.

 

โ€œThis site contains affiliate links for which OEMDTC may be compensatedโ€

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 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay 5700 vehicles; FreightlinereBay 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 North America LLC (DTNA), on behalf of its FreightlinereBay Trucks Division and wholly owned subsidiaries, Western StareBay Truck Sales, Inc., and FreightlinereBay 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 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 Radial Caliper School Bus 23-13315-110 SCRW HX,SCKTHD,M16-2X110,12.9 6 ea
FL816C Front & Rear Axle MeritoreBay 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 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 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 customerโ€™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 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 ownerโ€™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 North America LLC (DTNA), on behalf of its FreightlinereBay Trucks Division and wholly owned subsidiaries, Western StareBay Truck Sales, Inc., and FreightlinereBay Custom Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on specific FreightlinereBay 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay 5700 vehicles; FreightlinereBay 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 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 โ€œContact,โ€ scroll down to โ€œFind a Dealer,โ€ 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 DTNA.Warranty.Campaigns@Daimler.com, 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 DTNA.Warranty.Campaigns@Daimler.com, 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 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 North America LLC dealer.
Please speak with your Daimler TruckseBay North America LLC authorized dealer concerning this matter.  

Work Instructions

Subject: Caliper Mounting Bolts

Models Affected: Specific FreightlinereBay 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western StareBay 5700 vehicles; FreightlinereBay 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:
Caliper Type Campaign Group Letter/Axle Position Page Number
BendixeBay Axial FL816A (Front/Rear) 6
BendixeBay Axial (with radial runout) FL816E (Rear) 18
BendixeBay Radial FL816B (Front/Rear) F (Front/Rear) 10
MeritoreBay Axial FL816C (Front/Rear) 14
Wabco Axial FL816D (Front/Rear) 16
  Table 3  

Front and/or Rear Caliper/CarriereBay Assembly Inspection and Installation – BendixeBay 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.
ย 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 lbfยทft (475 Nยทm) 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 [lbfยทft (Nยทm)] Tool Setting [lbfยทft (Nยทm)]
0ยฐ 11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422613 0 350 (475) 296 (401)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422614 45 310 (420)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422668 60 320 (434)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422615 90 350 (475)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422669 120 386 (523)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422616 135 402 (545)
  Table 4, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005  
ย 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 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 assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay assembly using new caliper mounting bolts. See Fig. 2.
Fig. 2, BendixeBay Axial Mounted Caliper  
  1. Tighten the carriereBay mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all three bolts 40ยฑ20 lbfยทft (54ยฑ27 Nยทm), 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 40ยฑ20 lbfยทft (54ยฑ27 Nยทm), beginning with the inner-most bolt and moving to the outer-
    • Repeat this process, increasing the torque value to 375ยฑ25 lbfยทft (508ยฑ34 Nยทm). If the tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 5 for torque specifications.
BendixeBay/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle (degrees) Target Torque [lbfยทft (Nยทm)] Tool Setting [lbfยทft (Nยทm)]
0ยฐ 11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422613 0 375 (508) 317 (430)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422614 45 332 (450)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422668 60 343 (465)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422615 90 375 (508)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422669 120 413 (560)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422616 135 431 (584)
  Table 5, BendixeBay/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.
ย 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/CarriereBay Assembly Inspection and Installation – BendixeBay 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.
ย 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 lbfยทft (271 Nยทm) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, continue to step 6.
 
ย 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 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 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 assembly using new caliper mounting bolts. See Fig. 4.
Fig. 4, BendixeBay 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 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 โ€™Aโ€™), shown in Fig. 6, as the red zones are not within operational range.
  • Initially tighten all six bolts 45ยฑ5 lbfยทft (61ยฑ7 Nยทm). 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 225ยฑ22.5 lbfยทft (305ยฑ31 Nยทm). 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.ย ย ย  Right-hand brake (viewed from below). B.ย ย ย  Left-hand brake (viewed from below). C.ย ย  Sheer sleeve above in this location. D.ย ย  Shelf above in this location.
  Fig. 5, Tightening Pattern (viewed from below), BendixeBay Radial Mounted Caliper A. The caliper must move freely in the green zone (marked as โ€™Aโ€™) and have a minimum of 20 mm of travel in the green zone (marked as โ€™Aโ€™). 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.
ย 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/CarriereBay Assembly Inspection and Installation – MeritoreBay 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.
ย 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 lbfยทft (475 Nยทm) 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.
ย 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 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 axial mounted caliper is similar to the BendixeBay axial mounted caliper shown in Fig. 2.
  1. Align each caliper/carriereBay assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay assembly using new caliper mounting bolts.
  2. Tighten the carriereBay mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all of the bolts 45ยฑ5 lbfยทft (61ยฑ7 Nยทm). Then tighten the bolts on the other side of the caliper 45ยฑ5 lbfยทft (61ยฑ7 Nยทm). See Fig. 3.
    • Repeat this process, increasing the torque value to 400ยฑ50 lbfยทft (542ยฑ68 Nยทm). If tool DDC DSNCHA018005 referenced in tool letter 18TL18 is used, see Table 6 for torque specifications.
MeritoreBay Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View Extension Angle (degrees) Target Torque [lbfยทft (Nยทm)] Tool Setting [lbfยทft (Nยทm)]
0ยฐ 11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422613 0 400 (542) 338 (458)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422614 45 354 (480)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422668 60 366 (496)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422615 90 400 (542)
11/06/2018ย ย ย ย ย ย ย ย ย ย ย ย  f422669 120 441 (598)
11/28/2016ย ย ย ย ย ย ย ย ย ย ย ย  f422616 135 460 (624)
  Table 6, MeritoreBay 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.
ย 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/CarriereBay 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.
ย 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 lbfยทft (475 Nยทm) 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.
ย 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 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 axial mounted caliper shown in Fig. 2.
  1. Align each caliper/carriereBay assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carriereBay assembly using new caliper mounting bolts.
  2. Tighten the carriereBay mounting bolts in two steps as follows.
    • Start on one side of the caliper and tighten all of the bolts 45ยฑ5 lbfยทft (61ยฑ7 Nยทm). Then tighten the bolts on the other side of the caliper 45ยฑ5 lbfยทft (61ยฑ7 Nยทm). See Fig. 3.
    • Repeat this process, increasing the torque value to 375ยฑ25 lbfยทft (508ยฑ34 Nยทm). 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.
ย 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 Axial Caliper/CarriereBay 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 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.
ย 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 lbfยทft (475 Nยทm) 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.
ย 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 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 assembly with the rotor, pushing the caliper against the shelf on the torque plate,then install the caliper/carriereBay 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 assembly.
  2. Tighten the M20 X 2.5 carriereBay mounting bolts as follows. See Fig. 3.
    • Start on one side of the caliper and tighten all three bolts 40ยฑ20 lbfยทft (54ยฑ27 Nยทm), 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 40ยฑ20 lbfยทft (54ยฑ27 Nยทm), beginning with the inner-most bolt and moving to the outermost bolt.
    • Repeat this process, increasing the torque value to 375ยฑ25 lbfยทft (508ยฑ34 Nยทm). 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 oโ€™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 โ€œfinalโ€ 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.
ย 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.
 

2 Affected Products

Vehicles

NEWMARESSEX2019
NEWMARMOUNTAIN AIRE2019

 

5 Associated Documents

Defect Notice 573 Report

RCLRPT-19V384-3847.PDF 213.236KB

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Recall Acknowledgement

RCAK-19V384-9429.pdf 244.78KB

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Recall Quarterly Report #3, 2019-4

RCLQRT-19V384-2638.PDF 211.321KB

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Recall Quarterly Report #1, 2019-2

RCLQRT-19V384-1921.PDF 211.14KB

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Recall Quarterly Report #2, 2019-3

RCLQRT-19V384-8328.PDF 211.237KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V384&docType=RCL

 

NHTSA ID Number: 10161602

Manufacturer Communication Number: 19V 384

Summary

Daimler Trucks North America LLC has decided that a defect, which relates to motor vehicle safety, exists in specific motorhomes built on Freightliner chassis (NHTSA # 18V 367). In response, Newmar is releasing NHTSA # 19V 384. On certain motorhomes, the brake caliper mounting bolts may be incorrectly torqued. This could result in caliper bolts loosening.

RSB 545 NHTSA #19V 384
Jun. 19, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10161602
https://static.nhtsa.gov/odi/tsbs/2019/MC-10161602-0001.pdf
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SaleBestseller No. 9
VANPO 1/4-inch Drive Click Torque Wrench, 20-240 in. lb/2.3-27.1 Nm, Inch Pound Torque Wrench Set with 1/4' to 3/8' Adapter, 10cm Extension Bar, Small Bike Torque Wrench for MTB, Bicycle Maintenance
VANPO 1/4-inch Drive Click Torque Wrench, 20-240 in. lb/2.3-27.1 Nm, Inch Pound Torque Wrench Set with 1/4" to 3/8" Adapter, 10cm Extension Bar, Small Bike Torque Wrench for MTB, Bicycle Maintenance
  • ใ€High Precision & Easy Readingใ€‘With a dual-range scale of 20-240 in.lb/2.3-27.1 Nm, this inch pound torque wrench provides quick and precise readings, ideal for precision tasks in electronics, bicycles, and light machinery requiring lower torque levels.
  • ใ€ "Click" Typeใ€‘The 'Click' Type design of torque wrench produces a distinct sound or sensation to indicate when the fastener is properly tightened. When using the 1/4 torque wrench, turn it slowly, steadily, and smoothly, stopping when you hear or feel the click.
  • ใ€Durable Constructionใ€‘The aluminum shaft of this bike torque wrench offers superior fatigue resistance for higher and more precise usage compared to traditional materials. It also features a high-quality steel spring and chromium-molybdenum steel handle for rust prevention, ensuring durability and a longer lifespan.
  • ใ€Easy Torque Settingใ€‘To set the torque value, pull down and hold the locking knob, then adjust to the desired value. Release the knob to lock the torque setting. When not in use, set the torque key to the minimum value to maintain the bicycle torque wrench.
  • ใ€Convenient Storage & Versatile Useใ€‘This torque wrench set comes in a sturdy plastic shell storage box for convenient storage and organization. It is suitable for repairing various parts of a bicycle, including bolts, nuts, threaded components, handlebars, frames, brakes, and derailleurs. Additionally, it is backed by a 24-month warranty, with customer support available for any assistance needed.
$24.98 −$2.50 $22.48 Amazon Prime
Buy on Amazon Price incl. tax, excl. shipping
Bestseller No. 10
SUZUME 3PCS Torque Wrench Set 72 Teeth Dual-Direction Adjustable Torque Wrench Dual-Scales 1/4 & 3/8 & 1/2-Inch ยฑ3% Accuracy Click Torque Wrenches for Bicycle, Motorcycle, Car,Maintenance
SUZUME 3PCS Torque Wrench Set 72 Teeth Dual-Direction Adjustable Torque Wrench Dual-Scales 1/4 & 3/8 & 1/2-Inch ยฑ3% Accuracy Click Torque Wrenches for Bicycle, Motorcycle, Car,Maintenance
  • [๐Œ๐€๐“๐„๐‘๐ˆ๐€๐‹] SUZUME torque wrenches are made of CR-V steel to ensure the durability of the torque wrench. The surface is also chrome-plated, which not only improves corrosion and wear resistance, but also gives the torque wrench set automotive a mirror-like luster, adding a touch of eye-catching beauty. For the handle, we chose a lightweight aluminum alloy, whose low-density characteristics greatly reduce the overall weight of the tool, making it easier to operate.
  • [๐‡๐ˆ๐†๐‡ ๐€๐‚๐‚๐”๐‘๐€๐‚๐˜]The SUZUME 3PCS torque wrench set, covering torque wrench 1/2 drive,torque wrench 3/8 drive and 1/4 torque wrench, is each a commitment to superior workmanship. After rigorous fatigue testing, this torque wrench kit can withstand more than 10,000 repeated uses and still maintain an incredible ยฑ3% accuracy, which means you can use them with confidence and without worrying about re-calibration.
  • [๐‹๐จ๐ฎ๐ ๐‚๐ฅ๐ข๐œ๐ค] SUZUME torquimetro are designed with a bi-directional ratchet head that makes it easy to apply precise torque, whether you operate the wrench clockwise or counterclockwise. When your operation reaches the preset torque value, the wrench will immediately emit a clear "click" sound, accompanied by a vibration, to ensure that you can sense and stop the operation at the first time, avoiding damage to bolts, nuts and even torque wrench' due to excessive application of force.
  • [๐ƒ๐ฎ๐š๐ฅ-๐’๐œ๐š๐ฅ๐ž๐ฌ] precision at a glance! SUZUME strives for perfection in every detail of every product. Every click torque wrench is equipped with a clearly visible torque scale that makes setting and reading torque values effortless. We use laser printing technology to ensure the durability of these scales, so you don't have to worry about the values becoming blurred by wear and tear, even under frequent use over a long period of time.
  • [๐’๐ž๐ซ๐ฏ๐ข๐œ๐ž]We understand that superior products and service are the key to earning your trust. That's why SUZUME products are backed by a comprehensive aftermarket service, our commitment to quality and your peace of mind. Our mission is very clear - 'Your Reliable Tool Partner' Our team will respond promptly to any questions you have and resolve your queries and problems quickly.
$86.89 Amazon Prime
Buy on Amazon Price incl. tax, excl. shipping

Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API

 

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