SERVICE MANUAL 5. Remove   service   brake   chamber   clamp   band assembly   (clamp  closest   to  mounting bolts). 6. New  spring  brake  unit  should  have  release  bolt fully  extended  outward,  like  a  manual  released unit. Fig. 10 7. Inspect  diaphragm,  return  spring  and  inside  of non pressure (service brake) chamber. Replace  any  worn  or  damaged parts. 8. If   service   brake   diaphragm   is   being   replaced, position diaphragm on brake chamber. 9. Position spring brake unit (new if replaced or old if  only  service  brake  chamber  diaphragm  being replaced)  on  service  brake  chamber  half.  Align air hose ports. 10. Install  clamp  band.    Tap  the  clamp  band  all  the way around while tightening the clamp band nuts to  insure  proper    seating.  Tighten  nuts  to  27-34 N.m (20-25 ft lbs). 11. Apply   sealing   compound   to   hose   fittings   and install  fittings  and  air  hoses. Torque fittings to 34 N.m (25 ft lbs). Do not use impact wrench on air fittings. 12. Apply  air  to  service  brakes.   Remove locking pliers and check for air leaks. 13. Adjust service  brakes  as  outlined  in  the  Service Manual Section which applies. 14. Apply  air  to  spring  brake  by  pushing  control  at instrument      panel   to      release   mode.      Turn release  bolt  clockwise    to  manually  set  spring brake.  Turn  bolt  until  it  is  fully  engaged  into  the unit and the  slotted  nut  bottoms  on  the  unit. Tighten  nut  to  61-68  N.m  (45-50  ft  lbs).  Do  not use an impact wrench. 15. Snap breather cap in place over seal, with arrow on breather cap pointing to the ground. REPLACE SPRING BRAKE SUSPECTED DEFECTIVE PUSH ROD SEAL WARNING Do  not  attempt  to  disassemble  the  rower spring section while unit is on vehicle since it   is   spring      loaded.      Sudden   accidental release    of    the    power    spring    will    cause spring    brake    components  to  be  .  hurled with   dangerous   force   which   could   strike persons        In    the    area    causing    serious personal injury or death. 1. Refer     to text REPLACE SPRING BRAKE DIAPHRAGM.      Give    special  attention    to  the WARNING   references.      Perform   steps   1   thru and   including   7   to   remove   the   spring   brake chamber.  Then perform steps 3, 4 and 5 in the instructions    for    REPLACE     SPRING     BRAKE UNIT OR SERVICE BRAKE DIAPHRAGM. 2. Remove  the  pushrod  screw,  plate  and  rod.  The screws  are  secured  with  Loctite   material.      To remove the screws and pushrod assembly: a. Position  a  phillips  screwdriver  handle  in  a vise so that the blade extends outward. b. Heat one of the screws to ease their removal. c. Position the case assembly over the phillips screwdriver    in    the    vise;    with    a    second phillips  screwdriver  loosen  and  remove  the opposite screw (Fig. 11). Fig. 11 Fig. 12 It  is  important  to  hold  the  case  tight  against  the screwdriver    in    the    vise    and    slowly    remove pressure    to    prevent    the    return    spring    from releasing  suddenly.  Remove  all  parts  from  the case (Fig. 12). 3. Wash all parts in cleaning solvent. 4. Remove guide rings and pushrod seal (Fig. 13). The  seal  can  be  removed  by  inserting  a  small screwdriver behind the seal and carefully pry the seal out of the groove as shown in Fig.  14 CTS-4101W - Page 8