BENDIX BRSM0890 User's Manual
Contents
1. Clean remove dirt and debris C Check hardness on flange D Replace lining Turn per manufacturer s specifications Blow out debris Bolts Rivets Removal When removing bolts rivets from the brake shoes be careful to avoid doing any damage to the holes in the shoe Do not use a chisel to shear them off The force will elongate the bolt rivet holes Neglecting any elongated holes may result in a loose fitting installation If holes are burred they should be filed down flush with the shoe table Cleaning the Shoe Rust often developes on the surface of the shoe table under the brake lining or blocks During every reline job shoe tables should be cleaned thoroughly The best procedure is to steam clean the entire shoe or put it into a degreaser After cleaning the shoe the shoe should be scraped clean of rust and scale Any burrs or nicks should be filed smooth At the same time the entire shoe should be examined to see if it is worn or bent Shoe Inspection The shoe should be either reconditioned or discarded It is also necessary to check for flat spots on the shoe that can be caused by cleaning away the rust from the area that was under the block previously This can cause a mismatch of shoe and lining arcs After the shoe is cleaned and inspected it should be given a coating of rust preventative paint Treatment of a new unpainted shoe is also suggested to prevent the initial rusting problem Lining Inst2. the clevis pin or pins depending on type of slack adjuster 2 Remove retaining ring and shims from splined end of camshaft 3 Remove slack adjuster from the camshaft A CAUTION Do not hammer on slack adjuster to remove Serious damage to the slack adjuster and or the camshaft splines may result CAMSHAFT REMOVAL 1 Before removing camshaft check to see if cam bushings need replacement See Figure 4 on Page 12 2 Remove spacer from between slack adjuster and cam shaft bracket 3 Grasp camshaft at the camshaft head and pull in the outward direction to remove 4 Clean and inspect camshaft splines and head AIR CHAMBER CAMSHAFT BRACKET ASSMEBLY REMOVAL 1 Remove two nuts and washers that secure brake cham ber to camshaft bracket 2 Remove brake chamber and temporarily set it aside A CAUTION Do not let the air chamber hang by the air lines 3 Remove four bracket mounting bolts and lock washers 4 Remove bracket assembly from spider BRAKE DISASSEMBLY CONTINUED SPIDER REMOVAL 1 Mark the postion of the spider on the axle L H or R H and the orientation on the axle flange by making a reference mark on the spider and flange See Figure 4 2 Remove the spider to axle mounting bolts 3 Remove spider DUST SHIELD REMOVAL 1 Mark dust shields upper left lower right etc prior to removal 2 Detach dust sheild by removing the six cap screws using a 9 16 socket Do not remove dust shield unle
3. 00 0 Sequential Assembly Numbers BRAKE COMPONENTS STANDARD XTRALIFE 16 5 Retaining Ring Camshaft Adjusting O _ Washers Shims Camshaft Bushing On Steel cee we Grease Fitting H Grease Seal Air Chamber Pa Bracket Assembly Bracket Mounting Bolt Ze 70 80 Lb Ft 95 108 N m a Lock Washer Pa e Camshaft Bushing l Grease Seal Dustshield Mounting Bolt 3 8 in 16 20 28 Lb Ft 27 38 N m 4 Steel Spacer Plate Camshaft A Lock Washer Cam Roller I S Shoe Return Spring Retainer Springs Shoe and Lining Assembly Lining Return Spring Pin Rivet BRAKE COMPONENTS 16 5 CAST SHOE SERIES Retaining Ring Camshaft Adjusting O Washers Shims 26 Camshaft Bushing f Air Chamber RS x a Bracket Assembly Steel Spacer 8 Grease Fitting Grease Seal Bracket Mounting Bolt 70 80 Lb Ft 95 108 N m Lock Washer Camshaft Bushing Grease Seal Dustshield Mounting Bolt 3 8 in 16 20 28 Lb Ft 27 38 N m E Lock Washer y R Steel Spacer Plate Dust Shield Half e i ST Camshaft Anchor Pin Retainer Clip Anchor Pin Washer Retainer Clip Co Anchor Pin ET geeg L EE Anchor Pin SE SE Shoe and Lining Assembly Brake Lining Nut Pag 15 17 Lb Ft e 20 23 N m H Lock Washer Brake Lining Brake Lining Bronze Bushing Bolt BRAKE COMPONENTS 16 5 XL II SERIES BRAKE Retaining Ring Camsha
4. 826 HELP 4357 for more time on the road BRSM 0890 05 04 PDF Printed in USA
5. ACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT ATTEMPT TO SAND GRIND CHISEL FILE HAMMER OR ALTER BRAKE LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT FOLLOW 0 S H A STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED WHEN WORKING WITH BRAKE MATERIALS GENERAL PRECAUTIONS CONTINUED PREPARATION 1 Park vehicle on a level surface and prevent 5 Remove wheels and drums using the procedures movement by means other than the brakes specified in the vehicle maintenance manual 2 If equipped with spring brakes cage the spring on WARNING The long term effects of exposure to non all axles to be worked on asbestos has not been determined Avoid creating dust when performing service on brake assemblies Excessive exposure to brake dust may cause respira tory damage or other bodily harm 3 Raise the axle to be worked on until the tires clear the ground Support axle with heavy duty jack stands 4 Back off slack adjuster by turning adjusting nut until the brake shoes are fully retracted Safety glasses should be worn CAUTION Rockwell Auto Slacks require the pawl A at all times when assembling assembly to be removed before turning the adjust or disassembling brakes ing nut WARNING Never work under a vehicle supported only by a jack Always use a jack stand PREVENTATIVE MAINTENANCE A schedule should be established for periodic A CAUTION Drums displaying heat checks with adjustment inspect
6. CTION OF PARTS CONTINUED SHOES AND LINING CAST SHOE TYPE 1 Check shoes for cracks and elongated bolt holes 2 Measure the shoe span by loosely installing the anchor pin and cam roller in the appropriate ends of the shoe rib If the distance from center of anchor pin to center of cam roller exceeds 12 76 inches replace shoe 3 Check linings replace when any of the following conditions exist A Total lining thickness at thinnest point is 31 or less than 1 16 above screw head Also if the material is worn beyond the wear groove on the side of the lining B Linings are cracked or worn in an unusual or odd pattern For example lining wear tapered from side to side across the shoe table Un usual wear pattern can indicate damage to foundation brake parts C Screw holes are elongated D Lining is oil soaked E Lining can be moved by hand loose bolts TRANSIT BRAKE CAST SHOE ONLY DRUM LINING CROSS REFERENCE CHART 1 When installing new drums always use standard thickness lining If used drums are rebored care fully measure inside diameter in several places of rebored drum LINING MAXIMUM THICKNESS IN 867 Standard Thickness 927 1X Oversize 987 Premium Thickness BRAKE DRUMS 1 Inspect drums for cracks heat checking glazing grooving severe out of round condition or bell mouthing must not exceed 025 T I R Total Indicator Reading Replace any drums that are cracked T
7. Roadranger Dana Spicer Brakes Dana E T N 16 5 Series S Cam Cast M XTRALIFE P Series One Great Drivetrain from Two Great Companies XTRALIFE II Service Manual BRSM 0890 October 1997 For the most current information visit the Roadranger web site at www roadranger com TABLE OF CONTENTS Identification eene 2 Brake Components Standard Xtralife e 3 Brake Components Cast Series en 4 Brake Components XL II Series een 5 SPICER Brake Components P Series sssisccsanmundinncasiinn 6 Gegen eenegen 7 Preventative Maintenance een 9 N Brake Eenegung 11 Inspection of Parts ege 12 Brake deeler 15 Trouble Shooting Charts ssissscssssscsstssncsnsinascacnsersssinnsnss 18 Reline Procedure sssssssssssssssssessssrsseesstersseesssenseresneensrerssrese 21 GENUINE SPICER SERVICE PARTS Should a brake assembly require replacement component parts it is recommended that Spicer Brake Service Parts be used Spicer Brake Service Parts are manufactured under the same rigid specification as are original equipment brake components This assures the customer who uses genuine Spicer service parts maximum reliability for a Spicer Brake assembly They may be obtained through your vehicle manufacturer The use of non original Spicer service parts may cause premature compontent failure and may void the warranty The items included in this book are currently being offered as service parts at the time of printing The part num
8. actory brake performance When overhauling the brakes provide equal service to both the left and right side of an axle CAST SHOE amp P SERIES 1 Insert sturdy lever between end of shoe and spider Pry shoe away from cam until cam rollers can be removed Repeat procedure for opposite shoe 2 Unhook shoe return spring by pushing shoes together allow tension on spring to be reduced 3 Discard shoe return spring and replace with new at time of reassembly 4 Remove snap ring from anchor pin and push anchor pin through NOTE Tap lightly with brass drift if anchor pin will not push out with finger 5 Remove brake shoe and place on floor Repeat procedure for opposite shoe STANDARD XL amp XLII SERIES 1 Insert sturdy lever between end of shoe and spider Pry shoe away from cam until cam rollers can be removed Repeat procedure for opposite shoe 2 Unhook shoe return spring by pushing shoes together allow tension on spring to be reduced 3 Discard shoe return spring and replace with new at time of reassembly 4a STANDARD amp XL Remove shoes by rotating the bottom shoe off the anchor pin to release the tension on the two retaining springs 4b XLII SERIES Remove snap ring from anchor pin and push anchor pin through 5 Remove the two retaining springs and discard 6 Remove shoes from spider BRAKE DISASSEMBLY SLACK ADJUSTER REMOVAL 1 Disconnect clevis from slack adjuster arm by removing
9. allation IMPORTANT Never shim the brake linings Brake noise may result because of cracked and or loose lining since a tight installation is not possible with shims The inside surface of the correct arc to match the shoe table and the rivet bolt holes in the linings will only line up with holes in the shoes when they are in direct contact Prior to riveting bolting be sure the holes in the lining blocks and the shoes are exactly matched The sequence of riveting bolting should be such that the center of the block is attached first and then the ends See page 22 for bolting sequence 21 RELINE PROCEDURE Figure 16 The installation should be checked by attempting to insert a 006 feeler gage between the lining and shoe table It should not be possible to insert the feeler gage anywhere along the edge See Figure 16 The only exception is at each end and beyond the last row of rivets bolts A slightly larger clearance may exist in these areas Riveting Application Some brake failures result from the use of rivets which are too short too long or the wrong diameter Incor rect setting of the riveting machine may induce other types of failures The solid portion of the rivet should end just at the inner surface of the shoe The hollow portion of the rivet should extend past the inner surface of the shoe The proper size rivet must be used to completely fill the hole USE ONLY 10 8 RIVETS Brass plated steel rivets a
10. bers and illustrations are provided specifically for reference purposes only Therefore Spicer reserves the right to update this manual without notice or liability The brake assembly may be identified by a tag which is located on the camshaft bracket cylinder near the grease fitting The mylar brake assembly tag contains the following Dana assembly number bar coded customer assembly number and a numeric customer assembly number DANA ASSEMBLY NUMBER SPICER S JUNI sax cove BAR CODE 1 NUMBER Brake Assembly Tag BUILD DATE CUSTOMER APR 1997 AND LATER ASSEMBLY NUMBER SPICER IDENTIFICATION JULIAN DATE CODE MODEL YEAR DAY OF YEAR Two other markings that may be used to identify a Spicer Brake assembly are located on the assembly s components Spicer will be cast into the spider assembly just above the anchor pins Also the inside of the chamber bracket arm contains the following stamped part information Spicer julian date code and the part number BRAKE ASSEMBLY TAG CHAMBER ia BRACKET ARM STAMPED PART INFORMATION Camshaft Bracket STAMPED PART INFORMATION IN ONE OF THESE AREAS Camshaft MODEL IDENTIFICATION NUMBERING SYSTEM Model 165 16 5 Brake 150 15 Brake Alphabetical Code De WD Brake Assembly 165 WD 0
11. cap screws and lockwashers to 20 28 Lb Ft of torque SPIDER 1 Use a wire brush to remove heavy contamination from the spider mounting flange knuckle spider brake drum exterior and chamber mounting bracket 2 Install the spider and chamber bracket assembly onto the axle flange Be sure spider is properly oriented as noted during disassembly Tighten mounting fastener to manufacturer s specifications CAMSHAFT 1 Prior to reassembly verify the part number is correct there are L H and R H camshafts and they can not be interchanged See Figure 12 Left Hand Cam Right Hand Cam Figure 12 A CAUTION Left Hand and Right Hand does not establish which side of the vehicle the cam goes on Left and right are used to identify the two different types of cams only 2 Place steel spacer plate over splined end and slide next to cam head See brake components on pages 3 6 3 Coat bushing seals journals and camshaft spline with light film of chassis lube IMPORTANT Do not coat S cam head 4 Carefully install camshaft through the chamber bracket tube from spider end Cam must rotate freely when turned by hand IMPORTANT Be careful not to damage the grease seals SPICER S CAM BRAKE RETURN SPRINGS Brake Series Return Springs P N amp Color Standard 165WJ110 Dark Blue XL amp Cast Shoe 165WJ115 White XLII 165WJ129 Light Blue BRAKE SHOE ASSEMBLY STANDARD XL amp XLII SERIES 1 Install new r
12. d 1 282 Replace bushing if necessary STANDARD amp XL SERIES 2b The anchor pins are staked into the spider and are not serviced separately If the pins are loose or grooved more than 030 inch the spider assembly must be replaced Figure 7 ROLLERS AND ANCHOR PINS BUSHINGS 1 Inspect rollers and anchor pins for flat spots galling broken or cracked surfaces Replace as necessary See Figure 8 CEB Figure 8 INSPECTION OF PARTS SHOES AND LINING STANDARD XL XL II AND P SERIES 1 Check shoes for bent shoe ribs cracks in shoe table welds or ribs and elongated rivet holes Replace shoes if any of these conditions exist See Figure 9 Measure the shoe span by loosely installing the anchor pin and cam roller in the appropriate ends of the shoe rib If the distance from center of anchor pin to center of cam roller exceeds 12 76 inches replace shoe Check linings and replace when any of the following conditions exist See page 21 for reline procedure A Total lining thickness at thinnest point is 1 4 or less or 1 16 above the rivets B Linings are cracked or worn in an unusual or odd pattern For example lining wear tapered from side to side across the shoe table Un usual wear pattern can indicate damage to foundation brake parts C Rivet holes are elongated in lining or shoes D Lining is oil soaked E Linings can be moved by hand because of loose rivets Figure 9 INSPE
13. djust brake Deglaze linings or replace Replace linings Replace part Adjust clevice shorten push rod length Reposition Replace part Replace flat spotted parts Clean and lubricate Check for seal leakage A Clean and lubricate NnS ET o gt onmo gt I Replace part Replace flat spotted parts Replace lining Deglaze lining or replace Replace linings Replace linings Turn per manufacturer s specifications Replace part Clean and lubricate Replace part Adjust brakes Replace part Inspect and replace as necessary Use same size and type both ends of the axle SYMPTOM 1 Poor lining to drum contact 2 Linings tapered across width 3 Unequal wear on same brake 4 Unequal wear side to side brakes same axle 5 Wear on edge of lining 6 Glazed linings hard amp shiny oo gt mon gt op gt mo moO DP gt gt TO MON gt BRAKE SHOE amp LINING TROUBLESHOOTING CHART CAUSE Bell mouth drum Bent brake spider Bent or stretched brake shoe Undersize linings Loose wheel bearing Improper lining grind Bell mouth drum Bent brake shoe Bent brake spider Loose wheel bearings Mismatched lining friction codes Stretched shoe Flat spots on cam or roller Worn anchor pin Worn camshaft or bushings Mismatched lining friction codes Seized or binding camshaft Brake drum surface in poor condi
14. ement equals or exceeds the maximum readjust stroke the brakes need to be adjusted See Figure 3 If adjustment is required spin the wheel slowly and adjust the slack adjuster just enough for wheel to spin freely Be sure to adjust brakes equally on each axle 5 Apply and release brakes and observe slack adjusters Both slacks on each axle should respond rapidly and in unison during application and release 6 Drive vehicle at a low speed in a safe area and check for brake effectiveness prior to putting back in service A Released Position B Applied Postion Figure 3 BRAKE LUBRICTION Lubricate the camshaft thru the grease fitting on the camshaft bracket with the chassis lube specified by the vehicle manufacturer Lube once every six months or at every chassis lubrication BRAKE RELINE The life of the brake lining is dependent on many factors such as the material of the lining type of operation the vehicle is used for geographic terrain maintenance practice of the shop and the driver of the vehicle If driving conditions require frequent braking lining replacement will be required more often FOR RIVET LINING Reline when thickness of lining is 1 4 at thinnest point or 1 16 above rivet head FOR CAST SHOES WITH BOLTED LININGS Reline when lining is below wear indicator line or thickness is 31 at the thinnest point or 1 16 above bolt head BRAKE OVERHAUL As often as necessary to maintain satisf
15. eturn spring pins A Standard Series Wireform pin installed in shoe ribs with mallet B XL Series 2 piece kit assembly consisting of inner pin and outer pin 2 Apply a thin film of Lubriplate 630 A grease or its equivalent to the anchor pin 3 Install new brake retaining springs in the anchor end of shoes Place the top shoe onto the spider by engaging the open slots on the end with the retaining springs onto the anchor pin Place opposite end of the shoe against the S cam Swing the lower shoe with springs attached back until slots in the shoe engage the anchor pin Rotate the shoe toward the S cam Lower shoe may require support while completing assembly 4a Standard Series Utilize leg on shoe return spring to aid in assembly Place the one hook of the brake shoe return spring onto the return spring pin Hold shoes firmly against the S cam Push the other hook of the brake shoe return spring over the opposite return spring pin until it snaps in place 4b XL XL Il Series place the one hook of the brake shoe return spring onto the return spring pin located between the shoe ribs Hold both shoes against the S cam head Push the other hook of the return spring over the opposite shoe spring pin until it snaps in place 5 Apply a thin film of Lubriplate 630 A grease or its equivalent to the cam roller journal and the roller side only Do not put grease on the end of the roller which contacts the cam head 6 Insert stu
16. ft Adjusting Washer Steel Spacer 06 Grease Seal Grease Fitting Camshaft Bushing D Camshaft Bracket D Camshaft Bushing Grease Seal Bracket Mounting Bolt d 70 80 Lb Ft Dust Shield Hal 95 108 N m Og H Shield Half Lock Washer E Dustshield Mounting Bolt 3 8 in 16 20 28 Lb Ft Ga Shoe and Lock Washer Cam Roller Lining Assembly Camshaft Dust Shield Half Shoe Return Spring Shoe Retainer Spring Return Spring Pin BRAKE COMPONENTS 16 5 P SERIES BRAKE Retainer Ring Camshaft Adjusting Washer Steel Spacer Grease Seal e Camshaft Bushing 5 Grease Fitting Camshaft Bracket e Camshaft Bushing Bracket Mounting Bolt ge Seal 70 80 Lb Ft 95 108 N m Shield Half Lock Washer i i Cam Roller Dustshield Mounting Bolt 3 8 in 16 E Retainer Clip 20 28 Lb Ft 27 38 N m Lock Washer Anchor Pin Washer Snap Ring Cam Roller Q Shoe Return Spring Return Spring Pin Brake Lining Rivet GENERAL PRECAUTIONS A IMPORTANT READ THIS SECTION BEFORE STARTING ANY SERVICE PROCEDURES All Spicer original equipment or service parts for steering and drive axle brakes are manufactured using non asbestos brake lining It is recommended that original Spicer service parts be used when brake mainte nance is necessary SAFETY PRECAUTIONS Proper service and repair of vehicle compone
17. he drum should not be used if it exceeds the manufacturer s recommended maximum diameter stamped on the drum Measure the drum LD to be sure the maximum limit allowed stamped on drum has not been exceeded due to wear or machining A CAUTION Drums displaying heat checks with a continuous length of four inches or more and extend around the edge of the drum should be replaced See Figure 10 2 Figure 10 Refer to the chart below for proper oversized lining required based on drum measurements A CAUTION Never shim brake linings See page 21 Reline Procedure for more detail DRUM DIA IN AT RELINE 16 500 New 16 620 Over 16 620 CAUTION Maximum discard diameter is 16 750 BRAKE ASSEMBLY CHAMBER BRACKET ASSEMBLY Seal Installation NOTE Both lip seals point the same direction lip toward the slack uaa Lip Seal End Cam Slack Adjuster End Actuator Bracket and Cam Tube Figure 11 A CAUTION The lip of the grease seals must be installed correctly to prevent posssible damage The lip of the seal that is installed in the spider end must enter the opening first The lip of the seal that is installed in the opposite end of the cam tube must enter last See Figure 11 Install the chamber bracket and the cam tube assembly onto the spider using four cap screws and lockwashers Torque to 70 80 Lb Ft If removed reinstall the dust shields Tighten the six
18. ion and lubrication This sched a continuous length of four inches or more and ule is determined from vehicle owner operators extends around the edge of the drum should be experience and the type of operation replaced See Figure 1 BRAKE DRUMS Inspect for heat checks grooves hot spots glazing cracks and out of round Drums which are glazed grooved or have moderate heat checking may be resurfaced and returned to service The drum should not be used if it exceeds the manufacturer s recom mended maximum diameter stamped on the drum BRAKE ADJUSTMENT Brakes should be adjusted whenever the air chamber push rod stroke exceeds the maximum distance accord ing to the chart shown in Figure 2 To determine if Figure 1 brake adjustment is required measure the push rod stroke with the brakes applied as shown in Figure 3 on page 10 RECOMMENED AIR BRAKE ACTUATOR SERVICE STROKE Chamber Size Standard Chamber Long Stroke Chamber Type Rated Stroke Max Readjust Stroke Rated Stroke Max Readjust Stroke Source The Maintenance Council RP 635 Figure 2 PREVENTATIVE MAINTENANCE MEASURING PUSH ROD STROKE 1 Measure the distance between the air chamber mounting face and the center of the clevis pin with brakes released 2 Make an 70 90 PSI application and hold it Measure the distance between the air chamber and the mounting face and the center of the clevis pin 3 Subtract measurement A from measurement B If this measur
19. nts is important to the safe and reliable operation of all motor vehicles This applies particularly to brakes such as the ones described in this manual The procedures recom mended and described in this manual are tested effective methods for performing service operation Follow each procedure closely making use of both the text and pictures Some of these service procedures show the use of certain tools designed especially for the operation being performed It is not mandatory that these tools be used they are shown only as preferred means of performing the operation It is not practical to anticipate and advise the service trade of all possible alternate service methods and of all possible hazardous consequences that could result from any particular method Accordingly anyone who uses a service procedure or tool different than shown must insure that their safety and that the vehicle s safety will not be jeopardized by the service method selected A CAUTION When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may automatically apply as system pressure drops 2 Never connect or disconnect a hose or line con taining air pressure It may whip as air escapes Never remove a comp
20. onent or pipe plug unless you are certain all system pressure has been depleted Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools Use only genuine Spicer replacement parts and components A Only components devices mounting and attaching hardware specifically designed for use in air brake systems should be used Replacement hardware tubing hose fittings etc should be of equivalent size type length and strength as the original equipment Make certain that when replacing tubing or hose all supports clamps or suspending devices that were originally installed by the vehicle manufac turer are reinstalled Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted a CAUTION BRAKE LININGS CONTAIN NON ASBESTOS FIBERS BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM AVOID CREATING DUST DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT REPL
21. oper size rivets too long too short improper diameter Improper crimping of rivet Enlarged rivet holes in shoe Incorrect lining hole size or counter bore depth Rust build up on shoe table Wrong type rivets Rivets not properly crimped Dirt or rust on shoe table Wrong size lining counter bore Loose rivets A Replace or re machine Clean remove dirt and debris Re rivet Re rivet Replace part D Replace linings gt op gt Clean remove rust and paint shoe Replace part Replace lining Clean remove dirt and debris Replace linings Replace shoe and lining BRAKE DRUM TROUBLESHOOTING CHART CAUSE A Out round brake drum Eccentric mounting of drum Loose wheel bearing Glazed linings Improper friction materials for duty cycle of vehicle Overworked brake Driver abuse Wrong drum too light A Defective brake lining B Abrasive material between lining and drum C Soft drum D Excessive lining wear rivets contact ing drum E Drum not turned at last reline F Build up of abrasives in rivet holes 20 a gt REMEDY A Turn per manufacturer s specifications Inspect wheel and drum and replace defective part Correct as required Replace linings Consult vehicle manufacturer Check proper brake balance Correct as required Replace part A Replace linings
22. or its equivalent to the anchor pin 6 Place thin spacer onto opposite side of anchor pin and install snap ring 7 Hook shoe return spring by pushing shoes to gether 8 Insert sturdy lever between end of shoe and spider Pry shoe away from cam until cam rollers can be installed Repeat procedure for opposite side SLACK ADJUSTER ASSEMBLY 1 Reinstall thick camshaft flatwasher 2 Install new slack adjuster shims and a new snap ring In that sequence into the splined end of the camshaft 3 Adjust camshaft end play of the camshaft to between 005 and 045 by using the appropriate number of shims Make sure the snap ring is seated into the groove at the end of the splined camshaft BRAKE LUBRICATION 1 Lubricate the camshaft bushings by filling the camshaft tube with lube through the zerk fitting provided Fill until grease is forced out in the area of the slack adjuster Grease should not appear at the cam head end If it does the seal has not been properly installed or the old seals should be replaced 2 Reinstall brake drums and wheels Torque and adjust wheel bearings to manufacturer s specifica tions Figure 14 NOTE Due to the many combinations of slack adjusters and brake chambers follow vehicle manufacturer s specifications and procedures for assembly and final adjustment 3 Spin the wheel slowly and adjust the slack adjuster until wheel will no longer turn Back off slack adjuster just eno
23. rdy lever between end of shoe and the return spring pin See Figure 13 Pry away from the cam until cam rollers can be installed between BRAKE ASSEMBLY CONTINUED the S cam and the slots in the end of the brake shoe Make sure the cam rollers are in the lowest position on the cam Repeat procedure for oppo site side CAST SHOE SERIES 1 Apply a thin film of Lubriplate 630 A grease or its equivalent to the anchor pin Place snap ring on anchor pin end with grease fitting Place thin spacer onto anchor pin Align anchor pin end of cast shoe with spider bore Install anchor pin through backside of shoe and spider Repeat procedure for opposite shoe Figure 13 Place thin spacer onto opposite side of anchor pins and install snap rings Hook shoe return spring by pushing shoes to gether The cast shoe does not have a separate return spring pin The spring hook up feature is designed into the shoe casting Insert sturdy lever between end of shoe and spider Pry shoe away from cam until cam rollers can be installed Repeat procedure for opposite side See Figure 13 BRAKE ASSEMBLY CONTINUED P SERIES 1 Install new return spring pins See Figure 14 2 Alen lower end of fabricated shoe with spider bore 3 Place snap ring on anchor pin end with grease fitting Place thin spacer onto anchor pin 4 Install anchor pin through backside of shoe and spider 5 Apply a thin film of Lubriplate 630 A grease
24. re recommened The riveting machine must be adjusted so that the roll of the rivet is complete but the rivet should not split Always use a roll set never a star set when riveting brake linings A star set does not compress the rivet and expand it to fill the hole Consequently the lining may work loose in service RELINE PROCEDURE Bolting Application Use 3 8 inch diameter copper alloy bolts Torque bolts to 15 17 Lb Ft 20 23 N m Follow the sequence below for the bolt application only 16 5 x 6 inch 16 5 x 10 inch 22 Copyright Eaton and Dana Corporation 2002 EATON AND DANA CORPORATION National Institute for hereby grants its customers vendors or AUTOMOTIVE distributors permission to freely copy SERVICE reproduce and or distribute this document EXCELLENCE in printed format THIS INFORMATION IS NOT INTENDED FOR SALE OR RE O SALE AND THIS NOTICE MUST REMAIN ON ALL COPIES FTN One Great Drivetrain from Two Great Companies Roadranger The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced most trouble free drivetrain in the industry And it s backed by the Roadrangers the most experienced most expert most accessible drivetrain consultants in the business Visit our web site at www roadranger com For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800
25. ss there is apparent damage INSPECTION OF PARTS AIR CHAMBER BRACKET ASSEMBLY 1 Check assembly for bent chamber bracket broken welds cracks and correct alignment 2 Inspect camshaft bushings for signs of wear Bearing surfaces should be smooth and free of any pitting or fractures Insert camshaft and measure looseness up and down side to side at both ends with a dial indicator If more than 030 movement replace bushings and or camshaft See Figure 5 Figure 5 Figure 4 Figure 6 NOTE If it is determined that a bushing requires replacement both camshaft bushings and seals should be replaced All CAST SHOE and P SERIES brakes have bronze cam bushings The STANDARD XL and XLII SERIES brakes use nylon bushings with the bronze bushing as an option CAMSHAFT 1 Inspect camshaft spline and body for chips and excessive deformation Replace as necessary See Figure 6 2 Inspect cam head for cracks and its roller surfaces for flat spots brinneling or ridges NOTE Unusual wear patterns which may indicate an out of square condition Replace damaged cam shafts SPIDER 1 Inspect for cracked or broken surfaces on the spider at the cam anchor pins and mounting bolt holes Replace any spider with visible damage Do not attempt to weld or repair the spiders See Figure 7 XLII P amp CAST SHOE SERIES 2a Check the inside diameter of the anchor pin hole with bushing in place Diameter must not excee
26. tion Loose wheel bearing Relining one brake Wrong width lining Holes improperly drilled in lining Wrong drum or improperly machined Loose wheel bearing Improper wheel bearing or cone Bent brake shoe Bent brake spider Worn axle spindle Overheating due to unbalanced braking system Wrong type linings for service involved 19 a gt REMEDY oo gt op gt H mM OM EE mon gt gt TAO MON P gt Replace part Replace part Replace part Replace linings Correct as required Regrind linings to drum radius minus 015 Replace parts Replace parts Replace part Correct as required Replace linings Replace parts Replace flat spotted parts Correct as required Replace part Replace linings Clean and lubricate Replace or turn I D Correct as required Reline both brakes together Replace linings Replace linings Replace or turn I D Correct as required Correct as required Replace part Replace part Correct as required Correct as required Replace linings 7 Scored or grooved linings and drum 8 Loose lining 9 Cracked lining at rivet holes 10 Elongated rivet holes SYMPTOM 1 Brake drum heat checked 2 Excessive scoring of drum BRAKE SHOE AND LINING TROUBLESHOOTING CHART A gt DA D gt Scored or worn drum not machined at reline Abrasive material between lining and drum Impr
27. ugh for wheel to spin freely Be sure to adjust brakes equally on each axle 4 Apply the release brakes and observe slack adjust ers Both slacks on each axle should respond rapidly and in unison during application and release 5 Drive vehicle at a low speed in a safe area and check for brake effectiveness prior to putting back in service SYMPTOM 1 Degraded brake performance 2 Slow brake application 3 Slow brake release 4 Grabbing or pulling oo gt gt ram FOUNDATION BRAKE TROUBLESHOOTING CHART CAUSE Too much push rod free travel Severely glazed or worn out linings Grease or oil on linings Worn seared heat checked cracked drums Push rod length too long Air chamber in wrong position Broken or bent parts Flat spots on cam or rollers Cam shaft bushings binding Binding cam shaft and bushing Weak or broken shoe return spring Flat spotted cam or rollers A Grease oil or dirt on linings ammo ES Ars Glazed linings Brake linings not a balanced set different friction codes or lining brand Loose or broken linings Brake drum out of round Defective brake drum Clevis pin or camshaft binding at one or more wheels Defective slack adjuster Uneven brake adjustment side to side Broken or bent parts Loose spider or drum mounting bolts Different air chamber size or slack adjuster length side to side 902 gt zs Comp REMEDY A
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