Banda Bendix 2606672-1 Rev (1) .15 Sep.28, 2007

PDM Controlled InterleafDocument File, Received On 09/27/2007 09:43:14
Honeywell International Inc.

3520 Westmoor Street
South Bend, Indiana 46628-1373
U.S.A.
CAGE: 55284
Telephone: (800) 601-3099 (U.S.A.)
Telephone: (602) 365-3099 (International)
Web site: http://portal.honeywell.com/wps/portal/aero
Component Maintenance Manual

with Illustrated Parts List
737-200/300/400/500
Main Brake Assembly
PART NUMBERS
2606672-1, 2606672-2, 2606672-3, and 2606672-4
REVISION NOTICE: Latest revised pages

supersede the same pages of previous date.
Insert revised pages into basic document.
Destroy superseded pages.
This document contains technical data and is subject to U.S. export regulations. These commodities,
technology, or software were exported from the United States in accordance with the export administration
regulations. Diversion contrary to U.S. law is prohibited.
ECCN: 9E991, no license required.
Publication Number 12-557, Revision 15

32-40-08 Page T-1
Initial 31 Dec 1979
Revised 28 Sep 2007
E Honeywell International Inc. Do not copy without express permission of Honeywell.
File: 12-557.ildoc, Revision: 15, Status: Released, Released On 09/27/2007
COMPONENT MAINTENANCE MANUAL

2606672
Honeywell - Confidential
THIS DOCUMENT AND ALL INFORMATION AND EXPRESSION CONTAINED HEREIN ARE THE
PROPERTY OF HONEYWELL INTERNATIONAL INC., ARE PROVIDED IN CONFIDENCE, AND
MAY BE USED BY PERSONS REQUIRED BY FEDERAL AVIATION REGULATION PART 21.50 TO
COMPLY WITH ANY OF THE TERMS OF THESE INSTRUCTIONS. EXCEPT AS SET FORTH
ABOVE, NO PERSON MAY, IN WHOLE OR IN PART, USE, DUPLICATE OR DISCLOSE THIS
INFORMATION FOR ANY PURPOSE WITHOUT THE PRIOR WRITTEN PERMISSION OF
HONEYWELL INTERNATIONAL INC.
Honeywell Materials License Agreement

The documents and information contained herein (“the Materials”) are the proprietary data of Honeywell
International Inc. and Honeywell Intellectual Properties Inc. (collectively “Honeywell”). These Materials
are provided for the exclusive use of Honeywell Service Centers; Honeywell-authorized repair facilities;
operators of Honeywell aerospace products subject to an applicable product support agreement, their
wholly owned-subsidiaries or a formally designated third party service provider; and direct recipients of
Materials from Honeywell’s Aerospace Technical Publication Distribution. The terms and conditions of
this License Agreement govern your use of these Materials, except to the extent that any terms and
conditions of another applicable agreement with Honeywell regarding the operation, maintenance, or
repair of Honeywell aerospace products conflict with the terms and conditions of this License
Agreement, in which case the terms and conditions of the other agreement will govern. However, this
License Agreement will govern in the event of a conflict between its terms and conditions and those of a
purchase order or acknowledgement.
1. License Grant - If you are a party to an applicable product support agreement, a Honeywell Service Center agreement, or
an authorized repair facility agreement, Honeywell hereby grants you a limited, non-exclusive license to use these Materials to
operate, maintain, or repair Honeywell aerospace products only in accordance with that agreement.
If you are a direct recipient of these Materials from Honeywell’s Aerospace Technical Publication Distribution and are not a
party to an agreement related to the operation, maintenance or repair of Honeywell aerospace products, Honeywell hereby
grants you a limited, non-exclusive license to use these Materials to maintain or repair the subject Honeywell aerospace
products only at the facility to which these Materials have been shipped (“the Licensed Facility”). Transfer of the Materials to
another facility owned by you is permitted only if the original Licensed Facility retains no copies of the Materials and you
provide prior written notice to Honeywell.
2. Rights In Materials - Honeywell retains all rights in these Materials and in any copies thereof that are not expressly granted
to you, including all rights in patents, copyrights, trademarks, and trade secrets. No license to use any Honeywell trademarks
or patents is granted under this License Agreement.
3. Confidentiality - You acknowledge that these Materials contain information that is confidential and proprietary to Honeywell.
You agree to take all reasonable efforts to maintain the confidentiality of these Materials.
4. Assignment And Transfer - This License Agreement may be assigned to a formally designated service designee or
transferred to a subsequent owner or operator of an aircraft containing the subject Honeywell aerospace products. However,
the recipient of any such assignment or transfer must assume all of your obligations under this License Agreement. No
assignment or transfer shall relieve any party of any obligation that such party then has hereunder.
5. Copies of Materials - Unless you have the express written permission of Honeywell, you may not make or permit making of
copies of the Materials. Notwithstanding the foregoing, you may make copies of only portions of the Material for your internal
use. You agree to return the Materials and any copies thereof to Honeywell upon the request of Honeywell.
32-40-08 Page T-2

28 Sep 2007

2606672
6. Term - This License Agreement is effective until terminated as set forth herein. This License Agreement will terminate
immediately, without notice from Honeywell, if you fail to comply with any provision of this License Agreement or will terminate
simultaneously with the termination or expiration of your applicable product support agreement, authorized repair facility
agreement, or your formal designation as a third party service provider. Upon termination of this License Agreement, you will
return these Materials to Honeywell without retaining any copies and will have one of your authorized officers certify that all
Materials have been returned with no copies retained.
7. Remedies - Honeywell reserves the right to pursue all available remedies and damages resulting from a breach of this
License Agreement.
8. Limitation of Liability - Honeywell does not make any representation regarding the use or sufficiency of the Materials.
THERE ARE NO OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESS, IMPLIED OR STATUTORY,
INCLUDING, BUT NOT LIMITED TO, (i) WARRANTIES ARISING FROM COURSE OF PERFORMANCE, DEALING, USAGE,
OR TRADE, WHICH ARE HEREBY EXPRESSLY DISCLAIMED, OR (ii) WARRANTIES AGAINST INFRINGEMENT OF
INTELLECTUAL PROPERTY RIGHTS OF THIRD PARTIES, EVEN IF HONEYWELL HAS BEEN ADVISED OF ANY SUCH
INFRINGEMENT. IN NO EVENT WILL HONEYWELL BE LIABLE FOR ANY INCIDENTAL DAMAGES, CONSEQUENTIAL
DAMAGES, SPECIAL DAMAGES, INDIRECT DAMAGES, LOSS OF PROFITS, LOSS OF REVENUES, OR LOSS OF USE,
EVEN IF INFORMED OF THE POSSIBILITY OF SUCH DAMAGES. TO THE EXTENT PERMITTED BY APPLICABLE LAW,
THESE LIMITATIONS AND EXCLUSIONS WILL APPLY REGARDLESS OF WHETHER LIABILITY ARISES FROM BREACH
OF CONTRACT, WARRANTY, TORT (INCLUDING BUT NOT LIMITED TO NEGLIGENCE), BY OPERATION OF LAW, OR
OTHERWISE.
9. Controlling Law - This License shall be governed and construed in accordance with the laws of the State of New York
without regard to the conflicts of laws provisions thereof. This license sets forth the entire agreement between you and
Honeywell and may only be modified by a writing duly executed by the duly authorized representatives of the parties.
Copyright - Notice
Copyright 1980, 1984, 1986, 1987, 1989, 1990, 1991, 1992, 1998, 2002, 2004, 2005, 2007,
Honeywell International Inc.
All rights reserved.
Honeywell is a registered trademark of Honeywell International Inc.

All other marks are owned by their respective companies.
32-40-08 Page T-3

28 Sep 2007

2606672
Blank Page
32-40-08 Page T-4

28 Sep 2007

2606672
TO: Holders of Component Maintenance Manual (12-557) for the Honeywell Main
Brake Assembly used on the 737 Aircraft.
REVISION #15, DATED SEPTEMBER 28, 2007
HIGHLIGHTS
Pages revised are listed below, together with the revision highlights. Please delete those pages
that have been revised and replace them with the attached pages dated September 28, 2007.
Complete the “Date Inserted” block of the Record of Revisions sheet by entering the date that
Revision #15 is added to the basic manual.
Chapter/Section/Subject
and Page Number Description of Change
32-40-08
Global Change References to “Aircraft Landing Systems” and “ALS” were removed and
replaced with “Honeywell”. Title page and headers and footers in all affected
sections were updated per the new standard.
513 Changed the “X” to an “O” in the Overhaul Inspection Intervals column for
Outline Number 4.5.
Page 1 of 2
32-40-08 28 Sep 2007
File: 12-557_hlt.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

2606672
Blank Page
Page 2 of 2
32-40-08 28 Sep 2007
File: 12-557_hlt.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

2606672
RECORD OF REVISIONS
Issue Date Issue Date

Rev. No. Date Inserted By Rev. No. Date Inserted By
1 9/15/80 9/15/80 HON
2 7/1/84 7/1/84 HON
3 1/15/86 1/15/86 HON
4 8/15/86 8/15/86 HON
5 7/1/87 7/15/90 HON
6 8/15/89 7/15/90 HON
7 7/15/90 7/15/90 HON
8 1/31/91 6/30/92 HON
9 11/30/91 6/30/92 HON
10 6/30/92 6/30/92 HON
11 6/5/98 10/15/02 HON
12 10/15/02 10/15/02 HON
13 1/15/04 1/15/04 HON
14 4/18/05 4/18/05 HON
15 9/28/07
Page RR-1
32-40-08 28 Sep 2007
File: 12-557_ror.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

2606672
Blank Page
Page RR-2
32-40-08 28 Sep 2007
File: 12-557_ror.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

737-200/300/400/500 MAIN BRAKE ASSEMBLY, P/N 2606672
RECORD OF TEMPORARY REVISIONS
TEMP. REV. PAGE ISSUE DATE

NO. NUMBERS DATE BY REMOVED BY
Page RTR-1
32-40-08
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Oct 15/02
File: 12-557_rtr.ildoc, Revision: 1, Status: Released, Released On 10/15/2002


RECORD OF TEMORARY REVISIONS
This page intentionally left blank.
Page RTR-2
32-40-08
Oct 15/02
File: 12-557_rtr.ildoc, Revision: 1, Status: Released, Released On 10/15/2002

SERVICE BULLETIN LIST
The following is a numerical list of Aircraft Landing Systems (ALS) Service Bulletins (SB’s) followed
by the bulletin issue date and the date the bulletin information was incorporated into the overhaul
manual.
NOTE: ALS Service Information Letters (SIL’s) are normally issued to provide general information.
However, certain SIL’s may contain additional procedural or modification information which
was disseminated to the equipment user. Therefore, these SIL’s are listed along with the
SB’s.
Date
SB/SIL Number SB/SIL Title Date Issued Incorporated
2606672-32-025 Optional Rework of 737-200 HW and 5/8/91 6/30/92
737-300 Main Brake Assembly Stainless
Steel Piston, Change Letter C and Prior
2606672-32-026 Model 737-200 Landing Gear Main Brake 1/2/92 6/30/92
Compliance with Worn Brake RTO
Requirements
2606672-32-027 Landing Gear - Main Brake Assembly - 4/14/92 6/30/92
Revised Heat Stack Configuration
2606672-32-029 Main Landing Gear - 737 - Brake Assembly 3/31/95 N/A
- Modification of Torque Tube Backing Plate
to Prevent Contact with the Wheel
Assembly
2606672-32-031 Landing Gear - Brake Assembly - 9/15/99 10/15/02
737-200/300/400/500 - P/N 2606672 -
Introduction of Stator Plate, P/N 2614056
2606672-32-032 Landing Gear - Main Brake Assembly - 737 3/31/03 1/15/04
- P/N 2606672-2/3/4 - Introduction of
Optional Piston Bushing, P/N 2615477
495 Part Number Supersedure: Retainer P/N 11/26/90 10/15/02
2604333 to P/N 2610484
601 Modification of Brake Return Spring Washer 5/31/96 N/A
P/N 2608553
605 Notice of Elimination of “Broaching” Process 6/25/96 10/15/02
for Steel Brake Rotor Drive Slots
640 Introduction of Optional Chrome Plated 6/10/98 10/15/02
Piston Bushing P/N 2613673 for 737 Main
Brake P/N 2606672
653 Screw Thread Insert, P/N 2600715 3/15/99 10/15/02
656 Piston Land Inspection of 737 Piston P/N 4/30/99 10/15/02
2608279
679 Optional Chrome Plated Piston Bushing P/N 2/1/00 N/A
2613673 for 737 Main Brake P/N 2606672
Temporarily Discontinued
687 Misidentification of Brake Lining Segments, 5/3/00 N/A
P/N 357562
Page SBL-1
32-40-08
Apr 18/05
SERVICE BULLETIN LIST
Date
SB/SIL Number SB/SIL Title Date Issued Incorporated
693 Steel Rotor Assembly Strap and Rivet 7/20/00 10/15/02
Head/Formed Rivet Damage Allowances
706, Supplement 1 Use of Batco Grease X-8401 #2 on Piston 4/20/01 10/15/02
Bushing Threads
708 Introduction of Piston Wiper, P/N 2614815, 1/31/01 10/15/02
with Energized Preformed Packing Feature
717 Inspection Requirements and Repair Limits 10/31/01 10/15/02
for New Stator Plate, P/N 2614056,
Available for Use in Brake Assemblies, P/N
2606672-1/2/3/4
733 Piston Housing Inlet Repair 9/30/01 10/15/02
779 Brake Reline Instruction Plate, P/N 7/1/03 4/18/02
2602886, Discontinued
Page SBL-2
32-40-08
Apr 18/05

2606672
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page T-1 Sep 28/07 Disassembly (cont.) 305 Jan 15/04
T-2 Sep 28/07 306 Jan 15/04
T-3 Sep 28/07 307 Jan 15/04
T-4 Sep 28/07 308 Jan 15/04
Record of RR-1 Sep 28/07 309 Jan 15/04
Revisions RR-2 Sep 28/07 310 Jan 15/04
311 Jan 15/04
Record of RTR-1 Oct 15/02 312 Jan 15/04
Temporary RTR-2 Oct 15/02
Revisions Cleaning 401 Jan 15/04
Service Bulletin SBL-1 Apr 18/05 402 Jan 15/04
List SBL-2 Apr 18/05 403 Jan 15/04
404 Jan 15/04
List of LEP-1 Sep 28/07
Effective Pages LEP-2 Sep 28/07 Check 501 Sep 28/07
LEP-3 Sep 28/07 502 Sep 28/07
LEP-4 Sep 28/07 503 Sep 28/07
504 Sep 28/07
Table of TC-1 Apr 18/05
505 Sep 28/07
Contents TC-2 Apr 18/05
506 Sep 28/07
Introduction INTRO-1 Jan 15/04 507 Sep 28/07
INTRO-2 Jan 15/04 508 Sep 28/07
Description and 1 Apr 18/05 509 Sep 28/07
Operation 2 Apr 18/05 510 Sep 28/07
3 Apr 18/05 511 Sep 28/07
4 Apr 18/05 512 Sep 28/07
5 Apr 18/05 513 Sep 28/07
6 Apr 18/05 514 Sep 28/07
7 Apr 18/05 515 Sep 28/07
8 Apr 18/05 516 Sep 28/07
9 Apr 18/05 517 Sep 28/07
10 Apr 18/05 518 Sep 28/07
11 Apr 18/05 519 Sep 28/07
12 Apr 18/05 520 Sep 28/07
521 Sep 28/07
Testing 101 Jan 15/04 522 Sep 28/07
102 Jan 15/04 523 Sep 28/07
103 Jan 15/04 524 Sep 28/07
104 Jan 15/04 525 Sep 28/07
105 Jan 15/04 526 Sep 28/07
106 Jan 15/04 527 Sep 28/07
107 Jan 15/04 528 Sep 28/07
108 Jan 15/04 529 Sep 28/07
Disassembly 301 Jan 15/04 530 Sep 28/07
302 Jan 15/04 531 Sep 28/07
303 Jan 15/04 532 Sep 28/07
304 Jan 15/04 533 Sep 28/07
Page LEP-1
32-40-08 28 Sep 2007
File: 12-557_eff.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

2606672
Check (cont.) 534 Sep 28/07 Repair (cont.) 642 Apr 18/05
535 Sep 28/07 643 Apr 18/05
536 Sep 28/07 644 Apr 18/05
537 Sep 28/07 645 Apr 18/05
538 Sep 28/07 646 Apr 18/05
647 Apr 18/05
Repair 601 Apr 18/05
648 Apr 18/05
602 Apr 18/05
649 Apr 18/05
603 Apr 18/05
650 Apr 18/05
604 Apr 18/05
651 Apr 18/05
605 Apr 18/05
652 Apr 18/05
606 Apr 18/05
653 Apr 18/05
607 Apr 18/05
654 Apr 18/05
608 Apr 18/05
655 Apr 18/05
609 Apr 18/05
656 Apr 18/05
610 Apr 18/05
657 Apr 18/05
611 Apr 18/05
658 Apr 18/05
612 Apr 18/05
659 Apr 18/05
613 Apr 18/05
660 Apr 18/05
614 Apr 18/05
661 Apr 18/05
615 Apr 18/05
662 Apr 18/05
616 Apr 18/05
663 Apr 18/05
617 Apr 18/05
664 Apr 18/05
618 Apr 18/05
665 Apr 18/05
619 Apr 18/05
666 Apr 18/05
620 Apr 18/05
667 Apr 18/05
621 Apr 18/05
668 Apr 18/05
622 Apr 18/05
623 Apr 18/05 Assembly 701 Apr 18/05
624 Apr 18/05 702 Apr 18/05
625 Apr 18/05 703 Apr 18/05
626 Apr 18/05 704 Apr 18/05
627 Apr 18/05 705 Apr 18/05
628 Apr 18/05 706 Apr 18/05
629 Apr 18/05 707 Apr 18/05
630 Apr 18/05 708 Apr 18/05
631 Apr 18/05 709 Apr 18/05
632 Apr 18/05 710 Apr 18/05
633 Apr 18/05 711 Apr 18/05
634 Apr 18/05 712 Apr 18/05
635 Apr 18/05 713 Apr 18/05
636 Apr 18/05 714 Apr 18/05
637 Apr 18/05 715 Apr 18/05
638 Apr 18/05 716 Apr 18/05
639 Apr 18/05 717 Apr 18/05
640 Apr 18/05 718 Apr 18/05
641 Apr 18/05 719 Apr 18/05
Page LEP-2
32-40-08 28 Sep 2007

2606672
Assembly (cont.) 720 Apr 18/05 Special Tools, 908 Jan 15/04
721 Apr 18/05 Fixtures, and 909 Jan 15/04
722 Apr 18/05 Equipment (cont.) 910 Jan 15/04
723 Apr 18/05
724 Apr 18/05 Illustrated Parts 1001 Apr 18/05
725 Apr 18/05 List 1002 Apr 18/05
726 Apr 18/05 1003 Apr 18/05
727 Apr 18/05 1004 Apr 18/05
728 Apr 18/05 1005 Apr 18/05
729 Apr 18/05 1006 Apr 18/05
730 Apr 18/05 1007 Apr 18/05
731 Apr 18/05 1008 Apr 18/05
732 Apr 18/05 1009 Apr 18/05
733 Apr 18/05 1010 Apr 18/05
734 Apr 18/05 1011 Apr 18/05
735 Apr 18/05 1012 Apr 18/05
736 Apr 18/05 1013 Apr 18/05
1014 Apr 18/05
Fits and 801 Apr 18/05
1015 Apr 18/05
Clearances 802 Apr 18/05
1016 Apr 18/05
Special Tools, 901 Jan 15/04 1017 Apr 18/05
Fixtures, and 902 Jan 15/04 1018 Apr 18/05
Equipment 903 Jan 15/04
904 Jan 15/04 Appendix A A-1 Jan 15/04
905 Jan 15/04 A-2 Jan 15/04
906 Jan 15/04 A-3 Jan 15/04
907 Jan 15/04 A-4 Jan 15/04
Page LEP-3
32-40-08 28 Sep 2007

2606672
Blank Page
Page LEP-4
32-40-08 28 Sep 2007
TABLE OF CONTENTS
Subject Page No.

Introduction (Also refer to the Aircraft Landing Systems (ALS) Standard Practices Manual (SPM)
(ATA 32-49-01)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Assembly Dash Number Differences and Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Assembly Component Interchangeability and Modifications . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake Heat Stack Change and Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Collection of Data to Establish a Customized Steel Brake Configuration . . . . . . . . . . . . . . . . . . 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Tabular Definition of Testing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Testing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Unassigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Tabular Definition of Disassembly Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Disassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
General (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Clean Brake Assembly (Also refer to the ALS SPM, (ATA 32-49-01)) . . . . . . . . . . . . . . . . . . . . 401
Remove Carbon Deposits (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . . . . . . 401
Remove Paint from Aluminum Parts (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . 402
Remove Paint from Steel Parts (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . 402
Remove Corrosion from Aluminum Parts (Refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . 402
Remove Corrosion from Steel Parts (Refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . 402
Remove Anodize from Aluminum Parts (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . 402
Approved Agents (Refer to the ALS SPM (ATA32-49-01)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Special Tools and Materials (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . . . . 501
Service Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Early Removal Inspection Instructions (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . 503
Inspection Interval Schedules - Steel Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Tabular Definition of Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Check Instructions (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . . . . . . . . . . . . 507
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Tabular Definition of Repair Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repair Instructions (Also refer to the ALS SPM (ATA 32-49-01)) . . . . . . . . . . . . . . . . . . . . . . . . 602
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Tabular Definition of Assembly Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
Fits and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Page TC-1
32-40-08
Apr 18/05
TABLE OF CONTENTS
Subject Page No.

Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Special Service Tools and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Specialized Assembly Tools To Be Procured at Operator Option . . . . . . . . . . . . . . . . . . . . . . . . 902
Tools that May Be Locally Manufactured at Operator Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Appendix A - Vendor Contact information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Page TC-2
32-40-08
Apr 18/05
INTRODUCTION
The procedures contained in this manual for overhauling Aircraft Landing Systems (ALS) brake
assemblies P/N 2606672-1/2/3/4 have been verified in compliance with the intent of the
requirements specified in ATA Specification 100. The procedures are intended as a guide, and
they need not be strictly followed if equivalent or better procedures can be adapted to a particular
overhaul facility.
The procedures used must be consistent with standard shop practices and carefully evaluated to
ensure they do not detract from the safety, efficiency, and operation of the end item.
NOTE: The torque limits, service limits, and other specific values prescribed in this manual must
be strictly adhered to.
This manual is organized with separate page number blocks assigned to specific subjects. For
example, Description and Operation starts on page 1, Testing starts on page 101, etc. The page
number block starting with page 201 is not used in this manual. A complete listing of the page
number blocks and subject assignments are included in the Table of Contents.
An exploded view of the brake assembly and an accompanying detailed parts list are shown in the
Illustrated Parts List section.
Measurements, dimensions, and other values are expressed in U.S. units followed by the
appropriate SI (International System of Units) Metric units in parentheses, except where the
dimensions of standard tools or parts such as drills, taps, bolts, nuts, etc., are given. These
dimensions remain in U.S. units, as there are no equivalent metric tools or parts for the
application. A list of units of measure and abbreviations used in this manual is presented in
Table 1.
Standard cleaning, check, repair, and assembly procedures applicable to multiple models can be
found in the ALS Standard Practices Manual (SPM) (ATA 32-49-01). Accordingly, these
procedures have been removed from the individual component manuals.
Unit of Measure Abbreviation

Measurement or Dimension Standard Metric Standard Metric
Fluid Volume Fluid ounce Milliliter fl oz ml
Gallon Liter gal l
Linear Inch Millimeter in mm
Foot Meter ft m
Mile Kilometer mi km
Pressure Pounds Per Square Kilopascal psi kPa
Inch Bar ---
Degrees Temperature Fahrenheit Celsius °F °C
Torque Pound-inch Newton-Meter lb-in N⋅m
Pound-foot lb-ft
Weight Ounce Gram oz g
Pound Kilogram lb kg
Units of Measure and Abbreviations
Table 1
Page INTRO-1
32-40-08
Jan 15/04
INTRODUCTION
Page INTRO-2
32-40-08
Jan 15/04
DESCRIPTION AND OPERATION
Aircraft Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737-200H
Aircraft Landing Systems (ALS) Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2606672-1
Boeing Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61819-14
Aircraft Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737-200H/-300/-400/-500

ALS Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2606672-2/3/4
Boeing Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61819-17/-21/-28
Size and Type . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 x 9.75 in (406.4 x 247.7 mm), Four-Rotor Brake
Brake Assemblies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four per Aircraft
Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Segmented Steel
Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trapezoid Shape/Cerametallic
Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forged Aluminum
Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Per Boeing Specification BMS 3-11
Maximum Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 psi (20,685 kPa)
Reline Dimension . . . . . . . . . . . . . . . . . . . . . . . . . When indicator pin is flush with piston housing pad
(with brake parking pressure are applied)
Minimum Running Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.080 inch (2.03 mm) at 130 psi (896 kPa)
1. General.
CAUTION: THE USE OF UNAUTHORIZED SUBSTITUTE PARTS MAY SERIOUSLY
JEOPARDIZE THE RELIABILITY AND SAFETY OF REPAIRED BRAKES.
USE ONLY THE REPLACEMENT PARTS SPECIFIED IN THE ILLUSTRATED
PARTS LIST (IPL) SECTION.
NOTE: Item numbers (in parentheses) refer to the exploded view shown in the IPL
section of this manual.
A. The ALS main gear brake assembly for the 737-200H/300/400/500 aircraft is
manufactured to the highest quality standards to give the user optimum service life
with a minimum of maintenance. Use the same care with the main gear brake
assembly during installation, operation, and removal, that is accorded the basic
airframe primary structure.
B. The procedures specified in this Component Maintenance Manual (CMM) have been
engineered to provide parts satisfactory for continued service and maximum life. Since
part replacement and labor costs vary throughout the world, operators must
individually evaluate the cost of repair versus replacement.
C. ALS recommends visual inspection and functional/leak check of the piston housing
during heat stack changes.
D. ALS Material Safety Data Sheet (MSDS) information can be obtained by contacting:
Honeywell Aircraft Landing Systems
Attn: HS&E, Box 25
South Bend, Indiana 46628-1373, U.S.A.
Telephone: (574) 231-2000 - Safety Department, Monday through Friday, 8 a.m. to
4 p.m., Eastern Standard Time.
Fax: (574) 231-3426
E. Refer to the Special Tools, Fixtures, and Equipment section for acquisition of tools and
fixtures. ALS service tools are identified with a 255XXXX P/N format.
Page 1
32-40-08
Apr 18/05
F. During the manufacturing process, brake assemblies and piston housings are forged
or stamped with several important reference numbers. These reference numbers
should be used when documenting service history or corresponding with Honeywell
regarding warranty claims, service limits or repair guidelines. Format examples and
descriptions for these references are provided in Table 1. See reference number
locations in Figure 1.
Reference Number Description

Brake Assembly Identifies the top-level P/N for the assembly. Part numbers are
Part Number (P/N) followed by a dash number to designate significant changes to the
assembly level configuration. These are addressed in the
Illustrated Parts List under applicable effectivity codes as required.
The brake assembly P/N is generally preceded by “ASSY” on the
piston housing.
Brake Assembly S/N format is SN B####
Serial Number (S/N) When purchased from Honeywell as part of a complete brake
assembly, the piston housing will be stamped with a B" in the serial
number.
Service Piston S/N format is SNB C####
Housing Assembly When an individual piston housing is purchased from Honeywell, a
Serial Number (S/N) C" will be stamped in the serial number to designate this
component as a replacement service part.
Piston Housing S/N Format is x####. For example x0123.
Machined S/N The x" S/N is stamped into each individual piston housing.
Piston Housing Used to designate the drawing P/N from which the part was
Machined P/N machined.
Piston Housing Used to designate the forging P/N from which the part was
Forging P/N machined.
Change Each Piston Housing Assembly P/N, Machined P/N and Forging
(Revision Level) P/N has a corresponding change letter. This letter reflects the
Letters drawing revision level when an item was manufactured.
The change letters generally follow the P/N and are stamped.
Date of Manufacture Designates the date (month and year) a Piston Housing completed
the manufacturing process at Honeywell ALS.
The date of manufacture is generally preceded by MFD".
Brake Assembly Reference Numbers
Table 1
Page 2
32-40-08
Apr 18/05
CHANGE
LETTER
BRAKE ASSEMBLY
MANUFACTURED DATE
PISTON HOUSING
MACHINED PART
NUMBER
BRAKE
ASSEMBLY
PART NUMBER
BRAKE ASSEMBLY
SERIAL NUMBER
BOEING PISTON HOUSING

PART NUMBER FORGING PART NUMBER
NOTE:
FIGURE IS INTENDED ONLY AS A GUIDE FOR
THE LOCATION OF REFERENCE NUMBERS.
SPECIFIC REFERENCE NUMBERS SHOWN
ARE PROVIDED AS AN EXAMPLE. REF-
ERENCE THE ILLUSTRATED PARTS LIST TO
DETERMINE SPECIFIC PART NUMBERS.
LAG–5867
Brake Assembly Reference Numbers

Figure 1
Page 3
32-40-08
Apr 18/05
2. Description.
A. The main landing gear brake assembly, shown in Figure 2, is a size 16.00 x 9.75 inch
(406.4 x 247.7 mm) hydraulically actuated, four-rotor multiple disc-type brake. The
disc elements of the brake assembly are housed in an area between a hydraulically
operated piston housing assembly and an integral torque tube and backing plate
assembly, which is bolted to the piston housing. The brake assemblies are installed on
the axle with the torque tube bolted to the brake mounting flange. The assemblies are
interchangeable on any position of the aircraft main landing gear.
B. The rotating disc elements (rotors) of the brake assembly are of the segmented
design. Each rotor assembly consists of nine steel segments mounted on a
spider-type structural ring. The segments are retained as an assembly by riveted steel
straps around the outside diameter (OD). The rotor spider is slotted and serves to
engage the rotor drive keys of the wheel assembly during operation.
C. The brake stationary elements (pressure plate, stator plates, and stator torque tube
backing plate) serve as brake lining carrying members. The trapezoid-shaped brake
linings are made of a compound of inherently heat-stable ceramic and metallic
ingredients, balanced to retain strength and frictional properties at incandescent
temperature. The pressure plate and backing plate sections of the stator torque tube
are fitted with replaceable lining on their inner surfaces. Stator plates are positioned
between each rotor assembly, and both surfaces of the stator plates are fitted with
replaceable linings riveted back to back. The pressure plate and stator plates are
slotted on the inside diameter (ID) to index with and slide axially on the splines of the
stator torque tube.
D. The brake piston housing contains six equally spaced piston and bushing assemblies
that are interconnected by drilled passages. The four combination return spring and
automatic adjuster assemblies are housed in the piston housing, and are attached to
the pressure plate by adjuster pins. The piston housing assembly provides two
bleeder valve assemblies to effectively remove entrapped air during installation and
servicing.
E. Two reline indicator pins, attached to the pressure plate, provide a visual indication of
the wear remaining in the frictional brake elements. When the end of the reline
indicator pin is flush with the top of the pad on the piston housing with parking brake
pressure applied, the brake must be removed from the aircraft and disassembled for
inspection. See Figure 102.
F. The brake incorporates integral stops on the piston bushing ID to prevent piston
packing extrusion in the event that excessive heat stack wear were to occur. The
piston stop consists of an integral shoulder in the piston bushing OD adjacent to the
wiper groove and a shoulder on the piston OD adjacent to the packing groove. The
stop is capable of withstanding full aircraft system hydraulic pressure without the piston
being in contact with the friction stack.
Page 4
32-40-08
Apr 18/05
PRESSURE PLATE
PISTON AND PISTON
BUSHING ASSEMBLIES 3.03 (77.0)
(TYPICALLY 6 PLACES) TRAPEZOID
LININGS
BRAKE TIE BOLTS
STATOR TORQUE
TUBE ASSEMBLY
FULLY SEGMENTED
SPIDER ROTOR ASSEMBLY
PISTON HOUSING
STATOR PLATE
ASSEMBLY
AUTOMATIC BALL AND
SUSPENDED EXPANDER
TUBE ADJUSTER
MECHANISM
RETURN (TYPICALLY 4 PLACES)
SPRINGS
DIMENSIONS ARE PROVIDED IN INCHES WITH

WB–392B MILLIMETER CONVERSIONS IN PARENTHESES
Main Brake Assembly - Cutaway View

Figure 2
Page 5
32-40-08
Apr 18/05
3. Operation.
A. The brake assembly is normally operated by fluid pressure from the aircraft main
hydraulic system. Brake operation is controlled by actuation valves through linkages
and pushrods when the brake pedals are depressed. The aircraft also uses a
secondary brake control system to safely stop the aircraft in the event the primary
system becomes inoperative.
B. When brake pressure is applied, hydraulic fluid under system pressure enters the inlet
port of the brake piston housing and is distributed to the brake pistons through drilled
passages. Applied fluid pressure actuates the piston assemblies, moving them out
against the pressure plate, which presses the rotors and stators together against the
backing plate section of the torque tube. Rotational friction, generated between the
stationary lined plates and the brake rotors, provides the required braking.
C. The piston housing is attached to the pressure plate by four adjuster pins through the
return springs. Attached to the end of each adjuster pin is a spherical ball, which is
press set in the end of a metal adjuster tube. Outward movement of the pressure plate
pulls the adjuster pins and adjuster washers down, compressing the return springs.
When the adjuster washer contacts the shoulder on the ID of the adjuster cavity, the
adjuster pin then pulls the spherical ball through the adjuster tube, compensating for
brake wear. The distance the adjuster moves is the built-in running clearance.
4. Brake Assembly Dash Number Differences and Effectivity.
The information provided in this section regarding equipment usage on various airplane
models is provided for information only. This information does not allow interchangeability of
the brake assemblies, unless specifically authorized by Boeing Service Bulletins or by
Federal Aviation Authority approved interchangeability drawings.
A. P/N 2606672-1 Brake Assembly.
(1) Brake assembly P/N 2606672-1 was designed for use on the 737-200H
airplane. Use of this brake on the 737-300/-400/-500 airplanes is prohibited
due to the higher stopping energy requirements of these airplanes.
(2) Brake assembly P/N 2606672-1 was originally supplied with piston insulators
installed in the ID of the pistons as identified in the Brake Assembly Exploded
View (Figure 1001) of the IPL as “-1 Superseded”. ALS no longer supplies
components for reassembly of this configuration. These components were later
replaced by a one-piece piston as shown in the IPL.
B. P/N 2606672-2 Brake Assembly.
(1) Brake assembly P/N 2606672-2 was designed for the higher weight
requirements of the 737-300 airplane. It may be used on the
737-200H-300/-400/-500 airplanes.
(2) Brake assembly P/N 2606672-2 differs from brake assembly P/N 2606672-1 in
the following areas:
(a) Pistons and bushings have a larger diameter. Piston and bushing
assemblies from the P/N 2606672-1 brake assembly may not be
intermixed with piston and bushing assemblies from the P/N 2606672-2
brake assembly.
(b) An improved design adjuster mechanism simplifies installation and
reduces parts. This adjuster mechanism cannot be used in the
2606672-1 brake assembly.
Page 6
32-40-08
Apr 18/05
(c) The heat sink weight is increased because of the use of thicker rotors.
C. P/N 2606672-3/-4 Brake Assemblies.
(1) Brake assemblies P/N 2606672-3/-4 may be used on the
737-200H/-300/-400/-500 airplanes.
(2) Brake assemblies P/N 2606672-3/-4 are identical to brake assembly
P/N 2606672-2 in all aspects, except that the P/N 2606672-3/-4 brake
assemblies incorporate a provision for mounting a brake temperature sensor.
Brake assembly P/N 2606672-3 incorporated a single bolt for attaching the
temperature sensor. This mounting provision has been superseded by the
two-bolt attachment design of the P/N 2606672-4 brake assembly.
5. Brake Assembly Component Interchangeability and Modifications.
A. Several piston housing and stator torque tube P/N’s have been introduced for use on
the P/N 2606672 brake assemblies. These components may be interchanged as
referenced in the IPL. Rework to upgrade a brake assembly dash level or to upgrade
a component’s effectivity may be accomplished at operator option as follows:
(1) Upgrade of brake assembly P/N 2606672-1 to brake assembly P/N 2606672-2
requires modifications to the piston and bushing assemblies, the adjuster
assemblies, and the heat stack configuration as referenced in the IPL. Once
the required modifications have been performed, the brake assembly must be
remarked as ALS P/N 2606672-2 and Boeing P/N 10-61819-17.
NOTE: For the upgrades identified below, rework of the piston housing and
torque tube is only required when a temperature sensor is used.
Otherwise, brake assemblies P/N 2606672-2/-3/-4 offer identical heat
stack build requirements and identical stopping energy performance
when maintained to the requirements of this CMM.
(2) Piston housings identified as brake assemblies P/N 2606672-1/-2/-3 may be
upgraded to incorporate a two-bolt temperature sensor. The upgrade requires
that the piston housing be modified as shown in Figure 3. Once the piston
housing has been modified, the brake assembly should be remarked as ALS
P/N 2606672-4 and Boeing P/N 10-61819-28. If a piston housing identified as
brake assembly P/N 2606672-1 is being upgraded, modifications to the piston
and bushing assemblies, the adjuster assemblies, and the heat stack
configuration as referenced in the IPL for brake assembly P/N 2606672-4 must
also be performed.
(3) Stator torque tubes (240, 240A) may be upgraded for use in the
P/N 2606672-3/-4 brake assemblies if the modifications shown in Figure 4 are
performed.
Page 7
32-40-08
Apr 18/05
1 MISMATCH NOT ALLOWED BETWEEN 0.46 - 0.47 (11.7 - 11.9)

EXISTING MACHINE SURFACE AND DIA THRU (REF)
NEW MACHINE SURFACE G
0.31 (7.9) DIA THRU TO REMOVE

EXISTING THREADS FOR BRAKE
ASSEMBLY P/N 2606672-3 PRIOR
TO GENERATING MILLED SURFACE.
BLEND SHARP EDGES AFTER REWORK.
DO NOT DRILL HOLE WHEN UPGRADING
A P/N 2606672-1/-2 BRAKE ASSEMBLY.
1 A
4.280 0.43 (10.9)
0.55 (14.0) 0.42 (10.7) 6.88
(108.71)
0.53 (13.5) R (REF)
(174.8)
0.03 (0.8) DIA (REF)
A 0.02 (0.5) X 45°
B
0.10 (2.5)
0.08 (2.0) R
0.525
(13.34)
0.500
SECTION A–A
(12.70)
EXISTING TAPPED
A HOLE AND POCKET 0.257 - 0.264 (6.53 - 6.71)
FOR BRAKE 0.28 - 0.31 (7.1 - 7.9) DIA
0.33 (8.4) X 120° COUNTERSINK
0.31 (7.9) R ASSEMBLY
TAP THRU FOR MS124696
P/N 2606672-3
INSERT(.25-28-3B THREAD)
(MINOR DIA 0.2577 - 0.2646
(6.546 - 6.721))
(MAJOR DIA 0.2964 – 0.3038
(7.529 - 7.717))
NOTE: (PITCH DIA 0.2732 - 0.2754
REMOVE ALL BURRS AND SHARP EDGES 0.005 - 0.025 (0.127 - 0.635). (6.939 - 6.995))
SURFACE TREAT AND PAINT PER REPAIR SECTION INSTRUCTIONS. 2 HOLES
INSTALL INSERT PER REPAIR SECTION INSTRUCTIONS. 0.010 (0.25) A G

LAG-3010D MILLIMETER CONVERSIONS IN PARENTHESES
Rework of Piston Housing to Incorporate Two-Bolt Attachment for Temperature Sensor

Figure 3
Page 8
32-40-08
Apr 18/05
ALIGNMENT
PIN HOLE
DRILL HOLE IN
LINE 180° FROM
SPLINE THAT ALIGNMENT
HOUSES THERMAL PIN HOLE
PROBE LOCATION
REMOVE
BURRS
4.465 - 4.445
(113.41 - 112.90)
0.37 - 0.39
(9.4 - 9.9) DIA
0.33 - 0.36
(8.4 - 9.1) DEEP
CENTERED
ON SPLINE

LAG-5038 MILLIMETER CONVERSIONS IN PARENTHESES
Rework of Stator Torque Tube to Incorporate Temperature Sensor

Figure 4
Page 9
32-40-08
Apr 18/05
B. Based on service history, a few one-time optional modifications have been defined for
the pressure plate and torque tube of the P/N 2606672-4 brake assembly as follows:
(1) Operators who experience difficulty in removing adjuster pin (46) from pressure
plate (205) may rework the adjuster pin slots of the pressure plate as shown in
Figure 5. This problem should be experienced only with pressure plates that
are not identified with a revision letter following the part number. After
reworking the pressure plate, steel stamp the letter “A”, spaced at least 0.13
inch (3.3 mm) after P/N 2606703 on the pressure plate.
REMOVE SHADED AREA 7 PLACES USING A

0.500 (12.70) DIA CYLINDRICAL ROTARY FILE.
REMOVE ONLY ENOUGH MATERIAL TO ALLOW
HEAD OF ADJUSTER PIN (46) TO PASS THROUGH
HOLE AS SHOWN IN VIEW 2.
0.06 (1.5) APPROX
0.500 (12.70) DIA CYLINDRICAL ROTARY FILE
VIEW 1 – REMOVAL OF MATERIAL USING ROTARY FILE
0.59
USE ADJUSTER PIN (15.0)
(46) AS A GAGE MIN
ORIENT PIN HEAD AS SHOWN WITH

PIN SHAFT PERPENDICULAR TO PLATE
VIEW 2 – INSPECTION OF REWORK USING ADJUSTER PIN (46)

LAG-2836C MILLIMETER CONVERSIONS IN PARENTHESES
Rework of Pressure Plate if Adjuster Removal is Difficult

Figure 5
Page 10
32-40-08
Apr 18/05
(2) Based on service experience, it has been found that in some cases, stator
torque tubes (240, 240A, 240B) can contact the wheel, causing damage to the
hub and spoke areas. To prevent the possibility of this occurrence, the stator
torque tube may be modified at operator option as defined in Figure 6. After
reworking stator torque tubes (240, 240A), add an “X” after the existing revision
letter. For stator torque tube (240B), Revision D and prior, grind out the existing
revision letter and stamp an “E” in its place. Stator torque tube (240B) Revision
E and subsequent were manufactured with this modification.
REMOVE BURRS AND SHARP EDGES

0.005 - 0.025 (0.13 - 0.64)
65° $ 1/2°
65° $ 1/2° (REF)
7.42 (188.5)
7.38 (187.5)
MATERIAL REMOVED
7.42 (188.5)
7.38 (187.5)
(REF)
LAG-4483A MILLIMETER CONVERSIONS IN PARENTHESES
Rework of Stator Torque Tube to Prevent Possible Wheel Damage

Figure 6
Page 11
32-40-08
Apr 18/05
6. Brake Heat Stack Change and Overhaul Requirements.
A. The minimum inspection requirements to be performed at heat stack change and
overhaul are presented in the Check section. ALS recommends the replacement of all
packings at overhaul. More frequent inspection of piston and bushing assemblies and
replacement of packings may be required based on operator experience.
(1) Heat Stack Change.
Accomplish heat stack changes whenever the indicator pin is flush with the top
pad of the piston housing wear pin guide. See Figure 102. Minimum
requirements consist of a heat stack disassembly, inspection, repair (if
required), reassembly, and functional test per the appropriate sections.
(2) Overhaul Brake Assembly.
Overhaul of the brake assembly shall be accomplished at intervals of no more

than four heat stack changes. Overhaul consists of a complete breakdown of
the brake assembly. All components shall be inspected, repaired, or replaced
as required, then reassembled and functionally tested per the appropriate
sections.
7. Collection of Data to Establish a Customized Steel Brake Configuration.
A. The lining and rotor configurations presented in the Assembly section were developed
based on testing, and on worn brake data collected from field experience. Depending
on each operator’s lining wear pattern, it may be necessary to customize a brake
configuration. To accomplish this requires that new and worn brake measurements be
taken on 20 - 30 brake assemblies. The details of this data collection process are
defined in the Disassembly section, outline number 3.1.
Page 12
32-40-08
Apr 18/05
TESTING
1. Tabular Definition of Testing Requirements.
Topic Description
General Tabular The Testing section is presented using a tabular format to organize
Overview the test instructions. A breakdown of the tabular format is as
follows:
- Column 1 identifies the outline number for the test instructions
summarized in the table.
- Column 2 identifies the instructions that should be followed to
test the specified part or assembly.
Breakdown of Testing paragraphs are broken down as follows:
Assembly Paragraphs Paragraph Page
2.A. General Testing Guidelines . . . . . . . . . . . . . . . . . . . . 102
2.B. Bleed Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 103
2.C. Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.D. Functional Test and Checking of Running
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.E. Cutting and Measuring Reline Indicator
Pin Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Page 101
32-40-08
Jan 15/04
TESTING
2. Testing Instructions.
A. General Testing Guidelines.
1.1 General Instructions Applicable to the Testing Section

NOTE: Item numbers (in parentheses) refer to the exploded view shown in the
Illustrated Parts List (IPL) section of this manual.
WARNING: OBSERVE SAFETY RECOMMENDATIONS PROVIDED BY
MANUFACTURER WHEN WORKING WITH HYDRAULIC FLUID PER
BOEING SPECIFICATION BMS 3-11. IF HYDRAULIC FLUID IS
SPLASHED IN EYES, IMMEDIATELY WASH FOR AT LEAST 10
MINUTES IN A STREAM OF RUNNING WATER. FLUID IN CONTACT
WITH HANDS, FACE, OR BODY SKIN CAN BE WASHED OFF WITH
ORDINARY SOAP AND WATER. SHOULD IRRITATION PERSIST, A
PHYSICIAN SHOULD BE CONSULTED.
CAUTION: DO NOT ALLOW SPILLED HYDRAULIC FLUID TO REMAIN ON BRAKE
ASSEMBLY. WIPE ALL SURFACES IMMEDIATELY WITH A DRY, LOW
LINT, ABSORBENT CLOTH.
A. The brake assembly is designed to operate using hydraulic brake fluid per Boeing
Specification BMS 3-11.
WARNING: IMPROPER ASSEMBLY OF THE BRAKE MAY LEAD TO
MALFUNCTION OR HYDRAULIC FLUID SPRAY. ENSURE BRAKE
IS FULLY ASSEMBLED PER THE ASSEMBLY SECTION BEFORE
PERFORMING ANY TESTING.
CAUTION: BE CAREFUL DURING TESTING TO AVOID SPILLING OR
SPLASHING HYDRAULIC AND OTHER FLUIDS ON THE BRAKE
LININGS. THIS WILL ADVERSELY AFFECT BRAKE OPERATION,
AND THE PARTS MUST BE THOROUGHLY CLEANED WITH
ALCOHOL (OR OTHER APPROVED SOLVENTS) IF THIS
OCCURS.
B. Ensure that the brake assembly has been assembled per instructions in the
Assembly section.
C. Perform all testing operations in a clean area. For proper brake operation, it is
essential to prevent dirt, grit, and other foreign matter from entering the piston
cavities and fluid passageways of the piston housing.
Page 102
32-40-08
Jan 15/04
TESTING
B. Bleed Brake Assembly.
2.1 Bleed Brake Assembly

A. Assure that the brake has been assembled per instructions in the Assembly
section.
NOTE: Normally, a hydraulic fluid pressure of 3,000 psi (20,685 kPa) will be
needed to complete the test requirements. However, when an expansion
plug (173) has been replaced, hydraulic fluid pressure of 4,500 psi (31,028
kPa) will be required.
B. Attach hydraulic fluid line between the brake assembly and a pump capable of
delivering the required fluid pressure.
C. Carefully bleed the brake assembly of entrapped air as follows:
(1) If possible, position brake assembly on a test stand such that the bleeder
valves are at their highest position. This orientation will permit the maximum
amount of entrapped air from being purged.
(2) Remove screw (75) and lock washer (80) from bleeder screw (85). Connect
a flexible hose to the bleeder valve and submerge the free end in a clean
receptacle partially filled with the same type of fluid being used to test the
brake.
(3) Apply a fluid pressure of 150 psi (1,034 kPa) to the brake until pistons are
fully extended. Shut off the supply. Open the bleeder screw (85) and allow
the pistons to retract completely. Note the amount of aeration deposited in
the receptacle. Close the bleeder screw (85). Repeat this procedure until
all aeration disappears.
(4) Remove the bleed hose from bleeder screw (85). Tighten the bleeder screw
(85) to the torque value specified in Figure 801.
(5) Install lock washer (80) over screw (75) and install in bleeder screw (85).
Snug screw (75) by hand.
D. Safety wire screws (75) to bushings (90) with MS20995NC32 lockwire using the
double twist method. Also, ensure bushings (90) are safety wired together. If not,
accomplish per the Assembly section.
E. Wipe off any hydraulic fluid that may have spilled on the brake assembly with a low
lint, absorbent cloth.
Page 103
32-40-08
Jan 15/04
TESTING
C. Leakage Test.
3.1 Leakage Test

NOTE: If fluid passage expansion plugs (173) have been replaced, the high pressure
portion of this test must be performed using a fluid pressure of 4,500 ± 50 psi
(31,028 ± 345 kPa) instead of the normal 3,000 ± 50 psi (20,685 ± 345 kPa) fluid
pressure.
A. When 4,500 psi (31,028 kPa) pressure is to be applied, install spacer (similar to the
example shown in Figure 909) between the pressure plate and the first rotor to
prevent adjuster pull-through.
CAUTION: FOR SAFETY DURING PRESSURE TESTS, IT IS RECOMMENDED
THAT THE SIDES OF THE BRAKE BE COVERED WITH A METAL
OR PLEXIGLASS BOX TO PROTECT PERSONNEL FROM FLUID
LEAKS OR PLUG FAILURES.
B. Gradually apply a fluid pressure of 3,000 ± 50 psi (20,685 ± 345 kPa) to the brake
assembly and hold for five minutes. No fluid loss is permissible. If leakage is
noticed, isolate and repair leaks as outlined in Figure 101.
C. Apply a fluid pressure of 5 psi (34 kPa) to the brake assembly and hold for five
minutes. No fluid leakage or pressure loss is permissible. Isolate and repair leaks
as outlined in Figure 101.
D. If used, remove spacer at the completion of the leakage test.
D. Functional Test and Checking of Running Clearance.
4.1 Functional Test and Checking of Running Clearance

A. Cycle the brake five times from 0 - 1,000 psi (0 - 6,895 kPa) fluid pressure. Check
for fluid leakage and other malfunctions such as improper return of the
pistons/pressure plate. Fluid leakage or malfunction of pistons is not permitted.
Isolate and repair any leaks and malfunctions as outlined in Figure 101.
B. Reduce brake pressure to 130 psi (896 kPa) and check for proper running
clearance by measuring the clearance between the linings on the pressure plate
and the first rotor assembly in four equally spaced locations. The minimum brake
running clearance must be 0.080 inch (2.03 mm). If the running clearance
requirement is not met, ensure pistons are retracting properly. If pistons are
retracting properly, ensure heat stack configuration is correct per the Assembly
section. Adjustment of rotor thickness may be required to correct problem.
Page 104
32-40-08
Jan 15/04
TESTING
Fluid leaks from

brake assembly
Record brake assembly serial number,

wipe off excess fluid, and try to visually
determine leak origin
Check line Check piston housing Check passage plugs Check piston bushing
connections for obvious cracks in piston housing assemblies
Loose Crack Plug Leak

connection? found? leaking? found?
No No No No
Yes Yes Yes Yes
Repair in accordance Disassemble brake and

Tighten line connector Disassemble brake and
with CMM guidelines remove suspect piston
or replace replace piston housing
and re-evaluate bushing assembly
If unable to determine general area of 1

leak origin, disassemble brake, and
inspect piston housing for cracks and
Continued
other damage in accordance with
Next Page
CMM guidelines.
LAG-4908
Fault Isolation Chart

Figure 101 (Sheet 1 of 2)
Page 105
32-40-08
Jan 15/04
TESTING
Continued from
Previous Page
Disassemble
piston bushing
assembly per
CMM
Inspect
piston wiper
Wiper Remove wiper

condition and record
OK? No observations.
Yes
Check diameter and surface Record

conditions of piston bushing ID Check adjuster
observations and
and piston land OD. Record pin for scoring In limit?
No replace adjuster
dimensions and observations. per CMM.
pin.
Yes Yes
Repair/Replace piston
bushing and/or piston
as required per CMM. Replace all packings and
retainer packings. If wiper was
Are adjuster discarded earlier replace wiper,
pins used? No otherwise wiper may be reused.
Check preformed packing and retainer Rebuild piston bushing
packing geometry for deformities, assembly per CMM, then reset.
excess material, unusual shape, etc.
Record dimensions and observations.
Hold recorded observations

Check preformed packing and and all parts that are damaged
retainer packing for defects or worn beyond CMM limits for
such as cracks, splits, cuts, examination by local FSE.
etc. Record observations.
LAG-4909
Fault Isolation Chart

Page 106
32-40-08
Jan 15/04
TESTING
E. Cutting and Measuring Reline Indicator Pin Length.
5.1 Cutting Reline Indicator Pin Length

A. Pressurize the brake to 3,000 ± 50 psi (20,685 ± 345 kPa).
NOTE: The reline indicator pin (180) length, measured at 3,000 ± 50 psi (20,685 ±
345 kPa), must not exceed the limits in the Assembly section for the heat
stack configuration being tested. In some cases, operator lining wear
variability may require use of a shorter wear pin. In addition, the brake
assembly must also comply with piston extension requirements as
indicated below.
B. Cut the reline indicator pin to the maximum length permitted for the brake
configuration that was built per the following instructions:
(1) Identify the heat stack configuration that was assembled and the maximum
wear pin allowance defined per the Assembly section.
(2) Measure piston extension between the piston bushing and pressure plate as
shown in Figure 102.
- For the P/N 2606672-1 brake assembly, the sum of the desired wear
pin length plus piston extension must not exceed 1.83 inches
(46.5 mm).
- For the P/N 2606672-2/-3/-4 brake assemblies when used on a
737-300/-400/-500 airplane, the sum may not exceed 1.80 inches
(45.7 mm).
- When a P/N 2606672-2/-3/-4 brake assembly is specifically configured
for the 737-200H airplane, the sum must not exceed 2.00 inches
(50.8 mm).
If the sum of the piston extension and wear pin measurements exceed the
specified limits, then the wear pin length must be reduced. At operator
option, the brake could be reassembled with heavier (thicker) rotor
assemblies, which would also require replacement of adjuster tubes.
(3) Cut the wear pin as permitted for the configuration being built. In no case
shall the wear pin length be longer than the dimensions specified in the
Assembly section.
5.2 Measuring Reline Indicator Pin Length

WARNING: IMPROPER ASSEMBLY OF THE BRAKE OR MISSING PARTS FROM
THE BRAKE MAY LEAD TO MALFUNCTION OR HYDRAULIC FLUID
SPRAY. INSPECT BRAKE TO ENSURE BRAKE IS FULLY ASSEMBLED
AND NO APPARENT HYDRAULIC LEAKS ARE OBSERVED BEFORE
PERFORMING THIS TEST.
A. Apply 3,000 ± 50 psi (20,685 ± 345 kPa) pressure to the brake assembly and hold.
B. Measure reline indicator pins (180) as shown in Figure 102. Record measurements
on appropriate brake service history documentation.
Page 107
32-40-08
Jan 15/04
TESTING
WEAR PIN
MEASUREMENT
LOCATION
LINING WEAR
INDICATOR PIN S APPLY REQUIRED
BRAKE PRESSURE
S CHECK PISTON
EXTENSION
PRESSURE
S CUT WEAR PIN TO
PISTON EXTENSION PLATE
PERMITTED LENGTH
MEASUREMENT
LOCATION
LAG-2138C
Cutting and Measurement of Brake Reline Indicator Pin

Figure 102
Page 108
32-40-08
Jan 15/04
DISASSEMBLY
1. Tabular Definition of Disassembly Requirements.
Topic Description
General Tabular The Disassembly section is presented using a tabular format to
Overview organize the disassembly instructions. A breakdown of the tabular
format is as follows:
- Column 1 identifies the outline number for the disassembly
instructions summarized in the table.
disassemble the specified part or subassembly.
Breakdown of Disassembly paragraphs are broken down as follows:
Assembly Paragraph Page
Paragraphs
2.A. General Disassembly Guidelines . . . . . . . . . . . . . . . 302
2.B. Collection of Brake Service History, Part
Use History, and Worn Wear Pin Data . . . . . . . . . . 304
2.C. Collection of Data to Establish a Customized
Steel Brake Configuration . . . . . . . . . . . . . . . . . . . . . 306
2.D. Brake Disassembly - Requirements for Heat
Stack Change and Overhaul . . . . . . . . . . . . . . . . . . . 309
2.E. Brake Disassembly - Disassembly Requirements
for Overhaul Only, Unless Condition of Brake
Warrants Earlier Inspection . . . . . . . . . . . . . . . . . . . . 310
Superseded Piston Aircraft Landing Systems (ALS) no longer supplies components for
Insulator assembly of piston and bushing components used in the original
Disassembly P/N 2606672-1 brake assembly. These include components required to
Instructions assemble the internal piston insulator and are identified in the Brake
Assembly Exploded View (Figure 1001) as “-1 Superseded”. As these
components have been superseded, disassembly of them is no longer
detailed in this Disassembly section. Brakes that are built with these
components should be upgraded at next service.
Brake P/N Disassembly of the current P/N 2606672-1 and P/N 2606672-2/-3/-4 brake
2606672-1 assemblies are very similar. Most of the instructions in this Disassembly
Disassembly section are applicable for both brake assemblies. However, there are
Instructions slight deviations between some part numbers. Specific references to item
numbers from the Illustrated Parts List (IPL) are primarily for
P/N 2606672-2/-3/-4 brake assemblies. When assembling the
P/N 2606672-1 brake assembly, refer to the Brake Assembly Exploded
View (Figure 1001) of the IPL to correct part number references.
Page 301
32-40-08
Jan 15/04
DISASSEMBLY
2. Disassembly Instructions.
A. General Disassembly Guidelines.
1.1 General Instructions Applicable to the Disassembly Section

NOTE: Coordinate disassembly of all components with the requirements of the Cleaning
and Check sections. Components failing to meet the documented service limits
shall not be re-installed in the brake.
section of this manual.
A. Perform all disassembly operations in a clean area. For proper brake operation, it
is essential to prevent dirt, grit, and other foreign matter from entering the piston
B. The instructions listed in this section assume that all parts shown in the exploded
view are attached to the brake at the time it arrives for repair. If some parts are
missing, disregard the instructions that pertain to the disassembly of these parts.
MANUFACTURER WHEN WORKING WITH HYDRAULIC FLUID
PER BOEING SPECIFICATION BMS 3-11. IF HYDRAULIC FLUID
IS SPLASHED IN EYES, IMMEDIATELY WASH FOR AT LEAST 10
MINUTES IN A STREAM OF RUNNING WATER. FLUID IN
CONTACT WITH HANDS, FACE, OR BODY SKIN CAN BE
WASHED OFF WITH SOAP AND WATER. SHOULD IRRITATION
PERSIST, A PHYSICIAN SHOULD BE CONSULTED.
CAUTION: DO NOT ALLOW SPILLED HYDRAULIC FLUID TO REMAIN ON
BRAKE ASSEMBLY. WIPE ALL SURFACES IMMEDIATELY WITH A
DRY, LOW LINT, ABSORBENT CLOTH.
C. The brake assembly is designed to operate using hydraulic brake fluid per Boeing
D. Component level check, repair, and assembly instructions for the bulkhead coupling
half (67) should be coordinated with the supplier listed in the IPL.
Page 302
32-40-08
Jan 15/04
DISASSEMBLY
Page 303
32-40-08
Jan 15/04
DISASSEMBLY
B. Collection of Brake Service History, Part Use History, and Worn Wear Pin Data.
2.1 Collection of Brake Service History, Part Use History, and Worn Wear Pin Data
A. ALS recommends that brake assembly service and part use records be maintained
by each airline on copies of, or on a form similar to, the sample form shown in
Figure 301. These forms should be completed at each level of service
responsibility from brake removal, brake reline or overhaul, and until brake
assembly is returned to service. This will require the cooperation of personnel at
each level of aircraft maintenance.
B. Prior to performing any disassembly operations, thoroughly evaluate brake
assembly for leaks. If leaks are identified, mark locations and note occurrence in
brake assembly service history log.
C. If possible, pressurize brake assembly to 3,000 psi (20,685 kPa) and obtain wear
pin measurement as shown in Figure 102. Record wear pin measurement in brake
assembly service history log.
Page 304
32-40-08
Jan 15/04
DISASSEMBLY
LAG-3058
Brake Service History and Part Use Log

Figure 301
Page 305
32-40-08
Jan 15/04
DISASSEMBLY
C. Collection of Data to Establish a Customized Steel Brake Configuration.
3.1 Collection of Data to Establish a Customized Steel Brake Configuration

A. The standard lining and rotor configuration presented in the Assembly section were
developed based on testing and on worn brake data collected from field
experience. Based on brake operating procedures and route structures, the
amount of wear obtained on each lined surface may vary among operators.
B. Fully worn brakes should be evaluated at disassembly to ensure uniform wear is
occurring, and that no lined surface is consistently worn below 0.075 inch (1.91
mm). Lining wear below 0.075 inch (1.91 mm) greatly increases the chances for
in-service delines. If an unusual wear pattern is observed, lining and rotor
assembly wear data should be collected in order to determine if a customized brake
configuration is beneficial. Collection and submittal of data should be coordinated
through an ALS Field Service Representative as follows:
(1) Collect data on copies of the form shown in Figure 302.
(2) Obtain new and worn data from 20 - 30 brake assemblies. It is critical that
the data be collected in as short a time as possible, and that during the data
collection process, aircraft brake operating procedures are maintained
consistent with typical operator variation.
(3) At time of assembly, record the lining color code of all lined surfaces.
(4) At time of assembly, measure and record the rotor assembly weight for each
rotor. For used rotors, obtain weight following surface grinding. If possible,
measure and record the thickness of each rotor assembly. Obtain the
measurement near the center of one rotor segment from each rotor
assembly as shown in Figure 303.
(5) At brake removal, obtain accumulated landings, brake installation and
removal dates, aircraft model, number, and brake installed position data for
future reference.
(6) At disassembly, visually inspect each lined surface for uneven wear. It is not
unusual for some worn lined surfaces to be thinner than others. Select two
consecutive linings from the thinnest area of the lined surface. Measure and
record the thickness of the selected linings on a circumferential centerline
bisecting the fastener as shown in Figure 303. As an option, linings may be
removed and then measured in the area adjacent to the fastener hole.
Acquire thickness data on the actual wear surface and not at the bottom of
any lining break-out.
(7) At disassembly, obtain rotor assembly weight for each rotor before grinding.
If possible, measure and record the thickness of each rotor assembly.
Obtain the measurement near the center of one rotor segment from each
rotor assembly as shown in Figure 303.
C. Submit collected data to ALS for evaluation. If a configuration change is beneficial,
ALS will provide a recommended custom configuration.
Page 306
32-40-08
Jan 15/04
DISASSEMBLY
Brake Assembly P/N 2606672

Brake Assembly S/N
Airline
Aircraft Installation and Removal Data

Installation Data Removal Data
Data Compiled By Data Compiled By
Date Date
Number of Accumulated Landings
Date Installed on Aircraft
Date Removed From Aircraft
Aircraft Model 737-
Aircraft Number and Brake Position
Wear Pin Data - Measure under 3,000 PSI (207 bar) brake pressure. If flush, enter zero (0).
Installation Data Removal Data Calculations
Position 1 Position 2 Position 1 Position 2 Average Average
Wear Pin Used
(in or mm) (in or mm) (in or mm) (in or mm) Installation Removal
Lining Data - Measure thickness near the fastener hole from the two thinnest linings on each lined surface.
Thickness Position A Position B Minimum Lining % of Total
Position Color Code P/N
(in or mm) (in or mm) (in or mm) Thickness Wear Lining Wear
PP
S1
S2
S3
S4
S5
S6
BP
Lining Total
Rotor Data - For used rotors, obtain installation measurements after surface grinding and removal data prior
to surface grinding. Measure thickness at the center of a single rotor segment.
% of Rotor % of Total
Weight Thickness Weight Thickness Thickness Weight
Position Thickness Rotor Weight
(lb or kg) (in or mm) (lb or kg) (in or mm) Loss Loss
Loss Loss
Rotor 1
Rotor 2
Rotor 3
Rotor 4
Rotor Total
Brake Heat Stack Wear Data Log
Figure 302
Page 307
32-40-08
Jan 15/04
DISASSEMBLY
IDENTIFY LOCATION OF THE

THINNEST ROTOR SEGMENT
OBTAIN THICKNESS
MEASUREMENT IN CENTER
OF SEGMENT AS SHOWN
LAG-4898
MEASURE LININGS ON THIS

CENTER LINE ADJACENT TO
LINING FASTENER
IDENTIFY LOCATION OF THE

THINNEST LINING ON EACH
LINED SURFACE
OBTAIN LINING THICKNESS

ADJACENT TO FASTENER, AS
SHOWN, ON TWO CONSECUTIVE
LININGS THAT ARE THE
THINNEST OR MOST WORN
ACQUIRE THICKNESS DATA ON

THE ACTUAL WEAR SURFACE
AND NOT AT THE BOTTOM OF
ANY LINING BREAK-OUT
LAG-4899
Measurement Location for Brake Linings and Rotor Assemblies

Figure 303
Page 308
32-40-08
Jan 15/04
DISASSEMBLY
D. Brake Disassembly - Requirements for Heat Stack Change and Overhaul.
4.1 Brake Disassembly - Removal of Piston Housing and Adjuster Tubes

A. Lay the brake assembly on the bench so that it rests on the backing plate flange of
the stator torque tube (240).
B. Remove spring clips (5) or cotter pins (5A), bolt retainers (10), bolts (15), and
washers (20). Reuse spring clips and retainers on condition. Discard cotter pins.
C. Remove nuts (25) from the adjuster pins (four places).
D. Lift piston housing straight up to separate it from the remaining brake assembly.
E. If installed, remove torque tube spacer (162) from torque tube flange.
F. Remove adjuster tubes (36) from the piston housing adjuster cavities. Remove
adjuster sphere (30) from the adjuster tube. Discard the adjuster tube.
G. Drain fluid from piston housing. Examine fluid for discoloration or other
contaminates and then discard.
CAUTION: WHEN PUSHING BACK PISTONS, APPLICATION OF EXCESSIVE
FORCE MAY DAMAGE THE BOTTOM SURFACE OF PISTON
CAVITY.
NOTE: Use an arbor press or another method that applies a steady
continuous load to retract the pistons. Do not apply impact loads
(hammering) as damage to the piston housing may result.
H. Clean any build-up from the outside diameter of all pistons (141) per the Cleaning
section. Once cleaned, push the pistons back into the bushings until they bottom
against the bottom surface of the piston cavity or are flush with the face of the
bushing, whichever comes first.
4.2 Brake Disassembly - Disassemble Brake Stack

NOTE: Lining removal procedures are in the Repair section. To determine the brake
wear pattern, which is required to establish a customized brake lining service
configuration, obtain required data as defined per outline number 3.1.
A. Position stator torque tube (240), with heat stack installed, on bench so that it rests
on the backing plate flange.
B. Lift pressure plate (205) from stator torque tube (240) and place on bench with
attached pins facing up. Remove pin retainers (175) and remove reline indicator
pins (180) and discard. Remove pin retainers (50) from the pressure plate. Slide
the pin retainers into the hole portion of the key hole, tilt, and remove. Do not
remove pin retainers (195) from the pressure plate.
C. Lift rotor assemblies (210, 211, 212, 213) and three stator plate assemblies from
stator torque tube (240).
Page 309
32-40-08
Jan 15/04
DISASSEMBLY
E. Brake Disassembly - Disassembly Requirements for Overhaul Only, Unless Condition
of Brake Warrants Earlier Inspection.
5.1 Brake Disassembly - Disassemble Piston Housing

WARNING: WHEN REMOVING RETAINER RING (55), RESTRAIN HELICAL
COMPRESSION SPRING (65) AS IT IS PRELOADED.
CAUTION: DEPRESS HELICAL COMPRESSION SPRING (65) AND WASHER (61)
ONLY ENOUGH TO REMOVE RETAINING RING (55). AVOID LOADING
THE SPRING RETAINER AGAINST THE SHOULDER ON THE ID OF
THE ADJUSTER SPRING CAVITY.
A. Using arbor press and suitable adapter as shown in Figure 304, depress helical
compression spring (65) only enough to remove retaining ring (55) from groove.
Remove washer (61), helical compression spring (65), and anti-abrasion sheet (64)
from each adjuster cavity.
B. Remove bleeder screw as an assembly (75 through 85). As required, remove
screw (75) from bleeder screw (85) and remove lock washer (80). Cut safety wire
and remove bushing (90) and packing (95) from bleeder valve adapter. Discard
packing (95).
C. Remove bulkhead coupling half (67) from piston housing. Remove packing (380)
and discard. Do not remove the packing backup ring (370) at this time. Inspection
will determine the necessity for removal.
D. Place piston housing on a bench with pistons facing up. Cut the safety wire and
remove piston and bushing assemblies from the piston housing using a 2 7/16 inch
socket.
E. Do not remove spring pin (155) from the piston housing. Removal of the spring pin
is required only if it is damaged or when the piston housing is to be reanodized.
F. Do not remove fluid passage expansion plugs (173) and pins (172), or screw thread
inserts (165) from piston housing. Inspection will determine the necessity for
removal of these parts. Their removal is covered in the Repair section.
5.2 Brake Disassembly - Disassemble Piston and Bushing Assemblies

A. Remove piston (141) from piston bushing (151).
B. Remove packing (105) from each piston bushing (151). Remove piston wiper (146)
from piston bushing. Discard packings and wipers. Do not remove the packing
backup rings (100A) at this time. Inspection will determine the necessity for
removal.
C. Remove packing (116) from each piston (141). Discard all packings. Do not
remove the packing backup rings (111) at this time. Inspection will determine the
necessity for removal.
Page 310
32-40-08
Jan 15/04
DISASSEMBLY
PRESSURE
DRIVER
WARNING
WHEN REMOVING RETAINER
RING, RESTRAIN SPRING
RETAINER AS IT IS PRELOADED.
RETAINING
RING
WASHER
CAUTION
SPRING AVOID LOADING WASHER
AGAINST THIS SHOULDER.
DEPRESS ONLY ENOUGH
TO INSTALL RETAINING
RING.
PISTON
HOUSING
ANTI–ABRASION
SHEET
LAG-5032A
Retainer Ring Removal

Figure 304
Page 311
32-40-08
Jan 15/04
DISASSEMBLY
Page 312
32-40-08
Jan 15/04
CLEANING
1. Tabular Definition of Cleaning Requirements.
Topic Description
General Tabular The Cleaning section is presented using a tabular format to
Overview organize the cleaning instructions. A breakdown of the tabular
format is as follows:
- Column 1 identifies the outline number for the cleaning
- Column 2 identifies the guidelines that should be followed to
clean the specified part or assembly.
Breakdown of Cleaning Cleaning paragraphs are broken down as follows:
Section Paragraphs Paragraph Page
2.A. General Cleaning Guidelines . . . . . . . . . . . . . . . . . . 401
2.B. Clean Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 401
2.C. Cleaning Guidelines Specific to this Component
Maintenance Manual (CMM) . . . . . . . . . . . . . . . . . . . 402
2. Cleaning Instructions.
A. General Cleaning Guidelines.
1.1 General Cleaning Guidelines

NOTE: All item numbers in parentheses refer to the exploded view shown in the
Illustrated Parts List section.
NOTE: Equivalent substitutes may be used for the cleaning solutions and methods
outlined in this section.
A. Cleaning procedures applicable to multiple models can be found in the Aircraft
Landing Systems (ALS) Standard Practices Manual (SPM) (ATA 32-49-01),
Cleaning section.
B. See Figure 401 for references to cleaning guidelines. This is a complete list of
generic procedures that may be applied to both wheel and brake components. The
second column of Figure 401 identifies the location where the specified procedure
may be found. Most cleaning procedures are published in the ALS SPM
(ATA 32-49-01), Cleaning section.
B. Clean Brake Assembly.
2.1 Clean Brake Assembly

CAUTION: BEFORE USING PAINT STRIPPING OR CAUSTIC-TYPE CLEANERS ON
PISTON HOUSING AND PLUGS ASSEMBLY (160), USE RUBBER
PLUGS TO PLUG ENDS OF FLUID PASSAGEWAYS AT THEIR ENTRY
POINTS INTO THE BUSHING CAVITIES.
A. The most effective methods and products available for maintaining the brake
assembly are located in the ALS SPM (ATA 32-49-01), Cleaning section.
Page 401
32-40-08
Jan 15/04
CLEANING
2.1 Clean Brake Assembly
WARNING: TAKE PROPER PRECAUTIONS TO PREVENT CLEANING SOLVENT
FROM CONTACTING SKIN OR CLOTHING AND TO AVOID INHALING
VAPORS. FOLLOW THE SOLVENT MANUFACTURER’S
INSTRUCTIONS PERTAINING TO PRECAUTIONS TO OBSERVE.
B. Clean all metallic component parts of the brake assembly by spraying, brushing, or
soaking. Use the approved cleaning agents specified in the ALS SPM (ATA
32-49-01), Cleaning section. Follow the usage instructions and observe the
precautions specified by the cleaning agent manufacturer.
CAUTION: CLEANING AGENTS SPECIFIED ARE DETRIMENTAL TO RUBBER
PARTS. PARTS CLEANED MUST BE FREE OF ALL CLEANING
AGENTS AND/OR OILY RESIDUE AFTER CLEANING.
C. Rinse parts thoroughly in clean water. After rinsing, the rinse water must
completely wet the parts in a continuous film. If the water film does not cover the
surface, or if it forms droplets, the parts are not clean and shall be reprocessed.
D. Dry parts thoroughly. Dry nitrogen is recommended for drying the parts after
cleaning. If dry nitrogen is not available, filtered, dry compressed air must be used.
C. Cleaning Guidelines Specific to this CMM.
3.1 Cleaning Guidelines Specific to this CMM

A. No specific cleaning guidelines are defined for this CMM. See Figure 401 and the
ALS SPM (ATA 32-49-01), Cleaning section.
Page 402
32-40-08
Jan 15/04
CLEANING
Cleaning Procedure Where Found When

Remove Carbon Deposits Refer to the ALS SPM At overhaul and when necessary
(ATA 32-49-01), Cleaning at heat stack or tire change.
section.
Remove Corrosion from Refer to the ALS SPM Whenever corrosion is found
Aluminum Parts (ATA 32-49-01), Cleaning during inspection.
section.
Remove Corrosion from Refer to the ALS SPM Whenever corrosion is found
Steel Parts (ATA 32-49-01), Cleaning during inspection.
section.
Inboard Wheel Half Heat Refer to the ALS SPM At overhaul and when necessary
Shield Cleaning (ATA 32-49-01), Cleaning at tire change.
Procedures section.
Remove Paint from Refer to the ALS SPM Only remove paint when required
Aluminum Parts (ATA 32-49-01), Cleaning to facilitate NDT inspection or
section. repair procedures.
Remove Paint from Steel Refer to the ALS SPM Only remove paint when required
Parts (ATA 32-49-01), Cleaning to facilitate NDT inspection or
Remove Anodize from Refer to the ALS SPM Only remove the corrosion
Aluminum Parts (ATA 32-49-01), Cleaning protection layer when required by
Steel Brake Cleaning Refer to the ALS SPM At overhaul and when necessary
Procedures (ATA 32-49-01), Cleaning at tire change.
section.
Carbon Brake Cleaning Refer to the ALS SPM At overhaul and when necessary
Procedures (ATA 32-49-01), Cleaning at heat stack change.
section.
General Wheel Cleaning Refer to the ALS SPM At overhaul and when necessary
Procedures (ATA 32-49-01), Cleaning at heat stack or tire change.
section.
Clean Rubber Parts Refer to the ALS SPM At overhaul and when necessary
(ATA 32-49-01), Cleaning at heat stack or tire change.
section.
Wheel Bearing Cleaning Refer to the ALS SPM At overhaul and at each tire
Procedures (ATA 32-49-01), Cleaning change.
section.
Cleaning Procedure Overview
Figure 401
Page 403
32-40-08
Jan 15/04
CLEANING
Page 404
32-40-08
Jan 15/04

2606672
1. Special Tools and Materials.
Topic Description
Standard Tools and Refer to the Honeywell Standard Practices Manual (SPM)
Fixtures (ATA 32-49-01), for most current list of tools, fixtures, and
equipment common to multiple brake assemblies.
Special Gage Blocks Gage blocks and tooling used to assess wear limits in this
and Tooling Component Maintenance Manual (CMM) may be developed and
locally manufactured to facilitate inspection. Where specific gage
blocks or tooling is suggested, operators may elect to use the
illustrated method or develop their own equivalent method.
2. Service Definitions.
Topic Description
In-Service Definition For new brake assemblies, time in-service begins when the brake
assembly is first mounted on the aircraft, provided that the date is
documented.
Accumulated Time In Time in service accumulates continuously from the initial in-service
Service date of the brake assembly.
Brake Assemblies If verifiable service history is not available, all brakes purchased
Procured Used used should be overhauled to ensure compliance with the service
limits of this CMM.
Accumulated Fatigue Fatigue damage accumulates during the service life of the piston
Damage and Brake housing and torque tube.
Service Life The probability of fatigue crack initiation increases as the piston
Considerations housing and torque tube accumulates landings and time in-service.
Corrosion, if not removed or if improperly removed, can significantly
reduce the service life of a brake component, whether on or off the
aircraft.
Honeywell strongly encourages maintenance of the
anodize/primer/paint protection system during the life of each piston
housing to assist in preventing corrosion.
Page 501
32-40-08 28 Sep 2007
File: 12-557_chk.ildoc, Revision: 4, Status: Released, Released On 09/27/2007

2606672
Topic Description
Brakes Installed On At operator option, on-axle brake assemblies should be inspected
Low Use Aircraft at least one time per year if the following conditions apply (inspect
per next topic “Brake Storage”):
- For aircraft that receive less that one tire change per year,
Honeywell recommends that the wheel/tire assembly be
removed to permit inspection of the brake on a yearly basis.
- For brakes installed on aircraft that will not be overhauled in the
next two years, Honeywell recommends inspection of the
brakes at least one time per year at a regular tire change.
Brake Storage CAUTION: MOISTURE, GRIT, OR OTHER CONTAMINATES THAT
ARE ALLOWED ON THE SURFACES OF BRAKE
COMPONENTS MAY INCREASE THE LIKELIHOOD, OR
ACCELERATE THE DEVELOPMENT, OF CORROSION.
IF THE STORAGE HISTORY OF A BRAKE ASSEMBLY
IS NOT KNOWN, DISASSEMBLY OF THE BRAKE
SHOULD BE ACCOMPLISHED.
NOTE: Surface corrosion on the steel components of the brake
assembly that can be removed by light rubbing is typical
and will generally not impact normal operation of the
brake assembly.
Following last overhaul or heat stack change, brake assemblies
may be stored in a clean, dry environment without residual brake
pressure. At operator option, brakes stored longer than 24 months
should be pressure checked before installation on the aircraft to
ensure packings have not taken a permanent set.
Prior to on-aircraft installation, a visual inspection of the assembled
brake should be conducted.
- Careful attention should be paid to evaluating the piston
housing for corrosion. In particular, examine the mating
surfaces between the piston housing and the quick disconnect,
torque tube, and piston bushings for corrosion deposits. Any
evidence of corrosion requires the brake to be disassembled
and repairs made.
- Examine brake for hydraulic fluid leakage. Any evidence of
leakage requires the brake to be disassembled.
- Examine steel brake components for excessive corrosion
deposits. Any corrosion that has penetrated the base metal
requires the brake to be disassembled and the affected parts
thoroughly inspected.
Page 502
32-40-08 28 Sep 2007

2606672
3. Early Removal Inspection Instructions.
Topic Description
Hydraulic Fluid Brakes with hydraulic fluid leakage must be inspected to determine
Leakage the location of the fluid leakage for future repair.
Dragging Brake Due to When brake pressure is not applied to the piston housing and the
Loss of Running pistons do not retract enough to allow running clearance (free
Clearance space) between the brake’s rotors and stators, the brake will likely
experience a condition called brake drag. When the loss of running
clearance condition is traced back to the brake assembly, the brake
must be disassembled to correct the problem. In general,
improperly assembled pistons, a possible broken return spring,
improperly ground rotors, out-of-flat stator or pressure plates, worn
torque tube splines, a missing spacer, or a heat sink that is too thick
are probable causes for the dragging brake.
Brake Overheat Piston housings that exhibit evidence of overheat, such as paint
discoloration, must be inspected for hardness per the Honeywell
SPM (ATA 32-49-01).
- Minimum hardness for the piston housing is 75 HRB or 119
HB/10/500 when using the indentation method. Maximum
percent conductivity as determined by means of eddy current
is 41.5% International Annealed Copper Standard.
- If piston housings meet the minimum hardness requirements,
the piston housing must be overhauled per the requirements of
this Check section. In addition, it is recommended that the
leakage test defined per the Testing section be performed to
ensure adequate retention of the piston housing fluid
passageway expansion plugs and pins.
- All packings removed from brakes suspected of overheat should
be replaced.
- Piston housings not passing inspection requirements must be
scrapped. All other brake components should be inspected for
continued serviceability per the overhaul recommendations of
this CMM.
Page 503
32-40-08 28 Sep 2007

2606672
Topic Description
Inoperable Brake Due Based primarily on aircraft operating conditions and lining riveting
To Brake Deline methods, brake pressure plates, stator plates, or backing plates
may deline during service. This condition can cause damage to the
wheel and various components of the brake. If a deline occurs,
Honeywell requests that an Honeywell Field Service Engineering
Representative be contacted for evaluation of the delined brake.
Honeywell can recommend custom lining configurations to better
balance the resultant brake wear. This effort normally requires
collection of brake wear data for a minimum of 20 - 30 brake
assemblies. Measure brakes as outlined in the Disassembly
section, outline number 3.1.
Other Early Removals If damage occurs to the brake assembly as a result of other
in-service conditions, the operator, in conjunction with an Honeywell
Field Service Engineering Representative, should determine the
required level of inspection needed to thoroughly inspect the brake
assembly for continued serviceability.
Page 504
32-40-08 28 Sep 2007

2606672
4. Inspection Interval Schedules - Steel Brake Assemblies.
Topic Description
Guideline Development Brake service history, crack propagation rates, potential crack
Considerations locations, and safety considerations were used to develop the
inspection criteria and frequency of inspection guidelines outlined in
this CMM.
A wide variety of known operating conditions and repair practices
were considered in developing the inspection frequency criteria.
Collection of Brake Operators should collect brake service history data including
Service History landings achieved for each heat stack change, repairs made, and
any brake failure modes.
When a piston housing fails or is removed from service due to a
crack indication, notify an Honeywell Field Service Engineering
Representative.
If deemed necessary, failed brake components may be returned to
Honeywell for additional investigation. Service and repair history
should be submitted with the returned components.
Heat Stack Change Inspection requirements must be performed at all heat stack
Inspection Interval changes.
(Minor Servicing) For brakes installed on low use aircraft that receive less than one
tire change per year, refer to Paragraph 2. for inspection
recommendations.
Overhaul Inspection Operators should continually monitor failure modes of piston
Interval (Major housings and torque tubes within their fleet. As these components
Servicing) accumulate more landings, it may become necessary to increase
the overhaul inspection frequency or the level of Non-Destructive
Testing (NDT) inspection. These decisions may be made by each
operator based on their documented service history.
Honeywell encourages operators to overhaul brake assemblies
every fourth heat stack change.
- Increasing the overhaul frequency to every second or third heat
stack change should be strongly considered if corrosion is
frequently observed or if other service-related issues lead to
excessive early removals.
Page 505
32-40-08 28 Sep 2007

2606672
5. Tabular Definition of Inspection Requirements.
Topic Description
General Tabular The Check section requirements defined per Paragraph 6. are
Overview presented using a tabular format to assist in organizing the needed
inspections. A breakdown of the tabular format is as follows:
Column 1 identifies the outline number for the check instructions
Column 2 provides the required instructions that are to be
performed for the brake assembly component being inspected.
Columns 3 and 4 define the intervals for when each inspection
instruction is to be performed. The two intervals identified are “Heat
Stack Change” and “Overhaul.”
- An “X” for any inspection item indicates that the item must be
accomplished at the interval marked.
- An “O” for any inspection item indicates that the item is
desirable but optional based on operator experience.
Breakdown of Check Check paragraphs are broken down as follows:
Paragraphs Paragraph Page
6.A. General Brake Inspection Instructions . . . . . . . . . . 507
6.B. Piston Housing and Plugs Assembly
Inspection Instructions . . . . . . . . . . . . . . . . . . . . . . . . 508
6.C. Bulkhead Coupling Half (Brake Half Hydraulic
Quick Disconnect) and Attachment Hardware
Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . 512
6.D. External Adjuster Assembly Inspection
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
6.E. Piston and Bushing Assemblies Inspection
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
6.F. Pressure Plate and Stator Plates Inspection
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
6.G. Stator Torque Tube Inspection Requirements . . . . 526
6.H. Rotor Assemblies Inspection Requirements . . . . . 532
6.I. Machine (Tie) Bolts and Washers Inspection
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
Page 506
32-40-08 28 Sep 2007

2606672
6. Check Instructions.
A. General Brake Inspection Instructions.
Inspection
Intervals
Heat
Stack
1.0 General Brake Inspection Change Overhaul
1.1 General - Based on service records, determine the number of heat X X
stack changes since last inspection. Using criteria defined in
Paragraph 4., determine if a heat stack change or overhaul
inspection must be performed.
1.2 General - Prior to disassembly, inspect brake for missing parts and X X
evidence of component malfunction or other obvious failures. If
an overheat condition is observed on the piston housing, refer to
the “Brake Overheat” instructions in Paragraph 3. for additional
inspection instructions.
1.3 Disassembly - Remove piston housing mounting bolts, piston X X
housing, and heat stack components from stator torque tube.
1.4 Cleaning - As components are removed from the brake assembly, X X
they shall be thoroughly cleaned and dried per the Cleaning
section.
NOTE: Item numbers (in parentheses) refer to the exploded view shown in the Illustrated Parts
List (IPL) section.
NOTE: Any part not meeting the specified inspection instructions must be removed and
repaired within the limits of this CMM. All parts that cannot be repaired or are outside
the acceptable limits must be scrapped.
Page 507
32-40-08 28 Sep 2007

2606672
B. Piston Housing and Plugs Assembly Inspection Instructions.

Inspection
Intervals
Heat
Stack
2.0 Piston Housing and Plugs Assembly (160) Change Overhaul
CAUTION: CORROSION, NO MATTER HOW MINOR, MAY CAUSE PREMATURE FATIGUE
CRACKING. CORROSION PRODUCTS AND CORROSION PITTING MUST BE
REMOVED BEFORE RETURNING PISTON HOUSINGS TO SERVICE.
2.1 Disassembly - Remove piston and bushing assemblies. Refer to O X
the Check section instructions for piston and bushings when
defining requirements for heat stack change.
2.2 Disassembly - Remove quick disconnect fitting and brake bleeder O X
fittings.
2.3 Disassembly - Remove adjuster pins (45, 46) and adjuster X X
tubes (35, 36). Discard adjuster tubes.
2.4 Disassembly - Remove washers (60, 61) and helical compression O X
springs (65) from piston housing adjuster spring cavities.
2.5 Visual - Inspect all surfaces of the piston housing for damage to X X
the paint or corrosion protection layers. All piston housings that
have bare exposed metal must be repaired.
2.6 Visual - Carefully inspect all unpainted surfaces of the piston X X
housing for mechanical damage and corrosion using
magnification, if required. Evidence of damage or corrosion
requires immediate repair within the limits of the Repair section.
2.7 Visual - Inspect the following piston housing locations for corrosion X
or thread damage:
Inlet port quick disconnect mounting holes
Temperature sensor attachment holes
Bleeder valve port holes
Piston bushing mounting cavities
Brake alignment pin hole
2.8 Visual and Measurement - Inspect piston housing tie bolt X
mounting holes for wear or other damage. Holes may not exceed
a maximum diameter of 0.485 inch (12.32 mm).
2.9 Visual - Inspect adjuster spring cavity retaining ring land and X
washer pilot for wear or damage. Raised edges are not permitted
and must be repaired. Wear or damage may not exceed the limits
specified in Figure 501. Repair oversize washer pilot per the
Repair section.
Page 508
32-40-08 28 Sep 2007

2606672
1.0 (25.4)
MISSING MATERIAL FROM

RETAINER RING LAND.
UP TO 1.0 (25) OF MATERIAL
MAY BE MISSING FROM THE
CIRCUMFERENCE OF THE
RETAINER RING LAND. THE
MISSING MATERIAL NEED NOT
BE CONTINUOUS. BLEND ALL
ROUGH EDGES.
1.685
MAX WASHER PILOT
(42.80)
AREA ONLY
RETAINER RING
SHOULDER
SECTION A–A
LAG–5022 MILLIMETER CONVERSIONS IN PARENTHESES
Piston Housing Adjuster Spring Cavity Wear and Damage Allowances

Figure 501
Page 509
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
2.0 Piston Housing and Plugs Assembly (160) Change Overhaul
NOTE: NDT inspection should be performed at every overhaul. In addition, NDT inspection is
required whenever the brake has been overloaded, overheated, or if severe corrosion
is evident. Paint should only be removed if fluorescent penetrant inspection of the
piston housing is to be performed.
NOTE: Eddy current, ultrasonic, or fluorescent inspection methods may be used to detect
potential cracks in the areas specified below. The Honeywell SPM (ATA 32-49-01) may
be used as a general guide when performing NDT inspections. Any piston housing
found with crack indications cannot be returned to service, unless specifically authorized
by Honeywell per the Repair section. Most fatigue cracks are not repairable and require
immediate retirement of the piston housing.
NOTE: Brake service history should be monitored by each operator. Any area that exhibits a
documented service history of fatigue cracks should be inspected using NDT methods.
NOTE: NDT Level III specialists should be consulted to develop proper inspection methods
based on required reference standard sensitivity levels, available equipment,
processes, and techniques.
2.10 NDT - Inspect tie bolt hole area and support ribs for cracks. X - Refer
Refer to Figure 502. to Notes
2.11 NDT - Inspect piston domes for cracks. Inspect piston cavity for X - Refer
cracks, especially at the bottom of the bore, and in the areas to Notes
where the fluid passageways intersect the cavity. Refer to
Figure 502.
2.12 NDT - Inspect adjuster spring cavities for cracks. Refer to X - Refer
Figure 502. to Notes
2.13 NDT - Inspect piston housing mating face for cracks if significant X - Refer
damage or corrosion is observed. Refer to Figure 502. to Notes
2.14 NDT - Fluorescent penetrant inspect the piston housing per the O
Honeywell SPM (ATA 32-49-01). If the above identified areas can
be inspected by eddy current or ultrasonic inspection methods,
fluorescent penetrant inspection is optional. Refer to Figure 502.
2.15 NDT - Piston housings that exhibit evidence of overheat, such as X X
paint discoloration, must be inspected for structural adequacy and
hardness at locations identified in Figure 502. Refer to “Brake
Overheat” instructions in Paragraph 3. for inspection
requirements.
Page 510
32-40-08 28 Sep 2007

2606672
WHEN REQUIRED, PERFORM HARDNESS

TEST BETWEEN BRAKE TIE BOLT HOLES
ON THE MATING FACE SIDE OF THE
PISTON HOUSING. DO NOT PERFORM
TEST WITHIN 0.25 (6.4) OF BOLT HOLES
OR EDGE OF MATERIAL. REMOVE PAINT
AND POLISH AREA WHERE TEST IS TO
BE PERFORMED.
ADJUSTER
SPRING
CAVITIES
MATING
FACE
TIE BOLT
HOLES
PISTON CAVITY
SUPPORT RIBS
(12 LOCATIONS) FLUID PISTON
PASSAGEWAY DOMES
PISTON BORE POINT OF
INTERSECTION INTERSECTION
RADIUS

Piston Housing NDT and Hardness Inspection Areas

Figure 502
Page 511
32-40-08 28 Sep 2007

2606672
C. Bulkhead Coupling Half (Brake Half Hydraulic Quick Disconnect) and Attachment
Hardware Inspection Requirements.
Inspection
Intervals
Heat
3.0 Bulkhead Coupling Half (67) (Brake Half Hydraulic Quick Stack
Disconnect) and Attachment Bolts (390) Change Overhaul
3.1 Visual and Measurement - Inspect brake half hydraulic quick X
disconnect (67) as specified by supplier listed in the IPL section. If
safety wire routing posts are damaged or missing, discard the
quick disconnect.
Page 512
32-40-08 28 Sep 2007

2606672
D. External Adjuster Assembly Inspection Instructions.

Inspection
Intervals
Heat
Stack
4.0 External Adjuster Assemblies Change Overhaul
4.1 Disassembly - At each heat stack change, the adjuster pins X X
(45, 46), nut (25), adjuster sphere (30), and adjuster tubes
(35, 36) must be removed from the piston housing. Adjuster
tubes must be discarded.
4.2 Disassembly - At overhaul, retaining ring (55), washers (60, 61), X
and helical compression spring (65) must be removed from the
piston housing.
4.3 Visual - When not removed at heat stack change, inspect helical X
compression springs within the cavity to verify that they are
properly seated and that a spring has not prematurely failed within
the cavity.
4.4 Visual - Inspect general condition of adjuster pins (45, 46) and X X
adjuster sphere (30) for nicks, damage, cracks, or deformation
that might affect operation. If doubt exists as to whether or not a
crack is present, NDT inspection should be accomplished or the
pin should be replaced. No sharp edges or cracks are permitted.
4.5 NDT - At operator option or if in-service pin failures are O
experienced, inspect adjuster pins (45, 46) by fluorescent
penetrant inspection method per the Honeywell SPM
(ATA 32-49-01). No cracks are permitted.
4.6 Visual and Measurement - Inspect spring retainer washers (61) X
for excessive wear. If the inside diameter (ID) dimension
exceeds 0.533 inch (13.54 mm), the washer must be replaced.
4.7 Visual and Measurement - Inspect helical compression X
springs (65) for rust, nicks, distortion, and visible cracks. Replace
as necessary. Test springs for proper operating values.
A minimum height of 1.98 inches (50.3 mm) is required
under a load of 374 pounds (170 kg) for helical compression
spring (65A) used in the -1, -2, -3, or -4 brake assembly.
A minimum height of 1.95 inches (49.5 mm) is required
under a load of 345 pounds (156 kg) for helical compression
spring (65) used only in the -1 brake assembly.
Reject springs not within limits.
4.8 Measurement - Inspect locking feature of nut (25) for minimum X
reusable torque as shown in Figure 801. Replace nuts that do not
meet requirement.
Page 513
32-40-08 28 Sep 2007

2606672
E. Piston and Bushing Assemblies Inspection Requirements.
Inspection
Intervals
Heat
Stack
5.0 Piston (140A, 141) and Bushing (150, 151) Assemblies Change Overhaul
NOTE: Piston and bushing assemblies that are identified with leakage or other damage must
be inspected per the overhaul requirements.
NOTE: Components within the piston and bushing assemblies must be replaced based on
condition. Each operator must consider their operating conditions, service history, and
the early brake removal history when defining the appropriate replacement interval. In
general, all packings should be replaced at the Honeywell suggested overhaul
frequency. It may be necessary to overhaul the piston and bushing components more
frequently than the remaining brake components.
NOTE: When disassembling the pistons and bushings at heat stack change, components
should be replaced on cause. Exercise care to ensure components are not damaged
during disassembly. It is critical to inspect parts thoroughly to assist in preventing early
brake removal resulting from hydraulic fluid leakage.
NOTE: If the Teflon packing backup rings (100, 100A, 110, 111) are not removed from the
piston and bushing, check to ensure that the packing groove in the piston and bushing
are clean. The packing backup rings may be moved back and forth to facilitate cleaning
under them. Approved solvents for cleaning aluminum parts are not detrimental to the
Teflon packing backup rings.
5.1 Disassembly - Disassemble the piston and bushing assembly O - Refer X
by removing components for evaluation. Teflon packing to Notes
backup rings (100, 100A, 110, 111) may be left in-place at
operator option if components are not damaged. Discard all
packings (105, 115, 116) and wipers (145, 146). Discard all Teflon
packing backup rings that are removed from the piston and
bushing.
5.2 Visual - If Teflon packing backup rings (100, 100A, 110, 111) are X
not removed from the piston and bushing, check for breaks,
feathered edges on the outside diameter (OD), deformation, and
other obvious damage. Remove damaged backup rings and
discard.
5.3 Visual - Inspect pistons (140, 141) surface finish in preformed O - Refer X
packing grooves and along length of piston. No scratches or nicks to Notes
are permitted. Refer to Figure 503.
5.4 Measurement - Inspect pistons (140, 141) dimensions as specified O - Refer X
in Figure 503. Replace pistons that do not meet minimum/ to Notes
maximum dimensions.
5.5 NDT - Inspect pistons (140, 141) by the fluorescent penetrant O
inspection method per Honeywell SPM (ATA 32-49-01). No cracks
are allowed.
Page 514
32-40-08 28 Sep 2007

2606672
NO SCRATCHES OR NICKS
PERMITTED IN PACKING GROOVE
–2, –3, –4 1.305 (33.15) 1.545 (39.24)

DIA MIN DIA MIN
(141)
2.91 (73.91)
MIN
NO SCRATCHES OR NICKS
PERMITTED IN PACKING GROOVE
–1 (ONLY) 1.305 (33.15) 1.486 (37.74)

DIA MIN DIA MIN
(140A)
3.09 (78.49)
MIN

Piston Wear Limits

Figure 503
Page 515
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
5.0 Piston (140, 141) and Bushing (150, 151) Assemblies Change Overhaul
5.6 Visual - Inspect piston bushing (150, 151) OD threads for damage X
that would prevent free assembly into the piston housing.
5.7 Visual - Inspect piston stop on piston bushing (150, 151) for X
evidence of fracture. No cracks are permitted. Inspect piston stop
bore for wear. Wear may not exceed limits specified in Figure
504.
5.8 Visual and Measurement - Inspect inner bore of piston X
bushing (150, 151) for surface buildup, scratches, nicks, or any
blemish that would cause packing to malfunction. Hardcoat
surface may be worn and scuffed, provided ID of bore does not
exceed limits specified in Figure 504, and hardcoat has not broken
through to bare aluminum.
Page 516
32-40-08 28 Sep 2007

2606672
PISTON
STOP
–2, –3, –4 1.556 DIA 1.385 DIA

(151, 151A) (39.52) MAX (35.18) MAX
16 (0.4 µm)
PISTON
STOP
–1 ONLY 1.494 DIA 1.370 DIA

(37.95) MAX (34.80) MAX
(150)
16 (0.4 µm)

Piston Bushing Wear Limits

Figure 504
Page 517
32-40-08 28 Sep 2007

2606672
F. Pressure Plate and Stator Plates Inspection Requirements.

Inspection
Intervals
Heat
Stack
6.0 Pressure Plate (205) and Stator Plates (225) Change Overhaul
NOTE: Pressure plate (205) and stator plates (225) are subjected to severe operating
conditions. Distortions, cracks, and wear are typical in-service related occurrences.
The processes for flattening the plates and repairing cracks may result in additional
distortions. Based on Honeywell experience, weld repairs should be performed prior to
flattening the plates. In this way, any distortions from the welding operation can
be resolved when flattening the plates. Following flattening of the plates, each
plate should again be NDT inspected to ensure this operation does not introduce
new crack indications.
6.1 Disassembly - Remove rivets and linings from pressure plate (205) X X
and stator plates (225).
6.2 When not removed from pressure plate (205) for inspection or X X
repair, inspect the lining wear pin retainer (195) and rivet (200) for
damage and looseness. Replace as necessary.
6.3 Inspect general condition of adjuster pin retainer holes and slots. X X
Damage that may prevent proper attachment of the adjuster pin
may be weld repaired.
6.4 NDT - Inspect pressure plate (205) as shown in Figure 505 X X
and stator plates (225) as shown in Figure 506 for cracks
using magnetic particle inspection per the Honeywell SPM
(ATA 32-49-01). Inspect identified cracks per the following criteria:
Cracks that are within the limits specified in View 1 do not
require immediate repair.
Cracks exceeding the limits of View 1, but not exceeding the
limits of View 2, must be repaired before the plate may be
returned to service.
Cracks that exceed the limits specified in View 2 require the
plates to be scrapped.
Page 518
32-40-08 28 Sep 2007

2606672
CRACKS LESS THAN 0.125

(3.18) LONG - NO MORE THAN
CRACKS FROM OUTER NIB HOLE TO OUTER NIB HOLE ONE CRACK EXTENDING
OD OF PLATE - ALL LOCATIONS FROM EACH NIB HOLE
WITHIN DIMENSIONAL LIMIT
0.125 (3.18) CRACKS SPECIFIED
IN FASTENER
HOLE PERMISSIBLE
WITHOUT REPAIR
LINING
ATTACHMENT ADJUSTER PIN
RIVET HOLE ATTACHMENT
HOLE
DRIVE SLOT INNER NIB HOLE
VIEW 1 – CRACKS ALLOWED WITHOUT IMMEDIATE REPAIR
CRACKS GREATER THAN

0.25 (6.4) LONG
CRACKS
GREATER THAN
0.25 (6.4) LONG
CRACKS GREATER THAN

0.125 (3.18) LONG
VIEW 2 – CRACKS THAT ARE NOT REPAIRABLE AND REQUIRE PLATE TO BE SCRAPPED

Pressure Plate Crack Limits

Figure 505
Page 519
32-40-08 28 Sep 2007

2606672
CRACKS FROM OUTER NIB HOLE TO

OD OF PLATE - ALL LOCATIONS OUTER NIB HOLE
CRACKS LESS THAN
OD HEAT 0.125 (3.18) LONG
RELIEF SLOT
NO MORE THAN ONE

CRACK EXTENDING
FROM EACH LOCATION
TWO CRACKS
EXTENDING FROM ONE
CRACKS LESS HOLE, AS PER EXAMPLE
THAN 0.060 SHOWN, IF WITHIN
(1.52) LONG DIMENSIONAL LIMITS,
MUST BE REPAIRED
INNER NIB HOLE
ID HEAT
DRIVE SLOTS RELIEF SLOT
VIEW 1 – CRACKS ALLOWED WITHOUT IMMEDIATE REPAIR
CRACKS GREATER THAN

0.250 (6.35) LONG
CRACKS
EXTENDING
FROM OD
HEAT RELIEF
SLOT INTO
DIM “A”
CRACKS GREATER THAN
0.125 (3.18) LONG
DIM “A”
CRACKS GREATER THAN
0.250 (6.35) LONG
CRACKS GREATER THAN
0.125 (3.18) LONG
VIEW 2 – CRACKS THAT REQUIRE SCRAPPING OF STATOR PLATE

NOTE:
ILLUSTRATION IS FOR MOST CURRENT STATOR PLATE. ID HEAT RELIEF SLOTS WERE NOT
USED ON SUPERSEDED STATOR PLATES. LIMITS APPLY TO ALL STATOR PLATES.
DIMENSION “A” - View 2:

Dimension
Stator Plate P/N Inch (mm)
2606712 0.84 (21.3) Minimum
2608214 1.11 (28.2) Minimum
2614056 1.11 (28.2) Minimum
Stator Plate Crack Limits
Figure 506
Page 520
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
6.5 Measurement - Check out-of-flat condition by laying pressure X X
plate (205) and stator plates (225) on a clean, flat surface plate
using a bridge gage or other equivalent method. Maximum
measured thickness plus out-of-flat condition may not exceed the
limits specified in Figure 507 and requires repair.
STATOR OR PRESSURE PLATE SURFACE

PLATE
DIMENSION “A” MAXIMUM
OUT-OF-FLATNESS MEASUREMENT WHEN USING BRIDGE GAGE
LAG-4752A
DIMENSION “A”:
Maximum Dimension
Component Inch (mm)
Pressure Plate 0.305 (7.75)
Stator Plate 0.223 (5.66)
Stator and Pressure Plate Out-of-Flatness Limits
Figure 507
Page 521
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
6.6 Visual and Measurement - Inspect the lining attachment holes X X
of pressure plate (205) as shown in Figure 508, and stator
plates (225) as shown in Figure 509. Repair all features that
exceed the specified limits if permitted.
Inspect lining attachment holes for excessive wear, elongation,
or damage.
Inspect lining attachment holes and nib holes for shrinkage.
As an option to obtaining a specific measurement, a new lining
can be used as a gage at each lining location. If interference
is evident that does not allow the lining to lie flat without a gap,
tag the pressure plate for repair.
6.7 Visual and Measurement - Inspect the drive slots of pressure X X
plates (205) as shown in Figure 508, and stator plates (225) as
Repair all features that exceed the specified limits if permitted.
Inspect drive slots for excessive wear or damage. Drive slot
width may not exceed the maximum limit specified without
repair. Damage that exceeds the specified limits is not
repairable and the plate must be scrapped.
Inspect drive slot width for shrinkage. Drive slot width may not
exceed the minimum limit specified. Providing the pressure
plate passes the flatness check, evaluation of minimum drive
slot width can be accomplished by placing the pressure plate
over the splines of a torque tube in an area that is not worn.
All pressure plates that are not freely accepted by the stator
torque tube must be scrapped.
Page 522
32-40-08 28 Sep 2007

2606672
DIAMETER “C”
WEAR PIN RETAINER
ATTACHMENT HOLE
DIAMETER “A”
NIB HOLE
DIAMETER “B”
LINING ATTACHMENT
RIVET HOLE
DAMAGE GREATER THAN 0.060 (1.52)

ON EITHER SIDE OF DRIVE SLOT
DIMENSION “D”
REQUIRES PLATE TO BE SCRAPPED
DRIVE SLOT WIDTH
LAG-2334B
Area Identified Minimum Dimension Maximum Dimension

Above Description Inch (mm) Inch (mm)
“A” Nib Hole 0.390 (9.91) 0.430 (10.92)
“B” Lining Attachment Rivet 0.255 (6.48) 0.290 (7.37)
Hole
“C” Wear Pin Retainer 0.200 (5.08) 0.220 (5.59)
Attachment Hole
“D” Drive Slot Width 0.675 (17.15) 0.745 (18.93)
Pressure Plate Wear and Shrinkage Limits
Figure 508
Page 523
32-40-08 28 Sep 2007

2606672
DIAMETER “A”
NIB HOLE
DIAMETER “B”
LINING
ATTACHMENT
HOLE
DAMAGE GREATER THAN 0.060

DIMENSION “C”
(1.52) ON EITHER SIDE OF DRIVE
DRIVE SLOT
SLOT REQUIRES STATOR PLATE
WIDTH
TO BE SCRAPPED
NOTE:
ILLUSTRATION IS FOR MOST CURRENT STATOR PLATE. ID HEAT RELIEF SLOTS WERE NOT
USED ON SUPERSEDED STATOR PLATES. LIMITS APPLY TO ALL STATOR PLATES.


“A” Nib Hole 0.390 (9.91) 0.430 (10.92)
“B” Lining Attachment Hole 0.755 (19.18) 0.775 (19.69)
“C” Drive Slot Width 0.718 (18.24) 0.750 (19.05)
Stator Plate Wear and Shrinkage Limits

Figure 509
Page 524
32-40-08 28 Sep 2007

2606672
Blank Page
Page 525
32-40-08 28 Sep 2007

2606672
G. Stator Torque Tube Inspection Requirements.

Inspection
Intervals
Heat
Stack
7.0 Stator Torque Tube (240) Change Overhaul
NOTE: Stator torque tubes are subjected to severe operating conditions. Distortions, cracks,
and wear are typical in-service related occurrences. The processes for flattening the
backing plate and repairing cracks may result in additional distortions. Based on
Honeywell experience, weld repairs should be performed prior to flattening the backing
plate. In this way, any distortions from the welding operation can be resolved when
flattening the plates.
7.1 Disassembly - Remove rivets and linings from stator torque X X
tube (240) backing plate.
7.2 Visual - Examine stator torque tube (240) for excessive corrosion X X
deposits. Any corrosion that has penetrated the base metal
requires repair.
7.3 NDT - Inspect stator torque tube for cracks as shown in X X
Figure 510 using magnetic particle inspection method per the
Honeywell SPM (ATA 32-49-01). Inspect identified cracks per the
following criteria:
Cracks that are within the limits specified in View 1 do not
require immediate weld repair. At operator option, cracks that
do not exceed the limits specified in View 1 may be stop drilled
to prevent further growth as outlined in the Repair section of
this CMM.
Cracks exceeding the limits of View 1, but not exceeding the
limits of View 2, must be repaired before the stator torque tube
may be returned to service.
Cracks that exceed the limits specified in View 2 require the
stator torque tube to be scrapped.
Heat checking observed on the non-friction side of the backing
plate between the backing plate ribs may be repaired within
the limits of the Repair section.
7.4 Measurement - Check out-of-flat condition of backing plate using X X
an angle gage or an equivalent method. Maximum out-of-flatness
as measured at each rivet hole location may not exceed limits
specified in Figure 511. As an option, a clean, flat surface with
a 12.00 inch (304.8 mm) diameter hole through the center may be
used. Insert stator torque tube barrel through hole allowing
backing plate to rest on flat surface. Measure out-of-flat condition
at each rivet hole location.
Page 526
32-40-08 28 Sep 2007

2606672
CRACKS EXTENDING LESS THAN 1/2

DIMENSION “A”, THE DISTANCE BETWEEN NO MORE THAN ONE CRACK PERMITTED
THE NIB HOLE AND FASTENER HOLE. IN ANY ONE CIRCUMFERENTIAL LINING
CRACK MAY EXTEND FROM EITHER HOLE. ATTACHMENT LOCATION
DIMENSION “A”
OUTER NIB HOLE
CRACKS FROM OUTER
NIB TO OD OF PLATE -
ALL LOCATIONS
CRACKS EXTENDING LINING

LESS THAN 1/2 ATTACHMENT
DIMENSION “B”, THE RIVET HOLE
DISTANCE BETWEEN
THE NIB HOLE AND INNER NIB HOLE
FASTENER HOLE.
CRACK MAY EXTEND
FROM EITHER HOLE. DIMENSION “B”
VIEW 1 – CRACKS ALLOWED WITHOUT IMMEDIATE WELD REPAIR
CRACKS EXTENDING FROM

INNER NIB HOLE TO THE
STATOR TORQUE TUBE
BARREL INSIDE THE 120°
ZONE AND HAVE PROPAGATED
WITHIN 0.50 (12.7) OF THE
SPLINES AS SHOWN
0.40 (10.16) CRACKS EXTENDING

BEYOND THE
COUNTERBORE
DIAMETER OF THE
120°
MOUNTING HOLE
VIEW 2 – CRACKS THAT ARE NOT REPAIRABLE AND REQUIRE TORQUE TUBE TO BE SCRAPPED

Stator Torque Tube Crack Limits

Figure 510
Page 527
32-40-08 28 Sep 2007

2606672
MATERIAL: ALUMINUM OR STEEL

1.0 (25.4)
LOCAL MANUFACTURE
OF ANGLE GAGE
4.00 (101.6)
90° $ 0.25° 1.0 (25.4)
0.27 (6.9)
0.125 (3.18) 4.00 (101.6)

MINIMUM 0.27 (6.9)
REMOVE SHADED AREA TORQUE TUBE

FOR CLEARANCE AT RADIUS
TORQUE TUBE SPLINE
ANGLE GAGE
0.030 (0.76) MAX WITHIN

0.25 (6.4) OF BACKING
PLATE OD
USE FEELER GAGE TO MEASURE

GAP BETWEEN ANGLE GAGE AND
BACKING PLATE AT RIVET HOLE RIVET HOLE
LOCATION
Torque Tube Backing Plate Out-of-Flatness Limits

Figure 511
Page 528
32-40-08 28 Sep 2007

2606672
Blank Page
Page 529
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
7.0 Stator Torque Tube (240) Change Overhaul
7.5 Visual and Measurement - Inspect lining attachment holes of the X X
backing plate as shown in Figure 512. Repair all features that
exceed the specified limits if permitted.
Inspect lining attachment holes for excessive wear, elongation,
or damage.
Inspect lining attachment holes and nib holes for shrinkage.
As an option to obtaining a specific measurement, a new lining
can be used as a gage at each lining location. If interference
is evident that does not allow the lining to lie flat without a gap,
tag the stator torque tube for repair.
7.6 Visual and Measurement - Inspect sides and tops of splines for X X
damage and wear as shown in Figure 512. Irregularities within
dimensional limits specified must be uniform on each spline in the
plane of the stator position to ensure an even loading pattern, and
there must be a gradual transition into and out of the wear spot.
Wear may not exceed the dimensions specified without weld
repair.
7.7 Visual - Inspect stator torque tube tie bolt holes for corrosion or X
damaged threads.
7.8 Visual and Measurement - Inspect stator torque tube mounting X
bolt holes for wear or elongation. Holes may not exceed limits
specified in Figure 512.
Page 530
32-40-08 28 Sep 2007

2606672
DIAMETER “B” LINING

ATTACHMENT DIAMETER “A”
RIVET HOLE NIB HOLE
TIE BOLT HOLE -

INSPECT FOR
CORROSION AND
THREAD DAMAGE
MOUNTING
BOLT HOLE
0.576 (14.63)
MAX
WEAR ON EITHER SIDE OR TOP OF

THE SPLINES LESS THAN 0.030 (0.76)
MUST GRADUALLY TRANSITION INTO
AND OUT OF THE WEAR SPOT. ANY
IRREGULARITIES OR RIDGES MUST BE
DIMENSION “C” BLENDED. TOTAL WEAR MAY NOT RE-
SPLINE WIDTH SULT IN SPLINE HEIGHT OR WIDTH
VIOLATING MINIMUM DIMENSIONAL
DIMENSION “D” REQUIREMENTS.
SPLINE HEIGHT
WEAR DEEPER THAN 0.030 (0.76) ON
EITHER SIDE OR TOP OF THE SPLINE
MUST BE WELD REPAIRED


“A” Nib Hole 0.390 (9.91) 0.430 (10.92)
“B” Lining Attachment Rivet
Hole 0.255 (6.48) 0.290 (7.37)
“C” Spline Width 0.622 (15.80) N/A
“D” Spline Height 0.550 (13.97) N/A
Torque Tube Backing Plate and Spline Wear Limits
Figure 512
Page 531
32-40-08 28 Sep 2007

2606672
H. Rotor Assemblies Inspection Requirements.

Inspection
Intervals
Heat
Stack
8.0 Rotor Assemblies (210, 211, 212, 213) Change Overhaul
NOTE: As steel rotors wear, the trailing edge of the segments may become extruded and cause
difficulty in determining crack limits. The measurement for maximum crack limits shall
be taken from the reference point as shown in Figure 513.
8.1 Crack Limits: X X
Cracks emanating from the ID edge of the segment within
area “A” and traveling into the solid portion are permitted,
provided they do not exceed the limits specified in Figure 513.
Cracks emanating from the leading or trailing edge of the rotor
segment are permitted, provided they do not exceed the limits
Cracks emanating from the corners of the segments near
the straps are permitted, provided they do not exceed the
limits specified in Figure 513 and provided they do not follow
the pattern of milled slots, represented by dashed lines in
Figure 513.
8.2 Heat Check Limits: X X
Heat checks that are within the solid portion of the rotor
segment are permitted.
Intensive heat checks that follow the pattern or outline of the
spider groove in the segment, as indicated by the dashed lines
identified in Figure 513, are not permitted.
Refer to Figure 514 for acceptable and unacceptable
examples.
Page 532
32-40-08 28 Sep 2007

2606672
0.380 (9.65) MAX
ROTOR SEGMENT
STRAP
0.62 (15.7) R
AREA “A”
1.00 (25.4)
MAX
REFERENCE POINT
1.00
(25.4)
2.0 (50.8)
CENTERLINE
SPIDER LEG
SPIDER

Rotor Segment Crack Limits

Figure 513
Page 533
32-40-08 28 Sep 2007

2606672
ACCEPTABLE
NOT ACCEPTABLE
LAG-1665
Rotor Segment Heat Check Limits

Figure 514
Page 534
32-40-08 28 Sep 2007

2606672
Blank Page
Page 535
32-40-08 28 Sep 2007

2606672
Inspection
Intervals
Heat
Stack
8.0 Rotor Assemblies (210, 211, 212, 213) Change Overhaul
8.3 Retaining Strap and Attachment Rivet Damage: X X
Inspect the security and general condition of the rotor retaining
straps and rivets. Rivets shall not be loose.
Damage to the retaining strap resulting from service wear or
during clean-up machining of rotor segments is permitted. A
minimum retaining strap thickness of 0.095 inch (2.41 mm)
must be maintained as shown in Figure 515.
Both the rivet head and the formed rivet end may be worn/
machined flush with the retaining strap surface. In the original
equipment/non-worn condition, the rivet head may or may not
be flush with the retaining strap surface.
Rotors that have straps worn down to 0.095 inch (2.41 mm)
minimum and have defective rivet heads or formed rivet ends
that are below the worn strap surface are no longer
serviceable.
NOTE: Rotor segments may become tight on the rotor spider. This is a normal condition and is
not detrimental to brake operation.
8.4 Rotor Segment Damage: X X
Grooves on rotor segment wear surface are permitted.
Honeywell recommends removal of high spots and rough or
uneven surfaces from the rotor segment wear surfaces to
promote uniform lining wear as outlined in the Repair section.
Extrusion of the ID of the rotor segment is permitted as long
as it does not extend beyond 0.125 inch (3.18 mm) of the
spider ID. Metal extending beyond this limit must be repaired.
8.5 Rotor Weight: X X
Visual and Measurement - Weigh each rotor assembly and mark
its weight on one of the segment faces.
For the -2, -3, and -4 brake assemblies, rotors weighing less
than 18.5 pounds (8.4 kg) may not be reused.
For the -1 brake assembly, rotors weighing less than 17.0
pounds (7.7 kg) may not be reused.
Page 536
32-40-08 28 Sep 2007

2606672
ROTOR STRAPS
A
RIVET
SPIDER
A SECTION A – A
ROTOR SEGMENTS
0.095 (2.41) MINIMUM

STRAP THICKNESS
THICKNESS MEASUREMENT NOT
REQUIRED UNLESS DAMAGE OR
MACHINING IS VISIBLY EVIDENT
RIVET HEAD OR FORMED RIVET END MAY

BE FLUSH WITH STRAP SURFACE AS A
RESULT OF SERVICE WEAR OR CLEAN-UP
MACHINING, PROVIDING MINIMUM STRAP
THICKNESS IS NOT VIOLATED

Rotor Assembly Illustration and Damage Allowances to Strap/Rivet

Figure 515
Page 537
32-40-08 28 Sep 2007

2606672
I. Machine (Tie) Bolts and Washers Inspection Requirements.

Inspection
Intervals
Heat
Stack
9.0 Machine (Tie) Bolts (15) and Washers (20) Change Overhaul
9.1 Visual - Inspect machine (tie) bolt (15) for corrosion, thread X X
damage, and plating damage. Reject bolts based on criteria
defined per the Honeywell SPM (ATA 32-49-01).
9.2 NDT - At operator option based on past inspection and failure O
experience, inspect machine (tie) bolts (15) for cracks using
magnetic particle inspection method per the Honeywell SPM
(ATA 32-49-01). Retire bolts not meeting requirements.
9.3 Visual - Inspect washers (20) for damage, deformation, and X
out-of-flat. Replace as necessary.
Page 538
32-40-08 28 Sep 2007
REPAIR
1. Tabular Definition of Repair Requirements.
Topic Description
General Tabular The Repair section requirements defined per Paragraph 2. are
Overview presented using a tabular format to assist in organizing the needed
inspections. A breakdown of the tabular format is as follows:
- Column 1 identifies the outline number for the repair instructions
- Column 2 identifies the part and feature for which repair instructions
were written.
Breakdown of Repair paragraphs are broken down as follows:
Repair Paragraphs Paragraph Page
2.A. General Repair Guidelines . . . . . . . . . . . . . . . . . . . . 602
2.B. Piston Housing and Plugs Assembly Repair
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
2.C. Stator Torque Tube Repair Instructions . . . . . . . . . 634
2.D. Pressure Plate and Stator Plate Repair
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
2.E. Rotor Assembly Repair Instructions . . . . . . . . . . . . 662
2.F. Piston Bushing Repair Instructions . . . . . . . . . . . . . 665
2.G. Piston Repair Instructions . . . . . . . . . . . . . . . . . . . . . 666
2.H. Machine (Tie) Bolt Repair Instructions . . . . . . . . . . 667
Page 601
32-40-08
Apr 18/05
REPAIR
2. Repair Instructions.
A. General Repair Guidelines.
1.1 General Instructions Applicable to the Repair Section

NOTE: The repairs authorized and described in this section are intended to extend the
life of the parts to a degree. The repairs will not necessarily restore the parts to
a like-new condition.
NOTE: Replace all parts that do not meet the check or test requirements and cannot be
restored to a serviceable condition by allowable repairs. All parts that cannot be
repaired or are outside the acceptable limits must be scrapped.
NOTE: Item numbers (in parentheses) refer to the exploded view shown in the
Illustrated Parts List (IPL) section.
A. Repair or removal of material affecting stamped or forged markings will require
restoring such information in accordance with standard shop practices.
B. For all repairs accomplished, remove only the amount of material required to blend
out the area of damage or corrosion, while adhering to the specified limits for each
repair. Also, relieve all sharp corners or indentations that could result in stress
concentrations. When not specified, the surface finish of all repaired areas must be
equal to, or better than, the adjacent untouched surface.
C. For areas where repairs have not been developed, contact Aircraft Landing
Systems (ALS) Field Service Engineering to determine if repairs are feasible.
Digital photographs, if possible, and measurement of the surface area and depth of
damage must be submitted with the request.
Page 602
32-40-08
Apr 18/05
REPAIR
Page 603
32-40-08
Apr 18/05
REPAIR
B. Piston Housing and Plugs Assembly (160) Repair Instructions.
2.1 Piston Housing and Plugs Assembly (160) - General Repair Instructions
A. For all repairs accomplished, remove only that amount of material required to blend
out the area of damage or corrosion, and relieve all sharp corners or indentations
that could result in stress concentrations. The repair should result in a smooth
contoured area with a minimum blend radius of 0.5 inch (13 mm). When not
specified, the surface finish of repaired areas must be equal to, or better than, the
adjacent untouched surface.
B. Figure 601 identifies areas of the piston housing and plugs assembly that have
specific repairs permitted. Adhere to documented repair allowances in the
referenced outline numbers.
C. Damage or corrosion in areas not illustrated may be locally repaired by blending to
a maximum repair depth of 0.020 inch (0.51 mm) below the adjacent untouched
surface.
D. Surface treat all repaired areas of the piston housing and plugs assembly per the
ALS Standard Practices Manual (SPM) (ATA 32-49-01).
2.2 Piston Housing and Plugs Assembly (160) - Thermal Spray Coating Properties
A. When permitted by specific repair instructions, thermal spray may be applied using
an industry-accepted method (HVOF and TAFA are preferred).
B. To improve corrosion and wear resistance, use a thermal spray of 95% nickel and
5% aluminum composition. The nickel composition may be increased based on
coating availability.
C. The thermal spray process requires initial verification of the thermal spray process
capabilities and coating properties, as well as periodic inspections to ensure the
process remains in-control. The required thermal spray coating properties may be
verified on test strips of 2014 T6 aluminum alloy heat treated to approximately 75
HRB or 119 HB/10/500. The spray thickness shall be 0.040 inch (1.02 mm).
Required properties are as follows:
Hardness: 70 HRB minimum.
Bond strength: 5,000 PSI (34,475 kPa) minimum.
Microstructure properties of a cross-sectioned specimen in any field of view
(approximately 0.020 inch (0.51 mm) in length) when examined under 300X
magnification shall yield a maximum 10% porosity, a maximum 40% oxide
content, and a maximum of five unmelts. Cracks in coating or separation at
bond interface is not allowed.
D. When applying thermal spray, a minimum spray depth of 0.010 inch (0.25 mm) is
required for all repairs following final machining.
Page 604
32-40-08
Apr 18/05
REPAIR
STANDARD GUIDELINES: NOTE:

GENERAL REPAIRS (2.1) FEATURES ARE IDENTIFIED
INLET PORT SURFACE TREATMENT (2.27) FOLLOWED BY REPAIR
MOUNTING FACE PAINT DIAGRAM (2.28) INSTRUCTION OUTLINE
(2.18 - LOCAL POLISHING) NUMBER IN PARENTHESES
(2.19 - LOCAL MACHINING)
(2.20 - COMPLETE FACE MACHINING)
(2.21 - THERMAL SPRAY OR NICKEL PLATING)
INLET BORE OF PISTON HOUSING AND BLEEDER TIE BOLT HOLES
PLUGS ASSEMBLY (160) VALVE PORT AND SPOTFACE
INLET QUICK (2.3) (2.24)
DISCONNECT
FITTING MOUNTING AXLE BORE TEMPERATURE
HOLE SUPPORT SENSOR BOSS
(2.23) RING (2.13)
(2.11)
MATING FACE
(2.25 LOCAL)
(2.26 THERMAL
SPRAY)
ALIGNMENT
PIN HOLE
(2.4)
FLUID
PASSAGEWAY
(2.14)
PISTON BUSHING
BORE THREAD (2.5)
PISTON BUSHING
BORE CYLINDER
WALL/DOME
INTERSECTION SUPPORT RIBS
RADIUS (2.7) (2.10)
TOP OF PISTON
DOME (2.8) PISTON BUSHING BORE FLUID PASSAGEWAY TEMPERATURE SENSOR
CYLINDER WALL (2.6) INTERSECTION ATTACHMENT HOLES
(2.9) (2.12)
RETAINER RING
SHOULDER
(2.15)
ADJUSTER HOUSING
WASHER PILOT
(2.16)
ADJUSTER HOUSING
SPRING CAVITY
(2.17)
LAG-5006
Illustration of Piston Housing and Plugs Assembly Features and Repair References
Figure 601
Page 605
32-40-08
Apr 18/05
REPAIR
2.3 Piston Housing and Plugs Assembly (160) - Bleeder Valve Port Repair Instructions
A. If damage is not extensive, reform threads as required.
B. For stripped threads, rework the existing hole to a 0.625-18UNJF-3B thread per
MS33649-7. When threads are reworked per this option, repair bushing (90A) and
packing (95A) must be used at the time of assembly.
C. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
2.4 Piston Housing and Plugs Assembly (160) - Pin Removal and Replacement and
Installation Hole Repair Instructions
A. Damaged pin (155) may be removed and replaced per standard shop practices.
For reference purposes, the hole is machined to a depth of 0.48 - 0.52 inch (12.2 -
13.2 mm) and at a diameter of 0.250 - 0.256 inch (6.35 - 6.50 mm).
B. More extensive repair allowances have not been developed as of this Component
Maintenance Manual’s (CMM’s) publish date.
32-49-01).
2.5 Piston Housing and Plugs Assembly (160) - Piston Bushing Bore Thread Repair
Instructions
A. If damage is not extensive, reform threads as required.
B. Repair of stripped threads is not permitted.
32-49-01).
2.6 Piston Housing and Plugs Assembly (160) - Piston Bushing Bore Cylinder Wall
Repair Instructions
A. On the non-static seal surfaces of the piston housing cylinder wall, standard local
repair allowances apply (refer to outline number 2.1 - General Repair Instructions).
B. Light corrosion on the static seal surface of the piston bushing cylinder wall may be
performed using vapor blast or other methods. A maximum of 0.003 inch (0.08
mm) of material may be removed from the surface and a maximum inside diameter
(ID) of 2.000 inch (50.80 mm) is permitted. The static seal surface must be
polished to 32 RMS (0.8 µm) minimum.
32-49-01).
D. Inspect to ensure that no foreign objects or machining residue have become
entrapped in the piston housing passageways.
E. Pressure test piston housing per the Testing section.
Page 606
32-40-08
Apr 18/05
REPAIR
Page 607
32-40-08
Apr 18/05
REPAIR
2.7 Piston Housing and Plugs Assembly (160) - Piston Bushing Bore Cylinder
Wall/Dome Intersection Radius Repair Instructions
A. Cracks or other damage observed at the wall/dome intersection radius may be
repaired as defined in Figure 602. A one-time rework of a crack is permitted.
B. To prevent entry of machining residue, mask off the passageway openings in the
cavity bore that is to be repaired.
C. Remove material from the wall/dome intersection radius only to the depth required
to completely remove crack indications. Repairs may be made to the minimum
dome thickness and minimum wall thickness dimensions specified in Figure 602.
Blend repaired area to the minimum radius specified and achieve a smooth
transition of the repaired area in the ID of the bore circumference as shown in
Figure 602, while achieving the specified surface finish.
D. Etch the machined surface of the repaired area to remove smeared metal per the
ALS SPM (ATA 32-49-01).
E. Inspect reworked areas with eddy current or dye penetrant inspection to ensure that
all crack indications are removed. The repaired areas must be free from cracks,
nicks, and tool marks.
F. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
G. Inspect to ensure that no foreign objects or machining residue have become
2.8 Piston Housing and Plugs Assembly (160) - Outside Top of Piston Dome Repair
Instructions
A. Damage to the top of the piston dome may be repaired by local blending to a
minimum thickness of 0.230 inch (5.84 mm) as measured from the bottom of the
piston cavity to the outside top of the dome. Combinations of repairs to the top or
bottom of the dome may not result in a thickness less than that shown in Figure
602. Apply a minimum blend radius of 1.0 inch (25 mm) to the repaired areas.
B. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
Page 608
32-40-08
Apr 18/05
REPAIR
DIMENSION “X” MINIMUM PISTON DOME THICKNESS TO BE 0.230 (5.84)

DIMENSION “Y” MINIMUM PISTON CAVITY WALL THICKNESS TO BE 0.270 (6.86)
BLEND REWORK AREAS TO DEPTH REQUIRED TO ENSURE COMPLETE

REMOVAL OF CRACK. ACHIEVE A SMOOTH TRANSITION BETWEEN
REPAIRED AREAS AND ORIGINAL EQUIPMENT SURFACES.
SURFACE FINISH TO BE 32 RMS (0.8 µm) MINIMUM.
A
CRACK
0.18
(4.6)
R MIN
TOP OF
DOME A SECTION A–A
MATERIAL MAY BE REMOVED FROM
DOME TOP TO A MINIMUM THICKNESS
OF 0.230 (5.84) DIMENSIONS ARE PROVIDED IN INCHES WITH
Bushing Bore and Dome Intersection Repair

Figure 602
Page 609
32-40-08
Apr 18/05
REPAIR
2.9 Piston Housing and Plugs Assembly (160) - Piston Bushing Bore Cylinder
Wall/Fluid Passageway Intersection Repair Instructions
A. Cracks or other damage observed at the intersection point of the fluid passageway
with the bushing bore or bleeder port may be repaired as defined in Figure 603.
B. To prevent entry of machining residue, mask off the passageway openings in the
cavity bore that is to be repaired. A removable plug may be installed below the
depth of damage for the intersection point that is being repaired.
C. Remove material to the depth required to completely remove crack indications.
Repairs may be made to the maximum dimensions specified in Figure 603.
Smoothly transition the repair into the undamaged material.
D. Etch the machined surface of the repaired area to remove smeared metal per the
ALS SPM (ATA 32-49-01).
E. Inspect reworked areas with eddy current or dye penetrant inspection per the ALS
SPM (ATA 32-49-01) to ensure that all crack indications are removed. The repaired
areas must be free from cracks, nicks, and tool marks.
32-49-01).
G. Inspect to ensure that no foreign objects or machining residue have become
FLUID
PASSAGEWAY
BLEND TO A
0.35 (8.9) RADIUS
MAXIMUM. ALL
LOCATIONS MAY
BE REPAIRED.
CRACKS IN ACUTE ANGLE MAY

BE REMOVED AS SHOWN

Bushing Bore and Fluid Passageway Intersection Repair

Figure 603
Page 610
32-40-08
Apr 18/05
REPAIR
2.10 Piston Housing and Plugs Assembly (160) - Support Rib Repair Instructions
A. Standard local repair allowances apply (refer to outline number 2.1 - General
Repair Instructions).
B. More extensive repair allowances have not been developed as of this CMM’s
publish date.
32-49-01).
2.11 Piston Housing and Plugs Assembly (160) - Axle Bore Support Ring Repair
Instructions
A. Standard local repair allowances apply (refer to outline number 2.1 - General
Repair Instructions).
B. Damage on the corners of the axle bore may be repaired as shown in Figure 604.
C. More extensive repair allowances have not been developed as of this CMM’s
publish date.
D. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
REPAIRS UP TO 0.150 (3.81) 0.150 (3.81) X 45° MAX

DEEP AND 1.00 (25.4) IN MATERIAL MAY BE REMOVED
LENGTH MAY BE MADE TO FROM CORNER OVER
THE SUPPORT RING. REPAIRS FULL CIRCUMFERENCE
MUST BE SEPARATED BY
3.50 (38.9) OF UNDAMAGED
MATERIAL. SMOOTHLY BLEND
REPAIR INTO UNDAMAGED
MATERIAL WITH 1.00 (25.4)
BLEND RADIUS.

Axle Bore Support Ring Repair

Figure 604
Page 611
32-40-08
Apr 18/05
REPAIR
2.12 Piston Housing and Plugs Assembly (160) - Temperature Sensor Attachment Hole
Repair Instructions
A. Remove defective screw thread insert (165) per manufacture’s instructions.
B. Inspect hole for damage. If threads are not stripped or damaged beyond use,
reinstall a standard screw thread insert (165, 165C) per manufacturer’s instructions.
Ensure insert is installed 3/4 - 11/2 turns below the mounting surface and remove
installation tangs.
C. If threads are stripped to the extent that a standard screw thread insert (165)
cannot be used, or if threads are corroded, install an oversize insert as follows:
(1) The first option permits two oversize repairs using Heli-Coil thread inserts.
Heli-Coil #3891-4CN-500 should be used for the first oversize repair and
Heli-Coil #2391-4CN-500 (outer) and #4691-4CN-464 (inner) Twinsert
should be used for the second. Machine hole per the insert manufacturer’s
instructions. When using the second repair option (Twinsert), increase
countersink of hole to a diameter of 0.36 inch (9.1 mm) x 120 degrees.
Install insert per manufacturer’s instructions. Ensure insert is installed 3/4 -
11/2 turns below the mounting surface and remove installation tangs.
(2) The second option requires machining of the mounting hole and installation
of a self-tapping screw thread insert (165B). No additional repairs are
allowed with this method. Drill hole to a diameter of 0.349 - 0.356 inch
(8.86 - 9.04 mm) and to a depth of 0.58 - 0.60 inch (14.7 - 15.2 mm).
Countersink hole to a diameter of 0.38 inch (9.7 mm) x 120 degrees. Install
insert flush to 0.010 inch (0.25 mm) below top of countersink.
32-49-01).
2.13 Piston Housing and Plugs Assembly (160) - Temperature Sensor Installation Boss
Repair Instructions
A. Polish local corrosion and damage to a depth of 0.005 inch (0.13 mm) maximum.
B. More extensive repair allowances have not been developed as of this CMM’s
publish date.
32-49-01).
Page 612
32-40-08
Apr 18/05
REPAIR
2.14 Piston Housing and Plugs Assembly (160) - Expansion Plug (173) and Pin (172)
Repair Instructions
A. Remove defective plug and pin per the ALS SPM (ATA 32-49-01).
B. Inspect hole for damage.
C. If hole is not damaged, standard expansion plug (173) is to be installed.
D. If hole is damaged, machine hole to accept oversize expansion plug (173A) as
E. Clean all machining debris from passageway and piston cavity.
32-49-01).
G. Install required expansion plug and pin (172) per the ALS SPM (ATA 32-49-01).
The exposed end of the pin must be installed 0.005 inch (0.13 mm) above or 0.010
inch (0.25 mm) below the end of the plug.
NOTE: The oversize plug is 0.010 inch (0.25 mm) larger than the standard plug.
The pins are identical. The oversize plugs are dyed red and the standard
size are green.
H. Test retention of installed expansion plug per the Testing section.
45°
WITH PLUG BOTTOMED,
SET PIN TO 0.005 (0.13)
0.2903 - 0.2912 ABOVE TO 0.010 (0.24)
(7.374 - 7.396) DIA BELOW TOP EDGE OF PLUG
TO DEPTH SHOWN
0.38 - 0.40
(9.6 - 10.2)

Installation of Oversize Expansion Plugs

Figure 605
Page 613
32-40-08
Apr 18/05
REPAIR
2.15 Piston Housing and Plugs Assembly (160) - Adjuster Housing Retainer Ring
Shoulder
A. Standard local repair allowances apply for minor damage in this area (refer to
outline number 2.1 - General Repair Instructions).
B. If cracked or damaged, up to a 90-degree arc of the adjuster housing retainer ring
shoulder may be removed in one place. Blend and polish.
32-49-01).
2.16 Piston Housing and Plugs Assembly (160) - Adjuster Housing Washer Pilot Repair
Instructions
A. Damage, corrosion, or wear to the adjuster housing washer pilot diameter that
cannot be removed locally, or exceeds the maximum Check section diameter, may
be repaired using a locally fabricated steel split ring bushing.
B. Machine damage from the washer pilot diameter of the adjuster housing as
specified in Figure 606. At least 75% of the washer pilot diameter must clean up at
the maximum rework diameter of 1.775 inches (45.09 mm). If damage is beyond
this limit, scrap the piston housing.
(1) Machining instructions for an adjustable repair are provided to help minimize
the amount of material that must be removed. When using this repair
option, the split ring bushing outside diameter (OD) must be machined to
match the diameter of the repaired washer pilot.
(2) At operator option, three step repairs are also provided. These options
allow the operator to prefabricate the split ring bushing, and then to machine
the piston housing washer pilot to match the diameter of the prefabricated
split ring bushing.
C. Fabricate split ring bushing as shown in Figure 606 based on selected repair
option.
32-49-01).
E. Install split ring bushing into washer pilot ID.
Page 614
32-40-08
Apr 18/05
REPAIR
DIA “A” – APPLIES ONLY TO WASHER PILOT.

DO NOT MACHINE RETAINING RING LEDGE.
WASHER
PILOT 0.02 (0.5) R MAX
1.95 (49.5) MIN
0.24 (6.1)
0.26 (6.6)
0.33 (8.4)
DIA “B” 0.38 (9.7)
1.615 (41.02)
1.635 (41.53) DIA
0.03 (0.8) X 45° TO CLEAR
RADIUS AT BOTTOM OF
REWORKED WASHER PILOT
MATERIAL:
STEEL 4130 OR
EQUIVALENT OPTIONAL:
125,000 - 145,000 DRILL 0.625 (15.88) DIA THRU HOLE
PSI UTS MIN TWO PLACES TO AID REMOVAL.
CAD PLATE PER QQ–P–416 CENTER HOLE ON FACE OF
TYPE 1 CLASS 3 SPLIT RING AT LEAST
0.125 (3.18) FROM END

LAG-5002B MILLIMETER CONVERSIONS IN PARENTHESES
Piston Housing Washer Pilot Machined ID Repair Bushing OD

Repair Diameter “A” Diameter “B”
Option Inch (mm) Inch (mm)
Machine to provide a 0.000 - 0.005
1.700 (43.18) Minimum (0.00 - 0.13) interference fit with
Adjustable 1.775 (45.09) Maximum Diameter “A”
Step 1 1.700 - 1.705 (43.18 - 43.31) 1.705 - 1.710 (43.31 - 43.43)
Step 2 1.730 - 1.735 (43.94 - 44.07) 1.735 - 1.740 (44.07 - 44.20)
Step 3 1.770 - 1.775 (44.96 - 45.09) 1.775 - 1.780 (45.09 - 45.21)
Adjuster Housing Washer Pilot Repair

Figure 606
Page 615
32-40-08
Apr 18/05
REPAIR
2.17 Piston Housing and Plugs Assembly (160) - Adjuster Housing Spring Cavity Repair
Instructions
A. Corrosion on the surface of the adjuster spring cavity diameter may be repaired by
local polishing per the standard local repair allowances (refer to outline number 2.1
- General Repair Instructions). “Spring impressions” that are on the ID of the cavity
need not be repaired, unless sharp edges are observed. Blend sharp edges within
the specified limits.
B. Damage or corrosion to the adjuster housing spring cavity diameter that cannot be
removed locally may be repaired by machining the cavity to the dimensions shown
in Figure 607, View 1.
C. Damage, corrosion, or wear to the adjuster housing spring cavity washer ledge or
the base of the spring cavity may be repaired as shown in Figure 607, View 1.
D. Damage, corrosion, or wear to the adjuster housing spring cavity washer ledge that
could not be repaired as shown in Figure 607, View 1 may be repaired per View 2.
This requires fabrication of a steel split ring bushing.
(1) Machine damage from the washer ledge as shown in Figure 607, View 2.
(2) Fabricate split ring bushing as indicated in Figure 607, View 2. The split ring
bushing OD must be machined to match the diameter of the repaired
washer ledge.
(3) Surface treat repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
(4) Install split ring bushing into washer pilot ID.
E. If damage or wear to the adjuster spring cavity exceeds the above repair limits,
scrap the piston housing.
32-49-01).
Page 616
32-40-08
Apr 18/05
REPAIR
63 (1.6 µm)
SEE WASHER PILOT
1.44 REPAIR INSTRUCTIONS
(36.6)
DIA MAX
WASHER PILOT 0.02 (0.5) R MAX
LEDGE
IMPRESSIONS LEFT BY
SPRING MOVEMENT 1.95 (49.5) MIN
ON THE SPRING CAVITY (SEE VIEW 2 FOR
ID DO NOT NEED TO BE ADDITIONAL REPAIR
REPAIRED, UNLESS SHARP ALLOWANCES)
EDGES ARE PRESENT. 63 (1.6 µm)
0.10 - 0.02 0.10 (2.54) MIN

(0.3 - 0.5) R
VIEW 1 – MAXIMUM REPAIR WITHOUT REPAIR BUSHING
MACHINE TO PROVIDE A 0.40 (10.2)

0.000 - 0.005 (0.00 - 0.13) 0.35 (8.9)
INTERFERENCE FIT
WITH DIA “B”
OPTIONAL:
DRILL 0.625 (15.88) DIA THRU HOLE
TWO PLACES TO AID REMOVAL.
1.40 (35.6) CENTER HOLE ON FACE OF
DIA
1.38 (35.1) SPLIT RING AT LEAST
0.24 (6.1)
0.26 (6.6) 0.125 (3.18) FROM END.
0.03 (0.8) X 45° TO CLEAR

RADIUS AT BOTTOM OF
REWORKED WASHER PILOT
1.635 (41.53)
DIA “B” 1.470 (37.34) APPLIES ONLY TO THE MATERIAL
WASHER PILOT REMOVED FOR SPLIT RING BUSHING
LEDGE
MATERIAL REMOVED
FOR SPLIT RING
BUSHING
0.02 (0.5) R 1.95 - 1.96
MAX 1.755 - 1.765 (49.5 - 49.8)
(44.58 - 44.83) ORIGINAL
MATERIAL:
EQUIPMENT
STEEL
65,000 PSI UTS MIN
CAD PLATE PER QQ–P–416
TYPE 1 CLASS 3
VIEW 2 – MAXIMUM REPAIR WITH SPLIT RING REPAIR BUSHING
Adjuster Housing Spring Cavity Repairs

Figure 607
Page 617
32-40-08
Apr 18/05
REPAIR
2.18 Piston Housing and Plugs Assembly (160) - Inlet Port Mounting Face Repair
Instructions - Local Polishing
A. Remove localized damage or corrosion on the inlet mounting surface as follows.
One repair per 90-degree quadrant of the inlet port mounting surface is permitted.
Local repairs shall not exceed 0.040 inch (1.02 mm) in depth, and shall be limited to
0.5 square inch (13 square mm). Apply a minimum blend radius of 0.5 inch (12.7
mm) to all repairs. Local repairs shall not be within 0.040 inch (1.02 mm) of the
edge of the chamfer for the fitting bore, and not within 0.020 inch (0.51 mm) of the
edge of the chamfer for the four screw holes. Refer to outline numbers 2.19 and
2.20 if all corrosion or damage is not removed.
B. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
C. Inspect inlet bore, bleeder port valve ports, and passageway holes associated with
the piston housing inlet for metal shavings or other debris resulting from the repair.
Thoroughly clean as required.
Instructions - Local Machining
A. Localized corrosion damage on the inlet port mounting face in the area bordered by
the four attachment screw holes on the outside and the inlet fitting bore on the
inside is permitted as shown in Figure 608. Determine permitted machining depth
and complete machining as follows:
(1) Insert a gage pin of 0.30 - 0.32 inch (7.6 - 8.1 mm) diameter and 3.0 inch
(76 mm) minimum length through bleeder port hole and into passageway
hole. Use gage pin that provides tightest fit. Measure depth of bore from
mounting surface to the top of the gage pin. Record this dimension for
baseline purposes.
(2) Subtract 0.390 inch (9.91 mm) from the baseline measurement. The result
is the maximum repair depth for localized machining of the mounting face. If
corrosion is deeper than this dimension, scrap the piston housing.
(3) Machine the minimum amount of material required to remove all damage
without exceeding the specified limits shown in Figure 608.
B. Clean and degrease the repaired area.
C. Fill void left by machining with one part epoxy EC-2214 Hi-Temp, Devcon F, or
equivalent. Once cured, epoxy build-up should be machined flush to 0.010 inch
(0.25 mm) below the mounting surface. After machining, inspect epoxy for proper
bond.
NOTE: Refer to Appendix A for vendor information.
32-49-01).
E. Inspect inlet bore, bleeder port valve ports, and passageway holes associated with
Page 618
32-40-08
Apr 18/05
REPAIR
0.020 (0.51) MIN

0.040 (1.02) MIN
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
BREAK EDGES
REPAIR AREA
0.020 (0.51) R MIN
0.390 (9.91)
MIN REF.
0.390 (9.91) MIN

Inlet Port Mating Face Local Machining

Figure 608
Page 619
32-40-08
Apr 18/05
REPAIR
Instructions - Machining of Complete Surface
A. Machining of the complete inlet port mounting face to remove corrosion and
operational damage is permitted as shown in Figure 609. Determine permitted
machining depth and complete machining as follows:
(1) Insert a gage pin of 0.30 - 0.32 inch (7.6 - 8.1 mm) diameter and 3.0 inch
(76 mm) minimum length through bleeder port hole and into passageway
hole. Use gage pin that provides tightest fit. Measure depth of bore from
mounting surface to the top of the gage pin. Record this dimension for
baseline purposes.
(2) Subtract 0.430 inch (10.92 mm) from the baseline measurement. The result
is the maximum repair depth for full machining of the mounting face.
(3) Remove thread inserts from mounting holes.
(4) Machine the minimum amount of material required to remove all damage
without exceeding the specified limits as shown in Figure 609.
(5) Refer to outline number 2.21 for optional electroless nickel plate or thermal
spray repair allowances.
B. If the full mounting surface is machined to dimension “A” minimum limit specified in
Figure 609 and all corrosion or operational damage has not been removed,
determine if the repairs suggested in outline numbers 2.18 and 2.19 can be used to
salvage the piston housing. If not, scrap the piston housing.
C. Measure depth of the remaining threads in four mounting hole locations. If less
than 0.52 inch (13.2 mm), rework mounting holes and threads to dimensions
D. Machine chamfer at edge of inlet bore and mounting holes as defined in Figure
609.
E. Install new thread inserts.
32-49-01).
G. Inspect inlet bore, bleeder port valve ports, and passageway holes associated with
Page 620
32-40-08
Apr 18/05
REPAIR
0.860 (21.84) 0.860 (21.84)
FLUID PASSAGEWAY
0.257 - 0.264 (6.53 - 6.71) DIA

0.69 - 0.72 (17.5 - 18.3) DEEP
BLEEDER PORT TAP FOR INSERT (165C)
0.250-28UNF-3B THREAD,
0.58 (14.7) DEEP
32 (0.8 µm) 0.31 (7.9) DIA x 120_
COUNTERSINK
0.010 (0.25) A
32 (0.8 µm)
4 LOCATIONS
15_
0.001 (0.03) A
RESULT 0.08 (2.0)
–A–
0.520 (13.21) MIN THREAD DEPTH

FOLLOWING MACHINING OF
125 (3.2 µm) INLET MATING SURFACE
DIM “A”
0.430 (10.92) MIN
0.550 (13.97) MAX

FOLLOWING
APPLICATION AND
MACHINING OF OPTIONAL
PLATING/COATING

Full Machining of Inlet Mounting Surface

Figure 609
Page 621
32-40-08
Apr 18/05
REPAIR
Instructions - Electroless Nickel Plating or Thermal Spray Repair
A. Following initial machining of inlet mounting surface as defined per outline number
2.20, operators may elect to apply an electroless nickel plating or thermal spray
coating to the inlet mounting surface to help prevent the recurrence of corrosion.
Application of the plating/coating must be accomplished per an industry-accepted
process. The process should be validated on an aluminum test specimen before
attempting on the piston housing. When using thermal spray, the process
parameters defined per outline number 2.2 must be validated.
B. Clean and degrease the inlet mounting surface and the edge of the inlet bore
lead-in chamfer.
C. Use a suitable plug to mask the inlet bore to a depth just below the lead-in chamfer
to prevent material from being deposited into the inlet bore. Mask remaining
surfaces away from the inlet mounting surface.
D. Clean, condition, and apply nickel plating or thermal spray per verified method to a
depth sufficient to allow full clean-up. The electroless nickel plating should be
applied to a depth of 0.0025 - 0.0050 inch (0.064 - 0.127 mm). When applying
thermal spray, a minimum spray depth of 0.010 inch (0.25 mm) is required and a
maximum depth of 0.030 inch (0.76 mm) is suggested.
E. Machine or polish inlet mounting surface to the final dimensions and surface finish
requirements specified in Figure 609. Ensure that requirements for dimension “A”
are not exceeded following final machining. Machined thermal sprayed surface
must be free of defects. Following final machining, the machined plating/coating
shall be smooth, continuous, and adherent to the base metal. If not free from frosty
areas, pin holes, porosity, blisters, nodules, pits, or any other defect that may
interfere with the sealing and seating functions of the repair, the machining and
coating process must be repeated.
F. Complete remaining repair requirements per outline number 2.20, steps C. through
G.
Page 622
32-40-08
Apr 18/05
REPAIR
Page 623
32-40-08
Apr 18/05
REPAIR
2.22 Piston Housing and Plugs Assembly (160) - Inlet Port Bore Repair Instructions -
Electroless Nickel Plating or Thermal Spray Repair
A. Corrosion in the piston housing inlet bore may be repaired using electroless nickel
or thermal spray. This repair requires machining of the piston housing inlet bore to
remove corrosion, followed by application of the nickel plating or thermal spray
coating to restore the original bore diameter. Application of the plating/coating must
be accomplished per an industry accepted process. The process should be
validated on an aluminum test specimen before attempting on the piston housing.
When using thermal spray, the process parameters defined per outline number 2.2
must be validated.
B. Machine the inlet bore diameter to the oversize dimension shown in Figure 610 for
the plating/coating repair option selected. Machine to a depth that is 0.020 - 0.030
inch (0.51 - 0.76 mm) above the top of the bleeder port hole. Smoothly blend the
machined surface into the non-repaired surface.
C. Clean and degrease the inlet mounting surface and the edge of the inlet bore
lead-in chamfer.
D. Mask the inlet mounting surface, leaving a hole in the mask at the location of the
bore. A suitable plug should be fitted into the bore to allow plating only to the depth
of the removed material.
E. Clean, condition, and apply nickel plating or thermal spray per verified method to a
depth sufficient to allow full clean-up to the original equipment (OE) dimension
F. Machine or polish inlet bore diameter to the OE dimensions and surface finish
requirements specified in Figure 610. Machine lead-in chamfer of the inlet bore, if
required, to the requirements of Figure 610. Following final machining, the
machined plating/coating shall be smooth, continuous, and adherent to the base
metal. If not free from frosty areas, pin holes, porosity, blisters, nodules, pits, or any
other defect that may interfere with the sealing and seating functions of the repair,
the machining and coating process must be repeated.
G. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
H. Inspect inlet bore, bleeder valve ports, and passageway holes associated with the
piston housing inlet for metal shavings or other debris resulting from repair.
I. Following completion of repair, test brake assembly for leakage. If leakage occurs
at inlet, this procedure must be repeated. If machining limits for the inlet bore are
exceeded, the piston housing must be scrapped.
Page 624
32-40-08
Apr 18/05
REPAIR
MATERIAL REMOVED FOR

PLATING OPERATION
SMOOTH BLEND BETWEEN

ORIGINAL EQUIPMENT AND
MACHINED SURFACE
0.020 - 0.030 INITIAL MACHINING PRIOR TO

(0.51 - 0.76) PLATING:
1) FOR ELECTROLESS NICKEL
1.065 - 1.060 (27.05 - 26.92) DIA
32 (0.8 µm) 2) FOR THERMAL SPRAY
1.085 - 1.075 (27.56 - 27.31) DIA
32 (0.8 µm)
15_
1.055–1.053 (26.80 - 26.75) DIA
RESULT
ORIGINAL DIMENSION
FINAL MACHINED DIA
–A– AFTER PLATING
0.001 (0.03) A
0.08 (2.0)

Piston Housing Inlet Bore Nickel Plate or Thermal Spray Machining Instructions
Figure 610
Page 625
32-40-08
Apr 18/05
REPAIR
2.23 Piston Housing and Plugs Assembly (160) - Inlet Quick Disconnect Fitting Mounting
Hole Repair Instructions
A. Remove defective screw thread insert (165) per manufacture’s instructions.
B. Inspect hole for damage. If threads are not stripped or damaged beyond use,
reinstall a standard screw thread insert (165) per manufacturer’s instructions.
Ensure insert is installed 3/4 - 11/2 turns below the mounting surface and remove
installation tangs.
C. If threads are stripped to the extent that a standard screw thread insert (165)
cannot be used or if threads are corroded, install an oversize insert as follows:
(1) The first option permits two oversize repairs using Heli-Coil thread inserts.
Heli-Coil #3891-4CN-500 should be used for the first oversize repair and
Heli-Coil #2391-4CN-500 (outer) and #4691-4CN-464 (inner) Twinsert
should be used for the second. Machine hole per the insert manufacturer’s
instructions. When using the second repair option (Twinsert), increase
countersink of hole to a diameter of 0.36 inch (9.1 mm) x 120 degrees.
Install insert per manufacturer’s instruction. Ensure insert is installed 3/4 -
11/2 turns below the mounting surface and remove installation tangs.
(2) The second option requires machining of the mounting hole and installation
of a self-tapping screw thread insert (165B). No additional repairs are
allowed with this method. Drill hole to a diameter of 0.349 - 0.356 inch
(8.86 - 9.04 mm) and to a depth of 0.58 - 0.60 inch (14.7 - 15.2 mm).
Countersink hole to a diameter of 0.38 inch (9.7 mm) x 120 degrees. Install
insert flush to 0.010 inch (0.25 mm) below top of countersink.
32-49-01).
Page 626
32-40-08
Apr 18/05
REPAIR
Page 627
32-40-08
Apr 18/05
REPAIR
2.24 Piston Housing and Plugs Assembly (160) - Tie Bolt Hole and Spotface Repair
Instructions
A. Damage or corrosion identified in the tie bolt holes may be repaired by local
polishing to a depth of 0.005 inch (0.13 mm) maximum, while adhering to the
maximum hole diameter of 0.485 inch (12.32 mm). See Figure 611.
B. For more extensive damage or corrosion, the tie bolt holes may be reamed to a
maximum diameter of 0.485 inch (12.32 mm) as shown in Figure 611. The holes
may be reamed independent of each other. More extensive repairs of the tie bolt
holes including a bushing repair have not been approved as of this CMM’s publish
date.
C. Damage or corrosion identified on the tie bolt hole spotfaces may be repaired by
local polishing to a maximum depth of 0.030 inch (0.76 mm). Local repair is not
permitted directly under the bearing face of the tie bolt attachment washer as
D. Damage or corrosion identified on the tie bolt hole spotfaces may also be repaired
by machining the counterbore deeper. When machining deeper, the minimum
mounting flange width as measured from the spotface to the mating face of the
piston housing is 0.42 inch (10.7 mm). See Figure 611.
E. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
2.25 Piston Housing and Plugs Assembly (160) - Mating Face Repair Instructions - Local
Blending
A. Damage or corrosion identified on the mating face side of the piston housing may
be repaired by local polishing to a depth of 0.020 inch (0.51 mm). Local repair is
not permitted on the mating face in the area directly under the bearing face of the
tie bolt attachment washer as shown in Figure 611. Repairs are limited to 1.0
square inch (645 square mm) and must be separated by at least 2.0 inches (51
mm) of undamaged material.
B. If a raised edge or lip is associated with the tie bolt hole, check hole as defined per
piston housing and plugs assembly repair outline number 2.24. Machine lip flush
with mating face and break edge as shown in Figure 611.
32-49-01).
Page 628
32-40-08
Apr 18/05
REPAIR
TIE BOLT HOLE SPOTFACE

LOCAL BLENDING PERMITTED
TO 0.030 (0.76) MAX, EXCEPT
AREA AROUND TIE BOLT
HOLE AS NOTED.
0.78 (19.8) DIA 0.78 (19.8) DIA
NO REPAIR ALLOWED
NO REPAIR ALLOWED
IN THIS AREA AROUND
IN THIS AREA AROUND
TIE BOLT HOLES
TIE BOLT HOLES
TIE BOLT HOLE

0.005 (0.13) MAX LOCAL
POLISHING PERMITTED
LOCAL BLENDING
0.42 (10.7) MIN
1.04 - 1.08 (26.4 - 27.4)

DIA COUNTERBORE 0.485 (12.32) MAX
TO DEPTH SHOWN
0.08 - 0.12 (2.0 - 3.0) R
BREAK EDGE
0.005 - 0.025
(0.13 - 0.64)

Piston Housing Tie Bolt Hole, Spotface, and Local Mating Face Repair Instructions
Figure 611
Page 629
32-40-08
Apr 18/05
REPAIR
2.26 Piston Housing and Plugs Assembly (160) - Mating Face Repair Instructions -
Thermal Spray
A. Damage or corrosion on the mating face of piston housing may be repaired using
thermal spray. This repair requires machining of the piston housing mating face to
remove damage or corrosion followed by application of the thermal spray coating to
restore the original mating face thickness. Application of the coating must be
accomplished per an industry-accepted process. The process should be validated
on an aluminum test specimen before attempting on the piston housing. When
using thermal spray, the process parameters defined per outline number 2.2 must
be validated.
B. Machine damage from the piston housing mating face to the depth, diameter, and
blend radius requirements as shown in Figure 612, View 1. Depth measurements
are referenced from the tie bolt hole spotface.
C. NDT inspect machined area for cracks per the ALS SPM (ATA 32-49-01).
D. Clean and degrease the machined mating face.
E. Mask all surfaces not to receive thermal spray.
F. Perform final cleaning and condition surface to receive thermal spray as required.
Apply thermal spray per verified method to a depth sufficient to allow full clean-up to
the requirements as shown in Figure 612, View 2.
G. Machine thermal sprayed surfaces to the final dimensions shown in Figure 612,
View 2. Following final machining, the machined coating shall be smooth,
continuous, and adherent to the base metal. If not free from frosty areas, pin holes,
porosity, blisters, nodules, pits, or any other defect that may interfere with the
sealing and seating functions of the repair, the machining and coating process must
be repeated.
H. Surface treat all repaired areas of the piston housing per the ALS SPM (ATA
32-49-01).
Page 630
32-40-08
Apr 18/05
REPAIR
0.43 - 0.42
(10.9 - 10.7)
ORIGINAL
EQUIPMENT
DIM
0.40 (10.2)
MIN
10.4 (264.2) DIA MAX
REMOVE MATERIAL TO THE
MINIMUM DIAMETER REQUIRED
TO CLEAN UP ALL DAMAGE
MACHINE MATERIAL FROM THIS SURFACE TO THE LIMITS SPECIFIED.

LOCAL BLENDING BELOW THE MINIMUM THICKNESS LIMIT MAY BE
PERFORMED TO A DEPTH OF 0.010 (0.3) IF REQUIRED TO REMOVE
LOCALIZED CORROSION OR DAMAGE.
AT LEAST 0.010 (0.3) OF MATERIAL MUST BE REMOVED FROM THE

2.15 - 2.14 ENTIRE SURFACE TO ENSURE A SUFFICIENT THERMAL SPRAY
(54.6 - 54.4) COATING THICKNESS AFTER FINAL MACHINING
A
ORIGINAL
EQUIPMENT 0.25 (6.4) BLEND RADIUS
DIM
VIEW 1 – MACHINING PRIOR TO THERMAL SPRAY APPLICATION
6.90 - 6.88
DIA
(175.3 - 174.8)
0.43 - 0.42
(10.9 - 10.7)
FOLLOWING APPLICATION OF THERMAL SPRAY TO THIS

SURFACE, MACHINE THERMAL SPRAY FLUSH WITH THE
REMAINING UNTOUCHED ORIGINAL EQUIPMENT SURFACE.
BREAK ALL EDGES AT TIE BOLT HOLES, BOLT KEEPER HOLES,
ALIGNMENT PIN HOLE, THERMAL PROBE ATTACHMENT HOLES,
AND AXLE BORE. BREAKOUT OF THE THERMAL COATING
AROUND ALL HOLES AND THE EDGE OF THE AXLE BORE IS
PERMITTED, AS LONG AS THE BREAKOUT DOES NOT EXTEND
MORE THAN 0.050 (1.3) FROM THE EDGE AND, THERE IS NO
ADDITIONAL EVIDENCE OF BOND SEPARATION AT THE
2.15 - 2.14 THERMAL SPRAY INTERFACE.
(54.6 - 54.4) A MACHINE FLUSH WITH
THIS UNTOUCHED
SURFACE
VIEW 2 – MACHINING FOLLOWING THERMAL SPRAY

Piston Housing Mating Face Thermal Spray Repair Instructions

Figure 612
Page 631
32-40-08
Apr 18/05
REPAIR
2.27 Piston Housing and Plugs Assembly (160) - Surface Treatment Instructions
A. ALS strongly encourages operators to maintain surface treatment on the piston
housing and plugs assembly to prevent corrosion. Replace or repair damaged or
removed surface protection per the ALS SPM (ATA 32-49-01).
2.28 Piston Housing and Plugs Assembly (160) - Paint Instructions

A. ALS strongly encourages operators to apply and maintain paint on the surfaces of
the piston housing and plugs assembly to assist in preventing corrosion. Primer
and paint may be applied to the permitted piston housing surfaces as shown in
Figure 613.
B. As required, repair damaged paint or apply new paint to the piston housing. Refer
to the ALS SPM (ATA 32-49-01) for paint instructions.
Page 632
32-40-08
Apr 18/05
REPAIR
3
1
1
1 1
2
9.36 (237.7)
9.30 (236.2)
2 3
1
1
0.14 (3.5) MIN

TOPCOAT
PERMISSIBLE ON 1
SPOTFACE FILLET
RADIUS
1 NO PRIMER AND NO TOPCOAT
2 PRIMER ONLY
3 PRIMER AND TOPCOAT OVERSPRAY ALLOWED
ALL OTHER SURFACES TO HAVE PRIMER AND TOPCOAT

Piston Housing and Plugs Assembly Paint Instruction Diagram

Figure 613
Page 633
32-40-08
Apr 18/05
REPAIR
C. Stator Torque Tube (240) Repair Instructions.
3.1 Stator Torque Tube (240) - General Repair Instructions

NOTE: Surface corrosion on the steel components of the brake assembly that can be
removed by light rubbing is typical and will generally not impact normal operation
of the brake assembly.
out the area of damage or corrosion and relieve all sharp corners or indentations
which could result in stress concentrations. The repair should result in a smooth
contoured area blended smoothly into the adjacent untouched surfaces.
B. Figure 614 identifies areas of the torque tube that have specific repairs permitted.
Adhere to documented repair allowances in the referenced outline numbers.
surface.
D. Following repairs, ALS suggests coating all torque tube surfaces with an approved
paint or rust inhibitor. Refer to the ALS SPM (ATA 32-49-01).
Page 634
32-40-08
Apr 18/05
REPAIR
OUTER NIB HOLE (3.4)
LINING ATTACHMENT
RIVET HOLE (3.5)
INNER NIB HOLE (3.4)
DRIVE
SPLINE (3.9)
NOTE:
FEATURES ARE IDENTIFIED
FOLLOWED BY REPAIR
INSTRUCTION OUTLINE
NUMBER IN PARENTHESES
STANDARD GUIDELINES:
GENERAL REPAIRS (3.1)
WELD REPAIRS (3.11)
PAINT INSTRUCTIONS (3.12)
BACKING PLATE
NON–FRICTION (3.2 - LINING REMOVAL)
SIDE OF BACKING (3.3 - STRAIGHTENING)
PLATE (3.10) (3.6 - STOP DRILLING OF CRACKS)
(3.13 - RELINE)
SUPPORT
RIB
STATOR TORQUE
TUBE ELBOW TIE BOLT HOLE
THREADS (3.7)
MOUNTING
BOLT HOLE
AXLE MOUNTING
HOLE (3.8)
LAG-5013A
Illustration of Torque Tube Features and Repair References

Figure 614
Page 635
32-40-08
Apr 18/05
REPAIR
3.2 Stator Torque Tube (240) - Lining Removal From Backing Plate
CAUTION: ADEQUATELY SUPPORT THE BACKING PLATE TO PREVENT
INADVERTENT DAMAGE AND USE CARE TO PREVENT RIVET HOLE
DAMAGE.
A. Remove linings from stator torque tube using one of the following methods:
(1) Use a hydraulically or mechanically operated press fitted with a 0.250 inch
(6.35 mm) maximum diameter punch to deline the backing plate.
(2) Lay the backing plate on a drill press bed with the lining face up. Drill off the
countersunk portion of the rivet head using a 0.250 inch (6.35 mm) diameter
drill. Punch the remaining portion of the rivet out of the lining using a small
hand punch.
B. Inspect torque tube per the Check section for cracks and wear.
3.3 Stator Torque Tube (240) - Straighten Out-of-Flat Backing Plate

A. Straighten the stator torque tube backing plate per the ALS SPM (ATA 32-49-01).
Support the ribbed side of the stator torque tube backing plate flange on a steel
ring with a 1.0 inch (25 mm) minimum thickness and an ID of 15.5 inches (394 mm)
during the straightening process.
B. Inspect stator torque tube per the Check section backing plate straightness
requirements.
C. Inspect stator torque tube for cracks per the Check section to ensure straightening
process has not introduced new indications.
3.4 Stator Torque Tube (240) - Undersized or Damaged Lining Attachment and Nib Hole
Machining Repairs
A. Undersized or damaged lining attachment and nib holes may be reamed to the
specified dimensions as shown in Figure 615.
Page 636
32-40-08
Apr 18/05
REPAIR
NOTE:
CROSS SECTIONAL 0.11 (2.8) MAX
VIEW ILLUSTRATES
TYPICAL ALS 0.17 (4.3) MAX
COMPONENT
0.39 (9.9) MIN
DIA THRU
0.43 (10.9) MAX
0.255 (6.48) MIN 13 GROUPS OF 2 HOLES EACH
DIA THRU
0.290 (7.37) MAX
0.755 (19.18) MIN
DIA COUNTERSINK
0.775 (19.69) MAX
13 LOCATIONS TO DEPTH SHOWN
100° TO DIMENSION SHOWN
0.010 (0.25) MAX

REMOVE BURR
0.015 (0.38) R
MAX

Machine Repairs of Stator Torque Tube Backing Plate Lining Attachment and Nib Holes
Figure 615
Page 637
32-40-08
Apr 18/05
REPAIR
3.5 Stator Torque Tube (240) - Oversized Lining Attachment Hole Shouldered Washer
Repair
A. Oversized lining attachment holes may be repaired as shown in Figure 616 using a
fastener (209) when welding is not desirable. Blend and polish, but do not chamfer
holes.
0.571 - 0.564 (14.50 - 14.33) DIA THRU

0.76 - 0.74 (19.3 - 18.8) DIA COUNTERBORE
TO DEPTH SHOWN
0.005 - 0.020
(0.13 - 0.51) R
0.190 (4.83) BREAK CORNER

0.220 (5.59) 0.010 - 0.020 (0.25 - 0.51)

Shouldered Washer Repair of Stator Torque Tube Backing Plate Lining Attachment Hole
Figure 616
Page 638
32-40-08
Apr 18/05
REPAIR
3.6 Stator Torque Tube (240) - Stop Drilling of Backing Plate Cracks to Arrest Further
Growth
A. At operator option, cracks identified in the Check section that do not require
immediate weld repair may be stop drilled to arrest further growth. At the end of
crack, stop drill using a 0.125 inch (3.18 mm) drill bit. Cracks that exceed the
allowable limits specified in the Check section must be weld repaired if permitted.
3.7 Stator Torque Tube (240) - Tie Bolt Hole Thread Repair Instructions
A. Minor damage or corrosion identified in tie bolt hole threads may be repaired by
chasing the threads with a 0.4375-20 UNJF tap per AS8879 to a depth of 0.66 inch
(16.8 mm) minimum.
B. More extensive damage or corrosion in the tie bolt hole threads may be repaired by
installing a standard Heli-CoilR insert per the following procedure.
(1) Drill out holes using a 0.4531 inch (11.509 mm) diameter drill, 1.15 inch
(29.2 mm) deep.
(2) Countersink 0.50 inch (12.7 mm) by 120 degrees.
(3) Tap 0.75 inch (19.1 mm) min. deep using Heli-CoilR tap No. 44193-7.
(4) Remove chips.
(5) Install Heli-CoilR P/N 1191-7CN-0656 using Heli-CoilR gage No. 3694-7.
(6) Break off and remove tang.
3.8 Stator Torque Tube (240) - Axle Mounting Attachment Hole Repair Instructions
A. Damage or corrosion identified in axle mounting holes may be reamed to a
maximum diameter of 0.576 inch (14.63 mm) maximum.
B. Damage to the attachment hole that exceeds 0.576 inch (14.63 mm), but is not
outside the counterbore diameter, may be weld repaired per outline number 3.11.
Page 639
32-40-08
Apr 18/05
REPAIR
3.9 Stator Torque Tube (240) - General Blending and Burr Removal from Splines
A. Wear and damage to stator torque tube spline sides and top shall be repaired by
smoothing out irregularities and removing burrs with emery cloth or by hand
grinding within the limits of Figure 617.
B. Evaluate potential to weld repair damage that exceeds the specified blending limits.
C. If surface cracks were removed by grinding, inspect torque tube for cracks per the
Check section to ensure crack indications are completely removed.
Page 640
32-40-08
Apr 18/05
REPAIR
BLENDING PERMITTED
FULL LENGTH
DIAMETER “B” LINING
ATTACHMENT
RIVET HOLE
0.375 (9.53) MIN WELD REPAIR PERMITTED 0.90 (22.9) MIN

THIS LENGTH
NOTE:
WHEN OBTAINING MEASUREMENTS,
BRIDGE THE WEAR SPOT USING A
STRAIGHT EDGE RESTING ON THE
UNWORN SURFACES.
0.030 (0.76) MAX BLENDING PER WEAR SPOT.

BLENDING REPAIR IS NOT PERMITTED LESS THAN
MINIMUM SPLINE HEIGHT.
SPLINE WIDTH – 0.622 (15.80) 0.030 (0.76) MAX BLENDING ALLOWED

MINIMUM BEFORE WELD PER WEAR SPOT. BLENDING REPAIR MAY
REPAIR BE ACCOMPLISHED ON BOTH SIDES OF
SPLINE, BUT IS NOT PERMITTED LESS
WELD REPAIR MAY NOT BE THAN THE MINIMUM SPLINE WIDTH.
PERFORMED IF SPLINE
WIDTH IS LESS
THAN 0.550 (13.97)
SPLINE HEIGHT – 0.550 (13.97)

MINIMUM BEFORE WELD
REPAIR
WELD REPAIR MAY NOT BE

PERFORMED IF SPLINE
HEIGHT IS LESS
THAN 0.20 (5.1)

Torque Tube Spline Blending Allowances and Related Weld Restrictions

Figure 617
Page 641
32-40-08
Apr 18/05
REPAIR
3.10 Stator Torque Tube (240) - General Blending From Non-Friction Side of Backing
Plate
A. Heat checking and other defects between the ribs of the non-friction side of the
stator torque tube backing plate may be blended by hand grinding as defined in
Figure 618. When blending, do not remove material from the stator torque tube
backing plate ribs or the surface of the back radius of the torque elbow.
B. Evaluate potential to weld repair damage that exceeds the specified blending limits.
C. If surface cracks were removed by grinding, inspect stator torque tube for cracks
per the Check section to ensure crack indications are completely removed.
NO REPAIR ALLOWED
IN THIS AREA
3.15 (80.0)
WELD RESTRICTED WELD REPAIR ALLOWED
TO THIS SECTION OF ON BACKING PLATE RIBS
BACKING PLATE
REFERENCE MATERIAL REMOVAL PERMITTED

MEASUREMENTS FROM THIS SURFACE BETWEEN
FROM THIS THE BACKING PLATE RIBS DOWN
SURFACE TO THE LIMITS SPECIFIED
ALL AREAS BETWEEN BACKING

PLATE RIBS 0.110 (2.79) MINIMUM
ONE REPAIR BETWEEN EACH
PAIR OF RIBS MAY BE BLENDED
DOWN TO A THICKNESS OF 0.080
(2.03) MINIMUM, NOT TO EXCEED
AN AREA OF 0.5 SQUARE INCHES
(32.3 SQUARE MM).
Stator Torque Tube Backing Plate Blending Allowances and Related Weld Restrictions
Figure 618
Page 642
32-40-08
Apr 18/05
REPAIR
Page 643
32-40-08
Apr 18/05
REPAIR
3.11 Stator Torque Tube (240) - Weld Repairs For Identified Cracks, Worn Splines,
Oversized Lining Attachment, Nib, and Axle Mounting Holes
NOTE: Oversized lining attachment and nib holes, cracks identified per the Check
section that do not require the stator torque tube to be scrapped, worn or
damaged splines that do not require the stator torque tube to be scrapped, and
oversized axle mounting attachment holes may be weld repaired. Stator torque
tubes may be returned to service only with the permitted cracks identified in the
Check section.
A. Evaluate the Check section for maximum allowable crack sizes. Evaluate previous
outline numbers for maximum allowable wear limits. Scrap all torque tubes that
exceed documented limits.
B. Remove cracks with a saw cut. Do not cut beyond the limits illustrated per previous
outline numbers and Check section allowances. Bevel the edges of the saw cut on
one side. No weld repair is permitted at the base of the stator torque tube splines
near the backing plate or outside the counterbore diameter of the axle mounting
attachment holes as shown in Figure 619.
NOTE: When repairing splines, care must be exercised to repair all equally to
ensure uniform loading of the pressure and stator plates. When repairing
axle mounting attachment holes, exercise care to prevent distortion of the
mounting flange.
C. Perform allowable weld repair per the ALS SPM (ATA 32-49-01). Build up parent
metal with adequate weld to ensure full clean-up to dimensional limits specified in
Figures 619 and 620.
D. Following weld repair, machine welded stator torque tube features to the
requirements specified in Figures 619 and 620. Break all edges 0.010 inch (0.25
mm) maximum.
E. Inspect stator torque tube for cracks per the Check section to ensure weld repair
has not introduced new indications.
Page 644
32-40-08
Apr 18/05
REPAIR
0.11 - 0.09 (2.8 - 2.3)
0.17 - 0.15 0.42 (10.7)

(4.3 - 3.8) 0.39 (9.9) DIA THRU 13 GROUPS OF 2 HOLES EACH
0.960 (24.38)
0.920 (23.37)
0.255 (6.48)
0.765 (19.43) DIA COUNTERSINK 13 LOCATIONS TO DEPTH SHOWN
0.261 (6.63) DIA THRU
0.755 (19.18)
100° TO DIMENSION 0.010 (0.25) MAX

125
SHOWN REMOVE BURR (3.2 µm)
0.662 - 0.652
1.240 (31.50) (16.81 - 16.56)
1.200 (30.48)
0.015 (0.38) R MAX 0.120
13.08 (332.2)
(3.05) R
13.04 (331.2) DIA
NOTE: 0.58 - 0.61

TYPICAL CROSS (14.7 - 15.5)
SECTION VIEW
9.26 - 9.24
(235.2 - 234.7)
D
NO WELD NO WELD
0.375 (9.53) WELD PERMITTED 0.90 (22.9)
MIN THIS LENGTH MIN
0.140 (3.56)
0.110 (2.79)
6.816 (173.13)
3.15 (80.0) MAX 6.810 (172.97)
WELD PERMITTED
THIS ZONE 4.465 (113.41)
0.90 (22.9)
4.445 (112.90)
NO WELD DIA MAX 0.08 (2.0)
WELD 3.070 (77.98) x 45°
0.04 (1.0)
PERMITTED 3.060 (77.72)
15.92 (404.4)
DIA
15.88 (403.4)
8.58 (217.9)
DIA
8.54 (216.9)
0.04 (1.0)
R
0.03 (0.8)
0.12 (3.0)
0.11 (2.8)
9.26 (235.2) 0.390 (9.91)
DIA
9.24 (234.7) 0.380 (9.65)
4.29 (109.0)
DIA C
4.27 (108.5)
0.010 (0.25) D
5.395 (137.0)
DIA
5.355 (136.0)

Stator Torque Tube Machining Requirements, View 1, Following Weld Repair

Figure 619
Page 645
32-40-08
Apr 18/05
REPAIR
0.5695 - 0.5705
DIA THRU
(14.465 - 14.491)
0.90 - 0.86 (22.9 - 21.8) DIA COUNTERBORE
TO DIM SHOWN
0.70 - 0.66 (17.8 - 16.8) DIA X 90° INCLUDED ANGLE
12 HOLES
0.002 (0.05) C A
0.3888 - 0.3970
0.31 - 0.33 (7.9 - 8.4) DIA
(9.876 - 10.084)
DIA THRU 1 HOLE
1.15 (29.2) MIN DEEP
0.008 (0.20) D A 0.4375-20 UNJF-3B THREAD
0.66 (16.8) MIN DEEP PER AS8879
0.44 - 0.47 (11.2 - 11.9) DIA X 120°
COUNTERSINK
13 HOLES
0.008 (0.20) D A
8.58 (217.9)
8.54 (216.9)
3.720 (94.49)
3.680 (93.47)
5.395 (137.0)
5.355 (136.0)
1.364 (34.65)
1.324 (33.63)
2.347 (59.61)
2.307 (58.60)
2.707 (68.76)
2.667 (67.74)
0.34 - 0.36 (8.6 - 9.1) DIA THRU

0.020 (0.51) D A
ONE LOCATION
NOTE:
OLDER REVISIONS OF 1.364 (34.65)
STATOR TORQUE 1.324 (33.63)
TUBES HAVE ALL 13
SPLINES BORED 2.347 (59.61)
THROUGH. ONLY THIS 2.307 (58.60)
SPLINE NEEDS TO BE
RESTORED TO THE 2.707 (68.76)
THRU HOLE DIMENSION 2.667 (67.74)
FOLLOWING WELD.
Stator Torque Tube Machining Requirements, View 2, Following Weld Repair

Figure 620
Page 646
32-40-08
Apr 18/05
REPAIR
3.12 Stator Torque Tube (240) - Paint Instructions
A. At operator option, all surfaces of the stator torque tube may be painted. Repaired
areas of the stator torque tube can be locally touched up if there are small paint
imperfections. However, if the paint condition is generally poor, the stator torque
tube should be stripped of paint and repainted. As an alternative to paint, an
approved rust inhibitor may also be applied. Refer to the ALS SPM (ATA 32-49-01).
3.13 Stator Torque Tube (240) - Reline Stator Torque Tube Backing Plate
A. Procure linings and rivets specified per the Assembly section and the IPL. If torque
tube lining attachment holes were repaired using fastener (209), these will need to
be procured as well.
B. Reline stator torque tube backing plate using required parts. Refer to the ALS SPM
(ATA 32-49-01).
Page 647
32-40-08
Apr 18/05
REPAIR
D. Pressure Plate (205) and Stator Plate (225) Repair Instructions.
4.1 Pressure Plate (205) and Stator Plate (225) - General Repair Instructions
out the area of damage or corrosion and relieve all sharp corners or indentations,
which could result in stress concentrations. The repair should result in a smooth,
contoured area blended into the adjacent untouched surfaces.
B. Figure 621 identifies areas of the pressure plate and stator plate that have specific
repairs permitted. Adhere to documented repair allowances.
surface.
D. Following repairs, ALS suggests coating all plate surfaces with an approved paint
or rust inhibitor. Refer to the ALS SPM (ATA 32-49-01).
Page 648
32-40-08
Apr 18/05
REPAIR
WEAR PIN RETAINER

ATTACHMENT
HOLE – 2 PLACES (4.4)
ADJUSTER PIN ATTACHMENT
HOLE SLOT – 4 PLACES (4.4)
NIB HOLES – 13 GROUPS

OF 2 HOLES EACH (4.4)
PRESSURE PLATE
DRIVE SLOTS LINING ATTACHMENT

STANDARD GUIDELINES 13 PLACES HOLE – 13 PLACES
GENERAL REPAIRS (4.1) (4.4–REAMING)
LINING REMOVAL (4.2) (4.5–SHOULDERED WASHER)
STRAIGHTENING (4.3)
WELD (4.7)
PAINT (4.8)
RELINE (4.9)
NOTE:
FEATURES ARE IDENTIFIED FOLLOWED BY STATOR PLATE ILLUSTRATION IS
REPAIR INSTRUCTION OUTLINE NUMBER FOR MOST CURRENT STATOR
IN PARENTHESES PLATE. ID HEAT SLOTS NOT
NIB HOLES – 13 GROUPS USED ON SUPERSEDED STATOR
OF 2 HOLES EACH (4.4) PLATES.
LINING ATTACHMENT
HOLES – 13 PLACES (4.4)
OD HEAT
RELIEF SLOTS
STATOR PLATE ID HEAT

RELIEF SLOTS (4.6)
DRIVE SLOTS
13 PLACES (4.7)
LAG-5005A
Pressure Plate and Stator Plate Features and Repair References
Figure 621
Page 649
32-40-08
Apr 18/05
REPAIR
4.2 Pressure Plate (205) and Stator Plate (225) - Lining Removal from Plate
CAUTION: ADEQUATELY SUPPORT THE PLATE TO PREVENT INADVERTENT
DAMAGE AND USE CARE TO PREVENT RIVET HOLE DAMAGE.
A. Remove linings from plates using one of the following methods:
(1) Use a hydraulically or mechanically operated press fitted with a 0.250 inch
(6.35 mm) maximum diameter punch to deline the plate.
(2) Lay the plate on a drill press bed with the lining face up. Drill off the
countersunk portion of the rivet head using a 0.250 inch (6.35 mm) diameter
drill. Punch the remaining portion of the rivet out of the lining using a small
hand punch.
B. If damaged, or if pressure plate is to be straightened, remove wear pin retainers
(195) from pressure plate using one of the above methods. Use a 0.200 inch (5.08
mm) maximum diameter punch or drill bit as required.
C. Inspect plate per the Check section for cracks and wear.
4.3 Pressure Plate (205) and Stator Plate (225) - Straighten Out-of-Flat Plate
NOTE: Remove pin retainers (195) from pressure plate prior to straightening.
A. Straighten plates per the ALS SPM (ATA 32-49-01). If a straightening die is used,
fabricate with a 8.72 inch (221.5 mm) ID and a 16.00 inch (406.4 mm) OD per the
ALS SPM (ATA 32-49-01) requirements.
B. Inspect plates per the Check section plate maximum out-of-flat requirements.
C. Inspect plates for cracks per the Check section to ensure straightening process has
not introduced new indications.
4.4 Pressure Plate (205) and Stator Plate (225) - Undersized or Damaged Wear Pin
Retainer Attachment, Lining Attachment, and Nib Hole Machining Repairs
A. Undersized or damaged wear pin attachment holes in the pressure plate may be
reamed to the specified dimensions as shown in Figure 622.
B. Undersized or damaged lining attachment and nib holes may be reamed to the
specified dimensions as shown in Figure 622 for pressure plates and Figure 623 for
stator plates.
Page 650
32-40-08
Apr 18/05
REPAIR
0.390 (9.91)
REAM DIA THRU
0.430 (10.92) 0.11 (2.8)
0.09 (2.3)
A 0.17 (4.3)
0.94 (23.9) R
B 0.15 (3.8)
REMOVE BURRS
0.010 (0.25) MAX
99° - 101°
0.755 - 0.775
(19.18) - (19.69) DIA
B COUNTERBORE
1.22 (31.0) R TO DIM SHOWN
0.015 (0.38) R MAX
REMOVE BURRS
0.010 (0.25) MAX
SECTION A–A
0.255 (6.48)
DIA THRU
0.290 (7.37)
A 0.10 (2.5) MIN
0.03 (0.8) R MAX
0.220 (5.59) MAX

DIA THRU
SECTION B–B
Machine Repairs of Pressure Plate Nib and Lining and Pin Retainer Attachment Holes
Figure 622
Page 651
32-40-08
Apr 18/05
REPAIR
0.775 (19.69)
REAM DIA THRU
0.755 (19.18)
0.430 (10.92)
REAM DIA THRU
0.390 (9.91)
0.94 (23.9) R
MAX
STATOR PLATE ILLUSTRATION IS

FOR MOST CURRENT STATOR
PLATE. ID HEAT SLOTS NOT
USED ON SUPERSEDED STATOR
1.22 (31.0) R PLATES.
MAX

Machine Repairs of Stator Plate Nib and Lining Attachment Holes

Figure 623
Page 652
32-40-08
Apr 18/05
REPAIR
4.5 Pressure Plate (205) - Oversized Lining Attachment Hole Shouldered Washer Repair
A. When welding is not desirable, oversized lining attachment holes in the pressure
plate may be repaired as shown in Figure 624 using a fastener (209). Blend and
polish, but do not chamfer holes.
0.571–0.564 (14.50–14.33) DIA THRU

BREAK CORNER 0.76–0.74 (19.3–18.8) DIA COUNTER BORE TO DEPTH SHOWN
0.010 - 0.020 (0.25 - 0.51) R
0.09 (2.3) 0.005 - 0.020 (0.13 - 0.51) R

0.08 (2.0) NON-LINED SURFACE
14.500 (368.30) DIA

Shouldered Washer Repair of Pressure Plate Lining Attachment Hole

Figure 624
Page 653
32-40-08
Apr 18/05
REPAIR
4.6 Stator Plate (225) - Drill Repair of Cracks at Termination Hole of OD Heat Relief Slot
A. When welding is not desirable, cracks originating from the termination hole of the
OD heat relief slot in the stator plate may be drill repaired as shown in Figure 625.
Blend and polish, but do not chamfer holes.
DRILL REPAIR NOT

PERMITTED ON ID
HEAT RELIEF SLOT
125 (3.2 µm)

DIM “A”
MACHINE END OF SLOT 0.36 - 0.40
(9.1 - 10.2) DIA TO REMOVE CRACK
DRILL REPAIRS MUST NOT BREAK EDGES OF HOLE 0.01 - 0.05
EXTEND INTO DIM “A” AREA (0.3 - 1.3)

DIM “A”:
Dimension
Stator Plate P/N Inches (mm)
2606712 0.84 (21.3) Minimum
2608214 1.11 (28.2) Minimum
2614056 1.11 (28.2) Minimum
Drill Repair of the Stator Plate ID Heat Relief Slot

Figure 625
Page 654
32-40-08
Apr 18/05
REPAIR
Page 655
32-40-08
Apr 18/05
REPAIR
4.7 Pressure Plate (205) and Stator Plate (225) - Weld Repairs For Identified Cracks,
Oversized Backing Plate Lining Attachment and Nib Holes, Worn Drive Slots, and
Oversized Wear Pin Retainer Holes and Pin Attachment Slots
NOTE: Oversized lining attachment and nib holes, cracks identified per the Check
section that do not require the plate to be scrapped, worn or damaged drive slots
that do not require the plate to be scrapped, and oversized pressure plate pin
retainer attachment holes and pin attachment slots may be weld repaired.
Plates may be returned to service only with the permitted cracks identified in the
Check section.
A. Evaluate the Check section for maximum allowable crack sizes and wear limits.
Scrap all plates that exceed documented limits.
NOTE: When repairing the drive slots of stator or pressure plates, care must be
exercised to repair all equally to ensure uniform loading.
B. Remove cracks and damage. When removing cracks from the termination hole of
the outer heat relief slot, the saw cut must not extend into the area specified in
Figure 626.
C. Perform allowable weld repairs on pressure plates per the ALS SPM (ATA
32-49-01). Build up parent metal with adequate weld to ensure full clean-up to
dimensional limits shown in Figure 627 for pressure plates and Figure 628 for stator
plates.
D. Following weld repair, machine welded features on the pressure plates as shown in
Figure 627 and for stator plates as shown in Figure 628. Break all edges 0.010
inch (0.25 mm) maximum.
E. Inspect plate for cracks per the Check section to ensure weld repair has not
introduced new indications.
F. Inspect out-of-flat condition after weld repair.
Page 656
32-40-08
Apr 18/05
REPAIR
CRACK OR SAW
CUT MUST NOT
EXTEND INTO
THIS AREA
DIM “A” MIN
SAW CUT TO
REMOVE CUT
LAG-5018
DIM “A”:
Dimension
Stator Plate P/N Inches (mm)
2606712 0.84 (21.3) Minimum
2608214 1.11 (28.2) Minimum
2614056 1.11 (28.2) Minimum
Stator Plate Crack and Damage Removal Machining Allowances Prior to Weld Repair
Figure 626
Page 657
32-40-08
Apr 18/05
REPAIR
0.42 (10.7)
0.39 (9.9) DIA THRU
13 GROUPS OF 2 HOLES EACH EQUALLY SPACED
AND LOCATED WITHIN 0.020 (0.5) OF RADIAL
CENTERLINE OF LINING ATTACHMENT HOLE
6.482 (164.64)
0.765 (19.43) 5.374 (136.50)
0.756 (19.20) DIA COUNTERBORE
TO DIMENSION SHOWN - 13 PLACES 3.035
EQUALLY SPACED AND (77.09)
LOCATED AS SHOWN
3.710 6.530
(94.23) (165.86)
6.460 0.18R 0.787 5.782

(164.08) (4.6) (19.99) (146.86)
8.720
1.852 (47.04) (221.49) DIA 13.06 (331.7) DIA
2.316 6.340
(58.83) (161.04)
27° 41’ REF
0.690 (17.53)
0.682 (17.32) 5.00
(127.0) 4.888
(124.16)
1.220 (30.99) R
0.940 (23.88) R
1.563
27° 41’ 32” (39.70)
13 PLACES
4.330 (109.98) NOTE:
PART IS SYMMETRICAL ABOUT ± 0.020 (0.51) TOLERANCE
THIS CENTERLINE, EXCEPT 6.106 (155.09) UNLESS OTHERWISE
0.200 - 0.210 (5.08 - 5.33) DIA INDICATED
AND 0.38 (9.6) DIA
COUNTERSINK HOLES.
Pressure Plate Machining Allowances Following Weld Repair

Page 658
32-40-08
Apr 18/05
REPAIR
0.015 (0.38) R 0.030 (0.76)

MAX MAX
0.110
(2.79)
100° TO DIM SHOWN 0.210 (5.33)

16.03 (407.2)
13 PLACES 0.200 (5.08) DIA THRU
16.00 (406.4) DIA 0.380 (9.65) DIA
0.261 (6.63) COUNTERSINK TO DIM
0.255 (6.48) DIA THRU SHOWN 2 PLACES
SECTION B–B
REMOVE BURRS
0.010 (0.25) MAX
BOTH SIDES
REMOVE BURRS 26 HOLES
0.010 (0.25) MAX A
0.100 (2.54)
0.160 (4.06)
0.290 (7.37)
0.280 (7.11)
SECTION A–A
A
B
B
REMOVE BURRS
0.010 (0.25) MAX
D
C C
SECTION C–C D
0.75 (19.1) R
0.52 (13.2)
0.110 (2.79)
0.020
0.020 (0.51) (0.51) R NOTE:
MAX ± 0.020 (0.51) TOLERANCE
0.005 (0.13)
UNLESS OTHERWISE
BREAK EDGE
INDICATED
SECTION D–D

Pressure Plate Machining Allowances Following Weld Repair

Page 659
32-40-08
Apr 18/05
REPAIR
0.208 (5.28)
125 (3.2 µm) 0.192 (4.88)
NO BREAKOUT
PERMITTED BREAK EDGE
0.010 - 0.050 16.030 (407.16) REMOVE BURRS
(0.25 - 1.27) 16.000 (406.40) 0.010 (0.25) MAX
SECTION B–B
BOTH SIDES
26 HOLES
6.482 (164.64)
SECTION A–A
NOTE: 5.374 (136.50) 27° 41’ 32”
± 0.020 (0.51) TOLERANCE
13 PLACES
UNLESS OTHERWISE 3.035 0.765 (19.43)
INDICATED (77.09) DIA THRU
A 0.755 (19.18)
13 HOLES EQUALLY
SPACED AND
LOCATED AS SHOWN
5.782 0.730 (18.54)

(146.86) 0.718 (18.24)
A
13° 50’ 46”

6.530 3.710
(165.86) (94.23) 12.27 (311.6) DIA
0.625
R
(15.88)
0.787 8.740 (222.00) 13.06 (331.7) DIA

(19.99) 8.700 (220.98)
4.889
DIA
(124.18) 12.84 (326.1) DIA
0.21 (5.3)
0.17 (4.3) 4.90
6.340 2.316 1.22 (124.5)
(161.04) (58.83) R
(31.0)
B B
0.940
R
(23.88)
0.42 (10.7)
DIA THRU 1.563
0.39 (9.9)
(39.70) 27° 41’ 32” 55° 23’ 4”
13 GROUPS OF 2 HOLES
EACH, EQUALLY SPACED 6 PLACES
4.330 (109.98)
AND LOCATED WITHIN
0.020 (0.5) OF RADIAL
CENTERLINE OF LINING 6.106 (155.09) 13 SLOTS EQUALLY SPACED
ATTACHMENT HOLE AND LOCATED AS SHOWN
PART IS SYMMETRICAL
ABOUT THIS CENTERLINE DIMENSIONS ARE PROVIDED IN INCHES WITH
Stator Plate Machining Requirements Following Weld Repair

Figure 628
Page 660
32-40-08
Apr 18/05
REPAIR
4.8 Pressure Plate (205) and Stator Plate (225) - Paint Instructions
A. At operator option, all surfaces of the plates may be painted. Repaired areas can
be locally touched up if there are small paint imperfections. However, if the paint
condition is generally poor, the plate should be stripped of paint and repainted. As
an alternative to paint, an approved rust inhibitor may also be applied. Refer to the
ALS SPM (ATA 32-49-01).
4.9 Pressure Plate (205) and Stator Plate (225) - Installation of Wear Pin Retainers and
Relining of Plates
A. If the wear pin retainers (195) were previously removed from pressure plate,
procure required replacement parts and rivet into place. This must be
accomplished prior to riveting linings into place. Refer to the ALS SPM (ATA
32-49-01).
B. Procure linings and rivets specified per the Assembly section and the IPL. If
pressure plate lining attachment holes were repaired using fastener (209), these
must also be procured.
C. Reline plate using required parts. Refer to the ALS SPM (ATA 32-49-01).
Page 661
32-40-08
Apr 18/05
REPAIR
E. Rotor Assembly (210, 211, 212, 213, Service Parts) Repair Instructions.
5.1 Rotor Assembly (210, 211, 212, 213, Service Parts) - General Repair Instructions
A. Burrs and all sharp corners may be locally blended from spider, rotor segment, and
rotor strap edges.
B. Figure 629 identifies areas of the rotor assemblies that have specific repairs
permitted. Adhere to documented repair allowances. Replacement of parts within
the rotor assembly is not permitted.
C. Following completion of all rotor repairs, weigh each rotor assembly and mark the
weight on a rotor segment surface for assembly purposes. Rotors that do not meet
minimum rotor weight requirements as identified in the Check section must be
scrapped.
D. Following repairs, ALS suggests coating all plate surfaces with SAE #10 or SAE
#20 oil to prevent corrosion if rotors will not be reused immediately.
Page 662
32-40-08
Apr 18/05
REPAIR
ROTOR STRAPS
A
RIVET
SPIDER
A SECTION A – A
SPIDER ID
ROTOR SEGMENT ROTOR SEGMENTS

ID EDGES (5.3) WEAR SURFACES (5.2)
NOTE:
STANDARD GUIDELINES
FEATURES ARE IDENTIFIED FOLLOWED BY
GENERAL REPAIRS (5.1)
REPAIR INSTRUCTION OUTLINE NUMBER
IN PARENTHESES
LAG-4869
Rotor Assembly Features and Repair References

Figure 629
Page 663
32-40-08
Apr 18/05
REPAIR
5.2 Rotor Assembly (210, 211, 212, 213, Service Parts) - Grinding of Rotor Segment
Wear Surfaces
NOTE: ALS strongly encourages grinding the wear surfaces of the rotor segments. ALS
laboratory testing has confirmed that higher lining wear rates can occur during
the first several stops with non-surface ground rotors resulting in approximately
5% lower brake life. Clean-up of 30 - 50% should be accomplished between
each reuse.
NOTE: ALS studies have shown that grinding beyond 50% clean-up yields no additional
benefit. However, at operator discretion, grinding in excess of 50% may be
performed to facilitate brake running clearance.
NOTE: Based on individual operator experience, grinding less than 30% may be
acceptable.
CAUTION: EXCESSIVE GRINDING OF ROTOR STRAPS AND RIVETS MAY
RESULT IN RIVET PULL-THROUGH. USE CARE TO MINIMIZE
MACHINING ON STRAP AND RIVET HEAD SURFACES. IN SOME
WORN CONDITIONS, GRINDING OF THE FORMED RIVET END WILL
BE NECESSARY AND IS ALLOWED, AS LONG AS MINIMUM
RETAINING STRAP THICKNESS IS NOT VIOLATED. ROTOR STRAP
MINIMUM THICKNESSES ARE DEFINED IN THE CHECK SECTION.
A. Remove high spots and rough or uneven surfaces from the rotor segment surfaces
to promote uniform lining wear by light grinding. Surface grinding clean-up of
30 - 50% is suggested. Grinding of the rotor strap, rivet head, and formed end is
permitted, as long as damage limits are maintained as identified in the Check
section.
5.3 Rotor Assembly (210, 211, 212, 213, Service Parts) - Removal of Extruded ID Edges
CAUTION: AVOID DAMAGE TO ROTOR SPIDER DURING GRINDING.
A. Extruded edges of rotor segments that extend more than 0.125 inch (3.18 mm)
beyond the ID of the rotor spider should be ground or turned flush with rotor spider
ID.
Page 664
32-40-08
Apr 18/05
REPAIR
F. Piston Bushing (150, 151) Repair Instructions.
6.1 Piston Bushing (150, 151) - Repair Instructions

A. Minor damage and roughness on the ID surface of the piston bushing may be
repaired, as long as the hardcoat surface has not been worn through to the base
metal. Smooth any surface roughness on the operating surfaces using a fine
polishing cloth. The repaired area should be smoothly blended into the adjacent
untouched surface. Dimensional limits after repair must not exceed those specified
in the Check section.
B. If the hardcoat surface has been worn through, the remaining hardcoat surface of
the piston bushing may be removed and replaced by chrome plating per the ALS
SPM (ATA 32-49-01). Following completion of this process, the ID surface must be
restored to a diameter of 1.491 - 1.493 inches (37.87 - 37.92 mm) or 1.553 - 1.555
inches (39.45 - 39.50 mm).
C. Slight damage to the bushing threads may be repaired by reforming the threads.
D. Surface treat bare aluminum areas, as permitted, of the piston bushing per the ALS
SPM (ATA 32-49-01).
Page 665
32-40-08
Apr 18/05
REPAIR
G. Piston (140, 141) Repair Instructions.
7.1 Piston (140, 141) - Repair Instructions

A. Minor damage and roughness on the OD surface of the piston may be repaired
within the dimensional limits specified in the Check section. Smooth any surface
roughness using a fine polishing cloth. The repaired area should be smoothly
blended into the adjacent untouched surface. No blending is permitted in the
packing groove.
Page 666
32-40-08
Apr 18/05
REPAIR
H. Machine (Tie) Bolt (15) Repair Instructions.
8.1 Machine (Tie) Bolt (15) - Repair Instructions

A. Localized corrosion and mechanical damage may be removed with emery paper,
crocus cloth, or equivalent, up to a maximum depth of 0.016 inch (0.41 mm) in the
unthreaded shank area of the machine (tie) bolt. Repair must be a minimum of
0.30 inch (7.6 mm) below the flat on the underside or bearing face of the machine
(tie) bolt head. The repaired area should be smoothly blended into the adjacent
untouched surfaces.
B. Minor mutilation of the thread crests of the machine (tie) bolt should be polished out
with medium grade abrasive paper or stone.
C. Repeated assembly and disassembly along with normal maintenance activities will
degrade the cadmium plating. If corrosion occurs as a result of cadmium plating
loss, operators may choose to restore the cadmium plating as a preventive
measure. Bolts may be replated per the ALS SPM (ATA 32-49-01).
Page 667
32-40-08
Apr 18/05
REPAIR
Page 668
32-40-08
Apr 18/05
ASSEMBLY
1. Tabular Definition of Assembly Requirements.
Topic Description
General Tabular The Assembly section is presented using a tabular format to organize
Overview the assembly instructions. A breakdown of the tabular format is as
follows:
- Column 1 identifies the outline number for the assembly
properly assemble the specified part or sub-assembly.
Breakdown of Assembly paragraphs are broken down as follows:
Assembly Paragraph Page
Paragraphs
2.A. General Assembly Guidelines . . . . . . . . . . . . . . . . . 702
2.B. Hydraulic Packing Assembly Guidelines . . . . . . . . . 703
2.C. Piston and Bushing Assembly . . . . . . . . . . . . . . . . . 704
2.D. Piston Housing Assembly . . . . . . . . . . . . . . . . . . . . . 712
2.E. Heat Stack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 720
2.F. Final Brake Assembly Instructions . . . . . . . . . . . . . . 734
Superseded Piston Aircraft Landing Systems (ALS) no longer supplies components for
Insulator Assembly assembly of piston and bushing components used in the original
Instructions P/N 2606672-1 brake assembly. These include components required to
assemble the internal piston insulator and are identified in the Brake
Assembly Exploded View (Figure 1001) as “-1 Superseded”. As these
components have been superseded, assembly of them is no longer
detailed in this Assembly section. Brakes that are built with these
components should be upgraded at next service.
Brake P/N Assembly of the current P/N 2606672-1 and P/N 2606672-2/-3/-4 brake
2606672-1 assemblies are very similar. Most instructions in the assembly section are
Assembly applicable for both brake assemblies. However, there are slight deviations
Instructions between some part numbers. Specific references to item numbers from
the Illustrated Parts List (IPL) are primarily for P/N 2606672-2/-3/-4 brake
assemblies. When assembling the P/N 2606672-1 brake assembly, refer
to the Brake Assembly Exploded View (Figure 1001) to ensure the correct
part is being installed.
Page 701
32-40-08
Apr 18/05
ASSEMBLY
2. Assembly Instructions.
A. General Assembly Guidelines.
1.1 General Instructions Applicable to the Assembly Section

NOTE: All used components must be inspected per the Check section and repaired per
the Repair section, if required. Components failing to meet the documented
service limits shall not be reinstalled in the brake.
section. The IPL item numbers referenced in this section are for assembly of a
P/N 2606672-2, -3, or -4 brake assembly. When assembling a P/N 2606672-1
brake assembly, refer to the applicable assembly instruction and identify the
required component from the Brake Assembly Exploded View (Figure 1001).
A. Only those components identified in the exploded view illustration, Figure 1001, and
listed in the IPL or other service documentation approved by ALS, may be installed
in the brake assembly.
B. Perform all assembly operations in a clean area. For proper brake operation, it is
essential to prevent dirt, grit, and other foreign matter from entering the piston
MANUFACTURER WHEN WORKING WITH HYDRAULIC FLUID
PER BOEING SPECIFICATION BMS 3-11. IF HYDRAULIC FLUID
IS SPLASHED IN EYES, IMMEDIATELY WASH FOR AT LEAST 10
MINUTES IN A STREAM OF RUNNING WATER. FLUID IN
CONTACT WITH HANDS, FACE, OR BODY SKIN CAN BE
WASHED OFF WITH ORDINARY SOAP AND WATER. SHOULD
IRRITATION PERSIST, A PHYSICIAN SHOULD BE CONSULTED.
CAUTION: DO NOT ALLOW SPILLED HYDRAULIC FLUID TO REMAIN ON
BRAKE ASSEMBLY. WIPE ALL SURFACES IMMEDIATELY WITH A
DRY, LOW LINT, ABSORBENT CLOTH.
C. The brake assembly is designed to operate using hydraulic brake fluid per Boeing
D. For brakes that are being partially rebuilt, adjuster tubes (36) must be replaced if a
different piston housing and plugs assembly (160), stator torque tube (240),
pressure plate (205), stator plate (225), or rotor assemblies (210, 211, 212, 213)
are substituted in the brake assembly.
E. Component level check, repair, and assembly instructions for the bulkhead coupling
half (67) and disconnect should be coordinated with the supplier listed in the IPL.
Page 702
32-40-08
Apr 18/05
ASSEMBLY
B. Hydraulic Packing Assembly Guidelines.
2.1 Hydraulic Packing Assembly Guidelines - Instructions Applicable to the Assembly

of Hydraulic Packings
NOTE: Do not use any packings or packing retainers other than those specified in the
IPL.
NOTE: If a packing or packing retainer becomes twisted, cut, or nicked during
installation, remove and discard.
NOTE: When assembling the P/N 2606672-1 brake assembly, two packing retainers are
assembled in each of the piston and bushing packing grooves. The packing is
installed between the packing retainer. When assembling the
P/N 2606672-2/-3/-4 brake assemblies, only one packing retainer is installed on
the non-pressure side of each groove.
A. Packing retainers should not be intentionally stretched to aid installation.
B. Special tooling is required to properly size the continuous packing retainers after
installation. Tooling P/N references will be provided in the illustrations during the
assembly steps. Refer to the Special Tools, Fixtures, and Equipment section.
CAUTION: TOOLS WITH SHARP EDGES OR POINTS SHOULD NOT BE USED
DURING THE INSTALLATION PROCESS. EVEN WHEN USED
CAREFULLY, THESE TOOLS OFTEN DAMAGE THE PACKINGS AND
PACKING RETAINERS. ALS RECOMMENDS USE OF A SMOOTH,
SPLINTER-FREE WOODEN TOOL, POLISHED BRASS TOOL OR THE
INSTALLER’S THUMB WHEN INSTALLING PACKING RETAINERS AND
PACKINGS. ALL TOOLING SHOULD BE THOROUGHLY CLEANED
BEFORE EACH USE.
C. Maintain a clean work environment when assembling the piston and bushing
assemblies.
D. ALS does not recommend that parts be dipped or soaked in hydraulic fluid prior to
installation. Instead, packing retainers and packings should be installed dry. Prior
to installation, a light application of the appropriate fluid should be applied to the
packing groove. The fluid should not drip or run. Following installation, 100% of
the packing surface should be wetted with the appropriate fluid.
E. Store subassembled components and complete piston and bushing assemblies in a
clean, sealed container, free of dust or other contaminates. Sealing the assembled
hardware in plastic bags compatible with the hydraulic fluid is suggested.
Page 703
32-40-08
Apr 18/05
ASSEMBLY
C. Piston and Bushing Assembly.
3.1 Piston and Bushing Assembly - Piston Guide and Compression Spring Installation
A. Set piston housing and plugs assembly (160), mating face down, on assembly
bench.
NOTE: At operator option, and if space permits, two anti-abrasion sheets may be
installed in repaired cavities to minimize wear of the cavity wall.
B. Install helical compression spring (65) into adjuster spring cavity. Insert
anti-abrasion sheet (64) between cavity wall and helical compression spring (65).
C. Insert washer (61), with flat side down, against helical compression spring (65).
See Figure 701.
D. Insert internal retaining ring (55) over washer (61). At this point, the retaining ring
will not sit in the retaining ring groove.
WARNING: BE CERTAIN THAT INTERNAL RETAINING RING (55) IS FULLY
SEATED IN THE GROOVE IN THE INSIDE DIAMETER (ID) OF THE
ADJUSTER SPRING CAVITY BEFORE RELEASING PRESSURE
ON HELICAL COMPRESSION SPRING (65).
CAUTION: DEPRESS HELICAL COMPRESSION SPRING (65) AND WASHER
(61) ONLY ENOUGH TO INSTALL INTERNAL RETAINING RING
(55). AVOID LOADING THE SPRING RETAINER AGAINST THE
SHOULDER ON THE ID OF THE ADJUSTER SPRING CAVITY.
E. Using arbor press and suitable adapter as shown in Figure 701, depress helical
compression spring (65) only enough to install internal retaining ring (55) into
groove.
F. Inspect installation of spring to be certain the anti-abrasion sheet has not become
wrinkled in the bottom of the spring cavity, preventing the spring from seating
properly.
Page 704
32-40-08
Apr 18/05
ASSEMBLY
PRESSURE
DRIVER
WARNING:
BEFORE RELEASING PRESSURE,
ENSURE INTERNAL RETAINING RING
IS FULLY SEATED IN THIS GROOVE.
INTERNAL
RETAINING
RING
WASHER
CAUTION:
SPRING AVOID LOADING SPRING
RETAINER AGAINST THIS
SHOULDER. DEPRESS ONLY
ENOUGH TO INSTALL
INTERNAL RETAINING RING.
PISTON
HOUSING
AND PLUGS
ASSEMBLY
ANTI–ABRASION
SHEET
LAG-1433E
Compression Spring Installation into Piston Housing

Figure 701
Page 705
32-40-08
Apr 18/05
ASSEMBLY
3.2 Piston and Bushing Assembly - Piston OD Packing Installation
NOTE: At a minimum, new packings are to be used on the piston at each overhaul.
NOTE: Review Paragraph 2.B., “Hydraulic Packing Assembly Guidelines” for additional
information regarding packing installation.
A. As shown in Figure 702, View 1, assemble backup packing ring (111) in the outside
diameter (OD) packing groove of piston (141) as follows:
(1) Lightly lubricate OD packing groove of piston with clean hydraulic brake fluid
per Boeing Specification BMS 3-11.
(2) Start continuous packing retainer on one side of the reduced lip of the
packing groove, and then work it circumferentially into the groove using a
smooth, splinter-free wooden tool or the installer’s thumb. Be sure the
retainer is not twisted.
(3) Install the split spacer ring tool in the groove adjacent to the reduced
diameter of the piston bushing as illustrated.
(4) Install the compression sleeve, tapered end first, over the non-packing
groove end of the piston. Push the compression sleeve over the packing
retainer, hold momentarily, and then remove. Repeat this process one to
two more times to properly size the packing retainer. Depending on climatic
conditions, the compression sleeve may need to be held in-place for an
extended period to allow sufficient time for the packing retainer to return to
original size.
(5) Following sizing, remove the sleeve and split spacer ring tool. Inspect the
packing retainer to see if it looks the same as it did in the free state. Ensure
that the packing retainers are not wavy, coned, or twisted. Remove and
discard if required.
B. Slide backup packing ring (111) forward in the packing groove and install packing
(116) in the groove as shown in Figure 702, View 2. Ensure packing is not twisted
in the groove.
C. After installation, lightly lubricate the packing surface with clean hydraulic brake
fluid per Boeing Specification BMS 3-11.
D. If immediate use of the piston subassembly is not required, store in a clean, sealed
container that is free of dust or other contaminates.
Page 706
32-40-08
Apr 18/05
ASSEMBLY
SPACER COMPRESSION
RING SLEEVE
INSTALL PACKINGS/ INSTALL COMPRESSION

RETAINERS FROM SLEEVE TAPERED END
THIS END OF FIRST FROM THIS END
PISTON OF PISTON
PACKING
RETAINERS PISTON
PACKING
RETAINER
PACKING NOTE:
RETAINERS VIEW 1 COMPRESSION SLEEVE
AND SPACER RING TOOLS
MUST CONFORM TO
FIGURE 906
–1 ONLY
–1 ONLY
NOTE:
FOR THE P/N 2606671-1
BRAKE ASSEMBLY, ONLY
TWO PACKING RETAINERS
ARE REQUIRED. INSTALL
AS INDICATED. USE
COMPRESSION SLEEVE
AND SPACER RING
CONFORMING TO PACKING PACKING
FIGURE 905. RETAINER
VIEW 2
LAG-5026
Piston OD Packing and Backup Packing Ring Installation
Figure 702
Page 707
32-40-08
Apr 18/05
ASSEMBLY
3.3 Piston and Bushing Assembly - Piston Wiper Installation and Installation of Piston
Into Bushing
NOTE: At a minimum, a new piston wiper (146) should be used on the piston bushing at
each overhaul.
NOTE: Do not use any wipers other than those specified in the IPL.
A. Lightly lubricate ID groove of piston bushing with clean hydraulic brake fluid per
Boeing Specification BMS 3-11.
B. Install piston wiper (146) in the groove on the ID of piston bushing (151). Be sure
that the wiper lip is positioned as shown in Figure 703. If wiper is twisted, nicked, or
kinked during installation, remove and discard.
NOTE: Use of the compression sleeve when installing piston into piston bushing
bore will help prevent packing and packing retainer damage.
C. Obtain pre-assembled piston with packing/packing retainer installed. Install the
compression sleeve, tapered end first, over the non-packing groove end of the
piston. Push the compression sleeve over the packing retainers and packing. Hold
the sleeve on the packing/packing retainers momentarily, providing one last
opportunity for sizing the packing retainer.
D. Lightly lubricate the bore of the piston bushing with clean hydraulic brake fluid per
Boeing Specification BMS 3-11. Fluid should not run or drip.
E. Push the piston assembly into the lubricated piston bushing (151) by aligning the
piston assembly through the piston wiper (146) and applying gradual pressure until
the piston is fully inserted through the wiper. Push the piston into the piston
bushing approximately 1.0 inch (25 mm) and then pull back approximately 0.5 inch
(13 mm). If extreme difficulty is encountered, disassemble and inspect for damage.
Otherwise, push piston so it extends just beyond the face of the piston bushing.
F. If immediate use of the piston and piston bushing subassembly is not required,
store in a clean, sealed container that is free of dust or other contaminates.
Page 708
32-40-08
Apr 18/05
ASSEMBLY
NOTE:
FOR THE P/N 2606672-1
BRAKE ASSEMBLY, ONLY
TWO PACKING RETAINERS FOR
ARE REQUIRED. USE P/N 2606672-1
COMPRESSION SLEEVE ONLY
CONFORMING TO
–1 ONLY FIGURE 905.
WIPER
RING WIPER
RING
PACKING PACKING
RETAINER RETAINER
PACKING COMPRESSION PACKING

SLEEVE
NOTE:
COMPRESSION SLEEVE
MUST CONFORM TO
FIGURE 906
Piston Wiper Installation Into Bushing and Installation of Piston Into Piston Bushing
Figure 703
Page 709
32-40-08
Apr 18/05
ASSEMBLY
3.4 Piston and Bushing Assembly - Piston Bushing OD Packing Installation
NOTE: At a minimum, new packings are to be used on the piston bushing at each
overhaul.
NOTE: Review Paragraph 2.B., “Hydraulic Packing Assembly Guidelines” for additional
information regarding packing installation.
A. As shown in Figure 704, View 1, assemble backup packing ring (100A) in the OD
packing groove of piston bushing (151) as follows:
(1) Lightly lubricate OD packing groove of piston bushing with clean hydraulic
brake fluid per Boeing Specification BMS 3-11.
(2) Start the continuous packing retainer over the reduced diameter of the
piston bushing on one side of the packing groove, and then work it
circumferentially into the groove using a smooth, splinter-free wooden tool or
the installer’s thumb. Be sure the retainer is not twisted.
(3) Install the split spacer ring tool in the groove adjacent to the reduced
diameter of the piston bushing as illustrated.
(4) Install the compression sleeve, tapered end first, over the piston bushing.
Push the compression sleeve over the packing retainer, hold momentarily,
and then remove. Repeat this process one to two more times to properly
size the packing retainer. Depending on climatic conditions, the
compression sleeve may need to be held in-place for an extended period to
allow sufficient time for the packing retainer to return to original size.
(5) Following sizing, remove the sleeve and split spacer ring tool. Inspect to
see if the packing retainer looks the same as it did in the free state. Ensure
that the packing retainers are not wavy, coned, or twisted. Remove and
discard if required.
B. Slide backup packing ring (100A) forward in the packing groove, installing packing
(105) in the groove as shown in Figure 704, View 2. Ensure packing is not twisted
in the groove.
fluid per Boeing Specification BMS 3-11.
D. If immediate use of the piston and bushing assembly is not required, store in a
clean, sealed container that is free of dust or other contaminates.
Page 710
32-40-08
Apr 18/05
ASSEMBLY
SPACER PACKING
PACKING RING RETAINER
RETAINERS
NOTE: –1 ONLY
FOR THE P/N 2606671-1 BRAKE
ASSEMBLY ONLY, TWO PACKING
PACKING
RETAINERS ARE REQUIRED.
RETAINERS
INSTALL AS INDICATED.
NOTE:
COMPRESSION SLEEVE
COMPRESSION AND SPACING TOOLS
SLEEVE MUST CONFORM
–1 ONLY TO FIGURE 907
VIEW 1
PACKING PACKING
RETAINER
VIEW 2
LAG-5028
Piston Bushing OD Packing and Packing Retainer Installation
Figure 704
Page 711
32-40-08
Apr 18/05
ASSEMBLY
D. Piston Housing Assembly.
4.1 Piston Housing Assembly - Installation of Piston and Bushing Assemblies

A. At operator option, BATCO X-8401-2 grease may be applied to piston bushing
threads for corrosion protection. Care should be taken to prevent grease from
contacting the piston bushing packing (105) and packing retainer (100A).
B. Lightly lubricate the packing on the bushing OD and the seal areas of the
piston/bushing cavities of the piston housing with clean hydraulic brake fluid per
Boeing Specification BMS 3-11.
C. If BATCO grease or a different lubricant was not previously applied to the piston
bushing threads, lightly lubricate these with the specified hydraulic fluid. The
applied fluid should not run or drip.
NOTE: Use of the compression sleeve when installing piston bushing into the
piston/bushing cavity of the piston housing will help prevent packing and
packing retainer damage.
D. Obtain piston and bushing assembly with packings/packing retainers installed.
Install the compression sleeve, tapered end first, over the piston bushing. Refer to
Figure 704, View 1, except a packing has already been installed in place of the
spacer ring tool. Push the compression sleeve over the packing retainers and
packing. Hold the sleeve on the packing/packing retainer momentarily, providing
one last opportunity for sizing the packing retainer.
E. Carefully hand screw each piston/bushing assembly into the piston housing and
plugs assembly (160). If an excessive installation force or heavy drag is observed,
disassemble and visually inspect the packing and packing retainers for twist,
overlap, or coning. Replace damaged parts as required and reassemble.
F. Tighten piston/bushing assemblies to the torque specified in Figure 801. Safety
wire piston bushings in two groups of three as shown in Figure 705 using safety
cable (97) and ferrule (98) or as an alternate, the double twist method using wire
(97A).
Page 712
32-40-08
Apr 18/05
ASSEMBLY
SAFETY WIRE BUSHINGS IN

TWO GROUPS OF THREE,
USING SAFETY CABLE AND
FERRULE OR LOCKWIRE USING ADJUSTER ASSEMBLY
THE DOUBLE TWIST METHOD. LOCATION 4 PLACES
SAFETY CABLES OR
WIRES MUST NOT
INTERFERE WITH
ADJUSTER TUBES
OR RELINE PINS RELINE INDICATOR
PIN LOCATION
2 PLACES
BUSHINGS MAY BE
CONFIGURED WITH
EITHER THRU HOLES
OR SLOTS CUT ON
THE UNDERSIDE OF
THE BUSHING FLANGE
FOR SAFETY WIRE
INSTALLATION
USE OPENINGS IN PISTON BUSHINGS

NEAREST TO POSITIONS SHOWN
LAG-5029
Safety Wiring of Installed Piston Bushings

Figure 705
Page 713
32-40-08
Apr 18/05
ASSEMBLY
4.2 Piston Housing Assembly - Installation of Bleeder Adapters, Bleeder Screws, and
Warning Labels
NOTE: At a minimum, new packings are to be used on the bleeder valves at each
overhaul.
A. Install bushings (90) as follows:
(1) Place packing (95) on bushing (90).
(2) Install bushings (90) into piston housing and tighten to torque specified in
Figure 801.
(3) Safety wire bushings (90) to each other using safety cable (87) and ferrule
(88) as shown in Figure 706, or as an alternate, the double twist method
using wire (87A).
B. Install bleeder screws (85) as follows:
(1) Assemble bleeder screw (85) into bushing (90) and tighten screw to torque
(2) Install lock washer (80) over screw (75) and install into bleeder screw (85).
Tighten screw until snug. Apply final torque as shown in Figure 801.
C. Ensure spring pin (155) is installed on the mating face side of the piston housing. If
not, install a new pin into hole until it is fully seated.
D. Apply plates (245, 250) and decal (255) in the identified locations as shown in
Figure 706.
Page 714
32-40-08
Apr 18/05
ASSEMBLY
SAFETY WIRE BUSHINGS

TOGETHER AS SHOWN
USING SAFETY CABLE AND
FERRULE OR LOCKWIRE USING
FLUID THE DOUBLE TWIST METHOD
INSTRUCTION
PLATE (245)
NAME PLATE
DECAL (255)
BRAKE RELINE
INSTRUCTION
PLATE
(250)
LAG-5030
Safety Wiring of Bleeder Valve Adapters and Identification Plate Installation

Figure 706
Page 715
32-40-08
Apr 18/05
ASSEMBLY
4.3 Piston Housing Assembly - Installation of Inlet Hydraulic Coupling
NOTE: If hydraulic coupling is not to be installed at this time, install shipping plug (66) to
prevent contamination of the inlet port.
A. As shown in Figure 707, assemble packing backup rings (370) in the OD packing
groove of bulkhead coupling half (67) as follows:
(1) Lightly lubricate OD packing groove with clean hydraulic brake fluid per
Boeing Specification BMS 3-11. The applied fluid should not run or drip.
(2) Start a continuous packing backup ring over the coupling and work it
circumferentially into the packing groove using a smooth, splinter-free
wooden tool or the installer’s thumb. Be sure the retainer is not twisted.
Repeat process with second packing backup ring.
(3) Ensure that the packing backup rings are not wavy, coned, or twisted.
B. Install packing (380) in the groove between the packing backup rings or per
optional practice as shown in Figure 707. Ensure packing is not twisted in the
groove.
fluid per Boeing Specification BMS 3-11. The applied fluid should not run or drip.
D. At operator option, BATCO X-8401-2 grease may be applied to the hydraulic
coupling to prevent corrosion. Apply a light coating of BATCO grease on the
hydraulic coupling from the diametral surface above the upper backup ring to the
top of the coupling as shown in Figure 707. Care should be taken to prevent
excess grease from contacting the packing (380) and packing backup rings (370).
E. Lightly lubricate the seal areas of the piston housing inlet port with clean hydraulic
brake fluid per Boeing Specification BMS 3-11.
F. Carefully insert hydraulic coupling into the piston housing inlet port. Hand tighten
until coupling is flush with mating face of piston housing inlet. If an excessive
installation force is observed, disassemble and visually inspect the packing and
packing retainers for twist, overlap, or coning.
NOTE: At operator option, during on-airplane brake installation, a light coating of
BATCO X-8401-2 grease may be applied to the threads and shank of the
bolts (390) and to the underside of the hose half flange to help prevent
corrosion.
Page 716
32-40-08
Apr 18/05
ASSEMBLY
PACKING
BACKUP RING PACKING
OPTIONAL
CONFIGURATION
PACKING
BACKUP RINGS
PACKING
AT OPERATOR OPTION
APPLY LIGHT COAT OF
BATCO X-B401-2 GREASE
ON SURFACES BETWEEN
THIS ZONE
Hydraulic Coupling Installation

Figure 707
Page 717
32-40-08
Apr 18/05
ASSEMBLY
4.4 Piston Housing Assembly - Assembly of Adjuster Components and Reline Indicator
Pins
NOTE: One of two methods may be used to assemble the adjuster components. The
first requires that the piston housing and lined pressure plate be pre-assembled
as defined per the instructions that follow. The second permits the operator to
final assemble the adjusters after the lined pressure plate and piston housing
are installed over the stator torque tube as defined per outline numbers 5.7 and
6.1.
NOTE: For brakes that are being partially rebuilt, adjuster tubes (36) must be replaced if
a different piston housing and plugs assembly (160), stator torque tube (240),
pressure plate (205), stator plate (225), or rotor assembly (210, 211, 212, 213) is
substituted in the brake assembly.
A. Obtain properly lined pressure plate (205) for the brake heat stack configuration
that is to be assembled. Lay pressure plate (205) assembly on a clean flat surface
with linings face down. Insert heads of adjuster pins (46) into slots of pressure
plate at four locations. Install pin retainers (50) at each pin location as shown in
Figure 708.
B. Install reline indicator pins (180) through the piston housing from the mating face
side. Using masking tape, secure pin heads against underside of piston housing.
NOTE: A brake spacer may be used between the piston housing and stator torque
tube mounting flanges to increase the allowable heat stack height. The
increased heat stack height permits increased rotor mass and, in some
cases, can assist in obtaining required running clearance.
C. If used, install torque tube spacer (162), or an equivalent spacer locally fabricated
as shown in Figure 904, on top of the pressure plate assembly.
D. Lower piston housing assembly onto pressure plate so that the adjuster pins enter
the return spring cavities of the piston housing.
E. Install adjuster tube (36) into return spring cavity over adjuster pin (46) as shown in
Figure 709. Place adjuster sphere (30) over the end of adjuster pin. Assemble
self-locking nut (25) on pin and tighten nut forcing ball into tube until ball bottoms
on shoulder of pin. Torque the self-locking nut (25) as specified in Figure 801.
Note nut installation differences in Figure 709 when assembling the P/N 2606672-1
brake assembly.
F. Remove masking tape and lower reline indicator pins (180) so that the head is
resting in pin retainers (195). Insert pin retainers (175) through pin retainers and
spread ends to secure.
Page 718
32-40-08
Apr 18/05
ASSEMBLY
RETURN
PIN SPRING PIN
RETAINER
INSTALL PIN RETAINER BY PRESSURE PRESS PIN RETAINER INTO

STARTING CURVED END PLATE HOLE AS SHOWN. FOUR
UNDER HEAD OF PIN PLACES PER BRAKE.
LAG-2329B
Assembly of Adjuster Pin Retainers

Figure 708
NOTE: NOTE:
FOR THE P/N 2606672-1 BRAKE ASSEMBLY ONLY, ASSEMBLE REFER TO IPL
NUT ON PIN. TIGHTEN NUT FORCING BALL INTO TUBE UNTIL FOR P/N
HOLE IN PIN THREADS IS EXPOSED ENOUGH TO INSTALL DIFFERENCES
SAFETY WIRE. CUT A 0.75 (19.0) LONG PIECE OF MS2095C51
SAFETY WIRE AND INSTALL THROUGH HOLE IN ADJUSTER PIN.
WRAP WIRE IN THE FORM OF AN “S” TO RETAIN.
LOCKWIRE
ADJUSTER
HOUSING
NUT
PISTON
HOUSING BALL
PISTON
HOUSING
TUBE
PRESSURE ADJUSTER PIN PRESSURE

PLATE PLATE
–1 ONLY –2, –3, –4

LAG-2849D MILLIMETER CONVERSIONS IN PARENTHESES
Assembly of Adjuster Components

Figure 709
Page 719
32-40-08
Apr 18/05
ASSEMBLY
E. Heat Stack Assembly.
5.1 Heat Stack Configurations - P/N 2606672-1 Original Equipment (OE) Configuration
NOTE: Figure 710 defines the OE configuration for brake assembly P/N 2606672-1.
This configuration may be used on 737-200H airplanes only.
A. OE History:
(1) The heat stack configuration identified in Figure 710 was the first OE
configuration provided for brake assembly P/N 2606672.
(2) OE brakes built to this configuration are no longer procurable.
(3) The wear pin setting for the heat stack configuration identified in Figure 710
was 1.0 inch (25 mm) maximum.
B. Service Configuration Status:
(1) The heat stack configuration identified in Figure 710 may be used as a
service configuration at a maximum wear pin setting of 1.0 inches (25 mm).
(2) To better optimize brake life, ALS recommends that operators rebuild brake
assemblies to the service configuration defined per outline number 5.2. An
additional option would be to implement a custom configuration as defined
per outline number 5.6.
Page 720
32-40-08
Apr 18/05
ASSEMBLY
BRAKE PART NUMBER: . . . . . . . . . . . . 2606672–1

MAXIMUM WEAR PIN: . . . . . . . . . . . . . . 1.0 (25)
MINIMUM RUNNING CLEARANCE: . . 0.080 (2.03)
ROTOR DISTRIBUTION
LINING DISTRIBUTION
AS MINIMUM
MANUFACTURED WEIGHT FOR PART NUMBER /
SERVICE THICKNESS
PART NUMBER COLOR CODE
BUILD*
357453
0.255 (6.48)
2610611–620 2 ORANGE
HEAVIEST
OR ROTOR
2606711–620 357453
0.255 (6.48)
2 ORANGE
357453
0.255 (6.48)
2610611–580 2 ORANGE
2ND
OR HEAVIEST
2606711–580 ROTOR 357453
2 ORANGE 0.255 (6.48)
357453
2 ORANGE 0.255 (6.48)
2610611–580 3RD
OR HEAVIEST
2606711–580 ROTOR 357453
2 ORANGE 0.255 (6.48)
357453
LIGHTEST 2 ORANGE 0.255 (6.48)
2610611–540 ROTOR NOT
OR LESS THAN
2606711–540 17.00 LBS 357453
0.255 (6.48)
(7.7 Kg) 2 ORANGE
STATOR TORQUE TOTAL LINING 2.04

MINIMUM TOTAL ROTOR THICKNESS (51.8)
STACK WEIGHT TUBE
77.5 LBS (35.2 Kg)
* ROTOR ASSEMBLIES IDENTIFIED WITH THE 2610611 OR 2606711 PART NUMBER MAY BE USED
IN ANY ROTOR POSITION WITHOUT REGARD TO THICKNESS AS LONG AS MINIMUM ROTOR
WEIGHT IS ACHIEVED.

P/N 2606672-1 OE Configuration

Figure 710
Page 721
32-40-08
Apr 18/05
ASSEMBLY
5.2 Heat Stack Configurations - P/N 2606672-1 Recommended Service Configuration
NOTE: Figure 711 defines the recommended service configuration for brake assembly
P/N 2606672-1. This configuration may be used on 737-200H airplanes only.
A. Service Configuration History:
(1) The heat stack configuration identified in Figure 711 was developed for
brake assembly P/N 2606672-1 as a service configuration.
(2) The maximum wear pin for the heat stack configuration identified in Figure
711 is 1.38 inches (35.0 mm).
(3) To better optimize brake life or to rebalance lining wear, a custom
configuration may be implemented as defined per outline number 5.6.
Page 722
32-40-08
Apr 18/05
ASSEMBLY

MAXIMUM WEAR PIN: . . . . . . . . . . . . . . 1.38 (35.0)
ROTOR DISTRIBUTION
LINING DISTRIBUTION
AS MINIMUM
SERVICE THICKNESS
BUILD*
357486
0.335 (8.51)
2610611–620 1 ORANGE
HEAVIEST
OR ROTOR
2606711–620 357479
0.315 (8.00)
1 RED
357479
0.315 (8.00)
2610611–580 1 RED
2ND
OR HEAVIEST
2606711–580 ROTOR 357488
1 GREY 0.275 (6.99)
357488
1 GREY 0.275 (6.99)
2610611–580 3RD
OR HEAVIEST
2606711–580 ROTOR 357488
1 GREY 0.275 (6.99)
357488
LIGHTEST 1 GREY 0.275 (6.99)
2610611–540 ROTOR NOT
OR LESS THAN
2606711–540 17.00 LBS 357488
0.275 (6.99)
(7.7 Kg) 1 GREY

STACK WEIGHT TUBE
77.5 LBS (35.2 Kg)
WEIGHT IS ACHIEVED.

P/N 2606672-1 Recommended Service Configuration

Figure 711
Page 723
32-40-08
Apr 18/05
ASSEMBLY
5.3 Heat Stack Configurations - P/N 2606672-2/-3/-4 OE Configuration
NOTE: Figure 712 defines the OE configuration for brake assemblies
P/N 2606672-2/-3/-4. This configuration may be used on 737-200H, 737-300,
737-400, and 737-500 airplanes.
A. OE History:
(1) The heat stack configuration identified in Figure 712 is the current OE
configuration manufactured by ALS for brake assembly P/N 2606672-4.
(2) The as-manufactured wear pin setting for the heat stack configuration
identified in Figure 712 is 1.0 inch (25 mm) maximum.
(3) When procuring an as-manufactured brake, orders placed after October
2002 for brake assembly P/N 2606672-4 will be filled with the service-ready
brake assembly with a wear pin setting of 1.4 inches (36 mm) as defined per
outline number 5.4.
(1) The heat stack configuration identified in Figure 712 may be used as a
service configuration at a maximum wear pin setting of 1.0 inches (25 mm).
(2) To better optimize brake life, ALS recommends that operators rebuild brake
assemblies to the service configuration defined per outline number 5.5. An
additional option would be to implement a custom configuration as defined
Page 724
32-40-08
Apr 18/05
ASSEMBLY
BRAKE PART NUMBER: . . . . . . . . . . . . 2606672–2/–3/–4

MAXIMUM WEAR PIN: . . . . . . . . . . . . . . 1.00 (25.4)***
ROTOR DISTRIBUTION
LINING DISTRIBUTION
AS MINIMUM
SERVICE THICKNESS
BUILD*
357488
0.275 (6.99)
2610611–750 1 GREY
HEAVIEST
OR ROTOR
2606711–750 357488
0.275 (6.99)
1 GREY
357453
0.255 (6.48)
2610611–700 2 ORANGE
2ND
OR HEAVIEST
2606711–700 ROTOR 357543
1 BLACK, 1 YELLOW 0.235 (5.97)
357543
2610611–660 3RD 1 BLACK, 1 YELLOW 0.235 (5.97)
OR HEAVIEST
2606711–660 ROTOR 357543
1 BLACK, 1 YELLOW 0.235 (5.97)
357543
LIGHTEST 0.235 (5.97)
2610611–620 1 BLACK, 1 YELLOW
ROTOR NOT
OR LESS THAN
2606711–620 18.5 LBS 357543
0.235 (5.97)
(8.4 Kg) 1 BLACK, 1 YELLOW

STACK WEIGHT TUBE
88.0 LBS (40.0 Kg)**
* ROTOR ASSEMBLIES IDENTIFIED WITH THE 2610611 OR 2606711 PART NUMBER MAY BE USED IN
ANY ROTOR POSITION WITHOUT REGARD TO THICKNESS AS LONG AS MINIMUM ROTOR WEIGHT
IS ACHIEVED.
** WHEN USED ON THE 737–200H AIRPLANE, TOTAL STACK WEIGHT MAY BE REDUCED TO 82.0 LBS
(37.2 Kg) MINIMUM. IDENTIFY BRAKES BUILT TO THIS CONFIGURATION FOR USE ON 737–200H
ONLY.
*** THIS ASSEMBLY IS NO LONGER PROCURABLE IN THIS CONFIGURATION. SEE OUTLINE NUMBER
5.4 FOR AN AS–MANUFACTURED SERVICE READY BRAKE CONFIGURATION SUPPLIED WITH A 1.4
(36) WEAR PIN.
P/N 2606672-2/-3/-4 OE Configuration

Figure 712
Page 725
32-40-08
Apr 18/05
ASSEMBLY
5.4 Heat Stack Configurations - P/N 2606672-4 As-Manufactured Service-Ready Brake
Configuration with a 1.4 inch (36 mm) Wear Pin
NOTE: Figure 713 defines a service-ready brake configuration that may be purchased
from ALS. This configuration may be used on 737-200H, 737-300, 737-400, and
737-500 airplanes.
A. OE History:
(1) The heat stack configuration identified in Figure 713 is an optional OE
service-ready configuration manufactured by ALS for brake assembly
P/N 2606672-4.
(2) The as-manufactured wear pin setting for the heat stack configuration
identified in Figure 713 is 1.4 inches (36 mm).
(3) This brake assembly is manufactured with a torque tube spacer (162).
(4) The lining and rotor configuration is identical to the service configuration
defined per outline number 5.5, with the exception of the wear pin setting
and rotor 4 thickness.
(1) Refer to outline number 5.5.
Page 726
32-40-08
Apr 18/05
ASSEMBLY
SERVICE READY
MAXIMUM WEAR PIN: . . . . . . . . . . . . . . 1.4 (36)
ROTOR DISTRIBUTION
LINING DISTRIBUTION
AS MINIMUM
SERVICE THICKNESS
BUILD*
357562
0.365 (9.27)
2610611–750 2 RED
HEAVIEST
OR ROTOR
2606711–750 357562
0.365 (9.27)
2 RED
357484
0.295 (7.49)
2610611–700 1 BLACK
2ND
OR HEAVIEST
2606711–700 ROTOR 357484
1 BLACK 0.295 (7.49)
357453
2 ORANGE 0.255 (6.48)
2610611–660 3RD
OR HEAVIEST
2606711–660 ROTOR 357453
2 ORANGE 0.255 (6.48)
357543
LIGHTEST 0.235 (5.97)
2610611–580 1 BLACK, 1 YELLOW
ROTOR NOT
OR LESS THAN
2606711–580 18.5 LBS 357453
0.255 (6.48)
(8.4 Kg) 2 ORANGE

STACK WEIGHT TUBE
88.0 LBS (40.0 Kg)**
WEIGHT IS ACHIEVED.
** WHEN USED ON THE 737–200H AIRPLANE, TOTAL STACK WEIGHT MAY BE REDUCED TO
82.0 LBS (37.2 Kg) MINIMUM. IDENTIFY BRAKES BUILT TO THIS CONFIGURATION FOR USE ON
737–200H ONLY.

P/N 2606672-4 As-Manufactured Service-Ready Brake Configuration Kit

Figure 713
Page 727
32-40-08
Apr 18/05
ASSEMBLY
5.5 Heat Stack Configurations - P/N 2606672-2/-3/-4 Recommended Service
Configurations
NOTE: Figure 714 defines the recommended service configuration for the
P/N 2606672-2/-3/-4 brake assemblies. This configuration may be used on
737-200H, 737-300, 737-400, and 737-500 airplanes.
A. Service Configuration Status:
(1) The heat stack configuration identified in Figure 714 was developed for
brake assemblies P/N 2606672-2/-3/-4.
(2) The maximum wear pin for the heat stack configuration identified in Figure
714 is 1.6 inches (41 mm).
(3) When building this brake assembly, torque tube spacer (162), or an
equivalent spacer locally fabricated as shown in Figure 904, should be
installed in the brake assembly to provide additional running clearance.
(4) Based on operator experience, a wear pin reduction may be necessary to
ensure delines do not result from use of this configuration at the maximum
wear pin setting. Operators who experience problems with the service
configuration are encouraged to consult ALS for technical guidance.
(5) To better optimize brake life or to rebalance lining wear, a custom
configuration may be implemented as defined per outline number 5.6.
Page 728
32-40-08
Apr 18/05
ASSEMBLY
BRAKE PART NUMBER: . . . . . . . . . . . . 2606672–2/–3/–4

MAXIMUM WEAR PIN: . . . . . . . . . . . . . . 1.6 (41)
ROTOR DISTRIBUTION
LINING DISTRIBUTION
AS MINIMUM
SERVICE THICKNESS
BUILD*
357562
0.365 (9.27)
2610611–750 2 RED
HEAVIEST
OR ROTOR
2606711–750 357562
0.365 (9.27)
2 RED
357484
0.295 (7.49)
2610611–700 1 BLACK
2ND
OR HEAVIEST
2606711–700 ROTOR 357484
1 BLACK 0.295 (7.49)
357453
2 ORANGE 0.255 (6.48)
2610611–660 3RD
OR HEAVIEST
2606711–660 ROTOR 357453
2 ORANGE 0.255 (6.48)
357543
LIGHTEST 0.235 (5.97)
2610611–620 1 BLACK, 1 YELLOW
ROTOR NOT
OR LESS THAN
2606711–620 18.5 LBS 357453
0.255 (6.48)
(8.4 Kg) 2 ORANGE

STACK WEIGHT TUBE
88.0 LBS (40.0 Kg)**
WEIGHT IS ACHIEVED.
** WHEN USED ON THE 737–200H AIRPLANE, TOTAL STACK WEIGHT MAY BE REDUCED TO
82.0 LBS (37.2 Kg) MINIMUM. IDENTIFY BRAKES BUILT TO THIS CONFIGURATION FOR USE ON
737–200H ONLY.

P/N 2606672-2/-3/-4 Recommended Service Configuration

Figure 714
Page 729
32-40-08
Apr 18/05
ASSEMBLY
5.6 Heat Stack Configurations - Custom Heat Stack Configurations
A. Based on operator experience, heat stack configurations may be custom tailored to
help optimize brake service life and rebalance lining wear. At a minimum, the
following conditions must be met with any custom configuration:
(1) Conditions specific for the P/N 2606672-2/-3/-4 Brake Assemblies:
- Maximum wear pin - 1.6 inches (41 mm)
- Minimum total lining thickness - 2.320 inches (58.93 mm)
(2) Conditions specific for the P/N 2606672-1 Brake Assembly:
- Maximum wear pin - 1.38 inch (35.1 mm)
- Minimum total lining thickness - 2.34 inches (59.4 mm)
(3) Minimum rotor weights identified in Figure 715 must be achieved at each
rotor position in the brake assembly. Also, the minimum total rotor weight
must be achieved.
(4) Minimum running clearance of 0.080 inch (2.03 mm) must be achieved at
time of brake assembly.
(5) The lining configuration selected must ensure that in the fully worn
condition, no lined surface consistently wears below 0.075 inch (1.91 mm).
(6) In order to develop a custom configuration that modifies lining thickness,
20 - 30 brake assemblies should be measured as outlined per the
Disassembly section, outline number 3.1. This data should be submitted to
ALS for evaluation.
(7) Torque tube spacer (162), or an equivalent spacer locally fabricated as
shown in Figure 904, should be used with custom configured brakes to allow
increased rotor mass. In some cases the brake spacer will be required to
obtain required running clearance.
B. New and worn rotor assemblies identified with the 2610611 or 2606711 part
numbers, as shown in Figure 715, may be used in the brake assembly in any rotor
position, as long as the measured rotor weight is equal to or greater than the
minimum rotor weight specified. To optimize brake life, the brake assembly should
be built with the heaviest possible rotors installed in the brake assembly, while
ensuring the minimum running clearance requirement is met.
C. When custom tailoring brakes, lining part numbers, as identified in Figure 716, may
be used on any surface of the brake assembly as long as their safe use is
substantiated by the worn brake data collection effort. If the lining thickness for a
given lined surface must be adjusted by more than 0.050 inch (1.27 mm), ALS must
be consulted.
Page 730
32-40-08
Apr 18/05
ASSEMBLY
Minimum Allowable Rotor Weights and Part Numbers Available for Use
Minimum Weight Rotor P/N’s Available for Use
Pound (Kg)
Brake Assembly P/N
New
Rotor Position 2606672-1 2606672-2/-3/-4 2606672-2/-3/-4 Thickness
(737-200H Only) P/N Inch (mm)
Rotor 1 (Nearest
Pressure Plate) Heaviest 2610611-750 0.750 (19.05)
Rotor 2 Second Heaviest 2610611-700 0.700 (17.78)
Rotor 3 Third Heaviest 2610611-660 0.660 (16.76)
Lightest Rotor Not Less Than
Rotor 4 (Nearest
Backing Plate) 17.0 (7.7) 18.5 (8.4) 18.5 (8.4) 2610611-620 0.620 (15.75)
Total Rotor Stack 77.5 (35.2) 82.9 (37.6) 88.0 (40) 2610611-580 0.580 (14.73)
2610611-540 0.540 (13.72)
Minimum Allowable Rotor Weights and Part Numbers that May Be

Used for Custom Configurations
Figure 715
Lining Part Numbers Available for Use

New Thickness
P/N Inch (mm) Color Code
357562 0.365 (9.27) Two red stripes
357486 0.335 (8.51) One orange stripe
357479 0.315 (8.00) One red stripe
357484 0.295 (7.49) One black stripe
357488 0.275 (6.99) One gray stripe
357453 0.255 (6.48) Two orange stripes
357543 0.235 (5.97) One black and one yellow stripe
Lining Part Numbers that May Be Used for Custom Configurations

Figure 716
Page 731
32-40-08
Apr 18/05
ASSEMBLY
5.7 Heat Stack Assembly - Service Builds
NOTE: One of two methods may be used to assemble the adjuster components. The
first requires that the piston housing and lined pressure plate be pre-assembled
as defined per outline number 4.4. If using the first method, perform only steps
A. through C. below and steps B., C., and F. of outline number 6.1. The second
permits the operator to final assemble the adjusters after the lined pressure plate
and piston housing is installed over the stator torque tube as defined below and
A. Based on heat stack configuration to be assembled (selected per outline numbers
5.1 through 5.6), obtain piston housing and properly lined pressure plate (205),
stator torque tube (240) and bearing assembly, and three lined stator plates (225).
Verify correct lining is installed on each surface per the required color codes. The
lining color codes are marked with paint on the outer edge of the lining cup.
NOTE: If brake assembly will be placed in extended storage for more than six
months, lightly coat the rotor assemblies with SAE #10 or SAE #20 oil, if
not previously accomplished.
B. Obtain rotor assemblies required as identified for the brake configuration being
built. Ensure minimum rotor weight is achieved for each rotor position and that the
minimum total rotor stack weight is achieved. If the P/N 2606672-2/-3/-4 brake
assemblies were built specific for the 737-200H airplane using a minimum total rotor
weight of 82.0 pounds (37.2 Kg), identify selected piston housing with warning
decal (256) as shown in Figure 717. As an option, brake assembly
P/N 2606672-1 may also be identified as shown in Figure 717.
C. Place stator torque tube on assembly table with spline section facing up, and then
alternately install selected rotor and stator assemblies on the stator torque tube for
the brake configuration being assembled. Ensure rotors are installed correctly
based on minimum weight. Verify correct orientation of each lined surface of the
stator assemblies based on the required lining color code.
D. Locate a single 0.32 inch (8.1 mm) alignment hole in the stator torque tube
mounting flange. Obtain pressure plate and verify lining color codes. Install
pressure plate over stator torque tube splines so that alignment hole of the stator
torque tube is equally spaced between the two wear pin attachment brackets on the
pressure plate.
E. Insert heads of adjuster pins (46) into slots of pressure plate at four locations.
Install pin retainers (50) at each pin location as shown in Figure 708.
F. Insert head of reline indicator pins (180) into pin retainers (195). Secure pin by
sliding pin retainer (175) through the four holes in the pin retainer (195). Bend the
ends of pin retainer (175) around the pin retainer OD to prevent it from sliding out.
Page 732
32-40-08
Apr 18/05
ASSEMBLY
NOTE:
FLUID BASED ON PREVIOUS MARKING
INSTRUCTION SCHEMES, THE LABELS MAY BE
PLATE (245) AFFIXED TO DIFFERENT DOMES
NAME PLATE
DECAL (255)
BRAKE RELINE
INSTRUCTION
PLATE
(250)
737–200
ONLY
AS AN OPTION, MARK
WITH PAINT USING 737–200 WARNING
0.25 (6.4) HIGH DECAL (256)
MINIMUM LETTERING
NOTE:
THIS PLATE MUST BE INSTALLED IF BRAKE
ASSEMBLY P/N 2606672–2/–3/–4 WAS BUILT
SPECIFIC FOR THE 737–200H AIRPLANE AT THE
LOWER TOTAL ROTOR WEIGHT ALLOWANCE.
THIS PLATE IS OPTIONAL FOR THE P/N 2606672–1
BRAKE ASSEMBLY.
Identification of Brake Assemblies Built for Use on the 737-200H Airplane Only
Figure 717
Page 733
32-40-08
Apr 18/05
ASSEMBLY
F. Final Brake Assembly Instructions.
6.1 Final Brake Assembly Instructions - Assembly of Piston Housing to Torque Tube
NOTE: For brakes that are being partially rebuilt, adjuster tubes (36) must be replaced if
a different piston housing and plugs assembly (160), stator torque tube (240),
pressure plate (205), stator plate (225), or rotor assembly (210, 211, 212, 213) is
substituted in the brake assembly.
NOTE: A torque tube spacer may be used between the piston housing and stator torque
tube mounting flanges to increase the allowable heat stack height. The
increased heat stack height permits increased rotor mass and, in some cases,
can assist in obtaining required running clearance. Only one spacer is
permitted.
A. If required, install torque tube spacer (162), or an equivalent spacer locally
fabricated as shown in Figure 904, onto the mounting flange of the stator torque
tube. Locate a single 0.32 inch (8.1 mm) alignment hole in the torque tube
mounting flange. Rotate spacer as required to orient the spacer’s alignment hole
with that of the stator torque tube.
B. Locate the alignment pin on the piston housing mating face. Lower piston housing
assembly onto stator torque tube so that the alignment pin is oriented over the hole
in the stator torque tube flange. As the piston is lowered, guide the adjuster pins
through the return spring cavities of piston housing, and guide the reline indicator
pins through the integral mounting holes of the piston housing. Ensure the installed
alignment pin of the piston housing engages the stator torque tube.
C. Lubricate the threads and bearing surfaces of all washers (20) and bolts (15) with
appropriate lubrication as specified in Figure 801. Place washer (20) over bolt (15).
The chamfered side of the washer through hole must be placed next to the bolt
head.
D. Install two attachment bolt/washer pairs, approximately 180 degrees apart, through
the piston housing mounting flange. Hand tighten into the stator torque tube
attachment holes.
E. Install adjuster tube (36) into return spring cavity over adjuster pin (46) as illustrated
in Figure 709. Place adjuster sphere (30) over the end of adjuster pin. Assemble
self-locking nut (25) on pin and tighten nut forcing ball into tube until ball bottoms
on shoulder of pin. Torque the self-locking nut (25) to the minimum value specified
in Figure 801. Note nut installation differences in Figure 709 when assembling the
P/N 2606672-1 brake assembly.
F. Install remaining attachment bolt/washer pairs through the piston housing mounting
flange. Snug all bolts and torque each to the required value specified in Figure 801
for the lubrication used. Place bolt retainers over the heads of bolts (15) with tang
of retainer indexing in the holes in the piston housing. Drive the retainers over the
bolt heads with a driver that can be locally manufactured as shown in Figure 908.
Install spring clip (5) or cotter pin (5A) through holes in bolt head to secure
retainers.
Page 734
32-40-08
Apr 18/05
ASSEMBLY
6.2 Final Brake Assembly Instructions - Setting of Reline Indicator Pin
A. After assembly is complete, test brake and cut reline indicator pin in accordance
with instructions in the Testing section.
6.3 Final Brake Assembly Instructions - Brake Storage Instructions

A. During assembly of brakes for extended storage, fill the brake piston housing with
hydraulic fluid per Boeing Specification BMS 3-11, and securely install plug or brake
half of quick disconnect fitting to seal inlet. If brake half of quick disconnect is used,
thoroughly bleed brake so that it need only be plugged into airplane hydraulic
system upon installation. This will eliminate bleeding brakes on the airplane after
installation.
B. Place the brake assembly in a dust-proof container and give additional protection
against moisture as climatic conditions at the point of storage require.
C. Refer to the Check section for additional instructions regarding brake storage.
Page 735
32-40-08
Apr 18/05
ASSEMBLY
Page 736
32-40-08
Apr 18/05
FITS AND CLEARANCES
Torque Value
IPL Pound-Inches (Newton-Meters)
Fig. & Wrench Torque
Item Minimum (Target/Nominal Torque Value is
No. Item Lubrication* Reusable Underlined)
1-15 Machine Bolt MIL-T-83483 N/A 500 ± 25 (56.5 ± 2.8)
(Tie Bolt) or
MIL-PRF-83483
1-15 Machine Bolt AMS 2518 N/A 550 ± 25 (62.2 ± 2.8)
(Tie Bolt) or
MIL-T-5544
1-25 Nut (Self-Locking) None 3.5 (0.4) 70 ± 5 (7.9 ± 0.6)
1-85 Bleeder Screw None N/A 40 ± 10 (4.5 ± 1.1)**
1-90 Machine Thread None N/A 100 ± 15 (11.3 ± 1.7)
Bushing
1-150 Piston Bushing None N/A 225 ± 25 (25.4 ± 2.8)
(Batco Grease
X8401-2
Optional)
1-390 Bolt (Aircraft Half None N/A 77 ± 5 (8.7 ± 0.6)
Bulkhead (Batco Grease
Coupling X8401-2
Attachment) Optional)
CAUTION: IF ANY BOLT OR NUT IS INADVERTENTLY TIGHTENED TO A VALUE THAT IS
10% OR MORE ABOVE THE SPECIFIED FINAL TORQUE VALUE, THEN THAT
BOLT AND NUT SHOULD BE SCRAPPED. ALSO, EVALUATE MATERIAL
UNDER THE NUT AND BOLT FOR YIELDING.
NOTE: Torque wrenches must be accurate and capable of reproducing specified values
per Federal Specification GGG-W-686. Aircraft Landing Systems (ALS)
recommends torquing to the target/nominal value.
* When lubrication is specified, lubricate threads and bearing surfaces at each installation with
the specified compound. Use full strength. Do not dilute. Lubricants may be purchased from
lubrication vendors per the referenced MIL or AMS specifications identified above.
** If leakage is evident, the bleeder screw torque may be increased to a maximum value of
150.00 in-lb (16.9 N⋅m). The same torque value should be initially applied to the bushing (90)
to prevent advancement of the bushing. If leakage persists, replace bleeder screw (85) and
bushing (90).
Torque Values
Figure 801
Page 801
32-40-08
Apr 18/05
FITS AND CLEARANCES
Page 802
32-40-08
Apr 18/05
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
1. General.
NOTE: Equivalent substitutes may be used.
A. The following optional special tools and fixtures will facilitate the disassembly, repair,
testing, and reassembly of the brake assembly.
2. Special Service Tools and Fixtures.
NOTE: For acquisition of Aircraft Landing Systems special service tools and fixtures, refer
to Appendix A.
Figure No. Tool No. Description Application

901 2558121 Lifting Tool Used to lift brake assembly
and component
subassemblies.
902 2558564 Driver Used with a press to
depress adjuster springs so
the retaining ring can be
installed and removed.
Figure 901 Figure 902
Page 901
32-40-08
Jan 15/04
3. Specialized Assembly Tools To Be Procured At Operator Option.
A. No specialized assembly tools were illustrated as of the Component Maintenance
Manual’s publish date.
4. Tools That May Be Locally Manufactured At Operator Option.
Figure No. Description Application

903 Deleted.
904 Brake assembly spacer. Used to increase brake
assembly stack height.
Installed between piston
housing and stator torque
tube mating face.
905 Piston outside diameter (OD) packing sizing Used to size piston OD
tool used when assembling the P/N 2606672-1 packings after installation.
brake assembly.
906 Piston OD packing sizing tool used when Used to size piston OD
assembling the P/N 2606672-2/-3/-4 brake packings after installation.
assemblies.
907 Bushing OD packing sizing tool. Used to size bushing OD
packings after installation.
908 Tie bolt retainer driver. Used to install retainers onto

the heads of the tie bolts.
909 Assembly shim. Used to prevent excessive
adjuster pull through during
leakage tests.
Page 902
32-40-08
Jan 15/04
Deleted.
Figure 903
Page 903
32-40-08
Jan 15/04
0.32 (8.1) DIA
4.05 (102.9)
4.02 (102.1) TYP
6.88 (174.8)
0.12 (3.0) R
0.67 (17.0)
0.465 (11.81) - 0.475 (12.07) 1.989 (50.52)

DIA THRU 13 HOLES PART IS SYMMETRICAL
MATERIAL:
CORROSION RESISTANT
ABOUT THIS CENTERLINE STEEL MATERIAL
WITHIN 0.005 (0.13) TOTAL HEAT TREAT:
INDICATOR READING ANNEALED OR 1/4 HARD
NICKEL PLATE PER AMS 2403
0.0005 - 0.0010 (0.013 - 0.025)
THICK

Brake Assembly Spacer

Figure 904
Page 904
32-40-08
Jan 15/04
SPACER RING COMPRESSION SLEEVE
0.115 - 0.135 0.190 - 0.200

CENTER 0.15 - 0.17 (3.8 - 4.3)
(2.92 - 3.43) (4.83 - 5.08)
2.500 -
1.491 - 1.492 1.730 -
DIA 2.525
(37.87 - 37.90) 1.735
(63.50 -
(43.94 -
64.14)
44.07)
20° DIA.
DIA.
1.250 - 1.253
DIA 0.74 - 0.76
(31.75 - 31.83)
(18.8 - 19.3)
1.485 - 1.488
DIA
(37.72 - 37.80) 1.490 - 1.510
(37.85 - 38.35)
NOTE:
MATERIAL: ALUMINUM POLISH TAPER AND I.D. COMPLETE.
NO TOOL MARKS OR SHARP EDGES
ARE PERMITTED.
LOCALLY MANUFACTURED TOOLS FOR INSTALLING PISTON BACKUP RINGS

ON PISTON P/N 2606698 (140)

Piston OD Packing Sizing Tool Used When Assembling the P/N 2606672-1 Brake Assembly
Figure 905
Page 905
32-40-08
Jan 15/04
2.50 -
2.525
(63.5 -
64.1)
DIA.

Piston OD Packing Sizing Tool Used When Assembling the

P/N 2606672-2/-3/-4 Brake Assemblies
Figure 906
Page 906
32-40-08
Jan 15/04
0.193-0.203 0.176-0.186
(4.90-5.16) (4.47-4.82)
FOR BUSHING FOR BUSHING
(150) (151)

Bushing OD Packing Sizing Tool

Figure 907
Page 907
32-40-08
Jan 15/04

Machine (Tie) Bolt Retainer Driver

Figure 908
Page 908
32-40-08
Jan 15/04

Assembly Shim
Figure 909
Page 909
32-40-08
Jan 15/04
Page 910
32-40-08
Jan 15/04
ILLUSTRATED PARTS LIST
1. This Illustrated Parts List section illustrates, lists, and describes the procurable parts required to
comply with the instructions contained in the maintenance portion of this manual.
2. Parts are listed in order of disassembly, with the exception of attaching parts, and are grouped in
their respective subassemblies where applicable. An item number which carries an alpha
variant (Example 25A) identifies the part as an optional or alternate part. An item number
preceded by a dash (Example –25) is not illustrated, except when it is the top item in the
figure-item column. The attaching parts are listed in the same column as the assembly or item
which they attach and are captioned “Attaching Parts.” The end of the list of attaching parts is
indicated by this symbol: ---*---.
3. When a vendor number other than the Aircraft Landing Systems (ALS) part number is listed in
the “Part Number” column, the vendor code and the ALS code and part number appear in the
“Nomenclature” column. Paragraph 7. contains a list of the Commercial and Government Entity
Codes in the Illustrated Parts List.
4. The “Effectivity Code” column is used when two or more configurations of an assembly are listed
in the same parts list. A code letter is assigned to each main assembly. All items that are
peculiar to a particular assembly are identified by the same code letter as the main assembly.
When parts are common to all assemblies, the “Effectivity Code” column is left blank.
5. The “Units per Assembly” column shows the quantity of the listed part at that location only. In
the case of multiple usage of a part, the quantity listed is not the total used in the final assembly.
6. Abbreviations used in this section are:
AR - As required
V - Commercial and Government Entity Code
7. Commercial and Government Entity Codes.
Code Name and Address
55284 Honeywell International Inc., Aircraft Landing Systems, 3520 Westmoor Street, South
Bend, Indiana 46628-1373, U.S.A., Telephone: (574) 231-2000, Fax: (574) 231-2334,
Website: www.HoneywellAircraftLandingSystems.com.
Parts listed in Parts Price List should be ordered from Product Support Centers:
NOTE: When ordering vendor standard parts, use ALS part numbers rather than vendor part
numbers.
Honeywell International Inc., Aircraft Landing Systems, Product Support Center, 1730
North Topping, Kansas City, Missouri 64120, U.S.A., Telephone: (816) 231-8400, Fax:
(816) 231-2775, Website: www.HoneywellAircraftLandingSystems.com and click on the
Contact ALS link.
Honeywell European Distribution Center (EDC), Honeywell DC Hangar 14/SPLVR,

Hangar 14 Schiphol East, 1117 ZL Amsterdam Schiphol Airport, The Netherlands,
Telephone: +31 (0) 20 648 2269 or +31 (0) 20 649 4183, Fax: +31 (0) 20 648 2299,
Email: HONEYWELL.EDC@HONEYWELL.COM. Website:
www.HoneywellAircraftLandingSystems.com and click on the Contact ALS link.
Page 1001
32-40-08
Apr 18/05
11362 Parker Aerospace Customer Support, 14300 Alton Parkway, Irvine, California 92618,
U.S.A., Telephone: (949) 833-3000, Aircraft On Ground After Hours Support Telephone:
(949) 851-4357 (HELP), Website: www.parker.com/aeroCSCD/intro/index.asp.
73957 Groov-Pin Corporation, 1125 Hendricks Causeway, Ridgefield, New Jersey
07657-2105, U.S.A., Telephone: (201) 945-6780, Fax: (201) 945-8998, Website:
www.groove-pin.com.
92555 The Lee Company, 2 Pettipaug Road, P.O. Box 424, Westbrook, Connecticut
06498-0424, U.S.A., Telephone: (800) 633-7584 or (860) 399-6281, Fax: (860)
399-2270, Website: www.theleeco.com/LEEWEB/SER VICE.htm.
Page 1002
32-40-08
Apr 18/05
–1, –2
160 (UNMODIFIED)
–1, –2, –3, –4
160 (MODIFIED)
–1, –2, –3, –4
160A, 160B, 160C
–2, –3, –4
75 80 85 165 66
25 173 172
30 70 90 95
36
46
55 61
65A 116 111
–1 ONLY 64 141 105
100A
151
25 146
30 35
40 45 10 15
5 20 155
55 60 –2, –3, –4
65
64
115
140A
105 A
150
145
110
100
–1 ONLY
115
140
135 130
125 120
105
110 150
145
100
–1 SUPERSEDED
WB–500
Brake Assembly Exploded View
Page 1003
32-40-08
Apr 18/05
NOTE 1:
WHEN CUSTOM CONFIGURING BRAKE, IPL ITEMS 600 THROUGH 655,
MAY BE USED BASED ON ASSEMBLY SECTION REQUIREMENTS.
ROTOR NO. 1 ROTOR NO. 2 ROTOR NO. 3 ROTOR NO. 4

–1 210B 211B 212B 213B
213C
–2, –3, –4 210C 211C 212C 213D WHEN USED
WITH IPL ITEM 1A
CUSTOM NOTE 1 NOTE 1 NOTE 1 NOTE 1
CONFIGURATION –1, –2
240, 240A (UNMODIFIED)
205
–1, –2, –3, –4
225
50 240, 240A (MODIFIED)
225 –1, –2, –3, –4
240B
A
225
175 235
180
200
195
220
190
220 220
162
–2, –3, –4
SERVICE 185C 215C 216C 217C 218C 219C 222C 230C
CONFIGURATION
–2, –3, –4
AS 185B 215B 216B 217B 218B 219B 222B 230B
MANUFACTURED
–1
SERVICE 185A 215A 216A 217A 218A 219A 222A 230A
CONFIGURATION
–1
AS 185 215 216 217 218 219 222 230
MANUFACTURED
CUSTOM NOTE NOTE NOTE NOTE NOTE NOTE NOTE NOTE
CONFIGURATION 2 2 2 2 2 2 2 2
PP S1 S2 S3 S4 S5 S6 BP
NOTE 2:
WHEN CUSTOM CONFIGURING BRAKE, IPL ITEMS 500 THROUGH 530,
MAY BE USED BASED ON ASSEMBLY SECTION REQUIREMENTS.
WB–501A
Brake Assembly Exploded View

Page 1004
32-40-08
Apr 18/05
UNITS
FIG. PART AIRLINE EFF. PER
ITEM NUMBER PART NO. NOMENCLATURE CODE ASSY.
1-1 2606672-1 BRAKE ASSEMBLY, Main . . . . . . . . . . . . . . A REF
–1 2606672-2 BRAKE ASSEMBLY, Main . . . . . . . . . . . . . . B REF
–1 2606672-3 BRAKE ASSEMBLY, Main . . . . . . . . . . . . . . C REF
R –1 2606672-4 BRAKE ASSEMBLY, Main . . . . . . . . . . . . . . D REF
(Originally supplied with a 1.0 inch (25
mm) wear pin in the as-manufactured
configuration is now manufactured
with a 1.4 inch (36 mm) wear pin.)
R –1A 2615307 DELETED
–3 S283T002-10* SENSOR, Temperature (Optional) . . . . . . . D AR
(See items 300 through 340 for listing
of attaching hardware)
5 2607013 . CLIP, Spring . . . . . . . . . . . . . . . . . . . . . . . . . 13
–5A MS24665-71 . PIN, Cotter . . . . . . . . . . . . . . . . . . . . . . . . . 13
(Optional)
10 2604234 . RETAINER, Bolt . . . . . . . . . . . . . . . . . . . . . 13
15 2606737 . BOLT, Machine . . . . . . . . . . . . . . . . . . . . . . 13
20 MS20002C7 . WASHER, Recessed . . . . . . . . . . . . . . . . . 13
25 MS21042-4 . NUT, Self-locking . . . . . . . . . . . . . . . . . . . . 4
30 2604849 . SPHERE, Adjuster . . . . . . . . . . . . . . . . . . . 4
35 2603835-2 . TUBE, Adjuster . . . . . . . . . . . . . . . . . . . . . . A 4
36 2607528-5 . TUBE, Adjuster . . . . . . . . . . . . . . . . . . . . . . B,C,D 4
40 2604077-1 . HOUSING, Adjuster . . . . . . . . . . . . . . . . . . A 4
45 2605049-1 . PIN, Adjuster . . . . . . . . . . . . . . . . . . . . . . . . A 4
46 2607091-4 . PIN, Adjuster . . . . . . . . . . . . . . . . . . . . . . . . B,C,D 4
50 2604333 . RETAINER, Pin . . . . . . . . . . . . . . . . . . . . . . 4
(Superseded by 2610484, use until
exhausted)
–50A 2610484 . RETAINER, Adjuster pin . . . . . . . . . . . . . . 4
(Supersedes P/N 2604333)
55 MS16625-1162 . RING, Retaining, internal . . . . . . . . . . . . . 4
60 2607071 . WASHER, Recessed . . . . . . . . . . . . . . . . . A 4
61 2608553 . WASHER, Recessed . . . . . . . . . . . . . . . . . B,C,D 4
64 2603278 . SHEET, Anti-abrasion . . . . . . . . . . . . . . . . 4
* Procurable through Boeing Service Engineering.

Page 1005
32-40-08
Apr 18/05
UNITS
1-65 2606702 . SPRING, Helical compression . . . . . . . . . A 4
(Superseded by P/N 2608288, use
until exhausted)
R 65A 2608288 . SPRING, Helical compression . . . . . . . . . 4
66 2601743 . PLUG, Shipping . . . . . . . . . . . . . . . . . . . . . 1
–67 591305-3 . COUPLING HALF, Bulkhead . . . . . . . . . . 1
(V11362) (See Items 370 through 400
for listing of attaching hardware)
–67A 591305-13 . COUPLING HALF, Bulkhead (Optional) . 1
(V11362) (See Items 370 through 400
for listing of attaching hardware)
70 150635 . VALVE ASSEMBLY, Bleeder . . . . . . . . . . 2
75 AN502-10-6 . . SCREW, Machine . . . . . . . . . . . . . . . . . . . 2
80 MS35338-43 . . WASHER, Lock . . . . . . . . . . . . . . . . . . . . . 2
85 146938 . . SCREW, Bleeder . . . . . . . . . . . . . . . . . . . 2
–87 AS3510-0212C . CABLE, Safety . . . . . . . . . . . . . . . . . . . . . . 1
(Bleeder valve)
–87A MS20995NC32 . WIRE, Nickel-copper . . . . . . . . . . . . . . . . . AR
(Optional)
–88 F10-04 . FERRULE, Safety cable . . . . . . . . . . . . . . 1
(To be used with item 87)
90 2601079 . BUSHING, Machine thread . . . . . . . . . . . . 2
–90A 2604446 . BUSHING, Machine thread . . . . . . . . . . . . AR
(Service repair)
95 151890 . PACKING, Preformed . . . . . . . . . . . . . . . . 2
–95A 2604447 . PACKING, Preformed . . . . . . . . . . . . . . . . AR
(Service repair, use with repair
bushing P/N 2604446)
–97 AS3510-0212C . CABLE, Safety (piston bushings) . . . . . . 4
–97A MS20995NC32 . WIRE, Nickel-copper . . . . . . . . . . . . . . . . . AR
(Optional)
–98 F10-04 . FERRULE, Safety cable . . . . . . . . . . . . . . 4
(To be used with item 97)
100 2606799-224 . RING, Packing backup . . . . . . . . . . . . . . . A 12
R 100A 2606799-224 . RING, Packing backup . . . . . . . . . . . . . . . B,C,D 6
105 2605081 . PACKING, Preformed . . . . . . . . . . . . . . . . 6
110 2606799-218 . RING, Packing backup . . . . . . . . . . . . . . . A 12
Page 1006
32-40-08
Apr 18/05
UNITS
1-111 2606799-219 . RING, Packing backup . . . . . . . . . . . . . . . B,C,D 6
115 2605122 . PACKING, Preformed . . . . . . . . . . . . . . . . A 6
116 2605084 . PACKING, Preformed . . . . . . . . . . . . . . . . B,C,D 6
120 2606718 . PIN, Insulator hold down . . . . . . . . . . . . . . A 6
until exhausted)
125 2602300 . PROTECTOR, Insulator . . . . . . . . . . . . . . A 6
until exhausted)
130 2606699 . INSULATOR, Piston . . . . . . . . . . . . . . . . . . A 6
until exhausted)
–130A 2608844 . INSULATOR, Piston . . . . . . . . . . . . . . . . . . A 6
until exhausted)
135 149629 . CLIP, Split tubular . . . . . . . . . . . . . . . . . . . . A 6
until exhausted)
140 2606698 . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 6
until exhausted)
R 140A 2608422 . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 6
(Supersedes item numbers 120
through 140. Refer to the Assembly
section for details.)
141 2608279 . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . B,C,D 6
145 2607044 . WIPER, Piston . . . . . . . . . . . . . . . . . . . . . . . A 6
–145A 2602303 . WIPER, Piston (Optional) . . . . . . . . . . . . . A 6
146 2608287 . WIPER, Piston . . . . . . . . . . . . . . . . . . . . . . . B,C,D 6
until exhausted)
–146A 2614815 . WIPER, Piston . . . . . . . . . . . . . . . . . . . . . . . B,C,D 6
150 2606700 . BUSHING, Piston . . . . . . . . . . . . . . . . . . . . A 6
151 2608183 . BUSHING, Piston . . . . . . . . . . . . . . . . . . . . B,C,D 6
–151A 2613673 . BUSHING, Piston . . . . . . . . . . . . . . . . . . . . B,C,D 6
(Optional) (No Longer Procurable)
Page 1007
32-40-08
Apr 18/05
UNITS
R 1-151B 2615477 . BUSHING, Piston . . . . . . . . . . . . . . . . . . . . B,C,D 6
(Optional) (Steel with chrome plated
ID, Refer to SB 2606672-32-032)
155 MS9048-232 . PIN, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(Superseded by P/N MS171654,
use until exhausted)
–155A MS171654 . PIN, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(Supersedes P/N MS9048-232)
160 2606697 . PISTON HOUSING AND PLUGS . . . . . . A,B1 1
ASSEMBLY (Superseded by
P/N 2608981, use until exhausted)
(Identified by permanent marking
P/N 2606696)
R 160A 2608981 . PISTON HOUSING AND PLUGS . . . . . . 1
ASSEMBLY (Supersedes
P/N 2606697) (Superseded by
P/N 2609455-1, use until exhausted)
(Identified by permanent marking P/N
2608980)
R 160B 2609455-1 . PISTON HOUSING AND PLUGS . . . . . . 1
P/N 2608981) (Identified by
permanent marking 2608980)
(Superseded by P/N 2611514-1, use
until exhausted)
R 160C 2611514-1 . PISTON HOUSING AND PLUGS . . . . . . 1
P/N 2609455-1) (Identified by
permanent marking P/N 2611513)
162 2610556 . . SPACER, Torque tube . . . . . . . . . . . . . . . 1
163 MS124696 . . INSERT, Screw thread (temperature . . . 2
sensor mounting)
165 MS21209F4-20 . . INSERT, Screw thread . . . . . . . . . . . . . . . 4
(inlet fitting) (Superseded by
P/N MS124736, use until
exhausted)
–165A 2600715 DELETED AR
–165B 2600829 . . INSERT, Screw thread . . . . . . . . . . . . . . . AR
(Self-tapping) (Second oversize for
service repair)
1 Usablein -3 and -4 brake assemblies if modified for temperature sensor (see Description and
Operation section).
Page 1008
32-40-08
Apr 18/05
UNITS
1-165C MS124736 . . INSERT, Screw thread . . . . . . . . . . . . . . . 4
(Supersedes P/N MS21209F4-20)
–170 281101 . . PLUG, Expansion . . . . . . . . . . . . . . . . . . . 7
(Standard) (V92555) (Superseded
by P/N AS3122-07 and
P/N AS3121-07, use until
exhausted)
–170A 291101 . . PLUG, Expansion . . . . . . . . . . . . . . . . . . . AR
(Oversize) (V92555) (Superseded
by P/N AS3122-07 and
P/N AS3121-57, use until
exhausted)
172 AS3122-07 . . PIN, Expansion, long . . . . . . . . . . . . . . . . AR
(This item plus P/N AS3121-07
supersede P/N 281101)
173 AS3121-07 . . PLUG, Expansion, long . . . . . . . . . . . . . . AR
(This item plus P/N AS3122-07
supersede P/N 281101)
–173A AS3121-57 . . PLUG, Expansion, long . . . . . . . . . . . . . . AR
(Oversize) (This item plus
P/N AS3122-07 supersede
P/N 291101)
175 2603041 . . RETAINER, Pin . . . . . . . . . . . . . . . . . . . . . 2
180 2603057 . . PIN, Reline indicator . . . . . . . . . . . . . . . . 2
185 357453 . LINING, Cerametallic . . . . . . . . . . . . . . . . . A 13
(Pressure plate surface) Nominal
thickness 0.255 inch (6.48 mm) (Two
orange stripes)
185A 357486 . LINING, Cerametallic . . . . . . . . . . . . . . . . . A 13
thickness 0.335 inch (8.51 mm) (One
orange stripe)
185B 357488 . LINING, Cerametallic . . . . . . . . . . . . . . . . . B,C,D 13
gray stripe)
185C 357562 . LINING, Cerametallic . . . . . . . . . . . . . . . . . B,C,D 13
red stripes)
Page 1009
32-40-08
Apr 18/05
UNITS
ATTACHING PARTS
1-190 2608438-3 . . RIVET, Semitubular, 0.25 inch . . . . . . . . 13
(6.35 mm) diameter by 0.42 inch
(10.7 mm) long
–190A MS20427-8x8 . . RIVET, Solid, 0.25 inch (6.35 mm) . . . . AR
diameter by 0.50 inch (12.7 mm)
long (optional) (Carbon steel)
–190B 2606714-3 DELETED AR
–190C MS20427-8x9 DELETED AR
–190D 2608438-3 DELETED 13
---*---
195 2603038 . RETAINER, Pin . . . . . . . . . . . . . . . . . . . . . . 2
ATTACHING PARTS
200 MS20427M6-6 . . RIVET, Solid . . . . . . . . . . . . . . . . . . . . . . . 2
---*---
205 2606703 . PLATE, Pressure . . . . . . . . . . . . . . . . . . . . 1
R –209 2609283 . FASTENER, Ceramatallic lining . . . . . . . . AR
(Pressure plate and backing plate
lining fastener hole repair)
–210 2606711-620 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
(Rotor position No. 1) (0.620 inch
(15.75 mm) nominal thickness)
(Superseded by P/N 2610611-620,
–210A 2606711-750 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . B,C,D 1
210B 2610611-620 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
(Supersedes P/N 2606711-620)
210C 2610611-750 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . B,C,D 1
Page 1010
32-40-08
Apr 18/05
UNITS
1-211 2606711-580 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
R 211B 2610611-580 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
–212 2606711-580 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
–213 2606711-540 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . A 1
Page 1011
32-40-08
Apr 18/05
UNITS
1-213A 2606711-620 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . B,C,D 1
213D 2610611-580 . ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . B,C,D 1
(S1 surface) Nominal thickness 0.255
inch (6.48 mm) (Two orange stripes)
inch (8.00 mm) (One red stripe)
inch (6.99 mm) (One gray stripe)
inch (9.27 mm) (Two red stripes)
inch (8.00 mm) (One red stripe)
Page 1012
32-40-08
Apr 18/05
UNITS
1-216C 357484 . LINING, Cerametallic . . . . . . . . . . . . . . . . . B,C,D 13
inch (7.49 mm) (One black stripe)
inch (5.97 mm) (One black and one
yellow stripe)
inch (7.49 mm) (One black stripe)
yellow stripe)
yellow stripe)
Page 1013
32-40-08
Apr 18/05
UNITS
1-219C 357453 . LINING, Cerametallic . . . . . . . . . . . . . . . . . B,C,D 13
ATTACHING PARTS
220 2608438-1 . . RIVET, Semitubular . . . . . . . . . . . . . . . . . 39
0.25 inch (6.4 mm) diameter by 0.47
inch (11.9 mm) long
–220A MS20427-8x8 . . RIVET, Solid . . . . . . . . . . . . . . . . . . . . . . . AR
0.25 inch (6.4 mm) diameter by 0.50
inch (12.7 mm) long (Optional)
(Carbon steel)
–220B 2606714-3 DELETED AR
–220C MS20427-8x9 . . RIVET, Solid . . . . . . . . . . . . . . . . . . . . . . . AR
0.25 inch (6.35 mm) diameter by
0.5625 inch (14.288 mm) long
(Optional) (Carbon steel)
---*---
yellow stripe)
yellow stripe)
225 2606712 . PLATE, Stator . . . . . . . . . . . . . . . . . . . . . . . A 3
until exhausted)
–225A 2608214 . PLATE, Stator . . . . . . . . . . . . . . . . . . . . . . . 3
until exhausted)
–225B 2614056 . PLATE, Stator . . . . . . . . . . . . . . . . . . . . . . . 3
Page 1014
32-40-08
Apr 18/05
UNITS
1-230 357453 . LINING, Cerametallic . . . . . . . . . . . . . . . . . A 13
(Backing plate surface) Nominal
orange stripes)
gray stripe)
black and one yellow stripe)
orange stripes)
ATTACHING PARTS
235 2608438-3 . . RIVET, Semitubular . . . . . . . . . . . . . . . . . 13
0.42 inch (10.7 mm) long
–235A MS20427-8x8 . . RIVET, Solid . . . . . . . . . . . . . . . . . . . . . . . AR
0.50 inch (12.7 mm) long (Optional)
(Carbon steel)
–235B 2606714-3 DELETED AR
–235C MS20427-8x9 DELETED AR
–235D 2608438-3 DELETED 13
---*---
240 2606706 . TUBE, Stator torque . . . . . . . . . . . . . . . . . . A,B1 1
until exhausted)
R 240A 2607941 . TUBE, Stator torque . . . . . . . . . . . . . . . . . . A,B1 1
until exhausted)
R 240B 2608978-1 . TUBE, Stator torque . . . . . . . . . . . . . . . . . . 1
(Supersedes P/N 2606706 and
P/N 2607941) (Identified by
permanent marking P/N 2608978)
–244 2609283 . FASTENER . . . . . . . . . . . . . . . . . . . . . . . . . AR
1 Usablein -3 and -4 brake assemblies if modified for temperature sensor (see Description and
Operation section).
Page 1015
32-40-08
Apr 18/05
UNITS
1-245 2603435 . PLATE, Instruction (fluid) . . . . . . . . . . . . . . 1
R –250 2602886 . PLATE, Instruction . . . . . . . . . . . . . . . . . . . 1
(Brake reline) (Superseded by P/N
2609282, use until exhausted)
R –250A 2609282 . PLATE, Instruction . . . . . . . . . . . . . . . . . . . 1
(Brake reline) (Supersedes P/N
2602886)
–255 40726 . DECAL, Name plate . . . . . . . . . . . . . . . . . . 1
–256 2611469 . DECAL, Warning (I.D.) . . . . . . . . . . . . . . . . 1
(Optional use for 737-200 only)
TEMPERATURE SENSOR,
P/N S283T002-10 ATTACHING PARTS
(OPTIONAL)*
–300 2607013 . . CLIP, Spring . . . . . . . . . . . . . . . . . . . . . . . . D 2
–310 2604234 . . RETAINER, Bolt . . . . . . . . . . . . . . . . . . . . D 2
–320 MS20995NC32 . . WIRE, Nickel-copper . . . . . . . . . . . . . . . . D AR
(Optional when used with items
330A and 340A; replaces
P/N 2607013 and P/N 2604234)
–330 2606737 . . BOLT, Machine . . . . . . . . . . . . . . . . . . . . . D 2
–330A BACB30MT4HT3* . . BOLT, Machine . . . . . . . . . . . . . . . . . . . . . D 2
(Optional when used with items 320
and 340A)
–340 MS20002C7 . . WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . D 2
–340A BACW10BP4C* . . WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . D 2
(Optional when used with item
330A)
---*---
BULKHEAD COUPLING, P/N 591305-3
OR P/N 591305-13 ATTACHING PARTS
–370 MS28774-211 . . RING, Packing backup . . . . . . . . . . . . . . 2
–380 NAS1611-211 . . PACKING, Preformed . . . . . . . . . . . . . . . 1
–380A NAS1611-211A . . PACKING, Preformed . . . . . . . . . . . . . . . 1
(Optional)
–390 BACB30NM4HK3* . . BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–400 BACW10BP4ACU* . . WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . 3
---*---
* Procurable through Boeing Service Engineering.
Page 1016
32-40-08
Apr 18/05
UNITS
LIST OF SERVICE LININGS. SELECT
AS REQUIRED FOR SERVICE
CONFIGURATIONS.
1-500 357479 . LINING, Cerametallic . . . . . . . . . . . . . . . . . 13
Nominal thickness 0.315 inch (8.00
mm) (One red stripe)
–505 357484 . LINING, Cerametallic . . . . . . . . . . . . . . . . . 13
mm) (One black stripe)
mm) (One orange stripe)
mm) (One gray stripe)
mm) (Two orange stripes)
mm) (One black and one yellow
stripe)
mm) (Two red stripes)
LIST OF SERVICE ROTORS. SELECT
AS REQUIRED FOR SERVICE
CONFIGURATIONS.
–600 2606711-540 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . A 1
0.540 inch (13.72 mm) nominal
thickness
–605 2606711-580 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–610 2606711-620 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–615 2606711-660 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
Page 1017
32-40-08
Apr 18/05
UNITS
1-620 2606711-700 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–625 2606711-750 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–630 2610611-540 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . A 1
thickness
–635 2610611-580 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–640 2610611-620 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–645 2610611-660 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–650 2610611-700 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
–655 2610611-750 . ROTOR ASSEMBLY, . . . . . . . . . . . . . . . . . 1
thickness
Page 1018
32-40-08
Apr 18/05
APPENDIX A - VENDOR CONTACT INFORMATION
The following is a list of vendor contact information.
CMM
Section CMM Specification
Reference Reference Equivalence Code Vendor
Cleaning Turco 1N6B3 Henkel Service Technologies
Cleaner/Solvent 32100 Stephenson Highway
5948 R or 5948 Madison Heights, Michigan 48076,
DPM U.S.A.
Telephone: (800) 848-0085 or
(248) 583-9300
Fax: (248) 583-2976
Website: www.turcoproducts.com
Repair EC-2214 Hi-Temp 3M Engineered Adhesives Division
(One-Part 3M Center, Building 220-7E-01
Heat-Curing Epoxy St. Paul, Minnesota 55144-1000, U.S.A.
Adhesive) Telephone: (800) 362-3550
Fax: (651) 733-9175
Website: www.3M.com
Repair Devcon F 0RZG3 Devcon
30 Endicott Street
Danvers, Massachusetts 01923-3712,
U.S.A.
Telephone: (800) 933-8266 or
(978) 777-1100
Fax: (978) 774-0516
Website: www.devcon.com
Repair Heli-CoilR: 5W060 Olander Company Inc.
Thread Inserts 144 Commercial Street
#2391-4CN-500; Sunnyvale, California 94086-5298,
#3891-4CN-500; U.S.A.
Twinsert Telephone: (800) 538-1500 or
#4691-4CN-464; (408) 735-1850
Insert Fax: (408) 735-6515
P/N Website: www.olander.com
1191-7CN-0656;
Gage
P/N 3694-7;
Tap
P/N 44193-7
Assembly BATCO X-8401-2 60226 Battenfeld Grease and Oil Corporation
Grease P.O. Box 728
1174 Erie Avenue
North Tonawanda, New York
14120-0728, U.S.A.
Telephone: (716) 695-2100
Fax: (716) 695-0367
Website: www.battenfeld-grease.com
Page A-1
32-40-08
Jan 15/04
CMM
Special 06848 Honeywell Ground Support Equipment
Tools, Attn: Robert A. Battista
Fixtures, 717 North Bendix Drive
and South Bend, Indiana 46628, U.S.A.
Equipment Telephone: (574) 231-2706
Fax: (574) 231-4128
Email: robert.battista@honeywell.com
IPL 55284 Honeywell International Inc.,
Aircraft Landing Systems
South Bend, Indiana 46628-1373,
U.S.A.
Telephone: (574) 231-2000
Fax: (574) 231-2334
Website: www.
HoneywellAircraftLandingSystems.com
Honeywell International Inc.,
Aircraft Landing Systems
Product Support Center
1730 North Topping
Kansas City, Missouri 64120, U.S.A.
Telephone: (816) 231-8400
Fax: (816) 231-2775
Website: www.
HoneywellAircraftLandingSystems.com
(click on the Contact ALS link)
IPL 55284 Honeywell European Distribution
Center (EDC)
Honeywell DC Hangar 14/SPLVR
Hangar 14 Schiphol East
1117 ZL Amsterdam Schiphol Airport
The Netherlands
Telephone: +31 (0) 20 648 2269 or
+31 (0) 20 649 4183
Fax: +31 (0) 20 648 2299
Email: HONEYWELL.EDC@
HONEYWELL.COM
Website: www.HoneywellAircraft
LandingSystems.com (click on the
Contact ALS link)
IPL Parker Aerospace Customer Support
14300 Alton Parkway
Irvine, California 92618, U.S.A.
Telephone: (949) 833-3000
Aircraft On Ground After Hours Support
Telephone: (949) 851-4257 (HELP)
Website:
www.parker.com/aeroCSCD/intro/index.
asp.
Page A-2
32-40-08
Jan 15/04
CMM
IPL 73957 Groov-Pin Corporation
1125 Hendricks Causeway
Ridgefield, New Jersey 07657-2105,
U.S.A.
Telephone: (201) 945-6780
Fax: (201) 945-8998
Website: www.groove-pin.com
IPL 92555 The Lee Company
2 Pettipaug Road
P.O. Box 424
Westbrook, Connecticut 06498-0424,
U.S.A.
Telephone: (800) 633-7584 or
(860) 399-6281
Fax: (860) 399-2270
Website: www.theleeco.com/LEEWEB/
SERVICE.htm
Page A-3
32-40-08
Jan 15/04
Page A-4
32-40-08
Jan 15/04

Banda Bendix 2606672-1 Rev (1) .15 Sep.28, 2007

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Banda Bendix 2606672-1 Rev (1) .15 Sep.28, 2007

Uploaded by

Copyright:

Available Formats

PDM Controlled InterleafDocument File, Received On 09/27/2007 09:43:14

Honeywell International Inc.

Component Maintenance Manual

REVISION NOTICE: Latest revised pages

Publication Number 12-557, Revision 15

COMPONENT MAINTENANCE MANUAL

Honeywell Materials License Agreement

32-40-08 Page T-2

COMPONENT MAINTENANCE MANUAL

Honeywell is a registered trademark of Honeywell International Inc.

32-40-08 Page T-3

COMPONENT MAINTENANCE MANUAL

32-40-08 Page T-4

COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL

Issue Date Issue Date

COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL

TEMP. REV. PAGE ISSUE DATE

File: 12-557_rtr.ildoc, Revision: 1, Status: Released, Released On 10/15/2002

COMPONENT MAINTENANCE MANUAL

This page intentionally left blank.

File: 12-557_rtr.ildoc, Revision: 1, Status: Released, Released On 10/15/2002

COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL

SUBJECT PAGE DATE SUBJECT PAGE DATE

COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL

SUBJECT PAGE DATE SUBJECT PAGE DATE

Subject Page No.

Subject Page No.

Unit of Measure Abbreviation

This page intentionally left blank.

Aircraft Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737-200H/-300/-400/-500

Reference Number Description

BOEING PISTON HOUSING

Brake Assembly Reference Numbers

BRAKE TIE BOLTS

DIMENSIONS ARE PROVIDED IN INCHES WITH

Main Brake Assembly - Cutaway View

1 MISMATCH NOT ALLOWED BETWEEN 0.46 - 0.47 (11.7 - 11.9)

0.31 (7.9) DIA THRU TO REMOVE

DIMENSIONS ARE PROVIDED IN INCHES WITH

Rework of Piston Housing to Incorporate Two-Bolt Attachment for Temperature Sensor

DIMENSIONS ARE PROVIDED IN INCHES WITH

Rework of Stator Torque Tube to Incorporate Temperature Sensor

REMOVE SHADED AREA 7 PLACES USING A

0.06 (1.5) APPROX

0.500 (12.70) DIA CYLINDRICAL ROTARY FILE

VIEW 1 – REMOVAL OF MATERIAL USING ROTARY FILE

ORIENT PIN HEAD AS SHOWN WITH

VIEW 2 – INSPECTION OF REWORK USING ADJUSTER PIN (46)

DIMENSIONS ARE PROVIDED IN INCHES WITH

Rework of Pressure Plate if Adjuster Removal is Difficult

REMOVE BURRS AND SHARP EDGES

65° $ 1/2° (REF)

Rework of Stator Torque Tube to Prevent Possible Wheel Damage

Overhaul of the brake assembly shall be accomplished at intervals of no more

1.1 General Instructions Applicable to the Testing Section

2.1 Bleed Brake Assembly

3.1 Leakage Test

D. Functional Test and Checking of Running Clearance.