Westport Service Manual.pm7
Contents
1. SECTION IV GENERAL REPAIR REPLACEMENT BASIC INSPECTION 1 Inspect all front axle fasteners for looseness If loose retorque to proper value If worn replace Inspect axle parts for wear or damage bent or cracked If detected replace Make certain parts move freely through axle turn Inspect for tire wear patterns VERTICAL END PLAY OF STEER KNUCKLE Raise vehicle off the ground Support with jack stands With a dial indicator place magnetic base on 1 Place pointer end of indicator on upper king pin grease cap Pry the knuckle DOWN Set dial indicator to ZERO Pry the knuckle UP Reading must be between 002 010 inch If ZERO remove shims If reading exceeds 025 Inspect thrust bearing Replace if necessary readjust using shims KING PIN BUSHING INSPECTION Raise vehicle off the ground Support with jack stands With a dial indicator place magnetic base on 1 Place pointer end of indicator against upper steer arm lobe of knuckle Zero indicator Move tire wheel in and out with a push pull motion If dial indicator reads 010 inch or more king pin bushings need replacement Repeat process for lower bushing If either bushing indicates wear replace both WESTPORT 4 Rev 1 2 00 14 SECTION IV GENERAL REPAIR REPLACEMENT TIE ROD END INSPECTION 1 Grab crosstube to move in any direction If any movement or looseness is de2. 5c This now equals 1 4 turn see Figure 3 on next page 5d Proceed with inspection SPECIAL INSTRUCTIONS Follow instructions below for proper wheel bearing adjustment on all axle models having 12 or 14 pitch thread on wheel ends 5a After 50 Ft Lbs torque look for cotter pin hole alignment with nut slot which can be in vertical or horizontal position Note this slot 5b Select next clockwise adjacent nut slot 5c Rotate this slot counter clockwise to align with original viewed cotter pin hole 5d This now equals 1 6 turn see Figure 3 on next page 5e Proceed with inspection WESTPORT AAA _ d Rev 1 2 00 20 SECTION IV WHEEL BEARING ADJUSTMENT contd 1 4 TURN 1 6 TURN SELECT NEXT CLOCKWISE NUT SLOT HERE ROTATE BACK COUNTER CLOCKWISE TO THIS POSITION IF YOU SEE COTTER PIN HOLE NUT SLOT ALL OR PART HERE TYP Y COTTER PIN HOLES lt j 4 COTTER ae PIN HOLES IF YOU SEE COTTER PIN HOLE ROTATE ALL OR PART NUT SLOT BACK HERE COUNTER CLOCKWISE TO HERE FIGURE 3 TUBE AXLE REPAIR TUBE AXLE REPAIR WELDING AND ADD ON BRACKETS If the crack or break is in the weld area only grind or back gouge weld to base metal Reweld area Preferably use welding rod that will produce a minimum 70 000 psi weld Prior to welding clean weld joint of grease dirt paint slag rust etc Make sure axle is grounded However not throu
3. 1200 SEALED 145698 0053 2 OO o Cap Pin King Pin F3W 1300 F3W 1400 F3W 1600 F6W 1300 F6W 1400 F6W 1600 CONVENTIONAL 143698 0002 King Ping 2 earing Thrust T1920 ushing King Pin F3W 1300 F3W 1400 F3W 1600 F6W 1300 F6W 1400 F6W 1600 SEALED 123698 0052 2 Hom k Ta 7 fe o fas WESTPORT AAA AAA Rev 1 2 00 23 SECTION V REPAIR PARTS KITS F3W 2000 CONVENTIONAL Kit Number tem Description 4 Bearing muste O e shin Korn A 2 Pin tapered Upper 2 2 Pin Tapered e sa kmm A o esa ca ACI EE A Py AR AY PY Pp AY KNUCKLE KITS Contact Westport for kit identification NOTE Westport requires axle serial number See Section IX for location or Bill of Material Number Example 120600 0033 TIE ROD ENDS Contact Westport for part numbers NOTE Westport requires axle rating 9K 12K etc WESTPORT l Rev 1 2 00 24 WESTPORT Corporate Office BP Tower 200 Public Square Suite 2520 Cleveland Ohio 44114 216 875 7515 F 216 623 0620 sales westportaxle com www westportaxle com
4. WESTPORT I BEAM amp TUBULAR STEERABLE AXLES FRONT AXLE PUSHER amp TAG SERVICE MANUAL ISO 9001 INDEX THIS MANUAL COVERS THE FULL LINE OF WESTPORT AXLES Section Description Section IV General Repair Replacement General Precautions Inspections King Pin amp Knuckle Tie Rod End Wheel Bearing Tube Axle Repair Section V Repair Kits 1 All Kingpin Kits Conventional or Sealed 2 Knuckle Kits 3 Tie Rod Ends WESTPORT Rev 1 2 00 SECTION IV GENERAL REPAIR REPLACE MENT Cleanliness is very important FIG 1 BUSHING REMOVING AND when making repairs Provide a INSTALLING TOOL clean place to work When assembling apply an ample F4W 0800 quantity of lubricant to bearing 2 1 2 gt surfaces and king pins For safety purposes use stationary jacks under axle when removing wheels Do not allow weight to rest on a hydraulic jack for any length of time F5W 0900 F5W 1000 Use only suitable solvent such F5W 1200 as kerosene to wash parts Thoroughly dry all parts 21 2 dl immediately after cleaning 12 The tool illustrated in Figure 1 IS E OA should always be used when installing new knuckle bushings to prevent collapse or distortion of bushings F3W 1300 F6W 1300 F3W 1400 F6W 1400 F3W 1600 F6W 1600 F3W 2000 F3W 2000D MAKE LOCALLY FROM BAR STOCK WESTPORT l Rev 1 2 00 13
5. gh the axle hub or wheel Bring tube to be welded to 50 60 degrees F prior to welding Preheat area to be welded to 450 degrees minimum to prevent the formation of martensite Brittle metal Weld in a flat or horizontal position A multi pass weld is preferred The arc should not be broken at the end of each pass Back up the electrode to fill in the fillet crater at the end of each pass Do not weld on top or bottom of the tube Do not test weld on the axle tube When complete wrap the weld joint for controlled cool down This procedure is highly recommended NOTE This process should also be used when affixing brackets to the tube at the initial installation WESTPORT SSS SSS l Rev 1 2 00 21 SECTION V REPAIR PARTSKITS Several kits are offered for king pin and knuckle bushing replacement Provided in the king pin kit are parts for a complete rebuild There are separate kits for conventional or sealed style axles KING PIN REPAIR KITS Refer to pages 5 and 6 for part identification and item number F4W 0800 SEALED 143696 0040 Bushing King Pin F5W 0900 F5W 1000 F5W 1200 CONVENTIONAL 143698 0024 2 Pin Tapered Upper 2 2 Pin Tapered Lower Seal King Pin Cap King Pin 10 7 9 Gasket Cap not needed in sealed version i 5 5 a 7 Bushing King Pin WESTPORT Rev 1 2 00 22 SECTION V REPAIR PARTS KITS F5W 0900 F5W 1000 F5W
6. in hub cavity Install thrust washer and nut Hand tighten to draw hub and bearings together Refer to wheel bearing adjustment for final assembly Secure with cotter pin Install hub caps Add lubricant to fill line on hub cap or maximum to 1 8 over fill line Lube all fittings Adjust brakes if disturbed Remove jacks and lower vehicle Check toe in and adjust if necessary WESTPORT AAA Rev 1 2 00 17 SECTION IV KING PIN 6 KNUCKLE REPLACEMENT POSITION SEAL LIPS TOWARD BEAM GREASE SEALS INSTALL FLUSH WITH KNUCKLE SURFACE UPPER SEAL LOWER SEAL B REAM BUSHINGS IN LINE KNUCKLE BUSHING AND KING PIN SEAL INSTALLATION FIG 2 AXLE MODEL A BUSHING GAP B REAMED BUSHING DIMENSION F4W 0800 78 1 3020 160 1 3010 F5W 0900 F5W 1000 165 1 609 F5W 1200 135 1 608 All F3W 1300 F6W 1300 F3W 1400 F6W 1400 F3W 1600 F6W 1600 Flush with Top amp Bottom 1 8125 Conventional Knuckle Surface 1 8115 Grease Cap F3W 2000 F3W 2000D Conventional Flush with Top amp Bottom 2 0029 Grease Cap Knuckle Surface 2 0021 F3W 1300 F6W 1300 F3W 1400 F6W 1400 F3W 1600 F6W 1600 Sealed Grease Cap WESTPORT AAA 1 Rev 1 2 00 18 SECTION IV TIE ROD END TIE ROD END REPLACEMENT Remove tie rod assembly from tie rod arms Loosen clamp nut and unscrew tie rod ends Install tie rod ends so that the threaded end is past the slot in the tube Attach tie rod as
7. on tool shown in Figure 1 page 13 for this operation Ream Bushings to dimensions shown in Figure 2 page 18 Clean bore of shavings Install king pin seals See Figure 2 page 18 Install lube fittings If steer knuckle has provision Position and support knuckle on axle Install thrust bearing between lower face of 1 and lower leg of steer knuckle The seam created by the top and bottom half of the thrust bearing should point toward the ground Align holes of knuckle 1 and thrust bearing Place jack under steer knuckle Raise to obtain CRUSH on thrust bearing With feeler gauge check clearance between top face of 1 and upper leg of steer knuckle Clearance must not be less than 002 or more than 010 Install proper shims Align flat on king pin with lock pin holes in I beam Install king pin Remove jack Install tapered lock pin pins Flat on pin to flat on king pin Secure with locknut Install grease caps and gaskets Install foundation brake with bolts and locknuts Reconnect brake line Install tie rod assembly to tie rod arms Secure with nuts and new cotter pins Reconnect drag link to steer arm Secure with nuts and new cotter pins Install bearing cups if removed from hub Install oil seal on spindle Use installation tool Install inner wheel bearing on spindle Dip in oil first Wheel Hub Place on spindle Do not damage oil seal Dip outer bearing in oil and install on spindle
8. ring Cone remove Bearings lift off and set aside for cleaning and inspection Bearings Cups if necessary remove from wheel hub Oil Seal remove from spindle Drag Link disconnect at steering knuckle upper arm Tie Rod disconnect at knuckle lower arm Brake Line disconnect at brake chamber Foundation Brake Assembly remove from knuckle as a complete assembly by first removing nuts and bolts Grease Caps and Gaskets remove from top and bottom of knuckle yoke Tapered Pin Draw Key remove nut and drive out using bronze drift on threaded end King Pin drive out Knuckle Shims and Thrust Bearing remove Fittings remove lf installed in knuckle Knuckle Bushing Seal remove Knuckle Bushings if worn remove using tool as shown in Figure 1 NOTE These operations are for left side Repeat on opposite side with exception of Step No 9 WESTPORT 1 Rev 1 2 00 16 SECTION IV KING PIN amp KNUCKLE REPLACEMENT STEERING KNUCKLE INSTALLATION 1 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Knuckle Bushings conventional bolt on cap align lube holes on bushings with holes in knuckle Press bushings in Holes in knuckle and bushing must be in line Use installation tool shown in Figure 1 page 13 for this operation 1a Knuckle Bushings sealed screw in cap press bushings to dimensions shown Use installati
9. sembly to tie rod arm using nut and new cotter pin Adjust toe in Tighten clamp nuts On tie rod assemblies with rotating clamp position clamp away from 1 WESTPORT AAA Rev 1 2 00 19 SECTION IV WHEEL BEARING ADJUSTMENT WHEEL BEARING ADJUSTMENT 1 Screw wheel bearing adjusting nut against the thrust washer while wheel is rotated Be sure there is sufficient clearance between brake shoe and drum so that there will be no brake drag Tighten nut to 200 Ft Lbs of torque while rotating wheel in both directions Back off nut one full turn Tighten nut to 50 Ft Lbs of torque while rotating wheel in both directions Back off nut 1 6 to 1 4 turn see special instructions Check adjustment making sure wheel rotates freely With a dial indicator place magnetic base on wheel and pointer on end of spindle Grasp wheel of hub and drum and with a push pull action record amount of axial movement If movement between 001 005 inch secure with new cotter pin If movement greater than 005 repeat adjustment procedure If no movement recorded repeat adjustment SPECIAL INSTRUCTIONS Follow instructions below for proper wheel bearing adjustment on all axle models having 18 pitch thread on wheel ends 5a After 50 Ft Lbs torque look for cotter pin hole alignment with nut slot which can be in vertical or horizontal position Note this slot 5b Rotate this slot counter clockwise to next cotter pin hole
10. tected replace tie rod ends WHEEL BEARING INSPECTION 1 Remove bearings Clean bearings and spindle with a suitable solvent Inspect rollers cups and cones for wear pitting or chipped condition If detected replace bearings Inspect spindle for worn damaged or discolored burnt condition on bearing surfaces If detected replace knuckle If water or other contaminates are found in the wheel cavity replace oil seal If oil is detected on brake shoes or brake drum area replace oil seal TUBE AXLE INSPECTION Inspect welds on tube axles with regards to add on brackets axle seats etc for weld cracks or broken welds If the crack or break extends into the tube axle do not repair Replace axle tube If the crack or break is only in the weld refer to the weld repair section WESTPORT 15 Rev 1 2 00 SECTION IV KING PIN 6 KNUCKLE REPLACEMENT STEERING KNUCKLE REMOVAL NOTE This service and repair procedure is with axle l beam left in place on vehicle Disassembly operations should be performed in the following order 1 Hub caps remove Use a container to catch oil 2 Raise front end until wheels tires just clear floor Place stationary jacks under axle I beam Cotter Pin Nut and Washer remove from knuckle spindle Outer Bearing Cone shake wheel to remove then slide wheel off NOTE A wheel dolly should be used to facilitate the removal and installation of wheels Inner Bea
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