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Front Non-Drive Steering Axle - Central States Bus Sales, Inc.

1. The one piece thrust bearing with an be in contact with the bottom of axle integrated grease seal is completely i beam Figure 43 interchangeable with the two piece design It has a specified top and bottom orientation e The surface with the inner diameter seal must be on top e The surface with the outer diameter seal must be on the bottom Figure 42 1 EGAAL THAUST EBARIG SEAL ASSEMBLY Figure 43 Warning Wear gloves when you install shims Shims have sharp edges that can cause injury All American Front Axle 25 Directory Previous Next Inspect the shims for damage before reinstallation noting the following Replace damaged shims with same size shims or in combination that allow the least amount of knuckle end play If anew shim pack must be determined select the amount of shims that will give the least amount of end play After inspection place shims on top of axle beam bore machined surface Align shims for king pin installation Place the knuckle on the axle beam Place a pry bar between the steering arm boss and the axle beam Lift the knuckle and slide the shim pack between the top of the beam and the knuckle Figure 44 Make sure all the bores are aligned If the bores are not aligned the parts will be damaged when the king pin is installed Remove the pry bar Search Figure 44 Before installing the king pin into the top of the knuckle be sure to note the follow
2. remove the cotter pin from the adjusting nut Figure 63 DOUBLE NUT AND LOCK ADJUSTMENT GUTEN WHEEL LARTE HUT FIERCED LOCA AING ADJUSTING NUT WHEEL BEARING NUT LECH WASHER OBEND ONTO DUTEA WHEEL EEARANHO MUTI Cbi A I Figure 62 35 Directory Previous Next Note When removing or installing the adjusting nuts use the correct wrench socket to avoid damaging the adjusting nuts 8 Use a torque wrench to tighten the adjusting nut to 100 lb ft 136 Nem while rotating the tire in both directions Figure 64 Caution Do not strike the adjusting nut with a metal hammer Do not use a hammer and chisel or drift or loosen the adjusting nut This will damage the nut 9 Loosen the nut completely and then tighten the nut to 20 lb ft 27Nem while rotating the tire Figure 64 SINGLE NUT ADJUSTMENT TA Sa 1O MWUSTING NUT 2 U WASHER 3 COTTER PiN Figure 63 36 Search Exit 1 Tight n nutte 16 thf 198 Herr Fi Loosen ra completely 3 Tighten nut to 20 Beat 27 Hal Figure 64 10 Axles with Single Nut Fasteners a b 9 Back off the adjusting nut 1 8 turn Figure 65 Rotate the nut in either direction to line up a slot with the closest cotter pin hole in the spindle Install a new cotter pin in the nut Measure the end play The end play must be 0 001 0 005 inch 0 025 0 127 mm Refer to Steps 4 5 Readjust if necessary gure eni Siagie Met Partenos Back off mai
3. the stop bolt and the boss on the axle beam Turn the steering wheel until the boss on the axle beam touches the spacer in front of the stop bolt Figure 67 If the maximum turn angle does not meet vehicle manufacturer s specifications correct the maximum angle In a power steering system adjust the pressure relief In a manual steering system follow guidelines and specifications from Blue Bird TWO PIECE 2 4 INCH STEERING STOP BOLT AS RL TUAN ANGLE AXLE BEAM BOGS TEINGH SPLCER 3 4 1NICH STOP LAT Japa Pa 7 PIBCE STOP HOLT AGSETAULY Figure 67 Search 4 Exit When the maximum turn angle is correct Figure 67 a Loosen stop bolt jam nut b Insert 1 8 inch spacer and adjust the stop bolt c Tighten the jam nut on conventional knuckles from 65 85 lb ft 68 101 Nem Four Piece Steering 1 2 Inch Stop Bolt 1 Place washer onto adapter Apply adhesive patch material into the 3 4 inch knuckle bore stop screw adapter hole Install adapter with washer into threaded knuckle cavity Tighten adapter to 85 115 115 155 Nem Start jam nut onto 1 2 inch bolt and install bolt and jam nut assembly into adapter Place a 1 8 inch 3 mm spacer between the stop bolt and the boss on the axle beam Turn the steering wheel until the boss on the axle beam touches the spacer in from of the stop bolt Measure the turn angle If the maximum turn angle does not meet vehicle manufacturer s specifications a
4. tram Figure 38 Place the end cap for the knuckle on top of the seal Slide the king pin through the opposite knuckle bore Use the king pin to install the seal Figure 39 For Easy Steer and nylon bushing make sure the top of the seal is even with top of the knuckle Figure 40 KING PIH TAF Figure 39 Search Exit CaS Sa MICHINED SIAR Ce SEAL BUSHING EHUCELE EAE Figure 40 Turn the knuckle over in the vise The jaws of the vise must hold the bottom of the knuckle and the top of the knuckle must be toward you Place the seal in the top of the bottom knuckle bore The lip of the seal must be away from the bore Figure 38 Repeat step 3 of this procedure Install the Knuckle to Axle Beam 1 2 Clean the bores of the knuckle and the axle beam Install the seal on the thrust bearing On cover type seals install the seal over the open end of the bearing Figure 41 On flat type seals put the seal over the closed part of the bearing Figure 41 All American Front Axle Directory Previous Next Search Exit SEAL TYPES FLAT SEAL BEARING RETAIER BEARING CAGE OFEN SIDE UP TOP INNER DIAMETER SEAL BEARING RETAINER Li I BOTTOM EAL TEGRATED GREASE SEAL Figure 41 Figure 42 3 Place the seal and thrust bearing Integral Thrust Bearing assembly on the inner knuckle Make and Seal sure the seal will face upward toward the beam The top inner diameter will
5. 2 Table H Wheel End Oil Change Intervals and Specifications 1 Current designations are acceptable Multi weight engine oils are acceptable if the SAE rating ends in a 40 or 50 2 Current designations are acceptable Multi weight engine oils are acceptable if the SAE rating ends in a 30 Lubrication Tie Rod End Lubrication This procedure refers to all tie rod ends on Meritor non drive steering axles 1 Turn the vehicle wheels straight ahead Figure 77 2 Wipe the zerk fitting clean with shop towels Figure 78 3 Wipe the seal boot clean with shop towels 4 Attach a grease gun to the zerk fitting Either a hand or air pressure grease gun is acceptable If using air pressure do not exceed 150 psi 1035 kPa Figure 79 5 Discolored old grease should come out of the purge holes near the boot crimp or bellows area typically three or more places Figure 80 48 6 Ifthe tie rod end is designed for lube service and it does not accept grease a Remove the zerk fitting b Inspect the threaded zerk fitting hole in the tie rod end and remove any obstructions c Install a new zerk fitting d Continue the lubrication procedure Note Synthetic lubes are not yet approved for tie rod end lubrication 7 Apply grease until all old grease is purged from the boot All American Front Axle Directory Previous Next Search Exit WIMI Apply greasa t
6. 41 41 Kem Figure 84 Checking Steering Knuckle Vertical End Play 1 Place blocks in front and behind the rear wheels to prevent the vehicle from moving Warning Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury can result 2 Use a jack to raise the vehicle until the front wheels are off the ground Support the front axle with safety stands 3 Install a dial indicator so that the base is on the I beam and that the tip is on the top knuckle cap Figure 85 4 Place a pry bar between the boss for the tie rod arm and the I beam Push the knuckle to the bottom of vertical travel Figure 86 53 Directory Previous Next Search Exit Note If one bushing requires replacement then replace both bushings in the knuckle wn Set the dial indicator on zero 0 6 Use the pry bar to push the knuckle upward Record the reading on the dial indicator The reading must be 0 001 to 0 025 inch 0 025 0 635 mm for new or rebuilt axles and 0 001 to 0 065 inch 0 025 1 650 mm for axles in service Figure 86 WOM Fa If the reading is zero 0 remove the knuckle and remove shims from the shim pack Figure 86 If the reading is more than the maximum specification remove the knuckle and Checking the Upper and add shims
7. Tools section Warning Wear gloves when you remove or install shims Shims have sharp edges that can a ie008sea cause injury Figure 15 12 All American Front Axle Directory Previous Next 8 Remove the knuckle from the axle beam Remove the shims the thrust bearing and the seal between the beam and the knuckle Figure 16 9 Inspect the parts SHES RETWEEN SMLICKLE AND BEAM THEAIST NEARER AND BEAL Figure 16 King Pin Bushings Remove and discard the lower king pin seal Figure 17 2 Turn knuckle upside down and remove the upper king pin seal CONVENTIONAL Figure 17 3 Remove the old bushings as follows All American Front Axle Exit Nylon Bushings Remove the top and the bottom bushing from the knuckle bore Figure 18 LOSS Sia 1 YL BUSH Figure 18 Easy Steer and Bronze Bushings Warning Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury Note On FF FG and FL Series axles the bushings can be removed with Bushing Service Kit from Kent Moore Tools Refer to Table J in Special Tools section a Make a tool to remove the bushings Figure 19 b Place the knuckle in a vise Use a press with a 5 ton capacity Make sure the knuckle does not move when the bushings are removed c Install the tool into the upper king pin bushing Press the upper king 13 Directory Previous Next Search
8. Warning Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury 2 Put the knuckle in a press if used so that the top of the knuckle is toward the All American Front Axle Search Exit top of the press Make sure tops of the bores are parallel to the top of the press Place new bushing in the upper knuckle bore Using installation tool press start the bushing 1 8 inch 3 mm into the upper bore Release the pressure Make sure the bushing is straight into the upper bore Figure 33 o ipii he UPPER ENUCKLE WENCH DEPTH INSTALLATION MSTALLANON POOL SUSHI TUSHIS LOWER KRUSE LE 1HNECH DEPTH INSTALLATION Figure 33 On Easy Steer bushings and for MFS axles press the bushing farther to a depth of 0 352 to 0 382 inch 8 94 9 70 m below the top of the upper knuckle bore Figure 34 Turn the knuckle over so that the bottom of the knuckle is up Make sure the bore is parallel to the top of the press 21 Directory Previous Next EAST ETER TH BS UPPER KAUCKLE UTS 0 H70 IJITA ee LARS LOWER BAUCKLE CUTEIOE 2082 0 SNOW tisk TEMA Figure 34 7 Place new bushing in lower knuckle bore 8 Using installation tool press start the bushing 1 8 inch 3 mm into the lower bore Release the pressure Make sure the bushing is straight into the lower bore Figure 33 9 On Easy Steer bushings press the bushing f
9. all fasteners are tightened to the specified torque Make sure the leaf springs are not worn or damaged Make sure the bushings in the leaf springs are not worn or damaged Make sure the torque rods if used are correctly adjusted Make sure the frame is not bent Make sure the rear axle especially a tandem axle is correctly aligned Refer to any additional rear axle and suspension recommendations and specifications from Blue Bird Corporation Front Wheel Alignment Check the front wheel alignment when the following occur Every 200 000 miles 320 000 km or 24 months normal maintenance When the vehicle does not steer correctly To correct a tire wear condition Minor Front Wheel Alignment Perform a minor front wheel alignment for all normal maintenance conditions Perform the minor front wheel alignment in the following sequence 1 Inspect all the systems that affect the wheel alignment Refer to Inspection Before Alignment in this section 2 Check and adjust the wheel bearings or wheel bearing end ply for the truck hub unit 3 Check and adjust the toe in 34 Search Exit Major Front Wheel Adjustment Perform a major front wheel alignment to correct steering and tire wear conditions To perform the major front wheel alignment refer to the following sequence 1 Inspect all the systems that affect the wheel alignment Refer to section entitled Inspection Before Alignment Check a
10. date The first two digits indicate the year and the last three digits indicate the day of the year The entire necessary axle build information including assembly date for any Meritor front non drive axle is indicated on the axle Sean Figure 4 identification tag The identification tag is fastened to the For example 95327 would reflect the center of the beam at the front surface The 327 day o fl 995 November 22 axle assembly date is either located in the lower right hand or left hand corner of the tag 6 All American Front Axle Directory Previous Next Search Exit ASSY PLANT amp SERIAL NO AVF 95 DATE 95 327 WIEW OF AXLE BEAM FACING VEHICLE CUSTOMER NUMBER AXLE ASSEMBLY PLANT AND SERIAL NUMBER TAG EXAMPLE AXLE ASSEMBLY DATE MODEL AND SPECIFICATION NUMBER Figure 4 To identify the model number refer to the For a description of all models refer to identification plate on the front of the beam Table A Use the complete model number to order parts Figure 5 All American Front Axle 7 Directory Previous Next Search Exit Mentor deantification Basic Capacity A 5000 lbi l lis Brake Usage Brake Usage U 2m 1 00 non ts FF 981 LX 122 Major Variation Muamber Design Variation Pre PMV65 121 Deign Tapered Kirg Pin 1 Straight Sealad King Pin snd Mew Tie bod Assembly 1 Straight King Pin 2 Sealed King Fim Conswugtihan z Speci H Tia Fitis 3 Langer Ale
11. exceed the Knuckle Bore Maximum Diameter specifications Measurements taken at either the upper or the lower knuckle bores which exceed the Knuckle Bore Maximum Diameter in Table B indicate the knuckle requires removal and replacement RING PIN BUSHING MEASUREMENT i U 1006TA 1 Meanss hushing bere in hour poen isas 90 opponad Figure 21 All American Front Axle Search Exit Measure the king pin bushing inside diameter using a micrometer and a telescoping gauge for taking measurements If the average inside diameter measurement is greater than the King Pin Bushing Maximum Inner Diameter Table B install a new bushing Measure the inner diameter of the new bushing after installation and reaming Measure the inner diameter of the bushing in four positions and at two locations The two locations must be 90 degrees opposed from each other Figure 20 If the average measurement is more than the King Pin Bushing Maximum Inner Diameter specification in Table B replace the bushing Measure the inner bore diameter of the axle beam Rounding at the top and bottom of the beam is acceptable Measure the axle beam bore at four positions Figure 20 and at two specific locations 1 2 inch 12 7 mm below the top of the bore and 1 2 inch 12 7 mm above the bottom of the bore Figure 22 If the average measurement is greater than the Axle Beam Bore Maximum Diameter given in Table B the entire axle beam require
12. for assembly and disassembly procedures Do not hit steel parts with a steel hammer Pieces of a part can break off and cause serious personal injury Use a brass hammer and a steel drift to remove the draw key Place the drift on the small D shaped end of the key Figure 13 Remove Threaded Draw Keys a Loosen the threaded draw key lock nut until the top of the lock nut is even with the end of the draw key 11 Directory Previous Next Search Exit b Use a brass drift and a hammer to hit the end of the draw key Figure 14 c Remove the nut from the draw key Remove the draw key from the knuckle Warning Use a brass or leather mallet for assembly ad and disassembly procedures Do not hit r A i e a steel parts with a steel hammer Pieces of a part can break off and cause serious personal injury Caution Force must be directly applied to the bottom of the nut and the end of the key If force is not directly applied the draw key will be damaged Note If the bushings are not being replaced perform the following to prevent damaging the bushing during kin pin removal e Remove any flaring on the drift that may touch the bushings e Wrap tape to a thickness of 1 16 inch 1 5 mm on the end of the drift Figure 14 7 Use a brass drift and a hammer to remove the king pins from the knuckle Figure 15 If the king pin is hard to remove use a hydraulic king pin remover Refer to Table J in Special
13. have a minimum clearance of 1 8 inch 3 mm between the stop bolt and the axle beam boss Hydraulic steering gears with poppet valves are adjusted with a spacer between the stop bolt in the knuckle and the boss on the axle beam The poppet valves are adjusted to stop or reduce steering forces from t he 1 8 1 GENTEM LINE OF FRONT AXLE F CENTER LINE OF HEAR Awi E inch 3 mm specified distance between the a FENTERKINE OF CHABBIG beam boss and the spacer Figure 70 Figure 71 The angle is built into the design of the tie rod arms the tie rod ends and the cross tube assembly to give the best possible road 40 All American Front Axle Directory Previous Next contact and to minimize tire wear during turns Check the turning radius angle with the radius plates on the alignment equipment If the angle is not within specifications premature tire wear will occur Inspect the knuckle tie rod arms tie rod ends and cross tube for wear or damage Service as necessary King Pin Inclination King pin or steering axis inclination is the angle measured between the center line of the king pin and the vertical position as viewed from the front of the vehicle Figure 72 The king pin inclination and the camber angle are designed into the axle to place the tire tread center line in contact with the road This reduces steering effort and improves directional stability Use an alignment machine to check the king pin i
14. is not at the specified angle check the axle Search Exit beam and the steering knuckle for damage Service as necessary Conditions Old Camber Specification New Camber Specification Ales with Assembly Dates Axles with Assembly Dates No Date indicated on tag On or after Sep 1 1992 Prior to Aug 31 1992 92244 92245 with no P suffix Any date with a P Suffix Left Side Right Side Left and Right Sides Camber angles machined into 3 4 1 4 1 4 Nominal axles Nominal Nominal Hubs not installed Axles not installed in vehicle Load not applied on axle Camber angles of axles 3 4 1 4 1 4 47 16 equipped with hubs 7 16 7 16 or or or 11 16 to 3 16 final 1 3 16 to 11 16 to reading 5 16 final 3 16 final reading reading Camber angles under load 11 16 to 3 16 to 3 16 to 11 16 final Axle installed in vehicle 3 16 final 11 16 final reading reading reading Table D Camber Angle Recommendations Use an alignment machine to check the camber angle Refer to the procedure of the manufacturer of the alignment equipment The table above gives the specification Meritor builds into the axle Caster Angle Caster is the forward or rearward tilt of the king pin center line when viewed from the side of the vehicle The caster angle is the angle from the vertical position to the center line of the king pin If the top of the king pin a
15. must be raised and supported with stands Caution Do not grease the tie rod assembly before performing the inspection Doing so may provide inaccurate results Replace the entire tie rod end if the boot is torn or missing Do not replace the boot only 1 Place blocks in front of and behind the vehicle s rear wheels Using the bottom of the I beam or frame rails raise the front end off the ground and support with stands With the engine off turn wheels from full left to full right and then return to the straight ahead position This step will require more force for vehicles with power steering turned off Check that the boot is in place and completely installed over the tie rod end Note The boot may be missing completely or may not completely cover the ball joint 4 Check for cracking or tears in the boot Also check the boot seals for damage Replace the entire rod end if the boot is damaged Figure 91 All American Front Axle Directory Previous Next 10Na Grackad or tom boot pequires antre tle rad end regda ramant Figure 91 Warning A cotter pin must be installed through the tie rod end with the tie rod end nut tightened to torque specification to securely attach the tie rod Loss of the cotter pin will allow the tie rod end nut to become loose and affect vehicle steering and possibly result in loss of steering control 5 Check that the tie rod nut is installed and secured with a cotter pin
16. the parking brake 2 Lubricate the king pins through the top and the bottom king pin cap grease fittings Figure 81 3 Apply lubricant until new lubricant comes from between the upper shim pack and thrust bearing seal Exit THI GREASE FIMTERG Lube masi toma fram here 4 Lower the vehicle so that the wheels migare gl touch the ground 5 Apply lubricant to the bottom fitting n until new lubricant purges and fills the Grease Lubricated thrust bearing 1 2 Wiii Ts 1 MDE GREASE FITTING 2 TOP GARASE PITTIRES 9 Lube mart cere trom hor 3 Figure 81 Ball Studs on Steering Arm the Tie Rod Arm Ends and the Drag Link 1 Make sure the tires touch the ground DO NOT RAISE THE VEHICLE 2 Clean off all grease fittings prior to lubrication 3 Apply lubricant until new lubricant comes from the boot Figure 81 All American Front Axle Wheel Bearings Note This procedure applies to hubs with grease lubricated wheel bearings Remove the tire and wheel assembly Remove and disassemble the hub Refer to the section on Wheel Ends Remove the old lubricant from all parts Discard the seals Inspect the wheel bearings for wear or damage Replace worn or damaged bearings Refer to Preparing Parts for Assembly section Force the specified lubricant from the large end of the cones into the cavities between the rollers and cage Pack the hub between the bearing cups with lubricant to the level of the s
17. to the shim pack Lower King Pin Bushings for Wear 1 Place blocks in front and behind the rear wheels to prevent the vehicle from moving Warning Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury can result 2 Use a jack to raise the vehicle until the waza wheels are off the ground Support the vehicle with safety stands Figure 85 3 Check the upper king pin bushing for wear Install a dial indicator so that the base is on the I beam and that the tip is against the side of the top of the knuckle Figure 87 4 Set the dial indicator to zero 0 54 All American Front Axle Directory Previous Next Search Exit Note FRONT VIEW CURE SIDE If one bushing must be replaced replace both bushings in the knuckle 5 Move the top of the tire side to side towards and away from the vehicle If the dial indicator moves a total of 0 010 inch 0 254 mm the upper bushing is worn or damaged Replace both bushings Figure 87 Figure 88 Inspect the Tie Rod Ends 1 Park the vehicle with the steering wheels in the straight ahead position Figure 89 Figure 87 6 Check the lower king pin bushing Install a dial indicator so that the base is on the I beam and that the tip is against the side of the bottom of the knuckle Figur
18. 0 km 16 100 km 32 200 58 000 64 000 km 80 500 160 000 km 320 000 km Tie Rod Ends Group 2 Group 3 I L Inspect the Tie Rod Assembly for Movement Group 2 Group 3 Tie Rod End Shop Inspection Ball Stud on Steering Arms L Easy Steer Plus Axle Ball Studs Sealed Axle Ball Studs Drag Link L King Pins and Bushings L Steering Arm Bolts Thrust Bearings L 46 All American Front Axle Directory Previous Next Search Exit Steering Knuckle Vertical End Play Inspection Group 2 Group 3 Upper and Lower King Pin Bushings for Wear Group 2 Group 3 Draw Key Nuts New vehicle In service vehicle Sealed Hub Unit Inspection I Inspect L Lubricate T Tighten to Specifications If power washers are used during vehicle cleaning operations lubrication intervals need to be adjusted Frequent power washed vehicles will require more frequent lubrication Table F Lubrication Inspection and Maintenance Schedule Component Greasing Grease Meritor NLGI Grease Type Outside Interval Specification Grade Temperature King Pins and 100 000 Multi O 617 A 1 Lithium 12 Refer to the Bushings miles 160 Purpose Or or Hydroxystearate
19. 170 tum Double Hut and Lack Pasieners Hack of mui 1I pam Figure 65 All American Front Axle Directory Previous Next 11 Axles with Double Nut and Lock fasteners Back off the adjusting nut 1 3 turn Figure 65 Install the pierced lock ring the lock washer and the wheel bearing nut For wheel bearing nuts in sizes from 1 1 8 inches up to 2 5 8 inches tighten to 200 300 lb ft 271 407 Nem For wheel bearing nuts 2 5 8 inches and more tighten to 250 400 lb ft 339 542 Nem Measure the end play The end play must be 0 001 0 005 inch 0 025 0 127 mm Refer to Steps 4 5 Readjust if necessary If end play is to specification bend washer to at least one flat edge of outer wheel bearing nut Figure 62 12 Install the gasket and the cap on the hub Install the capscrews and tighten to 20 30 lb ft 27 41 Nem Lower the vehicle to the ground Check the correct vehicle operation 13 Adjust the Maximum Turn Angle The stop bolt on the back of the knuckle controls the maximum turn angle Caution Do not exceed the maximum turn angle specified by the vehicle manufacturer If the angle is exceeded the steering arms the cross tube and the tie rod ends will be damaged Check the angle if the front tires rub against the frame or if the steering gear has been serviced Use an alignment machine to check the angle Refer to procedures from the manufacturer of the alignment equipment All American Front Axle
20. 28 Exit Draw Key Lock Nuts Warning Use a brass or leather mallet for assembly and disassembly procedures Do not hit steel parts with a steel hammer Pieces of a part can break off and cause serious personal injury Caution Make sure the draw key is installed completely or the lock nut is tightened to the specified torque If not installed correctly the king pin and the axle beam will be damaged Note All models except FE 970 FF 971 and FL 901 use threaded draw keys Models FE 970 FF 971 and FL 901 use plain draw keys 1 Install the draw keys Refer to the following procedure Plain Draw Keys Use a hammer and a brass drift to install the draw key in the axle beam and knuckle Make sure the key is installed 1 32 to 1 8 inch 1 3 mm below the outer surface of the beam Figure 50 Threaded Draw Keys On threaded draw keys install the lock nut and tighten to 30 45 lb ft 41 61 Nem Figure 51 Install new gaskets and the caps on the top and the bottom of the knuckle Install the capscrews and the washers and tighten to 20 30 lb ft 28 40 Nem Figure 52 Connect the tie rod arm to the knuckle Refer to the procedure in this section All American Front Axle Directory Previous i Tighten nut be 3045 b h ATS Hmi Figure 51 All American Front Axle Exit Figure 52 Steering Arm 1 Press the key in the slot in the arm 2 Install the steering arm in the knuckle Caution Tighten the nu
21. 29 982 1 1 8 12 550 1025 746 1389 1 1 4 12 715 1450 1051 1965 1 1 2 12 1350 2525 1831 3423 4 Draw Key Nut 30 45 41 61 5 3 4 Stop Screw Adapter 65 115 88 155 6 1 2 Stop Screw Lock Jam Nut 7 16 20 50 75 68 101 7 3 4 Stop Screw Lock Jam Nut 65 85 88 115 8 Tie Rod Arm to Tie Rod End Nut 7 8 14 160 300 217 406 1 14 250 450 339 610 1 1 8 12 350 650 475 881 1 1 4 12 500 675 678 915 9 Cross Tube Clamp Nut 5 8 11 40 60 55 81 3 4 10 155 175 211 237 10 Tie Rod Arm to Knuckle Nut 7 8 14 250 450 339 610 1 14 390 725 529 982 1 1 8 12 550 1025 746 1389 1 1 4 12 715 1450 1051 1965 1 1 2 12 1350 2525 1831 3423 Table I Front Axle with Conventional Wheel Ends 62 All American Front Axle Directory Previous Next Special Tools Search Exit Description Kent Moore Owatonna Tool Snap On Tool References Tool Number Number 2 Number 3 1 King Pin Remover 4240 4240 20 Ton Disassembly CG430HYB Section King Pin Bushing 4 Disassembly Service Kit Section Basic Service Kit FF and FG Series PT 4375 A Kits PT 4370 10 FL Series Kit PT 4370 20 MN 55060 Table J Special Tools 1 Order Kent Moore tools from Kent Moore 28635 Mound Road Warrren MI 48092 2 Order Owatonna tools from OTC Tool and Equipment Division 655 Eisenhower Drive Owatonna 3 See your local S
22. Beant and Enuklis 35 Diop bori Center of Spindie to Pad 4 Eau Soer M Diiign 45 Deop ireen Canger of Spinde 5 Tubular Ache Bears to Pad and Special Te Bods Lightweight Axie Beam 5 Special Wheel Ends 7 Cemter Point Design E Oouble ioe Boom B Enay Geer Plu pila iade Figure 5 Model Capacity Wheel End and Knuckle Type Major Design Number lbs Variation Bottle Spindle with Bolted Tie Rod Arm FF 966 12 000 Individual Hub Bearings Seals Straight King Pin Bottle Spindle with Bolted Tie Rod Arm i eee Eee Individual Hub Bearings Seals Sree OE 5 Drop from Center FF 944 13 200 Bottle Spindle with Bolted Tie Rod Arm of Spindle to Pad and gt Individual Hub Bearings Seals Special Tie Rods Easy Steer Design 5 Drop from Center FG 943 w eee of Spindle to Pad Easy Individual Hub Bearings Seals Steer Design Table A Front Non Driving Axle Model Number Information s stands Do not work under a vehicle Disassembly Removal supported only by jacks Jacks can slip and fall over Serious personal injury can result Warning To prevent serious eye injury always wear 1 Raise the front of the vehicle until the eye protection when you perform vehicle front wheels are off the floor Support maintenance or service the vehicle with safety stands 2 Remove the capscrews that fasten the cap to the hub Remove the cap and the asket Wheel Ends Warni Note arning When the ad
23. Directory Previous Next Search Exit Front Non Drive Steering Axle BLUE BIRD Table of Contents Sub Headings Install Brake Components Wheel Safety 5 _ Ends 33 Warnings 5 Adjustments 33 Cautions 5 Inspection Before Alignment 33 Notes 5 Inspection 33 Introduction 5 Wheels and Tires 33 Descriptions 5 Front Suspension 33 Identification 6 Rear Axle and Rear Suspension 33 Disassembly 8 Front Wheel Alignment 34 Drag Link 9 Check Adjust Wheel Bearings 35 Steering Arm 10 Adjust Maximum Turn Angle 37 Tie Rod Arms Tie Rod Ends 10 Adjust Pressure Relief in Power Draw Keys King Pins Steering Steering l 39 Knuckle 11 Axles with Conventional Wheel Ends 39 King Pin Bushings 13 Hydraulic Pressure Relief 40 Nylon Bushings 13 Turning Radius Angle 40 Preparing Parts for Assembly 14 King Pin Inclination 41 Repair Parts 14 Camber Angle 41 Clean Ground or Polished Parts 15 Caster Angle 42 Clean Rough Parts 15 Adjust Toe In 43 Dry Cleaned Parts 15 Diagnostics 44 Corrosion Prevention on Cleaned Lubrication 48 Parts 15 King Pins 50 Install New Fasteners 15 Grease Lubricated Wheel Bearings 51 Install Original Used Fasteners 16 Oil Lubricated Wheel Bearings 52 Check Torque Values 16 Inspection and Maintenance 52 Inspect Parts 16 Checking Draw Key Nuts 53 Inspect Wheel Bearings 18 Checking Steering Knuckle End Play 53 Tie Rod Grease Fittings 19 Checking Upper Lower King Pin 54 Assembly 20 Inspect Tie Rod Ends 55 Installation 20 Inspect Tie Rod Assembly 56 Reami
24. Exit pin bushing from the knuckle bore POSITION OF BUSHINGS Figure 20 IN KNUCKLE d Turn knuckle upside down and install the tool in the lower king pin bushing Press the lower bushing from the knuckle bore Figure 20 io APP KING Pre MESHING 2 LOWEN kiho PIM nuUsHIG Figure 20 Axle Model Dimension X Dimension Y Number 0 001 in 0 025 mm 0 001 in 0 025 mm FF 966 1 786 45 364 1 911 48 539 FF 967 1 786 45 364 1 911 48 539 FF 944 1 786 45 364 1 911 48 539 FF 943 1 786 45 364 1 911 48 539 Figure 19 Dimensions for Bushing Removal and Installation Tool Preparing Parts for Caution Do not bend weld or heat any front axle Assembly component If the axle is bent welded or heated the strength of the axle is reduced and the warranty is voided An axle damaged by bending welding or heating may cause a vehicle accident and serious personal injury Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service The following operations are prohibited on front axle components Repair Parts 1 Welding of or to the steering arms tie The repair or reconditioning of front axle rod arms the knuckles the king pins components is not allowed Meritor the axle beams the tied rod assemblies recommends replacing damaged or out of the hubs the drums or the brakes specification components All major 2 Hot or cold ben
25. If the cotter pin is missing check the nut torque specification and then install a new cotter pin Always tighten tie rod nut to specified torque when setting the cotter pin Caution The tie rod ends must be at the end of the cross tube slot to ensure adequate thread engagement 6 Check that the tie rod end is threaded correctly into the cross tube and engaged deeper than the end of the cross tube slot The tie rod end must be visible the entire length of the cross tube slot Figure 92 Search Exit TOE Tie rod end angeged deeper than tee and of the cross else shot TIE ROD CROSS TUBE SLOT END fis rod threads must be visible the entire fength of the rods pbe ahy Figure 92 Check that zerk fittings are installed Replace a damaged zerk fitting with a new one Some tie rod ends are non greaseable and will not have zerk fittings Do not install fitting if tie rod end is non greaseable type Caution Do not use the following items or methods to check for movement of the tie rod assembly Damage to components can result if A crow bar pickle fork or 2 x 4 is used A tool instead of your hands is used to grasp the cross tube assembly that results in cross tube damage Pressure or force is applied to the ends or the joints of the assembly The tires are rocked either with the vehicle on the ground or with the wheels raised By hand or using a pipe wrench with jaw protectors to avoid gouging the cross tu
26. Search Exit For power steering systems the stop bolt should NOT touch the beam The stop bolt should always have a minimum clearance of 1 8 inch 3 mm when the knuckle is in the full turn position Figure 66 REFERENCES TO KNUCKLE FOR STOP BOLT ADJUSTMENT wire STOP BOLT TiEOH SPACER 1MCH 3 MM CLEARANGE BETAEEM STOP MOLT AG BOSS Liu AT BAXIMLI TURN APLE Figure 66 For manual steering systems Meritor recommends a stop bolt clearance of 1 8 inch 3 mm Stop bolt contact is acceptable if no other stops are used for the maximum turn angle of the steering knuckle Caution If the stop bolt is missing bent or broken the system requires adjustment Refer to Mechanical Stop in this section Note If the steering system is out of adjustment inspect the steering arm for damage Use a magnetic particle or liquid dye penetrant inspection procedure to inspect the steering arm Pay particular attention to the bend the taper and the area near the ball stud Refer to the manual from Blue Bird for additional inspection procedures 37 Directory Previous Next Caution In power Steering systems the hydraulic pressure should relieve or drop off at the end of the steering stroke with 1 8 inch or 3 mm minimum clearance at the stop bolt If the pressure does not relieve the components of the front axle will be damaged Two Piece Steering 3 4 Inch Stop Bolt 1 38 Put a 1 8 inch 3 mm spacer between
27. The threaded portion of the tie rod end must be installed into the cross tube beyond the end of the slot Make certain the clamp tab is firmly seated against the cross tube 9 Install the nuts on the tie rod ends Tighten to the specified torque Refer to Table I in Torque Specification section 10 Install the cotter pins If necessary tighten the nut until the holes are aligned Do not loosen the nut to install the cotter pin 11 Check and if necessary adjust the toe in Drag Link 1 Connect the drag link to the steering arm Figure 60 2 Connect the drag link to the Pitman arm Caution Tighten the nuts to the specified torque If the nuts are not tightened to the specified torque the parts will be damaged 3 Install the nuts Tighten to the specified torque Refer to Torque Specification section All American Front Axle Directory Previous Next 4 Install the cotter pins If necessary tighten the nut until the holes are aligned Do not loosen the nut to install the cotter pin 5 Lubricate the drag link Refer to Lubrication section 6 Check for correct operation 7 DRAG LINK J STEPRING ARM Figure 60 Install the Brake Components and Wheel Ends 1 Install the brake assembly on the knuckle Lubricate the wheel bearings Refer to Lubrication section Install the outer wheel bearing cone in the hub Install the adjusting nut Adjust the wheel bearings Refer to section entitled Check an
28. This procedure applies to all axles included in this manual 1 Remove the cotter pins from the ball studs Remove the nuts from the ball studs 3 Disconnect the drag link from the Pitman arm and the steering arm Figure 7 Inspect the drag link Next Directory Previous PITMAN ARM DRAG LAME STEERING AFAA Figure 7 Steering Arm 1 Remove the cotter pin and the nut that fastens the steering arm to the drag link Disconnect the steering arm from drag link Figure 8 WOO Sob 1 STEERING AAM 2 SAFETY STANDS Figure 8 2 Remove the cotter pin and the nut that fastens the steering arm to the knuckle 3 Remove the steering arm from the knuckle If necessary tap on the end of the rod with a leather or plastic mallet 4 Remove the key from the steering arm 5 Inspect the steering arm 10 Search Exit Tie Rod Arms Tie Rod Enas and Cross Tube 7 Remove the cotter pins and the nuts that fasten each tie rod end to the tie rod arms Figure 9 Disconnect the cross tube assembly from the tie rod arms If available use tie rod end puller to separate the tie rod end from the tie rod arm Figure 9 Remove the cotter pin and the nut that fasten the tie rod arms in the knuckle Figure 9 Remove the tie rod ends from the knuckle If necessary tap on the end of the knuckle with a leather or plastic mallet Remove the key TE ROD END Figure 9 If necessary remove the tie rod ends Refer to t
29. anufacturer s instructions to prevent irritation to the eyes and skin Note This procedure applies to ALL axles included in this manual Check steering arm bolts for minimum 300 lb ft 406 Nem torque If steering arm bolt torque has fallen below 300 Ib ft 406 Nem remove bolts clean all threads and install new Loctite Tighten bolts from 300 to 450 1b ft 406 610 Nem torque Check steering arm bolt torque every 200 000 miles 320 000 km or 24 months All American Front Axle Directory Previous Next Search Exit Note Torque Specifications Old Loctite must be removed from bolt threads and internal threads of knuckle itself Reapply new Loctite 680 Meritor Warning o 2297 K 5523 To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Front Non Drive Axles with Conventional Wheel Ends Figure 97 All American Front Axle 61 Directory Previous Next Search Front Axle with Conventional Wheel Ends Torque Specifications a Torque Range Item Description Size bft Nem 1 Steering Arm to Drag Link Nut 5 8 16 60 115 82 155 5 8 18 60 115 92 155 3 4 16 90 170 123 230 7 8 14 160 300 217 407 2 Knuckle Cap Screw 5 16 18 20 30 28 40 3 Steering Arm to Knuckle Nut 7 8 14 250 450 339 610 1 14 390 725 5
30. arther to a depth of 0 352 to 0 382 inch 8 94 9 70 mm below the top of the lower knuckle bore as viewed with the knuckle upside down Figure 34 Ream the bushings Refer to the procedures in this section 10 Reaming the King Pin Bushings Bronze and Easy Steer Bushings Caution Do not hone or burnish the bushings The bushings will be damaged by honing or burnishing 22 Search Exit Note Reamer tools are available from SPX Kent Moore at 1 800 328 6657 and from Wright Tool Company at 1 800 783 9826 1 2 Place the knuckle in a vise with brass jaws Refer to Figure 35 for the dimensions of the reamer tool REMOVABLE PILOT OPTIONAL AEAMER E D 246CHES 50 8 MRA WIRD TSINCHES bia Mipi MATERIAL HIGH SPEED STEEL NUMBER OF BLADES LUSE 10 14 BLADES CUT OF BLADES RRHT HAMED CUT LEFT HAND PLUTE LENGTH OF BLADES 2 504NCHES HIT MMI Figure 35 Slide the pilot of the reamer through the top bushing until the reamer blades touch the bushing Figure 36 Rotate the reamer with a light downward pressure Do not apply too much force Rotate the reamer smoothly After the reamer cuts most of the top bushing make sure the tool does not drop to the bottom bushing After cutting the top bushing guide the reamer into the bottom bushing Repeat Steps 3 5 Figure 37 Slide the reamer out of the bottom bushing If the reamer must be removed through the top bushing rotate the tool in
31. be rotate the cross tube toward the front of the vehicle and then toward the rear After rotating center the cross tube If the cross tube will not rotate in either direction replace both tie rod ends Position yourself directly below the ball stud socket Using both hands grab the assembly end as close to the socket as All American Front Axle 57 Directory Previous Next Search Exit possible no more than 6 inches or 152 4 mm Apply hand pressure 4 If any movement is detected at one tie approximately 100 pounds vertically rod end replace it and the other tie rod up and down in a push and pull end Always replace tie rod ends in motion several times Check for any pairs even if only one tie rod is found movement or looseness at both tie rod damaged end locations 10 If there is any movement in the tie rod Warning assembly replace both tie rod ends Do not attempt to straighten a bent cross tube Damage to the axle can result Be certain to replace any cross tube with an Tie Rod End Shop original equipment cross tube with the Insp ection same length diameter and threads Cauti 5 Inspect the cross tube and clamps for auton Replace the entire tie rod end if the boot is torn or missing Do not replace the boot only 1 Check the tie rod boot for cracks tears or other damage All tie rod ends with a damaged boot require that the entire tie rod end be replaced Figure 91 2 Grab by hand or using a pipe w
32. ch inch PR 48 818 45 6692 45 6180 mm mm mm Table B Axle Wear Limit Specifications Inspect the Wheel Bearings 1 WORN RADIUS 2 WORN SURFACE Inspect the wheel bearings when the hub is removed from the knuckle spindle Figure 23 18 All American Front Axle Directory Previous Next Search Exit o SPALLING AND FLAHIDEKI i CRACK 2 WEAR GROOVE Figure 27 Figure 24 WEAR MARKS Tie Rod Grease Fittings When inspecting the tie rod observe the following 1 Ifa grease fitting is missing install a new one Do not attempt to install a fitting if the tie rod end is a non greaseable design Figure 28 2 Tighten all grease fittings to the specified torque Figure 29 10041i4a GREASE ATTA ALTERNATE LOCATION Figure 28 Figure 26 All American Front Axle 19 Directory Previous Next IDS 150 1 GREASE ATTING ALTERNATE LOCATION 2 TORQUE WRENCH USED TO TIGHTEN GALASI AT TAG TO SPECIFICATION Figure 29 Assembly Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Installation King Pin Bushings Nylon Bushings Insert the nylon bushing in each knuckle bore by hand Be sure that the entire outer surface of the nylon bushing is in contact with the knuckle bore Check the nylon bushing installation before attempting to install the knuckle to the axle beam noting the following 1 Verify that each nylon b
33. d Adjust the Wheel Bearings Refer to the wheel end hardware manufacturer s procedures if necessary 2 Install the capscrews and tighten to 20 30 lb ft 27 41 Nem Install the wheel and tire assembly Lower the vehicle to the ground Check for correct operation Check and adjust the toe in All American Front Axle Install the cap and the gasket on the hub Search Exit Adjustments Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Inspection Before Alignment Check the following before doing a front wheel alignment Inspection Refer to section on Lubrication Inspection and Maintenance Wheels and Tires Check the following items e Make sure the tires are inflated to the specified pressure Make sure the front tires are the same size and type Make sure the lug nuts are tightened to the specified torque Make sure the wheels are balanced Check for bent or damaged wheels Front Suspension Check for the following items e Make sure all fasteners are tightened to the specified torque Inspect the leaf springs for wear and damage Inspect the shock absorbers for wear and damage Rear Axle and Rear Suspension Front tire wear can be caused by the rear axle If the outer edge of one front tire is 33 Directory Previous Next worn and the inner edge of the other front tire is worn check the following e Make sure
34. dicator Place the base on the knuckle Place the tip on the center of the king pin Set the dial indicator on zero 0 Figure 47 Figure 45A i MAGNETIC BASE LOCATED AT ETHER PLACI Figure 45A Figure 47 Check the Steer Knuckle beeen ee r a hydraulic jack is used to measure en Vertical End Play for Shim play use two safety stands to support the axle in the rest position If safety stands are not used the axle can fall Serious personal injury can occur Selection 1 Strike the boss of the knuckle with a rubber mallet to move the parts in position Figure 46 2 Turn the knuckle to the straight forward position 4 Use one of the following procedures to measure the end play e Place a pry bar between the knuckle and the top of the axle center Push All American Front Axle 27 Directory Previous Next the knuckle up and measure the end play Figure 48 Place a block of wood and a hydraulic jack under the bottom of the knuckle Raise the knuckle until the pointer on the dial indicator stops Figure 49 Search Figure 48 5 Repeat Steps 3 and 4 with the axle in the full right and full left turn positions 6 The end play must be 0 001 to 0 025 inch 0 025 0 635 mm in all positions If the knuckle binds or 0 zero end play is measured remove the shims from the shim pack If more than 0 025 inch 0 635 mm end play is measured add shims to the shim pack TODA as Figure 49
35. ding of the knuckles the components are heat treated and tempered steering arms the tie rod arms the ball studs the axle beams or the tie rod assemblies 14 All American Front Axle Directory Previous Next 3 Drilling out of the holes in the axle beam for the king pins 4 Drilling out of the draw key holds in the knuckle 5 Spray welding of bearing diameters on the knuckles or in the machined bores 6 Disassembly of unitized truck hub unit 7 Milling or machining of any component Clean Ground or Polished Parts Warning Solvent cleaners can be flammable poisonous and cause burns Examples of solvent cleaners are carbon tetrachloride emulsion type cleaners and petroleum based cleaners To avoid serious personal injury when you use solvent cleaners you must carefully follow the manufacturer s product instructions and these procedures Wear safe eye protection Wear clothing that protects your skin Work in a well ventilated area Do not use gasoline or solvents that contain gasoline Gasoline can explode You must use hot solution tanks or alkaline solutions correctly Follow the manufacturer s instructions carefully Use a cleaning solvent to clean ground or polished parts and surfaces Kerosene or diesel fuel can be used for this purpose Do not use gasoline Do not clean ground or polished parts in a hot solution tank or with water steam or alkaline solutions These solutions will cause corrosi
36. djust the maximum turn angle In a power steering system adjust the pressure relief In a manual steering system follow guidelines and specifications form Blue Bird When the maximum turn angle is correct a Loosen stop bolt jam nut Figure 68 b Insert 1 8 inch spacer between the stop bolt and the axle beam boss with the steering arm in the full turn position c Tighten the jam nut from 50 75 lb ft 68 101 Nem All American Front Axle Directory Previous Next FOUR PIECE 1 4 INCH STEERING STOP BOLT igbai MAXIMUM TURN AMOLE AKLE BEAM GOSS TEACH SPACER VZINCH STOP BOLT JM ALT AAT AECE STOF BOLT ASSEMBLY WASHER Ben ewe Figure 68 Adjust the Pressure Relief in the Power Steering System Setting the Maximum Turn Angle The pressure relief in the power steering system stops or reduces forces applied to the axle when the wheel is moved in the full turn position Check the pressure relief if the steering arm is damaged or the power steering gear is serviced Two types of systems are used to adjust the pressure relief e Mechanical Stop on the Pitman Arm or in the Assist Cylinder Hydraulic Pressure Relief in the Power Steering Gear All American Front Axle Search Exit Caution Meritor does not recommend a power steering system that does not have mechanical stops or pressure relief before the maximum turn angle is obtained The stops or the pressure relief are used to prevent damag
37. e If the fastener rotates any amount remove the fastener from the component Inspect the fastener and the hole for wear and damage Repair as necessary If the fastener and the hole are in good condition apply adhesive to the threaded hole Follow the procedure for installing old Dri Loc fasteners Inspect the Parts Carefully inspect all disassembled parts before assembly Refer to the following guidelines 1 Inspect and replace any parts that are worn cracked or damaged Check for cracks using dye penetrant magnetic flux or fluorescent particle testing methods Remove the old bushing from the knuckle Measure the upper knuckle bore inside diameter at two locations Always use a micrometer and a telescoping gauge when taking knuckle bore measurements Some rounding of the top and bottom bore edges is acceptable Measure the bore in four positions and at two locations The two locations must be 90 degrees opposed from each other Figure 20 If the average measurement is more than the Knuckle Bore Maximum Diameter specification in Table B replace the knuckle All American Front Axle Directory Previous Next MEASUREMENT PROCEDURE P aune hiri than miata food Ji UPPER BORE Dn same down here And repeat hare Figure 20 Repeat this procedure for measuring the lower knuckle bore Figure 21 Refer to the Knuckle Bore Maximum Diameter indicated in Table B Verify the average inside bore dimension does not
38. e 88 7 Set the dial indicator on zero 0 8 Move the bottom of the tire side to side towards and away from the vehicle If the dial indicator moves a total of 0 010 inch 0 2254 mm the lower bushing is worn or damaged Replace both r oe bushings Figure 88 PO GROSS TUBE Figure 89 All American Front Axle 55 Directory Previous Next 2 Place blocks in front and behind the rear wheels to prevent the vehicle from moving Set the parking brake 3 Remove dirt and grease from the tie rod end seals 4 Place indicator base on the bottom of the tie rod arm 5 Place the indicator tip near the ball stud center grease fitting of the tie rod end Figure 90 TIE RO Di Dead Figure 90 6 Set the dial indicator on zero 0 Caution Check the tie rod end play by hand Do not use a pry bar If a pry bar is used readings from the dial indicator will not be accurate 7 Move the tie rod and cross tube assembly up and down by hand Record the dial indicator reading If the dial indicates a reading of more than 0 060 inch 1 52 mm tie rod end replacement is required Place the dial indicator on the tie rod end assembly at the opposite side of vehicle and repeat Steps 1 through 8 8 56 Search Exit Inspect the Tie Rod Assembly for Movement This procedure applies to all tie rod assemblies To perform this inspection the entire system must be unloaded i e the front end of the vehicle
39. e nut on the tie rod arm Tighten to the specified torque Refer to Table I in Torque Specification section 4 Install the cotter pins If necessary tighten the nut slightly increasing the final torque value until the holes are All American Front Axle 31 Directory Previous Next aligned Do not loosen the nut to install the cotter pin Note The cross tube has right hand threads on one end and left hand threads on the other end Make sure the ends are installed on the tube 5 If removed install the tie rod ends on the cross tube to the position marked during removal If new tie rod ends are installed thread the ends equally on the cross tube to the required length Figure 58 6 Install the nuts and the bolts in the clamps Tighten to the specified torque Refer to Table I in Torque Specification section Figure 58 BOTTOM WIEW OTIA i Tio rod ene is insimier past cress tube siei TE AHO END MARES CROSS TUBE Teni SLOT Figure 58 7 The rotating style clamp on cross tubes can be rotated for easier accessibility when installing the clamp bolt and nut Tighten nut sufficiently to engage the locking element of the nut with the bolt Clamp and tie rod end must be free to rotate Make certain the clamp tab is firmly seated against the cross tube Figure 59 32 Exit CLAMP CRUSE TUPE BOLT AKD MUT Figure 59 8 Clean and dry tie rod taper and connect the tie rod ends into the tie rod arms
40. e to the axle Axles with Conventional Wheel Ends Mechanical Stop Use the mechanical stop in the steering system to adjust the pressure relief Do not use the stop bolt on the knuckle alone to adjust the poppet valve pressure relief Note Refer to the specified procedures from Blue Bird Caution Use a pressure gauge to make sure t hat the pressure drops from the maximum system delivery pressure to a maximum of 700 1000 psi 4825 6890 kPa BEFORE the full turning angle is achieved Steering systems with mechanical stops are adjusted when the wheels are turned to the full right and full left turn positions The stop travel is set at 1 8 inch 3 m before the top bolt contacts the axle beam boss Figure 69 39 Directory Previous Next Search Exit KNUCKLE POSITION AFTER PITMAN SAM CYLINDER STOPS RESET BMUCKLE POSITRON FOR POPPET VALVE SETTING STOP BOLT AKLE BEAM BOSE WAINGH SPACER 1 8 INCH 3 MBA CLEARANCE BETWEEN STOP DOLT AUR piaga pes ETA STOP BOLT 1 H SPAC APIA 3 MM CLEARANCE BETWEEN STOP BOLT AND BOS TAA TAA TURN ANGLE Figure 70 Figure 69 Turning Radius Angle When turning the inner wheel must turn at a greater angle than the outer wheel This Hydraulic Pressure angle is the turning radius angle often Relief in the Steering called the Ackerman angle Figure 71 Gear TURNING RADIUS OF ACKERMAN ANGLE Note Refer to the specified procedure from Blue Bird The stop bolt should always
41. evious Next Some tie rod ends have no zerk fittings because they are not greaseable Do not install a zerk fitting on a non greaseable design tie rod end Check that the cotter pin is in place Replace if missing Tighten the tie rod end nut to the specified torque and then insert the cotter pin through the castellated nut and the hole in the tie rod end paupa 1 AUTEINATE ZERK PITRE LOCATIONS Figure 94 Tie Rod Service Tips If available a service pit is recommended for tie rod inspection and maintenance If a service pit is not available use the following method 1 Use jacks to raise the vehicle using the following The vehicle must be on a level surface Put blocks under the wheels not being raised to keep the vehicle from moving Raise the vehicle so that the area to be serviced is off the ground Support the vehicle with safety stands Inspect and lubricate the tie rod ends as specified in Table E a b All American Front Axle Search Exit 2 Drive on ramps may also be used Observe all of the manufacturer s safety recommendations Tie Rods Effect of Tie Rod End Wear on Steering Linkage Unless tie rod end wear becomes excessive a safe steering linkage is maintained However tie rod end wear can affect uniform steering control and ultimately wear to the front tires Detecting Tie Rod End Wear During Vehicle Operation A driver may not always detect a loose tie rod end condit
42. f inspection and lubrication intervals 3 Replace boot Bent or broken cross 1 Too much pressure in t he power 1 Adjust power steering tube tie rod end ball steering pressure exceeds OEM system to specified stud steering arm or specification pressure tie rod end 2 Power steering system cut off 2 Adjust power steering Component requires pressure out of adjustment system to specified replacement 3 Vehicle operated under severe pressure conditions 3 Make sure vehicle is 4 Add on type of power steering operated correctly system not installed correctly 4 Correctly install add on 5 Steering gear overtravel poppets power steering system improperly set or malfunctioning 5 Check for proper 6 Axle stops improperly set operation or adjust overtravel of poppets to OEM specification 6 Set axle stops to OEM specification Worn or broken 1 Drag link fasteners tightened 1 Tighten drag link fasteners steering ball stud higher than OEM specified to specified torque 2 Lack of lubrication or incorrect 2 Lubricate linkage with lubricant specified lubricant 3 Power steering stops out of 3 Adjust stops to specified adjustment dimension Worn king pins and 1 Worn or missing seals and 1 Replace seals and gaskets king pin bushings gaskets 2 Lubricate axle with 2 Incorrect lubricant specified lubricant 3 Axle not lubricated at scheduled 3 Lubricate axle at frequency scheduled frequency 4 Incorrect lubricatio
43. f not correctly adhered to could result in injury or death Attention should be paid to sections of this manual where warnings appear Cautions Cautions apply to a procedure or practice that if not correctly adhered to could result in damage to or destruction of equipment Notes Notes are used to explain clarify or otherwise give additional insight for a given subject product or procedure Note that on occasion notes too may advise of potential safety issues Introduction The descriptions and procedures contained in this maintenance manual are applicable to all Meritor front non drive axles All American Front Axle Search Exit Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Descriptions Tie Rod Arm Knuckle and King Pin The right tie rod arm is a mirror image of the left and both are linked by the cross tube assembly The right knuckle and king pin assembly is similar to the left except that it does not have a steering arm attached to it in a manual steering system A power steering system uses an auxiliary assist cylinder attached to the right knuckle that requires a steering arm in various applications Steering Knuckle Steering knuckles are rated according to the capacity of the front axle All models use straight king pins Steering Arms The steering arm usually a forged component coverts the drag link force into a tu
44. g chart is for troubleshooting front non drive steering axle conditions Condition Cause Correction Tires wear out quickly 1 Tires have incorrect air pressure 1 Place specified air or have uneven tire 2 Tires out of balance pressure in tires tread wear 3 Incorrect tandem axle alignment 2 Balance or replace tires 4 Incorrect toe in setting 3 Align tandem axles 5 Incorrect steering arm geometry 4 Adjust toe in specified 6 Excessive wheel end play exists setting 5 Service steering system as necessary Readjust wheel bearings Vehicle is hard to 1 Power steering system pressure 1 Repair power steering steer low system 2 Steering gear linkage not 2 Assemble steering gear assembled correctly correctly 3 Steering linkage needs lubrication 3 Lubricate steering linkage 4 King pins binding 4 Replace king pins 5 Incorrect steering arm geometry 5 Service steering system as 6 Caster out of adjustment necessary 7 Tie rod ends hard to move 6 Adjust caster as necessary 8 Worn thrust bearing 7 Replace tie rod ends 8 Replace thrust bearing 44 All American Front Axle Directory Previous Next Search Exit Tie rod ends are worn 1 Tie rod ends require lubrication 1 Lubricate ends of cross and require 2 Severe operating conditions tube Make sure replacement 3 Damaged boot on tie rod end lubrication schedule is followed 2 Increase frequency o
45. grease Thrust 000 Grease O 617 B 2 or Lithium manufacturer s Bearings Ball kilometers Complex specifications Studs on or once a for the Steering Arm year temperature Tie Rod Ends whichever service limits and Drag Link comes first Truck Hub No Lube to Unit NONE Do Not Unit Hub Sealed for lubricate life of component Table G Front Non Driving Axle Greasing Intervals and Specifications All American Front Axle 47 Directory Previous Next Search Exit On Highway Off Highway Outside Temperature Operation Intervals Operation Intervals Check Petroleum Check Oil he i ee ius ate Oil Oil Change Level Oil F Cc Level Change 1 000 Whichever 1 000 miles Which Min Max Min Max miles comes first 1600 ever O 76A MIL L GL 5 SAE 10 None 12 None 1600 kilometers comes Gear Oil 2105 D 85W 140 kilo Seals first O 76D MIL L GL 5 SAE 15 None 26 None meters replaced Gear Oil 2105 D 80W 90 Seals O 76E MIL L GL 5 SAE 40 None 40 None Brakes replaced Gear Oil 2105 D 75W 90 relined O 76J MIL L GL 5 SAE 40 36 40 2 Brakes Gear Oil 2105 D 75W 100 000 relined Heavy MIL L API CD 10 None 12 None miles Duty 2104 B CE SFor 160 000 Oncea Engine C DorE SG kilometers year Oil SAE 40 or 50 1 Once a Heavy MIL L API CD 15 None 26 None year Duty 2104 B CE SF or Engine C DorE SG Oil SAE 30
46. he following procedure Figure 10 a Mark the position each tie rod end is installed in the cross tube b Remove the bolts and the nuts from the clamp on the cross tube c Remove the tie rod ends from the cross tube The rotating style clamp on cross tubes can be rotated for easier accessibility when removing the clamp bolt and nut Figure 11 Inspect the parts All American Front Axle Directory Previous Next BOTTOM VIEW igisa Goss Tune TIE AD END BARRE Figure 10 BOLT AMO NUT Figure 11 Draw Keys King Pins and Steering Knuckle 1 Remove the wheel ends as described in this section 2 Vent the air from the brake system Disconnect the air lines from the brakes 3 Remove the brake components Refer to procedures from the brake manufacturer 4 Remove the tie rod arms and the steering arm left side from the knuckle Refer to the procedure in this section 5 Remove the capscrews that fasten the kin pin caps to the top and the bottom of the knuckle Remove the caps and the gaskets Figure 12 All American Front Axle Search Exit Note All models except FC 901 FC 921 FE 970 FF 971 and FL 901 use threaded draw keys Models FC 901 FC 921 FE 970 FF 971 and FL 901 use plain draw keys 6 Remove the plain or the threaded draw keys Refer to the following procedure 1 a WALACKLE CAP GASKET Figure 12 Remove Plain Draw Keys Warning Use a brass or leather mallet
47. in any way without reducing the strength or life of the component and voiding the warranty and All American Front Axle Directory Previous Next may cause a vehicle accident which can result in serious personal injury Check the following during an inspection Fasteners Make sure all fasteners are tightened to the specified torque Use a torque wrench to check the torque in a tightening direction As soon as the fastener starts to move record the torque Correct if necessary Replace any worn or damaged fasteners Wear and Damage Inspect the parts of the axle for wear and damage Look for bent or cracked parts Replace all worn or damaged parts Pivot Points Make sure looseness does not exist at the pivot points Make sure the pivot points are lubricated Operation Make sure all the parts move freely through the complete turning radius Tire Wear Inspect the tires for wear patterns that indicate suspension damage or misalignment Steering Arm Bolts Check torque on Easy Steer Plus MFS 10 2015 and MFS 12 2015 axles every 200 000 miles 320 000 km Refer to the Checking Steering Arm Bolts in this section Checking Draw Key Nuts Tighten the draw key nuts from 30 to 45 1b ft 41 61 Nem at the following intervals Figure 84 e After the first 6 000 miles 10 000 km of new vehicle operation e Every 36 000 miles 58 000 km of operation All American Front Axle Exit 1 DAAN KEFY NUT 90 65 LEFT
48. ing e Apply the specified lubricant to bottom half of king pin 26 Exit Before placing the king pin into the top of the knuckle be sure the word TOP which is stamped on the king pin can be seen Figure 45 Rotate king pin so that two draw key slots of pin properly align with draw key slots in the knuckle Figure 45 Caution Do not force the pin through the top bushing or the shims will be damaged 9 Install the king pin into the top of the knuckle and through the area where shims are located Warning Use a brass or leather mallet for assembly and disassembly procedures Do not hit steel parts with a steel hammer Pieces of a part can break off and cause serious personal injury 10 If required use a hammer and a brass drift to apply direct force to king pin for seating it into the lower knuckle bore All American Front Axle Exit Directory Previous Next Search Note Do not drive or tighten the draw keys into the knuckle until the end play is checked and adjusted Note All models except FC 901 FC 921 FE 970 FF 971 and FL 901 use threaded draw keys Models FC 901 FC 921 FE 970 FF 971 and FL 901 use plain draw keys HEIST a 11 Seat top draw key into front of beam Seat bottom draw key in back of beam by striking with hammer and drift Figure 46 Make sure keys align with slots of king pin Do not install or tighten lock nuts before checking the knuckle end play Attach a dial in
49. into the threaded cross tube ends to the approximate depth marked during the tie rod assembly removal Both tie rod ends must be installed into the cross tube deeper than the end of the cross tube slot Figure 56 2 If you are installing new tie rod ends Thread the tie rod ends to the approximate original depth inside the cross tube Figure 56 Both tie rod ends must be installed into the cross tube deeper than the end of the cross tube slot Figure 56 3 Install the nuts and the bolts in the clamps Tighten to the specified torque All American Front Axle Directory Previous Next Search Exit Figure 55 Refer to Torque Specification section 4 Check that the tab on the clamps is firmly seated against the end of the cross tube Figure 59 iliii Tika 1 When sssmibling tha ta rada inta th cigar bibi eyoniee the thread depth si beth ends Figure 56 Tie Rod Arms Tie Rod Ends and Cross Tube Assembly Note If a different tie rod arm is installed such as for increasing the maximum turn angle the steering geometry is changed and may cause tire wear Contact your Meritor service representative ogia i o RMAPCKLE TIE RND ARMA 2 TE ROD Map 1 Press the key in the slot in the arm Figure 57 Figure 57 2 Install the tie rod arm in the knuckle Figure 57 Caution Tighten the nuts to the specified torque If the nuts are not tightened to the specified torque the parts will be damaged 3 Install th
50. ion during vehicle travel conditions This is why it is important to inspect tie rod ends for wear and allowable movement at regular intervals Refer to Table E for inspection intervals Tie Rod End Wear It is imperative that inspection and maintenance is performed at the recommended intervals to minimize the impact of tie rod end wear Tie rod end wear occurs over time under normal operating conditions As wear occurs the preload bearings inside each tie rod end provide less resistance Excessive tie rod end wear will affect steering and contribute to premature wear of the tires and other axle components Figure 95 59 Directory Previous Next boat 1a SALL STuUO HATURAL PIVOT WEAH BALLISTUO HATUIAL SEARING WEAR BALL STUD SOLID STEEL BEARING SUAPACE Figure 95 Tightening Draw Key Nuts Note This procedure applies to all except 901 903 and 970 Series axles These axles do not utilize a draw key Refer to the identification tag on the front of the axle beam 60 Search Exit Tighten the nuts that hold the draw keys on the side of the knuckle to 30 45 1b ft 41 61 Nem at the following times Figure 96 e After the first 6 000 miles 10 000 km of new vehicle operation e Every 36 000 miles 58 000 km of operation Tighten draw Bey nut 30 45 B A 21 61 Wem Figure 96 Checking Steering Arm Bolts Warning Take care when you use Loctite to avoid serious personal injury Follow the m
51. justing nuts are tightened or Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety loosened always use the correct size socket to avoid damaging the nut 8 All American Front Axle Directory Previous Next 3 Remove the fasteners for the wheel bearings Refer to the following procedure Double Nut and Lock Fasteners a Bend the tabs of the flattened lock washer away from the wheel bearing nut and the adjusting nut Figure 6 Remove the wheel bearing nut the lock washer the pierced lock ring and the adjusting nut from the knuckle Figure 6 Single Nut Fasteners a Remove the cotter pin from the adjusting nut Figure 7 Remove the adjusting nut and the D washer from the spindle Figure 7 Remove the outer wheel bearing cone from the hub 5 Remove the wheel and tire the hub and the drum as assembly DOUBLE NUT AND LOCK ADJUSTMENT WHEEL DEARI NUT PERCED LOCK AING SDSUSTING HUT WHEEL BEARING NUT LOCK WASHER Figure 6 All American Front Axle Search Exit SINGLE NUT ADJUSTMENT Figure 7 6 Remove the brake components per the manufacturer s procedures 7 Remove the oil seal from the hub Remove the inner wheel bearing cone 8 Inspect the wheel bearings Drag Link Caution Heating is not an acceptable method for the disassembly of front axle components Damage to the axle components could result Note
52. m Caution Most tire wear is caused by incorrect toe settings Do not change camber or caster settings to correct tire wear problems If the axle assembly is bent to change caster or camber the strength of the axle is reduced and the warranty is voided An axle damaged by bending may cause a vehicle accident and result in serious personal injury 1 Make sure the vehicle is on a level surface Place blocks behind the rear wheels to prevent the vehicle from moving Raise the vehicle so that the front tires are off the floor Warning Park the vehicle on a level surface Block the wheels to prevent moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks All American Front Axle Search Exit Jacks can slip and fall over Serious personal injury can result 2 Use jacks to raise vehicle so that front tires are off the ground Support the front axle with safety stands Use paint or chalk to mark the center area of both front tires around t he complete outer surface of the tire Place the pointers of a trammel bar on the marks of each tire Rotate the tires Make sure a straight line is marked on the outer surface of the tire Note Do not measure toe in with the front axle in the raised position The weight of the vehicle must be on the front axle when toe in is measured 5 Lower the vehicle to the floor Move the vehicle forward and backward 10 feet 3 meters Place
53. mall diameter of the cups Figure 82 51 Directory Previous Next TT Figure 82 4 Install the inner and outer bearing cones into the cups in the hubs The bearing cups must be pressed tight against the shoulder in the hubs Install new wheel seals in the hubs 6 Install the hub and the wheel and tire assembly Install the outer wheel bearing cone in the hub Install the adjusting nut 7 Adjust the wheel bearings Refer to Section entitled Check and Adjust the Wheel Bearings mi Oil Lubricated Wheel Bearings Note This procedure applies to hubs with oil lubricated wheel bearings Check the level on the cap If the oil level is not at the specified level on the cap remove the fill plug Add the specified oil until the oil is at the specified level Figure 83 52 Exit 1 CHL LEVEL Figure 83 Inspection and Maintenance Inspection Tools Before performing an inspection of axle components make sure the proper tools are available Using the proper tools will ensure safety and provide the most accurate results Check for the following tools Dial Indicator Tire Blocks Jack Safety Stands Pry Bar Torque Wrench Inspection Caution The repair or reconditioning of front axle components is not allowed Meritor recommends replacing damaged or out of specification components All major components are heat treated and tempered The components cannot be bent welded heated or repaired
54. n procedures 4 Use correct lubrication 5 Lubrication schedule does not procedures match operating conditions 5 Change lubrication schedule to match operating conditions Vibration or shimmy 1 Caster out of adjustment 1 Adjust caster of front axle during 2 Wheels and or tires out of 2 Balance or replace wheels operation balance and or tires 3 Worn shock absorbers 3 Replace shock absorbers Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service All American Front Axle 45 Directory Previous Next Search Exit Group Number Typical Vocations Vehicle Build Typical Operation Conditions 2 Fire and rescue city After July 1 1996 Lower mileage delivery inner city Before July 1 1996 operation less than coach heavy haul use Group Number 3 50 000 miles year 80 school bus motor 500 km year home transit coach 3 Logging oil field ALL Low mileage construction heavy haul yard tractor highway licensed residential refuse operation less than 25 000 miles year 40 250 km year Table E Vocational Groups Lubrication Inspection and Maintenance Schedule Service Intervals 48 First hrs Component 5 000 miles 100 hrs 6 000 miles of operation 10 000 miles 20 000 miles 36 000 miles 40 000 miles 50 000 miles 100 000 miles 200 000 miles 8050 km 10 00
55. nap On dealer 4 Use Basic Service Kit along with the correct axle series kit Back to Top All American Front Axle 63
56. nclination angle The king pin inclination is not adjustable If the inclination is not at the specified angle check the axle beam and knuckle for damage Service as necessary KING FIN INCLINATION ANGLE 1TH fi CAMBER ANGLE z Klee Fie ELIRA Ties Figure 72 All American Front Axle Search Exit Camber Angle Caution Axle camber is not adjustable Do not change the axle camber angle or bent the axle beam Bending the axle beam to change the camber angle can damage the axle and reduce axle strength and will void Meritor s warranty A bent axle beam can also cause a vehicle accident and serious personal injury Camber is the angle of the tire with respect to the ground Camber is positive when the distance between the top of the wheels is greater than the distance at the ground Figure 73 A small amount of positive camber is built into the knuckle because camber changes with load This results in a zero camber angle when the vehicle is operated at the normal load If camber is out of specification by more than 1 1 2 degrees rapid or uneven tire wear will occur Bias ply tires will show excess camber easily while with vehicles equipped with radial tires excess camber will not be as evident haa POSITIVE ZERO OF MEUTRAL LOAD Figure 73 The camber angle is not adjustable The camber angle is machined into both the axle 41 Directory Previous Next beam and the knuckle If the camber angle
57. nd adjust the wheel bearings For models with unitized hubs check wheel bearing end play for the truck hub unit Refer to section entitled Inspection of Sealed Hub Units under Lubrication Inspection and Maintenance Check and adjust the maximum turn angle If the vehicle has power steering check and adjust the pressure relief in the power steering system Refer to the procedure Adjust the Pressure Relief in the Power Steering System Setting the Maximum Turn Angle in this section Check and adjust the turning radius angle toe out on turns or Ackerman angle Refer to Turning Radius Angle in this section Check the king pin or steering axis inclination Refer to King Pin Inclination in this section Check the camber angle Refer to Camber Angle in this section Caution Axle camber is not adjustable Do not change the axle camber angle or bend the axle beam Bending the axle beam to change the camber angle can damage the axle and reduce axle strength and will void Meritor s warranty A bent axle beam can also cause a vehicle accident and serious personal injury 8 Check and adjust the caster angle Refer to Caster Angle in this section All American Front Axle Directory Previous Next 9 Check and adjust the toe in Refer to Adjust the Toe In in this section Check and Adjust the Wheel Bearings Warning Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Sup
58. ng King Pin Bushings 22 Tie Rod End Shop Inspection 58 Inner Knuckle Bore King Pin Seals 23 Tie Rod Service Tips 59 Install Knuckle to Axle Beam 24 Tie Rods 59 Check Steer Knuckle Vertical End 27 Tightening Draw Key Nuts 60 Draw Key Lock Nuts 28 Checking Steering Arm Bolts 60 Steering Arm 29 Torque Specifications 61 Tie Rod Ends into Cross Tube 30 Tie Rod Arms Cross Tube Assembly 31 Drag Link 32 All American Front Axle 1 Directory Previous Next Search Exit Tables Table G Greasing Intervals 47 Table A Front Non Driving Axle 8 Table H Wheel End Oil Changes 48 Table B Axle Wear Limit 18 Table I Front Axle with Table C Bushing Reamer Conventional Wheel Dimension 23 Torque Specifications 62 Table D Camber Angle 42 Table J Special Tools 62 Table E Inspect Lubrication 46 Table F Lubrication Inspection 46 2 All American Front Axle Directory Previous Next Search Exit Exploded View Figure 1 All American Front Axle 3 Directory Previous Next Search Double Nut Single Nut Cotter Pin Castle Nut Drag Link to Steering Arm Steering Arm Key Ball Stud Capscrew and Washer Grease Fitting Knuckle Cap Greaseable Knuckle Cap Sealed Gasket King Pin Bushing Easy Steer King Pin Bushing Bronze King Pin Bushing Nylon Knuckle Seal King Pin Bushing Castle Nut Tie Rod Arm to Knuckle Cotter Pin King Pin Hub Grease Seal Inner Wheel Bearing Cup Inner Wheel Bearing C
59. o all gerk tings whee eequined Wie 1O Abit dain of grease Milinga prior be applying lubi 2 IERE ATMHG ALTERNATIVE LOCATION Figure 78 All American Front Axle Figure 79 49 Directory Previous Next SLIDES Sal THE ADO Eran Exit AON REMOVABLE AMD ALLWEATHER BOOT SEAL TIE hob ENDE TAW LUBE PLAGES EVENLY PROM ILS CAF OCT O65 LUBE PURGES AOM THREE HOLES TOP OF BOT FAW LUGE PLAGES FGM BOOT ASE IN EVEN SMALL STREAMS LARESSO LUBE PURGES FROM TOP OF BOOT O45 LUBE PURGES PAO THREE HOLES TOP OF HIT DAS NON GREAPESABLE Figure 80 King Pins Straight King Pins Note This procedure applies to 901 903 910 935 952 and 970 front conventional axles Refer to the identification tag on the front of the axle beam 50 On conventional front axles the grease fittings are on the side of the knuckle Warning Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury can result All American Front Axle Directory Previous Next Search 1 Lift the vehicle so that the tires are off the ground The front tires should be off the ground when the king pins are lubricated Support the vehicle with safety stands Place blocks in front and behind the rear wheels to keep the vehicle from moving Set
60. on of the parts Clean Rough Parts Rough parts can be cleaned with the ground or polished parts Rough parts also can be cleaned in hot solution tanks with a weak alkaline solution Parts must remain in the All American Front Axle Search Exit hot solution tanks until they are completely cleaned and heated Dry Cleaned Parts Parts must be dried immediately after cleaning Dry parts with clean paper or rages or compressed air Do not dry bearings by spinning with compressed air Corrosion Prevention on Cleaned Parts Apply light oil to cleaned and dried parts that are not damaged and are to be immediately assembled Do NOT apply oil to the brake linings or the brake drums If parts are to be stored apply a good corrosion preventative to all surfaces Do NOT apply the material to the brake linings or the brake drums Store the parts inside special paper or other material that prevents corrosion Note Be sure that all tapered joints are clean and dry with no lubrication or corrosion preventative applied to mating surfaces Install New Fasteners with Pre applied Adhesive Patches 1 Clean the oil and dirt from threaded holes Use wire brush to remove old patch material There is no special cleaning required Caution Do not apply adhesives or sealants on new fasteners with pre applied adhesive patches or in the threaded holes If other adhesives or sealants are used the new adhesive will not function co
61. one Stud Hub Outer Wheel Bearing Cup Outer Wheel Bearing Cone Adjusting Nut Pierced Lock Ring Lock Washer Wheel Bearing Nut D Washer Adjusting Nut Cotter Pin Gasket Hubcap Capscrew and Washer Axle Beam Exit Axle with Conventional Wheel End Shims Tapered Draw Key Threaded Draw Key Nut Threaded Draw Key Thrust Bearing and Flat Type Bearing Seal Thrust Bearing and Cover Type Bearing Seal Integral Thrust Bearing and Oil Seal Castle Nut Steering Arm to Knuckle Castle Nut Flared Base Steering Arm to Knuckle 3 4 Inch Stop Bolt 3 4 Inch Jam Nut 1 2 Inch Stop Bolt 1 2 Inch Jam Nut 3 4 Inch Adapter Washer Cotter Pin Square Key Woodruff Key Knuckle Tie Rod Arm Cotter Pin Castle Nut Tie Rod Nut to Tie Rod End Tie Rod End Bolt Clamp Locknut Clamp Clamp Cross Tube Cross Tube All American Front Axle Directory Previous Next Front Axle Safety The purpose of this safety summary is twofold First it is to help ensure the safety and health of individuals performing service on or operation of the Blue Bird All American Series bus Second it is to help protect equipment Before performing any service or operating procedure on the All American bus individuals should read and adhere to the applicable warnings cautions and notes located throughout this Blue Bird Service Manual Warnings Warnings apply to a procedure or practice that i
62. port the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury can result 1 Raise the vehicle so that the wheels are off the floor Support the vehicle with safety stands 2 Remove the capscrews and remove the gasket and the cap from the hub 3 Make sure that the brake drum and the hub fasteners are tightened to the manufacturer s specifications 4 Attach a dial indicator with the magnetic base at the bottom of the hub or the brake drum Adjust the dial indicator so that the pointer is against the center of the knuckle Set the dial indicator on zero 0 Figure 61 Note Do not push pull at the top and the bottom of the hub or drum Pushing or pulling at the top and the bottom will not give a true reading of the end play 5 Measure the end play by pushing pulling on each side of the hub or drum while looking at the dial indicator The end play is the total travel observed If the end play is not within 0 001 to 0 005 inch 0 025 0 127 mm adjust the wheel bearings Figure 61 All American Front Axle Search Exit tae aa Wilh indicator mounted at bonam past pall ai sities of tire Figure 61 If necessary adjust the wheel bearings On Double Nut and Lock fasteners bend the lock washer off the wheel bearing nut Remove the wheel bearing nut the lock washer and the pierced lock ring Figure 62 On Single Nut Fasteners
63. rench with jaw protectors to avoid gouging the cross tube and slightly rotate the cross tube toward the front of the vehicle and then slightly toward the rear After this movement check in both directions centering the cross tube between the stop positions If the cross tube will not rotate in either direction replace both tie rod ends 3 Position yourself directly below the ball stud socket Using both hands grab the end as close to the socket as possible no more than 6 inches or 152 4 mm from the end Firmly apply hand pressure approximately 100 pounds in a vertical damage Figure 93 e Replace the cross tube if it is cracked or bent e Replace the clamps if they are damaged e Replace the entire cross tube assembly if either clamp is welded onto it TOL a CHS PURE CLAMP TRACK DA AGE Figure 93 push and pull motion several times 6 Check for proper installation of the tie When moving the assembly check for rod end clamp to the cross tube Be any movement at both tie rod ends certain that tie rod ends are threaded in the cross tube past the clamps and the slots at the cross tube ends Warning 7 Check that zerk fittings are installed If any movement is detected by hand replace the worn components with new components before releasing the vehicle back into service 58 Replace damaged zerk fittings Replace damaged zerk fittings Figure 94 Refer to Table E All American Front Axle Directory Pr
64. rning movement through the left king pin through the knuckle Pitman Arm The Pitman arm converts the output torque from the steering gear into the control force applied to the drag link This linkage component connects the steering gear to the linkage at the center link end Tie Rod Assembly Forged or cast tie rod assemblies are used on Meritor front non drive steering axles The tie rod assembly links both steering knuckles for uniform movement and maintains steering control Cross Tube and Clamp Assembly The cross tube and clamp assembly runs approximately parallel to the front axle The cross tube has right hand and left hand threads on the appropriate side of the vehicle Tie rod clamps secure tie rod ends into the cross tube Directory Previous Next Search Exit Tie Rod Ends The tie rod ends include a ball joint and boot that thread into the cross tube Depending on manufacturer design tie rod ends can be greaseable or non greaseable Tie rod ends are either right hand or left hand threaded and correspond to the inside threads at each end of the cross tube Figure 2 Meritor front non drive steering axles in this manual feature the components found in l CLAMP Figure 3 DOLT AND MAUT Figure 2 CONVENTIONAL NOMDRIVE STEER AXLE ENLPC RIE STEERING ARM TH AOO CROSS TUFE ASSEMBLY TH ACG ARM TE AOD EMD Figure 3 Or The Julian dating method is currently used Identification to indicate the axle assembly
65. rrectly 15 Directory Previous Next 2 Assemble parts using the new pre applied adhesive fasteners Note There is no drying time required for fasteners with pre applied adhesive 3 Tighten the fasteners to the required torque value for that size fastener Refer to Table I in Torque Specification section Install Original or Used Fasteners Using Meritor Liquid Adhesive 2297 C 7049 or Loctite 680 or Equivalent 1 Clean the oil dirt and old adhesive from all threads and threaded holes Use a wire brush Caution Do not apply adhesive to fastener threads that will be installed into a closed bore As the fastener is installed air pressure will force adhesive applied to fastener out of the closed bore Apply adhesive into threaded bore only 2 Apply four or five drops of Meritor Liquid Adhesive Loctite 680 or equivalent to each threaded hole or bore ONLY Make sure the adhesive is applied to the threads Tighten the fasteners to the required torque value for that size fastener Note There is no drying time required for Meritor Liquid Adhesive 2297 C 7049 Loctite 680 or equivalent 16 Search Exit Check the Torque Values of Dri Loc Fasteners Not Requiring Removal Note If Dri Loc fasteners do not require removal from components check the fasteners for correct torque value as follows 1 Apply the MINIMUM amount of torque required for that size fastener The fastener MUST NOT rotat
66. s replacement 17 Directory Previous Next Search Exit AXLE BEAM MEASUREMENT Remove all lubricant from the bearings knuckle hub and hubcap Inspect the cup the cone and the rollers and cage of all bearings If any of the following conditions exist the bearing MUST be replaced 1 The center of the large diameter end of the rollers is worn level or below the outer surface Figure 23 2 The radius at the large diameter end of the rollers is worn to a sharp edge Figure 23 e A visible roller groove in the cup or O8 INCH 12 7 MMI the cone inner race surfaces The a 6 Ea groove can be seen at the small or large diameter end of both parts Figure 22 Figure 24 e Deep cracks or breaks in the cup Model Knuckle Beam King Pin the cone inner race or the roller Number Bore Bore Bushing surfaces Figure 24 ewe Mas Max e Bright wear marks on the outer Diameter Diameter Inner Diameter surface of the roller cage Figure 25 1 9220 1 7980 1 7960 e Damage on the rollers and on the FF 966 inch inch inch surfaces of the cup and the cone 48 818 45 6692 45 6180 inner race that touch the rollers mm mm mm Figure 26 1 9220 1 7980 1 7960 e Damage on the cup and the cone inch inch inch inner surfaces that touch the rollers FF 967 p 48 818 45 6692 45 6180 Figure 27 mm mm mm 1 9220 1 7980 1 7960 FF 944 inch inch inch 48 818 45 67692 45 6180 mm mm mm 1 9220 1 7980 1 7960 inch in
67. the opposite cutting direction Clean all material from the bushings All American Front Axle Directory Previous Next Search Exit Bushing Reamer Dimensions Axle Lower Pilot Blade Upper Pilot Lower Pilot Upper Pilot Model Diameter Diameter Diameter C Length Length Dimension Dimension B 0 001 inch or Dimension D Minimum A 0 001 0 001 inch 0 0245 mm Dimension E inch or or 0 0245 0 0245 mm mm Inch Mm Inch Mm Inch Mm Inch Mm Inch Mm FF 966 1 7800 45 2120 1 7955 45 6057 1 7900 45 4660 10 25 260 35 12 25 311 15 FF 967 1 7800 45 2120 1 7955 45 6057 1 7900 45 4660 10 25 260 35 12 25 311 15 FF 944 1 7800 45 2120 1 7955 45 6057 1 7900 45 4660 10 25 260 35 12 25 311 15 FG 943 1 7800 45 2120 1 7955 45 6057 1 7900 45 4660 10 25 260 35 12 25 311 15 Table C Bushing Reamer Dimensions REARING UPP 1 Push dowen lightly Figure 36 All American Front Axle ER BUSHING 100g oa REAMING LOWER BUSHING i Push dran lightly Figure 37 TH Inner Knuckle Bore King Pin Seals 1 Place the top of the knuckle in a vise with brass jaws The bottom of the knuckle must be toward you 2 Place the seal in the bottom of the top knuckle bore The lip of the seal must be away from the bore Figure 38 23 t 24 Next Directory Previous Both appar and love bike dee lipi mun be gasy
68. the trammel bar at the back of the tires Raise the pointers so that the pointers are level with the spindles Align the pointers with the marks on the tires Measure and record the distance between the pointers Place the trammel bar at the front of the tires Raise the pointers so that the pointers are level with the spindles Align the pointers with the marks on the tires Measure and record the distance between the pointers Figure 75 Figure 75 43 Directory Previous Next Search Exit 8 To obtain the toe measurement subtract the distance reading between the front of the tires from the distance reading between the back of the tires Figure 76 9 Ifthe toe measurement is not at the specified distance refer to the following procedure a Loosen the tube clamp nut and bolt on each end of the cross tube b Turn the cross tube until the specified toe in distance is obtained c The threaded portion of the tie rod end must be installed into the cross tube beyond the point where the tube slot stops 1H Be Daphnia E MHUS A EQUALS TIEAN FRONT OF VEHICLE TOP Win d Tighten the nut and bolt on each end pigure 16 of the cross tube to the specified torque Diagnostics 10 Repeat Steps 1 8 to check the toe in dimension Warning To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Front Non Drive Steering Axle Diagnostic Chart The followin
69. ts to the specified torque If the nuts are not tightened to the specified torque the parts will be damaged 3 Install the nuts Tighten to the specified torque Refer to Table I in Torque Specification section 4 Install the cotter pins If necessary tighten the nut until the holes are aligned Do not loosen the nut to install the cotter pin 5 Lubricate the drag link end that connects to steering arm Refer to Lubrication section 6 Check for correct operation 29 Directory Previous Next VE 0b 1 STEERING AAM 2 SAFETY STANDS Figure 53 Tie Rod Ends into the Cross Tube Refer to Figure 54 BOTTOM VIEW Tote Tie rod ened is Insteiied past cress tube els THE AHO END MARES CROSS TUBE Teni SLOT Figure 55 1 If you are only replacing the cross tube When replacing the cross tube be certain that the replacement cross tubes is properly specified from OE manufacturing standards The 30 Exit H 168 TIE RID AAM NE M END CROSS TUNE Figure 54 Note The cross tube has right hand threads on the right side of the vehicle and left hand threads on the left side of the vehicle Make sure the tie rod end threads are correctly installed into the tube deeper than the end of the cross tube slot Figure 55 replacement tube should have the same length and diameter as the original removed tube that couples with the tie rod ends Use the thread count as a guide and install the tie rod ends
70. ushing is fully seated in the knuckle bore by passing the king pin through the upper and lower bores after insertion Note The nylon bushing installation is not a press fit in the knuckle bore as in cases where a bronze or Easy Steer bushing issued 20 Exit 2 Be sure that the bushing lube slots align with the grease ports in the knuckle Figure 30 NYLON BUSHING ALIGNMENT SIDE GREASE AITTINGS maniis NYLON BLES His iign bushing slots wilh grease paris BIDE GREASE FITTING Figure 30 Bronze and Easy Steer King Pin Bushings Axles with Conventional Wheel Ends Without a Press Note On the FF FG and FL Series axles the bushings can be installed without a press Use the Bushing Service Kit from Kent Moore Tools to install and ream the bushings Bronze and Easy Steer bushings have an interference fit in the knuckle bores and require a suitable installation tool for bushing installation Figure 31 All American Front Axle Directory Previous Next BUSHING REMOVAL AND INSTALLATION TOOL f 4 y x 1 J Tas O i SHINCHES 65 MM 2 SUITABLE LENGTH Figure 31 Position the bushings into outer end s of the knuckle bores Install to proper position using selected installation tool Figure 32 Ream the Easy Steer bushings after installation into the knuckle MO s7Gh 1 BASY STEER BUSHING Figure 32 With a Press 1 Install the top king pin bushing first
71. xis is toward the rear of the vehicle the caster is positive A slight positive caster creates a self aligning action that helps to stabilize the vehicle after turning and stabilizes it for driving straight ahead Figure 74 Always use an alignment machine to check the caster angle When checking caster refer to the instructional procedures from the alignment equipment manufacturer 42 If caster is too much steering effort will increase or may amplify a shimmy condition CASTER NEGATIVE CASTER POSITIVE CASTER POW AAD Figure 74 The caster angle is controlled by tapered shims installed under the leaf springs Adjust caster according to Blue Bird specifications and procedures All American Front Axle Directory Previous Next Meritor recommends a caster setting of 1 degree to 2 1 2 degrees for vehicles with manual steering and 2 degrees to 4 1 2 degrees for vehicles with power steering Adjust the Toe In Toe is the relationship of the distance between the front of the front tires and the rear of the front tires When the front distance is less than the rear distance the wheels are toed in Toe in is designed into the vehicle to counteract the tendency of the tires to toe out when the vehicle is driven Incorrect toe in will result in rapid tire wear Toe in specifications Unloaded vehicles 1 16 inch 1 587 m 1 31 inch 0 794 mm Loaded vehicles 1 32 inch 0 794 mm 1 32 inch 0 794 m

Front Non-Drive Steering Axle - Central States Bus Sales, Inc.

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