SDA-1800 Service & Parts Manual
Contents
1. Hdddll r doo Vas 19915 P ice E kas E ae lo 045 Wad d HdNN1 vi 5 TRE Mak AA um ta k rm E BAS TE 98 yv 998 GALS TVG NIdONIM H3ddfl 876 X OI 882 X 00 Sag 114130 ddd 19315 957798 LOH SEF X X Swai SAIS OTIM HIFI b AR A A 2 E 19315 IVIL dal 30 BSS HJAIHU ONIHSNG LJVHSNV2O 0176 MISES tg GFX sai BEE LO D STEEL 5 Ore MATERIAL CAMSHAFT SEAL DRIVER 11 21 0 9NIHS Id L3VEONYO AALS de ry LE i Te re haa lens e ir rat LUE je Lar ui tat 1 988 lHWd55v 2410 Belle NOT ld 1493530 d 1 Y IY11 N 34333102. LUN LOS HH amp 1 gt see 1708 HH 5 JM Sl 42 sez Ka 852 11 MES ri a a Ed dem www E 6 24 Te EL 998 WADHAH ONS 7372997315 IWIINZHdJJIO 6 SLAM Ql tre z or AYO EE i IE AY EN ES P ee E 1 oe FI E a s t F Li E E d 2 qx Lr D FO L L TIHO IBLE XIE HOVE MOBISSIMSMYHL OL 1990 Ol 31914 Sev MI S3 2 SEY 3448 OTIW SALON mr AAA U 998 ddldvOv IWAOWSH 44 HS 19915 1 eal V 711180 1595 8 TES NOI LO ES E ds E Bg E ET euo 9 t M RGSS eL 1 reas TP PE LEE aL LLL lddis ND I LS 3S mil NEZ Fl HdldVv v IwAONJdH ON3 d 9993445 951 6 nHHL THO 1998 X 20711 E
3. 2 SSW De Ea LIU bo LLEI 2 Y re m 175 FT LES STEERING STOF BOLT DETAILS 2000 TORQUE SPECIFICATIONS SDA 1800 lt MATERIAL WHEEL END INNER SEAL DRIVER 359 4 19915 mm uuu u u u 288 069 ddAld Was lddH mtu H MM HHH AAA PERSE INE pA m am mcm m arcu tk rae E ZS 99 910 BSS dJA18U Was MO 19315 E Ly RE im gin La zl L M NE 916 OSS d kaU NIdONIM 9450 MAS ILLA ta bat k t Beso 25 GE ddAldU Was A 19915 1 E HM CAC HA E e ERA AAA A AAA Rd CR m HU nz rie tra a m arcum 26
4. AUTOMOTIVE CORPORATION SDA 1800 STEERABLE DRIVE AXLE SERVICE MANUAL Fabco Automotive Corporation CA Ph 925 454 9500 1 800 967 8838 925 454 9501 www fabcoautomotive com 9 03 ASBESTOS WARNING SUGGESTED PROCEDURES FOR WORKING WITH COMPONENTS SUSPECTED OF CONTAINING ASBESTOS Asbestos has been found to be a primary cause of various forms of res piratory dis ease and cancer of several vital body organs Primary ingestion is by breathing or swallow ing airborne dustcontain ing fibers Smokers are ata greater risk than those who notsmoke The onsetof sucha fatal dis ease can be at an ex tended pe ri od of time several years after the exposure The Occupational and Safety Health Ad ministration OSHA has established very stringent limitations for exposure to as bes tos fibers by workers us ing the material and every pre caution shouldbe taken to minimize the risks involved The following are some sug gested pro dures to adopt when working with mate rialthathas ormay be sus pected of containing asbestos 1 Approved protective clothing gloves eye shield and aprons should be worn whenever working around the suspected material NIOSH amp OSHA approved respirator masks suitable for asbestos dust should be worn at all times Dispos able dust face masks are not allowed by OSHA 2 Donotsmoke while work ing on any as bes tos re lated mate rial tive apparel 3 Do not eat or drink food while we
5. tool number 866 744 see Section 9 8 should now be used to pull the upper king pin ball stud from the suspension yoke Using the upper king pin ball stud pul ler fit one tube over the lo cating dowel and the other is allowed to float freely Insert the 1 1 8 12 x 3 1 2 UNF bolt through the spacer and the tool s central hole The bolt should then be threaded into the top of the up per king pin ball stud Tighten the bolt un til the ball stud is pulled free from the suspension yoke Roll the jack backward to disengage the steer able end from the axle See Figure 29 amp 30 10 Figure 730 In stal la tion is the re verse of re moval See Section 8 0 for correct torque specifications After assembly complete the kingpin adjust ment procedure Section 3 3 and grease up per and lower king pins 7 2 DIFFERENTIAL CARRIER REMOVAL 1 1 96 Remove the oil drain and fill plugs from the dif ferential housing to drain lubricant Remove the tie rod and both steer able ends as described in Section 7 1 Withdraw both axle shafts from the axle Remove the two lowest bolts from the differen tial pinion bearing carrier maneuver the tool into place and reinstall the bolts through the tool and back into the differential Thread the 3 4 16 x 5 bolt up through the bottom of the base plate and into the nutclos est to the verti cal plate See Figure 31 Ad just the bolt to con tact and sup portthe differ entia
6. It is important that no dirt or for eign ma te rial be allowed to en ter the unit during repairs Referto the ploded views lo cated in the parts section as an aid in disassembly When disassembling the various assemblies lay all parts on a clean bench in the same se quence as removed This procedure will sim plify reassembly and reduce the possibility of los ing parts 4 2 1 96 Carefully wash and relubricate all bearings as removed and protectively wrap until ready for use Re move bear ings with pullers de signed for this pur pose or in a man ner which will not dam age those bear ings that will be re used When necessary to apply force to remove a part the use of a pul ler or press is pre ferred In some cases the use of a bar or soft hammer may be allowable BRAKE DRUM HUB AND WHEEL BEARINGS Raise the front the ve hi cle with a jack and se cure with jackstands of suitable capacity Also re move the front wheels Remove the brake drums WARNING WHEN REMOVING THE BRAKE DRUMS TAKE SUITABLE CAUTIONSIF THE POS SIBILITY OF EXPOSURE TO ASBESTOS DUST EXISTS SEE AS BES TOS WARNING LOCATED IN THE FRONT OF THIS MANUAL FABCO ORIGINAL EQUIPMENT 5 5 AS BESTOS BASED Remove the eight 5 8 outer drive flange locknuts The drive flange should be loose enough to re move by hand If it is not use two 1 2 20 bolts inthe extrac tor holes p
7. pri ate gear oil Check for leaks SAE 140 gear oil meet ing MIL L 2105 B is appropriate for most operating conditions For extreme conditions follow the vehicle manufacturers recommendations for the rear axle and apply them to the front axle 2 5 STEERING TIE ROD ENDS Tie rod ends should be lubricated every 1 000 miles at each chas sis lu bri ca tion In spect for loose bent or oth erwise dam aged com ponents Careful atten tion to such detail is a vital safety factor 3 0 AXLE ADJUSTMENT 3 1 GENERAL Adjustments may be necessary after an accident in re sponse to or to cor rect steer ing prob lems tire wear prob lems or as part of the reassembly process after a thorough inspection 3 2 WHEEL BEARING ADJUSTMENT 1 The front of the vehicle should be raised prop erly supported and the front wheels removed from the axle 2 Then remove the brake drum 3 Remove the eight 5 8 outer drive flange locknuts 4 The drive flange should be loose enough to re move by hand If itis not use two 1 2 20 bolts in the extractor holes pro vided for this pur pose See Figure 1 p Fig ure 1 7 99 5 Re move the wheel bear ing locknut washer from the spin and loosen the bear ing ad just ing nut Torque the bearing adjusting nut to 50 lb ft while simultaneously rotating the hub assem bly See Sec tion Spe cial Tools 9 16 Loosen the nut and repeat this procedure 2 3 times to
8. 2 97 Joo J Hd a li IT amp Badbldwv v 3 199434145 ve des INES V A MIO 1259 x Am 6 2 fis ECS 7 g en paa e D MT le _ 38 HdJdWwvHO X 111190 SEZA x g USE EITHER OF THE FOLLOWING 6 POINT SOCKETS OTC 1915 4 1 8 SNAP ON ANS 1915A 4 1 8 9 14 LOWER KINGPIN LOCKNUT TOOL 1001 UNLS NIaGUNIA EMO SLON WYP OAL PELL Mata DS Tit EH a 5 HO gs HH ad JNA la lA AS dues AL OUVONVIS 122 AL Y PI L age LA 2015 NOOVYXJH 91451 40 USE OF THE FOLLOWING 6 POINT SOCKETS 1915 4 1 8 SNAP ON ANS 1915A 4 1 8 9 16 HUB BEARING LOCKNUT TOOL
9. Haan aiu pute Lower Kingpin Ball Stud Removal Hub Bearing LOCK TOO u ati 22 22 23 24 25 26 27 28 29 30 31 32 33 34 39 36 37 38 39 40 41 42 Copy right 1996 Fabco Auto motive Cor 1249 67th Street Oak land Cali for nia 94662 1 0 INTRODUCTION AXLE HOUSIN 7 A y 12 AT h DIFFERENTIAL CARRIER 1 1 GENERAL DESCRIPTION The Fabco Steerable Drive Axle consists of four major assemblies the axle housing two steerable drive ends and a differential carrier steer ing tie rod links the right and leftsteer able ends and steering in putis de liv ered via asteering arm The steering arm is usu ally lo cated on the left steerable end although right hand or even dual steering arms are available 1 2 OPERATION Driv ing forces are put into the axle at the pin ion yoke on the differential car rier they pass through the dif fer en tial to the in ner axle shafts and on to the uni ver sal joints The yoke shafts get their power from the U joints and trans fer it by means of splines to the drive flanges which bolted to the wheel hubs thus rotating the wheels STEERABLE DRIVE END When steered the outer section of each steerable drive endrotates aboutthe king pin centerline The U joint cen tered on the king pin cen ter line al lows power to be trans mit ted through out the pos si ble range of steer ing in puts The axle is equipped wit
10. or steer ing arm 2 1 WHEEL BEARINGS Wheel bearings require cleaning inspection and pack ing with grease at each brake reline Wheel bearings should be lubricated in accordance with the vehicle manufacturer s recommendations When greasing lib erally pack both inner and outer bearings ensuringthat the grease has penetrated thor oughly into the cage and roller as sembly Priortore sembly coatthe race ways and inte rior hub surfaces as well 2 2 UNIVERSAL JOINTS Universal joints are lubricated and sealed at the factory and should require no additional maintenance through out their service life 2 3 KINGPIN BEARINGS King pin bear ings should be lu bri cated at each chas sis lu brication approxi mately 1 000 mileintervals Toensure thorough lubrication the front axle should be raised slightly to re lieve ve hi cle weight The lower king pin lube fitting is located at the bottom of the lower kingpin ball stud itself The up perking pin fitting is onthe steering arm or up per king pin cap 1 96 2 4 DIFFERENTIAL CARRIERS Differentialcarriers should havethelubricantchangedat the same interval as the rear axle on the vehicle or ap proximately 10 000 miles Drain while lu bricantis warm and clean the magnetic drain plug Removal of the fill plug will allow quicker drainage Be sure to allow the housing to drain completely Re in stall the drain plug and fillthe hous ing to the bot tom of the fill plug with the ap pro
11. 17 17 18 18 19 TABLE OF CONTENTS CONT D SDA 1800 7 0 ADDITIONAL SERVICE PROCEDURES 8 0 9 0 10 0 1 7 2 TORQUE SPECIFICATIONS SPECIAL TOOLS 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 9 11 9 12 9 13 9 13A 9 13B 9 13C 9 13D 9 14 9 15 9 16 ILLUSTRATED PARTS MANUAL Steerable Drive End Removal nin St Differential Carrier Wheel End Inner Seal Driver WEG HUD Sell DIVER MR O aa Lower Kingpin 26510161 tete cowed Lower Kingpin Bearing Upper Kingpin Seal DIV ro ho A AA Upper Kingpin Bearing In ner Axle Seal Driver Upper Kingpin Ball Stud Puller SO SS E Camshaft Seal Driver Brake Bracket Tc Camshaft Bushing Driver Brake Bracket Camshaft Seal Driver Spin dle Camshaft Bushing Driver Spindle Yoke a Differential amp Steerable End Removal Tool Differential amp Steerable End Re Tool Differential Re moval Adapter Steerable End Re moval Adapter 13 3 1 6 B C Steerable End Re moval Adapter 11 1 4 MCN Case qu
12. 6 2 SPINDLE INSTALLATION 1 96 1 If the in ner axle seal has been re moved smear grease on the inner bushing surface of the re place ment part and ap ply a thin bead of Loc tite gasket eliminator to the outer surface Drive it into the sus pen sion yoke un til it seats squarely against the shoul der of the bore CAUTION THE BRONZE INNER BUSHING SURFACEHAS AN OILPAS SAGE WHICH SHOULD BE LOCATED AT 3 OR 9 O CLOCK BEFORE THE SEAL IS DRIVEN IN Placethe lower king pin plate in the sus pen sion yoke and drive in the bearing and seal after it oee Figure 18 Both upper and lower kingpin seals must be installed in their bores w grease lips fac ing out ward Ifthe up per king pin bear ing has been re moved in stall the new part us ing et ther a pusher plate or the old part as a driver See Figure 19 Ifneces sary in stall a new up per kingpin seal against its shoulder opposite the upperkingpinbearing 3 4 Figure 19 If nec es sary in stall a new wheel end in ner seal See Figure 20 Grease lightly all seal lips and kingpin bearings Reinstall the drive axle shaft assembliesbeing careful not to score the inner axle seal is Figure 20 7199 5 Place the spin dle yoke onthe sus pen sion yoke optimally with some lifting device See Figure 21 stall the up per king pin ball stud and bolt Itis recom mended to re place the bolt with a new one from Fabco If a replace mentboltis not available use t
13. Arms 91 75 Inches Across Wheel Mounting Faces 2 100 Inch Di ameter 41 Spline In vo lute 1 95 Inch Diameter 35 SAE 90 140 80W 140 15 Quarts Est 1 890 Pounds Central Tire In fla tion Anti lock Braking System Sensors ABS ISO Hub Piloted Wheel Ends 5 31 5 61 5 91 6 21 6 65 7 21 7 60 8 38 8 96 9 77 iG Dg YHH DES Lee m VE f GGl x f ua B 53044 SLIM AC 9 HIBK31 3 SHI HE ANI CHIME 1935 SHINS 3 HEL 0 8811187 27 B SONS WA 9148 1 181 YUS 411 ML LR SA AAA TA 1 96 2 0 LUBRICATION Recommended Lubricants 1 Gear Oil Temperature Grade Above 32 F 0 C MIL L 2105 B SAE 140 MIL L 2105 C 80W 140 Below 32 F 0 C MIL L 2105 B SAE 90 MIL L 2105 C 80W 90 2 Chassis Grease Temperature Grade Above 32 F 0 C MIL G 10294 Below 32 F 0 C MIL G 10294 3 Wheel Bearing Grease Temperature Grade Above 32 F 0 C Below 32 F 0 C NLGI Grade 2 NLGI Grade 2 There are four lubrication points on each steerable end Thelocation of these grease fit tings is as fol lows in side the lower king pin ball stud tie rod end S camshaft tube and the up per king pin cap
14. aring protective clothing Always wash before eating drinking or smoking 4 Do not use compressed air for any dirt removal Use only approved high effi ciency vac uum clean ers suit able for use with as bes tos Do not dry brush de pos its or accumulations of dirt from components What cannot be removed with the high ef fi ciency vac uum cleaner should be washed with a wa ter soaked rag The rag should notbe wrung dry but should be dis posed of to gether with other wastes containing asbestos in specially sealed and marked containers in accordance with EPA and OSHA regulations 5 Donotwear protective cloth ing away from the working area vac uum clean cloth ing before removal Shower if possible before going home These suggestions are neither complete nor authoritative on the subject of working with asbestos but are meant as a warning of the possible risks It is the responsibility ofthe su pervis ing author ity to be aware ofthe possible dan gers involved and to provide suitable training precaution and protection for those working in an asbestos environment TABLE OF CONTENTS SDA 1800 1 0 2 0 3 0 4 0 9 0 6 0 INTRODUCTION 1 1 1 2 1 3 1 4 1 5 LUBRICATION 2 1 2 2 2 3 2 4 2 5 AXLE ADJUSTMENT 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 4 2 4 3 4 4 CLEANING AND INSPECTION 5 1 5 2 5 3 DRIVE END ASSEMBLY 6 1 6 2 6 3 6 4 General Descrip Na o do Q ba lt Oper
15. ation TETTE Operating Specifications Steerable Drive Axle CeneraDimensions Wheel Bele den et ef m 4 Universal dolls ne ala 1110101221116 en en Re HE acido General Wheel Bearing Adjustment PITA US elaine ros INHAGIUSIM NE c SOP AJU SIMEN SE Camber 1 72 IM de ede m Su nn STEERABLE DRIVE END DISASSEMBLY General Precautions for Brake Drum Hub and Wheel Bearings ss Brake and Wheel Spindle o nc OR Spin dle YOKE Re moval Choice of 0 ne Drying and oorrosiom INDIO General Precautions for ss Spindlelnstallation Brake Equip ment Wheel Bearings Hub and Brake Drum De o H OEY PAGE 00 JO O1 O1 O1 9 10 11 11 11 11 11 11 12 12 12 13 14 15 15 15 15 15 16 16 16
16. be wrapped in heavy waxed paper 5 3 INSPECTION Prior to reassembly parts which are to be reused must be care fully in spected for signs of wear or dam age Re place ment of such parts can pre vent costly down time future date All bearing and bushing surfaces in cludingroller bearing cups and cones should be ex am ined for pit ting wear or over heat ing Shafts may be nicked and marred or have damaged threads all structural members and welds closely for any signs of crack ing Parts which show any sign of dam age should be re paired or re placed 6 0 STEERABLE DRIVE END ASSEMBLY GENERAL PRECAUTIONS FOR ASSEMBLY 6 1 1 Assembly Ref er to the ploded views lo cated in the parts sec tion as an aid to as sem bly Initial Lubrication Splines and grease seal lips should be coated and filled with grease prior to as sem bly to pro vide lu brica tion upon start up Bearings Use of flanged end bearing drivers is recom mended for the installation of bearings and races These drivers only apply force to the races of the bearing preventing damage and maintaining alignment with the shaft and bore Seals Use a flanged type guide or driver to install seals If a driver is not available use of a soft ham mer and or wood blocks may be made pro videdthat care is exercised Proprietary drivers are avail able di rectly from Fabco and draw ings are also pro vided in Section 10 0
17. e shaft Pry the joint away from the shafts and re move See Figure 28 Figure 28 1 96 19 Loosen the upper kingpin adjusting screw nut and back out the adjusting screw until the spindle yoke stops moving downward and is resting on the suspension yoke Remove the steering arm or up per king pin cap nuts along with the brake bracket bolts Us ing a 7 16 socket rotate the hex extension on the front of the slack ad juster coun ter clock wise At the same time the brake bracket will be lifted back offthe steering arm or up per king pin cap Removethe steer ing arm or up per king pin cap If difficulty is encountered turn the adjusting screw back in to force the arm or cap off the studs Attach the steer able end re moval tool to a trans mission jack and mount it to the steerable end by means of the lowest three wheel studs and nuts Thread the 3 4 16 x 5 bolt up through the bot tom of the base plate and into the nut fur thest fromthe verti cal plate Adjustthe boltto con tact and support the brake drum CAUTION IF THE TOOL IS NOT AVAILABLE ALTERNATE MEANS TO SUP PORT THE STEERABLE END MUST BE FOUND BEF ORE CON TINUING THIS PROCEDURE Loosen the lower kingpin locknut see Section 9 14 Special Tools and com pletely re move the locknut lock washer and lower king pin ball stud see Section 9 15 Spe cial Tools from the spin dle yoke Remove the 1 14 upper kingpin bolt Special
18. ensure that the bearings are seated properly After the final tightening back off the nut 1 4 turn See Figure 2 Fig ure 2 In stall the wheel bear ing lock washer and wheel bearing adjustment nut then torque locknut to 400 lb ft See Section Special Tools 9 16 Next one tab on the lock washer should be bent inward and one bent out ward across the flat test part of the nut NOTE With the outer locknut torqued to specifications the wheel hub should rotate freely The wheel bear ing end play should be checked with a dial indicator as part of the adjustment proce dure See Figure3 The cor rect end play setting is no less than 002 and no more than 004 Fig ure 3 9 Reinstall the drive flange over the hub assem bly Then torque the drive flange locknuts to 175 lb ft 3 3 KINGPIN ADJUSTMENT 1 The front of the vehicle should be raised prop erly supported and the front wheels removed from the axle Loosen the lower kingpin locknut see Section 9 14 Special Tools and back it down enough to allow the lower kingpin lock washer to disen gage from its retaining dowel pin move the grease fitting Back the lower king pin ball stud see Section 9 15 Special Tools down four com plete turns Loosen the upper kingpin adjustment jam nut and back out the ad just ing screw four full turns The drive end assembly will begin to lower as the screw is turned out See Figure 4 Figure 4 Be
19. gin tightening the adjusting screw and con tinue until upward motion of the steerable end stops Ifa fin geris placed near the gap be tween the suspension and spindle yokes the point at which upward travel stops can be readily felt Additional re sis tance will also be feltin the ef fort re quired to turn the ad just ing screw The up per kingpin has now been seated in its bushing Place a stack of feeler gages or drift in the gap between the suspension and spindle yokes in the area of the lower kingpin ball stud The gages or drift should fit snugly Filling the gap No meas ure mentis necessary See Figure 5A 7 99 Figure 5 Advance the lower kingpin ball stud until the feeler gage stack or drift loos ens See Section Spe cial Tools 9 15 This in di cates that the ball stud threads are actually beginning to spread the suspension and spindle yokes apart See Figure 5A Figure 5A 7 Back off the ball stud enough to al low the clos est hole in the lower kingpin lock washer to en gage the retaining dowel pin Apply grease to the sur face of the lower king pin lock washer that will face the locknut This helps keep the washer from turning when the locknut is tight ened Torque the locknut to 2 000 lb ft See Sec tion Spe cial Tools 9 14 CAUTION DO NOT TORQUE LOWER KING PIN BALL STUD Back outthe up per king pin ad just ing screw just enough to re lieve pres sure so the end can turn freely ap proxi matel
20. h S cam air brakes and auto matic slack adjusters 1 3 OPERATING INSTRUCTIONS In con di tions where the ve hi cle s rear wheels might spin such as sand loose dirt mud snow ice or ascending grades the front drive axle can be shifted into operation for im proved trac tion En gage ment can be made at any vehicle speed pro that the rear wheels are not spin ning Engage mentis best ac com plished when the en gine is pulling lightly 1 4 STEERABLE DRIVE AXLE SPECIFICATIONS MODEL SDA 1800 1 96 MAXIMUMCAPACITY BRAKES Type Size Chamber Certification Slack Adjusters HOUSING CAMBER WHEELS Mounting Mini mum Wheel Size DIFFERENTIALCARRIER Ring Gear Diameter Pinion Spline Single Reduction Ratios UNIVERSAL JOINT KINGPINS Type Inclination STEERING TRACK AXLE SHAFTS Spline Body TURN ANGLE LUBRICATION Type Capacity WEIGHT Dry OPTIONS CTI ABS Wheel Ends DoubleReductionDifferential 18 000 Pounds Load Rating Drum ES S Cam 16 5 Diameter x6 Inch 30 Square Inch FMVSS 121 Automatic Fab ricated Steel Cast Banjo Cen ter Bowl 1 2 Positive 10 Studs on 11 25 Inch Bolt Cir cle 20 Inch Spiral Bevel 16 5 Inch 2 00 Diameter 39 Spline Involute 3 90 4 11 4 33 4 56 4 88 5 29 5 57 6 14 6 57 7 17 Single Cardan 9C Spherical NylatronRaces 5 Ackerman to Match Wheelbases 160 to 185 or 186 to 219 Left Right or Dual Steering
21. he existing bolt and apply Loctite 272 to its threads during assembly Torque the bolt to 1 000 lb ft Figure 21 6 Reinstall the yoke shaft bearing if removed making sure it is packed liberally with grease See Figure 22 Re place the thrust washer and snap ring Figure 22 emearthe spheri cal portion ofthe lower king pin ball stud with grease Screw the lower kingpin ball stud into the spin dle yoke En sure that the lo cat ing pin for the king pin lock washer is in po sition in the yoke then loosely install the lock washer and nut After wiping both mounting surfaces clean of grease push the steering armor up per king pin cap down over its mounting studs and pilot dowel install the two 3 4 nuts and torque to 250 lb ft Install the upper kingpin adjusting screw its jam nut and the lubrication fitting in the cap or arm zd 10 11 Com plete steps 4 7 of Section 3 3 King pin Ad just ment in this man ual In stall the spin dle over the yoke shaft and spin dle yoke studs See Figure 23 CAUTION THE KEYWAY MUST BE LO CATED IN THE 12 O CLOCK PO SITION Torque the spin dle nuts to 250 Ib ft us ing aunt formed torque sequence Figure 23 Re stall the tie rod end torque the cas tle nut to 100 lb ft and fit a new cotter pin 6 3 BRAKE EQUIPMENT 1 If neces sary press new seals and bush ings into the air chamber mounting bracket and spindle yoke Seals must be
22. installed flush so that the lip side with spring of both seals face toward the slack adjuster end of the bracket erly ori ented seals may al low grease to exit the cam shaft head end and con tami nate the brake linings CAUTION THE CAM HEAD END BUSHING SHOULD BE RECESSED 5 16 TO ALLOW CLEARANCE FOR THE SEAL THE BRAKE BRACKET BUSH ING SHOULD BE RECESSED 23 32 TO ALLOW CLEARANCE FOR THE SEAL Push the S camshaft all the way into the mount ing braket from the wheel side until the cam head contacts the bracket Next push the camshaft tube onto the shaft Make sure that the O rings are set in the grooves on the cam shaft tube CAUTION LEFT AND RIGHT HAND S CAMSHAFTS ARE NOT IN TER CHANGEABLE 7 99 3 Push the air cham ber mounting bracket onto the S camshaft Then align the bracket on the steering arm or upper kingpin cap Insert the two 7 8 bolts and torque to 250 Ib ft Fitthe air cham ber mounting studs through their holes in the bracket and se cure with the two 5 8 locknuts and wash ers Torque to 150 lb ft See Figure 24 Fig ure 24 Installthein ner washer and slack ad juster over the S camshaft with the 7 16 adjusting screw pointing toward the front of the axle Begin by placing two 060 and two 030 spacers over the end of the 5 In stall the snap ring See Figure 25 Figure 25 6 Tapon the cam end of the shaft with a soft mal letto movethe shaftin b
23. l car rier 20 CAUTION IF THE TOOL IS NOT AVAILABLE ALTERNATE MEANS TO SUP PORT THE DIFFERENTIAL CAR RIER MUST BE FOUND BEFORE CONTINUING THIS PROCE DURE Figure 31 Removealldiffer ential mounting bolts washers and nuts Roll the dif fer en tial car rier away from the axle NOTE Refer to the appropriate Eaton Axle Service Manual for information re gardingdifferential servicing Installation is the reverse of removal Apply a bead of Loctite gasket eliminator flange seal ant 515 or equivalent around the differential car rier mounting face on the axle hous ing See Sec tion 8 0 for cor rect torque val ues Clean the mag netic drain plug and fill the axle to the bot tom edge of the level hole with the ap propriate lubricant 75FT LBS ADDITIONALTORQUESPECIFICATIONS 20 FT LES AIR BRAKE CHAM BER NUTS 150 FT LBS ALL TORQUE VALUES IN FT LBS WITH DRY UNLUBRICATED THREADS 250FT LBS DIFFERENTIALMOUNTINGBOLTS 170FT LBS TIE ROD BALL JOINT CAS TLE NUTS 100 FT LBS ROD AD JUSTER CLAMP NUTS 75 FT LBS 250 FT LES 1000 FT LES Arm varies S Z Lg Niky Uy AU NE m M Z 120 FT LES 1 1 8 16 2 PILOTED 450 500FT L 22 1 5 le 450 500 FT LBS ie 202 lt 017 lt S NS NS I gt 175FT LBS
24. ngle and may affect the op era tion of the front drive shaft 3 8 BRAKE ADJUSTMENT After an initial setup procedure brake adjustment is made automatically by the slack adjusters and should require no attentionbetweenrelines Toadjustthe slack after a brake reline 1 Usinga 7 16socket rotate the hex exten sion on the front of the slack ad juster clock wise un til the shoes first con tactthe drum See Figure 7 Ro tate the hex extension 1 2 turn counterclock wise to back off the shoes and provide initial running clearance ratcheting noise while backing off is normal 1 96 ecd Tes Confirm that the drum ro tates freely Scrap ing noises are OK but no heavy drag should exist Ifexcessivefrictionis pres ent continue to back offthe hexextensionin 1 8turnin cre ments until free motionis re stored NOTE It is pref er able to have a slightly loose ini tial set ting than one that is too tight The adjuster will remove extra slack but cannot add any 4 0 STEERABLE DRIVE END DISASSEMBLY 4 1 GENERAL PRECAUTIONS FOR DISASSEMBLY CAUTION READ THIS SECTION BEFORE START INGTHEDISASSEMBLYPROCEDURES 1 Follow each proce dureclosely in each section making use of both text and figures The outside of the unit should be carefully cleaned before starting disassembly If steam cleaning ensure that breather and air fittings are covered to prevent moisture from entering the assembly Prepare a clean place to work
25. oard Attemptto in serta 030 spacer betweenthe existing spacers and the snap ring If the spacer slides easily be tween the two re move the snap ring and in stall the spacer Reinstall the snap ring and repeat this step un til a 030 spacer can no longer be in serted Thread the air cham ber push rod into the cle vis un til it bottoms out Then back off two turns and torque locknut to 75 lb ft Hook the two lower retaining springs into each brake shoe By grasping the shoes at the top and spreading them apart the cir cu lar re cess in the bot tom of each shoe can be fit over the an chor ing pin on the spin dle yoke Installthe large upper brake release spring Then using a bar pry the shoes away from the S cam and insert the cam shaft roll ers See Figure 26 CAUTION DONOT ALLOW YOUR FINGERS TO COME BETWEEN THE SHOE AND THE S CAM Figure 26 9 Refer to 3 8for brake ad just ment 6 4 WHEEL BEARINGS HUB AND BRAKE DRUM 1 Press both wheel bearing cups into the hub Thoroughly pack both bearing cones with grease and coat the in side surfaces of the hub and bear ing cups In stall the in ner wheel bear ing cone and the hub seal in the hub See Figure 27 Lightly coat the outer surface of the spin dle with grease to re duce the chance of the innerwheelbearing cocking uponinstallation of the hub 18 Figure 27 2 Grasp ing the outer cir cum fer ence of the hub at the 12 and 6 o clock positi
26. on 3 5 STEERING STOP ADJUSTMENT The steering stop adjustment is made at the factory There should be no need to al ter it un less a ma jor com ponent such as the axle housing or spindle yoke has been re placed for some rea son The turn an gle is set at 35 and this can be checked with a car penter s power saw pro trac tor on the wheel s in side rim and a T square laid along the frame rail with the ve ht cle s steer ing at full lock If an adjustment is necessary loosen the steer ing stop 12 point ad just ing screw onthe rear of the spindle yoke and add or remove washers to achieve de sired turn an gle Torque the jam nut to 75 lb ft The toe in adjustment Section 3 4 should be completed before perform ing this proce dure WARNING THE POWER STEERING GEAR S PRES SURE RELIEF SHOULD OCCUR AT LEAST 1 8 BEF ORE THE AXLE STEER ING STOPS ARE CONTACTED IF THE POWER STEERING PRESSURE RELIEF NEEDS ADJUSTMENT CONSULT THE VEHICLE MANUFACTURER BEFORE OPERATING THE VEHICLE FAILURE TO COMPLY CAN RESULT IN DAMAGE TO THE STEERABLE DRIVE AXLE AND OTHER STEERING COMPONENTS 3 6 CAMBER ADJUSTMENT Camber is set at the factory and is integral to the manu fac ture of the hous ing and steer able endcom ponents It cannot be changed 3 7 CASTER ADJUSTMENT Caster is specified by the vehiclemanufacturer and can be adjusted only by means of shims between the axle spring seat and the spring Changing the caster will change the pin ion a
27. ons push the hub straight on to the spin dle If dif fi culty is cour tered try rock ing the hub slightly to free the in ner bearing Once the hub is in position the outer bear ing and ad justing nutcan be installed Refer to Section 3 2 for wheel bearing adjust ment 3 Install drive flange over the drive studs Install the drive flange locknuts and torque to 175 us ing auni formed torque se quence 4 Mount the brake drum over the wheel studs 5 Grease all lubrication points before returning the vehicleto service 7 0 ADDITIONAL SERVICE PROCEDURES 7 1 STEERABLE DRIVE END REMOVAL This pro ce dure is use ful in cases where itis nec es sary to gain access to the in ner axle seal or to re move the dif fer en tial yetcom plete tear down of the steer able end is not desirable Removal of the steerable end will be greatly facilitated if acquisition or fabrication of the special mounting tool is possible The steerable end removal tool is avail able from Fabco or it can be fab ri cated from the drawings in Section 9 13 Special Tools 1 Remove the cotter pins from both tie rod ends Unscrew both castle nuts so that only a few threads re mainin engage ment Use asuit able pul ler to ex tract the tie rod end from the sus pen sion yoke Do not strike the tie rod end ball stud Completely re move the nuts and tie rod 2 Removeall eight 12 point cap screws which se cure the universal joint to the axle shaft and yok
28. r 866 744 see Section 9 8 Special Tools should now be used to pull the upper Kingpin ball stud from the suspension yoke see Figure 15A Fit one tube over the locating dowel and the other is al lowed to float freely In sert the 1 1 8 12 bolt through the spacer and the tool s central hole The bolt should then be threaded into the top of the upper kingpin ball stud Tighten the bolt un til the ball stud is pulled free of the sus pen sion yoke Re move the tool grasp the spindle yoke firmly and disengage it from the sus pen sion yoke An over head crane would make this procedure a lot easier Figure 15A CAUTION DO NOT TRY TO REMOVE THE UPPER KINGPIN BALL STUD BY ROCKING THE SPINDLE YOKE AS THIS MAY AFFECT THE CRITICAL PRESS FIT BETWEEN THE BALL STUD AND SUSPEN SION YOKE CAUTION DO NOT PROCEED FURTHER UNLESS THE DIF FERENTIALOIL HAS BEEN DRAINED the drive and axle shaft as sem blies by sliding them out of the axle hous ing be ing very care ful not to score the in ner axle seal SeeFig ure 16 No need to take this as sem bly apart un less plac ing the cross and bear ing 1 96 Figure 16 7 Remove the lower kingpin bearing and seal from the sus pen sion yoke by in serting a 7 8 or smaller flat headed bar through the up per king pin bolt hole so it contacts the lower kingpin plate See Figure 17 Strike the top of the bar to drive out the bear ing Do notre move the up per kingpin bearing from the
29. ro vided for this pur pose See Figure 8 Figure 8 Remove the wheel bearing locknut washer and adjusting nut from the spindle Rock the hub in place to loosen the outer wheel bearing cone Remove the cone and wrap it protec tively 2 6 Remove the hub initially attempting to pull the as sem bly straight off to avoid cock ing the in ner bear ing cone See Figure 9 If the cone binds against the spin dle try rock ing the hub to free it but it may be neces sary to use a pry bar un der the in ner sur face of the hub To avoid dam ag ing the inner seal pry against the hub only the inner bearing remains on the spindle when the hub is removed use a suit able pul ler to re move it pull ing only against the bear ing s race Alternately tap lightly on the race s outboard sur face with a small drift to cor rect its mis align ment and again attempt to remove it by hand L Figure 9 7 Wheel bear ing cups may be re moved from the hub using a suitable puller Pull the cup out evenly NOTE Thisisthelimitofroutine disassembly Brake shoes and wheel bearings may be ac cessed for main te nance but fur ther disassembly may be required to re place dam aged or bro ken parts 4 3 BRAKE AND WHEEL SPINDLE 1 Re moval of the brake shoes will be fa cili tated by turning out the 7 16 adjustment screw on the slack adjuster to relieve tension on the S cam rollers See Figure 10 Turn the
30. screw coun ter clock wise untilthe rollers rest at the low est point on the cam 2 3 1 96 Figure 10 In sert a suit able pry bar down be tween the top of the brake shoe and a spin dle locknut Pry the shoe away from the S cam and remove the roller Relax the spring tension then remove the op posite roller in like fashion SeeFigure 11 WARNING DO NOT ALLOW YOUR FIN GERS TO COME DIRECTLY BE TWEEN THE SHOE AND THE S CAM Figure 11 Next remove the push rod from the slack ad juster clevis by loosening the locknut See Figure 12 Figure 12 To remove the S camshaft pry the retaining snap ring located on the slack adjuster end of the S camshaft out of its groove then pull the S camshaft out of the air chamber mounting bracket At the same time remove the shims slack ad juster and the washer lo cated be tween the slack adjuster and air chamber bracket To remove the brake shoes detach the top re taining spring from the lower shoe Then with shoe in hand lower down to de tach the release springs at the an chor pins Now the other brake shoe is free to be removed Remove the two 5 8 air chamber mounting nuts and washers to detach the chamber from the mount ing bracket The mount ing bracket it self can be with drawn from the spin dle yoke fot lowing removal of its two 7 8 mounting bolts Remove the ten 3 4 self lock ing nuts which se cure the spindle A little per sua sion
31. spindle yoke unless it has been determined that replacement is nec es sary The up per bear ing may be driven out by the bottom of its inside edge using a chisel or drift Figure 17 15 5 0 CLEANING AND INSPECTION 5 1 CHOICE OF CLEANING METHODS 1 Steam may be used for external cleaning of completely assembled units Care must be taken to sure that wa ter is out of the as sembly by tightly closing breather caps and other openings 2 Rough parts such as housings which are too large to conveniently clean with solvents may be immersed lution tank contain ing a mild alkaline solution Parts cleaned in hot so lu tion tanks must be rinsed thor oughly to pre vent damage by traces of alkaline material 3 Parts with ground or pol ished sur faces such as bearings or shafts should be cleaned with emulsion clean ers or petroleum solvents Alka line hot solution tanks may damage the ma chined surfaces and should be avoided 5 2 DRYING AND CORROSION INHIBITION ooft clean shop tow els should be used to dry parts af ter cleaning Com pressed air may usedtoclean ac ces st ble areas of large parts such as the housing Bearings should not be spun dry with com pressed air as the lack of lubrication may cause damage to the mating surfaces Dry parts should be im me di ate ly coated with a light oil or acorrosioninhibitorto pre ventcorro sion dam age Parts which are to be stored should also
32. with a soft mal let may be nec es sary to free up these com ponents See Figure 13 Figure 13 4 4 SPINDLE YOKE REMOVAL 1 96 1 Due toits high torque loos ing the 4 1 8 lower kingpin locknut see Section 9 14 Special Tools will require substantial leverage Re move the grease fitting from the lower kingpin ball stud Now the ball stud can be removed See Section 9 15 Special Tools See Figure 14 Fig ure 14 Remove the cotter pins from both tie rod ends Unscrew both castle nuts so that only a few threads re main in en gage ment Use a suit able pul ler to ex tract the tie rod end from the sus sion yoke Com pletely re move the nuts and tie rod WARNING DO NOT STRIKE THE TIE ROD END BALL STUD Loosen the upper kingpin adjusting screw jam nut and back out the adjusting screw until the spindle yoke stops moving downward and is resting on the suspension yoke Remove the two 7 8 steering arm or upper kingpin cap locknuts and bolts Then pull the steering arm or cap up and off the mount ing studs and lo cat ing dowel If difficulty is encountered turn the ad just ing screw back in to force the arm or cap off the studs See Figure 15 Figure 15 14 Remove the drive yoke bearing retaining snap ring and thrust washer The yoke shaft bear ing removal is optional Remember to repack the bearing uponinstallation Remove the 1 14 upper kingpin bolt Special tool numbe
33. y 1 16 turn and torque the jam nut to 75 lb ft 0 3 4 TOE IN ADJUSTMENT is not recommended to raise the front of the truck to check toe at the fac tory the set ting is made with the axle loaded to simulate actual op erating conditions An expandable toe in alignment bar is recommended but if unavailable consult an alignment specialist Since the SDA 1800 2100 and 2300 axles use an offset tie rod tube adjustment is not made by turning the tube itself but rather by ro tat ing a small ad juster lo cated at the left or right end of the tie rod tube See Fig ure 6 Itis criti cal to making the adjustment accurately that the front wheels are as Close to straight ahead as pos si ble Loosen the tie rod adjuster and tie rod clamp Fig ure 6 1 Whichever end the tie rod adjuster is located toe in is increased by unscrewing the adjuster from the tie rod itself The correct setting is 0 1 8 toe in In the case of a vehicle with full time four wheel drive proportioning differen tial the setting reverts to 0 1 8 toe out greater distance in the front than the rear Consult a tire specialist for a specific recom mendation if specialized tires are used 2 Tighten both clamp bolts to 75 lb ft Roll the ve hicle forward a distance equal to four rotations of the wheels taking care to maintain their straight ahead alignment Recheck the toe in andre procedure if nec es sary to obtain the correct dimensi
Download Pdf Manuals
Related Search