1988-2002 Freightliner Business Class FL/MB Trucks (FL50, FL60, FL70, FL80, FL106, FL112, MB50, MB60, MB70, MB80) OEM Service & Repair Manual
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BUSINESS CLASS TRUCKS SERVICE MANUAL
Models: FL50
FL60
FL70
FL80
FL106
FL112
MB50
MB60
MB70
MB80
STI-267, S34 (1/08P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Foreword
The purpose of this manual is to assist the service technician when the vehicle is serviced. Major
drivetrain component service information is not included in this manual, but is located in each
manufacturer’s service manual.
Instructions and procedures are those recommended by Daimler Trucks North America LLC or
the component manufacturer.
Maintenance schedules and additional service information are included in the Business Class
®
Trucks Maintenance Manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time
of printing. Daimler Trucks North America LLC reserves the right to discontinue models
at any time, or change specifications and design without notice and without incurring
obligation.
For additional information, please contact Daimler Trucks North America LLC, Service Systems
and Documentation, P.O. Box 3849, Portland, OR 97208-3849, U.S.A. or refer to www.Daimler-
TrucksNorthAmerica.com and www.FreightlinerTrucks.com.
Environmental 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.
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.
© 1995-2008 Daimler Trucks 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 Trucks
North America LLC.
Daimler Trucks North America LLC
Service Systems and Documentation (POC-SSD)
P.O. Box 3849
Portland, OR 97208-3849
Daimler Trucks North America LLC distributes the following major service publications.
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, specifications, and troubleshooting.
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, procedures for adjustments and for checking the tightness of fasteners.
Maintenance manuals do not contain detailed repair or service information.
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 pretrip inspection and daily mainte-
nance of vehicle components. Driver’s/operator’s manuals do not contain de-
tailed repair or service information.
Parts Technical Manual Daimler Trucks North America LLC publishes this manual to aid in the identifica-
tion of serviceable replacement vehicle parts. This manual is used in conjunc-
tion with the parts book and the service parts catalog microfiche.
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.
Recall Bulletins These bulletins pertain to special situations that involve service work or replace-
ment of parts in connection with a recall notice. Recall bulletins pertain to mat-
ters of vehicle safety. All bulletins are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service
Modifications
This publication is concerned with non-safety-related service work or replace-
ment of parts. All field service modifications are distributed to dealers; custom-
ers receive notices that apply to their vehicles.
Introduction
Descriptions of Service Publications
Business Class Trucks Service Manual, Supplement 35, September 2008 I–1
For a page example of the printed manual, see Fig. 1.
A B C
F G
D
E
f020023
06/13/94
A. Subject Topic
B. Section Title
C. Section Number; made up of the Group Number (first
two digits) followed by a sequence number (last two
digits)
D. Subject Title
E. Manual Title
F. Supplement Number and Release (Supplement) Date
G. Subject Number/Subject Page Number
Fig. 1, Page Example of the Printed Manual
Introduction
Page Description
I–2 Business Class Trucks Service Manual, Supplement 35, September 2008
Group No. Group Title
00 ...................... General Information
01 ................................ Engine
09 .............................. Air Intake
13 ......................... Air Compressor
15 ................... Alternators and Starters
20 ................... Engine Cooling/Radiator
25 ................................ Clutch
26 ........................... Transmission
30 ......................... Throttle Control
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
60 .................................. Cab
72 ................................ Doors
82 ............. Windshield Wipers and Washer
83 ................. Heater and Air Conditioner
88 .............. Hood, Grille, and Cab Fenders
90 ................. Fire Suppression Systems
91 ............... Seats and Restraint Systems
98 ................................. Paint
Introduction
Service Manual Contents
Business Class Trucks Service Manual, Supplement 35, September 2008 I–3
Vehicle Receipt
Prior to signing for vehicle delivery from a transporter
company, the dealer is responsible for checking for
transporter-related shortages or damages, and noting
these discrepancies on the transporter’s delivery re-
ceipt.
The dealer is also responsible for ensuring that the
vehicle was built according to the Truck Sales Order/
Invoice.
Refer to Section 3 of the Freightliner LLC Warranty
Manual for details.
Vehicle Storage
There may be times when a vehicle is stored for long
periods before customer delivery. To protect all ve-
hicles from deterioration and weather, they must be
properly maintained. Adequate protection and stor-
age of new vehicles is the responsibility of the
dealer.
Claims arising from loss and damage to improp-
erly stored vehicles will not be reimbursed.
See Section 3 of the Freightliner LLC Warranty
Manual for instructions on storage of new vehicles.
Pre-Delivery Information
All pre-delivery inspections and services must be
performed at an authorized Freightliner LLC facility,
assigned to fully qualified service personnel and re-
corded on the "New Vehicle Pre-Delivery Inspection"
form.
Refer to Section 3 of the Freightliner LLC Warranty
Manual for details.
It is recommended the pre-delivery inspection be per-
formed within 30 days of vehicle receipt.
Vehicle Receipt, Storage, and Pre-Delivery Information 00.01
General Information
Business Class Trucks Service Manual, Supplement 29, October 2002 050/1
Cooling System
1. Cooling system hoses must clear all moving
parts by a minimum of 1/4 inch (6 mm).
2. The 1-inch (25-mm) hose from the surge tank to
the engine must be free of sumps and have al-
lowance for engine torque.
3. Cooling system hoses should not be twisted or
kinked.
4. Cooling system hoses must be routed at least six
inches (152 mm) from a heat source if the heat
source does not have a heat shield. If a heat
shield is provided, the hose must be routed at
least three inches (76 mm) from the heat source.
HVAC System
1. Cushion clamps are required to support all A/C
lines. Butterfly or figure-8 clamps (two cushion
clamps) may be used to prevent rubbing or chaf-
ing.
2. Tie straps may only be used to fasten together
A/C lines that are parallel to each other.
3. Heater hoses that are protected with convoluted
tubing may be fastened with tie straps. Other-
wise, only cushion clamps or butterfly clamps
may be used for heater hoses.
4. A/C lines cannot be secured to air lines, fuel
lines, or electrical wires.
5. HVAC hoses should be protected from damage
by routing them away from hazards of heat,
wheel splash (water, gravel, ice), human traffic,
and moving parts of the vehicle.
6. HVAC hoses should be routed away from sharp
points and edges (such as nuts, bolts, brackets,
and frame rail edges), moveable parts, and
sources of abrasion, cutting, pinching, or crush-
ing.
NOTE: If hoses are covered with convoluted
tubing, they may touch any of the above.
7. Hoses that are protected with convoluted tubing
may come in contact with the bends on frame
rails and filters.
8. HVAC hoses must be routed at least six inches
(152 mm) from a heat source if the heat source
does not have a heat shield. If a heat shield is
provided, the hose must be routed at least three
inches (76 mm) from the heat source.
9. HVAC hoses should be clamped every 12 to 18
inches (305 to 457 mm).
10. All HVAC hoses must be routed so that regularly
serviced components, such as fuel filters, fuel/
water separators, oil filters, air filters, belts, and
fill and drain plugs, are readily accessible for ad-
justment or replacement without the need to relo-
cate or remove the hoses.
Engine Plumbing
The engine oil pressure line should not rub or chafe
against the Teflon
®
discharge line.
Electrical Wiring
1. Wires that are bundled together should be fas-
tened at 8- to 12-inch (203- to 305-mm) intervals.
If anchor clamps are more than 12 inches (305
mm) apart, a tie strap must be used between the
anchor clamps.
2. Bundles of wires that are located in an exposed
area, such as under the cab or outside the frame
rail, need to be fastened with heavy-duty cable
ties.
3. Any wiring that will be exposed to water or heat
must be covered with either loom or convoluted
tubing. Loom or convoluted tubing need not butt
up against Weather Pack
®
connectors.
4. Any wiring routed across the vehicle, on the en-
gine crossmember, or across the rear of the en-
gine, must be secured with a clamp or tie strap,
and covered with either convoluted tubing or a
loom.
5. Any wiring that may come into contact with sharp
points and edges (such as nuts, bolts, brackets,
and frame rail edges), moveable parts, and
sources of abrasion, cutting, pinching, or crush-
ing, must be protected by either a loom or con-
voluted tubing.
6. Unprotected breakouts (individual wires) of up to
eight inches (203 mm) are acceptable as long as
these wires are routed safely away from sharp
Vehicle Receipt, Storage, and Pre-Delivery Information 00.01
Hoses and Electrical Wiring Routing Standards
Business Class Trucks Service Manual, Supplement 29, October 2002 100/1
points and edges, moveable parts, and sources
of abrasion, cutting, pinching, or crushing.
7. Gray, flame-retardant convoluted tubing may be
used to protect wiring in the cab or the chassis.
Black nylon convoluted tubing may only be used
in the chassis.
8. All wiring must be routed so that regularly ser-
viced components, such as fuel filters, fuel/water
separators, oil filters, air filters, belts, and fill and
drain plugs, are readily accessible for adjustment
or replacement without the need to relocate or
remove any wiring.
9. In exposed locations, such as the road light har-
ness near the headlights, loose loops of wire
must be secured with tie straps.
10. All wiring should be routed a minimum of four
inches (102 mm) from the exhaust. In situations
where the wiring is less than four inches (102
mm) from the exhaust, a heat shield must be
placed between the wiring and the exhaust.
Battery Cables
1. Battery cables must be routed along an unob-
structed path from the starter to the battery box.
The cables must not rub or chafe on brackets,
tanks, air lines or fuel lines.
2. Battery cables and electrical wiring cannot be
tied or secured to fuel lines, discharge lines, or
air lines.
3. Battery cables must have support brackets no
more than 30 inches (762 mm) apart. Tie straps
must be within six inches (152 mm) of both sides
of the support brackets, and every 12 inches
(305 mm) between the brackets.
4. Battery cables must have convoluted tubing from
the frame bracket to the batteries, and from the
frame bracket to the starter.
Fuel Lines
1. Fuel lines must not be clamped to A/C lines, bat-
tery cables, jumper cables, or any other electrical
wiring.
2. Stand-off brackets or clamps may be used to
prevent fuel lines from rubbing against the frame.
3. Fuel lines must be routed at least six inches (152
mm) from a heat source. If a heat shield is pro-
vided, the fuel line must be at least three inches
(76 mm) from the heat source.
4. Fuel lines that are parallel may be fastened to-
gether. Fuel lines that cross or that rub on metal,
plastic, or electrical parts, need to be separated
with butterfly clamps.
Chassis Air Lines and Brake
Hoses
1. Hoses may come in contact with each other if
they are parallel, or if they are bundled together.
2. If the hoses lie on the curve or flat surface of a
bracket or crossmember, they do not need con-
voluted tubing.
3. Brake hoses may be clamped at the top of the
axle housing, and touch or lie against the axle
housing in its path to the brake chamber as this
assembly moves together.
4. Brake hoses must have slack between the last
clamping point on the rail and brake chamber to
allow for full range of suspension travel.
5. Brake hoses should have butterfly clamps at
breakout points.
6. Air lines and brake hoses that are bundled to-
gether should be fastened at 8- to 12-inch (203-
to 305-mm) intervals. If anchor clamps are more
than 12 inches (305 mm) apart, a tie strap must
be used between the anchor clamps. Tie straps
may be closer than 12 inches (305 mm) apart.
7. Hoses or lines that may come into contact with
the sharp edge of a bracket or frame rail are to
be protected by convoluted tubing.
8. Air lines and brake hoses that are parallel may
be fastened together. Air lines and brake hoses
that cross or that rub on metal, plastic, or electri-
cal parts need to be separated with butterfly
clamps.
9. Nylon or STX (wire braid) chassis air lines may
be fastened together to prevent rubbing, as long
as the lines are stationary.
Vehicle Receipt, Storage, and Pre-Delivery Information 00.01
Hoses and Electrical Wiring Routing Standards
Business Class Trucks Service Manual, Supplement 29, October 2002 100/2
Refer to tables in this subject for conversion factors.
U.S. Customary to Metric Metric to U.S. Customary
When You Know
Multiply
By
To Get When You Know
Multiply
By
To Get
Length
inches (in) 25.4 millimeters (mm) 0.03937 inches (in)
inches (in) 2.54 centimeters (cm) 0.3937 inches (in)
feet (ft) 0.3048 meters (m) 3.281 feet (ft)
yards (yd) 0.9144 meters (m) 1.094 yards (yd)
miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)
Area
square inches (in
2
) 645.16 square millimeters (mm
2
) 0.00155 square inches (in
2
)
square inches (in
2
) 6.452 square centimeters (cm
2
) 0.15 square inches (in
2
)
square feet (ft
2
) 0.0929 square meters (m
2
) 10.764 square feet (ft
2
)
Volume
cubic inches (in
3
) 16387.0 cubic millimeters (mm
3
) 0.000061 cubic inches (in
3
)
cubic inches (in
3
) 16.387 cubic centimeters (cm
3
) 0.06102 cubic inches (in
3
)
cubic inches (in
3
) 0.01639 liters (L) 61.024 cubic inches (in
3
)
fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)
pints (pt) 0.47318 liters (L) 2.1134 pints (pt)
quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)
gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)
cubic feet (ft
3
) 28.317 liters (L) 0.03531 cubic feet (ft
3
)
cubic feet (ft
3
) 0.02832 cubic meters (m
3
) 35.315 cubic feet (ft
3
)
Weight/Force
ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)
pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)
U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)
U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)
Torque/Work Force
inch-pounds (lbf·in) 11.298 Newton-centimeters (N·cm) 0.08851 inch-pounds (lbf·in)
foot-pounds (lbf·ft) 1.3558 Newton-meters (N·m) 0.7376 foot-pounds (lbf·ft)
Pressure/Vacuum
inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)
pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)
Metric/U.S. Customary Conversion Chart 00.02
General Information
Business Class Trucks Service Manual, Supplement 0, June 1991 050/1
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1988-2002 Freightliner Business Class FL/MB Trucks OEM Service & Repair Manual
Models covered:
- Freightliner FL50
- Freightliner FL60
- Freightliner FL70
- Freightliner FL80
- Freightliner FL106
- Freightliner FL112
- Freightliner MB50
- Freightliner MB60
- Freightliner MB70
- Freightliner MB80
The 1988-2002 Freightliner Business Class FL/MB Trucks OEM Service & Repair Manual contains the official factory procedures and technical specifications used by Freightliner dealership technicians to diagnose, repair, and maintain FL- and MB-series medium-duty trucks. Designed to be an accurate reference rather than guesswork or generic guidance, this manual includes complete OEM servicing steps for major mechanical systems, drivetrain assemblies, chassis structures, brake systems, fuel and air systems, and electrical troubleshooting.
Whether you’re a professional fleet mechanic maintaining work trucks every day, or a dedicated DIY owner keeping an older Freightliner on the road, having access to the original service documentation is essential. The manual provides detailed teardown and rebuild procedures, inspection tolerances, component replacement steps, and troubleshooting methods written directly by the manufacturer. It walks through each system with clarity, making it suitable for both experienced technicians and newcomers learning their way around medium-duty truck service.
What’s Inside the Freightliner Business Class FL/MB Service & Repair Manual
General Information
Service practices, safety notes, service standards, and identification details for FL and MB model variations.
Engine System
Inspection procedures, adjustments, servicing instructions, rebuild steps, and operational specifications for supported engine configurations.
Air Intake System
Air filter housing service, induction components, airflow inspection, and intake troubleshooting methods.
Air Compressor System
Compressor removal and installation steps, air supply diagnostics, component inspection, and repair procedures.
Alternators & Starters
Charging and starter system troubleshooting, testing methods, component replacement, and electrical service techniques.
Cooling System / Radiator
Coolant flow analysis, radiator service, temperature control components, fan systems, and overheating diagnostics.
Clutch System
Clutch assembly removal and installation, inspection criteria, adjustment procedures, and component service guidelines.
Transmission System
Service instructions for manual and automatic transmissions including diagnostic workflows, removal and replacement steps, and major repair operations.
Throttle Control System
Throttle pedal and linkage adjustment, control components, and diagnosis of response issues.
Frame & Frame Components
Frame structure inspection criteria, repair methods, mounting points, and structural service guidelines.
Suspension System
Front and rear suspension servicing including spring systems, bushings, ride-height adjustments, and wear assessment.
Front Axle
Service steps for hubs, bearings, spindle components, and adjustment procedures including alignment considerations.
Rear Axle
Differential service, axle shafts, seals, bearing replacement, and gear assembly service techniques.
Wheels & Tires
Wheel installation, balancing, tire rotations, lug torque values, and inspection standards.
Driveline
Driveshaft inspections, universal joint servicing, carrier bearings, vibration diagnosis, and reinstall procedures.
Brake System
Hydraulic and air brake repair procedures, chamber service, adjustment techniques, component breakdowns, and inspection intervals.
Steering System
Steering gear service, power steering pump procedures, linkage inspection, and alignment troubleshooting.
Fuel System
Fuel tank components, pump service, line inspections, injector operation checks, and flow diagnostics.
Exhaust System
Exhaust manifolds, mufflers, piping layout, support hardware, and emissions-related components.
Electrical, Instruments & Controls
System troubleshooting charts, electrical hardware service, gauge testing, sensors, switches, and functional inspections.
Cab & Interior Components
Cab body structure, panel replacements, doors, lock systems, window mechanisms, and interior mechanical components.
Windshield Wipers & Washers
Wiper motor service, linkage inspection, washer pump and nozzle servicing, and operating adjustments.
Heater & Air Conditioner Systems
HVAC system testing, blower motors, control units, airflow issues, and service procedures for heating and cooling components.
Hood, Grille & Fenders
Exterior body panel adjustment, structural fitment, alignment procedures, and replacement steps.
Fire Suppression Systems
Factory-specified inspection processes, safety handling, layout understanding, and servicing of suppression equipment.
Seats & Restraint Systems
Seat mechanism service, restraint system operation, and safety component replacement.
Paint & Refinishing Specifications
Surface preparation, touch-up guidelines, coating notes, and reference paint codes.
Why Choose This Freightliner Business Class Service Manual?
This OEM manual provides the same factory-approved procedures technicians rely on when servicing medium-duty Freightliner work trucks. Clear, practical, and structured logically, it’s designed to support everything from routine maintenance to major overhaul projects without unnecessary complexity.
Format & Compatibility
Delivered as a fully searchable, high-resolution PDF suitable for use on desktop computers, laptops, tablets, or mobile devices for shop or field reference.
Download the 1988-2002 Freightliner Business Class FL/MB Service & Repair Manual
Whether you're troubleshooting a driveline vibration, servicing brake chambers, or performing transmission work, this manual provides the detailed OEM procedures required to get the job done right.
Language: English
Compatibility: Windows, macOS, Linux, iOS, Android
Requirements: PDF Reader (e.g., Adobe Reader)
