D6D TRACTOR POWER TRAIN – Brake Hydraulic Controls And Actuating Mechanisms

Remove And Install Brake Hydraulic Controls And Actuating Mechanisms

Start By:

a. tilt cab back (if so equipped)*

b. remove Roll-Over Protective Structure (if so equipped)*

c. remove support and seat group

d. remove fuel tank


*

1. Remove parking brake linkage (1) and shaft (2).

2. Remove spout (3) from the brake hydraulic control housing assembly. Remove tube assemblies (5) and (6). Disconnect clip (4) and move the air conditioner hoses away from the housing assembly.

3. Remove fuel line (7) and elbow (8).

4. Remove tube assembly (10). Check the condition of the O-ring seal in the tube assembly. If the seal has damage, use a new part for replacement.

5. Remove bolts (9) and washers that hold the brake hydraulic control housing assembly to the steering clutch case.

6. Install two 1/2″-13 NC forcing screws in the housing assembly. Tighten the screws evenly until housing assembly (11) is loose from the dowels in the steering clutch case. Remove the two forcing screws.

7. Install one 1/2″-13 NC forged eyebolt (12) in the housing assembly and one 5/16″-18 NC forged eyebolt (13) in the housing assembly. Fasten a hoist to the housing assembly and remove it. The weight of the housing assembly is 47.3 kg (105 kg).

8. Turn socket (15) counterclockwise until the brake band assemblies are loose around the brake drum.

9. Remove four bolts (14) and lockwashers that hold the actuating mechanism to the steering clutch case.

10. Fasten a hoist to brake actuating mechanism (16) and remove it from the steering clutch case. Make sure the brake band assemblies are disengaged from the struts on the actuating mechanism. The weight of the actuating mechanism is 44 kg (98 lb).

NOTE: The following steps are for the installation of the brake hydraulic controls and actuating mechanisms.

11. Make sure the machined surfaces of the steering clutch case and the brake hydraulic control housing assembly are clean and free of dirt and old liquid gasket material. Put 7M7260 Liquid Gasket Material on the contact surfaces of the steering clutch case and the brake hydraulic control housing assembly.

12. Fasten a hoist to brake actuating mechanism (16) and put it in position in the steering clutch case. Make sure the struts on the actuating mechanism are engaged with the brake band assemblies. Install the four bolts and washers that hold the actuating mechanism in position.

13. Fasten a hoist to the brake hydraulic control housing assembly and put it in position over the actuating mechanism. Do not remove the hoist at this time.

14. Install a pry bar through the front of the housing assembly as shown and pull the link assembly for the parking brake forward to permit the piston in the housing assembly to go in position behind the roller on the link assembly. This will let the housing assembly go down against the steering clutch case.

15. Install the bolts and washers that hold the housing assembly. Tighten the bolts to a torque of 135 ± 15 N·m (100 ± 11 lb.ft.).

16. Install the O-ring seal on tube assembly (10). Put clean oil on the O-ring seal. Install the tube assembly in the housing assembly and steering clutch case.

17. Install elbow (8). Install the fuel line from the fuel tank to the connection in front of the brake hydraulic control housing assembly. Install the clips that hold the fuel line.

18. Install tube assemblies (6) and (5).

19. Put the air conditioner hoses in position and install clip (4) that holds them to the rear of the brake hydraulic control housing assembly.

20. Install oil spout (3). Install parking brake linkage (1) and shaft (2).

21. Make adjustments to the brakes and parking brake. See Adjustment Procedures for the Brakes in Specifications.

End By:

a. install support and seat group

b. install fuel tank

c. install Roll-Over Protective Structure (if so equipped)*

d. tilt cab forward (if so equipped)*


*

Disassemble Brake Hydraulic Controls And Actuating Mechanism

Start By:

a. remove brake hydraulic controls and actuating mechanisms


NOTICE

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.


1. Remove cover (3) and the gasket.

------ WARNING! ------

There is spring pressure behind cover assembly (2). Do not remove the bolts that hold the cover until the spring pressure is released.

--------WARNING!------

2. Pull lever (4) back to release the spring pressure behind cover assembly (2). Remove four bolts (1) and washers. Remove the cover assembly.

3. Loosen bolt (6). Pull shaft (5) out of lever (8) until key (7) can be removed. Remove the shaft and lever from the cover assembly.

4. Remove the cotter pin, pin and roller (9) from lever (8).

5. Remove retainer (13), plunger assembly (12), spring (11) and spring (10).

6. Disassemble plunger assembly (12) as follows:

a. Remove spiral ring (19), valve (18), spring (17) and plunger (16) from plunger (15).

b. Remove O-ring seal (14). Check the condition of the seal. If the seal is damaged, use a new part for replacement.

7. Remove piston (20) and spring (21).

8. Use tooling (A) and remove sleeve (22).

9. Remove the pin from the parking brake pawl (24) and lever assembly (23) with a hammer and punch. Remove the lever assembly and pawl.

10. Remove the plug and lip type seal from the cover assembly at the location for lever assembly (23) with tooling (A).

11. Remove the lip type seal, two bearings and the plug from the bore for the brake control shaft with tooling (A).

12. Remove two springs (26). Remove the cotter pin, pin (27) and roller (25).

13. Remove the lock pin and pin that holds ratchet assembly (28) in position. Remove the ratchet assembly.

14. Disassemble ratchet assembly as follows:

a. Remove pin (31) with a hammer and punch.

b. Remove two links (29). Remove large pin (30) from ratchet (32).

15. Remove the pin from shaft (33) with a hammer and punch.

16. Remove two bolts (34) and the lock from each shaft assembly.

17. Remove shaft (33) and two shaft assemblies (35).

18. Remove brake lever assembly (36).

19. Remove the strut and lever assembly from the support assembly.

20. Remove two bolts (38), lock, shims and plate (37). Put identification on the shims for correct installation.

21. Remove ring (39). Remove pin (41) and strut (40).

22. Remove the two bearings from the lever assembly with tooling (A).

23. Remove the cotter pin and pin (42). Remove lever assembly (46).

24. Remove the cotter pin and pin (47). Remove bellcrank assembly (43). Remove the ring and pin (44). Remove lever assembly (45).

25. Remove the bearing from the bellcrank with tooling (A).

26. Remove the ring that holds pin (49) in position. Remove the pin and strut (48).

27. Remove the five bearings from the lever assembly with tooling (A).

28. Remove two locks, bolts (52) and nuts that hold spring (51). Remove the spring and socket (50).

29. Remove bolt (53) and washer from the support and wedge (54). Remove the support and wedge from the lever assembly.

30. Remove the three bearings from the lever assembly with tooling (A).

31. Remove the ring and pin (55). Make a separation of the five links.

Assemble Brake Hydraulic Controls And Actuating Mechanisms

NOTE: Make sure all the parts of the brake hydraulic controls and actuating mechanism are clean and free of dirt. Contaminants put into the system may cause rapid wear and shortened component life. Put clean oil on all pins, bearings, links and levers during assembly.

1. Put the five links in the positions shown. Install pin (5) and the ring that holds the unit together.

2. Install the three bearings in the lever assembly with tooling (A). Install the bearings until they are even with the outside machined surfaces on the lever assembly.

3. Install screw (53) in the lever assembly. Install wedge (54) and the support. Install the bolt and the washer that holds the wedge in position.

4. Install socket (50) over the screw. Install the spring over socket (51). Install the bolts, locks (52) and nuts.

5. Install the five bearings in the lever assembly with tooling (A). Install the smallest diameter bearing until it is 0.76 mm (.030 in.) below the outside of the lever assembly. Install the other four bearings even with the outside surfaces of the lever assembly as shown.

6. Put the lever assembly in the position shown. Put strut (48) in position on the lever. Make sure the mark “TOP” on the strut is up after assembly. Install pin (49) and the ring to hold the strut.

7. Install the bearing in the bellcrank with tooling (A). Install the bearing even with the outside surface of the bellcrank.

8. Put lever assembly (45) in position in the link assembly. Install pin (14) and the ring that holds the lever assembly.

9. Put bellcrank (43) in position in the link assembly as shown. Install pin (47) and the cotter pin that holds it.

10. Put lever assembly (46) in position on the link assembly as shown. Install pin (42) and the cotter pin that holds it.

11. Install the two bearings in the lever assembly with tooling (A). Install the smaller diameter bearing until it is 0.76 mm (.030 in.) below the outside surface of the lever assembly. Install the larger diameter bearing until it is 3.18 mm (.125 in.) below the outside surface of the lever assembly.

12. Put strut (40) in position on the lever assembly. Install pin (41) and ring (39) that holds the strut. Make sure the mark “TOP” is up after assembly.

13. Install original amount of the shims and plate (37). Install the two bolts (38) and locks that hold the shims and plate in the support assembly.

14. Put the lever assembly in position in the support assembly.

15. Put brake lever assembly (36) in position in the support assembly.

16. Install shaft assemblies (33) and (35).

17. Put the hole in shaft (33) in alignment with the hole in the support assembly. Install the pin.

18. Install two bolts (34) and the locks that hold the shaft assemblies in position.

19. Put two links (29) in position on each side of the ratchet. Install pin (30). Install pin (31) with a hammer and punch.

20. Put ratchet assembly (28) in position in the support assembly. Install the pin that holds it. Make sure the hole in the pin is in alignment with the hole in the support assembly. Install the lockpin that holds the pin.

21. Put the two links on the ratchet assembly on each side of the bellcrank. Install pin (27). Install the cotter pin that holds pin (27).

22. Install the two bearings in the cover assembly with tooling (A). Install the bearings until they are 0.79 mm (.031 in.) below the inside surfaces of the cover assembly.

23. Install the lip-type seal in the cover assembly with tooling (A). Install the seal with the lip toward the inside of the cover assembly and until it makes contact with the bottom of the counterbore in the cover assembly. Put clean oil on the lip of the seal.

24. Install the plug with tooling (A) until it makes contact with the bottom of the counterbore in the cover assembly. Make a mark (stake) in three places around the plug to hold it in position.

25. Install the lip type seal in the bore for the parking brake linkage shaft with tooling (A). Install the seal with the lip toward the inside of the cover assembly and until it makes contact with the bottom of the counterbore in the cover assembly. Put clean oil on the lip of the seal.

26. Install the plug in the opposite end of the bore with tooling (A). Install the plug until it makes contact with the bottom of the counterbore.

27. Put pawl (24) in position in the cover assembly as shown. Install lever assembly (23). Make sure the hole in the lever assembly is in alignment with the hole in the pawl. Install the lock pin with a hammer and punch.

28. Install sleeve (27) in the cover assembly with tooling (A). The sleeve must be in contact with the bottom of the counterbore in the cover assembly.

29. Install spring (21). Put clean oil on piston (20) and install it in the cover assembly as shown.

NOTE: Put clean oil on all parts of the plunger assembly before it is assembled.

30. Assemble the plunger assembly as follows:

a. Install plunger (16) and spring (17) in plunger (15).

b. Install valve (18) in spiral ring (19).

31. Install springs (10) and (11), plunger assembly (12) and retainer (13) in the cover assembly.

32. Put roller (9) in lever (8). Install the pin and the cotter pin.

33 Put shaft (5) in position in the cover assembly. Install key (7) in the shaft. Slide lever (8) over the key and tighten the bolt in the lever.

34. Install cover (3) with the gasket.

35. Put 7M7260 Liquid Gasket Material on the contact surface of cover assembly (2). Pull lever (4) back to release the spring tension and install cover assembly (2) and the bolts that hold it.

End By:

a. install brake hydraulic controls and actuating mechanisms

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