16
TC Series Front Axle 010-1 TC Series Front Axle Blue Bird Corporation assumes sole responsibility for ensuring that the information provided herein is accurate to the best of its knowledge at the time of printing. In keeping with its policy of continual product improvement, Blue Bird reserves the right to change product information without notice and without incurring obligation. Some information contained in this section has been re-published from the following publications: Spicer ® Heavy Axle and Brake Division, Spicer ® Gold Series Front Axles Service Manual, © Spicer/Dana, Form #SHABD 894-3. Contents TC Series Front Axle ............................................... 1 Spicer ® Heavy Axle and Brake Division, Spicer ® Gold Series Front Axles Service Manual, © Spicer/Dana, Form #SHABD 894-3........................................... 1 Contents ................................................................... 1 List of Figures .......................................................... 1 Safety ....................................................................... 2 Specifications ........................................................... 3 Torque Chart ............................................................ 3 Special Tools............................................................ 4 Lubrication ............................................................... 4 Service Parts and Axle Identification....................... 5 Precautions and King Pin Wear Limits .................... 7 Maximum Limits for Front Axle King Pin .............. 8 King Pin Bushing Replacement ............................... 9 Steering Knuckle Removal ...................................... 9 King Pin Bushing Removal ................................... 10 King Pin Bushing Installation ................................ 10 King Pin Seal Installation ...................................... 11 Steering Knuckle Installation ................................. 11 Steering Knuckle Stop Adjustment ........................ 12 Tie Rod Inspection and Replacement..................... 13 Remove Tie Rod Assembly and Tie Rod Steering Arm .......................................................... 14 Install Tie Rod Steering Arm and Tie Rod Assembly................................................................ 14 Wheel Bearing Adjustment .................................... 16 Front Axle Wheel Alignment and Balance ............ 16 List of Figures Figure 1—Model Identification Numbering System 5 Figure 2—Exploded View of Axle Steering Knuckle Assembly and Inspection Guidelines ................ 6 Figure 3—Identification Tag Type and Location ............................................................ 7 Figure 4—Typical Steering Knuckle ....................... 7 Figure 5—King Pin Bushing Wear Measurement ... 8 Figure 6—Spindle Vertical End Play Check............ 8 Figure 7—Removing Draw Key .............................. 9 Figure 8—Removing Steering Knuckle Cap ........... 9 Figure 9—Removing King Pin ................................ 9 Figure 10—Bushing Removal................................ 10 Figure 11—Installing Pre-sized Bushings.............. 10 Figure 12—Bushing Seating Depth ....................... 10 Figure 13—King Pin Bushing Seal Installation ...................................................... 11 Figure 14—Thrust Bearing Seal Installation ......... 11 Figure 15—Sealed Thrust Bearing......................... 11 Figure 16—Spindle Vertical End Play Check........ 11 Figure 17—Draw Key Installation to Front of Axle................................................................. 12 Figure 18—Steering Stop Adjustment ................... 12 Figure 19—Typical Tie Rod .................................. 13 Figure 20—Set Up Dial Indicator .......................... 13 Figure 21—Separate Rod End from Rod Arm....... 14 Figure 22—Proper Indexing of Tie Rods............... 15 Figure 23—Types of Tie Rod Clamps ................... 15

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Page 1: TC Series Front Axle - New & Used Bus Dealer | Coach ... · PDF fileTC Series Front Axle 010-5 Service Parts and Axle Identification ... This procedure is for determining if front

TC Series Front Axle

010-1

TC Series Front Axle

Blue Bird Corporation assumes sole responsibilityfor ensuring that the information provided herein isaccurate to the best of its knowledge at the time ofprinting. In keeping with its policy of continualproduct improvement, Blue Bird reserves the right tochange product information without notice andwithout incurring obligation. Some informationcontained in this section has been re-published fromthe following publications:

Spicer® Heavy Axle and Brake Division, Spicer®

Gold Series Front Axles Service Manual, ©Spicer/Dana, Form #SHABD 894-3.

ContentsTC Series Front Axle ............................................... 1

Spicer® Heavy Axle and Brake Division, Spicer®

Gold Series Front Axles Service Manual, ©Spicer/Dana, Form #SHABD 894-3........................................... 1

Contents ................................................................... 1List of Figures .......................................................... 1Safety ....................................................................... 2Specifications........................................................... 3Torque Chart ............................................................ 3Special Tools............................................................ 4Lubrication............................................................... 4Service Parts and Axle Identification....................... 5Precautions and King Pin Wear Limits.................... 7Maximum Limits for Front Axle King Pin .............. 8King Pin Bushing Replacement ............................... 9Steering Knuckle Removal ...................................... 9King Pin Bushing Removal ................................... 10King Pin Bushing Installation................................ 10King Pin Seal Installation ...................................... 11Steering Knuckle Installation................................. 11Steering Knuckle Stop Adjustment........................ 12

Tie Rod Inspection and Replacement..................... 13Remove Tie Rod Assembly and Tie RodSteering Arm.......................................................... 14Install Tie Rod Steering Arm and Tie RodAssembly................................................................ 14Wheel Bearing Adjustment .................................... 16Front Axle Wheel Alignment and Balance ............ 16

List of FiguresFigure 1—Model Identification Numbering System5Figure 2—Exploded View of Axle Steering Knuckle

Assembly and Inspection Guidelines................ 6Figure 3—Identification Tag Type and

Location ............................................................ 7Figure 4—Typical Steering Knuckle ....................... 7Figure 5—King Pin Bushing Wear Measurement ... 8Figure 6—Spindle Vertical End Play Check............ 8Figure 7—Removing Draw Key .............................. 9Figure 8—Removing Steering Knuckle Cap ........... 9Figure 9—Removing King Pin ................................ 9Figure 10—Bushing Removal................................ 10Figure 11—Installing Pre-sized Bushings.............. 10Figure 12—Bushing Seating Depth ....................... 10Figure 13—King Pin Bushing Seal

Installation ...................................................... 11Figure 14—Thrust Bearing Seal Installation ......... 11Figure 15—Sealed Thrust Bearing......................... 11Figure 16—Spindle Vertical End Play Check........ 11Figure 17—Draw Key Installation to Front of

Axle................................................................. 12Figure 18—Steering Stop Adjustment ................... 12Figure 19—Typical Tie Rod .................................. 13Figure 20—Set Up Dial Indicator .......................... 13Figure 21—Separate Rod End from Rod Arm....... 14Figure 22—Proper Indexing of Tie Rods............... 15Figure 23—Types of Tie Rod Clamps ................... 15

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Safety

WARNINGS and CautionsYou must adhere to the WARNINGS and Cautionsto work safely. The Warnings and Cautions listed inthis manual are emphasized at point of use. Theseshould be required prior to performing themaintenance step following the WARNING orCaution to prevent personal injury or equipmentdamage.

SERIOUS PERSONAL INJURY OREXTENSIVE PROPERTY DAMAGE CAN

RESULT IF THE WARNINGINSTRUCTIONS ARE NOT FOLLOWED.

Minor personal injury can result or a part,an assembly, or the engine can be

damaged if the Caution instructions arenot followed.

MOST FRONT AXLE SERVICEPROCEDURES REQUIRE THE VEHICLETO BE LIFTED OFF THE GROUND ANDSUPPORTED BY ALTERNATE MEANS.

UNDER THESE CIRCUMSTANCES,ALWAYS USE LIFTING EQUIPMENTRATED AT, OR HIGHER THAN, THE

VEHICLE WEIGHT. DO NOT RELY ONA HYDRAULIC JACK AS THE ONLY

SUPPORT DURING SERVICING. AMALFUNCTION IN A HYDRAULIC

JACK MAY RESULT IN THE VEHICLESUDDENLY DROPPING TO THE

GROUND. ALWAYS HAVE A SAFETYBACKUP TO SUPPORT THE WEIGHT

OF THE VEHICLE.

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Specifications, Torques and Special Tools

Specifications

Spicer Model I-120SA/SG and I-146SA/SG

King Pin Bushing Diameter I.D. 1.8608 —1.8652 inch 47.264—47.376 mm

King Pin Diameter 1.8595 —1.8600 inch 47.231—47.244 mm

I-Beam Bore Diameter 1.8608—1.8622 inch 47.264—47.300 mm

Torque Chart

Size Torque

ft-lbs. N·m

Location

Diameter(Inches)

No. ofThreads

Minimum Maximum Minimum Maximum

Tie Rod End Nut (Note 1) ¾

7/8

16

14

80

120

105

160

108

160

143

218

Tie Rod Clamp Bolt 5/8 11 45 60 61 81

Steering Arm Nut and TieRod Arm Nut (Note 1)

1-1/8

1-1/4

12

12

450

775

650

1200

610

1050

881

1625

King Pin Draw Key Nut (Note2)

3/8 16 25 31 34 42

King Pin Cap Bolts 5/16 18 17 25 23 34

Note 1: If cotter pin cannot be installed after minimum torque is attained, the nut must be advanced until the cotterpin can be installed. Torque specified is for taper and threads which are clean and oil free.

Note 2: Torque to specifications. Tap unthreaded end of draw key sharply with a hammer, and re-torque drawkey nut to specifications.

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Special ToolsSpecial service tools are available from:

OTC Division, Service Tools, 655 Eisenhower Drive, Owatonna, MN 55060

Telephone: 1-800-533-0492

Fax Number: 1-800-283-8665

The following is a list of tools needed to service the front axles in this manual. These tool numbers are from OTCTool Division. Dana makes no warranty or representation of these tools.

Models Serviced Description Tool Number

Tools to service all axlemodels

King Pin Bushing Basic Set ZTSE 4330A

Tools to service axle modelsI-200SA/SG and I-146SA/SG

Bushing Installer

Seal Installer

ZTSE 4330-5A

ZTSE 4330-55

Lubrication and Maintenance Schedule

LubricationRecommended Maintenance Schedule for On-Highway Use

Interval Component Procedure

6,000 miles/monthly Wheel Bearings (Oil) Check level and fill with GL-5gear lube as required

25,000 miles/6 month King Pins* and Tie Rod Ends Lube with NLGI-2 LithiumGrease EP-2 Moly Grease

30,000 miles/annually Wheel Bearings (Grease) Repack w/NGLI-2 LithiumGrease EP-2 Moly Grease

100,000 miles/annually Wheel Bearings (Oil) Change Lubricant GL-5

Distribution of grease through the king pin bushing pockets may be enhanced by lifting weight off of front wheelsduring lubrication process.

Recommended Maintenance Schedule for On/Off Highway Use (Low Mileage/High Hour Operation)

Interval Component Procedure

3,000 miles/monthly Wheel Bearings (Oil) Check level and fill with GL-5gear lube as required

6,000 miles or every 6 mo. or300 hrs. of operation

King Pins* and Tie Rod Ends Lube with NLGI-2 LithiumGrease EP-2 Moly Grease

12,000 miles or annually or600 hrs. of operation

Wheel Bearings (Grease) Repack w/NGLI-2 LithiumGrease EP-2 Moly Grease

24,000 miles or annually or1000 hrs. of operation

Wheel Bearings (Oil) Change Lubricant GL-5

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Service Parts and Axle Identification

Genuine Spicer Service PartsShould an axle assembly require replacement component parts, it is recommended that Spicer Heavy Axle ServiceParts be used. Spicer Heavy Axle Service Parts are manufactured under the same rigid specification as areoriginal equipment axle components. This assures the customer who uses genuine Spicer service parts maximumreliability for a Spicer Heavy Axle assembly. They may be obtained through your vehicle manufacturer. The useof non-original Spicer Service Parts may cause premature component failure and may void the warranty.

The items included in this book are currently being offered as service parts at the time of printing. The partnumbers and illustrations are provided specifically for reference purposes only. Therefore, Spicer reserves theright to update this manual without notice or liability.

Figure 1—Model Identification Numbering System

Note: All axle models with the SA designation are now designated as SG axles.

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Front Axle Inspection Guidelines and Description

Figure 2—Exploded View of Axle Steering Knuckle Assembly and Inspection Guidelines

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TC Series Front Axle

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Figure 3—Identification Tag Type and Location

All front axles identified with either an aluminum or mylar tag located between the spring pads, on the front sideof the center beam section. (See Figure 3)

Precautions and King Pin Wear LimitsThe front axles covered in this section are I-beamtype, non-driving units. Front axles are machinedwith different king pin angles to compensate forcrowned road surfaces. The axle must be installedwith the identification tag to the front of the vehicle.Some applications may also have the word “front”cast into the lower flange of the I-beam.

Figure 4—Typical Steering Knuckle

PrecautionsSpicer strictly prohibits the modifying orreconditioning of any front non-driving axlecomponent for any reason. Spicer recommendsreplacing any component which is damaged or out ofspecification. All of the major components are heattreated and therefore, cannot be bent, twisted,welded, heated or reconditioned withoutexperiencing a strength and/or fatigue life reduction.

• Examples of specific prohibited operationsare:

1. Hot or cold bending or twisting of I-beam, tierod arms for any reason.

2. Welding of, or to, steering arms, tie rod arms, I-beams, steering knuckles, king pins or tie rodassemblies.

3. The re-drilling or re-boring of I-beam king pinholes for a bushing.

4. Milling or machining of any component.

5. Spray welding of bearing diameters or othermachined surfaces.

6. The re-drilling or re-boring of draw key holes.

7. Relocation or removal of tie rod clamps.

8.

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Maximum Limits for King PinThis procedure is for determining if front axle kingpin bushing wear (side play) and spindle vertical endplay measurements exceed the maximum wear limitsfor normal service and decide if maintenance isnecessary.

King Pin Bushing Wear CheckThe simplest method for checking king pinlooseness is to use a canber gauge in this particularoperation are as follows:

Note

King pins and bushings must not have beenrecently lubricated before making this check.

Measurements must be made beforelubrication.

Figure 5—King Pin Bushing WearMeasurement

1. Block the rear wheels.

2. Raise and support axle on two jack stands. If theaxle is supported on only one jack stand, a falsereading will be obtained.

3. Apply brakes to eliminate wheel bearing playand to ensure a correct reading.

4. Mark the tire at 17.5 inches (444.5 mm) radiusfrom the center of the spindle. Position a dialindicator at 17.5 inches (444.5 mm) mark tomeasure tire movement. Accurate resultsdepend upon measurement at specified radius.

5. Push the wheel inward at the top and measurethe movement obtained on the dial indicator at17.5 inches (444.5 mm) radius mark on the tire.

Note

If more than 0.125 inch (3.175 mm) isobtained at the 17.5 inches (444.5 mm) mark,

the king pin bushing should be replaced.

Measure Spindle Vertical End Play1. Block rear wheels.

2. Raise and support the axle.

3. Lift the wheel and tire (spindle only if wheel isremoved) so that all clearance is taken upbetween the steering knuckle and axle pin boss.

Figure 6—Spindle Vertical End Play Check

4. Measure clearance using a feeler gauge asshown in Figure 6.

Note

If more than 0.060 inch (1.524 mm) ismeasured, add shims as needed to reduceclearance to 0.005—0.015 inch (0.1270—

0.3810 mm).

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King Pin Bushing ReplacementSteering Knuckle Removal

The following procedure applies to one knuckle,repeat the procedure for the remaining wheel end.

Block rear wheels.

Raise the vehicle. Support vehicle on stands.

Remove wheels as instructed.

Remove the dirt shield screws and shields.

On the models equipped with hydraulic disc brakes,calipers must be removed before hub. Supportcalipers so weight of caliper does not hang fromhydraulic hose.

Remove hubs on vehicle with disc brakes. Removehub and drums on vehicles with drum brakes.

Remove brake backing plate or caliper mountingbracket from the knuckle. It will be necessary tosupport drum brake backing plate so the weight ofthe backing plate is not on the air hose.

Remove tie rod assembly and drag link from steeringarms using a suitable tool. Remove draw key.

Figure 7—Removing Draw Key

Staked draw keys: drive the staked draw key out atthe opposite end of the staking using a drift andbrass hammer. (See Figure 7)

Threaded draw keys: remove nut and Bellevillewashers. Strike the threaded end of draw key withdrift and brass hammer.

Note

All front axles use dual draw keys. I-120SGand I-146SG axles use dual threaded draw

keys. All axles should be serviced withoriginal draw key configuration.

Figure 8—Removing Steering Knuckle Cap

Remove top and bottom steering knuckle caps. (SeeFigure 8). If there are O-rings under the caps, theymust be removed.

Figure 9—Removing King Pin

Drive out the king pin (Figure 9).

Note

Draw key must be removed prior to king pinremoval.

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Do not heat axle to loosen king pin. Heat canweaken axle and cause excessive vehicle

damage.

Remove steering knuckles, thrust bearings and anyspacer shims present.

Thoroughly clean and inspect all parts.

Kingpin Bushing RemovalSelect the appropriate service tool kit (pilots,remover and installer) for axle code number. Allaxles incorporate pre-sized bushings.

Figure 10—Bushing Removal

Assemble screw, support plate, and remover asshown in Figure 10.

Tighten screw with wrench until bushing is removedfrom knuckle.

Assemble tool at opposite end to remove remainingbushing.

Important: Screw threads must be lubricatedwith high pressure lubricant.

Clean and inspect knuckle prior to installation ofnew bushings. Replace if damaged.

Bushing Installation (Pre-sized Type)

Figure 11—Installing Pre-sized Bushings

Assemble screw, support plate and installer withupper bushing as shown in Figure 11.

Figure 12—Bushing Seating Depth

Tighten screw to pull bushing into knuckle. Installbushing to specified dimension as shown in Figure12.

Install lower bushing following the same procedureused in installing the upper bushing (except oppositeend).

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King Pin Seal InstallationInstalling Upper and Lower Seals

Figure 13—King Pin Bushing SealInstallation

Position knuckle vertically to install top seal intobore. (See Figure 13)

Hand start seal with sealing lip out or rounded edgeinto bore. (See Figure 13)

Using adapter or steel plate, press seal into knucklebore until it is flush with knuckle surface.

Install bottom seal as outlined is steps 2 and 3.

Steering Knuckle InstallationBefore installing king pins, lubricate inside of thebushings and outside of king pins with Fleetrite EP2Moly Grease or equivalent NLGI No.2 multipurposelithium grease to provide initial lubrication.

Make certain that knuckle pin hole in axle center isclean and dry.

Figure 14—Thrust Bearing Seal Installation

There may be two styles of thrust bearings. Onetype is installed on thrust bearing with seal on top asshown in Figure 14.

Figure 15—Sealed Thrust Bearing

The second style thrust bearing is a one piece designwith seal lip installed towards the bottom of theknuckles as shown in Figure 15.

Slide the thrust bearing between the lower face ofaxle center and lower steering knuckle yoke.

Figure 16—Spindle Vertical End Play Check

Align the steering knuckle yoke holes with axle andthrust bearing holes.

Place a jack under the lower side of steering knuckleyoke and raise knuckle so that all clearance is takenup between lower yoke, thrust bearing and lowerface of axle center end. See Figure 16.

Check the clearance between the top face of upperaxle center end and lower face of upper knuckle pinboss. Shims are available in various thickness toprovide a desired clearance of 0.005—0.015 inch(0.1270—0.3810 mm). (See Figure 16)

Note

Lubricate the king pin at installation to assureinitial lubrication of parts.

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Install king pin from the top, taking care to alignnotch with draw key holes in I-beam.

Note

The machined flats are located closer to thetop of the king pin to allow installation of the

thrust bearing, while maintaining correctvertical position of king pin. The flats are

also wider than the draw key allowing slightadjustment. The king pin must be verticallycentered in the knuckle. This allows both topand bottom king pin end caps to be installed

without interference.

Figure 17—Draw Key Installation to Front ofAxle

Install draw keys. Threaded draw keys will replacestaked draw keys as follows:

Install top draw key with the threaded end of key tofront of axle as shown in Figure 17.

To seat the draw key, strike unthreaded end of keywith the drift and a hammer.

Install Belleville washers as shown in Figure 17.

Install nut and tighten to specified torque. (Refer toSpecifications, Torques, and Special Tools in thisgroup). Install bottom draw key with threaded endto rear of axle.

Repeat steps B,C, and D to finish installation ofbottom draw key.

Install king pin caps and O-ring. (See Figure 17)Tighten cap screws to specified torque. (Refer toSpecifications, Torques, and Special Tools in thisgroup).

To make sure the king pins will accept lubricant,lubricate upper and lower king pin bushings throughthe cap grease fittings. If problems arise, you willnot have to remove the brakes again to make repairs.

Reinstall tie rod ends into the steering arms. Tightenthe nuts to the specified torque. (Refer toSpecifications, Torques, and Special Tools in thisgroup). Then install the cotter pin.

Reinstall brake components. Refer to Group 030.2(Remove and Replace Hub and Rotor Assembly.).

Clean and inspect the front wheel bearings. Refer toGroup 030.2 Wheel End Components (WheelBearing Inspection). Install the bearings in the hubassembly using new seals. Refer to Group 030.2(Remove and Replace Hub and Rotor Assembly.).

Assemble hub and bearings on spindle. Remove andreplace hub and rotor assembly. Install wheel rimsand tires.

Remove vehicle from floor stands.

Check toe in by following original equipmentmanufacturer’s guidelines for correct toe inadjustment.

Steering Knuckle Stop AdjustmentThe steering arm stop screw should be adjusted topermit maximum turning angle. With powersteering, the stop screw should be adjusted to assurethat the power steering unit will not override the axlestop.

Figure 18—Steering Stop Adjustment

To prevent overriding, adjust power steering systemsand stop screws so that the power is cut off beforecontact with the axle stop screw. (See Figure 18)

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Adjust the axle steering stops to contact when themaximum turning angle of the specific axle isreached, and lock with jam nut.

Adjust the power steering unit to stop ½ � to 1�before axle steering stops contact (maximum turningangle).

Note

Maximum turn angle specifications to bechecked at the inside wheel.

The adjustment of both axle steering stops andpower steering unit should be periodically checkedand corrected if necessary.

For more detailed instructions pertaining to wheelstop adjustment, follow the original equipmentmanufacturer’s guidelines for turning angles andfront wheel alignment.

Tie Rod Inspection and Replacement

Note

Prior to performing a front wheel alignment,verify rear axle alignment in Group 020 (Rear

Axle Alignment).

Figure 19—Typical Tie Rod

The tie rods are of a three piece construction,consisting of a tie rod and two rod end assemblies.The ends are threaded to the rod and locked withclamp bolts. (See Figure 19) Right and left handthreads are provided for toe in adjustment. Tensionon ball stud in the rod ends is self adjusting andrequires no attention in service other than periodicinspection to see that ball studs are tight in steeringknuckle arms.

Fittings are provided for periodic lubrication onsome types of rod ends. Where no fittings are used,the tie rods have been lubricated at assembly and nofurther lubrication is necessary. If the tie rod taperjoint is loose or the cotter pin is missing, remove,inspect and replace the tie rod arm/tie rod end if thecontact surfaces are worn.

Replacement Criteria – InspectionCarefully wipe seal clean and examine for splits ortears that allow contaminants into the socket.

If seal is acceptable, shake tie rod assembly by handonly.

Prying on steering linkage can result indamage, creating false indication of looseness.

Figure 20—Set Up Dial Indicator

If looseness is detected, set up a dial indicator asshown in Figure 20. Jack up that side of the axleand measure movement at the tie rod end. Move thetire in and out as illustrated in Figure 20.

Note

C-clamp setup is recommended for testing thetie rod end for looseness.

The tie rod end should be replaced if a reading of0.030 inch or more is taken. Replace tie rod end atthe next service interval.

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NoteWe do not recommend removing the tapered studfrom the arm to check rotating torque. This maydamage the seal or socket assembly. The full bootclamped seal can give false rotational torquereading.

At assembly, insure that the slotted nut is tightenedaccording to specifications. (Refer to Specifications,Torques, and Special Tools in this group). If thecotter pin cannot be installed, tighten nut to the nextslot. Do not back off once minimum torque isreached.

When tie rod linkage ends are replaced, theymust be threaded into the tie rod or drag linksufficiently to allow positioning of the clampover the threads if not welded on the ball jointend. Position clamp bolt so it crosses the slot

in rod end.

Remove Tie Rod Assembly and Tie RodSteering ArmThis procedure includes removing the tie rod endsfrom tie rod. Refer to the precautions in this section.

Remove the cotter pins and the nuts which secureeach tie rod to the tie rod arm.

Figure 21—Separate Rod End from RodArm

Separate tie rod assembly from the tie rod arms,using a tie rod separator tool. (See Figure 21)

Remove the cotter pin and the nut that fastens the tierod arms in the knuckle.

Remove the tie rod arms from the knuckle. Ifnecessary, tap on the end of the rod with the stud nutassembled loosely on the stud (to avoid damage tothe threads) using a brass drift and hammer.Remove the key.

If necessary, use the following procedure to removethe tie rod ends from the rods.

Mark the position of each tie rod end in the tie rodtube.

Remove the clamp bolts and nut from the clamp onthe tie rod.

Thread the tie rod ends out of the tube rod.

Install Tie Rod Steering Arm and Tie RodAssemblyThis procedure includes installing the tie rod ends tothe tie rod.

Press the key in the slot in the steering arm.

Install the tie rod arm in the knuckle.

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Install the nut on the tie rod arm. Tighten to thespecified value. (Refer to Specifications, Torques,and Special Tools in this group).

Install the cotter pins. If necessary, tighten the nutuntil the holes are aligned. Do not loosen the nut toinstall the cotter pin. If the cotter pin can not beinstalled, tighten nut to the next stop.

Note

The tie rod has right hand threads on one endand left hand threads on the other end. Make

sure the ends are installed properly on thetube.

Figure 22—Proper Indexing of Tie Rods

Note

Proper indexing, or alignment of tie rod ends,(left tie rod end parallel to right tie rod end)will eliminate restricted movement of the tierod assembly. This restriction could cause

premature failure of tie rod end.(See Figure 22).

Toe in should be checked and adjusted to vehiclespecifications if necessary.

Figure 23—Types of Tie Rod Clamps

When tie rod ends are replaced or toe in is adjusted,both ends must be threaded into the tie rod tube farenough to completely cover the slots in the tube.(See Figure 23)

If removed, install the tie rod ends on the tie rod tothe position marked during removal.

If new tie rod ends are installed, thread the endsequally on the cross tube to the required length.Refer to CAUTION in tie rod text.

Install the nuts and the bolts in the clamps. Tightento the specified value. (Refer to Specifications,Torques, and Special Tools in this group).

Assemble the tie rod ends into the tie rod steeringarms.

Install the tie rod stud nuts. Tighten to specifiedvalue. (Refer to Specifications, Torques, and SpecialTools in this group).

Install the cotter pins. If necessary, tighten the nutuntil the holes are aligned. Do not loosen the nut toinstall the cotter pin.

Lubricate tie rod ends.

Check toe in by following original equipmentmanufacturer’s guidelines for correct toe inadjustment.

Some tie rod clamps will be free to rotate around thetie rod allowing setting of toe in while avoidingcontact of the axle. There are two ways mechanicalstops will position the clamps. One style of clamp islimited by a spot weld on the tube. The second styleof clamp is limited by a tab that will lock against theend of the tube. Refer to Figure 23.

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Wheel Bearing Adjustment

Adjust wheel bearings by original equipmentmanufacturer maintenance schedules or afterany unscheduled maintenance that requiresdisturbing proper adjustment of the wheel

bearings.

After the hub and bearings are assembled in place onthe spindle, install the retaining washer andadjusting nut. Tighten the wheel bearing adjustingnut to 120 − 140 ft-lb (163—190 N⋅m). Whilerotating hub to seat bearing, loosen adjusting nut ½turn. Tighten adjusting nut again to 50 ft-lb (68N⋅m). While rotating the hub loosen the nut ¼ turn.

Check bearing adjustment with a dial indicator and amagnetic base. Make sure dial indicator is orientedparallel to the vehicle axle.

Bearing endplay should not exceed 0.010 inch (0.25mm).

When bearing adjustment is correct, the hub shouldrotate freely without excess play.

If hub binds or shows excessive endplay, repeatprocedure.

Front Axle Wheel Alignment and BalanceHendricksonAxles

SpringSuspension

TCFE 3+/-1DegreePositive

0 Degree ±

7/16 Degree

0 Degree ±

7/16 Degree

0 to 1/16Inch

HendricksonAir Suspension

TCFE

TCRE

3+/-1DegreePositive

0 Degree ±

7/16 Degree

0 Degree ±

7/16 Degree

0 to 1/16Inch

TC Series Front Axle Wheel Alignment and Balance

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