FL845 – Insufficiently Tightened Brake Caliper Bolts – 2019-2020 Thomas Built Saf-T-Liner HDX, EFX, & C2 School Buses

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March 3, 2020 NHTSA CAMPAIGN NUMBER: 20V126000

Insufficiently Tightened Brake Caliper Bolts

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

 

NHTSA Campaign Number: 20V126

Manufacturer Daimler TruckseBay North America LLC

Components SERVICE BRAKES, AIR

Potential Number of Units Affected 618

 

Summary

Daimler TruckseBay North America LLC (DTNA) is recalling certain 2019-2020 Thomas Built Saf-T-Liner HDX, EFX, and C2 school buses equipped with air disc brakes. The brake caliper mounting bolts may have been insufficiently tightened.

 

Remedy

DTNA will notify owners, and dealers will inspect and repair the vehicles, free of charge. The recall began May 2, 2020. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-845.

 

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

April 2020
FL845A-X
NHTSA #20V-127 (Non-School Bus)
NHTSA #20V-126 (School Bus)
Transport Canada #2020-086 (Non-School Bus)
Transport Canada #2020-085 (School Bus)

Subject: Brake Caliper Mounting Bolts

Models Affected: Specific FreightlinereBay 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; FreightlinereBay Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-TLiner C2, EFX, and HDX buses manufactured September 4,2018, through March 29 2019, 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., FreightlinereBay Custom Chassis Corporation, and Thomas Built Buses, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.

There are approximately 3,413 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. Each group in the recall may 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 FL845, 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 FL845

Campaign NumberVehicle Type / Population Qty.Part NumberPart DescriptionQty. per Caliper
FL845A Front & Rear Axle BendixeBay Axial CaliperTruck

1,063

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845B Front Axle BendixeBay Axial CaliperTruck

77

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845C Front & Rear Axle BendixeBay Radial CaliperTruck

7

23-13315-110SCRW HX,SCKTHD,M16-2X110,12.96 ea
FL845D Front Axle BendixeBay Radial CaliperTruck

1

23-13315-110SCRW HX,SCKTHD,M16-2X110,12.96 ea
FL845E Front Axle BendixeBay Radial CaliperTruck

98

23-13315-110SCRW HX,SCKTHD,M16-2X110,12.96 ea
FL845E Rear Axle BendixeBay Axial Caliper23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845F Front & Rear Axle Wabco Radial CaliperTruck

5

23-13843-070SCREW-CAP,SKT HD,M20X1.5X706 ea
FL845G Front Axle Wabco Radial CaliperTruck

1

23-13843-070SCREW-CAP,SKT HD,M20X1.5X706 ea
FL845H Front Axle Wabco Radial CaliperTruck

17

23-13843-070SCREW-CAP,SKT HD,M20X1.5X706 ea
FL845H Rear Axle Wabco Axial Caliper23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845I Front & Rear Axle Wabco Axial CaliperTruck

207

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845J Front Axle Wabco Axial CaliperTruck

15

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845K Front & Rear Axle MeritoreBay Axial CaliperTruck

480

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845L Front Axle MeritoreBay Axial CaliperTruck

22

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845M Front & Rear Axle MeritoreBay H Axial CaliperTruck

105

23-14285-055BOLT-HEX,PC10.9,PO,M20X1.5X556 ea
FL845N Front Axle MeritoreBay Radial CaliperTruck

8

TDA 41X1801CAPSCREW M204 ea
FL845O Front Axle MeritoreBay Radial CaliperTruck

52

TDA 41X1801CAPSCREW M204 ea
FL845O Rear Axle MeritoreBay Axial Caliper23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845P Front & Rear Axle BendixeBay Axial CaliperShuttle Bus

17

23-09114-004 N210931 020001WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20X60,10.9,P/O

6 ea
23-09114-004

23-12893-060

WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20,10.9,ZN,YL

FL845Q Front Axle BendixeBay Axial CaliperRV & Shuttle Bus

569

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845R Rear Axle BendixeBay Axial CaliperRV

66

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
23-12893-060SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845S Front & Rear Axle BendixeBay Radial CaliperShuttle Bus

5

23-13315-110SCRW HX,SCKTHD,M16-2X110,12.96 ea
FL845T Front & Rear Axle BendixeBay Axial CaliperSchool Bus

169

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845U Front & Rear Axle BendixeBay Radial CaliperSchool Bus

416

23-13315-110SCRW HX,SCKTHD,M16-2X110,12.96 ea
FL845V Front Axle BendixeBay Axial CaliperRV

8

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
N210931 020001SCREW-CAP,HEX,M20X60,10.9,P/O
FL845W Front & Rear Axle BendixeBay Axial CaliperRV

4

23-09114-004 N210931 020001WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20X60,10.9,P/O

6 ea
23-09114-004

23-12893-060

WASHER-HRDN,0.81X1.47X.177,ZN

SCREW-CAP,HEX,M20,10.9,ZN,YL

FL845X Rear Axle BendixeBay Axial CaliperRV

1

23-09114-004WASHER-HRDN,0.81X1.47X.177,ZN6 ea
23-12893-060SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845A-XAllWAR260BLANK COMPLETION STICKER1 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 2 – Labor Allowance

Campaign Number/GroupProcedureTime Allowed (hours)SRT CodeCorrective Action
FL845

B,D,G,J,L & N

(Truck)

Inspect caliper bolts, front axle1.0996-R088A06-Inspect
Torque caliper bolts, front axle996-R088B12-Repair

Recall/Campaign

FL845

A,C,E,F,H,I,K,

M,O,S & U

(Truck)

Inspect caliper bolts, front and rear axle2.0996-R088C06-Inspect
Torque caliper bolts, front and rear axle996-R088D12-Repair

Recall/Campaign

FL845A-O

(Truck)

Inspect caliper bolts, each additional rear axle1.1996-R088E06-Inspect
Torque caliper bolts, each additional rear axle996-R088F12-Repair

Recall/Campaign

FL845Q & V

(RV/Bus)

Inspect caliper bolts, front axle, with radial runout check1.2996-R088G06-Inspect
Torque caliper bolts, front axle, with radial runout check996-R088H12-Repair

Recall/Campaign

FL845R & X

(RV/Bus)

Inspect caliper bolts, rear axle, with radial runout check1.2996-R088I06-Inspect
Torque caliper bolts, rear axle, with radial runout check996-R088J12-Repair

Recall/Campaign

FL845 P, T & W

(RV/Bus)

Inspect caliper bolts, front and rear axle, with radial runout check2.4996-R088K06-Inspect
Torque caliper bolts, front and rear axle, with radial runout check996-R088L12-Repair

Recall/Campaign

FL845A-X (Truck/RV/Bus)Replace caliper bolts, one caliper

(claim this SRT once for each caliper requiring new bolts, up to 6 times)

0.5996-R088G12-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. FL845-A, FL845-B, etc.).
  • In the Primary Failed Part Number field, enter 25-FL845-000.
  • In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table.
  • Vehicles in FL845P, Q, R, V, W, & X are required to record the “final” radial runout , note the wheel location, and include the information in the claim story of the recall claim.
  • 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
  • The VMRS Component Code is F99-999-005 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 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 North America LLC (DTNA), on behalf of its FreightlinereBay Trucks Division and wholly owned subsidiaries, Western StareBay Truck Sales, Inc., FreightlinereBay Custom Chassis Corporation, and Thomas Built Buses, 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 4700 and 5700 vehicles; FreightlinereBay Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-T Liner C2, EFX, and HDX buses manufactured September 4, 2018, through March 29, 2019, 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 “Contact,” scroll down to “Find a Dealer,” and select the appropriate brand. The Recall will take up to four 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: Brake Caliper Mounting Bolts

Models Affected: Specific FreightlinereBay 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; FreightlinereBay Custom Chassis S2C, S2G, XB, and XC chassis; and Thomas Built Buses Saf-TLiner C2, EFX, and HDX buses manufactured September 4,2018, through March 29 2019, 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. See Table 3 to determine the type of caliper installed on the vehicle and the page number for the instructions.
Caliper TypeCampaign Group Letter and Axle PositionPage Number
BendixeBay AxialFL845A (Front/Rear)

FL845B (Front)

FL845E (Rear)

9
BendixeBay RadialFL845C (Front/Rear)

FL845D (Front)

FL845E (Front)

FL845S (Front/Rear)

FL845U (Front/Rear)

14
MeritoreBay AxialFL845K (Front/Rear)

FL845L (Front)

FL845M (Front/Rear) FL845O (Rear)

18
MeritoreBay RadialFL845N (Front) FL845O (Front)20
WABCO Maxxus AxialFL845H (Rear)

FL845I (Front/Rear)

FL845J (Front)

23
WABCO Maxxus RadialFL845F (Front & Rear)

FL845G (Front) FL845H (Front)

25
BendixeBay Axial (with radial runout)FL845P (Front/Rear)

FL845Q (Front)

FL845R (Rear)

FL845T (Front/Rear) FL845V (Front)

FL845W (Front/Rear)

FL845X (Rear)

28

 

Table 3, Caliper Type and Instruction Page Number

 

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 FL845 (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 FL845, 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, go 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 Fig. 1. for a 47 in (119 cm) long wrench. see Table 4. for torque specifications.

 

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 ViewExtension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0350 (475)296 (401)
45°

11/28/2016             f422614

45310 (420)
60°

11/06/2018             f422668

60320 (434)
90°

11/28/2016             f422615

90350 (475)
120°

11/06/2018             f422669

120386 (523)
135°

11/28/2016             f422616

135402 (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 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.
  2. Tighten the carriereBay 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 outermost bolt. See 3 for the left-front caliper and Fig. 4 for the right-front caliper.
    • 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.

 

10/01/2018 f422664
1. Caliper/CarriereBay Assembly (showing service actuator)
2. Mounting Bolts and Washers (qty. 6)
3. Anchor Plate/Torque Plate

Fig. 2, BendixeBay Axial Mounted Caliper

 

03/26/2020 f422665

Fig. 3, Tightening Pattern, Left-Front BendixeBay AxialCaliper

 

03/26/2020 f422665a

Fig. 4, Tightening Pattern, Right-Front BendixeBay Axial Caliper

 

BendixeBay/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle ViewExtension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0375 (508)317 (430)
45°

11/28/2016             f422614

45332 (450)
60°

11/06/2018             f422668

60343 (465)
90°

11/28/2016             f422615

90375 (508)
120°

11/06/2018             f422669

120413 (560)
135°

11/28/2016             f422616

135431 (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.

 

 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, FL845, 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 FL845 (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 FL845, 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, go 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 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. 5.

 

04/01/2020 f422704
NOTE: Washers are not used on radial mounted assemblies.
1. Caliper Mounting Bolts
2. Large Caliper Sliding Pin

Fig. 5, 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. 6.

NOTE: A slide-ability test must be performed in the green zone (marked as ’A’), shown in Fig. 7, 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
  • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

04/21/2020 f422705
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View
1. Large Caliper Sliding Pin

Fig. 6, Tightening Pattern, BendixeBay Radial Mounted Caliper

 

NOTICE

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.

 

05/21/2019 f422674
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. 7, 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, FL845, 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 FL845 (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 FL845, 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, go 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 Fig. 1. 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 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 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 Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle ViewExtension Angle
(degrees)
Target Torque
[lbf·ft (N·m)]
Tool Setting
[lbf·ft (N·m)]

11/28/2016             f422613

0400 (542)338 (458)
45°

11/28/2016             f422614

45354 (480)
60°

11/06/2018             f422668

60366 (496)
90°

11/28/2016             f422615

90400 (542)
120°

11/06/2018             f422669

120441 (598)
135°

11/28/2016             f422616

135460 (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.
 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, FL845, 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 Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (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 FL845, 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, go 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 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. 8 and Fig. 9.

 

07/30/2018 f422654
1. Caliper Mounting Bolts

Fig. 8, MeritoreBay 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. 9
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
    • Perform a final tightening spec of 400±50 lbf·ft (542±68 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

07/30/2018 f422655
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View B. Right Hand, Bottom View

Fig. 9, Tightening Pattern, MeritoreBay Caliper

 

NOTICE

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, FL845, 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 FL845 (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 FL845, 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, go 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 Fig. 1. for a 47 in (119 cm) long wrench. 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 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 Bendix 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 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, FL845, 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 Radial Mounted Calipers

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (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 FL845, 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 273 lbf·ft (370 N·m) and tighten the caliper mounting bolts. If they do not turn, go to step 13. If they turn, go 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/carrier 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/carrier assembly with the rotor by pushing the fixed pin side of the caliper against the shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts. See Fig. 10 and Fig. 11.

07/30/2018 f422656
1. Carrier Mounting Bolts

Fig. 10, Wabco Maxxus Radial Mounted Calipers

 

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 carrier mounting bolts in two steps, using the pattern shown in Fig. 11.
    • 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.
    • Perform a final tightening spec of 295±22 lbf·ft (400±30 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. Repeat the torque pattern again, if that does not resolve the binding issue, replace the caliper.

 

07/30/2018 f422657
Tighten the fasteners in the order indicated.
A. Left Hand, Bottom View
B. Right Hand, Bottom View

Fig. 11, Wabco Maxxus Radial Mounted Caliper Tightening Pattern

 

NOTICE

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.
  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, FL845, on a completion sticker(Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

Bendix Axial Caliper/Carrier 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.

  1. Check the base label (Form WAR259) for a completion sticker for FL845 (Form WAR260) indicating this work has been completed. The base label is usually located on the front wall under the dash on RVs and over the drivers window on buses. If a sticker is present for FL845, 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 Fig. 12. Write down the measurement for later use to avoid vibration complaints.
  3. Mark the two studs closest to the valve stem as shown in Fig. 13, for proper wheel assembly location when reinstalling the wheel assembly on the hub.

 

07/30/2018 f400373a
1. Radial Runout

Fig. 12, Radial Runout Check for Tires

 

07/318/2018 f400390a
1. Valve Stem

Fig. 13, 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. 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 the caliper bolts and washers (if installed) and discard.

IMPORTANT: The caliper/carrier 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/carrier assembly with the rotor, pushing the caliper against the shelf on the torque plate,then install the caliper/carrier assembly using new caliper mounting bolts and washers. See Table 1 for parts information. See Fig. 2 for an example of the front caliper/carrier assembly.
  2. Tighten the M20 X 2.5 carrier 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 wheel locations 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, FL845, on a red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed.

 


Daimler TruckseBay
North America LLC

 

July 2020
FL845
Recall Correction Notice
NHTSA #20V-127

 

IMPORTANT SAFETY RECALL

See enclosed VIN list

Subject: Brake Caliper Mounting Bolts

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

In April of this year, a letter was sent informing you that your vehicle was included in recall FL845, Brake Caliper Mounting Bolts.  Please note the letter was sent in error.

 

Upon further investigation, it was confirmed your vehicle has documentation of correct caliper torque.  Your vehicle does not require this recall.

 

We apologize for any inconvenience this may have caused. If you have questions or require further information, 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.

 

WARRANTY CAMPAIGNS DEPARTMENT

 

Enclosure

 



6 Affected Products

Vehicles

MAKEMODELYEAR
THOMAS BUILT BUSESSAF-T-LINER C22019-2020
THOMAS BUILT BUSESSAF-T-LINER EFX2019-2020
THOMAS BUILT BUSESSAF-T-LINER HDX2019-2020

 


14 Associated Documents

Recall 573 Report- Amendment 1

RCLRPT-20V126-1843.PDF 214.102KB

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Recall Acknowledgement

RCAK-20V126-4579.pdf 244.774KB

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Defect Notice 573 Report

RCLRPT-20V126-8638.PDF 213.778KB

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Miscellaneous Document- Defect Information Report

RMISC-20V126-6784.pdf 447.757KB

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Manufacturer Notices(to Dealers,etc)

RCMN-20V126-7769.pdf 1696.798KB

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Miscellaneous Document- 573 Defect Information Report

RMISC-20V126-6019.pdf 884.323KB

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Remedy Instructions and TSB

RCRIT-20V126-1189.pdf 1002.955KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V126-3116.pdf 41.626KB

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Remedy Instructions and TSB

RCRIT-20V126-5767.pdf 999.035KB

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Remedy Instructions and TSB

RCRIT-20V126-3528.pdf 1014.734KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V126-8079.pdf 56.299KB

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V126-2502.PDF 211.342KB

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V126-4283.PDF 211.151KB

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V126-7618.PDF 211.253KB

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Latest Recalls Documents

 


 

Bestseller No. 1
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. 2
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.
SaleBestseller No. 3
SUERCUP 3/8-Inch Drive Click Torque Wrench - 5-45 Ft-Lb/6.8-61Nm Torque Wrench, Dual-Direction Adjustable 72 Tooth Click Torque Wrench for Bike, Motorcycle and Car Repair
  • High Precision and Quick Reading: 3/8 torque wrench has high contrast and dual range scale( 5-45 Ft-Lb/6.8-61 Nm),making it clear and easy to read. We have professional torque wrench production technology, and after 20000 tests, the calibration error range of the torque wrench is around 3%, making it an essential helper for you
  • Safe and Reliable Operation: Equipped with a bidirectional drive ratchet head, torque can be measured clockwise or counterclockwise. When the set torque value is reached, a "click" sound will remind you to stop applying force to prevent damage to the item due to excessive torque
  • Good Quality and Durable Material: Made of hardened chromium vanadium steel alloy (Cr-V). At the same time, the bottom buckle tail plug adopts a red anodizing process to improve the product's oxidation resistance during use and enhance surface wear resistance. 72 tooth ratchet head, made of chromium molybdenum steel.We use the quality materials which are resist corrosion and are durable
  • Quick Torque Setting: Simple and fast torque setting, pull down the locking knob and hold it down to rotate to the torque you need. Release the hand and the locking knob will automatically rebound to lock the torque value. And the designer referred to the appearance of the flashlight handle and designed a non slip and labor-saving knurled handle, making it more comfortable and easy to hold when using
  • Easy to Store and Widely Use: You will receive the 3/8-inch drive click torque wrench with a sturdy plastic shell storage box, which is very delicate and durable. Torque wrench is suitable nuts and bolts on various occasions, such as bike, motorcycle, car spark, and torque wrench is suitable for repairing cars and motorcycles, which are essential maintenance tools for car owners
SaleBestseller No. 4
CRAFTSMAN Torque Wrench, 3/8" Drive (CMMT99433)
  • Portability: durable case for portability or storage
  • Added comfort: bi-material handle for comfort and grip
  • Hassle free use: locking feature adjusts quick and easily for hassle free use
  • Quick identification: scales stamped into housing showing inch and metric torque setting
  • Meets or exceeds ASME specifications
SaleBestseller No. 5
TEKTON 3/8 Inch Drive Micrometer Torque Wrench (10-80 ft.-lb.) | 24330
  • Includes 1-pc. 3/8 in. drive torque wrench; Storage case; Product manual with torque conversion chart
  • Wrench emits a click that can be heard and felt when the preset value is reached
  • Permanently marked, high-contrast dual-range scale is easy to read, even in low light
  • Reversible ratchet head drives in both directions and measures torque in clockwise direction
  • Durable all-steel construction has no plastic parts to break or wear out
SaleBestseller No. 6
VANPO 1/4 3/8 1/2-inch Drive Click Torque Wrench, 3Pcs Torque Wrench Set 20-240 in.lb, 5-45 ft.lb, 20-160 ft.lb, Dual-Direction Adjustable 72-Tooth Torque Wrench for Bike, Moto, Car Maintenance
  • 3Pcs Torque Wrench Set: The calibration error range is around 3%, each torque wrench has a calibration certificate. The 3-in-1 torque wrench set can meet your different needs. Including 1/4 inch 20-240 in.lb, 3/8 inch 5-45 ft.lb, 1/2 inch 20-160 ft.lb.
  • Safe and Reliable: When the 1/2 torque wrench reaches the preset torque value, it makes a clear "click" sound, accompanied by an obvious hand vibration that reminds you no longer to apply force, prevent damage caused. 72-tooth reversible ratchet head, it can be used both clockwise and counterclockwise directions.
  • Quick Release Button: This 3/8 torque wrench has a quick release button with which accessories can easily be installed and removed, the accessories can grip and is not easy to fall down. It is more convenient to use. The torque wrench is made of CR-MO with a higher hardness.
  • Easy to Set: First pull down the locking knob and hold it down and then start setting the desired torque value. Release the hand and the locking knob will automatically rebound to lock the torque value. If you do not use, please set the torque key to the minimal torque value.
  • Widely Use: The torque wrenches can satisfy you in bicycle, motorcycle, car, truck and wheel screws, wheel nuts and in the device installation, electrical engineering, etc. We insist on bringing customers a good shopping experience.
SaleBestseller No. 7
Hairich 1/2 Inch Drive Click Torque Wrench, Dual-direction Torque Wrench 10-170.0ft.lb/13.60-230.5Nm, 72-tooth Torque Wrenches with Dual Range Scales, ±3% High Precision Torque Wrench For Bike
  • ±3% HIGH PRECISION AND COOL APPEARANCE: 1/2 inch drive torque wrench (10-170ft.-lb/13.6-230.5Nm)has a calibration error range of ±3%, high precision, and comes with a corresponding serial number, which is easy to trace the original data, and you can use it with confidence.Hairich torque wrench not only has superior quality but also has a superior appearance. The classic combination of black and red is fashionable and textured, allowing you to enjoy a visual feast during use.
  • PREMIUM MATERIAL AND DURABLE: Experience the ultimate durability and antiskid with the torque wrench. The main body of Hairich torque wrench set is made of chrome vanadium steel alloy, which is more strong and more durable. The head of the inch-pound torque wrench adopts a ratchet design with a reversing device to improve work efficiency. The square knurled handle is made of aluminum titanium alloy, which is ergonomic and comfortable to hold for long-time use.
  • DUAL SCALE AND QUICK SETTING: Laser Printed by dual-range(ft-lb and Nm). Our professional torque wrench is easy to read and provides direct unit conversion, When the set torque value is reached, the torque wrench will make an audible and felt click to remind you to stop applying force. Pull down the lock knob and hold it until the torque setting is completed. Release the hand, and the lock knob will automatically rebound back to lock the value.
  • ERGONOMIC DESIGN AND POWERFUL: Every design of our industrial torque wrench conforms to ergonomic, easy to handle.72-tooth ratchet, 5° ratcheting arc head, a quick-release button for easy loading and unloading, and an aluminum non-slip handle for excellent grip and control. A recent research review that, 72-tooth ratchets are very professional tooth ratchets, you just only rotate 5 degrees to finish it. Not easy to slip and wear, can be used in small spaces, and is more durable and powerful.
  • EASY OPERATION AND SAFETY: Thanks to its bidirectional drive ratchet head, our torque wrench can be measured both clockwise and counterclockwise. When the set torque value is reached, a "click" sound will remind you to stop applying force to prevent damage to the item due to excessive torque. Notice: At low Nm settings under 5 Nm the "click" sound can be too light to hear.
Bestseller No. 8
SuZhi 1/2 & 3/8-Inch Drive Click Torque Wrench 10-160FT-LB/13.6-217.1Nm, For Car Wheels(usually 88 ft.lb) & Engine, Transmission System, Spark Plug, Oil change.(11 sizes to choose)
  • Please contact us on Amazon Seller Support, we can give you 24h online after-sale service if you have any problem. We hope to help you solve and make you satisfied.
  • !!!Attention!!!: 1,Torque wrench cannot be used to remove the nut, because the sudden torque for removing is much higher. 2,Keep the set value proper, avoid to set a small value but actual needs a bigger value, this can break the wrench 3, When not in use, always keep torque at the lowest setting. 2,when in use,keep the direction select in leftmost or rightmost position, not middle. 3,use just proper size socket and right direction button in case of skipping. 4,keep all the package well in case of returning in the future. 5,do not use excessive force during use to avoid affecting the accuracy of torque and even damaging the wrench.
  • 【Easy to use】: Our torque wrench 1/2 feature high contrast and dual unit measurement for easy reading and setting of the required torque.Turn the bottom knob to make it in unlocked state, then turn the handle to set the torque, and finally lock the bottom knob.Adjusting the head paddle allows the 1/2 inch torque wrench to be used in both directions.
  • 【Safe and reliable】: When the set torque value is reached, the automotive torque wrench will emits "Click" sound to remind you to stop applying force to prevent over torque damage to your items. Also the knurled handle provides non-slip operation.
  • 【Practicality of accessories】: 1/2 inch Torque wrench set with 5-Inch extension bar and 1/2" drive to 3/8" drive adapter,which can help to take the screw or nut out in deep space.Use this dual direction torque wrench can easy to deal with car or bike repairing problem.
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
  • 【High Precision & Easy Reading】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.
  • 【 "Click" Type】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.
  • 【Durable Construction】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.
  • 【Easy Torque Setting】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.
  • 【Convenient Storage & Versatile Use】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.
Bestseller No. 10
SUZUME 3PCS Torque Wrench Set 72 Teeth Dual-Direction Adjustable Torque Wrench Dual-Scales 1/4 & 3/8 & 1/2-Inch ±3% Accuracy Click Torque Wrenches for Bicycle, Motorcycle, Car,Maintenance
  • [𝐌𝐀𝐓𝐄𝐑𝐈𝐀𝐋] 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.
  • [𝐇𝐈𝐆𝐇 𝐀𝐂𝐂𝐔𝐑𝐀𝐂𝐘]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 ±3% accuracy, which means you can use them with confidence and without worrying about re-calibration.
  • [𝐋𝐨𝐮𝐝 𝐂𝐥𝐢𝐜𝐤] 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.
  • [𝐃𝐮𝐚𝐥-𝐒𝐜𝐚𝐥𝐞𝐬] 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.
  • [𝐒𝐞𝐫𝐯𝐢𝐜𝐞]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.

Last update on 2025-04-15 / Affiliate links / Images from Amazon Product Advertising API


 

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