TM 9-2320-361-20

Section Il. SERVICE BRAKE AND HYDRAULIC SYSTEMS MAINTENANCE

8-6. SERVICE BRAKE AND HYDRAULIC SYSTEMS MAINTENANCE

PARA. TITLE PAGE

NO. NO.
8-7. Service Brakeshoes Maintenance 8-18
8-8. Service Brake Adjustment 8-22
8-9. Hydraulic Wheel Cylinder Replacement 8-24
8-10. Hydraulic Master Cylinder Replacement 8-26
8-11. Air-Hydraulic Cylinder Replacement 8-30
8-12. Service Brake Bleeding 8-32
8-13. Brake Pedal Lever Replacement 8-36
8-14. Brake Pedal Adjustment 8-38
8-15. Hydraulic Brake Line Replacement 8-40
8-16. Flexible Hydraulic Brake Line Modification 8-42

8-7. SERVICE BRAKESHOES MAINTENANCE

This task covers:
a. Removal c. Installation
b. Cleaning and Inspection
INITIAL SETUP:
APPLICABLE MODELS EQUIPMENT CONDITION
All Parking brake set (TM 9-2320-361-10).
Front hubs and brakedrums removed (para. 9-3).
MATERIALS/PARTS
Engine accessories modification kit GENERAL SAFETY INSTRUCTIONS
P/N 8332057 Do not use a dry brush or compressed air to clean
Two slotted retainers brakeshoes.
Grease (Appendix C, Item 13) Eyeshield protection is required when using wire
Drycleaning solvent (Appendix C, Item 26) brush for cleaning.
Rags (Appendix C, Item 21) Keep fire extinguisher nearby when using
drycleaning solvent.
PERSONNEL REQUIRED
Two
REFERENCES (TM)
TM 9-2320-361-10
TM 9-2320-361-20P

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8-7. SERVICE BRAKESHOES MAINTENANCE (Contd)

WARNING
Do not use a dry brush or compressed air to clean brakeshoes.
There may be asbestos dust on brakeshoes which can be dangerous
to your health if you breathe it. (Brakeshoes must be wet, and soft
bristle brush must be used.)
NOTE
The replacement procedure for front and rear service brakeshoes
are done the same way. This procedure covers the front service
brakes.
If any brakeshoes are to be replaced, replace all brakeshoes on
both ends of an axle.

a. Removal
1. Remove brakeshoe return spring (24) from brakeshoes (2) and (19).
2. Remove two nuts (7), washers (6), anti-rattle springs (4), washers (3), and upper (long) guide pins (1)
from backing plate (5). Discard nuts (7), washers (6), and guide pins (1).
3. Remove two nuts (10), washers (11), lower (short) guide pins (20), and retainer washers (18) from
backing plate (5). Discard nuts (10), washers (11), and guide pins (20).
4. Remove two slotted retainers (22) and washers (23) from two anchor pins (21). Discard slotted
retainers (22).
5. Remove two brakeshoes (2) and (19), retainer washers (17), and felt washers (14) from anchor
pins (21), backing plate (5), and wheel cylinder pushrods (8).
6. Remove two cams (16), springs (15), and acdjusting pins (9) from backing plate (5).
7. Remove two nuts (12), washers (13), and anchor pins (21) from backing plate (5).

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TM 9-2320-361-20

8-7. SERVICE BRAKESHOES MAINTENANCE (Contd)

b. C1eaninig and Inspection

WARNING
Eye protection is required when using wire brush for cleaning.
Failure to do so may result in injury to personnel.
Drycleaning solvent is flammable and will not be used near open
flame. Use only in well-ventilated places. Failure to do so may
result in injury to personnel.
1. Wash all parts, except brakeshoes (2) and (23), in drycleaning solvent and wipe dry with clean rag.
Clean outer brakeshoe side of backing plate (5) with rag saturated in drycleaning solvent and
wipe dry.
2. Measure top, middle, and bottom thickness of brakeshoes (2) and (23). If minimum thickness is
0.33 in. (8.33 mm) or less, replace.
3. Inspect backing plate (5) for cracks, breaks, and elongated holes. If backing plate (5) is broken,
cracked, or holes are elongated, replace. If rear axle backing plate (5) is damaged, replace rear
axle housing.
4. Inspect anchor plate (15) for loose or missing rivets (14). If any rivets (14) are loose or missing,
replace backing plate (5).
5. Inspect anchor pins (27) for cracks, looseness, and chipped or broken retaining clip slots (26). If
anchor pins (27) are cracked, loose in backing plate (5), or retaining clip slots (26) are damaged,
replace.
6. Inspect wheel cylinder (7) for cracks, leaks, torn boots (6), and bent or broken pushrods (10). If
cracked, leaking, boots (6) are torn, or pushrods (10) are bent or broken, replace wheel cylinder (7).
7. Inspect cams (20), springs (19), and adjusting pins (11) for cracks, bends, or breaks. If cracked, bent,
or broken, replace.
8. Inspect return spring (30) and anti-rattle springs (4) for breaks. bends. or distorted coils. If broken,
bent, or coils are distorted, replace.

c. Installation
1. Mark ends of new or old anchor pins (27) with center punch indicating highest cam lobe position.
2. Apply light coat of grease on backing plate (5) where brakeshoes (2) and (23) may rub.
NOTE
Perform steps 3 and 4 if anchor pins and cams have been
removed.
Final tightening of cam nuts and anchor pin nuts is done in
brakeshoe adjustment.
3. Install felt washers (18), retainer washers (21), and anchor pins (27) on backing plate (5) with two
washers (17) and nuts (16). Do not tighten nuts (17).
4. Install two adjusting pins (11), springs (19), and cams (20) on backing plate (5). Peen ends of two
adjusting pins (11) securely against cams (20) to hold in place.
5. Turn anchor pins (27) so that center punch marks (25) are close together.
6. Set cam (20) so that tip points down.
NOTE
Brakeshoes must be a matched set on both ends of axle.
7. Install two brakeshoes (2) and (23) on anchor pins (27) against wheel cylinder pushrods (10) and
against backing plate (5) with two retainer washers (22), new lower (short) guide pins (24),
washers (13), and nuts (12).

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 TM 9-2320-361-20

8-7. SERVICE BRAKESHOES MAINTENANCE (Contd)

8. Install two anti-rattle springs (4) and washers (3) between two brakeshoes (2) and (23) and backing
plate (5) with two upper (long) guide pins (1), washers (8), and nuts (9).
9. Tighten upper guide pin nuts (9) 19-24 lb-ft (26-33 NŽm) and lower guide pin nuts (12) 11-16 lb-ft
(15-22 NŽm).
10. Install two retainer washers (29) and new retaining clips (28) on anchor pins (27). Squeeze retaining
clips (28) into slots of anchor pins (27).
NOTE
Ensure brakeshoes are still positioned against wheel cylinder
pushrods after brakeshoe return spring is installed.
11. Install brakeshoe return spring (30) on two brakeshoes (2) and (23).

FOLLOW-ON TASKS: Replace hub and brakedrums (para. 9-3).

Perform service brake adjustment (para. 8-8).

8-21
TM 9-2320-361-20

8-8. SERVICE BRAKE ADJUSTMENT

This task covers:
Service Brake Adjustment
INITIAL SETUP:
APPLICABLE MODELS EQUIPMENT CONDITION
All Parking brake set (TM 9-2320-361-10).
Front or rear wheels removed (para. 9-2).
MATERIALS/PARTS Adjust wheel bearing (para. 9-5).
Lockwasher
REFERENCES [TM]
TM 9-2320-361-10
TM 9-2320-361-20P

NOTE
The adjustment procedure for front and rear brakes is done the
same way. This procedure covers the front brakes.
Allow brakes to cool before adjusting.

Service Brake Adjustment

1. Remove nut (1), lockwasher (2), and inspection slot cover (3) from brakedrum (4). Discard
lockwasher (2).
2. Turn brakedrum (4) to position inspection slot (5) at 8 o’clock location.
3. Loosen jamnut (8) on anchor pin (9) one full turn.
4. Turn anchor pin (9) clockwise or counterclockwise until gap between brakeshoe lining (13) and inner
brakedrum surface (12) measures .010 in. (.25 mm). Tighten jamnut (8) on anchor pin (9)
80-110 lb-ft (109-149 NŽm).
5. Turn brakedrum (4) to position inspection slot (5) at 11 o’clock location.
6. Turn cam stud (7) clockwise until gap between brakeshoe lining (13) and inner brakedrum
surface (12) measures .020 in. (.50 mm).
7. Turn brakedrum (4) to position inspection slot (5) at 5 o’clock location.
8. Loosen jamnut (10) on anchor pin (11) one full turn.
9. Turn anchor pin (11) clockwise or counterclockwise until gap between brakeshoe lining (13) and
inner brakedrum surface (12) measures .010 in. (.25 mm). Tighten jamnut (10) on anchor pin (11)
80-110 lb-ft (109-149 NŽm).
10. Turn brakedrum (4) to position inspection slot (5) at 1 o’clock location.
11. Turn cam stud (6) counterclockwise until gap between brakeshoe lining (13) and inner brakedrum
surface (12) measures .020 in. (.50 mm).
12. Install inspection slot cover (3) on brakedrum (4) with new lockwasher (2) and nut (1).
13. Turn brakedrum (4) by hand and turn cam stud (6) counterclockwise until brakedrum (4) drags.
Loosen cam stud (6) until brakedrum (4) slightly drags.
14. Turn brakedrum (4) by hand and turn cam stud (7) clockwise until brakedrum (4) drags. Loosen cam
stud (7) until brakedrum (4) slightly drags.
15. Repeat steps 1 through 14 to do service adjustment of other wheel on axle.

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 TM 9-2320-361-20

8-8. SERVICE BRAKE ADJUSTMENT (Contd)

FOLLOW-ON TASK Install front or rear wheels (para. 9-2).

8-23
TM 9-2320-361-20

8-9. HYDRAULIC WHEEL CYLINDER REPLACEMENT

This task covers:
a. Removal b. Installation

INITIAL SETUP:
APPLICABLE MODELS EQUIPMENT CONDITION
All Parking brake set (TM 9-2320-361-10).
Remove front or rear hubs and drums (para. 9-3
MATERIALS/PARTS or 9-4).
Two lockwashers
Two washers
Cap and plug set (Appendix C, Item 8)
REFERENCES (TM)
LO 9-2320-209-12-1
TM 9-2320-361-10
TM 9-2320-361-20P

CAUTION
Cap or plug all openings immediately stir disconnecting brake
lines and hoses to prevent contamination. Failure to do so may
result in internal parts damage.
NOTE
Front and rear wheel cylinders are replaced the same way. This
procedure covers the left front.

1. Remove brakeshoe return spring (9) from two brakeshoes (7) and (13).
NOTE
Have drainage container ready to catch brake fluid.
2. Remove brake line screw (2), two washers (1), and hose connector (3) from wheel cylinder (10).
3. Remove two screws (4) and lockwashers (5) from backing plate (6) and wheel cylinder (10). Discard
lockwashers (5).
4. Slide brakeshoes (7) and (13) off slotted pushrods (8) and remove wheel cylinder (10) and dust-
shield (12) from backing plate (6).
5. Remove, clean, and inspect bleeder screw (11) from wheel cylinder (10). If damaged, replace.

b. Installation
1. Install bleeder screw (11) into wheel cylinder (10). Tighten bleeder screw (11) 120-168 lb-in.
(14-19 NŽm).
2. Install dustshield (12) and wheel cylinder (10) on backing plate (6) with slotted pushrods (8) placed
in brakeshoes (7) and (13) slots.
3. Install two new lockwashers (5) and screws (4) into wheel cylinder (10) and backing plate (6).
Tighten screws (4) 27-35 lb-ft (37-48 NŽm).
4. Install hose connector (3) to wheel cylinder (10) with two washers (1) and brake line screw (2).
Tighten screw (2) 65 lb-ft (88 NŽm).
5. Install brakeshoe return spring (9) on two brakeshoes (7) and (13).

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8-9. HYDRAULIC WHEEL CYLINDER REPLACEMENT (Contd)

FOLLOW-ON TASKS: Install front or rear hubs and drums (para. 9-3 or 9-4).
Bleed service brakes (para. 8-12).
Adjust service brakes (para. 8-8).

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TM 9-2320-361-20

8-10. HYDRAULIC MASTER CYLINDER REPLACEMENT

This task covers:
a. Internal Leakage Test c. Installation
b. Removal
INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All LO 9-2320-209-12-1
TM 9-2320-361-10
MATERIALS/PARTS TM 9-2320-361-20P
Cotter pin
Two gaskets EQUIPMENT CONDITION
Four lockwashers Parking brake set (TM 9-2320-361-10).
Screw-assembled lockwasher Adjust brake pedal (para. 8-14).
Antiseize tape (Appendix C, Item 27) Hydraulic hoist pump propeller shaft (M342A2)
Cap and plug set (Appendix C, Item 8) removed (para. 12-14).
Plug P/N 218-5154 Hydraulic hoist pump control linkage (M342A2)
Brake fluid (Appendix C, Item 7) removed (para. 13-22).
Transmission PTO shift linkage (M342A2)
PERSONNEL REQUIRED removed (para. 13-20).
Two
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to
prevent dirt from entering and causing internal parts damage.
Remove caps and plugs prior to installation.

I a. Internal Leakage Test

I
1. Remove screw-assembled lockwasher (6) from brace (2) and open access door (1). Discard screw-
assembled lockwasher (6).
2. Disconnect line (3) from adapter (5).
3. Remove two screws (8) and shield (9) from air-hydraulic cylinder (7).

Have drainage container ready to catch brake fluid.

4. Remove line (10) and two gaskets (11) from adapter (12) and adapter (13). Discard gaskets (11).
NOTE
Have plug ready to replace adapter before removing adapter.
5. Remove adapter (12) from master cylinder (4) and quickly install plug (14).
6. Make sure master cylinder (4) is filled with brake fluid 0.5 in. (12.7 mm) from top (refer to
LO 9-2320-209-12-1).
NOTE
Assistant will help with steps 7 and 8.
7. Measuring distance alongside of brake pedal (15), step down slowly but firmly on brake pedal (15).
Maintain steady firm pressure for 30 seconds.
8. Brake pedal (15) should not move more than 0.125-0.25 in. (3.18 -6.35 mm).
9. If brake pedal (15) moves more than 0.125-0.25 in. (3.18 -6.35 mm) in 30 seconds. there is an
internal leak. Replace master cylinder (4).

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 TM 9-2320-361-20

8-10. HYDRAULIC MASTER CYLINDER REPLACEMENT (Contd)

NOTE
Have drainage container ready to catch brake fluid.
10. Remove plug (14) and install adapter (12) in master cylinder (4).
11. Install line (10) on adapter (12) and adapter (13).
12. Install shield (9) on air-hydraulic cylinder (7) with two screws (8).
13. Fill master cylinder (4) 0.5 in. (12.7 mm) from top (LO 9-2320-209-12-1).
14. Connect line (3) on adapter (5).
15. Close access door (1) and secure to brace (2) with new screw-assembled lockwasher (6).

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TM 9-2320-361-20

8-10. HYDRAULIC MASTER CYLINDER REPLACEMENT (Contd)

CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to
prevent dirt from entering and causing internal parts damage.
Remove plugs prior to installation.

1. Remove screw-assembled lockwasher (6) from brace (2) and open access door (1).
2. Disconect line (4) from adapter (5).
3. Remove two screws (8) and shield (9) from air-hydraulic cylinder (7).
4. Remove two screws (10) from bracket (20) and master cylinder (2). Push bracket (20) away from
master cylinder (3).
5. Remove spring (14) from clevis pin (11) and bracket (13).
6. Remove cotter pin (15) from clevis pin (11). Discard cotter pin (15).
NOTE
Brake pedal must be supported in full extended position for ease
when installing master cylinder.
7. Scribe or measure position of jamnut (17).
8. Loosen jamnut (17) and remove clevis pin (11) and yoke (16) from brake pedal lever (12).
9. Remove pushrod (18) and boot (19) from master cylinder (3).
NOTE
Have drainage container ready to catch brake fluid.
10. Remove line (21) and two gaskets (22) from adapters (23) and (24). Discard gaskets (22).
11. Remove four screws (25), lockwashers (26), and master cylinder (3) from bracket (27). Discard
lockwashers (26).
12. Remove adapter (23) and adapter (5) from master cylinder (3).

c. Installation
NOTE
All male pipe threads must be wrapped with antiseize tape before
installation.
1. Install adapter (23) and adapter (5) on master cylinder (3).
2. Install master cylinder (3) on bracket (27) with four new lockwshers (26) and screws (25).
3. Install boot (19) and pushrod (18) on master cylinder (3).
4. Install two new gaskets (22) and line (21) on adapters (23) and (24).
5. Install yoke (16) on pushrod (18) to measured distance or scribed mark, ensure yoke (16) forked end
alines with brake pedal lever (12).
6. Tighten jamnut (17) on pushrod (18).
7. Aline brake pedal lever (12) with yoke (16) holes and install with clevis pin (11) and new cotter pin (15).
8. Install spring (14) on clevis pin (11) and bracket (13).
9. Install bracket (20) on master cylinder (3) with two screws (10).
10. Install shield (9) on air-hydraulic cylinder (7) with two screws (8).
11. Fill master cylinder (3) 0.5 in. (12.7 mm) from top (LO 9-2320-209-12-1).
12. Connect line (4) on adapter (5).
13. Close and secure access door (1) on brace (2) with new screw-assembled lockwasher (6).

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8-10. HYDRAULIC MASTER CYLINDER REPLACEMENT (Contd)

FOLLOW-ON TASKS: Install transmission PTO shift linkage (M342A2) (para. 13-20).
Install hydraulic hoist control linkage (M342A2) (para. 13-22).
Install hydraulic hoist pump propeller shaft (M342A2) (para. 12-14).
Bleed service brake (para. 8-12).

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TM 9-2320-361-20

8-11. AIR-HYDRAULIC CYLINDER REPLACEMENT

This task covers
a. Removal b. Installation
INITIAL SETUP:
APPLICABLE MODELS
All EQUIPMENT CONDITION
Parking brake set (TM 9-2320-361-10).
MATERIALS/PARTS Air system drained (TM 9-2320-361-10).
Two gaskets
Antiseize tape (Appendix C, Item 27) GENERAL SAFETY INSTRUCTIONS
Cap and plug set (Appendix C, Item 8) Do not disconnect air lines before draining air
reservoirs.
REFERENCES (TM)
LO 9-2320-209-12-1
TM 9-2320-361-10
TM 9-2320-361-20P

WARNING
Do not disconnect air lines before draining air reservoirs. Small
parts under pressure may shoot out with high velocity, causing
injury to personnel.
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to
prevent dirt from entering and causing internal parts damage.
Remove plugs prior to installation.
NOTE
Tag all air and hydraulic lines for installation.

NOTE
Have drainage container ready to catch brake fluid.
1. Remove two screws (10) and shield (11) from air-hydraulic cylinder (2).
2. Remove master cylinder hydraulic line (5) and gasket (3) from adapter (4). Discard gasket (3).
3. Loosen nut (6) and turn master cylinder hydraulic line (5) out of the way.
4. Disconnect hydraulic pressure line (7) from adapter (8).
5. Remove vent line (12) and gasket (13) from elbow (14). Discard gasket (13).
6. Disconnect trailer air line (21) from elbow (22).
7. Disconnect air supply line (16) from elbow (15).
8. Disconnect connector (20) from stoplight switch (19).
9. Remove screw (1) and air-hydraulic cylinder (2) from brackets (9) and (17).
10. Remove stoplight switch (19) from tee adapter (18).
11. Remove elbows (14), (15), and (22) and adapters (4) and (8) from air-hydraulic cylinder (2).
12. Remove, tag, clean, and inspect all adapters and elbows from air-hydraulic cylinder (2). Inspect for
cracks, breaks, or stripped threads. If damaged, discard.

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8-11. AIR-HYDRAULIC CYLINDER REPLACEMENT (Contd)

b. Installation

NOTE
All male pipe threads must be wrapped with antiseize tape before
installation.
1. Install elbows (14), (15), and (22) and adapters (4) and (8) on air-hydraulic cylinder (2).
2. Install stoplight switch (19) on tee adapter (18).
3. Install air-hydraulic cylinder (2) on brackets (17) and (9) with screw (1).
4. Connect connectors (20) to stoplight switch (19).
5. Connect air supply line (16) to elbow (15).
6. Connect trailer air line (21) to elbow (22).
7. Install new gasket (13) and connect vent line (12) to elbow (14).
8. Connect hydraulic pressure line (7) to adapter (8).
9. Install new gasket (3) and master cylinder hydraulic line (5) to adapter (4).
10. Tighten nut (6).
11. Install shield (11) on air-hydraulic cylinder (2) with two screws (10).

FOLLOW-ON TASKS: Fill master cylinder (LO 9-2320-209-12-1).

Bleed service brakes (para. 8-12).

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TM 9-2320-361-20

8-12. SERVICE BRAKE BLEEDING

This task covers:
a. Pressure Tank Method b. Manual Method

INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All LO 9-2320-209-12-1
MATERIALS/PARTS TM 9-2320-361-10
TM 9-2320-361-20P
Hose
Screw-assembled lockwasher EQUIPMENT CONDITION
Brake fluid (Appendix C, Item 7) Parking brake set (TM 9-2320-361-10).
Rags (Appendix C, Item 21) Master cylinder filled (LO 9-2320-209-12-1).
PERSONNEL REQUIRED
Two

a. Pressure Tank Method

1. Remove screw-assembled lockwasher (7) from brace (2) and open access door (1) exposing top of
master cylinder (6). Discard screw-assembled lockwasher (7).
2. Disconnect vent line (3) from adapter (4).
3. Clean top of master cylinder (6) and remove filler plug (5).
4. Fill master cylinder (6) with fresh brake fluid to 1/2 in. (1.27 cm) from top.
5. Install adapter plug (9) and male quick-disconnect coupling (8) on master cylinder (6).
6. Make sure brake bleeder tank (10) is charged with brake fluid and is pressurized 20-25 psi
(138-172 kPa). Follow manufacturers instructions for purging and preparation before connecting to
brake system. Turn flow valve (13) “OFF’ on tank hose (11), if so equipped.
7. Connect female quick-disconnect coupling (12) to male quick-disconnect coupling (8).
8. Turn flow valve (13) “ON’, if so equipped.
9. Check for leaks and correct as necessary.
CAUTION
Always bleed air-hydraulic cylinder before bleeding downstream
hydraulic components. Failure to do so may result in damage to
equipment.
10. Clean around bleeder screw (19) located on top front of air-hydraulic cylinder (18).
11. Fill transparent container (17) 1/3 to 1/2 full of brake fluid.
12. Install flexible snug-fitting hose (16) on bleeder screw (19) and immerse other end of hose (15) in
transparent container (17). Keep hose (16) end under surface of brake fluid at all times.
13. Loosen bleeder screw (19) 3/4 turn until brake fluid is flowing. Allow brake fluid to flow until no air
bubbles are observed.
NOTE
If brake fluid doesn’t flow after 3/4 turn, go to step 14; otherwise, go
to step 15.
14. Turn valve (13) “OFF’ and remove female quick-disconnect coupling (12). Remove and clean bleeder
screw (14). Install bleeder screw (19) and repeat steps 7 through 13.
15. Close bleeder screw (19) and remove hose (16) from bleeder screw (19). Tighten bleeder screw (19)
10-20 lb-ft (14-27 NŽm).
16. If hydraulic components of any one wheel were worked on, go to that wheel, clean around bleeder
screw (19), and bleed brake system by performing steps 11 through 15. Install end of hose (16) on
bleeder screw (15) and immerse other end of hose (16) in brake fluid in transparent container (17).

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8-12. SERVICE BRAKE BLEEDING (Contd)

17. If all wheel cylinders (14) need to be bled, start with wheel cylinder farthest from air-hydraulic
cylinder (18) and progressively go in distance sequence to wheel cylinder (18) nearest to air-
hydraulic cylinder (18). Tighten wheel cylinder bleeder screws (15) 10-15 lb-ft (14-20 NŽm).
18. When finished bleeding hydraulic system, turn valve (13) “OFF’ and disconnect female quick-
disconnect coupling (12) on tank hose (11) from male quick-disconnect coupling (8) and adapter
plug (9).

CAUTION
Dispose of brake fluid in approved disposal area.
Do not reuse brake fluid. Reusing brake fluid may result in
damage to equipment.
19. Remove adapter plug (9) with male quick-disconnect coupling (8) and install filler plug (5) and
adapter (4) in master cylinder (6). Tighten filler plug (5) 15-20 lb-ft (20-27 NŽm).
20. Connect vent line (3) to adapter (4).
21. Remove bleeder tank (10) from cab. Follow equipment manufacturers instructions for placing
bleeder tank (10) in storage.
22. Close access door (1) and install new screw-assembled lockwasher (7).

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8-12. SERVICE BRAKE BLEEDING (Contd)

b. Manual Method

1. Perform task a, steps 1 through 4.

2. Install filler plug (5).
CAUTION
Always bleed air-hydraulic cylinder before bleeding downstream
hydraulic components. Failure to do so may result in damage to
equipment.
3. Clean area around bleeder screw (8) on air-hydraulic cylinder (11).
4. Connect a snug fitting flexible hose (9) on bleeder screw (8) and immerse other end of hose (9) in a
transparent container (10) 1/3 to 1/2 filled with brake fluid. Keep end of hose (9) always under
surface of brake fluid.
NOTE
Assistant is required for steps 5 through 11.
5. Have assistant slowly apply and release brake pedal (12) twice, then slowly apply and hold down
brake pedal (12). Have assistant tell you when holding down brake pedal (12).
6. While assistant holds brake pedal (12) down, open bleeder screw (8) 3/4 turn on air-hydraulic
cylinder (11) or bleeder screw (14) on wheel cylinder (13). Observe for air bubbles in container (10)
or (16).
7. Close bleeder screw (8) or (14) and inform assistant to release brake pedal (12). Refill master
cylinder (6) with brake fluid.
8. Repeat steps 5 through 7 until no air bubbles appear when brake pedal (12) is applied.
9. Remove hose (9) from bleeder screw (8) and tighten bleeder screw (8) 10-20 lb-ft (14-27 NŽm).
NOTE
If wheel cylinders are to be bled, go to step 10. If not, go to
step 14.
If more than one wheel cylinder is to be bled, start with wheel
cylinder farthest from master cylinder and progress in sequence
to wheel cylinders closest to master cylinder.
10. Clean around bleeder screw (14) on wheel cylinder (13).
11. Connect a snug fitting flexible hose (15) to bleeder screw (14) and immerse end of hose (15) in a
transparent container (16) 1/3 to 1/2 filled with brake fluid. Keep end of hose (15) always under
surface of brake fluid.
12. Repeat steps 5,6,7, and 8.
13. When finished bleeding wheel cylinder (13), remove hose (15) and tighten bleeder screw (14)
10-15 lb-ft (14-20 NŽm).

Do not reuse brake fluid. Reusing brake fluid may result

in damage to equipment.
Dispose of brake fluid in approved disposal area.
14. Ensure master cylinder (6) is filled with fresh brake fluid to 0.5 in. (1.27 cm) from top.
15. Install filler plug (5) on master cylinder (6) and tighten to 15-20 lb-ft (21-28 NŽm).
16. Connect line (3) to adapter (4).
17. Close access door (1) on brace (2) and install with screw-assembled lockwasher (7).

8-34
 TM 9-2320-361-20

8-12. SERVICE BRAKE BLEEDING (Contd)

8-35
TM 9-2320-361-20

8-13. BRAKE PEDAL LEVER REPLACEMENT

This task covers:
a. Removal b. Installation
INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All TM 9-2320-361-10
TM 9-2320-361-20P
MATERIALS/PARTS
Cotter pin EQUIPMENT CONDITION
Two woodruff keys Parking brake set (TM 9-2320-361-10).
Remove hydraulic hoist pump propeller shaft
PERSONNEL REQUIRED (M342A2) (para. 12-14).
Two Remove transmission PTO shift linkage (if so
equipped) (para. 13-20).
Remove hydraulic hoist control linkage (M342A2)
(para. 13-22).

a. Removal

1. Unhook clutch return (1) from relay lever (2).

2. Unhook brake pedal return spring (14) from clevis pin (8).
3. Remove nut (19), washer (20), screw (3), and yoke rod (4) from relay lever (2).
4. Remove screw (5) and nut (21) from relay lever (2).
5. Remove relay lever (2) and woodruff key (18) from shaft (6). Discard woodruff key (18).
6. Remove screw (22), clutch pedal rod (24), and bumper (23) from arm (28).
7. Remove screw (27), clutch pedal arm (28), and woodruff key (26) from shaft (6). Discard woodruff
key (26).
8. Remove screw (12), washer (11), brake pedal lever (13), and bumper (10) from brake pedal rod (9).
Remove brake pedal rod (9) from cab.
9. Remove cotter pin (15), clevis pin (8), and yoke (16) from brake pedal lever (13). Discard cotter
pin (15).
NOTE
Assistant will help with steps 10 and 11.
On vehicles equipped with transmission power takeoff, pull shaft
free of inside of bracket and brake pedal lever until lever can be
removed.
10. Remove shaft (6) through bracket (17) and brake pedal lever (13) until brake pedal lever (13) cab be
removed from bracket (17).
11. Remove shaft (6) from frame (25).
12. Remove grease fitting (7) from brake pedal lever (13).

b. Installation
NOTE
Assistant will help with step 1.
When installing shaft make sure enough room is afforded for
installation of relay lever and clutch pedal arm.
1. Position brake pedal lever (13) in bracket (17) and yoke (16), and install shaft (6) through frame
(25), bracket (17), and brake pedal lever (13).

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 TM 9-2320-361-20

8-13. BRAKE PEDAL LEVER REPLACEMENT (Contd)

2. Install grease fitting (7) on brake pedal lever (13).
3. install clevis pin (8) through yoke (16) and brake pedal lever (13) with new cotter pin (15).
4. Install new woodruff key (18) and relay lever (2) on shaft (6) with screw (5) and nut (21).
5. Connect relay lever (2) to yoke rod (4) with screw (3), washer (20), and nut (19).
6. Install brake pedal rod (9) through cab floor and bumper (10) onto brake pedal lever (13) with
washer (11) and screw (12).
7. Install new woodruff key (26) and clutch pedal arm (28) on shaft (6) with screw (27).
8. Install clutch pedal rod (24) through cab floor and bumper (23) and onto clutch pedal arm (28) with
screw (22).
9. Connect brake pedal return spring (14) to clevis pin (8).

FOLLOW-ON TASKS: Install hydraulic hoist control linkage (M342A2) (para. 13-22).
Install transmission power takeoff shift linkage (if so equipped) (para. 13-20).
Install hydraulic hoist pump propeller shaft (M342A2) (para. 12-14).

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TM 9-2320-361-20

8-14. BRAKE PEDAL ADJUSTMENT

This task covers:
Adjustment
INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All TM 9-2320-361-10
TM 9-2320-361-20P
MATERIALS/PARTS
Cotter pin EQUIPMENT CONDITION
Chalk (Appendix C, Item 9) Parking brake set (TM 9-2320-361-10).

Adjustment

1. Mark brake pedal rod (2) with chalk, marking it even with cab floor (3).
2. Push brake pedal (1) down until freeplay is gone.
3. Mark brake pedal rod (2) with chalk, marking it even with cab floor (3), and then release brake
pedal (1).
4. Measure distance between two marks (4). If distance is 0.25 -0.5 in. (6.35 -12.7 mm), adjustment is
correct. If out of adjustment, proceed with steps 5 through 7.
5. Unhook spring (11) from clevis pin (8).
6. Remove cotter pin (10), clevis pin (8), and yoke (7) from brake pedal lever (9). Discard cotter pin (10).
7. Loosen jamnut (5) and adjust pushrod (6) until proper adjustment is obtained.
8. Install yoke (7) on brake pedal lever (9) with clevis pin (8).
9. Hook spring (11) to clevis pin (8).
10. Repeat steps 1 through 9 until freeplay is correct as indicated in step 4.
11. Install new cotter pin (10) through clevis pin (8).
12. Tighten jamnut (5) against pushrod (6).

8-38
 TM 9-2320-361-20

8-14. BRAKE PEDAL ADJUSTMENT Contd)

8-39
TM 9-2320-361-20

8-15. HYDRAULIC BRAKE LINE REPLACEMENT

This task covers

INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All LO 9-2320-209-12-1
TM 9-2320-361-10
MATERIALS/PARTS TM 9-2320-361-20P
Lockwasher
Locknut EQUIPMENT CONDITION
Two screw-assembled lockwashers Parking brake set (TM 9-2320-361-10).
Cap and plug set (Appendix C, Item 8)
GENERAL SAFETY INSTRUCTIONS
New, longer hydraulic brake line must be installed.

WARNING
Short front flexible hydraulic brake lines are subject to failure during
full steering travel and must be replaced with new, longer flexible
hydraulic brake lines P/N 7409330. Failure to do this may cause
injury or death to personnel. Refer to para. 8-16 for replacement.
CAUTION
Cap or plug all openings immediately after disconnecting lines and
hoses to prevent contamination. Failure to do so may result in
internal parts damage.
NOTE
All hydraulic brake and compressed air lines are replaced the same.
This procedure covers the front flexible hydraulic brake line.

a. Removal
1. Disconnect spring (7) from spring plate (5).
2. Remove nut (3), lockwasher (4), and spring plate (5) from steering arm (2). Discard lockwasher (4).
3. Remove locknut (14), screw (6), spring (7), and clamp (8) from flexible hydraulic brake line (15).
Discard locknut (14).
NOTE
Have container ready to catch hydraulic fluid.
4. Disconnect flexible hydraulic brake line (15) from inlet connector (1).
5. Remove brake line (13) from flexible hydraulic brake line (15).
6. Remove nut (12) and flexible hydraulic brake line (15) from bracket (10).
7. Remove two screw-assembled lockwashers (9) and bracket (10) from axle housing (11) and
brake line (13). Discard screw-assembled lockwashers (9).
b. Installation
1. Install bracket (10) on axle housing (11) with two new screw-assembled lockwashers (9).
2. Connect flexible hydraulic brake line (15) to inlet connector (1).
3. Install flexible hydraulic brake line (15) on bracket (10) with nut (12).
4. Install brake line (13) on flexible hydraulic brake line (15).
5. Install clamp (8) on flexible hydraulic brake line (15) with spring (7), screw (6), and new locknut (14).

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 TM 9-2320-361-20

8-15. HYDRAULIC BRAKE LINE REPLACEMENT (Contd)

5. Install spring plate (5) on steering arm (2) with new lockwasher (4) and nut (3). Tighten nut (3) to
130-167 lb-ft (176-227 NŽm).
6. Connect spring (7) on spring plate (5).

FOLLOW-ON TASKS: Fill master cylinder (LO 9-2320-209-12-1).

Bleed service brakes (para. 8-12).

8-41
TM 9-2320-361-20

8-16. FLEXIBLE HYDRAULIC BRAKE LINE MODIFICATION

This task covers:
a. Removal c. Installation
b. Modification
INITIAL SETUP:
APPLICABLE MODELS REFERENCES (TM)
All LO 9-2320-209-12-1
TM 9-2320-361-10
MATERIALS/PARTS TM 9-2320-361-20P
Three lockwashers
Two screw-assembled lockwashers EQUIPMENT CONDITION
Locknut Parking brake set (TM 9-2320-361-10).
Screw
Spring plate GENERAL SAFETY INSTRUCTIONS
Spring New, longer hydraulic brake line must be installed.
Clamp
Brake line P/N 7409330
Cap and plug set (Appendix C, Item 8)

WARNING
Ensure new, longer front hydraulic brake lines, currently used on 5-
ton trucks, are installed on all 2-1/2-ton trucks. Old, shorter front
hydraulic brake lines are subject to failure during full steering
travel and must be replaced with new, longer front brake hoses.
Failure to do this will result in injury or death to personnel.
CAUTION
Cap or plug all openings immediately after disconnecting lines and
hoses to prevent contamination. Failure to do so may result in
internal parts damage.
NOTE
Left and right front flexible hydraulic lines are replaced the same.
This procedure covers the left front.

a. Removal
1. Remove two nuts (2), lockwashers (1), and steering guard (4) from steering arm (7). Discard
lockwashers (1).
2. Remove locknut (6), screw (3), and bracket (5) from steering guard (4). Discard screw (3) and
locknut (6).
NOTE
Have container ready to catch hydraulic fluid.
3. Disconnect steel brake line (15) from inlet connector (14).
4. Disconnect brake line (12) from flexible hydraulic brake line (13).
5. Remove nut (11), old flexible hydraulic brake line (13) with steel brake line (15), and bracket (5)
from bracket (10). Discard nut (11), old flexible hydraulic brake line (13) with steel brake line (15),
and bracket (5).
6. Remove two screw-assembled lockwashers (9) and bracket (10) from axle housing (8). Discard screw-
assembled lockwashers (9).

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 TM 9-2320-361-20

8-16. FLEXIBLE HYDRAULIC BRAKE LINE MODIFICATION (Contd)

b. Modification
1. Bend bracket (10) tab to a 45º angle. Check bracket (10) for cracks. If cracked, replace bracket (10)
and repeat step.
2. Locate and drill 0.46 in. (10.3 mm) hole (17), 0.5 in. (12.7 mm) from bracket corners (16).

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TM 9-2320-361-20

8-16. FLEXIBLE HYDRAULIC BRAKE LINE MODIFICATION (Contd)

c. Installation
1. Loosen brake cylinder inlet conector (17) and rotate 180° (1/2 turn) so that inlet connector (17) is
toward rear of vehicle. Tighten brake cylinder inlet conector (17).
2. Install new, altered bracket (10) on axle housing (11) with two new screw-assembled lock-
washers (9).
3. Install new, longer flexible hydraulic brake line (16) to inlet connector (17), and other end to new,
altered bracket (10) with new nut (13).
4. Install brake line (12) to brake line (16).
5. Install new spring plate (6) on steering arm (18) with new lockwasher (5) and nut (4). Tighten
nut (4) to 130-167 lb-ft (176-227 NŽm).
6. Install new clamp (15) and spring (8) on new, long flexible hydraulic brake line (16) with screw (7)
and new locknut (14).
7. Connect new spring (8) on spring plate (6).
8. Install steering guard (1) on steering arm (18) with two new lockwashers (3) and nuts (2). Tighten
nuts (2) 130-167 lb-ft (176-227 NŽm).

FOLLOW-ON TASKS: Fill master cylinder (LO 9-2320-209-12-1).

Bleed service brakes (para. 8-12).

8-44