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IFS 1200/1320/1370 I&M Manual

1. Air Spring Assembly IFS1200 9 8103323 Lock Washer 1 2 Cd 1 Air Spring Assembly IFS120082 Hex Nut 1 2 13 Gr 5 Air Spring Assembly IFS1370 Jam Nut 3 4 16 Gr 5 8295 HCV and Linkage Assy Ridewell 5 HCV Assy Left Hadley HCV Assy Right Hadley Hex Head Bolt 5 16 18x1 Gr 8 HCV Assy Neway Shock Absorber IFS1200 Hex Head Bolt 1 4 20x3 Gr 8 Hadley Shock Absorber IFS1370 Hex Head Bolt 1 4 20x1 Gr 8 Neway Lock Nut 1 4 20 Gr C ig Height Control Valve Linkage Assy Hadley 6 701671 01 HHB 3 4 10 x 4 50 Gr 8 ZN Height Control Valve Linkage Assy Neway LFN 3 4 10 Gr G 700049 01 Hex Head Bolt 1 2 13 x 4 25 Gr 5 1FS1200 700137 01 Hex Head Bolt M12 1 75 x 110 Gr 10 97 FS1370 HCV Height Control Valve Note See sway bar part list section for height control valve components used on sway bar equipped suspensions Section 1 Introduction 5 8 89422299 LN 7 16 14UNCGr 8 14 2 702895 02 Bushing Split Sway Bar 6 2 100702 P1 HHB 1 4 20x1Gr 8ZN 15 8 702898 01 Washer Sway Bar 100703 P1 LN 1 4 Stover Gr 8 Plated 703286 01 HCV w Smaller Dead band 8 1 70154601 703356 01 Arm HCV 9 4 702797 01 FHB 7 16 14x1 25 Gr 8 ZP TC197 Aqua Shield Grease Sway Bar ee UD ae ee Cres fe z N e N Top View Side r
2. 23 Wheel Bearings and Hub Cap eee enn 24 Maintenancedschedile 5e aser tO a 25 Maintenance Record sse NNNM ws 26 Table of Contents SUBJECT PAGE 5 Adjustments and Alignment cccccccssscccccssssssccccccssssscccceeesccees 27 Adjusting the Suspension Ride Height eseeeesess 27 Checking and Adjusting the Wheel Bearings ccccccesseeeees 29 Adjusting the Maximum Turn Angle cccccccccsssssseeeeeeeceeeeeees 30 Inspection Before Alignment ssseeeeeeeee nnn 32 Front Wheel Alignment eeeeseeeeeeeeee nennen 33 Adjusting Camber Angle ccccccccccceccccccceesseccceeeeeseecccesueesecceseaueeses 34 Adjusting Caster Angle o1 bese ecuicancillusta axe HP Eva are Uva DUMP D RUTAS 35 Adusune the POG D oe e ed voee lb oem 36 6 Repa 50550500095000505500000560000 06000660000 SEEEN 38 Repair of Parts a t aaa RR AREE YR A Rd 38 Cleanse OF PotiStuiseiniusssesusenuithPPREEEDEOUE OLD a 38 Replacine the Drag Link ous RE RW ARA ARA ARA e 39 Replacing the Relay Rod and Outer Tie Rods 39 Replacing the Ball Joints 22 2 tasa EEaau tii nd E tioseasaosssedasassseanaaacaais 41 Replacing the Bell Crank and Idler Steering Arm Bearings 44 Replacing the Upper and Lower Control Arm Bushings 45 Replacing Wheel Bearings Oil Seals and Hub Caps 47 Replacing Brake Components itii oi Er
3. stands 7 Place the control arm in its mount location Install the control arm 3 Ifthe wheel nuts have chrome mount bolts into subframe snug covers remove them with special tight pliers equipped with plastic non 8 Support the control arm such that marring jaws Place them in a it is at ride height and tighten the container to prevent damage or bolts to 950 1050 Ibfeft See loss Torque Table 4 On aluminum wheels place a plastic anti scuff guard over the wheel nuts and loosen the wheel nuts On steel wheels remove the hub cap nuts if present and the hub cap before loosening the wheel nuts Place the hub cap in safe location to prevent damage Place the wheel and or hub cap nuts in a 9 Reconnect the steering knuckle to the lower control arm if disconnected Follow the installation procedure in Replacing the Lower Ball Joint Section 47 Section 6 Repair container to prevent contamination or loss 5 Remove the wheel and tire assembly and place it aside Mark the tire to ensure it can be identified for installation on same side as removed 6 Remove the brake drum and place 1t aside Mark the brake drum to ensure it can be identified for installation on same side as removed Removal 1 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 2
4. Loosen the jam nuts on both ends of the right and or left outer tie rod which requires length adjustment The outer tie rod reference length is 20 3 4 inches Note The jam nut with the left hand threads has a groove in each hex point around the circumference Adjust the length of the outer tie rods such that they are within 1 8 inch of each other Tighten the jam nuts to 110 130 Ibfeft See Torque Table Loosen the relay rod jam nuts and the U bolts that secure the steering damper mount bracket to the relay rod Note The jam nut with the left hand threads has a groove in each hex point around the circumference Adjust the length of relay rod such that the toe in on each side is 1 16 1 32 and the over all toe in is 1 8 1 16 Tighten jam nuts to 110 130 Ibfeft See Torque Table Re secure the steering damper mount bracket to the relay rod The bracket should be mounted such that the distance between damper mounts is 19 inches when the suspension is steered straight See Repair Section 6 for damper installation Tighten U bolt lock nuts to 25 30 Ibfeft See Torque Table Section 5 Adjustments and Alignments 8 10 Adjust the length of the drag link accordingly such the steering gear remains centered and the wheels are steered straight ahead with equal toe in side to side Reconnect it to the bell crank steering arm Tighten the ball stud castle nut to 130 150 Ibfeft Tighten the jam nuts
5. Check that the front tires are the same size and type Check that all the wheel nuts are tightened to the specified torque of 450 500 Ibfeft See Torque Table Check that the wheels are balanced Front Suspension 1 Check that all fasteners are tightened to the specified torque Check the suspension ride height and adjust as needed to the specified height Check for worn ball joints tie rod ends steering arm bearings control arm bushings and damaged suspension components Replace worn components as needed Check for loose ball joint and tie rod end tapered connections tie rod end jam nuts steering arm mounts and chassis steering system components Inspect connections for wear and replace as needed Tighten connections as needed Check the wheel bearing adjustment and adjust as needed Inspect the shock absorbers for wear and damage Rear Axle and Suspension Section 5 Adjustments and Alignments Front tire wear and incorrect steering can be caused by the rear axle and or suspension 1 Check that all fasteners are tightened to the specified torque 2 Check the suspension ride height and adjust as needed to specified height 3 Check that all connection joints between the suspension and axle are secure 4 Check for worn suspension bushings or damaged suspension components 5 Check that the rear axle is correctly aligned Check that the frame is not bent Refer to any addi
6. Rotate the hub such that the drain hole faces downward and drain the oil from hub cavity Wait a few minutes for most of the oil to drain before continuing to the next step 3 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that the hub cap window may be damaged by solvents NOTE When removing or installing the inner and outer spindle nuts use the correct wrench sockets to avoid damaging the nuts Do not use impact driver to tighten inner and outer nuts Only use a torque wrench to tighten the nuts 4 Unbend the spindle washer and remove the spindle outer nut spindle washer locking D 48 washer and the inner spindle nut Retain all components for re assembly except discard the spindle washer Place a shop towel on top of the lower brake shoe to prevent oil from dripping onto the brake lining Tug sharply on the hub to unseat the outer bearing without completely removing the hub Wipe up any oil spilled on the brake assembly as quickly and completely as possible Remove the outer bearing and place it in a container to prevent contamination Remove the hub from the spindle and place it on the floor with its stud side facing downwards Protect the wheel studs from damage Wipe the excess oil off spindle with a clean shop towel to prevent oil dripping onto the brake assembly If
7. strength yield strength proof load and hardness These specifications are carefully considered in initial selection of Figure 35 Grade Markings on Bolts fasteners for a given application To Grade Lock Nut Lock Nut Grade B F Grade C G Grade 1 or 2 assure continued satisfactory vehicle performance replacement fasteners used Tdendficn on should be of the correct strength as well as the correct nominal diameter thread pitch 3 Det 6 Dots length and finish Figure 36 Grade Markings on Lock Nuts Torque Table 1 APPLICATIONS FASTENER SIZE TORQUE SPECIFICATION LBFeFT CLEAN AND DRY Lower Control Arm Bushing Pivot Bolt 1 1 8 12 Grade 8 950 1050 Upper Control Arm Bushing Pivot Bolt without Eccentric Adapters Upper Control Arm Bushing Pivot Bolt with Eccentric Adapters 1 2 13 Grade 5 30 40 170 190 Steering Damper Mount Nut Tighten only enough so that bushing is retaining washer expanded to the diameter of the outer Steering Arm Mount Lock Nut 7 8 9 Grade C 350 Steering Stop Jam Nut 5 8 11 Grade 5 90 110 Tie Rod and Drag Link Length Adjustment Nuts 1 1 4 12 110 130 Outer Tie Rod Relay Rod amp Drag Link Ball Stud Castle Nuts Except at Pitman Arm Connection Height Control Valve Body Mount Lock Nut 1420GradeC CC Height Control Valve Linkage Stud Mount Nut 1 Torque applied to bolt head 2 Apply thread adhesive Loctite 242 or equivalent to threads of fastener threaded into tap
8. 13 200 Ibs IFS1370 HP 13 700 Ibs IFS1370S SB 13 700 lbs 1 Stud Piloted Wheels 2 Hub Piloted Wheels Sway Bar Equipped Identification The suspension model and serial number are stamped on an aluminum tag that is riveted to the driver side steering arm mount on the subframe assembly See Figure 2 The serial number is used by ReycoGranning for control purposes and should be referred to when servicing the suspension See Figure 1 REVCA Engen Granning Pace ae SUSPENSIONS Bretton IN Q SERIAL 000000 GAWRILBS O woe IFS1200 12 000 MAY BE COVERED BY THE FOLLOWING PATENTS OTHER PENDING US 4 506 810 6 158 750 6 176 501 Figure 1 Suspension Identification Figure 2 Suspension Identification Location Section 1 Introduction Description Structural Components Steering Knuckle Assembly LH IFS120082 IFS1320 IFS1370 705382 01 Ball Joint 40mm Thread In 705382 02 Castle Nut M30 x 1 5 Steering Knuckle Assembly RH F IFS1200S2 IFS1320 IFS1370 2r 705382 03 Cotter Pin 1 50 x 15 Dia Steering Knuckle Assembly RH IFS1200 Steering Knuckle Assembly LH FS1200 K705382 Kit Ball Joint 40mm 2 Hex Head Bolt 1 1 8 12 x 7 1 2 Gr 8 22 705383 01 Ball Joint 65mm Lock Nut 1 1 8 12 Gr C 23 705383 02 Castle Nut M24 x 1 5 Hardened Flat Washer 1 1 8 705383 03 Cotter Pin 1 95 x 24 Dia 12 100122 P1
9. 17 next to the automatic slack adjuster See Figure 17 3 Apply lubricant to the automatic slack adjuster until new lubricant discharges from the cone clutch adjacent the adjusting hex nut See Figure 17 I Figure 17 Location of lubrication fittings Note Left side only shown 23 Section 4 Lubrication and Maintenance Wheel Bearings and Hub Cap 1 Review lubricant specification and interval requirements before servicing Check oil level through hub cap window If level is below the add level line then remove the pipe plug and fill with recommended oil until full level is achieved See Figure 18 Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window Check the hub cap for external oil marks The vent plug will normally weep a small amount of 24 oil Oil marks in other locations should be addressed by replacing the hub cap seal window gasket or tightening the pipe fill plug Figure 18 Wheel Bearing Oil Level Section 4 Lubrication and Maintenance MAINTENANCE SCHEDULE GENERAL MAINTENANCE SERVICE TO BE PERFORMED pou omens asl San cee rrr eL sp mame eene TR Te checker ecson
10. 6 Yoke 61 This page intentionally left blank SUSPENSIONS ISO 9001 2008 Certified 1 800 753 0050 www reycogranning com Reyco Granning Mount Vernon 1205 Industrial Park Drive Mount Vernon MO 65712 800 753 0050 Fax 417 466 3964
11. Disconnect the steering damper mount from the relay rod 4 Disconnect the relay rod from the bell crank and idler steering arms The ball stud may be forced from mm the tapered hole by use of a RUE suitable tool 5 Disconnect the outer tie rod from ul the bell crank or idler steering arm AL and the steering knuckle The ball stud may be forced from the tapered hole by use of a suitable tool AN CAUTION Do not strike the steering arms or the steering Figure 24 Tie Rod Steering Arm Connection knuckles directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 6 Inspect the relay rod and or the ui outer tie rod and mating tapers Figure 25 Steering Damper Mount See Section 3 If grease boot 1s Location damaged during removal replace it before installation AN CAUTION Tighten the castle Installation nuts to the specified torque If 1 Connect the relay rod to the bell the castle nuts are not crank and idler steering arms See tightened to the specified Figure 24 torque the parts will be damaged and serious personal 2 Connect the steering damper i injury may occur mount to the relay rod such that the distance between damper mounts is i8 inch s when the 4 Tighten the castle nuts to 130 150 suspension is steered straight See Ibfeft See Torque Table Torque Table See Figure 25 5 Install the cotter pins If necessar
12. Install the rebound bumper stop and mounting fasteners 2 Tighten the bolt head to 25 30 ft Ibs See Torque Table Replacing the Shock Absorber AN CAUTION The shock absorber is gas pressurized and must not be punctured or be subjected to excessive heat which can result in serious personal injury Section 6 Repair Preparation NOTE The outer tie rod may need to be temporarily removed from the bell crank and or idler arm for access to the lower shock absorber mount Please refer to the Replacing the Relay Rod and Outer Tie Rod section for the proper procedure 1 Setthe parking brake and block the drive wheels to prevent vehicle movement Note Early models of the IFS1200 suspension were equipped with shock absorber mounting studs Subsequent IFS1200 suspensions and all IFS1320 models utilized through bolts Removal Stud Mount Version 1 Remove the upper and lower 3 4 10 lock nuts which secure the shock eye to the shock mount stud The shock mount stud should be held such that it is not loosened from its mount 2 Remove the upper and lower outer retaining washers from the shock mount studs Note the orientation of the retaining washers AN WARNING The shock absorber is gas pressurized and should be restrained from expansion during removal and installation 3 Dislodge the upper and lower shock eye from the shank portion of the shock mount stud and pry the outer shock eye b
13. Vendor P N P N Vendor Wheel End Components or Euclid E 2299 or Euclid E 2297 or Euclid E 2298 or Euclid E2296 IFS1320 SP Stemco 343 4024 and Drum Assy IFS1320 SP LH Hub Assy Stud Pilot IFS1200 8881 Dayton Walther 05 15556 003 IFS1320 SP Webb 1521F PLT Hub Cap Gasket Hub Pilot IFS1320 HP 330 3024 LH Hub amp Drum Assy Stud Pilot 15x4 Brake IFS1200 SP 6942 Dayton Walther 15 15556 059 Webb 1521FKZKLT 10 LH Hub amp Drum Assy Stud Pilot 16 5x5 Brake IFS1320 1370 SP Dayton Walther 15 15556 111 Hub amp Drum Assy Hub Pilot 16 5x5 Brake FS1320 1370 HP Dayton Walther 15 15632 167 Hub amp Drum Assy Hub Pilot 16 5x5 Brake IFS1320 1370 HP 705088 01 25201G54T 10 Hub Cap Gasket Hub Pilot 705015 01 and Many 1786 Stemco 330 3009 705088 01 Hub and Drum Assy Hub amp Drum Assy Hub Pilot 15x4 Brake IFS1200 HP Dayton Walther 15 15632 305 RH Hub amp Drum Assy Stud Pilot 15x4 Brake IFS1200 SP 6943 Dayton Walther 15 15556 058 Webb 1521FKZKRT 10 Hub Assy Hub Pilot IFS1320 HP 8882 Dayton Walther 05 15632 004 Brake Drum 15x4 Stud Pilot IFS1200 8639 Dayton Walther 85 123382 002 8376 Webb 65541B Brake Drum 16 5x5 Hub Pilot IFS1320 HP Dayton Walther 85 123370 002 Brake Drum 16 5x5 Stud Pilot IFS1320 SP Dayton Walther 85 123383 002 Hub and Drum Components Hub amp Drum Assy Hub Pilot 15x4 Brake IFS1200 HP 705015 01 25291JK4T 10 RH Hub amp Drum Assy Stud Pilot 16 5x5 Brake I
14. be diagnosed by a qualified technician before the anti lock brake sensor or the tone ring are replaced Replacement parts must be equivalent to the vehicle manufacturers to ensure proper function of the anti lock brake system The anti lock brake sensor and tone ring cannot be repaired and must be replaced if damaged or malfunctioning Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Remove the tires and check that the air springs are deflated Sensor Removal 1 Remove the brake drum to provide access to sensor 2 Press sensor out of steering knuckle Do not pull sensor out by its lead wire Section 6 Repair 3 Remove tie straps that secure the sensor lead wire and disconnect the sensor lead wire from the chassis Sensor Installation 1 Check that the sensor bushing is properly seated in the steering knuckle and the sensor spring retainer is seated properly in the sensor bushing 2 Press the sensor into the steering knuckle until the sensor end contacts the tone ring 9 Connect a volt meter to the co
15. control arm 2 Loosen and remove the 3 4 10 upper shock absorber mount bolt from the nut AN WARNING The shock absorber is gas pressurized and should be restrained from expansion during removal and installation Installation 1 Apply Loctite 242 or equivalent to the threads of the lower shock absorber mount bolt 2 Install the bolt into the lower mount of the shock Refer to Figure 32 3 Thread into the LCA and torque to 170 190 Ibfeft See Torque Table 4 Reinstall the upper mount of the shock absorber using the 3 4 10 54 bolt and lock nut Refer to Figure 30 5 Torque the bolt to 170 190 Ibfeft See Torque Table Figure 32 Shock Absorber Mount Replacing the Air Spring When replacing the air spring be sure that the correct replacement air spring is installed The use of a substitute air spring that is not recommended by Granning may cause unequal load sharing between the air springs which may be detrimental to vehicle ride and handling Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Section 6 Repair AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal in
16. d EE EET 51 Replacing the ABS Sensor and Tone Ring eess 51 Replacing the Rebound Bumper Stop eee 52 Replacing the Shock Absorber 4 suse rH rr EE EE EHE 52 Replacing the Air S prin iscsicocsscassascccceasaasaecccasapaancccasagancascosagaaaasicss 54 Replacing the Steering Dampetl ccccccccsssesccceeessesceceeeseesceeseees 55 Replacing the Suspension Subframe eee 56 Replacing the Height Control Valves eeeeeern 56 Keplacine the Sway Baf ussseet eee vea n o Once odas 58 1 Torque Specifications ues ce ee EEF FEE EEEEER OQ EN NEN Nd 59 8 Special Ball Joint Tools 2 RR NNNM RXRRRHEN RR EMEN 61 iii Section 1 Introduction Introduction ReycoGranning Air Suspensions has developed this service manual to aid in the maintenance of ReycoGranning s Independent Front Suspensions installed on Spartan Motors chassis These suspensions incorporate the latest in design and manufacturing technologies The suspensions have been designed and tested to provide improved ride and handling compared to I beam type axles Overloading the suspension may result in adverse ride and handling characteristics Model Capacity IFS1200 SP 12 000 lbs IFS1200 SP 12 000 lbs IFS1200 S2 12 000 lbs IFS1200S SB 12 000 lbs IFS120082 12 000 lbs IFS120082 SB 12 000 lbs IFS1320 SP 13 200 Ibs IFS1320 HP
17. millivolts and the voltage source to AC volts Rotate the wheel hub and record the voltage output from the ABS sensor A minimum output of 800 millivolts is normal If the minimum voltage output is not achieved check lead wire connections and repeat Step 3 Otherwise if the minimum voltage output is not achieved after repeating step 3 then go to Step 5 Check physical gap between the sensor and tone ring See Figure 11 The brake drum must be removed to inspect gap The maximum allowable gap is 027 inch If the gap is greater than 027 inch press on the wire lead end of the sensor and push the sensor into contact with the tone ring Check that the ABS spring retainer and bushing are not unseated Re seat components as needed Inspect the tone ring on the hub for physical damage and proper installation onto the hub The tone ring should have a maximum run out of 008 inch relative to the hub spindle centerline Repeat Step 3 If voltage output is less than 800 millivolts then replace the ABS sensor Note Check voltage output of new sensor 1 027 4 MAX Figure 11 ABS Sensor and Tone Ring Gap Section 3 Inspection Checking the Shock Absorber Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle 4 Check the air spring piston for build up of foreign material Remove any foreign material that is present Height Control Valve Inspection 1 Check the heig
18. oil saturates or significantly contaminates the brake lining then replace the lining Remove the hub seal and discard it Inspect the axle ring on the spindle and remove it if worn Inspect the inner cup outer bearing race for the inner bearing and outer cup in the hub for damage Replace the inner cup if damaged Section 6 Repair Installation 6 Install the inner spindle nut and tighten hand tight 1 Remove the axle ring from the f I replacement hub seal assembly 7 Seat the bearings by tightening P N 7977 if the axle ring is not the inner spindle nut to 180 Ibfeft removed from the spindle Note while rotating the wheel in both axle ring orientation Place the directions hub seal onto the axle ring with 8 Rotate the hub and drum ten 10 flange of the axle ring Seat the f hub seal firmly against the axle 9 Loosen the inner spindle nut ring flange If the axle ring is completely and then re tighten the removed install the hub seal inner nut to 20 Ibfeft assembly with appropriate seal 10 Back off the inner spindle nut installation tool Reference turn St P N 555 5098 ie 11 Install the spindle locking D NOTE Do not drive bearing onto spindle with a steel hammer or similar instrument Inner race is a tight slip fit with spindle washer NOTE If the dowel pin of the inner spindle nut and a hole in the locking washer are not aligned turn the locking washer over and re install If requi
19. or unevenly loaded Improper mismatched tires and wheels Incorrect toe in setting Tires have incorrect pressure Loose steering gear mounting Tie rod end connection loose or ball stud worn Loose wheel nuts Ball joints binding or worn Steering column linkage worn 10 Wheel bearings out of adjustment 11 Steering gear adjustment 12 Steering column misaligned 13 Steering damper binding or malfunction 14 Steering arm mounts loose Improper mismatched tires and wheels Tires have incorrect pressure Vehicle unevenly loaded Improper brake adjustment Incorrect rear axle alignment Unequal ride height side to side Wheel bearings out of adjustment Loose steering gear mounting Tie rod end connection loose or ball stud worn 10 Bent spindle or steering arm 11 Frame or underbody out of alignment 12 Incorrect toe in setting 13 Misaligned belts in radial tires 14 Steering gear valve binding 15 Steering gear not centered 16 Excessive internal steering gear leakage 17 Incorrect caster and or camber setting 11 10 11 12 13 14 10 11 12 13 14 15 16 17 Check wheel loads and correct as needed Install correct tire and wheel combination Adjust toe in to specified setting Put specified air pressure in tires Check mounting and secure as needed Inspect ball stud connections and wear Check and tighten to specification Inspect ball joints for we
20. shock mount from the lower control arm Follow the removal procedure in Replacing the Shock Section Section 6 Repair 10 Reconnect the lower shock mount Follow the installation procedure AN WARNING The steering in Replacing the Shock Section knuckle is heavy and unevenly balanced Use a portable crane Replacing Wheel or suitable jack to support it prior to disconnecting it from Bearings Oil Seals and the control arm or removing the control arm with the Hub Caps steering knuckle attached Pr ep aration 2 If desired disconnect the lower 1 Set the parking brake and block control arm from the steering the drive wheels to prevent vehicle knuckle Follow the removal movement procedure in Replacing the Lower 2 Raise the vehicle until the front Ball Joint Section wheels are off the ground See 3 Loosen and remove the control jacking instructions Support mount bolts raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle 4 Press the bushing out of the control arm housing Be sure to properly support the housing 5 Inspect the housing bores and A remove any burrs in the housing WARNING Never work under a by honing vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety 6 Press the bushing into the control arm housing Be sure to properly support the housing
21. the subframe to the chassis frame rails Tighten the fasteners to recommended torque of chassis manufacturer Reconnect the ABS sensor air lines and drag link Replacing the Height Control Valve When replacing the height control valve HCV be sure that the correct replace ment HCV is installed see Section 3 Height Control Valve Inspection The use of a substitute HCV that is not recommended by ReycoGranning may cause unequal load sharing between the air springs which may be detrimental to vehicle ride and handling Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands Do not place jacks or safety stands under the lower Section 6 Repair control arms to support the Installation vehicle 1 Assemble the actuation arm and the vertical link of the replacement HCV the same as the removed HCV For Ridewell HCV s note the orientation of the actuation arm at the pivot mount AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety 2 For Ridewell HCV s only Trim the stands lengths of the linkages of the replacement HCV to be the same 3 Deflate the air springs as the removed HCV Tighten the set bolt and clamp screw to 8 12 Removal Ibfeft See Torque Table 1 M
22. to 110 130 Ibfeft See Torque Table Re measure the right left and overall toe of the suspension The right and left toe in should be 1 16 1 32 and overall toe in should be 1 8 1 16 Skip to end of procedure Loosen the relay rod jam nuts and the U bolts that secure the steering damper mount bracket to the relay rod Note The jam nut with the left hand threads has a groove in each hex point around the circumference 37 11 12 13 Adjust the length of relay rod such that the toe in on each side is 1 16 1 32 and the over all toe in is 1 8 1 16 Tighten jam nuts to 110 130 Ibfeft See Torque Table Re secure the steering damper mount bracket to the relay rod The bracket should be mounted such that the distance between damper mounts is 19 inches when the suspension is steered straight See Repair Section 6 for damper installation Tighten U bolt lock nuts to 25 30 Ibfeft See Torque Table Re measure the right left and overall toe of the suspension The right and left toe in should be 1 16 1 32 and overall toe in should be 1 8 zh 1 16 Section 6 Repair Repairing of Parts The repair or reconditioning of front suspension components is not allowed ReycoGranning recommends replacing damaged or worn components Several major components are heat treated and tempered The components cannot be bent welded heated or repaired in any way without reducin
23. Connecting to other subframe areas or suspension components can result in suspension damage or disconnection of vehicle while being towed Figure 3 Tow Point Locations Section 2 Troubleshooting Suspension System General SYMPTOMS Tires wear out quickly or have uneven tire tread wear Note Wear pattern will indicate possible cause s Consult tire manufacturer for guidance Vehicle is difficult to steer Tires have incorrect pressure Tires out of balance Incorrect toe in setting Incorrect ride height Incorrect rear axle alignment Incorrect steering arm geometry Improper mismatched tires and wheels Improper oversized tires Tires not uniform Tires have incorrect pressure Incorrect steering arm geometry Steering arms binding Ball joints binding Tie rod ends binding Steering column linkage binding Steering miter box binding Steering gear valve binding Steering damper binding or malfunction 10 11 12 Steering wheel to column interference 13 Power steering pump fluid level low and possible leak in system 14 Power steering pump pressure and flow below specification Put specified air pressure in tires Balance or replace tires Adjust toe in to specified setting Adjust ride height to specified setting Align rear axle to specified thrust angle Adjust tie rod lengths as required In
24. FS1320 1370 SP Dayton Walther 15 15556 110 i I RH Hub Assy Stud Pilot IFS1200 8880 Dayton Walther 05 15556 002 IFS1320 SP Webb 1521F PRT Section 1 Introduction Description Brake Service Part List Description Model ReycoGranning Recommended Vendor P N P N Vendor ABS Components i XL15x4 Brake Components prior to June 1999 Mfg Date gt Dana Brake Relining Kit Shoe amp Lining Asy and Spring IFS1200 8300 Dana 150KB129X Kit 1 Side S Cam Seal and Bushing Kit 1 Side Spring Kit 1 Side Dust Shield Kit 1 Side S Cam Roller amp Spring Kit 1 Side S Cam Roller Spring amp Lining Kit 1 Side Air Chamber Assy Type 16 Automatic Slack Adjuster 165WD389 3 165WD389 4 165WN126 4X ES1504D 15x4 Brake Components LH Brake Assy 15x4 IFS1200 RH Brake Assy 15x4 IFS1200 703957 02 Kit 1 Side Automatic Slack Adjuster ES1655D 16 5x5 Brake Components LH Brake Assy 16 5x5 IFS1320 703958 01 RH Brake Assy 16 5x5 IFS1320 703958 02 Kit 1 Side Section 1 Introduction Tow Point Locations If a vehicle is disabled and needs to be towed by the front end to a service center the towing apparatus may be attached to the suspension subframe in the designated locations as shown in Figure 3 The towing apparatus should be attached securely for safe towing The towing apparatus may not be connected to any subframe area or suspension component other than that shown in Figure 3
25. Gear Service Manual for readjusting the poppets Figure 22 Steering Arm Stop Bolt Steering Arm Stop Settings Model Max Steer Angle Min Dim A IFS1370 HP 45 1 12 IFS1200 HP 45 1 12 IFS1200S2 50 0 875 Table 5 1 AN CAUTION In power steering systems the hydraulic pressure should relieve or drop off when the steered wheels approach the steering stops in either direction If the pressure does not relieve the components of the front suspension may be damaged 3l Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Place the front tires on a suitable device that allows the front wheels to turn and measures the wheel turn angle 3 Check that the steering gear 1s centered and the tires are steered straight ahead with equal toe in side to side If either of these two conditions is not met then adjust toe in first before centering the steering gear See Adjusting the Toe In Section and refer to Spartan chassis service guidelines for centering the steering gear NOTE Unequal toe in side to side or an out of center steering gear can result in unequal turn angles and steering pull while steering straight ahead The drag link length may be adjusted to attain steering gear on center condition while maintaining equal toe in side to side 4 Check that the lengths of the outer tie rods are equal to each other within 1 8 in
26. Lock Nut 7 8 9 Gr C Note The IFS1200 may be equipped with either Press In style or Thread In style Upper Ball Joints Items 17 amp 19 When ordering replacement parts please note which style is installed in your suspension 16 17 19 0 1 22 23 4 7 10 11 2 Ball Joint kits for service use The kits subcomponents may not be ordered individually Castle nuts and Cotter Pins are part of the Ball Joint Kit Section 1 Introduction Description Steering Components Hex Head Bolt 7 8 9 x 7 1 2 Gr 8 U Bolt 3 8 24 Gr 5 Lock Nut 7 8 9 Gr C 6 7271 8090 Bell Crank 7331 Snap Ring p 7256 Drag Link Assy 31 3 8 L See Note Below 19 8 8223511 Steering Stop Bolt 5 8 11 x 1 1 2 Gr 8 7948 Drag Link Assy 43 3 8 L See Note Below 9 100276 P1 Steering Stop Jam Nut 5 8 11 Gr 5 Drag Link Assy 45 1 4 L See Note Below Drag Link Assy 39 7 8 L See Note Below Outer Tie Rod Assembly Relay Rod Assembly Note The IFS1200 may be equipped with various length drag links depending on the chassis front overhang Measure length of drag link when ordering replacement parts Mounting hardware for the Steering Damper are included with the assembly Castle nuts part of drag link assembly Castle nuts part of tie rod assembly Section 1 Introduction Description Air Spring and Shock Absorber Assy
27. RENI S EAESRREHA SEARCH ERR EN SEHE FEAR EUREN ER SSS 1 TGCIMIPICATION TI 1 IB uH u m 2 DEVICE PATUTE ERNE ER EINEFEPISUEE I NUN UNEUNIUEE MM TUE 8 Tow OO Cal Oso d MS 9 2 LroubleshoOUb Seinnse 10 LSD EC EL T T TEE Aa A A AO SA 14 General IMS pec Iob ane REED EORR E IRE 14 Checking the Ball Joint Axial End Play sss 14 Checking the Control Arm Bushings for Wear s 17 Cheekine the Tie Rod Endg aus ise btt rtt t baa E er On 18 Checking the Automatic Slack Adjusters and Brake System 18 Checking the ABS Sensor and Tone Ring ees 19 Checking the Shock Absorber ccccccccesecccceceseescecseeesescceseeeeeess 20 Checking the Air Spring and Height Control Valve 20 Checking the Steering Damper eee 21 Checking the Steering Arm Bearings eee 2 Checking the Rebound Bumper Stop eee 21 4 Lubrication and Maintenance eee eene eee eee eee eee teet 22 Lubrication Specification and Intervals sess 22 General DubptIed ITE eiie dd dai daa A AMARI EE MMA RAO 22 Ball donis is eer n e nete eere v e sd 22 Ball Studs on Tie Rods Relay Rod and Drag Link 22 Bell Crank and Idler Steering Arms eee 23 Brake S Cam Tube and Automatic Slack Adjuster
28. Reyco Granning SUSPENSIONS Motorhome Suspensions Owner s Manual IFS1200 1320 1370 Independent Front Suspension Maintenance Instructions Service Parts Document D9834 Revision P Revision Date 12 09 Reyco Granning Suspensions 1 1205 Industrial Park Drive Mount Vernon MO 65712 Phone 417 466 2178 www reycogranning com ge oua COMPANY PROFILE Reyco Granning Suspensions was formed by the merger and acquisition of two well known names in the heavy duty vehicle suspension industry Reyco and Granning Reyco grew out of the Reynolds Mfg Co and was first known as a major supplier of brake drums for heavy duty vehicles and later developed a full line of air and steel spring suspensions for trucks busses trailers and motorhomes Granning Air Suspensions was founded in 1949 in Detroit Michigan as a manufacturer of auxiliary lift axle suspensions Granning later became an innovator of independent front air suspensions for the motorhome industry Reyco Granning LLC was formed in early 2011 through a partnering of senior managers and MAT Capital a private investment group headquartered in Long Grove Illinois Reyco Granning manufacturing facilities are certified to the ISO9001 2008 standards a globally recognized assurance that quality standards have been established and are maintained by regular rigorous audits Service Notes This Service Manual describes the correct service an
29. aight ahead Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 4 Deflate the air springs The air spring may be deflated by disconnecting the vertical link from the height control valve HCV horizontal link or the upper control arm mount and positioning the HCV horizontal link Section 3 Inspection downward Secure the HCV link to Lower Ball Joint Axial End Play ensure it does not move and re Inspection inflate the air spring 1 Place a support under the tire or brake drum to position the suspension near its ride height The shock length at ride height is 5 Remove the tires as needed for access to inspect seals and make measurements NOTE Care must be taken to not poe damage ball joint seals during in 2 Install a dial indicator with a spection Seals that are ruptured magnetic base so that the base is during inspection must be replaced fixed to the lower control arm Do not apply excessive force to pry Place the indicator tip on the ball joints bottom of the lower ball joint base See Figure 4 Lower and Upper Ball Joint Seal Inspection 1 Inspect the ball joint seal outer surface for p
30. ails and other components removed Nuts ond brocket for clarity ore on top SECTION A A INSTALL SWAY BAR WITH UNIT AT RIDE HEIGHT Section 1 Introduction acil ic eg End SAd ak l 1 1784 Inner Bearing Cone 705015 01 pene pe and Drum es LH and RH Hub 2 NA ImnerBearingCup Piloted 15x4 Brakes IFS1200 HP 3 6972 Outer Bearing Cone 6942 Hub and Drum Assembly LH Stud Piloted 15x4 Brakes IFS1200 SP 5 7977 Hub Seal gm Hub Cap IFS1200 1320 1370 SP Hub and Drum Assembly LH Stud Piloted HN Hub Cap Gasket IFS1200 1320 1370 SP 16 5x5 Brakes IFS1320 1370 SP ar ac 01 Hub Cap Gasket IFS1200 1320 1370 HP Hub and Drum Assembly RH Stud Piloted Inner Spindle Nut Inner Spindle Nut Nut 6943 M 5x4 Brakes IFS1200 SP 4 NA Outer Bearing Cup Hub and Drum Assembly Hub Piloted 16 5x5 Brakes LH and RH IFS1320 1370 HP 700017 01 Hub Cap IFS1200 1320 1370 HP HES Spindle Lock Washer Hub and Drum Assembly RH Stud Piloted 16 5x5 Brakes IFS1320 1370 SP 6969 Spindle Washer 6970 Outer Spindle Nut 1328 ABS Sensor Hub Cap Bolt 5 16 18 x 3 4 Gr 5 7329 ABS Bushing Lug Nut refer to Hub and Drum ABS Spring Retainer Wheel End Wheel End Assembly LE SSSSNN ABS Components Brake Assembly Components See Service List on Next Page Section 1 Introduction Description Wheel End Service Part List Description Model ReycoGranning Recommended
31. al motion Observe bearing movement Figure 16 Steering Arms Checking the Rebound Bumper Stop Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Inspection 1 Check the rebound bumper stop for deformed shape and chafing Replace rebound bumper stop as needed Section 4 Lubrication and Maintenance Lubricant Specification and Intervals COMPONENT SERVICE INTERVAL CHANGE INTERVAL LUBRICANT SPECIFICATION Ball Studs on Ends of Which ever comes first Every Multi Purpose Chassis Grease Tie Rods Relay Rod oil change or every 6 months Drag Link Premium Multi Purpose Chassis Grease NLGI Grade 2 Bell Crank and Idler Arm Which ever comes first Multi Purpose Chassis Grease 50 000 miles 80 000 kilometers or once a year NLGI Grade 1 or 2 Lithium Base Brake S Cam Tube and Which ever comes first Premium Multi Purpose Chassis Automatic Slack Brakes relined 50 000 miles Grease NLGI Grade 2 Adjuster 80 000 kilometers or once a year Wheel End 1000 miles 1600 kilometers Which ever comes first Seals Gear Oil Check fluid level replaced brakes relined 100 000 miles 160 000 km or once a year SAE 80W 90 or equivalent 1 Moly disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the automatic slack adjuster General Lubrication B
32. all Joints Proper lubrication practices are important The ball joints are lubricated and sealed in maximizing the service life of your for their service life and do not require ReycoGranning Independent Front lubrication Check for oil or grease marks Suspension on the exterior of the seal and if found verify that the seal has not been ruptured If the seal has been ruptured CAUTION Do not mix then the ball joint must be replaced lubricants of different grades because it cannot be re lubricated Do not mix mineral and synthetic lubricants Different Ball Studs on Tie Rods brands of the same grade ma pep iu Rod and Drag In 1 Review lubricant specification and interval requirements before servicing AN CAUTION Never mix oil bath and grease packed wheel ends 2 Apply lubricant to grease fitting until new lubricant discharges from the dust boot See Figure 17 22 Section 4 Lubrication and Maintenance Bell Crank and Idler Brake S Cam Tube and Steering Arms Automatic Slack 1 Review lubricant specification and Adjuster interval requirements before 1 Review lubricant specification and interval requirements before 2 Apply lubricant to the bell crank servicing and idler steering arms until new ubricant discharges from the servicing 2 Apply lubricant to the S cam tube bearing seal or from the pressure hau m eA A E relief port of the grease fitting rom the S camsha i uS ME nen See Figures
33. alve and linkage should be checked regularly for proper clearance operation and adjustment NOTE Improperly adjusted ride height will result in incorrect alignment measurements and may result in abnormal tire wear Check ride height prior to front suspension alignment The ride height of the front suspension is the distance from the bottom of the chassis frame rail to the center of the wheel spindle Properly adjusted ride height results in correct suspension travel and alignment The ride height should not be adjusted to adjust chassis rake angle Preparation 1 Park the vehicle on a level surface 2 Setthe parking brake and block the drive wheels to prevent vehicle movement 3 Check that the rear suspension is adjusted to the correct ride height per the vehicle manufacturers Specifications 4 Check height control valve plumbing to ensure there are not any air leaks 5 Make sure shock mounts are mounted securely and not bent NOTE Before performing any adjustment or maintenance identify the style of the height control valve See Section 3 Height Control Valve Inspection 27 Adjustment Ridewell Valve 1 Measure the distance between the centers of the shock mounts If the distance is not within 16 1 8 1 8 inches then adjust as follows 2 Disconnect height control valve linkage on the opposite side and allow the air spring to deflate by rotating the height control valve arm down Do n
34. ar or contamination and replace as required Check for wear and repair or replace as needed Check wheel bearing end play and adjust as required Check and adjust to specification Realign steering column as required Check and replace as needed Check and tighten to specification Install correct tire and wheel combination Put specified air pressure in tires Check wheel loads and correct as needed Inspect adjust and correct as required Align rear axle to specified thrust angle Inspect ride height and adjust to specified setting Check wheel bearing end play and adjust as required Check mounting and secure as needed Inspect ball stud connections and wear Inspect and replace as required Inspect and correct as required Adjust toe in to specified setting Check and replace as needed Inspect repair or replace as required Inspect and adjust as required Inspect repair or replace as required Install and or adjust eccentric adapters in upper control arm Section 2 Troubleshooting Suspension System General Cont d Vehicle pulls to one side with the brakes Grease oil or dirt on brake linings applied Brake linings are glazed Brake linings are not a balanced set different friction codes or lining brand Loose or broken brake linings Brake drum out of round Defective brake drum Brake air chamber clevis pin or camshaft binding Defective slack adjuster Un
35. ark air line connections for re 3 Assemble any other plumbing assembly Disconnect the air lines fixtures to the HCV as marked for from the HCV If any other plumbing fixtures are connected to re connection the HCV mark them for re 4 Mount the replacement HCV to the assembly subframe with bolts nuts and f f washers Tighten the nuts to 10 2 Disconnect the vertical link from 15 Ibfeft See Torque Table the upper control arm d 5 Reconnect air lines and check for 3 Remove the mounting bolts nuts proper operation and leaks washers and HCV from the subframe 6 Check and adjust ride height per Adjusting Suspension Ride Height 4 Remove any other plumbing Section fixtures from the HCV 57 Section 6 Repair Replacing the Sway Bar AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement 2 Removal and replacement of the sway bar is best done while the suspension is at ride height to remove all loading from the sway bar It is recommended that this service be performed in a service environment that provides access to the undercarriage while at ride height such as a pit or full vehicle lift Removal 1 Disconnect the height control arm from the sway bar AN WARNING It is recommended to se
36. as of taper x x x xx x x De checker eater pris tals xe x x x x x e even E sees eye Il E ere pare Taman aan N E I T a a a a 3 el P Rt D EN D t Co xxx x x x7 E al ioe 1 4 E TUTTI TET NN E E E ER EN E E E ce a orba iei oriens x x X x x X lume necnmemueprenee x T de EET ee E B D E loose fasteners or worn bushings em IT TUE m E B E E E In eee o id Ri E P ends loose fasteners or worn bushings SEn Fee 7 ase ETE EIER EE spel sings a aa xx x x xx x e dtes checker stored shape ard caine Dx Dx Dx x Dx Dx x Wes a PP T T T were pontoon TL XL X 1 Ai Ftings nd A Unce ape ala wang somywaircouion x 1 1 Wheel nuts must be re tightened to proper torque specifications as per the vehicle or chassis manufacturer s Owner Guide 2 Continue to perform specified maintenance every 12 000 miles or at previous interval 3 Toe in should be inspected after vehicle completion by final stage manufacturer 25 Section 4 Lubrication and Maintenance MAINTENANCE RECORD Date of Purchase Name and Address of Dealer Model of Vehicle Vehicle Identification Number Suspension Model Number Suspension Serial Number IFS1200 IFS1320 HP IFS1320 SP Inspection and Maintenance Item Service Performed 26 Section 5 Adjustments and Alignments Adjusting Suspension Ride Height The height control v
37. ch If not adjust lengths according to the Adjusting the Toe In Section before adjusting the steering stops NOTE Do not adjust the length of the drag link or tie rods to center the steering wheel This can cause the steering gear to become off center Section 5 Adjustments and Alignments Adjustment 1 Turn the steering wheel until the steering arm contacts the stop bolt or the steering wheel stops turning See Figure 22 Measure the turn angle of the wheel on the same side as the turn i e inside wheel If the wheel turn angle differs from Table 5 1 then adjust as follows Loosen the jam nut on the stop bolt Turn the stop bolt until the specified wheel turn angle is achieved and the bolt head contacts the steering arm Tighten the jam nut to 90 110 Ibfeft See Torque Table AN CAUTION After readjusting the steering stop s check that the steering poppets are reset properly and that the front 6 tires do not contact the frame suspension or body Also check for 1 2 minimum clearance between the air spring and brake dust cover Repeat checking and adjustment for turning the opposite direction Inspection Before Alignment Check the following before conducting front wheel alignment measurements Inspection See General Inspection in Section 3 Wheels and Tires 32 1 Check that the front tires are inflated to the appropriate pressure based on the wheel loading
38. cure the height control valve arm such that the valve will not dump air while the sway bar is being replaced Remove the bushing brackets 3 Remove the sway bar Note orientation of sway bar ends 4 Remove the sway bar bushings from the bar 5 Inspect bushings for any damage Installation 58 10 11 Lubricate the bushings inner diameter with Aqua Shield Grease TC1920 Install the two split bushings over the sway bar Install the bar to the suspension Note The ends of the sway bar should tip up on the lower control arms Install the two bushing brackets over the split bushings Torque the fasteners to 52 lbfeft See torque table Lubricate the two non split bushings Install these two bushings over the ends of the bar Install the two bushing brackets over the remaining two bushings Torque to 52 Ibfeft See torque table Loosely install the height control arm to the sway bar Pin Hole Set the height control valve arm on the valve to level It is recommended to use the wood dowel through the pin hole located in back of the height control valve Tighten the retaining U bolts to the sway bar to 20 30 Ibfeft See torque table Remove the wood dowel if necessary Section 7 Torque Specifications TORQUE SPECIFICATIONS Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile
39. d before 1 8 3mm movement occurs 5 Check dust boot for damage Replace as needed Figure 10 Tie Rod Checking the Automatic Slack Adjusters and Brake System Automatic Slack Adjusters The suspension system is equipped with Haldex brand automatic slack adjusters for steer axles Refer to Haldex technical service guideline 485 89007 for inspection and adjustment procedure Brake System The suspension system is equipped with Dana 15x4 S cam air brakes Refer to Dana maintenance manual SHA 589 1 5M service procedures Section 3 Inspection Checking the ABS Sensor and Tone Ring Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a 3 vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands The tires and brake drums may be removed if needed to ease inspection of tone ring and sensor Disconnect the ABS sensor lead from the chassis connector The ABS sensor test will require a volt meter which can measure AC voltage on a millivolt scale Inspection 1 Connect the volt meter to the connector pins of the ABS sensor lead Set the volt meter scale to
40. d repair procedures for the ReycoGranning IFS1200 1320 1370 Independent Front Suspension The information contained in this manual was current at the time of printing and is subject to change without notice or liability You must follow your company safety procedures when you service or repair the suspension Be sure you read and understand all the procedures and instructions before you begin work on the suspension Granning uses the following types of notes to give warning of possible safety problems and to give information that will prevent damage to equipment N WARNING A warning indicates procedures that must be followed exactly Serious personal injury can occur if the procedure is not followed N CAUTION A caution indicates procedures that must be followed exactly Damage to equipment or suspension components and personal injury can occur if the procedure is not followed NOTE A note indicates an operation procedure or instruction that is important for correct service Some procedures require the use of special tools for safe and correct service Failure to use these special tools when required can cause personal injury or damage to suspension components ReycoGranning Air Suspensions reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation Table of Contents SUBJECT PAGE I IntrOOUctlOLDos 55 ERR IIR EN CEERIAS SUR RY
41. e Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Section 6 Repair 3 Remove the tires and check that the air springs are deflated Place the spacer into the bushing Insert an eccentric adapter on each end of the upper control arm mounting plate Upper Control Arm 1 Disconnect height control valve linkage from the upper control arm Follow the removal procedure in Replacing the Height Control Valve Section AN WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm or removing the control arm with the steering knuckle attached If desired disconnect the upper control arm from the steering knuckle Follow the removal procedure in Replacing the Upper Ball Joint Section Loosen and remove the control mount arm bolts Remove any existing eccentric components Note the orientation of the set screws for reinstallation Press the bushing out of the control arm housing Be sure to proper
42. e and fitting leaks Figure 12 Ride Height Measurement fus with soapy water solution O afi uw I gt 3 Check to see that there is minimum of 1 inch clearance around the W a circumference of the air spring while it Figure 13 Height Control Valve is energized with air Ridewell 20 Section 3 Inspection Hadley Figure 15 Height Control Valve Neway Checking the Steering Damper Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Inspection 1 Check steering damper for oil leakage bent components missing or broken components excessive corrosion or worn bushings Replace the damper if any of the above items is present Checking the Steering Arm Bearings Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement 21 Inspection 1 Check that steering arm pivots are free of foreign material and bearing seals are in place Lubricate as needed 2 Start vehicle engine Oscillate the steering wheel and observe the motion of the steering arms See Figure 16 The steering arms should not exhibit any noticeable conical motion about their pivot axes 3 If any conical motion is observed check pivot bolt torque which should be 350 Ibfeft See Torque Table Otherwise replace the bearing set of steering arm which exhibited conic
43. e off the ground Support the raised vehicle with safety stands Do not place jacks or safety 1 4 1 4 1 4 1 4 stands under the lower control Right 1 4 1 4 1 4 1 4 arms to support the vehicle HE The set screw in the eccentric adapter denotes the orientation of the eccentricity of the adapter When the set screw is in the 6 o clock or 12 o clock position then the adapter is in the neutral position There are two adapters at each control arm mount and they must be oriented the AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands same When the set screws in both control arm Adjusting the Camber mounts are oriented closer to the frame Angle rail the wheel camber becomes more positive When the set screws in both control arm mounts are oriented farther from the frame rail the wheel camber becomes more negative The eccentric adapters at both upper control arm mounts must be oriented the same to affect only camber AN CAUTION ReycoGranning does not recommend adjusting the ride height or altering components to adjust the suspension camber Alteration of components may cause a 1 Turn the wheel to provide access to vehicle accident and serious the upper control arm mount personal injury 2 Loosen both upper control arm mounting bolts at the eccentric Camber is the ang
44. e safety NOTE Do not push pull at the top and the bottom of the tire drum or stands hub Pushing or pulling at the top and the bottom will not yield a true 9 Ifthe tire and wheel are not measurement of the end play removed make sure all the wheel nuts are tightened to the specified 3 Measure the end play by torque of 450 500 Ibfeft See simultaneously pushing pulling on Torque Table each side of the tire drum or hub A Ir bedreand whesl arer mored while observing the dial indicator recommended for aluminum The end play is the total travel wheels secure the brake drum to observed If the end play is not tho h b wii ea eel ante on within 001 004 inch adjust the wheel bearings per steps 4 16 See Figure 21 Otherwise skip to step 5 Remove the vent plug from the 17 hub cap remove the brake drum 4 Place an oil drip tub beneath the Adjustment hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 1 Attach a dial indicator with a magnetic base to the face of the wheel hub or brake drum The dial indicator may also be attached to the bottom of the brake drum if 5 Rotate the hub such that the drain the wheel is removed hole faces downward and drain the oil from hub cavity Wait a few 29 Section 5 Adjustments and Alignments minutes for most of the oil to drain before conti
45. e the sleeve Retain shims 3 Support the steering arm bearing housing and press the bearing out of each end of the steering arm Installation 1 Clean out the steering arm grease cavity 2 Inspect steering arm bearing housing bores and remove burrs by honing Replace steering arm if the bore is damaged 3 Support the steering arm bearing housing and press the replacement bearing into each end of the steering arm Note that the seal side of the bearing should face out Replacement bearings with seals on each side should have one seal removed to allow grease access 4 Inspect the pivot sleeve and remove burrs with emery cloth 5 Use a rubber mallet or similar tool to drive the inner sleeve up such that the bottom retaining ring is seated against the bottom inner race Do not use a steel hammer to install the sleeve because bearing raceways can be damaged 6 Install upper retaining ring Determine the number of shims p n 8611 needed by stacking the shims and placing the stack between the upper retaining ring Section 6 Repair and inner race until a snug fit is achieved Remove one shim from the stack and this is the number of shims needed A maximum of six shims may be used 8 Remove the upper retaining ring install the shims determined in step 7 onto the inner sleeve at upper inner race and re install the upper retaining ring Check that upper retaining ring is properly seated in the groove of
46. even brake adjustment side to side 10 Different brake air chamber size or slack adjuster length side to side 11 Air pressure uneven side to side 12 Unequal brake air chamber stroke side to side 13 Rear axle brakes misadjusted 14 Air leak or obstruction in air brake lines 15 Brake air chamber air leak or diaphragm damaged Vehicle rolls side to side excessively Front and or rear shock absorbers worn Shock mounting loose Shock eye bushings worn Control arm pivot bushings worn Internal leak in height control valve Front tires lock up during hard braking or ABS sensor malfunction ABS malfunction light remains lit ABS CPU or system malfunction ABS sensor electrical connection faulty Tone ring on hub damaged 12 10 11 12 13 14 15 Replace brake linings as required Deglaze brake linings or replace as required Replace brake linings as required Replace brake linings as required Re machine brake drum as required Inspect for defects and replace as required Check and lubricate as needed Inspect for defects and replace as required Adjust slack adjuster as required Replace with same size brake air chambers and length slack adjusters Check side to side air pressure and correct as needed Check side to side stroke and adjust as required Check and adjust as required Check fittings with soapy water solution and remove obstructions Check c
47. for suspension to settle after adjusting to verify correct adjustment NOTE The height control valves must be adjusted individually Adjusting Bolt Figure 19 Hadley Height Control Valve Adjustment 28 5 Tighten the adjusting bolt on the actuation arm 6 Reconnect the height control valve linkage on the other side and repeat steps 2 4 for the opposite side as needed 7 Verify that the ride height is correct on both sides NOTE Sway bar equipped suspensions have only one height control valve installed to the center of the sway bar Adjustment is similar to above Adjusting Bolt Figure 20 Neway Height Control Valve Adjustment Section 5 Adjustments and Alignments H H i 2 Place the tip of the dial indicator Checking and Adjusting on the center of the steering the Wheel Bearings knuckle spindle Set the dial indicator on zero See Figure 21 Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a vehicle supported by only a Figure 21 Wheel End Play Measurement jack Jacks can slip or fall over and cause serious personal injury Always us
48. g the strength or life of the component and voiding the warranty The following operations are prohibited on front suspension components 1 Welding of or to the steering knuckles lower control arms steering arms tie rod assemblies the brakes the hubs and the brake drums 2 Hot or cold bending of the steering knuckles the upper and lower control arms the steering arms the tie rod assemblies the ball joints and the subframe except control arm and steering arm mounts which may be cold bent to facilitate bushing and bearing replacement 3 Drilling out control arm and steering arm mounting holes and ball stud tapered holes 4 Spray welding of bearing diameters on the steering knuckle spindle steering arm bores and pivot tube Spray welding of ball studs or tapered holes for the ball joint and tie rod ends 5 Milling or machining of any component except that control arm bushing bores may be honed to remove any burrs AN WARNING If you use cleaning solvents hot solution tanks or alkaline solutions incorrectly serious personal injury can occur To prevent injury follow the instructions supplied by the manufacturer Do NOT use gasoline to clean parts Gasoline can explode Cleaning the Parts Ground or Polished Parts Use a cleaning solvent to clean ground or polished parts and surfaces Do NOT clean ground or polished parts with hot solution tank or with water steam or alkaline s
49. hamber for air leak and damaged diaphragm Replace shock absorbers as needed Check and tighten as required Check and replace as needed Inspect and replace as required Check height control valve and replace as required Inspect ABS sensor installation and replace sensor as required Check and repair or replace as required Check ABS sensor connection and lead wire Check for damage and replace as required Section 2 Troubleshooting Suspension System General Cont d Vehicle ride is too harsh and or suspension contacts stops excessively Vehicle ride is too soft Vehicle has unequal turning radius right to left Suspension does not maintain ride height Brakes are noisy 1 2 3 4 5 6 7 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 Front shock absorbers worn Incorrect ride height Vehicle overloaded Air spring supply lines leaking or obstructed Vehicle system air pressure below specification Rebound bumper worn or missing Jounce bumper in air spring worn or broken Front shock absorbers worn Incorrect ride height Incorrect steering arm geometry Steering gear not centered Steering gear poppet valves set incorrectly Air leak Internal leak in height control valve Height control valve linkage loose Air spring chafed or worn Grease oil or dirt on brake linings Brake linings are glazed Bra
50. he brake drum 50 Section 6 Repair 23 Install the wheel and tire assembly and the wheel nuts 24 On aluminum wheels use a plastic anti scuff guard over the wheel nuts Tighten the wheel nuts to 450 500 Ibfeft See Torque Table for sequence 25 Replace the hub cap nuts and hub caps 1f removed to service the wheel bearings 26 Remove jack stands and jacks Replacing Brake Components Brake Drums The brake drums should be replaced if they are damaged or exceed the drum manufacturers recommended maximum diameter or runout specification Refer to manufacturer brake drum guidelines for inspection and specifications Automatic Slack Adjuster The automatic slack adjusters are not serviceable and should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the automatic slack adjuster Brake Chambers The brake air chambers should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the brake air chambers Other Brake Components The brake shoe linings should be replaced when they are worn beyond the manufacturers limits When the brake linings are serviced other components such as the S cam rollers and return springs should also be serviced Refer to 51 the brake manufacturers guidelines for servicing the brakes Replacing the ABS Sensor and Tone Ring The anti lock brake system ABS of the vehicle should
51. his connection Connect the drag link to pitman arm AN CAUTION Tighten the castle nuts to the specified torque If the castle nuts are not tightened to the specified torque the parts will be damaged and serious personal injury may occur Tighten the castle nut at the steering and pitman arm connection to 130 150 Ibfeft See Torque Table 4 Install the cotter pins If necessary tighten the castle nut to align the hole 1n the ball stud and slots in the castle nut Do not loosen the castle nut to install the EY Sod I I 5 Lubricate the drag link See BENE Section 4 Lubrication and Maintenance Figure 23 Drag Link Ball Stud 6 Check for correct operation See Section 5 Alignment and A Adjustment CAUTION Do not strike the steering arm or the pitman arm Replacing the Relay Rod directly with a steel hammer Parts can break and cause and Outer Tie Rods serious personal injury Wear eye protection Preparation 1 Set the parking brake and block 4 Inspect the drag link and mating the drive wheels to prevent vehicle tapers See Section 3 If grease movement boot is damaged during removal replace it before installation 39 Section 6 Repair Removal 3 Connect the outer tie rod from the bell crank or idler steering arm 1 Remove the cotter pins from the and the steering knuckle See ball studs See Figure 24 Figure 24 2 Remove the castle nuts from the ball studs 3
52. ht control valve and movement linkage for damage Replace components as needed 2 Measure the ride height of the suspension The ride height should be 6 1 16 inches It is measured at the Inspection 1 Check shock absorber for oil leakage bent components missing or broken components excessive corrosion or worn bushings axle centerline and is the distance from the bottom of the chassis frame Replace shock if any of the above items 1s present Checking the Air Spring and Height Control Valve rail to the center of the wheel See Figure 12 An alternate measurement may be taken as the distance between the center of the shock mounts which should be 16 1 8 inches These measurements can be Preparation taken with the vehicle empty or 1 Set the parking brake and block eee the drive wheels to prevent vehicle 3 The actuation arm of the height movement control valve should be horizontal at ride height See Figures 13 14 and 15 See section 5 for adjusting to correct ride height 2 Refer to Firestone s Preventative Maintenance Checklist for additional air spring information Air Spring Inspection 1 Check the outside diameter of the Lr LGB air spring for irregular wear or RIDE HEIGHT heat checking 2 Check air lines to make sure contact does not exist between the air lines and the outside diameter of the air spring Re secure air lines to prevent contact as needed Check for air lin
53. indicator reading Mounting A reading greater than 040 will require ball joint replacement 3 Using a C clamp squeeze the knuckle and the upper control arm together to seat the ball joint See Figure 7 Do not apply excessive clamp load 3 Inspect ball joint seal for damage and replace the ball joint if damaged during measurement process Upper Ball Joint Axial End Play Inspection 4 Set the dial indicator on zero 1 Place a support under the tire or brake drum to position the suspension near its ride height The shock length at ride height is 16 12 2 Install a dial indicator with a fixed to the upper control arm 5 Release the clamp Place the pry Place the indicator tip on the bar between the upper control arm bottom of the upper ball joint base and steering knuckle See Figure See Figure 6 7 Do not allow the pry bar to contact the ball joint seal Firmly pry downward using the steering knuckle as a fulcrum to lower the upper control arm The pry load must not cause the tire or brake drum to be lifted off its support thus causing the suspension to change position 6 Record the dial indicator reading A reading greater than 040 will require ball joint replacement 16 Section 3 Inspection 7 Inspect ball joint seal for damage and replace the ball joint if damaged during measurement process Checking the Control Arm Bushings for Wear Preparation 1 Set the parking bra
54. jury Always use safety stands 3 Deflate the air springs Removal 1 Disconnect the air line at the air spring and remove the connection fitting 2 Remove the nuts and washers from the upper air spring mount studs See Figure 33 3 Remove the bolts that secure the air spring to the lower control arm See Figure 34 4 Remove the air spring Figure 33 Air Spring Upper Mount Figure 34 Air Spring Lower Mount 55 Installation 1 Assemble the air spring to the lower control arm Tighten the bolts to 30 40 Ibfeft See Torque Table 2 Assemble the nuts and washers that connect the air spring to the upper air spring mount on the subframe Tighten the nuts to 30 40 Ibfeft See Torque Table 3 Install the connection fitting into the air spring Use Permatex or equivalent thread sealant 4 Connect the air line to the air spring 5 Lower the vehicle frame and inflate the air springs 6 Check the air fittings for leaks Replacing the Steering Damper Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement Removal 1 Remove the mounting nuts from each end of the steering damper 2 Remove the steering damper Installation 1 Install the steering damper in the subframe and relay rod bracket mounts 2 Tighten the mounting nuts See Torque Table Section 6 Repair Replacing the Suspension Subframe When replacing the suspension s
55. ke and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Remove the tires NOTE If one of the bushings in a control arm is worn then both control arm bushings must be replaced It is recommended that the bushings in all of the control arms be replaced at the same time if one is worn Inspection 1 Check clearance between each control arm and subframe bushing mount See Figures 8 amp 9 Look for contact pattern as evidence of bushing wear Replace worn bushings in both control arm housings as needed Figure 8 Upper Control Arm Bushing Clearances Figure 9 Lower Control Arm Bushing Clearances 2 Check for bushing bulging between the control arm and subframe mount or presence of small rubber particles near subframe bushing mount 3 Check that the control arm mounting bolts are tight Recommended torque is 950 1050 Ibfeft on lower control arms and upper control arms without eccentric adapters installed The recommended torque for upper control arms with eccentric adapters installed is 460 490 Ibfeft See Torque Table A loose joint will res
56. ke linings are not a balanced set different friction codes or lining brand Loose or broken brake linings Brake drum out of round Defective brake drum Excessive dirt build up in brake drum cavity 13 1 2 3 4 5 6 7 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 7 Replace shock absorbers as needed Adjust ride height to specified setting Check wheel loads and correct as needed Check air line connections and remove obstructions Check air pressure and correct as needed Check and replace as needed Check and replace air spring as required Replace shock absorbers as needed Adjust ride height to specified setting Adjust tie rod lengths as required Inspect and adjust as required Check wheel turn angles and adjust as required Check connections with soapy water solution and repair or replace as needed Check height control valve and replace as required Check and tighten linkage as needed Check air spring and replace as needed Replace brake linings as required Deglaze brake linings or replace as required Replace brake linings as required Replace brake linings as required Re machine brake drum as required Inspect for defects and replace as required Remove excessive dirt from brake drum cavity Section 3 Inspection General Inspection Perform a thorough visual inspection of the suspension to ensure pro
57. late for adjustment Loosen the set screws 4 Rotate the eccentric adapters at the forward and rearward control arm mounts opposite one another as needed based on measured wheel caster The eccentric adapters at each control arm mount must have the same orientation 5 Tighten the adapter locknuts to 460 490 Ibfeft See Torque Table 6 Tighten the set screws to 30 40 Ibfein See Torque Table 7 Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 8 Re measure caster and readjust as needed Adjusting the Toe In AN WARNING Most tire wear is caused by incorrect toe in settings ReycoGranning does not recommend altering components to adjust the suspension toe in except the tie rod lengths Alteration of components may cause a vehicle accident and serious personal injury Toe is the relationship of the distance between the front and rear of the front tires When the front distance 1s less than the rear distance the wheels are toed in Toe in is designed into the suspension to counteract the tendency of the tires to toe out when the vehicle is driven straight 36 ahead Incorrect toe in can result in rapid tire wear 1 Measure the length of the outer tie rods If the lengths of the outer tie rods are not within 1 8 inch of each other follow steps 2 8 otherwise skip to step 10 Disconnect the drag link at the bell crank steering arm
58. le Section 6 Repair Lower Ball Joint Installation 1 Inspect the threads in the steering knuckle and remove any burrs or debris 2 Apply thread adhesive Loctite 242 or equivalent to the ball joint threads and thread the ball joint into the steering knuckle 3 Tighten the base of the ball joint to 525 575 lbfeft See Torque Table 4 Connect the ball joint to the lower control arm 5 Tighten the castle nut to 330 370 Ibfeft See Torque Table 6 Install the cotter pin If necessary tighten the castle nut to align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin Replacing the Bell Crank and Idler Steering Arm Bearings Replace the bell crank and idler steering arm bearings in sets The replacement bearings should be installed by pressing on the outer raceway only Pressing on the inner raceway will damage the bearing The inner grease cavity of the steering arms should be cleaned when the bearings are replaced Preparation 1 Follow the procedures for removal of the ball studs of the drag link relay rod and outer tie rods from the steering arms before replacing the bell crank and idler steering arm bearings Removal 1 Remove the pivot bolt that mounts the steering arm and remove the steering arm from the subframe 2 Remove the snap rings from the pivot sleeve and remove the sleeve A rubber or brass hammer may be used to remov
59. le of the tire with adapters Do not remove the bolts when the distance between the top of the 34 Section 5 Adjustments and Alignments engaged in control arm mounting plate for adjustment Loosen the set screws 4 Rotate each eccentric adapter to the same orientation as needed based on measured wheel camber The eccentric adapters at each control arm mount must have the same orientation 5 Tighten the adapter locknuts to 460 490 Ibfeft See Torque Table 6 Tighten the set screws to 30 40 Ibfein See Torque Table 7 Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 8 Re measure the camber and readjust as needed Adjusting the Caster Angle AN CAUTION ReycoGranning does not recommend adjusting the ride height or altering components to adjust the suspension caster Alteration of components may cause a vehicle accident and serious personal injury The caster angle 1s the angle from the vertical position to the axis defined by the ball joints when seen from the side of the vehicle When the top of ball joint axis is toward the rear of the vehicle then the caster is positive Positive caster creates a self aligning moment to stabilize the vehicle when driving straight ahead The caster is indirectly measured from the change in wheel camber as the wheel 35 is turned through a prescribed arc Therefore the calculated caster of
60. ly support the housing Inspect the housing bores and remove any burrs in the housing by honing Press the bushing into the control arm housing Be sure to properly support the housing Place the control arm in its mount location If not equipped with eccentrics install the control arm mount bolts into subframe snug tight and skip to step 15 46 10 11 12 13 14 15 16 17 18 Place bolt and washer through the spacer and bushing as shown Install washer and locking nut Repeat the process for the rear upper control arm mounting bolt Rotate the eccentric adapters on the front mounting bolt such that the set screws are located as previously orientated Vehicle alignment may have to be checked Please refer to Section 5 When the eccentric adapters are properly oriented tighten the bolts Support the control arm such that it is at ride height and tighten the bolts to 950 1050 Ibfeft without eccentrics or 460 490 Ibfeft with eccentrics See Torque Table Install and tighten the set screw on any eccentrics installed to 30 40 Ibfein Refer to Torque Table Reconnect the steering knuckle to the control arm if disconnected Follow the installation procedure in Replacing the Upper Ball Joint Section Reconnect the height control valve linkage Follow the installation procedure in Replacing the Height Control Valve Section Lower Control Arm 1 Disconnect the lower
61. ng brake to prevent vehicle movement NOTE An out of center steering gear can result in unequal turn angles The steering gear should remain centered during toe in adjustment NOTE Do not adjust the length of the drag link or tie rods to center the steering wheel This can cause the steering gear to become off center 3 Check that the steering gear 1s centered when the tires are steered straight ahead i e equal toe in Section 5 Adjustments and Alignments side to side Center the steering wheels is greater than the distance at the gear according to Spartan s ground A small amount of positive guidelines camber is built into the suspension because camber changes with load and 4 Measure and record the individual chassis roll wheel camber caster and toe in of the front suspension Also measure The camber of the suspension is affected and record the cross camber cross by the ride height of the suspension If the caster and overall toe in ride height is set too high then the camber measurement will be more positive See the Checking and Adjusting Suspension Ride Height sections before measuring camber The table below lists the recommended camber angles 5 If adjustment to camber and caster is required then follow the steps below Otherwise go to the Adjusting the Toe In section to adjust the toe in as needed 6 Raise the vehicle until the front Nominal Camber Values Degrees wheels ar
62. nnector pins of the sensor lead wire Set the volt meter to read AC voltage on a scale of 1V 10V 4 Spin the hub by hand and read the voltage output of the sensor A minimum reading of 8V AC is normal Skip to step 8 if minimum reading is obtained 5 Ifthe minimum reading is not obtained then check the volt meter connection and proximity of the sensor and tone ring The air gap between the sensor and tone ring should not exceed 027 Repeat step 4 6 If the minimum reading is not obtained check the tone ring for damage and its installation The tone ring should have a maximum runout of 008 Replace as needed and repeat step 4 7 Ifthe minimum reading is still not obtained then replace the sensor and repeat the installation procedure 8 Route and secure the sensor lead wire the same as the removed sensor 52 9 Connect the sensor lead wire to the chassis 10 Install the brake drum and tires Tone Ring Follow the hub manufacturers guidelines for removal and installation of the tone ring Replacing the Rebound Bumper Stop Both of the rebound bumper stops should be replaced at the same time if service on one bumper is required Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Deflate the suspension to provide access Removal 1 Turn the tire to provide access 2 Remove mounting fasteners and the rebound bumper stop Installation 1
63. nuing to the next step 6 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for reinstal lation Place the components in a location to prevent contamination Note that the hub cap window may be damaged by solvents NOTE When removing or installing the inner and outer spindle nuts use the correct wrench sockets to avoid damaging the nuts Do not use impact driver to tighten inner and outer nuts Only use a torque wrench to tighten the nuts 7 Unbend the retainer washer and remove the spindle outer nut retainer washer and locking washer Loosen the inner spindle nut 8 Seat the bearings by tightening the inner spindle nut to 180 Ibfeft while rotating the wheel in both directions 9 Rotate the hub and drum ten 10 complete revolutions 10 Loosen the inner spindle nut completely and then tighten the nut to 20 Ibfeft 11 Back off the inner spindle nut 1 4 turn 12 Install spindle locking washer NOTE If the dowel pin of the inner spindle nut and a hole in the locking washer are not aligned turn the locking washer over and re install If required loosen the inner spindle nut just enough for alignment 30 AN CAUTION Never tighten the inner spindle nut to align the dowel pin with hole in locking washer This can pre load the bearings and cause premature bearing failure 13 Install the retainer washer and outer spindle nut Tighten outer spindle nut
64. olutions These solutions will cause corrosion of the parts Rough Parts Rough parts can be cleaned with the ground and polished parts Rough parts also can be cleaned in hot solution tanks with a weak alkaline solution Parts should remain in the hot solution tanks until they are completely cleaned Drying Parts must be dried immediately after cleaning Dry parts with clean paper or rags or compressed air Do not dry bearings by spinning with compressed air Preventing Corrosion Apply a light oil to cleaned and dried parts that are not damaged and are to be immediately assembled Do NOT apply oil to the brake linings or the brake drums If the parts are to be stored apply a good corrosion preventative to all surfaces and place them inside special paper or containers that prevent corrosion Do Section 6 Repair NOT apply corrosion preventative to the brake linings or the brake drums Replacing the Drag Link Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Removal 1 Remove the cotter pins from the ball studs See Figure 23 2 Remove the castle nuts from the ball studs 3 Disconnect the drag link from the bell crank steering arm and the pitman arm The ball stud may be forced from the tapered hole by use of a suitable tool Installation 1 Connect the drag link to the bell crank steering arm See Figure 22 Note that the ball stud is smaller at t
65. om will not yield a true measurement of the end play 15 Measure the end play by simultaneously pushing pulling on each side of the hub while observing the dial indicator The end play is the total travel observed If the end play is not within 001 004 inch re adjust the wheel bearings per steps 7 11 Otherwise continue to step 16 18 19 Fill the hub cavity with the appropriate amount approx pint and type of lubricant 90W gear oil Check oil level through the hub cap window See Figure 30 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window Figure 30 Wheel Bearing Oil Level 20 Install the hub cap drain plug 21 Check the hub cap for external oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the Figure 29 Wheel End Play Measurement 16 Bend the spindle washer over one wrench flat of the outer nut 17 Install the hub cap gasket and hub gasket The vent plug will cap Tighten the cap screws to 20 normally weep a small amount of 30 Ibfeft See Torque Table for oil e id 22 Install t
66. ot alter length when disconnecting 3 Loosen clamp on vertical link of the height control linkage to be adjusted 4 Adjust the length of the vertical link to achieve specified ride height If the measured distance is less than 16 1 8 inches then decrease the length of the vertical link If the measured distance is more than 16 1 8 inches then increase the length of the vertical link Wait 30 seconds for suspension to settle after adjusting to verify correct adjustment NOTE The horizontal link must remain horizontal during adjustment to ensure proper operation of the height control valve Tighten the clamp on vertical link 6 Reconnect the height control valve linkage on the other side and repeat steps 2 4 for the opposite side as needed 7 Verify that the ride height is correct on both sides NOTE The height control valves must be adjusted individually Section 5 Adjustments and Alignments Height Control Valve Adjustment 1 Measure the distance between the centers of the shock mounts If the distance is not within 16 1 8 1 8 inches then adjust as follows Disconnect height control valve linkage on the opposite side and allow the air spring to deflate by rotating the height control valve arm down Do not alter length when disconnecting Loosen adjusting bolt see Figures 19 and 20 on actuation arm Rotate the actuation arm to achieve specified ride height Wait 30 seconds
67. ped hole 3 Install cotter pin after tightening 59 Section 7 Torque Specifications Torque Table 1 Cont APPLICATIONS FASTENER SIZE TORQUE SPECIFICATION LBFeFT CLEAN AND DRY Height Control Valve Control Arm Pivot Set Bolt 5 16 18 Grade 2 60 80 Ibf in Height Control Valve Linkage Clamp Screw Tighten clamp until rod is tight 1 Torque applied to bolt head 2 Apply thread adhesive Loctite 242 or equivalent to threads of fastener threaded into tapped hole 3 Install cotter pin after tightening Torque Table 2 APPLICATIONS FASTENER SIZE TORQUE SPEC TORQUE SEQUENCE LBFeFT CLEAN AND DRY Steering Damper Tie Rod Mount Lock Nut 9 924 Grade 5 Brake Spider Mount Cap 5 8 18 Grade 8 170 190 52 Screw Hub Cap Bolt 5 16 18 Grade 5 20 30 1 1 8 16 Stud Piloted 450 500 Wheel Nut M22x1 5 Dry Threads Hub Piloted 1 Torque applied to bolt head 2 Apply thread adhesive Loctite 242 or equivalent to threads of fastener threaded into tapped hole 3 Recheck wheel nut torque after first 50 100 miles 60 Section 8 Special Ball Joint Tools To install or remove upper and lower ball joints ReycoGranning Air Suspensions recommends the use of the following special tools l ME N J Lower Ball Joint Special Tool Part Number A7250B a Recommended Ball Joint Puller Snap On Bar Type CJ Pullers 4 3 8 Jaws 3 4 16x4 1 4 Pressure Screw 3 1 2 to
68. per assembly and to identify broken parts and loose fasteners each time the vehicle suspension is serviced Do the following during an inspection Wheel Alignment Follow the guidelines in Section 5 for wheel alignment inspection intervals Check wheel alignment if excessive steering effort vehicle wander or abnormal tire wear is evident Fasteners Check that all the fasteners are tightened to the proper tightening torque Use a calibrated torque wrench to check torque Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all worn or damaged components Operation Check that all components move freely through the complete turning arc AN CAUTION ReycoGranning recommends replacing any damaged or out of specification components Reconditioning or field repairs of major front suspension components is not allowed Note Refer to Section 1 for identification of components 14 AN CAUTION All cast components are heat treated These com ponents cannot be bent welded heated or repaired in any way without reducing the strength or life of the component voiding the warranty and may cause a vehicle accident which can result in serious personal injury Checking the Ball Joint Seal and Axial End Play Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Steer the front wheels str
69. propriate tools be used to remove the ball stud 41 taper from the control arms and to remove the ball joints from the steering knuckle A suspension alignment should be performed after ball joint replacement NOTE Be careful to not displace or damage ball joint seals during removal from the control arm taper hole Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Remove the tires and check that the air springs are deflated Upper Ball Joint Removal Press In Mount 1 Remove the cotter pin from the ball stud 2 Remove the castle nut from the ball stud Section 6 Repair AN WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm 3 Disconnect the upper control arm The ball stud may be forced from the tapered hole by use of a suitable tool Figure 26 Press In Mount Upper Ball AN CAUTION Do not strike the Joint Retainer Clips upper control arm directly with a steel hammer Parts can b
70. reak and cause serious personal injury Wear eye protection 4 Inspect the ball joint taper and upper control arm tapered hole If abnormal wear exists on the ball stud taper or in the tapered hole replace the upper control arm 5 Loosen socket head cap screws and remove the retainer clips See Figure 26 6 Place support under steering knuckle upper ball joint mount Press upper ball joint out of steering knuckle by applying load Figure 27 Press In Mount Upper Ball to the bottom of its base See Joint Removal Figure 27 Upper Ball Joint Removal Thread In Mount 1 Follow steps 1 4 for press in mount type 2 Secure steering knuckle in a vise or similar device Loosen the ball joint and remove it from the steering knuckle 42 Section 6 Repair Upper Ball Joint Installation Press In Mount lis Inspect ball joint bore in the steering knuckle and remove any burrs by honing Place the new ball joint into a support tube such that it 1s supported only by the step diameter Align the upper ball joint bore of the steering knuckle with the ball joint Press the steering knuckle onto the ball joint until the step diameter is seated against the steering knuckle Install the retainer clips and socket head cap screws Tighten the socket head cap screws to 15 20 Ibfeft See Torque Table Connect the ball joint to the upper control arm Tighten the castle nut to 155 170 Ibfef
71. red loosen the inner spindle nut just enough for alignment 2 Place the replacement inner bearing P N 1784 onto spindle with small end of taper facing outward Seat the inner race against the step of the spindle 3 Press the ABS sensor outward about 4 Do not use a sharp tool AN CAUTION Never tighten the on lead wire end of the sensor See inner spindle nut to align the section 3 for the inspection of ABS dowel pin with hole in locking sensor as needed washer This can pre load the 4 Place the hub onto the spindle bearings and cause premature until it seats on the inner bearing bearing failure Do not ram the hub onto the seal 12 Install the replacement spindle 5 Place the replacement outer washer BIN 6259 ane the eurer bearing onto the spindle until it seats on the outer cup in the hub The inner spindle nut may be used to guide the bearing onto the spindle The hub should be supported to prevent misalignment and binding 49 13 spindle nut Tighten the outer spindle nut to 200 300 Ibfeft See Torque Table for sequence Attach a dial indicator with a magnetic base to the face of the hub See Figure 29 Note the brake drum is shown for reference only Section 6 Repair 14 Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero NOTE Do not push pull at the top and the bottom of the hub Pushing or pulling at the top and the bott
72. resence of oil wetting The entire outer seal surface should be dry Use a mechanics mirror and flashlight to ATA inspect the entire seal Use a blunt 313 object as needed to inspect between seal convolutes Figure 4 Lower Ball Joint Dial Indicator Mounting 2 If oil wetting is found then inspect the entire wet area to confirm the 3 Using a C clamp squeeze the seal has a rupture s and oil source knuckle and the lower control arm is from internal grease leaking together to seat the ball joint See from the ball joint If seal is Figure 5 Do not apply excessive ruptured then the ball joint must clamp load be replaced 4 Set the dial indicator on zero 3 Skip ball joint end play measurement NOTE Care must be taken to not damage ball joint seals during inspection Seals that are ruptured during inspection must be replaced Do not apply excessive force to pry ball joints Figure 5 Ball Joint Pry Bar Locations 15 Section 3 Inspection 0 Release the clamp Place the pry bar between the lower control arm and steering knuckle See Fig 4 Do not allow the pry bar to contact the ball joint seal 1 Firmly pry downward using the steering knuckle as a fulcrum to lift the lower control arm The pry load must not cause the tire or brake drum to be lifted off its support thus causing the suspension to change position Figure 6 Upper Ball Joint Dial Indicator 2 Record the dial
73. stall correct tire and wheel combination Install correct tire and wheel combination Install correct tire and wheel combination Put specified air pressure in tires Adjust tie rod lengths as required Check steering arm bearings and lubricate as needed Inspect ball joints for wear and replace as required Inspect tie rod ends for wear and lubricate as needed Align or adjust as required Check steering miter box and repair or replace as required Inspect repair or replace as required Check and replace as needed 10 11 12 Align or adjust as required 13 Add fluid tighten connections and correct as needed 14 Conduct pump flow and relief pressure tests and adjust repair or replace as needed 15 Air in power steering system 15 Add fluid tighten connections and bleed system 16 Contaminated or incorrect fluid 16 Replace with correctly specified fluid 17 Obstruction within steering gear or 17 Inspect remove obstruction s and lines repair or replace as required 18 Excessive internal steering gear 18 Inspect repair or replace as required leakage 10 Section 2 Troubleshooting Suspension System General Cont d POSSIBLECAUSES REMEDIES SYMPTOMS Vehicle wanders side to side loose steering Steering wheel has large amplitude rotational oscillations when hitting large bumps Vehicle pulls to one side without the brakes applied Vehicle overloaded
74. t See Torque Table Install the cotter pin If necessary tighten the castle nut to align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin Upper Ball Joint Installation Thread In Mount 1 Inspect the threads in the steering knuckle and remove any burrs or debris Apply thread adhesive Loctite 242 or equivalent to the ball joint threads and thread the ball joint into the steering knuckle Tighten the base of the ball joint to 325 375 lbfeft See Torque Table 43 4 Follow steps 6 8 for press in mount type Lower Ball Joint Removal 1 3 Remove the cotter pin from the ball stud Remove the castle nut from the ball stud AN WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm Disconnect the lower control arm The ball stud may be forced from the tapered hole by use of a suitable tool AN CAUTION Do not strike the lower control arm directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection Inspect the ball joint taper and upper control arm tapered hole If abnormal wear exists on the ball stud taper or in the tapered hole replace the lower control arm Secure steering knuckle in a vise or similar device Loosen the ball joint and remove it from the steering knuck
75. the wheel is affected by the ride height of the suspension See the Checking and Adjusting Suspension Ride Height sections before measuring caster The table below lists the recommended caster angles Nominal Caster Values Degrees 3 1 2 3 41 2 3 1 2 4 1 2 3 1 2 1 2 The set screw in the eccentric adapter denotes the orientation of the eccentricity of the adapter When the set screw is in the 6 o clock or 12 o clock position then the adapter is in the neutral position There are two adapters at each control arm mount and they must be oriented the same When the set screws in the forward control arm mount are oriented closer to the frame rail and the set screws in the rearward control arm mount are oriented farther from the frame rail the wheel caster becomes more positive When the set screws in the forward control arm mount are oriented farther from the frame rail and the set screws in the rearward control arm mount are oriented closer to the frame rail the wheel caster becomes more negative The eccentric adapters at both upper control arm mounts must be oriented opposite each other to affect caster 1 Turn the wheel to provide access to the upper control arm mount 2 Loosen both upper control arm mounting bolts at the eccentric adapters Do not remove the bolts because the adapters must remain Section 5 Adjustments and Alignments engaged in control arm mounting p
76. the inner sleeve See Figure 28 9 Place the steering arm in its mount and install the pivot bolt Tighten the pivot bolt lock nut to 350 Ibfeft See Torque Table 10 Follow the procedures for installation of the drag link relay rod and outer tie rods Inner Race Retaining Ring Inner Sleeve Check Shim Height Here Figure 28 Location of Shims Replacing the Upper and Lower Control Arm Bushings The subframe control arm mounts may require widening to accommodate replacement bushings The width may be increased by inserting a suitable jack between the bushing mounts and cold bending the mounts Care must be taken to not exceed 5 00 width after widening 45 The control arm mounts should be inspected for damage Both control arm bushings and mounting fasteners must be replaced in a control arm when bushings are serviced ReycoGranning recommends replacing the control arm bushings and mounting fasteners in all of the control arms at the same time The control arm housings must be properly supported during bushing removal The bores of the control arm housings may be honed to remove any burrs If the control arm is to be separated from the steering knuckle follow the removal and installation procedures in the Replacing the Ball Joint Section AN CAUTION Use of a cutting torch to remove control arm bolts will permanently damage control arm bushings and can result in damage to subfram
77. tional recommendations and specifications from the manufacturer of the chassis on rear axles and suspensions NOTE Total vehicle alignment is recommended when aligning the front suspension Front Wheel Alignment Equipment Granning recommends that suitable alignment equipment be used to measure the wheel alignment characteristics camber caster and toe in The alignment equipment must be properly calibrated for accurate measurements Only qualified personnel should conduct the wheel alignment measurements General 33 The overall toe in of the front wheels should be checked every 24 000 miles or 2 years When the vehicle does not steer correctly or the front tires develop an abnormal tire wear pattern the camber caster and toe in should be measured and adjusted as needed Toe in typically has the largest effect on tire wear The maximum wheel turn angle should be checked and adjusted as needed Eccentric adapters may or may not be installed in left or right hand upper control arm mounts The purpose of the adapters is to provide additional adjustment of camber and caster to minimize vehicle drifts or pulls to one side of the road The eccentric adapters must be installed in the upper control arm mounts to adjust the camber and or caster of the respective wheel Preparation 1 Follow the manufacturer s procedures for preparing the vehicle for front and rear wheel alignment measurements 2 Setthe parki
78. to 200 300 Ibfeft See Torque Table 14 Verify that wheel end play is between 001 004 1nch See step 3 If not repeat by altering amount of inner nut back off until end play is achieved 15 Bend retainer washer over one wrench flat of the outer nut 16 Install hub cap gasket and hub cap Tighten the cap screws to 20 30 Ibfeft See Torque Table Replace the hub cap vent plug if removed in Preparation step 5 17 Fill the hub cavity with the appropriate amount and type of lubricant See Section 4 for lubricant specifications 18 Install vent plug Adjusting the Maximum Turn Angle AN CAUTION See Table 5 1 for the proper turn angle Do not exceed this set angle Mis adjustment of the turn angle can cause damage to steering system components Check the turn angle if the front tires rub against the frame suspension body or if Section 5 Adjustments and Alignments the steering gear has been serviced Use an alignment machine to check the angle See the procedure of the alignment machine manufacturer The steering stop bolt on the suspension subframe controls the maximum turn angle If the stop bolt 1s missing bent or broken replace the stop bolt s or jam nut s and follow the procedure below for adjustment Inspect other suspension components for damage In the course of adjusting the steering stop s the steering gear poppet valves may require readjustment Refer to TRW s TAS Steering
79. ubframe use the proper size and grade fasteners The subframe may be removed from and installed to the chassis frame with suspension fully assembled Preparation 1 Setthe parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms or the suspension subframe to support the vehicle AN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Remove the tires and deflate the air springs Removal 1 Disconnect the drag link 2 Disconnect the air lines to the height control valves and brakes 3 Disconnect the ABS sensor lead wire 4 Support the bottom of the subframe with a suitable jack or lift mechanism 5 Remove fasteners connecting the subframe to the chassis frame rail 56 6 Lower the subframe from the chassis frame rails and remove from the chassis 7 Remove all other suspension components from the subframe See the appropriate section for removal of each component Installation 1 Install all other suspension components to the subframe See the appropriate section for installation of each component 2 Place the subframe under the chassis and raise it into location on the chassis frame rails 3 Connect
80. ult in wear between the bushing inner sleeve and subframe mount Section 3 Inspection Checking the Tie Rod Ends Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement AN WARNING Do not use a wrench or other object to apply leverage when inspecting tie rod end sockets Applying leverage can yield incorrect results and damage components Component damage can lead to the loss of Steering control Inspection 1 With the engine on lightly rock the steering wheel and observe any looseness in the two mating tapers or any movement of the stud nut at both ends of the tie rod See Figure 10 If looseness 1s found in either place go to step 2 otherwise skip to step 3 2 Remove the tie rod end ball stud from the taper mount and visually inspect both If either of the mating tapers show distortion or wear then both components must be replaced Torque tie rod castle nuts to 130 150 Ibfeft See Torque Table 3 With the engine off and the wheels steered straight ahead grab the tie rod near its end and try to move the socket in a direction parallel to the ball stud axis See Figure 10 Be sure to only apply hand pressure to the tie rod 18 4 Measure the axial movement with a scale If the movement is greater than 1 8 inch 8mm replace the tie rod end immediately If the socket moves but the movement is less than 1 8 inch 3mm then the tie rod end should be replace
81. ushing from the eye Discard the bushing 53 4 Pry the inner shock eye bushing from the eye and remove the shock absorber Discard the bushing Installation 1 Check that the upper and lower shock mount studs are properly tightened The lower stud should be tightened at 200 225 Ibfeft If the lower shock mount stud was loosened from the lower control arm LCA during shock removal then remove the stud from the LCA apply Loctite 242 or equivalent to the threads which thread into the LCA and torque to 200 225 Ibfeft The upper flange lock nut 3 4 10 should be tightened to 200 225 Ibfeft If the upper shock mount stud was loosened from the subframe during removal then re torque to 200 225 Ibfeft See Torque Table 2 Place the inside retaining washers shock sleeves and the inside shock eye bushings on the upper and lower shock mount Note the orientation of the washer and bushing See Figure 31 3 Install the shock on the shock mounts 4 Place the outside shock eye bushings and the outside retaining washers on the upper and lower shock mount Note the orientation of the washer and bushing See Figure 31 5 Install the upper and lower 3 4 10 lock nuts and tighten to 90 110 Ibfeft See Torque Table Section 6 Repair ajo mom gJcap C mcm Figure 31 Shock Absorber Mount Removal Bolt Mount Versions 1 Loosen and remove the 3 4 10 lower shock absorber mount bolt from the lower
82. y tighten the castle nut to 40 Section 6 Repair align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin 6 Lubricate the relay rod and or outer tie rod See Section 4 Lubrication and Maintenance 7 Check for correct operation See Section 5 Alignment and Adjustment Replacing the Ball Joints Ball joints may be replaced individually however it is recommended to replace upper and lower ball joints at the same time The ball joints cannot be rebuilt or repaired Press In Mount The pressed in mount type of upper ball joint is installed by pressing the base of the ball joint into the steering knuckle and securing the base with retainer clips The steering knuckle should be properly supported during removal of the upper ball joint The upper ball joint should be properly supported during installation of the ball joint Thread In Mount The thread in mount type upper and lower ball joints are installed with a thread adhesive and may require the threads to be warmed to ease removal If heat is applied to the ball joint threads the steering knuckle temperature must not exceed 300 F and the heat should be applied at the bottom of the ball joint base only Applying heat to the ball joint will damage the ball joint by destroying the ball stud seal permanently degrading the lubricant and restricting ball stud movement It is recommended that the ap

IFS 1200/1320/1370 I&M Manual

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IFS 1200/1320/1370 I&amp;M Manual

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IFS 1200/1320/1370 I&M Manual