Usage:
START BY:
a. remove stabilizer rod
1. Disconnect hose assembly (2) at both ends, and remove it from the vehicle.
2. Remove clip (3). Disconnect hose assembly (1) from the manifold, and connect the hose assembly to tube assembly (4).
3. Disconnect hose (6) from slack adjuster (5). Disconnect hose (7) from block (8).
4. Put plugs and caps on all brake line openings.
5. Connect tooling (A) to block (8) as shown.
6. Loosen top four bolts (9) on trunnion cap (10).
7. Remove the body retaining pins, and lower the truck body.
8. Put tooling (B) in position under the frame as shown. Use tooling (B) as a support for the rear of the machine.
9. Remove the rear suspension cylinders. See Remove Rear Suspension Cylinders in Vehicle Systems Disassembly And Assembly.
10. Install tool (C) on the differential as shown. Put tool (D) in position under tool (C).
11. Remove bolts (9). Move cap (10) and the shims back to the kingbolt.
12. Use tooling (B) to lift the frame high enough to clear the rear axle housing.
| NOTICE |
|---|
Do not exceed 3450 kPa (500 psi) pressure with tooling (A) or damage to the brake can result. |
13. Use tooling (A) to release the parking brakes so the rear wheels will roll.
14. Fasten a lift truck to the rear axle housing as shown, and pull the rear axle housing and differential away from the truck.
Install Rear Axle Housing And Differential
1. Remove two bolts (1) and socket (2) from the frame. Remove the O-ring seal from the socket.
2. Put socket (2) in position on cap (4), and install four bolts and nuts (3) spaced evenly around the socket.
3. Tighten the bolts evenly until there is a small amount of restriction to the movement of the cap and socket on the kingbolt.
4. Use a feeler gauge to measure the distance between cap (4) and socket (2). Make a shim pack the same thickness as measured plus 0.03 to 0.15 mm (.001 to .006 in.). Keep this shim pack for assembly.
5. Remove socket (2) from the cap, and install the socket on the frame. Put the O-ring seal in position on the socket.
6. Put the shim pack determined in Step 4 in position on the kingbolt next to cap (4).
7. Put 5P0960 Multipurpose Type Grease on the round (spherical) surface of the kingbolt.
8. Use tooling (A) to lift the truck frame high enough to clear the rear axle housing.
9. Install tooling (C) and (D) on the rear axle housing.
| NOTICE |
|---|
Do not exceed 3450 kPa (500 psi) pressure with tooling (B) or damage to the brakes can result. |
10. Use tooling (B) to release the parking brakes so the rear wheels will roll.
11. Put the rear axle housing and differential in under the frame as shown.
12. Put the shim pack and cap (4) in position on socket (2), and install eight bolts (5). Tighten the bolts to a torque of 525 ± 20 N·m (390 ± 15 lb.ft.).
13. Remove tooling (C) and (D) from the rear axle housing.
14. Install the rear suspension cylinders, and charge with nitrogen. See Install Rear Suspension Cylinder And Charge Rear Suspension Cylinder (Nitrogen) in Vehicle Systems Disassembly And Assembly section.
15. Remove tooling (A) from the frame.
16. Raise the truck body, and install body retaining pins. Disconnect hydraulic control linkage for the truck body.
17. Remove tooling (B).
18. Connect hose (8) to block (9), and connect hose (7) to slack adjuster (6).
19. Disconnect hose assembly (10) from tube assembly (13). Connect hose assembly (10) to the manifold, and install clip (12) on the hose assembly.
20. Install hose assembly (11).
21. Bleed the brake system. See Testing And Adjusting. Fill the hydraulic tank to the correct level. See the Maintenance Guide.
END BY:
a. install stabilizer rod