Description

DAF LF45, LF55 2004 Workshop Manual

If you are turning wrenches on a DAF LF45 or LF55 from 2004, you already know the brake system on these trucks is all air – full pneumatic, with Wabco or Knorr disc brakes. I have seen too many guys try to rely on a generic aftermarket PDF and end up with a trailer that won’t release or a spring brake that locks at highway speed. That is why you need the DAF LF45, LF55 2004 Workshop Manual – the one DAF printed for their own dealers. 188 pages, factory specs, no guesswork.

Torque Specs and Fluid Capacities

Section 1.2 gives you the tightening torques for every fastener on the brake circuit – from the compressor mounting bolts to the wheel-end hardware. I have seen too many stripped threads because somebody used a generic chart from an online forum. The values on page 1-12 are factory-verified, not a guess. Lubricants are covered on page 1-16. Do not use the wrong grease on a Knorr calliper thrust piece; the manual tells you exactly what spec.

Does This Manual Cover Diagnostics?

Yes. Section 1 Diagnostics includes a full fault-finding table for disc brake construction. If you have a dragging brake, uneven pad wear, or a slow release, the table walks you through likely causes – worn bearing bushes, stuck load sensing valve, or a failed ABS valve. It is not a generic list; it is specific to the LF45/LF55 air system. After you have checked the basics, go straight to the brake diagrams in Section 2 to trace the pneumatic lines.

Brake Diagrams for Fully Pneumatic System

The manual devotes an entire section to brake diagrams with a legend for every port and component. You get the full pneumatic circuit – compressor, air supply unit, relay valves, load sensing valves, ABS and ASR solenoids. If you are chasing a pressure drop or a stuck water blow-off valve, you follow the air path on the diagram, not a photograph from a forum. These diagrams are from DAF’s own engineering, not redrawn by some third-party publisher.

Wabco vs Knorr: What the Manual Covers

Section 3 Operation of Brake Components breaks down both Wabco PAN 17, PAN 19-1+, PAN 19-2 and Knorr SB700, SN700 disc brake constructions. You get overview drawings with callouts for every component – including the brass bearing bush, the calliper carrier, the thrust piece bellows. If you are replacing brake pads on a Knorr SB7000, the removal and installation steps on page 3-7 through 3-13 give the exact procedure, including the torque sequence for the calliper bolts. I have seen guys skip the thrust piece bellows inspection and then wonder why the brake chirps. This manual does not let you skip.

18 Removal and Installation Procedures

Section 4.3 lists eighteen separate removal and installation procedures – from quick-release coupling replacement to brake calliper carrier removal. Each procedure has a required tool list and a warning about air system depressurization. You don’t get that from a Chilton manual. The manual also tells you how to check brake disc runout and measure pad thickness with a caliper. If you are working on a fleet of these trucks, these procedures save you from doing a job twice.

Who Actually Needs This Manual?

Fleet mechanics who see LF45/LF55 trucks daily. Owner-operators who do their own brakes. Any shop that touches a DAF air brake system. The manual is not for someone who wants a quick overview; it is for someone who needs the exact pressure setting for the load sensing valve with leaf suspension (Section 4.2.4) or the correct advance in the trailer control valve (Section 4.2.8). If you have ever had a spring brake cylinder fail to release because the parking brake valve was adjusted wrong, you understand why the factory procedure matters.

Source Validity – OEM vs Aftermarket

This is a direct copy of DAF’s own workshop publication, part number DW23259602. I have bought aftermarket manuals for trucks that claimed to cover the LF45 – they left out the Knorr SN7000 calliper procedures entirely. They also had torque values rounded to the nearest 10 Nm, which is useless when the factory spec is 195 Nm not 200 Nm. This manual has the page numbers, the original DAF copyright, and the exact chapter structure DAF intended. If you want to trust your brakes to a third-party reprint, good luck. I would not.

Frequently Asked Questions

Is this manual specific to the 2004 model year?

Yes, it is published in 2004 and covers the LF45 and LF55 chassis produced in that year. Brake components changed after 2005 with new ABS valve configurations.

Does it include torque values for the brake calliper?

Yes, page 1-12 lists tightening torques for all brake system fasteners including calliper bolts, compressor mounting, and spring brake cylinder.

What about the electric braking system?

This manual covers the fully pneumatic brake system. For hybrid-electric brake control or EBS, you need the DAF LF/CF/XF Series Diagnostics Manual DAF LF/CF/XF Series Diagnostics Manual.

Can I use this to rebuild a Wabco PAN 19-2 calliper?

Absolutely. Section 3 gives an overview drawing and Section 4.3 covers removal and installation of the calliper, thrust piece bellows, bearing bushes, and brake disc. You will need a torque wrench and a dial indicator for disc runout – both are listed in the tool requirements.

If you are also working on the drivetrain, check the DAF LF45 LF55 2004 Technical Manual for engine and chassis specs, and the DAF LF45 LF55 Gearboxes and Clutch Workshop Manual for transmission work. The brake system often interacts with the drivetrain on these trucks, especially if you have a Manual Transmission that shares the same engine bell housing. Also, if you need to troubleshoot the ABS valve electrical connections, the wiring is tied into the Manual Transmission speed sensor circuit – the manual does not cover that, so keep the wiring diagram handy.

Do not waste time chasing ghosts. Get the factory data that every DAF technician used. Access the Factory Manual from AutoRepairManuals and keep a copy on your tablet in the bay.