When working with heavy-duty axle systems, proper installation and maintenance are essential for ensuring performance, safety, and longevity. Dexter Axle provides a wide range of components and detailed instruction sheets for various systems, including brakes, suspension, and actuation. These resources are particularly relevant to U.S. users engaged in vehicle modification, fleet maintenance, or DIY mechanical projects involving trailers, commercial vehicles, and recreational vehicles.
This article compiles verified installation and operational information from Dexter’s instruction sheets and product documentation, focusing on key components such as disc brakes, air ride suspension, brake line kits, and hydraulic actuators. The goal is to present a comprehensive, reliable overview of installation procedures, specifications, and compatibility data, strictly based on the available source material.
Dexter Axle Product Lines and Instruction Sheets
Dexter Axle offers a broad range of products for different applications, from commercial and vocational vehicles to recreational trailers and agricultural equipment. The instruction sheets available on Dexter’s website cover several critical components, each with specific installation requirements and guidelines.
A selection of available instruction sheets includes:
- Actuator Adapter (059-Z23-00)
- Aiflex Air Ride Suspension System (059-809-00)
- Air Compressor for DexAir System (059-A39-00)
- Bearing Cone and Cup Replacement (059-A24-00)
- Bolt-On Grease Cap (059-Z39-00)
- Brake Bleeding of Surge Actuators (059-906-00)
- Brake Caliper Kit for 6,000 lbs. to 8,000 lbs. Hydraulic Disc Brakes (059-799-00)
- Brake Line Kit (059-Z01-01)
- Brake Line Kit Installation Instructions (059-B17-00)
- Brake Pad Kit for 6-8K Hydraulic Disc Brakes (059-798-00)
- 10-16K Disc Brake Pad Instruction Sheet (059-214-00)
- 12-1/4” Electric Brake Shoe and Lining Kit (059-046-00, 059-653-00)
- 70LP Button Instruction Sheet (059-Z01-16)
- 80LP/85LP Actuator Instruction Sheet (059-Z01-08)
- Tow Assist Brakes (059-Z27-00)
These documents provide step-by-step guidance for installing and maintaining various components, often including diagrams, torque specifications, and compatibility information.
Installation Procedures for Dexter Axle Components
Installation of Dexter Axle components must follow precise guidelines to ensure proper function and safety. Below are detailed procedures for selected components based on the available instruction sheets.
Disc Brake Installation for Heavy-Duty Applications
Dexter offers multiple disc brake kits for different load capacities, including kits rated for 6,000 to 8,000 lbs. and 10,000 to 16,000 lbs. Each kit comes with a dedicated instruction sheet outlining the installation process.
General Installation Steps for Disc Brake Kits:
- Preparation: Ensure the vehicle is supported on a stable lift or jack stands. Disconnect the battery to avoid accidental electrical activation.
- Remove Old Components: Remove the existing brake assembly, including rotor, caliper, and mounting hardware.
- Inspect and Clean Components: Check for wear or damage on the rotor and mounting surfaces. Clean all surfaces with a degreaser.
- Mount the New Rotor: Install the new rotor using the appropriate bolts. Torque to specifications provided in the instruction sheet (typically 80–100 ft-lbs).
- Install the Caliper: Mount the new caliper using the provided hardware. Ensure the caliper is aligned with the rotor.
- Attach Brake Pads: Install the new brake pads into the caliper bracket. Make sure the pads are seated correctly and not obstructed.
- Bleed the Brake System: Use the brake bleeding procedure outlined in the instruction sheet (e.g., 059-906-00 for surge actuators).
- Reconnect Electrical Components: If applicable, reconnect electrical wiring for electrically actuated systems.
- Test the System: Perform a test run to ensure the brakes function correctly and without noise or vibration.
Instruction sheets such as 059-799-00 and 059-214-00 include torque values, component diagrams, and compatibility data for specific models.
Air Ride Suspension System Installation (Aiflex)
The Aiflex Air Ride Suspension System (059-809-00) is designed for vehicles requiring enhanced suspension control and comfort. The installation process includes the following key steps:
- Prepare the Vehicle: Ensure the vehicle is supported on a lift or jack stands. Disconnect the battery to prevent accidental activation of electrical components.
- Install the Air Bags: Mount the air bags according to the specified orientation and alignment. Secure them with bolts or brackets provided in the kit.
- Connect the Air Lines: Route the air lines according to the diagram in the instruction sheet. Ensure all connections are tight and free of kinks.
- Mount the Air Compressor: Install the air compressor in a secure location, ensuring it has proper ventilation and access to the air system.
- Install the Air Valve and Controls: Mount the air valve and controls according to the diagram. Connect them to the air compressor and the air bags.
- Test the System: Apply air pressure and test the suspension system for proper inflation and deflation. Adjust the pressure as needed.
The instruction sheet includes torque specifications for bolts and guidelines for routing and securing air lines. Proper installation ensures the air ride system functions effectively and safely.
Brake Line Kit Installation
Brake line kits such as 059-Z01-01 and 059-B17-00 provide essential components for connecting the brake system to the vehicle’s frame or hub. Installation steps are outlined in the instruction sheet and typically include:
- Prepare the Vehicle: Support the vehicle on a lift or jack stands. Disconnect the battery.
- Remove Existing Lines: Carefully remove the old brake lines and inspect for leaks or damage.
- Install New Lines: Route the new brake lines according to the diagram provided. Ensure the lines are not kinked or obstructed.
- Secure the Lines: Use clamps or brackets to secure the lines in place. Ensure they are not in contact with moving parts.
- Connect the Lines: Connect the lines to the caliper and the frame. Tighten the fittings according to the torque specifications.
- Bleed the System: Follow the brake bleeding procedure to ensure the system is free of air bubbles.
- Test the System: Test the brakes to ensure they respond correctly and without delay.
The instruction sheet provides torque values and diagrams for routing and securing the lines.
Actuator Installation for Hydraulic Systems
Actuators such as the 80LP/85LP model (059-Z01-08) are used in hydraulic brake and suspension systems. Installation steps typically include:
- Mount the Actuator: Secure the actuator to the vehicle frame using the provided hardware. Ensure the mounting is stable and aligned with the system components.
- Connect Hydraulic Lines: Route and connect the hydraulic lines according to the diagram. Ensure all connections are tight and leak-free.
- Install Control Components: Mount the control components according to the instructions. Connect electrical wiring if applicable.
- Test the System: Apply pressure and test the actuator for proper movement and response.
- Adjust as Necessary: Adjust the actuator’s settings according to the instruction sheet to achieve the desired performance.
The instruction sheet provides torque specifications and diagrams for the installation.
Compatibility and Technical Specifications
Dexter’s instruction sheets also include compatibility data for different models and applications. For example:
- The Brake Caliper Kit for 6,000 lbs. to 8,000 lbs. Hydraulic Disc Brakes (059-799-00) is compatible with vehicles requiring high-torque braking systems.
- The 12-1/4” Electric Brake Shoe and Lining Kit (059-046-00, 059-653-00) is designed for vehicles with stamped backing plates and standard brake configurations.
- The 70LP Button (059-Z01-16) and 80LP/85LP Actuator (059-Z01-08) are used in hydraulic and electric actuation systems, with specifications for load capacity and stroke length.
Users are advised to consult the instruction sheets for specific compatibility details to ensure the selected components are appropriate for their vehicle.
Safety and Compliance
All Dexter Axle components and installation procedures are designed to meet safety and compliance standards for heavy-duty applications. The instruction sheets emphasize proper torque values, correct installation practices, and the use of appropriate tools and protective equipment.
Users are advised to:
- Follow all safety guidelines provided in the instruction sheets.
- Use only Dexter-approved components and tools.
- Ensure the vehicle is supported on a stable lift or jack stands during installation.
- Test the system thoroughly before use.
Conclusion
Dexter Axle provides a comprehensive range of components and installation guides for heavy-duty applications, including disc brakes, air ride suspension, brake line kits, and hydraulic actuators. The instruction sheets offer detailed procedures, diagrams, and technical specifications to ensure safe and effective installation.
By following the guidelines provided in the instruction sheets, users can ensure their systems are installed correctly and function as intended. This is particularly important for applications involving commercial vehicles, trailers, and recreational vehicles where performance and safety are critical.