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  • 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 1Model Identification Numbering System5Figure 2Exploded View of Axle Steering Knuckle

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

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

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

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

  • TC Series Front Axle

    010-2

    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.

  • TC Series Front Axle

    010-3

    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 47.26447.376 mm

    King Pin Diameter 1.8595 1.8600 inch 47.23147.244 mm

    I-Beam Bore Diameter 1.86081.8622 inch 47.26447.300 mm

    Torque Chart

    Size Torque

    ft-lbs. Nm

    Location

    Diameter(Inches)

    No. ofThreads

    Minimum Maximum Minimum Maximum

    Tie Rod End Nut (Note 1)

    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.

  • TC Series Front Axle

    010-4

    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

  • TC Series Front Axle

    010-5

    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 1Model Identification Numbering System

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

  • TC Series Front Axle

    010-6

    Front Axle Inspection Guidelines and Description

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

  • TC Series Front Axle

    010-7

    Figure 3Identification 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 cov