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For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 1999 🢒 Isuzu MD Steel Tilt (F Model) 🢒 Brakes 🢒 Air Drums 🢒 Trailer Coupling Hose and Line Bracket Replacement

Trailer Coupling Hose and Line Bracket Replacement Nylon and Metal - Compression

Removal Procedure

    Object Number: 201481 Size: SH

    Notice: When replacing tubing, make sure that the tubing is free of burrs, cuttings, and dirt. While wearing safety glasses, use compressed air to blow out contaminants. Contaminants can destroy the air brake valve sealants.

    Notice: Nylon air line should be used to replace existing nylon lines only. Do not route nylon air lines in areas where temperatures could exceed 93°C (200°F). Damage to the nylon lines could occur.

  1. Apply the parking brake.
  2. Block the wheels.
  3. Remove the exhaust air from the lines. Refer to Draining Reservoirs

Assembly and Disassembly Procedure

    Object Number: 201481 Size: SH
  1. Remove the clips or the tubing clamps.
  2. Remove the air line.
  3. Remove the tube nuts from each fitting.
  4. Remove the compression ring from the tube.
  5. Clean the fittings and the tube nuts with a clean cloth.
  6. Inspect the fittings and the tube nuts for the following conditions:
    7. • Nicks
    • Burrs
    • Wear Spots
  7. Replace any damaged components.

    8. Object Number: 201499 Size: SH

    Important: Do not use the flared-type fittings in the air brake system. When replacing the air lines, use the end fitting kits to make new air line assemblies. Special tools are not required.

  8. Cut the tube squarely at each end the same length as the old tube. Shape the metal tube to match the old tube.
  9. Assemble the tube nut on the new tube.
  10. Assemble the compression ring on the tube.

    11. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important: Check that the tubing is completely inserted as far as it will go into the fitting.

  11. Assemble the fitting and the tube.

    12. Tighten
    Tighten the tube nut until 1½ threads remain exposed between the tube nut and the fitting.

Installation Procedure

    Object Number: 201481 Size: SH
  1. Install the air line.
  2. Install the clips or the tubing clamps.
  3. Start the engine.
  4. Charge the system air pressure to the governor cut-out point.
  5. Check for leaks using a soap solution. Leaks are not permissible.
  6. Check for the proper brake operation.
  7. Remove the wheel blocks.

Trailer Coupling Hose and Line Bracket Replacement Nylon - Push-In

Removal Procedure

    Notice: Nylon air line should be used to replace existing nylon lines only. Do not route nylon air lines in areas where temperatures could exceed 93°C (200°F). Damage to the nylon lines could occur.

    Notice: When replacing air lines connected to the push-in type fittings, be certain that the nylon air line is pushed-in and seated in the fitting. Install the tube into the fitting until no tube color is visible between the gauge band and the fitting. The air line may blow out if the tube is not properly seated in the fitting.

  1. Apply the parking brake.
  2. Block the wheels.
  3. Remove the exhaust air from the lines. Refer to Draining Reservoirs .

    4. Object Number: 201509 Size: SH
  4. Remove the clips or the tubing clamps as needed.

    5. Important: Once removed, the nylon tube can be reinserted up to five times before it must be replaced.


    Object Number: 227738 Size: SH
  5. Remove the nylon tube from the fitting using the following procedure:
    6. 5.1. Push the nylon tube into the fitting until it bottoms on the tube stop.
    5.2. Depress the collet.
    5.3. Continue to depress the collet, while removing the tube from the fitting.
  6. Inspect the fitting for the following conditions:
    7. • Nicks
    • Burrs
    • Wear spots
  7. Replace the fitting if any of the aforementioned conditions exist.

    8. Object Number: 201499 Size: SH
  8. Cut the nylon tube with a sharp tube cutter.

    9. Object Number: 201515 Size: SH
  9. Check that the nylon tube is cut square and is free of burrs.
  10. Assemble the nylon tube into the fitting. Push the tube firmly into the fitting until it bottoms on the tube stop.

Installation Procedure
  1. Place tape around the air line to bundle it with the other air lines.
  2. Start the engine.
  3. Charge the system air pressure to the governor cut-out point.
  4. Check for leaks with a soap solution around the fittings. Leakage is not permissible.
  5. Check for proper brake operation.
  6. Remove the wheel blocks.

Trailer Coupling Hose and Line Bracket Replacement Flexible Hose

Removal Procedure
  1. Apply the parking brake.
  2. Block the wheels.
  3. Exhaust the air from the lines. Refer to Draining Reservoirs .
  4. Remove the air line.

    5. Object Number: 228434 Size: SH
  5. Unscrew the nipple from the socket and the flexible hose.

    6. Object Number: 201523 Size: SH
  6. Disassemble the flexible hose. Turn the hose clockwise in order to unscrew the hose from the socket.
  7. Clean the nipple and the socket with a clean cloth.
  8. Inspect the nipple and the socket for the following conditions:
    9. • Nicks
    • Burrs
    • Wear spots
  9. Replace any damaged components.

    10. Object Number: 201546 Size: SH
  10. Use a fine tooth hacksaw or cutting wheel in order to cut the flexible hose squares the same length as the original part.

    11. Object Number: 201555 Size: SH
  11. Assemble the flexible hose into the socket. Turn the hose counterclockwise in the socket until it bottoms; then back of the flexible hose ¼ turn.

    12. Object Number: 201548 Size: SH
  12. Lubricate the nipple threads with clean engine oil.
  13. Assemble the nipple.

    14. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  14. Tighten the nipple.

    15. Tighten
    Tighten the nipple, leaving a 0.8 mm (0.03 in) clearance between the nipple hex and the socket.

Installation Procedure

    Object Number: 201561 Size: SH
  1. Install the air line.
  2. Start the engine.
  3. Charge the system air pressure to the governor cut-out point.
  4. Check for leaks with a soap solution. No leakage is permissible.
  5. Test the brakes for proper operation.
  6. Remove the wheel blocks.

Trailer Coupling Hose and Line Bracket Replacement Trailer Brake Coupling

Removal Procedure

    Object Number: 201579 Size: SH
  1. Apply the parking brake.
  2. Block the wheels.
  3. Remove the trailer air brake coupling from the stud.

Installation Procedure

    Object Number: 201579 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the trailer air brake coupling to the stud.

    2. Tighten
    Tighten the trailer air brake coupling to 35 N·m (26 lb ft).

  2. Remove the wheel blocks.

Trailer Coupling Hose and Line Bracket Replacement Trailer Brake Dummy Cap

Removal Procedure

    Object Number: 201619 Size: SH
  1. Apply the parking brake.
  2. Block the wheels.
  3. Remove the following components:
    4. 3.1. The nut
    3.2. The washer
    3.3. The bolt
  4. Remove the trailer air brake dummy coupling from the trailer air brake coupling.

Installation Procedure

    Object Number: 201619 Size: SH
  1. Install the trailer air brake dummy coupling to the trailer air brake coupling.
  2. Install the following components:
    3. 2.1. The bolt
    2.2. The washer

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    2.3. The nut

    Tighten
    Tighten the nut to 30 N·m (22 lb ft).

  3. Remove the wheel blocks.