Iveco Stralis AT/AD. Manual - part 263

Overhaul braking unit, observing — in dismounting
and overhauling the brake caliper — the procedure
described for front disk brakes, since it is similar.

527417

Replacing brake linings

Park the vehicle on level ground. Put the parking brake lever
into the off position and loosen the nuts fixing the rear wheels.
Using a hydraulic jack, lift the vehicle at the rear and rest it on
the special stands. Using the hydraulic trolley 99321024 (1),
take off the wheels.

Figure 122

Fully unscrew the screw (2) to manually release the combined
cylinder (1) and detach it from the brake calliper.

Figure 123

Figure 124

72744

Place a container under the wheel hub to collect the oil.
Block wheel hub (1) rotation with the retaining tool 99370317
(3).
Take out the screws (2) and extract the drive shaft (4).

Figure 125

72745

Lift the notch on the ring nut (5). With wrench 99355175 (1)
and multiplier 99389816 (2), take off the ring nut (5) holding
the wheel hub bearing. Remove the retaining ring (4).

39950

39951

Examine the state of wear of the brake disc surfaces. If you find
different values to the ones given in the characteristics and
data table, remove it as follows.

Figure 126

Remove the wheel hub (1). Should this prove difficult, use the
extractor comprising the brackets 99341017 (2), bridge
99341003 (3) and block 99345049 (4) fitted as shown in the
figure.

72746

TRALIS

AT/AD

110

AIR SYSTEM - BRAKES

Base - January 2003

OVERHAULING REAR DISC
BRAKES

72749

72748

72755

72757

72748

Figure 127

Figure 128

Figure 129

Figure 130

Figure 131

The phonic wheel (1) is removed from the wheel hub (2) with
general tools.
To assemble the phonic wheel, heat it to approx. 150

°C and

fit it on the wheel hub (2).
On completing assembly, make sure the phonic wheel (1)
rests correctly on the hub seat.

Screw the tool 99370700 (2) onto the sleeve (1) of the rear
axle housing.
Lubricate the outside of the tool (1) with Tutela Truck
Fe-Axle.

Fit the wheel hub (3) on the sleeve of the rear axle housing
and with the dial gauge (1) with a magnetic base check that the
error of concentricity of the phonic wheel (2) is no greater
than 0.2 mm. Remove the wheel hub (3).

Fit the brake disc (3) onto the wheel hub (1) and screw down
the screws (2).

Check the state of the wheel hub bearing, rear axle housing
sleeve and calliper mounting plate. Replace any worn or
damaged parts as described under ”Overhauling the wheel
hubs” of rear axle MS 13-175 with disc brakes.

Take out the screws (2) and remove the wheel hub (1) from
the brake disc (3). Turn and grind the brake disc as described
in the section or replace it if necessary.

AIR SYSTEM - BRAKES

111

TRALIS

AT/AD

72758

72759

72760

72761

Figure 132

Figure 133

Figure 134

Figure 135

Figure 136

Sling the brake disc (1) with a rope and hook this onto a lift.
Fit the wheel hub (2) onto the sleeve of the rear axle housing.
Remove the tool 99370700 (3).

Position the retaining ring (4) so as to insert the tab into the
groove in the sleeve. Lastly, screw down the ring nut (5).
Using wrench 99355175 (1), the multiplier 99389/816 (2) and
the torque wrench (3), tighten the ring nut (5) to the required
torque.

After tightening with a specific tool, make the cut and bend to
prevent the ring nut unscrewing, as shown in the figure.
The arrow shows the direction of unscrewing the ring nut.

Block rotation of the wheel hub (2) with tool 99370317 (4)
and tighten the screws (3) fixing the brake disc (1) to the
wheel hub to the required torque.

Figure 137

39954

After overhauling and refitting the braking assembly, fit the
cylinder (1) following the procedure described for the front
brake cylinder.
Supply the cylinder (1) by pressing the service brake and tighten
the fixing ring nut to the required torque with the wrench
99356006. Restore operation of the cylinders (1) governing the
parking brake by fully screwing down the screw (2).

Spread IVECO 1905685 sealant (LOCTITE 14780) onto the
contact surfaces, drive shaft flange and wheel hub and insert
the drive shaft into the rear axle housing.
Screw down the screws (2) fixing the drive shaft (3) to the
wheel hub and tighten with the torque wrench (4) to the
required torque. Remove the tool 99370317 (5).

74371

TRALIS

AT/AD

112

AIR SYSTEM - BRAKES

Base - January 2003

Figure 138

Figure 139

Figure 140

Using the hydraulic trolley 99321024 fit on the wheels. Lower
the vehicle. Lock the nuts fixing the rims to the required
tightening torque according to the diagram shown in the figure
Proceed as described on the opposite side.
On completing this process, start the engine to recharge the
pneumatic system.
Drive the vehicle in both directions, press the brake pedal
repeatedly, to let the brake linings settle in.

40564

38597

527411

OVERHAULING BRAKE DISCS

Examine the state of wear of the surfaces of the brake discs.
Finding other values to the ones given in the characteristics and
data, turn and grind the brake discs or, if necessary, replace them.
Remove the screws (1) and detach the hub (2) from the disc (3).
Replace the disc (3) and refit it following the reverse
procedure to the one described above.

35707

- Key onto the shaft of the lathe 99301001 (2) the brake

disc (1) together with the hub.

- Key onto the shaft a set of spacers that eliminate the end

float of the assembly; screw on the locking nut and fit the
mount of the lathe shaft.

- Position the tool holder (3) in line with the brake disc (1),

then adjust the depth of the tools.

- Proceed with turning and grinding the brake disc (1),

operating with one or more passes to remove material
depending on the scoring found.

Figure 141

35704

Using the specific grinding tool 99301001 (1) fitted to the lathe
99301001, grind both working surfaces of the brake disc.

When grinding, move the sector wheel forwards
gradually, to remove all remains of turning.

AIR SYSTEM - BRAKES

113

TRALIS

AT/AD

527411

TURNING AND GRINDING
BRAKE DISCS

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