Removal and Installation

REMOVAL





1. Disconnect shackle No.2 from bracket.
a. Remove the cotter pin.
b. Remove the nut and cushion retainer, and disconnect the shackle No.2.
c. Remove the 2 bushings and collar.
2. Remove Load Sensing Proportioning and Bypass Valve (LSP & BV) assembly





a. Using Special Service Tool (SST) 09751-36011 or equivalent, disconnect the brake lines from the valve body.
b. Remove the valve bracket mounting bolts and the LSP & BV assembly.

INSTALLATION





1. Install LSP & BV assembly to frame.
Torque: 29 Nm (22 ft. lbs.)
2. Connect brake line.
Using SST 09751-36011, connect the brake lines.
Torque: 15 Nm (11 ft. lbs.)





3. Connect shackle No.2 bracket.
a. Install the shackle No.2 to the load sensing spring.
b. Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 inch)
Torque: 25 Nm (18 ft. lbs.)
c. Connect the shackle No.2 to the shackle bracket.
Torque: 13 Nm (9 ft. lbs.)
d. Install a new cotter pin.





4. Set rear axle load.
Rear axle load (includes vehicle weight):
2WD:
1 ton: 850 kg (1,874 lbs.)
0.5 ton standard: 800 kg (1,764 lbs.)
0.5 ton option (soft ride): 850 kg (1,874 lbs.)
4WD: 1,050 kg (2,315 lbs.)





5. Set valve body.
a. When pulling down the load sensing spring, check that the valve piston moves down smoothly.
b. Position the valve body so that the valve piston lightly contacts with the load sensing spring.
c. Tighten the valve body mounting nuts.
Torque: 13 Nm (9 ft. lbs.)
6. Bleed brake line.





7. Check and adjust LSP & BV fluid pressure.
8. Apply sealant to shackle No.2.
Apply sealant to the top portion of the shackle No.2 bolt threads not to lose the upper lock nut.
Sealant: THREE BOND 1324 or equivalent