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IFS1700S I&M Manual

1. 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 chains straps etc to suspension upper and lower control arms sway bar and brackets brake components tie rods steering arm assemblies or steering knuckle carrier assemblies Figure 3 Sway Bar fa Upper Control Arm EA A N JAG ts Steering D ye be a oh Steering Arm Lower Brake Assemblies Control Arm Components Figure 3 Improper Tow Equipment Attachment Locations D711987 6 IFS1700S 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
2. VIEW A A LH Front Eccentric View Scale 1 2 Neutral Position 6 Positive Camber OS Negative Camber VIEW B B LH Rear Eccentric View Scale 1 2 FORWARD Figure 14 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 Figure 14 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 D711987 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 Tighten the adapter locknuts to 465 485 ft lb See Torque Table Tighten the setscrews to 30 40 ft lb See Torque Table Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 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 on the end is configured such that it can
3. ABS sensor malfunction Inspect ABS sensor installation and replace sensor as required 1 Front tires lock up during j r 7 hard braking or ABS ABS CPU or system malfunction Check and repair or replace as reguired Check ABS sensor connection and lead wire Check for damage and replace as required malfunction light remains lit ABs sensor electrical connection faulty Tone ring on hub damaged D711987 26 IFS1700S SYMPTOMS POSSIBLE CAUSES REMEDIES Front shock absorbers worn Replace shock absorbers as reguired Vehicle ride is too harsh Incorrect ride height Adjust ride height to specified setting and or suspension contacts Vehicle overloaded Check wheel loads and correct as reguired stops excessively 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 reguired specification Rebound bumper worn or missing Check and replace as reguired Jounce bumper in air spring worn or Check and replace air spring as reguired broken Front shock absorbers worn Replace shock absorbers as reguired Vehicle ride is too soft Incorrect ride height Adjust ride height to specified setting Incorrect steering arm geometry Adjust tie rod lengths as required Steering gear not centered Inspect and adjust as required Vehicle has unequal turning r
4. Install steering knuckle carrier mounting bolts in control arms Note orientation of bar pin Apply Loctite 271 to mounting bolt threads and tighten to 350 370 ft lb See Torque Table This page intentionally left blank D711987 62 IFS1700S Torgue Tables Most threaded fasteners are covered by specifications that define required O N mechanical properties such as tensile lt lt gt strength yield strength proof load and ES ae rr as ed hardness These specifications are carefully considered in initial selection of Grade Markings on Bolts fasteners for a given application To assure continued satisfactory vehicle pare eee performance replacement fasteners used Identification should be of the correct strength as well as the correct nominal diameter thread pitch 3 Dots 6 Dots length and finish Grade Markings on Lock Nuts Torque Table 1 TORQUE SPECIFICATION ft lb APPLICATIONS FASTENER SIZE CLEAN AND DRY Upper Control Arm Bushing Pivot Bolt 1 1 8 12 x 7 Gr 8 950 1050 Lower Control Arm Bushing Pivot Bolt 7 8 9 x 8 Gr 8 465 485 Eccentric Setscrew 10 24 x 3 8 30 40 in lb Steering Knuckle Carrier Mounting Bolt 3 4 10x 2 Gr8 350 3700 A 2 4 5 8 18 x3 Gr 8 1 4 Lower Air Spring Mount Bolt into Carrier 5 8 18 x 1 Gr 8 170 190 Air Spring Upper Mount Bolt thru Cradle 3 8 16x1Gr8_ 15 20 Air Spring Lower Mount Bolt into Air Spring
5. 2 Press the sensor into the steering knuckle until the sensor end contacts the tone ring 3 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 0 10V 4 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 5 Ifthe minimum reading is not obtained then check the volt meter connection and proximity of the sensor and tone ring The air gap between the sensor and tone ring should not exceed 027 Repeat step 4 6 If the minimum reading is not obtained check the tone ring for damage and its installation The tone ring should have a maximum run out of 008 Replace as needed and repeat step 4 7 If the minimum reading is still not obtained then replace the sensor and repeat the installation procedure 8 Route and secure the sensor lead wire the same as the removed sensor 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 leng
6. 4 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination NOTE Hub cap window may be damaged by solvents D711987 54 NOTE When removing or installing the outer spindle nut use the correct wrench sockets to avoid damaging the nuts Do not use impact driver to tighten outer nut Only use a torque wrench to tighten the nuts 5 Remove the keeper from the nut 6 Al 3 Use a small screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released 7 Remove the retaining nut 8 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 9 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 10 Remove the hub seal and discard it Remove the wear ring from the spindle and discard it IFS1700S 11 12 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 Inspect the bearing areas
7. LH K705382 Kit Ball Joint and Hardware 2 700973 02 Tie Rod Assembly RH 12 705382 01 Ball Joint 40mm 3 701924 01 Crank Arm Assembly 13 705382 02 Slotted Nut M20x1 5 4 700973 05 Crank Rod Assembly 14 705382 03 Cotter Pin 1 40 x 15 Dia 5 705619 01 Bell Crank Assembly 15 701925 01 Crank Arm 6 702030 01 Relay Rod 16 700949 01 Bell Crank 7 705620 01 Idler Arm Assembly 17 700951 01 Idler Arm 8 167 Hex Head Bolt 1 14 x 6 Gr 8 K710622 Kit Bearing Replacement 9 89422312 Lock Nut 1 Gr C 18 8654 Shim 10 2571 Hardened Flat Washer 1 19 701378 01 Bearing 11 101445 P1 Cotter Pin 1 8 X 1 1 2 20 6966 Snap Ring 21 7348 Spacer Components of Ball Joint Kit K705382 Components of Bearing Replacement Kit K710622 Cy 20 Idler Arm a F Bell Crank Assembly Assembly Assembly D711987 12 IFS1700S Tie Rod Assemblies Item Part No Description Item Part No Description 1 103712 Tie Rod End RH 5 101445 P1 Cotter Pin Not Shown 2 6632 Clamp 6 710671 01 Tie Rod End LH 3 700971 01 Tube Tie Rod 7 700971 02 Tube Crank Rod 4 103736 Tie Rod End LH 8 710671 02 Tie Rod End RH fs AN a i i Crank Rod Tie Rod Assembly Assembly 18 D711987 Air Spring and Shock Components Item Part No Description Item Part No Descr
8. D711987 GENERAL SERVICE TO BE PERFORMED ER ee EN MAINTENANCE 12 24 36 48 60 72 84 96 Steering Arm Assembly Ball Check axial endplay K x Joints Inspect for ruptured seals XIXIXIXIXIXIX De Check that cotter pin is installed xlxixixixixixi l Control Arm Bushings Check bolt torque TE N xl el ee x Inspect for control arm and mount contact els xi x xixi x xX Inspect for bushing wear xlix xi x xix x xX Tie Rod Ends Inspect ball socket endplay xixixixi xix x xX Check for taper connection looseness Del X Check cotter pin installation Deel DE Brake System Inspect Brake Pads for excessive or uneven wear K K K x Inspect Brake Caliper for minimum free play K K K x Inspect for Air Leaks using soapy water solution El AA NA NANA NA FT Air Springs Inspect for proper clearance 1 minimum all around x hem IE er lee Ik Ed Check upper mount nut and lower mount bolt torque EER EE ESE le Inspect for signs of chafing or wear DI x NG Inspect for air leaks using soapy water solution K Height Control Valve and Inspect for signs of bending binding or slippage K XIXIXIX XIX x Linkage Inspect for air leaks using soapy water solution X Shock Absorbers Check mounting nut torque X Inspect shocks for signs of fluid leak broken eye xixixi x x x xl ends loose fasteners or worn bushings Kingpins Check for wear x
9. GE ED Da aa aan aa ate cA cline e ae 57 Sersor Masta atone EO RE E S 57 Tone Ring Removal and Installation iese esse see se ee ee RA GR Re ee RA Ge Re ee RA ee ee 58 Replacing the Shock BSOrbeE EE ER EE oe Ge Ee Ee 58 RCT VAL sac Ee Ee ES EE AE eee 58 ATTA NAOT es aan aaa a a coal EE ER ER GE ER EG EG ie 58 Replacing the Air SPIN SE Eie EK ERGE Ek RE EE NE 58 Saai GIE ae EE AA a LE N eas D AE 58 istallato SS GR EG GE Ge SG Ge 58 Replacing the Height Control Valve de eie se ase SE de esse 59 ERETON E DE N GE E T OG EE E TA 59 ate ARE nna EE a a aa EE a 59 Replacing the Sway Bar and Components cccccscccseseceeseeeteeeeeteeeseeeeesaes 59 Vertical Linkag Removals nern GE EE ER a e aa an ea a a aa a e nagan eag 59 Vertical Linkage lista Maori iS AE EG ER AE RD AG ico GE SE EG shies 59 Sway Bar Removal ass isan EG EO sd De ke Di Gie es Desai Ve ARE NN de 59 Sway Bar Installations ss kase De es eke ee divas eth ek Ge a ei ee ee pena Ba ber Ee ne 59 Replacing the Steering Knuckle Carrier Bearings oaaoaneen ee ee RR ani 60 Removal SR De ed gee ee Ge ee tid toed Ge cede as 60 Trista dE ah Oty is Es ee RR a ee ee de aa RR ee sg Sa 61 Tardue ables se ke ds ee GE ig 0 D711987 3 Introduction Service Notes This Service Manual describes the correct service and repair procedures for the ReycoGranning IFS1700S Independent Front Suspension model with 17 000 Ibs Gross Axle Weight Rating GAWR Overloading the suspe
10. HCV Installation 1 Apply Permatex or equivalent thread sealant to the threads of the air connection fittings or plumbing fixtures and install the fittings or plumbing fixtures in the HCV 2 Attach the HCV to the sub frame with mounting hardware Orient the horizontal arm horizontally and tighten the mounting nuts to 7 9 ft lb See Torque Table 3 Connect airlines as marked during removal D711987 59 4 Connect the vertical linkage to the horizontal arm 5 Recharge system with air and check for air leaks 6 Check the ride height and adjust per section on adjusting the ride height as needed Replacing the Sway Bar and Components 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 75 85 ft Ib See Torque Table Sway Bar Removal 1 Follow the instructions for removal of the sway bar vertical linkage for both sides 2 Remove mounting hardware from D ring sway bar mounts on rear of suspension sub frame Retain hardware for installation 3 Rem
11. and secure drain plug 16 Check oil level through the hub cap window Figure 5 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub NOTE The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window 17 Check the hub cap for external oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the gasket The vent plug will normally weep a small amount of oil Adjusting the Maximum Wheel Turn Angle D711987 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 or replaced Use an alignment machine to check the wheel turn angle See the measurement procedure of the alignment machine manufacturer The 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 d
12. 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 D711987 4 Lower the jack to align the bar pin with the control arm Apply Loctite 271 to mounting bolt threads and tighten to 350 370 ft lb See Torque Table Adjusting the Caster Angle Positive Negative Caster Caster FORWARD Figure 15 Caster Angle ZX CAUTION Do not adjust the suspensio
13. ee a a A AN aka ae lucas cad eg Ne na apaa sajah 49 Replacing Tie Rod PAAS dee Ode Ed io Ge ee n Ee ne 49 WR GING less ttn EG SG acum Ue kai EG NE SE Baga Goa tic nah rd 49 Installation eh a OE EE EE N 49 Replacing the Relay Rod Ball JONES ee se ee ee RR Re RA ee ee 50 Remoyal AE IE EA EE OE EE E gan 50 MMISTAM AIO SN N aana A N ee De Ega ap an a Dee 50 Replacing the Bell Crank Idler Arm and Crank Arm Bearings 4 50 RETO Va ETA EE N EE EE N RE N gagah Ka ag ba aa gan ka 51 Tras teal Ee Ott yice ds cay i sada cosa EO EE aa na Gaga as 51 D711987 2 IFS1700S Table of Contents Replacing the Upper and Lower Control Arm BushingS esse esse esse ee 51 Upper Control Arm Removals iiser EG aaa N ee 52 Upper Control Arm Installation asses de EE EE kg de He de ORE N Eg go Ai ke RE Ne 52 Lower Control Arm Removal eise es Rek ek RE Se aarp A SAES ARRE a 52 Lower Control Arm Installation a0seseees Se ER Ee GE Ge nenen nean ee eg 53 Replacing Wheel Bearings Oil Seals and Hub CapS sesse esse see nana ee 53 Removal aaa ie aa aab se a ee a Ta a a ga eee eda Mae Ga ie es 54 MAYS Ged BE ea CHOI ed ee Ee ng sos NT E a DER Ed aa 55 Replacing Brake Components se ase ee desde ek Re ke ee weke eo 57 Brake ROOS SE DE GE N OG ng Ba a GE Ee ana Nga aie 57 Br ke Chamberse EE Be Ge eg 57 Other Brake COmpOnenits EE OG GE EE Re Ge 57 Replacing the ABS Sensor and Tone Ring ees ee ee RA nana Re 57 Sensor REMOVAL EE ES N
14. instruction that is important for correct service D711987 4 IFS1700S 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 ReycoGranning for control purposes and should be referred to when servicing the suspension or requesting technical support Figure 2 Ta Pele Aaa mG MAP i t Mi N Figure 1 Suspension Identification Location Reyco Granning ee SERIAL 000000 GAWRILBS monet IFS1700S SB 17 000 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 GAWR Wheel Disc Sway f Model Ib Cut Brakes Bar Height Control IFS1700S No Dual Valve gt IFS1700S SB 17 000 55 Bendix Yes Single IFS1700S SHC ADB22X No Electronic Dual IFS1700S SHCSB Yes Sensor Single Table 1 Model Identification D711987 5 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
15. 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 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 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 Press the ABS sensor outward about Vi Do not use a sharp tool on lead wire end of the sensor See section for the inspection of ABS sensor as needed Place the hub onto the spindle until it seats on the inner bearing Do not ram the hub onto the seal D711987 Pre lubed outer bearing and place it onto the spindle until it seats on the outer cup in the hub The bearing retaining washer may be used to guide the bearing onto the spindle The hub should be supported to prevent misalignme
16. sensor Disconnect the ABS sensor lead from the chassis connector The ABS sensor test will reguire a voltmeter that can measure AC voltage on a 0 10V scale Connect the voltmeter to the connector pins of the ABS sensor lead Set the voltmeter scale to millivolts and the voltage source to AC volts Rotate the wheel hub by hand and record the voltage output from the ABS sensor A minimum output of 0 8V AC 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 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 D711987 10 Repeat Step 3 If voltage output is less than 0 8V AC then replace the ABS sensor NOTE Check voltage output of new sensor 1 027 N MAK Figure 7 ABS Sensor and Tone Ring Gap Inspecting the Shock Absorber 1 30 Check shock absorbers for oil leakage bent compone
17. thru 19 until proper endplay is achieved 21 Install hub cap gasket and hub cap Tighten the cap screws to 20 30 ft lb See Torque Table Replace the hub cap vent plug if removed 22 Fill the hub cavity with the appropriate amount and type of lubricant and secure drain plug 23 Check oil level through the hub cap window Figure 18 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 D711987 NOTE 56 The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window Figure 18 Wheel Bearing Oil Level 24 Check the hub cap for external oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the gasket The vent plug will normally weep a small amount of oil 25 Install the Brake Caliper and Pads 26 Install the wheel and tire assembly and the Wheel Nuts 27 On aluminum wheels use a plastic anti scuff guard over the Wheel Nuts Tighten the Wheel Nuts in sequence to 450 500 ft Ib See Torque Table 28 Replace the wheel hub cap nuts and hub caps if removed to service the wheel bearings IFS1700S Replacing Brake Components Brake Rotors The brake rotor should be
18. tire and wheel combination Put correct air pressure in tires based on wheel load Adjust toe in to specified setting Adjust wheel caster to specified setting Inspect ball stud connections and wear Check and tighten to specification Inspect ball joints for wear or contamination and replace as required Check and replace 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 required Loose pitman arm Check pitman arm and tighten as required Steering column linkage worn Check for wear and repair or replace as required Steering gear adjustment Steering column misaligned Worn knuckle carrier bearings Loose knuckle carrier mounting bolts Check and adjust to specification Realign steering column as required Check adjust or replace as required Check and tighten as required Loose Wheel Nuts Vehicle overloaded or unevenly loaded driver side to passenger side Check and tighten to specification Improper mismatched tires and wheels Install correct tire and wheel combination Tires have incorrect pressure Put correct air pressure in tires based on wheel load Unequal ride height side to side Inspect ride height and adjust to specified setting Improper brake adjustment Incorrect rear axle alignment Inspect and adjust slack adjusters as required Align rear
19. 1 2 13 x 1 Gr 8 20 30 Idler Arm Bell Crank amp Crank Arm Mount Bolt 1 14x6 Gr 8 575 625 Idler Arm amp Bell Crank Ball Joint Base M56 1 5 325 3757 Idler Arm amp Bell Crank Ball Joint Castle Nut M20 1 5 155 175 Tie Rod Castle Nut 7 8 14 90 100 Tie Rod Clamp Nut 5 8 11 Grade B 50 60 Upper Shock Eye Mount Lock Nut 8 4 10 Grade C 170 190 Lower Shock Eye Mount Lock Nut 3 4 10 Grade C 170 190 Lower Shock Mount Bracket Bolt 3 8 16 x 1 Gr 8 30 40 Steering Stop Jam Nut 1 2 20 Grade B 50 75 Steering Arm Assembly Castle Nut 1 1 8 12 Grade C 550 1025 Sway Bar Mounting Bracket Nut 7116 14 Grade C 50 55 Sway Bar Linkage Nut 1 2 13 Gr 8 75 85 Sway Bar Upper Control Arm Bracket Nut 1 2 13 Gr 8 75 85 Kingpin Draw Key Nut 1 2 20 Grade G 30 45 Kingpin Cap Bolt 5 16 18 x 1 Gr 8 20 30 Height Control Valve Mount Lock Nut 1 4 20 Grade C 7 9 Height Control Valve Linkage Stud Mount Nut 5 16 18 Grade B 8 12 Height Control Valve Adjuster Nut 1 720 neta 24 28 in Ib 1 Torque applied to bolt head 2 Apply thread adhesive Loctite 242 or equivalent to threads of fastener threaded into tapped hole 3 Install cotter pin after tightening 4 Apply thread adhesive Loctite 271 or equivalent to threads of fastener threaded into tapped hole D711987 63 Pro Torg Spindle Nut 1 18 See Adjusting Wheel End Play Disc Brake Caliper Mount Screw M20 2 5 x 60 325 375 Torgue Tables T
20. 11987 Adjusting the Toe In ZN CAUTION Do not alter components to adjust the toe in Acaution 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 the tendency of the tires to toe out when the vehicle is driven straight ahead Incorrect toe in can result in rapid tire wear IFS1700S 3 Measure the length of the outer tie rods Reference length is 17 inches If the 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 tie rod and turn the center tube to change the length Adjust the length of both outer tie rods equally such that the toe in on each side is 1 16 1 32 and the overall toe in is 1 8 1 16 Tighten tie rod clamp nuts to 50 60 ft lb See Torque Table Refer to Figure 6 for tie rod clamp orientation D711987 47 Repairs General Procedures Repair or reconditioning of front suspension components is not allowed Components that are damaged or worn must be replaced Several major components are heat treated and tempered Z WARNING The comp
21. Adjust toe in to specified setting Note Wear pattern 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 Install correct tire and wheel combination l Improper oversized tires l Install correct tire and wheel combination l 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 a A E F steering assist Steering arm assemblies binding Check steering arm assembly bearings and lubricate as reguired Steering arm assembly ball joints binding Inspect ball joints for wear and replace as reguired Tie rod ends binding Inspect tie rod ends for wear and lubricate as reguired Kingpin binding Inspect lubricate and repair as reguired Steering column linkage binding Align or adjust as reguired Steering miter bok 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 i
22. Do not loosen the castle nut to install the cotter pin 4 Lubricate tie rod end as needed Replacing the Relay Rod Ball Joints The thread in mount type ball joints are installed with a thread adhesive and may reguire the threads to be warmed to ease removal If heat is applied to the ball joint threads the steering arm assembly 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 assembly 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 Relay Rod tapered hole using a suitable tool 4 Secure the steering arm assembly and remove the ball joint using a ball joint spanner wrench or similar device on the base Steering arm assembly may be removed to facilitate ball joint removal See the steering arm assembly replacement sec
23. Gati O0N ie se Re RE sation site KE KA Ge Ke ee be ee a D RR Ge a a 5 Vehicle Towing Information ese EE vo gen Do Ee 6 Maintenance See dues scx HE N EE RE GE be Ge Ee 7 Maintenance Record RE Ee anaa aana naa aana nana ana EE Se 8 Paris iste an aga anan a De nagan ana aan aa aaa ai I Unt Assembly insna r aa ERr a bah BA En soe tiation 9 Co trol Arm Components oen ee eg ea GE E EEE E oe 10 Control Ar Assembles EG ER EE E ga EE enacts 11 Steering Components s side De id de ese EEE EAT AAE Se NA ed 12 Air Spring and Shock ComponentS iis ee Re RR Re RA Re RA ee 14 HCV Components non SHC Models Only sees see ese ee ee ee an ee ee 15 Height Sensor Components SHC Models Only ees sees esse ese ee se ee ee ane 16 Sway Bar Components SB Models Only ee Re RR RR Re an e 17 Disc Brake Components EERS ERGE GE DR ER Ges ee De ese 18 King Pin GCOMpPONENTSA ES DE Ee DS oe Go id EE ee 19 Steering Knuckle Carrier Component iese ee RA a nenanem wanan 20 LubricatiOn sis sesse soos ok Re Sk ee Ge ig es ee ke ie dL Lubricant Specifications and Intervals ie sesse Ee es Rd BE ge ee be ei 21 General TWD CANON RE N E ENE ANG ANA NA Ka WA GE Ve Ge es 21 Ball JOS ee Ee EE Ee EEE De ee ae Ge ee Ee 21 Rod Ends on Tie Rods Crank Rod sedes ls sesse ss se el se se Oe gee 22 Carrier Bearing and Kingpin SS ES EG GE SR EG GE n anane 22 Wheel Daarmee ste Dade bie ee EE DR Ee AE Re ag ese ed advan een a ea ee Ek 23 Troibleshooting is aan ga aaa aa
24. Reyco Granning SUSPENSIONS IFS1 7008S Independent Front Suspension Maintenance Instructions Service Parts Document D711987 Revision A Revision Date 11 12 Reyco Granning Suspensions 1 8 0 0 5 3 0 0 5 0 1205 Industrial Park Drive m m Mount Vernon MO 65712 Phone 417 466 2178 www reycogranning com Es COMPANY PROFILE Reyco Granning Suspensions was formed by the merger and acquisition of two well known names in the heavy duty vehicle suspension industry Reyco and Granning Reyco grew out of the Reynolds Mfg Co and was first known as a major supplier of brake drums for heavy duty vehicles and later developed a full line of air and steel spring suspensions for trucks busses trailers and motorhomes Granning Air Suspensions was founded in 1949 in Detroit Michigan as a manufacturer of auxiliary lift axle suspensions Granning later became an innovator of independent front air suspensions for the motorhome industry Reyco Granning LLC was formed in early 2011 through a partnering of senior managers and MAT Capital a private investment group headquartered in Long Grove Illinois Reyco Granning manufacturing facilities are certified to the ISO9001 2008 standards a globally recognized assurance that quality standards have been established and are maintained by regular rigorous audits Table of Contents Introduction ss EE ee Service NOS ie sd N ada ian a es ds aa a bea a De GE ON aa ag 4 Tdenti
25. Ride Height Unit Ride Height A Air Spring B IFS1700S 6 61 9 25 Properly adjusted ride height results in correct suspension travel and alignment The ride height should not be adjusted to adjust chassis rake angle D711987 36 A CAUTION Adjusting the ride height can cause the front end to raise or lower unexpectedly due to vertical movements at the connection of the vertical link and the horizontal arm of the height control valve 1 Park the vehicle on a level surface 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 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 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 5 After adjusting the length it is recommen
26. Sensor Spring Retainer 15 705013 15 Torque Plate Assembly LH 4 705011 01 Steering Knuckle Assembly LH 705013 16 Torque Plate Assembly RH 705011 02 Steering Knuckle Assembly RH 16 1786 Hub Cap Gasket 5 8223752 Hex Head Bolt 4 16 x 2 Gr 8 ZN 17 700690 04 Hex Head Bolt M20x1 5 50 Gr 10 9 6 705051 01 Bearing Cone Inner 705013 17 Caliper Assembly LH 705051 02 Bearing Cup Inner 18 705013 18 Caliper Assembly RH 7 705052 01 Bearing Cone Outer 705013 04 Brake Pads Set of 4 705052 02 Bearing Cup Outer 19 703553 02 HFW M20 ZN 8 705017 01 Arm Steering LH 20 89422308 Lock Nut 16 x 75 Gr G PH 705017 02 Arm Steering RH 21 103003 HFW 3 4 9 705011 21 Castle Nut 1 12 22 708181 01 Nut Spindle Pro Torg 10 705011 26 Key 23 709226 01 Hub Cap 11 705011 22 Assembly Steering Stop 24 707819 01 Hub and Rotor Assembly 12 705011 20 Cotter Pin 3 16 x 2 1 2 D711987 18 IFS1700S King Pin Components 705011 15 Bolt King Pin Cap 11 705316 01 Nut Draw Key Item Part No Description Item Part No Description 1 705011 07 Shim 005 thick 7 705011 17 Cap King Pin 2 705011 08 Shim 010 thick 8 705011 18 O Ring 3 705011 09 Shim 020 thick 9 705011 19 King Pin 4 705011 14 Assembly Bearing Thrust 10 705315 01 Draw Key Long 3 80 5 6 705011 16 Grease Fitting Straight Oil seal is on the bottom
27. a dan aana A INS PCCUON iss ER aaa N N Nga D General Inspection iets eer RR SE ee aos Ie RE Ee eo Be ed ge ke 28 Inspecting the Control Arm Bushings for Wear ccceescceseeeeeeeeeeneeeneeees 28 Inspecting the Tie Rod Ends es EE RE aon aN ES GN 29 Inspecting the Brake System SE EE EG ee ace 29 Brake Syste us ese se ie ee cau Ka Ee ee eek ie de BE Ge Ee Ee EE ee 29 Inspecting the ABS Sensor and Tone Ring sesse se ee RA Re ee 30 Inspecting the Shock Absorber i e id se Ge dee se Age ee ee ee de eN ie 30 Inspecting the Air Spring and Height Control Valve ss esse ese ese ee 31 Air Spring INSPEC OMe in EE Ge Ee GE E de 31 Height Control Valve Inspection se GE ee corde aana pene lacs receding segues 31 D711987 1 Table of Contents Inspecting the Idler Arm amp Crank Arm BearingS eise ese ee ee ee RR ene 31 Inspecting the Relay Rod Ball Joints ees ee ee RR ee ee ne 32 seal SPEED se De ee AG oe De ge AG ant ee Ge Oe Ve Eg aaa 32 Endplay SPEEL crises oo aa Ga Re AG NAN EE De a a a waga sada 32 Inspecting Wheel Bearing EndplaY esse esse esse nenanem anana aana nenanem nenen ane 32 Inspecting the Knuckle Carrier Bearing and Seal see Re ee nana 33 Inspecting the Kingpin Vertical Endplay esse sesse esse se ee ee ee ee ee 33 Adj ustments N OE EE EG OD GE Oo Adjusting Wheel End Play is so EE ee ed ee Re 34 Adjusting Suspension Ride Height 0 ccccscccssssessteessscseeeessseceeeeeseseeenenes 36 Adjustin
28. adius right to left Steering gear poppet valves set Check wheel turn angles and adjust as incorrectly required Tie rod clamps positioned improperly Check orientation and adjust as reguired Air leak Check connections with soapy water solution and repair or replace as reguired Suspension does not Internal leak in height control valve Check height control valve and replace as maintain ride height reguired Height control valve linkage loose Check and tighten linkage as reguired Air spring chafed or worn Check air spring and Replace as reguired 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 Brake pads are not a balanced set Replace brake pads as required Brakes are noisy different friction codes or brand Loose or broken brake pads Replace brake pads as required Brake Rotor Warped Re machine or Replace as reguired Defective Brake Rotor Inspect for defecis and Replace as reguired Refer to Bendix Disc Brakes manual Y006471 for troubleshooting of the disc brakes or contact Customer service at 1 800 247 2725 D711987 27 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 Whee
29. amage 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 IFS1700S Figure 12 Steering Stop Bolt Unit Steering Stop Length A IFS1700S 1 38 1 angle 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 Crank Rod length may be adjusted to attain steering gear on center condition while maintaining equal toe in side to side Do not adjust the length of the Crank Rod or Tie Rods to center the steering wheel This can cause the steering gear to become off center Drive the front tires on a suitable device that allows the front wheels to turn and measures the wheel turn Secure the vehicle by setting the parking brake and block the drive D711987 39 Check that the steering gear is
30. axle to specified thrust angle Incorrect caster and or camber setting Check wheel loads and correct as reguired Check and adjust as required Wheel bearings out of adjustment Check wheel bearing end play and adjust as required Loose steering gear mounting Tie rod end connection loose or ball stud worn Check mounting and secure as required Inspect ball stud connections and wear Bent spindle or steering arm Frame or underbody out of alignment Incorrect toe in setting Inspect and correct as required Adjust toe in to specified setting Mis aligned belts in radial tires Check and replace as required Steering gear valve binding Inspect repair or replace as required Steering gear not centered Excessive water puddling on road 25 Excessive internal steering gear leakage Inspect and adjust as required Inspect repair or replace as required Avoid water puddles on road Inspect and replace as required ___svweroms POSSIBLE GAUSES SYMPTOMS POSSIBLE CAUSES REMEDIES Grease oil or dirt on brake pads Replace brake pads as reguired Vehicle pulls to one side Brake pads are glazed Deglaze brake pads by burnishing or replace with the brakes applied as reguired 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 required Brake rotor warped Re machine
31. bsorber and connect the lower control arm to the lower shock bracket using the mounting hardware Tighten the nuts to 30 40 ft lb See Torque 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 hub cap nuts if present and the wheel hub cap before loosening the Wheel Nuts Place the wheel hub cap in safe location to prevent damage Place the wheel and or wheel hub cap 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 hub cap drain plug is facing upwards Remove the drain plug from the hub cap 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 Brake Caliper
32. centered and the tires are steered straight ahead with equal toe in side to side If either of these two conditions is not met then adjust toe in first before centering the steering gear See Adjusting the Toe In Section and refer to Spartan chassis service guidelines for centering the steering gear 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 If the wheel turn angle differs from Spartan chassis guidelines then adjust as follows Loosen the jam nut on the stop bolt Turn the stop bolt until the specified wheel turn angle is achieved and the bolt head contacts the knuckle carrier Tighten the jam nut to 50 75 ft lb 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 opposite direction Inspection before Alignment See the General Inspection section and check the following before conducting front wheel a
33. ction for kingpin 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 If the 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 D711987 33 Adjustments Adjusting Wheel End Play A 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 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 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination jacks or safety stands under the lower NOTE Solvents may damage the hub cap control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury ZX WARNING Failure to follow this instruction could cause the wheel to come off an
34. d cause bodily injury The PRO TORQ Spindle Nut is sold as an assembly with the keeper in place DO NOT attempt to place the nut on the spindle or tighten or loosen the nut on the spindle while the keeper is locked inside the nut Doing so may deform the keeper and allow the nut to unthread during operation 1 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands 3 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hub cap drain plug is facing upwards Remove the drain plug from the hub cap and place it in a container for re installation D711987 34 window 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 6 Remove the keeper from the nut 7 Al Bl Use a small screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released 8 Seat the bearing with the hub rotor only using a torgue wrench 9 Tighten the nut to 200 ft lb Spin the wheel at least one full rotation 10 Repeat step 9 two more times 11 Back the nut off until it is loose IFS1700S Highly Visible Adju
35. ded to dump and re inflate the air suspension to obtain the ride height Allow the suspension to settle IFS1700S 6 If not already completed adjust the 6 Remove the hub cap bolts hub cap rear suspension per manufacturer s and gasket Take care not to damage recommendations the gasket for re installation Place the 7 Verify at each axle that the side to side ee ae WA ROCA EO PEER ride heights are within 25 of each etnias ea other NOTE Solvents may damage the hub cap Adjusting Wheel window 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 ZN WARNING a torque wrench to tighten the nuts Bearing Endplay 1 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement Never work under a vehicle supported 7 Remove the cotter pin and loosen the by only a jack s Jacks can slip or fall spindle nut over and cause serious personal injury 8 Seat the bearings by tightening the Always use safety stands Do not place spindle nut to 200 ft lb while rotating jacks or safety stands under the lower the wheel in both directions control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury 10 Loosen the spindle nut 1 2 turn and then ti
36. e are secure 4 Check for worn suspension bushings or damaged suspension components 5 Check that the rear axle is correctly aligned Check that the frame is not bent 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 ReycoGranning 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 IFS1700S 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 bar pins of the knuckle carrier bearing marked with a B may also be used to provide add
37. en the steering arm assembly and the Relay Rod Do not allow the pry bar to contact the ball joint seal Firmly pry upward using the steering arm assembly as a fulcrum to lift the Relay Rod The pry load must not cause the Relay Rod to rotate thus causing the Relay Rod to change orientation Record the dial indicator reading A reading greater than 040 will require ball joint replacement Inspect ball joint seal for damage and replace the ball joint if damaged during measurement process joint must be replaced Inspecting Wheel 3 Skip ball joint endplay measurement Beari ng End play NOTE 2 Remove the hub cap 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 4 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 assembly Place the indicator tip on the flat area of the Relay Rod adjacent the castle nut 2 Using a C clamp squeeze the Relay Rod and the steering arm assembly together to seat the ball joint Do not apply excessive clamp load 3 Set the dial indicator on zero D711987 32 Remove the tire and wheel 3 Attach a dial indicator with a magnetic base to the face of the hub Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zer
38. er Control Arm Assembly 11 700178 06 Shock Absorber 4 700245 01 Boss Eccentric 12 700973 01 Tie Rod Assembly LH 5 705633 01 Carrier Assembly LH 13 702030 01 Relay Rod 6 705633 02 Carrier Assembly RH 14 700973 02 Tie Rod Assembly RH 7 705013 17 Caliper Assembly LH 15 703915 01 Height Control Linkage Assembly 8 705013 18 Caliper Assembly RH 16 706899 01 Height Control Arm D711987 Control Arm Components Item Part No Description Item Part No 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 11 168 Hardened Flat Washer 1 1 8 6 100122 P1 Lock Nut 7 8 9 Gr C 12 166 Lock Nut 1 1 8 12 Gr C D711987 IFS1700S Control Arm Assemblies Item Part No Description Item Part No Description 1 703181 01 Upper Control Arm LH amp RH 3 8382 Bushing 2 700939 01 Lower Control Arm LH amp RH D711987 11 Steering Components Item Part No Description Item Part No Description 1 700973 01 Tie Rod Assembly
39. g Wheel Bearing Fndplay sesse sesse ees se ee ee ee ee Ge Re ee ee anana ee ee 37 Adjusting the Maximum Wheel Turn Angle ees see se Re RR anana RA 38 Inspection before Al Omiment Ee GR Ee ee Pr ie nane 40 Wh els and Tiresia RS ERG EDE SG a ba ah NGNE NGE Aa aha 40 Front Suspension ieni a aan ER GE Arg Scot Mist EE alate 40 Rear Axle and SUSDENSION is ers een a ee N SE Ge de a ee Ge ee N 40 Front Wheel Alignment aen asa EG EE ER Ee cued ee GE E tees 40 E UIE jae haat sce cae hs sande N GE SE GE ie 40 General SE ED N N ED EG GO GE N EG tinea ET 41 Preparation EE ee E a AN ea tease A a ae GE aa E gg BR eet E ie 41 Adjusting the Camber Anglo as ME EE Ee anana anaa ana nana ee nane 42 Eccentric Camber AdjuStmeRE sessies See anna anan aan aana adie nana ee ek ee ek ie 42 Bar Pad Camber Ad SWERE mecsre al eis ses ee GE a Na a EG N aa 44 Adjusting the Caster Angle ES EG Se ER RE GE Ee ee ee aane 44 Eccentric Caster AdjuStment cis mcerar cece as Ee GE tenets tenure GE GE EE EE 45 Adjusting the Toe In ses EE ee Ee Ge RR ERK GE GR es es SR Ge 46 Repair 60606060606060606060606060606060606060606060606060660606060606060606060606060606060606606606606606606606060606606606060060 ss General Procedures ise anak naban ag E Rents ge DS 48 Cleaning he Par S RE a dawns a aa Da a Ge a Gee 48 Ground r Polished Paris aaa EG GE sine 48 Rough Parts SG a a aa a a A GE De EA BB a a A E a ga 49 Da N EE A EE EI EE ENE 49 Preventing WOM OSION ss ae ER ie ee
40. g and carrier Grease Fittings ca EN Grease Fittings Grease Fittings Figure 4 Location of Lubrication Fittings Note Left side only shown D711987 22 IFS1700S 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 3 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 ZN CAUTION Do not remove or twist the red plug on the front of the hub cap This will damage the hub cap and cause oil to leak Add oil only thru the pipe plug or warranty will be void Figure 5 Wheel Bearing Oil Level D711987 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
41. ght Measurement Unit Ride Height A Air Spring B IFs1700s_ 6 61 9 25 Inspecting the Idler Arm amp Crank Arm Bearings 1 Check that steering arm assembly 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 the steering arm assemblies Figure 9 The steering arm assemblies should not exhibit any noticeable conical motion about their pivot axes 3 If any conical motion is observed check pivot bolt torque which should be 575 625 ft lb See Torque Table Otherwise replace the bearing set of the steering arm assembly that exhibits conical motion Figure 9 Steering Arm Assemblies Inspecting the Relay 4 Release the clamp Place the pry bar Rod 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 5 seal convolutes 2 If oil wetting is found then inspect the entire wet area to confirm the seal 6 has a rupture s and oil source is from internal grease leaking from the ball joint If seal is ruptured then the ball betwe
42. ghten the nut to 50 ft lb 9 After torquing the castle nut to 200 ft Ib rotate the hub and rotor ten 10 complete revolutions 2 Raise the vehicle until the front wheels are off the ground Support the raised 11 Back off the spindle nut 1 8 turn vehicle with safety stands 12 Verify that wheel endplay is between 3 Remove the tire and wheel 001 005 inches See inspecting wheel endplay section If not loosen spindle nut re index the spindle nut accordingly and repeat Steps 9 thru 12 until proper endplay is achieved 4 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hub cap drain plug is facing upwards Remove the drain plug from the hub cap and place it in a container for re 13 Install cotter pin and bend over if installation cotter pin hole is not lined up loosen t to first locki ition 5 Rotate the hub such that the drain hole bana a ca BA 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 D711987 37 Z CAUTION Never tighten the spindle nut to align the cotter pin with hole in locking washer This can pre load the bearings and cause premature bearing failure 14 Install hub cap gasket and hub cap Tighten the cap screws to 20 30 ft lb See Torque Table Replace the hub cap vent plug if removed 15 Fill the hub cavity with the appropriate amount and type of lubricant
43. he 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 lbs 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 D711987 12 13 14 15 16 17 18 19 20 Using the gap measurement from Step 10 place a number of shims eguivalent to the gap measurement onto the bar pin against the inner raceway Place the spacer onto the bar pin Apply approximately 400 lbs 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 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
44. honing 2 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 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 lb See Torque Table 6 Reconnect the sway bar linkage Tighten mounting bolt to 75 85 ft lb See Torque Table 7 Apply Loctite 271 to mounting bolt threads and tighten to 350 370 ft lb See Torque Table Lower Control Arm Removal 1 Place a portable jack under the knuckle carrier to secure and support it IFS1700S 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 se
45. housings may be honed to remove any burrs Z CAUTION Use of a cutting torch to remove control arm bolts will permanently damage control arm bushings and can result in damage to sub frame 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 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 D711987 52 3 Disconnect sway bar connector at sway bar if so equipped with a sway bar 4 Loosen and remove control mounting locknuts arm 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 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
46. iption 1 705951 01 Air Spring Assembly 14 706026 01 Brake Line Bracket LH 2 700178 06 Shock Assembly 706026 02 Brake Line Bracket RH 3 705692 01 Cast Lower Air Spring Mount LH 12 152 HFW 3 4 Used as Spacers on Forward Side 705692 02 Cast Lower Air Spring Mount RH 13 302 FHB 3 8 16 x 1 25 Gr 8 ZN 4 707357 01 Lower Shock Mount 14 208 LFN 3 4 10 Gr G ZN 5 263 HFW 3 8 15 8131017 FW 3 4 812 x 1 469 x 134 ZP 6 8120382 SLW 3 8 16 100678 P1 HHB 3 4 10 x 3 5 Gr 8 ZN 7__ 100263 P1 HHB 3 8 16 x 1 Gr 8 ZN 17 149 HHB 5 8 18 x 3 00 Gr 8 ZN 8 276 FHB 1 2 13x1 75 GR 8 18 706899 01 Height Control Arm 9 100039 P1 HHB 3 4 10 x 2 75 Gr 8 ZN 19 100727 P1 HHB 3 4 10 x 4 00 Gr 8 ZN 10 89422850 HFW 5 8 20 700184 04 HHB 5 8 18 x 1 3 4 Gr 8 ZN D711987 14 Notched Corner Toward Front IFS1700S HCV Components non SHC Models Only Item Part No Description Item Part No Description 1 5608 HCV Standard 5 703915 01 Assembly Linkage 2 702606 02 HHB 1 4 20 x 1 25 Gr 8 ZN 6 705932 01 Pin 3 100703 P1 LN 1 4 7 705967 01 1 4 Nylock Nut 4 8120392 FW 1 4 8 705967 02 5 16 Nylock Nut G 6 D711987 15 Height Sensor Components SHC Models Only Item Part No Description Item Part No Description 1 702606 02 HHB 1 4 20
47. itional camber adjustment Preparation 1 Follow the alignment equipment manufacturer s procedures for preparing the vehicle for front and rear wheel alignment measurements 2 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement D711987 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 Crank Rod or Tie Rods to center the steering wheel This can cause the steering gear to become off center 3 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 Spartan s 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 If adjustment to camber and caster is required then follow the steps below Otherwise go to the Adjusting the Toe In section to adjust the toe in as needed 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 cau
48. l Alignment section for wheel alignment inspection intervals Check wheel alignment if excessive steering effort vehicle wander or abnormal tire wear is evident Fasteners Check that all the fasteners are tightened to the proper tightening torque Use a calibrated torque wrench to check torque Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all worn or damaged components Operation Check that all components move freely through the complete wheel turning arc JX 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 D711987 A 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 o
49. l 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 4 Support fixed shoulder end of the bar pin 5 Remove retaining clip and outer collar from the split ring 6 Apply approximately 400 lbs press load to the spacer and remove the split collar Z CAUTION Do not apply excessive preload to bearings 7 Remove spacer and shims 8 Press bar pin out of bearing cones 9 Remove outer seals from both sides of bearings Remove bearing raceways from the steering knuckle carrier Do not damage bores 11 Clean the remaining grease from the bearing cavity IFS1700S Installation 1 10 11 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 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 bearing cone is seated in t
50. lent or once a year EE EE y NEE EE EE E I 1 Moly disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the automatic slack adjuster 2 Use caution when using an automatic grease gun or seals could possibly be blown out and damaged General Lubrication Ball Joints Proper lubrication practices are important The ball joints are lubricated and sealed in maximizing the service life of your for their service life and do not require ReycoGranning Independent Front lubrication Check for oil or grease marks Suspension on the exterior of the seal and if found verify that the seal has not been ruptured If the seal has been ruptured then the ball A C AUTION joint must be replaced because it cannot be re lubricated Do not mix lubricants of different grades Do not mix mineral and synthetic lubricants Different brands of the same grade may be mixed ZN CAUTION Never mix oil bath and grease packed wheel ends D711987 21 Rod Ends on Tie Rods Crank Rod 1 Review lubricant specification and interval requirements before servicing 2 Apply lubricant to grease fitting until new lubricant discharges from the dust boot Figure 4 Carrier Bearing and Kingpin 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 housin
51. lignment 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 assemblies are balanced and tire Front Suspension 1 Check that all fasteners are tightened to the specified torque 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 assembly 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 assembly 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 D711987 40 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 and adjust as needed to specified height 3 Check that all connection joints between the suspension and axl
52. n 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 15 IFS1700S 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 n Negative Caster Lower Control Arm Front Eccentrics FORWARD Figure 16 Lower Control Arm Movement D711987 45 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 forward lower control arm mount are oriented closer to the frame rail and the setscrews in the rearward lower control arm mount are o
53. n safety stands by the suspension sub frame 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 sub frame 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 sub frame mount or presence of small rubber particles near sub frame bushing mount IFS1700S 3 Check that the control arm mounting bolts are tight Recommended torque is 465 485 ft lb for lower control arms and 950 1050 ft lb 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 ma
54. njury 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 A 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 IFS1700S 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 all 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 brake pads o
55. nsion 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 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 ReycoGranning reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation ReycoGranning 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
56. nt and binding Remove the keeper from the nut 8 Al 3 Use a small screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released Seat the bearing with the hub rotor only using a torque wrench Tighten the nut to 200 ft lb Spin the wheel at least one full rotation Repeat step 9 two more times Back the nut off until it is loose Highly Visible Adjustment Marks Give mechanics precise control of nut backoff amount during installation Infinite Locking Positions Nut and spring steel keeper mate and lock at any point on the axle spindle in 001 axial increments Adjust the bearing by tightening the nut to 100 ft lb Spin the wheel at least one full rotation 14 Repeat step 12 two more times 15 Back the nut off one raised face mark 1 4 turn 16 Install the keeper with the orange side facing out 17 Align the flat of the keeper with the milled flat on the spindle and insert the single keeper tab into the undercut groove of the nut Install the keeper with the orange side facing out 18 Engage the mating teeth 19 Compress and insert the keeper arms one at a time into the undercut groove with a small screwdriver 20 Refer to the Wheel Bearing Endplay Adjustment section to measure and adjust the endplay to 001 005 inch Adjust by loosening spindle nut re indexing the spindle nut accordingly and repeat Steps 8
57. nterference Align or adjust as required Power steering pump fluid level low Add fluid tighten connections and correct as and or possible leak in system required Power steering pump pressure and flow Conduct pump flow and relief pressure tests below specification and adjust repair or replace as required 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 Excessive internal steering gear leakage Inspect repair or replace as reguired D711987 24 IFS1700S SYMPTOMS Vehicle wanders side to side loose steering Steering wheel has large amplitude rotational oscillations when hitting large bumps Vehicle pulls to one side without the brakes applied D711987 POSSIBLE CAUSES Vehicle overloaded or unevenly loaded driver side to passenger side AE REMEDIES Check wheel loads and correct as reguired Improper mismatched tires and wheels Tires have incorrect pressure Incorrect toe in setting Incorrect wheel caster setting Tie rod end connection loose or ball stud worn Steering arm assembly mounts loose Steering arm assembly ball joints binding or worn Kingpin worn Install correct
58. nts missing or broken components excessive corrosion or worn bushings Replace shock absorbers if any of the above items is present IFS1700S Inspecting the Air Spring and Height Control Valve Air Spring Inspection 1 Refer to Firestone s Preventative Maintenance Checklist for additional air spring information 2 Check the outside diameter of the air spring for irregular wear or heat checking 3 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 4 Check to see that there is a minimum of 1 inch clearance around the circumference of the air spring while it is energized with air 5 Check the air spring piston for buildup of foreign material Remove any foreign material that is present Height Control Valve Inspection 1 Check the height control valve and linkage for damage Replace components as needed 2 Dump and re inflate the air suspension 3 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 4 The actuation arm of the height control valve should be horizontal at ride height Figure 8 See section for adjusting to correct ride height D711987 31 Figure 8 Ride Hei
59. o Figure 10 Figure 10 Wheel End Play Measurement IFS1700S 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 NOTE Do not push pull at the top and the bottom of the hub Pushing or pulling at the top and the bottom will not yield a true measurement of the endplay 3 Place a portable jack and a suitable Measure the endplay by simultaneously pushing pulling on opposite sides of the hub while observing the dial indicator The endplay is the total travel observed If the endplay is not within 001 005 see the section on adjusting the wheel bearing endplay Inspecting the Knuckle Carrier Bearing and Seal 1 2 Inspect the seals for damage Place the magnetic base of a dial indicator on the knuckle carrier and block one with clearance for the grease fitting under the lower king pin grease cap area Set the dial 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 006 012 inches If the steering knuckles binds or less than 001 inch endplay is measured remove shims from the shim pack See repair section for kingpin If the vertical endplay measurement is more than 012 inches then install shims See repair se
60. of the thrust bearing towards the knuckle side D711987 Steering Knuckle Carrier Components Item Part No Description Item Part No Description 1 705632 01 Machining Carrier LH 7 702834 01 Bearing Cone 705632 02 Machining Carrier RH 8 702622 01 Spacer 2 Upper Bar Pin 9 702835 01 Bearing Cup 3 ese DI Lower Bar Pin 10 702623 02 Shim 010 4 702836 01 Seal 11 702618 01 Split Collar 5 702619 01 Outer Collar 12 702620 01 Retaining Clip 6 702623 01 Shim 004 13 7352 Grease Zerk Hydraulic Shutoff D711987 Left Hand Steering Knuckle Carrier Shown IFS1700S Lubrication Lubricant Specifications and Intervals EE EE COMPONENT SERVICE INTERVAL CHANGE INTERVAL LUBRICANT SPECIFICATION KK III EE Rod Ends of Tie Whichever comes first Every oil Multi Purpose Chassis Grease Rods amp Crank Rod change or every 6 months N A Premium Multi Purpose Chassis Grease NLGI Grade 2 Kingpin Whichever comes first Every oil Multi Purpose Chassis Grease change or every 6 months A f N A Premium Multi Purpose Chassis Grease NLGI Grade 2 Whichever comes first 50 000 Mobillith AW2 miles 80 000 kilometers or N A Amoco L Industrial 861 oncea year Exxon Ronex MP Wheel End 1000 miles 1600 kilometers Whichever comes first Seals Gear Oil Check fluid level replaced brakes relined 100 000 miles 160 000 km SAE 80W 90 or equiva
61. onents 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 arm assemblies knuckle carrier tie rod assemblies the brakes the hubs and the brake rotors 2 Hot or cold bending of the steering knuckles control arms steering arm assemblies knuckle carrier tie rod assemblies ball joints and the sub frame except control arm and steering arm assembly mounts which may be cold bent to facilitate bushing and bearing replacement 3 Drilling out control arm and steering arm assembly mounting holes and ball stud tapered holes 4 Spray welding of bearing diameters on the steering knuckle spindle steering arm assembly 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 48 A 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 i
62. or replace brake rotor as required Defective brake rotor Inspect for defects and replace as required Brake air chamber clevis pin or camshaft Check and lubricate as required binding Uneven brake adjustment side to side Adjust Caliper as required Different brake air chamber size side to Replace with same size brake air chambers side Brake chambers air pressure uneven side Check side to side air pressure and correct to side as required Rear axle brakes misadjusted or Check adjust or replace as required contaminated ABS system malfunction Check ABS system for proper function Air leak or obstruction in air brake lines Check fittings with soapy water solution and remove obstructions 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 Replace shock absorbers as required Check and tighten as required Front and or rear shock absorbers worn Shock mounting loose Shock eye bushings worn Check and replace as reguired Sway bar bushings worn Check sway bar bushings and replace as Vehicle rolls side to side reguired excessively Sway bar mounting brackets loose Check sway bar mounting brackets and tighten as reguired Control arm pivot bushings worn Inspect and replace as reguired Internal leak in height control valve Check height control valve and replace as required
63. orque Table 2 TORQUE SPEC APPLICATIONS FASTENER SIZE ft lb CLEAN AND TORQUE SEQUENCE DRY Torque Plate Mount 414 46 Grade 8 290 320 Cap Screws Hub Cap Bolt 5 16 18 Grade 5 20 30 M22x1 5 450 500 Wheel Nul Hub Piloted Dry Threads 1 Torgue applied to bolt head 2 Recheck Wheel Nut torque after first 50 100 miles D711987 64 IFS1700S Reyco Granning SUSPENSIONS ISO 9001 2008 Certified 1 800 753 0050 crate Mount Vernon MO 65712
64. ove the D rings and bushings from the sway bar Sway Bar Installation 1 Replace the D ring bushings 2 Apply TC 1920 Agua Shield Grease to the inside of the bushing Attach the D rings and bushings to the sway bar in the same location as removal 3 Attach the sway bar to the sub frame using the mounting hardware 4 Tighten the mounting nuts to 50 55 ft Ib See Torque Table 5 Follow the instructions for installation of the sway bar vertical linkage for both sides 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 Acaution The knuckle carrier must be secured and supported properly when upper and lower mounting bolfs 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 D711987 60 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 2 Remove the steering knuckle carrier mounting bolts from the upper and lower control arms Heat may need to be applied to the contro
65. parate the bar pin from the control arm 4 Remove and retain the lower shock bar pin mounting hardware Shock will extend due to internal gas charge Rotate bar pin to provide clearance with mounting bracket 5 Note orientation of eccentric adapters for installation 6 Loosen and remove control arm mounting locknuts 7 Support control arm and remove control arm mounting bolts Retain eccentric adapters for installation Remove the control arm 8 Remove spacer tubes from bushings and retain for installation D711987 53 9 Press the bushings out of the housings Support the housing properly Lower Control Arm Installation 1 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 3 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 465 485 ft lb 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 271 to mounting bolt threads and tighten to 350 370 ft lb See Torque Table Compress shock a
66. r the brake rotors 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 pads or the brake 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 D711987 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 castle nut
67. replaced if they are damaged or exceed the rotor manufacturers recommended minimum thickness or run out specification Refer to Brake Rotor manufacturer guidelines for inspection and specifications 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 manufacturer s limits Refer to the brake manufacturers guidelines for servicing the brakes Replacing the ABS Sensor and Tone Ring The anti lock brake system ABS of the vehicle should be diagnosed by a qualified technician before the anti lock brake sensor or the tone ring is 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 Caliper to provide access to sensor 2 Press sensor out of steering knuckle Do not pull sensor out by its lead wire D711987 3 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
68. riented farther from the frame rail the caster becomes more negative Figure 17 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 Neutral Position Negative Caster VIEW A A LH Front Eccentric View Scale 1 2 Negative Caster 1 VIEW B B LH Rear Eccentric View B 1 Scale 1 2 FORWARD Figure 17 Eccentric Caster Adjustment 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 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 the adapter locknuts to 465 485 ft Ib See Torque Table 5 Tighten the setscrews to 30 40 in 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 caster and readjust as needed D7
69. rmine the number of shims needed by stacking the shims and placing the stack 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 assembly 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
70. s for removal of the Relay Rod from the ball joint in the bell crank and idler arm 2 Follow the procedures for removal of tie rod ends for the crank arm 3 Remove the pivot bolts that mount the idler arm and bell crank Remove them from the sub frame 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 assembly bearing housing and press the bearing out of each end Installation 1 Clean out the steering arm assembly grease cavity 2 Inspect steering arm assembly bearing housing bores and remove burrs by honing Replace steering arm assembly if the bore is damaged 3 Pack the steering bearing with grease arm assembly 4 Support the steering arm assembly bearing housing and press the bearing into each end 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 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 D711987 51 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 Dete
71. sing 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 Camber Negative Camber Figure 13 Camber Angle AX CAUTION Do not alter components to adjust the camber Camber is the angle of the wheel with respect to the ground as viewed from the front or rear of the vehicle Figure 13 Camber is positive when the distance between centers of the front wheels at the top is greater than the distance at the ground 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 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 D711987 42 Right TAFELS Nominal Camber Values Degrees Unloaded Loaded 1 4 4 1 4 1 4 1 4 Left 1 4 41 4 IFS1700S o Q Neutral Position PEER Positive Camber Negative Camber
72. stment Marks Give mechanics precise control of nut backoff amount during installation Infinite Locking Positions Nut and spring steel keeper mate and lock at any point on the axle spindle in 001 axial increments 12 Adjust the bearing by tightening the nut to 100 ft lb Spin the wheel at least one full rotation 13 Repeat step 12 two more times 14 Back the nut off one raised face mark 1 4 turn 15 Install the keeper with the orange side facing out 16 Align the flat of the keeper with the milled flat on the spindle and insert the single keeper tab into the undercut groove of the nut Install the keeper with the orange side facing out 17 Engage the mating teeth 18 Compress and insert the keeper arms one at a time into the undercut groove with a small screwdriver 19 Verify the end play D711987 20 2 22 23 24 25 Attach a dial indicator with a magnetic base to the face of the hub rotor Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero Measure the endplay by simultaneously pushing pulling on opposite sides of the hub rotor while observing the dial indicator The endplay is the total travel observed If the endplay is not within 001 005 a readjustment will be required Install hub cap gasket and hub cap Tighten the cap screws in sequence to 20 30 ft lb See Torque Table Replace the h
73. th if not restrained Removal 1 Remove the lower shock thru bolt mounting hardware and retain for installation Do not remove the lower shock mount bracket from the lower control arm 2 Remove upper shock bushing mounting hardware and retain for installation Note location and quantity of washers and spacers Installation 1 Loosely attach upper shock bushing to sub frame with mounting hardware spacers on forward side of shock 2 Position shock in suspension such that the thru bolt is connected to the lower shock mounting bracket tabs 3 Tighten lower thru mounting bolt and nut to 170 190 ft lb See Torque Table Tighten lower shock bracket mounting bolts to 30 40 ft lb See Torque Table 4 Tighten upper mounting nut to 170 190 ft lb See Torque Table D711987 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 bol
74. ting tapers or any movement of the stud nut at both 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 D711987 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 Figure 6 Tie Rod Inspecting the Brake System Brake System The suspension system is equipped with Bendix ADB22X air brakes Refer to Bendix service data publication SD 23 7541 for inspection and Service procedures Inspecting the ABS Sensor and Tone Ring 1 The wheels and may need to be removed to ease inspection of tone ring and
75. tion as needed D711987 50 5 Inspect 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 assembly of any contamination 2 Apply thread adhesive Loctite 242 to the ball joint base threads and thread it into the steering arm assembly 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 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 5 Tighten the castle nut to 155 175 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 Arm and Crank 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 IFS1700S The inner grease cavity of the steering arm assemblies should be cleaned when the bearings are replaced Removal 1 Follow the procedure
76. ts that secure the air spring to the lower air spring mount Installation 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 lb See Torque Table 3 Tighten the upper mounting bolts to 15 20 ft lb 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 IFS1700S 7 Check the airline and fitting for air leaks Replacing the Height Control Valve The correct height control valve HCV must be installed The use of a substitute HCV is not allowed and may cause unequal load sharing between the air springs and cause adverse ride and handling characteristics Removal 1 Drain the air from the supply reservoir on the chassis connected to the front suspension 2 Disconnect the vertical HCV linkage from the horizontal arm 3 Mark airlines and connections for re assembly Disconnect the airlines from the HCV If any other plumbing fixtures are connected to the HCV mark them for re assembly 4 Remove the HCV mounting hardware from the sub frame 5 Remove any other air fittings or plumbing fixtures from the
77. ub cap vent plug if removed Fill the hub cavity with the appropriate amount and type of lubricant and secure drain plug Check oil level through the hub cap window Figure 5 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub NOTE The hub cap window can only be 35 26 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 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 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 Figure 11 O gil kg H 3 Figure 11 Measurement at
78. x Inspect vertical endplay x x Steering Arm Assembly Check Mounting Nut torgue K NG Bearings Inspect bearings for excessive radial play X X X x K K K De Carrier Bearings Check axial endplay x Wheels Check Wheel Bearing endplay TT TX PY x Check Wheel Nut torque OD DE Front Alignment Inspect toe in se TKI x Air Fittings and Air Lines Inspect for air leaks using soapy water solution BET EP GE ef Inspect for signs of chafing cracking or wear x K K K K K K De Sway Bar Bushings Check mounting bolt torgue K NG Inspect for bushing wear K K K K K K K De Maintenance Record Name of Owner Address of Owner Date of Purchase Name and Address of Dealer Model of Vehicle Vehicle Identification Number Suspension Model Number IFS1700S IFS1700S SB Suspension Serial Number IFS1700S SHC IFS1700S SHCSB Inspection and Maintenance Item Date Mileage Service Performed D711987 8 IFS1700S Unit Assembly Item Part No Description Item Part No Description 1 711511 01 Sub frame Assembly 9 707819 01 Hub and Rotor Assembly 2 700944 01 Lower Control Arm Assembly 10 705951 01 Air Spring Assembly 3 703182 01 Upp
79. x 1 25 Gr 8 ZN 5 705378 01 Height Control Sensor Electronic 2 100703 P1 LN Va 6 705932 01 Pin 3 8120392 FW va 7 705967 01 1 4 Nylock Nut 4 703915 01 Assembly Linkage 8 705967 02 5 16 Nylock Nut D711987 16 IFS1700S Sway Bar Components SB Models Only Item Part No Description Item Part No Description 1 703124 01 Sway Bar 8 118 EW 1 2 2 703165 01 Assembly Mount UCA Sway Bar 9 102550 HHB 1 2 13 x 2 75 Gr 8 Zinc K706842 Kit Sway Bar Mount 10 700144 23 HHB 1 2 13 x3 50 Gr 8 Zinc 3 703127 03 Link UCA Sway Bar 11 8455001 HHB 1 2 13 x 2 00 Gr 8 Zinc 4 703128 01 Mount UCA Sway Bar 12 307 FHB 1 2 13 x 1 50 Gr 8 Zinc 5 702895 02 Bushing Split Sway Bar 13 702898 01 Washer Cut Sway Bar 6 702894 01 Mount D Ring Sway Bar 14 89422299 LN 7 16 14 Gr 8 K705273 Kit Sway Bar Fasteners 15 89422301 LN 1 2 13 Gr 8 Zinc 7 702797 01 FHB 7 16 14 x 1 25 Gr 8 ZP Items included with K706842 Items included with K705273 D711987 17 Disc Brake Components Item Part No Description Item Part No Description 1 266 _ Flange Head Bolt 5 16 18x 75 Gr 5 ZC 13 705011 27 JABS Sensor Bushing 2 7328 ABS Sensor Straight w Lead 14 705084 01 Oil Seal Assembly 3 6946 ABS

IFS1700S I&M Manual

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IFS1700S I&amp;M Manual

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IFS1700S I&M Manual