SAF P89 User manual

XL-SA20018UM-en-US Rev H
P89 Disc Brake Axles
Service Manual

2XL-SA20018UM-en-US Rev H · 2017-12-14 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF, and logos are trademarks of
SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Contents
Contents PageContents Page
Introduction......................................................................... 2
Warranty.............................................................................. 2
Notes, Cautions, and Warnings ............................................. 2
Section 1 – General Safety Instructions ................................ 3
Section 2 – General Service and Maintenance Instructions ... 4
Section 3 – Model Identification........................................... 5
Section 4 – Identification Tag ............................................... 5
INTEGRAL®Disc Brake Exploded View and Parts List............. 6
U-Shaped Rotor Brake Exploded View and Parts List............. 7
Section 5 – Caliper Identification ......................................... 8
Section 6 – Disc Brake Inspection......................................... 9
Section 7 – Hub, Bearing and Seal Removal........................ 11
Section 8 – Bearing Inspection ........................................... 13
Section 9 – Rotor Replacement .......................................... 13
Section 10 – Hub Wheel Bolt Servicing ............................... 15
Section 11 – Seal, Bearing and Hub Installation.................. 15
Section 12 – Hub Lubrication (Oil)...................................... 20
Section 13 – Hub Cap Installation ...................................... 20
Section 14 – Caliper Installation......................................... 21
Section 15 – Wheel Installation Procedure.......................... 22
Section 16 – Optional Equipment ....................................... 23
Section 17 – Lubrication and Torque Specifications............. 24
Section 18 – Troubleshooting Chart.................................... 25
Section 19 – Routine Service Schedule ............................... 27
Notes, Cautions, and Warnings
Before starting any work on the unit, read and understand all
the safety procedures presented in this manual. This manual
contains the terms “NOTE”, “IMPORTANT”, “CAUTION”, and
“WARNING” followed by important product information. These
terms are defined as follows:
NOTE: Includes additional information to enable accurate
and easy performance of procedures.
IMPORTANT: Includes additional information that,
if not followed, could lead to hindered
product performance.
Used without the safety alert symbol,
indicates a potentially hazardous
situation which, if not avoided, could
result in property damage.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Introduction
This manual provides the necessary information for the maintenance,
inspection and safe operation of the SAF®P89 disc brake. Refer
to XL-SA20024UM-en-US for P89 Plus disc brake System.
Knorr®is a registered trademark of the Knorr-Bremse Group.
Read this manual before using or servicing this product and
keep it in a safe location for future reference. Updates to this
manual, which are published as necessary, are available on
the internet at www.safholland.us.
When replacement parts are required, SAF-HOLLAND®highly
recommends the use of only SAF-HOLLAND®Original Parts. A
list of technical support locations that supply SAF-HOLLAND®
Original Parts and an Aftermarket Parts Catalog are available
on the internet at www.safholland.us or contact Customer
Service at 888-396-6501.
Warranty
Refer to the complete warranty for the country in which the product
will be used. A copy of the written warranty is included with the
product or available on the internet at www.safholland.com.

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
General Safety
1. General Safety Instructions
General and Servicing Safety Instructions
Read and observe all Warning and Caution hazard alert
messages. The alerts provide information that can help prevent
serious personal injury, damage to components, or both.
Failure to follow the instructions and safety
precautions in this manual could result in
improper servicing or operation leading to
component failure which, if not avoided,
could result in death or serious injury.
All maintenance should be performed by a properly
trained
technician using proper/special tools, and safe procedures.
NOTE: In the United States, workshop safety requirements
are defined by federal and/or state Occupational
Safety and Health Act (OSHA). Equivalent laws may
exist in other countries. This manual is written based
on the assumption that OSHA or other applicable
employee safety regulations are followed by the
location where work is performed.
Properly support and secure the vehicle from unexpected
movement when servicing the unit.
Failure to properly support and secure the
vehicle and axles prior to commencing work
could create a crush hazard which, if not
avoided, could result in death or serious injury.

Several maintenance procedures in this manual require re-positioning
of the brake chamber, brake calipers and/or ABS system. Consult
the manufacturer’s manual for procedures on the proper
operation of brake chamber, brake calipers and/or ABS system.
Service both roadside and curbside of an axle. Worn parts
should be replaced in sets. Key components on each axle’s
braking system, such as friction material and rotors will
normally wear over time.
IMPORTANT: Key components on each axle’s braking
system, including brake pads and brake
rotors, are intended to wear over time. Worn
parts should be replaced in sets on both
the driver and curb side of an axle.
Failure to follow manufacturer’s instructions
regarding spring pressure or air pressure
control could allow uncontrolled release
of energy which, if not avoided, could
result in death or serious injury.
The wheel contact surfaces between the wheel and hub
MUST NOT receive additional paint.
IMPORTANT: The wheel contact surfaces MUST be clean,
smooth and free from grease.
Failure to keep wheel and hub contact surfaces
clean and clear of foreign material could
allow wheel/hub separations which, if not
avoided, could result in death or serious injury.
Only the wheel and tire sizes approved by the trailer builder
can be used.
Operational and Road Safety Instructions
Before operating vehicle, ensure that the maximum permissible
axle load is not exceeded and that the load is distributed
equally and uniformly.
Make sure that the brakes are not overheated from
continuous operation.
Failure to minimize the use of brakes during
overheating conditions could result in
deterioration of brake efficiency which
could result in death or serious injury.
The parking brake MUST NOT be immediately applied
when the brakes are overheated. Refer to the rotor wear
inspection information in Section 6.2.
If the parking brake is immediately
applied to the brakes when overheated,
the brake discs could be damaged by
different stress fields during cooling.
Observe the operating recommendation of the trailer
manufacturer for off-road operation of the installed axles.
IMPORTANT: The definition of OFF-ROAD means driving
on non-asphalt/non-concrete routes, e.g.
gravel roads, agricultural and forestry tracks,
on construction sites and in gravel pits.
IMPORTANT: Off-road operation of axles beyond
the approved application design could
result in damage and impair suspension
system performance.
SAF®axles require routine service, inspection and
maintenance in order to maintain optimum performance,
and operational safety as well as an opportunity to
recognize natural wear and defects before they become
serious. Refer to the Routine Service Schedule in Section 19.
Failure to inspect and maintain the SAF-
HOLLAND®P89 disc brake axle as outlined
in Section 19 can result in brake or wheel
bearing failure which, if not avoided, could
result in death or serious injury.
IMPORTANT: Use only SAF-HOLLAND®Original Parts to
service the SAF-HOLLAND®P89 disc brake
axle.
Failure to maintain the SAF-HOLLAND®
P89 disc brake with SAF-HOLLAND®Original
Parts can result in brake or wheel bearing
failure which, if not avoided, could result
in death or serious injury.

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
General Service and Maintenance
2. General Service and
Maintenance Instructions
1. Conduct regular visual checks of the brakes, tires
and all chassis components. Refer to Section 19 for
more information:
Inspect for secure mounting, wear, leaks,corrosion
and damage.
Check for loose, broken or cracked air hoses, air
system leaks, and damaged components.
Check that brake hoses and cables are properly secured.
For proper brake pad wear, check that there is enough
clearance to allow the caliper full movement during
normal operation.
2. Check the brake pads at regular service intervals to
ensure that the brake pad hold down springs are in
the correct position, and that brake pads are not worn
beyond the minimum wear limits described in this manual.
3. When replacing brake pads, inspect the rotors for signs of
wear, cracks, grooves, scoring or hot spots.
4. Visually check the brake caliper at regular service
intervals as defined by the brake caliper manufacturer’s
basic inspection program. Refer to Section 5 of this
manual for further information.
5. Check the spring brake chambers to make sure the
parking springs are NOT caged in the released position.
Be sure the dust plugs are properly installed.
6. Make sure that the vent holes in the air brake chamber
are not covered with snow, ice, mud, etc.
7. Inspect the wheel bearing unit for grease leaks at every
brake pad change.
8. Visually check the brake assembly (e.g. pads, rotor, etc.)
for oil or grease contamination.
9. Check that all dust caps and boots are present and in
good condition.
10. Regularly conduct general safety checks in accordance
with any applicable laws.
11. After every wheel change, the wheel nuts MUST be
re-tightened to the specified torque level after the initial
100 miles of operation, and then at every regular
service interval.
Failure to re-tighten wheel nuts at
specified intervals could result in
component failure which, if not avoided,
could result in damage to property.
IMPORTANT: Use only SAF-HOLLAND®Original Parts
to service the SAF-HOLLAND®P89 disc
brake axle.

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Model Identification
Figure 2
Figure 1
3. Model Identification
The disc brake axle serial tag is located near the center of the
axle tube (Figure 1).
4. Identification Tag
The sample tag shown will help interpret the information on
the SAF-HOLLAND®USA, Inc. serial number tag. The model
number, axle body part number and serial number are listed
on the tag (Figure 2).
Record the tag numbers below for future quick reference.
Axle Body Part Number: ______________________________
Model Number: _____________________________________
Serial Number: _____________________________________
SERIAL NUMBER TAG LOCATED
BETWEEN BEAMS OF EACH AXLE TUBE

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
P89 INTEGRAL®Disc Brake Exploded View and Parts List
5
5a
5b
3
2
8
4
9
20
1
710
19
16
15
17
18
14
6
11
12
13
ITEM DESCRIPTION QTY. / AXLE
1 Bolt, Hub Cap 12
2 Hub Cap 2
3 Gasket, Hub Cap 2
4Nut, Axle Pro-Torq®2
4A Three Piece Axle Nut 2
5 Hub with Bearing Cups 2
5a* Bearing Cup, Outer 2
5b* Bearing Cup, Inner 2
6 Cone, Bearing, Outer 2
7 Wheel Studs 20
8 INTEGRAL®Rotor with ABS Tone Ring 2
9Rotor Attachment Bolts 20
ITEM DESCRIPTION QTY. / AXLE
10 Cone, Bearing, Inner 2
11 Seal, Hub 2
12 ABS Sensor (WABCO) 2
13 Clamping Bush 2
14
Brake Caliper Left-Hand
Brake Caliper Right-Hand 1
15 M18 x 1.5"Bolt, Standard 6
16 M18 x 1.5"Bolt, Shoulder 2
17 Brake Chamber 2
18 Brake Chamber nut 4
19 Dust Shield with Clamp (optional) 2
20 Washers 20
* Included in hub, item number 5, but can be serviced.
4A, Three Piece Axle Nut

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
5
5a
5b
3
2
8
4
9
1
7
10
19
16
15
17
18
14
6
11
12
13
ITEM DESCRIPTION QTY. / AXLE
1 Bolt, Hub Cap 12
2 Hub Cap 2
3 Gasket, Hub Cap 2
4Nut, Axle Pro-Torq®2
4A Three Piece Axle Nut 2
5 Hub with Bearing Cups and ABS
Tone Ring
2
5a* Bearing Cup, Outer 2
5b* Bearing Cup, Inner 2
6 Cone, Bearing, Outer 2
7 Wheel Studs 20
8 U-Shaped Rotor 2
ITEM DESCRIPTION QTY. / AXLE
9Rotor Attachment Bolts 20
10 Cone, Bearing, Inner 2
11 Seal, Hub 2
12 ABS Sensor (WABCO) 2
13 Clamping Bush 2
14
Brake Caliper Left-Hand
Brake Caliper Right-Hand 1
15 M18 x 1.5"Bolt, Standard 6
16 M18 x 1.5"Bolt, Shoulder 2
17 Brake Chamber 2
18 Brake Chamber nut 4
19 Dust Shield with Clamp (optional) 2
* Included in hub, item number 5, but can be serviced.
New P89 (U-Shaped Rotor Brake) Exploded View and Parts List
4A, Three Piece Axle Nut

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Inspection
5. Caliper Identification and inspection
SAF®P89 axles are equipped with one of two disc brake
calipers, SAF-HOLLAND®SBS 2220 K0 Calipers, or Knorr-
Bremse®SK7 calipers.
5.1 SAF-HOLLAND®SBS 2220 K0 Caliper
The SAF-HOLLAND®SBS 2220 K0 has a smooth forward face
of the caliper and SAF®logo on the rear side (Figure 3).
The inner and outer brake pads for the SBS 2220 K0 are
different in shape. The inner brake pad has two "circle X's"
on the back side, while the outer brake pad has a relatively
smooth back. There is also a notch on the pads to keep them
from being installed in the wrong position (Figure 4).
For instructions on SBS 2220 KO brake caliper inspection and
repair, refer to XL-AS20032RM-en-US which can be found at
www.safholland.com.
5.2 Knorr-Bremse®SK7 Caliper
The Knorr-Bremse®SK7 Caliper has a large indentation on
the forward face and no SAF®logo on the rear of the caliper
(Figure 5).
The brake pads in the SK7 caliper are the same for the inner
and outer side of the caliper. The back of the brake pad has the
Knorr-Bremse®logo and six (6) slots on the back of the caliper
(Figure 6).
For instructions on SK7 brake caliper inspection and repair, refer to
Knorr-Bremse Pneumatic Disc Brake SN6-SN7-SK7 Service Manual
Y006471 which can be found at www.knorr-bremsecvs.com/en/.
Figure 4
Figure 3
Figure 6Figure 5
SK7
SBS 2220 K0
SK7 BRAKE PAD
INBOARD AND OUTBOARD
SBS 2220 K0 BRAKE PADS
INNER BRAKE PAD
SLOTS
KNORR-BREMSE
LOGO
OUTER BRAKE PAD
SMOOTH
CALIPER FACE
LARGE INDENT ON
CALIPER FACE
SAF®LOGO
NO SAF®
LOGO

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Inspection
6. Disc Brake Inspection
IMPORTANT: During removal inspect components for
wear and replace worn components.
Failure to properly support axle during
maintenance could allow axle to fall
which, if not avoided, could result in
death or serious injury.
NOTE: For further disc brake inspection information, refer
to the latest version of the TMC recommended
practice RP 652–Service and Inspection of Air Disc
Brakes (TMC DVD supplement).
6.1 Pad Wear Inspection
Check the brake pads for proper thickness at regular service
intervals based on vehicle usage. Brake pad inspections should
be carried out at least every three (3) months or 20,000 miles,
whichever comes first, and in accordance with any legal
requirements. Refer to Routine Service Schedule in Section 19.
NOTE: Regular service intervals may be required more
frequently for severe duty applications. Refer to
Section 19.
A quick visual inspection of the condition of the brake pads
can be performed without removing the wheel:
1. Compare the position of the caliper marking to the
carrier marking located on the underside of the caliper
unit (Figure 7).
a. Figure 7 - View A shows the positions of the two (2)
markings when the brake pads are in good condition.
b. Figure 7 - View B shows the positions of the two (2)
markings when the wheel MUST be removed for further
inspection of wear to the brake pads and brake rotor.
For further inspection of the brake pads, the wheel and brake
pads MUST be removed. Refer to Section 5 for caliper and service
manual identification.
IMPORTANT: After inspecting the brake pads, check that
the brake system is functioning properly.
IMPORTANT: When replacing worn brake pads, ALL pads
on the axle MUST be replaced.
If the friction material of the brake pad is less than 0.43" (2 mm) at
its thinnest area, the brake pad MUST be replaced. (Figure 10).
NOTE: Minor breakouts at the edges are permitted. Major
breakouts on the surface of the brake pad are NOT
permitted (Figure 8).
Figure 8
Figure 7
CARRIER
MARKING
CARRIER
MARKING
PERMITTED NOT PERMITTED
VIEW A VIEW B
CALIPER
MARKING
CALIPER
MARKING

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Caliper Identification and Inspection
6.2 Rotor Wear Inspection
1. Carefully inspect both sides of the brake rotor friction
surface (Figure 9).
a. Spider web cracking is acceptable (Area A).
b. Radial cracks less than 0.06" (1.5 mm) deep or wide
with lengths less than 75% of the width of the rotor
friction surface (Area B) are acceptable.
c. Grooves in the rotor surface are acceptable only if
they are less than 0.06" (1.5 mm) deep (Area C).
d. Cracks that run completely to either edge of the hub
are NOT acceptable, regardless of depth (Area D).
2. Measure the brake rotor thickness and re-surface, if
necessary. For proper brake function, the minimum
thickness for re-surfacing the brake rotor is defined as
1.54" (39 mm).
Re-surfacing the brake rotor beyond
the minimum thickness could cause
component failure which, if not avoided,
could result in death or serious injury.
IMPORTANT: DO NOT use high-pressure cleaners or
liquid cleaners on the brake rotor.
If the overall wear limits for the brake rotor or brake pads are
exceeded (Figure 10), the rotor and pads MUST be replaced.
Refer to rotor replacement instructions as detailed in Section
9. For brake pad replacement, refer to caliper instruction
manuals identified in Section 5.
For both the inner and outer pads, the maximum brake pad
wear difference is 0.2" (5.0 mm).
Failure to replace brake rotor and pads
when minimum wear limits are reached
could cause component failure which,
if not avoided, could result in death or
serious injury.
NOTE: When replacing the brake pads or brake rotor, use
only Original SAF-HOLLAND®rotors and approved
brake pads.
IMPORTANT: When replacing worn brake pads, ALL pads
on the axle MUST be replaced.
NOTE: During brake repairs, conduct a visual inspection of
the seals on the brake caliper. Refer to Section 6.3
for more information.
BRAKE ROTOR BRAKE PAD
DIAMETER “A” NEW
“B”
WEAR LIMIT “C” NEW
“D”
WEAR LIMIT
430 mm 45 mm 37 mm 23 mm 2 mm
16.93" 1.77" 1.46" 1.18" 0.08"
Figure 10
"A"
NEW
ROTOR
"B"
WORN
ROTOR
"C"
NEW PAD
"D"
WORN
PAD
Figure 9
0.06" (1.5 MM)
MAX. DEPTH
AREA A
ROTOR
FRICTION
SURFACE
AREA B
75%
OF
ROTOR
WIDTH
AREA C
AREA C
CROSS SECTION VIEW
AREA D

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
7. Hub, Bearing and Seal Removal
NOTE: Before beginning any axle/brake service procedures,
park the vehicle on a level surface. Block the wheels
to prevent the vehicle from moving. Support the
vehicle and axles(s) with safety stands. DO NOT
work under a vehicle supported only by jacks.
Jacks can slip or fall over. Serious personal injury
and damage to components can result.
Failure to properly support the vehicle
and axles prior to commencing work could
create a crush hazard which, if not avoided,
could result in death or serious injury.
1. Release the trailer brakes, and cage the spring brakes
according to the spring brake manufacturer’s instructions.
Remove the tire and wheel assembly to access hub
and rotor.
2. Remove wheels from hub using support device such as a
wheel dolly.
Failure to support weight during installation
or removal of wheels could create a crush
hazard which, if not avoided, could result
in minor to moderate injury.
3. Remove the ABS sensor by following the instructions
detailed in Section 16.1.
4. Detach the brake chamber from the brake caliper by
loosening and removing the two (2) mounting nuts
(Figure 11).
5. Remove the brake caliper from the brake spider by using
a size 24 mm socket to loosen. Discard all four (4) brake
caliper bolts (Figure 12).
6. With a 1/2" socket, remove the six (6) hub cap bolts and
the hub cap (Figure 13).
NOTE: Be prepared to collect lubrication fluid when
removing hub cap.
Figure 12
Figure 11
MOUNTING NUTS (2)
BRAKE CHAMBER
BRAKE CALIPER
BOLTS (4)
BRAKE SPIDER
BRAKE CALIPER
Figure 13
HUB CAP GASKET
HUB CAP
HUB CAP
BOLTS (6)

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
7. Remove the axle nut(s)
Three (3) piece axle nut (Figure 14).
a Remove the set screws.
b Remove the outer axle nut from the spindle using
a wrench with the axle nut socket.
c Remove the axle washer and the inner axle nut
from the spindle.
Pro-Torq®axle nut (Figure 15).
a Utilizing a screwdriver, carefuly pry the orange
keeper arm from the undercut groove on each
side of the Pro-Torq®wheel nut until the keeper is
released from it.
b Remove the axle nut from the spindle using a
wrench with the axle nut socket.
8. Using a standard P- or N-Spindle wheel nut socket,
remove the axle spindle nut ( Pro-Torq®) by rotating the nut
in a counter-clockwise direction (Figure 15) .
NOTE: All axle nuts on SAF-HOLLAND®P89 Disc Brake
Axles are right-hand threaded.
9. Remove the outer hub bearing from the spindle
(Figure 15).
NOTE: With the axle nut(s) removed, it is possible
to access the outer bearing.
DO NOT hit steel parts with a steel
hammer as parts could break, sending
flying steel fragments in any direction
creating a hazard which, if not avoided,
could result in minor to moderate injury.
10. Grasp the head unit with both hands and pull the head
unit off the axle spindle (Figure 16).
NOTE: Depending on type of hub seal, the hub seal and
inner bearing may remain on spindle or come off
with the head unit.
Figure 15
HEAD UNIT
Figure 16
OUTER HUB BEARING
PRO-TORQ®NUT
KEEPER ARM
Figure 14
AXLE WASHER
INNER AXLE NUT
SET SCREWS
OUTER HUB BEARING
3-PIECE SPINDLE NUT SHOWN
AXLE NUT

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
12. Remove the inner hub bearing from the spindle or from
the inside of the hub (Figure 17).
13. The spindle mount hub seal can be driven off the spindle
by striking the ring from the back side or prying off with
a crow’s foot bar. Be careful not to gouge the spindle
shoulder. Discard the used seal. A new seal is required
when re-assembled (Figure 17).
DO NOT use a chisel to cut the seal. The
shoulder can be damaged, resulting in a
leak which, if not avoided, could lead to
wheel end and/or brake failure.
8. Bearing Inspection
Thoroughly clean bearings. DO NOT mix
a synthetic base grease or oil with an
organic/mineral base lubricant.
DO NOT dry hub bearings with compressed
air. Bearing damage could result.
1. After removing the head unit, clean excess grease from
the bearings.
IMPORTANT: A bearing which has been removed from a
vehicle should be cleaned with solvent. NEVER
use steam or water which will rust bearings.
IMPORTANT: Bearings that are rusted, flaked, pitted, or
have damaged cages should be replaced. It
is recommended to replace all questionable
bearings and ALWAYS replace the cup and
cone as a matched set.
IMPORTANT: NEVER re-assemble a tapered roller bearing
in a damaged or worn bearing cup or spindle.
Bearing cup or spindle should be replaced
and NOT re-machined if damaged or worn.
9. Rotor Replacement
Failure to follow these instructions could
cause component failure which, if not avoided,
could result in death or serious injury.
9.1 INTEGRAL®Rotor
Refer to pages 6 and 7 for Integral and U-Shaped
Identification. See Section 9.2 for U-Shaped Rotor.
1. Remove the ABS sensor by following the instructions
detailed in Section 16.1.
2. Remove the hub, refer to Section 6 instructions.
3. Remove the rotor from the hub using a size 15 mm
socket to loosen and discard all ten (10) connection bolts
(Figure 18).
Figure 17
HUB SEAL
INNER HUB
BEARING

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
4. Clean the rotor contact surface on the hub. Using
compressed air, clean the tapped holes in the hub. Check
to make sure the threads are undamaged.
5. Attach the new rotor to the hub using ten (10) new SAF®
specific INTEGRAL®bolts and washers (Figure 18).
Using a torque wrench, pre-torque the bolts to 40 ft.-lbs.
(54 N•m). For final torque, tighten the bolts to 140 ft.-lbs.
(190 N•m) using a crisscross pattern. Refer to the Torque
Chart in Section 17 for more information.
IMPORTANT: When attaching a new rotor to the head
unit, use only new SAF®specified connection
bolts. Bolts MUST be clean and free from
oil and grease.
Failure to use only SAF®specified connection
bolts could cause component failure which,
if not avoided, could result in death or
serious injury.
When installing new washers, the
attachment bolts can interfere with the
ABS sensor block. Ensure that there is
clearance provided for ABS Sensor Block
(Figure 19). Failure to provide clearance
can cause damage to property. Refer to
service bulletin XL-SA20031SB-en-US
9.2 U-Shaped Rotor
1. Remove the ABS sensor by following the instructions
detailed in Section 16.1.
2. Remove the head unit, Refer to Section 6 instructions.
3. Remove the rotor from the hub using a size 15/16"
socket. Loosen and discard all ten (10) connection bolts
and washers.
4. Clean the rotor contact surface on the hub. Using
compressed air, clean the tapped holes in the hub. Check
to make sure the threads are undamaged.
5. Attach the new rotor using ten (10) new bolts and washers
supplied in the rotor kit (Figure 20). Using a torque wrench,
tighten the bolts to 190 to 210 ft.-Lbs. (260-285 N•m).
IMPORTANT: When attaching a new rotor to the hub,
use only SAF®specified connection bolts
and washers. Bolts MUST be clean and free
from oil and grease.
Failure to use only SAF®specified
connection bolts and washers could cause
component failure which, if not avoided,
could result in death or serious injury.
Figure 18
Figure 19
Figure 20
ROTOR
WASHERS
HEAD UNIT
BOLTS
CONNECTION BOLTS
ABS SENSOR BLOCK
MODIFIED ABS
SENSOR BLOCK
3/16" CHAMFER

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
Figure 23
HUB SEAL
KEYWAY
AXLE SPINDLE INNER SHOULDER
10. Hub Wheel Bolt Servicing
When replacing the wheel bolts, refer to the rotor removal
instructions described in Section 9.
NOTE: NOT all bolts may need to be replaced. ONLY replace
bolts that are damaged or in need of replacement.
1. Remove the wheel bolts by pressing them out of the head
unit and discard (Figure 21).
2. Install new wheel bolts by pressing them into the head unit.
3. For INTEGRAL®rotor hub, ensure correct alignment of the
bolts during installation, position the flat side of each
wheel bolt head so that it is facing the center of the hub
(Figure 22).
DO NOT hit steel parts with a steel
hammer as parts could break, sending
flying steel fragments in any direction
creating a hazard which, if not avoided,
could result in minor to moderate injury.
11. Seal, Bearing, and Hub Installation
and Adjustment
IMPORTANT: DO NOT mix oil and grease wheel end
lubricants. All SAF-HOLLAND®P89 Disc Brake
wheel ends can be serviced with oil or grease.
Before servicing the SAF-HOLLAND®P89 wheel
end with oil, all grease MUST be cleaned with
appropriate solvent from the bearings and hub.
NOTE: Although all SAF-HOLLAND®P89 Disc Brake wheel
ends are manufactured with spindle mounted wheel
seals they can be serviced with either spindle or
hub mounted seals.
11.1 Spindle mounted wheel seal Installation
instructions. (Refer to 11.2 for hub mounted
wheel seal instructions)
1. Before installing the wheel seal on the axle spindle, inspect
the machined spindle seal surface for nicks, scratches, burrs
or marks. If needed, use crocus cloth or emery cloth to
repair any damaged areas.
2. Clean the threads and keyway thoroughly with a wire
brush to avoid false bearing adjustments and to avoid
introduction of contaminants into the lubricant cavity.
Figure 22
WHEEL BOLTS,
TEN (10)
FLAT SIDE OF BOLT HEAD
Figure 21
WHEEL BOLTS (10)
HEAD UNIT

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 24
HUB SEAL INSTALLATION TOOL
Figure 25
INNER BEARING CUP
OUTER
BEARING CUP
INNER BEARING
DISC HEAD UNIT
DISC SPIDER
Disc Brake Servicing
3. Thoroughly clean the spindle and spindle threads of rust,
dirt, grease or any other contaminants that could damage
the hub seal and cause it to leak.
NEVER install a spindle mounted wheel
seal in the hub and then force it onto the
axle spindle by tightening the axle nut.
Damage to seal will result.
To avoid damaging the seal, support the hub
against the spindle inner shoulder until the
outer bearing and adjusting nut are installed.
4. Apply a thin layer of sealant to the O.D. of the spindle
shoulder. Place the wheel seal on the spindle with the
side labeled “oil-bearing side” facing out towards the
end of the spindle (Figure 23).
5. Seat wheel seal into place using a hub seal installation tool and
hammer. Rotate the wheel seal installation tool 1/4-turn with
every hammer tap until the seal is properly seated with the
metal face of the seal flush with the inner shoulder of the axle
spindle (Figure 24). Clean and remove any excess sealant.
6. Prepare the hub. Remove the old lube and thoroughly clean
the hub cavity and hub bore. If needed, use emery cloth
to remove any burrs or old bore sealant. Inspect the hub
bore for damage. Replace if necessary.
7. Install new inner and outer bearing cups into the hub as
necessary (Figure 25).
8. Install inner bearing on spindle (Figure 25).
NOTE: If using oil for lubrication, coat bearings with oil
before installation. Refer to Section 12 for proper
wheel end oil lubrication instructions (Figure 27).
Failure to lubricate bearing correctly and
maintain proper lubrication could result in
bearing damage.
NOTE: If using grease and NOT oil for hub lubrication, the
inner and outer bearing, and the hub cavity MUST be
pre-packed with grease before installation. Lubricate
wheel end components with grease specified in Section 17.
9. Lubricate inside of hub cavity and install on spindle (Figure 25).
NOTE: Be sure wheel seals are properly installed before
performing the hub bearing adjustment procedure.
Figure 26
INNER BEARING
HUB BEARING CUP
DISC HEAD UNIT

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
11.2 Hub Mounted Wheel Seal Installation
Instructions (Refer to 11.1 for spindle
mounted seal installation)
1. Remove all burrs from the hub bore and spindle. Thoroughly
clean hub cavity and spindle.
NOTE: DO NOT apply any sealant to the spindle shoulder.
2. Place the hub on a smooth, hard surface in a horizontal
position. Pre-lube the inner bearing and place it into the
hub bearing cup (Figure 26).
NOTE: When using grease, pre-pack the inner bearing
before placement into the hub.
3. Place the wheel seal on the installation tool, make sure
that the words “oil-bearing side” faces the inner bearing.
Position the tool (with the seal correctly mounted in the
tool head) into the hub bore. Use a three to five pound
hammer to drive against the end of the tool. Drive seal
into bore until complete bottoming is assured (Figure 27).
Remove the installation tool and apply a thin layer of
lubricant on the I.D surface of the seal.
NOTE: DO NOT apply lubricant to the O.D. of the seal.
11.3 Hub Installation and Bearing Adjustment
1. Gently push the head unit onto the spindle to the proper
position. Fill the hub cavity with lubricant until it runs
over the outer bearing cup.
NOTE: When using grease, pre-pack the hub cavity. The
grease fill amount should be to a 3 o’clock and
9 o’clock level. This is to ensure a 50% hub cavity
fill. Use a template to hold grease in place while
filling the hub cavity (Figure 28). 3shoulder. This
could damage the wheel seal.
2. Coat the outer bearing with
lubricant and place the outer bearing
on the spindle and into the bearing cup (Figure 28).
Install outer bearing on spindle.
3. Install the axle nut(s)
Three (3) piece axle nut:
a. Install the bearing inner-axle adjustment nut finger
tight against the outer bearing (Figure 29).
b. While rotating the hub assembly, tighten the inner
axle adjustment nut to 200 ft.-lbs. (271 N•m).
c. Back off the inner axle adjustment nut one full turn
and then re-torque the nut to 50 ft.-lbs. (68 N•m)
while rotating the hub assembly.
Figure 28
PRE-PACK OUTER
BEARING WITH GREASE
PRE-PACK HUB CAVITY
WITH GREASE
GREASE LEVEL
TEMPLATE
Figure 27
HUB SEAL
INSTALLATION TOOL
DISC HEAD UNIT
Figure 29
OUTER BEARING
INNER AXLE NUT

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 31
OUTER BEARING
RAISED MARK
PRO-TORQ®WHEEL NUT
KEEPER
Disc Brake Servicing
d. Back off the inner axle nut approximately 1/4 turn and
install the axle lock washer (Figure 30). DO NOT
include socket backlash in the 1/4 turn.
e. Install the lock washer. If the hole in the washer is
NOT aligned with the pin on the inner nut, turn the
washer around and re-install. If the pin and hole are
still NOT aligned, slightly adjust parts as needed.
f. Install the outer axle nut finger tight against the axle
lock washer (Figure 30).
g. Tighten the outer axle nut to 200-300 ft.-lbs.
(271-407 N•m).
h. Measure wheel bearing end play (distance wheel
end assembly moves in and out) with a dial
indicator gauge. Wheel bearing end play to be
.001-.005" (.03- .13mm).
NOTE: if wheel end bearing end play needs adjustment,
remove the outer nut and lock washer, then
tighten or loosen inner nut as needed. Return to
step "6.e".
i. Install the set screw into an accessible threaded
hole in the lock washer. The set screw must contact
the inner adjusting nut. Tighten to 16 - 20 in.-lbs.
(1.8 - 2.2 N•m).
Pro-Torq®axle nut (Figure 31):
a. Use a screwdriver to carefully pry the keeper arm
from the undercut groove on each side until the
keeper is released.
b. Seat the bearing. Using a torque wrench, tighten
the nut to 200 ft.-lbs. (271 N•m) and spin the wheel
at least one (1) full rotation. PERFORM THIS STEP
THREE (3)TIMES.
c. Back the nut off until it is loose.
d. Adjust the bearing. Using a torque wrench, tighten
the nut to 100 ft.-lbs. (137 N•m). Spin the wheel
at least one (1) full rotation. PERFORM THIS STEP
THREE (3) TIMES.
e. Back the nut off one raised face mark (1/8 of a turn)
(Figure 31).
f. Install the keeper with orange side facing out by
inserting the keeper tab into the undercut groove
of the nut and engage the keyway tang in the axle
keyway. Insert keeper tab with bent legs facing out.
g. Engage the mating teeth of the keeper with the
teeth of the wheel nut.
h. Compress and insert the keeper arms, one at a
time, into the undercut groove with a screwdriver.
i. If the keeper teeth DO NOT line up with teeth in
nut, loosen the nut slightly until they engage.
Figure 30
AXLE LOCK WASHER
OUTER AXLE NUT

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SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Disc Brake Servicing
Figure 33
Figure 34
DIAL INDICATOR
Figure 32
KEYWAY TANG
ABS BLOCK MUST CLEAR ROTOR
ATTACHMENT BOLTS
KEYWAY
NO CONTACT
IMPORTANT: DO NOT tighten nut to align teeth.
Failure to properly tighten nut could
result in bearing damage which, if not
avoided, could result in bearing failure.
j. Using a dial indicator, verify that end play reading is
.001" (0.03 mm) to .003" (0.08 mm). Re-adjust bearing,
if necessary.
k. Make sure that the keeper tab and keeper
arms are fully seated into the undercut groove.
Inspect the keyway tang to ensure it does not
contact the bottom of the keyway (Figure 32).
If contact exists, immediately notify a Pro-Torq®
representative.
Failure to ensure that the keeper is
properly installed could cause wheel
separation which, if not avoided, could
result in death or serious injury.
4. ABS sensor block must clear rotor attachment bolts. Refer
to Section 9.
When installing new washers, the
attachment bolts can interfere with the
ABS sensor block. Ensure that there is
clearance provided for ABS Sensor Block
(Figure 33). Failure to provide clearance
can cause damage to property. Refer to
service bulletin XL-SA20031SB-en-US for
ABS Sensor Block Modification Procedure.
5. Check the wheel bearing end play as follows:
a. Attach the magnetic base of a dial indicator to the
spindle. Touch dial indicator stem to hub cap gasket
face (Figure 34).
b. Reading Number One - Slightly rotate wheel-end in both
directions while pushing inward until dial indicator does
not change. Set the dial indicator to zero (Figure 34).
c. Reading Number Two - Slightly rotate hub in both
directions while pulling outward until dial indicator
does not change (Figure 34).
d. End play is the difference between reading number
one and reading number two.
NOTE: Final adjustment should allow the wheel to rotate
freely with 0.001" - 0.003" (0.03 mm - 0.08 mm)
end play. If end play is not within specification,
re-adjustment of bearing is required.
IMPORTANT: If end play is not within specification,
re-adjustment is required.
Failure to maintain proper hub bearing
adjustment could allow bearing failure and
wheel-end separation which, if not avoided,
could result in death or serious injury.

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Disc Brake Servicing
12. Hub Lubrication (Oil)
IMPORTANT: DO NOT mix oil with grease. If the bearing
assembly has been lubricated with grease,
DO NOT add oil.
Failure to correctly lubricate bearings could
damage bearings which, if not avoided,
could result in death or serious injury.
1. Remove plug and fill the hub to the FULL mark with specified
lubricant (oil), through the hole in the hub cap (Figure 35).
2. Allow the oil to flow through the bearings and level off.
3. Insert the plug into the hole in the hub cap (Figure 35).
IMPORTANT: Axles equipped with a centralized tire inflation
system MUST use a vented hub cap.
4. Re-install wheel on hub using support device such as a
wheel dolly jack.
Failure to support weight during installation
or removal of brake drum could create a
crush hazard which, if not avoided, could
result in minor to moderate injury.
Failure to uncage spring brakes in accordance
with manufacturer’s instructions after
servicing is complete will prohibit proper
brake function which could result in
uneven brake system component wear.
13. Hub Cap Installation
1. Install the hub cap assembly, making sure the hub cap
gasket is in place (Figure 36).
IMPORTANT: When installing hub cap, make sure the
hub cap gasket is not bent or damaged.
IMPORTANT: DO NOT over torque. This can crush the
hub cap gasket.
Failure to avoid damaging the hub cap gasket
could allow lubricant to lead which, if not
avoided, could result in bearing failure.
2. Install the six (6) bolts to secure the hub cap assembly
(Figure 36). Tighten bolts to 12-16 ft.-lbs. (16-21 N•m).
O
I
L
L
E
V
E
L
O
I
L
L
E
V
E
L
F
U
L
L
A
D
D
F
U
L
L
A
D
D
Figure 35
OIL FILL LEVEL
PLUG
Figure 36
HUB CAP GASKET
HUB CAP
HUB CAP
BOLTS (6)