16-031Ins

TECHNICAL SERVICE BULLETIN
TSB#:
16-031
Date of Publication:
Job Code: 9801314
Flat Rate:
2 hr
October 2016
NOTE: This Technical Service Bulletin will be valid within (1) year from the original date of publication.
Action required
Change out two 5200lb over slung axles to two 4400lb under slung axles.
Affected Units
2017 Octane Super Lite TT
H1V20171 - H1V20206
Parts Kit 16-031J
2 4400lb under slung axle
1 Attaching Kit
Tools / Supplies
4 Jack stands (Minimum 6,000 lbs each)
Wire crimpers
Wire cutters
Impact driver
Impact sockets: 3/4" and 11/16" deepwells
Wrench 13/16" open end / box end
Floor Jack
Screwdriver or punch
Small sledge hammer
Safety glasses
Torque Wrench (Ft / lbs)
INSTRUCTIONS
FIG 1
1
FIG 2
Fig 1: Loosen all lug nuts on all 4 wheels using a 3/4 inch deepwell socket and impact driver.
Fig 2: Jack up the trailer with 4 jack stands under the trailer frame and lift the entire trailer and wheels off the ground.
NOTE: JACK STANDS MUST BE RATED MINIMUM OF 6,000 LBS EACH
Remove all 4 wheels from the axles.
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TO REMOVE THE FRONT AXLE
Front Axle
FIG 3
1
Front Axle
FIG 4
Cut front
brake wires at
the copper
sleeves
Fig 3: Place a floor jack under the front axle for support while the hardware is removed.
Fig 4: Cut the brake wires on the front axle located on the Off Door Side of the trailer.
Cut the wires at the copper sleeve connectors making total of 6 individual wires.
Front Axle
Front Axle
Remove front
spring hanger
bolt
FIG 5
3
FIG 6
Remove front
axle equalizer
bolt
Fig 5: Use the 11/16 socket and the 13/16 box end wrench to remove the nut from the spring hanger bolt.
Fig 6: Use the 11/16 socket and the 13/16 box end wrench to remove the nut from the equalizer
When nuts are removed, the bolts(2) must be driven out with a sledge hammer and a screwdriver or punch.
Discard old hardware, DO NOT USE ON NEW AXLE Use new hardware from the parts kit.
Do NOT remove the equalizers.
Repeat Step 3 to remove the same nuts and bolts on the Door Side of the trailer.
Lower and remove the front axle.
TO REMOVE THE REAR AXLE
Place a floor jack under the rear axle for support while the hardware is removed.
Cut the brake wires - Blue and Black / White and Black
Cut the wires at the copper sleeve connectors making a total of 4 individual wires.
Rear Axle
FIG 7
5
Remove rear
spring hanger
bolt
Remove this
bolt from
equalizer
FIG 8
Fig 7: Use the 11/16 socket and the 13/16 box end wrench to remove the nut from the spring hanger bolt.
Fig 8: Use the 11/16 socket and the 13/16 box end wrench to remove the nut from the equalizer
When nuts are removed, the bolts(2) must be driven out with a sledge hammer and a screwdriver or punch.
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Discard old hardware, DO NOT USE ON NEW AXLE Use new hardware from the parts kit.
Lower and remove the rear axle.
INSTALL NEW FRONT AXLE
TORQUE TO
45 FT/LBS
Attach new
axle to lower
hole
Front Axle
Knurled area
at the bolt
head
FIG 10
FIG 9
6
7
Fig 9: Raise new front axle in position under the trailer with the floor jack.
Install a new bolt from the kit in the LOWER hole in the front spring bracket.
Fig 10: Bolts have a knurled area under the bolt head. Bolts must be driven in with a sledge hammer to seat properly.
The bolt head must be flush against the spring bracket to be seated correctly.
Install a new nut on the bolt, and at least 3 threads of the bolt must be visible once the nut is tightened.
Use the torque wrench with the 11/16 socket and 13/16 box end wrench to TORQUE THE BOLT TO 45 FT/LBS
TORQUE TO
45 FT/LBS
FIG 11
8
Front Axle
Install a new
front equalizer
bolt
Fig 11: Install a new bolt and nut on the equalizer and TORQUE TO 45 FT/LBS.
The bolt head must be driven flush to the equalizer bracket with the sledge hammer.
Install a new nut on the bolt and at least 3 threads must be visible once the nut is tightened.
Repeat the bolt installation for the other side of the trailer for the front axle.
INSTALL NEW REAR AXLE
Repeat Steps 6-8 Figures 9-11
Front & Rear Axle
Strip brake
wires approx.
1/2 inch
Front Axle
3"
Strip back
shield approx.
3 inches
9
FIG 12
FIG 13
Fig 12: Strip back approx. 3 inches of the brake wire shielding.
Fig 13: At the front axle; strip 6 wires approximately 1/2 inch (2 blue, 2 white and 2 black)
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At the rear axle; strip 4 wires approximately 1/2 inch (2 black, 1 blue and 1 white)
Front Axle
Rear Axle
Rubber cap
Rubber cap
Copper sleeve
Copper sleeve
FIG 14
FIG 15
10 Fig 14: Front Axle brake wire connections:
Crimp 2 blue wires and 1 black wire together with a copper crimp sleeve.
Crimp 2 white wires and 1 black wire together with a copper crimp sleeve.
Install a rubber cap over each copper sleeve.
Fig 15: Rear axle brake wire connections:
11 Crimp 1 blue wire and 1 black wire together with a copper crimp sleeve.
Crimp 1 white wire and 1 black wire together with a copper crimp sleeve.
Install a rubber cap over each copper sleeve.
Tie the brake wires up to the axle to prevent contact with suspension.
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