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IFS1460S-JT I&M Manual

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1. 1 703181 01 Upper Control Arm LH amp RH 8382 Bushin 2 700939 01 Lower Control Arm LH amp RH Steering Components Item Part No Description item Part No Description 1 700973 01 Tie Rod Assembly LH 11 705382 02 Slotted Nut M20x1 5 700973 02 Tie Rod Assembly RH 705382 03 Cotter Pin 1 40 x 15 Dia 3 700975 01 Bell Crank 13 101445 PI Cotter Pin 1 8 X 1 1 2 KH 705620 01 Idler Arm Assembly H 6966 Snap Ring 5 701925 01 Crank Arm 15 8654 Shim 6 700973 03 Crank Rod Assembly 16 701378 01 Bearing 7 167 Hex Head Bolt 1 14 x 6 Gr 8 17 705382 01 Ball Joint 40mm 8 257 Hardened Flat Washer 1 18 7348 Spacer 9 702030 01 Relay Rod 19 701924 01 Crank Arm Assembly 10 89422312 Lock Nut 1 Gr C 20 705619 01 Bell Crank Assembly Components are the same in Bell Crank Idler Arm and Crank Arm Components of Ball Joint Kit K705382 12 Tie Rod Assemblies 1 103712 Tie Rod End RH 5 101445 P1 Cotter Pin 2 6632 Clamp 6 105564 Tie Rod End LH 3 700971 01 Tube Tie Rod 7 700971 02 Tube Link 4 103736 Tie Rod End LH 8 8455 Tie Rod End RH 13 Air Spring and Shock Components Item Part No Description item PartNo Description 1 705951 01 Air Spring A
2. MR Ww 702836 01 702618 01 Split Collar 702619 01 Outer Collar 702620 01 Retaining Ring 6 702623 01 Shim 004 13 7352 Grease Zerk Hydraulic Shutoff Left Hand Steering Knuckle Carrier Shown 18 Lubrication Lubricant Specifications and Intervals COMPONENT SERVICE INTERVAL Ball Studs on Ends of Tie Rods Crank Rod Drag Link CHANGE INTERVAL Which ever comes first 50 000 miles 80 000 kilometers or once a year N A LUBRICANT SPECIFICATION Multi Purpose Chassis Grease NLGI Grade 1 or 2 Lithium Base Multi Purpose Chassis Grease Adjuster Wheel End kilometers or once a year Which ever comes first Seals replaced brakes relined 100 000 miles 160 000 km or once a year 1000 miles 1600 kilometers Check fluid level 1 Moly disulfide type grease is not recommended since it may lower friction capabilities in t automatic slack adjuster General Lubrication Proper lubrication practices are important in maximizing the service life of your ReycoGranning Independent Front Suspension Kingpin Which ever comes first 50 000 miles 80 000 kilometers or N A E once a year NLGI Grade 1 or 2 Lithium Base Carrier Bearings Which ever comes first 50 000 Mobillith AW2 miles 80 000 kilometers or N A Amoco L Industrial 861 once a year Exxon Ronex MP Brake S Cam Tube Which ever comes first Brakes and Automatic Slack relined 50 000 miles
3. Do not push pull at the top and the bottom of the tire drum or hub Pushing or pulling at the top and the bottom will not yield a true measurement of the endplay 6 Measure the endplay by simultaneously pushing pulling on each side of the tire drum or hub while observing the dial indicator The endplay is the total travel observed If the endplay is not within 001 004 see the section on adjusting the wheel bearing endplay Inspecting the Knuckle Carrier Bearing and Seal 1 Inspect the seals for damage 2 Place the magnetic base of a dial indicator on the knuckle carrier and position the tip of the dial on the end of the bar pin such that axial movement can be measured Set the dial indicator to 0 zero 4 Place a pry bar between the control arm and carrier and pry to measure axial movement of the bar pin Do not pry on seal Measure and record the dial indicator reading 5 Ifthe axial endplay is more than 0 inch then replace the carrier bearings See repair section on knuckle carrier Inspecting the Kingpin Vertical Endplay 1 Turn the tire straight ahead 2 Place the magnetic base of a dial indicator on the knuckle carrier and position the tip of the dial on top of the king pin bearing cap such that vertical movement can be measured 3 Place a portable jack and a suitable block one with clearance for the grease fitting under the lower king pin grease cap area 4 Set the di
4. Idler Arm Bell Crank amp Crank Arm Mount Lock Bolt 1 14 Grade 8 Idler Arm amp Bell Crank Ball Joint Base M56x1 5 575 625 325 375 Idier Arm amp Bell Crank Ball Joint Castle Nut M20x1 5 Tie Rod Castle Nut 7 8 14 155 170 90 100 Tie Rod Clamp Nut Upper Shock Eye Mount Lock Nut 5 8 11 Grade B 3 4 10 Grade C 50 60 170 190 Lower Shock Eye Mount Lock Nut 3 4 10 Grade C 170 190 Lower Shock Mount Bracket Bolt 3 8 16 Grade 8 Steering Stop Adapter 3 4 10 30 40 85 115 1 2 20 Grade B 1 1 8 12 Grade C Steering Stop Jam Nut Steering Arm Castle Nut 50 75 550 1025 Sway Bar Upper Control Arm Bracket Nut 1 2 13 Grade C Kingpin Draw Key Nut 7 16 20 Grade G 75 85 30 45 Kingpin Cap Bolt 5 16 18 Grade 8 Spindle Nut 1 1 2 18 20 3077 See Adjusting the Wheel Bearings Section 1 1 2 12 M20x2 5 Spindle Outer Nut Disc Brake Caliper Mount Screw 200 300 300 330 1 Torque applied to bolt head 2 Apply thread adhesive Loctite 242 or equivalent to threads of fastener threaded 3 Install cotter pin after tightening 4 Apply thread adhesive Loctite 271 or equivalent to threads of fastener threaded 57 into tapped hole into tapped hole Torque Tables Torque Table 2 APPLICATIONS FASTENER SIZE TORQUE SPEC TORQUE SEQUENCE ft lb CLEAN AND DRY Brake Spider and Torque Plate Mount Capscrews 5 8 18 Grade 8 170 190 Driver
5. 80 000 NA Mult Purpose Chassis Grease NLGI Grade 1 or 2 Lithium Base Gear Oil SAE 80W 90 or equivalent he adjusting clutch parts of the Ball Joints The ball joints are lubricated and sealed for their service life and do not require lubrication Check for oil or grease marks on the exterior of the seal and if found verify that the seal has not been ruptured Z CAUTION Do not mix lubricants of different grades Do not mix mineral and synthetic lubricants Different brands of the same grade may be mixed re lubricated Crank Ro Link Z CAUTION Never mix oil bath and grease packed wheel ends interval requ Apply lubric If the seal has been ruptured then the ball joint must be replaced because it cannot be Ball Studs on Tie Rods d and Drag Review lubricant specification and irements before servicing ant to grease fitting until new lubricant discharges from the dust boot Figure 4 19 Brake S Cam Tube and Automatic Slack Adjuster 1 Review lubricant specification and interval requirements before servicing 2 Apply lubricant to the S cam tube until new lubricant discharges from the S camshaft bushing seal next to the automatic slack adjuster Figure 4 Grease Fittings Figure 4 Location of lubrication fittings 20 Apply lubricant to the automatic slack adjuster until new lubricant discharges from the cone clutch adjacent th
6. Steering stops mis algined Adjust as necessary Tie rod clamps positioned improperly Check orientation and adjust as needed Air leak Check connections with soapy water solution and repair or replace as needed Internal leak in height control valve Check height control valve and replace as Suspension does not required maintain ride height Height control valve linkage loose l Check and tighten linkage as needed l Air spring chafed or worn l Check air spring and replace as needed l Vehicle system pressure too low Check air pressure and correct as needed Grease oil or dirt on brake pads Replace brake pads as required Brake pads are glazed Deglaze brake pads by burnishing or replace as required i Brake pads are not a balanced set Replace brake pads as required Brakes are noisy different friction codes or pad brand Brake rotor warped Re machine brake rotor as required Defective brake rotor Inspect for defects and replace as required Refer to Bendix Disc Brakes manual Y006471 for troubleshooting of the disc brakes or contact Customer service at 1 800 247 2725 25 Inspection General Inspection Perform a thorough visual inspection of the suspension to ensure proper 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 the Front Wheel Alignment section for wheel a
7. extend due to internal gas charge Rotate bar pin to provide clearance with mounting bracket 5 Note orientation of eccentric adapters for installation 48 Loosen and remove control arm mounting locknuts Support control arm and remove control arm mounting bolts Retain eccentric adapters for installation Remove the control arm Remove spacer tubes from bushings and retain for installation Press the bushings out of the housings Support the housing properly Lower Control Arm Installation Inspect the housing bores and remove any burrs in the housing bores by honing Press the bushings into the housings using a suitable tool to apply pressure to only the outer metal of the bushing Support the housing properly Install the spacer tubes in bushings Place the control arm in its mount location Install the control arm eccentric adapters and mounting hardware and tighten snugly Orient the eccentric adapters the same as before removal Orient the control arm at suspension ride height and tighten the bolts to 460 490 ft Ib See Torque Table Note orientation of bar pin in carrier bearing Lower the jack to align the bar pin with the control arm Apply Loctite 242 to mounting bolt threads and tighten to 350 375 ft Ib See Torque Table Compress shock absorber and connect the lower bar pin mount to the lower shock bracket using the mounting hardware Tighten the nuts to 30 40 ft Ib See Torq
8. vertical link and the horizontal arm of the height control valve 1 Park the vehicle on a level surface 2 Exhaust or dump and re inflate the air suspension Allow the Suspension to settle 3 Check ride height of rear suspension A On vehicles with front suspension equipped with 2 height control valves check and adjust the rear suspension first B On vehicles with front suspension equipped with a single height control valve check and adjust the rear suspension after finish adjusting the front 4 Measure either the wheel center to bottom of frame A or air spring height B If the dimensions are not within 1 8 of measurements in Figure 11 adjust as follows A Loosen the height control valve linkage stud retaining nuts B Raise or lower the L shaped linkage stud as necessary 5 C Tighten the retaining nuts Note It is recommended that the upper and lower studs be positioned parallel to each other Torque to 8 12 ft lb After adjusting the length it is recommended to dump and re inflate the air suspension to obtain the ride height Allow the suspension to settle 6 Ifnot already completed adjust the rear suspension per manufacturer s recommendations Verify at each axle that the side to side ride heights are within 25 of each other 32 Adjustments Adjusting Wheel End Play 1 Secure the vehicle by setting the parking brake and block the drive wheels to
9. while maintaining equal toe in side to side 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 Check that the steering gear is centered and the tires are steered straight ahead with equal toe in side to side If either ofthese two conditions is not met then adjust toe in first before centering the steering gear See Adjusting the Toe In Section 4 Check that the lengths of the outer tie rods are equal to each other within 1 8 inch If not adjust lengths according to the adjusting the toe in section before adjusting the steering stops Turn the steering wheel until the steering stop bolt contacts the knuckle carrier or the steering wheel stops turning Measure the turn angle of the wheel on the same side as the direction of turn 6 Ifthe wheel turn angle differs from guidelines then adjust as follows 7 Loosen the jam nut on the stop bolt 8 Turn the stop bolt until the specified wheel turn angle is achieved and the bolt head contacts the knuckle carrier 9 Tighten the jam nut to 50 75 ft Ib See Torque Table Z CAUTION After readjusting the steering stop s check that the steering poppets are reset properly and that the front tires do not contact the frame suspension or body Also check that other components are not abnormally contacting one another 10 Repeat checking and adjustment for turning the opposi
10. CPU or system malfunction ABS sensor electrical connection faulty Inspect ABS sensor installation and replace sensor as required Front tires lock up during hard braking or ABS malfunction light remains lit Check and repair or replace as required Check ABS sensor connection and lead wire Tone ring on hub damaged Check for damage and replace as required 24 SYMPTOMS PossieLE CAUSES REMEDIES Front shock absorbers worn Replace shock absorbers as needed Vehicle ride is too harsh Incorrect ride height Adjust ride height to specified setting and or suspension contacts Vehicle overloaded stops excessively Check wheel loads and correct as needed Air spring supply lines leaking or Check air line connections and remove obstructed obstructions Vehicle system air pressure below Check air pressure and correct as needed specification Jounce bumper in air spring worn or Check and replace air spring as required broken ridi Front shock absorbers worn Replace shock absorbers as needed Vehicle ride is too soft 1 1 Incorrect ride height Adjust ride height to specified setting Loose or broken brake pads Replace brake pads as required Incorrect steering arm geometry Adjust tie rod lengths as required Vehicle has unequal turning Steering gear not centered Inspect and adjust as required radius right to left
11. Installation EE 50 Replacing Brake Components eurer 51 Brake Chambers siy erea ie bete E E e aa aAa LU i Ata 51 Other Brake Components lalla SI Replacing the ABS Sensor and Tone Ring SI Sensor Remoy l m T 52 Sensor Installation rn es ieri 52 Tone Ring RemovalandInstallation ana a ar 22 Replacing the ShoekADSOPDGE rele 52 Removal toner lie 52 Installation RICA ORO tiu tuta A ee ee 53 Replacing the Air Spring ret iaia 53 Removal NUN e 53 I taal Ott m aE 53 Replacing the Sway Bar and Components sse 53 Vertical Linkage Removal anna ea ie 33 Vertical Linkage Installatiot un dalia iti 53 Replacing the Steering Knuckle Carrier Bearings n 54 Riina deal ei 54 Installation ER 54 Torque Dables iodsvestebeeeeees eese e ea eei Cue and Introduction Service Notes This Service Manual describes the correct service and repair procedures for the ReycoGranning IFS1460 Independent Front Suspension model with 14 600 Ib Gross Axle Weight Rating GAWR Overloading the suspension may result in adverse ride and handling characteristics You must read and understand all procedures and safety precautions presented in this manual before conducting any service work on the suspension Proper tools must be used to perform the maintenance and repair procedures in this manual Some procedures
12. Preparati otier rai dead ee E 37 Adjusting the Camber Angler arretra agi 38 Eccentric Camber Adjustment s sites eei etie rete essen ieii ta Sadi nie 38 BarPanCamberAdjusiment eretica ata 39 Adjusting the Caster Angle ea ea a la 40 Eccentrie Caster Adjustment u a aa la do de e d 4 Adjusinp the Toe Mewes rallo 42 RepDalbS 2o lla lai General Procedures risata iano ii 43 Cleaning theater 43 Ground or Polished Partsi fellatio leali 43 Roush PAIS MT liacle Mailing un 44 BLUE C um pA S IR E E Ex LM UM MAIS 44 Preventing OPO SION E sensu p A e diat cup oe tecto osa 44 Replacimg Tie Bod Ends nennen 44 Removal se aloni ME CE area adh nat Neca A AENEA 44 Installation cesis outdated de tau ollare dadini 44 Replacing the Steering Arm Ball Joints essere 45 Romuvibs acu sio 3 0 nd Eo cub lo e ut lillo MU 45 Installation ers LEE TR 45 Replacing the Bell Crank Idler and Crank Steering Arm Bearings 45 JE aa VA e L AE 46 Histaan oneen poco ld o i DU ta onum DI 46 Replacing the Upper and Lower Control Arm Bushings 46 Upper Control Arm Remoaval iude at doa ee 47 Upper Control Arm Installations en ze NE 47 Lower Control Arm Removals ti teet o elle 48 Table of Contents Lower Control Arm Installation e ederet ee eat 48 Replacing Wheel Bearings Oil Seals and Hub Caps 49 Removal iu ah TR RUN RAT SO ade Ws aoe aes pas We dea 49
13. Using a C clamp squeeze the relay arm and the steering arm together to seat the ball joint Do not apply excessive clamp load Set the dial indicator on zero 4 Release the clamp Place the pry bar between the steering arm and relay arm Do not allow the pry bar to contact the ball joint seal Firmly pry upward using the steering arm as a fulcrum to lift the relay arm The pry load must not cause the relay arm to rotate thus causing the relay to change orientation 5 Record the dial indicator reading A reading greater than 040 will require ball joint replacement 6 Inspect ball joint seal for damage and replace the ball joint if damaged during measurement process Inspecting Wheel Bearing Endplay 1 Ifthe tire and wheel are not removed make sure all the wheel nuts are tightened to the specified torque of 450 500 ft Ib See Torque Table 2 Ifthe tire and wheel are removed recommended for aluminum wheels secure the brake drum to the hub with the wheel nuts or remove the brake drum 3 Remove the vent plug from the hubcap 30 4 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 the wheel is removed 5 Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero Figure 10 Figure 10 Wheel End Play Measurement NOTE
14. and binding 7 Install the inner spindle nut and tighten hand tight 8 Seatthe bearings by tightening the inner spindle nut to 180 ft Ib while rotating the wheel in both directions 9 Rotate the hub and drum ten 10 11 Back off the inner spindle nut 1 4 turn complete revolutions 10 Loosen the inner spindle nut completely and then tighten the nut to 20 ft Ib 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 Z CAUTION Never tighten the spindle nut to align the cotter pin with hole in castle nut This can pre load the bearings and cause premature bearing failure 12 Install spindle locking D washer retainer washer and outer spindle nut Tighten outer spindle nut to 200 300 ft Ib See Torque Table 13 Verify that wheel endplay is between 001 004 inches See inspecting wheel endplay section If not loosen outer nut re index the inner nut accordingly and repeat Steps 8 thru 12 until proper endplay is achieved 14 Bend retainer washer over one wrench flat of the outer nut 15 Install hubcap gasket and hubcap Tighten the cap screws to 20 30 ft lb See Torque Table Replace the hubcap vent plug if removed 16 Fill the hub cavity with the appropriate amount and type of lubricant and secure drain plug 17 Check oil
15. arms are not stationary components and could move allowing the vehicle drop causing serious personal injury 6 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands Adjusting the Camber Angle Positive Negative Camber Camber Figure 14 Camber Angle Camber is the angle of the wheel with respect to the ground as viewed from the front or rear of the vehicle Fig 14 Camber is positive when the distance between centers of the front wheels at the top is greater than the distance at the ground The wheel camber angle is affected by the ride height of the suspension If the ride height is set too high then the camber measurement will be more positive See the inspecting and adjusting suspension ride height sections before measuring camber The table below lists the recommended camber angles Nominal Camber Values Degrees Unloaded Loaded Left 1 4 41 4 1 4 1 4 Right 1 4 1 4 1 4 1 4 Eccentric Camber Adjustment The setscrew in the eccentric adapter denotes the orientation of the eccentricity of the adapter When the setscrew is in the 12 o clock position then the adapter is in the neutral position There are two adapters at each lower control arm mount and they must be oriented the same AN CAUTION Do not alter components to adjust the camber 38 Neutral Po
16. axle to specified thrust angle Incorrect caster and or camber setting Check wheel loads and correct as needed Check and adjust as required Wheel bearings out of adjustment Check wheel bearing end play and adjust as required Loose steering gear mounting Check mounting and secure as needed Tie rod end connection loose or ball stud worn Inspect ball stud connections and wear Bent spindle or steering arm Inspect and replace as required Frame or underbody out of alignment Incorrect toe in setting Mis aligned belts in radial tires Adjust toe in to specified setting Check and replace as needed Steering gear valve binding Inspect repair or replace as required Steering gear not centered Inspect and adjust as required Excessive water puddling on road 23 Excessive internal steering gear leakage Inspect repair or replace as required Inspect and correct as required Avoid water puddles on road SYMPTOMS REMEDIES POSSIBLE CAUSES Grease oil or dirt on brake pads Brake pads are glazed Replace brake pads as required Deglaze brake pads by burnishing or replace Vehicle pulls to one side gt as required with the brakes applied Brake pads are not a balanced set Replace brake pads as required different friction codes or pad brand Loose or broken brake pads Replace brake pads as req
17. bearing cone is seated in the raceway Turn the steering knuckle carrier over and support the shoulder end of the bar pin Pack a bearing cone with grease and place it onto the bar pin end opposite the shoulder and seat it in the raceway Place the spacer onto the bar pin and seat it against the inner raceway Apply approximately 400 Ib of press load to the spacer Place the split collar into the groove of the bar pin and against the spacer Use a feeler gage to measure the gap between the split collar and shoulder of the groove in the bar pin Record measurement Remove the load Then remove the split collar and spacer Using the gap measurement from Step 10 place a number of shims equivalent to the gap measurement onto the bar pin against the inner raceway Place the spacer onto the bar pin Apply approximately 400 Ib of press load to the spacer such that the split collar can be inserted into the groove of the bar pin Make sure the split collar is fully seated in the groove Remove the press load 16 17 18 19 20 Place the outer collar around the split collar Install the retaining clip around the split collar on the outside of the outside collar Press a seal into each seal bore until fully seated Check bearing preload by rotating the bar pin Slight to medium drag should be felt If too loose add one shim If too tight remove one shim Fill bearing cavity with grease
18. castle nut Do not loosen the castle nut to install the cotter pin 4 Lubricate tie rod end as needed Replacing the Steering Arm Ball Joints The thread in mount type 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 arm 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 its internal components as well as the external seal permanently degrading the lubricant and restricting ball stud movement It is recommended that the appropriate tools be used to remove the ball stud taper from the relay rod and to remove the ball joint base from the steering arm Removal 1 Remove the cotter pins from the ball joint ball stud s 2 Remove the castle nuts from the ball joint ball stud s Z CAUTION Do not strike the component mating taper directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 3 Disconnect the ball joint ball stud from the steering arm tapered hole using a suitable tool 4 Secure the steering arm and remove the ball joint using a ball joint spanner wrench or similar device on the base Steering arm may be removed to facilitate ball joint removal See the steering arm replacement section as needed 5 Inspec
19. chains straps etc to suspension upper and lower control arms sway bar and brackets brake components tie rods steering arms or steering knuckle carrier assemblies Figure 3 Upper 7 Control Steering _ S Knuckle I dl Carrier j wi Steering Arm Tie Rod Lower Brake Control Components Arm Figure 3 Improper Tow Equipment Attachment Locations Maintenance Schedule 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 Final stage manufacturer should complete toe in inspection and adjustment after completion of vehicle GENERAL SERVICE TO BE PERFORMED MILEAGE IN THOUSANDS MAINTENANCE 12 24 36 48 60 72 84 96 Steering Arm Ball Joints Check axial endplay GR x Inspect for ruptured seals xlix xi x xix x x Check that cotter pin is installed Xi ix ix IK IX x Control Arm Bushings Check bolt torque LET p neue x Inspect for contact between control arm and mount XIX X X X X x x Inspect for bushing wear xX xX xX x x x x X Tie Rod Ends Inspect ball socket endplay IxIx x x xIxIix x Check for looseness of taper connection XI XI XIXI XI XIXIX Check that cotter pin is installed xlix
20. co alano General IMS Pee HOD snitte itte htoudatespte eii ge Se sebe suot ufin odas 26 Inspecting the Control Arm Bushings for Wear sese 26 Inspecting the Tie Rod Enden essen 27 Inspecting the ABS Sensor and Tone Ring ii 27 Inspecting the Shock Absorber iii 28 Inspecting the Air Spring and Ride Height 28 Alsprino Inspectiofials laser 28 Ride Height Inspection ce ee ole ale io e cino el s 28 Inspecting the Steering Arm Bearings ii 29 Inspecting the Steering Arm Ball Joints 29 ScalInspechomi 8 cine e ai ni Ale ii Sao fieri e 29 Table of Contents Endplay Inspeetion uo v destra dte EEE ie 30 Inspecting Wheel Bearing Endplay essere 30 Inspecting the Knuckle Carrier Bearing and Seal n 3 Inspecting the Kingpin Vertical Endplay 3 Adjusting Suspension Ride Height iii 3 AU USTEDES i aires ees eto to sva Devo Deos eee Adjusting Wheel End Pay ae mie 33 Adjusting the Maximum Wheel Turn Angle 34 Inspection Before Alignment rss sa eu 36 Wheels and res sso axe QU Se ESAE hes alianti 36 Front SUSPENSION tein aussen ka Fade a taie reet 36 Rear Axle and Suspension s eee a be ua estu ated od ua rccte Du UR ipae sut doo que duod 36 Rronk Nhecl AHenment rail 37 QUIT CIN REPE diario e anita ehemaligen 37 Generali riali 37
21. level low Add fluid tighten connections and correct as and or possible leak in system needed Power steering pump pressure and flow Conduct pump flow and relief pressure tests below specification and adjust repair or replace as needed Air in power steering system Add fluid tighten connections and bleed system Contaminated or incorrect fluid Replace with correctly specified fluid Obstruction with steering gear pitman arm Inspect remove obstruction s and repair or or within hydraulic lines replace as required Obstruction within wheelhouse Inspect remove obstruction s as required l Excessive internal steering gear leakage l Inspect repair or replace as required 22 SYMPTOMS Vehicle wanders side to side loose steering Steering wheel has large amplitude rotational oscillations when hitting large bumps m Vehicle pulls to one side without the brakes applied PossiBte CAUSES Vehicle overloaded or unevenly loaded driver side to driver side to passenger side side _Improper mismatched tires and wheels REMEDIES Check wheel loads and correct as needed Install correct tire and wheel combination correct tire and wheel combination Tires have incorrect pressure Put correct air pressure in tires based on wheel load Incorrect toe in setting Incorrect wheel caster setting Adjust wheel caster to specified setting worn Steering arm
22. level through the hubcap window Figure 19 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 hubcap 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 19 Wheel Bearing Oil Level 51 18 Check the hubcap 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 gasket The vent plug will normally weep a small amount of oil 19 Install the wheel and tire assembly and the wheel nuts 20 On aluminum wheels use a plastic anti scuff guard over the wheel nuts Tighten the wheel nuts to 450 500 ft Ib See Torque Table for sequence 21 Replace the wheel hubcap nuts and hubcaps if removed to service the wheel bearings Replacing Brake Components 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 pads should be replaced when they are worn beyond the manufacturers limits Refer to the brake manufacturers guidelines for servicing the brakes Replacing the ABS Sensor and Tone Ring The anti lock b
23. nut to 170 190 ft Ib See Torque Table Replacing the Air Spring The correct air spring must be installed The use of a substitute air spring is not allowed and may cause unequal load sharing between the air springs and cause adverse ride and handling characteristics Removal 1 Deflate the air spring by disconnecting one end of the vertical HCV linkage from the horizontal arm Rotate the horizontal HCV arm downward and secure it in place 2 Disconnect the airline at the air spring inlet port and remove the connection fitting from the inlet port 3 Remove the bolts and washers from the upper air spring mount studs Note location of bolts and washers 4 Remove the bolts that secure the air spring to the lower air spring mount Installation 53 1 Attach air spring to upper air spring mount Note that the shorter bolt is located towards the front Tighten mounting hardware snugly 2 Attach air spring to lower air spring mount Tighten lower mounting bolts to 20 30 ft Ib See Torque Table 3 Tighten the upper mounting bolts to 20 30 ft Ib See Torque Table 4 Apply Permatex or equivalent thread sealant to the threads of the air connection fitting and install the fitting Connect the airline to the fitting 6 Inflate the air spring by un securing the HCV horizontal arm and reconnecting the vertical linkage to it 7 Check the airline and fitting for air leaks Replacing the Sway Bar and Compone
24. require a voltmeter that can measure AC voltage on a millivolt scale 4 Connect the voltmeter to the connector pins of the ABS sensor lead 5 Set the voltmeter scale to millivolts and the voltage source to AC volts 6 10 Rotate the wheel hub by hand 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 Figure 7 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 IE ODER MAX Figure 7 ABS Sensor amp Tone Ring Gap 28 Inspecting the Shock Absorber l Check shock absorbers for oil leakage bent components missing or broken componen
25. require the use of special tools for safe and correct service Failure to use the proper and or special tools when required can cause personal injury and or damage to suspension components You must follow your company safety procedures and use proper safety equipment when you service or repair the suspension The information contained in this manual was current at the time of printing and is subject to change without notice or liability Reyco Granning LLC reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation Reyco Granning LLC uses the following types of notices for potential safety problems and to give information that will prevent damage to equipment Z WARNING A warning indicates procedures that must be followed exactly Serious personal injury can occur if the procedure is not followed Z 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 Identification The suspension model and serial number are stamped on an aluminum tag that is riveted to the front of the suspension sub frame assembly Figure 1 The serial number is used by Reyco Granning LLC for control purposes and should be refer
26. steering arm 2 Follow the procedures for removal of tie rod ends for the crank steering arm 3 Remove the pivot bolt that mounts the steering arm and remove the steering arm from the subframe 4 Remove the retaining rings from the pivot sleeve and remove the sleeve A rubber or brass hammer may be used to remove the sleeve Retain shims 5 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 Pack the steering arm bearing with grease 4 Support the steering arm bearing housing and press the bearing into each end of the steering arm Note that the seal side of the bearing should face out 5 Inspect the pivot sleeve and remove burrs with emery cloth 6 Install one retaining ring onto pivot sleeve 46 7 Insert the pivot sleeve into the lower bearing Use a rubber mallet or similar tool to drive the inner sleeve into the bearings 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 8 Install upper retaining ring Reseat lower retaining ring against the lower inner race as needed 9 Determine the number of shims needed by stacking the shims and placing the stack
27. Install steering knuckle carrier mounting bolts in control arms Note orientation of bar pin Apply Loctite 242 to mounting bolt threads and tighten to 350 375 ft lb See Torque Table This page intentionally left blank Torque Tables Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are L i ER rade Markings on Bolt carefully considered in initial selection of Grade E SH INS fasteners for a given application To g d isf hicl Grade Lock Nut Lock Nut assure continued satisfactory vehicle Grade B F Grade C G performance replacement fasteners used Identification should be of the correct strength as well as 3 Dots 6 Dots the correct nominal diameter thread pitch length and finish Gr ade Markings on Lock Nuts Torque Table 1 APPLICATIONS FASTENER SIZE Upper Control Arm Bushing Pivot Bolt 1 1 8 12 Grade C TORQUE SPECIFICATION ft lb CLEAN AND DRY 950 1050 7 8 9 Grade C 10 24x3 8 Lower Control Arm Bushing Pivot Bolt Eccentric Set Screw 460 490 30 40 in Ib Steering Knuckle Carrier Mounting Bolt 3 4 10 Grade 8 Lower Air Spring Mount Bolt into carrier 5 8 18 Grade 8 350 3751 170 190 Air Spring Upper Mount Bolt into cradle 3 8 16 Grade 5 3 8 16 Grade 8 Air Spring Lower Mount Bolt 1 2 13 Grade 8 20 30 20 30 20 30
28. ON Do not adjust the suspension ride height or alter components to adjust the caster The caster angle is the angle between a vertical axis and the axis defined by the king pin when viewed from the side of the vehicle When the king pin axis appears rotated clockwise relative to the vertical axis then the caster is positive Positive caster creates a self aligning moment to stabilize the vehicle when driving straight ahead Figure 16 The caster angle is indirectly measured from the change in wheel camber as the wheel is turned through a prescribed turn angle Therefore the calculated caster is affected by the ride height of the suspension See the inspecting and adjusting suspension ride height sections before measuring caster The table below lists the recommended caster angles Nominal Caster Values Degrees Unloaded Loaded Left 135705129 3 1 2 Right 3 1 2 3 1 2 _ Positive My Li Caster LA 7 Negative Caster Lower Control Arm Front Eccentrics FORWARD Figure 17 Lower control arm movement Eccentric Caster Adjustment The setscrew in the eccentric adapter denotes the orientation of the eccentricity of the adapter When the setscrew is in the 12 o clock position then the adapter is in the neutral position There are two adapters at each lower control arm mount and they must be oriented the same When the setscrews in the forw
29. Reyco Granning SUSPENSIONS Motorhome Suspensions Owner s Manual FS 4 460S JT Independent Front Suspension Maintenance Instructions Service Parts Document 4 D707623 Revision B Revision Date 5 12 Reyco Granning Suspensions 1 1205 Industrial Park Drive Mount Vernon MO 65712 Phone 417 466 2178 www reycogranning com ee Table of Contents Introduction sibili ee ee Service Not c M 4 Identificatie ricicla 5 Vehicle Towing Information rsa iaia 6 Maintenance Senet les os asse cn eae odds EIER ES EN ari 7 Maintenance Record galli cara 8 Pars Lists Unt C nbl TTE 9 Control Arm Components ana 10 Control Arm Assembles tirisna en R Rai ae 11 Steering Components een niert 12 Air Spring and Shock Components i 14 Sway Bar COMPENSI 15 Disc Brake Components an 16 King Pin Components an ii iaia 17 Steering Knuckle Carrier Components nennen 18 L ubrication ses Lubricant Specifications and Intervals sese 19 General EubricaliOb sor ccnl illa deme Sau 19 Billionaire asp M ocu N 19 Ball Studs on Tie Rods Crank Rod and Drag Link 19 Brake S Cam Tube and Automatic Slack Adjuster 20 Carrier Bearing and Kin cits vobi vict n eet dated Guetta dos odio 20 Wheel Bearings RET UU I ULL 21 Froubl shootmo c glieli 22 InspecttoIl uiii eia
30. Side Hub Cap Bolt 5 16 18 Grade 5 20 30 M22x1 5 450 500 Vibe NUT Hub Piloted Dry Threads D Torque applied to bolt head 2 Recheck wheel nut torque after first 50 100 miles 58 Reyco Granning SUSPENSIONS ISO 9001 2008 Certified 1 800 753 0050 cera Mount Vernon MO 65712 www reycogrann in g com 800 753 0050 Fax 417 466 3964
31. al indicator to 0 zero 5 Raise the jack until the dial indicator shows the end of vertical travel Measure and record the dial indicator reading Vertical inspection clearance must be 001 025 inches 3l 6 Ifthe steering knuckles binds or less than 001 inch endplay is measured remove shims from the shim pack See repair section for kingpin 7 Ifthe vertical endplay measurement is more than 025 inches then install shims See repair section for kingpin Adjusting Suspension Ride Height The height control valve HCV and linkage should be checked regularly for proper clearance operation and adjustment NOTE Improperly adjusted ride height will result in incorrect wheel alignment measurements and may result in abnormal tire wear Check the 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 An alternate measurement may be taken as the height of the air spring See Figure 11 Figure 11 Unit Ride Height A Air Spring B IFS1460 6 19 9 00 Properly adjusted ride height results in correct suspension travel and alignment The ride height should not be adjusted to adjust chassis rake angle Z CAUTION Adjusting the ride height can cause the front end to raise or lower unexpectedly due to vertical movements at the connection of the
32. ard lower control arm mount are oriented closer to the frame rail and the setscrews in the rearward lower control arm mount are oriented farther from the frame rail the caster becomes more negative Fig 18 When the setscrews in the forward lower control arm mount are oriented farther from the frame rail and the setscrews in the rearward control arm mount are oriented closer to the frame rail the caster becomes more positive The eccentric adapters at both lower control arm mounts must be oriented opposite each other to affect caster o Neutral Position Negative Caster VIEW A A LH Front Eccentric View Scale 1 2 Negative Caster VIEW B B LH Rear Eccentric View Scale 1 2 FORWARD Figure 18 Eccentric Caster Adjusment 1 Loosen both lower control arm the tendency of the tires to toe out when mounting bolts at the eccentric the vehicle is driven straight ahead adapters Do not remove the bolts Incorrect toe in can result in rapid tire because the adapters must remain wear engaged in control arm mounting plate for adjustment 1 Measure the length of the outer tie gt Transen esses rods Reference length is 17 inches 2 Ifthe lengths of the outer tie rods are not within 1 8 inch of each other then adjust their lengths such that they are within 1 8 inch of each other Loosen the tie rod clamps on each end of the ti
33. between the upper retaining ring 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 10 Remove the upper retaining ring install the shims determined in step 9 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 the inner sleeve 11 Place the steering arm in its mount and install the pivot bolt Tighten the pivot bolt lock nut to 575 625 ft lb See Torque Table 12 Follow the procedures for installation of the relay rod or tie rod Replacing the Upper and Lower Control Arm Bushings The sub frame control arm mounts may require widening to accommodate replacement bushings A suitable jack may be used to increase the width of the control arm mounts by cold bending Care must be taken to not exceed 5 00 width after widening The control arm mounts should be inspected for damage Both control arm bushings and mounting hardware except eccentric adapters must be replaced in a control arm when bushings are serviced It is recommended to replace 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 Z CAUTION Use of a cutting torc
34. 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 52 7 Ifthe minimum reading is still not obtained then replace the sensor and repeat the installation procedure Route and secure the sensor lead wire the same as the removed sensor 9 Connect the sensor lead wire to the chassis Secure wire lead to prevent damage during suspension movement Tone Ring Removal and Installation Follow the hub manufacturer s guidelines for removal and installation of the tone ring Replacing the Shock Absorber Z 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 The shock will expand to its full extended length if not restrained Removal 1 Remove lower shock thru bolt mounting hardware and retain for installation Do not remove lower shock mount bracket from lower control arm Remove upper shock bushing mounting hardware and retain for installation Installation 1 Position shock in suspension such that the thru bolt is connected to the lower shock mounting bracket tabs 2 Attach upper shock bushing to suspension sub frame with mounting hardware Do not tighten 3 Tighten lower thru mounting bolt and nut to 170 190 ft Ib See Torque Table Tighten nuts to 30 40 ft Ib See Torque Table 4 Tighten upper mounting
35. d 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 6 Check that the frame is not bent 7 Refer to any additional 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 Tuthill 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 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 are installed in the lower 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
36. e adjusting hex nut Figure 4 Carrier Bearing and Kingpin l Apply lubricant to both upper and lower carrier bearings and kingpin bushings until new lubricant discharges from the carrier bearing seals and in between the steering knuckle kingpin housing and carrier Grease Fittings Grease Fittings Note Left side only shown Wheel Bearings 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 Figure 5 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 oil Oil marks in other locations should be addressed by replacing the hub cap seal window gasket or tightening the pipe fill plug Figure 5 Wheel Bearing Oil Level Troubleshooting SYMPTOMS POSSIBLE CAUSES REMEDIES Tires have incorrect pressure Put specified air pressure in tires Tires out of balance Balance or replace tires Tires wear out quickly or have uneven tire tread wear Incorrect toe in setting Adjust toe in to specified setting Note Wear patter
37. e heat treated and tempered Z WARNING The components cannot be bent welded heated altered or repaired in any way without reducing 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 control arms steering arms knuckle carrier tie rod assemblies the brakes the hubs and the brake drums 2 Hot or cold bending of the steering knuckles control arms steering arms knuckle carrier tie rod assemblies 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 43 Repairs IN WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop cau
38. e outer nut 16 Install hubcap gasket and hubcap Tighten the cap screws to 20 30 ft Ib See Torque Table Replace the hubcap vent plug if removed 17 Fill the hub cavity with the appropriate amount and type of lubricant and secure drain plug 18 Check oil level through the hubcap window Figure 12 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 hubcap 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 34 19 Check the hubcap 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 gasket The vent plug will normally weep a small amount of oil Figure 12 Wheel Bearing Oil Level Adjusting the Maximum Wheel Turn Angle Z CAUTION Do not adjust maximum wheel turn angle greater than 55 Mis adjustment of the wheel turn angle can cause damage to steering system components The turn angle may require adjustment if the front tires rub against the frame suspension body or the steering gear has been serviced replaced Use an alignment machine to check the wheel turn angle See the measurement procedure of the alignment machine manufacturer T
39. e rod and turn the center tube to change the length 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 4 Tighten th ter locknuts to 460 A re ag 3 Adjust the length of both outer tie rods 490 ft Ib See Torque Table equally such that the toe in on each 5 Tighten the setscrews to 30 40 in Ib side is 1 16 1 32 and the over all See Torque Table toe in is 1 8 1 16 Tighten tie rod clamp nuts to 50 60 ft Ib See Torque Table Refer to Figure 6 for tie rod clamp orientation 6 Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 7 Re measure caster and readjust as needed Adjusting the Toe In AN CAUTION Do not alter components to adjust the toe in Z CAUTION Improperly oriented tie rod clamps can cause binding in the suspension steering system Wheel toe in is the relationship of the distance between the centers of the front and rear of the front wheels When the front distance is less than the rear distance the wheels are toed in Toe in is designed into the suspension to counteract 42 General Procedures Repair or reconditioning of front suspension components is not allowed Components that are damaged or worn must be replaced Several major components ar
40. earing areas on the spindle for wear or damage Burrs may be removed by light application of emery cloth Replace steering knuckle if the spindle is damaged Installation 1 Place the hub seal assembly with axle ring onto the spindle so the words Oil Bearing Side face outboard Do not place the seal in the hub bore 2 Drive the seal onto the spindle using the appropriate seal installation tool and a 3 5lb hammer Reference Stemco P N 0155220 The wear ring is fully seated when it is square and flush with the face of the inner bearing shoulder of the spindle Reseat the seal onto the wear ring if it becomes dislodged after seating NOTE Do not drive bearings onto the spindle with a steel hammer or similar instrument Bearing inner race is a tight slip fit with spindle 3 Pre lube the inner bearing and place it onto spindle with small end of taper facing outward Seat the inner race against the shoulder of the spindle 4 Press the ABS sensor outward about 4 Do not use a sharp tool on lead wire end of the sensor See section for the inspection of ABS sensor as needed 5 Place the hub onto the spindle until it seats on the inner bearing Do not ram the hub onto the seal 50 6 Pre lubed outer bearing and place it 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
41. h to remove control arm bolts will permanently damage control arm bushings and can result in damage to subframe It is recommended that the wheel and tire be removed to provide proper accessibility Disconnect the vertical height control valve linkage from the horizontal arm to prevent unintentional inflation of the air spring Upper Control Arm Removal 1 Place a portable jack under the knuckle carrier to secure and support it Z CAUTION Do not remove both upper and lower knuckle carrier mounting bolts at the same time unless the knuckle carrier is properly secured 47 2 Remove knuckle carrier mounting bolts from the control arm Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts 3 Disconnect sway bar connector at sway bar if so equipped with a sway bar 4 Loosen and remove control arm mounting locknuts 5 Support control arm and remove control arm mounting bolts Remove the control arm 6 Remove the sway bar bracket and linkage from the control arm and retain for installation 7 Press the bushings out of the housings Support the housing properly Upper Control Arm Installation 1 Inspect the housing bores and remove any burrs in the housing bores by honing 2 Press the bushings into the housings using a suitable tool to apply pressure to only the
42. he hub cap window may be damaged by solvents 49 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 outer spindle nut spindle washer locking D washer and 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 6 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 7 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 oil saturates or significantly contaminates the brake lining then replace the lining Remove the hub seal and discard it Remove the wear ring from the spindle and discard it 9 Inspect the inner cup outer bearing race for the inner bearing and outer cup in the hub for damage Replace the bearing cups if worn or damaged 10 Inspect the b
43. he steering stop bolt on the steering knuckle controls the maximum turn angle If the stop bolt is 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 Z 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 If the steering stop bolts are adjusted to reduce wheel turn angle the steering gear poppet valves will require readjustment If the poppets are not re adjusted properly then the steering gear will not reduce power assist properly and steering components will be damaged Refer to TRW s TAS Steering Gear Service Manual for readjusting the poppets Unit Steering Stop Length A IFS1460 16 Figure 13 Steering Stop Bolt 35 Drive the front tires on a suitable device that allows the front wheels to turn and measures the wheel turn angle 2 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement 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
44. 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 8 Unbend the retainer washer and remove the spindle outer nut retainer washer and locking washer Loosen the inner spindle nut 9 Seat the bearings by tightening the inner spindle nut to 180 ft Ib while rotating the wheel in both directions 10 Rotate the hub and drum ten 10 complete revloutions 11 Loosen the inner spindle nut completely and then tighten the nut to 20 ft lb 12 Back off the inner spindle nut 1 4 turn 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 33 Z 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 spindle locking washer retainer washer and outer spindle nut Tighten outer spindle nut to 200 300 ft Ib See Torque Table 14 Verify that wheel endplay is between 001 004 inches See inspecting wheel endplay section If not loosen outer nut re index the inner nut accordingly and repeat Steps 9 thru 13 until proper endplay is achieved 15 Bend retainer washer over one wrench flat of th
45. ke 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 NOT apply corrosion preventative to the brake linings or the brake drums rotors Replacing Tie Rod Ends Removal 1 Remove the cotter pins from the tie rod end ball stud s 2 Remove the castle nuts from the tie rod end ball stud s Z CAUTION Do not strike the component mating taper directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 3 Disconnect the tie rod end ball stud from the mating component tapered hole using a suitable tool 44 4 Inspect the tie rod end ball stud and mating component tapered hole s Replace components with worn tapered hole s If the grease seal is damaged during removal replace it before installation Installation 1 Clean the mating component tapered hole s of any contamination Insert the tie rod end ball stud into the tapered hole and secure it with the castle nut A 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 2 Tighten the castle nut to 90 100 ft lb See Torque Table 3 Install the cotter pins If necessary tighten the castle nut to align the hole in the ball stud and slots in the
46. lignment 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 wheel turning arc Z CAUTION Reyco Granning LLC recommends replacing any damaged or out of specification components Reconditioning or field repairs of front suspension components is prohibited Some cast components are heat treated These components as well as other non heat treated castings cannot be bent welded heated or repaired in any way without reducing the strength or life of the component thus voiding the warranty Only genuine ReycoGranning replacement components are allowed 26 IN WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury The vehicle may be supported on safety stands by the suspensi
47. lower bar pin of the knuckle carrier bearing marked with a B may also be used to provide additional camber adjustment Preparation 1 Follow the alignment equipment manufacturer s procedures for preparing the vehicle for front and rear wheel alignment measurements Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement NOTE An out of center steering gear can result in unequal wheel turn angles The steering gear should remain centered during toe in adjustment 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 Check that the steering gear is centered when the tires are steered straight ahead i e equal toe in side to side Center the steering gear according to guidelines 4 Measure and record the individual wheel camber caster and toe in of the front suspension Also measure and record the cross camber cross caster and overall toe in 5 Ifadjustment 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 Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control
48. mounts loose Steering arm ball joints binding or worn Adjust toe in to specified setting Check and tighten to specification Inspect ball joints for wear or contamination and replace as required Kingpin worn Wheel bearings out of adjustment Loose steering gear mounting Loose pitman arm Steering column linkage worn Steering gear adjustment Check and replace as required Check wheel bearing end play and adjust as required Check mounting and secure as needed Check pitman arm and tighten as required Check for wear and repair or replace as needed Check and adjust to specification Steering column mis aligned Realign steering column as required Worn knuckle carrier bearings Inspect ball stud connections and wear Check adjust or replace as needed Tie rod end connection loose or ball stud Loose knuckle carrier mounting bolts Loose wheel nuts Vehicle overloaded or unevenly loaded driver side to passenger side Improper mismatched tires and wheels Tires have incorrect pressure Unequal ride height side to side Improper brake adjustment Incorrect rear axle alignment Check and tighten as needed Check and tighten to specification Install correct tire and wheel combination Put correct air pressure in tires based on wheel load Inspect ride height and adjust to specified setting Inspect and adjust calipers as required Align rear
49. n will indicate Incorrect ride height Adjust ride height to specified setting possible cause s Consult tire manufacturer for Incorrect rear axle alignment Align rear axle to specified thrust angle guidance Incorrect steering arm geometry Adjust tie rod lengths as required Improper mismatched tires and wheels l Install correct tire and wheel combination Improper oversized tires Install correct tire and wheel combination Vehicle is difficult to steer Tires not uniform Install correct tire and wheel combination Note Engine must be running for Tires have incorrect pressure Put specified air pressure in tires power steering to be active Incorrect steering arm geometry Adjust tie rod lengths as required and able to provide steering assist Steering arms binding Check steering arm bearings and lubricate as needed Steering arm ball joints binding Inspect ball joints for wear and replace as required Tie rod ends binding Inspect tie rod ends for wear and lubricate as needed l Kingpin binding l Inspect lubricate and repair as required l Steering column linkage binding l Align or adjust as required l Steering miter box binding Check steering miter box and repair or replace as required Steering gear valve binding Inspect repair or replace as required Steering wheel to column interference Align or adjust as required Power steering pump fluid
50. nsion Model Number IFS1460S JT Address of Owner Name and Address of Dealer Vehicle Identification Number Suspension Serial Number Inspection and Maintenance Item Date Mileage Service Performed Parts List Unit Assembly Item Part No Description Item Part No Description 1 706988 01 Sub frame Assembly 9 705633 02 Carrier Assembly RH O 2 700944 01 Lower Control Arm Assembly 10 705951 01 Air Spring Assembly 3 700973 02 4 703182 01 Upper Control Arm Assembly 12 702030 01 Relay Rod 5 705619 01 Bell Crank Assembly LH 13 705800 01 Height Control Valve Arm LH 6 705620 01 Idler Arm Assembly 14 705800 02 Height Control Valve Arm RH 7 701924 01 Crank Arm Assembly Crank Arm Link Assembly 8 705633 01 Carrier Assembly LH SZ eG Control Arm Components Item Part No Description tem PartNo Description 1 703182 01 Assembly Upper Control Arm 7 293 Socket Set Screw 10 24 x 38 2 700944 01 Assembly Lower Control Arm 8 701683 04 Hardened Flat Washer 7 8 3 700245 01 Boss Eccentric 9 100039 P1 Hex Head Bolt 3 4 10 x 2 75 Gr 8 Zn 4 8490 Spacer 10 702516 02 Hex Head Bolt 1 1 8 12 x 7 75 Gr 8 ZY 5 292 Hex Head Bolt 7 8 9 x 8 50 Gr 8 ZN 6 100122 P1 Lock Nut 7 8 9 Gr C 10 Control Arm Assemblies Description Item Part No Part No
51. nts It is recommended that the sway bar mounting bushings and the vertical linkages be replaced all at the same time Vertical Linkage Removal 1 Disconnect sway vertical linkage at upper control arm bracket on both sides Retain hardware for installation 2 Secure the sway bar to prevent rotation and disconnect the lower connection to the sway bar on both sides Vertical Linkage Installation 1 Attach the sway bar vertical linkage to the upper and lower mounts 2 Tighten the mounting nuts to 80 90 ft Ib See Torque Table Replacing the Steering Knuckle Carrier Bearings It is recommended to replace all the steering knuckle carrier bearings at the same time The wheel and tire should be removed to provide access The steering knuckle may be removed to provide easier handling of steering knuckle carrier assembly Z CAUTION and lower mounting bolts are removed The knuckle carrier must be secured and supported properly when upper Removal 1 Note installed orientation of the upper and lower bar pin Lower bar pins are factory installed with the B located closest to the lower control arm Z CAUTION Do not apply excessive preload to bearings NOTE Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed to align the lower control arm with the knuckle carrier bar pin 54 Remove the steering knuckle carrier mo
52. on subframe or chassis frame for inspections that require removal of the wheel and tires or deflation of the air springs Always secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement before inspections Inspecting the Control Arm Bushings for Wear NOTE It is recommended that the bushings in all of the control arms be replaced at the same time if one is found worn 1 Check clearance between each control arm and subframe bushing mount Look for contact pattern as evidence of bushing wear Replace worn bushings in both control arm housings as needed 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 460 490 ft Ib for lower control arms and 950 1050 ft Ib for upper control arms See Torque Table A loose joint will result in wear between the bushing inner sleeve and sub frame mount Inspecting the Tie Rod Ends Z 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 1 With the engine on lightly rock the steering wheel and have an assistant observe any looseness in the two mating tapers or any movement of the stud nut at b
53. on the end is configured such that it can be re oriented to provide camber adjustment Lower bar pins are factory installed with the B located closest to the lower control arm The wheel camber becomes more positive when the lower bar pin is re oriented such that the B is located farthest from the lower control arm 1 Place a portable jack under the tire to secure and support it Z CAUTION Do not remove both upper and lower knuckle carrier mounting bolts at the same time The knuckle carrier must be secured and supported properly if both upper and lower mounting bolts are removed NOTE Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed to align the lower control arm with the knuckle carrier bar pin 2 Remove the bottom knuckle carrier mounting bolts from the lower control arm Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts 3 Raise the jack to separate the bar pin from the control arm and re orient it 4 Lower the jack to align the bar pin with the control arm Apply Loctite 271 to mounting bolt threads and tighten to 275 300 ft Ib See Torque Table 40 Adjusting the Caster Angle Positive Caster Negative Caster FORWARD Figure 16 Caster Angle A CAUTI
54. oth ends of the tie rod Figure 6 If looseness is 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 shows distortion or wear then both components must be replaced Torque tie rod castle nuts to 90 100 ft Ib 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 Figure 6 Be sure to only apply hand pressure to the tie rod 27 4 Measure the axial movement with a scale If the movement is greater than 1 8 inch 3mm 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 replaced before 1 8 3mm movement occurs 5 Check dust boot for damage Replace as needed 6 Check tie rod clamp orientation Figure 6 tu Figure 6 Tie Rod Inspecting the ABS Sensor and Tone Ring 1 The tires and brake drums may be removed if needed to ease inspection of tone ring and sensor 2 Disconnect the ABS sensor lead from the chassis connector 3 The ABS sensor test will
55. outer metal of the bushing Support the housing properly 3 Re install the sway bar bracket and linkage if removed 4 Place the control arm in its mount location Install the control arm mounting hardware and tighten snugly 5 Orient the control arm at suspension ride height and tighten the bolts to 950 1050 ft Ib See Torque Table 6 Reconnect the sway bar linkage Tighten mounting bolt to 75 85 ft lb See Torque Table 7 Apply Loctite 242 to mounting bolt threads and tighten to 350 375 ft lb See Torque Table Lower Control Arm Removal 1 Place a portable jack under the knuckle carrier to secure and support it Z CAUTION Do not remove both upper and lower knuckle carrier mounting bolts at the same time unless the knuckle carrier is properly secured NOTE Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed to align the lower control arm with the knuckle carrier bar pin 2 Remove knuckle carrier mounting bolts from the control arm Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts 3 Note orientation of lower bar pin in carrier bearing Raise the jack as needed to separate the bar pin from the control arm 4 Remove and retain the lower shock bar pin mounting hardware Shock will
56. prevent vehicle movement Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury 2 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands 3 Ifthe tire and wheel are not removed make sure all the wheel nuts are tightened to the specified torque of 450 500 ft Ib See Torque Table 4 Ifthe tire and wheel are removed recommended for aluminum wheels secure the brake drum to the hub with the wheel nuts or remove the brake drum 5 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 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 7 Remove the hubcap bolts hubcap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that solvents may damage the hubcap window NOTE When removing or installing the
57. rake system ABS of the vehicle should be diagnosed by a qualified technician before the anti lock brake sensors or the tone rings 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 Sensor Removal 1 Remove the brake drum to provide access to sensor Press sensor out of steering knuckle Do not pull sensor out by its lead wire Remove tie straps that secure the sensor lead wire and disconnect the sensor lead wire from the chassis wire harness 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 Press the sensor into the steering knuckle until the sensor end contacts the tone ring Connect a volt meter to the connector pins of the sensor lead wire Set the volt meter to read AC voltage on a scale of 1 10V Spin the hub by hand and read the voltage output of the sensor A minimum reading of 0 8V AC is normal Skip to step 8 if minimum reading is obtained If the 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 If the minimum reading is not obtained
58. red to when servicing the suspension or requesting technical support Figure 2 Serial Tag Figure 1 Suspension Identification Location Reyco Granning eia SERIAL 000000 GAWRILBS move IFS1460S JT 14 600 MAY BE COVERED BY THE FOLLOWING PATENTS OTHER PENDING U S 4 506 910 6 158 750 6 176 501 7 434 821 CANADA 1 194 044 Figure 2 Suspension Serial Number Tag Model GAWR Wheel Sway Disc Drum Ib Cut Bar Brakes Brakes IFS1460S JT 14 600 55 x Model Identification Table Vehicle Towing Information If a vehicle is disabled and needs to be towed by the front end to service center check the OEM Coach Builder towing procedures for the recommended method Check with local authorities and Department of Transportation DOT for permissible towing methods before towing Some states do not permit towing by chains and or straps The preferred towing apparatus is the type that cradles the front tires If the towing apparatus cannot be attached to the front tires or directly to the chassis frame rails then the suspension sub frame may be used for attachment Z WARNING Attaching towing equipment to improper locations and failure to utilize OEM Coach Builder recommended towing methods could result in one or more of the following Loss of vehicle control Possible disconnection from tow vehicle Damage to the suspension and or vehicle Do Not attach tow apparatus hooks
59. ring Stop 8 6969 Washer Spindle IFS 22 705988 06 Hub and Rotor Assembly 9 6970 Spindle Outer Nut IFS 23 707240 01 Caliper Assy LH 10 266 Flange Head Bolt 5 16 18x 75 Gr 5 ZC 707240 02 Caliper Assy RH 11 7328 ABS Sensor Straight w Lead 24 700690 04 Hex Head Bolt M20x2 5 60 Gr 10 9 12 6946 ABS Sensor Spring Retainer 25 703553 02 Flat Washer 20mm 13 7329 ABS Sensor Bushing 26 707306 01 Torque Plate Assy LH 14 700947 01 Steering Arm LH 27 707306 02 Torque Plate Assy RH 700947 02 Steering Arm LH 28 700024 01 Hub Cap Gasket Stemco 15 700525 22 Castle Nut 1 1 8 29 700017 01 Hub Cap 16 700525 21 Cotter Pin 3 16 30 705998 05 Brake Pads Not Shown 16 King Pin Components 1 1700984 04 Thrust Bearing w 7000984 05 Oil Seal 2 700525 12 Shim 010 8 100507 P1 HHB 5 16 18x1 3 700525 13 Shim 005 9 700525 11 King Pin 4 700525 03 King Pin Cap 10 700525 08 Draw Key Short 5 700525 04 Gasket King Pin Cap 11 700984 03 Draw Key Long 6_ 8191758 Grease Fitting 1 8 27 NPT Oil seal is on the top of the thrust bearing towards the carrier side 17 Steering Knuckle Carrier Components 705632 01 Machining Carrier LH 702834 01 705632 02 Machining Carrier RH 8 702621 01 Upper Bar Pin 702622 01 Spacer 702621 02 702835 01 Cup 702623 02 Shim 010 9 Lower Bar Pin
60. sing serious personal injury The vehicle may be supported on safety stands by the suspension sub frame or chassis frame for repairs that require removal of the wheel and tires or deflation of the air springs Always secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement before performing repairs Cleaning the Parts 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 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 solutions 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 light oil to cleaned and dried parts that are not damaged and are to be immediately assembled Do NOT apply oil to the bra
61. sition Negative Camber VIEW A A LH Front Eccentric View Scale 1 2 Neutral Position ga Positive Camber Negative Camber 1 VIEW B B LH Rear Eccentric View Be Scale 1 2 FORWARD Figure 15 Eccentric Camber Adjustment When the setscrews in both lower control arm mounts are oriented closer to the suspension centerline the tire camber becomes more negative When the setscrews in both control arm mounts are oriented farther from the suspension centerline the tire camber becomes more positive Fig 15 The eccentric adapters at both lower control arm mounts must be oriented the same to affect only camber 1 Loosen both lower control arm mounting bolts at the eccentric adapters Do not remove the bolts because the adapters must remain engaged in control arm mounting plate for adjustment 2 Loosen the setscrews 3 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 4 Tighten the adapter locknuts to 460 490 ft Ib See Torque Table 5 Tighten the setscrews to 30 40 ft lb See Torque Table 6 Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 7 Re measure the camber and readjust as needed Bar Pin Camber Adjustment The lower bar pin of the knuckle carrier bearing marked with a B
62. ssembly IFS1460 11 700184 04 HHB 5 8 18 x 1 75 Gr 8 ZN 2 100727 P1 HHB 3 4 10 x 4 0 Gr 8 ZN 12 89422850 HFW 5 8 3 705692 01 Lower Air Spring Mount LH 13 276 FHB 1 2 13 x 1 75 Gr 8 ZN 4 705692 02 Lower Air Spring Mount RH 14 30 FHB3 8 16x 125 Gr 8 ZN 5 707357 01 Lower Shock Mount 15 208 LEN 3 4 10 Gr G ZN 6 152 HFW 3 4 16 8131017 FW 3 4 7 263 HFW 3 8 17 100678 P1 HHB 3 4 10 x 3 5 Gr 8 ZN 8 149 HHB 5 8 18 x 3 0 Gr 8 ZN 9 100263 P1 HHB 3 8 16 x 1 Gr 8 ZN DES Arm HCV LH 19 10 8120382 SLW 3 8 Arm HCV RH Notch on lower shock mou the always is towards the front unit Sway Bar Components Part No Description Part No Pr Fe 2 03165 01 Asy Mount UCA Sway Bar 3 89422301 LN 1 2 13 Gr 8 307 FHB 1 2 13 x 1 50 Gr 8 Zinc 15 Disc Brake Components Item No Part No Description Item No Part No Description 1 126 Hex Head Bolt 5 8 18x2 Gr 8 ZN 17 700525 14 Adapter Steering Stop 2 4599 Locking Flange Nut 5 8 18x 75 Gr G PH 18 700525 18 FW 7 8 3 7977 Oil Seal Assy Guardian 700525 17 Jan Nut 1 2 4 1784 Bearing Taper 2 5 8 HM212049 19 700984 01 Steering Knuckle Assy LH 5 6972 Bearing Taper 1 3 4 3782 700984 02 Steering Knuckle Assy RH 6 6967 Inner Nut IFS 20 700525 16 Key 7 6968 Spindle Lockwasher 21 700984 06 Assy Stee
63. t the ball joint stud and relay rod tapered hole s Replace relay rod if tapered hole s is worn Installation 1 Clean the threaded hole in steering arm of any contamination 2 Apply thread adhesive Loctite 242 to the ball joint base threads and thread it into the steering arm by hand 3 Tighten the base of the ball joint to 325 375 ft lb See Torque Table 4 Clean the relay rod tapered hole s of any contamination Insert the ball joint stud into the tapered hole and secure it with the castle nut ACAUTION 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 5 Tighten the castle nut to 155 170 ft lb See Torque Table 6 Install the cotter pins 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 Idler and Crank Steering Arm Bearings Replace the bell crank idler and crank 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 Removal 1 Follow the procedures for removal of the relay rod from the ball joint in the bell crank and idler
64. te direction Inspection Before Alignment See the General Inspection section and check the following before conducting front wheel alignment measurements Wheels and Tires 1 Check that the front tires are inflated to the appropriate pressure based on the tire loading 2 Check that the front tires are the same size and type 3 Check that all the wheel nuts are tightened to the specified torque of 450 500 ft Ib See Torque Table 4 Check that the wheel and tire assemblies are balanced Front Suspension 1 Check that all fasteners are tightened to the specified torque 36 2 Check the suspension ride height and adjust as needed to the specified height 3 Check for worn ball joints tie rod ends steering arm bearings control arm bushings knuckle carrier bearings and damaged suspension components Replace worn components as needed 4 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 5 Check the wheel bearing adjustment and adjust as needed 6 Inspect the shock absorbers for wear and damage Rear Axle and Suspension 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 an
65. the steering arms Figure 9 The steering arms should not exhibit any noticeable conical motion about their pivot axes 3 Ifany conical motion is observed check pivot bolt torque which should be 460 490 ft lb See Torque Table Otherwise replace the bearing set of the steering arm that exhibits conical motion 29 i su k 2 fil i EP TE Me cS sane SR de m T es i L I T qe 1 E A x Rae ve Ht ges dU EA N Bearings Figure 9 Inspecting the Steering Arm Ball Joints Seal Inspection 1 Inspect the ball joint seal outer surface for presence of oil wetting The entire outer seal surface should be dry Use a mechanics mirror and flashlight to inspect the entire seal Use a blunt object as needed to inspect between seal convolutes 2 If oil wetting is found then inspect the entire wet area to confirm the seal has a rupture s and oil source is from internal grease leaking from the ball joint If seal is ruptured then the ball joint must be replaced 3 Skip ball joint endplay 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 Endplay Inspection 1 Install a dial indicator with a magnetic base so that the base is fixed to the steering arm Place the indicator tip on the flat area of the relay rod adjacent the castle nut 2
66. ts excessive corrosion or worn bushings Replace shock absorbers if any of the above items is present Inspecting the Air Spring and Ride Height Air Spring Inspection 4 Refer to Firestone s Preventative Maintenance Checklist for additional air spring information Check the outside diameter of the air spring for irregular wear or heat checking Check airlines to make sure contact does not exist between the airlines and the outside diameter of the air spring Re secure airlines to prevent contact as needed Check for airline and fitting leaks with soapy water solution Check to see that there is minimum of 1 inch clearance around the circumference of the air spring while it is energized with air Check the air spring piston for build up of foreign material Remove any foreign material that is present Ride Height Inspection l Dump and re inflate the air suspension Verify the ride height by measuring from wheel center to the bottom of the frame A or air spring height B If the dimensions are not within 125 of Figure 8 readjust Unit Ride Height A Air Spring B IFSI460 6 19 9 00 Figure 8 Ride Height Measurement Inspecting the Steering Arm Bearings 1 Check that steering arm pivots are free of foreign material and bearing seals are in place 2 Start vehicle engine Oscillate the steering wheel and observe the motion of
67. ue Table Replacing Wheel Bearings Oil Seals and Hub Caps If the wheel nuts have chrome covers remove them with special pliers equipped with plastic non marring jaws Place them in a container to prevent damage or loss On aluminum wheels place a plastic anti scuff guard over the wheel nuts and loosen the wheel nuts On steel wheels remove the wheel hubcap nuts if present and the wheel hubcap before loosening the wheel nuts Place the wheel hubcap in safe location to prevent damage Place the wheel and or wheel hubcap nuts in a container to prevent contamination or loss 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 Remove the brake rotor assembly and place it aside Mark the rotor assembly 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 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 hubcap bolts hubcap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that t
68. uired Brake rotor warped Re machine or replace brake rotor as required Defective brake rotor Inspect for defects and replace as required l Uneven brake adjustment side to side l Adjust caliper as required l Different brake air chamber size l Replace with same size brake air chambers l Brake chambers air pressure uneven side Check side to side air pressure and correct to side as needed Rear axle brakes mis adjusted or Check adjust or replace as required contaminated ABS system malfunction Check ABS system for proper function remove obstructions Air leak or obstruction in air brake lines Check fittings with soapy water solution and Brake air chamber air leak or diaphragm Check chamber for air leak and damaged damaged diaphragm Excessive water puddling on road Avoid water puddles on road Front and or rear shock absorbers worn Replace shock absorbers as needed l Shock mounting loose l Check and tighten as required l Shock eye bushings worn Check and replace as needed Sway bar bushings worn Check sway bar bushings and replace as Vehicle rolls side to side needed excessively Sway bar mounting brackets loose Check sway bar mounting brackets and tighten as needed Control arm pivot bushings worn Inspect and replace as required Internal leak in height control valve Check height control valve and replace as required ABS sensor malfunction ABS
69. unting bolts from the upper and lower control arms Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts 3 Remove steering knuckle carrier Support fixed shoulder end of the bar pin Remove retaining clip and outer collar from the split ring Apply approximately 400 Ib press load to the spacer and remove the split collar 7 Remove spacer and shims 8 Press bar pin out of bearing cones 10 11 Remove outer seals from both sides of bearings Remove bearing raceways from the steering knuckle carrier Do not damage bores Clean the remaining grease from the bearing cavity Installation l Inspect bearing raceway and seal bores in steering knuckle carrier for burrs or damage Inspect the bar pin for burrs or damage Remove burrs and replace damaged components Press a bearing race into each steering knuckle carrier bore until fully seated Pack a bearing cone with grease and place it onto the bar pin and seat the inner race on the shoulder 10 11 12 13 14 15 Note the position and orientation of bar pin relative to the carrier The shoulder end of the bar pin faces forward on the upper bar pin location The shoulder end of the bar pin faces rearward on the lower bar pin location Insert the bar pin into the steering knuckle carrier until the
70. xi x xix Xx x Brake System Inspect slack adjuster for correct stroke ESESESESESESES x Inspect for air leaks using soapy water solution E E EET RE ERR RS RT Air Springs Inspect for proper clearance 1 minimum all around peces nt bit ki oft Check upper mount nut and lower mount bolt torque X Inspect for signs of chafing or wear X X X X XX xX xX Inspect for air leaks using soapy water solution X Inspect for air leaks using soapy water solution X Shock Absorbers Check mounting nut torque Bel its we a aa Inspect shocks for signs of fluid leak broken eye IXIx x x xIxIx x ends loose fasteners or worn bushings Kingpins Check for wear x x Inspect vertical endplay x x Steering Arm Bearings Check nut torque X x Inspect bearings for excessive radial play X x X X X X X x Carrier Bearings Check axial endplay Mn x Wheels Check bearing endplay Ix x Check wheel nut torque IXIX X X X x x xX Front Alignment Inspect toe in x xf x x Air Fittings and Air Lines Inspect for air leaks using soapy water solution X Inspect for signs of chafing cracking or wear X X X X X X X x Sway Bar Bushings Check mounting bolt torque X x Inspect for bushing wear X X x X X X X x Maintenance Record Name of Owner Date of Purchase Model of Vehicle Suspe

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