NHTSA ID Number: 10238240
Manufacturer Communication Number: 45B-001-2023
TSB/Document Date: 2023-06-28
Summary
Lippert
suspects that some hub and brake assemblies used on the Curt axles installed on Brinkley’s Model Z 5th Wheels may have been damaged in the production and/or inspection process at Lippert. As a result, Lippert has elected to replace all hub and brake assemblies on certain units. This will affect dealer inventory as well as retail owned vehicles. The VINs affected are provided in the attached TSB. A copy of all communications pertaining to this TSB by Brinkley RV to its retail customers and dealer partners between the dates of June 23, 2023 and June 28, 2023 are attached.
1222593
2 ea
- RH Brake Assy
1224513
2 ea
- Hub Assy
380827
4 ea
- Cotter Pin
122075
4 ea
- Sealed Wire Conn122084
8 ea
- Keps Nuts
122077
20 ea
- Dust Cap
85373929
4 ea
- TSB Instructions CCD-0007981 1 ea
•
•
•
•
•
•
•
•
Cordless or electric drill or screw gun
Appropriate drive bits
9/16" socket and ratchet
Torque wrench
Rubber mallet
Wire cutters
Floor jacks
Appropriately-rated jack stands
NOTE: It is important that ALL NEW parts are ordered using KIT PN 2023040017. Utilize ALL NEW
parts. Do NOT reuse the old parts, even if the old parts do not appear to be compromised.
Rev. 06.23.2023
Page 3
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
Hub Removal
1.
Lift and support trailer per manufacturer’s requirements.
Lift trailer by the frame and never the axle or suspension. Do not go under trailer unless it is properly
supported by jack stands. Unsupported trailers can fall causing death or serious injury.
2.
Remove the rubber plug from the adjusting slot on the bottom of the brake backing plate (Fig. 1).
3.
Insert a screwdriver or standard adjusting tool into the adjusting slot to rotate the starwheel (Fig. 2) of
the adjuster assembly to retract the brake shoes.
Fig. 1
Rubber Plug
Adjusting Slot
Fig. 2
Starwheel
Rev. 06.23.2023
Page 4
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
4.
Remove the lug nuts from the wheel and set aside (Fig. 3).
5.
Remove the wheel from the axle hub and set aside (Fig. 4).
Fig. 3
Fig. 4
6.
Unscrew the dust cap and remove from hub (Fig. 5).
7.
Pull the cotter pin from the castle nut and DISCARD THE COTTER PIN (Fig. 6).
Fig. 6
Fig. 5
Cotter Pin
Dust Cap
Axle Hub
Rev. 06.23.2023
Page 5
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
8.
Remove the castle nut from the spindle (Fig. 7).
9.
Remove the spindle washer from the spindle (Fig. 8).
10. Place hand over nose of hub during removal to contain outer bearing cone or remove outer bearing
cone prior to removal of hub. Remove the hub from the spindle (Fig. 9).
Fig. 8
Fig. 7
Spindle Washer
Fig. 9
Brake Assembly
Hub Assembly
Spindle
Rev. 06.23.2023
Page 6
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
Replace Brake Assembly
Procedure
1.
2.
3.
Using a 9/16" socket and ratchet, remove the nuts holding the brake assembly to the spindle (Fig. 10).
Cut the brake wires on the back side of the brake assembly.
Remove the brake assembly from the spindle (Fig. 10).
NOTE: If necessary, gently tap the brake assembly with a rubber mallet.
4.
5.
Place the new brake assembly onto the spindle and install by hand two of the nuts previously
removed.
Hand tighten the nuts to hold the brake assembly in place.
NOTE: If brake has 36” lead wires, cut back to 18" to avoid excess wire hanging down.
6.
7.
8.
Using sealed wire connectors (Fig. 11), reconnect the brake wires.
Install by hand the remaining nuts and tighten in a sequential pattern as shown in Fig. 12.
After the brake assembly nuts are fully hand tightened, torque the nuts to 25-35 ft-lbs in the sequential
pattern shown in Fig. 12 until proper torque is indicated by the torque wrench.
Fig. 10
Brake assembly
Fig. 12
Fig. 11
1
Wire Connector
4
3
2
5
5 Fastener Sequence
Spindle
Rev. 06.23.2023
Page 7
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
Hub Replacement
NOTE: All grease MUST be wiped from spindle, inside of drum and off bottom of grease seal prior to hub
install to prevent brake contamination.
1.
Place hub assembly onto the axle spindle followed by the spindle washer and castle nut (Fig. 13).
Castle nut should be torqued to 50 ft-lbs. Rotate the hub during the tightening process.
Fig. 13
Hub Assembly
Spindle Washer
Spindle
2.
Loosen castle nut to back off the torque.
3.
Tighten castle nut finger tight until snug.
4.
Insert NEW cotter pin (Fig. 14). If cotter pin does not line up with hole, back castle nut up slightly until
pin can be inserted.
5.
Bend cotter pin over to lock nut in place (Fig. 15). Nut should be free to move with only the cotter pin
keeping it in place.
Fig. 14
Fig. 15
Rev. 06.23.2023
Page 8
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
6.
Reinstall dust cap onto the hub assembly by screwing it in at 20 ft-lbs (Fig. 16).
7.
Reinstall the wheel onto the hub assembly (Fig. 17).
8.
Reinstall the lug nuts onto the hub studs (Fig. 18) using sequential pattern as shown in Torque
Requirement Chart (Fig 19).
Fig. 17
Fig. 16
Dust Cap
Hub Assembly
Axle Hub
Fig. 18
Fig. 19
Hub Studs
Rev. 06.23.2023
Wheel Size
Stud Size
16"
16.5" x 6.75"
9/16"
9/16"
Torque Requirement Chart
Torque Sequence
1st Stage
2nd Stage
20-25 ft-lbs
60-70 ft-lbs
20-25 ft-lbs
60-70 ft-lbs
Page 9
3rd Stage
120-130 ft-lbs
120-130 ft-lbs
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
9.
Labor Rate: 2.5 hours per axle
Remove the rubber plug from the adjusting slot on the bottom of the brake backing plate (Fig. 20).
10. Insert a screwdriver or standard adjusting tool into the adjusting slot to rotate the starwheel (Fig. 21) of
the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the
linings against the drum makes the wheel very difficult to turn.
11. Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag.
NOTE: A second screwdriver will be needed to push the auto adjusting lever away from the starwheel so
that the starwheel can be rotated backwards.
12. Replace the rubber plug in the adjusting slot and lower the wheel to the ground.
13. Repeat the above procedure on all brakes. For best results, the brakes should all be set at the same
clearance.
Fig. 20
Rubber Plug
Adjusting Slot
Fig. 21
Starwheel
Rev. 06.23.2023
Page 10
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
Measuring Amperage
The Braking System amperage is the amount of current flowing through the system when all magnets have
been energized. The amperage will change proportionately with the voltage. To ensure that the battery is
indicating a full charge, the towing vehicle engine should be running with the coach coupler connected
when checking the voltage.
If a resistor is used in the brake system, it must be set at zero or bypassed completely to obtain the
maximum amperage reading. Individual amperage draw can be measured by inserting the ammeter in the
line at the magnet you want to check. Disconnect one of the magnet lead wire connectors and attach the
ammeter between the two wires. Consult Amperage Chart below for normal amp readings.
Make sure that the wires are properly reconnected and sealed after testing is completed. Testing for
Amperage can be done with probes (Fig. 22) or alligator clips on the leads or an amp clamp (Fig. 23).
Fig. 22
Fig. 23
Amperage Chart
Amps/Magnet
3.0
Rev. 06.23.2023
Two Brakes
6.0
Page 11
Four Brakes
12.0
Six Brakes
18.0
CCD-0007981
HUB AND BRAKE ASSEMBLY REPLACEMENT
ON BRINKLEY MODEL Z 5TH WHEELS
TSB Number: 45B-001-2023
Product: Hub and Brake Assembly
Date: June 23, 2023
Labor Rate: 2.5 hours per axle
Break-in Period for Electric Drum Brakes (Burnishing)
Prior to any adjustments, trailer brakes should be burnished. The break-in period is a typical phenomenon
with drum brakes and especially electric drum brakes. Electric drum brakes will require a break-in period to
achieve full performance. This break-in period applies for new axles and any time new brake shoes and/or
magnets are installed as part of regular maintenance.
Lippert has found through brake testing that the break-in period for drum brakes can range from 20 to 50
brake applications. Brakes can be seated in by applying approximately 8-10 volts to the trailer brakes at an
initial speed of 40 mph and allowing the truck/trailer combination to slow down to 20 or 25 mph. For best
results do not use truck brakes during this procedure.
The trailer brakes will seat in faster by using them to stop both the truck and trailer. The easiest method is to
apply the trailer brakes using the manual activation lever located on the in-cab brake controller. Care must
be taken to not overheat the lining material; therefore, brake applications conducted at one-mile intervals
will suffice. The driver should feel a noticeable difference in the brake performance during this period,
sometimes in as few as 10 applications. After 50 applications, the brake lining material will be fully cured
from the heat and develop close to 100 percent contact with the brake drum surface.
This break-in period not only seats the shoe lining material but also seats in the brake magnets. During the
break-in period, the linings will wear at a faster rate than they do after they are seated in.
NOTE: Brakes should be manually adjusted after the first 200 miles of operation and periodically thereafter,
at approximately 3,000 mile intervals.
Related Video on web site lci1.com
Proper Way to Burnish your Trailer Brakes
Related Document on web site lci1.com
TI-086 - Electric Drum Brake Break-in Period
Full TI-086 link:
https://lci-support-doc.s3.amazonaws.com/technical-information-sheets/axles-and-suspension/ccd-0001947.pdf
As a supplier of a broad array of highly-engineered components in the recreation and transportation product markets, safety, education and customer satisfaction are
our primary concerns. Should you have any questions, please do not hesitate to contact us at 432-LIPPERT (432-547-7378) or by email at [email protected].
Self-help tips, technical documents, product videos and a training class schedule are available at lippert.com or by downloading the LippertNOW app.
Rev. 06.23.2023
Page 12
CCD-0007981
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS
, disc and drum brake systems - Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: 45B-001-2023
Replacement Service Bulletin Number:
MFR Communication Date: 2023-06-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, HYDRAULIC
MFR Component System:
MFR Component Subsystem:
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