vehicle at least once a year. Remember that regular maintenance and
replacement of worn components will usually prevent serious problems
from developing later.
Making modifications to various parts, components and systems
of the vehicle, such as brake and steering systems can adversely
affect the quality, reliability and operation of your vehicle and could
result in property damage, personal injury or death. Such modifications
must be avoided.
The lubrication intervals present a good opportunity to inspect the
vehicle. It is suggested that the various points listed herein be checked
at the lubrication or other recommended intervals.
Failure to properly perform maintenance and servicing
procedures could result in vehicle damage, personal injury or
death.
If the owner/operator of the vehicle is a skilled technician and intends on
performing the vehicle maintenance and service, he is strongly urged to
purchase a service manual.
Take care when performing any maintenance, system check or
service on your vehicle. Some of the materials may also be
hazardous if used, serviced or handled improperly and could result in
property damage, personal injury or death.
Air conditioning system checks
Have your air conditioning system checked each spring. The refrigerant
charge, cleanliness of the condenser-evaporator cores and belt condition
is essential to air conditioning performance.
When the air conditioning system is being used daily, remove the fresh
air filter (if equipped) once each season and check for dirt, lint, etc.
Replace the filter if necessary. Vehicles operating in unusually dusty
conditions may require inspecting and replacing the fresh air filter more
often.
Front axle - general service information
Maintaining the front axle alignment to specifications is very important
and should only be performed by a qualified technician. Toe-in
adjustment is particularly important with radial tires.
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Check to make sure that the axle mounting U-bolt nuts, attaching or
mounting bolts and nuts are securely tightened. Regularly check front
axle for damage, binding, worn parts and adequate lubrication.
At regular intervals, or during other scheduled maintenance, (tire
rotation/service, wheel bearing service, alignment, etc.) the kingpins
should be checked for excessive wear. Refer to the service manual for
proper procedures.
Toe-in setting - general inspection
Inspecting steer axle tires in the first 3,000–10,000 service miles
(4,800–16,000 service km) will generally show if tires are wearing
normally.
Rapid outside shoulder wear on both tires indicates too much toe-in.
Rapid inside shoulder wear on both tires indicates too much toe-out. In
P&D-type service, left-to-right steer tire tread life differentials up to 40%
can be observed depending on routes and other variables.
Follow the tire manufacturer’s recommended cold inflation pressure for
the tire size, load range (ply rating) and steer axle loading typical for
their operation (each steer axle tire will equal
1⁄2steer axle loading).
Special applications may warrant a setting based on past experience with
the type of tire operating loads and conditions. Radial tires are more
sensitive to toe-in setting than bias ply tires. While not insensitive to
vehicle alignment, fine tuning school bus alignment to line-haul truck
standards will not drastically improve tire tread life.
It is essential that correct toe-in and tire pressure be maintained for
optimum tire wear.
Rear axle - general inspection
Check to make sure that the axle mounting U-bolts, attaching or
mounting bolts and nuts are securely tightened. Refer toU-bolt nut
torque chartin this chapter. Regularly check the rear axle for damaged,
binding or worn parts.
NoSpin Detroit Locker positive locking differential
Vehicle equipped with this type differential have the operator’s manual
supplied with the vehicle. Refer to this manual for maintenance checks.
Brake system - general inspection
Your vehicle is equipped with non-asbestos brake linings. However,
exposure to excessive amounts of brake material (whether asbestos or
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Note:Always observe the following instructions:
•Always loosen rim clamps before complete removal of nut from stud
(cast spoke wheels). With loosened nuts on stud, strike clamps with a
heavy hammer and be sure each clamp is loose.
•Always deflate tires completely before removing locks or side rings.
•Always inflate tires in a safety cage.
•Never mix rim side rings or lock rings of different types,
manufacturers or sizes.
•Never use cracked, bent or badly rusted parts.
•Never re-inflate flat tires on-vehicle; use the spare tire.
•Never add air until each side ring or lock ring is fully seated.
•
Never hammer side ring or lock ring on a partially- or fully-inflated tire.
Failure to follow these instructions could result in property
damage, personal injury or death
Proper torque
It is important to tighten and maintain wheel and rim mounting nuts to the
proper torque. Loose nuts or over-tightened nuts can lead to premature
wear and possible failure of the wheel and/or mounting hardware.
Changing wheel types
Consult your dealer or wheel/rim distributor before attempting any wheel
or fastener changes.
Use only the same type and style wheels and mounting hardware
to replace original parts. Failure to do so may result in an
assembly that looks fine, but does not fit together properly. This could
possibly cause wheel or fastener failures which could result in property
damage, personal injury or death.
Note:Do not attempt to mix stud-piloted wheels or fasteners with
hub-piloted wheels or fasteners.
Note:Do not change from aluminum wheels to steel wheels or
vice-versa without changing the mounting hardware required or, with
flange-nut mounting systems, changing the hub and stud assembly.
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Daily Owner
ChecksEngine system
Check the air filter restriction indicator
Check the engine oil
Inspect the coolant level - for Power Stroke engine (for
Caterpillar and Cummins engines, refer to the Owner’s Manual)
Brake system
Drain the air brake system reservoir - manual valve
Check the air brake system reservoir automatic drain valve
operation
Transmission system
Visually check the automatic transmission for fluid leakage
Steering system
Check the power steering pump fluid level and check the system
for leaks
Check the entire vehicle for evidence of fluid leaks
U.S. Department of Transportation, Federal Highway
Administration requirements (ensure that the entire
system is functioning properly)
Check the service brakes
Check the parking brake
Check the steering mechanism
Check the lighting devices and reflectors
Check the tires
Check the horn
Check the windshield wipers
Check the rear vision mirrors
Check the wheels and rims
Check the emergency equipment
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Maintenance Operation Frequency - Observation
Inspect the automatic slack
adjuster functionInsufficient power shown in loaded
practice stop
Check the operation of the
brakes, the clutch, and the
steering (A, B)Vehicle handling qualities not up to
par
Inspect the vehicle for missing,
damaged, or mislocated noise
shieldsExcessive noise emanates from under
the cab or engine compartment
Check the engine performance
and the engine governorExcessive engine noise
Inspect the fan, the fan shroud,
and the fan clutchEngine overheats, fans runs at high
speed constantly, excessive fan noise,
or fan wobble due to worn bearings
Check for operation of ABS
warning lampAt each engine start up
Inspect the entire exhaust
system (including inlet pipe,
muffler, outlet pipe and all
exhaust clamps and fasteners)
for holes, leakage, breakage,
looseness and corrosive
damageExcessive noise or the smell of fumes
is experienced
Inspect the engine air
induction system (including the
air ducts, the air cleaner, and
the air cleaner element) for
loose fitting, damaged or
missing componentsExcessive noise emanates from the
engine compartment
Inspect the tires and check the
air pressure (C)Poor steering, wandering or excessive
tire wear
Balance the wheels and the
tiresVibration or abnormal tire wear
indicates imbalance
Check the front end alignment
(C)Poor steering, wandering or excessive
tire wear
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Maintenance Operation Frequency - Observation
Check the transmission and
engine mountings (B)Hard shifting or excessive vibration
Check and adjust transmission
controls (B)High effort to shift or noisy
transmission
Check fuel pump pressure Insufficient full-throttle power or
backfiring
Clean radiator cap seal. Clean
and inspect the cap surface on
the radiatorWhen the cap does not hold pressure
Check the battery terminals for
corrosionWhenever electrical power supply has
diminished
Tighten the wheel mounting
nuts to the specified torque.
Refer toServicing your
wheels and tiresRequired initially at 500 and 1000
miles (800 and 1600 km). Perform
again at 500 and 1000 mile (800 and
1600 km) intervals after each tire
removal/replacement.
A - During maintenance and repair, protect the fuel tube and the hose
assemblies, the power steering lines, and the brake lines from the
external heat, the acids and the abrasion that could damage the lines.
B - Check for (free) linkage action and ensure that (return) spring
force is adequate to maintain pedal free play.
C - Adjust, repair or replace as required with the same or equivalent
parts.
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Parking brake ......................95, 102
warning light .............................21
Power door locks ........................64
Power mirrors .............................57
Power point .................................54
Power steering ..........................182
fluid, checking and adding ....183
fluid, refill capacity ................223
fluid, specifications .................213
Power Windows ...........................55
R
Radio ..........................30, 32, 35, 39
Relays ........................................141
Remote entry system
locking/unlocking doors ...........64
Roadside assistance ..................139
S
Safety belts
(see Safety restraints) .........70–72
Safety defects, reporting ..........157
Safety restraints ....................70–72
belt minder ...............................75
cleaning the safety belts ..........79
extension assembly ..................78
for adults .............................71–72
for children .........................79–80
lap belt ......................................74
warning light and
chime .............................21, 74–75
Safety seats for children ............83
Seat belts
(see Safety restraints) ...............70
Seats ............................................65
child safety seats ......................83heated ........................................69
Servicing your vehicle ..............231
Special notice ................................6
Specification chart,
lubricants ...................................213
Speed control ..............................58
Speedometer ...............................26
Starting your vehicle ..................87
jump starting ..........................147
preparing to start your
vehicle .......................................87
Steering .....................................182
Steering wheel
controls ................................53, 58
tilting .........................................53
Suspension ........................115, 201
T
Tachometer .................................26
Temperature control
(see Climate control) ...........44–45
Tires
checking the pressure ............210
Towing
wrecker ....................................150
Traction control
off light ......................................21
Transmission .....................118, 123
automatic operation ...............118
fluid, checking and adding
(automatic) .............................185
fluid, checking and adding
(manual) .................................186
fluid, refill capacities ..............223
lubricant specifications ..........213
manual operation ....................123
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Index
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