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IFS1000-WF I&M Manual

1. Steering Components ITEM PART NO DESCRIPTION 1 712070 02 STEERING GEAR ASY ZF 8016 FR 712070 03 STEERING GEAR ASY ZF 8016 RR 2 711868 01 PITMAN ARM ZF SPLINE 3 8089 IDLER ARM MACHINED 4 711775 3284 RELAY ROD ASY 5 711775 2084 TIE ROD ASY 1 Please call customer service with serial number to determine which gear box you have A Ne 77 h f i KAVY PYR Jes x IES 5 1 y z 4 iat Bel RSE po Ve TNN I eS fi o JW SAN A 7 i j M d L O 3 4 c 5 Y ES 4 2 E 12 IFS1000 WF D712230 Steering Gear Components ITEM PART NO DESCRIPTION 1 712070 02 STEERING GEAR ASY ZF 8016 FR 712070 03 STEERING GEAR ASY ZF 8016 RR 2 711868 01 PITMAN ARM ZF SPLINE 3 100122 P1 7 8 9 UNC STOVER LOCK NUT GRADE C 4 102354 P1 7 8 FLAT WASHER 938 X 1 75 X 141 ZINC PLATED 5 702637 02 7 8 9 X 4 IN HEX HEAD BOLT GRADE 8 1 Please call customer service with serial number to determine which gear box you have ZA Jave N y s S St l 1043 z iS ad EE 0 V CI 1 PITMAN ARM NUT INCLUDED IN STEERING GEAR ASSEMBLY D712230 13 IFS1000 WF Steering Gear Assembly ITEM PART NO DESCRIPTION 1 704730 01 ASY GEARBOX ZF 8016 FR 704730 02 ASY GEARBOX ZF 8016 RR 2 710376 01 90DEG ELBOW O8 ORB M X 08 JIC M 3 712071 01 1 2 BARB X 08 37DEG JIC F FITTING 4 7121
2. ile i TEN SL g TRE LOWER CONTROL ARM FRONT RELAY ROD CROSSMEMBER VIE ROD Figure 3 Improper Tow Equipment Attachment Locations D712230 6 IFS1000 WF Maintenance Schedule GENERAL MAINTENANCE SERVICE TO BE PERFORMED MILEAGE IN THOUSANDS 12 24 36 48 60 72 84 96 Check axial endplay x Inspect for ruptured seals X x X X X x Steering Knuckle Ball Joints Check nut torgue Check that cotter pin is installed X X X X X X x Check bolt torgue X x Control Arm Bushings Inspect for contact between control arm and mount X X X X X X Xx x Inspect for bushing wear XXIX IX XX X X Inspect ball socket endplay X X x x x X X x Relay Rod and Tie Rod Check for looseness of taper connection X X X X X Xx Xx xX Ends Check nut torque X Check that cotter pin is installed X X X X x Inspect slack adjuster for correct stroke X xX Brake System Inspect for air leaks using soapy water solution X Inspect for proper clearance 1 minimum all x around y Check upper mount nut and lower mount bolt torque X Air Springs Inspect for signs of chafing or wear X X X X X X X x Inspect for air leaks using soapy water solution X Check upper mounting bol nut torgue X Shock Absorbers Check lower mounting bolt torgue X Inspect shocks for signs of fluid leak broken eye 2 ends loose fasteners and worn
3. IFS1000 WF Lower Ball Joint Installation 1 Inspect the threads in the steering knuckle and remove any burrs or debris Apply thread adhesive Loctite 242 or equivalent to the ball joint threads and thread the ball joint into the steering knuckle Tighten the base of the ball joint to 525 575 Ibfeft See Torque Table Connect the ball joint to the lower control arm Tighten the castle nut to 330 370 Ibfeft See Torque Table Install the cotter pin If necessary tighten the castle nut to align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin Checking and Adjusting the Wheel Bearings Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle D712280 37 ZN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Ifthe tire and wheel are not removed make sure all the wheel nuts are tightened to the specified torque of 450 500 Ibfeft See Torque Table 4 Ifthe tire and wheel are removed recommended for aluminum wheels secure the brake drum to the hub with the wheel nuts or remove the brake drum
4. D712230 64 IFS1000 WF This page intentionally left blank D7 12230 65 IFS1000 WF Reyco Granning SUSPENSIONS ISO 9001 2008 Certified 1 800 753 0050 crate Mount Vernon MO 65712
5. 4 X 148 120 9 8757 ASY LOWER A ARM LH 4 308 LFN 1 2 13 GR G ZINC 10 8756 ASY LOWER A ARM RH 5 1001601 WSHR FLAT 1 2 X 1 06 137 JIT 11 8274318 HHB 1 2 20 X 5 GR 8 ZN 6 pee eee 12 8120384 SLW 1 2 523 X 873 X 135 ZN 712335 01 AIR SPRING RELO BRACKET LH Left hand components shown exploded Items 7 and 10 are Right Hand components 1 Please call customer service with serial number to determine which air spring and brackets you have D712230 18 IFS1000 WF Shock Components ITEM NO PART NO DESCRIPTION 1 700178 14 SHOCK ABSORBER 2 8223833 HHB 3 4 16 X 4 GR 8 ZY 3 20852 01 WSHR FLAT 3 4 X 148 120 4 178 LFN 3 4 16 GRG 5 100678 P1 HHB 3 4 10 X 3 1 2 GR 8 ZY D712230 19 IFS1000 WF Wheel End Components ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 712153 01 BRAKE ASY 15X4 16 CHAMBER LH 9 6967 INNER NUT IFS 2 712153 02 BRAKE ASY 15X4 16 CHAMBER RH 10 6968 SPINDLE LOCKWASHER IFS 3 287 HHB 5 8 18 X 1 1 2 GR 8 ZY 11 6969 WASHER SPINDLE IFS 4 7977 OIL SEAL 12 6970 SPINDLE OUTER NUT IFS 5 1784 BEARING TAPER 2 5 8 13 700024 01 HUB CAP GASKET 6 711878 01 HUB DRUM ASY 14 700017 01 HUB CAP 7 705310 01 FN M22 X 1 5 X 31 2PC LUG NUT 15 266 FHB 5 16 18 X 3 4 GR 5 ZC W LS 8 6972 BEARING TAPER 1 3 4 Left hand components shown exploded Items 2 and 4 are Right Hand components D712230
6. 5 Remove the vent plug from the hub cap Adjustment Note Some models equipped with conmet preset hubs contact customer service with serial number for specification 1 Place an oil drip tub beneath the hub to catch oil Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 2 Rotate the hub such that the drain hole faces downward and drain the oil from hub cavity Wait a few minutes for most of the oil to drain before continuing to the next step 3 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for reinstal lation Place the components in a location to prevent contamination Note that the hub cap window may be damaged by solvents IFS1000 WF hub while observing the dial indicator The end play is the total travel observed If the end play is not within 001 004 inch for standard nuts and 001 005 for preset hub adjust the wheel bearings per steps 4 16 See Figure 21 Otherwise skip to step 21 For standard nut 4 Attach a dial indicator with a magnetic base to the face of the wheel hub or brake drum The dial indicator may also be attached to the bottom of the brake drum if the wheel is d i q NA continue with step 7 15 and 21 5 Place the tip of the dial indicator 23 For preset hub skip to step on the center of the steering 16 21 knuckle spindle Set the dial in
7. Chassis Grease Rods amp Idler Arm change or every 6 months a q y Premium Multi Purpose Chassis Grease NLGI Grade 2 Auto Slack Whichever comes first Every oil Multi Purpose Chassis Grease Adudjuster change or every 6 months a A g y Premium Multi Purpose Chassis Grease NLGI Grade 2 3 Wheel End Every 1000 miles Whichever comes first Seals Gear Oil l Hub oil replaced brakes relined SAE 80W 90 or equivalent 100 000 miles 160 000 km or once a year 1 Moly disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the automatic slack adjuster 2 Use caution when using an automatic grease gun or seals could possibly be blown out and damaged 3 Only check level at ride height and only after coach has not move for 15 min or more Failure to wait will result in false readings General Lubrication Proper lubrication practices are important in maximizing the service life of your ReycoGranning Independent Front Suspension See figure 4 Z CAUTION Do not mix lubricants of different grades Do not mix mineral and synthetic lubricants Different brands of the same grade and type may be mixed ZN CAUTION Never mix oil bath and grease packed wheel ends D712230 23 IFS1000 WF Rod Ends Tie Rod and Relay Rod Ends on Tie Rods GREASE FITTINGS RIGHT SIDE SH N DUPLICATE FITTINGS ON LEFT SIDE OF UNIT Figure 4 Locations of Lubric
8. ET 4 Vels jie Uie EA o A err 5 Vehicle Towing InforiallOE sees GREG e RE ed o 6 Maintenance SOMO CUS icc esse Ro SR nn REGEER kn en T EEA E E E E cda 9 Unit SPE N EK ter pri rer N EEN EE tre 9 Control Arm ASSEMDINGS sissies RR OE EE GREG ROER Ge ie eene 10 Control AffESAPERERS SEER ER sis 11 Steering COMPON MG SS EER ee RE SE EE De rennene 1 2 Air Spring and Shock Components iese esse sees ee ee AA 18 Wheel ERSORDONGNIE oet aa k ho Panta 20 Steering Knuckle Carrier Components ie ee ee trne nn 22 EACEA as EE ee ED EE oo genase 23 Lubricant Specifications and Intervals ee ee rn 23 Greig side NE eds ie RO EE N NE N N N 23 Rod Ends on Tie BodselayRod ee non oo 24 Wheel Beers EES EE a 25 Troubleshooting se EE EE Ee nn 26 MODOC IO se ee Ee Oe AD N Di 30 General eend Oi N N EE OE EE EE EK 30 Inspecting the Control Arm Bushings for Wear ee 30 Inspecting the Tie Rod ERAS ss ER SR ED EG GR ER SR 31 Inspecting the Brake VS issie aRE Ee RE EGGO DE RR NEE De 31 Inspecting the ABS Sensor and Tone RING sesse ee esse ee ee 31 Inspecting the SHOCK ABSOIDER sees ss Eb SS GEGEE nn 32 Inspecting the Air Spring and Height Control Valve oom 33 Air Spring IS pecho ER A A EE 33 Inspecting te Idler Ai EE EK 33 P E E AE 33 Inspecting Wheel Bearing EndplaY iss sesse sesse ee Bee ee ee ee ee ee nn 34 PACI SeSe ee EE k 35 Adjusting Wiel Ed Planta EKS SEER rn 37 Adjusting Suspension Ride Heigh
9. Reference length is 17 inches 2 If the lengths of the outer tie rods are not within 1 8 inch of each other then adjust their lengths such that they are within 1 8 inch of each other Loosen the tie rod clamps on each end of the tie rod and turn the center tube to change the length 3 Adjust the length of both outer tie rods equally such that the toe in on each side is 1 16 1 32 and the overall toe in is 1 8 1 16 Tighten tie rod clamp nuts to 50 60 ft Ib See Torque Table D712230 49 IFS1000 WF Repairs General Procedures Repair or reconditioning of front suspension components is not allowed Components that are damaged or wom must be replaced Several major components are heat treated and tempered Z WARNING The components cannot be bent welded heated altered or repaired in any way without reducing the strength or life of the component and voiding the warranty The following operations are prohibited on front suspension components 1 Welding of or to the steering knuckles control arms steering arm assemblies knuckle carrier tie rod assemblies the brakes the hubs and the brake rotors 2 Hot or cold bending of the steering knuckles control arms steering arm assemblies knuckle carrier tie rod assemblies ball joints and the sub frame except control arm and steering arm assembly mounts which may be cold bent to facilitate bushing and bearing replacement 3 Drilli
10. The Castor is adjusted by using the rey align bolt located on the upper control arm SEE FIGURE 16 for detail ZN CAUTION Do not adjust the suspension ride height or alter components to adjust the caster IFS1000 WF Figure 16 Eccentric Caster Adjustment Note Movement of upper control arm towards rear will increase caster Movement of upper control arm towards front will decrease caster 1 Loosen both upper control arm mounts DO NOT REMOVE BOLTS 2 Loosen jam nuts on rey aligner and adjust to correct caster values 3 Re torque rey align bolt and nut to 350 ft lb 4 Re torque upper control arm mounts to 190 ft lb 5 Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height 6 Re measure caster and readjust as needed D712230 48 IFS1000 WF Adjusting the Toe In A CAUTION Do not alter components to adjust the toe in ZN CAUTION Improperly oriented tie rod clamps can cause binding in the suspension steering system Wheel toe in is the relationship of the distance between the centers of the front and rear of the front wheels When the front distance is less than the rear distance the wheels are toed in Toe in is designed into the suspension to counteract the tendency of the tires to toe out when the vehicle is driven straight ahead Incorrect toe in can result in rapid tire wear 1 Measure the length of the outer tie rods
11. The steering arm assemblies should not exhibit any noticeable conical motion about their pivot axes If any conical motion is observed check pivot bolt torque which should be 575 625 ft lb See Torque Table Otherwise replace the bearing set of the steering arm assembly that exhibits conical motion Figure 8 Steering Arm Assemblies Endplay Inspection 1 Install a dial indicator with a magnetic base so that the base is fixed to the steering arm assembly Place the indicator tip on the flat area of the Relay Rod adjacent the castle nut Using a C clamp squeeze the Relay Rod and the steering arm assembly together to seat the ball joint Do not apply excessive clamp load Set the dial indicator on zero IFS1000 WF 4 Release the clamp Place the pry bar between the steering arm assembly and the Relay Rod Do not allow the pry bar to contact the ball joint seal Firmly pry upward using the steering ISEND BAY arm assembly as a fulcrum to lift the pa Relay Rod The pry load must not j cause the Relay Rod to rotate thus causing the Relay Rod to change orientation 5 Record the dial indicator reading A reading greater than 040 will require ball joint replacement 6 Inspect ball joint seal for damage and replace the ball joint if damaged during measurement process Inspecting Wheel Bearing Endplay Figure 9 Wheel End Play 1 Remove the tire and wheel Measurement 2 Remove the hub cap 3 A
12. added See Figure 14 Adding shims will make a positive adjustment and removing shims with make a negative adjustment Once adjustment is made and set re torque all upper control arm bolts and nuts to 190 ft lb Remove the jack stands and lower vehicle completely Check that the suspension is at the proper ride height Re measure the camber and readjust as needed D712230 NOTE Adding shims increases camber Removing shims decreases camber IFS1000 WF Adjusting the Caster Angle Positive Caster Negative Caster FORWARD Figure 15 Caster Angle The caster angle is the angle between a vertical axis and the axis defined by the king pin when viewed from the side of the vehicle Figure 15 When the king pin axis appears rotated clockwise relative to the vertical axis then the caster is positive Positive caster creates a self aligning moment to stabilize the vehicle when driving straight ahead The caster angle is indirectly measured from the change in wheel camber as the wheel is turned through a prescribed turn angle Therefore the calculated caster is affected by the ride height of the suspension See the inspecting and adjusting suspension ride height sections before measuring caster The table below lists the recommended caster angles D712230 47 Nominal Caster Values Degrees Unloaded mad 3 1 2 FEN El 66127 Upper control arm Caster adjustment
13. aligned turn the locking washer over and re install If required loosen the inner spindle nut just enough for alignment 17 Attach a dial indicator with a magnetic base to the face of the hub See Figure 17 Note the brake drum is shown for reference only 18 Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero ZN CAUTION Never tighten the inner spindle nut to align the dowel pin with hole in locking washer This can pre load the bearings and cause premature bearing failure NOTE Do not push pull at the top and the bottom of the hub Pushing or pulling at the top and the bottom will 12 Install the replacement spindle not yield a true measurement of the end washer P N 6969 and the outer play spindle nut Tighten the outer spindle nut to 200 300 Ibfeft 15 Measure the end play by See Torque Table for sequence simultaneously pushing pulling on each side of the hub while 13 Place 2 4 Drops of oil on spindle observing the dial indicator The threads Align retainer cage tab end play is the total travel ED flat on locking spindle nut observed If the end play is not with D flat on spindle Rotate within 001 004 inch re adjust socket by hand clockwise until the wheel bearings per steps 7 locking spindle nut contacts 11 Otherwise continue to step outer bearing in hub assembly 16 Do not use powered tool to run bearing down against bea
14. and adjustment procedure Brake System The suspension system is equipped with Dana 15x4 S cam air brakes Refer to Dana maintenance manual SHA 589 1 5M service procedures IFS1000 WF Inspecting the ABS Sensor and Tone Ring 1 The wheels and may need to be removed to ease inspection of tone ring and sensor Disconnect the ABS sensor lead from the chassis connector The ABS sensor test will reguire a voltmeter that can measure AC voltage on a 0 10V scale Connect the voltmeter to the connector pins of the ABS sensor lead Set the voltmeter scale to millivolts and the voltage source to AC volts Rotate the wheel hub by hand and record the voltage output from the ABS sensor A minimum output of 0 8V AC 1s normal If the minimum voltage output is not achieved check lead wire connections and repeat Step 3 Otherwise 1f the minimum voltage output is not achieved after repeating Step 3 then go to Step 5 Check physical gap between the sensor and tone ring Figure 7 The maximum allowable gap is 027 inch If the gap is greater than 027 inch press on the wire lead end of the sensor and push the sensor into contact with the tone ring Check that the ABS spring retainer and bushing are not unseated Re seat components as needed Inspect the tone ring on the hub for physical damage and proper installation onto the hub The tone ring should have a maximum run out of 008 inch relative to the hub spind
15. bushings X X A A x A A S Check pitman arm retention nut torgue X on Esalboc Plan Check mounting bolt nut torque Inspect for signs of fluid leak or loose fasteners Xx X X X X X x Check hub bearing endplay X x Wheels Check wheel nut torque X X X X x X2 Inspect toe in X xX Front Alignment Inspect caster and camber x xX Inspect for air leaks using soapy water solution X Air Fittings and Air Lines Inspect for signs of chafing cracking or wear X X X X X X x 1 Wheel Nuts must be re tightened to proper torque specifications as per the vehicle or chassis manufacturer s Owner Guide 2 Continue to perform specified maintenance every 12 000 miles or at previous interval 3 Final stage manufacturer should complete toe in inspection and adjustment after completion of vehicle D712230 IFS1000 WF Maintenance Record Name of Owner Address of Owner Date of Purchase Name and Address of Dealer Model of Vehicle Vehicle Identification Number Suspension Model Number 1FS1000 WF Suspension Serial Number Inspection and Maintenance ltem Date Mileage Service Performed D712230 IFS1000 WF Unit Assembly ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 711792 01 Cradle Assembly 9 707819 01 Brake Assembly LH 2 8757 Lower Control Arm Ass
16. it in a container to prevent contamination Remove the hub from the spindle and place it on the floor with its stud side facing downwards Protect the wheel studs from damage Wipe the excess oil off spindle with a clean shop towel to prevent oil dripping onto the brake assembly If oil saturates or significantly contaminates the brake lining then replace the lining Remove the hub seal and discard it Inspect the axle ring on the spindle and remove it if worn Inspect the inner cup outer bearing race for the inner bearing and outer cup in the hub for damage Replace the inner cup if damaged D712230 56 Installation 1 Remove the axle ring from the replacement hub seal assembly P N 7977 if the axle ring is not removed from the spindle Note axle ring orientation Place the hub seal onto the axle ring with the ribbed rubber side facing the flange of the axle ring Seat the hub seal firmly against the axle ring flange If the axle ring is removed install the hub seal assembly with appropriate seal installation tool Reference Stemco P N 555 5098 NOTE Do not drive bearing onto spindle with a steel hammer or similar instrument Inner race is a tight slip fit with spindle 2 Place the replacement inner bearing P N 1784 onto spindle with small end of taper facing outward Seat the inner race against the step of the spindle Press the ABS sensor outward about 1 4 Do not use a sharp tool on
17. ride height to specified setting Incorrect steering arm geometry Adjust tie rod lengths as required Steering gear not centered Inspect and adjust Pitman arm as reguired Vehicle has unegual turning radius right to left Steering gear poppet valves set incorrectly Check wheel turn angles and adjust as required Tie rod clamps positioned improperly Air leak Check orientation and adjust as required Check connections with soapy water solution and repair or replace as required Check height control valve and replace as Suspension does not Internal leak in height control valve required maintain ride height Height control valve linkage loose Check and tighten linkage as required Air spring chafed or worn Check air spring and Replace as required Insufficient air pressure do to back flow Install check valves to prevent back flow Grease oil or dirt on brake shoes Replace brake shoes as required Brake shoes are glazed Deglaze brake shoes by burnishing or Replace as required Brake shoes are not a balanced set Brakes are noisy different friction codes or brand Loose or broken brake shoes Replace brake shoes as reguired Replace brake shoes as reguired Brake Drum Warped Re machine or Replace as reguired Defective Brake Drum Inspect for defects and Replace as reguired Contact Customer service at 1 800 753 0050 D 712230 29 IFS1000 WF Adjustments General Inspection Perform a thorough visual inspect
18. shims may be used Remove the upper retaining ring install the shims determined in step 9 onto the inner sleeve at upper inner race and re install the upper retaining ring Check that upper retaining ring is properly seated in the groove of the inner sleeve Place the steering arm assembly in its mount and install the pivot bolt Tighten the pivot bolt lock nut to 575 625 ft Ib See Torque Table Follow the procedures for installation of the Relay Rod or tie rod Replacing the Upper and Lower Control Arm Bushings The subframe control arm mounts may require widening to accommodate IFS1000 WF replacement bushings The width may be increased by inserting a suitable jack between the bushing mounts and cold bending the mounts Care must be taken to not exceed 5 00 width after widening The control arm mounts should be inspected for damage Both control arm bushings and mounting fasteners must be replaced in a control arm when bushings are serviced ReycoGranning recommends replacing the control arm bushings and mounting fasteners in all of the control arms at the same time The control arm housings must be properly supported during bushing removal The bores of the control arm housings may be honed to remove any burrs If the control arm is to be separated from the steering knuckle follow the removal and installation procedures in the Replacing the Ball Joint Section ZN CAUTION Use of a cutting torc
19. 0 59 The anti lock brake sensor and tone ring cannot be repaired and must be replaced if damaged or malfunctioning Sensor Removal 1 Remove the Brake Caliper to provide access to sensor 2 Press sensor out of steering knuckle Do not pull sensor out by its lead wire 3 Remove tie straps that secure the sensor lead wire and disconnect the sensor lead wire from the chassis wire harness Sensor Installation 1 Check that the sensor bushing is properly seated in the steering knuckle and the sensor spring retainer is seated properly in the sensor bushing 2 Press the sensor into the steering knuckle until the sensor end contacts the tone ring 3 Connect a volt meter to the connector pins of the sensor lead wire Set the volt meter to read AC voltage on a scale of 0 10V 4 Spin the hub by hand and read the voltage output of the sensor A minimum reading of 0 8V AC is normal Skip to step 8 if minimum reading is obtained 5 Ifthe minimum reading is not obtained then check the volt meter connection and proximity of the sensor and tone ring The air gap between the sensor and tone ring should not exceed 027 Repeat step 4 6 If the minimum reading is not obtained check the tone ring for damage and its installation The tone ring should have a maximum run out of 008 Replace as needed and repeat step 4 IFS1000 WF 7 If the minimum reading is still not obtained then replace the sensor and repeat
20. 20 IFS1000 WF Wheel End Components ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 712153 01 BRAKE ASY 15X4 16 CHAMBER LH 7 712216 01 BRAKE DRUM 15X4 2 712153 02 BRAKE ASY 15X4 16 CHAMBER RH 8 705310 01 FN M22 X 1 5 X 31 2PC LUG NUT 3 287 HHB 5 8 18 X 1 1 2 GR 8 ZY 9 700024 01 HUB CAP GASKET 4 7977 OIL SEAL included in hub asy 10 700017 01 HUB CAP 5 712211 01 PRESET HUB ASY 11 266 FHB 5 16 18 X 3 4 GR 5 ZC W LS 6 712284 01 SPINDLE NUT LOCKING D712230 21 IFS1000 WF Steering Knuckle Components ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 8745 ASY STEER KNUCKLE 12K DUC LH 8 705383 01 LOWER BALL JOINT 2 8741 MACHINED KN CASTING LH 9 705383 02 SN M30X 1 5 3 8744 ASY STEER KNUCKLE 12K DUC RH 10 705383 03 COTTER PIN 1 4 X 1 95 ZN 4 8740 MACHINED KN CASTING RH 11 7328 ABS SENSOR STRAIGHT WITH LEAD 5 705382 01 UPPER BALL JOINT 12 705011 27 SLEEVE ABS MOUNTING 6 705382 02 SN M22 X 1 5 13 6946 ABS SENSOR SPRING RETAINER 7 705382 03 COTTER PIN 5 32 X 1 40 ZN Left hand components shown exploded Items 3 and 4 are right hand components Item 1 is an assembly containing items 2 5 and 8 Item 3 not shown is an assembly containing items 4 5 and 8 D712230 22 IFS1000 WF Lubrication Lubricant Specifications and Intervals Rod Ends of Tie Whichever comes first Every oil Multi Purpose
21. 54 01 1 2 IN RUBBER CAP 5 710215 01 SODEG ELBOW O8 ORB M X 08 6 710216 01 EXTENSION 08 ORM M X 08 7 710345 01 CAP STEEL 8 FOR SHIPPING PURPOSES ONLY 1 Please call customer service with serial number to determine which gear box you have D712230 14 IFS1000 WF Idler Arm Components ITEM PART NO DESCRIPTION 1 100122 P1 LN 7 8 9 UNC STOVER GR C 1 2 102354 P1 FW 7 8 938 X 1 75 X 141 ZP 3 7331 SNAP RING 3 4 8611 SHIM 1 3 8 X 1 7 8 X 004 5 7332 BEARING SINGLE ROW ONE SEAL 6 8089 IDLER ARM MACHINED 7 89411019 GREASE FITTING 1 8 27 NPT 90 DEG s 8 7271 SLEEVE 9 292 HHB 7 8 9 X 8 50 GR 8 ZN D712230 15 IFS1000 WF IDLER ARM INSTALLED IN CRADLE D712230 16 IFS1000 WF Tie Rod Assemblies ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 711774 2684 RELAY ROD ASY 4 103712 BALL JOINT RH 2 711774 1484 TIE ROD TUBE 5 6632 TUBE CLAMP 3 103736 BALL JOINT LH 6 101445 P1 COTTER PIN TIE ROD ASSEMBLY RELAY ROD ASSEMBLY D712230 17 IFS1000 WF Air Spring Components ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION si 7593 AIR SPRING E 712210 02 AIR SPRING RELO BRACKET RH 712283 01 AIR SPRING 712335 02 AIR SPRING RELO BRACKET RH 2 178 LFN 3 4 16 GR G 8 709640 02 SFCS 1 2 13 X 1 0 3 20852 01 WSHR FLAT 3
22. RIAL 000000 GAWRILBS O monet IFS 1000 WF 10 000 J MAY BE COVERED BY THE FOLLOWING PATENTS OTHER PENDING U S 4 506 910 6 158 750 6 176 501 7 434 821 CANADA 1 194 044 Figure 2 Suspension Serial Number Tag D712230 5 IFS1000 WF Vehicle Towing Information If a vehicle is disabled and needs to be towed by the front end to service center check the OEM Coach Builder towing procedures for the recommended method Check with local authorities and Department of Transportation DOT for permissible towing methods before towing Some states do not permit towing by chains and or straps The preferred towing apparatus is the type that cradles the front tires If the towing apparatus cannot be attached to the front tires or directly to the chassis frame rails then the suspension sub frame may be used for attachment Z WARNING Attaching towing equipment to improper locations and failure to utilize OEM Coach Builder recommended towing methods could result in one or more of the following Loss of vehicle control Possible disconnection from tow vehicle Damage to the suspension and or vehicle Do Not attach tow apparatus hooks chains straps etc to suspension upper and lower control arms front cross member brake components tie rods relay rod or steering knuckle assemblies Figure 3 UPPER CONTROL ARM STEERING al Ek UPPER CONTROL KNUCKLE sA AK R STEERING KNUCKLE gt EER ES Z
23. ake shoes as required Loose or broken brakeshoes Replace brake shoes as required Brake drum warped Re machine or replace brake rotor as required Defective brake drum Inspect for defects and replace as required Brake air chamber clevis pin or camshaft Check and lubricate as required binding High spots on one set brake shoes Match machine shoes to drums with respect to opposite side Uneven brake adjustment side to side Adjust brake as required Different brake air chamber size side to side Replace with same size brake air chambers Brake chambers air pressure uneven side to side Check side to side air pressure and correct as required Rear axle brakes misadjusted or contaminated Check adjust or replace as required ABS system malfunction Check ABS system for proper function Air leak or obstruction in air brake lines Check fittings with soapy water solution and remove obstructions Brake air chamber air leak or diaphragm damaged Check chamber for air leak and damaged diaphragm Excessive water puddling on road Avoid water puddles on road Front and or rear shock absorbers worn Replace shock absorbers as required Shock mounting loose Check and tighten as required Shock eye bushings worn Check and replace as required Sway bar bushings worn Check sway bar bushings and replace as Vehicle rolls side to side required excessively Sway bar mounting brackets loose Check sway bar mounting brackets and tighte
24. an alignment machine to check the wheel turn angle See the measurement procedure of the alignment machine manufacturer The steering stop bolt on the steering knuckle controls the maximum turn angle If the stop bolt is missing bent or broken replace the stop bolt s or jam nut s and follow the procedure below for adjustment Inspect other suspension components for damage ZN CAUTION In power steering systems the hydraulic pressure should relieve or drop off when the steered wheels approach the steering stops in either direction If the pressure does not relieve the components of the front Unit Steering Stop Length A Figure 12 Steering Stop Bolt suspension may be damaged IFS1000WF 1 75 1 Drive the front tires on a suitable device that allows the front wheels to turn and measures the wheel turn angle If the steering stop bolts are adjusted to reduce wheel turn angle the steering gear poppet valves will require readjustment If the poppets are not re adjusted properly then the steering gear will not reduce power assist properly and steering components will be damaged Refer to ZF Steering Gear Service Manual for readjusting the poppets Unequal toe in side to side or an out of center steering gear can result in unequal turn angles and steering pull while steering straight ahead The Crank Rod length may be adjusted to attain steering gear on center condition while main
25. and cause premature bearing failure 13 Install the retainer washer and outer spindle nut Tighten outer spindle nut to 200 300 Ibfeft See Torque Table 14 Verify that wheel end play is between 001 004 inch See step 6 If not repeat by altering amount of inner nut back off until end play is achieved 15 Bend retainer washer over one wrench flat of the outer nut 16 Use 2 1 8 socket to loosen locking spindle nut 17 Place 2 4 Drops of oil on spindle threads Align retainer cage tab D flat on locking spindle nut with D flat on spindle Rotate socket by hand clockwise until locking spindle nut contacts outer bearing in hub assembly Do not use powered tool to run bearing down against bearing If locking spindle nut will not rotate freely on spindle nut may be cross threaded Rotate counter clockwise until threads disengage Repeat locking spindle nut installation D712230 39 18 Rotate hub assembly back and forth while tightening locking spindle nut to final torque of 300 ft lb 19 Remove socket and verify locking clip tabs have engaged the adjustment slots in retainer cage on locking spindle nut 20 Measure end play between hub assembly and spindle with dial indicator Acceptable end play between hub and spindle is 001 004 inches 21 Install hub cap gasket and hub cap Tighten the cap screws to 20 30 Ibfeft See Torque Table Replace the hub cap vent plug if remov
26. as le OE ST IR Reyco Granning Motorhome Suspensions Owners Manual E S 1000 WF Independent Front Suspension Maintenance Instructions Service Parts Document D712230 Revision OR Revision Date 11 13 Reyco Granning Suspensions 1205 Industrial Park Drive 1 800 7 53 0050 Mount Vernon MO 65712 Phone 417 466 2178 www reycogranning com N on COMPANY PROFILE Reyco Granning Suspensions was formed by the merger and acquisition of two well known names in the heavy duty vehicle suspension industry Reyco and Granning Reyco grew out of the Reynolds Mfg Co and was first known as a major supplier of brake drums for heavy duty vehicles and later developed a full line of air and steel spring suspensions for trucks busses trailers and motorhomes Granning Air Suspensions was founded in 1949 in Detroit Michigan as a manufacturer of auxiliary lift axle suspensions Granning later became an innovator of independent front air suspensions for the motorhome industry Reyco Granning LLC was formed in early 2011 through a partnering of senior managers and MAT Capital a private investment group headquartered in Long Grove Illinois Reyco Granning manufacturing facilities are certified to the ISO9001 2008 standards a globally recognized assurance that quality standards have been established and are maintained by regular rigorous audits Table of Contents Introduction EA NEE N N EE no 4 Service NO RE ER eee
27. ation Fittings D712230 24 IFS1000 WF Wheel Bearings 1 Review lubricant specification and interval requirements before servicing Check oil level through hub cap window If level is below the add level line then remove the pipe plug and fill with recommended oil until full level is achieved Figure 5 Add oil slowly since the heavy weight oil will settle slowly in the hub Check only after coach has been at rest for at least 15 minutes If coach has been moved oil may be distributed around cavity and in bearings resulting in a false low measurement 3 Check the hub cap for external oil marks The vent plug will normally weep a small amount of oil Oil marks in other locations should be addressed by replacing the hub cap seal window gasket or tightening the pipe fill plug NOTE The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window ZN CAUTION Do not remove or twist the red plug at the center of the hub cap This will damage the hub cap and cause oil to leak Add oil only thru the pipe plug or warranty will be void Figure 5 Wheel Bearing Oil Level D712230 25 IFS1000 WF Troubleshooting Tires have incorrect pressure Put specified air pressure in tires Tires wear out quickly or have Tires out of balance Balance or replace tires uneven tire tread wear Incorrect toe in setting Adjust
28. dicator on zero See Figure 10 NOTE When removing or installing the inner and outer spindle nuts use the correct wrench sockets to avoid ei ae END PLAY damaging the nuts Do not use impact driver to tighten inner and outer nuts Only use a torque wrench to tighten the nuts 7 Unbend the retainer washer and remove the spindle outer nut retainer washer and locking washer Loosen the inner spindle nut 8 Seat the bearings by tightening the inner spindle nut to 180 Ibfeft while rotating the wheel in both directions 9 Rotate the hub and drum ten 10 Figure 10 Wheel End Play Measurement complete revolutions 10 Loosen the inner spindle nut completely and then tighten the NOTE Do not push pull at the top and nut to 20 Ibfeft the bottom of the tire drum or hub Pushing or pulling at the top and the 11 Back off the inner spindle nut 1 4 bottom will not yield a true sun measurement of the end play 12 Install spindle locking washer 6 Measure the end play by simultaneously pushing pulling on each side of the tire drum or D712280 38 IFS1000 WF NOTE If the dowel pin of the inner spindle nut and a hole in the locking washer are not aligned turn the locking washer over and re install If required loosen the inner spindle nut just enough for alignment A CAUTION Never tighten the inner spindle nut to align the dowel pin with hole in locking washer This can pre load the bearings
29. ean ground or polished parts and surfaces DO NOT clean ground or polished parts with hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts IFS1000 WF Rough Parts Rough parts can be cleaned with the ground and polished parts Rough parts also can be cleaned in hot solution tanks with a weak alkaline solution Parts should remain in the hot solution tanks until they are completely cleaned Drying Parts must be dried immediately after cleaning Dry all parts with clean paper or rags or compressed air Do not dry bearings by spinning with compressed air Preventing Corrosion Apply light oil to cleaned and dried parts that are not damaged and are to be immediately assembled Do NOT apply oil to the brake pads or the brake rotors If the parts are to be stored apply a good corrosion preventative to all surfaces and place them inside special paper or containers that prevent corrosion Do NOT apply corrosion preventative to the brake pads or the brake rotors Replacing Tie Rod Ends Removal 1 Remove the cotter pins from the tie rod end ball stud s 2 Remove the castle nuts from the tie rod end ball stud s Z CAUTION Do not strike the component mating taper directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection 3 Disconnect the tie rod end ball stud from the mating component tapered hole using a su
30. ed in Preparation step 5 22 Fill the hub cavity with the appropriate amount and type of lubricant See Section 4 for lubricant specifications 23 Install vent plug Adjusting Suspension Ride Height The height control valve HCV and linkage should be checked regularly for proper clearance operation and adjustment Improperly adjusted ride height will result in incorrect wheel alignment measurements and may result in abnormal tire wear Check the ride height prior to front suspension alignment The ride height of the front suspension is the distance from the bottom of the chassis frame rail to the center of the wheel IFS1000 WF spindle An alternate measurement may be taken as the height of the air spring Figure 11 Figure 11 Measurement at Ride Height Unit Ride Height A SHOCK HT B IFS1000WF 9 377 15 597 Properly adjusted ride height results in correct suspension travel and alignment The ride height should not be adjusted to adjust chassis rake angle Z CAUTION Adjusting the ride height can cause the front end to raise or lower unexpectedly due to vertical movements at the connection of the vertical link and the horizontal arm of the height control valve Park the vehicle on a level surface Exhaust or dump and re inflate the air suspension Allow the Suspension to settle Check ride height of rear suspension A On vehicles with fro
31. embly LH 10 705951 01 Brake Assembly RH 711878 01 Hub and Drum Assembly 3 8756 Lower Control Arm Assembly RH 11 712211 01 Conmet Hub and Drum 4 711772 01 Upper Control Arm Assembly LH 12 711775 3284 Relay Rod Assembly 5 711772 02 Upper Control Arm Assembly RH 13 711775 2084 Tie Rod Assembly 712070 02 Steering Gear Assembly 6 8745 Knuckle Assembly LH 14 712070 03 Steering Gear Assy RR 7 8744 Knuckle Assembly RH 15 7593 Air Spring Assembly 8 700178 14 Shock Absorber 16 711868 01 Pitman Arm 1 Please call customer service with serial number to determine which gear box and hub assembly you have ED J D712230 9 IFS1000 WF Control Arm Assemblies ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 8757 ASY LOWER A ARM LH 5 165 HHB 1 125 12 X 7 5 GR 8 ZY 2 8756 ASY LOWER A ARM RH 6 168 HFW 1 1 8 ZP 3 711772 01 ASY UCA LH 7 166 LN 1 1 8 12 XGR C ZY 4 711772 02 ASY UCA RH 5 6X7 2 2 NS i to A I A Y x ma A 4 de A 4 j N 2 J 5 J 6 7 ae ND e NT AN Ca NZ D 712230 10 IFS1000 WF Upper Control Arm Mounts Control Arm Components ITEM PART NO DESCRIPTION 1 711771 01 ASY UCA MACHINE LH 2 711771 02 ASY UCA MACHINE RH 3 8737 Machined LCA Casting LH 4 8736 Machined LCA Casting RH 5 8382 LCA Bushing D712230 IFS1000 WF
32. erage can yield incorrect results and damage components Component damage can lead to the loss of steering control 1 With the engine on lightly rock the steering wheel and have an assistant observe any looseness in the two mating tapers or any movement of the stud nut at both ends of the tie rod If looseness is found in either place go to step 2 otherwise skip to step 3 2 Remove the tie rod end ball stud from the taper mount and visually inspect both If either of the mating tapers shows distortion or wear then both components must be replaced Torque Tie Rod Castle Nuts to 90 100 ft Ib See Torque Table 3 With the engine off and the wheels steered straight ahead grab the tie rod near its end and try to move the socket in a direction parallel to the ball stud axis Figure 6 Be sure to only apply hand pressure to the tie rod D712230 31 4 Measure the axial movement with a scale If the movement is greater than 1 8 inch 3mm replace the tie rod end immediately If the socket moves but the movement is less than 1 8 inch 3mm then the tie rod end should be replaced before 1 8 3mm movement occurs 5 Check dust boot for damage Replace as needed 6 Check tie rod clamp orientation Figure 6 Tie Rod Inspecting the Brake System The suspension system is equipped with Haldex brand automatic slack adjusters for steer axles Refer to Haldex technical service guideline 485 89007 for inspection
33. ft blank D712230 62 IFS1000 WF Torque Tables Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of fasteners for a given application To assure continued satisfactory vehicle performance replacement fasteners used Identification should be of the correct strength as well as the correct nominal diameter thread pitch length and finish Grade Markings on Lock Nuts Grade 8 Torque Table 1 ee Torque Specification ft lb 950 1050 EF Torque applied to fastener head Apply thread adhesive Loctite 242 or equivalent to threads of fastener Install cotter pin after properly torquing nut Stake nut to steering gear output shaft a Locate notch in output shaft b Use punch or dull chisel to drive raised section of pitman arm nut into notch in output shaft c Take care not to tear raised section of pitman arm nut while staking h 7 2 3 4 D712230 63 IFS1000 WF Torque Tables Torque Table 2 TORQUE SPEC APPLICATIONS FASTENER SIZE ft lb CLEAN AND TORQUE SEQUENCE DRY Torque Plate Mount 7 Cap Screws 5 8 18 Grade 8 170 190 Hub Cap Bolt 5 16 18 Grade 5 20 30 M22x1 5 450 500 wngelNut Hub Piloted Dry Threads 1 Torque applied to bolt head 2 Recheck Wheel Nut torque after first 50 100 miles
34. h to remove control arm bolts will permanently damage control arm bushings and can result in damage to subframe Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement ZN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands D712230 53 under the lower control arms to support the vehicle 3 Remove the tires and check that the air springs are deflated Upper Control Arm 1 Disconnect height control valve linkage from the upper control arm Follow the removal procedure in Replacing the Height Control Valve Section A WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm or removing the control arm with the steering knuckle attached 2 If desired disconnect the upper control arm from the steering knuckle Follow the removal procedure in Replacing the Upper Ball Joint Section 3 Loosen and remove the control mount arm bolts Remove any existing eccentric components Note the orientation of the set screws for reinstallation 4 Press the bushing out of the control arm housing Be sure to properly
35. il Rotate the hub such that the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and place it in a container for re installation 2 Rotate the hub such that the drain hole faces downward and drain the oil from hub cavity Wait a few minutes for most of the oil to drain before continuing to the next step 3 Remove the hub cap bolts hub cap and gasket Take care not to damage the gasket for re installation Place the components in a location to prevent contamination Note that the hub cap window may be damaged by solvents Skip to step 5 for Ax Lock hub NOTE When removing or installing the inner and outer spindle nuts use the correct wrench sockets to avoid damaging the nuts Do not use impact driver to tighten inner and outer nuts Only use a torque wrench to tighten the nuts 4 Unbend the spindle washer and remove the spindle outer nut spindle washer locking D washer and the inner spindle IFS1000 WF 10 nut Retain all components for re assembly except discard the spindle washer For Ax Lock use 2 1 8 socket to remove hub nut and continue with step 6 Place a shop towel on top of the lower brake shoe to prevent oil from dripping onto the brake lining Tug sharply on the hub to unseat the outer bearing without completely removing the hub Wipe up any oil spilled on the brake assembly as quickly and completely as possible Remove the outer bearing and place
36. ines replace as required Excessive internal steering gear leakage Note Engine must be running for Tires have incorrect pressure Put specified air pressure in tires Vehicle is difficult to steer Install correct tire and wheel combination Steering arm assembly ball joints binding Inspect ball joints for wear and replace as required D712230 26 IFS1000 WF Vehicle overloaded or unevenly loaded Check wheel loads and correct as required driver side to passenger side Ve hicle wanders side to Improper mismatched tires and wheels Install correct tire and wheel combination side loose steering Tires have incorrect pressure Put correct air pressure in tires based on Steering wheel has large wheel load amplitude rotational j Incorrect toe in setting Adjust toe in to specified setting oscillations when hitting large bumps Incorrect wheel caster setting Adjust wheel caster to specified setting Tie rod end connection loose or ball stud Inspect ball stud connections and wear worn Steering arm assembly mounts loose Check and tighten to specification Steering arm assembly ball joints binding Inspect ball joints for wear or contamination or worn and replace as required Wheel bearings out of adjustment Check wheel bearing end play and adjust as required Loose steering gear mounting Check mounting and secure as required Check pitman arm and tighten as required Steering gear lash adjustment Check and adjust to specification S
37. ion of the suspension to ensure proper assembly and to identify broken parts and loose fasteners each time the vehicle suspension is serviced Do the following during an inspection Wheel Alignment Follow the guidelines in the Front Wheel Alignment section for wheel alignment inspection intervals Check wheel alignment if excessive steering effort vehicle wander or abnormal tire wear is evident Fasteners Check that all the fasteners are tightened to the proper tightening torque Use a calibrated torque wrench to check torque Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all wom or damaged components Operation Check that all components move freely through the complete wheel turning arc ZN CAUTION Reyco Granning LLC recommends replacing any damaged or out of specification components Reconditioning or field repairs of front suspension components is prohibited Some cast components are heat treated These components as well as other non heat treated castings cannot be bent welded heated or repaired in any way without reducing the strength or life of the component thus voiding the warranty Only genuine ReycoGranning replacement components are allowed D712230 Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not p
38. itable tool D712230 51 4 Inspect the tie rod end ball stud and mating component tapered hole s Replace components with worn tapered hole s If the grease seal is damaged during removal replace it before installation Installation 1 Clean the mating component tapered hole s of any contamination Insert the tie rod end ball stud into the tapered hole and secure it with the castle nut A CAUTION Tighten the castle nuts to the specified torque If the castle nuts are not tightened to the specified torque the parts will be damaged and serious personal injury may occur 2 Tighten the castle nut to 90 100 ft lb See Torque Table 3 Install the cotter pins If necessary tighten the castle nut to align the hole in the ball stud and slots in the castle nut Do not loosen the castle nut to install the cotter pin 4 Lubricate tie rod end as needed IFS1000 WF Replacing the Idler Arm Bearings Replace the idler bearings in sets The replacement bearings should be installed by pressing on the outer raceway only Pressing on the inner raceway will damage the bearing The inner grease cavity of the steering arm assemblies should be cleaned when the bearings are replaced Removal 1 Follow the procedures for removal of the center rod pitman arm and idler arm Follow the procedures for removal of tie rod ends for the idler arm Remove the pivot bolts that mount the idler arm Remove them fr
39. lace jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury The vehicle may be supported on safety stands by the suspension sub frame or chassis frame for inspections that require removal of the wheel and tires or deflation of the air springs Always secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement before inspections Inspecting the Control Arm Bushings for Wear It is recommended that the bushings in all of the control arms be replaced at the same time if one is found worn 1 Check clearance between each control arm and sub frame bushing mount Look for contact pattern as evidence of bushing wear Replace worn bushings in both control arm housings as needed 2 Check for bushing bulging between the control arm and sub frame mount or presence of small rubber particles near sub frame bushing mount IFS1000 WF 3 Check that the control arm mounting bolts are tight Recommended torque is 465 485 ft lb for lower control arms and 950 1050 ft lb for upper control arms See Torque Table A loose joint will result in wear between the bushing inner sleeve and sub frame mount Inspecting the Tie Rod Ends Z WARNING Do not use a wrench or other object to apply leverage when inspecting tie rod end sockets Applying lev
40. le centerline D712230 10 Repeat Step 3 If voltage output is less than 0 8V AC then replace the ABS sensor NOTE Check voltage output of new sensor 1 0271 MAX Figure 7 ABS Sensor and Tone Ring Gap 92 Inspecting the Shock Absorber 1 Check shock absorbers for oil leakage bent components missing or broken components excessive corrosion or worm bushings Replace shock absorbers if any of the above items is present IFS1000 WF Inspecting the Air Spring Air Spring Inspection 1 Refer to Firestone s Preventative Maintenance Checklist for additional air spring information Check the outside diameter of the air spring for irregular wear or heat checking Check airlines to make sure contact does not exist between the airlines and the outside diameter of the air spring Re secure airlines to prevent contact as needed Check for airline and fitting leaks with soapy water solution Check to see that there is a minimum of 1l inch clearance around the circumference of the air spring while it is energized with air Check the air spring piston for buildup of foreign material Remove any foreign material that is present Inspecting the Idler Arm 1 Check that steering arm assembly pivots are free of foreign material and bearing seals are in place D712230 2 Start vehicle engine Oscillate the steering wheel and observe the motion of the steering arm assemblies see figure 8
41. lead wire end of the sensor See section 3 for the inspection of ABS sensor as needed Place the hub onto the spindle until it seats on the inner bearing Do not ram the hub onto the seal Place the replacement outer bearing onto the spindle until it seats on the outer cup in the hub The inner spindle nut may be used to guide the bearing onto the spindle The hub should be supported to prevent misalignment and binding For Ax Lock hub skip to step 13 16 Install the inner spindle nut and tighten hand tight IFS1000 WF 7 Seat the bearings by tightening be cross threaded Rotate counter the inner spindle nut to 180 clockwise until threads Ibfeft while rotating the wheel in disengage Repeat locking both directions spindle nut installation 8 Rotate the hub and drum ten 10 14 Rotate hub assembly back and complete revolutions forth while tightening locking spindle nut to final torque of 300 9 Loosen the inner spindle nut ft lb completely and then re tighten the inner nut to 20 Ibfeft 15 Remove socket and verify locking clip tabs have engaged the 10 Back off the inner spindle nut 1 4 f E ean adjustment slots in retainer cage i on locking spindle nut 11 Install the spindle locking D ae esla 16 Measure end play between hub assembly and spindle with dial indicator Acceptable end pl NOTE If the dowel pin of the inner an de E on spindle nut and a hole in the locking 0G inches washer are not
42. linkage Follow the installation procedure in Replacing the Height Control Valve Section Lower Control Arm 1 Disconnect the lower shock mount from the lower control arm Follow the removal procedure in Replacing the Shock Section D712230 54 A WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm or removing the control arm with the steering knuckle attached If desired disconnect the lower control arm from the steering knuckle Follow the removal procedure in Replacing the Lower Ball Joint Section Loosen and remove the control mount bolts Press the bushing out of the control arm housing Be sure to properly support the housing Inspect the housing bores and remove any burrs in the housing by honing Press the bushing into the control arm housing Be sure to properly support the housing Place the control arm in its mount location Install the control arm mount bolts into subframe snug tight Support the control arm such that it is at ride height and tighten the bolts to 950 1050 Ibfeft See Torque Table Reconnect the steering knuckle to the lower control arm if disconnected Follow the installation procedure in Replacing the Lower Ball Joint Section IFS1000 WF 10 Reconnect the lower shock mount Follow the installation procedure i
43. mponents You must follow your company safety procedures and use proper safety equipment when you service or repair the suspension The information contained in this manual was current at the time of printing and is subject to change without notice or liability ReycoGranning reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation ReycoGranning uses the following types of notices for potential safety problems and to give information that will prevent damage to equipment Z WARNING A warning indicates procedures that must be followed exactly Serious personal injury can occur if the procedure is not followed ZN CAUTION A caution indicates procedures that must be followed exactly Damage to equipment or suspension components and personal injury can occur if the procedure is not followed A note indicates an operation procedure or instruction that is important for correct service D712230 4 IFS1000 WF Identification The suspension model and serial number are stamped on an aluminum tag that is riveted to the front of the suspension sub frame assembly Figure 1 The serial number is used by ReycoGranning for control purposes and should be referred to when servicing the suspension or requesting technical support Figure 2 Figure 1 Suspension Identification Location Reyco mee u Granning Es SUSPENSIONS SE
44. n Replacing the Shock Section Replacing Wheel Bearings Oil Seals and Hub Caps Preparation 1 Set the parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground See jacking instructions Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle ZN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Ifthe wheel nuts have chrome covers remove them with special pliers equipped with plastic non marring jaws Place them in a container to prevent damage or loss 4 On aluminum wheels place a plastic anti scuff guard over the wheel nuts and loosen the wheel nuts On steel wheels remove the hub cap nuts if present and the hub cap before loosening the wheel nuts Place the hub cap in safe location to prevent damage Place the wheel and or hub cap nuts in a container to prevent contamination or loss D712230 55 5 Remove the wheel and tire assembly and place it aside Mark the tire to ensure it can be identified for installation on same side as removed 6 Remove the brake drum and place it aside Mark the brake drum to ensure it can be identified for installation on same side as removed Removal 1 Place an oil drip tub beneath the hub to catch o
45. n and check the following before conducting front wheel alignment measurements Wheels and Tires 1 Check that the front tires are inflated to the appropriate pressure based on the tire loading Check that the front tires are the same size and type Check that the wheel and tire assemblies are balanced Check that all the Wheel Nuts are tightened to the specified torque of 450 500 ft Ib See Torque Table Front Suspension 1 Check that all fasteners are tightened to the specified torgue Check the suspension ride height and adjust as needed to the specified height Check for worn ball joints tie rod ends steering arm assembly bearings control arm bushings knuckle carrier bearings and damaged suspension components Replace wom components as needed After readjusting the steering stop s check that the steering poppets are reset properly and that the front tires do not contact the frame suspension or body Also check that other components are not abnormally contacting one another D712230 42 IFS1000 WF 4 Check for loose ball joint and tie rod end tapered connections tie rod end jam nuts steering arm assembly mounts and chassis steering system components Inspect connections for wear and replace as needed Tighten connections as needed 5 Check the wheel bearing adjustment and adjust as needed 6 Inspect the shock absorbers for wear and damage Rear Axle and Suspension Front
46. n as required Control arm pivot bushings worn Inspect and replace as required Internal leak in height control valve Check height control valve and replace as required ABS sensor malfunction Inspect ABS sensor installation and replace sensor as reguired Front tires lock up during hard braking or ABS ABS CPU or system malfunction malfunction light remains lit ABS sensor electrical connection faulty Tone ring on hub damaged Check and repair or replace as required Check ABS sensor connection and lead wire Check for damage and replace as required D712230 28 IFS1000 WF Front shock absorbers worn Vehicle ride is too harsh Incorrect ride height and or suspension contacts vehicle overloaded stops excessively Replace shock absorbers as required Adjust ride height to specified setting Check wheel loads and correct as required Check air line connections and remove obstructions Air spring supply lines leaking or obstructed Vehicle system air pressure below specification Check air pressure and correct as required Rebound bumper worn or missing Check and replace as required Jounce bumper in air spring worn or Check and replace air spring as required broken Vehicle air pressure insufficient Install check valves to prevent air back flow Vehicle ride is too soft Insufficient load Add load to increase spring rate Front shock absorbers worn Replace shock absorbers as required Incorrect ride height Adjust
47. ng out control arm and steering arm assembly mounting holes and ball stud tapered holes 4 Spray welding of bearing diameters on the steering knuckle spindle steering arm assembly bores and pivot tube Spray welding of ball studs or tapered holes for the ball joint and tie rod ends 5 Milling or machining of any component except that control arm bushing bores may be honed to remove any burrs D712230 Z WARNING Never work under a vehicle supported by only a jack s Jacks can slip or fall over and cause serious personal injury Always use safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury The vehicle may be supported on safety stands by the suspension sub frame or chassis frame for repairs that require removal of the wheel and tires or deflation of the air springs Always secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement before performing repairs Cleaning the Parts A WARNING If you use cleaning solvents hot solution tanks or alkaline solutions incorrectly serious personal injury can occur To prevent injury follow the instructions supplied by the manufacturer Do NOT use gasoline to clean parts Gasoline can explode Ground or Polished Parts Use a cleaning solvent to cl
48. not allowed and may cause unequal load sharing between the air Lower control arm may move downward due to the internal gas charge in the shock absorber A portable jack may be needed to align the lower control arm with the knuckle carrier bar pin springs and cause adverse handling characteristics ride and Removal 1 Drain the air from the supply reservoir on the chassis connected to the front suspension 2 Disconnect the vertical HCV linkage from the horizontal arm 3 Mark airlines and connections for re assembly Disconnect the airlines from the HCV If any other plumbing fixtures are connected to the HCV mark them for re assembly D712230 61 4 Remove the HCV mounting hardware from the sub frame 5 Remove any other air fittings or plumbing fixtures from the HCV Installation 1 Apply Permatex or equivalent thread sealant to the threads of the air connection fittings or plumbing fixtures and install the fittings or plumbing fixtures in the HCV 2 Attach the HCV to the sub frame with mounting hardware Orient the horizontal arm horizontally and tighten the mounting nuts to 7 9 ft Ib See Torque Table 3 Connect airlines as marked during removal 4 Connect the vertical linkage to the horizontal arm 5 Recharge system with air and check for air leaks 6 Check the ride height and adjust per section on adjusting the ride height as needed IFS1000 WF This page intentionally le
49. nstalled The use of a substitute air spring is not allowed and may cause unequal load sharing between the air springs and cause adverse ride and handling characteristics Removal 1 Deflate the air spring by disconnecting one end of the vertical HCV linkage from the horizontal arm Rotate the horizontal HCV arm downward and secure it in place 2 Disconnect the airline at the air spring inlet port and remove the connection fitting from the inlet port 3 Remove the bolts and washers from the upper air spring mount studs Note location of bolts and washers 4 Remove the bolts that secure the air spring to the lower air spring mount Installation 1 Attach air spring to upper air spring mount Note that the shorter bolt is located towards the front Tighten mounting hardware snugly 2 Attach air spring to lower air spring mount Tighten lower mounting bolts to 20 30 ft Ib See Torque Table IFS1000 WF 3 Tighten the upper mounting bolts to 15 20 ft lb See Torque Table 4 Apply Permatex or equivalent thread sealant to the threads of the air connection fitting and install the fitting Connect the airline to the fitting 6 Inflate the air spring by un securing the HCV _ horizontal arm and reconnecting the vertical linkage to it 7 Check the airline and fitting for air leaks Replacing the Height Control Valve The correct height control valve HCV must be installed The use of a substitute HCV is
50. nt suspension equipped with 2 height control valves check and adjust the rear suspension first D712230 40 B On vehicles with front suspension equipped with a single height control valve check and adjust the rear suspension after finish adjusting the front 4 Measure either the wheel center to bottom of frame A or air spring height B If the dimensions are not within 1 8 of measurements in Figure 11 adjust as follows A Loosen the height control valve linkage stud retaining nuts B Raise or lower the L shaped linkage stud as necessary C Tighten the retaining nuts NOTE It is recommended that the upper and lower studs be positioned parallel to each other Torque to 8 12 ft lb 5 After adjusting the length it is recommended to dump and re inflate the air suspension to obtain the ride height Allow the suspension to settle 6 If not already completed adjust the rear suspension per manufacturer s recommendations 7 Verify at each axle that the side to side ride heights are within 25 of each other Adjusting the Maximum Wheel Turn Angle Z CAUTION Do not adjust maximum wheel turn angle greater than 42 59 Mis adjustment of the wheel turn angle can cause damage to steering system components IFS1000 WF The turn angle may require adjustment if the front tires rub against the frame suspension body or the steering gear has been serviced or replaced Use
51. ole If abnormal wear exists on the ball stud taper or in the tapered hole replace the upper control arm Secure steering knuckle in a vise or similar device Loosen the ball joint and remove it from the Upper Ball Joint Installation Thread In Mount Inspect the threads in the steering knuckle and remove any burrs or debris Apply thread adhesive Loctite 242 or equivalent to the ball joint threads and thread the ball joint into the steering knuckle Tighten the base of the ball joint to 325 375 lbfeft See Torque Table Follow steps 6 8 for press in mount type Lower Ball Joint Removal 1 Remove the cotter pin from the ball stud 2 Remove the castle nut from the ball stud D712230 ZN WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm 3 Disconnect the lower control arm The ball stud may be forced from the tapered hole by use of a suitable tool ZN CAUTION Do not strike the lower control arm directly with a steel hammer Parts can break and cause serious personal injury Wear eye protection Inspect the ball joint taper and upper control arm tapered hole If abnormal wear exists on the ball stud taper or in the tapered hole replace the lower control arm Secure steering knuckle in a vise or similar device Loosen the ball joint and remove it from the steering knuckle
52. om the sub frame Remove the retaining rings from the pivot sleeve and remove the sleeve A rubber or brass hammer may be used to remove the sleeve Retain shims Support the steering arm assembly bearing housing and press the bearing out of each end Installation 1 Clean out the steering arm assembly grease cavity Inspect steering arm assembly bearing housing bores and remove burrs by honing Replace steering arm assembly if the bore is damaged Pack the steering bearing with grease arm assembly Support the steering arm assembly bearing housing and press the bearing into each end The seal side of the bearing should face out D712280 52 Nn 10 11 12 Inspect the pivot sleeve and remove burrs with emery cloth Install one retaining ring onto pivot sleeve Insert the pivot sleeve into the lower bearing Use a rubber mallet or similar tool to drive the inner sleeve into the bearings such that the bottom retaining ring is seated against the bottom inner race Do not use a steel hammer to install the sleeve because bearing raceways can be damaged Install upper retaining ring Reseat lower retaining ring against the lower inner race as needed Determine the number of shims needed by stacking the shims and placing the stack between the upper retaining ring and inner race until a snug fit is achieved Remove one shim from the stack and this is the number of shims needed A maximum of six
53. orgue Table for seguence Replace the hub cap nuts and hub caps if removed to service the wheel bearings Remove jack stands and jacks IFS1000 WF Replacing Brake Components Brake Drums The brake drums should be replaced if they are damaged or exceed the drum manufacturers recommended maximum diameter or runout specification Refer to manufacturer brake drum guidelines for inspection and specifications Automatic Slack Adjuster The automatic slack adjusters are not serviceable and should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the automatic slack adjuster Brake Chambers The brake air chambers should be replaced if damaged or malfunctioning Refer to manufacturer guidelines for correct function of the brake air chambers Other Brake Components The brake shoe linings should be replaced when they are worn beyond the manufacturers limits When the brake linings are serviced other components such as the S cam rollers and return springs should also be serviced Refer to the brake manufacturers guidelines for servicing the brakes Replacing the ABS Sensor and Tone Ring The anti lock brake system ABS of the vehicle should be diagnosed by a qualified technician before the anti lock brake sensor or the tone ring is replaced Replacement parts must be equivalent to the vehicle manufacturers to ensure proper function of the anti lock brake system D71223
54. record the individual wheel camber caster and toe in of the front suspension Also measure and record the cross camber cross caster and overall toe in 5 If adjustment to camber and caster is required then follow the steps below Otherwise go to the Adjusting the Toe In section to adjust the toe in as needed D712230 44 IFS1000 WF Adjusting the Camber Angle NEGATIVE POSITIVE CAMBER CAMBER Figure 13 Camber Angle Camber is the angle of the wheel with respect to the ground as viewed from the front or rear of the vehicle Figure 13 Camber is positive when the distance between centers of the front wheels at the top is greater than the distance at the ground Wheel Camber Angle is affected by the ride height of the suspension If the ride height is set too high then the camber measurement will be more positive See the inspecting and adjusting suspension ride height sections before measuring camber The table below lists the recommended camber angles Upper Control Arm Camber Adjustment To adjust camber the upper control arm mounts will need to be loosened and shims D712230 45 will need to be added or removed Nominal Camber Values Degrees Unloaded depending if positive or negative adjustment is needed IFS1000 WF Figure 14 Upper Control Arm Camber Adjustment Loosen both upper control arm mounts DO NOT REMOVE BOLTS This will allow shims to be removed or
55. ring If locking spindle nut will not rotate freely on spindle nut may D712230 57 IFS1000 WF Figure 18 Wheel Bearing Oil Level Figure 17 Wheel End Play Measurement 20 Install the hub cap drain plug 16 Bend the spindle washer over 21 Check the hub cap for external 17 18 19 one wrench flat of the outer nut Install the hub cap gasket and hub cap Tighten the cap screws to 20 30 Ibfeft See Torque Table for sequence Fill the hub cavity with the appropriate amount approx pint and type of lubricant 90W gear oil Check oil level through the hub cap window See Figure 18 If level is below the add level line then fill with recommended oil until full level is achieved Add oil slowly since the heavy weight oil will settle slowly in the hub Note The hub cap window can only be cleaned with mild soap and water Aromatic solvents should not be used as they will impair the transparency of the window D712230 22 23 24 25 26 oil leakage at the drain plug or gasket For leaks at the drain plug check for application of thread sealant to threads and tightness For leaks at the gasket replace the gasket The vent plug will normally weep a small amount of oil Install the brake drum Install the wheel and tire assembly and the wheel nuts On aluminum wheels use a plastic anti scuff guard over the wheel nuts Tighten the wheel nuts to 450 500 Ibfeft See T
56. rol arms and to remove the ball joints from the steering knuckle A suspension alignment should be performed after ball joint replacement NOTE Be careful to not displace or damage ball joint seals during removal from the control arm taper hole Preparation D712230 35 1 Set the parking brake and block the drive wheels to prevent vehicle movement 2 Raise the vehicle until the front wheels are off the ground Support raised vehicle with safety stands Do not place jacks or safety stands under the lower control arms to support the vehicle ZN WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands 3 Remove the tires and check that the air springs are deflated Upper Ball Joint Removal Thread In Mount 1 Remove the cotter pin from the ball stud 2 Remove the castle nut from the ball stud ZN WARNING The steering knuckle is heavy and unevenly balanced Use a portable crane or suitable jack to support it prior to disconnecting it from the control arm 3 Disconnect the upper control arm The ball stud may be forced from the tapered hole by use of a suitable tool IFS1000 WF CAUTION Do not strike the upper control arm directly witha steel hammer Parts can break and cause serious personal injury Wear eye protection Inspect the ball joint taper and upper control arm tapered h
57. se Es Ee ge ran a GO ee SS Ee ae ge ba oe honor Eg 59 Brake banier a 59 Other Brake OC OmpOnEMtS EE ES a Re DR Ge Ee Ge RR oan 59 Replacing the ABS Sensor and Tone Ring sees see ee ee RA ee ee 59 A vated wet ede 59 Sensor Installationschs e v 59 Tone Ring Removal and Installation 20 0 0 ce see se ee ee RA Re ee RA RA Re ee ee ee ee ee 60 Replacing the Shock Absorber iss ee ED EE Re GE ER Re eN EE es Rd Ak Eg 60 TOS 60 Instala i 60 Replacing the Air Sri aia DE Sie 60 Removal eaan a E ee ee Ptr Ree ae a e eer en a 60 D712230 2 IFS1000 WF Table of Contents A OM EE EG ke NU O L 60 Replacing the Height Control Valve des dd 61 A hehe side nae in DE EG A A 61 Stalin A na 61 Lorque Table ainia ni OS D712230 3 IFS1000 WF Service Notes This Service Manual describes the correct service and repair procedures for the ReycoGranning IFS1000 WF Independent Front Suspension model with 10 000 lb Gross Axle Weight Rating GAWR Overloading the suspension may result in adverse ride and handling characteristics You must read and understand all procedures and safety precautions presented in this manual before conducting any service work on the suspension Proper tools must be used to perform the maintenance and repair procedures in this manual Some procedures require the use of special tools for safe and correct service Failure to use the proper and or special tools when required can cause personal injury and or damage to suspension co
58. support the housing 5 Inspect the housing bores and remove any burrs in the housing by honing 6 Press the bushing into the control arm housing Be sure to properly support the housing 7 Place the control arm in its mount location If not equipped with eccentrics install the control arm IFS1000 WF mount bolts into subframe snug tight and skip to step 15 8 Place the spacer into the bushing 10 11 12 13 14 15 16 17 18 Insert an eccentric adapter on each end of the upper control arm mounting plate Place bolt and washer through the spacer and bushing as shown Install washer and locking nut Repeat the process for the rear upper control arm mounting bolt Rotate the eccentric adapters on the front mounting bolt such that the set screws are located as previously orientated Vehicle alignment may have to be checked Please refer to Section 5 When the eccentric adapters are properly oriented tighten the bolts Support the control arm such that it is at ride height and tighten the bolts to 950 1050 Ibfeft without eccentrics or 460 490 Ibfeft with eccentrics See Torque Table Install and tighten the set screw on any eccentrics installed to 30 40 Ibfein Refer to Torque Table Reconnect the steering knuckle to the control arm if disconnected Follow the installation procedure in Replacing the Upper Ball Joint Section Reconnect the height control valve
59. t esse ese see ee ee ee ed 39 Adjusting the Maximm Wheel Turn Angle iss sesse ees ee see ee ee 40 Inspection before Alignment ooooooononnn nn 42 a and TIE carre D712230 1 IFS1000 WF Table of Contents Front SUSPCHSIOM sos eo Re alee Geen Waleed ae ee hee tees 42 Rear Ase and SUS Pen sini Se as 43 Front Wheel Aloe ds Ee ES N V nen 43 EdOIDRERE ss er E A ad 43 Es RE EE RE RE EE 43 A i aa 44 Adjusting the Camber Angle ssa u TE 45 Adjusting the Caster Ame EE ae Ge St a Ee N aoni 47 Adjusting the Tos Marti Ge DR Ee ke ino Re 49 Repair ER OE EE E Genera Pro CS TES rd 50 Clea ino tie Pants on dai 50 Ground ot Polished Pants ica 50 Rowe Parts EE Ee Re 51 D r TA Notas ORE A S 51 Preventine COMM OSIOM se Ee ER se RA sa oo nula o hav 51 Replacing Tie Rod Enda ss Deeds es ke se ees eke N ee GE GE en ee 51 IRATON I EA O 51 Ed Eie sd ER EE EE EE ean 51 Replacing the Idler AM as i Tu 52 IRC TTY AN sco ure EN LAE OR EE OE KUR OR EG 52 An ENE ole sis ore asp O AE EE ED ts 52 Replacing the Upper and Lower Control Arm BushingS esse ese ee se 52 Upper Control Arm Removal ET SEE Ee au erase va 33 Upper Control Arm Installation anda iria 53 bower omtrol Atm Remo 54 Lower Control Arm Installation resten a aae aE aRt 54 Replacing Wheel Bearings Oil Seals and Hub CapS sesse sesse esse ee se ke ee 55 Removal ME ER OR OR ibn 55 MIDGET Deo See SG o 55 Replacing Brake Components ies VEE gese IE rn 59 Brake ROTS
60. taining equal toe in side to side Do not adjust the length of the Crank Rod or Tie Rods to center the steering wheel This can cause the steering gear to become off center D712230 41 IFS1000 WF Secure the vehicle by setting the parking brake and block the drive wheels to prevent vehicle movement Check that the steering gear is centered and the tires are steered straight ahead with equal toe in side to side If either of these two conditions is not met then adjust toe in first before centering the steering gear See Adjusting the Toe In Section and refer to pitman arm center mark alignment info Check that the lengths of the outer tie rods are equal to each other within 1 8 inch If not adjust lengths according to the adjusting the toe in section before adjusting the steering stops Turn the steering wheel until the steering stop bolt contacts the knuckle carrier or the steering wheel stops turning Measure the turn angle of the wheel on the same side as the direction of turn If the wheel turn angle differs then adjust as follows Loosen the jam nut on the stop bolt Turn the stop bolt until the specified wheel turn angle is achieved and the bolt head contacts the knuckle carrier Tighten the jam nut to 50 75 ft lb See Torque Table Z CAUTION 10 Repeat checking and adjustment for turning the opposite direction See Figure 12 Inspection before Alignment See the General Inspection sectio
61. teering column misaligned Realign steering column as required Loose Wheel Nuts Check and tighten to specification Unequal ride height side to side Inspect ride height and adjust to specified setting Improper brake adjustment Inspect and adjust slack adjusters as required Incorrect rear axle alignment Align rear axle to specified thrust angle Incorrect caster and or camber setting Check and adjust as required Rd ha de doc i i without the brakes applied Improper mismatched tires and wheels Install correct tire and wheel combination Vehicle overloaded or unevenly loaded Check wheel loads and correct as required driver side to passenger side Tires have incorrect pressure Put correct air pressure in tires based on wheel load Wheel bearings out of adjustment Check wheel bearing end play and adjust as required Loose steering gear mounting Check mounting and secure as required Tie rod end connection loose or ball stud Inspect ball stud connections and wear worn Boot contact w bottom of steering column Inspect Repair Adjust as required Steering column linkage worn Check for wear and repair or replace as required D712230 27 IFS1000 WF Grease oil or dirt on brake pads Vehicle pulls to one side Brake shoes are glazed with the brakes applied Replace brake shoes as required Deglaze brake shoes by burnishing or replace as required Brake shoes are not a balanced set different friction codes or pad brand Replace br
62. the installation procedure 8 Route and secure the sensor lead wire the same as the removed sensor 9 Connect the sensor lead wire to the chassis Secure wire lead to prevent damage during suspension movement Tone Ring Removal and Installation Follow the hub manufacturer s guidelines for removal and installation of the tone ring Replacing the Shock Absorber Z CAUTION The shock absorber is gas pressurized and must not be punctured or be subjected to excessive heat which can result in serious personal injury The shock will expand to its full extended length if not restrained Removal 1 Remove the lower shock thru bolt mounting hardware and retain for installation Do not remove the lower shock mount bracket from the lower control arm 2 Remove upper shock bushing mounting hardware and retain for installation Note location and quantity of washers and spacers Installation 1 Loosely attach upper shock bushing to sub frame with mounting hardware spacers on forward side of shock D712230 60 2 Position shock in suspension such that the thru bolt is connected to the lower shock mounting bracket tabs 3 Tighten lower thru mounting bolt and nut to 170 190 ft Ib See Torque Table Tighten lower shock bracket mounting bolts to 30 40 ft lb See Torque Table 4 Tighten upper mounting nut to 170 190 ft Ib See Torque Table Replacing the Air Spring The correct air spring must be i
63. tire wear and incorrect steering can be caused by the rear axle and or suspension 1 Check that all fasteners are tightened to the specified torque 2 Check the suspension ride height and adjust as needed to specified height 3 Check that all connection joints between the suspension and axle are secure 4 Check for worn suspension bushings or damaged suspension components 5 Check that the rear axle is correctly aligned Check that the frame is not bent 7 Refer to any additional recommendations and specifications from the manufacturer of the chassis on rear axles and suspensions Total vehicle alignment is recommended when aligning the front suspension Front Wheel Alignment D712230 Equipment ReycoGranning recommends that suitable alignment equipment be used to measure the wheel alignment characteristics camber caster and toe in The alignment equipment must be properly calibrated for accurate measurements Only qualified personnel should conduct the wheel alignment measurements General The overall toe in of the front wheels should be checked every 24 000 miles or 2 years When the vehicle does not steer correctly or the front tires develop an abnormal tire wear pattern the camber caster and toe in should be measured and adjusted as needed Toe in typically has the largest effect on tire wear The maximum wheel turn angle should be checked and adjusted as needed Shims between the
64. toe in to specified setting Note Wear pattern will indicate incorrect ride height Adjust ride height to specified setting possible cause s Consult tire manufacturer for Incorrect caster camber adjustment Adjust caster camber guidance Incorrect steering arm geometry Adjust tie rod lengths as required Improper mismatched tires and wheels Install correct tire and wheel combination Improper oversized tires Install correct tire and wheel combination power steering to be active Incorrect steering arm geometry Adjust tie rod lengths as required and able to provide i F steering assist Steering arm assemblies binding Check steering arm assembly bearings and lubricate as required Tie rod ends binding Inspect tie rod ends for wear and lubricate as required Steering column linkage binding Align or adjust as required Steering miter box binding Check steering miter box and repair or replace as required Steering gear valve binding Inspect repair or replace as required Steering wheel to column interference Align or adjust as required Power steering pump fluid level low Add fluid tighten connections and correct as and or possible leak in system required Power steering pump pressure and flow Conduct pump flow and relief pressure tests below specification and adjust repair or replace as required Air in power steering system Add fluid tighten connections and bleed system Inspect remove obstruction s and repair or or within hydraulic l
65. ttach a dial indicator with a magnetic base to the face of the hub 4 Place the tip of the dial indicator on the center of the steering knuckle spindle Set the dial indicator on zero Figure 9 Do not push pull at the top and the bottom of the hub Pushing or pulling at the top and the bottom will not yield a true measurement of the endplay 5 Measure the endplay by simultaneously pushing pulling on opposite sides of the hub while observing the dial indicator The endplay is the total travel observed If the endplay is not within 001 005 see the section on adjusting the wheel bearing endplay D712230 34 IFS1000 WF Replacing the Ball Joints Ball joints may be replaced individually however it is recommended to replace upper and lower ball joints at the same time The ball joints cannot be rebuilt or repaired Thread In Mount The thread in mount type upper and lower ball joints are installed with a thread adhesive and may require the threads to be warmed to ease removal If heat is applied to the ball joint threads the steering knuckle temperature must not exceed 300 F and the heat should be applied at the bottom of the ball joint base only Applying heat to the ball joint will damage the ball joint by destroying the ball stud seal permanently degrading the lubricant and restricting ball stud movement It is recommended that the appropriate tools be used to remove the ball stud taper from the cont
66. upper control arm mounts are used for additional adjustment of camber Add and remove as needed The ray align on the upper control arm will adjust castor to minimize drifts or pulls to one side of the road IFS1000 WF Preparation Z WARNING 1 Follow the alignment equipment manufacturer s procedures for Never work under a vehicle supported preparing the vehicle for front and rear by only a jack s Jacks can slip or fall wheel alignment measurements over and cause serious personal injury 2 Secure the vehicle by setting the Always use safety stands Do not place parking brake and block the drive jacks or safety stands under the lower wheels to prevent vehicle movement control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle drop causing serious personal injury An out of center steering gear can 6 Raise the vehicle until the front wheels result in unequal wheel turn angles are off the ground Support the raised The steering gear should remain vehicle with safety stands centered during toe in adjustment Do not adjust the length Tie Rods to center the steering wheel This can cause the steering gear to become off center 3 Check that the steering gear is centered when the tires are steered straight ahead i e equal toe in side to side Center the steering gear according to the pitman arm center marks on the steering box 4 Measure and

IFS1000-WF I&M Manual

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IFS1000-WF I&amp;M Manual

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IFS1000-WF I&M Manual