SERVICE PROGRAM SP NOVEMBER 2007 SERVICE MANAGERS / PARTS MANAGERS NOTE:

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1 ATTENTION: SUBJECT: SERVICE MANAGERS / PARTS MANAGERS INCORRECT SPACING AND ALIGNMENT BETWEEN THE FAN, FAN RING, AND RADIATOR SHROUD; INCORRECT FAN RING SEAL INSTALLED To determine whether a particular vehicle is affected by this service program (or any other service program), 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 programs. VEHICLES AFFECTED: PROGRAM EXPIRES: 01 JUNE 2008 CERTAIN AUTOCAR WX AND WXLL MODEL VEHICLES BUILT BETWEEN 29 JAN 2007 AND 12 NOV 2007, VIN RANGE TO The repair procedure outlined in this service program may have been completed as a proactive measure by Autocar while the vehicle was at a body builder facility. The Service & Warranty link - available through Autocar s website - will display whether this repair procedure had been previously performed for the vehicle. Service Program Information Autocar has discovered an issue which may affect the operation of 2007 EPA-compliant emissions WX and WXLL heavy-duty class 8 vehicles. The spacing between the radiator shroud and the fan ring may be too large; the radiator shroud to fan ring alignment may not be correct; or the incorrect size fan ring seal may have been installed. In any of these cases, the suction created by the engine cooling fan may pull the fan ring seal into the engine fan. This service program describes the repair procedure necessary to correct the radiator shroud to fan ring spacing and - if necessary - to install the correct fan ring seal. Vehicles Affected There are 627 affected vehicles that were manufactured between 29 JAN 2007 and 12 NOV 2007, within VIN range to Refer to the VIN lists, beginning on page 4. Inspection and Repair If the vehicle s VIN is within the specified VIN range and included in the accompanying VIN list on page 4, perform the REPAIR PROCEDURE beginning on page 11. Depending on the vehicle s build date, a replacement fan ring seal may or may not be required. In the VIN list beginning on page 4, vehicles (identified by VIN) are shown in four separate lists. VINs included in A-WX and A-WXLL will require a replacement fan ring seal. VINs included in B-WX and B-WXLL do not require a replacement fan ring seal; the original seal may be reused. Only WX and WXLL vehicles equipped with 2007 EPA-compliant emissions systems are affected by this service program. A quick visual inspection will help determine if a suspect vehicle is affected by this service program; if the engine is painted red, it features the 2007 EPA-compliant emissions system, and is likely included in this service program. Check the VIN list on page 4 to verify that the vehicle is affected by this service program. 1 of 22

2 Time Allowance 1.5 hours per vehicle (WX vehicles). 2.0 hours per vehicle (WXLL vehicles). Parts Set forth below are the parts to replace one fan ring seal, and the parts necessary to correctly adjust the spacing and alignment between the fan, fan ring, and radiator shroud. Call the Warranty Administrator at (extension 6016) to order repair parts. When ordering parts, have the vehicle identification number (VIN) available for reference. If the inspection reveals that the radiator shroud to fan ring spacing should be adjusted, and/or the fan ring seal should be replaced, the following parts will be required: Part number and description Quantity Fan ring seal (A )...1 Fan ring adjustment kit (S B001)...1 Includes the following: Metal band...1 1/4 spacer...4 1/2 spacer...4 3/16 rivet...4 Flat washer...4 Bent tab washer...4 Hex head flange screw...4 Vehicles in VIN list A-WX require kit number S B001 and part number A Vehicles in VIN list A-WXLL require kit number S B001 and part number A , and the individual parts from the list below. Vehicles in VIN list B-WX only require kit number S B001. Vehicles in VIN list B-WXLL require kit number S B001, and the individual parts from the list below. Part number and description Quantity 1-1/2 Spacer ( )...2 5/8-11 x 3.5 HHFS ( )...2 5/8-11 Flanged hex nut ( )...2 Tools The following tools are required to perform this service program: Rivet gun Impact gun Drill motor Grinder 13/64 drill 15/16 box wrench (2) 13mm box wrench 15mm box wrench 16mm box wrench 3/8 drive ratchet 1/2 drive ratchet Torque wrench 5/16 socket 7/16 socket 9/16 socket 11mm socket 12mm socket 15mm socket Pry bar Hydraulic floor jack Thread locking compound 2 section of 1/4 air line Huck removal tool (WXLL vehicles only) 2 of 22

3 Claims for Reimbursement Submit a claim following the published instructions in the Claim Preparation section of the Warranty Administration Manual. Claim Coding Information Authorization Number: Repair Number (WX): (1.5 hours) Repair Number (WXLL): (2.0 hours) Expiration Date: 01 JUNE 2008 Dealer Responsibility Dealers must perform this service program on affected vehicles at no charge to the owner regardless of vehicle mileage, age, or ownership of the vehicle. If a vehicle affected by this service program is taken into or is in your vehicle inventory or at your dealership for service, you must perform this service program before the vehicle is sold or released to the owner. 3 of 22

4 Affected Vehicles (by VIN) Affected vehicles, sorted by last (6) digits of VIN, in ascending order from left to right, then top to bottom: VIN List A-WX - WX vehicles which require a replacement fan ring seal (and the radiator shroud to fan ring space to be adjusted, and installation of the new fan ring seal) 5VCDC6JF87H VCDC6JFX7H VCDC6JF17H VCDC6JF87H VCDC6JF27H VCDC6JF47H VCDC6JF67H VCDC6JF58H VCDC6KE58H VCDC6KE78H VCDC6KE98H VCDC6JF48H VCDC6KE08H VCDC6KE28H VCDC6KE48H VCDC6KE08H VCDC6KE28H VCDC6KE48H VCDC6KEX8H VCDC6JF88H VCDC6JFX8H VCDC6JF98H VCDC6KE98H VCDC6JF98H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JF48H VCDC6JF58H VCDC6KF98H VCDC6JF98H VCDC6JF08H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JF28H VCDC6JF48H VCDC6HF98H VCDC6JF48H VCDC6JF98H VCDC6JF48H VCDC6JF68H VCDC6HE18H VCDC6HE38H VCDC6KF38H VCDC6JF48H VCDC6KFX8H VCDC6JFX8H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF98H VCDC6KF28H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF68H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H of 22

5 5VCDC6KF48H VCDC6KF68H VCDC6JF68H VCDC6KFX8H VCDC6KF18H VCDC6JF18H VCDC6JF38H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCD36JF78H VCDC6JF98H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF58H VCDC6JF78H VCDC6LE38H VCDC6LE58H VCDC6LE78H VCDC6LE98H VCDC6LE08H VCDC6LE48H VCDC6LE68H VCDC6LE28H VCDC6LE68H VCDC6LE88H VCDC6LEX8H VCDC6LE18H VCDC6LE38H VCDC6LE58H VCDC6JF28H VCDC6JF48H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF58H VCDC6JF78H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6KFX8H VCDC6KF18H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF08H VCDC6JF28H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF28H VCDC6JF48H VCDC6KF88H VCDC6JF88H VCDC6JFX8H VCDC6KF58H VCDC6HE98H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H of 22

6 VIN List A-WXLL - WXLL vehicles which require a replacement fan ring seal (and the radiator shroud to fan ring space to be adjusted, and installation of the new fan ring seal) 5VCHC6JF48H VCHC6JF08H VCHC6JF28H VCHC6JF48H VCHC6KE48H VCHC6KE68H VCHC6KE88H VCHC6KEX8H VCHC6KE18H VCHC6JFX8H VCHC6JF18H VCHC6JFX8H VCHC6HE98H VCHC6HE58H VCHC6HE78H VCHC6KE08H VCHC6KE78H VCHC6KE98H VCHC6KE08H VCHC6KE28H VCHC6KE48H VCHC6KE68H VCHC6KE88H VCHC6KEX8H VCHC6KE18H VCHC6KE38H VCHC6KEX8H VCHC6KE18H VCHC6KE38H VCHC6KE58H VCHC6KE78H VCHC6KE98H VCHC6KE08H VCHC6KE28H VCHC6KE48H VCHC6JF88H VCHC6JFX8H VCHC6JE28H VCHC6JE98H VCH36JFX8H VCH36JF18H VCH36JF38H VCH36JF58H VCH36JF78H VCH36JF98H VCHC6JF48H VCHC6JF68H VCHC6KE08H VCHC6KE28H VCHC6KE48H VCHC6KE68H VCH36HE38H VCH36JF08H VCH36JF28H VCHC6KE68H VCHC6KE88H VCHC6HE48H VCHC6HE68H VCHC6JF58H VCHC6JF78H VCHC6JF98H VCHC6JF08H VCHC6JF28H VCHC6JF48H VCHC6JF08H VCHC6JF28H VCHC6HE08H VCH36JF58H VCH36JF78H VCHC6HE78H VCHC6HE98H VCHC6HE08H VCHC6JF28H of 22

7 VIN List B-WX - WX vehicles which DO NOT require a replacement fan ring seal (which still require adjusting the radiator shroud to fan ring space and securing the existing fan ring seal) 5VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6KF38H VCDC6KF58H VCDC6KF78H VCDC6LE68H VCDC6LE98H VCD36LE08H VCDC6JF58H VCDC6JF98H VCDC6JF08H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6KF88H VCDC6KFX8H VCDC6KF18H VCDC6KF38H VCDC6KF58H VCDC6KF18H VCDC6KF38H VCDC6KF58H VCDC6KF78H VCDC6KF98H VCDC6KF08H VCDC6KF28H VCDC6KF48H VCDC6KF68H VCDC6KF88H VCDC6JF28H VCDC6JF48H VCDC6JFX8H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6KF18H VCDC6KF38H VCDC6KFX8H VCDC6KF18H VCDC6KF38H VCDC6KF58H VCDC6KF78H VCDC6KF98H VCDC6KF08H VCDC6KF28H VCDC6KF68H VCDC6KF28H VCDC6KF48H VCDC6KF68H VCDC6KF88H VCDC6KE28H VCDC6JF18H VCDC6JF38H VCDC6HE98H VCDC6HE08H VCDC6HE78H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6KF48H VCDC6JF48H VCDC6JF98H VCDC6JF08H VCD36HE68H VCDC6KF08H VCDC6KF28H VCDC6KF48H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCD36HF58H VCD36HF78H VCD36HF98H VCDC6LE28H VCDC6LE48H VCDC6KE48H VCDC6KE68H VCDC6KE88H VCDC6KE38H VCDC6KE58H VCDC6KE78H VCDC6KE98H VCDC6KE08H VCDC6KE78H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6KF98H VCDC6KF08H of 22

8 5VCDC6JF28H VCDC6KF68H VCDC6KF38H VCDC6KF58H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6HE18H VCDC6HE38H VCDC6HE58H VCDC6HE78H VCDC6JF58H VCDC6LE18H VCDC6JF98H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6LE68H VCDC6JF38H VCDC6JFX8H VCDC6JF18H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6KG58H VCDC6JF68H VCDC6JF28H VCDC6JF18H VCDC6JF38H VCDC6KG88H VCDC6KGX8H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF88H VCDC6JFX8H VCDC6HE78H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6LE58H VCDC6LE98H VCDC6JF68H VCDC6KE08H VCDC6KE28H VCDC6KE48H VCDC6KE68H VCDC6KE88H VCDC6KEX8H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF28H VCDC6LE28H VCDC6KE68H VCDC6KE88H VCDC6KF28H VCDC6KF48H VCDC6KFX8H VCDC6KF98H VCDC6KF38H VCDC6HE78H VCDC6JF58H VCDC6KE48H VCDC6KG98H VCDC6KG08H VCDC6KG28H VCDC6KF88H VCDC6KFX8H VCDC6KF18H VCDC6JF18H VCD36HE98H VCDC6JF28H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF58H VCDC6JF78H VCDC6JF38H VCDC6JF58H VCDC6JF78H VCDC6JF98H VCDC6JF08H VCDC6JF28H VCDC6JF48H VCDC6JF88H VCDC6JFX8H VCDC6JF68H VCDC6JF88H VCDC6JFX8H VCDC6JF18H VCDC6JF38H of 22

9 VIN List B-WXLL - WXLL vehicles which DO NOT require a replacement fan ring seal (which still require adjusting the radiator shroud to fan ring space and securing the existing fan ring seal) 5VCHC6HE68H VCHC6HE88H VCHC6JF48H VCHC6JF68H VCHC6JF88H VCH36HE88H VCH36HEX8H VCHC6JF98H VCHC6JF28H VCHC6KF68H VCHC6KF88H VCHC6HEX8H VCHC6LE98H VCHC6LE28H VCHC6LE98H VCHC6LE08H VCHC6LE28H VCHC6LE48H VCHC6HE58H VCHC6HE78H VCHC6HE98H VCHC6HE38H VCHC6HE58H VCHC6JF38H VCH36HE98H VCH36HE08H VCHC6KE78H VCHC6KE98H VCHC6KE08H VCHC6KE28H VCHC6KE48H VCHC6JFX8H VCHC6JF18H VCHC6JF88H VCHC6JF58H VCHC6JF78H VCHC6JF98H VCHC6JF08H VCHC6JF28H VCHC6JF48H VCHC6JF68H VCHC6JF28H VCHC6JF48H VCHC6JF68H VCHC6JFX8H VCHC6JF68H VCHC6JF88H VCHC6JF48H VCHC6JF88H VCHC6JFX8H VCHC6JF18H VCHC6JF38H VCHC6JF98H VCHC6KF48H VCHC6KF08H VCHC6JF78H VCHC6KF18H of 22

10 LOCKOUT/TAGOUT 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 performing any work on the vehicle: 1. Place the transmission in PARK. 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. GENERAL SAFETY NOTICES WARNING To prevent eye injury, always wear eye protection when performing vehicle maintenance, service, or inspection. WARNING Do not perform the repair procedures while the vehicle s engine is running. The fan operation is engagement by a clutch system, and the fan may start without warning. Contact with the fan while it is rotating may result in severe personal injury. 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. 10 of 22

11 REPAIR PROCEDURE STEP 1: Raise the cab WARNING Due to the danger of sustaining personal injury and/or damage to the vehicle, never attempt to raise the cab outdoors under extremely windy conditions. The strong wind conditions could force the cab beyond the normal limits of its travel. Remove or secure all loose articles and close all doors before raising the cab. The area above and ahead of the cab must be clear from obstructions. Place front wheels in a straight ahead position. Remove the pump handle from its storage on the inside wall of the driver or passenger side door. Place the selector lever on the hydraulic pump in the RAISE position. Insert the pump handle into the pump and operate the handle in an up and down motion. The hydraulic cab latches will open, then the hydraulic cylinders will lift the cab until the midpoint (top) is reached. Once the cab has reached its midpoint, the cab will free fall forward to the fully open position. The safety pin in the cab tilt lock device must be installed when the holes line up in the sliding bar. DANGER Never rely on the hydraulic pressure to hold the cab in an open position. Always use the safety pin in the cab tilt lock tube to prevent serious personal injury or death. CAUTION Remove the pump handle when not in use. It may stick out and could cause injury to passersby. 11 of 22

12 STEP 2: Check for contact between the charge air cooler and the cab After tilting the cab forward, check the intake pipe for the charge air cooler for a black mark (Figure 1). Figure 2 Figure 1 The presence of a black mark indicates that the charge air cooler was in contact with the cab, and the radiator angle must be adjusted. Refer to Step 5 for the radiator angle adjustment procedure. There must be a minimum of 1/4 of clearance between the radiator / charge air cooler and the cab. In the case of the charge air cooler making contact with the cab, there will be a corresponding mark on the cab (Figure 2). 12 of 22

13 STEP 3: Remove the metal band Using a 5/16 socket, remove the metal band from rubber fan ring seal on the radiator shroud. Discard the metal band. STEP 4: Check the size of the fan ring seal (Perform Step 4 for vehicles with a loose fan ring seal, as identified in VIN list A-WX and A-WXLL ) The fan ring seal should fit snugly on the radiator shroud, around the entire circumference of the fan ring. If the fan ring seal is of the correct size, proceed to Step 5. If the incorrect fan ring seal was installed, it will feel loose at the bottom of the radiator shroud, or may have ridges where the extra fan ring material was taken up by the metal band. If the fan ring seal is not the correct size, remove and discard the fan ring seal. STEP 5: Verify the angle of the radiator (if necessary) If evidence of contact between the cab and charge air cooler was found in Step 2, the radiator angle must be adjusted. Using (2) 15/16 box wrenches, adjust the radiator stay rods so the radiator and charge air cooler do not interfere with the cab when the cab is lowered. It may be necessary to raise and lower the cab several times to check and adjust the radiator angle to provide clearance for the cab. There should be a minimum of 1/4 clearance between the charge air cooler intake pipe (Figure 1) and the welded flange on the cab (Figure 2). On some WX-series vehicles, it may be necessary to grind away some material in the fan ring to provide additional clearance for the radiator stays, as the radiator angle is adjusted back (Figure 3). (Only for vehicles with a loose fan ring seal, as identified in VIN list A-WX and A-WXLL ) Figure 3 13 of 22

14 STEP 6: Remove the serpentine fan belt To facilitate the correct re-installation of the serpentine belt, note the routing of the serpentine belt on the engine. Using a 1/2 drive ratchet, loosen the tension on the serpentine belt. Insert the ratchet drive in the belt tensioner and pull the tensioner toward the right side of the truck. Remove the serpentine belt from the truck. STEP 7: OBJECTIVE: Adjust the fan ring so that it is concentrically (center to center) aligned with the fan (if necessary) TOLERANCE: Minimum of 1/8 space between the end of all fan blades and the inside of the fan ring METHODOLOGY: Rotate the fan, checking for at least 1/8 of clearance between the ends of the fan blades and the inside of the fan ring (as measured at the 3, 6, 9, and 12 o clock positions). If tolerance is less than 1/8 at the 3, 6, 9, and 12 o clock positions (or not equal at all four positions), loosen the (4) fan bracket to engine / fan clutch fasteners using an appropriately sized box wrench (Figure 4). See Table 1 for a list of wrench sizes and their respective fan ring bracket to engine / fan clutch fasteners. Figure 4 (2) additional fasteners located at bottom of engine Move the fan ring / bracket assembly (vertically and/or horizontally, as required) to achieve a minimum of 1/8 space between the end of all blades and the inside of the fan ring. Table 1 Engine Wrench size for UPPER hex head cap screws Wrench size for LOWER hex head cap screws ISM 13mm 16mm ISL 16mm 15mm ISC 16mm 15mm A pry bar may be used to provide additional leverage to move the fan ring / bracket assembly. Rotate the fan, checking for at least 1/8 of clearance between the ends of the fan blades and the inside of the fan ring (as measured at the 3, 6, 9, and 12 o clock positions). Apply thread locking compound to the fan bracket fasteners. Using an appropriately sized box wrench, tighten the (4) fan ring bracket to engine / fan clutch fasteners. 14 of 22

15 STEP 8: OBJECTIVE: Adjust the radiator shroud to fan ring alignment (vertically, if necessary) TOLERANCE: No more than 1/4 difference in vertical alignment between the radiator shroud and fan ring METHODOLOGY: If the vertical alignment between the radiator shroud and fan ring differs by more than 1/4, use a 11mm socket to loosen the (10) hex nuts securing the radiator shroud to the radiator (Figure 5). 5 hex nuts on each sideof radiator shroud Figure 5 Move the radiator shroud (up or down, as required) to align the radiator shroud to the fan ring. No more than 1/4 of space should exist between the radiator shroud and fan ring (as measured at the 6 and 12 o clock positions). Using a 11mm socket and torque wrench, torque the (10) radiator shroud to radiator hex nuts to 10 ft-lbs (± 1 ft-lb). 15 of 22

16 STEP 9: OBJECTIVE: Adjust the radiator shroud to fan ring alignment (horizontally, if necessary) A pry bar may be used to provide additional leverage to move the fan ring / bracket assembly. TOLERANCE: No more than 1/4 difference in horizontal alignment between the radiator shroud and fan ring METHODOLOGY: If the horizontal alignment between the radiator shroud and fan ring differs by more than 1/4, use a 15/16 socket and box wrench to loosen the (2) hex head cap screws securing the radiator brackets to the forward frame cross member. Move the radiator (left or right, as required) to align the radiator shroud to the fan ring. Rotate the fan, checking for at least 1/8 of clearance between the ends of the fan blades and the inside of the fan ring (as measured at the 3, 6, 9, and 12 o clock positions). Apply thread locking compound to the fan bracket fasteners. Using a 9/16 box wrench, tighten the fan ring bracket to fan clutch fasteners. A pry bar may be used to provide additional leverage to move the radiator / charge air cooler assembly (a minimum of 1/4 clearance between the radiator / charge air cooler and cab must be maintained). No more than 1/4 of space should exist between the radiator shroud and fan ring (as measured at the 3 and 9 o clock positions) (Figure 6). Using a 15/16 socket, torque wrench, and box wrench, torque the radiator bracket (2) HHFS to 110 ft-lbs (± 11 ft-lbs). If additional horizontal adjustment is required to bring the alignment difference to 1/4 (or less) between the radiator shroud and fan ring, loosen the fan bracket to fan clutch fasteners using a 9/16 box wrench. Move the fan ring / bracket assembly (horizontally, as required) to achieve a maximum of 1/4 difference in alignment between the fan ring and radiator shroud (as measured at the 3 and 9 o clock positions, while still maintaining a minimum of 1/8 space between the end of all blades and the inside of the fan ring). Maximum variance = 1/4 Figure 6 16 of 22

17 STEP 10: Install radiator stay rod spacers (WXLL vehicles only; for WX vehicles skip to Step 11) Install (2) 1-1/2 spacers between the frame rail and the stay rod bracket (Figure 8). On WXLL vehicles, adjusting the radiator angle to set the spacing between the radiator shroud and the fan will cause the left-side radiator stay rod to interfere with the fan ring. In this case, spacers must be installed between the frame rail and the left-side radiator stay rod bracket to provide clearance between the stay rod and the fan ring. Using a grinder or Huck removal tool, carefully cut the Huck fasteners securing the left-side stay rod bracket (Figure 7). Remove and discard the Huck fasteners. Remove (x2) Figure 8 Install the 5/8 hex head flange screw through the stay rod bracket, spacers, and frame rail. Install the 5/8 flanged hex nut on the HHFS. Using a 15/16 socket, torque wrench, and box wrench, torque the (2) stay rod HHFS to 200 ft-lbs (± 10 ft-lbs). Figure 7 17 of 22

18 STEP 11: OBJECTIVE: Adjust the radiator angle to set the fan to radiator shroud spacing (if necessary) TOLERANCE: Minimum of 3/4 space between the leading edge of the fan blades and the radiator shroud METHODOLOGY: If the radiator shroud to fan blade spacing is less than 3/4, use (2) 15/16 box wrenches to adjust the radiator stay rods to adjust the angle of the radiator forward or backward. Adjust the radiator angle until a minimum space of 3/4 (Figure 9) is achieved between the leading edge of the fan blades and the radiator shroud. STEP 12: OBJECTIVE: Adjust the fan ring to radiator shroud spacing (front to back, if necessary) TOLERANCE: 1/4 to 1/2 space between the forward edge of the fan ring and the radiator shroud METHODOLOGY: Add or remove the 1/4 or 3/8 fan ring spacers as necessary to achieve a 1/4 to 1/2 space between the fan ring and the radiator shroud (as measured at the 3, 6, 9, and 12 o clock positions) (Figure 10). Minumum gap = 3/4 Gap = 3/8-1/2 Figure 10 Figure 9 Using 15/16 box wrenches, tighten the radiator stay rod adjusting nuts. Apply thread locking compound to the fan ring fasteners. Using a 12mm socket and torque wrench, torque the fan ring fasteners to 16 ft-lbs (± 2 ft-lbs). If additional 1/2 spacers are required, a longer hex head flange screw may need to be installed. (4) flange screws are provided with the repair kit, S B of 22

19 STEP 13: Install the new fan ring seal on the radiator shroud (Perform Steps 13 and 14 if the vehicle is included in VIN lists A-WX or A-WXLL. Otherwise, use the existing fan ring seal, as identified in VIN lists B-WX and B-WXLL.) Carefully pull the lower side of the fan ring seal between the radiator shroud and the fan ring, to the bottom of the radiator shroud. Install the new fan ring seal on the radiator shroud, pushing the fan ring seal as far onto the radiator shroud as is possible. Check around the circumference of the radiator shroud to ensure no folds or pinches in the fan ring seal, and that it is properly seated on the radiator shroud. STEP 14: Install the fan ring seal on the fan ring (if required) Fold the fan ring seal over the fan ring. Check the installation of the fan ring seal on the radiator shroud and adjust as needed. The fan ring seal should not be folded or pinched, and should smoothly transition between the radiator shroud and the fan ring. Check around the circumference of the fan ring to ensure no folds or pinches in the fan ring seal, and that it is properly seated on the fan ring. 19 of 22

20 STEP 15: Attach the fan ring seal and metal band Using a 13/64 drill, bore (4) holes for rivets through the fan ring seal and the radiator shroud (in the channel which the metal band will lie in). The left-side (upper) hole should be drilled directly forward of the upper fan ring bracket (Figure 11). The right-side (upper) hole should be drilled between the charge air cooler pipe and the upper radiator pipe (Figure 12). The left-side (lower) and right-side (lower) holes should be drilled as low on the radiator shroud as is possible (Figures 13 and 14). TOP-RIGHT RIVET LOCATION Figure 12 Place the drilled rivet holes as close as is reasonably possible to the location of the fan ring to fan ring bracket attachment points. When drilling the lower holes in the shroud, ensure that the holes are drilled perpendicular to the surface of the radiator shroud and fan ring seal. LOWER-LEFT RIVET LOCATION Figure 13 TOP-LEFT RIVET LOCATION LOWER-RIGHT RIVET LOCATION Figure 11 Figure of 22

21 STEP 16: Install the rivet/washer assembly Position a rivet through a bent tab washer and insert the rivet through the hole drilled in the fan ring seal and radiator shroud. The bent tab washer must be installed on the OUTSIDE of the radiator shroud and fan ring. Install a flat washer over the rivet on the INSIDE of the radiator shroud. A short section of 1/4 air line may temporarily installed over the INSIDE end of the rivet to prevent the inside washer from falling off of the rivet. Using a rivet gun, close the rivet and washer assembly from inside the fan ring. If the 1/4 air line was used to prevent the inside washer from falling off the rivet, remove the air line prior to closing the rivet. Repeat Step 16 for the remaining three drilled holes. STEP 17: Install the metal band Replace the metal band around the fan ring seal and radiator shroud. The metal band should lie in the channel in the fan ring seal. The bent tab washers on the outside of the fan ring seal must be oriented so the metal band lies between the tabs on each washer (Figure 15). Using a 5/16 socket, tighten the metal band around the fan ring seal and radiator shroud so that the band is tight enough that it cannot be moved in the channel on the fan ring seal. Figures 11 through 15 show a u-channel in place of the bent tab washer. The parts kit associated with this service program may use bent tab washers. Figure of 22

22 STEP 18: Install the fan belt Loosely route the serpentine belt as it was installed before removal in Step 6. Using a 1/2 ratchet, loosen the tension pulley on the front of the engine. Slip the serpentine belt over the tension pulley and release the tension on the ratchet. Check the serpentine belt to ensure that it is correctly routed, and properly seated on all accessory pulleys. STEP 19: Check for fan clearance With the cab still tilted forward: Start the engine. Visually check for fan to fan ring clearance. Using a hydraulic floor jack, raise the frontleft corner of the chassis 6 and visually check for fan to fan ring seal clearance. Lower the front-left corner of the chassis. Using a hydraulic floor jack, raise the frontright corner of the chassis 6 and visually check for fan to fan ring seal clearance. Lower the front-right corner of the chassis. If contact between the fan and fan ring, or contact between the fan and fan ring seal is evident, return to Steps 7 through 12 and repeat the radiator shroud and fan ring alignment and spacing adjustment procedures. Turn the vehicle OFF. STEP 20: Lower the cab Remove the safety pin in the sliding cab tilt lock bar. Place the selector lever on the hydraulic pump to the LOWER position. Insert the pump handle into the pump and operate the handle in an up and down motion. The hydraulic cylinders then lower the cab until the midpoint (top) is reached. Once the cab has reached its midpoint, stop pumping and the cab will free fall rearward to the fully lowered position. When the cab is lowered, the hydraulic cab latches will automatically close, securing the cab to the frame. CAUTION Remove the pump handle when not in use. It may stick out and could cause injury to passersby. Please direct all questions regarding this service program to: info@autocartruck.com or call the service hotline at (extension 6062). 22 of 22

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