TITLE PAGE

Landing Systems - Wheels & Brakes

Goodrich Corporation
101 Waco Street
P.O. Box 340
Troy, Ohio 45373
U.S.A.
Tel: +1 937 339 3811
e-mail: awb.techpubs@utas.utc.com
https://techpubs.goodrich.com

CAGE 97153

COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST

MAIN LANDING GEAR BRAKE ASSEMBLY

GOODRICH CESSNA
PART NUMBER PART NUMBER
2-1502 9914136-2
2-1502-1 9914136-4
2-1502-2 9914136-6
2-1502-3 9914136-9

EXPORT CLASSIFICATION

U.S. Export Classification: EAR 9E991

PROPRIETARY INFORMATION

THIS DOCUMENT IS THE PROPERTY OF UTC AEROSPACE SYSTEMS. YOU MAY NOT POSSESS, USE, COPY OR DISCLOSE THIS
DOCUMENT OR ANY INFORMATION IN IT, FOR ANY PURPOSE, INCLUDING WITHOUT LIMITATION, TO DESIGN, MANUFACTURE OR
REPAIR PARTS, OR OBTAIN ANY GOVERNMENT APPROVAL TO DO SO, WITHOUT UTC AEROSPACE SYSTEM’S EXPRESS WRITTEN
PERMISSION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT ALONE, FROM ANY SOURCE, CONSTITUTES SUCH
PERMISSION. POSSESSION, USE, COPYING OR DISCLOSURE BY ANYONE WITHOUT UTC AEROSPACE SYSTEM’S EXPRESS WRITTEN
PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.

UTC AEROSPACE SYSTEMS PROPRIETARY

Issued: Apr 11/86 32-46-41 Page TP-1
Rev. 4
Jan 20/16

** Printed copies are considered UNCONTROLLED - Verify current issue before use**
 GOODRICH CORPORATION
COMPONENT MAINTENANCE MANUAL
Part Number 2-1502

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COMPONENT MAINTENANCE MANUAL
Part Number 2-1502

REVISION HIGHLIGHTS
Revision No. 4
Dated: Jan 20/16

This Revision No. 4 replaces Revision No. 3 of this manual, dated Oct 15/02.

THE
REVISIONS (Dated Jan 20/16)
AFFECTED
DESCRIPTION OF CHANGE
SECTIONS
Changed the arrangement of the company name and revised the
Title page
format with proprietary statements.
Added “UTC Aerospace Systems Proprietary” statement to footer.
Added “Printed copies are considered UNCONTROLLED - Verify
current issue before use” statement to footer.
Revised the manual format to add TASK and SUBTASK codes.
Added text to parts to show that the parts could have cadmium plating.
Revised all pages to use new “value engineered” procedures for
maintenance of Goodrich aircraft brake assemblies.
“Value engineered” procedures remove, add, or move data to make
procedures more efficient.
All Added change bars only to show important changes to data. Change
bars are not added to show the changes made by “value engineered”
procedures or by “ASD-STE100 Simplified English”.
Added a note to indicate the measurement units format in illustrations
that show dimensions.
Changed the name or nomenclature from carrier and lining assembly
to rotor.
Change the nomenclature for “pressure plate and wear plate
assembly” to “pressure plate assembly”.
Ranges were added to all dimensions except for minimum and
maximum dimensions.
All sections with a Added the words “INTENTIONAL BLANK PAGE” and an issue date to
blank last page totally blank pages.

Added/revised some warnings and cautions on:

- Use of hydraulic fluid.
- Cadmium plated parts.
All sections
- Application of pressure without use of protective shields.
with warnings and
- Use of pliers to cut lockwire.
cautions
- Use of sharp, hard tools to remove O-rings and backup rings.
- Use of specified cleaning materials.
- Use of paint.
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COMPONENT MAINTENANCE MANUAL
Part Number 2-1502

REVISION HIGHLIGHTS

THE
REVISIONS (Dated Jan 20/16)
AFFECTED
DESCRIPTION OF CHANGE
SECTIONS
Revised the replacement parts policy, warnings, and added the TSO
approval.
Added addresses for sources of ASTM and AMS specifications and
Introduction changed the address for the source of MIL specifications.
Added reference to the Goodrich wheel and brake publications web
site: https://techpubs.goodrich.com
Added a list of abbreviations and acronyms used in the manual.

Description and Revised figures on the description details of the brake assembly.
Operation Removed the item numbers for the parts in the section.
Added a procedure for “Preparation Before Tests”.
Testing and Fault
Revised the functional test procedure.
Isolation
Revised the Fault Isolation Table.
Added general instructions to be followed for disassembly procedures.
Revised the procedures on preparation for disassembly.
Added a procedure for the piston housing assembly removal.
Added a procedure to discard the bleeder screws and bleeder fittings
Disassembly for P/N 2-1502, 2-1502-1, and 2-1502-2 configurations.
Added a procedure to identify positions on heat sink disks that will be
removed and installed again.
Revised the procedures to remove and discard insulators for the
P/N 2-1502, 2-1502-1, and 2-1502-2 configurations.
Revised the procedure for chemical removal of paint from the piston
Cleaning
housing, torque plate, and pressure plate.
Added an inspection interval table and procedures for all the brake
parts.
Revised the procedure for Heli-Coil® insert inspection.
Revised the procedures for pressure plate, stator, and torque plate
Check
inspection.
Revised the figure for the spring inspection.
Added a new “Special Inspections” procedure for the inspection of
parts for an overheated brake assembly.

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COMPONENT MAINTENANCE MANUAL
Part Number 2-1502

REVISION HIGHLIGHTS

THE
REVISIONS (Dated Jan 20/16)
AFFECTED
DESCRIPTION OF CHANGE
SECTIONS
Replaced “MIL-C-5541 Class 1A conversion coat” with “QPL-81706
Class 1A conversion coating”.
Revised procedure for conversion coating of piston housing.
Added a procedure for Lee plug repair.
Revised the procedure for Heli-Coil® inserts repair.

Repair Added a procedure to apply high temperature paint or a rust

prevention product such as Rust Veto spray to the pressure plate or
the torque plate.
Revised the rivet head diameter dimensions after installation on the
wear plates using spin riveting or compression riveting procedures.
Revised procedures for application of paint to the piston housing.
Revised the procedure for installation of the identification plate.
Added Bergen Safety Cable™ as an alternate to lockwire.
Revised the procedure to assemble the shuttle valve assembly parts.
Added a procedure to install new bleeder plugs to replace the
discarded bleeder screws and bleeder fittings of the P/N 2-1502,
2-1502-1, and 2-1502-2 configurations.
Revised the procedure to install the piston housing assembly.
Assembly Revised the procedure to install new insulators for the P/N 2-1502-3
configuration.
Revised the procedures for the adjustment of the rod and insert
assemblies with new heat sink components.
Revised the procedure to install the shuttle valve assembly.
Torque values were removed from the ASSEMBLY section and are
referenced in the FITS AND CLEARANCES section only.
Fits and Clearances Revised torque values.
Removed the LIST OF SPECIAL MATERIALS and added a revised list
of consumables to the SPECIAL TOOLS, FIXTURES, EQUIPMENT,
Special Tools,
AND CONSUMABLES section.
Fixtures,
Equipment, and Added tool part numbers for all special tools used on the brake
Consumables assembly.
Revised the dimensional tolerances for the tools.

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Part Number 2-1502

REVISION HIGHLIGHTS

THE
REVISIONS (Dated Jan 20/16)
AFFECTED
DESCRIPTION OF CHANGE
SECTIONS

Storage (Including Moved the storage data for the brake assembly parts to a new section
Transportation) in the CMM.

Added the statements in the IPL nomenclature column for hazardous

materials.
Revised the list of vendors.
Revised the parts list to include necessary parts.
Illustrated Parts Revised the Heli-Coil® part numbers to agree with the manufacturer’s
List part number system. The part did not change.
Revised the Lee plug part number to agree with the manufacturer’s
part number system. The part did not change.
Added the bleeder screw and the bleeder fitting as service parts that
are used in the testing of the brakes.

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Part Number 2-1502

RECORD OF REVISIONS
Put revised pages in the manual. Complete the table below for each revision.

DATE DATE
PAGES PAGES
PAGES PAGES
REV. REV. ARE REV. REV. ARE
ADDED ADDED
NO. DATE ADDED NO. DATE ADDED
BY BY
TO TO
MANUAL MANUAL

0 Apr 11/86
1 Apr 28/89
2 Mar 14/97
3 Oct 15/02
4 Jan 20/16

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Part Number 2-1502

RECORD OF REVISIONS

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Part Number 2-1502

RECORD OF TEMPORARY REVISIONS

DATE PAGES
TEMPORARY AFFECTED PAGES DATE PAGES PAGES
ARE ADDED
REVISION PAGE ADDED ARE REMOVED REMOVED
TO
NUMBER NUMBERS BY FROM MANUAL BY
MANUAL

32-1 1006 Aug 7/88 --- Apr 28/89 BKM

32-2 705, 706 May 20/94 BKM Mar 14/97 BKM
32-3 513 Feb 28/02 BKM Oct 15/02 MJS
32-4 302, 710, Jan 3/05 Troy Jan 20/16 GEC
713

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Part Number 2-1502

RECORD OF TEMPORARY REVISIONS

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Part Number 2-1502

SERVICE BULLETIN LIST

Service Bulletins and Service Letters are included (incorporated) in the manual at the dates in
the “DATE ADDED TO THE MANUAL” column. These Bulletins and Letters caused changes
to the manual.

“Active” in the “DATE ADDED TO THE MANUAL” column shows a Bulletin or Letter that
remains active for this brake assembly and is not incorporated in the manual.

“No Effect” in the “DATE ADDED TO THE MANUAL” column shows a Bulletin or Letter that
was active for this brake assembly for some time. The Bulletin or Letter did not cause a
change to the manual at the revision date that is shown and does not apply to this brake
assembly after that date.

DATE DATE
SERVICE SERVICE
REV. ISSUED ADDED
BULLETIN LETTER DESCRIPTION
NO. OR TO THE
NUMBER NUMBER
REVISED MANUAL
1370 1 Oct 24/86 Apr 28/89 Additional brake inspection

1451 Nov 27/90 Apr 28/89 Wear pin setting on used

parts

2-1502-32-1 Sep 20/93 Mar 14/97 Cracked stator disk

(Goodrich
No. 633)

1532 Aug 24/90 Mar 14/97 Improved carrier and lining

assembly

1727 1 Jan 20/97 Jan 20/16 Introduction of a new main

brake and wheel assembly
2-1502-32-2 Apr 15/98 Oct 15/02 Introduction of a new
(Goodrich stainless steel piston
No. 740) insulator

1812 Apr 10/00 Oct 15/02 Introduction of anti-seize

compound SAE AMS2518

1854 --- Active Shelf-life limits and storage

recommendations for
elastomeric seals and seal
assemblies
1914 1 Feb 3/06 Jan 20/16 Warning on installation of
parts that are not approved
by Goodrich

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COMPONENT MAINTENANCE MANUAL
Part Number 2-1502

SERVICE BULLETIN LIST

DATE DATE
SERVICE SERVICE
REV. ISSUED ADDED
BULLETIN LETTER DESCRIPTION
NO. OR TO THE
NUMBER NUMBER
REVISED MANUAL
2-1502-32-3 1 Oct 27/00 Oct 15/02 Introduction of new brake
(Goodrich assembly (P/N 2-1502-3)
No. 814)
1977 1 Jul 30/07 Jan 20/16 Safety precautions for
chemicals and materials
1988 1 Jul 21/04 Jan 20/16 Permitted leakage
2048 Nov 16/06 Jan 20/16 Introduction of a new paint
primer
2126 1 Aug 4/10 Jan 20/16 Optional retaining ring
2131 Nov 12/10 Jan 20/16 Clarification of the
conversion coating (surface
treatment) specifications:
MIL-C-5541, MIL-C-5541
Class 1A, and
MIL-DTL-5541
2178 Apr 11/12 Jan 20/16 Correct rivet procedures
and minimum rivet head
diameters
2-1502-32-4 Aug 28/12 Jan 20/16 Replacement of bleeder
(Goodrich screws and bleeder fittings
No. 1125) with bleeder plugs
2222 Jun 29/15 Jan 20/16 Part numbers of Lee plugs
2229 Oct 6/15 Jan 20/16 Heli-Coil® insert part
number change to remove
a zero character

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Part Number 2-1502

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page TP-1 Jan 20/16 Testing and Fault 1007 Jan 20/16
TP-2 Jan 20/16 Isolation 1008 Jan 20/16
(Continued) 1009 Jan 20/16
Revision Highlights RH-1 Jan 20/16 1010 Jan 20/16
RH-2 Jan 20/16 1011 Jan 20/16
RH-3 Jan 20/16 1012 Jan 20/16
RH-4 Jan 20/16 1013 Jan 20/16
1014 Jan 20/16
Record of Revisions ROR-1 Jan 20/16
ROR-2 Jan 20/16 Disassembly 3001 Jan 20/16
3002 Jan 20/16
Record of RTR-1 Jan 20/16 3003 Jan 20/16
Temporary Revisions RTR-2 Jan 20/16 3004 Jan 20/16
3005 Jan 20/16
Service Bulletin List SBL-1 Jan 20/16 3006 Jan 20/16
SBL-2 Jan 20/16 3007 Jan 20/16
3008 Jan 20/16
List of Effective LEP-1 Jan 20/16 3009 Jan 20/16
Pages LEP-2 Jan 20/16 3010 Jan 20/16
3011 Jan 20/16
Table of Contents TOC-1 Jan 20/16 3012 Jan 20/16
TOC-2 Jan 20/16 3013 Jan 20/16
TOC-3 Jan 20/16 3014 Jan 20/16
TOC-4 Jan 20/16
Cleaning 4001 Jan 20/16
Introduction INTRO-1 Jan 20/16 4002 Jan 20/16
INTRO-2 Jan 20/16 4003 Jan 20/16
INTRO-3 Jan 20/16 4004 Jan 20/16
INTRO-4 Jan 20/16 4005 Jan 20/16
INTRO-5 Jan 20/16 4006 Jan 20/16
INTRO-6 Jan 20/16 4007 Jan 20/16
INTRO-7 Jan 20/16 4008 Jan 20/16
INTRO-8 Jan 20/16 4009 Jan 20/16
4010 Jan 20/16
Description and 1 Jan 20/16
Operation 2 Jan 20/16 Check 5001 Jan 20/16
3 Jan 20/16 5002 Jan 20/16
4 Jan 20/16 5003 Jan 20/16
5 Jan 20/16 5004 Jan 20/16
6 Jan 20/16 5005 Jan 20/16
7 Jan 20/16 5006 Jan 20/16
8 Jan 20/16 5007 Jan 20/16
5008 Jan 20/16
Testing and Fault 1001 Jan 20/16 5009 Jan 20/16
Isolation 1002 Jan 20/16 5010 Jan 20/16
1003 Jan 20/16 5011 Jan 20/16
1004 Jan 20/16 5012 Jan 20/16
1005 Jan 20/16 5013 Jan 20/16
1006 Jan 20/16 5014 Jan 20/16
5015 Jan 20/16
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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Check 5016 Jan 13/16 Assembly 7010 Jan 13/16

(Continued) 5017 Jan 13/16 (Continued) 7011 Jan 13/16
5018 Jan 13/16 7012 Jan 13/16
5019 Jan 13/16 7013 Jan 13/16
5020 Jan 13/16 7014 Jan 13/16
5021 Jan 13/16 7015 Jan 13/16
5022 Jan 13/16 7016 Jan 13/16
5023 Jan 13/16 7017 Jan 13/16
5024 Jan 13/16 7018 Jan 13/16
7019 Jan 13/16
5025 Jan 13/16
7020 Jan 13/16
5026 Jan 13/16
7021 Jan 13/16
5027 Jan 13/16 7022 Jan 13/16
5028 Jan 13/16
5029 Jan 13/16 Fits and Clearances 8001 Jan 13/16
5030 Jan 13/16 8002 Jan 13/16
5031 Jan 13/16
5032 Jan 13/16 Special Tools, Fixtures, 9001 Jan 13/16
Equipment, and 9002 Jan 13/16
Repair 6001 Jan 13/16 Consumables 9003 Jan 13/16
6002 Jan 13/16 9004 Jan 13/16
6003 Jan 13/16 9005 Jan 13/16
6004 Jan 13/16 9006 Jan 13/16
6005 Jan 13/16 9007 Jan 13/16
6006 Jan 13/16 9008 Jan 13/16
6007 Jan 13/16 9009 Jan 13/16
6008 Jan 13/16 9010 Jan 13/16
6009 Jan 13/16 9011 Jan 13/16
6010 Jan 13/16 9012 Jan 13/16
6011 Jan 13/16 9013 Jan 13/16
6012 Jan 13/16 9014 Jan 13/16
6013 Jan 13/16
6014 Jan 13/16 Storage (Including
6015 Jan 13/16 Transportation) 15001 Jan 13/16
6016 Jan 13/16 15002 Jan 13/16
6017 Jan 13/16
Illustrated Parts List 10001 Jan 13/16
6018 Jan 13/16
10002 Jan 13/16
6019 Jan 13/16 10003 Jan 13/16
6020 Jan 13/16 10004 Jan 13/16
6021 Jan 13/16 10005 Jan 13/16
6022 Jan 13/16 10006 Jan 13/16
10007 Jan 13/16
Assembly 7001 Jan 13/16 10008 Jan 13/16
7002 Jan 13/16 10009 Jan 13/16
7003 Jan 13/16 10010 Jan 13/16
7004 Jan 13/16 10011 Jan 13/16
7005 Jan 13/16 10012 Jan 13/16
7006 Jan 13/16 10013 Jan 13/16
7007 Jan 13/16 10014 Jan 13/16
7008 Jan 13/16
7009 Jan 13/16
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TABLE OF CONTENTS

SUBJECT OR PARAGRAPH TITLE PAGE

INTRODUCTION
General ................................................................................................................................... 1
TSO Approval .......................................................................................................................... 2
Dates of Verification by Simulation ......................................................................................... 2
Replacement Parts Policies .................................................................................................... 2
Warnings for the Full Manual .................................................................................................. 4
Specification Sources .............................................................................................................. 6
Abbreviations and Acronyms in This Manual .......................................................................... 7
DESCRIPTION AND OPERATION
Brake Data .............................................................................................................................. 1
Description .............................................................................................................................. 1
Operation ................................................................................................................................ 6
TESTING AND FAULT ISOLATION
Testing and Fault Isolation ................................................................................................ 1001
Preparation Before Tests .............................................................................................. 1003
High-pressure Leak Test .............................................................................................. 1005
Functional Test ............................................................................................................. 1006
Shuttle Valve Assembly Test ........................................................................................ 1009
Post-test Procedures .................................................................................................... 1010
Fault Isolation .................................................................................................................... 1011
Fault Isolation Chart ..................................................................................................... 1011
DISASSEMBLY
Disassembly ...................................................................................................................... 3001
Preparation for Disassembly ........................................................................................ 3002
Piston Housing Assembly Removal .............................................................................. 3004
Heat Sink Removal ....................................................................................................... 3006
Pressure Plate Assembly Removal .............................................................................. 3007
Torque Plate and Wear Plate Assembly Removal ....................................................... 3008
Piston Housing Disassembly ........................................................................................ 3008
Adjuster Assembly Disassembly .................................................................................. 3010
Shuttle Valve Disassembly ........................................................................................... 3013
CLEANING
Parts Cleaning ................................................................................................................... 4001
Metal Parts Cleaning .................................................................................................... 4003

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TABLE OF CONTENTS

SUBJECT OR PARAGRAPH TITLE PAGE

CLEANING (Continued)
Non-Metal Parts Cleaning ............................................................................................ 4004
Paint Removal ................................................................................................................... 4005
Paint Removal of the Piston Housing ........................................................................... 4007
Paint Removal of the Torque Plate and Pressure Plate ............................................... 4009
CHECK
General Inspection ............................................................................................................ 5001
Inspection Intervals ....................................................................................................... 5003
Wear Plate Inspection .................................................................................................. 5006
Pressure Plate Inspection ............................................................................................. 5007
Rotor Inspection ........................................................................................................... 5009
Stator Inspection ........................................................................................................... 5012
Torque Plate Inspection ................................................................................................ 5015
Piston Housing Assembly Inspection ........................................................................... 5017
Adjuster Assembly Parts Inspection ............................................................................. 5020
Shuttle Valve Assembly Inspection .............................................................................. 5026
Inspection of Other Parts .............................................................................................. 5027
Special Inspections ....................................................................................................... 5030
REPAIR
General Repair Data ......................................................................................................... 6001
General Surface Repair Procedures ............................................................................ 6005
Pressure Plate Assembly ............................................................................................. 6005
Rotor Repair ................................................................................................................. 6007
Stator Repair ................................................................................................................ 6008
Torque Plate and Wear Plate Assembly Repair ........................................................... 6008
Piston Housing Assembly Repair ................................................................................. 6010
Conversion Coating Application ................................................................................... 6016
Apply Paint ................................................................................................................... 6017
Shuttle Valve Assembly Repair .................................................................................... 6020
Installation of a New Identification Plate ....................................................................... 6020
ASSEMBLY
Assembly ........................................................................................................................... 7001
Lubricant Application .................................................................................................... 7003
Assemble Adjuster Assembly ....................................................................................... 7003

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TABLE OF CONTENTS

SUBJECT OR PARAGRAPH TITLE PAGE

ASSEMBLY (Continued)
Assemble Shuttle Valve Assembly ............................................................................... 7009
Assemble Piston Housing Assembly ............................................................................ 7011
Installation of the Pressure Plate Assembly on the Piston Housing ............................. 7016
Installation of the Stud Assembly (Wear Indicator Pin) ................................................ 7016
Installation of the Heat Sink on the Torque Plate and Wear Plate Assembly ............... 7018
Adjustment of the Rod and Insert Assemblies with New Heat Sink Components ........ 7021
FITS AND CLEARANCES
Fits and Clearances .......................................................................................................... 8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES
Special Tools ..................................................................................................................... 9001
Aqueous Cleaner Consumables ....................................................................................... 9008
Other Consumables .......................................................................................................... 9012
STORAGE (INCLUDING TRANSPORTATION)
Storage Instructions ........................................................................................................ 15001
Storage ....................................................................................................................... 15002
ILLUSTRATED PARTS LIST
Purpose ........................................................................................................................... 10001
Explanation of Data ......................................................................................................... 10001
Vendors ........................................................................................................................... 10005
“True” (Full) Part Numbers .............................................................................................. 10006
Exploded View, Main Brake Assembly ............................................................................ 10008
Parts List ......................................................................................................................... 10009

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TABLE OF CONTENTS

INTENTIONAL BLANK PAGE

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INTRODUCTION
TASK 32-46-41-871-801-A01

1. General

A. General

This manual gives maintenance procedures that can keep the brake assembly in an
airworthy condition. Get applicable service documents, that are not incorporated, from
the web site that is shown below.

All publications for this assembly are available from the Goodrich wheel and brake
publications web site: https://techpubs.goodrich.com

An overhaul facility can use other maintenance procedures, but the overhaul facility
controls these other procedures. The facility must make sure these other procedures
are safe, keep the brake assembly airworthy, and obey applicable government
regulations.

A maintenance facility can use the special tools shown in this manual or use other
tools that give the same result.

General industry specifications in this manual (for example: MIL, ASTM, SAE) let
maintenance facilities use locally-available materials permitted by a specification.
Goodrich does not control approval of these materials.

The weights and measurements in this manual are in U.S. (English) units. S.I.
(International System of Units) metric units are shown in parentheses. English units
have a period for the decimal point. Metric units have a comma for the decimal point.

Carefully read all WARNING and CAUTION statements in this manual. Refer to the
descriptions of these statements and a NOTE statement that follows:

• A “WARNING” statement is given to prevent personal injury or damage to

health.

• A “CAUTION” statement is given to prevent damage to equipment.

• A “NOTE” statement is given to make easier work.

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INTRODUCTION

2. TSO Approval
The conditions and tests for Technical Standard Order (TSO) approval of this article are
minimum performance standards. Those installing this article, on or in a specific type or
class of aircraft, must determine that the aircraft installation conditions are within the TSO
standards. TSO articles must have separate approval for installation in an aircraft. The
article may be installed only according to 14 CFR Part 43 or the applicable airworthiness
requirements.

3. Dates of Verification by Simulation:

Testing Disassembly Assembly

Oct 15/02 Oct 15/02 Oct 15/02

4. Replacement Parts Policies

WARNING: REGARDLESS OF ANY FAA APPROVALS OR DEMONSTRATED

COMPLIANCE WITH AIRFRAME MANUFACTURER'S ORIGINAL
EQUIPMENT REQUIREMENTS, GOODRICH DOES NOT WARRANT OR
ASSUME THE RISK OF THE INSTALLATION OF REPLACEMENT PARTS
THAT ARE NOT APPROVED BY GOODRICH FOR INSTALLATION IN A
SPECIFIED ASSEMBLY. OPERATORS WHO USE REPLACEMENT
PARTS THAT ARE NOT APPROVED BY GOODRICH DO SO AT THEIR
OWN RISK AND TAKE FULL RESPONSIBILITY FOR ALL PROPERTY
DAMAGE, PERSONAL INJURY, OR DEATH CAUSED BY SUCH
REPLACEMENTS PARTS. USE ONLY GOODRICH-APPROVED
REPLACEMENT PARTS THAT ARE GIVEN IN THE ILLUSTRATED
PARTS LIST OF THE COMPONENT MAINTENANCE MANUAL OR IN
SERVICE BULLETINS OR SERVICE LETTERS THAT ARE ISSUED BY
GOODRICH.

CAUTION: GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR ANY
FEDERAL AVIATION ADMINISTRATION SANCTIONS, PRODUCT
MALFUNCTIONS, PROPERTY DAMAGE, PERSONAL INJURIES, OR
SIMILAR INCIDENTS THAT OCCUR AFTER SUBSTITUTION OF PARTS
THAT ARE NOT APPROVED BY GOODRICH, OR SUBSTITUTION OF
PARTS WITH ALTERATIONS THAT ARE NOT APPROVED BY
GOODRICH MANUALS OR OTHER WRITTEN PROCEDURES THAT ARE
ISSUED BY GOODRICH.

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INTRODUCTION

CAUTION: THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED BY

GOODRICH FOR INSTALLATION IN A SPECIFIED ASSEMBLY WILL
AUTOMATICALLY VOID ALL WARRANTIES EXTENDED BY GOODRICH.

The Federal Aviation Administration (FAA) has approved replacement parts that are
different from specified parts in applicable Goodrich assemblies. Goodrich has not done
tests on these FAA-approved parts and does not give approval for the installation of
these parts.

Goodrich uses proprietary design procedures and rigorous tests to show that Goodrich
assemblies give specified performance or better-than-specified performance. Tests were
done with Goodrich-approved parts in each assembly to show that related subsystems
correctly work together as a system for qualification and certification. Some examples of
related subsystems include: landing gear, brake control (anti-skid), wheels, brakes, and
tires.

Goodrich makes wheel assemblies and brake assemblies to aircraft manufacturer

specifications, to FAA requirements, and to all other applicable regulations. Goodrich
design procedures also use data on wear distribution, thermal balance, dynamic stability,
reliability, endurance, torque sensitivity, and environmental exposure. The environmental
exposure includes: humidity, icing, salt fog, shock, and vibration. Installation of parts that
do not have equivalent design procedures or test results can decrease the performance
of wheel assemblies, brake assemblies, or related subsystems.

FAA approval of replacement parts in Goodrich assemblies usually is given after tests
that are less extensive than performance tests by the aircraft manufacturer and by
Goodrich. The Aircraft Flight Manual, Component Maintenance Manuals, and warranties
are based on performance tests by the aircraft manufacturer and by Goodrich. The
operation of each subsystem depends on all related subsystems to give safe and reliable
take-offs and landings. When equivalent tests with FAA-approved parts are not done,
Goodrich cannot make sure that the assemblies give safe and reliable performance.

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INTRODUCTION

5. Warnings for the Full Manual

A. Asbestos

WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST CONTAINS

ASBESTOS FIBERS THAT CAN CAUSE CANCER AND LUNG
DISEASE. DO NOT USE COMPRESSED AIR TO CLEAN PARTS OR
ASSEMBLIES THAT POSSIBLY CONTAIN ASBESTOS DUST. IF
MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO
ASBESTOS DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND
OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN ASBESTOS.

Obey the warning above before you do maintenance on parts.

B. Cadmium

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM
DISEASE. AFTER YOU TOUCH CADMIUM PLATED PARTS, CLEAN
YOUR HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY
INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR EMPLOYER
TO SUPPLY RESPIRATORS, VENTILATION, AND/OR PROCEDURES
TO PREVENT EXPOSURE TO PERSONNEL.
WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH ADMINISTRATION
(OSHA) HAS AN APPLICABLE DANGER WARNING (29 CFR
1910.1027 (m)(3)(ii)) AS FOLLOWS: DANGER: CONTAINS
CADMIUM. CANCER HAZARD. AVOID CREATING DUST. CAN
CAUSE LUNG AND KIDNEY DISEASE.

Obey the warnings below before you touch or do maintenance on parts that are
cadmium plated. Refer to the ILLUSTRATED PARTS LIST to identify parts that could
have cadmium plating. The Occupational, Safety, and Health Administration (OSHA)
sets mandatory limits on exposure to cadmium dust (29 CFR 1910.1027).

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C. Chemicals

WARNING: BEFORE YOU USE CHEMICALS, READ, KNOW AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS (MSDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT OBEYED,
CHEMICALS CAN CAUSE INJURY TO YOU OR CAUSE HEALTH
PROBLEMS. AN MSDS/SDS GIVES INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD CHEMICALS.
SPEAK WITH YOUR EMPLOYER FOR INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD CHEMICALS.

Obey the warning above before you do maintenance on parts.

D. Hydraulic Fluid

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND OBEY
ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT OBEYED,
HYDRAULIC FLUID CAN CAUSE INJURY TO YOU OR CAUSE
HEALTH PROBLEMS. AN MSDS/SDS GIVES THE INSTRUCTIONS
YOU MUST FOLLOW TO SAFELY USE, KEEP, AND DISCARD
HYDRAULIC FLUID. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP, AND
DISCARD HYDRAULIC FLUID.

Obey the warning above before you do maintenance on parts.

E. Torque Values

WARNING: OBEY TORQUE LIMITS AND OTHER SPECIFIC VALUES THAT ARE
GIVEN IN THIS MANUAL. THESE LIMITS AND VALUES THAT ARE
NOT OBEYED CAN CAUSE PROPERTY DAMAGE, PERSONAL
INJURY, OR DEATH.

Obey the warning above before you do maintenance on parts.

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INTRODUCTION

6. Specification Sources

It is recommended to use the latest revision or replacement of an industry specification

for procedures, materials, or industry-standard parts (with P/Ns that start with “MS”,
“NAS”, etc.).

A. Get Federal and MIL specifications that are referred to in this manual from the source
that follows:

DAPS
ASSIST
Bldg 4/D
700 Robbins Avenue
Philadelphia, Pennsylvania 19111
U.S.A.

Web: http://assist.daps.dla.mil/online/start/

B. Get AMS specifications that are referred to in this manual from the source that
follows:

SAE Customer Service

400 Commonwealth Drive
Warrendale, Pennsylvania 15096-0001
U.S.A.

Tel: 724-776-4970
Web: www.sae.org

C. Get ASTM specifications that are referred to in this manual from the source that
follows:

American Society for Testing and Materials

100 Barr Harbor Drive
West Conshohocken, Pennsylvania 19428
U.S.A.

Tel: 610-832-9500
Web: www.astm.org

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INTRODUCTION

7. Abbreviations and Acronyms in This Manual

ABBREVIATION or
FULL NOMENCLATURE (NAME)
ACRONYM
ASTM American Society for Testing Materials
bar Measurement unit of pressure
BHN Brinell Hardness Number
CAGE Commercial And Government Entity
EAR Export Administration Regulations
FAA Federal Aviation Authority
IACS International Annealed Copper Standard
in inch
IPL Illustrated Parts List
MAX. maximum
MIN. minimum
mm millimeter
MOH Mohs Scale of Mineral Hardness
MSDS/SDS Material Safety Data Sheet or Safety Data Sheet
Nm Newton meter
OSHA Occupational Safety and Health Administration
P/N Part Number
psi pounds per square inch
Rb Rockwell B Hardness
Rc Rockwell C Hardness
SAE Society of Automotive Engineers
SI International System of Units (metric system)
VHT Very High Temperature

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INTRODUCTION

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DESCRIPTION AND OPERATION

TASK 32-46-41-870-801-A01

1. Brake Data

A. Fluid used: MIL-PRF-83282 hydraulic fluid

B. Maximum brake operating pressure: 2000 psi (137,9 bar)

C. Running clearance:

- 0.060 inch (1,52 mm) minimum for a brake assembly with a new heat sink

- 0.030 inch (0,76 mm) minimum for a brake assembly with a used heat sink

D. Number of pistons: Six

E. Piston housing: Aluminum alloy 2014, T6

2. Description

A. The brake assembly (refer to Figure 1) uses pistons to compress steel disks in the
heat sink. Each brake assembly operates from the aircraft hydraulic system and uses
MIL-PRF-83282 hydraulic fluid.

B. The brake assembly, P/N 2-1502, is the initial design brake assembly with a new
brake wear pin setting of 0.350 inch (8,89 mm) with the brake pressurized.

The brake assembly, P/N 2-1502-1, has a decreased wear pin setting of 0.160 inch
(4,06 mm) with the brake pressurized.

The brake assembly, P/N 2-1502-2, introduces changes to the rotors, and new piston
insulators and spacers. The 2-1502-2 brake assembly has a new brake wear pin
setting of 0.315 inch (8,00 mm). The brake assembly, P/N 2-1502-2, can only be
used with main wheel assemblies, P/Ns 3-1399-5 and 3-1399-6.

The brake assembly P/N 2-1502-3 replaces brake assemblies P/N 2-1502, 2-1502-1,
and 2-1502-2. The wear pin setting for this brake is 0.260 inch (6,60 mm).

C. The brake assembly contains three primary parts as follows (refer to Figure 1):

(1) Piston housing assembly

(2) Steel heat sink

(3) Torque plate and wear plate assembly

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DESCRIPTION AND OPERATION

D. The forged aluminum piston housing assembly engages, disengages, and adjusts the
brake assembly. Bolts, washers, and nuts attach the piston housing assembly to the
torque plate and wear plate assembly with the heat sink installed on the torque plate
and wear plate assembly.

(1) The piston housing assembly contains six adjuster assemblies (attached with
retaining rings), actuating pistons, spacers, and insulators, four bleeder plugs,
and a shuttle valve assembly.

(2) O-rings on the bleeder plugs prevent leakage of hydraulic fluid.

(3) Two bolts and washers attach a shuttle valve assembly to the piston housing
assembly. If the main source of hydraulic pressure is not available, the shuttle
valve assembly disconnects the main source and connects an alternate source
of pneumatic pressure to the brake assembly.

If a brake assembly is installed on the other gear, the shuttle valve assembly
can be turned 180 degrees in the port for correct connections.

(4) Two lining wear indicators are installed about 180 degrees apart, in the piston
housing assembly. Each indicator consists of a rod and insert assembly which
thread onto a stud assembly that is attached to the pressure plate assembly.
When the brake is pressurized, the rod extends through the piston housing
assembly and gives a visual indication of heat sink wear.

When the end of a rod becomes flush with the surface of the piston housing
assembly, the brake heat sink is fully worn and the brake must be overhauled.

(5) The adjuster assemblies engage and disengage the brake assembly and keep
correct running clearance for a worn heat sink (refer to Figure 2).

E. Steel Heat Sink

The steel heat sink includes steel disks which turn with the wheel and disks which
cannot turn. The heat sink includes all the parts that have friction surfaces which
cause the brake assembly to stop the rotation of the wheel. The heat sink is installed
on a one-piece, steel torque plate and wear plate assembly. The steel heat sink has:

- A pressure plate assembly

- Rotors

- Stators

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(1) The pressure plate assembly has drive lugs on the inner diameter that engage
the slots in the torque plate and wear plate assembly. The pressure plate
assembly has six wear plates that are attached to the pressure plate with rivets.
The pressure plate assembly has six key-hole slots that accept the adjuster pins
in the adjuster assemblies. The pressure plate assembly does not turn, but
slides as necessary on the torque plate and wear plate assembly as the brake
assembly operates.

(2) Three rotors have drive slots on the outer diameter that engage the drive inserts
in the wheel. Each rotor has a steel carrier with lining material sintered to each
side. The rotors turn with the wheel, and slide as necessary on the drive inserts
of the wheel as the brake assembly operates.

(3) Two stators have drive lugs on the inside diameter that engage the slots in the
torque plate and wear plate assembly. The stators do not turn, but slide on the
torque plate and wear plate assembly as necessary when the brake assembly
operates.

F. Bolts, washers, and nuts attach the piston housing assembly to the torque plate and
wear plate assembly. The torque plate and wear plate assembly holds the pressure
plate assembly and stators in correct alignment with the rotors. The six wear plates
are attached to the backleg of the steel torque plate with rivets.

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DESCRIPTION AND OPERATION

Brake Assembly Description (Sheet 1 of 2)

Figure 1 / GRAPHIC 32-46-41-991-001-A01

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Cross-Section View of the Brake Assembly (Sheet 2 of 2)

Figure 1 / GRAPHIC 32-46-41-991-001-A01

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DESCRIPTION AND OPERATION

Description of an Adjuster Assembly

Figure 2 / GRAPHIC 32-46-41-991-002-A01

3. Operation

A. Pressurized hydraulic fluid in the piston housing assembly pushes the pistons and
insulators against the pressure plate assembly. The pressure plate assembly pushes
the rotors and the stators against the torque plate and wear plate assembly (refer to
Figure 1). The friction between the disks decreases the speed of the rotors and the
aircraft wheel.

B. As the pistons and pressure plate assembly continue to advance, the three rotors
and two stators are clamped between the pressure plate assembly and torque plate
and wear plate assembly. The friction that is caused by the turning and non-turning
parts causes the braking action.

C. When the brake is pressurized, the pressure plate assembly moves forward and
pulls on each adjuster pin, which compresses the spring in each adjuster. One edge
of the pin retainer touches, releasing its hold on the sleeve. Any further movement of
the pressure plate assembly (caused by lining wear) will pull the adjuster pin and
sleeve further through the pin retainer where it will be held.

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DESCRIPTION AND OPERATION

D. When the pressure is decreased, the spring pulls the pressure plate assembly back.
The distance the plate is pulled back is equal to the travel of the pin retainer from
the bottom to the original position. This gives a constant running clearance after
each brake release. The distance that the sleeve is pulled through the pin retainer
compensates for lining wear.

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TESTING AND FAULT ISOLATION

TASK 32-46-41-700-801-A01

1. Testing and Fault Isolation

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-101-A01

Tools, Fixtures, and Equipment - Table 1001

TOOLS SPECIFICATIONS SUPPLIER

or or and USE
EQUIPMENT PART NUMBER (CAGE)

Protective shields Sufficient size to prevent injury Commercially To prevent

to personnel available injury to
personnel
Special tool Shims, P/N 114-1601 Make tool High pressure
locally (refer to test
Figure 9004)
Test stand for brakes Sufficient size and pressure to To test the
conduct brake tests brakes
Commercially
Torque wrench Pound-inches or Nm available Preparation for
(4 percent maximum permitted the tests
error)

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(2) Consumables

NOTE: Except for hydraulic fluid, equivalent alternatives are permitted for the
materials in the table that follows:

TABLE 32-46-41-99A-102-A01

Consumables - Table 1002

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)

Drain/Bleeder hose ---

Hydraulic fluid MIL-PRF-83282 Commercially available
Petrolatum VV-P-236

(3) Referenced Information

TABLE 32-46-41-99A-103-A01

Referenced Information - Table 1003

REFERENCE DESCRIPTION

Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

C. Job Set-up

Not applicable

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D. Procedure

Subtask 32-46-41-780-001-A01

(1) Preparation Before Tests

NOTE: Refer to the FITS AND CLEARANCES section for torque values.

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT
OBEYED, HYDRAULIC FLUID CAN CAUSE INJURY TO YOU
OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP,
AND DISCARD HYDRAULIC FLUID. SPEAK WITH YOUR
EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Put the brake assembly on a clean work surface.

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(b) Put a 2.0 to 3.0 inches (51 to 76 mm) thick wood or cardboard block under
one edge of the torque plate and wear plate assembly (100) to put one
bleeder plug at the highest position.

(c) Connect the hydraulic pressure source to the HYD inlet fittings on the
shuttle valve assembly (25).

CAUTION: REMOVE HYDRAULIC FLUID THAT FALLS ON BRAKE PARTS.

HYDRAULIC FLUID CAN CAUSE DAMAGE TO PARTS.

(d) Cover the heat sink with a material that cannot let hydraulic fluid touch the
parts.

(e) Lubricate an O-ring (225) with a thin layer of petrolatum (VV-P-236) or

hydraulic fluid (MIL-PRF-83282).

WARNING: WEAR EYE PROTECTION WHEN YOU CUT LOCKWIRE. THE

WIRE CUTTER TOOL CAN EJECT A PIECE OF LOCKWIRE AT
HIGH SPEED.

CAUTION: DO NOT USE PLIERS TO BREAK THE LOCKWIRE OR SAFETY

CABLE™. USE DIAGONAL CUTTERS TO CUT THE LOCKWIRE
OR SAFETY CABLE™ FROM THE PARTS. INCORRECT
REMOVAL OF THE LOCKWIRE OR SAFETY CABLE™ CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY OR OTHER
PARTS.

(f) Cut and remove the lockwire and loosen the bleeder plug (220) that is at
the highest location on the brake assembly, to drain the hydraulic fluid that
remains in the piston housing assembly (240). Discard the lockwire.

(g) Remove the bleeder plug (220) that is at the highest location on the brake
assembly. Discard the O-ring (225).

(h) Install the lubricated O-ring (225) on the bleeder fitting (325) and install the
fitting in the bleeder plug port in the piston housing. Tighten the bleeder
fitting to 95 to 105 pound-inches (10,7 to 11,9 Nm).

(i) Install a bleeder screw (320) in the bleeder fitting and connect a drain hose
to the bleeder screw.

(j) Put the end of the drain hose into a fluid waste container.

(k) Pressurize the brake assembly to 100 to 150 psi (6,89 to 10,34 bar).

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Part Number 2-1502

TESTING AND FAULT ISOLATION

(l) Slowly loosen the bleeder screw (320). Tighten the bleeder screw when
you see only hydraulic fluid, and no air bubbles, flow through the drain
hose.

(m) Decrease pressure to 0 psi (0 bar).

(n) Disconnect the drain hose.

(o) Remove the bleeder screw and the bleeder fitting.

(p) Install the bleeder plug (220) that was removed, and a new O-ring (225).

(q) Tighten the bleeder plug (refer to the FITS AND CLEARANCES section for
the torque value).

(r) Install lockwire to the bleeder plug (refer to the ASSEMBLY section).

Subtask 32-46-41-790-001-A01

(2) High-pressure Leak Test

NOTE: The high-pressure leak test is only necessary after you replace a
Lee plug (245) in the piston housing assembly. If a Lee plug was not
replaced, ignore this “High-pressure Leak Test” and go to “Functional Test”
in this section.

(a) Put the brake assembly on the work surface so that the piston housing
assembly (240) is on the top.

(b) Put shims (Figure 9004) between the pressure plate assembly (65) and the
first rotor (90).

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT
OBEYED, HYDRAULIC FLUID CAN CAUSE INJURY TO YOU
OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP,
AND DISCARD HYDRAULIC FLUID. SPEAK WITH YOUR
EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.

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Part Number 2-1502

TESTING AND FAULT ISOLATION

WARNING: DO NOT APPLY MORE PRESSURE TO THE HYDRAULIC

SYSTEM THAN THE SPECIFIED MAXIMUM PRESSURE. MORE
PRESSURE THAN THE MAXIMUM PRESSURE CAN CAUSE
DAMAGE TO THE BRAKE ASSEMBLY AND CAN CAUSE IT TO
EJECT PARTS OR HYDRAULIC FLUID.

(c) Cover the heat sink with a material that cannot let hydraulic fluid touch the
parts.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

(d) Put protective shields around the brake assembly.

(e) Increase the pressure to 3050 to 3100 psi (210,3 to 213,7 bar) in the brake
assembly. Keep this pressure for five minutes.

(f) Decrease pressure to 0 psi (0 bar).

(g) Remove the protective shields.

(h) Do an inspection for hydraulic fluid leakage. If you see leakage, reject the
brake assembly.

(i) Remove the shims.

(j) Do the functional test [refer to paragraph (3)].

Subtask 32-46-41-780-003-A01

(3) Functional Test

(a) Static Leakage Test

WARNING: DO NOT APPLY MORE PRESSURE TO THE HYDRAULIC

SYSTEM THAN THE SPECIFIED MAXIMUM PRESSURE.
MORE PRESSURE THAN THE MAXIMUM PRESSURE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY AND CAN
CAUSE IT TO EJECT PARTS OR HYDRAULIC FLUID.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

If the High-pressure Leak Test in paragraph (2) was done, ignore steps
2 thru 6 that follow.
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TESTING AND FAULT ISOLATION

1 Put a cover on the heat sink with a material that will not let the
hydraulic fluid touch the heat sink parts.

2 Put protective shields around the brake assembly.

3 Increase the pressure to 2025 to 2075 psi (139,6 to 143,1 bar) in the
brake assembly. Keep this pressure for five minutes.

4 Decrease the pressure to 0 psi (0 bar).

5 Remove the protective shields.

6 Do an inspection for hydraulic fluid leakage. Leakage that is too small

to be measured (less than one drop) is permitted. If you see one drop
or more of leakage, reject the brake assembly.

7 Increase the pressure to 3 to 7 psi (0,21 to 0,48 bar).

8 Hold the pressure for five minutes.

9 Do an inspection for hydraulic fluid leakage. Leakage that is too small

to be measured (less than one drop) is permitted. If you see one drop
or more of leakage, reject the brake assembly.

10 Decrease the pressure to 0 psi (0 bar).

(b) Dynamic Leakage Test

WARNING: DO NOT APPLY MORE PRESSURE TO THE HYDRAULIC

SYSTEM THAN THE SPECIFIED MAXIMUM PRESSURE.
MORE PRESSURE THAN THE MAXIMUM PRESSURE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY AND CAN
CAUSE IT TO EJECT PARTS OR HYDRAULIC FLUID.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

1 Put protective shields around the brake assembly.

2 Increase the pressure to 2025 to 2075 psi (136,6 to 143,1 bar) and
decrease the pressure to 0 psi (0 bar) in the brake assembly for
25 cycles.

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TESTING AND FAULT ISOLATION

3 Examine the brake assembly for equal retraction of each piston (195).
All insulators (185) must return to approximately the same initial
position each time that the pressure is released. Reject a brake
assembly with an insulator that does not return to its initial position.

4 At the end of 25 cycles, decrease the pressure to 0 psi (0 bar).

5 Remove the protective shields.

6 Do an inspection for hydraulic fluid leakage. Leakage that is too small

to be measured (less than one drop) is permitted. If you see one drop
or more of leakage, reject the brake assembly.

(c) Clearance Test

WARNING: DO NOT APPLY MORE PRESSURE TO THE HYDRAULIC

SYSTEM THAN THE SPECIFIED MAXIMUM PRESSURE.
MORE PRESSURE THAN THE MAXIMUM PRESSURE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY AND CAN
CAUSE IT TO EJECT PARTS OR HYDRAULIC FLUID.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

1 Put protective shields around the brake assembly.

2 Increase the pressure to 2025 to 2075 psi (139,6 to 143,1bar) and

then decrease the pressure to 95 to 105 psi (6,5 to 7,2 bar). Keep this
pressure.

3 Remove the protective shields and measure the distance between the
pressure plate assembly (65) and the first rotor (90). Reject the brake
assembly if the minimum clearance is,

- more than 0.060 inch (1,52 mm) for brake assemblies with new
heat sinks
- more than 0.030 inch (0,76 mm) for brake assemblies with used
heat sinks

4 Decrease the pressure to 0 psi (0 bar).

5 Disconnect the hydraulic pressure source.

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TESTING AND FAULT ISOLATION

Subtask 32-46-41-780-004-A01

(4) Shuttle Valve Assembly Test

(a) Connect the hydraulic fluid source to the HYD inlet fittings on the shuttle
valve assembly (25).

(b) Cover the heat sink with a material that will not let the hydraulic fluid touch
the parts.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

(c) Put protective shields around the brake assembly.

(d) Increase pressure to 100 to 150 psi (6,9 to 10,3 bar) in the brake
assembly.

(e) Decrease the pressure to 45 to 55 psi (3,10 to 3,79 bar) in the brake
assembly and keep this pressure for one minute. Hydraulic fluid leakage is
permitted when you apply the pressure. When the 45 to 55 psi
(3,10 to 3,79 bar) pressure is obtained, no leakage or leakage that is too
small to be measured (less than one drop) is permitted from the
unconnected AIR port on the shuttle valve assembly (25). If you find a drop
or more leakage, replace or overhaul the shuttle valve assembly.

(f) Increase the pressure to 2025 to 2075 psi (139,6 to 143,1 bar) in the brake
assembly and keep this pressure for one minute. Only no leakage or
leakage that is too small to be measured (less than one drop) is permitted
from the unconnected AIR port on the shuttle valve assembly (25). If you
find a drop or more leakage, replace or overhaul the shuttle valve
assembly.

(g) Decrease the pressure to 0 psi (0 bar).

(h) Remove the protective shields.

(i) Remove and connect the hydraulic fluid source to the unconnected AIR
port on the shuttle valve assembly.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

(j) Put protective shields around the brake assembly.

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TESTING AND FAULT ISOLATION

(k) Increase pressure to 100 to 150 psi (6,9 to 10,3 bar) in the brake
assembly.

(l) Decrease the pressure to 45 to 55 psi (3,10 to 3,79 bar) and keep this
pressure for one minute. Hydraulic fluid leakage is permitted when you
apply the pressure. When the 45 to 55 psi (3,10 to 3,79 bar) is obtained,
no leakage or leakage that is too small to be measured (less than one
drop) is permitted from the unconnected HYD port on the shuttle valve
assembly (25). If you find a drop or more leakage, replace or overhaul the
shuttle valve assembly.

(m) Increase pressure to the brake assembly to 2025 to 2075 psi (139,6 to
143,1 bar) and keep this pressure for one minute. No leakage or leakage
that is too small to be measured (less than one drop) is permitted from the
unconnected HYD port on the shuttle valve assembly (25). If you find a
drop or more leakage, replace or overhaul the shuttle valve assembly.

NOTE: A rejected shuttle valve assembly can be overhauled with parts

kit (280).

(n) Decrease the pressure to 0 psi (0 bar).

(o) Remove the protective shields.

(p) Disconnect the hydraulic pressure source.

Subtask 32-46-41-780-004-A01

(5) Post-test Procedures

(a) Tag or mark the brake assembly as passed or failed the functional test.

(b) If a brake assembly failed the functional test, refer to Table 1004, Fault
Isolation Chart.

(c) Clean the unwanted hydraulic fluid from the brake assembly.

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TESTING AND FAULT ISOLATION

TASK 32-46-41-810-801-A01

2. Fault Isolation

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

Not applicable

C. Job Set-up

Not applicable

D. Procedure

Subtask 32-46-41-810-001-A01

(1) Fault Isolation Chart

NOTE: Refer to the FITS AND CLEARANCES section for torque values. Refer to
the REPAIR section for repair procedures.

TABLE 32-46-41-99A-104-A01

Fault Isolation Chart - Table 1004 (Sheet 1 of 3)

FAULT ISOLATION POSSIBLE CAUSE CORRECTION
Fluid leakage from a Loose bleeder plug (220). Tighten the bleeder plug to
bleeder plug. the correct torque (refer to the
FITS AND CLEARANCES
section for the torque value).
Damaged bleeder plug (220) or Replace the defective parts.
O-ring (225).

Hydraulic fluid Worn or damaged O-ring (200) or Replace defective parts.

leakage from the backup ring (205).
piston area. Damaged piston (195) or bore of piston Replace a damaged piston.
housing (270).
Hydraulic fluid leaks Lee plug (245) is not correctly installed or Install a new Lee plug (refer to
from a Lee plug. is damaged. the REPAIR section).
NOTE: Hydraulic fluid leakage that can not be measured is permitted (less than one drop).

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Part Number 2-1502

TESTING AND FAULT ISOLATION

Fault Isolation Chart - Table 1004 (Sheet 2 of 3)

FAULT ISOLATION POSSIBLE CAUSE CORRECTION
Heat sink is warped more than the limit. Repair or replace the heat
sink.
Weak adjuster spring (165). Measure spring load as
First rotor (90) cannot shown in Figure 5008 in the
be turned with hand CHECK section. Replace a
force or less than defective spring.
running clearance An adjuster pin (145) is broken or a Replace the damaged
given in refer to nut (135) is loose. adjuster pins. Examine the
paragraph 1.D.(3)(c). self-locking function of the
nut. Replace a defective part.
The nut could have cadmium
plating.
Weak or broken adjuster spring (165). Measure spring load as
shown in Figure 5008 in the
CHECK section. Replace a
defective spring.
An adjuster pin (145) is broken or a Replace the damaged
nut (135) is loose or missing. adjuster pins. Examine the
self-locking function of the
nut. Replace a defective part.
The brake drags or The nut could have cadmium
does not release plating.
Heat sink warped beyond tolerance. Replace defective parts.
Incorrect assembly. Disassemble and reset
adjusters. Brake must have
initial running clearance when
assembled.
Excessively worn sleeve (150) Examine the sleeve as
referenced in the CHECK
section.
Brake will not operate Damaged shuttle valve assembly (25). Do an overhaul or replace a
when the emergency defective shuttle valve
hydraulic system is assembly. Do an overhaul of
applied. a shuttle valve assembly with
a parts kit (280).
Shuttle valve Damaged O-rings (30) or Replace defective parts.
assembly (25) leaks. backup ring (35).
NOTE: Hydraulic fluid leakage that can not be measured is permitted (less than one drop).

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TESTING AND FAULT ISOLATION

Fault Isolation Chart - Table 1004 (Sheet 3 of 3)

FAULT ISOLATION POSSIBLE CAUSE CORRECTION
Shuttle valve Damaged shuttle valve assembly (25). Do an overhaul or replace a
assembly leaks from defective shuttle valve
unconnected port. assembly. Do an overhaul of
a shuttle valve assembly with
a parts kit (280).
NOTE: Hydraulic fluid leakage that can not be measured is permitted (less than one drop).

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TESTING AND FAULT ISOLATION

INTENTIONAL BLANK PAGE

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DISASSEMBLY
TASK 32-46-41-000-801-A01

1. Disassembly

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-301-A01

Tools, Fixtures, and Equipment - Table 3001

TOOLS SPECIFICATIONS SUPPLIER

or or and USE
EQUIPMENT PART NUMBER (CAGE)
Arbor press or drill press --- To disassemble
adjuster assembly
parts
Goggles --- Eye protection
Press table --- To disassemble
adjuster assembly
Commercially
parts
available
Protective shields Sufficient size to To prevent injury to
prevent injury to personnel
personnel
Test stand for brakes Sufficient size and Preparation for
pressure to conduct disassembly
brake tests

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DISASSEMBLY

(2) Consumables

NOTE: Except for hydraulic fluid, equivalent alternatives are permitted for the
materials in the table that follows:

TABLE 32-46-41-99A-302-A01

Consumables - Table 3002

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)
Hydraulic fluid MIL-PRF-83282 Commercially available

(3) Referenced Information

TABLE 32-46-41-99A-303-A01
Referenced Information - Table 3003

REFERENCE DESCRIPTION
Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

C. Job Set-up
Not applicable
D. Procedure

Subtask 32-46-41-020-001-A01
(1) Preparation for Disassembly

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT
OBEYED, HYDRAULIC FLUID CAN CAUSE INJURY TO YOU
OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP,
AND DISCARD HYDRAULIC FLUID. SPEAK WITH YOUR
EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.

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DISASSEMBLY

WARNING: INSTALL PROTECTIVE SHIELDS AROUND THE UNIT BEFORE

YOU APPLY HYDRAULIC PRESSURE TO THE UNIT. SHIELDS
CAN PREVENT INJURY TO PERSONNEL AND DAMAGE TO
TEST EQUIPMENT.

(a) Connect the hydraulic fluid pressure source to the inlet port on the shuttle
valve of the piston housing assembly (240) (refer to the paragraph 1.D.(1)
in the TESTING AND FAULT ISOLATION section).

(b) Put a protective shield around the brake assembly.

(c) Pressurize the brake assembly to 2000 to 2050 psi (137,9 to 141,3 bar)
and keep this pressure.

(d) Measure the length of each rod and insert assembly (55) from the piston
housing assembly (240) (refer to Figure 3001). Measure to the nearest
0.0001 inch (0,40 mm) and record the shortest measurement.

Do not change the length of each rod and insert assembly of a brake
assembly that is removed from an aircraft for a reason other than wear.

(e) Decrease the pressure to 0 psi (0 bar).

(f) Remove the protective shields.

(g) Disconnect the brake assembly from the pressure source.

(h) Put caps on the hydraulic ports.

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DISASSEMBLY

Brake Wear Measurement

Figure 3001 / GRAPHIC 32-46-41-991-301-A01

Subtask 32-46-41-020-002-A01
(2) Piston Housing Assembly (265) Removal

NOTE: Brakes that are removed from the aircraft for reasons other than wear
should not have heat sink parts disturbed unless necessary. Return the
brakes to service with the same rod and insert assembly (55) length.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

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DISASSEMBLY

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Put the brake assembly on a flat clean work surface with the piston
housing assembly (240) on top.

(b) If necessary, remove an identification plate (5) that is loose or that you
cannot read.

(c) Connect a temporary drain tube on the shuttle valve assembly (65) and
drain the hydraulic fluid or use other procedures to make sure that the
drained hydraulic fluid goes into a fluid waste container.

(d) Clean the part of each piston (195) that you can see (refer to the
CLEANING section).

CAUTION: INSULATORS THAT ARE PUSHED INTO THE PISTON HOUSING

CAN CAUSE HYDRAULIC FLUID TO BE EJECTED OUT OF AN
OPEN PORT. MAKE SURE THAT THE FLUID DRAINS INTO A
CONTAINER.

(e) Use hand force to push the pressure plate to towards the piston housing
assembly. This pushes the pistons into the piston housing assembly and
pushes any remaining hydraulic fluid out of the piston housing assembly.

CAUTION: DO NOT USE PLIERS TO BREAK THE LOCKWIRE. USE

DIAGONAL CUTTERS TO CUT THE LOCKWIRE FROM THE
PARTS. INCORRECT REMOVAL OF THE LOCKWIRE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY OR OTHER
PARTS.

(f) Cut and remove the lockwire, then remove the bolts (15), washers (20),
and the shuttle valve assembly (25) from the piston housing
assembly (240). The bolts and washers could have cadmium plating.

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DISASSEMBLY

(g) Remove the O-ring (30) and backup ring (35) from the shuttle valve
assembly. Discard the O-ring and backup ring.

(h) Remove the nuts (40), washers (45), and bolts (50). The nuts, washers,
and bolts could have cadmium plating.

CAUTION: DO NOT USE PLIERS TO BREAK THE LOCKWIRE. USE

DIAGONAL CUTTERS TO CUT THE LOCKWIRE FROM THE
PARTS. INCORRECT REMOVAL OF THE LOCKWIRE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY OR OTHER
PARTS.

(i) Cut and remove the lockwire and remove each bleeder plug (220) from the
piston housing assembly. Discard the lockwire.

(j) Remove the O-ring (225) from each bleeder plug. Discard the O-ring.

(k) Remove the bleeder screws (230) and bleeder fittings (235), if installed.
Discard the bleeder screws and bleeder fittings.

(l) Remove the drain tubes.

(m) Remove the piston housing assembly (240) with the attached pressure
plate assembly (65) from the torque plate and wear plate assembly (100).

Subtask 32-46-41-020-003-A01
(3) Heat Sink Removal

(a) If the disks will be removed, but will be installed again, identify each disk
so that it can be installed again in the same position. The friction surfaces
of the disks must touch the same friction surfaces of mating disks that they
touched before the disks were removed.

Use tape or chalk to mark the parts for identification and for position in the
heat sink (1, 2, or 3) and which way each part faces.

(b) Remove the rotors (90) and stators (95) from the torque plate and wear
plate assembly (100).

NOTE: The heat sink parts are designed to last until they are fully worn. If
the wear pin is flush (refer to Figure 3001), the heat sink must be
replaced and no inspection of heat sink parts (wear plates, rotors,
stators) is necessary. If the brake is removed and disassembled
before an overhaul is necessary, the heat sink parts should be
installed again (refer to the ASSEMBLY section).

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DISASSEMBLY

Subtask 32-46-41-020-004-A01
(4) Pressure Plate Assembly (65) Removal

(a) Put the piston housing assembly (240) on a flat surface with the
pressure plate assembly (65) on top.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(b) Remove the rod and insert assembly (55) from the stud assembly (60).
Loosen the self-locking nut on the stud assembly (60) and remove the stud
assembly from the pressure plate assembly (65). The stud assembly could
have cadmium plating.

(c) Press down on the pressure plate assembly (65) and turn it clockwise to
release the adjuster pins (145). Lift and remove the pressure plate
assembly (65) from the piston housing assembly (240).

NOTE: Do not remove wear plates (75) from the pressure plate
assembly (65) unless they are damaged or fully worn (refer to the
REPAIR section).

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DISASSEMBLY

Subtask 32-46-41-020-005-A01
(5) Torque Plate and Wear Plate Assembly (100) Removal

NOTE: Do not remove wear plates (110) from the torque plate and wear plate
assembly (100) unless they are damaged or fully worn (refer to the
REPAIR section).

NOTE: Refer to the REPAIR section for wear plate replacement.

Subtask 32-46-41-020-006-A01
(6) Piston Housing (270) Disassembly

NOTE: Do not remove a Heli-Coil® insert (250, 255), torque clips (215),
bushings (260, 265), except to replace these parts when damaged (refer
to the REPAIR section).

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET OR
SAFETY DATA SHEET (MSDS/SDS), AND GOVERNMENT
REGULATIONS. IF SAFETY INSTRUCTIONS ARE NOT
OBEYED, HYDRAULIC FLUID CAN CAUSE INJURY TO YOU
OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP,
AND DISCARD HYDRAULIC FLUID. SPEAK WITH YOUR
EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT

YOU SWALLOW CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH PARTS THAT
CONTAIN CADMIUM, CLEAN YOUR HANDS BEFORE YOU EAT
OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR
EMPLOYER. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL.

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DISASSEMBLY

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Remove each retaining ring (120) and adjuster assembly (125) from the
piston housing assembly (240).

(b) Piston Disassembly

WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST

CONTAINS ASBESTOS FIBERS THAT CAN CAUSE
CANCER AND LUNG DISEASE. DO NOT USE
COMPRESSED AIR TO CLEAN PARTS OR ASSEMBLIES
THAT POSSIBLY CONTAIN ASBESTOS DUST. IF
MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO
ASBESTOS DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD PARTS THAT CONTAIN ASBESTOS.

NOTE: Remove and discard insulators (185 and 185A) and spacers
(190 and 190A). The insulators (185 and 185A) could contain
asbestos.

1 Remove each insulator (185B) from each piston (195).

CAUTION: DO NOT USE SHARP, HARD TOOLS TO REMOVE O-RINGS

AND BACKUP RINGS. THESE TOOLS CAN CAUSE DAMAGE
TO ALUMINUM PARTS.

2 Remove the piston (195), O-ring (200), and backup ring (205) from
each piston bore.

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DISASSEMBLY

Subtask 32-46-41-020-007-A01
(7) Adjuster Assembly (125) Disassembly

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT

YOU SWALLOW CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH PARTS THAT
CONTAIN CADMIUM, CLEAN YOUR HANDS BEFORE YOU EAT
OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR
EMPLOYER. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

WARNING: DO NOT REMOVE PARTS WITH CORRECT TOOLS AND

PROCEDURES. INCORRECT TOOLS AND PROCEDURES CAN
CAUSE AN ADJUSTER SPRING AND OTHER PARTS TO
EJECT AT HIGH SPEED.

(a) Remove the retaining ring (130) from the inner diameter groove of each
adjuster housing (125).

(b) Remove the subassemblies from the piston housing (270).

(c) Put an adjuster subassembly on the press table with the pin retainer (175)
on top (refer to Figure 3002, VIEW A).

CAUTION: DO NOT COMPRESS THE SPRING TO LESS THAN THE

MINIMUM HEIGHT. DAMAGE TO THE SPRING CAN OCCUR.

(d) Lower the tool (refer to Figure 9002) on the spring retainer (160) and push
the spring down until you can remove the sleeve (150) and pin
retainer (175).

(e) Lock the press and remove the sleeve and pin retainer.

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DISASSEMBLY

(f) Unlock the press and slowly release the pressure on the spring
retainer (160) lift the tool from the spring.

(g) Remove the nut (135), washer (140), and adjuster pin (145) from each
sleeve (150). A screwdriver slot is provided in the head of each
adjuster pin (145) to help remove the nut. The nuts and washers could
have cadmium plating.

(h) Turn the remaining subassembly so that the retaining ring (155) is on the
top. Set the subassembly on the press table under the tool (refer to
Figure 3002, VIEW B).

(i) Lower the tool against the spring retainer (160) and push down to move
the spring retainer away from the retaining ring (155).

(j) Lock the press and remove the retaining ring (155) from the sleeve (150).

(k) unlock the press and slowly release the force on the spring retainer (160)
and lift the tool away from the subassembly.

(l) Remove the spring retainers (160) and spring (165) from the sleeve (170).

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DISASSEMBLY

Adjuster Disassembly
Figure 3002 / GRAPHIC 32-46-41-991-302-A01
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DISASSEMBLY

Subtask 32-46-41-020-008-A01
(8) Shuttle Valve (25) Disassembly

WARNING: WEAR EYE PROTECTION WHEN YOU CUT LOCKWIRE. THE

WIRE CUTTER TOOL CAN EJECT A PIECE OF LOCKWIRE AT
HIGH SPEED.

CAUTION: DO NOT USE PLIERS TO BREAK THE LOCKWIRE. USE

DIAGONAL CUTTERS TO CUT THE LOCKWIRE FROM THE
PARTS. INCORRECT REMOVAL OF THE LOCKWIRE CAN
CAUSE DAMAGE TO THE BRAKE ASSEMBLY OR OTHER
PARTS.

CAUTION: DO NOT DISASSEMBLE THE SHUTTLE VALVE UNLESS IT IS

TO BE OVERHAULED AND THE PARTS KIT, P/N 380-123, IS
AVAILABLE. THE SHUTTLE VALVE BODY (285) AND END
CAP (290) ARE NOT AVAILABLE IN THE PARTS KIT.

(a) Cut and remove the lockwire from the end cap (290). Discard the lockwire
and the lead seal.

CAUTION: DISASSEMBLE THE SHUTTLE VALVE IN A LOCATION THAT

PREVENTS LOSS OF SMALL PARTS.

(b) Carefully remove the end cap (290) which contains the poppet (295),
balls (305), and spring (310) from the shuttle valve body (285) (refer to
Figure 3003).

(c) Carefully remove the poppet assembly, balls, and spring from the end cap.
Discard the poppet assembly, spring, and balls.

(d) Remove the O-rings (315) from each end of the poppet. Discard the
O-rings.

(e) Remove the O-ring (300) from the end cap. Discard the O-ring.

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Part Number 2-1502

DISASSEMBLY

Shuttle Valve Disassembly

Figure 3003 / GRAPHIC 32-46-41-991-303-A01

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CLEANING
TASK 32-46-41-100-801-A01
1. Parts Cleaning
A. Reason for the Job
(1) Clean brake assembly parts are necessary before you examine, repair, or install
the parts.
B. Job Set-up Information
(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-401-A01

Tools, Fixtures, and Equipment - Table 4001

TOOLS SPECIFICATIONS SUPPLIER

or or and USE
EQUIPMENT PART NUMBER (CAGE)
Cleaning brushes Brushes that cannot be
damaged by cleaning materials Cleaning
Dry compressed air source Nozzle must keep the pressure Commercially parts
with a hose and nozzle to an OSHA-specified limit. available
Goggles --- Eye
protection

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CLEANING

(2) Consumables

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for the sources of materials. The list of
consumables gives recommended concentrations and temperatures of
aqueous cleaners.

NOTE: Equivalent alternatives are permitted for the materials in the table that
follows:

TABLE 32-46-41-99A-402-A01

Consumables - Table 4002

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)
Aqueous cleaners Refer to the NOTE above Refer to the NOTE above
Degreasing Solvent
Cleaner MIL-PRF-680 Type II or III
Commercially available
Butyl alcohol
Clean and soft lint-free cloth ---

(3) Referenced Information

TABLE 32-46-41-99A-403-A01
Referenced Information - Table 4003

REFERENCE DESCRIPTION
Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

C. Job Set-up
Not applicable

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CLEANING

D. Procedure
Subtask 32-46-41-110-001-A01
(1) Metal Parts Cleaning

WARNING: BEFORE YOU USE A SPECIFIED CLEANING MATERIAL,

READ, KNOW, AND OBEY ALL SAFETY INSTRUCTIONS FOR
THE CLEANING MATERIAL. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET OR SAFETY DATA SHEET (MSDS/SDS),
AND GOVERNMENT REGULATIONS. IF SAFETY
INSTRUCTIONS ARE NOT OBEYED, CLEANING MATERIAL
CAN CAUSE INJURY TO YOU OR CAUSE HEALTH
PROBLEMS. AN MSDS/SDS GIVES THE INSTRUCTIONS YOU
MUST FOLLOW TO SAFELY USE, KEEP, AND DISCARD
CLEANING MATERIAL. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE, KEEP,
AND DISCARD CLEANING MATERIAL.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

CAUTION: DO NOT USE A WIRE BRUSH TO CLEAN ALUMINUM PARTS. A

WIRE BRUSH CAUSES DAMAGE TO THE ANODIZE LAYER ON
THESE PARTS.

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CLEANING

CAUTION: DO NOT USE ALKALINE CLEANING SOLVENTS TO CLEAN

ALUMINUM PARTS. THESE SOLVENTS CAN CAUSE DAMAGE
TO THESE PARTS.

CAUTION: CAREFULLY OBEY THE INSTRUCTIONS FROM THE

MANUFACTURER FOR USE OF AQUEOUS CLEANING
MATERIALS. INCORRECT PROCEDURES CAN CAUSE
DAMAGE TO PARTS OR UNSATISFACTORY CLEANING.

CAUTION: MAKE SURE THAT CONTAMINATION IS REMOVED FROM THE

BOLTS AND NUTS THAT HOLD THE BRAKE ASSEMBLY
TOGETHER. CONTAMINATION CAN PREVENT FULL
INSPECTION OF THE BOLTS AND NUTS. CONTAMINATION
CAN CAUSE INCORRECT BOLT TENSION WHEN THE NUTS
ARE TORQUED.

(a) Clean metal parts with MIL-PRF-680 Type II or III solvent or aqueous
cleaning materials.

(b) Use clean, dry compressed air to dry parts. Make sure that all bolt threads
are fully clean. Some of these parts could have cadmium plating (refer to
the ILLUSTRATED PARTS LIST to find these parts).

Subtask 32-46-41-110-002-A01

(2) Non-Metal Parts Cleaning

WARNING: BEFORE YOU USE BUTYL ALCOHOL, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE BUTYL
ALCOHOL. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS
FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, BUTYL ALCOHOL CAN CAUSE INJURY
TO YOU OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS
GIVES THE INSTRUCTIONS YOU MUST FOLLOW TO SAFELY
USE, KEEP, AND DISCARD BUTYL ALCOHOL. SPEAK WITH
YOUR EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW
TO SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL.

CAUTION: USE ONLY SPECIFIED CLEANING MATERIALS TO CLEAN

NON-METAL PARTS. SOME OTHER CLEANING MATERIALS
(FOR EXAMPLE: MIL-PRF-680) CAN CAUSE DAMAGE TO
THESE PARTS.

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CLEANING

CAUTION: APPLY CLEANING MATERIALS FOR ONLY THE TIME THAT IS

NECESSARY TO CLEAN THE PARTS. CLEANING MATERIALS
THAT YOU APPLY FOR A LONGER TIME THAN THE
SPECIFIED TIME CAN CAUSE DAMAGE TO SOME PARTS.

(a) Clean non-metal parts with a soft, clean cloth and butyl alcohol or aqueous
cleaning materials.

(b) Use clean, dry compressed air to dry the parts.

TASK 32-46-41-100-802-A01

2. Paint Removal

NOTE: Remove the paint before penetrant inspection of the piston housing. Do not
remove the paint for eddy current inspection.

A. Reason for the Job

(1) Clean brake assembly parts are necessary before you examine, repair, or install
the parts.

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-404-A01

Tools, Fixtures, and Equipment - Table 4004

TOOLS SPECIFICATIONS SUPPLIER

or or and USE
EQUIPMENT PART NUMBER (CAGE)
Abrasive-media paint ---
removal equipment
Abrasive blast equipment --- Commercially
Paint removal
available
Dry compressed air source Nozzle must keep the
with a hose and nozzle pressure to an
OSHA-specified limit.

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CLEANING

(2) Consumables
NOTE: Equivalent alternatives are permitted for the materials in the table that
follows:.

TABLE 32-46-41-99A-405-A01

Consumables - Table 4005

MATERIAL SPECIFICATIONS SUPPLIER

and
(CAGE)
Mask material ---
Paint remover SAE-AMS-1375
Plastic Media
MIL-P-85891 Type II
(maximum media hardness of
Commercially available
3.5 MOH)
Paint removal abrasive
Sodium Bicarbonate
Walnut Hulls
MIL-G-5634 Type II or Type III,
Grade 20/30

(3) Referenced Information

TABLE 32-46-41-99A-406-A01
Referenced Information - Table 4006

REFERENCE DESCRIPTION
Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

C. Job Set-up

Not applicable

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CLEANING

D. Procedure

Subtask 32-46-41-120-001-A01

(1) Paint Removal of the Piston Housing (270)

Remove paint before penetrant inspection of the piston housing (270), by one
procedure of the two procedures that follow:

WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS

FROM YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND
DISCARD THE PAINT THAT IS REMOVED. THE PAINT THAT IS
REMOVED IS POSSIBLY DANGEROUS AND CAN CAUSE
INJURY TO YOU OR CAUSE HEALTH PROBLEMS.

CAUTION: DO NOT USE A WIRE BRUSH OR USE SAND OR GLASS

BEADS IN THE ABRASIVE-BLAST PROCEDURE TO CLEAN
ALUMINUM PARTS. A WIRE BRUSH, SAND, OR GLASS BEADS
CAUSE DAMAGE TO THE ANODIZE LAYER ON ALUMINUM
PARTS.

(a) Remove Paint from the Piston Housing by Abrasive Blast

1 Apply mask material to hydraulic ports and threaded holes. Put plugs
in the fluid ports and in the holes that contain Heli-Coil®
inserts (250, 255).

2 Blast the parts by the procedures in MIL-STD-1504. Use media that

does not cause damage to the anodize layer - for example:

- Plastic media (MIL-P-85891 Type II) (maximum media hardness

of 3.5 MOH).

- Walnut hulls (MIL-G-5634 Type II or Type III) (grain-soft abrasive

walnut hulls, Grade 20/30).

- Sodium Bicarbonate.

3 Use clean, dry, compressed air to remove plastic media and paint
debris from the piston housing. Remove plugs and mask material and
make sure that cavities, holes, and fluid passages are clean.

4 If the abrasive media caused damage to the anodize layer, apply

conversion coating to the damaged areas (refer to the REPAIR
section).

5 Fully remove the abrasive blast material.

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CLEANING

(b) Remove Paint from the Piston Housing with a Chemical

WARNING: BEFORE YOU USE PAINT REMOVER, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE PAINT
REMOVER. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE
MATERIAL SAFETY DATA SHEET OR SAFETY DATA
SHEET (MSDS/SDS), AND GOVERNMENT REGULATIONS.
IF SAFETY INSTRUCTIONS ARE NOT OBEYED, PAINT
REMOVER CAN CAUSE INJURY TO YOU OR CAUSE
HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD PAINT REMOVER. SPEAK WITH
YOUR EMPLOYER FOR INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD PAINT
REMOVER.

WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS

FROM YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND
DISCARD THE PAINT THAT IS REMOVED. THE PAINT THAT
IS REMOVED IS POSSIBLY DANGEROUS AND CAN CAUSE
INJURY TO YOU OR CAUSE HEALTH PROBLEMS.

CAUTION: DO NOT USE A WIRE BRUSH TO REMOVE PAINT ON

ALUMINUM PARTS. A WIRE BRUSH CAUSES DAMAGE TO
THE ANODIZE LAYER ON THESE PARTS.

1 If you put the piston housing fully into the paint remover, put plugs in
piston cavities, in fluid ports, and in holes that contain
Heli-Coil® inserts (250, 255).

2 Apply the paint remover (SAE AMS1375) that can remove urethane
paint and epoxy primer and does not cause damage to aluminum
parts. Refer to instructions from the manufacturer of the paint remover.

3 Fully remove the paint remover.

4 Use clean, dry, compressed air to remove all contamination or water

from the piston housing. Remove plugs and mask material and make
sure that cavities, holes, and fluid passages are clean and dry.

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CLEANING

Subtask 32-46-41-120-002-A01

(2) Paint Removal of the Torque Plate (115) and Pressure Plate (80) (if necessary):

WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS

FROM YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND
DISCARD THE PAINT THAT IS REMOVED. THE PAINT THAT IS
REMOVED IS POSSIBLY DANGEROUS AND CAN CAUSE
INJURY TO YOU OR CAUSE HEALTH PROBLEMS.

NOTE: The torque plate (115) and pressure plate (80) can be abrasive blasted to
clean these parts or to remove corrosion.

(a) Remove Paint and Corrosion from Torque Plate and Pressure Plate by
Abrasive Blast

Lightly abrasive blast areas of the torque plate (115) and the pressure
plate (80) to remove paint and corrosion. Blast with 40 to 80 mesh
abrasive media such as steel grit, sand, or aluminum oxide. Steel grit
(not shot) abrasive media is recommended. Make sure not to remove
excess material in this procedure. Use clean, dry compressed air to
remove dust from the part.

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INTENTIONAL BLANK PAGE

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TASK 32-46-41-200-801-A01

1. General Inspection

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-501-A01

Tools, Fixtures, and Equipment - Table 5001 (Sheet 1 of 2)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Bright lights 100 foot candles Visual
(1076 Lux) minimum on inspections
inspection surface
Conductivity meter ASTM E1004 NDT
MIL-STD-1537 inspections
SAE-ARP891
SAE-AMS-2658
Hardness test equipment Rockwell or Brinell Inspection of
hardness test equipment hardness of
Commercially stator, pressure
available plate, torque
plate, and
piston housing
Magnetic particle inspection ASTM E1444 NDT
equipment inspections
Magnifiers 3X to 10X Visual
inspections
Measurement tools Accurate to 0.001 inch Measurement
(0,03 mm) inspections

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Tools, Fixtures, and Equipment - Table 5001 (Sheet 2 of 2)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Penetrant inspection equipment ASTM E1417 Type I, NDT
Method A, Level 2 inspections
Spring test equipment ---
Commercially Inspection of
available the spring load
limit at each
heat sink
change

(2) Consumables

NOTE: Equivalent alternatives are permitted for the materials in the table that
follows:

TABLE 32-46-41-99A-502-A01

Consumables - Table 5002

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)
Magnetic particle inspection fluid ASTM E1444
Penetrant inspection fluid ASTM E1417 Type I, Commercially available
Method A, Level 2

(3) Referenced Information

TABLE 32-46-41-99A-503-A01

Referenced Information - Table 5003

REFERENCE DESCRIPTION

Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

C. Job Set-up

Not applicable

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D. Procedure

Subtask 32-46-41-210-001-A01

(1) Inspection Intervals

NOTE: The procedures in the CHECK section are necessary only when the heat
sink is fully worn (the rod and insert assembly (55) is flush or below flush
with the piston housing) and before you install a replacement heat sink. Do
not inspect a fully worn heat sink. If the brake assembly is disassembled
before a rod and insert assembly (55) is flush, examine the parts that have
damage as given in the Inspection Intervals table below.

NOTE: This CHECK section uses the word “damage” many times. Corrosion,
cracks, dents, and bent areas are typical types of “damage”. Other types
of damage are possible.

NOTE: Refer to all pages in this CHECK section for full inspection procedure data.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/
OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Do inspections for indications of an overheated brake assembly. For

example if a thermal relief plug (in the wheel) melted and released tire
pressure, do the “Special Inspections” in this CHECK section. Do these
inspections before you do the scheduled inspections.

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(b) Do an inspection of all metal parts for corrosion, cracks, nicks, scratches,
gouges, distortion, damaged threads, and other defects. Discard damaged
parts that are not economically repairable. Some of the parts could have
cadmium plating.

(c) Discard O-rings (30, 200, 225, 300, 315) and backup rings (35, 205) at
each heat sink change.

TABLE 32-46-41-99A-504-A01

Inspections at Each Heat Sink Change - Table 5004 (Sheet 1 of 2)

INSPECTION PART
TYPE DESCRIPTION
O-rings (30, 200, 225)
O-rings (300, 315) (If Removed)
Backup rings (35, 205)
Discard
Rivets (70, 105) (If Removed)
Balls (305) (If Removed)
Spring (310) (If Removed)
Nut (40, 135)
Washer (20, 45, 140)
Bolt (15, 50)
Screw (210)
Identification plate (5)
Rod and insert assembly (55)
Stud assembly (60)
Heli-Coil® insert (85, 250, 255)
Poppet (295) (If Removed)
Visual Pressure plate (80)
Rotor (90) (Refer to NOTE 1)
Stator (95) (Refer to NOTE 1)
Torque plate (115)
Retaining ring (120, 130, 155)
Adjuster Pin (145)
Sleeve (150, 170)
Spring retainer (160)
Spring (165)
Adjuster housing (180)

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Inspections at Each Heat Sink Change - Table 5004 (Sheet 2 of 2)

INSPECTION PART
TYPE DESCRIPTION
Insulator (185B)
Piston (195)
Lee plug (245)
Piston housing assembly (240)
Wear plate (75, 110) (Refer to NOTE 1)
Visual Torque clip (215) (If Removed)
Bleeder plug (220)
Bushing (260, 265)
Plug cap (275)
Pin retainer (175)
Shuttle valve assembly (25)
Pressure plate (80)
Rotor (90) (Refer to NOTE 1)
Stator (95) (Refer to NOTE 1)
Torque plate (115)
Adjuster housing (180)
Measurement
End cap (290) (If Removed)
Piston (195)
Sleeve (150)
Spring (165)
Wear plate (75, 110) (Refer to NOTE 1)
Rotor (90) (Refer to NOTE 1)
NDT Stator (95) (Refer to NOTE 1)
Adjuster pin (145)
NOTE 1: Do these inspections if the heat sink is not fully worn and is installed again.

TABLE 32-46-41-99A-505-A01

Added Inspections at Each 3rd Heat Sink Change - Table 5005

Pressure plate (80)

NDT Torque plate (115)

Piston housing assembly (240)

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Subtask 32-46-41-220-001-A01

(2) Wear Plate (75, 110) Inspection

(a) Examine each wear plate (75, 110) (refer to Figure 5001). Replace all the
wear plates if one wear plate is defective. Do not install a mixture of new
and used wear plates.

(b) Examine each wear plate for loose or damaged rivets (70, 105). Replace
loose or damaged rivets (refer to the REPAIR section).

(c) Examine each wear plate for cracks. No more than one crack is permitted
in each rivet hole.

(d) Examine each wear plate for edge curl. Edge curl is permitted when the
wear plates are attached to the pressure plate (80) or torque plate (115).

NOTE: Knife edge curl and wear that is not even between the wear plates
is permitted.

Wear Plate Inspection

Figure 5001 / GRAPHIC 32-46-41-991-501-A01

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Subtask 32-46-41-220-002-A01

(3) Pressure Plate (80) Inspection

(a) If the brake was overheated and caused the thermal relief plugs (in the
wheel assembly) to melt and release tire pressure, a hardness
measurement is necessary (refer to “Special Inspections” in this CHECK
section).

(b) Visual Inspection

1 Do a visual inspection for cracks at each wear plate change. Discard

a pressure plate if:

a Cracks that start from the disk outer diameter and go toward the
inner diameter are more than 0.250 inch (6,35 mm) long.

b There is a crack that starts at a thermal expansion stop hole or at

the junction of the disk inner diameter and the drive lug (refer to
Figure 5002).

2 Do a visual inspection for thread damage and do a test of the internal

thread-locking element of each Heli-Coil® insert (85). Install a clean,
and dry stud assembly (60) into the Heli-Coil® insert. If the stud
assembly turns with hand force through the locking element or if the
back-off torque is less than 1.5 pound-inches (0,2 Nm), replace the
Heli-Coil® insert (refer to the REPAIR section).

(c) Measurement Inspection

1 Measure the width of each drive lug for wear. Discard a pressure plate
with a drive lug that is worn to more than the limits (refer to
Figure 5002).

2 Measure the thickness of the pressure plate. Discard a pressure plate

with a thickness that is less than the limit (refer to Figure 5002).

3 Measure the inner diameter of the pressure plate. Discard a pressure

plate with an inner diameter that is less than the limit (refer to
Figure 5002).

4 Examine the pressure plate for flatness. Cold-flatten a pressure plate if

it is warped or dished more than 0.020 inch (0,51 mm) (refer to the
REPAIR section).

5
Examine each rivet hole for damage and wear. Discard the pressure
plate if the diameter of a rivet hole is more than the limit (refer to
Figure 5002).
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(d) Nondestructive Test (NDT) Inspections

NOTE: Refer to ASTM E1417 Type I, Method A, Level 2 for procedures to

do all penetrant inspections.

NOTE: A Nondestructive Test (NDT) manual gives a general description

of eddy current and penetrant inspection procedures. This manual
is available from the Goodrich wheel and brake publications
web site: https://techpubs.goodrich.com

WARNING: BEFORE YOU USE MAGNETIC PARTICLE FLUID (ASTM

E1444) OR PENETRANT FLUID (ASTM E1417 TYPE I,
METHOD A, LEVEL 2), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, THIS FLUID CAN CAUSE INJURY TO
YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD THIS
FLUID. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD THIS FLUID.

1 Do a magnetic particle (ASTM E1444) or penetrant inspection

(ASTM E1417 Type I) at every third wear plate change for cracks.
Discard a pressure plate with a crack that is not permitted.

2 Do a magnetic particle or penetrant inspection for cracks after a

pressure plate is made flat. Discard a pressure plate with a crack that
is not permitted.

NOTE: It is recommended to let the penetrant fluid remain on the part

for 30 minutes minimum before inspection.

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Pressure Plate Inspection

Figure 5002 / GRAPHIC 32-46-41-991-502-A01

Subtask 32-46-41-220-003-A01

(4) Rotor (90) Inspection

(a) If the brake was overheated and caused the thermal relief plugs (in the
wheel assembly) to melt and release tire pressure, a hardness
measurement is necessary (refer to “Special Inspections” in this CHECK
section).

(b) Visual Inspection

1 Visually examine the rotor (90) for cracks (refer to Figure 5003).
Cracks are permitted in the lining material. Cracks in the steel carrier
are not permitted. Discard a defective rotor.

(c) Measurement Inspection

1 Measure the wear surfaces for minimum thickness. Discard a rotor that
is worn to more than the limits (refer to Figure 5003).

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2 Measure each drive slot width. Discard a rotor with a slot width more
than the limits (refer to Figure 5003).

3 Pitting is permitted if the area(s) of pitting is not more than a

maximum diameter of 0.500 inch (12,70 mm) and covers no more
than 20 percent of the lining area on each side.

4 Crumbling of the lining material is permitted on the inner and outer

diameters, and around thermal expansion slots if it is not more than
0.500 inch (12,70 mm) wide (in from the edge).

5 Examine rotors for flatness. If a rotor is warped or dished more than

0.020 inch (0,51 mm), repair the rotor (refer to the REPAIR section).

Rotor Inspection
Figure 5003 / GRAPHIC 32-46-41-991-503-A01

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(d) Nondestructive Test (NDT) Inspections

NOTE: Refer to ASTM E1417 Type I, Method A, Level 2 for procedures to

do all penetrant inspections.

NOTE: A Nondestructive Test (NDT) manual gives a general description

of eddy current and penetrant inspection procedures. This manual
is available from the Goodrich wheel and brake publications
web site: https://techpubs.goodrich.com

WARNING: BEFORE YOU USE MAGNETIC PARTICLE FLUID (ASTM

E1444) OR PENETRANT FLUID (ASTM E1417 TYPE I,
METHOD A, LEVEL 2), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, THIS FLUID CAN CAUSE INJURY TO
YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD THIS
FLUID. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD THIS FLUID.

1 If the rotor is cold-flattened, do a magnetic particle (ASTM E1444) or

penetrant inspection (ASTM E1417 Type I). Discard a rotor with a
crack in the steel carrier.

NOTE: It is recommended to let the penetrant fluid remain on the part

for 30 minutes minimum before inspection.

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Subtask 32-46-41-220-004-A01

(5) Stator (95) Inspection

(a) If the brake was overheated and caused the thermal relief plugs (in the
wheel assembly) to melt and release tire pressure, a hardness
measurement is necessary (refer to “Special Inspections” in this CHECK
section).

(b) Visual Inspection

1 Do a visual inspection for cracks at each wear plate change. Discard a

stator if:

a Cracks that start from the disk outer diameter and go toward the
inner diameter are more than 0.250 inch (6,35 mm) long.

b There is a crack that starts at the stop holes or at the junction of

the disk inner diameter and a drive lug (refer to Figure 5004).

(c) Measurement Inspection

1 Measure the width of each drive lug for wear. Discard a stator with a
drive lug that is worn to more than the limits (refer to Figure 5004).

2 Measure the thickness of the stator. Discard a stator with a thickness

that is less than the limit (refer to Figure 5004).

3 Measure the inner diameter of the stator. Discard a stator with an

inner diameter that is less than the limit (refer to Figure 5004).

4 Examine stators for flatness. If a stator is warped or dished more than

0.020 inch (0,51 mm), repair the stator (refer to the REPAIR section).

(d) Nondestructive Test (NDT) Inspections

NOTE: Refer to ASTM E1417 Type I, Method A, Level 2 for procedures to

do all penetrant inspections.

NOTE: A Nondestructive Test (NDT) manual gives a general description

of eddy current and penetrant inspection procedures. This manual
is available from the Goodrich wheel and brake publications
web site: https://techpubs.goodrich.com

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WARNING: BEFORE YOU USE MAGNETIC PARTICLE FLUID (ASTM

E1444) OR PENETRANT FLUID (ASTM E1417 TYPE I,
METHOD A, LEVEL 2), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, THIS FLUID CAN CAUSE INJURY TO
YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD THIS
FLUID. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD THIS FLUID.

1 Do a magnetic particle (ASTM E1444) or penetrant inspection

(ASTM E1417 Type I) at every wear plate change for cracks. Discard
a stator with a crack that is not permitted.

2 If the stator is cold-flattened, do a magnetic particle (ASTM E1444) or

penetrant inspection (ASTM E1417 Type I). Discard a stator with a
crack that is not permitted.

NOTE: It is recommended to let the penetrant fluid remain on the part

for 30 minutes minimum before inspection.

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Stator Inspection
Figure 5004 / GRAPHIC 32-46-41-991-504-A01

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Subtask 32-46-41-220-005-A01

(6) Torque Plate (115) Inspection

(a) If the brake was overheated and caused the thermal relief plugs (in the
wheel assembly) to melt and release tire pressure, a hardness
measurement is necessary (refer to “Special Inspections” in this CHECK
section).

(b) Visual Inspection

1 Do a visual inspection of the torque plate for cracks at each wear plate
change.

2 Surface cracks, gouges, or grooves that are 0.030 inch (0,76 mm) in
depth or less can be removed by local blending in the areas shown in
Figure 5005 (refer to the REPAIR section). Discard a torque plate with
a crack, scores, gouge, or groove in an area where repair is not
permitted (refer to Figure 5005).

3 Do a visual inspection of the slots in the torque plate outer diameter

for roughness. Slots must be smooth to permit the stators to move
easily. Remove all burrs, radius sharp edges, and polish areas where
the stators touch the slots.

(c) Measurement Inspection

1 Measure the dimension from the torque plate mounting flange to the
backleg at equally-spaced locations (refer to Figure 5005). The
dimension must not be more than the limit (refer to Figure 5005). The
total variation of measured dimensions must not be more than
0.015 inch (0,38 mm).

2 If a backleg of the torque plate is warped or dished more than

0.020 inch (0,51 mm), repair the torque plate (refer to the REPAIR
section).

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Torque Plate Inspection

Figure 5005 / GRAPHIC 32-46-41-991-505-A01

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(d) Nondestructive Test (NDT) Inspections

NOTE: Refer to ASTM E1417 Type I, Method A, Level 2 for procedures to

do all penetrant inspections.

NOTE: A Nondestructive Test (NDT) manual gives a general description

of eddy current and penetrant inspection procedures. This manual
is available from the Goodrich wheel and brake publications
web site: https://techpubs.goodrich.com

WARNING: BEFORE YOU USE MAGNETIC PARTICLE FLUID

(ASTM E1444) OR PENETRANT FLUID (ASTM E1417 TYPE I,
METHOD A, LEVEL 2), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, THIS FLUID CAN CAUSE INJURY TO
YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD THIS
FLUID. SPEAK WITH YOUR EMPLOYER FOR
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD THIS FLUID.

1 Do a magnetic particle (ASTM E1444) or penetrant inspection

(ASTM E1417 Type I) at every third wear plate change for cracks.
Discard a torque plate with a crack that is not permitted.

NOTE: It is recommended to let the penetrant fluid remain on the part

for 30 minutes minimum before inspection.

Subtask 32-46-41-220-006-A01

(7) Piston Housing Assembly (240) Inspection

(a) If the brake was overheated and caused the thermal relief plugs (in the
wheel assembly) to melt and release tire pressure, a hardness
measurement is necessary (refer to “Special Inspections” in this CHECK
section).

(b) Visual Inspection

1 Do a visual inspection of the full piston housing assembly (240) at

each heat sink change for cracks and damage. Refer to the REPAIR
section for limits of repair. Discard a piston housing if the damage is
more than the limits specified.

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2 Do a visual inspection of the piston bore cavities for damage to the

seal surfaces. If damage cannot be repaired, discard the piston
housing.

3 Do a visual inspection of each Lee plug (245) for leakage. Replace a

Lee plug that leaks with a new Lee plug. (refer to the REPAIR
section).

4 Do a visual inspection for thread damage and do a test of the internal

thread-locking element of each Heli-Coil® insert (250, 255). Replace a
damaged Heli-Coil® insert (refer to the REPAIR section).

(c) Measurement Inspection

1 Examine each bushing (260, 265) in the piston housing

assembly (240) for damage and a maximum diameter of 2.134 inches
(54,20 mm) (refer to Figure 5006.) Discard a bushing if not to the limits
(refer to the REPAIR section).

Piston Housing Bushing Inspection

Figure 5006 / GRAPHIC 32-46-41-991-506-A01
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(d) Nondestructive Test (NDT) Inspections

NOTE: Refer to ASTM E1417 Type I, Method A, Level 2 for procedures to

do all penetrant inspections.

NOTE: A Nondestructive Test (NDT) manual gives a general description

of penetrant inspection procedures. This manual is available from
the Goodrich wheel and brake publications web site:
https://techpubs.goodrich.com

WARNING: BEFORE YOU USE PENETRANT FLUID (ASTM E1417 TYPE

I, METHOD A, LEVEL 2), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE PENETRANT FLUID.
THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM
THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET OR SAFETY DATA SHEET OR SAFETY DATA SHEET
(MSDS/SDS), AND GOVERNMENT REGULATIONS. IF
SAFETY INSTRUCTIONS ARE NOT OBEYED, PENETRANT
FLUID CAN CAUSE INJURY TO YOU OR CAUSE HEALTH
PROBLEMS. AN MSDS/SDS GIVES THE INSTRUCTIONS
YOU MUST FOLLOW TO SAFELY USE, KEEP, AND
DISCARD PENETRANT FLUID. SPEAK WITH YOUR
EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD PENETRANT FLUID.

1 Do a penetrant inspection (ASTM E1417 Type I, Method A, Level 2) or

eddy current inspection of all areas on the piston housing assembly at
the every third wear plate change. Reject an assembly with a crack
that starts at a threaded hole or at a hole for the bolts.

NOTE: Remove paint on the piston housing assembly before

penetrant inspection (refer to the CLEANING section). It is not
necessary to remove the Lee plugs (245), Heli-Coil®
inserts (250, 255), or bushings (260, 265).

NOTE: Let the fluid stay on the piston housing assembly for a
minimum of 30 minutes before the inspection is done.

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Subtask 32-46-41-220-007-A01

(8) Adjuster Assembly (125) Parts Inspection

(a) Adjuster Housing (180) Inspection

1 Do a visual inspection of each adjuster housing (180). Discard a

defective adjuster housing.

2 Measure the inner diameter of each adjuster housing. Discard the

adjuster housing if the diameter is not within the limits as shown in
Figure 5007.

Adjuster Housing Inspection

Figure 5007 / GRAPHIC 32-46-41-991-507-A01

(b) Retaining Ring (130, 155) Inspection

1 Do a visual inspection of each retaining ring (130, 155) for cracks,

distortion, and wear. Replace a defective retaining ring.

(c) Adjuster Pin (145) Inspection

1 Visual Inspection

a
Do a visual inspection of each adjuster pin (145) for corrosion,
scratches, thread damage, and straightness. Discard a defective
adjuster pin.
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(d) Washer (140) Inspection

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT

IS SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR
SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR
EMPLOYER. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEN YOU DISCARD THE PARTS THAT
CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR

DUST. THESE PARTICLES, FUMES, OR DUST CAN CAUSE
LUNG OR KIDNEY DISEASE. IF MAINTENANCE
PROCEDURES MAKE CADMIUM PARTICLES, FUMES, OR
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION, AND/OR PROCEDURES TO PREVENT
EXPOSURE TO PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY
DISEASE.

1 Do an inspection of each washer (140) for corrosion and damage. The

washer could have cadmium plating. Discard a defective washer.

(e) Nut (135) Inspection

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT

IS SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR
SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR
EMPLOYER. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEN YOU DISCARD THE PARTS THAT
CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR

DUST. THESE PARTICLES, FUMES, OR DUST CAN CAUSE
LUNG OR KIDNEY DISEASE. IF MAINTENANCE
PROCEDURES MAKE CADMIUM PARTICLES, FUMES, OR
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION, AND/OR PROCEDURES TO PREVENT
EXPOSURE TO PERSONNEL.

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WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY
DISEASE.

1 Visual Inspection

a Do a visual inspection at each heat sink change for corrosion,

cracks, and damage in the threads or on the chamfer where the
threads start. The nuts could have cadmium plating. Discard a
damaged nut.

2 Locking Function Inspection

a Do this inspection when the nuts are installed (refer to the

ASSEMBLY section).

b Turn the nut onto a bolt two or three threads past the end of the
nut. Use a torque wrench to remove the nut and measure the
back-off torque. Replace a nut when the minimum back-off torque
is less than 2.0 pound-inches (0,2 Nm).

(f) Spring (165) Inspection

1 Do a visual inspection of the spring for cracks, corrosion, or damage.

Defective a defective spring.

2 Examine each spring (165) for load limit at each heat sink change
(refer to Figure 5008) as follows:

a Set the indicator to read zero at the spring height dimension

shown (refer to Figure 5008).

b Put the spring below the ram at the center of the ram.

WARNING: DO NOT DO THE TEST WITHOUT A PROTECTIVE

SHIELD AROUND THE SPRING TEST MACHINE. A
SPRING THAT IS NOT IN THE CORRECT POSITION
CAN EJECT FROM THE TEST MACHINE WITH MUCH
FORCE.

c Put a protective shield around the spring test machine.

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d Compress the spring with the ram until the indicator shows zero. A
minimum of 92 pounds (41,7 kg) is necessary to compress a
satisfactory spring to make the indicator show zero. Discard a
defective spring.

Spring Inspection
Figure 5008 / GRAPHIC 32-46-41-991-508-A01

(g) Pin Retainer (175) Inspection

1 Visual Inspection

a Do a visual inspection of the each pin retainer (175) for surface

damage and for wear. Discard a defective pin retainer.

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2 Measurement Inspection

a Put each pin retainer (175) on the fixture (Figure 9003) and
measure the gap between the pin retainer and the fixture. Discard
a pin retainer that is not within the limits shown in Figure 5009.

Pin Retainer Inspection

Figure 5009 / GRAPHIC 32-46-41-991-509-A01

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(h) Sleeve (150, 170) Inspection

1 Visual Inspections

a Examine each sleeve (150) for corrosion, surface damage,

gouges, or burrs. Polish to remove minor burrs. If the
initial (unused) surface is in limits and not damaged
90 degrees from two used areas, the sleeve can be reused (refer
to Figure 5010).

Each sleeve (150) can be turned end-for-end for more reuse.

Do a visual inspection of the sleeve (170) for damage or

corrosion. Discard a defective sleeve.

2 Measurement Inspection of Sleeve (150)

a Measure the initial (unused) area of each sleeve (refer to the

Figure 5010 for limits). Discard a sleeve that is not in limits.

Sleeve (150) Wear Limits

Figure 5010 / GRAPHIC 32-46-41-991-510-A01

(i) Spring Retainer (160) Inspection

1 Visual Inspection

a Do a visual inspection of each spring retainer for corrosion or

damage. Discard a defective spring retainer.

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Subtask 32-46-41-220-008-A01

(9) Shuttle Valve Assembly (25) Inspection

(a) Do a visual inspection of the shuttle valve assembly (65) for corrosion,
cracks, gouges, or other damage to visible parts of the assembly. If
damage is found, discard the shuttle valve assembly.

(b) If it is necessary to disassemble and repair the shuttle valve assembly,

visually examine the shuttle valve body (285), end cap (290), and
poppet (295) for corrosion, cracks, gouges, or other damage. Discard the
shuttle valve assembly if one of these parts is damaged.

(c) Measure the inner diameter of the end cap (290) (refer to Figure 5011).
Discard the shuttle valve assembly if the measurement is more than the
limit.

NOTE: The shuttle valve body (285), end cap (290), and poppet (295) are
not in the shuttle valve overhaul kit, a new shuttle valve assembly
must be ordered.

Inspection of Shuttle Valve End Cap

Figure 5011 / GRAPHIC 32-46-41-991-511-A01

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Subtask 32-46-41-220-009-A01

(10) Inspection of Other Parts

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Bolt (15, 50) Inspection

1 Do a visual inspection of each bolt (15, 50). Examine for cracks,

surface damage, and thread damage. The bolts could have cadmium
plating. Discard damaged bolts.

(b) Washer (20, 45) Inspection

1 Do an inspection of each washer (20, 45) for corrosion and damage.

These washers could have cadmium plating. Discard a defective
washer.

(c) Nut (40) Inspection

1 Visual Inspection

a Do a visual inspection at each heat sink change for corrosion,

cracks, and damage in the threads or on the chamfer where the
threads start. The nut could have cadmium plating. Discard a
damaged nut.

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2 Locking Function Inspection

a Do this inspection when the nuts are installed (refer to the

ASSEMBLY section).

b Turn the nut onto a bolt two or three threads past the end of the
nut. Use a torque wrench to remove the nut and measure the
back-off torque. Replace a nut when the minimum back-off torque
is less than 6.5 pound-inches (0,7 Nm).

(d) Rod and Insert Assembly (55) and Stud Assembly (60) Inspection

1 Do a visual inspection of each rod and insert assembly for damage,

distortion or other damage that will prevent correct operation. The stud
assembly could have cadmium plating. Discard defective parts.

(e) Inspection of the Bleeder Plug (220)

1 Do an inspection of the bleeder plug. Replace a bleeder plug with

thread damage, corrosion, or other damage.

(f) Identification Plate (5) Inspection

1 Do a visual inspection of the identification plate for corrosion, damage

or that you cannot read. Discard a defective identification plate.

(g) Retaining Ring (120) Inspection

1 Do a visual inspection of the retaining ring. Discard a defective

retaining ring.

(h) Insulator (185B) Inspection

1 Do a visual inspection of each insulator (185B) for damage and wear.

Discard a defective insulator.

(i) Piston (195) Inspection

1 Visual Inspection

a Do a visual inspection of the each piston (195) for surface

damage and for wear. Small surface scratches that cannot be felt
with a fingernail, plastic pick, or a ball point pen are permitted. If
you see wear on an outer surface, measure the diameter (refer to
Figure 5012). Discard a damaged piston or a piston with dents
around the O-ring and backup ring areas.

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2 Measurement Inspection

a Measure the diameters as shown in Figure 5012. Discard a piston

that is not within the limits.

Piston Inspection
Figure 5012 / GRAPHIC 32-46-41-991-512-A01

(j) Screw (210) Inspection

1 Do a visual inspection of the screw (210) for thread damage. Discard a

defective screw.

(k) Torque Clip (215) Inspection

1 Do a visual inspection of the torque clip (215) for damage. Discard a

defective torque clip.

(l) Plug Cap (275) Inspection

1 Do a visual inspection of the plug cap (275) for damage. Discard a

defective plug cap.

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Subtask 32-46-41-280-001-A01

(11) Special Inspections

(a) Hardness Inspections for an Overheated Brake Assembly

NOTE: A hardness measurement is necessary if the brake was

overheated and caused the thermal relief plugs (in the wheel
assembly) to melt and release tire pressure.

1 Torque Plate (115)

a Do hardness tests at four or more equally-spaced locations on a

flat surface between the mounting holes as shown in Figure 5005.
If the average of all hardness values is less than 301 BHN
(Rockwell C 32), discard the torque plate.

2 Pressure Plate (80)

a Do hardness tests on three or more equally-spaced drive lugs.

Measure the hardness on the drive lugs. If the hardness value on
a drive lug is less than 336 BHN (Rockwell C 36) (refer to
Figure 5002), discard the pressure plate.

3 Stator (95)

a Do hardness tests on three equally-spaced drive lugs. Measure

the hardness on the drive lugs. If the hardness value on a drive
lug is less than 336 BHN (Rockwell C 36) (refer to
Figure 5004), discard the stator.

4 Piston Housing (270)

a Do hardness tests on the backside between mounting bolt

holes (refer to Figure 5013). If the hardness value is less than
120 BHN or Rb76, measure the conductivity. Remove paint and
the anodized layer at the test areas before you do the hardness
tests.

If the conductivity value is more than 40.5 percent IACS, discard

the piston housing assembly).

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Piston Housing Hardness Inspection

Figure 5013 / GRAPHIC 32-46-41-991-513-A01

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INTENTIONAL BLANK PAGE

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REPAIR
TASK 32-46-41-300-801-A01

1. General Repair Data

A. Reason for the Job
Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-601-A01

Tools, Fixtures, and Equipment - Table 6001 (Sheet 1 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Arbor press --- Installation of
busings into
piston
housing bore
Bright lights 100 foot candles (1076 Lux) Visual
minimum on inspected surface inspections
Bolt and striker tools --- Removal of
Commercially
Lee plugs
available
Drill bit 3/16 inch (5 mm) diameter To drill the
head off the
rivet
Freezer Adjustable to 0°F (-18°C) Bushing
replacement
in piston
housing

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Tools, Fixtures, and Equipment - Table 6001 (Sheet 2 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
P/N 1227-6
P/N 3695-2
P/N 3695-3
P/N 3695-4
P/N 7551-2 Heli-Coil®
Heli-Coil® tools
P/N 7552-3 repairs
P/N 7552-4
P/N 56187-2-2
P/N 56193-2-2
P/N 56193-4-2
Machining equipment --- Repairs
and local blend tools
Magnetic particle ASTM E1444 NDT
inspection equipment inspections
Magnifiers 3X to 10X Commercially Visual
available inspections
Mallet and pin-punch --- To push out
rivets
Measurement tools Accurate to 0.001 inch Measurement
(0,03 mm) inspections
Needle-nose pliers --- Removal of
Heli-Coil®
inserts
Oven Adjustable to 600°F (315°C) To hold a
pressure plate
or torque
plate
Paint equipment --- Paint applied
after repairs
Peen and anvil riveting P/N 114-151-1 (Anvil tool used Make tool Peen and
tools on pressure plate and torque locally (refer to anvil tool to
plate) Figure 9001) rivet the wear
plates to the
P/N 114-151-2 (Peen tool used pressure plate
on pressure plate and torque and the
plate) torque plate

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Tools, Fixtures, and Equipment - Table 6001 (Sheet 3 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Penetrant inspection ASTM E1417 Type I, Method A, NDT
equipment Level 2 Commercially inspections
Pin punch and drill press --- available To push out
rivets

(2) Consumables
NOTE: Equivalent alternatives are permitted for the materials in the table that
follows:

TABLE 32-46-41-99A-602-A01

Consumables - Table 6002 (Sheet 1 of 2)

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)
Abrasive cloth #320, #400 grit
Alkyd Primer TT-P-1757B
Commercially available
Cleaner Degreasing Solvent
MIL-PRF-680 Type II or III
Commercially available
or
Base Coat, 683-3-2
Clear Sealant Akzo Nobel Aerospace
Curing Solution, X-310A
Coatings, Inc.
www.akzonobel.com
Conversion coating QPL-81706 Class 1A
Commercially available
Corrosion removal SAE AMS 1640
Corrosion prevention compound Rust Veto Spray Houghton International, Inc.
Madison and Van Buren
Avenues
Valley Forge, Pennsylvania
19482
U.S.A.

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Consumables - Table 6002 (Sheet 2 of 2)

SUPPLIER
MATERIAL SPECIFICATIONS and
(CAGE)
High temperature paint “VHT” Paint SP-117
(aluminum color)
or per spec (TT-P-28)
Magnetic particle inspection fluid ASTM E1444
Polyurethane paint MIL-PRF-85285
Commercially available
OEM Color:
Medium Gray
Penetrant inspection fluid ASTM E1417 Type I,
Method A, Level 2
Thinner MIL-T-81772 Types I, ll or lll
Thinner-reducible MIL-PRF-23377 Commercially available
Epoxy Polyamide Primer Type I, Class C1, C2, or N or
(Class N is Non-Chromate) Hentzen Coatings, Inc.
Tel: 414-353-4200
www.hentzen.com
Water-reducible MIL-PRF-85285 Commercially available
Epoxy Polyamide Primer Type I, Class C1, C2, or N or
(Class N is Non-Chromate) Deft, Inc.
Tel: 800-544-3338
www.deftfinishes.com

(3) Referenced Information

TABLE 32-46-41-99A-603-A01

Referenced Information - Table 6003

REFERENCE DESCRIPTION

Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of
a material)

C. Job Set-up

Not applicable

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REPAIR

D. Procedure

Subtask 32-46-41-310-001-A01

(1) General Surface Repair Procedures

NOTE: This REPAIR section uses the word “damage” many times. Cracks,
corrosion, dents, and bent areas are typical types of “damage”. Other
types of damage are possible.

NOTE: Replace the parts that you cannot repair to the limits in this REPAIR
section.

CAUTION: DO NOT MAKE A SUDDEN CHANGE IN THE CONTOUR OF

REPAIRED AREAS. DO NOT MAKE A ROUGH SURFACE IN
REPAIRED AREAS. A CRACK CAN START AT A DAMAGED
AREA THAT IS NOT REPAIRED OR IS REPAIRED
INCORRECTLY.

(a) General Description of a Blend Repair

A “blend repair” gradually changes the contour from the repaired surface to
the adjacent initial surfaces. A blend repair removes a minimum quantity of
metal and makes a smooth surface (without tool marks or scratches). Use
#400 grit abrasive cloth to remove scratches that are made by initial blend
tools or large-grit abrasive cloth. Do a blend repair only on small areas.

Subtask 32-46-41-310-002-A01

(2) Pressure Plate Assembly (65) Repair

(a) Wear Plate Removal

1 Remove damaged or fully worn wear plates (75) (refer to

Figure 5001 in the CHECK section).

2 Use a 3/16 inch (5 mm) drill bit to remove the dimpled (non-upset)
rivet (70) head on the wear plate.

3 Use a mallet and pin-punch to push the remaining shank of the

rivet (70) out of the pressure plate.

(b) Examine the pressure plate rivet holes (refer to CHECK section for the
limits).

(c) Mask the threaded holes for the rod and insert assembly (55).

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REPAIR

(d) The pressure plate can be lightly abrasive blasted to remove corrosion
(refer to the CLEANING section). Examine the pressure plate for minimum
thickness after abrasive blasting (refer to Figure 5002 in the CHECK
section).

(e) Cold-flatten a warped or dished pressure plate to 0.020 inch (0,51 mm). Do
a magnetic particle or penetrant inspection for cracks, after cold-flattening
(refer to the CHECK section).

(f) Apply rust prevention material to the pressure plate as follows:

1 Clean the pressure plate (refer to the CLEANING section).

2 Mask all threaded ports.

3 Apply a rust prevention material such as Rust Veto spray or high

temperature paint to the pressure plate. Refer to the instructions from
the manufacturer.

NOTE: If high temperature paint is applied, bake the pressure plate at

500°F (260°C) for two hours.

4 Remove the mask material from all threaded ports.

(g) Wear Plate Installation

1 Install the wear plates (75) on the pressure plate (80).

NOTE: Replace the wear plates in sets. Do not install a mixture of

new and used wear plates.

2 Align rivet holes in the wear plates (75) and pressure plate (80) and
insert new rivets (70) through the wear plates and into the pressure
plate.

3 Upset a rivet head on each rivet on the pressure plate side using
peen and anvil tools (Figure 9001) or an equivalent tool. The upset
rivet head diameter must be 0.349 inch (8,86 mm) or larger if spin
riveting is used. The upset rivet head diameter must be 0.311 inch
(7,90 mm) or larger if compression riveting is used.

(h) Replacement of Heli-Coil® insert (if damaged)

1 Installation of an Initial-Size Heli-Coil® Insert (85)

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

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b Install a new Heli-Coil® insert with a Heli-Coil® installation tool,

P/N 7551-2.

c Install the Heli-Coil® insert (85) 1 to 1 1/2 turns below the top
surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-2.

2 Installation of an Oversize Heli-Coil® Insert (85A)

If the hole has damage that prevents correct installation of an initial

size Heli-Coil® insert (85), install an oversize Heli-Coil® insert (85A)
as follows:

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

b Tap the hole with a Heli-Coil® tap, P/N 56187-2-2, to the full
depth of the hole.

c Install the oversize Heli-Coil® (85A) with a Heli-Coil® tool,

P/N 7551-2. Turn the Heli-Coil® insert until the top coil is 1/4 to
1/2 turn below the top surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-2.

Subtask 32-46-41-310-003-A01

(3) Rotor (90) Repair

(a) Repair a rotor (90) with a drive slot width of 0.900 inch (22,86 mm) or less.
If a rotor has less than 0.010 inch (0,25 mm) of lining on each side,
discard the rotor (refer to Figure 6001).

(b) Cold-flatten a warped or dished rotor to 0.020 inch (0,51 mm). Do a

magnetic particle or penetrant inspection after cold flattening (refer to the
CHECK section).

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REPAIR

Rotor Repair
Figure 6001 / GRAPHIC 32-46-41-991-601-A01

Subtask 32-46-41-310-004-A01

(4) Stator (95) Repair

(a) Cold-flatten a warped or dished stator to 0.020 inch (0,51 mm) or less. Do
a magnetic particle or penetrant inspection after cold flattening (refer to the
CHECK section).

Subtask 32-46-41-310-005-A01

(5) Torque Plate and Wear Plate Assembly (100) Repair

(a) Wear Plate Removal

1 Remove damaged or fully worn wear plates (110) (refer to

Figure 5001 in the CHECK section).

2 Use a 3/16 inch (5 mm) drill bit to remove the dimpled (non-upset)
rivet (145) head on the wear plate.

3 Use a mallet and pin-punch to push the remaining shank of the

rivet (145) out of the torque plate.

(b) Examine the torque plate rivet holes (refer to the CHECK section for the
limits).
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REPAIR

(c) Do a blend repair to remove gouges, surface cracks, and pitting to

0.030 inch (0,76 mm) maximum depth, but not in the areas that are shown
in Figure 5005.

Make the rough areas smooth in the slots to 0.030 inch (0,76 mm)
maximum depth. Remove burrs, radius sharp edges, and polish rubbing
surfaces with #320 grit (or finer) abrasive cloth

(d) The torque plate can be lightly abrasive blasted to remove corrosion (refer
to the CLEANING section). Examine the torque plate for minimum
thickness after abrasive blasting (refer to Figure 5005 in the CHECK
section).

(e) Cold-flatten a warped torque plate to 0.020 inch (0,51 mm). Do a magnetic
particle or penetrant inspection for cracks, after cold-flattening (refer to the
CHECK section).

(f) Apply rust prevention material to the torque plate as follows:

1 Clean the torque plate (refer to the CLEANING section).

2 Mask all threaded ports.

3 Apply a rust prevention material such as Rust Veto spray or high

temperature paint to the torque plate. Refer to the instructions from
the manufacturer.

NOTE: If high temperature paint is applied, bake the torque plate at

500°F (260°C) for two hours.

4 Remove the mask material from all threaded ports.

(g) Wear Plate Installation

1 Install the wear plates (110) on the torque plate (115).

NOTE: Replace the wear plates in sets. Do not install a mixture of

new and used wear plates.

2 Align rivet holes in the wear plates (110) and torque plate (115) and
insert new rivets (105) through the wear plates and into the torque
plate.

3 Upset a rivet head on each rivet back leg side of the torque plate
using peen and anvil tools (Figure 9001) or an equivalent tool. The
upset rivet head diameter must be 0.349 inch (8,86 mm) or larger if
spin riveting is used. The upset rivet head diameter must be
0.311 inch (7,90 mm) or larger if compression riveting is used.

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REPAIR

Subtask 32-46-41-310-006-A01

(6) Piston Housing Assembly (240) Repair

CAUTION: DO NOT REMOVE METAL FROM THE PISTON BORE IN THE

PISTON HOUSING.

(a) Do a blend repair on gouges or surface cracks (refer to Figure 6002 for
repair limits). Remove nicks, scratches, and corrosion from the piston
housing (270) with #400 grit abrasive cloth (refer to the repair limits in
Figure 6002).

(b) Apply conversion coating, primer, and paint to the repaired areas. Refer to
“Conversion Coating Application” and “Apply Paint” in this REPAIR section.

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REPAIR

Piston Housing Repair Limits

Figure 6002 / GRAPHIC 32-46-41-991-602-A01
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(c) Installation of a New Lee Plug (245) in the Piston Housing

1 Removal of a defective Lee plug (245)

Use a procedure that does not cause damage to the hole. A special
bolt and striker is recommended, as shown in Figure 6003.

a Drill and tap a hole in the pin. Install the special bolt and hit the
bolt head with the striker as shown to remove the pin.

a Drill and tap the plug. Use the special bolt and striker to remove
the plug.

PIN REMOVAL PIN STRIKER

PIN REMOVAL TOOL

PISTON HOUSING
ASSEMBLY

PLUG REMOVAL STRIKER

PLUG

PISTON HOUSING PLUG REMOVAL TOOL

ASSEMBLY 2-1502-02

Removal of a Lee Plug

Figure 6003 / GRAPHIC 32-46-41-991-603-A01

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REPAIR

2 Installation of the Lee Plug (245)

Measure the diameter of the hole for the Lee plug (245) in the piston
housing. If the hole diameter is 0.2187 to 0.2212 inch (5,555 to
5,618 mm), and the hole has a good finish (63 Ra or better), install a
Lee plug as follows:

CAUTION: DO NOT REMOVE THE LAYER OF WAX ON THE LEE

PLUG OR APPLY A LUBRICANT TO THE PLUG. A LEE
PLUG CAN LEAK IF THE REAMED HOLE AND THE
REPLACEMENT PLUG ARE NOT CLEAN AND DRY.

a Push the plug into the hole until the plug firmly touches the bottom
of the hole.

CAUTION: MAKE SURE TO START THE PIN IN THE HOLE

STRAIGHT. THIS IS NECESSARY TO CORRECTLY
INSTALL THE PIN.

b Push the small end of the pin straight into the plug.

c Firmly hold the piston housing. Hit the end of the pin 2 or 3 times
with a hammer and flat punch to make the end of the pin flush
with the end of the plug, ±0.005 inch (±0,13 mm). Make sure that
the outer diameter of the punch is smaller than the outer diameter
of the pin. To decrease damage to the pin, do not hit the pin
many times.

d Do a high-pressure leak test on the fully-assembled brake

assembly (refer to the TESTING AND FAULT ISOLATION
section).

(d) Replacement of a Torque Clip Heli-Coil® Insert (250) in the Piston Housing

1 Installation of an Initial-Size Heli-Coil® Insert (250)

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

b Install a new Heli-Coil® insert with a Heli-Coil® installation tool,

P/N 7552-3.

c Install the Heli-Coil® insert (250) 3/4 to 1 1/2 turns below the top
surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-3.

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2 Installation of an Oversize Heli-Coil® Insert (250A)

If the hole has damage that prevents correct installation of an initial

size Heli-Coil® insert (250), install an oversize Heli-Coil® insert (250A)
as follows:

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

b Tap the hole with a Heli-Coil® tap, P/N 56193-2-2, to the full
depth of the hole.

c Install the oversize Heli-Coil® (250A) with a Heli-Coil® tool,

P/N 7552-3. Turn the Heli-Coil® insert until the top coil is 1/4 to
1/2 turn below the top surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-3.

(e) Replacement of a Shuttle Valve Heli-Coil® Insert (255) in the Piston

Housing

1 Installation of an Initial-Size Heli-Coil® Insert (255)

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

b Install a new Heli-Coil® insert with a Heli-Coil® installation tool,

P/N 7552-4.

c Install the Heli-Coil® insert (250) 3/4 to 1 1/2 turns below the top
surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-4.

2 Installation of an Oversize Heli-Coil® Insert (255A)

If the hole has damage that prevents correct installation of an initial

size Heli-Coil® insert (255), install an oversize Heli-Coil® insert (255A)
as follows:

a Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-6,

to remove a damaged Heli-Coil® insert.

b Tap the hole with a Heli-Coil® tap, P/N 56193-4-2, to the full
depth of the hole.

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c Install the oversize Heli-Coil® (255A) with a Heli-Coil® tool,

P/N 7552-4. Turn the Heli-Coil® insert until the top coil is 1/4 to
1/2 turn below the top surface.

d Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-4.

(f) Replacement of Bushings (260, 265) in the Piston Housing

1 Remove a damaged or worn bushing with a soft metal drift. Do not

remove metal from the piston housing.

2 Clean the new bushing (260, 265) (refer to the CEANING section).

3 Put the bushing in a freezer at 0°F (-18°C) for 30 minutes.

WARNING: BEFORE YOU USE ALKYD PRIMER, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THIS ALKYD
PRIMER. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS
FROM THE MANUFACTURER, THE MATERIAL SAFETY
DATA SHEET OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, ALKYD PRIMER CAN CAUSE INJURY
TO YOU OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS
GIVES THE INSTRUCTIONS YOU MUST FOLLOW TO
SAFELY USE, KEEP, AND DISCARD ALKYD PRIMER.
SPEAK WITH YOUR EMPLOYER FOR INSTRUCTIONS YOU
MUST FOLLOW TO SAFELY USE, KEEP, AND DISCARD
ALKYD PRIMER.

4 Apply a thin layer of alkyd primer to the piston housing bushing bore.

5 Remove bushing (260, 265) from the freezer.

6 Use an arbor press to install the bushings correctly into the piston
housing bore.

7 If the bushing does not go straight into the bore, immediately remove
the bushing and do the installation procedure again.

NOTE: A light tap with a small mallet is permitted to seat the

bushings.

8 Try to put a 0.002 inch (0,05 mm) feeler gauge between the bushing
flange and piston housing. If you can insert the feeler gauge between
the bushing flange and piston housing the bushing is not seated.
Immediately remove the bushing and do the installation procedure
again.
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REPAIR

9 Let the frost on the bushing melt and use a clean, dry cloth to wipe all
water off of the bushing and the piston bore.

10 Remove the alkyd primer over-spray with a thinner.

(g) Seal Groove Repair

1 Machine the O-ring Groove and the outer edge of the piston (refer to
Figure 6002, Area “G” for the repair limits).

2 Apply conversion coating, primer, and paint to the repaired areas.

Refer to “Conversion Coating Application” and “Apply Paint” in this
REPAIR section.

Subtask 32-46-41-310-007-A01

(7) Conversion Coating Application

(a) Clean repaired areas and areas where the anodize layer is damaged (refer
to the CLEANING section).

WARNING: BEFORE YOU USE CONVERSION COATING

(QPL-81706 Class 1A), READ, KNOW, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CONVERSION
COATING. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE
MATERIAL SAFETY DATA SHEET OR SAFETY DATA
SHEET (MSDS/SDS), AND GOVERNMENT REGULATIONS.
IF SAFETY INSTRUCTIONS ARE NOT OBEYED,
CONVERSION COATING CAN CAUSE INJURY TO YOU OR
CAUSE HEALTH PROBLEMS. AN MSDS/SDS GIVES THE
INSTRUCTIONS YOU MUST FOLLOW TO SAFELY USE,
KEEP, AND DISCARD CONVERSION COATING. SPEAK
WITH YOUR EMPLOYER FOR INSTRUCTIONS YOU MUST
FOLLOW TO SAFELY USE, KEEP, AND DISCARD
CONVERSION COATING.

(b) Apply conversion coating on repaired areas and areas where the anodize
layer is damaged. Obey the instructions from the manufacturer to apply the
conversion coating.

(c) Air dry the part. Do not touch conversion coated surfaces until the surfaces
are dry.

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Subtask 32-46-41-310-008-A01

(8) Apply Paint

NOTE: Refer to the CLEANING section for paint removal instructions.

WARNING: DO NOT DISCARD WASTE FROM WATER-BORNE PAINT IN

THE SAME WASTE CONTAINER AS WASTE FROM
SOLVENTBORNE PAINTS THAT CONTAIN ALUMINUM
POWDER (SUCH AS METALLIC PAINT). DISCARD THESE
DIFFERENT TYPES OF WASTE MATERIALS IN SEPARATE,
FIRE-PROOF CONTAINERS. WHEN WATER TOUCHES
ALUMINUM POWDER (WHICH MAKES HYDROGEN GAS), A
FIRE OR EXPLOSION IS POSSIBLE.

WARNING: BEFORE YOU USE PAINT MATERIALS, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE PAINT
MATERIALS. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS
FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET OR SAFETY DATA SHEET (MSDS/SDS), AND
GOVERNMENT REGULATIONS. IF SAFETY INSTRUCTIONS
ARE NOT OBEYED, PAINT MATERIALS CAN CAUSE INJURY
TO YOU OR CAUSE HEALTH PROBLEMS. AN MSDS/SDS
GIVES THE INSTRUCTIONS YOU MUST FOLLOW TO SAFELY
USE, KEEP, AND DISCARD PAINT MATERIALS. SPEAK WITH
YOUR EMPLOYER FOR INSTRUCTIONS YOU MUST FOLLOW
TO SAFELY USE, KEEP, AND DISCARD PAINT MATERIALS.

(a) Paint touch-up

1 Use #320 abrasive cloth to decrease the paint thickness to bare metal
around areas to be touched up, then use #400 abrasive cloth to make
the surface very smooth.

2 Apply conversion coating to all bare aluminum and let it fully dry.

3 Clean surfaces and apply primer and paint (refer to the following
paragraph).

(b) Paint piston housing

1 Use thinner to clean the piston housing.

2 Apply mask material for primer as shown in Figure 6004.

3
Apply one layer of epoxy polyamide primer. Refer to the instructions
from the manufacturer.
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4 Apply mask material for paint as shown in Figure 6004.

5 Apply two layers of paint. Refer to the instructions from the

manufacturer.

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Mask Piston Housing for Paint

Figure 6004 / GRAPHIC 32-46-41-991-604-A01

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REPAIR

Subtask 32-46-41-310-009-A01

(9) Shuttle Valve Assembly (25) Repair

(a) Repairs on the shuttle valve assembly are not permitted.

Subtask 32-46-41-310-010-A01

(10) Installation of a New Identification Plate

(a) If you removed a plate, install a new identification plate (5) as follows (refer
to Figure 6005):

WARNING: BEFORE YOU USE MIL-PRF-680 TYPE II OR III SOLVENT,

READ, KNOW, AND OBEY ALL SAFETY INSTRUCTIONS FOR
THE SOLVENT. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET OR SAFETY DATA SHEET (MSDS/SDS),
AND GOVERNMENT REGULATIONS. IF SAFETY
INSTRUCTIONS ARE NOT OBEYED, THE SOLVENT CAN
CAUSE INJURY TO YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST FOLLOW
TO SAFELY USE, KEEP, AND DISCARD THE SOLVENT.
SPEAK WITH YOUR EMPLOYER FOR INSTRUCTIONS YOU
MUST FOLLOW TO SAFELY USE, KEEP, AND DISCARD THE
SOLVENT.

(b) Use solvent to clean the area of the piston housing (270) where the
identification plate (5) will be installed.

CAUTION: DO NOT TOUCH THE ADHESIVE WITH YOUR FINGERS.

CONTAMINATION OF THE ADHESIVE ON THE IDENTIFICATION
PLATE CAN CAUSE IT TO COME OFF.

(c) Peel the paper off the rear side of the identification plate while you hold the
plate on a flat surface. Do not bend the identification plate and hold it only
at its edges.

(d) Install the identification plate. Push first at the center of the identification
plate and then push to the edges. Use a hand roller on the full surface of
the identification plate.

NOTE: Replace an identification plate that is wrinkled or creased when

you install a new plate.

(e) Use a clean cloth that is moist with solvent to clean the identification plate
and adjacent areas.
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REPAIR

(f) Mix a small amount of clear sealant as instructed by the manufacturer.

(g) Apply the mixed sealant to the top and edges of the plate. Let the sealant
cure for 4 hours.

IDENTIFICATION
PLATE (5)

PISTON HOUSING
ASSEMBLY (240)

2-1502-024

Install Identification Plate

Figure 6005 / GRAPHIC 32-46-41-991-605-A01

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REPAIR

INTENTIONAL BLANK PAGE

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ASSEMBLY
TASK 32-46-41-400-801-A01

1. Assembly

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND

CONSUMABLES section for full data on special tools.

NOTE: Equivalent alternatives are permitted for the equipment in the table that
follows:

TABLE 32-46-41-99A-701-A01

Tools, Fixtures, and Equipment - Table 7001

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Arbor press or drill press --- To assemble adjuster
assembly parts
Goggles --- Eye protection
Press table --- To assemble adjuster
assembly parts
Protective shields Sufficient size to To prevent injury to
prevent injury to Commercially personnel
personnel available
Test stand for brakes Sufficient size and High pressure test
pressure to conduct
brake tests
Torque wrench Pound-inches or Assembly of brake
Nm (4 percent
maximum permitted
error)

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Part Number 2-1502

ASSEMBLY

(2) Consumables

NOTE: Equivalent alternatives are permitted for the materials in the table that
follows, but not for anti-seize compound.

TABLE 32-46-41-99A-702-A01

Consumables - Table 7002

MATERIAL SPECIFICATIONS SUPPLIER
and
(CAGE)
Anti-seize compound SAE-AMS-2518 Commercially available
(MIL-T-5544 is optional) or
Armite Laboratories
Tel: 949-646-9035
Fax: 949-646-8319
www.armitelabs.com
Clean and soft lint-free cloth ---
Hydraulic fluid MIL-PRF-83282 or
MIL-PRF-87257
Commercially available
Lockwire MS20995C32 (Bergen
Safety Cable™ system is
optional)
Lubricant UniFlor™, P/N NYE8512S TAI Lubricants
P.O. Box 1579
Hockessin, Delaware
19707
U.S.A.
Tel: 302-326-0200
Fax: 302-326-0400
Web: www.lubekits.com
Petrolatum VV-P-236
Commercially available
Thread-lock Compound Loctite® 262

(3) Referenced Information

TABLE 32-46-41-99A-703-A01

Referenced Information - Table 7003

REFERENCE DESCRIPTION
Material Safety Data Sheet or Safety Data Sheet Safety data for each consumable
(MSDS/SDS) (available from the manufacturer of a
material)

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ASSEMBLY

C. Job Set-up
Not applicable
D. Procedure

NOTE: Replace O-rings (30, 200, 225, 300, 315) and backup rings (35, 205) at each
heat sink change.

Subtask 32-46-41-640-001-A01

(1) Lubricant Application

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, KNOW, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS/SDS), AND GOVERNMENT REGULATIONS. IF SAFETY
INSTRUCTIONS ARE NOT OBEYED, HYDRAULIC FLUID CAN
CAUSE INJURY TO YOU OR CAUSE HEALTH PROBLEMS. AN
MSDS/SDS GIVES THE INSTRUCTIONS YOU MUST FOLLOW
TO SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.
SPEAK WITH YOUR EMPLOYER FOR INSTRUCTIONS YOU
MUST FOLLOW TO SAFELY USE, KEEP, AND DISCARD
HYDRAULIC FLUID.

(a) Apply lubricant to O-rings and other parts at the specified times. The
permitted lubricant is a thin layer of lubricant (VV-P-236) or UniFlor™ or
hydraulic fluid (MIL-PRF-83282 or MIL-PRF-87257).

Subtask 32-46-41-420-001-A01

(2) Assemble Adjuster Assembly

NOTE: Refer to the FITS AND CLEARANCES section for torques and specified
anti-seize compounds.

NOTE: Assembly of all six adjuster assemblies is the same; therefore, only one
procedure is given.

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

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ASSEMBLY

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

WARNING: INSTALL PARTS WITH CORRECT TOOLS AND PROCEDURES.

INCORRECT TOOLS AND PROCEDURES CAN CAUSE AN
ADJUSTER SPRING AND OTHER PARTS TO EJECT AT HIGH
SPEED.

(a) Install a spring retainer (160) on sleeve (170). The spring retainer could
have cadmium plating.

(b) Install the spring (165) on the sleeve (170) against the spring
retainer (160).

(c) Install a second spring retainer (160) on top of the spring (165).

(d) Put the assembled parts (160, 165, 170) on a press table with the flange
end of the sleeve (170) on the table (refer to Figure 7001, View A).

(e) Install the adjuster tool (Figure 9002) in the chuck of the press. Lower the
adjuster tool until it touches the spring retainer (160).

CAUTION: DO NOT COMPRESS THE SPRING TO LESS THAN THE

MINIMUM HEIGHT. DAMAGE TO THE SPRING CAN OCCUR.

(f) Compress the spring retainer (160) until the retaining ring groove in
sleeve (170) can be fully seen.

(g) Lock the press.

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ASSEMBLY

WARNING: MAKE SURE THE RETAINING RING IS FULLY AGAINST THE

BOTTOM TO THE GROOVE. IF THE RING IS NOT FULLY IN
THE GROOVE, THE PARTS CAN QUICKLY COME APART.
INJURY TO PERSONNEL CAN OCCUR.

(h) Install the retaining ring (155).

(i) Make sure that the retaining ring is fully installed into the groove, then
unlock the press and slowly release the spring tension on the spring
retainer (160).

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ASSEMBLY

Assemble Adjuster Housing

Figure 7001 / GRAPHIC 32-46-41-991-701-A01
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ASSEMBLY

(j) Assemble the adjuster pin (145) in the sleeve (150) and attach with the
washer (140) and nut (135). The nut and washer could have cadmium
plating.

NOTE: If reused, the damaged/used area of the sleeve (150) must be

installed 90 degrees from the contact surface (refer to
Figure 7002). Refer to the CHECK section for the reuse limits.

PIN RETAINER
USED AREA (175)
(INSTALLED AT 90°
IN A REUSED SLEEVE) CONTACT
SURFACE

SLEEVE (150) CONTACT

SURFACE

2-1502-026

Assembly of a Reused Sleeve (150) Through a Pin Retainer (175)

Figure 7002 / GRAPHIC 32-46-41-991-702-A01

(k) Torque the nut (refer to the FITS AND CLEARANCES section for the
torque value). A screwdriver slot is provided in the head of adjuster
pin (145) to hold the pin so the nut can be torqued.

(l) Turn the assembled part over and put under the adjuster tool (refer to
Figure 7001, View B).

(m) Lower the adjuster tool until it touches the spring retainer (160). Compress
the spring retainer until the pin retainer (175) can be installed.

(n) Lock the press.

(o) Install the pin retainer (175).

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ASSEMBLY

(p) Install the assembled adjuster pin (145) and sleeve (150) through the pin
retainer (175) and into sleeve (150). Push the sleeve down until the
sleeve (150) comes out of the pin retainer a minimum of 0.050 inch
(1,27 mm) (refer to Figure 7001, View B).

NOTE: The chamfered end of sleeve (150) must be above the pin
retainer (175) 0.050 inch (1,27 mm) to make sure a brake with a
new heat sink has the correct clearance and provides the
necessary adjuster pin height to lock the adjuster pins to the
pressure plate assembly (65).

(q) Unlock the press and slowly decrease the force on spring retainer (160).
Remove the subassembly from the press table.

(r) Install the subassembly part [with the screw driver slotted-end of adjuster
pin (145) first] in the adjuster housing (180).

NOTE: Make sure the spring retainer (160) is seated at the bottom of the
largest inner diameter of adjuster housing.

(s) Install the retaining ring (130) in the groove in the inner surface of the
adjuster housing.

(t) Assemble each of the remaining adjuster assemblies (125) as defined in

steps (a) thru (s).

(u) Install each of the remaining adjuster assemblies in the piston housing
assembly (240) and install retaining rings (120) to hold the adjuster
assemblies in position.

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ASSEMBLY

Subtask 32-46-41-420-002-A01

(3) Assemble Shuttle Valve Assembly

NOTE: The shuttle valve body (285), end cap (290) and poppet (295) are not
available in the parts kit (280). The parts kit (280) is used to overhaul the
shuttle valve assembly (25) only if the in-service parts are rejected during
the inspection procedures (refer to the CHECK section).

WARNING: WEAR EYE PROTECTION. OBEY THE ASSEMBLY

INSTRUCTIONS. THE SHUTTLE VALVE CONTAINS
SPRING-LOADED PARTS THAT CAN CAUSE SERIOUS EYE
INJURY TO PERSONNEL.

CAUTION: ASSEMBLE THE SHUTTLE VALVE ASSEMBLY IN A LOCATION

THAT PREVENTS THE LOSS OF SMALL PARTS.

(a) Install a new, lubricated large diameter O-ring (300) on the outer diameter
of the end cap (290) (refer to Figure 7003).

(b) Install the new, lubricated small diameter O-rings (315) on each end of the
poppet (295).

(c) Install the spring (310) and balls (305) into the poppet (295) (refer to
Figure 7003).

(d) Put the poppet and assembled parts into the end cap (290) until the
balls (305) engage the shoulder, and the spring holds the poppet in
position.

(e) Carefully install the end cap (290) with assembled parts into the shuttle
valve body (285).

(f) Torque the end cap (refer to the FITS AND CLEARANCES section for the
torque value).

(g) Install lockwire to the end cap and shuttle valve body.

NOTE: It is not necessary to install a lead seal.

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ASSEMBLY

O-RING
(300) O-RING
(315)

END CAP
(290)

SHUTTLE
VALVE BODY
(285) POPPET
(295) SPRING
2X BALL (310)
(305) 2-1502-027

Shuttle Valve Assembly

Figure 7003 / GRAPHIC 32-46-41-991-702-A01

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ASSEMBLY

Subtask 32-46-41-420-003-A01

(4) Assemble Piston Housing Assembly

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Examine the piston housing (270) to make sure that all the Lee
plugs (245), Heli-Coil® inserts (250, 255), and bushings (260, 265) are
installed. Install the parts as necessary (refer to the REPAIR section).

(b) Install a new, lubricated O-ring (225) in the bleeder plugs (220).

(c) Install the bleeder plugs in the piston housing (270).

(d) Torque each bleeder plug (refer to the FITS AND CLEARANCES section
for the torque value).

(e) Install lockwire to the bleeder plugs and piston housing assembly (240).

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ASSEMBLY

Installation of Bleeder Plugs

Figure 7004 / GRAPHIC 32-46-41-991-703-A01
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ASSEMBLY

(f) Install torque clips (215) with screws (210).

(g) Torque each screw (refer to the FITS AND CLEARANCES section for the
torque value).

(h) Install a new, lubricated backup ring (35) and a new O-ring (30) on the
shuttle valve assembly (25) (refer to Figure 7003).

(i) Apply the anti-seize compound to the threads and bearing surfaces of
shuttle valve bolts (15) and washers (20) as shown in Figure 7005. Refer
to Figure 7006 that shows a bolt and washer with a sufficient layer of
anti-seize compound. These bolts and washers could have cadmium
plating.

NOTE: Anti-seize compound, SAE AMS 2518 or MIL-T-5544, can

separate during storage. A new container should be fully mixed
when first opened and covered when not in use to prevent
contamination. Mix every 60 days to prevent separation.

Location on Bolts and Washers to Apply Anti-seize Compound

Figure 7005 / GRAPHIC 32-46-41-991-704-A01

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Part Number 2-1502

ASSEMBLY

2-1502-030

Sufficient Layer of Anti-seize Compound (Example Bolt and Washer Only)

Figure 7006 / GRAPHIC 32-46-41-991-705-A01

(j) Attach the shuttle valve assembly (25) to the piston housing
assembly (240) with bolts (15) and washers (20) (refer to Figure 7004).

(k) Torque each bolt (refer to the FITS AND CLEARANCES section for the
torque value).

(l) Install a new, lubricated backup ring (205) and a new, lubricated
O-ring (200) on the inner diameter of each piston housing (270) piston
cavity (refer to Figure 7007).

(m) Install a piston (195) in each piston cavity.

(n) Install an insulator (185B) on each of the pistons.

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Part Number 2-1502

ASSEMBLY

PISTON HOUSING
ASSEMBLY (240)
BACKUP RING (205)

INSULATOR (185B)
PISTON (195)
O-RING (200) 2-1502-031

Installation of O-rings, Backup Rings, Insulator, and Piston in the Piston Housing Assembly
Figure 7007 / GRAPHIC 32-46-41-991-706-A01

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ASSEMBLY

Subtask 32-46-41-420-004-A01

(5) Installation of the Pressure Plate Assembly on the Piston Housing

(a) Put the piston housing assembly (240) and assembled parts on a flat
surface with the pistons (195) face up.

(b) Make sure the sleeves (150) extend a minimum of 0.050 inch (1,27 mm)
minimum from the adjuster assemblies (125) (refer to “Assemble Adjuster
Housing” in this section).

(c) Put the pressure plate assembly (65) with the word “TOP” (impression
stamped on the pressure plate) at an angle of
180 degrees from the shuttle valve assembly (25).

(d) Align the adjuster pins (145) with keyhole slots of the pressure plate
assembly (65).

(e) Turn the pressure plate assembly (65) counterclockwise to lock the
adjuster pins (145) in the keyhole slots of the pressure plate assembly.

(f) Make sure the parts are fully attached before lifting the assembly.

Subtask 32-46-41-420-005-A01

(6) Installation of the Stud Assembly (60) (Wear Indicator Pin)

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

UTC AEROSPACE SYSTEMS PROPRIETARY

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Part Number 2-1502

ASSEMBLY

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Clean the stud assembly (60) to remove oil, grease, and other
contaminants. The stud assemblies could have cadmium plating.

(b) Apply 2 or 3 drops of Loctite® sealant to the threads on the end of the
stud (refer to Figure 7008).

(c) Install the nut on the stud as shown in Figure 7008.

(d) Put the stud assembly (60) through the piston housing
assembly (240) and into the pressure plate assembly (65).

(e) Torque the stud assembly nut (refer to the FITS AND CLEARANCES
section for the torque value).

(f) Install the rod and insert assembly (85) on each stud assembly (90) four to
five turns.

Stud Assembly and Rod and Insert Assembly

Figure 7008 / GRAPHIC 32-46-41-991-707-A01

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ASSEMBLY

Subtask 32-46-41-420-006-A01

(7) Installation of the Heat Sink on the Torque Plate and Wear Plate Assembly

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE
SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH

ADMINISTRATION (OSHA) HAS AN APPLICABLE DANGER
WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS FOLLOWS:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.

(a) Put the torque plate assembly (100) on a flat surface with the mounting
bolt holes in the up position.

(b) Install three rotors (90) with two stators (95) between the three rotors on
the torque plate assembly (100) (refer to IPL Figure 1).

(c) Put the piston housing assembly (with the pressure plate assembly
attached) onto the torque plate and wear plate assembly (with the rotors
and stators assemblies). Make sure the word “TOP” (hammer stamped on
the pressure plate) and the word “TOP” (hammer stamped on the mating
face of the torque plate) are in line.

(d) Apply the anti-seize compound to the threads of the bolts (50),
washers (45), and nuts (40) as shown in Figure 7009. Refer to Figure 7010
that shows a bolt and nut with a sufficient layer of anti-seize compound.
These bolts, washers, and nuts could have cadmium plating.

NOTE: Anti-seize compound, SAE AMS 2518 or MIL-T-5544, can

separate during storage. A new container should be fully mixed
when first opened and covered when not in use to prevent
contamination. Mix every 60 days to prevent separation.
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ASSEMBLY

Location on Bolts, Washers, and Nuts to Apply Anti-seize Compound

Figure 7009 / GRAPHIC 32-46-41-991-708-A01

2-1502-034

Sufficient Layer of Anti-seize Compound (Example Bolt, Nut, and Washer Only)
Figure 7010 / GRAPHIC 32-46-41-991-709-A01

CAUTION: INSTALL THE WASHERS WITH THE COUNTERSUNK SIDE

AGAINST THE BOLT HEAD. A WASHER THAT IS NOT
CORRECTLY INSTALLED CAN CAUSE A BOLT TO BREAK.

(e) Install a washer (45) on each bolt (50) with the countersunk side toward
the head of the bolt.

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ASSEMBLY

(f) Install the bolts (50) with washers (45) through the piston housing
assembly (240) and through the torque plate and wear plate
assembly (100).

(g) Install a nut (40) on each bolt (50).

(h) Torque all of the nuts (40) in crisscross sequence to the preliminary torque
(refer to Figure 7011). Refer to the FITS AND CLEARANCES section for
the torque value.

(i) Apply a final torque to the nuts in a clockwise sequence (refer to

Figure 7011). Make one continuous turn of each nuts to the final position.
Tighten the first and second bolts again to the final torque. Refer to the
FITS AND CLEARANCES section for the torque value.

Sequences to Torque the Nuts (40)

Figure 7011 / GRAPHIC 32-46-41-991-710-A01

(j) Do a functional test of the brake assembly (refer to TESTING AND FAULT
ISOLATION section).

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Part Number 2-1502

ASSEMBLY

Subtask 32-46-41-420-007-A01

(8) Adjustment of the Rod and Insert Assemblies with New Heat Sink Components

WARNING: DO NOT APPLY MORE PRESSURE TO THE HYDRAULIC

SYSTEM THAN THE SPECIFIED MAXIMUM PRESSURE. MORE
PRESSURE THAN THE MAXIMUM PRESSURE CAN CAUSE
DAMAGE TO THE BRAKE ASSEMBLY AND CAN CAUSE IT TO
EJECT PARTS OR HYDRAULIC FLUID.

WARNING: DO NOT PRESSURIZE THE BRAKE ASSEMBLY WITHOUT

PROTECTIVE SHIELDS AROUND THE BRAKE ASSEMBLY.
SHIELDS CAN PREVENT INJURY TO PERSONNEL.

(a) Connect the brake assembly to a hydraulic pressure source.

(b) Put protective shields around the brake assembly.

(c) Increase the pressure in the brake assembly to 2000 to 2050 psi
(137,9 to 141,3 bar) and keep this pressure.

(d) Remove the protective shields.

(e) Adjust or turn each rod and insert assembly (55) to obtain the correct rod
length as shown in the Table 7004 below. Measure from the top of the rod
to the piston housing assembly (refer to Figure 3001).

TABLE 32-46-41-99A-704-A01

Length Adjustment of Rod and Insert Assembly - Table 7004

BRAKE ASSEMBLY PART NUMBER WEAR PIN SETTING
2-1502 0.350 inch (8,89 mm)
2-1502-1 0.160 inch (4,06 mm)
2-1502-2 0.315 inch (8,00 mm)
2-1502-3 0.260 inch (6,60 mm)

(f) Decrease the pressure to 0 psi (0 bar).

(g) Disconnect the brake assembly from the hydraulic pressure source.

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ASSEMBLY

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FITS AND CLEARANCES

TASK 32-46-41-940-801-A01

1. Fits and Clearances

CAUTION: REFER TO THE ASSEMBLY SECTION FOR PROCEDURES TO

CORRECTLY APPLY ANTI-SEIZE COMPOUND AND TO TORQUE PARTS.
IF YOU USE INCORRECT PROCEDURES, THE PARTS CAN BREAK.

CAUTION: USE TOOLS THAT APPLY TORQUE AND ARE ACCURATE TO LIMITS AS
FOLLOWS: TORQUE WRENCH (±4 PERCENT OF TORQUE),
AUTOMATIC WRENCHING MACHINE (±2 PERCENT OF TORQUE).

TABLE 32-46-41-99A-801-A01

Torque Values - Table 8001

ITEM
TORQUE SPECIFIED
NUMBER NOMENCLATURE
VALUE COMPOUND
FROM IPL
15 Bolt (Shuttle valve) 75 pound-inches Anti-seize compound
(8,5 Nm) (SAE AMS 2518)
(MIL-T-5544 optional)
110 pound-inches
(12,4 Nm) Anti-seize compound
40 Nut (Preliminary) (SAE AMS 2518)
220 pound-inches (MIL-T-5544 optional)
(24,8 Nm)
(Final)
60 Nut (Stud Assembly) 38 pound-inches Loctite® sealant
(4,3 Nm) (No. 262)
135 Nut (Adjuster Pin) 25 pound-inches None
(2,8 Nm)
210 Screw (Torque Clip) 35 pound-inches None
(4,0 Nm)
220 Bleeder Plug 100 pound-inches None
(11,3 Nm)
290 End cap (Shuttle Valve) 70 pound-inches None
(8,0 Nm)

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FITS AND CLEARANCES

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SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

TASK 32-46-41-940-802-A01

1. Special Tools

The usual maintenance tools and equipment are not shown below. Many of the special
tools that are shown below, or equivalent replacements, are necessary.

Use the drawings in this section to locally make special tools. These special tools are not
available from Goodrich Corporation.

Hammer stamp the tool part number on each tool to help the maintenance personnel find
the correct tool for a procedure.

TABLE 32-46-41-99A-901-A01

Tools, Fixtures, and Equipment - Table 9001 (Sheet 1 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Abrasive-media --- Paint removal
paint removal
equipment
Bolt and striker --- Removal of Lee plugs
tools
Bright lights 100 foot candles Visual inspections
(1076 Lux) minimum
on inspected surface
Cleaning Brushes that cannot Cleaning parts
brushes be damaged by
cleaning materials Commercially
available
Compressed air 0 to 2050 psi Leak test for brakes
source (0 to 141,3 bar)
Conductivity ASTM E1004
meter MIL-STD-1537
NDT inspections
SAE-ARP891
SAE-AMS-2658
Dry compressed Nozzle must keep Cleaning parts and paint
air source with the pressure to an removal
a hose and OSHA-specified limit
nozzle

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SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

Tools, Fixtures, and Equipment - Table 9001 (Sheet 2 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Eddy current ---
inspection
equipment
NDT inspections
Hardness test ASTM E140
equipment ASTM E10
ASTM D2583
P/N 1227-6
P/N 3695-2
P/N 3695-3
P/N 3695-4
P/N 7551-2
Heli-Coil® tools Heli-Coil® insert repairs
P/N 7552-3
P/N 7552-4
P/N 56187-2-2
P/N 56193-2-2
P/N 56193-4-2
Machining --- Repairs
equipment and
local blend tools Commercially
available
Magnetic ASTM E1444 NDT inspections
particle
inspection
equipment
Magnifiers 3X to 10X Visual inspections
Accurate to
Measurement
0.001 inch Measurement inspections
tools
(0,03 mm)
Oven Adjustable to 600°F To hold a pressure plate or
(315°C) torque plate
Protective Sufficient size and Pressure retention test
shields strength to contain
fast ejection of parts
Paint equipment --- Paint applied after repairs
Penetrant ASTM E1417 Type I, NDT inspections
inspection Method A,
equipment Level 2

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Tools, Fixtures, and Equipment - Table 9001 (Sheet 3 of 3)

TOOLS SPECIFICATIONS SUPPLIER
or or and USE
EQUIPMENT PART NUMBER (CAGE)
Spring tester --- Commercially Load test for springs
available
P/N 114-151-1 Make tool locally Peen and anvil tool to rivet
P/N 114-151-2 (refer to Figure 9001) the wear plates to the
pressure plate and the
torque plate
P/N 114-1599-1 Make tool locally Tool to assemble and
P/N 114-1599-2 (refer to Figure 9002) disassemble adjuster
Special tool assembly
P/N 114-1600 Make tool locally Tool to hold the pin retainer
(refer to Figure 9003) for measurement
inspections
P/N 114-1601 Make tool locally Test shims to do a
(refer to Figure 9004) high-pressure test of the
brake assembly
Test stand for Sufficient size and Brake tests
brakes pressure to conduct
brake tests
Commercially
Torque wrench Pound-inches or available Assembly of the brake
Nm (4 percent
maximum permitted
error)

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Peen and Anvil Tools to Rivet the Wear Plates to the Pressure Plate and Torque Plate,
Tool P/Ns 114-151-1 and 114-151-2
Figure 9001 / GRAPHIC 32-46-41-991-901-A01

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Tool to Assemble and Disassemble Adjuster Assembly,

Tool P/Ns 114-1599-1 and 114-1599-2
Figure 9002 / GRAPHIC 32-46-41-991-902-A01

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Tool to Hold the Pin Retainer, Tool P/N 114-1600

Figure 9003 / GRAPHIC 32-46-41-991-903-A01

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Test Shim, P/N 114-1601

Figure 9004 / GRAPHIC 32-46-41-991-904-A01

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SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

TASK 32-46-41-940-803-A01

2. Aqueous Cleaner Consumables

NOTE: Refer to paragraph 3. “Other Consumables”.

TABLE 32-46-41-99A-902-A01

Aqueous Cleaner Consumables - Table 9002 (Sheet 1 of 4)

RECOMMENDED
PRODUCT
CONCENTRATION & VENDOR
NAME
TEMPERATURE
Aerodet 10% at 130°F (54°C) Magnus Inc.
www.magnus.ca
Applied 4-204 Cleaner 30% at 120°F (49°C) Applied Chemical NZ
www.apchem.co.nz
custserv@appliedaustralia.com
Tel:130-055-4446
Aqueous PL 72 A23 5% at 130°F (54°C) Hubbard-Hall Inc.
(formerly Aquaspray 102) www.hubbardhall.com
Aquatene 571 20% at 160°F (71°C) Graymills Corporation
Removes chromate www.graymills.com
sealer.
Ardrox 6333 20% at 150°F (66°C) Chemetall Oakite Inc.
www.chemetall.com
Search by the cleaners name.
Armakleen M-HP2 3% at 130°F (54°C) The ArmaKleen Company
or http://armakleen.com.
10% at 160°F (71°C)
Big Blue 2 oz /1 galUS B & B Tritech, Inc.
at 150°F (66°C) P.O. Box 660776
Hialeah, Florida 33266-0776
U.S.A.
Tel: 1-305-888-5247
Brulin 1990 GD 4% at 130°F (54°C)
or
10% at 150°F (66°C)
Brulin 815 GD 5% at 130°F (54°C) Brulin & Co., Inc.
or http://brulin.com
10% at 160°F (71°C)
or
20% at 180°F (82°C)

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Aqueous Cleaner Consumables - Table 9002 (Sheet 2 of 4)

RECOMMENDED
PRODUCT
CONCENTRATION & VENDOR
NAME
TEMPERATURE
Cal Clean 657-LF 1% at 120°F (49°C)
Calvary Industries, Inc.
Cal Clean 733-AS 5% at 135°F (57°C)
www.calvaryindustries.com
Cal Clean 849-AM 3% at 110°F (43°C)
Calgon 6215 3% at 130°F (54°C) Calgon Corporation
& at 160°F (71°C) P.O. Box 1346
Calgon RT-825 4% at 135°F (57°C) Pittsburgh, Pennsylvania 15024
U.S.A.
Cee-Bee A-7X7 10% at 130°F (54°C) and
160°F (71°C)
or
25% at 140°F (60°C)
Cee-Bee 280 Cleaner 10% at 130°F (54°C)

Cee-Bee Super Bee 25% at 160°F (71°C) McGean Specialty Chemicals

300LFG Division
Cee-Bee 300LF 3% at 140°F (60°C) www.mcgean.com
or
10% at 160°F (71°C)
or
20% at 160°F (71°C)
(one hour max.)
Cee-Bee 400TG 15% at 140°F (60°C)
ClearClean Plus 1:100 at 130°F (54°C) Diversey Australia Pty. Limited
http://www.diversey.com
DuBois 200 Concentrate
140°F (60°C)
Removes chromate
sealer.
DuBois 422 6% at 175°F (79°C)
Removes anodize sealer. DuBois Chemicals. Inc.
or http://store.duboischemicals.com
3% at 160°F (71°C)
DuBois IEM-14 2% at 160°F (71°C)
Slightly discolors
cadmium plating.
DuBois IPR-1000 3% at 140°F (60°C)

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Aqueous Cleaner Consumables - Table 9002 (Sheet 3 of 4)

RECOMMENDED
PRODUCT
CONCENTRATION & VENDOR
NAME
TEMPERATURE
EFS 1927 L.F.(T) 2 oz/1 galUS at room Engineered Finishing Systems
temperature 3748 Middlebrook Ave.
Cincinnati, OH 45208
U.S.A.
Tel: 513-604-7594
Eldorado ED-306LF 3% at 160°F (71°C) Eldorado Chemical Company
& at 180°F (82°C) www.eldoradochem.com
HDL-330 10% at 150°F (66°C) Magnus Inc.
www.magnus.ca
Mirachem 500 15% at 110°F (43°C)
Mirachem Corporation
Mirachem 750 3:1 at 145°F (63°C) www.mirachem.com
Low Foam
Oakite 95 10 grams/L at 176°F Chemetall Oakite Inc.
(80°C) www.chemetall.com
Search by the cleaners name.
Rainbow Jet 5% and 10% ADN Chemicals
at 140°F (60°C) 2720 Reynolds Road
Winston Salem, North Carolina
27106 U.S.A.
Ram Wash H.D. 20% at 160°F (71°C) Ram Environmental Tech.
www.ramsorb.com
Rodarmer Products 1927 2 oz/1 galUS at room Rodarmer Products, Inc.
temperature 9036 W Rs Avenue Schoolcraft,
MI 49087
U.S.A.
Sag 710 (anti-foam) 8 oz/100 galUS Witco Corporation
at 140°F (60°C) 1 American Lane
Greenwich, Connecticut 06831
U.S.A.
Soluwax 10% at 130°F (54°C) Magnus Inc.
www.magnus.ca
Spot Free Rinse 977 GA 10% at 120°F (49°C) Calvary Industries, Inc.
www.calvaryindustries.com
Super Bee 300LF 10% at 120°F (49°C), Mogean-Rohco, Inc.
130°F (54°C), 140°F Cee-Bee Division, 9520 East
(60°C) Cee-Bee Drive, Downey CA. 90241
U.S.A.

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Aqueous Cleaner Consumables - Table 9002 (Sheet 4 of 4)

RECOMMENDED
PRODUCT
CONCENTRATION & VENDOR
NAME
TEMPERATURE
Turco 3878 LF-NC 20% at 140°F (60°C)
Turco 6751-L 4% at 140°F (60°C)
Turco 6849 4% at 140°F (60°C)
or
20% at 140 to 160°F
Henkel Surface Technologies
(60 to 71°C)
www.henkel.com
Turco Aviation 2 oz/1 galUS
at 150°F (66°C)
Turco Sprayeze NPLT 3% at 130°F (54°C)
or
10% at 160°F (71°C)
Zip Chem Calla 301A 50% at 100°F (38°C) Zip Chem Products
Tel: 408-782-2335
www.zipchem.com
ZOK27 20% at 160°F (71°C) Zokman International
www.zok.com

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TASK 32-46-41-940-804-A01

3. Other Consumables

NOTE: You can replace the materials shown below with equivalent materials that are
permitted by the specified MIL or SAE specification. Equivalent materials are not
permitted for anti-seize compound. If materials cannot be purchased locally, they
can be purchased from the vendors shown below.

TABLE 32-46-41-99A-903-A01

Other Consumables - Table 9003 (Sheet 1 of 3)

TYPE OF MATERIAL VENDOR’S

CONSUMABLE NAME NAME AND ADDRESS

Anti-seize SAE AMS 2518 Commercially available

Compound (MIL-T-5544 is optional) or
Armite Laboratories
Tel: 949-646-9035
Fax: 949-646-8319
www.armitelabs.com
Degreasing Solvent
Cleaner MIL-PRF-680 Type II or III Commercially available
Butyl Alcohol
Clear Sealant Base Coat, 683-3-2 Commercially available
Curing Solution, X-310A or
Akzo Nobel Aerospace Coatings,
Inc.
www.akzonobel.com

Conversion Coating QPL-81706 Class 1A

Commercially available
Corrosion Removal SAE AMS 1640

Corrosion Rust Veto Spray Houghton International, Inc.

Prevention Madison and Van Buren
Compound Avenues
Valley Forge, Pennsylvania
19482
U.S.A.

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Other Consumables - Table 9003 (Sheet 2 of 3)

TYPE OF MATERIAL VENDOR’S

CONSUMABLE NAME NAME AND ADDRESS
“VHT” Paint SP-117
High Temperature (aluminum color)
Paint or
Paint per specification TT-P-28
MIL-PRF-83282 or
Commercially available
Hydraulic Fluid MIL-PRF-87257
[To lubricate O-ring (225)]
MS20995C32
Lockwire (Bergen Safety Cable™ system is
optional)
Lubricant UniFlor™, P/N NYE8512S TAI Lubricants
P.O. Box 1579 Hockessin,
Delaware 19707
U.S.A.
Tel: 302-326-0200
Fax: 302-326-0400
Web: www.lubekits.com
Plastic Media
MIL-P-85891 Type II (maximum
Paint Removal media hardness of 3.5 MOH)
Abrasive Walnut Hulls
A-A-1722 Type II, Grade 20/30
Sodium Bicarbonate
Paint Remover SAE AMS 1375

Penetrant ASTM E1417 Type I, Method A, Commercially available

Inspection Fluid Level 2

MIL-PRF-85285

Polyurethane Paint OEM Color:

Medium Gray
Thinner MIL-T-81772 Types I, II, & III
Thinner-reducible MIL-PRF-23377 Commercially available
Epoxy Polyamide Type I, Class C1, C2, or N or
Primer (Class N is Non-Chromate) Hentzen Coatings, Inc.
Tel: 414-353-4200
www.hentzen.com
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Other Consumables - Table 9003 (Sheet 3 of 3)

TYPE OF MATERIAL VENDOR’S

CONSUMABLE NAME NAME AND ADDRESS

Thread-Lock
Loctite® 262 Commercially available
Compound
MIL-PRF-85582
Type I, Class C1, C2, or N Commercially available
Water-reducible (Class N is Non-Chromate) or
Epoxy Polyamide Deft, Inc.
Primer Product No. 44-GN-007 (Class C1) Tel: 800-544-3338
www.deftfinishes.com
Product No. 44-GN-098 (Class N)

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STORAGE (INCLUDING TRANSPORTATION)

TASK 32-46-41-500-801-A01

1. Storage Instructions

A. Reason for the Job

Self-explanatory

B. Job Set-up Information

(1) Special Tools, Fixtures, and Equipment

Not applicable

(2) Consumables
NOTE: An equivalent alternative is permitted for the material in the table that
follows:

TABLE 32-46-41-99A-151-A01

Consumables - Table 1501

MATERIAL SPECIFICATIONS SUPPLIER

and
(CAGE)
Corrosion Rust Veto Spray Houghton International, Inc.
prevention Madison and Van Buren Avenues
compound Valley Forge, Pennsylvania 19482
U.S.A.

(3) Referenced Information

TABLE 32-46-41-99A-152-A01

Referenced Information - Table 1502

REFERENCE DESCRIPTION
Goodrich Service Letter No. 1854 Shelf life limits and storage recommendations
for elastomeric seals and seal assemblies

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STORAGE (INCLUDING TRANSPORTATION)

C. Job Set-up
Not applicable
D. Procedure
Subtask 32-46-41-550-001-A01
(1) Storage

(a) Refer to Goodrich Service Letter No. 1854 for the storage life of rubber
parts that are not installed. Refer to SAE ARP5316.

(b) If the brake assembly is kept in storage, apply Rust Veto Spray or
equivalent to the brake disks. Refer to the SPECIAL TOOLS, FIXTURES,
EQUIPMENT, AND CONSUMABLES section for recommended corrosion
inhibitors.

NOTE: It is not necessary to remove the Rust Veto material before the
brake is installed on the aircraft. The first brake cycle causes the
material to burn off and show a little smoke.

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ILLUSTRATED PARTS LIST

TASK 32-46-41-871-808-A01

1. Purpose

A. General

CAUTION: GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR ANY
FEDERAL AVIATION ADMINISTRATION SANCTIONS, PRODUCT
MALFUNCTIONS, PROPERTY DAMAGE, PERSONAL INJURIES, OR
SIMILAR INCIDENTS THAT OCCUR AFTER SUBSTITUTION OF
PARTS THAT ARE NOT APPROVED BY GOODRICH, OR
SUBSTITUTION OF PARTS WITH ALTERATIONS THAT ARE NOT
APPROVED BY GOODRICH MANUALS OR OTHER WRITTEN
PROCEDURES THAT ARE ISSUED BY GOODRICH.

CAUTION: THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED

BY GOODRICH FOR INSTALLATION IN A SPECIFIED ASSEMBLY
WILL AUTOMATICALLY VOID ALL WARRANTIES EXTENDED BY
GOODRICH.

(1) This section identifies the parts of the assemblies that you can disassemble,
repair or replace, and assemble.

TASK 32-46-41-871-809-A01

2. Explanation of Data

A. Item Numbers

An item number identifies a part in all sections of the manual. The item number for a
part usually does not change, but you can add alpha variants of the item number.
Refer to paragraph 2.B.

A figure number is shown before the item number when there is more than one
figure supplied in the illustrated parts list.

An “R”, adjacent to an item number, shows that the part was added or removed or
has changed data.

B. Alpha Variant Item Numbers

An “Alpha Variant” is an alphabetic letter which follows the item number. This letter
“varies” (changes) when that item number is shown again. This letter is shown in a
figure to identify a part that has a different shape or location than the initial part.

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The letters “A” through “Z”, but not I and O, follow repeated item numbers when the
parts list must show:

(1) Added items

(2) Items that a Service Bulletin modifies

(3) Different configurations

(4) Alternate or Optional parts

(5) Improved parts that a Service Bulletin does not introduce

C. Parts Not Illustrated

(1) Parts that are not shown in an exploded view have a dash (-) before the item
number.

D. Indenture System to Show the Parts in an Assembly or Subassembly

The parts list shows how parts are related to other parts in each assembly or
subassembly. The periods before the part name show the number of spaces that the
part name is indented in the NOMENCLATURE column. Each part or subassembly is
related to the next higher subassembly or assembly as follows:

1 2 3 4 5 6 7 (Spaces that the part name is indented)

Assembly (End item)
. Detail parts of the assembly
. Subassembly
. Parts that attach the subassembly
. . Detail parts for the subassembly
. . . Detail installation parts for the subassembly (included when installation
parts are returned to the maintenance area as part of the assembly).

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E. Parts Replacement Data:

You can interchange parts when you obey the terms that follow. These terms are
shown in the NOMENCLATURE (part name) column of the parts list.

TERM ABBREVIATIONS DEFINITION

Alternate Alt This part can replace the specified part,
but the part has a different dimension, is
installed differently, or you must add or
remove other parts.
Optional Opt This part is optional and interchangeable
with the specified part.
Nonprocurable Nonproc1, This part cannot be purchased -
Nonproc2, ETC. purchase the subsequent higher
assembly.
Service part --- This part is available for maintenance,
but is not supplied with the brake
assembly.
Superseded by Supsd by A different part replaces this part and the
parts are not interchangeable.
Supersedes Supsds This different part replaces a part and
the parts are not interchangeable.
Replaced by Repld by A different part replaces this part and the
parts are interchangeable.
Replaces Repls This different part replaces a part and
the parts are interchangeable.
Vendor V Commercial and Government Entity
(CAGE) No. for the maker of the part.

F. Service Bulletins that are Included

(1) A Service Bulletin can add, remove, change, or replace assemblies,

subassemblies, and detail parts. The NOMENCLATURE (part name) column
shows “PRE SB XXX” (pre-Service Bulletin) when identification of the initial
configuration is necessary. “POST-SB XXX” (post-Service Bulletin) is shown to
identify affected assemblies, subassemblies, or detail parts.

(2) “PRE SB XXX” or “POST SB XXX” are not shown for the conditions that follow:

(a) The “EFF. CODE” column clearly shows the pre- or post-Service Bulletin
condition of the assemblies, subassemblies, or detail parts.

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(b) The Service Bulletin changes the end-item assembly and no change is
necessary to its part number. There is no factory-manufactured equivalent
of the changed assembly.

(3) “PRE SB XXX” is not shown, and “POST SB XXX” is shown, when a Service
Bulletin changes a subassembly or detail part with no change to its part number.
An alpha variant letter is also added to the item number.

G. Effectivity Code

(1) A reference letter (A,B,C, etc.) is shown in the EFF. CODE column for each
end-item assembly when there is more than one end-item assembly shown in
the parts list. This same reference letter is shown in the EFF. CODE column for
each detail part or subassembly that you can install in the end-item assembly
with the same reference letter. You can install detail parts and subassemblies in
all end-item assemblies if no reference letter is shown.

H. Quantity for Each Assembly

(1) The UNITS FOR EACH ASSY. column usually shows the full number of parts
that are necessary for each assembly or subassembly.

(2) The letters “AR” identify the parts that are installed “as required” (for example:
lockwire).

(3) The letters “RF” identify the parts that are given only for reference.

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TASK 32-46-41-871-810-A01

3. Vendors

A part is FAA approved as part of the Goodrich Quality Assurance System when you see
a vendor cage code number (V79136, for example) in the “NOMENCLATURE” column of
the ILLUSTRATED PARTS LIST. Sources of these parts, other than Goodrich, must have
alternate FAA approval (refer to Federal Aviation Regulations [14 CFR Part 21].

CAGE CODE VENDOR INTERNET

NO. VENDOR NAME AND ADDRESS
ADDRESS

V01556 Emhart Industries Inc. www.emhart.com

50 Shelton Technology Center
P.O. Box 859
Shelton, Connecticut 06484-4517
U.S.A.
V56878 SPS Technologies Inc. www.spstech.com
301 Highland Avenue
Jenkintown, Pennsylvania 19046-2630
U.S.A.
V79136 Truarc Company LLC www.truarc.com
125 Bronico Way
Phillipsburg, New Jersey 07004
U.S.A.
V80756 Spirolox, Inc. www.smalley.com
555 Oakwood Rd
Lake Zurich, Illinois 60047-1558
U.S.A.
V99017 Caplugs LLC www.caplugs.com
2150 Elmwood Ave
Buffalo, New York 14207-7198
U.S.A.
V92555 The Lee Company www.theleeco.com
2 Pettipaug Road
Westbrook, Connecticut 06498-1591
U.S.A.

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TASK 32-46-41-871-811-A01

4. “True” (Full) Part Numbers

A. True part numbers that contain a slash (/) between any character, or a dash (-)
between a letter and number are not permitted by ATA. The dash (-) is not allowed
as the last position of a part number. Use the true part number as shown in the
NOMENCLATURE column to order part with a slash (/) or dash (-) in this location.

EXAMPLE: Item 315, shown as “M83461-1-006” in the PART NUMBER column has
a slash between numbers. “True P/N is M83461/1-006” in the
NOMENCLATURE column shows the full part number.

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Exploded View, Main Brake Assembly

IPL Figure 1 / GRAPHIC 32-46-41-991-1001-A01
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5. Parts List

NOMENCLATURE UNITS
FIG. & AIRLINE
PART EFF. PER
ITEM STOCK 1 2 3 4 5 6 7
NUMBER CODE EACH
NO. NO.
ASSY.
R 1-1 2-1502 Brake Assembly, Multiple Disk A RF
R 1-1 2-1502-1 Brake Assembly, Multiple Disk B RF
R 1-1 2-1502-2 Brake Assembly, Multiple Disk C RF
R 1-1 2-1502-3 Brake Assembly, Multiple Disk D RF
5 50-491-16 . Identification Plate A, B 1
R -5A 50-705 . Identification Plate C 1
R -5B 50-769 . Identification Plate D 1
R 10 MS20995C32 . Deleted (Added to AR
Consumables Table 9004)
R 15 AN4H5A . Bolt (Part is plated with 2
cadmium)
R 20 AN960-416 . Washer, Flat (Part is plated 2
with cadmium)
25 195-171 . Valve Assembly, Shuttle 1
30 MS28775-012 . O-ring 1
35 56-627 . Ring, Backup 1
R 40 42FLW524 . Nut, Self-Locking (Part is 6
plated with cadmium)
(V56878)
R 45 MS20002C5 . Washer (Countersunk one 6
side) (Part is plated with
cadmium)
R 50 MS21250-05008 . Bolt, 12 Point (Part is plated 6
with cadmium)
55 463-6 . Rod and Insert Assembly A 2
R -55A 463-10 . Rod and Insert Assembly B, C, D 2

- Item not illustrated

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NOMENCLATURE UNITS
FIG. & AIRLINE
PART EFF. PER
ITEM STOCK 1 2 3 4 5 6 7
NUMBER CODE EACH
NO. NO.
ASSY.
R 60 534-1 . Stud Assembly 2
(Part is plated with cadmium)
65 309-21-3 . Assembly, Pressure Plate 1
70 78-135 . . Rivet 12
75 93-438 . . Plate, Wear 6
80 93-770-3 . . Plate, Pressure RF
(Nonprocurable)
R 85 3585-2CN164 . . Insert, Heli-Coil® (V01556) 2
R -85A 3885-2CN164 . . Insert, Heli-Coil® AR
(Oversized Service Part)
(V01556)
R 90 244-537-4 . Rotor A, B 3
R -90A 244-704 . Rotor C 3
R -90B 244-756 . Rotor D 3
R 95 133-593 . Stator 2
100 278-17 . Torque Plate and Wear Plate 1
Assembly
105 78-135 . . Rivet 12
110 93-438 . . Plate, Wear 6
115 184-831 . . Torque Plate NP
(Nonprocurable)
R 120 MS16624-3143 . Ring, Retaining 6
R -120A 5100-143 . Ring, Retaining 6
(Alt to Item 120) (V79136)
125 107-352 . Adjuster Assembly 6
130 N5000-131 . . Ring, Retaining (V79136) 1
R -130A MS16625-3131 . . Ring, Retaining 1
(Alt to Item 130)

- Item not illustrated

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NOMENCLATURE UNITS
FIG. & AIRLINE
PART EFF. PER
ITEM STOCK 1 2 3 4 5 6 7
NUMBER CODE EACH
NO. NO.
ASSY.
R 135 MS21042-3 . . Nut, Self-locking (Part is 1
plated with cadmium)
R 140 AN960-10 . . Washer, Flat (Part is 1
plated with cadmium)
145 20-543 . . Pin 1
150 54-398 . . Sleeve 1
155 RS75 . . Ring, Retaining (V80756) 2
160 56-690 . . Retainer, Spring 1
R 165 40-598-1 . . Spring 1
R 170 54-371 . . Sleeve (Part is plated with 1
cadmium)
175 56-630 . . Retainer, Pin 1
180 260-815 . . Housing, Adjuster 1
R 185 115-256 . Insulator (Repld by Item 185A) A, B 6
(Part can contain asbestos)
R -185A 115-256-2 . Insulator C 6
(Pre SB 2-1502-32-2)
(Part can contain asbestos)
R -185B 115-256-3 . Insulator B, C, D 6
(Repls Item 185A and 190A)
(Post SB 2-1502-32-2)
190 60-498 . Spacer (Pre SB 2-1502-32-2) A, B 6
R -190A 60-498-1 . Spacer C 6
195 74-830 . Piston 6
200 MS28775-214 . O-ring 6
205 68-728 . Ring, Backup 6
R 210 MS35276-260 . Screw 2
215 53-195 . Clip, Torque 2

- Item not illustrated

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NOMENCLATURE UNITS
FIG. & AIRLINE
PART EFF. PER
ITEM STOCK 1 2 3 4 5 6 7
NUMBER CODE EACH
NO. NO.
ASSY.
R 220 MS24391D4L . Plug, Bleeder 4
(Supsds Item 230 and
Item 235) (Post SB1125)
R -220A AS5169D04L . Plug, Bleeder 4
(Alt to Item 220)
225 MS28778-4 . O-ring 4
R -230 F6446 . Screw, Bleeder 2
(Supsd by Item 220)
(Pre SB1125) (V63477)
R -235 274-36 . Fitting, Bleeder 2
(Supsd by Item 220)
(Pre SB1125)
R 240 266-217 . Piston Housing Assembly 1
R 245 PLGA2180010A . . Lee Plug (V92555) 2
R 250 3591-3CN190 . . Insert, Heli-Coil® (V01556) 2
R -250A 3891-3CN190 . . Insert, Heli-Coil® AR
(Oversized) (Service Part)
(V01556)
R 255 3591-4CN375 . . Insert, Heli-Coil® (V01556) 2
R -255A 3891-4CN375 . . Insert, Heli-Coil® AR
(Oversized) (Service Part)
(V01556)
260 26-299 . . Bushing 1
265 26-336 . . Bushing, Axle 1
270 260-814 . . Housing, Piston RF
(Nonprocurable)
R -275 324-17 . Cap, Plug (Shipping part) 2
(Repld by Item 275A)
R -275A RPO-104 . Plug (Shipping part) 2
(Repls Item 275) (V99017)

- Item not illustrated

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NOMENCLATURE UNITS
FIG. & AIRLINE
PART EFF. PER
ITEM STOCK 1 2 3 4 5 6 7
NUMBER CODE EACH
NO. NO.
ASSY.

-280 380-123 Overhaul Kit - Shuttle Valve B,C,D AR

R 285 --- . Body, Shuttle Valve AR
(Not included in kit)
(Nonprocurable)
R 290 --- . Cap, End RF
(Not included in kit)
(Nonprocurable)
R 295 --- . Poppet RF
(Not included in kit)
(Nonprocurable)
R 300 MS28778-8 . O-ring (Nonprocurable) RF
R 305 05380 . Ball (Nonprocurable) RF
R 310 80613 . Spring (Nonprocurable) RF
-- 05924 . Spring (Alt to Item 310) RF
(Nonprocurable)
R 315 M83461-1-006 . O-ring RF
(True P/N is M83461/1-006)
(refer to paragraph 6.)
(Nonprocurable)
R -320 F6446 Screw, Bleeder (Service Part) AR
R -325 274-36 Fitting, Bleeder (Service Part) AR

- Item not illustrated

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