Usage:
start by:
a) remove rear drive shaft
b) remove stablizer rod
1. Lift the body of the truck and put FT1437 Body Support in position. See INSTALL AND REMOVE BODY SUPPORT on Page 7.
2. Put identification on the manifold and hoses for assembly. Disconnect and remove brake cooler return hose (5) from tube (4) and manifold (6). Disconnect brake cooler supply hose (2) from manifold (6). Remove two bolts (3) and remove bracket (1) from the body.
3. Connect hose (2) to tube (4) as shown.
4. Disconnect service and retarder brake hose (8) from slack adjuster (7). Disconnect parking and emergency brake hose (10) from block (9). Put plugs and caps in all brake line openings.
5. Connect tooling (A) to block (9) as shown.
6. Remove supports and lower the truck body.
7. Put tooling (B) in position under the frame as shown. Use tooling (B) as a support for the rear of the machine.
8. Remove the rear suspension cylinders. See REMOVE REAR SUSPENSION CYLINDERS in VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY section.
9. Install tool (C) on the differential as shown. Put tool (D) in position under tool (C).
10. Remove eight bolts (11) and lockwashers that fasten cap (13) to the frame. Remove the shims from between the cap and socket (12).
11. Use tooling (B) to lift the frame until the distance from the bottom of the frame to the floor is approximately 51 in. (129.5 cm).
| NOTICE |
|---|
Do not exceed 500 psi (3450 kPa) pressure with tooling (A). |
12. Use tooling (A) to release the parking brakes so the rear wheels will roll.
13. Use tool (D) as a support for tool (C). Fasten a chain and lift truck to the axle housing as shown. Pull the rear axle housing away from the truck.
Install Rear Axle Housing And Differential
1. Find the thickness of shims (1) needed between cap (2) and socket (5) as follows:
a) Remove the two bolts that hold socket (5) to the frame and remove the socket.
b) Put the socket on cap (2) with four bolts (4) and nuts that are put the same distance apart. Do not install the O-ring seal in the socket or shims (1) at this time.
c) Tighten bolts (4) evenly until there is a small restriction to the movement of the cap and socket on kingbolt (3).
d) Use a feeler gauge to measure the distance between the socket and the cap.
e) Make shim pack (1) the same as the distance measured plus .001 to .006 in. (0.03 to 0.15 mm). Keep this shim pack for assembly
f) Remove the socket from the cap and install on the frame with two bolts and lockwashers.
2. Put 5P960 Multipurpose Type Grease on the round (spherical) surface of kingbolt (3). Put the O-ring seal in position in the socket.
| NOTICE |
|---|
Do not exceed 500 psi (3450 kPa) pressure with tooling (A) or damage to the brakes can be the result. |
3. Install tooling (A), (B) and (C) on the rear axle housing. Use tooling (A) to release the parking brake so the rear wheel will roll.
4. Use tooling (D) to lift the frame until the distance from the bottom of the frame to the floor is approximately 51 in. (129.5 cm). Put the rear axle and differential in position under the frame.
5. Put shim pack (1) in position between the cap and socket. Install eight bolts (4) and lockwashers that fasten the cap to the frame. Tighten the bolts evenly to a torque of 390 ± 15 lb. ft. (530 ± 20 N·m). Remove tooling (A), (B) and (C).
6. Install the rear suspension cylinders and charge with nitrogen. See INSTALL REAR SUSPENSION CYLINDERS and CHARGE REAR SUSPENSION CYLINDERS (NITROGEN) in VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY section. Remove tooling (D).
7. Lift the truck body and put support under it. Install service and retarder brake hose (7) on slack adjuster (6). Install parking and service brake hose (9) on block (8).
8. Disconnect brake cooler supply hose (11) from tube (13) and connect to manifold (12). Connect brake cooler return hose (14) to the manifold and tube (13). Install bracket (10) on the frame with two bolts and lockwashers.
9. Remove the support and lower the truck body. Remove the air (bleed) from the brake system. See TESTING AND ADJUSTING. Fill the hydraulic tank to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.
end by:
a) install stabilizer rod
b) install rear drive shaft