freightliner Custom Classic MT45 2022 User manual

WALK-IN VAN CHASSIS MAINTENANCE MANUAL
Models: MT45
MT45 G
MT50e
MT55
MT55 G
STI-471-7 (06/18/2022) Published by
Daimler Truck North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

Foreword
Scheduled maintenance provides a key element for safe operation of your vehicle. A proper maintenance program
also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information
necessary for years of safe, reliable, and cost-efficient vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instructions.
Perform daily pretrip inspection and maintenance as outlined in the vehicle operator’s manual. Perform the
operations in this maintenance manual at scheduled intervals based upon distance traveled or months of operation.
Your authorized servicing dealer has the qualified technicians and equipment to perform this maintenance for you.
Your dealership can also set up a scheduled maintenance program tailored specifically to your needs. Optionally,
your dealership can assist you in learning how to perform the maintenance procedures in this manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.
Freightliner Custom Chassis Corporation (FCCC) reserves the right to discontinue models and to change
specifications or design at any time without notice and without incurring obligation. Descriptions and
specifications contained in this publication provide no warranty, expressed or implied, and are subject to
revision and editions without notice.
Refer to https://northamerica.daimlertruck.com and www.FreightlinerChassis.com for more information, or
contact Daimler Truck North America LLC at the address below.
Environmental and Safety Concerns and Recommendations
Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them.
To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.
Servicing vehicles may result in contact with items known to the state of California to cause harm.
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause can-
cer and birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to
the outside. Do not modify or tamper with the exhaust system. Do not idle the engine except as neces-
sary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and Reproductive Harm www.P65warnings.ca.gov/diesel.
IMPORTANT: Modifications to fuel systems, emission related components, or air conditioning systems
may constitute a noncompliant EPA or CARB vehicle and such actions are prohibited.
NOTICE: Parts Replacement Considerations
Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used
parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage.

© 1997–2022 Daimler Truck North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval
system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Daimler Truck North America LLC. Daimler Truck North America LLC is a
Daimler company.
Daimler Truck North America LLC
Service Systems and Documentation
P.O. Box 3849
Portland, OR 97208–3849

Daimler Truck North America LLC distributes the following major service publications in paper and electronic
formats. Refer to www.DTNAConnect.com.
Workshop/Service
Manual
Workshop/service manuals contain service and repair information for all vehicle
systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifica-
tions, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Maintenance manuals should not be used for covering plant quality or quality
assurance issues. The purpose of maintenance manuals is to increase the life
of the component being maintained. These are recommendations, not require-
ments.
Driver’s/Operator’s
Manual
Driver’s/operator’s manuals contain information needed to enhance the driver’s
understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
ments, and related information. Some service bulletins are updates to informa-
tion in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
www.DTNAConnect.com website.
DTNAConnect DTNAConnect provides Web-based access to the most up-to-date versions of
the publications listed above. In addition, the Service Solutions feature provides
diagnostic assistance with Symptoms Search, by connecting to a large knowl-
edge base gathered from technicians and service personnel. Search results for
both documents and service solutions can be narrowed by initially entering ve-
hicle identification data.
PartsProX PartsProX® is an electronic parts catalog system, showing the specified vehi-
cle’s build record.
Introduction
Descriptions of Service Publications
Walk-In Van Chassis Maintenance Manual, July 2018 I–1

EZWiring EZWiring™makes Freightliner Custom Chassis Corporation, Freightliner, Ster-
ling, Western Star, and Thomas Built Buses products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.
Warranty-related service information available on the www.DTNAConnect.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.
Introduction
Descriptions of Service Publications
I–2 Walk-In Van Chassis Maintenance Manual, July 2018

For a page example of a Maintenance Manual page, see Fig. 1.
f020085
ABC
DE
10/27/98
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example of a Maintenance Manual Page
Introduction
Page Description
Walk-In Van Chassis Maintenance Manual, July 2018 I–3

Group No. Group Title
00...................... General Information
01................................ Engine
09.............................. AirIntake
15................... Alternators and Starters
20................... Engine Cooling/Radiator
26........................... Transmission
31 ............. Frame and Frame Components
32............................ Suspension
33 ............................. Front Axle
35 ............................. Rear Axle
40........................ Wheels and Tires
41 .............................. Driveline
42................................ Brakes
46............................... Steering
47 ................................. Fuel
49............................... Exhaust
54.......... Electrical, Instruments, and Controls
Introduction
Maintenance Manual Contents
I–4 Walk-In Van Chassis Maintenance Manual, July 2018

Title of Maintenance Operation (MOP) MOP Number
General Maintenance Schedule Information...............................................00–01
Noise Emission Controls Maintenance...................................................00–03
Vehicle Maintenance Schedule Table ................................................... 00–02
Verification of Inspections Log.........................................................00–04
General Information 00
Index, Alphabetical
Walk-In Van Chassis Maintenance Manual, May 2022

General Maintenance Schedule
Information
Performing regular maintenance on your vehicle will
help ensure that your vehicle delivers safe reliable
service and optimum performance for years to come.
Failure to follow a regular maintenance program can
result in inefficient operation and unscheduled down
time.
When the vehicle reaches the distance given for a
maintenance interval, see the Vehicle Maintenance
Schedule Table for a list of the maintenance opera-
tions to be performed at that maintenance interval.
Use the maintenance operation reference numbers to
find detailed instructions in the manual for each op-
eration.
NOTE: Maintenance instructions in this manual
are based on average vehicle use and normal
operating conditions. Unusual vehicle operating
conditions may require service at more frequent
intervals.
For specific engine maintenance information, see the
Cummins or Mercedes-Benz Operation and Mainte-
nance Manual.
IMPORTANT: Maintenance operations appearing
in italics in the following table are for noise
emission control components. Numbers in the
table are reference numbers matching those in
the text of this manual.
General Information 00
General Maintenance Schedule Information: 00–01
Walk-In Van Chassis Maintenance Manual, May 2022 00/1

Vehicle Maintenance Schedule
Maintenance Operation Number
and Description
Maintenance Interval in Miles x 1000
510152025 30354045505560 65 70 75 80 85 90 95 100
Maintenance Interval in Kilometers x 1000
8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160
01–01 Engine-Support Fasteners
Checking •••• •
01–02 Engine Drive Belt Inspecting • • • • •
01–03 Engine Oil and Filter Checking and
Changing, Gasoline Engines
For 6.0 L gasoline engines, change the engine oil and filter every 5000 miles
(8045 km).
For 6.6 L gasoline engines, change the engine oil and filter every 7500 miles
(12 068 km); more frequent oil changes may be required for severe driving
conditions.
01–04 Spark Plugs and Wires—Gasoline,
Propane and CNG Engines
For gasoline engines, replace spark plugs and wires every 97,500 miles (157
000 km).
For propane and CNG engines, replace the spark plugs every 50,000 miles (80
450 km).
01–05 Evaporative Control System
Inspecting, Gasoline Engines •• •••• • • • •
08–01 Electric Motor Inspection, Electric
Vehicle ••••• ••••••• ••••••••
09–01 Air Cleaner Element Inspecting
and Replacing
Inspect the air filter every six months. Replace the air filter every 12 months, or
when filter restriction reaches 25 inH
2
0 for Cummins diesel engines OR when
the air restriction indicator is completely red for gasoline and Detroit™diesel
engines (if equipped with an air restriction indicator).
09–02 Air Cleaner Filter Minder Gauge
Checking ••••• ••••••• ••••••••
09–03 Air Intake System Inspecting ••••• ••••••• ••••••••
09–04 Charge Air Cooler Checking ••••• ••••••• ••••••••
15–01 Alternator, Battery, and Starter
Connections Check •• • • •
20–01 Coolant Replacement
Replace the organic acid technology (OAT) coolant every 600,000 miles (965
400 km); supplemental coolant additives (SCAs) are not used with OAT coolant.
Replace SCA pre-charge ethylene glycol coolants every 35,000 miles (56 315
km). You must check and, if necessary, recharge the SCA levels and freeze
point every 25,000 miles (40 225 km) or 6 months, whichever comes first.
Replace DEX-COOL coolant (gasoline engines only) every 150,000 miles (241
350 km). See the applicable engine operation and maintenance manual for
further information.
20–02 Cooling Fan Inspection (Noise
Emission Control) •• • • •
20–03 Coolant Heater Check, Webasto Inspect the coolant heater every 12 months.
General Information00
Vehicle Maintenance Schedule Table: 00–02
Walk-In Van Chassis Maintenance Manual, May 202200/2

Vehicle Maintenance Schedule
Maintenance Operation Number
and Description
Maintenance Interval in Miles x 1000
510152025 30354045505560 65 70 75 80 85 90 95 100
Maintenance Interval in Kilometers x 1000
8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160
20–04 Coolant Replacement, Electric
Vehicle
Replace the organic acid technology (OAT) coolant every 600,000 miles (965
400 km); supplemental coolant additives (SCAs) are not used with OAT coolant.
Replace SCA pre-charge ethylene glycol coolants every 35,000 miles (56 315
km). You must check and, if necessary, recharge the SCA levels and freeze
point every 25,000 miles (40 225 km) or 6 months, whichever comes first.
Replace DEX-COOL coolant (gasoline engines only) every 150,000 miles (241
350 km). See the applicable engine operation and maintenance manual for
further information.
31–01 Interlube Chassis Lubrication
System Inspecting ••••• ••••••• ••••••••
32–01 Suspension Inspecting ••••• ••••••• ••••••••
32–02 Freightliner Suspension Inspecting ••••• ••••••• ••••••••
32–03 Component Inspecting and
Operation Checking, Freightliner AirLiner ••••• ••••••• ••••••••
32–04 Suspension U-Bolt Torque
Checking ••••• ••••••• ••••••••
33–01 Grease-Lubricated Wheel Bearing
Cleaning, Inspecting, Repacking, and
Adjusting, Front Axle
••• •
33–02 Knuckle Pin Lubricating*••• • •
33–03 Tie-Rod End Lubricating and
Inspecting†Lubricate twice each month. Lubricate the tie-rod ends each time the chassis is power-washed.
33–04 All-Axle Alignment Checking ••
33–05 Oil-Filled Hubs Oil Level Checking •••• •••• •••• ••••
33–06 Oil-Filled Hubs Oil Changing •• • •
35–01 Axle Lubricant Changing
For Detroit™rear axles with petroleum-based oil, change the lubricant every
100,000 miles (160 900 km) or every 12 months, whichever comes first; if
synthetic oil is used, change the lubricant every 250,000 miles (402 250 km) or
every 36 months, whichever comes first. For Meritor rear axles with petroleum-
based oil, change the lubricant at 100,000 miles (160 900 km) or at 12 months
of service, whichever comes first, and every 24 months thereafter; if synthetic oil
is used, change the lubricant every 250,000 miles (402 250 km) or every 36
months, whichever comes first.
35–02 Axle Lubricant Checking ••••• ••••••• ••••••••
35–03 Axle Breather Checking • • • • • • • ••••• ••••••••
40–01 Wheel Nut Checking‡••••• ••••••• ••••••••
41–01 Driveline Inspection and
Lubrication ••••• ••••••• ••••••••
42–01 Bendix Hydro-Max® Brake System
Inspection ••• • •
General Information 00
Vehicle Maintenance Schedule Table: 00–02
Walk-In Van Chassis Maintenance Manual, May 2022 00/3

Vehicle Maintenance Schedule
Maintenance Operation Number
and Description
Maintenance Interval in Miles x 1000
510152025 30354045505560 65 70 75 80 85 90 95 100
Maintenance Interval in Kilometers x 1000
8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160
42–02 Brake Lines Check, Hydraulic Disc
Brakes ••••• ••••••• ••••••••
42–03 Brake Lining Wear Check,
Hydraulic Disc Brakes§•••••
42–04 Brake Caliper Slide Pin
Lubrication, Bosch Brakes
No specific lubrication interval. See the Bosch Pin Slide Disc Brakes Service
Manual for more information.
42–05 Brake Inspection ••••• ••••••• ••••••••
42–06 Slack Adjuster Lubrication • • • • • • • ••••• ••••••••
42–07 Air Dryer Desiccant and
Coalescent Filter Replacement
Replace the Bendix AD9 filter and the Haldex PURest air dryer filter kit every 36
months.
42–08 Air Dryer Check Perform the air dryer check every six months.
42–09 Versajust Slack Adjuster Inspection
and Lubrication
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500
operating hours, whichever comes first.
42–10 Bendix Automatic Drain Valve
Operating and Leakage Tests
The automatic drain valve should be inspected every 6 months or 1500
operating hours, whichever comes first.
46–01 Drag Link Lubricating Lubricate twice each month. Lubricate the drag link ends each time the chassis
is power-washed.
46–02 Power Steering Hose Checking • • • • •
46–03 Steering Driveline Lubricating • • • ••
46–04 Steering Gear Bolts Torque
Checking •• •
46–05 Power Steering Reservoir Fluid
and Filter Changing •
46–06 Power Steering Motor Lubrication,
Electric Vehicle
Lubricate the power steering motor in the electric vehicle every 6000 miles
(9654 km) or 12,000 operating hours, whichever comes first.
46–07 Power Steering Fluid and Filter
Changing, Electric Vehicle •
47–01 CNG High-Pressure Fuel Filter
Replacement ••••• ••••••• ••••••••
47–02 CNG Fuel Leak Test ••••• ••••••• ••••••••
47–03 CNG High-Pressure Fuel Filter
Draining Drain the high-pressure fuel filter every 2500 miles (4023 km).
47–04 CNG Fuel Block Housing Draining •• • •
47–05 CNG Low-Pressure Fuel Filter
Replacement •• • •
47–06 CNG Low-Pressure Fuel Filter
Draining •••• •••• •••• ••••
General Information00
Vehicle Maintenance Schedule Table: 00–02
Walk-In Van Chassis Maintenance Manual, May 202200/4

Vehicle Maintenance Schedule
Maintenance Operation Number
and Description
Maintenance Interval in Miles x 1000
510152025 30354045505560 65 70 75 80 85 90 95 100
Maintenance Interval in Kilometers x 1000
8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160
47–07 CNG Fuel Tank Visual Inspection Inspect the fuel tank every 12 months. The fuel tank must be replaced every 15
years.
47–08 Diesel Fuel Filter Replacement •• •••• • • • •
47–09 Gasoline Fuel Filter Replacement Replace the fuel filter every five years or 150,000 miles (241 350 km),
whichever comes first.
49–01 Exhaust System Inspecting (Noise
Emission Control) •••• • •
54–01 Battery Voltage Check ••••• ••••••• ••••••••
54–02 Battery, Battery Box, and Cable
Checking and Cleaning ••••• ••••••• ••••••••
54–03 Ground Cables Checking and
Cleaning ••••• ••••••• ••••••••
54–04 Electrical System Checking •• • • •
54–05 Battery Voltage Checking ••••• ••••••• ••••••••
54–06 Charge Port Inspection, Electric
Vehicle
Inspect the charge port every 16,000 miles (25 750 km) or 12 months,
whichever comes first.
54–07 Battery Pack Desiccant
Replacement, Electric Vehicle
Replace the battery pack desiccant every 16,000 miles (25 750 km) or 12
months, whichever comes first.
*Lubricate knuckle pins at first 5000 miles (8000 km); thereafter, at indicated intervals OR every 12 months, whichever comes first. For vehicles with Detroit
axles, complete this procedure once a year or every 5000 miles (8000 km), whichever comes first.
†For vehicles with Detroit axles, complete this procedure once per year or at 5000 miles (8000 km), whichever comes first.
‡Wheel nuts must be retightened to torque specifications at 50 and 500 miles (80 and 900 km), OR at new vehicle operation, and at any wheel change or any
time the nuts have been loosened; thereafter, at indicated intervals.
§Check brake lining at first 5,000 miles (8045 km); thereafter, at indicated intervals OR every 12 months, whichever comes first.
Table 1, Vehicle Maintenance Schedule
General Information 00
Vehicle Maintenance Schedule Table: 00–02
Walk-In Van Chassis Maintenance Manual, May 2022 00/5

Noise Emission Controls
Maintenance
Federal Law, Part 205:
Transportation Equipment Noise
Emission Controls
Part 205, Transportation Equipment Noise Emission
Controls, requires the vehicle manufacturer to fur-
nish, with each new vehicle, such written instructions
for the proper maintenance, use, and repair of the
vehicle by the ultimate purchaser to provide reason-
able assurance of the elimination or minimization of
noise-emission-control degradation throughout the
life of the vehicle. In compliance with the law, the
noise emission controls maintenance information in
each applicable group of this manual, in conjunction
with the vehicle workshop manual, provides these
instructions to owners.
Recommendations for
Replacement Parts
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freight-
liner Custom Chassis Corporation (FCCC) parts. If
other than genuine FCCC parts are used for replace-
ment or repair of components affecting noise emis-
sion control, the owner should be sure that such
parts are warranted by their manufacturer to be
equivalent to genuine FCCC parts in performance
and durability.
Freightliner Noise Emission
Controls Warranty
See the vehicle owner’s warranty information book
for warranty information concerning noise emission
controls.
Tampering With Noise Controls is
Prohibited
Federal law prohibits the following acts or the caus-
ing thereof:
1. The removal or rendering inoperative by any per-
son (other than for purposes of maintenance,
repair, or replacement) of any device or element
of design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser, or while it is in
use.
2. The use of the vehicle after such device or ele-
ment of design has been removed or rendered
inoperative by any person.
Among those acts presumed to constitute tam-
pering are the acts listed below:
A. Removal of, or rendering inoperative, the en-
gine speed governor so as to allow engine
speed to exceed manufacturer’s specifica-
tions.
B. Removal of, or rendering inoperative, the fan
clutch, including bypassing the control on
any thermostatic fan drive to cause it to op-
erate continuously.
C. Removal of the fan shroud.
D. Removal of, or rendering inoperative, ex-
haust components, including exhaust pipe
clamping.
E. Removal of air intake components.
Maintenance Instructions
Scheduled intervals are in the maintenance table in
this group. A "Verification of Inspections Log (Groups
20 and 49)" follows, and should be filled in each time
noise emission controls on the vehicle are main-
tained or repaired.
General Information00
Noise Emission Controls Maintenance: 00–03
Walk-In Van Chassis Maintenance Manual, May 202200/6

Verification of Inspections Log
Verification of Inspections Log, Groups 20 and 49
Date Mileage Item Cost Maintenance Facility
Group 20 — Fan Clutch
Group 49 — Exhaust System Components
General Information 00
Verification of Inspections Log: 00–04
Walk-In Van Chassis Maintenance Manual, May 2022 00/7

Title of Maintenance Operation (MOP) MOP Number
Engine Drive Belt Inspecting..........................................................01–02
Engine Oil and Filter Checking and Changing, Gasoline Engines...............................01–03
Engine-Support Fasteners Checking....................................................01–01
Evaporative Control System Inspecting, Gasoline Engines....................................01–05
Safety Precautions.................................................................01–00
Spark Plugs and Wires Inspecting and Replacing—Gasoline, Propane and CNG
Engines.........................................................................01–04
Engine 01
Index, Alphabetical
Walk-In Van Chassis Maintenance Manual, May 2022