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MCi 102D Series Maintenance Manual

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102D SERIES MAINTENANCE MANUAL
FRONT AXLE 16,000 LBS GAWR
SUBJECT
General Description
Components
Maintenance
Lubrication
Troubleshooting
Specifications
Fastener Torque Chart
Service Tools
GENERAL DESCRIPTION
The front and trailing axle assemblies are drop center
cast or forged beam design with forged steel knuckle pin
ends (Figure 1). Knuckle pin ends are integral parts of the
axle center beam.
Steering knuckles have grease fittings in both knuckle
pin bosses for lubrication of the knuckle bushings. The
bushings are of the Easy Steer" type. Covers and plugs
prevent dust and moisture from entering bushings and
serve as seals.
Identification
The axle model number identification plate is on the
axle center. Use the model number to order the correct
parts (Figure 2).
COMPONENTS
Axle Beam
WARNING
Do not attempt to straighten the axle. Any
manipulation or straightening of the axle could
severely reduce load rating and driveability.
01-FRONT AXLE
SECTION 1B
CONTENTS OF THIS SECTION
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The axle beam is cast or forged. The other axle
components assemble to this part.
Tie rod assembly
The tie rod assembly attaches to the tie rod arm, and to
the axle through the steering arm and knuckles. It
maintains the correct steering geometry. The tie rod
assembly has an adjustable center section and sealed
replaceable ball joint ends.
Knuckle ends
Steering knuckles are attached to the axle ends with
straight king pins and are retained by a set of draw keys.
Knuckles are fitted with special king pin bushings. King
pin bushing covers, spacers and seals prevent dust and
moisture from entering the bushings.
Stop screws installed on each knuckle assembly limit
the wheels' turning angle. Knuckles mount all steering
and wheel end components: tie rod arms, brakes and
wheel bearings and hubs).
August 2000
Date
1B 1
Page
PAGE
1B 1
1B 1
1B 3
1B 20
1B 23
1B 27
1B 28
1B 30

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  • Page 1 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 1 Page SECTION 1B FRONT AXLE 16,000 LBS GAWR CONTENTS OF THIS SECTION SUBJECT PAGE General Description ..........

  • Page 2: Front Axle

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 2 Page Tie Rod Tie Rod Arm Threaded King Pin Cap Grease Fitting Steering Arm Shims Bushing Axle Tie Rod Arm Bearing Steering Knuckle King Pin Q Plus Cam Brake Bushing (Refer to Sect.

  • Page 3: Maintenance

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 3 Page 4. If the seal and ring are acceptable, try to move the tie rod cross tube by hand (Figure 3). If movement or looseness is detected, set up a dial indicator, (as shown in Figures 4 and 5).

  • Page 4: Removal And Disassembly

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 4 Page REMOVAL AND DISASSEMBLY Tie rod, tie rod arms and tie rod ends WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.
  • Page 5 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 5 Page 8. Remove the tie rod arms from the knuckle. You may have to tap on the end of the arm with a leather or plastic mallet to separate the arm from the knuckle.
  • Page 6 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 6 Page 5. Use a brass drift and hammer (Figure 10) to CAUTION remove the king pins from the knuckle. If the king pin is difficult to remove, use a hydraulic king pin remover. (See the Service Tools subsection at the end of this document).
  • Page 7 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 7 Page REPAIRING PARTS WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Repairing or reconditioning front and trailing axle parts is prohibited.

  • Page 8: Inspecting Parts

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 8 Page solution tanks with a weak alkaline solution. The parts must stay in the hot solution tanks until they are completely cleaned and heated. Drying cleaned parts Parts must be dried immediately after cleaning. Dry the parts with clean paper or rags, or with compressed air.
  • Page 9 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 9 Page Table 1 Axle Wear Limit Specifications Knuckle bore: maximum Beam bore: maximum Knuckle bushing bore: maximum diameter inches (mm) diameter inches (mm) diameter inches (mm) 1.922 (48.818) 1.7980 (45.6692) 1.796 (45.618)
  • Page 10 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 10 Page FIGURE 19. Roller cage wear indicators f. Damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers (Figure FIGURE 17. Wear indicators 20).

  • Page 11: Assembly And Installation

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 11 Page ASSEMBLY AND INSTALLATION 5. Press the bushing into the bore until the bottom of the bushing is 0.148 to 0.178 inch (3.75 to 4.52 mm) above the bottom of the knuckle bore (Figure 23).
  • Page 12 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 12 Page 8. Clean all material from the bushings, knuckle, and king pin cap threads. Installing the inner knuckle bushing seal 1. Place the knuckle in a vise with brass jaws, so that the vise jaws hold the top of the knuckle.
  • Page 13 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 13 Page 3. Use a brass drift, a hammer, and the correct size driver or socket to install the seal. Install the seal until the top of the seal is even with the knuckle's machined surface (Figure 26).
  • Page 14 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 14 Page b. If a new shim pack must be used, select the b. Install the king pin in the top of the knuckle. amount of shims that will give the least end play: 0.001 Make sure the word TOP"...
  • Page 15 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 15 Page NOTE: Do not drive the draw keys into the knuckle until after the end play is checked and adjusted. MAGNETIC BASE LOCATED AT EITHER PLACE Figure 33. Dial Indicator Installation d.
  • Page 16 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 16 Page Put a block of wood and a hydraulic jack under the bottom of the knuckle. Raise the knuckle until the pointer on the dial indicator stops (Figure 35).
  • Page 17 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 17 Page 14. Install the outer wheel bearing cone in the hub. 15. Adjust the wheel bearings. See the following subsection, titled Adjustments." 16. Install the hub and gasket on the knuckle. Install the capscrews and tighten them to 20 to 30 lb ft (27 to 41 N m).
  • Page 18 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 18 Page ADJUSTMENTS Wheel bearings WARNING Support the vehicle with safety stands. Do not work under a vehicle supported only with jacks; jacks can slip or fall over and cause serious personal injury or death.
  • Page 19 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 19 Page 2. Measure the end play by pushing or pulling on 0.005 inch (0.127 mm) reduce the amount the adjusting each side of the hub while looking at the dial indicator.
  • Page 20 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 20 Page NOTE: The stop bolt should NOT touch the beam. it c. T ighten the jam nut to 65 to 85 lb ft (68 to 101 should always have a minimum clearance of 0.125 N m).

  • Page 21: Lubrication Schedule

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 21 Page LUBRICATION SCHEDULE LUBRICATION PROCEDURE King pins King pins, tie rod assemblies, and ball studs 1. Make sure the tires touch the ground. DO NOT Lubricate king pins, bushings, and the ends of cross raise the vehicle.
  • Page 22 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 22 Page 3. Apply lubricant until new lubricant comes out of the boot (Figure 46). LUBRICANT MUST COME FROM HERE Figure 46. Lubrication of cross tube Oil lubricated wheel bearings Check the level on the cap.

  • Page 23: Troubleshooting

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 23 Page TROUBLESHOOTING Use the following table to troubleshoot axle problems. Condition Cause Correction Tires wear out quickly or 1. Incorrect tire pressure 1. Put specified pressure in tires have uneven tire wear 2.
  • Page 24 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 24 Page Inspection WARNING WARNING Support the vehicle with safety stands. Do not work under a vehicle supported only with jacks; jacks can slip or fall over and cause serious To prevent a serious eye injury, always wear safe personal injury or death.
  • Page 25 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 25 Page NOTE: If one bushing requires replacement, replace both bushings in the knuckle. 5. Set the dial indicator to zero. 6. Use the pry bar to push the knuckle upward.
  • Page 26 102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 26 Page Tie rod ends 8. Set the dial indicator to zero. 1. Park the vehicle with the steering wheel in the 9. Move the bottom of the tire side to side towards straight ahead position.

  • Page 27: Specifications

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 27 Page SPECIFICATIONS LUBRICANT SPECIFICATIONS: FRONT AND TRAILING AXLE Description Lubricant specification Spindle pins, bushings, ends of tie Chassis grease, 6% 12 hydroxy lithium stearate grease, NLGI Grade No. rods, drag link ball studs, wheel bear 1, Rockwell specification 0 617 A or equivalent.

  • Page 28: Fastener Torque Chart

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 28 Page FASTENER TORQUE CHART...

  • Page 29: Special Tools

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 29 Page Torque Chart (Cont.) Torque Value Range Lb Ft Item Description Size Tie rod arm nut 1.125"-12 775 to 1050 1050 to 1425 Tie rod end nut 0.875"-14 160 to 215...

  • Page 30: Service Tools

    102D SERIES MAINTENANCE MANUAL August 2000 Date 01-FRONT AXLE 1B 30 Page SERVICE TOOLS MANY TOOLS LISTED IN THIS SECTION ARE SPECIALLY DESIGNED TO MEET THE NEEDS OF VARIOUS SERVICE OPERATIONS. THEY ARE AVAILABLE FOR PURCHASE THROUGH MOTOR COACH INDUSTRIES, SERVICE PARTS DIVISION AND UNIVERSAL COACH PARTS OR, WHERE PRACTICAL, MAY BE MANUFACTURED BY THE OPERATOR.

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