Neway IFS Series Maintenance Manual

Neway IFS Series Maintenance Manual
IFS SERIES
MAINTENANCE
MANUAL
IFS Series
Independent Front
Air-Ride Suspension
Maintenance Manual
XL-AK397-01
Holland Neway Technical/Customer Service Tel: 1-800-237-8932
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Maintenance Schedule . . . . . . . . . . . . . . . . . . .3
Serial Number Tag Information . . . . . . . . . . . . .4
Vehicle Towing Information . . . . . . . . . . . . . . .5
Torque Specifications . . . . . . . . . . . . . . . . . .6-7
Pre-Operational Inspection . . . . . . . . . . . . . . . . . .8
Control Arm Bushing . . . . . . . . . . . . . . . . . . . .8
Tie Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . .9
Automatic Slack Adjusters . . . . . . . . . . . . . . . .9
Air Spring Adjustment . . . . . . . . . . . . . . . . . .10
Height Control Valve Adjustment . . . . . . . . . .10
Adjusting Suspension Ride Height . . . . . . . . .11
Type CR and IR Height Control Valves . . . .11-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Greasing Knuckle Post Assembly . . . . . . . . . .13
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Wheel Bearing and Hub Caps . . . . . . . . . . . . .14
Checking and Adjusting . . . . . . . . . . . . . . . . . . . .15
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . .15
Maximum Turn Angle . . . . . . . . . . . . . . . . . . .16
Inspection Before Alignment . . . . . . . . . . . . .17
Front Wheel Alignment . . . . . . . . . . . . . . . . . .18
Caster Angle Adjustment . . . . . . . . . . . . . . . .18
Camber Angle Adjustment . . . . . . . . . . . . . . .19
Adjusting Toe-In . . . . . . . . . . . . . . . . . . . . . .19
Part Replacement . . . . . . . . . . . . . . . . . . . . . . . .20
Parts Repair . . . . . . . . . . . . . . . . . . . . . . . . . .20
Parts Cleaning . . . . . . . . . . . . . . . . . . . . . . . .20
Upper and Lower Control Arm . . . . . . . . . .20-21
Shock Absorber Replacement . . . . . . . . . . . . .22
Air Spring Replacement . . . . . . . . . . . . . . . . .23
Knuckle Post Connection . . . . . . . . . . . . .23-24
Steering Gear Replacement . . . . . . . . . . . . . .25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .26-27
Parts List Information . . . . . . . . . . . . . . . . . . .28-31
Introduction
You must read and understand all of the safety
procedures presented in this manual before starting
any work on the IFS suspension.
Proper tools must be used to perform the maintenance and repair procedures described in this
manual. Many of these procedures require special
tools.
Failure to use the proper equipment could result in
personal injury and/or damage to the suspension.
IMPORTANT: Includes additional information
that if not followed could lead to hindered
product performance and/or product failure.
CAUTION
Used without the safety alert symbol, indicates a
potentially hazardous situation which, if not avoided,
may result in property damage.
Safety glasses must be worn at all times when
performing the procedures covered in this
manual.
Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
Throughout this manual, you will notice the terms
“NOTE, ” “IMPORTANT,” “CAUTION” and
“WARNING” followed by important product information. So that you may better understand the manual,
those terms are as follows:
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION
WARNING
NOTE: Includes additional information to enable
accurate and easy performance of procedures.
2
IFS Series Suspension
Introduction
Table 1 - Maintenance Schedule
Mileage in the Thousands (X 1,000)
General Maintenance
Service to be performed
Control Arm Bushings
Check for proper torque on bolts
Upper and Control Lower Arms
Inspect for contact between Control Arm and Mount Brkts
X
X
X
X
X
X
X
X2
Inspect for bushing wear
X
X
X
X
X
X
X
X2
Inspect ball socket end play
X
X
X
X
X
X
X
X2
Check for looseness of taper connection
X
X
X
X
X
X
X
X2
Check that cotter pin is installed
X
X
X
X
X
X
X
X2
Inspect slack adjuster for correct stroke
X
X
X
X
X
X
X
X2
Inspect for air leaks using soapy water solution
X
Inspect for proper clearance (1" minimum all around)
X
Check upper mount nut and lower mount bolt torque
X
Inspect for signs of chafing or wear
X
X
X
X
X
X
X
X2
Check for air line fitting torque
X
Inspect for air leaks using soapy water solution
X
Inspect for signs of bending, binding, or slippage
X
X
X
X
X
X
X
X2
X
X
X
X
X
X
X2
X
X
X
X
X
X
X2
12
Tie Rod Ends
Brake System
Air Springs
Height Control Valve Linkage
Shock Absorbers
Steering Arms
Wheels
24
36
X
Check stud mount and lock nut torque
X
Inspect shocks for signs of fluid leak, broken eye
ends, loose fasteners, or worn bushings
X
Check for proper torque on nuts
X
Inspect bearings for excessive radial play
X
60
X
Check bearing end play
Check for proper torque on wheel nuts1
48
72
84
X
X2
X2
X
X
Front Alignment
Inspect toe-in3
Air Fittings and Air Lines
Inspect for air leaks using soapy water solutions
X
Inspect airlines for signs of chafing, cracking, or wear
X
X
X
X
X
X
X
X
X
X
96
X
X
X
X
X
X2
X2
X
X2
1.Wheel nuts must be re-tightened to proper torque specifications as per the vehicle or chassis manufacturer's Owner Guide.
2.Continue to perform specified maintenance every 12,000 miles.
3.Toe-in should be inspected after vehicle completion by final stage manufacturer.
IFS Series Suspension
3
Introduction (Continued)
Serial Number Tag Location
Serial Number Tag Description
The IFS Series Suspension Serial Tag is attached to
the forward front subframe bulkhead (Fig.1).
Stamped on this tag are the suspension model and
serial number and parts list number (Fig.2).
The sample tag shown below will help you interpret
the information on the Holland Neway Serial Tag.
The model number is on the first line along with the
suspension capacity. The second line contains the
serial number and the third line has the parts list
numbers (Fig. 2). This information will aid you
when contacting the chassis manufacturer or Holland
Neway.
The serial number is used by Holland Neway for
control purposes and should be referred to when
servicing the suspension.
NOTE: This manual applies to the suspension
series shown on front cover. However, we urge you
to reference your specific parts lists number, write
that information below and use it when obtaining
information or replacement parts. Holland Neway
reserves the right to modify or change the suspension
described in this manual, its specifications and its
repair and maintenance procedures at any time without notice or incurring any obligation.
Figure 2. - Holland Neway Serial Number Tag Example
HOLLAND NEWAY
INTERNATIONAL, INC
MUSKEGON, MICH., U.S.A.
MODEL NO.
CAPACITY (LBS.)
IFS-114-P
14,000 LBS.
SERIAL NO.
IF-0213021-CD
PARTS LIST NO.
90547128
COVERED BY ONE OR MORE OF THE FOLLOWING PATENTS (OTHER PATENTS PENDING)
4,193,612
4,322,061
4,595,216
4,634,141
4,700,968
4,729,579
4,262,929
4,405,154
4,615,539
4,693,486
4,726,571
4,736,958
4,854,409
5,083,812
5,201,898
5,335,695
5,393,096
4,858,949
5,088,763
5,203,585
5,335,932
5,413,374
4,991,872
5,112,078
5,288,100
5,375,819
5,192,101
5,058,916
5,116,075
5,315,918
5,058,917
5,333,645
JAPAN PATENT 2038539
PART #93800269
6,116,626
MODEL NUMBER:
SERIAL NUMBER:
PARTS LISTS NUMBER:
IN SERVICE DATE:
The Parts List Number is directly related to Coach Builders IFS
Bill of Material and will be most useful in determining proper
replacement parts.
Figure 1. - Serial Number Tag Location
Serial Number
Plate Location
4
IFS Series Suspension
Introduction (Continued)
Vehicle Towing Information
BEFORE attempting any type of towing procedures
the OEM/Coach Builder must be referred to for the
recommended towing methods.
NOTE: Before towing vehicle check with local
authorities (Department Of Transportation) for
permissible towing methods. Some States DO NOT
permit towing vehicles by chains or towing straps.
DO NOT attach tow apparatus (hooks, chains,
straps, etc.) to Control Arms (upper or lower), Sway
Bar, Brake Components, Tie Rods or Knuckle Post
Assemblies (Fig. 4).
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:
• Damage to the suspension and/or vehicle.
• Loss of vehicle control.
• Possible disconnect from the vehicle.
Figure 4. - Improper Tow Equipment
Attachment Locations,
DO NOT attach towing equipment to
any of the identified components.
Upper
Control
Arms
Brake Chamber
& Components
Knuckle Post
Assembly
Tie Rod
Tie Rod
Lower Control Arms
IFS Series Suspension
5
Introduction (Continued)
Figure 4. - IFS Pre-Operational Torque Checklist
Torque Specifications
IMPORTANT: Most of the
fasteners used in this suspension are graded fasteners. These
fasteners have the strength and
hardness properties required
for their particular function.
When replaced, they must be
replaced with fasteners of the
same grade, size and form as
the original in order to prevent
failure.
1
3
6
4
9
19
2
11
8
7
5
Table 2 - Torque Chart
Item
Fastener Size
Bolt - (Dia. x Thd./Inch x Length)
Nut - (Dia. - Thd./Inch)
7/8" - 9 x 3.5"
Application
1
Steering Gear Attachment
2
Knuckle Post/Spindle Tapered Lock Pin
3
Upper Control Arm Inner Sub-Frame Connection
1" - 8 x 5"
4
Knuckle Post/Control Arm Connections
1 1/4" - 12 x 8.5"
5
Lower Control Arm Inner Sub-Frame Connection
5/8" - 11 x 3.5"
6
Shock Absorber Connections
3/4" - 10 x 3.5"
7
Steer Arm to Spindle Connections
1 3/8" - 12
8
Tie Rod Assembly Clamp Bolts
5/8" - 11
9
Steer Arm to Tie Rod Assembly
7/8" - 14
10
Brake Chamber to Brake Bracket
5/8" - 11 x 1.5"
11
*Wheel Spindle Nut/Wheel Bearing Adjustment
1 1/2" - 18
12
Pitman Arm Retaining Bolt (TRW Gear Only)
3/4" - 10 x 4"
13 N/S Pitman Arm Retaining Tab Lock (Sheppard Gear Only)
14 N/S Pitman Arm to Tie Rod Assembly
7/8" - 14
15 N/S Foundation S-cam Brake Assembly to Spindle
5/8" - 18 x 2.25"
16 N/S Air Spring Upper Mounting Nut (Air Inlet)
3/4" - 16
17 N/S Air Spring Upper Mounting Nut
1/2" - 13
18 N/S Air Spring Lower Attachment Nut
1/2" - 13
19
King Pin Caps w/Grease Fittings
20 N/S Steering Stop Jam Nut
5/8" - 18
21 N/S Sway Bar Attachments (Country Coach Models Only)
1/2" - 13
22 N/S Height Control Valve Bracket to Sub-Frame
1/2" - 13 x 1.5"
23 N/S Height Control Valve to Bracket (if applicable)
3/8" - 16
24 N/S Height Control Valve Linkage
1/4" - 20
Numbered items are called out in Figure 4. - IFS Pre-Operational Torque Check list.
Item number plus N/S equals "Not Shown".
10
Fastener
Grade
Gr 5
Gr 8
Gr B
Gr 8
Gr 5
Gr 5
Gr 5
Gr 5
Gr 8
Gr 8
Gr 8
Gr B
Gr 5
Gr 5
Gr 5
Gr 5
19
9
Torque Specification
Clean, Dry Threads**
(Ft. Lb.)
400 - 450
55 - 60
450 - 550
630 - 770*
150 - 200
90 - 110
680 - 740*
50 minimum
125 - 135*
130 - 170
See Wheel Bearing Adj.
125 - 150
430 - 470
125 - 135*
220 - 260
30 - 40
30 - 40
30 - 40
68 - 82
90 - 110
40 - 50
70 - 80
20 - 30
5 - 10
* Indicates cotter pin installation necessary after torque attainment.
** Torque spec's do not take into consideration the utilization of anti-friction or anti-seize compounds.
*** All torques listed are for tightening of the nuts unless otherwise noted.
Figure 5. - Bolt Grade Markings & Lock Nut Grade Markings
Grade
Grade 1 or 2
6
Grade 5
Grade 8
IFS Series Suspension
Lock Nut
Grade B
Lock Nut
Grade C
3 Dots
6 Dots
Identification
Introduction (Continued)
Torque Specifications
Table 3 - Torque Chart
Applications
Brake Spider Mount
Fastener Size
Torque Sequence
5/8" - 18
Torque Specifications
FT. LB.
(Clean & Dry)
170 - 190 (1 & 2)
Driver Side
Hub Cap Bolt
5/16" - 18 Grade 5
20 - 30 (1)
1 1/8" - 16
(Stud Piloted)
450 - 500 (3)
Wheel Nut
M22 x 1.5
(Hub Piloted)
(Dry Threads)
IFS Series Suspension
7
Pre-Operational Inspection
Introduction
Control Arm Bushings & Connections
IMPORTANT: Safety glasses must be worn at all
times when performing the procedures covered in
this manual.
The control arm bushings must be inspected for wear.
A thorough visual inspection of the suspension is
necessary to ensure proper assembly and identify
problem parts and loose fasteners before servicing.
Perform all of the following during the inspection.
• Operation - All components must be checked
to assure that they move freely through the
complete turning arch of the steering.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack(s) only. Jacks can
slip or fall over and cause serious personal
injury. 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.
Inspection Procedures
• Wheel Alignment - See page 3 for inspection
intervals. See Wheel Alignment guidelines (page
18) if excessive steering effort, vehicle wander,
or abnormal tire wear is evident.
1. Secure the vehicle by setting the parking brake
and blocking the drive wheels.
• Fasteners - Use a calibrated torque wrench to
check that all fasteners are tightened to the
torque specifications listed in Table 2 & 3 on
pages 6 & 7.
3. Support the vehicle with safety stands.
• Wear and Damage - Visually check suspension
for broken or bent parts. All worn, damaged or
out-of-spec components must be replaced.
WARNING
Altering or attempting to repair or modify a
component can adversely effect the suspension strength and performance and could
result in the loss of vehicle control.
IMPORTANT: Repair or reconditioning of
suspension components is prohibited. Most parts
are heat treated and tempered and can not be
welded, bent, heated or repaired in any way
without reducing the strength or the life of the
component thus voiding the warranty. Genuine
component replacement only is allowed.
2. Jack the vehicle up to raise the front wheels off
from the ground.
4. Remove the tires.
5. Look for bushing bulge between the upper and
lower control arms and the sub-frame mounting
brackets. Look for small rubber particles near
the sub-frame mounting brackets (Fig. 6 & 7).
If either condition is found, replace bushings.
6. Look for loose mounting bolts (8 places) in the
upper and lower control arms (Fig. 6 & 7).
Make sure that the mounting bolts are tight. A
loose joint will result in wear between the
bushing inner sleeve and the subframe mounting
brackets. See Torque Specs on pages 6 & 7.
NOTE: It is recommended that if one bushing is
found to be worn, all control arm bushings must be
replaced. See page 20 for bushing replacement.
Figure 6. - Upper Control Arm to Sub-Frame Connection
Refer to Part Replacement Instructions, pages 20-25.
Refer to Parts List on pages 28 - 31 for
identification of suspension components.
Most parts are heat treated and tempered and cannot
be welded, bent, heated or repaired in any way
without reducing the strength or the life of the component thus voiding the warranty.
8
IFS Series Suspension
Pre-Operational Inspection (Continued)
Figure 7. - Lower Control Arm to Sub-Frame Connection
3. With the engine off remove the tie rod end ball
stud from the taper mount and visually inspect
both. If either of the mating tapers show
distortion or wear, then both components must
be replaced. See Torque Specs on pages 6 & 7.
4. With the engine off and the wheels straight
ahead, grasp the tie rod near its end (Fig. 8) and
try to move the socket in all directions. Be sure
to only apply hand pressure to the tie rod.
Lower Control
Arm Mounting
Bolts (8 total)
Tie Rod Ends
5. The side-to-side movement (Arrows A & B Fig. 8) of the socket must be measured with a
scale. If it moves more than 1/8 inch (3mm)
then replace the tie rod end immediately. If
there is detectable movement, but it is less than
1/8 inch (3mm) then the tie rod end should be
replaced before it gets worse.
6. Check dust boot for damage and replace if
necessary.
WARNING
DO NOT use wrenches or other similar objects
to apply leverage when inspecting tie rod
sockets. This could cause incorrect results
and damage components leading to loss of
steering control.
Inspection Procedure
1. Secure the vehicle by setting the parking brake
and blocking the drive wheels.
2. Turn the engine on and rock the steering wheel
lightly. Observe any looseness in the mating
tapers or movement of the stud nuts at both ends
of the tie rod (Fig. 8). If looseness is found, go
to step 3, otherwise move forward to step 4.
Automatic Slack Adjusters and
Brake System
Automatic Slack Adjusters
The suspension system is equipped with slack
adjusters for steer axles. For inspection and adjustment procedures refer to the slack adjuster
manufacturers technical service guidelines.
Brake System
The suspension system comes equipped with Eaton
15 x 4 or 16 1/2 x 5 S-cam brake assemblies (Fig. 9).
For service procedures refer to Eaton maintenance
manual #BRSM-0033.
Figure 8. - Tie Rod End Inspection
Figure 9. - Brake System
A
B
Check for Side-to-side movement
IFS Series Suspension
9
Pre-Operational Inspection (Continued)
ABS Sensor and Tone Ring
Height Control Valve
Please refer to Coach Manufacturer's Manual for
sensor type and proper maintenance guidelines.
Inspection Procedures
Shock Absorbers
Inspection Procedure
Visually check for shock absorber oil leakage,
bent, missing or broken components, excessive
corrosion, or worn bushings. If you find any of
the above problems replace the shock.
Air Spring
Air Spring Inspection Procedures
1. Secure the vehicle by setting the parking brake
and blocking the drive wheels.
2. Remove any build-up of foreign material present
around the air spring piston. The air spring
should be checked (externally) for irregular
wear, over extension or cracking.
1. Check the height control valve and linkage
assembly for damaged parts and replace them
(Fig. 11).
2. Measure the ride height of the suspension
(Fig.12). Measure the distance from the bottom
of the chassis frame rail to the center of the
wheel. An alternate measurement may be taken
between the center of the shock mounts. See
Chassis builder manufacturer for correct ride
height. The vehicle can be empty or loaded
while taking these measurements.
NOTE: An alternate way to measure ride height is
to measure from centerline CL of spindle to
ground “A” dim. and from frame rail to ground “B”
dim. Then subtract “A” from “B” to establish ride
height measurement (Fig. 12).
Figure 11. - Height Control Valve Linkage Assy.
(Type IR HCV Shown)
3. Make sure contact does not exist between the air
lines and the outside diameter of the air spring.
Re-secure air lines to prevent contact as needed.
Check for leaks along the air line and fittings
with soapy water solution. If leaks are found
replace air line and/or fittings.
4. Make sure the air spring, while energized with
air, has a minimum of 1 inch clearance around
its circumference (Fig. 10).
5. Refer to Air Spring Manufacturers Preventative
Maintenance Checklist for additional formation.
Figure 10. - Air Spring Check
Control Arm
Height
Control Valve
(IR shown)
1" Min.
Clearance
Required
Around
Air Spring
10
Linkage
Assembly
Lower Linkage Brackets
(connection could vary per vehicle)
IFS Series Suspension
Pre-Operation Inspection (Continued)
Figure 12. - Ride Height Measurement
Bottom of
Chassis
Frame
Bottom of
Chassis
Frame
Ride Height
CL
"B"
"A"
Ground Line
Adjusting Suspension Ride Height
NOTE: Before performing any adjustment or maintenance, identify the style of the height control
valve. The IFS suspension can be equipped with
either a Holland Neway Type CR (Controlled
Response) or a Type IR (Immediate Response)
height control valve. Follow the proper adjustment
procedures for your height control valve.
The height control valve and linkage should be
checked frequently for proper clearance, operation
and adjustment.
NOTE: Improperly adjusted ride height will result
in incorrect alignment measurements and may result
in poor ride quality and abnormal tire wear. Check
ride height prior to front suspension alignment.
The front suspension ride height is the distance
between the bottom of the chassis frame rail to the
center of the wheel spindle (Fig.12). Properly
adjusted ride height results in correct suspension
travel and alignment. DO NOT adjust the ride
height to adjust chassis rake angle.
Adjustment Procedure (Type CR Valve)
2. Pressurize the air system with a constant supply
of air in excess of 105 P.S.I.G. All air springs
should inflate and be set to the chassis manufacturers ride height.
3. Make sure the rear suspension is adjusted to the
correct ride height per the vehicle manufacturers
specifications.
4. Check the height control valve plumbing for air
leaks using a water/liquid soap solution.
5. Make sure shock absorbers are mounted
securely and mounting connections are not bent.
6. If ride height is incorrect, adjust ride height by
the adjusting lock nut (Fig.13). Loosen the 1/4"
nut, push up adjusting block to increase ride
height and pull down to decrease ride height.
Re-tighten 1/4" lock nut to 15-25 in. lbs.
NOTE: Valve has a built in time delay feature;
therefore, several seconds may elapse prior to air
flow.
NOTE: If proper ride height is not obtained or air
springs do not inflate properly, check air pressure
and pressure protection valve, check for proper piping and check Type CR height control valve (Fig.13)
and repeat above steps. Then if not functioning
properly, contact Chassis Manufacturer or Holland
Neway Service Department.
Figure 13. - Type CR Height Control Valve Adjustment.
Intake (Up)
Control
Arm
1/4" Adjusting
Lock Nut
Adjusting
Block
Exhaust (Down)
Exhaust
1. Park the vehicle on a level surface and secure
the vehicle by setting the parking brake and
blocking the drive wheels.
"Out" To Air Spring
"In" Air Supply
Locating Pin
Manufactured
Date Code
IFS Series Suspension
11
Pre-Operational Inspection (Continued)
Figure 14. - Type IR Height Control Valve Adjustment
Adjustment Procedure (Type IR Valve)
1. Prior to adjustment, the vehicle must be in an
unloaded condition and on a level floor.
2. Pressurize the air system with a constant supply
of air in excess of 105 P.S.I.G. (5.5 Bar) All air
springs should inflate and be a proper ride
height.
3. If ride height is off, adjust height control valve
by loosening the hose clamps (Fig. 14) on the
universal connection fitting. Push up to raise ride
height and push down to lower ride height
(Retighten hose clamps after adjustment).
Hose
Clamps
Universal Connection
(Valve Adjustment)
NOTE: If proper ride height is not obtained or air
springs do not inflate properly, check air pressure
and pressure protection valve, check for proper piping and repeat above steps. Then if not functioning
properly, contact the chassis manufacturer or
Holland Neway Service Department.
Figure 14A. - Type IR Height Control Valve Adjustment
NOTE: The Type IR-HCV can be installed with
the control arm in either left-hand or right-hand
position. Refer to Form 94100535 or contact
Holland Neway Service Dept. for information.
12
IFS Series Suspension
Lubrication
Table 4. - Lubrication Specification and Intervals
Component
Service Interval
Change Interval
On Ends of Tie Rods,
Relay Rod, Drag Link
Which ever comes first:
50,000 miles (80,000
kilometers) or once a year.
Brake S-Cam Tube and
Automatic Slack
Adjuster1
Which ever comes first:
Brakes relined. 50,000 miles
(80,000 kilometers) or once a
Year.
Wheel End
1000 miles (1600 kilometers)
Check fluid level
1
Lubricant Specification
Multi-Purpose Chassis Grease
N/A
NLGI Grade 1 or 2 Lithium Base
Multi-Purpose Chassis Grease
N/A
NLGI Grade 1 or 2 Lithium Base
Which ever comes first: Seals
replaced, brakes relined, 100,000
miles (160,000 km), or once a year.
Gear Oil
SAE 80W/90 or equivalent
Moly-disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the automatic slack adjuster.
General Lubrication
Recommended Procedure
It’s important to use proper lubrication practices to
gain maximum service life for your Holland Neway
Independent Front Suspension.
NOTE: The specified grease is lithium based NLGI
Grade 2.
IMPORTANT: DO NOT mix 2 lubricants of
different grades. DO NOT mix mineral and
synthetic lubricants. Parts may experience premature failure. Different brands of the same
grade may be mixed.
IMPORTANT: Never mix oil bath and grease
packed wheel ends. Parts may experience premature failure.
Greasing Knuckle Post Assembly
The knuckle post assembly (Fig. 15) is designed to
be a factory installed assembly that is permanently
greased for the life of the vehicle. The joints are
sealed by four (4) O-rings on each knuckle post
assembly designed to hold in grease, under pressure,
while preventing outside contamination. Although
greased at the factory, two (2) Zerk style grease
fittings have
been installed on Figure 15. - Knuckle Post Assembly
each knuckle
post assembly,
Upper Grease
Fittings
(Fig. 15). This
allows reapplication of
grease after
maintenance or
replacing
components.
IMPORTANT: While injecting grease always
maintain visual sight of O-rings. At first sign of
O-ring movement stop pumping grease. Slight
movement indicates a "full" grease cavity.
IMPORTANT : DO NOT over pump grease into
grease fittings. The grease gun type must not
exceed 250 psi max. If a high-pressure grease
gun is used it could cause an O-ring to extrude
out of the groove and degrade its function. This is
usually indicated by a large amount of grease
extruding from the O-ring joints and the O-rings
being visually distorted or damaged.
1. Using a proper grease gun (250 psi max.), pump
grease into grease fitting until slight O-ring
movement has occurred.
2. Look to ensure O-rings are not distorted or
damaged.
a. If distorted or damaged replace rubber O-ring
seals.
b. If not distorted or damaged, knuckle post
assembly is properly lubed.
3. Repeat for both upper & lower fittings on each
knuckle post assembly.
Lower Grease
Fitting
IFS Series Suspension
13
Lubrication (Continued)
Grease Fittings
Figure 18. - Lubricate Automatic Slack Adjuster
Tie Rods Ends
NOTE: Before servicing, review lubricant
specifications and interval requirements, Table 4.
1. Ensure grease gun is filled with proper lube.
2. Apply lubricant to grease fittings until new
lubricant discharges from the dust boot (Fig. 16).
Figure 16 . - Lubricate Grease Fittings
Slack Adjuster
Zerk location
Wheel Bearings and Hub Cap
Tie Rod Grease Fittings (4 total) on Tie Rods.
Brake S-Cam Tube and Automatic
Slack Adjuster
1. Apply lubricant to the S-cam tube until new
lubricant discharges from the S-cam bushing seal
next to the automatic slack adjuster (Fig.17).
2. Apply lubricant to the automatic slack adjuster
until new lubricant discharges from the cone
clutch adjacent the adjusting hex nut (Fig. 18).
Figure 17. - Lubricate S-Cam Tube
NOTE: Before servicing. Review lubricant
specifications and interval requirements, Table 4
page 13. Clean the hub cap window with mild soap
and water only. Aromatic solvents will impair the
transparency of the window.
1. Check oil level through the hub cap window. If
below the “add” level line remove the pipe plug
and fill with recommended oil to the “full” level
(Fig. 19). Add oil slowly since the heavy weight
oil will settle slowly.
2. Visually check the hub cap for external oil leaks.
Usually the vent plug will drip a small amount
of oil. Oil leaks in other places should be fixed
by replacing either the hub cap seal, window
gasket, or tightening the pipe fill plug.
Figure 19. Wheel Bearing Oil Level
Grease Fittings
(one per adjuster)
14
S-cam Bushing Seal
Hub Cap
Window
IFS Series Suspension
Checking and Adjusting
Wheel Bearings
Preparation
1. To prevent vehicle movement. Set the parking
brake and block the drive wheels.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
2. Raise the vehicle until the front wheels are off
the ground. Then support the vehicle with safety
stands.
3. Remove the vent plug from the hub cap.
Adjustment
1. Attach a dial indicator with a magnetic base to
the face of the hub, wheel, or brake drum. If the
wheel is removed, the dial indicator may also be
attached to the bottom of the brake drum.
4. Place a pail beneath the hub to catch the oil.
Rotate the hub so that the hubcap drain plug is
facing upwards. Remove the drain plug from the
hubcap and store it for installation later.
5. Turn hub so that the drain hole faces downward
and drain the oil from the hub cavity. Wait for
most of the oil to drain before continuing to the
next step.
6. Remove the hub cap, hub cap bolts, and gasket.
If not damaged the gasket can be re-installed
later. To prevent component contamination place
them in a clean container. Note that solvents
could damage the hub cap window.
CAUTION
To avoid damage removing or installing the
inner and outer spindle nuts DO NOT use an
impact driver. Use a torque wrench with the
proper socket.
7. Screw wheel bearing adjusting nut against the
thrust washer while wheel is rotated. Be sure
there is sufficient clearance between brake shoe
and drum so that there will be no brake drag.
8. Tighten nut to 200 ft.-lbs. of torque while rotating wheel in both directions.
2. Place the tip of the dial indicator on the center of
the steering knuckle spindle. Then set the dial
indicator on zero (Fig. 20).
9. Back off nut one full turn.
Figure 20. Wheel End Play
Measurement
11. Back off nut 1/6 to 1/4 turn.
10. Tighten nut to 50 ft.-lbs. of torque while rotating
wheel in both directions.
12. Check adjustment, making sure wheel rotates
freely. With a dial indicator, place magnetic base
on wheel and pointer on end of spindle. Grasp
wheel of hub and drum, and with a push/pull
action, record amount of axial movement.
13. If movement is greater than .005, repeat adjustment procedure. If no movement is recorded,
repeat adjustment.
NOTE: Do not push/pull at the top/bottom of the
tire, drum, or hub. This will not yield a true
measurement of the end play.
3. Measure the end play by pushing/pulling on
each side of the tire, drum, or hub at the same
time while observing the dial indicator. The end
play is the total travel observed. If the end play
is not within .001-.005 inch adjust the wheel
bearings per steps 4-10. Otherwise no adjustment required. Go to step 17.
14. If movement is between .001 - .005 inch, secure
with new cotter pin. Replace hub cap, refer to
Table 3 on page 7 for proper torque specifications.
15. Fill the hub cavity with the prescribed amount
and type of lubricant. See Table 4 on page 13.
for lubricant specifications.
16. Install drain plug.
17. Repeat for other wheel.
IFS Series Suspension
15
Checking and Adjusting (Continued)
Maximum Turn Angle Adjustment
Figure 21. - Steering Arm Stop Bolt
IMPORTANT: DO NOT adjust angle more than
50º. An over adjustment of the turn angle can
cause damage to system components.
1. Check the turn angle if the front tires rub against
the frame, suspension, body, or if the steering
gear has been serviced. Use an alignment
machine to check the angle.
NOTE: Follow the alignment machine manufacturers alignment procedure.
2. The maximum turn angle is controlled by the
steering stop bolt located on the spindle assembly, (Fig. 21). If the stop bolt is bent, broken or
missing, replace the stop bolt(s) or jam nut(s)
and follow the procedure below for adjustment.
Inspect other suspension components for
damage.
3. While adjusting the steering stop(s), the steering
gear poppet valves may also need readjustment.
Refer to Steering Gear Manufacturers Service
Manual for readjusting the poppets.
IMPORTANT: In power steering systems,
hydraulic pressure should relieve or “drop off”
when the turned wheels approach the steering
stops in either direction. The front suspension
components may be damaged if the pressure does
not relieve.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
Steering Arm Stop Bolt
IMPORTANT: Unequal toe-in side to side or an
off-center steering gear can result in unequal turn
angles and steering pull while steering straight
ahead. The drag link length may be adjusted to
attain steering gear on center condition while
maintaining equal toe-in side to side. Failure to
obtain equal toe-in or on-center steering gear may
result in premature tire wear.
IMPORTANT: DO NOT adjust the length of the
drag link or tie rods to center the steering wheel.
This can cause the steering gear to become off
center and result in premature tire wear.
Adjustment
1. Turn the steering wheel until the steering arm
contacts the stop bolt or stops turning (Fig.21).
Measure the turn angle of the wheel on the same
side as the turn (i.e. inside wheel).
2. If the wheel turn angle differs from the chassis
manufacturer guidelines, adjust as follows.
3. Loosen the stop bolt jam nut.
4. Rotate the stop bolt until the correct wheel turn
angle is achieved and the bolt head contacts the
steering arm.
5. Tighten the jam nut to 90-110 ft. lbs. See Torque
Specs on pages 6 & 7.
NOTE: Refer to OEM Chassis Manufacturer for
proper alignment procedures.
16
IFS Series Suspension
Checking and Adjusting (Continued)
IMPORTANT: After readjustment of the
steering stop(s) make sure the steering poppets
are reset properly and the front tires DO NOT
contact the frame, suspension, or body. A 1/2"
minimum clearance between the air spring and
brake dust cover is required. Failure to maintain
1/2" clearance may result in air spring and/or tire
damage.
6. Repeat Adjustment Steps 1 thru 5 for turning the
opposite direction.
Front Wheel Alignment
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
Inspection Before Alignment
Before conducting front wheel alignment
measurements check the following requirements.
Wheels and Tires
1. Inflate the front tires to the appropriate pressure
based on the wheel loading.
2. The front tires need to be the same size and type.
3. Make sure the wheel nuts are tightened to the
specified torque of 450-500 ft.-lbs. See Torque
Specs on pages 6 & 7.
NOTE: Refer to OEM Chassis Manufacturer for
proper alignment procedures.
4. Check if the wheels are balanced. Use standard
procedures.
Front Suspension
1. Torque all fasteners to the right specifications.
NOTE: Refer to OEM Chassis Manufacturer for
proper alignment procedures. Follow the
manufacturer's procedures to prepare the vehicle
for front and rear wheel alignment measurements.
IMPORTANT: Holland Neway recommends that
professional alignment equipment be used to
measure the wheel alignment characteristics:
caster, camber, and toe-in. The equipment must
also be properly calibrated. Only qualified
personnel should conduct the wheel alignment
measurements.
IMPORTANT: Toe-in of the front wheels should
be checked every 24,000 miles or 2 years. If the
vehicle does not steer correctly or the front tires
develop an abnormal tire wear pattern, the
caster, camber, and toe-in should be measured
and adjusted. Toe-in usually has the largest effect
on tire wear. See Maintenance Schedule Chart
on page 3.
2. Check the suspension ride height and adjust as
needed to the specified height.
NOTE: Maximum wheel turn angle should also be
checked and adjusted (refer to page 16).
3. All worn ball joints, tie rod ends, steering arm
bearings, control arm bushings, and damaged
suspension components need to be replaced.
NOTE: Adjusting the length of the drag link or tie
rods to center the steering wheel could cause the
steering gear to become off center.
4. Inspect for wear and replace and tighten all loose
ball joint and tie rod end tapered connections, tie
rod end jam nuts, steering arm mounts, and
chassis steering system components.
5. Check the wheel bearings and adjust as needed.
6. Inspect all shock absorbers for possible wear and
damage.
IFS Series Suspension
17
Checking and Adjusting (Continued)
Caster Angle Adjustment
WARNING
Adjusting the ride height or altering components to adjust the suspension caster is
strictly prohibited. Alteration of components
could result in loss of vehicle control.
Table 5 - Nominal Caster Values
Suspension
Parts List No.
Degrees
90546687
3.0° ± 1°
90547128
4.5° ± 1°
90547129
4.5° ± 1°
90547183
4.5° ± 1°
90547185
4.5° ± 1°
Caster is pre-set at the factory.
NOTE: Caster is preset at the factory and should
not need to be adjusted. If adjusting is needed, the
camber adjuster shims can be used for caster
adjustment.
By offsetting the number of shims on the front lower
control arm connection to the number of shims on
the rear lower control arm connection (Fig. 22 &
24), a change in caster will occur.
NOTE: The knuckle post casting has a large
embossed number near the king pin hole.
This number designates the pre-set caster angle
(Fig. 23).
Figure 23. - Embossed Number
Figure 22. - Caster Angle Adjustment
Front Lower
Arm Connection
18
Rear Lower
Arm Connection
IFS Series Suspension
Embossed number on knuckle post
designates pre-set caster angle
Checking and Adjusting (Continued)
Camber Angle Adjustment
1. Set park brake and block rear tires.
2. Raise front of vehicle off ground and support
with safety stands.
WARNING
Adjusting the ride height or altering components to adjust the suspension camber is
strictly prohibited. Alteration of components
could result in loss of vehicle control.
Camber is the angle of the tire with respect to the
ground. Camber is “positive” when the distance
between the top of both wheels is more than the
distance at the ground.
NOTE: A small amount of positive camber is built
into the suspension because camber changes with
load and chassis roll.
NOTE: The camber of the suspension is affected by
the ride height of the suspension. If the ride height is
set too high then the camber measurement will be
more positive.
Table 6 - Nominal Camber Values
Left
Unloaded
+1/4°(+1/4°)
Loaded
+1/4°(+1/4°)
Right
+1/4°(+1/4°)
+1/4°(+1/4°)
3. Support front tires with safety stands.
4. Loosen all lower control arm mounting bolts (4)
at the sub-frame. (2) bolts per lower control arm
bushing (Fig. 24).
5. Add/remove shims between bushing bar pin and
subframe. One .06" shim per bolt 4 places = .1°
of camber adjustment. Add to increase camber
and remove to reduce camber (Fig. 24).
6. Tighten bolts to 150-200 ft. lbs. See Torque
Specs on pages 6 & 7.
7. Remove safety stands and lower vehicle. Make
sure the suspension is at the proper ride height
(refer to manufacturers ride specification).
8. Remeasure the camber and readjust as needed.
Adjusting the Tire Toe-ln
IMPORTANT: Nearly all tire wear is caused by
incorrect toe-in settings. Holland Neway does not
recommend altering components to adjust the
suspension toe-in. Toe-in must be set by adjusting
the tie rod lengths only.
WARNING
Figure 24. - Camber Angle Adjustment
Adjusting the ride height or altering components to adjust the tire toe-in is strictly
prohibited. Alteration of components could
result in loss of vehicle control.
NOTE: Toe-in is the measurement of the distance
between the front and the rear of the two front
tires. When the front distance is less than the rear
distance, the wheels are "toed-in”. Toe-in is designed
into the suspension to stop the tendency of the tires
to “toe-out” when the vehicle is driven straight
ahead.
Shims
Mounting
Bolt
IFS Series Suspension
19
Checking and Adjusting (Continued)
Figure 25. - Tie Rod Measurement
IMPORTANT: The following repair methods and
actions are NOT allowed on IFS suspension
components; including rod assemblies, ball joints,
and subframe.
• NO welding that involves the steering knuckles,
steering arms, lower control arms, tie rod
assemblies, hubs, brakes, or brake drums.
• NO bending (hot or cold) of the spindle assembly,
steering arms, upper and lower control arms and
tie rod assemblies.
Tie Rod Length
• NO drilling out of the control arm and steering
arm mounting holes and/or the ball stud tapered
holes.
Toe-in Specifications = 1/32" +- 1/32"
1. Use a professional alignment system to determine if toe-in adjustment is needed. If adjustment is needed follow Steps 2 through 6.
2. Measure the length of both tie rods (Fig. 25).
If the lengths are not within 1/8" of each other
the tie rods must be adjusted. Tie rods are
properly adjusted if found to be within the 1/8"
measurement.
3. Block rear wheels.
4. Raise front end of suspension and support with
safety stands.
5. Loosen tie rod clamps bolts and adjust tie rod
length as needed.
6. Re-tighten tie rod clamp bolts to torque specs
listed on page 6.
7. Lower vehicle and remeasure (Fig. 25). Repeat
procedures as necessary.
PARTS REPLACEMENT
WARNING
Altering or attempting to repair or modify a
component can adversely effect the suspension strength and performance and could
result in the loss of vehicle control.
IMPORTANT: Repair or reconditioning of
suspension components is prohibited. Most parts
are heat treated and tempered and can not be
welded, bent, heated or repaired in any way
without reducing the strength or the life of the
component thus voiding the warranty. Genuine
component replacement only is allowed.
20
• NO spray welding of bearing diameters on the
spindle assembly, steering arm bores and pivot
tube. Spray welding of tapered holes or ball studs
for ball joint and tie rod ends.
• NO milling/machining of any component is not
allowed. The only exception is the honing of the
control arm bushing bores to remove any burrs.
IMPORTANT: DO NOT apply oil or corrosion preventative to the brake linings, brake drums or bushings.
CAUTION
Vehicle air supply system must be completely
exhausted (dumped). Failure to exhaust before
servicing vehicle could result in sudden component movement resulting in personal injury.
Upper and Lower Control Arm
Bushing Replacement
Inspect the control arms and mounts for damage. If
damage is found replace the complete control arm
bushing assembly.
NOTE: Holland Neway recommends replacing the
bushings and mounting fasteners in all of the control
arms at the same time.
CAUTION
Using a cutting torch to remove the control
arm bolts will permanently damage control
arm bushings and could result in subframe
damage.
IFS Series Suspension
Part Replacement
Preparation
1. Apply the parking brake and block the drive
wheels to prevent vehicle movement.
7. Set control arm into its mount location. Place the
control arm mount bolts into subframe snug
tight.
8. Reconnect knuckle post to the outer end of the
upper control arm.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
2. Raise the vehicle front wheels off the ground
and support with safety stands.
9. Reconnect the height control valve linkage to the
knuckle post bracket.
10. Set Suspension to proper ride height.
11. Torque the upper control arm bolts to 450-550 ft.
lbs. See Torque Specs on pages 6 & 7.
IMPORTANT: IFS suspension must be realigned
after control arm/bushing replacement.
Figure 26. - Upper Control Arm Removal
3. Remove the front tires. Disconnect the Height
Control Valve (HCV) linkage from the lower
bracket (Fig. 11 - page 10).
Upper Control Arm
1. Use a portable crane or jack and support the
steering knuckle prior to disconnecting it from
the control arm or removing the control arm
with the steering knuckle attached. The knuckle
post assembly is heavy and unbalanced and must
be supported properly.
CAUTION
Upper Control Arm Bolts
Lower Control Arm
Failure to properly support the knuckle post
assembly could result in personal injury to
hands or feet.
2. Detach the upper control arm from the knuckle post.
NOTE: DO NOT press on center metal core of
bushing; apply load to outer metal casing of the
bushing.
3. Remove the upper control arm mount bolts and
remove the upper control arm (Fig. 26).
4. Support the control arm properly during bushing
removal and replacement. Bushing hole of the
control arms should be free of any burrs before
replacing new bushings.
5. Using a hydraulic press with a 15 ton capacity,
push bushing out of the control arm housing
while supporting it securely.
6. Using the same hydraulic press from Step 5,
push new bushing back into the control arm
housing while supporting it securely.
1. Use a portable crane or jack and support the
steering knuckle prior to disconnecting it from
the control arm or removing the control arm with
the steering knuckle attached. The knuckle post
assembly is heavy and unbalanced and must be
supported properly.
CAUTION
Failure to properly support the knuckle post
assembly could result in personal injury to
hands or feet.
2. Detach the lower control arm from the knuckle
post assembly.
3. Remove the sub-frame control arm assembly
mounting bolts.
NOTE: DO NOT press on center of bushing; apply
load to metal casing of bushing.
IFS Series Suspension
21
Part Replacement (Continued)
Figure 27. - Lower Control Arm Bushings
Shock Absorber Replacement
WARNING
Shock absorber is “gas pressurized” DO NOT
puncture of expose to excessive heat, serious
personal injury can result.
Preparation
Apply
pressure to
outer metal
casing of
bushing when
removing or
replacing.
1. Apply the parking brake and block the drive
wheels to prevent vehicle movement.
Removal
1. Remove the 3/4-10 lower shock absorber
mounting bolt from the Knuckle Post Shock
Bracket (Fig. 28).
4. Using a hydraulic press with 15 ton capacity,
support and secure control arm and push
bushing out of the control arm housing (Fig. 27).
Figure 28. - Shock Absorber
NOTE: Be certain to apply pressure to outer metal
casing of bushing when removing or replacing
(Fig. 27).
5. Bushing hole of the control arms should be free
of any burrs before replacing new bushings.
6. Using the same hydraulic press from step 3,
push new bushing back into the control arm
housing while supporting it securely.
7. Place the control arm in its mount location and
install the control arm mount bolts into subframe snug tight.
8. Reconnect lower control arm to the knuckle post
assembly.
9. The control arm should be supported in such a
way such that it is at ride height, then torque the
bolts to the recommended torque specs. See
Torque Specs on pages 6 & 7.
NOTE: Improperly adjusted ride height will result
in incorrect alignment measurements and may result
in abnormal tire wear. Check ride height prior to
front suspension alignment, see pages 10 - 12.
2. Remove the 3/4-10 upper shock absorber mount
bolt (Fig. 28).
Installation
1. Install the shock absorber into the upper mounting bracket and secure with mounting bolt.
2. Place the shock absorber into lower mounting
bracket and secure with mounting bolt.
Wheel Bearing, Oil Seal, and Hub Cap
Replacement
See Coach Manufacturer's Service Manual for
replacement guidelines.
22
Shock Absorber
Mounting Bolts
3. Torque bolts to recommended specifications. See
Torque Specs on pages 6 & 7.
IFS Series Suspension
Part Replacement (Continued)
Installation
Air Spring Replacement
IMPORTANT: When replacing the air spring,
make sure you use the correct replacement. Using
an air spring that is not recommended by Holland
Neway may be detrimental to vehicle ride and
handling.
1. Mount the air spring to the knuckle post mounting plate. Torque the bolts to 30-40 ft.-lbs. See
Torque Specs on pages 6 & 7.
Preparation
2. Assemble the nuts and washers that connect the
air spring to the upper air spring mount on the
subframe. Torque the nuts to 30-40 ft. lbs. See
Torque Specs on pages 6 & 7.
1. Apply the parking brake and block the drive
wheels to prevent vehicle movement.
3. Install connection fitting into the air spring. Use
Permatex or equivalent thread sealant.
2.
4. Connect air line to the air spring.
Raise the vehicle until the front wheels are off the
ground. Then support the vehicle with safety
stands. DO NOT place jacks or safety stands under
the lower control arms to support the vehicle.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
3. Remove the front tires. Disconnect the Height
Control Valve (HCV) linkage from the lower
connection bracket (Fig. 11 - page 10).
Removal
1. Remove air line at the air spring, then remove
the connection fitting.
2. Remove all nuts and washers from the upper air
spring mounting studs.
3. Remove bolts that secure the air spring piston to
the knuckle post mounting plate (Fig. 29).
4. Remove the air spring.
Figure 29. - Air Spring Replacement
Upper Air
Spring
Mounting
Studs
5. Lower vehicle frame and inflate the air springs.
6. Use water/liquid soap spray to check air fittings
for leaks.
Knuckle Post Connection Replacement
IMPORTANT: The Holland Neway IFS utilizes
precision roller bearings at each (upper and lower)
knuckle post connection. This connection is very
robust and tightly toleranced for ease of assembly
and repair. Care should be taken to insure the
machined surfaces of the control arms and bearing
races are protected from damage. If a bearing
element needs replacement, it is strongly suggested
the outer bearing race be replaced at the same time.
Removal
1. Apply the parking brake and block the drive
wheels to prevent vehicle movement.
2. Raise the front wheels off the ground and
support with safety stands. DO NOT support the
vehicle with jacks or stands under the control arms.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
Air Spring
Piston
3. Remove the front tires. Disconnect the Height
Control Valve (HCV) linkage from the lower
connection bracket (Fig. 11 - page 10).
Knuckle Post
Mounting
Plate
4. Remove bolts that secure the air spring piston to
the knuckle post mounting plate.
IFS Series Suspension
23
Part Replacement (Continued)
5. Use a portable crane or jack and support the
steering knuckle post assembly at its lowest
position prior to disconnecting it from the control arm or removing the control arm with the
steering knuckle attached. The knuckle post
assembly is heavy and unbalanced and must be
properly supported.
CAUTION
Failure to properly support the knuckle post
assembly could result in personal injury to
hands or feet.
6. Remove knuckle bolt cotter pins. Loosen the
knuckle bolt nuts and remove.
7. Pull the knuckle post bolt assemblies from the
upper and lower control arm connections and
completely remove it.
8. Swing the knuckle post outward or swing the
control arms (upper or lower) aside until full
access is available to the upper and lower bearings.
NOTE: Care should be taken to insure the roller
bearing elements do not fall out by slowly moving
the knuckle post or control arms aside.
9. Remove the roller bearing elements and the
O-rings from both sides of the knuckle post
opening (Fig. 30).
Figure 30. - Knuckle Post Connection Replacement
Cylinder
Bolt Sleeve
Roller
Bearing
Outer
Bearing
Race
10. If the outer bearing race needs to be removed; a
long flat nosed punch will be required to gently
tap out the outer race from the back side of the
race.
NOTE: The area will likely be filled with grease
and the grease will need to be removed to allow
a clear view of the inside inner edge of the bearing cups.
11. Remove the cylindrical bolt sleeve.
Installation
1. Place the cylindrical bolt sleeve(s) in the
knuckle post opening.
2. If removed, install new outer bearing races into
the knuckle post opening(s) by gently tapping in
the race with a block of wood placed between
the race and the hammer (Fig. 30).
NOTE: It is very important to completely seat the
bearing race in the knuckle post receptacle. A 0.002"
feeler gage should not fit between the backside of
the race and the mating shoulder in the knuckle post.
IMPORTANT: Care should be taken to insure the
bearing race surface is not damaged.
3. Prepack the roller bearing elements with grease
and apply grease to the outer bearing races and
machined faces of the control arms.
4. Place the roller bearing elements and O-ring in
each side. Typically, the grease will hold the
roller elements in place until the control arms are
moved into place.
5. Swing the knuckle post or control arm ends into
alignment with the bore of the tapered roller
elements.
NOTE: Care should be taken to insure the O-ring
does not get pinched between the knuckle post,
control arm, and roller element bore.
6. Insert the knuckle post bolt assembly through the
connection.
O-Ring
7. Install nut and torque to 630-770 ft. lbs. Install
cotter pin. See Torque Specs on pages 6 & 7.
Roller
O-Ring Bearing
24
Cylinder
Bolt
Sleeve
Outer
Bearing
Race
8. Re-lubricate connection per lubrication instructions on page 15.
9. Replace bolts that secure the air spring piston to
the knuckle post mounting plate.
IFS Series Suspension
Part Replacement (Continued)
Steering Gear Replacement Procedure
NOTE: Not all IFS units are fitted with a steering
gear supplied by Holland Neway. The approximate
weight of each gear with fluid is between 80 and
100 lbs. and may require some external means to
support it during removal. See chassis manufacturer
for detailed steering gear information.
IMPORTANT: Steering gear case is very heavy
and a proper support device should be used during removal.
5. Disconnect all hydraulic lines and the steering
input shaft to the gear case and remove the 7/8"
attaching fasteners. It is necessary to support the
steering gear case with a support device due to
its weight.
6. Remove the steering gear case.
Installation
1. Install and support the steering gear case in
position on the underside of the sub-frame
mounting plate.
2. Install the 7/8" fasteners and torque to 400-450
ft. lbs. See Torque Specs on pages 6 & 7.
CAUTION
Failure to properly support the steering gear
could result in personal injury to hands or feet.
3. Connect the steering input shaft to the steering
gear case input spline.
4. Connect the hydraulic fluid supply lines.
Removal
1. Apply the parking brake and block the drive
wheels to prevent vehicle movement.
2. Raise the front wheels off the ground and
support vehicle with safety stands. DO NOT
support the vehicle with jacks or stands under
the control arms.
WARNING
Always use safety stands. Never work under a
vehicle supported by a jack only. Jacks can
slip or fall over and cause serious personal
injury. 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.
3. Disconnect the tie rod assembly from the pitman
arm at the tapered ball joint connection by
removing the cotter pin and nut.
4. Loosen and remove the 3/4" retainer fastener
from the pitman arm. The pitman arm can be
lowered from the output shaft drive spline and
removed.
5. Install the pitman arm to the steering gear output
splined shaft. A timing mark is provided on the
bottom of the pitman arm which is intended to
line up with the steering gear timing marks on
the gear case and output shaft. When all three
timing marks are aligned, the pitman arm and
gear are in the straight-ahead position.
6. With the pitman arm in place, tighten the
retaining fastener to the following torque level
depending upon the manufacturer:
TRW-(3/4" fastener) 125 to 150 ft. lbs.
See Torque Specs on pages 6 & 7.
7. Connect the tie rod arm tapered ball joint ends to
the mating end of the pitman arm and tighten the
nut to 125 to 135 ft.-lb. Install cotter pin. See
Torque Specs on pages 6 & 7.
8. Bleed gear case per manufacturers recommendations.
NOTE: Refer to Steering Gear Manufacturer’s
service manual for other detailed information.
9. Realign the vehicle per manufacturer's
specifications or the wheel alignment section of
this manual (page 18).
NOTE: Depending upon clearances, it may be
necessary to loosen and remove the steering gear
case 7/8" attachment fasteners to allow the gear to
be moved backward. This will allow easier access
to the pitman arm/gear output shaft connection.
IFS Series Suspension
25
Troubleshooting - Suspension System
SYMPTOMS
Tires wear out quickly or have
uneven tire tread wear.
NOTE: Wear pattern will indicate
possible cause(s). Consult with
tire manufacturer for guidance.
Vehicle is difficult to steer.
Vehicle wanders side to
side...loose steering.
Steering wheel has large
amptitude, rotational
oscillations when hitting
large bumps.
26
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 rear axle alignment.
Align rear axle to specified thrust angle.
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.
Tires not uniform.
Install correct tire and wheel combination.
Tires have incorrect pressure.
Put specified air pressure in tires.
Incorrect steering arm geometry.
Adjust tie rod lengths as required.
Steering arms binding.
Check steering arm bearings and lubricate
as needed.
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 needed.
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 damper binding or malfunction.
Check and replace as needed.
Steering wheel to column interference.
Align or adjust as required.
Power steering pump fluid level low
and possible leak in system.
Add fluid, tighten connections and correct
as needed.
Power steering pump pressure and
flow below specification.
Conduct pump flow and relief pressure tests
and adjust, repair or replace as needed.
Air in power steering system.
Add fluid, tighten connections & bleed system.
Contaminated or incorrect fluid.
Replace with correctly specified fluid.
Obstruction within steering gear or lines.
Inspect, remove obstruction(s) and repair or
replace as required.
Excessive internal steering gear leakage.
Inspect, repair or replace as required.
Vehicle overloaded or unevenly loaded.
Check wheel loads and correct as needed.
Improper (mismatched) tires and wheels.
Install correct tire and wheel combination.
Incorrect toe-in setting.
Adjust toe-in to specified setting.
Tires have incorrect pressure.
Put specified air pressure in tires.
Loose steering gear mounting.
Check mounting and secure as needed.
Tie rod end connection loose or ball stud worn.
Inspect ball stud connections and wear.
Loose wheel nuts.
Check and tighten to specification.
Ball joints binding or worn.
Inspect ball joints for wear or contamination
and replace as required.
Steering column linkage worn.
Check for wear and repair or replace as needed.
Wheel bearings out of adjustment.
Check wheel bearing end play and adjust
as required.
Steering gear adjustment.
Check and adjust to specification.
Steering column mis-aligned.
Realign steering column as required.
Steering arm mounts loose.
Check and tighten to specification.
IFS Series Suspension
Troubleshooting - Suspension System (Continued)
SYMPTOMS
Vehicle pulls to one side
without the brakes applied.
Vehicle pulls to one side with
the brakes applied.
Vehicle rolls side to side
excessively.
POSSIBLE CAUSES
REMEDIES
Improper (mismatched) tires and wheels.
Install correct tire and wheel combination.
Tires have incorrect pressure.
Put specified air pressure in tires.
Vehicle unevenly loaded.
Check wheel loads and correct as needed.
Improper brake adjustment.
Inspect, adjust and correct as required.
Incorrect rear axle alignment.
Align rear axle to specified thrust angle.
Unequal ride height side to side.
Check ride height and adjust to specified setting.
Wheel bearings out of adjustment.
Check wheel bearing end play and adjust
as required.
Loose steering gear mounting.
Check mounting and secure as needed.
Tie rod end connection loose or ball stud worn.
Inspect ball stud connections and wear.
Bent spindle or steering arm.
Inspect and replace as required.
Frame or underbody out of alignment.
Inspect and correct as required.
Incorrect toe-in setting.
Adjust toe-in to specified setting.
Mis-aligned belts in radial tires.
Check and replace as needed.
Steering gear valve binding.
Inspect, repair or replace as required.
Steering gear not centered.
Inspect and adjust as required.
Excessive internal steering gear leakage.
Inspect, repair or replace as required.
Incorrect caster and/or caster setting.
Install and/or adjust eccentric adapters in
upper control arm.
Grease, oil or dirt on brake linings.
Replace brake linings as required.
Brake linings are glazed.
Deglaze brake linings or replace as
required.
Brake linings are not a balanced set,
different friction codes or lining brand.
Replace brake linings as required.
Loose or broken brake linings.
Replace brake linings as required.
Brake drum out of round.
Re-machine brake drum as required.
Defective brake drum.
Inspect for defects and replace as
required.
Brake air chamber clevis pin or camshaft binding.
Check and lubricate as needed.
Defective slack adjuster.
Inspect for defects and replace as
required.
Uneven brake adjustment side to side.
Adjust slack adjuster as required.
Different brake air chamber size or
slack adjuster length side to side.
Replace with same size brake air
chambers and length slack adjusters.
Air pressure uneven side to side.
Check side to side air pressure and
correct as needed.
Unequal brake air chamber stroke side to side.
Check side to side stroke and adjust as required.
Rear axle brakes mis-adjusted.
Check and adjust as required.
Air leak or obstruction in air brake lines.
Check fittings with soapy water
solution and remove obstruction
Brake air chamber air leak or diaphragm
damaged.
Check chamber for air leak and damaged
diaphragm.
Front and/or rear shock absorbers worn.
Replace shock absorbers as needed.
Shock mounting loose.
Check and tighten as required.
Shock eye bushings worn.
Check and replace as needed.
Control arm pivot bushings worn.
Inspect and replace as required.
Internal leak in height control valve.
Check height control valve and replace
as required.
IFS Series Suspension
27
Parts List
Sub Frame Assembly
VEHICLE
FRONT
4
18
40
1
5
21
38
44
42
18
26
23
23A
11
10
22
26
43
22
29
42
21
27
16
20
17
28
45
16
32
See Page 32 for
Sway Bar Info
25
24
19
14
39
13
41
47
41
27
12
13
3
31
30
15
16
46
12
16
39
31
19
41
28
IFS Series Suspension
29
15
Parts List
Sub Frame Assembly
Item
Part No.
Description
Qty.
Item
Part No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23A
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
93600168
93400502
93003383
93600150
93400490
93400511
93600180
93002909
93400480
93800069
93800292
93004277
93600548
93003821
93003831
Upper Arm Assembly
Lower Arm Assembly-LH (not shown)
Lower Arm Assembly-RH
Suspension Sub-Frame
Air Spring
Spindle Hardware Kit (not shown)
O-Ring Seal - Knuckle Post (not shown)
Knuckle Post Bearings (not shown)
Knuckle Bolt Sleeve (not shown)
1" Flat Washer
1" - 8 Lock Nut
5/8" -11x3.5" GR8 Hex Bolt
5/8" Flat Washer
5/8" - 11 Hex Nut GR C
1.25" - 12 Hex Nut GR B
1.37" Flat Washer
1/2" - 13x1.5 Hex Bolt GR 8
1/2" -13 Hex Lock Nut - GR B
Cotter Pin
Grease Fitting
1" -8x5” Hex Bolt GR 8
2" Flat Wear Washer
7/8" -9x4 Hex Bolt GR 8
7/8”-9x4.5 Hex Bolt GR 5
4
1
1
1
2
1
8
8
4
8
4
8
16
8
4
8
2
4
4
4
4
4
3
1
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
93400498
93600162
93003597
93400492
93003330
93800303
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
93400417
See OEM
93600072
93002607
93400472
93400265
93003621
90034424
7/8" Lock Nut
7/8" Flat Washer
3/4" - 10x3.5" Hex Bolt GR 5
3/4" - 10 Lock Nut GR B
5/8" - 18x1.25 Hex Bolt GR 8
Cotter Pin 0.156" x 1.5"
Pitman Arm
Tie Rod Arm
Steering Gear
Brake Assembly
Slack Adjuster (not shown)
Hub & Drum Assembly (not shown)
Height Control Valve (not shown)
HCV Linkage Assy. (not shown)
Shocks
Knuckle Post Bolt
3/4" - 16 Thin Locknut GR B
7/8" - 14 Castlenut
1/2" Lock Washer
3/8" - 16 x 2.5 GR5 bolt
3/8" - 16 GRB Nut
5/8" - 18 Jam Nut GRB
3/4" - 10 x 4.5 GR5 Bolt
Shims
3
3
4
5
2
2
1
2
1
2
2
1
2
2
2
4
2
4
4
4
4
2
1
32
NOTE: Part numbers for major suspension components will vary by suspension model part number.
Contact the vehicle OEM for proper component part
number.
IMPORTANT: Most of the fasteners used in this
suspension are graded fasteners. These fasteners
have the strength and hardness properties
required for their particular function. When
replaced, they must be replaced with fasteners of
the same grade, size and form as the original in
order to prevent failure.
Bolt Grade Markings
Grade 1 or 2
Grade 5
Grade 8
Lock Nut Grade Markings
Grade
Lock Nut
Grade B
Lock Nut
Grade C
33
Identification
3 Dots
6 Dots
IFS Series Suspension
29
Parts List
Sway Bar Kit
9
7
10
8
6
5
4
2
1
3
Item
Part No.
Description
Qty.
1
2
3
4
5
6
7
8
9
10
90045372
Sway Bar
Sway Bar, Bushing
Sway Bar, Bracket
7/16" - 14 Lock Nut
7/16" - Flat Washer
Grommet
Link
1/2" - 13x1.5 GR 8 Bolt
1/2" - 13 GRB Nut
Washer Flat Narrow .5
1
2
2
4
8
8
2
4
4
4
Item Numbers
2 - 10 are
available in
Kit Number
90546699
NOTE: Swaybar shown is NOT available with the following IFS Model Number
configurations: #90547128, #90547129, #90547183 & #90547185.
IMPORTANT: Most of the fasteners used in this suspension are graded
fasteners. These fasteners have the strength and hardness properties
required for their particular function. When replaced, they must be
replaced with fasteners of the same grade, size and form as the original
in order to prevent failure.
30
IFS Series Suspension
Parts List
Knuckle Post Assembly
1
3
4
8
5
6
4
7
18
15
22
21
24
3
20
16
2
19
17
9
5
6
10
4
11
3
23
8
12
14
NOTE: Quantities shown are for 1 (one) Knuckle Post
Assy. There are 2 (two) Assy's per suspension.
13
Item
Part No.
Description
Qty.
Item
Part No.
Description
Qty.
1
See OEM
See OEM
90045356
90045357
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
Knuckle Post Assembly - RH
Knuckle Post Assy. - LH (Not Shown)
Spindle - RH
Spindle - LH (Not Shown)
O-Ring
Knuckle Post Bearings
Knuckle Post Bearings Race
Knuckle Bolt Sleeve
King Pin
Cap-King Pin
Oil Seal
Inner Bearing
Outer Bearing
Washer - "D" Shape
1
1
1
1
4
4
4
2
1
2
1
1
1
1
13
14
15
16
17
18
18
18
19
20
21
22
23
24
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
See OEM
9/64" Cotter Pin
Nut (Wheel Bearing)
Taper Pin
Lock Nut - Flanged
Thrust Bearings
Shim - .016
Shim - .005
Shim - .010
3/16" Cotter Pin
Woodruff Key
Steering Stop Bolt - 5/8" - 18
Steering Arm
Slotted Hex Nut
5/8" Jam Nut
1
1
1
1
1
2
3
4
5
6
7
8
9
10
11
12
*
*
*
1
1
1
1
1
1
* Shim size and quantity is determined
during the manufacturing process.
IFS Series Suspension
31
HOLLAND USA, INC.
1950 Industrial Blvd. • Muskegon, MI 49443 • Phone 888-396-6501 • Fax 800-356-3929
www.thehollandgroupinc.com
Copyright © January 2002 • The Holland Group, Inc.
Holland USA, Inc. Facilities:
Holland International, Inc.
Holland Hitch of Canada, Ltd.
Holland Equipment, Ltd.
Holland Hitch Western, Ltd.
Denmark, SC
Dumas, AR
Holland, MI
Milpitas, CA
Holland, MI
Phone:
616-396-6501
Fax:
616-396-1511
Woodstock, Ontario • Canada
Phone:
519-537-3494
Fax:
800-565-7753
Norwich, Ontario • Canada
Phone:
519-863-3414
Fax:
519-863-2398
Surrey, British Columbia • Canada
Phone:
604-574-7491
Fax:
604-574-0244
Muskegon, MI
Warrenton, MO
Whitehouse Station, NJ
Wylie, TX
Ph: 888-396-6501 Fax: 800-356-3929
XL-AK397-01
Print Qty. 4M
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