Assembly Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
1P-7405 |
(3/8 inch NC Lifting Eye) |
2 |
| B |
FT-0841 |
Spring Compressor |
1 |
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| Illustration 1 | g00440250 |
- Install O-ring seal (32) on ring (29) .
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| Illustration 2 | g00440249 |
- Install plate (30) , 44 bolts (31) , and the washers on ring (29) . The weight of plate (30) is 110 kg (242.5 lb). Tighten bolts (31) to a torque of 500 ± 50 N·m (368.8 ± 36.9 lb ft).
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| Illustration 3 | g00440247 |
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| NOTICE |
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
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- Turn over the assembly. Install two dampers (27) , the 15 friction discs, and 14 plates (28) on the service brake assembly.
Note: When the two dampers, the 15 friction discs, and the 14 plates are installed, begin with a damper. Next, install a friction disc. Then, install a plate. Continue installing the friction discs and the plates. After the last friction disc is installed, install the other damper.
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| Illustration 4 | g00440245 |
- Install eight studs (26) on ring (29) . Tighten studs (26) to a torque of 100 ± 15 N·m (73.8 ± 11.1 lb ft).
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| Illustration 5 | g00466478 |
- Install four plugs (23) and the four O-rings on anchor (3) .
- Install 21 studs (25) and 47 studs (24) on anchor (3) . Tighten studs (24) to a torque of 230 ± 30 N·m (169.6 ± 22.1 lb ft). Tighten studs (25) to a torque of 400 ± 40 N·m (295.0 ± 29.5 lb ft).
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| Illustration 6 | g00466472 |
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| Illustration 7 | g00466473 |
- Install three O-ring seals (19) , (20) , and (21) on anchor (3) .
- Install 12 studs (22) on anchor (3) .
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| Illustration 8 | g00466471 |
- Install 46 springs (17) and 42 inner springs (18) on anchor (3) .
Note: There are four springs (17) at location (X) that do not have inner springs (18) . Refer to the identification marks on the springs for installation purposes.
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| Illustration 9 | g00439623 |
- Install guide spring (6) and guide (7) in piston (13) . Use Tooling (B) to compress guide spring (6) . Install the pin. Repeat this step for the remaining three pins, guides (7) , and guide springs (6) .
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| Illustration 10 | g00439583 |
- Install O-ring seal (16) on piston (13) .
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| Illustration 11 | g00439495 |
- Install two seal rings (14) . Install two seal rings (15) on housing (12) .
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| NOTICE |
|---|
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
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Note: During installation, proper orientation of the seal rings is important. Improper installation of the seal rings can cause the seals to leak.
Note: The yellow side (C) of inside seal ring (D) must face out.
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| Illustration 12 | g00467514 |
Seal rings that are incorrectly installed. |
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| Illustration 13 | g00467518 |
Seal rings that are correctly installed. |
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| Illustration 14 | g00467520 |
- Install piston (13) on anchor (3) .
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| Illustration 15 | g00467526 |
- Install housing (12) on the service brake assembly. Install 12 nuts (11) on housing (12) . Tighten nuts (11) by one turn at a time in order to draw the housing downward. After 12 nuts (11) have bottomed out, tighten the nuts to a torque of 271 ± 24 N·m (200 ± 18 lb ft). The nuts should be tightened in a crisscross pattern.
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| Illustration 16 | g00466468 |
- Install two ring seals (9) . Install two ring seals (10) on piston (5) .
Note: During installation, proper orientation of the seal rings is important. Improper installation of the seal rings can cause the seals to leak.
Note: The yellow side (C) of inside seal ring (D) must face out.
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| Illustration 17 | g00467514 |
Seal rings that are incorrectly installed. |
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| Illustration 18 | g00467518 |
Seal rings that are correctly installed. |
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| Illustration 19 | g00466445 |
- Use Tool (A) and a suitable lifting device to install piston (5) . The weight of piston (5) is 83 kg (183.0 lb).
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| Illustration 20 | g00466443 |
- Press down piston (5) . Install four pins (8) in four guides (7) .
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| Illustration 21 | g00466441 |
- Install two 3/8 inch - 16 NC forcing screws in piston (5) . Evenly tighten forcing screws in order to compress the guide springs.
- Remove the four pins from four guides (7) .
- Remove the forcing screws from piston (5) .
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| Illustration 22 | g00466436 |
- Turn over anchor (3) . Use a suitable lifting device to install anchor (3) on the ring. Anchor (3) weighs approximately 206 kg (454.2 lb).
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| Illustration 23 | g00466170 |
- Install eight nuts (4) on anchor (3) .
- Tighten eight nuts (4) by one turn at a time in order to draw anchor (3) downward. After all eight nuts (4) have bottomed out, tighten the nuts to a torque of 270 ± 25 N·m (199.1 ± 18.4 lb ft). Tighten the nuts in a crisscross pattern.
- Install 55 bolts (2) and the 55 washers which hold anchor (3) in place.
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| Illustration 24 | g00466169 |
- Turn over the service brake assembly. Install twelve bolts (1) and the washers that are identified in the picture on the service brake assembly.
End By:
Install the front service and parking brakes that are on the right or the left. Refer to Disassembly and Assembly, "Service and Parking Brake (Rear) - Install" for the correct procedure.
