SERVICE CAMPAIGN SP JULY, 2007 SERVICE MANAGERS / PARTS MANAGERS HAULMAAX SUSPENSION PLATE UPGRADE EXPIRES: 31 DECEMBER 2007

Transcription

1 ATTENTION: SUBJECT: SERVICE MANAGERS / PARTS MANAGERS HAULMAAX SUSPENSION PLATE UPGRADE EXPIRES: 31 DECEMBER 2007 Service Campaign Information This service campaign is a product modification that Autocar recommends be performed on all affected vehicles. As a proactive customer support measure, Autocar is implementing this service campaign to replace all suspect rear suspension fasteners with fasteners of a type which are not susceptible to fastener relaxation, as well as to replace the outboard upper suspension bracket with a revised part which includes (4) additional fastener mounting holes. Inspection If the vehicle s VIN number is within the specified VIN range and included in the accompanying VIN list on page 3, visually inspect the vehicle. Observe the fasteners securing the upper outboard suspension bracket to the frame rail. If the upper outboard suspension bracket is assembled to the frame with flanged hex head cap screws and flanged hex nuts (as opposed to Huck Spin fasteners), the service campaign should be completed for the vehicle. Vehicles Affected There are a total of 338 vehicles affected, with VIN numbers ranging from to Refer to the list of individual VIN numbers, beginning on page 3. Affected vehicles were built between 01 MAY 2005 and 30 MAY Vehicles outside of the build date or VIN range are not subject to this service campaign. NOTE: To determine whether a particular vehicle is affected by this service campaign (or any other service campaign), consult the Service & Warranty link through Autocar s website: After logging in to the dealer section of the website, enter the VIN into the VIN Profile; the system will display any outstanding service campaigns. Repair Remove and discard all rear suspension fasteners and the upper outboard suspension bracket. Replace the upper outboard suspension bracket and all suspensions fasteners according to the REPAIR PROCEDURE beginning on page 7. The instructions and illustrations within this manual are relevant to the vehicle s left and right side. After all steps have been performed for one side of the vehicle, the repair procedure must be repeated for the opposite side of the vehicle. Time Allowance Repair: 6.0 hours per vehicle Labor Operation Code: of 23

2 Parts In most cases, all necessary replacement parts have been shipped to the truck s registered owner. In cases where replacement parts have not been shipped, contact an Autocar representative to order replacement parts: Mike Thompson mthompson@autocartruck.com Tim McGinnis tmcginnis@autocartruck.com Chad Semler csemler@autocartruck.com Sally Johnson sjohnson@autocartruck.com The following suspension brackets and fasteners are required in order to complete this service campaign: Part Description and Specification Quantity Revised upper outboard suspension bracket...2 5/8-11 x 2.25 flanged hex head cap screw, phosphate and oil coated, grade /8-11 flanged hex nut, phosphate and oil coated, grade M20x2.5-6G 65mm hex head cap screw, phosphate and oil coated...20 M20x2.5-6H hex nut, phosphate and oil coated...20 M20 hardened washer /8 x Huck pin, grade /8 x Huck pin, grade /8 x Huck pin, grade /8 Huck collar 40 Tools Required 1. Huck Spin fastening tool 2. Huck fastener removal tool 3. Drill motor 4. Ø.656 drill 5. For 5/8 flanged hex head cap screws and flanged hex nuts: a. 15/16 box wrench b. 15/16 socket c. Torque wrench capable of 200 ft-lbs +/- 20 ft-lbs (271 N m +/- 27 N m) 6. For M20 hex head cap screws and hex nuts: a. M30 (1-3/16 ) box wrench b. M30 (1-3/16 ) socket c. Torque wrench capable of 335 ft-lbs +/- 30 ft-lbs (454 N m +/- 41 N m) 7. Pneumatic impact wrench 8. Tapered drift pin (2) 9. Center punch 10. Hammer 11. Steam cleaning tool 12. Hole inspection pin Ø.625 (GO / NO-GO gauge) 2 of 23

3 Vehicles Affected, by VIN Number Affected vehicles, sorted by last (6) digits of VIN, in ascending order from left to right, top to bottom: of 23

4 of 23

5 of 23

6 SAFETY NOTICES 6 of 23 WARNING To prevent eye injury, always wear eye protection when performing vehicle maintenance, service, or inspection. DANGER Before working on a vehicle, turn the engine to off, set the parking brake, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement, resulting in serious personal injury or death. DANGER Only perform this repair procedure on an unloaded vehicle. A loaded vehicle may be susceptible to load-shift, which may cause the vehicle to fall from the jack stands, resulting in serious personal injury or death. DANGER The 5/8 hex head cap screws and hex nuts must be accurately torqued. These fasteners secure structural components on the truck. If these fasteners are not secured properly, there is a risk of failure of the components or fasteners, which could result in further structural failure, which could result in serious personal injury or death. DANGER Do not use a plasma torch to remove Huck fasteners from the vehicle - a Huck fastener removal tool must be used. The heat from a plasma torch could reduce the strength of the vehicle s frame rails, which could result in the failure of the vehicle s frame, further resulting in a collision or loss of control which could result in serious personal injury or death. TAGOUT/LOCKOUT PROCEDURES Before entering the vehicle or vehicle body, read and follow OSHA regulations concerning entry and working in CONFINED SPACE OSHA and LOCKOUT/TAGOUT OSHA Follow OSHA regulations while performing any work on the vehicle. The vehicle must be disabled by the following steps before proceeding: 1. Place the transmission in NEUTRAL. 2. Set the parking brake. 3. Shut the engine OFF. 4. Turn the battery disconnect switch OFF. 5. Lock cab doors, keep the key in your pocket, and block the wheels before entering the body or performing any work on the vehicle. 6. Place magnetic DANGER signs on both cab doors before entering the body or performing any work on the vehicle. NOTICE The revised upper outboard suspension bracket will occupy a larger area on the outside of the frame rail as compared to the original bracket. Equipment or utility body components installed after the assembly of the chassis may interfere with the revised suspension bracket. Modifications to the utility body or other equipment may be necessary in order to install the revised suspension bracket.

7 DISASSEMBLY PROCEDURE Step 1: Remove any load from the vehicle prior to performing this procedure. Park the vehicle on a level, clean work surface, free from oil and other contamination. Step 6: Using an impact wrench with an M30 (1-3/16 ) socket and an M30 box wrench, remove the (10) M20x2.5-6G 65mm HHCS and hex nuts securing the outboard suspension bracket to the lower saddle assembly (Figure 1). Step 2: Follow the safety instructions on the previous page, and ensure the engine is switched OFF. Position the battery disconnect switch to OFF, and follow all necessary lockout/tagout procedures. Discard these fasteners. Step 3: Steam clean the rear suspension mounting brackets and the inside and outside of the frame rails. NOTICE If the rear axles are equipped with axle breather filters, cover the breathers to prevent water and contaminants from entering the axle housing prior to steam cleaning the chassis. Step 4: Step 5: Using a lifting device of adequate weight rating, support the vehicle at ride height. Raise the vehicle only enough to unload the rear suspension, but not to a point where the rear tires are above the floor. If possible, safely raise and support the utility body from the frame in order to facilitate easier access to the suspension brackets and fasteners located inside of the frame rails. Figure 1 7 of 23

8 Step 7: Using the lifting device already in place under the frame, raise the vehicle s frame off of the suspension, until there is approximately (1) inch of clearance between the saddle assembly and outboard suspension bracket (Figure 2). Figure 3 Figure 2 Step 8: Using an impact wrench with a 15/16 socket and a 15/16 box wrench, remove the (12) 5/8-11 x 2.25 flanged HHCS and flanged hex nuts securing the upper outboard suspension bracket to the frame rail (Figure 3). Discard these fasteners. 8 of 23

9 Step 9: Using an impact wrench with a 15/16 socket and a 15/16 box wrench, remove the (2) 5/8-11 x 2.25 flanged HHCS and flanged hex nuts securing the upper outboard suspension bracket to the inboard suspension bracket (Figure 4). Discard these fasteners. Remove the upper outboard suspension bracket from the vehicle and discard. Figure 4 9 of 23

10 Step 10: Using an impact wrench with a 15/16 socket and 15/16 box wrench, remove the (4) 5/8-11 x 2.25 fl anged HHCS and fl anged hex nuts securing the inboard suspension bracket (Figure 5) to the suspension crossmember. REPEAT STEPS 6-10 (DISASSEMBLY PROCEDURE) FOR THE OPPOSITE SIDE OF THE VEHICLE. Discard these fasteners and remove the inboard suspension bracket from the vehicle. Figure 5 10 of 23

11 INSPECTION PROCEDURE Step 11: All mating surfaces between ALL suspension brackets, frame rails, and frame crossmembers must be clean and free of any contamination. Any dirt or road contamination must be scraped and/or ground off of the mating surfaces and wiped clean. If any paint runs or sags exist on any mating components, they must be sanded smooth. If any weld-spatter exists on the mating surfaces, it must be ground off prior to re-assembly. If any burrs exist at the edges of the thru-holes (frame rail or suspension brackets), they must be removed. Refer to the section OVERSIZED HOLE FITMENT, beginning on page 22 for information on determining whether a the diameter of a bolt hole in the frame is beyond the maximum tolerance, and the Autocar-recommended procedures for working with out-of-tolerance hole diameters. The frame rails, outboard and inboard suspension brackets, suspension crossmember, and suspension crossmember end-gussets musts be inspected for elongated holes, flaws, and cracks. If any component of the vehicle is found to have bolt holes that are beyond the established tolerance, or frame or suspension components are found to have un-repairable damage, contact an Autocar service representative to address issues of out-of-tolerance and non-conforming components: Tim McGinnis... National Service Manager Mike Sroczynski... Central Regional Service Manager Mike Hopper... Western Regional Service Manager REPEAT STEP 11 (INSPECTION PROCEDURE) FOR THE OPPOSITE SIDE OF THE VEHICLE. 11 of 23

12 SUSPENSION BRACKET INSTALLATION PROCEDURE Step 12: Align the holes in the revised outboard suspension bracket with the corresponding holes in the frame rail, using (2) tapered drift pins through the #1 and #6 holes (Figure 6). Install the revised outboard suspension bracket, using (2) new 5/8-11 x 2.25 flanged HHCS and 5/8-11 flanged hex nuts through the #9 and #10 holes (Figure 6). Step 13: Four additional holes must be drilled in the frame rail in order to accommodate the revised outboard suspension bracket. Using a center punch and a hammer, mark the frame rail through the center of the #25, #26, #27, and #28 holes in the outboard suspension bracket (Figure 7). Figure 6 DO NOT APPLY TORQUE TO THE FASTENERS. THESE FASTENERS ARE TO BE HAND-TIGHT ONLY. Figure 7 Remove the drift pins and 5/8 flanged HHCS and 5/8 flanged hex nuts that were installed in Step 12. Remove the outboard suspension bracket from the vehicle. Step 14: Drill (4) Ø.656 holes through the frame rail in the marked locations. Remove any burrs or sharp edges from the holes. NOTICE Before drilling through the frame rail, check the inside of the rail for electrical, air, fuel, or hydraulic lines. Care must be taken to ensure that any lines inside of the rail will not be damaged when the drill penetrates the frame rail. 12 of 23

13 Step 15: Re-install the outboard suspension bracket using (2) tapered drift pins through the #6 and #1 holes (Figure 8) to ensure that the holes in the suspension bracket are aligned with the holes in the frame rail. Install (2) 5/8-11 x 2.25 HHCS and 5/8-11 flanged hex nuts through the #9 and #10 holes in the outboard suspension bracket (Figure 8). Step 16: Insert (2) 5/8 x Huck fasteners through the #3 and #4 holes from inside of the frame rail (Figure 9). While holding the threaded Huck pin in a bottomed-out state from inside of the frame rail, thread the Huck collar on to the pin by hand so that the collar is flush against the outboard suspension bracket. Figure 8 Figure 9 Using a torque wrench with a 15/16 socket and a 15/16 box wrench, torque the (2) 5/8 HHCS to a value of 200 ft-lbs +/- 20 ft-lbs (271 N m +/- 27 N m). Step 17: Place the head of the Huck fastening tool over the collar, ensuring that the collar is still flush against the outboard suspension bracket. Using the Huck tool, crimp the (2) Huck collars. 13 of 23

14 Step 18: Insert (4) 5/8 x Huck fasteners through the #2, #5, #8, and #11 holes from the inside of the frame rail (Figure 10). While holding the threaded Huck pin in a bottomed-out state from inside of the frame rail, thread the Huck collar on to the pin by hand so that the collar is flush against the outboard suspension bracket. Step 20: Insert (4) 5/8 x Huck fasteners through the #1, #6, #7, and #12 holes from the inside of the frame rail (Figure 11). While holding the threaded Huck pin in a bottomed-out state from inside of the frame rail, thread the Huck collar on to the pin by hand so that the collar is flush against the outboard suspension bracket. Figure 11 Figure 10 Step 19: Place the head of the Huck fastening tool over the collar, ensuring that the collar is still flush against the outboard suspension bracket. Using the Huck tool, crimp the (4) Huck collars in the order; #8, #11, #2, then #5. Step 21: Place the head of the Huck fastening tool over the collar, ensuring that the collar is still flush against the outboard suspension bracket. Using the Huck tool, crimp the (4) Huck collars in the order; #7, #12, #1, then #6. Remove the tapered drift pins. 14 of 23

15 Step 22: Insert (4) 5/8 x Huck fasteners through the #25, #26, #27, and #28 holes from the inside of the frame rail (Figure 12). While holding the threaded Huck pin in a bottomed-out state from inside of the frame rail, thread the Huck collar on to the pin by hand so that the collar is flush against the outboard suspension bracket. Figure 12 Step 23: Place the head of the Huck fastening tool over the collar, ensuring that the collar is still flush against the outboard suspension bracket. Using the Huck tool, crimp the (4) Huck collars in the order; #25, #26, #27, then # of 23

16 Step 24: Attach the inboard suspension bracket to the outboard suspension bracket. Insert (2) 5/8 x Huck fasteners through the #13 and #14 holes from the outside of the outboard suspension bracket (Figure 13). While holding the threaded Huck pin in a bottomed-out state from outside of the outboard suspension bracket, thread the Huck collar on to the pin by hand so that the collar is flush against the inboard suspension bracket. DO NOT APPLY TORQUE TO THE FASTENERS. THESE FASTENERS ARE TO BE HAND-TIGHT ONLY. Figure of 23

17 Step 25: Attach the inboard suspension bracket to the suspension crossmember. Insert (4) 5/8 x Huck fasteners through the holes in the suspension crossmember (inside the frame rail) from the above the holes (Figure 14). While holding the threaded Huck pin in a bottomedout state from above the suspension crossmember fl ange, thread the Huck collar on to the pin by hand so that the collar is fl ush against the bottom of the inboard suspension bracket. DO NOT APPLY TORQUE TO THE FASTENERS. THESE FASTENERS ARE TO BE HAND-TIGHT ONLY. Figure 14 Step 26: Step 27: Using the Huck fastening tool, secure the inboard suspension bracket to the outboard suspension bracket. Place the head of the Huck fastening tool over the collar, ensuring that the collar is still fl ush against the inboard suspension bracket. Using the Huck tool, crimp the (2) Huck collars joining the inboard and outboard suspension brackets. Using the Huck fastening tool, secure the inboard suspension bracket to the suspension crossmember (installed in Step 25). Place the head of the Huck fastening tool over the collar, ensuring that the collar is still fl ush against the inboard suspension bracket. Using the Huck tool, crimp the (4) Huck collars joining the inboard suspension bracket to the suspension crossmember. REPEAT STEPS (SUSPENSION BRACKET INSTALLATION PROCEDURE) FOR THE OPPOSITE SIDE OF THE VEHICLE. 17 of 23

18 SUSPENSION BRACKET TO SADDLE ASSEMBLY Step 28: Using the lifting device that is still in place under the frame, carefully lower the rear portion of the frame so that the upper outboard suspension brackets (left and right side) make contact with the lower saddle brackets. Align the holes in the upper outboard suspension brackets with the holes in the lower saddle brackets, using (2) tapered drift pins in the #17 and #18 holes, if necessary (Figure 15). Step 29: Install (2) new M20x2.5-6G 65mm HHCS, with (2) M20x2.5-6H hex nuts and (4) M20 hardened washers through the #15 and #16 holes (Figure 16). Figure 15 NOTICE Do not allow the vehicle s weight to rest on the lower saddle brackets. The outboard suspension bracket should ONLY make contact with the lower saddle bracket. NOTE: NOTE: Figure 16 The (2) tapered drift pins are not shown for clarity. The M20x2.5-6G 65mm HHCS must be inserted so that the threads are oriented toward the inside (threaded end pointing upward) of the outboard suspension bracket. The washers should be installed between the hex nut and the suspension bracket, and between the screw head and suspension bracket. 18 of 23

19 Step 30: Torque may be applied to the M20x2.5-6G 65mm HHCS OR to the (2) M20x2.5-6H hex nuts installed in Step 29. To apply torque to the HHCS: Hold the hex nut stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the HHCS Apply a torque value of 335 ft-lbs +/- 35 ft-lbs (454 N m +/- 47 N m) to the hex head cap screw To apply torque to the hex nut: Hold the HHCS stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the hex nut Apply a torque value of 310 ft-lbs +/- 30 ft-lbs (420 N m +/- 41 N m) to the hex nut Step 32: Install (2) new M20x2.5-6G 65mm HHCS, with (2) M20x2.5-6H hex nuts and (4) M20 hardened washers through the #17 and #18 holes (Figure 17). Step 31: Remove the (2) tapered drift pins from the #17 and #18 holes. Figure 17 NOTE: The M20x2.5-6G 65mm HHCS must be inserted so that the threads are oriented toward the inside (threaded end pointing upward) of the outboard suspension bracket. The washers should be installed between the hex nut and the suspension bracket, and between the screw head and suspension bracket. 19 of 23

20 Step 33: Torque may be applied to the M20x2.5-6G 65mm HHCS OR to the (2) M20x2.5-6H hex nuts installed in Step 32. To apply torque to the HHCS: Hold the hex nut stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the HHCS Apply a torque value of 335 ft-lbs +/- 35 ft-lbs (454 N m +/- 47 N m) to the hex head cap screw To apply torque to the hex nut: Hold the HHCS stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the hex nut Apply a torque value of 310 ft-lbs +/- 30 ft-lbs (420 N m +/- 41 N m) to the hex nut Figure 18 REPEAT STEPS FOR THE OPPOSITE SIDE OF THE VEHICLE. Step 34: Install (6) new M20x2.5-6G 65mm HHCS, with (6) M20x2.5-6H hex nuts and (12) hardened washers through the #19, #20, #21, #22, #23, and #24 holes (Figure 18). NOTE: The M20x2.5-6G 65mm HHCS must be inserted so that the threads are oriented toward the inside of the outboard suspension bracket. The washers should be installed between the hex nut and the suspension bracket, and between the screw head and suspension bracket. 20 of 23

21 Step 35: Torque may be applied to the (6) M20x2.5-6G 65mm HHCS OR to the (6) M20x2.5-6H hex nuts installed in Step 34. To apply torque to the HHCS: Hold the hex nut stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the HHCS Apply a torque value of 335 ft-lbs +/- 35 ft-lbs (454 N m +/- 47 N m) to the hex head cap screw Step 36: Step 37: Step 38: Step 39: Using the lifting device under the frame, lower the vehicle to the ground. If the utility body was raised from the frame in Step 5, lower the utility body back on to the frame and re-attach. Remove the lockout/tagout safety equipment installed in Step 2. Record the chassis VIN and a description of the work done to the truck. To apply torque to the hex nut: Hold the HHCS stationary with an M30 (1-13/16 ) box wrench Use a torque wrench with an M30 socket to apply torque to the hex nut Apply a torque value of 310 ft-lbs +/- 30 ft-lbs (420 N m +/- 41 N m) to the hex nut This service campaign is now complete. Please direct all questions regarding this campaign to: info@autocartruck.com, or call the service hotline at , extension REPEAT STEPS 34 AND 35 FOR THE OPPOSITE SIDE OF THE VEHICLE. 21 of 23

22 OVERSIZED HOLE FITMENT Definitions The term Joint describes a fastening system that consists of: A hex head cap screw (HHCS) and hex nut, A flanged HHCS and flanged hex nut, A Huck Spin pin and collar Max diameter is the maximum hole diameter through all of parts held together by the joint. Table 1: Maximum size hole which do not require an additional hardened washer: Nominal fastener size Maximum hole size* Torque (as applied to HHCS) 5/8 (Ø.625 ) Ø ft-lbs +/- 20 ft-lbs * see ASME B , Table 2 - Normal Hole Diameter Maximum. Tools A Hole inspection pin Ø.625 (GO / NO-GO gauge) GO = Ø.698 NO-GO = Ø.741 Refer to Figure 19 Ø.741 (NO-GO) Ø.698 (GO) Figure of 23

23 Procedure After removal of hex head cap screw and hex nut from the joint, attempt to insert the hole inspection pin into the hole (small end of pin first). The following results can occur: Case 1 - Hole to specification The GO (small) end of the pin does not fit into the hole. This means the hole(s) is smaller than Ø.698, and sized within original specification. Hole OK. Case 2 - Oversize hole - use washer The GO (small) end of the pin fits through thru some or all components, but the NO-GO (large) end does not fit. This means the hole(s) is oversized, but still within allowable tolerance. Use a 1/4 thick hardened washer between the head of the Huck bolt and the non-conforming hole (inside the frame rail), appropriate to the installation. Case 3 - Oversized holes - replace components For hole sizes greater than the maximum allowable diameter, when the NO-GO (large) end of the pin can be inserted through the holes in components, the hole diameter is out of specification and the suspension components must be replaced. Replacement suspension components can include the suspension spacer plate, inboard suspension bracket, or suspension crossmember. In the majority of instances, hole elongation will be isolated only to the upper outboard suspension bracket, which must be replaced with the revised bracket as directed under this Service Campaign. Case 4 - Multiple components with oversized holes If the NO-GO (large) end of pin can be inserted through the outboard suspension bracket and through the frame rail, consult Autocar engineering for further repair procedures: Tim McGinnis... National Service Manager Mike Sroczynski... Central Regional Service Manager Mike Hopper... Western Regional Service Manager of 23