Table of Contents TE ae SUBJECT PAGE 1. Description .... : : : 2 General Information . oo 2 Identification 4 2. Coolant Draining and Filling poorequbooe 5 Draining and Filling of Coolant in the Brake Housing 5 Sump Cooling Systems with Hub Seals : 5 ‘Sump Cooling System without Hub Seals 5 Forced Cooling Systems 7 3. Removal 8 Removing the Brake Housing 8 4. Disassembly ocua 15 Disassembling the Brake Housing .... 15 5. Preparing the Parts for Assembly 5 5 18 Cleaning the Ground and the Polished Parts : 18 Cleaning the Parts with a Rough Finish : oe 18 Cleaning the Wet Disc Brake Assembly : 5 18 Drying the Parts That Have Been Cleaned .. . coos : 18 Preventing Corrosion and Rust on the Cleaned Parts Boos 18 Inspecting the Parts pode 18 Face Seals 7 = 18 Applying the Silicone (RTV) Gasket Material 19 Repairing or Replacing the Parts 19 6. Assembly oe : ‘i : : 21 Assembling the Brake Housing 6506 soscaneco : 24 7. Installation : oeue bees 27 Installing the Hub Oil Seals : cae 27 Double Oil Seals in the Hub 27 Single Oil Seals in the Hub 27 Installing the Brake Housing 28 8. Torque Chart : ee . 39 Wheel Hub and Brake Housing Torque Chart... 7 : 40 Cover of the Brake Housing Torque Chart 6608 4a 9. Coolant and Hydraulic Fluid Specifications... .. ae pene 42 Coolant Specifications and Applications 42 Coolant Change Intervals... .. : 43 Hydraulic Fluid Specifications 43 Page 1Service Notes This Field Maintenance Manual describes the recommended safety, service and repair procedures for Rockwell Wet Disc Brakes The information in this manual was current at the time of printing, The information is subject to change without notice or liability You must follow your company safety procedures when you service or repair brakes. Be sure you understand all the procedures and instructions before you begin work. Rockwell uses the following types of notes to give warning of possible safety problems and to give information that will prevent damage to equipment. A WARNING: A warning indicates procedures that must be followed exactly. Personal injury can occur if the procedure is not followed. A CAUTION: A caution indicates procedures that must be followed exactly. If the procedure is not followed, damage to equipment and components can occur. Personal injury can also occur in addition to damaged or malfunctioning equipment or components. oO TORQUE This symbol is used to indicate fasteners that must be tightened to a specific torque value. NOTE A note indicates an operation, procedure or instruction is important for correct service. A note can also give information that will make service quicker and easier. ‘Some procedures require the use of special tools for safe and correct service. Failure to use these special tools, when required, can cause injury to service personnel or damage to vehicle components. This manual is written in Rockwell Universal Language System (RULS). Copyright 1987 Rockwell International.ww W3H, W4H AND W5H WET DISC BRAKE ONE-PIECE HOUSING (TYPICAL) BRAKE COVER— WITHOUT TEMPERATURE SENSOR BRACKET ITEM| DESCRIPTION ITEM| DESCRIPTION ITEM | DESCRIPTION 1 | Capscrew, Coverto-Brake 13_| Stationary Dise 22 | Capscrew—Temperature Housing 1} Friction Dae Sensor Bracket 2_| Washer, Coverto-Brare 15 | Spacer 2 | Washer — Temperature Sensor L Housing 16 | Brake Housing Bracket 3_| Bleeder Serew 7 | Pier ean Song Goce |S Yano Sear Baia 4 | Plug (Forced Coating Only) Pin Type Pi 25 | Plug—Temperature Sensor 10 5_| Plug—Brake Housing Cover_}-—7g—} pinto Fey Spring Bracket Hole 6 | Plug—iniet Fitting Pin Type Plug 25 _| Fill and Level Plug 7 | Brake Housing Cover TA Brake Fetum Spang Guide— Magnetic Drain Plug | Washer, Coverto-Axie Hous Hole Type 28 | Plog—Iotet Fitting 3 | Capscrew, Coverto-Axle TE | Fision, fete pring—Hole | 23] Brake Inlet Fiting — Tapered Housing Type Plu Seat T0_| Piston Sear TH] Peston Rear Spine PUSS] A] Beate ret Fitna Oring 11 | Bison ing Round Shape Hole Plug Type Piston Seals Only 20 | Plug Brake Housing 12 | Fiston i] Face Sealssection Description General Information The W3H, W4H and WSH Dura-Disc wet disc brakes are friction brakes that are hydraulically actuated, Three sizes of housings are available, The W3H series uses a 13 inch (330 mm.) brake housing, The W4H series uses a 17 inch (432 mm.) brake housing, Thy “VSH series uses a 22 inch (560 mm.) brake Nousing. A number of discs (from two to ten friction and stationary discs) are used in the housing depending on the requirements of the brake system. Two types of dises are in each housing; stationary discs and friction discs. The stationary discs are locked to the brake housing. The friction discs. rotate with the wheel hub. Each friction dise is between stationary discs. Hydraulic pressure pushes a piston against the first stationary disc. The action of the piston pushes all of the discs, together to stop the rotating of the wheel assembly. Figure 1. core ons SIDE VIEW (8 FRICTION DISC MODEL SHOWN) ee Ol ae oe snap nia WASHER TERNAL ant eS wMoout™ Soue noes} ne Se uwa gum cooteo (eovete Seay hanes on = yi cork Sones A] re SHANG OMY coven ro semoLe Coca fanien wone.s penta wala) some OES) ‘Rowe wesc up SEAL camaue SAUSOutRcnone VIEW A PISTON RETURN SPRING PLUG ASSEMBLY— HOLE TYPE GUIDE ellis ials/siaiaiziai VIEW B HYDRAULIC LINE FITTING TAPERED SEAT TYPE: VIEW C PISTON SEALS —ROUND SHAPE aoe ‘O-RINGsection Description All brake housings except the two disc model use a ‘one-piece brake housing. The two disc model uses. a two-piece housing. The outer cover of the two- piece housing contains the discs while the brake housing contains the piston and the piston seals. Figure 2. ‘Two types of cooling systems are used; sump cooling and forced cooling, The sump cooling system uses the lubricant in the brake housing as a coolant. The discs are submerged in coolant. The coolant removes the heat that the discs generate during the braking operation. To remove additional heat from the discs a forced cooling system is used. The forced cooling system uses a circulating coolant system in the brake housing. The forced cooling system moves the fluid from a reservoir to the brake housing and returns the fluid to the reservoir. Hub seals are used to separate the coolant in the brake housing (and axle housing in sump cooling systems) from the lubricant in the wheel end. Hub seals are used on all forced cooling systems and ‘on most sump cooling systems. Aawarnine In sump cooling systems, the operating temperature of the coolant must never reach or exceed 250°F (120°C), Use a forced cooling system if the temperature reaches or exceeds 250°F (120°C). In @ ‘sump cooling system, if the operating temperature of the coolant reaches or exceeds 250°F (120°C), the internal components of the brake will be damaged. Figure 2 SIDE VIEW (2 FRICTION DISC. MODEL SHOWN) HYDRAULIC he ‘OUTER INLET COVER FITTING O-RING TYPE FACE SEALS PISTON SEALS 'ZSHAPE PISTON BRAKE HOUSING VIEW A HYDRAULIC INLET FITTING—TAPERED SEAT VIEW B PISTON SEALS —ROUND SHAPE] RUBBER ‘O-RING Page 3section An identification tag is on the inboard side of the cover for the brake housing, The tag indicates the model number and the design level of the brake assembly. Figure 3. The brake model is also indicated by the model ‘number of the planetary front driving axle. The model number of the front driving axle is found on a tag that is on the axle housing. Figure 4. ‘The brake assembly can also be identified by the Bill of Material for the axle. Figure 3. BRAKE HOUSING IDENTIFICATION TAG LOCATION IDENTIFICATION TAG. Model No, W4H-43208: Customer No. Serial No. Ratio wa 492 08 ar oo HOUSING NUMBER OF INDIVIDUAL MODEL DIAMETER FRICTION. «BRAKE NUMBER MILLIMETER _DISCS. SSEMBLY W3H 330 mm (13 INCH) wat WSH 452 mm (17 INCH) ‘560 mm (22 INCH) Figure 4 AXLE IDENTIFICATION TAG LOCATION IDENTIFICATION Mode! No, ,PRLC-1756.-W3H-108 Customer No. Serial No. Ratio Date PRLC 1756 WsH 108, ‘AXLE MODEL BRAKE MODEL wos oH W=WweT, HOUSING H=HYDRAULIC Disc DIAMETER, ‘ACTUATION BRAKE 560 mm (22 INCH) Page 4¢ Coolant Draining = and Filling : Draining and Filling of Coolant in the Brake Housing Change the coolant at the following times: * First Coolant Change. Change the coolant after the first month or after the first 200-250 hours of operation. + Regular Maintenance Coolant Change. Change the coolant every six months or every 3,000 hours. of operation. Sump Cooling Systems with Hub Seals ‘When hub seals are used in sump cooling systems, coolant is in each brake housing. At the specified times, coolant is changed in each housing 1. Make sure the axle and brake housing assembly is in a level position, 2. Put a container under each brake housing 3. Remove the two magnetic drain plugs from the bottom of each brake housing. Drain the coolant from each brake housing, Discard the coolant. Figure 5, COOLANT FILL COOLANT FILL PLUG. BS insouene DRAIN PLUGS 4. Clean the drain plugs. Install and tighten the drain plugs to a minimum torque of 20 Ib-ft (27 N.m), 5. Remove the coolant fill plugs that are next to the fittings for the hydraulic fluid. Figure 5 6. Fill the brake housings with the specified coolant until the coolant flows from the bottom of the holes for the fill plugs. See Section 9, Coolant and Hydraulic Fluid Specifications. 7. Install and tighten the fill plugs to a minimum, torque of 36 Ib (47 Nm). Operate the brakes. Check for leaks and that the brake system operates correctly. Sump Cooling Systems without Hub Seals In sump cooling systems without hub seals, the brake housings, the wheel ends and the axle housing use the same fluid. The fluid cools the discs in the brake housing also lubricates and cools the components in the wheel ends and the axle housing. At the specified times, fluid is changed in the complete assembly. A warnina: Do not work under a vehicle that ls supported by pee Peyronie employ ver and cause inary. 1. Use a jack to raise the vehicle until the tires are off the ground. Put safety stand under the spring seats to support the axle. Remove the Jack. 2. Make sure of the follwing: * The axle and brake housing assembly is in a level position. * The OIL. LEVEL line on the covers of the Wheel ends are parallel to the ground. Figure 6. ‘* The drain plusgs in the covers of the wheel ends are below the OIL LEVEL lines. Figure 6. Page 5Coolant Draining and Filling DRAIN/FILL PLUG OIL LEVEL PLUG 3. Puta container under: + Each Brake Housing, ‘+ Each Wheel End. * The Bottom of the Axle Housing. NOTE: Give enough time when the assembly is drained to reve all of the fluid. 4. Drain the fluid by removing the drain plugs from the bottom of: Each Wheel End. Figure 6, ‘+ Each Brake Housing, Figure 5. * The Axle Housing. Figure 7. Discard the coolant. 5. Clean the drain plugs. Install the drain plugs and tighten to a minimum torque of 20 Ib-ft (27 N.m). oe 6. Rotate the wheel ends so that the DRAIN/FILL plugs are above the OIL LEVEL lines. NOTI Give enough time when the assembly is filled to make sure the fluid flows through the complete assembly. 7. Remove the fill plug from the axle housing. Remove the OIL LEVEL plugs from the wheel ends, Figure 6 and Figure 7. NOTE. Use the specified type of fluid and the specified amount of fluid when the assembly is filled. See Section 9, Coolant and Hydraulic Fluid Specifications. 8. Fill the axle housing until fluid flows from the hole for the fill plug Fill each wheel end until fluid flows from the OIL LEVEL holes. 10. Install the fill plug in the axle housing and the OIL LEVEL plugs in the wheel ends. Tighten to the specified torque of the equipment manufacturer. 11. Operate the brakes. Check for leaks and that the brake system operates correctly. LOCATION OF PLUGS— HOUSING BOWL (TYPICAL) TR is i , |} dy cannieR mouse y= * cannien ~s2onain PLus| Bowl & ona Plus | (naan 3 sow PINION STANDARD. PINION INVERTEDCoolant Draining section and Filling Forced Cooling Systems Brake housings with forced cooling systems use a ump to move coolant in and out of the housings. Coolant is supplied from a reservoir. The movement of coolant removes heat from the discs. A hub seal separates the brake housing from the wheel end assembly. At the specified times, coolant is changed in the complete brake cooling system, 1. Make sure the axle and brake housing assembly is in a level position, Put a container under each brake housing. 3. If the cooling system uses shut-off valves, make sure the valves are in the ON position so that fluid flows to the brake housing, 4. Remove the two magnetic drain plugs from the bottom of each brake housing. Drain the coolant from each brake housing, Discard the coolant. Figure 8, 5. Clean the drain plugs. Install and tighten the drain plugs to a minimum torque of 20 Ib-ft erNm, 6 10. Fill the reservoir with the specified coolant. See Section 9, Coolant and Hydraulic Fluid Specifications. Loosen the plug in the top of the cover of the brake housing. When the housing is filled, the loose plug permits air to be removed. Figure 8. Put the transmission in the NEUTRAL position and start the engine. When the level in the reservoir goes down, add coolant to adjust the level to the specified position, See the recom: mendations of the equipment manufacturer for the specified level in the reservoir. Stop the engine if the coolant leaks from the loose plug in the cover of the housing, Tighten the plug at the top of the cover of the brake housing to a minimum torque of 20 Ib-ft C7 Nm. Operate the brakes. Check for leaks and that the brake system operates correctly. Figure 8 LOOSEN PLUG WHEN FILLING HOUSING WITH COOLANT MAGNETIC. DRAIN PLUGS Page 7section Removal Removing the Brake Housing Use a jack to raise the vehicle until the tires are off the ground. Make sure the oil level line on the cover is parallel to the floor and that the drain plug is below the OIL LEVEL line. Figure 6, 2. Put safety stands under the spring seats to sup: port the axle. Remove the jack. A warnine: Det work under a vehicle that is only supported by Jacks or iting tools. Jacks and litingteols con of pee pery 3. Remove the nuts that fasten the tire and rim assembly to the hub. Remove the tire and rim assembly. NOTE: Unless a fluid change is necessary, do not drain the fluid from the axle housing. 4. If necessary, drain the fluid from the axle housing. Put a container under the axle housing, Remove the drain plug from the bottom of the axle housing. Drain the fluid from the axle housing. install the drain plug. Figure 7. NOTE. The fluid can also be drained from the wheel end by loosening the capscrews fastening the cover of the planetary spider to the hub. If necessary, cut the ga__3t material between the cover and the wheel hub. Do not remove the cover or the capscrews until all the fluid is drained. 5. Remove the drain plug from the cover of the wheel end. Drain the fluid from the wheel end, On some wheel ends, the bottom capscrew that fastens the cover to the planetary spider is used as a drain plug, Install the drain plug after the fluid is drained. Figure 6. 6. Drain the coolant from the brake housing, Use one of the following procedures. Page 8 Forced Coolin: with Shut-off ‘Systems falves Use the following procedure to remove the minimum amount of coolant from the forced cooling system, a. Put a container under the inboard side of the brake housing. b, Make sure the shut-off valves are in the OFF position so that coolant does not flow into the brake housing, c. Measure and record the amount of coolant that is drained from the housing. Remove the drain plugs from the bottom of the inboard side of the brake housing. Drain the coolant from the housing. Figure 9. d. When the coolant is drained, install the drain plug. Forced Cooling Systems without Shut-off Valves Use this procedure to remove the minimum amount of coolant from the forced cooling system. a. Put a container under the inboard side of the brake housing. b. Disconnect the coolant output line from the brake housing. Put a plug in the coolant out- Put line. Drain the coolant until the coolant does not flow from the output port. Figure 9. ©. Disconnect the coolant input line from the brake housing. Put a plug in the coolant in- Put line. Drain the coolant until the coolant does not flow from the input port. Figure 9. 4. Measure and record the amount of coolant that is drained from the housing. Remove the drain plug from the bottom of the brake housing. Drain all of the coolant that remains in the brake housing, €. When the coolant is drained, install the drain plug.Figure 9 COOLANT INPUT PORT LEFT-HAND HOUSING COOLANT OUTPUT PORT— LEFT-HAND HOUSING COOLANT ouTPUT PORT—SOME 17 INCH (482 mm) LEFT-HAND HOUSINGS —(RIGHT-HAND ‘SIDE NOT SHOWN) COOLANT INPUT PORT —RIGHT-HAND HOUSING COOLANT OUTPUT PORT—RIGHT-HAND HOUSING MAGNETIC. DRAIN PLUGS Sump Cooling System NOTE: On housings without hub seals most of the coolant is removed when the fluid is removed from the wheel end. a. Put a container under the inboard side of the brake housing, b. Remove the drain plug from the bottom of the brake housing. Drain all of the coolant from the brake housing. Figure 5. cc. When the coolant is drained, install the drain plug, 7. Remove the capscrews that fasten the cover of the planetary spider to the wheel end. Remove the cover from the planetary spider. Remove all ‘gasket material from the cover-to-planetary spider mounting surfaces. Figure 10. If possible, pull the axle shaft straight out of the axle housing. The thrust washer can remain behind the sun gear when the axle shaft is removed. If the axle shaft cannot be removed, the planetary spider must be removed before the axle shaft. Figure 11 and Figure 12. Figure 10 SON GEAR THRUST WASHER. Page 93 Removal SN eA SS LEE REE PRAT NOTE: The sun gear is held on thi ing. Do not disassemble the axle shaft. If the axle shaft needs to be serviced, see Field Maintenance Manual Number 9, Planetary Axle Wheel Ends. xle shaft with a snap 3. Remove the capscrews and washers that fasten the planetary spider to the wheel hub. 10. Separate but do not remove the planetary spider from the wheel hub. ‘= Planetary Spider with Notches: Put a pry bar in the notches of the assembly. Use the pry bar to separate the planetary spider from the wheel hub. Do not use a pry bar to separate the planetary spider from the wheel hub if notches are not used in the assembly. + Planetary Spider with Puller Holes: Install a capscrew that is the correct size in the puller holes in the planetary spider until the capscrews touch the hub. Tighten each capscrew the same amount until the assembly separates from the hub. ‘= If puller holes or notches are not on the planetary spider, tap on the assembly with a plastic or leather mallet to separate it from the hub. 11. Use a lifting device to remove the planetary spider from the wheel hub. Figure 13. Figure 13, NOTE: If the planetary spider needs to be serviced, see Field Maintenance Manual Number 9, Planetary ‘Axle Wheel Ends. LIFTING Figure 14. LIFTING TOOL DIMENSIONS (USE ON HUBS WITH A WHEEL MOUNT FLANGE.) Page 10section Removal A CAUTION: The wheel end must be supported before the adjusting nut for the whee! bearing is removed. The adjusting nut fastens the hub of the ring gear and the wheel end to the spindle. if the wheel end is not supported after the adjusting nut is removed, the wheel end can fall from the spindle and cause injury and damage the wheel end. 12. Support the wheel end or the wheel end and the brake housing according to the following. * Brake Housings That Use Lock Wire To Hold ‘The Discs In The Housing. The brake housing and the wheel end must both be supported. + If the wheel hub has a flange, attach a lifting tool and strap assembly to the wheel hub and brake housing assembly. The lifting tool and the strap decreases the movement of the wheel hub and brake assembly during removal. Connect a chain to the eye of the lifting tool keep tension ‘on the assembly. See Figure 14 for the dimensions and the specifications that are necessary to make a lifting tool. ‘If the wheel hub does not have a flange or a lifting tool is not available, use lifting devices and straps to support both the wheel end and the brake housing * Brake Housings That Do Not Use Lock Wire To Hold The Discs In The Housing. Support the wheel end with a lifting device and a strap, ‘+ When you do not know if the brake uses housing lock wire, use the procedure for a brake housing that uses lock wire. Figure 15 ADJUSTING 13. If used, remove the two capscrews that fasten the lock for the adjusting nut lock to the hub of the ring gear. Remove the lock for the adjusting nut. If used, remove the dowel from the adjusting nut. Figure 15. NOTE: On some models, the ring gear must be removed before the adjusting nut is removed. 14, Remove the adjusting nut for the whee! bearing from the spindle. NOTE: Make sure the wheel hub is supported when the ring gear and the hub of the ring gear is removed. 15, Remove the ring gear and the ring gear hub from the wheel housing. The ring gear and the hub is removed as an assembly or removed ‘separately from the wheel end, depending on ‘the model of the wheel end. To remove the ring gear and the hub as an ‘assembly, pull the gear and hub straight out of the Wheel hub and off of the spindle. Figure 16. RING GEAR AND HUB ASSEMBLY Page 111S Removal To remove the ring gear and hub separately, first pull he ring gear off of the hub. Remove the hub by pull rng the hub straight out of the wheel hub and off of, he spindle. Figure 17. RING GEAR f the hub of the ring gear cannot be removed oy hand: ‘Install capscrews of the correct size in the puller holes. Tighten each capscrew the same amount to separate the hub of the ring gear from the wheel hub. * If puller holes are not used, tap on the hub of the ring gear with a leather or plastic hammer to separate it from the wheel hub. NOTE: It the hub of the ring gear needs to be serviced, see Fi Maintenance Manual Number 9, Planetary 16. On brake housings that do not use lock wire to hold the discs in the housing, remove the vhee! hub. Pull the wheel hub out of the brake nousing and off the spindle. Put the wheel hub ‘on the floor so that the splines are toward you. ‘Support the brake housing with a chain and a strap. Figure 18. 17. If equipped, remove the capscrews and washers that fasten the bracket and the temperature sensor to the cover of the brake housing. Remove the bracket and the sensor. Page 12 18. Remove the following components from the back (inboard) side of the cover of the brake housing. Figure 19. Figure 19 BLEEDER SCREW O-RING FITTING TAPERED SEAT FITTING HYDRAULIC INLET. FITTING TAPERED SEAT + Bleeder Screw. * Inlet Fitting for the Hydraulic Line. Two types of fittings are used: a tapered seat fitting and an O-ring fitting, = Plug. The plug is opposite from the hydraulic line fitting on the cover of the brake housing, @section Removal 19. Make sure the brake housing is supported. Remove the capscrews and the washers that fasten the cover to the brake housing. Figure 20. Figure 20 20. On brake housings that do not use lockwire to hold discs in the housing, use the lifting device to remove the brake housing from the cover. Figure 21. Figure 21 A CAUTION: Do not drop the metal sealing rings. The sealing rings are damaged if they are dropped. 21. On brake housings that do not use lock wire to, hold the discs in the housing. Remove the face seals, Remove the inner face seal from the inside of the brake housing. Remove the outer face seal from the wheel hub. Separate the rub- ber elements from the metal sealing rings. Figure 22 and Figure 23. ——————— Figure 22 BRAKE HOUSING Figure 23 Page 13,3 Removal 2. On brake housings that use lock wire to hold the discs in the housing, remove the wheel hub and brake housing as an assembly. Pull the assembly straight off the spindle. Put the assembly on the floor so that the brake housing is toward you. Figure 24. |. Remove all gasket material from the mounting surfaces between the brake housing and the cover. 24, If damaged or leaking, remove and discard the hub oil seals from the inner diameter of the wheel hub. NOTE: One or two hub oil seals are used on all brake rousings with forced cooling and on most brake rousings with sump cooling. 4\ caution: 3uyort the spindle or hold the spindle against the vor when removing the spindle and the cover rom the axle assembly. When the capscrews are omoved, the ATV sealant holds the spindte against ‘he cover. immediately remove the spindle and 20 “when the capscrews are removed. 25 If necessary, remove the spindle and the cover of the brake housing from the axle housing according to the following procedure. a. Support the cover of the brake housing with a lifting device. A caution: Do not demage the spindle in the areas where the sare nataled when you remove the copectews ‘he washers rage 14 A CAUTION: Hold the spindle against the cover of the brake housing when the capscrews are removed. The spindle must be supported until the cover and assembly is put on a bench. If the spindle is not ‘supported in the cover, the spindle can fall and ‘cause injury and can cause damage to the spindle. b. Remove the capscrews and the washers that fasten the spindle and cover the brake hous: ing to the axle housing. Figure 25. Figure 25 ¢. Use the lifting device to remove the spindle and cover assembly from the axle housing If necessary, tap on the cover with a leather or plastic mallet to separate the cover from. the axle housing. Figure 26. Figure 26 4. Put the spindle and cover assembly on a bench so that the spindle is toward you. Remove the spindle from the cover. If necessary, tap the spindle with a leather or plastic mallet to separate the spindle from the cover. @. Remove all gasket material from the mounting surfaces between the sj the cover and from the cover and the axle housing,Disassembly section Disassembling the Brake Housing ‘On brake housings that use lock wire to hold the discs in the housing, cut the lock wire that keeps the stationary and the friction discs together. Discard the lock wire. Figure 27. Figure 27 Put pry bars under the inner diameter of the piston. Use the pry bars to lift the piston out of the housing. The two piston seals and, if used, the O-ring are removed when the piston is removed from the housing. Remove the two piston seals and, if used, the O-ring from the piston. Figure 28. 3. Remove the stationary discs and the friction discs from the brake housing. The stationary discs engage the splines of the inner diameter of the brake housing. The friction discs engage the splines of the outer diameter of the wheel hub. Figure 29. Figure 29, STATIONARY 4, Remove the disc spacer from the bottom of the brake housing. Figure 30. DISC SPACER Figure 30, Page 15Al Disassembly On brake housings that use lock wire to hold e. Remove the outer face seal from the whee! the discs in the housing hub, Separate the rubber element from the metal sealing ring. Figure 33. a, Install two eye-bolts in the brake housing Figure 33 b. Connect a chain or a strap to the eye bolts, Connect the chain or the strap to a lifting device. ¢. Lift the brake housing off of the wheel hub. Make sure the inner face seal remains in the brake housing. The outer face seal remains ‘on the wheel hub. Put the brake housing on a bench so that the wheel hub side of the housing is toward you. Figure 31. =z) G gag Figure 31 Ua al Qim}) 6 If necessary, remove the four piston return spring assemblies with the following procedure. Figure 34. Figure 34 pisToN RETURN ‘SPRING ASSEMBLY Aa CAUTION: 2o not drop the metal sealing rings. The sealing ings are damaged if they are dropped. u. Remove the inner face seal from the inside of the brake housing. Separate the rubber ‘element from the metal sealing ring Figure 32. Figure 32 A WARNING: The piston return spring assembly has pressure applied to the plug. Use the following procedure to remove the plug from the assembly. If the wrong procedure is used, the spring can push the plug out of the housing with enough force to cause injury. Page 16section Disassembly a. Put the brake housing on a bench so that the outboard side is toward you. b. Use a press to apply pressure to the plug. Figure 35. & warnine: The press must always touch the plug until the coils of the spring are in the fully expanded position. c. Slowly release pressure while disengaging the threads on the plug from the housing. d. After the threads of the plug are disengaged, slowly release pressure on the plug until the coils of the spring are in fully expanded position. Figure 36. ‘SPRING—FULLY EXPANDED. SPRING GUIDE e. Remove the plug and roll pin assembly, the spring and the spring guide from the housing. Figure 37. Figure 37 & SPRING O-RING SPRING GUIDE— HOLE TYPE SPRING GUIDE =PIN TYPE ROLL PIN AND PLUG ASSEMBLY NOTE: Two types of spring guides are used. One type of guide has a pin on the bottom that is installed inside the roll pin. The other type of guide has a hole in the bottom so that the end of the roll pin is installed in- side the guide. f. Inspect the O-ring on the plug. If necessary, remove and replace the O-ring. Page 17Preparing the section Cleaning the Ground and the Polished Parts A CAUTION: 90 9 clean the ground or polished parts in a hot soluuon tank, water, steam or alkaline solutions. 1. Use a cleaning solvent to clean the ground or polished parts or surfaces. Kerosene or diesel ‘el can be used to clean the parts. DO NOT SE GASOLINE, & warnine: deertul ten using cleaning solvents. Follow the ore neopied by the manutacturer to safely use the solvent. 2. Use a knife or a tool with a sharp blade to remove gasket material from the parts. Be careful not to damage the surfaces on the parts. Cleaning the Parts with a Rough Finish 1. Parts with a rough finish can be cleaned with vaning solvent, or in a hot solution tank with a weak alkaline solution 2. Parts must remain in the hot solution tanks until completely cleaned and heated. 4 WARNING: Be careful when using the hot solution tanks and the alkaline solutions. Follow the instructions sup: plied by the alkaline manufacturer to safely use the tanks and the solutions. 3. Parts must be washed with water until the alkaline solution is removed. Cleaning the Wet Disc Brake Assembly 4. Use steam to clean the wet disc brake and axle assembly on the outside to remove dirt Page 18 Parts for Assembly 2. Before the assembly is cleaned, close or put a cover over all the openings. Breathers or vents in the axle assembly are some examples of openings. Drying the Parts that Have Been Cleaned 4. Dry the parts immediately after the parts are cleaned and washed. 2. Dry the parts with soft, clean paper or rags. 3. The parts, except for the bearing cones, can be dried with compressed air. & caution: Mica uTres can be damaged ifthe cones are ae ee orn mith compressed alt Preventing Corrosion and Rust on the Cleaned Parts 4. Apply the fluid used in the brake housing to the cleaned and the dried parts that are not damaged and are to be assembled. See Section 9, Coolant and Hydraulic Fluid Specifications. 2. Apply to all the surfaces, a special material that prevents corrosion and rust. Put the parts ina special paper that prevents corrosion and rust. Inspecting the Parts Inspect all the parts before assembling the wet disc brake. Check all parts for wear and replace the damaged parts. Replacing worn or damaged parts prevents the failure of the assembly later. Face Seals Inspect the rubber element and the metal sealing ring of the face seal. Make sure the inner and the outer diameter of the sealing ring is flat. Replace any worn or damaged parts of the face seals. If the rubber elements must be replaced. If one metal ‘sealing ring is damaged, both face seal assemblies must be replaced. Figure 38.Preparing the Parts section ) for Assembly FACE SEAL ASSEMBLY RINGS RUBBER, ELEMENTS Applying the Silicone (RTV) Gasket Material Silicone (RTV) gasket material is used between the following mounting surfaces: + Axle Housing and Cover * Spindle and Cover * Brake Housing and Cover + Whee! Hub and Planetary Spider Assembly * Planetary Spider Assembly and Cover NOTE: The following silicone gasket products or equivalent can be used on Rockwell components. 1. Dow Corning Silicone Rubber Sealant, Number 732 Black, 2. General Electric, Number RTV-1473 Black. 3. From Rockwell International: + 40 pound containers, Part Number 1199.0-2981 ‘Ten ounce tubes, Part Number 1250-X-388. * Three ounce tubes, Part Number 1199-7-3842 METAL SEALING| & warning: Some acid vapors prevent when silicone gasket Serre aris erp. prevent posoisi ney make Ture thor ia yosd ventilation inthe work tat sitcone’ qpatet material gets in your eyes, lush toe core An eater tor is autas! Hare your eyes Thockad by a doctor 4. Remove all gasket material from both surfaces. 2. Clean the surfaces where the silicone gasket material will be applied. Remove all oil, grease, dirt and moisture. 3. Dry both surfaces. Apply a 1/8 inch (3.0 mm) diameter continuous bead of the silicone gasket material around the ‘edge of all the fastener holes on that surface. A caution: {he amount of slfcone gasket material that is apr must not exceed a 1/8 inch (3.0 mm) ePemeter bead. Too much gasket material blocks the pesaages and damages tne components 5. Assemble the components immediately to permit the silicone gasket material to com- press equally between the parts. Tighten the fasteners to the required torque value for that size fastener. There is not a special procedure or an additional torque value required. 6. Wait 20 minutes before filling the assembly with fluid Repairing or Replacing the Parts Replace worn or damaged parts of the wet disc brake assembly. The following are some examples to check. 1, Replace any fasteners if the corners of the head are worn, Replace the washers if damaged, 3. Replace the oil seals, face seals and gaskets when the components are separated from each other. 4, Clean the parts before applying silicone gasket material Page 19section [= Preparing the Parts for Assembly Remove small damage from the parts that have machined or ground surfaces. Use a fine-tooth file, india stone, emery cloth or crocus cloth for this purpose. Clean and repair the threads of the fasteners and the holes. Use a tap or a die of the correct size or a fine-tooth file for this purpose. Page 20 & caution: The throeds must be cleen and not damaged so that accurate adjustments and correct torque values can be applied to fasteners and parts. 7. Tighten all fasteners to the correct torque value, See Section 8, Torque Chart for the torque value of the fasteners.@ Assembly section Assembling the Brake Housing 1. If the piston return spring assemblies were removed, the assemblies must be installed in the housing. See the following procedure. & warnine: The piston return apving assembly hee pressure applied tothe plug, Use the following procedure to install the plug in the brake housing. If the wrong procedure fs used, the spring can push the plug out the housing with enough force fo cause ilury. NOTE: Two types of spring guides are used. One type of guide has a pin on the bottom that is installed inside the roll pin. The other type of guide has a hole in the bottom so that the end of the roll pin is installed in the guide. Use the correct parts for the piston return spring assembly. Do not mix parts of, the different assemblies. Use only one type of spring guide on each brake housing assembly. Figure 39. ae SPRING GUIDE —PIN TYPE SPRING O-RING, SPRING GUIDE— HOLE TYPE ROLL PIN AND. PLUG ASSEMBLY a. Put the brake housing so that the wheel hub side of the housing is toward you. b. Install the O-ring on the plug, . Put the spring guide inside the brake hous- ing below the plug hole. Make sure the flat area of the guide is against the housing, Figure 40. d. Install the spring on top of the guide. Figure 40. Figure 40 _ — APPLY PRESSURE e. Put the plug and roll pin assembly in the hole in the brake housing and through the return spring 1. Apply and hold pressure on the plug while the plug is installed into the housing. Make sure that the roll pin is correctly installed in the spring guide and that the flat areas on the spring guide are against the housing When the threads engage the housing, release the pressure on the plug. Figure 41. SPRING GUIDE Page 21section Assembly @. Tighten the plug to 500-650 Ib-ft (678-881 N.m). 2. Before the inner and the outer face seals are installed, inspect and clean the following areas: 1a, The bore for the outer face seal in the wheel hub and the bore for the inner face seal in the brake housing. Remove small marks in the bore with a fine emery cloth or india stone, If the marks cannot be removed, the assembly must be replaced. Clean the bore with a solvent that removes grease and a clean cloth. Figure 42. INSPECT BORES . Inner and outer face seals, Clean the inner and the outer face seals with a solvent that removes grease and a clean, lint-free cloth. Hf new face seals are being installed, make sure the seals are clean. 3, Install the rubber element on the metal ring of the face seal. The lip on the outer diameter of *¢ rubber element must be toward the sealing 9. Figure 43. & caution: The rubber element must be installed on the metal ‘ing betore the face seal is installed. If the rubber nlement is installed when the face seal is installed 1 the housing or hub, fluid can leak between the rousing and the hub. 4. Use a light oil to lubricate the metal rings in the areas where the rings touch each other when they are installed. Figure 43. Page 22 Figure 43, LP MUST BE TOWARD SEALING RING LUBRICATE THE RINGS WHERE THEY TOUCH EACH OTHER, METAL SEALING RINGS RUBBER ELEMENTS —MUST TOUCH THE CORNERS OF THE BORES FACE SEAL ASSEMBLY 5. Put the wheel hub and the brake housing so that the bore for the face seal is toward you. Install the inner and the outer face seals as follows: ‘a. Put the face seal in the bore so that the rubber element is toward the bottom of the bore. Figure 44 and Figure 45. Figure 44 INNER FACE ‘SEAL—RUBBER ELEMENT MUST| BE TOWARD| BOTTOM OF BORE] OUTER FACE ‘SEAL—RUBBER| ELEMENT MUST| BE TOWARD. BOTTOM OF BOREsection Assembly b. To put the complete face seal into the bore, push the rubber element in position. Make sure the rubber element is installed in the corners of the bores. Figure 46. Figure 46 é 7. On housings that use lock wire to hold discs in the housing, install the brake housing on the wheel hub. See the following procedure, Figure 47. FACE SEAL a. Put the wheel hub so that the splines of the hub are toward you. b. Install two eye-bolts in the brake housing. ¢. Connect a chain or a strap to the eye bolts. Connect the chain or strap to a lifting device. d. Lift the brake housing over the wheel hub. eign e. Disconnect the chain or the strap from the eye bolts. Remove the eye bolts from the brake housing. 8 On housings that do not use lock wire to hold the discs in the housing, put the brake housing ‘on a bench. The cover side of the housing must be toward you. 9. Install the disc spacer in the bottom of the brake housing. Figure 48. DISC SPACER 10. Install the disc pack as follows: a. Apply the same fluid used in the brake cooling system to each surface of the disos. . Install a stationary disc in the housing. Make sure the splines on the outer diameter of the stationary disc engage the splines in the brake housing. Make sure the wide spaces on the outer diameter of the disc are over the return spring assemblies. Figure 49. Page 236 Assembly . Install a friction disc in the housing Figure 50. Figure 52 Figure 50 FLATTEN WIRE L-AGAINST THIS. SURFACE SPLINE SPACE +. Complete the installation of the disc pack. Repeat steps ‘b’ and ‘c’ until the complete disc pack is installed. Before the last stationary disc is installed in the housing, make sure of the following, 11. On housings that do not use lock wire, align all of the teeth on the inner diameter of the fric- tion discs. When the discs are aligned, the wheel hub can be installed without damaging the dises. = Apply a grease such as petroleum jelly G-322L, or equivalent, to the surface between the last friction disc and stationary disc. The grease holds the last stationary disc against the friction disc when the assembly is in- stalled on the spindle, 12. Lower the piston into the housing until the é piston is installed on the guides of the return springs. Make sure the surfaces on the piston and the housing are not damaged when the piston is installed. Figure 53. + On housings that use lock wire, install anew [Figure 53 lock wire. Put the lock wire around the splines, ‘on the outer diameter of the wheel hub. Twist the ends of the lock wire together. Bend the lock wire toward the spindle bore. Push so that the lock wire is flat on the surface of the wheel hub.Figure 51 and Figure 62. S PLANETARY WHEEL HUB NOTE: 1. One O-ring and Two Rubber Round-Shape Seals. Figure 54. 2. Two ‘Z'-Type Seals. Figure 55.section Assembly PLASTIC SEAL. ‘BODY RUBBER ‘O-RING Figure 54 ROUND-SHAPE Figure 56 FIRST (INNER) PISTON SEAL CTYPE SEAL RUBBER ae | DAVPE RUBBER seals (and the O-ring if used) between the housing and the piston. Use fingers or a non-metallic object to prevent damage to the surfaces of the piston and the housing. Fluid can leak between the housing and the piston if the surfaces are damaged. 13. Put the first seal in the space between the housing and the piston. The rubber part of the seal must be toward you. Push on the seal until the complete plastic bottom surface of the seal touches the shoulder of the piston. Figure 56. RUBBER ELEMENT | TOWARD YOU PLASTIC 44, On housings that use round-shape seals, install Figure 55 SEAL BODY the O-ring around the outer diameter of the piston. Push on the O-ring until the entire bottom surface of the O-ring touches the top of the first seal. Figure 54 and Figure 57. O-RING (ROUND SHAPE SEALS ONLY) Figure §7 Page 256 Assembly 5. Put the second seal in the space between the housing and the piston on top of the first seal ‘The rubber part of the seal must be away from you. Install the second seal according to the following procedure: * Round-Shape Seals. Push on the side of the ‘seal that is toward the inner diameter of the housing until the rubber part of the seal touches the O-ring. Make sure the seal is cor- rectly installed in the housing. The seals must be parallel to each other. Install the complete seal with this method. Figure 54 and Figure 58. = 'Z-Type Seals. Push on the plastic part of the seal until the rubber parts of the seals touch. Figure 55 and Figure 58. Page 26 ‘SECOND (OUTER) PISTON SEAL RUBBER PART ‘AWAY FROM, ROUND-SHAPE — SEAL "D-TYPE SEALInstallation section Installing the Hub Oil Seals NOTE: ‘Single of double hub oil seals are used on all brake housing with forced cooling and some brake housing with sump cooling. Installing The Double Oil Seals In The Hub igure 59 ' 4 INCH = | couse YsNe# | HUB INNER BEARING cup INNER BEARING CONE 4. Put the wheel hub (and if attached, brake housing) so that the wheel hub is flat on the floor. 2. Put the first or outer seal over the hub bore so that the rubber part of the seal is toward you. 3, Use a sleeve that is 1/16 inch. (1.5 mm) less than the diameter of the seal and a leather or plastic mallet to install the seal. Tap on the sleeve until the rubber part of the seal is 1/4 inch (6.0 mm) from the top of the bore. Figure 59. NOTI When installed, the second or inner seal pushes the first or outer seal into the correct position. 4. Put the second or inner seal pushes the first or outer seal into the correct position. NOTE: When correctly installed the rubber parts of the inner seal and the outer seal must touch each oth 5. Use a sleeve that is 1/16 inch (1.5 mm) less than the diameter of the seal and a leather or plastic hammer to install the seal. Tap on the sleeve until the metal part of the second seal is even with the top of the bore. Installing the Single Oil Seal in the Hub Figure 60 SEALS WITHOUT FLANGES: i= ‘SEALS WITH FLANGES + 4. Put the whee! hub and brake housing so that the wheel hub is flat on the floor. 2. Put the seal over the bore so that the metal part of the seal is toward you. & caution: Be mit Coa cresare to the Inner metal part ofthe costae pressure only to the outer diameter of Tre inge Bre seat The application of pressure to {he im ciammeter of the tng damages the seal 3. Use a sleeve that is installed on the outer metal flange of the seal and a leather or plastic mallet to install the seal. On seals with flanges, tap on the sleeve until the flange touches the outer suface of the hub. On seals without flanges, press the seal in the hub until the bot: tom of ihe seal is even with the outer surface of the hub. Figure 60. Page 27i i Installation nstalling the Brake Housing It necessary, install the spindle and the cover of the brake housing on the axle housing according to the following procedure. a. Apply a bead of silicone gasket material on the mounting surface between the spindle and cover of the brake housing. See Applying the Silicone (ATV) Gasket Material on page 19. The bead must go around each capscrew hole. Figure 61. Fiaure 61 b. Install the spindle on the cover of the brake housing. Make sure that the capscrews holes in the spindle are aligned with the holes in the cover. Make sure the spindle is installed is against the cover of the brake housing, If necessary, tap on the spindle with a leather or plastic mallet. ~ Apply a bead of silicone gasket material on the axle housing where the cover of the brake housing is mounted. See Applying the Silicone (RTV) Gasket Material on page 19. The bead must go around each capscrew hole. Figure 62. HOUSING FLANGE Page 28 d. Install two of the capscrews that fasten the cover and the spindle to the axle housing. & caution gecareful when lting the spindle and the cover on Fe cae housing. Make sure the spindle remains In the cover. e. Attach a lifting device to the cover. The word ‘TOP’ on the outer diameter of the cover must be installed toward the top of the axle housing. {. Lift the spindle and the cover on to the axle housing, Use the two capscrews to install the spindle and the cover against the housing. Figure 63. Figure 63, g. Install the remaining washers and capscrews. Tighten to the torque specified inthe Torque Chart on page 41. Figure 64. a h. Disconnect the lifting device from the cover.Apply a bead of silicone gasket material on the mounting surface between the cover and the brake housing. See Applying the Silicone (RTV) Gasket Material on page 19. The bead must go around each capscrew hole. Figure 65. Figure 65 section Installation ‘On housings that use lock wire hold the discs in the housing, install the housing and the wheel hub as an assembly. See the following procedure. a. Lubricate the cups and the cones on the in: ner and outer wheel bearings on the hub with the fluid that is used in the wheel end. . If the wheel hub has a flange, attach a lifting tool and a strap to the wheel hub and brake housing assembly. The lifting tool and the strap decreases the movement of the assembly during installation. See Figure 14 for the dimensions and the specifications that are necessary to make a lifting tool ¢. If the wheel hub does not have a flange or a lifting too! is not available, use lifting devices and straps to support both the wheel end and the brake housing d. Connect a lifting device to the brake housing. Connect the lifting device so that the bores for the bleeder screw and the inlet fitting in the housing are aligned with the correct holes in the cover. e. Install two studs in the brake housing. The studs are installed opposite each other. Make the stud by removing the head of a housing: to-cover capscrew. Cut a flat-bladed screwdriver slot in the end of the stud without the threads. The studs help install the housing correctly on to the cover. Figure 66. f. Lift the brake housing and whee! hub assembly so that the spindle enters the bore of the hub. Make sure the spindle does not damage the hub oil seals. Install the ‘assembly so that the studs go through the holes in the cover. Make sure the bores for the bleeder screw and the inlet fitting in the housing are aligned with the correct holes in the cover. Push and hold the brake housing against the cover. Figure 66. GUIDE STUDa Installation a& b. Install two studs in the brake housing. The ‘AUTION studs are installed opposite each other. Make > me brake housing and wheel hub the stud by removing the head of a housing: sembly on the spindle. Movement of the housing eC RET Slr r— without the threads. The studs help install the housing correctly on to the cover. 4g. Install the capscrews and the washers that Figure 68. Remove the two suas ang natal he ¢: Lift the housing on to the cover. nstal the capscrews and the washers. Tighten the housing so that the studs go through the Capscrews to the specified torque. See the holes in the cover. Make sure the bores for Torque Chart on page 42. Figure 67. the bleeder screw and the inlet fitting are aligned with the holes in the cover. Push and hold the brake housing against the cover. Figure 68. ArcauTion onetenevs the Ating devees unt! the adiueting _d,Inaall he capacreva arc the washer thal 212 ihe eee! bearing Is Intalod the ub and fasten the cover tothe brake housleg. e housing are not supported, the assembly can fall Remove the two studs and install the om the spindle and cause injury and damage. capscrews and the washers. Tighten the Capscrews to the specified fora, See the flock wie is not used to hold the discs inthe Feraue Gna on page «2 Howe 87. gy hocsing snd the wheel hub must bo inetlled Coa Nerd aera e. Remove the lifting device from the brake a. Connect a lifting device to the brake housing. housing. Gonnect te iting device so thatthe bores forthe bleeder screw and the init fitting in f. Install the face seals inthe brake housing the Rousing are aligned withthe correct SO ee € holes inithe cover, Section 6. Figure 69 and 70. age 30section Installation Figure 71 |. Lubricate the cups and the cones on the inner and outer wheel bearings on the hub with the fluid that is used in the wheel end. Make sure all of the splines on the inside diameter of the friction discs in the brake housing are aligned. Connect a lifting device to the wheel hub. Lift and install the wheel hub into the brake housing. Make sure the splines on the hub do not damage the friction discs and the spindle seals. Figure 71. A caution: De not remove the Hitng devices until the adjusting rat forthe whee! bearing is Installed Ifthe hub and the housing tre not supported, the assembly can fall from the spindle and cause injury and damage 5. Install and tighten the following components on. the back (inboard) side of the cover of the brake housing. See the following procedure. Figure 72. Figure 72 BLEEDER RING FITTING SCREW \ D ° 3 o\\Y TAPERED : Sear ern SCE \ 0 le Anvorauuic (2G | eS a ) —TAPERED SEAT * Bleeder Screw: Tighten to 15-20 Ib-ft 2027 Nm) @ * Inlet Fitting for the Hydraulic Line: Two types of fittings are used; a tapered seat fitting and an O-ring fitting. A CAUTION Use the correct fitting. Do not replace a tapered seat fitting with an O-ring fitting. Do not repl fitting with a tapered seat fitting. If the is used, the housing and the fitting will be damay an O-ring 9 fitting 9d. Page 31a Installation a, Tapered Seat Fitting: Make sure all of the threads are clean. Install the fitting in the brake housing, Tighten the fitting to 25-95 Ibst (04-47 N.m) BUT DO NOT TIGHTEN THE TAPERED SEAT FITTING MORE THAN 35 LEFT 7 Nm). @ b. Oxring Fitting: Make sure all of the threads. are clean. Inspect the O-ring. Replace the O-ring if it is damaged. Install the fitting in the brake housing. Tighten the fitting to 25.35 lb-ft (34-47 N.m) Plug: The plug is opposite from the inlet fitting for the hydraulic line. Tighten the plug to 25-35 Ib ft, 47 Num), If 2 temperature sensor is used, install the sen- sor in the brake housing. Put the bracket over the sensor on the housing. Install and tighten. capscrews and washers. If the wheel end uses a ring gear and ring gear hub as a single assembly, install the ring gear and hub (with outer bearing cone) on to the spindle. Figure 73. RING GEAR AND HUB ‘ASSEMBLY It une wheel end uses a separate ring gear and ring gear hub, install the ring gear hub (with other bearing cone) on to the spindle. Install the ring gear on the hub. Make sure the splines on the ring gear engage the teeth on the hub. Figure 74. age 32 Figure 74 RING GEAR HUB 9. Install the adjusting nut for the wheel bearing ‘on the spindle. The nut must be against the hub. 10. Remove the lifting devices from the brake housing and the the whee! hub. 11. Adjust the wheel bearing according to the following procedure. Spindles with Single Adjusting Nuts See Figure 75 DOWEL RETAINER FOR Figure 75 ADJUSTING NUT ‘ADJUSTING. power AOvUST RING PLATE RETAINER FOR ADJUSTING NUT a. Rotate the wheel hub while the adjusting nut is tightened to the following torque. ‘Axle Models PR-35-68, PR-130-265, PS-50-60 and PS-165.200: Tighten the adjusting nut to 100 Ib-ft (135 N.m). All Other Axle Models: Tighten the adjusting nut to 400 Ib-ft (542 N.m),section Installation b. Rotate the whee! hub in each direction and hr Stop a untl the adjusting nut cannot be tightoned without the speetied torque from Ll .. proloed on the wheel boatngs. Tighton the Sajueting nut to the torque specie’ ahah chen 1 TORQUE AXLE MODEL | Lb-Ft Num [pr-3568, Pr-130265, PESO, PS-165 200 100 335 PR-100, PR-344.614, PS-100, PS.334 eam 200) 270nnea PR-150-200, PR-672-677, PS-150-200, PS-614-825, 200 | 270 [’pr.250, PR868-1757, PS-250270, PS826-1714 30 a7 PR.300-440, PR-1923-4025, PS.360, PS-1874-1676 40 542 PR500, PR42644807, PS-500, PS4664 400 a2 PR700. PR7314 00 7064 d. If used, put the lock plate for the adjusting nut in the hub. Put the flat side or the side with the notch against the bottom of the adjusting nut. If necessary, tighten the a¢- justing nut so that the lock plate can be installed. . Install the fasteners for lock plate according to the following procedure. Capscrews: Use new capscrews with a pre- applied locking solution on the threads. If ew capscrews are not used, put several drops of Loctite #277 or equivalent to the threads in the bore of the hub. Tighten the capscrews to the torque specified for Grade B fasteners In the torque chart on page 33. @y Flat Head Screws: Use flat head screws to fasten lockplates that have countersunk holes in the plate. f. If a dowel is used to lock the adjusting nut, install the dowel in the hole of the ring gear. If necessary tighten the adjusting nut so that the dowel can be installed. NOTE: The dowel pin is used on axle models PR-35-69, PR-130-265, PS-50-60 and PS-165-200. Spindles with Double Adjusting Nuts See Figure 76. Figure 76 ADJUSTING NUT WASHER JAM NUT TAB a. Rotate the wheel hub while tightening the adjusting nut to the following torque. Axle Models PR-35-68, PR-130-265, PS-50-60 and PS-165-200: Tighten the adjusting nut to 100 Ib-ft (135 N.m). All Other Axle Models: Tighten the adjusting rut to 400 Ib-ft (642 N.m) b. Rotate the wheel hub in each direction and repeat step ‘a’ of this procedure. Repeat step ‘a’ until the adjusting nut cannot be tightened without the specified torque trom in step ‘a’ being exceeded. Page 33,Installation c. Loosen the adjusting nut to release the preload on the wheel bearings. d. Tighten the adjusting nut to 25 Ib-ft (34 N.m), e. Install the lock washer over the spindle and against the adjusting nut. Make sure the tab (on the washer is in the slot on the spindle and that the tab on the adjusting nut is through the hole in the washer. If necessary, tighten the adjusting nut so that the tab on the nut can be installed through the hole in the washer. Install the jam nut against the lock washer. Tighten the jam nut to 800 bt (1084 N.m). 2. Check the brake housing for leaks to the following procedure: «=. Put a plug in the coolant inlet and outlet ports on the inboard side of the cover of the brake housing. Figure 77. b. Remove the plug at the top of the cover of the brake housing. Install a 3/8-inch or 5/6 inch adapter and male fitting for an air hose. Figure 77. c. Connect an air pressure gauge and regulator assembly to the male fitting on the adapter. The gauge must measure pressure accurately to 15 psi (103 kPa). Figure 78. 4. Connect an auxiliary air supply system to the gauge and regulator assembly. Figure 78. . Apply 15 psi (103 kPa) of pressure to the brake housing. Turn the regulator to the CLOSED position. Look at the gauge for 35 minutes. The pressure in the brake housing must remain at 15 psi (103 kPa). If pressure falls below 15 psi (103 kPa), find the cause of the loss of pressure. See the following procedures ‘+ Apply a soap and water solution to the capscrews, the fittings and the joints. ‘+ Apply and hold 15 psi (103 kPa) of pressure in the brake housing + If bubbles appear at any location, service the cause of the leak ‘= If bubbles do not appear at any location, disassemble the housing and remove and replace the hub seal. Repeat the leak test procedure, Remove the plugs from the inlet and outlet ports. Remove the air pressure gauge and fegulator assembly, 13. Apply a grease such as petroleum jelly or equivalent to the tab side of the thrust washer for the sun gear. Put the washer on the end of the spindle so that the tabs engage the slots in the adjusting nut. The grease holds the washer on the spindle. Figure 79. Fig +77 — COOLANT INPUT PORT LEFT-HAND HOUSING COOLANT OUTPUT PORT—LEFT-HAND. HOUSING COOLANT OUTPUT PORT-SOME 17 INCH (432 mm) LEFT-HAND HOUSINGS—(RIGHT-HAND SIDE NOT SHOWN) PUT ADAPTER AND ‘MALE FITTING HERE COOLANT INPUT PORT —RIGHT-HAND HOUSING COOLANT OUTPUT PORT—RIGHT-HAND HOUSING MAGNETIC DRAIN PLUGS age 34