Dana Spicer Axles & Brakes

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Dana Spicer Axles & Brakes Information Bulletin ABIB-0316 Bulletin Type: Service Information Topic: The Importance of Steer Axle Kingpin Joint Over Haul Repair Procedures Affected Models: All Dana

1 Dana Spicer Axles & Brakes Information Bulletin ABIB-0316 Bulletin Type: Service Information Topic: The Importance of Steer Axle Kingpin Joint Over Haul Repair Procedures Affected Models: All Dana Steer Axles Dana service manual AXSM-0038 gives step-by-step overhaul procedures that must be followed to insure that a proper repair is done when overhauling the kingpin joint. This bulletin stresses the critical areas of these recommended repair procedures and the Failure Condition associated with them if not followed. KINGPIN JOINT INSPECTION VERTICAL PLAY MEASUREMENT BUSHING INSTALLATION KNUCKLE SEAL INSTALLATION DRAW KEY INSTALLATION KINGPIN JOINT LUBRICATION Vertical and Endplay measurements must be within proper specifications after doing a repair. Kingpin bushings and knuckle seals must be installed at the correct depth, bushing seams must be installed in the correct clocking position. Along with the proper installation of the Draw Keys, the use of proper bushing and seal installation tools are important. Adhering to proper kingpin joint lubrication is critical to the enhancement and longevity of the steer axle components and related components, such as tires. As a quick reference handout for your maintenance shop, print out and laminate pages 2-4! This bulletin contains product information. Dana Corporation is not committed or liable for canvassing existing product.

2 Kingpin Joint Inspection Use a dial indicator to measure the endplay of the kingpin joint. This measurement will tell you the amount of movement between the kingpin and the bushings. The movement should not exceed.015. If the movement measures more than.015 the bushings should be replaced. Endplay measurement should always be taken after a repair has been completed. Endplay should not exceed.008. FAILURE CONDITION: Failure to maintain proper kingpin joint endplay may cause premature tire and/or bushing wear. Measure Top Bushing Measure Lower Bushing Vertical Play Measurements When shimming the knuckle assembly, use a jack and a piece of wood to push up on the bottom of knuckle. This will compress the thrust bearing joint and make it easier to add shim. Add as much shim as you can, try to use one or two thicker shims in place of many thin shims. Example: Better to use one.0 and one.005 shim than two.015 and a.005 shims if you need.035 total. The vertical play should not be greater than to.005 is what you should shoot for. Push Up On The Bottom Of The Knuckle Verify That Vertical Play Is Between.001 and.005 FAILURE CONDITION: Failure to maintain proper vertical adjustment will cause premature bushing wear due to contamination ingestion. 2

3 Bushing Installation When installing the new bushing, position the seam as shown below. If the seam is not correctly positioned the life of the bushing will be dramatically reduced. X Bushing seam locate in either area marked "X" 90 X Bushings must be installed at the correct depth. Use the chart below to determine the depth of the bushing for the axle model you are working on. FAILURE CONDITION: If the bushing is installed to high in the knuckle bore the chamfer of the kingpin will cause damage to the bushing material. This will reduce the life of the bushing. Bushing Bushing Recess Bushing From Top of Knuckle Surface Axle Type Bushing Depth E - Family.55" EFA- Family.25" I1SG, I160SG, I180SG,.0" I1SA/GA, I1SA/GA, I146SA/GA 1.22" Bushing Depth Chart Knuckle Seal Installation All Dana knuckle seals have an installation depth of.060. It is important that the seal is installed straight in the bore, always use a piloted seal driver. Make sure that the seal lip of the seal is pointing towards the center of the knuckle as shown in the figure below. Grease Seals Install Top Seal Lip Down Install Bottom Seal Lip Up Seal Installed at.060 Depth Seal Lips Point to Center of Knuckle FAILURE CONDITION: Improper seal installation may cause premature bushing wear due to contamination ingestion. If a grease seal is installed with the lip of the seal facing the wrong direction you will be unable to grease the joint properly. 3

4 Draw Key Installation Single and Dual When installing the draw keys it is important that the ramp on the key lines up with the slot in the kingpin. See figure below. Correct Incorrect Use a hammer and a drift to seat the draw keys. Now install the washers as show in the figure below. Install the nut and torque to spec. Important *** The draw keys must always be reseated after torquing the nut. Using a hammer and drift, reseat the draw keys. Now retorque the nut. E-Series Duel Draw Key I-Series Dual Draw Key FAILURE CONDITION: Failure to reseat draw keys will cause the kingpin to loosen in the bore of the steer beam. This condition will cause wear to the beam bore and the kingpin that will lead to the replacement of the steer axle beam. Kingpin Joint Lubrication Proper lubrication practices are important in maximizing the service life of the kingpin joint. There are 3 important steps to follow went greasing a kingpin joint. Grease Type: Always use a heavy-duty multipurpose lithium base (#2 grade) grease. Do not mix with sodium-based grease. Grease Intervals: Grease intervals will change depending on the environment that the vehicle is running. Contamination is the leading cause of premature bushing wear, so understanding how often to grease for your application becomes critical for long bushing life. Grease Procedure: The most important thing to remember when greasing a kingpin joint is you must pass enough grease through the system to purge out any contamination. It takes only a small amount grease to keep the kingpin joint lubricated if contamination is not present. A kingpin joint is designed so that grease will flow through the cap, past the bushings, past the grease seal and through the thrust bearing and/or shim pack. Greasing should continue until clean grease is observed coming from between the joints components. 4

For spec ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 8-332-1515). Or visit our web site at: http://www.roadranger.

5 For spec ing or service assistance, call HELP (4357) 24 hours a day, 7 days a week, (Mexico: ). Or visit our web site at: Dana Corporation ABIB-0316 Copyright Dana Corporation, 03 Commercial Vehicle Axle Division December 03 All Rights Reserved. P.O. Box 97 Printed in U.S.A. Kalamazoo, MI

PRE-ALIGNMENT INSPECTION

PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional