Mack Kits Service & Assemblies 2009

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Handbook for Mack Parts

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<p>UPDATED 06/10/09</p> <p>REFERENCE GUIDE</p> <p>KSA&amp;AKITS SERVICE ASSEMBLIES &amp; ACCESSORIES</p> <p>Updated 06/10/09</p> <p>MACK TRUCKS, INC. 2100 MACK BOULEVARD P.O. BOX M ALLENTOWN, PA 18105-5000</p> <p>2008 TO: MACK SUBSIDIARIES AND DISTRIBUTORS ATTENTION: PARTS MANAGER SUBJECT: KITS, SERVICE ASSEMBLIES AND ACCESSORIES CATALOG This online KSA&amp;A Catalog replaces the paper catalog (August, 2006). It is an excellent reference to help service your customers. This catalog contains new and updated information in several areas and is updated as necessary. For your convenience hyperlinks have been added to the index. Just click on the hyperlink to go to that section of the catalog. Due to ongoing changes, we no longer reference "2QS" Service Cabs and "1QS" Cab Shells in the Kits Service Assemblies and Accessories (KSA&amp;A) Catalog. Requests for "1QS" and "2QS" cabs should be faxed to the Parts Specifications Department at 610-709-3088. Keep in mind that in some cases groomed replacement cabs are not an exact match to your customers' existing cab. Before quoting your customer a price, please refer to your particular model in the Cab section of this catalog (pages 20-41). This will reference the features that are included in your 2QS Service Cab. Please note: CHN/CXN Service Cabs: There is no groomed cab for an automatic transmission. Please be advised, if you do not follow the above procedure, we WILL NOT be responsible for any incorrect cab you receive. Frame rail requests must be submitted to the Spec Department via fax or electronic request. Please see pages 99-100 in the online catalog. Please note that updates will not be sent for the paper catalog dated August 2006. The online KSA&amp;A Catalog is the only updated and current version. If you have any additions or deletions, please mail or fax to the undersigned. Sincerely, Sandy Turner Manager, Specifications Mack Trucks, Inc. PO Box M, 3W3 Allentown, PA 18105 Fax: 610-709-3088</p> <p>CONTROL + CLICK ON THE LINK TO GO TO THAT SECTION OF THE CATALOG CONVERSION CHARTS Fractional Inches and Millimeters to Decimal Inches Decimal Equivalents of Millimeters Length Calculations Inches/Millimeters Ruler AXLE FRONT King Pin Sets Mack King Pin Sets Rockwell AXLE REAR Carrier Bearing &amp; Oil Seal Kits Mack Power Divider Lockout Differential Gears Kit BRAKE LINING SETS Lining Sets BRAKE OVERHAUL KITS ROCKWELL (For 16-1/2 x 7 Q Brakes Minor Overhaul Kits (w/o Brake Linings) Major Overhaul Kits Automatic Slack Adjuster Repair Kits Dura-Master Air Disc Brake Repair Kits CAB (Please review for Service Cab Features) CH, CL Service Cabs CH Keystone Service Cabs CV Service Cabs CX Service Cabs CHN/CXN Service Cabs CTP Service Cabs DM Service Cabs LE Service Cabs MR Service Cabs RB &amp; RD Service Cabs Air Suspended Isolated Cab Mount Kits CH Sleeper Box Mounting Bracket Kits &amp; Closure Kits CX &amp; CH Keystone Interior w/1QS51122M Cab CH, CL, CX Sleeper Boxes Sleeper Box Shell w/o Roof &amp; Floor Current Service Doors High Visibility Door Shells Current Window Regulators LINK Conversion1 Conversion2 Conversion3 Conversion4 PAGE 7 8 9 9</p> <p>Axle1 Axle2</p> <p>10 11</p> <p>Axle3 Axle4 Axle5</p> <p>12 13 13</p> <p>Brake1</p> <p>14</p> <p>Brake2 Brake3 Brake4 Brake5 ServiceCab1 ServiceCab2 ServiceCab3 ServiceCab4 ServiceCab5 ServiceCab6 ServiceCab7 ServiceCab8 ServiceCab9 ServiceCab10 ServiceCab11 Cab1 Cab2 Cab3 Cab4 Cab5 Cab6 Cab7 Cab8</p> <p>17 18 18 18</p> <p>20 22 24 26 28 30 34 36 38 40 42 42 42 42 45 46 47 48</p> <p>3</p> <p>CAB (continued) Air Window Lift &amp; Air Door Lock Kits Air Horns Air Conditioning Kits for MR &amp; LE Air Conditioning Kits for Mid-Liner (Red Dot) Air Conditioning Retrofit Kits Interior Grooming Kits Tool Kit Wiper Kit Interior Sun Visors Exterior Sun Visor Kits Standard Mirrors Bulldog Mirrors (Mack) Mirror Bracket Kits Fender Mirror Kit Under Cab Thermal Kit Air Deflector Kits Carpet Kits/Floor Mats CH Roof Fairing Kits CH Fog Lamp Kits CH Keystone Fog Lamp Kits CX Fog Lamp Kits Cab Foot Control Co-Pilot HARDWARE TOOL KIT ENGINE Bearing Kits, Engine Main Bearing Pairs, Connecting Rod Gasket Sets Engine ESI Engine Conversion Kits Aset Filter Kits ESI Plus Filter Kits MP7/MP8 Filter Service Kit Injection Pump Drive Kit Fuel Pro-Fuel Water Separator Rear Engine Insulator Kits Water Pump Gasket Kits Water Pump Repair Kits Cylinder Head Gasket Kits Bright Finished Cylinder Head Covers for Limited Edition Elite CL Turbo Mounting Kit Cylinder Liner Gasket Kit 4</p> <p>LINK Cab9 Cab10 Cab11 Cab11 Cab13 Cab14 Cab15 Cab16 Cab17 Cab18 Cab19 Cab20 Cab21 Cab22 Cab23 Cab24 Cab25 Cab26 Cab27 Cab28 Cab29 Cab30 Cab31 Hardware ToolKit</p> <p>PAGE 48 49 49 49 50 50 50 50 50 51 51 51 52 52 52 53 53 53 53 54 54 54 54 54 54</p> <p>Engine1 Engine2 Engine3 Engine4 Engine5 Engine6 Engine7 Engine8 Engine9 Engine10 Engine11 Engine12 Engine13 Engine14 Engine15 Engine16</p> <p>55 56 57 59 59 59 59 59 60 60 60 60 61 61 62 62</p> <p>ENGINE (continued) Inlet/Exhaust Manifold Gasket Kit Rear Engine PTO Fuel Water Separator Holset Compressor CMCAC Kit Conversion Kit V-MAC I V-MAC II Electronic Unit Pump O-Ring Kit Oil Lube Kits Thermostat Kits Jake Brake Kits Cylinder Rebuild Kits Engine Overhaul Kits Muzzle Loaders Muzzle Loader Overhaul Kits Exhaust Manifold Kits E6 &amp; E7 Stud, Exhaust, Manifold Kits Oil Cooler Gasket Kit Rear Engine Insulators Oil Cooler &amp; Water Pump Inlet Tube Replacement Kits Camshaft Kits Bearing Shell Kit Camshaft Thrust Washer Service Assembly, Center Main Bearing Camshaft Bushing Kits Auxiliary Shaft Bushing Kits Crankshaft Kits Piston Ring Kit Shims, Cylinder Liner Short Block Assembly History of Oil Pans History of TimingGear Covers Basic or Engine Service Assembly Mid-Liner Vehicle Data Mid-Liner Remanufactured Basic Engines: MS200/250/300 Mid-Liner Remanufactured Basic Engines: CS200/250/300 FRAME Request for Frame Rails (Sample Form) DRIVELINE Universal Joints (Wing Type) DRIVE SHAFT Universal Joint Kits</p> <p>LINK Engine17 Engine18 Engine19 Engine20 Engine21 Engine22 Engine23 Engine24 Engine25 Engine26 Engine27 Engine28 Engine29 Engine30 Engine31 Engine32 Engine33 Engine34 Engine35 Engine36 Engine37 Engine38 Engine39 Engine40 Engine41 Engine42 Engine43 Engine44 Engine45 Engine46 Engine47 Engine48 Engine49 Engine50 Frame1 Frame2</p> <p>PAGE 62 62 62 62 62 62 63 63 63 63 65 68 68 69 70 70 70 70 70 71 71 71 72 72 72 72 73 75 75 75 75 92 97 98 99 100</p> <p>Driveline1</p> <p>101</p> <p>DriveShaft1</p> <p>102</p> <p>5</p> <p>STEERING Joints Kits Steering Shaft Steering Gear Input Shaft Seal Kit Drag Link Repair Kits Bearing Cap Shaft Kit Power Steering Retrofit Kit Cross Steering Tube Engine Repair Kit CLUTCH CABLE TRANSMISSION KITS Bearing &amp; Oil Seal Kits Mack Transmission Snap Ring Set Shim Kits Mid-Liner (CS-MS 200-250) Transmission Air Shift Cover O-Ring Kit T200 Short Compound Shaft Cover O-Ring Kit T200 Long Compound Shaft Cover O-Ring Kit T300 Compound Shaft Cover O-Ring Kit Transmission Oil Cooler Kits Mack Synchronizer Kit Shift Valve Interlock Kit Fuller Transmissions Kits Spicer Transmissions (Main) Kits Spicer Transmissions (Auxiliary) Kits GASKET SETS TRANSMISSION Mack Transmissions Fuller Transmissions Gasket Kit Auxiliary Fuller Spicer Transmissions (Main Kits) Spicer Transmissions (Auxiliary Kits) TRANSMISSION BASIC OVERHAUL KITS Fuller Transmissions Basic Rebuild Kits Fuller Transmission Major &amp; Minor Overhaul Kits Spicer Transmission Fuller Transmissions</p> <p>Steering1 Steering2 Steering3 Steering4 Steering5 Steering6 ClutchCable</p> <p>103 103 103 103 103 103 104</p> <p>Trans1 Trans2 Trans3 Trans4 Trans5 Trans6 Trans7 Trans8 Trans9 Trans10 Trans11 Trans12 Trans13 Trans14</p> <p>105 105 105 106 106 106 106 106 106 106 106 106 107 107</p> <p>Gasket1 Gasket2 Gasket3 Gasket4 Gasket5</p> <p>108 108 108 109 109</p> <p>TransOH1 TransOH2 TransOH3 TransOH4</p> <p>109 109 113 115</p> <p>6</p> <p>CONVERSION CHARTS</p> <p>FRACTIONAL INCHES AND MILLIMETERS TO DECIMAL INCHESINCHES1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2</p> <p>DECIMAL.015625 .03125 .03937 .046875 .0625 .078125 .07874 .09375 .109375 .11811 .125 .140625 .15625 .15748 .171875 .1875 .19685 .203125 .21875 .234375 .23622 .250 .265625 .26559 .28125 .296875 .3125 .31496 .328125 .34375 .35433 .359375 .375 .390625 .3937 .40625 .421875 .43307 .4375 .453125 .46875 ,47244 .484375 .500</p> <p>MM33/64 1 35/64</p> <p>INCHES17/32</p> <p>DECIMAL.515625 .51181 .53125 .546875 .55118 .5625 .578125 .59055 .59375 .609375 .625 .62992 .640625 .65625 .66929 .671875 .6875 .703125 .70866 .71875 .734375 .74803 .750 .765625 .781250 .7874 .796875 .8125 .82677 .828125 .84375 .859375 .86614 .8750 .890625 .90551 .90625 .921875 .9375 .94488 .953125 .96875 .98425 .984375</p> <p>MM13</p> <p>14</p> <p>9/16 2 37/64 19/32 3 39/64 5/8 41/64 4 43/64 5 45/64 23/32 6 47/64 3/4 7 49/64 25/32 51/64 8 53/64 9 55/64 7/8 10 57/64 29/32 11 59/64 15/16 61/64 12 63/64 31/32 27/32 13/16 11/16 21/32</p> <p>15</p> <p>16</p> <p>17</p> <p>18</p> <p>19</p> <p>20</p> <p>21</p> <p>22</p> <p>23</p> <p>24</p> <p>25</p> <p>7</p> <p>CONVERSION CHARTS</p> <p>DECIMAL EQUIVALENTS OF MILLIMETERSMM25 . 26 27 28 29 30 . 31 32 33 34 35 . 36 37 38 39 40 . 41 42 43</p> <p>INCHES0.98425 1.02362 1.06299 1.10236 1.14173 1.18110 1.22047 1.25984 1.29921 1.33858 1.37795 1.41732 1.45669 1.49606 1.53543 1.57480 1.61417 1.65354 1.69291</p> <p>MM44 45 . 46 47 48 49 50 . 51 52 53 54 55 . 56 57 58 59 60 . 61 62</p> <p>INCHES1.73228 1.77165 1.81102 1.85039 1.88976 1.92913 1.96850 2.00787 2.04724 2.08661 2.12598 2.16535 2.20472 2.24409 2.28346 2.32283 2.36220 2.40157 2.44094</p> <p>MM63 64 65 . 66 67 68 69 70 . 71 72 73 74 75 . 76 77 78 79 80 . 81</p> <p>INCHES2.48031 2.51968 2.55905 2.59842 2.63779 2.67716 2.71653 2.75590 2.79527 2.83464 2.87401 2.91338 2.95275 2.99212 3.03149 3.07086 3.11023 3.14960 3.18897</p> <p>MM82 83 84 85 . 86 87 88 89 90 . 91 92 93 94 95 . 96 97 98 99 100 .</p> <p>INCHES3.22834 3.26771 3.30708 3.34645 3.38582 3.42519 3.46456 3.50393 3.54330 3.58267 3.62204 3.66141 3.70078 3.74015 3.77952 3.81889 3.85826 3.89763 3.93700</p> <p>8</p> <p>CONVERSION CHARTS</p> <p>CONVERSION CHART FOR ENGLISH AND METRIC VALUESLENGTH CALCULATIONMULTIPLYInches Inches Feet Feet Yard Yards Miles Millimeters Centimeters Centimeters Centimeters Meters Meters Kilometers</p> <p>BY2.540 25.40 30.48 0.3048 91.44 0.9144 1.609 0.03937 0.3937 0.0328 0.0109 3.281 1.094 0.6214</p> <p>TO OBTAINCentimeters Millimeters Centimeters Meters Centimeters Meters Kilometers Inches Inches Feet Yards Feet Yards Miles</p> <p>INCHES 1 2 3 4 5 6</p> <p>10</p> <p>20</p> <p>30</p> <p>40</p> <p>50</p> <p>60</p> <p>70</p> <p>80</p> <p>90</p> <p>100</p> <p>110</p> <p>120</p> <p>130</p> <p>140</p> <p>150</p> <p>MILLIMETERS</p> <p>9</p> <p>AXLE FRONT</p> <p>KING PIN SETS MACKPART NO. 301SQ47D 301SQ21 301SQ47D 301SQ52A 301SQ52A 301SQ17 301SQ31C 301SQ17 301SQ21 301SQ17 301SQ17 301SQ28E 301SQ31C 301SQ17 301SQ31C 301SQ28E 301SQ33A 301SQ20 301SQ22 301SQ32B 301SQ33A 301SQ32B 301SQ45A 301SQ28E 301SQ46B 301SQ32B 301SQ45A 301SQ28E 301SQ46B 301SQ35A 301SQ47E 301SQ45A 301SQ46B 301SQ28E 301SQ31C 301SQ52A 301SQ43 301SQ49 301SQ53</p> <p>APPLICATIONFA10.5/FAW10.5/FA12/FAW12 FA13 FA14.3/FAW14.3 FAW18 FAW20 FA23/FA27/28 FA26 FA27/28 FA30 FA36/37/38 (Prior to 1949) FA44/45 (Prior to 1949) FA46 FA48 FA51 (Prior to 1949) FA54 FA55 (Prior to 1950) FA55 (1950 &amp; up) FA200/201 FA300/301 FA400/401 FA403 FA500/501/505 (Prior to 1963) FA505 (1963 &amp; up) FA507/508 (Prior to 1963) FA507 (1963 &amp; up) FA511 (Prior to 1963) FA511 (1963 &amp; up) FA512/514/517 (Prior to 1963) FA512/514/517 (1963 &amp; up) FA522/523 (Prior to 1963) FA522/523 (1963 &amp; up) FA532/536/537/538, FAW536/537/538,FS5521/5231 FA534 FA535 FA561/562 FA600/601 FA616/617, FAW616/617 FA900/901 FA1002 FXL12, FXL14.6, FXL18, FXL20, FXL23</p> <p>Kits are not available. Must order pieces.</p> <p>10</p> <p>AXLE FRONT</p> <p>KING PIN SETS MACK (continued)PART NO.301SQ46B 301SQ45A 301SQ46B 301SQ35A 2719-806355</p> <p>APPLICATIONFA5071 FA5111 FA5141 FA5221/5231 (Prior to 1963) EFA-12FA</p> <p>NOTE: Kits prior to 1963 had Thrust Button Design, After 1963 Thrust Bearing. All king pin sets are not necessarily available but are listed for quick reference. For those that are not available, please see your Mack RO cards or MACSPEC for unit prices.</p> <p>KING PIN SETS ROCKWELLROCKWELL AXLE MODEL NO.FE900, 903** FG900, 903** FC901* FD901* FF901* FH901* FL901* FC902* FD902, 903* FC903* FE910* FU910* FF921* FF923* FF930** FD931* FF931* FF931A* FG931* FL931* FF932* FD933* FF933* FA941*** FF941* FF941A* FG941*</p> <p>BRONZE BUSHING KIT NO.8235-KIT144 8235-KIT153 8235-KIT143 NLA 8235-KIT172 8235-KIT170 8235-KIT170 8235-KIT143 NLA 8235-KIT143 8235-KIT144 8235-KIT194 8235-KIT199 8235-KIT199 8235-KIT121 8235-KIT196 8235-KIT195 NLA 8235-KIT1310 8235-KIT198 8235-KIT195 8235-KIT196 8235-KIT195 8235-KIT46 8235-KIT195 8235-KIT1310</p> <p>DELRIN BUSHING KIT NO.8235-KIT123 8235-KIT146 8235-KIT155 8235-KIT154 8235-KIT167 8235-KIT168 8235-KIT168 8235-KIT155 8235-KIT154 8235-KIT155 8235-KIT123 8235-KIT145 NLA </p> <p>EASY STEER BUSHING KIT NO. 8235-KIT1307 8235-KIT1308 8235-KIT1309 8235-KIT1307 8235-KIT1307 8235-KIT1307 8235-KIT1308 8235-KIT1309</p> <p>* DOUBLE DRAW KEY NOTCH</p> <p>** TAPERED WITH NUT</p> <p>*** SINGLE DRAW KEY NOTCH</p> <p>11</p> <p>AXLE FRONT</p> <p>KING PIN SETS ROCKWELL (continued)ROCKWELL AXLE MODEL NO.FL941* FL941* FL9411 FLW941 FF981 FF942, FF943** FG943* FL943* FL951* FAE951*** FF951* FF961* FF966* FE970* FF971* 16930** 16931** 17100* 17101*</p> <p>BRONZE BUSHING KIT NO.8235-KIT198 8235-R200195 8235-KIT195 8235-R201419 8235-KIT195 8235-KIT1310 8235-KIT198 8235-KIT198 8235-KIT173 8235-KIT198 __ 8235-KIT188 8235-KIT1300 8235-KIT121 8235-KIT121 8235-KIT1310 8235-KIT1310</p> <p>DELRIN BUSHING KIT NO. </p> <p>EASY STEER BUSHING KIT NO.8235-KIT1312 8235-R201307 8235-R201476</p> <p> 8235-KIT171 __ 8235-KIT156 8235-KIT145 8235-KIT145 </p> <p>8235-KIT1307 8235-KIT1309 8235-KIT1312 8235-KIT1312 8235-KIT1315 8235-R201315 8235-KIT1309 8235-KIT1309*** SINGLE DRAW KEY NOTCH</p> <p>* DOUBLE DRAW KEY NOTCH</p> <p>** TAPERED WITH NUT</p> <p>AXLE REAR MACK CARRIER BEARING &amp; OIL SEAL KITSPART NO.205SP 45B</p> <p>APPLICATIONCRD116, 1161, 117, 1171, CRD1171S 11KH4159, 4159A, 4159B, 4159C, 4165, 4165A, 4166, 4166A, 4167, 4167A, 4167B, 4202, 4202A, 4203 CRD93, CRD931, CRDL93, CRD113, CRD1131 11KH5326, 5327, 5328, 5330, 5341, 5342, 5343, 5374, 5375, 5376, 5377, 5378, 5386 CRDPC92, CRDLP92, CRDPC921, CRDPC112 w/o P.D. Lockout 11KH5236, 5237, 5312, 5316, 5317, 5322, 5323, 5333, 5362, 5366, 5367, 5380 CRDPC92, CRDLP93, CRDPC921, CRDPC112 w/P.D. Lockout 11KH5241, 5313, 5318, 5319, 5324, 5334, 5335, 5363,5368, 5369, 5372, 5381 CRDP95, CRDP951 11KH5232, 5232A, 5232B, 5233, 5233A, 5233B, 5234, 5234A, 5234B, 5235, 5235A, 5235B, 5352, 5353, 5393, 5394</p> <p>205SP 71B</p> <p>205SP 72B 205SP 73B 205SP 75B</p> <p>Kit applies to all P Numbers unless otherwise noted. 12</p> <p>AXLE REAR</p> <p>MACK CARRIER BEARING &amp; OIL SEAL KITS (continued)PART NO.205SP 76B 205SP 77A 205SP 78A 205SP 79A</p> <p>APPLICATIONCRD96, CRD961 11KH4228, 4228A, 4229, 4229A, 5354, 5395 CRD201, CRD2011, CRD203, CRD2031 11KH5421, 5422, 5453, 5454, 5482, 5483, 5484, 5485 CRDP200, CRDP2001, CRDP202, CRDP2021 11KH5425, 5426, 5459, 5461, 5476, 5478, 5480 (Power Divider w/o...</p>