Dana®Spicer ® Brakes 16.5" Series S-Cam XTRALIFE TM XTRALIFE II TM Cast P-Series Service Manual BRSM-0890 October 1997 For the most current information, visit the Roadranger web site at www.roadranger.
TABLE OF CONTENTS 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 ..................................
IDENTIFICATION The brake assembly may be identified by a tag which is located on the camshaft bracket cylinder, near the grease fitting. JULIAN DATE CODE 97 170 The mylar brake assembly tag contains the following: Dana assembly number, bar coded customer assembly number, and a numeric customer assembly number. MODEL YEAR DAY OF YEAR DANA ASSEMBLY NUMBER Two other markings that may be used to identify a Spicer Brake assembly are located on the assembly's components.
BRAKE COMPONENTS STANDARD/ XTRALIFE 16.5" Retaining Ring Camshaft Adjusting Washers (Shims) Camshaft Bushing Grease Fitting Steel Spacer Grease Seal Air Chamber Bracket Assembly Bracket Mounting Bolt (70 - 80 Lb-Ft) (95 - 108 N-m) Lock Washer Camshaft Bushing Grease Seal Dustshield Mounting Bolt 3/8 in.
BRAKE COMPONENTS 16.5" CAST SHOE SERIES Retaining Ring Camshaft Adjusting Washers (Shims) Camshaft Bushing Air Chamber Bracket Assembly Steel Spacer Grease Seal Grease Fitting Bracket Mounting Bolt (70 - 80 Lb-Ft) (95 - 108 N-m) Lock Washer Camshaft Bushing Grease Seal Spider Dustshield Mounting Bolt 3/8 in.
BRAKE COMPONENTS 16.5" XL II SERIES BRAKE Retaining Ring Camshaft Adjusting Washer Steel Spacer Grease Seal Camshaft Bushing Grease Fitting Camshaft Bracket Camshaft Bushing Grease Seal Bracket Mounting Bolt (70 - 80 Lb-Ft) (95 - 108 N-m) Dust Shield (Half) Lock Washer Spider Dustshield Mounting Bolt 3/8 in.
BRAKE COMPONENTS 16.5" P SERIES BRAKE Retainer Ring Camshaft Adjusting Washer Steel Spacer Grease Seal Camshaft Bushing Grease Fitting Camshaft Bracket Camshaft Bushing Grease Seal Bracket Mounting Bolt (70 - 80 Lb-Ft) (95 - 108 N-m) Dust Shield (Half) Lock Washer Spider Dustshield Mounting Bolt 3/8 in.
GENERAL PRECAUTIONS IMPOR TANT IMPORT READ THIS SECTION BEFORE ST AR TING STAR ARTING ANY SER VICE PROCEDURES SERVICE Never remove a component or pipe plug unless you are certain all system pressure has been depleted. 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 maintenance is necessary.
GENERAL PRECAUTIONS (CONTINUED) PREPARATION 1. Park vehicle on a level surface and prevent movement by means other than the brakes. 5. 2. If equipped with spring brakes, cage the spring on all axles to be worked on. 3. Raise the axle, to be worked on until the tires clear the ground. Support axle with heavy duty jack stands. WARNING: The long tterm erm effect xposur o noneffectss of eexposur xposuree tto ea ting a sbe st os ha Avv oid cr crea eating sbest stos hass no nott been de dettermined.
PREVENTATIVE MAINTENANCE A schedule should be eest st ablished for periodic stablished adjustment, inspection and lubrica tion. This schedlubrication. ule is de om vvehicle ehicle oowner/oper wner/oper dettermined fr from wner/operaa tor orss experience and the ttype ype of oper operaa tion tion. CA UTION: Drums displa ying hea CAUTION: displaying heatt checks with a contin uous length of four inche continuous inchess or mor moree and ext ends ar ound the edge of the drum should be xtends around replaced.
PREVENTATIVE MAINTENANCE 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. 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.
BRAKE DISASSEMBLY CAST SHOE & "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. SLACK ADJUSTER REMOVAL 1. Disconnect clevis from slack adjuster arm by removing the clevis pin or pins depending on type of slack adjuster. 2. Unhook shoe return spring by pushing shoes together, allow tension on spring to be reduced. 2. Remove retaining ring and shims from splined end of camshaft. 3.
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 FFigur igur iguree 4. 2. Remove the spider to axle mounting bolts. 3. Remove spider. DUST SHIELD REMOVAL 1. Mark dust shields (upper left, lower right, etcprior to removal. 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.
INSPECTION OF PARTS 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 F igur iguree 7 7.. 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 F igur iguree 9. XLII, P, & CAST SHOE SERIES 2.
INSPECTION 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. BRAKE DRUMS 1.
BRAKE ASSEMBLY CHAMBER BRACKET ASSEMBLY Seal Installation NO TE: Bo th lip seals point the same NOTE: Both dir ection, lip tto ow ar d the slack adjust er direction, ard adjuster Left Hand Cam Right Hand Cam Lip Seal Lip Seal F igur 2 iguree 1 12 End Cam Slack A djust er End Adjust djuster CA UTION: Left Hand and Right Hand does not CAUTION: establish which side of the vehicle the cam goes on. Left and right are used to identify the two different types of cams only.
BRAKE ASSEMBLY (CONTINUED) BRAKE SHOE ASSEMBLY 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 opposite side. STANDARD, XL & XL II SERIES 1. Install new return spring pins: A. St andar d Serie Standar andard Seriess - Wireform pin installed in shoe ribs with mallet. CAST SHOE SERIES 1. Apply a thin film of Lubriplate 630-A grease or its equivalent to the anchor pin. B.
BRAKE ASSEMBLY (CONTINUED) “P” SERIES 1 . Install new return spring pins. See FFigur igur 4. iguree 1 14. 2. Align 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 or its equivalent to the anchor pin. 6. Place thin spacer onto opposite side of anchor pin and install snap ring. 7.
FOUNDATION BRAKE TROUBLESHOOTING CHART SYMPTOM 1. Degraded brake performance. CAUSE REMEDY A. Too much push rod free travel. A. Adjust brake. B. Severely glazed or worn out linings. B. Deglaze linings or replace. C. Grease or oil on linings. C. Replace linings. D. Worn, seared, heat checked, cracked drums. D. Replace part. E. Push rod length too long. E. Adjust clevice, shorten push rod length F. F. Air chamber in wrong position. Reposition. G. Broken or bent parts. G. Replace part. H.
BRAKE SHOE & LINING TROUBLESHOOTING CHART 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 & shiny). CAUSE REMEDY A. Bell-mouth drum. A. Replace part. B. Bent brake spider. B. Replace part. C. Bent or stretched brake shoe. C. Replace part. D. Undersize linings. D. Replace linings. E. Loose wheel bearing. E. Correct as required. F. F.
BRAKE SHOE AND LINING TROUBLESHOOTING CHART 7. Scored or grooved linings and drum. 8. Loose lining. 9. Cracked lining at rivet holes. 10. Elongated rivet holes. A. Scored or worn drum, not machined at reline. A. Replace or re-machine. B. Abrasive material between lining and drum. B. Clean, remove dirt and debris. A. Improper size rivets (too long, too short, improper diameter). A. Re-rivet. B. Improper crimping of rivet. B. Re-rivet. C. Enlarged rivet holes in shoe. C. Replace part. D.
RELINE PROCEDURE 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.
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.
Copyright Eaton and Dana Corporation, 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 RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. 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.
