ifs1200, ifs1320, ifs1370 independent front suspension service manual

ifs1200, ifs1320, ifs1370 independent front suspension service manual
IFS1200, IFS1320, IFS1370
INDEPENDENT FRONT
SUSPENSION SERVICE
MANUAL
D9834 Rev. N
10/07
Service Notes
This Service Manual describes the correct service and repair procedures for the
ReycoGranning® IFS1200/1320/1370 Independent Front Suspension.
The information contained in this manual was current at the time of printing and is
subject to change without notice or liability.
You must follow your company safety procedures when you service or repair the
suspension. Be sure you read and understand all the procedures and instructions before
you begin work on the suspension.
Granning uses the following types of notes to give warning of possible safety problems and
to give information that will prevent damage to equipment.
WARNING
A warning indicates procedures that must be followed exactly. Serious personal
injury can occur if the procedure is not followed.
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.
NOTE
A note indicates an operation, procedure or instruction that is important for
correct service.
Some procedures require the use of special tools for safe and correct service. Failure to use
these special tools when required can cause personal injury or damage to suspension
components.
ReycoGranning® Air Suspensions reserves the right to modify the suspension and/or
procedures and to change specifications at any time without notice and without incurring
obligation.
i
Table of Contents
SUBJECT
PAGE
1. Introduction..................................................................................... 1
Identification ....................................................................................1
Description .......................................................................................2
Service Part ......................................................................................8
Tow Point Locations.........................................................................9
2. Troubleshooting ............................................................................ 10
3. Inspection ....................................................................................... 14
General Inspection .........................................................................14
Checking the Ball Joint Axial End Play........................................14
Checking the Control Arm Bushings for Wear .............................17
Checking the Tie Rod Ends............................................................18
Checking the Automatic Slack Adjusters and Brake System ......18
Checking the ABS Sensor and Tone Ring .....................................19
Checking the Shock Absorber ........................................................20
Checking the Air Spring and Height Control Valve .....................20
Checking the Steering Damper .....................................................21
Checking the Steering Arm Bearings............................................21
Checking the Rebound Bumper Stop.............................................21
4. Lubrication and Maintenance.................................................... 22
Lubrication Specification and Intervals ....................................... 22
General Lubrication .......................................................................22
Ball Joints ......................................................................................22
Ball Studs on Tie Rods, Relay Rod, and Drag Link ......................22
Bell Crank and Idler Steering Arms .............................................23
Brake S-Cam Tube and Automatic Slack Adjuster.......................23
Wheel Bearings and Hub Cap........................................................24
Maintenance Schedule ...................................................................25
Maintenance Record.......................................................................26
ii
Table of Contents
SUBJECT
PAGE
5. Adjustments and Alignment ....................................................... 27
Adjusting the Suspension Ride Height .........................................27
Checking and Adjusting the Wheel Bearings ...............................29
Adjusting the Maximum Turn Angle ............................................30
Inspection Before Alignment .........................................................32
Front Wheel Alignment .................................................................33
Adjusting Camber Angle................................................................34
Adjusting Caster Angle ..................................................................35
Adjusting the Toe-In ......................................................................36
6. Repair .............................................................................................. 38
Repair of Parts ...............................................................................38
Cleaning of Parts............................................................................38
Replacing the Drag Link................................................................39
Replacing the Relay Rod and Outer Tie Rods ...............................39
Replacing the Ball Joints ...............................................................41
Replacing the Bell Crank and Idler Steering Arm Bearings........44
Replacing the Upper and Lower Control Arm Bushings ..............45
Replacing Wheel Bearings, Oil Seals, and Hub Caps ...................47
Replacing Brake Components........................................................51
Replacing the ABS Sensor and Tone Ring ....................................51
Replacing the Rebound Bumper Stop............................................52
Replacing the Shock Absorber .......................................................52
Replacing the Air Spring ...............................................................54
Replacing the Steering Damper.....................................................55
Replacing the Suspension Subframe .............................................56
Replacing the Height Control Valves ............................................56
Replacing the Sway Bar.................................................................58
7. Torque Specifications .................................................................. 59
8. Special Ball Joint Tools ................................................................61
iii
Section 1
Introduction
Introduction
Identification
ReycoGranning® Air Suspensions has
developed this service manual to aid in
the maintenance of ReycoGranning’s®
Independent Front Suspensions installed
on Spartan Motors chassis. These
suspensions incorporate the latest in
design and manufacturing technologies.
The suspensions have been designed and
tested to provide improved ride and
handling compared to I-beam type axles.
The suspension model and serial number
are stamped on an aluminum tag that is
riveted to the driver side steering arm
mount on the subframe assembly. (See
Figure 2). The serial number is used by
ReycoGranning® for control purposes and
should be referred to when servicing the
suspension. (See Figure 1).
Overloading the suspension may result in
adverse ride and handling characteristics.
Model
Capacity
1
IFS1200-SP
12,000 lbs.
IFS1200-SP2
12,000 lbs.
2
IFS1200-S2
12,000 lbs.
IFS1200S-SB2,3
12,000 lbs.
IFS1200S22
12,000 lbs.
IFS1200S2-SB2,3
12,000 lbs.
IFS1320-SP1
13,200 lbs.
2
IFS1320-HP
13,200 lbs.
IFS1370-HP2
13,700 lbs.
2,3
IFS1370S-SB
13,700 lbs.
1 Stud Piloted Wheels
2 Hub Piloted Wheels
3 Sway Bar Equipped
Figure 1: Suspension Identification
Figure 2: Suspension Identification Location
1
Section 1
Introduction
Description—Structural Components
Item
1
2
Part No.
7257
Description
Item
Part No.
13
292
Hex Head Bolt, 7/8”-9 x 8.5”, Gr. 8
14
293
Socket Set Screw, #10-24 x .38”
Subframe Assembly (Non-Sway Bar units)
702906-01 Subframe Assembly (Sway Bar units)
8757
Lower Control Arm Assembly, LH
15
Description
702897-01 Eccentric Boss
3
8756
Lower Control Arm Assembly, RH
16
8490
Bushing Sleeve Spacer
4
7260
Upper Control Arm Assembly, LH
17
6975
Upper Ball Joint (Press In)
18
291
Hardended Flat Washer, 3/4”
5
6
7
7261
Upper Control Arm Assembly, RH
8745
Steering Knuckle Assembly, LH (IFS1200)
*
8747
Steering Knuckle Assembly, LH
(IFS1200S2 / IFS1320 / IFS1370)
19
705382-01 - Ball Joint (40mm) (Thread In)
8744
Steering Knuckle Assembly, RH (IFS1200)
20
705382-02 - Castle Nut, M30 x 1.5
8746
Steering Knuckle Assembly, RH
(IFS1200S2 / IFS1320 / IFS1370)
21
705382-03 - Cotter Pin, 1.50 x .15 Dia.
K705382 Kit, Ball Joint (40mm)
8
8382
Bushing
*
9
165
Hex Head Bolt, 1 1/8”-12 x 7 1/2”, Gr. 8
22
10
166
Lock Nut, 1 1/8”-12, Gr. C
23
705383-02 - Castle Nut, M24 x 1.5
11
168
Hardened Flat Washer, 1 1/8”
24
705383-03 - Cotter Pin, 1.95 x .24 Dia.
12
K705383 Ball Joint Kit (65mm)
705383-01 - Ball Joint (65mm)
100122-P1 Lock Nut, 7/8”-9, Gr. C
Note: The IFS1200 may be equipped with either Press In style or Thread In style Upper Ball Joints (Items 17 & 19). When
ordering replacement parts, please note which style is installed in your suspension.
*Ball Joint kits for service use. The kits’ subcomponents may not be ordered individually.
20
4
16
15
1
7
5
18
8
21
14
13
6
17 19
10
9
11
22
2 3
23
2
24
Castle nuts and
Cotter Pins are
part of the Ball
Joint Kit.
Section 1
Introduction
Description—Steering Components
Item
Part No.
Description
Item
Part No.
Description
1
7780
Steering Damper Assembly
13 89430596 Hex Head Bolt, 7/8”-9 x 7-1/2”, Gr. 8
2 701546-01 U-Bolt, 3/8”-24, Gr. 5
14 100122-P1 Lock Nut, 7/8”-9, Gr. C
3
89422298 Lock Nut, 3/8”-24, Gr. 8
15 102354-P1 Hardened Flat Washer, 7/8”
4
263
Hardened Flat Washer, 3/8”
16
8611
Shim
5
7332
Bearing
17
8089
Idler Arm
6
7271
Sleeve
18
8090
Bell Crank
7
7331
Snap Ring
7256
Drag Link Assy, 31 3/8” L – See Note Below
8
8223511 Steering Stop Bolt, 5/8”-11 x 1 1/2”, Gr. 8
7948
Drag Link Assy, 43 3/8” L – See Note Below
19
9 100276-P1 Steering Stop Jam Nut, 5/8”-11, Gr. 5
8277
Drag Link Assy, 45 1/4” L – See Note Below
10
7352
Grease Fitting
8355
Drag Link Assy, 39 7/8” L – See Note Below
11
7254
Outer Tie Rod Assembly
20 701748-01 Steering Damper Mount Bracket Assembly
12
7638
Relay Rod Assembly
21 101445-P1 Cotter Pin, 1/8 x 1-1/2
Note: The IFS1200 may be equipped with various length drag links depending on the chassis front overhang. Measure
length of drag link when ordering replacement parts.
3
Section 1
Introduction
Description—Air Spring and Shock Absorber Assy.
Item
Part No.
Description
7593
Air Spring Assembly (IFS1200)
1 703667-01 Air Spring Assembly (IFS1200S2)
700136-01 Air Spring Assembly (IFS1370)
8295
HCV* and Linkage Assy. (Ridewell)
8451
HCV* Assy., Left, (Hadley)
2
8452
HCV* Assy., Right, (Hadley)
8718
HCV* Assy., (Neway)
8257
Shock Absorber (IFS1200)
3
8643
Shock Absorber (IFS1370)
4 100678-P1 HHB 3/4-10 x 3.50” Gr. 8 ZN
5 100703-P1 Lock Nut, 1/4”-20, Gr. C
6 701671-01 HHB 3/4-10 x 4.50” Gr. 8 ZN
7
208
LFN 3/4-10 Gr. G
700049-01 Hex Head Bolt, 1/2”-13 x 4.25”, Gr. 5(IFS1200)
8
700137-01 Hex Head Bolt, M12-1.75 x 110,Gr. 10.9(IFS1370)
* HCV: Height Control Valve
Note: See sway bar part list section
for height control valve components
used on sway bar equipped
suspensions.
4
Item
Part No.
9
10
11
12
13
14
15
8103323
8120378
8219758
8131017
7327
100507-P1
8273802
230
100702-P1
8120392
701747-01
8719
16
17
18
Description
Lock Washer, 1/2”
Hex Nut, 1/2”-13, Gr. 5
Jam Nut, 3/4”-16, Gr. 5
Flat Washer, 3/4”
Rebound Stop
Hex Head Bolt, 5/16”-18x1”, Gr. 8
Serrated Flange Nut, 5/16”-18, Grade G
Hex Head Bolt, 1/4”-20x3”, Gr. 8 (Hadley)
Hex Head Bolt, 1/4”-20x1”, Gr. 8 (Neway)
Flat Washer, 1/4”
Height Control Valve Linkage Assy, (Hadley)
Height Control Valve Linkage Assy, (Neway)
Section 1
Introduction
Item
1
2
3
4
5
6
7
8
9
Qty.
2
1
4
2
8
2
2
1
4
Part No.
263
8719
8120392
89422298
89422299
100702-P1
100703-P1
701546-01
702797-01
Description
HFW 3/8 .406x.812x.065
Linkage, HCV
FW 1/4 .281x.625x.065 ZP
LN 3/8-24 Gr. 8
LN 7/16-14 UNC Gr. 8
HHB 1/4-20x1 Gr. 8 ZN
LN 1/4 Stover Gr. 8 Plated
U-Bolt
FHB 7/16-14x1.25 Gr. 8 ZP
Item
10
11
12
13
14
15
16
17
18
Qty.
4
1
4
2
2
8
1
1
1
Part No.
702797-02
702892-01
702894-01
702895-01
702895-02
702898-01
703286-01
703356-01
TC197
Top View
(Side rails and other
components removed
for clarity.)
INSTALL SWAY BAR WITH
UNIT AT RIDE HEIGHT
5
Description
HHB 7/16-14 x 1.5 Gr. 8 ZP
Sway Bar
Mount, D-Ring, Sway Bar
Bushing, Solid, Sway Bar
Bushing, Split, Sway Bar
Washer, Sway Bar
HCV w/ Smaller Dead band
Arm, HCV
Aqua Shield Grease Sway Bar
Section 1
Introduction
Description—Wheel End Components
Item
Part No.
1
2
3
4
5
1784
N/A
6972
N/A
7977
1779
6
7
Description
Item
Inner Bearing Cone
Inner Bearing Cup
Outer Bearing Cone
Outer Bearing Cup
Hub Seal
Hub Cap (IFS1200, 1320, 1370-SP)
14
700017-01 Hub Cap (IFS1200, 1320, 1370-HP)
1786
Hub Cap Gasket (IFS1200, 1320, 1370-SP)
700024-01 Hub Cap Gasket (IFS1200, 1320, 1370-HP)
8
6967
Inner Spindle Nut
9
10
11
12
13
6968
6969
6970
266
N/A
Spindle Lock Washer
Spindle Washer
Outer Spindle Nut
Hub Cap Bolt, 5/16”-18 x 3/4”, Gr. 5
Lug Nut (refer to Hub and Drum)
Part No.
6943
15
8493
16
17
18
6
Description
Hub and Drum Assembly, LH and RH, Hub
705015-01
Piloted, 15x4 Brakes (IFS1200-HP)
Hub and Drum Assembly, LH, Stud Piloted,
6942
15x4 Brakes (IFS1200-SP)
Hub and Drum Assembly, Hub Piloted,
705088-01 16.5x5 Brakes, LH and RH (IFS1320, 1370HP)
Hub and Drum Assembly, LH, Stud Piloted,
8494
16.5x5 Brakes (IFS1320, 1370-SP)
7328
7329
6946
Hub and Drum Assembly, RH, Stud Piloted,
15x4 Brakes (IFS1200-SP)
Hub and Drum Assembly, RH, Stud Piloted,
16.5x5 Brakes (IFS1320, 1370-SP)
ABS Sensor
ABS Bushing
ABS Spring Retainer
Section 1
Introduction
Description—Wheel End Service Part List
Description
Model
ReycoGranning®
P/N
Recommended
Vendor
Vendor P/N
Inner Bearing Cone
Inner Bearing Cup
Outer Bearing Cone
Outer Bearing Cup
Hub Seal & Axle Ring
Inner Spindle Nut
Both
Both
Both
Both
Both
Both
1784
N/A
6972
N/A
7977
6967
Spindle Lock Washer
Both
6968
Spindle Washer
Both
6969
Spindle Outer Nut
Both
6970
IFS1200,
IFS1320-SP
IFS1320-HP
7324
Timkin
Timkin
Timkin
Timkin
Stemco (Gardian)
Rockwell
(or Euclid)
Rockwell
(or Euclid)
Rockwell
(or Euclid)
Rockwell
(or Euclid)
Dual Dynamics
HM 212049
HM 212011
3782
3720
308-0836
1227-L-194
(E-2299)
1229-G-475
(E-2297)
1229-F-474
(E-2298)
1227-B-106
(E2296)
DG-6PS
Many
1779
Dual Dynamics
(Stemco)
Stemco
DG6-F4.5S
(343-4024)
343- 4009
IFS1200,
IFS1320-SP
IFS1320-HP
Many
8377
Stemco
330-3122
N/A
1786
Stemco
Stemco
330-3024
330-3009
IFS1200-SP
6942
15-15556-059,
1521FKZKLT-10
15-15632-305,
25291JK4T-10
15-15556-111
15-15556-058,
1521FKZKRT-10
15-15556-110
15-15632-167
Wheel End Components
Hub Cap(Stud Pilot)
Hub Cap(Hub Pilot)
Hub Cap(Hub Pilot 705015-01 and 705088-01
Hub and Drum Assy)
Hub Cap Gasket(Stud Pilot)
Hub Cap Gasket(Hub Pilot)
Hub Cap Gasket(Hub Pilot 705015-01 and
705088-01 Hub and Drum Assy)
7483
Hub and Drum Components
LH Hub & Drum Assy.(Stud Pilot 15x4 Brake)
Hub & Drum Assy.(Hub Pilot 15x4 Brake)
IFS1200-HP
Hub & Drum Assy.(Hub Pilot 15x4 Brake)
IFS1200-HP
LH Hub & Drum Assy.(Stud Pilot 16.5x5 Brake) IFS1320, 1370-SP
RH Hub & Drum Assy.(Stud Pilot 15x4 Brake)
IFS1200-SP
7784
705015-01
8494
6943
RH Hub & Drum Assy.(Stud Pilot 16.5x5 Brake) IFS1320, 1370-SP
Hub & Drum Assy.(Hub Pilot 16.5x5 Brake)
IFS1320, 1370HP
Hub & Drum Assy.(Hub Pilot 16.5x5 Brake)
IFS1320, 1370HP
LH Hub Assy.(Stud Pilot)
IFS1200,
IFS1320-SP
RH Hub Assy.(Stud Pilot)
IFS1200,
IFS1320-SP
Hub Assy.(Hub Pilot)
IFS1320-HP
Brake Drum 15x4(Stud Pilot)
IFS1200
8493
8456
Dayton Walther,
Webb
Dayton Walther
Webb
Dayton Walther
Dayton Walther,
Webb
Dayton Walther
Dayton Walther
705088-01
Webb
25201G54T-10
8881
Dayton Walther,
Webb
Dayton Walther,
Webb
Dayton Walther
Dayton Walther,
Webb
Dayton Walther
Dayton Walther
05-15556-003,
1521F--PLT
05-15556-002,
1521F--PRT
05-15632-004
85-123382-002,
65541B
85-123370-002
85-123383-002
Brake Drum 16.5x5(Hub Pilot)
Brake Drum 16.5x5(Stud Pilot)
IFS1320-HP
IFS1320-SP
7
8880
8882
8639,
8376
8642
8641
Section 1
Introduction
Description—Brake Service Part List
Description
Model
ReycoGranning®
P/N
Recommended
Vendor
Vendor P/N
Both
Both
Both
7328
7329
6946
Rockwell-Wabco
Midland
Rockwell Wabco
441 032 900 0
101328-AB
899 760 510 4
IFS1200
IFS1200
IFS1200
8315
8316
8300
Dana
Dana
Dana
150WD126-5
150WD126-6
150KB129X
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Dana
Dana
Dana
Dana
Dana
Dana
Dana
Dana
Dana
150KB100 X
150KB101 X
150KB102 X
150KB106 X
150KB115 X
150WK103 5
150WK102 5
150WR115 1
150WR105 2
8407
8408
8645
Dana
Dana
Dana
165WD389-3
165WD389-4
165WN126-4X
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Dana
Dana
Dana
Dana
Dana
Dana
Dana
165KB100X
150KB116X
150KB117X
165WK111-5
165WK110-5
165WR130-1
165WR136-1
IFS1200
IFS1200
IFS1200
703957-01
703957-02
700036-07
Dana
Dana
Dana
329464
329465
N/A
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
IFS1200
700036-05
700036-06
N/A
N/A
N/A
N/A
Dana
Dana
Dana
Dana
Dana
Dana
127808
326514
974683
974682
974840
819471
IFS1320
IFS1320
IFS1320
703958-01
703958-02
700033-07
Dana
Dana
Dana
329466
329467
N/A
IFS1320
IFS1320
IFS1320
IFS1320
IFS1320
IFS1320
700036-05
700033-06
N/A
N/A
N/A
N/A
Dana
Dana
Dana
Dana
Dana
Dana
127808
808330
808709
808708
165WR130-1
819472
ABS Components
ABS Sensor
ABS Bushing
ABS Spring Retainer
XL15x4 Brake Components (prior to June 1999 Mfg. Date)
LH Brake Assy., 15x4 *
RH Brake Assy., 15x4 *
Brake Relining Kit(Shoe & Lining Asy and
Spring Kit;1 Side)
S-Cam Seal and Bushing Kit(1 Side)
Spring Kit(1 Side)
Dust Shield Kit(1 Side)
S-Cam Roller & Spring Kit(1 Side)
S -Cam Roller, Spring, & Lining Kit(1 Side)
RH S-Camshaft
LH S-Camshaft
Air Chamber Assy.(Type 16)
Automatic Slack Adjuster
XL16.5x5 Brake Components (prior to June 1999 Mfg. Date)
LH Brake Assy., 16.5x5 *
IFS1320
RH Brake Assy., 16.5x5 *
IFS1320
Brake Relining Kit(Shoe & Lining Asy and
IFS1320
Spring Kit;1 Side)
S-Cam Seal and Bushing Kit(1 Side)
IFS1320
Spring Kit(1 Side)
IFS1320
S-Cam Roller & Spring Kit(1 Side)
IFS1320
RH S-Camshaft
IFS1320
LH S-Camshaft
IFS1320
Air Chamber Assy.(Type 20)
IFS1320
Automatic Slack Adjuster
IFS1320
* Components no longer available. Replace with ES assemblies.
ES1504D 15x4 Brake Components
LH Brake Assy., 15x4
RH Brake Assy., 15x4
Brake Relining Kit(Shoe & Lining Asy and
Spring Kit;1 Side)
S-Cam Seal and Bushing Kit(1 Side)
S-Cam Roller & Spring Kit(1 Side)
RH S-Camshaft
LH S-Camshaft
Air Chamber Assy.(Type 20)
Automatic Slack Adjuster
ES1655D 16.5x5 Brake Components
LH Brake Assy., 16.5x5
RH Brake Assy., 16.5x5
Brake Relining Kit(Shoe & Lining Asy and
Spring Kit;1 Side)
S-Cam Seal and Bushing Kit(1 Side)
S-Cam Roller & Spring Kit(1 Side)
RH S-Camshaft
LH S-Camshaft
Air Chamber Assy.(Type 20)
Automatic Slack Adjuster
8
Section 1
Introduction
towing apparatus may not be connected to
any subframe area or suspension
component other than that shown in
Figure 3. Connecting to other subframe
areas or suspension components can
result in suspension damage or
disconnection of vehicle while being
towed.
Tow Point Locations
If a vehicle is disabled and needs to be
towed by the front end to a service center,
the towing apparatus may be attached to
the suspension subframe in the
designated locations, as shown in Figure
3. The towing apparatus should be
attached securely for safe towing. The
Figure 3: Tow Point Locations
9
Section 2
Troubleshooting
Suspension System--General
SYMPTOMS
POSSIBLE CAUSES
Tires wear out quickly or have uneven tire
tread wear.
1) Tires have incorrect pressure.
1) Put specified air pressure in tires.
2) Tires out of balance.
2) Balance or replace tires.
Note: Wear pattern will indicate possible
cause(s). Consult tire manufacturer for
guidance.
Vehicle is difficult to steer.
REMEDIES
3) Incorrect toe-in setting.
3) Adjust toe-in to specified setting.
4) Incorrect ride height.
4) Adjust ride height to specified setting.
5) Incorrect rear axle alignment.
5) Align rear axle to specified thrust
angle.
6) Incorrect steering arm geometry.
6) Adjust tie rod lengths as required.
7) Improper(mismatched) tires and
wheels.
7) Install correct tire and wheel
combination.
1) Improper oversized tires.
1) Install correct tire and wheel
combination.
2) Tires not uniform.
2) Install correct tire and wheel
combination.
3) Tires have incorrect pressure.
3) Put specified air pressure in tires.
4) Incorrect steering arm geometry.
4) Adjust tie rod lengths as required.
5) Steering arms binding.
5) Check steering arm bearings and
lubricate as needed.
6) Ball joints binding.
6) Inspect ball joints for wear and
replace as required.
7) Tie rod ends binding.
7) Inspect tie rod ends for wear and
lubricate as needed.
8) Steering column linkage binding.
8) Align or adjust as required.
9) Steering miter box binding.
9) Check steering miter box and repair or
replace as required.
10) Steering gear valve binding.
10) Inspect, repair or replace as required.
11) Steering damper binding or
malfunction.
11) Check and replace as needed.
12) Steering wheel to column
interference.
12) Align or adjust as required.
13) Power steering pump fluid level low
and possible leak in system.
13) Add fluid, tighten connections and
correct as needed.
14) Power steering pump pressure and
flow below specification.
14) Conduct pump flow and relief
pressure tests and adjust , repair or
replace as needed.
15) Air in power steering system.
15) Add fluid, tighten connections and
bleed system.
16) Contaminated or incorrect fluid.
16) Replace with correctly specified fluid.
17) Obstruction within steering gear or
lines.
17) Inspect, remove obstruction(s) and
repair or replace as required.
18) Excessive internal steering gear
leakage.
18) Inspect, repair or replace as required.
10
Section 2
Troubleshooting
Suspension System--General (Cont’d)
SYMPTOMS
POSSIBLE CAUSES
REMEDIES
Vehicle wanders side to side-loose
steering.
1) Vehicle overloaded or unevenly
loaded.
2) Improper(mismatched) tires and
wheels.
3) Incorrect toe-in setting.
4) Tires have incorrect pressure.
5) Loose steering gear mounting.
1) Check wheel loads and correct as
needed.
2) Install correct tire and wheel
combination.
3) Adjust toe-in to specified setting.
4) Put specified air pressure in tires.
5) Check mounting and secure as
needed.
6) Inspect ball stud connections and
wear.
7) Check and tighten to specification.
8) Inspect ball joints for wear or
contamination and replace as
required.
9) Check for wear and repair or replace
as needed.
10) Check wheel bearing end play and
adjust as required.
11) Check and adjust to specification.
12) Realign steering column as required.
13) Check and replace as needed.
Steering wheel has large amplitude,
rotational oscillations when hitting large
bumps.
6) Tie rod end connection loose or ball
stud worn.
7) Loose wheel nuts.
8) Ball joints binding or worn.
9) Steering column linkage worn.
10) Wheel bearings out of adjustment.
11) Steering gear adjustment.
12) Steering column misaligned.
13) Steering damper binding or
malfunction.
14) Steering arm mounts loose.
Vehicle pulls to one side without the
brakes applied.
1) Improper(mismatched) tires and
wheels.
2) Tires have incorrect pressure.
3) Vehicle unevenly loaded.
4) Improper brake adjustment.
5) Incorrect rear axle alignment.
6) Unequal ride height side to side.
7) Wheel bearings out of adjustment.
8) Loose steering gear mounting.
9) Tie rod end connection loose or ball
stud worn.
10) Bent spindle or steering arm.
11) Frame or underbody out of alignment.
12) Incorrect toe-in setting.
13) Misaligned belts in radial tires.
14) Steering gear valve binding.
15) Steering gear not centered.
16) Excessive internal steering gear
leakage.
17) Incorrect caster and/or camber
setting.
11
14) Check and tighten to specification.
1) Install correct tire and wheel
combination.
2) Put specified air pressure in tires.
3) Check wheel loads and correct as
needed.
4) Inspect, adjust and correct as
required.
5) Align rear axle to specified thrust
angle.
6) Inspect ride height and adjust to
specified setting.
7) Check wheel bearing end play and
adjust as required.
8) Check mounting and secure as
needed.
9) Inspect ball stud connections and
wear.
10) Inspect and replace as required.
11) Inspect and correct as required.
12) Adjust toe-in to specified setting.
13) Check and replace as needed.
14) Inspect, repair or replace as required.
15) Inspect and adjust as required.
16) Inspect, repair or replace as required.
17) Install and/or adjust eccentric
adapters in upper control arm.
Section 2
Troubleshooting
Suspension System--General (Cont’d)
SYMPTOMS
POSSIBLE CAUSES
REMEDIES
Vehicle pulls to one side with the brakes
applied.
1) Grease, oil or dirt on brake linings.
1) Replace brake linings as required.
2) Brake linings are glazed.
2) Deglaze brake linings or replace as
required.
3) Brake linings are not a balanced set,
different friction codes or lining brand.
3) Replace brake linings as required.
4) Loose or broken brake linings.
4) Replace brake linings as required.
5) Brake drum out of round.
5) Re-machine brake drum as required.
6) Defective brake drum.
6) Inspect for defects and replace as
required.
7) Brake air chamber clevis pin or
camshaft binding.
7) Check and lubricate as needed.
8) Defective slack adjuster.
8) Inspect for defects and replace as
required.
9) Uneven brake adjustment side to
side.
9) Adjust slack adjuster as required.
10) Different brake air chamber size or
slack adjuster length side to side.
10) Replace with same size brake air
chambers and length slack adjusters.
11) Air pressure uneven side to side.
11) Check side to side air pressure and
correct as needed.
12) Unequal brake air chamber stroke
side to side.
12) Check side to side stroke and adjust
as required.
Vehicle rolls side to side excessively.
Front tires lock up during hard braking or
ABS malfunction light remains lit..
13) Rear axle brakes misadjusted.
13) Check and adjust as required.
14) Air leak or obstruction in air brake
lines.
14) Check fittings with soapy water
solution and remove obstructions.
15) Brake air chamber air leak or
diaphragm damaged.
15) Check chamber for air leak and
damaged diaphragm.
1) Front and/or rear shock absorbers
worn.
1) Replace shock absorbers as needed.
2) Shock mounting loose.
2) Check and tighten as required.
3) Shock eye bushings worn.
3) Check and replace as needed.
4) Control arm pivot bushings worn.
4) Inspect and replace as required.
5) Internal leak in height control valve.
5) Check height control valve and
replace as required.
1) ABS sensor malfunction.
1) Inspect ABS sensor installation and
replace sensor as required.
2) ABS CPU or system malfunction.
2) Check and repair or replace as
required.
3) ABS sensor electrical connection
faulty.
3) Check ABS sensor connection and
lead wire.
4) Tone ring on hub damaged.
4) Check for damage and replace as
required.
12
Section 2
Troubleshooting
Suspension System--General (Cont’d)
SYMPTOMS
POSSIBLE CAUSES
REMEDIES
Vehicle ride is too harsh and/or
suspension contacts stops excessively.
1) Front shock absorbers worn.
1) Replace shock absorbers as needed.
2) Incorrect ride height.
2) Adjust ride height to specified setting.
3) Vehicle overloaded.
3) Check wheel loads and correct as
needed.
4) Air spring supply lines leaking or
obstructed.
4) Check air line connections and
remove obstructions.
5) Vehicle system air pressure below
specification.
5) Check air pressure and correct as
needed.
6) Rebound bumper worn or missing.
6) Check and replace as needed.
7) Jounce bumper in air spring worn or
broken.
7) Check and replace air spring as
required.
Vehicle ride is too soft.
1) Front shock absorbers worn.
1) Replace shock absorbers as needed.
2) Incorrect ride height.
2) Adjust ride height to specified setting.
Vehicle has unequal turning radius right to
left.
1) Incorrect steering arm geometry.
1) Adjust tie rod lengths as required.
2) Steering gear not centered.
2) Inspect and adjust as required.
3) Steering gear poppet valves set
incorrectly.
3) Check wheel turn angles and adjust
as required.
1) Air leak.
1) Check connections with soapy water
solution and repair or replace as
needed.
2) Internal leak in height control valve.
2) Check height control valve and
replace as required.
Suspension does not maintain ride height.
Brakes are noisy.
3) Height control valve linkage loose.
3) Check and tighten linkage as needed.
4) Air spring chafed or worn.
4) Check air spring and replace as
needed.
1) Grease, oil or dirt on brake linings.
1) Replace brake linings as required.
2) Brake linings are glazed.
2) Deglaze brake linings or replace as
required.
3) Brake linings are not a balanced set,
different friction codes or lining brand.
3) Replace brake linings as required.
4) Loose or broken brake linings.
4) Replace brake linings as required.
5) Brake drum out of round.
5) Re-machine brake drum as required.
6) Defective brake drum.
6) Inspect for defects and replace as
required.
7) Excessive dirt build up in brake drum
cavity.
7) Remove excessive dirt from brake
drum cavity.
13
Section 3
Inspection
General Inspection
CAUTION: All cast components
are heat treated. These components cannot be bent, welded,
heated, or repaired in any way
without reducing the strength
or life of the component;
voiding the warranty; and may
cause a vehicle accident which
can result in serious personal
injury.
Perform a thorough visual inspection of
the suspension to ensure proper assembly
and to identify broken parts and loose
fasteners each time the vehicle
suspension is serviced. Do the following
during an inspection.
•
•
•
•
Wheel Alignment - Follow the
guidelines in Section 5 for wheel
alignment inspection intervals.
Check wheel alignment if excessive
steering effort, vehicle wander, or
abnormal tire wear is evident.
Checking the Ball Joint
Seal and Axial End Play
Fasteners - Check that all the
fasteners are tightened to the proper
tightening torque. Use a calibrated
torque wrench to check torque.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Wear and Damage - Inspect
components of the suspension for
wear and damage. Look for bent or
broken components. Replace all
worn or damaged components.
2. Steer the front wheels straight
ahead.
3. Raise the vehicle until the front
wheels are off the ground. Support
the raised vehicle with safety
stands. Do not place jacks or safety
stands under the lower control
arms to support the vehicle.
Operation - Check that all
components move freely through the
complete turning arc.
CAUTION: ReycoGranning®
recommends replacing any
damaged or out-of-specification
components. Reconditioning or
field repairs of major front
suspension components is not
allowed.
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.
Note: Refer to Section 1 for identification
of components.
4. Deflate the air springs. The air
spring may be deflated by
disconnecting the vertical link
from the height control valve
(HCV) horizontal link or the upper
control arm mount and positioning
the HCV horizontal link
14
Section 3
Inspection
Lower Ball Joint Axial End Play
Inspection
downward. Secure the HCV link to
ensure it does not move and reinflate the air spring.
1. Place a support under the tire or
brake drum to position the
suspension near its ride height.
The shock length at ride height is
16.12”.
5. Remove the tires as needed for
access to inspect seals and make
measurements.
NOTE: Care must be taken to not
damage ball joint seals during inspection. Seals that are ruptured
during inspection must be replaced.
Do not apply excessive force to pry
ball joints.
2. Install a dial indicator with a
magnetic base so that the base is
fixed to the lower control arm.
Place the indicator tip on the
bottom of the lower ball joint base.
(See Figure 4).
Lower and Upper Ball Joint Seal
Inspection
1. Inspect the ball joint seal outer
surface for presence of oil
“wetting”. The entire outer seal
surface should be dry. Use a
mechanics mirror and flashlight to
inspect the entire seal. Use a blunt
object as needed to inspect
between seal convolutes.
Figure 4 - Lower Ball Joint Dial Indicator
Mounting
2. If oil wetting is found, then inspect
the entire wet area to confirm the
seal has a rupture(s) and oil source
is from internal grease leaking
from the ball joint. If seal is
ruptured, then the ball joint must
be replaced.
3. Using a C-clamp, squeeze the
knuckle and the lower control arm
together to seat the ball joint. (See
Figure 5) Do not apply excessive
clamp load.
4. Set the dial indicator on “zero”.
3. Skip ball joint end play
measurement.
NOTE: Care must be taken to not
damage ball joint seals during
inspection. Seals that are ruptured
during inspection must be replaced.
Do not apply excessive force to pry
ball joints.
Figure 5 - Ball Joint Pry Bar Locations
15
Section 3
Inspection
0. Release the clamp. Place the pry
bar between the lower control arm
and steering knuckle. (See Fig. 4).
Do not allow the pry bar to
contact the ball joint seal.
1. Firmly pry downward using the
steering knuckle as a fulcrum to
lift the lower control arm. The pry
load must not cause the tire or
brake drum to be lifted off its
support thus causing the
suspension to change position.
Figure 6 - Upper Ball Joint Dial Indicator
Mounting
2. Record the dial indicator reading.
A reading greater than .040” will
require ball joint replacement.
3. Using a C-clamp, squeeze the
knuckle and the upper control arm
together to seat the ball joint. (See
Figure 7). Do not apply excessive
clamp load.
3. Inspect ball joint seal for damage
and replace the ball joint if
damaged during measurement
process.
4. Set the dial indicator on “zero”.
Upper Ball Joint Axial End Play
Inspection
1. Place a support under the tire or
brake drum to position the
suspension near its ride height.
The shock length at ride height is
16.12”.
2. Install a dial indicator with a
magnetic base so that the base is
fixed to the upper control arm.
Place the indicator tip on the
bottom of the upper ball joint base.
(See Figure 6).
Figure 7 - Ball Joint Pry Bar Locations
5. Release the clamp. Place the pry
bar between the upper control arm
and steering knuckle. (See Figure
7). Do not allow the pry bar to
contact the ball joint seal.
Firmly pry downward using the
steering knuckle as a fulcrum to
lower the upper control arm. The
pry load must not cause the tire or
brake drum to be lifted off its
support thus causing the
suspension to change position.
6. Record the dial indicator reading.
A reading greater than .040” will
require ball joint replacement.
16
Section 3
Inspection
7. Inspect ball joint seal for damage
and replace the ball joint if
damaged during measurement
process.
Checking the Control
Arm Bushings for Wear
Figure 8 - Upper Control Arm Bushing
Clearances
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. Support
raised vehicle with safety stands.
Do not place jacks or safety stands
under the lower control arms to
support the vehicle.
Figure 9 - Lower Control Arm Bushing
Clearances
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. Check for bushing bulging between
the control arm and subframe
mount or presence of small rubber
particles near subframe bushing
mount.
3. Check that the control arm
mounting bolts are tight.
Recommended torque is 950-1050
lbf••ft. on lower control arms and
upper control arms without
eccentric adapters installed. The
recommended torque for upper
control arms with eccentric
adapters installed is 460-490
lbf••ft. See Torque Table. A loose
joint will result in wear between
the bushing inner sleeve and
subframe mount.
3. Remove the tires.
NOTE: If one of the bushings in a
control arm is worn then both
control arm bushings must be
replaced. It is recommended that the
bushings in all of the control arms be
replaced at the same time if one is
worn.
Inspection
1. Check clearance between each
control arm and subframe bushing
mount. (See Figures 8 & 9). Look
for contact pattern as evidence of
bushing wear. Replace worn
bushings in both control arm
housings as needed.
17
Section 3
Inspection
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.
Checking the Tie Rod
Ends
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
5. Check dust boot for damage.
Replace as needed.
WARNING: Do not use a wrench
or other object to apply
leverage when inspecting tie
rod end sockets. Applying
leverage can yield incorrect
results and damage
components. Component
damage can lead to the loss of
steering control.
Inspection
1. With the engine on, lightly rock
the steering wheel and observe
any looseness in the two mating
tapers or any movement of the
stud nut at both ends of the tie
rod. (See Figure 10). If looseness is
found in either place go to step 2,
otherwise skip to step 3.
Figure 10 - Tie Rod
Checking the Automatic
Slack Adjusters and
Brake System
2. Remove the tie rod end ball stud
from the taper mount and visually
inspect both. If either of the
mating tapers show distortion or
wear, then both components must
be replaced. Torque tie rod castle
nuts to 130-150 lbf••ft. See Torque
Table.
Automatic Slack Adjusters
The suspension system is equipped with
Haldex brand automatic slack adjusters
for steer axles. Refer to Haldex technical
service guideline #485-89007 for
inspection and adjustment procedure.
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. (See
Figure 10). Be sure to only apply
hand pressure to the tie rod.
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.
18
Section 3
Inspection
4. If the minimum voltage output is
not achieved, check lead wire
connections and repeat Step 3.
Otherwise, if the minimum voltage
output is not achieved after
repeating step 3 then go to Step 5.
Checking the ABS
Sensor and Tone Ring
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
5. Check physical gap between the
sensor and tone ring (See Figure
11) The brake drum must be
removed to inspect gap. The
maximum allowable gap is .027
inch. If the gap is greater than
.027 inch, press on the wire lead
end of the sensor and push the
sensor into contact with the tone
ring. Check that the ABS spring
retainer and bushing are not
unseated. Re-seat components as
needed.
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.
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.
6. Inspect the tone ring on the hub
for physical damage and proper
installation onto the hub. The tone
ring should have a maximum run
out of .008 inch relative to the
hub/spindle centerline.
3. The tires and brake drums may be
removed if needed to ease
inspection of tone ring and sensor.
7. Repeat Step 3. If voltage output is
less than 800 millivolts then
replace the ABS sensor (Note:
Check voltage output of new
sensor).
4. Disconnect the ABS sensor lead
from the chassis connector.
5. The ABS sensor test will require a
volt meter which can measure AC
voltage on a millivolt scale.
Inspection
1. Connect the volt meter to the
connector pins of the ABS sensor
lead.
2. Set the volt meter scale to
millivolts and the voltage source to
AC volts.
3. Rotate the wheel hub and record
the voltage output from the ABS
sensor. A minimum output of 800
millivolts is normal.
Figure 11 - ABS Sensor and Tone Ring
Gap
19
Section 3
Inspection
4. Check the air spring piston for
build up of foreign material.
Remove any foreign material that
is present.
Checking the Shock
Absorber
Preparation
Height Control Valve Inspection
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
1. Check the height control valve and
linkage for damage. Replace
components as needed.
Inspection
2. Measure the ride height of the
suspension. The ride height should be
6-1/16 inches. It is measured at the
axle centerline and is the distance
from the bottom of the chassis frame
rail to the center of the wheel (See
Figure 12). An alternate
measurement may be taken as the
distance between the center of the
shock mounts which should be 16-1/8
inches. These measurements can be
taken with the vehicle empty or
loaded.
1. Check shock absorber for oil
leakage, bent components, missing
or broken components, excessive
corrosion, or worn bushings.
Replace shock if any of the above
items is present.
Checking the Air Spring
and Height Control Valve
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
3. The actuation arm of the height
control valve should be horizontal at
ride height (See Figures 13, 14 and
15). See section 5 for adjusting to
correct ride height.
2. Refer to Firestone’s Preventative
Maintenance Checklist for
additional air spring information.
Air Spring Inspection
1. Check the outside diameter of the
air spring for irregular wear or
heat checking.
2. Check air lines to make sure
contact does not exist between the
air lines and the outside diameter
of the air spring. Re-secure air
lines to prevent contact as needed.
Check for air line and fitting leaks
with soapy water solution.
Figure 12 - Ride Height Measurement
3. Check to see that there is minimum of
1 inch clearance around the
circumference of the air spring while it
is energized with air.
Figure 13 - Height Control Valve
(Ridewell)
20
Section 3
Inspection
Inspection
1. Check that steering arm pivots are
free of foreign material and
bearing seals are in place.
Lubricate as needed.
2. Start vehicle engine. Oscillate the
steering wheel and observe the
motion of the steering arms (See
Figure 16). The steering arms
should not exhibit any noticeable
conical motion about their pivot
axes.
Figure 14 – Height Control Valve
(Hadley)
3. If any conical motion is observed
check pivot bolt torque which
should be 350 lbf••ft. See Torque
Table. Otherwise, replace the
bearing set of steering arm which
exhibited conical motion.
Figure 15 – Height Control Valve
(Neway)
Checking the Steering
Damper
Preparation
Observe
bearing
movement
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Figure 16 - Steering Arms
Inspection
Checking the Rebound
Bumper Stop
1. Check steering damper for oil
leakage, bent components, missing
or broken components, excessive
corrosion, or worn bushings.
Replace the damper if any of the
above items is present.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Checking the Steering
Arm Bearings
Inspection
1. Check the rebound bumper stop
for deformed shape and chafing.
Replace rebound bumper stop as
needed.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
21
Section 4
Lubrication and Maintenance
Lubricant Specification and Intervals
COMPONENT
SERVICE INTERVAL
Ball Studs on Ends of
Tie Rods, Relay Rod,
Drag Link
Which ever comes first:
50,000 miles (80,000
kilometers) or once a year.
N/A
Bell Crank and Idler
Arm
Which ever comes first:
50,000 miles (80,000
kilometers) or once a year.
N/A
Brake S-Cam Tube and
Automatic Slack
Adjuster 1
Which ever comes first:
Brakes relined. 50,000 miles
(80,000 kilometers) or once a
year.
Wheel End
1000 miles (1600 kilometers)
Check fluid level.
CHANGE INTERVAL
LUBRICANT SPECIFICATION
Multi-Purpose Chassis Grease
NLGI Grade 1 or 2 Lithium Base
Multi-Purpose Chassis Grease
NLGI Grade 1 or 2 Lithium Base
Multi-Purpose Chassis Grease
N/A
NLGI Grade 1 or 2 Lithium Base
Which ever comes first: Seals
replaced, brakes relined, 100,000
miles (160,000 km), or once a
year.
Gear Oil
SAE 80W/90 or equivalent
1. Moly-disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the
automatic slack adjuster.
General Lubrication
Ball Joints
Proper lubrication practices are
important in maximizing the service life
of your ReycoGranning® Independent
Front Suspension.
The ball joints are lubricated and sealed
for their service life and do not require
lubrication. Check for oil or grease marks
on the exterior of the seal and if found
verify that the seal has not been
ruptured. If the seal has been ruptured
then the ball joint must be replaced
because it cannot be re-lubricated.
CAUTION: Do not mix
lubricants of different grades.
Do not mix mineral and
synthetic lubricants. Different
brands of the same grade may
be mixed.
Ball Studs on Tie Rods,
Relay Rod, and Drag
Link
1. Review lubricant specification and
interval requirements before
servicing.
CAUTION: Never mix oil bath
and grease packed wheel ends.
2. Apply lubricant to grease fitting
until new lubricant discharges
from the dust boot (See Figure 17).
22
Section 4
Lubrication and Maintenance
Bell Crank and Idler
Steering Arms
Brake S-Cam Tube and
Automatic Slack
Adjuster
1. Review lubricant specification and
interval requirements before
servicing.
1. Review lubricant specification and
interval requirements before
servicing.
2. Apply lubricant to the bell crank
and idler steering arms until new
lubricant discharges from the
bearing seal or from the pressure
relief port of the grease fitting.
(See Figures 17).
2. Apply lubricant to the S-cam tube
until new lubricant discharges
from the S-camshaft bushing seal
next to the automatic slack
adjuster. (See Figure 17).
3. Apply lubricant to the automatic
slack adjuster until new lubricant
discharges from the cone clutch
adjacent the adjusting hex nut.
(See Figure 17).
Figure 17 – Location of lubrication fittings. Note: Left side only shown.
23
Section 4
Lubrication and Maintenance
oil. Oil marks in other locations
should be addressed by replacing
the hub cap seal, window gasket,
or tightening the pipe fill plug.
Wheel Bearings and Hub
Cap
1. Review lubricant specification and
interval requirements before
servicing.
2. 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. (See
Figure 18). 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.)
Figure 18 - Wheel Bearing Oil Level
3. Check the hub cap for external oil
marks. The vent plug will
normally weep a small amount of
24
Section 4
Lubrication and Maintenance
MAINTENANCE SCHEDULE
GENERAL MAINTENANCE
SERVICE TO BE PERFORMED
MILEAGE IN THOUSANDS
12
Ball Joints
Control Arm Bushings
Tie Rod Ends
Brake System
Air Springs
24
Check axial end play.
36
48
60
X
72
84
96
X
Inspect for ruptured seals.
X
X
X
X
X
X
X
X2
Check that cotter pin is installed.
X
X
X
X
X
X
X
X2
Check bolt torque.
X
X
X2
X
Inspect for contact between control arm and mount.
X
X
X
X
X
X
X
X2
Inspect for bushing wear.
X
X
X
X
X
X
X
X2
Inspect ball socket end play.
X
X
X
X
X
X
X
X2
Check for looseness of taper connection.
X
X
X
X
X
X
X
X2
Check that cotter pin is installed.
X
X
X
X
X
X
X
X2
Inspect slack adjuster for correct stroke.
X
X
X
X
X
X
X
X2
Inspect for air leaks using soapy water solution.
X
Inspect for proper clearance (1” minimum all around).
X
Check upper mount nut and lower mount bolt torque.
X
Inspect for signs of chafing or wear.
X
X
X
X
X
X
X
X2
Check for air line fitting torque.
X
X
X
X
X
X
X
X2
X
X
X
X
X
X
X2
X
X
X
X
X
X
X2
Inspect for air leaks using soapy water solution.
X
Height Control Valve
Linkage
Inspect for signs of bending, binding, or slippage.
X
Shock Absorbers
Check stud mount and lock nut torque.
X
Inspect shocks for signs of fluid leak, broken eye
ends, loose fasteners, or worn bushings.
X
Check the stud mount and relay rod connection.
X
Inspect dampers for signs of fluid leak, broken eye
ends, loose fasteners, or worn bushings.
X
Check nut torque.
X
Inspect bearings for excessive radial play.
X
X
X
X
X
X
X
X2
Rebound Bumpers
Check for deformed shape and chafing.
X
X
X
X
X
X
X
X2
Wheels
Check bearing end play.
Steering Dampers
Steering Arms
X2
X
Check wheel nut torque1.
X
3.
Front Alignment
Inspect toe-in
Air Fittings and Air Lines
Inspect for air leaks using soapy water solution.
X
X
X
X
X
X
X
X
X
X2
X2
X
Inspect for signs of chafing, cracking, or wear.
X
X
X
X
X
X
X X2
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. Toe-in should be inspected after vehicle completion by final stage manufacturer.
25
Section 4
Lubrication and Maintenance
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:
Suspension Serial Number:
IFS1200
IFS1320-HP
IFS1320-SP
Inspection and Maintenance Item
Date
Mileage
26
Service Performed
Section 5
Adjustments and Alignments
Adjustment (Ridewell Valve)
Adjusting Suspension
Ride Height
1. Measure the distance between the
centers of the shock mounts. If the
distance is not within 16-1/8 ± 1/8
inches then adjust as follows.
The height control valve and linkage
should be checked regularly for proper
clearance, operation and adjustment.
2. Disconnect height control valve
linkage on the opposite side and
allow the air spring to deflate by
rotating the height control valve
arm down. Do not alter length
when disconnecting.
NOTE: Improperly adjusted ride
height will result in incorrect
alignment measurements and may
result in abnormal tire wear. Check
ride height prior to front suspension
alignment.
3. Loosen clamp on vertical link of
the height control linkage to be
adjusted.
The ride height of the front suspension is
the distance from the bottom of the
chassis frame rail to the center of the
wheel spindle. Properly adjusted ride
height results in correct suspension travel
and alignment. The ride height should
not be adjusted to adjust chassis rake
angle.
4. Adjust the length of the vertical
link to achieve specified ride
height. If the measured distance is
less than 16-1/8 inches then
decrease the length of the vertical
link. If the measured distance is
more than 16-1/8 inches then
increase the length of the vertical
link. Wait 30 seconds for
suspension to “settle” after
adjusting to verify correct
adjustment.
Preparation
1. Park the vehicle on a level surface.
2. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
NOTE: The horizontal link must
remain horizontal during adjustment
to ensure proper operation of the
height control valve.
3. Check that the rear suspension is
adjusted to the correct ride height
per the vehicle manufacturers
specifications.
5. Tighten the clamp on vertical link.
4. Check height control valve
plumbing to ensure there are not
any air leaks.
6. Reconnect the height control valve
linkage on the other side and
repeat steps 2-4 for the opposite
side as needed.
5. Make sure shock mounts are
mounted securely and not bent.
7. Verify that the ride height is
correct on both sides.
NOTE: Before performing any
adjustment or maintenance, identify
the style of the height control valve.
See Section 3, Height Control Valve
Inspection.
NOTE: The height control valves
must be adjusted individually.
27
Section 5
Adjustments and Alignments
Height Control Valve
Adjustment
5. Tighten the adjusting bolt on the
actuation arm.
1. Measure the distance between the
centers of the shock mounts. If the
distance is not within 16-1/8 ± 1/8
inches then adjust as follows.
6. Reconnect the height control valve
linkage on the other side and
repeat steps 2-4 for the opposite
side as needed.
2. Disconnect height control valve
linkage on the opposite side and
allow the air spring to deflate by
rotating the height control valve
arm down. Do not alter length
when disconnecting.
7. Verify that the ride height is
correct on both sides.
3. Loosen adjusting bolt (see Figures
19 and 20) on actuation arm.
NOTE: Sway bar equipped
suspensions have only one height
control valve installed to the center
of the sway bar. Adjustment is
similar to above.
4. Rotate the actuation arm to
achieve specified ride height. Wait
30 seconds for suspension to
“settle” after adjusting to verify
correct adjustment.
NOTE: The height control valves
must be adjusted individually.
Adjusting Bolt
Adjusting Bolt
Figure 20 – Neway Height Control Valve
Adjustment.
Figure 19 – Hadley Height Control Valve
Adjustment.
28
Section 5
Adjustments and Alignments
2. Place the tip of the dial indicator
on the center of the steering
knuckle spindle. Set the dial
indicator on zero. (See Figure 21).
Checking and Adjusting
the Wheel Bearings
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. Support
raised vehicle with safety stands.
Do not place jacks or safety stands
under the lower control arms to
support the vehicle.
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.
Figure 21 - Wheel End Play Measurement
NOTE: Do not push/pull at the top
and the bottom of the tire, drum, or
hub. Pushing or pulling at the top
and the bottom will not yield a true
measurement of the end play.
3. If the tire and wheel are not
removed make sure all the wheel
nuts are tightened to the specified
torque of 450-500 lbf••ft. See
Torque Table.
3. Measure the end play by
simultaneously pushing/pulling on
each side of the tire, drum, or hub
while observing the dial indicator.
The end play is the total travel
observed. If the end play is not
within .001-.004 inch adjust the
wheel bearings per steps 4-16. (See
Figure 21). Otherwise skip to step
17.
4. If the tire and wheel are removed
(recommended for aluminum
wheels) secure the brake drum to
the hub with the wheel nuts or
remove the brake drum.
5. Remove the vent plug from the
hub cap.
4. 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.
Adjustment
1. Attach a dial indicator with a
magnetic base to the face of the
wheel, hub, or brake drum. The
dial indicator may also be attached
to the bottom of the brake drum if
the wheel is removed.
5. Rotate the hub such that the drain
hole faces downward and drain the
oil from hub cavity. Wait a few
29
Section 5
Adjustments and Alignments
minutes for most of the oil to drain
before continuing to the next step.
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.
6. Remove the hub cap bolts, hub
cap, and gasket. Take care not to
damage the gasket for reinstallation. Place the components in a
location to prevent contamination.
Note that the hub cap window may
be damaged by solvents.
13. Install the retainer washer and
outer spindle nut. Tighten outer
spindle nut to 200-300 lbf••ft. See
Torque Table.
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.
14. Verify that wheel end play is
between .001-.004 inch. (See step
3). 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.
7. Unbend the retainer washer and
remove the spindle outer nut,
retainer washer, and locking
washer. Loosen the inner spindle
nut.
16. Install hub cap gasket and hub
cap. Tighten the cap screws to 2030 lbf•ft. See Torque Table.
Replace the hub cap vent plug if
removed in Preparation step 5.
8. Seat the bearings by tightening
the inner spindle nut to 180 lbf••ft.
while rotating the wheel in both
directions.
17. Fill the hub cavity with the
appropriate amount and type of
lubricant. (See Section 4 for
lubricant specifications).
9. Rotate the hub and drum ten (10)
complete revolutions.
18. Install vent plug.
10. Loosen the inner spindle nut
completely and then tighten the
nut to 20 lbf••ft.
Adjusting the Maximum
Turn Angle
11. Back off the inner spindle nut 1/4
turn.
12. Install spindle locking washer.
CAUTION: See Table 5-1 for the
proper turn angle. Do not
exceed this set angle. Misadjustment of the turn angle
can cause damage to steering
system components.
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.
Check the turn angle if the front tires rub
against the frame, suspension, body, or if
30
Section 5
Adjustments and Alignments
Preparation
the steering gear has been serviced. Use
an alignment machine to check the angle.
See the procedure of the alignment
machine manufacturer.
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
The steering stop bolt on the suspension
subframe 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.
2. Place the front tires on a suitable
device that allows the front wheels
to turn and measures the wheel
turn angle.
3. Check that the steering gear is
centered and the tires are steered
straight ahead with equal toe-in
side to side. If either of these two
conditions is not met, then adjust
toe-in first before centering the
steering gear. See Adjusting the
Toe-In Section and refer to
Spartan chassis service guidelines
for centering the steering gear.
In the course of adjusting the steering
stop(s), the steering gear poppet valves
may require readjustment. Refer to
TRW’s TAS Steering Gear Service
Manual for readjusting the poppets.
NOTE: Unequal toe-in side to side or
an out-of-center steering gear can
result in unequal turn angles and
steering pull while steering straight
ahead. The drag link length may be
adjusted to attain steering gear on
center condition while maintaining
equal toe-in side to side.
Figure 22 - Steering Arm Stop Bolt
4. Check that the lengths of the outer
tie rods are equal to each other
within 1/8 inch. If not, adjust
lengths according to the Adjusting
the Toe-In Section before adjusting
the steering stops.
Steering Arm Stop Settings
Model
Max. Steer Angle
Min. Dim. “A”
IFS1370-HP
45°
1.12”
IFS1200-HP
45°
1.12”
IFS1200S2
50°
0.875”
Table 5-1
NOTE: Do not adjust the length of
the drag link or tie rods to center the
steering wheel. This can cause the
steering gear to become off center.
CAUTION: In power steering
systems, the hydraulic pressure
should relieve or “drop off” when
the steered wheels approach the
steering stops in either direction. If
the pressure does not relieve, the
components of the front suspension
may be damaged.
31
Section 5
Adjustments and Alignments
Adjustment
Wheels and Tires
1. Turn the steering wheel until the
steering arm contacts the stop bolt
or the steering wheel stops turning
(See Figure 22). Measure the turn
angle of the wheel on the same
side as the turn (i.e. inside wheel).
1. Check that the front tires are
inflated to the appropriate
pressure based on the wheel
loading.
2. Check that the front tires are the
same size and type.
2. If the wheel turn angle differs
from Table 5-1 then adjust as
follows.
3. Check that all the wheel nuts are
tightened to the specified torque of
450-500 lbf••ft. See Torque Table.
3. Loosen the jam nut on the stop
bolt.
4. Check that the wheels are
balanced.
4. Turn the stop bolt until the
specified wheel turn angle is
achieved and the bolt head
contacts the steering arm.
Front Suspension
1. Check that all fasteners are
tightened to the specified torque.
5. Tighten the jam nut to 90-110
lbf••ft. See Torque Table.
2. Check the suspension ride height
and adjust as needed to the
specified height.
3. Check for worn ball joints, tie rod
ends, steering arm bearings,
control arm bushings, and
damaged suspension components.
Replace worn components as
needed.
CAUTION: After readjusting
the steering stop(s) check that
the steering poppets are reset
properly and that the front
tires do not contact the frame,
suspension, or body. Also check
for 1/2” minimum clearance
between the air spring and
brake dust cover.
4. Check for loose ball joint and tie
rod end tapered connections, tie
rod end jam nuts, steering arm
mounts, and chassis steering
system components. Inspect
connections for wear and replace
as needed. Tighten connections as
needed.
6. Repeat checking and adjustment
for turning the opposite direction.
Inspection Before
Alignment
5. Check the wheel bearing
adjustment and adjust as needed.
Check the following before conducting
front wheel alignment measurements.
6. Inspect the shock absorbers for
wear and damage.
Inspection
See “General Inspection” in Section 3.
32
Section 5
Adjustments and Alignments
Rear Axle and Suspension
General
Front tire wear and incorrect steering can
be caused by the rear axle and/or
suspension.
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.
1. Check that all fasteners are
tightened to the specified torque.
2. Check the suspension ride height
and adjust as needed to specified
height.
The maximum wheel turn angle should be
checked and adjusted as needed.
3. Check that all connection joints
between the suspension and axle
are secure.
Eccentric adapters may or may not be
installed in left or right hand upper
control arm mounts. The purpose of the
adapters is to provide additional
adjustment of camber and caster to
minimize vehicle drifts or pulls to one
side of the road. The eccentric adapters
must be installed in the upper control
arm mounts to adjust the camber and/or
caster of the respective wheel.
4. Check for worn suspension
bushings or damaged suspension
components.
5. Check that the rear axle is
correctly aligned.
6. Check that the frame is not bent.
7. Refer to any additional
recommendations and
specifications from the
manufacturer of the chassis on
rear axles and suspensions.
Preparation
1. Follow the manufacturer’s
procedures for preparing the
vehicle for front and rear wheel
alignment measurements.
NOTE: Total vehicle alignment is
recommended when aligning the
front suspension.
2. Set the parking brake to prevent
vehicle movement.
NOTE: An out-of-center steering
gear can result in unequal turn
angles . The steering gear should
remain centered during toe-in
adjustment.
Front Wheel Alignment
Equipment
Granning 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.
NOTE: Do not adjust the length of
the drag link or tie rods to center the
steering wheel. This can cause the
steering gear to become off center.
33
Section 5
Adjustments and Alignments
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
Spartan’s guidelines.
Camber is the angle of the tire with
respect to the ground. Camber is positive
when the distance between the top of the
wheels is greater than the distance at the
ground. A small amount of positive
camber is built into the suspension
because camber changes with load and
chassis roll.
4. Measure and record the individual
wheel camber, caster, and toe-in of
the front suspension. Also measure
and record the cross camber, cross
caster, and overall toe-in.
The camber of the suspension 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 “Checking and Adjusting
Suspension Ride Height” sections before
measuring camber. The table below lists
the recommended camber angles.
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.
Nominal Camber Values-Degrees
6. Raise the vehicle until the front
wheels are off the ground. Support
the raised vehicle with safety
stands. Do not place jacks or safety
stands under the lower control
arms to support the vehicle.
Unloaded
Loaded
Left
+1/4°(±1/4°)
+1/4°(±1/4°)
Right
+1/4°(±1/4°)
+1/4°(±1/4°)
The set screw in the eccentric adapter
denotes the orientation of the eccentricity
of the adapter. When the set screw is in
the 6 o’clock or 12 o’clock position, then
the adapter is in the “neutral” position.
There are two adapters at each control
arm mount and they must be oriented the
same.
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.
When the set screws in both control arm
mounts are oriented closer to the frame
rail, the wheel camber becomes more
positive. When the set screws in both
control arm mounts are oriented farther
from the frame rail, the wheel camber
becomes more negative. The eccentric
adapters at both upper control arm
mounts must be oriented the same to
affect only camber.
Adjusting the Camber
Angle
CAUTION: ReycoGranning®
does not recommend adjusting
the ride height or altering
components to adjust the
suspension camber. Alteration
of components may cause a
vehicle accident and serious
personal injury.
1. Turn the wheel to provide access
to the upper control arm mount.
34
Section 5
Adjustments and Alignments
self-aligning moment to stabilize the
vehicle when driving straight ahead.
2. Loosen both upper control arm
mounting bolts at the eccentric
adapters. Do not remove the bolts
because the adapters must remain
engaged in control arm mounting
plate for adjustment.
The caster is indirectly measured from
the change in wheel camber as the wheel
is turned through a prescribed arc.
Therefore, the calculated caster of the
wheel is affected by the ride height of the
suspension. See the “Checking and
Adjusting Suspension Ride Height”
sections before measuring caster. The
table below lists the recommended caster
angles.
3. Loosen the set screws.
4. Rotate each eccentric adapter to
the same orientation as needed
based on measured wheel camber.
The eccentric adapters at each
control arm mount must have the
same orientation.
Nominal Caster Values-Degrees
5. Tighten the adapter locknuts to
460-490 lbf••ft. See Torque Table.
Left
6. Tighten the set screws to 30-40
lbf••in. See Torque Table.
Right
7. Remove the jack stands and lower
vehicle completely. Check that the
suspension is at the proper ride
height.
Unloaded
Loaded
+3°(±1/2°)
+3°(±1/2°)
+3-1/2°(±1/2°)
+3-1/2°(±1/2°)
The set screw in the eccentric adapter
denotes the orientation of the eccentricity
of the adapter. When the set screw is in
the 6 o’clock or 12 o’clock position, then
the adapter is in the “neutral” position.
There are two adapters at each control
arm mount and they must be oriented the
same.
8. Re-measure the camber and
readjust as needed.
Adjusting the Caster
Angle
When the set screws in the forward
control arm mount are oriented closer to
the frame rail and the set screws in the
rearward control arm mount are oriented
farther from the frame rail, the wheel
caster becomes more positive. When the
set screws in the forward control arm
mount are oriented farther from the
frame rail and the set screws in the
rearward control arm mount are oriented
closer to the frame rail, the wheel caster
becomes more negative. The eccentric
adapters at both upper control arm
mounts must be oriented opposite each
other to affect caster.
CAUTION: ReycoGranning®
does not recommend adjusting
the ride height or altering
components to adjust the
suspension caster. Alteration of
components may cause a
vehicle accident and serious
personal injury.
The caster angle is the angle from the
vertical position to the axis defined by the
ball joints when seen from the side of the
vehicle. When the top of ball joint axis is
toward the rear of the vehicle, then the
caster is positive. Positive caster creates a
1. Turn the wheel to provide access
to the upper control arm mount.
35
Section 5
Adjustments and Alignments
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.
2. Loosen both upper control arm
mounting bolts at the eccentric
adapters. Do not remove the bolts
because the adapters must remain
engaged in control arm mounting
plate for adjustment.
1. Measure the length of the outer tie
rods. If the lengths of the outer tie
rods are not within 1/8 inch of each
other, follow steps 2-8, otherwise
skip to step 10.
3. Loosen the set screws.
4. Rotate the eccentric adapters at
the forward and rearward control
arm mounts opposite one another
as needed based on measured
wheel caster. The eccentric
adapters at each control arm
mount must have the same
orientation.
2. Disconnect the drag link at the
bell crank steering arm.
3. Loosen the jam nuts on both ends
of the right and/or left outer tie rod
which requires length adjustment.
The outer tie rod reference length
is 20-3/4 inches. Note: The jam
nut with the left hand threads has
a groove in each hex point around
the circumference.
5. Tighten the adapter locknuts to
460-490 lbf••ft. See Torque Table.
6. Tighten the set screws to 30-40
lbf••in. See Torque Table.
7. Remove the jack stands and lower
vehicle completely. Check that the
suspension is at the proper ride
height.
4. Adjust the length of the outer tie
rods such that they are within 1/8
inch of each other. Tighten the
jam nuts to 110-130 lbf••ft. See
Torque Table.
8. Re-measure caster and readjust as
needed.
5. Loosen the relay rod jam nuts and
the U-bolts that secure the
steering damper mount bracket to
the relay rod. Note: The jam nut
with the left hand threads has a
groove in each hex point around
the circumference.
Adjusting the Toe-In
WARNING: Most tire wear is
caused by incorrect toe-in
settings. ReycoGranning® does
not recommend altering
components to adjust the
suspension toe-in except the tie
rod lengths. Alteration of
components may cause a
vehicle accident and serious
personal injury.
6. Adjust the length of relay rod such
that the toe-in on each side is 1/16”
± 1/32” and the over all toe-in is
1/8” ± 1/16”. Tighten jam nuts to
110-130 lbf••ft. See Torque Table.
7. Re-secure the steering damper
mount bracket to the relay rod.
The bracket should be mounted
such that the distance between
damper mounts is 19 inches when
the suspension is steered straight.
Toe is the relationship of the distance
between the front and rear of the front
tires. When the front distance is less than
the rear distance, the wheels are “toed36
Section 5
Adjustments and Alignments
with the left hand threads has a
groove in each hex point around
the circumference.
See Repair Section 6 for damper
installation. Tighten U-bolt lock
nuts to 25-30 lbf••ft. See Torque
Table.
11. Adjust the length of relay rod such
that the toe-in on each side is 1/16”
± 1/32” and the over all toe-in is
1/8” ± 1/16”. Tighten jam nuts to
110-130 lbf••ft. See Torque Table.
8. Adjust the length of the drag link
accordingly such the steering gear
remains centered and the wheels
are steered straight ahead with
equal toe-in side to side.
Reconnect it to the bell crank
steering arm. Tighten the ball
stud castle nut to 130-150 lbf••ft.
Tighten the jam nuts to 110-130
lbf••ft. See Torque Table.
12. Re-secure the steering damper
mount bracket to the relay rod.
The bracket should be mounted
such that the distance between
damper mounts is 19 inches when
the suspension is steered straight.
See Repair Section 6 for damper
installation. Tighten U-bolt lock
nuts to 25-30 lbf••ft. See Torque
Table.
9. Re-measure the right, left, and
overall toe of the suspension. The
right and left toe-in should be
1/16” ± 1/32” and overall toe-in
should be 1/8” ± 1/16”. Skip to end
of procedure.
13. Re-measure the right, left, and
overall toe of the suspension. The
right and left toe-in should be
1/16” ± 1/32” and overall toe-in
should be 1/8” ± 1/16”.
10. Loosen the relay rod jam nuts and
the U-bolts that secure the
steering damper mount bracket to
the relay rod. Note: The jam nut
.
37
Section 6
Repair
Repairing of Parts
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.
The repair or reconditioning of front
suspension components is not allowed.
ReycoGranning® recommends replacing
damaged or worn components. Several
major components are heat treated and
tempered.
The components cannot be bent,
welded, heated or repaired in any
way without reducing the strength or
life of the component and voiding the
warranty.
Cleaning the Parts
Ground or Polished Parts
The following operations are prohibited
on front suspension components.
Use a cleaning solvent to clean ground or
polished parts and surfaces. Do NOT
clean ground or polished parts with hot
solution tank or with water, steam or
alkaline solutions. These solutions will
cause corrosion of the parts.
1. Welding of or to the steering
knuckles, lower control arms,
steering arms, tie rod assemblies,
the brakes, the hubs, and the
brake drums.
2. Hot or cold bending of the steering
knuckles, the upper and lower
control arms, the steering arms,
the tie rod assemblies, the ball
joints, and the subframe except
control arm and steering arm
mounts which may be cold bent to
facilitate bushing and bearing
replacement.
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
3. Drilling out control arm and
steering arm mounting holes and
ball stud tapered holes.
Parts must be dried immediately after
cleaning. Dry parts with clean paper or
rags, or compressed air. Do not dry
bearings by spinning with compressed
air.
4. Spray welding of bearing
diameters on the steering knuckle
spindle, steering arm bores and
pivot tube. Spray welding of ball
studs or tapered holes for the ball
joint and tie rod ends.
Preventing Corrosion
Apply a light oil to cleaned and dried
parts that are not damaged and are to be
immediately assembled. Do NOT apply oil
to the brake linings or the brake drums.
If 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
5. Milling or machining of any
component except that control arm
bushing bores may be honed to
remove any burrs.
38
Section 6
Repair
Installation
NOT apply corrosion preventative to the
brake linings or the brake drums.
1. Connect the drag link to the bell
crank steering arm. (See Figure
22). Note that the ball stud is
smaller at this connection.
Replacing the Drag Link
Preparation
2. Connect the drag link to pitman
arm.
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Removal
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.
1. Remove the cotter pins from the
ball studs. (See Figure 23)
2. Remove the castle nuts from the
ball studs.
3. Disconnect the drag link from the
bell crank steering arm and the
pitman arm. The ball stud may be
forced from the tapered hole by use
of a suitable tool.
3. Tighten the castle nut at the
steering and pitman arm
connection to 130-150 lbf••ft. See
Torque Table.
4. 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.
5. Lubricate the drag link. See
Section 4, Lubrication and
Maintenance.
Figure 23 - Drag Link Ball Stud
6. Check for correct operation. See
Section 5 Alignment and
Adjustment.
CAUTION: Do not strike the
steering arm or the pitman arm
directly with a steel hammer.
Parts can break and cause
serious personal injury. Wear
eye protection.
Replacing the Relay Rod
and Outer Tie Rods
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
4. Inspect the drag link and mating
tapers. See Section 3. If grease
boot is damaged during removal,
replace it before installation.
39
Section 6
Repair
Removal
3. Connect the outer tie rod from the
bell crank or idler steering arm
and the steering knuckle. (See
Figure 24).
1. Remove the cotter pins from the
ball studs. (See Figure 24).
2. Remove the castle nuts from the
ball studs.
3. Disconnect the steering damper
mount from the relay rod.
4. Disconnect the relay rod from the
bell crank and idler steering arms.
The ball stud may be forced from
the tapered hole by use of a
suitable tool.
5. Disconnect the outer tie rod from
the bell crank or idler steering arm
and the steering knuckle. The ball
stud may be forced from the
tapered hole by use of a suitable
tool.
CAUTION: Do not strike the
steering arms or the steering
knuckles directly with a steel
hammer. Parts can break and
cause serious personal injury.
Wear eye protection.
Figure 24 - Tie Rod Steering Arm
Connection
6. Inspect the relay rod and/or the
outer tie rod and mating tapers.
See Section 3. If grease boot is
damaged during removal, replace
it before installation.
Figure 25 - Steering Damper Mount
Location
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.
Installation
1. Connect the relay rod to the bell
crank and idler steering arms.
(See Figure 24).
2. Connect the steering damper
mount to the relay rod such that
the distance between damper
mounts is 18 inches when the
suspension is steered straight. See
Torque Table. (See Figure 25).
4. Tighten the castle nuts to 130-150
lbf••ft. See Torque Table.
40
Section 6
Repair
It is recommended that the appropriate
tools be used to remove the ball stud
taper from the control arms and to
remove the ball joints from the steering
knuckle. A suspension alignment should
be performed after ball joint replacement.
5. 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.
6. Lubricate the relay rod and/or
outer tie rod. See Section 4,
Lubrication and Maintenance.
NOTE: Be careful to not displace or
damage ball joint seals during
removal from the control arm taper
hole.
7. Check for correct operation. See
Section 5 Alignment and
Adjustment.
Preparation
Replacing the Ball Joints
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
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.
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.
Press-In Mount
The pressed in mount type of upper ball
joint is installed by pressing the base of
the ball joint into the steering knuckle
and securing the base with retainer clips.
The steering knuckle should be properly
supported during removal of the upper
ball joint. The upper ball joint should be
properly supported during installation of
the ball joint.
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.
Thread-In Mount
3. Remove the tires and check that
the air springs are deflated.
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.
Upper Ball Joint Removal Press-In Mount
1. Remove the cotter pin from the
ball stud.
2. Remove the castle nut from the
ball stud.
41
Section 6
Repair
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.
Figure 26 - Press-In Mount Upper Ball
Joint Retainer Clips
CAUTION: Do not strike the
upper control arm directly with
a steel hammer. Parts can
break and cause serious
personal injury. Wear eye
protection.
4. 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 upper control arm.
5. Loosen socket head cap screws and
remove the retainer clips. (See
Figure 26).
6. Place support under steering
knuckle upper ball joint mount.
Press upper ball joint out of
steering knuckle by applying load
to the bottom of its base. (See
Figure 27).
Figure 27 - Press-In Mount Upper Ball
Joint Removal
Upper Ball Joint Removal Thread-In Mount
1. Follow steps 1-4 for press-in
mount type.
2. Secure steering knuckle in a vise
or similar device. Loosen the ball
joint and remove it from the
steering knuckle.
42
Section 6
Repair
Upper Ball Joint Installation Press-In Mount
4. Follow steps 6-8 for press-in
mount type.
Lower Ball Joint Removal
1. Inspect ball joint bore in the
steering knuckle and remove any
burrs by honing.
1. Remove the cotter pin from the
ball stud.
2. Place the new ball joint into a
support tube such that it is
supported only by the step
diameter.
2. Remove the castle nut from the
ball stud.
3. Align the upper ball joint bore of
the steering knuckle with the ball
joint. Press the steering knuckle
onto the ball joint until the step
diameter is seated against the
steering knuckle.
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.
4. Install the retainer clips and
socket head cap screws.
3. Disconnect the lower control arm.
The ball stud may be forced from
the tapered hole by use of a
suitable tool.
5. Tighten the socket head cap
screws to 15-20 lbf••ft. See Torque
Table.
6. Connect the ball joint to the upper
control arm.
CAUTION: Do not strike the
lower control arm directly with
a steel hammer. Parts can
break and cause serious
personal injury. Wear eye
protection.
7. Tighten the castle nut to 155-170
lbf••ft. See Torque Table.
8. 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.
4. 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.
Upper Ball Joint Installation Thread-In Mount
1. Inspect the threads in the steering
knuckle and remove any burrs or
debris.
5. Secure steering knuckle in a vise
or similar device. Loosen the ball
joint and remove it from the
steering knuckle.
2. Apply thread adhesive Loctite
#242 or equivalent to the ball joint
threads and thread the ball joint
into the steering knuckle.
3. Tighten the base of the ball joint to
325-375 lbf••ft. See Torque Table.
43
Section 6
Repair
Removal
Lower Ball Joint Installation
1. Inspect the threads in the steering
knuckle and remove any burrs or
debris.
1. Remove the pivot bolt that mounts
the steering arm and remove the
steering arm from the subframe.
2. Apply thread adhesive Loctite
#242 or equivalent to the ball joint
threads and thread the ball joint
into the steering knuckle.
2. Remove the snap rings from the
pivot sleeve and remove the sleeve.
A rubber or brass hammer may be
used to remove the sleeve. Retain
shims.
3. Tighten the base of the ball joint to
525-575 lbf••ft. See Torque Table.
3. Support the steering arm bearing
housing and press the bearing out
of each end of the steering arm.
4. Connect the ball joint to the lower
control arm.
Installation
5. Tighten the castle nut to 330-370
lbf••ft. See Torque Table.
1. Clean out the steering arm grease
cavity.
6. 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.
2. Inspect steering arm bearing
housing bores and remove burrs by
honing. Replace steering arm if the
bore is damaged.
3. Support the steering arm bearing
housing and press the replacement
bearing into each end of the
steering arm. Note that the seal
side of the bearing should face out.
Replacement bearings with seals
on each side should have one seal
removed to allow grease access.
Replacing the Bell Crank
and Idler Steering Arm
Bearings
Replace the bell crank and idler steering
arm bearings in sets. The replacement
bearings should be installed by pressing
on the outer raceway only. Pressing on
the inner raceway will damage the
bearing.
4. Inspect the pivot sleeve and
remove burrs with emery cloth.
5. Use a rubber mallet or similar tool
to drive the inner sleeve up 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.
The inner grease cavity of the steering
arms should be cleaned when the
bearings are replaced.
Preparation
1. Follow the procedures for removal
of the ball studs of the drag link,
relay rod, and outer tie rods from
the steering arms before replacing
the bell crank and idler steering
arm bearings.
6. Install upper retaining ring.
7. Determine the number of shims
(p/n 8611) needed by stacking the
shims and placing the stack
between the upper retaining ring
44
Section 6
Repair
The control arm mounts should be
inspected for damage.
and inner race until a snug fit is
achieved. Remove one shim from
the stack and this is the number of
shims needed. A maximum of six
shims may be used.
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.
8. Remove the upper retaining ring,
install the shims determined in
step 7 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. (See Figure 28).
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.
9. Place the steering arm in its
mount and install the pivot bolt.
Tighten the pivot bolt lock nut to
350 lbf••ft. See Torque Table.
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.
10. Follow the procedures for
installation of the drag link, relay
rod, and outer tie rods.
CAUTION: Use of a cutting
torch to remove control arm
bolts will permanently damage
control arm bushings and can
result in damage to subframe.
Inner Race
Retaining Ring
Inner Sleeve
Preparation
Check Shim
Height Here
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Figure 28 – Location of Shims
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.
Replacing the Upper and
Lower Control Arm
Bushings
The subframe control arm mounts may
require widening to accommodate
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.
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.
45
Section 6
Repair
8. Place the spacer into the bushing.
3. Remove the tires and check that
the air springs are deflated.
9. Insert an eccentric adapter on each
end of the upper control arm
mounting plate.
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.
10. Place bolt and washer through the
spacer and bushing as shown.
11. Install washer and locking nut.
12. Repeat the process for the rear
upper control arm mounting bolt.
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.
13. Rotate the eccentric adapters on
the front mounting bolt, such that
the set screws are located as
previously orientated.
14. Vehicle alignment may have to be
checked. Please refer to Section 5.
When the eccentric adapters are
properly oriented, tighten the
bolts.
2. If desired, disconnect the upper
control arm from the steering
knuckle. Follow the removal
procedure in “Replacing the Upper
Ball Joint” Section.
15. Support the control arm such that
it is at ride height and tighten the
bolts to 950-1050 lbf••ft. (without
eccentrics) or 460-490 lbf••ft. (with
eccentrics). See Torque Table.
3. Loosen and remove the control
mount arm bolts. Remove any
existing eccentric components.
Note the orientation of the set
screws for reinstallation.
16. Install and tighten the set screw
on any eccentrics installed to 3040 lbf••in. Refer to Torque Table.
17. Reconnect the steering knuckle to
the control arm if disconnected.
Follow the installation procedure
in “Replacing the Upper Ball
Joint” Section.
4. Press the bushing out of the
control arm housing. Be sure to
properly support the housing.
5. Inspect the housing bores and
remove any burrs in the housing
by honing.
18. Reconnect the height control valve
linkage. Follow the installation
procedure in “Replacing the Height
Control Valve” Section.
6. Press the bushing into the control
arm housing. Be sure to properly
support the housing.
Lower Control Arm
1. Disconnect the lower shock mount
from the lower control arm. Follow
the removal procedure in
“Replacing the Shock” Section.
7. Place the control arm in its mount
location. If not equipped with
eccentrics, install the control arm
mount bolts into subframe snug
tight and skip to step 15.
46
Section 6
Repair
10. Reconnect the lower shock mount.
Follow the installation procedure
in “Replacing the Shock” Section.
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.
Replacing Wheel
Bearings, Oil Seals, and
Hub Caps
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
2. If desired, disconnect the lower
control arm from the steering
knuckle. Follow the removal
procedure in “Replacing the Lower
Ball Joint” Section.
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.
3. Loosen and remove the control
mount bolts.
4. Press the bushing out of the
control arm housing. Be sure to
properly support the housing.
5. Inspect the housing bores and
remove any burrs in the housing
by honing.
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.
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. Install the control arm
mount bolts into subframe snug
tight.
3. If the wheel nuts have chrome
covers, remove them with special
pliers equipped with plastic nonmarring jaws. Place them in a
container to prevent damage or
loss.
8. Support the control arm such that
it is at ride height and tighten the
bolts to 950-1050 lbf••ft. See
Torque Table.
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
9. Reconnect the steering knuckle to
the lower control arm if
disconnected. Follow the
installation procedure in
“Replacing the Lower Ball Joint”
Section.
47
Section 6
Repair
container to prevent
contamination or loss.
spindle washer, locking “D”
washer, and the inner spindle nut.
Retain all components for reassembly except discard the
spindle washer.
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.
5. Place a shop towel on top of the
lower brake shoe to prevent oil
from dripping onto the brake
lining.
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.
6. Tug sharply on the hub to unseat
the outer bearing without
completely removing the hub.
Wipe up any oil spilled on the
brake assembly as quickly and
completely as possible. Remove the
outer bearing and place it in a
container to prevent
contamination.
Removal
1. Place an oil drip tub beneath the
hub to catch oil. Rotate the hub
such that the hubcap drain plug is
facing upwards. Remove the drain
plug from the hubcap and place it
in a container for re-installation.
7. 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.
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 reinstallation. Place the components
in a location to prevent
contamination. Note that the hub
cap window may be damaged by
solvents.
8. Remove the hub seal and discard
it. Inspect the axle ring on the
spindle and remove it if worn.
9. 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.
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,
48
Section 6
Repair
Installation
6. Install the inner spindle nut and
tighten hand tight.
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)
7. Seat the bearings by tightening
the inner spindle nut to 180 lbf••ft
while rotating the wheel in both
directions.
8. Rotate the hub and drum ten (10)
complete revolutions.
9. Loosen the inner spindle nut
completely and then re-tighten the
inner nut to 20 lbf••ft.
10. Back off the inner spindle nut ¼
turn.
11. Install the spindle locking “D”
washer.
NOTE: Do not drive bearing onto
spindle with a steel hammer or
similar instrument. Inner race is a
tight slip fit with spindle.
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.
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.
3. Press the ABS sensor outward
about ¼”. Do not use a sharp tool
on lead wire end of the sensor. See
section 3 for the inspection of ABS
sensor as needed.
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.
4. Place the hub onto the spindle
until it seats on the inner bearing.
Do not “ram” the hub onto the
seal.
12. Install the replacement spindle
washer P/N 6969 and the outer
spindle nut. Tighten the outer
spindle nut to 200-300 lbf••ft. See
Torque Table for sequence.
5. 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.
13. Attach a dial indicator with a
magnetic base to the face of the
hub. (See Figure 29). Note the
brake drum is shown for reference
only.
49
Section 6
Repair
18. Fill the hub cavity with the
appropriate amount(approx ½
pint) and type of lubricant(90W
gear oil).
14. Place the tip of the dial indicator
on the center of the steering
knuckle spindle. Set the dial
indicator on zero.
19. Check oil level through the hub
cap window. (See Figure 30). 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.)
NOTE: 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 end play.
15. Measure the end play by
simultaneously pushing/pulling on
each side of the hub while
observing the dial indicator. The
end play is the total travel
observed. If the end play is not
within .001-.004 inch re-adjust the
wheel bearings per steps 7-11.
Otherwise continue to step 16.
Figure 30 - Wheel Bearing Oil Level
20. Install the hub cap drain plug.
21. Check the hub cap for external oil
leakage at the drain plug or
gasket. For leaks at the drain plug
check for application of thread
sealant to threads and tightness.
For leaks at the gasket, replace
the gasket. The vent plug will
normally weep a small amount of
oil.
Figure 29 - Wheel End Play Measurement
16. Bend the spindle washer over one
wrench flat of the outer nut.
17. Install the hub cap gasket and hub
cap. Tighten the cap screws to 2030 lbf••ft. See Torque Table for
sequence.
22. Install the brake drum.
50
Section 6
Repair
23. Install the wheel and tire
assembly and the wheel nuts.
the brake manufacturers guidelines for
servicing the brakes.
24. On aluminum wheels, use a plastic
anti-scuff guard over the wheel
nuts. Tighten the wheel nuts to
450-500 lbf••ft. See Torque Table
for sequence.
Replacing the ABS
Sensor and Tone Ring
Replacing Brake
Components
The anti-lock brake system(ABS) of the
vehicle should be diagnosed by a qualified
technician before the anti-lock brake
sensor or the tone ring are replaced.
Replacement parts must be equivalent to
the vehicle manufacturers to ensure
proper function of the anti-lock brake
system. The anti-lock brake sensor and
tone ring cannot be repaired and must be
replaced if damaged or malfunctioning.
Brake Drums
Preparation
25. Replace the hub cap nuts and hub
caps if removed to service the
wheel bearings.
26. Remove jack stands and jacks
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.
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.
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.
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.
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.
3. Remove the tires and check that
the air springs are deflated.
Other Brake Components
Sensor Removal
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
1. Remove the brake drum to provide
access to sensor.
2. Press sensor out of steering
knuckle. Do not pull sensor out by
its lead wire.
51
Section 6
Repair
9. Connect the sensor lead wire to
the chassis.
3. Remove tie straps that secure the
sensor lead wire and disconnect
the sensor lead wire from the
chassis.
10. Install the brake drum and tires.
Tone Ring
Sensor Installation
Follow the hub manufacturers guidelines
for removal and installation of the tone
ring.
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.
Replacing the Rebound
Bumper Stop
2. Press the sensor into the steering
knuckle until the sensor end
contacts the tone ring.
Both of the rebound bumper stops should
be replaced at the same time if service on
one bumper is required.
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 1V-10V.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
4. Spin the hub by hand and read the
voltage output of the sensor. A
minimum reading of .8V AC is
normal. Skip to step 8 if minimum
reading is obtained.
2. Deflate the suspension to provide
access.
Removal
5. If the 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.
1. Turn the tire to provide access.
2. Remove mounting fasteners and
the rebound bumper stop.
Installation
1. Install the rebound bumper stop
and mounting fasteners.
6. If the minimum reading is not
obtained, check the tone ring for
damage and its installation. The
tone ring should have a maximum
runout of .008”. Replace as needed
and repeat step 4.
2. Tighten the bolt head to 25-30 ftlbs. See Torque Table.
Replacing the Shock
Absorber
7. If the minimum reading is still not
obtained, then replace the sensor
and repeat the installation
procedure.
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.
8. Route and secure the sensor lead
wire the same as the removed
sensor.
52
Section 6
Repair
Preparation
4. Pry the inner shock eye bushing
from the eye and remove the shock
absorber. Discard the bushing.
NOTE: The outer tie rod may need to
be temporarily removed from the bell
crank and/or idler arm for access to
the lower shock absorber mount.
Please refer to the Replacing the
Relay Rod and Outer Tie Rod section
for the proper procedure.
Installation
1. Check that the upper and lower
shock mount studs are properly
tightened. The lower stud should
be tightened at 200-225 lbf••ft. If
the lower shock mount stud was
loosened from the lower control
arm(LCA) during shock removal,
then remove the stud from the
LCA, apply Loctite #242(or
equivalent) to the threads which
thread into the LCA, and torque to
200-225 lbf••ft. The upper flange
lock nut(3/4-10) should be
tightened to 200-225 lbf••ft. If the
upper shock mount stud was
loosened from the subframe during
removal, then re-torque to 200-225
lbf••ft. See Torque Table.
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Note: Early models of the IFS1200
suspension were equipped with
shock absorber mounting studs.
Subsequent IFS1200 suspensions and
all IFS1320 models utilized through
bolts.
Removal (Stud Mount Version)
1. Remove the upper and lower 3/410 lock nuts which secure the
shock eye to the shock mount stud.
The shock mount stud should be
held such that it is not loosened
from its mount.
2. Place the inside retaining washers,
shock sleeves, and the inside shock
eye bushings on the upper and
lower shock mount. Note the
orientation of the washer and
bushing. (See Figure 31).
2. Remove the upper and lower outer
retaining washers from the shock
mount studs. Note the orientation
of the retaining washers.
3. Install the shock on the shock
mounts.
4. Place the outside shock eye
bushings and the outside retaining
washers on the upper and lower
shock mount. Note the orientation
of the washer and bushing. (See
Figure 31).
WARNING: The shock absorber
is gas pressurized and should
be restrained from expansion
during removal and
installation.
5. Install the upper and lower 3/4-10
lock nuts and tighten to 90-110
lbf••ft. See Torque Table.
3. Dislodge the upper and lower
shock eye from the shank portion
of the shock mount stud and pry
the outer shock eye bushing from
the eye. Discard the bushing.
53
Section 6
Repair
bolt and lock nut. Refer to Figure
30.
5. Torque the bolt to 170-190 lbf••ft.
See Torque Table.
Figure 31 - Shock Absorber Mount
Removal (Bolt Mount Versions)
1. Loosen and remove the 3/4-10
lower shock absorber mount bolt
from the lower control arm.
Figure 32 - Shock Absorber Mount
Replacing the Air Spring
2. Loosen and remove the 3/4-10
upper shock absorber mount bolt
from the nut.
When replacing the air spring be sure
that the correct replacement air spring is
installed. The use of a substitute air
spring that is not recommended by
Granning may cause unequal load
sharing between the air springs which
may be detrimental to vehicle ride and
handling.
WARNING: The shock absorber
is gas pressurized and should
be restrained from expansion
during removal and
installation.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Installation
1. Apply Loctite #242(or equivalent)
to the threads of the lower shock
absorber mount bolt.
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.
2. Install the bolt into the lower
mount of the shock. (Refer to
Figure 32).
3. Thread into the LCA, and torque
to 170-190 lbf••ft. See Torque
Table.
4. Reinstall the upper mount of the
shock absorber using the 3/4-10
54
Section 6
Repair
Installation
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.
1. Assemble the air spring to the
lower control arm. Tighten the
bolts to 30-40 lbf••ft. See Torque
Table.
2. Assemble the nuts and washers
that connect the air spring to the
upper air spring mount on the
subframe. Tighten the nuts to 3040 lbf••ft. See Torque Table.
3. Deflate the air springs.
Removal
1. Disconnect the air line at the air
spring and remove the connection
fitting.
3. Install the connection fitting into
the air spring. Use Permatex or
equivalent thread sealant.
2. Remove the nuts and washers
from the upper air spring mount
studs. See Figure 33.
4. Connect the air line to the air
spring.
5. Lower the vehicle frame and
inflate the air springs.
3. Remove the bolts that secure the
air spring to the lower control arm.
See Figure 34.
6. Check the air fittings for leaks.
Replacing the Steering
Damper
4. Remove the air spring.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
Removal
Figure 33 - Air Spring Upper Mount
1. Remove the mounting nuts from
each end of the steering damper.
2. Remove the steering damper.
Installation
1. Install the steering damper in the
subframe and relay rod bracket
mounts.
2. Tighten the mounting nuts. See
Torque Table.
Figure 34 - Air Spring Lower Mount
55
Section 6
Repair
Replacing the
Suspension Subframe
6. Lower the subframe from the
chassis frame rails and remove
from the chassis.
When replacing the suspension subframe
use the proper size and grade fasteners.
The subframe may be removed from and
installed to the chassis frame with
suspension fully assembled.
7. Remove all other suspension
components from the subframe.
See the appropriate section for
removal of each component.
Installation
Preparation
1. Install all other suspension
components to the subframe. See
the appropriate section for
installation of each component.
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
2. Place the subframe under the
chassis and raise it into location on
the chassis frame rails.
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 or
the suspension subframe to
support the vehicle.
3. Connect the subframe to the
chassis frame rails. Tighten the
fasteners to recommended torque
of chassis manufacturer.
Reconnect the ABS sensor, air
lines, and drag link.
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.
Replacing the Height
Control Valve
When replacing the height control valve
(HCV) be sure that the correct replacement HCV is installed (see Section 3,
Height Control Valve Inspection). The
use of a substitute HCV that is not
recommended by ReycoGranning® may
cause unequal load sharing between the
air springs which may be detrimental to
vehicle ride and handling.
3. Remove the tires and deflate the
air springs.
Removal
1. Disconnect the drag link.
2. Disconnect the air lines to the
height control valves and brakes.
Preparation
3. Disconnect the ABS sensor lead
wire.
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
4. Support the bottom of the
subframe with a suitable jack or
lift mechanism.
2. Raise the vehicle until the front
wheels are off the ground.
Support the raised vehicle with
safety stands. Do not place jacks
5. Remove fasteners connecting the
subframe to the chassis frame rail.
56
Section 6
Repair
Installation
or safety stands under the lower
control arms to support the
vehicle.
1. Assemble the actuation arm and
the vertical link of the
replacement HCV the same as the
removed HCV. For Ridewell
HCV’s, note the orientation of the
actuation arm at the pivot mount.
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. For Ridewell HCV’s only: Trim
the lengths of the linkages of the
replacement HCV to be the same
as the removed HCV. Tighten the
set bolt and clamp screw to 8-12
lbf••ft. See Torque Table.
3. Deflate the air springs.
Removal
3. Assemble any other plumbing
fixtures to the HCV as marked for
re-connection.
1. Mark air line connections for reassembly. Disconnect the air lines
from the HCV. If any other
plumbing fixtures are connected to
the HCV, mark them for reassembly.
4. Mount the replacement HCV to
the subframe with bolts, nuts, and
washers. Tighten the nuts to 1015 lbf••ft. See Torque Table.
2. Disconnect the vertical link from
the upper control arm.
5. Reconnect air lines and check for
proper operation and leaks.
3. Remove the mounting bolts, nuts,
washers, and HCV from the
subframe.
6. Check and adjust ride height per
Adjusting Suspension Ride Height
Section.
4. Remove any other plumbing
fixtures from the HCV.
57
Section 6
Repair
Replacing the Sway Bar
Installation
1. Lubricate the bushings’ inner
diameter with Aqua Shield Grease
(TC1920).
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. Install the two split bushings over
the sway bar.
3. Install the bar to the suspension.
Note: The ends of the sway bar
should tip up on the lower control
arms.
Preparation
1. Set the parking brake and block
the drive wheels to prevent vehicle
movement.
4. Install the two bushing brackets
over the split bushings. Torque
the fasteners to 52 lbf•ft. See
torque table.
2. Removal and replacement of the
sway bar is best done while the
suspension is at ride height to
remove all loading from the sway
bar. It is recommended that this
service be performed in a service
environment that provides access
to the undercarriage while at ride
height (such as a pit or full vehicle
lift).
5. Lubricate the two non-split
bushings.
6. Install these two bushings over the
ends of the bar.
7. Install the two bushing brackets
over the remaining two bushings.
Torque to 52 lbf•ft. See torque
table.
Removal
8. Loosely install the height control
arm to the sway bar.
1. Disconnect the height control arm
from the sway bar.
WARNING: It is recommended
to secure the height control
valve arm such that the valve
will not “dump” air while the
sway bar is being replaced.
Pin Hole
9. Set the height control valve arm
(on the valve) to level. It is
recommended to use the wood
dowel through the pin hole located
in back of the height control valve.
2. Remove the bushing brackets.
3. Remove the sway bar. Note
orientation of sway bar ends.
4. Remove the sway bar bushings
from the bar.
10. Tighten the retaining U-bolts to
the sway bar to 20-30 lbf•ft. See
torque table.
5. Inspect bushings for any damage.
11. Remove the wood dowel if
necessary.
58
Section 7
Torque Specifications
TORQUE SPECIFICATIONS
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
should be of the correct strength, as well as
the correct nominal diameter, thread pitch,
length, and finish.
Figure 35: Grade Markings on Bolts
Grade
Lock Nut
Grade B, F
Lock Nut:
Grade C, G
3 Dots
6 Dots
Identification
Figure 36: Grade Markings on Lock Nuts
Torque Table 1
APPLICATIONS
FASTENER SIZE
Lower Control Arm Bushing Pivot Bolt
Upper Control Arm Bushing Pivot Bolt (without Eccentric
Adapters)
Upper Control Arm Bushing Pivot Bolt (with Eccentric
Adapters)
Eccentric Set Screw
Upper Ball Joint Base
Upper Ball Joint Retention Clip SHCS
Upper Ball Joint Ball Stud Castle Nut
Lower Ball Joint Base
Lower Ball Joint all Stud Castle Nut
Air Spring Upper Mount Nut
1-1/8-12 Grade 8
1-1/8-12 Grade 8
TORQUE SPECIFICATION (LBF••FT.)
(CLEAN AND DRY)
950-1050(1)
950-1050(1)
7/8-9 Grade 8
460-490(1)
#10-24x3/8
M56x1.5
1/4-28
M20x1.5
M85x1.5
M30x1.5
3/4-16 Grade 5
1/2-13 Grade 5
1/2-13 Grade 5
3/4-10 Grade G
3/4-10 Grade C
3/4-10 Grade 8
3/4-10 Grade C
3/4-10 Grade C
3/4-10 Grade 8
5/16-18 Grade G
30-40 lbf.-in.
325-375(2)
15-20
155-170(3)
525-575(2)
330-370 (3)
30-40
30-40
30-40 (1)
200-225
90-110
200-225(2)
90-110
170-190
170-190(2)
25-30
Tighten only enough so that bushing is
expanded to the diameter of the outer
retaining washer.
350
90-110
110-130
110-130
130-150 (3)
Air Spring Lower Mount Bolts
Upper Shock Stud Mount Flange Lock Nut (stud version)
Upper Shock Eye Mount Lock Nut (stud version)
Lower Shock Stud Mount (stud version)
Lower Shock Eye Mount Locknut (stud version)
Upper Shock Mount Lock Nut (bolt version)
Lower Shock Mount Bolt (bolt version)
Rebound Bumper Mount Flange Lock Nut
Steering Damper Mount Nut
Steering Arm Mount Lock Nut
Steering Stop Jam Nut
Tie Rod and Drag Link Length Adjustment Nuts
7/8-9 Grade C
5/8-11 Grade 5
1-1/8-12
1-1/4-12
7/8-14
Outer Tie Rod, Relay Rod, & Drag Link Ball Stud Castle
Nuts (Except at Pitman Arm Connection)
Drag Link Ball Stud Castle Nut at Pitman Arm
7/8-14
120-170 (3)
Connection
Subframe to Chassis Mount Flange Lock Nut
1/2-13 Grade G
90-100
Height Control Valve Body Mount Lock Nut
1/4-20 Grade C
9
Height Control Valve Linkage Stud Mount Nut
1/4-20 Gr. 5
60-80
1) Torque applied to bolt head.
2) Apply thread adhesive Loctite #242 or equivalent to threads of fastener threaded into tapped hole.
3) Install cotter pin after tightening.
59
Section 7
Torque Specifications
Torque Table 1 (Cont)
APPLICATIONS
FASTENER SIZE
TORQUE SPECIFICATION (LBF••FT.)
(CLEAN AND DRY)
60-80 lbf.-in.
Tighten clamp until rod is tight.
See Section 5 Adjusting the Wheel Bearings
200-300
20-30
52
Height Control Valve Control Arm Pivot Set Bolt
5/16-18 Grade 2
Height Control Valve Linkage Clamp Screw
Spindle Inner Nut
1-1/2-12
Spindle Outer Nut
1-1/2-12
Height Control Valve Arm, Sway Bar Mount
3/8-24 Gr. 8
Sway Bar Bushing Mount
7/16-14 UNC Gr. 8
1) Torque applied to bolt head.
2) Apply thread adhesive Loctite #242 or equivalent to threads of fastener threaded into tapped hole.
3) Install cotter pin after tightening.
Torque Table 2
APPLICATIONS
Steering Damper Tie
Rod Mount Lock Nut
FASTENER SIZE
TORQUE SPEC.
(LBF••FT.) (CLEAN
AND DRY)
3/8-24 Grade 5
25-30
TORQUE SEQUENCE
1
3
2
5
6
4
4
2
6
Brake Spider Mount
Cap screw
5/8-18 Grade 8
7
170-190(1 & 2)
5
1
3
Driver Side
1
6
Hub Cap Bolt
5/16-18 Grade 5
3
20-30(1)
4
5
2
Wheel Nut
1)
2)
3)
1-1/8-16
(Stud Piloted)
M22x1.5
(Hub Piloted)
9
(3)
450-500
(Dry Threads)
1
6
7
3
8
4
10
2
5
Torque applied to bolt head.
Apply thread adhesive Loctite #242 or equivalent to threads of fastener threaded into tapped hole.
Recheck wheel nut torque after first 50-100 miles.
60
Section 8
Special Ball Joint Tools
To install or remove upper and lower ball joints, ReycoGranning® Air Suspensions
recommends the use of the following special tools:
Upper Ball Joint Special Tool, Part Number: A7250A.
Lower Ball Joint Special Tool, Part Number: A7250B.
Recommended Ball Joint Puller,
Snap-On Bar-Type “CJ” Pullers, 4-3/8” Jaws,
3/4”-16x4-1/4” Pressure Screw, 3-1/2” to 6” Yoke
61
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