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FOREWORD

This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.

Applicable for HINO 238, 258LP, 268, 338 series, equipped with J08E-VB and J08E-VC engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Drivers / Owners Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.

Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys-
tems in these vehicles.

Manual Name Pub. No.

Chassis Workshop Manual S1-UNAE11A 2/2
J08E-VB, VC Engine Workshop Manual S5-UJ08E11A
S7-UNAE11A 1/3
Trouble Shooting Workshop Manual S7-UNAE11A 2/3
S7-UNAE11A 3/3
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-UNAE11A 1/2 (U.S.A.), S1-CNAE11A 1/2 (CANADA)
MODELS HINO 238, 258LP, 268, 338, 358
CHAPTER
Production Model
NE8J, NF8J, NJ8J, NV8J
Code

GENERAL INTRODUCTION GN02-001

CLUTCH MAIN UNIT CL02-001 CL02-002

CLUTCH CONTROL CL03-001

TRANSMISSION MAIN UNIT TR02-001

AUTOMATIC TRANSMISSION TR04-001 TR04-002

TRANSMISSION/TRANSFER CONTROL TR06-001 TR06-002

PROPELLER SHAFT PP02-001

DIFFERENTIAL CARRIER DF02-001

BRAKE EQUIPMENT BR01-001 BR01-002

SERVICE BRAKE BR02-001 BR02-002

ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001 BR03-002

EXHAUST BRAKE BR05-001

PARKING BRAKE BR07-001

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

FRONT AXLE AX02-001

REAR AXLE AX03-001

WHEEL & TIRE AX04-001

SUSPENSION SU02-001

CHASSIS FRAME FC02-001

CAB CA02-001

ELECTRICAL EQUIPMENT EL01-001

ELECTRIC WIRE EL02-001

This manual does not contain items on half-tone dot meshing.

 INDEX: CHASSIS GROUP 1/4

GENERAL INTRODUCTION

CLUTCH EQUIPMENT

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

AUTOMATIC TRANSMISSION

PTO (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

PROPELLER SHAFT

DIFFERENTIAL EQUIPMENT

DIFFERENTIAL CARRIER

BRAKE EQUIPMENT

SERVICE BRAKE

ABS
INDEX: CHASSIS GROUP 2/4

ES START (EASY & SMOOTH START) SYSTEM

EXHAUST BRAKE

RETARDER BRAKE

PARKING BRAKE

STEERING EQUIPMENT

STEERING UNIT

POWER STEERING

AXLE EQUIPMENT

FRONT AXLE

REAR AXLE

WHEEL & TIRE

SUSPENSION EQUIPMENT

SUSPENSION

CHASSIS EQUIPMENT

CHASSIS FRAME

COUPLER (5TH WHEEL)

PINTLE HOOK
INDEX: CHASSIS GROUP 3/4

CAB EQUIPMENT

CAB

ELECTRICAL EQUIPMENT

ELECTRIC WIRE

HYBRID SYSTEM
INDEX: CHASSIS GROUP 4/4

ENGINE CONTROL

FUEL CONTROL

BRAKE CONTROL

SUSPENSION CONTROL

CAB EQUIPMENT CONTROL

OTHERS
 GENERAL INTRODUCTION (CHASSIS) GN021

GENERAL INTRODUCTION (CHASSIS)

GN02

GN02-001

GENERAL INTRODUCTION.....................GN02-2
GENERAL PRECAUTIONS .............................GN02-2
IDENTIFICATION INFORMATION ...................GN02-5
HOW TO USE
THIS WORKSHOP MANUAL.........................GN02-12
PRECAUTIONS .............................................GN02-15
SEALANT ON THE TAPERED SCREW
FOR PIPING ..................................................GN02-18
NYLON TUBE REPLACEMENT METHOD ...GN02-19
METRIC INFORMATION ...............................GN02-21
SPECIFIED TORQUE
FOR STANDARD BOLTS AND NUTS ...........GN02-23
SPECIFIED TORQUE
FOR FLANGE BOLTS AND NUTS ................GN02-23
RECOMMENDED LUBRICANTS ..................GN02-25
VEHICLE LIFT
AND SUPPORT LOCATIONS........................GN02-27
INFORMATION DISPLAY ..............................GN02-29
SYMPTOM SIMULATION ..............................GN02-34
GLOSSARY ...................................................GN02-36
GLOSSARY OF SAE AND HINO TERMS .....GN02-39
GN022 GENERAL INTRODUCTION (CHASSIS)

GENERAL INTRODUCTION
GENERAL PRECAUTIONS
EN00Z00020100001

Some recommended and standard maintenance services for your vehicle are included in this section. When performing main-
tenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction
of the vehicle which may result in personal injury and/or property damage. If you have any question about performing mainte-
nance, please consult your Hino dealer.

WARNING
When working on your vehicle, observe the following general precautions to prevent death, personal injury and/or
property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.

Always wear safety glasses or goggles to protect your eyes.

Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
Bind long hair securely behind the head.
When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and
block the wheels.
Always turn off the starter switch to stop the engine, unless the operation requires the engine running. Remov-
ing the key from the switch is recommended.
To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-
tor, muffler, exhaust pipe and tail pipe.
Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
Take utmost care when working on the battery. It contains corrosive sulfuric acid.
Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
Read carefully and observe the instructions specified on the jack before using it.
Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a
vehicle supported only by a jack.
If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly
applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.
Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
Be careful not to damage lines and hoses by stepping or holding your feet on them.
Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.

DEFINITION OF SAFETY TERMS

Indicates an extremely hazardous situation if proper procedures are not followed and could
result in death or serious injury.

Indicates a potential hazardous situation if proper procedures are not followed and could
result in death or serious injury.

Indicates a hazardous situation if proper procedures are not followed and could result in
serious injury or damage to parts/equipment.

Indicates the need to follow proper procedures and to pay attention to precautions so that
efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

 GENERAL INTRODUCTION (CHASSIS) GN023

TOWING
When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to
protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near
the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.

1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is
defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and
entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15 in horizontal and vertical
directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a
vehicle trapped in a gutter.
(4) Keep the gear shift lever in Neutral.
(5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be
available for the brake. This is dangerous, as the brake system does not function if the engine is not running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn,
making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed
for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the
transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle
lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles
equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check and
refill the rear axle housing with lubricant if necessary.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-ahead
position.

CLEAN AIR ACT

1. Heavy-duty engine rebuilding practices.

86.004-40
The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are
applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of
engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also
may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine. Any deviation
from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air Act (42 U.S.C.
7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis for
knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tolerances,
calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A reasonable
basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and func-
tion of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emis-
sions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
In accordance with the original engine manufacturer's instructions; or
Where data or other reasonable technical basis exists that such parameter adjustment or design element change,
when performed on the engine or similar engines, is not expected to adversely affect in-use emissions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a configu-
ration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine
must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.
GN024 GENERAL INTRODUCTION (CHASSIS)

(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset with-
out diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to
satisfy requirements in 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be
free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during
the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt engine, all
critical emissions-related components listed in 86.004-25(2) not otherwise addressed by paragraphs (1) through (3) of
this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufacturer recom-
mended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The records
shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emis-
sions-related control components including a listing of parts and components used, engine parameter adjustments, emis-
sions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understandable to an
EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format
when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal business prac-
tices including information on activities not conducted by themselves or information that they cannot reasonably
access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine
rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.
86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in 86.007-11, as applicable, the manufacturer
shall furnish or cause to be furnished to the ultimate purchaser a statement that
"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway die-
sel fuel, including a 15 ppm sulfur cap)."
 GENERAL INTRODUCTION (CHASSIS) GN025

IDENTIFICATION INFORMATION
EN00Z00020200001

1. VEHICLE IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN label is affixed to the left pillar
of the cab.
These numbers are used for identification purposes when you have a vehicle registered or inspected. Please quote these
numbers when ordering spare parts or reporting technical matter to receive prompt service attention.
The following is an explanation of the items that are listed on the VIN label.

VIN
label
GN026 GENERAL INTRODUCTION (CHASSIS)

(1) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.
(2) P.S. (PRODUCTION SERIES) AND VEHICLE COMPONENTS

PRODUC- TRANS-
TRANSMISSION RATIO REAR SER- PARK-
MODEL TION CODE CLUTCH MIS- SUSPEN-
AXLE VICE ING
(CLASS) SIZE SION BRAKE BRAKE
SION
SERIES
MODEL SERIES SERIES 1st 2nd 3rd 4th 5th 6th Rev.

RS17-145
2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145

RS17-145 L
HINO238
NE8J HBC - 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49 H D or
(6) RS19-145 A
RS17-145
2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS19-145

RS17-145
GBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS19-145

RS17-145
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145 L
NE8J H D or
RS17-145 A
HBC - 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145

RS17-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
HINO258 RS19-145
(6) RS17-145
JBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 F W A
RS19-145

RS17-145
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145
NJ8J
RS17-145 L
KBC - 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49 F W or
RS19-145 A
RS17-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS19-145

RS17-145
GBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS19-145

RS17-145
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145 L
HINO268
NE8J H D or
(6) RS17-145 A
HBC - 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS19-145

RS17-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS19-145
 GENERAL INTRODUCTION (CHASSIS) GN027

PRODUC- TRANS-
TRANSMISSION RATIO REAR SER- PARK-
MODEL TION CODE CLUTCH MIS- SUSPEN-
AXLE VICE ING
(CLASS) SIZE SION BRAKE BRAKE
SION
SERIES
MODEL SERIES SERIES 1st 2nd 3rd 4th 5th 6th Rev.

RS17-145
JBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS19-145

RS17-145
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
HINO268 RS19-145
NJ8J
(6) RS17-145 L
F W
KBC - 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49 or
RS19-145 A
RS17-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS19-145

RS21-145
NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS23-160

RS21-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS23-160

RS21-145
PBC - 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS23-160

RS21-145
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
HINO268 NV8J RS23-160
(7) RS21-145 L
TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 F W or
RS23-160 A
RS21-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS23-160

RS21-145
SBC - 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS23-160

RS21-145
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS23-160

DBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS21-145
NF8J H D
EBC - 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09 RS21-145 L
HINO338
or
(7) RS21-145 A
NV8J NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 F W
RS23-160
GN028 GENERAL INTRODUCTION (CHASSIS)

PRODUC- TRANS-
TRANSMISSION RATIO REAR SER- PARK-
MODEL TION CODE CLUTCH MIS- SUSPEN-
AXLE VICE ING
(CLASS) SIZE SION BRAKE BRAKE
SION
SERIES
MODEL SERIES SERIES 1st 2nd 3rd 4th 5th 6th Rev.

RS21-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS23-160

RS21-145
PBC - 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS23-160

RS21-145
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS23-160

RS21-145 L
HINO338
NV8J TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 F W or
(7) RS23-160 A
RS21-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS23-160

RS21-145
SBC - 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS23-160

RS21-145
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS23-160

NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS23-160

- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03 RS23-160 L

PBC F W or
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00 RS23-160 A
HINO358 NH8J
(8) TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS23-160

- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03 RS23-160 L

SBC F W or
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00 RS23-160 A

CODE SERVICE BRAKE PARKING BRAKE CONTROL CODE SUSPENSION

H: Hydraulic D: ACTING ON DIFFERENTIAL L: LEAF
F: Full air W: ACTING ON REAR WHEEL A: AIR
 HINO VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE FOR U.S.A. and CANADA (2015MY)
WMI VDS CD VIS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

5 P V N J 8 J T 4 F 4 S 1 0 0 0 1

ENGINE MODEL CHECK DIGIT ASSEMBLY PLANT SEQUENTIAL NUMBER

MANUFACTURER TYPE MAKE, MODEL WHEEL BASE MODEL YEAR MODIFICATION

LINE & CAB/BODY TYPE,
SERIES, BRAKE SYSTEM

CODE YEAR CODE YEAR CODE DESCRIPTION

CODE MANUFACTURER TYPE F 2015 M 2021 S A NEW LETTER
T WILL BE ALLOTTED
JHA HINO MOTORS, LTD. TRUCK G 2016 N 2022
U AT EVERY MAJOR
JHB HINO MOTORS, LTD. INCOMPLETE VEHICLE H 2017 P 2023 ... MODIFICATION
Z
HINO MOTORS J 2018 R 2024
5PV MANUFACTURING INCOMPLETE VEHICLE K 2019 S 2025
U.S.A., INC.
L 2020 T 2026 CODE ASSEMBLY PLANT
HINO MOTORS HINO MOTORS, LTD.
2AY INCOMPLETE VEHICLE 1
CANADA, LTD. HINO PLANT IN JAPAN
LENGTH 3 Canada Plant
MODEL Intended GVWR and Vehicle Class BRAKE CODE NE - NV 4 W.V Plant
MAKE LINE & CAB/BODY TYPE
CODE and Class SYSTEMS mm in.
G 3,861 152
8846 kg. - 11793 kg or less J 4,445 175
HINO NE INCOMPLETE VEHICLE HYDRAULIC
[19,501 - 26,000 (lbs.)] (CLASS 6)
L 4,750 187
M 5,207 205
10434 kg. - 11793 kg or less FULL AIR
HINO NJ INCOMPLETE VEHICLE N 5,385 212
GENERAL INTRODUCTION (CHASSIS)

[23,001 - 26,000 (lbs.)] (CLASS 6)

P 5,512 217
R 5,969 235
13609 kg. - 14968 kg or less
HINO NF INCOMPLETE VEHICLE HYDRAULIC T 6,426 253
[30,001 - 33,000 (lbs.)] (CLASS 7)
V 6,883 271

13609 kg. - 14968 kg or less

HINO NV INCOMPLETE VEHICLE FULL AIR
[30,001 - 33,000 (lbs.)] (CLASS 7)
CODE MANUFACTURER MODEL DESCRIPTION
J08E-VC 7.6 LITERS, DIESEL 220HP
14969 kg - 15875 kg or less 8J HINO MOTORS, LTD.
HINO NH INCOMPLETE VEHICLE [33,001 - 35,000 (lbs.) ] (CLASS 8) FULL AIR J08E-VB 7.6 LITERS, DIESEL 260HP

SHTS00Z000200007
GN029
GN0210 GENERAL INTRODUCTION (CHASSIS)

2. VEHICLE NOISE EMISSION CONTROL INFORMATION

The Vehicle Noise Emission Control Information is affixed to the side
For all models of the left door. The name of manufacturer, production year and
VEHICLE NOISE EMISSION CONTROL INFORMATION
month, and noise emission applicable to medium and heavy trucks in
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE
EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
conformity with U.S. EPA Regulations are displayed.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE
PROHIBITED BY THE NOISE CONTROL ACT OF 1972.
(A)THE REMOVAL OR RENDERING INOPERATIVE. OTHER THAN FOR
PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY
NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE
OWNER' S MANUAL) INCORPORATED INTO THIS VEHICLE IN
COMPLIANCE WITH THE NOISE CONTROL ACT.
(B)THE USE OF THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF
DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.
MFD BY:HINO MOTORS, LTD. DATE OF MANUFACTURE 03/2009

SHTS00Z000200010

3. ENGINE SERIAL NUMBERS.

Please quote these numbers when ordering spare parts or reporting
technical matter to receive prompt service attention.
The engine serial number is engraved on the engine cylinder block.

SHTS00Z000200011

4. CHASSIS SERIAL NUMBER

Chassis serial number is engraved on the left side frame near the
front wheel.

SHTS00Z000200012

5. CLEAN IDLE CERTIFIED LABEL FOR U.S.

Make sure that the following clean engine idling certified label is
affixed to the outside of the left door.
By the CARB below, the label must be affixed there to prove that the
new vehicle with diesel engine manufactured from Jan., 2008 con-
forms to this low.

CARB 1956.8. Exhaust Emission Standard and Test Procedure

(a) (b) Heavy-Duty Diesel Engine Idling Requirements

SHTS00Z000200013-C
 GENERAL INTRODUCTION (CHASSIS) GN0211

6. VEHICLE EMISSION CONTROL INFORMATION

The Vehicle Emission Control Information is affixed to the side of the
left door. The name of manufacturer, production year and month, and
VIN emission applicable to medium and heavy trucks in conformity with
label U.S. EPA Regulations are displayed.
Vehicle emission
control information

GN02-13-1-0

For example

GN02-13-1-1
GN0212 GENERAL INTRODUCTION (CHASSIS)

HOW TO USE THIS WORKSHOP MANUAL

EN00Z00020200002

This workshop manual is designed as a guide for servicing the vehicle.

An INDEX is provided on the first page of each chapter.

TROUBLESHOOTING is dealt with in each chapter.

When beginning operations, refer to the TROUBLESHOOTING section for
a guide to appropriate diagnosis.

SPECIAL TOOL is dealt with in each chapter.

When ordering a special tool, confirm the part number with the applicable
parts catalog.

RERAIR PROCEDURES
Repair procedures when self-explanatory, such as simple installation
and removal of parts, have been omitted. Illustrations, such as the
one below, have been provided to make such simple procedures
clear. Only essential procedures requiring specific directions have
been dealt with explicitly.
 GENERAL INTRODUCTION (CHASSIS) GN0213

MAIN CYLINDER
EXAMPLE:

SHTS00Z000200014

1 Clevis 8 Return spring

2 Lock nut 9 Body
3 Push rod 10 Hose joint
4 Boot 11 O-ring
5 Retainer ring 12 Soft washer
6 Thrust washer 13 Bolt
7 Piston

Tightening torque Unit: Nm {kgfcm, lbfft}

A 2.5-4.4 {25-45, 1.8-3.2}

In some cases, illustrations may be of parts which differ in some nonessen-

tial way from the parts found on your particular vehicle. In such cases, the
principle or procedure being illustrated applies regardless of such nones-
sential differences.
DEFINITION OF TERMS
Definition of vehicle right and left.
Right and left refers to the left and right sides of the vehicle as seen
while looking down the center line from the rear towards the front.
GN0214 GENERAL INTRODUCTION (CHASSIS)

SHTS00Z000200015C
 GENERAL INTRODUCTION (CHASSIS) GN0215

PRECAUTIONS
EN00Z0002C100001

PRECAUTIONS FOR ELECTRICAL SYSTEM

1. REMOVING THE BATTERY CABLE

! WARNING
Be sure to wait for at least ten minutes after the starter key is
turned to "LOCK" position before you disconnect the battery ter-
Loosen
minals from the battery, as the vehicle data is recorded on ECU
and DCU starts working for the exhaust gas after treatment after
the starter key is turned to "LOCK" position. Otherwise, the vehi-
cle data will not be recorded on ECU properly and DCU will not
complete working properly, which may result in the malfunction
saph00z000200008
of DPR system and DEF-SCR system.
The MIL (malfunction indicator light) may come on when the
starter key is turned to "ON" position again, even if you wait for
at least ten minutes before disconnecting the battery terminals
from the battery after the starter key is turned to "LOCK" posi-
tion. In this case, use HINO DX to clear the DTC (P204F and
P068A), to turn off the MIL and to conduct DPR regeneration
manually.
(1) Before electrical system work, remove the cable from the minus termi-
nal of the battery in order to avoid burning caused by short-circuiting.
(2) To remove the battery cable, fully release the nut to avoid damage to
the battery terminal. Never twist the terminal.

2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
(4) Do not remove the harness connector, electric component box, and
cover except for repair and inspection.
If removal is necessary, pay attention that water and foreign matters
Incorrect
do not attach or enter to the connector, terminals, electric component
box, and cover.
In restoration, make sure there is no attachment or entry of water and
foreign matters and mount them properly, because it causes degrada-
saph00z000200009 tion of waterproof function.

3. HANDLING OF WIRE HARNESS

Incorrect (1) Perform marking on a clamp and a clip and secure then in original
position so that the wire harness will not interfere with the end and
Incorrect
acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.

Incorrect

saph00z000200010
GN0216 GENERAL INTRODUCTION (CHASSIS)

4. HANDLING OF CONNECTOR
(1) To remove a connector, hold the connector (indicated by an arrow in
the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the con-
nector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.

Incorrect
Incorrect

Correct

saph00z000200011

5. INSTALLATION OF BATTERY DISCONNECT SWITCH

! WARNING
Installation of the battery disconnect switch on the power supply
circuit for the dosing control unit of DEF-SCR (DCU) may dam-
age or result in the malfunction of DEF-SCR system.
Be sure to read and follow the procedures and instructions on
the service bulletin before the installation of the battery discon-
nect switch.

6. HANDLING OF BATTERY DISCONNECT SWITCH

! WARNING
Wait for at least one minute before using the battery disconnect
switch after the starter key is turned to "LOCK" position.
Otherwise, the vehicle data will not be recorded on ECU properly,
which may result in the malfunction of DPR system.
 GENERAL INTRODUCTION (CHASSIS) GN0217

PRECAUTIONS FOR ELECTRIC WELDING

1. PRECAUTION FOR ELECTRIC WELDING

Electrical components such as the alternator and tachograph are
directly connected to the battery and one end is earthed to the
chassis frame. Under these conditions, welding current will flow
back along the earth circuit if electric welding is carried out and
damage may be caused to the alternator, tachograph, electrical
components, etc. Consequently, the following precautions are
always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and
earth the welding equipment securely to the frame itself. (Do not fit the
welding equipment earth to such things as the tire rims, brake pipes
or fuel pipes and leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.

Computer

Alternator
etc. Battery

Disconnect the ground terminal for

battery at the connecting point on the
frame and disconnect the ground for
computer as well.

Chassis frame Chassis frame

Connect the ground of the ARC welding

machine near the place on the frame to be
ARC welding welded but not connect it to plated parts such
machine as fuel pipes, brake pipes and leaf spring.

saph00z000200012
(2) In order to prevent damage to ancillary equipment components from
sparks during welding, take steps such as putting fire-resistant covers
over things like the engine, meters, steering wheel, hoses, tubes, leaf
spring and tires.
GN0218 GENERAL INTRODUCTION (CHASSIS)

SEALANT ON THE TAPERED SCREW FOR

PIPING
EN00Z00020200003

To the tapered thread of the air pipe joint is applied the sealant "LOC-TITE
#575". Follow the procedure below to remove/attach the piping.

1. REMOVAL
(1) The sealant (LOCTITE #575) has a high sealing capability. The return
torque of taper joint is about 1.5 times as high as the initial tightening
torque. To remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability, remove the
auxiliaries with the joint attached then remove the joint.

SHTS00Z000200021

2. ATTACHING
(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe the
dirt off the sealing section, directly apply the sealant by a quarter turn
(three ridges) starting from the second ridge from the tip, then assem-
ble in accordance with the tightening torque table below.
Wipe dirt off the mating part (female screw) before tightening it.
! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.

Tightening torque of tapered joint Unit: Nm {kgfcm, lbfft}

SHTS00Z000200022
Screw diameter
1/8 1/4 3/8 1/2
Material
4910
Steel {500100, 6415 {650150, 4710}
205 36.27.2}
{20050,
14.43.6} 255 345 445
Aluminum, brass {25050, {35050, {45050,
18.13.6} 25.33.6} 32.53.6}

(2) To replace vulcanized tape with sealant, remove the tape before-
hand, same as (1).
NOTICE
Take special care not to let dirt and foreign matters enter the piping.
(3) In the event of air leakage after sealant is applied and piping attached,
retightening cannot check the air leakage. Follow the steps (1) and (2)
to reassemble the piping.
 GENERAL INTRODUCTION (CHASSIS) GN0219

NYLON TUBE REPLACEMENT METHOD

EN00Z00020200004

NYLON TUBE REPLACEMENT METHOD

In this vehicle, nylon tubes are used for all the air tubes except those
One-touch joint on the charge line and the rear axle, the tubing for the wheel power
signal, a portion of the accessory system tubing, and for the unloader
tubing, and it is also used in joints, depending on the connection con-
ditions of the two types of joints; one-touch joints and caulking joints.
NOTICE
Caulking joint Since the function and quality of nylon tubes and joints are guaran-
teed as tube and joint sets, the use of parts other than Hino Genuine
Parts must be avoided.

SHTS00Z000200023

1. ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH

Nylon tube DIAMETER INSERTION LENGTH
Insertion length (Outside diameter x inside diam- mm {in.}
eter)
1/4 in. 14-19 {0.55-0.75}
3/8 in. 18-23 {0.71-0.91}
1/2 in. 21-26 {0.83-1.02}

SHTS00Z000200024

2. REMOVAL OF A ONE-TOUCH JOINT

(1) Make sure there is no dirt or grease stuck to the connector end. If the
end is dirty, clean it thoroughly by air blowing or other means.
(2) Using the special tool for removing the nylon tube to push the connec-
tor end, pull off the nylon tube with your hand in one stroke, without
stopping partway, pulling the tube in the connector axial direction.
SST: Puller (S0942-11490)

SHTS00Z000200025

INSTALLATION OF A ONE-TOUCH JOINT AND CAULK-

ING JOINT
Make sure the joint interior is free of dirt grease. If the interior is dirty,
clean it thoroughly by air blowing or other means.
Cut off the tube end where the tube surface is scarred by the joint
pinch marks, and make sure that the part of the tube inserted into the
joint has no surface damage. If the tube is damaged, cut off the dam-
aged part (provided that the tube length is more than sufficient).
Less than 5
NOTICE
Use the special nylon tube cutter when cutting the nylon tube, and cut
the tube so that the angle of the cut end to the axial center is 85-95.
SHTS00Z000200026

1. INSTALLATION OF A ONE-TOUCH JOINT

GN0220 GENERAL INTRODUCTION (CHASSIS)

Before inserting the tube, mark the insertion length on the tube with a
white-out pen or similar implement, in accordance with the dimen-
sions, "ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH."
Then insert the tube firmly in place as far as the marked point.

2. INSTALLATION OF A CAULKING JOINT

Press in the tube so that it does not move (will not come out), and
tighten the sleeve nut with the tightening tool to the torque shown in
the following table.

3. NYLON TUBE NUT TIGHTENING TORQUE

Unit: Nm {kgfcm, lbfft}
NUT DIAMETERS TIGHTENING TORQUE
1/4 in. 20-26 {200-270, 15-19}
3.8 in. 35-45 {350-460, 26-33}
1/2 in. 50-60 {500-610, 37-44}

NOTICE
Nuts must be tightened to 5- 35C.

4. ASSEMBLING THE CAULKING JOINT (AFTER THE TUBE HAS

FIRST BEEN REMOVED FROM THE JOINT AND THEN RE-
INSTALLED IN THE SAME PLACE)
Aligning marks (1) Make aligning marks on the connector and union to mark their posi-
tions before loosening the nut.
(2) When re-assembling the joint, tighten the nut until the pre-disassem-
bly position (position of aligning marks) is reached, and then tighten
the nut 60 more.
(3) Always check air leakage after assembling the joint. If air is leaking
from the joint, continue tightening the sleeve nut until the leak stops.
(4) If the air leak does not stop, replace the tube, sleeve, and insert with
SHTS00Z000200027 new parts. If the air leak still continues, replace the nut and connector
/ union.
NOTICE
During repair or other work, make sure the temperature limit of
the nylon tube is within -40-90C, especially during paint drying
work.
During boring, welding, sanding, and other work, protect nylon
tubes from tools, cuts, heat sources, and sparks, or remove the
nylon tubes beforehand.
Do not attach a welding equipment clamp near the nylon tube.
Do not pour battery fluid or other acidic fluid on the nylon tube.
Do not bend the nylon tube beyond the nylon tube bending
radius R values shown in the following table. Also, do not use
the remaining portion of a tube that has broken due to overbend-
ing.

OUTSIDE DIAMETER OF MINIMUM BENDING RADIUS DURING

TUBE HANDLING: R mm {in.}
1/2 in. 30 {1.18}
3/8 in. 65 {2.56}
1/2 in. 70 {2.76}
 GENERAL INTRODUCTION (CHASSIS) GN0221

METRIC INFORMATION
EN00Z00021200001

METRIC FASTENERS

1. Most threaded fasteners on the Hino trucks series are metric.

Be careful not to mix them up with threaded fasteners using the
inch system.
Mismatched or incorrect bolts, nuts and screws can cause dam-
age or malfunction, resulting in personal injury and/or property
damage.

2. When bolts, nuts and screws are removed from the vehicle, they
should be kept for reuse whenever possible.
If they are not re-usable, parts that are equivalent to the original
parts in dimensions, strength, and thread pitch must be
selected.

3. Most original bolts are marked with identification numbers indi-

cating the strength of the bolts. The markings are shown below.

4. When replacing bolts, be careful to use bolts with the same

markings as the original bolts.

Nomenclature for bolts

Metric system Bolt strength identification

Bolt M12-1.75 25

D T L

P
T

7 D 7 9

D- Nominal Diameter P- Property Class Metric Bolts P Identification class numbers corre-
(millimeters) (bolt strength) spond to bolt strength. Increasing numbers rep-
L- Length (millimeters) T- Thread Pitch (thread resent increasing strength.
width crest to crest
millimeters)

SHTS00Z000200028
GN0222 GENERAL INTRODUCTION (CHASSIS)

DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal In. Metric mm. Fractions Decimal In. Metric mm.

1/64 0.015625 0.397 33/64 0.515625 13.097

1/32 0.03125 0.794 17/32 0.53125 13.494

3/64 0.046875 1.191 35/64 0.546875 13.891

1/16 0.0625 1.588 9/16 0.5625 14.288

5/64 0.078125 1.984 37/64 0.578125 14.684

3/32 0.09375 2.381 19/32 0.59375 15.081

7/64 0.109375 2.778 39/64 0.609375 15.478

1/8 0.125 3.175 5/8 0.625 15.875

9/64 0.140625 3.572 41/64 0.640625 16.272

5/32 0.15625 3.969 21/32 0.65625 16.669

11/64 0.171875 4.366 43/64 0.671875 17.066

3/16 0.1875 4.763 11/16 0.6875 17.463

13/64 0.203125 5.159 45/64 0.703125 17.859

7/32 0.21875 5.556 23/32 0.71875 18.256

15/64 0.234375 5.953 47/64 0.734375 18.653

1/4 0.250 6.35 3/4 0.750 19.05

17/64 0.265625 6.747 49/64 0.765625 19.447

9/32 0.28125 7.144 25/32 0.78125 19.844

19/64 0.296875 7.54 51/64 0.796875 20.241

5/16 0.3125 7.938 13/16 0.8125 20.638

21/64 0.328125 8.334 53/64 0.828125 21.034

11/32 0.34375 8.731 27/32 0.84375 21.431

23/64 0.359375 9.128 55/64 0.859375 21.828

3/8 0.375 9.525 7/8 0.875 22.225

25/64 0.390625 9.922 57/64 0.890625 22.622

13/32 0.40625 10.319 29/32 0.90625 23.019

27/64 0.421875 10.716 59/64 0.921875 23.416

7/16 0.4375 11.113 15/16 0.9375 23.813

29/64 0.453125 11.509 61/64 0.953125 24.209

15/32 0.46875 11.906 31/32 0.96875 24.606

31/64 0.484375 12.303 63/64 0.984375 25.003

1/2 0.500 12.7 1 1.00 25.4

 GENERAL INTRODUCTION (CHASSIS) GN0223

SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS

EN00Z00023200001

Unit: Nm {kgfcm, lbfft.}

Class 4T 7T 9T

Representation

7 q
Diameter No Mark

4.4-6.6 7.2-10.8 9.5-13.5

M6
{45-67, 3.3-4.8} {74-110, 5.4-7.9} {94-140, 6.8-10.1}

18.0-26.0 23.5-34.5
M8 11.5-16.5 {114-172, 8.3-12.4}
{179-269, 13.0-19.4} {237-355, 17.2-25.6}

22.0-32.0 34.5-51.5 46.0-68.0

M10
{221-331, 16.0-23.9} {351-527, 25.4-38.1} {466-698, 33.7-50.4}

38.5-57.5 61.0-91.0 80.0-120.0

M12
{392-588, 28.4-42.5} {621-931, 44.9-67.3} {816-1,224, 59.0-88.5}

62.0-92.0 96.0-144.0 128.0-192.0

M14
{629-943, 45.5-68.1} {976-1,464, 70.6-105.8} {1,304-1,956, 94.3-141.4}

96.0-144.0 152.0-228.0 200.0-300.0

M16
{976-1,464, 70.6-105.8} {1,552-2,328, 112.3-168.3} {2,040-3,060, 147.5-221.2}

132.0-198.0 208.0-312.0 276.0-414.0

M18
{1,344-2,016, 97.2-145.7} {2,120-3,180, 153.3-229.9} {2,816-4,224, 203.6-305.4}

188.0-282.0 296.0-444.0 392.0-588.0

M20
{1,920-2,880, 138.8-208.2} {3,024-4,536, 218.7-327.9} {4,000-6,000, 289.3-433.8}

256.0-384.0 405.0-605.0 540.0-800.0

M22
{2,616-3,924, 189.2-283.7} {4,120-6,180, 297.9-446.8} {5,470-8,210, 395.5-593.6}

324.0-486.0 515.0-765.0 680.0-1,010.0

M24
{3,304-4,956, 238.9-358.3} {5,220-7,840, 377.5-566.8} {6,900-10,340, 499.0-747.6}

SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS

EN00Z0002C100002

Unit: Nm {kgfcm, lbfft.}

Class
7T 9T 12T Shape
Diameter

18.0-26.0
M8
{184-265, 13.3-19.2}

41.5-61.5 55.0-82.0
M10
{421-631, 30.5-45.6} {560-840, 40.5-60.7}

73.0-109.0 96.0-114.0
M12
{744-1,116, 53.8-80.7} {979-1,469, 70.8-106.2}

86.0-142.0
M14
{877-1,448, 63.4-104.7}
GN0224 GENERAL INTRODUCTION (CHASSIS)

With new flange (w/o grooves)

Unit: Nm {kgfcm, lbfft.}

Class
8.8T 10.9T Shape
Diameter

21.7-40.3 27.3-50.7
M8
{221-411, 16.0-29.7} {278-517, 20.1-37.4}

24.5-45.5 32.7-60.3
M10
{250-464, 18.1-33.6} {333-615, 24.1-44.5}

44.1-81.9 57.4-106.6
M12
{450-835, 32.5-60.4} {585-1087, 42.3-78.6}

91-169
{928-1723, 67.1-124.6}
M14
104-156*
{106-1590, 76.7-115.1}
 GENERAL INTRODUCTION (CHASSIS) GN0225

RECOMMENDED LUBRICANTS
EN00Z0002H600001

No. LUBRICANTS POSITONS VISCOSITY RECOMENDATIONS (SAE)

Engine oil
A.P.I.: CJ-4
1 Cylinder Block
JASO: DH-2
ACEA: E6, E-9

No. LUBRICANTS POSITONS ATMOSPHERIC TEMP. S.A.E. No

Heavy duty engine oil Above 10F (12C) 50
MIL-L-2104D, API-CD, or Cat Above 10F (12C) 40
TO-4 EATON Fuller
2 Below 10F (12C) 30
FS-5406A,FS-6406A
Above 10F (12C) 80W-90
Automotive gear oil API-MT-1
Below 10F (12C) 75W
Mobil Delvac Synthetic
Transmission Fluid 50,
Shell SPIRAX GSX SAE 50,
EATON Roadranger SAE 50, EATON Fuller
3 All 50
EATON Approved Synthetic FS-5406A, FS-6406A
Transmission oil,
or equivalent (See Eaton
Lubrication Manual for detail)
Allison 2200HS, 2200RDS,
Automatic transmission fluid;
2500RDS, 3000RDS,
TES 389-approved fluid
3500RDS
4
Allison 2200HS, 2200RDS,
Automatic transmission fluid;
2500RDS, 3000RDS,
TES 295-approved fluid
3500RDS
Above 10F (12C) 85W/140
Axle lubricant
Above 15F (26C) 80W/140
Non- Extended Drain Lubri-
cants Above 15F (26C) 80W/90
(Petroleum with EP Additives) Above 40F (40C) 75W/90
(A.P.I. GL-5) (MIL-PRF-2105E
From 40F (40C) to 35F (2C) 75W
5 and SAE J2360) Rear axle
Above 40F (40C) 75W/140
Axle lubricant Above 15F (26C) 80W/90
Extended Drain Lubricants Above 15F (26C) 80W/90
(Petroleum with EP Additives)
(A.P.I. GL-5) (MIL-PRF-2105E Above 40F (40C) 75W/140
and SAE J2360) Above 40F (40C) 75W/90
GN0226 GENERAL INTRODUCTION (CHASSIS)

No. LUBRICANTS POSITONS

6 POWER STEERING FLUID (ATF DEXRON 2 or 3) Integral Power Steering Gear
7 BRAKE AND CLUTCH FLUID (DOT-3) or (DOT-4) Brake & Clutch
WHEEL BEARING GREASE
8 (MIL-G-10924B/18709A) (N.L.G.I.'s No.2 LITHIUM- Propeller Shaft Universal Joint and Slip Joint
SOAP)
Clutch Disc Hub Spline
T/M Main Drive Shaft Spline
HEAT RESISTANCE GREASE
9 Q-Plus Brake (Retainer Clip, Anchor Pin, Roller (Jour-
(MIL-G-22615/23549/21164) (N.L.G.I.'s No.2 or No.3)
nal only), Camshaft, Automatic Slack Adjuster, Clevis
Pin) Parking Brake (Camshaft, Anchor Pin, Shoe web)
10 SPECIAL GREASE (KLUBER GLKO) B-Frame Disc Brake (Guide buss, Caliper body, Piston)
Bushing, Clutch, Drive Shaft, Pinion Shaft Lever &
11 STARTER GREASE (N.L.G.I.'s No.2 LITHIUM-SOAP)
Reduction Gear
Clutch Release Sleeve
Clutch Release Shaft
12 BEARING GREASE (N.L.G.I.'s No.2 LITHIUM-SOAP)
Alternator Bearing
Starter Bearing
CHASSIS GREASE (MIL-G-17740) (N.L.G.I.'s No.1
13 Chassis Grease Fitting
CALCIUM or LITHIUM-SOAP)
14 LONG LIFE COOLANT Engine, Radiator
15 Mobil Synthetic 75W-90 Front Wheel Hub (Oil Lubricated Bearings)

No. LUBRICANTS POSITONS SHEEL MOBIL EXXON

LITHIUM BASE DISULFIDE Drag Link & Tie Mobil Grease
16 Retinax AM Beacon Q2
MOLYBDENUM GREASE Rod Ball Joint Special
GENERAL INTRODUCTION (CHASSIS) GN0227

VEHICLE LIFT AND SUPPORT LOCATIONS

EN00Z0002A200001

1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP

(1) As a rule, vehicle must be in an unloaded condition and never jack up
or lift up the vehicle with things of heavy weight.
(2) If removing any things of heavy weight like the engine and transmis-
sion, the center of gravity of the vehicle moves. Therefore, place a bal-
ance weight so as to keep it from rolling, or hold the jacking support
location using the transmission jack.

2. NOTICE FOR USING 4 POST LIFT

(1) Follow the instruction manual for a safety operation.
(2) Do not damage tires or wheels with a free wheel beam.
(3) Using a wheel stopper, fix the vehicle.

3. NOTICE FOR USING JACK AND SAFETY STAND

(1) Work in a flat place using a wheel stopper all the time.
(2) Support the specified location with a jack and safety stand accurately.
(3) Do not work or leave the vehicle supported only by a jack. Be sure to
support the vehicle together with a safety stand.
(4) Be careful and accurate in jacking up and down the vehicle.
(5) Care must be taken when jacking up and supporting the vehicle. Be
sure to lift and support the vehicle at the proper locations.
Cancel the parking brake on a level place and shift the transmission in
Neutral.
When jacking up the front wheels of the vehicle at first place stoppers
behind the rear wheels.
When jacking up the rear wheels of the vehicle at first place stoppers
behind the front wheels.
When either the front or rear wheels only should be jacked up, set
safety stands and place stoppers in front and behind the other wheels
on the ground.
After the vehicle is jacked up, be sure to support it on the safety
stands. It is extremely dangerous to perform any work on a vehicle
raised on a jack alone, even for a small job that can be finished
quickly.
GN0228 GENERAL INTRODUCTION (CHASSIS)

Front Rear

Leaf suspension

Air suspension

Garage jack position Air spring

Front Center of front axle beam
Rear Center of rear axle housing

Oil jack position

Support position
Safety stand
If necessary, remove the front bumper.

SHTS00Z000200034
 GENERAL INTRODUCTION (CHASSIS) GN0229

INFORMATION DISPLAY
EN00Z0002A200002

1. INFORMATION DISPLAY ITEMS

Information display shows following items.
(1) Ordinary display
Trip meter, voltage, date, fuel consumption, average speed and
engine or vehicle maintenance information etc.
(2) Warning display
The warning display is automatically displayed and shows messages.
NOTICE
When turn the key to "ON" position, display shows last message.
But in case of device operating, the warning display is prior to
ordinary display.

Information
display

Information display control switch

SHTS00Z000200035C

2. INFORMATION DISPLAY CONTROL SWITCH

The following information is shown with the key turned on. Each time
you push the "MODE" button, the displayed information is changed.
NOTICE
Diagram on the next page shows the operation method of the
information display.
If you push and hold "SET/RESET" button, as the display case,
data may be reset.
MODE
Press the "MODE" button more than 1 second to release the
warning information.
SELECT

SET/RESET

SHTS00Z000200036
GN0230 GENERAL INTRODUCTION (CHASSIS)

(Starter key ON)

The system remembers last display at each function.
Push down "MODE " button
Push button "SET/RESET" at the same time
Push up "SELECT " button
Other : Those displays are broken in automatically

Normal display item

Returns to last display automatically

Operation menu Control menu
Setting cannot be made while driving.
Secondary Water temp
Fuel consumption monitor
Secondary
Voltage
Setting
DPR
Maintenance
Current
Self check
Average
Trip data Setting

Main menu
Clock
Push and hold
for at least 1sec. Language
Units
Operation time Display
Conversion rate

Maintenance

Engine oil
DPR T/M oil
Diff oil
Coolant
Fuel filter
Belt

Water temperature DPR

Turbo
Starter
Alternator
Radiator
Voltage meter Battery
Air dryer
Customize 1
Customize 2
Self check
Customize 3

Interruption display

Push and hold

for at least 1sec.

SHTS00Z000200037
GENERAL INTRODUCTION (CHASSIS) GN0231

3. WARNING DISPLAY
(1) Warning display

Display Warning Display remarks

Engine control system has malfunction. This is

important and must be addressed immediately.

DPR cleaner needs to be manually regenerated.

NOTICE
The display shows DPR MANUAL REGENERATE REQUIRED with
the buzzer sound when DPR cleaner needs to be manually regen-
erated.
(2) Information display

Display Display remarks

Appears when idling is stopped due to emer-

gency.

DPR regenerate on time.

DPR remaining for few minute.

DPR regenerate completed.

DPR regeneration interrupted, push DPR but-

ton to resume.

NOTICE
The DPR system automatically regenerates when the quantity of
soot collected in the DPR cleaner exceeds a specific quantity.
This prevents an abnormal accumulation of soot and keeps the
DPR cleaner in good condition. Use of high-performance catalyst
and an electronically controlled common rail fuel injection sys-
tem has made it possible to burn (regenerate) the soot while
driving.
GN0232 GENERAL INTRODUCTION (CHASSIS)

4. SELF DIAGNOSIS SYSTEM

If the vehicle has fault, display shows the trouble.
(1) Select to "Self check" and push "SET/RESET" button.
(2) Select to "System check" and push "SET/RESET" button, display
shows "No fault" in case of no trouble. If it has trouble, display shows
fault item.
(3) If display shows trouble warning, Immediately get the vehicle checked
and repaired at an authorized Hino dealer.
(4) In case of "Engine malfunction" displayed, push and hold "SELECT"
button for more than 1 sec. until the display shows trouble code.
Push "SELECT" button, display shows another trouble codes, if there
are.
(5) Push and hold "SELECT" button for longer than 1 sec. to display the
SHTS00Z000200044 "Inactive".
(6) Trouble code display

Initial Display Remarks

It has no trouble.

It has trouble.

Yellow background.
It has trouble code, now.
Get the vehicle checked and repaired.

It had trouble code, previously.

5. RESETTING PROCEDURE
EX.Differential oil change period
(1) Scroll up and select "Maintenance" and push "SET/RESET" button.
(2) Scroll up and select the preferred setting item and push "SET/
RESET" button.
(3) Push and hold "SET/RESET" button for longer than 1 sec.
NOTICE
In the case of the other item on trouble code, data may be reset
599999
599000
as the same procedure.
Disable
But, especially in the case of "DPR", push and hold "MODE" and
"SET/RESET" button at the same time for more than 20sec. to
SHTS00Z000200049 reset. (Following to the low, use only at an authorized Hino
dealer.)
GENERAL INTRODUCTION (CHASSIS) GN0233

6. AVAILABLE SETTING ITEMS

Engine oil
T/M oil
Diff oil
Coolant
Fuel filter
Belt
DPR
Turbo
Starter
Alternator
Radiator
Battery
Air dryer
Customize1
Customize2
Customize3
GN0234 GENERAL INTRODUCTION (CHASSIS)

SYMPTOM SIMULATION
EN00Z0002A200003

HINT
The most difficult case in troubleshooting is when no problem symp-
toms occur. In such a case, a thorough problem analysis must be car-
ried out. A simulation of the same or similar conditions and
environment in which the problem occurred in the customer's vehicle
should be carried out. No matter how much skill or experience a tech-
nician has, troubleshooting without confirming the problem symp-
toms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result
of vibration caused by the road during driving, the problem can never
be determined if the symptoms are being checked on a stationary
vehicle or a vehicle with a warmed-up engine. Vibration, heat or water
penetration (moisture) is difficult to reproduce. The symptom simula-
tion tests below are effective substitutes for the conditions and can
be applied on a stationary vehicle. Important points in the symptom
simulation test: In the symptom simulation test, the problem symp-
toms as well as the problem area or parts must be confirmed. First,
narrow down the possible problem circuits according to the symp-
toms. Then, connect the tester and carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal.
Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possi-
ble causes.

1. VIBRATION METHOD: When malfunction seems to occur as a

result of vibration.
Vibrate slightly
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected
to be the cause of the problem, and check whether or not the malfunc-
tion occurs.
NOTICE
Applying strong vibration to relays may open relays
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT
The connector joint and fulcrum of the vibration are the major areas
Shake slightly that should be checked thoroughly.

2. HEAT METHOD: When a malfunction seems to occur when the

area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with
Vibrate a hair dryer or similar device. Check if the malfunction occurs.
slightly NOTICE
Do not heat to more than 60C (140F). Exceeding this tempera-
ture may damage components.
SHTS00Z000200050 Do not apply heat directly to the parts in the ECU.
 GENERAL INTRODUCTION (CHASSIS) GN0235

3. WATER SPRINKLING METHOD: When a malfunction seems to

occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE
Never sprinkle water directly into the engine compartment. Indi-
rectly change the temperature and humidity by spraying water
onto the front of the radiator.
Never apply water directly onto the electronic components.
HINT
If the vehicle has or had a water leakage problem, the leakage may
SHTS00Z000200051 have damaged the ECU or connections. Look for evidence of corro-
sion or short circuits. Proceed with caution during water tests.

4. HIGH ELECTRICAL LOAD METHOD: When a malfunction seems

to occur when electrical load is excessive.
(1) Turn on the heater blower, headlight, rear window defogger and all
other electrical loads. Check if the malfunction reoccurs.
GN0236 GENERAL INTRODUCTION (CHASSIS)

GLOSSARY
DEFINITION OF ABBREVIATION IN THIS MANUAL

LIST OF ABBREVIATION

SAE
SAE TERMS
ABBREVIATIONS

A/C Air conditioner

ABS Anti-lock Brake System

ACC Accessory

AMT Automated Manual Type

ATC After Turbo catalyst

ATF Automatic Transmission Fluid

CA Crank Angle

CAN Controller Area Network

CD-ROM Compact Disc Read Only Memory

CPU Central Processing Unit

dB Decibel

DC Direct Current

D-CAT Diesel-Clean Advanced Technology System

DC motor Direct Current Motor

DCU Dosing Control Unit

DEF Diesel Exhaust Fluid

DPR Diesel Particulate active Reduction System

DSS Driving Support System

ECU Electronic Control Unit

EEPROM Electronically Erasable and Programmable Read Only Memory

EGR Exhaust Gas Recirculation

ELR Emergency Locking Retractor

ENG Engine

ES START Easy and Smooth start system

F/A Front axle

FCCB Fuel Control Cylinder Balance

FCV Fuel Cutoff Valve

FF Shift Feather touch & Finger shift

FL Fusible link

Fr Front

FRP Fiber Reinforces Plastic

 GENERAL INTRODUCTION (CHASSIS) GN0237

SAE
SAE TERMS
ABBREVIATIONS

FUP Front Underrun Protector

GND Ground

GVW Gross Vehicle Weight

Hi High

HINO DX Hino Diagnostic eXplorer

HVAC Heating, Ventilating and Air-Conditioning unit

I.S.C. Idle Speed Control

IC Integrated Circuits

ID Identification

IPD Intelligent Power Device

IS Idle Stop

ISO International Organization for Standardization

JIS Japanese Industrial Standards

LED Light Emitting Diode

LEV Low Emission Vehicle

LH Left Hand

LLC Long Life Coolant

Lo Low

MAX Maximum

MIN Minimum

MS evaporator Multi-rank and Super slim structure evaporator

No Number

NOx Nitrogen Oxide

NMR No load Maximum Revolution

OHC Over Head Camshaft

PC Personal Computer

PCD Pitch Circle Diameter

PCS Pre-Crash Safety

PCV Pump Control Valve

PCV valve Positive Crankcase Ventilation valve

PM Particulate Matter

PPG Glass-fiber-reinforced Polypropylene

PPm Parts Per Million

PS pump Power Steering Pump

GN0238 GENERAL INTRODUCTION (CHASSIS)

SAE
SAE TERMS
ABBREVIATIONS

PVD Physical Vapor Deposit

PWR Power

QE code Quick Response Code

R/A Rear axle

RH Right Hand

SCR Selective Catalytic Reduction

SW Switch

T/M Transmission
 GENERAL INTRODUCTION (CHASSIS) GN0239

GLOSSARY OF SAE AND HINO TERMS

EN00Z00020200005

This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as
well as their HINO equivalents.

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

A/T AUTOMATIC TRANSMISSION Automatic transmission

AAT AMBIENT AIR TEMPERATURE Ambient Air Temperature

ACL AIR CLEANER Air cleaner

ACL Element ACL (Air Cleaner) Element Air Cleaner element

ACL Element AIR CLEANER Element Air Cleaner element

ACL Housing AIR CLEANER Housing Air cleaner body assembly

ACL Housing Cover AIR CLEANER Housing Cover Air Cleaner Housing Cover

AFTERTREATMENT DIESEL EXHAUST

AFTDEF DEF
FLUID

AFTERTREATMENT DIESEL EXHAUST

AFTDEFDU DCU
FLUID DOSING UNIT

AFTERTREATMENT DIESEL OXIDATION

AFTDOC DOC (Diesel Oxidation Catalyst)
CATALYST

AFTDOS AFTERTREATMENT DOSER AFTDOS DEF injector

AFTERTREATMENT DIESEL PARTICULATE

AFTDPF DPR filter
FILTER

Aftertreatment Diesel Particulate Filter Differ-

AFTDPFDP DPR differential pressure
ential Pressure

AFTERTREATMENT EXHAUST GAS TEM-

AFTEGT Exhaust gas temperature
PERATURE

AP ACCELERATOR PEDAL Accelerator pedal

AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor

APP ACCELERATOR PEDAL POSITION Accelerator Pedal Position

CAC CHARGE AIR COOLER Intercooler

CPP Switch CLUTCH PEDAL POSITION Switch Clutch Switch

DCC DIAGNOSTIC CONNECTOR, Cab Diagnosis connector

DCU DIAGNOSTIC CONNECTOR, Underhood Diagnosis connector

DRIVER DRIVER driver

DTC DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code

DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch

EBP EXHAUST BACK PRESSURE Backpressure

EBP EXHAUST BACK PRESSURE Exhaust backpressure

EBP Sensor EXHAUST BACK PRESSURE Sensor Back Pressure Sensor

GN0240 GENERAL INTRODUCTION (CHASSIS)

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

EXHAUST BACK PRESSURE REGULATOR

EBPR Valve Exhaust control valve
Valve

EC ENGINE CONTROL Engine control

ECT ENGINE COOLANT TEMPERATURE Coolant Temperature

ECT ENGINE COOLANT TEMPERATURE Water Temperature

EFT ENGINE FUEL TEMPERATURE Fuel temperature

EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor

EGR EXHAUST GAS RECIRCULATION EGR

EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve

EXHAUST GAS RECIRCULATION TEMPER-

EGRT EGR temperature
ATURE

EXHAUST GAS RECIRCULATION TEMPER-

EGRT Sensor EGR exit temperature sensor
ATURE Sensor

EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature

EI ELECTRONIC IGNITION Ignition coil

EOP ENGINE OIL PRESSURE Oil Pressure

EOT ENGINE OIL TEMPERATURE Oil Temperature

FP FUEL PUMP Fuel pump

FUEL PRESSURE Sensor FUEL PRESSURE Sensor Fuel Pressure sensor

GLOW PLUG GLOW PLUG Glow plug

GND GROUND GROUND

IA INTAKE AIR Air Intake

IA System INTAKE AIR System Air Intake System

IAT INTAKE AIR TEMPERATURE Intake temperature

IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor

IDLE IDLE idle

IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor

IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor

INJ INJECTOR Injector

MAF Sensor MASS AIR FLOW Sensor Air flow sensor

MIL MALFUNCTION INDICATOR LIGHT MIL (Malfunction Indicator Light)

OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor

OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor

PC Solenoid Valve PRESSURE CONTROL Solenoid Valve Solenoid control valves

PCV POS CRANKCASE VENTILATION PCV (Positive Crankcase Vent)

PCV Valve POS CRANKCASE VENTILATION Valve PCV (Positive Crankcase Vent) Valve
 GENERAL INTRODUCTION (CHASSIS) GN0241

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve

PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve

PNP PARK/NEUTRAL POSITION Neutral position

PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch

RFP RAIL FUEL PRESSURE Common rail Pressure

RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor

SPARK PLUG SPARK PLUG Spark plug

SRI SERVICE REMINDER INDICATOR Check engine

ST SCAN TOOL Diagnostic tool

TC TURBOCHARGER Turbocharger

TCC TORQUE CONVERTER CLUTCH Torque Converter

TP Sensor THROTTLE POSITION Sensor Throttle Sensor

TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor

VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor

VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit

VSS VEHICLE SPEED SENSOR Vehicle Speed sensor

 CLUTCH MAIN UNIT (EATON 1401) CL021

CLUTCH MAIN UNIT (EATON 1401)

CL02

CL02-001

CLUTCH ASSEMBLY
(EATON SAS1401).................................... CL02-2
DATA AND SPECIFICATIONS ..........................CL02-2
DESCRIPTION .................................................CL02-2
TROUBLESHOOTING ......................................CL02-3
SPECIAL TOOL ................................................CL02-5
COMPONENT LOCATOR.................................CL02-6
OVERHAUL ......................................................CL02-7

CLUTCH ASSEMBLY
(EATON SOLO1401) ............................... CL02-14
DATA AND SPECIFICATIONS ........................CL02-14
COMPONENT LOCATOR...............................CL02-14
OVERHAUL ....................................................CL02-15
INSPECTION AND REPAIR ...........................CL02-22
CL022 CLUTCH MAIN UNIT (EATON 1401)

CLUTCH ASSEMBLY (EATON SAS1401)

DATA AND SPECIFICATIONS
EN02Z0202I200001

CLUTCH FACING Unit: mm {in.}

Material Sintered metal (Ceramic metal)

Type Dry single plate with damper spring

Inside diameter 222 {8.8}

Outside diameter 350 {13.8}

Thickness 11.5 {0.45}

DESCRIPTION
EN02Z0202C100001

2 1

SHTS02Z020200001

1 Clutch disc 2 Clutch cover

 CLUTCH MAIN UNIT (EATON 1401) CL023

TROUBLESHOOTING
EN02Z0202F300001

Symptom Possible cause Remedy/Prevention

Clutch dragging. Clutch disc distorted or warped. Replace clutch disc.
Transmission input shaft worn. Replace input shaft and check clutch
hub for excessive wear. If worn,
replace disc. Check flywheel housing
alignment.
Excessive clutch control parts wear. Replace control parts.
Clutch control parts not functioning Replace control parts.
properly.
Improper clutch control adjustment. Adjust clutch control.
Clutch disc assembly too thick. Replace clutch disc.
Clutch slipping. Release lever and release bearing Adjust clearance.
clearance incorrectly adjusted.
Clutch disc facing gummed with oil or Replace disc assembly.
grease.
Release bearing worn. Replace bearing.
Clutch pedal free-play incorrectly Adjust free-play.
adjusted.
Compression spring weak. Replace cover assembly.
Clutch facing worn. Replace disc assembly.
Failing to remove plate from the clutch Remove plate.
pressure plate assembly.
Driver riding clutch pedal. Do not ride the clutch pedal.
Vehicle vibrates when starting. Improper engine idling. Adjust idling.
Clutch control incorrectly adjusted. Adjust clutch control
Clutch disc facing gummed with oil or Replace disc assembly.
grease.
Glazed flywheel friction surface. Deglaze flywheel surface with coarse
emery cloth, stroking parallel to
machining lines.
Clutch disc distorted or warped. Replace disc.
Improper clutch cover tightening. Tighten bolts.
Flywheel housing misalignment. Replace flywheel housing.
Abnormal noise in transmission. Malfunction of engine. Tune up engine.
Improper clutch disc used. Replace proper clutch disc.
Trouble in transmission. Check transmission.
The engine idle speed is low. Increase the idle speed.
CL024 CLUTCH MAIN UNIT (EATON 1401)

Symptom Possible cause Remedy/Prevention

Noisy clutch. Release bearing worn or dried. Replace release bearing.
Pilot bearing worn or dried. Replace pilot bearing.
Clutch disc distorted or warped. Replace clutch disc.
Flywheel housing misalignment. Replace flywheel housing.
Transmission input shaft or clutch disc Clean and lubricate or replace.
spline worn.
Insufficient lubrication of pedal and its Lubricate.
accessories.
Insufficient lubrication of release shaft Lubricate.
and release bearing hub.
Transmission input shaft retainer Clean or replace if rusted.
rusted or soiled.
Clutch pedal free-play incorrectly Adjust free-Play.
adjusted.
Clutch pedal cannot be depressed. Clutch control incorrectly adjusted. Adjust clutch control.
Insufficient lubricant release shaft and Lubricate.
release bearing hub.
Change in clutch pedal give. Air trapped in clutch fluid. Bleed air.
 CLUTCH MAIN UNIT (EATON 1401) CL025

SPECIAL TOOL
EN02Z0202K100001

Prior to starting a clutch overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

CLUTCH PILOT BEARING

S0965-01970
PULLER

S0942-01442 SLIDING HAMMER

S0966-21410 CLUTCH ALIGNING ARBOR

S0940-91200 CRANKING TOOL

CL026 CLUTCH MAIN UNIT (EATON 1401)

COMPONENT LOCATOR
EN02Z0202D100001

SHTS02Z020200006

1 Clutch cover 3 Adjusting screw

2 Clutch disc 4 Bolt

Tightening torque Unit: Nm {kgfcm, lbfft}

A 50-64 {510-655, 37-47}
 CLUTCH MAIN UNIT (EATON 1401) CL027

OVERHAUL
EN02Z0202H200001

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO

PREVENT DAMAGE TO THE BEARING AND DISCS.
1.Remove the
transmission
2. INSTALL TWO WOODEN SPACERS 1"-1-1/2" THICK BETWEEN
RELEASE BEARING AND COVER ASSEMBLY.

3. REMOVE THE CLUTCH FROM THE FLYWHEEL.

SHTS02Z020200007

IMPORTANT POINT - INSPECTION AND REPLACE-

MENT

1. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)

SHTS02Z020200008

(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.

SHTS02Z020200009

2. CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY

A. WORN COMPONENTS:
Check cross-shafts (1) Cross-shafts and bushings
and bushings
NOTICE
Excessive wear at these points can cause a side loading condition.
Also, inspect the remaining pivot points of the linkage for excessive
wear.

SHTS02Z020200010
CL028 CLUTCH MAIN UNIT (EATON 1401)

(2) Release yoke fingers

B.
Check release yoke
fingers

SHTS02Z020200011

(3) Splines on the input shaft

D. NOTICE
Check splines on the Any wear on the splines will prevent the newly installed driven discs
input shaft from sliding freely, thus causing poor release (clutch drag). Select a
disc out of the new installation and slide it full length on the transmis-
sion splines. This will detect a twisted input shaft. Replace input shaft
if disc does not freely slide.

(4) Smooth area of input shaft

SHTS02Z020200012

(5) Mating surfaces

NOTICE
Inspect the mating surfaces of both the transmission bell housing and
the flywheel housing. Any appreciable wear on either housing will
cause misalignment. Most wear will occur between the 3 and 8 o'clock
positions.
E. Replace housings if worn.
Check smooth
area of input
shaft for wear /
roughness

SAPH02Z080200001
 CLUTCH MAIN UNIT (EATON 1401) CL029

IMPORTANT POINT - MOUNTING

1.
Insert 2 guide studs 1. INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS
INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL.
Guide studs

SHTS02Z020200014

2. INSTALL THE DISC BY INSERTING THE ALIGNING TOOL

2. THROUGH THE DISC SPLINES AND THEN INTO THE PILOT
Insert the aligning BEARING.
tool through release SST: Clutch Aligning Arbor (S0966-21410)
bearing sleeve
NOTICE
Make sure the side marked "Pressure Plate Side" faces the pressure
plate.

Aligning tool 3. WITH THE ALIGNING TOOL STILL IN PLACE, CAREFULLY SLIDE
THE CLUTCH ASSEMBLY OVER THE ALIGNING TOOL AND THE
TWO (2) GUIDE STUDS WITH THE KWIK-ADJUST ALIGNED WITH
SHTS02Z020200015
THE ACCESS HOLE IN THE BELL HOUSING.

4. INSTALL LOCKWASHER AND SIX (6) 3/8" x 16 UNC GRADE 5 OR

BETTER MOUNTING BOLTS AND HAND TIGHTEN.
2 (1) Remove the two (2) guide studs and replace with the remaining
6
7 mounting bolts with lockwasher. Using a torque wrench, progressively
tighten the eight (8) mounting bolts using the following crisis-cross
4 3 pattern. Starting at lower left.
Remove the shipping blocks from between the release bearing and
8
5 the cover assembly.
4. 1 Tightening Torque:
Place disc on aligning
tool properly 50-64 Nm{510-665 kgfcm, 37-47 lbfft}
orientated

SHTS02Z020200016
! CAUTION
Failure to tighten these bolts in this manner can:
Prevent the clutch cover from "centering" into the pilot area of
the flywheel.
Cause permanent damage to the clutch cover (i.e. become
cracked or broken).
Cause the clutch assembly to be out-of balance with the fly-
wheel.
CL0210 CLUTCH MAIN UNIT (EATON 1401)

5. REMOVE THE ALIGNING TOOL.

5.
Remove aligning tool

SHTS02Z020200017

6. SHIFT THE TRANSMISSION INTO GEAR.

Shift into gear

6.
Shift transmission into gear

SHTS02Z020200018

7. POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE

TO AND ALIGNED WITH THE ENGINE.

7.
Align the transmission
to the engine

SHTS02Z020200019
 CLUTCH MAIN UNIT (EATON 1401) CL0211

8. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE

OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES
OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH
EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST
ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP
POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE
BEARING HOUSING INTO THEIR FINAL POSITION.
! CAUTION
Do not use the cross-shaft release lever (or a pipe over it) to pull
the transmission into its final position.
Do not excessively force the transmission into the clutch assem-
bly or engine housing. If it does not enter freely, investigate the
cause of the problem and make any necessary changes.
If the input shaft will not slide into the discs, they may need to be
repositioned. Do not let the transmission drop or hang unsup-
ported in the driven discs.
This can cause the discs to become distorted and the clutch will
8. not release.
Mesh input shaft and
disc (s) by rotating
output shaft 9. INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE
TO THE PROPER SPECIFICATION.
Tightening Torque:
37.5-48.5 Nm{382-494 kgfcm, 28-35 lbfft}
SHTS02Z020200020

IMPORTANT POINT - ADJUSTMENT

1. CHECK LOCATION OF THE KWIK-ADJUSTER

(1) Remove the cover of inspection hole at the bottom of the clutch hous-
ing.

SHTS02Z020200021

(2) If the Kwik-Adjuster exists in approachable position, adjustment can

Kwik-adjuster be performed.
If position of the Kwik-Adjuster cannot be identified, perform following
procedure.

Socket wrench

SHTS02Z020200022
CL0212 CLUTCH MAIN UNIT (EATON 1401)

2. ARRANGE THE KWIK-ADJUSTER

Crank (1) Set SST the crank pulley.
pulley
SST:
SST
Cranking Tool (S0940-91200)

Torque
wrench

SHTS02Z020200023

(2) Turn the crank pulley till the Kwik-Adjuster matches the inspection
Kwik-adjuster hole.

SHTS02Z020200024

3. ADJUSTING PROCEDURES
(1) Adjust the release bearing position;
When the clutch disc is worn (pedal play less than limit)
Pedal play limit: 35 mm {1.38 in.}
When the clutch disc replaced.

1 STEP: Master cylinder (2) Adjust the free travel by release cylinder push rod only;
push rod play When the clutch disc or control linkage is replaced.
NOTICE
2 STEP: Clutch pedal play
Release cylinder
The above adjusting should be made after adjusting the release bear-
push rod play ing position.
SHTS02Z020200025

(3) Manual Adjust: Kwik-Adjust

Depress adjusting bolt and rotate.
Kwik-Adjust will re-engage at 1/3 of a turn.
NOTICE
Adjausting bolt
(push toward Open-end wrenches are not recommended.
clutch) Internal adjustments are performed with pedal down (clutch
released).
Kwik-adjust

SAPH02Z080200006
 CLUTCH MAIN UNIT (EATON 1401) CL0213

4. ADJUST THE RELEASE BEARING POSITION

(1) Set 1.75" (44 mm) dimension: With pedal down, turn adjusting ring to
obtain approximately 1.75" (44 mm). Turning the adjusting ring clock-
wise moves the release bearing toward the transmission. Turning the
adjusting ring counterclockwise moves the release bearing toward the
Pedal Pedal
UP DOWN engine.
(2) Check release travel dimensions with release yoke rotated toward
release bearing, eliminating excess play in system. Having set this,
depress pedal down fully releasing clutch and check release travel to
settings shown.
NOTICE
SHTS02Z020200027 It may be necessary to reduce the 1.75" (44 mm) settings to be able to
achieve 0.500"-0.562" (13-14 mm) travel on some models of transmis-
sions.

5. ADJUST THE FREE TRAVEL

(1) Remove the return spring.
(2) Loosen the lock nut and turn the push rod counterclockwise until the
release bearing contacts the release lever plate or release lever.

Push rod

0
Master cylinder

SHTS02Z020200028

(3) Turn the push rod clockwise about 3 1/3 turns.

Standard: Clearance between release bearing and
release yoke: 3.18 mm {0.125 in.}

(4) Tighten the lock nut.

Lock nut

3.18

SHTS02Z020200029
CL0214 CLUTCH MAIN UNIT (EATON 1401)

CLUTCH ASSEMBLY (EATON SOLO1401)

DATA AND SPECIFICATIONS
EN02Z0202I200002

CLUTCH FACING Unit: mm {in.}

Material Sintered metal (Ceramic metal)

Type Dry single plate with damper spring

Inside diameter 222 {8.8}

Outside diameter 350 {13.8}

Thickness 11.5 {0.45} Adjustment-Free

COMPONENT LOCATOR
EN02Z0202D100002

Shipping bolts (4)

to be removed
at installation

Wear indicator

Section B-B

SHTS02Z020200030

1 Clutch cover 3 Bolt

2 Clutch disc

Tightening torque Unit: Nm {kgfcm, lbfft}

A 50-64 {510-655, 37-47}
 CLUTCH MAIN UNIT (EATON 1401) CL0215

OVERHAUL
EN02Z0202H200002

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO

PREVENT DAMAGE TO THE BEARING AND DISCS.
1.
Remove the NOTICE
transmission If a SOLO Clutch is to be removed and reinstalled on the flywheel, four
(4) shipping bolts must be installed prior to unbolting the clutch (3/8"
x 16 UNC x 1-1/4").

SHTS02Z020200031

2. LOCATE FOUR (4) 3/8" x 16 UNC x 1 - 1/4", HEX HEAD MACHINE

SCREWS. INSTALL THEM IN THE 4 COVER HOLES, TURNING
THEM ONE COMPLETE TURN AFTER THEY CONTACT THE
COVER.

2. 3. REMOVE THE CLUTCH FROM THE FLYWHEEL.

Located 4 hex head
machine screws

(4) 3/8" x 16 x 1-1/4" UNC

SHTS02Z020200032

IMPORTANT POINT - INSPECTION AND REPLACE-

MENT

1. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)

SHTS02Z020200033
CL0216 CLUTCH MAIN UNIT (EATON 1401)

(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.

2. CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY

WORN COMPONENTS.

SHTS02Z020200034

(1) Cross-shafts and bushings

A. NOTICE
Check cross-shaftsand Excessive wear at these points can cause a side loading condition.
and bushings
Also, inspect the remaining pivot points of the linkage for excessive
wear.

SAPH02Z080200002

(2) Release yoke fingers

B.
Check release
yoke fingers

SAPH02Z080200003

(3) Splines on the input shaft

D. NOTICE
Check sptrings on the
Any wear on the splines will prevent the newly installed driven discs
input shaft
from sliding freely, thus causing poor release (clutch drag). Select a
disc out of the new installation and slide it full length on the transmis-
sion splines. This will detect a twisted input shaft. Replace input shaft
if disc does not freely slide.

SAPH02Z080200004
 CLUTCH MAIN UNIT (EATON 1401) CL0217

(4) Smooth area of input shaft

(5) Mating surfaces
NOTICE
Inspect the mating surfaces of both the transmission bell housing and
the flywheel housing. Any appreciable wear on either housing will
cause misalignment. Most wear will occur between the 3 and 8 o'clock
E. positions.
Check smooth Replace housings if worn.
area of input
shaft for wear /
roughness

SAPH02Z080200005

IMPORTANT POINT - MOUNTING

1.
Insert 2 guide studs 1. INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS
INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL.
Guide studs

SHTS02Z020200039

2. INSTALL THE DISC BY INSERTING THE ALIGNING TOOL

2. THROUGH THE DISC SPLINES AND THEN INTO THE PILOT
Insert the aligning BEARING.
tool through release SST: Clutch Aligning Arbor (S0966-21410)
bearing sleeve
NOTICE
Make sure the side marked "Pressure Plate Side" faces the pressure
plate.

Aligning tool 3. WITH THE ALIGNING TOOL STILL IN PLACE, CAREFULLY SLIDE
THE CLUTCH ASSEMBLY OVER THE ALIGNING TOOL AND THE
TWO (2) GUIDE STUDS.
SHTS02Z020200040

4. INSTALL LOCKWASHER AND SIX (6) 3/8" x 16 UNC MOUNTING

BOLTS HAND TIGHTEN.
2 (1) Remove the two (2) guide studs and replace with the remaining
6
7 mounting bolts with lockwasher. Using a torque wrench, progressively
tighten the eight (8) mounting bolts using the following crisis-cross
4 3 pattern. Starting at lower left.
Tightening Torque:
8
5 50-64 Nm{510-665 kgfcm, 37-47 lbfft}
4. 1
Place disc on aligning
tool properly ! CAUTION
orientated Failure to tighten these bolts in this manner can:
SHTS02Z020200041 Prevent the clutch cover from "centering" into the pilot area of
the flywheel.
Cause permanent damage to the clutch cover (i.e. become
cracked or broken).
Cause the clutch assembly to be out-of balance with the fly-
wheel.
CL0218 CLUTCH MAIN UNIT (EATON 1401)

(2) Remove the four (4) gold colored shipping bolts in a criss-cross pat-
tern.
NOTICE
Save these four (4) bolts for future use in case you need to remove,
then reinstall the SOLO Clutch.

5. REMOVE THE ALIGNING TOOL.

5.
Remove aligning tool

SHTS02Z020200042

6. SHIFT THE TRANSMISSION INTO GEAR.

Shift into gear

6.
Shift transmission into gear

SHTS02Z020200043

7. POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE

TO AND ALIGNED WITH THE ENGINE.

7.
Align the transmission
to the engine

SHTS02Z020200044
 CLUTCH MAIN UNIT (EATON 1401) CL0219

8. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE

OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES
OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH
EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST
ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP
POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE
BEARING HOUSING INTO THEIR FINAL POSITION.
! CAUTION
Do not use the cross-shaft release lever (or a pipe over it) to pull
the transmission into its final position. Doing so may release the
clutch and "overstroke" the release bearing. The SOLO will
incorrectly "set" the release bearing position too close to the
transmission and cause the wear indication tab to move to 1/3-1/
2 the distance towards the "REPLACE" position.
Do not excessively force the transmission into the clutch assem-
bly or engine housing. If it does not enter freely, investigate the
cause of the problem and make any necessary changes.
8. If the input shaft will not slide into the discs, they may need to be
Mesh input shaft and repositioned. If the clutch is to be unbolted from the flywheel, re-
disc (s) by rotating install the shipping bolts and tighten one turn past contact with
output shaft the clutch. Now the installation shaft can be installed to reposi-
tion the discs and the clutch bolts re-torqued. Remove the ship-
ping bolts to clamp the discs.
Do not let the transmission drop or hang unsupported in the
SHTS02Z020200045
driven discs.
This can cause the discs to become distorted and the clutch will
not release.

9. INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE

TO THE PROPER SPECIFICATION.
Tightening Torque:
37.5-48.5 Nm{382-494 kgfcm, 28-35 lbfft}
CL0220 CLUTCH MAIN UNIT (EATON 1401)

IMPORTANT POINT-SET-UP

1. ADJUST LINKAGE
(1) Remove the return spring.
(2) Loosen the lock nut and turn the push rod counterclockwise until the
release bearing contacts the release lever plate or release lever.

Push rod

0 Master cylinder

SHTS02Z020200046

(3) Fully press the pedal up to 5 times to move the release bearing
slightly closer to the transmission and gain free-play in the cab.

Stroke
pedal
5 times

SHTS02Z020200047

2. ADJUST THE FREE TRAVEL

(1) Turn the push rod counterclockwise until the release bearing contacts
the release lever plate or release lever.

Push rod

0 Master cylinder

SHTS02Z020200046

(2) Turn the push rod clockwise about 3 1/3 turns.

Standard: Clearance between release bearing and
release yoke: 3.18 mm {0.125 in.}

(3) Tighten the lock nut.

Lock nut

3.18

SHTS02Z020200048
 CLUTCH MAIN UNIT (EATON 1401) CL0221

IMPORTANT POINT-CHECK WEAR INDICATOR

1. REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM

OF THE CLUTCH HOUSING.

2. CHECK WEAR INDICATOR

Reflects clutch wear and indicates when it is time to replace clutch.
When replacing clutch, should change clutch disc together with clutch
cover.

New
Replace

SAPH02Z080200007
CL0222 CLUTCH MAIN UNIT (EATON 1401)

INSPECTION AND REPAIR

EN02Z0202H300001

EATON SAS1401 and SOLO1401 Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Clutch facing thickness 11.43 8.26 Replace disc Measure

{0.45} {0.33} assembly.

Clutch disc misalignment 0-0.38 0.38 Replace. Measure

{0-0.0149} {0.0149}

Oily facings, Loose rivets, Replace disc Visual check

Broken or loose damper assembly, if nec-
springs essary.

Clearance between clutch 0.05-0.15 0.5 Replace the Measure

disc hub and transmission {0.0020-0.0059} {0.020} clutch disc or the
Clutch disk
input shaft spline transmission
input shaft. Clearance

Input
Shaft

Pressure plate misalign- 0-0.102 0.76 Replace the Measure

ment {0-0.040} {0.029} clutch cover
assembly

Pressure plate friction sur- Replace the Visual check

face scoring or heat crack- clutch cover
ing assembly.
NOTICE
Regrinding of the
pressure plate is
not possible.

Flywheel misalignment 0.05 1.0 {0.039} Replace. Measure

{0.0020}
or less
 CLUTCH MAIN UNIT (EATON 1401) CL0223

Inspection item Standard Limit Remedy Inspection procedure

Flywheel friction surface Grind limit Regrind the fric- Visual check
scoring or heat cracking 1.0 {0.039} tion surface or
Deflection replace, if neces-
limit sary.
0.04 NOTICE
{0.00157} Do not grind the
flywheel over the
limit.

Flywheel misalignment 0.15 Regrind the fric- Measure

{0.0059} tion surface or
replace.

Pilot bearing improper Replace, if neces- Visual check

rotation sary.
CL0224 CLUTCH MAIN UNIT (EATON 1401)

LUBRICATION (EATON SAS1401 and SOLO1401)

1. RELEASE BEARING
(1) The cast iron bearing housing will be equipped with either a standard
grease fitting or a lube tube extension. If a lube tube is not present, it
is necessary to remove the inspection cover to gain access to the
grease fitting. Apply grease until it purges from the rear of the hous-
ing.

2. RELEASE BEARING WEAR PADS

(1) Where the release fork contacts the bearing housing; there are small
hardened steel pads. Apply a small amount of grease to the wear
pads where the clutch release fork contacts.

3. CROSS-SHAFT BUSHINGS
(1) Lubricate both the left and the right cross-shaft bushings.

4. PILOT BEARING
(1) The pilot bearing inside the flywheel is a sealed for life bearing and
requires no lubrication.

RECOMMENDED LUBRICATION
Use a lithium soap base E.P. (Extreme Pressure) grease with a minimum of
+325 degree F operating range. It must meet the N.L.G.I.'s Grade 2 or 3
specs.
! CAUTION
Incorrect grease and improper lube procedures will cause bearing
failures, bushing wearout, yoke tip and bearing wear pad wear.

Recommended Lubrication

Supplier Product Supplier Product

American Oil Co. Amoco Uthium-M.P. Grease Texaco Multifak #2

City Service Co. Citgo Premium Lithium Grease #2 Shell Oil Co. Retinax A

Fiske Refining Co. Lubriplate 630-2 Shell Oil Co. Aivania #2

Keystone Lubricating Co. #81 Ught *Chevron Oil Co. S.R.I. 1~

Mobil Mobilgrease M.P. *Texaco Premium RB

Humble Oil Co. Udok 2 *Exxon Unirex N3

Atlantic Richfield Co. Arco M.P.

* Approved for vendor prepack, other greases listed are for service only.
 CLUTCH MAIN UNIT (EATON 1402) CL021

CLUTCH MAIN UNIT (EATON 1402)

CL02

CL02-002

CLUTCH ASSEMBLY
(EATON SAS1402).................................... CL02-2
DATA AND SPECIFICATIONS ..........................CL02-2
DESCRIPTION .................................................CL02-2
TROUBLESHOOTING ......................................CL02-3
SPECIAL TOOL ................................................CL02-5
COMPONENT LOCATOR.................................CL02-6
OVERHAUL ......................................................CL02-7

CLUTCH ASSEMBLY
(EATON SOLO1402) ............................... CL02-16
DATA AND SPECIFICATIONS ........................CL02-16
COMPONENT LOCATOR...............................CL02-16
OVERHAUL ....................................................CL02-17
INSPECTION AND REPAIR ...........................CL02-27
CL022 CLUTCH MAIN UNIT (EATON 1402)

CLUTCH ASSEMBLY (EATON SAS1402)

DATA AND SPECIFICATIONS
EN02Z0202I200001

CLUTCH FACING Unit: mm {in.}

Material Sintered metal (Ceramic metal)

Type Dry two plate with damper spring

Inside diameter 222 {8.8}

Outside diameter 350 {13.8}

Thickness 11.5 {0.45}

DESCRIPTION
EN02Z0202C100001

3 1 2 1

SHTS02Z020200001

1 Clutch disc 3 Clutch cover

2 Intermediate plate
 CLUTCH MAIN UNIT (EATON 1402) CL023

TROUBLESHOOTING
EN02Z0202F300001

Symptom Possible cause Remedy/Prevention

Clutch dragging. Clutch disc distorted or warped. Replace clutch disc.
Transmission input shaft worn. Replace input shaft and check clutch
hub for excessive wear. If worn,
replace disc. Check flywheel housing
alignment.
Excessive clutch control parts wear. Replace control parts.
Clutch control parts not functioning Replace control parts.
properly.
Improper clutch control adjustment. Adjust clutch control.
Clutch disc assembly too thick. Replace clutch disc.
Clutch slipping. Release lever and release bearing Adjust clearance.
clearance incorrectly adjusted.
Clutch disc facing gummed with oil or Replace disc assembly.
grease.
Release bearing worn. Replace bearing.
Clutch pedal free-play incorrectly Adjust free-play.
adjusted.
Compression spring weak. Replace cover assembly.
Clutch facing worn. Replace disc assembly.
Failing to remove plate from the clutch Remove plate.
pressure plate assembly.
Driver riding clutch pedal. Do not ride the clutch pedal.
Vehicle vibrates when starting. Improper engine idling. Adjust idling.
Clutch control incorrectly adjusted. Adjust clutch control.
Clutch disc facing gummed with oil or Replace disc assembly.
grease.
Glazed flywheel friction surface. Deglaze flywheel surface with coarse
emery cloth, stroking parallel to
machining lines.
Clutch disc distorted or warped. Replace disc.
Improper clutch cover tightening. Tighten bolts.
Flywheel housing misalignment. Replace flywheel housing.
Abnormal noise in transmission. Malfunction of engine. Tune up engine.
Improper clutch disc used. Replace proper clutch disc.
Trouble in transmission. Check transmission.
The engine idle speed is low. Increase the idle speed.
CL024 CLUTCH MAIN UNIT (EATON 1402)

Symptom Possible cause Remedy/Prevention

Noisy clutch. Release bearing worn or dried. Replace release bearing.
Pilot bearing worn or dried. Replace pilot bearing.
Clutch disc distorted or warped. Replace clutch disc.
Flywheel housing misalignment. Replace flywheel housing.
Transmission input shaft or clutch disc Clean and lubricate or replace.
spline worn.
Insufficient lubrication of pedal and its Lubricate.
accessories.
Insufficient lubrication of release shaft Lubricate.
and release bearing hub.
Transmission input shaft retainer Clean or replace if rusted.
rusted or soiled.
Clutch pedal free-play incorrectly Adjust free-Play.
adjusted.
Clutch pedal cannot be depressed. Clutch control incorrectly adjusted. Adjust clutch control.
Insufficient lubricant release shaft and Lubricate.
release bearing hub.
Change in clutch pedal give. Air trapped in clutch fluid. Bleed air.
 CLUTCH MAIN UNIT (EATON 1402) CL025

SPECIAL TOOL
EN02Z0202K100001

Prior to starting a clutch overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

CLUTCH PILOT BEARING

S0965-01970
PULLER

S0942-01442 SLIDING HAMMER

S0966-21420 CLUTCH ALIGNING ARBOR

S0940-91200 CRANKING TOOL

CL026 CLUTCH MAIN UNIT (EATON 1402)

COMPONENT LOCATOR
EN02Z0202D100001

5-A

2 1

SHTS02Z020200006

1 Clutch cover 4 Adjusting screw

2 Clutch disc 5 Bolt
3 Intermediate plate

Tightening torque Unit: Nm {kgfcm, lbfft}

A 50-64 {510-655, 37-47}
 CLUTCH MAIN UNIT (EATON 1402) CL027

OVERHAUL
EN02Z0202H200001

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO

PREVENT DAMAGE TO THE BEARING AND DISCS.
1.
Remove the
transmission 2. INSTALL TWO WOODEN SPACERS 1"-1-1/2" THICK BETWEEN
RELEASE BEARING AND COVER ASSEMBLY.

3. REMOVE THE CLUTCH FROM THE FLYWHEEL.

SHTS02Z020200007

IMPORTANT POINT - INSPECTION AND REPLACE-

MENT

1. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)

SHTS02Z020200008

(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.

SHTS02Z020200009

2. CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY

A. WORN COMPONENTS:
Check cross-shafts (1) Cross-shafts and bushings
and bushings
NOTICE
Excessive wear at these points can cause a side loading condition.
Also, inspect the remaining pivot points of the linkage for excessive
wear.

SAPH02Z080200001
CL028 CLUTCH MAIN UNIT (EATON 1402)

(2) Release yoke fingers

B.
Check release yoke
fingers

SAPH02Z080200002

(3) Splines on the input shaft

D. NOTICE
Check splines on the Any wear on the splines will prevent the newly installed driven discs
input shaft from sliding freely, thus causing poor release (clutch drag). Select a
disc out of the new installation and slide it full length on the transmis-
sion splines. This will detect a twisted input shaft. Replace input shaft
if disc does not freely slide.

SAPH02Z080200003

(4) Smooth area of input shaft

(5) Mating surfaces
NOTICE
Inspect the mating surfaces of both the transmission bell housing and
the flywheel housing. Any appreciable wear on either housing will
cause misalignment. Most wear will occur between the 3 and 8 o'clock
E. positions.
Check smooth Replace housings if worn.
area of input
shaft for wear /
roughness

SAPH02Z080200004
 CLUTCH MAIN UNIT (EATON 1402) CL029

IMPORTANT POINT - MOUNTING

1.
Insert 2 guide studs 1. INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS
INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL.
Guide studs

SHTS02Z020200014

2. INSTALL THE FRONT DISC BY INSERTING THE ALIGNING TOOL

2. THROUGH THE DISC SPLINES AND THEN INTO THE PILOT
Insert the aligning BEARING.
tool through release SST:
bearing sleeve Clutch Aligning Arbor (S0966-21420)

NOTICE
Make sure the side marked "Flywheel" faces the flywheel.

Aligning tool

SHTS02Z020200015

3. INSTALL THE INTERMEDIATE PLATE ASSEMBLY OVER THE

TWO (2) GUIDE STUDS AND SLIDE IT FORWARD UNTIL IT
TOUCHES THE FLYWHEEL.
NOTICE
Make sure the side marked "Pressure Plate Side" is facing the pres-
sure plate (the drive straps must face the pressure plate).

3.
Place intermediate
plate properly
orientated

SHTS02Z020200016
CL0210 CLUTCH MAIN UNIT (EATON 1402)

4. REMOVE THE ALIGNING TOOL AND INSTALL IT THROUGH THE

SPLINES OF THE REAR DISC, AND INSERT THE ALIGNING
TOOL THROUGH THE FRONT DISC AND ALSO THE PILOT
BEARING.
NOTICE
Make sure the side of the disc marked "Pressure Plate Side" is facing
Buttons the pressure plate. As you complete this step, ensure that the ceramic
buttons align with each other as closely as possible. Doing so will aid
the function of the positive separator pins (roll pins).

4.
Remove aligning tool

SHTS02Z020200017

5. WITH THE ALIGNING TOOL STILL IN PLACE, SLIDE THE COVER

ASSEMBLY OVER BOTH THE ALIGNING TOOL AND THE TWO (2)
GUIDE STUDS UNTIL IT RESTS AGAINST THE INTERMEDIATE
PLATE ASSEMBLY.

5.
Slide cover assembly
over aligning tool
and guide studs

SHTS02Z020200018
 CLUTCH MAIN UNIT (EATON 1402) CL0211

6. INSTALL LOCKWASHER AND SIX (6) 3/8" x 16 UNC MOUNTING

BOLTS HAND TIGHTEN.
2 (1) Remove the two (2) guide studs and replace with the remaining
6
7 mounting bolts with lockwasher. Using a torque wrench, progressively
tighten the eight (8) mounting bolts using the following criss-cross pat-
4 3 tern. Starting at lower left.
Tightening Torque:
8
5 50-64 Nm{510-665 kgfcm, 37-47 lbfft}
6. 1
Place disc on aligning ! CAUTION
tool properly orientated
Failure to tighten these bolts in this manner can:
Prevent the clutch cover from "centering" into the pilot area of
SHTS02Z020200019
the flywheel.
Cause permanent damage to the clutch cover (i.e. become
cracked or broken).
Cause the clutch assembly to be out-of balance with the fly-
wheel.

7. REMOVE THE ALIGNING TOOL.

7.
Remove aligning tool

SHTS02Z020200020

8. USING A 1/4" (6 mm) DIAMETER FLAT NOSE PUNCH, LIGHTLY

TAP EACH OF THE FOUR (4) POSITIVE SEPARATOR PINS
TOWARD THE FLYWHEEL. PERFORMING THIS STEP WILL VER-
IFY THAT ALL FOUR (4) PINS ARE FLUSH AGAINST THE FLY-
WHEEL.

! CAUTION
Failure to perform this step properly may cause the clutch to drag
(clutch does not release). Excessive force can damage the pins and
cause a release problem
SHTS02Z020200021 NOTICE
The four (4) pins can also be set through the inspection opening of
the transmission bell housing if they were not to set prior to transmis-
sion installation.
CL0212 CLUTCH MAIN UNIT (EATON 1402)

Top view
Access hole

Roll pin

Clutch cover

SHTS02Z020200022

Side view
Flywheel
Roll pin (Qty.4)
Access hole
Gap
0.20"-0.30"
(0.5-0.8mm)

Clutch cover

SHTS02Z020200023

9. SHIFT THE TRANSMISSION INTO GEAR.

Shift into gear

9.
Shift transmission into gear

SHTS02Z020200024

10. POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE

TO AND ALIGNED WITH THE ENGINE.

10.
Align the transmission
to the engine

SHTS02Z020200025
 CLUTCH MAIN UNIT (EATON 1402) CL0213

11. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE

OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES
OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH
EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST
ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP
POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE
BEARING HOUSING INTO THEIR FINAL POSITION.
! CAUTION
Do not use the cross-shaft release lever (or a pipe over it) to pull
the transmission into its final position.
Do not excessively force the transmission into the clutch assem-
bly or engine housing. If it does not enter freely, investigate the
cause of the problem and make any necessary changes.
If the input shaft will not slide into the discs, they may need to be
repositioned. Do not let the transmission drop or hang unsup-
ported in the driven discs.
This can cause the discs to become distorted and the clutch will
11. not release.
Mesh input shaft and
disc (s) by rotating
output shaft 12. INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE
TO THE PROPER SPECIFICATION.
Tightening Torque:
37.5-48.5 Nm{382-494 kgfcm, 28-35 lbfft}
SHTS02Z020200026

IMPORTANT POINT - ADJUSTMENT

1. CHECK LOCATION OF THE KWIK-ADJUSTER

(1) Remove the cover of inspection hole at the bottom of the clutch hous-
ing.

SHTS02Z020200027

(2) If the Kwik-Adjuster exists in approachable position, adjustment can

Kwik-adjuster be performed.
If position of the Kwik-Adjuster cannot be identified, perform following
procedure.

Socket wrench

SHTS02Z020200028
CL0214 CLUTCH MAIN UNIT (EATON 1402)

2. ARRANGE THE KWIK-ADJUSTER

Crank pulley (1) Set SST the crank pulley.
SST:
SST Cranking Tool (S0940-91200)

Torque
wrench

SHTS02Z020200029

(2) Turn the crank pulley till the Kwik-Adjuster matches the inspection
Kwik-adjuster hole.

SHTS02Z020200030

3. ADJUSTING PROCEDURES
(1) Adjust the release bearing position;
When the clutch disc is worn (pedal play less than limit)
Pedal play limit; 35 mm {1.38 in.}
When the clutch disc replaced.

1 STEP: Master cylinder (2) Adjust the free travel by release cylinder push rod only;
push rod play When the clutch disc or control linkage is replaced.
NOTICE
2 STEP: Clutch pedal play
Release cylinder
The above adjusting should be made after adjusting the release bear-
push rod play ing position.
SHTS02Z020200031

(3) Manual Adjust: Kwik-Adjust

Depress adjusting bolt and rotate.
Kwik-Adjust will re-engage at 1/3 of a turn.
NOTICE
Adjusting
bolt (push Open-end wrenches are not recommended.
toward Internal adjustments are performed with pedal down (clutch
clutch) released).
Kwik-
adjust

SAPH02Z080200005
 CLUTCH MAIN UNIT (EATON 1402) CL0215

4. ADJUST THE RELEASE BEARING POSITION

(1) Set 0.75" (19 mm) dimension: With pedal down, turn adjusting ring to
obtain approximately 0.75" (19 mm). Turning the adjusting ring clock-
wise moves the release bearing toward the transmission. Turning the
Pedal Pedal adjusting ring counterclockwise moves the release bearing toward the
Clutch UP DOWN
engine.
Transmission
MIN. 1.25
(2) Check release travel dimensions with release yoke rotated toward
0.75" (19mm) (32mm) release bearing, eliminating excess play in system. Having set this,
MAX. 1.32 depress pedal down fully releasing clutch and check release travel to
(33mm)
settings shown.
NOTICE
SHTS02Z020200033 It may be necessary to reduce the 0.75" (19 mm) settings to be able to
achieve 0.500"-0.562" (13-14 mm) travel on some models of transmis-
sions.

5. ADJUST THE FREE TRAVEL

(1) Remove the return spring.
(2) Loosen the lock nut and turn the push rod counterclockwise until the
release bearing contacts the release lever plate or release lever.

Push rod

0
Master cylinder

SHTS02Z020200034

(3) Turn the push rod clockwise about 3 1/3 turns.

Standard: Clearance between release bearing and
release yoke: 3.18 mm {0.125 in.}

(4) Tighten the lock nut.

Lock nut

3.18

SHTS02Z020200035
CL0216 CLUTCH MAIN UNIT (EATON 1402)

CLUTCH ASSEMBLY (EATON SOLO1402)

DATA AND SPECIFICATIONS
EN02Z0202I200002

CLUTCH FACING Unit: mm {in.}

Material Sintered metal (Ceramic metal)

Type Dry two plate with damper spring

Inside diameter 222 {8.8}

Outside diameter 350 {13.8}

Thickness 11.5 {0.45} Adjustment-Free

COMPONENT LOCATOR
EN02Z0202D100002

Shipping bolts (4)

to be removed
at installation

Wear indicator

SHTS02Z020200036

1 Clutch cover 3 Intermediate plate

2 Clutch disc 4 Bolt

Tightening torque Unit: Nm {kgfcm, lbfft}

A 50-64 {510-655, 37-47}
 CLUTCH MAIN UNIT (EATON 1402) CL0217

OVERHAUL
EN02Z0202H200002

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO

PREVENT DAMAGE TO THE BEARING AND DISCS.
1.
Remove the NOTICE
transmission If a SOLO Clutch is to be removed and reinstalled on the flywheel, four
(4) shipping bolts must be installed prior to unbolting the clutch (3/8"
x 16 UNC x 1-1/4").

SHTS02Z020200037

2. LOCATE FOUR (4) 3/8" x 16 x 1 - 1/4" UNC, HEX HEAD MACHINE

SCREWS. INSTALL THEM IN THE 4 COVER HOLES, TURNING
THEM ONE COMPLETE TURN AFTER THEY CONTACT THE
COVER.

2. 3. REMOVE THE CLUTCH FROM THE FLYWHEEL.

Located 4 hex head NOTICE
machine screws
Mark the proper position of the discs and intermediate plate adapter
ring (for reinstallation).
(4) 3/8" x 16 x 1-1/4" UNC

SHTS02Z020200038

IMPORTANT POINT - INSPECTION AND REPLACE-

MENT

1. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)

SHTS02Z020200039
CL0218 CLUTCH MAIN UNIT (EATON 1402)

(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.

SHTS02Z020200040

2. CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY

A. WORN COMPONENTS:
Check cross-shafts (1) Cross-shafts and bushings
and bushings
NOTICE
Excessive wear at these points can cause a side loading condition.
Also, inspect the remaining pivot points of the linkage for excessive
wear.

SAPH02Z080200006

(2) Release yoke fingers

B.
Check release yoke
fingers

SAPH02Z080200007

(3) Splines on the input shaft

D. NOTICE
Check splines on the Any wear on the splines will prevent the newly installed driven discs
input shaft from sliding freely, thus causing poor release (clutch drag). Select a
disc out of the new installation and slide it full length on the transmis-
sion splines. This will detect a twisted input shaft. Replace input shaft
if disc does not freely slide.

SAPH02Z080200008
 CLUTCH MAIN UNIT (EATON 1402) CL0219

(4) Smooth area of input shaft

(5) Mating surfaces
NOTICE
Inspect the mating surfaces of both the transmission bell housing and
the flywheel housing. Any appreciable wear on either housing will
cause misalignment. Most wear will occur between the 3 and 8 o'clock
E. positions.
Check smooth Replace housings if worn.
area of input
shaft for wear /
roughness

SAPH02Z080200009

IMPORTANT POINT - MOUNTING

1.
Insert 2 guide studs 1. INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS
INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL.
Guide studs

SHTS02Z020200045

2. INSTALL THE FRONT DISC BY INSERTING THE ALIGNING TOOL

2. THROUGH THE DISC SPLINES AND THEN INTO THE PILOT
Insert the aligning BEARING.
tool through release SST:
bearing sleeve Clutch Aligning Arbor (S0966-21420)

NOTICE
Make sure the side marked "Flywheel" faces the flywheel.

Aligning tool

SHTS02Z020200015
CL0220 CLUTCH MAIN UNIT (EATON 1402)

3. INSTALL THE INTERMEDIATE PLATE ASSEMBLY OVER THE

TWO (2) GUIDE STUDS AND SLIDE IT FORWARD UNTIL IT
TOUCHES THE FLYWHEEL.
NOTICE
Make sure the side marked "Pressure Plate Side" is facing the pres-
sure plate (the drive straps must face the pressure plate).

3.
Place intermediate
plate properly
orientated

SHTS02Z020200046

4. REMOVE THE ALIGNING TOOL AND INSTALL IT THROUGH THE

SPLINES OF THE REAR DISC, AND INSERT THE ALIGNING
TOOL THROUGH THE FRONT DISC AND ALSO THE PILOT
BEARING.
NOTICE
Make sure the side of the disc marked "Pressure Plate Side" is facing
Buttons the pressure plate. As you complete this step, ensure that the ceramic
buttons align with each other as closely as possible. Doing so will aid
the function of the positive separator pins (roll pins).

4.
Remove aligning tool

SHTS02Z020200017
 CLUTCH MAIN UNIT (EATON 1402) CL0221

5. WITH THE ALIGNING TOOL STILL IN PLACE, SLIDE THE COVER

ASSEMBLY OVER BOTH THE ALIGNING TOOL AND THE TWO (2)
GUIDE STUDS UNTIL IT RESTS AGAINST THE INTERMEDIATE
PLATE ASSEMBLY.

5.
Slide cover assembly
over aligning tool
and guide studs

SHTS02Z020200018

6. INSTALL LOCKWASHER AND SIX (6) 3/8" x 16 UNC MOUNTING

BOLTS HAND TIGHTEN.
2 (1) Remove the two (2) guide studs and replace with the remaining
6
7 mounting bolts with lockwasher. Using a torque wrench, progressively
tighten the eight (8) mounting bolts using the following criss-cross pat-
4 3 tern. Starting at lower left.
Tightening Torque:
8
5 50-64 Nm{510-665 kgfcm, 37-47 lbfft}
6. 1
Place disc on aligning ! CAUTION
tool properly orientated
Failure to tighten these bolts in this manner can:
Prevent the clutch cover from "centering" into the pilot area of
SHTS02Z020200019
the flywheel.
Cause permanent damage to the clutch cover (i.e. become
cracked or broken).
Cause the clutch assembly to be out-of balance with the fly-
wheel.
CL0222 CLUTCH MAIN UNIT (EATON 1402)

7. REMOVE THE FOUR (4) GOLD COLORED SHIPPING BOLTS IN A

CRISS-CROSS PATTERN.
NOTICE
Save these four (4) bolts for future use in case you need to remove,
then reinstall the SOLO Clutch.

7.
Remove the 4
shipping bolts

SHTS02Z020200047

8. REMOVE THE ALIGNING TOOL.

8.
Remove aligning tool
SHTS02Z020200048

9. USING A 1/4" (6 mm) DIAMETER FLAT NOSE PUNCH, LIGHTLY

TAP EACH OF THE FOUR (4) POSITIVE SEPARATOR PINS
TOWARD THE FLYWHEEL. PERFORMING THIS STEP WILL VER-
IFY THAT ALL FOUR (4) PINS ARE FLUSH AGAINST THE FLY-
WHEEL.

! CAUTION
Failure to perform this step properly may cause the clutch to drag
(clutch does not release). Excessive force can damage the pins and
cause a release problem
SHTS02Z020200049 NOTICE
The four (4) pins can also be set through the inspection opening of
the transmission bell housing if they were not to set prior to transmis-
sion installation.
 CLUTCH MAIN UNIT (EATON 1402) CL0223

Top view
Access hole

Roll pin

Clutch cover

SHTS02Z020200050

Side view
Flywheel
Roll Pin (Qty.4)
Access hole
Gap
0.20"-0.30"
(0.5-0.8mm)

Clutch cover

SHTS02Z020200051

10. SHIFT THE TRANSMISSION INTO GEAR.

Shift into gear

10.
Shift transmission into gear

SHTS02Z020200052

11. POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE

TO AND ALIGNED WITH THE ENGINE.

11.
Align the transmission
to the engine

SHTS02Z020200053
CL0224 CLUTCH MAIN UNIT (EATON 1402)

12. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE

OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES
OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH
EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST
ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP
POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE
BEARING HOUSING INTO THEIR FINAL POSITION.
! CAUTION
Do not use the cross-shaft release lever (or a pipe over it) to pull
the transmission into its final position. Doing so may release the
clutch and "overstroke" the release bearing. The SOLO will
incorrectly "set" the release bearing position too close to the
transmission and cause the wear indication tab to move to 1/3-1/
2 the distance towards the "REPLACE" position.
Do not excessively force the transmission into the clutch assem-
bly or engine housing. If it does not enter freely, investigate the
cause of the problem and make any necessary changes.
12. If the input shaft will not slide into the discs, they may need to be
Mesh input shaft and repositioned. If the clutch is to be unbolted from the flywheel, re-
disc (s) by rotating install the shipping bolts and tighten one turn past contact with
output shaft the clutch. Now the installation shaft can be installed to reposi-
tion the discs and the clutch bolts re-torqued. Remove the ship-
ping bolts to clamp the discs.
Do not let the transmission drop or hang unsupported in the
SHTS02Z020200054
driven discs.
This can cause the discs to become distorted and the clutch will
not release.
 CLUTCH MAIN UNIT (EATON 1402) CL0225

13. INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE

TO THE PROPER SPECIFICATION.
Tightening Torque:
37.5-48.5 Nm{382-494 kgfcm, 28-35 lbfft}

IMPORTANT POINT-SET-UP

1. ADJUST LINKAGE
(1) Adjust the clutch linkage until the yoke fingers contact the release
bearing (zero free-play in the cab).
(2) Loosen the lock nut and turn the push rod counterclockwise until the
release bearing contacts the release lever plate or release lever.

SHTS02Z020200055

(3) Fully press the pedal up to 5 times to move the release bearing
slightly closer to the transmission and gain free-play in the cab.

Stroke
pedal
5 times

SHTS02Z020200056

2. ADJUST THE FREE TRAVEL

(1) Turn the push rod counterclockwise until the release bearing contacts
the release lever plate or release lever.

Push rod

0
Master cylinder

SHTS02Z020200057

(2) Turn the push rod clockwise about 3 1/3 turns.

Standard: Clearance between release bearing and
release yoke: 3.18 mm {0.125 in.}

(3) Tighten the lock nut.

Lock nut

3.18

SHTS02Z020200058
CL0226 CLUTCH MAIN UNIT (EATON 1402)

IMPORTANT POINT-CHECK WEAR INDICATOR

1. REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM

OF THE CLUTCH HOUSING.

2. CHECK WEAR INDICATOR

Reflects clutch wear and indicates when it is time to replace clutch.
When replacing clutch, should change clutch disc together with clutch
cover.

New
Replace

SAPH02Z080200010
 CLUTCH MAIN UNIT (EATON 1402) CL0227

INSPECTION AND REPAIR

EN02Z0202H300001

EATON SAS1402 and SOLO1402 Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Clutch facing thickness 11.43 8.26 Replace disc Measure

{0.45} {0.33} assembly.

Clutch disc misalignment 0-0.38 0.38 Replace. Measure

{0-0.0149} {0.0149}

Oily facings, Loose rivets, Replace disc Visual check

Broken or loose damper assembly, if nec-
springs essary.

Clearance between clutch 0.05-0.15 0.5 Replace the Measure

disc hub and transmission {0.0020-0.0059} {0.020} clutch disc or the
Clutch disc
input shaft spline transmission
input shaft. Clearance

Input
shafe

Pressure plate misalign- 0-0.102 0.76 Replace the Measure

ment {0-0.040} {0.029} clutch cover
assembly

Pressure plate friction sur- Replace the Visual check

face scoring or heat crack- clutch cover
ing assembly.
NOTICE
Regrinding of the
pressure plate is
not possible.

Flywheel misalignment 0.05 1.0 {0.039} Replace. Measure

{0.0020}
or less
CL0228 CLUTCH MAIN UNIT (EATON 1402)

Inspection item Standard Limit Remedy Inspection procedure

Flywheel friction surface Grind limit Regrind the fric- Visual check
scoring or heat cracking 1.0 {0.039} tion surface or
Deflection replace, if neces-
limit sary.
0.04 NOTICE
{0.00157} Do not grind the
flywheel over the
limit.

Flywheel misalignment 0.15 Regrind the fric- Measure

{0.0059} tion surface or
replace.

Pilot bearing improper Replace, if neces- Visual check

rotation sary.
 CLUTCH MAIN UNIT (EATON 1402) CL0229

LUBRICATION (EATON SAS1402 and SOLO1402)

1. RELEASE BEARING
(1) The cast iron bearing housing will be equipped with either a standard
grease fitting or a lube tube extension. If a lube tube is not present, it
is necessary to remove the inspection cover to gain access to the
grease fitting. Apply grease until it purges from the rear of the hous-
ing.

2. RELEASE BEARING WEAR PADS

(1) Where the release fork contacts the bearing housing; there are small
hardened steel pads. Apply a small amount of grease to the wear
pads where the clutch release fork contacts.

3. CROSS-SHAFT BUSHINGS
(1) Lubricate both the left and the right cross-shaft bushings.

4. PILOT BEARING
(1) The pilot bearing inside the flywheel is a sealed for life bearing and
requires no lubrication.

RECOMMENDED LUBRICATION
Use a lithium soap base E.P. (Extreme Pressure) grease with a minimum of
+325 degree F operating range. It must meet the N.L.G.I.'s Grade 2 or 3
specs.
! CAUTION
Incorrect grease and improper lube procedures will cause bearing
failures, bushing wearout, yoke tip and bearing wear pad wear.

Recommended Lubrication

Supplier Product Supplier Product

American Oil Co. Amoco Uthium-M.P. Grease Texaco Multifak #2

City Service Co. Citgo Premium Lithium Grease #2 Shell Oil Co. Retinax A

Fiske Refining Co. Lubriplate 630-2 Shell Oil Co. Aivania #2

Keystone Lubricating Co. #81 Ught *Chevron Oil Co. S.R.I. 1~

Mobil Mobilgrease M.P. *Texaco Premium RB

Humble Oil Co. Udok 2 *Exxon Unirex N3

Atlantic Richfield Co. Arco M.P.

* Approved for vendor prepack, other greases listed are for service only.
 CLUTCH CONTROL CL031

CLUTCH CONTROL
CL03

CL03-001

CLUTCH CONTROL UNIT........................ CL03-2

DESCRIPTION .................................................CL03-2
INSPECTION AND ADJUSTMENT ..................CL03-3

CLUTCH PEDAL AND RELEASE UNIT... CL03-6

COMPONENT LOCATOR.................................CL03-6
OVERHAUL ......................................................CL03-7
INSPECTION AND REPAIR .............................CL03-9

CLUTCH MASTER CYLINDER .............. CL03-10

COMPONENT LOCATOR...............................CL03-10
OVERHAUL ....................................................CL03-11
INSPECTION AND REPAIR ...........................CL03-11
CL032 CLUTCH CONTROL

CLUTCH CONTROL UNIT

DESCRIPTION
EN02Z0203C100001

CLUTCH RELEASE UNIT

SHTS02Z020300001

1 Clutch master cylinder 3 Clutch pedal

2 Reservoir tank 4 Pedal bracket
 CLUTCH CONTROL CL033

INSPECTION AND ADJUSTMENT

EN02Z0203H300001

AIR BLEEDING

1. BLEED THE AIR FROM HYDRAULIC LINE.

NOTICE
Do not mix the clutch fluid with different types or brands.
Be careful not to spill clutch fluid from the reservoir tank or from
the air bleeder during air bleeding. Clutch fluid can damage the
paint finish on the body or floor.
There are two methods of bleeding, gravity bleeding and manual
air bleeding.

2. GRAVITY BLEEDING
(1) Connect a funnel to a vinyl tube.
(2) Connect the other end of the vinyl tube to the bleeder screw.
(3) Hold the funnel about 1.5 m {4.92 ft} higher than the reservoir tank.
(4) Loosen the bleeder screw and pour the clutch fluid into the funnel.
(5) Observe the flow of clutch fluid into the reservoir tank.
(6) When the air bubbles cease, close the bleeder screw.
(7) Check the fluid level. If necessary, add or remove clutch fluid in order
to match the "MAX" level.

1. Funnel filled with clutch fluid

2. Vinyl tube (inside diameter: 6 mm)

3. Bleeder

4. Slave cylinder

5. About 1.5 m {4.92 ft}

6. Clutch pedal

7. Master cylinder
SHTS02Z020300002

8. Reservoir tank

3. MANUAL BLEEDING
(1) Fill the reservoir with clutch fluid.
(2) Connect the bleeder tube to the slave cylinder bleeder screw. Place
the other end of tube in a container half-filled with clutch fluid.

SHTS02Z020300003
CL034 CLUTCH CONTROL

(3) Slowly pump the clutch pedal several times. While pressing on the
pedal, loosen the bleeder screw. Repeat this procedure until there are
no more air bubbles in the fluid.
NOTICE
Do not return the clutch pedal before closing the bleeder screw.
Keep the reservoir filled with clutch fluid.
Re-bleeding will be necessary if the reservoir is emptied during
bleeding operation.

SHTS02Z020300004

(4) Check the fluid level. If necessary, add or remove clutch fluid in order
to match the "MAX" level.

SHTS02Z020300005

4. AFTER BLEEDING, MAKE SURE THE PUSH ROD STROKE IS AS

SPECIFIED.
(1) Depress the clutch pedal fully and measure the push rod stroke. If the
stroke is less than standard, re-bleed the hydraulic system.
Standard:

Model Standard

HINO 238 (NE), 258 (NE, NJ), 268

More than 22.5 mm {0.886 in.}
(NE, NF, NJ), 338 (NF, NV), 358 (NH)

SHTS02Z020300006
 CLUTCH CONTROL CL035

CHECK AND ADJUSTMENT

1. CHECK AND ADJUST THE CLUTCH PEDAL PLAY.

(1) Check the push rod play.
a. If necessary, adjust the push rod play.

1 STEP: Push rod play

2 STEP Clutch pedal play

SHTS02Z020300007

b. Loosen the lock nut and turn the master cylinder push rod until
the push rod play is correct.
Standard:
Clearance between push rod and piston:
0.5 mm {0.0197 in.}
Push rod play at pedal top: 2-4 mm {0.079-0.157 in.}
c. Tighten the lock nut.

SHTS02Z020300008

(2) Check the clutch pedal play.

a. Push the pedal until the beginning of clutch resistance is felt.
Assembly Standard:

Model Standard Limit

HINO 238 (NE), 258 (NE, NJ),

44-59 mm
268 (NE, NF, NJ), 338 (NF, NV), 35 mm {1.38 in.}
{1.73-2.32 in.}
358 (NH)

NOTICE
SHTS02Z020300009 For adjustment of clutch, refer to the chapter "CLUTCH MAIN UNIT".

2. CHECK THE CLUTCH PEDAL HEIGHT AND STROKE.

Assembly Standard:
Pedal Height 205-215 mm {8.07-8.46 in.}
Pedal Stroke 205-215 mm {8.07-8.46 in.}

SHTS02Z020300010
CL036 CLUTCH CONTROL

CLUTCH PEDAL AND RELEASE UNIT

COMPONENT LOCATOR
EN02Z0203D100001

SHTS02Z020300011

1 Reservoir tank 6 Pedal pad

2 Master cylinder 7 Switch (For cruise control)
3 Return spring 8 Switch (For clutch on start)
4 Clutch pedal 9 Pedal shaft
5 Bracket 10 Pedal bracket

Tightening torque Unit: Nm {kgfcm, lbfft}

A 41.5-61.5 {424-627, 30-46} B 18-26 {184-265, 14-19}
 CLUTCH CONTROL CL037

OVERHAUL
EN02Z0203H200001

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE PEDAL UNIT ASSEMBLY.

(1) Remove the 10 bolts and 2 nuts and dismount the pedal bracket
assembly from the vehicle.
NOTICE
Be careful not to damage the vehicle.

SHTS02Z020300012

2. REMOVE THE CLUTCH PEDAL.

(1) Remove the clip, and tap the pedal shaft lightly to remove the clutch
pedal using a brass bar and a hammer.

SHTS02Z020300013

IMPORTANT POINT - MOUNTING

1. INSTALL THE CLUTCH PEDAL.

(1) Apply lithium grease to the inner side and outer periphery of the bush-
ing, and install the bushing to the inserting hole on the shaft part of
the clutch pedal.
(2) Install the clutch pedal to the installing axle for pedal shaft and install
the pedal shaft to the pedal bracket using a plastic hammer.

2. INSTALL THE PEDAL UNIT ASSEMBLY.

SHTS02Z020300014
CL038 CLUTCH CONTROL

3. INSTALL THE SWITCH FOR CRUISE CONTROL AND CLUTCH ON

START.
(1) Install the switch bushing into the switch bracket.

SHTS02Z020300015

(2) Push the switch into the switch bushing until the switch pounds the
buffer, then fix the switch by turning if clockwise.

NOTICE
Check that the switch body does not contact the buffer and also that
the switch rightly functions.

SHTS02Z020300016

SHTS02Z020300017

IMPORTANT POINTS - ASSEMBLY

1. APPLY BEARING GREASE OR HEAT RESISTANCE GREASE.

(1) Apply bearing grease to the following parts.
a. The release fork and the release bearing hub contact point.
b. The release bearing hub inner groove.
(2) Apply heat resistance grease to the transmission input shaft spline.
NOTICE
Apply a small amount of grease to the spline.

SHTS02Z020300018
 CLUTCH CONTROL CL039

INSPECTION AND REPAIR

EN02Z0203H300002

Inspection item Standard Limit Remedy Inspection procedure

Release bearing improper Replace release Visual check

rotation bearing,
if necessary.

Release fork and release Replace the Visual check

hub: parts,
Wear and damage if necessary.

Release shaft bush: Bush inner diameter Replace the Visual check
Wear and damage 25.48-25.52 mm bush,
(1.003-1.005 in.) if necessary.
After pressing in
a new bush, grind
inner diameter of
the bush to be fit-
ted to standard
specification.
CL0310 CLUTCH CONTROL

CLUTCH MASTER CYLINDER

COMPONENT LOCATOR
EN02Z0203D100002

SHTS02Z020300021

1 Clevis 9 Clamp
2 Lock nut 10 Reservoir cap
3 Push rod 11 Gasket
4 Boot 12 Oil reservoir strainer
5 Retainer ring 13 Reservoir tank
6 Piston 14 Stopper bolt
7 Return spring 15 O-ring
8 Body

Tightening torque Unit: Nm {kgfcm, lbfft}

A 11.5-16.9 {118-172, 8.5-12.4} B 2.4-4.4 {24-45, 1.8-3.2}
 CLUTCH CONTROL CL0311

OVERHAUL
EN02Z0203H200002

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE MASTER CYLINDER.

NOTICE
Before removing the master cylinder, drain the clutch fluid from
the hydraulic line.
Place a small drain pan under the master cylinder to catch the
hydraulic fluid. Do not let the clutch fluid remain on a painted
floor. Wash it off immediately.

IMPORTANT POINT - ASSEMBLY

1. INSTALL THE RETURN SPRING AND PISTON TO THE CYLINDER.

NOTICE
Lubricate the cylinder bore and piston with clean clutch fluid.

INSPECTION AND REPAIR

EN02Z0203H300003

Inspection item Standard Limit Remedy Inspection procedure

Piston seal and cup: Replace the pis- Visual check

Wear and damage ton assembly
Cylinder body bore: and/or cylinder
Scoring and corrosion body, if neces-
sary.
 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) TR021

TRANSMISSION MAIN UNIT

TR02

(EATON FS 5406/6406) TR02-001

TRANSMISSION ASSEMBLY................... TR02-2

DATA AND SPECIFICATION............................ TR02-2
DISMOUNTING AND MOUNTING .................. TR02-3
TR022 TRANSMISSION MAIN UNIT (EATON FS 5406/6406)

TRANSMISSION ASSEMBLY
DATA AND SPECIFICATION
EN03Z0302I200001

Six forward speeds, one reverse

Type
1, 2, 3, 4, 5, 6th Synchromesh, Reverse, Constant mesh

1st 9.01

2nd 5.27

3rd 3.22

Gear ratios 4th 2.04

5th 1.36

6th 1.00

Reverse 8.63

Number of teeth: input shaft 24

1st gear 10

2nd gear 16

3rd gear 25

Number of teeth: counter shaft 4th gear 31

5th gear 38

6th gear 46

Reverse gear 10

1st gear 47

2nd gear 44

3rd gear 42

Number of teeth: main shaft 4th gear 33

5th gear 27

6th gear 24

Reverse gear 45

Number or teeth: reverse idle gear 21

Oil capacity: gear box Approx. 9.2 liters {2.02 lmp.gal/2.44 US gal.}

NOTICE
For other details, refer to EATON manuals.
 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) TR023

DISMOUNTING AND MOUNTING

EN03Z0302H100001

IMPORTANT POINTS-DISMOUNTING
! WARNING
Do not work on the transmission while it is hot. This can result in per-
sonal injury.

1. BLOCK THE WHEELS

2. DRAIN THE TRANSMISSION OIL

3. DISCONNECT THE PROPELLER SHAFT

4. DISCONNECT THE ELECTRIC HARNESS AND OTHER ATTACH-

MENTS.

5. DISCONNECT THE TRANSMISSION CONTROL LEVER

SHTS03Z030200001 6. DISCONNECT THE CLUTCH SLAVE CYLINDER

NOTICE
Do not remove the clutch control piping unless absolutely necessary.
Air bleeding is not required when reassembling.

7. REMOVE THE TRANSMISSION.

(1) Remove the lower bolts around the clutch housing.
(2) Support the transmission using a transmission jack or lifting wires to
prevent it from falling.
(3) Remove the remaining bolts around the clutch housing.
(4) Remove the transmission.

SHTS03Z030200002
TR024 TRANSMISSION MAIN UNIT (EATON FS 5406/6406)

IMPORTANT POINTS-MOUNTING

1. APPLY HEAT-RESISTANT GREASE TO THE INPUT SHAFT

SPLINE.

Grease:
Refer to RECOMMENED LUBRICATION in the chapter "CLUTCH
MAIN UNIT."

SHTS03Z030200003

2. INSTALL THE TRANSMISSION.

(1) Jack up the transmission until the input shaft spline and the clutch
disc spline align.
NOTICE
Do not let the rear of the transmission drop and do not let the trans-
mission hang unsupported in the spline hubs of the driven discs
because it distorts them and could cause poor clutch operation or
clutch release problems.
(2) Install the upper nuts or bolts around the clutch housing.
(3) Lower the transmission jack and pull the jack out from under the vehi-
cle.
SHTS03Z030200004

(4) Install the remaining nuts or bolts around the clutch housing.
Tightening Torque:
37.5-48.5 Nm {382-494 kgfcm, 28-35 lbfft}

3. INSTALL THE CLUTCH SLAVE CYLINDER.

4. CONNECT THE TRANSMISSION CONTROL LEVER.

5. CONNECT THE ELECTRIC HARNESS AND OTHER ATTACH-

MENTS.

SHTS03Z030200005
6. CONNECT THE PROPELLER SHAFT.

7. FILL THE TRANSMISSION OIL.

DISASSENBLY AND ASSEMBLY

NOTICE
When disassembling and assembling the transmission, refer to the
MANUFACTURE ORIGINAL MANUAL.
 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR041

AUTOMATIC TRANSMISSION
TR04

(ALLISON 2200RDS, 2500RDS, 2200HS) TR04-001

AUTOMATIC TRANSMISSION
ASSEMBLY ............................................... TR04-2
TROUBLESHOOTING ..................................... TR04-2
SPECIAL TOOL ............................................... TR04-2
DISMOUNTING AND MOUNTING .................. TR04-2
TR042 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)

AUTOMATIC TRANSMISSION ASSEMBLY

TROUBLESHOOTING
EN03Z0304F300001

NOTICE
When diagnosing transmission problems, refer to the Allison Shop Manual or troubleshooting procedures for
detailed information on items that could be causing the problem.

SPECIAL TOOL
EN03Z0304K100001

Prior to removal and installing of automatic transmission, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

S0965-71370 SPACER COUPLING GUIDE

DISMOUNTING AND MOUNTING

EN03Z0304H100001

IMPORTANT POINTS - DISMOUNTING

NOTICE
Allison transmission repairs are to be performed by an authorized
Allison service dealer.

! WARNING
Do not work on the transmission while it is hot. This can result in per-
sonal injury.

1. BLOCK THE WHEELS.

(1) Park the vehicle on level ground.
(2) Block the wheels.
NOTICE
Be sure to apply wheel stoppers at the front tires.

SHTS03Z030400002

2. DRAIN THE AUTOMATIC TRANSMISSION FLUID.

(1) Place the drain pan under the transmission.
(2) Remove the drain plug from the transmission and allow the fluid to
drain.

SHTS03Z030400003
AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR043

3. REMOVE THE PROPELLER SHAFTS.

(1) Disconnect the yoke from the propeller spider and remove the center
bearing holder.
(2) Move the forward end of the propeller shaft out of the way.

SHTS03Z030400004

4. DISCONNECT THE ELECTRICAL HARNESS FROM THE REAR OF

THE TRANSMISSION.

SHTS03Z030400005

5. DISCONNECT THE OIL COOLER LINES AT THE TRANSMISSION.

SHTS03Z030400006

6. DISCONNECT THE SHIFT CABLE FROM THE MANUAL LEVER AT

THE TRANSMISSION.

SHTS03Z030400007
TR044 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)

7. REMOVE THE SUPPORT OF THE OIL LEVER GAUGE FROM THE

ENGINE CYLINDER BLOCK.

Rear view Side view

SHTS03Z030400008

8. REMOVE INSPECTION COVER FROM THE BOTTOM FRONT SIDE

OF THE FLYWHEEL HOUSING.

SHTS03Z030400009

9. REMOVE THE SIX COUPLING BOLTS FROM THE FLYWHEEL.

(1) Turn the flywheel manually to match the attaching bolt to the slot on
the inspection opening at the bottom front side of the flywheel hous-
ing.
(2) Remove the coupling bolts one by one.

SHTS03Z030400010

10. REMOVE THE CONVERTER HOUSING ATTACHING BOLTS.

SHTS03Z030400011
AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR045

11. POSITION A TRANSMISSION JACK UNDER THE TRANSMISSION

AND SECURE THE TRANSMISSION TO THE JACK WITH A
SAFETY CHAIN OR WIRE CABLE.

12. REMOVE THE REMAINING CONVERTER HOUSING FROM THE

FLYWHEEL HOUSING ATTACHING BOLTS.

13. PULL OUT THE TRANSMISSION BACKWARDS.

! WARNING
Do not lower the front end of the transmission. If lowered, the torque
converter may slide out of the transmission and you may be injured.
SHTS03Z030400012
TR046 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)

IMPORTANT POINTS - MOUNTING

1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND WEAR

PLATE.
Tightening Torque:
78.5-87.5 Nm {801-893 kgfcm, 58-64.5 lbfft}
NOTICE
Before tightening, face the chamfered outer rim of the wear plate to
the flex plate. If assembled to the contrary, the wear plate edge hits
the flex plate and its strength is reduced. Painted surface of the wear
plate should be located facing the transmission side.

SHTS03Z030400013

2. TIGHTEN THE TORQUE CONVERTER AND THE FLEX PLATE.

Tightening Torque:
57-68 Nm {582-693 kgfcm, 42-50 lbfft}

SHTS03Z030400014

NOTICE
Apply grease containing molybdenum disulfide to the boss at the end
of the torque converter before assembling. Without grease, the flex
plate will not slide well and abnormal force will be generated, causing
the flex plate to break.

SHTS03Z030400015

3. MOUNT THE TRANSMISSION ASSEMBLY ON A TRANSMISSION

JACK. THEN MOVE THE ASSEMBLY INTO THE POSITION.

! WARNING
Do not lower the front end of the transmission. If lowered, the torque
converter may slide out of the transmission and you can be injured.

SHTS03Z030400012
AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR047

4. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO THE

SPACER COUPLING OF THE TRANSMISSION ASSEMBLY.
ROTATE THE TORQUE CONVERTER SO THAT THE GUIDE
FACES DOWNWARD.
SST: Spacer coupling guide (S0965-71370)

SHTS03Z030400016

5. ROTATE THE ENGINE TO ALIGN THE FITTING HOLE OF THE

ENGINE FLYWHEEL AND SPACER COUPLING WITH THE
INSPECTION HOLE ON THE FRONT OF THE FLYWHEEL HOUS-
ING.
NOTICE
First switch off the power so that the engine will not start.

6. MOVE THE TRANSMISSION JACK SLOWLY AND INSERT THE

GUIDE INTO THE FITTING HOLE OF THE FLYWHEEL.
! WARNING
Do not lower the front side of the transmission. If lowered, the torque
converter may slide out of the transmission and you may be injured.

7. MOVE THE TRANSMISSION JACK SLOWLY AND ADJUST BY

BRINGING THE FITTING FACES OF THE TORQUE CONVERTER
HOUSING AND THE FLYWHEEL HOUSING.

8. TIGHTEN THE BOLTS TO JOIN THE TORQUE CONVERTER

HOUSING AND THE FLYWHEEL HOUSING.
Tightening Torque:
37-57 Nm {378-581 kgfcm, 28-42 lbfft}

SHTS03Z030400017

9. LOWER AND REMOVE THE TRANSMISSION JACK.

10. TAKE THE GUIDE OUT OF THE INSPECTION HOLE ON THE FLY-
WHEEL HOUSING FRONT WITH A SCREW DRIVER.

SHTS03Z030400018
TR048 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)

11. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLYWHEEL AND

THE SPACER COUPLING THROUGH THE INSPECTION HOLE. IN
ORDER TO TIGHTEN THE BOLTS, TURN THE RING GEAR WITH
A SCREW DRIVER THROUGH THE TIMING ADJUSTMENT HOLE
ON THE UPPER PART OF THE FLYWHEEL HOUSING.
NOTICE
If the ring gear does not turn smoothly with a screw driver, remove the
transmission and repeat the procedure again from 5 above, because
the hub ends of the flywheel and the spacer coupling do not fit well.
Tightening bolts in such a condition will cause damage to the bolts
and jamming of the engine.
SHTS03Z030400019
12. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11.
Tightening Torque:
64-85 Nm {653-867 kgfcm, 48-62 lbfft}

13. CONNECT THE ELECTRICAL HARNESS TO THE REAR PART OF

THE TRANSMISSION.

SHTS03Z030400020

14. INSTALL THE SHIFT CABLE TO THE LEVER AND BRACKET.

SHTS03Z030400007

SHTS03Z030400021
 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR049

15. INSTALL THE SUPPORT OF THE OIL LEVEL GAUGE TO THE

ENGINE CYLINDER BLOCK.

Rear view Side view

SHTS03Z030400008

Cover

Plate

SHTS03Z030400022

16. INSTALL THE PROPELLER SHAFT YOKE TO THE TRANSMIS-

SION YOKE.
Tightening Torque:
61-81 Nm {622-826 kgfcm, 45-60 lbfft}

17. INSTALL THE CENTER BEARING HOLDER TO THE FRAME.

SHTS03Z030400023

18. CONNECT THE OIL COOLER LINE.

(1) For connecting the transmission case and joints, insert O-rings in the
grooves of the joints before tightening.
NOTICE
Apply automatic transmission fluid to the O-rings when inserting
them. If the fluid is not applied, the O-rings will not be inserted
smoothly and will thus be damaged, causing oil to leak.

19. REMOVE THE CAP OF THE OIL FILLER TUBE AND POUR AUTO-
MATIC TRANSMISSION FLUID INTO THE TUBE.

SHTS03Z030400024 Automatic transmission fluid:

Refer to RECOMMENDED LUBRICANTS LIST in the chapter
GENERAL INTRODUCTION (CHASSIS).

NOTICE
For further details, consult your nearest ALLISON representative or
ALLISON service station.
 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR041

AUTOMATIC TRANSMISSION (ALLISON 3000RDS,

TR04

3500RDS) TR04-002

AUTOMATIC TRANSMISSION
ASSEMBLY ............................................... TR04-2
TROUBLESHOOTING ..................................... TR04-2
SPECIAL TOOL ............................................... TR04-2
DISMOUNTING AND MOUNTING .................. TR04-2
TR042 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)

AUTOMATIC TRANSMISSION ASSEMBLY

TROUBLESHOOTING
EN03Z0304F300001

NOTICE
When diagnosing transmission problems, refer to the Allison Shop Manual or troubleshooting procedures for
detailed information on items that could be causing the problem.

SPECIAL TOOL
EN03Z0304K100001

Prior to removal and installing of automatic transmission, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

S0965-71370 SPACER COUPLING GUIDE

DISMOUNTING AND MOUNTING

EN03Z0304H100001

IMPORTANT POINTS - DISMOUNTING

NOTICE
Allison transmission repairs are to be performed by an authorized
Allison service dealer.

! WARNING
Do not work on the transmission while it is hot. This can result in per-
sonal injury.

1. BLOCK THE WHEELS.

(1) Park the vehicle on level ground.
(2) Block the wheels.
NOTICE
Be sure to apply wheel stoppers at the front tires.

SHTS03Z030400002

2. DRAIN THE AUTOMATIC TRANSMISSION FLUID.

(1) Place the drain pan under the transmission.
(2) Remove the drain plug from the transmission and allow the fluid to
drain.

3. REMOVE THE PROPELLER SHAFTS.

(1) Disconnect the yoke from the propeller spider and remove the center
bearing holder.
(2) Move the forward end of the propeller shaft out of the way.

SHTS03Z030400003
 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR043

4. REMOVE THE CONNECTORS OF MAIN CONNECTOR, SPEED

SENSOR AND CONVERTER TURBINE SENSOR.

Speed
sensor
Main
Converter turbine sensor
connector
SHTS03Z030400004C

5. DISCONNECT THE OIL COOLER LINES AT THE TRANSMISSION.

SHTS03Z030400005

6. REMOVE THE SUPPORT OF THE OIL LEVEL GAUGE FROM THE

ENGINE CYLINDER BLOCK.

Rear view Side view

SHTS03Z030400007

7. REMOVE INSPECTION COVER FROM THE BOTTOM FRONT SIDE

OF THE FLYWHEEL HOUSING.

SHTS03Z030400008
TR044 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)

8. REMOVE THE SIX COUPLING BOLTS FROM THE FLYWHEEL.

(1) Turn the flywheel manually to match the attaching bolt to the slot on
the inspection opening at the bottom front side of the flywheel hous-
ing.
(2) Remove the coupling bolts one by one.

SHTS03Z030400009

9. REMOVE THE CONVERTER HOUSING ATTACHING BOLTS

LOWER THE TRANSMISSION.

SHTS03Z030400010

10. POSITION A TRANSMISSION JACK UNDER THE TRANSMISSION

AND SECURE THE TRANSMISSION TO THE JACK WITH A
SAFETY CHAIN OR WIRE CABLE.

11. REMOVE THE REMAINING CONVERTER HOUSING FROM THE

FLYWHEEL HOUSING ATTACHING BOLTS.

12. PULL OUT THE TRANSMISSION BACKWARDS.

! WARNING
Do not lower the front end of the transmission. If lowered, the torque
converter may slide out of the transmission and you can be injured.
SHTS03Z030400011C
AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR045

IMPORTANT POINTS - MOUNTING

1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND WEAR

PLATE.
Tightening Torque:
64-85 Nm {653-867 kgfcm, 48-62 lbfft}
NOTICE
Before tightening, face the chamfered outer rim of the wear plate to
the flex plate. If assembled to the contrary, the wear plate edge hits
the flex plate and its strength is reduced. Painted surface of the wear
plate should be located facing the transmission side.

SHTS03Z030400012

2. TIGHTEN THE TORQUE CONVERTER AND THE ADAPTER.

Tightening Torque:
33.5-38.5 Nm {342-392 kgfcm, 25-28 lbfft}
NOTICE
Apply grease containing molybdenum disulfide to the boss at the end
of the torque converter before assembling. Without grease, the flex
plate will not slide well and abnormal force will be generated, causing
the flex plate to break.

SHTS03Z030400013

3. INSTALL THE FLEX PLATE, SPACER COUPLING AND WEAR

PLATE. THEN TIGHTEN THE FLEX PLATE AND ADAPTER
TOGETHER.
Tightening Torque:
63-73 Nm {643-744 kgfcm, 47-53 lbfft}
NOTICE
Flex plate's hole (A) and spacer's hole (B) must be same position (by
this, lock the flywheel and (A)'s bolt is suitable)

SHTS03Z030400014

4. MOUNT THE TRANSMISSION ASSEMBLY ON A TRANSMISSION

JACK. THEN MOVE THE ASSEMBLY INTO THE POSITION.

! WARNING
Do not lower the front end of the transmission. If lowered, the torque
converter may slide out of the transmission and you can be injured.

SHTS03Z030400015C
TR046 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)

5. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO THE

SPACER COUPLING OF THE TRANSMISSION ASSEMBLY.
ROTATE THE TORQUE CONVERTER SO THAT THE GUIDE
FACES DOWNWARD.
SST: Spacer coupling guide (S0965-71370)

SHTS03Z030400016

6. ROTATE THE ENGINE TO ALIGN THE FITTING HOLE OF THE

ENGINE FLYWHEEL AND SPACER COUPLING WITH THE
INSPECTION HOLE ON THE FRONT OF THE FLYWHEEL HOUS-
ING.
NOTICE
First switch off the power so that the engine will not start.

7. MOVE THE TRANSMISSION JACK SLOWLY AND INSERT THE

GUIDE INTO THE FITTING HOLE OF THE FLYWHEEL.
! WARNING
Do not lower the front side of the transmission. If lowered, the torque
converter may slide out of the transmission and you can be injured.

8. MOVE THE TRANSMISSION JACK SLOWLY AND ADJUST BY

BRINGING THE FITTING FACES OF THE TORQUE CONVERTER
HOUSING AND THE FLYWHEEL HOUSING.

9. TIGHTEN THE BOLTS TO JOIN THE TORQUE CONVERTER

HOUSING AND THE FLYWHEEL HOUSING.
Tightening Torque:
37-57 Nm {439-520 kgfcm, 32-38 lbfft}

SHTS03Z030400017

10. LOWER AND REMOVE THE TRANSMISSION JACK.

11. TAKE THE GUIDE OUT OF THE INSPECTION HOLE ON THE FLY-
WHEEL HOUSING FRONT WITH A SCREW DRIVER.

SHTS03Z030400018
 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR047

12. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLYWHEEL AND

THE SPACER COUPLING THROUGH THE INSPECTION HOLE. IN
ORDER TO TIGHTEN THE BOLTS, TURN THE RING GEAR WITH
A SCREW DRIVER THROUGH THE TIMING ADJUSTMENT HOLE
ON THE UPPER PART OF THE FLYWHEEL HOUSING.
NOTICE
If the ring gear does not turn smoothly with a screw driver, remove the
transmission and repeat the procedure again from 6 above, because
the hub ends of the flywheel and the spacer coupling do not fit well.
Tightening bolts in such a condition will cause damage to the bolts
and jamming of the engine.

13. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 12.

Tightening Torque:
64-85 Nm {653-867 kgfcm, 48-62 lbfft}

SHTS03Z030400019

14. INSTALL THE SPEED SENSOR HARNESS TO THE REAR PART

OF THE TRANSMISSION.

15. CONNECT THE CONNECTORS OF WIRING.

16. INSTALL THE PROPELLER SHAFT YOKE TO THE TRANSMIS-

SION YOKE.

Speed 17. INSTALL THE CENTER BEARING HOLDER TO THE FRAME.

sensor
Main
Converter turbine sensor
connector
SHTS03Z030400020

18. CONNECT THE OIL COOLER LINE.

(1) For connecting the transmission case and joints, insert O-rings in the
grooves of the joints before tightening.
NOTICE
Apply automatic transmission fluid to the O-rings when inserting
them. If the fluid is not applied, the O-rings will not be inserted
smoothly and will thus be damaged, causing oil to leak.

SHTS03Z030400022
TR048 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)

19. INSTALL THE SUPPORT OF THE OIL LEVEL GAUGE TO THE

ENGINE CYLINDER BLOCK.

20. REMOVE THE CAP OF THE OIL FILLER TUBE AND POUR AUTO-
MATIC TRANSMISSION FLUID INTO THE TUBE.

Automatic transmission fluid:

Refer to RECOMMENDED LUBRICANTS LIST in the chapter
GENERAL INTRODUCTION (CHASSIS).
Rear view Side view
NOTICE
For further details, consult your nearest ALLISON representative or
Notice: Cover over the plate ALLISON service station.

Cover

Plate

SHTS03Z030400023
 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) TR061

TRANSMISSION/TRANSFER CONTROL
TR06

(EATON MANUAL TRANSMISSION) TR06-001

TRANSMISSION CONTROL UNIT ........... TR06-2

TROUBLESHOOTING ..................................... TR06-2
COMPONENT LOCATOR................................ TR06-3
OVERHAUL ..................................................... TR06-4
TR062 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)

TRANSMISSION CONTROL UNIT

TROUBLESHOOTING
EN03Z0306F300001

1. MANUAL TRANSMISSION
Symptom Possible cause Remedy/Prevention
Unable to shift the gear or very diffi- Damaged shift lever assembly Replace shift lever.
cult to shift when the engine is Damaged or broken transmission Replace.
turned off. upper cover (lever, spring, etc.)
The looseness of tightening bolt and Inspect and tighten each bolt and nut.
nut
Gear disengages when driving on Loose control lever joint Tighten or replace.
bumpy roads.
The play of the lever is excessive. A joint is seriously worn Replace the joint.
The looseness of tightening bolt and Inspect and tighten each bolt and nut.
nut
 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) TR063

COMPONENT LOCATOR
EN03Z0306D100001

1. MANUAL TRANSMISSION CONTROL

SHTS03Z030600001

1 Knob 4 Isolator
2 Shift lever 5 Stub lever
3 Boot

Tightening torque Unit: Nm {kgfcm, lbfft}

A 14-16 {143-163, 10-11.8}
TR064 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)

OVERHAUL
EN03Z0306H200001

IMPORTANT POINT - ASSEMBLY

1. MANUAL TRANSMISSION CONTROL

(1) When you connect the shift lever and the stub lever, tighten the nut
with the isolator steadily.
Tightening Torque:
14-16 Nm {143-163 kgfcm, 10-11.8 lbfft}

(2) Check the shift and select stroke.

[FS5406, 6406] Unit: mm {in.}
TM FS5406, 6406
R 1 3 5
S1 70-90 (2.76-3.54)
S4

S3 S1 S2 S2 70-90 (2.76-3.54)

N S3 70-90 (2.76-3.54)
S4 100-120 (3.93-4.72)
S5

S5 100-120 (3.93-4.72)
2 4 6

SHTS03Z030600002
 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) TR061

TRANSMISSION/TRANSFER CONTROL
TR06

(ALLISON AUTOMATIC TRANSMISSION) TR06-002

TRANSMISSION CONTROL UNIT ........... TR06-2

TROUBLESHOOTING ..................................... TR06-2
COMPONENT LOCATOR................................ TR06-2
OVERHAUL ..................................................... TR06-4
TR062 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)

TRANSMISSION CONTROL UNIT

TROUBLESHOOTING
EN03Z0306F300001

1. AUTOMATIC TRANSMISSION
(1) Allison 2200RDS, 2200HS, 2500RDS, 3000RDS, 3500RDS auto-transmission problem, refer to the Allison shop manual
or troubleshooting procedures for detailed information on items that could be causing the problem.

COMPONENT LOCATOR
EN03Z0306D100001

1. AUTOMATIC TRANSMISSION CONTROL

L
2
D
OD
P RN
Side view Rear view
SAPH03Z030600001

1 Selector assembly 2 Shift cable assembly

 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) TR063

[Allison 3000RDS,3500RDS button-type]

SAPH03Z030600002

1 Selector assembly
TR064 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)

OVERHAUL
EN03Z0306H200001

IMPORTANT POINT - ASSEMBLY

1. AUTOMATIC TRANSMISSION CONTROL

[Allison 2200RDS, 2200HS, 2500RDS MODEL]
(1) Before installation the cable, check the shift cable for wear and dam-
age, if necessary, replace the parts.

SAPH03Z030600004

(2) When you install the shift cable, it should not bent sharply. Any loop-
ing should have a radius of more than 150 mm (5.91 in.).

SAPH03Z030600005
 PROPELLER SHAFT (SPL 100, 140) PP021

PROPELLER SHAFT (SPL 100, 140)

P 02

PP02-001

PROPELLER SHAFT ASSEMBLY ........... PP02-2

DATA AND SPECIFICATIONS ......................... PP02-2
DESCRIPTION ................................................ PP02-2
TROUBLESHOOTING ..................................... PP02-3
COMPONENT LOCATOR................................ PP02-3
OVERHAUL ..................................................... PP02-5
PP022 PROPELLER SHAFT (SPL 100, 140)

PROPELLER SHAFT ASSEMBLY

DATA AND SPECIFICATIONS
EN04Z0402I200001

Manufacturer Spicer

Type Tubular shaft type

Universal joint All metal, round bearing type with needle roller bearing

DESCRIPTION
EN04Z0402C100001

SHTS04Z040200001

1 Bearing assembly 7 Washer

2 Cross assembly 8 Nut
3 Snap ring 9 Slip yoke assembly
4 Yoke shaft assembly 10 Clamp
5 Center bearing assembly 11 Boot
6 End yoke
 PROPELLER SHAFT (SPL 100, 140) PP023

TROUBLESHOOTING
EN04Z0402F300001

Symptom Possible cause Remedy/Prevention

Abnormal vibration when driving. Looseness of universal joint yoke and Tighten the nuts.
flange tightening nuts.
Looseness of universal joint flange Replace the lock nut with new one,
lock nut. then tighten the lock nut with specified
torque and caulk the nut securely.
Excessively bent propeller shaft. Replace the shaft.
Worn or damaged universal joint. Replace the universal joint.
Worn or damaged center bearing. Replace the bearing.
Worn or damaged center bearing rub- Replace the rubber cushion.
ber cushion.
Incorrect phasing of the yokes. Match the phasing arrows correctly.

COMPONENT LOCATOR
EN04Z0402D100001

SHTS04Z040200002

Tightening torque Unit: Nm {kgfcm, lbfft}

A 61-81 {625-825, 45-60} B 128-156 {1,300-1,600, 95-115}

! WARNING
Never allow grease and oil to adhere stamped straps, stamped strap bolts and bold holes. The grease and/or oil
which adhere to the stamped retainer bolts, stamped straps, stamped strap bolts, damaged bearing retainers or used
inferior grade bolts can cause driveline failure, which can result in separation of driveline from the vehicle. A sepa-
rated driveline can result in death, serious personal injury or property damage.
PP024 PROPELLER SHAFT (SPL 100, 140)

SHTS04Z040200003

Tightening torque Unit: Nm {kgfcm, lbfft}

A 143-169 {1,457-1,723, 105-125} B 128-156 {1,300-1,600, 95-115}

! WARNING
Never allow grease and oil to adhere stamped straps, stamped strap bolts and bold holes. The grease and/or oil
which adhere to the stamped retainer bolts, stamped straps, stamped strap bolts, damaged bearing retainers or used
inferior grade bolts can cause driveline failure, which can result in separation of driveline from the vehicle. A sepa-
rated driveline can result in death, serious personal injury or property damage.
 PROPELLER SHAFT (SPL 100, 140) PP025

OVERHAUL
EN04Z0402H200001

IMPORTANT POINT - DISMOUNTING

1. DISCONNECT THE PROPELLER SHAFT FROM THE ALL CON-

NECTING POINTS.
(1) Park the vehicle on level ground, apply the parking brake and apply
wheel stoppers at the front or rear tires.
(2) Make aligning marks on all bearing positions, spline positions, shaft
locations and all bearing retainers.
(3) Working from the rear end, support the propeller shaft with support
straps as illustrated in Figure. Be sure to support the shaft assembly
at the rear, at the slip member, behind the center bearing end fitting
and in front of center bearing, with support straps.
SHTS04Z040200004

SHTS04Z040200005

Four piece

8 7 6 5 4 3 2 1

Front Rear
Final
coupling Coupling Coupling Drive-
shaft shaft shaft shaft

SHTS04Z040200006
PP026 PROPELLER SHAFT (SPL 100, 140)

(4) Remove the bearing retainers or stamped straps and bolts at rear
end. Discard bolts. Discard stamped straps (if applicable).
! WARNING
Bearing retainers CAN be reused if there is no damage. If dam-
aged, replace.
Stamped straps CANNOT be reused.
DO NOT reuse bearing retainer bolts, stamped strap bolts.
DO NOT reuse bearing retainer bolts, stamped straps, stamped
strap bolts, damaged bearing retainers, or use inferior grade
bolts. Reuse of bearing retainer bolts, stamped straps, stamped
SHTS04Z040200007 strap bolts, damaged bearing retainers or the use of inferior
grade bolts can cause driveline failure, which can result in sepa-
ration of driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.

SHTS04Z040200008

(5) Inspect all end yoke cross hole surfaces and bolt hole threads for
damage. If the bolt hole threads are damaged, the yoke must be
replaced.
Raised metal or fretting on open yoke cross holes can be removed
with a fine-toothed file and/or emery cloth.
! WARNING
DO NOT deform yoke cross holes by removing excessive metal.
Raised metal or deformed yoke cross holes can be a cause of cross
and bearing failure, which can result in separation of driveline from
vehicle. A separated driveline can result in death, serious personal
injury or property damage.
SHTS04Z040200009

(6) Inspect the end yoke cross holes for distortion using the appropriate
Spicer alignment bar. Slide alignment bar through both cross holes
simultaneously. If alignment bar will not pass through both cross
holes simultaneously, cross holes are distorted and yoke must be
replaced.
! WARNING
Failure to replace damaged driveline components can cause driveline
failure, which can result in separation of driveline from vehicle. A sep-
arated driveline can result in death, serious personal injury or prop-
erty damage.
Refer to the Chapter transmission, parking brake or rear axle for
SHTS04Z040200010
removal procedures.
 PROPELLER SHAFT (SPL 100, 140) PP027

IMPORTANT POINTS - DISASSEMBLY

1. DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SNAP RING

STYLE).
(1) Using snap-ring pliers, remove all snap rings. If snap rings are
severely corroded or out-of-round, snap rings must be replaced.
! WARNING
DO NOT reuse severely corroded or out-of-round snap rings. Reuse of
snap rings can cause universal joint failure and can result in separa-
tion of the driveline from the vehicle. A separated driveline can result
in death, serious personal injury or property damage.
SHTS04Z040200011

(2) Remove the outboard bearing cup assemblies.

SHTS04Z040200012

(3) Make sure the universal joint cross assembly is not tilted in yoke.

SHTS04Z040200013

(4) Place bearing cup spacer onto the base of the arbor press and under
the yoke. If the arbor is larger than the bearing cup diameter, a
smaller diameter push rod will be needed to avoid damage to the
yoke or bearing.
Using the arbor press, press down on the upper bearing cup assem-
bly until the shoulder of the journal cross makes contact with the
inside of the yoke ear. Bearing cup is not designed to drop out of
yoke.
! CAUTION
DO NOT over press the bearing cup and journal cross. This can dam-
age the inside of the yoke ear.
SHTS04Z040200014
PP028 PROPELLER SHAFT (SPL 100, 140)

(5) Grip the bearing cup in bench vise. Strike the yoke ear with a soft-
faced hammer until bearing is removed.

SHTS04Z040200015

(6) Place the yoke in the arbor press with remaining bearing cup face
down. Using a push rod, press on the end of journal cross trunnion.
Continue to press down on journal cross trunnion until the shoulder of
the journal cross makes contact with the inside of yoke ear. Bearing
cup is not designed to drop out of yoke. Repeat step (5).
(7) Remove journal cross from yoke.

SHTS04Z040200016

(8) Inspect the tube yoke and flange yoke (if applicable) cross hole sur-
faces for damaged or raised metal. Raised metal or fretting can be
removed from yoke cross holes with a fine-toothed file and/or emery
cloth.
! WARNING
DO NOT deform yoke cross holes by removing excessive metal.
Raised metal or deformed yoke cross holes can be a cause of cross
and bearing problems and can result in separation of driveline from
vehicle. A separated driveline can result in death, serious personal
injury or property damage.

SHTS04Z040200017

(9) Inspect the yoke for distorted cross holes using the appropriate Spicer
alignment bar. Slide alignment bar through both cross holes simulta-
neously. If alignment bar will not pass through both cross holes simul-
taneously, cross holes are distorted and the shaft assembly must be
replaced.
! WARNING
Failure to replace a damaged driveline can cause driveline failure,
which can result in separation of driveline from vehicle. A separated
driveline can result in death, serious personal injury or property dam-
age.
 PROPELLER SHAFT (SPL 100, 140) PP029

2. DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SPRING

TAB STYLE)
(1) Remove and discard spring tabs and bolts.
! WARNING
DO NOT reuse spring tabs, spring tab bolts or use inferior grade
bolts. Reuse of spring tabs, spring tab bolts and use of inferior grade
bolts, can cause driveline failure, which can result in separation of
driveline from the vehicle. A separated driveline can result in death,
serious personal injury or property damage.

SHTS04Z040200018

(2) Remove the outboard bearing cup assemblies.

SHTS04Z040200019

(3) Make sure universal joint cross assembly is not tilted in the yoke.

SHTS04Z040200020

(4) Place bearing cup spacer onto the base of the arbor press and under
the yoke. If the arbor is larger than the bearing cup diameter, a
smaller diameter push rod will be needed to avoid damaging the yoke
or bearing.
Using an arbor press, press down on the upper bearing cup assembly
until the shoulder of the journal cross makes contact with the inside of
the yoke ear.
! CAUTION
DO NOT over press the bearing cup and journal cross. This can dam-
age the inside of the yoke ear.

SHTS04Z040200021
PP0210 PROPELLER SHAFT (SPL 100, 140)

(5) The bearing cup is not designed to drop out of the yoke. It will be nec-
essary to use a soft-faced hammer to tap the partially pressed-out
bearing cup from side to side, to "walk" the bearing cup out of the
yoke ear.

SHTS04Z040200022

(6) Place the yoke in the press, with the remaining bearing cup face
down. Using a push rod, press on end of the journal cross trunnion.
Continue to press down on the journal cross trunnion until the shoul-
der of the journal cross makes contact with the inside of the yoke ear.
(7) Repeat step (5).
(8) Remove the journal from the yoke.

SHTS04Z040200023

(9) Inspect the tube yoke cross hole surfaces for damage or raised metal.
Raised metal or fretting can be removed from yoke cross holes with a
fine-toothed file and/or emery cloth.
! WARNING
DO NOT deform yoke cross holes by removing excessive metal.
Raised metal or deformed yoke cross holes can be a cause of cross
and bearing problems and can result in separation of driveline from
vehicle. A separated driveline can result in death, serious personal
injury or property damage.

SHTS04Z040200024

(10) Inspect the tube yoke or flange yoke (if applicable) for distorted cross
holes using an appropriate Spicer alignment bar. Slide alignment bar
through both cross holes simultaneously. If alignment bar will not
pass through both cross holes simultaneously, the cross holes are
distorted and the shaft assembly must be replaced.
! WARNING
Failure to replace a damaged driveline can cause driveline failure,
which can result in separation of driveline from vehicle. A separated
driveline can result in death, serious personal injury or property dam-
age.

SHTS04Z040200025
 PROPELLER SHAFT (SPL 100, 140) PP0211

3. REMOVE THE MEMBER BOOT

! CAUTION
Seal can style slip member assemblies are NOT serviceable. If seal
can or seal is damaged, replacement of the complete driveshaft
assembly is necessary.

(1) Remove and discard both boot clamps. Clamps may be separated
using a chisel to disengage locking hooks. DO NOT reuse clamps.
! WARNING
Reuse of boot clamps could allow intrusion of contaminants into
SHTS04Z040200026
slip member and can cause driveline failure, which can result in
separation of the driveline from the vehicle. A separated drive-
line can result in death, serious personal injury or property dam-
age.
The following step is an additional marking process to that
described in step one. Be sure to mark as directed.
(2) Completely collapse the boot toward the yoke shaft to expose weld
ring and spline sleeve area. Wipe weld ring and spline sleeve areas
clean.
(3) Mark spline sleeve and end of weld ring with a marking stick, paint
marker or other legible marking device. This assures that the slip
member can be reassembled in its original phased condition.
! WARNING
Reassembly of a driveline out of original phase can cause vibration
and failure of the driveline and attaching components. Failure of a
driveline can result in separation of driveline from the vehicle, which
can result in death, serious personal injury or property damage.

SHTS04Z040200027

4. REMOVE THE CENTER BEARING

(1) Remove midship nut. Reference midship nut. Discard nut. If washer is
damaged, discard and replace. Otherwise, reuse washer.
! WARNING
DO NOT reuse midship nut. Reuse of midship nut can cause driveline
failure, which can result in separation of driveline from the vehicle. A
separated driveline can result in death, serious personal injury or
property damage.

! CAUTION
The following step (2) is an additional marking process to that
SHTS04Z040200028
described in step (1). Be sure to mark as directed.
PP0212 PROPELLER SHAFT (SPL 100, 140)

(2) Mark the counterbore of end yoke to midship "nose" with marking
stick, paint marker or other legible marking device. This assures
proper reassembly of the center bearing end yoke in its original
phased position.
! WARNING
Reassembly of a driveline out of original phase can cause vibration
and failure of the driveline and attaching components. Failure of a
driveline can result in separation of driveline from the vehicle, which
can result in death, serious personal injury or property damage.

SHTS04Z040200029

(3) Using a puller, remove the yoke. The yoke has a press fit and should
NOT be removed with a hammer. If the yoke is loose enough to be
removed by hand, the entire coupling shaft must be replaced.
Remove and discard slinger from the yoke.
! WARNING
Failure to replace damaged driveline components can cause driveline
failure, which can result in separation of driveline from vehicle. A sep-
arated driveline can result in death, serious personal injury or prop-
erty damage.

SHTS04Z040200030

(4) Visually inspect the splines of the center bearing end yoke. If the yoke
splines are damaged, missing or twisted, the yoke must be replaced.
If the yoke hub is cracked, the yoke must be replaced. See warning,
step (3).
(5) Visually inspect the midship splines and threads. If the splines or
threads are damaged, missing or twisted, replacement of the entire
coupling shaft is necessary. See warning, step (3).
(6) Remove and discard center bearing bracket. Remove and discard
rubber cushion.

SHTS04Z040200031

(7) Use a puller to remove the bearing assembly from the midship. Dis-
card the center bearing.

SHTS04Z040200032
 PROPELLER SHAFT (SPL 100, 140) PP0213

(8) Inspect midship for wear on the bearing diameter. If the midship is
damaged from a seized bearing, replacement of the entire coupling
shaft is necessary.
! WARNING
Failure to replace damaged driveline components can cause driveline
failure, which can result in separation of driveline from vehicle. A sep-
arated driveline can result in death, serious personal injury or prop-
erty damage.

(9) If no damage is apparent, remove slinger.

SHTS04Z040200033

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SPRING TAB

STYLE).
(1) Remove needle retaining plugs from all bearing cup assemblies.
Using a high-quality, N.L.G.I.*, E. P. Grade 2 lubricating grease, wipe
each bearing cup assembly with grease. Fill all cavities between the
needle rollers. Also apply a liberal coating of grease on the bottom of
each bearing cup assembly and on the lip of the seal.
*National Lubricating Grease Institute
! WARNING
SHTS04Z040200034 Inadequate lubrication can cause driveline failure, which can result in
separation of the driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.

! CAUTION
DO NOT Wipe the outside of bearing cup assemblies or yoke cross
holes with grease, oil or silicone-based sprays. This could cause
bearing cup assembly rotation in yokes.

! WARNING
Rotating bearing cup assemblies can result in yoke cross hole wear
and distortion. Distorted yokes can result in separation of the drive-
line from the vehicle. A separated driveline can result in death, seri-
ous personal injury or property damage.

(2) Position the journal cross into the yoke cross holes with the grease
zerk (nipple) fitting inward toward tubing. The double-headed, grease
zerk (nipple) fitting should be perpendicular to the yoke cross holes.
Failure to properly position the universal joint will result in the inability
to grease the universal joint. See warning, step (1), regarding inade-
quate lubrication.

SHTS04Z040200035
PP0214 PROPELLER SHAFT (SPL 100, 140)

(3) Move one end of the journal cross to cause a trunnion to project
through the cross hole beyond the outer machined face of the yoke
ear. Take one bearing cup assembly and position an installation
height tool on the end of the bearing cup assembly. Place the bearing
cup assembly over the protruding trunnion diameter and align it to the
yoke cross hole.

SHTS04Z040200036

(4) Align the yoke in an arbor press with the bearing assembly resting on
the base of the press. (See photo 109, left.) Cover the yoke ear with a
metal plate that has 0.25 inch (6.4 mm) minimum thickness. Push the
yoke onto the bearing cup assembly until the installation height tool is
flush with the cross hole face. Do not remove the installation height
tool.

SHTS04Z040200037

(5) Flip yoke 180 degrees. Position the remaining installation height tool
on the end of another bearing cup assembly. Place bearing cup
assembly over trunnion diameter and align it to the yoke cross hole.
Push the bearing cup assembly until both installation height tools are
flush with the cross hole face. Remove and discard both installation
height tools.

SHTS04Z040200038

(6) Install new spring tabs and 8 mm thread bolts. Make sure that no
grease or foreign material is present between the contact areas of the
spring tabs, bearing cups and yoke cross hole faces. Tighten bolts to
the required torque. See spring tab bolt torque specification Table
below.

SPRING TAB BOLT SPECIFICATIONS

THREAD HEAD BOLT TORQUE
SERIES KIT P/N*
SIZE SIZE Nm LB. FT.
8 mm x 8 mm,
SPL140 35-40 25-30 211941X
1.00 6 point
SHTS04Z040200039
* Bolts are specially heat-treated.
DO NOT substitute inferior grade bolts.

! WARNING
Reuse of spring tabs or spring tab bolts or failure to properly tighten
spring tab bolts to required specifications can cause the driveline to
loosen and separate from the vehicle. A separated driveline can result
in death, serious personal injury or property damage.
 PROPELLER SHAFT (SPL 100, 140) PP0215

2. ASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SNAP RING

STYLE).
(1) Using a high quality N.L.G.I.*, E. P. Grade 2 lubricating grease, wipe
each bearing cup assembly with grease. Fill all cavities between the
needle rollers. Also apply a liberal coating of grease on the bottom of
each bearing cup assembly and on the lip of the seal.
*National Lubricating Grease Institute
! WARNING
Inadequate lubrication can cause driveline failure, which can result in
separation of the driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.
SHTS04Z040200040
! CAUTION
DO NOT Wipe the outside of bearing cup assemblies or yoke cross
holes with grease, oil or silicone-based sprays. This could cause
bearing cup assembly rotation in yokes.

! WARNING
Rotating bearing cup assemblies can result in yoke cross hole wear
and distortion. Distorted yokes can result in separation of the drive-
line from the vehicle. A separated driveline can result in death, seri-
ous personal injury or property damage.

(2) Position the journal cross into the yoke cross holes with grease zerk
(nipple) fitting inward toward tubing. The double-headed, grease zerk
(nipple) fitting should be perpendicular to the yoke cross holes.
Failure to properly position the universal joint kit will result in the
inability to grease the universal joint. See warning step (1), regarding
inadequate lubrication.

SHTS04Z040200041

(3) Move one end of the journal cross to cause a trunnion to project
through the cross hole beyond the outer machined face of the yoke
ear. Place the bearing cup assembly over the protruding trunnion
diameter and align it to the yoke cross hole.
Align the yoke in an arbor press with the bearing assembly resting on
the base of the press. Cover the yoke ear with a metal plate that has
0.25 inch (6.4 mm) minimum thickness. Push the yoke onto the bear-
ing cup assembly until it is flush with the cross hole face.

SHTS04Z040200042
PP0216 PROPELLER SHAFT (SPL 100, 140)

(4) Place a push rod that is smaller than the diameter of the bearing cup
assembly under the bearing cup assembly and continue pressing into
the yoke cross hole until it is far enough to install a snap ring.
(5) Remove yoke from arbor press. Install a snap ring using snap ring pli-
ers.

SHTS04Z040200043

(6) Flip yoke 180 degrees. Place another bearing cup assembly over
trunnion diameter and align it to yoke cross hole. Align yoke in arbor
press with previously installed bearing cup assembly resting on base
of press. Place a push rod that is smaller than the bearing cup assem-
bly on top of the bearing cup assembly. Press bearing cup assembly
into the yoke cross hole until far enough to install a snap ring.
(7) Remove yoke from arbor press. Install a snap ring using snap ring pli-
ers.

SHTS04Z040200044

(8) Seat the snap rings into grooves using a small chisel or punch. Com-
panion flange style proceed to step (9). Without flange style proceed
to (18).
(9) Position flange yoke cross holes over remaining trunnions.
(10) Place a bearing cup assembly over a protruding trunnion diameter
and align it to the flange yoke cross hole.
(11) Align the yoke in an arbor press with the bearing assembly resting on
the base of the press. Cover the yoke ear with a metal plate that has
0.25 inch (6.4 mm) minimum thickness. Push the yoke onto the bear-
ing cup assembly until it is flush with the cross hole face.
(12) Place a push rod that is smaller than the diameter of the bearing cup
SHTS04Z040200045 assembly under the bearing cup assembly and continue pressing into
the flange yoke cross hole until it is far enough to install a snap ring.
(13) Remove yoke from arbor press. Install a snap ring using snap ring pli-
ers.
(14) Flip yoke 180 degrees. Place remaining bearing cup assembly over
trunnion diameter and align it to flange yoke cross hole. Align yoke in
arbor press with previously installed bearing cup assembly resting on
base of press. Place a push rod that is smaller than the bearing cup
assembly on top of the bearing cup assembly. Press bearing cup
assembly into the yoke cross hole until it is far enough to install a snap
ring.
(15) Remove yoke from arbor press. Install a snap ring using snap ring pli-
ers.
(16) Seat the snap rings into grooves using a small chisel or punch.
 PROPELLER SHAFT (SPL 100, 140) PP0217

(17) Flex the journal cross to make sure it moves freely in bearings. If the
joint is stiff, place a plate on the yoke ear and hit the plate with a ham-
mer to seat the bearing cup assemblies.
! WARNING
When using hammer, TO PREVENT eye injury, always wear safety
glasses when performing maintenance or service. Failure to wear
safety glasses could result in death, serious personal injury or prop-
erty damage.
(18) Flex the journal cross to make sure it moves smoothly and freely in
bearings. If not, disassemble and inspect the journal and bearing
assemblies for skewed or dropped needle rollers. Reference removal
procedures for universal joints, snap ring style.

SHTS04Z040200046

3. INSTALL THE SLIP MEMBER BOOT.

(1) Clean ALL grease from yoke shaft and spline sleeve. Make sure
grease-cutting solvent does not intrude into the tube through the vent
hole in the spline sleeve plug. Be sure the phasing marks made dur-
ing disassembly are not removed.

SHTS04Z040200047

(2) After all traces of grease-cutting solvent have been removed from
yoke shaft and spline sleeve, apply enough N.L.G.I*, E. P. Grade 2
grease (provided in slip member boot replacement kit) to fill the entire
length of all teeth in the spline sleeve. Wipe any excess grease on the
teeth of the yoke shaft.
*National Lubricating Grease Institute
! WARNING
Inadequate lubrication can cause driveline failure, which can result in
separation of the driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.

SHTS04Z040200048
PP0218 PROPELLER SHAFT (SPL 100, 140)

(3) Measure and place a mark 2.25 inches (55-60mm) from yoke shaft
shoulder with a marking stick, paint marker or other legible marking
device.
(4) Position a clamp on each end of the new boot. Slide the boot onto the
grease-free yoke shaft shoulder.
(5) Collapse the boot and insert the yoke shaft into the splined sleeve,
making sure phasing marks are in line. Position the end of the boot at
the 2.25 inches (55-60mm) mark made on the yoke shaft shoulder
and tighten boot clamps to the specified torque. Yoke shaft shoulder
must be clean, dry and grease-free. See boot clamp torque specifica-
tion.
SHTS04Z040200049
BOOT CLAMP SPECIFICATIONS
CLAMP TORQUE
SERIES CLAMP P/N
Nm LB. FT.
SPL100 TBD TBD TBD
SPL140 232757 136-180 100-130

! WARNING
Failure to properly install and tighten boot clamps could allow intru-
sion of contaminants and can cause driveline failure, which can result
in separation of the driveline from the vehicle. A separated driveline
can result in death, serious personal injury or property damage.
(6) Before the driveshaft is completely installed in the vehicle, slowly col-
lapse and extend the driveshaft to make sure the boot clamps are sta-
tionary. If the clamps are not stationary, recheck for proper clamp
torque. If clamps still are not stationary, repeat disassembly and
assembly procedure. DO NOT reuse clamps.
! WARNING
Reuse of boot clamps or failure to properly tighten boot clamps to
required specifications could allow intrusion of contaminants onto
slip member and can cause driveline failure, which can result in sepa-
ration of the driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.

4. INSTALL THE CENTER BEARING.

(1) Wipe the bearing surface of the midship tube shaft with a fine emery
cloth.
(2) Install a new slinger (included in center bearing replacement kit) on
the midship tube shaft using a section of tubing to avoid damaging
slinger. Make sure the slinger is completely seated against the mid-
ship tube shaft shoulder.

SHTS04Z040200050
 PROPELLER SHAFT (SPL 100, 140) PP0219

(3) Before installing the new center bearing assembly, be sure to fill the
entire cavity around the bearing with waterproof lubricant. (See photo
131, above.) Enough lubricant must be applied to fill the cavity to the
extreme edge of the slinger surrounding the bearing. Lubricants must
be water proof. See Table, below for recommended lubricants.
! WARNING
Inadequate lubrication can cause driveline failure, which can result in
separation of the driveline from the vehicle. A separated driveline can
result in death, serious personal injury or property damage.

RECOMMENDED CENTER BEARING LUBRICANTS

SHTS04Z040200051
LUBRICANTS SOURCE
Rykon Premium No. 3 Amoco Oil Company
Amolith 8516 Amoco Oil Company
Van Talgar No. 4 Exxon Company

(4) Carefully align the new center bearing assembly with the ground sur-
face of the midship tube shaft. Physically push the center bearing
onto the midship tube shaft.
(5) Press remaining slinger on end yoke using a section of tubing to avoid
damaging slinger.
(6) Using a soft-faced hammer, tap the yoke onto midship tube shaft,
making sure phasing marks from driveshaft removal procedure are in
line. Continue to tap the yoke until it is completely seated against the
center bearing.

SHTS04Z040200052

(7) Install a washer (if required) and new midship nut and torque nut to
specifications. See midship nut specifications, Table.
! WARNING
Failure to torque midship nut to required specifications can cause
driveline failure, which can result in separation of the driveline from
the vehicle. A separated driveline can result in death, serious per-
sonal injury or property damage.

MIDSHIP NUT SPECIFICATIONS

WASHER HEAD NUT TORQUE
SERIES NUT P/N
SHTS04Z040200053
P/N SIZE* Nm LB. FT.
SPL100 TBD TBD TBD TBD TBD
SPL140 250-74-11 230123-6 41mm* 644-712 475-525
* A 1 5/8" socket may be used.
PP0220 PROPELLER SHAFT (SPL 100, 140)

IMPORTANT POINT - MOUNTING

1. CONNECT THE PROPELLER SHAFT TO THE ALL CONNECTING

POINTS.
(1) Position support straps to make sure that the driveshaft will be prop-
erly supported at the slip member, behind the center bearing end fit-
tings and in front of center bearing, with support straps.
(2) Working from the front end, use a soft-faced hammer to tap the uni-
versal joint into the front end yoke. Make sure to align the universal
joint in the front end yoke, matching up phasing marks made during
removal to ensure the driveshaft is reinstalled in its original orienta-
SHTS04Z040200054 tion.
(3) Install the bearing retainers or new stamped straps and new bolts.
Torque the bolts down evenly and to required specifications. Check to
make sure the bearing cup assemblies are fully seated in yoke ears.
! WARNING
Improperly seated bearing cup assemblies can cause driveline
failure, which can result in separation of the driveline from the
vehicle. A separated driveline could result in death, serious per-
sonal injury or property damage.
Failure to install new stamped straps and new bolts and to
torque bolts to specification can cause driveline failure, which
can result in separation of the driveline from the vehicle. A sepa-
SHTS04Z040200055
rated driveline can result in death, serious personal injury or
property damage.

Four piece BOLT SPECIFICATIONS

THREAD BOLT TORQUE
SERIES HEAD SIZE
SIZE Nm LB. FT.
8 7 6 5 4 3 2 1
0.375 in. x 3/8 in.
SPL100 61-81 45-60
24UNF 12 point
Front Rear 12 mm x 1/2 in.
Final
SPL140 143-169 105-125
1.25 12 point
coupling Coupling Coupling Drive-
shaft shaft shaft shaft * Bolts are specially heat-treated.
DO NOT substitute inferior grade bolts.
SHTS04Z040200056

(4) Install proper center bearing bracket bolts.

! WARNING
Failure to torque bolts to specification can cause driveline failure,
which can result in separation of the driveline from the vehicle. A sep-
arated driveline can result in death, serious personal injury or prop-
erty damage.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF021

DIFFERENTIAL CARRIER
DF02

(MERITOR RS17.19.21&23) DF02-001

DIFFERENTIAL CARRIER ASSEMBLY... DF02-2

DATA AND SPECIFICATIONS ......................... DF02-2
DESCRIPTION ................................................ DF02-4
TROUBLESHOOTING ..................................... DF02-7
SPECIAL TOOL ............................................... DF02-8
COMPONENT LOCATOR.............................. DF02-10
OVERHAUL ................................................... DF02-14
INSPECTION AND REPAIR .......................... DF02-54

DRIVER-CONTROLLED
MAIN DIFFERENTIAL LOCK ................. DF02-63
OVERHAUL ................................................... DF02-63
INSPECTION AND REPAIR .......................... DF02-66
DF022 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

DIFFERENTIAL CARRIER ASSEMBLY

DATA AND SPECIFICATIONS
EN05Z0502I200001

CAPACITY
MODEL AXLE MODEL GEAR RATIOS
U.S. Pints Liters

3.07, 3.90, 4.11, 4.88,

HINO 238 (NE8J), HINO 258 (NE8J, NJ8J) RS17-145 33.6 15.9
5.13, 5.29

3.73, 3.90, 4.11, 4.88,

HINO 268 (NE8J, NJ8J) RS19-145 33.2 15.7
5.13, 5.29, 5.57

3.90, 4.11, 4.33, 4.63,

HINO 338 (NF8J, NV8J) RS21-145 4.88, 5.13, 5.29, 5.57, 32.3 15.3
5.86, 6.14

3.91, 4.10, 4.56, 4.89,

HINO 358 (NH8J) RS23-160 39.5 18.7
5.38, 5.63, 6.14

Single-Reduction Differential Carrier

8
2

7
3

6 5

SHTS05Z050200001

1 TAPERED ROLLER BEARINGS 5 BEVEL DIFFERENTIAL GEARS

2 CARRIER 6 HOUSING
3 STRAIGHT ROLLER BEARING 7 TAPERED ROLLER BEARING
4 TAPERED ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF023

Single-Reduction Differential carrier with Differential Lock

1
8 2
3

7 9

6 5 4

SHTS05Z050200002

1 TAPERED ROLLER BEARINGS 6 HOUSING

2 CARRIER 7 TAPERED ROLLER BEARING
3 STRAIGHT ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR
4 TAPERED ROLLER BEARING 9 DIFFERENTIAL LOCK ASSEMBLY
5 BEVEL DIFFERENTIAL GEARS
DF024 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

DESCRIPTION
EN05Z0502D100001

Single-Reduction Differential Carrier

1
2 3
3A
31 4
8
5 9
6
7

30

29
32
28
27 8

26 12
25

24 9
22 10
23

13
20 11
21 17
16
18 15
19 14

SHTS05Z050200003

1 Nut Drive Pinion* 17 Carrier

2 Washer Drive Pinion* 18 Adjusting Ring
3 Input Yoke* or Flange* 19 Cotter Pin Adjusting Ring
3A Deflector 20 Jam Nut* Thrust Screw*
4 POSETM seal 21 Thrust Screw*
5 Triple Lip (Main) Seal 22 Snap Ring
6 Bearing Cone Outer 23 Spigot Bearing
7 Bearing Cup Inner 24 Drive Pinion
8 Capscrews* Lock Plate* 25 Bearing Cone Pinion Inner
9 Washers* Lock Plate* 26 Bearing Cup Pinion Inner
10 Lock Plate Adjusting Ring 27 Spacer Pinion Bearing
11 Capscrews Differential Bearing Cap 28 Shims
12 Washers 29 Bearing Cage Drive Pinion
13 Caps Differential Bearing 30 Capscrew Bearing Cage
14 Capscrews Differential Bearing Cap 31 Washer
15 Washers 32 Clip and Cable Holder
16 Caps Differential Bearing
*Some Meritor carriers do not have these described parts.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF025

7
8
6

2 5
4

2
3

9
1
5
11 10

12
20 2
21
2
19

13 3

14

15
18
16
17

SHTS05Z050200004

1 Side Gears Differential 12 Spider Differential

2 Thrust Washers Differential Pinion 13 Bolts* or Rivets* Ring Gear and Case Half
3 Pinions Differential 14 Ring Gear (Pinion Drive Gear)
4 Differential Side Gears 15 Case Half Flange
5 Thrust Washers Differential Side Gear 16 Washers Case Half
6 Cone Differential Bearing 17 Nuts* Case Half
7 Cup Differential Bearing 18 Bearing Cone Differential L.H.
8 "Thru" Bolt 19 Bearing Cup Differential L.H.
9 Bolts* Differential Case 20 Washer for "Thru" Bolt
10 Washers Differential Case 21 Nut for "Thru" Bolt
11 Case Assembly Main Differential
*Some Meritor carriers do not have these described parts.
DF026 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

Differential lock assembly

8
7
6
5
4
3
1 2
9
12 10
11

12

SHTS05Z050200005

1 SENSOR SWITCH 7 AIR CYLINDER TUBE

2 SHIFT FORK 8 SCREW-IN DIFFERENTIAL LOCK
3 SHIFT SHAFT SPRING 9 PISTON O-RING
4 SHIFT SHAFT 10 PISTON
5 SPRING RETAINING PIN 11 SHIFT COLLAR
6 FLAT WASHER, OR SILASTIC AS REQUIRED 12 SHIFT FORK ROLL PINS
*Some Meritor carriers do not have these described parts.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF027

TROUBLESHOOTING
EN05Z0502F300001

Symptom Possible cause Remedy/Prevention

Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings.
Worn or damaged differential side Replace bearings.
bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
Abnormal noise (Gear system) Inadequate backlash on ring gear and Adjust backlash.
pinion gear
Worn thrust washers Replace.
Worn differential spider Replace.
Worn or damaged ring gear and pinion Replace.
Worn or damaged differential side gear Replace.
and pinion
Loose ring gear bolts Tighten bolts.
Inadequate tooth contact of ring gear Replace or adjust tooth contact.
and pinion gear
Worn opinion spline Replace.
Abnormal noise (rear axle system) Worn rear axle shaft spline Replace.
Worn hub bearings Replace.
Loose hub bearings Adjust bearing preload.
Loose differential case tightening bolts Tighten bolts.
Abnormal noise (Oil system, etc.) Insufficient oil Add oil, check for leakage.
Poor oil quality Change oil.
Abnormal propeller shaft noise Refer to chapter "PROPELLER
SHAFT".
DF028 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

SPECIAL TOOL
EN05Z0502K100001

Prior to starting a differential carrier overhaul, it is necessary to have these special tools.

2
1
12

11
3

6
10
4

9
5

8 SPX Kent-Moore
part number J-3409-D

SHTS05Z050200006

1 PLATES 8' LONG X 3/4" THICK X 1-1/4" WIDE WITH 7 23-1/2" CENTER TO CENTER OF PIPE
A TONGUE TO FIT SLOT IN BAR WELD PLATES TO
BAR
2 HANDLE 7" LONG WITH SLOT IN ONE END TO FIT 8 CHAMFER END OF PIPE FOR WELDING
CLAMP SCREW
3 BAR 2" DIAMETER X 9" LONG WITH ONE END 9 4" DIAMETER PIPE
SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN 10 PLUG 4" DIAMETER X 7" LONG WITH ONE END
PIPE TURNED 3" LONG TO FIT PIPE. DRILL 2" HOLE AND
MILL 3/16" WIDE SLOT 2" FROM TOP
5 WELD 11 SCREW 3-1/2" LONG X 5/8" DIAMETER WITH FLATS
ON END TO FIT HANDLE AND 2-1/2" LENGTH OF
THREAD ON OTHER END
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER 12 DRILL 3/8" HOLE THROUGH HANDLE AND SCREW
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF029

1. HOW TO MAKE A YOKE BAR

A (1) Measure dimensions A and B of the yoke you are servicing.

1 YOKE 1

SHTS05Z050200007

(2) Calculate dimensions C and D of the yoke bar by adding 0.125-0.250-

inch to dimensions A and B of the yoke.
1

! WARNING
D Wear safe clothing and eye protection when you use welding equip-
ment. Welding equipment can burn you and cause serious personal
injury. Follow the operating instructions and safety procedures rec-
ommended by the welding equipment manufacturer.
C
(3) To make the box section, cut and weld 1.0-inch x 2.0-inch mild steel
square stock according to dimensions C and D.
1 YOKE BAR (4) Cut a 4.0-foot x 1.25-inch piece of mild steel round stock to make the
SHTS05Z050200008
yoke bar handle. Center weld this piece to the box section.
To increase yoke bar rigidity: Weld two angle pieces onto the handle.

2. HOW TO ORDER TOOLS AND SUPPLIES SPECIFIED IN THIS

MANUAL
Call ArvinMeritor's Commercial Vehicle Aftermarket at 888-725-9355
to order Meritor tools and supplies.

SPX Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092. Call

the company's customer service center at 800-345-2233, or visit their
website at spxkentmoore.com.
DF0210 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

COMPONENT LOCATOR
EN05Z0502D100002

5
4
3

12 6 19
20
18
7
14 16

15 17
10
11
8
13

10

SHTS05Z050200009
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0211

Fastener Thread Size Torque Value lb-ft (Nm)

1. Capscrew, Axle Shaft .31-24 18-24 (24-33)
.50-13 85-115 (115-156)
2. Nut, Axle Shaft Stud Plain Nut 50-75 (68-102)
.44-20 75-115 (102-156)
.50-20 110-165 (149-224)
.56-18 150-230 (203-312)
.62-18
Lock Nut 40-65 (54-88)
.44-20 65-100 (88-136)
.50-20 100-145 (136-197)
.56-18 130-190 (176-258)
.62-18
3. Breather .38-18 20 minimum (27 minimum)
4. Plug, Oil Fill, Housing .75-14 35 minimum (47.5 minimum)
5. Plug, Heat Indicator .50-14 25 minimum (34 minimum)
6. Plug, Oil Drain .50-14 25 minimum (34 minimum)
7. Capscrew, Differential Case .38-16 35-50 (48-68)
.44-14 60-75 (81-102)
.50-13 85-115 (115-156)
.56-12 130-165 (176-224)
.62-11 180-230 (244-312)
Grade 10.9 Flange Head M12 x 1.75 85-103 (115-140)
Grade 10.9 Standard Hex Head M12 x 1.75 74-96 (100-130)
Grade 12.9 Standard Hex Head M12 x 1.75 105-125 (143-169)
Grade 12.9 Flange Head M16 x 2 203-251 (275-340)
Grade 12.9 Standard Head M16 x 2 220-310 (300-420)
8. Nut, Differential Case Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.75 74-96 (100-130)
M16 x 2 220-310 (300-420)
9. Nut, Ring Gear Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.25 66-81 (90-110)
M12 x 1.75 77-85 (104-115)
Flange Head M16 x 1.5 192-214 (260-290)
Standard Hex Head M16 x 1.5 196-262 (265-355)
10. Capscrew, Bearing Cap .56-12 110-145 (149-197)
.62-11 150-190 (203-258)
.75-10 270-350 (366-475)
.88-14 360-470 (488-637)
.88-9 425-550 (576-746)
M16 x 2 181-221 (245-300)
M20 x 2.5 347-431 (470-585)
M22 x 2.5 479-597 (650-810)
11. Nut, Housing to Carrier Stud .44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
DF0212 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

Fastener Thread Size Torque Value lb-ft (Nm)

12. Capscrew, Carrier to Housing .44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
.75-10 270-400 (366-542)
M12 x 1.75 74-89 (100-120)
M16 x 2 181-221 (245-300)
13. Jam Nut, Thrust Screw .75-16 150-190 (203-258)
.88-14 150-300 (203-407)
1.12-16 150-190 (203-258)
M22 x 1.5 148-210 (200-285)
M30 x 1.5 236-295 (320-400)
14. Input Yoke-to-Input Shaft Nut Refer to page DF02-12.
15. Capscrew, Bearing Cage .38-16 30-50 (41-68)
.44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
M12 x 1.75 70-110 (90-150)
16. Plug, Oil Fill, Carrier .75-14 25 minimum (34 minimum)
1.5-11.5 120 minimum (163 minimum)
M24 x 1.5 35 minimum (47 minimum)
17. Capscrew, Lock Plate .31-18 20-30 (27-41)
M8 x 1.25 21-26 (28-35)
18. Lock Nut, Sensor Switch M16 x 1.0 25-35 (35-45)
19. Air Cylinder M60 x 2.0 80-100 (109-136)
20. Screw-in DCDL Cylinder Plug or M60 x 2.0 80-100 (109-136)
Cup

Input and Output Yoke Pinion Nut Fastener Torque Specifications Single Axles
Axle
RS-145 RS-160
Model
Pinion Nut Torque value Torque value
Fastener Size Fastener Size
Location lb-ft (Nm) lb-ft (Nm)
Carrier input yoke 920-1130 1000-1230
M39 x 1.5 M45 x 1.5
(1250-1535) (1350-1670)
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0213

TORQUE VALUES FOR FASTENERS

1. GENERAL INFORMATION
1
(1) The torque values on page DF02-1112 are for fasteners that have a
2 light application of oil on the threads.
If the fasteners are dry: Increase the torque values by 10%.
3 If the fasteners have a heavy application of oil on the threads:
Decrease the torque values by 10%.
(2) If you do not know the size of the fastener that is being installed, mea-
1 AMOUNT OF THREADS IN 1"
sure the fastener. Use the following procedure.
2 1"
3 X
2. AMERICAN STANDARD FASTENERS
X DIMENSION = EXAMPLE 1/2" .

SHTS05Z050200010
a. Measure the diameter of the threads in inches, dimension X.
b. Count the amount of threads in 1-inch.

Example
American Standard size fastener is 0.50-13.
0.50 is the diameter of the fastener in inches or dimension X.
13 is the amount of threads in 1-inch.

3. METRIC FASTENERS
.

1 a. Measure the diameter of the threads in millimeters (mm), dimension

X.
b. Measure the distance of 10 threads, point to point in millimeters (mm),
dimension Y. Make a note of dimension Y.
2
c. Divide dimension Y by 10. The result will be the distance between two
3
threads or pitch.
1 PITCH
2 X
3 Y
X DIMENSION = EXAMPLE M8 OR 8 MM Example
Y DIMENSION = DIST ANCE OF 10 THREADS
Metric size fastener is M8 x 1.25. M8 is the diameter of the fastener in
SHTS05Z050200011 millimeters (mm) or dimension X.
1.25 is the distance between two threads or pitch.
(1) Compare the size of fastener measured in 1. (2) above to the list of
fasteners on page DF02-1112 to find the correct torque value.
DF0214 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

OVERHAUL
EN05Z0502H200001

BEFORE YOU BEGIN

This manual provides instructions for the Meritor RS-Series axles. Before
you begin procedures:
.

1. Read and understand all instructions and procedures before you

begin to service components.
2. Read and observe all Caution and Warning safety alerts that precede
instructions or procedures you will perform. These alerts help to avoid
damage to components, serious personal injury, or both.
3. Follow your company's maintenance and service, installation, and
diagnostics guidelines.
4. Use special tools when required to help avoid serious personal injury
and damage to components.

1. SAFETY ALERTS, TORQUE SYMBOL AND NOTES

! WARNING A Warning alerts you to an instruc-

tion or procedure that you must
follow exactly to avoid serious per-
sonal injury.

! CAUTION A Caution alerts you to an instruc-

tion or procedure that you must
follow exactly to avoid damage to
components.

NOTICE A Note provides information or

suggestions that help you correctly
service a component.

2. ACCESS PRODUCT AND SERVICE INFORMATION ON OUR WEB-

SITE
Visit the DriveTrain PlusTM by ArvinMeritor Tech Library at arvinmeri-
tor.com to access and order product and service information.

3. TO ORDER INFORMATION BY PHONE

Call ArvinMeritor's Customer Service Center at 800-535-5560 to
order the following publications.
Lubrication
Single-Reduction Differential Carriers
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0215

IMPORTANT POINTS - DISMOUNTING

! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving. Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. Jacks can slip and fall
over. Serious personal injury can result.

Use a brass or leather mallet for assembly and disassembly proce-

dures. Do not hit steel parts with a steel hammer. Pieces of a part can
break off and cause serious personal injury.

1. REMOVAL OF DIFFERENTIAL CARRIER FROM THE AXLE HOUS-

ING
(1) Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving.
(2) Use a jack or other lifting tool to raise the vehicle so that the wheels to
be serviced are off the ground. Support the vehicle with safety stands.
(3) Place a drain pan under the rear axle.

1 SAFETY STANDS

SHTS05Z050200012

(4) Remove the plug from bottom of axle housing. Drain lubricant from
the assembly.
(5) Disconnect the driveline universal joint from the pinion input yoke or
flange on the carrier.
(6) Remove the capscrews and washers or stud nuts and washers, if
EASY SERVICE TM 1 equipped, from the flanges of both axle shafts.
(7) Loosen the tapered dowels, if equipped, in the axle flanges of both
2
9 axle shafts using one of the following methods.
3

8 4
5
6
7

1 FULL ROUND BEARING

CUPS
2 END YOKE For details,
3 YOKE SADDLE Refer to the
4 WELD YOKE
5 BEARING STRAP Propeller shaft chapter.
6 CAPSCREWS
7 EASY-SERVICE
BEARING CUPS
8 U-JOINT CROSS
9 SLIP YOKE

SHTS05Z050200013
DF0216 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(8) Brass Drift Method

! WARNING
Do not strike the round driving lugs on the flange of an axle shaft.
Pieces can break off and cause serious personal injury.
a. Hold a 1-1/2-inch diameter brass drift or brass hammer against
the center of the axle shaft, inside the round driving lugs.
1
b. Strike the end of the drift with a large hammer, five to six pounds,
and the axle shaft and tapered dowels will loosen.
c. Mark each axle shaft before it is removed from the axle assembly.
2

1 BRASS HAMMER
2 DRIVING LUGS

SHTS05Z050200014

d. Remove the tapered dowels and separate the axle shafts from the
main axle hub assembly.
1 3
2 4 5
e. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed.

(9) Air Hammer Vibration Method

9 8 7
6

1 STUD NUT ! WARNING

2 WASHER
3
4
TAPERED DOWEL
GASKET
Wear safe eye protection when using an air hammer. When using
5
6
STUD
SHAFT HUB AXLE power tools, axle components can loosen and break off causing seri-
7 AXLE SHAFT OR FLANGE
8
9
WASHER
CAPSCREW
ous personal injury.

SHTS05Z050200015 ! CAUTION
Do not use a chisel or wedge to loosen the axle shaft and tapered
dowels. Using a chisel or wedge can result in damage to the axle
shaft, the gasket and seal, and the axle hub.
a. Use a round hammer bit and an air hammer to loosen tapered
ROUND HAMMER BIT
BETWEEN HUB STUDS dowels and axle shaft.
b. Place the round hammer bit against the axle shaft or flange
between the hub studs. Operate the air hammer at alternate loca-
tions between the studs to loosen the tapered dowels and axle
shaft from the hub.
c. Mark each axle shaft before it is removed from the axle assembly.
d. Remove the tapered dowels and separate the axle shaft from the
main axle hub assembly.

SHTS05Z050200016
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0217

2. CARRIER FROM THE AXLE

(1) Place a hydraulic roller jack under the differential carrier to support the
assembly.
(2) Remove all but the top two carrier to housing capscrews or stud nuts
and washers.
(3) Loosen the top two carrier-to-housing fasteners and leave attached to
the assembly. The fasteners will hold the carrier in the housing.
1
(4) Loosen the differential carrier in the axle housing. Use a leather mallet
to hit the mounting flange of carrier at several points.
(5) After the carrier is loosened, remove the top two fasteners.
1 WOOD BLOCK 2
2 ROLLER JACK
! CAUTION
When using a pry bar, be careful not to damage the carrier or housing
SHTS05Z050200017
flange. Damage to these surfaces will cause oil leaks.
(6) Use the hydraulic roller jack to remove the carrier from the axle hous-
ing. Use a pry bar that has a round end to help remove the carrier
from the housing.
NOTICE
A carrier stand is available from SPX Kent-Moore. Refer to DF02-89
(7) Use a lifting tool to lift the differential carrier by the input yoke or flange
1 and place the assembly in a repair stand. Do not lift by hand.

1 DIFFERENTIAL CARRIER 2 REPAIR STAND

SHTS05Z050200018
DF0218 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

IMPORTANT POINTS - DISASSEMBLY

1. DIFFERENTIAL AND RING GEAR FROM THE CARRIER

1
NOTICE
Before working on the differential carrier, inspect the hypoid gear set
for damage. If inspection shows no damage, the same gear set can be
used again. Measure the backlash of the gear set and make a record
of the dimension. Refer to page DF02-44.
(1) Loosen the jam nut on the thrust screw, if equipped.
(2) Remove the thrust screw and jam nut, if equipped, from the differen-
tial carrier.
1 DIAL INDICATOR
SHTS05Z050200019

SHTS05Z050200020

1 THRUST SCREW AND JAM NUT

SHTS05Z050200021

(3) Rotate the differential carrier in the repair stand until the ring gear is at
1 the top of the assembly.

2
(4) Mark one carrier leg and bearing cap to correctly match the parts dur-
ing carrier assembly. Mark the parts using a center punch and ham-
mer.

3
1 BEARING CAP
2 CARRIER LEG
3 M ATCH MARKS

SHTS05Z050200022
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0219

(5) Remove the cotter keys, pins or lock plates, if equipped, that hold the
bearing adjusting rings in position. Use a small drift and hammer to
remove pins. Each lock plate is held in position by two capscrews.
1 2

1 REMOVING COTTER KEY

2 REMOVING LOCK PLATE

SHTS05Z050200023

(6) Remove the capscrews and washers that hold the two bearing caps
on the carrier. Each cap is held in position by two capscrews and
washers.

1 BEARING CAP
SHTS05Z050200024

(7) Remove the bearing caps and bearing adjusting rings from the carrier.
1
2

1 BEARING CAP
2 BEARING ADJUSTING RING
SHTS05Z050200025

(8) Safely lift the main differential and ring gear assembly from the carrier.
Place the assembly on a work bench.

SHTS05Z050200026
DF0220 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

2. DISASSEMBLY OF DIFFERENTIAL AND RING GEAR ASSEMBLY

! WARNING
Observe all warnings and cautions provided by the press manufac-
turer to avoid damage to components and serious personal injury.
(1) If the match marks on the case halves of the differential assembly are
not visible, mark each case half with a center punch and hammer.
(2) Remove the capscrews and washers or bolts, nuts and washers, if
equipped, that hold the case halves together.
1
(3) Separate the case halves. If necessary, use a brass, plastic or leather
mallet to loosen the parts.
1 1

1 M ATCH MARKS

SHTS05Z050200027

(4) Remove the differential spider or cross, four pinion gears, two side
gears and six thrust washers from inside the case halves.
1
(5) If the ring gear needs to be replaced, remove the bolts, nuts, and
2
3 washers, if equipped, that hold the gear to the flange case half.
! CAUTION
Do not remove the rivets or rivet heads with a chisel and hammer.
Using a flat edge tool can cause damage to the flange case.
1 THRUST WASHER
2 SIDE GEAR
3 SPIDER, PINIONS AND THRUST WASHERS

SHTS05Z050200028

(6) If rivets hold the ring gear to the flange case half, remove the rivets as
follows.
.

a. Carefully center punch each rivet head in the center, on the ring gear
side of the assembly. Do not use a chisel and hammer.
b. Drill each rivet head on the ring gear side of the assembly to a depth
equal to the thickness of one rivet head. Use a drill bit that is 0.03125-
1 2 inch (0.79375 mm) smaller than the body diameter of the rivets.
c. Press the rivets through holes in the ring gear and flange case half.
1 CORRECT DRILLING RIVETS FROM HEAD Press from the drilled rivet head.
2 WRONG CHISELING RIVETS FROM HEAD

SHTS05Z050200029

(7) Use a press to separate the case half and ring gear. Support the
2 assembly under the ring gear with metal or wood blocks. Press the
1
3 case half through the gear.

1 CASE HALF
2 PRESS
3 PLATE
4 SUPPORTS

SHTS05Z050200030
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0221

(8) If the differential bearings need to be replaced, use a bearing puller or

press to remove the bearing cones from the case halves.
PULLER

PRESS

SHTS05Z050200031

3. REMOVAL OF DRIVE PINION AND BEARING CAGE FROM THE

CARRIER
(1) Fasten a flange bar to the input yoke or flange. When the nut is
removed, the bar will hold the drive pinion in position.
1
(2) Remove the nut and washer, if equipped, from the drive pinion.
(3) Remove the yoke or flange bar.
! CAUTION
Do not use a hammer or mallet to loosen and remove the yoke or
flange. A hammer or mallet can damage the parts and cause driveline
runout, or driveline imbalance problems after carrier to driveline
assembly.
1 FLANGE BAR 2
2 YOKE BAR
SHTS05Z050200032

(4) Remove the yoke or flange from the drive pinion. Do not use a ham-
YOKE PULLER mer or mallet.
If the yoke or flange is tight on the pinion:
Use a puller for removal.

FLANGE PULLER

SHTS05Z050200033

(5) Remove the capscrews and washers that hold the bearing cage in the
1 carrier.

! CAUTION
Do not use a pry bar to remove the bearing cage from the carrier. A
pry bar can damage the bearing case, shims and carrier.
2

1 BEARING CAGE
2 CARRIER

SHTS05Z050200034
DF0222 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(6) Remove the drive pinion, bearing cage and shims from the carrier. Do
1 not use a pry bar.
If the bearing cage is tight in the carrier:
Hit the bearing cage at several points around the flange area with a
leather, plastic or rubber mallet.
(7) If the shims are in good condition, keep the shims together to use
2 when the carrier is assembled.
(8) If shims are to be discarded because of damage, first measure the
total thickness of the pack. Make a note of the dimension. The dimen-
sion will be needed to calculate the depth of the drive pinion in the
1 DRIVE PINION AND BEARING CAGE
2 SHIMS carrier when the gear set is installed.
SHTS05Z050200035
4. DISASSEMBLY OF DRIVE PINION AND BEARING CAGE
! WARNING
Observe all warnings and cautions provided by the press manufac-
turer to avoid damage to components and serious personal injury.
(1) Place the drive pinion and bearing cage in a press. The pinion shaft
1 2 must be toward the top of the assembly.
3

6 5

1 DRIVE PINION 5 SPIGOT BEARING

2 OIL SEAL 6 SNAP RING
3 OUTER BEARING, CUP 7 BEARING SPACER
AND CONE
4 INNER BEARING, CUP AND
CONE

SHTS05Z050200036

(2) Support the bearing cage under the flange area with metal or wood
blocks.
2

1 3
(3) Press the drive pinion through the bearing cage. The inner bearing
4
cone and bearing spacer will remain on the pinion shaft.
5
If a press is not available: Use a leather, plastic or rubber mallet to
6
7
drive the pinion through the bearing cage.
! CAUTION
1 PRESS 5 SUPPORT Be careful when removing the seal. Do not damage the wall of bore.
2 DRIVE PINION 6 SPIGOT BEARING
3
4
OIL SEAL
BEARING CAGE
7 SUPPORT Damage to the bore wall can result in oil leaks.

SHTS05Z050200037

(4) Use a press and a sleeve to remove the triple-lip or unitized oil seal
from the bearing cage.
If a press is not available: Place a tool with a flat blade under the
flange to remove the oil seal from the cage.

SHTS05Z050200038
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0223

(5) If the pinion bearings need to be replaced, remove the inner and outer
bearing cups from the inside of cage. Use a press and sleeve, bearing
BEARING puller or a small drift hammer. The type of tool used depends on the
DRIVER
BEARING design of the bearing cage.
PULLER
When a press is used, support the bearing cage under the flange
area with metal or wood blocks.

SHTS05Z050200039

(6) If the pinion bearings need to be replaced, remove the inner bearing
cone from the drive pinion with a press or bearing puller. The puller
1
2
MUST fit under the inner race of the cone to remove the cone cor-
rectly without damage.
5
3

(7) If the spigot bearing needs to be replaced, place the drive pinion in a
vise. Install a soft metal cover over each vise jaw to protect the drive
pinion.
4

1 PRESS 4 SUPPORTS
2 DRIVE PINION 5 INNER BEARING CONE
3 BEARING PULLER

SHTS05Z050200040

(8) Remove the snap ring, if equipped, from the end of drive pinion with
1
snap ring pliers that expand.

1 SPIGOT BEARING 2 SNAP RING

SHTS05Z050200041

(9) Remove the spigot bearing from the drive pinion with a bearing puller.
Some spigot bearings are fastened to the drive pinion with a special
1
peening tool.

1 PEENING POINTS

SHTS05Z050200042
DF0224 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

1 BEARING PULLER 2 SPIGOT BEARING

SHTS05Z050200043

(10) If the spigot bearings are a two-piece assembly, remove the inner race
1 from the pinion with a bearing puller. Remove the outer race and roller
assembly from the carrier with a drift or a press.

1 Remove outer race and roller assembly from carrier.

2 Remove inner race from pinion.

SHTS05Z050200044

5. GEAR SETS
Refer to the following examples for information on identifying gear
sets with matched parts. Always check match numbers to verify that
the gear set you will install has matched parts.
(1) Gear Set
1

2 3 Parts Number Location

4
Conventional ring 36786 On the front face or
5
gear outer diameter
ALTERNATE LOCATIONS: Conventional drive 36787 At the end at threads
1 PART NUMBER, TOOTH COMBINATION NUMBER ,
GEAR SET MATCH NUMBER, PINION CONE pinion
VARIATION NUMBER
2 PART NUMBER, TOOTH COMBINATION NUMBER
3 GEAR SET MATCH NUMBER, PINION CONE Generoid ring gear 36786 K or 36786 K2 On the front face or
VARIATION NUMBER
4 PART NUMBER, TOOTH COMBINATION NUMBER ,
GEAR SET MATCH NUMBER
outer diameter
5 PART NUMBER, TOOTH COMBINATION NUMBER
GEAR SET MATCH NUMBER
Generoid drive pinion 36787 K or 36787 K2 At the end at threads
SHTS05Z050200045

(2) Gear Set Tooth Combination Number

Gear Set Teeth Drive Pinion Loca- Ring Gear Location

tion
5-37 = gear set has a At the end at threads On the front face or
five-tooth drive pin- outer diameter
ion and a 37-tooth
ring gear
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0225

(3) Gear Set Match Number

NOTICE
Meritor's drive pinions and ring gears are only available as matched
sets. Each gear in a set has an alpha-numeric match number.

Match Number Drive Pinion Loca- Ring Gear Location

tion
M29 At the end of the On the front face or
gear head outer diameter

(4) Pinion Cone Variation Number

NOTICE
Don't use the pinion cone variation number when you check for a
matched gear set. Use this number when you adjust the pinion depth
in the carrier. Refer to page DF02-34.

Pinion Cone (PC) Drive Pinion Location Ring Gear Location

Variation Number
PC+3 At the end of the pinion At the end of the pinion
+2 gear head gear head
+0.01 mm
PC-5
-1

IMPORTANT POINTS - ASSEMBLY

! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

Use a brass or leather mallet for assembly and disassembly proce-

dures. Do not hit steel parts with a steel hammer. Pieces of a part can
break off and cause serious personal injury.

Observe all warnings and cautions provided by the press manufac-

turer to avoid damage to components and serious personal injury.

1. ASSEMBLY OF DRIVE PINION, BEARINGS AND BEARING CAGE

(1) Place the bearing cage in a press.
1 2 (2) Support the bearing cage with metal or wood blocks.
(3) Press the bearing cup into the bore of bearing cage until cup is flat
4
3 against bottom of the bore. Use a sleeve of the correct size to install
bearing cup.
NOTICE
Use the same procedure for both bearing cups.

5
1 PRESS 4 CAGE
2 SLEEVE 5 SUPPORTS
3 BEARING CUP

SHTS05Z050200046
DF0226 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(4) Place the drive pinion in a press with the gear head or teeth toward
the bottom.

1 (5) Press the inner bearing cone on the shaft of the drive pinion until the
cone is flat against the gear head. Use a sleeve of the correct size
against the bearing inner race.
2 NOTICE
Spigot bearings are usually fastened to the drive pinion with a snap
ring. Some are fastened with a peening tool, and some are a two-piece
bearing assembly with the inner race pressed on the nose of the pin-
1 SLEEVE 2 INNER BEARING CONE
ion and the outer race pressed into its bore in the carrier.
(6) Install the spigot bearing using one of the following three procedures.
SHTS05Z050200047

2. INSTALLATION OF ONE-PIECE SPIGOT BEARING ON THE DRIVE

PINION WITH SNAP RING
NOTICE
1 The following procedure applies to all axles except:
2
Some 160 Series single axles may use snap rings.
3
(1) Place the drive pinion in a press with the gear head or the teeth
toward the top.
(2) Press the spigot bearing on the end of drive pinion. The bearing must
be flat against the gear head. Use a sleeve of the correct size against
the bearing inner race.
1 PRESS
2 SLEEVE
3 SPIGOT BEARING

SHTS05Z050200048

(3) Use snap ring pliers to install the snap ring, if equipped, into the
groove in the end of the drive pinion.

1 SNAP RING
2 SPIGOT BEARING

SHTS05Z050200049

3. INSTALLATION OF ONE-PIECE SPIGOT BEARING ON THE DRIVE

PINION WITHOUT SNAP RING
NOTICE
The following procedure applies to existing snap ring components.

For ordering information about the staking tool, refer to page DF02-9.
1

1 PUNCH
2 TUBE

SHTS05Z050200050
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0227

(1) Place the drive pinion and the tube of the staking tool in a press with
the spigot bearing toward the top.
1 (2) When using a staking tool and press, apply 6,614 lb (3,000 kg) force
on a 0.375-inch (10 mm) ball. Calculate the force required on the tool
2
as follows.
3

6,614 lb (3,000 kg) x amount of balls in tool = pounds or kilograms

4

1 PRESS Example
2 Install and center the punch on the end of pinion.
3 SPIGOT BEARING
4 Place the shaft of pinion into tube.
6,614 lb (3,000 kg) x 3 balls = 19,842 pounds (9,000 kg)
SHTS05Z050200051
(3) Place the punch of the staking tool over the end of the pinion and
spigot bearing. Apply the required amount of force on the punch.

! CAUTION
Do not align new points with the grooves in the end of the drive pinion
or in old points. If the new staked points are placed in the wrong
areas, the spigot bearing will not be held correctly on the pinion shaft.
NOTICE
If a three-ball stake tool is used, rotate the tool 180 degrees.
(4) Stake the end of the drive pinion at a minimum of five points. Rotate
the punch as many times as required for a minimum of five points.
1 Repeat Step (3) for each point.

1 STAKING POINTS

SHTS05Z050200052

4. INSTALLATION OF TWO-PIECE SPIGOT BEARING ON THE

DRIVE PINION
NOTICE
This procedure applies to some 160 Series single rear axles. These
axles may also use a one-piece spigot bearing with a snap ring
retainer.

The inner race of two-piece spigot bearings must be staked in place

on RS-160 series rear axles. Before you stake the pinion, you must
heat the pinion stem to soften it.

SPX Kent-Moore kit number J-39039 includes the staking tool, temper-
ature indicating liquid, heat shield and plastigage needed for this pro-
cedure. To obtain this kit, refer to the page DF02-9.
DF0228 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(1) Apply two stripes of temperature indicating liquid on the pinion stem
from the top to the bottom. Apply a green stripe to indicate 400F
(205C) and a blue stripe to indicate 500F (260C).

1 ! CAUTION
You must use the heat shield when you heat the pinion stem. Do not
heat the pinion stem without the heat shield in place. Damage to com-
ponents can result.

1 TEMPERATURE INDICATING LIQUID APPLICATION

SHTS05Z050200053

(2) Place the heat shield over the pinion stem so that you can see the
temperature indicating liquid through the hole in the shield.

! WARNING
Read the manufacturer's instructions before using a torch. Always
wear safe clothing, gloves and eye protection when working with a
torch for heating parts to prevent serious personal injury during
assembly.
(3) Put on safe clothing, gloves and eye protection.
! CAUTION
Do not overheat the pinion stem or you will weaken the metal. Dam-
SHTS05Z050200054 age to components can result.
NOTICE
Correct heating will take approximately 25-35 seconds, depending on
how hot the torch is.
(4) Light and adjust the torch until the white part of the flame is approxi-
1 mately 0.25-inch (6 mm) long. Keep the white part of the flame
approximately 0.125-inch (3 mm) from the top of the stem. Move the
flame around the outer diameter of the top of the pinion stem. The
green temperature indicating liquid will turn black before the blue liq-
uid does. Heat the stem until the blue liquid turns black at a point in
2 3
4
the middle of the window.
(5) Remove the flame and the heat shield from the pinion. Let the pinion
6
5 air cool for 10 minutes. Use a razor blade to remove the temperature
1 TORCH 4 0.125-INCH (3 MM) indicating liquid.
2 WHITE PART OF FLAME 5 PINION
3 0.25-INCH (6 MM) 6 HEAT SHIELD
! CAUTION
SHTS05Z050200055
Do not press or directly strike the new inner race. Damage to the bear-
ing will result.
(6) Use a press, if available, or a brass hammer to install the new inner
race. Use the old inner race as a sleeve. The face is completely
seated when you cannot fit a 0.002-inch (0.0508 mm) feeler gauge
between the race and the pinion shoulder.
NOTICE
To hold the races in place, use a staking tool, not the old race, to start
the new race on the stem. The old race can be used to completely seat
the new race.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0229

(7) Place the staking tool over the bearing race. Cut a 1-inch (25 mm)
1 piece from the green plastigage strip and place in between the punch
2
5 and the staking tool. You do not need to use the plastigage for every
3
stake. Use the plastigage until you are sure you are hitting the punch
with the correct amount of force.
4

(8) Strike the punch with a 2-3 pound (0.9-1.4 kg) brass hammer to upset
the end of the pinion stem. Remove the strip and measure its thick-
ness against the gauge on the strip's wrapper. The strip must not be
less than 0.003-inch (0.0762 mm) thick. This thickness indicates that
1 PUNCH 4 BEARING INNER RACE you are using enough force when you hit the punch. If the strip is too
2 PLASTIGAGE 5 STAKES
3 STAKING TOOL thin, then you must hit the punch harder so the stake will hold the race
SHTS05Z050200056 in place. Rotate the tool and repeat this procedure until there are six
evenly spaced stake marks around the stem.
(9) With a press or a soft mallet and sleeve, install the outer race and
roller assembly into its bore in the carrier. Use a sleeve that is the
same size as the outer race. Press the bearing until it is squarely
against the shoulder in the bottom of its bore.

5. INSTALLATION OF DRIVE PINION

(1) Apply axle lubricant to the bearing cups and to the bearing cones in
the cage.
(2) Install the drive pinion into the bearing cage.
(3) Install the bearing spacer or spacers onto the pinion shaft against the
1 inner bearing cone. The spacer or spacers control the preload adjust-
ment of the drive pinion bearings.
(4) Install the outer bearing cone onto the pinion shaft against the spacer.
2 Do not install the pinion seal in the bearing cage.

4
5

1 OUTER BEARING CONE

2 BEARING SPACER
3 BEARING CAGE
4 INNER BEARING CONE
5 DRIVE PINION

SHTS05Z050200057
DF0230 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

6. ADJUSTMENT OF PINION BEARING PRELOAD BY PRESS

METHOD
If a press is not available, or the press does not have a pressure
gauge, use the yoke or flange method to adjust pinion bearing pre-
load. Refer to DF02-31.
NOTICE
Do not read starting torque. Read only the torque value after the cage
starts to rotate. Starting torque will give an incorrect reading.
(1) Place the drive pinion and cage assembly in a press, gear head or
teeth toward the bottom.
1 (2) Install a sleeve of the correct size against the inner race of the outer
2 bearing.
(3) Apply and hold the correct amount of pressure to the pinion bearings.
Refer to table below. As pressure is applied, rotate the bearing cage
several times so that the bearings make normal contact.

1 PRESS
2 SLEEVE

SHTS05Z050200058

Thread Press Pressure Needed on Torque Value Needed on

Size of Bearings for Correct Preload Pinion Nut for Correct
Pinion Bearing Preload
Shaft pounds/ (kg/metric- lb-ft (Nm)
tons tons)
7/8"-20 22,000/1 (9979/10) 200-275 (271-373)
1"-20 30,000/15 (13 608/13.6) 300-400 (407-542)
1-1/4"-12 54,000/27 (24 494/24.5) 700-900 (949-1220)
1-1/4"-18 54,000/27 (24 494/24.5) 700-900 (949-1220)
1-1/2"-12 54,000/27 (24 494/24.5) 800-1100 (1085-1491)
1-1/2"-18 54,000/27 (24 494/24.5) 800-1100 (1085-1491)
1-3/4"-12 50,000/25 (22 680/22.7) 900-1200 (1220-1627)
2"-12 50,000/25 (22 680/22.7) 1200-1500 (1627-2034)

(4) While pressure is held against the assembly, wind a cord around the
bearing cage several times.
(5) Attach a spring scale to the end of the cord.
(6) Pull the cord on a horizontal line. As the bearing cage rotates, read
the value indicated on the scale. Record the reading.
(7) Measure the diameter of the bearing cage where the cord was wound.
Measure in inches or centimeters.
(8) Divide the dimension in half to get the radius. Record the radius
dimension.

1 Measure diameter of cage.

SHTS05Z050200059
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0231

(9) Use the following procedure to calculate the bearing preload or

torque.
Pounds Pulled x Radius (inches) = lb-in Preload
Preload x 0.113 = Nm Preload
Kilograms Pulled x Radius (cm) = kgcm lb-in Preload
Preload x 0.098 = Nm Preload
or

Example
Reading from spring scale = 7.5 pounds (3.4 kg)
Diameter of bearing cage = 6.62-inches (16.8 cm)
Radius of bearing cage = 3.31-inches (8.4 cm)
7.5 lb x 3.31 in = 24.8 in-lb Preload
Preload x 0.113 = 2.8 Nm Preload
or
3.4 kg x 8.4 cm = 28.6 kgcm Preload
Preload x 0.098 = 2.8 Nm Preload

(10) If the preload or torque of pinion bearings is not within 5-45 lb-in
(0.56-5.08 Nm) for new pinion bearings or 10-30 lb-in (1.13-3.39 Nm)
for used pinion bearings in good condition, adjust the spacer and
repeat Steps (1) to (9).
To increase preload: Install a thinner bearing spacer.
To decrease preload: Install a thicker bearing spacer.

(11) Check the bearing preload with the drive pinion and cage assembly
installed in the carrier. Follow the procedures to adjust pinion bearing
preload, yoke or flange method.

7. ADJUSTMENT OF PINION BEARING PRELOAD BY YOKE OR

FLANGE METHOD
! CAUTION
Do not install tight-fitting yokes or flanges on shafts using a hammer
or mallet. A hammer or mallet will damage the yoke or flange.
(1) Use a press to install the input yoke or flange, nut and washer, if
equipped, onto the drive pinion. The yoke or flange must be seated
against the outer bearing.
1

1 PRESS
2 INPUT FLANGE SHOWN

SHTS05Z050200060
DF0232 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(2) Install the drive pinion and cage assembly into the carrier. Do not
install shims under the bearing cage.
(3) Install the bearing cage-to-carrier capscrews. Washers are not
required at this time. Hand-tighten the capscrews.

SHTS05Z050200061

(4) Fasten a yoke or flange bar to the input yoke or flange. The bar will
hold the drive pinion in position when the nut is tightened.
(5) Tighten the drive pinion nut to the correct torque value. Refer to page
DF02-30.
(6) Remove the yoke or flange bar.

1 FLANGE BAR SHOWN

SHTS05Z050200062

(7) Attach a torque wrench on the drive pinion nut. Rotate the drive pinion
and read the value indicated on torque wrench.
(8) If the pinion bearing preload or torque is not within 5-45 lb-in (0.56-
1
5.08 Nm) for new pinion bearings or 10-30 lb-in (1.13-3.39 Nm) for
used pinion bearings in good condition, remove the pinion and cage
assembly from the carrier. Adjust the spacer and repeat Steps (1) to
(7).
To increase preload: Install a thinner bearing spacer.
1 Read torque value.
To decrease preload: Install a thicker bearing spacer.
(9) After adjusting pinion bearing preload, remove the drive pinion and
bearing cage from the carrier. Refer to page DF02-21.
SHTS05Z050200063

(10) Install a new triple-lip seal.

3
1
! CAUTION
The seal lips must be clean. Dirt and particles may cause a leak
between the yoke and the seal.

4 2
a. Apply the same lubricant used in the axle housing to the outer
surface of the seal and the seal bore in the bearing cage.
5 b. Place the drive pinion and cage assembly in a press with the seal
bore toward the top.
1 Apply grease. 4 BEARING CAGE
2 TRIPLE-LIP, MAIN SEAL 5 DRIVE PINION
3 Apply lubricant to seal bore.

SHTS05Z050200064
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0233

c. Press the seal into the bearing cage. The seal flange must be flat
against the top of the bearing cage. Use a sleeve or seal driver of
the correct size that fits against the metal seal flange. The diame-
1 4
ter of the sleeve or driver must be larger than the flange diameter.
2
5
If a press is not available: Use a mallet and the sleeve or driver to
3
6
install the seal.
7
d. After the triple-lip seal is installed, a gap of approximately 0.015-
0.030-inch (0.38-0.76 mm) between the flange and bearing cage
1 PRESS 5 SEAL
2 SLEEVE 6 BEARING CAGE is normal.
3 SUPPORTS 7 DRIVE PINION
4 SLEEVE e. Check the gap with a feeler gauge at several points around the
seal. The gap must be within 0.015-0.030-inch (0.38-0.76 mm).
SHTS05Z050200065 The difference between the largest and smallest gap measure-
ment must not exceed 0.010-inch (0.0254 mm).

1 SEAL DRIVER

SHTS05Z050200066

1 0.015-0.030" (0.38-0.76 MM)

SHOWN WITHOUT BEARINGS AND PINION

SHTS05Z050200067
DF0234 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

8. ADJUSTMENT OF SHIM PACK THICKNESS FOR A NEW DRIVE

PINION
NOTICE
Use this procedure if you'll install a new drive pinion and ring gear
set, or if you have to adjust the depth of the drive pinion.
(1) Use a micrometer to measure the thickness of the shim pack that was
removed from under the pinion cage. Record the measurement.
2
1

1 SHIM PACK 2 BEARING CAGE

CONTROLS DEPTH OF 3 CARRIER
PINION

SHTS05Z050200068

SHTS05Z050200069

(2) Find the pinion cone (PC) variation number on the drive pinion you'll
replace. Record the number. The pinion cone number can be one of
the following values.
1
PC +3, PC -3, +3 or -3 = 0.003-inch
PC +.03, PC 0.03 mm, +0.03 mm or -0.03 = 0.03 mm
(3) If you can't find the PC number or it's unreadable, install a new shim
pack of the same thickness that you measured in 8. (1).
(4) If the old pinion cone number is a plus (+) number, subtract the num-
1 PINION CONE VARIATION NUMBER
ber from the old shim pack thickness that was measured in 8. (2).
(5) If the old pinion cone number is a minus (-) number, add the number
to the old shim pack thickness that was measured in 8. (2).
SHTS05Z050200070 (6) Find the pinion cone (PC) variation number on the new drive pinion
that will be installed. Record the number.
(7) If the new pinion cone number is a plus (+) number, add the number to
the standard shim pack thickness that was calculated in 8. (4) or 8.
(5). Use new shims to make a shim pack to the correct thickness.
Refer to page DF02-35.
(8) If the new pinion cone number is a minus (-) number, subtract the
number from the standard shim pack thickness that was calculated in
8. (4) or 8. (5). Use new shims to make a shim pack to the correct
thickness. Refer to page DF02-35.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0235

Example Inches mm
1. Old Shim Pack Thickness. Old PC 0.030-0.002 = 0.028+0.005 = 0.033 0.760-0.050 = 0.710+0.130 = 0.840
Number, PC +2 inches (+0.05 mm)

Standard Shim Pack Thickness.

New PC Number, PC +5 inches
(+0.13 mm)

New Shim Pack Thickness

2. Old Shim Pack Thickness Old PC 0.030+0.002 = 0.032+0.005 = 0.037 0.760+0.050 = 0.810+0.130 = 0.940
Number, PC -2 inches (-0.05 mm)

Standard Shim Pack Thickness.

New PC Number, PC +5 inches
(+0.13 mm)

New Shim Pack Thickness

3. Old Shim Pack Thickness Old PC 0.030-0.002 = 0.032-0.005 = 0.023 0.760-0.050 = 0.710-0.130 = 0.580
Number, PC -2 inches (-0.05 mm)

Standard Shim Pack Thickness.

New PC Number, PC -5 inches (-
0.13 mm)

New Shim Pack Thickness

4. Old Shim Pack Thickness Old PC 0.030+0.002 = 0.032-0.005 = 0.027 0.760+0.050 = 0.810-0.130 = 0.680
Number, PC -2 inches (-0.05 mm)

Standard Shim Pack Thickness.

New PC Number, PC -5 inches (-
0.13 mm)

New Shim Pack Thickness

9. INSTALLATION OF DRIVE PINION, BEARING CAGE AND SHIM

PACK INTO THE CARRIER
NOTICE
If a new drive pinion and ring gear set is installed, or if the depth of
the drive pinion has to be adjusted, calculate the thickness of the
shim pack. Refer to the procedure Shim Pack Thickness for a New
Drive Pinion on page DF02-34.
(1) Select the correct shim pack and install it between the bearing cage
1
and carrier.
(2) Apply Loctite 518 Gasket Eliminator to the carrier face.
(3) Align the oil slots in the shims with oil slots in the bearing cage and
carrier. Use guide studs to help align the shims.
(4) Apply Loctite 518 Gasket Eliminator to the top of the shim pack.

1 GUIDE STUDS
2 CARRIER

SHTS05Z050200071
DF0236 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(5) Install the drive pinion and bearing cage into the carrier. If necessary,
use a rubber, plastic or leather mallet to hit the assembly into position.
1

1 DRIVE PINION AND BEARING CAGE

2 SHIMS
3 CARRIER

SHTS05Z050200072

(6) Install the bearing cage-to-carrier capscrews and washers. Tighten

the capscrews to the correct torque value. Refer to page DF02-12.

SHTS05Z050200073

10. INSTALLATION OF TIGHT FIT YOKES AND POSETM SEAL

! CAUTION
Do not install tight fit yokes on shafts using a hammer or mallet.
Using a hammer or mallet can damage the yoke.

The seal lips must be clean. Dirt and particles may cause a leak
between the yoke and the POSETM seal.
NOTICE
Do not install POSETM seal all the way against the yoke shoulder. This
seal is designed to position itself as yoke is installed.
(1) Apply axle lubricant on the yoke seal.
(2) Check all surfaces of the yoke hub for damage.
1
(3) If the carrier uses a POSETM seal element, install a new POSETM
seal.
2
a. Lightly lubricate the yoke journal with the same lubricant used in
the axle housing.
4 3
b. Partially install the POSETM seal onto the yoke 0.25-0.5-inch (6-
13 mm).
1 Lubricate triple-lip or main seal.
2 INPUT SHAFT, PINION c. Before installing the yoke onto the drive pinion, lubricate the yoke
3 POSETM SEAL, 0.25-0.50" (6-13 MM) ONTO HUB
4 Check yoke hub. with the same lubricant used in the axle housing.
(4) Slide the yoke over the input shaft pinion. Align the yoke splines with
SHTS05Z050200074 the shaft splines.
! CAUTION
Do not use a hammer or mallet to install the yoke to the input pinion
shaft. Using a hammer or mallet can damage the yoke or flange.
(5) Install the input yoke flange onto the drive pinion shaft. The yoke or
flange must be fully seated against the outer differential bearing
before the nut is tightened to specifications.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0237

(6) Install the drive pinion nut and washer on the input pinion shaft and
against the yoke collar. Tighten the nut against yoke collar to torque
specifications. Refer to page DF02-12.

1 Use flange or yoke bar.

SHTS05Z050200075

11. INSTALLATION OF ANY TYPE YOKE WITH A UNITIZED PINION

SEAL (UPS)
NOTICE
Once the yoke is partially or fully installed and then removed for any
reason, the unitized pinion seal will be damaged and unusable. If the
yoke and unitized pinion seal are removed after partial or full installa-
tion, remove and discard the original unitized pinion seal and replace
it with another new unitized pinion seal.

If the inner sleeve of the seal is removed, the seal is not usable. A new
seal is required. This will occur if a yoke is installed into the seal and
then removed.
(1) Remove the replacement unitized seal from the package.
(2) Select the correct seal driver from page DF02-38. Each seal driver is
designed to correctly install a specific diameter seal. To determine the
yoke seal diameter, measure the yoke journal. Refer to page DF02-
38.

(3) Position the seal on the driver.

! CAUTION
UNITIZED SEAL Use a rubber mallet to install the seal. Do not use a steel, brass or
plastic hammer. Damage to the seal and driver tool can result.

SHTS05Z050200076

(4) Use a rubber mallet to drive the seal into or against the bearing cage.
1 2
The seal must fully seat into or against the bearing cage.

The seal must

be fully seated
3 in or against
the bearing cage.

1 RUBBER MALLET
2 REFERENCE MARK
3 SEAL DRIVER R4422401

SHTS05Z050200077
DF0238 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(5) Use a 0.010-inch (0.25 mm) shim to check for clearance between the
entire seal flange circumference and the bearing cage.
1
If the 0.010-inch (0.25 mm) shim slides between the seal flange
and bearing cage: Correctly position the seal driver and drive the
seal into the bore until the 0.010-inch (0.25 mm) shim cannot slide
between the seal flange and bearing cage at any point around the
seal flange.

MEASURING SEAL GAP

1 0.010" (0.25 MM)

SHTS05Z050200078

Unitized Pinion Seals and Seal Drivers

Single Models Meritor Unitized Pinion Seal Installation Location Meritor Seal Driver Yoke Seal Diameter
Seal Inches
RS17-145 A-1205-N-2588 Single Rear Input 145 R4422401 3.000
RS19-145 models 3.005
RS21-145
RS23-160 A-1205-Q-2591 Single Rear Input 160 R4422402 3.250
models 3.225
To obtain Meritor seal driver KIT 4454, refer to page DF02-9

12. CLEAN, INSPECT AND INSTALL THE YOKE AFTER INSTALLING

A UNITIZED PINION SEAL
! WARNING
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, and emulsion-
type and petroleum-base cleaners. Read the manufacturer's instruc-
tions before using a solvent cleaner, then carefully follow the instruc-
tions. Also follow the procedures below.
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
You must use hot solution tanks or alkaline solutions correctly.
Read the manufacturer's instructions before using hot solution
tanks and alkaline solutions. Then carefully follow the instruc-
tions. safe eye protection.
(1) Use a clean shop towel and a safe cleaning solvent to clean the
ground and polished surface of the yoke journal. Do not use gasoline,
abrasive cleaners, towels, or scrubbers to clean the yoke. Do not
attempt to polish the yoke.
NOTICE
The unitized seal features a rubber inner sleeve that is designed to
seal and rotate with the yoke. This feature allows you to reuse a yoke
with minor grooves.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0239

(2) Inspect the yoke seal surface for grooves.

If you find grooves on the yoke: Use calipers to measure the groove
diameters. If any groove diameter measures less than the dimensions
A B shown in figure, replace the yoke.
! CAUTION
Do not install a POSETM seal after you install a unitized pinion seal.
Yoke Seal Minimum Yoke Diameter
Diameter at Groove (Inches) The use of a POSETM seal will prevent correct seating of the unitized
3.000/3.005" 2.990"
3.250/3.255" 3.240" pinion seal on the yoke and can result in lubricant leakage at the seal.
1 MINIMUM GROOVE DEPTH-DIAMETER POSETM seal installation is recommended only for triple lip and other
2 YOKE SEAL DIAMETER
previous design seals. Damage to components can result.

SHTS05Z050200079
Do not use thin metal wear sleeves to refresh the yoke surface. Wear
sleeves pressed onto the yoke can prevent correct seating of the pin-
ion seal, damage the pinion seal assembly and can cause the seal to
leak. Damage to components can result.
(3) Before you install the yoke, lightly lubricate or coat the yoke seal jour-
nal with axle oil.
(4) Align the yoke splines with the shaft splines. Slide the yoke over the
shaft spline.
! CAUTION
Do not use a hammer or mallet to install the yoke to the input pinion
shaft. Using a hammer or mallet can damage the yoke or flange.
(5) Install the input yoke flange onto the drive pinion shaft. The yoke or
flange must be fully seated against the outer differential bearing
1
before the nut is torqued to specifications.
(6) Install the drive pinion nut, and washer if required, on the input pinion
1 Use flange or yoke bar.
shaft and against the yoke collar. Tighten the nut against yoke collar
to torque specifications. Refer to page DF02-12.
SHTS05Z050200080

13. ASSEMBLY OF MAIN DIFFERENTIAL AND RING GEAR ASSEM-

BLY
! CAUTION
Heat the ring gear before seating it onto the differential case. Do not
press a cold ring gear on the flange case half. A cold ring gear will
damage the case half because of the tight fit.
(1) Heat the ring gear in a tank of water to a temperature of 160F-180F
(71C-82C) for 10 to 15 minutes.
! WARNING
Wear safe clothing and gloves when working with the hot ring gear to
prevent serious personal injury.
(2) Use a lifting tool to safely lift the ring gear from the tank of water.
(3) Install the ring gear on the flange case half immediately after the gear
is heated.
If the ring gear does not fit easily on the case half: Heat the gear
again.
DF0240 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(4) Align the ring gear and the flange case half fastener holes. Rotate the
ring gear as necessary.
2

1 NOTICE
If rivets were used to hold the ring gear to the flange case half,
replace them with bolts, nuts and washers.
(5) Install the bolts, nuts and washers that hold the ring gear to the flange
case half. Install the bolts from the gear side of the assembly. The bolt
3
heads must be against the ring gear.
1 FLANGE CASE HALF
2 RING GEAR
3 BOLT HEAD AGAINST GEAR

SHTS05Z050200081

(6) Tighten the bolts and nuts to the correct torque value. Refer to page
DF02-12.
(7) Use a 0.003-inch (0.08 mm) feeler gauge to check for gaps between
the back surface of the ring gear and the case flange. Check for gaps
at four points around the assembly.
If the gaps exceed specifications: Check the flange case half and
ring gear for the problem that causes the gap. Repair or replace parts.
1 Assemble the ring gear on the flange case half. Repeat the procedure
1 Check for 0.003" (0.08 mm) gap at four locations. in Tight Fit Yokes and POSETM Seal. Refer to page DF02-36.

SHTS05Z050200082

(8) Use a press and the correct size sleeve to install the bearing cones on
1
both of the case halves.
2
(9) Apply axle lubricant on the inside surfaces of both case halves, spider
3
6
or cross, thrust washers, side gears and differential pinions.
(10) Place the flange case half on a bench with the ring gear teeth toward
the top.
5 4

1 PRESS 4 SUPPORT
2 SLEEVE 5 SUPPORT
3 BEARING CONE 6 CASE HALF

SHTS05Z050200083

(11) Install one thrust washer and side gear into the flange case half.

1 ! CAUTION
The side gears in some carrier models have hubs of different lengths.
2

3
Install the correct length side gear into the flange case half. Other-
wise, damage to components can result.

1 SIDE GEAR
2 THRUST WASHER
3 FLANGE CASE HALF

SHTS05Z050200084
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0241

(12) Install the spider or cross, differential pinions and thrust washers into
the flange case half.
1

1 SPIDER, PINION AND THRUST WASHERS

SHTS05Z050200085

(13) Install the second side gear and thrust washer over the spider and dif-
ferential pinions.
1

1 THRUST WASHER
2 SIDE GEAR
3 PLAIN CASE HALF

SHTS05Z050200086

(14) Place the plain half of the differential case over the flange half and
gears. Rotate the plain half to align the match marks.
1

1 PLAIN CASE HALF

2 M ATCH MARKS

SHTS05Z050200087

(15) Install Dri-Loc fasteners into the case halves. Refer to page DF02-58.
a. Install four capscrews and washers or bolts, nuts and washers, if
10 6 equipped, into the case halves. The distance between the fasten-
4 2
13 15
ers must be equal. Tighten the fasteners to the correct torque
8 12 value in a progressive criss-cross pattern opposite each other.
Refer to page DF02-12.
11 7 b. Install the other fasteners into the case halves. Tighten the fasten-
1 14 ers to the correct torque value. Refer to page DF02-12.
16 3
5 9 (16) Check the differential gears rotating resistance.

SHTS05Z050200088
DF0242 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

14. DIFFERENTIAL GEARS ROTATING RESISTANCE CHECK

(1) Make an inspection tool using an axle shaft that matches the spline
size of the differential side gear. Cut the shaft to approximately 12-
1 inches (304.8 mm). Weld a nut onto the end of the shaft.

2
3
4

1 APPROXIMATELY 12" (304.8 MM)

2 SIDE VIEW
3 Weld nut to end of shaft.
4 END VIEW

SHTS05Z050200089

(2) Place the differential and ring gear assembly in a vise. Install soft
metal covers over vise jaws to protect the ring gear.

1 (3) Install the tool into the differential until the splines of the tool are
engaged with one side gear.

1 TOOL FOR CHECKING RESISTANCE

2 SOFT METAL COVER

SHTS05Z050200090

(4) Place a torque wrench onto the nut of the tool and rotate the differen-
tial gears. As the differential gears rotate, read the value indicated on
the torque wrench.
If the torque value exceeds 50 lb-ft (67.8 Nm): Disassemble the dif-
ferential gears from the case halves. Inspect the case halves, spider,
gears and thrust washers. Repair or replace parts. Assemble the
parts and repeat 14. (2) to (4).
1

1 Read torque value.

SHTS05Z050200091

15. INSTALLATION OF DIFFERENTIAL AND RING GEAR ASSEMBLY

(1) Clean and dry the bearing cups and bores of the carrier legs and
bearing caps.
1 2
(2) Apply axle lubricant on the inner diameter of the bearing cups and on
both bearing cones that are assembled on the case halves.
3 (3) Apply adhesive into the bearing bores of the carrier legs and bearing
caps. Adhesive must not contact the adjusting ring threads. Refer to
page DF02-59.

1 ADHESIVE
2 BEARING CAP
3 CARRIER LEG

SHTS05Z050200092
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0243

(4) Install the bearing cups over the bearing cones that are assembled on
the case halves.
(5) Safely lift the differential and ring gear assembly and install it into the
1 carrier. The bearing cups must be flat against the bores between the
2 carrier legs.
3

1 BEARING CUP
2 BEARING CUP
3 LEG BORE

SHTS05Z050200093

(6) Install both of the bearing adjusting rings into position between the
carrier legs. Turn each adjusting ring hand-tight against the bearing
1 cup.

2
1 ADJUSTING RING
2 LEG

SHTS05Z050200094

(7) Install the bearing caps over the bearings and adjusting rings. Align
the match marks you made when you removed the caps.

! CAUTION
1
If bearing caps are not installed in correct locations, the bores and
threads in caps will not match the carrier. You will have problems
2
assembling the caps on the carrier and damage to parts can occur. Do
not force the bearing caps into position.
(8) Seat each bearing cap with a light leather, plastic or rubber mallet.
1 BEARING CAP The caps must fit easily against the bearings, adjusting rings and car-
2 M ATCH MARKS
rier. Do not force the bearing caps into position.
SHTS05Z050200095 If bearing caps do not correctly fit into position: Check the align-
ment of match marks between caps and carrier. Remove the caps
and repeat 15. (6) to (8).
(9) Install the capscrews and washers that hold bearing caps to the car-
rier. Hand-tighten the capscrews four to six turns. Tighten the cap-
screws to the correct torque value. Refer to page DF02-12.
NOTICE
Do not install the cotter keys, pins or lock plates, if equipped, that
hold the bearing adjusting rings in position.
(10) Adjust differential bearing preload and hypoid gear backlash. Check
the tooth contact patterns.
DF0244 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

16. ADJUST DIFFERENTIAL BEARING PRELOAD

Differential Bearing All Carrier Models 15-35 lb-in

Preload (1.7-3.9 Nm)
Expansion between RS-145 and RS-160 0.002-0.009-inch
bearing caps carrier models (0.05-0.229 mm)

17. METHOD 1
(1) Attach a dial indicator onto the carrier mounting flange so that the
plunger or pointer is against the ring gear back surface.
1
! CAUTION
When you turn the adjusting rings, always use a tool that engages two
or more opposite notches in the ring. A T-bar wrench can be used for
this purpose. If the tool does not correctly fit into the notches, dam-
age to the lugs will occur.

1 DIAL INDICATOR

SHTS05Z050200096

(2) Use a T-bar wrench to loosen the bearing adjusting ring that is oppo-
site the ring gear. A small amount of end play will show on the dial
1 indicator.

1 T-BAR WRENCH
2 ADJUSTING RING OPPOSITE RING GEAR

SHTS05Z050200097

(3) Use one of the following methods to move the differential and ring
gear to the left and right while you read the dial indicator.
a. Insert two pry bars between the bearing adjusting rings and ends
of the differential case. The pry bars must not touch the differen-
tial bearings.
b. Insert two pry bars between the differential case or ring gear and
1
the carrier at locations other than described in (3) a. The pry bars
must not touch the differential bearings.
(4) Tighten the bearing adjusting ring until the dial indicator reads ZERO
1 Bars must not touch bearings. end play. Move the differential and ring gear to the left and right as
needed. If necessary, repeat (3) a. or b.
SHTS05Z050200098 (5) Tighten each bearing adjusting ring one notch from ZERO.

(6) Proceed to check ring gear runout.

1 Bars must not touch bearings.

SHTS05Z050200099
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0245

18. METHOD 2
(1) Hand-tighten both adjusting rings against the differential bearings.
(2) Use a micrometer to measure distance X or Y between the opposite
surfaces of the bearing caps. Record the measurement.
(3) Tighten each bearing adjusting ring one notch.
(4) Measure distance X or Y again. Compare the measurement with the
one you obtained in 18. (2). The difference between the two dimen-
sions is the amount the bearing caps have expanded.

Example
Measurements of RS-145 carrier
Distance X or Y
SHTS05Z050200100
before tightening adjusting rings = 13.927-inch (353.74 mm).
Distance X or Y
after tightening adjusting rings = 13.936-inch (353.97 mm).
1 13.936-inch 13.927-inch = 0.009-inch 0.23 mm) difference.
If the dimension is within specifications:
Continue by checking ring gear runout.
If the dimension is less than specifications:
Repeat 18(3) and 18(4) as needed.

1 MICROMETER

SHTS05Z050200101

19. CHECK RING GEAR RUNOUT

(1) Attach a dial indicator onto the carrier mounting flange.

1
(2) Adjust the dial indicator so that the plunger or pointer is against the
back surface of the ring gear. Set the dial indicator to ZERO.
(3) Rotate the differential and ring gear. Read the dial indicator. Runout
2
must not exceed 0.008-inch (0.20 mm).
If runout exceeds specifications: Remove the differential and ring
gear assembly from the carrier. Refer to Differential and Ring Gear
from the Carrier on page DF02-18 and 19. (4) and (5).
If runout is within specifications: Proceed to Ring Gear Backlash
1 Rotate ring gear .
2 DIAL INDICATOR Adjustment.
(4) Check the differential parts including the carrier for wear and damage.
SHTS05Z050200102
Repair or replace parts.
(5) Install the differential and ring gear into the carrier. Refer to page
DF02-42. Repeat the preload adjustment of the differential bearings.
DF0246 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

20. RING GEAR BACKLASH ADJUSTMENT

Ring Gear Pitch Range of Backlash Backlash Setting for

Diameter Setting New Gear Sets
Less than 17-inches 0.008-0.018-inch 0.012-inch (0.30 mm)
1 (431.8 mm) (0.20-0.46 mm)
Greater than 17- 0.010-0.020-inch 0.015-inch (0.38 mm)
inches (431.8 mm) (0.25-0.51 mm)

1 Measure outer diameter for approximate pitch

diameter.
Measure the outer diameter of ring gear for approximate pitch diame-
ter.
SHTS05Z050200103
If the old gear set is installed: Adjust the backlash to the setting that
was measured before the carrier was disassembled.
If a new gear set is installed: Adjust the backlash to the correct
specification for new gear sets.

After checking the tooth contact patterns, the backlash can be

adjusted within specification limits, if needed. To change the location
of the pattern use the following procedures.

(1) Attach a dial indicator onto the mounting flange of the carrier.
(2) Adjust the dial indicator so that the plunger or pointer is against the
tooth surface.
(3) Adjust the indicator dial to ZERO. Hold the drive pinion in position.
(4) After reading the dial indicator, rotate the differential and ring gear a
small amount in both directions against the drive pinion teeth.
If the backlash reading is within specifications: Check the tooth
contact patterns.
If the backlash reading is not within specifications: Adjust back-
lash as needed.

SHTS05Z050200104

(5) Loosen one bearing adjusting ring one notch then tighten the opposite
ring the same amount.
1
To increase backlash: Move the ring gear away from the drive pin-
ion.

2 3

1 Tighten adjusting ring this side.

2 Increase backlash.
3 Loosen adjusting ring this side.

SHTS05Z050200105

To decrease backlash: Move the ring gear toward the drive pinion.
NOTICE
1 When you adjust backlash, move the ring gear only. Do not move the
drive pinion.
2

(6) Repeat 20. (2) to (5) until the backlash is within specifications.

1 Loosen adjusting ring this side.

2 Decrease backlash.
3 Tighten adjusting ring this side.

SHTS05Z050200106
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0247

21. CHECK GEAR SET TOOTH CONTACT PATTERNS (BACKLASH)

Some Meritor carriers have a generoid hypoid gear set. The tooth
contact patterns for each type of gear set are different. Check the part
1
2 numbers to determine what type of gear set is in the carrier.Refer to
3 figure for the location of part numbers.

Example
1 PART NUMBER Part numbers for generoid gear sets
2 PART NUMBER
3 PART NUMBER OPTION
36786-K or 36786-K2 for the ring gear
36787-K or 36787-K2 for the drive pinion
SHTS05Z050200107

In the following procedures, movement of the contact pattern in the

length of the tooth is indicated as toward the heel or toe of the ring
gear.

Always check tooth contact patterns on the drive side of the gear
2
teeth.

1 HEEL
2 TOE

SHTS05Z050200108

1 DRIVE SIDE, CONVEX

SHTS05Z050200109

(1) Adjust the backlash of a new gear set to either 0.012-inch (0.305 mm)
or 0.015-inch (0.380 mm) depending on the size of the ring gear.
Adjust the backlash of an old gear set to the setting that you mea-
sured before the carrier was disassembled. Refer to page DF02-46.
(2) Apply a marking compound onto approximately 12 gear teeth of the
ring gear. Rotate the ring gear so that the 12 gear teeth are next to the
drive pinion.
(3) Rotate the ring gear forward and backward so that the 12 gear teeth
go past the drive pinion six times to get the contact patterns. Repeat if
needed to get a clearer pattern.

SHTS05Z050200110
DF0248 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(4) Look at the contact patterns on the ring gear teeth. Compare the pat-
terns to figures.

The location of good hand-rolled contact patterns for new conven-

tional and generoid gear sets is toward the toe of the gear tooth and in
the center between the top and bottom of the tooth.

When the carrier is operated, a good pattern will extend approxi-

mately the full length of the gear tooth. The top of the pattern will be
GOOD HAND-ROLLED PATTERN, HYPOID GENEROID
GEARS
near the top of the gear tooth.

SHTS05Z050200111 The location of a good hand-rolled contact pattern for an old gear set
must match the wear pattern in the ring gear. The new contact pattern
will be smaller in area than the old wear pattern.
A high contact pattern indicates that the drive pinion was not installed
deep enough into the carrier. A low contact pattern indicates that the
drive pinion was installed too deep in the carrier.

If the contact patterns require adjustment: Continue by following

21. (5) to move the contact patterns between the top and bottom of
the gear teeth.
If the contact patterns are in the center of the gear teeth: Con-
HIGH PATTERN tinue by following 21. (6).
HIGH PATTERN, HYPOID GENEROID GEARS

SHTS05Z050200112

LOW PATTERN, HYPOID GENEROID GEARS

SHTS05Z050200113

GOOD PATTERN IN OPERATION, GENEROID GEARS

SHTS05Z050200115
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0249

(5) Change the thickness of the shim pack under the bearing cage to
move the contact patterns between the top and bottom of the gear
teeth. Use the following procedure.
a. Remove the drive pinion and bearing cage from the carrier. Refer
to Drive Pinion and Bearing Cage from the Carrier on page DF02-
21.
To correct a high contact pattern: Decrease the thickness of the
1
shim pack under the bearing cage. When decreasing the thickness of
the shim pack, the drive pinion will move toward the ring gear.
1 Decrease shim pack.
To correct a low contact pattern: Increase the thickness of shim
pack under the bearing cage. When increasing the thickness of the
SHTS05Z050200114
shim pack, the drive pinion will move away from the ring gear.
b. Install the drive pinion, bearing cage and shims into the carrier.
Refer to page DF02-34 in this section.
c. Repeat 21. (2) to (5) until the contact patterns are in the center
between the top and bottom of the gear teeth.

1 Increase shim pack.

SHTS05Z050200116

(6) Adjust backlash of the ring gear within the specification range to move
the contact patterns to the correct location in the length of the gear
1 teeth. Refer to page DF02-46.
2 a. Decrease backlash to move the contact patterns toward the toe of
the ring gear teeth.
b. Increase backlash to move the contact patterns toward the heel of
3
the ring gear teeth.
1 Move pattern toward toe, loosen adjusting ring this c. Repeat 21. (2) to (4) and 21. (6) until the contact patterns are at
side.
2 Decrease backlash.
the correct location in the length of the gear teeth.
3 Tighten adjusting ring.
! CAUTION
If the carrier has cotter keys, lock the adjusting rings only with cotter
SHTS05Z050200117
keys. If the carrier has roll pins, reuse the roll pins or lock the adjust-
ing rings with cotter keys. Do not force a roll pin into a cotter key hole.
Damage to components can result.
(7) Install the cotter keys, pins, or lock plates, if equipped, that hold the
2 two bearing adjusting rings in position. Use the following procedures.
a. Install cotter keys between the lugs of the adjusting ring and
1 3
through the boss of the bearing cap. Bend the two ends of the cot-
4
ter key around the boss.
b. Use a drift and hammer to install the pin through the boss of the
bearing cap until the pin is between the lugs of the adjusting ring.
c. Install the lock plate on the bearing cap so that the tab is between
1 COTTER KEY the lugs of the adjusting ring. Install the two capscrews that hold
2 PIN
3 LOCK PLATE the lock plate to the bearing cap. Tighten the capscrews to correct
4 THREADED HOLES IN CAP WHEN LOCK PLATE IS
USED torque value. Refer to page DF02-12.
SHTS05Z050200118
DF0250 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

22. ADJUST THE THRUST SCREW

(1) Rotate the carrier in the repair stand until the back surface of ring gear
is toward the top.
(2) Install the jam nut on the thrust screw, if equipped, one half the dis-
1
tance between both ends.

1 THRUST SCREW AND JAM NUT

SHTS05Z050200119

(3) Install the thrust screw. Clearance between the thrust screw and the
ring gear must be 0.025-0.045-inch (0.65-1.14 mm).
(4) Loosen the thrust screw 1/2 turn, 180 degrees.

1 Loosen thrust screw 1/2 turn.

SHTS05Z050200120

(5) Tighten the jam nut, if equipped, to the correct torque value against
the carrier. Refer to page DF02-12.

1 Hold thrust screw in position.

2 Tighten jam nut to correct torque value.

SHTS05Z050200121
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0251

23. INSTALLATION OF DIFFERENTIAL CARRIER INTO AXLE HOUS-

ING
! WARNING
When you apply some silicone gasket materials, a small amount of
acid vapor is present. To prevent serious personal injury, ensure that
the work area is well-ventilated. Read the manufacturer's instructions
before using a silicone gasket material, then carefully follow the
instructions. If a silicone gasket material gets into your eyes, follow
the manufacturer's emergency procedures. Have your eyes checked
by a physician as soon as possible.

Solvent cleaners can be flammable, poisonous and cause burns.

Examples of solvent cleaners are carbon tetrachloride, and emulsion-
type and petroleum-base cleaners. Read the manufacturer's instruc-
tions before using a solvent cleaner, then carefully follow the instruc-
tions. Also follow the procedures below.
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
You must use hot solution tanks or alkaline solutions correctly.
Read the manufacturer's instructions before using hot solution
tanks and alkaline solutions. Then carefully follow the instruc-
tions.
(1) Use a cleaning solvent and rags to clean the inside of the axle hous-
ing and the carrier mounting surface. Refer to page DF02-54.
(2) Inspect the axle housing for damage. Repair or replace the axle hous-
ing.
(3) Check for loose studs, if equipped, in the mounting surface of the
housing where the carrier fastens. Remove and clean the studs that
are loose.
(4) Apply liquid adhesive to the threaded holes. Install the studs into axle
housing. Refer to page DF02-58. Tighten the studs to correct torque
value. Refer to page DF02-11.
(5) Apply silicone gasket material to the mounting surface of the housing
where the carrier fastens. Refer to DF02-59.
1

! CAUTION
Do not install the carriers using a hammer or mallet. A hammer or
mallet will damage the mounting flange of carrier and cause oil leaks.

1 0.125" (3 MM) DIA. SILICONE GASKET BEAD

SHTS05Z050200122
DF0252 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(6) Use a hydraulic roller jack or a lifting tool to install the carrier into the
axle housing.
(7) Install nuts and washers or capscrews and washers, if equipped, in
the four corner locations around the carrier and axle housing. Hand-
tighten the fasteners.
(8) Carefully push the carrier into position. Tighten the four fasteners two
or three turns each in a pattern opposite each other.
(9) Repeat 23. (8) until the four fasteners are tightened to the correct
torque value. Refer to page DF02-11.
(10) Install the other fasteners and washers that hold the carrier in the axle
housing. Tighten fasteners to the correct torque value. Refer to page
SHTS05Z050200123 DF02-11.
(11) Connect the driveline universal joint to the pinion input yoke or flange
on the carrier.
(12) Install the gaskets and axle shafts into the axle housing and carrier.
1 The gasket and flange of the axle shafts must fit flat against the wheel
2 3 4 5 6 hub.

10 9
8 7
11

1 TAPERED DOWEL 8 AXLE SHAFT OR

RETENTION FLANGE
2 STUD NUT 9 WASHER
3 WASHER 10 CAPSCREW
4 TAPERED DOWEL 11 NON-TAPERED
5 GASKET DOWEL
6 STUD RETENTION
7 SHAFT HUB AXLE

SHTS05Z050200124

24. INSTALLATION OF STRAIGHT HOLES, NUTS AND HARDENED

WASHERS
(1) Clean the mating surfaces of the axle shaft and the wheel hub.
(2) If silicone gasket material is used, apply a 0.125-inch (3 mm) diameter
bead of the gasket material around the mating surface of the hub and
around the edge of each fastener hole.
(3) Install the gasket and the axle shaft into the housing. The gasket and
the flange of the axle shaft must fit flat against the wheel hub.
(4) Install the Grade 8 nuts and hardened washers on the stud. Lock
washers are an acceptable alternative. Tighten the stud nuts to the
torque specified.

Shaft-to-Hub Torque Fastener Chart Non-Tapered Dowel Appli-

cations

Fastener Thread Size Torque Value Grade 8 Nuts lb-ft (Nm)

Plain Nut Lock Nut
Stud Nut, 0.62-18 150-230 (244-312) 130-190 (203-258)
Axle Shaft 0.75-16 310-400 (420-542) 270-350 (366-475)
Studs All Install the course thread end of stud into
hub and tighten to last thread.

25. INSTALLATION OF TAPERED DOWEL, HARDENED WASHER

AND HARDENED NUT
(1) Clean the mating surfaces of the axle shaft and the wheel hub.
(2) If silicone gasket material is used, apply a 0.125-inch (3 mm) diameter
bead of the gasket material around the mating surface of the hub and
around the edge of each fastener hole.
(3) Install the gasket and the axle shaft into the housing. The gasket and
the flange of the axle shaft must fit flat against the wheel hub.
DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0253

(4) Install solid tapered dowels over each stud and into the flange of the
axle shaft. Use a punch or a drift and hammer, if necessary.
(5) Install the Grade 8 nuts and hardened washers on the stud. Lock
washers are an acceptable alternative. Tighten the stud nuts to the
torque specified.

Shaft-to-Hub Torque Fastener Chart Tapered Dowel Applications

Fastener Thread Size Torque Value Grade 8 Nuts lb-ft (Nm)

Plain Nut Lock Nut
Stud Nut, 0.44-20 50-70 (81-102) 40-65 (67-88)
Axle Shaft 0.50-20 75-115 (115-156) 65-100 (102-136)
0.56-18 110-165 (176-224) 100-145 (149-197)
0.62-18 150-230 (244-312) 130-190 (203-258)
Studs All Install the course thread end of stud into
hub and tighten to last thread.
DF0254 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

INSPECTION AND REPAIR

EN05Z0502H300001

1. CLEAN AND INSPECT YOKES

! CAUTION
Do not install a press on shaft excluder or POSETM seal after installa-
tion of a unitized pinion seal. The use of a POSETM seal will prevent
correct seating of the unitized pinion seal on the yoke and will result
in lubricant leakage at the seal. POSETM seal installation is recom-
mended only for triple lip and other previous design seals.

Do not use thin metal wear sleeves to refresh the yoke surface. Wear
sleeves pressed onto the yoke will prevent correct seating of the pin-
ion seal and damage the pinion seal assembly. Wear sleeve usage will
cause the seal to leak.
(1) Clean the ground and polished surface of the yoke journal using a
clean shop towel and a safe cleaning solvent. Do not use abrasive
cleaners, towels, or scrubbers to clean yoke or flange surface. Do not
A B use gasoline.
(2) Inspect the yoke seal surface for any grooves.
.

Yoke Seal Minimum Yoke Diameter

a. If grooves are present on yoke hubs used with single or triple lip seals,
Diameter at Groove (Inches) the yokes must be replaced.
3.000/3.005" 2.990"
3.250/3.255" 3.240" b. If grooves are present, use calipers to measure the groove diameters.
A MINIMUM GROOVE DEPTH-DIAMETER If any of the yoke grooves measure less than the dimensions in,
B YOKE SEAL DIAMETER
replace the yoke.
UNITIZED PINION SEAL (UPS)

SHTS05Z050200125
2. CLEAN GROUND AND POLISHED PARTS
(1) Use a cleaning solvent to clean ground or polished parts or surfaces.
Kerosene or diesel fuel oil can be used for this purpose. Do not use
gasoline.
(2) Use a tool with a flat blade if required, to remove sealant material from
parts. Be careful not to damage the polished or smooth surfaces.
! CAUTION
Do not use hot solution tanks or water and alkaline solutions to clean
ground or polished parts. Damage to parts can result.
(3) Do not clean ground or polished parts with water or steam. Do not
immerse ground or polished parts in a hot solution tank or use strong
alkaline solutions for cleaning, or the smooth sealing surface may be
damaged.

3. CLEAN ROUGH PARTS

(1) Clean rough parts with the same method as cleaning ground and pol-
ished parts.
(2) Rough parts can be cleaned in hot solution tanks with a weak or
diluted alkaline solution.
(3) Parts must remain in hot solution tanks until heated and completely
cleaned.
(4) Parts must be washed with water until all traces of the alkaline solu-
tion are removed.

4. CLEAN AXLE ASSEMBLIES

(1) A complete axle assembly can be steam cleaned on the outside to
remove dirt.
(2) Before the axle is steam cleaned, close or place a cover over all open-
ings in the axle assembly. Examples of openings are breathers or
vents in air chambers.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0255

5. DRY PARTS AFTER CLEANING

(1) Parts must be dried immediately after cleaning and washing.
(2) Dry the parts using soft, clean paper or cloth rags.
! CAUTION
Damage to bearings can result when they are rotated and dried with
compressed air.
(3) Except for bearings, parts can be dried with compressed air.

6. PREVENT CORROSION ON CLEANED PARTS

(1) Apply axle lubricant to cleaned and dried parts that are not damaged
and are to be assembled.
(2) To store parts, apply a special material that prevents corrosion to all
surfaces. Wrap cleaned parts in a special paper that will protect the
parts from moisture and prevent corrosion.

7. INSPECT PARTS
It is very important to inspect all parts carefully and completely before
the axle or carrier is assembled. Check all parts for wear and replace
damaged parts.
(1) Inspect the cup, cone, rollers and cage of all tapered roller bearings in
the assembly. If any of the following conditions exist, replace the bear-
ing.
The center of the large-diameter end of the rollers is worn level with or
1 below the outer surface.
The radius at the large-diameter end of the rollers is worn to a sharp
edge.

1 WORN RADIUS 2
2 WORN SURFACE

SHTS05Z050200126

There is a visible roller groove in the cup or cone inner race surfaces.
The groove can be seen at the small- or large-diameter end of both
parts.

2
There are deep cracks or breaks in the cup, cone inner race or roller
1
surfaces.

1 CRACK
2 WEAR GROOVE

SHTS05Z050200127
DF0256 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

There are bright wear marks on the outer surface of the roller cage.

WEAR MARKS

SHTS05Z050200128

There is damage on the rollers and on the surfaces of the cup and
cone inner race that touch the rollers.
ETCHING AND PITTING

SHTS05Z050200129

There is damage on the cup and cone inner race surfaces that touch
the rollers.

1 SPALLING AND FLAKING

SHTS05Z050200130

! CAUTION
A drive pinion and ring gear are machined as a matched set. When
you replace either a drive pinion or a ring gear, you must replace both
parts as a matched set. Do not mix old and new parts. Damage to
components can result.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0257

(2) Inspect hypoid pinions and gears for wear and damage. Replace
1
gears that are worn or damaged.
! CAUTION
DIFFERENTIAL A thrust washer, differential side gear and pinion gear are machined
CASE HALVES as a matched set. When you replace any of these parts, you must
install a new matched set. Do not mix old and new parts. Damage to
components can result.
(3) Inspect the following main differential assembly parts for wear or
2 3 4 stress. Replace parts that are damaged.
Inside surfaces of both case halves
DIFFERENTIAL Both surfaces of all thrust washers
GEAR NEST
ASSEMBLY The four trunnion ends of the spider or cross
5
Teeth and splines of both differential side gears
Teeth and bore of all differential pinions
(4) Inspect axle shafts for wear and cracks at the flange, shaft and
6 splines. Replace the axle shafts, if required.
7 (5) Inspect the breather.
.

1 Inspect inside surfaces.

2 PINION AND THRUST W ASHER
a. Remove the breather from the axle housing.
3 SIDE GEAR AND THRUST WASHER b. Clean the breather. If the breather remains dirty after cleaning,
4 Inspect.
5 Inspect. replace the breather.
6 SPIDER OR CROSS
7 Inspect. c. Apply compressed air to the breather. If compressed air does not
pass through the breather, replace the breather.
SHTS05Z050200131
d. Install the breather in the axle housing.

8. REPAIR OR REPLACE PARTS

NOTICE
Threads must be without damage and clean so that accurate adjust-
ments and correct torque values can be applied to fasteners and
parts.
(1) Replace any fastener if corners of the head are worn.
(2) Replace washers if damaged.
(3) Replace gaskets, oil seals or grease seals at the time of axle or carrier
repair.
(4) Clean parts and apply new silicone gasket material where required
when axle or carrier is assembled.
(5) Remove nicks, mars and burrs from parts with machined or ground
surfaces. Use a fine file, India stone, emery cloth or crocus cloth.
(6) Clean and repair threads of fasteners and holes. Use a die or tap of
the correct size or a fine file.
DF0258 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

FASTENERS

1. REMOVING FASTENERS SECURED WITH ADHESIVE

If it is difficult to remove fasteners secured with Dri-Loc, Meritor
adhesive or Loctite 277 adhesive, use the following procedure.

When you remove fasteners secured with adhesive, slowly heat the
fastener to 350F (177C). Do not exceed this temperature, or heat
fasteners quickly. Damage to components can result.

(1) Heat the fastener for three to five seconds. Try to loosen the fastener
with a wrench. Do not use an impact wrench or hit the fastener with a
hammer.
(2) Repeat step (1) until you can remove the fastener.

2. NEW FASTENERS WITH PRE-APPLIED ADHESIVE

NOTICE
No drying time is required for fasteners with pre-applied adhesive.
(1) Use a wire brush to clean the oil and dirt from threaded holes.
(2) Install new fasteners with pre-applied adhesive to assemble parts. Do
not apply adhesives or sealants to fasteners with pre-applied adhe-
sive, or to fastener holes.
(3) Tighten the fasteners to the required torque value for that size fas-
tener.

3. ORIGINAL OR USED FASTENERS

(1) Use a wire brush to clean the oil, dirt and old adhesive from all
threads and threaded holes.
NOTICE
There is no drying time required for Meritor liquid adhesive 2297-C-
7049, Loctite 680 liquid adhesive or equivalent.
(2) Apply four or five drops of Meritor liquid adhesive, Loctite 680 liquid
adhesive or equivalent inside each threaded hole or bore. Do not
apply adhesive directly to the fastener threads.
(3) Tighten the fasteners to the required torque value for that size fas-
tener.

1 4 TO 5 DROPS ON BORE THREADS

SHTS05Z050200132
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0259

APPLYING ADHESIVE AND SILICONE GASKET MATE-

RIAL

1. MERITOR SPECIFICATION 2297-T-4180 ADHESIVE IN DIFFEREN-

TIAL BEARING BORES
NOTICE
Use Meritor specification 2297-T-4180 adhesive for all axles.
(1) Clean the oil and dirt from outer diameters of bearing cups and bear-
ing bores in the carrier and bearing caps. There is no special cleaning
required.
(2) Apply axle lubricant to the bearing cones and the inner diameters of
the bearing cups of the main differential. Do not get oil on the outer
diameter of the bearing cup and do not permit oil to drip onto the
bearing bores.
NOTICE
Meritor specification 2297-T-4180 adhesive will dry in approximately
two hours. You must complete the procedure within two hours from
the time you apply the adhesive. If two hours have passed since appli-
cation, clean the adhesive from the parts and apply new adhesive.
(3) Apply a single continuous bead of the adhesive to the bearing bores
in the carrier and bearing caps. Apply the adhesive around the cir-
1 2
cumference of the smooth, ground surfaces only. Do not place adhe-
sive on threaded areas.

3 (4) Install the main differential assembly, bearing cups and bearing caps
into the carrier. Refer to page DF02-42.
(5) Adjust preload of the differential bearings, backlash and tooth contact
patterns of the gear set as required. Refer to page DF02-44, 46.
1 ADHESIVE
2 BEARING CAP
3 CARRIER LEG 2. THREE BOND 1216, OR EQUIVALENT, SILICONE GASKET MATE-
RIAL
SHTS05Z050200133
! WARNING
When you apply some silicone gasket materials, a small amount of
acid vapor is present. To prevent serious personal injury, ensure that
the work area is well-ventilated. Read the manufacturer's instructions
before using a silicone gasket material, then carefully follow the
instructions. If a silicone gasket material gets into your eyes, follow
the manufacturer's emergency procedures. Have your eyes checked
by a physician as soon as possible.
NOTICE
The following silicone gasket products or equivalent can be used for
Meritor components:
Three Bond Liquid Gasket TB 1216 (Grey)
Loctite Ultra Grey Adhesive/sealant #18581
From Meritor: Ten-ounce tubes, part number 2297-F-7052
DF0260 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

(1) Use a tool with a flat blade, if required, to remove all old gasket mate-
rial from surfaces.
1

(2) Use a cleaning solvent to clean the surfaces where you will apply sili-
cone gasket material. Remove all oil, grease, dirt and moisture with-
out damaging the mating surfaces.
(3) Dry surfaces.
! CAUTION
Apply silicone gasket material in a continuous 0.125-inch (3 mm)
1 Remove old sealant material.
bead. If you use more than this amount, gasket material can break off
HOUSING AND CARRIER SHOWN
and plug lubrication passages. Damage to components can result.

SHTS05Z050200134

(4) Apply 0.125-inch (3 mm) diameter continuous bead of the silicone

gasket material around one surface. Also apply the gasket material
around the edge of all fastener holes on that surface.
(5) Assemble the components immediately to permit the silicone gasket
material to compress evenly between the parts. Tighten fasteners to
the required torque value for that size fastener. Refer to page DF02-
12.
(6) Wait 20 minutes before filling the assembly with lubricant.
1

1 0.125" (3 MM) DIAMETER SILICONE GASKET BEAD

SHTS05Z050200135
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0261

CARRIER-TO-HOUSING JOINT

1. REPAIR
(1) Remove the carrier from the housing. Refer to page DF02-15.
(2) Remove all debris from inside the housing.
(3) Use a rotary tool with a ScotchBriteTM pad to clean all silicone residue
from the housing and carrier faces. Surfaces must be clean, dry and
free of foreign matter. The surfaces must not be oily to the touch.
(4) Remove metal filings from the magnets inside the housing.
(5) Use solvent to clean the inside of the housing.
(6) Use Loctite ODC Free cleaner or brake cleaner to clean the housing
and carrier faces.
(7) Dry the housing and carrier faces.
(8) Use a rotary wire brush to remove any nylon patch material and clean
CLEANING HOUSING FACE WITH ROTARY TOOL AND the carrier-to-housing capscrew threads. Use a clean cloth to wipe the
SCOTCHBRITETM PAD
threads.
SHTS05Z050200136 (9) Use a tap to clean the internal threads in the housing.
! WARNING
When you apply some silicone gasket materials, a small amount of
acid vapor is present. To prevent serious personal injury, ensure that
the work area is well-ventilated. Read the manufacturer's instructions
before using a silicone gasket material, then carefully follow the
instructions. If a silicone gasket material gets into your eyes, follow
the manufacturer's emergency procedures. Have your eyes checked
by a physician as soon as possible.
(10) Apply a 0.25-inch (6 mm) bead of Loctite 5699 silicone gasket mate-
rial to the housing face. Do not use Three Bond 1216E silicone prod-
ucts.
(11) Install two long studs in the carrier to guide the carrier into the hous-
ing.
(12) Immediately install the carrier into the housing to permit the silicone
gasket material to compress evenly between the faces.
! CAUTION
Apply silicone gasket material in a continuous 0.125-inch (3 mm)
bead. If you use more than this amount, gasket material can break off
and plug lubrication passages. Damage to components can result.
(13) Apply a 0.125-inch (3 mm) bead of Loctite 242 threadlocker around
the capscrew threads approximately 0.25-inch (6 mm) from the end.
1
Apply a 0.125-inch (3 mm) bead of LoctiteR242 threadlocker across
the length of the threads.
(14) Install the capscrews. Use a crossing pattern to tighten the capscrews
evenly. The capscrews must be tightened within 10 minutes of initial
application of Loctite 242 threadlocker.
2

1 360 LOCTITE BEAD

Tighten 1/2-inch capscrews to 140 lb-ft (190 Nm).
2 0.25" (6 MM)
LOCTITE 242 THREADLOCKER APPLICATION Tighten 5/8-inch capscrews to 225 lb-ft (306 Nm).
(15) Wait a minimum of 60 minutes before filling the assembly with lubri-
cant.
SHTS05Z050200137
DF0262 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

INSTALLING TIGHT FIT YOKES AND POSETM SEAL

1. INSTALLATION
(1) Apply the same lubricant used in the axle housing to the hub of the
yoke or flange.
Inspect and verify that the lips of the POSETM seal and the outer
1
(2)
retainer of the triple-lip seal or main seal are clean and free from dirt
2 and particles that may cause lubricant leakage between the seals.

4 3

1 Lubricate triple-lip or main seal.

2 INPUT SHAFT OR PINION
3 POSETM SEAL, 0.25-0.50" (6.4-12.7 MM) ONTO HUB
4 Inspect yoke hub.

SHTS05Z050200138

(3) Install the POSETM seal on the hub of the yoke or flange by hand. The
lips of the seal must face toward the end of the hub or the opposite
1
shoulder. Slide the POSETM seal on the hub until the lips are from
0.25-0.50-inch (6.4-12.7 mm) from the end of the hub. Do not install
the POSETM seal against the shoulder.
NOTICE
2
The POSETM seal will position itself correctly as the yoke or flange is
pressed on the shaft.
3
1 0.25-0.50" (6.4-12.7 MM) (4) Before you install the yoke or flange on the shaft, apply the same
2 YOKE HUB
3 FACE SEAL ASSEMBLY, POSETM SEAL ELEMENT lubricant used in the axle housing to the hub.
(5) Install the yoke or flange using the correct procedure. The yoke must
SHTS05Z050200139
be completely seated before tightening the pinion nut to the input
shaft.
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0263

DRIVER-CONTROLLED MAIN DIF-

FERENTIAL LOCK
OVERHAUL
EN05Z0502H200002

IMPORTANT POINTS - DISMOUNTING

! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving. Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. Jacks can slip and fall
over. Serious personal injury can result.

Use a brass or leather mallet for assembly and disassembly proce-

dures. Do not hit steel parts with a steel hammer. Pieces of a part can
break off and cause serious personal injury.

1. REMOVAL OF DIFFERENTIAL CARRIER FROM THE AXLE HOUS-

ING
(1) Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving.
(2) Use a jack or other lifting tool to raise the vehicle so that the wheels to
be serviced are off the ground. Support the vehicle with safety stands.
(3) Place a drain pan under the rear axle.

1 SAFETY STANDS

SHTS05Z050200012

(4) Remove the plug from bottom of axle housing. Drain lubricant from
1
the assembly.
EASY SERVICE TM

(5) Disconnect the driveline universal joint from the pinion input yoke or
2
9 flange on the carrier.
3 (6) Remove the capscrews and washers or stud nuts and washers, if
8 4 equipped, from the flanges of both axle shafts.
5
(7) Loosen the tapered dowels, if equipped, in the axle flanges of both
6
7
axle shafts using one of the following methods.
(8) Brass Drift Method. (Refer to DF02-16)
1 FULL ROUND BEARING
CUPS (9) Disconnect the vehicle air line from the differential lock actuator
2 END YOKE For details, assembly.
3 YOKE SADDLE Refer to the
4 WELD YOKE
5 BEARING STRAP Propeller shaft chapter.
6 CAPSCREWS
7 EASY-SERVICE
BEARING CUPS
8 U-JOINT CROSS
9 SLIP YOKE

SHTS05Z050200013
DF0264 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

IMPORTANT POINTS-DISASSEMBLY

1. SCREW-IN STYLE DIFFERENTIAL LOCK CYLINDER

Use the following manual engaging method to lockout the screw-in
DCDL assembly.
(1) Follow Steps 1-5 of Axle Setup for DCDL Disassembly in this section.
(2) Remove the manual engaging capscrew from the storage hole in the
carrier casting, next to the cylinder.
(3) Remove air line and fitting. Install the manual engaging capscrew into
the threaded hole in the center of the cylinder cover.
(4) Turn the manual adjusting capscrew to the right until the head is
approximately 0.25-inch(6 mm) from the cylinder cover. Do not turn
the capscrew beyond its normal stop. The capscrew is now in the ser-
vice position and the main differential lock is completely engaged.
(5) Remove the carrier from the axle housing as described in steps 1-7 of
page DF02-17.

SHTS05Z050200140 2. REMOVAL OF THE DIFFERENTIAL LOCK SLIDING COLLAR

(1) Carriers with roll pins, tap out the two retainer roll pins, if equipped,
until they are level with the inner face of the shift fork. Release the dif-
ferential lock if it is manually engaged.
(2) For carriers without roll pins, snap out collar from fork.
(3) If required, remove the DCDL assembly at this time.

SHTS05Z050200141

3. REMOVAL OF THE DIFFERENTIAL LOCK ASSEMBLY

(1) Removal of the lock cylinder
a. Remove the sensor switch.
b. Remove the cylinder by turning hex nut at the top of the cylinder
with a wrench. The cylinder may be secured to the carrier casting
with Loctite adhesive or equivalent pre-applied liquid adhesive.
To brake down these secured fasteners follow the heating proce-
dure. Refer to page DF02-58.
c. Remove the shift shaft, spring and shift fork.
(2) Remove the cotter keys, pins or lock plates that hold the two bearing
adjusting rings in position. Use a small drift and hammer to remove
pins. Each lock plate is held in position by two capscrews.
(3) Mark one bearing cap and one carrier leg so that these parts will be
assembled in the correct positions. Remove the bearing cap cap-
screws and washers, the bearing caps and the adjusting rings.
(4) Lift the differential and gear assembly from the carrier. Tilt the assem-
bly as required to permit the ring gear to clear the support for the pin-
ion spigot bearing.
Further disassembly of these carries is the same as axles with-
out the driver-controlled main differential lock. To continue dis-
assembly, follow the procedures starting with "remove the
differential and ring gear from the carrier." (Refer to page DF02-
18)
Prepare parts for assembly, adjustments, and carrier assembly
(up to the point if "install differential carrier into axle housing
(Refer to page DF02-51)") are also the same for both axles.
SHTS05Z050200142
 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF0265

IMPORTANT POINTS-ASSEMBLY

1. SCREW-IN STYLE DIFFERENTIAL LOCK ASSEMBLY INTO CAR-

RIER
Install the differential shift assembly after the differential carrier is
assembled and the gear and bearing adjustments are completed.
(1) Install the shift spring and fork into the correct position in the carrier
case. Compress the spring slightly while installing the fork.
(2) Install the shift shaft into the shaft bore of the carrier. Slide the shaft
through the shift fork bore and shift spring inside diameter.
(3) Inspect the piston O-ring. Replace the O-ring if there is any evidence
of cuts, cracks, abrasion or wear.
(4) Lightly lubricate the O-ring and DCDL cylinder bore with the same
lubricant used in the axle housing.
(5) Install the piston and O-ring assembly into the DCDL cylinder. Slide
the piston to the port end of the cylinder.
(6) Coat the DCDL cylinder threads with Loctite518 Gasket Eliminator.

SHTS05Z050200143

(7) Screw the DCDL cylinder in place. Tighten the cylinder to 80-100 lb-ft
(109-136 Nm) torque.
(8) Snap the shift collar into the fork. Engage the shift collar splines with
the splines of the differential case. Use the manual actuation cap-
screw to move the shift collar splines into the differential case splines.
(9) Install the sensor switch into its hole. Tighten the switch to 25-35 lb-ft
(35-45 Nm).
(10) Connect a battery or bulb tester to the sensor switch. With the DCDL
engaged, the tester light should go on.
If the light does not go on, perform the following steps:
.

SHTS05Z050200144
a. Verify fork position - Is it aligned with the sensor switch when in
engaged position?
b. Loose connection - Is the electrical wiring connector tightly seated?
c. Sensor switch position - Is it fully seated against spot face of carrier?
If light fails to go on after these checks, the sensor switch should be
replaced.
DF0266 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

2. Differential Lock Assembly Cover Plates

NOTICE
For carriers without the differential lock or air shift, assemble the sen-
sor switch plug and cover plate as follows.
(1) Apply Loctite518 liquid adhesive to the plate threads.
NOTICE
When the carrier is to be installed into the axle housing, the shift
collar must be held in the engaged position. This can be done
using the manual engaging bolt. Failure to keep the differential in
the locked (engaged) position will make it impossible to install
the carrier assembly into the axle housing.
After the carrier is installed into the axle housing, shift the differ-
ential into the unlocked (disengaged) position to permit the
installation of the right-hand axle shaft.

SHTS05Z050200145

INSPECTION AND REPAIR

EN05Z0502H300002

1. Check the Differential Lock

(1) Shift the vehicle transmission to neutral. Start the engine to get the
system air pressure to the normal level.
! WARNING
During DCDL disassembly, when the DCDL is in the locked or
engaged position and one of the vehicles wheels is raised from the
floor, do not start the engine and engage the transmission. The vehi-
cle can move and cause serious personal injury.
(2) Place the differential lock switch, in the cab of the vehicle, in the
unlocked or disengaged position.
(3) Drive the vehicle at 5-10 mph (8-16 km/h) and check the differential
lock indicator light. The light must be off when the switch is in the
unlocked or disengaged position.
(4) Continue to drive the vehicle and place the differential lock switch in
the locked or engaged position. Let up on the accelerator to remove
the driveline torque and permit the shift. The light must be on when
the switch is in the locked position.
If the indicator light remains ON with the switch in the unlocked posi-
tion: The differential is still in the locked position. Verify that the man-
ual engaging capscrew was removed from the cylinder cover of the
actuator assembly.
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR011

BRAKE EQUIPMENT BR01

(MODELS WITH HYDRAULIC BRAKE) BR01-001

SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING ..................................... BR01-5
BRAKE SYSTEM AIR BLEEDING................... BR01-9
POWER STEERING SYSTEM
AIR BLEEDING.............................................. BR01-11
BRAKE TEST ................................................ BR01-12
BR012 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0680101C100001

Type of service brake Hydraulic disc type wheel brake with ABS and hydraulic booster (HYDRO-MAX)

HYDRO-MAX The Hydro-Max is a hydraulically powered brake booster which provides power
assist for applying hydraulic brakes. The booster reduces the pedal effort required
to apply the brakes as compared to a non-power system.
The hydraulic booster is comprised of an open center valve and reaction feed back
mechanism, a power piston, a 12 volt backup pump and an integral flow switch. It
is powered by either the power steering pump or other hydraulic source. The
backup pump provides a secondary power source for the hydraulic booster and is
controlled by the integral flow switch.
The master cylinder is a split system type with separate fluid chambers, pistons
and outlet ports for the front and rear brake circuits. A differential pressure switch
is equipped.
Refer to DIAGRAM on page BR01-3

ABS (Anti-Lock Braking System) The ABS system comprises of sensor rings mounted on the wheels. The ABS
computer receives signals from wheel sensors that monitor the rotational speed of
the wheels and sends out signals to maintain the appropriate braking force. The
ABS modulator maintains the appropriate braking force based on the control sig-
nals.

Hydraulic disc brake Model: HINO 238, 258, 268 (NE8J) and 258 (NF8J), 338
Four-Piston fixed mount Caliper.

NOTICE
Above components were made by the following manufacturer's;
HYDRO-MAX: BOSCH
ABS MODULATOR: MERITOR WABCO
DISC BRAKE CALIPER: MERITOR
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR013

DIAGRAM
EN0680101J100001

MODEL: HINO238(NE8J), 258(NE8J/NF8J), 268(NE8J) AND 338(NF8J) HYDRAULIC BRAKE (E version)

6 7 10 : POWER STEERING FLUID LINE

: ELECTRICAL CIRCUIT
: OIL PIPE
: OIL HOSE
: AIR PIPE
: NYLON TUBE
9
3
5
1 2
4
12 8 13

12
11

13

23 24
16
4 23
17 16
18

21 22
21 22
15
14
16
CIRCUIT OF 23 CIRCUIT OF
EXHAUST BRAKE AIR SUSPENSION, 23
UNLOADER CIRCUIT OF AIR SUSPENSION HEIGHT CONTROL

16 25

19
20 CIRCUIT OF CAB AIR
CIRCUIT OF AIR HORN SUSPENSION SEAT 16
SHTS068010100002C
BR014 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

1 Hydro-Max booster and master cylinder 15 Air dryer

2 Stop light switch 16 Air tank
3 Flow switch 17 Magnetic valve
4 Pressure switch 18 Exhaust brake
5 Power steering oil reservoir 19 Magnetic valve
6 Power steering pump 20 Air horn (if so equipped)
7 Power steering gear 21 Air suspension protection valve
8 Backup pump & motor 22 Leveling valve
9 Relay 23 Air suspension bellows
10 Hydro max controller 24 Magnetic valve (if so equipped)
11 ABS modulator and ECU 25 Air suspension seat
12 Speed sensor-front
13 Speed sensor-rear
14 Air compressor
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR015

TROUBLESHOOTING
EN0680101F300001

Symptom Possible cause Remedy/Prevention

No response upon working the Insufficient seal of master cylinder sec- Replace master cylinder assembly.
pedal or there is the feeling of step- ondary cup
ping on sponge (Air trapped in the
brake lines) Insufficient air bleeding Bleed air from brake line.
No response upon working the Vapor lock in brake system Bleed air from brake.
pedal or there is the feeling of step- Leakage of fluid from brake system Tighten further or replace gasket, O-
ping on sponge ring, cup, etc.
Poor quality brake fluid or improper Drain the system, flush and refill with
fluid (low boil point) the recommended fluid.
Brake fluid decreases Leakage of brake fluid from brake sys- Tighten further or replace gasket, O-
tem ring, etc.
Leakage of brake fluid from master cyl- Replace master cylinder assembly.
inder
Worn pad Replace pad if it is worn to limit. Refill
brake fluid.
Excessive pedal travel (though Insufficient brake fluid in the master Search the cause of insufficient fluid,
there is response upon working the cylinder repair or replace it.Then refill fluid and
pedal) bleed air.
Air trapped in the brake lines Bleed air from brake lines.
Leakage of fluid from brake system Check the leak point, repair or replace.
Poor quality brake fluid or improper Drain the system, flush and refill with
fluid the recommended fluid.
Contamination of the brake fluid Replace the brake system and refill
with the recommended fluid.
Insufficient seal of the master cylinder Replace master cylinder assembly.
cup
Unequal or unstable braking Pad is wet with grease or fluid Replace the pad.
Defective pad material (improper com- Replace the pad.
bination)
Non-uniform pad contact Correct.
Excessive abrasion loss of rotors Correct or replace.
Distorted rotors Correct or replace.
Loose hub bearing Adjust or replace the bearing.
Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Clogging of brake system Replace, the pipe, hose, etc.
Abnormal piston operation of the disc Check the piston seal.
brake
BR016 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

Symptom Possible cause Remedy/Prevention

Brake drags or does not release Improper return of master cylinder pis- Replace master cylinder assembly.
ton
Clogging of brake system Replace the pipe, hose, etc.
Constricted master cylinder reservoir Clean vent passage in reservoir cap.
vent
Self applied booster (fluid flow too Repair or replace power steering
high) pump.
Soft or swollen master cylinder seals Flush out old brake fluid then replace
due to brake fluid contamination master cylinder and add new brake
fluid.
Clogging compensating valve of mas- Replace master cylinder assembly.
ter cylinder
Improper return of brake pedal Repair or replace.
Improper return of brake booster piston Replace booster assembly.
Improper installation pad Check the installed condition of the
pad. Repair.
Improper return of caliper piston Repair or replace.
Not enough braking, or too much Pad is wet with grease or fluid Replace the pad.
pedal resistance (Wheel brake and Improper contact of rotor and pad Correct.
rotor)
Improper pad material or glazed pad Correct.
Deformation or hardening of rotor Correct or replace.
Excessively worn pad Replace.
Glazed rotor Correct.
Not enough braking, or too much Leakage of brake fluid from brake sys- Tighten further or replace gasket.
pedal resistance (Control system tem
pipings)
Not enough braking, or too much Improper operation of power steering Repair or replace.
pedal resistance (Lack of power pump
steering pump pressure) Clogging of brake system Replace pipe, hose, etc.
Not enough braking, or too much Check the pipe joints for tightness Repair.
pedal resistance (Not enough power There is a rupture or twist in the pipe Replace.
steering pump pressure or rise of leading to the power steering pump
power steering pump pressure)
The hose is ruptured or collapsed Replace.
Power steering pump relief valve set- Replace power steering pump.
ting too low
Fluid contamination Drain, flush and refill system, replace
booster or master cylinder as appropri-
ate and power steering reservoir filter
as necessary.
Not enough braking, or too much Lack of brake fluid Supply brake fluid periodically.
pedal resistance Improper power steering pump Replace.
Stuck piston in the master cylinder Replace master cylinder assembly.
Insufficient power steering fluid Refill to proper level.
Air trapped in the power steering fluid Search the cause, refill the fluid and
or brake fluid bleed air.
Binding brake pedal linkage Overhaul and lubricate.
Worn or damaged brake booster Replace booster assembly.
Leakage around the check ball in the Replace the backup pump.
backup pump
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR017

Symptom Possible cause Remedy/Prevention

Brake squeal Improper pad material or glazed pad Replace pad.
Pad back plate contact with rotor Replace pad.
Deformation or wear of rotor Repair or replace.
Intrusion of foreign matter between Clean the surface of pad or replace.
rotor and pad
Loose hub bearing Adjust or replace bearing.
Hardening of pad surface Replace pad.
Different pad Replace proper pad.
Rotor is wet with grease, fluid and dust Check the leakage position and repair.
Clear the rotor.
Impossible to bleed air completely Piston cup of master cylinder sucks in Replace master cylinder assembly.
air
Improper tightness of joints of brake Tighten further or replace gasket.
system
Pulsating brake pedal ABS operation Feature of ABS operation (No prob-
lem).
Wheel bearings loose or worn Readjust or replace.
Excessive rotor thickness variation Repair or replace.
Decreasing pedal travel Clogging of the compensating valve of Replace master cylinder assembly.
master cylinder
Swollen pressure seals of master cylin- Replace master cylinder assembly.
der
Improper return of the master cylinder Replace master cylinder assembly.
piston
Delay pedal return Broken return spring Replace master cylinder assembly.
Restricted fluid return line of the power Remove the obstruction and replace
steering or hydraulic pump the line.
Swollen power piston seal of the Replace booster assembly.
booster
Backup pump operates continu- Abnormal brake switch Replace.
ously Abnormal monitor module Replace.
Abnormal relay Replace.
Abnormal flow switch Remove switch components, clean
and inspect for damage or contamina-
tion and replace if necessary.
Binding pedal linkage Disassemble and lubricate.
Backup pump does not operate Abnormal brake switch Replace.
Abnormal monitor module Replace.
Abnormal relay Replace.
Abnormal flow switch Remove switch components, clean
and inspect for damage or contamina-
tion and replace if necessary.
Binding pedal linkage Disassemble and lubricate.
Abnormal backup pump Replace backup pump.
Abnormal battery Recharge or replace.
BR018 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

Symptom Possible cause Remedy/Prevention

Power steering pump is noisy Insufficient power steering fluid Refill proper level.
Air trapped in the power steering fluid Bleed air from power steering system.
Contamination in the power steering Replace power steering pump and
fluid fluid.
Severe reaction to pedal pressure Throttle valve cut in spring defective Replace booster assembly.
(Grabby brakes) Binding brake pedal linkage Disassemble and lubricate.
Incorrect pads, or pads loose on plate Replace pads. Be sure pads are tight
on caliper.
Grease or brake fluid on pad Repair grease seal or caliper as
required. Replace pads in axle sets.
Loose caliper on caliper mounting Retighten.
bracket
Leakage between booster and mas- Primary pressure seal or backup ring Replace master cylinder assembly.
ter cylinder of the master cylinder is worn or dam-
aged
Seal or O-ring of the booster end cap Replace booster assembly.
assembly is worn or damaged
Leakage from booster or power Seal between backup pump and Replace the seals.
steering pump booster is worn or damaged
Backup pump mounting screw is loose Retighten.
Booster housing or power steering Replace booster assembly or power
pump is worn or damaged steering pump.
Backup pump is worn or damaged Replace backup pump.
Seal of the booster flow switch is worn Replace flow switch seals.
or damaged
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR019

BRAKE SYSTEM AIR BLEEDING

EN0680101F300002

1. PREPARATION
(1) Apply the parking brake and block the wheels.
Turn the starter switch to "LOCK" position and disconnect the battery
terminals.
NOTICE
The starter switch must remain at "LOCK" position for the entire
bleeding procedure.
(2) Fill the reservoir with new DOT 3 or DOT 4 hydraulic brake fluid.

2. AIR BLEEDING
(1) Depress the brake pedal five times using the stroke between 1/3
travel and maximum travel in 5 seconds.
(2) Release the pedal for 5 to 10 seconds. Air bubbles will rise the reser-
voir while depressing and releasing pedal.
(3) Repeat Steps (1) and (2) another three times, or until sufficient pedal
resistance is felt.
! WARNING
Do not let the brake master cylinder fluid get below the minimum level
during the bleeding operation. Failure to keep the brake reservoir
level above minimum could result in more air entering system, mak-
ing it impossible to effectively bleed the system.
(4) Bleed the brake system. Put a wrench on the brake actuator bleeder
fitting. Start with the farthest from the modulator, (typically the right
rear), then attach a length of clear plastic tubing to the bleeder fitting.
Make sure the tube fits snugly.
(5) Submerge the tubing in a container of clean brake fluid.
NOTICE
Both the tubing and container must be able to withstand the effects of
brake fluid.
(6) Depress the brake pedal 10 to 15 times, using the maximum available
stroke.
(7) Loosen the bleeder fitting until the fluid begins to flow, (about 3/4
turn), while depressing the brake pedal through its maximum available
stroke.
(8) Tighten the fitting firmly prior to releasing the brake pedal.
(9) Repeat Steps (4) through (6) several times until the discharged fluid is
free of air bubbles.
(10) Repeat Steps (1) through (7) to bleed the remaining three brake actu-
ators. Bleed in sequence of the longest to the shortest circuit from the
modulator.

SHTS068010100003
BR0110 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

(11) Check the travel of the brake pedal. If a firm resistance is felt the man-
ual bleeding procedure is complete.
(12) Check the fluid level in reservoir and fill if required. Replace reservoir
cap and dispose of used brake fluid.
NOTICE
The brake fluid level shall be within the range of 1 in.(25.4mm)
below bottom of ring. Fill to bottom of ring if brake fluid is more
than 1 in. (25.4mm) below bottom of ring.
Remove the excess brake fluid from the reservoir when the worn
brake pads are replaced, otherwise there is a possibility the
Bottom of ring brake fluid will overflow from the master cylinder reservoir.
1 in. (25.4mm)

SHTS068010100004
 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR0111

POWER STEERING SYSTEM AIR BLEED-

ING
EN0680101H200001

1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
Use only specified fluid.
Do not overfill the oil reservoir.
Replace old fluid with new fluid after overhauling power steering
gear unit or power steering pump.
Specified fluid....Refer to recommended lubricant list.

! WARNING
Do not use brake fluid. Mixing brake fluid with power steering fluid
will damage the seals and O-rings in the Hydro-Max booster, the
power steering pump and power steering gear unit, resulting in possi-
ble steering loss.

2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME WITH

STANDS.
NOTICE
Block the rear wheels.

SHTS068010100005

3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.

4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add fluid, if necessary.
! WARNING
When checking the fluid level of the power steering reservoir or add-
ing fluid to the reservoir, be careful not to contaminate fluid with dirt
in the reservoir. Fluid contaminated with dirt can result in a shorter
life of the pump, and can result in personal injury and/or property
damage due to improper operation of relief valve, central valve, etc.
SHTS068010100006

5. START THE ENGINE AND TURN THE STEERING WHEEL FULLY

IN BOTH DIRECTIONS SEVERAL TIMES WITH ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished while
air bleeding so that the oil reservoir never becomes empty.

6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.

SHTS068010100007
BR0112 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

7. CHECK THE BRAKE OPERATION.

(1) Release the parking brake.
(2) Turn the starter switch to "ON" position (engine is not running). The
brake pressure warning light and buzzer should come on. Depress
the brake pedal, and the backup pump should start.
(3) Start the engine and depress the brake pedal. The brake pressure
warning light and buzzer should not come on, and the backup pump
should not start. If they come on there is a malfunction. See trouble-
shooting to find the problem.

8. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS STOPPED.

(1) If necessary, add or decrease the power steering fluid to match
between "MAX" and "MIN".
! CAUTION
If air bleeding is not done properly, and the engine is stopped, power
steering fluid could overflow from the reservoir.

MAX.

MIN.

SHTS068010100008

BRAKE TEST
EN0680101F300003

Measure the braking effect of each wheel on the brake tester. If no brake
tester is on hand, perform the brake test from low speed 510 km/h (3.1
3.6 miles/h) and check the braking performance. Also check to see that
there are no irregularities in general.
 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR011

BRAKE EQUIPMENT BR01

(MODELS WITH FULL AIR BRAKE) BR01-002

SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DATA AND SPECIFICATIONS ......................... BR01-3
DIAGRAM ........................................................ BR01-4
TROUBLESHOOTING ..................................... BR01-5
BR012 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)

SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0680201C100001

Type of service brake Full air, S-cam brake (Q-plus) with automatic adjuster.

Air charging system Air charging is from piston type air compressor and air flow is directed and
controlled by a pressure regulator, the necessary valves, and lines as
required.
Pressure sensor and air pressure warning switch are used for indicating
the pressure level in the system.

Service brake control system Two independent lines for front and rear wheels with air flow controlled by
a brake valve, and each line comprises of a group of valves and brake
chambers (one/wheel).
Two stop light switches (one/line) are used to operate the stop lights.

Spring brake control system Single line for rear spring brake chambers.
The line comprises a control valve which controls air flow, the other neces-
sary valve and spring brake chambers.
A parking brake switch is used to turn OFF the warning buzzer and to turn
ON the parking brake warning light.

ABS (Anti-Lock Braking System) The ABS system comprises sensor rings mounted on the wheels, the ABS
ECU which receives signals from wheel sensors that monitor the rotational
speed of the wheels and sends out signals to maintain the appropriate
braking force, the ABS control valves which increase or decrease the brak-
ing force based on the control signals.
 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR013

DATA AND SPECIFICATIONS

EN0680201I200001

Parts name Maker Model specification

Front axle wheel brake MERITOR 15 x 4 Q-Plus Cam Brake with Cast Spider, auto-
matic slack adjuster (Slack length: 5.5, type:
handed)
Drum: 15 in. Outboard mounted

Front Brake chamber MGM C20 20 x 2.25 in. standard

Rear axle wheel brake MERITOR 16.5 x 7 or 15 x 8.625 Q-Plus Cam Brake with Cast
Spider, automatic slack adjuster (Slack length: 5.5
or 6.0, type: handed)
Drum: 16.5 in. Outboard mounted

Rear Spring brake chamber MGM TR3030 3030 x 2.50 in. standard

Brake valve Bendix E-8P

Check valve Bendix SC-3

Spring brake control valve Bendix PP-DC

Spring brake modulating valve Bendix SR-7

Rear relay valve Bendix R-14 (No.102860)

Air dryer Bendix AD-IS

Brake chamber setting

0 0
Bolt center line
Front axle

Chamber clamp bolt

insert direction

Rear axle

22 22
SHTS068020100001
BR014 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)

DIAGRAM
EN0680201J100001

MODEL: HINO 258, 268 (NJ8J), 338 (NV8J), AND 358 (NH8J) FULL AIR BRAKE

5 15
CAB SIDE CHASSIS SIDE 5 15
19 17 5
18
3 CIRCUIT OF CAB AIR CIRCUIT OF
SUSPENSION DIFFERENTIAL LOCK CIRCUIT OF AIR HORN
13
21

5
12
20
7 14
2
1 9 11
2 R 21
S
CIRCUIT OF
4 AIR SUSPENSION
10
15
6 8
4 21
14
13
5
3
12 20
5
: AIR HOSE
: AIR PIPE 16 15
: NYLON TUBE CIRCUIT OF
AIR SUSPENSION 21
HEIGHT CONTROL

SHTS068020100002

1 Brake valve 12 Brake chamber-Rear

2 Stop light switch 13 ABS control valve - Front
3 Brake chamber - Front 14 ABS control valve - Rear
4 Air pressure sensor 15 Magnetic valve
5 Air dryer 16 Exhaust brake
6 Spring brake control valve 17 Air horn (if so equipped)
7 Air compressor 18 Air suspension seat
8 Air tank - Front 19 Differential lock
9 Air tank - Rear 20 Leveling valve
10 Relay valve (for service brake) 21 Air suspension bellows
11 Spring brake modulating valve
 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR015

TROUBLESHOOTING
EN0680201F300001

Symptom Possible cause Remedy/Prevention

Not enough braking (Wheel brake Lining is wet with grease or oil Replace lining.
and drum) Improper contact of drum and lining Correct.
Improper lining material or hardening Replace lining.
lining
Deformation or hardening of drum Correct or replace.
Excessively worn lining Replace.
Improper adjustment of shoe clearance Check automatic slack adjuster.
Not enough braking (Control sys- Leakage of compressed air from brake Tighten further or replace gasket.
tem) system
Lack of compressed air pressure due Use properly.
to excessive use
Improper operation of air compressor Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve Repair or replace.
Improper operation of spring brake Repair or replace.
control valve
Improper operation of spring brake Repair or replace.
chamber
Clogging of brake system Replace pipe, hose, etc.
Unequal or unstable braking (Wheel Lining is wet with grease or oil Replace lining.
brake and drum) Defective lining material (Improper Replace lining.
combination)
Non-uniform lining contact Correct.
Non-uniform brake chamber rod stroke Check automatic slack adjuster.
Distorted drums Correct or replace.
Excessive abrasion of drums Correct or replace.
Unequal or unstable braking (Con- Clogging of brake system Replace pipe, hose, etc.
trol system)
Unequal or unstable braking (Oth- Loose hub bearing Adjust or replace bearing.
ers) Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Brake drags or does not release Improper adjustment of shoe clearance Check automatic slack adjuster.
(Wheel brake and drum) Defective shoe return spring Replace.
Brake drags or does not release Lack of pedal play Adjust.
(Control system) Improper return of brake pedal Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve Repair or replace.
Leakage of air pressure from brake Tighten connections further or replace
system gaskets.
Improper operation of spring brake Repair or replace.
control valve
Improper operation of spring brake Repair or replace.
chamber
Improper operation of air compressor Repair or replace.
Clogging of brake system Replace pipe, hose, etc.
BR016 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)

Symptom Possible cause Remedy/Prevention

Brake squeal (Wheel brake and Improper lining material or glazed lin- Replace lining.
drum) ing
Loose lining rivet Replace or tighten the rivet further.
Lining rivet in contact with drum Replace lining and rivet.
Deformation or wear of drum Repair or replace.
Intrusion of foreign matter between Clean the surface of lining or replace.
drum and lining
Brake squeal (Others) Loose hub bearing Adjust or replace bearing.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR021

SERVICE BRAKE (HYDRAULIC BRAKE)

BR02

BR02-001

HYDRAULIC BRAKE ................................BR02-2

INSPECTION AND ADJUSTMENT ................. BR02-2

HYDRO-MAX HYDRAULIC BRAKE BOOSTER

AND MASTER CYLINDER .......................BR02-5
DATA AND SPECIFICATIONS ......................... BR02-5
DESCRIPTION ................................................ BR02-5
PRINCIPLE OF OPERATION .......................... BR02-7
COMPONENT LOCATOR................................ BR02-9

HYDRO-MAX BOOSTER........................BR02-10
OVERHAUL ................................................... BR02-10

MASTER CYLINDER ..............................BR02-16

OVERHAUL ................................................... BR02-16
PRESSURE TESTS ...................................... BR02-18

ABS MODULATOR .................................BR02-19

DATA AND SPECIFICATIONS ....................... BR02-19
DESCRIPTION .............................................. BR02-19

WHEEL BRAKE (TYPE: 4 PISTON).......BR02-20

DATA AND SPECIFICATIONS ....................... BR02-20
DESCRIPTION .............................................. BR02-21
TROUBLESHOOTING ................................... BR02-22
BR022 SERVICE BRAKE (HYDRAULIC BRAKE)

HYDRAULIC BRAKE
INSPECTION AND ADJUSTMENT
EN1680102H600001

1. REMAINING THICKNESS OF PAD

Inspect the pad thickness. If the pad thickness is less than the
service limit or if it is foreseen that it may be worn to the service
limit before the next inspection, replace it with a new one.
Four piston type
Assembly Standard: 18.5 mm {0.728 in.}
Service Limit: 3.2 mm {0.125 in.}
! WARNING
If a pad which has become thinner than the limit is left unreplaced, the
rotor may be damaged by the pad back-plate and the braking force will
be badly degraded. Be sure to check carefully the worn state of the
brake pad of all wheels.

2. BRAKE FLUID LEAK AND POWER STEERING FLUID LEAK

(1) Check for fluid leaks.
a. Fluid leaks from lines.
With the brake pedal depressed, visually check for leaks of brake
fluid from the brake hydraulic line including the pipes, connection,
hoses, etc. If any leak is found, repair or replace with the corre-
sponding parts.
b. When checking for leaks, check also the following items and
repair or replace with the corresponding parts as required.
a) Check that the pipes and hoses are not hitting or rubbing other
parts. Check that the pipe clips are not loose.
b) Check that the pipes have no cracks and that they have not
become rusty.
c) Check that the hoses are not deteriorated, deformed, or swol-
len.
NOTICE
As a general rule, the brake hoses should be replaced with new ones
every 36,000 miles (60,000 km) or 12 months. When any defects as
above have been found, replace immediately with new ones.
c. Fluid leaks from components other than lines.
If the pedal stroke gradually increases as the brake pedal is kept
pressed (in the worst case the brake pedal reaches the cab floor),
a probable cause is that there is an internal leak in any one of the
following components;
Master cylinder
Hydraulic booster
Caliper piston in wheel brake
 SERVICE BRAKE (HYDRAULIC BRAKE) BR023

3. BRAKE FLUID
When the brake fluid is used for a long time, water may get into
the brake fluid and its boiling point may become low, thereby
causing a possibility of vapor lock which is very dangerous.
Replace old brake fluid with fresh brake fluid (Use DOT3 or DOT4
brake fluid) every 36,000 miles (60,000 km) or 12 months.
(1) Hydraulic brake fluid color check
Check the color of the brake fluid in the brake fluid reservoir.
Check that the color is as specified by FMVSS116 (transparent or
amber).
Replace the brake fluid if it has become discolored.
Probable causes of discoloration are as follows:
.

a. Thermal load
b. Aging
c. Oxidation
d. Ingression of mineral oil
(2) Brake fluid level check.
Check the fluid level of the brake fluid reservoir which is located under
the hood on the driver side of the vehicle. Fluid level should be within
1 inch below bottom of ring. Replenish reservoir with DOT3 or DOT4
brake fluid to bottom of ring if fluid level drops below 1 inch.

! WARNING
Remove the excess brake fluid from the reservoir when the worn
brake pads are replaced, otherwise there is a possibility the
brake fluid will overflow from the master cylinder reservoir.
NOTICE
Bottom of ring Be sure to use clean brake fluid. Note that if a foreign substance is
mixed with the brake fluid, components of the brake line may be dam-
aged and their functions may be degraded, thereby causing insuffi-
1 in. (25.4mm)

cient braking force.

Before removing the brake fluid reservoir cap, clean the vicinity
of the cap.
If foreign matter has settled on the bottom of the reservoir, clean
the reservoir.
Check that the container and tools used for brake fluid replenish-
ment are clean. If they are dusty or dirty, clean them.
Be sure to clean the strainer of the reservoir when replacing the
brake fluid.
SAPH168010200001 Brake fluid is highly hygroscopic, and absorbs moisture. Be sure
to securely tighten the caps of the containers to prevent entry of
moisture.
Do not leave the reservoir cap removed for a long time.
When replenishing or replacing brake fluid outdoors on a rainy
day, exercise care so that no water gets into the brake fluid.
Pay attention that no mineral oil is mixed into brake fluid. Mineral
oil will cause swelling of the rubber parts of the brake line, caus-
ing insufficient braking force.
Do not mix different types of brake fluid.
BR024 SERVICE BRAKE (HYDRAULIC BRAKE)

4. BRAKE PRESSURE WARNING LIGHT

(1) Check for brake pressure warning light failure.
If the brake pressure warning light does not turn on when the starter
switch is turned to the ON position, the light has burned out. Replace
any burned out light with a new one.

[USA] [CANADA]

Brake pressure
warning light

SAPH168010200002

(2) Check the differential pressure switch.

Purposely loosen either the front or rear brake line.
Start the engine, depress the brake pedal and confirm that the warn-
ing lights up. Confirm warning light condition with other brake line
(front and rear). If in both conditions the warning light comes on, the
differential pressure switch is normal.

Differential
presure switch

SAPH168010200003
 SERVICE BRAKE (HYDRAULIC BRAKE) BR025

HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER

CYLINDER
DATA AND SPECIFICATIONS
EN1680102I200001

Manufacturer BOSCH
Type HYDRO-MAX II and master cylinder
Master cylinder diameter 50.80 mm {2.00 in}

DESCRIPTION
EN1680102D100001

SAPH168010200004
BR026 SERVICE BRAKE (HYDRAULIC BRAKE)

SAPH168010200005

1 Reservoir cap with diaphragm 9 Check valve seat

2 Differential pressure switch 10 Check ball
3 Tube seat 11 Hydro-Max booster assembly
4 Master cylinder assembly 12 Check ball retainer
5 Flow switch 13 Adapter
6 O-ring 14 Face seal
7 Flow piston 15 Backup pump
8 Flow piston spring 16 Backup pump relay
NOTICE
The above parts can be replaced if necessary. Any malfunctions to master cylinder or Hydro-max booster assembly
requires complete assembly replacement.
SERVICE BRAKE (HYDRAULIC BRAKE) BR027

PRINCIPLE OF OPERATION
EN1680102C100001

1. HYDRO-MAX BOOSTER
During normal system operation, fluid flow from a hydraulic
power source (the power steering pump) enters the inlet port of
the Hydro-Max booster, flows through the power piston, around
the throttle valve and through the flow switch, exiting through
the outlet port.
Force applied to the brake pedal by the vehicle operator is multi-
plied by the lever ratio of the pedal mechanism to move the pedal
rod of the booster. This movement closes the throttle valve
which restricts flow. This restriction of flow, which results in a
pressure increase acting on the power piston, applies an ampli-
fied force to the master cylinder primary piston. A reaction pis-
ton, inside the power piston subassembly, provides the driver
"pedal feel" during an application of the brake pedal.
Fluid flow through the flow switch opens the backup pump elec-
trical circuit during normal operation. A separate check valve in
the backup pump prevents back-flow through the pump during
normal power applications. In the event normal flow from the
power source is interrupted, the backup pump provides the
power at a reduced rate for stopping. Upon flow interruption, the
Integral flow switch closes, energizing a relay, providing electri-
cal power to the backup pump.
During backup operation, the pump re-circulates fluid within the
booster assembly with pressure built on demand via the throttle
valve. Fluid is retained within the booster by the inlet port check
valve.

2. MASTER CYLINDER
The primary circuit is separated from the secondary hydraulic
circuit. Hydraulic leakage in one circuit does not affect the func-
tion of the other circuit.
A differential pressure switch is available. It illuminates a light on
the dash panel to warn when there is a pressure differential
between the primary and secondary brake circuits caused by a
leak in one circuit. This may occur when one circuit leaks or is
improperly bled.
BR028 SERVICE BRAKE (HYDRAULIC BRAKE)

SAPH168010200006

NOTICE
This illustration is a representative model for operation reference.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR029

COMPONENT LOCATOR
EN1680102D100002

SAPH168010200007

1 Brake hose 14 Stop light switch

2 Brake hose clip 15 Stop light switch cover
3 Brake pipe bracket 16 Return spring
4 Brake pipe 17 Bushing
5 Sub harness 18 Brake pedal
6 Harness clamp 19 Collar
7 Hydro-Max booster and master cylinder 20 Pedal pad
8 Retainer 21 Power steering fluid reservoir
9 Plane washer 22 Hose clamp
10 Clevis pin 23 Power steering fluid hose
11 Pedal bracket 24 Power steering fluid pipe
12 Seal 25 Pipe clamp
13 Shaft

Tightening torque Unit: Nm {kgfcm, lbfft}

A 20-30 {204-305, 15-22} D 33.9-40.7 {346-415, 25-30}
B 18-26 {184-265, 14-19} E 22-34 {224-346, 16-25}
C 18-26 {184-265, 14-19}
BR0210 SERVICE BRAKE (HYDRAULIC BRAKE)

HYDRO-MAX BOOSTER
OVERHAUL
EN1680102H200001

IMPORTANT POINT-DISMOUNTING
! CAUTION
The Hydro-Max booster and the master cylinder use two distinctly dif-
ferent incompatible hydraulic fluids. They must not be mixed. Using
the incorrect fluid will permanently damage the seals and can cause
malfunctioning brakes.

1. BEFORE DISMOUNTING THE HYDRO-MAX BOOSTER

(1) Be sure to block the wheels.
(2) Disconnect the battery cable from the battery ground terminal.

Battery dround terminal

SAPH168010200008

2. DISCONNECT THE HARNESS CONNECTORS AND HARNESS

Flow switch (1) Disconnect the connectors of differential pressure switch, flow switch,
backup pump sub harness and relay.
Clamp Pipe
(2) Remove the sub harness from the backup pump terminal.

Hose
3. DISCONNECT THE HYRDAULIC HOSE AND PIPE FROM THE
HYDRO-MAX BOOSTER
Drain the power steering fluid.

Differential
Relay
pressure switch

SAPH168010200009

4. DISCONNECT THE MASTER CYLINDER

HINT
Brake pipe By removing the brake pipe bracket or brake hose clips, it is pos-
bracket sible to remove the Hydro-Max booster without removing the
master cylinder from the vehicle.
It is not necessary to disconnect the brake pipes from the master
Master cylinder cylinder.
(1) Remove the brake pipe bracket or brake hose clips.
(2) Remove the nuts to disconnect the master cylinder.
Hose clip

SAPH168010200010
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0211

5. REMOVE THE HYDRO-MAX BOOSTER

Stop light (1) Remove the stop light switch cover.
switch cover Stop light switch (2) Remove the clevis pin to disconnect the brake pedal, stop light switch
and push rod.
(3) Remove the Hydro-Max booster tightening nuts.
(4) Move the master cylinder forward to allow for the Hydro-Max booster
removal and support it in that position.
(5) Remove the Hydro-Max booster.

Pin

SAPH168010200011

IMPORTANT POINTS-DISASSEMBLY

1. REMOVE THE BACKUP PUMP

Retainer (1) Remove the two tightening bolts.
Check ball (2) Remove the backup pump and adapter.
Adapter ! CAUTION
Do not damage the contact surface.
Fece seal
Backup pump NOTICE
The power steering fluid will drain out from Hydro-Max booster.
(3) Remove and discard the four face seals.
SAPH168010200012 (4) Remove the check ball. (If necessary)

2. REMOVE THE FLOW SWITCH ASSEMBLY

(1) Remove the flow switch.
O-ring Spring (2) Remove and discard the O-ring from the flow switch.
(3) Using a small magnet, remove the flow piston and spring.

Flow piston
Flow switch

SAPH168010200013

3. REMOVE THE INLET CHECK VALVE

O-ring (1) Using a hook wire remove and discard the inlet check valve seat with
O-ring from inlet port.
Check valve seat (2) Remove the check ball.

Check ball
4. USE CLEAN POWER STEERING FLUID FOR CLEANING THE
REUSED PARTS AND NEW SEALS
! CAUTION
Do not use brake fluid.

SAPH168010200014
BR0212 SERVICE BRAKE (HYDRAULIC BRAKE)

IMPORTANT POINTS-ASSEMBLY
O-ring
1. INSTALL THE INLET CHECK VALVE
Check valve seat (1) Install the check ball to inlet port.
(2) Lubricate and install the O-ring in the inlet check seat.
Check ball
(3) Install the inlet check valve seat.

SAPH168010200015

2. INSTALL THE FLOW SWITCH ASSEMBLY

(1) Install the flow spring and piston.
O-ring Spring (2) Lubricate and install the O-ring in the flow switch.
(3) Install the flow switch.
Tightening Torque:
2.3-4.5 Nm{23-45 kgfcm, 20.4-39.8 lbfin}

Flow piston
Flow switch

SAPH168010200016

3. INSTALL THE BACKUP PUMP

(1) Install the check ball in the delivery port (If removed). If not replaced,
make sure the check ball is in the delivery port.
Retainer
(2) Lubricate and install the four face seals in the adapter and backup
pump.
Check ball
(3) Install the adapter and backup pump.
Adapter
NOTICE
Fece seal Ensure that the delivery ports for hydraulic pump, adaptor and Hydro-
Backup pump Max booster correspond during installation.
Do not confuse mating surfaces.
Install the backup pump in its proper position.
SAPH168010200017 (4) Tighten the two bolts.
Tightening Torque:
24.5-33.9 Nm {250-345 kgfcm, 18-25 lbfft}
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0213

IMPORTANT POINTS-MOUNTING
Stop light switch cover
1. INSTALL THE HYDRO-MAX BOOSTER
(1) Install the Hydro-Max booster and tighten the nuts.
Tightening Torque:
33.9-40.7 Nm {346-415 kgcm, 25-30 lbfft}

(2) Install the clevis pin to connect the brake pedal, stop light switch and
Brake pedal
push rod.
Pin Srop light (3) Install the stop light switch cover.
switch

SAPH168010200018

Stop light
switch

Brake pedal

SAPH168010200019

2. CONNECT THE MASTER CYLINDER

(1) Connect the master cylinder to Hydro-Max booster and tighten the
nuts.
Brake pipe Tightening Torque:
bracket 33.9-40.7 Nm {346-415 kgfcm, 25-30 lbfft}

(2) Install the brake pipe bracket or brake hose clips.

Master cylinder

Hose clip

SAPH168010200020

3. CONNECT THE HYRDAULIC HOSE AND PIPE FROM THE

Flow switch HYDRO-MAX BOOSTER
(1) Connect hydraulic pipe and tighten the flare nut.
Clamp Pipe
Tightening Torque:
22-34 Nm {224-346 kgfcm, 16-25 lbfft}
Hose

Differential
Relay
pressure switch

SAPH168010200021
BR0214 SERVICE BRAKE (HYDRAULIC BRAKE)

(2) Connect hydraulic hose and tighten the clamp.

Tighten the clamp until dimension L = 4-5 mm (0.16-0.19 in.).

SAPH168010200022

4. CONNECT THE HARNESS CONNECTORS AND HARNESS

(1) Install the sub harness to the backup pump terminal.
(2) Connect the connectors of differential pressure switch, flow switch,
backup pump sub harness and relay.

5. CONNECT THE BATTERY CABLE TO THE BATTERY GROUND

TERMINAL

6. BLEEDING OF HYDRO-MAX SYSTEM

Refer to POWER STEERING SYSTEM AIR BLEEDING of chapter
Battery dround terminal "BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)"
SAPH168010200023
BR01-11.
! WARNING
Any Hydro-Max booster or brake hydraulic line removed or discon-
nected should be properly bled before attempting to move the vehicle,
as the braking force will not be sufficient.

7. BLEEDING OF BRAKE HYDRAULIC SYSTEM

If the master cylinder was removed, bleed the brake hydraulic
system.
Refer to BRAKE SYSTEM AIR BLEEDING of chapter "BRAKE
EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)" BR01-9.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0215

8. BRAKE PEDAL HEIGHT

Check that the pedal height H from the floor is within the stan-
dard dimension.
Standard: 162.5-172.5 mm {6.4-6.7 in}

Flooe panel

SAPH168010200024
BR0216 SERVICE BRAKE (HYDRAULIC BRAKE)

MASTER CYLINDER
OVERHAUL
EN1680102H200002

IMPORTANT POINTS-DISMOUNTING
! WARNING
If the brake pressure warning light continues to light up after the
engine has started, the vehicle should not be operated for safety rea-
sons. During normal driving a longer stopping distance is required so
extreme caution should be taken as there is a risk of personal injury
[USA] [CANADA] or property damage.

Brake pressure
warning light

SAPH168010200002

1. BLOCK THE WHEELS

Brake pipe
2. DISCONNECT THE BRAKE PIPES
(1) Drain the fluid from the master cylinder into a container.
(2) Disconnect the brake pipe from the master cylinder.
NOTICE
Observe the position of the brake pipe to master cylinder before
removal to prevent mix-up during assembly.
(3) Cover the pipe end to prevent entry of foreign matter.

SAPH168010200025

3. DISCONNECT THE MASTER CYLINDER

(1) Remove the tightened nuts.
(2) Disconnect the master cylinder.

Master cylinder

SAPH168010200026
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0217

IMPORTANT POINTS-ASSEMBLY

1. INSTALL THE PRESSURE DIFFERENTIAL SWITCH

Tightening Torque:
1.1-1.7 Nm {11-17 kgfcm, 9.7-15 lbfin.}

Pressure differential switch

SAPH168010200027

2. INSTALL THE TUBE SEAT

(1) If the tube seat was removed, install the new parts.
Press the tube seat by using a tube nut.
Make sure the seat is completely inserted in the bottom.
(2) Check installation condition of the sealing surface.
If necessary, clean and rinse the master cylinder ports to remove any
metal fragments.

Tube seat

Tube nut

SAPH168010200028

IMPORTANT POINTS-MOUNTING

1. CONNECT THE MASTER CYLINDER

(1) Connect the master cylinder to Hydro-Max booster.
(2) Tighten the nut.
Tightening Torque:
33.9-40.7 Nm {346-415 kgfcm, 25-30 lbfft}

Master cylinder

SAPH168010200029

2. CONNECT THE BRAKE PIPES

Brake pipe (1) Remove cover from the pipe end.
(2) Connect the brake pipe to the master cylinder.
Tightening Torque:
20-30 Nm {204-305 kgfcm, 15-22 lbfft}

3. BRAKE SYSTEM AIR BLEEDING

Refer to BRAKE SYSTEM AIR BLEEDING of chapter "BRAKE
EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)" BR01-9.

SAPH168010200030
BR0218 SERVICE BRAKE (HYDRAULIC BRAKE)

PRESSURE TESTS
EN1680102H600002

1. CHECK THE BRAKE LINE PRESSURE

(1) To measure the brake line pressure, install a 0 to 13,800 kPa {140 kgf/
cm2, 2,000 lbf/in2} gauge to the brake caliper.
(2) Depress the brake pedal while the engine is not running.
The backup pump should start and produce pressure approximately
5,515 kPa {56 kgf/cm2, 800 lbf/in2}.
(3) Warm-up the engine until the power steering fluid reaches normal
operating temperature.
(4) Depress the brake pedal while the engine is at idling speed.
The pressure should be approximately 12,400 kPa {126 kgf/cm2,
1,800 lbf/in2}.

2. AIR BLEEDING
(1) Remove the pressure gauge.
(2) Bleed air from the pressure gauge installed line.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0219

ABS MODULATOR
DATA AND SPECIFICATIONS
EN1680102I200002

Manufacturer MERITOR WABCO

Type Hydraulic ABS modulator

DESCRIPTION
EN1680102D100003

E version

Modulator valve

SAPH168010200031

NOTICE
For removal and installation of ABS MODULATOR. refer to chapter "BRAKE CONTROL (ABS: HYDRAULIC) (E ver-
sion)" DN03-20.
BR0220 SERVICE BRAKE (HYDRAULIC BRAKE)

WHEEL BRAKE (TYPE: 4 PISTON)

DATA AND SPECIFICATIONS
EN1680102I200003

Manufacturer MERITOR
Type 4 PISTON FIXED MOUNT CALIPER
Brake pad Thickness Above Metal (New) 0.73" (18.5 mm)
Minimum Thickness Above Metal (Discard) 0.125" (3.2 mm)
Brake Fluid High-Performance Brake Fluid DOT 3 or DOT 4
Rotor Rotor Diameter 15.38" (390.7 mm)
Thickness (New) 1.54" (39.1 mm)
Thickness (Discard) 1.42" (36.1 mm)
Vehicle Model HINO 238, 258, 268, 338 (NE8J, NF8J): Front, Rear
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0221

DESCRIPTION
EN1680102D100004

Hex
Spring bolt

Lining
assembly

button Piston
head bolt
Seal Dust
Lining piston Dust boot Piston
spacer boot seal

Piston

Caliper
housing

SAPH168010200032

TORQUE SPECIFICATIONS
Description Specification
ABS Sensor Bolts 5/16-18 9-12 lb-ft (12.2-16.3 Nm)
Brake Hose Hold Down Clamp Bolt 5/16-18 9-12 lb-ft (12.2-16.3 Nm)
Banjo Bolt 30-40 lb-ft (40.8-54.4 Nm)
Pad Retainer Spring Bolt M10x1.5x16 28-32 lb-ft (38.1-43.5 Nm)
Caliper-to-Support Bolts M20 320-360 lb-ft (435.2-489.6 Nm)
Cross Over Tube Nuts 7/16-24 9-12 lb-ft (12.2-16.3 Nm)
Bleed Screw 7/16-24 9-12 lb-ft (12.2-16.3 Nm)
Lining Rail Covers M8x1.25x14 12-18 lb-ft (16.3-24.5 Nm)
Rotor to Hub Bolt (9/16-12 bolt) 100-125 lb-ft (136.0-170.0 Nm)
Rotor to Hub Bolt (9/16-18) with Lock Nuts 70-95 lb-ft (95.2-129.2 Nm)
Rotor to Hub Bolt (9/16-18) with Plain Nuts 130-165 lb-ft (176.8-224.4 Nm)
Support to Axle
(5/8-18 bolt) 190-250 lb-ft (258.4-340.0 Nm)
(9/16-18 bolt) 130-165 lb-ft (176.8-224.4 Nm)
BR0222 SERVICE BRAKE (HYDRAULIC BRAKE)

TROUBLESHOOTING
EN1680102F300001

Symptom Possible cause Remedy/Prevention

Excessive Pedal Effort Pads worn below minimum thickness Install new pads.
Faded, overheated condition, glazed Replace the rotor and/or reface pads if
pads, blued or heat-checked rotors sufficient lining remains.
Grease, oil and/or brake fluid on linings Install new pads in the axle sets.
Seized or frozen pistons Disassemble the calipers and free pis-
tons, or replace the caliper.
Pedal Pulsation (Brake Roughness Excessive lateral runout of brake rotor Check with a dial indicator. Install a
or Chatter) new rotor if the runout exceeds the
maximum specified.
Excessive out-of-parallelism of brake Check the parallelism or rotor thick-
rotor ness variation with a micrometer.
Resurface the rotor or install a new
rotor if the parallelism exceeds the
maximum allowed.
Loose or worn steering or suspension Replace the parts and realign.
parts
Excessive front bearing clearance Readjust the bearing to specifications.
Vehicle Pulls to One Side Brake fluid, oil and/or grease on linings Install new pads in the axle sets.
Unmatched linings, uneven lining Install new pads in the axle sets.
wear, distorted pads
Rough rotor surfaces on one rotor Resurface or replace the rotor in the
axle sets.
Seized or frozen pistons Disassemble the caliper and repair or
replace.
Loose caliper mounting bolts Tighten to specifications.
Uneven tire pressure, tread wear or Equalize to the recommended pres-
size, right to left sures. Install the correct size tires with
good tread.
Excessive rotor parallelism or runout Resurface or replace the rotor.
Restricted hose or line Examine the hoses and lines, and
replace as necessary.
Front end out of alignment Reset the alignment.
Leaky Caliper Cylinder bore surface scored or cor- Disassemble the calipers, clean the
roded bore and replace the seals and boots.
Caliper piston seal damaged or worn Disassemble the calipers and install
new seals and boots.
Caliper piston damaged Replace the piston.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0223

Symptom Possible cause Remedy/Prevention

No Braking Effect or Excessive Reservoir fluid level low Check for causes of fluid leak, repair
Pedal Travel as required and refill the reservoir.
Bleed the system as needed.
Air in the hydraulic system Bleed the system.
Bleed screw loose or open Bleed the system and tighten the
bleed screw.
Caliper piston seal damaged Disassemble the caliper and replace
the piston seals. Replace the piston if
it is damaged.
Excessive rotor runout or bent rotor Check the rotor with a dial indicator.
Install a new rotor if the runout
exceeds the maximum specified.
Worn or excessively loose wheel bear- Adjust or replace the bearings as
ings needed.
Low quality brake fluid Drain and clean the system. Replace
with the recommended brake fluid.
Weak brake hose that expands under Replace the hoses.
pressure
Brake Noise (Chatter) Excessive lateral runout of rotor Check the runout with a dial indicator.
Install a new rotor if the runout
exceeds the maximum specified.
Lack of rotor parallelism Check the parallelism with a microme-
ter. Resurface or install a new rotor as
required.
Loose wheel bearing Readjust the bearing to the specified
torque.
Brake Noise (Scraping) Rust or mud build-up on edges of rotor Clean or replace as necessary.
and on caliper housing
Worn pad or pad installed backward Replace the pads in the axle sets only
with the friction surface against the
rotor.
Incorrect caliper alignment permitting Correct the alignment.
rotor to scrape on housing
Brake Noise (Groan) Pressure on the brake pedal too light Slightly increase the pedal effort to
eliminate the noise.
Brake Noise (Rattle) Excessive clearance between the shoe Install new pads.
and caliper
Pad retainer spring missing or not cor- Install a new pad retainer spring or
rectly positioned position it correctly.
Brake Noise (Squeal) Glazed pads Resurface or replace the pads in the
axle sets only.
Weak pad retainer spring Install a new pad retainer spring.
Pad wear indicator contacting rotor Install new pads in the axle sets only.
Foreign material embedded in linings Replace the pads in the axle sets only.
BR0224 SERVICE BRAKE (HYDRAULIC BRAKE)

REMOVAL
! WARNING
To prevent serious personal injury, always wear safe eye protection
when you perform vehicle maintenance or service.

1. BRAKE PADS
(1) Visually inspect all brake pads. Replace pads when the remaining lin-
ing reaches 1/8-inch (3.175 mm) thickness.
If you replace pads: Replace all disc brake pads at the same time to
maintain original brake balance.
If a complete vehicle pad replacement is not necessary or desir-
able: Replace the pads on both wheel ends on the same axle.

2. REPLACE BRAKE PADS

(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly according to manufacturer's rec-
ommendation.
(3) Remove the master cylinder reservoir filler cap. Check the brake fluid
level in the reservoir. If necessary, remove fluid to keep the reservoir
from overflowing when compressing pistons into the caliper.
(4) Remove the pad retainer spring bolt.

Brake pad
retainer
spring bolt

SAPH168010200033

(5) Compress the caliper pistons.

SAPH168010200034

(6) Remove the brake pads.

Brake pad

SAPH168010200035
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0225

3. BRAKE CALIPER
! WARNING
Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving. Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. Jacks can slip and fall
over. Serious personal injury can result.
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly according to manufacturer's
instructions.
(3) Remove the brake hose hold down clamp bolt, if equipped.

Brake hose
hold down
clamp bolt

SAPH168010200036

(4) Remove the brake hose/tube from the caliper.

Brake
tube

SAPH168010200037

(5) Remove four caliper-to-support assembly bolts. Do not disassemble

the four bolts joining the two halves of the caliper.

Caliper-to-support
bolts

SAPH168010200038
BR0226 SERVICE BRAKE (HYDRAULIC BRAKE)

4. SUPPORT
(1) Remove the caliper from vehicle as described in Brake Caliper in this
section.
(2) Remove the splash shield if installed from the support.
(3) Remove the hub and rotor assembly according to vehicle manufac-
turer's recommended service procedure.
(4) Remove the ABS sensor.
(5) Remove the support-to-axle mounting bolts.

Mounting
bolt

SAPH168010200039

5. ROTOR
NOTICE
The thickness of the resurfaced rotor must exceed the minimum thick-
ness dimension stamped or cast into the rotor. Replace if necessary.
(1) Check the rotor while assembled to the hub or spoke wheel and
mounted on the axle spindle. The lateral runout of the rotor friction
surfaces should not exceed 0.015-inches (0.381 mm) total indicator
reading (TIR). The thickness variation of the rotor should not exceed
0.0012-inches (0.0300 mm).
If the lateral runout and/or the thickness variation exceed the
above values: Resurface or replace the rotor.
(2) Remove the caliper. Refer to Brake Caliper in this section.
(3) Remove the hub/spoke wheel and rotor assembly from the axle
according to vehicle manufacturer's recommendation.
(4) Remove the hub-to-rotor attachment fasteners (hat-shaped rotor). For
the U-shaped rotor, remove the studs holding the hub and rotor.

6. DISASSEMBLE AND OVERHAUL THE BRAKE CALIPER

(1) Remove the brake caliper. Refer to Brake Caliper in this section.
(2) Drain all fluid from the caliper.
(3) Push all four pistons to the bottom of their bores.
(4) Remove the piston boots by prying the metal ring portion of the boot
out of the bore with a screwdriver. Use care to avoid damage to the
piston or bore. Discard the boots.
NOTICE
The C-clamp must be between the pistons on the opposite side so
they may move to the wood block without striking the C-clamp. Cover
pistons with shop rag to prevent brake fluid spray.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0227

(5) Place a block of wood (7-5/8 x 3-1/2 x 2-9/16-inches thick) between

the caliper pistons. Use a C-clamp to hold the block of wood against
the pistons on one side of the caliper.

Wood ! WARNING
block When you use compressed air to remove the pistons form the caliper
bore, do not place your hands or fingers near the bore to catch or pro-
tect the pistons. Serious personal injury can result.

! CAUTION
When you remove the pistons from the caliper bore, only direct
enough compressed air into the caliper brake fluid inlet to ease the
SAPH168010200040 pistons out of the bore. Do not exceed 25 psi (172 kPa). Damage to
components will result.
(6) Apply low air pressure (no more than 25 psi [172 kPa]) to the fluid port
in the caliper to move the caliper pistons out to the wood block.
(7) With the pistons in contact with the wood block, there will be a small
Air
supply amount of seal engagement remaining. Remove the C-clamp and the
wood block. The pistons may now be removed by hand.
(8) To remove the pistons from the other side of the caliper, place the
block of wood now over the empty bores (from where the pistons
have been removed) with a thick sheet of rubber (3/8-inch) between
the wood and the caliper bores.
NOTICE
Use the C-clamp to hold the block of wood in position against the
SAPH168010200041 empty bores. The C-clamp must be between the pistons on the oppo-
site side so they may move out to the wood block without striking the
C-clamp. Cover pistons with a shop rag to prevent brake fluid spray.
(9) Apply low air pressure (no more than 25 psi [172 kPa]) to the fluid port
in the caliper to move the caliper pistons out to the wood block.
(10) With the pistons in contact with the wood block, there will be a small
amount of seal engagement remaining. Remove the C-clamp and the
wood block. The pistons may now be removed by hand.

Caliper
piston

SAPH168010200042
BR0228 SERVICE BRAKE (HYDRAULIC BRAKE)

(11) Remove the piston seals with a non-metallic device and discard them.
Do not knock, scratch or otherwise scar piston bores or seal grooves.
NOTICE
Do not hone the caliper bores. Pistons are not available for honed cal-
iper bores. If the caliper bores are excessively scored or corroded,
install a new caliper.

! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

SAPH168010200043
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, emulsion-type
cleaners and petroleum-based cleaners. To avoid serious personal
injury when you use solvent cleaners, you must carefully follow the
manufacturer's instructions and these procedures:
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline or solvents that contain gasoline. Gasoline
can explode.
You must use hot solution tanks or alkaline solutions correctly.
Carefully follow the manufacturer's instructions.

CLEAN, DRY AND INSPECT PARTS

1. CLEAN PARTS FOR GROUND OR POLISHED METAL PARTS

! CAUTION
Do not use hot solution tanks or water and alkaline solutions to clean
ground or polished parts. Damage to parts will result.
Use a cleaning solvent or kerosene or diesel fuel to clean ground or
polished metal parts or surfaces.

2. FOR ROUGH METAL PARTS

Use a cleaning solvent or a weak alkaline solution in a hot solution
tank to clean rough metal parts.
If you use a hot solution tank, follow the instructions below.
(1) Leave the rough parts in the tank until they are completely cleaned
and heated.
(2) Remove the rough parts from the tank.
(3) Wash the parts with water until you remove the alkaline solution.

3. DRY AND INSPECT PARTS

(1) Use soft, clean paper or cloth rags or compressed air to completely
dry parts immediately after you clean them.
(2) Carefully inspect all parts for wear or damage before you assemble
them.
(3) Repair or replace worn or damaged parts.

4. APPLY CORROSION PROTECTION

(1) Apply a thin layer of brake grease to cleaned, dried parts. Be careful
that you do not apply the grease to the linings or rotor.
(2) If you will store the parts, apply a special material, which prevents cor-
rosion and rust, to all surfaces. Store parts inside special paper or
other material that prevents rust and corrosion.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0229

ASSEMBLY
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

1. BRAKE CALIPER
NOTICE
When using compressed air, use air lines that are completely free of
oil and moisture.
All brake parts must be clean and completely dried of cleaning fluid.
Use ONLY ArvinMeritor replacement parts to ensure proper caliper
performance.
(1) Clean caliper, caliper piston bores and fluid ports with solvent. Use
compressed air to clean out and dry grooves and passages.
(2) Dip new piston seals in new, clean DOT 3 hydraulic brake fluid and
install in piston seal groove in caliper piston bores. Make sure that
they are properly seated. Apply a thin film of silicon grease or brake
fluid to the caliper bore seal land between the piston boot and seal
groove. Apply the grease or brake fluid around the entire circumfer-
ence of the caliper bore.

Caliper
bore

SAPH168010200044

(3) Apply DOT 3 hydraulic brake fluid to the outside of the caliper pistons
Caliper and install them in caliper bores, making sure that they are square to
piston the bore.

SAPH168010200045

(4) Be careful not to cock the caliper pistons and press them into the
bores.

SAPH168010200046
BR0230 SERVICE BRAKE (HYDRAULIC BRAKE)

(5) Install the piston boots over the projecting ends of the pistons and
press the ring side of the boots into the boot bore. An old bearing cup
equal to the boot ring size helps install the boots. Make sure the pis-
ton boot bead is seated back against the shoulder of the projecting
end of the piston. Boots for the 64 mm and 70 mm pistons are color-
coded.

Piston (6) If required, replace the two stainless steel wear rails by removing the
boot button head bolts.
NOTICE
Inspect the caliper prior to reinstalling it onto the support. Pistons
must be fully retracted into the caliper. Piston boots must be fully
SAPH168010200047 seated in the caliper boot grooves.
 SERVICE BRAKE (HYDRAULIC BRAKE) BR0231

INSTALLATION

1. ROTOR
NOTICE
Do not resurface a new replacement rotor.
(1) To install, reverse the removal processes, making sure that the mat-
ing surfaces of the hub or spoke wheel and rotor are clean and free of
rust build-up.
(2) Check the rotor for lateral runout. If the lateral runout exceeds 0.015-
inches (0.381 mm), the rotor may be rotated to a different mounting
hole position on the hub or spoke wheel to reduce the value.

2. CALIPER
(1) Inspect the caliper for leakage, damage or defects to piston seals or
pistons. If leakage, damage or defect is found, caliper disassembly
may be required.

SAPH168010200048

(2) To install, reverse the removal process.

(3) Bleed the brake system and road test the vehicle.

Brake
tube

SAPH168010200049

Brake hose
hold down
clamp bolt

SAPH168010200050
BR0232 SERVICE BRAKE (HYDRAULIC BRAKE)

3. BRAKE PADS
(1) Inspect the rotor for scoring, warping, cracks, bluing, heat spots or
other damage or defects and minimum thickness. Repair or replace if
necessary.
(2) Inspect the disc brake calipers for leakage, damage or defects to pis-
ton boots, seals or pistons. Replace or repair the parts as required.
(3) Clean and inspect the lining rail covers. If they are worn, they must be
replaced.
NOTICE
The inboard and outboard brake pads are identical, except when they
are equipped with a mechanical wear sensor.
(4) Install the brake pads. Ensure that the friction surface is against the
rotor. Install the pad retainer spring and tighten the bolt to 30 lb-ft (40
Nm) of torque.
Brake pad NOTICE
retainer
spring bolt
Brake pad clearance adjustment is automatic.

(5) Fill the master cylinder reservoir with new, clean, high-performance
DOT 3 brake fluid or equivalent. Make several brake applications to
move the brake pistons and linings out into contact with the brake
rotors.
(6) Recheck master cylinder reservoir and top off as necessary to manu-
facturer's recommended level.
SAPH168010200051
(7) Bleed the brake system.
(8) Install the tire and wheel assembly according to the manufacturer's
instructions.
(9) Lower the vehicle and road test for correct operation.

4. ASSEMBLE THE SUPPORT

(1) Install the support mounting bolts. Tighten the bolts to the specified
Mounting torque. Refer to Section 8.
bolt
(2) Install the ABS sensor. Tighten the bolt to 8 lb-ft (11 Nm).
(3) Install the hub and rotor assembly according to vehicle manufacturer's
recommended service procedure.
(4) Install the splash shield, if equipped.
(5) Install the caliper as described in Caliper in this section.

SAPH168010200052
SERVICE BRAKE (HYDRAULIC BRAKE) BR0233

INSPECT PARTS
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

1. CALIPER
(1) Clean the area around the brake hose. Use brake parts cleaner.
(2) Inspect the heat shields (previous style only) for wear and damage.
Replace worn or damaged shields.
(3) Inspect the caliper lining spacers for wear and damage. Replace worn
or damaged spacers.
(4) Inspect the housing for cracks or damage.
Replace a cracked or damaged housing.
! CAUTION
The OUTSIDE diameter of the piston is the caliper's primary sealing
surface and is manufactured to very close tolerances. Replace a pis-
ton if the OUTSIDE diameter is damaged.
Do not refinish or use abrasives, including an emery cloth, on the pis-
ton. Damage to components can result.
(5) Inspect the OUTSIDE diameter of the pistons for scoring, nicks, corro-
sion, wear and damage.
If any of these conditions are evident:
Replace the pistons. Do not refinish or use abrasives.
(6) Inspect the caliper bore for scoring, nicks, corrosion, wear and dam-
age.
If any of these conditions are evident:
Replace the caliper.
! CAUTION
Use a crocus cloth to remove minor stains and corrosion from the cal-
iper bore. Do not use abrasives, including an emery cloth. If you can-
not remove minor stains and corrosion, replace the caliper bore to
avoid damage to components.
(7) Inspect the caliper bore for minor stains and corrosion.
If these conditions are evident: Use a crocus cloth to remove stains
or corrosion. Clean the caliper bore after using a crocus cloth. Do not
use abrasives, including an emery cloth.
If you cannot remove stains and corrosion from the caliper bore:
Replace the caliper.

2. CALIPER MOUNTING PLATE

(1) Inspect caliper mounting plate area for rust, corrosion. Replace a
damaged or worn mounting plate.
(2) Use a wire brush to clean the caliper mounting area.
(3) Inspect the mounting plate for cracks or elongated bolt holes.
If these conditions are evident: Replace the mounting plate.

3. BRAKE SYSTEM BLEEDING PROCEDURE

Refer to manufacturer's service information for ABS bleeding instruc-
tions.
(1) Check the master cylinder reservoir and fill, if necessary, with DOT 3
or DOT 4 brake fluid.
(2) Bleed brakes in the following order: right rear, left rear, right front and
left front.
(3) Each four-piston caliper is equipped with two bleeder screws. Loosen
the inner bleeder screw (which is always on the top) and purge the air.
Tighten it loosely.
BR0234 SERVICE BRAKE (HYDRAULIC BRAKE)

(4) Open the outer bleeder screw and purge the air and tighten the
bleeder screw to 9-12 lb-ft (12.2-16.3 Nm).
(5) Now again open the inner bleeder screw and purge the air and tighten
the bleeder screw to 9-12 lb-ft (12.2-16.3 Nm).
(6) Repeat this procedure for all other brakes in the sequence specified in
step 2.
(7) Test brakes prior to returning vehicle to service. A firm pedal should
be felt during brake application.
 SERVICE BRAKE (FULL AIR BRAKE) BR021

SERVICE BRAKE (FULL AIR BRAKE)

BR02

BR02-002

AIR DRYER AND RESERVOIR SYSTEM BRAKE CHAMBER (REAR) .................. BR02-46
(MODEL: BENDIX AD-IS).........................BR02-2 DATA AND SPECIFICATIONS....................... BR02-46
DESCRIPTION ................................................ BR02-2 DESCRIPTION .............................................. BR02-47
AD-IS AIR DRYER RESERVOIR SYSTEM COMPONENT LOCATOR ............................. BR02-48
TROUBLESHOOTING CHART...................... BR02-13 INSPECTION AND REPAIR .......................... BR02-49

CHECK VALVE........................................BR02-17 PROTECTION VALVE ............................ BR02-60

DATA AND SPECIFICATIONS ....................... BR02-17 DATA AND SPECIFICATIONS....................... BR02-60
DESCRIPTION .............................................. BR02-17 DESCRIPTION .............................................. BR02-60
INSPECTION AND REPAIR .......................... BR02-18 INSPECTION................................................. BR02-61

BRAKE PEDAL .......................................BR02-20 WHEEL BRAKE ..................................... BR02-63

OVERHAUL ................................................... BR02-20 DATA AND SPECIFICATIONS....................... BR02-63
DESCRIPTION .............................................. BR02-64
COMPONENT LOCATOR ............................. BR02-65
BRAKE VALVE........................................BR02-23
OVERHAUL ................................................... BR02-67
DATA AND SPECIFICATIONS ....................... BR02-23 INSPECTION AND REPAIR .......................... BR02-84
DESCRIPTION .............................................. BR02-23
COMPONENT LOCATOR.............................. BR02-24
INSPECTION AND REPAIR .......................... BR02-25
AUTOMATIC SLACK ADJUSTER.......... BR02-86
DESCRIPTION .............................................. BR02-86
DIAGNOSTICS .............................................. BR02-87
RELAY VALVE.........................................BR02-29
COMPONENT LOCATOR ............................. BR02-88
DATA AND SPECIFICATIONS ....................... BR02-29 OVERHAUL ................................................... BR02-90
DESCRIPTION .............................................. BR02-29 INSTALLING THE SLACK ADJUSTER
INSPECTION AND REPAIR .......................... BR02-29 ONTO THE CAMSHAFT ............................... BR02-98
CHECK & ADJUSTMENT ........................... BR02-100
SPRING BRAKE
MODULATING VALVE ............................BR02-33
DESCRIPTION .............................................. BR02-33
COMPONENT LOCATOR.............................. BR02-34
INSPECTION AND REPAIR .......................... BR02-35

SPRING BRAKE CONTROL VALVE ......BR02-37

DESCRIPTION .............................................. BR02-37
COMPONENT LOCATOR.............................. BR02-38
INSPECTION AND REPAIR .......................... BR02-39

BRAKE CHAMBER (FRONT).................BR02-42

DATA AND SPECIFICATIONS ....................... BR02-42
DESCRIPTION .............................................. BR02-42
COMPONENT LOCATOR.............................. BR02-43
OVERHAUL ................................................... BR02-44
INSPECTION AND REPAIR .......................... BR02-45
BR022 SERVICE BRAKE (FULL AIR BRAKE)

AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-

IS)
DESCRIPTION
EN0680202C100001

SHTS068020200001
TABLE 1 - PORT DESIGNATIONS
Air Connection Port ID Function/Connection QTY
1 IN Inlet Port (air in). 1
21 PRI Delivery Port out (to Primary reservoir) 1
22 SEC Delivery Port out (to Secondary reservoir) 1
24 AUX 1 Auxiliary Delivery Port (air out). 4
23 AUX 2 Auxiliary Delivery Port (air out). 1
UNL Unloader Control Air (D-2ATM Governor) 2
RES Common Reservoir Pressure (D-2ATM Governor) 2
EXH Governor Exhaust. 1

The function of the Integrated Solution Air Dryer (AD-IS) and Reservoir System is to provide heavy vehicles with an inte-
grated vehicle air dryer, purge reservoir, governor and a number of the charging valve components in a module. These have
been designed as an integrated air supply system.
The AD-IS air dryer and reservoir system collects and removes air system contaminants in solid, liquid and vapor form before
they enter the brake system. It provides clean, dry air to the components of the brake system which increases the life of the
system and reduces maintenance costs. The necessity for daily manual draining of the reservoirs is eliminated.
 SERVICE BRAKE (FULL AIR BRAKE) BR023

SHTS068020200002
The function of the pressure protection valves is to protect each reservoir from a pressure loss in the other reservoir or a pres-
sure loss in an air accessory. Each of the pressure protection valves in the AD-IS air dryer and reservoir system may have
different pressure settings, but these are factory set and must not be changed or adjusted.
The air dryer and reservoir system consists of a "spin on" desiccant cartridge secured to a base assembly. The base assembly
contains a delivery check valve assembly, safety valve, heater and thermostat assembly, pressure protection valves, threaded
air connections and the purge valve assembly.
The removable purge valve assembly incorporates the purge valve mechanism and a turbocharger cut-off feature that is
designed to prevent loss of engine "turbo" boost pressure during the purge cycle of the AD-IS air dryer and reservoir system.
For ease of maintenance, all replaceable assemblies can be serviced without removal of the air dryer and reservoir system
from its mounting on the vehicle. Refer to Preventive Maintenance section.
NOTICE
The AD-IS air dryer and reservoir system purge piston has a purge control channel drain. This allows any condensa-
tion in this area to flow past a diaphragm in the top of the purge piston and out through a channel in the middle of the
central bolt of the purge assembly to be drained. During the purge cycle this drain is closed.
BR024 SERVICE BRAKE (FULL AIR BRAKE)

SHTS068020200003

AD-IS AIR DRYER AND RESERVOIR SYSTEM OPERATION: GENERAL (Refer to Figure 2)
The AD-IS air dryer and reservoir system is designed to receive compressed air from the vehicle air compressor, clean and
dry the air, deliver air to the vehicle's primary reservoir, secondary reservoir and accessories, and control the compressor/
dryer charge cycle.

AIR DRYER AND RESERVOIR SYSTEM OPERATION: GENERAL

The AD-IS air dryer and reservoir system alternates between two operational modes or "cycles" during operation: the Charge
Cycle and the Purge Cycle. The following descriptions are separated into these "cycles" of operation.
 SERVICE BRAKE (FULL AIR BRAKE) BR025

CHARGE CYCLE (Refer to Figure 2)

When the compressor is loaded (compressing air) compressed air flows through the compressor discharge line to the inlet (1/
IN) port of the air dryer body. The compressed air often includes contaminates such as oil, oil vapor, water and water vapor.
Traveling through the discharge line and into the air dryer, the temperature of the compressed air falls, causing some of the
contaminants to condense and drop to the bottom of the air dryer and reservoir system purge valve assembly, ready to be
expelled at the next purge cycle. The air then flows into the desiccant cartridge, where it flows through an oil separator which
removes liquid oil and solid contaminants.
Air then flows into the desiccant drying bed and becomes progressively drier as water vapor adheres to the desiccant material
in a process known as "ADSORPTION."
Dry air exits the desiccant cartridge through the center of the base assembly. The air then flows to the delivery check valve and
also through an orifice into the purge reservoir. The delivery check valve opens, supplying air to the pressure protection valves
(A) through (D) simultaneously, the safety valve, and also to the reservoir port of the attached governor. The purge reservoir
fills, storing air that will be used to reactivate the desiccant during the purge cycle. This air is available to supply downstream
components during the charge mode.
When the air pressure reaches approximately 106 psi, the four pressure protection valves will open and air will be supplied to
the primary reservoir, secondary reservoir and accessories. If the pressure protection valves are preset to different values the
valves will open in order of lowest setting to highest setting when charging a flat system.
The air dryer and reservoir system will remain in the charge cycle until the air brake system pressure builds to the governor
cut-out setting of approximately 130 p.s.i.

PURGE CYCLE (Refer to Figure 3.)

When air brake system pressure reaches the cut-out setting of the governor, the governor unloads the compressor and the
purge cycle of the air dryer and reservoir system begins.
The governor unloads the compressor by allowing air pressure to fill the line leading to the compressor unloader mechanism -
causing the delivery of compressed air to the AD-IS air dryer and reservoir system to be suspended.
Similarly, the governor also supplies air pressure to the AD-IS air dryer and reservoir system purge control channel. The AD-
IS air dryer and reservoir system purge piston moves down in response to this air pressure, causing the purge valve to open
to the atmosphere and the turbo cut-off valve to close off the supply of air from the compressor (this will be further discussed in
the Turbo Cut-off Feature section). Water and contaminants which have collected in the purge valve base are expelled immedi-
ately when the purge valve opens. Also, air which was flowing through the desiccant cartridge changes direction and begins to
flow toward the open purge valve. Oil and solid contaminants collected by the oil separator are removed by air flowing from the
purge reservoir through the desiccant drying bed to the open purge valve.
The initial purge and desiccant cartridge decompression lasts only a few seconds and is evidenced by an audible burst of air at
the AD-IS air dryer and reservoir system exhaust.
The actual reactivation of the desiccant drying bed begins as dry air from the purge reservoir flows through the purge orifice
into the desiccant bed. Pressurized air from the purge reservoir expands after passing through the purge orifice; its pressure is
lowered and its volume increased. The flow of dry air through the drying bed reactivates the desiccant material by removing
the water vapor adhering to it. Approximately 30 seconds are required for the entire contents of the purge reservoir of a stan-
dard AD-IS air dryer and reservoir system to flow through the desiccant drying bed.
The delivery check valve assembly prevents air pressure in the brake system from returning to the air dryer and reservoir sys-
tem during the purge cycle. After the purge cycle is complete, the air dryer and reservoir system is ready for the next charge
cycle to begin.

TURBO CUT-OFF FEATURE (Refer to Figure 3.)

The primary function of the turbo cut-off valve is to prevent loss of engine turbocharger air pressure through the AD-IS air
dryer and reservoir system when the dryer is in the unloaded mode.
At the onset of the purge cycle, the downward travel of the purge piston is stopped when the turbo cut-off valve (tapered por-
tion of purge piston) contacts its mating metal seat in the purge valve housing. With the turbo cut-off valve seated (closed posi-
tion), air in the compressor discharge line and AD-IS air dryer and reservoir system inlet port cannot enter the air dryer and
reservoir system. In this manner the turbo cut-off effectively maintains turbo charger boost pressure to the engine.
BR026 SERVICE BRAKE (FULL AIR BRAKE)

PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing any intrusive maintenance procedures. An extended warranty may
be voided if intrusive maintenance is performed during this period. Purge valve maintenance is permissible during the warranty
period only when using a genuine Bendix purge valve kit.
Because no two vehicles operate under identical conditions, maintenance and maintenance intervals will vary. Experience is a
valuable guide in determining the best maintenance interval for any one particular operation.
Every 900 operating hours, or 25,000 miles or three (3) months:
.

1. Check for moisture in the air brake system by opening reservoir drain valves and checking for presence of water. If mois-
ture is present, the desiccant cartridge may require replacement; however, the following conditions can also cause water
accumulation and should be considered before replacing the desiccant:
.

a. An outside air source has been used to charge the system. This air did not pass through the drying bed.
b. Air usage is exceptionally high and not normal for a highway vehicle.
This may be due to accessory air demands or some unusual air requirement that does not allow the compressor to load
and unload (compressing and non-compressing cycle) in a normal fashion. Check for high air system leakage. If the vehi-
cle vocation has changed it may be necessary to upgrade the compressor size. Refer to Bendix Specification BW-100-A,
Appendix D to determine if any changes are necessary.
c. Location of the air dryer and reservoir system is too close to the air compressor. Refer to Bendix Specification BW-100-A,
Appendix B for discharge line lengths.
d. In areas where more than a 30 degree range of temperature occurs in one day, small amounts of water can temporarily
accumulate in the air brake system due to condensation. Under these conditions, the presence of small amounts of mois-
ture is normal.
NOTICE
A small amount of oil in the system is normal and should not be considered as a reason to replace the desiccant car-
tridge. Some oil at the dryer exhaust is normal.
2. Visually check for physical damage such as chaffed or broken air and electrical lines and broken or missing parts.
3. Check the AD-IS air dryer and purge reservoir bolts for tightness. See Figure 1. Re-torque the three air dryer bolts to
360-420 inch pounds and the four purge reservoir bolts to 300-360 inch pounds.
4. Perform the Operation & Leakage Tests listed in this publication.
! WARNING
This air dryer and reservoir system is intended to remove moisture and other contaminants normally found in the air
brake system. Do not inject alcohol, anti-freeze, or other de-icing substances into or upstream of the air dryer and
reservoir system. Alcohol is removed by the dryer, but reduces the effectiveness of the device to dry air. Use of these
or other substances can damage the air dryer and reservoir system and may void the warranty.

SHTS068020200004
 SERVICE BRAKE (FULL AIR BRAKE) BR027

OPERATION & LEAKAGE TESTS (ALSO SEE VIDEO BW2327)

.

1. Check all lines and fittings leading to and from the air dryer and reservoir system for leakage and integrity. Repair any
leaks found.
2. Build up system pressure to governor cut-out and note that the AD-IS air dryer and reservoir system purges with an
audible escape of air. Watch the system pressure and note the pressure fall-off for a ten minute period. If pressure drop
exceeds, for a single vehicle - 1 psi/minute from either service reservoir; or for tractor trailer - 3 psi/minute from either ser-
vice reservoir, inspect the vehicle air systems for sources of leakage and repair them. Refer to section entitled Trouble-
shooting, Symptoms 1 and 4.
3. Caution: Be sure to wear safety glasses in case of a purge blast. Check for excessive leakage around the purge
valve with the compressor in the loaded mode (compressing air). Apply a soap solution to the purge valve exhaust port
and observe that leakage does not exceed a 1" bubble in 1 second. If the leakage exceeds the maximum specified, refer
to section entitled Troubleshooting, Symptom 4.
4. Build up system pressure to governor cut-out and note that the AD-IS air dryer and reservoir system purges with an
audible burst of air, followed immediately by approximately 30 seconds of air flowing out of the purge valve. "Fan" the ser-
vice brakes to reduce system air pressure to governor cut-in. Note that the system once again builds to full pressure and
is followed by an AD-IS air dryer and reservoir system purge. If system does not follow this pattern, refer to section enti-
tled Troubleshooting, Symptoms 5 and 6.
5. Check the operation of the end cover heater and thermostat assembly during cold weather operation as follows:
.

a. Electric Power to the Dryer

With the ignition or engine kill switch in the RUN position, check for voltage to the heater and thermostat assembly using
a voltmeter or testlight. Unplug the electrical connector at the air dryer and reservoir system and place the test leads on
each of the connections of the female connector on the vehicle power lead. If there is no voltage, look for a blown fuse,
broken wires, or corrosion in the vehicle wiring harness. Check to see if a good ground path exists.
b. Thermostat and Heater Operation
NOTICE
These tests are not possible except in cold weather operation.
Turn off the ignition switch and cool the thermostat and heater assembly to below 40 degrees Fahrenheit. Using an ohm-
meter, check the resistance between the electrical pins in the air dryer and reservoir system connector half. The resis-
tance should be 1.5 to 3.0 ohms for the 12 volt heater assembly and 6.0 to 9.0 ohms for the 24 volt heater assembly.
Warm the thermostat and heater assembly to approximately 90 degrees Fahrenheit and again check the resistance. The
resistance should exceed 1000 ohms. If the resistance values obtained are within the stated limits, the thermostat and
heater assembly is operating properly. If the resistance values obtained are outside the stated limits, replace the heater
and thermostat assembly.
6. Pressure Protection Valves. Observe the pressure gauges of the vehicle as system pressure builds from zero. The pri-
mary or secondary gauge should rise until it reaches approximately 106 p.s.i. (6 p.s.i.), then level off (or a momentary
slight fall) as the next pressure protection valve opens supplying its reservoir. When that pressure gauge passes through
approximately 106 p.s.i. (6 p.s.i.) there should be an associated leveling off (or momentary slight fall) of pressure as the
third and fourth pressure protection valves open. Then the primary and secondary gauges should increase together until
they reach their full pressure of approximately 130 psi (5 psi).
If the AD-IS air dryer and reservoir system does not perform within the pressure ranges as described above, recheck
using gauges known to be accurate. If the readings remain outside of the ranges outlined above, replace the AD-IS air
dryer and reservoir system. NOTE: There are no kits available for the servicing of the pressure protection valves. WARN-
ING: Do not attempt to adjust or service the pressure protection valves - incorrect pressure protection valve set-
tings can result in automatic application of the vehicle spring brakes without prior warning in the event one of
the supply circuits experiences rapid pressure loss.
BR028 SERVICE BRAKE (FULL AIR BRAKE)

REBUILDING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM

GENERAL SAFETY GUIDELINES
! WARNING
PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following general precautions should be observed at all times.
.

1. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses.
2. Stop the engine and remove ignition key when working under or around the vehicle. When working in the engine com-
partment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the
engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with mov-
ing, rotating, leaking, heated or electrically charged components.

SHTS068020200005

! WARNING
DO NOT ATTEMPT TO ADJUST OR SERVICE THE PRESSURE PROTECTION VALVES. INCORRECT PRESSURE PRO-
TECTION VALVE SETTINGS CAN RESULT IN AUTOMATIC APPLICATION OF VEHICLE SPRING BRAKES WITHOUT
PRIOR WARNING.
 SERVICE BRAKE (FULL AIR BRAKE) BR029

SHTS068020200006

3. Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand
the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle's air brake system, or any auxiliary pressurized air systems, make certain to
drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an AD-
IS air dryer system or a dryer reservoir module, be sure to drain the purge reservoir.
5. Following the vehicle manufacturer's recommended procedures, deactivate the electrical system in a manner that safely
removes all electrical power from the vehicle.
6. Never exceed manufacturer's recommended pressures.
7. Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless
you are certain all system pressure has been depleted.
8. Use only genuine Bendix replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc.
must be of equivalent size, type and strength as original equipment and be designed specifically for such applications
and systems.
9. Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs
requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating
condition.
11. For vehicles with Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator light should be ON)
prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and mov-
ing.
BR0210 SERVICE BRAKE (FULL AIR BRAKE)

GENERAL
When rebuilding or replacing components of the air dryer and reservoir system use only genuine Bendix parts. For ease in ser-
vicing, the AD-IS air dryer and reservoir system has been designed so that any of the following maintenance kits can be
installed without removing the air dryer and reservoir system from the vehicle.
CAUTION: Always depressurize the air dryer and reservoir system purge reservoir, and all other reservoirs on the
vehicle to 0 p.s.i. before servicing the air dryer and reservoir system. If, after completing the routine operation and
leakage tests, it has been determined that one or more components of the air dryer and reservoir system requires
replacement or maintenance, refer to the following list to find the appropriate kit(s).

MAINTENANCE KITS AVAILABLE:

Service New Desiccant Cartridge Kit - Part Number 5008414: This kit contains the parts necessary to change the desic-
cant cartridge only.
Delivery Check Valve Maintenance Kit - Part Number 5004052: This kit contains the parts necessary to replace the deliv-
ery check valve.
Purge Valve Maintenance Kit - Part Number 5018313: This kit contains the parts necessary to replace and relubricate the
purge valve sealing rings.
Governor/Delivery Check Valve Kit - Part Number 5004049: This kit contains the parts necessary to replace both the gov-
ernor and delivery check valve.
12 volt or 24 volt Heater and Thermostat Kit - Part Numbers 109495 & 109496: Contains a replacement heater and ther-
mostat assembly and related components required for replacement.
Purge Valve Housing Rebuild Kit - Part Number 5003547: This kit contains the parts necessary to rebuild the purge valve
sub-assembly.
Service New Purge Valve Housing Assembly - Part Number 800404: Contains a service new assembly and related com-
ponents to change the purge valve subassembly.
Pressure Protection Valve Boot Replacement- Part Number 5005163.
AD-IS Air Dryer Replacement: Replaces the complete air dryer assembly. Includes air dryer assembly and governor.
AD-IS Air Dryer Splash Shield Replacement Kit - Part Number 5006698.
Purge Reservoir Drain Valve: Replaces the drain valve on the purge reservoir.

SEE THE AD-IS AIR DRYER CATALOG PAGE (STARTING ON PAGE 08-A-24) FOR A FULL
LIST OF MAINTENANCE KITS AVAILABLE.
NOTICE
Kits are not available for the servicing of the pressure protection valves (See Figure 5). Do not attempt to adjust or
service the pressure protection valves - these are not service items.

TESTING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM

Before placing the vehicle in service, perform the following tests:
.

1. Close all reservoir drain valves.

2. Build up system pressure to governor cut-out and note that the AD-IS air dryer and reservoir system purges with an
audible burst of air, followed immediately by approximately 30 seconds of air flowing out of the purge valve.
3. "Fan" the service brakes to reduce system air pressure to governor cut-in. Note that the system once again builds to full
pressure and is followed by a purge at the AD-IS air dryer and reservoir system exhaust.
4. It is recommended that the total air system be tested for leakage to assure that the AD-IS air dryer and reservoir system
will not cycle excessively.
See Bendix publication BW5057 "Air Brake Handbook."

BRAKING SYSTEM PROTECTION

The AD-IS air dryer and reservoir system allows the system to maintain one brake circuit up to about 100 psi even after a
pressure loss in the other brake circuit. This allows a vehicle to be moved (in an emergency), but with reduced braking capac-
ity. Compare this to a conventional system where a loss of pressure in one service tank leaves the vehicle with a limited num-
ber of reduced braking capacity applications before the parking brakes automatically apply and stay on.
 SERVICE BRAKE (FULL AIR BRAKE) BR0211

ROADSIDE INSPECTION
In the event of a roadside inspection the system behavior will be as follows: When the system is charged to governor cut-out,
and then one reservoir drain valve is opened, initially both reservoir gauges will fall, however, the AD-IS air dryer and reser-
voir system primary and secondary pressure protection valves will close at pressures above 70 psi, protecting the remaining
brake circuit from further loss of pressure.

TEMPORARY AIR DRYER AND RESERVOIR SYSTEM BYPASS

To temporarily bypass the air dryer, the following procedure needs to be followed:
Follow the Maintenance Precautions outlined elsewhere in this document.
Make sure that all residual pressure has been released and the air dryer purge reservoir has been drained to 0 p.s.i., then
remove the air supply line from the compressor to the inlet port (1/IN). Remove the safety valve from the AD-IS air dryer and
reservoir system body (see Figure 1 for location). Note that a short puff of trapped air may vent from the safety valve port when
the valve is being removed. Install a T-fitting into the port. Using any adapters necessary, reinstall the safety valve in one of the
branches of the T-fitting. Using any adapters necessary, install the air supply line into the remaining T-fitting port. After testing
the T-fitting for any air leakage, by using a soap solution after charging to system cut-out pressure (a 1" bubble in 10 seconds
is acceptable), the vehicle may be returned to temporary service.
NOTICE
This is a temporary bypass of the air dryer, and full repair of the unit must be carried out at the earliest opportunity.
With the air dryer and reservoir system removed from the system, contaminants will be entering the air system: reservoirs will
need to be manually drained daily until the repairs are completed. At end of each working day, park vehicle and slowly drain
pressure through the drain valves - leave open to the atmosphere, for several hours if possible. When repairs are carried out,
be sure to check that all reservoirs (including the air dryer purge reservoir) are emptied of all contaminants.
If after bypassing the air dryer and reservoir system the system pressure still does not build, use the following procedure to
remove, clean and reinstall the delivery check valve.

SHTS068020200007
BR0212 SERVICE BRAKE (FULL AIR BRAKE)

DELIVERY CHECK VALVE CLEANING PROCEDURE

(Note: This is only required if system pressure does not build after temporary bypass is completed.)
See Figure 7 throughout this procedure. Depressurize the air brake system following the general safety precautions outlined
elsewhere in this document. Also, always depressurize the air dryer purge reservoir before servicing the air dryer.
This procedure does not require removal of the AD-IS air dryer and reservoir system from the vehicle.
.

1. Remove the line from the governor and mark for easy reinstallation.
2. Remove the bolts attaching the governor to the AD-IS air dryer and reservoir system and retain for reassembly.
3. Remove the governor from the air dryer. Be aware that a short puff of trapped air may vent when the governor is
removed. Retain the governor gasket for reassembly if a new governor gasket is not available. Remove and retain the o-
ring from the adapter.
4. The spring/delivery check valve can now be removed.
5. Remove and retain the o-ring from check valve body.

CLEANING & INSPECTION

.

1. Use a suitable solvent to clean all metal parts, and use a cotton swab to clean the bore (Note: Do not use abrasives or
tools to clean the bore: any scratches caused may necessitate replacing the AD-IS air dryer and reservoir system.)
Superficial external corrosion and/or pitting is acceptable.
2. Clean the o-rings with a clean dry cloth. Do not use solvents.
3. Inspect for physical damage to the bore and the check valve seat. If the bore is damaged (by scratches etc. that would
prevent delivery check valve from seating), replace the AD-IS air dryer.
4. Inspect the delivery check valve, o-rings, etc. for wear or damage. Replace if necessary using the check valve replace-
ment kit available at authorized Bendix parts outlets.
5. Inspect all air line fittings for corrosion and replace as necessary.

ASSEMBLY
.

1. Lubricate the smaller o-ring and check valve body with Bendix supplied barium or silicon grease.
2. Install this o-ring on the check valve body by sliding the o-ring over the set of 4 tapered guide lands. The o-ring groove
holds the o-ring in its correct location.
3. At the other end of the check valve body, the spring is installed over the set of 4 straight guide lands. When the spring has
been pushed to the correct location, the check valve body is designed to hold the end of the spring in position - be sure
that the spring is not loose before continuing with this installation.
4. Install the assembled check valve body/o-ring/spring in the delivery port so that the o-ring rests on its seat and the free
end of the spring is visible.
5. Grease the adapter and the remaining larger o-ring and install it onto the fitting.
6. Position the Bendix supplied gasket, then insert the governor mounting bolts through the governor and tighten (to 125 in-
lbs). (Note: Do not replace with a standard compressor/governor gasket.)
7. Reattach line to the governor.
8. Before placing vehicle back into service, check to see that the system pressure now builds to full operational pressure.
 SERVICE BRAKE (FULL AIR BRAKE) BR0213

AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART

EN0680202F300001

SYMPTOMS CAUSE REMEDY

1. Dryer is constantly "cycling" A. Excessive system A. Test for excessive system leakage.
or purging leakage Allowable leakage observed at dash gauge:
Single vehicle - 1 psi/minute.
Tractor trailer - 3 psi/minute.
Using soap solution, test vehicle for leakage at fit-
tings, drain valves and system valves. Repair or
replace as necessary.

B. Defective delivery check B. Build system pressure to governor cut-out. Wait 1

valve. minute for completion of purge cycle. Using soap
solution at exhaust of purge valve, leakage should
not exceed a 1" bubble in less than 5 seconds. If a
rapid loss of pressure is found, the following proce-
dure will determine if the delivery check valve is
malfunctioning:
Build system pressure to governor cut-out and
allow a full minute for the normal dryer purge cycle
to empty the purge reservoir. Switch off the engine
and "fan" the brakes so that the system pressure
reaches governor cut-in. The purge valve will
return to its closed position. The purge reservoir
has a drain valve which is opened by moving the
center lever away from its closed position. Open
the drain valve and wait 10 seconds to allow any
residual purge pressure to be released. Release
the lever, closing the drain valve. Carefully remove
the air dryer cartridge using a strap wrench and
then test for air leaking through the center of the
threaded boss by applying a soap solution to the
boss.
Replace the delivery check valve if there is exces-
sive leakage (exceeding a 1" bubble in 5 seconds).
Regrease the seal on the air dryer cartridge before
reinstalling. Be sure the drain valve on the purge
reservoir is not leaking before restoring vehicle to
service.

C. Defective governor. C. Check governor at both "cut-in" and "cut-out" posi-

tion for (i) proper pressures and (ii) excessive leak-
age at fittings and exhaust.

D. Compressor unloader D. Remove air strainer or fitting from compressor inlet

mechanism leaking cavity. With compressor unloaded, check for
excessively. unloader piston leakage. Slight leakage is permis-
sible.
BR0214 SERVICE BRAKE (FULL AIR BRAKE)

SYMPTOMS CAUSE REMEDY

2. Water in vehicle reservoirs. A. Maximum air dryer inlet A. Check for excessive carbon build up in compressor
temperature is exceeded discharge line. Replace if required. Make certain
due to improper discharge that discharge line length is at least 6 ft. Increase
line length. discharge line length and/or diameter to reduce air
dryer inlet temperature.

B. Air system charged from B. If system must have outside air fill provision, out-
outside air source (out- side air should pass through air dryer.
side air not passing
through air dryer).

C. Excessive air usage - Air C. Refer to Bendix Advanced Troubleshooting Guide

dryer not compatible with for Air Brake Compressors (BW1971) for proper
vehicle air system require- application of the AD-IS air dryer and reservoir
ment (Improper air dryer/ system. An extended purge model (AD-ISEP) is
vehicle application). available for many higher air usage vehicles, such
as city buses and construction vehicles.
If the vehicle is equipped with high air usage
accessories such as trailer pump-off systems or
central tire inflation, the air for these accessories
must by-pass the dryer reservoir system.

D. Desiccant requires D. Replace desiccant cartridge assembly.

replacement.

E. Air by-passes desiccant E. If vehicle uses Holset compressor, inspect feed-

cartridge assembly. back check valve for proper installation and opera-
tion.

F. Air dryer not purging. F. Refer to Symptom 6.

G. Purge (air exhaust) time G. Refer to Symptom 1.

insufficient due to exces-
sive system leakage.

3. Safety valve on air dryer A. Defective AD-IS air A. Test to determine if air is passing through check
"popping off" or exhausting dryer and reservoir sys- valve. Repair or replace. Refer to Symptom 1,
air. tem delivery check valve. Remedy B.

B. Safety valve setting too B. Replace safety valve.

low (<150 p.s.i.)

C. System pressure too high C. Test with accurate gauge. Replace governor if nec-
(>135 p.s.i.) essary.

D. Excessive pressure pul- D. Increase volume in discharge line. This can be

sations from compressor. accomplished by adding a 90 cubic inch (or larger)
(Typical single cylinder reservoir between the compressor and the AD-IS
type). air dryer and reservoir system.
 SERVICE BRAKE (FULL AIR BRAKE) BR0215

SYMPTOMS CAUSE REMEDY

4. Constant exhaust of air at A. Air dryer purge valve leak- A. With compressor loaded, apply soap solution on
air dryer purge valve ing excessively. purge valve exhaust, to test for excessive leakage.
exhaust or unable to build Repair or replace purge valve as necessary. Refer
system pressure. (Charge to Technical Bulletin TCH-008-040.
mode.)
B. Purge valve frozen open - B. Refer to paragraph 5 of Operation and Leakage
faulty heater and thermo- Tests for heater and thermostat test.
stat, wiring, blown fuse.

C. Defective AD-IS air C. Refer to Symptom 1, Remedy B.

dryer delivery check
valve.

D. Leaking Turbo Cut-Off D. Repair or replace purge valve assembly.

valve.

E. Defective governor. E. Check governor at both "cut-in" and "cut-out" posi-

tion for (i) proper pressures and (ii) excessive leak-
age at fittings and exhaust.

F. Leaking purge valve con- F. Repair or replace purge valve assembly.

trol piston quad-ring.

5. Cannot build system air A. Kinked or blocked A. Check to determine if air passes through dis-
pressure. (plugged) discharge line. charge line. Check for kinks, bends, excessive car-
bon deposits, or ice blockage.

B. Excessive bends in dis- B. Discharge line should be constantly sloping from

charge line (water collects compressor to air dryer with as few bends as pos-
and freezes). sible.

C. Pressure protection C. Replace air dryer (pressure protection valves are

valve(s) in air dryer will not serviceable).
not open.

D. Refer to Symptom 4. D. Refer to Symptom 4, Remedy A.

E. Refer to Symptom 7. E. Refer to Symptom 7, Remedies A and B.

6. Air dryer does not purge or A. Faulty air dryer purge A. After determining air reaches purge valve control
exhaust air. valve. port by installing a T-fitting with a pressure gauge
into the governor unloader port, repair purge valve
if necessary.

B. See Causes B, E, and F B. Refer to Symptom 4, Remedies B, E, and F. Also

for Symptom #4. refer to Symptom 1, Remedy B.

7. Desiccant material being A. Faulty dryer cartridge. A. Replace AD-IS air dryer cartridge and/or AD-IS
expelled from air dryer air dryer.
purge valve exhaust (may
look like whitish liquid or B. Excessive dryer vibration. B. Check the AD-IS air dryer mounting for loose-
paste or small beads.) ness or damage. Repair mounting and replace car-
tridge.

8. Unsatisfactory desiccant life. A. Excessive system leak- A. Refer to Symptom 1, Remedy A.

age.

B. Wrong vehicle application B. Refer to Symptom 2, Remedy C.

for AD-IS air dryer.

C. Compressor passing C. Check for proper compressor installation; if symp-

excessive oil. toms persist, replace compressor. Refer to Bendix
Advanced Troubleshooting Guide for Air Brake
Compressor (BW1971).
BR0216 SERVICE BRAKE (FULL AIR BRAKE)

SYMPTOMS CAUSE REMEDY

9. "Pinging" noise excessive A. Single cylinder compres- A. A slight "pinging" sound may be heard during sys-
during compressor loaded sor with high pulse cycles. tem build up when a single cylinder compressor is
cycle. used. If this sound is deemed objectionable, it can
be reduced substantially by increasing the dis-
charge line volume.
This can be accomplished by adding a 90 cubic
inch (or larger) reservoir between the compressor
and the AD-IS air dryer and reservoir system.

10. The air dryer purge piston A. Compressor fails to A. Check air hose from governor to compressor for a
cycles rapidly in the com- "unload". missing, kinked or restricted line. Install or repair
pressor unloaded (noncom- air hose.
pressing) mode. Repair or replace compressor unloader.
 SERVICE BRAKE (FULL AIR BRAKE) BR0217

CHECK VALVE
DATA AND SPECIFICATIONS
EN0680202I200001

Type Spring type, wafer type valve

DESCRIPTION
EN0680202C100002

INLET OUTLET

SPRING

INLET OUTLET

WAFER-TYPE
CHECK VALVE

SHTS068020200008
BR0218 SERVICE BRAKE (FULL AIR BRAKE)

INSPECTION AND REPAIR

EN0680202H300001

1. PREVENTATIVE MAINTENANCE
Every 6 months, 1,800 operating hours or every 50,000 miles inspect
all parts.
Replace any check valves leaking or showing signs of wear or deteri-
oration. Check for proper operation.

2. OPERATION & LEAKAGE CHECKS

NOTICE
Depending upon installation, it may be easier or necessary to com-
pletely remove check valves so that the following checks may be
made.
With air pressure present at outlet side of check valve and the inlet
side open to atmosphere, coat the open end of the check valve with
soap suds; a 1" bubble in 5 seconds is permissible.

If the check valve does not function as described, or leakage is exces-

sive, it is recommended that it be replaced with a new genuine Bendix
part available at any Bendix parts outlet.

3. REMOVAL
Block and hold vehicle by means other than air brakes.
Completely drain all reservoirs.
Disconnect air lines at single check valve and remove.

4. DISASSEMBLY/ASSEMBLY
NOTICE
There are no Disassembly/Assembly procedures for SC-3 valves.
They are non-serviceable items. If a valve does not meet the Opera-
tional and Leakage tests, it should be replaced at any authorized Ben-
dix parts outlet.

5. TESTING AND TROUBLESHOOTING

Perform "2.OPERATION & LEAKAGE CHECK".

6. IMPORTANT! PLEASE READ

When working on or around a vehicle, the following general pre-
cautions should be observed:
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels.
(2) Stop the engine when working around the vehicle.
(3) If the vehicle is equipped with air brakes, make certain to drain the air
pressure from all reservoirs before beginning ANY work on the vehi-
cle.
(4) Following the vehicle manufacturer's recommended procedures,
deactivate the electrical system in a manner that removes all electrical
power from the vehicle.
(5) When working in the engine compartment the engine should be shut
off. Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated, or elec-
trically charged components.
(6) Never connect or disconnect a hose or line containing pressure; it
may whip. Never remove a component or plug unless you are certain
all system pressure has been depleted.
(7) Never exceed recommended pressures and always wear safety
glasses.
SERVICE BRAKE (FULL AIR BRAKE) BR0219

(8) Do not attempt to install, remove, disassemble or assemble a compo-

nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
(9) Use only genuine Bendix replacement parts, components, and kits.
Replacement hardware, tubing, hose, fittings, etc. should be of equiv-
alent size, type, and strength as original equipment and be designed
specifically for such applications and systems.
(10) Components with stripped threads or damaged parts should be
replaced rather than repaired. Repairs requiring machining or welding
should not be attempted unless specifically approved and stated by
the vehicle or component manufacturer.
(11) Prior to returning the vehicle to service, make certain all components
and systems are restored to their proper operating condition.
BR0220 SERVICE BRAKE (FULL AIR BRAKE)

BRAKE PEDAL
OVERHAUL
EN0680202H200001

IMPORTANT POINTS-DISMOUNTING

1. DISCONNECT THE NYLON TUBE FROM THE BRAKE VALVE AND

CLUTCH PIPE FROM THE MASTER CYLINDER

2. REMOVE THE CLUTCH MASTER CYLINDER AND DISCONNECT

THE STEERING SHAFT

3. REMOVE THE PEDAL BRACKET ASSEMBLY

(1) Loosen the bolts and remove the pedal bracket assembly.

SHTS068020200009

4. REMOVE THE BRAKE PEDAL.

(1) Tap the shaft lightly using a brass rod and a hammer, remove the
brake pedal from the pedal bracket assembly.
NOTICE
Do not pull out the shaft because the brake pedal and the clutch pedal
are installed by one shaft.

5. DISCONNECT THE PUSH ROD JOINT FROM THE BRAKE PEDAL

LEVER

6. REMOVE THE BRAKE VALVE ASSEMBLY

SHTS068020200010
 SERVICE BRAKE (FULL AIR BRAKE) BR0221

IMPORTANT POINTS-MOUNTING

1. INSTALL THE BRAKE VALVE ASSEMBLY

Install the brake valve assembly with the 4 nuts.
Tightening Torque:
18-26 Nm{184-265 kgfcm, 13-19 lbfft}

2. CONNECT THE PUSH ROD JOINT TO THE BRAKE PEDAL LEVER

NOTICE
A: The boot has to be securely fit into the groove of the push rod.
B: After assembling boot into the pedal bracket.
Make sure that the projection of all around the boot all around is seen
above the surface of the pedal bracket.

SHTS068020200011

3. INSTALL THE BRAKE PEDAL

(1) Apply thinly lithium grease, Fuji sunlight 2000 or its equivalent to the
pedal bushing.
(2) Install the shaft into the pedal bracket and the pedal.
(3) Insert 2 snap rings to the pedal shaft.

4. INSTALL THE PEDAL BRACKET ASSEMBLY

Install the pedal bracket assembly with bolts.
Tightening Torque:
18-26 Nm{184-265 kgfcm, 13-19 lbfft}

SHTS068020200012
5. INSTALL THE CLUTCH MASTER CYLINDER AND THE STEERING
SHAFT

6. CONNECT THE NYLON TUBE TO THE BRAKE VALVE CONNEC-

TOR
Tightening Torque:
3/8: 35-45 Nm{375-459 kgfcm, 26-33 lbfft}
1/2: 50-60 Nm{510-612 kgfcm, 37-44 lbfft}

NOTICE
When assembling the nylon tubes be careful not to press them
down by foot, and pinch them between other parts and so on.
When fitting the joint to the nylon tube, be careful not to fold the
tube. If it is folded or damaged, replace it with a new one.

7. INSPECT THE BRAKE PEDAL PLAY

(1) Make sure that the installing height of the brake pedal "C" and the
pedal play "B".
B: 2-5 mm {0.0788-0.1968 in.}
C: 164.6-174.6 mm {6.48-6.87 in.}

SHTS068020200013
BR0222 SERVICE BRAKE (FULL AIR BRAKE)

(2) If the pedal play is out of the standard value, loosen the lock nut and
turn the push rod to adjust the pedal play to the standard value.
NOTICE
If you have loosened the push rod lock nut for the adjustment,
retighten it securely.
Tightening Torque:
17.5-32.5 Nm{179-332 kgfcm, 12.9-24 lbfft}

SHTS068020200014

8. ADJUST AND INSPECT THE STOP LIGHT SWITCH

(1) After installing bushing to the switch bracket, insert the stop light
switch then twist it clockwise while making contact with the tip of the
switch and the buffer, and fix it.
(2) After installing the switch, when releasing the brake pedal, make sure
there is no contact between the switch and buffer.
Confirm the operation of the switch surely.

SHTS068020200015

(3) Check the clearance between stop light switch and buffer.
"D": 0.5-1.5 mm {0.0197-0.0590 in.}

SHTS068020200016
 SERVICE BRAKE (FULL AIR BRAKE) BR0223

BRAKE VALVE
DATA AND SPECIFICATIONS
EN0680202I200002

Type Dual pistons and valves with a plunger type pedal

DESCRIPTION
EN0680202C100003

16 18
19 25

15 27 26
28 22

23 UPPER BODY

33
DEL - 1
24
17 31
SUP - 1
20 21
30 14

LOWER BODY

32
SUP - 2
BODY ATTACHING
SCREWS
13
DEL -2

10
EXHAUST COVER
ATTACHING SCREWS
11 12
9

SHTS068020200017

9 Screw 21 Relay piston spring

10 Exhaust diaphragm 22 Primary piston
11 Washer 23 Graduating spring
12 Exhaust cover 24 Washer
13 Inlet valve 25 Primary piston spring seat nut
14 Seal ring 26 Spring seat
15 Primary piston retainer 27 Rubber spring
16 Lock nut 28 Piston O-ring
17 Stem 30 O-ring
18 Spring seat 31 O-ring
19 Stem spring 32 Retaining ring
20 Relay 33 Primary inlet and exhaust valve
BR0224 SERVICE BRAKE (FULL AIR BRAKE)

COMPONENT LOCATOR
EN0680202D100001

33

32
21

16
18 24
31
19

25 20
15

30
26
27
17
22

28
14
LOWER
BODY
23
UPPER
BODY BODY
13 ATTACHING
SCREWS
(QTY. 4)

12
10

11 EXHAUST
COVER
9 ATTACHING
SCREWS
(QTY. 4)

SHTS068020200018

9 Screw 21 Relay piston spring

10 Exhaust diaphragm 22 Primary piston
11 Washer 23 Graduating spring
12 Exhaust cover 24 Washer
13 Inlet valve 25 Primary piston spring seat nut
14 Seal ring 26 Spring seat
15 Primary piston retainer 27 Rubber spring
16 Lock nut 28 Piston O-ring
17 Stem 30 O-ring
18 Spring seat 31 O-ring
19 Stem spring 32 Retaining ring
20 Relay piston 33 Primary inlet and exhaust valve
SERVICE BRAKE (FULL AIR BRAKE) BR0225

INSPECTION AND REPAIR

EN0680202H200002

1. PREVENTIVE MAINTENANCE
Important Note: Review the warranty policy before performing any
intrusive maintenance procedures. An extended warranty may be
voided if intrusive maintenance is performed during this period.
Because no two vehicles operate under identical conditions, mainte-
nance and maintenance intervals will vary. Experience is a valuable
guide in determining the best maintenance interval for any one partic-
ular operation.
Visually check for physical damage to the AD-IP such as chaffed or
broken air and electrical lines and broken or missing parts.
Every 3 months, or 25,000 miles or 900 operating hours:
Clean any accumulated dirt, gravel, or foreign material away from the
heel of the treadle, plunger boot, and mounting plate.
Using light oil, lubricate roller, roller pin, and hinge pin.
Check the rubber plunger boot for cracks, holes or deterioration and
replace if necessary. Also, check mounting plate and treadle for integ-
rity.
Apply 2 to 4 drops of oil between plunger and mounting plate - do not
over oil!
Every year, or 100,000 miles, or 3,600 operating hours:
Disassemble: clean parts with mineral spirits, replace all rubber parts,
or any part worn or damaged. Check for proper operation before plac-
ing vehicle in service.

2. SERVICE CHECKS
(1) Operating check
Check the delivery pressure of both primary and secondary circuits
using accurate test gauges. Depress the treadle to several positions
between the fully released and fully applied positions, and check the
delivered pressure on the test gauges to see that it varies equally and
proportionately with the movement of the brake pedal.
After a full application is released, the reading on the test gauges
should fall off to zero promptly. It should be noted that the primary cir-
cuit delivery pressure will be about 2 PSI greater than the secondary
circuit delivery pressure with both supply reservoirs at the same pres-
sure. This is normal for this valve.
IMPORTANT
A change in vehicle braking characteristics or a low pressure warning
may indicate a malfunction in one or the other brake circuit, and
although the vehicle air brake system may continue to function, the
vehicle should not be operated until the necessary repairs have been
made and both braking circuits, including the pneumatic and mechan-
ical devices, are operating normally. Always check the vehicle brake
system for proper operation after performing brake work and before
returning the vehicle to service.
(2) Leakage check
a. Make and hold a high pressure (80 psi) application.
b. Coat the exhaust port and body of the brake valve with a soap
solution.
c. Leakage permitted is a one inch bubble in 3 seconds. If the brake
valve does not function as described above or leakage is exces-
sive, it is recommended that it be re-placed with a new or remanu-
factured unit, or repaired with genuine Bendix parts available at
authorized Bendix parts outlets.
Refer to figures on page BR02-23 and 24 for item numbers referenced in
parenthesis.
BR0226 SERVICE BRAKE (FULL AIR BRAKE)

3. REMOVAL
(1) Chock the vehicle wheels or park the vehicle by mechanical means.
(Block and hold vehicle by means other than air brakes.) Drain all air
system reservoirs.
(2) Identify and disconnect all supply and delivery lines at the brake valve.
(3) Remove the brake valve and treadle assembly from the vehicle by
removing the three cap screws on the outer bolt circle of the mounting
plate. The basic brake valve alone can be removed by removing the
three cap screws on the inner bolt circle.

4. DISASSEMBLY
(1) If the entire brake valve and treadle assembly was removed from the
vehicle, remove the three cap screws securing the treadle assembly
to the basic brake valve.
(2) Remove the screw (9) securing the exhaust diaphragm (10) and
washer (11) to the exhaust cover (12).
(3) Remove the four screws that secure the exhaust cover (12) to the
lower body.
(4) Remove the secondary inlet and exhaust valve assembly (13) from
the lower body.
(5) Remove the four hex head cap screws securing the lower body to the
upper body and separate the body halves.
(6) Remove the rubber seal ring (14) from the lower body.
(7) For E-8P: While applying thumb pressure to the primary piston (22),
lift out and up on the three lock tabs of the primary piston retainer
(15).
! CAUTION
Before proceeding with the disassembly, refer to figures on pages
BR02-23 and 24, and note that the lock nut (16) and stem (17) are used
to contain the primary piston return spring (for E-8P: 23), stem spring
(19), and the relay piston spring (21). The combined force of these
springs is approximately 50 pounds and care must be taken when
removing the lock nut as the spring forces will be released. It is rec-
ommended that the primary piston and relay piston be manually or
mechanically contained while the nut and stem are being removed.
(8) Using a 3/8" wrench, hold the lock nut (16) on the threaded end of the
stem (17). Insert a screwdriver to restrain the stem, remove the lock
nut (16), spring seat, (18) and stem spring (19).
(9) Remove the relay piston (20), relay piston spring (21), primary piston
(E-8P: 22) and primary piston return spring (E-8P: 23) from the upper
body. Use care so as not to nick seats.
(10) A small washer (24) will be found in the cavity of the lower side of the
primary piston (for E-8P: 22).
(11) For E-8P: Disassemble the primary piston by rotating the spring seat
nut (25) counterclockwise. Separate the spring seat nut, spring seat
(26), and rubber spring (27) and remove the piston o-ring (28).
(12) Remove the large and small o-rings (30 & 31) from the relay piston
(20).
(13) Remove the retaining ring (32) securing the primary inlet and exhaust
valve assembly (33) in the upper body and remove the valve assem-
bly.

5. CLEANING AND INSPECTION

(1) Wash all metal parts in mineral spirits and dry.
(2) Inspect all parts for excessive wear or deterioration.
(3) Inspect the valve seats for nicks or burrs.
(4) Check the springs for cracks or corrosion.
(5) Replace all rubber parts and any part not found to be serviceable dur-
ing inspection, use only genuine Bendix replacement parts.
SERVICE BRAKE (FULL AIR BRAKE) BR0227

6. ASSEMBLY
Prior to reassembling, lubricate all o-rings, o-ring grooves, piston
bores, and metal to metal moving surfaces with Dow Corning 55 o-
ring lubricant (Bendix piece number 291126).
IMPORTANT
All torques specified in this manual are assembly torques and can be
expected to fall off, after assembly is accomplished. Do not retorque
after initial assembly torques fall.
(1) Install the primary inlet and exhaust assembly (33) in the upper body
and replace the retaining ring (32) to secure it. Be sure the retaining
ring is seated completely in its groove.
(2) Install the large and small o-rings (30 & 31) on the relay piston (20).
(3) For E-8P: Install o-ring (28) in the primary piston (22) o-ring groove.
(4) For E-8P: Install the rubber spring (do not lubricate) (27), concave
side down in the primary piston (22) and place the spring seat (26),
flat side up, over the rubber spring.
(5) For E-8P: Install the primary piston spring seat nut (25), with its hex
closest to the spring seat, and rotate clockwise until the top surface of
the spring seat is even with the top surface of the piston. Set aside.
(6) Place relay piston spring (21) in concave portion of relay piston (20)
and install relay piston through primary inlet/exhaust assembly (33)
into under side of upper body.
(7) Place screwdriver, blade up, in vise. Insert stem (17) through the relay
piston upper body sub assembly, slide this assembly over the blade of
the secured screwdriver, engage the screwdriver blade in the slot in
the head of the stem.
(8) Place the washer (24) over the stem (17) and on top of the relay pis-
ton (20).
(9) Install primary return spring (E-8P: 23) in upper body piston bore.
(10) For E-8P: Install the primary piston rubber spring sub assembly (1.
(4) and (5)) over the stem, into the up-per body piston bore.
(11) Compress piston(s) (For E-8P: the relay piston (20)) and retaining
ring into the upper body from either side and hold compressed, either
manually or mechanically. See the cautionary note under 3. (7) in
the Disassembly section of this manual.
(12) Place the stem spring (19) (E-8P: place over the spring seat nut (25)),
the spring seat (18) (concave side up) and lock nut (16) on the stem
(17). Torque to 20-30 inch pounds.
(13) For E-8P: Install the primary piston retainer (15) over the piston, mak-
ing certain all three lock tabs have engaged the outer lip of the body.
(14) Replace the rubber seal ring (14) on the lower body.
(15) Install the 4 hex head cap screws securing the lower body to the
upper body. Torque to 30-60 inch pounds.
(16) Install the secondary inlet and exhaust valve assembly (13) on the
lower body.
(17) Install the screws that secure the exhaust cover (12) to the lower
body. Torque to 20-40 inch pounds.
(18) Secure the screw (9) holding the exhaust diaphragm (10) and the dia-
phragm washer (11) to the exhaust cover (12). Torque to 5-10 inch
pounds.
(19) Install all air line fittings and plugs making certain thread sealant
material does not enter valve.

7. VALVE INSTALLATION
(1) Install the assembled brake valve on the vehicle.
(2) Reconnect all air lines to the valve using the identification made dur-
ing VALVE REMOVAL step 2.
(3) After installing the brake valve assembly, perform the "OPERATION
AND LEAKAGE CHECKS" before placing the vehicle in service.
BR0228 SERVICE BRAKE (FULL AIR BRAKE)

8. IMPORTANT: MAINTENANCE PRECAUTIONS

When working on or around a vehicle, the following general precau-
tions should be observed:
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels.
(2) Stop the engine when working around the vehicle.
(3) Drain the air pressure from all reservoirs before beginning ANY work
on the vehicle.
(4) Following the vehicle manufacturer's recommended procedures,
deactivate the electrical system in a manner that removes all electrical
power from the vehicle.
(5) When working in the engine compartment the engine should be shut
off. Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated, or elec-
trically charged components.
(6) Never connect or disconnect a hose or line containing pressure; it
may whip. Never remove a component or plug unless you are certain
all system pressure has been depleted.
(7) Never exceed recommended pressures and always wear safety
glasses.
(8) Do not attempt to install, remove, disassemble, or assemble a compo-
nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
(9) Use only genuine Bendix replacement parts, components, and kits.
Replacement hardware, tubing, hose, fittings, etc. should be of equiv-
alent size, type, and strength as original equipment and be designed
specifically for such applications and systems.
(10) Components with stripped threads or damaged parts should be
replaced rather than repaired. Repairs requiring machining or welding
should not be attempted unless specifically approved and stated by
the vehicle or component manufacturer.
(11) Prior to returning the vehicle to service, make certain all components
and systems are restored to their proper operating condition.
 SERVICE BRAKE (FULL AIR BRAKE) BR0229

RELAY VALVE
DATA AND SPECIFICATIONS
EN0680202I200003

Type Diaphragm type with double check valve combined

Pressure difference between signal and outlet pressure 29.4 kPa {0.3 kgf/cm2, 4.26 lbf/in2.}

DESCRIPTION
EN0680202C100004

BALANCE/QUICK EXHAUST
PORT (ANTI-COMPOUND)
EXHAUST COVER

EXHAUST
SEAT

SERVICE (1) DIAPHRAGM

RELAY
PISTON

INLET
EXHAUST
SUPPLY (2) VALVE
DELIVERY ASSEMBLY
EXHAUST PORT
RETAINING RING
EXTERIOR R-14H R-14H

SHTS068020200019

INSPECTION AND REPAIR

EN0680202H200003

1. PREVENTIVE MAINTENANCE
Important Note: Review the warranty policy before performing any
intrusive maintenance procedures. An extended warranty may be
voided if intrusive maintenance is performed during this period.
Because no two vehicles operate under identical conditions, mainte-
nance and maintenance intervals will vary. Experience is a valuable
guide in determining the best maintenance interval for any one partic-
ular operation.
(1) Every 3 months or 25,000 miles or 900 operating hours check for
proper operation.
BR0230 SERVICE BRAKE (FULL AIR BRAKE)

(2) Every 12 months or 100,000 miles or 3,600 operating hours: disas-

semble valve, clean parts with mineral spirits. Replace all rubber parts
and any part worn or damaged. Check for proper operation before
placing vehicle in service.

2. OPERATIONAL AND LEAKAGE TEST

(1) Chock the wheels, fully charge air brake system and adjust the
brakes.
(2) Make several brake applications and check for prompt application and
release at each wheel.
(3) Check for inlet valve and o-ring leakage.
a. Make this check with the service brakes released when the R-12
or R-14 is used to control the service brakes.
b. Make the check with the spring brakes applied (PARK) when the
R-14 is used to control the spring brakes. Coat the exhaust port
and the area around the retaining ring with a soap solution; a 1
inch bubble in 3 seconds leakage is permitted.
(4) Check for exhaust valve leakage.
a. Make this check with the service brakes fully applied if the R-12 or
R-14 control the service brakes.
b. Make this check with the spring brakes fully released if the R-14 is
used to control the spring brakes. Coat the exhaust port with a
soap solution; a 1 inch bubble in 3 seconds leakage is permitted.
Coat the outside of the valve where the cover joins the body to
check for seal ring leakage; no leakage is permitted.
(5) If the R-14 is used to control the spring brakes, place the park control
in the released position and coat the balance port with a soap solution
to check the diaphragm and its seat. Leakage equivalent to a 1 inch
bubble in 3 seconds is permitted.
NOTICE
If the anti-compound feature is in use, the line attached to the balance
port must be disconnected to perform this test.
If the valves do not function as described above, or if leakage is
excessive, it is recommended that the valves be replaced with new or
remanufactured units or repaired with genuine Bendix parts, available
at any authorized Bendix parts outlet.

3. REMOVAL
(1) Block and hold vehicle by means other than air brakes.
(2) Drain air brake system reservoirs.
(3) If entire valve is to be removed, identify air lines to facilitate installa-
tion.
(4) Disconnect air lines from valve*.
(5) Remove valve from reservoir or if remotely mounted, remove mount-
ing bolts and then valve.
*It is generally not necessary to remove entire valve to service the inlet/
exhaust valve. The inlet/exhaust valve insert can be removed by removing
the snap ring, exhaust cover assembly and then inlet/exhaust valve.
! CAUTION
Drain all reservoirs before attempting to remove the inlet exhaust
valve.

4. DISASSEMBLY
NOTICE
Prior to disassembly, mark the location of the mounting bracket to the
cover and the cover to the body.
(1) Remove the four (4) cap screws and lockwashers securing the cover
to the body.
(2) Remove the cover, sealing ring, and mounting bracket.
SERVICE BRAKE (FULL AIR BRAKE) BR0231

(3) Remove the piston and o-ring from the body.

(4) While depressing the exhaust cover, remove the retaining ring and
slowly relax the spring beneath the exhaust cover.
(5) Remove the exhaust cover assembly and o-rings.
(6) Remove the inlet/exhaust valve return spring from the body.
(7) Remove the inlet/exhaust valve from the body.
(8) Remove the valve retainer from the inlet/exhaust valve.
(9) Remove the Phillips head screw and exhaust cover from the R-14
cover.
(10) Remove the service port cap nut and o-ring from the R-14.
(11) Remove the diaphragm from the R-14 cover.

5. CLEANING AND INSPECTION

(1) Wash all metal parts in mineral spirits and dry them thoroughly.
NOTICE
When rebuilding, all springs and all rubber parts should be replaced.
(2) Inspect all metal parts for deterioration and wear, as evidenced by
scratches, scoring and corrosion.
(3) Inspect the exhaust valve seat on the relay piston for nicks and
scratches which could cause excessive leakage.
(4) Inspect the inlet valve seat in the body for scratches and nicks, which
could cause excessive leakage.
(5) Inspect the exhaust seat of the quick release diaphragm in the R-14
cover and make sure all internal air passages in this area are open
and clean and free of nicks and scratches.
(6) Replace all parts not considered serviceable during these inspections
and all springs and rubber parts. Use only genuine Bendix replace-
ment parts, available from any authorized Bendix parts outlet.

6. ASSEMBLY
NOTICE
All torque specified in this manual are assembly torque and can be
expected to fall off slightly after assembly. Do not re-torque after ini-
tial assembly torque fall. For assembly, hand wrenches are recom-
mended.
Prior to assembly, lubricate all o-rings, o-ring bores and any sliding
surface with a silicone lubricant equivalent to Dow Corning #10.
(1) Install large piston o-ring on piston.
(2) Install inner and outer o-rings in the exhaust cover assembly.
(3) Install the sealing ring on the cover.
(4) Install piston in body, taking care not to damage the piston o-ring.
(5) Noting the reference marks made during disassembly, install the
cover on the valve body and the mounting bracket on the cover.
(6) Secure the mounting bracket and cover to the body using the four (4)
cap screws and lock washers. Torque to 80-120 inch pounds.
(7) Install the valve retainer on the inlet/exhaust valve and install in the
body.
(8) Install the inlet/exhaust valve return spring in the body.
(9) Install the exhaust cover assembly in the body, taking care not to dam-
age the o-ring.
(10) While depressing the exhaust cover, install the retaining ring. Make
certain the retainer is completely seated in its groove in the body.
(11) Install the R-14 service port cap nut o-ring on the cap nut. Install the
diaphragm in the R-14 cover making certain it is positioned between
the guide ribs in the cover.
(12) Install the service port cap nut and torque to 150 inch pounds.
(13) If the quick release exhaust port was protected with an exhaust cover,
install the cover using the #10-24 Phillips head screw. Torque to
approx. 15-25 inch pounds.
BR0232 SERVICE BRAKE (FULL AIR BRAKE)

(14) Test the valves as outlined in the Operational and Leakage Test on
page BR02-30 before returning the valve to service.

7. INSTALLATION
(1) Clean air lines.
(2) Inspect all lines and/or hoses for damage and replace as necessary.
(3) Install valve and tighten mounting bolts.
(4) Connect air lines to valve (plug any unused ports).
(5) Test valve as outlined in Operational and Leakage Tests.

8. IMPORTANT! PLEASE READ

When working on or around a vehicle, the following general precau-
tions should be observed:
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels.
(2) Stop the engine when working around the vehicle.
(3) If the vehicle is equipped with air brakes, make certain to drain the air
pressure from all reservoirs before beginning ANY work on the vehi-
cle.
(4) Following the vehicle manufacturer's recommended procedures,
deactivate the electrical system in a manner that removes all electrical
power from the vehicle.
(5) When working in the engine compartment the engine should be shut
off. Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated, or elec-
trically charged components.
(6) Never connect or disconnect a hose or line containing pressure; it
may whip. Never remove a component or plug unless you are certain
all system pressure has been depleted.
(7) Never exceed recommended pressures and always wear safety
glasses.
(8) Do not attempt to install, remove, disassemble or assemble a compo-
nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
(9) Use only genuine Bendix replacement parts, components, and kits.
Replacement hardware, tubing, hose, fittings, etc. should be of equiv-
alent size, type, and strength as original equipment and be designed
specifically for such applications and systems.
(10) Components with stripped threads or damaged parts should be
replaced rather than repaired. Repairs requiring machining or welding
should not be attempted unless specifically approved and stated by
the vehicle or component manufacturer.
(11) Prior to returning the vehicle to service, make certain all components
and systems are restored to their proper operating condition.
 SERVICE BRAKE (FULL AIR BRAKE) BR0233

SPRING BRAKE MODULATING VALVE

DESCRIPTION
EN0680202C100005

PARK CONTROL
(FROM DASH VALVE)

BALANCE PORT

SUPPLY PORT
DELIVERY
EXHAUST

SHTS068020200020
BR0234 SERVICE BRAKE (FULL AIR BRAKE)

COMPONENT LOCATOR
EN0680202D100002

MAIN PISTON

DOUBLE CHECK VALVE CONTROL PISTON

O-RING
SPRING GUIDE
CHECK VALVE UPPER BODY
COVER
RETAINING
RING
O-RING
PARK CONTROL
PORT
O-RING
SPACER
IN-LINE SINGLE MAIN PISTON
CHECK VALVE SPRING
BALANCE PORT
SPRING STATIC PISTON
O-RING
O-RING O-RING
SUPPLY PORT CONTROL PORT
STATIC PISTON
SPRING
O-RING
CHECK VALVE
GUIDE O-RING

O-RING O-RING

LOWER BODY
DELIVERY TO
SPRING BRAKES
BALL CHECK VALVE
VALVE RETAINER
SPRING
SPRING
O-RING 1/4-20 MACHINE
SCREWS
O-RING
INLET/EXHAUST
VALVE SEAT VALVE
LOWER VALVE
GUIDE
RETAINING RING
EXHAUST PORT RETAINING
RING
DIAPHRAGM
#10 TORX HEAD SCREW
DIAPHRAGM WASHER
SHTS068020200021
SERVICE BRAKE (FULL AIR BRAKE) BR0235

INSPECTION AND REPAIR

EN0680202H200004

1. PREVENTIVE MAINTENANCE
The SR-7TM valve should be inspected every 6 months or 1500
operating hours, whichever comes first, for proper operation.
Should the SR-7TM valve not meet the elements of the opera-
tional tests noted in this document, further investigation and ser-
vice of the valve may be required.

2. SERVICE CHECKS
(1) Operating tests
Block vehicle and hold by means other than vehicle brakes.
Charge air brake system to governor cut-out pressure.
a. Place parking control valve in "park" position. Observe that spring
brake actuators apply promptly. Remove one line from delivery
port of the SR-7TM valve and install test gauge known to be accu-
rate. Place parking control valve in "release" position. Observe
that spring brake actuators release fully.
b. With parking control valve in "release" position, note gauge pres-
sure reading. (Correct spring brake actuator hold-off pressure is
107 psi nominally.)
c. Place parking control valve in "park" position - gauge reading
should drop to zero promptly. A lag (more than 3 seconds) in drop
of pressure would indicate faulty operation.
d. With the parking control valve in the "park" position, gradually
apply foot brake valve and note a pressure reading increase on
the gauge installed in the SR-7TM valve delivery port.
e. Place parking control valve in "release" position.
f. Drain the reservoir, which supplies the rear service brake circuit,
apply the foot brake valve several times and note that pressure
reading on gauge decreases each time foot brake valve is applied
(spring brake modulation). After the foot brake valve has been
applied several times, pressure on gauge will drop to the point
where release of the spring brake actuators will no longer occur.

3. LEAKAGE TEST
Place the park control valve in the "release" position; using a soap
solution, coat all ports including the exhaust port. A 1" bubble in 3 sec-
onds is permitted.

If the valve does not function as described, or if leakage is excessive,

it is recommended that it be replaced with a new or remanufactured
unit available from a Bendix parts outlet.
! WARNING
DO NOT ATTEMPT TO DISASSEMBLE THE SR-7TM VALVE. THE VALVE
CONTAINS HIGH SPRING FORCES THAT COULD RESULT IN PER-
SONAL INJURY IF DISASSEMBLY IS ATTEMPTED!
BR0236 SERVICE BRAKE (FULL AIR BRAKE)

4. WARNING! PLEASE READ AND FOLLOW THESE INSTRUC-

TIONS TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following general precau-
tions should be observed at all times.
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels. Always wear safety glasses.
(2) Stop the engine and remove ignition key when working under or
around the vehicle. When working in the engine compartment, the
engine should be shut off and the ignition key should be removed.
Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated or electri-
cally charged components.
(3) Do not attempt to install, remove, disassemble or assemble a compo-
nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
(4) If the work is being performed on the vehicle's air brake system, or
any auxiliary pressurized air systems, make certain to drain the air
pressure from all reservoirs before beginning ANY work on the vehi-
cle. If the vehicle is equipped with an AD-ISTM air dryer system or a
dryer reservoir module, be sure to drain the purge reservoir.
(5) Following the vehicle manufacturer's recommended procedures,
deactivate the electrical system in a manner that safely removes all
electrical power from the vehicle.
(6) Never exceed manufacturer's recommended pressures.
(7) Never connect or disconnect a hose or line containing pressure; it
may whip. Never remove a component or plug unless you are certain
all system pressure has been depleted.
(8) Use only genuine Bendix replacement parts, components and kits.
Replacement hardware, tubing, hose, fittings, etc. must be of equiva-
lent size, type and strength as original equipment and be designed
specifically for such applications and systems.
(9) Components with stripped threads or damaged parts should be
replaced rather than repaired. Do not attempt repairs requiring
machining or welding unless specifically stated and approved by the
vehicle and component manufacturer.
(10) Prior to returning the vehicle to service, make certain all components
and systems are restored to their proper operating condition.

5. REMOVAL
(1) Prior to removing the SR-7TM valve, apply the parking brakes and
drain all the vehicle reservoirs.
(2) Identify all air lines before disconnecting.
(3) Remove the two mounting nuts that secure the valve to the frame rail
and remove the valve.

6. INSTALLATION
(1) Align the mounting studs with the mounting holes on the vehicle frame
rail. Tighten the mounting nuts to 180-220 in. lbs.
(2) Install the valve onto the vehicle ensuring all ports are connected as
marked during disassembly.

7. TESTING THE REPLACEMENT SR-7TM SPRING BRAKE MODU-

LATING VALVE
Perform operating and leakage tests as outlined in "Operating Tests"
section.
 SERVICE BRAKE (FULL AIR BRAKE) BR0237

SPRING BRAKE CONTROL VALVE

DESCRIPTION
EN0680202C100006

SUPPLY
DELIVERY

EXHAUST

COVER

BUTTON

Ports:
Port Embossed I.D.
Primary Reservoir Supply Supply 11
Secondary Reservoir Supply Supply 12
Delivery Delivery 21
Exhaust Exhaust 3

SHTS068020200022
BR0238 SERVICE BRAKE (FULL AIR BRAKE)

COMPONENT LOCATOR
EN0680202D100003

BUTTON

SCREW

COVER

CHECK VALVE SEAT

GUIDE
SPOOL

2 7

BODY
3 8

PLUNGER
STEM

PLUNGER 9

INDEX TABS

SHTS068020200023
SERVICE BRAKE (FULL AIR BRAKE) BR0239

INSPECTION AND REPAIR

EN0680202H200005

1. PREVENTIVE MAINTENANCE
(1) Every 3 months; 25,000 miles; or 900 operating hours; or during the
vehicle chassis lubrication interval, make the visual inspections noted
in "SERVICE CHECKS."
(2) Every 12 months; 100,000 miles; or 3,600 operating hours, perform
"OPERATIONAL AND LEAKAGE TESTS."

2. SERVICE CHECKS
(1) Remove any accumulated contaminants. Visually inspect the valve's
exterior for excessive wear or physical damage. Repair/replace as
necessary.
(2) Inspect all air lines connected to the valve for signs of wear or physical
damage. Repair/replace as necessary.
(3) Test air line fittings for excessive leakage. Repair/replace as neces-
sary.

3. LEAKAGE AND OPERATIONAL TESTS

To perform the following tests, connect two separate 120 psi air
sources to the PP-DC supply ports. Tee an accurate test gauge into
the supply lines, and provide for a means to control supply line pres-
sure. Connect a small volume with a gauge to the delivery port.
(1) Leakage test
a. Supply the valve with 120 psi from the primary reservoir supply
port. With the button out, coat the exhaust port and the plunger
stem with a soap solution. Leakage should not exceed a 1" bubble
in 5 seconds. There should be no leakage from the secondary
reservoir supply port.
b. With the button out, supply the valve with 120 psi from the sec-
ondary reservoir supply port. There should be no leakage from
the primary reservoir supply port.
c. With the button in, coat the exhaust port and the plunger stem
with a soap solution. Leakage at both areas should not exceed a
1" bubble in 3 seconds.
(2) Operational test
a. With the button out, supply either supply port with 120 psi of air.
Then push the button in. Air pressure should rise in the delivery
volume equivalent to supply pressure.
b. Pull the button out. Delivery pressure should exhaust to 0 psi.
c. Build each supply source to 120 psi. Decrease supply pressure at
the secondary service reservoir supply port at a rate of 10 psi per
second. Primary supply pressure and delivery pressure should
not drop below 100 psi.

Repeat the test for decreasing primary service reservoir pressure.

d. Build each supply source to 120 psi. Then decrease both supply
pressures to below 20 to 30 psi. The button should automatically
"pop" out when pressure drops within that range.

4. REMOVAL
(1) Identify and mark or label all air lines and their connections on the
valve.
(2) Remove the PP-DC from the vehicle and save the mounting hard-
ware.
BR0240 SERVICE BRAKE (FULL AIR BRAKE)

5. INSTALLATION
(1) Install the PP-DC in its location on the dashboard. Using the mounting
hardware saved in "REMOVAL," secure the valve to the vehicle.
(2) Reconnect all air lines to the valve using the identification made in
"REMOVAL."
(3) Perform "OPERATIONAL AND LEAKAGE TESTS" before placing the
vehicle back in service.

6. DISASSEMBLY
The following disassembly and assembly procedures are for reference
only. Always have the appropriate maintenance kit on hand and use
its instructions in lieu of those presented here. Refer to figure on page
BR02-38 throughout the procedure.
(1) Turn the button counterclockwise to remove it from the plunger stem.
(2) Remove the four screws that secure the cover to the body, and
remove the cover.
(3) Pull the plunger stem to remove the plunger and the guide spool from
the body.
(4) Remove plunger spring(6) and discard.
(5) If necessary, use a screwdriver to carefully remove the check valve
seat from the body. Be sure not to damage the check valve seat or the
body.
(6) Remove and discard check valve seat o-rings(7) and (8).
(7) Turn the body upside down and gently tap it on a flat surface to
remove check valve(9). Discard the check valve.
(8) Remove the guide spool from the plunger. Remove and discard o-
ring(1) from the guide spool.
(9) Remove and discard o-rings(2), (3) and (5) from the plunger. Also
remove and discard exhaust seal(4).

7. CLEANING & INSPECTION

(1) Wash all metal parts in mineral spirits and thoroughly dry.
(2) Inspect all re-usable parts for excessive wear or damage. Inspect the
body for gouges or deep scuffing. Replace key numbers 1-9 (and any
parts not determined usable) with genuine Bendix replacements.

8. ASSEMBLY
Before assembly, lubricate all o-rings, o-ring grooves, rubbing sur-
faces and bores with Bendix silicone lubricant (Pc. No. 291126) or
equivalent.
(1) Place check valve(9) into its seat in the body with its flat surface facing
upward. If necessary, reach into the body to make sure the valve is
seated evenly in the bore.
(2) Install o-rings(7) and (8) on the check valve seat and install the check
valve seat into the body. Make sure the seat is fully seated-its surface
should be even with the body's surface.
(3) Install plunger spring(6) into the body. Make sure it stands upright and
is seated properly in the body bore. (It should surround the protrusion
or "lip" at the bottom of the body bore.)
(4) Install o-rings(2), (3), (5) and exhaust seal(4) onto the plunger. Then
install the plunger into the body. Line up the plunger's index tabs with
the spaces in the body bore for ease of installation.
(5) Install o-ring(1) onto the guide spool. Then install the guide spool over
the plunger and into the body. Press the guide spool into place firmly.
(6) Place the cover onto the body and secure with its four screws. Torque
to 35 in. lbs.
(7) Thread the button clockwise onto the plunger stem. It should take
approximately 3 full button revolutions to install it on the plunger. The
protrusions on the side of the plunger should line up with the button
grooves. Push on the button a number of times to make sure the
plunger moves freely throughout its range of motion.
SERVICE BRAKE (FULL AIR BRAKE) BR0241

NOTICE
Before placing the vehicle back into service, perform the "leakage and
operational tests" in this manual.
If the PP-DC fails to function as described, or if leakage is excessive, repair
the valve or replace it at the nearest authorized Bendix Commercial Vehicle
Systems parts outlet.

9. IMPORTANT! PLEASE READ

When working on or around a vehicle, observe the following general
precautions.
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels.
(2) Stop the engine when working around the vehicle.
(3) Drain the air pressure from all reservoirs before beginning ANY work
on the vehicle.
(4) When working in the engine compartment the engine should be shut
off. Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated, or elec-
trically charged components.
(5) Never connect or disconnect a hose or line containing pressure; it
may whip.
(6) Never remove a component or plug unless you are certain all system
pressure has been depleted.
(7) Never exceed recommended pressures and always wear safety
glasses.
(8) Do not attempt to install, remove, disassemble or assemble a compo-
nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to the use of those tools.
(9) Use only genuine Bendix replacement parts, components and kits.
Replacement hardware, tubing, hose, fittings, etc. should be of equiv-
alent size, type and strength as original equipment and should be
designed specifically for such applications and systems.
(10) Components with stripped threads or damaged parts should be
replaced rather than repaired. Repairs requiring machining or welding
should not be attempted unless specifically approved and stated by
the vehicle or component manufacturer.
BR0242 SERVICE BRAKE (FULL AIR BRAKE)

BRAKE CHAMBER (FRONT)

DATA AND SPECIFICATIONS
EN0680202I200004

P/N Series 1420

Model C20
Size 20
Stroke 2.25"
Part Number 1420001
Wt. (Lbs.) 7.55
A 4.16
B 3.41
C 6.92
D 4.75
E 5/8"-11UNC
F 5/8"-18UNF
Inlets 3/8"-NPTF
X-Min. (in the caged position) 8.00"

DESCRIPTION
EN0680202C100007

A
B

X
E
D F

SHTS068020200024
 SERVICE BRAKE (FULL AIR BRAKE) BR0243

COMPONENT LOCATOR
EN0680202D100004

11

3
4

1
6

8
9

10
SHTS068020200025

1 Kit - NP Chamber (b) 7 Kit - Center Hole Shield

2 Kit - Nuts & Bolts 8 NP Chamber Assembly
3 Clamp Band Assembly 9 Kit - Nuts & Washers
4 Diaphragm 10 Hex Nut - Yoke
5 Kit - Push-Rod Assembly (b) 11 Pressure Cap (2-inlets/steel) (a)
6 Return Spring
BR0244 SERVICE BRAKE (FULL AIR BRAKE)

OVERHAUL
EN0680202H200006

IMPORTANT POINT-DISMOUNTING
Brake chamber
Threaded clevis
1. DISMOUNTING OF THE BRAKE CHAMBER
(1) Before dismounting, apply aligning mark to the chamber, clamp and
chamber cover.
(2) Apply a position mark "R" or "L" to identify the side where the cham-
Port ber was installed.
A

Push rod

SHTS068020200026

IMPORTANT POINTS-ASSEMBLY

1. ASSEMBLING THE BRAKE CHAMBER

(1) Replace the diaphragm with new one.
(2) Align the aligning mark "A" of the chamber, clamp and chamber cover.
(3) Insert the bolt from opposite side of drain hole and tighten the bolts
evenly with nut within the specified torque.

SHTS068020200027

2. CHECKING FOR AIR LEAKAGE

Soapy water (1) Apply soapy water to the chamber as shown and charge with com-
B pressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in2.} from the inlet port "B"
then check for leakage.

SHTS068020200028

3. INSTALLING CLEVIS
(1) Install the clevis to the push rod.
Threaded clevis

Port
A

Push rod

SHTS068020200029
 SERVICE BRAKE (FULL AIR BRAKE) BR0245

IMPORTANT POINT-MOUNTING

1. INSTALLING THE BRAKE CHAMBER

(1) The chamber must be mounted on the side a s marked when dis-
mounting.
NOTICE
See the position mark ("R" or "L") which was applied when dis-
mounting.
When connecting the clevis with the slack adjuster, lubricate the
clevis pin hole and clevis pin with sufficient chassis grease.

INSPECTION AND REPAIR

EN0680202H300002

Inspection Item Standard Limit Remedy Inspection Procedure

Cover, clamp, push rod, Replace, If neces- Visual check

return spring, retainer, dust sary.
seal, holder and chamber:
Wear and damage
BR0246 SERVICE BRAKE (FULL AIR BRAKE)

BRAKE CHAMBER (REAR)

DATA AND SPECIFICATIONS
EN0680202I200005

Type Diaphragm type

P/N Series 3430

Model TR3030
Size 3030
Stroke 2.50"
P/N Combination 3430051
P/N Single/Piggyback 3430001
P/N Piggyback Plus Kit 3430008
Wt.Combination (Lbs.) 20.0
Wt. Single (Lbs.) 11.6
A 9.04
B 6.66
C 8.31
D 8.21
E 4.75"
F 5/8" - 11UNC
G 5/8" - 18UNF
Inlets 3/8" - NPTF
X - Min. (in the caged position) 8.00" (b)
SERVICE BRAKE (FULL AIR BRAKE) BR0247

DESCRIPTION
EN0680202C100008

F
E
G
C

SHTS068020200031
BR0248 SERVICE BRAKE (FULL AIR BRAKE)

COMPONENT LOCATOR
EN0680202D100005

5
2

6
4
3
11

12

13

10
9
8
1
14

7 Center Hole Shield

Permits visual inspection of
stroke alert but prevents
entry of contaminants.

SHTS068020200032

1 Kit-NP Chamber (b) 8 NP Chamber Assembly

2 Kit-Nuts & Bolts 9 Kit-Nuts & Washers
3 Clamp Band Assembly 10 Hex Nut - Yoke
4 Diaphragm 11 Kit-WeathersealTM Plug
5 Kit-Push-Rod Assembly (b) 12 Kit-Release Bolt
6 Return Spring 13 Piggyback
7 Kit-Center Hole Shield 14 Kit-Piggyback Plus
 SERVICE BRAKE (FULL AIR BRAKE) BR0249

INSPECTION AND REPAIR

EN0680202H300003

! CAUTION
The MGM Brakes Tamper Resistant spring brake chambers are an
important part of your braking system. While they do not require
scheduled servicing, it is good preventative maintenance to make the
following routine inspections while they are in the shop for regular
servicing of other components or at a minimum of every 50,000 miles.

! WARNING
Your MGM brakes tamper resistant spring brake has been factory
sealed for your protection. There are no user-serviceable parts inside
the spring brake chamber. If you experience any damage or failure of
your spring brake chamber, remove either the entire actuator as in
section (3) of this manual, or the single (piggyback) as in section (5) of
this manual. See section (8) of this manual for disposal instructions.
Never attempt to disassemble the spring brake chamber as serious
personal injury could result from accidental sudden release of the
high energy spring.

1. RECOMMENDED INSPECTION POINTS

Model TR Series
(1) The plastic END CAP on all "TR" and "TR-T" models requires no posi-
tioning or maintenance, but must be snapped tightly into place.
Inspect the cap for damage and replace as necessary. "TR-T" units
SHTS068020200033
equipped with a breather tube and the white WEATHER SEAL END
CAP must be equipped with a rubber O-ring to ensure proper sealing
of the spring chamber. Operating units equipped with the
BREATHER TUBE without the END CAP or DUST CAP securely in
place will void the MGM Brakes warranty without remedy.
(2) Visually inspect the exterior surfaces of the unit for signs of damage
from outside sources, corrosion and/or rust. If any of these are seen
or suspected, cautiously remove the complete combination chamber
by following the directions in Section 3 on page BR02-51 of this man-
ual. Per CVSA out of service criteria any non-manufactured hole or
crack will place the vehicle out of service. (Not Shown)
(3) Inspect SERVICE BRAKE CLAMP RING to be sure it is securely in
place and damage free. If any damage is seen or suspected, cau-
tiously remove the complete piggyback/spring brake chamber by fol-
lowing directions in Section 5 on page BR02-54 of this manual. MGM
Brakes recommends 30-35 Lbs.-Ft. torque on CLAMP BOLTS.
(4) Check to ensure the MOUNTING STUD NUTS are tightened to 133-
155 Lbs.-Ft. torque (clockwise) and washers are in place between
the nut and bracket.
(5) Inspect air lines, hoses and fittings attached to chamber. Replace any
damaged or leaking parts. MGM Brakes recommends the fittings
be tightened to 25-30 Lbs.-Ft. torque into the chamber air inlet
ports.

IMPORTANT
Inspect the air ports to determine the model of brake. Round
ports denote (2.50 inch) standard stroke model, square ports
denote (3.00 inch) long stroke model. This information is impor-
tant when replacing the service diaphragm and determining the
chamber's rated stroke.
(6) Inspect the PUSH-ROD to be sure it is working free, not bent, not
binding and is square to the chamber bottom within 3 in any direc-
tion at any point in the stroke of the chamber. If the PUSH-ROD is not
square, make corrections by repositioning the chamber on the mount-
ing bracket and/or by shimming the slack adjuster to the right or left on
the camshaft as required.
BR0250 SERVICE BRAKE (FULL AIR BRAKE)

(7) Inspect the YOKE ASSEMBLY being sure YOKE PIN is installed and
locked into place with a COTTER PIN. Replace any damaged, worn
or missing parts. MGM Brakes recommends the YOKE LOCKNUT
be tightened to 25-50 Lbs.-Ft. torque. (Not Shown)
(8) On units equipped with a DUST BOOT, check the BOOT for damage
and replace as necessary. (Not Shown).
(9) On units equipped with an external BREATHERTUBE be sure both
ends of the connector tube are engaged a minimum of 1/2-inch into
each of the flexible elbows. The tube must be glued to both of the
elbows with a high quality rubber adhesive or secured with a clamp
that may be purchased with the MGM Brakes BREATHER TUBE KIT.
These units must be mounted with the BREATHER TUBE in the upper
half of the non-pressure chamber facing away from the road surface.

IMPORTANT: Failure to operate any MGM Brakes Model Series "TR-T" or

"TR-TS" chamber without the EXTERNAL BREATHER TUBE and END
CAP with O-ring being present and in good condition will void the MGM
Brakes Warranty without remedy.

2. MANUAL RELEASE-PARKING BRAKES

(1) Before releasing the parking brakes, chock wheels of the vehicle to
prevent a vehicle movement.
(2) Remove the plastic end cap from the spring brake chamber.

SHTS068020200034

(3) Using a 3/4 inch wrench, unscrew the release-nut and remove the nut,
flat washer, and release-bolt from their storage pocket on side of
chamber for all "TR" series brakes.

IMPORTANT
If these parts are not stored on the chamber, they must be
obtained from vehicle tool box or service department, as the pig-
gyback/spring brake cannot be manually released without them.

SHTS068020200035

(4) Insert the release-bolt into the center hole of the head and, being sure
that the formed end of the bolt has entered the hole in the piston
inside the chamber, continue to insert the bolt until it reaches the bot-
tom.

IMPORTANT
If you are not absolutely sure of correct bolt-to-piston engage-
ment, repeat 1. (4) until you are sure.

SHTS068020200036

(5) Turn the release-bolt 1/4 turn clockwise and pull the bolt out to lock
the formed end into the piston.
 SERVICE BRAKE (FULL AIR BRAKE) BR0251

IMPORTANT
If the bolt does not lock into the piston in less than 1/2 inch out-
ward movement, repeat 1. (4) and (5) until you are sure it does
lock.
(6) Holding the bolt locked into the piston, install the flat washer and the
release nut on the end of the release-bolt, and turn down the nut
against the flat washer until finger tight.

SHTS068020200037

(7) Using a 3/4 inch handwrench (DO NOT USE AN IMPACT WRENCH)
turn the release-nut clockwise until the following length of bolt extends
above the nut.
Measure 3.25 inch-Type 3030 Chamber

! WARNING
Do not exceed these lengths and do not exceed 50 lbs.-ft. torque on
release nut at any time or damage may occur which could prevent any
future correct manual-releasing of the piggyback spring brake cham-
ber.
NOTICE
SHTS068020200038 For easier manual-releasing, apply 90-125 psi air pressure to
inlet port marked "SPRING BRAKE" before 1. (4) above, but be
sure to exhaust all air pressure after 1. (7) is completed.
To reactivate the piggyback/spring brake from its manually-
released position, reverse the order of 1. (1)-(7) above.
When re-installing the release-bolt, flat washer and release-nut
into the storage pocket, MGM Brakes recommends 10 Lbs.-Ft.
torque on nut against the flat washer.

3. REMOVAL AND INSTALLATION INSTRUCTIONS FOR "COMBINA-

TION CHAMBERS"
NOTICE
Before removing air brake chamber to be replaced to ensure that the
brake chamber being replaced was properly installed with the correct
rod length.
(1) Determine the manufacturer of the single (piggyback) spring brake or
combination chamber to be removed from the vehicle and, following
that manufacturer's instructions exactly, manually release the spring
Y brake completely. (Instructions for all MGM Brakes Model Series "TR",
"TR-T" and single (piggyback) spring brakes having removable bolts
X are given in Section 2 on page BR02-50 of this manual. (Service Man-
uals for all other design series of MGM Brakes piggyback spring
brakes are also available upon request to MGM Brakes.)
(2) Remove the cotter pin from the yoke pin, knock out the yoke pin, and
remove both air lines from the assembly.

SHTS068020200039 IMPORTANT
Be sure to mark the air line from the inlet port marked "SPRING
BRAKE" for later re-installation reference.
BR0252 SERVICE BRAKE (FULL AIR BRAKE)

(3) Using a 15/16 inch wrench, unscrew hex nuts on mounting bolts and
cautiously remove the old chamber from the mounting bracket.
(4) Cut the service push-rod to proper length.
(5) Remove the hex nut and the flat washers on the mounting bolts of the
new chamber, clean the face of the mounting bracket and install the
chamber on the bracket with close attention given to positioning the
chamber air inlet ports for correct alignment to the vehicle lines. Then
install one flat washer and hex nut on each mounting bolt and using a
15/16 inch hand wrench (DO NOT USE AN IMPACT WRENCH),
tighten nuts to MGM Brakes recommended 133-155 Lbs-Ft. torque.

SHTS068020200040 IMPORTANT
If it is required to reposition the air inlet ports to assure proper
mating and alignment with vehicle air lines, refer to Section 5 on
page BR02-55 and 56 of this manual and follow Steps (3) through
(6) very carefully.
When installing any MGM Brakes model with the breather tube it
Breather Tube is mandatory to position the non-pressure chamber end of the
breather tube in upper half of chamber facing away from the road
Yes Yes
surface. Failure to comply will void the MGM Brakes Warranty on
these models.
(6) Reconnect yoke to the slack adjuster, being sure that the correct
diameter and length of yoke pin is installed into the correct hole in the
slack adjuster. Secure the yoke pin with a new cotter pin.
No No
IMPORTANT: When making a reconnection to an automatic slack
Road Surface adjuster follow the vehicle manufacturer's recommendations for instal-
lation and set-up.
SHTS068020200041 (7) Inspect the push-rod to be sure that it is working free, not bent, not
binding an is square to the chamber bottom within 3 in any direction
at any point in the stroke of the chamber. If the push-rod is not square,
make corrections by repositioning the chamber on the mounting
bracket and/or by shimming the slack adjuster to the right or left on
the camshaft as required.
(8) Apply a non-hardening sealing compound to the hose fittings and re-
install both of the air lines to the chamber being sure each is mated to
the correct air inlet port according to the markings made earlier. MGM
Brakes recommends the fittings be tightened to 25-30 Lbs.-Ft.
torque into the chamber air-inlet ports.
(9) Using the vehicle system air, charge the spring brake with full line
pressure (minimum 100 psi). Spray only soapy water or leak detection
solution (NEVER ANY TYPE OF OIL!) to the air line fittings and
inspect for air leaks. If bubbles appear, tighten fittings slightly, but not
over 30 Lbs.-Ft. torque.
IMPORTANT: If the service brake clamp ring was loosened to reposi-
tion air inlet ports in Step(5) above, apply air to the spring brake and
then apply and hold foot brake treadle valve down to charge the ser-
vice brake chamber. Test for air leaks around the circumference of the
service clamp ring using soapy water or leak detection solution. If
bubbles appear, firmly tap the circumference of the clamp ring with a
hammer and retighten the clamp nuts until leaks cease. MGM Brakes
recommends 30-35 Lbs-Ft. torque on clamp hex nuts. Completely
exhaust air from both of the chambers when complete.
(10) With air pressure now exhausted from the service chamber, but still
applied on the spring brake, remove release-nut, washer and release-
bolt for all "TR" models. Replace these parts in their storage pocket on
chamber (or in vehicle tool box if storage pocket is not present on
chamber) and tighten nut against flat washer to 10 Lbs.-Ft. torque.
(11) Replace the END CAP properly. Operating units equipped with the
EXTERNAL BREATHER TUBE without the END CAP and O-RING
 SERVICE BRAKE (FULL AIR BRAKE) BR0253

securely in place will void the MGM Brakes Warranty without

remedy.
IMPORTANT: If chamber is fitted with an external breather tube be
sure both ends of the connector tube are engaged a minimum of 1/2
inch into each of the flexible elbows. The tube must be glued to both
of the elbows with a high quality rubber adhesive or secured with a
clamp that may be purchased with the MGM Brakes Breather Tube
Kit. These units must be mounted with the BREATHER TUBE in the
upper half of the non-pressure chamber facing away from the road
surface.
! WARNING
After replacement of any brake chamber, the chamber pushrod stroke
and actuating alignment must be checked to assure correct installa-
tion and foundation brake adjustment. It is very important to recog-
nize that no foundation adjustments can be made at either the spring
brake chamber, or at the service brake chamber, and that all "stroke
adjustments" must be made at the slack adjuster according to the
specific recommendations of the foundation brake manufacturer or
the vehicle manufacturer.

4. PROCEDURE TO CUT THE SERVICE PUSH-ROD TO PROPER

LENGTH

! WARNING
Do not attempt to service or disassemble the spring chamber or any
spring brake actuator. A large spring in the spring chamber having
extreme force could cause serious bodily injury if it were suddenly
released due to inadvertent removal of this clamp or tamper resistant
head.
IMPORTANT: Place blocks under wheels to prevent vehicle runaway
before removing air brake actuators.
SHTS068020200042
(1) REMOVE WORN OR NON-FUNCTIONAL UNIT FROM VEHICLE:
Determine manufacturer and model of unit to be replaced. Refer to
that manufacturer's service manual for caging and removal instruc-
tions.
BR0254 SERVICE BRAKE (FULL AIR BRAKE)

(2) Make sure the spring chamber of the removed actuator is fully
released (power spring caged) and the service brake push-rod is fully
retracted to zero stroke position (i.e., brake fully released).
(3) Measure and record the "X" and "Y" dimensions.
"X" Dimension - The dimension from bottom of actuator to end of
push-rod. "Y" Dimension - The dimension from bottom of actuator to
center line of yoke pin.
NOTICE
If for some reason the spring chamber power spring cannot be caged
and fully released, then the "X" and "Y" dimensions will need to be
measured from another actuator of the exact type from the same vehi-
cle provided it is retracted to its zero stroke position (brake fully
released) and was operating correctly.
(4) Before marking push-rod to be cut on a new unit, be sure the spring
chamber and push-rod are fully retracted to the zero position. (This
may be done with the manual caging bolt or by applying 90-100 psi air
pressure to the spring chamber air inlet port.)
(5) Take measured "X" dimension from the removed unit and mark push-
rod of new unit from the bottom of the actuator.
(6) Thread yoke jam nut past mark on push-rod. Align bottom edge of nut
with mark.
(7) Use a sharp hack-saw and cut push-rod on the mark.
(8) After cutting rod, thread jam nut off to clean up the thread.
(9) Thread jam nut back onto the push-rod a sufficient length to allow
SHTS068020200043
assembly of the yoke.
(10) Thread yoke onto the push-rod. Yoke from removed unit may be
reused provided yoke pin hole is not worn. Adjust yoke to the same
"Y" dimension as measured from the removed unit.
(11) Hold yoke to prevent it from turning and tighten locknut against yoke
25-35 Lbs.-Ft. torque.
TO INSTALL NEW UNIT ON VEHICLE: Refer to MGM Brakes Service
Manual for the model that is being installed.

5. REMOVAL AND INSTALLATION INSTRUCTIONS FOR SINGLE

(PIGGYBACK) SPRING BRAKES
The removal and installation of a single spring brake chamber (with-
out removal of the service brake chamber) can be made easier by
"locking off" the service chamber piston. To do this apply the service
brake by applying the driver's foot brake treadle valve and, while
applied, clamp vise-grip pliers on push-rod so that vice-grips abut
mounting bracket to prevent rod from retracting when air pressure is
released.
(1) Determine manufacturer of the single spring brake to be removed
from the vehicle and, following that manufacturer's instructions
SHTS068020200044 exactly, manually release the spring brake completely. (Instructions for
all MGM Brakes Model Series "TR", "TR-T" and single spring brakes
having removable release bolts are given in Section 2 on page BR02-
50 of this manual.) (Service Manuals for all other design series of
MGM Brakes single spring brakes are also available upon request to
MGM Brakes.)
(2) Remove both air lines from the chamber.

IMPORTANT
Be sure to mark the air line from the inlet port marked "SPRING
BRAKE" for later re-installation reference.
 SERVICE BRAKE (FULL AIR BRAKE) BR0255

(3) On all MGM Brakes models fitted with external breather tubes, dis-
connect the tube and elbow from the service chamber housing.

Apply
Adhesive
Here

1/2-inch
Minimum
Engagement

1/2-inch
Diameter Hole

SHTS068020200045

(4) Using a 9/16 inch wrench or socket, remove the clamp nuts on the
service clamp ring. Then, while holding the single spring brake
securely in place, remove the clamp ring to allow removal of the single
brake from the service chamber.

IMPORTANT
At this time take the opportunity to inspect all parts in the ser-
vice chamber (especially the diaphragm) and replace the return
spring, and any other parts which may be damaged or worn. Use
only genuine MGM Brakes Engineered replacement parts!

SHTS068020200046
BR0256 SERVICE BRAKE (FULL AIR BRAKE)

(5) Make sure the new single (piggyback) spring brake is fully released as
outlined in Section 2 on page BR02-50 of this manual. Position the
diaphragm in the bottom recess of the chamber and, with very close
attention taken to assure all mating parts are aligned straight and the
air lines are positioned to mate with the vehicle air supply lines,
replace the service clamp ring.
(6) Re-install the clamp bolts and nuts. Alternately tighten each nut in
5-10 Lbs.Ft. torque increments while constantly rechecking mating
parts alignment. (If re-alignment is required, loosen clamp nuts and
repeat Step (5) above). Firmly tap around circumference of the clamp
ring with a hammer to assure the full seating of the clamp and tighten
the nuts to 30-35 Lbs-Ft. torque.
(7) Apply a non-hardening sealing compound to the hose fittings and re-
install both of the air lines to the chamber, being sure each is mated to
the correct air inlet port according to the markings made earlier. MGM
Brakes recommends the fittings be tightened to 25-30 Lbs.-Ft.
torque into the chamber air inlet ports.
(8) Using the vehicle system air, charge the spring brake with full line
pressure (minimum 100 psi). Spray only soapy water or leak detection
solution (NEVER ANY TYPE OF OIL!) to the air line fittings and
inspect for air leaks. If bubbles appear, tighten fittings slightly, but
not over 30 Lbs.-Ft. torque.
(9) With the spring brake still fully charged with full line pressure, apply
and hold foot brake treadle valve down to charge the service brake
SHTS068020200047
chamber.
IMPORTANT
At this time, remove the vise-grip pliers from the service push-
rod so that the piston can return to a normal position in the
chamber. Now test for air leaks around the circumference of the
service clamp ring by spraying with soapy water or leak detec-
tion solution. If bubbles appear, firmly tap the circumference of
the clamp ring with a hammer and retighten the clamp nuts until
leaks cease. MGM Brakes recommends 30-35 Lbs.-Ft. torque on
the clamp hex nuts.
(10) On all MGM Brakes models fitted with an EXTERNAL BREATHER
TUBE, wipe the open end of the connector tube clean to be sure that
no oil is present, apply a high quality rubber cement to the tube and
re-insert tube into flexible elbow a minimum 1/2 inch engagement.

If the old single unit was not equipped with an EXTERNAL

BREATHER TUBE, drill a 1/2 inch diameter hole 1 inch from the top of
the non-pressure chamber, at a point closest to the center line
between the air ports, but in the upper half of the chamber facing
away from the road surface. Remove any burrs around the hole, install
Apply a new rubber elbow in the non-pressure chamber, wipe the open end
Adhesive of connector tube clean to be sure no oil is present. Apply a high qual-
Here ity rubber cement to the tube and insert the tube into the flexible
elbow with a minimum 1/2 inch engagement.
IMPORTANT
These units must be mounted with the BREATHER TUBE in the
upper half of the non-pressure chamber facing away from the
1/2-inch
road surface and the tube glued or clamped securely into the
Minimum rubber elbows. Failure to comply with these installation instruc-
Engagement tions will void the MGM Brakes Warranty without remedy.
(11) With air pressure exhausted from the service chamber, but with line
pressure still on the spring brake, remove the release nut, washer and
bolt for all "TR" models. Replace these parts in their storage pocket on
the chamber (or in the vehicle tool box if a storage pocket is not on the
SHTS068020200048
chamber) and tighten the nut against the flat washer to 10 Lbs.-Ft.
torque.
 SERVICE BRAKE (FULL AIR BRAKE) BR0257

(12) Replace the end cap properly. Operating these units without the END
CAP securely in place will void the MGM Brakes Warranty without
remedy.

6. REMOVAL AND INSTALLATION INSTRUCTIONS FOR "SERVICE

BRAKE DIAPHRAGM"
(1) Follow all instructions given in Section 5 of this manual and install the
new diaphragm in Step 5-(5). Use only genuine MGM Brakes Engi-
neered replacement diaphragms!
! WARNING
When servicing a 3-inch "long stroke" model brake, be sure to replace
with the correct diaphragm. Installation of a standard (2.50 inch)
stroke diaphragm in a 3-inch "long stroke" chamber could result in
catastrophic failure of the unit.
IMPORTANT: It may not be necessary to disconnect the air lines from the
spring brake during this procedure as long as correct and straight parts
alignment can be obtained during the re-assembly operations.

SHTS068020200049
BR0258 SERVICE BRAKE (FULL AIR BRAKE)

7. CAM BRAKE ADJUSTMENT - ALL MODELS SPRING BRAKE

AND SERVICE BRAKE ACTUATORS.
NOTICE
The last half of an air chamber stroke is less efficient than the first
half. Therefore, the following adjustments are recommended for maxi-
mum efficiency when using manually adjusted slack adjusters.

BRAKES OFF - NOT APPLIED PROPERLY - ADJUSTED BRAKES ON - APPLIED

Angle must always be greater than 90 due to various slack To check brake adjustment, apply 90 to 100 psi air pressure to the
adjuster lengths and installation setups. (Refer to axle or service chamber. Consult the vehicle manufacturer for the correct
OEM manufacturers manual for recommended angle). angle between the slack adjuster arm and push-rod and/or the
push-rod length. This is necessary since different dimensions are
Stroke should be as short as possible with no lining to drum
required for automatic or manual slacks, various slack lengths and
contact.
different slack adjuster manufacturers.
Effective Approx. Maximum B MV/MA
IMPROPERLY ADJUSTED BRAKES ON - APPLIED Type Area Diaphragm Rated Stroke Stroke with Recommended
(Maximum recommended readjustment stroke has been exceeded) (SQ. IN.) O.D. of Chamber Brakes Readjustment
Adjusted Stroke
MGM Brakes Stroke Alert Inches MM Inches MM Inches MM
(Excessive Stroke Warning) 9 9 5.00 125 1.75 45 SHOULD 1.35 35
12 12 5.50 140 1.75 45 BE AS 1.35 35
16 16 6.00 150 2.25 57 SHORT AS 1.75 45
16L 16 6.00 150 2.50 64 POSSIBLE 2.00 51
20 20 6.50 165 2.25 57 WITHOUT 1.75 45
20L 20 6.50 165 2.50 64 LINING TO 2.00 51
24 24 7.00 175 2.25 57 DRUM 1.75 45
24L 24 7.00 175 2.50 64 CONTACT 2.00 51
24LP3 24 7.00 175 3.00 76 2.50 64
30 30 8.00 200 2.50 64 2.00 51
30LP3 30 8.00 200 3.00 76 2.50 64
36 36 9.00 230 3.00 76 2.25 57
SOURCE: MVMA (Motor Vehicle Manufacturers Association)
See chart on right for recommended
readjustment stroke
Note: The push-rod must remain perpendicular to the bottom surface of the
non-pressure chamber (NPC) within 3 zero to full stroke.
SHTS068020200050
SERVICE BRAKE (FULL AIR BRAKE) BR0259

8. RECOMMENDED SPRING BRAKE ACTUATOR DISARMING PRO-

CEDURE
! WARNING
This procedure must be strictly adhered to. never attempt to
remove the spring chamber clamp ring from a double diaphragm
actuator or the spring chamber retaining ring from a piston actu-
ator. both actuators employ a high energy power spring that
could cause serious bodily injury if the spring were suddenly
released due to improper disassembly.
All retired spring brake actuators must be safely disarmed before
they are disposed of to prevent serious personal injury from
accidental sudden release of the high energy spring (as much as
2,700 Lbs. of force) in the parking chamber. To disarm the unit,
remove it from the vehicle following the instructions in Section 3
on page BR02-51 for combination chambers, or Section 5 on
page BR02-54 for single/piggyback chambers. Be sure to release
the brake per Section 2 on page BR02-50 of this manual. Never
attempt to remove the head which contains the power spring.
Observe all safety precautions. Place the unit in a steel *con-
tainer and use an acetylene torch to cut a hole through the head
housing the power spring. Cut completely through at least two
spring coils. The steel container must have openings to expose
the head where it is to be cut with the acetylene torch and it must
be strong enough to prevent parts from hurtling out should the
unit suddenly separate before it is safely disarmed. It is the users
responsibility to ensure the steel container is safe.

*Information concerning a suitable container is available through

your MGM Brakes Representative.
BR0260 SERVICE BRAKE (FULL AIR BRAKE)

PROTECTION VALVE
DATA AND SPECIFICATIONS
EN0680202I200006

Type Spring type

Operating pressure Close 70 PSI

DESCRIPTION
EN0680202C100009

SPRING CAP

PISTON

VALVE
INLET
PORT

DELIVERY
PORT

PR-4

SHTS068020200051
SERVICE BRAKE (FULL AIR BRAKE) BR0261

INSPECTION
EN0680202H200007

1. PREVENTIVE MAINTENANCE
Every 3 months, 900 operating hours or 25,000 miles, whichever if
first, it is recommended that the operation and leakage checks
described in this manual be performed.

2. OPERATING CHECKS
(1) Provide a pressure gauge and drain valve at the supply side and
delivery side of the pressure protection valve being checked.
(2) Build up the air system to full pressure and shut off the engine.
(3) While watching the gauges on the supply and delivery sides of the
valve, slowly begin to exhaust pressure from the delivery side. Note
that both gauges will show pressure loss until the closing pressure of
the pressure protection valve is reached.
The pressure protection valve should close at approximately (5 psi)
the pressure indicated on the valve's label or in the vehicle handbook.
The gauge on the delivery side of the valve should continue to show
loss of pressure while the gauge on the supply side should stop at the
same pressure as the setting of the valve.
(4) (PR-3 only) Build pressure up again and shut off engine. Slowly
exhaust air from the supply side of the PR-3. The gauge on the deliv-
ery side of the valve should remain at the highest pressure previously
attained.

3. LEAKAGE CHECKS
(1) Build up the air system to full pressure and shut off the engine.
(2) Apply a soap solution around the cap of the pressure protection valve.
A one-inch bubble in three seconds or longer is acceptable. PR-3 - No
leakage permissible at bottom of valve.
(3) Drain the air pressure from the delivery side of the pressure protection
valve and disconnect the air line to it.
(4) Apply a soap solution to the delivery port. A one inch bubble in five
seconds or more is acceptable.

4. REMOVING
(1) Block or hold the vehicle by means other than air brakes.
(2) Drain all system reservoirs individually, to 0 psi.
(3) Disconnect and identify (supply and delivery) the air lines leading to
and from the pressure protection valve.
(4) Remove the mounting bolts, if any, that secure the valve.

5. INSTALLING
(1) Re-install the mounting bolts and secure the replacement valve to the
vehicle.
(2) Reconnect the supply delivery air lines to the proper ports of the
replacement valve.

6. GENERAL
After installing a replacement valve, it is recommended that the oper-
ating and leakage checks be performed as outlined in this manual. If
the proper setting cannot be attained by moderate adjustment of the
cap, the valve may have the wrong spring and will have to be
exchanged for the correct valve. The PR-4 is not adjustable.
BR0262 SERVICE BRAKE (FULL AIR BRAKE)

7. WHEN WORKING ON OR AROUND A VEHICLE, THE FOLLOW-

ING GENERAL PRECAUTIONS SHOULD BE OBSERVED AT ALL
TIMES:
! WARNING
Please read and follow these instructions to avoid personal injury or
death.
(1) Park the vehicle on a level surface, apply the parking brakes, and
always block the wheels.
(2) Stop the engine when working around the vehicle.
(3) If the vehicle is equipped with air brakes, make certain to drain the air
pressure from all reservoirs before beginning ANY work on the vehi-
cle.
(4) Following the vehicle manufacturer's recommended procedures,
deactivate the electrical system in a manner that removes all electrical
power from the vehicle.
(5) When working in the engine compartment the engine should be shut
off. Where circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking, heated, or elec-
trically charged components.
(6) Never connect or disconnect a hose or line containing pressure; it
may whip. Never remove a component or plug unless you are certain
all system pressure has been depleted.
(7) Never exceed recommended pressures and always wear safety
glasses.
(8) Do not attempt to install, remove, disassemble or assemble a compo-
nent until you have read and thoroughly understand the recom-
mended procedures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
(9) Use only genuine Bendix replacement parts, components, and kits.
Replacement hardware, tubing, hose, fittings, etc. should be of equiv-
alent size, type, and strength as original equipment and be designed
specifically for such applications and systems.
(10) Components with stripped threads or damaged parts should be
replaced rather than repaired. Repairs requiring machining or welding
should not be attempted unless specifically approved and stated by
the vehicle or component manufacturer.
(11) Prior to returning the vehicle to service, make certain all components
and systems are restored to their proper operating condition.
 SERVICE BRAKE (FULL AIR BRAKE) BR0263

WHEEL BRAKE
DATA AND SPECIFICATIONS
EN0680202I200007

Drum brake with internally expanding, leading-trailing

Type shoes operated by camshaft and automatic slack
adjuster in all wheels.
Brake drum inside diameter Front 15 x 4 in. (381 x 102 mm), 16.5 x 5 in. (419 x 127 mm)
x lining width Rear 16.5 x 7 in. (419 x 178 mm)

Brake drum inside diameter Front 15 x 4 in. (381 x 102 mm)

x lining width
(Low floor type vehicle with
full air brake) Rear 15 x 8.625 in. (381 x 219 mm)
BR0264 SERVICE BRAKE (FULL AIR BRAKE)

DESCRIPTION
EN0680202C100010

HOLD DOWN CLIP (2) CAM BRACKET MOUNTING (4)

(some models) PUSH ROD LOCK NUT (1)
0.500"-13 thread
0.250"-28 thread 0.625"-18 thread
Grade 8 = 90-120 lb-ft (122-163 Nm)
105-135 lb-in (12-15 Nm) 25-50 lb-ft (34-68 Nm)
Grade 5 = 65-100 lb-ft (88-136 Nm)
0.500"-20 thread
0.625"-18 thread
20-30 lb-ft (27-41 Nm)
DUST SHIELD Plain nut = 150-190 lb-ft (203-258 Nm)
MOUNTING (4) or (6) Lock nut = 130-165 lb-ft (176-224 Nm)
(some models)
0.312"-18 thread
12-20 lb-ft (16-27 Nm)
Add camshaft spacing
0.375"-16 thread washers so that slack
Grade 8 = 30-50 lb-ft (41-68 Nm) adjuster is aligned
Grade 5 = 25-35 lb-ft (34-47 Nm)
with air chamber clevis.

ANCHOR PIN
SET SCREW (2)
(some models)
0.375"-16 thread
10 lb-ft (14 Nm)
minimum

ANCHOR PIN (2)

(T brake only)
0.750"-16 thread
185-350 lb-ft (250-474 Nm)

(15 X 4 Q brake only)

325-375 lb-ft (441-509 Nm)
GREASE FITTING (1)
(some models)
BRAKE MOUNTING BOLTS 1/8" dryseal
3-5 lb-ft (4-7 Nm)
Grade 8 bolts with lock nuts and two
hardened washers on each bolt.
Bolt
Size Torque AIR CHAMBER MOUNTING (2)
Add camshaft spacing
7/16"-20 60-75 lb-ft (81-102 Nm)
1/2"-20 85-115 lb-ft (115-156 Nm)
washers to provide no
9/16"-18 130-165 lb-ft (176-224 Nm) more than 0.060" (1.52 mm)
5/8"-18 180-230 lb-ft (244-312 Nm) end play.

SHTS068020200052

Grade 8 Nuts and Hard Flat Washers

Chamber Size 9 12 16 20 24 30 36 Spring Chamber
Bendix 20-30 lb-ft 30-45 lb-ft 45-65 lb-ft 65-85 lb-ft
(27-41 Nm) (41-61 Nm) (61-88 Nm) (88-115 Nm)
Haldex 35-50 lb-ft (48-68 Nm) 70-100 lb-ft (95-136 Nm)
MGM 35-40 lb-ft (48-54 Nm) 133-155 lb-ft (180-210 Nm)
Anchorlok/Haldex 130-150 lb-ft (177-203 Nm)
 SERVICE BRAKE (FULL AIR BRAKE) BR0265

COMPONENT LOCATOR
EN0680202D100006

FRONT

24

23

1
22

10
11 21
2 8 7
20
3
18 19
4

17

15 16
13 14

12
11

9 10

7 8
6
5

SHTS068020200053

1 Shoe and Lining Assembly 13 Cast spider brake

2 Spring shoe retaining 14 Seal chamber bracket
3 Bushing anchor pin 15 Bracket camshaft and chamber
4 Anchor Pin brake shoe 16 Capscrew chamber bracket
5 Camshaft "S" head 17 Fitting grease
6 Washer camhead 18 Washer camshaft (thick)
7 Seal camshaft (grease) 19 Slack Adjuster automatic
8 Bushing camshaft 20 Washer spacing
9 Pin return spring 21 Snap Ring camshaft
10 Roller brake shoe 22 Dust Shield
11 Retainer shoe roller 23 Capscrew dust shield
12 Spring brake shoe return 24 Plug
BR0266 SERVICE BRAKE (FULL AIR BRAKE)

SHTS068020200054
SERVICE BRAKE (FULL AIR BRAKE) BR0267

OVERHAUL
EN0680202H200008

! WARNING
ArvinMeritor Automatic Slack Adjusters (ASA's) should not need
to be manually adjusted in service. ASA's should not have to be
adjusted to correct excessive pushrod stroke. The excessive
stroke may be an indication that a problem exists with the foun-
dation brake, ASA, brake actuator or other system components.
ArvinMeritor recommends troubleshooting the problem, replac-
ing suspect components and then confirming proper brake oper-
ation prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although
should not be a common practice), a service appointment and
full foundation brake, ASA, and other system component inspec-
tion should be conducted as soon as possible to ensure integrity
of the overall brake system.

IMPORTANT POINTS-DISASSEMBLY

1. BEFORE YOU BEGIN

This manual describes the correct service and repair procedures for
Meritor cam brakes. Before you begin procedures:
(1) Read and understand all instructions and procedures before you
begin to service components.
(2) Read and observe all Caution and Warning safety alerts that precede
instructions or procedures you will perform. These alerts help to avoid
damage to components, serious personal injury, or both.
(3) Follow your company's maintenance and service, installation, and
diagnostics guidelines.
(4) Use special tools when required to help avoid serious personal injury
and damage to components.

Safety Alerts, Torque Symbol and Notes

! WARNING A Warning alerts you to an

instruction or procedure that
you must follow exactly to avoid
serious personal injury.

! CAUTION A Caution alerts you to an

instruction or procedure that
you must follow exactly to avoid
damage to components.

NOTICE A Note provides information or

suggestions that help you cor-
rectly service a component.

2. HOW TO ORDER TOOLS, SUPPLIES AND BRAKE CONVERSION

KITS
Call ArvinMeritor's Commercial Vehicle Aftermarket at 888-725-9355
to order tools and supplies specified in this manual. You also can
order the following brake conversion kits.
A kit to convert Q Series cam brake shoes (except models with cast
shoes) to Q Series brakes with "quick change" shoes
A kit to convert standard 16.5-inch Q Series cam brakes to Q PlusTM
cam brakes
BR0268 SERVICE BRAKE (FULL AIR BRAKE)

! WARNING
Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos fibers,
whose long-term effects to health are unknown. You must use
caution when you handle both asbestos and non-asbestos mate-
rials. Refer to page BR02-66 in this manual for hazard summaries
and recommended work practices.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance and service.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
Do not work under a vehicle supported only by jacks. Jacks can
slip or fall over. Serious personal injury and damage to compo-
nents can result.

3. REMOVAL
(1) Wheel Components
a. Park the vehicle on a level surface.
b. Block the wheels to prevent the vehicle from moving.
c. Raise the vehicle, so that the area you will service is off of the
ground. Support the vehicle with safety stands.
! WARNING
Before you service a spring chamber, carefully follow the manufac-
turer's instructions to compress and lock the spring to completely
release the brake. Verify that no air pressure remains in the service
chamber before you proceed. Sudden release of compressed air can
cause serious personal injury and damage to components.
d. If the brake has spring chambers, carefully cage and lock the
spring, so that the spring cannot actuate during assembly.
(2) Automatic Slack Adjuster
For complete maintenance and service information on Meritor's auto-
matic slack adjuster, refer to Automatic Slack Adjuster.
! CAUTION
You must disengage a pull pawl before rotating the manual adjusting
nut, or you will damage the pawl teeth. A damaged pawl will not allow
the slack adjuster to automatically adjust brake clearance. Replace
damaged pawls before putting the vehicle in service.
a. Disengage the pull pawl. Use a screwdriver or equivalent tool to
pry the pull pawl at least 1/32-inch (0.8mm) to disengage the
teeth.
If the slack adjuster has a conventional pawl: Remove the pawl.
PAWL

PRY UP
CONVENTIONAL PULL PAWL
PAWL

SHTS068020200055
 SERVICE BRAKE (FULL AIR BRAKE) BR0269

b. Use a wrench to turn the manual adjusting nut COUNTER-

CLOCKWISE until the brake shoes are fully retracted, and the lin-
ing clears the drum.

! WARNING
When you remove a clevis pin that has a spring, hold the spring with
pliers. The spring can disengage from the clevis with enough force to
cause serious personal injury.
c. Remove both clevis pins, and retainer clips or cotter pins. Move
the slack adjuster away from the clevis.
COUNTERCLOCKWISE
d. Follow the manufacturer's instructions to remove the wheel and
SHTS068020200056
drum from the axle.

(3) Brake Shoes

All Q Plus and Q Series 15-Inch and 16.5-Inch Brakes
1. Push down on the bottom brake shoe. Pull on the cam roller retainer
.

clip to remove the bottom cam roller.

2. Lift the top brake shoe and pull on the cam roller retainer clip to
remove the top cam roller.

SHTS068020200057

3. Lift the bottom shoe to release the tension on the brake shoe return
spring.

SHTS068020200058

4. Rotate the bottom shoe to release the tension on the brake shoe
retainer springs.
5. Remove the shoe retainer springs and the brake shoes.

SHTS068020200059
BR0270 SERVICE BRAKE (FULL AIR BRAKE)

(4) Check Cam-to-Bushing Radial Free Play and Axial End Play
Before you remove the automatic slack adjuster and camshaft, move
the camshaft as shown in figure. Use a feeler gauge to verify that the
cam-to-bushing radial free play and axial end play are within specifi-
cation.
If radial free play movement is less than 0.030-inch (0.76 mm): Do
not replace the bushings and seals.
If radial free play movement exceeds 0.030-inch (0.76 mm):
Replace the bushings and seals.
If axial end play movement exceeds 0.060-inch (1.52 mm):
Remove the snap ring. Add an appropriate number of spacing wash-
ers between the slack adjuster and snap ring to achieve the correct
SHTS068020200060
specification of 0.005-0.060-inch (0.127-1.52 mm).
(5) Remove the Automatic Slack Adjuster and Camshaft
a. Remove the snap ring, washers and spacers from the camshaft.
b. Remove the automatic slack adjuster from the camshaft.
If the slack adjuster has a "quick connect" clevis, and the gap
between the clevis and clevis collar exceeds 0.060-inch (1.52
mm): Remove the clevis from the push rod.
c. Remove the camshaft from the spider. Use the correct size driver
to remove the camshaft bushings from the spider and spider
bracket.
! WARNING
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, and emulsion-
type and petroleum-base cleaners. Read the manufacturer's instruc-
tions before using a solvent cleaner, then carefully follow the instruc-
tions. Also follow the procedures below.
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
You must use hot solution tanks or alkaline solutions correctly.
Read the manufacturer's instructions before using hot solution
tanks and alkaline solutions. Then carefully follow the instruc-
tions.

! CAUTION
Do not use hot solution tanks or water and alkaline solutions to clean
ground or polished parts. Damage to parts can result.
(6) Clean and Dry Parts
Use soap and water to clean non-metal parts. Dry parts immediately
after cleaning with soft, clean paper or cloth, or compressed air.
(7) Corrosion Protection
a. If you assemble parts immediately after you clean them:
Lubricate parts with grease to prevent corrosion. Parts must be
clean and dry before you lubricate them.
b. If you store parts after you clean them: Apply a corrosion-pre-
ventive material. Store parts in a special paper or other material
that prevents corrosion.
 SERVICE BRAKE (FULL AIR BRAKE) BR0271

4. IMPORTANT POINTS-ASSEMBLY
(1) Automatic Slack Adjuster
a. If the slack adjuster has a "quick connect" clevis, check the gap
between the clevis and the collar.
If the gap exceeds 0.060-inch (1.52 mm): Replace the clevis with a
one-piece threaded clevis.
b. Check the clevis pins, clips and bushing in the slack adjuster arm
for wear and damage.
Replace worn or damaged parts. Check the bushing's diameter to
ensure it does not exceed 0.531-inch (13.5 mm).
If the bushing diameter exceeds 0.531-inch (13.5 mm): Replace
the bushing.
! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
adjust brake clearance. Replace damaged pawls before putting the
vehicle in service.
NOTICE
When you service an automatic slack adjuster with a conventional
pawl, replace the conventional pawl with a pull pawl.
c. Disengage the pull pawl. Use a screwdriver or equivalent tool to
pry the pull pawl at least 1/32-inch (0.8mm) to disengage the
teeth.
PAWL If the slack adjuster has a conventional pawl: Remove the pawl.
! CAUTION
PRY UP Only turn the adjusting nut counterclockwise when you check gear
CONVENTIONAL PULL PAWL torque on an automatic slack adjuster. If you turn the adjusting nut
PAWL incorrectly, you will damage the pawl teeth. A damaged pawl will pre-
vent the slack adjuster from automatically adjusting clearance
between the linings and drum. Damage to components can result.

SHTS068020200061

d. Use a lb-in torque wrench and turn the adjusting nut COUNTER-
CLOCKWISE to rotate the gear 360 degrees (22 turns of the
22 TURNS wrench) as you read the torque scale on the wrench. The value
should remain at less than 25 lb-in (2.83 Nm) as you rotate the
gear.
If the torque value remains less than 25 lb-in (2.8 Nm) as you
rotate the gear: The slack adjuster is operating correctly.
If the torque value exceeds 25 lb-in (2.8 Nm) as you rotate the
ROTATE GEAR 360 gear: The slack adjuster is not operating correctly.
Disassemble the slack adjuster. Check that it's assembled correctly.
Check that parts are aligned correctly.
SHTS068020200062 e. Re-engage the pull pawl. Remove the screwdriver or equivalent
tool. The pull pawl will re-engage automatically.
If the slack adjuster has a conventional pawl: Install the pawl
assembly into the housing. Tighten the capscrew to 12-17 lb-ft (16-23
Nm).
NOTICE
If necessary, install a camshaft into the slack adjuster gear to mini-
mize grease flow through the gear holes.
f. Use a grease gun to apply Meritor lubricant specification O-616-
A, O-692 or O-645 to the slack adjuster grease fitting, until grease
flows from around the camshaft splines and pawl assembly.
BR0272 SERVICE BRAKE (FULL AIR BRAKE)

Automatic Slack Adjuster Grease Specifications

Components Meritor NLGI Grade Grease Type Outside Temperature

Specification

Automatic Slack Adjuster O-616-A 1 Clay Base Down to -40F (-40C)

O-692 1 and 2 Lithium Base Down to -40F (-40C)

O-645 2 Synthetic Oil, Clay Down to -65F (-54C)

Base

Clevis Pins Any of Above See Above See Above See Above

O-637 1-1/2 Calcium Base Refer to the grease manu-

facturer's specifications for
O-641 Anti-Seize the temperature service lim-
its.

*Do not mix Meritor grease specification O-637 (part number 2297-U-4571), a calcium-base, rust-preventive grease,
with other greases.

(2) Camshafts
NOTICE
Install new camshaft bushings and seals whenever you install a new
camshaft.
a. Tighten all spider bolts to the correct torque.
b. Use a seal driver to install new camshaft seals and new bushings
into the cast spider and camshaft bracket.

Bolt
Size Torque
7/16"-20 60-75 lb-ft 81-102 Nm
1/2"-20 85-115 lb-ft 115-156 Nm
9/16"-18 130-165 lb-ft 176-224 Nm
5/8"-18 180-230 lb-ft 244-312 Nm

SHTS068020200063

If the brake has a stamped spider: Install both bushings into the
bracket. Install the seals with the seal lips toward the slack adjuster.

SHTS068020200064
 SERVICE BRAKE (FULL AIR BRAKE) BR0273

! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.

SEAL SEAL
LIP LIP
SPIDER
CAMSHAFT
BRACKET

SHTS068020200065

! WARNING
Do not use the straight-center bar shoe return spring with the Q Plus
camshaft. The shoe spring can interfere with the camshaft and affect
braking performance. Serious personal injury and damage to compo-
nents can result.

! CAUTION
Only install a Q Plus camshaft in a Q Plus brake. A Q Series hammer-
claw camshaft will not provide enough clearance between the brake
shoe and the brake drum. Brake drag and damage to components can
result.
To install a new brake drum so that it fits correctly over a Q Plus brake
shoe, you must install a Q Plus camshaft to prevent damage to com-
ponents.

5. INSTALLATION
(1) Camshaft
a. Install the cam head thrust washer onto the camshaft. Apply Mer-
itor specification O-617-A or O-617-B grease to the camshaft
bushings and journals.
b. Install the camshaft through the spider and bracket so that the
camshaft turns freely by hand.

SHTS068020200066

(2) Shoe Return Spring

Install the new offset shoe return spring with the open end of the
spring hooks toward the camshaft.

Q PLUSTM
CAM
NEW INSTALLATION
OFFSET RETURN
Install the spring SPRING
with the open end of (MERITOR PART
the hook TOWARD the 2258-Y-1273)
cam head.

SHTS068020200067
BR0274 SERVICE BRAKE (FULL AIR BRAKE)

(3) Automatic Slack Adjuster onto the Camshaft

a. Check the camshaft and bushings and seals for wear and corro-
sion. Turn the camshaft by hand to check for smooth operation.
Repair or replace parts as required.
b. Apply the service brake and spring brake several times. Check
that the chamber return spring retracts the push rod quickly and
completely. If necessary, replace the return spring or the air
chamber.
c. Verify that the new automatic slack adjuster is the same length as
the one you are replacing. Refer to Table below.

Chamber and Automatic Slack Adjuster Sizes

Length of Slack Adjuster Size of Chamber (Square Inches)

(Inches)

5 9*, 12*, 16, 20, 24, 30

5-1/2 9*, 12*, 16, 20, 24, 30, 36

6 24, 30, 36

6-1/2 30, 36

* Use an auxiliary spring on slack adjusters used with these size cham-
bers. A size 9 or 12 chamber return spring cannot supply enough spring
tension to completely retract the slack adjuster.

! WARNING
Before you service a spring chamber, carefully follow the manufac-
turer's instructions to compress and lock the spring to completely
release the brake. Verify that no air pressure remains in the service
chamber before you proceed. Sudden release of compressed air can
cause serious personal injury and damage to components.
d. If the vehicle has spring brakes, follow the chamber manufac-
turer's instructions to compress and lock springs to completely
release the brakes. Verify that no air pressure remains in the ser-
vice chambers.
! CAUTION
Most Meritor automatic slack adjusters manufactured after January
1990 have lubrication holes in the gear splines. Do not operate the
actuator rod before you install the slack adjuster. Lubricant can pump
through the holes and onto the splines. Damage to components can
result.
e. If the automatic slack adjuster gear has a 10-tooth spline, apply
Meritor specification O-637 (part number 2297-U-4571) anti-seize
compound, or equivalent. This specification is a corrosion-control
grease. Do not mix this grease with other greases.
NOTICE
Install the slack adjuster so that you can remove a conventional pawl
or disengage a pull pawl when you adjust the brake.
f. Install the slack adjuster onto the camshaft. Position the slack
adjuster so that you can access the pawl when you adjust the
brake.
g. Verify that camshaft axial end play is 0.005-0.060-inch (0.127-
1.52 mm).
If axial end play exceeds 0.060-inch (1.52 mm): Remove the snap
ring. Add an appropriate number of spacing washers to achieve the
correct specification.
h. Install the clevis onto the push rod.
 SERVICE BRAKE (FULL AIR BRAKE) BR0275

! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
ALIGN adjust brake clearance. Replace damaged pawls before putting the
HOLES vehicle in service.
Disengage a
pull pawl or i. Disengage the pull pawl or remove a conventional pawl. Turn the
remove a manual adjusting nut to align the holes in the slack adjuster arm
conventional and clevis.
pawl.

SHTS068020200068

(4) Welded Clevis

a. Check the clevis position. Apply Meritor specification O-637 (part
number 2297-U-4571) anti-seize compound or equivalent to the
large and small clevis pins. This specification is a corrosion-con-
trol grease. Do not mix this grease with other greases.
! CAUTION
Always replace used clevis pin retainer clips with new ones when you
service an automatic slack adjuster or chamber. Do not reuse retainer
clips. Discard used clips. When you remove a retainer clip, it can bend
or "gap apart" and lose retention. Damage to components can result.
NOTICE
Meritor recommends that you replace cotter pins with clevis retainer
clips at assembly.
b. Install new clevis pin retainer clips or cotter pins to secure the cle-
vis pins. Retainer clips must be fully installed and positioned
around the side of the clevis pin.

CLEVIS LARGE CLEVIS PIN

AND RETAINER CLIP LARGE CLEVIS PIN
RETAINER CLIP
ACTUATOR MERITOR PART
ROD 2257-D-1174

SMALL CLEVIS PIN

RETAINER CLIP
MERITOR PART
SMALL CLEVIS PIN 2257-C-1173
AND RETAINER CLIP

The clevis pin retainer

clips must be fully
installed and positioned
around the side
of clevis pin.

SHTS068020200069

(5) Threaded Clevis

Adjust the Clevis Position on the Chamber Push Rod

Automatic Slack Adjuster Template Method for Standard Stroke

Chambers Only
BR0276 SERVICE BRAKE (FULL AIR BRAKE)

! WARNING
Meritor provides a slack adjuster template for truck and tractor,
trailer, and coach drum brakes. These templates are not inter-
changeable. You must use the correct template when you install
the clevis.
If you use the wrong template, the automatic slack adjuster will
not adjust the brakes correctly. Under-adjustment can increase
stopping distances. Over-adjustment can cause the linings to
drag. Serious personal injury and damage to components can
result.
a. Install the large clevis pin through the large clevis pin hole in the
correct slack adjuster template for the drum brake you're servic-
ing.
b. Select the hole at the small end of the template that matches the
slack adjuster arm length. Position and hold the hole on the cen-
ter of the camshaft.

Color of Part
Template Number Applications
Dark brown TP-4786 Truck or tractor drum brake
Tan TP-4787 Trailer drum brake
White TP-4781 Coach drum brake

Measure slack
adjuster
arm length.

CAMSHAFT CENTER

SHTS068020200070

c. Look through the small clevis pin slot on the template to see if the
small clevis hole completely aligns within the slot.
THREADED
CLEVIS If the small clevis hole doesn't align within the slot: Adjust the cle-
vis until you can see the small clevis pin hole within the slot.

SLOT

CAMSHAFT END

SHTS068020200071
 SERVICE BRAKE (FULL AIR BRAKE) BR0277

d. Verify that thread engagement between the clevis and push rod is
1/2-5/8-inch (12.7-15.9 mm).
MINIMUM 1/2"
e. Verify that the push rod does not extend through the clevis more
than 1/8-inch (12.7 mm).
If the push rod extends through the clevis more than 1/8-inch
THREADED
CLEVIS
(12.7 mm): Cut the push rod, or install a new air chamber and push
MAXIMUM 1/8" rod.
f. Tighten the jam nut against the clevis to the torque specification.

Jam Nut Torque Specifications

SHTS068020200072 Threads Torque

1/2-20 20-30 lb-ft (27-41 Nm)

5/8-18 35-50 lb-ft (48-68 Nm)

(6) Brake Slack Adjuster Position (BSAP) Method for Standard

Stroke and Long Stroke Chambers
When you install the slack adjuster, verify that the BSAP chamber
dimension matches the table in figure.
3.750" AND 3.812"
BRACKET OFFSET
BSAP 0.125"

SLACK
LENGTH
5.00"
5.50"
6.00"
6.50"

Standard Stroke Long Stroke

Chamber Clevis Chamber Clevis
(1.38") 1.38" (1.30") 1.30"
Slack
Adjuster
Size
5.00" 2.75" 2.25"
5.50" 2.75" 2.25"
6.00" 2.75" 2.25"
6.50" 2.62" 2.25"
0.125" Tolerance. You must use the correct clevis with
the correct chamber type.
Correct positions of the automatic slack adjuster are
3.750-inch and 3.812-inch offsets only. For other
bracket offsets, refer to the vehicle manufacturer's
specifications.

SHTS068020200073

(7) Brake Shoes

NOTICE
Meritor recommends that you replace springs, rollers, anchor pins
and cam bushings at each reline.
Q Plus and Q Series 16.5-Inch Brakes
a. Place the upper brake shoe into position on the top anchor pin.
Hold the lower brake shoe on the bottom anchor pin. Install two
new brake shoe retaining springs.

SHTS068020200074
BR0278 SERVICE BRAKE (FULL AIR BRAKE)

b. Rotate the lower brake shoe forward. Install a new brake shoe
return spring with the open end of the spring hooks toward the
camshaft.

SHTS068020200075

c. Pull each brake shoe away from the camshaft to enable you to
install the camshaft roller and roller retainer. Press the retainer
"ears" to fit into the retainer between the brake shoe webs.

WEBS
SQUEEZE
"EARS"

SHTS068020200076

d. Push the camshaft roller retainer into the brake shoe until the
"ears" lock into the shoe web holes.

WEB
HOLE
PUSH

SHTS068020200077

e. Use Meritor specification grease O-617-A or O-617-B to lubricate

Q PLUS AND P SERIES the camshaft roller pin and anchor pin.
Lubricate Lubricate
here only. entirely.

CAM
ANCHOR PIN
Do not
lubricate here.
CAM ROLLER PIN
SHTS068020200078
 SERVICE BRAKE (FULL AIR BRAKE) BR0279

Cam Brake Grease Specifications

Components Meritor NLGI Grade Grease Type Outside Temperature

Specification

Retainer Clips O-616-A 1 Clay Base Down to -40F (-40C)

Anchor Pins
O-617-A 1 Lithium 12-Hydroxy Refer to the grease manufac-
Rollers (Journals Only) or Stearate or Lithium Com- turer's specifications for the tem-
Camshaft Bushings O-617-B 2 plex perature service limits.

O-645 2 Synthetic Oil, Clay Base Down to -65F (-54C)

O-692 1 and 2 Lithium Base Down to -40F (-40C)

Camshaft Splines Any of Above See Above See Above See Above

O-637* 1-1/2 Calcium Base Refer to the grease manufac-

turer's specifications for the tem-
O-641 Anti-Seize perature service limits.

*Do not mix Meritor grease specification O-637 (part number 2297-U-4571), a calcium-base, rust-preventive grease,
with other greases.
BR0280 SERVICE BRAKE (FULL AIR BRAKE)

6. ADJUST THE BRAKES

When you perform preventive maintenance procedures on an in-ser-
vice brake, check both the free stroke and adjusted chamber stroke.
Refer to Commercial Vehicle Safety Alliance (CVSA) Guidelines to
Measure Push Rod Travel (Adjusted Chamber Stroke) in this section.

Free stroke sets the clearance between the linings and drum. The in-
service free stroke may be slightly longer than 1/2-5.8-inch (12.7-15.9
mm) specified in this procedure. This is not a concern if the adjusted
chamber stroke is within the limits shown in Table on page BR02-82.
(1) Measure Free Stroke
! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
adjust brake clearance. Replace damaged pawls before putting the
vehicle in service.
a. Disengage a pull pawl. Use a screwdriver or equivalent tool to pry
the pull pawl at least 1/32-inch to disengage the teeth.
If the slack adjuster has a conventional pawl: Remove the pawl.
b. Use a wrench to turn the manual adjusting nut COUNTER-
CLOCKWISE until the brake shoes are fully retracted, and the lin-
ing clears the drum. Then back-off the adjusting nut one-half turn
in the opposite direction.

DISENGAGE
PAWL

SHTS068020200079

c. Measure the distance from the center of the large clevis pin to the
MEASURE FREE STROKE bottom of the air chamber while the brake is released. The mea-
surement you obtain is "X" in figure.
Y
X d. Use a pry bar to move the slack adjuster and position the linings
against the drum (brakes applied). Measure the same distance
again while the brakes are applied. The measurement you obtain
FREE STROKE = Y" MINUS X is "Y" in figure.
Drum brake free stroke must be
1/2-5/8 (12.7-15.9 mm). ! CAUTION
Disc brake free stroke must be Do not set free stroke shorter than 1/2-5/8-inch (12.7-15.9 mm) for
3/4-7/8 (19.1-22.2 mm). drum brakes. If the measurement is too short, linings can drag. Dam-
age to components can result.
SHTS068020200080
e. Subtract "X" from "Y" to obtain the in-service free stroke. The
measurement must be 1/2-5/8-inch (12.7-15.9 mm) for drum
brakes.
If the free stroke measurement is not within specification: Turn
the adjusting nut COUNTERCLOCKWISE 1/8 turn to adjust free
stroke. Follow the steps above to check free stroke again, until the
measurement is within specification.
 SERVICE BRAKE (FULL AIR BRAKE) BR0281

f. Re-engage the pull pawl by removing the screwdriver or equiva-

lent tool. The pull pawl will re-engage automatically.
Disengage
pull pawl If the slack adjuster has a conventional pawl: Install the pawl
or remove
assembly into the housing. Tighten the capscrew to 12-17 lb-ft (16-23
conventional
pawl. Nm).
SHORTEN g. If the brakes have spring chambers, carefully release the springs.
STROKE
LENGTHEN
Test the vehicle before you return it to service.
STROKE

SHTS068020200081

7. COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA) GUIDE-

LINES
(1) Measure Push Rod Travel (Adjusted Chamber Stroke)
Use the following procedure to check in-service push rod travel
(adjusted chamber stroke) on truck and tractor brakes.
NOTICE
Hold the ruler parallel to the push rod and measure as carefully as
possible. A measurement error can affect CVSA re-adjustment limits.
CVSA states that "any brake 1/4-inch or more past the re-adjustment
limit, or any two brakes less than 1/4-inch beyond the re-adjustment
limit, will be cause for rejection."
a. The engine must be OFF. If the brake has a spring chamber, fol-
low the manufacturer's instructions to release the spring. Verify
that no air pressure remains in the service section of the cham-
ber.
b. Verify that pressure is 100 psi (689 kPa) in the air tanks. Deter-
mine the size and type of brake chambers on the vehicle.
c. With the brakes released, mark the push rod where it exits the
chamber. Measure and record the distance. Have another person
apply and hold the brakes on full application.
d. Measure push rod travel (adjusted chamber stroke) from where
the push rod exits the brake chamber to your mark on the push
Mark push rod here
to measure stroke. rod. Measure and record the distance.
e. Subtract the measurement you recorded in Step c. from the mea-
surement you recorded in Step d. The difference is push rod travel
(adjusted chamber stroke).
Spring brakes f. Refer to Table on page BR02-82 to verify that the stroke length is
released
correct for the size and type of air chambers on the vehicle.
Service brakes
not applied If push rod travel (adjusted chamber stroke) is greater than the
maximum stroke shown in on page BR02-82: Inspect the slack
STROKE adjuster and replace it, if necessary.
100 psi (689 kPa) in air
tank engine OFF

Spring brakes
released
Service brakes
applied

SHTS068020200082
BR0282 SERVICE BRAKE (FULL AIR BRAKE)

"Standard Stroke" Clamp-Type Brake Chamber Data

Type Outside Diameter Brake Adjustment Limit (inches)

(inches)

6 4-1/2 1-1/4

9 5-1/4 1-3/8

12 5-4/16 1-3/8

16 6-3/8 1-3/4 As short as possible

without lining to drum
20 6-25/32 1-3/4 contact
24 7-7/32 1-3/4

30 8-3/32 2

36 9 2-1/4

"Long Stroke" Clamp-Type Brake Chamber Data

Type Outside Diameter Brake Adjustment Limit (inches)

(inches)

16 6-3/8 2.0

20 6-25/32 2.0
As short as possible
24 7-7/32 2.0 without lining to drum
contact
24* 7-7/32 2.5

30 8-3/32 2.5

* For 3" maximum stroke type 24 chambers.

(2) Alternate Method to Measure Push Rod Travel (Adjusted Chamber

Stroke)
Use the CVSA procedure, except in Steps c and d, measure the dis-
tance from the bottom of the air chamber to the center of the large cle-
vis pin on each of the brakes.
(3) CVSA North American Out-of-Service Criteria Reference Tables
Information contained in the following tables is for reference only. Con-
sult the CVSA's Out-of-Service Criteria Handbook for North American
Standards, Appendix A. Visit their website at http://64.35.82.7/ to
order the handbook.

8. IMPORTANT INFORMATION ON LININGS AND PRIMARY SHOE

TANDEM AXLES FRONT AXLE LOCATIONS
(1) Use the Correct Lining Material
Use the lining material specified by the vehicle manufacturer. This will
help to ensure that the brakes perform correctly and meet Department
of Transportation (DOT) performance regulations.

Also note that the drums and linings on a front axle can be different
than drums and linings on a rear axle.
Both wheel ends of each axle must (2) Single Axles
have identical drums and lining. Always reline both wheels of a single axle at the same time.
SHTS068020200083
Always install the same linings and drums on both wheels of a single
axle.
 SERVICE BRAKE (FULL AIR BRAKE) BR0283

(3) Combination Friction Linings

! CAUTION
When you install combination friction linings, you must install the pri-
mary lining on the primary brake shoe. If you install combination fric-
tion linings incorrectly, damage to components will result. Carefully
follow instructions included with the replacement linings.
You can combine brake linings, which means that the linings you
install on the primary shoe will have a different friction rating than the
linings you install on the secondary shoe.

However, you must install the primary lining on the primary shoe.
Carefully follow the instructions included with the replacement combi-
nation linings.
(4) Primary Shoe Locations
RIGHT WHEEL ROTATION The first shoe past the camshaft in the direction of wheel rotation is
WHEEL ROTATION
the primary shoe. The primary shoe can be either at the top or bottom
WHEEL ROTATION
position, depending on the location of the camshaft.

If the camshaft is behind the axle, the top shoe is the primary shoe.

If the cam is in front of the axle, the top shoe is the primary shoe.

CAM BEHIND AXLE CAM IN FRONT OF AXLE

LEFT WHEEL ROTATION

WHEEL ROTATION WHEEL ROTATION

CAM IN FRONT OF AXLE CAM BEHIND AXLE

SHTS068020200084

9. BEFORE YOU RETURN THE VEHICLE TO SERVICE

(1) Check the complete air system for worn hoses and connectors. With
air pressure at 100 psi (689 kPa), brakes released and engine off, loss
of tractor air pressure must not exceed two psi a minute. Total tractor
and trailer loss must not exceed three psi per minute.
(2) Check to see that the air compressor drive belt is tight. Air system
pressure must rise to approximately 100 psi (689 kPa) in two minutes.
(3) The governor must be checked and set to the specifications supplied
by the vehicle manufacturer.
(4) Both the tractor and trailer air systems must match the specifications
supplied by the vehicle manufacturer.
BR0284 SERVICE BRAKE (FULL AIR BRAKE)

(5) Both wheel ends of each axle must have the same linings and drums.
TANDEM AXLES FRONT AXLE All four wheel ends of tandem axles also must have the same linings
and drums. It is not necessary for the front axle brakes to be the same
as the rear driving axle brakes.
(6) Always follow the specifications supplied by the vehicle manufacturer
for the correct lining to be used. Vehicle brake systems must have the
correct friction material and these requirements can change from
vehicle to vehicle.
(7) The return springs must retract the shoes completely when the brakes
Both wheel ends of each axle must are released. Replace the return springs each time the brakes are
have identical drums and lining. relined. The spring brakes must retract completely when they are
SHTS068020200085 released.

(8) The air chamber area multiplied by the length of the automatic slack
adjuster is called the "AL" factor. This number must be equal for both
ends of a single axle and all four ends of a tandem axle.

"A"

"L"

"AL" FACTOR = A x L
A = AIR CHAMBER AREA
L = LENGTH OF SLACK ADJUSTER
SHTS068020200086

INSPECTION AND REPAIR

EN0680202H300004

1. INSPECT PARTS
(1) Check the spider for expanded anchor pin holes and for cracks.
Replace damaged spiders and anchor pin bushings.
(2) Check the camshaft bracket for broken welds, cracks and correct
alignment. Replace damaged brackets.
(3) Check anchor pins for corrosion and wear. Replace worn or damaged
anchor pins.
(4) Check brake shoes for rust, expanded rivet holes, broken welds and
correct alignment. Replace a shoe with any of the above conditions.

2. 16.5-INCH BRAKE SHOES ONLY

Anchor pin holes must not exceed 1.009-inches (25.63 mm) in diame-
ter. The distance from the center of the anchor pin hole to the center
of the roller hole must not exceed 12.779-inches (32.46 cm). Replace
brake shoes with measurements that do not meet specifications.
(1) Check the camshaft for cracks, wear and corrosion. Check the cam
head, bearing journals and splines. Replace worn or damaged cam-
shafts.
(2) Inspect the large and small clevis pins for wear or damage. Replace
worn or damaged parts.
! CAUTION
Always replace used clevis pin retainer clips with new ones when you
service an automatic slack adjuster or chamber. Do not reuse retainer
clips. Discard used clips. When you remove a retainer clip, it can bend
or "gap apart" and lose retention. damage to components can result.
 SERVICE BRAKE (FULL AIR BRAKE) BR0285

NOTICE
If you remove cotter pins from a slack adjuster during maintenance
and service procedures, Meritor recommends that you install clevis
pin retainer clips at assembly.
(3) Inspect clevis pin retainer clips or cotter pins for wear or damage.
Replace worn or damaged retainer clips or cotter pins. Do not reuse
clevis pin retainer clips. Always replace used retainer clips with new
ones. Discard used clips.
! WARNING
Do not operate the vehicle with the brake drum worn or machined
beyond the discard dimension indicated on the drum. The brake sys-
tem may not operate correctly and damage to components and seri-
ous personal injury can result.
(4) Use the following procedure to inspect the brake drums.
a. Check the brake drums for cracks, severe heat checking, heat
spotting, scoring, pitting and distortion. Replace drums as
required. Do not turn or rebore brake drums, which decreases the
strength and heat capacity of the drum.
b. Measure the inside diameter of the drum in several locations with
a drum caliper or internal micrometer. Replace the drum if the
diameter exceeds the specifications supplied by the drum manu-
facturer.
(5) Check dust shields for wear and damage. Repair or replace worn or
damaged parts as necessary.
SHTS068020200087
3. RELINE THE BRAKES
! CAUTION
Reline the brakes when the lining thickness is 0.25-inch (6.3 mm) at
the thinnest point. The rivets or bolts must not touch the drum. Dam-
age to components will result.
Meritor recommends that you replace springs, rollers, camshaft bush-
ings and anchor pins at each reline.

Reline the brake when the lining thickness is 0.25-inch (6.3 mm) at
the thinnest point.

Replace shoe retainer springs, check the drum, and perform a major
inspection when you reline the brakes.
BR0286 SERVICE BRAKE (FULL AIR BRAKE)

AUTOMATIC SLACK ADJUSTER

DESCRIPTION
EN0680202C100011

PUSH LARGE
ROD CLEVIS
PIN LARGE CLEVIS PIN
BRAKE AIR CLEVIS RETAINER CLIP
CHAMBER
SMALL CLEVIS PIN
RETAINER CLIP

SMALL CLEVIS PIN

JAM ACTUATOR ROD

NUT
BOOT
COLLAR
BOOT RETAINING
HOUSING CLAMP

PISTON
ROLLER (PIN) RETAINING RING

ACTUATOR ACTUATOR PISTON

(ADJUSTING SLEEVE)

PULL PAWL ASSEMBLY

Correct position for "unhanded" design.
Shown 90 out of position for handed design.
GEAR

GASKET

WORM

GREASE FITTING WORM RETAINING

RING

GEAR RETAINER/SEAL WORM GREASE SEAL

MANUAL ADJUSTING
NUT (END OF WORM)

SHTS068020200088
 SERVICE BRAKE (FULL AIR BRAKE) BR0287

DIAGNOSTICS
EN0680202F300002

Symptom Possible Causes Corrective Actions

Adjusted stroke is too long. The slack adjuster part number is
Check with WD or OEM.
No adjustment. incorrect.
Use correct template or BSAP setting
The clevis angle is incorrect.
to install clevis correctly.
Excessive wear exists between the
clevis and collar (more than 0.060" Replace with threaded clevis.
[1.52 mm]).
The jam nut at the clevis is loose. Tighten to specification.
There is a worn clevis pin bushing in
slack arm (ID larger than 0.53" [13.46 Replace bushing.
mm]).
There is a weak or damaged air
chamber spring. Spring force must
Replace return spring or air chamber.
be at least 32 lb (142.4 N) at first push
rod movement.
The spring brake does not retract
Repair or replace spring brake.
fully.
There are worn or damaged teeth on
Replace pawl or actuator.
the pawl or actuator.
High torque is required to rotate
worm when slack is removed from
vehicle.
In service slack maximum worm Rebuild or replace slack adjuster.
torque: 45 lb-in (5.09 Nm)
New or rebuilt slack maximum worm
torque: 25 lb-in (2.83 Nm)
Excessive looseness exists between
Replace powershaft, gear or auto-
the splines of the camshaft and the
matic slack adjuster as needed.
slack adjuster gear.
A cam brake has worn components
Replace components.
(cam bushing, for example).
Adjusted stroke is too short. OEM replacement linings are not
Linings drag. installed.
Use Meritor-approved linings.
Linings exhibit excessive swell or
growth.
The slack adjuster part number is
Check with WD or OEM.
incorrect.
Use correct template to install clevis
The clevis angle is incorrect.
correctly.
The jam nut at the clevis is loose. Tighten to specification.
The spring brake does not retract
Repair or replace spring brake.
fully.
The manual adjustment is incorrect. Adjust brake.
Poor contact exists between the lin-
ings and the drum. The drum is out- Repair or replace drums or linings.
of-round.
Brake temperature is not even. Correct brake balance.
BR0288 SERVICE BRAKE (FULL AIR BRAKE)

COMPONENT LOCATOR
EN0680202D100007

BOOT
RETAINING BOOT
CLAMP SMALL
CLEVIS PIN
ACTUATOR ROD
PISTON RETAINING
LARGE RING ACTUATOR
CLEVIS PIN ROLLER (PIN) ASSEMBLY
RETAINER CLIP
ACTUATOR PISTON

ACTUATOR
(ADJUSTING SLEEVE)
SMALL
LARGE CLEVIS PIN
CLEVIS PIN RETAINER
CLIP HOUSING
STRAIGHT
OR OFFSET
CLEVIS
WORM GEAR
BUSHING
GASKET MANUAL
ADJUSTING
NUT (END
PULL PAWL ASSEMBLY OF WORM)
(Replaces all previous pawl assemblies.)
WORM
RETAINING
RING
FACE WORM
NOTE: Parts shown in this box are SEAL GREASE
not serviceable or interchangeable SEAL
with parts from earlier models. GEAR
GREASE
RETAINER/SEAL FITTING

SHTS068020200089

OFFSET CLEVIS FOR FRONT AXLE SLACK ADJUSTER

OFFSET CLEVIS CLEVIS

LARGE COTTER COLLAR
CLEVIS PIN SPRING
PIN

Use with
type 9 and 12
air chambers. LARGE
CLEVIS
PIN

ACTUATOR ROD
SPRING SLACK
ADJUSTER
SMALL ARM
CLEVIS PIN

SHTS068020200090
 SERVICE BRAKE (FULL AIR BRAKE) BR0289

1. "QUICK CONNECT" CLEVIS

Some models of Meritor's automatic slack adjuster have a "Quick
CLEVIS Connect" clevis.
A "Quick Connect" clevis is a three-piece assembly that cannot be
separated after it is assembled.
RETAINING
The collar has a threaded hole for the push rod.
RING GROOVE A "Quick Connect" clevis can be straight or offset. Use an offset clevis
RETAINING RING when more clearance is necessary between the air chamber and the
"QUICK CONNECT" tire on the front axle.
COLLAR
THREADS
SHTS068020200091

2. ONE-PIECE THREADED CLEVIS

OFFSET Most of Meritor's automatic slack adjusters, including the factory-
CLEVIS installed slack adjusters on the new Q PlusTMLX500 and MX500 cam
brakes, have a one-piece threaded clevis.
The clevis has a threaded hole for the push rod.
The one-piece threaded clevis can be straight or offset.
STRAIGHT All service replacement automatic slack adjusters have one-piece
CLEVIS threaded clevises.

This publication provides maintenance and service procedures for

THREADS Meritor's automatic slack adjuster. The information contained in this
SHTS068020200092
publication was current at the time of printing and is subject to revision
without notice or liability.
(1) You must understand all procedures and instructions before you begin
maintenance and service procedures.
(2) You must follow your company's maintenance and service guidelines.
(3) You must use special tools, when required, to avoid serious personal
injury and damage to components.

Meritor uses the following notations to alert the user of possible safety
issues and to provide information that will help to prevent damage to
equipment and components.

! WARNING A WARNING indicates a proce-

dure that you must follow
exactly to avoid serious per-
sonal injury.

! CAUTION A CAUTION indicates a procedure

that you must follow exactly to
avoid damaging equipment or
components. Serious personal
injury can also occur.

NOTICE A NOTICE indicates an operation,

procedure or instruction that is
important for proper service.
A NOTICE can also supply infor-
mation that will help to make ser-
vice quicker and easier.
BR0290 SERVICE BRAKE (FULL AIR BRAKE)

OVERHAUL
EN0680202H200009

! WARNING
ArvinMeritor Automatic Slack Adjusters (ASA's) should not need
to be manually adjusted in service. ASA's should not have to be
adjusted to correct excessive pushrod stroke. The excessive
stroke may be an indication that a problem exists with the foun-
dation brake, ASA, brake actuator or other system components.
ArvinMeritor recommends troubleshooting the problem, replac-
ing suspect components and then confirming proper brake oper-
ation prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although
should not be a common practice), a service appointment and
full foundation brake, ASA, and other system component inspec-
tion should be conducted as soon as possible to ensure integrity
of the overall brake system.

IMPORTANT POINTS-DISASSEMBLY

1. REMOVAL
! WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
When you work on a spring chamber, carefully follow the service
instructions of the chamber manufacturer. Sudden release of a
compressed spring can cause serious personal injury.
Block the wheels to prevent the vehicle from moving. Support
the vehicle with safety stands. Do not work under a vehicle sup-
ported only by jacks. Jacks can slip and fall over. Serious per-
sonal injury can result.
(1) If the brake has a spring brake, compress and lock the spring, so that
the brake is released completely. Check that no air pressure remains
in the service half of the air chamber.
(2) If it is necessary to raise the vehicle, use a jack and support the vehi-
cle with safety stands.
! WARNING
When you remove a clevis pin that has a spring, hold the spring with
pliers. The spring can disengage from the clevis with enough force to
cause serious personal injury.
(3) Remove both clevis pins.
(4) Remove a conventional pawl or disengage a pull pawl: Use a
screwdriver or equivalent tool to lift the button of a pull pawl assembly
at least 1/32-inch from the actuator.
! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
adjust brake clearance. Replace damaged pawls before putting the
vehicle in service.
 SERVICE BRAKE (FULL AIR BRAKE) BR0291

(5) Use a wrench to turn the manual adjusting nut in the direction shown
in figure. Move the slack adjuster away from the clevis.
(6) Remove the snap ring and washers from the camshaft. Remove the
slack adjuster from the camshaft.
(7) Remove the clevis from the push rod if the gap between the clevis and
the collar of a "Quick Connect" clevis exceeds 0.060-inch (1.52 mm).
You do not have to remove the clevis if it is in good condition.

SHTS068020200093

2. DISASSEMBLY
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.
(1) Cut the clamp and remove it from the boot.
Use a new clamp and boot when you assemble the slack adjuster.
(2) Remove the boot from the housing. Pull the actuator assembly from
the housing.

SHTS068020200094

(3) Use a small screwdriver to push down on one side of the piston retain-
ing ring to force the ring out of the groove.
Pull ring out. (4) Extend the coils of the ring.
Push ring down. (5) Use pliers to unwind the ring and pull it out of the groove.
(6) Use a new ring when you assemble the slack adjuster.
(7) Pull the actuator rod, piston and pin from the actuator.

SHTS068020200095

(8) Remove the pin from the rod and piston, if necessary.
NOTICE
PIN You do not have to remove the slack adjuster arm bushing unless it is
worn or "egg-shaped."
PISTON
(9) Inspect the condition and fit of the slack adjuster arm bushing.
(10) If necessary, install a new bushing onto the clevis pin. Use the clevis
pin and mallet to drive out the old bushing while you drive in the new
bushing.
ACTUATOR ROD

SHTS068020200096
BR0292 SERVICE BRAKE (FULL AIR BRAKE)

NOTICE
Steps (11) through (21) apply only to automatic slack adjusters manu-
factured BEFORE January 1993. The gear set and seals are not ser-
viceable on automatic slack adjusters manufactured AFTER January
1993. Refer to the exploded views on pages (2) and (3) of this manual
for more information.
(11) Use a small screwdriver to remove the grease seal from around the
worm bore.
Discard the seal. Use a new seal when you assemble the slack
adjuster.

SHTS068020200097

(12) Use snap ring pliers to remove the retaining ring from the worm bore.

SHTS068020200098

(13) Use a wrench to turn the manual adjusting nut and wind the worm out
of the bore.
(14) Remove the retaining rings and thrust washers from both sides of the
gear.
(15) Fit a small screwdriver into the notch at the end of the retaining ring.
(16) Remove the end of the retaining ring from the groove.

SHTS068020200099

(17) Unwind the ring by hand and pull it out of the groove.
(18) Remove the thrust washer.
NOTCH
! CAUTION
Push one seal out of one side of the slack adjuster housing and the
other seal out of the other side of the housing to avoid damaging the
seals.
(19) Push the gear out of the housing only far enough to enable you to
remove one gear seal.
(20) Push the gear out of the opposite side of the housing and remove the
other seal.
SHTS068020200100 (21) Inspect the seals. Discard damaged seals.
SERVICE BRAKE (FULL AIR BRAKE) BR0293

IMPORTANT POINTS-INSPECTION

1. PREPARE PARTS FOR ASSEMBLY

! WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, emul-
sion-type cleaners and petroleum-based cleaners. To avoid seri-
ous personal injury when you use solvent cleaners, you must
carefully follow the manufacturer's product instructions and
these procedures:
.

a. Wear safe eye protection.

b. Wear clothing that protects your skin.
c. Work in a well-ventilated area.
d. Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
e. You must use hot solution tanks or alkaline solutions correctly.
Follow the manufacturer's instructions carefully.

! CAUTION
Do not use hot solution tanks or water and alkaline solutions to
clean ground or polished parts. Damage to parts will result.
Only use solvent cleaners on metal parts. Damage to parts will
result.

2. CLEAN PARTS
(1) Use solvent cleaners to clean all automatic slack adjuster parts that
have ground or polished surfaces; for example, the gear, the worm
and the inner bores of the housing.
(2) Use soap and water to clean non-metal parts.
(3) Use soft paper or cloth that is free from dirt, oil or abrasives to dry the
parts completely.

3. DRY PARTS AFTER CLEANING

Dry the parts immediately after cleaning. Dry parts with clean paper
or rags, or compressed air.

4. INSPECT PARTS
(1) You must carefully inspect all slack adjuster parts, including pawl
teeth, for wear and damage before you assemble the slack adjuster.
(2) Replace any part that is worn or damaged.

5. CORROSION PROTECTION
NOTICE
Parts must be clean and dry before you lubricate them.
(1) If you assemble parts immediately after you clean them: Lubricate
parts with grease to prevent corrosion. Parts must be clean and dry
before you lubricate them.
(2) If you store parts after you clean them: Apply a corrosion-preven-
tive material. Store parts in a special paper or other material that pre-
vents corrosion.
BR0294 SERVICE BRAKE (FULL AIR BRAKE)

6. AUTOMATIC SLACK ADJUSTERS

! CAUTION
Always replace used clevis pin retainer clips with new ones when ser-
vicing the automatic slack adjuster or chamber. Do not reuse clevis
pin retainer clips after removing them. Discard used clips. When
removed for maintenance or service, clevis pin retainer clips can be
bent or "gapped apart" and can lose retention. Damage to compo-
nents can result.
Check the clevis pins and the bushing in the arm of the slack adjuster.
Replace the pins if they are worn. Replace the bushing if its diameter
exceeds 0.531-inch (13.5 mm).

IMPORTANT POINTS-ASSEMBLY
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.
NOTICE
Steps 3 through 11 apply only to automatic slack adjusters manufac-
tured BEFORE January 1993. The gear set and seals are not service-
able on automatic slack adjusters manufactured AFTER January
1993. If you are working on a current model, skip to Step (10).

1. ASSEMBLY
(1) Remove any corrosion-preventive material that may have been
applied to the parts you will assemble.
(2) Use grease to lubricate the gear bore in the housing.
! CAUTION
Follow Steps (3), (4) and (5) exactly when you install the seals so that
the sharp edges of the worm bore will not damage the seals.
(3) Install the gear straight into the bore in the housing without the seals,
keeping one seal groove outside of the housing.
(4) Install a seal into the groove.
(5) Lubricate the seal with grease that meets Meritor's specifications.
Compress the seal in its groove. Push the gear into the housing.
(6) Push the gear out of the opposite side of the housing only until the
other seal groove is visible. Repeat Steps (4) and (5) to install the sec-
ond seal.
(7) Lubricate a thrust washer with grease that meets Meritor's specifica-
tions. Refer to page BR02-106. Install the washer around the gear.

SHTS068020200101
 SERVICE BRAKE (FULL AIR BRAKE) BR0295

(8) Expand the retaining ring coil. Install one end of the coil into the
groove in the outer diameter of the gear. Work around the gear and
press the coil into the groove.

SHTS068020200102

(9) Repeat Steps 7 and 8 for the opposite side of the gear.
(10) Install the worm into the bore. Turn the adjusting nut to wind the worm
completely into the bore.

SHTS068020200103

(11) Use snap ring pliers to install the retaining ring into the worm bore.
! CAUTION
Install the seal with the lips OUTSIDE of the bore and the metal
retainer INSIDE of the bore to prevent contamination from enter-
ing the slack adjuster housing. Damage to components can
result.
Do not hit the seal after it reaches the bottom of the bore. Dam-
age to seal will result.

SHTS068020200104

(12) Place the seal directly over the worm bore. Use a hammer and 1-3/
16-inch (30.2 mm) diameter seal driver to install the seal straight into
the bore.

OUTSIDE INSIDE

SHTS068020200105
BR0296 SERVICE BRAKE (FULL AIR BRAKE)

(13) If you removed the pin, install it into the rod and piston.
(14) Install the actuator rod and piston assembly into the actuator (adjust-
PIN
ing sleeve).
(15) Slide the piston retaining ring over the rod.
PISTON (16) Extend the coils of the ring.

ACTUATOR ROD

SHTS068020200106

(17) Use a small screwdriver to press one end of the ring into the groove.

START BOTTOM COIL RING IN GROOVE

SHTS068020200107

(18) Keep the coil extended. Press on the ring and work around the groove
until the ring is in the groove completely.
(19) Check to ensure that the ring is installed correctly in the groove. You
cannot pull the piston out of the actuator if the retaining ring is
installed correctly.
(20) Install the actuator assembly into the housing so that the actuator
slides along the worm splines.
(21) Slip the boot over the actuator rod.
NOTICE
Do not seal the boot to the tapered part of the actuator rod.
If the rod has a groove: The top of the boot must fit into the groove.
If the rod does not have a groove: Use silicone sealant to seal the
top of the boot to the round part of the rod.
(22) Fasten the bottom of the boot to the housing with a retaining clamp.
(23) Conventional Pawl: Install the pawl assembly into the housing.
Tighten the capscrew to a torque of 15-20 lb-ft (20-27 Nm).
(24) Pull Pawl: Remove the screwdriver or equivalent tool. The pull pawl
will re-engage automatically.
(25) Use a grease gun to lubricate the slack adjuster through the grease
fitting. If necessary, install a camshaft into the slack adjuster gear to
minimize grease flow through the gear holes.
(26) Apply lubrication that meets Meritor's specifications until new grease
purges from around the camshaft splines and from the pawl assembly.
Refer to page BR02-106.
! CAUTION
In Step (28) turn the adjusting nut only in the direction shown in fig-
ure. If you turn the adjusting nut in the opposite direction while the
pawl is installed, you will damage pawl teeth.
Damaged teeth prevent automatic adjustment.
Replace damaged pawls before putting the vehicle in service.
(27) Use a torque wrench that measures lb-in.
 SERVICE BRAKE (FULL AIR BRAKE) BR0297

(28) As you turn the adjusting nut in the direction shown in figure, read the
torque scale and rotate the gear 360 degrees (22 turns of the
wrench).

22 TURNS

ROTATE GEAR 360

SHTS068020200108

(29) The torque value must remain less than 25 lb-in (2.83 Nm) during the
complete 360-degree rotation of the gear.
(30) If the torque value remains less than 25 lb-in (2.8 Nm): The slack
adjuster is working correctly.
(31) If the torque value exceeds 25 lb-in (2.8 Nm): The slack adjuster is
not working correctly.
Disassemble the slack adjuster.
Check that the slack adjuster is assembled correctly.
Check that parts are aligned correctly.
BR0298 SERVICE BRAKE (FULL AIR BRAKE)

INSTALLING THE SLACK ADJUSTER

ONTO THE CAMSHAFT
EN0680202H200010

1. INSTALLATION
! WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Block the wheels to prevent the vehicle from moving. Support
the vehicle with safety stands. Do not work under a vehicle sup-
ported only by jacks. Jacks can slip and fall over. Serious per-
sonal injury can result.
(1) Check the camshaft and bushings and seals for wear and corrosion.
(2) Turn the camshaft by hand to check for smooth operation.
(3) Repair or replace parts as required.
(4) Apply the service brake and spring brake several times. Check that
the chamber return spring retracts the push rod quickly and com-
pletely. If necessary, replace the return spring or the air chamber.
(5) The new automatic slack adjuster must be the same length as the one
you are replacing.
Table below shows the length of slack adjuster that is used with each
brake chamber size.

Chamber and Automatic Slack Adjuster Sizes

Length of Slack Adjuster Size of Chamber (Square Inches)

(Inches)

5 9*, 12*, 16, 20, 24, 30

5-1/2 9*, 12*, 16, 20, 24, 30, 36

6 24, 30, 36

6-1/2 30, 36

*Use an auxiliary spring on slack adjusters used with these size cham-
bers. A size 9 or 12 chamber return spring cannot supply enough spring
tension to completely retract the slack adjuster.

(6) Place blocks in front of and behind the vehicle's wheels to prevent it
from moving.
! WARNING
When you work on a spring chamber, carefully follow the service
instructions of the chamber manufacturer. Sudden release of a com-
pressed spring can cause serious personal injury.
(7) If the brake has a spring brake, compress and lock the spring to com-
pletely release the brake. No air pressure must remain in the service
half of the air chamber.
! CAUTION
Most Meritor automatic slack adjusters manufactured after January
1990 have lubrication holes in the gear splines. Do not operate the
actuator before you install the slack adjuster.
Lubricant can pump through the holes and onto the splines. Damage
to components can result.
 SERVICE BRAKE (FULL AIR BRAKE) BR0299

(8) If the automatic slack adjuster gear has a 10-tooth spline, apply anti-
seize compound to the slack adjuster and cam splines. Use Meritor
specified O-637, Southwest SA 8249496 or equivalent lubricants.
NOTICE
Install the slack adjuster so that you can remove a conventional pawl
or disengage a pull pawl when you adjust the brake.
(9) Install the slack adjuster onto the camshaft. Position the slack adjuster
so that you can remove the pawl when you adjust the brake.
(10) If necessary, install spacing washers and the snap ring at a maximum
clearance of 0.062-inch (1.57 mm).
(11) Install the clevis onto the push rod. Do not tighten the jam nut against
the clevis.
! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
adjust brake clearance. Replace damaged pawls before putting the
vehicle in service.
(12) Disengage the pawl. Turn the manual adjusting nut to align the holes
in the slack adjuster arm and the clevis.
(13) If the slack adjuster has a welded clevis: Apply anti-seize com-
pound to the two clevis pins.
Install the clevis pins through the clevis and the slack adjuster.
ALIGN (14) If the slack adjuster has a threaded clevis: Refer to page BR02-
HOLES
100.
Disengage a pull pawl ! CAUTION
or remove a
conventional pawl.
Always replace used clevis pin retainer clips with new ones when ser-
vicing the automatic slack adjuster or chamber. Do not reuse clevis
pin retainer clips after removing them. Discard used clips. When
SHTS068020200109
removed for maintenance or service, clevis pin retainer clips can be
bent or "gapped apart" and can lose retention. Damage to compo-
nents can result.
(15) Install new clevis pin retainer clips to hold the clevis in place.

CLEVIS LARGE CLEVIS PIN

AND
RETAINER CLIP

ACTUATOR LARGE CLEVIS PIN

ROD RETAINER CLIP
P/N 2257-D-1174

SMALL CLEVIS PIN

RETAINER CLIP
P/N 2257-C-1173
SMALL CLEVIS PIN
AND RETAINER CLIP

The clevis pin

retainer clips
must be fully
installed and
positioned
around the SIDE
of clevis pin.

SHTS068020200110
BR02100 SERVICE BRAKE (FULL AIR BRAKE)

CHECK & ADJUSTMENT

EN0680202H200011

CHECK BRAKE CHAMBER PUSH ROD STROKE AND

ADJUST THE CLEVIS POSITION
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.
NOTICE
You cannot adjust the clevis position on a chamber push rod that is
equipped with a welded clevis.
There are two methods you can use to adjust the clevis position on a cham-
ber push rod that is equipped with a threaded clevis:
The Brake Slack Adjuster Position (BSAP) method for standard and
long stroke chambers.
Meritor's automatic slack adjuster template method for standard
stroke chambers only.

1. BRAKE SLACK ADJUSTER POSITION (BSAP) METHOD

When installing the automatic slack adjuster, verify that the BSAP
3.750" AND 3.812" dimension of the chamber matches the table in figure.
BRACKET OFFSET

SLACK BSAP 0.125"

LENGTH
5.00"
5.50"
6.00"
6.50"

SLACK ADJ. 0.125" LONG

SIZE BSAP STROKE
5.00" 2.75" -
5.50" 2.75" 2.25"
6.00" 2.75" -
6.50" 2.62" -
Correct position of automatic slack adjuster:
3.750" and 3.812" offsets only. For other
bracket offsets, refer to the vehicle
manufacturer's specifications.

SHTS068020200111

2. AUTOMATIC SLACK ADJUSTER TEMPLATES

Order the correct automatic slack adjuster template from Meritor's
Customer Service Center at 800-535-5560.
! CAUTION
There are five different installation templates for Meritor automatic
slack adjusters. The templates are NOT interchangeable. You MUST
use the correct template and you MUST adjust the clevis position as
described below. If you use the wrong template and install the clevis
in the wrong position, the slack adjuster will not adjust the brake cor-
rectly. If the slack adjuster under-adjusts, then stopping distances are
increased. If the slack adjuster over-adjusts, then the linings may drag
and damage the brake.
 SERVICE BRAKE (FULL AIR BRAKE) BR02101

3. MEASURE THE SLACK ADJUSTER

NOTICE
For long stroke chambers, use the BSAP method to measure the auto-
matic slack adjuster.
(1) Use the correct Meritor automatic slack adjuster template to measure
the length of the slack adjuster. The marks by the holes in the small
end of the template indicate the length of the slack adjuster.

Color of Part Use to Install

Template Number Slack Adjusters On
Dark TP-4786 Truck or tractor drum brake
brown
Tan TP-4787 Trailer drum brake
White TP-4781 Coach drum brake
Green TP-4788 Disc brake with offset clevis
Yellow TP-4789 Disc brake with straight clevis

Measure slack
adjuster
arm length.

CAMSHAFT CENTER

SHTS068020200112

4. INSTALL A THREADED CLEVIS

(1) Install the large clevis pin through the large holes in the template and
the clevis.
(2) Select the hole in the template that matches the length of the slack
adjuster. Hold that hole on the center of the camshaft.
(3) Look through the slot in the template. If necessary, adjust the position
THREADED
CLEVIS
of the clevis until the small hole in the clevis is completely visible
through the template slot.

SLOT

CAMSHAFT END

SHTS068020200113
BR02102 SERVICE BRAKE (FULL AIR BRAKE)

(4) Check for these specifications:

MINIMUM 1/2" Thread engagement between the clevis and the push rod must be at
least 1/2-inch (12.7 mm).
The push rod must not extend through the clevis more than 1/8-inch
(3.18 mm). If necessary, cut the push rod, or install a new push rod
with a new air chamber.
MAXIMUM 1/8"
(5) Tighten the jam nut against the clevis to torque specifications.

Jam Nut Torque Specifications

THREADED CLEVIS
Threads Torque
SHTS068020200114
1/2-20 20-30 lb-ft (27-41 Nm)

5/8-18 35-50 lb-ft (48-68 Nm)

5. FREE STROKE MEASUREMENT

! CAUTION
You must disengage a pull pawl or remove a conventional pawl before
rotating the manual adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster to automatically
adjust brake clearance. Replace damaged pawls before putting the
vehicle in service.
NOTICE
During preventive maintenance on an in-service brake, check both the
free stroke as described below and the adjusted chamber stroke as
described on page BR02-104.
On some applications, you may find the in-service free stroke to be
slightly longer than specified in Step (5). However, this is not neces-
sarily a concern, as long as the adjusted chamber stroke is within the
limits shown in the Commercial Vehicle Safety Alliance (CVSA) charts
on page BR02-105.
(1) Disengage a pull pawl or remove a conventional pawl.
(2) Turn the adjusting nut in the direction shown in figure until the linings
touch the drum, and then turn the adjusting nut in the opposite direc-
tion:
1/2 turn for drum brakes
3/4 turn for disc brakes

Disengage a
pull pawl or remove
a conventional pawl.

SHTS068020200115
 SERVICE BRAKE (FULL AIR BRAKE) BR02103

(3) Measure the distance from the center of the large clevis pin to the bot-
MEASURE FREE STROKE
tom of the air chamber while the brake is released. Refer to "X" in
figure.
Y
(4) Use a pry bar to move the slack adjuster so that the linings are
X
against the drum (applying the brakes). Measure the same distance
again while the brakes are applied. Refer to "Y" in figure.
! CAUTION
Do not set free stroke shorter than specifications. If free stroke is too
short, linings can drag and damage the brake.
(5) The difference between measurement "X" and measurement "Y" is
the free stroke, which sets the clearance between the linings and
drum.
Free stroke must be within the following specifications.
Drum Brakes:
1/2-inch-5/8-inch (12.7-15.9 mm)
Disc Brakes:
3/4-inch-7/8-inch (19.1-22.2 mm)
FREE STROKE = Y MINUS X
Drum brake free stroke must be
1/2 5/8 (12.7-15.9 mm).
Disc brake free stroke must be
3/4 7/8 (19.1-22.2 mm).
SHTS068020200116

(6) If it is necessary to adjust the stroke, turn the adjusting nut 1/8 turn in
Disengage a the direction shown in figure and check the stroke again. Continue to
pull pawl or
measure and adjust the stroke until it is adjusted correctly.
remove a
conventional (7) Release a pull pawl or install a conventional pawl.
pawl.
! WARNING
SHORTEN
STROKE When you work on a spring chamber, carefully follow the service
LENGTHEN instructions of the chamber manufacturer. Sudden release of a com-
STROKE
pressed spring can cause serious personal injury.
(8) If the brake has spring chambers, carefully release the spring.
(9) Test the vehicle to ensure that the brake system is operating correctly
SHTS068020200117 before you return the vehicle to service.
BR02104 SERVICE BRAKE (FULL AIR BRAKE)

COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA)

GUIDELINES TO MEASURE PUSH ROD TRAVEL
(ADJUSTED CHAMBER STROKE)
Use the following procedures to check in-service push rod travel (adjusted
chamber stroke) on truck or tractor air brakes with automatic slack adjust-
ers.

Hold the ruler parallel to the push rod and measure as carefully as possible.
An error in measurement can affect CVSA re-adjustment limits, which state
that "any brake 1/4-inch or more past the re-adjustment limit, or any two
brakes less than 1/4-inch beyond the re-adjustment limit will be cause for
rejection."
! WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
When you work on a spring chamber, carefully follow the service
instructions of the chamber manufacturer. Sudden release of a
compressed spring can cause serious personal injury.

1. MEASURE PUSH ROD TRAVEL (ADJUSTED CHAMBER STROKE)

(1) The engine must be OFF. If the brake has spring chambers, carefully
release the spring.
(2) Check the gauges in the cab to ensure that air pressure in the tanks is
100 psi (689 kPa).
(3) Determine the size and type of brake chamber you are inspecting.
(4) With the brakes released, mark the push rod where it exits the cham-
Mark push rod here ber.
to measure stroke.
Measure and record the distance.
(5) Have another person apply and hold the brakes one full application.
(6) Measure push rod travel distance (adjusted chamber stroke) from
Spring brakes where the push rod exits the brake chamber to your mark on the push
released
Service brakes rod. Measure and record the distance.
not applied (7) To determine push rod travel (adjusted chamber stroke): Subtract
the measurement you obtained in Step (4) from the measurement you
obtained in Step (6). The difference is the push rod travel (adjusted
chamber stroke).
Push rod travel (adjusted chamber stroke) must not be greater than
the stroke length shown in the CVSA reference charts for the size and
100 psi (689 kPa) in air type of air chamber you are inspecting.
tank engine OFF
If push rod travel (adjusted chamber stroke) is greater than the maxi-
STROKE mum stroke shown in the CVSA reference charts, inspect the slack
adjuster and replace it if necessary.

Spring brakes
released
Service brakes
applied

SHTS068020200118
SERVICE BRAKE (FULL AIR BRAKE) BR02105

COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA)

NORTH AMERICAN OUT-OF-SERVICE CRITERIA REF-
ERENCE CHARTS
NOTICE
A brake found at the adjustment limit is not a violation.

"Standard Stroke" Clamp-Type Brake Chamber Data

Type Outside Diameter Brake Adjustment Limit (inches)

(inches)

6 4-1/2 1-1/4

9 5-1/4 1-3/8

12 5-4/16 1-3/8

16 6-3/8 1-3/4 Should be as short as

possible without lining
20 6-25/32 1-3/4 to drum contact
24 7-7/32 1-3/4

30 8-3/32 2

36 9 2-1/4

* For 3" maximum stroke type 24 chambers

"Long Stroke" Clamp-Type Brake Chamber Data

Type Outside Diameter Brake Adjustment Limit (inches)

(inches)

16 6-3/8 2.0

20 6-25/32 2.0
Should be as short as
24 7-7/32 2.0 possible without lining
to drum contact
24* 7-7/32 2.5

30 8-3/32 2.5

1. ANTI-SEIZE COMPOUND
Meritor lubricant specification O-637 (part number 2297-U-4571) is a
corrosion control grease. Do not mix this grease with other greases.
This compound is also available from the Southwest Petro-Chemical
Division of Witco Chemical Corporation, 1400 South Harrison, Olathe,
KS 66061, as "Corrosion Control," part number SA 8249496.
Use anti-seize compound on the clevis pins of all slack adjusters.
Also use anti-seize compound on the automatic slack adjuster and
cam splines if the slack adjuster gear has no grease groove and holes
around its inner diameter.
BR02106 SERVICE BRAKE (FULL AIR BRAKE)

LUBRICANTS

Conventional Automatic Slack Adjuster Grease Specifications

Components Meritor NLGI Grade Grease Type Outside Temperature

Specification

Automatic Slack Adjuster O-616-A 1 Clay Base Down to -40F (-40C)

O-692 1 and 2 Lithium Base Down to -40F (-40C)

O-645 2 Synthetic Oil, Clay Down to -65F (-54C)

Base

Clevis Pins Any of Above See Above See Above See Above

O-637 1-1/2 Calcium Base Refer to the grease manu-

facturer's specifications for
O-641 Anti-Seize the temperature service lim-
its.

MAINTENACE

1. AT BRAKE RELINE
(1) Before you perform brake maintenance, check the free stroke and the
adjusted chamber stroke as described on BR02-104.
(2) If the free stroke is not correct, refer to the Diagnostics table on page
BR02-87 to correct the stroke before you adjust the chamber stroke.
(3) Inspect the boot for cuts or other damage. If the boot is cut or dam-
aged, remove the pawl and inspect the grease.
(4) If the grease is in good condition, replace the damaged boot with a
new boot.
(5) Use a grease gun to lubricate the slack adjuster through the grease
fitting. If necessary, install a camshaft into the slack adjuster gear to
minimize grease flow through the gear holes.
(6) Lubricate until new grease purges from around the inboard camshaft
splines and from the pawl assembly.
(7) Measure the gap between the clevis and the collar on a "Quick Con-
0.060" (1.52 MM) MAXIMUM nect" clevis. Replace the clevis if the gap exceeds 0.060-inch (1.52
GAP BETWEEN
mm).
COLLAR AND CLEVIS

SHTS068020200119
 ABS (ABS : HYDRAULIC (E VERSION)) BR031

ABS (ABS : HYDRAULIC (E VERSION))

BR03

BR03-001

ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
BR032 ABS (ABS : HYDRAULIC (E VERSION))

ABS
OVERVIEW
EN0680103C100001

ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear
of the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
ECU sends signals to the ABS modulator and immediately adjusts the
brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.
 ABS (ABS : HYDRAULIC (E VERSION)) BR033

COMPOSITION AND OPERATION

EN0680103C100002

The ABS system is comprised of sensor rings mounted on the wheels, the
ABS ECU, which receives signals from the wheel sensors that monitor the
rotational speed of the wheels and outputs control signals to maintain the
appropriate braking force; ABS modulator, which increase or decrease the
braking force, based on the control signals; the warning light, which gives
an alarm if the system malfunctions; the piping, wire harnesses, etc., that
link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS ECU. The ABS ECU then calcu-
lates the wheels' rotational speed, acceleration, deceleration, and amount
of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS ECU immediately transmits signals to the ABS modula-
tor to adjust any excess braking force.
ABS system operates as following table.

FRONT AXLE REAR AXLE

Independently control Independently control

CONTROL SYSTEM
right and left wheels right and left wheels

1. SYSTEM COMPOSITION DIAGRAM

Power steering Power steering

pump gear Power steering pipe
Brake hose
Brake pipe
Brake wiring
Hydro MAX
controller
rESERVOIR

Hydro
MAX
M

Wheel
Front Wheel Rear
sensor Cab side
brake sensor brake
chassis side
(RH) (RH)

ABS
modulator

ABS ECU

Wheel Front ABS Wheel Rear

sensor brake Warning sensor brake
(LH) light (LH)

SAPH068010300001
BR034 ABS (ABS : HYDRAULIC (E VERSION))

2. ABS CONTROL FLOWCHART

Input signals ABS ECU Output signals

Front right Front right pres-

wheel sensor sure maintenance
solenoid valve

Front left Front right pres-

sure reduction
wheel sensor solenoid valve

Rear right Front left pres-

ABS ECU sure maintenance
wheel sensor solenoid valve

Rear left Front left pres-

sure reduction
wheel sensor solenoid valve

Rear right pres-

sure maintenance
solenoid valve

Rear right pres-

sure reduction
solenoid valve

Rear left pressure

maintenance sole-
noid valve

Rear left pressure

reduction sole-
noid valve

Exhaust brake cut

relay

ABS warning light

Malfunction code
(diagnostic code)

SAPH068010300002
 ABS (ABS : HYDRAULIC (E VERSION)) BR035

BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being braked. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.

Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the
road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.

SAPH068010300004

OPERATION
The ABS ECU calculates the wheel speed and wheel acceleration speed
for each of the 4 wheels, from 4 wheel sensor signals, and determines the
Wheel speed wheel slip conditions. And depending on these conditions, control signals
HIGH Vehicle body speed
are output to the ABS actuator solenoid valves in 3 modes (pressure
SPEED

increase, pressure maintenance, and pressure reduction). Control signals

are output independently to the front and rear wheels and to the left and
LOW right wheels.

+
tionaccelera

0
Wheel

speed

Control signal

Pressure
reduction
Pressure
maintenance
Pressure
increase

HIGH
Wheel cylinder
fluid pressure

0
TIME

SAPH068010300005
BR036 ABS (ABS : HYDRAULIC (E VERSION))

FUNCTION
EN0680103C100003

FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.

EXHAUST BRAKE CONTROL FUNCTION

The ABS of this vehicle is equipped with a function that controls the
exhaust brake while ABS is operating. If the exhaust brake is applied inde-
pendently or in conjunction with the service brake on a road surface with an
abnormally low friction coefficient, the drive wheels may lock. This ABS
prevents the drive wheels from locking in such situations by automatically
releasing the exhaust brake, if necessary, during ABS operation.
 ABS (ABS : HYDRAULIC (E VERSION)) BR037

PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0680103F100001

Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.

CHECK POINTS REMEDIAL ACTIONS

Even with ABS, the braking distance on a wet or slippery

road will be longer than on a dry road, and if the road
surface is covered with ice, snow or gravel, the braking Even with ABS, always drive safely, tak-
distance will be even greater. ing into consideration the road and traffic
conditions and the condition of your tires,
including tire type and tire wear. Always
keep a safe distance from any vehicle
ABS does not operate when the vehicle is starting, ac-
being driven in front of you.
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
ing distance.
Even if the ABS is operational, where the coefficient of If engine braking causes instability or fish-
friction is very low, such as on an icy roadway, skidding, tailing, the clutch should be engaged or
inability to steer, and instability may occur because of the transmission shifted to neutral, to pre-
insufficient traction by the tires. vent the application of the engine brak-
ing to the drive wheels.
Where engine braking, as a result of downshifting, oc-
curs on a surface with a low coefficient of friction, such Vibrations and noise during the operation
as ice, the drive wheels may lock, causing fishtailing or of ABS are not malfunctions. Remain calm
vehicle instability. ABS does not operate unless the brake and continue to steer the vehicle in an
pedal is applied. appropriate manner.

When ABS is activated, the driver may experience a small If the warning light lights up again when
amount of vibration (especially if the road surface be- you reach a speed of about 6 km/h
tween the left and right tires is different) and difficulty in (4 mile/h), the ABS system may not be
steering. Also, the operation of the ABS may generate functioning properly. Have it inspected and
some noise. repaired if necessary. *The warning light
can be reset by turning off the engine
The ABS warning light will come on when you turn the while the vehicle is at rest. If the warning
starter switch to the "on" position. It stays on briefly and light fails to go out after the engine is re-
then turns off automatically. If the light does not come started and the speed indicated above is
on, have your vehicle inspected and serviced immedi- reached, or if it lights frequency while the
ately at your nearest Hino service dealer. vehicle is being driven, the ABS must be
inspected.

OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS modulator, harnesses,
or connectors. Also, under no circumstances should the ABS ECU or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS ECU and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SAPH068010300006
BR038 ABS (ABS : HYDRAULIC (E VERSION))

OVERVIEW AND FUNCTION

EN0680103C100004

ABS ECU (INTEGRATED WITH ABS MODULATOR)

Based on pulse signals from the wheel sensors, the ABS ECU mounted in
the vehicle calculates and evaluates the slip ratio and the acceleration/
deceleration speed of the wheels. Based on the results, it sends signals to
the modulator assembly as necessary, causing them to operate and apply
the brakes to maintain the slippage of the wheels within the optimal range.
During braking, the fluid pressure applied to the brake cylinder is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, modulator assembly, ABS ECU, and wire harnesses are constantly
being checked by the ABS ECUs fail-safe circuit. If some sort of malfunc-
tion occurs, the fail-safe circuit warns the driver by lighting the ABS warning
light. At the same time, the ABS system that is experiencing the malfunc-
tion is shut off and braking is restored to normal (non-ABS) operation.

SAPH068010300007

ABS MODULATOR ASSEMBLY

1. Overview
The ABS modulator is mounted between the Hydro booster and disc
brake caliper. It controls the fluid pressure to the disc brake caliper,
regulating the pressure according to signals from the ABS ECU in
three modes: pressure maintenance, pressure reduction, and pres-
sure increase.

SAPH068010300008
ABS (ABS : HYDRAULIC (E VERSION)) BR039

SAPH068010300009
BR0310 ABS (ABS : HYDRAULIC (E VERSION))

2. Operation
(1) During Normal Braking (ABS is not operating)
Since there is no control signal input from the ABS ECU, the pressure
maintenance solenoid valve port A is open, and the pressure reduc-
tion solenoid valve port B is closed. Accordingly, when the fluid pres-
sure generated by the Hydro booster rises according to the fluid
pressure from the master cylinder produced when the brake pedal is
depressed, brake fluid is fed through port A to the wheel cylinder.
Brake fluid is not sent to the pump side at this time because of the
check valve 1 installed on that side. Then, when the brake pedal is
released, the wheel cylinder brake fluid is returned to the master cylin-
der through the pressure maintenance solenoid valve port A to the
Hydro booster.

Each Port Status

ABS ECU signal Port status

Pressure mainte-
OFF Port A: Open
nance solenoid valve

Pressure reduction
OFF Port B: Closed
solenoid valve

SAPH068010300010
ABS (ABS : HYDRAULIC (E VERSION)) BR0311

(2) During ABS Braking

a. Pressure Reduction Mode
When the wheels are about to lock, the pressure maintenance sole-
noid valve port A closes and the pressure reduction solenoid valve
port B opens according to control signals from the ABS ECU. Accord-
ingly, the wheel cylinder brake fluid is fed through the pressure reduc-
tion solenoid valve port B to the reservoir, reducing the wheel cylinder
fluid pressure. While the ABS is in operation, the ABS ECU outputs a
normal operating signal to the pump, which pumps out the brake fluid
that accumulates in the reservoir and returns it to the Hydro booster.

Each Port Status

ABS ECU signal Port status

Pressure mainte-
ON Port A: Closed
nance solenoid valve

Pressure reduction
ON Port B: Open
solenoid valve

SAPH068010300011
BR0312 ABS (ABS : HYDRAULIC (E VERSION))

b. During Pressure Maintenance

When the wheel cylinder fluid pressure is reduced or increased to the
required fluid pressure, the pressure maintenance solenoid valve port
A and the pressure reduction solenoid valve port B simultaneously
close according to control signals from the ABS ECU. This closes
both the Hydro booster side and reservoir side oil routes, maintaining
the wheel cylinder fluid pressure.

Each Port Status

ABS ECU signal Port status

Pressure mainte-
ON Port A: Closed
nance solenoid valve

Pressure reduction
OFF Port B: Closed
solenoid valve

SAPH068010300012
ABS (ABS : HYDRAULIC (E VERSION)) BR0313

c. During Pressure Increase

When the wheel cylinder fluid pressure needs to increase rapidly, the
pressure maintenance solenoid valve port A opens and the pressure
reduction solenoid valve port B closes according to control signals
from the ABS ECU. This condition is the same as the normal condi-
tion, and Hydro booster brake fluid is fed to the wheel cylinder, caus-
ing the wheel cylinder fluid pressure to rise. If there is any brake fluid
remaining in the reservoir at this time, it is pumped out by the pump
and sent to the wheel cylinder. The speed of the pressure increase is
controlled by combination of the pressure increase and the pressure
maintenance.

Each Port Status

ABS ECU signal Port status

Pressure mainte-
OFF Port A: Open
nance solenoid valve

Pressure reduction
OFF Port B: Closed
solenoid valve

SAPH068010300013
BR0314 ABS (ABS : HYDRAULIC (E VERSION))

WHEEL SENSOR
These sensors are mounted facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnetic sensors consisting of a permanent
magnet core with a coil of wire wrapped around it. The frequency of the
pulse signals generated by magnetic inductance between the sensors and
the sensor rings they face is proportional to the rotational speed of the
wheels. These pulse signals are sent to the ABS ECU and are used to
determine the wheels' rotational status.

SAPH068010300014

SENSOR RING
The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel or integrated in the brake rotor on the front and rear axles, and they
face the wheel sensors described in the preceding section. The sensor
rings are made of a magnetic material, and teeth are cut into the surface
which faces the wheel sensor at regular intervals.Also, when the sensor
ring performs one complete rotation, the sensor generates pulse signals
corresponding to the number of teeth.

Sensor ring position and number of teeth

238 258LP 268 338

SAPH068010300015 Model
NE NE NE, NF NF
Position Rotor integrated
Front
Teeth No. 100
Position Rotor integrated
Rear
Teeth No. 100
 ABS (ABS : HYDRAULIC (E VERSION)) BR0315

CLAMPING BUSHING
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled properly
(the clamping bushings should be pushed in to place so that the stoppers
on the clamping bushings come in contact with the holder), the clamping
bushings serve to eliminate the need to adjust the clearance between the
wheel sensors and sensor rings.

SAPH068010300016

WARNING LIGHT
The ABS is equipped with the following warning light.

ABS warning light

[USA] [CANADA]
or

SAPH068010300017C

1. ABS WARNING LIGHT

This light indicates the status of the ABS. It lights once when the
starter switch is turned on and automatically goes off if the ABS is
functioning normally. If a malfunction occurs in the ABS while the vehi-
cle is being driven, the light comes on to alert the driver.
Also used as the diagnostic display light.
NOTICE
Trouble shooting and Testing of the ABS refer to MERITOR WABCO
Maintenance Manual.Cab-Mounted ECU and D Version Hydraulic ABS.
BR0316 ABS (ABS : HYDRAULIC (E VERSION))

WHEEL SENSOR WIRE HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS, from electromagnetic interference. Under
no circumstances should any part of the wheel sensor wire harness be cut
or connected to any other wire. In the event that the wire harness should
become cut, have it replaced by an authorized Hino dealer.

SAPH068010300018

ABS WIRE HARNESSES

1. Front axle ABS wire harness

The wire harness that runs from the side frame to the front axle wheel
sensor must absorb the steering angle of the front wheel and the
movement of the chassis springs. It is therefore necessary to always
maintain an optimal spacing between the clips.

SAPH068010300019

The optimal spacing between the clips is achieved when the wheel
sensor connectors are attached in the regular locations shown in the
diagram such that the sensor cabling within the frame is not loose.
When disassembling and reassembling, confirm that the connector
and sensor cable layout is appropriate.

SAPH068010300020
ABS (ABS : HYDRAULIC (E VERSION)) BR0317

2. Rear axle ABS wire harness

The wheel sensor wire harness is arranged so that the left and right
wheel sensor wire harnesses are near each other. Therefore, special
care should be taken not to make incorrect connections if the har-
nesses have been removed for inspection or repairs. If incorrect con-
nections are made, it will interfere with the functioning of the ABS. For
this reason, caution plates indicating "LEFT" and "RIGHT" are affixed
to the wire harnesses. Be sure to check when connecting the har-
nesses. The wheel sensor wire harnesses, just like the front axle har-
nesses, must absorb the movement of the chassis springs. It is
therefore necessary to always maintain an optimal spacing between
the clips.
When disassembling and re-assembling, confirm that the connector is
secured in its proper place as shown in the diagram and that the sen-
sor cables in the frame and over the axle are not hanging loosely.

SAPH068010300021
BR0318 ABS (ABS : HYDRAULIC (E VERSION))

HANDLING WIRE HARNESSES

The various sensors, valves, relays and wire harness connections to
the ABS ECU employ multipolar harness connectors suitable for use
with the weak currents used by electronic circuitry. Be very careful
when handling them.

1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.

2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.

3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.

4. Remove unnecessary connectors and do not plug them.

5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.

SAPH068010300022

6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.

7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.

8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
ABS (ABS : HYDRAULIC (E VERSION)) BR0319

ADDITIONAL PRECAUTIONS

1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS ECU.

2. Make sure to unplug all the harness connectors from the ABS
ECU before performing welding on the chassis or body of the
vehicle. Also be careful that welding sputter does not get onto
the harnesses.

3. When cleaning the interior of the model, make sure water does
not get onto the ABS ECU, various relays, connectors, or any
other component.

4. Use of a circuit tester

If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 k inside the voltage measurement range.

5. Installation of a radio or other electronic equipment

All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS ECU and wire harness as possi-
ble. Installation of certain electronic and radio equipment can also
cause the ABS ECU to malfunction. All such equipment must also
conform to all applicable laws. If you wish to install a radio or other
electronic equipment, please contact your Hino service representa-
tive.

6. Quick battery charge

When charging batteries using a quick charger, do it with both battery
terminals removed.

7. Installation of electrical equipment inside of the cab

When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
 ABS (ABS : FULL AIR) BR031

ABS (ABS : FULL AIR)

BR03

BR03-002

ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
INSPECTION (FRONT WHEEL BRAKE) ...... BR03-13
INSPECTION (REAR WHEEL BRAKE)......... BR03-15
BR032 ABS (ABS : FULL AIR)

ABS
OVERVIEW
EN0680203C100001

ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear of
the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
ECU sends signals to the ABS control valve and immediately adjusts the
brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.

SHTS068020300001

1 Wheel sensors 3 Relay valve

2 ABS control valves 4 ABS ECU
 ABS (ABS : FULL AIR) BR033

COMPOSITION AND OPERATION

EN0680203C100002

The ABS system is comprised of sensor rings mounted on the wheels. The
ABS ECU, which receives signals from the wheel sensors that monitor the
rotational speed of the wheels and outputs control signals to maintain the
appropriate braking force; ABS control valves, which increase or decrease
the braking force, based on the control signals; the warning light, which
gives an alarm if the system malfunctions; the piping, wire harnesses, etc.,
that link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS ECU. The ABS ECU then calcu-
lates the wheels' rotational speed, acceleration, deceleration, and amount
of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS ECU immediately transmits signals to the ABS control
valves to adjust any excess braking force.
This ABS system controls the four wheels, front, rear, right, and left, inde-
pendently.

1. SYSTEM COMPOSITION DIAGRAM

SHTS068020300002

1 Brake valve 5 ABS ECU

2 Brake chamber 6 Wheel sensor
3 Relay valve 7 ABS warning light
4 ABS control valve A From air tank
BR034 ABS (ABS : FULL AIR)

2. ABS CONTROL FLOWCHART

Input signals ABS ECU Output signals

Front left wheel sensor

ABS control valve for
front left wheel

Front right wheel sensor

ABS control valve for
front right wheel

Rear left wheel sensor

ABS control valve for

rear left wheel
Rear right wheel sensor

ABS ECU ABS control valve for

rear right wheel

Exhaust brake
cut relay

Malfunction code
(diagnostic code)

ABS warning light

SHTS068020300003
 ABS (ABS : FULL AIR) BR035

BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being halted. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.

Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed

Slip ratio 0 % : No slipping between the wheels and the

road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.

SHTS068020300005

OPERATION
The ABS control characteristics line graph at left illustrates how the vehi-
cle's speed, the wheels' rotational speed, the wheel acceleration/decelera-
tion, and the air pressure at the ABS control valve outlet change over time
after the brakes are applied.
When the brakes are applied, the vehicle's speed and the wheels' rotational
speed drop and at the same time, the wheel acceleration/deceleration
speed also drops. At point T1, a gap begins to open between the wheels'
rotational speed and the vehicle's speed. Passing on point T2, the ABS
ECU detects that the wheels are beginning to lock and is lowering the outlet
air pressure of the ABS control valve to prevent wheel locking from occur-
ring.
At point T3, the wheel acceleration/deceleration speed is starting to return
to normal one, and the ABS ECU stops lowering the air pressure at the
ABS control valve outlet and maintains it at a constant level.
At point T5, the wheels' rotational speed and the vehicle's speed are about
the same. The ABS ECU detects that the wheels are no longer likely to be
locked and increases the air pressure at the ABS control valve outlet.
The above processes is repeated over and over until the vehicle comes to a
complete stop.

SHTS068020300006
BR036 ABS (ABS : FULL AIR)

FUNCTION
EN0680203C100003

FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.

EXHAUST BRAKE CONTROL FUNCTION

The ABS of this vehicle is equipped with a function that controls the
exhaust brake while ABS is operating. If the exhaust brake is applied inde-
pendently or in conjunction with the service brake on a road surface with an
abnormally low friction coefficient, the drive wheels may lock. This ABS pre-
vents the drive wheels from locking in such situations by automatically
releasing the exhaust brake, if necessary, during ABS operation.
 ABS (ABS : FULL AIR) BR037

PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0680203F100001

Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.

CHECK POINTS REMEDIAL ACTIONS

Even with ABS, the braking distance on a wet or slippery Even with ABS, always drive safely, tak-
road will be longer than on a dry road, and if the road ing into consideration the road and traffic
surface is covered with ice, snow or gravel, the braking conditions and the condition of your tires,
distance will be even greater. including tire type and tire wear. Always
keep a safe distance from any vehicle
being driven in front of you.
ABS does not operate when the vehicle is starting, ac-
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
If engine braking causes instability or fish-
ing distance.
tailing, the clutch should be engaged or
Even if the ABS is operational, where the coefficient of
the transmission shifted to neutral, to pre-
friction is very low, such as on an icy roadway, skidding,
vent the application of the engine brak-
inability to steer, and instability may occur because of
ing to the drive wheels.
insufficient traction by the tires.

If the air pressure becomes low and the

Where engine braking, as a result of downshifting, oc- air pressure warning light comes on and
curs on a surface with a low coefficient of friction, such a buzzer sounds, immediately stop the
as ice, the drive wheels may lock, causing fishtailing or vehicle in a safe place. Begin driving
vehicle instability. ABS does not operate unless the brake again only after the return to normal air
pedal is applied. pressure.

If the ABS engages, the vehicle's air consumption rate Vibrations and noise during the operation
will be higher than usual. of ABS are not malfunctions. Remain calm
and continue to steer the vehicle in an
appropriate manner.
When ABS is activated, the driver may experience a small
amount of vibration (especially if the road surface be-
tween the left and right tires is different) and difficulty in If the warning llight lights up again when
steering. Also, the operation of the ABS may generate you reach a speed about 6 km/h (4 mph)
some noise. the ABS system may not be functioning
properly. Have it inspected and repaired
The ABS warning light will come on when you turn the if necessary *
starter switch to the "on" position. It stays on briefly and The warning light can be reset by turn-
then turns off automatically. If the light does not come ing off the engine while the vehicle is
on, have your vehicle inspected and serviced immedi- at rest. If the warning light fails to go
ately at your nearest HIno service dealer. out after the engine is restarted and the
speed indicated above is reached, or if
it lights frequency while the vehicle
is being driven, the ABS must be

OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS control valves, harnesses, or
connectors. Also, under no circumstances should the ABS ECU or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS ECU and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SHTS068020300007
BR038 ABS (ABS : FULL AIR)

OVERVIEW AND FUNCTION

EN0680203C100004

1. ABS ECU
Based on pulse signals from the wheel sensors, the ABS ECU mounted in
the vehicle calculates and evaluates the slip ratio and the acceleration/
deceleration speed of the wheels. Based on the results, it sends signals to
the ABS control valves as necessary, causing them to operate and apply
the brakes to maintain the slippage of the wheels within the optimal range.
During braking, the air pressure applied to the brake chambers is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, control valves, ABS ECU, and wire harnesses are constantly being
checked by the ABS ECU's fail-safe circuit. If some sort of malfunction
occurs, the fail-safe circuit warns the driver by lighting the ABS warning
light. At the same time, the ABS system that is experiencing the malfunc-
tion is shut off and braking is restored to normal (non-ABS) operation.

SHTS068020300008

2. ABS CONTROL VALVES

(1) Overview
Also available with The ABS control valves are positioned in the brake air circuit on the
Air out open-style connector
way to brake chambers. Based on signals from the ABS ECU, they
adjust the air pressure sent to the brake chambers in one of three
Air in
modes: pressure increase, pressure reduction, or pressure mainte-
nance.
Bayonet-style
connector

SHTS068020300009
 ABS (ABS : FULL AIR) BR039

SHTS068020300010
(2) Operation
Pressure increase a. PRESSURE INCREASE MODE
14 5 When the driver steps on the brake pedal, air from the relay valve
10
enters through inlet port (6), pushes open diaphragm (5), passes
through outlet port (9), and flows into the brake chamber. At this point,
Valve operating status

6
3
solenoid coil (1) is not energized, so solenoid valve (3) is closed and
9
pilot chamber (14) is open to the atmosphere. Also, solenoid coil (2) is
13 also not energized, so solenoid valve (4) is closed. As a result, air
passes through pilot hole (10) and enters pilot chamber (12). It then
pushes up diaphragm (11) and closes exhaust valve (13).
1
2
4 12 11

Solenoid valve for driving inlet

OFF
Status

valve 3
Solenoid valve for driving
OFF
exhaust valve 4
Brake chamber
Pressure

pressure

0 Time
SHTS068020300011
BR0310 ABS (ABS : FULL AIR)

b. PRESSURE REDUCTION MODE

Pressure reduction
When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5
also flows into pilot chamber (14). It pushes down on diaphragm (5),
shutting off chambers (7) and (8). At the same time, solenoid coil (2)
is also energized. This causes solenoid valve (4) to open and the
Valve operating status

7 operating air from pilot chamber (12) passes through exhaust port
3 9 (15) and is released into the atmosphere. Consequently, the air from
8
the outlet port (9) side (brake chamber) pushes down on diaphragm
(11) and air is released into the atmosphere. This causes the air pres-
sure of the brake chamber to decrease.
1

2
12
4 15 11
Solenoid valve for driving inlet
ON
Status

valve 3
Solenoid valve for driving
ON
exhaust valve 4
Brake chamber
Pressure

pressure

0 Time
SHTS068020300012

c. PRESSURE MAINTENANCE MODE

Pressure maintenance
When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5 flows through chamber (7) and acts on pilot chamber (14). On the
10 other hand, since solenoid coil (2) is not energized, solenoid valve (4)
is closed and air flows through pilot hole (10) and acts on pilot cham-
Valve operating status

3 ber (12). This causes diaphragms (5) and (11) to shut off their air pas-
8 sages, and the chamber (8) pressure, that is to say the air acting on
the brake chamber, is maintained at the pressure that was current
when the switch from the pressure reduction mode to the pressure
maintenance mode took place.
1

2
11
12
4

Solenoid valve for driving inlet

ON
Status

valve 3
Solenoid valve for driving
OFF
exhaust valve 4
Brake chamber
Pressure

pressure

0 Time
SHTS068020300013
 ABS (ABS : FULL AIR) BR0311

3. WHEEL SENSORS
These sensors are mounted, facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnet sensors consisting of a permanent
magnet core with a coil of wire wrapped around it.
The frequency of the pulse signals generated by magnetic inductance
between the sensors and the sensor rings they face is proportional to the
rotational speed of the wheels. These pulse signals are sent to the ABS
ECU and are used to determine the wheels, rotational status.

SHTS068020300014

SHTS068020300015

4. SENSOR RINGS
The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel on the front and rear axles, and they face the wheel sensors
described in the preceding section. The sensor rings are made of a mag-
netic material, and teeth are cut into the surface which faces the wheel sen-
sor at regular intervals. Also, when the sensor ring performs one complete
rotation, the sensor generates pulse signals corresponding to the number
of teeth.

SHTS068020300016

5. CLAMPING BUSHINGS
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled prop-
erly, the clamping bushings serve to eliminate the need to adjust the clear-
ance between the wheel sensors and sensor rings.

SHTS068020300017
BR0312 ABS (ABS : FULL AIR)

6. WHEEL SENSOR HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS system, from electromagnetic interference.
Under no circumstances should any part of the wheel sensor wire har-
nesses be cut or connected to any other wire.

SHTS068020300018

7. ABS WARNING LIGHT

The status of the ABS system is indicated.
It lights when the starter switch is turned "ON" and automatically goes off
[USA] [CANADA]
when the system functions correctly.
or If malfunction occurs in the ABS system while the vehicle is being driven,
the light comes on to alert the driver.
However, when a defects code is eliminated after repairing it and the

ABS starter switch is turned "ON", the light will remain lit until the vehicle speed
reaches about 6 km/h {4 mile/h}.
Then, note that even when the warning light is lit, the ABS system, unaf-
fected by the malfunction, continues to operate. Also, the brake whose ABS
system experiences the malfunction is reverted to normal braking operation
SHTS068020300019 without ABS.
When a Diagnosis switch is turned "ON", this light will goes on and off,
which indicates defect code.

8. EXHAUST BRAKE CUT RELAY

When this relay is energized during ABS operation, the relay contact
opens, the current to the solenoid valve for the exhaust brake is shut down,
and the exhaust brake is released.

9. DIAGNOSIS SWITCH OF ABS SYSTEM

It is positioned at the side of diagnosis connector in the instrument panel of
driver seat front side.
By switching the starter key "ON" and pushing to "ON" this ABS diagnosis
switch, which is led to the diagnosis mode, the ABS warning light flashes
on and off to inform the trouble codes.
NOTICE
ABS diagnosis switch reverts automatically to "OFF" position.

SHTS068020300020
 ABS (ABS : FULL AIR) BR0313

INSPECTION (FRONT WHEEL BRAKE)

EN0680203H300001

1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.

SHTS068020300021

2. INSPECTION OF THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and press it in with a press again.

SHTS068020300022

3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.

SHTS068020300023

4. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}

SHTS068020300024
BR0314 ABS (ABS : FULL AIR)

5. MOUNTING THE WHEEL HUB AND BRAKE DRUM

(1) Refer to CHAPTER, FRONT AXLE.
NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs and
the like on that axle could cause internal damage to the wheel sen-
sors. Either mount the tire and then tap on the tire or tap on the wheel
hub after removing the right and left wheel sensors.

6. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
knuckle's wheel sensor holder.
(2) Apply a light coating of chassis grease to the hub of the wheel sensor.
Then push it forcefully into the clamping bushing until you feel that the
wheel sensor has made contact with the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place with a screwdriver, or the like. Doing so
could damage the wheel sensor.
(3) Slowly turn the wheel hub and brake drum and confirm that they move
SHTS068020300025
smoothly.
(4) Mount the drum dust cover.

7. INSPECT THE WHEEL SENSOR

(1) Arrange the wire harness.
(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)

SHTS068020300026
 ABS (ABS : FULL AIR) BR0315

INSPECTION (REAR WHEEL BRAKE)

EN0680203H300002

1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.

SHTS068020300027

2. INSPECTION OF THE SENSOR RING.

(1) Make visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring becomes loose from the wheel hub, use a dolly
block and a press to pressure mount it again.

SHTS068020300028

3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that the wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.

4. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
wheel sensor holder.

SHTS068020300029

(2) Push the wheel sensor fully in the wheel sensor holder with hands
until the wheel sensor makes contact with the clamping bushing.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place using a screwdriver, or the like. Doing so
could damage the wheel sensor.

(3) Arrange the wire harness.

SHTS068020300030
BR0316 ABS (ABS : FULL AIR)

5. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}

SHTS068020300031
6. MOUNTING THE WHEEL HUB AND BRAKE DRUM
(1) Refer to CHAPTER REAR AXLE.
NOTICE
Be careful not to push back the wheel sensor too far when
mounting the wheel hub and brake drum. Also, make sure they
are straight so that you do not bump the tip of the wheel sensor.
When inserting the outer hub bearing, avoid tapping on it with a
hammer as this will expose the wheel sensor to bumps. Insert
the outer hub bearing carefully with a lock nut.

7. INSPECT THE WHEEL SENSOR

(1) Arrange the wire harness.
(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at 2), remove the dust cover
located on the back plate unit. Then push the wheel sensor by using a
round end bar until the sensor contacts with the sensor ring.
NOTICE
Do not tap with a hammer or turn when pushing the wheel sensor.
This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the axle
shaft.
Refer to CHAPTER, REAR AXLE.

8. ABS WIRE HARNESSES

(1) Front axle ABS wire harnesses
The front axle chassis harnesses, particularly the ones that pass over
the front axle and extend as far as the wheel sensors, must absorb
the movement when the wheels are turned and when the springs
move. It is therefore necessary to always maintain an optimal spacing
between the clips.
In addition, if there is a large amount of variation in the spacing
between the clips, the wheel sensor harnesses can come into contact
with tire chains and sustain damage.
The wire harness for the front axle wheel sensor extends directly from
the clip on top of the king pin cover to the frame. In particular, make
sure that the distance between the clip on top of the king pin cover
and the clip on the frame side is as indicated in the diagram below.
There are markings on the wheel sensors in cases where the wheel
sensor harness clips are in locations where the relative movement is
particularly great. These places should be inspected regularly to
ensure that the clip positions are still meeting with the same marking.
ABS (ABS : FULL AIR) BR0317

SHTS068020300032
BR0318 ABS (ABS : FULL AIR)

(2) Rear axle chassis harness

The rear axle chassis harnesses is arranged so that the left and right
wheel sensor harnesses are near each other. Therefore, special care
should be taken not to make incorrect connections if the harnesses
have been removed for inspection or repairs.
If incorrect connections are made, it will interfere with the functioning
of the ABS system. For this reason, caution plates indicating "LEFT"
and "RIGHT" are affixed to the harnesses. Be sure to check when
connecting the harnesses. (The left harness is on the left side of the
vehicle when viewed from the behind and facing toward the front, and
the right harness is on the right side of the vehicle.)
The wheel sensor harnesses are arranged along the top of the rear
axle housing. Therefore, make sure to allow sufficient harness length
between the chassis and the rear axle so that the harnesses can
absorb the up-and-down motion of the rear axle.

SHTS068020300033
ABS (ABS : FULL AIR) BR0319

HANDLING WIRE HARNESSES

The various sensors, valves, relays and wire harness connections to
the ABS ECU employ multipolar harness connectors suitable for use
with the weak currents used by electronic circuitry. Be very careful
when handling them.

1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.

2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.

3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.

4. Remove unnecessary connectors and do not plug them.

5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.

SHTS068020300034

6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.

7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.

8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
BR0320 ABS (ABS : FULL AIR)

ADDITIONAL PRECAUTIONS

1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS ECU.

2. Make sure to unplug all the harness connectors from the ABS
ECU before performing welding on the chassis or body of the
vehicle. Also be careful that welding sputter does not get onto
the harnesses.

3. When cleaning the interior of the model, make sure water does
not get onto the ABS ECU, various relays, connectors, or any
other component.

4. Use of a circuit tester

If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 k inside the voltage measurement range.

5. Installation of a radio or other electronic equipment

All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS ECU and wire harness as possi-
ble. Installation of certain electronic and radio equipment can also
cause the ABS ECU to malfunction. All such equipment must also
conform to all applicable laws. If you wish to install a radio or other
electronic equipment, please contact your Hino service representa-
tive.

6. Quick battery charge

When charging batteries using a quick charger, do it with both battery
terminals removed.

7. Installation of electrical equipment inside of the cab

When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
 EXHAUST BRAKE BR051

EXHAUST BRAKE
BR05

BR05-001

EXHAUST BRAKE SYSTEM ....................BR05-2

SYSTEM DIAGRAM ........................................ BR05-2
TROUBLESHOOTING ..................................... BR05-3
ADJUSTMENT................................................. BR05-3

BRAKE CYLINDER...................................BR05-5
DATA AND SPECIFICATIONS ......................... BR05-5
DESCRIPTION ................................................ BR05-5
BR052 EXHAUST BRAKE

EXHAUST BRAKE SYSTEM

SYSTEM DIAGRAM
EN06Z0805J100001

Manual transmission

Fine line : Electric line

Thick line : Air line
Dotted line : In case of manual transmission

4
2

A 5
10 12
1

3 11
7
6

B 9

Automatic transmission and ultrashift transmission

No. 2, 10 and 12 circuit are less. Three is No. 3 instead of this with automatic transmission and UltraShift transmission.
(One point chain line)
SHTS06Z080500001

1 ABS exhaust cut relay 8 Exhaust brake magnetic valve

2 Neutral switch (Manual T/M) 9 Exhaust control cylinder
3 Wiper and retarder switch (Automatic T/M and Ultra- 10 Exhaust clutch switch (Manual T/M)
Shift T/M)
4 Exhaust brake light 11 Signal of neutral
5 Engine U2 ECU 12 Wiper and retarder switch (Manual T/M)
6 U2 exhaust relay A From power source
7 Signal of engine stop B From air tank
 EXHAUST BRAKE BR053

TROUBLESHOOTING
EN06Z0805F300001

Symptom Possible cause Remedy/Prevention

Switch does not work Defective contacts Check and correct.
Open circuit in harness Check and correct.
Valve does not close Valve clogged with carbon Remove carbon.
Burnt shaft Check and correct.

ADJUSTMENT
EN06Z0805H300001

ACCELERATOR SWITCH ADJUSTMENT

1. ADJUST THE ACCELERATOR PEDAL HEIGHT.

(1) Adjust the accelerator pedal height at the accelerator pedal assembly
mounting section.
(2) ADJUST THE OUTPUT VOLTAGE OF THE ACCELERATOR PEDAL
STROKE SENSOR.
a. Use HINO DX to check the output voltage of the accelerator
pedal stroke sensor. In case the output voltage does not conform
to the standard, shift the mounting position of the sensor in the
direction of rotation (at the long hole of the sensor) for adjustment
or replace the sensor with new one.
Specific value Units: V
Idle Sensor No.1 0.7-1.0
(Pedal stroke: 0 mm {0 in.}) Sensor No.2 1.5-1.8
Sensor No.1 3.1-4.0
Full (Pedal stroke: MAX)
Sensor No.2 3.9-4.8
Exhaust brake switch "ON" 0.7-1.0

SHTS06Z080500003
BR054 EXHAUST BRAKE

CLUTCH SWITCH ADJUSTMENT (MANUAL TRANSMIS-

SION)
The clutch switch should not be knocked against.
With the clutch pedal release, the clearance between the plastic bush and
the clutch switch's tip should be 0.5-1.5 mm {0.020-0.059 in.}.
Assembly standard: 0.5-1.5 mm {0.020-0.059 in.}

SHTS06Z080500004
 EXHAUST BRAKE BR055

BRAKE CYLINDER
DATA AND SPECIFICATIONS
EN06Z0805I200001

Type Butterfly valve

DESCRIPTION
EN06Z0805C100001

10

11

9 12
6

7 4 8

SHTS06Z080500005

1 Control cylinder 7 Body

2 Plate 8 Seal ring
3 Plate 9 Lever
4 Valve 10 Pin
5 Shaft 11 Clevis
6 Bush 12 Pin
 PARKING BRAKE (BOSCH 12") BR071

PARKING BRAKE (BOSCH 12")

BR07

BR07-001

PARKING BRAKE ASSEMBLY ................BR07-2

DATA AND SPECIFICATIONS ......................... BR07-2
DESCRIPTION ................................................ BR07-2
TROUBLESHOOTING ..................................... BR07-3
COMPONENT LOCATOR................................ BR07-4
OVERHAUL ..................................................... BR07-6
INSPECTION AND REPAIR .......................... BR07-20
ADJUSTMENT............................................... BR07-21
BR072 PARKING BRAKE (BOSCH 12")

PARKING BRAKE ASSEMBLY

DATA AND SPECIFICATIONS
EN06Z0807I200001

Parking brake type Duplex Cam mechanical brake, internal expanding acting type

Parking brake control type Lever type control with control cable

Drum inside diameter 304.8 mm {12.0 in.}

Brake lining Width 76.2 mm {3.0 in}

DESCRIPTION
EN06Z0807C100001

SHTS06Z080700001

1 Parking brake lever 5 Parking brake cable

2 Knob 6 Parking brake switch
3 Brake lever bracket 7 Parking brake assembly
4 Knob cover
 PARKING BRAKE (BOSCH 12") BR073

TROUBLESHOOTING
EN06Z0807F300001

Symptom Possible cause Remedy/Prevention

Light force or lack of resistance Shoe cage under-adjusted(*1) Adjust shoes per cage adjustment pro-
when applying brake lever (on man- cedure.
ual apply systems) Worn or deformed actuation compo- Inspect and replace per Anchor Screw,
nents (lever, cam lugs shoe ends) Lever and Cam.
Replacement procedure or Shoe
Replacement procedure
Maladjusted control linkage Readjust.
Heavy force or excessive resistance Over adjusted brake Adjust brake cage clearance diameter.
when applying when applying brake Apply system over adjusted. Adjust or repair per manufactures rec-
lever (on manual apply system) ommended procedures.
Brake does not release. Internal damage to brake. Inspect and replace damaged compo-
nents.
Apply cable bound up. Check cable for corrosion, binding,
kinks, or damage.
The parking brake lever in the cab is Check the parking brake lever assem-
binding bly for damage or corrosion.
Repair or replace as needed.
Brake does not hold vehicle on hill. Grease, oil or other foreign material on Replace shoes and clean drum(*2).
or embedded in shoe linings.
Damaged or incorrect shoes. Replace with correct shoes.
Worn out lining (metal shoe run con- Replace shoes and resurface or
tacting drum) replace drum as necessary.
Excessive drum runout. Resurface or replace drum per manu-
facturers recommended procedure.
Shoe cage under-adjusted. Adjust shoes per primary (or alternate)
Shoe Cage Adjustment procedure.
Worn or deformed actuation compo- Inspect and replace per Anchor,
nents (lever, cam lugs, shoe). Screw, Lever and Cam.
Replacement procedure

*1: Inspect adjuster components to see if any are damaged or jammed.

*2: Inspect the rear pinion seal for leakage that can contaminate the park brake system part. Repair as necessary.
BR074 PARKING BRAKE (BOSCH 12")

COMPONENT LOCATOR
EN06Z0807D100001

PARKING BRAKE LEVER

SHTS06Z080700002

1 Parking brake lever 5 Parking brake switch

2 Knob 6 Bolt
3 Brake lever bracket 7 Knob cover
4 Clevis 8 Bolt

Tightening torque Unit: Nm {kgfcm, lbfft}

A 42-62 {430-630, 31-46} B 1.1-1.9 {12-19, 0.9-1.4}
 PARKING BRAKE (BOSCH 12") BR075

PARKING BRAKE

SHTS06Z080700003
BR076 PARKING BRAKE (BOSCH 12")

1 Brake drum 10 Adjuster nut

2 Parking brake assembly 11 Lever return spring
3 Companion flange 12 Lower return spring
4 End yoke 13 Upper return spring
5 Backing plate 14 Hold-down bracket
6 Brake shoe 15 Hold-down spring
7 Lever 16 Auto adjuster lever
8 Cam plate 17 Adjuster cable
9 Adjuster screw 18 Auto adjuster spring

Tightening torque Unit: Nm {kgfcm, lbfft}

A 1,251-1,535 {12,757-15,653, 923-1,132 } C 55-75 {561-765, 41-55}
B 270-350 {2,753-3,569, 200-258} D 90-110 {918-1,120, 67-81}

OVERHAUL
EN06Z0807H200001

SHOE REPLACEMENT

1. REMOVING THE SHOES

(1) Block the front wheels to keep the vehicle from moving.
(2) With the engine off and battery disconnected, place the transmission
in gear and release the parking brake.
(3) If recommended in vehicle manufacturers service manual, raise the
rear of the vehicle so the wheels clear the floor and install safety
stands to support.
(4) Remove the drum. See vehicle manufacturers service manual for
details, if necessary.

! CAUTION
Do not use a drum puller or a torch to remove a brake drum.
SHTS06Z080700004 Drum distortion may result.
NOTICE
If the drum proves difficult to remove, insert a thin flat bladed screw-
driver through the brake adjusting hole in the backing plate and dis-
engage the adjuster lever from the adjuster nut teeth. With the
adjuster lever disengaged as shown in Figures 8 and 9, insert a brake
adjusting tool (or flat bladed screw driver) through the adjusting hole
to engage the adjusting nut teeth. Move the teeth upward enough
times to retract the brake shoes to clear the drum. If the drum is
rusted to the axle input flange yoke pilot, tap the center of the brake
drum with a nonmetallic mallet to loosen.
(5) Inspect the brake per the INSPECTION PROCEDURE in this service
manual.
(6) Detach adjuster cable from adjuster lever, slide cable off of adjuster
cable guide, and remove the cable retaining tab if so equipped. See
Figure 1.
(7) Remove the adjuster lever and the adjuster spring. (These parts will
need to be placed on the new replacement shoe, along with the
adjuster lever mounting pin, in the opposite order removed.) See Fig-
ure 1.
 PARKING BRAKE (BOSCH 12") BR077

(8) Remove both shoe-return springs. Use pliers, vice-grips, or a heavy

duty brake spring tool as shown in Figure 2.

SHTS06Z080700005

(9) Remove both shoe hold-down springs. Use a brake shoe spring tool
as shown in Figure 3.
HINT
Detach the parking brake apply cable and lever return spring from the
end of the lever to allow easier access to the spring on the lever side.
NOTICE
If the brake is a Release 2 level design with a lever guide present, it
will need to be removed to provide access to the spring underneath
with the tool shown in Figure 9. Upon removal of the hold down
springs, the shoes, and the adjuster nut screw assembly will fall if not
SHTS06Z080700006
secured by hand.
(10) Remove brake shoes from backing plate.
(11) Disassemble the adjuster nut and screw assembly for cleaning and
inspection of the threads.
BR078 PARKING BRAKE (BOSCH 12")

2. INSTALLING THE SHOES

! WARNING
Failure to correctly assemble the Adjuster Cable may result in
reduced brake performance that could cause personal injury or
property damage.
Torque all fasteners to the manufacturers recommended torque
using a torque wrench. Failure to do so could possibly result in
personal injury or property damage.
(1) Clean backing plate and adjuster screw assembly. Remove old grease
from shoe contact points and adjuster threads as well as debris and
corrosion that could contaminate linings or interfere with proper brake
operation.
(2) Apply a light film of Wolfrakote paste ledge grease to the six (6) back-
ing plate shoe ledges and one (1) anchor post as shown in Figure 4.
(3) Apply Chevron RPM heavy duty, lithium complex, molybdenum
disulfide, extreme pressure grease, or equivalent, to the cam plate
lugs where they contact the shoe ends, the end of the shoes that con-
tact the cam lugs, and the brake lever.

SHTS06Z080700007

(4) Apply Chevron RPM heavy duty, lithium complex, molybdenum

disulfide, extreme pressure grease to the threads of the adjuster
screw, adjuster nut, and the socket ends of the adjuster nut and install
the screw fully into the adjuster nut. Insure the screw moves in and out
freely. If any damage to the threads prohibits free movement, or if the
starwheel is damaged, replace adjuster assembly. See Figure 4.
NOTICE
Only use the approved lubricants as specified. Do not substitute.
When installing new shoes, make sure the shoe with the adjuster
cable guide and adjuster lever pin is installed on the correct side
of the shoe. See Figure 5.
(5) Place one shoe into the installed position. Reattach shoe hold-down
spring and pin. See Figures 3 and 5.
! CAUTION
For Steps (5) through (10), proper orientation of the various springs,
including their hook-ends must be maintained, as shown in Figure 5,
for proper brake function.
(6) Position the second shoe and the adjuster nut and screw assembly as
shown in Figure 5. The adjuster nut (internally threaded) should be
seated against the shoe with the adjuster cable guide and pin. Reat-
tach shoe hold-down spring to shoe hold-down pin using the brake
spring tool as shown in Figure 3.
(7) Install both shoe-return springs as shown in Figure 5.
(8) Install the adjuster spring and the adjuster lever. Ensure that the
adjuster lever is properly seated against the starwheel as shown in
Figure 5.
PARKING BRAKE (BOSCH 12") BR079

(9) If the lever has been removed, reinstall lever and associated compo-
nents per the ANCHOR SCREW, LEVER, AND CAM REPLACE-
MENT section in the manual.

SHTS06Z080700008
(10) Route the adjuster cable around the adjuster cable guide, under the
shoe hold down spring, and attach to the adjuster lever as shown in
Figure 6. Install adjuster cable retaining tab if so equipped.
NOTICE
Correctly assembled, the adjuster cable end-fitting is behind the
adjuster lever, with the spring hook facing out as shown in Figure 6.
(11) The shoe cage should be adjusted now per the SHOE CAGE
ADJUSTMENT PRIMARY procedure or after the drum has been rein-
stalled per the SHOE CAGE ADJUSTMENT ALTERNATE procedure
in this service manual.
(12) Make a final inspection of the shoe linings and the inside of the drum
to ensure that no grease or other contamination was accidentally
applied.
! WARNING
Keep grease and other foreign materials away from the shoe lining
and drum surfaces. Contamination of shoe linings or drum surface
may result in degradation of brake holding capability, possibly result-
ing in personal injury or property damage.
(13) Inspect, service and reinstall drum per the vehicle manufacturer's ser-
vice manual.
BR0710 PARKING BRAKE (BOSCH 12")

(14) Lower the vehicle and test the brake for proper function before return-
ing the vehicle for service use. If necessary, make adjustments per
the vehicle manufacturer's service manual.

SHTS06Z080700009
PARKING BRAKE (BOSCH 12") BR0711

SHOE CAGE ADJUSTMENT PROCEDURES

1. ADJUSTMENT WITH DRUM OFF - PRIMARY PROCEDURE

(1) Use a 12 inch caliper, or inside micrometer, to measure the inside
diameter of the drum. Subtract 0.025 inches from the drum inside
diameter measurement. Set the measurement caliper to this value,
and lock the set screw.
(2) Rotate the axle input flange yoke as necessary to provide clearance
for the measurement caliper.
(3) Place the pre-adjusted caliper over the shoes at the center of the
shoes.
(4) To adjust brake, rotate the starwheel until the shoes touch the mea-
surement caliper jaws. It is necessary to disengage the adjuster lever
away from the starwheel. See Figure 7.
NOTICE
During adjustment the calipers should be moved up and down around
the shoe center points to ensure adjustment at the highest points
across the width of the shoes.

SHTS06Z080700010
BR0712 PARKING BRAKE (BOSCH 12")

2. ADJUSTMENT WITH DRUM INSTALLED - ALTERNATE PROCE-

DURE
(1) With the engine off, the battery disconnected, and the tires blocked to
prevent vehicle movement, place transmission in neutral and fully
release the parking brake. Check to see if the drum can be rotated
back and forth by hand. If the drum cannot rotate, it will be necessary
to raise the rear wheels off the ground, in order to allow rotation of the
drum. Support the vehicle with suitable floor stands.
NOTICE
Some vehicles may not have enough clearance behind the park brake
to have direct access through the access slot to the adjuster lever. In
these cases, an adjuster lever tool can be made from 3/32"diameter
welding filler rod. See Figure 10.
(2) Insert the adjuster lever tool or a thin flat bladed screw driver through
the adjusting slot in the backplate and push on the adjuster lever to
disengage it from the adjuster starwheel. Insert a brake adjusting tool
(or flathead screwdriver) through the adjusting slot and move the star-
wheel teeth downward to expand the brake shoes outward. See Fig-
ures 8and 9. Continue expanding the shoes until the drum can not be
rotated by hand.
(3) Now adjust the starwheel teeth upward to retract the shoes until the
drum just begins to rotate freely by hand (without drag from the
shoes). See Figures 8 and 9.

SHTS06Z080700011
PARKING BRAKE (BOSCH 12") BR0713

3. DISENGAGING ADJUSTER LEVER FROM ADJUSTER STAR-

WHEEL TO ALLOW RETRACTING THE BRAKE SHOES (LOOSEN
BRAKE)
NOTICE
Some vehicles may not have enough clearance behind the park brake
to have direct access through the access slot to the adjuster lever. In
these cases, an adjuster lever tool can be made from 3/32 inch diame-
ter welding filler rod. See Figure 10.

SHTS06Z080700012
BR0714 PARKING BRAKE (BOSCH 12")

ANCHOR SCREW, LEVER AND CAM REPLACEMENT

1. REMOVING COMPONENTS
NOTICE
The anchor screw, lever, and cam should all be replaced at the same
time. Do not replace just one or two of the three parts at any time.
Inspection of these parts is recommended at 250,000 miles or 5 years
for typical use, or more often under severe operating conditions.
(1) Block the front wheels to keep the vehicle from moving.
(2) With the engine off and battery disconnected, place the transmission
in gear and fully release the parking brake.
(3) If recommended in vehicle manufacturer's service manual, raise the
rear of the vehicle so the wheels clear the floor and install safety
stands to support.
(4) Remove the drum. See vehicle manufacturer's service manual for
details, if necessary.
! CAUTION
Do not use a drum puller or a torch to remove a brake drum.
Drum distortion may result.
NOTICE
If the drum proves difficult to remove, insert a narrow screwdriver
through the brake adjusting hole in the backing plate and disengage
the adjuster lever from the adjuster nut starwheel teeth. With adjuster
lever disengaged as shown in Figures 8 and 9, insert a brake adjust-
ing tool (or screw driver) through the adjusting hole to engage the
adjusting nut teeth. Move the teeth upward enough times to retract
the brake shoes to clear the drum. If the drum is rusted to the axle
input flange yoke pilot, tap the center of the brake drum with a non-
metallic mallet to loosen.
(5) Inspect the brake per the INSPECTION procedure in this service
manual.
(6) Detach the parking brake apply cable and lever return spring from end
of brake lever. Remove the apply lever guide (on Release brakes).
(7) Detach adjuster cable from the adjuster lever and slide adjuster cable
off the adjuster cable guide, remove retaining tab if so equipped. See
Figure 1.
(8) Remove the anchor screw. See Figure 11.
NOTICE
On Release 1 brakes with a hex socket anchor screw, the use of a
thread-locking compound may prevent removal of the anchor screw
with a hex key and torque in excess of 55 Nm (40 ft.-lbs.) May break or
deform a 6 mm hex key. If necessary, use a pipe wrench, vice grips, or
similar tool on the knurling of the head to loosen the anchor screw.
Replace screw if removed, regardless of condition.
PARKING BRAKE (BOSCH 12") BR0715

(9) Remove the flat washers (if installed on your application for Release 1
level brake), anti-rattle spring, lever, cam, and adjuster cable. See Fig-
ure 11.

SHTS06Z080700013

2. INSTALLING COMPONENTS
NOTICE
If for any reason the cam, lever, and anchor screw is removed, a com-
plete new set is recommended for service.
(1) Remove the cured thread-locking compound from the anchor post
hole threads. Run the appropriate size tap completely into the anchor
post and back out to clean the threads. Remove loose debris from
anchor post hole.
NOTICE
For brakes with a hex socket head anchor screw, use an M10 x 1.5 tap
(brakes manufactured prior to April 2002). For brakes with an external
hex head anchor screw, use and M12 x 1.75 tap (brakes manufactured
after April 2002).
(2) Apply Chevron heavy duty lithium complex extreme pressure grease,
or equivalent, to the cam plate lugs where they contact the shoes and
the apply lever, to the cam plate slotted hole and top and bottom
faces. Apply grease to the brake lever pivot hole and the contact sur-
faces with the cam plate lugs. Apply grease to the non-threaded por-
tion of the anchor screw. Do not get grease on anchor screw threads
or in anchor post threaded hole.
BR0716 PARKING BRAKE (BOSCH 12")

(3) Reinstall the adjuster cable, new cam plate, new lever, anti-rattle
spring (small coil end toward screw head for Release 2), flat washers
(if previously installed on your application), and new anchor screw as
shown in Figure 12. Make sure the adjuster cable end fitting is
installed to allow the cam plate to sit flat on the fitting and anchor post.
Stepped type end fitting - the step faces towards the backplate. See
Figure 12.
Alternate "eyelet" type fitting - cable crimp portion faces towards the
backplate. See Figure 12.
! CAUTION
Only thread anchor screw into the anchor post 1 to 2 turns to
temporarily hold assembly together. Do not thread in completely
until ready to tighten to specification (step (4)).
A faulty installation will result if the thread-locking compound is
activated and begins to cure prior to tightening the screw.
When installing the hex socket head anchor screw, careful atten-
tion should be taken during reassembly to ensure that the
adjuster cable-end fitting is not clamped underneath the shoul-
der of the anchor screw during reassembly.
Clamping the adjuster cable may prevent proper functioning of
the brake selfadjust feature.
(4) Tighten the anchor screw per the appropriate specification:
For the internal hex socket anchor screw tighten to 503 Nm (372 ft-
lbs.)
For the external hex head anchor screw tighten to 10010 Nm (747
ft-lbs.)
! CAUTION
To tighten the anchor screw, only use a recently calibrated, known
good, clicker type torque wrench set to the correct torque specifica-
tion. Do not use add on devices such as universal joints, swivels,
crows feet or other devices as these can cause inaccurate tightening
results. Do not attempt this repair if a recently calibrated, known good
clicker type torque wrench is not available.
Failure to do so could result in personal injury or property damage.
NOTICE
Remove excess grease that could contaminate brake drum or linings
while the brake is in service.
(5) Reinstall the lever return spring and parking brake cable to the end of
the brake lever.
(6) Route the adjuster cable around the adjuster cable guide, under the
shoe hold-down spring, and attach to the adjuster lever as shown in
Figure 6. Install adjuster cable retainer tab if equipped.
NOTICE
When correctly assembled, the adjuster cable end-fitting is behind the
adjuster lever with the spring hook facing out as shown in Figures 6
and 12. Failure to do so may result in reduced brake operation.
PARKING BRAKE (BOSCH 12") BR0717

SHTS06Z080700014
(7) The shoe cage should now be adjusted per the SHOE CAGE
ADJUSTMENT PRIMARY procedure or after the drum has been rein-
stalled, per the SHOE CAGE ADJUSTMENT ALTERNATE procedure
in this service manual.
(8) Make a final inspection of the shoe linings and the inside of the drum
to ensure that no grease or other contamination is present.
! CAUTION
Keep grease and other foreign materials away from the shoe lining
and drum surfaces. Contamination of shoe linings or drum surface
may result in degradation of brake holding capability, possibly result-
ing in personal injury or property damage.
(9) Inspect, service, then reinstall drum per the vehicle manufacturer's
service manual.
(10) Lower vehicle and remove the blocks or wheel chocks from the front
wheels.
(11) Test the brake for proper function before returning the vehicle for ser-
vice use. If necessary, make adjustments per the vehicle manufac-
turers service manual.
BR0718 PARKING BRAKE (BOSCH 12")

INSPECTION

1. INSPECT PARTS.
NOTICE
It is not necessary to raise vehicle for inspection in most cases.
However, if required, follow steps (1) through (3) in SHOE REPLACE-
MENT section.
Anytime service is required, it is recommended that a complete
visual inspection be performed on all components in the park
brake assembly. This includes:
(1) Follow manufacturers recommended procedures to ready the vehicle
for servicing. Pay attention to all WARNING and CAUTION notes
throughout this booklet.
(2) Remove the drum. See section on SHOE REPLACEMENT.
(3) Clean the individual brake components, removing dust and grease.
(4) Visually inspect the brake shoes (Figure 13). Shoes should be
replaced if there is uneven lining wear or when the remaining lining
reaches 0.76 mm (0.030 in. or approximately 1/32 in.) thickness or
less above the shoe. If grease, automotive fluids, or other foreign
material that would compromise operation is found on, soaked into or
embedded in the linings, the shoes should be replaced. Also, if
cracks, excessive deformation, or wear on either end is found, the
shoes should be replaced. See section on SHOE REPLACEMENT for
service details.
(5) Visually inspect the brake lever and cam (COMPONENT LOCATOR).
If cracks, excessive wear, or abnormal deformation is found in either
part, they should be replaced. Light wear, which typically shows up as
polishing is acceptable. If unsure, replace brake lever, cam plate and
anchor screw. See section on ANCHOR SCREW, LEVER, AND CAM
REPLACEMENT for service details.
(6) Inspect various springs and hold down pins (Figure 13) for excessive
wear, heat discoloration, heavy corrosion or other damage and
replace as necessary. See section on SHOE REPLACEMENT for ser-
vice.
! WARNING
Whenever possible, work on brakes in a separate area away from
other operations. Always wear a respirator approved by NIOSH or
MSHA during all brake service procedures. NEVER use compressed
air or dry brushing to clean brake parts or assemblies. OSHA recom-
mends that you use cylinders that enclose the brake. These cylinders
have vacuums with high efficiency HEPA filters and workers arm
access sleeves. But, if such equipment is not available, carefully
clean parts and assemblies in the open air.
Clean brake parts and assemblies in the open air. During disassem-
bly, carefullyhandle all parts to avoid getting dust in the air. Use an
industrial vacuum cleanerwith a HEPA filter system to clean dust from
the brake drums, backing plates and other brake parts. After using the
vacuum, remove any remaining dust with a rag soaked in water and
wrung until nearly dry.
(7) Inspect adjuster cable assembly for damage or wear (Figure 13).
Replace as necessary. See section on SHOE REPLACEMENT for
service details.
(8) Inspect adjuster nut and screw (Figure 13) for any damage or corro-
sion to the threads or burrs, chips, corrosion or other damage to the
teeth on the adjuster nut starwheel. Damaged teeth or threads may
prevent proper function of the brake self-adjusting function. Replace
as necessary. See section SHOE REPLACEMENT for service details.
PARKING BRAKE (BOSCH 12") BR0719

(9) Clean-out all dust or grease present on the inside of drum. Use a 12
inch caliper or an inside diameter micrometer to measure the manu-
facturers recommended inside diameter of the drum. Replace drum if
it exceeds maximum inside diameter (which typically is stamped on
the inside of the drum near the mounting holes), is worn unevenly, has
deep grooves, heavy corrosion or excessive runout.
(10) Inspect the parking brake lever-apply cable for excessive wear or
damage, and replace as necessary.
(11) Inspect the axle pinion oil seal for leakage that can contaminate the
park brake system parts and repair as necessary. See the section
"REAR AXLE" for details.
(12) After a thorough inspection, if the brake and its components are found
to be in good working condition, check parking brake for proper shoe
cage adjustment. See the section "SHOE CAGE ADJUSTMENT
PROCEDURES" for details.

SHTS06Z080700015
BR0720 PARKING BRAKE (BOSCH 12")

INSPECTION AND REPAIR

EN06Z0807H300001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Brake lining: 7.00 0.76 Replace. Measure

Lining thickness {0.277} {0.03}

Brake drum: 304.8 305.7 Replace. Measure

Inside diameter {12} {12.035}
 PARKING BRAKE (BOSCH 12") BR0721

ADJUSTMENT
EN06Z0807H300002

1. INSTALL THE CABLE

(1) Connect the cable inner wire to the brake assy and set the cable to
cab side.
(2) Pull and release the parking brake cable 2 to 3 times with specified
force.
Pull up force: 220-270 N (22-28 kgf, 49-62 lbf) at 207 mm (8.1 in.)
from pivot of the lever.
(3) Adjust the cable connecting pin at specified distance A (See figure on
page BR07-4) by turning the knob.
Distance A: 65 mm (2.56 in.)
(4) Connect the clevis to the parking brake lever.

2. ADJUST THE PARKING BRAKE LEVER

(1) Pull up the parking brake lever 2 to 3 times.

SHTS06Z080700018

(2) Adjust pull up force of parking brake lever to specified force by tighten-
(Example)
ing up a turnbuckle.
Pull up force: 220-270 N (22-28 kgf, 49-62 lbf) at 207 mm (8.1 in.)
from pivot of the lever.
Turnbuckle Turnbuckle Tighten torque:
22-32 Nm (224-326 kgfcm, 16-24 Ibfft)
NOTICE
When connecting the cable or adjusting the turnbuckle, confirm that
the lever is off and there is no tension on the cable.
No.1 cable No.2 or 3 cable (3) Confirm that the male thread end of a turnbuckle is fitted into the
SHTS06Z080700019
female thread more than 12.7 mm (0.5 in.).
(4) Check that there is no drag feeling of the brake with parking lever
released.
(5) Check proper working, holding and cancellation of parking brake by
actually operating the parking brake lever.

3. BRAKE BURNISHING
(1) Burnishing of lining
When replacing lining or drum of parking brake with new parts, be
sure to perform lapping by the following procedure.
Braking force may be extremely lowered without lapping, so be sure to
perform the lapping.
NOTICE
Apply parking brake burnishing only after replacing the lining and in
an emergency when the vehicle is moving.
a. Release parking brake and turn adjusting knob until a control
force becomes approximately 18 kgf (40lbf).
b. Mark ten (10) stops from 16 km/h (10 mph) on a dry, hard surface
road using only parking brake to stop vehicle.
c. After each stop, release parking brake and drive vehicle at 32 km/
h (20 mph) for 4 km (2.5 miles) to cool the brake.
d. After operation, adjust hand lever adjusting knob.
BR0722 PARKING BRAKE (BOSCH 12")

(2) Confirmation of parking brake application.

After completing all-brake adjustment, stop the vehicle on a safe slope
or using a brake tester, confirm whether the parking brake is securely
applied.
Hino Motors Sales U.S.A., Inc.
41180 Bridge Street, Novi, MI 48375
Telephone: (248) 699-9300
PRINTED IN JAPAN

Pub.No. S1-UNAE11A 1/2 '13.11