MCi 102D Series - User Manual

102D SERIES MAINTENANCE MANUAL
01-FRONT AXLE
1BĆ1
Page
August 2000
Date
SECTION 1B
FRONT AXLE 16,000 LBS GAWR
CONTENTS OF THIS SECTION
SUBJECT PAGE
General Description 1BĆ1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components 1BĆ1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 1BĆ3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 1BĆ20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 1BĆ23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1BĆ27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torque Chart 1BĆ28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tools 1BĆ30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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).

Summary

SECTION 1 B FRONT AXLE

General Description

Overview of the front axle assembly design, including beam type and steering knuckle features.

Axle Components Identification

Details on identifying the axle model number and its main parts for ordering.

FRONT AXLE MAINTENANCE PROCEDURES

Tie Rod End Inspection

Steps for inspecting tie rod ends for wear and damage to ensure proper alignment.

King Pin Bushing Inspection

Methods for measuring king pin bushing inside diameter and checking for wear.

Wheel Bearing Inspection

Procedures to inspect wheel bearings for wear, damage, and proper function.

FRONT AXLE REMOVAL AND DISASSEMBLY

Tie Rod Assembly Removal

Detailed steps for removing tie rod, arms, and ends from the axle.

Knuckle and King Pin Removal

Instructions for removing the steering knuckle, king pin, and associated components.

Bushing Removal Process

Procedures for removing king pin bushings from the knuckle assembly.

FRONT AXLE ASSEMBLY AND INSTALLATION

Bushing Installation and Reaming

Guide for installing new king pin bushings and reaming them to specified dimensions.

King Pin Installation and End Play Adjustment

Steps for installing the king pin and adjusting end play using shims.

Tie Rod Assembly Installation

Procedures for reinstalling tie rod ends and arms with correct torque values.

AXLE ADJUSTMENTS AND SPECIFICATIONS

Wheel Bearing Adjustment

How to adjust wheel bearing end play to the specified limits.

Steering Stop Adjustment

Procedure for setting the vehicle's maximum steering turn angle.

Lubricant Specifications

Details the types of lubricants required for various axle components.

Alignment Data

Key alignment parameters including Camber, Caster, and Toe-In.

TROUBLESHOOTING AND GENERAL INSPECTION

Troubleshooting Common Axle Issues

Table of problems, causes, and corrections for axle operation.

General Inspection Procedures

Covers inspection of fasteners, wear, damage, pivot points, and operation.

Steering Knuckle End Play Measurement

Method for checking vertical end play in the steering knuckle assembly.

FASTENER TORQUE AND SPECIAL TOOLS

Fastener Torque Chart

A list of torque values for critical fasteners on the front axle.

Specialized Service Tools

Identifies specific tools needed for front axle maintenance and repair.

MCi 102D Series Specifications

General

Brand	MCi
Model	102D Series
Category	Lighting Equipment
Language	English