March 20, 2020 NHTSA CAMPAIGN NUMBER: 20V167000

Insufficiently Tightened Brake Caliper Bolts

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

 

NHTSA Campaign Number: 20V167

Manufacturer Thor Motor Coach

Components SERVICE BRAKES, AIR

Potential Number of Units Affected 85

 

Summary

Thor Motor Coach (TMC) is recalling certain 2019-2020 Aria 3401, 3601, 3901, 3902, and Venetian G36, J40, L40, M37, R40, and S40 motorhomes built on DTNA chassis. The brake caliper mounting bolts may have been insufficiently tightened.

 

Remedy

DTNA will notify owners, and DTNA dealers will inspect and repair the vehicles, free of charge. The recall began on May 20, 2020. Owners may contact DTNA customer service at 1-800-547-0712 or TMC customer service at 1-877-855-2867.

 

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.

 

---

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 Freightliner 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner 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 Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division and wholly owned subsidiaries, Western Star Truck Sales, Inc., Freightliner 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 Number	Vehicle Type / Population Qty.	Part Number	Part Description	Qty. per Caliper
FL845A Front & Rear Axle Bendix Axial Caliper	Truck 1,063	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845B Front Axle Bendix Axial Caliper	Truck 77	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845C Front & Rear Axle Bendix Radial Caliper	Truck 7	23-13315-110	SCRW HX,SCKTHD,M16-2X110,12.9	6 ea
FL845D Front Axle Bendix Radial Caliper	Truck 1	23-13315-110	SCRW HX,SCKTHD,M16-2X110,12.9	6 ea
FL845E Front Axle Bendix Radial Caliper	Truck 98	23-13315-110	SCRW HX,SCKTHD,M16-2X110,12.9	6 ea
FL845E Rear Axle Bendix Axial Caliper		23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845F Front & Rear Axle Wabco Radial Caliper	Truck 5	23-13843-070	SCREW-CAP,SKT HD,M20X1.5X70	6 ea
FL845G Front Axle Wabco Radial Caliper	Truck 1	23-13843-070	SCREW-CAP,SKT HD,M20X1.5X70	6 ea
FL845H Front Axle Wabco Radial Caliper	Truck 17	23-13843-070	SCREW-CAP,SKT HD,M20X1.5X70	6 ea
FL845H Rear Axle Wabco Axial Caliper		23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845I Front & Rear Axle Wabco Axial Caliper	Truck 207	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845J Front Axle Wabco Axial Caliper	Truck 15	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845K Front & Rear Axle Meritor Axial Caliper	Truck 480	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845L Front Axle Meritor Axial Caliper	Truck 22	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845M Front & Rear Axle Meritor H Axial Caliper	Truck 105	23-14285-055	BOLT-HEX,PC10.9,PO,M20X1.5X55	6 ea
FL845N Front Axle Meritor Radial Caliper	Truck 8	TDA 41X1801	CAPSCREW M20	4 ea
FL845O Front Axle Meritor Radial Caliper	Truck 52	TDA 41X1801	CAPSCREW M20	4 ea
FL845O Rear Axle Meritor Axial Caliper		23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845P Front & Rear Axle Bendix Axial Caliper	Shuttle Bus 17	23-09114-004 N210931 020001	WASHER-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 Bendix Axial Caliper	RV & Shuttle Bus 569	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845R Rear Axle Bendix Axial Caliper	RV 66	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		23-12893-060	SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845S Front & Rear Axle Bendix Radial Caliper	Shuttle Bus 5	23-13315-110	SCRW HX,SCKTHD,M16-2X110,12.9	6 ea
FL845T Front & Rear Axle Bendix Axial Caliper	School Bus 169	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845U Front & Rear Axle Bendix Radial Caliper	School Bus 416	23-13315-110	SCRW HX,SCKTHD,M16-2X110,12.9	6 ea
FL845V Front Axle Bendix Axial Caliper	RV 8	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		N210931 020001	SCREW-CAP,HEX,M20X60,10.9,P/O
FL845W Front & Rear Axle Bendix Axial Caliper	RV 4	23-09114-004 N210931 020001	WASHER-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 Bendix Axial Caliper	RV 1	23-09114-004	WASHER-HRDN,0.81X1.47X.177,ZN	6 ea
		23-12893-060	SCREW-CAP,HEX,M20,10.9,ZN,YL
FL845A-X	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 2 – Labor Allowance

Campaign Number/Group	Procedure	Time Allowed (hours)	SRT Code	Corrective Action
FL845 B,D,G,J,L & N (Truck)	Inspect caliper bolts, front axle	1.0	996-R088A	06-Inspect
	Torque caliper bolts, front axle		996-R088B	12-Repair Recall/Campaign
FL845 A,C,E,F,H,I,K, M,O,S & U (Truck)	Inspect caliper bolts, front and rear axle	2.0	996-R088C	06-Inspect
	Torque caliper bolts, front and rear axle		996-R088D	12-Repair Recall/Campaign
FL845A-O (Truck)	Inspect caliper bolts, each additional rear axle	1.1	996-R088E	06-Inspect
	Torque caliper bolts, each additional rear axle		996-R088F	12-Repair Recall/Campaign
FL845Q & V (RV/Bus)	Inspect caliper bolts, front axle, with radial runout check	1.2	996-R088G	06-Inspect
	Torque caliper bolts, front axle, with radial runout check		996-R088H	12-Repair Recall/Campaign
FL845R & X (RV/Bus)	Inspect caliper bolts, rear axle, with radial runout check	1.2	996-R088I	06-Inspect
	Torque caliper bolts, rear axle, with radial runout check		996-R088J	12-Repair Recall/Campaign
FL845 P, T & W (RV/Bus)	Inspect caliper bolts, front and rear axle, with radial runout check	2.4	996-R088K	06-Inspect
	Torque caliper bolts, front and rear axle, with radial runout check		996-R088L	12-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)	0.5	996-R088G	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. 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 International 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 Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division and wholly owned subsidiaries, Western Star Truck Sales, Inc., Freightliner Custom Chassis Corporation, and Thomas Built Buses, has decided that a defect that relates to motor vehicle safety exists on specific Freightliner 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner 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 Trucks 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 [email protected], or the Customer Assistance Center at (800) 385-4357 after normal business hours. If you are not able to have the defect remedied without charge and within a reasonable time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236 (TTY: 800-424-9153); or to https://www.safercar.gov. For the Notice to Canadian Customers: If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected], or the Customer Assistance Center at (800) 385-4357 after normal business hours.

We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety.

WARRANTY CAMPAIGNS DEPARTMENT

Enclosure

---

Reimbursement to Customers for Repairs

Performed Prior to Recall

If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.

Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Daimler Trucks 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 Trucks North America LLC dealer.

Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter.

 

Work Instructions

Subject: Brake Caliper Mounting Bolts

Models Affected: Specific Freightliner 108SD, 114SD, Argosy, Business Class M2, Cascadia, and Columbia vehicles; Western Star 4700 and 5700 vehicles; Freightliner 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 Type	Campaign Group Letter and Axle Position	Page Number
Bendix Axial	FL845A (Front/Rear) FL845B (Front) FL845E (Rear)	9
Bendix Radial	FL845C (Front/Rear) FL845D (Front) FL845E (Front) FL845S (Front/Rear) FL845U (Front/Rear)	14
Meritor Axial	FL845K (Front/Rear) FL845L (Front) FL845M (Front/Rear) FL845O (Rear)	18
Meritor Radial	FL845N (Front) FL845O (Front)	20
WABCO Maxxus Axial	FL845H (Rear) FL845I (Front/Rear) FL845J (Front)	23
WABCO Maxxus Radial	FL845F (Front & Rear) FL845G (Front) FL845H (Front)	25
Bendix 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/Carrier Assembly Inspection and Installation – Bendix 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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 View	Extension Angle (degrees)	Target Torque [lbf·ft (N·m)]	Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613	0	350 (475)	296 (401)
45° 11/28/2016             f422614	45		310 (420)
60° 11/06/2018             f422668	60		320 (434)
90° 11/28/2016             f422615	90		350 (475)
120° 11/06/2018             f422669	120		386 (523)
135° 11/28/2016             f422616	135		402 (545)

 

Table 4, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005

 

WARNING

When replacing brake pads, shoes, rotors, or drums, always replace components as an axle set.

• Always reline both sets of brakes on an axle at the same time.
• Always replace both rotors/drums on an axle at the same time.
• Always install the same type of linings/pads or drums/rotors on both axle ends of a single axle, and all four axle ends of a tandem axle, at the same time. Do not mix component types.

Failure to do so could cause uneven braking and loss of vehicle control, resulting in property damage, personal injury, or death.

6. 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.
7. Remove the brake pads.
8. 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.

9. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts. See Fig. 2.
10. Tighten the carrier 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/Carrier Assembly (showing service actuator)
2. Mounting Bolts and Washers (qty. 6)
3. Anchor Plate/Torque Plate

Fig. 2, Bendix Axial Mounted Caliper

 

03/26/2020 f422665

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

 

03/26/2020 f422665a

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

 

Bendix/Wabco Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View	Extension Angle (degrees)	Target Torque [lbf·ft (N·m)]	Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613	0	375 (508)	317 (430)
45° 11/28/2016             f422614	45		332 (450)
60° 11/06/2018             f422668	60		343 (465)
90° 11/28/2016             f422615	90		375 (508)
120° 11/06/2018             f422669	120		413 (560)
135° 11/28/2016             f422616	135		431 (584)

 

Table 5, Bendix/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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.

16. 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.
17. 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 – Bendix 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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.

6. 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.
7. Remove the brake pads.
8. 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.

9. 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. 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, Bendix 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.

10. Tighten the carrier 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, Bendix 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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. 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

 

14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.

16. 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.
17. 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 – Meritor 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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.

6. 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.
7. Remove the brake pads.
8. 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.

NOTE: The Meritor axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 2.

9. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts.
10. Tighten the carrier 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.

 

Meritor Installation with a 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005
Angle View	Extension Angle (degrees)	Target Torque [lbf·ft (N·m)]	Tool Setting [lbf·ft (N·m)]
0° 11/28/2016             f422613	0	400 (542)	338 (458)
45° 11/28/2016             f422614	45		354 (480)
60° 11/06/2018             f422668	60		366 (496)
90° 11/28/2016             f422615	90		400 (542)
120° 11/06/2018             f422669	120		441 (598)
135° 11/28/2016             f422616	135		460 (624)

 

Table 6, Meritor 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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.

16. 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.
17. 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 – Meritor 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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.

6. 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.
7. Remove the brake pads.
8. 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.

9. 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. 8 and Fig. 9.

 

07/30/2018 f422654
1. Caliper Mounting Bolts

Fig. 8, Meritor 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.

10. Tighten the carrier 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, Meritor 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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.

16. 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.
17. 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 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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.

6. 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.
7. Remove the brake pads.
8. 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.

NOTE: The Wabco axial mounted caliper is similar to the Bendix axial mounted caliper shown in Fig. 2.

9. Align each caliper/carrier assembly with the rotor by pushing the caliper against the shelf on the torque plate, then install the caliper/carrier assembly using new caliper mounting bolts.
10. Tighten the carrier 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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.
14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. Charge the air system and check for leaks.

 

WARNING

Do notoperate 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.

16. 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.
17. 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.

3. Raise the vehicle and support it on jack stands.
4. 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).

5. 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.

6. 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.
7. Remove the brake pads.
8. 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.

9. 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.

10. 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.

11. Install the brake pads. Provided it is in good condition, use the brake pad hardware removed earlier.
12. Back off the adjuster nut three clicks.
13. Install the wheel assemblies.

14. Raise the vehicle, remove the jack stands, then lower the vehicle.
15. 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.

16. 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.
17. 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.

3. Raise the vehicle and place jack stands under the frame rails to ensure the vehicle cannot drop.
4. 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.
5. 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. Stem

Fig. 13, Marking Wheel Studs

 

6. 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).

7. 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.

8. 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.
9. Remove the brake pads.
10. 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.

11. 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.
12. 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.

13. Install the brake pads. Provided it is good condition, use the brake pad hardware removed earlier.
14. Back off the adjuster nut three clicks.
15. Using the two studs marked earlier as a guide, install the wheel assembly. When correctly installed, a line drawn from the valve stem through the center of the wheel assembly should go between the two marked studs.
16. Using a tire runout gauge, measure and record the radial runout of the tire and wheel assembly. Mark the highest 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.
17. 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.
18. Raise the vehicle, remove the jack stands, then lower the vehicle.
19. 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.

20. 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.
21. 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.

 

---

RECREATIONAL VEHICLE
SAFETY RECALL NOTICESafety Recall: 20V-167
Safety Advisory: RC000186
May 2020

 

IMPORTANT SAFETY RECALL

This notice applies to your vehicle:  «VIN»

«Owner_name»
«Street»
«City», «State»  «Zip»

 

Dear «Owner_name»:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Thor Motor Coach (TMC) has decided that a safety defect exists in certain TMC motorhomes based upon notification by Daimler Trucks North America LLC (DTNA) that a defect which relates to motor vehicle safety exists in certain Freightliner chassis that were used to manufacture your TMC motorhome. DTNA was issued recall 20V-127 by the National Highway and Safety Administration (NHTSA) to remedy this defect. DTNA’s recall number is FL845. To assist DTNA and NHTSA in identifying the final vehicles manufactured, TMC is also conducting a safety recall.  We apologize for any inconvenience this action may cause you; however your safety and continued satisfaction are of the utmost importance to us.

Reason for this recall	It has been decided that certain TMC motorhomes subject to this recall campaign have insufficiently torqued caliper mounting bolts that may not provide adequate clamping force between the brake caliper and the brake anchor plate, potentially resulting in reduced brake effectiveness, which could increase the risk of a crash.
What we will do	TMC has provided your address and owner information to DTNA to assist them in contacting you and providing you with all of the details available to remedy your vehicle. DTNA will be handling the repair of your vehicle at an authorized Freightliner dealer.  This will be done for you, the owner. free of charge.
What we need you to do	You should have received or will be receiving a recall notice from DTNA regarding this recall and what you need to do to have your vehicle repaired.  If you have questions about this Recall, please contact the DTNA Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected]. For other concerns, you may contact the DTNA Customer Assistance Center at (800) 385-4357 or the TMC Warranty/Service Department at (877) 855-2867.

 

If after contacting DTNA or TMC Customer Service you are still not satisfied we have done our best to remedy this situation, you may also submit a written complaint to: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590. You may call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY:  1-800-424-9153; or go to https://www.safercar.gov.) Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Thank you for your attention and cooperation in this matter.                                                    

 

Sincerely,

Thor Motor Coach

 

Hanah Klodzinski
Recall Compliance Coordinator
cc:  National Highway Traffic Safety Administration (NHTSA)

 

---

IMPORTANT SAFETY RECALL

TMC# RC000186

«Dealer_name»
«Street»
«City», «State»  «Zip»

 

Dear Dealer:

This Safety Recall Notice is sent to you in accordance with the requirements of the United States National Traffic and Motor Vehicle Safety Act and The Canadian Motor Vehicle Safety Act and is important for your safety.  

Thor Motor Coach (TMC) has decided that a safety defect exists in certain TMC motorhomes based upon notification by Daimler Trucks North America LLC (DTNA) that a defect which relates to motor vehicle safety exists in certain Freightliner chassis that were used to manufacture your TMC motorhome. DTNA was issued recall 20V-127 by the National Highway and Safety Administration (NHTSA) to remedy this defect. DTNA’s recall number is FL845. To assist DTNA and NHTSA in identifying the final vehicles manufactured, TMC is also conducting a safety recall. 

It has been decided that certain TMC motorhomes subject to this recall campaign have insufficiently torqued caliper mounting bolts that may not provide adequate clamping force between the brake caliper and the brake anchor plate, potentially resulting in reduced brake effectiveness, which could increase the risk of a crash.

Owners should be directed to take their motorhome to an authorized Freightliner dealer to have the repair completed.

If the referenced unit on this letter has been retail sold you are asked to notify the retail owner as soon as possible of this recall because their vehicle was not registered at the time the retail notice was mailed.  Please immediately register any retail sold units on this list.  As a reminder, you are required by law to complete this recall on any stock units in inventory prior to retail sale.  Any vehicle lessor receiving this notice must forward a copy to the lessee within 10 days.    

 Please find attached a copy of the retail notification letter.  Owners were instructed to contact DTNA at 1-800-547-0712 to have their vehicles serviced. If you have questions concerning this recall, you can also contact DTNA at that same number. If you still have questions, please contact the TMC Warranty/Service Department by mail at TMC, P.O. Box 1486, Elkhart, IN 46515-1486, or by phone at 877-500-1020.

We apologize for this inconvenience; however, we have taken this action in the interest of customer safety and continued satisfaction with our products.

 

Sincerely,

 

Hanah Klodzinski
Recall Compliance Coordinator

Re: NHTSA Recall No. 20V-167
TC Recall No. 2020-114

 

Units Affected by Recall

4UZAB2FC0KCLF3388	4UZACHFC4KCLC9854	4UZACHFE7KCLG2817
4UZAB2FC0KCLG7291	4UZACHFC4KCLF3393	4UZACHFE7KCLH9164
4UZAB2FC1KCLH9157	4UZACHFC4KCLH4678	4UZACHFE8KCLF3396
4UZAB2FC2KCLS4608	4UZACHFC4KCLS1533	4UZACHFE9KCLG2818
4UZAB2FC3KCLC9845	4UZACHFC5KCLG2815	4UZACHFE9KCLH9165
4UZAB2FC3KCLS1524	4UZACHFC5KCLH9159	4UZACHFEXKCLF3397
4UZAB2FC3KCLS7985	4UZACHFC5KCLH9162	4UZACHFEXKCLG7283
4UZAB2FC4KCLJ3643	4UZACHFC5KCLL5229
4UZAB2FC5KCLH4673	4UZACHFC5KCLL5232
4UZAB2FC5KCLS1525	4UZACHFC7KCLC9847
4UZAB2FC5KCLS7986	4UZACHFC7KCLC9850
4UZAB2FC7KCLM4661	4UZACHFC7KCLH4674
4UZAB2FC7KCLS7987	4UZACHFC7KCLH9163
4UZAB2FC9KCLF3387	4UZACHFC7KCLS1526
4UZAB2FCXKCLG7279	4UZACHFC8KCLG2811
4UZAB2FCXKCLH9156	4UZACHFC9KCLC9851
4UZACHFC0KCLC9849	4UZACHFC9KCLF3390
4UZACHFC0KCLC9852	4UZACHFC9KCLG7287
4UZACHFC0KCLF3391	4UZACHFC9KCLG7290
4UZACHFC0KCLG7288	4UZACHFC9KCLH4675
4UZACHFC0KCLH4676	4UZACHFC9KCLS1527
4UZACHFC0KCLL5235	4UZACHFC9KCLS1530
4UZACHFC0KCLS1528	4UZACHFCXKCLG2812
4UZACHFC0KCLS1531	4UZACHFCXKCLM4668
4UZACHFC0KCLS5076	4UZACHFE0KCLG2819
4UZACHFC1KCLG2813	4UZACHFE0KCLH4680
4UZACHFC1KCLH9160	4UZACHFE0KCLH9166
4UZACHFC1KCLL2490	4UZACHFE0KCLL5236
4UZACHFC1KCLL5230	4UZACHFE1KCLC9876
4UZACHFC2KCLC9853	4UZACHFE1KCLG7284
4UZACHFC2KCLF3389	4UZACHFE1KCLM0462
4UZACHFC2KCLF3392	4UZACHFE2KCLH9167
4UZACHFC2KCLG7289	4UZACHFE2KCLJ3674
4UZACHFC2KCLH4677	4UZACHFE3KCLG7285
4UZACHFC2KCLS1529	4UZACHFE4KCLC9855
4UZACHFC2KCLS1532	4UZACHFE4KCLF3394
4UZACHFC3KCLG2814	4UZACHFE4KCLH4679
4UZACHFC3KCLH9158	4UZACHFE5KCLG2816
4UZACHFC3KCLH9161	4UZACHFE5KCLG7286
4UZACHFC3KCLL5228	4UZACHFE6KCLF3395
4UZACHFC3KCLL5231	4UZACHFE6KCLJ8327

 

---

4 Affected Products

Vehicles

MAKE	MODEL	YEAR
THOR MOTOR COACH	ARIA	2019-2020
THOR MOTOR COACH	VENETIAN	2019-2020

 

---

7 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-20V167-6339.pdf 433.984KB

 

---

ISSUED Owner Notification Letter(Part 577)

RCONL-20V167-0387.pdf 56.299KB

 

---

Manufacturer Notices(to Dealers,etc) – FL845 – Copy

RCMN-20V167-6369.pdf 1037.532KB

 

---

Defect Notice 573 Report

RCLRPT-20V167-9823.PDF 215.587KB

 

---

Recall Acknowledgement

RCAK-20V167-5798.pdf 244.605KB

 

---

Manufacturer Notices(to Dealers,etc)

RCMN-20V167-9964.pdf 407.189KB

 

---

ISSUED Owner Notification Letter(Part 577)

RCONL-20V167-5756.pdf 145.648KB

 

---

Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V167&docType=RCL

 

---

 

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

---

 

This product presentation was made with AAWP plugin.