Conmet Conventional Service Manual Download

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ConMet | 5701 SE Columbia Way, Vancouver, WA 98661 | 800.547.9473 | conmet.com

Part No. 10085395A

10-2021 Printed in the USA

DISC BRAKE ROTOR REPLACEMENT

Install the brake rotor using only the hardware provided in the kit.

1. Clean the rotor mounting surfaces and position the rotor onto the hub.
2. Using the new fasteners included in the kit, thread all 10 cap screws with a

washer on each into the rotor. Torque in a star pattern to 200 ft-lbs.

Service Kit Part Number 10020682

ConMet U-Shaped Rotor 10020109

Rotor Minimum Thickness 1.46" (37mm)

ConMet 10020109 U-Shaped Rotor

1. Hub Assembly (not included)

2. 10020109 U-Shaped Rotor

3. M16X1.5 MM Hex Head Cap Screws

4. Flat Washers (10 Ea.)

SEE CONMET SERVICE MANUAL FOR

DETAILED HUB SERVICE INFORMATION.

Clean all component mating

surfaces before reassembly.

Torque in a star pattern

to 200 ft-lbs.

NOTE

Failure to follow the stated instructions can jeopardize the rotor attachment

and potentially lead to failure of the rotor and/or damage to the wheel hub.

WARNING

ConMet

Summary of Contents for Conventional

Page 1: ...SERVICE MANUAL For Steer Drive andTrailer Hub Assemblies Conventional HubAssemblies PreSetPlus HubAssemblies Hub Rotor Assemblies PreSet HubAssemblies...

Page 2: ...we will use the following colors to help identify specific areas that reference Conventional PreSet and PreSet Plus ConMet hubs Conventional PreSet PreSet Plus If a color is not specified then you ca...

Page 3: ...ACEMENT 9 HUB DRUM AND WHEEL INSPECTION 9 ABS TONE RING INSPECTION AS APPLICABLE 9 REMOVAL AND INSTALLATION OF MACHINED ABS TONE RING 10 REMOVAL AND INSTALLATION OF STAMPED STEEL ABS TONE RING 10 REMO...

Page 4: ...ALLING THE PRESET PLUS WHEEL HUB ASSEMBLY 37 SERVICE PARTS 38 7 LUBRICATION 41 DRIVE HUB LUBRICATION 41 STEER AND TRAILER HUBS WITH OIL LUBRICANT 41 TRAILER HUBS WITH SEMI FLUID GREASE LUBRICANT 41 8...

Page 5: ...hub assemblies with pre adjusted bearings and an integrated spindle nut PreSet Plus Hub Assemblies ConMet PreSet Plus hub assemblies feature the same PreSet technology and include the same precision m...

Page 6: ...nge gasket Oil fill plug Oil seal leakage indicated by lubricant on the hub brake components or inside of the wheel 4 Check lubricant condition via hub cap window on steer and trailer hubs Lubricant t...

Page 7: ...cover the ends of the bearing rollers If the lubricant has a dry and caked appearance remove the wheel end from the vehicle and clean and inspect all components Replace damaged or worn components as n...

Page 8: ...ls on all aspects of the ConMet hub This section is devoted to finding and understanding the different identification numbers associated with ConMet hubs Vehicle Identification Number VIN The quickest...

Page 9: ...3 Identification continued 14 106827a BARREL OF HUB Barrel of Hub FIGURE 16 Final Hub Assembly Number This number is stamped on one of the following Mounting flange face see figure 13 Diameter of the...

Page 10: ...3159a FIGURE 21 4 Remove the tire and wheel assembly using procedures specified by the wheel manufacturer see figure 22 20 103160a FIGURE 22 Suddenreleaseofcompressedaircancauseserious personalinjurya...

Page 11: ...n type andpetroleum basecleaners Readthe manufacturer sinstructionsbeforeusingasolvent cleaner thencarefullyfollowtheinstructions Also followtheproceduresbelow Wearsafeeyeprotection Wearclothingthatpr...

Page 12: ...elbar beingcarefulnottodamage thehub NOTE 25 106856a Welding Bead FIGURE 27 2 Inspect the bearing cup bore for evidence of cup rotation or spun cups If cup rotation exists replace the hub REMOVING CUP...

Page 13: ...ype CAUTION 1 To install a new stud support the hub evenly around and adjacent to the stud being installed 2 Press the new stud all the way into the hub Be sure the stud is fully seated and that the s...

Page 14: ...ABSsystemfunctionsproperly CAUTION Forsteerhubs becertaintheinsidediameter flangeisfacingup NOTE 3 Place the hub in a press and place the ABS ring on the hub ring seat 4 Using ConMet ring installatio...

Page 15: ...rotherseals refertothespecific manufacturers instructions NOTE ConMet Installation Tools Axle Type Part Number FF Steer 10084010 FL Steer 10084011 R Drive 10084012 TN Trailer 10084013 TP Trailer 10084...

Page 16: ...lenutorsinglenutsystems Forself lockingsinglenutsystems consult manufacturers instructions NOTE 1 Lubricate the bearings with clean lubricant of the same type used in the axle sump or hub assembly 2 I...

Page 17: ...non drive 12 Single nut with cotter pin 1 6 turn Install cotter pin to lock spindle nut into position from step 6 18 1 4 turn 12 Double nut system with bendable tang washer or dowel pin and washer 1 3...

Page 18: ...22 500 Tapered spindle TP Trailer 25 000 Parallel spindle or Propar NOTE These axle ratings are to be used as a reference only Refer to the vehicle s door plate for your specific application ConMet S...

Page 19: ...Axle Inner Cup Cone 10041905 Set 413 Outer Cup Cone 10041906 Set 406 FL Steer Axle Inner Cup Cone 10041925 Set 423 Outer Cup Cone 10041926 Set 424 L Drive Axle Inner Cup Cone 10037959 Not available i...

Page 20: ...009780 10000776 10009780 Iron Disc 10011945 10009780 10019965 10023558 Drum 10005604 10009780 FL Steer Aluminum Drum 10012265 10019840 Iron Disc 10005561 107912 L Drive 190 Iron Disc 10020602 10023559...

Page 21: ...yorpropertydamage Neverworkunderavehiclesupportedbyajack withoutsupportingthevehiclewithstandsand blockingthewheels Wearsafeeyeprotection WARNING 1 Park the vehicle on a level surface Block the wheels...

Page 22: ...e seal if it needs to be returned for warranty consideration 12 Remove the inner bearing cone and spacer see figure 44 7 106804c INNER BEARING CONE SPACER FIGURE 44 COMPONENT INSPECTION AND REPLACEMEN...

Page 23: ...linings or the brake drums Store the parts inside special paper or other material that prevents corrosion INSPECTING BEARING CUPS AND CONES AND BEARING SPACER PreSetandPreSetPlushubsuseaprecision mac...

Page 24: ...of the bearing bore 10 105742a Bearing Cup Pressed into Hub FIGURE 47 WHEEL STUDS Replace all wheel studs that have damaged or distorted threads are broken or bent or are badly corroded Also replace...

Page 25: ...toothed ring passes a sensor and generates a signal that is sent to the ABS computer There are three types of ABS rings used on ConMet hubs machined stamped steel and bolt on see figure 48 11 106805b...

Page 26: ...with a hammer or mallet until the ring seats on the hub see figure 53 A swift initial blow with an 8 lb hammer may be necessary to start the ring onto the hub 5 PreSet Wheel Hubs Recommended Service 1...

Page 27: ...irethepropertoolfor installation RefertothetablebelowforaConMet sealinstallationtoolorflatplatedimensions For otherseals refertothespecificmanufacturers instructions NOTE ConMet Seal Installation Tool...

Page 28: ...ssembly 5 PreSet Wheel Hubs Reassembly 9 Lubricate the outer bearing cone with the same lubricant as will be used in the hub and install it into the hub assembly see figure 58 21 105749a Installing th...

Page 29: ...9 Spindle Nut Torque 5 One Piece Spindle Nut System Pro Torq and Axilok If a one piece spindle nut system is being used torque the nut to a minimum of 300 ft lbs 150 ft lbs for PreSet FC medium duty s...

Page 30: ...er 25 000 Parallel spindle or Propar NOTE These axle ratings are to be used as a reference only Refer to the vehicle s door plate for your specific application PreSet Service Kits and Components PreSe...

Page 31: ...Aftermarket Bearings Description ConMet Number Bearing Set Number FC Steer Axle Inner Cup Cone 10037695 Not available in sets Outer Cup Cone 10037696 FF Steer Axle Inner Cup Cone 10041905 Set 427 Oute...

Page 32: ...10000776 10009780 Iron Disc 10011945 10009780 10019965 10023558 Drum 10005604 10009780 FL Steer Aluminum Drum 10012265 10019840 Iron Disc 10005561 107912 L Drive 190 Iron Disc 10020602 10023559 Drum...

Page 33: ...Vehiclesonjackscanfall causingseriouspersonal injuryorpropertydamage Neverworkundera vehiclesupportedbyajackwithoutsupporting thevehiclewithstandsandblockingthewheels Wearsafeeyeprotection WARNING 1...

Page 34: ...pindle nut to remove the hub from the spindle The internal snap ring will act as a hub puller and will aid in removal of the hub from the spindle Do not exceed 50 ft lbs of torque when removing the hu...

Page 35: ...he hub and all wheel end components 2 Do NOT clean ground or polished parts in a hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts 3 Clean a...

Page 36: ...large hammer and a mild steel bar or a hydraulic press Take precaution to avoid damaging the bearing cup bore and shoulder 2 Inspect the bearing cup bore for evidence of cup rotation or spun cups If...

Page 37: ...b whichcancreateacrack inthehub resultinginseriousinjuryandproperty damage IfastudheadisEmbeddedinahub replacethehub WARNING HUB DRUM AND WHEEL INSPECTION 1 Inspect the drum pilots wheel pilots and mo...

Page 38: ...NOTE 3 Place the hub in a press and place the ABS ring on the hub ring seat 4 Using ConMet ring installation tool part number 107119 center the tool over the ABS ring Each type of ring fits a corresp...

Page 39: ...et sealinstallationtoolorflatplatedimensions For otherseals refertothespecificmanufacturers instructions NOTE ConMet Seal Installation Tools Axle Type Part Number FF Steer 10084010 FL Steer 10084011 R...

Page 40: ...IGURE 82 2 Position the spindle nut and washer against the outer bearing see figure 83 24 106873b Positioning Nut Washer Against Bearing FIGURE 83 6 PreSet Plus Wheel Hubs Reassembly 3 Install the spi...

Page 41: ...mooth firm motion and place the hub onto the spindle When the threads on the nut engage the threads on the spindle rotate the nut in a clockwise direction to fully engage the threads 5 Torque the spin...

Page 42: ...eSet Plus Service Kits and Components PreSet Hubs Rebuild Kit Seal and Spacer Kit Magnetic Fill Plug Nut Assembly Kit Red Locking Snap Ring FF Flat 10081727 10081518 N A 10036548 10026174 FF Keyway 10...

Page 43: ...et Plus Aftermarket Bearings Description ConMet Number Bearing Set Number FC Steer Axle Inner Cup Cone 10037695 Not available in sets Outer Cup Cone 10037696 FF Steer Axle Inner Cup Cone 10041905 Set...

Page 44: ...09780 10000776 10009780 Iron Disc 10011945 10009780 10019965 10023558 Drum 10005604 10009780 FL Steer Aluminum Drum 10012265 10019840 Iron Disc 10005561 107912 L Drive 190 Iron Disc 10020602 10023559...

Page 45: ...It may be necessary to add lubricant more than once to adequately fill the hub see figure 86 27 105753a Filling the Hub with Oil FIGURE 86 2 Be certain the hubcap is properly filled to the oil level...

Page 46: ...28 0 10 10083557 25 0 28 0 TP Aluminum Drum 10 100510 41 4 41 4 8 101259 41 4 41 4 10 10001216 41 4 41 4 10 10033028 41 4 41 4 Disc 10 10016225 41 4 41 4 10 10016620 46 9 46 9 Iron Drum 10 10003654 55...

Page 47: ...faces on the hub drum and nuts Remove loose paint scale and any material building around the pilots of the drum hub and wheels Be sure paint is fully cured on recently refurbished wheels Careshouldbet...

Page 48: ...rdamagetothewheelorhub If thetorqueisappliedatelevatedtemperatures thesystemmaybecomelooseandloseclampat lowertemperatures resultinginwheeldamage andbrokenwheelstuds Ifthenutsmustbe torquedatextremete...

Page 49: ...the ball socket of the wheel see figure 96 38 106815a INNER CAP NUT AT 12 O CLOCK POSITION Tightening the Inner Cap Nuts FIGURE 96 6 To properly center the wheel snug the remaining wheel nuts Verify...

Page 50: ...be obtained from the vehicle or component manufacturer s published service information Part Number Identification Before you perform any service procedures you must first determine if the vehicle is e...

Page 51: ...ly inspect both sides of the rotor for the out of service conditions detailed in this section If any of these conditions are found remove the hub and replace the rotor according to the instructions in...

Page 52: ...ning friction rating lightly dragging brakes or a rotor resurfaced to too fine of a microfinish To correct this condition sand the braking surface on the rotor and the brake pads with 80 grit emery cl...

Page 53: ...g of the brake rotor 58 106859a Clogged Vent Holes FIGURE 116 Rotor Runout Lateral runout or wobble on the rotor braking surface should not exceed 0 020 in one full revolution of the rotor The measure...

Page 54: ...F ROTOR Bottom of Rotor FIGURE 121 Rotor Resurfacing ConMet does not recommend resurfacing disc brake rotors However if rotor resurfacing is necessary be sure that at least 0 060 of material is left a...

Page 55: ...assembly RefertoConventional PreSetandPreSetPlushub removalproceduresinthismanualforspecific spindlenutremovalinstructions NOTE 6 Slide the hub and rotor assembly off the spindle Be careful not to da...

Page 56: ...n all mating surfaces 3 Place the stainless steel insulator for aluminum hubs only and the rotor on the hub 4 Install and torque the new included rotor mounting nuts in a star pattern to 200 ft lbs 5...

Page 57: ...um hubs 2 Clean all mating surfaces 3 Place the stainless steel insulator for aluminum hubs only and the rotor on the hub 4 Install and torque the new included rotor mounting nuts in a star pattern to...

Page 58: ...b Assembly not included 2 10019996 Flat Rotor 3 1 2 FlatWasher 10 ea 4 1 2 20 UNF Rotor Cap Screw 10 ea SEE CONMET SERVICE MANUAL FOR DETAILED HUB SERVICE INFORMATION Clean all component mating surfac...

Page 59: ...F Front Flat Rotor 10083733 Rotor MinimumThickness 1 46 37mm 2 3 4 ConMet 10083733 Flat Rotor 1 Hub Assembly not included 2 Stainless Steel Insulator not included for aluminum hubs only 3 10083733 Fla...

Page 60: ...he service kit in a star pattern to 200 ft lbs 5 Place the ABS tone ring on the rotor 6 Secure the ABS tone ring on the rotor using the snap retaining ring Ensure the snap retaining ring is fully seat...

Page 61: ...ted in the grooves of the rotor tabs Service Kit Part Number 10085621 ConMet Flat Rotor 10084701 Rotor MinimumThickness 1 46 37mm 1 2 3 4 5 6 ConMet 10084701 Flat Rotor 1 Hub Assembly not included 2 S...

Page 62: ...FF Front Flat Rotor 10034621 Rotor MinimumThickness 1 46 37 mm ConMet 10034621 Flat Rotor 1 Hub Assembly not included 2 Stainless Steel Insulator not included for aluminum hubs only 3 10034621 Flat Ro...

Page 63: ...Drive Flat Rotor 10034621 Rotor MinimumThickness 1 46 37 mm ConMet 10034621 Flat Rotor 1 Hub Assembly not included 2 Stainless Steel Insulator not included for aluminum hubs only 3 10034621 Flat Rotor...

Page 64: ...hubs only and the rotor on the hub 4 Install and torque the new included rotor mounting nuts in a star pattern to 200 ft lbs 5 Press the ABS ring onto the hub Service Kit Part Number 10041215 ConMet...

Page 65: ...ern to 200 ft lbs 5 Place the ABS tone ring on the rotor 6 Install and torque the new included 1 4 20 UNF button head screws in a star pattern to 160 in lbs Service Kit Part Number 10041217 ConMet R D...

Page 66: ...the new rotor as was removed from the hub assembly Service Kit Part Number 10030921 ConMet Hat Shaped Rotor 10003830 Rotor MinimumThickness 1 32 33 5 mm ConMet 10003830 Hat Shaped Rotor 1 Hub Assembly...

Page 67: ...041006 Rotor MinimumThickness 1 46 37 0 mm ConMet 10041006 U Shaped Rotor 1 Hub Assembly not included 2 10041006 U Shaped Rotor 3 5 8 11 UNC x 1 75 SEMS Fasteners 10 ea SEE CONMET SERVICE MANUAL FOR D...

Page 68: ...a star pattern to 200 ft lbs Service Kit Part Number 10020682 ConMet U Shaped Rotor 10020109 Rotor MinimumThickness 1 46 37mm ConMet 10020109 U Shaped Rotor 1 Hub Assembly not included 2 10020109 U Sh...

Page 69: ...o 200 ft lbs Service Kit Part Number 10082181 ConMet U Shaped Rotor 10080753 Rotor MinimumThickness 1 46 37 0 mm ConMet 10080753 U Shaped Rotor 1 Hub Assembly not included 2 10080753 U Shaped Rotor 3...

Page 70: ...r pattern to 220 ft lbs Service Kit Part Number 10086065 ConMet U Shaped Rotor 10082120 Rotor MinimumThickness 1 46 37 0 mm ConMet 10082120 U Shaped Rotor 1 Hub Assembly not included 2 10082120 U Shap...

Page 71: ...1218 R Drive 10037760 Flat Rotor 1 46 37 0 mm 10041215 FF Steer 10041217 R Drive 10083733 Flat Rotor 1 46 37 0mm 10086065 10084701 Flat Rotor 1 46 37 0mm 10085621 10086207 Flat Rotor 1 46 37 0mm 10086...

Page 72: ...Cap 5 16 18 12 18 Minimum SAE Grade 5 fasteners flat washers only Oil Fill Plug 1 4 NPT 20 25 O Ring Style 3 8 NPT 9 16 18 Bolt On ABS Ring Screw 8 32 18 22 in lbs 1 4 20 155 165 in lbs Disc Brake Rot...

Page 73: ...69 ConMet Notes...

Page 74: ...70 ConMet Notes...

Page 75: ...71 ConMet Notes...

Page 76: ...s of Consolidated Metco Inc All other trademarks are the property of their respective owners Consolidated Metco Inc 2022 All rights reserved ConMet 5701 SE ColumbiaWay Vancouver WA 98661 800 547 9473...

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