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caution - Spartan Chassis

1. Unit Ride Height A Air Spring B IFS1660 6 60 9 25 IFS1800 9 06 9 25 Figure 8 Ride Height Measurement Inspecting the Steering Arm Bearings 1 Check that steering arm pivots are free of foreign material and bearing seals are in place 2 Start vehicle engine Oscillate the steering wheel and observe the motion of the steering arms Figure 9 The steering arms should not exhibit any noticeable conical motion about their pivot axes 3 If any conical motion is observed check pivot bolt torque which should be 460 490 Ibf ft See Torque Table Otherwise replace the bearing set of the steering arm that exhibits conical motion Inspecting the Steering Arm Ball Joints Seal Inspection 1 Inspect the ball joint seal outer surface for presence of oil wetting The entire outer seal surface should be dry Use a mechanics mirror and flashlight to inspect the entire seal Use a blunt object as needed to inspect between seal convolutes 2 If oil wetting is found then inspect the entire wet area to confirm the seal has a rupture s and oil source is from internal grease leaking from the ball joint If seal is ruptured then the ball joint must be replaced 3 Skip ball joint endplay measurement Care must be taken to not damage ball joint seals during inspection Seals that are ruptured during inspection must be replaced Do n
2. 5 Tighten the setscrews to 30 40 Ibf in 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 48 Adjusting the Toe In Z CAUTION Improperly oriented tie rod clamps can cause binding in the suspension steering system Wheel toe in is the relationship of the distance between the centers of the front and rear of the front wheels When the front distance is less than the rear distance the wheels are toed in Toe in is designed into the suspension to counteract the tendency of the tires to toe out when the vehicle is driven straight ahead Incorrect toe in can result in rapid tire wear Measure the length of the outer tie rods Reference length is 17 inches Ifthe lengths of the outer tie rods are not within 1 8 inch of each other then adjust their lengths such that they are within 1 8 inch of each other Loosen the tie rod clamps on each end of the 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 over all toe in is 1 8 1 16 Tighten tie rod clamp nuts to 50 60 Ibf ft See Torque Table Refer to Figure 6 for tie rod clamp orientation 49 Repairs General Procedures Repair or reconditioning of front suspension components is not allowed Component
3. Align rear axle to specified thrust angle Incorrect steering arm geometry Adjust tie rod lengths as required Improper mismatched tires and wheels Install correct tire and wheel combination Improper oversized tires Install correct tire and wheel combination Vehicle is difficult to steer Tires not uniform Install correct tire and wheel combination Tires have incorrect pressure Put specified air pressure in tires Note Engine must be running for power steering to be active Incorrect steering arm geometry and able to provide steering assist Adjust tie rod lengths as required Steering arms binding Check steering arm bearings and lubricate as needed Steering arm ball joints binding Inspect ball joints for wear and replace as required Tie rod ends binding Inspect tie rod ends for wear and lubricate as needed Kingpin binding Inspect lubricate and repair as required Steering column linkage binding Align or adjust as required Steering miter box binding Check steering miter box and repair or replace as required Steering gear valve binding Inspect repair or replace as required Steering wheel to column interference Align or adjust as required Power steering pump fluid level low and or possible leak in system Add fluid tighten connections and correct as needed Power steering pump pressure and flow below specification Conduct pump flow and relief pressure tests and adjust
4. engaged in control arm mounting plate Bar Pin Camber Adjustment for adjustment The lower bar pin of the knuckle carrier bearing marked with a B on the end is configured such that it can be re oriented 2 Loosen the setscrews 45 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 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 46 4 Lower the jack to align the bar pin with the control arm Apply Loctite 271 to mounting bolt threads a
5. R 1660 1800FT INDEPENDENT FRONT eyco SUSPENSION SERVICE MANUAL Granning SUSPENSIONS Quality Providing Worry Free Reliability Value Exceeding Customer Expectations Availability Delivering on Our Promise On Time Every Time Reyco 1205 Industrial Park Drive 9098 West 800 South D707676 G sy Mount Vernon Missouri USA 65712 Brookston Indiana USA 47923 Rev J rannING Tei 417 466 2178 Fax 417 466 3964 Tel 219 279 2801 Fax 219 279 2390 05 11 SMe PENS ain SS www reycogranning com www reycogranning com Table of Contents Introduction ens ses sens ee ses dens en sine Service Note Semere a svens ones desde hen E e A rensar EA Er RTE aS 4 E A AA 5 Vehicle Towing Information ssssrsesrrerserrrerrrerrerrrernrernrerrrsrrssrnssrrsrrrs rn rs nn rr nr en 6 Maintenance sencilla se NN a 7 Maintenance Record naar 8 Par s Lists acacia POT AS SETAD LY rt td 9 Control Arm Components sulle cin ist daa ada iaa 10 Control Arm Assemblies esos 11 Steering Components IFS1660 sssesssrsssrrssrrsrrrsrsrsrresrrnesnrssrrssrrssnrsnrrrnnrrnr rn nen 12 Steering Components 1800FT s sssessersssrrssrrsersrsrnesrresrnesnrssrnrssrnrsrnrsnrrsnnrrnrrnnen 13 Air Spring and Shock Components IFS1660 s ssssssserssrsssrsssrsssrrsernrsnrernrennen 15 Air Spring amp Shock Components IFS1800 s sssssssrssrrssrsssrsssnnssnrsernrserernrennrn 16 HEN COMPONEN 17 HCV Components IFS1660SHC ONLY coooocccoocccoccccoocncnoncnonnnonnnn
6. COMPONENT SERVICE INTERVAL CHANGE INTERVAL LUBRICANT SPECIFICATION Ball Studs on Ends Which ever comes first Every Multi Purpose Chassis Grease of Tie Rods Crank oil change or every 6 months Rod Drag Link Premium Multi Purpose Chassis Grease NLGI Grade 2 Kingpin Which ever comes first Every Multi Purpose Chassis Grease oil change or every 6 months k Premium Multi Purpose Chassis Grease NLGI Grade 2 Carrier Bearings Which ever comes first 50 000 Mobillith AW2 miles 80 000 kilometers or Amoco L Industrial 861 once a year Exxon Ronex MP Brake S Cam Tube Which ever comes first Brakes 5 and Automatic Slack relined 50 000 miles 80 000 a Chassis Adjuster kilometers or once a year Wheel End 1000 miles 1600 kilometers Which ever comes first Seals Gear Oil Check fluid level replaced brakes relined A 100 000 miles 160 000 km SAE 80W 90 or equivalent or once a year 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 ReycoGramning Independent Front lubrication Check for oil or grease marks Susp
7. HCV Components IFS1660SHC only Item PartNo Description item patno Description 610595201 pin SSS 100703 P1 LN 4 8120392 705967 01 1 4 Nylock Nut 703915 01 Assembly Linkage 8 705967 02 5 16 Nylock Nut 18 Sway Bar Components IFS1660S SB amp IFS1800S FTSB models only Ja Yo 2 ro eed 1 703124 01 SwayBar 9 ts wre _ HHB 1 2 13 x 2 75 Gr 8 Zinc 6 307 _ FHB 1 2 13 x 1 50 Gr 8 Zine 14 702894 01 Mount D Ring Sway Bar LN 1 2 13 Gr 8 8 702797 01 FHB 7 16 14 x 1 25 Gr 8 ZP 16 89422299 LN 7 16 14 UNC Gr 8 Items included with K703129 Items included with K705273 19 Disc Brake Components Item No Part No Description Item No Part No Description 1 266 Flange Head Bolt 5 16 18x 75 Gr 5 ZC 705013 01 Torque Plate Assembly LH 2 7328 ABS Sensor Straight w Lead 705013 02 Torque Plate Assembly RH 3 6946 ABS Sensor Spring Retainer 15 705013 11 Torque Plate Assembly LH 4 705011 01 Steering Knuckle Assembly LH 705013 12 Torque Plate Assembly RH 705011 02 Steering Knuckle Assembly RH 705013 15 Torque Plate Assembly LH 5 126 Hex Head Bolt 5 8 18x2 Gr 8 ZN 705013 16 Torque Plate Assembly RH 6 705051 01 Bearing Inner 6 1786 Hub Cap Gasket 705051 02 Bearing Race Inner T 700690 04 Hex Head Bolt M20x1 5 50 Gr 10 9 7
8. loosening spindle nut re indexing the spindle nut accordingly and repeat Steps 8 thru 19 until proper endplay is achieved Install hubcap gasket and hubcap Tighten the capscrews to 20 30 Ibf ft See Torque Table Replace the hubcap 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 hubcap window Figure 20 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hubcap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window Figure 20 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 drum 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 to 450 500 Ibf ft See Torque Table for sequence 28 Replace the wheel hubcap nuts and hubcaps if removed to service the wheel bearings Replacing Brake Components Brake Drums Th
9. an oil drip tub beneath the hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 31 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 32 Remove the hubcap bolts hubcap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that solvents may damage the hubcap window 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 33 34 35 36 37 38 39 Remove the cotter pin and loosen the spindle nut Seat the bearings by tightening the spindle nut to 200 Ibf ft while rotating the wheel in both directions After torquing the castle nut to 200 Ibf ft rotate the hub and rotor ten 10 complete revolutions Loosen the spindle nut 1 2 turn and then tighten the nut to 50 Ibf ft Back off the spindle nut 1 8 turn Verify that wheel endplay is between 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
10. at the air spring inlet port and remove the connection fitting from the inlet port 3 Remove the bolts and washers from the upper air spring mount studs Note location of bolts and washers 4 Remove the bolts that secure the air spring to the lower air spring mount Installation 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 Ibf ft See Torque Table 3 Tighten the upper mounting bolts to 20 30 Ibf ft See Torque Table 4 Apply Permatex or equivalent thread sealant to the threads of the air connection fitting and install the fitting 5 Connect the airline to the fitting 6 Inflate the air spring by un securing the HCV horizontal arm and reconnecting the vertical linkage to it 7 Check the airline and fitting for air leaks Replacing the Height Control Valve The correct height control valve HCV must be installed The use of a substitute HCV is not allowed and may cause 61 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 HC
11. be attached to the bottom of the brake drum if the wheel is removed Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero Figure 10 Set the dial indicator to 0 zero 4 Place a pry bar between the control arm and carrier and pry to measure axial movement of the bar pin Do not pry on seal Measure and record the dial indicator reading 5 Ifthe axial endplay is more than 0 inch then replace the carrier bearings See repair section on knuckle carrier Inspecting the Kingpin Figure 10 Wheel End Play Measurement Vertical End play 1 Turn the tire straight ahead 2 Place the magnetic base of a dial indicator on the knuckle carrier and Do not push pull at the top and the position the tip of the dial on top of the bottom of the tire drum or hub king pin bearing cap such that vertical Pushing or pulling at the top and the movement can be measured bottom will not yield a true 3 Place a portable jack and a suitable measurement of the endplay block one with clearance for the grease fitting under the lower king pin 6 Measure the endplay by grease cap area simultaneously pushing pulling on each side of the tire drum or hub 4 Set the dial indicator to 0 zero while observing the dial indicator The 5 Raise the jack until the dial indicator endplay is the total travel observed If shows the end of vertical travel th
12. chambers and length slack adjusters Brake chambers air pressure uneven side Check side to side air pressure and correct to side as needed Unequal brake air chamber stroke side to Check side to side stroke and adjust as side required Rear axle brakes mis adjusted or contaminated Check adjust or replace as required 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 damaged Check chamber for air leak and damaged diaphragm Excessive water puddling on road Avoid water puddles on road Front and or rear shock absorbers worn Replace shock absorbers as needed Shock mounting loose Check and tighten as required Shock eye bushings worn Check and replace as needed Sway bar bushings worn Check sway bar bushings and replace as Vehicle rolls side to side needed excessively Sway bar mounting brackets loose Check sway bar mounting brackets and tighten as needed Control arm pivot bushings worn Inspect and replace as required Internal leak in height control valve Check height control valve and replace as required ABS sensor malfunction Inspect ABS sensor installation and replace sensor as required Front tires lock up during ABS CPU or system malfunction hard braking or ABS malfunction light remains lit ABS sensor electrical
13. endplay is achieved Install cotter pin and bend over if cotter pin hole is not lined up loosen nut to first locking position 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 40 Install hubcap gasket and hubcap 41 42 43 Tighten the capscrews to 20 30 Ibf ft See Torque Table Replace the hubcap 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 hubcap window Figure 12 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hubcap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window Check the hubcap for external oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the gasket The vent plug will normally weep a small amount of oil Adjusting the Maximum Wheel Turn Angle Z CAUTION Do not adjust maximum wheel turn angle greater than 55 Mis adjustment of the wheel turn angle can cause damage to steering system components The turn angle
14. hardware Tighten the nuts to 30 40 Ibf ft 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 hubcap nuts if present and the wheel hubcap before loosening the wheel nuts Place the wheel hubcap in safe location to prevent damage Place the wheel and or wheel hubcap nuts in a container to prevent contamination or loss Remove the wheel and tire assembly and place it aside Mark the tire to ensure it can be identified for installation on same side as removed Remove the brake rotor assembly and place it aside Mark the rotor assembly to ensure it can be identified for installation on same side as removed Removal 1 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 2 Rotate the hub such that the drain hole faces downward and drain the oil from hub cavity Wait a few minutes for most of the oil to drain before continuing to the next step 3 Remove the hubcap bolts hubcap and gasket Take care not to damage the gasket for re installation Place the component
15. 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 Ibf ft 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 31 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 Automatic Slack Adjusters and Brake System Automatic Slack Adjusters The suspension system is equipped with automatic slack adjusters for steer axles For inspection and adjustment refer the Crewson Bruner Adjustment Guidelines Brake System The suspension system is equipped with Dana 16 5x5 S cam air brakes Refer to Dana maintenance manual SHA 589 1 5M inspection and service procedures Inspecting the ABS Sensor and Tone Ring 1 The tires and brake drums may be removed if needed to ease inspection of tone ring and sensor 2 Disconn
16. tightened to the proper tightening torque Use a calibrated torque wrench to check torque Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all worn or damaged components Operation Check that all components move freely through the complete wheel turning arc Z CAUTION Tuthill Transport Technologies 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 Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury The vehicle may be supported on safety stands by the suspension subframe or chassis frame for inspections that require removal of the wheel and tires or deflation of the air springs Always secure the vehicle by setting the parking brake
17. 705052 01 Bearing Outer 705013 03 Caliper Assembly LH 705052 02 Bearing Race Outer 8 705013 08 Caliper Assembly RH 3 705017 01 Arm Steering LH 705013 04 Brake Pads Set of 4 705017 02 Arm Steering RH 9 704078 01 Flat Washer 20mm 9 705011 21 Castle Nut 1 1 4 12 20 89422308 Locking Flange Nut 5 8 18x 75 Gr G PH 10 700525 16 Key 21 103003 HFW 3 4 11 705011 22 Assembly Steering Stop 22 708181 01 INut Spindle Pro Torq 12 705011 23 Cotter Pin 3 16 x 2 1 2 23 708182 01 Hub Cap 13 705011 27 ABS Sensor Bushing 24 705013 05 Hub and Rotor Assembly 14 705084 01 Oil Seal Assembly 705013 10 Hub and Rotor Assembly 20 King Pin Components CONICET 7 2 705011 08 Shim 010 thick Cid 3_ 705011 09 Shim 020 thick 9 4 705011 7 705011 17 Cap King Pin 7050 11 18 7 7 05011 19 05315 01 Draw Key Long 3 80 705316 01 Nut Draw Key 5 05011 15 Bolt King Pin Cap 6 705011 16 Grease Fitting Straight Oil seal is on the bottom of the thrust bearing towards the knuckle side 21 Steering Knuckle Carrier Components pe e gt AA SS Ao Machining Carrier LH 705014 02 Machining Carrier RH 8 702622 01 Spacer 2 702621 01 Upper Bar Pin 9 702835 01 Cup 6 702623 01 Shim 004 0B 7352 Grease Zerk Hydraulic Shutoff Left Hand Steering Knuckle Carrier Shown 22 Lubrication Lubricant Specifications and Intervals
18. AND aa a e A A oa RAA SMR NBA 59 O 59 Other Brake COMPONEN a iii 59 Replacing the ABS Sensor and Tone Ring cooooccnoccnoconcnonnnonnnonononononoconnncnnnss 59 Sens t RM a o o o O 59 o O A 59 Tone Ring Removal and Installation ssssesssssssserssrrrsrssrrssrenrrsrrssresrrsrnsrrerrrrr ns nn rr rr rn nn nn 60 Replacing the Shock ADSOTDE Edie idas 60 REMOVAL eta sinnen AeA ease as ate aie ates on UTSER A e heed SKARS NINGEN NEANDER 60 TH STAL AOU A A A atone aoai 60 Replacing the Air SP po 60 Removals pennas haa on ra Nn Beas Ark ASSR STRAND Ar SST a aon FINNER SA SNARAST OR DNS ANAR 61 E ations 225 v bad bodd ved arsrs sn odederard a a TEN NASAS SANNE SST AR neds tod chins Guus hed Sek a ra Are 61 Replacing the Height Control Valve sm sssmessesssesresrrerrsrerresnrersrernrerrnrsrrrsrnssrrsnr rna 61 Remova RO 61 std ia 61 Replacing the Sway Bar and Components sesseessersrerrsrsrrersrersrernrsrrnrsrnnssrnsnr rs 62 Vertical Linkage R CiOy al ica e le o So cado ES 62 Vertical Linkage Installation ii AA A AA AAA rr nr rna 62 Sway Bar Removal ni ii ss 62 Sway Bar Install a 62 Replacing the Steering Knuckle Carrier Bearings smsmsmmsnsssrerersresresrrsrreressrennen 62 REMOVAL is sac sans och svor red bra seven E 62 A a Oda Sag Sas 63 Torque Tables snsssposssiissssossssosivassstoosonssosvssosssenter rsnsssss 00 Introduction Service Notes This Service Manual describes the correct service and repair procedures for the ReycoGra
19. Tighten the jam nut to 50 75 Ibf ft 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 44 Repeat checking and adjustment for turning the opposite direction 42 Inspection Before Alignment See the General Inspection section and check the following before conducting front wheel alignment measurements Wheels and Tires 1 Check that the front tires are inflated to the appropriate pressure based on the tire loading 2 Check that the front tires are the same size and type 3 Check that all the wheel nuts are tightened to the specified torque of 450 500 Ibf ft See Torque Table 4 Check that the wheel and tire assemblies are balanced Front Suspension 1 Check that all fasteners are tightened to the specified torque 2 Check the suspension ride height and adjust as needed to the specified height 3 Check for worn ball joints tie rod ends steering arm bearings control arm bushings knuckle carrier bearings and damaged suspension components Replace worn components as needed 4 Check for loose ball joint and tie rod end tapered connections tie rod end jam nuts steering arm mounts and chassis steering system components Inspect connections for wear and replace as needed Tight
20. Torque Plate Mount Capscrews 3 4 16 Grade 8 290 320 Hub Cap Bolt 5 16 18 Grade 5 M22x1 5 450 500 Hub Piloted Dry Threads Wheel Nut 1 Torque applied to bolt head 2 Recheck wheel nut torque after first 50 100 miles 67
21. V If any other plumbing fixtures are connected to the HCV mark them for re assembly 4 Remove the HCV mounting hardware from the subframe 5 Remove any other air fittings or plumbing fixtures from the 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 subframe with mounting hardware Orient the horizontal arm horizontally and tighten the mounting nuts to 7 9 Ibf ft See Torque Table 3 Connect airlines as marked during removal 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 3 Attach the sway bar to the subframe section on adjusting the ride height as using the mounting hardware nec 4 Tighten the mounting nuts to 52 Ibf ft Replacing the Sway Bar Bee Forde able 5 Follow the instructions for installation and Com ponents of the sway bar vertical linkage for It is recommended that the sway bar both sides mounting bushings and the vertical linkages be replaced all at the same time Replacing the Steering Di Knuckle Carrier 1 Disconnect sway vertical linkage at upper control arm bracket on both Beari ngs sides Retain hardware for installation Vertical Linkage Removal 1 Secure the sway bar to prevent It is recommended to replace all the r
22. aida 45 Adjusting the Caster Angle ccs s cen uittn sass dncdthsssat uadily Dhar sevisd Sieionl nas Soeiuticatn thed hed 46 Eccentric Caster AUS IM dd at darla 47 Adj stine the TOS id 48 Repair AI II A A General PTOCE St Wis A E A EAE E 50 Cleaning the Parana anoanckeaseiescesebpasaranvetasetivauvetes 50 O 50 TO 51 DE SAA A AL ts 51 PREV ENUM COMO A TA EE A AO init cs 51 Replacing Tie Rod EA cad 51 REMOVAL oiin irea aira a aaa aia a a A iana aaaea aiaia 51 Tri Stall A O E RA A DA 51 Replacing the Steering Arm Ball Joints s smssssssssessrersrerersrresrrernrerrnesrnssrnssrnsnr rna 52 REMO Arteta 52 sta seed a aaia iska iaa aeai aa ae ea i aeaa krk sier AAA Arn 52 Table of Contents Replacing the Bell Crank Idler and Crank Steering Arm Bearings 52 Removal setora sans baden db koden ra desde sue and e a a a a asain SAR ANAR 53 E ices bug dess anse i Sa cea E 53 Replacing the Upper and Lower Control Arm Bushings sssssssesoossrenoen 53 Upper Control Arm REMO ass 54 Upper Control Arm Installation ai o rr r sne sr nr renen 54 Lower Control Arm Removal aiii rr seen ere sr rr ere seen rr rr en 55 Lower Control Arm Install id aa 55 Replacing Wheel Bearings Oil Seals and Hub CaPS ssssrrsersresressrsssrnssrnss 56 A A A A A cas A Sees 56 O 57 Replacing Brake OMPI ad 59 Brake Pr Cina sni a decade dandu dias tucaenceducgeretvsetadesdecti aa a aiaa a aiaee taisi 59 A t matic Slack Adj stet ieni SS A O RA N
23. and block the drive wheels to prevent vehicle movement before inspections Inspecting the Control Arm Bushings for Wear It is recommended that the bushings in all of the control arms be replaced at the same time if one is found worn 1 Check clearance between each control arm and subframe bushing mount Look for contact pattern as evidence of bushing wear Replace worn bushings in both control arm housings as needed 2 Check for bushing bulging between the control arm and subframe mount or presence of small rubber particles near subframe bushing mount 3 Check that the control arm mounting bolts are tight Recommended torque is 460 490 Ibf ft for lower control arms and 950 1050 Ibf ft for upper control arms See Torque Table A loose joint will result in wear between the bushing inner sleeve and subframe mount Inspecting the Tie Rod Ends Z WARNING Do not use a wrench or other object to apply leverage when inspecting tie rod end sockets Applying leverage can yield incorrect results and damage components Component damage can lead to the loss of steering control 1 With the engine on lightly rock the steering wheel and have an assistant observe any looseness in the two mating tapers or any movement of the stud nut at 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
24. ary components and could move allowing the vehicle drop causing serious personal injury The vehicle may be supported on safety stands by the suspension subframe 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 Z WARNING If you use cleaning solvents hot solution tanks or alkaline solutions incorrectly serious personal injury can occur To prevent injury follow the instructions supplied by the manufacturer Do NOT use gasoline to clean parts Gasoline can explode Ground or Polished Parts Use a cleaning solvent to clean ground or polished parts and surfaces DO NOT clean ground or polished parts with hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts Rough Parts Rough parts can be cleaned with the ground and polished parts Rough parts also can be cleaned in hot solution tanks with a weak alkaline solution Parts should remain in the hot solution tanks until they are completely cleaned Drying Parts must be dried immediately after cleaning Dry parts with clean paper or rags or compressed air Do not dry bearings by spinning with compressed air Preventing Corrosion Apply light oil to cleaned and dried parts that are not damaged and ar
25. 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 lower bar pin of the knuckle carrier bearing marked with a B may also be used to provide additional camber adjustment Preparation 1 Follow the alignment equipment manufacturer s procedures for preparing the vehicle for front and rear wheel alignment measurements 2 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement An out of center steering gear can result in unequal wheel turn angles The steering gear should remain centered during toe in adjustment Do not adjust the length of the drag link or tie rods to center the steering wheel This can cause the steering gear to become off center 45 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 46 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 47 If adjustment to camber and caster is required then follow the ste
26. at previous interval 3 Final stage manufacturer should complete toe in inspection and adjustment after completion of vehicle Maintenance Record Name of Owner Address of Owner Name and Address of Dealer Vehicle Identification Number Suspension Model Number IFS1660S IFS1660S SB IFS1800S FT IFS1800S FTSB Parts List Unit Assembly ren Penne IO CE rat A ie 701900 01 Sub frame Assembly 10 705951 01 Air Spring Assembly 1 Sub frame Assembly Air Spring Assembly Sub frame Assembly 6 705620 01 Idler Arm Assembly 16 705800 01 Height Control Valve Arm LH 705619 02 Bell Crank Assembly RH 17 705800 02 Height Control Valve Arm RH 7 701924 01 Crank Arm Assembly 18 700973 04 Crank Arm Link Assembly 8 705633 01 Carrier Assembly LH 19 705573 01 Crossmember 9 705633 02 Carrier Assembly RH Used with IFS1660S Units Used with IFS1660S SB Units Used with IFS1800FT Units Control Arm Components AN 7 e ea 1 703182 01 Assembly Upper Control Arm 8 701683 04 Hardened Flat Washer 7 8 Assembly Lower Control Arm Hex Head Bolt 3 4 10 x 2 75 Gr 8 Zn Boss Eccentric 9 ee Hex Head Bolt 3 4 10 x 2 75 Gr 9 Zn 6 100122 P1 Lock Nut 7 8 9 Gr C Lock Nut 1 1 8 12 Gr C Socket Set Screw 10 24 x 38 Used with IFS1800FT Units 10 Control Arm Assemblies It
27. connection faulty Check and repair or replace as required Check ABS sensor connection and lead wire Tone ring on hub damaged Check for damage and replace as required 28 SYMPTOMS POSSIBLE CAUSES Front shock absorbers worn Replace shock absorbers as needed Vehicle ride is too harsh Incorrect ride height Adjust ride height to specified setting and or suspension contacts Vehicle overloaded Check wheel loads and correct as needed 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 needed specification Rebound bumper worn or missing Check and replace as needed Jounce bumper in air spring worn or Check and replace air spring as required broken k een Front shock absorbers worn Replace shock absorbers as needed Vehicle ride is too soft Incorrect ride height Adjust ride height to specified setting Incorrect steering arm geometry Adjust tie rod lengths as required F g Steering gear not centered Inspect and adjust as required Vehicle has unequal turning radius 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 needed Air leak Check connections with soapy water solution and repair or replace as needed Suspension does not Internal leak in height contro
28. dicates procedures that must be followed exactly Damage to equipment or suspension components and personal injury can occur if the procedure is not followed A note indicates an operation procedure or instruction that is important for correct service Identification The suspension model and serial number are stamped on an aluminum tag that is riveted to the front of the suspension subframe assembly Figure 1 The serial number is used by Tuthill Transport Technologies for control purposes and should be referred to when servicing the suspension or requesting technical support Figure 2 Serial Tag Figure 1 Suspension Identification Location Mae ty l Sersem M sera 000000 cameras o woa _IFS1660S_ 16 600 MAY DC COVERED OY THE FOLLOWING PAFTNES VA 48 2 6 164 00 4 10 CAMADA t 194 044 Figure 2 Suspension Serial Number Tag Wheel Sway Disc Drum Model GAWR Cut Bar Brakes Brakes IFS1660S 16 600 Ibs 55 X IFS1660S SB 16 600 Ibs 55 X X IFS1800S FT 17 000 Ibs 55 X IFS1800S FTSB 17 000 Ibs 55 X X Model Identification Table Vehicle Towing Information If a vehicle is disabled and needs to be towed by the front end to service center check the OEM Coach Builder towing procedures for the recommended method Check with local authorities and Department of Transportation DOT for permissible towing methods before towing Some states do not permit towing by chain
29. e EJES EJES x check for looseness of taper conneston X x x x x x Check inat cotter pin is installeg PRA inspect slack adjuster for comect stroke Ax inspector ar leas using soapy water sourn x1 _ inspect for proper clearance 1 minimum arron x _ checkepperneuninaterdtnermonboriome x LT 7 inspector signs ofchatngorwear PX PR X x A x X Inspect for air leaks using soapy water solution Inspect for air leaks using soapy water solution air leaks using soapy water solution x xi il CCCo Inspect for signs of bending binding or slippage HEHE Inspect for air leaks using soapy water solution Inspect for air leaks using soapy water solution air leaks using soapy water solution Check mounting nut torque Check mounting nut torque nut ae Ea al I IE ends loose fasteners or worn bushings Check for wear ss for Check for wear Sea SSBB Fnspectvericalendplay TT TXT TT De check nuttorgue TT TXT TT De Carrier Barns Cheskaxarendpa TTT Wheels chook bearing endel 1 100100 E E 0000 ES CT TI 1 S xt Air Fittings and Air Lines Sway Bar Bushings inspector air Isak using soapy water sion x _ cheek mounting bot torg 10 TT ES TT E 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
30. e 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 36 3 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 4 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 5 Remove the hubcap bolts hubcap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that solvents may damage the hubcap window 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 A B C 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 or hub and drum only using a torque wrench 9 10 11 Tighten the nut to 200 ft Ib
31. e brake drums should be replaced if they are damaged or exceed the drum manufacturers recommended maximum diameter or runout specification Refer to manufacturer brake drum guidelines for inspection and specifications Automatic Slack Adjuster The automatic slack adjusters are not serviceable and should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the automatic slack adjuster Brake Chambers The brake air chambers should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the brake air chambers 59 Other Brake Components The brake shoe linings should be replaced when they are worn beyond the manufacturers limits When the brake linings are serviced other components such as the S cam rollers and return springs should also be serviced Refer to 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 are replaced Replacement parts must be equivalent to the vehicle manufacturers to ensure proper function of the anti lock brake system The anti lock brake sensor and tone ring cannot be repaired and must be replaced if damaged or malfunctioning Sensor Removal 1 Remove the brake drum to provide access to sensor 2 Press sensor o
32. e chassis frame rail to the center of the wheel spindle An alternate measurement may be 38 taken as the height of the air spring See Figure 11 Unit Ride Height A Air Spring B IFS1660 6 60 9 25 IFS1800FT 9 06 9 25 Figure 11 Measurement at Ride Height Properly adjusted ride height results in correct suspension travel and alignment The ride height should not be adjusted to adjust chassis rake angle Z CAUTION Adjusting the ride height can cause the front end to raise or lower unexpectedly due to vertical movements at the connection of the vertical link and the horizontal arm of the height control valve 1 Park the vehicle on a level surface 2 Exhaust or dump and re inflate the air suspension Allow the Suspension to settle 3 Check ride height of rear suspension A On vehicles with front suspension equipped with 2 height control valves check and adjust the rear suspension first B On vehicles with front suspension equipped with a single height control valve check and adjust the rear suspension after finish adjusting the front 4 Measure either the wheel center to bottom of frame A or air spring height B If the dimensions are not within 1 8 of measurements in Figure 11 adjust as follows A Loosen the height control valve linkage stud retaining nuts B Raise or lower the L shaped linkage stud a
33. e endplay is not within 001 005 Measure and record the dial indicator see the section on adjusting the wheel reading Vertical inspection clearance bearing endplay must be 006 012 inches 6 Ifthe steering knuckles binds or less than 001 inch endplay is measured Inspecti ng the Knuckle remove shims from the shim pack See Carrier Bearin g an d repair section for kingpin Seal 7 Ifthe vertical endplay measurement is more than 012 inches then install 1 Inspect the seals for damage shims See repair section for kingpin 2 Place the magnetic base of a dial indicator on the knuckle carrier and position the tip of the dial on the end of the bar pin such that axial movement can be measured 35 Adjustments Adjusting Wheel End Play Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury Z WARNING Failure to follow this instruction could cause the wheel to come off and 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 th
34. e to be immediately assembled Do NOT apply oil to the brake linings or the brake drums If the parts are to be stored apply a good corrosion preventative to all surfaces and place them inside special paper or containers that prevent corrosion Do NOT apply corrosion preventative to the brake linings or the brake drums rotors Replacing Tie Rod Ends Removal 1 Remove the cotter pins from the tie rod end ball stud s 2 Remove the castle nuts from the tie rod end ball stud s Z CAUTION Do not strike the component mating taper directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 3 Disconnect the tie rod end ball stud from the mating component tapered hole using a suitable tool 50 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 Z 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 51 Tighten the castle nut to 90 100 Ibf ft See Torque Table 52 Install the cotter pins If necessary tighten the cas
35. ect the ABS sensor lead from the chassis connector 3 The ABS sensor test will require a voltmeter that can measure AC voltage on a millivolt scale 4 Connect the voltmeter to the connector pins of the ABS sensor lead 5 Set the voltmeter scale to millivolts and the voltage source to AC volts 6 Rotate the wheel hub by hand and record the voltage output from the ABS sensor A minimum output of 800 millivolts is normal 7 Ifthe 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 32 8 Check physical gap between the sensor and tone ring Figure 7 The brake drum must be removed to inspect gap The maximum allowable gap is 027 inch If the gap is greater than 027 inch press on the wire lead end of the sensor and push the sensor into contact with the tone ring Check that the ABS spring retainer and bushing are not unseated Re seat components as needed 9 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 10 Repeat Step 3 If voltage output is less than 800 millivolts then replace the ABS sensor Note Check voltage output of new sensor tt 027 a MAX Figure 7 ABS Sensor and Tone Ring Gap Inspecting the Shock Absorber 1 Chec
36. em Part No Description tem PartNo 703181 01 Upper Control Arm LH amp RH 8382 700939 01 Lower Control Arm LH amp RH Bushing Steering Components IFS1660 700973 01 Tie Rod Assembly LH 705382 02 Slotted Nut M20x1 5 700973 02 Tie Rod Assembly RH 705382 03 Cotter Pin 1 40 x 15 Dia 700975 01 Bell Crank 101445 P1 Cotter Pin 1 8 X 1 1 2 705620 01 Idler Arm Assembly 6966 Snap Ring AA O E Bearing SSCS Ts 2571 Hardened Flat Washer O 7348 TT o 702030 0T Relay Rod Lock Nut I Gr C Components are the same in Bell Crank Idler Arm and Crank Arm Components of Ball Joint Kit K705382 12 Steering Components 1800FT Crank Arm Assembly 6 70097304 Crank Rod Assembly Hex Head Bolt 1 14 x 67 Gr 8 8 2571 HF WI 1062x2 00x 134 o 702030 0T Relay Rod LN 1 14 Or C CP Components are the same in Bell Crank and Crank Arm Components of Ball Joint Kit K705382 13 Tie Rod Assemblies CONTO CET 103712 _ Tie Rod End RH 101445 P1 705824 01 Tie Rod End LH 2 6632 Clamp 3 y e i 4 103736 rie Rod End LH 8 705824 02 Tie Rod End RH Castle nuts are part of the tie rod assembly 14 Air Spring and Shock Components IFS1660 Item PartNo Description tem Pareno Description Shock Assembly 11 Brake Line Bracket LH Lower Air Spring Mount Cast LH Brake Line Bracket RH 3 Lower Air Spring M
37. en connections as needed 5 Check the wheel bearing adjustment and adjust as needed 6 Inspect the shock absorbers for wear and damage Rear Axle and Suspension Front tire wear and incorrect steering can be caused by the rear axle and or suspension 1 Check that all fasteners are tightened to the specified torque 2 Check the suspension ride height and adjust as needed to specified height 3 Check that all connection joints between the suspension and axle are secure 4 Check for worn suspension bushings or damaged suspension components 5 Check that the rear axle is correctly aligned 6 Check that the frame is not bent Refer to any additional recommendations and specifications from the manufacturer of the chassis on rear axles and suspensions Total vehicle alignment is recommended when aligning the front suspension Front Wheel Alignment Equipment Tuthill recommends that suitable alignment equipment be used to measure the wheel alignment characteristics camber caster and toe in The alignment equipment must be properly calibrated for accurate measurements Only qualified personnel should conduct the wheel alignment measurements General The overall toe in of the front wheels should be checked every 24 000 miles or 2 years When the vehicle does not steer correctly or the front tires develop an abnormal tire wear pattern the camber caster and toe in should be measured and adjusted
38. enotes the orientation of the eccentricity are two adapters at each lower control arm of the adapter When the setscrew is in the mount and they must be oriented the same 6 o clock or 12 o clock position then the EA BGs ia Negative Camber Negative Camber LH Front Eccentric Vi LH Rear Eccentric Vi aa lew Ly A Be Ta lew FORWARD Figure 15 Eccentric Camber Adjustment 3 Rotate each eccentric adapter to the When the setscrews in both lower control same orientation as needed based on arm mounts are oriented closer to the measured wheel camber The eccentric suspension centerline the tire camber adapters at each control arm mount becomes more negative When the must have the same orientation setscrews in both control arm mounts are 4 Tighten the adapter locknuts to 460 oriented farther from the suspension 490 Ibf ft See Torque Table centerline the tire camber becomes more positive Fig 15 The eccentric adapters 5 Tighten the setscrews to 30 40 Ibf in at both lower control arm mounts must be See Torque Table oriented the same to affect only camber 6 Remove the jack stands and lower vehicle completely Check that the 1 Loosen both lower control arm suspension is at the proper ride height mounting bolts at the eccentric f adapters Do not remove the bolts 7 Re measure the camber and readjust as because the adapters must remain needed
39. ension 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 1t cannot be re lubricated Do not mix lubricants of different grades Do not mix mineral and Ball Studs on Tie Rods 7 synthetic lubricants Different brands of the same grade may be mixed Crank Rod and Drag Link A C AUTION 1 Review lubricant specification and interval requirements before servicing Never mix oil bath and grease packed 2 Apply lubricant to grease fitting until wheel ends new lubricant discharges from the dust boot Figure 4 23 Brake S Cam Tube and 3 Apply lubricant to the automatic slack adjuster until new lubricant discharges Automatic Slack from the cone clutch adjacent the Adj uster adjusting hex nut Figure 4 1 Review lubricant specification and Carrier Beari ng and interval requirements before servicing Kin g pi n 2 Apply lubricant to the S cam tube until new lubricant discharges from the S camshaft bushing seal next to the automatic slack adjuster Figure 4 1 Apply lubricant to both upper and lower carrier bearings and kingpin bushings until new lubricant discharges from the carrier bearing seals and in between the steering knuckle kingpin housing and carrier Grease Fittings Grease Fittings Grease Fittings Figure 4 Location of lubrication fittings Note Left side
40. g arm Frame or underbody out of alignment Incorrect toe in setting Mis aligned belts in radial tires Steering gear valve binding Steering gear not centered Excessive internal steering gear leakage Excessive water puddling on road Inspect and replace as required Inspect and correct as required Adjust toe in to specified setting Check and replace as needed Inspect repair or replace as required Inspect and adjust as required Inspect repair or replace as required Avoid water puddles on road 3 o D oa 0 a 27 SYMPTOMS POSSIBLE CAUSES Grease oil or dirt on brake linings Vehicle pulls to one side Brake linings are glazed with the brakes applied Replace brake linings as required Deglaze brake linings by burnishing or replace as required Brake linings are not a balanced set different friction codes or lining brand Replace brake linings as required Loose or broken brake linings Replace brake linings as required Brake drum out of round Re machine or replace brake drum as required Defective brake drum Inspect for defects and replace as required Brake air chamber clevis pin or camshaft Check and lubricate as needed binding Defective slack adjuster Inspect for defects and replace as required Uneven brake adjustment side to side Adjust slack adjuster as required Different brake air chamber size or slack adjuster length side to side Replace with same size brake air
41. he endplay is the total travel observed If the endplay is not within 001 005 a readjustment will be required 23 Install hubcap gasket and hubcap Tighten the capscrews to 20 30 Ibf ft See Torque Table Replace the hubcap vent plug if removed 24 Fill the hub cavity with the appropriate amount and type of lubricant and secure drain plug 25 Check oil level through the hubcap window Figure 12 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hubcap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window 26 Check the hubcap for external oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the gasket The vent plug will normally weep a small amount of oil Adjusting Suspension Ride Height The height control valve HCV and linkage should be checked regularly for proper clearance operation and adjustment 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 th
42. he 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 in its mount and install the pivot bolt Tighten the pivot bolt lock nut to 575 625 Ibf ft 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 subframe control arm mounts may require widening to accommodate replacement bushings A suitable jack may be used to increase the width of the control arm mounts by cold bending Care must be taken to not exceed 5 00 width after widening The control arm mounts should be inspected for damage Both control arm bushings and mounting hardware except eccentric adapters must be replaced in a control arm when bushings are serviced It is recommended to replace the control arm bushings and mounting fasteners in all of the control arms at the same time The control arm housings must be properly supported during bushing removal The bores of the control arm housings may be h
43. ing a suitable tool to apply pressure to only the outer metal of the bushing Support the housing properly Re install the sway bar bracket and linkage if removed Place the control arm in its mount location Install the control arm mounting hardware and tighten snugly Orient the control arm at suspension ride height and tighten the bolts to 950 1050 Ibf ft See Torque Table Reconnect the sway bar linkage Tighten mounting bolt to 75 85 Ibf ft See Torque Table 7 Apply Loctite 271 to mounting bolt threads and tighten to 350 375 Ibf ft See Torque Table Lower Control Arm Removal 1 Place a portable jack under the knuckle carrier to secure and support it Z CAUTION Do not remove both upper and lower knuckle carrier mounting bolts at the same time unless the knuckle carrier is properly secured Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed to align the lower control arm with the knuckle carrier bar pin 2 Remove knuckle carrier mounting bolts from the control arm Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts 3 Note orientation of lower bar pin in carrier bearing Raise the jack as needed to separate the bar pin from the control arm 4 Remove and retain the lower shock bar pin mount
44. ing 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 55 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 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 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 Install the spacer tubes in bushings 4 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 5 Orient the control arm at suspension ride height and tighten the bolts to 460 490 Ibf ft See Torque Table 6 Note orientation of bar pin in carrier bearing Lower the jack to align the bar pin with the control arm 7 Apply Loctite 271 to mounting bolt threads and tighten to 350 375 Ibf ft See Torque Table 8 Compress shock absorber and connect the lower bar pin mount to the lower shock bracket using the mounting
45. k shock absorbers for oil leakage bent components missing or broken components excessive corrosion or worn bushings Replace shock absorbers if any of the above items is present 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 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 build up 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 Figures 8 See section for adjusting to correct ride height 33
46. l valve Check height control valve and replace as maintain ride height required Height control valve linkage loose Check and tighten linkage as needed Grease oil or dirt on brake linings Replace brake linings as required Brake linings are glazed Deglaze brake linings by burnishing or replace as required Brake linings are not a balanced set Replace brake linings as required different friction codes or lining brand Brakes ale noisy Loose or broken brake linings Replace brake linings as required Brake drum out of round Re machine brake drum as required Defective brake drum Inspect for defects and replace as required Excessive dirt built up in brake drum Remove excessive dirt from brake drum cavity cavity Refer to Bendix Disc Brakes manual Y006471 for troubleshooting of the disc brakes or contact Customer service at 1 800 247 2725 Air spring chafed or worn Check air spring and replace as needed 29 Inspection General Inspection Perform a thorough visual inspection of the suspension to ensure proper assembly and to identify broken parts and loose fasteners each time the vehicle suspension is serviced Do the following during an inspection Wheel Alignment Follow the guidelines in the Front Wheel Alignment section for wheel 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
47. maged 12 Inspect the bearing areas on the spindle for wear or damage Burrs may be removed by light application of emery cloth Replace steering knuckle if the spindle is damaged Installation 1 Place the hub seal assembly with axle ring onto the spindle so the words Oil Bearing Side face outboard Do not place the seal in the hub bore 2 Drive the seal onto the spindle using the appropriate seal installation tool and a 3 5lb hammer Reference Stemco P N 0155220 The wear ring is fully seated when it is square and flush with the face of the inner bearing shoulder of the spindle Reseat the seal onto the wear ring if it becomes dislodged after seating drive bearings onto the spindle with a steel hammer or similar instrument Bearing inner race is a tight slip fit with spindle 57 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 Ys Do not use a sharp tool on lead wire end of the sensor See section for the inspection of ABS sensor as needed 5 Place the hub onto the spindle until it seats on the inner bearing Do not ram the hub onto the seal 6 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 suppo
48. may require adjustment if the front tires rub against the frame suspension body or the steering gear has been serviced replaced Use an alignment machine to check the wheel turn angle See the measurement procedure of the alignment machine manufacturer 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 damage Z CAUTION In power steering systems the hydraulic pressure should relieve or drop off when the steered wheels approach the steering stops in either direction If the pressure does not relieve the components of the front suspension may be damaged If the steering stop bolts are adjusted to reduce wheel turn angle the steering gear poppet valves will require readjustment If the poppets are not re adjusted properly then the steering gear will not reduce power assist properly and steering components will be damaged Refer to TRW s TAS Steering Gear Service Manual for readjusting the poppets 41 Unit Steering Stop Length A IFS1660 1 38 IFS1800 1 38 Figure 13 Steering Stop Bolt Drive the front tires on a suitable device that allows the front wheels to turn and measures the wheel turn angle 2 Secure the vehicle by setting the parking brake and bl
49. mning IFS1660 Independent Front Suspension model with 16 600 Ibs and the IFS1800FT Independent Front Suspension Model with 18 000 lbs Gross Axle Weight Rating GAWR Overloading the suspension may result in adverse ride and handling characteristics You must read and understand all procedures and safety precautions presented in this manual before conducting any service work on the suspension Proper tools must be used to perform the maintenance and repair procedures in this manual Some procedures 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 Tuthill Transport Technologies reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation Tuthill Transport Technologies 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 AN CAUTION A caution in
50. moval of the relay rod from the ball joint in the bell crank and idler steering arm 2 Follow the procedures for removal of tie rod ends for the crank steering arm 3 Remove the pivot bolt that mounts the steering arm and remove the steering arm from the subframe 4 Remove the retaining rings from the pivot sleeve and remove the sleeve A rubber or brass hammer may be used to remove the sleeve Retain shims 5 Support the steering arm bearing housing and press the bearing out of each end of the steering arm Installation 1 Clean out the steering arm grease cavity 2 Inspect steering arm bearing housing bores and remove burrs by honing Replace steering arm if the bore is damaged 3 Pack the steering arm bearing with grease 4 Support the steering arm bearing housing and press the bearing into each end of the steering arm Note that the seal side of the bearing should face out 5 Inspect the pivot sleeve and remove burrs with emery cloth 6 Install one retaining ring onto pivot sleeve 53 7 Insert the pivot sleeve into the lower bearing Use a rubber mallet or similar tool to drive the inner sleeve into the bearings such that the bottom retaining ring is seated against the bottom inner race Do not use a steel hammer to install the sleeve because bearing raceways can be damaged 8 Install upper retaining ring Reseat lower retaining ring against the lower inner race as needed 9 Determine t
51. nd tighten to 275 300 Ibf ft See Torque Table Adjusting the Caster Angle Positive Caster Negative Caster FORWARD Figure 16 Caster Angle Z CAUTION Do not adjust the suspension ride height or alter components to adjust the caster The caster angle is the angle between a vertical axis and the axis defined by the king pin when viewed from the side of the vehicle When the king pin axis appears rotated clockwise relative to the vertical axis then the caster is positive Positive caster creates a self aligning moment to stabilize the vehicle when driving straight ahead Figure 16 The caster angle is indirectly measured from the change in wheel camber as the wheel is turned through a prescribed turn angle Therefore the calculated caster is affected by the ride height of the suspension See the inspecting and adjusting suspension ride height sections before measuring caster The table below lists the recommended caster angles Nominal Caster Values Degrees Unloaded Loaded 3 41 2 3 41 2 3 1 2 3 1 2 Negative Caster Lower Control Arm Front a FORWARD 47 Figure 17 Lower control arm movement Eccentric Caster Adjustment The setscrew in the eccentric adapter denotes the orientation of the eccentricity of the adapter When the setscrew is in the 6 o clock or 12 o clock position then the adapter is in
52. ng and secure as needed Loose pitman arm Check pitman arm and tighten as required Steering column linkage worn Check for wear and repair or replace as Kingpin worn Wheel bearings out of adjustment Steering gear adjustment Steering column mis aligned Worn knuckle carrier bearings Loose knuckle carrier mounting bolts Loose wheel nuts Check and adjust to specification Realign steering column as required Check adjust or replace as needed Check and tighten as needed Check and tighten to specification Vehicle overloaded or unevenly loaded Check wheel loads and correct as needed driver side to passenger side 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 Inspect ride height and adjust to specified setting Inspect and adjust slack adjusters as required Align rear axle to specified thrust angle Check and adjust as required Check wheel bearing end play and adjust as required Check mounting and secure as needed Inspect ball stud connections and wear Vehicle pulls to one side without the brakes applied Unequal ride height side to side Improper brake adjustment Incorrect rear axle alignment Incorrect caster and or camber setting Wheel bearings out of adjustment Loose steering gear mounting Tie rod end connection loose or ball stud worn Bent spindle or steerin
53. nononocononinnnss 18 Sway Bar Components IFS1660S SB amp IFS1800S FTSB models only 19 Dis Brake Components sectaria D EE a E 20 Kina Pin Components a 21 Steering Knuckle Carrier Components ssssessersserrsrresrresrrssrnrssrnrssrrsnrrrnrrnnrrnnen 22 L brication cuna Lubricant Specifications and INtervalS s ssesseersersrerrererrersrerrrernrsrrnesrrssrnrnn rna 23 General TENG AN ON cao Sd 23 NA II O Sed RA DAS SRA NO SNAM RSS teak 23 Ball Studs on Tie Rods Crank Rod and Drag Link ssssssserssrsssrsssesssrssrnss 23 Brake S Cam Tube and Automatic Slack AdjuSter ssserssrrssrsssosssossrns 24 Carrier Bearing and OPI a 24 Wheel Berria 25 Troubleshooting sssseccecceccccsssssssesseceocoossssssseseeees 20 Inspeccion s0 General Inspeccion 30 Inspecting the Control Arm Bushings for Wear s sssssessorsressresresersrreressrennen 30 Inspecting the Tie Rod Ends tri 31 Inspecting the Automatic Slack Adjusters and Brake System 31 Automatic Slack AJUSTES ii is 31 Brake SUS td AA oe 32 Inspecting the ABS Sensor and Tone RiNB coooocnnocociccccnonnconnnonononononoconnnnnnoss 32 Inspecting the Shock Absorber ii ilar eee 32 Table of Contents Inspecting the Air Spring and Height Control Valve sssesssesrrssrerersrennen 33 Ait Spring Inspection sessioner en n wa nasvaidaeh Ass E A ES 33 Height Control Valve Inspection rociar 33 Inspecting the Steering Arm Bearings smmmmmss
54. o align the lower control arm with the knuckle carrier bar pin 10 11 Remove the steering knuckle carrier mounting bolts from the upper and lower control arms Heat may need to be applied to the control arm to loosen the thread adhesive The control arm temperature must not exceed 300 F Do not apply heat directly to the bar pin or mounting bolts Remove steering knuckle carrier Support fixed shoulder end of the bar pin Remove retaining clip and outer collar from the split ring Apply approximately 400 Ib press load to the spacer and remove the split collar Remove spacer and shims Press bar pin out of bearing cones Remove outer seals from both sides of bearings Remove bearing raceways from the steering knuckle carrier Do not damage bores Clean the remaining grease from the bearing cavity 63 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
55. ock the drive wheels to prevent vehicle movement Unequal toe in side to side or an out of center steering gear can result in unequal turn angles and steering pull while steering straight ahead The drag link length may be adjusted to attain steering gear on center condition while maintaining equal toe in side to side Do not adjust the length of the drag link or tie rods to center the steering wheel This can cause the steering gear to become off center Check that the steering gear is centered and the tires are steered straight ahead with equal toe in side to side If either 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 4 Check that the lengths of the outer tie rods are equal to each other within 1 8 inch If not adjust lengths according to the adjusting the toe in section before adjusting the steering stops Turn the steering wheel until the steering stop bolt contacts the knuckle carrier or the steering wheel stops turning Measure the turn angle of the wheel on the same side as the direction of turn 6 Ifthe wheel turn angle differs from Spartan chassis guidelines then adjust as follows 7 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 9
56. oned 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 subframe It is recommended that the wheel and tire be removed to provide proper accessibility Disconnect the vertical height control valve linkage from the horizontal arm to prevent unintentional inflation of the air spring Upper Control Arm Removal 1 Place a portable jack under the knuckle carrier to secure and support it Z CAUTION Do not remove both upper and lower knuckle carrier mounting bolts at the same time unless the knuckle carrier is properly secured 54 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 Disconnect sway bar connector at sway bar if so equipped with a sway bar Loosen and remove control arm mounting locknuts Support control arm and remove control arm mounting bolts Remove the control arm 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 honing Press the bushings into the housings us
57. only shown 24 Wheel Bearings 3 Check the hub cap for external oil marks The vent plug will normally 1 Review lubricant specification and weep a small amount of oil Oil marks interval requirements before servicing in other locations should be addressed 2 Check oil level through hub cap by replacing the hub cap seal window gasket or tightening the pipe fill plug Z CAUTION 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 Do not remove or twist the red plug on oil will settle slowly in the hub Note the front of the hub cap This will The hub cap window can only be damage the hub cap and cause oil to cleaned with mild soap and water leak Add oil only thru the pipe plug or Aromatic solvents should not be used warranty will be void as they will impair the transparency of the window Figure 5 Wheel Bearing Oil Level 25 Troubleshooting Tires have incorrect pressure Put specified air pressure in tires Tires wear out quickly or have Tires out of balance Balance or replace tires uneven tire tread wear Incorrect toe in setting Note Wear pattern will indicate possible cause s Consult tire manufacturer for Incorrect rear axle alignment guidance Adjust toe in to specified setting Incorrect ride height Adjust ride height to specified setting
58. ot apply excessive force to pry ball joints Endplay Inspection 1 Install a dial indicator with a magnetic base so that the base is fixed to the steering arm Place the indicator tip on the flat area of the relay rod adjacent the castle nut 2 Using a C clamp squeeze the relay arm and the steering arm together to seat the ball joint Do not apply excessive clamp load 3 Set the dial indicator on zero 34 Release the clamp Place the pry bar between the steering arm and relay arm Do not allow the pry bar to contact the ball joint seal Firmly pry upward using the steering arm as a fulcrum to lift the relay arm The pry load must not cause the relay arm to rotate thus causing the relay to change orientation 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 Inspecting Wheel Bearing Endplay 1 If the tire and wheel are not removed make sure all the wheel nuts are tightened to the specified torque of 450 500 Ibf ft See Torque Table Ifthe tire and wheel are removed recommended for aluminum wheels secure the brake drum to the hub with the wheel nuts or remove the brake drum Remove the vent plug from the hubcap Attach a dial indicator with a magnetic base to the face of the wheel hub or brake drum The dial indicator may also
59. otation and disconnect the lower steering knuckle carrier bearings at the connection to the sway bar on both same time sides The wheel and tire should be removed to provide access The steering knuckle may 1 Attach the sway bar vertical linkage to be removed to provide easier handling of the upper and lower mounts steering knuckle carrier assembly 2 Tighten the mounting nuts to 80 90 Ibf ft See Torque Table A C AUTION Vertical Linkage Installation The knuckle carrier must be secured Sway Bar Removal and supported properly when upper and lower mounting bolts are removed 1 Follow the instructions for removal of the sway bar vertical linkage for both sides Removal 2 Remove mounting hardware from D ring sway bar mounts on rear of suspension subframe Retain hardware for installation 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 3 Remove the D rings and bushings from the sway bar Sway Bar Installation 1 Replace the D ring bushings 2 Apply TC 1920 Aqua Shield Grease to the inside of the bushing Attach the D rings and bushings to the sway bar in the same location as removal 62 Z CAUTION Do not apply excessive preload to bearings NOTE Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed t
60. ount Cast RH Lower Air Spring Mount Fab LH FHB 3 8 16 x 1 25 Gr 8 ZN Lower Air Spring Mount Fab RH LFN 3 4 10 Gr G ZN 8131017 FW 3 4 812 x 1 469 x 134 ZP 100678 P1 HHB 3 4 10 x 3 5 Gr 8 ZN 5 263 JHEW3 gh 8120382 HHB 5 8 18 x 3 00 Gr 8 ZN 707357 01 Lower Shock Mount 5 8120382 SLW 3 8 100727 P1 HHB 3 4 10 x 4 00 Gr 8 ZN 700184 04 HHB 5 8 18 x 1 3 4 Gr 8 ZN Arm HCV 276 263 276 FHB 1 2 13x1 75 GR 8 100039 P1 HHB 3 4 10 x 2 75 Gr 8 ZN Notch on lower shock mount always is towards the front B the unit 15 Air Spring amp Shock Components IFS1800 706841 01 Air Spring Assembly 11 706026 01 Brake Line Bracket LH 700178 06 Shock Assembly 706026 02 Brake Line Bracket RH 3 705692 02 Lower Air Papa Mount Cast RH 302 FHB 3 8 16 x 1 25 Gr 8 ZN 704508 01 Lower Air Spring Mount Fab tH 14 20 JN VAIO Ge ZN O U UE 704508 02 Lower Air Spring Mount Fab RH 15 8131017 FW 3 4 812 x 1 469 x 134 ZP 6 8120378 N 1 2 13 Gr 5 ZP 18 706899 01 Am HCV SLW 1 2 8 702638 02 FHB 1 2 13x2 00 GR 8 9 100039 P1 HHB 3 4 10 x 2 75 Gr 8 ZN HFW 5 8 Notch on lower shock mount 4 X always is towards the front B the unit 16 HCV Components Item PartNo Description tem artos Description HHB 1 4 20 x 1 25 Gr 8 ZN 6 705932 01 Pin LN 1 4 4 8120392 FW 14 8 705967 02 5 16 Nylock Nut 17
61. pin location Insert the bar pin into the steering knuckle carrier until the bearing cone is seated in the raceway Turn the steering knuckle carrier over and support the shoulder end of the bar pin Pack a bearing cone with grease and place it onto the bar pin end opposite the shoulder and seat it in the raceway Place the spacer onto the bar pin and seat it against the inner raceway Apply approximately 400 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 12 13 14 15 16 17 18 19 20 Using the gap measurement from Step 10 place a number of shims equivalent to the gap measurement onto the bar pin against the inner raceway Place the spacer onto the bar pin Apply approximately 400 Ibs 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 fel
62. ps 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 causing serious personal injury 44 48 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands Adjusting the Camber Angle Negative Camber Positive Camber Camber is the angle of the wheel with respect to the ground as viewed from the front or rear of the vehicle Fig 14 Camber is positive when the distance between centers of the front wheels at the top is greater than the distance at the ground The wheel camber angle is affected by the ride height of the suspension If the ride height is set too high then the camber measurement will be more positive See the inspecting and adjusting suspension ride height sections before measuring camber The table below lists the recommended camber angles Nominal Camber Values Degrees Unloaded ESA 1 4 21 49 1 4 21 49 1 4 41 49 1 4 41 4 Eccentric Camber Adjustment The setscrew in the eccentric adapter adapter is in the neutral position There d
63. repair or replace as needed Air in power steering system Add fluid tighten connections and bleed system Contaminated or incorrect fluid Replace with correctly specified fluid Obstruction with steering gear pitman arm Inspect remove obstruction s and repair or or within hydraulic lines replace as required Obstruction within wheelhouse Inspect remove obstruction s as required Excessive internal steering gear leakage Inspect repair or replace as required 26 Vehicle overloaded or unevenly loaded Check wheel loads and correct as needed driver side to passenger side Vehicle wanders side to Improper mismatched tires and wheels Install correct tire and wheel combination side loose steering Tires have incorrect pressure Put correct air pressure in tires based on Steering wheel has large wheel load amplitude rotational A Incorrect toe in setting Adjust toe in to specified setting oscillations when hitting large bumps Incorrect wheel caster setting Adjust wheel caster to specified setting Tie rod end connection loose or ball stud Inspect ball stud connections and wear worn Steering arm mounts loose Steering arm ball joints binding or worn Check and tighten to specification Inspect ball joints for wear or contamination and replace as required Check and replace as required Check wheel bearing end play and adjust as required Loose steering gear mounting Check mounti
64. rted to prevent misalignment and binding 7 Remove the keeper from the nut 8 A B C Use a small screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released 9 Seat the bearing with the hub or hub and drum only using a torque wrench 10 Tighten the nut to 200 ft lbs Spin the wheel at least one full rotation 11 Repeat step 9 two more times 12 Back the nut off until it is loose 13 14 15 16 17 19 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 lbs Spin the wheel at least one full rotation Repeat step 12 two more times Back the nut off one raised face mark 1 4 turn Install the keeper with the orange side facing out 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 Engage the mating teeth Compress and insert the keeper arms one at a time into the undercut groove with a small screwdriver 20 21 22 23 Refer to the Wheel Bearing Endplay Adjustment section to measure and adjust the endplay to 001 005 inch Adjust by
65. s 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 12 13 14 15 16 17 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 lbs Spin the wheel at least one full rotation Repeat step 12 two more times Back the nut off one raised face mark 1 4 turn Install the keeper with the orange side facing out 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 Engage the mating teeth 37 18 Compress and insert the keeper arms one at a time into the undercut groove with a small screwdriver 19 Verify the end play 20 Attach a dial indicator with a magnetic base to the face of the wheel hub or brake drum The dial indicator may also be attached to the bottom of the brake drum if the wheel is removed 21 Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero 22 Measure the endplay by simultaneously pushing pulling on each side of the tire drum or hub while observing the dial indicator T
66. s and or straps The preferred towing apparatus is the type that cradles the front tires If the towing apparatus cannot be attached to the front tires or directly to the chassis frame rails then the suspension subframe 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 arms or steering knuckle carrier assemblies Figure 3 Tie rod Sv A Steering knuckle Steering rrier carrie arm Lower control arm components Figure 3 Improper Tow Equipment Attachment Locations Maintenance Schedule GENERAL MAINTENANCE Steering Arm Ball Joints Control Arm Bushings Tie Rod Ends Brake System Air Springs Height Control Valve and Linkage Shock Absorbers Kingpins Steering Arm Bearings SERVICE TO BE PERFORMED MILEAGE IN THOUSANDS 12 24 36 as 60 72 sa 96 heokaxarenepa TTT E TT E Pereso TTT spect Tor contact belvsen cono am and mount x X x x x x Inspect for bushing wear pe Eas Hala Inspect ball socket endplay X x x x x x x Ad
67. s in a location to prevent contamination Note that the hub cap window may be damaged by solvents 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 4 Remove the keeper from the nut 5 A B C Use a small screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released 6 Remove the retaining nut 7 Place a shop towel on top of the lower brake shoe to prevent oil from dripping onto the brake lining 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 56 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 If oil saturates or significantly contaminates the brake lining then replace the lining 10 Remove the hub seal and discard it Remove the wear ring from the spindle and discard it 11 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 da
68. s 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 Ibf ft 5 After adjusting the length it is recommended to dump and re inflate the air suspension to obtain the ride height Allow the suspension to settle 6 If not already completed adjust the rear suspension per manufacturer s recommendations 7 Verify at each axle that the side to side ride heights are within 25 of each other Adjusting Wheel Bearing Endplay 1 Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement 39 Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury 27 Raise the vehicle until the front wheels are off the ground Support the raised vehicle with safety stands 28 If the tire and wheel are not removed make sure all the wheel nuts are tightened to the specified torque of 450 500 Ibf ft See Torque Table 29 If the tire and wheel are removed recommended for aluminum wheels secure the brake drum to the hub with the wheel nuts or remove the brake drum 30 Place
69. s that are damaged or worn must be replaced Several major components are heat treated and tempered Z WARNING The components cannot be bent welded heated altered or repaired in any way without reducing the strength or life of the component and voiding the warranty The following operations are prohibited on front suspension components 1 Welding of or to the steering knuckles control arms steering arms knuckle carrier tie rod assemblies the brakes the hubs and the brake drums 2 Hot or cold bending of the steering knuckles control arms steering arms knuckle carrier tie rod assemblies ball joints and the subframe except control arm and steering arm mounts which may be cold bent to facilitate bushing and bearing replacement 3 Drilling out control arm and steering arm mounting holes and ball stud tapered holes 4 Spray welding of bearing diameters on the steering knuckle spindle steering arm bores and pivot tube Spray welding of ball studs or tapered holes for the ball joint and tie rod ends 49 Milling or machining of any component except that control arm bushing bores may be honed to remove any burrs 50 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 station
70. ssssrrerrrersrerrrsrresrrnerrnrsrnrnrsrnrssrrsrrnsnnrna 33 Inspecting the Steering Arm Ball Joints oooonnocononnncoonncnononoonncnonnnnonoss 34 Seal Inspectiom oraria eeii e E AEA NUR ENA one SRA Ta dees EE duces SRS SANS AT ol HN 34 Endplay Inspeccion aid a eds nr sr bor Sea saa vd a season a sida 34 Inspecting Wheel Bearing Endplay s ssesssesrseerresrrerrererrrsrrerrrernrsrrnrsrresrnssrrsnn rna 34 Inspecting the Knuckle Carrier Bearing and Seal osssessserssrsrsrsrsrrrsrnssrnnssnrsn 35 Inspecting the Kingpin Vertical Endplay msmmessesrrerrsrerrsrssrersrersrernrsrrnesrnresrrsrr rss 35 Adj ustments A O Adjusting Wheel End Play visciciccasispsisiandecderseiantadynsacerdossastadsnnniacnveancsbastanines 36 Adjusting Suspension Ride Height oooooocnoccccocccoocncoonccconononn conocio nono nocnnnnnonnss 38 Adjusting Wheel Bearing Endplay ciooovioi con nincinns eoascccdscesoatecs ssveaseessartacvens 39 Adjusting the Maximum Wheel Turn Angle somssrsssrrserssrsssrrsernssnrsernrserrsnrennrn 40 Inspection Before Alentar dia 42 Wheels and A O IO 42 Rront SUSPe A O 42 Rear Axle atid SUSPensiOt cng cys ace At ae ii 43 Front Wheel Alta e a n a 43 EUA A n eae ian E A aa ER en ASS 43 C I E E TEA RR SKANNER bok SRA SNARARE Rb Sk Ark 43 TCP AL AON obit dette avec chad us theta sedated aaa e a a a a Aa a qonest aE E 43 Adjusting the Camber Angle La ada 44 Eccentric Camber AUS ME aan eas nr rna 44 Bar Pin Camber Aqjus tment
71. t If too loose add one shim If too tight remove one shim Fill bearing cavity with grease Install steering knuckle carrier mounting bolts in control arms Note orientation of bar pin Apply Loctite 271 to mounting bolt threads and tighten to 275 300 Ibf ft See Torque Table 64 This page intentionally left blank 65 Torque Tables Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of fasteners for a given application To assure continued satisfactory vehicle performance replacement fasteners used Identification should be of the correct strength as well as the correct nominal diameter thread pitch 0008 length and finish Grade Markings on Lock Nuts Torque Table 1 TORQUE SPECIFICATION Ibf ft APPLICATIONS FASTENER SIZE CLEAN AND DRY 950 1050 460 490 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 5 Used with IFS1800FT units 66 Torque Tables Torque Table 2 APPLICATIONS FASTENER SIZE TORQUE SPEC TORQUE SEQUENCE Ibf ft CLEAN AND DRY 1FS1660 1800FT Brake Spider and
72. 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 oriented farther from the frame rail the caster becomes more negative Fig 18 When the setscrews in the forward lower control arm mount are oriented farther from the frame rail and the setscrews in the rearward control arm mount are oriented closer to the frame rail the caster becomes more positive The eccentric adapters at both lower control arm mounts must be oriented opposite each other to affect caster Negative Caster VIEW A A LH Front Eccentric View Scale 1 2 Negative Caster VIEW B B LH Rear Eccentric View Scale 1 2 FORWARD Figure 18 Eccentric Caster Adjusment 1 Loosen both lower control arm mounting bolts at the eccentric adapters Do not remove the bolts because the adapters must remain engaged in control arm mounting plate for adjustment 2 Loosen the setscrews 3 Rotate 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 460 490 Ibf ft See Torque Table
73. the steering arm replacement section as needed 52 3 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 of any contamination 2 Apply thread adhesive Loctite 242 to the ball joint base threads and thread it into the steering arm by hand 3 Tighten the base of the ball joint to 325 375 Ibf ft 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 Z 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 56 Tighten the castle nut to 155 170 Ibf ft See Torque Table 57 Install the cotter pins If necessary tighten the castle nut to align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin Replacing the Bell Crank Idler and Crank Steering Arm Bearings Replace the bell crank idler and crank steering arm bearings in sets The replacement bearings should be installed by pressing on the outer raceway only Pressing on the inner raceway will damage the bearing The inner grease cavity of the steering arms should be cleaned when the bearings are replaced Removal 1 Follow the procedures for re
74. tle 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 53 Lubricate tie rod end as needed Replacing the Steering Arm Ball Joints The thread in mount type ball joints are installed with a thread adhesive and may require the threads to be warmed to ease removal If heat is applied to the ball joint threads the steering arm temperature must not exceed 300 F and the heat should be applied at the bottom of the ball joint base only Applying heat to the ball joint will damage the ball joint by destroying its internal components as well as the external seal permanently degrading the lubricant and restricting ball stud movement It is recommended that the appropriate tools be used to remove the ball stud taper from the relay rod and to remove the ball joint base from the steering arm Removal 1 Remove the cotter pins from the ball joint ball stud s 2 Remove the castle nuts from the ball joint ball stud s Z CAUTION Do not strike the component mating taper directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 54 Disconnect the ball joint ball stud from the steering arm tapered hole using a suitable tool 55 Secure the steering arm and remove the ball joint using a ball joint spanner wrench or similar device on the base Steering arm may be removed to facilitate ball joint removal See
75. ut of steering knuckle Do not pull sensor out by its lead wire 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 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 1 10V 4 Spin the hub by hand and read the voltage output of the sensor A minimum reading of 8V AC is normal Skip to step 8 if minimum reading is obtained 5 Ifthe minimum reading is not obtained then check the volt meter connection and proximity of the sensor and tone ring The air gap between the sensor and tone ring should not exceed 027 Repeat step 4 6 Ifthe minimum reading is not obtained check the tone ring for damage and its installation The tone ring should have a maximum runout of 008 Replace as needed and repeat step 4 7 Ifthe minimum reading is still not obtained then replace the sensor and repeat the installation procedure 8 Route and secure the sensor lead wire the same as the removed sensor 9 Connect the sensor lead wire to the chassis Secure wire lead to prevent damage during suspension movement Tone Ring Remo
76. val and Installation Follow the hub manufacturers guidelines for removal and installation of the tone ring Replacing the Shock Absorber 60 Z CAUTION The shock absorber is gas pressurized and must not be punctured or be subjected to excessive heat which can result in serious personal injury The shock will expand to its full extended length if not restrained Removal 1 Remove the thru bolt on and retain for installation Do not remove lower shock mount bracket from lower control arm 2 Remove upper shock bushing mounting hardware and retain for installation Installation 1 Position shock in suspension such that the thru bolt is connected to the lower shock mounting bracket tabs 2 Attach upper shock bushing to suspension subframe with mounting hardware Do not tighten 3 Tighten lower thru mounting bolt and nut to 170 190 Ibf ft See Torque Table Tighten nuts to 30 40 Ibf ft See Torque Table 4 Tighten upper mounting nut to 170 190 Ibf ft See Torque Table Replacing the Air Spring The correct air spring must be installed The use of a substitute air spring is not allowed and may cause unequal load sharing between the air springs and cause adverse ride and handling characteristics Removal 1 Deflate the air spring by disconnecting one end of the vertical HCV linkage from the horizontal arm Rotate the horizontal HCV arm downward and secure it in place 2 Disconnect the airline

caution - Spartan Chassis

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