Manual Eixo Dianteiro 2012-06 ING

MAINTENANCE MANUAL

Edition october/11

Front Axle (Non-tractive)

MFS 06MFS 07MFS 08MFS 14

MM11135

MAINTENANCE MANUAL

Index

1 - Important information .......................................................................................... 03

2 - Exploded view .................................................................................................... 04

3 - Introduction and description ............................................................................... 06

4 - Failure correction ................................................................................................ 10

5 - Inspection ........................................................................................................... 12

6 -LubrificacioneMaintenance ............................................................................... 15

7 - Adjustments ........................................................................................................ 21

8 - Removal ............................................................................................................. 33

9 - Preparation of parts for assembly ....................................................................... 40

10 - Installation ......................................................................................................... 45

11-Torquespecifications .......................................................................................... 60

12 - Special tools ....................................................................................................... 62

3

Important information

MAINTENANCE MANUAL

Updating of Changes in the Axle To maintain the maintenance manual up-to-date, for each change that occurs in the axle, a Technical Instruction will be issued with the data and the implications stemming from these changes. At the foot of each of each page of this manual, there is an area designated for noting the number of each Technical Instruction that in-volves possible changes occurring on that page, as shown in the example below:

Safety The use of safety equipment is of extreme im-portance at the time of maintenance of the axle. • Upon using a hammer or carrying out any

operation that involves impact, use safety goggles.

• Upon handling hot parts, use appropriategloves.

ASBESTOS AND NON-ASBESTOS FIBERS Some brake linings contain asbestos fibers,a hazardous cancer and pulmonary disease causingagent.Somebrake linings contain fi-bers without asbestos, but for which the effects of prolonged exposure are unknown. Great care must be taken upon handling both types of material.

Exloded view

4 MAINTENANCE MANUAL

NO

N-D

RIV

E

FRO

NT

AX

LE

DOUBLE

NUT

SINGLE

NUT

SINGLE

NUT

UPPERAND

LOW

ER

5

Exloded view

MAINTENANCE MANUAL

ITEM DESCRIPTION ITEM DESCRIPTION

1 Cotter pin2 Castle nuts3 Steering arm4 Key5 Pivot6 Bolt7 Lubrificationpin8 Shaft end cover - with hole for lubri-

cation9 Shaft end cover - sealed10 Gasket11 Needle bearing12 Tip shaft bronze bushing13 Tip shaft nylon bushing14 Stub axle15 Castle nuts16 Cotter pin17 Seal - Tip shaft bushing18 Nut limiter bolt19 Steering limiter bolt20 Porca Castelo21 Cotter pin22 Shim23 Beam24 Flat key25 Cotter threaded26 Key nut27 Axial bearing and plan seal28 Axial bearing and seal29 Whole axial bearing and seal30 King pin31 Key32 Connecting arm33 Cotter pin34 Castle nuts35 Pivot of the tie bar36 Screw clamp37 Lock nut38 Connecting bar39 Sealer cub40 Internal bearing cone41 Internal bearing cup

42 Wheel bolt43 Hub44 Bearing wheel cup - internal45 Bearing wheel cone - internal46 Adjustment nut47 Lock ring pierced48 Lock washer49 Counter nut50 Washer “D”51 Adjustment nut52 Cotter pin53 Gasket54 Cover hub55 Bolt and nut56 Shaft end cover57 Washer key

Introduction and description


Description Thefrontnon-driveaxlesMeritorhavethefol-lowing components: (Figure 1). • Tie bar, stub axle and king pin. The right side tie bar is the mirror image of

the left side tie bar and converts the force of the tie bar into movement to turn the right side stub axle, wheel and tire around the king pin. The stub axle and king pin assembly is similar to the left side, except for the absence of the steering arm.

• Stub axle Stub axles are evaluated in accordance with

the front axle capacity. All models use straight stub axle pins. Three types of bushings are used: nylon, bronze and Easy Steer®.

• Steering Arm The steering arm (normally a cast component)

converts the force of the steering arm in a turn-ing movement through the left side axle stub king pin.

Figure 1

Figure 1a

CONNECTING ARM

TIE BAR PIVOT

TIE BAR

STEERING ARM

STUBAXLE

7


MAINTENANCE MANUAL

Identification of the Axles All the information necessary for any Meritorfrontaxleisindicatedontheaxleidentificationplate. Figure 2. Before beginning service operations, identify theunit toberepaired,consulting the identifi-cation plate fastened on the beam. This infor-mation will allow correct identification of thespare parts desired, thus allowing execution of a more rapid and precise service operation.

Model (Model)Cust.No. (Customer n°)Part.No. (Part n°)Ratio (Reductions of the differential)Série No. (Serie n°)Date (Date of manufacture)Designation of the model. See Figures 3 and 3A. For information regarding all models, see Figure 4.

IdentificationPlate

Figure 2

Figure 3

FRONT AXLE

FF - 931 - NX-122

BASIC CAPACITYA 5.000 lbs (2268 Kg)B 6.000 lbs (2722 Kg)C 7.000-8.000 lbs (3175-3629 Kg)D 9.000 lbs (4082 Kg)E 10000 lbs (4536 Kg)F 12.000-13.200 lbs (5443-5987 Kg)G 14.600 lbs (6622 Kg)L 16.000-20.000 lbs (7258-9072 Kg)LX 30.000 lbs (13.608 Kg)U28.000-30.000 lbs (12.701-13.608

Kg)

BASIC SERIES

BRAKE

SPECIFICATION NUMBER

NUMERICALSEQUENCE

VARIACIÓN PRINCIPAL0 ConceptualdesignFMVSS-1211 Stub axle of straight axle with seal and new steering arm assembly 2 Const.. stub pin with seal3 Larger beam and stub axle4 Easy Steer® Bushing5 Tubular beam6 Low weight beam7 Modelwithcenterpoint8 Easy Steer® Plus Bushing

ALTERACIÓN DE PROYECTO0 Tempered king pin1 Straight king pin2 Special connecting arm 3 Distance of 127 mm (5”) from the center of

the stub axle to the spring seat 4 Distance of 127 mm (5”) from the center of

the stub axle to the spring seat and special connectingARMS.

5 Special wheel end 6 Double lowering of the beam

MODEL

CUST. NO.

PART. NO.

SER. NO.

RATIO

DATE



MFS-XX-000X-NXXXX

NEW MODELS

Meritor

F = Front

S = Non-drive steering axle

GAWR pounds or tone INDICATES VARIATION ON THE

BEAMKINGPINORBUSHING:1 - Straight king pin –Easy Steer® 2 - bushing – Tapered king pin – needle be-

aring 3 - Beam of alloy material (India) 4 - Straight king pin – bronze bushing

KPI

0 - No Standard1 - 68” (1727,2 mm)2 - 69” (1752,6 mm)3 - 71” (1803,4 mm)4 - 71,5” (1816,1 mm)5 - 72” (1828,8 mm)6 - 65,25” (1657,4 mm)7 - 60” (1524,0 mm)8 - 67,5” (1714,5 mm)9 - 68,5” (1739,9 mm)

HEIGHTFROMTHECENTEROF THE BOSS FOR THE

KINGPINTOTHESURFACEOF THE SPRING SEAT

0 - No Standard1 - 3,30” (83,8 mm)2 - 3,50” (88,9 mm)3 - 3,74” (3,74 mm)4 - 5,00” (127,0 mm)5 - 2,50” (63,5 mm)

MAINDESIGNVARIATION

A - Conventional stub axleB - Whole connecting armC - Whole connecting arm and backing

plateD - Whole connecting arm, brake spider

and unitized hub

GAWR = Gross Axle Weight Rating

KPI = king Pin Inclination

“ = Inches

MANUFACTURINGLOCATION

N - North America S - South AmericaE - EuropeA - Australia / Asia

NUMERICALSEQUENCE

BRAKE

Figure 3A

9


MAINTENANCE MANUAL

ForaxlesmanufacturedinBrazilidentifiedbytheinitial8,adoptthevaluesfortheaxlesidentifiedbytheinitial9.

E.g., FF-844 adopt values indicated for FF-944.

Figure 4 - INFORMATION ON MODELS OF THE NON-DRIVE FRONT AXLESNUM./MOD. CAPACITY MAINVARIATION DESIGN ALTERATION

FC-901 3.175 Kg (7.000 lbs) ConceptualdesignFMVSS-121 Straight stub axle pin

FC-903 3.175 Kg (7.000 lbs) ConceptualdesignFMVSS-121 Distance 127 mm (5”) from stub axle cen-ter to spring seat

FC-921 3.175 Kg (7.000 lbs) ConceptualdesignFMVSS Straight stub axle pin

FC-941 3.629 Kg (8.000 lbs) Easy Steer® Design Straight stub axle pin

FD-833 2.070 Kg (4.560 lbs) Larger beam and stub axle Straight stub axle pin

FC-901 4.082 Kg (9.000 lbs) ConceptualdesignFMVSS-121 Straight stub axle pin

FC-931 4.082 Kg (9.000 lbs) Larger beam and stub axle Straight stub axle pin

MFS-09 4.082 Kg (9.000 lbs) Larger beam and stub axle Distance 127 mm (5”) from stub axle cen-ter to spring seat

FD-961 4.536 Kg (10.000 lbs) Low weight beam Straight stub axle pin

FE-970 4.536 Kg (10.000 lbs) Centered point design Tempered stub pin

FF-921 5.443 Kg (12.000 lbs) Sealed stub axle pin Straight stub axle pin – off road

FF-931 5.443 Kg (12.000 lbs) Straight stub axle pin

FF-932 5.443 Kg (12.000 lbs) Special connecting arm

FF-933 5.443 Kg (12.000 lbs) Distance 127 mm (5”) from stub axle center to spring seat

FF-934 5.443 Kg (12.000 lbs) Distance 127 mm (5”) from stub axle center to spring seat and special connecting arm

FF-941 5.443 Kg (12.000 lbs) Easy Steer® Design Straight stub axle pin

FF-942 5.987 Kg (13.200 lbs) Easy Steer® Design Distance 127 mm (5”) from stub axle center to spring seat

FF-943 5.443 Kg (12.000 lbs) Easy Steer® Design Special connecting arm

MFS-13

FF 944

5.443 Kg (12.000 lbs) Easy Steer® Design Distance 127 mm (5”) from stub axle center to spring seat and special connecting arm

FF-961 5.443 Kg (12.000 lbs) Straight stub axle pin

FF-971 5.443 Kg (12.000 lbs) Centered point design Straight stub axle pin

FG-931 6.622 Kg (14.600 lbs) Straight stub axle pin

FG-933 6.622 Kg (14.600 lbs) Distance 127 mm (5”) from stub axle center to spring seat

FG-941 6.622 Kg (14.600 lbs) Easy Steer® Design Straight stub axle pin

FG-943 6.622 Kg (14.600 lbs) Easy Steer® Design Distance 127 mm (5”) from stub axle center to spring seat

FL-931 9.072 Kg (20.000 lbs) Straight stub axle pin

FL-933 9.072 Kg (20.000 lbs) Distance 127 mm (5”) from stub axle center to spring seat

FL-941 9.072 Kg (20.000 lbs) Easy Steer® Design Straight stub axle pin

FL-943 9.072 Kg (20.000 lbs) Easy Steer® Design Distance 127 mm (5”) from stub axle center to spring seat

FL-951 9.072 Kg (20.000 lbs) Tubular axle beam Straight stub axle pin

FU-910 12.600 Kg Sealed stub axle pin and connecting arm assembly

Tapered stub axle pin

FU-935 13.608 Kg Special wheel ends

MFS-06

5301

2.631 Kg (5.800 lbs) Easy Steer® Design Straight stub axle pin

Easy Steer® bushing

MFS-07

MFS-08RA

3.171 Kg (7.000 lbs) Easy Steer® Design Straight stub axle pin

Easy Steer® bushing

Failure correction


Failure correction Check the tables below to correct possible failures in the axle

CONDITION CAUSe CORRECTION

Tires wear out rapidly or have ir-regular wear

1. Tires with incorrect calibration. 2.Unbalancedtires.3. Incorrect alignment of tandem

axles.4. Incorrect divergence.5. Incorrect steering arm geom-

etry.6. Excessive play of the wheel

hub

1. Calibrate the tires with the specifiedpressure.

2. Balance or change tires.3. Align the tandem axles. 4. Adjust the divergence.5. Repair the steering arm as

necessary.6. Readjust the play of the end

bearings.

Vehiclewithsteeringdifficulty 1. Low pressure in the hydraulic steering system.

2. Steering joints need lubrica-tion.

3. King pin stuck.4. Incorrect steering arm geom-

etry.5. Caster out of adjustment.6.Connecting arm ends difficult

to move.7. Worn back-up ring.

1. Repair the steering system. 2. Lubricate the steering joints.3. Replace the king pin.4. Correct the steering system as

necessary.5. Adjust the caster.6. Replace the ends.7. Replace the ring.

Tie bar terminals worn 1. Tie bar pivots need lubrication.2. Severe operating conditions.3. Damaged cowl in the pivot of

the tie bar

1. Lubricate the pivots of the tie bar. Check that the lubrication tables are being followed.

2. Increase the frequency of lu-brication inspection.

3. Replace the cowl.

Tie bar, pivot, steering arm or connecting arm crooked or bro-ken

1. A great deal of pressure in the steering power system.

2. Interruption pressure of the steering power system out of adjustment.

3. Vehicle working under severe conditions.

4. Steering box poorly adjusted or not operating well.

5. Steering limits adjusted incor-rectly.

1. Adjust the pressure of the steering power system.

2. Check that the vehicle is oper-ating correctly.

3. Install the Add-on type system correctly.

4. Check.5. Check adjustments of steering

limits

11

Failure correction

MAINTENANCE MANUAL

Failure Correction Check the tables below to correct possible failure in the axle.

CONDITION CAUSE CORRECTION

Steering pivot worn or broken 1. Torque of the tie rod greater thanspecified.

2. Lack of lubrication or incorrect lubrication.

3. Directional steering limit out of adjustment.

1. Tighten the fasteners of the tie rod fasteners with the speci-fiedtorques.

2. Lubricate the steering joints. 3. Adjust the limits with the speci-fieddimensions.

King pins and bushings worn 1. Gaskets or seals lacking or worn.

2. Incorrect lubrication. 3. The axle is not lubricated with thespecifiedfrequency.

4. Incorrect lubrication proce-dures.

5. Lubrication frequency incom-patible with the operating con-ditions.

1. Replace the gaskets and seals.

2.Usethespecifiedlubricant3. Lubricate the axle with the specifiedfrequency.

4.Usethecorrectprocedures.5. Change the frequency to be

compatible with the operating conditions.

Front axle vibrating or “shaking” during operation

1. Caster out of adjustment. 2.Unbalanced wheels and/or

tires.3. Worn shock absorbers.

1. Adjust the caster. 2. Balance or replace the wheels

and/or tires. 3. Replace the shock absorbers.

Inspection


Inspection Perform the following procedures during an in-spection: • Fasteners – Check that all the fastening elements are tightened with the specifiedtorques. Use a torquemeter to check thetorques. Reading must be made as soon as the bolt or nut begins to move. Correct the torque if necessary. Replace any damaged fastener.

CAUTIONREPAIR OR RECOVERy OF THE FRONT AXLE COMPONENTS IS NOT PERMITTED. MERITOR RECOMMENDS REPLACEMENT OF COMPONENTS WHICH ARE DAMAgED OR OUTSIDE OF SPECIFICATION. MOST OF THE COMPONENTS UNDERgO THER-MAL TREATMENT. THE COMPONENTS MAy NOT bE STRAIgHTENED, WELDED, HEATED OR REPAIRED IN ANy WAy WITH-OUT THE RESISTANCE OR DURAbILITy OF THE COMPONENT bEINg REDUCED AND INVALIDATINg THE gUARANTEE AND MAy EVEN CAUSE ACCIDENTS WITH THE VEHICLE RESULTINg IN DAMAgES OR PERSONAL INjURy. • Damage and wear – Inspect the parts of the

axle in regard to damage and wear. Look for bends or cracks. Replace all damaged or worn parts.

• Puntos de pivote – Asegúrese que no hay-an puntos de pivote sueltos. Cerciórese que los puntos de pivote estén lubricados.

• Operación – Asegúrese que todas las pie-zas muévanse libremente por todo el radio de giro.

• Desgaste de neumático - Inspeccione los neumáticos cuanto a evidencias de daños o desalineación de la suspensión.

Check the vertical play of the stub axle 1. Place blocks in the front and back of the rear

wheel to keep the vehicle from moving.

WARNINgDo not work under the vehicle supported only by a jack. The jack might slip and cause injury. Useadequatesupports.

2.Useajacktoraisethevehicleuntilthefrontwheels are suspended. Support the front axle on safe stands.

3. Support a magnetic base with a dial indica-tor on the beam and support the thickness gauge of the dial indicator on the top of the stub axle. Figure 5.

4. Place a crowbar between the boss of the steering arm and the beam. Force the stub axle upward. Figure 6.

5. Clear the dial indicator. 6. Force the stub axle upward with the crowbar

and take a reading and note the result.

Figure 5

13

Inspection

MAINTENANCE MANUAL

The result of the reading must be between 0.02 - 0.64 mm (0.001- 0.025”) for new or reconstruct-ed axles and 0.025 - 1.650 mm (0.001-0.065”) for axles in use. Figure 6.If the reading is 0 (zero), remove the stub axle and remove shims from the shim pack. See the Removal and installation sections of this manual. If the reading is greater than the maximum spec-ified,removethestubaxleandaddshimstothepackage. See the Removal and Installation sec-tions of this manual.

Check wear of the stub axle bushings1. Place blocks in the front and back of the rear

wheel to keep the vehicle from moving.

WARNINgDo not work under the vehicle supported only by a jack. The jack might slip and cause injury.

2.Useajacktoraisethevehicleuntilthefrontwheels are suspended. Support the vehicle on safe stands.

3. Check the wear of the upper bushing of the stub axle. Install a magnetic base with a dial indicator on the beam and support the thick-ness gauge on the side of the boss of the steering arm on the stub axle. Figure 7.

4. Clear the dial indicator.

NOTE:If a bushing is damaged, it is necessary to exchange the two bushings of the stub axle.

5. Laterally move the top of the side of the tire several times. If the dial indicator indicates play of 0.25mm (0.010”), the bushing is worn or damaged. Replace the two bushings. See the Removal and Installation sections of this manual. Figure 7A.

6. Check the lower bushing of the stub axle. In-stall a magnetic base with a dial indicator on the beam and support the thickness gauge of the dial indicator on the boss of the connect-ing arm on the lower part of the stub axle. Figure 8.

Figure 6

Figure 7A

CROWBAR

Inspection


7. Clear the dial indicator. 8. Laterally move the lower part of the side of

the tire several times. If the dial indicator indi-cates play of 0.25 mm (0.010”), or more, the lower bushing is worn or damaged. Replace the two bushings. See the Removal and In-stallation sections of this manual. Figure 8A.

Check tie bar ends Hold and try to move the tie bar in any direc-tion. If any movement or play is felt between the ends of the tie bar and the connecting arms, remove and replace the pivots of the tie bar. See the Removal and installation sections of this manual. Figure 9.

Figure 8A

Figure 9

C O N N E C T -INGARM

PIVOT OF THE BAR

TIE BAR

15

Lubrification and maintenance

MAINTENANCE MANUAL

Classification Table of vehicles according to the application group, date of manu-facture and operating conditions.

Application group table.

group(See page 20)

Aplication year Production Operation Condition

1 Only on paved roads or high-ways, transportation lines

After July 1996Before July 1996, use the group 3.

Operations of high mile-age (over 80.500Km / year [50,000 miles]) 95% on paved roads or highways.

2Firefighters,UrbanDelivery,buses, heavy Highways, School Bus,MotorHome

After July 1996Before July 1996, use the group 3.

Low mileage Operations (less than 80,500 km / year [50,000 miles]).

3Timber, Oil, Construction, Heavy transport, road tractor, Residen-tial Trash.

All Low mileage Opera-tions (less than 40,200 km / year [25,000 miles]) heavy Load and substantial off-road operation.

4 Mining,Off-roadTractor,Graveland earth Heavy freight service

5 Mining,Timber,ConstructionHighly heavy work and 80 to 100% off-road operations



Lubricant SpecificationsFigure 10 Table w / Highway and Urban Delivery (Applicable in FF and FD including FD-931, FD-933 and FD-961)

Figure 11 Table of Specification and greasing intervals for non-tractive Front Axle

Figure 12 Specification Table and Wheel Hub Oil Change Intervals

1 AcceptableDesignations.MotorOilsMultiWeightsareacceptableifSAEvaluesendin40or50.

2 AcceptableDesignations.MotorOilsMultiWeightsareacceptableifSAEvaluesendin0.

Note:TheconditionsstatedintheUser’sVehicleManufactureroverridetheconditionscontainedinthismanual

1 Applies to pivots on Easy Steer shafts and Conventional. Inspect pivots every 160,000 km (100,000 miles) for wear and damage. Perform maintenance as necessary.

2 Meritorrecognizesthattheindustrycontinuallyseekstoimprovetheselectionanduseofsyntheticgreaseinvehiclemaintenance.However,asweknow,somesealantsexpandintocontactwithsyntheticgrease.SeeMeritorreferencesabouttheapplicationofsynthetic grease before using it in vehicle maintenance.

1 Applies to pivots on Easy Steer shafts and Conventional. Inspect pivots every 160,000 km (100,000 miles) for wear and damage. Perform maintenance as necessary.

Part greasing interval grease 2 MeritorSpecification

NLgIgraduation Grase classification

• Kingpins

• Kinpinbush

• Pivotsdirectionarms

• Pivotsconnectionarms

• Directionbar1

Once a year or whievercomesfirst

Multipurposegrease 2

0-617-A 16% Lítio

12-Hidroxyl Stearato

0-617-B 28% Lítio

12-Hidroxyl Stearato

Part greasing interval grease MeritorSpecification

NLgIgraduation

grase clas-sification

Temperatura externa

• Kingpins

• Kinpinbush

• Pivotsdirectionarms

• Pivotsconnectionarms

• Directionbar1

Once a year or whievercomesfirst

Multipur-pose grease

0-617-A

ou

0-6187B

1

ou

2

6% Lithium

12-Hidroxyste-arato or lithium complex

See the grease manufacturer’sspecificationsregarding working temperature limit.

CubeUnitSealedforTrucks Cubedoesn’tre-quire lubrication Sealed unit None No

Oper. on Road/Intervals

Intervals for off-road operation Meritor

Specif.MilitarSpecif.

Oil descrip-tion

External temperature

Checkoil level

Cambiaroil

Checkoil level

Cambiaroil

C° F°

Min Max. Min. Max.

1.600 km

(1.000 miles)

O que ocorrer primeiro:

Troca de veda-dores.

Realin-hamento de Freios.

160.000 km

(100.000 miles)

Umavezao ano

1.600 km

(1.000 miles)

O que ocor-rer primeiro:

Troca de ve-dadores.

Realin-hamento de Freios.

160.000 km

(100.000 miles)

Umavezaoano

0-76A

Oil GearMIL-L-2105-D GL-5 SAE

85W/140 12 No 10 No

0-76D

Oil GearMIL-L-2105-D GL-5SAE

80W/90 -26 No -15 No

0-76E


85W/140 -40 No -40 No

0-76J


75W -40 2 -40 36

ÓleoMotor

Carga Pesada

MIL-L-2104-B

-C, -D ou E

API-CD, -CE-SF ou -SGSAE 40 ou 50

12 No 10 No

ÓleoMotor

Carga Pesada

MIL-L-2104-B

-C, -D ou E

API-CD, -CE-SF ou -SGSAE 30

-26 No No

17


MAINTENANCE MANUAL

general Lubricate the king pins, the pivots at the end of the connecting arms, the pivots on the steer-ing arms and the greased bearings with the ap-proved lubricant. See Figures 10, 11 and 12, Lubrication tables. Lubricate the wheel ends lubricated with oil with theoilspecifiedinFigure12.Whentolubricateand perform maintenance on the assemblies. See the Table in Figure 18 on the end of this section. King pins – conventional front axles.

NOTE:These procedures apply to the conventional front axles 833, 901, 903, 910, 935, 952 and 970. See the identification plate on the axle beam. On conventional axles, the greasers are locat-ed at the side of the stub axle.

WARNINg:Do not work under the vehicle supported only by the jack. The jack might slip and cause serious injuries.

1. Raise the vehicle until the tires leave the ground. The tires must be suspended when the king pins are lubricated. Place the vehicle on stands. Place shims in front and back of the rear wheels to keep the vehicle from moving.

2. Lubricate the king pins through the upper and lower greasers (grease zerks) at the side of the stub axle. Figure 13.

3. Apply lubricant until the new lubricant passes between the upper shim pack and the seal.

4. Lower the vehicle until the wheels touch the ground.

5. Apply lubricant in the lower lubrication pin un-tilthenewlubricantflowsandfillsthering.

King pins – sealed front axles and Easy Steer®

NOTE:his procedure applies to the front axles se-ries: 833, 911, 921, 931, 932, 933, 934, 941, 942, 943, 951, 961, 963, 971 and 975. See the identification plate on the beam.On the sealed front axles and Easy Steer®, the greasers are located on the upper and lower covers of the king pins on the stub axle. 1. Check that the tires are touching the ground.

DO NOT RAISE THE VEHICLE. 2. Lubricate the kings pins through the greasers

on the top and on the lower part of the stub axles. Figure 14.

3. Apply lubricant until the new lubricant passes between the upper shim pack and the seal.

NOTE:On Axle 5301 (MFS-06) the lubricant passes through the seal and on the surfaces of the junction of the beam with the stub axle.

Figure 13

LUBRICATING

PIN

The lubricant must flowfromhere



Pivots of the steering arms, pivots of the tie bars, and tie rods. 1. Check that the tires are touching the ground. 2.Applythelubricantuntilthenewlubricantflows

from the cowl.

Wheel bearings lubricated with greaseVer la Figure 16.1. Remove the tire and wheel assembly. Re-

move and disassemble the hub. See Remov-al of the Wheel End.

2. Remove the old lubricant from all the parts. Discard the seals. Inspect the wheel bearings in regard to damage or wear. Replace them if there is damage or wear. See Preparation of Parts for Assembly.

3. Force the entry of lubricant through the cavi-ties between the rollers and the cage through the larger side of the cone. Place lubricant on the hub in the space between the bearing covers up to the level of their least diameter. Figure 16.

4. Install the inner and outer cones on the re-spective hub covers. The caps must be pre-cisely seated on the hub seat.

5. Install the new seals on the hubs. 6. Install the wheel assembly and tires. Install the

outside cone bearing of the wheel on the hub. Install the adjusting nut.

7. Adjust the wheel bearings. See the Section Adjustment of wheel bearings.

Figure 14

Figure 15

Figure 16



LUBRICANT

PIN

LUBRICANT

LUBRICANT

PIN

19


MAINTENANCE MANUAL

Tightening the nuts of the king pin keys

NOTE:This procedure applies to all the models of the front axle, except for 901, 903 and 970. Check the identification plate on the beam. Tighten the nuts that fasten the keys on the side of the stub axle with a torque of 30-55 ft-lbf (41 - 61 N.m) at the frequency indicated below. Fig-ure 18. • Afterthefirst10,000Km(6,000Miles)ofve-

hicle operation. • Atevery58,000Km(36,000Miles)ofopera-

tion.

Figure 18

Figure 17

LUBRICANT

Key nut

Wheel bearings lubricated with oilCheck the level on the cover. If the oil level is notwithinspecificationgradedonthecover,re-movethefillplugandputtheoiluptothelevelindicated. Figura 17.



Lubrification and MaintenanceFigure 19 Lubrication, inspection and maintenance table

Component

(See page 15)

Service Intervals

48

hours

8.000 km/ 100

hours

Primeros 10.000 km operación

16.100 km

32.200 km

58.000 km

64.000 km

80.500 km

160.000 km

320.000 km

5.000 miles

6.000 miles

10.000 miles

20.000 miles

36.000 miles

40.000 miles

50.000 miles

100.000 miles

200.000 miles

Tie bar end

Group 1 Application I L*

Group 2 Application I L*

Group 3 Application I, L*



Inspect the tie bar as-sembly

Group 1 Application I

Group 2 Application I L



Group 5 Application I I L

Inspect tie bar I L

Steering arm pivot I L

Easy Steer® axle pivot I L

Sealed pivot I L

Steering arm I L

King pins, bushings I L

Sttering arm bolt I L

Axle bearings I L

Inspect vertical play in


Group 2 Application I L




Desgaste bujes superi-ores y inferiores de los pernos maestro






Key nuts

New vehicle T

Vehicle in use T

Inspection sealed hub unit I

I = InspectL = LubricateT=Tightenwiththespecifiedtorque*Ifyourvehicleiswashedwithapressurewasher,thelubricationintervalsmustbemorefrequent.ForthemodelsMF06(5301),FMS07,FMS07RA,lubrication must be performed every 20.000 km.

21

Adjustments

MAINTENANCE MANUAL

Inspection before alignmentCheck the items below before performing align-ment of the front wheels.

InspectionSee the Inspection section. Page 12.

Wheels and Tires

• Checkthatthetireshavecorrectcalibration.• Checkthatthefronttiresareofthesamesize

and type. • Check that the nuts are tightened with thespecifiedtorque.

• Checkthatthewheelsarebalanced.

Front suspension• Check that the fasteningelementsare tight-enedwiththespecifiedtorque.

• Checkifthespringsaredamaged.• Checkifthestopsarewornordamaged.

Rear axle and rear suspension Wear of the front tire may be caused by the rear axle. If the outside treat of a front tire is worn and the inside tread of the other front tire is worn, check the following:• Checkthatallthefastenersaretightenedwiththespecifiedtorque.

• Checkthatthespringsarenotwornordam-aged.

• Checkthatthebushingsofthespringassem-bly are not damaged or worn.

• Checkthatthetorquesoftherods(ifused)arecorrectly adjusted.

• Checkthatthechassisisnottwisted.• Checkthattherearaxle(especiallyatandem

axle) is correctly aligned. See the procedures of the vehicle or suspension manufacturer.

• References to any recommendations andspecifications of the vehicle or suspensionmanufacturer.

Adjustments


Front wheel alignmentVerifique el alineamiento de las ruedas del-anteras cuando ocurrir las siguientes situacio-nes: • Every 320,0000 Km (200,000 Miles) or 24

months (normal maintenance). • Whenthevehicledoesnotsteercorrectly.• Tocorrectconditionsoftirewear.Thereare

two types of alignment of the front wheels. Onesimplifiedalignment andanothermorecomplete alignment.

Simplified alignment of the front wheels Performsimplifiedalignmentofthefrontwheelsfor all normal maintenance conditions. Performsimplifiedalignmentofthefrontwheelsin the following sequence: 1. Inspect all the systems that may affect align-

ment. See Inspection Before Alignment, in this section.

2. Check and adjust wheel bearings. 3. Check and adjust divergence.

Complete alignment of the front wheels Perform complete alignment of the front wheels to correct steering and tire wear. Perform complete alignment of the front wheels in the following sequence: 1. Inspect all the systems that may affect align-

ment. See Inspection Before Alignment, in this section.

2. Check and adjust the wheel bearings. 3. Check and adjust the maximum turning angle. 4. If the vehicle has a hydraulic steering system,

check and adjust the pressure release in the hydraulic steering system. See the procedure on page 26.

5. Check and adjust the turning angle (diver-gence in the turns and Ackerman angle).

6. Check the inclination of the king pin (or steer-ing axle).

7. Check the Camber angle. 8. Check and adjust the Caster angle. 9. Check and adjust the divergence.

23

Adjustments

MAINTENANCE MANUAL

Checking and adjustments of the wheel bearings

WARNINg:Do not work under the vehicle supported only by a jack. The jack may slip and cause injury. 1.Useajacktoraisethevehicleunderthefront

wheels are suspended. Support the vehicle on secure stands.

2. Remove the bolts and remove the gasket and the hub cover.

3. Check that the brake drum and the hub fas-teners are tightenedwith the specificationsfrom the manufacturer.

4. Fasten a magnetic base with a dial indicator on the lower part of the hub or of the brake drum.

Adjust the thickness gauge on the center of the stub axle and clear the indicator. Figure 19.

NOTE:Do not push or pull the hub or the brake drum by the upper part and the lower part. Pulling or pushing by the upper and lower part will not give the correct reading.

5.Measuretheplaypushingandpullingoneachside of the hub or drum while making the read-ing. The play is the total of the distance be-tween pushing and pulling. If the play is not within 0.02 - 0.25 mm (0.001-0.005”), adjust the wheel bearings. Figure 19.

6. If necessary, adjust the wheel bearings. See items from 7 to 13.

7. On the fasteners locked with double nuts, take off the lock washer from the lock nut. Remove the check nut, the lock washer and the perforated lock washer. Figure 20.

On the fasteners with single nuts, remove the cotter pin from the adjustment nut. Figure 21.

NOTE: When removing or installing adjustment nuts, use the correct size socket so as not to damage the hex form of the nut.

Figure 20

Figure 20a

Figure 21

CHECKNUT

PERFORATED RETAINING RING

With the magnetic base mounted on the lower part, push and pull the sides of the tire

LOCK WASHER OF THE CHECK-NUT

ADJUSTMENTNUT

Adjustments


NOTE:Do not strike the adjustment nut with a met-al hammer. Do not use a chisel or punch to loosen the adjustment nut. This may cause damage to the nut.

8. Useatorquemetertotightentheadjustmentnut with 100 ft-lbf (136 N.m) while turning the tire in both directions.

9. Loosen the nut completely and then tighten with a torque of 20 ft-lbf (27 N.m) while turn-ing the tire.

10. On the single nut fasteners, do the following:

a. Return the adjustment nut 1/8 turn. Figure 23.

b. Turn the adjustment nut to align the slot with the nearest hole in the stub axle for placing the cotter pin.

c. Install a new cotter pin in the nut. d. Measureaxialplay.Playmustbewithin0.02

- 0.25 mm (0.001-0.005”). See items 4 - 5. Readjust if necessary.

11. On the double nut and lock fasteners, do the following:

a. Return the adjustment nut 1/3 turn. Figure 24.

b.Install the perforated retaining ring, the lock washer and the cotter pin.

c. For checknuts of 41.3 mm (1 1/8”) to 66.7mm (2 1/8”), tighten with a torque of 200 - 300 ft-lbf (271 - 407 N.m).

For checknuts of 66.7 mm (2 1/8”) or more, tighten with a torque of 250 -400 ft-lbf (339 - 542 N.m). d. Measureaxialplay.Theplaymustbewithin

0.02 - 0.25 mm (0.001-0.005”). See items 4 - 5. Readjust if necessary.

12. Install the gasket and hub cover. Install the bolts and tighten with a torque of 20 - 30 ft-lbf (27 - 41 N.m).

13. Lower the vehicle to the ground. Check if the vehicle operates correctly. .

Figure 22

Figure 23

Figure 24

1. TIGHTENTHENUT100ft-lbf.(136 N.m)

2. RELEASETHENUTCOM-PLETELY

3. RELEASETHENUT 20 ft-lbf.. (27 N.m)

“D” OR WEDGED WASHER

RETURNTHENUT1/8TURNONTHESINGLENUTFASTENERAND1/3TURNONTHEDOUBLENUT

COTTER PIN

ADJUSTMENT

NUT

25

Adjustments

MAINTENANCE MANUAL

Adjustment of the maximum turning angle

CAUTION:ADjUST THE MAXIMUM TURNINg ANgLE ONLy IF THE VEHICLE MANUFACTURER SPECIFIES THIS ADjUSTMENT. DO NOT IN-CREASE THE MAXIMUM TURNINg ANgLE. IF THE ANgLE IS INCREASED, THE CON-NECTINg ARMS, THE TIE bAR AND THE END OF THE TIE bAR WILL bE DAMAgED.

Check the angle if the front tires rub against the fender or if the steering gear has under-gonemaintenance.Use alignment equipmentto check the angle. Follow the procedures of the equipment manufacturer. The limiter bolt at the rear of the stub axle con-trols the maximum turning angle. or a hydraulic steering system, the limiter bolt MUSTNOT touch the stub axle or the beam(depending on where it is installed). The limiter bolt must always have minimum play of 3 mm (1/8”), as shown in Figure 24. Forthemanualsteeringsystem,Meritorrecom-mends play in the steering limiter bolt of 3 mm (1/8”). Contact with the limiter bolt is acceptable if no other limiters are used in the steering sys-tem.

CAUTION:IF THE LIMITER bOLT IS MISSINg, bENT OR bROKEN, THE SySTEM REqUIRES AD-jUSTMENTS. SEE MECHANICAL LIMITER IN THIS SECTION.

NOTE:If the steering system is out of adjustment, check if the steering arm is not damaged. Use magnetic particles or penetrating fluid to check for the existence of cracks in the steering arm. Pay special attention to the el-bow, cone and the area near the pivot. See the vehicle manufacturer manual in regard to other procedures.

CAUTION:IN THE HyDRAULIC STEERINg SySTEM, HyDRAULIC PRESSURE MUST bE RE-LIEVED OR REDUCED AT THE END OF THE STEERINg STROKE (WITH 3 MM OR 1/8 MINIMUM PLAy ON THE LIMITER bOLT). IF THE PRESSURE IS NOT RELEASED, THE FRONT AXLE COMPONENTS WILL bE DAMAgED.

1. Place a 3mm (1/8”) spacer between the lim-iter bolt and the boss on the axle beam.

2. Turn the wheel until the boss on the axle beam touches the spacer in front of the lim-iterbolt.Measuretheturningangle.

3. If the turning angle is out of vehicle manufac-turerspecification,dothefollowing:

A. Loosen the checknut on the limiter bolt. B.Turnthelimiterboltuntilthespecifiedangleis

obtained. Figure 25. C. Tighten the checknut with the torque in accor-

dance with the table on page 60.

Figure 25

CHECKNUT

MAXIMUMTURNINGANGLE

POSITIONOFSTUBAXLEINREGARDTOADJUSTMENTOFTHELIMITERBOLT

LIMITERBOLT

Adjustments


Adjustment of pressure relief on the Hydraulic Steering SystemPressure relief on the hydraulic steering system ceases or reduces the pressure applied to the axle in the entire turning stroke. Check pressure relief if the steering arm is dam-aged or if there is maintenance in the steering gear. Two types of systems are used for adjustment of pressure relief: • Mechanical limiteron thePitmanarmoron

the auxiliary cylinder. • Hydraulicpressurereliefonthesteeringgear.

CAUTION:MERITOR DOES NOT RECOMMEND A Hy-DRAULIC STEERINg SySTEM THAT DOES NOT HAVE A MECHANICAL LIMITER OR A PRESSURE RELIEF bEFORE ObTAIN-INg THE MAXIMUM TURNINg ANgLE. THE LIMITERS OR PRESSURE RELIEVERS ARE USED TO PREVENT DAMAgE TO THE AXLE.

Mechanical Limiter Useamechanicallimiteronthesteeringsystemto adjust the pressure relief. Do not use the limiter bolt of the stub axle to ad-just the pressure relief.

NOTE:See the recommended procedure in the ve-hicle manufacturer manual.

CAUTION:USE A PRESSURE gAUgE TO CHECK THE FALL OF PRESSURE IN THE MAXIMUM RELEASE SySTEM UP TO A LIMIT OF 700 - 1.000 PSI (4825 - 6890 KPA) bEFORE COM-PLETINg THE TOTAL TURN.Systems with mechanical limiters are adjusted by 1/8 turn before the limiter bolt touches the boss on the axle beam. Adjustment is made in the turning positions to-tally to the left and totally to the right. Figure 26.

Figure 26

CHECKNUT

POSITIONOFSTUBAXLEAFTERPITMAN/CYLINDERARMLIMITERS

CLEARED

MAXIMUMTURN-ING ANGLE

LIMITERBOLT

27

Adjustments

MAINTENANCE MANUAL

Hydraulic Pressure Relief in the Stee-ring gear.

NOTE:See vehicle manufacturer specification.

NOTE:The limiter bolt will always have minimum play of 3 mm (1/8”). Hydraulic steering gears with a poppet valve are adjusted with a spacer between the limiter bolt on the stub axle and the boss on the axle beam. The poppet valves are adjusted for cut-ting or reducing the pressure at the distance of the spacer. Figure 27.

Turning Radius Angle See Figure 28.When one performs a curve, the internal wheel must turn at a greater angle than the external wheel. This angle is the turning radius angle (fre-quently called the Ackerman angle). The angle is constructed in the design of the connecting arms, ends of the connecting arms and the tie rod assembly to give the greatest possible con-tact of the tire with the ground and minimize wear during curves. Check the turning radius angle with the radius plates on the equipment for alignment. See the procedure in the equipment manufacturer manual.

Figure 27Figure 28

CHECKNUTSPACER

POSITIONOFSTUBAXLEFORADJUST-MENTOFTHEPOPPETVALVE

TURNINGRADIUSANGLE

TURNING

ANGLE

CENTER LINE OF THE FRONT AXLE

CHASSIS CENTER

LINE

CENTER LINE OF THE REAR AXLE

LIMITERBOLT

Adjustments


Inclination of the king pinSee Figure 29.

NOTE:See vehicle manufacturer specifications in regard to inclination of the king pin.Inclination of the king pin (or steering axle) is the angle measured between the center line of the king pin and the vertical position (as seen from the front of the vehicle). The inclination of the king pin and the camber angle places approxi-mately the center of the tire tread in contact with the ground. This reduces the force of the steer-ing turn and improves steering stability. Usealignmentequipment tocheck the inclina-tion angle of the king pin. See the equipment manufacturer procedure. The inclination of the king pin is not adjustable. Iftheinclinationdoesnothavethespecifiedan-gle, check if the axle beam or the stub axle is not damaged. Perform maintenance if necessary.

Camber angle See Figure 30.THE CAMbER ANgLE IS NOT ADjUST-AbLE. MERITOR DOES NOT RECOMMEND CHANgINg THE CAMbER ANgLE OR CURVE OF THE AXLE bEAM. IF THE AXLE bEAM IS CURVED TO CHANgE THE CAM-bER ANgLE, RESISTANCE OF THE AXLE IS REDUCED AND THE gUARANTEE IS AN-NULLED. THE AXLE MAy bE DAMAgED. AN AXLE DAMAgED by bENDINg OF THE bEAM MAy CAUSE ACCIDENTS AND CON-SEqUENT PERSONAL INjURy. Camber is the tire angle with the respective ground. The camber is positive when the dis-tance between the top of the wheels is greater than the distance at the base of the wheels. Creating a small positive camber is performed at the stub axle because the camber changes in accordance with the load. This results in a zero camber angle when the vehicle operates under normal load. If the camber is more than 1 1/2 degrees out-sideof thatspecified, tirewearwilloccur.Di-agonal tires more easily show camber excess, while in radial tires, this excess is not so evi-dent.

Figure 29

Figure 30

CAMBER

INCLINATION OF THE KING PIN

ZERO OR NEUTRAL

LOAD

POSITIVE

CAMBER

INCLINATION OF THE KING PIN

29

Adjustments

MAINTENANCE MANUAL

The camber is not adjustable. The camber angle is obtained in machining of the axle beam. If the camberangleisnotwithinspecifications,checkthe axle beam or the stub axle in regard to wear or damage. Perform maintenance if necessary. Use alignment equipment to verify camberangle. See the equipment manufacturer proce-dures.

See vehicle manufacturer specifications in re-gard to the correct camber. The table in Figure 31showsthespecificationsthatMeritorusesonthe axles, but always in accordance with the ve-hiclemanufacturerspecifications.

CAMBERANGLERECOMMENDATIONS

Figure 30

CONDITIONSLEFTSIDE

RIGHTSIDE

LEFT AND RIGHT SIDES

•Camberanglemachined in the axle

•Hubsnotinstalled•Hubnotinstalledinthe

vehicle•Axlewithoutload

•Axlecamberanglewithhubs installed•Axlenotinstalledinthevehicle•Axlewithouload.

•Camberanglewithload•Axleinstalledinthe

vehicle

OLDCAMBERSPECIFICATION

AXLESWITHASSEMBLYDATES:

NEWCAMBERSPECIFICATION

AXLES WITH AS-SEMBLYDATES:

September 11992 or after

without“P”suffix

+45’Nominal +15’Nominal +15’Nominal + 1º Nominal

+45’(26’)ou

+1º11’a+19’(finalreading)

+41’a11’(finalreading)

No date on the plateAugust 1992 or beforeAnydatesuffix“P”

+15’(26’)ou

+41’a-11’(finalreading)

+_ +_ +_ +_ +15’(26’)ou


+1°(26’)ou

+1°26’a34’(finalreading)



+1°26’a34’(finalreading)

NOTE:MFS-013

FF844CURRENTONLYAMERICAN

AXLES

MFS08RAFD833-MFS-095301-MFS06FC845-MFS07

LEFT AND RIGHT SIDES

AXLES IN BRAZIL

Adjustments


Identification of the assembly date of the front axleAll the necessary information regarding assem-blyoftheaxle,includingthedate,foranyMeritoraxleisontheidentificationplate.Figure31.Theidentificationplateisfastenedinthecenterof the axle beam.

Before beginning service operations, identify the unit to be repaired. This information will allow correctidentificationofthesparepartsdesired,thus allowing execution of a more rapid and pre-cise service operation.

Model(Model)Cust.No. (Customer number)Part.No. (Product number)Ratio (Reductions of the differential)Série No. (Series n°)Date (Date of manufacture)

Figure 31

BEAMSEENFROMFRONTOFVEHICLE

EXAMPLEOFIDENTIFICATIONPLATE

31

Adjustments

MAINTENANCE MANUAL

Caster angleSee Figure 33.The caster angle is the angle of the vertical line up to the center line of the king pin when viewed from the side of the vehicle. If the top of the cen-ter line of the king pin is turned toward the rear of the vehicle, the caster angle will be positive. The positive caster creates a moment of self align-ment to stabilize the vehicle when traveling in a straight line forward. If the caster angle is too much, it will increase the steering turning effort or it may increase vibration of the front wheels. The caster angle is controlled by tempered shims installed under the spring assembly. Ad-just the caster angle in accordance with the ve-hicle manufacturer procedure. Use alignment equipment to verify the casterangle. See the vehicle manufacturer procedure. hecasterspecificationsareprovidedbytheve-hicle manufacturer. See the vehicle manufactur-erspecificationstoadjustthecasterangle.Ifthemanufacturer specifications are not available,Meritorrecommendsacasteradjustmentof+1oto + 2- 1/2o for vehicles with manual steering and +2o to +4 -1/2o for vehicles with hydraulic steering. Axles model FE-970 and FE-971 have a recommended caster angle of -1/2o to -2o.

Divergence adjustmentSpecifications:In accordance with vehicle manufacturer specifications. Divergence is the ratio of distance between the fronts of the front tires and the back of these same tires. When the distance in front is less than in back, the wheels are in divergence. Di-vergence is necessary to go against the ten-dency for “convergence” of the tires when the vehicle is in movement. Incorrect divergence re-sults in rapid wear of tires.

CAUTION:MOST CASES OF TIRE WEAR ARE CAUSED by INCORRECT DIVERgENCE. DO NOT CHANgE THE CAMbER OR ADjUST THE CASTER TO CORRECT TIRE WEAR PROb-LEMS. IF THE AXLE ASSEMbLy WAS DAM-AgED (bENT) TO CORRECT CASTER OR CAMbER, AXEL RESISTANCE IS REDUCED AND, AS A RESULT, THE gUARANTEE IS ANNULLED. AN AXLE DAMAgED by bEND-INg OF THE bEAM MAy CAUSE ACCIDENTS AND CONSEqUENTLy PERSONAL INjURy.

1.Check that the vehicle is on a flat surface.Place shims under the rear wheels to keep the vehicle from moving. Raise the vehicle until the tires are off the ground.

2.Usepaintorchalktomarkthecentralareaofboth tires around their entire perimeter.

3. Place the calibrator bar indicators on the marks of each tire. Check that a straight line will be marked on each tire, completely around it.

Figure 33

FORWARD

NEGATIVE

CASTER

POSITIVE

CASTER

Center line of the king pin

Adjustments


NOTE:Do not measure divergence with the front axle raised (off the ground). The weight of the vehicle must be on the axle when diver-gence is measured.

4Lower the vehicle to the ground.Move thevehicle forward and backward at a distance of 3 meters.

5. Place the calibrator bar behind the tires. Raise the pointers until they are at the same height as the stub axles. Align the pointers with the marks on the tires. Measure andnote the distance between the pointers.

6. Place the calibrator bar in front of the tires. Raise the pointers until they are at the same height as the stub axles. Align the pointers with the marks on the tires. Measure andnote the distance between the pointers. Figure 33.

7. To obtain the result of the measurement, subtract the value obtained in the front of the tire from the value from the back. Figure 34.

8.Ifthedivergenceisoutsideofspecifications,use the following procedure: a. Loosen the nut and bolt in each end of the

tie bar. b.Turn the tiebaruntil thespecifieddiver-

gence is obtained. c. Tighten the nut and bolt at each end of the tiebarwith thespecified torque.See theTorque Table.

9. Repeat items from 1 to 7 to check the dimen-sion of the divergence.

Figure 34

Figure 35

FRONT OF VEHICLE

BMINUSAISEQUALTODIVERGENCE

33

Adjustments

MAINTENANCE MANUAL

Removal of the tie rod

See Figure 36.

1. Remove the cotter pins from the pivots. 2. Remove the nuts from the pivots.3. Disconnect the tie rod from the Pitman arm

and from the steering arm. 4. Inspect the tie rod. See the section Prepara-

tion of Parts for Assembly.

Removal of the steering arm

See Figure 37.1. Remove the cotter pin and the nut that fasten

the steering arm to the tie rod. Disconnect the steering arm.

2. Remove the cotter pin and the nut that fasten the steering arm to the stub axle.

3. Remove the steering arm from the stub axle. If necessary, strike the end of the arm with a plastic or leather hammer to separate the steering arm from the stub axle.

4. Remove the key from the steering arm. 5. Inspect the steering arm. See the section

Preparation of Parts for Assembly.

Figure 36

Figure 37

PITMANARM

TIE RODSTEERING

ARM STEERINGARM

TIE ROD

Removal


Removal of the connecting arms, pivots of the tie bar, and the tie bar1. Remove the cotter pins and the nuts that fas-

ten each pivot to the connecting arms. 2. Disconnect the tie bar, connecting arm as-

sembly Is necessary, use a tool to separate the connecting arm from the tie bar. Figure 38.

3. Remove the cotter pins and the nuts that fas-ten connecting arms to the stub axles.

4. Remove the connecting arms from the stub axles. If necessary, strike with a plastic or leather hammer to separate the connecting arm from the stub axle. Remove the key.

5. If necessary, remove the ends of the tie bar. Follow the following procedures: Figure 38.

7.Inspect the parts. See the section Preparation of Parts for Assembly.

a.Mark the position at which each end is in-stalled on the tie bar.

b. Remove the nuts and bolts of the clamp on the tie bar.

c. Remove the pivots of the tie bar.

6. The clamp may be turned to facilitate removal of the nut and bolt. Figure 40.

Figure 38

Figure 39

Figure 40

TIE BAR

MARKS

PIVOT OF THE TIE BAR

CLAMP

NUTANDBOLT

PIVOT OF THE TIE BAR

CONNECTING ARM

35

Removal

MAINTENANCE MANUAL

Removal of the wheel ends

WARNINg:Do not work under the vehicle that is supported only by a jack because the jack might slip and cause serious personal injuries.1. Raise the vehicle until the wheels leave the

ground. Support the vehicle with safe stands.2. Remove the bolts that fasten the hub cover.

Remove the cover and gasket.

NOTE:When loosening or tightening the adjust-ment nuts, always use a correct size socket to avoid damaging the nuts.

3. Remove the fasteners of the wheel bearings. Follow the procedures below:

Double Nut Fasteners a.Unfold the loops of the lock washer of the

checknut and adjustment nut. b.Remove the checknut, the lock washer, the

perforated retaining ring and the adjustment nut of the stub axle. Figure 40.

Fasteners with Single Nut a. Remove the cotter pin from the adjustment

nut. Figure 4. b. Remove the adjustment nut and the “D” or

wedged washer as may be the case from the stub axle. Figure 42.

4. Remove the cone of the outside wheel bear-ing from the hub.

5. Remove the wheel and the tire, the hub and the drum as a set.

Removal of the king pins and stub ax-les1. Remove the wheel ends as described in this

section. 2. Remove the air from the brake system. Dis-

connect the air lines of the brakes. 3. Remove the braking assembly from the stub

axle. 4. Remove the connecting arms, steering arm

from the stub axle. See the procedure in this section.

Figure 41

Figure 42

PERFORATEDRETAINING RING

ADJUSTMENTNUT

CHECKNUT

LOCK WASH-ER OF THE CHECKNUT

ADJUSTMENTNUT

COTTER PIN“D” OR WEDGE

WASHER

DOUBLENUTANDADJUSTMENTLOCK

ADJUSTMENTWITHSINGLENUT

Removal


5. Remove the bolts of the covers on the top and lower part of the stub axle. Remove the covers and gaskets. Figure 43.

NOTE:All models except for FC-901, FC-922, FE-970, FF-971 and FL-901 use threaded keys. The models FC-901, FC-922, FE-970, FF-971 and FL-901 use flat keys.

6.Removetheflatorthreadedkeys.Followthefollowing procedure:

Removal of the Flat Key

WARNINg:Wear safety goggles. Do not strike steel parts or tools with a steel hammer because fragments may come off and cause injury. a.Useabronzehammerandasteelpunchto

remove the key. Support the punch at the smallerend(“D”profile)ofthekey.Figure44.

Removal of the Threaded Keys a. Loosen the lock nut until the top of the nut

is even with the end of the key.

WARNINg:Wear safety goggles. Do not strike steel parts or tools with a steel hammer because fragments may come off and cause injury.

CAUTION:FORCE MUST bE APPLIED DIRECTLy ON THE EXTREMITy OF THE NUT EVEN WITH THE KEy. IF FORCE IS NOT APPLIED DI-RECTLy AT THIS LOCATION, THE KEy MAy bE DAMAgED.

b.Use a bronze punch and a hammer tostrike the end of the nut to loosen the key. Figure 44.

c. Remove the nut of the key. Remove the key from the stub axle.

Figure 43

Figure 44

COVER

GASKET

37

Removal

MAINTENANCE MANUAL

NOTE:If the bushings are not replaced, follow the following procedure to prevent any damage during removal of the king pin.

1. Remove any chip on the punch that may touch the king pin.

2. Cover the end of the punch with adhesive tape.

NOTE:o optimize tire wear on roads with regular surfaces, the housings of the right and left king pins on the beam are machined for slightly different angles of the king pin. The front of the beam must be installed turned to the front of the vehicle. The front of the beam is marked by the iden-tification plate fastened on it and/or a small paint mark on the left side of the beam. If the plate and the paint mark are absent, identify the front of the beam for correct installation. In brazil, only the FF front axle model needs this identification.

7.Use a bronze punch and a hammer to re-move the king pin from the stub axle. Figure 46.

If there isdifficulty in removalof thekingpin,use a hydraulic king pin remover. See Table of Special Tools section.

WARNINg:Usegloveswhenremovingtheshimsbecausethey have sharp edges.

NOTE:Identify the stub axle in relation to the side of the beam.

8. Remove the stub axle from the beam. Re-move the shims (if any), the axial bearing and the seal between the beam and the stub axle. Figure 47.

9. Inspect the parts. See Preparation of Parts for Assembly section.

Figure 45Figure 46

Figure 47

KEY

NUT

PINO MAESTRO

SHIMS(BE-TWEEN THE BEAMANDTHESTUBAXLE)

AXIAL BEARING AND SEAL

Removal


Removal of bushings from the stub axle1. Remove and discard the front seal of the

bushing. Figure 48.

2. Remove the bushings in accordance with the following procedure: Nylon bushings

a. Remove the upper and lower bushings from the stub axle. Figure 49.

bronze and Easy Steer® bushings NOTE:In the axle series FF, Fg and FL, the bush-ings may be removed with a kit for bush-ing Maintenance. See Special Tool Table. Página 62

a.Makeatooltoremovethebushings.Seethedimensions for the tool in Figure 50.

b. Place the stub axle in a 5 ton capacity press. Check that the stub axle will not move during removal of the bushing.

c. Install the tool on the top bushing. Press the bushing out of the housing in the stub axle. Figure 50.

d.Install the tool on the lower bushing. Press the bushing out of the housing in the stub axle. Figure 50.

Figure 48

Figure 49

Figure 50

SEAL

NYLONBUSHING

UPPERBUSHING

LOWERBUSHING

39

Removal

MAINTENANCE MANUAL

MOD/NUM

DIMENSION“X” DIMENSION“Y”

_(+ 0,025 mm) _(+ 0,001 mm) _(+ 0,025 mm) _(+ 0,001 mm)

FC-901 31.191 1.128 34.290 1.350

FC-903 31.191 1.128 34.290 1.350

FC-921 31.191 1.128 34.290 1.350

FC-941 37.922 1.493 41.097 1.618

FD-901 36.245 1.427 39.420 1.552

FD-931 40.640 1.600 43.815 1.725

MFS-09FD-833

40.640 1.600 43.815 1.725

FD-933 40.640 1.600 43.815 1.725

FD-961 45.364 1.786 48.539 1.911

FE-970 40.640 1.600 43.815 1.725

FF-921 45.389 1.787 48.539 1.911

FF-931 45.389 1.787 48.539 1.911

FF-932 45.389 1.787 48.539 1.911

FF-933 45.389 1.787 48.539 1.911

FF-934 45.389 1.787 48.539 1.911

FF-941 45.364 1.786 48.539 1.911

FF-942 45.364 1.786 48.539 1.911

FF-943 45.364 1.786 48.539 1.911

MFS-13FF 944

45.364 1.786 48.539 1.911

FF-961 45.364 1.786 48.539 1.911

FF-971 40.640 1.600 43.815 1.725

FG-931 45.389 1.787 48.539 1.911

FG-933 45.389 1.787 48.539 1.911

FG-941 45.364 1.786 48.539 1.911

FG-943 45.364 1.786 48.539 1.911

FL-931 50.596 1.992 53.746 2.116

FL-933 50.596 1.992 53.746 2.116

FL-941 50.546 1.990 53.746 2.116

FL-943 50.546 1.990 53.746 2.116

FL-951 50.596 1.992 53.746 2.116

FU-910 52.171 2.054 55.346 2.179

FU-935 52.171 2.054 55.346 2.179

MFS-07MFS-08RA

31.191 1.228 34.290 1.350

MFS-06

530128.448 1.120 31.5514 1.242

Figure 51

DIMENSIONSOFTHEBUSHINGINSTALLATIONANDREMOVALTOOL

APPROPRIATE LENGTH

Preparation for the assembly


Recovery of partsThe recovery or reconditioning of parts of the frontaxleisnotpermitted.Meritorrecommendsreplacement of parts which are damaged or outsideofspecification.Mostofthepartshavethermal treatment (tempered). Parts may not be curved, welded, heated or reconditioned under any circumstances without reducing their resistance and dura-bility and thus annulling their guarantee. The following operations are prohibited on the front axle components: 1. Welding on the steering arm, stub axle, king

pins, axle beam, tie bar assembly, hubs and brake drums.

2. Bending (twisting), either hot or cold, the stub axle, steering arm, connecting arms, pivots, axle beam and tie bar.

3. Enlarging the holes for the king pin in the beam.

4. Enlarging the holes for the key in the stub axle.

5. Weld spatters on the diameters for stub axle bearings and machined housings.

6. Grinding or machining any component.

WARNINg:If you use solvents, hot solution tanks or alka-line solutions incorrectly, you are subject to se-rious accidents that may cause you injury. To handle these elements correctly and prevent accidents,readthemanufacturer’sinstructions.DO NOT use gasoline to clean parts because it is explosive.

Cleaning of ground or polished partsUseachemicalproductappropriateforclean-ing of the ground or polished surfaces. Kero-sene or diesel fuel may be used for this pur-pose.DONOTUSEGASOLINE.DO NOT wash ground or polished parts in tanks with hot solutions or water, steam or alkaline solutions. These solutions cause corrosion of the parts.

Cleaning of non-machined partsNon-machined parts may be washed together with the ground or polished parts.Non machined parts may also be washed in tanks with light alkaline and hot solutions. The parts may be left in the tank with a hot solution until they are completely clean.

Drying of the washed partsThe parts must be dried immediately after washing. Dry the parts with paper, clean cloths or compressed air. Do not use compressed air on bearings.

Rust and corrosion prevention on wa-shed partsApply a thin layer of oil on the washed and dried parts that are not damaged and will be immedi-ately reassembled. DO NOT apply oil on brake linings and brake drums.If the parts are stored, apply a coat layer of anti-rust oil on all the surfaces. DO NOT apply oil on brake linings and brake drums. Store the parts wrapped in special paper or other material that protects them from rust.

41


MAINTENANCE MANUAL

Inspection of partsCarefully inspect all the parts before assem-bling them. See the procedures below:A. Inspect and replace any part that is worn,

cracked or damaged. Check for the existence ofcrackswithmagneticorfluorescentparticles.

B.Useamicrometeroraboregaugetomeasurethe housing on the stub axle. Measurementmade at the top and at the bottom of the hous-ing around the perimeter is acceptable. Check that the bushings were removed from the stub axle.

Measure the diameter of the upper housing at two positions 90° opposite. If the means of the values obtained are greater than that speci-fiedfor themaximumdiameterof thehousingof the bushing on the stub axle in Figure 60, replace the stub axle. Figure 52. Use the sameprocedure formeasurement ofthe lower housing.

C. UseAmicrometer or bore gauge tomea-sure the diameters of the bushings on the stub axle.

Measurethediameteroftheupperbushingattwo positions 90° opposite. If the means of the valuesobtainedaregreaterthanthatspecifiedfor the maximum internal diameter of the king pin bushing in Figure 60, replace the bushing of the stub axle. Figure 53. Use the sameprocedure formeasurement ofthe lower bushing. Figure 53

D. Use amicrometer or bore gauge tomea-sure the housing on the beam. Measure-ment made at the top and bottom around the perimeter is acceptable.

Measure the diameter of the housing of the upper side at three positions with 90° opposi-tion (13 mm below the top and 13 mm above the bottom and in the center of the length). If the means of the values obtained are greater thanthatspecifiedforthemaximumdiameterofthe boss on the beam in Figure 60, replace the beam. Figure 54.

Figure 52

Figure 53

MEASURETHEHOUSINGONTHESTUBAXLEIN4POSITIONS WITH 90° OP-POSITION

MEASURETHEDIAMETEROFTHEBUSHINGONTHESTUBAXLEIN4POSI-TIONS WITH 90° OPPOSI-TION



Inspection of the wheel bearingsInspect the wheel bearings when the stub axle is inspected or undergoes maintenance. Remove all the lubricant from the bearings, stub axle, hub and hub cover. Inspect the cover, the cone, the rollers and the cage of all the bearing. If any of the following conditions are found, the bearing must be re-placed. 1. Accentuated wear on the broad surface of

the tapered rollers, with nearly total elimina-tion of the center recess. Figure 55.

2. Worn radius, with sharp edges on the broad surface of the rollers. Figure 55.

3. Wear (with visible recess) on the track of the cover or of the cone. Wear may be seen on the larger or smaller diameters of the cover or the cone. Figure 56.

4. Deep indentations, cracks or breakage in the seats of the cover and/or of the cone, or on the surfaces of the tapered rollers.

Figure 54

Figure 55

Figure 56

MEASURETHEHOUSINGONTHEBEAMIN4 POSITIONS WITH 90° OP-

POSITION

RECESSED CENTER

LEVEL OF WEAR

SHARP EDGES

43


MAINTENANCE MANUAL

5. Signs of friction on the cage of the tapered rollers.

6. Corrosion (chemical action) or cavities on the rollers and on the surfaces of the tracks of the cover and of the cone. Figure 58.

7. Chipping or scaling on the surface of the cov-er and/or of the cone. Figure 59.

Figure 57

Figure 58

Figure 59



NOTES:

*Stub axle with nylon bushings.

**Stub axle with bronze bushings.

MOD/NUM

MAXIMUM DIAMETER OF THE bUSHINg HOUSINg ON THE

STUb AXLE

MAXIMUM DIAMETER OF bOSS ON bEAM

MAXIMUM DIAMETER OF THE INNER PART OF THE KINg PIN

bUSHINg

FC-901* 34.569 mm (1.361”) 31.445 mm (1.238”) 31.496 mm (1.240”)

FC-903** 34.569 mm (1.361”) 31.445 mm (1.238”) 31.442 mm (1.238”)

FC-921* 34.569 mm (1.361”) 31.445 mm (1.238”) 31.496 mm (1.240”)

FC-941** 34.569 mm (1.361”) 31.445 mm (1.238”) 31.442 mm (1.238”)

FC-921 34.582 mm (1.3615”) 31.445 mm (1.238”) 31.407 mm (1.2365”)

FC-941 41.389 mm (1.6295”) 38.202 mm (1.504”) 38.151 mm (1.502”)

FD-901 39.700 mm (1.563”) 36.512 mm (1.4375”) 36.525 mm (1.438”)

FD-931 44.094 mm (1.736”) 40.919 mm (1.6110”) 40.907 mm (1.6105”)

MFS-09

FD-83344.094 mm (1.736”) 40.919 mm (1.6110”) 40.907 mm (1.6105”)

FD-933 44.094 mm (1.736”) 40.919 mm (1.6110”) 40.907 mm (1.6105”)

FD-961 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FE-970 44.094 mm (1.736”) 40.919 mm (1.6110”) 40.907 mm (1.6105”)

FF-921 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FF-931 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FF-932 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FF-933 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FF-934 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FF-941 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FF-942 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FF-943 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

MFS-13FF 944

48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FF-961 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FF-971 44.094 mm (1.736”) 40.906 mm (1.6105”) 40.907 mm (1.6105”)

FG-931 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FG-933 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.656 mm (1.7975”)

FG-941 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FG-943 48.818 mm (1.922”) 45.669 mm (1.7980”) 45.618 mm (1.796”)

FL-931 54.025 mm (2.127”) 50.876 mm (2.0030”) 50.825 mm (2.0010”)

FL-933 54.025 mm (2.127”) 50.876 mm (2.0030”) 50.825 mm (2.0010”)

FL-941 54.025 mm (2.127”) 50.876 mm (2.0030”) 50.825 mm (2.001”)

FL-943 54.025 mm (2.127”) 50.876 mm (2.0030”) 50.825 mm (2.001”)

FL-951 54.025 mm (2.127”) 50.876 mm (2.0030”) 50.876 mm (2.0030”)

FU-910 55.626 mm (2.190”) 52.464 mm (2.0655”) 52.438 mm (2.0645”)

FU-935 55.626 mm (2.190”) 52.464 mm (2.0655”) 52.438 mm (2.0645”)

MFS-07

FC-84534.540 mm (1.359”) 31.394 mm (1.2356”) 28.530 mm (1.1232”)

MFS-06

530131.788 mm (1.251”) 28.715 mm (1.1305”) 31.270 mm (1.2311”)

Figure60-SPECIFICATIONSOFWEARLIMITS

45

Installation

MAINTENANCE MANUAL

Installation of nylon bushings on the stub axleInstall the bushings on the housings of the stub axles. Check that the bushings are well seated in the housing. Place the king pin to check if the installation is correct. Figure 61.

Installation of bronze bushings on the stub axle1. First install the upper bushing. 2. Place the stub axle in a press such that the

top of the stub axle is turned toward the pis-ton of the press. Check that the housings are parallel with the piston of the press.

3. Install the bushing in the housing. Check that the hole in the bushing is aligned with the hole in the housing. Figure 62.

4.Usetheinstallationtoolandpressthebush-ing 3.17 mm (1/8”) into the housing. Release the pressure from the press. Check the bush-ing alignment.

5. Press the bushing until it is from 3.0 to 4.0 mm (0.135 to 0.165”) from the bottom of the housing. Figure 63.

6. Turn the stub axle until the housing of the lower bushing is turned to the piston of the press. Check that the housing is parallel to the piston of the press.

7. Install the lower bushing in the housing. Check that the hole in the bushing is aligned with the hole in the housing.

8.Usetheinstallationtoolandpressthebush-ing 3.17 mm (1/8”) into the housing. Release the pressure from the press. Check the bush-ing alignment.

9. Press the bushing until it is from 3.0 to 4.0 mm (0.135 to 0.165”) from the bottom of the housing. Figure 64.

10. Ream the bushings. See the procedure in this section.

Installation of bronze and Easy Steer® bushings on the stub axle NOTE:On the axles series FF, Fg and FL, the bush-ings may not be installed without the aid of a press. Use the bushing installation kit. Use the tool shown in Figure 51 to install the bushings.Useapresswithminimumcapacityof5tons.Check that the bushing does not move out of alignment during installation. Ream the bronze and Easy Steer® bushing af-ter installation.

Figure 61

NYLONBUSHING

Installation


Installation of the Easy Steer® bushin-gs on the stub axle1. First install the upper bushing. 2. Place the stub axle in a press such that the

top of the stub axle is turned to the piston of the press. Check that the housings are paral-lel to the piston of the press.

3. Install the bushing in the housing. 4.Usetheinstallationtoolandpressthebush-

ing 3.17 mm (1/8”) into the housing. Release the pressure from the press. Check the bush-ing alignment.

5. Press the bushing until it is from 8.9 to 9.7 mm (0.352 to 0.382”) below the top of the housing on the stub axle. Figure 65.

6. Turn the stub axle until the housing of the lower bushing is turned to the piston of the press. Check that the housing is parallel to the piston of the press.

7. Install the lower bushing in the housing. 8.Usetheinstallationtoolandpressthebush-

ing 3.17 mm (1/8”) into the housing. Release the pressure from the press. Check

the bushing alignment. 9. Press the bushing until it is from 8.9 to 9.7

mm (0.352 to 0.382”) below the top of the housing on the stub axle. Figure 65.

10. Ream the bushings. See the procedure in this section.

Figure 62

Figure 63

Figure 64

Figure 65

INSTALLATIONTOOL

UPPERBUSHING

LOWERBUSHING

DIAMETEROFTHEREAMEDBUSHINGS

TOP OF THE LOWER BUSHING

TOP OF THEUPPERBUSHING

47

Installation

MAINTENANCE MANUAL

Installation of needle bearing on the shaft1. First install the upper bushing. 2. Place the stub axle in a press such that the

top of the stub axle is turned to the piston of the press. Check that the housings are paral-lel to the piston of the press.

3.Install the bushing in the housing. 4.Usetheinstallationtoolandpressthebush-

ing housing. Release the pressure of the press. Be sure of the alignment of the bush-ing.

5. Press the upper bushing until it is 8:40 to 9.0 mm (0331 to 0362 “) below the top of the housing on the shaft end. Figure 65.

6. Rotate the shaft end until the lower bushing housing is facing the piston of the press. Be sure that the bushing is parallel with the pis-ton of the press.

7. Install the lower bushing in the housing. 8.Usetheinstallationtoolandcrushthebushing

housing. Release the pressure of the press. Be sure of the alignment of the bushing.

9. Press the lower bushing until it is in 6.10 to 6.90 mm (0240 to 0272 “) below the top of the housing on the shaft end. Figure 65.

Figure 66

Figure 67

Figure 68 Figure 69

INSTALLATIONTOOL

UPPERBUSHING

LOWERBUSHING

TOP OF THE LOWER BUSHING

TOP OF THEUPPERBUSHING

Installation


Reaming of the bronze and Easy Steer® bushings on the stub axle

CAUTION: THE ONLy RECOMMENDED PROCEDURE IS REAMINg WITH A FIXED REAMER. DO NOT gRIND OR PERFORM bURNISHINg ON THE bUSHINgS bECAUSE THEy MAy bE DAMAgED. 1. Place the stub axle in a vice with bronze jaws

or other soft metal. 2. See Figure 70 in regard to the dimension of

the reamer. 3. Guide the reamer with the pilot until the

blades touch the upper bushing. Figure 66.

4. Turn the reamer, pressing it lightly down-ward. Do not apply a great deal of force. Turn the reamer gently.

5.Upon finishing reaming the upper bushing,do not allow the reamer to fall on the lower bushing.

6. After reaming the upper bushing, place the reamer in the lower bushing and repeat steps 3 and 5. Figure 71.

7. Remove the reamer from the lower bushing. If the reamer must be removed through the up-per bushing, turn it in the direction opposite to the cut.

8. Clean all the material removed by the reamer that remained on the bushings. Figure 70

Figure 71

Figure 72

TURNTHEREAMERPRESSING LIGHTELY

DOWNWARD

MATERIAL:HIGHSPEEDSTEELNUMBEROFBLADES:USE10-14BLADES

REAMER

REMOVABLEPILOT OPTIONAL

CUTOFTHEBLADES:TOTHERIGHT,SPLINETOTHELEFTLENGTHOFTHEBLADES:63,5MM(2,5”)

DIMENSIONSOFTHEBUSHINGREAMERS(seethetable)

GENERALSPECIFICATIONSFORREAMERS

TURNTHEREAMERPRESSING LIGHTELY

DOWNWARD

MINIMUM

49

Installation

MAINTENANCE MANUAL

MOD/NUM

LOWER PILOT DIAMETER DIMEN-SION “A” _(+ 0.025

mm or 0.0001”

DIAMETER OF THE bLADES DIMEN-

SION “A” _(+ 0.013 mm or 0.0005”

UPPER PILOT DIAMETER DIMEN-SION “C” _(+ 0.025

mm or 0.0001”

LOWER PILOT LENgTH DIMEN-

SION “D”

UPPER PILOT MINIMUM LENgTH

DIMENSION “E”

mm inch mm inch mm inch mm inch mm inch

FC-901 31.051 1.2225 31.432 1.2375 31.293 1.2320 171.45 6.75 222.25 8.75

FC-901* 31.051 1.2225 31.432 1.2375 31.293 1.2320 171.45 6.75 222.25 8.75

FC-903 31.051 1.2225 31.432 1.2375 31.293 1.2320 171.45 6.75 222.25 8.75

FC-921 31.051 1.2225 31.432 1.2360 31.298 1.2320 171.45 6.75 222.25 8.75

FC-941 37.782 1.4875 38.138 1.5015 37.999 1.4960 226.06 8.90 276.86 10.90

FC-901 36.118 1.4220 36.499 1.4370 36.360 1.4315 215.90 8.50 266.70 10.50

FD-901* 36.118 1.4220 36.499 1.4370 36.360 1.4315 215.90 8.50 266.70 10.50

FD-931 40.513 1.5950 40.894 1.6100 41.669 1.6405 215.90 8.50 266.70 10.50

MFS-09FD-833

40.513 1.5950 40.894 1.6100 41.669 1.6405 215.90 8.50 266.70 10.50

FD-933 40.513 1.5950 40.894 1.6100 41.669 1.6405 215.90 8.50 266.70 10.50

FD-961 45.212 1.7800 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FE-970 40.513 1.5950 40.894 1.6100 41.669 1.6405 215.90 8.50 266.70 10.50

FF-921 45. 263 1.7800 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FF-931 45. 263 1.5950 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FF-932 45. 263 1.7820 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FF-933 45. 263 1.7820 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FF-934 45.263 1. 7820 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FF-941 45.212 1. 7820 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FF-942 45.212 1. 7820 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FF-943 45.212 1.7800 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

MFS-13FF 944

45.212 1.7800 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FF-961 45.212 1.7800 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FF-971 40.513 1.5950 40.894 1.6100 41.669 1.6405 215.90 8.50 266.70 10.50

FG-931 45.263 1.7820 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FG-933 45.263 1.7820 45.644 1.7970 45.504 1.7915 236.22 9.30 287.02 11.30

FG-941 45.212 1.7800 45.606 1.7955 45.466 1.7900 260.35 10.25 311.15 12.25

FG-943 45.212 1.7800 45.606 1.7955 45.479 1.7900 260.35 10.25 311.15 12.25

FL-931 50.470 1.9870 50.863 2.0025 50.724 1.9970 256.54 10.10 307.34 12.10

FL-933 50.470 1.9870 50.863 2.0025 50.724 1.9970 256.54 10.10 307.34 12.10

FL-941 50.419 1.9850 50.813 2.0005 50.673 1.9950 256.54 10.10 307.34 12.10

FL-943 50.419 1.9850 50.813 2.0005 50.673 1.9950 256.54 10.10 307.34 12.10

FL-951 50.419 1.9850 50.813 2.0005 50.673 1.9950 256.54 10.10 307.34 12.10

FU-910 52.045 2.0490 52.426 2.0640 52.285 2.0585 287.52 11.32 338.32 12.32

FU-935 52.045 2.0490 52.426 2.0640 52.285 2.0585 287.52 11.32 338.32 12.32

MFS-07FC-845

30.950 1.2185 31.394 1.2359 31.331 1.2335 183.2 7.232 250.0 9.84

MFS-065301

28.205 1.1104 28.717 1.1310 28.652 1.1280 183.2 7.232 250.0 9.84

*UsethesespecificationsatthetimeofreplacingtheoldbushingbyanEasySteer®bushing.

Figure68(continuation)-DIMENSIONSOFTHEBUSHINGREAMERS

Installation


Installation of the bushing seals of the stub axle1. Place the top of the stub axle in a vice with

bronze jaws. The lower part must be turned toward you.

2.Place the seal in the top of the housing. The lip of the seal must be turned outward from the housing. Figure 73.

3. Place the cover of the stub axle on top of the seal. Slide the king pin through the housing. Usethekingpintoinstalltheseal.Figure75.

For bronze bushings, check that the seal touch-es the bushing. For Easy Steer® and plastic bushings, check that the top of the seal is even with the stub axle. Figure 76.

4. Turn the stub axle in the vice securing the lower part such that the upper part is turned toward you.

5. Place the seal in the top of the housing. The lip of the seal must be turned outward from the housing. Figures 73 e 76.

6. Repeat step 3 of this procedure.

Figure 73

Figure 75

Figure 74Figure 76

COVER

LIP OF THE SEAL

MACHINEDSURFACE

STUBAXLEHOUSING

BUSHING

KINGPIN

THELIPSMUSTBETURNEDOUTWARDFROM

THEHOUSING

51

Installation

MAINTENANCE MANUAL

Installation of the stub axleNOTE:To optimize tire wear on roads with regu-lar surfaces, the housings of the right and left king pins on the beam are machined for slightly different king pin angles. The front of the beam must be installed turned to the front of the vehicle. Assemble the axle in accordance with the identification made in the Note on page 37. 1. Clean the housings on the stub axles and

beam. 2. Place the stub axle on the beam. 3.Install the seal on the axial bearing. On the

seals that use a cover, install the seal on the open end of the bearing. Figure 77.

Onthe“flat”seals,installthesealontheclosedend of the bearing. Figure 77.

Whole axial bearing with seal The single part bearing with integrated grease seal is completely interchangeable with the two part axial bearing. It has specification for topand bottom.• Thesurfacewith innerdiameterof theseal

must remain on top. • Thesurfacewithouterdiameterof theseal

must remain at the bottom. Figure 78.

4. Slide the bearing and seal set between the bottom of the beam and the stub axle. Check that the seal is turned toward the beam. Fig-ure 79.

Figure 77

Figure 78

Figure 79

COVER

TOP

BOTTOM

FLAT

BEARINGBODY

TIPO DE SELLADORES

BEARINGCAGE

BEARINGBODY

BEARING AND SEAL SET

SEAL

Installation


CAUTION:WEAR gLOVES DURINg INSTALLATION OF THE SHIMS, bECAUSE ITS EDgES ARE SHARP.1. Install the shims according to the following

procedures: A. Inspect the shims. Replace the damaged

shims.B. If a new shim pack must be arranged, select

assembly that results in the least play pos-sible.

C. Place a crowbar between the boss of the steering arm and the beam. Raise the stub axle and place the shim pack between the top of the beam and the stub axle. Figure 80.

D. Check that all the housings are aligned. If the housings are not aligned, the parts will be damaged during installation of the king pin.

E. Remove the crowbar. 6. Install the king pin according to the follow-

ing procedure. Figure 81.A. Apply the specified lubricant on the lower

half of the king pin. B. Install the pin in the top of the stub axle.

Check that the word “TOP” is turned toward you.

C. Turn the pin until the slots are aligned with the holes of the stub axle.

Figure 80

Figure 81

CROWBAR

TOP

KINGPIN

53

Installation

MAINTENANCE MANUAL

CAUTION:DO NOT FORCE THE PIN THROUgH THE UPPER bUSHINg bECAUSE THE SHIMS MAy bE DAMAgED.D. Push the pin through the upper bushing of

the seal and of the shim pack. If there is resistance in installation of the pin, check if the parts are aligned.

WARNINg:Wear safety goggles. Do not strike steel parts with a steel hammer because frag-ments may come off and injure your eyes. E. Push the pin through the lower bushing.If necessary, use a bronze hammer to strike the pin. Check if the parts are aligned.F. Check that the slots in the pin are aligned

with the holes of the stub axle.

NOTE:Do not install or tighten the key on the stub axle before checking play and adjusting it.

NOTE:All models except FC- 901, FC- 921, FE- 970, FF- 971 and FL- 901 use threaded keys. Models FC- 901, FC- 921, FE- 970, FF- 971 and FL- 901 use flat keys.

7. Install the upper key in the front part of the stub axle. Install the lower key in the back part of the stub axle. Check that the keys are in the slots of the king pin. Figure 82.

Figure 82

Installation


8. Check the play of the stub axle in accordance with the following procedure:

A. Strike the boss on the stub axle with a rub-ber hammer to move the parts into position. Figure 83.

B. Turn the stub axle to a straight position. C. Fasten a magnetic base with dial indicator on

the beam. Place the thickness gauge on the center of the king pin and clear the indicator.Figure 84.

D.Usethefollowingprocedurestomeasuretheclearance.

• Placealeverbetweentheshaft end and the top of the beam. Pry the shaft end up and measure the clearance. Figure 80.

Figure 83

Figure 84

Figure 85

MAGNETICBASE LOCA-

TION

55

Installation

MAINTENANCE MANUAL

WARNINg:If a hydraulic jack is used to measure the play, use two stands to support the axle because without them, the axle may cause injury and damages. • Placeablockofwoodandahydraulic jack

under the lower part of the stub axle. Raise the stub axle until the pointer of the dial indi-cator stops moving. Figure 86.

E. Repeat steps C and D with the axle turned totally to the right and to the left.

F. Play must be from 0.02 - 0.64 mm (0.001 - 0.025”) in all positions.

If the stub axle does not have play (zero), re-move shims from the shim pack. OnlytheaxlemodelMFS-06(5301),MFS-07(FC845)andMFS08RA,thatdonotuseshims,may have zero play without compromising the operation of the assembly.If play is greater than 0.635 mm (0.025”), add shims to the pack. For axles model MFS-06(5301),MFS-07(FC845)andMFS08RA,iftheplay is greater than the value indicated, replace the components of the system beginning by the axial bearing.

NOTE:Assemble the thickest shims up against the surface of the stub axle, the midsized shims up against the surface of the beam and the thin ones between them. In the model FD 833, if the play is greater than 0.62 mm, add shims.

WARNINg:Wear safety goggles. Do not strike steel parts with a steel hammer because fragments may come off and wound your eyes.

CAUTION:CHECK THAT THE KEy IS COMPLETELy INSTALLED AND THAT THE LOCK NUT IS TIgHTENED WITH THE SPECIFIED TORqUE. IF THE KEyS ARE NOT COR-RECTLy INSTALLED, THE KINg PIN AND THE bEAM MAy bE DAMAgED. CHECK THE TORqUE OF THE NUT AND POSITION OF THE KEy EVERy 20,000 KM.Check the torque of the nut and cotter position-ing every 20,000 Km

NOTE:All the models except for FE- 970, FF- 971 and FL- 901 use threaded keys. Models FE- 970, FF- 971 and FL- 901 use flat keys.

9.Install the keys in accordance with the follow-ing procedure:

Figure 86

BLOCK OFWOOD

Installation


Flat Keys Useabronzehammerandpunchtoinstallthekey in the axle beam. Check that the key is installed with a depth from 1 to 3 mm (1/32 to 1/8) below the outside sur-face of the beam.

Threaded KeysOn threaded keys, install the lock nut and tight-en with a torque of 30 - 45 ft-lbf (41 - 54 N.m). Figure 88.

Install the new gaskets and cover on the upper and lower part of the stub axle. Install the bolts and nuts tightening them with a torque of 20 – 30 ft-lbf (28 - 40 N.m). FortheaxlesmodelMFS-06(5301)andMFS-07 (FC 845), the torque is from 38 to 57 ft-lbf (4.5 to 6.5 N.m) If the cover is threaded, install them in the up-per and lower parts of the stub axle and tighten with a torque of 60 - 90 ft-lbf (80 to 120 N.m).

11. Connect the connecting arm to the stub axle. See the procedure in this section.

12. Install the brake assembly on the stub axle. See the vehicle manufacturer procedure.

13. Lubricate the wheel bearings. See the pro-cedure in the Lubrication section.

14. Install the drum and the tire and wheel as-sembly.

15. Lubricate the wheel bearings. See the pro-cedure in the Lubrication section.

Figure 87

Figure 88

Figure 89

GASKET

COVER

THREADEDCOVER

57

Installation

MAINTENANCE MANUAL

16. Install the outside wheel bearing on the hub. Install the adjustment nut.

17. Adjust the wheel bearings. See the Adjust-ment section.

18. Install the cover and the gasket on the hub. Install the bolts and tighten with a torque of:

1. Prensa la chaveta en la ranura del brazo. Figure 90.2. Instale el brazo de unión en la punta de eje.

19. Lower the vehicle to the ground. Check is it is operating normally.

20. Check and adjust the camber. See the Ad-justments section.

Installation of the connecting arms, pi-vots of the connecting arms and tie bar

NOTE:If a new connecting arm is installed (such as to increase the maximum turning angle), the steering geometry is changed and may cause tire wear. Check the Meritor Technical Service Aid Manual, TSA- 87121 to choose the correct connecting arm. Contact your Meritor service representative.

CAUTION:TIgHTEN THE NUTS WITH THE SPECIFIED TORqUE. IF THE NUTS ARE NOT TIgHT-ENED WITH THE SPECIFIED TORqUE, THE PARTS MAy bE DAMAgED.

3. Install the nut on the connecting arm. Tighten with the specified torque. See theTorque Table.

Torque

American axles20 a 30 ft-lbf27 a 41 N.m

FD and FF Axles (Brazil)

13 a 17 ft-lbf 17 a 23 N.m

MFS-06(5301)andMFS-07(FC845)Axles(Brazil-threaded cover)

45 a 55 ft-lbf 60 a 75 N.m

Figure 90

CONNECTING ARM

PIVOT

Installation


4. Install the cotter pins. If necessary, tighten the nut until the holes are aligned. Do not loosen the nut to install the cotter pin.

NOTE:The tie bar has a right thread at one end and a left thread at the other. Check that the piv-ots are installed on the bar.

5. If removed, install the pivots on the tie rod in the position marked during removal. Fig-ure 91.

If new connecting arms are installed, screw the pivots equally on the tie bar to the necessary length.

6. Install the nuts and bolts on the clamps. Tightenwiththespecifiedtorque.

7. The rotating type clamp on the tie bar may be turned to facilitate installation of the bolt andnut.Tightenthenutsufficientlytofastenthe locking element of the nut with the bolt. The clamp and the bar must be free to turn. Figure 92.

8. Connect the tie bar on the connecting arms. 9. Install the nuts on the pivots. Tighten with

thespecifiedtorque.SeeTorqueTable. 10. Install the cotter pins. If necessary, tighten

the nut until the holes are aligned. Do not loosen the nut to install the cotter pin.

11. Check the camber adjustment if necessary. See the Adjustment section.

Figure 91

Figure 92

TIE BARPIVOT

MARKS

PIVOT

CLAMP

TIE BAR

NUTANDBOLT

59

Installation

MAINTENANCE MANUAL

Installation of the steering arm See Figure 93.1. Press the key in the slot of the arm. 2. Install the steering arm on the stub axle. 3. Connect the steering arm to the tie rod.

CAUTION:TIgHTEN THE NUTS WITH THE SPECIFIED TORqUE. IF THE NUTS ARE NOT TIgHT-ENED WITH THE CORRECT TORqUE, THE PARTS MAy bE DAMAgED.

4.Install the nuts. Tighten with the specifiedtorque. See Torque Table.

5.Install the cotter pins. If necessary, tighten the nut until the holes are aligned. Do not loosen the nut to install the cotter pin.

6. Lubricate the steering arm. See the Lubrica-tionandMaintenancesection.

7. Check if it is operating correctly.

Installation of the Tie RodSee Figure 94.1. Connect the tie rod on the steering arm.2. Connect the tie rod on the Pitman arm.

CAUTION:TIgHTEN THE NUTS WITH THE SPECIFIED TORqUE. IF THE NUTS ARE NOT TIgHT-ENED WITH THE CORRECT TORqUE, THE PARTS MAy bE DAMAgED.

3.Install the nuts. Tighten with the specifiedtorque. See Torque Table.

4. Install the cotter pins. If necessary, tighten the nut until the holes are aligned. Do not loosen the nut to install the cotter pin.

5. Lubricate the tie rod. See the Lubrication and Maintenancesection.

6. See if it is operating correctly.

Figure 93 Figure 94

STEERING ARM

TIE BAR

PITMANARM

TIEROD

STEERING ARM

Torque specifications



ILLUSTRATIONOFTORQUEOFTHEFRONTAXLE

61


MAINTENANCE MANUAL

TORQUESPECIFICATIONSOFTHEFRONTAXLE

ITEM DESCRIPTION THREAD SIZE SPECIFIED TORqUE

ft-lbf N.m

01 Nut for fastening the steering arm on the tie rod

5/8” - 16 60 - 115 82 - 1555/8” - 18 60 - 115 82 - 1553/4” - 16 90 - 170 123 - 2307/8” - 14 160 - 300 217 - 407

02 Cover bolt stub axle 5/16” - 18 20 - 30 28 - 40

03 Fastening bolt of the steering arm on the stub axle

7/8” - 14 250 - 450 339 - 6101” - 14 390 - 725 529 - 982

1-1/8” - 12 550 - 1025 746 - 13891-1/4” - 12 775 - 1450 1051 - 19651-1/2” - 12 1350 - 2525 1831 - 3423

04 Key nut 7/16” - 20 30 - 45 41 - 6105 Adaptor limiter bolt 3/4” - 10 65 - 115 85 - 15506 Checknut limiter bolt 1/2” - 13 50 - 75 68 - 10107 Checknut limiter bolt 3/4” - 10 65 - 85 88 - 115

08Fastening nut of the connect-ing arm on the terminal of the

tie bar

7/8” - 14 160 - 300 217 - 4061” - 14 250 - 450 339 - 610

1 1/8” - 12 350 - 650 475 - 8811 1/4” - 12 500 - 675 678 - 915

09 Clamp nut of the tie bar 5/8” - 11 40 - 60 55 - 813/4” - 10 155 - 175 211 - 237

10 Fastening nut of the connect-ing arm on the stub axle.

7/8” - 14 250 - 450 339 - 6101” - 14 390 - 725 529 - 982

1 1/8” - 12 550 - 1025 746 - 13891 1/4” - 12 775 - 1450 1050 - 19651 1/2” - 12 1350 - 2525 1831 - 3423

11 Cover of the stub axle (threaded) 2” - 20 60 - 90 80 - 120

12 Lubrication pin 1/4” - 27 10 14

Special tools


Special tools

NOTE:1. Requests for Kent-Moore, 28635 Mound Road, Warren, MN 55060.2. Requests for Owatona Tool and Equipment OTC Tools Division, 655 Eisenhower Drive,

Oeatona, MN 55060.3. Find your local Snap-On supplier.4. Use the basic kit for own use for the axis model.

DescriptionTool numberKent-Moore 1

Tool numberOwatona 2

Tool numberSnap-on 3

King pin remover 4240 4240

20 TON:GC430HYB

35 TON:CG730HY

Kit for King pin bushBasic kit

Kit Series FF - e FG - Kit serie FL -

4PT 4375-APT 4370-10PT 4370-20

MAINTENANCE MANUAL

AlwaysusetheTechnicalManualsfrom...

Always use original parts

For more details, see the Spare Parts Catalog

Customer service

0800 55 55 30

PurchasetheCD-ROMfailureanalysisofcomponentsoftheaxistraction

Customer ServiceAv. João Batista, 825 - Osasco - SP - 06097-105

0800 55 55 30

AfterMarket(Replaceparts)Rod. Presidente Castelo Branco Km 30,5 - n° 11.250 - Barueri - SP - 06421-400

0800 55 55 30

www.meritor.com/brasil

Documents

Manual Eixo Dianteiro 2012-06 ING