IFS1000-WF I&M Manual

IFS1000-WF I&M Manual
Motorhome Suspensions
Owner’s Manual
IFS1000-WF | Independent Front Suspension
Maintenance Instructions
Service Parts
Document #: D712230
Revision: OR
Revision Date: 11/13
1-800-753-0050
w w w. r e y c o g r a n n i n g . c o m
Reyco Granning Suspensions
1205 Industrial Park Drive
Mount Vernon, MO 65712
Phone: 417-466-2178
Fax: 417-466-3964
COMPANY PROFILE
Reyco Granning Suspensions was formed by the merger and acquisition of two
well-known names in the heavy-duty vehicle suspension industry: Reyco and
Granning.
Reyco grew out of the Reynolds Mfg. Co. and was first known as a major supplier
of brake drums for heavy-duty vehicles, and later developed a full line of air and
steel spring suspensions for trucks, busses, trailers, and motorhomes.
Granning Air Suspensions was founded in 1949 in Detroit, Michigan as a
manufacturer of auxiliary lift axle suspensions. Granning later became an
innovator of independent front air suspensions for the motorhome industry.
Reyco Granning LLC was formed in early 2011 through a partnering of senior
managers and MAT Capital, a private investment group headquartered in
Long Grove, Illinois.
Reyco Granning manufacturing facilities are certified to the ISO9001:2008
standards, a globally recognized assurance that quality standards have been
established and are maintained by regular rigorous audits.
Table of Contents
Introduction ................................
................................
.4
Service Notes
................................
................................
................................
.....4
Identification................................
................................
................................
......5
Vehicle Towing Information................................
................................
.............6
Maintenance Schedule
................................
................................
.......................
7
Parts Lists ................................
................................
....9
Unit Assembly................................
................................
................................
...9
Control Arm Assemblies
................................
................................
.................10
Control Arm Components................................
................................
...............11
Steering Components
................................
................................
......................
12
Air Spring and Shock Components
................................
................................
.18
Wheel EndComponents
................................
................................
................20
Steering Knuckle Carrier Components
................................
...........................
22
Lubrication ................................
................................
23
Lubricant Specifications and Intervals
................................
............................
23
General Lubrication
................................
................................
.........................
23
Rod Ends on Tie Rods
RelayRod................................
................................
...24
Wheel Bearings................................
................................
...............................
25
Troubleshooting................................
.........................
26
Inspection……………………………………………30
General Inspection
................................
................................
...........................
30
Inspecting the Control Arm Bushings for Wear
................................
.............30
Inspecting the Tie Rod Ends
................................
................................
...........31
Inspecting the Brake System
................................
................................
...........31
Inspecting the ABS Sensor and Tone Ring
................................
.....................
31
Inspecting the Shock Absorber
................................
................................
.......32
Inspecting the Air Spring and Height Control Valve
................................
......33
Air Spring Inspection................................
................................
................................
...... 33
Inspecting the Idler Arm................................
................................
.................33
Endplay Inspection
................................
................................
................................
..........33
Inspecting Wheel Bearing Endplay
................................
................................
.34
Adjustments ................................
...............................
35
Adjusting Wheel End Play
................................
................................
..............37
Adjusting Suspension Ride Height
................................
................................
.39
Adjusting the Maximum Wheel Turn Angle................................
..................
40
Inspection before Alignment
................................
................................
...........42
Wheels and Tires
................................
................................
................................
.............42
D712230
1
IFS1000 -WF
Table of Contents
Front Suspension ............................................................................................................. 42
Rear Axle and Suspension .............................................................................................. 43
Front Wheel Alignment ...................................................................................43
Equipment ....................................................................................................................... 43
General ............................................................................................................................ 43
Preparation ...................................................................................................................... 44
Adjusting the Camber Angle ...........................................................................45
Adjusting the Caster Angle .............................................................................47
Adjusting the Toe-In .......................................................................................49
Repair .........................................................................50
General Procedures..........................................................................................50
Cleaning the Parts ............................................................................................50
Ground or Polished Parts ................................................................................................ 50
Rough Parts ..................................................................................................................... 51
Drying ............................................................................................................................. 51
Preventing Corrosion ...................................................................................................... 51
Replacing Tie Rod Ends ..................................................................................51
Removal .......................................................................................................................... 51
Installation....................................................................................................................... 51
Replacing the Idler Arm ..................................................................................52
Removal .......................................................................................................................... 52
Installation....................................................................................................................... 52
Replacing the Upper and Lower Control Arm Bushings ................................52
Upper Control Arm Removal.......................................................................................... 53
Upper Control Arm Installation ...................................................................................... 53
Lower Control Arm Removal ......................................................................................... 54
Lower Control Arm Installation...................................................................................... 54
Replacing Wheel Bearings, Oil Seals, and Hub Caps .....................................55
Removal .......................................................................................................................... 55
Installation....................................................................................................................... 55
Replacing Brake Components .........................................................................59
Brake Rotors ................................................................................................................... 59
Brake Chambers .............................................................................................................. 59
Other Brake Components ................................................................................................ 59
Replacing the ABS Sensor and Tone Ring .....................................................59
Sensor Removal .............................................................................................................. 59
Sensor Installation ........................................................................................................... 59
Tone Ring Removal and Installation .............................................................................. 60
Replacing the Shock Absorber ........................................................................60
Removal .......................................................................................................................... 60
Installation....................................................................................................................... 60
Replacing the Air Spring .................................................................................60
Removal .......................................................................................................................... 60
D712230
2
IFS1000-WF
Table of Contents
Installation....................................................................................................................... 60
Replacing the Height Control Valve ...............................................................61
Removal .......................................................................................................................... 61
Installation....................................................................................................................... 61
Torque Tables ............................................................63
D712230
3
IFS1000-WF
Introduction
Service Notes
This Service Manual describes the correct service and repair procedures for the
ReycoGranning® IFS1000-WF Independent Front Suspension model with 10,000 lb Gross
Axle Weight Rating (GAWR). Overloading the suspension may result in adverse ride and
handling characteristics.
You must read and understand all procedures and safety precautions presented in this manual
before conducting any service work on the suspension.
Proper tools must be used to perform the maintenance and repair procedures in this manual.
Some procedures require the use of special tools for safe and correct service. Failure to use
the proper and/or special tools when required can cause personal injury and/or damage to
suspension components.
You must follow your company safety procedures and use proper safety equipment when you
service or repair the suspension.
The information contained in this manual was current at the time of printing and is subject to
change without notice or liability. ReycoGranning® reserves the right to modify the
suspension and/or procedures and to change specifications at any time without notice and
without incurring obligation.
ReycoGranning® uses the following types of notices for potential safety problems and to
give information that will prevent damage to equipment.
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.
D712230
4
IFS1000-WF
Identification
The suspension model and serial number are stamped on an aluminum tag that is riveted to
the front of the suspension sub-frame assembly (Figure 1). The serial number is used by
ReycoGranning® for control purposes and should be referred to when servicing the
suspension or requesting technical support (Figure 2).
Figure 1 - Suspension Identification Location
Figure 2 - Suspension Serial Number Tag
D712230
5
IFS1000-WF
Vehicle Towing Information
If a vehicle is disabled and needs to be towed by the front end to service center, check the
OEM/Coach Builder towing procedures for the recommended method. Check with local
authorities and Department of Transportation (DOT) for permissible towing methods before
towing. Some states do not permit towing by chains and/or straps.
The preferred towing apparatus is the type that cradles the front tires. If the towing apparatus
cannot be attached to the front tires or directly to the chassis frame rails, then the suspension
sub-frame may be used for attachment.
WARNING
Attaching towing equipment to improper locations and failure to utilize OEM/Coach
Builder recommended towing methods could result in one or more of the following:
··Loss of vehicle control.
··Possible disconnection from tow vehicle.
··Damage to the suspension and/or vehicle.
Do Not attach tow apparatus (hooks, chains, straps, etc.) to suspension upper and lower
control arms, front cross-member, brake components, tie rods, relay rod, or steering knuckle
assemblies (Figure 3).
Figure 3 – Improper Tow Equipment Attachment Locations
D712230
6
IFS1000-WF
Maintenance Schedule
MILEAGE IN THOUSANDS
GENERAL MAINTENANCE
SERVICE TO BE PERFORMED
12
24
36
Check axial endplay
48
60
72
84
X2
X
Inspect for ruptured seals
X
Check nut torque
X
Check that cotter pin is installed
X
96
X
X
X
X
X
X
X2
X
X
X
X
X
X
X2
Steering Knuckle Ball Joints
Check bolt torque
Control Arm Bushings
Relay Rod and Tie Rod
Ends
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 endplay
X
X
X
X
X
X
X
X2
Check for looseness of taper connection
X
X
X
X
X
X
X
X2
Check nut torque
X
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
Inspect for air leaks using soapy water solution
X
Check upper mounting bolt/nut torque
X
Check lower mounting bolt torque
X
Inspect shocks for signs of fluid leak, broken eye
ends, loose fasteners, and worn bushings
X
X
X
X
X
X
X
X2
Check pitman arm retention nut torque
X
Check mounting bolt/nut torque
X
Inspect for signs of fluid leak or loose fasteners
X
X
X
X
X
X
X
X2
Brake System
Air Springs
Shock Absorbers
Steering Gearbox / Pitman
Arm
Check hub bearing endplay
Wheels
Front Alignment
X2
X
Check wheel nut torque1
X
X
X
X
X
X
X
Inspect toe-in3
X
X
X
X2
Inspect caster and camber3
X
X
X
X2
Inspect for air leaks using soapy water solution
X
Inspect for signs of chafing, cracking, or wear
X
Air Fittings and Air Lines
X
X
X
X
X
1. Wheel Nuts must be re-tightened to proper torque specifications as per the vehicle or chassis manufacturer’s Owner Guide
2. Continue to perform specified maintenance every 12,000 miles or at previous interval
3. Final stage manufacturer should complete toe-in inspection and adjustment after completion of vehicle
D712230
X2
7
IFS1000-WF
X
X2
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:
IFS1000-WF
Inspection and Maintenance Item
D712230
Date
Mileage
8
Service Performed
IFS1000-WF
Parts Lists
Unit Assembly
ITEM
PART NO
1
711792-01
ITEM
PART NO
Cradle Assembly
2
3
DESCRIPTION
9
707819-01
Brake Assembly-LH
DESCRIPTION
8757
Lower Control Arm Assembly-LH
10
705951-01
Brake Assembly-RH
Hub and Drum Assembly
Lower Control Arm Assembly-RH
111
711878-01
8756
712211-01
Conmet Hub and Drum
4
711772-01
Upper Control Arm Assembly-LH
12
711775-3284
Relay Rod Assembly
5
711772-02
Upper Control Arm Assembly-RH
13
711775-2084
Tie Rod Assembly
6
8745
Knuckle Assembly-LH
141
7
8744
8
700178-14
712070-02
Steering Gear Assembly
712070-03
Steering Gear Assy. RR
Knuckle Assembly-RH
15
7593
Shock Absorber
16
711868-01
Air Spring Assembly
Pitman Arm
1. Please call customer service with serial number to determine which gear box and hub
assembly you have.
D712230
9
IFS1000-WF
Control Arm Assemblies
ITEM
1
2
3
4
D712230
PART NO
8757
8756
711772-01
711772-02
DESCRIPTION
ASY, LOWER A-ARM, LH
ASY, LOWER A-ARM, RH
ASY-UCA, LH
ASY-UCA, RH
10
ITEM
5
6
7
PART NO
165
168
166
DESCRIPTION
HHB 1.125-12 X 7.5 GR 8 ZY
HFW 1-1/8 ZP
LN 1-1/8-12 XGR C ZY
IFS1000-WF
Upper Control Arm Mounts
Control Arm Components
ITEM
1
2
3
4
5
D712230
PART NO
711771-01
711771-02
8737
8736
8382
DESCRIPTION
ASY-UCA MACHINE-LH
ASY-UCA MACHINE-RH
Machined LCA Casting - LH
Machined LCA Casting - RH
LCA Bushing
11
IFS1000-WF
Steering Components
ITEM
11
2
3
4
5
PART NO
712070-02
712070-03
711868-01
8089
711775-3284
711775-2084
DESCRIPTION
STEERING GEAR ASY, ZF 8016 FR
STEERING GEAR ASY, ZF 8016 RR
PITMAN ARM-ZF SPLINE
IDLER ARM (MACHINED)
RELAY ROD ASY
TIE ROD ASY
1. Please call customer service with serial number to determine which gear box you
have.
D712230
12
IFS1000-WF
Steering Gear Components
ITEM
11
2
3
4
5
PART NO
712070-02
712070-03
711868-01
100122-P1
102354-P1
702637-02
DESCRIPTION
STEERING GEAR ASY, ZF 8016 FR
STEERING GEAR ASY, ZF 8016 RR
PITMAN ARM, ZF SPLINE
7/8-9 UNC STOVER LOCK NUT GRADE C
7/8 FLAT WASHER .938 X 1.75 X .141 ZINC PLATED
7/8-9 X 4 IN HEX HEAD BOLT GRADE 8
1. Please call customer service with serial number to determine which gear box you
have.
D712230
13
IFS1000-WF
Steering Gear Assembly
ITEM
PART NO
DESCRIPTION
704730-01 ASY GEARBOX ZF 8016 FR
11
704730-02 ASY GEARBOX ZF 8016 RR
2
710376-01 90DEG ELBOW O8 ORB-M X 08 JIC-M
3
712071-01 1/2 BARB X 08 37DEG JIC-F FITTING
4
712154-01 1/2 IN RUBBER CAP**
5
710215-01 90DEG ELBOW O8 ORB-M X 08
6
710216-01 EXTENSION 08 ORM-M X 08
7
710345-01 CAP, STEEL #8**
** FOR SHIPPING PURPOSES ONLY
1. Please call customer service with serial number to determine which gear box you
have.
D712230
14
IFS1000-WF
Idler Arm Components
ITEM
1
2
3
4
5
6
7
8
9
D712230
PART NO
100122-P1
102354-P1
7331
8611
7332
8089
89411019
7271
292
DESCRIPTION
LN 7/8-9 UNC STOVER GR C
FW 7/8 .938 X 1.75 X .141 ZP
SNAP RING
SHIM 1-3/8 X 1-7/8 X .004
BEARING SINGLE ROW ONE SEAL
IDLER ARM (MACHINED)
GREASE FITTING 1/8-27 NPT 90 DEG
SLEEVE
HHB 7/8-9 X 8.50 GR 8 ZN
15
IFS1000-WF
D712230
16
IFS1000-WF
Tie Rod Assemblies
ITEM
1
2
3
D712230
PART NO
711774-2684
711774-1484
103736
DESCRIPTION
RELAY ROD ASY
TIE ROD TUBE
BALL JOINT-LH
ITEM
4
5
6
17
PART NO
103712
6632
101445-P1
DESCRIPTION
BALL JOINT-RH
TUBE CLAMP
COTTER PIN
IFS1000-WF
Air Spring Components
ITEM
PART NO
7593
AIR SPRING
712283-01
AIR SPRING
1
1
2
178
3
20852-01
4
308
5
1
6
DESCRIPTION
ITEM
7
1
PART NO
DESCRIPTION
712210-02
AIR SPRING RELO BRACKET-RH
712335-02
AIR SPRING RELO BRACKET-RH
SFCS 1/2-13 X 1.0
LFN 3/4-16 GR G
8
709640-02
WSHR, FLAT 3/4 X 148, .120
9
8757
ASY, LOWER A-ARM, LH
LFN 1/2-13 GR G ZINC
10
8756
ASY, LOWER A-ARM, RH
1001601
WSHR, FLAT 1/2 X 1.06, .137 JIT
11
8274318
HHB 1/2-20 X 5 GR 8 ZN
712210-01
AIR SPRING RELO BRACKET-LH
12
8120384
712335-01
AIR SPRING RELO BRACKET-LH
SLW 1/2 .523 X .873 X .135 ZN
Left hand components shown exploded. Items 7 and 10 are Right Hand components.
1. Please call customer service with serial number to determine which air spring and
brackets you have.
D712230
18
IFS1000-WF
Shock Components
ITEM NO
1
2
3
4
5
D712230
PART NO
700178-14
8223833
20852-01
178
100678-P1
DESCRIPTION
SHOCK ABSORBER
HHB 3/4-16 X 4 GR 8 ZY
WSHR, FLAT 3/4 X 148, .120
LFN 3/4-16 GR G
HHB 3/4-10 X 3-1/2 GR 8 ZY
19
IFS1000-WF
Wheel End Components
ITEM
PART NO
DESCRIPTION
ITEM
PART NO
1
712153-01 BRAKE ASY, 15X4, -16 CHAMBER-LH
9
6967
2
712153-02 BRAKE ASY, 15X4, -16 CHAMBER-RH
10
6968
3
287
HHB 5/8-18 X 1-1/2 GR 8 ZY
11
6969
4
7977
OIL SEAL
12
6970
5
1784
BEARING-TAPER 2-5/8
13
700024-01
6
711878-01 HUB/DRUM ASY
14
700017-01
7
705310-01 FN M22 X 1.5 X 31 2PC LUG NUT
15
266
8
6972
BEARING-TAPER 1-3/4
Left hand components shown exploded. Items 2 and 4 are Right Hand components.
D712230
20
DESCRIPTION
INNER NUT (IFS)
SPINDLE LOCKWASHER (IFS)
WASHER SPINDLE (IFS)
SPINDLE OUTER NUT (IFS)
HUB CAP GASKET
HUB CAP
FHB 5/16-18 X 3/4 GR 5 ZC W/LS
IFS1000-WF
Wheel End Components
ITEM
1
2
3
4
5
6
PART NO
712153-01
712153-02
287
7977
712211-01
712284-01
D712230
DESCRIPTION
BRAKE ASY, 15X4, -16 CHAMBER-LH
BRAKE ASY, 15X4, -16 CHAMBER-RH
HHB 5/8-18 X 1-1/2 GR 8 ZY
OIL SEAL (included in hub asy)
PRESET HUB ASY
SPINDLE NUT-LOCKING
ITEM
7
8
9
10
11
21
PART NO
712216-01
705310-01
700024-01
700017-01
266
DESCRIPTION
BRAKE DRUM, 15X4
FN M22 X 1.5 X 31 2PC LUG NUT
HUB CAP GASKET
HUB CAP
FHB 5/16-18 X 3/4 GR 5 ZC W/LS
IFS1000-WF
Steering Knuckle Components
ITEM
PART NO
1
8745
2
DESCRIPTION
ITEM
PART NO
DESCRIPTION
ASY STEER KNUCKLE 12K (DUC) LH
8
705383-01
LOWER BALL JOINT
8741
MACHINED KN CASTING-LH
9
705383-02
SN M30X 1.5
3
8744
ASY STEER KNUCKLE 12K (DUC) RH
10
705383-03
COTTER PIN 1/4 X 1.95 ZN
4
8740
MACHINED KN CASTING-RH
11
7328
5
705382-01
UPPER BALL JOINT
12
705011-27
6
705382-02
SN M22 X 1.5
13
6946
ABS SENSOR (STRAIGHT WITH LEAD)
SLEEVE ABS MOUNTING
ABS SENSOR SPRING RETAINER
7
705382-03
COTTER PIN 5/32 X 1.40 ZN
Left hand components shown exploded. Items 3 and 4 are right hand components.
Item 1 is an assembly containing items 2, 5, and 8.
Item 3 (not shown) is an assembly containing items 4, 5, and 8.
D712230
22
IFS1000-WF
Lubrication
Lubricant Specifications and Intervals
COMPONENT
SERVICE INTERVAL
CHANGE INTERVAL
Rod Ends of Tie
Rods & Idler Arm
Whichever comes first: Every oil
change or every 6 months
N/A
Auto Slack
Adudjuster
Whichever comes first: Every oil
change or every 6 months
Wheel End
Hub oil
Every 1000 miles3
LUBRICANT SPECIFICATION
Multi-Purpose Chassis Grease
Premium Multi-Purpose Chassis
Grease NLGI Grade 2
Multi-Purpose Chassis Grease
N/A
Whichever comes first: Seals
replaced, brakes relined,
100,000 miles (160,000 km),
or once a year
Premium Multi-Purpose Chassis
Grease NLGI Grade 2
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.
2.
3.
Use caution when using an automatic grease gun or seals could possibly be blown out and damaged.
Only check level at ride height and only after coach has not move for 15 min or more. Failure to wait will result in
false readings.
General Lubrication
Proper lubrication practices are important
in maximizing the service life of your
ReycoGranning®
Independent Front
Suspension. See figure 4.
CAUTION
Do not mix lubricants of different
grades. Do not mix mineral and
synthetic lubricants. Different brands
of the same grade and type may be
mixed.
CAUTION
Never mix oil bath and grease packed
wheel ends.
D712230
23
IFS1000-WF
Rod Ends - Tie Rod and
Relay Rod Ends on Tie Rods
Figure 4 – Locations of Lubrication Fittings
D712230
24
IFS1000-WF
Wheel Bearings
3. Check the hub cap for external oil
marks. The vent plug will normally
weep a small amount of oil. Oil marks
in other locations should be addressed
by replacing the hub cap seal, window
gasket, or tightening the pipe fill plug.
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. (Figure 5) Add
oil slowly since the heavy weight oil
will settle slowly in the hub. Check
only after coach has been at rest for at
least 15 minutes. If coach has been
moved oil may be distributed around
cavity and in bearings resulting in a
false low measurement.
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
CAUTION
Do not remove or twist the red plug at
the center of the hub cap. This will
damage the hub cap, and cause oil to
leak. Add oil only thru the pipe plug or
warranty will be void.
Figure 5 – Wheel Bearing Oil Level
D712230
25
IFS1000-WF
Troubleshooting
Troubleshooting
SYMPTOMS
POSSIBLE CAUSES
REMEDIES
Tires have incorrect pressure
Put specified air pressure in tires.
Tires out of balance
Balance or replace tires
Incorrect toe-in setting
Adjust toe-in to specified setting
Incorrect ride height
Adjust ride height to specified setting
Incorrect caster/camber adjustment
Adjust caster/camber
Incorrect steering arm geometry
Adjust tie rod lengths as required
Improper (mismatched) tires and wheels
Install correct tire and wheel combination
Improper oversized tires
Install correct tire and wheel combination
Vehicle is difficult to steer
Tires not uniform
Install correct tire and wheel combination.
Note: Engine must be running for
power steering to be active
and able to provide
steering assist.
Tires have incorrect pressure
Put specified air pressure in tires
Incorrect steering arm geometry
Adjust tie rod lengths as required
Steering arm assemblies binding
Check steering arm assembly bearings and
lubricate as required
Steering arm assembly ball joints binding
Inspect ball joints for wear and replace as
required
Tie rod ends binding
Inspect tie rod ends for wear and lubricate as
required
Steering column linkage binding
Align or adjust as required
Steering miter box binding
Check steering miter box and repair or
replace as required
Steering gear valve binding
Inspect, repair or replace as required
Steering wheel to column interference
Align or adjust as required
Power steering pump fluid level low
and/or possible leak in system
Add fluid, tighten connections and correct as
required
Power steering pump pressure and flow
below specification
Conduct pump flow and relief pressure tests
and adjust, repair or replace as required
Air in power steering system
Add fluid, tighten connections and bleed
system
Contaminated or incorrect fluid
Replace with correctly specified fluid
Obstruction with steering gear pitman arm
or within hydraulic lines
Inspect, remove obstruction(s) and repair or
replace as required
Obstruction within wheelhouse
Inspect, remove obstruction(s) as required
Excessive internal steering gear leakage
Inspect, repair or replace as required
Tires wear out quickly or have
uneven tire tread wear
Note: Wear pattern will indicate
possible cause(s). Consult
tire manufacturer for
guidance.
D712230
26
IFS1000-WF
SYMPTOMS
Vehicle wanders side-toside…loose steering
Steering wheel has large
amplitude, rotational
oscillations when hitting large
bumps
POSSIBLE CAUSES
REMEDIES
Vehicle overloaded or unevenly loaded
driver side to passenger side
Improper (mismatched) tires and wheels
Tires have incorrect pressure
Check wheel loads and correct as required
Incorrect toe-in setting
Incorrect wheel caster setting
Tie rod end connection loose or ball stud
worn
Steering arm assembly mounts loose
Steering arm assembly ball joints binding
or worn
Wheel bearings out of adjustment
Adjust toe-in to specified setting
Adjust wheel caster to specified setting
Inspect ball stud connections and wear
Loose steering gear mounting
Loose pitman arm
Steering column linkage worn
Vehicle pulls to one side
without the brakes applied.
Check and tighten to specification
Inspect ball joints for wear or contamination
and replace as required
Check wheel bearing end play and adjust as
required
Check mounting and secure as required
Check pitman arm and tighten as required
Check for wear and repair or replace as
required
Steering gear lash adjustment
Steering column misaligned
Loose Wheel Nuts
Check and adjust to specification
Realign steering column as required
Check and tighten to specification
Vehicle overloaded or unevenly loaded
driver side to passenger side
Improper (mismatched) tires and wheels
Tires have incorrect pressure
Check wheel loads and correct as required
Unequal ride height side to side
Improper brake adjustment
Incorrect rear axle alignment
Incorrect caster and/or camber setting
Wheel bearings out of adjustment
Loose steering gear mounting
Tie rod end connection loose or ball stud
worn
Bent spindle or steering arm
Frame or underbody out of alignment
Incorrect toe-in setting
Mis-aligned belts in radial tires
Steering gear valve binding
Steering gear not centered
Excessive internal steering gear leakage
Excessive water puddling on road
Boot contact w/ bottom of steering column
D712230
Install correct tire and wheel combination
Put correct air pressure in tires based on
wheel load
27
Install correct tire and wheel combination
Put correct air pressure in tires based on
wheel load
Inspect ride height and adjust to specified
setting
Inspect and adjust slack adjusters as
required
Align rear axle to specified thrust angle
Check and adjust as required
Check wheel bearing end play and adjust as
required
Check mounting and secure as required
Inspect ball stud connections and wear
Inspect and replace as required
Inspect and correct as required
Adjust toe-in to specified setting
Check and replace as required
Inspect, repair or replace as required
Inspect and adjust as required
Inspect, repair or replace as required
Avoid water puddles on road
Inspect, Repair, Adjust as required
IFS1000-WF
SYMPTOMS
Vehicle pulls to one side
with the brakes applied
Vehicle rolls side to side
excessively
Front tires lock up during
hard braking or ABS
malfunction light remains lit
D712230
POSSIBLE CAUSES
REMEDIES
Grease, oil or dirt on brake pads
Replace brake shoes as required
Brake shoes are glazed
Deglaze brake shoes by burnishing or
replace as required
Brake shoes are not a balanced set,
different friction codes or pad brand
Replace brake shoes as required
Loose or broken brakeshoes
Replace brake shoes as required
Brake drum warped
Re-machine or replace brake rotor as
required
Defective brake drum
Inspect for defects and replace as required
Brake air chamber clevis pin or camshaft
binding
Check and lubricate as required
High spots on one set brake shoes
with respect to opposite side
Match machine shoes to drums
Uneven brake adjustment side to side
Adjust brake as required
Different brake air chamber size side to
side
Replace with same size brake air chambers
Brake chambers air pressure uneven side
to side
Check side-to-side air pressure and correct
as required
Rear axle brakes misadjusted or
contaminated
Check, adjust, or replace as required
ABS system malfunction
Check ABS system for proper function
Air leak or obstruction in air brake lines
Check fittings with soapy water solution and
remove obstructions
Brake air chamber air leak or diaphragm
damaged
Check chamber for air leak and damaged
diaphragm
Excessive water puddling on road
Avoid water puddles on road
Front and/or rear shock absorbers worn
Replace shock absorbers as required
Shock mounting loose
Check and tighten as required
Shock eye bushings worn
Check and replace as required
Sway bar bushings worn
Check sway bar bushings and replace as
required
Sway bar mounting brackets loose
Check sway bar mounting brackets and
tighten as required
Control arm pivot bushings worn
Inspect and replace as required
Internal leak in height control valve
Check height control valve and replace as
required
ABS sensor malfunction
Inspect ABS sensor installation and replace
sensor as required
ABS CPU or system malfunction
Check and repair or replace as required
ABS sensor electrical connection faulty
Check ABS sensor connection and lead wire
Tone ring on hub damaged
Check for damage and replace as required
28
IFS1000-WF
SYMPTOMS
Vehicle ride is too harsh
and/or suspension contacts
stops excessively
Vehicle ride is too soft
Vehicle has unequal turning
radius right to left
Suspension does not
maintain ride height
Brakes are noisy
POSSIBLE CAUSES
REMEDIES
Front shock absorbers worn
Replace shock absorbers as required
Incorrect ride height
Adjust ride height to specified setting
Vehicle overloaded
Check wheel loads and correct as required
Air spring supply lines leaking or
obstructed
Check air line connections and remove
obstructions
Vehicle system air pressure below
specification
Check air pressure and correct as required
Rebound bumper worn or missing
Check and replace as required
Jounce bumper in air spring worn or
broken
Check and replace air spring as required
Vehicle air pressure insufficient
Install check valves to prevent air back flow
Insufficient load
Add load to increase spring rate
Front shock absorbers worn
Replace shock absorbers as required
Incorrect ride height
Adjust ride height to specified setting
Incorrect steering arm geometry
Adjust tie rod lengths as required
Steering gear not centered
Inspect and adjust Pitman arm as required
Steering gear poppet valves set
incorrectly
Check wheel turn angles and adjust as
required
Tie rod clamps positioned improperly
Check orientation and adjust as required
Air leak
Check connections with soapy water solution
and repair or replace as required
Internal leak in height control valve
Check height control valve and replace as
required
Height control valve linkage loose
Check and tighten linkage as required
Air spring chafed or worn
Check air spring and Replace as required
Insufficient air pressure do to back flow
Install check valves to prevent back flow
Grease, oil or dirt on brake shoes
Replace brake shoes as required
Brake shoes are glazed
Deglaze brake shoes by burnishing or
Replace as required
Brake shoes are not a balanced set,
different friction codes or brand
Replace brake shoes as required
Loose or broken brake shoes
Replace brake shoes as required
Brake Drum Warped
Re-machine or Replace as required
Defective Brake Drum
Inspect for defects and Replace as required
Contact Customer service at 1-800-753-0050
D712230
29
IFS1000-WF
Adjustments
Inspection
WARNING
General Inspection
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 the Front Wheel Alignment section for
wheel alignment inspection intervals.
Check wheel alignment if excessive
steering effort, vehicle wander, or
abnormal tire wear is evident.
Fasteners - Check that all the fasteners are
tightened to the proper tightening torque.
Use a calibrated torque wrench to check
torque.
Wear and Damage - Inspect components
of the suspension for wear and damage.
Look for bent or broken components.
Replace
all
worn
or
damaged
components.
Operation - Check that all components
move freely through the complete wheel
turning arc.
Never work under a vehicle supported
by only a jack(s). Jacks can slip or fall
over and cause serious personal injury.
Always use safety stands. Do not place
jacks or safety stands under the lower
control arms to support the vehicle.
Lower control arms are not stationary
components and could move allowing
the vehicle to drop causing serious
personal injury.
The vehicle may be supported on safety
stands by the suspension sub-frame, or
chassis frame for inspections that require
removal of the wheel and tires or deflation
of the air springs. Always secure the
vehicle by setting the parking brake and
block the drive wheels to prevent vehicle
movement before inspections.
Inspecting the Control
Arm Bushings for Wear
NOTE
CAUTION
It is recommended that the bushings in
all of the control arms be replaced at
the same time if one is found worn.
Reyco Granning LLC recommends
replacing any damaged or out-ofspecification components.
Reconditioning or field repairs of front
suspension components is prohibited.
Some cast components are heattreated. These components as well as
other non-heat treated castings cannot
be bent, welded, heated, or repaired in
any way without reducing the strength
or life of the component thus voiding
the warranty. Only genuine
ReycoGranning® replacement
components are allowed.
D712230
1. Check clearance between each control
arm and sub-frame bushing mount.
Look for contact pattern as evidence of
bushing wear. Replace worn bushings
in both control arm housings as
needed.
2. Check for bushing bulging between the
control arm and sub-frame mount or
presence of small rubber particles near
sub-frame bushing mount.
30
IFS1000-WF
3. Check that the control arm mounting
bolts are tight. Recommended torque
is 465-485 ft-lb for lower control arms
and 950-1050 ft-lb for upper control
arms (See Torque Table). A loose
joint will result in wear between the
bushing inner sleeve and sub-frame
mount.
4. Measure the axial movement with a
scale. If the movement is greater than
1/8 inch (3mm) replace the tie rod end
immediately. If the socket moves but
the movement is less than 1/8 inch
(3mm) then the tie rod end should be
replaced before 1/8” (3mm) movement
occurs.
5. Check dust boot for damage. Replace
as needed.
Inspecting the Tie Rod
Ends
6. Check tie rod clamp orientation
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.
1. With the engine on, lightly rock the
steering wheel and have an assistant
observe any looseness in the two
mating tapers or any movement of the
stud nut at both ends of the tie rod. If
looseness is found in either place go to
step 2, otherwise skip to step 3.
Figure 6 - Tie Rod
2. Remove the tie rod end ball stud from
the taper mount and visually inspect
both. If either of the mating tapers
shows distortion or wear, then both
components must be replaced. Torque
Tie Rod Castle Nuts to 90-100 ft-lb
(See Torque Table).
Inspecting the Brake
System
The suspension system is equipped with
Haldex brand automatic slack adjusters
for steer axles. Refer to Haldex technical
service guideline #485-89007 for
inspection 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 (Figure 6). Be sure to only apply
hand pressure to the tie rod.
D712230
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.
31
IFS1000-WF
Inspecting the ABS
Sensor and Tone Ring
1. The wheels and may need to be
removed to ease inspection of tone
ring and sensor.
10. Repeat Step 3. If voltage output is less
than 0.8V AC then replace the ABS
sensor.
NOTE: Check voltage output of new sensor.
2. Disconnect the ABS sensor lead from
the chassis connector.
3. The ABS sensor test will require a
voltmeter that can measure AC voltage
on a 0-10V scale.
4. Connect the voltmeter to the connector
pins of the ABS sensor lead.
5. Set the voltmeter scale to millivolts
and the voltage source to AC volts.
Figure 7 - ABS Sensor and Tone Ring Gap
6. Rotate the wheel hub by hand and
record the voltage output from the
ABS sensor. A minimum output of
0.8V AC is normal.
Inspecting the Shock
Absorber
1. Check shock absorbers for oil leakage,
bent components, missing or broken
components, excessive corrosion, or
worn bushings. Replace shock
absorbers if any of the above items is
present.
7. 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.
8. Check physical gap between the sensor
and tone ring (Figure 7).
The
maximum allowable gap is .027 inch.
If the gap is greater than .027 inch,
press on the wire lead end of the
sensor and push the sensor into contact
with the tone ring. Check that the
ABS spring retainer and bushing are
not unseated. Re-seat components as
needed.
9. 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.
D712230
32
IFS1000-WF
2. Start vehicle engine. Oscillate the
steering wheel and observe the motion
of the steering arm assemblies (see
figure 8). The steering arm assemblies
should not exhibit any noticeable
conical motion about their pivot axes.
Inspecting the Air
Spring
Air Spring Inspection
1. Refer to Firestone’s Preventative
Maintenance Checklist for additional
air spring information.
3. If any conical motion is observed
check pivot bolt torque which should
be 575-625 ft-lb (See Torque Table).
Otherwise, replace the bearing set of
the steering arm assembly that exhibits
conical motion.
2. Check the outside diameter of the air
spring for irregular wear or heat
checking.
3. Check airlines to make sure contact
does not exist between the airlines and
the outside diameter of the air spring.
Re-secure airlines to prevent contact as
needed. Check for airline and fitting
leaks with soapy water solution.
4. Check to see that there is a minimum
of 1-inch clearance around the
circumference of the air spring while it
is energized with air.
5. Check the air spring piston for buildup
of foreign material. Remove any
foreign material that is present.
Figure 8 - Steering Arm Assemblies
Endplay Inspection
1. Install a dial indicator with a magnetic
base so that the base is fixed to the
steering arm assembly. Place the
indicator tip on the flat area of the
Relay Rod adjacent the castle nut.
2. Using a C-clamp, squeeze the Relay
Rod and the steering arm assembly
together to seat the ball joint. Do not
apply excessive clamp load.
3. Set the dial indicator on “zero”.
Inspecting the Idler Arm
1. Check that steering arm assembly
pivots are free of foreign material and
bearing seals are in place.
D712230
33
IFS1000-WF
4. Release the clamp. Place the pry bar
between the steering arm assembly and
the Relay Rod. Do not allow the pry
bar to contact the ball joint seal.
Firmly pry upward using the steering
arm assembly as a fulcrum to lift the
Relay Rod. The pry load must not
cause the Relay Rod to rotate thus
causing the Relay Rod to change
orientation.
5. Record the dial indicator reading. A
reading greater than .040” will require
ball joint replacement.
6. Inspect ball joint seal for damage and
replace the ball joint if damaged
during measurement process.
Inspecting Wheel
Bearing Endplay
Figure 9 - Wheel End Play
Measurement
1. Remove the tire and wheel.
2. Remove the hub cap.
3. Attach a dial indicator with a magnetic
base to the face of the hub.
NOTE
4. Place the tip of the dial indicator on
the center of the steering knuckle
spindle. Set the dial indicator on zero
(Figure 9).
Do not push/pull at the top and the
bottom of the hub. Pushing or pulling
at the top and the bottom will not yield
a true measurement of the endplay.
5. Measure
the
endplay
by
simultaneously pushing/pulling on
opposite sides of the hub while
observing the dial indicator. The
endplay is the total travel observed. If
the endplay is not within .001-.005”,
see the section on adjusting the wheel
bearing endplay.
D712230
34
IFS1000-WF
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.
Replacing the Ball
Joints
Ball joints may be replaced individually,
however, it is recommended to replace
upper and lower ball joints at the same
time. The ball joints cannot be rebuilt or
repaired.
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
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.
3. Remove the tires and check that
the air springs are deflated.
Upper Ball Joint Removal Thread-In Mount
1.
2
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.
Remove the cotter pin from the
ball stud.
Remove the castle nut from the
ball stud.
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.
NOTE: Be careful to not displace or
damage ball joint seals during
removal from the control arm taper
hole.
3
Disconnect the upper control arm.
The ball stud may be forced from
the tapered hole by use of a
suitable tool.
Preparation
D712230
35
IFS1000-WF
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
5
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.
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.
3. Disconnect the lower control
arm. The ball stud may be forced
from the tapered hole by use of a
suitable tool.
Secure steering knuckle in a vise
or similar device. Loosen the ball
joint and remove it from the
CAUTION: Do not strike the
lower control arm directly
with a steel hammer. Parts
can break and cause serious
personal injury. Wear eye
protection.
Upper Ball Joint
Installation - Thread-In
Mount
1. Inspect the threads in the
steering knuckle and remove any
burrs or debris.
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.
2. Apply thread adhesive Loctite
#242 or equivalent to the ball
joint threads and thread the ball
joint into the steering knuckle.
5. Secure steering knuckle in a vise
or similar device. Loosen the ball
joint and remove it from the
steering knuckle.
3. Tighten the base of the ball joint
to 325-375 lbfft. See Torque
Table.
4. Follow steps 6-8 for press-in
mount type.
Lower Ball Joint Removal
1. Remove the cotter pin from the
ball stud.
2. Remove the castle nut from the
ball stud.
D712230
36
IFS1000-WF
Lower Ball Joint 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. Inspect the threads in the
steering knuckle and remove any
burrs or debris.
2. Apply thread adhesive Loctite
#242 or equivalent to the ball
joint threads and thread the ball
joint into the steering knuckle.
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. Tighten the base of the ball joint
to 525-575 lbfft. See Torque
Table.
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.
4. Connect the ball joint to the
lower control arm.
5. Tighten the castle nut to 330-370
lbfft. See Torque Table.
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.
5. Remove the vent plug from the
hub cap.
Adjustment
Note: Some models equipped with conmet
preset hubs, contact customer service with
serial number for specification.
1. Place an oil drip tub beneath the
hub to catch oil. Rotate the hub
such that the hubcap drain plug
is facing upwards. Remove the
drain plug from the hubcap and
place it in a container for reinstallation.
Checking and Adjusting
the Wheel Bearings
Preparation
1. Set the parking brake and block
the drive wheels to prevent
vehicle movement.
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.
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.
D712230
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.
37
IFS1000-WF
hub while observing the dial
indicator. The end play is the
total travel observed. If the end
play is not within .001-.004 inch
for standard nuts and .001-.005
for preset hub adjust the wheel
bearings per steps 4-16. (See
Figure 21). Otherwise skip to
step 21. For standard nut
continue with step 7-15 and 2123. For preset hub skip to step
16-21.
4. Attach a dial indicator with a
magnetic base to the face of the
wheel, hub, or brake drum. The
dial indicator may also be
attached to the bottom of the
brake drum if the wheel is
removed.
5. Place the tip of the dial indicator
on the center of the steering
knuckle spindle. Set the dial
indicator on zero. (See Figure
10).
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.
7. Unbend the retainer washer and
remove the spindle outer nut,
retainer washer, and locking
washer. Loosen the inner
spindle nut.
8. Seat the bearings by tightening
the inner spindle nut to 180
lbfft. while rotating the wheel
in both directions.
9. Rotate the hub and drum ten (10)
complete revolutions.
Figure 10 - Wheel End Play Measurement
10. Loosen the inner spindle nut
completely and then tighten the
nut to 20 lbfft.
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.
11. Back off the inner spindle nut 1/4
turn.
12. Install spindle locking washer.
6. Measure the end play by
simultaneously pushing/pulling
on each side of the tire, drum, or
D712230
38
IFS1000-WF
18. Rotate hub assembly back and
forth while tightening locking
spindle nut to final torque of 300
ft-lb.
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.
19. Remove socket and verify locking
clip tabs have engaged the
adjustment slots in retainer cage
on locking spindle nut.
20. Measure end play between hub
assembly and spindle with dial
indicator. Acceptable end play
between hub and spindle is .001.004 inches.
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.
21. Install hub cap gasket and hub
cap. Tighten the cap screws to
20-30 lbfft. See Torque Table.
Replace the hub cap vent plug if
removed in Preparation step 5.
13. Install the retainer washer and
outer spindle nut. Tighten outer
spindle nut to 200-300 lbfft.
See Torque Table.
22. Fill the hub cavity with the
appropriate amount and type of
lubricant. (See Section 4 for
lubricant specifications).
14. Verify that wheel end play is
between .001-.004 inch. (See step
6). If not, repeat by altering
amount of inner nut back off
until end play is achieved.
23. Install vent plug
15. Bend retainer washer over one
wrench flat of the outer nut.
Adjusting Suspension
Ride Height
16. Use 2 1/8” socket to loosen
locking spindle nut.
The height control valve (HCV) and
linkage should be checked regularly for
proper
clearance,
operation
and
adjustment.
17. Place 2-4 Drops of oil on spindle
threads. Align retainer cage tab
(“D” flat) on locking spindle nut
with “D” flat on spindle. Rotate
socket by hand clockwise until
locking spindle nut contacts
outer bearing in hub assembly.
Do not use powered tool to run
bearing down against bearing. If
locking spindle nut will not
rotate freely on spindle, nut may
be cross threaded. Rotate counter
clockwise until threads
disengage. Repeat locking
spindle nut installation.
D712230
NOTE
Improperly adjusted ride height will
result in incorrect wheel alignment
measurements and may result in
abnormal tire wear. Check the ride
height prior to front suspension
alignment.
The ride height of the front suspension is
the distance from the bottom of the chassis
frame rail to the center of the wheel
39
IFS1000-WF
spindle. An alternate measurement may be
taken as the height of the air spring
(Figure 11).
B: On vehicles with front suspension
equipped with a single height control
valve, check and adjust the rear
suspension after finish adjusting the
front.
4. Measure either the wheel center to
bottom of frame (“A”) or air spring
height (“B”). If the dimensions are not
within ±1/8” of measurements in
Figure 11 adjust as follows.
A: Loosen the height control valve
linkage stud retaining nuts.
B: Raise or lower the L-shaped linkage
stud as necessary.
Figure 11 – Measurement at Ride
Height
Unit
IFS1000WF
Ride Height “A”
9.37”
C: Tighten the retaining nuts.
SHOCK HT “B”
15.59”
NOTE: It is recommended that the upper
and lower studs be positioned
parallel to each other. Torque to 812 ft-lb.
Properly adjusted ride height results in
correct suspension travel and alignment.
The ride height should not be adjusted to
adjust chassis rake angle.
5. After adjusting the length, it is
recommended to dump and re-inflate
the air suspension to obtain the ride
height. Allow the suspension to settle.
CAUTION
6. If not already completed, adjust the
rear suspension per manufacturer’s
recommendations.
Adjusting the ride height can cause the
front end to raise or lower
unexpectedly due to vertical
movements at the connection of the
vertical link and the horizontal arm of
the height control valve.
7. Verify at each axle that the side-to-side
ride heights are within .25” of each
other.
1. Park the vehicle on a level surface.
Adjusting the Maximum
Wheel Turn Angle
2. Exhaust or “dump” and re-inflate the air
suspension. Allow the Suspension to
settle.
CAUTION
3. Check ride height of rear suspension:
Do not adjust maximum wheel turn
angle greater than 42.5°. Misadjustment of the wheel turn angle can
cause damage to steering system
components.
A: On vehicles with front suspension
equipped with (2) height control
valves, check and adjust the rear
suspension first.
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IFS1000-WF
The turn angle may require adjustment if
the front tires rub against the frame,
suspension, body, or the steering gear has
been serviced or replaced.
Use an
alignment machine to check the wheel turn
angle. See the measurement procedure of
the alignment machine manufacturer.
The steering stop bolt on the steering
knuckle controls the maximum turn angle.
If the stop bolt is missing, bent, or broken;
replace the stop bolt(s) or jam nut(s) and
follow the procedure below for
adjustment.
Inspect other suspension
components for damage.
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.
Figure 12 - Steering Stop Bolt
Unit
IFS1000WF
Steering Stop Length “A”
1.75”
1. Drive the front tires on a suitable
device that allows the front wheels to
turn and measures the wheel turn
angle.
If the steering stop bolts are adjusted to
reduce wheel turn angle, the steering gear
poppet valves will require readjustment. If
the poppets are not re-adjusted properly,
then the steering gear will not reduce
power assist properly and steering
components will be damaged. Refer to ZF
Steering Gear Service Manual for
readjusting the poppets.
NOTE
Unequal toe-in side to side or an outof-center steering gear can result in
unequal turn angles and steering pull
while steering straight ahead. The
Crank Rod length may be adjusted to
attain steering gear on center condition
while maintaining equal toe-in side to
side. Do not adjust the length of the
Crank Rod or Tie Rods to center the
steering wheel. This can cause the
steering gear to become off center.
D712230
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IFS1000-WF
2. Secure the vehicle by setting the
parking brake and block the drive
wheels to prevent vehicle movement.
10. Repeat checking and adjustment for
turning the opposite direction. ( See
Figure 12)
Inspection before
Alignment
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 ToeIn Section and refer to pitman arm
center mark alignment info.
See the General Inspection section and
check the following before conducting
front wheel alignment measurements.
Wheels and Tires
1. Check that the front tires are inflated to
the appropriate pressure based on the
tire loading.
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.
2. Check that the front tires are the same
size and type.
3. Check that the wheel
assemblies are balanced.
5. Turn the steering wheel until the
steering stop bolt contacts the knuckle
carrier or the steering wheel stops
turning. Measure the turn angle of the
wheel on the same side as the direction
of turn.
tire
4. Check that all the Wheel Nuts are
tightened to the specified torque of
450-500 ft-lb (See Torque Table).
6. If the wheel turn angle differs then
adjust as follows.
Front Suspension
7. Loosen the jam nut on the stop bolt.
1. Check that all fasteners are tightened
to the specified torque.
8. Turn the stop bolt until the specified
wheel turn angle is achieved and the
bolt head contacts the knuckle carrier.
2. Check the suspension ride height and
adjust as needed to the specified
height.
9. Tighten the jam nut to 50-75 ft-lb (See
Torque Table).
3. Check for worn ball joints, tie rod
ends, steering arm assembly bearings,
control arm bushings, knuckle carrier
bearings, 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 that other
components are not abnormally
contacting one another.
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and
42
IFS1000-WF
Equipment
4. Check for loose ball joint and tie rod
end tapered connections, tie rod end
jam nuts, steering arm assembly
mounts, and chassis steering system
components. Inspect connections for
wear and replace as needed. Tighten
connections as needed.
ReycoGranning®
recommends
that
suitable alignment equipment be used to
measure
the
wheel
alignment
characteristics: camber, caster, and toe-in.
The alignment equipment must be
properly
calibrated
for
accurate
measurements. Only qualified personnel
should conduct the wheel alignment
measurements.
5. Check the wheel bearing adjustment
and adjust as needed.
6. Inspect the shock absorbers for wear
and damage.
General
Rear Axle and 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.
Front tire wear and incorrect steering can
be caused by the rear axle and/or
suspension.
1. Check that all fasteners are tightened
to the specified torque.
2. Check the suspension ride height and
adjust as needed to specified height.
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.
Shims between the upper control arm
mounts are used for additional adjustment
of camber. Add and remove as needed.
The ray align on the upper control arm
will adjust castor to minimize drifts or
pulls to one side of the road.
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.
NOTE
Total vehicle alignment is
recommended when aligning the front
suspension.
Front Wheel Alignment
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IFS1000-WF
Preparation
WARNING
1. Follow the alignment equipment
manufacturer’s
procedures
for
preparing the vehicle for front and rear
wheel alignment measurements.
Never work under a vehicle supported
by only a jack(s). Jacks can slip or fall
over and cause serious personal injury.
Always use safety stands. Do not place
jacks or safety stands under the lower
control arms to support the vehicle.
Lower control arms are not stationary
components and could move allowing
the vehicle drop causing serious
personal injury.
2. Secure the vehicle by setting the
parking brake and block the drive
wheels to prevent vehicle movement.
NOTE
An out-of-center steering gear can
result in unequal wheel turn angles.
The steering gear should remain
centered during toe-in adjustment. Do
not adjust the length Tie Rods to
center the steering wheel. This can
cause the steering gear to become off
center.
6. Raise the vehicle until the front wheels
are off the ground. Support the raised
vehicle with safety stands.
3. Check that the steering gear is centered
when the tires are steered straight
ahead (i.e. equal toe-in side to side).
Center the steering gear according to
the pitman arm center marks on the
steering box.
4. Measure and record the individual
wheel camber, caster, and toe-in of the
front suspension. Also measure and
record the cross camber cross caster,
and overall toe-in.
5. If adjustment to camber and caster is
required then follow the steps below.
Otherwise, go to the “Adjusting the
Toe-In” section to adjust the toe-in as
needed.
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IFS1000-WF
will need to be added or removed
Adjusting the Camber
Angle
Nominal Camber Values-Degrees
Unloaded
Loaded
Left
+1/4°(±1/4°)
+1/4°(±1/4°)
Right
+1/4°(±1/4°)
+1/4°(±1/4°)
depending if positive or negative
adjustment is needed.
Figure 13 – Camber Angle
CAUTION
Do not alter components to adjust the
camber.
Camber is the angle of the wheel with
respect to the ground as viewed from the
front or rear of the vehicle (Figure 13).
Camber is positive when the distance
between centers of the front wheels at the
top is greater than the distance at the
ground.
Wheel Camber Angle is affected by the
ride height of the suspension. If the ride
height is set too high, then the camber
measurement will be more positive. See
the inspecting and adjusting suspension
ride height sections before measuring
camber.
The table below lists the
recommended camber angles.
Upper Control Arm Camber
Adjustment
To adjust camber the upper control arm
mounts will need to be loosened and shims
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IFS1000-WF
Figure 14 – Upper Control Arm Camber Adjustment
1. Loosen both upper control arm
mounts. DO NOT REMOVE BOLTS.
This will allow shims to be removed or
added. (See Figure 14)
NOTE: Adding shims increases
camber. Removing shims decreases
camber.
2. Adding shims will make a positive
adjustment and removing shims with
make a negative adjustment.
3. Once adjustment is made and set retorque all upper control arm bolts and
nuts to 190 ft-lb.
4. Remove the jack stands and lower
vehicle completely. Check that the
suspension is at the proper ride height.
5. Re-measure the camber and readjust as
needed.
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IFS1000-WF
Nominal Caster Values-Degrees
Unloaded
Loaded
Left
+3°(±1/2°)
+3°(±1/2°)
Right
+3°(±1/2°)
+3°(±1/2°)
Adjusting the Caster
Angle
Positive
Caster
Negative
Caster
Upper control arm Caster
adjustment
The Castor is adjusted by using the reyalign bolt located on the upper control
arm. SEE FIGURE 16 for detail.
Figure 15 – Caster Angle
The caster angle is the angle between a
vertical axis and the axis defined by the
king pin when viewed from the side of the
vehicle. (Figure 15) When the king pin
axis appears rotated clockwise relative to
the vertical axis, then the caster is positive.
Positive caster creates a self-aligning
moment to stabilize the vehicle when
driving straight ahead The caster angle is
indirectly measured from the change in
wheel camber as the wheel is turned
through a prescribed turn angle. Therefore,
the calculated caster is affected by the ride
height of the suspension. See the
inspecting and adjusting suspension ride
height sections before measuring caster.
The table below lists the recommended
caster angles.
D712230
CAUTION
Do not adjust the suspension ride
height or alter components to adjust
the caster.
47
IFS1000-WF
Figure 16 – Eccentric Caster Adjustment
Note: Movement of upper control arm towards rear will increase caster.
Movement of upper control arm towards front will decrease caster.
1. Loosen both upper control arm
mounts. DO NOT REMOVE BOLTS.
2. Loosen jam nuts on rey-aligner and
adjust to correct caster values.
3. Re-torque rey-align bolt and nut to 350
ft-lb.
4. Re-torque upper control arm mounts to
190 ft-lb.
5. Remove the jack stands and lower
vehicle completely. Check that the
suspension is at the proper ride height.
6. Re-measure caster and readjust as
needed.
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IFS1000-WF
Adjusting the Toe-In
CAUTION
Do not alter components to adjust the
toe-in.
CAUTION
Improperly oriented tie rod clamps
can cause binding in the suspension
steering system.
Wheel toe-in is the relationship of the
distance between the centers of the front
and rear of the front wheels. When the
front distance is less than the rear distance,
the wheels are “toed-in”. Toe-in is
designed into the suspension to counteract
the tendency of the tires to toe-out when
the vehicle is driven straight ahead.
Incorrect toe-in can result in rapid tire
wear.
1. Measure the length of the outer tie
rods. Reference length is 17 inches.
2. If the lengths of the outer tie rods are
not within 1/8 inch of each other, then
adjust their lengths such that they are
within 1/8 inch of each other. Loosen
the tie rod clamps on each end of the
tie rod and turn the center tube to
change the length.
3. Adjust the length of both outer tie rods
equally such that the toe-in on each
side is 1/16” ± 1/32” and the overall
toe-in is 1/8” ± 1/16”. Tighten tie rod
clamp nuts to 50-60 ft-lb (See Torque
Table).
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IFS1000-WF
Repairs
Repair
WARNING
General Procedures
Repair or reconditioning of front
suspension components is not allowed.
Components that are damaged or worn
must be replaced. Several major
components are heat treated and tempered.
Never work under a vehicle supported
by only a jack(s). Jacks can slip or fall
over and cause serious personal injury.
Always use safety stands. Do not place
jacks or safety stands under the lower
control arms to support the vehicle.
Lower control arms are not stationary
components and could move allowing
the vehicle drop causing serious
personal injury.
WARNING
The components cannot be bent,
welded, heated altered, or repaired in
any way without reducing the strength
or life of the component and voiding
the warranty.
The vehicle may be supported on safety
stands by the suspension sub-frame or
chassis frame for repairs that require
removal of the wheel and tires or deflation
of the air springs. Always secure the
vehicle by setting the parking brake and
block the drive wheels to prevent vehicle
movement before performing repairs.
The following operations are prohibited on
front suspension components.
1. Welding of or to the steering knuckles,
control arms, steering arm assemblies,
knuckle carrier, tie rod assemblies, the
brakes, the hubs, and the brake rotors.
Cleaning the Parts
2. Hot or cold bending of the steering
knuckles, control arms, steering arm
assemblies, knuckle carrier, tie rod
assemblies, ball joints, and the subframe except control arm and steering
arm assembly mounts which may be
cold bent to facilitate bushing and
bearing replacement.
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.
3. Drilling out control arm and steering
arm assembly mounting holes and ball
stud tapered holes.
Ground or Polished Parts
4. Spray welding of bearing diameters on
the steering knuckle spindle, steering
arm assembly bores and pivot tube.
Spray welding of ball studs or tapered
holes for the ball joint and tie rod ends.
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.
5. Milling or machining of any
component except that control arm
bushing bores may be honed to remove
any burrs.
D712230
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IFS1000-WF
Rough Parts
4. Inspect the tie rod end ball stud and
mating component tapered hole(s).
Replace components with worn
tapered hole(s). If the grease seal is
damaged during removal, replace it
before installation.
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.
Installation
Drying
1. Clean the mating component tapered
hole(s) of any contamination. Insert
the tie rod end ball stud into the
tapered hole and secure it with the
castle nut.
Parts must be dried immediately after
cleaning. Dry all parts with clean paper or
rags, or compressed air. Do not dry
bearings by spinning with compressed air.
CAUTION
Preventing Corrosion
Apply light oil to cleaned and dried parts
that are not damaged and are to be
immediately assembled. Do NOT apply
oil to the brake pads or the brake rotors. If
the parts are to be stored, apply a good
corrosion preventative to all surfaces and
place them inside special paper or
containers that prevent corrosion. Do
NOT apply corrosion preventative to the
brake pads or the brake rotors.
Tighten the castle nuts to the specified
torque. If the castle nuts are not
tightened to the specified torque, the
parts will be damaged and serious
personal injury may occur.
2. Tighten the castle nut to 90-100 ft-lb
(See Torque Table).
3. Install the cotter pins. If necessary,
tighten the castle nut to align the hole
in the ball stud and slots in the castle
nut. Do not loosen the castle nut to
install the cotter pin.
Replacing Tie Rod Ends
Removal
4. Lubricate tie rod end as needed.
1. Remove the cotter pins from the tie rod
end ball stud(s).
2. Remove the castle nuts from the tie rod
end ball stud(s).
CAUTION
Do not strike the component mating
taper directly with a steel hammer.
Parts can break and cause serious
personal injury. Wear eye protection.
3. Disconnect the tie rod end ball stud
from the mating component tapered
hole using a suitable tool.
D712230
51
IFS1000-WF
5. Inspect the pivot sleeve and remove
burrs with emery cloth.
Replacing the Idler Arm
Bearings
6. Install one retaining ring onto pivot
sleeve.
Replace the idler bearings in sets. The
replacement bearings should be installed
by pressing on the outer raceway only.
Pressing on the inner raceway will damage
the bearing.
The inner grease cavity of the steering arm
assemblies should be cleaned when the
bearings are replaced.
Removal
7. Insert the pivot sleeve into the lower
bearing. Use a rubber mallet or similar
tool to drive the inner sleeve into the
bearings such that the bottom-retaining
ring is seated against the bottom inner
race. Do not use a steel hammer to
install the sleeve because bearing
raceways can be damaged.
1. Follow the procedures for removal of
the center rod, pitman arm, and idler
arm.
8. Install upper retaining ring. Reseat
lower retaining ring against the lower
inner race as needed.
2. Follow the procedures for removal of
tie rod ends for the idler arm.
9. Determine the number of shims needed
by stacking the shims and placing the
stack between the upper retaining ring
and inner race until a snug fit is
achieved. Remove one shim from the
stack and this is the number of shims
needed. A maximum of six shims may
be used.
3. Remove the pivot bolts that mount the
idler arm. Remove them from the subframe.
4. Remove the retaining rings from the
pivot sleeve and remove the sleeve. A
rubber or brass hammer may be used
to remove the sleeve. Retain shims.
10. Remove the upper retaining ring,
install the shims determined in step 9
onto the inner sleeve at upper inner
race, and re-install the upper retaining
ring. Check that upper retaining ring is
properly seated in the groove of the
inner sleeve.
5. Support the steering arm assembly
bearing housing and press the bearing
out of each end.
Installation
1. Clean out the steering arm assembly
grease cavity.
11. Place the steering arm assembly in its
mount and install the pivot bolt.
Tighten the pivot bolt lock nut to 575625 ft-lb (See Torque Table).
2. Inspect steering arm assembly bearing
housing bores and remove burrs by
honing. Replace steering arm assembly
if the bore is damaged.
3. Pack the steering
bearing with grease.
arm
12. Follow the procedures for installation
of the Relay Rod or tie rod.
assembly
Replacing the Upper
and Lower Control Arm
Bushings
4. Support the steering arm assembly
bearing housing and press the bearing
into each end. The seal side of the
bearing should face out.
D712230
The subframe control arm mounts may
require widening to accommodate
52
IFS1000-WF
replacement bushings. The width may be
increased by inserting a suitable jack
between the bushing mounts and cold
bending the mounts. Care must be taken to
not exceed 5.00” width after widening.
The control arm mounts should be
inspected for damage.
Both control arm bushings and mounting
fasteners must be replaced in a control arm
when bushings are serviced.
ReycoGranning® recommends replacing
the control arm bushings and mounting
fasteners in all of the control arms at the
same time.
The control arm housings must be
properly supported during bushing
removal. The bores of the control arm
housings may be honed to remove any
burrs.
If the control arm is to be separated from
the steering knuckle, follow the removal
and installation procedures in the
“Replacing the Ball Joint” Section.
under the lower control arms to
support the vehicle.
3. Remove the tires and check that
the air springs are deflated.
Upper Control Arm
1. Disconnect height control valve
linkage from the upper control
arm. Follow the removal procedure
in “Replacing the Height Control
Valve” Section.
WARNING: The steering knuckle
is heavy and unevenly balanced.
Use a portable crane or suitable
jack to support it prior to
disconnecting it from the control
arm or removing the control arm
with the steering knuckle
attached.
2. If desired, disconnect the upper
control arm from the steering
knuckle. Follow the removal
procedure in “Replacing the Upper
Ball Joint” Section.
CAUTION: Use of a cutting torch
to remove control arm bolts will
permanently damage control arm
bushings and can result in
damage to subframe.
3. Loosen and remove the control
mount arm bolts. Remove any
existing eccentric components.
Note the orientation of the set
screws for reinstallation.
Preparation
1. Set the parking brake and block
the drive wheels to prevent
vehicle movement.
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.
2. Raise the vehicle until the front
wheels are off the ground. Support
raised vehicle with safety stands.
Do not place jacks or safety stands
D712230
7. Place the control arm in its mount
location. If not equipped with
eccentrics, install the control arm
53
IFS1000-WF
mount bolts into subframe snug
tight and skip to step 15.
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.
8. Place the spacer into the bushing.
9. Insert an eccentric adapter on each
end of the upper control arm
mounting plate.
10. Place bolt and washer through the
spacer and bushing as shown.
11. Install washer and locking nut.
2. If desired, disconnect the lower
control arm from the steering
knuckle. Follow the removal
procedure in “Replacing the Lower
Ball Joint” Section.
12. Repeat the process for the rear
upper control arm mounting bolt.
13. Rotate the eccentric adapters on the
front mounting bolt, such that the
set screws are located as previously
orientated.
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.
14. Vehicle alignment may have to be
checked. Please refer to Section 5.
When the eccentric adapters are
properly oriented, tighten the bolts.
5. Inspect the housing bores and
remove any burrs in the housing by
honing.
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.
6. Press the bushing into the control
arm housing. Be sure to properly
support the housing.
16. Install and tighten the set screw on
any eccentrics installed to 30-40
lbfin. Refer to Torque Table.
7. Place the control arm in its mount
location. Install the control arm
mount bolts into subframe snug
tight.
17. Reconnect the steering knuckle to
the control arm if disconnected.
Follow the installation procedure
in “Replacing the Upper Ball
Joint” Section.
8. Support the control arm such that it
is at ride height and tighten the
bolts to 950-1050 lbfft. See
Torque Table.
18. Reconnect the height control valve
linkage. Follow the installation
procedure in “Replacing the Height
Control Valve” Section.
9. Reconnect the steering knuckle to
the lower control arm if
disconnected. Follow the
installation procedure in
“Replacing the Lower Ball Joint”
Section.
Lower Control Arm
1. Disconnect the lower shock mount
from the lower control arm. Follow
the removal procedure in
“Replacing the Shock” Section.
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IFS1000-WF
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.
10. Reconnect the lower shock mount.
Follow the installation procedure
in “Replacing the Shock” Section.
Replacing Wheel
Bearings, Oil Seals, and
Hub Caps
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.
Preparation
Removal
1. Set the parking brake and block
the drive wheels to prevent
vehicle movement.
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 reinstallation.
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.
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.
WARNING: Never work under a
vehicle supported by only a jack.
Jacks can slip or fall over and
cause serious personal injury.
Always use safety stands.
3. Remove the 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. Skip to
step 5 for Ax-Lock hub.
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.
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. On aluminum wheels, place a
plastic anti-scuff guard over the
wheel nuts and loosen the wheel
nuts. On steel wheels, remove
the hub cap nuts if present and
the hub cap before loosening the
wheel nuts. Place the hub cap in
safe location to prevent damage.
Place the wheel and/or hub cap
nuts in a container to prevent
contamination or loss.
D712230
4. Unbend the spindle washer and
remove the spindle outer nut,
spindle washer, locking “D”
washer, and the inner spindle
55
IFS1000-WF
nut. Retain all components for
re-assembly except discard the
spindle washer.
Installation
1. Remove the axle ring from the
replacement hub seal assembly
P/N 7977 if the axle ring is not
removed from the spindle. Note
axle ring orientation. Place the
hub seal onto the axle ring with
the ribbed rubber side facing the
flange of the axle ring. Seat the
hub seal firmly against the axle
ring flange. If the axle ring is
removed, install the hub seal
assembly with appropriate seal
installation tool. (Reference
Stemco P/N 555-5098)
5. For Ax-Lock use 2 1/8” socket to
remove hub nut and continue
with step 6.
6. Place a shop towel on top of the
lower brake shoe to prevent oil
from dripping onto the brake
lining.
7. 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.
NOTE: Do not drive bearing onto
spindle with a steel hammer or
similar instrument. Inner race is a
tight slip fit with spindle.
8. 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. 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.
9. Remove the hub seal and discard
it. Inspect the axle ring on the
spindle and remove it if worn.
4. Place the hub onto the spindle
until it seats on the inner
bearing. Do not “ram” the hub
onto the seal.
10. 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.
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. For
Ax-Lock hub skip to step 13-16.
6. Install the inner spindle nut and
tighten hand tight.
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56
IFS1000-WF
be cross threaded. Rotate counter
clockwise until threads
disengage. Repeat locking
spindle nut installation.
7. Seat the bearings by tightening
the inner spindle nut to 180
lbfft while rotating the wheel in
both directions.
14. Rotate hub assembly back and
forth while tightening locking
spindle nut to final torque of 300
ft-lb.
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.
15. Remove socket and verify locking
clip tabs have engaged the
adjustment slots in retainer cage
on locking spindle nut.
10. Back off the inner spindle nut ¼
turn.
11. Install the spindle locking “D”
washer.
16. Measure end play between hub
assembly and spindle with dial
indicator. Acceptable end play
between hub and spindle is .000.006 inches.
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.
17. Attach a dial indicator with a
magnetic base to the face of the
hub. (See Figure 17). Note the
brake drum is shown for
reference only.
18. Place the tip of the dial indicator
on the center of the steering
knuckle spindle. Set the dial
indicator on zero.
CAUTION: Never tighten the
inner spindle nut to align the
dowel pin with hole in locking
washer. This can pre-load the
bearings and cause premature
bearing failure.
NOTE: Do not push/pull at the top and
the bottom of the hub. Pushing or
pulling at the top and the bottom will
not yield a true measurement of the end
play.
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.
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 711. Otherwise continue to step
16.
13. Place 2-4 Drops of oil on spindle
threads. Align retainer cage tab
(“D” flat) on locking spindle nut
with “D” flat on spindle. Rotate
socket by hand clockwise until
locking spindle nut contacts
outer bearing in hub assembly.
Do not use powered tool to run
bearing down against bearing. If
locking spindle nut will not
rotate freely on spindle, nut may
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IFS1000-WF
Figure 18 - Wheel Bearing Oil Level
Figure 17 - Wheel End Play
Measurement
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.
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 20-30 lbfft. See Torque Table
for sequence.
18. Fill the hub cavity with the
appropriate amount(approx ½
pint) and type of lubricant(90W
gear oil).
22. Install the brake drum.
23. Install the wheel and tire
assembly and the wheel nuts.
19. Check oil level through the hub
cap window. (See Figure 18). If
level is below the “add” level line,
then fill with recommended oil
until “full” level is achieved. Add
oil slowly since the heavy weight
oil will settle slowly in the hub.
(Note: The hub cap window can
only be cleaned with mild soap
and water. Aromatic solvents
should not be used as they will
impair the transparency of the
window.)
D712230
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.
25. Replace the hub cap nuts and
hub caps if removed to service
the wheel bearings.
26. Remove jack stands and jacks
58
IFS1000-WF
Replacing Brake
Components
The anti-lock brake sensor and tone ring
cannot be repaired and must be replaced if
damaged or malfunctioning.
Brake Drums
Sensor Removal
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. Remove the Brake Caliper to provide
access to sensor.
2. Press sensor out of steering knuckle.
Do not pull sensor out by its lead wire.
3. Remove tie straps that secure the
sensor lead wire and disconnect the
sensor lead wire from the chassis wire
harness.
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.
Sensor Installation
1. Check that the sensor bushing is
properly seated in the steering knuckle
and the sensor spring retainer is seated
properly in the sensor bushing.
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.
2. Press the sensor into the steering
knuckle until the sensor end contacts
the tone ring.
3. Connect a volt meter to the connector
pins of the sensor lead wire. Set the
volt meter to read AC voltage on a
scale of 0-10V.
Other Brake Components
The brake shoe linings should be replaced
when they are worn beyond the
manufacturers limits. When the brake
linings are serviced, other components
such as the S-cam rollers and return
springs should also be serviced. Refer to
the brake manufacturers guidelines for
servicing the brakes.
4. Spin the hub by hand and read the
voltage output of the sensor. A
minimum reading of 0.8V AC is
normal. Skip to step 8 if minimum
reading is obtained.
5. 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.
Replacing the ABS
Sensor and Tone Ring
The anti-lock brake system (ABS) of the
vehicle should be diagnosed by a qualified
technician before the anti-lock brake
sensor or the tone ring is replaced.
Replacement parts must be equivalent to
the vehicle manufacturers to ensure proper
function of the anti-lock brake system.
D712230
6. If the minimum reading is not
obtained, check the tone ring for
damage and its installation. The tone
ring should have a maximum run out
of .008”. Replace as needed and
repeat step 4.
59
IFS1000-WF
7. If the minimum reading is still not
obtained, then replace the sensor and
repeat the installation procedure.
2. Position shock in suspension such that
the thru bolt is connected to the lower
shock mounting bracket tabs.
8. Route and secure the sensor lead wire
the same as the removed sensor.
3. Tighten lower thru mounting bolt and
nut to 170-190 ft-lb (See Torque
Table). Tighten lower shock bracket
mounting bolts to 30-40 ft-lb (See
Torque Table).
9. Connect the sensor lead wire to the
chassis. Secure wire lead to prevent
damage during suspension movement.
4. Tighten upper mounting nut to 170190 ft-lb (See Torque Table).
Tone Ring Removal and
Installation
Replacing the Air
Spring
Follow the hub manufacturer’s guidelines
for removal and installation of the tone
ring.
The correct air spring must be installed.
The use of a substitute air spring is not
allowed and may cause unequal load
sharing between the air springs and cause
adverse ride and handling characteristics.
Replacing the Shock
Absorber
CAUTION
Removal
1. Deflate the air spring by disconnecting
one end of the vertical HCV linkage
from the horizontal arm. Rotate the
horizontal HCV arm downward and
secure it in place.
The shock absorber is gas pressurized
and must not be punctured or be
subjected to excessive heat which can
result in serious personal injury. The
shock will expand to its full extended
length if not restrained.
2. Disconnect the airline at the air spring
inlet port and remove the connection
fitting from the inlet port.
Removal
1. Remove the lower shock thru bolt
mounting hardware and retain for
installation. Do not remove the lower
shock mount bracket from the lower
control arm.
3. Remove the bolts and washers from
the upper air spring mount studs. Note
location of bolts and washers.
4. Remove the bolts that secure the air
spring to the lower air spring mount.
2. Remove
upper
shock
bushing
mounting hardware and retain for
installation.
Note location and
quantity of washers and spacers.
Installation
1. Attach air spring to upper air spring
mount. Note that the shorter bolt is
located towards the front. Tighten
mounting hardware snugly.
Installation
1. Loosely attach upper shock bushing to
sub-frame with mounting hardware
(spacers on forward side of shock).
D712230
2. Attach air spring to lower air spring
mount. Tighten lower mounting bolts
to 20-30 ft-lb (See Torque Table).
60
IFS1000-WF
3. Tighten the upper mounting bolts to
15-20 ft-lb (See Torque Table).
4. Remove the HCV mounting hardware
from the sub-frame.
4. Apply Permatex or equivalent thread
sealant to the threads of the air
connection fitting and install the
fitting.
5. Remove any other air fittings or
plumbing fixtures from the HCV.
5. Connect the airline to the fitting.
1. Apply Permatex or equivalent thread
sealant to the threads of the air
connection fittings or plumbing
fixtures and install the fittings or
plumbing fixtures in the HCV.
Installation
6. Inflate the air spring by un-securing
the HCV horizontal arm and
reconnecting the vertical linkage to it.
7. Check the airline and fitting for air
leaks.
2. Attach the HCV to the sub-frame with
mounting hardware. Orient the
horizontal arm horizontally and tighten
the mounting nuts to 7-9 ft-lb (See
Torque Table).
Replacing the Height
Control Valve
3. Connect airlines as marked during
removal.
The correct height control valve (HCV)
must be installed. The use of a substitute
HCV is not allowed and may cause
unequal load sharing between the air
4. Connect the vertical linkage to the
horizontal arm.
5. Recharge system with air and check
for air leaks.
NOTE
6. Check the ride height and adjust per
section on adjusting the ride height as
needed.
Lower control arm may move
downward due to the internal gas
charge in the shock absorber. A
portable jack may be needed to align
the lower control arm with the knuckle
carrier bar pin.
springs and cause adverse ride and
handling characteristics.
Removal
1. Drain the air from the supply reservoir
on the chassis connected to the front
suspension.
2. Disconnect the vertical HCV linkage
from the horizontal arm.
3. Mark airlines and connections for reassembly.
Disconnect the airlines
from the HCV. If any other plumbing
fixtures are connected to the HCV,
mark them for re-assembly.
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D712230
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IFS1000-WF
Torque Tables
Torque Tables
Most threaded fasteners are covered by
specifications that define required
mechanical properties, such as tensile
strength, yield strength, proof load, and
hardness.
These specifications are
carefully considered in initial selection of
fasteners for a given application. To
assure continued satisfactory vehicle
performance, replacement fasteners used
should be of the correct strength, as well as
the correct nominal diameter, thread pitch,
length, and finish.
Grade Markings on Bolts
Grade
Lock Nut
Grade B, F
Lock Nut:
Grade C, G
3 Dots
6 Dots
Identification
Grade Markings on Lock Nuts
Torque Table 1
Applications
Fastener Size
Upper Control Arm Bushing Pivot Bolt
Lower Control Arm Bushing Pivot Bolt
Lower Steering Knuckle Ball Joint Nut Castle Nut
Upper Steering Knuckle Ball Joint Nut Castle Nut
Upper Control Arm Mount Brackets
Air Spring Lower Mount Bolt (into Air Spring)
1-1/8-12 x 7.5 Gr 8
1-1/8-12 x 7.5 Gr 8
M30 x 1.5
M20 x 1.5
5/8-11 x 2.5 Gr 8
SFCS 1/2-13 x 1
1/2-20 x 5 Gr 8
1/2-13 Gr G
3/4-16 Gr G
7/8-9 x 4 Gr 8
7/8-9 x 8.5 Gr 8
M20-1.5
5/8-11 Grade B
3/4-10 Grade C
3/4-10 Grade C
1/2-20 Grade B
1 1/8-12 Grade C
Air Spring Locating Bracket
Upper Air Spring Mount Nuts
Steering Gear Mounting Bolts
Idler Arm Pivot Bolt
Tie Rod and Relay Rod Ball Joint Castle Nut
Tie Rod Clamp Nut
Upper Shock Eye Mount Lock Nut
Lower Shock Eye Mount Lock Nut
Steering Stop Jam Nut
Pitman Arm Nut
Hub Cab Bolts
5/16-18 x 3/4 Gr 5
1) Torque applied to fastener head
2) Apply thread adhesive Loctite #242 or equivalent to threads of fastener
3) Install cotter pin after properly torquing nut
4) Stake nut to steering gear output shaft.
a) Locate notch in output shaft
b) Use punch or dull chisel to drive raised section of pitman arm nut into notch in output shaft.
c) Take care not to tear raised section of pitman arm nut while staking
D712230
63
Torque Specification (ft-lb)
(Clean and Dry)
950-1050(1)
950-1050(1)
350-360(3)
160-170(3)
170-190(1)
7-10(2)
50-55(2)
25-35(2)
40-50(2)
325-375(1)
325-375(1)
90-100(3)
50-60
170-190(1)
170-190
50-75
345-420(4)
17-22
IFS1000-WF
Torque Tables
Torque Table 2
APPLICATIONS
FASTENER SIZE
TORQUE SPEC.
(ft-lb) (CLEAN AND
DRY)
TORQUE SEQUENCE
4
2
6
7
Torque Plate Mount
Cap Screws
5/8-18 Grade 8
5
170-190
1
3
Driver Side
1
Hub Cap Bolt
5/16-18 Grade 5
6
3
4
5
20-30(1)
2
9
Wheel Nut
M22x1.5
(Hub Piloted)
(2)
450-500
(Dry Threads)
1
6
7
3
4
8
10
2
5
1) Torque applied to bolt head
2) Recheck Wheel Nut torque after first 50-100 miles
D712230
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IFS1000-WF
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D712230
65
IFS1000-WF
IS0 9001:2008 Certified
1-800-753-0050
w w w. r e y c o g r a n n i n g . c o m
Mount Vernon
1205 Industrial Park Drive
Mount Vernon,MO 65712
(800) 753-0050,Fax (417) 466-3964
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