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6.
The master cylinder <6> and pushrod assembly components <13> can now be assembled. Apply a light coat of
brake fluid to the small opening of the rubber boot on the front of the master cylinder. This will ease assembly and
reduce the chance of damaging the boot. The spring guide washer <18> can be identified by the attached 1/8
inch steel break-away cable and break-away lever. THIS PUSHROD ASSEMBLY SHOULD NEVER BE
DISASSEMBLED OR ADJUSTED. Press the pushrod assembly into the rubber boot of the master cylinder. See
the assembly diagram at the end of the manual. Place the plated master cylinder cover plate <7> in the actuator
outer case with the four holes in alignment and the threaded flange for the filler cap up through the opening in the
outer case. Lay the master cylinder gasket <8> over the cover plate. Pull the inner coupler <3> forward to full
extension. Thread the break-away cable and lever through the outer case, from the inside-out. Lower the master
cylinder and bracket into the outer case. The front of the pushrod assembly passes through the hole in the inner
coupler.
7.
Slip the 1/4 inch lock washers <12> over the 1/4 inch bolts <11>. With the assembly still upside down, lift the rear
of the outer case slightly, and from the outside screw the bolts through the two rear-most master cylinder holes in
the outer case. The 1/4 inch bolts will ensure the correct position of both the master cylinder cover and the
gasket.
8.
Rotate the damper <4> back down towards the rear of the actuator. Secure it with the last ½ inch bolt <25>, ½
inch washer <27> and a ½ inch lock nut <26>, by passing the bolt through the damper tube and outer case holes.
9.
Turn the assembly over, right side up. Check that the master cylinder gasket is still correctly aligned to the
forward two bolt holes. Place the break-away catch pin <39> in the space between the break-away lever's upper
notch and the actuator case. Position the break-away catch spring <38> on top of the outer case over the bolt
holes, with its tab pointing forwards. Make sure the spring's edges trap the break-away catch pin. Set the cable as
described in the "HITCHING TRAILER" section of this manual. Secure the components with two 1/4 inch bolts
and 1/4 inch lock washers. Tighten all four 1/4 inch master cylinder bolts to 108-132 inch-pounds torque, to
ensure a positive master cylinder seal.
10.
For the handle <31> assembly, place the handle torsion spring under the strut of the inner coupler. See Figure 7.
Lower the handle into place being sure that the handle torsion spring legs are trapped above the permanently
fixed pin in the handle. Rotate the ball latch casting forward by pulling it on the under side of the actuator. This will
allow the handle to fall into its final position. Secure the handle with the 1/4 inch diameter groove pin and 1/4 inch
retaining ring. Be sure that the pin passes through both handle spring loops.
11.
Check the filler cap diaphragm and o-ring for damage. Screw the filler cap and gasket into the master cylinder
cover. The filler cap only needs to be finger tight.
12.
The actuator should now be fully assembled and ready for installation as described in this manual.
* NOTE: <#> is the reference number shown in the assembly diagram of the actuator located at the end of this manual
AERO 7500 ASSEMBLY (cont.)
Page 10 of 13
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