Component Maintenance Manual With Illustrated Parts List Main Brake Assembly

Aircraft Wheels & Brakes
Goodrich Corporation
P.O. Box 340
Troy, Ohio 45373
U.S.A
TEL: 937-339-3811
FAX: 937-440-2055
https://techpubs.goodrich.com
CAGE 97153
COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
MAIN BRAKE ASSEMBLY
Goodrich Cessna
Part Number Part Number
2-1559-1 9912398-5
2-1559-2 9912398-6
2-1559-3 9912398-8
These commodities, technology, or software are controlled by the U.S. Export Administration Regulations (EAR).
Diversion contrary to U.S. law is prohibited.
ECCN: 9E991
© 2009
Initial Issue: Jan 30/93 32-46-46 TP1
Rev 4
Aug 11/09
GOODRICH CORPORATION
Part Number 2-1559
TITLE PAGE
INTENTIONAL BLANK PAGE
32-46-46 TP 2
Aug 11/09
This document is subject to the controls and restrictions on the first page.
Part Number 2-1559
REVISION HIGHLIGHTS
Revision No. 4
Dated: Aug 11/09
This manual is issued to replace the previous manual, dated Aug 15/95.
AFFECTED
REVISIONS
SECTIONS
Replaced all pages to show the new "Goodrich Corporation" name All
Converted all text to (AECMA SIMPLIFIED ENGLISH) (international
aerospace maintenance language) (refer to AECMA document
PSC-85-16598)
All
Change bars were not added because of the large number of changes
to the data and by the conversion to (AECMA Simplified English)
Added some warnings and revised other warnings All sections
with Warnings
Added CESSNA part numbers to the Title page Title Page
Added the words INTENTIONAL BLANK PAGE and an issue date to All sections with a
totally blank pages blank last page
Added reference to the Goodrich wheel and brake publications web
Introduction
site: https://techpubs.goodrich.com
Added 2-1559-3 configuration information Description and
Operation,
Assembly,
Illustrated Parts List
Added a high-pressure leakage test Testing and Fault
Isolation
Removed MIL-STD-1949 and replaced it with ASTM E1444 as the
Check
procedure for magnetic particle inspection
Added rivet hole inspections for torque plate and pressure plate Check
Added measurement inspection for adjuster housing Check
Added dimensional check for pressure plate Check
Added hardness inspection for stators when overheated Check
Added visual inspection for various small metal components Check
Added reidentification section Repair
RH
Page 1
32-46-46
Aug 11/09
Part Number 2-1559
REVISION HIGHLIGHTS
AFFECTED
REVISIONS
SECTIONS
Added instruction on how to install a new identification plate and cover
Repair
with a layer of clear coat
Added cold flattening procedures for pressure plate, stators, and
Repair
torque plate
Added penetrant inspection requirement for piston housings Repair
Added repair limits for piston housings Repair
Added shuttle valve assembly repair Repair
Torque values were removed from the ASSEMBLY section and are
Assembly
referenced in the FITS AND CLEARANCES section only
All torque values were converted to a nominal torque value Fits and Clearances
Removed the LIST OF SPECIAL MATERIALS and added a list of Special Tools,
consumables to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND Fixtures,
CONSUMABLES section Equipment, and
Consumables
RH
Page 2
32-46-46
Aug 11/09
Part Number 2-1559
RECORD OF REVISIONS
Put revised pages in the manual. Complete the table below for each revision.
DATE DATE
REV. REV. PAGES ARE REV. REV. PAGES ARE
INITIALS INITIALS
NO. DATE PUT IN NO. DATE PUT IN
MANUAL MANUAL
Issued Jan 30/93

1 Mar 8/93
2 Apr 15/94
3 Aug 15/95
4 Aug 11/09
32-46-46 RR
Page 1
Aug 11/09
Part Number 2-1559
RECORD OF REVISIONS
32-46-46 RR
Page 2
Aug 11/09
Part Number 2-1559
RECORD OF TEMPORARY REVISIONS
Put each temporary revision page in the manual opposite the affected page. Do not remove
the yellow sheets until the manual is revised to include the temporary revision. Complete the
table below for each temporary revision.
TEMPORARY AFFECTED DATE PAGES DATE PAGES ARE

REVISION PAGE ARE PUT INTO INITIALS REMOVED FROM INITIALS
NUMBER NUMBERS MANUAL MANUAL
32-1 703 Apr 4/03 BKM Aug 11/09 BWT
RTR
32-46-46 Page 1
Aug 11/09
Part Number 2-1559
RECORD OF TEMPORARY REVISIONS
RTR
32-46-46 Page 2
Aug 11/09
Part Number 2-1559
SERVICE BULLETIN LIST
Service Bulletins and Service Letters are included (incorporated) in the manual at the dates in
the "DATE INCLUDED" column. These Bulletins and Letters caused changes to the manual.
"Active" in the "DATE INCLUDED" column shows a Bulletin or Letter that remains active for
this brake assembly and is not incorporated in the manual.
"No Effect" in the "DATE INCLUDED" column shows a Bulletin or Letter that was active for
this brake assembly for some time. The Bulletin or Letter did not cause a change to the
manual at the revision date that is shown and does not apply to this brake assembly after that
date.
DATE DATE
SERVICE SERVICE
REV. ISSUED INCLUDED
BULLETIN LETTER DESCRIPTION
NO. OR INTO THE
NUMBER NUMBER
REVISED MANUAL
1662 Nov 23/94 Aug 15/95 Introduction and conversion

to the 2-1559-2 brake
assembly
2-1559-32-1 Jan 7/94 Apr 15/94 Cracked stator disks
(Goodrich 642)
2-1559-32-2 Feb 2/94 Aug 15/95 Introduction of a new
(Goodrich 643) adjuster tube
2-1559-32-2 Jul 25/97 Aug 11/09 Introduction of a new piston
(Goodrich 726) insulator
2-1559-32-3 May 12/03 Aug 11/09 Replacement of bleeder
(Goodrich 891) screw assemblies and
bleeder fittings with bleeder
plugs
2-1559-32-4 Jul 3/08 Aug 11/09 Introduction of new brake
(Goodrich assembly P/N 2-1559-3
1059)
1812 Apr 10/00 Aug 11/09 Introduction of SAE-AMS-
2518 anti-seize compound
1854 -- -- Active Shelf-life limits and storage
recommendations for
elastomeric seals and seal
assemblies
1914 1 Feb 3/06 Aug 11/09 Warnings on installation of
parts that are not approved
by Goodrich
32-46-46 SBL
Page 1
Aug 11/09
Part Number 2-1559
SERVICE BULLETIN LIST
DATE DATE
SERVICE SERVICE
REV. ISSUED INCLUDED
BULLETIN LETTER DESCRIPTION
NO. OR INTO THE
NUMBER NUMBER
REVISED MANUAL
1977 1 Jul 30/07 Aug 11/09 Safety precautions for

chemicals and materials
1988 -- -- Active Permitted leakage
2035 Jul 20/06 Aug 11/09 Introduction of a shuttle
valve assembly
2048 Nov 16/06 Aug 11/09 Introduction of a new paint
primer
2086 Aug 1/08 No Effect Introduction of optional
lubrication fitting
32-46-46 SBL
Page 2
Aug 11/09
Part Number 2-1559
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page 1 Aug 11/09 Disassembly 301 Aug 11/09

2 Aug 11/09 302 Aug 11/09
303 Aug 11/09
Revisions Highlights 1 Aug 11/09 304 Aug 11/09
2 Aug 11/09 305 Aug 11/09
306 Aug 11/09
Record of Revisions 1 Aug 11/09 307 Aug 11/09
2 Aug 11/09 308 Aug 11/09
309 Aug 11/09
Record of 1 Aug 11/09 310 Aug 11/09
Temporary Revisions 2 Aug 11/09
Cleaning 401 Aug 11/09
Service Bulletin List 1 Aug 11/09 402 Aug 11/09
2 Aug 11/09 403 Aug 11/09
404 Aug 11/09
List of Effective 1 Aug 11/09
Pages 2 Aug 11/09 Check 501 Aug 11/09
502 Aug 11/09
Table of Contents 1 Aug 11/09 503 Aug 11/09
2 Aug 11/09 504 Aug 11/09
505 Aug 11/09
Introduction 1 Aug 11/09 506 Aug 11/09
2 Aug 11/09 507 Aug 11/09
3 Aug 11/09 508 Aug 11/09
4 Aug 11/09 509 Aug 11/09
5 Aug 11/09 510 Aug 11/09
6 Aug 11/09 511 Aug 11/09
512 Aug 11/09
Description and 1 Aug 11/09 513 Aug 11/09
Operation 2 Aug 11/09 514 Aug 11/09
3 Aug 11/09 515 Aug 11/09
4 Aug 11/09 516 Aug 11/09
5 Aug 11/09 517 Aug 11/09
6 Aug 11/09 518 Aug 11/09
519 Aug 11/09
Testing and Fault 101 Aug 11/09 520 Aug 11/09
Isolation 102 Aug 11/09
103 Aug 11/09
104 Aug 11/09
105 Aug 11/09
106 Aug 11/09
107 Aug 11/09
108 Aug 11/09
109 Aug 11/09
110 Aug 11/09
32-46-46 LEP
Page 1
Aug 11/09
Part Number 2-1559
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Repair 601 Aug 11/09 Special Tools, Fixtures, 901 Aug 11/09
602 Aug 11/09 Equipment, and 902 Aug 11/09
603 Aug 11/09 Consumables 903 Aug 11/09
604 Aug 11/09 904 Aug 11/09
605 Aug 11/09 905 Aug 11/09
606 Aug 11/09 906 Aug 11/09
607 Aug 11/09 907 Aug 11/09
608 Aug 11/09 908 Aug 11/09
609 Aug 11/09 909 Aug 11/09
610 Aug 11/09 910 Aug 11/09
611 Aug 11/09
612 Aug 11/09 Illustrated Parts List 1001 Aug 11/09
613 Aug 11/09 1002 Aug 11/09
614 Aug 11/09 1003 Aug 11/09
615 Aug 11/09 1004 Aug 11/09
616 Aug 11/09 1005 Aug 11/09
617 Aug 11/09 1006 Aug 11/09
618 Aug 11/09 1007 Aug 11/09
1008 Aug 11/09
Assembly 701 Aug 11/09 1009 Aug 11/09
702 Aug 11/09 1010 Aug 11/09
703 Aug 11/09 1011 Aug 11/09
704 Aug 11/09 1012 Aug 11/09
705 Aug 11/09
706 Aug 11/09
707 Aug 11/09
708 Aug 11/09
709 Aug 11/09
710 Aug 11/09
711 Aug 11/09
712 Aug 11/09
713 Aug 11/09
714 Aug 11/09
715 Aug 11/09
716 Aug 11/09
Fits and Clearances 801 Aug 11/09

802 Aug 11/09
32-46-46 LEP
Page 2
Aug 11/09
Part Number 2-1559
TABLE OF CONTENTS
SECTION PAGE
DESCRIPTION AND OPERATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TESTING AND FAULT ISOLATION

Preparation for Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
High Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Static Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Dynamic Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Clearance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Shuttle Valve Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Set the Rod and Insert Assembly (wear pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
AUTOMATIC TEST EQUIPMENT (ATLAS) . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE
DISASSEMBLY
Preparation for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Heat Sink Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Pressure Plate Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Torque Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Piston Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Adjuster Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Shuttle Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
CLEANING
Clean Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Clean Non-Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Remove Paint from the Piston Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Abrasive Blast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Chemical Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Remove Corrosion from the Torque Plate and Pressure Plate . . . . . . . . . . . . . . . . . 404
Abrasive Blast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
CHECK
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Wear Plate Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Pressure Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Stator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Torque Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Adjuster Assembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Piston Housing Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
32-46-46 TC
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Aug 11/09
Part Number 2-1559
TABLE OF CONTENTS
SECTION PAGE
CHECK Cont’d
Shuttle Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Miscellaneous Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
REPAIR
Pressure Plate Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Rotor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Stator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Torque Plate Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Piston Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Shuttle Valve Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Installation of a New Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Reidentifiaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
ASSEMBLY
Assemble Adjuster Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Assemble Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Assemble Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Install Pressure Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
Installation of Wear Indicator Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
Installation of the Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
Installation of the Piston Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
Shuttle Valve Installation with Union Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
Bleeder Screw, Bleeder Fitting, and Bleeder Plug Installation . . . . . . . . . . . . . . . . . . 711
Adjust Rod and Insert Assemblies with New Heat Sink Components . . . . . . . . . . . . 712
Adjust Rod and Insert Assembly with Used Heat Sink Components. . . . . . . . . . . . . 714
Do the Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
FITS AND CLEARANCES

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Aqueous Cleaner Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Other Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
32-46-46 TC
Page 2
Aug 11/09
Part Number 2-1559
INTRODUCTION
1. General
This manual gives maintenance procedures that can keep the brake assembly in an
airworthy condition. Overhaul facilities can use other maintenance procedures, but the
overhaul facility is responsible for these other procedures. The facility must make sure
these other procedures are safe, keep the brake assembly airworthy, and obey applicable
government regulations.
All publications for this assembly are available from the Goodrich wheel and brake
publications web site: https://techpubs.goodrich.com
A maintenance facility can use the special tools given in this manual or use other tools
that give the same result.
General industry specifications in this manual (for example: MIL, ASTM, SAE) let
maintenance facilities use locally-available materials permitted by a specification.
Goodrich is not responsible for approval of materials controlled by these specifications.
Refer to the TABLE OF CONTENTS for the page numbers of sections and data in the
sections.
Refer to the Introduction in the ILLUSTRATED PARTS LIST section for a description of
how to use that section.
Weights and measurements in this manual are in U.S. (English) units. S.I. (International
System of Units) metric units are shown in parentheses. English units have a period for
the decimal point. Metric units have a comma for the decimal point.
Carefully read and obey all CAUTION and WARNING statements in this manual. Refer to
the descriptions of these statements that follow:
• A "CAUTION" statement is given to prevent damage to equipment.
• A "WARNING" statement is given to prevent personal injury or illness.
• A "NOTE" statement is given to make a job easier.
2. TSO Approval
The existence of TSO approval of the article displaying the required marking does not
automatically constitute the authority to install and use the article on an airplane. The
conditions and tests required for TSO approval of this article are minimum performance
standards. It is the responsibility of those desiring to install this article either on or within
a specific type or class of airplanes to determine that the airplane operating conditions
are within the capacity of the article demonstrated in accordance with the TSO standards.
The article may be installed only if further evaluation by the user/installer documents an
acceptable installation and the installation is approved by the Administrator.
32-46-46 INTRO
Page 1
Aug 11/09
Part Number 2-1559
INTRODUCTION
Additional requirements may be imposed based on airplane specifications, wheel and

brake design, and quality control specifications. In-service maintenance, modifications,
and use of replacement components must be in compliance with the performance
standards of this TSO, as well as any additional specific airplane requirements.
3. Verification Dates: Disassembly Testing Assembly

Jul 8/92 Jul 8/92 Jul 8/92
4. Replacement Parts Policies
The Federal Aviation Administration (FAA) has approved replacement parts that are
different from specified parts in applicable Goodrich publications. Goodrich has not done
tests on these FAA-approved parts and does not give approval for the installation of
these parts.
Goodrich uses proprietary design procedures and rigorous tests to show that Goodrich
assemblies give specified performance or better-than-specified performance. Tests were
done with Goodrich-approved parts in each assembly to show that related subsystems
correctly work together as a system for qualification and certification. Some examples of
related subsystems include: landing gear, brake control (anti-skid), wheels, brakes, and
tires.
Goodrich makes wheel assemblies and brake assemblies to aircraft manufacturer

specifications, to FAA requirements, and to all other applicable regulations. Goodrich
design procedures also use data on wear distribution, thermal balance, dynamic stability,
reliability, endurance, torque sensitivity, and environmental exposure. The environmental
exposure includes: humidity, icing, salt fog, shock, and vibration. Installation of parts that
do not have equivalent design procedures or test results can decrease the performance
of wheel assemblies, brake assemblies, or related subsystems.
FAA approval of replacement parts in Goodrich assemblies usually is given after tests
that are less extensive than performance tests by the aircraft manufacturer and by
Goodrich. The Aircraft Flight Manual, Component Maintenance Manuals, and warranties
are based on performance tests by the aircraft manufacturer and by Goodrich. The
operation of each subsystem depends on all related subsystems to give safe and reliable
take-offs and landings. When equivalent tests with FAA-approved parts are not done,
Goodrich cannot make sure that the assemblies give safe and reliable performance.
Goodrich has policies that follow:
32-46-46 INTRO
Page 2
Aug 11/09
Part Number 2-1559
INTRODUCTION
WARNING: REGARDLESS OF ANY FAA APPROVALS OR DEMONSTRATED

COMPLIANCE WITH AIRFRAME MANUFACTURER'S ORIGINAL
EQUIPMENT REQUIREMENTS, GOODRICH DOES NOT WARRANT OR
ASSUME THE RISK OF THE INSTALLATION OF REPLACEMENT PARTS
THAT ARE NOT APPROVED BY GOODRICH FOR INSTALLATION IN A
SPECIFIED ASSEMBLY. OPERATORS WHO USE REPLACEMENT PARTS
THAT ARE NOT APPROVED BY GOODRICH DO SO AT THEIR OWN
RISK AND TAKE FULL RESPONSIBILITY FOR ALL PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH CAUSED BY SUCH REPLACEMENTS
PARTS. USE ONLY GOODRICH-APPROVED REPLACEMENT PARTS
THAT ARE GIVEN IN THE ILLUSTRATED PARTS LIST OF THE
COMPONENT MAINTENANCE MANUAL OR IN SERVICE BULLETINS OR
SERVICE LETTERS THAT ARE ISSUED BY GOODRICH.
CAUTION: GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR ANY
FEDERAL AVIATION ADMINISTRATION SANCTIONS, PRODUCT
MALFUNCTIONS, PROPERTY DAMAGE, PERSONAL INJURIES, OR
SIMILAR INCIDENTS THAT OCCUR AFTER SUBSTITUTION OF PARTS
THAT ARE NOT APPROVED BY GOODRICH, OR SUBSTITUTION OF
PARTS WITH ALTERATIONS THAT ARE NOT APPROVED BY
GOODRICH MANUALS OR OTHER WRITTEN PROCEDURES THAT ARE
ISSUED BY GOODRICH.
CAUTION: THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED BY

GOODRICH FOR INSTALLATION IN A SPECIFIED ASSEMBLY WILL
AUTOMATICALLY VOID ALL WARRANTIES EXTENDED BY GOODRICH.
5. Warnings for the Full Manual
WARNING: OBEY TORQUE LIMITS AND OTHER SPECIFIC VALUES THAT ARE
GIVEN IN THIS MANUAL. THESE LIMITS AND VALUES THAT ARE NOT
OBEYED CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR
DEATH.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
32-46-46 INTRO
Page 3
Aug 11/09
Part Number 2-1559
INTRODUCTION
A. Cadmium
Obey the warnings below before you touch or do maintenance on parts that are
cadmium plated. Refer to the ILLUSTRATED PARTS LIST to identify parts that can
be cadmium plated. The Occupational, Safety, and Health Administration (OSHA)
sets mandatory limits on exposure to cadmium dust (29 CFR 1910.1027).
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM
DISEASE. AFTER YOU TOUCH CADMIUM PLATED PARTS, CLEAN
YOUR HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY
INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN CADMIUM.
WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR EMPLOYER
TO SUPPLY RESPIRATORS, VENTILATION, AND/OR PROCEDURES
TO PREVENT EXPOSURE TO PERSONNEL.
WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH ADMINISTRATION
(OSHA) HAS AN APPLICABLE DANGER WARNING (29 CFR
1910.1027 (m)(3)(ii)) AS FOLLOWS: DANGER: CONTAINS CADMIUM.
CANCER HAZARD. AVOID CREATING DUST. CAN CAUSE LUNG
AND KIDNEY DISEASE.
6. Specification Sources
A. Get Federal and MIL specifications that are referred to in this manual from the source
that follows:
DAPS
ASSIST
BLDG 4/D
700 ROBBINS AVENUE
PHILADELPHIA, PENNSYLVANIA 19111
U.S.A.
Tel: 215-697-6257
Web: http://assist.daps.dla.mil/online/start/
32-46-46 INTRO
Page 4
Aug 11/09
Part Number 2-1559
INTRODUCTION
B. Get AMS specifications that are referred to in this manual from the source that
follows:
SAE CUSTOMER SERVICE

400 COMMONWEALTH DRIVE
WARRENDALE, PENNSYLVANIA 15096-0001
U.S.A.
Tel: 724-776-4970
Fax: 724-776-0790
Web: www.sae.org
C. Get ASTM specifications that are referred to in this manual from the source that
follows:
AMERICAN SOCIETY FOR TESTING AND MATERIALS

100 BARR HARBOR DRIVE
WEST CONSHOHOCKEN, PENNSYLVANIA 19428
U.S.A.
Tel: 610-832-9500
Web: www.astm.org
32-46-46 INTRO
Page 5
Aug 11/09
Part Number 2-1559
INTRODUCTION
32-46-46 INTRO
Page 6
Aug 11/09
Part Number 2-1559
1. Description
A. The brake assembly is a piston-operated multiple disk brake. Each brake assembly
operates from the aircraft hydraulic system and uses MIL-PRF-5606 or
MIL-PRF-83282 hydraulic fluid. The maximum brake operating pressure is 800 psi
(55,2 bar).
The 2-1559-1 brake assembly is the initial design brake assembly.
The 2-1559-2 brake assembly has a longer wear pin setting and thicker stators with
the expansion slots turned 30 degrees.
The 2-1559-3 brake assembly has four bleeder plugs installed. Two of the bleeder
plugs are installed in place of the two bleeder fittings, two bleeder screws, and two
O-rings.
B. The brake assembly consists of three primary parts: the piston housing assembly,
the steel heat sink, and the torque plate assembly (refer to Figure 1).
C. The piston housing assembly performs the actuation, retraction, and clearance
adjustment functions of the brake. The piston housing assembly is bolted to the
torque plate assembly and axle flange with six bolts, washers, and nuts.
(1) The 2014-T6 aluminum piston housing assembly contains six adjuster
assemblies, two wear indicator pins, six pistons and insulators, and a shuttle
valve assembly.
Brake assembly 2-1559-1 contains two bleeder screws, two bleeder fittings, and
two bleeder plugs.
Brake assembly 2-1559-2 contains either two bleeder screws, two bleeder
fittings, and two bleeder plugs, or four bleeder plugs.
Brake assembly 2-1559-3 contains four bleeder plugs.
(2) O-rings and backup rings are installed on the shuttle valve assembly to seal
against fluid leakage.
(3) Two wear indicator pins (rod and insert assembly) are attached to the pressure
plate assembly and project through the piston housing assembly. The wear
indicator pins give a visual inspection to find heat sink wear.
(4) The shuttle valve assembly automatically connects the brake assembly to an
emergency pneumatic system if the primary source of hydraulic pressure stops.
(5) Each adjuster assembly contains the parts that follow: nut, ball, adjuster tube,
adjuster pin, retaining ring, tube retainer, spring, and adjuster housing (refer to
Figure 2).
32-46-46 Page 1
Aug 11/09
Part Number 2-1559

(6) Each piston cavity has six pistons and insulators. O-rings and backup rings
installed in the piston bore grooves seal against fluid leakage.
D. The heat sink includes all the parts that have friction surfaces which cause the brake
assembly to stop the rotation of the wheel. These parts include one pressure plate
assembly, three rotors, two stators, and a steel torque plate assembly.
(1) The pressure plate assembly has drive lugs on the inner diameter that engage
the slots in the torque plate assembly. Twelve wear plates are attached to the
pressure plate with rivets. The pressure plate assembly has six key-hole slots
that accept the adjuster pins in the adjuster assemblies. The pressure plate
assembly does not turn, but slides as necessary on the torque plate assembly
as the brake assembly operates.
(2) The rotors have drive slots on the outer diameter that engage the drive inserts
in the wheel. Each rotor has a steel carrier with lining material sintered to each
side. The rotors turn with the wheel, and slide as necessary on the drive inserts
of the wheel as the brake assembly operates.
(3) The stators have drive lugs on the inner diameter that engage the slots in the
torque plate assembly. The steel stator does not turn, but slides on the torque
plate as necessary as the brake assembly operates.
(4) The torque plate holds the pressure plate assembly and stators in correct
alignment with the rotor assemblies. Twelve wear plates are attached to the
torque plate with rivets.
32-46-46 Page 2
Aug 11/09
Part Number 2-1559
Figure 1 (Sheet 1 of 2). Main Brake Assembly Description
32-46-46 Page 3
Aug 11/09
Part Number 2-1559
Figure 1 (Sheet 2 of 2). Main Brake Assembly Description
32-46-46 Page 4
Aug 11/09
Part Number 2-1559
Figure 2. Adjuster Assembly Description
2. Operation
A. Pressurized hydraulic fluid in the piston housing assembly forces the six pistons and
insulators against the pressure plate assembly, which causes it to advance.
B. As the pistons and pressure plate assembly continue to advance, the three rotors
and two stators are clamped between the pressure plate assembly and torque plate
assembly. The drag imposed by the turning and non-turning parts causes the braking
action.
C. When the brake assembly is operated, the pressure plate assembly moves forward
and pulls the adjuster pin, ball, nut, tube retainer, and adjuster tube forward, which
compresses the adjuster spring. The tube retainer touches the bottom of the adjuster
housing, and prevents more movement of the spring and the adjuster tube. More
movement of the pressure plate because of lining wear, pulls the pin and ball deeper
into the adjuster tube.
D. When the hydraulic pressure is decreased, the springs pull the pressure plate
assembly back a distance that is equal to the travel of the tube retainer from the
bottom position to its initial position. This gives a constant running clearance after
each brake release.
32-46-46 Page 5
Aug 11/09
Part Number 2-1559
32-46-46 Page 6
Aug 11/09
Part Number 2-1559
Equipment and Materials
NOTE: Equivalent alternatives are permitted for the equipment and materials that follow:
- 1200 psi (82,7 bar) minimum pressure source

- Hydraulic fluid
- Shims (refer to Figure 901)
- Anti-seize compound
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS SWALLOWED

CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM DISEASE. AFTER YOU
TOUCH CADMIUM PLATED PARTS, CLEAN YOUR HANDS BEFORE YOU
EAT OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER.
OBEY GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD
PARTS THAT CONTAIN CADMIUM.
WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST. THESE

PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY DISEASE. IF
MAINTENANCE PROCEDURES MAKE CADMIUM PARTICLES, FUMES, OR
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.
WARNING: THE OCCUPATIONAL, SAFETY, AND HEALTH ADMINISTRATION (OSHA)

HAS AN APPLICABLE DANGER WARNING (29 CFR 1910.1027 (m)(3)(ii)) AS
FOLLOWS: DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID
CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.
WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, UNDERSTAND, AND OBEY
ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE INSTRUCTIONS
HYDRAULIC FLUID MAY CAUSE INJURY TO YOU OR MAKE YOU SICK
WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
HYDRAULIC FLUID. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW
YOU MUST SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.
CAUTION: REMOVE HYDRAULIC FLUID THAT FALLS ON BRAKE PARTS (REFER TO

THE CLEANING SECTION). HYDRAULIC FLUID CAN CAUSE DAMAGE TO
PARTS.
32-46-46 Page 101

Aug 11/09
Part Number 2-1559
1. Preparation for Functional Test
A. Assemble the brake assembly (refer to the ASSEMBLY section).
WARNING: INSTALL THE SPACER (SIMULATED AXLE FLANGE) ON THE TOP OF

THE PISTON HOUSING ASSEMBLY. THE BRAKE ASSEMBLY COULD
COME APART WITH FORCE IF THE SPACER IS NOT INSTALLED.
B. Install the spacer (refer to Figure 101) on top of the piston housing assembly (240),
aligning the spacer holes with tie-bolt holes in the piston housing assembly.
NOTE: This spacer is used to simulate the axle flange.
Figure 101. Spacer, P/N 114-1371
C. Apply anti-seize compound to bolts (35), washers (30), and nuts (25) (refer to Figure
710).
D. Install the bolts (35) through the torque plate and wear plate assembly (115), piston
housing assembly (240), and up through the spacer. Install the washers (30) and
nuts (25).
E. Torque the nuts (25).
32-46-46 Page 102

Aug 11/09
Part Number 2-1559
F. If a bleeder valve is not installed in your brake assembly, install a bleeder valve as
follows:
(1) Remove the bleeder plug (205) that is at the highest location on the brake
assembly.
(2) Apply a thin layer of petrolatum or hydraulic fluid to an O-ring (210).
(3) Install the O-ring (210) on a bleeder fitting (235).
(4) Install the bleeder fitting (235) in the port where the bleeder plug (205) was
removed.
(5) Torque the bleeder fitting (235).
(6) Install a bleeder valve (230) into the bleeder fitting (235).
G. Remove the screw (220) and washer (225) and connect a drain hose to the bleeder
valve (230).
H. Put the end of the bleeder hose into a fluid waste container.
I. Put the brake assembly in a position that causes air in the piston housing to collect
at the bleeder valve (230).
J. Connect the hydraulic pressure source to one of the union fittings (10, 17) on the
shuttle valve assembly (50).
WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A LEE

PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH FORCE DURING
A PRESSURE LEAK TEST.
K. Put a protective shield around the brake assembly.
L. Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar) and hold for one
minute.
M. Reduce the pressure of the brake assembly to 150 - 200 psi (10,3 - 13,8 bar).
N. Remove the protective shield.
O. Loosen each bleeder valve (230) and bleed the brake assembly until there are no air
bubbles in the hydraulic fluid.
P. Tighten each bleeder valve (230).
Q. Decrease the brake pressure to 0 psi (0 bar).
32-46-46 Page 103

Aug 11/09
Part Number 2-1559
2. High Pressure Leak Test
CAUTION: USE THE SHIMS TO MAKE SURE THAT STRUCTURAL MOVEMENT

DOES NOT CAUSE A LOSS OF BRAKE RUNNING CLEARANCE.
NOTE: Do a high-pressure leak test on a brake assembly when a Lee plug (245) is
replaced. If a Lee plug was not replaced, go to paragraph 3, Functional Test.
A. Install the shims (Figure 901) between the pressure plate assembly (80) and the first
rotor (105).
B. Put a cover on the heat sink that will not let the hydraulic fluid touch the heat sink
parts.

A HIGH-PRESSURE LEAK TEST.
C. Put a protective shield around the brake assembly.
D. Pressurize the brake assembly to 1200 - 1250 psi (82,7 - 86,2 bar).
E. Hold the pressure for five minutes.
F. At the end of five minutes, decrease the pressure to 0 psi (0 bar).
G. Remove the protective shield.
H. Examine the brake assembly for leakage. No leakage that can be measured is
permitted (less than one drop). Reject the brake assembly if leakage is found.
I. Remove the shims.
J. Do the Functional Test (refer to paragraph 3).
32-46-46 Page 104

Aug 11/09
Part Number 2-1559
3. Functional Test
A. Static Leakage Test
NOTE: Paragraphs 3.A.(2) thru 3.A.(7) are not necessary if paragraph 2,

High Pressure Leak Test, is completed.
(1) Put a cover on the heat sink that will not let the hydraulic fluid touch the heat
sink parts.
WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A

LEE PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH FORCE
DURING A PRESSURE LEAK TEST.
(2) Put a protective shield around the brake assembly.
(3) Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar).
(4) Hold the pressure for five minutes.
(5) At the end of five minutes, decrease the pressure to 0 psi (0 bar).
(6) Remove the protective shield.
(7) Examine the brake assembly for leakage. No leakage that can be measured is
(8) Pressurize the brake assembly to 3 - 7 psi (0,21 - 0,48 bar).
(9) Hold the pressure for five minutes.
(10) At the end of five minutes, decrease the pressure to 0 psi (0 bar).
32-46-46 Page 105

Aug 11/09
Part Number 2-1559
B. Dynamic Leakage Test

(2) Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar) and decrease
to 0 psi (0 bar) for 25 cycles.
(3) After the 25 cycles, decrease the pressure to 0 psi (0 bar).
C. Clearance Test

(2) Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar) and decrease
to 7 - 10 psi (0,5 - 0,7 bar) and hold.
(4) Measure the distance between the pressure plate assembly (80) and the first
rotor (105). Reject the brake assembly if the measurement is less than 0.025
inch (0,64 mm).
(5) Decrease the pressure to 0 psi (0 bar).
32-46-46 Page 106

Aug 11/09
Part Number 2-1559
4. Shuttle Valve Assembly Test
A. Connect the hydraulic source to one of the union fittings (10, 17) on the shuttle valve
assembly (50) if necessary.
B. Put a cover on the heat sink that will not let the hydraulic fluid touch the heat sink
parts.

A SHUTTLE VALVE ASSEMBLY LEAK TEST.
E. Decrease the pressure to 2 - 7 psi (0,14 - 0,48 bar) and hold for one minute.
Hydraulic fluid leakage is permitted when you apply the pressure. When the 2 - 7 psi
(0,14 - 0,48 bar) is obtained, no leakage that can be measured is permitted (less
than one drop) from the disconnected side on the shuttle valve assembly (50).
Replace or repair the shuttle valve assembly if leakage is found.
F. Pressurize the brake assembly 750 - 800 psi (51,7 - 55,2 bar) and hold for one
minute. No leakage that can be measured is permitted (less than one drop) from the
disconnected side on the shuttle valve assembly (50). Replace or repair the shuttle
valve if leakage is found.
G. Decrease the pressure to 0 psi (0 bar).
H. Remove the protective shield.
I. Remove the hydraulic source from the union fitting (10, 17) on the shuttle valve
assembly (50).
J. Connect the hydraulic source to the other union fitting (10, 17) on the shuttle valve
assembly (50).
K. Put a protective shield around the brake assembly.
L. Pressurize the brake assembly to 100 - 150 psi (6,9 - 10,3 bar).
M. Decrease the pressure to 2 - 7 psi (0,14 - 0,48 bar) and hold for one minute.
Hydraulic fluid leakage is permitted when you apply the pressure. When the 2 - 7 psi
(0,14 - 0,48 bar) is obtained, no leakage that can be measured is permitted (less
than one drop) from the disconnected side on the shuttle valve assembly (50).
Replace or repair the shuttle valve assembly if leakage is found.
32-46-46 Page 107

Aug 11/09
Part Number 2-1559
N. Pressurize the brake assembly to 750 - 800 psi (51,7 - 55,2 bar) and hold for one
minute. No leakage that can be measured is permitted (less than one drop) from the
disconnected side on the shuttle valve assembly (50). Replace or repair the shuttle
valve assembly if leakage is found.
O. Decrease the pressure to 0 psi (0 bar).
P. Remove the protective shield.
NOTE: Repair a rejected shuttle valve assembly with parts kit (900A).
Q. Remove the bleeder hoses from the bleeder valves (230).
R. Disconnect the hydraulic line and install shipping cap plugs (265, 270) on both union
fittings (10, 17).
S. For brake assemblies, P/Ns 2-1559-1 or 2-1559-2:
(1) Torque the bleeder valve (230).
(2) Install the flat washer (225) and screw (220).
(3) Torque the screw (220).
T. For brake assembly, P/N 2-1559-3:
(1) Remove the bleeder screw (230) from the bleeder fitting (235).
(2) Remove the bleeder fitting (235) and O-ring (210).
(3) Install a bleeder plug (205) and O-ring (210).
(4) Torque the bleeder plug and lock with wire (20).
U. Tag or mark the brake assembly as passed or failed the functional test.
V. If a brake assembly fails the functional test, refer to paragraph 6, Fault Isolation
Chart.
5. Set the Rod and Insert Assembly (wear pin)
A. Refer to the ASSEMBLY section to set the rod and insert assembly (65).
32-46-46 Page 108

Aug 11/09
Part Number 2-1559
6. Fault Isolation Chart
FAULT POSSIBLE CAUSE CORRECTION

NOTE: Hydraulic fluid leakage that can not be measured is permitted (less than one drop).
Hydraulic fluid leaks Loose bleeder screw, bleeder fitting, or Tighten the bleeder parts to
from a bleeder valve bleeder plug. the correct torque (refer to
(230), bleeder fitting page 801).
(235), or a bleeder
Damaged bleeder screw, bleeder fitting, Replace the defective parts.
plug (205).
or bleeder plug.
Damaged O-rings (210).

Hydraulic fluid leaks Worn or damaged O-ring (195) or backup Replace the defective parts.
from the piston area. ring (200).
Damaged piston (190). Replace a damaged piston.
Damaged piston (190) bore. Replace a damaged piston
housing.
Fluid leakage from a The Lee plug is damaged or is not Replace a Lee plug that
Lee plug (245). installed correctly. leaks.
Less than running The heat sink is warped more than the Repair or replace the heat
clearance (refer to limit. sink.
paragraph 3.C).
Weak adjuster springs (175). Measure the spring load as
shown in Figure 507. Replace
a defective spring.
The brake is out of adjustment. Replace the adjuster tubes
(160).
The brake drags or Weak adjuster springs (175). Measure the spring load as
does not release. shown in Figure 507. Replace
a defective spring.
Soft or damaged adjuster tubes (160). Replace defective adjuster
tubes.
Adjuster pin (155) is broken, loose, or the Replace broken adjuster pins.
nut (145) is missing.
Examine self-locking function
of the nut. Tighten to the
correct torque (refer to page
801) or replace the nut.
32-46-46 Page 109

Aug 11/09
Part Number 2-1559
FAULT POSSIBLE CAUSE CORRECTION
The brake will not Damaged shuttle valve Repair or replace a defective
operate when assembly (50). shuttle valve assembly. Repair a
emergency shuttle valve assembly (50) with
hydraulic system is a parts kit (900A).
applied.
Fluid leakage from Damaged O-ring (60), backup Replace a defective O-ring and/
the shuttle valve retainer (55) or shuttle valve or backup ring.
assembly (50). assembly (50). Repair or replace a defective
shuttle valve assembly.
Fluid leakage from Damaged O-rings (15, 18) or Replace defective O-rings.
the inlet ports on damaged shuttle valve port. Repair or replace a defective
the shuttle valve shuttle valve assembly.
assembly (50).
32-46-46 Page 110

Aug 11/09
Part Number 2-1559
DISASSEMBLY
- 3/8 inch (9 mm) outside diameter plug

- Arbor or drill press
NOTE: Refer to the TESTING AND FAULT ISOLATION section to find the most possible
cause of the brake assembly malfunction.
1. Preparation for Disassembly

A. Install the spacer (refer to Figure 101) on top of the piston housing assembly (240),
aligning the spacer holes with tie-bolt holes in the piston housing assembly.
NOTE: This spacer is used to simulate the axle flange
B. Connect the brake assembly to a pressure source (refer to the paragraph 1 in the
TESTING AND FAULT ISOLATION, section).

PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH FORCE WHEN
A BRAKE ASSEMBLY IS PRESSURIZED.
D. Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar) and hold this
pressure.
E. Remove the protective shield.
F. Measure the length of each rod and insert assembly (65) from the piston housing
assembly (240) (refer to Figure 301). Measure to the nearest 0.0001 inch
(0,003 mm) and record the shortest measurement.
G. Decrease the pressure to 0 psi (0 bar).
H. Disconnect the brake assembly from the pressure source.
I. Cap the hydraulic ports.
J. Remove the spacer.
Page 301
32-46-46
Aug 11/09
Part Number 2-1559
DISASSEMBLY
Figure 301. Brake Wear Measurement

2. Heat Sink Removal
A. Put the brake assembly on a flat, clean work surface.
NOTE: Brakes that are removed from the aircraft for reasons other than wear
should not have heat sink parts disturbed unless necessary. Return the
brakes to service with the same rod and insert assembly length.
NOTE: If the disks will be removed, but will be installed again, identify each disk so
that it can be installed again in the same position. The friction surfaces of
the disks must touch the same friction surfaces of mating disks that they
touched before the disks were removed.
NOTE: Use tape or chalk to mark the parts for identification and for position in the
heat sink (1, 2, or 3) and which way each part faces, or mark two parallel
lines on the edges of the disks at a 40 to 60 degree angle.
Page 302
32-46-46
Aug 11/09
Part Number 2-1559
DISASSEMBLY
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT YOU

SWALLOW CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM
DISEASE. AFTER YOU TOUCH PARTS THAT CONTAIN CADMIUM,
CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY
INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT AND
OSHA REGULATIONS WHEN YOU DISCARD THE PARTS THAT
CONTAIN CADMIUM.

PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY
DISEASE. IF MAINTENANCE PROCEDURES MAKE CADMIUM
PARTICLES, FUMES, OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.

HAS AN APPLICABLE DANGER WARNING (29 CFR 1910.1027 (m)(3)(ii))
AS FOLLOWS: DANGER: CONTAINS CADMIUM. CANCER HAZARD.
AVOID CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.
B. Remove the bolts (35), washers (30), and nuts (25) from the piston housing
assembly (240) if installed. The bolts, washers, and nuts can be cadmium plated.
C. Remove the screws (75) from the torque plate assembly (115). The screws can be
cadmium plated.
D. Remove the piston housing assembly (240) (with the attached pressure plate
assembly (80)) from the torque plate assembly (115).
E. Remove the rotors (105) and stators (110) from the torque plate assembly (115).
NOTE: The heat sink parts are designed to last until they are fully worn (a rod and
insert assembly is flush with piston housing as shown in Figure 301). If the
brake is removed and disassembled before a lining change is necessary, the
heat sink parts should be installed again (refer to the ASSEMBLY section).
3. Pressure Plate Assembly Removal
A. Remove rod and insert assembly (65) from the stud assembly (70).
Page 303
32-46-46
Aug 11/09
Part Number 2-1559
DISASSEMBLY

CONTAIN CADMIUM.

PERSONNEL.

B. Loosen the self-locking nut on the stud assembly and remove the stud assembly (70)
from the pressure plate assembly (80). The stud assembly can be cadmium plated.
C. Remove the nut (145), ball (150), and adjuster tube (160) from each adjuster
assembly (160).
NOTE: No more disassembly is required to replace adjuster tubes.
D. Lift and remove the piston housing assembly (240) from the pressure plate assembly
(80).
E. Remove the adjuster pins (155) from the pressure plate assembly (80).
F. Do not remove Heli-Coil® inserts (95) unless damaged (refer to the REPAIR
section).
G. Do not remove wear plates (90) from the pressure plate assembly (80) unless they
are damaged or fully worn (refer to the REPAIR section).
Page 304
32-46-46
Aug 11/09
Part Number 2-1559
DISASSEMBLY
4. Torque Plate Disassembly
Do not remove wear plates (125) from the torque plate assembly (115) unless they are
damaged or fully worn (refer to the REPAIR section).
5. Piston Housing Disassembly
WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, UNDERSTAND, AND

OBEY ALL SAFETY INSTRUCTIONS FOR HYDRAULIC FLUID. THESE
HYDRAULIC FLUID MAY CAUSE INJURY TO YOU OR MAKE YOU SICK
WHEN YOU DO NOT OBEY SAFETY INSTRUCTIONS. THE MSDS TELLS
HOW TO SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID. GET
INSTRUCTIONS FROM YOUR EMPLOYER THAT TELLS HOW TO
SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.
CAUTION: INSULATORS THAT ARE PUSHED INTO THE PISTON HOUSING CAN
CAUSE HYDRAULIC FLUID TO BE EJECTED OUT OF AN OPEN PORT.
MAKE SURE THAT THE FLUID DRAINS INTO A CONTAINER.

CONTAIN CADMIUM.

PERSONNEL.

A. Remove the caps (265, 270) and install a temporary drain tube, to the union fittings
(10, 17) on the shuttle valve assembly (50) or use other procedures to make sure
that drained hydraulic fluid goes into a waste-fluid container.
B. Clean the exposed part of each piston (190).
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Part Number 2-1559
DISASSEMBLY
C. Push each insulator (185) fully into the piston housing assembly (240) to force out
the hydraulic fluid.
D. If the brake assembly has bleeder screw assemblies installed, remove the screws
(220) and washers (225). Loosen the bleeder valves (230) and hold the piston
housing assembly in a vertical position to drain hydraulic fluid from the shuttle valve
into a waste-fluid container.
E. Remove the bleeder valves (230) and bleeder fittings (235) from the piston housing
assembly.
F. Remove the O-rings (210) from the bleeder fittings (235). Discard the O-rings.
NOTE: If the brake assembly will be converted to a 2-1559-3, the bleeder screw
assembly and bleeder fitting can be discarded.
G. Cut the lockwire (20) and remove the bleeder plugs (205) from the piston housing
assembly.
H. Remove the O-rings (210) from the bleeder plugs (205). Discard the O-rings.
I. Remove the union fittings (10, 17) from the shuttle valve assembly (50).
J. Remove and discard the O-rings (15, 18) from the union fittings (10, 17).
K. Cut the lockwire (20) and remove the bolts (40), washers (45), and shuttle valve
assembly (50). The bolts and washers can be cadmium plated.
L. Do not disassemble the shuttle valve assembly unless it will be overhauled. Seal all
of the hydraulic ports to prevent contamination.
M. Remove the O-ring (60) from the shuttle valve assembly (50). Discard the O-ring.
N. If the backup retainer (55) is damaged, remove it from the shuttle valve (50) and
discard the backup retainer.
NOTE: Do not remove the Lee plugs (245) or Heli-Coil® inserts (250, 255) unless
damaged (refer to the REPAIR section).
O. Remove the identification plate (5) if damaged, cannot be read, if the piston housing
must be NDT examined, or if the brake assembly is being converted.
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DISASSEMBLY
CAUTION: DO NOT USE SHARP, HARD TOOLS TO REMOVE O-RINGS AND

BACKUP RINGS. THESE TOOLS CAN CAUSE DAMAGE TO ALUMINUM
PARTS.
P. Remove the insulators (185), pistons (190), O-rings (195), and backup rings (200)
from each piston bore of the piston housing assembly (240).
NOTE: A 1/4-28UNF-2A bolt can be threaded into the center of the piston to help
remove them from the piston bores.
(1) Discard the O-ring (195).
(2) The backup rings (200) can be used again if not damaged.
Q. Remove each retaining ring (135) and adjuster assembly (140) from the piston
housing assembly (240).
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DISASSEMBLY
6. Adjuster Disassembly
WARNING: OBEY THE INSTRUCTIONS TO REMOVE THE SPRING IN EACH

ADJUSTER ASSEMBLY. THE SPRING IS COMPRESSED UNDER HIGH
LOAD. IF YOU DO NOT REMOVE THE SPRING WITH CORRECT
EQUIPMENT OR DO NOT OBEY THE INSTRUCTIONS, PARTS CAN BE
EJECTED AND CAUSE INJURY TO PERSONNEL.

CONTAIN CADMIUM.

PERSONNEL.

A. Install a 3/8 inch (9 mm) outer diameter plug in a drill or arbor press.
Figure 302. Adjuster Assembly Parts
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Part Number 2-1559
DISASSEMBLY
B. Put the adjuster housing (180) on the press table, with the tube retainer (170) in the
up position (refer to Figure 303).
C. Lower the press until the plug touches the tube retainer (170). Push down on the
tube retainer just enough to permit the retaining ring (165) to be removed.
D. Lock the press and remove the retaining ring (165).
E. Unlock the press and slowly release the pressure on the tube retainer (170) until all
of the spring (175) pressure is released.
F. Remove the tube retainer (170) and spring (175) from the adjuster housing (180).
Figure 303. Adjuster Disassembly
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DISASSEMBLY
7. Shuttle Valve Disassembly
CAUTION: DO NOT DISASSEMBLE THE SHUTTLE VALVE UNLESS IT MUST BE

OVERHAULED AND THE PARTS KIT (900A), IS AVAILABLE. THE
SHUTTLE VALVE BODY (905), END CAP (910), AND POPPET (915) ARE
NOT AVAILABLE IN THE PARTS KIT.
A. Cut the lockwire (20) from the end cap (910). Discard the lockwire and the lead seal.
WARNING: WEAR EYE PROTECTION. THE SHUTTLE VALVE CONTAINS

SPRING-LOADED PARTS. DISASSEMBLY WITHOUT COMPLIANCE WITH
THE INSTRUCTIONS THAT FOLLOW CAN CAUSE SERIOUS EYE
INJURY TO PERSONNEL.
CAUTION: THE SHUTTLE VALVE CONTAINS SMALL PARTS THAT ARE EASILY
LOST.
B. Carefully remove the end cap (910) which contains the poppet assembly (945), balls
(930), and spring (935) (refer to Figure 304).
C. Carefully remove the poppet assembly (945), balls (930), and spring (935).
D. Remove the two O-rings (940) that are installed on the poppet assembly (945).
Discard the O-rings.
E. Remove the O-rings (920, 925). Discard these parts.
Figure 304. Shuttle Valve Disassembly
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Part Number 2-1559
CLEANING
- Media blast equipment

- Paint remover (SAE-AMS-1375)
- Solvent, degreasing (MIL-PRF-680 Type II or III)
- Aqueous cleaning products
- Solvent, butyl alcohol
NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

section for the sources of materials. The list of consumables gives recommended
concentrations and temperatures of aqueous cleaners.
WARNING: BEFORE YOU USE A SPECIFIED CLEANING PRODUCT, READ,

UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE
CLEANING PRODUCT. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS
FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS), AND GOVERNMENT REGULATIONS. A CLEANING PRODUCT MAY
CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD A CLEANING
PRODUCT. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD A CLEANING PRODUCT.
1. Clean Metal Parts

OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN
CADMIUM.

RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO PREVENT
EXPOSURE TO PERSONNEL.

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Part Number 2-1559
CLEANING
CAUTION: MAKE SURE THAT CONTAMINATION IS FULLY REMOVED FROM
BOLTS. CONTAMINATION CAN PREVENT FULL INSPECTION OF THE
BOLTS. CONTAMINATION CAN CAUSE INCORRECT BOLT TENSION
WHEN THE BOLTS ARE TORQUED.
CAUTION: DO NOT USE A WIRE BRUSH TO CLEAN ALUMINUM PARTS. A WIRE

BRUSH CAUSES DAMAGE TO THE ANODIZE LAYER ON THESE PARTS.
CAUTION: DO NOT USE ALKALINE CLEANING SOLVENTS TO CLEAN ALUMINUM

PARTS. THESE SOLVENTS CAN CAUSE DAMAGE TO THESE PARTS.
CAUTION: CAREFULLY OBEY THE INSTRUCTIONS FROM THE MANUFACTURER

FOR USE OF AQUEOUS CLEANING PRODUCTS. INCORRECT
PROCEDURES CAN CAUSE DAMAGE TO PARTS OR UNSATISFACTORY
CLEANING.
A. Clean metal parts with MIL-PRF-680 Type II or III solvent or aqueous cleaning
products. Make sure that bolt threads are fully clean. You can clean the shuttle valve
with the backup retainer (55) that is not removed. Use clean, dry, compressed air to
dry the parts. Some of these parts can be cadmium plated (refer to the
ILLUSTRATED PARTS LIST to find these parts).
2. Clean Non-Metal Parts
WARNING: BEFORE YOU USE BUTYL ALCOHOL, READ, UNDERSTAND, AND OBEY
ALL SAFETY INSTRUCTIONS FOR THE ALCOHOL. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. BUTYL ALCOHOL MAY CAUSE INJURY
TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD BUTYL ALCOHOL.
CAUTION: USE ONLY SPECIFIED CLEANING PRODUCTS TO CLEAN

NON-METALLIC PARTS. SOME OTHER CLEANING PRODUCTS
(FOR EXAMPLE: MIL-PRF-680) CAN CAUSE DAMAGE TO THESE
PARTS.
A. Clean non-metal parts with butyl alcohol or aqueous cleaning products.
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Part Number 2-1559
CLEANING
3. Remove Paint from the Piston Housing Assembly (if necessary) by one of the two
procedures that follow:
NOTE: It is necessary to remove paint before penetrant inspection. It is not necessary to

remove paint for eddy current.
A. Abrasive Blast Removal
WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS FROM

YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND DISCARD
PAINT THAT IS REMOVED. PAINT THAT IS REMOVED IS POSSIBLY
DANGEROUS TO THE SKIN, EYES, AND LUNGS.
CAUTION: DO NOT USE A WIRE BRUSH OR USE SAND OR GLASS BEADS IN

THE ABRASIVE-BLAST PROCEDURE TO CLEAN ALUMINUM PARTS.
A WIRE BRUSH, SAND, OR GLASS BEADS CAUSE DAMAGE TO
THE ANODIZE LAYER ON ALUMINUM PARTS.
(1) Put plugs or a mask material in the piston cavities, in fluid ports, and in the
holes that contain Heli-Coil® inserts (250, 255).
(2) Blast the parts (MIL-STD-1504) with plastic media (MIL-P-85891) (maximum
media hardness of 3.5 MOH) or with walnut hulls (A-A-1722 Type II) (grain-soft
abrasive walnut hulls, Grade 20/30).
(3) Use clean, dry, compressed air to remove plastic media and paint debris from
the piston housing. Remove plugs and mask material and make sure that
cavities, holes, and fluid passages are clean.
(4) If the abrasive media caused damage to the anodize layer, apply conversion
coat (MIL-C-5541 Class 1A) to the damaged areas (refer to the REPAIR
section).
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Aug 11/09
Part Number 2-1559
CLEANING
B. Chemical Removal
WARNING: BEFORE YOU USE PAINT REMOVER, READ, UNDERSTAND, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE PAINT REMOVER.
THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS),
AND GOVERNMENT REGULATIONS. PAINT REMOVER MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD PAINT REMOVER. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD PAINT REMOVER.
WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS FROM

YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND DISCARD
PAINT THAT IS REMOVED. PAINT THAT IS REMOVED IS POSSIBLY
DANGEROUS TO THE SKIN, EYES, AND LUNGS.
CAUTION: DO NOT USE A WIRE BRUSH TO REMOVE PAINT ON ALUMINUM

PARTS. A WIRE BRUSH CAUSES DAMAGE TO THE ANODIZE
LAYER ON THESE PARTS.
(1) If you put the piston housing fully into the paint remover, put plugs in piston
cavities, in fluid ports, and in holes that contain Heli-Coil® inserts (250, 255).
(2) Apply paint remover (SAE-AMS-1375) that can remove urethane paint and
epoxy primer and does not cause damage to aluminum or steel parts. Refer to
instructions from the manufacturer of the paint remover.
(3) Remove the paint remover.
(4) Use clean, dry, compressed air to remove all water from the piston housing.
Remove plugs and mask material and make sure that cavities, holes, and fluid
passages are clean and dry.
4. Remove Corrosion from the Torque Plate and Pressure Plate:
A. Abrasive Blast Removal
Lightly abrasive blast the torque plate or pressure plate to remove corrosion with
40 - 80 mesh abrasive media such as steel grit, sand, plastic media, or aluminum
oxide. Steel grit (not shot) abrasive media is recommended. Be careful not to remove
too much material during the abrasive blast procedure.
NOTE: The torque plate and pressure plate can be abrasive blasted to clean these
parts or to remove corrosion.
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Part Number 2-1559
CHECK
- Penetrant inspection equipment (ASTM E1417 Type I, Method A, Level 2)

- Magnetic particle inspection equipment (ASTM E1444)
- Torque wrench (accurate to 4% or better)
- Spring test equipment (Figure 507)
- Micrometer
- Hardness test equipment (Rockwell or Brinell)
WARNING: MEASURE THE HARDNESS ON A BRAKE ASSEMBLY THAT CAUSED A

THERMAL RELIEF PLUG (IN THE WHEEL) TO RELEASE THE TIRE
PRESSURE.
NOTE: The heat sink parts can last for the full interval between lining change. The inspection
of specified parts is not necessary until a lining change. However, if you must remove
the brake assembly before a lining change, the heat sink parts can be used again
unless the manual tells you to discard the parts. Assemble the brake assembly with
used parts as referenced in the ASSEMBLY section.
1. General Inspection

CADMIUM.


A. Examine all metal parts for corrosion, cracks, nicks, scratches, gouges, distortion,
damaged threads, and other defects. Discard damaged parts that are not
economically repairable. Some of the parts can be cadmium plated.
B. Replace the O-rings (15, 18, 60, 195, 210) at each heat sink or lining change.
Replace backup rings (55, 200) only if damaged.
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CHECK
2. Wear Plate Inspection
A. Examine each wear plate (90, 125) (refer to Figure 501). Replace all of the wear
plates if one wear plate is defective. Do not install a mixture of new and used wear
plates.
B. Examine each wear plate for a loose rivet. Replace a loose rivet. Do not hit a rivet to
make it tight.
C. Examine each wear plate for a crack. No more than one crack is permitted in each
rivet hole.
D. Examine each wear plate for a high ridge of material at the inner diameter which can
cause brake chatter. Remove this ridge (refer to the REPAIR section).
E. Examine each wear plate for edge curl. Edge curl is permitted when the wear plates
are attached to the pressure plate assembly (80) or torque plate assembly (115).
NOTE: Knife edge curl and wear that is not even between the wear plates is usual.
Figure 501. Wear Plate Inspection

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CHECK
3. Pressure Plate Inspection
A. Do a hardness inspection on the pressure plate at each wear plate change and if the
brake assembly was overheated.
NOTE: A hardness measurement is necessary on a brake that was overheated and

has caused the thermal relief plugs in the wheel assembly to release.
(1) Measure the hardness of the pressure plate (100) on the torque lugs.
(2) Measure three or more torque lugs equally spaced.
(3) Discard the pressure plate if a hardness value is less than 332 BHN (Rockwell
C 36) (refer to Figure 502).
WARNING: BEFORE YOU USE MAGNETIC PARTICLE FLUID (ASTM E1444) OR

PENETRANT FLUID (ASTM E1417 TYPE I, METHOD A, LEVEL 2), READ,
FLUID. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
GOVERNMENT REGULATIONS. THIS FLUID MAY CAUSE INJURY TO
YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
SAFELY USE, KEEP, AND DISCARD THIS FLUID. GET INSTRUCTIONS
FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP,
AND DISCARD THIS FLUID.
B. Visually examine for cracks at each wear plate change. Do a magnetic particle or
penetrant inspection at each wear plate change for cracks as follows:
NOTE: It is recommended to let the penetrant fluid remain on the part for 30
minutes minimum before inspection.
(1) Cracks that start from the disk outer diameter and go toward the inner diameter
are permitted if they are not more than 0.250 inch (6,35 mm) long. A crack from
one rivet hole to another is not permitted.
(2) If a crack is found at the junction of the disk inner diameter, at a torque lug, or
at a thermal expansion slot, discard the pressure plate (refer to Figure 502).
C. Measure the width of each torque lug for wear. Discard a pressure plate with a
torque lug that is worn to more than the limits (refer to Figure 502).
D. Measure the thickness of the pressure plate. Discard a pressure plate with a
thickness that is less than the limit (refer to Figure 502).
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Part Number 2-1559
CHECK
E. Measure the inner diameter of the pressure plate. Discard a pressure plate with an
inner diameter that is less than the limit (refer to Figure 502).
F. Examine the pressure plate for flatness. Cold-flatten or furnace-flatten a pressure

plate if it is warped or curved on the inner surface to more than 0.015 inch (0,38
mm) (refer to the REPAIR section).
G. Do a magnetic particle or penetrant inspection for cracks after a pressure plate is

made flat. Discard a pressure plate with a crack that is not permitted.
H. Examine each rivet hole for damage and wear. Discard the pressure plate if the
diameter of a rivet hole is more than 0.215 inch (5,46 mm).
I. Heil-Coil® Insert (95) Inspection
(1) Examine each Heil-Coil® insert for damage to the threads and internal
thread-locking element.
(2) Install a new, clean, and dry 8-32 UNC-3A screw into the Heli-Coil® insert.
(3) Replace the Heli-Coil® insert if the screw turns with hand force through the
locking element or if the back-off torque is less than 1.5 pound-inches (0,2 Nm)
(refer to the REPAIR section).
Figure 502. Pressure Plate Inspection

Page 504
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Part Number 2-1559
CHECK
4. Rotor Inspection

A. Visually examine each rotor for cracks (refer to Figure 503). Do a magnetic particle
or penetrant inspection for cracks. Cracks are permitted in the lining material. Cracks
in the steel carrier are not permitted.
B. Measure the wear surfaces for minimum thickness. Discard a rotor that is worn to
more than the limits (refer to Figure 503).
C. Measure the torque slot width. Discard the rotor with a slot width more than the limits
(refer to Figure 503).
D. Pitting is permitted if the area(s) of pitting covers no more than 25% of the lining
area on each side.
E. Crumbling of the lining material is permitted on the inner and outer diameters, and
around thermal expansion slots if it is not more than 0.25 inch (6,4 mm) wide (in
from the edge).
F. Measure the rotor for flatness. If the rotor is out of flat more than 0.020 inch (0,51
mm), discard the rotor.
Page 505
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Part Number 2-1559
CHECK
Figure 503. Rotor Inspection
5. Stator Inspection
A. Hardness Inspection
NOTE: The hardness measurement is only necessary if the thermal relief plugs in
the wheel assembly released the tire pressure.
(1) If the brake assembly was overheated, measure the hardness of the stator (110)
on the torque lugs.
(2) Measure three or more torque lugs equally spaced.
(3) Discard the stator if a hardness value is less than 332 BHN (Rockwell C 36)
Page 506
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Aug 11/09
Part Number 2-1559
CHECK
B. Measure the width of each torque lug for wear. Discard a stator with a torque lug
that is worn to more than the limits (refer to Figure 504).
C. Measure the thickness of the stator. Refer to Figure 708 for usability of stator.
D. Measure the inner diameter of the stator. Discard a stator with an inner diameter that
is less than the limit (refer to Figure 504).

E. Visually examine the stator for cracks. Do a magnetic particle or penetrant inspection
for cracks as follows:
(1) If a crack is found at a thermal expansion slot, or at the torque lug junction of
the disk inner diameter, discard the disk.
(2) Cracks that start from the disk outer diameter and go to the inner diameter are
permitted if the cracks are not more than 0.250 inch (6,35 mm) long. A crack
that starts from one slot and goes to a different slot is not permitted.
F. Examine the stator for flatness. Cold-flatten or furnace-flatten a stator if it is warped

or curved to more than 0.015 inch (0,38 mm) (refer to the REPAIR section).
G. Do a magnetic particle or penetrant inspection for cracks after the stator is made flat.
Discard a stator with a crack that is not permitted.
Page 507
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Part Number 2-1559
CHECK
Figure 504. Stator Inspection of P/N 133-991-1 Only
6. Torque Plate Inspection
NOTE: A hardness measurement is necessary only on a brake that was overheated

and has caused the thermal relief plugs in the wheel assembly to release.
(1) If the brake assembly was overheated, examine the torque plate for minimum
hardness on a flat surface between the mounting bolt holes.
(2) Measure at four or more locations equally spaced.
(3) Discard the torque plate if a hardness value is less than 297 BHN
(Rockwell C 32) (refer to Figure 505).
Page 508
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Part Number 2-1559
CHECK
B. When the wear plates are changed on the torque plate, visually examine the torque
plate for cracks. At each wear plate change, magnetic particle or penetrant inspect
for cracks. Surface cracks can be removed to a maximum depth of 0.030 inch (0,76
mm), but not in the areas shown in Figure 505.
C. Surface cracks, gouges, grooves, or pitting that is 0.030 inch (0,76 mm) deep or less
can be removed by local blending in the areas shown in Figure 505 (refer to the
REPAIR section). Discard a torque plate with a crack, gouge, or groove in an area
where repair is not permitted (refer to Figure 505).
D. Measure the distance from the torque plate mounting flange to the backleg at four
equally-spaced locations. Reject the torque plate if this distance is more than the
limit shown in Figure 505 or if the measurement changes more than 0.015 inch
(0,38 mm) from one location to another.
E. Visually inspect the slots in the torque plate outer diameter for roughness. Slots must
be smooth to permit the stator to move easily. Remove burrs, radius sharp edges,
and polish areas where the stator touches the slots (refer to the REPAIR section).
F. Examine each rivet hole for damage and wear. Discard the torque plate if the
diameter of a rivet hole is more than 0.215 inch (5,46 mm).
Page 509
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Part Number 2-1559
CHECK
Figure 505. Torque Plate Inspection
Page 510
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CHECK
7. Adjuster Assembly Inspection
A. Visually examine adjuster parts for wear and damage. Replace parts that are worn or
damaged.
B. Visually examine each adjuster housing (180) (refer to Figure 506). Discard a
defective adjuster housing.
Figure 506. Adjuster Housing Inspection
C. Replace all adjuster tubes (160) at each wear plate or heat sink component change.
D. Visually examine each retaining ring (165) for cracks, distortion, and wear. Replace a
retaining ring that is cracked, bent, or worn.
E. Visually examine each adjuster pin (155) for corrosion, thread damage, and
straightness. Discard a defective adjuster pin.
F. Visually examine each ball (150) for scored, galled, or corroded areas. Scored areas
are permitted if they are less than 10% of the total area. Discard a galled or corroded
ball.
Page 511
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CHECK
G. Adjuster Nut (145) Inspection

CADMIUM.


(1) Visual Inspection - Do an inspection for corrosion, cracks, and damage in the
threads or on the chamfer where the threads start. The nuts can be cadmium
plated. Discard a damaged nut.
(2) Locking Function Inspection
Do this inspection when the nut is installed (refer to the ASSEMBLY section).
H. Spring Inspection
(1) Examine each spring (175) for load limit at each heat sink change (refer to
Figure 507).
(2) Position the dial indicator to read zero at the spring height dimension shown
(3) Put the spring on the platform, centered under the ram.
WARNING: PUT A PROTECTIVE SHIELD AROUND THE SPRING. A SPRING

THAT IS NOT PUT IN THE CORRECT POSITION CAN EJECT FROM
THE TEST EQUIPMENT WITH MUCH FORCE.
(4) Compress the spring until the dial indicator shows zero. Discard a spring that
does not meet the minimum spring load.
Page 512
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CHECK
TEST HEIGHT SPRING LOAD MINIMUM
1.440 inch (36,58 mm) 20 lb. (9,1 Kg)
Figure 507. Spring Inspection
Page 513
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Part Number 2-1559
CHECK
8. Piston Inspection
A. Visually examine each piston (190) for surface damage and for wear. Small surface
scratches that cannot be felt with a sharp plastic pick or single-edged razor blade are
permitted. If you see wear on an outer surface, measure the diameter (refer to Figure
508). Discard a damaged piston or a piston with dents around the O-ring and backup
ring areas.
Figure 508. Piston Inspection
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Part Number 2-1559
CHECK
9. Piston Housing Assembly Inspection
NOTE: A hardness measurement is necessary only on a brake assembly that was

overheated and has caused the thermal relief plugs in the wheel assembly
to release.
(1) If a brake assembly was overheated, measure the hardness of the piston
housing assembly (240) on the mating face between mounting bolt holes (refer
to Figure 509).
(2) Measure the hardness at four or more locations equally spaced.
(3) Discard the piston housing assembly if a hardness value is less than 120 BHN
(Rockwell B 76) or if a conductivity value is more than 40.5% IACS.
Figure 509. Piston Housing Hardness Inspection
Page 515
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Part Number 2-1559
CHECK
B. At each heat sink change, visually examine the piston housing assembly (240) for
surface defects, cracks, and thread damage (refer to the REPAIR section).
WARNING: BEFORE YOU USE PENETRANT FLUID (ASTM E1417 TYPE I, METHOD
A, LEVEL 2), READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE FLUID. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY
DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. THIS FLUID
MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD THIS FLUID.
GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD THIS FLUID.
C. At each third heat sink change, do a penetrant inspection of the piston housing as
follows:
NOTE: A Nondestructive Test (NDT) manual gives a general description of eddy

current and penetrant inspection procedures. This manual is available from
the Goodrich wheel and brake publications web site:
https://techpubs.goodrich.com
(1) Penetrant inspect the full piston housing. Let the fluid stay on the piston housing
for a minimum of 30 minutes before the inspection is done. Refer to Figure 605
if a crack is found.
NOTE: Remove the paint and primer from the piston housing before penetrant
inspection (refer to the CLEANING section). It is not necessary to remove
paint and primer before eddy current inspection.
D. Eddy current examine the areas on the piston housing at each wear plate change
when a penetrant inspection is not done (refer to Figure 510). Refer to Figure 605 if
a crack is found.
E. Do an inspection for corrosion. Repair the areas with corrosion (refer to the REPAIR
section). Discard the piston housing if the repair is more than the limits specified.
F. Discard the piston housing if a crack starts at the bolt holes or a threaded hole.
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Figure 510. Eddy-Current Inspection of Piston Housing
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G. Do a visual inspection of each Lee plug (245) for leakage. Replace a Lee plug that
leaks (refer to the REPAIR section).
H. Heli-Coil® Insert Inspection
(1) Visually examine Heli-Coil® inserts (250, 255) for thread damage. Replace a
damaged Heli-Coil® insert (refer to the REPAIR section).
(2) Install a new, clean, and dry screw (75) into the Heli-Coil® insert (250).
(3) Install a new, clean, and dry bolt (40) into the Heli-Coil® insert (255).
(4) Replace the Heli-Coil® insert if the bolt or screw turns with hand force through
the locking element (refer to the REPAIR section).
10. Shuttle Valve Inspection
A. If it is not necessary to disassemble and overhaul the shuttle valve assembly, visually
examine the shuttle valve body (905) for corrosion, cracks, or gouges, or other
damage, which can be locally blend repaired (refer to the REPAIR section).
B. If the shuttle valve assembly was disassembled:
(1) Visually examine the shuttle valve body (905) and end cap (910) for corrosion,
cracks, gouges, stripped or crossed threads, and other damage. Examine all
sealing surfaces and packing grooves. Discard a damaged part.
(2) Measure the inner diameter of the end cap (910) (refer to Figure 511). Discard
a defective end cap.
NOTE: The valve body (905), end cap (910), and poppet (915) are not
included in the shuttle valve overhaul kit. If replacement of these parts
is necessary, order a new shuttle valve assembly (50). A poppet
assembly (945) can be purchased separately.
Figure 511. Inspection of the End Cap for the Shuttle Valve
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11. Miscellaneous Inspections

CADMIUM.


A. Bolt (35, 40) Inspection
(1) Visual Inspection
Do an inspection for corrosion, cracks, and damage in the threads or on the

radius below the bolt head. These bolts can be cadmium plated. Discard a
defective bolt.
B. Nut (25) Inspection
(1) Visual Inspection
Do an inspection for cracks and damage in the threads or on the chamfer where
the threads start. These nuts can be cadmium plated. Discard a defective nut.
(2) Locking Function Inspection
Do this inspection when the nuts are installed (refer to the ASSEMBLY section).
C. Washer (30, 45) Inspection
Do an inspection of each washer for corrosion and damage. The washers can be
cadmium plated. Discard a defective washer.
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D. Rod and Insert Assembly (65) Inspection
(1) Visually examine each rod and insert assembly for damage, distortion or other
damage that will prevent correct operation.
(2) Install a rod and insert assembly (65) on clean and dry stud assembly (70).
Replace the rod and insert assembly if it turns with hand force through the
locking element. The stud assembly can be cadmium plated. Discard defective
parts.
E. Insulators (185)
(1) Visually examine the insulators (185) for chips or signs of disintegration. Discard
the insulator if it shows signs of disintegration.
(2) Measure the insulators for 0.305 inch (7,75 mm) minimum thickness. Discard
the insulator if it is below minimum thickness.
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- Abrasive cloth
- Chemical that removes corrosion (SAE-AMS-1640)
- Conversion coat (MIL-C-5541 Class 1A)
- Degreasing solvent (MIL-PRF-680 Type II or III)
- Feeler gauges
- Grinding/deburring equipment
- Magnetic particle inspection equipment (ASTM E1444)
- Micrometers or vernier calipers
- Paint equipment
- Penetrant inspection equipment (ASTM E1417 Type I, Method A, Level 2)
- Mallet
- Pin punch
- 3/16 inch (4 mm) drill bit
NOTE: Replace the parts that cannot be repaired to the limits in the REPAIR section.
1. Pressure Plate Assembly Repair
A. Remove the high ridge of material at the inner diameter with a grinder. Remove the
material until the surface is even, or lower than the remaining wear surfaces (refer to
Figure 601).
Figure 601. Wear Plate Ridge Material Removal
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B. Wear Plate Removal
(1) Remove damaged or fully worn wear plates (90) (refer to Figure 501).
(2) Use a 3/16 inch (4 mm) drill bit to remove the dimpled (non-upset) rivet (85)
head on the wear plate. Then use a mallet and pin punch to push out the rivet.
C. Abrasive blast the pressure plate to remove corrosion (refer to the CLEANING
section).
D. Measure the thickness of the pressure plate after abrasive blasting (refer to Figure
502). Discard a pressure plate that is too thin.
E. Examine the pressure plate (refer to the CHECK section).
F. Cold-flatten or furnace-flatten a warped pressure plate to 0.015 inch (0,38 mm) or

less.

(1) Furnace Flatten Procedure
(a) Place pressure plate(s) or disk(s) in the fixture (refer to Figure 602).
Tighten the nut until the parts are held completely flat.
(b) Place the fixture assembly in the furnace for 4 1/2 hours at a temperature
of 1150°F (621°C), then air cool to room temperature.
(c) Inspect parts after furnace flattening for cracks (refer to the CHECK
section).
(2) Magnetic particle or penetrant inspect for cracks after a pressure plate is
flattened (refer to the CHECK section).
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Figure 602. Fixture
G. Heli-Coil® Insert (95) Replacement
(1) Use needle-nose pliers or a Heli-Coil® extraction tool, P/N 1227-06, to remove a
damaged Heli-Coil® insert.
(2) Install a new Heli-Coil® insert with a Heli-Coil® installation tool P/N 7551-2.
(3) Install the Heli-Coil® insert (95) 1/4 -3/4 turns below the top surface.
(4) Break off the tang with Heli-Coil® tang break-off tool, P/N 3695-2.
H. Apply Rust Prevention to the Pressure Plate
(1) Clean the pressure plate (refer to the CLEANING section).
(2) Mask all threaded ports.
(3) Apply a rust prevention product such as rust veto spray to the pressure plate.
Refer to the instructions from the manufacturer.
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I. Wear Plate Installation
(1) Install the wear plates (90) on the pressure plate (100).
NOTE: Replace the wear plates in sets. Do not install a mixture of new and used
wear plates.
(2) Align rivet holes in the wear plates (90) and pressure plate (100) and insert new
rivets (85) through the wear plates and into the pressure plate.
(3) Upset a rivet on the pressure plate side using peen and anvil tools (Figure 902).
The upset rivet head diameter must be 0.262 (6,65 mm) or larger.
2. Rotor Repair
Repairs on the rotor (105) are not permitted.
3. Stator Repair

A. Cold-flatten or furnace-flatten a warped stator to 0.015 inch (0,38 mm) or less.
(1) Place pressure plate(s) or disk(s) in the fixture (refer to Figure 602). Tighten the
nut until the parts are held completely flat.
(2) Place the fixture assembly in the furnace for 4 1/2 hours at a temperature of
1150°F (621°C), then air cool to room temperature.
(3) Inspect parts after furnace flattening for cracks (refer to the CHECK section).
B. Magnetic particle or penetrant inspect for cracks after flattening (refer to the CHECK
section).
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4. Torque Plate Assembly Repair
A. Remove the high ridge of material at the inner diameter with a grinder. Remove the
material until the surface is even, or lower than the remaining wear surfaces (refer to
Figure 601).
B. Wear Plate Removal
(1) Remove damaged or fully worn wear plates (125) (refer to Figure 501).
(2) Use a 3/16 inch (4 mm) drill bit to remove the dimpled (non-upset) rivet (120)
head on the wear plate. Then use a mallet and pin punch to push out the rivet.
C. Abrasive blast the torque plate to remove corrosion (refer to the CLEANING section).
D. Measure the thickness of the torque plate barrel after you do an abrasive blast. (refer
to Figure 505). Discard a torque plate that is below the minimum thickness.
E. Inspect the torque plate for cracks (refer to the CHECK section).
F. Cold-flatten the backleg if it is not to the limits of Figure 505.

G. Magnetic particle or penetrant inspect for cracks after the torque plate is
cold-flattened (refer to the CHECK section). Discard a torque plate that is cracked to
more than the limit.
NOTE: The penetrant inspection includes a step to etch a blend-repaired surface to

remove metal that is smeared (pushed) into a fault.
H. Locally blend to remove gouges, surface cracks, and pitting to 0.030 inch (0,76 mm)
maximum depth.
NOTE: A "blend" repair is done with hand tools to remove the damaged material.
The repair is done with a very slow change in the contour from the repaired
surface to the adjacent initial surface(s).
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I. Smooth rough areas in the slots to 0.030 inch (0,76 mm) maximum depth. Remove
burrs, radius sharp edges, and polish rubbing surfaces with 320 grit (or finer)
abrasive cloth.

J. Magnetic particle or penetrant inspect for cracks after blend repair (refer to the
CHECK section). Discard a torque plate that is cracked to more than the limit.
NOTE: The penetrant inspection includes a step to etch a blend-repaired surface to

remove metal that is smeared (pushed) into a fault.
K. Apply Rust Prevention to the Torque Plate
(1) Clean the torque plate (refer to the CLEANING section).
(2) Mask all threaded ports.
(3) Apply a rust prevention product such as rust veto spray to the torque plate.
Refer to the instructions from the manufacturer.
L. Wear Plate Installation
(1) Install the wear plates (125) on the torque plate (130).
NOTE: Replace the wear plates in sets. Do not install a mixture of new and used
wear plates.
(2) Align rivet holes in the wear plates (125) and torque plate and insert new rivets
(120) through the wear plates and into the torque plate.
(3) Upset each rivet on the torque plate side using peen and anvil tools (Figure
902). The upset rivet head diameter must be 0.262 (6,65 mm) or larger.
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5. Piston Housing Repair
CAUTION: DO NOT MAKE SHARP CHANGES IN CONTOUR OR A ROUGH

SURFACE IN REPAIRED AREAS. AN INCREASED POSSIBILITY OF
CRACKS CAN BE THE RESULT IF DAMAGED AREAS ARE NOT
REPAIRED CORRECTLY.
A. Remove gouges or surface cracks by local blending (refer to Figure 604 for repair
limits).
NOTE: A "blend" repair is done with hand tools to remove damaged material. The
repair is done with a very slow and continuous change in contour from the
repaired surface to the adjacent initial surface(s).
B. Do a penetrant inspection of each repaired area to find cracks. Discard a piston

housing that has a crack that is repaired to the maximum depth limit.
NOTE: The penetrant inspection includes a step to etch a blend-repair surface to

remove metal that is smeared (pushed) into a fault. You can use eddy
current inspection to make sure that the fault is removed.
C. Lee Plug (245) Repair
(1) Removal of a defective Lee plug:
Use a procedure that does not cause damage to the hole. A special bolt and
striker is recommended, as shown in Figure 603.
(a) Drill and tap a hole in the pin. Install the special bolt and hit the bolt head
with the striker as shown to remove the pin.
(b) Drill and tap the plug. Use the special bolt and striker to remove the plug.
Figure 603. Removal of a Lee Plug
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(2) Installation of a standard-size Lee plug (245)
(a) Measure the diameter of the hole for the Lee plug (245) in the piston
housing. If the diameter is 0.2187 - 0.2212 inch (5,555 - 5,618 mm), and
the surface finish is 63 Ra or better, install a standard-size Lee plug
(245).
CAUTION: DO NOT REMOVE THE LAYER OF WAX ON THE LEE PLUG OR

APPLY A LUBRICANT TO THE PLUG. A LEE PLUG CAN LEAK
IF THE REAMED HOLE AND THE REPLACEMENT PLUG ARE
NOT CLEAN AND DRY.
(b) Push the plug into the hole until the plug firmly touches the bottom of the
hole.
(c) Push the small end of the pin straight into the plug.
(d) Firmly hold the piston housing. Hit the end of the pin 2 or 3 times with a
hammer and flat punch to make the end of the pin flush with the end of the
plug, + 0.005 inch (0,13 mm). Make sure that the outer diameter of the
punch is smaller than the outer diameter of the pin. To decrease damage
to the pin, do not hit the pin many times.
(e) Do a high-pressure leak test on the fully-assembled brake assembly (refer

to the TESTING AND FAULT ISOLATION section).
(3) Installation of an oversize Lee plug (245A) (first rework)
NOTE: If the hole is larger than the specified size, or has a surface finish that is
rougher than 63 Ra, install an oversize Lee plug as follows:
(a) Ream the hole to a diameter of 0.2287 - 0.2312 inch (5,809 - 5,872 mm),
with a surface finish of 63 Ra or better.
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WARNING: BEFORE YOU USE CONVERSION COAT (MIL-C-5541 CLASS

1A), READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CONVERSION COAT. THESE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS), AND GOVERNMENT REGULATIONS. THIS
CONVERSION COAT MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD THIS CONVERSION COAT. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD THIS CONVERSION COAT.
(b) Apply conversion coat (MIL-C-5541 Class 1A) to the hole and let it dry.

NOT CLEAN AND DRY.
(c) Push the plug into the hole until the plug firmly touches the bottom of the
hole.
(d) Push the small end of the pin straight into the plug.
(e) Firmly hold the piston housing. Hit the end of the pin 2 or 3 times with a
(f) Do a high-pressure leak test on the fully-assembled brake assembly (refer

(4) Installation of an oversize Lee plug (245B) (second rework)
NOTE: If the hole is larger than the specified size, or has a surface finish that is
rougher than 63 Ra, install an oversize Lee plug as follows:
(a) Ream the hole to a diameter of 0.2500 - 0.2525 inch (6,350 - 6,414 mm),
with a surface finish of 63 Ra or better.
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WARNING: BEFORE YOU USE CONVERSION COAT (MIL-C-5541 CLASS

1A), READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CONVERSION COAT. THESE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS), AND GOVERNMENT REGULATIONS. THIS
CONVERSION COAT MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD THIS CONVERSION COAT. GET
(b) Apply conversion coat (MIL-C-5541 Class 1A) to the hole and let it dry.

NOT CLEAN AND DRY.
(c) Push the plug into the hole until the plug firmly touches the bottom of the
hole.
(d) Push the small end of the pin straight into the plug.
(e) Firmly hold the piston housing. Hit the end of the pin 2 or 3 times with a
(f) Do a high-pressure leak test on the fully-assembled brake assembly (refer

D. Heli-Coil® Insert (250) Replacement
NOTE: Do not remove a Heli-Coil® insert unless damaged.
(3) Install the Heli-Coil® insert 3/4 - 1 1/2 turns below the top surface.
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E. Heli-Coil® Insert (255) Replacement
NOTE: Do not remove a Heli-Coil® insert unless damaged.
(3) Install the Heli-Coil® insert 3/4 - 1 1/2 turns below the top surface.
Figure 604 (Sheet 1 of 2). Piston Housing Repair Limits
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REPAIR
MAX. DEPTH
AREA OF REPAIR PERMITTED REPAIR
(INCH (MM))
A 0.001 (0,03) Blend on a sealing surface

B 0.005 (0,13) Blend to 0.125 sq. in. (81 sq. mm) maximum area
C 0.020 (0,51) Blend to 0.250 sq. in. (161 sq. mm) maximum area
0.030 (0,76) Blend to 0.250 sq. in. (161 sq. mm) on external areas that are
not defined
Figure 604 (Sheet 2 of 2). Piston Housing Repair Limits
F. Piston Housing Conversion Coat
WARNING: BEFORE YOU USE THINNER (MIL-T-81772 TYPE I OR II), READ,

THINNER. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
GOVERNMENT REGULATIONS. THE THINNER MAY CAUSE INJURY TO
OBEYED. THE MSDS GIVES INSTRUCTIONS ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD THIS THINNER. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD THIS THINNER.
(1) Clean the surface with thinner.
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WARNING: BEFORE YOU USE CONVERSION COAT (MIL-C-5541 CLASS 1A),

READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS
FOR THE CONVERSION COAT. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
THE CONVERSION COAT MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. THE
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD THIS CONVERSION COAT. GET
(2) Apply conversion coat with a brush, sponge, pad, or spray to repaired areas or
to the fretted areas on the mating surface of the piston housing.
(3) Fully air dry the parts after application of conversion coat. Do not touch treated
surfaces until they are fully dry.
G. Paint Piston Housing
NOTE: Refer to the CLEANING section for paint removal instructions.
WARNING: DO NOT DISCARD WASTE FROM WATER-BORNE PAINT IN THE

SAME WASTE CONTAINER AS WASTE FROM SOLVENT-BORNE
PAINTS THAT CONTAIN ALUMINUM POWDER (SUCH AS METALLIC
PAINT). DISCARD THESE DIFFERENT TYPES OF WASTE
PRODUCTS IN SEPARATE, FIRE-PROOF CONTAINERS. WHEN
WATER TOUCHES ALUMINUM POWDER (WHICH MAKES
HYDROGEN GAS), A FIRE OR EXPLOSION IS POSSIBLE.
WARNING: BEFORE YOU USE PAINT MATERIALS, READ, UNDERSTAND, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THESE MATERIALS.
THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS),
AND GOVERNMENT REGULATIONS. THESE MATERIALS MAY
CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN YOU DO NOT
OBEY SAFETY INSTRUCTIONS. THE MSDS TELLS HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD THESE MATERIALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER THAT TELL HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD THESE MATERIALS.
(1) Use thinner to clean the piston housing.
(2) Apply mask material for primer as shown in Figure 605.
(3) Apply one layer of primer. Refer to the instructions from the manufacturer.
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(4) Apply mask material for paint as shown in Figure 605.
(5) Apply two layers of paint. Refer to the instructions from the manufacturer.
6. Shuttle Valve Assembly Repair
A. Use #400 grit abrasive cloth to locally blend the outer surface of the shuttle valve
body (905) to remove scratches, gouges, or corrosion to maximum depth of 0.010
inch (0,25 mm) from initial surface.
If the shuttle valve assembly is not disassembled for overhaul, seal all of the
hydraulic ports to prevent contamination of internal parts.
An overhaul kit (900A) is available to overhaul shuttle valve assemblies (50A and
50B). If the overhaul kit is used to overhaul the shuttle valve assembly,
P/N 195-191-1, ink stamp the shuttle valve assembly with "195-191-2" in a visible
location.
NOTE: Any brakes or shuttle valves made or overhauled since November 1996
already have the stronger spring incorporated and should be identified as
P/N 195-191-2.
B. Apply conversion coat and paint to the repaired areas (refer to paragraph 5.F. and
G. in this section).
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Figure 605. Piston Housing Paint Masking
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7. Installation of a New Identification Plate
Install a new identification plate (5) as follows (refer to Figure 606):
WARNING: BEFORE YOU USE DEGREASING SOLVENT (MIL-PRF-680 TYPE II OR

TYPE III), READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE DEGREASING SOLVENT. THESE INCLUDE
MANUFACTURER’S INSTRUCTIONS, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. DEGREASING
SOLVENT MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD
DEGREASING SOLVENT. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW TO SAFELY USE, KEEP, AND DISCARD DEGREASING
SOLVENT.
A. Use the solvent to clean the area on the piston housing assembly (240) where the
identification plate will be installed.
CAUTION: DO NOT TOUCH THE ADHESIVE WITH YOUR FINGERS.

CONTAMINATION OF THE ADHESIVE ON THE IDENTIFICATION PLATE
CAN CAUSE IT TO COME OFF.
B. Hold the identification plate on a flat surface and remove the paper on the back of
the plate. Do not bend the identification plate and hold it only at the edges.
C. Install the center of the identification plate and push to the outer edges. Use a hand
roller and roll on the full surface of the identification plate.
NOTE: Replace an identification plate that is wrinkled or creased during the

installation.
D. Let the identification plate set for 24 hours, to let the adhesive become hard.
E. Use a clean cloth that is moist with the solvent to clean the identification plate and
adjacent areas.
F. Mix the clear sealant. Refer to the instructions from the manufacturer (refer to the
SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES, section for the
manufacturer).
G. Apply the clear sealant on and around the edges of the identification plate (5).
H. Let the clear sealant to dry.
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Figure 606. Installation of the Identification Plate
8. Reidentification
A. If you are converting a brake assembly from a P/N 2-1559-1 or 2-1559-2 to a P/N
2-1559-3, reidentify the piston housing assembly as follows:
(1) Obliterate the suffix "1" or "2" to make the part number read "2-1559-".
(2) Hammer stamp a suffix "3" to make the part number read "2-1559-3".
Hammer stamp with 1/8 inch (3 mm) high character.
(3) Apply conversion coat, primer, and paint to hammer-stamped areas on the
piston housing (refer to this REPAIR section).
NOTE: Make sure the correct identification plate (5) is installed (refer to the
ILLUSTRATED PARTS LIST).
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NOTE: Equivalent alternatives are permitted for the equipment and materials that follow, but
not for anti-seize compound.
- 3/8 inch (9 mm) diameter plug

- Arbor press or drill press
- Anti-seize compound (SAE-AMS-2518)
- Freezer (0 °F (-17 °C))
- Loctite® No. 262 or 243
- Corrosion inhibitor
NOTE: Refer to the FITS AND CLEARANCES section for torques and specified anti-seize
compounds.
1. Assemble Adjuster Assemblies
WARNING: OBEY THE INSTRUCTIONS TO INSTALL THE SPRING IN EACH

ADJUSTER ASSEMBLY. THE SPRING IS COMPRESSED UNDER HIGH
LOAD. IF YOU DO NOT INSTALL THE SPRING WITH CORRECT
EQUIPMENT OR DO NOT OBEY INSTRUCTIONS, PARTS CAN BE
EJECTED AND CAUSE SERIOUS INJURY TO PERSONNEL.
A. Put a spring (175) and tube retainer (170) (with the WARNING side up) into each
adjuster housing (180) (refer to Figure 701).
B. Install a 3/8 inch (9 mm) diameter plug in the chuck of the press.
C. Put the assembled parts (170, 175, 180) on the arbor press table.
CAUTION: EXAMINE EACH RETAINING RING (165) FOR A ROUNDED EDGE THAT
IS CAUSED WHEN THE RING IS MADE. IF THE RETAINING RING HAS
ONE EDGE THAT IS ROUNDED MORE THAN THE OTHER EDGE,
INSTALL THE ROUNDED EDGE DOWN.
D. Install the retaining ring (165) on the plug shaft (refer to Figure 701).
E. Lower the plug tool onto the tube retainer (170).
F. Compress the spring (175) and tube retainer (170) far enough to install the retaining
ring (165).
G. Lock the press and install the retaining ring (165).
H. Make sure that the retaining ring (165) is fully into the groove.
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I. Unlock the press and slowly release pressure on the tube retainer (170).
J. Remove the assembled adjuster housing (180) from the press.
K. Install the adjuster pin (155) through the bottom side of the adjuster housing (180).
L. Install the adjuster tube (160), ball (150), and nut (145) (flanged side towards ball)
through the retaining ring (165) side of the adjuster housing and onto the adjuster pin
(155). Thread the nut on the adjuster pin until the top on the nut is even with the top
of the pin.
Do a test of the nuts - Use your hand to turn each nut as far as possible on a bolt.
Discard the nut if the bolt extends out of the nut.
Figure 701. Assemble Adjusters
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2. Assemble Shuttle Valve
A. Replace all O-rings (920, 925, 940) at each shuttle valve overhaul.
B. Lubricate the O-rings (920, 925, 940) with hydraulic fluid.
C. Install the O-rings (920, 925) on the outer diameter of the end cap (910) (refer to
Figure 702).
D. Install an O-ring (940) on each end of the poppet (915).
E. Install the spring (935) and balls (930) into the poppet (915) (refer to Figure 702).
F. Put the poppet and assembled parts into the end cap (910) until the balls (930) go
over the internal rib, which holds the poppet in position.
G. Install the end cap (910) with assembled parts into the valve body (905).
H. Dry torque the end cap (910) and lock with wire (20).
32-46-46 Page 703

Aug 11/09
Part Number 2-1559
ASSEMBLY
Figure 702. Shuttle Valve Assembly
32-46-46 Page 704

Aug 11/09
Part Number 2-1559
ASSEMBLY
3. Assemble Piston Housing
A. Replace the O-rings (15, 18, 60, 195) and scraper ring (240) at each heat sink
change. Replace backup rings (55, 200) when damaged.
B. Check to make sure Lee plugs (245), and Heli-Coils® (250, 255) are installed (refer
to the REPAIR section).
C. Install one each O-ring (195) and backup ring (200) in the piston bores of the piston
housing assembly (240). Make sure O-rings and retainers are properly seated in the
grooves (refer to Figure 703).
D. Install the pistons (190) and insulators (185). Make sure the pistons are bottomed in
piston housing assembly bores (refer to Figure 703).
NOTE: A mixture of insulators (185, 185A) can be used in a brake assembly.
Figure 703. Installation of Backup Ring and O-ring on a Piston
E. Install each adjuster assembly (140) in the piston housing assembly (240) and attach
with a retaining ring (135).
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Aug 11/09
Part Number 2-1559
ASSEMBLY
4. Install Pressure Plate Assembly
A. Put the piston housing assembly (240) and assembled parts on a flat surface with the
pistons (190) and insulators (185) face up.
NOTE: Make sure the adjuster pins (155) (refer to Figure 704) are protruding
equally from the adjuster assemblies (140).
B. Install the pressure plate assembly (80) on the piston housing assembly (240).
Figure 704. Adjuster Pins
32-46-46 Page 706

Aug 11/09
Part Number 2-1559
ASSEMBLY
C. Install the Pressure Plate Assembly on P/N 2-1559-1 Brake Assemblies
(1) Check to make sure the insulators (185) are installed correctly.
(2) Align the Heli-Coil® inserts in the pressure plate and wear plate assembly (80)
with the wear indicator hole in the piston housing assembly (240).
(3) With both components in position, align adjuster pins (155) with keyhole slots of
the pressure and wear plate assembly.
(4) Turn the piston housing assembly (240) and the pressure plate and wear plate
assembly (80) over.
(5) Align and engage the adjuster pins (155) in the keyhole slots of the pressure
plate and wear plate assembly (80).
(6) Put the short end of the allen wrench in the keyhole slot of the pressure plate
and slide it into the slot in the head of the adjuster pin (refer to Figure 705).
Turn the nut on the adjuster pin to align the pin head slot.
(7) Hold the allen wrench in the slot of the adjuster pin and remove the nut.
NOTE: Keep the allen wrench in the slot of the adjuster pin head.
(8) Apply a thin layer of Loctite® sealant No. 262 to the threads of the adjuster pin
and threads of the nut.
(9) Hold the allen wrench in the slot of the adjuster pin and install the nut (145).
Torque the nut. Make sure components are securely attached before lifting the
assembled unit.
32-46-46 Page 707

Aug 11/09
Part Number 2-1559
ASSEMBLY
Figure 705. Stud Assembly and Rod and Insert Assembly
D. Install the Pressure Plate Assembly on P/N 2-1559-2 and P/N 2-1559-3 Brake
Assemblies
(1) Check to make sure the insulators (185) are installed correctly.
(2) Align the helical coil inserts in the pressure plate assembly (80A) with the wear
indicator hole in the piston housing assembly (240).
(3) With both components in position, align adjuster pins (155A) with keyhole slots
of the pressure plate assembly (80A).
(4) Turn the piston housing assembly (240) and pressure plate assembly (80A)
over.
(5) Align and engage the adjuster pins (155A) in the keyhole slots of the pressure
plate assembly (80A).
(6) Apply a thin layer of Loctite® sealant No. 262 to the threads of the adjuster pin
and threads of the nut.
(7) Torque the nut. Make sure components are securely attached before lifting the
assembled unit.
32-46-46 Page 708

Aug 11/09
Part Number 2-1559
ASSEMBLY
5. Installation of Wear Indicator Parts
A. Assemble and install the stud assembly (70)
(1) Clean stud assemblies (70) to remove oil, grease and other contaminants.
(2) Apply 2 or 3 drops of Loctite® sealant, No. 262 or 243 on the end of the stud
(3) Install the nut on the stud as shown in Figure 706.
(4) Put the stud assemblies (70) through the piston housing assembly (240) and
into the pressure plate assembly (80).
(5) Torque the stud assembly nut.
B. Install the rod and insert assembly (65) on each stud assembly (70) four to five
turns.
Figure 706. Stud Assembly and Rod and Insert Assembly
6. Installation of the Heat Sink
A. Put the torque plate assembly (115) on a flat surface with the mounting bolt holes in
the up position.
NOTE: If a used rotor and stator are installed in the brake assembly and you need
to recalculate the wear pin setting, refer to paragraph 11 in this section.
B. Alternately install three rotors (105), and two stators (110) on the torque plate
assembly (115) with the stators installed between the rotors (refer to IPL).
NOTE: Make sure the ID lugs of the stators are properly engaged in the torque
plate slots.
32-46-46 Page 709

Aug 11/09
Part Number 2-1559
ASSEMBLY
7. Installation of the Piston Housing Assembly

CONTAIN CADMIUM.

PERSONNEL.

CAUTION: CORRECTLY APPLY ANTI-SEIZE COMPOUND. ANTI-SEIZE COMPOUND

THAT IS NOT APPLIED CORRECTLY CAN CAUSE INCORRECT BOLT
TENSION WHICH CAN CAUSE A BOLT TO BREAK.
A. Put the piston housing assembly (240) with attached pressure plate assembly on the
torque plate assembly (115). Align the screw (75) holes in the piston housing
assembly with the holes in the torque plate assembly.
B. Install the screws (75) through the torque plate assembly (115) and into the piston
housing assembly (240). The screws can be cadmium plated.
C. Torque the screws (75).
32-46-46 Page 710

Aug 11/09
Part Number 2-1559
ASSEMBLY
8. Shuttle Valve Installation with Union Fittings
A. Lubricate the O-ring (60) and backup retainer (55).
B. Install a lubricated backup retainer (55) and O-ring (60) on the shuttle valve
assembly (65) (refer to Figure 1, View D).
C. Install the shuttle valve assembly (50) in the piston housing assembly (240).
D. Attach the shuttle valve assembly (50) with bolts (40) and washers (45).
E. Torque the bolts (40) and lock with wire (20).
F. Install the O-ring (15) on the union fitting (10).
G. Install the union fitting in the shuttle valve assembly (50) and torque.
H. Install the shipping plug (265) on the union fitting.
I. Install the O-ring (18) on the union fitting (17).
J. Install the union fitting in the shuttle valve assembly (50) and torque.
K. Install the shipping plug (270) on the union fitting.
9. Bleeder Screw, Bleeder Fitting, and Bleeder Plug Installation
Use paragraph 9.A. to assemble brake assembly, P/N 2-1559-1.
Use paragraph 9.A. or 9.B. to assemble brake assembly, P/N 2-1559-2. If you assemble
brake assembly, P/N 2-1559-2 with paragraph 9.B., reidentify the brake assembly as,
P/N 2-1559-3 (refer to the REPAIR section).
Use paragraph 9.B. to assemble brake assembly, P/N 2-1559-3.
A. Install two bleeder fittings (235), two bleeder screw assemblies (215), and two
bleeder plugs (205) as follows:
(1) Lubricate the O-rings (210) with hydraulic fluid.
(2) Install the lubricated O-rings (210) on each bleeder fitting (235) and bleeder
plugs (205).
(3) Install the bleeder fittings (235) in the piston housing assembly (240).
(4) Torque the bleeder fittings (235).
(5) Install the bleeder screw assemblies (215) into the bleeder fittings (235).
32-46-46 Page 711

Aug 11/09
Part Number 2-1559
ASSEMBLY
(6) Torque the bleeder screw assemblies (215).
(7) Install the bleeder plugs (205) in the piston housing assembly (240).
(8) Torque the bleeder plugs (205) and lock with wire (20).
B. Install four bleeder plugs:
(1) Lubricate the O-rings (210) with hydraulic fluid.
(2) Install the lubricated O-rings (210) on four bleeder plugs (205).
(3) Install the bleeder plugs (205) in the piston housing assembly (240).
(4) Torque the bleeder plugs (205) and lock with wire (20).
10. Adjust Rod and Insert Assemblies with New Heat Sink Components

A. Do a Functional Test (refer to TESTING AND FAULT ISOLATION).
B. Pressurize the brake assembly to 800 - 850 psi (55,2 - 58,6 bar) and hold.
C. Turn the rod and insert assembly (65) to the dimensions shown in Figure 707.
D. Decrease the pressure to 0 psi (0 bar).
E. Disconnect the brake assembly and install the shipping plugs (265, 270).
32-46-46 Page 712

Aug 11/09
Part Number 2-1559
ASSEMBLY
Figure 707. New and Worn Indicator Rod Positions
32-46-46 Page 713

Aug 11/09
Part Number 2-1559
ASSEMBLY
11. Adjust Rod and Insert Assemblies with Used Heat Sink Components
NOTE: This section applies to only brake assemblies P/N 2-1559-2 and P/N 2-1559-3.
A. Measure the thickness of pressure plate assembly (80), each rotor (105), each stator
(110), and three wear plates (125) that are attached to the torque plate assembly in
three equally spaced locations.
B. For each part, find the adjustment of the rod and insert assembly (65) that agrees
with the average part thickness (refer to Figure 708). Make sure you use the shortest
measurement of all measurements.
NOTE: The shaded areas in Figure 708 agree with the measurements in the
example Figure 709.
C. If all the parts are thicker than the dimensions in Figure 708, adjust the rod and
insert assembly (65) at the longest setting for the brake assembly.
TORQUE PLATE
PRESSURE PLATE LENGTH OF ROD
ROTOR STATOR ASSEMBLY WEAR
AND WEAR PLATE AND INSERT
THICKNESS THICKNESS PLATE
THICKNESS ASSEMBLY
THICKNESS
0.265 (6,73) 0.308 (7,82) 0.208 (7,11) 0.087 (2,21) 0.400 (10,16)
0.264 (6,71) 0.304 (7,72) 0.277 (7,04) 0.086 (2,19) 0.380 (9,65)
0.263 (6,68) 0.299 (7,59) 0.274 (6,96) 0.085 (2,17) 0.361 (9,17)
0.262 (6,65) 0.295 (7,49) 0.272 (6,91) -- 0.341 (8,66)
0.261 (6,63) 0.291 (7,39) 0.269 (6,83) 0.084 (2,13) 0.322 (8,18)
0.260 (6,60) 0.288 (7,32) 0.266 (6,76) 0.083 (2,11) 0.307 (7,80)
0.259 (6,58) 0.282 (7,16) 0.264 (6,71) 0.082 (2,09) 0.283 (7,19)
0.258 (6,55) 0.278 (7,06) 0.261 (6,63) 0.081 (2,07) 0.263 (6,68)
0.257 (6,53) 0.274 (6,96) 0.258 (6,55) -- 0.244 (6,20)
0.256 (6,50) 0.270 (6,86) 0.255 (6,48) 0.080 (2,03) 0.224 (5,69)
0.255 (6,48) 0.265 (6,73) 0.253 (6,43) 0.079 (2,01) 0.205 (5,21)
0.255 (6,48) 0.261 (6,63) 0.250 (6,35) 0.078 (1,99) 0.185 (4,70)
0.254 (6,45) 0.257 (6,53) 0.247 (6,27) -- 0.166 (4,22)
0.253 (6,43) 0.253 (6,43) 0.244 (6,20) 0.077 (1,95) 0.146 (3,71)
0.252 (6,40) 0.248 (6,30) 0.242 (6,15) 0.076 (1,93) 0.127 (3,23)
0.251 (6,38) 0.244 (6,20) 0.239 (6,07) 0.075 (1,91) 0.107 (2,72)
0.250 (6,35) 0.240 (6,10) 0.236 (5,99) 0.074 (1,89) 0.088 (2,24)
0.249 (6,32) 0.236 (5,99) 0.234 (5,94) -- 0.068 (1,73)
0.248 (6,30) 0.231 (5,87) 0.231 (5,87) 0.073 (1,85) 0.049 (1,24)
0.247 (6,27) 0.227 (5,77) 0.228 (5,79) 0.072 (1,83) 0.029 (0,74)
0.246 (6,25) 0.222 (6,64) 0.225 (5,72) 0.071 (1,81) 0.010 (0,25)
Figure 708. Adjust the Rod and Insert Assemblies with Used Heat Sink Parts
32-46-46 Page 714

Aug 11/09
Part Number 2-1559
ASSEMBLY
AVERAGE LENGTH OF ROD

THICKNESS OF AND INSERT
PART NAME
USED PARTS ASSEMBLY
(INCH (mm)) (INCH (mm))
Pressure Plate Assembly 0.257 (6,54) 0.244 (6,20)
Stator #1 0.254 (6,45) 0.205 (5,21)
Stator #2 0.250 (6,35) 0.185 (4,70)
Rotor #1 0.272 (6,91) 0.224 (5,69)
Rotor #2 0.257 (6,53) 0.166 (4,22)
Rotor #3 0.253 (6,43) 0.146 (3,71)
Wear Plates on the Torque Plate Assembly 0.074 (1,89) 0.088 (2,24)
Shortest Rod and Insert Adjustment is: 0.088 (2,24)
Figure 709. Example to Determine the Length of Rod and Insert Assembly
E. Turn the rod and insert assemblies (65) to the shortest measurement that is shown
for all the parts in the heat sink (refer to the example in Figure 709). Measure from
the top of the rod to the surface of the rod access hole in the piston housing
assembly.
F. Decrease the pressure to 0 psi (0 bar).
G. If the brake is to be installed on the aircraft, apply anti-seize compound to the bolts
(35), washers (30), and threads of the nuts (25) (refer to Figure 710).
H. Install the brake on the axle of the aircraft. Align the holes in the piston housing
assembly (240) to the holes on the axle flange. Insert the bolts through the holes on
the torque plate and wear plate assembly (115), piston housing assembly, and axle
flange. Install the washers (30), nuts (25), and preliminary torque the nuts with
anti-seize compound in a crisscross sequence. Final torque in a clockwise sequence.
I. Connect the hydraulic and pneumatic lines to the shuttle valve assembly (50).
32-46-46 Page 715

Aug 11/09
Part Number 2-1559
ASSEMBLY
Figure 710. Locations to Apply Anti-seize Compound
12. Do the functional test (refer to the TESTING AND FAULT ISOLATION section).
13. Storage Instructions
A. Refer to Goodrich Service Letter No. 1854 for the storage life of rubber parts that are
not installed. Refer to SAE ARP5316.
B. If the brake is kept in storage, apply Rust Veto Spray or equivalent to the brake
disks. Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND
CONSUMABLES section for recommended corrosion inhibitors.
NOTE: It is not necessary to remove the Rust Veto material before the brake is
installed on the aircraft. The first brake cycle causes the material to burn off
and show a little smoke.
32-46-46 Page 716

Aug 11/09
Part Number 2-1559
FITS AND CLEARANCES

CAUTION: REFER TO THE ASSEMBLY SECTION FOR PROCEDURES TO CORRECTLY
APPLY ANTI-SEIZE COMPOUND AND TO TORQUE PARTS. PARTS CAN
BREAK IF YOU USE INCORRECT PROCEDURES.
ITEM TORQUE SPECIFIED

NOMENCLATURE
NUMBER VALUE COMPOUND
10, 17 Union Fittings 75 pound-inches None
(8,5 Nm)
25 Nut PRELIMINARY
(Tie Bolt) 180 pound-inches
(20 Nm) SAE-AMS-2518
(MIL-T-5544 is
FINAL optional)
240 pound-inches
(27 Nm)
40 Shuttle Valve Bolts 75 pound-inches None
(8,5 Nm)
70 Stud Assembly Nut 38 pound-inches Loctite®
(4,3 Nm) (No. 262 or 243)
75 Screw 55 pound-inches None
(7,3 Nm)
145 Adjuster Nut 15 pound-inches None
(1,7 Nm)
205 Bleeder Plug 75 pound-inches None
(8,5 Nm)
220 Bleeder Screw 40 pound-inches None
(4,5 Nm)
230 Bleeder Valve 40 pound-inches None
(4,5 Nm)
235 Bleeder Fitting 75 pound-inches None
(8,5 Nm)
910 End Cap 70 pound-inches None
(7,9 Nm)
Page 801
32-46-46 Aug 11/09
Part Number 2-1559
FITS AND CLEARANCES
Page 802
32-46-46 Aug 11/09
Part Number 2-1559

1. Special Tools
The usual maintenance tools and equipment are not shown below. Many of the special
tools, fixtures, and equipment that are shown below, or their equivalent replacements, are
necessary.
Use the drawings in this section to locally make special tools, fixtures, and equipment.
Special tools, fixtures, and equipment are not available from Goodrich Corporation.
Hammer stamp the tool part number on each tool to help the maintenance personnel find
the correct tool for a procedure.
FIGURE TOOL P/N DESCRIPTION APPLICATION
507 --- Spring Tester Necessary to measure spring

load
603 --- Special Bolt and Striker Necessary to remove Lee
plugs
901 114-1370 Test Shims Necessary for high pressure
test
902 114-1215 Peen Tool Necessary to rivet the wear
114-1216 Anvil Tool plates to the torque plate and
to the pressure plate
903 114-1371 Spacer Necessary to perform functional
test
904 114-1372 Furnace Flattening Used to flatten pressure plate
Fixture and stators
Page 901
32-46-46 Aug 11/09
Part Number 2-1559
MATERIAL: STEEL
Figure 901. Test Shims, P/N 114-1370
Page 902
32-46-46 Aug 11/09
Part Number 2-1559
Figure 902. Riveting Peen, P/N 114-1215, and Anvil P/N 114-1216, for Installation of Wear
Plates to the Torque Plate and to the Pressure Plate
Page 903
32-46-46 Aug 11/09
Part Number 2-1559
Figure 903. Spacer, P/N 114-1371
Page 904
32-46-46 Aug 11/09
Part Number 2-1559
Figure 904. Furnace Flattening Fixture, P/N 114-1372
Page 905
32-46-46 Aug 11/09
Part Number 2-1559
2. Aqueous Cleaner Consumables
NOTE: Refer to paragraph 3. Other Consumables.
RECOMMENDED
PRODUCT
CONCENTRATION & VENDOR
NAME
TEMPERATURE
Applied 4-204 Cleaner 30% at 120 °F (49 °C) Applied Chemical Technologies, Inc.
1045 Georgetown Road
Bldg. C-4
Lexington, Kentucky 40511
U.S.A.
Aquaspray 102 5% at 130 °F (54 °C) Hubbard-Hall Inc.
1101 Compton Bridge Road
Inman, South Carolina 29349
U.S.A.
Ardrox 6333 20% at 150 °F (66 °C) Chemetall Oakite Inc.
50 Valley Road
Berkeley Heights, New Jersey
07922
U.S.A.
Armakleen M-HP2 3% at 130 °F (54 °C) Church & Dwight Co. Inc.
or 469 North Harrison Street
10% at 160 °F (71 °C) Princeton, New Jersey 08543
U.S.A.
Big Blue 2 oz. / U.S. gal. B & B Tritech, Inc.
at 150 °F (66 °C) 875 West 20th Street
Hialeah, Florida 33010
U.S.A.
Brulin 1990 GD 3% at 130 °F (54 °C) Brulin & Co., Inc.
or P.O. Box 270
10% at 150 °F (66 °C) Indianapolis, Indiana 46206
Brulin 815 GD 5% at 130 °F (54 °C) U.S.A.
or
10% at 160 °F (71 °C)
or
20% at 180 °F (82 °C)
Cal Clean 657-LF 1% at 120 °F (49 °C) Calvary Industries
9233 Seward Road,
Fairfield, Ohio 45014
U.S.A.
Page 906
32-46-46 Aug 11/09
Part Number 2-1559
RECOMMENDED
PRODUCT NAME CONCENTRATION & VENDOR
TEMPERATURE
Calgon 6215 3% at 130 °F (54 °C) Calgon Corporation
& at 160 °F (71 °C) P.O. Box 1346
Pittsburgh, Pennsylvania 15024
U.S.A.
Cee-Bee A7X7 10% at 130 °F (54 °C) McGean-Rohco Inc
The Republic Bldg, Suite 1100
Cee-Bee 280 10% at 130 °F (54 °C)
25 West Prospect Avenue
Cee-Bee 300LF 10% at 140 °F (60 °C) Cleveland, Ohio 44115-1000
U.S.A.
Dubois Multi-Terj 1012 1% at 110 °F (43 °C) Dubois Chemicals
3630 East Kemper Road
Cincinnati, Ohio 45241
U.S.A.
Eldorado ED-306LF 3% at 130 °F (54 °C) Eldorado Chemical Company
& at 180 °F (82 °C) P.O. Box 34837
San Antonio, Texas 78265
U.S.A.
Magnus HDL-330 10% at 150 °F (66 °C) Mag-Chem Inc.
190 Boul. Industries
Magnus Soluwax 10% at 130 °F (54 °C)
Boucherville, Quebec
Magnus Aerodet 10% at 130 °F (54 °C) Canada J4B 2X3
Mirachem 500 Mirachem Corporation
15% at 110 °F (43 °C) 1045 S. Edward Road
Tempe, Arizona 85281
Mirachem 750LF
U.S.A.
25% at 145 °F (63 °C)
Rainbow Jet 5% and 9% ADN Chemicals
at 140 °F (60 °C) 2720 Reynolds Road
Winston Salem, North Carolina
27106 U.S.A.
Ram Wash H.D. 17% at 160 °F (71 °C) Ram Environmental Tech.
Birmingham, Alabama
U.S.A.
Page 907
32-46-46 Aug 11/09
Part Number 2-1559
RECOMMENDED
PRODUCT NAME CONCENTRATION & VENDOR
TEMPERATURE
SAG 710 0.8 oz./U.S. gal Witco Corporation

(anti-foam) at 140 °F (60 °C) One American Lane
Greenwich, Connecticut 06831
U.S.A.
Superclean RP 98 A 12 oz./U.S. gal. at ambient Lubrichem Environmenta
(room) temperature 2108 Plantside Drive
Louisville, Kentucky 40299
U.S.A.
Turco 3878 LF-NC 20% at 140 °F (60 °C) LA CIE Deane & Co.
190 Oneida Drive
Turco 6751-L 2% at 140 °F (60 °C) Pointe-Claire, Quebec
Turco 6849 4% at 145 °F (63 °C) Canada H9R 1AB
or
20% at 140 ° - 160 °F
(60 ° - 71 °C)
Turco Aviation 2 oz. /U.S. gal.
at 150 °F (66 °C)
Turco Sprayeze NPLT 3% at 130 °F (54 °C)
or
10% at 160 °F (71 °C)
ZOK27 20% at 160 °F (71 °C) Zokman Products
1220 East Gump Road
Fort Wayne, Indiana 46845
U.S.A.
Tel: 800-727-6027
Fax: 800-844-3227
Page 908
32-46-46 Aug 11/09
Part Number 2-1559
3. Other Consumables
NOTE: You can replace the materials shown below with equivalent materials that are
permitted by the specified MIL or SAE specification. Equivalent materials are not
permitted for bearing grease and anti-seize compound. If materials cannot be
purchased locally, they can be purchased from the vendors shown below.
TYPE OF PRODUCT VENDOR’S

CONSUMABLE NAME NAME AND ADDRESS
Degreasing Solvent
Approved Vendor
Cleaner MIL-PRF-680 Type II or III
Butyl Alcohol Commercially Available
Plastic Media
MIL-P-85891 Type II (maximum Approved Vendor
Paint Removal media hardness of 3.5 MOH)
Abrasive
Walnut Hulls
A-A-1722 Type II, Grade 20/30
Paint Remover SAE-AMS-1375
Commercially Available
Corrosion Removal SAE-AMS-1640
ASTM E1417 Type I, Method A,

Penetrant Fluid
Level 2
Rust Veto Spray Houghton International, Inc.
Madison & Van Buren Avenues
Valley Forge, Pennsylvania
Anti-Corrosion 19482
Product
Sperex VHT, SP-117 Sperex VHT Co
High Temperature Paint TT-P-28 16131 South Maple Avenue
Gardena, California 90248
Conversion Coat MIL-C-5541 Class 1A Approved Vendor
MIL-PRF-23377 Approved Vendor or
Type I, Class C1, C2, or N Hentzen Coatings, Inc.
Thinner-reducible (Class N is Non-Chromate) 6937 West Mill Road
Epoxy Polyamide Milwaukee, Wisconsin 53218
Primer U.S.A.
Tel: 414-353-4200
www.hentzen.com
Page 909
32-46-46 Aug 11/09
Part Number 2-1559
TYPE OF PRODUCT VENDOR’S

CONSUMABLE NAME NAME AND ADDRESS
MIL-PRF-85582 Deft, Inc.
Type I, Class C1, C2, or N 17451 Von Karman Avenue
Water-reducible (Class N is Non-Chromate) Irvine, California 92614
Epoxy Polyamide U.S.A.
Primer Product No. 44-GN-007 (Class C1) Tel: 800-544-3338
www.deftfinishes.com
Product No. 44-GN-098 (Class N)
MIL-PRF-85285
Urethane Paint
Medium Gray Approved Vendor
(FED-STD-595 color no. 16444)
Thinner MIL-T-81772 Types I, II, and III
Petrolatum VV-P-236 Commercially Available
Thread-Lock Loctite® 243

Commercially Available
Compound Loctite® 262
Base Coat, 683-3-2 or 683-3-20 Akzo Nobel Aerospace Coatings,
Curing Solution, X-310A Inc.
Thinner, TL-59 East Water Street
Clear Sealant
Waukegan, Illinois 60085
U.S.A.
www.akzonobel.com
Hydraulic Fluid MIL-PRF-83282 or MIL-PRF-5606 Approved Vendor
SAE-AMS-2518 Armite Laboratories

(MIL-T-5544 is optional) 1560 Superior Avenue
Costa Mesa, CA 92627
Anti-seize U.S.A.
Compound
Tel: 949-646-9035
Fax: 949-646-8319
www.armitelabs.com
Page 910
32-46-46 Aug 11/09
Part Number 2-1559
1. Introduction
CAUTION: GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR ANY
FEDERAL AVIATION ADMINISTRATION SANCTIONS, PRODUCT
MALFUNCTIONS, PROPERTY DAMAGE, PERSONAL INJURIES, OR
SIMILAR INCIDENTS THAT OCCUR AFTER SUBSTITUTION OF PARTS
THAT ARE NOT APPROVED BY GOODRICH, OR SUBSTITUTION OF
PARTS WITH ALTERATIONS THAT ARE NOT APPROVED BY
GOODRICH MANUALS OR OTHER WRITTEN PROCEDURES THAT ARE
ISSUED BY GOODRICH.
CAUTION: THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED BY

GOODRICH FOR INSTALLATION IN A SPECIFIED ASSEMBLY WILL
AUTOMATICALLY VOID ALL WARRANTIES EXTENDED BY GOODRICH.
A. Purpose
This section identifies the parts of the assemblies that you can disassemble, repair or
replace, and assemble.
B. Explanation of Data
(1) Item Numbers
An item number identifies a part in all sections of the manual. The item number
for a part usually does not change, but you can add alpha variants of the item
number. Refer to paragraph 1.B.(2).
A figure number is shown before the item number when there is more than one
figure supplied in the illustrated parts list.
An "R", adjacent to an item number, shows that the part was added or removed
or has changed data.
(2) Alpha Variant Item Numbers
An "Alpha Variant" is an alphabetic letter which follows the item number. This
letter "varies" (changes) when that item number is shown again. This letter is
shown in a figure to identify a part that has a different shape or location than
the initial part.
The letters "A" through "Z", but not I and O, follow repeated item numbers when
it is necessary to show:
(a) Added items
(b) Items that a Service Bulletin modifies
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Aug 11/09
Part Number 2-1559
(c) Different configurations
(d) Alternate or Optional parts
(e) Improved parts that a Service Bulletin does not introduce
(3) Parts that are not illustrated have a dash (-) before the item number.
(4) Indenture System to Show the Order of Assembly:
The parts list shows how parts are related to other parts in each assembly or
subassembly. The periods before the part name show the number of spaces
that the part name is indented in the NOMENCLATURE column. Each part or
subassembly is related to the next higher subassembly or assembly as follows:
1 2 3 4 5 6 7 (Spaces that the part name is indented)

Assembly (End item)
. Detail parts of the assembly
. Subassembly
. Parts that attach the subassembly
. . Detail parts for the subassembly
. . . Detail installation parts for the subassembly (included when installation
parts are returned to the maintenance area as part of the assembly.)
32-46-46 Page 1002

Aug 11/09
Part Number 2-1559
(5) Parts Replacement Data:
You can interchange parts when you obey the terms that follow. These terms
are shown in the NOMENCLATURE (part name) column of the parts list.
TERM ABBREVIATIONS DEFINITION

Alternate Alt This part can replace the specified
part, but has a different dimension,
is installed differently, or you must
add or remove other parts.
Optional Opt This part is optional and
interchangeable with the specified
part.
Non-Procurable Non-Proc This part cannot be purchased -
purchase the subsequent higher
assembly.
Superseded by Supsd by A different part replaces this part
and the parts are not
interchangeable.
Supersedes Supsds This different part replaces a part
and the parts are not
interchangeable.
Replaced by Repld by A different part replaces this part
and the parts are interchangeable.
Replaces Repls Item This different part replaces a part
and the parts are interchangeable.
Vendor V Commercial and Government Entity
(CAGE) No. for the maker of the
part.
(6) Service Bulletins that are Included
(a) A Service Bulletin can add, remove, change, or replace assemblies,

subassemblies, and detail parts. The NOMENCLATURE (part name)
column shows "PRE SB XXX" (pre-Service Bulletin) when identification of
the initial configuration is necessary. "POST-SB XXX" (post-Service
Bulletin) is shown to identify affected assemblies, subassemblies, or detail
parts.
(b) PRE SB XXX or POST SB XXX are not shown when:
1 The "EFF. CODE" column clearly shows the pre- or post-Service

Bulletin condition of the assemblies, subassemblies, or detail parts.
32-46-46 Page 1003

Aug 11/09
Part Number 2-1559
2 The Service Bulletin changes the end-item assembly and no change is

necessary to its part number. There is no factory-manufactured
equivalent of the changed assembly.
(c) "PRE SB XXX" is not shown, and "POST SB XXX" is shown, when a
Service Bulletin changes a subassembly or detail part with no change to its
part number. An alpha variant letter is also added to the item number.
(7) Effectivity Code
When there is more than one end-item assembly shown in the parts list, a
reference letter (A,B,C, etc.) is shown in the EFF. CODE column for each
end-item assembly. This same reference letter is shown in the EFF. CODE
column for each detail part or subassembly that you can install in the end-item
assembly with the same reference letter. You can install detail parts and
subassemblies in all end-item assemblies if no reference letter is shown.
(8) Quantity for Each Assembly
The UNITS FOR EACH ASSY column usually shows the full number of parts
that are necessary for each assembly, subassembly, or sub-subassembly.
The letters "AR" identify the parts that are installed "as required" (for example:
lockwire).
The letters "RF" identify the parts that are given only for reference.
32-46-46 Page 1004

Aug 11/09
Part Number 2-1559

C. Vendors
If a part has a vendor code number (V39BV2, for example) in the

“NOMENCLATURE” column of the ILLUSTRATED PARTS LIST, that part is FAA
approved as part of the Goodrich Quality Assurance System. Sources of these parts,
other than Goodrich, must have alternate FAA approval under Federal Aviation
Regulations (14 CFR Part 21).
CAGE CODE VENDOR INTERNET

VENDOR NAME AND ADDRESS
NO. ADDRESS
01178 Lourdes Industries, Inc. www.lourdesinc.com
65 Hoffman Avenue
Hauppauge, New York 11788-4716
01556 Emhart Teknologies LLC
50 Shelton Technology Center
Shelton, Connecticut 06484-4517
09257 Trelleborg Sealing Solutions US Inc.
2531 Bremer Road
Fort Wayne, Indiana 46803-3014
79136 Truarc Company LLC
Waldes Truarc
125 Bronico Way
Phillipsburg, New Jersey 08865-2778
92555 The Lee Company www.theleeco.com
2 Pettipaug Road
Westbrook, Connecticut 06498-1591
97153 Goodrich Corporation www.goodrich.com
Aircraft Wheels and Brakes
P.O. Box 340
101 Waco Street
Troy, Ohio 45373-3872
99017 Caplugs LLC
Mokon Division
2150 Elmwood Avenue
Buffalo, New York 14207-7198
32-46-46 Page 1005

Aug 11/09
Part Number 2-1559
Figure IPL 1. Exploded View, Main Brake Assembly.
32-46-46 Page 1006

Aug 11/09
Part Number 2-1559
UNITS
FIG.& AIRLINE NOMENCLATURE
PART EFF. FOR
ITEM STOCK
NUMBER CODE EACH
NO. NO. 1 2 3 4 5 6 7
ASSY.
1-1 2-1559-1 Brake, Multiple Disk (Non-Proc) A RF

R 1-1A 2-1559-2 Brake, Multiple Disk B RF
R 1-1B 2-1559-3 Brake, Multiple Disk C RF
5 50-611 . Identification Plate A 1
-5A 50-663 . Identification Plate B 1
R -5B 50-906 . Identification Plate C 1
10 274-212 . Fitting, Union 1
R 15 MS28778-4 . O-ring 1
17 274-211 . Fitting, Union 1
18 MS28778-6 . O-ring 1
20 MS20995C32 . Wire, Lock AR
R 25 MS21042-5 . Nut, Self-locking
(Part can be cadmium plated) 6
R 30 MS20002-5 . Washer, Flat
R 35 MS21250-05010 . Bolt, 12 point
R 40 NAS1304-4H . Bolt
R 45 AN960-416 . Washer, Flat
50 195-191 . Valve Assembly, Shuttle
(Repld by Item 50A) 1
R -50A 195-191-1 . Valve Assembly, Shuttle
(Supsd by Item 50B) 1
- Items not illustrated.

* Do not remove unless damaged
32-46-46 Page 1007

Aug 11/09
Part Number 2-1559
UNITS
PART EFF. FOR
ITEM STOCK
NUMBER CODE EACH
NO. NO. 1 2 3 4 5 6 7
ASSY.
R -50B 195-191-2 . Valve Assembly, Shuttle

(Supsds Item 50A and 50B) 1
R 55 56-627 . Retainer, Backup 1
R 60 M83461/1-012 . O-ring 1
65 463-13 . Rod and Insert Assembly 2
R 70 534-1 . Stud Assembly
R 75 MS24693S270 . Screw
R 80 309-42 . Pressure Plate Assembly A 1
(Non-proc)
R -80A 309-42-1 . Pressure Plate Assembly B, C 1
85 78-265 . . Rivet 24
90 93-909-1 . . Plate, Wear 12
R 95 3585-2CN164 . . Insert, Heli-Coli® (V01556) 2
R 100 93-946 . . Plate, Pressure (Non-proc) A 1
R -100A 93-946-1 . . Plate, Pressure (Non-proc) B, C 1
R 105 244-657 . Rotor (Non-proc) A 3
R -105A 244-657-1 . Rotor B, C 3
R 110 133-991 . Stator (Non-proc) A 2
R -110A 133-991-1 . Stator B, C 2
R 115 4-337 . Torque Plate Assembly 1
120 78-265 . . Rivet 24
125 93-909-1 . . Plate, Wear 12
R 130 184-878 . . Torque Plate (Non-proc) 1

* Do not remove unless damaged
32-46-46 Page 1008

Aug 11/09
Part Number 2-1559
UNITS
PART EFF. FOR
ITEM STOCK
NUMBER CODE EACH
NO. NO. 1 2 3 4 5 6 7
ASSY.
135 5100-75 . Ring, Retaining (V79136) 6

R 140 107-398 . Adjuster Assembly (Non-proc) A 6
-140A 107-398-1 . Adjuster Assembly B, C 6
R 145 MS21042L04 . . Nut, Self-locking
150 130-24 . . Ball 1
155 20-616 . . Pin, Adjuster (Non-proc) A 1
-155A 20-676 . . Pin, Adjuster B, C 1
R 160 45-239 . . Tube, Adjuster
(Repld by Item 160A) 1
R -160A 45-239-1 . . Tube, Adjuster
(Repls Item 160) 1
165 N5000-75 . . Ring, Retaining (V79136) 1
170 56-966 . . Retainer, Tube 1
175 40-677 . . Spring, Helical 1
180 260-844 . . Housing, Adjuster 1
R 185 115-355 . Insulator
(Repld by Item 185A)
(Non-Proc) 6
R -185A 115-355-1 . Insulator
(Repls Item 185) 6
190 74-875 . Piston 6
195 M83461/1-219 . O-ring 6
200 S12587-219 . Ring, Backup (V09257) 6
R 205 MS24391D4L . Plug, Bleeder A, B

* Do not remove unless damaged.
32-46-46 Page 1009

Aug 11/09
Part Number 2-1559
UNITS
PART EFF. FOR
ITEM STOCK
NUMBER CODE EACH
NO. NO. 1 2 3 4 5 6 7
ASSY.
R -205A MS24391D4L . Plug, Bleeder B, C

R 210 MS28778-4 . O-ring A, B 2
R -210A MS28778-4 . O-ring B, C 4
R 215 155-11 . Bleeder Screw Assembly A, B 2
R 220 MS51958-60 . . Screw A, B 1
R 225 MS35338-100 . . Washer, Flat A, B 1
R 230 84-28 . . Valve, Bleeder A, B
R 235 274-36 . Fitting, Bleeder A, B 2
240 266-255-1 . Piston Housing Assembly 1
245 PLGA2180010 . . Lee Plug (V92555) 6
R -245A PLGA2280010 . . Lee Plug (Oversized)
(Service Part) (V92555) AR
R -245B PLGA2500010 . . Lee Plug (Oversized)
(Service Part) (V92555) AR
R 250 3591-3CN190 . . Insert, Helical Coil (V01556) 2
R 255 3591-4CN250 . . Insert, Helical Coil (V01556) 2
R 260 260-870-1 . . Housing, Piston (Non-proc) 1
265 ASC4DN . Threaded Cap and Gasket
(V99017) 1
270 ASC6DN . Threaded Cap and Gasket
(V99017) 1
R -900 380-111 DELETED AR
R -900A 380-111-1 Overhaul Kit, Shuttle Valve
(Used to overhaul Items 50A or
50B) AR

* Do not remove unless damaged.
32-46-46 Page 1010

Aug 11/09
Part Number 2-1559
UNITS
PART EFF. FOR
ITEM STOCK
NUMBER CODE EACH
NO. NO. 1 2 3 4 5 6 7
ASSY.
R 905 -- . Body, Shuttle Valve (Not in kit)

(V01178) (Non-proc) 1
R 910 -- . Cap, End (Not in kit) (V01178) 1
(Non-proc)
R 915 -- . Poppet (Not in kit) (V01178) 1
(Non-proc)
R 920 -- . O-ring (V01178) 1
R 925 -- . O-ring (V01178) 1
R 930 -- . Ball (V01178) 2
R 935 -- . Spring 1
R 935A -- . Spring (Opt to Item 935) 1
R 940 -- . O-ring (V01178) 2
R -945 80306-1 Poppet Assembly (Service Part) 1
(Includes Items 915 and 940)
(V01178)
32-46-46 Page 1011

Aug 11/09
Part Number 2-1559
32-46-46 Page 1012

Aug 11/09

Component Maintenance Manual With Illustrated Parts List Main Brake Assembly

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Aircraft Wheels & Brakes

COMPONENT MAINTENANCE MANUAL

MAIN BRAKE ASSEMBLY

INTENTIONAL BLANK PAGE

Issued Jan 30/93

INTENTIONAL BLANK PAGE

RECORD OF TEMPORARY REVISIONS

TEMPORARY AFFECTED DATE PAGES DATE PAGES ARE

32-1 703 Apr 4/03 BKM Aug 11/09 BWT

RECORD OF TEMPORARY REVISIONS

INTENTIONAL BLANK PAGE

SERVICE BULLETIN LIST

1662 Nov 23/94 Aug 15/95 Introduction and conversion

SERVICE BULLETIN LIST

1977 1 Jul 30/07 Aug 11/09 Safety precautions for

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page 1 Aug 11/09 Disassembly 301 Aug 11/09

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Fits and Clearances 801 Aug 11/09

DESCRIPTION AND OPERATION

TESTING AND FAULT ISOLATION

AUTOMATIC TEST EQUIPMENT (ATLAS) . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE

FITS AND CLEARANCES

SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES

ILLUSTRATED PARTS LIST

• A "CAUTION" statement is given to prevent damage to equipment.

• A "WARNING" statement is given to prevent personal injury or illness.

• A "NOTE" statement is given to make a job easier.

Additional requirements may be imposed based on airplane specifications, wheel and

3. Verification Dates: Disassembly Testing Assembly

4. Replacement Parts Policies

Goodrich makes wheel assemblies and brake assemblies to aircraft manufacturer

WARNING: REGARDLESS OF ANY FAA APPROVALS OR DEMONSTRATED

CAUTION: GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CAUTION: THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED BY

5. Warnings for the Full Manual

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST.

SAE CUSTOMER SERVICE

AMERICAN SOCIETY FOR TESTING AND MATERIALS

INTENTIONAL BLANK PAGE

DESCRIPTION AND OPERATION

The 2-1559-1 brake assembly is the initial design brake assembly.

Brake assembly 2-1559-3 contains four bleeder plugs.

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

Figure 1 (Sheet 1 of 2). Main Brake Assembly Description

DESCRIPTION AND OPERATION

Figure 1 (Sheet 2 of 2). Main Brake Assembly Description

DESCRIPTION AND OPERATION

Figure 2. Adjuster Assembly Description

DESCRIPTION AND OPERATION

INTENTIONAL BLANK PAGE

TESTING AND FAULT ISOLATION

Equipment and Materials

- 1200 psi (82,7 bar) minimum pressure source

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS SWALLOWED