Freightliner M915 / M916 -
Installation Manual P/N 0257550622-00
Crew Protection Kit
(Doc No.: II113500-1 D)
5.18.2 Installation Instructions
1. Assemble the upper hinge and spacers (#914, #915, #916 and #923) to the door. The
spacer #914 is positioned on the inside surface of the door; all other items are on the
outside surface of the door. Note that spacers #915 and #916 are provided to allow
adjustment of the door, and that not all spacers may be needed; however, the same
number and combination of spacers should be used on the upper and lower hinge for each
application. Snug the bolts down, but do not fully tighten at this time.
2. Assemble the lower hinge and spacers (#914, #915, #916, and #924) to the door. The
spacer #914 is positioned on the inside surface of the door; all other items are on the
outside surface of the door. Snug the bolts down, but do not fully tighten at this time.
3. Raise the door into position with a fork lift or similar lifting device. Install bolts (19) and
washers (31) to attach the hinges to the cab. Omit the center bolt on the lower hinge at
this time. Refer to Figure 5-92. Snug the bolts down, but do not fully tighten at this time.
Note that washers are not used on these bolts.
4. Adjust the position of the door so that it is properly aligned with the door opening and the
striker post. Ensure that the door is high enough to prevent the door seal from dragging
on the door step.
5. Adjust the position of the hinges to provide centerline alignment of the upper and lower
hinge pins. Laying a straight edge from the upper hinge pin knuckles to the lower hinge
pin knuckles will aid this task.
6. Tighten the hinge bolts and remove the lift device. Verify operation of the door. Adjust the
hinges as necessary to achieve smooth operation of the door.
7. Remove each bolt individually, apply thread-locking compound, re-install the bolt and
tighten.
8. Install the door detent as shown in Figure 5-94. Snug the bolts down, but do not fully
tighten at this time.
9. Install the door bumper as shown in Figure 5-95. These fasteners may be fully tightened.
10. Operate the door through the full-open position. Align the door detent components as
necessary to ensure that there is not interference or bending load applied to the
components. After satisfactory alignment is achieved, tighten the fasteners.
11. Adjust the ball-spring plungers in the door detent as required to obtain satisfactory detent
force.
12. Install OEM mirrors using original hardware. For electric mirrors, remove the bolt indicated
in Figure 5-92 and pass the wire through the resulting hole.
