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Assembly Tips for D.I.Y. Kits - Hydraulic Axle Assembly

**WARNING**

These instructions assume some basic mechanical knowledge and the ability to weld to an acceptable standard. if in doubt please refer the job to qualified personnel.

1. Pack bearings with grease and fit large inner bearings to hubs and Hubdrums

2. Fit grease seals to rear of hubs and hubdrums.

3. Fit hubs to lazy axle. Fit small outer bearings and tighten down castle nut firmly.
This ensures bearing cups are pressed firmly into hubs. Back off castle nut until hub is loose,
then re-tension until free-play in hub is gone
but bearings are under no pre-load (over tightening shortens bearing life)

4. Fit split pin and dust cap. Lazy axle is now assembled.

5. Bolt hydraulic brake backing flanges to hydraulic brake backing assemblies.

6. Slide hydraulic brake assemblies onto braked axle. Note- LH(RL) & RH(RR) orientation. Ensure brake bleeders are to top of axle

7. Fit hubdrums to brakes axle with same procedure as steps (3) & (4)

8. Slide hydraulic brake backing assemblies completely into hubdrum assemblies now fitted onto axle.
Mark axle from flange to a point approx 6mm back.
Withdraw brake backing assemblies to this point and use shoe adjustment cam nuts to square up backing assemblies inside hubs.
This holds assembled firm and square inside hubdrums for welding.

9. Weld backing flange to axle (from outside all around), using mig or low hydrogen electrodes.

10. Back off cam adjustment nuts until hubdrums can be rotated with a slight drag on brake shoes.Weld 1/4" BSW x 1" long mounting bolts head to rear side of axle approx. 350mm from RH side hydraulic brake backing assembly.

11. Weld 1/4" BSW x 1" long mounting bolts head to rear side of axle approx. 350mm from RH side hydraulic brake backing assembly

12. Weld tabs to secure brake lines - 3 to long side and 1 to short side.

13. Fit 3-way block to mounting bolt.

14. Fit hydraulic brake adaptors and copper washers to slave cylinders of brake assemblies.

15. Run long side and short side brake lines in 3/16" bundy tube using short tube nuts and double flare to length as required and fit under tabs welded into position.

16. Fit flexible brake line to inlet of 3-way block.Fit brake bleeders. Hydraulic braked axle is now assembled..

Final Assembly

1. Fit 2.0T hydraulic coupling to drawbar.

2. Run remaining 3/16" bundy tube from flexible brake line using a double flare and short tube nut up to master cylinder on coupling. Fit off at master cylinder using long tube nut and compression olive.

3. To bleed brakes, fill master cylinder with brake fluid. Use handbrake assembly on coupling to manually bleed. Bleed long side first (LH side), then short side. No air is present in system when hand brake lever actuator does not "pump up" on repeated operation.

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