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: www.autocartruck.com. 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 205322 TO 206636 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 205322 to 206636. 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
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 877-973-3486 (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 (A2010135-001)...1 Fan ring adjustment kit (S2010001B001)...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 S2010001B001 and part number A2010135-001. Vehicles in VIN list A-WXLL require kit number S2010001B001 and part number A2010135-001, and the individual parts from the list below. Vehicles in VIN list B-WX only require kit number S2010001B001. Vehicles in VIN list B-WXLL require kit number S2010001B001, and the individual parts from the list below. Part number and description Quantity 1-1/2 Spacer (41405-3929)...2 5/8-11 x 3.5 HHFS (8397084)...2 5/8-11 Flanged hex nut (8397202)...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
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): 26316-1-00 (1.5 hours) Repair Number (WXLL): 26316-1-01 (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
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) 5VCDC6JF87H205322 5VCDC6JFX7H205340 5VCDC6JF17H205341 5VCDC6JF87H205370 5VCDC6JF27H205400 5VCDC6JF47H205401 5VCDC6JF67H205402 5VCDC6JF58H205506 5VCDC6KE58H205513 5VCDC6KE78H205514 5VCDC6KE98H205515 5VCDC6JF48H205528 5VCDC6KE08H205547 5VCDC6KE28H205548 5VCDC6KE48H205549 5VCDC6KE08H205550 5VCDC6KE28H205551 5VCDC6KE48H205552 5VCDC6KEX8H205569 5VCDC6JF88H205614 5VCDC6JFX8H205615 5VCDC6JF98H205623 5VCDC6KE98H205627 5VCDC6JF98H205654 5VCDC6JF28H205656 5VCDC6JF48H205657 5VCDC6JF68H205658 5VCDC6JF88H205659 5VCDC6JF48H205660 5VCDC6JF58H205666 5VCDC6KF98H205667 5VCDC6JF98H205668 5VCDC6JF08H205669 5VCDC6JF78H205670 5VCDC6JF98H205671 5VCDC6JF08H205672 5VCDC6JF28H205673 5VCDC6JF48H205674 5VCDC6JF68H205675 5VCDC6JF88H205676 5VCDC6JF28H205687 5VCDC6JF48H205688 5VCDC6HF98H205689 5VCDC6JF48H205691 5VCDC6JF98H205704 5VCDC6JF48H205707 5VCDC6JF68H205711 5VCDC6HE18H205712 5VCDC6HE38H205713 5VCDC6KF38H205714 5VCDC6JF48H205786 5VCDC6KFX8H205810 5VCDC6JFX8H205811 5VCDC6JF38H205813 5VCDC6JF58H205814 5VCDC6JF78H205815 5VCDC6JF98H205816 5VCDC6JF08H205817 5VCDC6JF28H205818 5VCDC6JF48H205819 5VCDC6JF08H205820 5VCDC6JF28H205821 5VCDC6JF48H205822 5VCDC6JF68H205823 5VCDC6JF88H205824 5VCDC6JFX8H205825 5VCDC6JF38H205830 5VCDC6JF58H205831 5VCDC6JF78H205832 5VCDC6JF98H205833 5VCDC6JF08H205834 5VCDC6JF68H205837 5VCDC6JF88H205838 5VCDC6JFX8H205839 5VCDC6JF68H205840 5VCDC6JF88H205841 5VCDC6JFX8H205842 5VCDC6JF18H205843 5VCDC6JF38H205844 5VCDC6JF58H205845 5VCDC6JF78H205846 5VCDC6JF98H205847 5VCDC6JF08H205848 5VCDC6JF28H205849 5VCDC6JF98H205850 5VCDC6KF28H205851 5VCDC6JF28H205852 5VCDC6JF48H205853 5VCDC6JF68H205854 5VCDC6JF88H205855 5VCDC6JFX8H205856 5VCDC6JF18H205857 5VCDC6JF38H205889 5VCDC6JF68H205899 5VCDC6JF98H205900 5VCDC6JF08H205901 5VCDC6JF28H205902 5VCDC6JF48H205903 5VCDC6JF68H205904 5VCDC6JF88H205905 5VCDC6JFX8H205906 5VCDC6JF18H205907 5VCDC6JF38H205908 5VCDC6JF58H205909 5VCDC6JF18H205910 5VCDC6JF38H205911 5VCDC6JF58H205912 5VCDC6JF78H205913 5VCDC6JF98H205914 5VCDC6JF08H205915 5VCDC6JF28H205916 5VCDC6JF48H205917 5VCDC6JF68H205918 5VCDC6JF88H205919 5VCDC6JF48H205920 5VCDC6JF68H205921 5VCDC6JF88H205922 5VCDC6JFX8H205923 5VCDC6JF18H205924 5VCDC6JF38H205925 5VCDC6JF58H205926 5VCDC6JF78H205927 5VCDC6JF98H205928 5VCDC6JF08H205929 4 of 22
5VCDC6KF48H205933 5VCDC6KF68H205934 5VCDC6JF68H205935 5VCDC6KFX8H205936 5VCDC6KF18H205937 5VCDC6JF18H205938 5VCDC6JF38H205939 5VCDC6JFX8H205940 5VCDC6JF18H205941 5VCDC6JF38H205942 5VCDC6JF58H205943 5VCD36JF78H205944 5VCDC6JF98H205945 5VCDC6JF68H205952 5VCDC6JF88H205953 5VCDC6JFX8H205954 5VCDC6JF18H205955 5VCDC6JF38H205956 5VCDC6JF58H205957 5VCDC6JF78H205958 5VCDC6JF98H205959 5VCDC6JF58H205960 5VCDC6JF78H205961 5VCDC6LE38H205962 5VCDC6LE58H205963 5VCDC6LE78H205964 5VCDC6LE98H205965 5VCDC6LE08H205966 5VCDC6LE48H205968 5VCDC6LE68H205969 5VCDC6LE28H205970 5VCDC6LE68H205972 5VCDC6LE88H205973 5VCDC6LEX8H205974 5VCDC6LE18H205975 5VCDC6LE38H205976 5VCDC6LE58H205977 5VCDC6JF28H205978 5VCDC6JF48H205979 5VCDC6JF08H205980 5VCDC6JF28H205981 5VCDC6JF48H205982 5VCDC6JF68H205983 5VCDC6JF88H205984 5VCDC6JFX8H205985 5VCDC6JF18H205986 5VCDC6JF58H205988 5VCDC6JF78H205989 5VCDC6JF38H205990 5VCDC6JF58H205991 5VCDC6JF78H205992 5VCDC6JF98H205993 5VCDC6JF08H205994 5VCDC6JF28H205995 5VCDC6JF48H205996 5VCDC6JF68H205997 5VCDC6JF88H205998 5VCDC6JFX8H205999 5VCDC6JF08H206000 5VCDC6JF28H206001 5VCDC6JF48H206002 5VCDC6JF68H206003 5VCDC6JF88H206004 5VCDC6JFX8H206005 5VCDC6JF18H206006 5VCDC6JF38H206007 5VCDC6JF58H206008 5VCDC6JF78H206012 5VCDC6JF98H206013 5VCDC6JF08H206014 5VCDC6KFX8H206052 5VCDC6KF18H206053 5VCDC6JF78H206057 5VCDC6JF98H206058 5VCDC6JF08H206059 5VCDC6JF08H206062 5VCDC6JF28H206063 5VCDC6JF88H206066 5VCDC6JFX8H206067 5VCDC6JF18H206068 5VCDC6JF38H206069 5VCDC6JFX8H206070 5VCDC6JF18H206071 5VCDC6JF38H206072 5VCDC6JF58H206073 5VCDC6JF78H206074 5VCDC6JF98H206075 5VCDC6JF08H206076 5VCDC6JF28H206077 5VCDC6JF48H206078 5VCDC6JF68H206079 5VCDC6JF28H206080 5VCDC6JF48H206081 5VCDC6KF88H206082 5VCDC6JF88H206083 5VCDC6JFX8H206084 5VCDC6KF58H206086 5VCDC6HE98H206090 5VCDC6JF78H206091 5VCDC6JF98H206092 5VCDC6JF08H206093 5VCDC6JF28H206094 5VCDC6JF88H206102 5VCDC6JFX8H206103 5VCDC6JF18H206104 5VCDC6JF38H206105 5 of 22
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) 5VCHC6JF48H205479 5VCHC6JF08H205480 5VCHC6JF28H205481 5VCHC6JF48H205482 5VCHC6KE48H205522 5VCHC6KE68H205523 5VCHC6KE88H205524 5VCHC6KEX8H205525 5VCHC6KE18H205526 5VCHC6JFX8H205602 5VCHC6JF18H205603 5VCHC6JFX8H205616 5VCHC6HE98H205619 5VCHC6HE58H205620 5VCHC6HE78H205621 5VCHC6KE08H205629 5VCHC6KE78H205630 5VCHC6KE98H205631 5VCHC6KE08H205632 5VCHC6KE28H205633 5VCHC6KE48H205634 5VCHC6KE68H205635 5VCHC6KE88H205636 5VCHC6KEX8H205637 5VCHC6KE18H205638 5VCHC6KE38H205639 5VCHC6KEX8H205640 5VCHC6KE18H205641 5VCHC6KE38H205642 5VCHC6KE58H205643 5VCHC6KE78H205644 5VCHC6KE98H205645 5VCHC6KE08H205646 5VCHC6KE28H205647 5VCHC6KE48H205648 5VCHC6JF88H205677 5VCHC6JFX8H205678 5VCHC6JE28H205679 5VCHC6JE98H205680 5VCH36JFX8H205681 5VCH36JF18H205682 5VCH36JF38H205683 5VCH36JF58H205684 5VCH36JF78H205685 5VCH36JF98H205686 5VCHC6JF48H205692 5VCHC6JF68H205693 5VCHC6KE08H205694 5VCHC6KE28H205695 5VCHC6KE48H205696 5VCHC6KE68H205697 5VCH36HE38H205812 5VCH36JF08H205835 5VCH36JF28H205836 5VCHC6KE68H205893 5VCHC6KE88H205894 5VCHC6HE48H205897 5VCHC6HE68H205898 5VCHC6JF58H205930 5VCHC6JF78H205931 5VCHC6JF98H205932 5VCHC6JF08H205947 5VCHC6JF28H205948 5VCHC6JF48H205949 5VCHC6JF08H205950 5VCHC6JF28H205951 5VCHC6HE08H206030 5VCH36JF58H206060 5VCH36JF78H206061 5VCHC6HE78H206087 5VCHC6HE98H206088 5VCHC6HE08H206089 5VCHC6JF28H206095 6 of 22
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) 5VCDC6JF68H205661 5VCDC6JF88H205662 5VCDC6JFX8H205663 5VCDC6JF18H205664 5VCDC6JF38H205665 5VCDC6JF28H206015 5VCDC6JF48H206016 5VCDC6JF68H206020 5VCDC6JF88H206021 5VCDC6JFX8H206022 5VCDC6JF18H206023 5VCDC6JF38H206024 5VCDC6JF58H206025 5VCDC6JF78H206026 5VCDC6JF98H206027 5VCDC6JF08H206028 5VCDC6JF28H206029 5VCDC6JF08H206031 5VCDC6JF28H206032 5VCDC6JF48H206033 5VCDC6JF68H206034 5VCDC6JF88H206035 5VCDC6JF38H206041 5VCDC6JF58H206042 5VCDC6JF78H206043 5VCDC6JF98H206044 5VCDC6JF08H206045 5VCDC6KF38H206054 5VCDC6KF58H206055 5VCDC6KF78H206056 5VCDC6LE68H206099 5VCDC6LE98H206100 5VCD36LE08H206101 5VCDC6JF58H206106 5VCDC6JF98H206108 5VCDC6JF08H206109 5VCDC6JF78H206110 5VCDC6JF98H206111 5VCDC6JF08H206112 5VCDC6JF28H206113 5VCDC6JF48H206114 5VCDC6KF88H206115 5VCDC6KFX8H206116 5VCDC6KF18H206117 5VCDC6KF38H206118 5VCDC6KF58H206119 5VCDC6KF18H206120 5VCDC6KF38H206121 5VCDC6KF58H206122 5VCDC6KF78H206123 5VCDC6KF98H206124 5VCDC6KF08H206125 5VCDC6KF28H206126 5VCDC6KF48H206127 5VCDC6KF68H206128 5VCDC6KF88H206129 5VCDC6JF28H206130 5VCDC6JF48H206131 5VCDC6JFX8H206134 5VCDC6JF58H206137 5VCDC6JF78H206138 5VCDC6JF98H206139 5VCDC6JF58H206140 5VCDC6JF78H206141 5VCDC6JF98H206142 5VCDC6KF18H206148 5VCDC6KF38H206149 5VCDC6KFX8H206150 5VCDC6KF18H206151 5VCDC6KF38H206152 5VCDC6KF58H206153 5VCDC6KF78H206154 5VCDC6KF98H206155 5VCDC6KF08H206156 5VCDC6KF28H206157 5VCDC6KF68H206159 5VCDC6KF28H206160 5VCDC6KF48H206161 5VCDC6KF68H206162 5VCDC6KF88H206163 5VCDC6KE28H206165 5VCDC6JF18H206166 5VCDC6JF38H206167 5VCDC6HE98H206168 5VCDC6HE08H206169 5VCDC6HE78H206170 5VCDC6JF58H206171 5VCDC6JF78H206172 5VCDC6JF98H206173 5VCDC6JF08H206174 5VCDC6KF48H206175 5VCDC6JF48H206176 5VCDC6JF98H206187 5VCDC6JF08H206188 5VCD36HE68H206189 5VCDC6KF08H206190 5VCDC6KF28H206191 5VCDC6KF48H206192 5VCDC6JF48H206193 5VCDC6JF68H206194 5VCDC6JF88H206195 5VCDC6JFX8H206196 5VCDC6JF18H206197 5VCDC6JF38H206198 5VCDC6JF58H206199 5VCDC6JF88H206200 5VCDC6JFX8H206201 5VCDC6JF18H206202 5VCDC6JF38H206203 5VCDC6JF58H206204 5VCDC6JF78H206205 5VCDC6JF98H206206 5VCD36HF58H206242 5VCD36HF78H206243 5VCD36HF98H206244 5VCDC6LE28H206245 5VCDC6LE48H206246 5VCDC6KE48H206250 5VCDC6KE68H206251 5VCDC6KE88H206252 5VCDC6KE38H206255 5VCDC6KE58H206256 5VCDC6KE78H206257 5VCDC6KE98H206258 5VCDC6KE08H206259 5VCDC6KE78H206260 5VCDC6JF58H206266 5VCDC6JF78H206267 5VCDC6JF98H206268 5VCDC6JF08H206269 5VCDC6KF98H206270 5VCDC6KF08H206271 7 of 22
5VCDC6JF28H206273 5VCDC6KF68H206274 5VCDC6KF38H206281 5VCDC6KF58H206282 5VCDC6JF58H206283 5VCDC6JF78H206284 5VCDC6JF98H206285 5VCDC6JF08H206286 5VCDC6JF28H206287 5VCDC6JF48H206288 5VCDC6JF68H206289 5VCDC6JF28H206290 5VCDC6JF48H206291 5VCDC6JF68H206292 5VCDC6HE18H206293 5VCDC6HE38H206294 5VCDC6HE58H206295 5VCDC6HE78H206296 5VCDC6JF58H206297 5VCDC6LE18H206298 5VCDC6JF98H206299 5VCDC6JF18H206300 5VCDC6JF38H206301 5VCDC6JF58H206302 5VCDC6JFX8H206313 5VCDC6JF18H206314 5VCDC6JF38H206315 5VCDC6JF58H206316 5VCDC6JF78H206317 5VCDC6JF98H206318 5VCDC6JF08H206319 5VCDC6JF78H206320 5VCDC6JF98H206321 5VCDC6JF08H206322 5VCDC6JF28H206323 5VCDC6JF48H206324 5VCDC6JF68H206325 5VCDC6JF88H206326 5VCDC6JFX8H206327 5VCDC6LE68H206328 5VCDC6JF38H206329 5VCDC6JFX8H206330 5VCDC6JF18H206331 5VCDC6JF38H206332 5VCDC6JF58H206333 5VCDC6JF78H206334 5VCDC6JF98H206335 5VCDC6JF08H206336 5VCDC6JF28H206337 5VCDC6KG58H206338 5VCDC6JF68H206339 5VCDC6JF28H206340 5VCDC6JF18H206345 5VCDC6JF38H206346 5VCDC6KG88H206348 5VCDC6KGX8H206349 5VCDC6JF58H206350 5VCDC6JF78H206351 5VCDC6JF98H206352 5VCDC6JF08H206353 5VCDC6JF28H206354 5VCDC6JF48H206355 5VCDC6JF68H206356 5VCDC6JF88H206357 5VCDC6JFX8H206358 5VCDC6JF18H206359 5VCDC6JF88H206360 5VCDC6JFX8H206361 5VCDC6HE78H206363 5VCDC6JF58H206364 5VCDC6JF78H206365 5VCDC6JF98H206366 5VCDC6JF08H206367 5VCDC6JF28H206368 5VCDC6JF48H206369 5VCDC6LE58H206370 5VCDC6LE98H206372 5VCDC6JF68H206373 5VCDC6KE08H206374 5VCDC6KE28H206375 5VCDC6KE48H206376 5VCDC6KE68H206377 5VCDC6KE88H206378 5VCDC6KEX8H206379 5VCDC6JF38H206380 5VCDC6JF58H206381 5VCDC6JF78H206382 5VCDC6JF98H206383 5VCDC6JF08H206384 5VCDC6JF28H206385 5VCDC6JF48H206386 5VCDC6JF68H206387 5VCDC6JF28H206404 5VCDC6LE28H206410 5VCDC6KE68H206413 5VCDC6KE88H206414 5VCDC6KF28H206417 5VCDC6KF48H206418 5VCDC6KFX8H206424 5VCDC6KF98H206432 5VCDC6KF38H206457 5VCDC6HE78H206458 5VCDC6JF58H206459 5VCDC6KE48H206460 5VCDC6KG98H206472 5VCDC6KG08H206473 5VCDC6KG28H206474 5VCDC6KF88H206504 5VCDC6KFX8H206505 5VCDC6KF18H206506 5VCDC6JF18H206510 5VCD36HE98H206560 5VCDC6JF28H206578 5VCDC6JF08H206580 5VCDC6JF28H206581 5VCDC6JF48H206582 5VCDC6JF68H206583 5VCDC6JF88H206584 5VCDC6JFX8H206585 5VCDC6JF58H206588 5VCDC6JF78H206589 5VCDC6JF38H206590 5VCDC6JF58H206591 5VCDC6JF78H206592 5VCDC6JF98H206593 5VCDC6JF08H206594 5VCDC6JF28H206595 5VCDC6JF48H206596 5VCDC6JF88H206598 5VCDC6JFX8H206599 5VCDC6JF68H206602 5VCDC6JF88H206603 5VCDC6JFX8H206604 5VCDC6JF18H206605 5VCDC6JF38H206606 8 of 22
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) 5VCHC6HE68H206064 5VCHC6HE88H206065 5VCHC6JF48H206096 5VCHC6JF68H206097 5VCHC6JF88H206098 5VCH36HE88H206132 5VCH36HEX8H206133 5VCHC6JF98H206143 5VCHC6JF28H206145 5VCHC6KF68H206146 5VCHC6KF88H206147 5VCHC6HEX8H206164 5VCHC6LE98H206177 5VCHC6LE28H206179 5VCHC6LE98H206180 5VCHC6LE08H206181 5VCHC6LE28H206182 5VCHC6LE48H206183 5VCHC6HE58H206184 5VCHC6HE78H206185 5VCHC6HE98H206186 5VCHC6HE38H206247 5VCHC6HE58H206248 5VCHC6JF38H206249 5VCH36HE98H206253 5VCH36HE08H206254 5VCHC6KE78H206261 5VCHC6KE98H206262 5VCHC6KE08H206263 5VCHC6KE28H206264 5VCHC6KE48H206265 5VCHC6JFX8H206278 5VCHC6JF18H206279 5VCHC6JF88H206280 5VCHC6JF58H206303 5VCHC6JF78H206304 5VCHC6JF98H206305 5VCHC6JF08H206306 5VCHC6JF28H206307 5VCHC6JF48H206308 5VCHC6JF68H206309 5VCHC6JF28H206310 5VCHC6JF48H206311 5VCHC6JF68H206312 5VCHC6JFX8H206362 5VCHC6JF68H206388 5VCHC6JF88H206389 5VCHC6JF48H206390 5VCHC6JF88H206392 5VCHC6JFX8H206393 5VCHC6JF18H206394 5VCHC6JF38H206395 5VCHC6JF98H206398 5VCHC6KF48H206419 5VCHC6KF08H206420 5VCHC6JF78H206609 5VCHC6KF18H206636 9 of 22
LOCKOUT/TAGOUT PROCEDURES Before entering the vehicle or vehicle body, read and follow OSHA regulations concerning entry and working in CONFINED SPACE OSHA 1910.146 and LOCKOUT/TAGOUT OSHA 1910.147. 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
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
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
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
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
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
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
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
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, S2010001B001. 18 of 22
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
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 14 20 of 22
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 15 21 of 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 877-973-3486 (extension 6062). 22 of 22