2/25/13 335 FS226005-06_Br3

AXLE SCISSOR LINK ASSEMBLY PROCEDURE - FRONT 226005-06

TOP & BOTTOM SCISSOR LINK PINS -

PART 1

The following procedures apply to both thetop and the bottom scissor link pin assem-blies. All parts are to be clean and free ofburrs from machining.

1. Press both bearing cups (31) so they arefully seated in the link bores as shown.

If the cups are cooled

and installed, then after

the cup has warmed, place a steel rod at

its perimeter and strike the rod to

ensure the cup is fully seated in its

bore.

2. Fit one bearing cone (32) into a cup (31). Install an o-ring(35) in the seal carrier (56) groove and then press the sealcarrier into the link bore. The carrier must be flush withthe link surface as shown. Install the lip seal (60) onto theseal carrier as shown.

3. Repeat step 2 to install the other bearing cone, seal carrierand seal.

4. While being careful not to damage the seals (60), positionthe link so the bearing bores and the bores of the housingears are aligned in preparation for installing the pin (58).

Wear protective clothing to protect

against frostbite when working with cold components.5. Cool the pin (58) to shrink it for installation. (At room temperature the bearing cones are press fit on the

pin.)6. When the pin is sufficiently cooled, quickly install it through the bearing cones, slide the spacer (57) over

the pin, install the retainer (34) backwards with the tapered holes toward the pin. Install three hexheadcapscrews (.75 UNC x 1.75 inch) with flatwashers and torque these capscrews to 125 ft-lbs. (169 N·m).Apply anti-seize (T11093) to washers only. Rotate the pin 3 revolutions and re-torque. A capscrew can be threaded into the opposite end of the pin and then a wrench can be

attached to keep the pin from rotating while torquing.

7. Allow the pin (58) to return to room temperature before proceeding. This could take as long as 24hours. If the pin is not allowed to warm up before final torque of the capscrews, the bearings will nothave the proper preload. The ends of the pin can be warmed, but not beyond 250° F (121° C).

8. When the pin has returned to room temperature, torque the three hexhead capscrews to 125 ft-lbs. (169N·m). Rotate the pin (52) 3 full revolutions.

9. Repeat step 8 until the cap-screws maintain specified torque. Measure and document rotational torque(not breakaway) of pin.

2/25/13 336 FS226005-06_Br3

CENTER SCISSOR LINK PIN ASSEMBLY - PART 2

Center scissor link bearings are a matched set consisting of

2 cups, 2 cones, and a cone spacer. All parts must be used

together as shown in the first image to the right.

10.The bearing cups (17) are to be fully seated against the bottom of their

respective bores.

11. Install one bearing cone (17) into the inboard bearing cup and then

install one half of the seal assembly (19) into the link to hold the bear-

ing cone in position.

12. Repeat step 11 to the other scissor link.

13. Position the bores of the top link and the bottom link in alignment with

each other being careful not to damage the seal (19) in the process. The

bottom portion of the suspension assembly may have to slightly rotated

to allow the two halves of the seal to pass by each other.

14. Slide one bearing cone (17) onto the pin (18) with the tapered rollers

end going on last. Slide the respective cone spacer on the pin. Install

the pin into the lower link bore, through the inboard bearing cone of the

lower and upper link assemblies until the outboard bearing cone seats

against its cup (17).

15. Install the outboard cone spacer and bearing cone (17) into the upper

link bore until it seats against its cup.

16. Install the washer (16) over the threaded end of the pin (18) as shown

on the right. Do not use the washer provided with the locknut. Use

Kress washer with insert tab.

17. Thread the locknut (59) onto the pin until it is snug enough to have

pulled the seal halves (19) together.

18. Apply Superbolt Molybdenum jackscrew lubricant on each jackscrew

prior to torquing.

19. Using the star torque pattern shown to the right torque each of the jack-

screws to 6 ft-lbs. (8.13 N·m) to ensure the bearings are at proper pre-

load. Rotate pin 3 revolutions.

20. Using the same pattern, torque jackscrews to 29 ft-lbs (39.30 N.m).

Rotate pin 3 revolutions.

21. Using a circular pattern as shown to the right, torque jackscrews to 44

ft-lbs (60.58 N.m). Rotate pin 3 revolutions.

22. Using the same pattern, torque jackscrews to 58 ft-lbs (79.85 N.m).

23. Repeat step 22 until jackscrews maintain specified torque. Rotate pin 1

revolution. Measure and document rotational torque (not break away)

of pin.

66

66

2/25/13 337 FS226005-06_Br3

24. Install an o-ring (1) into the groove on the outside

diameter of both end caps (27).

25. Install both end caps (27) and then install the wire

retainers (9) into their grooves to hold the end caps in

place. One end cap should have a grease relief fitting

and the other cap should have a grease zerk installed.

26. Pump grease into the grease zerk in the end cap (27)

until grease exits the grease relief fitting in the other

end cap (27).

TOP & BOTTOM SCISSOR LINK PINS - PART 3

27. Place thin wedge type tooling between the link and housing to keep gaps “C” & “D” equal ± .060 in.

(1.524 mm).

28. Install the locking assembly (Ringfeder) adapter (55) with the small inside diameter portion going in firstuntil it contacts the bearing (32). It needs to be installed far enough to be flush with the outside housing sur-face. Attach the tooling ring (MF4212) with two capscrews to hold the adapter flush with the housing.

29. Lightly oil the locking assembly (54) (Do not use grease or molycoat type products) and insert it over

the pin and into the bore as far as it will go. Hand tighten the screws in the locking assembly and then

torque them to 50 ft-lbs. (68 N·m). Use the sequence shown at right when tightening the screws.

30. Confirm gaps “C” & “D” are equal ± 0.060 inches (1.524 mm). Loosen the locking assembly and re-

position if necessary.

Measure to the “milled surface” on the inside of the ears, not to the rough inside

face of the ear when centering the links in their individual mounts.

31. Torque the locking assembly screws in the order shown equally to 70 ft-lbs. (95 N·m). Then retorque

them to 107 ft-lbs. (145 N·m). Continue checking each capscrew using the sequence until all cap-

screws are at 107 ft-lbs. (145 N·m).

32. Repeat steps 28 through 30 on other end of pin.

33. Then remove the hexhead capscrews, washers and retainer (34). Install the retainer with the tapered holesout using the tapered head capscrews. Torque these capscrews to 110 ft-lbs. (149 N·m).

GAP “D”GAP “C”

1

2

3

4

5

6

7

8 9

10

11

12

13

14

2/25/13 338 FS226005-06_Br3

226005-06 FRONT SUSPENSION MODULE

1 O-ring

2 Bolt - .50-20NF x 2.00

3 Grease Fitting, Straight

4 Bolt - .63-18NF x 1.50

5 Bolt - .50-20NF x 2.50

6 Bolt - 1.00-14NF x 4.00

7 O-Ring

8 O-Ring

9 Retaining Wire

10 Washer, Hard - 1.00

11 Fitting, Relief 1/8 NPT

12 Washer, Hard - .62

13 Washer, Hard - .50

14 Retainer Stop

15 Lifting Eye

16 Washer

17 Seal Assembly

18 Pin

19 Seal HDDF Heavy Duty

20 O-Ring

21 Cap Nut -4 ORS

22 Bolt - Drilled Head 1.00-14NF x 4.50

23 Pin, Tapered

24 Retainer Plate, Lower

25 Wiper Seal

26 Bushing, Tapered

27 End Cap Structure

28 Retainer Plate, Upper

29 Capscrew - 12pt - .50NF x 1.25

30 End Cap

31 Bearing Cup

32 Bearing Cone

33 Screw, Flat Sockethead - .75 x 1.50NC

34 Retainer

35 O-Ring

36 Spacer, Plastic

37 Fitting, Straight -4ORS-4BOSS

38 Scissor Link

39 Scissor Link Structure

40 Thrust Bearing, Lower - 115 degree

41 Thrust Bearing, Lower - 60 degree

42 Thrust Bearing, Lower - 60 degree

43 Bearing, Lower

44 Bushing, Tapered

45 Spacer

46 Rod Retainer Plate

47 Cylinder, Front Suspension

48 Axle Assembly, Front

49 Brake Lines, Front

50 Steering Tube, Front

51 Valve Extension

52 Valve Stem Assembly

53 Leveling Group, Front

54 Locking Assembly - 3.937 x 5.709

55 Adapter, Locking Assembly

56 Carrier, Seal

57 Spacer, Shaft

58 Pin, Scissor Link

59 Locknut, Bearing

60 Seal, V-Ring - 6.89 - 7.29 Viton

226005-06 FRONT SUSPENSION MODULE

34. Apply a bead of non-acid type sealant such as GE RTV160 to the end caps (30) as shown. Install the end caps with vent hole as near the top (as mounted in vehicle) as is possible and torque the capscrews to 117 ft-lbs. (159 N·m).35. Fill cavities with grease until grease comes out of the vent holes in both end caps.36. Install one relief vent (9) in each end cap vent hole.

2/25/13 339 FS226005-06_Br3

FRONT SUSPENSION MODULE - ASSEMBLY/DISASSEMBLY

Fig. 1

SECTION B-B

B

B

G

G

C C

50

47

156, 10

39

53

A

A

38

48

49

15

21

20

37

7

F F

8

46

52

10, 22

51

45

50

41

25

2/25/13 340 FS226005-06_Br3

FRONT SUSPENSION MODULE - ASSEMBLY/DISASSEMBLY

Fig. 2

SECTION A-A

SECTION C-CENLARGD 2x

SECTION D-DENLARGD 4x

SECTION F-FENLARGD 2x

SECTION G-GENLARGD 1.6x

29

55

58

30

54

60 56 31 35

29

55

54

30

34

33

5732

35

3

27

17

19

9

1

59TORQUE TO 6 FT-LBS.

18

11

D

D

28

50

28

26

23

36

44

24

5, 13

2, 13

14

4, 12

40

4141

42

50

48

3

2/25/13 341 FS226005-06_Br3

FRONT SUSPENSION MODULE - ASSEMBLY/DISASSEMBLY

Fig. 3

3

11

3

11

2/25/13 342 FS226005-06_Br3

Fig. 4

REMOVAL OF FRONT SUSPENSION MODULE FROM TRUCK

The following steps refer to figures 4& 5.

1. Lower the vehicle to its full down position and leave the leveling switch in the “down” position to

relieve the hydraulic oil pressure in the cylinder.

2. Align the front of the front suspension module so it is pointing toward the front of the vehicle. Block

these tires and the tires of the other suspension module so they will not roll in either direction

3. Disconnect and cap the brake hose at the top of module being replaced. Also disconnect the wire con-

nector (for leveling) if the left hand module is being removed.

4. Disconnect the drag link from the steering housing. The procedures concerning the whiffletree and

drag link are located in the Kress Service Manual.

5. Bleed the nitrogen pressure from both the bottom and top chambers of the suspension module being

removed. Use Kress Regulator and Charging Kits 224500 (high pressure) & 224506 (low pressure).

Carefully remove the two hoses attached to the top of the cylinder for the nitrogen and hydraulic oil.

Cap the hydraulic hose securely because pressure will be applied later.

6. Remove the bolts and washers (1, 2) from the top of the cylinder and remove the retainer plate (5).

Remove the fittings for the hydraulic hose and nitrogen hose and install plugs in these cylinder ports.

7. Install the lifting eye at the top of the cylinder and attach it to an overhead hoist or crane. The approxi-

mate weight of the suspension module with tires is 20,000 lbs. (9072 kg). The cable or chain from the

hoist to the lift eye must be long enough to lower the lift eye to the floor.

8. One mounting hole is tapped for a grease fitting. Attach a high pressure grease pump to this fitting.

Pump grease into the fitting until the cylinder pops loose from the body structure.

To raise the vehicle, either use the hydraulic manual leveling system or attach another

hoist to the body.

If the cylinder did not come loose, then shake the module with a fork truck to jar the

cylinder loose. Raise the vehicle about two inches (51 mm) to remove the weight from the cylinder.

2/25/13 343 FS226005-06_Br3

9. If the cylinder still is not free, then lower the vehicle, remove the lifting eye, and install the upper

taper popper (Kress tool 018022). Pump grease into the Upper Taper Popper fitting and force the cyl-

inder loose from the body taper. If the cylinder still is not free, the pusher piston plate (see illustration)

may be struck with a large sledgehammer.

10. Remove the tool and reinstall the lift eye. Attach the overhead hoist to the lift eye. Raise the vehicle

body far enough to allow the module to be rolled free of the vehicle. Securely block the body up at

this height.

11. Carefully lower and roll the module away from the vehicle until the lifting eye is at the floor.

Fig. 5

INSTALLING STRUT CYLINDER INTO MODULE

1. Remove 5/8-18UNF x 7.00 LG bolts, washers and remove the retaining ring being careful not to dam-

age the wiper. The retaining ring is part of the cylinder assembly and is shown positioned below the

lower thrust bearing (40-42). Put two 5/8-18UNF x 7.00 bolts back in without retainer plate and hand

tighten to prevent the gland from sliding out in the next procedure.

2. Ensure the lower bearing (43) and wiper (25) are installed in the steering tube (50) and then insert the

strut cylinder into the steering tube from the top.

5RETAINER

1,2TORQUE BOLTSTO 927 FT-LBS

& LOCKWIRE

DETAIL A

R.H. L.H.

PUSHER PISTONSTRUCTURE

TORQUE TO1030 FT-LBS

MAX

UPPER TAPERPOPPER STRUCTURE

FRONT SUSPENSION BEAM

UPPER PART OF CYLINDERWITH UPPER TAPER POPPER INSTALLED

A

2/25/13 344 FS226005-06_Br3

3. Raise the strut cylinder up relative to the steering tube enough to expose the groove for the lower thrust

bearings (40-42). Remove the two bolts installed in step 1. Install the lower thrust bearings by first in-

stalling one 40. Then two 41, one on each side of the 40 so the ends are flush with each other. Then

insert one 42 into the remaining space.

4. Lower the strut cylinder against the lower thrust bearings. Install the retainer plate being careful not to

damage wiper seal (25).

5. Install the 5/8-18UNF x 7.00 LG bolts and washers.

6. Torque bolts to 190 ft-lbs. (258 N·m).

REMOVING STRUT CYLINDER FROM MODULE

1. Remove 5/8-18UNF x 7.00 LG bolts, washers and retainer plate, being careful not to damage wiper (25).

2. Raise the strut cylinder up relative to the steering tube enough to expose the lower thrust bearings (40-

42) and then remove the lower thrust bearings.

3. Remove the strut cylinder from the steering tube through the top.

ATTACHING AXLE TO MODULE

1. Apply antiseize to the tapered end of cylinder rod and insert it into female taper of front axle assembly

along with the spacer (57).

2. Install the retainer plate (46).

3. Install 1.00-14UNF x 4.50 LG bolts and washers (22, 10).

4. Torque bolts to 927 ft-lbs. (1257 N·m).

5. After bolts have been properly torqued, install the lockwire through holes in bolt heads.

REMOVING AXLE FROM MODULE

1. Cut off the lockwire and remove 1.00-14UNF x 4.50 LG bolts and washers (22, 10).

2. Remove plate-rod retainer (46).

The following six steps use the item numbers

shown in the illustration to the right when using

the 220730 Lower Taper Popper.

1. Install the tapped ring (2) on housing with

the relieved area for the retainer (3) going on

last so that the ring is entirely above the

groove in the spindle housing (axle).

2. Install the retaining wire (3) into the housing

groove and pull the tapped ring (2) down

over the retaining wire as shown.3. Apply antiseize to the threads of twelve 1.25-7 UNC x 4.5 inch capscrews (4), install a hardened flat

washer (5) on each capscrew. Using these capscrews, install the pusher plate (1) with the with the ring

up so it will contact the end of the cylinder rod as shown.

4. Pump grease into the drilled passage located approximately six (6) inches above the groove for the

retaining wire (3). This drilled passage extends into the taper area where the rod fits into the spindle

structure. The pressure of the grease will aid in forcing the rod from the taper in the spindle housing.

5. Begin by tightening the capscrews (4) evenly to a torque of 500 ft-lbs. (678 N·m). Use a crossing pat-

tern when tightening these capscrews so the pusher plate is pulled evenly toward the tapped plate.

Then, evenly increase the torque of each capscrew in increments of 200 ft-lbs. (271 N·m) until the ta-

per is freed, or, to a maximum torque of 1300 ft-lbs. (1763 N·m).

Wear protective goggles and clothing whenever striking objects with a hammer.

6. If the cylinder rod still has not loosened after torquing the capscrews and applying grease pressure,

then strike the pusher plate (1) with a large sledge hammer to jar the rod from the spindle housing.

STRUT ROD

SPINDLE

STRUCTURE

1

2

4

5

3

PUMP GREASE

HERE

2/25/13 345 FS226005-06_Br3

NOTES

1. All bolt threads to be lubricated with anti-seize.

2. Be sure that entire inside of steering tube is sprayed with rust veto 2728.

3. Initial lubrication fill for steering tube after assembly: Fill grease through grease zerk (3) until grease

comes out of top dust seal (8).

INSTALLATION OF FRONT SUSPENSION MODULE INTO TRUCK

The following steps refer to figure 6.

1. Apply anti-seize to the tapered portion of the top of the suspension cylinder and the mating tapered

socket area of the body structure. Install the lifting eye to the top of the cylinder.

2. Position the module so the top of the cylinder is directly beneath the tapered hole for it in the body sim-

ilar to what is shown in the illustration show earlier.

3. Lower a chain or cable through the body's tapered hole for the cylinder and attach it to the lifting eye

on the cylinder. Remember the approximate weight of the module is 20,000 lbs. (9072 kg.), so the

hoist and cable or chain must be of sufficient strength to support this weight.

4. Raise the top of the cylinder so

it is directly beneath the

tapered body hole making sure

the drag link eye is forward of

the outside steering stop.

Lower the body, keeping the

cylinder in line with the body

taper until the body weight is

resting on the module, and the

cylinder is properly fitting into

the taper. Release the tension

on the lift eye and remove the

lifting eye from the cylinder.

5. Place the retainer plate (5) over

the top of the cylinder. Apply

anti-seize to the threads of the

capscrews (1), add washers (2),

and screw them into the cylin-

der end cap. Torque these capscrews (1) to 927 ft. lbs. (1257 N·m) and repeat this torquing until all

capscrews are to 927 ft. lbs. (1257 N·m) and lockwire them.

Observe the retainer plate (5) configuration in the illustration and be sure the larger

outside diameter portion of the retainer is down against the body with the smaller outside diameter

portion up. If this is installed the other way, the cylinder will not be held securely in the body taper

and damages will result.

6. Install the hose fittings for the nitrogen and hydraulic oil. Completely relieve the pressure from the

leveling system hose and then attach this hose to the cylinder fitting. Attach the nitrogen hose.

Replace the body opening cover.

7. Attach the drag link (see Toe-in Procedures). Connect the brake hose, and if left hand module, attach

the electrical connector and adjust the leveling switch so the vehicle is at proper ride height.

8. Bleed the air from the brake lines.

9. Check the steering stop contact.

10. Precharge the nitrogen chambers of the front suspension cylinder and check for leaks.

11. Cycle the cylinder up and down several times. Steer the front wheels full left and right, making sure

the hoses of the steering linkage are not rubbing. Repair any defects and leaks before placing the vehi-

cle in service.

GREASE ZERKUSED TO AIDREMOVAL OF

CYLINDER

PLASTIC PLUGS IN PULLER HOLES

STANDARD TORQUE927 FT-LBS(1257 N.m.)

NOTE DIRECTION OFPLATE MOUNTING

APPLY ANTI-SEIZETO TAPER PRIOR TOINSTALLATION

5 1, 2

Fig. 6

2/25/13 346 FS226005-06_Br3

After the 1st LOAD is hauled, retorque the upper and lower retainers on both front

suspension cylinders. Torque bolts to 927 ft-lbs. (1257 N·m). After the 1st full shift of operation is com-

plete, retorque the upper and lower retainers on both front suspension cylinders. Torque bolts to 927 ft-lbs.

(1257 N·m).