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Motorhome Suspensions

IFS1660S3/1800S3/2000S3

Owner’s Manual

Reyco Granning Suspensions1205 Industrial Park DriveMount Vernon, MO 65712 Phone: 417-466-2178 Fax: 417-466-3964

1-800-753-0050www.reycogrann ing .com

Revision Date: 5/12

Document #: D710551Revision: C

| Independent Front Suspension

Service PartsMaintenance Instructions

Table of Contents

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Introduction .................................................................4Service Notes.....................................................................................................4Identification......................................................................................................5Vehicle Towing Information .............................................................................6Maintenance Schedule.......................................................................................7Maintenance Record..........................................................................................8

Parts Lists ....................................................................9Unit Assembly ...................................................................................................9Control Arm Components ...............................................................................10Control Arm Assemblies .................................................................................11Steering Components (IFS1660S3).................................................................12Steering Components (IFS1800S3/2000S3) ...................................................13Air Spring and Shock Components.................................................................14HCV Components ...........................................................................................15Sway Bar Components ....................................................................................16Disc Brake Components..................................................................................17King Pin Components .....................................................................................18Steering Knuckle Carrier Components ...........................................................19

Lubrication ................................................................20Lubricant Specifications and Intervals............................................................20General Lubrication.........................................................................................20Ball Joints ........................................................................................................20Ball Studs on Tie Rods....................................................................................20Carrier Bearing and Kingpin ...........................................................................21Wheel Bearings ...............................................................................................22

Troubleshooting.........................................................23Inspection ...................................................................27

General Inspection...........................................................................................27Inspecting the Control Arm Bushings for Wear .............................................27Inspecting the Tie Rod Ends ...........................................................................28Inspecting the ABS Sensor and Tone Ring.....................................................28Inspecting the Shock Absorber .......................................................................29Inspecting the Air Spring and Height Control Valve......................................29

Air Spring Inspection...................................................................................................... 29Height Control Valve Inspection .................................................................................... 29

Inspecting the Steering Arm and Relay Rod Ball Joints.................................30Seal Inspection ................................................................................................................ 30Endplay Inspection.......................................................................................................... 30

Table of Contents

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Inspecting Wheel Bearing Endplay.................................................................31Inspecting the Knuckle Carrier Bearing and Seal ...........................................31Inspecting the Kingpin Vertical Endplay........................................................31

Adjustments ...............................................................33Adjusting Wheel End Play ..............................................................................33Adjusting Suspension Ride Height .................................................................35Adjusting the Maximum Wheel Turn Angle ..................................................36Inspection Before Alignment ..........................................................................37

Wheels and Tires............................................................................................................. 37Front Suspension............................................................................................................. 37Rear Axle and Suspension .............................................................................................. 38

Front Wheel Alignment...................................................................................38Equipment ....................................................................................................................... 38General ............................................................................................................................ 38Preparation ...................................................................................................................... 38

Adjusting the Camber Angle...........................................................................40Eccentric Camber Adjustment ........................................................................................ 40Bar Pin Camber Adjustment ........................................................................................... 41

Adjusting the Caster Angle .............................................................................42Eccentric Caster Adjustment........................................................................................... 42

Adjusting the Toe-In .......................................................................................44Repair .........................................................................45

General Procedures..........................................................................................45Cleaning the Parts............................................................................................45

Ground or Polished Parts ................................................................................................ 45Rough Parts ..................................................................................................................... 46Drying ............................................................................................................................. 46Preventing Corrosion ...................................................................................................... 46

Replacing Tie Rod Ends..................................................................................46Removal .......................................................................................................................... 46Installation....................................................................................................................... 46

Replacing the Steering Arm Ball Joints ..........................................................47Removal .......................................................................................................................... 47Installation....................................................................................................................... 47

Replacing the Idler Arm Bearings (IFS1660S3).............................................47Removal .......................................................................................................................... 48Installation....................................................................................................................... 48

Replacing the Upper and Lower Control Arm Bushings................................48Upper Control Arm Removal.......................................................................................... 49Upper Control Arm Installation ...................................................................................... 49Lower Control Arm Removal ......................................................................................... 49Lower Control Arm Installation...................................................................................... 50

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Replacing Wheel Bearings, Oil Seals, and Hub Caps.....................................50Removal .......................................................................................................................... 51Installation....................................................................................................................... 51

Replacing Brake Components .........................................................................54Brake Rotors ................................................................................................................... 54Brake Chambers.............................................................................................................. 54Other Brake Components................................................................................................ 54

Replacing the ABS Sensor and Tone Ring .....................................................54Sensor Removal .............................................................................................................. 54Sensor Installation........................................................................................................... 54Tone Ring Removal and Installation .............................................................................. 55

Replacing the Shock Absorber........................................................................55Removal .......................................................................................................................... 55Installation....................................................................................................................... 55

Replacing the Air Spring.................................................................................55Removal .......................................................................................................................... 55Installation....................................................................................................................... 55

Replacing the Height Control Valve ...............................................................56Removal .......................................................................................................................... 56Installation....................................................................................................................... 56

Replacing the Sway Bar and Components ......................................................56Vertical Linkage Removal .............................................................................................. 56Vertical Linkage Installation........................................................................................... 56Sway Bar Removal ......................................................................................................... 56Sway Bar Installation...................................................................................................... 56

Replacing the Steering Knuckle Carrier Bearings ..........................................57Removal .......................................................................................................................... 57Installation....................................................................................................................... 57

Replacing the Steering Gearbox/Slave Unit Assembly ..................................59Removal .......................................................................................................................... 59Installation....................................................................................................................... 59

Steering Gear Poppet Readjustment................................................................59Torque Tables............................................................61

Introduction

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Introduction

Service NotesThis Service Manual describes the correct service and repair procedures for theReycoGranning® IFS1660S3 Independent Front Suspension model with 16,600 lb, theIFS1800S3 Independent Front Suspension Model with 18,000 lb and the IFS2000S3Independent Front Suspension Model with 20,000 lb Gross Axle Weight Rating (GAWR).Overloading the suspension may result in adverse ride and handling characteristics.

You must read and understand all procedures and safety precautions presented in this manualbefore conducting any service work on the suspension.

Proper tools must be used to perform the maintenance and repair procedures in this manual.Some procedures require the use of special tools for safe and correct service. Failure to usethe proper and/or special tools when required can cause personal injury and/or damage tosuspension components.

You must follow your company safety procedures and use proper safety equipment when youservice or repair the suspension.

The information contained in this manual was current at the time of printing and is subject tochange without notice or liability. Reyco Granning LLC reserves the right to modify thesuspension and/or procedures and to change specifications at any time without notice andwithout incurring obligation.

Reyco Granning LLC uses the following types of notices for potential safety problems and togive information that will prevent damage to equipment.

WARNINGA warning indicates procedures that must be followed exactly. Serious personalinjury can occur if the procedure is not followed.

CAUTIONA caution indicates procedures that must be followed exactly. Damage to equipmentor suspension components and personal injury can occur if the procedure is notfollowed.

NOTEA note indicates an operation, procedure or instruction that is important for correctservice.

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IdentificationThe suspension model and serial number are stamped on an aluminum tag that is riveted tothe front of the suspension sub-frame assembly (Figure 1). The serial number is used byReyco Granning LLC for control purposes and should be referred to when servicing thesuspension or requesting technical support (Figure 2).

Figure 1– Suspension Identification Location

Figure 2 – Suspension Serial Number Tag

Model GAWR(lb)

WheelCut

IFS1660S3-[Options] 16,600 58°IFS1800S3-[Options] 18,000 58°IFS2000S3-[Options] 20,000 58°

Table 1 - Model IdentificationDisc

BrakesHeight Control

ValveSensor Height

ControlSwayBar

BilsteinShocks

KoniShocks

Std DualStd

Singlew/-SB

Dual-SHC

Singlew/-SHCSB -SB Std -F

Table 2 - Options Identification

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Vehicle Towing InformationIf a vehicle is disabled and needs to be towed by the front end to service center, check theOEM/Coach Builder towing procedures for the recommended method. Check with localauthorities and Department of Transportation (DOT) for permissible towing methods beforetowing. Some states do not permit towing by chains and/or straps.

The preferred towing apparatus is the type that cradles the front tires. If the towing apparatuscannot be attached to the front tires or directly to the chassis frame rails, then the suspensionsub-frame may be used for attachment.

WARNINGAttaching towing equipment to improper locations and failure to utilize OEM/CoachBuilder recommended towing methods could result in one or more of the following:··Loss of vehicle control.··Possible disconnection from tow vehicle.··Damage to the suspension and/or vehicle.

Do Not attach tow apparatus (hooks, chains, straps, etc.) to suspension upper and lowercontrol arms, sway bar and brackets, brake components, tie rods, steering arms, or steeringknuckle carrier assemblies (Figure 3).

Figure 3 – Improper Tow Equipment Attachment Locations

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Maintenance ScheduleGENERALMAINTENANCE

SERVICE TO BE PERFORMED MILEAGE IN THOUSANDS

12 24 36 48 60 72 84 96

Steering Arm Ball Joints Check axial endplay X X2

Inspect for ruptured seals X X X X X X X X2

Check that cotter pin is installed X X X X X X X X2

Control Arm Bushings Check bolt torque X X2

Inspect for contact between control arm and mount X X X X X X X X2

Inspect for bushing wear X X X X X X X X2

Tie Rod Ends Inspect ball socket endplay X X X X X X X X2

Check for looseness of taper connection X X X X X X X X2

Check that cotter pin is installed X X X X X X X X2

Brake System Inspect for air leaks using soapy water solution X

Air Springs Inspect for proper clearance (1” minimum all around) X

Check upper mount nut and lower mount bolt torque X

Inspect for signs of chafing or wear X X X X X X X X2

Inspect for air leaks using soapy water solution X

Height Control Valve andLinkage

Inspect for signs of bending, binding, or slippage X X X X X X X X2

Inspect for air leaks using soapy water solution X

Shock Absorbers Check mounting nut torque X

Inspect shocks for signs of fluid leak, broken eyeends, loose fasteners, or worn bushings

X X X X X X X X2

Kingpins Check for wear X X2

Inspect vertical endplay X X2

Steering Arm Bearings Check nut torque X X2

Inspect bearings for excessive radial play X X X X X X X X2

Carrier Bearings Check axial endplay X2

Wheels Check bearing endplay X X2

Check wheel nut torque1 X X X X X X X X2

Front Alignment Inspect toe-in3 X X X X2

Air Fittings and Air Lines Inspect for air leaks using soapy water solution X

Inspect for signs of chafing, cracking, or wear X X X X X X X X2

Sway Bar Bushings Check mounting bolt torque X X2

Inspect for bushing wear X X X X X X X X2

Gearbox Lubrication Lubricate output shaft X X 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 or at previous interval.3. Final stage manufacturer should complete toe-in inspection and adjustment after completion of vehicle.

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Maintenance RecordName of Owner Address of Owner

Date of Purchase Name and Address of Dealer

Model of Vehicle Vehicle Identification Number

Suspension Model Number:

IFS_______S3-__________

(Ex. IFS1800S3-SHCSB)

Suspension Serial Number:

Inspection and Maintenance Item Date Mileage Service Performed

Parts List

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Parts Lists

Unit AssemblyItem Part No. Description Item Part No. Description

1 709736-01 Sub frame Assembly* 10 5608 HCV Assembly (Standard Option)***710353-01 Sub frame Assembly** 705378-01 Electronic Height Control Sensor (-SHC Option)***

2 700944-01 Lower Control Arm Assembly* 11 703915-01 HCV Linkage Assembly705847-01 Lower Control Arm Assembly** 12 702030-01 Relay Rod*

3 700973-01 Tie Rod Assembly, LH* 705867-01 Relay Rod**708177-01 Tie Rod Assembly, LH** 13 705480-01 Assembly, Wheel End and Brakes, LH*

4 703182-01 Upper Control Arm Assembly* 709679-01 Assembly, Wheel End and Brakes, LH**705849-01 Upper Control Arm Assembly** 14 705480-02 Assembly, Wheel End and Brakes, RH*

5 710366-01 Carrier Assembly, LH* 709679-02 Assembly, Wheel End and Brakes, RH**705853-01 Carrier Assembly, LH** 15 705800-01 Height Control Valve Arm, LH

6 710366-02 Carrier Assembly, RH* 16 705800-02 Height Control Valve Arm, RH705853-02 Carrier Assembly, RH** 17 710180-01 Assembly, Gearbox*

7 705951-01 Air Spring Assembly* 710180-02 Assembly, Gearbox**705859-01 Air Spring Assembly** 18 710355-02 Assembly, Slave, Gearbox**

8 708385-01 Shock Absorber 19 700973-02 Tie Rod Assembly, RH*9 705620-01 Idler Arm* 708177-02 Tie Rod Assembly, RH**

*Used with IFS1660S3 Units**Used with IFS1800S3/2000S3 Units***Sway Bar Units (-SB) have a single (L) HCV/HCS, Non Sway Bar Units have Dual (R&L) HCV/HCS

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Control Arm ComponentsItem Part No. Description Item Part No. Description

1 703182-01 Upper Control Arm Assembly* 7 293 Socket Set Screw 10-24 x .38”705849-01 Upper Control Arm Assembly** 8 701683-04 Hardened Flat Washer, 7/8”

2 700944-01 Lower Control Arm Assembly* 9 100039-P1 Hex Head Bolt 3/4-10 x 2.75, Gr. 8, Zn*705847-01 Lower Control Arm Assembly** 705829-01 SHCS 7/8-9 X 2.75 PH**

3 700245-01 Boss, Eccentric 10 702516-02 Hex Head Bolt 1 1/8-12 x 7.75, Gr. 8, ZY4 8490 Spacer 11 168 Hardened Flat Washer, 1 1/8”5 292 Hex Head Bolt 7/8-9 x 8.50, Gr. 8, ZN 12 166 Lock Nut 1 1/8-12, Gr. C6 100122-P1 Lock Nut 7/8-9”, Gr. C

*Used with IFS1660S3 Units**Used with IFS1800S3/2000S3 Units

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Control Arm AssembliesItem Part No. Description Item Part No. Description

1 703181-01 Upper Control Arm, LH/RH* 3 8382 Bushing705850-01 Upper Control Arm, LH/RH**

2 700939-01 Lower Control Arm, LH/RH*705848-01 Lower Control Arm, LH/RH**


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Steering Components (IFS1660S3)Item Part No. Description �� Part No. Description

1 710135-01 Assembly, Steering Gearbox 14 8223752 HHB 3/4-16 x 2.00, Gr. 8.2 700973-02 Assembly, Bleed Line 15 705382-01 Ball Joint, 40mm*3 710171-01 Assembly, Bulkhead 16 705620-01 Idler Arm Assembly4 710172-01 Assembly, Bleed Port 17 702030-01 Relay Rod5 709714-02 Pitman Arm 18 705382-02 SN M20- x 1.5*6 709309-01 Mount, Gearbox, LH 19 705382-03 Cotter Pin*7 709725-01 Steering Gearbox/Shock Mounting Plate, LH 20 103712 Tie Rod End, RH8 701671-01 HHB 3/4-10 x 4.50, Gr. 8, ZN 21 6632 Clamp, Tie Rod9 103003 HFW 3/4 22 700971-01 Tube, Tie Rod

10 208 LFN 3/4-10, Gr. G, ZN 23 103736 Tie Rod End, LH11 709386-01 HHB 7/8-14 x 2.00, Gr. 8, ZN 24 167 HHB 1.0-14 X 6 Gr. 8 ZY12 104098 HFW 7/8 25 2571 HFW 1"13 709388-01 HHB 3/4-16 x 1.50, Gr. 8, ZN 26 89422312 LN 1-14 Gr. C Phos & Oil

*Parts included in kit K705382

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Steering Components (IFS1800S3/2000S3)Item Part No. Description �� Part No. Description

1 710180-02 Assembly, Steering Gearbox, Master 13 709388-01 HHB 3/4-16 x 1.50, Gr. 8, ZN2 710355-02 Assembly, Steering Gearbox, Slave 14 8223752 HHB 3/4-16 x 2.00, Gr. 8.3 710359-02 Steering Line, Front 15 705382-01 Ball Joint, 40mm*4 710359-01 Steering Line, Rear 16 709309-02 Mount, Gearbox, RH5 709714-02 Pitman Arm 17 705867-01 Relay Rod6 709309-01 Mount, Gearbox, LH 18 705382-02 SN M20- x 1.5*7 709725-01 Steering Gearbox/Shock Mounting Plate, LH 19 705382-03 Cotter Pin*8 701671-01 HHB 3/4-10 x 4.50, Gr. 8, ZN 20 710671-02 Tie Rod End, RH (Supersedes 705824-02)9 103003 HFW 3/4 21 6632 Clamp, Tie Rod

10 709725-02 Steering Gearbox/Shock Mounting Plate, RH 22 708178-01 Tube, Tie Rod11 709386-01 HHB 7/8-14 x 2.00, Gr. 8, ZN 23 710671-01 Tie Rod End, LH (Supersedes 705824-01)12 104098 HFW 7/8 24 208 LFN 3/4-10, Gr. G, ZN

*Parts included in kit K705382

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Air Spring and Shock ComponentsItem Part No. Description Item Part No. Description

1 705951-01 Air Spring Assembly* 7 707357-01 Assembly, Shock Mount705859-01 Air Spring Assembly** 8 208 LFN 3/4-10, Gr. G, ZN

2 705860-01 Spacer, Air Spring** 9 8131017 FW 3/4" .812 x 1.469 x .134, ZP3 706899-01 Arm , HCV 10 700178-10 Shock Assembly (Standard)

4 276 FHB 1/2-13 X 1.75 Gr.8 ZN * 708385-01 Shock Assembly (-F Model Option)702638-02 FHB 1/2-13 X 2.00 Gr.8 ZN ** 11 100263-P1 HHB 3/4-10 x 2.75, Gr. 8, ZN

5 302 FHB 3/8-16 X 1.25 Gr. 8 ZN 12 8120382 SLW 3/8 ZP6 100678-P1 HHB 3/4-10 x 3.5, Gr. 8, ZN


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HCV ComponentsItem Part No. Description Item Part No. Description

1 5608 HCV Assembly (Standard Option)* 5 703915-01 Assembly, Linkage705378-01 Electronic Height Control Sensor (-SHC Option)* 6 705932-01 Pin

2 702606-02 HHB 1/4-20 x 1.25”, Gr. 8, ZN 7 705967-01 1/4” Nylock Nut3 100703-P1 LN 1/4” 8 705967-02 5/16” Nylock Nut4 8120392 FW 1/4”

*Sway Bar Units (-SB) have a single (L) HCV/HCS, Non Sway Bar Units have Dual (R&L) HCV/HCS

25

6

1

8

3

4

7

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Sway Bar ComponentsItem Part No. Description Item Part No. Description

1 703124-01 Sway Bar 9 118 FW 1/2” **2 703165-01 Assembly, Mount, UCA, Sway Bar 10 703128-01 Mount, UCA, Sway Bar *3 703127-03 Mount, UCA, Sway Bar * (Supersedes 703127-01) 11 100580-P1 HHB 1/2-13 x3.50, Gr. 8, Zinc **4 89422301 LN 1/2-13, Gr. 8, Zinc ** 12 8455001 HHB 1/2-13 x 2.00, Gr. 8, Zinc **5 102550 HHB 1/2-13 x 2.75, Gr. 8, Zinc ** 13 702895-01 Bushing, Split, Sway Bar *6 307 FHB 1/2-13 x 1.50, Gr. 8, Zinc ** 14 702894-01 Mount, D-Ring Sway Bar *7 89422301 LN 1/2-13, Gr. 8 ** 15 702898-01 Washer, Cut, Sway Bar8 702797-01 FHB 7/16-14 x 1.25, Gr. 8, ZP ** 16 89422299 LN 7/16-14 UNC, Gr. 8 **

* Items included with K706842 (Supersedes K703129)** Items included with K705273NOTE: 703127-01 must be replaced in pairs with 703127-03

Generic View Shown

2

748

9 1011 12

13 14 15 16

1

6

3

5

4

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Disc Brake ComponentsItem No. Part No. Description Item No. Part No. Description

1 266 Flange Head Bolt 5/16-18x.75, Gr. 5, ZC 13 705011-27 ABS Sensor Bushing2 7328 ABS Sensor (Straight w/Lead) 14 705084-01 Oil Seal Assembly - Guardian3 6946 ABS Sensor Spring Retainer 15 705013-15 Torque Plate Assembly, LH

4 705011-01 Steering Knuckle Assembly, LH 705013-16 Torque Plate Assembly, RH705011-02 Steering Knuckle Assembly, RH 16 1786 Hub Cap Gasket Stemco

5 126 Hex Head Bolt 5/8-18x2, Gr. 8, ZN 17 700690-04 Hex Head Bolt M20x1.5-50 Gr. 10.96 705051-01 Bearing - Inner

18705013-17 Brake Caliper, LH (Supersedes 705013-03)

7 705052-01 Bearing - Outer 705013-18 Brake Caliper, RH (Supersedes 705013-08)

8

705017-01 Arm, Steering, LH* 705013-04 Brake Pad Service Kit705017-02 Arm, Steering, RH* 19 704078-01 Flat Washer 20mm708105-01 Arm, Steering, LH** 20 89422308 Locking Flange Nut 5/8-18x.75, Gr. G, PH708105-02 Arm, Steering, RH** 21 103003 HFW 3/4”

9 705011-21 Castle Nut 1 1/4 - 12 22 708181-01 Nut, Spindle, Pro-Torq10 700525-16 Key 23 708182-01 Hub Cap11 705011-22 Assembly, Steering Stop 24 707819-01 Hub and Rotor Assembly12 705011-23 Cotter Pin 3/16 x 2-1/2


4 8

5

23

9

1

7

6

1120 21

15

14

13 12

18

22 16

23

24

1017

19

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King Pin ComponentsItem Part No. Description Item Part No. Description

1 705011-07 Shim, .005” thick 7 705011-17 Cap, King Pin2 705011-08 Shim, .010” thick 8 705011-18 O-Ring3 705011-09 Shim, .020” thick 9 705011-19 King Pin4 705011-14 Assembly, Bearing, Thrust 10 705315-01 Draw Key, (Long 3.80)5 705011-15 Bolt, King Pin Cap 11 705316-01 Nut, Draw Key6 705011-16 Grease Fitting, Straight

6

57

82

13

9

411

10

Oil seal is on the bottomof the thrust bearing

towards the carrier side

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Steering Knuckle Carrier ComponentsItem Part No. Description Item Part No. Description

1

705632-01 Machining, Carrier, LH* 7 702623-01 Shim, .004705632-02 Machining, Carrier, RH* 8 702834-01 Bearing705852-01 Machining, Carrier, LH** 9 702835-01 Cup705852-02 Machining, Carrier, RH** 10 702623-02 Shim, .010

2 702621-02 Bar Pin* 11 702836-01 Seal705854-02 Bar Pin** 12 7352 Grease Zerk, Hydraulic Shutoff

3 702622-01 Spacer 13 287 HHB 5/8-18 X 1-1/2 Gr.8 ZN4 702618-01 Split Collar 14 89422850 HFW 5/8 ZN5 702620-01 Retaining Ring 15 705692-01 Machining, Lower Air Spring Mount6 702619-01 Outer Collar 16 149 HHB 5/8-18 X 3Gr. 8 ZN


Left Hand Steering Knuckle Carrier Shown

Lubrication

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Lubrication

Lubricant Specifications and IntervalsCOMPONENT SERVICE INTERVAL CHANGE INTERVAL LUBRICANT SPECIFICATION

Ball Studs on Endsof Tie Rods

Whichever comes first: Everyoil change or every 6 months N/A

Multi-Purpose Chassis Grease

Premium Multi-Purpose ChassisGrease NLGI Grade 2

KingpinWhichever comes first: Everyoil change or every 6 months N/A

Multi-Purpose Chassis Grease

Premium Multi-Purpose ChassisGrease NLGI Grade 2

Carrier Bearings1Whichever comes first: 50,000miles (80,000 kilometers) or

once a yearN/A

Mobillith AW2Amoco L Industrial 861Exxon Ronex MP

Gearbox Shaft1Whichever comes first: Everyoil change or every 6 months N/A Premium Multi-Purpose Chassis

Grease NLGI Grade 2 or 3

Wheel End 1000 miles (1600 kilometers)Check fluid level

Whichever comes first: Sealsreplaced, brakes relined,100,000 miles (160,000 km),or once a year

Gear Oil

SAE 80W/90 or equivalent

1. Use a Manual Grease Gun only

General LubricationProper lubrication practices are importantin maximizing the service life of yourReycoGranning® Independent FrontSuspension.

CAUTIONDo not mix lubricants of differentgrades. Do not mix mineral andsynthetic lubricants. Different brandsof the same grade may be mixed.

CAUTIONNever mix oil bath and grease packedwheel ends.

Ball JointsThe ball joints are lubricated and sealedfor their service life and do not requirelubrication. Check for oil or grease markson the exterior of the seal and if foundverify that the seal has not been ruptured.If the seal has been ruptured then the balljoint must be replaced because it cannot bere-lubricated.

Ball Studs on Tie Rods1. Review lubricant specification and

interval requirements before servicing.

2. Apply lubricant to grease fitting untilnew lubricant discharges from the dustboot (Figure 4).

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Carrier Bearing andKingpin

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Figure 4 – Location of lubrication fittings. Note: Left side only shown.

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Wheel Bearings1. Review lubricant specification and

interval requirements before servicing.

2. Check oil level through hub capwindow while at ride height. If level isbelow the “add” level line then removethe pipe plug and fill withrecommended oil until “full” level isachieved. (Figure 5). Add oil slowlysince the heavy weight oil will settleslowly in the hub. (Note: The hub capwindow can only be cleaned with mildsoap and water. Aromatic solventsshould not be used, as they will impairthe transparency of the window.)

3. Check the hub cap for external oilmarks. The vent plug will normallyweep a small amount of oil. Oil marksin other locations should be addressedby replacing the hub cap seal, windowgasket, or tightening the pipe fill plug.

CAUTIONDo not remove or twist the red plug onthe front of the hub cap. This willdamage the hub cap, and cause oil toleak. Add oil only thru the pipe plug orwarranty will be void.

Figure 5 – Wheel Bearing Oil Level

Troubleshooting

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TroubleshootingSYMPTOMS POSSIBLE CAUSES REMEDIES

Tires wear out quickly or haveuneven tire tread wearNote: Wear pattern will indicate

possible cause(s). Consulttire manufacturer forguidance.

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

Vehicle is difficult to steer

Note: Engine must be running forpower steering to be activeand able to providesteering assist.

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


Steering arms binding Check steering arm bearings and lubricateas needed

Steering arm ball joints binding Inspect ball joints for wear and replace asrequired

Tie rod ends binding Inspect tie rod ends for wear and lubricate asneeded

Kingpin binding Inspect, lubricate, and repair as required

Steering column linkage binding Align or adjust as required

Steering miter box binding Check steering miter box and repair orreplace as required

Steering gear valve binding Inspect, repair or replace as required.

Steering wheel to column interference Align or adjust as required

Power steering pump fluid level lowand/or possible leak in system

Add fluid, tighten connections and correct asneeded

Power steering pump pressure and flowbelow specification

Conduct pump flow and relief pressure testsand adjust, repair or replace as needed

Air in power steering system Add fluid, tighten connections and bleedsystem

Contaminated or incorrect fluid Replace with correctly specified fluid

Obstruction with steering gear pitman armor within hydraulic lines

Inspect, remove obstruction(s) and repair orreplace as required

Obstruction within wheelhouse Inspect, remove obstruction(s) as required

Excessive internal steering gear leakage Inspect, repair or replace as required

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SYMPTOMS POSSIBLE CAUSES REMEDIES

Vehicle wanders side-to-side…loose steering

Steering wheel has largeamplitude, rotationaloscillations when hitting largebumps

Vehicle overloaded or unevenly loadeddriver side to passenger side

Check wheel loads and correct as needed

Improper (mismatched) tires and wheels Install correct tire and wheel combinationTires have incorrect pressure Put correct air pressure in tires based on

wheel loadIncorrect toe-in setting Adjust toe-in to specified settingIncorrect wheel caster setting Adjust wheel caster to specified settingTie rod end connection loose or ball studworn

Inspect ball stud connections and wear

Steering arm mounts loose Check and tighten to specificationSteering arm ball joints binding or worn Inspect ball joints for wear or contamination

and replace as requiredKingpin worn Check and replace as requiredWheel bearings out of adjustment Check wheel bearing end play and adjust as

requiredLoose steering gear mounting Check mounting and secure as neededLoose pitman arm Check pitman arm and tighten as requiredSteering miter box binding Check steering miter box and repair or

replace as requiredSteering column linkage worn Check for wear and repair or replace as

neededSteering gear adjustment Check and adjust to specificationSteering column mis-aligned Realign steering column as requiredWorn knuckle carrier bearings Check, adjust, or replace as neededLoose knuckle carrier mounting bolts Check and tighten as neededLoose wheel nuts Check and tighten to specification

Vehicle pulls to one sidewithout the brakes applied

Vehicle overloaded or unevenly loadeddriver side to passenger side

Check wheel loads and correct as needed

Improper (mismatched) tires and wheels Install correct tire and wheel combinationTires have incorrect pressure Put correct air pressure in tires based on

wheel loadUnequal ride height side to side Inspect ride height and adjust to specified

settingImproper brake adjustment Inspect and adjust as requiredIncorrect rear axle alignment Align rear axle to specified thrust angle.Incorrect caster and/or camber setting Check and adjust as requiredWheel bearings out of adjustment Check wheel bearing end play and adjust as

requiredLoose steering gear mounting Check mounting and secure as neededTie rod end connection loose or ball studworn

Inspect ball stud connections and wear

Bent spindle or steering arm Inspect and replace as requiredFrame or underbody out of alignment Inspect and correct as requiredIncorrect toe-in setting Adjust toe-in to specified settingMis-aligned belts in radial tires Check and replace as neededSteering gear valve binding Inspect, repair or replace as requiredSteering gear not centered Inspect and adjust as requiredExcessive internal steering gear leakage Inspect, repair or replace as requiredExcessive water puddling on road Avoid water puddles on road

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Vehicle pulls to one sidewith the brakes applied

Grease, oil or dirt on brake linings Replace brake linings as required

Brake linings are glazed Deglaze brake linings by burnishing orreplace 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

Uneven brake adjustment side to side Adjust as required

Different brake air chamber size or slackadjuster length side to side

Replace with same size brake air chambersand length slack adjusters

Brake chambers air pressure uneven sideto side

Check side-to-side air pressure and correctas needed

Rear axle brakes mis-adjusted orcontaminated

Check, adjust, or replace as required

ABS system malfunction Check ABS system for proper function

Air leak or obstruction in air brake lines Check fittings with soapy water solution andremove obstructions

Brake air chamber air leak or diaphragmdamaged

Check chamber for air leak and damageddiaphragm

Excessive water puddling on road Avoid water puddles on road

Vehicle rolls side to sideexcessively

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

Sway bar bushings worn Check sway bar bushings and replace asneeded

Sway bar mounting brackets loose Check sway bar mounting brackets andtighten as needed

Control arm pivot bushings worn Inspect and replace as required

Internal leak in height control valve Check height control valve and replace asrequired

Front tires lock up duringhard braking or ABSmalfunction light remains lit

ABS sensor malfunction Inspect ABS sensor installation and replacesensor as required

ABS CPU or system malfunction Check and repair or replace as required

ABS sensor electrical connection faulty Check ABS sensor connection and lead wire

Tone ring on hub damaged Check for damage and replace as required

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Vehicle ride is too harshand/or suspension contactsstops excessively

Front shock absorbers worn Replace shock absorbers as needed


Vehicle overloaded Check wheel loads and correct as needed

Air spring supply lines leaking orobstructed

Check air line connections and removeobstructions

Vehicle system air pressure belowspecification

Check air pressure and correct as needed

Jounce bumper in air spring worn orbroken

Check and replace air spring as required

Vehicle ride is too softFront shock absorbers worn Replace shock absorbers as needed


Vehicle has unequal turningradius right to left


Steering gear not centered Inspect and adjust as required

Steering gear poppet valves setincorrectly

Check wheel turn angles and adjust asrequired

Tie rod clamps positioned improperly Check orientation and adjust as needed

Suspension does notmaintain ride height

Air leak Check connections with soapy water solutionand repair or replace as needed

Internal leak in height control valve Check height control valve and replace asrequired

Height control valve linkage loose Check and tighten linkage as needed

Air spring chafed or worn Check air spring and replace as needed

Brakes are noisy

Grease, oil or dirt on brake linings Replace brake linings as required

Brake linings are glazed Deglaze brake linings by burnishing orreplace 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

Refer to Bendix Disc Brakes manual Y006471 for troubleshooting of the disc brakesor contact Customer service at 1-800-247-2725.

Inspection

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Inspection

General InspectionPerform a thorough visual inspection ofthe suspension to ensure proper assemblyand to identify broken parts and loosefasteners each time the vehicle suspensionis serviced. Do the following during aninspection. Wheel Alignment - Follow the

guidelines in the Front WheelAlignment section for wheel alignmentinspection intervals. Check wheelalignment if excessive steering effort,vehicle wander, or abnormal tire wear isevident.

Fasteners - Check that all the fastenersare tightened to the proper tighteningtorque. Use a calibrated torque wrenchto check torque.

Wear and Damage - Inspect componentsof the suspension for wear and damage.Look for bent or broken components.Replace all worn or damagedcomponents.

Operation - Check that all componentsmove freely through the complete wheelturning arc.

CAUTIONReyco Granning LLC recommendsreplacing any damaged or out-of-specification components.Reconditioning or field repairs of frontsuspension components is prohibited.Some cast components are heat-treated. These components as well asother non-heat treated castings cannotbe bent, welded, heated, or repaired inany way without reducing the strengthor life of the component thus voidingthe warranty. Only genuineReycoGranning® replacementcomponents are allowed.

WARNINGNever work under a vehicle supportedby only a jack(s). Jacks can slip or fallover and cause serious personal injury.Always use safety stands. Do not placejacks or safety stands under the lowercontrol arms to support the vehicle.Lower control arms are not stationarycomponents and could move allowingthe vehicle drop causing seriouspersonal injury.

The vehicle may be supported on safetystands by the suspension sub-frame orchassis frame for inspections that requireremoval of the wheel and tires or deflationof the air springs. Always secure thevehicle by setting the parking brake andblock the drive wheels to prevent vehiclemovement before inspections.

Inspecting the ControlArm Bushings for Wear

NOTEIt is recommended that the bushings inall of the control arms be replaced atthe same time if one is found worn.

1. Check clearance between each controlarm and sub-frame bushing mount.Look for contact pattern as evidence ofbushing wear. Replace worn bushingsin both control arm housings asneeded.

2. Check for bushing bulging between thecontrol arm and sub-frame mount orpresence of small rubber particles nearsub-frame bushing mount.

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3. Check that the control arm mountingbolts are tight. Recommended torque is460-490 ft-lb for lower control armsand 950-1050 ft-lb for upper controlarms (See Torque Table). A loosejoint will result in wear between thebushing inner sleeve and sub-framemount.

Inspecting the Tie RodEnds

WARNINGDo not use a wrench or other object toapply leverage when inspecting tie rodend sockets. Applying leverage canyield incorrect results and damagecomponents. Component damage canlead to the loss of steering control.

1. With the engine on, lightly rock thesteering wheel and have an assistantobserve any looseness in the twomating tapers or any movement of thestud nut at both ends of the tie rod.(Figure 6). If looseness is found ineither place go to step 2, otherwiseskip to step 3.

2. Remove the tie rod end ball stud fromthe taper mount and visually inspectboth. If either of the mating tapersshows distortion or wear, then bothcomponents must be replaced. TorqueTie Rod castle nuts to 90-100 ft-lb(See Torque Table).

3. With the engine off and the wheelssteered straight ahead, grab the tie rodnear its end and try to move the socketin a direction parallel to the ball studaxis (Figure 6). Be sure to only applyhand pressure to the tie rod.

4. Measure the axial movement with ascale. If the movement is greater than1/8 inch (3mm) replace the tie rod endimmediately. If the socket moves butthe movement is less than 1/8 inch(3mm) then the tie rod end should bereplaced before 1/8” (3mm) movementoccurs.

5. Check dust boot for damage. Replaceas needed.

6. Check tie rod clamp orientation(Figure 6)

Figure 6 – Tie Rod

Inspecting the ABSSensor and Tone Ring1. The tires may be removed if needed to

ease inspection of tone ring and sensor.

2. Disconnect the ABS sensor lead fromthe chassis connector.

3. The ABS sensor test will require avoltmeter that can measure AC voltageon a millivolt scale.

4. Connect the voltmeter to the connectorpins of the ABS sensor lead.

5. Set the voltmeter scale to millivoltsand the voltage source to AC volts.

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6. Rotate the wheel hub by hand andrecord the voltage output from theABS sensor. A minimum output of800 millivolts is normal.

7. If the minimum voltage output is notachieved, check lead wire connectionsand repeat Step 3. Otherwise, if theminimum voltage output is notachieved after repeating Step 3 then goto Step 5.

8. Check physical gap between the sensorand tone ring (Figure 7). Themaximum allowable gap is .027 inch.If the gap is greater than .027 inch,press on the wire lead end of thesensor and push the sensor into contactwith the tone ring. Check that the ABSspring retainer and bushing are notunseated. Re-seat components asneeded.

9. Inspect the tone ring on the hub forphysical damage and properinstallation onto the hub. The tone ringshould have a maximum run out of.008 inch relative to the hub/spindlecenterline.

10. Repeat Step 3. If voltage output is lessthan 800 millivolts then replace theABS sensor (Note: Check voltageoutput of new sensor).

Figure 7 – ABS Sensor & Tone Ring Gap

Inspecting the ShockAbsorber1. Check shock absorbers for oil leakage

(light film of oil ok, misting), bentcomponents, missing or brokencomponents, excessive corrosion, orworn bushings. Replace shockabsorbers if any of the above items ispresent.

Inspecting the AirSpring and HeightControl Valve��-�� .�!��

1. Refer to Firestone’s PreventativeMaintenance Checklist for additionalair spring information.

2. Check the outside diameter of the airspring for irregular wear or heatchecking.

3. Check airlines to make sure contactdoes not exist between the airlines andthe outside diameter of the air spring.Re-secure airlines to prevent contact asneeded. Check for airline and fittingleaks with soapy water solution.

4. Check to see that there is a minimumof 1-inch clearance around thecircumference of the air spring while itis energized with air.

5. Check the air spring piston for buildupof foreign material. Remove anyforeign material that is present.

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1. Check the height control valve andlinkage for damage. Replacecomponents as needed.

2. Dump and re-inflate the airsuspension.

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3. Verify the ride height by measuringfrom wheel center to the bottom of theframe (“A”) or air spring height (“B”).If the dimensions are not within +/-.125” of (Figure 8), readjust.

4. The actuation arm of the height controlvalve should be horizontal at ride height(Figure 8). See section for adjusting tocorrect ride height.

Figure 8 – Ride Height MeasurementUnit Ride Height “A” Air Spring “B”

IFS1660S3 6.60” 9.25”IFS1800S3 6.60” 9.25”IFS2000S3 6.60” 9.25”

Table 3– Ride Height Dimensions

Inspecting the SteeringArm and Relay Rod BallJoints-��.�!��

1. Inspect the ball joint seal outer surfacefor presence of oil “wetting”. Theentire outer seal surface should be dry.Use a mechanics mirror and flashlightto inspect the entire seal. Use a bluntobject as needed to inspect betweenseal convolutes.

2. If oil “wetting” is found, then inspectthe entire wet area to confirm the sealhas a rupture(s) and oil source is frominternal grease leaking from the balljoint. If seal is ruptured, then the balljoint must be replaced.

3. Skip ball joint endplay measurement.

NOTECare must be taken to not damage balljoint seals during inspection. Seals thatare ruptured during inspection mustbe replaced. Do not apply excessiveforce to pry ball joints.

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1. Install a dial indicator with a magneticbase so that the base is fixed to thesteering arm. Place the indicator tip onthe flat area of the relay rod adjacentthe castle nut.

2. Using a C-clamp, squeeze the relayarm and the steering arm together toseat the ball joint. Do not applyexcessive clamp load.

3. Set the dial indicator on “zero”.

4. Release the clamp. Place the pry barbetween the steering arm and relayarm. Do not allow the pry bar tocontact the ball joint seal. Firmly pryupward using the steering arm as afulcrum to lift the relay arm. The pryload must not cause the relay arm torotate thus causing the relay to changeorientation.

5. Record the dial indicator reading. Areading greater than .040” will requireball joint replacement.

6. Inspect ball joint seal for damage andreplace the ball joint if damagedduring measurement process.

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Inspecting WheelBearing Endplay1. If the tire and wheel are not removed

make sure all the wheel nuts aretightened to the specified torque of450-500 ft-lb (See Torque Table).

2. Attach a dial indicator with a magneticbase to the face of the wheel, hub, orbrake rotor. The dial indicator mayalso be attached to the bottom of thebrake drum if the wheel is removed.

3. Place the tip of the dial indicator onthe center of the steering knucklespindle. Set the dial indicator on zero.(Figure 9).

Figure 9 – Wheel End Play Measurement

NOTEDo not push/pull at the top and thebottom of the tire, rotor, or hub.Pushing or pulling at the top and thebottom will not yield a truemeasurement of the endplay.

4. Measure the endplay bysimultaneously pushing/pulling oneach side of the tire, rotor, or hubwhile observing the dial indicator. Theendplay is the total travel observed. Ifthe endplay is not within .001-.005”,see the section on adjusting the wheelbearing endplay.

Inspecting the KnuckleCarrier Bearing andSeal1. Inspect the seals for damage.

2. Place the magnetic base of a dialindicator on the knuckle carrier andposition the tip of the dial on the endof the bar pin such that axialmovement can be measured.

3. Set the dial indicator to “0” (zero).

4. Place a pry bar between the controlarm and carrier and pry to measureaxial movement of the bar pin. Do notpry on seal. Measure and record thedial indicator reading.

5. If the axial endplay is more than .002inch, then replace the carrier bearings.See repair section on knuckle carrier.

Inspecting the KingpinVertical Endplay1. Turn the tire straight ahead.

2. Place the magnetic base of a dialindicator on the knuckle carrier andposition the tip of the dial on top of theking pin bearing cap such that verticalmovement can be measured.

3. Place a portable jack and a suitableblock (one with clearance for thegrease fitting) under the lower king pingrease cap area.

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4. Set the dial indicator to “0” (zero).

5. Raise the jack until the dial indicatorshows the end of vertical travel.Measure and record the dial indicatorreading. Vertical inspection clearancemust be .006-.012 inches.

6. If the steering knuckles binds or lessthan .001 inch endplay is measured,remove shims from the shim pack. Seerepair section for kingpin.

7. If the vertical endplay measurement ismore than .012 inches, then installshims. See repair section for kingpin.

Adjustments

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Adjustments

Adjusting Wheel EndPlay

1. Secure the vehicle by setting theparking brake and block the drivewheels to prevent vehicle movement.

2. Raise the vehicle until the front wheelsare off the ground. Support the raisedvehicle with safety stands.

3. Place an oil drip tub beneath the hub tocatch oil. Rotate the hub such that thehubcap drain plug is facing upwards.Remove the drain plug from thehubcap and place it in a container forre-installation.

4. Rotate the hub such that the drain holefaces downward and drain the oil fromhub cavity. Wait a few minutes formost of the oil to drain beforecontinuing to the next step.

5. Remove the hubcap bolts, hubcap, andgasket. Take care not to damage thegasket for re-installation. Place thecomponents in a location to preventcontamination. Note that solvents maydamage the hubcap window.

NOTEWhen removing or installing the innerand outer spindle nuts, use the correctwrench sockets to avoid damaging thenuts. Do not use impact driver totighten inner and outer nuts. Only usea torque wrench to tighten the nuts.

6. Remove the keeper from the nut.

7. A, B, C Use a small screwdriver tocarefully pry the keeper arm from theundercut groove on each side until thekeeper is released.

8. Seat the bearing, with the hub or huband drum only using a torque wrench.

9. Tighten the nut to 200 ft-lb Spin thewheel at least one full rotation

10. Repeat step #9 two more times

11. Back the nut off until it is loose.

12. Adjust the bearing by tightening thenut to 100 ft-lbs. Spin the wheel atleast one full rotation.


WARNINGFailure to follow this instruction couldcause the wheel to come off and causebodily injury. The PRO-TORQ®Spindle Nut is sold as an assembly withthe keeper in place. DO NOT attemptto place the nut on the spindle ortighten or loosen the nut on the spindlewhile the keeper is locked inside thenut. Doing so may deform the keeperand allow the nut to unthread duringoperation.

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14. Back the nut off one raised face mark(1/4 turn)

15. Install the keeper with the orange sidefacing out.

16. Align the flat of the keeper with themilled flat on the spindle and insert thesingle keeper tab into the undercutgroove of the nut. Install the keeperwith the orange side facing out.

17. Engage the mating teeth

18. Compress and insert the keeper arms,one at a time, into the undercut groovewith a small screwdriver.

19. Verify the end play

20. Attach a dial indicator with a magneticbase to the face of the wheel, hub, orbrake rotor. The dial indicator mayalso be attached to the bottom of thebrake rotor if the wheel is removed.

21. Place the tip of the dial indicator onthe center of the steering knucklespindle. Set the dial indicator on zero.

22. Measure the endplay bysimultaneously pushing/pulling oneach side of the tire, drum, or hubwhile observing the dial indicator. Theendplay is the total travel observed. Ifthe endplay is not within .001-.004”, areadjustment will be required.

23. Install hubcap gasket and hubcap.Tighten the cap screws to 20-30 ft-lb(See Torque Table). Replace thehubcap vent plug if removed.

24. Fill the hub cavity with the appropriateamount and type of lubricant andsecure drain plug.

25. Check oil level through the hubcapwindow (Figure 5). If level is belowthe “add” level line, then fill withrecommended oil until “full” level isachieved. Add oil slowly since theheavy weight oil will settle slowly inthe hub.

NOTE: The hubcap window can only becleaned with mild soap and water.Aromatic solvents should not beused, as they will impair thetransparency of the window.)

26. Check the hubcap for external oilleakage at the drain plug or gasket. Forleaks at the drain plug check forapplication of thread sealant to threadsand tightness. For leaks at the gasket,replace the gasket. The vent plug willnormally weep a small amount of oil.

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Adjusting SuspensionRide HeightThe height control valve (HCV) andlinkage should be checked regularly forproper clearance, operation andadjustment.

NOTEImproperly adjusted ride height willresult in incorrect wheel alignmentmeasurements and may result inabnormal tire wear. Check the rideheight prior to front suspensionalignment.

The ride height of the front suspension isthe distance from the bottom of the chassisframe rail to the center of the wheelspindle. An alternate measurement may betaken as the height of the air spring(Figure 10).

Figure 10 – Measurement at Ride HeightUnit Ride Height “A” Air Spring “B”

IFS1660S3 6.60” 9.25”IFS1800S3 6.60” 9.25”IFS2000S3 6.60” 9.25”

Table 4 – Measurement at Ride Height

Properly adjusted ride height results incorrect suspension travel and alignment.The ride height should not be adjusted toadjust chassis rake angle.

CAUTIONAdjusting the ride height can cause thefront end to raise or lowerunexpectedly due to verticalmovements at the connection of thevertical link and the horizontal arm ofthe height control valve.

1. Park the vehicle on a level surface.

2. Exhaust or “dump” and re-inflate theair suspension. Allow the Suspensionto settle.

3. Check ride height of rear suspension:

A: On vehicles with front suspensionequipped with (2) height controlvalves, check and adjust the rearsuspension first.

B: On vehicles with front suspensionequipped with a single height controlvalve, check and adjust the rearsuspension after finish adjusting thefront.

4. Measure either the wheel center tobottom of frame (“A”) or air springheight (“B”). If the dimensions are notwithin ±1/8” of measurements in Table4, adjust as follows.

A: Loosen the height control valvelinkage stud retaining nuts.

B: Raise or lower the L-shaped linkagestud as necessary.

C: Tighten the retaining nuts. Note: Itis recommended that the upper andlower studs be positioned parallel toeach other. Torque to 8-12 ft-lb.

5. After adjusting the length, it isrecommended to dump and re-inflatethe air suspension to check adjustment.Allow the suspension to settle.

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6. If not already completed, adjust therear suspension per manufacturer’srecommendations.

7. Verify at each axle that the side-to-sideride heights are within .25” of eachother.

Adjusting the MaximumWheel Turn Angle

CAUTIONDo not adjust maximum wheel turnangle greater than 55°. Mis-adjustment of the wheel turn angle cancause damage to steering systemcomponents.

The turn angle may require adjustment ifthe front tires rub against the frame,suspension, body, or the steering gear hasbeen serviced or replaced. Use analignment machine to check the wheel turnangle. See the measurement procedure ofthe alignment machine manufacturer.

The steering stop bolt on the steeringknuckle controls the maximum turn angle.If the stop bolt is missing, bent, or broken;replace the stop bolt(s) or jam nut(s) andfollow the procedure below foradjustment. Inspect other suspensioncomponents for damage.

CAUTIONIn power steering systems, thehydraulic pressure should relieve or“drop off” when the steered wheelsapproach the steering stops in eitherdirection. If the pressure does notrelieve, the components of the frontsuspension may be damaged.

If the steering stop bolts are adjusted toreduce wheel turn angle, the steering gearpoppet valves will require readjustment. Ifthe poppets are not re-adjusted properly,then the steering gear will not reducepower assist properly and steeringcomponents will be damaged. Refer toTRW’s TAS Steering Gear ServiceManual for readjusting the poppets.

Figure 11 – Steering Stop BoltUnit Steering Stop Length “A”

IFS1660S3 1.38”IFS1800S3 1.38”IFS2000S3 1.38”

Table 5 – Steering Stop Dimension

1. Drive the front tires on a suitabledevice that allows the front wheels toturn and measures the wheel turnangle.


3. Check that the steering gear is centeredand the tires are steered straight aheadwith equal toe-in side to side. If eitherof these two conditions is not met, thenadjust toe-in first before centering thesteering gear. See Adjusting the Toe-In Section and refer to Spartan chassisservice guidelines for centering thesteering gear.

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NOTEUnequal toe-in side to side or an out-of-center steering gear can result inunequal turn angles and steering pullwhile steering straight ahead. Thedrag link length may be adjusted toattain steering gear on center conditionwhile maintaining equal toe-in side toside. Do not adjust the length of thedrag link or tie rods to center thesteering wheel. This can cause thesteering gear to become off center.

4. Check that the lengths of the outer tierods are equal to each other within 1/8inch. If not, adjust lengths accordingto the adjusting the toe-in sectionbefore adjusting the steering stops.

5. Turn the steering wheel until thesteering stop bolt contacts the knucklecarrier or the steering wheel stopsturning. Measure the turn angle of thewheel on the same side as the directionof turn.

6. If the wheel turn angle differs fromchassis guidelines then adjust asfollows.

7. Loosen the jam nut on the stop bolt.

8. Turn the stop bolt until the specifiedwheel turn angle is achieved and thebolt head contacts the knuckle carrier.

9. Tighten the jam nut to 50-75 ft-lb (SeeTorque Table).

10. Repeat checking and adjustment forturning the opposite direction.

CAUTIONAfter readjusting the steering stop(s)check that the steering poppets arereset properly and that the front tiresdo not contact the frame, suspension,or body. Also check that othercomponents are not abnormallycontacting one another.

Inspection BeforeAlignmentSee the General Inspection section andcheck the following before conductingfront wheel alignment measurements.

1��!��'��!

1. Check that the front tires are inflated tothe appropriate pressure based on thetire loading.

2. Check that the front tires are the samesize and type.

3. Check that all the wheel nuts aretightened to the specified torque of450-500 ft-lb (See Torque Table).

4. Check that the wheel and tireassemblies are balanced.

2��-�!��!��

1. Check that all fasteners are tightenedto the specified torque.

2. Check the suspension ride height andadjust as needed to the specifiedheight.

3. Check for worn ball joints, tie rodends, steering arm bearings, controlarm bushings, knuckle carrierbearings, and damaged suspensioncomponents. Replace worncomponents as needed.

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4. Check for loose ball joint and tie rodend tapered connections, tie rod endjam nuts, steering arm mounts, andchassis steering system components.Inspect connections for wear andreplace as needed. Tighten connectionsas needed.

5. Check the wheel bearing adjustmentand adjust as needed.

6. Inspect the shock absorbers for wearand damage.

3��4��-�!��!��

Front tire wear and incorrect steering canbe caused by the rear axle and/orsuspension.

1. Check that all fasteners are tightenedto the specified torque.

2. Check the suspension ride height andadjust as needed to specified height.

3. Check that all connection jointsbetween the suspension and axle aresecure.

4. Check for worn suspension bushingsor damaged suspension components.

5. Check that the rear axle is correctlyaligned.

6. Check that the frame is not bent.

7. Refer to any additionalrecommendations and specificationsfrom the manufacturer of the chassison rear axles and suspensions.

NOTETotal vehicle alignment isrecommended when aligning the frontsuspension.

Front Wheel Alignment(5��$��

Reyco Granning LLC recommends thatsuitable alignment equipment be used tomeasure the wheel alignmentcharacteristics: camber, caster, and toe-in.The alignment equipment must beproperly calibrated for accuratemeasurements. Only qualified personnelshould conduct the wheel alignmentmeasurements.

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The overall toe-in of the front wheelsshould be checked every 24,000 miles or 2years. When the vehicle does not steercorrectly or the front tires develop anabnormal tire wear pattern, the camber,caster, and toe-in should be measured andadjusted as needed. Toe-in typically hasthe largest effect on tire wear.

The maximum wheel turn angle should bechecked and adjusted as needed.

Eccentric adapters are installed in thelower control arm mounts. The purpose ofthe adapters is to provide additionaladjustment of camber and caster tominimize vehicle drifts or pulls to one sideof the road.

The lower bar pin of the knuckle carrierbearing marked with a “B” may also beused to provide additional camberadjustment.

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1. Follow the alignment equipmentmanufacturer’s procedures forpreparing the vehicle for front and rearwheel alignment measurements.


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3. Check that the steering gear is centeredwhen the tires are steered straightahead (i.e. equal toe-in side to side).Center the steering gear according toSpartan’s guidelines.

NOTEAn out-of-center steering gear canresult in unequal wheel turn angles.The steering gear should remaincentered during toe-in adjustment. Donot adjust the length of the drag linkor tie rods to center the steering wheel.This can cause the steering gear tobecome off center.

4. Measure and record the individualwheel camber, caster, and toe-in of thefront suspension. Also measure andrecord the cross camber cross caster,and overall toe-in.

5. If adjustment to camber and caster isrequired then follow the steps below.Otherwise, go to the “Adjusting theToe-In” section to adjust the toe-in asneeded.


6. Raise the vehicle until the front wheelsare off the ground. Support the raisedvehicle with safety stands.

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Adjusting the CamberAngle

PositiveCamber

NegativeCamber

Figure 12 – Camber Angle

CAUTIONDo not alter components to adjust thecamber.

Camber is the angle of the wheel withrespect to the ground as viewed from thefront or rear of the vehicle (Figure 12).Camber is positive when the distancebetween centers of the front wheels at the

top is greater than the distance at theground.The wheel camber angle is affected by the

ride height of the suspension. If the rideheight is set too high, then the cambermeasurement will be more positive. Seethe inspecting and adjusting suspensionride height sections before measuringcamber. The table below lists therecommended camber angles.

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The setscrew in the eccentric adapterdenotes the orientation of the eccentricityof the adapter. When the setscrew is in the12 o’clock position, then the adapter is inthe “neutral” position. There are twoadapters at each lower control arm mountand they must be oriented the same.

FORWARD

Neutral Position

Positive Camber

Negative Camber Negative Camber

Positive Camber

Neutral Position

Figure 13 – Eccentric Camber Adjustment

Nominal Camber Values-DegreesUnloaded Loaded

Left +1/4°(±1/4°) +1/4°(±1/4°)Right +1/4°(±1/4°) +1/4°(±1/4°)

Adjustments

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When the setscrews in both lower controlarm mounts are oriented closer to thesuspension centerline, the tire camberbecomes more negative. When thesetscrews in both control arm mounts areoriented farther from the suspensioncenterline, the tire camber becomes morepositive (Figure 13). The eccentricadapters at both lower control arm mountsmust be oriented the same to affect onlycamber.1. Loosen both lower control arm

mounting bolts at the eccentricadapters. Do not remove the boltsbecause the adapters must remainengaged in control arm mounting platefor adjustment.

2. Rotate each eccentric adapter to thesame orientation as needed based onmeasured wheel camber. The eccentricadapters at each control arm mountmust have the same orientation.

3. Tighten the adapter locknuts to 460-490 ft-lb (See Torque Table).

4. Remove the jack stands and lowervehicle completely. Check that thesuspension is at the proper ride height.

5. Re-measure the camber and readjust asneeded.

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The lower bar pin of the knuckle carrierbearing marked with a “B” on the end isconfigured such that it can be re-orientedto provide camber adjustment. Lower barpins are factory installed with the “B”located closest to the lower control arm.The wheel camber becomes more positivewhen the lower bar pin is re-oriented suchthat the “B” is located farthest from thelower control arm.1. Place a portable jack under the tire to

secure and support it.

CAUTIONDo not remove both upper and lowerknuckle carrier mounting bolts at thesame time. The knuckle carrier mustbe secured and supported properly ifboth upper and lower mounting boltsare removed.

NOTELower control arm may movedownward due to the internal gascharge in the shock absorber. Aportable jack may be needed to alignthe lower control arm with the knucklecarrier bar pin.

2. Remove the bottom knuckle carriermounting bolts from the lower controlarm. Heat may need to be applied tothe control arm to loosen the threadadhesive. The control arm temperaturemust not exceed 300°F. Do not applyheat directly to the bar pin or mountingbolts.

3. Raise the jack to separate the bar pinfrom the control arm and re-orient it.

4. Lower the jack to align the bar pinwith the control arm. Apply Loctite#242 to mounting bolt threads andtighten to 450-500 ft-lb (See TorqueTable).

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Adjusting the CasterAngle

PositiveCaster

NegativeCaster

Figure 14 – Caster Angle

CAUTIONDo not adjust the suspension rideheight or alter components to adjustthe caster.

The caster angle is the angle between avertical axis and the axis defined by theking pin when viewed from the side of thevehicle. When the king pin axis appearsrotated clockwise relative to the verticalaxis, then the caster is positive. Positivecaster creates a self-aligning moment tostabilize the vehicle when driving straightahead (Figure 14).

The caster angle is indirectly measuredfrom the change in wheel camber as thewheel is turned through a prescribed turnangle. Therefore, the calculated caster isaffected by the ride height of thesuspension. See the inspecting andadjusting suspension ride height sectionsbefore measuring caster. The table belowlists the recommended caster angles.

FORWARD

FrontEccentrics

RearEccentrics

PositiveCaster

NegativeCaster

LowerControl Arm

Figure 15 – Lower control arm movement

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The setscrew in the eccentric adapterdenotes the orientation of the eccentricityof the adapter. When the setscrew is in the12 o’clock position, then the adapter is inthe “neutral” position. There are twoadapters at each lower control arm mountand they must be oriented the same.

When the setscrews in the forward lowercontrol arm mount are oriented closer tothe frame rail and the setscrews in therearward lower control arm mount areoriented farther from the frame rail, thecaster becomes more negative (Figure16).

When the setscrews in the forward lowercontrol arm mount are oriented fartherfrom the frame rail and the setscrews inthe rearward control arm mount areoriented closer to the frame rail, the casterbecomes more positive.

The eccentric adapters at both lowercontrol arm mounts must be orientedopposite each other to affect caster.

Nominal Caster Values-DegreesUnloaded Loaded

Left +3°(±1/2°) +3°(±1/2°)Right +3°(±1/2°) +3°(±1/2°)

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FORWARD

A

A

B

B

Neutral Position

Positive Caster

Negative Caster Negative Caster

Positive Caster

Neutral Position

LH Rear Eccentric ViewScale 1:2

VIEW B-BLH Front Eccentric View

VIEW A-A

Scale 1:2

Figure 16 – Eccentric Caster Adjustment

1. Loosen both lower control armmounting bolts at the eccentricadapters. Do not remove the boltsbecause the adapters must remainengaged in control arm mounting platefor adjustment.

2. Rotate the eccentric adapters at theforward and rearward control armmounts opposite one another as neededbased on measured wheel caster. Theeccentric adapters at each control armmount must have the same orientation.

3. Tighten the adapter locknuts to 460-490 ft-lb (See Torque Table).

4. Remove the jack stands and lowervehicle completely. Check that thesuspension is at the proper ride height.

5. Re-measure caster and readjust asneeded.

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Adjusting the Toe-In

CAUTIONDo not alter components to adjust thetoe-in.

CAUTIONImproperly oriented tie rod clampscan cause binding in the suspensionsteering system.

Wheel toe-in is the relationship of thedistance between the centers of the frontand rear of the front wheels. When thefront distance is less than the rear distance,the wheels are “toed-in”. Toe-in isdesigned into the suspension to counteractthe tendency of the tires to toe-out whenthe vehicle is driven straight ahead.Incorrect toe-in can result in rapid tirewear.

1. Measure the length of the outer tierods. Reference length is 17.00 inchesfor IFS1660S3 and 16.76 inches forIFS1800/2000S3.

2. If the lengths of the outer tie rods arenot within 1/8 inch of each other, thenadjust their lengths such that they arewithin 1/8 inch of each other. Loosenthe tie rod clamps on each end of thetie rod and turn the center tube tochange the length.

3. Adjust the length of both outer tie rodsequally such that the toe-in on eachside is 1/16” ± 1/32” and the overalltoe-in is 1/8” ± 1/16”. Tighten tie rodclamp nuts to 50-60 ft-lb (See TorqueTable). Refer to Figure 17 for tie rodclamp position.

Figure 17 – Tie Rod Clamp Position

Repairs

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Repair

General ProceduresRepair or reconditioning of frontsuspension components is not allowed.Components that are damaged or wornmust be replaced. Several majorcomponents are heat treated and tempered.

WARNINGThe components cannot be bent,welded, heated altered, or repaired inany way without reducing the strengthor life of the component and voidingthe warranty.

The following operations are prohibited onfront suspension components.

1. Welding of or to the steering knuckles,control arms, steering arms, knucklecarrier, tie rod assemblies, the brakes,the hubs, and the brake drums.

2. Hot or cold bending of the steeringknuckles, control arms, steering arms,knuckle carrier, tie rod assemblies, balljoints, and the sub-frame exceptcontrol arm and steering arm mountswhich may be cold bent to facilitatebushing and bearing replacement.

3. Drilling out control arm and steeringarm mounting holes and ball studtapered holes.

4. Spray welding of bearing diameters onthe steering knuckle spindle, steeringarm bores and pivot tube. Spraywelding of ball studs or tapered holesfor the ball joint and tie rod ends.

5. Milling or machining of anycomponent except that control armbushing bores may be honed to removeany burrs.


The vehicle may be supported on safetystands by the suspension sub-frame orchassis frame for repairs that requireremoval of the wheel and tires or deflationof the air springs. Always secure thevehicle by setting the parking brake andblock the drive wheels to prevent vehiclemovement before performing repairs.

Cleaning the Parts

WARNINGIf you use cleaning solvents, hotsolution tanks or alkaline solutionsincorrectly, serious personal injury canoccur. To prevent injury, follow theinstructions supplied by themanufacturer. Do NOT use gasoline toclean parts. Gasoline can explode.

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Use a cleaning solvent to clean ground orpolished parts and surfaces. DO NOTclean ground or polished parts with hotsolution tank or with water, steam oralkaline solutions. These solutions willcause corrosion of the parts.

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Rough parts can be cleaned with theground and polished parts. Rough partsalso can be cleaned in hot solution tankswith a weak alkaline solution. Parts shouldremain in the hot solution tanks until theyare completely cleaned.

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Parts must be dried immediately aftercleaning. Dry parts with clean paper orrags, or compressed air. Do not drybearings by spinning with compressed air.

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Apply light oil to cleaned and dried partsthat are not damaged and are to beimmediately assembled. Do NOT apply oilto the brake linings or the brake drums. Ifthe parts are to be stored, apply a goodcorrosion preventative to all surfaces andplace them inside special paper orcontainers that prevent corrosion. Do NOTapply corrosion preventative to the brakelinings or the brake drums/rotors.

Replacing Tie Rod Ends3�$�0��

1. Remove the cotter pins from the tie rodend ball stud(s).

2. Remove the castle nuts from the tie rodend ball stud(s).

CAUTIONDo not strike the component matingtaper directly with a steel hammer.Parts can break and cause seriouspersonal injury. Wear eye protection.

3. Disconnect the tie rod end ball studfrom the mating component taperedhole using a suitable tool.

4. Inspect the tie rod end ball stud andmating component tapered hole(s).Replace components with worntapered hole(s). If the grease seal isdamaged during removal, replace itbefore installation.

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1. Clean the mating component taperedhole(s) of any contamination. Insert thetie rod end ball stud into the tapered holeand secure it with the castle nut.

CAUTIONTighten the castle nuts to the specifiedtorque. If the castle nuts are nottightened to the specified torque, theparts will be damaged and seriouspersonal injury may occur.

2. Tighten the castle nut to 90-100 ft-lb(See Torque Table).

3. Install the cotter pins. If necessary,tighten the castle nut to align the hole inthe ball stud and slots in the castle nut.Do not loosen the castle nut to install thecotter pin.

4. Lubricate tie rod end as needed.

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Replacing the SteeringArm Ball JointsThe thread-in mount type ball joints areinstalled with a thread adhesive and mayrequire the threads to be warmed to easeremoval. If heat is applied to the ball jointthreads, the steering arm temperature mustnot exceed 300°F and the heat should beapplied at the bottom of the ball joint baseonly. Applying heat to the ball joint willdamage the ball joint by destroying itsinternal components as well as the externalseal permanently, degrading the lubricant,and restricting ball stud movement.

It is recommended that the appropriatetools be used to remove the ball stud taperfrom the relay rod and to remove the balljoint base from the steering arm.

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1. Remove the cotter pins from the balljoint ball stud(s).

2. Remove the castle nuts from the balljoint ball stud(s).

CAUTIONDo not strike the component matingtaper directly with a steel hammer.Parts can break and cause seriouspersonal injury. Wear eye protection.

3. Disconnect the ball joint ball stud fromthe steering arm tapered hole using asuitable tool.

4. Secure the steering arm and removethe ball joint using a ball joint spannerwrench or similar device on the base.Steering arm may be removed tofacilitate ball joint removal. See thesteering arm replacement section asneeded.

5. Inspect the ball joint stud and relay rodtapered hole(s). Replace relay rod iftapered hole(s) is worn.

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1. Clean the threaded hole in steering armof any contamination.

2. Apply thread adhesive Loctite #242 tothe ball joint base threads and thread itinto the steering arm by hand.

3. Tighten the base of the ball joint to325-375 ft-lb (See Torque Table).

4. Clean the relay rod tapered hole(s) ofany contamination. Insert the ball jointstud into the tapered hole and secure itwith the castle nut.

CAUTIONTighten the castle nuts to the specifiedtorque. If the castle nuts are nottightened to the specified torque, theparts will be damaged and seriouspersonal injury may occur.

5. Tighten the castle nut to 155-170 ft-lb(See Torque Table).

6. Install the cotter pins. If necessary,tighten the castle nut to align the holein the ball stud and slots in the castlenut. Do not loosen the castle nut toinstall the cotter pin.

Replacing the Idler ArmBearings (IFS1660S3)Replace the idler arm bearings in sets. Thereplacement bearings should be installedby pressing on the outer raceway only.Pressing on the inner raceway will damagethe bearing.

The inner grease cavity of the steeringarms should be cleaned when the bearingsare replaced.

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1. Follow the procedures for removal of therelay rod from the ball joint in the idlersteering arm.

2. Remove the pivot bolt that mounts thesteering arm and remove the steeringarm from the sub-frame.

3. Remove the retaining rings from thepivot sleeve and remove the sleeve. Arubber or brass hammer may be used toremove the sleeve. Retain shims.

4. Support the steering arm bearinghousing and press the bearing out ofeach end of the steering arm.

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1. Inspect steering arm bearing housingbores and remove burrs by honing.Replace steering arm if the bore isdamaged.

2. Inspect the pivot sleeve and removeburrs with emery cloth.

3. Install one retaining ring onto pivotsleeve.

4. Insert the pivot sleeve into the lowerbearing. Use a rubber mallet or similartool to drive the inner sleeve into thebearings such that the bottom-retainingring is seated against the bottom innerrace. Do not use a steel hammer toinstall the sleeve because bearingraceways can be damaged.

5. Install upper retaining ring. Reseat lowerretaining ring against the lower innerrace as needed.

6. Determine the number of shims neededby stacking the shims and placing thestack between the upper retaining ringand inner race until a snug fit isachieved. Remove one shim from thestack and this is the number of shimsneeded. A maximum of six shims maybe used.

7. Remove the upper retaining ring, installthe shims determined in step 9 onto theinner sleeve at upper inner race, and re-install the upper retaining ring. Checkthat upper retaining ring is properlyseated in the groove of the inner sleeve.

8. Place the steering arm in its mount andinstall the pivot bolt. Tighten the pivotbolt lock nut to 575-625 ft-lb (SeeTorque Table).

9. Follow the procedures for installation ofthe relay rod or tie rod.

Replacing the Upperand Lower Control ArmBushingsThe sub-frame control arm mounts mayrequire widening to accommodatereplacement bushings. A suitable jack maybe used to increase the width of the controlarm mounts by cold bending. Care must betaken to not exceed 5.00” width afterwidening. The control arm mounts shouldbe inspected for damage.

Both control arm bushings and mountinghardware except eccentric adapters mustbe replaced in a control arm whenbushings are serviced. It is recommendedto replace the control arm bushings andmounting fasteners in all of the controlarms at the same time.

The control arm housings must beproperly supported during bushingremoval. The bores of the control armhousings may be honed to remove anyburrs.

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CAUTIONUse of a cutting torch to removecontrol arm bolts will permanentlydamage control arm bushings and canresult in damage to sub-frame.

It is recommended that the wheel and tirebe removed to provide properaccessibility. Disconnect the verticalheight control valve linkage from thehorizontal arm to prevent unintentionalinflation of the air spring.

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1. Place a portable jack under the knucklecarrier to secure and support it.

CAUTIONDo not remove both upper and lowerknuckle carrier mounting bolts at thesame time unless the knuckle carrier isproperly secured.

2. Remove knuckle carrier mountingbolts from the control arm. Heat mayneed to be applied to the control arm toloosen the thread adhesive. The controlarm temperature must not exceed300°F. Do not apply heat directly tothe bar pin or mounting bolts.

3. Disconnect sway bar connector atsway bar if so equipped with a swaybar.

4. Loosen and remove control armmounting locknuts.

5. Support control arm and removecontrol arm mounting bolts. Removethe control arm.

6. Remove the sway bar bracket andlinkage from the control arm and retainfor installation.

7. Press the bushings out of the housings.Support the housing properly.

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1. Inspect the housing bores and removeany burrs in the housing bores byhoning.

2. Press the bushings into the housingsusing a suitable tool to apply pressureto only the outer metal of the bushing.Support the housing properly.

3. Re-install the sway bar bracket andlinkage if removed.

4. Place the control arm in its mountlocation. Install the control armmounting hardware and tighten snugly.

5. Orient the control arm at suspensionride height and tighten the bolts to950-1050 ft-lb (See Torque Table).

6. Reconnect the sway bar linkage.Tighten mounting bolt to 75-85 ft-lb(See Torque Table).

7. Apply Loctite #242 to carriermounting bolt threads and tighten to450-500 ft-lb (See Torque Table).

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1. Place a portable jack under the knucklecarrier to secure and support it.

CAUTIONDo not remove both upper and lowerknuckle carrier mounting bolts at thesame time unless the knuckle carrier isproperly secured.

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2. Remove knuckle carrier mountingbolts from the control arm. Heat mayneed to be applied to the control arm toloosen the thread adhesive. The controlarm temperature must not exceed300°F. Do not apply heat directly tothe bar pin or mounting bolts.

3. Note orientation of lower bar pin incarrier bearing. Raise the jack asneeded to separate the bar pin from thecontrol arm.

4. Remove and retain the lower mountinghardware. Shock will extend due tointernal gas charge. Rotate bar pin toprovide clearance with mountingbracket.

5. Note orientation of eccentric adaptersfor installation.

6. Loosen and remove control armmounting locknuts.

7. Support control arm and removecontrol arm mounting bolts. Retaineccentric adapters for installation.Remove the control arm.

8. Remove spacer tubes from bushings andretain for installation.

9. Press the bushings out of the housings.Support the housing properly.

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1. Inspect the housing bores and remove anyburrs in the housing bores by honing.

2. Press the bushings into the housingsusing a suitable tool to apply pressure toonly the outer metal of the bushing.Support the housing properly.

3. Install the spacer tubes in bushings.

4. Place the control arm in its mountlocation. Install the control arm eccentricadapters and mounting hardware andtighten snugly. Orient the eccentricadapters the same as before removal.

5. Orient the control arm at suspension rideheight and tighten the bolts to 460-490 ft-lb (See Torque Table).

6. Note orientation of bar pin in carrierbearing. Lower the jack to align the barpin with the control arm.

7. Apply Loctite #242 to mounting boltthreads and tighten to 350-375 ft-lb (SeeTorque Table).

8. Compress shock absorber and connect thelower shock mount to the lower shockbracket using the mounting hardware.Tighten the nuts to 170-190 ft-lb (SeeTorque Table).

Replacing WheelBearings, Oil Seals, andHub CapsIf the wheel nuts have chrome covers,remove them with special pliers equippedwith plastic non-marring jaws. Place themin a container to prevent damage or loss.

On aluminum wheels, place a plastic anti-scuff guard over the wheel nuts and loosenthe wheel nuts. On steel wheels, removethe wheel hubcap nuts if present and thewheel hubcap before loosening the wheelnuts. Place the wheel hubcap in safelocation to prevent damage. Place thewheel and/or wheel hubcap nuts in acontainer to prevent contamination or loss.

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Remove the wheel and tire assembly andplace it aside. Mark the tire to ensure itcan be identified for installation on sameside as removed. Remove the brake caliperassembly and place it aside. Mark thecaliper assembly to ensure it can beidentified for installation on same side asremoved.

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1. Place an oil drip tub beneath the hub tocatch oil. Rotate the hub such that thehubcap drain plug is facing upwards.Remove the drain plug from thehubcap and place it in a container forre-installation.

2. Rotate the hub such that the drain holefaces downward and drain the oil fromhub cavity. Wait a few minutes formost of the oil to drain beforecontinuing to the next step.

3. Remove the hubcap bolts, hubcap, andgasket. Take care not to damage thegasket for re-installation. Place thecomponents in a location to preventcontamination. Note that the hub capwindow may be damaged by solvents.

NOTEWhen removing or installing the outerspindle nut, use the correct wrenchsockets to avoid damaging the nuts. Donot use impact driver to tighten outernut. Only use a torque wrench totighten the nuts.



6. Remove the retaining nut

7. Tug sharply on the hub to unseat theouter bearing without completelyremoving the hub. Wipe up any oilspilled on the brake assembly asquickly and completely as possible.Remove the outer bearing and place itin a container to preventcontamination.

8. Remove the hub from the spindle andplace it on the floor with its stud sidefacing downwards. Protect the wheelstuds from damage. Wipe the excessoil off spindle with a clean shop towelto prevent oil dripping onto the brakeassembly. If oil saturates orsignificantly contaminates the brakelining then replace the lining.

9. Remove the hub seal and discard it.Remove the wear ring from the spindleand discard it.

10. Inspect the inner cup (outer bearingrace for the inner bearing) and outercup in the hub for damage. Replace thebearing cups if worn or damaged.

11. Inspect the bearing areas on thespindle for wear or damage. Burrs maybe removed by light application ofemery cloth. Replace steering knuckleif the spindle is damaged.

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1. Inspect to be sure spindle shoulder isclean. If pitted apply sealant, Place thehub seal assembly with axle ring ontothe spindle so the words “Oil BearingSide” face outboard. Do not place theseal in the hub bore.

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2. Drive the seal onto the spindle usingthe appropriate seal installation tooland a 3-5lb hammer. (ReferenceStemco P/N 0155220) The wear ring isfully seated when it is square and flushwith the face of the inner bearingshoulder of the spindle. Reseat the sealonto the wear ring if it becomesdislodged after seating.

NOTEt drive bearings onto the spindle with asteel hammer or similar instrument.Bearing inner race is a tight slip fitwith spindle.

3. Pre-lube the inner bearing and place itonto spindle with small end of taperfacing outward. Seat the inner raceagainst the shoulder of the spindle.

4. Press the ABS sensor outward about ¼”.Do not use a sharp tool on lead wire endof the sensor. See section for theinspection of ABS sensor as needed.

5. Clean and Inspect seal bore in hub, Placethe hub onto the spindle until it seats onthe inner bearing. Do not “ram” the hubonto the seal.

6. Pre-lubed outer bearing and place it ontothe spindle until it seats on the outer cupin the hub. The bearing retaining washermay be used to guide the bearing ontothe spindle. The hub should be supportedto prevent misalignment and binding.



9. Seat the bearing, with the hub or huband drum only using a torque wrench.

10. Tighten the nut to 200 ft-lb. Spin thewheel at least one full rotation


12. Back the nut off until it is loose.

13. Adjust the bearing by tightening the nutto 100 ft-lb. Spin the wheel at least onefull rotation.


15. Back the nut off one raised face mark(1/4 turn)

16. Install the keeper with the orange sidefacing out.

17. Align the flat of the keeper with themilled flat on the spindle and insert thesingle keeper tab into the undercutgroove of the nut. Install the keeperwith the orange side facing out.

18. Engage the mating teeth

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19. Compress and insert the keeper arms,one at a time, into the undercut groovewith a small screwdriver.

20. Refer to the Wheel Bearing EndplayAdjustment section to measure andadjust the endplay to .001-.004 inch.Adjust by loosening spindle nut, re-indexing the spindle nut accordingly,and repeat Steps 8 thru 19 until properendplay is achieved.

21. Install hubcap gasket and hubcap.Tighten the cap screws to 20-30 ft-lb(See Torque Table). Replace thehubcap vent plug if removed.

22. Fill the hub cavity with the appropriateamount and type of lubricant and securedrain plug.

23. Check oil level through the hubcapwindow at ride height. (Figure 18). Iflevel is below the “add” level line, thenfill with recommended oil until “full”level is achieved. Add oil slowly sincethe heavy weight oil will settle slowlyin the hub.

NOTE: The hubcap window can only becleaned with mild soap and water.Aromatic solvents should not beused, as they will impair thetransparency of the window.

Figure 18 – Wheel Bearing Oil Level

24. Check the hub cap for external oilleakage at the drain plug or gasket. Forleaks at the drain plug check forapplication of thread sealant to threadsand tightness. For leaks at the gasket,replace the gasket. The vent plug willnormally weep a small amount of oil.

25. Install the caliper.

26. Install the wheel and tire assembly andthe wheel nuts.

27. On aluminum wheels, use a plastic anti-scuff guard over the wheel nuts.Tighten the wheel nuts to 450-500 ft-lb(See Torque Table for sequence).

28. Replace the wheel hubcap nuts andhubcaps if removed to service the wheelbearings.

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Replacing BrakeComponents8��"��3��!

The brake rotors should be replaced if theyare damaged or exceed the rotormanufacturers recommended minimumthickness specification. Refer tomanufacturer brake drum guidelines forinspection and specifications.

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The brake air chambers should be replacedif damaged or malfunctioning. Refer tomanufacturer guidelines for correctfunction of the brake air chambers.

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The brake shoe linings should be replacedwhen they are worn beyond themanufacturer’s limits. When the brakelinings are serviced, other componentsshould also be serviced. Refer to the brakemanufacturers guidelines for servicing thebrakes.

Replacing the ABSSensor and Tone RingThe anti-lock brake system (ABS) of thevehicle should be diagnosed by a qualifiedtechnician before the anti-lock brakesensors or the tone rings are replaced.Replacement parts must be equivalent tothe vehicle manufacturers to ensure properfunction of the anti-lock brake system. Theanti-lock brake sensor and tone ringcannot be repaired and must be replaced ifdamaged or malfunctioning.

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1. Press sensor out of steering knuckle.Do not pull sensor out by its lead wire.

2. Remove tie straps that secure thesensor lead wire and disconnect thesensor lead wire from the chassis wireharness.

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1. Check that the sensor bushing isproperly seated in the steering knuckleand the sensor spring retainer is seatedproperly in the sensor bushing.

2. Press the sensor into the steeringknuckle until the sensor end contactsthe tone ring.

3. Connect a volt meter to the connectorpins of the sensor lead wire. Set thevolt meter to read AC voltage on ascale of 1-10V.

4. Spin the hub by hand and read thevoltage output of the sensor. Aminimum reading of 0.8V AC isnormal. Skip to step 8 if minimumreading is obtained.

5. If the minimum reading is not obtainedthen check the volt meter connectionand proximity of the sensor and tonering. The air gap between the sensorand tone ring should not exceed .027”.Repeat step 4.

6. If the minimum reading is notobtained, check the tone ring fordamage and its installation. The tonering should have a maximum run outof .008”. Replace as needed and repeatstep 4.

7. If the minimum reading is still notobtained, then replace the sensor andrepeat the installation procedure.

8. Route and secure the sensor lead wirethe same as the removed sensor.

9. Connect the sensor lead wire to thechassis. Secure wire lead to preventdamage during suspension movement.

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Follow the hub manufacturer’s guidelinesfor removal and installation of the tonering.

Replacing the ShockAbsorber

CAUTIONThe shock absorber is gas pressurizedand must not be punctured or besubjected to excessive heat which canresult in serious personal injury. Theshock will expand to its full extendedlength if not restrained.

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1. Remove the thru lower bolt and retainfor installation. Do not remove lowershock mount bracket from lowercontrol arm.

2. Remove upper thru bolt and retain forinstallation.

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1. Position shock in suspension such thatthe thru bolt is connected to the lowershock mounting bracket tabs.

2. Attach upper shock bushing tosuspension sub-frame with mountinghardware. Do not tighten.

3. Tighten lower thru mounting bolt andnut to 170-190 ft-lb (See TorqueTable).

4. Tighten upper mounting nut to 170-190 ft-lb (See Torque Table).

Replacing the AirSpringThe correct air spring must be installed.The use of a substitute air spring is notallowed and may cause unequal loadsharing between the air springs and causeadverse ride and handling characteristics.

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1. Deflate the air spring by disconnectingone end of the vertical HCV linkagefrom the horizontal arm. Rotate thehorizontal HCV arm downward andsecure it in place.

2. Disconnect the airline at the air springinlet port and remove the connectionfitting from the inlet port.

3. Remove the bolts and washers fromthe upper air spring mount. Notelocation of bolts and washers.

4. Remove the bolts that secure the airspring to the lower air spring mount.

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1. Attach air spring to upper air springmount. Tighten mounting hardwaresnugly.

2. Attach air spring to lower air springmount. Tighten lower mounting boltsto 20-30 ft-lb (See Torque Table).

3. Tighten the upper mounting bolts to20-30 ft-lb (See Torque Table).

4. Apply Permatex or equivalent threadsealant to the threads of the airconnection fitting and install thefitting.

5. Connect the airline to the fitting.6. Inflate the air spring by un-securing

the HCV horizontal arm andreconnecting the vertical linkage to it.

7. Check the airline and fitting for airleaks.

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Replacing the HeightControl ValveThe correct height control valve (HCV)must be installed. The use of a substituteHCV is not allowed and may causeunequal load sharing between the airsprings and cause adverse ride andhandling characteristics.

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1. Drain the air from the supply reservoiron the chassis connected to the frontsuspension.

2. Disconnect the vertical HCV linkagefrom the horizontal arm.

3. Mark airlines and connections for re-assembly. Disconnect the airlinesfrom the HCV. If any other plumbingfixtures are connected to the HCV,mark them for re-assembly.

4. Remove the HCV mounting hardwarefrom the sub-frame.

5. Remove any other air fittings orplumbing fixtures from the HCV.

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1. Apply Permatex or equivalent threadsealant to the threads of the airconnection fittings or plumbingfixtures and install the fittings orplumbing fixtures in the HCV. Be surethere is no sealant on the leading edgeof the fitting.

2. Attach the HCV to the sub-frame withmounting hardware. Orient thehorizontal arm horizontally and tightenthe mounting nuts to 7-9 ft-lb (SeeTorque Table).

3. Connect airlines as marked duringremoval.

4. Connect the vertical linkage to thehorizontal arm.

5. Recharge system with air and checkfor air leaks.

6. Check the ride height and adjust persection on adjusting the ride height asneeded.

Replacing the Sway Barand ComponentsIt is recommended that the sway barmounting bushings and the verticallinkages be replaced all at the same time.

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1. Disconnect sway vertical linkage atupper control arm bracket on bothsides. Retain hardware for installation.

2. Secure the sway bar to prevent rotationand disconnect the lower connection tothe sway bar on both sides.

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1. Attach the sway bar vertical linkage tothe upper and lower mounts.

2. Tighten the mounting nuts to 80-90 ft-lb (See Torque Table).

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1. Follow the instructions for removal ofthe sway bar vertical linkage for bothsides.

2. Remove mounting hardware from “D”ring sway bar mounts on rear ofsuspension sub-frame. Retainhardware for installation.

3. Remove the “D” rings and bushingsfrom the sway bar.

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1. Replace the “D” ring bushings.

2. Apply Aqua Shield Grease to theinside of the bushing. Attach the “D”rings and bushings to the sway bar inthe same location as removal.

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3. Attach the sway bar to the sub-frameusing the mounting hardware.

4. Tighten the mounting nuts to 52 ft-lb(See Torque Table).

5. Follow the instructions for installationof the sway bar vertical linkage forboth sides.

Replacing the SteeringKnuckle CarrierBearingsIt is recommended to replace all thesteering knuckle carrier bearings at thesame time.The wheel and tire should be removed toprovide access. The steering knuckle maybe removed to provide easier handling ofsteering knuckle carrier assembly.

CAUTIONThe knuckle carrier must be securedand supported properly when upperand lower mounting bolts are removed.

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1. Note installed orientation of the upperand lower bar pin. Lower bar pins arefactory installed with the “B” locatedclosest to the lower control arm.Steering knuckle/spindle may beremoved for ease of handling orplacing in press.


2. Remove the steering knuckle carriermounting bolts from the upper andlower control arms. Heat may need tobe applied to the control arm to loosenthe thread adhesive. The control armtemperature must not exceed 300°F.Do not apply heat directly to the barpin or mounting bolts.

3. Remove steering knuckle carrier.

4. Support fixed shoulder end of the barpin.

5. Remove retaining clip and outer collarfrom the split ring.

6. Apply approximately 400 lb press loadto the spacer and remove the splitcollar.

7. Remove spacer and shims.

8. Press bar pin out of bearing cones.

9. Remove outer seals from both sides ofbearings.

10. Remove bearing raceways from thesteering knuckle carrier. Do notdamage bores.

11. Clean the remaining grease from thebearing cavity.

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1. Inspect bearing raceway and seal boresin steering knuckle carrier for burrs ordamage. Inspect the bar pin for burrsor damage. Remove burrs and replacedamaged components.

CAUTIONDo not apply excessive preload tobearings.

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2. Press a bearing race into each steeringknuckle carrier bore until fully seated.

3. Pack a bearing cone with grease andplace it onto the bar pin and seat theinner race on the shoulder.

4. Note the position and orientation ofbar pin relative to the carrier. Theshoulder end of the bar pin facesforward on the upper bar pin location.The shoulder end of the bar pin facesrearward on the lower bar pin location.

5. Insert the bar pin into the steeringknuckle carrier until the bearing coneis seated in the raceway.

6. Turn the steering knuckle carrier overand support the shoulder end of the barpin.

7. Pack a bearing cone with grease andplace it onto the bar pin end oppositethe shoulder and seat it in the raceway.

8. Place the spacer onto the bar pin andseat it against the inner raceway.

9. Apply approximately 400 lbs of pressload to the spacer. Place the split collarinto the groove of the bar pin andagainst the spacer.

10. Use a “feeler” gage to measure the gapbetween the split collar and shoulderof the groove in the bar pin. Recordmeasurement.

11. Remove the load. Then remove thesplit collar and spacer.

12. Using the gap measurement from Step10, place a number of shims equivalentto the gap measurement onto the barpin against the inner raceway.

13. Place the spacer onto the bar pin.

14. Apply approximately 400 lbs of pressload to the spacer such that the splitcollar can be inserted into the grooveof the bar pin. Make sure the splitcollar is fully seated in the groove.

15. Remove the press load.

16. Place the outer collar around the splitcollar. Install the retaining clip aroundthe split collar on the outside of theoutside collar.

17. Press a seal into each seal bore untilfully seated.

18. Check bearing preload by rotating thebar pin. Slight to medium drag shouldbe felt. If too loose, add one shim. Iftoo tight, remove one shim.

19. Fill bearing cavity with grease.

20. Install steering knuckle carriermounting bolts in control arms. Noteorientation of bar pin. Apply Loctite#242 to mounting bolt threads andtighten to 450-500 ft-lb (See TorqueTable).

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Replacing the SteeringGearbox/Slave UnitAssemblyThis procedure covers one side of the unit.Duplicate for opposite side.

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1. Remove the shock absorber from thegearbox side plate mount and lowercontrol arm shock bracket.

2. Remove the (5) side plate bolts thatconnect the side plate to the gearboxassembly and cradle.

3. Remove the pitman bolt. Noteorientation of the timing mark on thepitman arm to the center spline of thegearbox. Remove the pitman arm androtate to the side.

4. Disconnect the power steering or bleedport line and cap or plug the ends.

5. Disconnect and drop the steering slipshaft out of the way.

6. Remove the (8) gearbox mountingbolts.

7. Slide the gearbox out of the unit.

� Disconnect the (1) remaining bolt onthe gearbox mounting plate.

.�!��

1. Clean all bolts of Loctite beforereinstalling into the gearbox

2. Install the gearbox mounting plate ontothe gearbox with the single mountingbolt. Be sure to align all holes ongearbox with plate. Apply Loctite#242 to 7/8" mounting bolt threads andtighten to 475-525 ��.

3. Slide the gearbox back into the unit.

Align all holes. Apply Loctite #242 tosingle 3/4" mounting bolt threads andtighten to 290-310 ��.

5. Align the timing mark on the pitmanarm and slide back on the gearboxshaft. Install the hardware and tightento 170-190 ��.

Connect the power steering lines orbleed port line back onto the gearbox.

� Install the side cover plate back on thegearbox/cradle. Apply Loctite #242 to(3) mounting bolt threads and tightento 410-430 ��. Side rail bolts withuse nuts.

8. Reinstall the shock absorber onto thegearbox mounting plate and lowercontrol arm bracket. Tighten to 170-190��.

Steering Gear PoppetReadjustmentRefer to TRW’s TAS Steering GearService Manual for readjusting thepoppets.

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Torque Tables

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Torque TablesMost threaded fasteners are covered byspecifications that define requiredmechanical properties, such as tensilestrength, yield strength, proof load, andhardness. These specifications arecarefully considered in initial selection offasteners for a given application. To assurecontinued satisfactory vehicle performance,replacement fasteners used should be of thecorrect strength, as well as the correctnominal diameter, thread pitch, length, andfinish.

Torque Table 1

APPLICATIONS FASTENER SIZE TORQUE SPECIFICATION (ft-lb)(CLEAN AND DRY)

Upper Control Arm Bushing Pivot Bolt 1-1/8-12 Grade C 950-1050(1)

Lower Control Arm Bushing Pivot Bolt 7/8-9 Grade C 460-490(1)

Eccentric Set Screw #10-24x3/8 30-40 in-lb

Steering Knuckle Carrier Mounting Bolt 3/4-10 x 2.75 Gr 8 350-370(1,3)

3/4-10 x 2.75 Gr 9 380-410(1,3,)

Lower Air Spring Mount Bolt (into carrier) 5/8-18 Grade 8 170-190(1,3)

Air Spring Upper Mount Bolt (into cradle) 3/8-16 x 1.75 Gr 8 20-30(1)

3/8-16 x 2.00 Gr 8 20-30(1)

Air Spring Lower Mount Bolt 1/2-13 Grade 8 20-30(1)

Idler Arm Mount Lock Bolt (IFS1660S3) 1-14 Grade 8 575-625(1)

Idler Arm Ball Joint Base (IFS1660S3) M56x1.5 325-375(2)

Idler Arm Ball Joint Castle Nut (IFS1660S3) M20x1.5 155-170(3)

Tie Rod Castle Nut 7/8-14 90-100(3)

Tie Rod Clamp Nut 5/8-11 Grade B 50-60Upper Shock Eye Mount Lock Nut 3/4-10 Grade C 170-190Lower Shock Eye Mount Lock Nut 3/4-10 Grade C 170-190Lower Shock Mount Bracket Bolt 3/8-16 Grade 8 30-40(1)

Pitman Arm Attachment Bolt 3/4-16 Grade 8 295-315(1)

Steering Gear Attachment Bolt 3/4-16 Grade 8 410-430(1,2)

Steering Gear Attachment Bolt 7/8-14 Grade 8 650-670(1,2)

Steering Gear Side Cover Bolt 3/4-16 Grade 8 295-315(1)

Steering Stop Adapter 3/4-10 85-115(2)

Steering Stop Jam Nut 1/2-20 Grade B 50-75Steering Arm Castle Nut 1-1/8-12 Grade C 550-1025(3)

Sway Bar Mounting Bracket Nut 7/16-14 Grade C 48-56Sway Bar Linkage Nut 1/2-20 Grade C 75-85Sway Bar Upper Control Arm Bracket Nut 1/2-13 Grade C 75-85Kingpin Draw Key Nut 7/16-20 Grade G 30-45Kingpin Cap Bolt 5/16-18 Grade 8 20-30(1)

Height Control Valve Body Mount Lock Nut 1/4-20 Grade C 10-15Height Control Valve Linkage Stud Mount Nut 5/16-18 Grade B 8-12Height Control Valve Adjuster Nut 1/4-20 24-28 in-lbSpindle Outer Nut 1-1/2-12 200-300Disc Brake Caliper Mount Screw M20x2.5 300-330Upper Crossmember Bolts 5/8-18 Grade 8 150-180(1)

1) Torque applied to bolt head.2) Apply thread adhesive Loctite #242 or equivalent to threads of fastener threaded into tapped hole.3) Install Cotter pin after tightening

Grade Markings on Bolts

Grade Lock NutGrade B, F

Lock Nut:Grade C, G

Identification

3 Dots 6 Dots

Grade Markings on Lock Nuts

Torque Tables

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Torque Table 2

APPLICATIONS FASTENER SIZE TORQUE SPEC.(ft-lb) (CLEAN AND

DRY)

TORQUE SEQUENCE

IFS1660/1800FTBrake Spider and

Torque Plate MountCap Screws

3/4-16 Grade 8 290-320

1

2

3

4

5

7

ABS

6

Driver Side

Hub Cap Bolt 5/16-18 Grade 5 20-30(1)

1

2

3

4 5

6

Wheel Nut M22x1.5(Hub Piloted)

450-500(2)

(Dry Threads)

1

2

3

45

67

8

9

10

1) Torque applied to bolt head2) Recheck wheel nut torque after first 50-100 miles.

IS0 9001:2008 Certified

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Mount Vernon1205 Industrial Park DriveMount Vernon,MO 65712

(800) 753-0050,Fax (417) 466-39641-800-753-0050

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