Bendix Bw7274 Users Manual 165sman2

2015-04-02

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Page Count: 26

Table of Contents
Identification
Components - Standard & XL
Components - Cast Shoe Series
Components - 16.5" XL II
Components - 16.5" P Series
General Precautions
Preventative Maintenance
Brake Disassembly
Inspection of Parts
Brake Assembly
Troubleshooting Chart, Foundation Brake
Troubleshooting Chart, Shoe & Lining
Troubleshooting Chart, Brake Drum
Reline Procedure

For the most current information, visit the Roadranger web site at www.roadranger.com

16.5" Series S-Cam Cast

XTRALIFE TM  P-Series

XTRALIFE II TM

Dana®Spicer®Brakes

Service Manual BRSM-0890 October 1997

TABLE OF CONTENTS

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 numbers and illustrations are provided specifically for reference purposes

only. Therefore, Spicer reserves the right to update this manual without notice or liability.

Identification ..................................................................... 2

Brake Components (Standard/Xtralife) ...................... 3

Brake Components (Cast Series).................................. 4

Brake Components (XL II Series).................................. 5

Brake Components (“P” Series) .................................... 6

General Precautions ......................................................... 7

Preventative Maintenance............................................... 9

Brake Disassembly ............................................................ 11

Inspection of Parts ........................................................... 12

Brake Assembly ................................................................. 15

Trouble Shooting Charts ................................................. 18

Reline Procedure ............................................................... 21

97 170

IDENTIFICATION

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.

DAY OF YEARMODEL YEAR

JULIAN DATE CODE

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

CUSTOMER

ASSEMBLY

NUMBER

CUSTOMER

BAR CODE

NUMBER

165 WD 000 0

MODEL IDENTIFICATION NUMBERING SYSTEM

Alphabetical Code

(i.e., WD = Brake Assembly)

Model (165 = 16.5" Brake)

(150 = 15" Brake)

DANA

ASSEMBLY NUMBER

Sequential Assembly

Numbers

Camshaft Bracket

CHAMBER

BRACKET ARM

STAMPED PART

INFORMATION

BRAKE ASSEMBLY TAG

Camshaft

STAMPED PART

INFORMATION

(IN ONE OF THESE AREAS)

"SPICER"

Spider

BUILD DATE

(APR 1997 AND LATER)

BRAKE COMPONENTS

STANDARD/ XTRALIFE 16.5"

Retaining Ring

Camshaft Adjusting

Washers (Shims)

Grease Fitting

Air Chamber

Bracket Assembly

Grease Seal

Steel Spacer

Camshaft Bushing

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Grease Seal

Steel Spacer Plate

Camshaft

Shoe Return Spring

Cam Roller

Spider

Lining

Shoe and Lining

Assembly

Brake Lining

Rivet

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Return Spring Pin

Retainer Springs

BRAKE COMPONENTS

16.5" CAST SHOE SERIES

Retaining Ring

Camshaft Adjusting

Washers (Shims)

Grease Fitting

Air Chamber

Bracket Assembly

Grease Seal

Steel Spacer

Camshaft Bushing

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Grease Seal

Lock Washer

Dust Shield Half

Spider

Steel Spacer Plate

Camshaft

Anchor Pin Bushing

Grease Fitting

Brake Lining Nut

(15-17 Lb-Ft)

(20-23 N-m)

Shoe Return Spring

Cam Roller

Anchor Pin

Retainer Clip

Brake Lining

Bronze Bushing

Anchor Pin

Retainer Clip

Lining

Shoe and Lining

Assembly

Brake Lining

Bolt

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Washer

Lock Washer

BRAKE COMPONENTS

16.5" XL II SERIES BRAKE

Retaining Ring

Camshaft Adjusting Washer

Steel Spacer

Grease Seal

Camshaft Bushing

Camshaft Bracket

Camshaft Bushing

Grease Seal

Spider

Steel Spacer Plate

Camshaft

Shoe and

Lining Assembly

Cam Roller

Shoe Retainer Spring

Shoe Return Spring

Anchor Pin

Anchor Pin Bushing

Return Spring Pin

Lining

Dust Shield (Half)

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Grease Fitting

Lock Washer

Brake Lining Rivet

Cam Roller

Retainer Clip

BRAKE COMPONENTS

16.5" P SERIES BRAKE

Retainer Ring

Camshaft Adjusting Washer

Steel Spacer

Grease Seal

Camshaft Bushing

Camshaft Bracket

Camshaft Bushing

Grease Seal

Spider

Steel Spacer Plate

Camshaft

Cam Roller

Shoe Return Spring

Anchor Pin

Anchor Pin Bushing

Return Spring Pin

Lining

Dust Shield (Half)

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Grease Fitting

Lock Washer

Brake Lining Rivet

Cam Roller

Retainer Clip

Washer

Snap Ring

GENERAL PRECAUTIONS

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 components 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.

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: When wWhen w

When wWhen w

When working on or arorking on or ar

orking on or arorking on or ar

orking on or around airound air

ound airound air

ound air

brbr

brakak

akak

ake se s

e se s

e syy

ystst

stst

stems and componentems and component

ems and componentems and component

ems and components, the follos, the follo

s, the follos, the follo

s, the followingwing

wingwing

wing

prpr

precautions should be observecautions should be observ

ecautions should be observecautions should be observ

ecautions should be observed:ed:

ed:ed:

ed:

1.1.

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.

2.2.

2. Never connect or disconnect a hose or line con-

taining air pressure. It may whip as air escapes.

IMPORIMPOR

IMPORTT

TANTANT

ANTANT

ANT

READ THIS SECTION BEFORE STREAD THIS SECTION BEFORE ST

READ THIS SECTION BEFORE STARAR

ARAR

ARTINGTING

TINGTING

TING

ANY SERANY SER

ANY SERVICE PROCEDURESVICE PROCEDURES

VICE PROCEDURESVICE PROCEDURES

VICE PROCEDURES

Never remove a component or pipe plug unless you

are certain all system pressure has been depleted.

3.3.

3. 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.

4.4.

4. 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.

5.5.

5. Use only genuine Spicer replacement parts and

components.

A. A.

A. Only components, devices, mounting and

attaching hardware specifically designed for use

in air brake systems should be used.

B. B.

B. Replacement hardware, tubing, hose, fittings, etc.

should be of equivalent size, type, length and

strength as the original equipment.

C. C.

C. 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.

6.6.

6. Devices with stripped threads or damaged parts

should be replaced. Repairs requiring machining

should not be attempted.

CAUTION

BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND

MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM.

FOLLOW 0.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED

WHEN WORKING WITH BRAKE MATERIALS.

BRAKE LININGS CONTAIN NON-ASBESTOS FIBERS

AVOID CREATING DUST

DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT REPLACE 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.

PREPARATION

1.1.

1. Park vehicle on a level surface and prevent

movement by means other than the brakes.

2.2.

2. If equipped with spring brakes, cage the spring on

all axles to be worked on.

3.3.

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.

CACA

CAUTION: RUTION: R

UTION: RUTION: R

UTION: Rockwockw

ockwockw

ockwell Autell Aut

ell Autell Aut

ell Auto Slacks ro Slacks r

o Slacks ro Slacks r

o Slacks requirequir

equirequir

equire the pae the pa

e the pae the pa

e the pawlwl

wlwl

assemblssembl

ssemblssembl

ssembly ty t

y ty t

y to be ro be r

o be ro be r

o be remoemo

emoemo

emovv

ved befored befor

ed befored befor

ed before turning the adjuste turning the adjust

e turning the adjuste turning the adjust

e turning the adjust--

ing ning n

ing nut.ut.

ut.ut.

ut.

WARNING: NeARNING: Ne

ARNING: NeARNING: Ne

ARNING: Nevv

ver wer w

er wer w

er work under a vork under a v

ork under a vork under a v

ork under a vehicle supporehicle suppor

ehicle supporehicle suppor

ehicle supportt

teded

eded

onlonl

only by b

y by b

y by a jack. Alwy a jack. Alw

y a jack. Alwy a jack. Alw

y a jack. Alwaa

ayy

ys use a jack sts use a jack st

s use a jack sts use a jack st

s use a jack stand.and.

and.and.

and.

GENERAL PRECAUTIONS (CONTINUED)

5.5.

5. Remove wheels and drums using the procedures

specified in the vehicle maintenance manual.

WARNING: The long tARNING: The long t

ARNING: The long tARNING: The long t

ARNING: The long term effecterm effect

erm effecterm effect

erm effects of es of e

s of es of e

s of exposurxposur

xposurxposur

xposure te t

e te t

e to non-o non-

o non-o non-

o non-

asbesbe

sbesbe

sbestst

stst

stos haos ha

os haos ha

os has nos no

s nos no

s not been det been de

t been det been de

t been dett

termined. Aermined. A

ermined. Aermined. A

ermined. Avv

void croid cr

oid croid cr

oid creaea

eaea

eatingting

tingting

ting

dust when perdust when per

dust when performing service on brforming service on br

forming service on brforming service on br

forming service on brakak

akak

ake ae a

e ae a

e assembliessemblie

ssembliessemblie

ssemblies.s.

s.s.

ExEx

Excece

cece

cessivssiv

ssivssiv

ssive ee e

e ee e

e exposurxposur

xposurxposur

xposure te t

e te t

e to bro br

o bro br

o brakak

akak

ake dust mae dust ma

e dust mae dust ma

e dust may cause ry cause r

y cause ry cause r

y cause ree

espirspir

spirspir

spira-a-

a-a-

tory damage or oory damage or o

ory damage or oory damage or o

ory damage or other bodilther bodil

ther bodilther bodil

ther bodily harm.y harm.

y harm.y harm.

y harm.

Safety glasses should be worSafety glasses should be wor

Safety glasses should be wornn

at all times when assemblingat all times when assembling

at all times when assembling

or disassembling brakes.or disassembling brakes.

or disassembling brakes.

Standard Chamber Long Stroke Chamber

Rated Stroke Max Readjust Stroke Rated Stroke Max Readjust Stroke

12 1.75 1.38 2.00 1.50

16 2.25 1.75 2.50 2.00

20 2.25 1.75 2.50 2.00

24 2.25 1.75 2.50 2.00

30 2.50 2.00 2.75 2.25

36 3.00 2.25 - -

A schedule should be eA schedule should be e

A schedule should be estst

stst

stablished for periodicablished for periodic

ablished for periodicablished for periodic

ablished for periodic

adjustment, inspection and lubricaadjustment, inspection and lubrica

adjustment, inspection and lubrication. This sched-tion. This sched-

tion. This sched-tion. This sched-

tion. This sched-

ule is deule is de

ule is dett

termined frermined fr

ermined frermined fr

ermined from vom v

om vom v

om vehicle oehicle o

ehicle oehicle o

ehicle owner/operwner/oper

wner/operwner/oper

wner/operaa

att

toror

oror

orss

experience and the txperience and the t

xperience and the txperience and the t

xperience and the type of operype of oper

ype of operype of oper

ype of operaa

ationtion

tiontion

tion.

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 FF

Figurigur

igurigur

igure 2e 2

e 2e 2

e 2. To determine if

brake adjustment is required measure the push rod

stroke with the brakes applied as shown in FF

Figurigur

igurigur

igure 3e 3

e 3e 3

e 3 onon

onon

page 1page 1

page 1

0.0.

PREVENTATIVE MAINTENANCE

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: Drums displaDrums displa

Drums displaDrums displa

Drums displaying heaying hea

ying heaying hea

ying heat checks witht checks with

t checks witht checks with

t checks with

a contina contin

a continuous length of four incheuous length of four inche

uous length of four incheuous length of four inche

uous length of four inches or mors or mor

s or mors or mor

s or more ande and

e ande and

e and

extxt

xtxt

xtends arends ar

ends arends ar

ends around the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should be

replaced. eplaced.

eplaced. eplaced.

eplaced. See FSee F

See FSee F

See Figurigur

igurigur

igure 1.e 1.

e 1.e 1.

e 1.

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

Figurigur

igurigur

igure 2e 2

e 2e 2

e 2

Chamber Size

Type

RECOMMENED AIR BRAKE ACTUATOR SERVICE STROKE

Source: The Maintenance Council RP 635

PREVENTATIVE MAINTENANCE

A.A.

A. Released Position

B. B.

B. Applied Postion

MEASURING PUSH ROD STROKE

1.1.

1. Measure the distance between the air chamber

mounting face and the center of the clevis pin,

with brakes released.

2.2.

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.

3.3.

3. Subtract measurement A from measurement B. If

this measurement equals or exceeds the maximum

readjust stroke the brakes need to be adjusted.

See FSee F

See Figurigur

igurigur

igure 3.e 3.

e 3.e 3.

e 3.

4.4.

4. 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.

5.5.

5. Apply and release brakes and observe slack

adjusters. Both slacks on each axle should respond

rapidly and in unison during application and

release.

6.6.

6. Drive vehicle at a low speed in a safe area and

check for brake effectiveness prior to putting back

in service.

F F

Figurigur

igurigur

igure 3e 3

e 3e 3

e 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 satisfactory brake

performance. When overhauling the brakes, provide equal

service to both the left and right side of an axle.

BRAKE DISASSEMBLY

CAST SHOE & "P" SERIES

1.1.

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.

2.2.

2. Unhook shoe return spring by pushing shoes

together, allow tension on spring to be reduced.

3.3.

3. Discard shoe return spring and replace with new at

time of reassembly.

4.4.

4. Remove snap ring from anchor pin and push anchor

pin through.

NONO

NOTE: TTE: T

TE: TTE: T

TE: Tap lightlap lightl

ap lightlap lightl

ap lightly with bry with br

y with bry with br

y with braa

ass drift if anchor pin willss drift if anchor pin will

ss drift if anchor pin willss drift if anchor pin will

ss drift if anchor pin will

nono

not push out with fingert push out with finger

t push out with fingert push out with finger

t push out with finger.....

5.5.

5. Remove brake shoe and place on floor. Repeat

procedure for opposite shoe.

STANDARD, XL, & XLII SERIES

1.1.

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.

2.2.

2. Unhook shoe return spring by pushing shoes

together, allow tension on spring to be reduced.

3.3.

3. Discard shoe return spring and replace with new at

time of reassembly.

4a.4a.

4a. SS

STT

TANDAND

ANDAND

ANDARD & XLARD & XL

ARD & XLARD & XL

ARD & XL

Remove shoes by rotating the bottom shoe off the

anchor pin to release the tension on the two

retaining springs.

4b.4b.

4b. XLII SERIESXLII SERIES

XLII SERIESXLII SERIES

XLII SERIES

Remove snap ring from anchor pin and push anchor

pin through.

5.5.

5. Remove the two retaining springs and discard.

6.6.

6. Remove shoes from spider.

CAMSHAFT REMOVAL

1.1.

1. Before removing camshaft check to see if cam bushings

need replacement. See F See F

See F See F

See Figurigur

igurigur

igure 4 on Pe 4 on P

e 4 on Pe 4 on P

e 4 on Page 1age 1

age 1age 1

age 1

2.2.

2. Remove spacer from between slack adjuster and cam

shaft bracket.

3.3.

3. Grasp camshaft at the camshaft head and pull in the

outward direction to remove.

4.4.

4. Clean and inspect camshaft splines and head.

AIR CHAMBER/ CAMSHAFT BRACKET

ASSMEBLY REMOVAL

1.1.

1. Remove two nuts and washers that secure brake cham-

ber to camshaft bracket.

2.2.

2. Remove brake chamber and temporarily set it aside.

3.3.

3. Remove four bracket mounting bolts and lock washers.

4.4.

4. Remove bracket assembly from spider.

CA CA

CAUTION: UTION:

UTION: UTION:

UTION: Do noDo no

Do noDo no

Do not hammer on slack adjustt hammer on slack adjust

t hammer on slack adjustt hammer on slack adjust

t hammer on slack adjuster ter t

er ter t

er too

remoemo

emoemo

emovv

ve. Serious damage te. Serious damage t

e. Serious damage te. Serious damage t

e. Serious damage to the slack adjusto the slack adjust

o the slack adjusto the slack adjust

o the slack adjuster and/er and/

er and/er and/

er and/

or the camshaft splineor the camshaft spline

or the camshaft splines mas ma

s mas ma

s may ry r

y ry r

y ree

esult.sult.

sult.sult.

sult.

SLACK ADJUSTER REMOVAL

1.1.

1. Disconnect clevis from slack adjuster arm by

removing the clevis pin or pins depending on type

of slack adjuster.

2.2.

2. Remove retaining ring and shims from splined end

of camshaft.

3.3.

3. Remove slack adjuster from the camshaft.

CA CA

CAUTION: UTION:

UTION: UTION:

UTION: Do noDo no

Do noDo no

Do not let le

t let le

t let the air chamber hang bt the air chamber hang b

t the air chamber hang bt the air chamber hang b

t the air chamber hang byy

the air linethe air line

the air liness

AIR CHAMBER BRACKET ASSEMBLY

INSPECTION OF PARTS

SPIDER REMOVAL

1.1.

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 FSee F

See Figurigur

igurigur

igure 4.e 4.

e 4.e 4.

e 4.

2. 2.

2. Remove the spider to axle mounting bolts.

3. 3.

3. Remove spider.

DUST SHIELD REMOVAL

1.1.

1. Mark dust shields (upper left, lower right, etc-

prior to removal.

2.2.

2. Detach dust sheild by removing the six cap screws

using a 9/16" socket. Do not remove dust shield

unless there is apparent damage.

BRAKE DISASSEMBLY (CONTINUED)

Figurigur

igurigur

igure 4e 4

e 4e 4

e 4

1.1.

1. Check assembly for bent chamber bracket, broken

welds, cracks, and correct alignment.

2.2.

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 FSee F

See FSee F

See Figurigur

igurigur

igure 5.e 5.

e 5.e 5.

e 5.

NONO

NOTE: If it is deTE: If it is de

TE: If it is deTE: If it is de

TE: If it is dett

termined thaermined tha

ermined thaermined tha

ermined that a bushing rt a bushing r

t a bushing rt a bushing r

t a bushing requirequir

equirequir

equiree

ess

replacement, boeplacement, bo

eplacement, boeplacement, bo

eplacement, both camshaft bushings and sealsth camshaft bushings and seals

th camshaft bushings and sealsth camshaft bushings and seals

th camshaft bushings and seals

should be rshould be r

should be replaced. All CASeplaced. All CAS

eplaced. All CASeplaced. All CAS

eplaced. All CAST SHOE and P SERIEST SHOE and P SERIES

T SHOE and P SERIEST SHOE and P SERIES

T SHOE and P SERIES

brbr

brakak

akak

akee

es has ha

s has ha

s havv

ve bre br

e bre br

e bronze cam bushings. The Sonze cam bushings. The S

onze cam bushings. The Sonze cam bushings. The S

onze cam bushings. The STT

TANDAND

ANDAND

ANDARD,ARD,

ARD,ARD,

ARD,

XL, and XLII SERIES brXL, and XLII SERIES br

XL, and XLII SERIES brakak

akak

akee

es use ns use n

s use ns use n

s use nylon bushings withylon bushings with

ylon bushings withylon bushings with

ylon bushings with

the brthe br

the bronze bushing aonze bushing a

onze bushing aonze bushing a

onze bushing as an ops an op

s an ops an op

s an option.tion.

tion.tion.

tion.

CAMSHAFT

1.1.

1. Inspect camshaft spline and body for chips and

excessive deformation. Replace as necessary.

See FSee F

See Figurigur

igurigur

igure 6.e 6.

e 6.e 6.

e 6.

2.2.

2. Inspect cam head for cracks, and its roller surfaces

for flat spots, brinneling, or ridges.

NONO

NOTE: UnTE: Un

TE: UnTE: Un

TE: Unusual wusual w

usual wusual w

usual wear paear pa

ear paear pa

ear patt

ttt

terns which maerns which ma

erns which maerns which ma

erns which may indicay indica

y indicay indica

y indicatt

te ane an

e ane an

e an

outout

out-of-squar-of-squar

-of-squar-of-squar

-of-square condition. Re condition. R

e condition. Re condition. R

e condition. Replace damaged cam-eplace damaged cam-

eplace damaged cam-eplace damaged cam-

eplace damaged cam-

shaftshaft

shafts.s.

s.s.

Figurigur

igurigur

igure 5e 5

e 5e 5

e 5

Figurigur

igurigur

igure 6e 6

e 6e 6

e 6

SHOES AND LINING

STANDARD, XL, XL II AND P SERIES

1.1.

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. SeeSee

SeeSee

See

Figurigur

igurigur

igure 9.e 9.

e 9.e 9.

e 9.

2.2.

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.

3.3.

3. Check linings and replace when any of the following

conditions exist: See page 21 for reline procedure.

A.A.

A. Total lining thickness at thinnest point is 1/4"

or less, or 1/16" above the rivets.

B. B.

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. C.

C. Rivet holes are elongated in lining or shoes.

D. D.

D. Lining is oil soaked.

E. E.

E. Linings can be moved by hand because of loose

rivets.

SPIDER

1.1.

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. SeeSee

SeeSee

See

Figurigur

igurigur

igure 7e 7

e 7e 7

e 7

.....

XLII, P, & CAST SHOE SERIES

2a2a

2a. Check the inside diameter of the anchor pin hole

with bushing in place. Diameter must not exceed

1.282”. Replace bushing if necessary.

STANDARD & XL SERIES

2b.2b.

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.

ROLLERS AND ANCHOR PINS, BUSHINGS

1.1.

1. Inspect rollers and anchor pins for flat spots,

galling, broken or cracked surfaces. Replace as

necessary. See FSee F

See FSee F

See Figurigur

igurigur

igure 8.e 8.

e 8.e 8.

e 8.

INSPECTION OF PARTS

Figurigur

igurigur

igure 7e 7

e 7e 7

e 7

Figurigur

igurigur

igure 8e 8

e 8e 8

e 8 FF

Figurigur

igurigur

igure 9e 9

e 9e 9

e 9

INSPECTION OF PARTS (CONTINUED)

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

TRANSIT BRAKE (CAST SHOE ONLY) DRUM/

LINING CROSS REFERENCE CHART

1.1.

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) DRUM DIA. (IN) AT RELINE

.867” (Standard Thickness)

.927” (1X Oversize)

.987” (Premium Thickness)

16.500”- New

16.620”

Over 16.620”

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: NeNe

NeNe

Nevv

ver shim brer shim br

er shim brer shim br

er shim brakak

akak

ake linings. See pagee linings. See page

e linings. See pagee linings. See page

e linings. See page

21, R1, R

1, R1, R

1, Reline Preline Pr

eline Preline Pr

eline Procedurocedur

ocedurocedur

ocedure, for more, for mor

e, for more, for mor

e, for more dee de

e dee de

e dett

tail.ail.

ail.ail.

ail.

2.2.

2. Refer to the chart below for proper oversized lining

required based on drum measurements.

SHOES AND LINING

CAST SHOE TYPE

1.1.

1. Check shoes for cracks and elongated bolt holes.

2.2.

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.

3.3.

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.B.

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.C.

C. Screw holes are elongated.

D.D.

D. Lining is oil soaked.

E.E.

E. Lining can be moved by hand. (loose bolts)

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: Drums displaDrums displa

Drums displaDrums displa

Drums displaying heaying hea

ying heaying hea

ying heat checks witht checks with

t checks witht checks with

t checks with

a contina contin

a continuous length of four incheuous length of four inche

uous length of four incheuous length of four inche

uous length of four inches or mors or mor

s or mors or mor

s or more ande and

e ande and

e and

extxt

xtxt

xtend arend ar

end arend ar

end around the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should be

replaced. eplaced.

eplaced. eplaced.

eplaced. See FSee F

See FSee F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

0.0.

BRAKE DRUMS

1.1.

1. Inspect drums for cracks, heat checking, glazing,

grooving, severe out-of-round condition or bell

mouthing mm

must noust no

ust noust no

ust not et e

t et e

t exx

xceed .0ceed .0

ceed .0ceed .0

ceed .022

25 T5 T

5 T5 T

5 T.I.R. (T.I.R. (T

.I.R. (T.I.R. (T

.I.R. (Too

ott

talal

alal

IndicaIndica

Indicatt

tor Ror R

or Ror R

or Reading) eading)

eading) eading)

eading) Replace any drums that are

cracked. The drum should not be used if it exceeds

the manufacturer’s recommended maximum

diameter stamped on the drum.

2.2.

2. Measure the drum I.D. to be sure the maximum limit

allowed (stamped on drum) has not been exceeded

due to wear or machining.

CAUTION: Maximum discard

diameter is 16.750”

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: 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.

2.2.

2. Place steel spacer plate over splined end and slide

next to cam head. (See br(See br

(See br(See br

(See brakak

akak

ake componente component

e componente component

e components ons on

s ons on

s on

pagepage

pages 3-6)s 3-6)

s 3-6)s 3-6)

s 3-6)

3.3.

3. Coat bushing, seals, journals and camshaft spline

with light film of chassis lube.

IMPORIMPOR

IMPORTT

TANTANT

ANTANT

ANT: Do no: Do no

: Do no: Do no

: Do not coat coa

t coat coa

t coat "S" cam head.t "S" cam head.

t "S" cam head.t "S" cam head.

t "S" cam head.

4.4.

4. Carefully install camshaft through the chamber

bracket tube, from spider end. Cam must rotate

freely when turned by hand.

IMPORIMPOR

IMPORTT

TANTANT

ANTANT

ANT: Be car: Be car

: Be car: Be car

: Be careful noeful no

eful noeful no

eful not tt t

t tt t

t to damage the gro damage the gr

o damage the gro damage the gr

o damage the greaea

eaea

easese

sese

seals.seals.

seals.

SPICER S-CAM BRAKE RETURN SPRINGS

Br Br

Brakak

akak

ake Seriee Serie

e Seriee Serie

e Seriess

sRR

Ree

eturn Springs P/N & Colorturn Springs P/N & Color

turn Springs P/N & Colorturn Springs P/N & Color

turn Springs P/N & Color

Standard 165WJ110 Dark Blue

XL & Cast Shoe 165WJ115 White

XLII 165WJ129 Light Blue

BRAKE ASSEMBLY

CA CA

CAUTION:UTION:

UTION:UTION:

UTION: The lip of the grThe lip of the gr

The lip of the grThe lip of the gr

The lip of the greaea

eaea

ease seals mse seals m

se seals mse seals m

se seals must beust be

ust beust be

ust be

instinst

installed corralled corr

alled corralled corr

alled correctlectl

ectlectl

ectly ty t

y ty t

y to pro pr

o pro pr

o pree

evv

vent posssible damage. Theent posssible damage. The

ent posssible damage. Theent posssible damage. The

ent posssible damage. The

lip of the seal thalip of the seal tha

lip of the seal that is instt is inst

t is instt is inst

t is installed in the spider end malled in the spider end m

alled in the spider end malled in the spider end m

alled in the spider end mustust

ustust

ust

entent

enter the opening firer the opening fir

er the opening firer the opening fir

er the opening first. The lip of the seal thast. The lip of the seal tha

st. The lip of the seal thast. The lip of the seal tha

st. The lip of the seal that ist is

t ist is

t is

instinst

installed in the oppositalled in the opposit

alled in the oppositalled in the opposit

alled in the opposite end of the cam tube me end of the cam tube m

e end of the cam tube me end of the cam tube m

e end of the cam tube mustust

ustust

ust

entent

enter laer la

er laer la

er last. st.

st. st.

st. See FSee F

See FSee F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

1. Inst. Inst

. Inst. Inst

. Install the chamberall the chamber

all the chamberall the chamber

all the chamber

brbr

brackack

ackack

ackee

et and the cam tube at and the cam tube a

t and the cam tube at and the cam tube a

t and the cam tube assemblssembl

ssemblssembl

ssembly onty ont

y onty ont

y onto the spidero the spider

o the spidero the spider

o the spider

using four cap scrusing four cap scr

using four cap scree

eww

ws and lockws and lockw

s and lockws and lockw

s and lockwaa

ashersher

shersher

shers. Ts. T

s. Ts. T

s. Toror

oror

orque tque t

que tque t

que too

70-80-8

0-80-8

0-80 Lb-Ft.0 Lb-Ft.

0 Lb-Ft.0 Lb-Ft.

0 Lb-Ft.

If removed, reinstall the dust shields. Tighten the six cap

screws and lockwashers to 20-28 Lb-Ft of torque.

SPIDER

1.1.

1. Use a wire brush to remove heavy contamination

from the spider mounting flange, knuckle, spider,

brake drum exterior, and chamber mounting

bracket.

2.2.

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

1.1.

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 FSee F

See FSee F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

2.2.

Seal Installation

CHAMBER BRACKET ASSEMBLY

Lip SealLip Seal

Lip Seal

SpiderSpider

Spider

Actuactua

ctuactua

ctuatt

tor Bror Br

or Bror Br

or Brackack

ackack

ackee

ett

and Cam Tand Cam T

and Cam Tubeube

ubeube

ube

Slack ASlack A

Slack Adjustdjust

djustdjust

djuster Ender End

er Ender End

er End

NONO

NOTE: BoTE: Bo

TE: BoTE: Bo

TE: Both lip seals point the sameth lip seals point the same

th lip seals point the sameth lip seals point the same

th lip seals point the same

dirdir

direction, lip tection, lip t

ection, lip tection, lip t

ection, lip too

oww

warar

arar

ard the slack adjustd the slack adjust

d the slack adjustd the slack adjust

d the slack adjusterer

erer

Lip SealLip Seal

Lip Seal

End CamEnd Cam

End Cam

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

Right Hand CamRight Hand Cam

Right Hand Cam

Left Hand CamLeft Hand Cam

Left Hand Cam

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

BRAKE SHOE ASSEMBLY

STANDARD, XL & XL II SERIES

1.1.

1. Install new return spring pins:

A. StA. St

A. Standarandar

andarandar

andard Seried Serie

d Seried Serie

d Seriess

s- Wireform pin installed in shoe

ribs with mallet.

B. XL SerieB. XL Serie

B. XL Seriess

s- 2 piece kit assembly consisting of

inner pin and outer pin.

2.2.

2. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

3.3.

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.4a.

4a. StSt

StSt

Standarandar

andarandar

andard Seried Serie

d Seried Serie

d Seriess

s- 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.4b.

4b. XL/XL II SerieXL/XL II Serie

XL/XL II SerieXL/XL II Serie

XL/XL II Seriess

s- 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.

5.5.

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.

6.6.

6. Insert sturdy lever between end of shoe and the

return spring pin. See FSee F

See FSee F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

3. 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

1.1.

1. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

2.2.

2. Place snap ring on anchor pin end with grease

fitting. Place thin spacer onto anchor pin.

3.3.

3. Align anchor pin end of cast shoe with spider bore.

4.4.

4. Install anchor pin through backside of shoe and

spider. Repeat procedure for opposite shoe.

5.5.

5. Place thin spacer onto opposite side of anchor pins

and install snap rings.

6.6.

6. 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.

7..... 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. SeeSee

SeeSee

See

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

3.3.

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

BRAKE ASSEMBLY (CONTINUED)

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

“P” SERIES

1. Install new return spring pins. See FSee F

See FSee F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

4.4.

2.2.

2. Align lower end of fabricated shoe with spider bore.

3.3.

3. Place snap ring on anchor pin end with grease

fitting. Place thin spacer onto anchor pin.

4.4.

4. Install anchor pin through backside of shoe and

spider.

5.5.

5. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

6.6.

6. Place thin spacer onto opposite side of anchor pin

and install snap ring.

7..... Hook shoe return spring by pushing shoes to-

gether.

8.8.

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

1.1.

1. Reinstall thick camshaft flatwasher.

2.2.

2. Install new slack adjuster, shims, and a new snap

ring (In that sequence) into the splined end of the

camshaft.

3.3.

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

1.1.

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.

2.2.

2. Reinstall brake drums and wheels. Torque and

adjust wheel bearings to manufacturer’s specifica-

tions.

NONO

NOTE: Due tTE: Due t

TE: Due tTE: Due t

TE: Due to the mano the man

o the mano the man

o the many combinay combina

y combinay combina

y combinations of slacktions of slack

tions of slacktions of slack

tions of slack

adjustadjust

adjusterer

erer

ers and brs and br

s and brs and br

s and brakak

akak

ake chambere chamber

e chambere chamber

e chambers, follos, follo

s, follos, follo

s, follow vw v

w vw v

w vehicleehicle

ehicleehicle

ehicle

manman

manufacturufactur

ufacturufactur

ufacturer’er’

er’er’

er’s specificas specifica

s specificas specifica

s specifications and prtions and pr

tions and prtions and pr

tions and procedurocedur

ocedurocedur

oceduree

es fors for

s fors for

s for

assemblssembl

ssemblssembl

ssembly and final adjustment.y and final adjustment.

y and final adjustment.y and final adjustment.

y and final adjustment.

3.3.

3. Spin the wheel slowly and adjust the slack adjuster

until wheel will no longer turn. Back off slack

adjuster just enough for wheel to spin freely. Be

sure to adjust brakes equally on each axle.

4.4.

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.

5.5.

5. Drive vehicle at a low speed in a safe area and

check for brake effectiveness prior to putting back

in service.

4.4.

4. Grabbing or pulling. A.A.

A.A.

A. Grease, oil, or dirt on linings.

B.B.

B. Glazed linings.

C.C.

C. Brake linings not a balanced set,

different friction codes, or lining brand.

D.D.

D. Loose or broken linings.

E.E.

E. Brake drum out-of-round.

F..... Defective brake drum.

G.G.

G. Clevis pin or camshaft binding at one

or more wheels.

H.H.

H. Defective slack adjuster.

I.I.

I. Uneven brake adjustment (side to side).

J.J.

J. Broken or bent parts.

K.K.

K. Loose spider or drum mounting bolts.

L.L.

L. Different air chamber size or slack

adjuster length (side to side).

A.A.

A. Replace lining.

B.B.

B. Deglaze lining or replace.

C.C.

C. Replace linings.

D.D.

D. Replace linings.

E.E.

E. Turn, per manufacturer's specifications.

F..... Replace part.

G.G.

G. Clean and lubricate.

H.H.

H. Replace part.

I.I.

I. Adjust brakes.

J.J.

J. Replace part.

K.K.

K. Inspect and replace as necessary.

L.L.

L. Use same size and type both ends of

the axle.

FOUNDATION BRAKE TROUBLESHOOTING CHART

1.1.

1. Degraded brake

performance.

SYMPTOM CAUSE REMEDY

A.A.

A. Too much push rod free travel.

B.B.

B. Severely glazed or worn out linings.

C.C.

C. Grease or oil on linings.

D.D.

D. Worn, seared, heat checked, cracked

drums.

E.E.

E. Push rod length too long.

F..... Air chamber in wrong position.

G.G.

G. Broken or bent parts.

H.H.

H. Flat spots on cam or rollers.

2.2.

2. Slow brake

application.

A.A.

A. Adjust brake.

B.B.

B. Deglaze linings or replace.

C.C.

C. Replace linings.

D.D.

D. Replace part.

E.E.

E. Adjust clevice, shorten push rod length

F..... Reposition.

G.G.

G. Replace part.

H.H.

H. Replace flat-spotted parts.

A.A.

A. Cam shaft bushings binding. A.A.

A.A.

A. Clean and lubricate. Check for seal

leakage.

3.3.

3. Slow brake release. A.A.

A.A.

A. Binding cam shaft and bushing.

B.B.

B. Weak or broken shoe return

spring.

C.C.

C. Flat spotted cam or rollers.

A.A.

A. Clean and lubricate.

B.B.

B. Replace part.

C.C.

C. Replace flat-spotted parts.

5.5.

5. Wear on edge of

lining. A.A.

A.A.

A. Wrong width lining.

B.B.

B. Holes improperly drilled in lining.

C.C.

C. Wrong drum, or improperly machined.

D.D.

D. Loose wheel bearing

E.E.

E. Improper wheel bearing or cone.

F..... Bent brake shoe.

G.G.

G. Bent brake spider.

H.H.

H. Worn axle spindle.

A.A.

A. Replace linings.

B.B.

B. Replace linings.

C.C.

C. Replace or turn I.D.

D.D.

D. Correct as required.

E.E.

E. Correct as required.

F..... Replace part.

G.G.

G. Replace part.

H.H.

H. Correct as required.

4.4.

4. Unequal wear side

to side brakes,

same axle.

A.A.

A. Replace linings.

B.B.

B. Clean and lubricate.

C.C.

C. Replace or turn I.D.

D.D.

D. Correct as required.

E.E.

E. Reline both brakes together.

A.A.

A. Mismatched lining friction codes.

B.B.

B. Seized or binding camshaft.

C.C.

C. Brake drum surface

in poor condition.

D.D.

D. Loose wheel bearing.

E.E.

E. Relining one brake.

6.6.

6. Glazed linings

(hard & shiny).

A.A.

A. Overheating, due to unbalanced

braking system.

B.B.

B. Wrong type linings for service

involved.

A.A.

A. Correct as required.

B.B.

B. Replace linings.

2.2.

2. Linings tapered

across width.

A.A.

A. Replace parts.

B.B.

B. Replace parts.

C.C.

C. Replace part.

D.D.

D. Correct as required.

A.A.

A. Bell-mouth drum.

B.B.

B. Bent brake shoe.

C.C.

C. Bent brake spider.

D.D.

D. Loose wheel bearings.

A.A.

A. Bell-mouth drum.

B.B.

B. Bent brake spider.

C.C.

C. Bent or stretched brake shoe.

D.D.

D. Undersize linings.

E.E.

E. Loose wheel bearing.

F..... Improper lining grind.

A.A.

A. Replace part.

B.B.

B. Replace part.

C.C.

C. Replace part.

D.D.

D. Replace linings.

E.E.

E. Correct as required.

F..... Regrind linings to drum

radius minus .015"

3.3.

3. Unequal wear on

same brake.

A.A.

A. Replace linings.

B.B.

B. Replace parts.

C.C.

C. Replace flat-spotted parts.

D.D.

D. Correct as required.

E.E.

E. Replace part.

A.A.

A. Mismatched lining friction codes.

B.B.

B. Stretched shoe.

C.C.

C. Flat spots on cam or roller.

D.D.

D. Worn anchor pin.

E.E.

E. Worn camshaft or bushings.

1.1.

1. Poor lining to drum

contact.

BRAKE SHOE & LINING TROUBLESHOOTING CHART

SYMPTOM CAUSE REMEDY

BRAKE DRUM TROUBLESHOOTING CHART

A.A.

A. Turn, per manufacturer’s specifications.

B.B.

B. Inspect wheel and drum and replace

defective part.

C.C.

C. Correct as required.

D.D.

D. Replace linings.

E.E.

E. Consult vehicle manufacturer.

F..... Check proper brake balance.

G.G.

G. Correct as required.

H.H.

H. Replace part.

A.A.

A. Out round brake drum.

B.B.

B. Eccentric mounting of drum.

C.C.

C. Loose wheel bearing.

D.D.

D. Glazed linings.

E.E.

E. Improper friction materials for duty

cycle of vehicle.

F..... Overworked brake.

G.G.

G. Driver abuse.

H.H.

H. Wrong drum, too light.

2.2.

2. Excessive scoring

of drum. A.A.

A.A.

A. Replace linings.

B.B.

B. Clean, remove dirt and debris.

C.C.

C. Check hardness on flange.

D.D.

D. Replace lining.

E.E.

E. Turn per manufacturer’s specifications.

F..... Blow out debris.

A.A.

A. Defective brake lining.

B.B.

B. Abrasive material between lining and

drum.

C.C.

C. Soft drum.

D.D.

D. Excessive lining wear, rivets contact

ing drum.

E.E.

E. Drum not turned at last reline.

F..... Build up of abrasives in rivet holes.

A.A.

A. Re-rivet.

B.B.

B. Re-rivet.

C.C.

C. Replace part.

D.D.

D. Replace linings.

E.E.

E. Clean, remove rust and paint shoe.

A.A.

A. Improper size rivets (too long, too

short, improper diameter).

B.B.

B. Improper crimping of rivet.

C.C.

C. Enlarged rivet holes in shoe.

D.D.

D. Incorrect lining hole size or counter

bore depth.

E.E.

E. Rust build up on shoe table.

8.8.

8. Loose lining.

A.A.

A. Replace part.

B.B.

B. Replace lining.

C.C.

C. Clean, remove dirt and debris.

D.D.

D. Replace linings.

A.A.

A. Wrong type rivets.

B.B.

B. Rivets not properly crimped.

C.C.

C. Dirt or rust on shoe table.

D.D.

D. Wrong size lining counter bore.

9.9.

9. Cracked lining at

rivet holes.

A.A.

A. Loose rivets.

10.0.

0.0.

0. Elongated rivet

holes.

A.A.

A. Replace shoe and lining.

BRAKE SHOE AND LINING TROUBLESHOOTING CHART

1.1.

1. Brake drum heat

checked.

A.A.

A. Scored or worn drum, not

machined at reline.

B.B.

B. Abrasive material between

lining and drum.

A.A.

A. Replace or re-machine.

B.B.

B. Clean, remove dirt and debris.

7..... Scored or grooved

linings and drum.

RELINE PROCEDURE

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 F See F

See F See F

See Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

6.6.

6. 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 ONLUSE ONL

USE ONLY 1Y 1

Y 1Y 1

Y 1

0-80-8

0-8

1/2 1/2

1/2

RIVETSRIVETS

RIVETS

Brass plated steel rivets are 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.

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 Installation

IMPORIMPOR

IMPORTT

TANTANT

ANTANT

ANT: Ne: Ne

: Ne: Ne

: Nevv

ver shim the brer shim the br

er shim the brer shim the br

er shim the brakak

akak

ake linings.e linings.

e linings.e linings.

e 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 2 See page 2

See page 2 See page 2

See page 22 for bolting sequence.2 for bolting sequence.

2 for bolting sequence.2 for bolting sequence.

2 for bolting sequence.

Figurigur

igurigur

igure 1e 1

e 1e 1

e 1

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

BRSM-0890

05/04 PDF

Printed in USA

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: 001-800-826-HELP (4357)) for more time on the road.

2002. EATON AND DANA CORPORATION

hereby grants its customers, vendors, or

distributors permission to freely copy,

reproduce and/or distribute this document

in printed format. THIS INFORMATION IS

NOT INTENDED FOR SALE OR RE-

SALE, AND THIS NOTICE MUST REMAIN

ON ALL COPIES.

Bendix Bw7274 Users Manual 165sman2

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