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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

0152-P-002-0114

TAK-4 INDEPENDENT FRONT SUSPENSION


1. INTRODUCTION
This TAK-4 suspension is an independent, non-driving
torsion bar design, with four available weight ratings: 18K,
19.5K, 22.8K, and 24K. This choice of weight ratings will
allow the addition of more features and equipment without
exceeding GVW restrictions. Front braking is accomplished
by ABS-controlled, self-adjusting pneumatic disc brakes.
The main steering system components are the primary and
secondary hydraulic-assist-type steering gears. The
steering gears are connected together by a non-adjusting
tie link to ensure gear synchronization. Steering motion out
to the wheel ends is through adjustable toe links that
connect the steering gear pitman arms to the steering arms
on each wheel end. This independent suspension has nonadjustable 4 caster, -0.5 camber, and 6 kingpin
inclination angles. The only adjustable setting is the toe-in.
The upper and lower control arms are the attachment point
for the wheel end assemblies. Shock absorbers control
wheel end dampening.

4. Jack up the wheel/tire assembly until the tire is no


longer touching the ground.
NOTE: For repairs that require the frame to be
supported, position suitable jack stands, evenly
spaced, under both of the side plates.
5. Support the lower control arm with a safety stand.

3. PNEUMATIC DISC BRAKE CALIPER


REPLACEMENT
a. Removal
1. Drain the air system completely. (Refer to Operation &
Maintenance Manual.)
2. Attach a DO NOT START tag to truck ignition switch.
3. Remove the wheel/tire assembly. (See Front Wheel
and Tire Service, Group 0705-P-001.)
5

The wheel hubs ride on tapered roller bearings and are gear
oil filled or grease packed.
This maintenance manual covers the removal, repair,
cleaning, adjustment, and installation of the TAK-4
suspension components.

12

2. JACK POSITIONING PROCEDURE

! WARNING
DO NOT get under the truck in any way after it is
raised unless the truck is supported with safety
stands or blocks. The hydraulic jack is used for
lifting the vehicle only, and not for supporting the
vehicle in the raised position. Failure to correctly
support the truck could let the truck fall, causing
serious injury or death.
1. Make sure truck is on a level surface.

! WARNING

10
11

12
16

15

Place blocks under the wheels not being serviced


to keep the vehicle from moving, which may
cause personal injury.
NOTE: Refer to Front Wheel and Tire Service, Group
0710-P-001 for additional instructions on removing
the wheel/tire assembly.
2. Block the wheels to prevent the vehicle from moving.
3. Locate a suitable hydraulic jack under the lower control
arm. Position jack so that it supports the lower control
arm under the shock mount.
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13 14

4. Remove screw (1), locknut (2), and cushion clamp (3).


NOTE: Note routing of ABS wire harness to ensure
correct installation.

TAK-4 INDEPENDENT FRONT SUSPENSION

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FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

5. Cut cable ties (4) holding ABS wire harness (5) to air
brake line (6) as needed.
6. Remove air brake line (6) from the brake chamber (7).
7. Remove three short screws (8) and washers (9).

1. Apply Loctite 242 (Pierce P/N 1198896) to screws


(8 and 10) and shoulder bolt (13) threads.

NOTE: Note the orientation of the stand-off bracket


before removing to ensure correct installation.

NOTE: Install the stand-off bracket in the same


orientation as noted during removal.

8. Remove two long screws (10), washers (11), and


stand-off bracket (12).
9. Remove socket-head shoulder bolt (13) and washer
(14), and remove brake caliper (15) from the steering
knuckle (16).

b. Installation
5

12

NOTE: Check the service interval for the truck and


service the brake caliper if close to the
recommended service interval. (Refer to
Operation & Maintenance Manual.)

2. Install brake caliper (15) on the steering knuckle (16)


using three short screws (8) and washers (9), two long
screws (10), washers (11), stand-off bracket (12),
shoulder bolt (13) and washer (14).
NOTE: Connect brake lines to the same locations as
noted during removal.

3. Install air brake line (6) on the brake chamber (7).


4. Apply Loctite 242 (Pierce P/N 1198896) to threads of
screw (1).

5. Install the air line cushion clamp (3) using screw (1) and
locknut (2).
6. Tighten three short screws (8) and two long screws (10)
to 180 lb-ft (244 Nm).
7. Tighten shoulder bolt (13) to 190 lb-ft. (258 Nm).
8. Apply Sentry Seal (Pierce P/N 95-1356) to screws (1,
8, and 10) and shoulder bolt (13).

9. Secure ABS wire harness (5) to air brake line (6) using
cable ties (4) as needed.

10. Adjust brake caliper to specifications. (See Bendix


SN7 Air Disc Brakes, Group 0251-V-005.)

10
11

12
16

15

11. Install the wheel/tire assembly. (See Front Wheel and


Tire Service, Group 0705-P-001.)
12. Remove the jack stand and lower the wheel/tire
assembly to the ground.
13. Remove DO NOT START tag from truck ignition
switch.

13 14

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
Page 1-2

14. Verify proper operation of the brake system. Stops


should be consistent and free from vibration or pulling.
DO NOT OPERATE OR RELEASE A TRUCK FOR
SERVICE WITH A KNOWN BRAKE PROBLEM.

4. PNEUMATIC DISC BRAKE CALIPER AND


BRAKE CHAMBER REPAIR
See Bendix SN7 Air Disc Brakes, Group 0251-V-005 for
repair of the pneumatic disc brake caliper, and for removal
and installation instructions of the pneumatic disc brake
chamber.

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

5. WHEEL HUB REPLACEMENT


a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove the wheel/tire assembly. (See Front Wheel
and Tire Service, Group 0705-P-001.)
3. Remove brake caliper. (See Pneumatic Disc Brake
Caliper Replacement on page 1-1)
2

NOTE: Place a drain pan under the wheel hub to catch


oil dripping from hub cap and wheel hub.
4. Remove six screws (1), lockwashers (2), and the hub
cap (3).
5. See Wheel Bearing Adjustment on page 1-4 for
removal and installation instructions for the spindle nut
(5) and outer wheel bearing (6).

! WARNING
The wheel hub assembly weighs an estimated
180 lb (82 kg). Have an assistant help during
removal or use a suitable lifting device. Failure to
comply could result in injury to personnel.
6. Remove wheel hub assembly (7) from steering knuckle
(8).
7. Inspect hub assembly components. Repair or replace
components as needed. (See Wheel Hub Assembly
Repair on page 1-5)

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Page 1-3

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

b. Wheel Bearing Adjustment

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TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

c. Installation
2

6. WHEEL HUB ASSEMBLY REPAIR


6

a. Disassembly
1. Remove wheel hub. (See Wheel Hub Replacement
on page 1-3)
5

6
1
8

9
7

1. Position wheel hub assembly (7) over steering knuckle


(8).
2. See Wheel Bearing Adjustment on page 1-4 for
outer wheel bearing (6) and spindle nut (5) installation
information.

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
3. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (1).
4. Apply Loctite 592 (Pierce P/N 95-1305) to the hub cap
(3) flange, and install the hub cap (3) with six
lockwashers (2) and screws (1). Tighten screws to 13
lb-ft (18 Nm).
5. Wheel hubs can be lubricated either by oil or grease:
Oil-Filled Wheel Hubs: Fill the hub cavity with gear oil
through the fill plug in the hub cap until oil is at full mark.
Reinstall fill plug.

2. Remove ten screws (1) and brake rotor (2) from the
wheel hub (3).
3. Remove oil seal (4) and the inner bearing cone (5) from
the wheel hub (3).
NOTE: Ensure that the bearing cups are kept with their
mating cones.
4. Remove the inner (6) and outer (7) bearing cups from
the wheel hub (3).
NOTE: The ABS exciter ring is a shrink fit on the wheel
hub. Removal will require heat to be applied to the
ring to expand it. Remove the ABS exciter ring only
if replacement is required.
5. Remove and discard ABS exciter ring (8) from the
wheel hub (3).
NOTE: The wheel studs are press fit in the wheel hub.
Remove the wheel studs only if replacement is
required.
6. If required, remove and discard the wheel studs (9)
from wheel hub (3).

Grease-Filled Wheel Hubs: Pack bearings with


grease. (See Wheel Bearings on page 1-74)
6. Install brake caliper. (See Pneumatic Disc Brake
Caliper Replacement on page 1-1)
7. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
8. Remove DO NOT START tag from truck ignition
switch.

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GROUP 0152-P-002-0114

b. Cleaning and Inspection

! WARNING
Dry-Cleaning Solvent (P-D-680) is TOXIC and
flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.
If personnel become dizzy while using cleaning
solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with
cold water. If solvent contacts eyes, immediately
flush eyes with water and get immediate medical
attention.

1. Large ends of rollers worn flush to the recess, or the


radii at the large ends of the rollers worn sharp.

1. Clean all metal parts with dry-cleaning solvent.


2. Inspect all parts for wear, nicks, burrs, or scratches.
3. Replace damaged parts.

c. Cleaning Ground and Polished Surfaces


Parts having ground and polished surfaces, such as
bearing assemblies, should be cleaned in a suitable
solvent, such as kerosene, diesel fuel oil, or dry-cleaning
solvent.

1. DRYING
Parts should be completely dried immediately after
cleaning. Use soft, clean, lintless absorbent paper towels,
or cloth free of abrasive material such as lapping
compound, metal fillings, or contaminated oil. Bearings
should never be dried by spinning with compressed air.

2. Visible step wear, particularly at the small end of the


roller track, or deep indentations, cracks, or breaks in
the bearing cup and/or cone surfaces.

2. CORROSION PREVENTION
Parts that have been cleaned, dried, and inspected, and
are to be immediately reassembled, should be coated with
light oil to prevent corrosion. If these parts are to be stored
for any length of time, they should be treated with a good
rust preventive and wrapped in special paper or other
material designed to prevent corrosion.

d. Inspection
Inspect the bearing cones and cups. If any bearings are
found to be defective, they must be replaced as a complete
set (cup and cone).

3. Bright rubbing marks on the dark phosphate surface of


the bearing cage.

If any of the following bearing conditions exist, bearings


must be replaced:
4. Etching or pitting on functioning surface.

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TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION


4. Wheel hubs can be lubricated either by oil or grease:
Oil-Filled Wheel Hubs: Apply gear oil to the inner
bearing cone (5) and cup (6) and install the inner
bearing cone in the wheel hub (3).
Grease-Filled Wheel Hubs: Apply grease to the inner
bearing cone (5) and cup (6) and install the bearing
cone in the wheel hub (3).
NOTE: Always use new seals for installation.
5. Apply gear oil or grease to the oil seal lips and install the
seal (4) using a suitable driver. Ensure the seal is
seated squarely in the wheel hub bore.

! WARNING
5. Spalling or flaking on the bearing cup and/or cone
surfaces.

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

e. Assembly
5

6. Apply a SMALL amount of anti-seize compound


(Pierce P/N 95-0809) on the brake rotor (2) face where
it contacts the hub. Remove any excess with a clean
rag and brake cleaner.

7. Apply Loctite 242 (Pierce P/N 1198896) to all screw


threads (1).
9

1. If removed, install the wheel studs (9) in the wheel hub


(3).
NOTE: Apply heat to ABS exciter ring to expand it
enough for installation on wheel hub. Use an oven
at a setting no higher than 500F (260C). Do not
use a torch to heat the hub.
2. If removed, install ABS exciter ring (8).
3. Install the inner (6) and outer (7) bearing cups in the
wheel hub (3). Ensure cups are fully seated in the
wheel hub bores.

8. Install the brake rotor (2) on the wheel hub (3) with ten
screws (1). Tighten screws to 220 lb-ft (298 Nm)
following a standard cross-torque sequence.
9. Apply Sentry Seal (Pierce P/N 95-1356) to the wheel
hub screws (1).
10. Install wheel hub. (See Wheel Hub Replacement on
page 1-3)

7. WHEEL END ASSEMBLY REPLACEMENT


a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3. Unload the torsion bar, by jacking up the frame and
allowing the control arms to hang down.

NOTE:
The preferred wheel end lube is SAE 75w90 GL5
synthetic gear oil. Additional approved lubes
include SAE 85w140 GL5 and SAE 80w90 GL5
gear oil.
The preferred wheel bearing grease is a Lithium
NLGI grade EP2 grease.

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FRONT AXLE & SUSPENSION

7. Remove cotter pin (8), castle nut (9), and toe control
link (10) from steering arm (11). Discard the cotter pin.

GROUP 0152-P-002-0114

12
16
~

13

14
15

6
4
Lower Ball Joint

! CAUTION
Use caution when removing the ABS sensor. Do
not pull on the wire harness to remove it. Possible
damage to the sensor could occur if sensor is
removed by pulling on the wire harness.

8. Grasp the ABS sensor body (12) and pull out of the
bushing in the steering knuckle (13).
4. Remove screw (1), locknut (2), and cushion clip (3).
NOTE: Note routing of ABS wire harness to ensure
correct installation.
5. Cut cable ties (4) holding ABS wire harness (5) to air
brake lines (6) as needed.
6. Remove air brake line (6) from the brake chamber (7).

! WARNING
The wheel end assembly is heavy and must be
supported. Use a suitable lifting device to support
the wheel end assembly before removing the ball
joint nuts. Failure to comply could result in injury
to personnel.
9. Remove nut (14) and washer (15) from the lower ball
joint stud (16).

10

8
11

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TAK-4 INDEPENDENT FRONT SUSPENSION

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b. Installation

18
18
17
17

19

19

Upper Ball Joint

Upper Ball Joint

! CAUTION
Ensure assistant is holding steering knuckle
securely. Failure to comply may result in damage
to equipment.
11. With the aid of an assistant and a pry bar, apply
pressure between steering knuckle (13) and upper and
lower control arm ball joints, while hammering on side
of the steering knuckle.

12
16

13
~

10. Remove nut (17) and washer (18) from the upper ball
joint stud (19).

14
15

12. Remove the wheel end assembly using a suitable lifting


device.

Lower Ball Joint

! WARNING
The wheel end assembly is heavy and must be
supported. Use a suitable lifting device to support
the wheel end assembly. Failure to comply could
result in injury to personnel.

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GROUP 0152-P-002-0114

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

1
2
3

1. Install the steering knuckle (13) on the upper (19) and


lower (16) control arm ball studs.
2. Apply Loctite 242 (Pierce P/N 1198896) to ball stud
threads. Install a washer (15 or 18) and nut (14 or 17)
on each ball joint stud. Tighten the nuts to 600 lb-ft (814
Nm).
3. Apply Sentry Seal (Pierce P/N 95-1356) to the upper
and lower ball joint nuts (14 and 17) and washers (15
and 18).
NOTE: Grease must be mineral oil-based and contain
molydisulfide. It should have excellent anticorrosion and adhesion characteristics, and be
capable of continuous function within a
temperature range of 40 to 300F
(40 to 150C).

6
4

4. Apply grease (Pierce P/N 1234272) and install the ABS


sensor (12) in the steering knuckle (13).

7. Route air brake line (6) to brake chamber (7) as noted


during removal.
10

NOTE: Connect brake lines to the same locations as


noted during removal.
8. Connect air brake line (6) to brake chamber (7).
NOTE: Always use new locknuts for installation.

8
11

NOTE: Toe control link taper and steering knuckle


socket must be clean and free of grease or oil.
5. Install the toe control link (10) on the steering arm (11)
using a castle nut (9). Tighten castle nut to 150 lb-ft
(204 Nm). If needed, continue to tighten the castle nut
until the cotter pin (8) can be installed.

9. Install cushion clip (3) using screw (1) and locknut (2).
10. Secure ABS wire harness (5) to air brake line (6) with
cable ties (4) as needed.
11. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
12. Remove DO NOT START tag from truck ignition
switch.

6. Install a new cotter pin (8) and bend over the cotter pin
ends.

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TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

8. SHOCK ABSORBER REPLACEMENT

a. Removal

! CAUTION
When removing shock absorbers, do not allow
wheel ends to hang without support. When shock
absorbers are not attached, the lower control arm
must be supported to prevent ball joint boot tears.

1. Attach a DO NOT START tag to truck ignition switch.


2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3. Support the wheel end assembly/lower control arm
using suitable lifting device.

10
12
11

5. Remove locknut (4), flat washer (5), two steel caps (6),
and rubber bushing (7) from the shock absorber piston
rod (8).

6. Remove shock absorber (2) from side plate (9).


7. Remove the spacer tube (10), rubber bushing (11), and
steel cap (12) from the shock absorber piston rod (8).

4. Remove two screws (1) and the shock absorber (2)


from the lower control arm (3).

b. Installation

! CAUTION
3 in. and 4 in. jounce suspensions use different
length shock absorbers that are not
interchangeable. 3 in. jounce shock absorbers
are shorter in length.

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GROUP 0152-P-002-0114

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

5. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads (1).
10

6. Install the shock absorber (2) on the lower control arm


(3) using two screws (1). Tighten screws to 210 lb-ft
(285 Nm).

12
11

7. Apply Sentry Seal (Pierce P/N 95-1356) to screws (1).

8. Install wheel/tire assembly. (See Front Wheel and Tire


Service, Group 0705-P-001.)
9. Remove DO NOT START tag from truck ignition
switch.

9. JOUNCE STOP REPLACEMENT


a. Removal
1. Install rubber bushing (11), steel cap (12), and spacer
tube (10) on the shock absorber piston rod (8).

1. Attach a DO NOT START tag to truck ignition switch.

2. Install shock absorber (2) in side plate (9).

2. Remove wheel/tire assembly. (See Front Wheel and


Tire Service, Group 0705-P-001.)

NOTE: Always use new locknuts for installation.


3. Install one steel cap (6), rubber bushing (7), steel cap
(6), flat washer (5), and locknut (4) on the shock
absorber piston rod (8). Tighten locknut to 59 lb-ft (80
Nm).

3. Place the suspension in rebound, by jacking up the


frame and allowing the control arms to hang down.
1

4. Apply Sentry Seal (Pierce P/N 95-1356) to locknut (4).


2

4. Remove the locknut (1), screw (2), and jounce stop (3)
from side plate (4).

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GROUP 0152-P-002-0114

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b. Installation

1. Attach a DO NOT START tag to truck ignition switch.


2. Remove the wheel/tire assembly. (See Front Wheel
and Tire Service, Group 0705-P-001.)

2
1

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
1. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (2).

3. Remove cotter pin (1), castle nut (2), and toe control
link (3) from steering arm (4). Discard the cotter pin.
4. Unload the torsion bar by jacking up the frame and
allowing the control arms to hang down.
9

NOTE:
Be sure the locknut is installed on the top of the side
plate.

Always use new locknuts for installation.

2. Install the jounce stop (3) on the side plate (4) with a
screw (2) and locknut (1). Tighten locknut to 120 lb-ft
(163 Nm).

3. Apply Sentry Seal (Pierce P/N 95-1356) to locknut (1).


4. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
5. Remove DO NOT START tag from truck ignition
switch.

10. UPPER BALL JOINT REPLACEMENT

! WARNING
The wheel end assembly is heavy and must be
supported. Use a suitable lifting device to support
the wheel end assembly before removing the ball
joint nuts. Failure to comply could result in injury
to personnel.
5. Remove nut (5) and washer (6) from the upper ball joint
stud (7).

a. Removal

! CAUTION

! CAUTION

The ball joint boot should be routinely inspected


for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69)

Ensure assistant is holding steering knuckle


securely. Failure to comply may result in damage
to equipment.

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6. With the aid of an assistant and a pry bar, apply


pressure between steering knuckle (8) and upper
control arm (9) ball joint while hammering on side of
steering knuckle.

7. Remove wheel end assembly from lower control arm.


(See Wheel End Assembly Replacement on
page 1-7)

b. Repair (Original Type)

1. DISASSEMBLY
Figure 1-1: Original Type Ball Joint

1. Remove ball joint boot ring (1) and boot (2) from ball
joint.
3

11

NOTE: In October 2013 a new design of ball joint was


phased into production. The original type ball joint
is identified by a plug at the top of the control arm
(see Figure 1-1), while the new ball joints can be
identified by a large nut in the same location.
If your vehicle is equipped with the original type ball
joint, proceed here. If your vehicle is equipped with
the new type ball joint, refer to Repair (New
Type) on page 1-17.
NOTE: The control arm upper ball joint can be replaced
either on or off the truck. The procedure is the same
unless noted.

! CAUTION
The ball joint boot should be routinely inspected
for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69)

9
10
8
7
6

5
2

NOTE: The thrust washer should be replaced when the


upper ball joint is replaced.
2. Remove plug (3) from upper control arm (4).
3. Remove ball joint snap ring (5), ball joint (6), large
diameter shim(s) (7), thrust washer (8), small diameter
shim(s) (9), and two roll pins (10). Do not discard.
NOTE: Perform step 4 if expansion plugs are damaged.
4. Remove expansion plugs (11) from upper control arm
(4).

Page 1-14

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

2. CLEANING AND INSPECTION

3. ASSEMBLY
3

! WARNING
Dry-Cleaning Solvent (P-D-680) is TOXIC and
flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.

11

1. Clean all metal parts with dry-cleaning solvent.

10

2. Inspect all parts for wear, nicks, burrs, or scratches.

8
7

12

5
2

NOTE: Perform step 1 if expansion plug was removed.


1. Install expansion plugs (11) on upper control arm (4).
3. Inspect control arm snap ring groove (12) for obvious
cracks or other damage.
4. Replace damaged parts.

2. Measure the height of original ball joint race. Record


this as dimension A.
3. Measure the thickness of the original large diameter
shims (7). Record this as dimension B.
4. Add height of original ball joint race (dimension A) to
large diameter shim (7) thickness (dimension B).
Record this as original overall height (dimension C).
Original ball joint
race height
Dimension A

Original large
+ diameter shim height =
Dimension B

Original overall
height
Dimension C

5. Measure thickness of new ball joint race. Record this as


dimension D.
6. Subtract new ball joint race height (dimension D) from
original overall height (dimension C). Record result as
new shim height (dimension E).
Original overall
height
Dimension C

New ball joint race


height
Dimension D

New large diameter


shim height
Dimension E

7. Using new large diameter shims (7), stack up enough


shims to equal the new shim height (dimension E).

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-15

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

13

6
2

12

8. Measure thickness of old thrust washer (8) and old


small diameter shims (9). Record this as small
diameter shim/thrust washer thickness (dimension
F).

12. Fill ball joint boot (2) with approximately three cubic
inches of grease (Pierce P/N 1234269).
NOTE:
Install ball joint boot ring before installing ball joint
boot.
Ensure ball joint boot is fully seated in upper control
arm bore.
Metal boot band must be flush with the face of the
control arm.
13. Install ball joint boot ring (1) and ball joint boot (2) on
upper control arm ball joint (6).

9
10

NOTE: When ball joint boot is seated in the control arm


bore, the rim of the ball joint boot will be positioned
slightly below the edge of the upper control arm
bore.

8
7

14. Using the boot driver (12) (Pierce Special Tool P/N
1422903), install the ball joint boot (2) in the upper
control arm bore (13).

9. Using new thrust washer (8) and new small diameter


shims (9), stack up enough shims to equal the small
diameter shim/thrust washer thickness (dimension
F).

10. Install roll pins (10). The roll pins must not extend past
the bottom plane of the thrust washer (8).
11. Install new small diameter shims (9), new thrust washer
(8), new large diameter shims (7), ball joint (6), and
snap ring.
4

15. Install plug (3) in upper control arm (4).


16. Refer to Installation on page 1-19 to reinstall the
assembly to the vehicle.

Page 1-16

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

c. Repair (New Type)


3

1. DISASSEMBLY
1

Figure 1-2: New Style Ball Joint

Shown Removed
From Vehicle For
Clarity
2. Remove nut (1) from top of ball joint (2).
3. Remove ball joint from control arm (3).

2. CLEANING AND INSPECTION

! WARNING
NOTE: In October 2013 a new design of ball joint was
phased into production. The new design ball joint
is identified by a large nut at the top of the control
arm (see Figure 1-2), while the original type ball
joints can be identified by a plug in the same
location.
If your vehicle is equipped with the new type ball
joint, proceed here. If your vehicle is equipped with
the original type ball joint, refer to Repair
(Original Type) on page 1-14.

Dry-Cleaning Solvent (P-D-680) is TOXIC and


flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.
1. Clean all metal parts with dry-cleaning solvent.

! CAUTION

2. Inspect all parts for wear, nicks, burrs, or scratches.


12

The ball joint boot should be routinely inspected


for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69).
Unstake nut at notch to
relieve locking feature

3. Inspect control arm cup (12) for obvious cracks or other


damage.
1. Unstake nut at the notch in the top of the ball joint to
relieve locking feature.

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4. Replace damaged parts.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-17

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

3. ASSEMBLY
Stake nut at notch to
lock nut in place
1

4
2

6. Stake the nut at the indentation on the ball joint to lock


nut in place.
Grease Application

7. Apply Sentry Seal (Pierce P/N 95-1356) to the nut and


control arm.
8. Refer to Installation on page 1-19 to reinstall the
assembly to the vehicle.

1. Install o-ring (4) onto ball joint (2).


2. Apply Dow Corning Molykote Longterm 2/78 grease
to control arm cup and ball joint as shown above.

Notch

3. Install ball joint (2) into control arm (3) and align so that
the notched area of the ball joint is aligned with the
notch on the control arm. The notch should be pointed
toward the vehicle.
4. Apply Loctite 242 (Pierce P/N 1198896) to the ball
joint threads.
5. Install retaining nut (1). Torque to 400 ft lbs (542 Nm)

Page 1-18

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

d. Installation

6. Install the toe control link (3) on the steering arm (4)
using a castle nut (2). Tighten castle nut to 150 lb-ft
(204 Nm). If needed, continue to tighten the castle nut
until the cotter pin (1) can be installed.

7. Install a new cotter pin (1) and bend over the cotter pin
ends.
8. Install the wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

7
6
5
8

9. Remove DO NOT START tag from truck ignition


switch.

11. LOWER BALL JOINT REPLACEMENT


a. Removal

! CAUTION

1. Using a suitable lifting device, install wheel end


assembly on lower control arm. (See Wheel End
Assembly Replacement on page 1-7)

The ball joint boot should be routinely inspected


for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69)

NOTE: Tapered socket in steering knuckle and control


arm assembly ball joint taper must be clean and
free of oil and grease.
2. Apply Loctite 242 (Pierce P/N 1198896) to the ball
joint (7) stud threads.

1. Remove wheel/tire assembly. (See Front Wheel and


Tire Service, Group 0705-P-001.)
3

3. Install the upper control arm assembly ball joint (7) in


the steering knuckle (8).
4. Install the washer (6) and nut (5). Tighten nut to 600 lbft (814 Nm).
5. Apply Sentry Seal (Pierce P/N 95-1356) to locknut (5)
and washer (6).
3

1
4

2. Remove cotter pin (1), castle nut (2), and toe control
link (3) from steering arm (4). Discard the cotter pin.
3. Unload the torsion bar, by jacking up the frame and
allowing the control arms to hang down.
1
4

NOTE: Toe control link taper and steering knuckle


socket must be clean and free of grease or oil.

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-19

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

b. Repair (Original Type)


6

1. DISASSEMBLY
Figure 1-3: Original Type Ball Joint

! WARNING
The wheel end assembly is heavy and must be
supported. Use a suitable lifting device to support
the wheel end assembly. Failure to comply could
result in injury to personnel.
4. Use a suitable lifting device to support the wheel end
assembly.
5. Remove two screws (5) and the shock absorber (6)
from the lower control arm (7).
11

NOTE: In October 2013 a new design of ball joint was


phased into production. The original type ball joint
is identified by a plug at the top of the control arm
(see Figure 1-3), while the new ball joints can be
identified by a large nut in the same location.
If your vehicle is equipped with the original type ball
joint, proceed here. If your vehicle is equipped with
the new style ball joint, refer to Repair (New
Type) on page 1-22.
NOTE: The control arm lower ball joint can be replaced
either on or off the truck. The procedure is the same
unless noted.

! CAUTION
The ball joint boot should be routinely inspected
for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69)

10

6. Remove locknut (8) and washer (9) from the lower ball
joint stud (10).

! CAUTION

Ensure assistant is holding steering knuckle


securely. Failure to comply may result in damage
to equipment.
7. With the aid of an assistant and a pry bar, apply
pressure between steering knuckle (11) and lower
control arm ball joint (10) while hammering on side of
steering knuckle.

Page 1-20

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

3. ASSEMBLY
2
5
6
7

1. Remove ball joint boot ring (1) and boot (2) from ball
joint.
2. Remove plug (3) from lower control arm (4).
3. Remove ball joint snap ring (5), ball joint (6), and large
diameter shim(s) (7). Do NOT discard.

1. Measure the height of original ball joint race. Record


this as dimension A.

2. CLEANING AND INSPECTION

2. Measure the thickness of the original large diameter


shims (7). Record this as dimension B.

! WARNING
Dry-Cleaning Solvent (P-D-680) is TOXIC and
flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.
1. Clean all metal parts with dry-cleaning solvent.
2. Inspect all parts for wear, nicks, burrs or scratches.
12

3. Add height of original ball joint race (dimension A) to


large diameter shim (7) thickness (dimension B).
Record this as original overall height (dimension C).
Original ball joint
race height
Dimension A

Original large
+ diameter shim height =
Dimension B

Original overall
height
Dimension C

4. Measure thickness of new ball joint race. Record this as


dimension D.
5. Subtract new ball joint race height (dimension D) from
original overall height (dimension C). Record result as
new shim height (dimension E).
Original overall
height
Dimension C

New ball joint race


height
Dimension D

New large diameter


shim height
Dimension E

6. Using new large diameter shims, stack up enough


shims to equal the new shim height (dimension E).
2
5
6
7

3. Inspect control arm snap ring groove (12) for obvious


cracks or other damage.
4. Replace damaged parts.

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-21

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

7. Install new ball joint (6) with new large diameter shims
(7).
8

10
1
2

11. Apply a bead of Dow Corning 732 Multi-Purpose


Silicone Sealant, Black (10) (Pierce P/N 95-1317)
around the base of the ball joint boot.

NOTE: Perform step 13 if plug was removed.


8. Fill ball joint boot (2) with approximately three cubic
inches of grease (Pierce P/N 1234269).

12. Install plug (3) in lower control arm (4).


13. Refer to Installation on page 1-24 to reinstall on the
vehicle.

NOTE:
Install ball joint boot ring before installing ball joint
boot.
Ensure ball joint boot is fully seated in lower control
arm bore.

c. Repair (New Type)


1. DISASSEMBLY
Figure 1-4: New Type Ball Joint

Metal boot band must be flush with the face of the


control arm.
9. Install ball joint boot ring (1) and ball joint boot (2) on
lower control arm ball joint (6).
NOTE: When ball joint boot is seated in the control arm
bore, the rim of the ball joint boot will be positioned
slightly below the edge of the upper control arm
bore.
10. Using the boot driver (8) (Pierce Special Tool P/N
1422903), install the ball joint boot (2) in the lower
control arm bore (9).

NOTE: In October 2013 a new design of ball joint was


phased into production. The new design ball joint
is identified by a large nut at the top of the control
arm (see Figure 1-4), while the original type ball
joints can be identified by a plug in the same
location.
If your vehicle is equipped with the new type ball
joint, proceed here. If your vehicle is equipped with
the original type ball joint, refer to Repair
(Original Type) on page 1-20.

Page 1-22

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION


1. Clean all metal parts with dry-cleaning solvent.

! CAUTION

2. Inspect all parts for wear, nicks, burrs, or scratches.


12

The ball joint boot should be routinely inspected


for tears or cracks, etc. If the boot is found to be
damaged, the ball joint should be inspected. (See
Ball Joint Inspection on page 1-69)
Unstake nut at notch to
relieve locking feature

3. Inspect control arm cup (12) for obvious cracks or other


damage.
1. Unstake nut at the notch in the top of the ball joint to
relieve locking feature.

4. Replace damaged parts.

3. ASSEMBLY

3
2

Shown Removed
From Vehicle
For Clarity

4
Grease Application

2. Remove nut (1) from top of ball joint (2).


3. Remove ball joint from control arm (3).

2. CLEANING AND INSPECTION

! WARNING

1. Install o-ring (4) onto ball joint (2).


2. Apply Dow Corning Molykote Longterm 2/78 grease
to control arm cup and ball joint as shown above.

Dry-Cleaning Solvent (P-D-680) is TOXIC and


flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.

DocID

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-23

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
8. Apply a bead of Dow Corning 732 Multi-Purpose
Silicone Sealant, Black (5) (Pierce P/N 95-1317)
around the base of the ball joint boot.
9. Refer to Installation on page 1-24 to reinstall on the
vehicle.

d. Installation
Notch

11

3. Install ball joint (2) into control arm (3) and align so that
the notched area of the ball joint is aligned with the
notch on the control arm. The notch should be pointed
toward the vehicle.

10

4. Apply Loctite 242 (Pierce P/N 1198896) to the ball


joint threads.

5. Install retaining nut (1). Torque to 400 ft lbs (542 Nm)

! WARNING

Stake nut at notch to


lock nut in place

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

6. Stake the nut at the indentation on the ball joint to lock


nut in place.
7. Apply Sentry Seal (Pierce P/N 95-1356) to the nut and
control arm.

NOTE: Tapered socket in steering knuckle and control


arm assembly ball joint taper must be clean and
free of oil and grease.
1. Apply Loctite 242 (Pierce P/N 1198896) to the ball
joint stud threads (10).
2. Install the lower control arm assembly ball joint (10) in
the steering knuckle (11).
3. Install the washer (9) and locknut (8). Tighten nut to
600 lb-ft (814 Nm).
4. Apply Sentry Seal (Pierce P/N 95-1356) to locknut (8)
and washer (9).

Page 1-24

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION


11. Remove DO NOT START tag from truck ignition
switch.
6

12. UPPER CONTROL ARM REPAIR


a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3. Remove the wheel end assembly. (See Wheel End
Assembly Replacement on page 1-7)
4. Remove the torsion bar. (See Torsion Bar
Replacement on page 1-45)

5. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads (5).

6. Install the shock absorber (6) on the lower control arm


(7) using two screws (5). Tighten screws to 210 lb-ft
(285 Nm).
7. Apply Sentry Seal (Pierce P/N 95-1356) to screws (5).
3
Upper Control ArmFront Autolube Fitting
3
~

1
4

NOTE: Toe control link taper and steering knuckle


socket must be clean and free of grease or oil.
8. Install the toe control link (3) on the steering arm (4)
using a castle nut (2). Tighten castle nut to 150 lb-ft
(204 Nm). If needed, continue to tighten the castle nut
until the cotter pin (1) can be installed.

Upper Control ArmRear Autolube Fitting

5. Disconnect autolube fittings (1 and 2) (if equipped)


from upper control arm (3).

9. Install a new cotter pin (1) and bend over the cotter pin
ends.
10. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-25

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

! WARNING
The control arm is heavy and must be supported.
Use a suitable lifting device to support the control
arm. Failure to comply could result in injury to
personnel.

6. Remove four locknuts (4) and screws (5) from the twobolt pivot pin mounting blocks (6).
7. Remove four screws (7) from the four-bolt pivot pin
mounting block (8).
8. Remove upper control arm (3).
3

b. Disassembly
7

2
Quantum Axle
(Rotated 180)

All Other
Applications

Quantum Axle
(Rotated 180)

8
All Other
Applications

2
10

1. Remove two screws (1) and washers (2) from pin (3).

Page 1-26

TAK-4 INDEPENDENT FRONT SUSPENSION

DocID

GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

NOTE: Depending on the application, the type and


orientation of the blocks may vary. Note the type
and orientation of blocks before removing to
ensure correct installation.
2. Remove two-bolt pivot pin mounting blocks (4) from pin
(3).
3. Remove two thrust washers (5) and pin (3) from the
upper control arm bushing bore (6).

NOTE: The bushings are press fit in the bore of the


upper control arm and are not serviceable
items.The upper control arm must be replaced if
the bushings are damaged.
5. Inspect the upper control arm bushing bores (6 and 8).
Replace the upper control arm (9) if the bushings are
worn or damaged.
6. Remove grease fitting (10) (if equipped).

4. Remove and discard the two bushings (7) from the


upper control arm bushing bore (6).
13

15
16

14

17
16

12

15

18

11

NOTE: When pressing the keyed pin out of the upper


control arm rear bore, the pin will force the front
control arm pivot pin insert out as well.
7. Remove the keyed pin (11) and front control arm pivot
pin insert (12).
8. Remove the four-bolt pivot pin mounting block (13) as
an assembly from the upper control arm (9).
9. If required, remove the roll pin (14) from the pivot pin
insert (12). Discard the roll pin.
10. Remove two thrust washers (15) and bushing
assemblies (16) from the four-bolt pivot pin mounting
block (17). Discard bushing assemblies.
11. Remove the grease fittings (18) from the four-bolt pivot
pin mounting block (17) and the upper control arm (9).

c. Cleaning and Inspection

! WARNING
Dry-Cleaning Solvent (P-D-680) is TOXIC and
flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flash
point for Type I Dry-Cleaning Solvent is 100F
(38C) and for Type II Dry-Cleaning Solvent is
140F (60C). Failure to do so may result in injury
or death to personnel.
1. Clean all metal parts with dry-cleaning solvent.
2. Inspect all parts for wear, nicks, burrs, or scratches.
3. Replace damaged parts.

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-27

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

4. If ball joint was not removed, check that the total axial
movement of the ball joint in the race does not exceed
0.025 in. (0.6 mm). Replace ball joint if wear exceeds
these limits. (See Upper Ball Joint Replacement
on page 1-13)

5. If thrust washer was in contact with side plate, replace


upper control arm pivot bushing. Check for witness
marks or check before disassembly of control arm.

d. Assembly
13

15
16

14

17
16

12
18

15

11

1. Install the grease fitting (18) in the four-bolt pivot pin


mounting block (17) and upper control arm (9).

7. Apply anti-seize compound (Pierce P/N 95-0809) to


front pivot pin insert (12).

2. Apply grease (Pierce P/N 1691545) to outside face of


both bushing assemblies (16) and install in the four-bolt
pivot pin mounting block (17).

8. Install the front control arm pivot pin insert (12) on the
keyed pin (11) and into the front bore.

NOTE: Install both thrust washers with lip towards the


bushing assemblies.
3. Install the two thrust washers (15) on the four-bolt pivot
pin mounting block (17).
4. If removed, install a new roll pin (14) in the pivot pin
insert (12). Install the roll pin to a depth that will just
contact the bottom of the keyway.
5. Position the four-bolt pivot pin mounting block
assembly (13) between the bores of the upper control
arm (9).
NOTE: Ensure that the key slot on the keyed pin and roll
pin are aligned.
6. Apply grease (Pierce P/N 1691545) to the keyed pin
(11) and push the keyed pin assembly into the front
bore of the upper control arm (9) and through the
bushing assemblies in the four-bolt pivot pin mounting
block assembly (13).

Page 1-28

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

2
Quantum Axle
(Rotated 180)

All Other
Applications

Quantum Axle
(Rotated 180)

8
All Other
Applications

2
10

9. Install the grease fitting (10) in the upper control arm


(9).
10. Apply grease (Pierce P/N 1691545) to the outside face
of the bushing assemblies (7) and install in the upper
control arm bushing bore (6).
11. Apply grease (Pierce P/N 1691545) and install the pin
(3) in the bushing assemblies (7).
NOTE: Install both thrust washers with lip towards the
bushing assemblies.
12. Install two thrust washers (5) on the pin (3).
NOTE: Install the two-pin pivot mounting blocks in the
same orientation as noted during disassembly.

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
14. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (1).
15. Install two washers (2) and screws (1) on the pin.
Tighten screws to 18 lb-ft (24 Nm).

13. Install two-bolt pivot pin mounting blocks (4) on the pin
(3).
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Page 1-29

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
3. Position the four-bolt pivot pin mounting block (8) on
the side plate and loosely install four screws (7). This
mounting hardware will be tightened when the torsion
bar has been centered in the clearance hole in the
torsion bar bracket.

5.562 in. 0.030 in.


(14 cm 0.8 mm)

4. Apply Sentry Seal (Pierce P/N 95-1356) to screws


(5 and 7) and locknuts (4).

16. After tightening screws, verify that the dimension


between the centerlines of both of the two-bolt pivot pin
mounting blocks is 5.562 in. 0.030 in. (14 cm 0.8
mm).

e. Installation
8

Upper Control ArmFront Autolube Fitting


3

6
~

5
2

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
1. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (5 and 7).
NOTE: Always use new locknuts for installation.
2. Position the two-bolt pivot pin mounting blocks (6) on
the side plate and loosely install the four screws (5) and
locknuts (2). This mounting hardware will be tightened
when the torsion bar has been centered in the
clearance hole in the torsion bar bracket.

Page 1-30

Upper Control ArmRear Autolube Fitting

NOTE: Perform steps 5 and 6 if the vehicle is equipped


with an autolube system.
5. Before connecting the autolube fittings, pre-lube the
control arm bushings with the appropriate grease. (See
Independent Suspension Components on
page 1-73 for grease specifications.)
6. Connect autolube fittings (1 and 2) (if equipped) to
upper control arm (3).
7. Install wheel end assembly. (See Wheel End
Assembly Replacement on page 1-7)
8. Install torsion bar. (See Torsion Bar Replacement
on page 1-45)
9. Apply grease to all fittings until grease is purged from
the assembly.

TAK-4 INDEPENDENT FRONT SUSPENSION

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10. Install wheel/tire assembly. (See Front Wheel and Tire


Service, Group 0705-P-001.)
11. Remove DO NOT START tag from truck ignition
switch.

13. LOWER CONTROL ARM REPAIR


a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

3. Remove wheel end assembly. (See Wheel End


Assembly Replacement on page 1-7)
4. Remove torsion bar. (See Torsion Bar
Replacement on page 1-45)
1

6. Remove two screws (4) and the shock absorber (5)


from the lower control arm (6).
10

8
9

3
Lower Control ArmFront Autolube Fitting
2

7. If the truck is equipped with a proximity switch bracket


assembly (7), remove the front two locknuts (8) and
screws (9) from the front two-bolt pivot pin mounting
block (10), and move the proximity switch bracket
aside.

3
Lower Control ArmRear Autolube Fitting

5. Disconnect autolube fittings (1 and 2) (if equipped)


from lower control arm (3).

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Page 1-31

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

13

1. Remove two screws (1) and washers (2) from the pin
(3).

9
10

2. Remove the two-bolt pivot pin mounting blocks (4) from


the pin (3).

11

3. Remove two thrust washers (5), pin, and two bushing


assemblies (6) from the lower control arm bushing bore
(7). Discard bushing assemblies.
10

4. Remove the grease fitting (8) from the lower control


arm (9).

c. Cleaning and Inspection


12

8. Note the orientation of the chamfers (11) and slots (12)


on the pivot pin mounting blocks (10) to ensure correct
installation.
9. Remove eight locknuts (8) and screws (9) from the four
two-bolt pivot pin mounting blocks (10), and remove the
lower control arm assembly (13).

b. Disassembly
NOTE:

! WARNING
Dry-Cleaning Solvent (P-D-680) is TOXIC and
flammable. Wear protective goggles, face shield,
and gloves; use only in a well-ventilated area;
avoid contact with skin, eyes, and clothes, and do
not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the
flashpoint for Type I Dry-Cleaning Solvent is
100F (38C) and for Type II Dry-Cleaning Solvent
is 140F (60C). Failure to do so may result in
injury or death to personnel.

Both lower control arm bushing assemblies are the


same. Repair of either one will use the following
procedures.

1. Clean all metal parts with dry-cleaning solvent.

Note the orientation of the two-bolt pivot pin


mounting blocks to aid in reassembly.

3. Replace damaged parts.

2. Inspect all parts for wear, nicks, burrs, or scratches.


4. If ball joint was not removed, check that the total axial
movement of the ball joint in the race does not exceed
0.025 in. (0.6 mm). Replace ball joint if wear exceeds
these limits. (See Lower Ball Joint Replacement
on page 1-19)
5. Measure distance between thrust washer and face of
pivot block. If thrust washer extends past the face of the
pivot block more than 1/16 inch (1.6 mm) replace lower
control arm pivot bushing.

Page 1-32

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6. If the thrust washer was in contact with the side plate,


replace lower control arm pivot bushing. Check for
witness marks or check before disassembly of control
arm.

5.562 in. 0.030 in.


(14 cm 0.8 mm)

d. Assembly
1

7. After tightening screws, verify that the dimension


between the centerlines of both of the two-bolt pivot pin
mounting blocks is 5.562 in. 0.030 in. (14 cm 0.8
mm).
9

e. Installation
8

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
1. Apply pipe thread sealing compound to threads of
grease fitting (8) and install in the lower control arm (9).
(See Pipe Thread Sealing Procedure Group 2000-P002.)
2. Apply grease (Pierce P/N 1691545) to the outside face
of both bushing assemblies (6) and install the bushing
assemblies and pin (3) in the lower control arm bushing
bore (7).
NOTE: Install both thrust washers with lip towards the
bushing assemblies.
3. Install the two thrust washers (5) on pin (3).
4. Apply grease (Pierce P/N 1691545) and install the twobolt pivot pin mounting blocks (4) on the pin (3).
5. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (1).
6. Install two washers (2) and screws (1) on the pin (3).
Tighten screws to 18 lb-ft (24 Nm).

DocID

13

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
1. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (9).

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-33

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

NOTE:
Always use new locknuts for installation.
If equipped with a proximity switch bracket
assembly, install the bracket in the same position
as noted during removal.

2. Install the lower control arm assembly (13) on the side


plate with eight screws (9) and locknuts (8). Tighten
locknuts to 375 lb-ft (508 Nm).
3

3. Apply Sentry Seal (Pierce P/N 95-1356) to screws (9)


and locknuts (8).

5
Lower Control ArmRear Autolube Fitting

NOTE: Perform steps 7 and 8 if the vehicle is equipped


with an autolube system.

7. Before connecting the autolube fittings, pre-lube the


control arm bushings with the appropriate grease. (See
Independent Suspension Components on
page 1-73 for grease specifications.)
8. Connect autolube fittings (1 and 2) (if equipped) to
lower control arm (3).

4. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads (4).
5. Install the shock absorber (5) on the lower control arm
(6) using two screws (4). Tighten screws to 210 lb-ft
(285 Nm).
6. Apply Sentry Seal (Pierce P/N 95-1356) to screws (4).

9. Install wheel end assembly. (See Wheel End


Assembly Replacement on page 1-7)
10. Remove torsion bar. (See Torsion Bar
Replacement on page 1-45)
11. Apply grease (Pierce P/N 1234269) to all lubrication
fittings, until grease purges from the assembly.
12. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
13. Remove DO NOT START tag from truck ignition
switch.

14. STEERING KNUCKLE REPLACEMENT


1

a. Removal
NOTE: Both steering knuckles are removed the same
way.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3
Lower Control ArmFront Autolube Fitting

Page 1-34

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14

12
10
6

1
4

11

3. Remove cotter pin (1), castle nut (2), and toe control
link (3) from steering arm (4). Discard the cotter pin.

13

15

! WARNING

The steering knuckle assembly weighs an


estimated 120 lb (54 kg). Have an assistant help
during removal or use a suitable lifting device.
Failure to comply could result in injury to
personnel.

! CAUTION
Ensure assistant is holding steering knuckle
securely. Failure to comply may result in damage
to equipment.

! CAUTION
Use caution when removing the ABS sensor. Do
not pull on the wire harness to remove it. Possible
damage to the sensor could occur if sensor is
removed by pulling on the wire harness.
4. Grasp the ABS sensor body (5) and pull out of the
bushing in the steering knuckle (6).

7. With the aid of an assistant and a pry bar, apply


pressure between steering knuckle (6) and upper (8)
and lower (9) control arm ball joints, while hammering
on side of the steering knuckle. Remove two nuts (10
and 11), washers (12 and 13), and steering knuckle
from the upper (14) and lower (15) control arms.

b. Installation
NOTE: Both steering knuckles are installed the same
way.

5. Remove brake caliper (7). (See Pneumatic Disc


Brake Caliper And Brake Chamber Repair on
page 1-2)
6. Remove the wheel hub assembly. (See Wheel Hub
Replacement on page 1-3)

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Page 1-35

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
NOTE: Toe control link taper and steering knuckle
socket must be clean and free of grease or oil.

14

4. Install the toe control link (3) on the steering arm (4) and
tighten castle nut (2) to 150 lb-ft (204 Nm). If needed,
continue to tighten the castle nut until the cotter pin (1)
can be installed.

12

5. Install a new cotter pin (1) and bend over the cotter pin
ends.

10
6

7
~

11
13

15

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
Loctite

1. Apply
242 (Pierce P/N 1198896) to upper (8)
and lower (9) control arm ball stud threads.
2. Install the steering knuckle (6) on the upper (8) and
lower (9) control arms with two washers (12 and 13)
and nuts (10 and 11). Tighten the nuts to 600 lb-ft (814
Nm).
3. Apply Sentry Seal (Pierce P/N 95-1356) to the upper
and lower ball joint nuts (10 and 11) and washers (12
and 13).

6. Install the wheel hub assembly. (See Wheel Hub


Replacement on page 1-3)
7. Install the brake caliper assembly (7). (See
Pneumatic Disc Brake Caliper Replacement on
page 1-1)
NOTE: Grease must be mineral oil-based and contain
molydisulfide. It should have excellent anticorrosion and adhesion characteristics, and be
capable of continuous function within a
temperature range of 40 to 300F
(40 to 150C).
8. Apply grease (Pierce P/N 1234272) and install the ABS
sensor body (5) in the steering knuckle (6).
9. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)

10. Remove DO NOT START tag from truck ignition


switch.

15. STEERING ARM REPLACEMENT


1
4

Page 1-36

a. Removal
NOTE: Both steering arms are removed and installed
the same way.

TAK-4 INDEPENDENT FRONT SUSPENSION

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1. Attach a DO NOT START tag to truck ignition switch.


2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
11

8
9
10

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
NOTE: Perform steps 1 and 2 if studs were removed
from the steering knuckle.
1. Apply Loctite 242 (Pierce P/N 1198896) to the threads
at the end of the stud (10) with one inch of threads.

4
1
5

10

3. Remove cotter pin (1), castle nut (2), and toe control
link (3) from steering arm (4). Discard the cotter pin.
4. Remove two screws (5) and lockwashers (6) from the
steering arm (4).
5. Remove two nuts (7), lockwashers (8), and dowels (9)
from the steering knuckle studs (10).
6. Remove the steering arm (4) from the steering knuckle
(11).
7. If required, remove studs (10) from steering knuckle
(11).

2. Install studs (10) in the steering knuckle (11).


3. Position the steering arm (4) on the steering knuckle
(11), and install the two dowels (9) on the steering
knuckle studs (10).
4. Apply Loctite 242 (Pierce P/N 1198896) to the threads
of the steering knuckle studs (10), and install two
lockwashers (8) and nuts (7). Tighten the nuts to hand
tight only.
5. Apply Loctite 242 (Pierce P/N 1198896) to the screw
(5) threads.
6. Install two lockwashers (6) and screws (5). Tighten the
screws to hand tight only.
NOTE: Tighten nuts first.
7. Tighten two nuts (7) to 320 lb-ft (434 Nm).

b. Installation

8. Tighten two screws (5) to 320 lb-ft (434 Nm).


11

9. Apply Sentry Seal (Pierce P/N 95-1356) to screws (5)


and nuts (7).

NOTE: Toe control link taper and steering knuckle


socket must be clean and free of grease or oil.

8
9
10

10. Install the toe control link (3) on the steering arm (4)
using a castle nut (2). Tighten castle nut to 150 lb-ft
(204 Nm). If needed, continue to tighten the castle nut
until the cotter pin (1) can be installed.

11. Install a new cotter pin (1) and bend over the cotter pin
ends.
1
5

DocID

10

12. Install wheel/tire assembly. (See Front Wheel and Tire


Service, Group 0705-P-001.)
13. Remove DO NOT START tag from truck ignition
switch.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-37

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

16. TIE CONTROL LINK REPLACEMENT

b. Installation

a. Removal
1

1. Attach a DO NOT START tag to truck ignition switch.


2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

2
1

2
5

3
5

4
5

6 NOT SHOWN

NOTE: Tie control link taper and pitman arm sockets


must be clean and free of grease or oil.
3

6 NOT SHOWN

3. Remove cotter pin (1) and castle nut (2) from the tie
control link ball joint (3) at each end of the tie control link
(4). Discard the cotter pins.
4. Remove the tie control link (4) from the pitman arms (5
and 6).

1. Install the tie control link (4) in the pitman arms (5 and
6) and install two castle nuts (2). Tighten the castle nuts
to 150 lb-ft (204 Nm). If needed, continue to tighten the
castle nuts until the cotter pins can be installed.
2. Install two new cotter pins (1) and bend the ends over.
3. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
4. Remove DO NOT START tag from truck ignition
switch.

17. TOE CONTROL LINK REPLACEMENT

! CAUTION
The toe control link steering joint should be
routinely inspected for wear. (See Toe Control
Link Inspection on page 1-71).

Page 1-38

TAK-4 INDEPENDENT FRONT SUSPENSION

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a. Removal

NOTE: Both of the toe control links are removed the


same way.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3

4
6

NOTE: Toe control link taper, pitman arm, and steering


arm socket must be clean and free of grease or oil.
1. Install toe control link (3) in the steering arm (4) and
pitman arm (7) with two castle nuts (2 and 6).

3. Remove cotter pin (1), castle nut (2), and toe control
link (3) from steering arm (4). Discard the cotter pin.
NOTE: Note the length of the toe control link if a new
toe control link is being installed.
4. Remove the cotter pin (5) and castle nut (6), and
remove toe control link (3) from pitman arm (7). Discard
cotter pin.

b. Installation

2. Tighten both of the castle nuts (2 and 6) to 150 lb-ft


(204 Nm). If needed, continue to tighten the castle
nuts until the cotter pins can be installed.
3. Install new cotter pins (1 and 5) and bend over the
ends.
4. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
5. Check toe-in and adjust as needed. (See Setting
Wheel Toe-In on page 1-51)
6. Remove DO NOT START tag from truck ignition
switch.

18. PITMAN ARM REPLACEMENT

NOTE:
Both of the toe control links are installed the same
way.

a. Removal

If installing a new toe control link, adjust the new


link to the same length as noted during removal.
(See Toe-In Adjustment Procedure on
page 1-52 for link adjustment procedure.)

NOTE:
Both of the pitman arms are removed the same
way.
The primary and secondary pitman arms are
similar, but are not interchangeable.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove the steering gear from the steering gear tray.
(See Steering Gear Replacement on page 1-41)

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Page 1-39

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

b. Installation

! CAUTION
~

Ensure the bellows is installed over the steering


gear shaft before installing the pitman arm.
Failure to comply may result in premature failure
of the steering gear seal.
NOTE:
Both pitman arms are installed the same way.
The primary and secondary pitman arms are
similar, but are not interchangeable. Attempting to
install the wrong arm will result in the timing marks
being off by 180.

3. Bend up tabs (1) on the pitman arm retainer lockwasher


(2).
4. Remove pitman arm retainer (3) and retainer
lockwasher (2).
4

6
8

7
5

1. Install bellows (8) over the steering gear shaft (7).


4

5. Note the position of the timing mark (4) on the pitman


arm (5) in relation to the timing mark (6) on the steering
gear shaft (7).

6. Remove pitman arm (5) from steering gear shaft (7)


using a puller.
7
7

2. Install the pitman arm (5) on the steering gear shaft (7)
by aligning timing marks (4 and 6).
7. Remove bellows (8) from steering gear shaft (7).

Page 1-40

TAK-4 INDEPENDENT FRONT SUSPENSION

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FRONT AXLE & SUSPENSION

2
10

3. Install retainer lockwasher (2), aligning the two unbent


tabs (9) of the pitman arm retainer lockwasher with the
two slots (10) on the pitman arm (5).
4. Install pitman arm retainer (3). Tighten the pitman arm
retainer to 550 lb-ft (746 Nm). Upon reaching the
specified torque, continue to advance the pitman arm
retainer until the notches in the retainer are aligned with
the next bent tab (1) of the retainer lockwasher. Bend
the two opposing tabs of the pitman arm retainer
lockwasher into the notches of the pitman arm retainer.
5. Install steering gear. (See Steering Gear
Replacement on page 1-41)

19. STEERING GEAR REPLACEMENT

NOTE: Perform steps 4 and 5 if removing the primary


steering gear.
4. Match mark the steering shaft and U-joint before
removing steering shaft.
5. Remove locknut (1) and screw (2) from U-joint (3), and
remove U-joint from primary steering gear (4).
8

10

a. Removal
NOTE: Both the primary and secondary steering gears
are removed the same way.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3. Remove rear crossmember. (See Rear
Crossmember Replacement on page 1-57)

11

Primary Steering Gear Side Shown

6. Remove cotter pin (5), castle nut (6), and toe control
link (7) from pitman arm (8). Discard the cotter pin.
7. Remove cotter pin (9), castle nut (10) and tie control
link (11) from pitman arm (8). Discard the cotter pin.

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Page 1-41

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

12

15

14

16
Hydraulic Hose ConnectionsRear of Primary Steering
Gear

13
Hydraulic Hose ConnectionsFront of Primary Steering
Gear

11. Carefully loosen hydraulic hose fitting (16) to relieve


trapped hydraulic pressure.
12. Remove hydraulic hose (16) from the steering gear.

! WARNING
The hydraulic steering system operates at high
pressures. Ensure there is no pressure remaining
in the hydraulic hoses before you remove them.
Failure to comply could result in serious injury or
death.

13. Plug hydraulic hose (16) and cap fitting on the steering
gear to prevent contamination of the hydraulic system.

15

NOTE:
Position a drain pan to catch oil draining from
hoses and steering gear.
The number and location of hoses may vary.
Mark the locations of the hoses before removing to
ensure correct installation.
8. Carefully loosen hydraulic hose fittings (12 through 14)
to relieve trapped hydraulic pressure.
20

9. Remove hydraulic hoses (12 through 14) from the


steering gear (15).
10. Plug hydraulic hose (12 through 14), and cap the
fittings on the steering gear to prevent contamination of
the hydraulic system.

19

18

17

Primary Steering Gear Shown

Page 1-42

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

! WARNING

! WARNING

The steering gear weighs 120 lb (54 kg). Have an


assistant help during removal or use a suitable
lifting device. Failure to comply could result in
injury to personnel.

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

NOTE: Note orientation and location of chamfered


block to ensure correct installation.
14. Remove three screws (17), washers (18), chamfered
block (19), and the steering gear (15) from the steering
gear tray (20).

b. Installation

2. Apply Loctite 242 (Pierce P/N 1198896) to all screw


threads (17).
NOTE: Install the chamfered block in the same location
and orientation as noted during removal.
3. Install the steering gear (15) with three washers (18),
chamfered block (19), and screws (17). Tighten screws
to 460 lb-ft (624 Nm).

15

20
19
16
18

Hydraulic Hose ConnectionsRear of Primary Steering


Gear

4. Remove plug from hydraulic hose (16) and cap from


fitting on the steering gear.

17

NOTE:
Primary Steering Gear Shown

1. Position the steering gear (15) on the steering gear tray


(20).

Install all hoses and fittings in the same location


and orientation as noted during removal.
See Hydraulic Hose & Fitting Torque
Specifications, Group 9600-P-003 for torque
specifications.
5. Install hydraulic hose (16) to steering gear.

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FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
9. Install the toe control link (7) on the pitman arm (8)
using a castle nut (6). Tighten castle nut to 150 lb-ft
(204 Nm). If needed, continue to tighten the castle nut
until the cotter pin (5) can be installed.
10. Install a new cotter pin (5) and bend over the cotter pin
ends.

12

15

14
2
13
Hydraulic Hose ConnectionsFront of Primary Steering
Gear

6. Remove plugs from hydraulic hoses (12 through 14)


and cap from fittings on the steering gear.
7. Connect hydraulic hoses (12 through 14) to the same
fittings on the steering gear (15).
8

10

NOTE:
Perform step 11 if the primary steering gear was
removed.

Always use new locknuts for installation.


11. Connect the steering shaft U-joint (3) to the primary
steering gear (4), aligning the match marks. Secure the
U-joint using a screw (2) and locknut (1).
12. Install rear crossmember. (See Rear Crossmember
Replacement on page 1-57)
13. Adjust steering gears. (See Torsion Bar
Replacement on page 1-45)
14. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
15. Remove DO NOT START tag from truck ignition
switch.
11

16.
17.

NOTE: Tie control link taper, toe control link taper and
pitman arm must be clean and free of grease or oil.
8. Install tie control link (11) on pitman arm (8) using castle
nut (10). Tighten castle nut to 150 lb-ft (204 Nm). If
needed, continue to tighten the castle nut until the
cotter pin (9) can be installed.

Page 1-44

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20. TORSION BAR REPLACEMENT


3

a. Removal
2
~

! WARNING
DO NOT get under the truck in any way after it is
raised unless the truck is supported with safety
stands or blocks. The hydraulic jack is used for
lifting the vehicle only, and not for supporting the
vehicle in the raised position. Failure to correctly
support the truck could let the truck fall, causing
serious injury or death.

! WARNING

6. If the upper control arm, torsion bar, and torsion bar


anchor is being reinstalled, matchmark (1) the torsion
bar anchor (2) and torsion bar bracket (3).

Place blocks under the rear wheels to keep the


vehicle from moving, which may cause personal
injury.
NOTE:
If the upper control arm, torsion bar, and torsion bar
anchor are being replaced and not reused, it will be
necessary to perform the adjustment procedures
found in Installation on page 1-47 If the above
mentioned parts are to be reused, it is much faster
and easier to matchmark the torsion bar plate and
torsion bar anchor.
The left and right side torsion bars are removed the
same way. Identify the left- and right-hand sides by
marking the torsion bars with a pen.
1. Raise cab. (Refer to Operation & Maintenance
Manual.)
2. Attach a DO NOT START tag to truck ignition switch.
3. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

! CAUTION
Failure to support the lower control arm when
removing the shock absorbers could damage the
ball joint boots.
4. Remove shock absorber. (See Shock Absorber
Replacement on page 1-11)
5. Use a suitable jack to raise the frame on both sides so
that the suspension is allowed to hang down under its
own weight.

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Page 1-45

FRONT AXLE & SUSPENSION

19

20

GROUP 0152-P-002-0114

21

25
23

14
6

26

24
15

11

13

10

12

22

24

18

17

16

7. Loosen, but do not remove the screw (4) on front of the


torsion bar (5).

NOTE: Note correct orientation of the anchor pivot


block.

8. Unbend two locking tab washers (6).

18. Remove locknut (22), screw (23), two locking tab


washers (6), and locking tab plates (24). Discard
locking tab washers.

9. Loosen inner nut (7).


10. If necessary, apply heat to tube (8) where threaded rod
(9) is installed in the tube. This will loosen the thread
sealant.

19. If required remove two screws (25) and the anchor


pivot block (26) from the torsion bar mounting bracket
(3).

11. Using outer nuts (10 and 11), unscrew the threaded rod
(9), and remove it along with the inner nut (7) and pin
(12).
12. Remove two outer nuts (10 and 11) and lockwasher
(13) from the threaded rod (9).
13. Remove four locknuts (14), screws (15), and plate (16)
from the torsion bar bracket (3).
14. Remove screw (17) and spacer (18) from the torsion
bar (5).
15. Remove torsion bar anchor (2) from torsion bar (5).
16. Remove screw (4), lockwasher (19), washer (20), and
wave washer (21) from torsion bar (5).
17. Remove the torsion bar (5) by pulling out through the
hole in the torsion bar bracket (3).

Page 1-46

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

b. Installation
4

19

20

27

21

25
23

14
6

26

24
15

11

13

10

12

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
1. Apply Loctite 242 (Pierce P/N 1198896) to screw
threads (25).
2. If removed, position the anchor pivot block (26) on the
torsion bar mounting bracket (3) using two screws (25).
Do not tighten the screws at this time.
3. Apply Tef-Gel (Pierce P/N 3253324) to curved
surface of anchor pivot block (26).

22

24

18

17

16

4. Install two locking tab plates (24) and locking tab


washers (6) on the torsion bar mounting bracket (3)
using a screw (23) and locknut (22). Do not tighten the
locknut at this time.
NOTE: The torsion bars are right- and left-handed.
Ensure the correct torsion bar is installed on each
side of the truck.
5. Apply Tef-Gel (Pierce P/N 3253324) to internal
splines (27) of the upper control arm. Install the torsion
bar (5) through hole in the torsion bar bracket (3) and
engage the splined end in the upper control arm.
6. Apply Tef-Gel (Pierce P/N 3253324) to internal
splines of the torsion bar anchor (2) and install on the
torsion bar, indexing it using one of the following
methods:
a. If reinstalling used parts: Indexing the torsion bar
anchor as matchmarked during disassembly.

NOTE: Always use new locknuts for installation.

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Page 1-47

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

b. If installing new parts: The upper control arm must


be positioned in rebound (supported by the shock).
Index and install anchor on splines to achieve
dimension A (0.50 in.). Install jam nuts to achieve
dimension B (0.030). Refer to
Table 1 for installation dimensions.

Table 1-1: Torsion Bar Anchor Initial


Installation Dimensions
AXLE RATING (lbs)
4 JOUNCE
3 JOUNCE

Dimension A
Gap B
Dimension A
Gap B

18,000

19,500

22,800

24,000

4.98 in.
0.27 in.
5.09 in.
0.16 in.

5.31 in.
0.00 in.
5.33 in.
0.00 in.

4.77 in.
0.48 in.
4.98 in.
0.27 in.

4.97 in.
0.28 in.
5.12 in.
0.13 in.

7. Apply Loctite 242 (Pierce P/N 1198896) to the screw


threads (4).
8. Apply grease to the keyway slot and wave washer seat
to prevent corrosion.
9. Install the wave washer (21), washer (20), lockwasher
(19) and screw (4) in the torsion bar (5). Tighten screw
to 29 lb-ft (39 Nm).
10. Apply Loctite 272 (Pierce P/N 3062748) to the
threaded rod (9).
NOTE: Inner nut (7) will be torqued during the Ride
Adjustment Procedure. See (Ride Height
Adjustment on page 1-74)

13. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads (17). Install the spacer (18) and screw in the
torsion bar. Tighten the screw to 110 lb-ft (149 Nm).
14. Apply RTV (Pierce PN 95-1317) to area where torsion
bar enters the torsion bar anchor and to arm where the
torsion bar enters upper control arm to seal out
contaminants.
NOTE: Tighten the nut only enough to remove play
between the pin and the torsion bar anchor.
15. Install the pin (12) and nut (10) on the threaded rod (9).
16. Install the lockwasher (13) and nut (11) on the threaded
rod (9). Tighten nut to 180 lb-ft (244 Nm).

11. Install threaded rod (9) and inner nut (7) into tube (8).
Install threaded rod until it bottoms out in the tube.

NOTE: Always use new locknuts for installation.

12. Position the flats on the tube (8) so that they face
downward.

17. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads (15). Install the end plate (16) using four
screws (15) and locknuts (14). Tighten the locknuts to
210 lb-ft (285 Nm).

Page 1-48

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

30

4
29

1
2
3

1
2

28

18. If this repair was performed because the upper control


arm (28) was removed, tighten the upper control arm
mounting hardware to the final torque specifications:
Tighten the four-bolt pivot mounting block screws
(29) to 280 lb-ft (380 Nm).
Tighten the two-bolt pivot block mounting locknuts
(30) to 375 lb-ft (508 Nm).
19. Raise the wheel end two to three inches to put the
torsion bar under a partial load. This will allow the
anchor pivot block (26) and torsion bar anchor (2) to
align with each other. Tighten the anchor pivot block
mounting screws (25) to 170 lb-ft (231 Nm).
20. Install shock absorber. (See Shock Absorber
Replacement on page 1-11)

NOTE: Perform step 3 only if the cab latch assembly is


mounted directly on the torsion bar mounting
bracket.
3. Remove four locknuts (1), washers (2), and screws (3)
and move the cab latch assembly (4) and spacer (5)
aside.

21. Install wheel/tire assembly. (See Front Wheel and Tire


Service, Group 0705-P-001.)
22. Lower cab. (Refer to Operation & Maintenance
Manual.)
23. Remove the jackstands and lower the front suspension
to the ground.

24. Adjust the ride height. (See Ride Height


Adjustment on page 1-74)

21. TORSION BAR MOUNTING BRACKET


REPLACEMENT
6

a. Removal
NOTE: Both torsion bar mounting brackets are
removed the same way.

4. Remove the torsion bar (6) and torsion bar anchor (7).
(See Torsion Bar Replacement on page 1-45)

1. Attach a DO NOT START tag to truck ignition switch.


2. Raise cab. (Refer to Operation & Maintenance
Manual.)

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Page 1-49

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

13

1. Apply Loctite 242 (Pierce P/N 1198896) to all screw


threads (9 and 11).

10

NOTE: Always use new locknuts for installation.


9

2. Position the torsion bar mounting bracket (12) on the


frame (13) and install six screws (2) and locknuts (1).
Tighten locknuts to 210 lb-ft (285 Nm).
3. Apply Sentry Seal (Pierce P/N 95-1356) to screws
(9 and 11) and locknuts (8 and 10).

11

12
7

5. Remove two lower locknuts (8) and screws (9).


6. Remove the four upper locknuts (10) and screws (11)
and remove torsion bar mounting bracket (12) from the
frame (12).

b. Installation
6

NOTE: Both torsion bar mounting brackets are installed


the same way.
13

4. Install the torsion bar anchor (7) and torsion bar (6).
(See Torsion Bar Replacement on page 1-45)

10

1
12

2
3

1
2

11

3
8

12

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

Page 1-50

NOTE: Perform step 5 only if the cab latch assembly is


mounted directly to the torsion bar mounting
bracket.
5. Install cab latch assembly (4) and spacer (5) on torsion
bar mounting bracket (12) using four screws (3),
washers (2), and locknuts (1).

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION


If this step is ignored, the toe-in measurements
will be inaccurate.

6. Lower cab. (Refer to Operation & Maintenance


Manual.)
7. Remove DO NOT START tag from truck ignition
switch.

22. STEERING SYSTEM ADJUSTMENT

2. Visually check the front wheels to ensure they are


centered with the rear axle.
3. Attach a DO NOT START tag to truck ignition switch.
4. Using a suitable jack, raise the front tire off the ground
until the tire can be rotated freely.

a. Setting Wheel Toe-In


1. CHECK TOE-IN
NOTE: To ensure an accurate adjustment:
The vehicle should be parked on a flat, level
surface.
The vehicle should be at its normal operating
weight.

The tires must be properly inflated.


1

NOTE:
2

A metal scribe, punch screwdriver, etc., can be


used as a marking device. Whatever marking
device is used, it must be able to place a visible
mark on the tire.
The mark should be made as close to the
centerline of the tire as possible to attain the most
accurate reading.
For best results, attach the marking device to a
stationary device.

NOTE:
Do not measure to the adjustable set screw hard
stops.

5. Place a marking device against the tire (3), and rotate


the tire until a reference line (4) is visible.

When steering is centered, the pitman arms will not


be parallel to the frame.
1. Center the pitman arms (1) by adjusting the gap
between the side plate opening (2) and the pitman
arms. Both pitman arms should be about four inches
(10 cm) from the side plate openings (as shown). There
must be no more than 1/8 inch (3.2 mm) difference
between both gaps.

! CAUTION
Even after the pitman arms are centered by
measurement, the front wheels must be visually
checked to make sure they are centered with the
rear axle.

DocID

6. Lower the tire on a portable turntable/slip plate (WheelA-Matic PN WA1841 or equivalent).


7. Repeat steps 4 through 6 for the other tire.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-51

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

PT928
5
2
4

8. Check toe-in:
a. Measure the distance (5) between the scribed lines
(4) at the front of the tires and approximately halfway up the tire. Note the distance.
b. Measure the distance between the reference lines at
the rear of the tires at approximately half-way up the
tire.
c. Subtract the measurement at the front of the tires
from the measurement at the rear of the tires to
determine toe-in. The toe-in should be set at 3/16
inch 1/32 inch (4.8 mm 0.8 mm).
9. If toe-in does not meet specifications, perform
adjustment procedure. (See Toe-In Adjustment
Procedure on page 1-52)

1. Unbend the folding lockwasher tabs (1) at both ends of


both toe links.
2. Loosen two jam nuts (2) on each of the toe control links.
3. Rotate the connecting tube (3) on each toe control link
to adjust the tire toe-in.

I MPORTANT
Every time a toe adjustment is made, sight down
the front-to-rear tires to make sure the front tires
are still centered with the rear.

2. TOE-IN ADJUSTMENT PROCEDURE

! CAUTION

4. Recheck toe-in. (See Check Toe-In on page 1-51)


4

The ideal adjustment procedure is to adjust both


toe links equally. This may not always be
possible. One toe link may need to be adjusted
more than the other, or one toe link may need to
be turned the opposite direction as the other, or
all adjustment may need to come from one toe link
(depending on the location of the wheels at the
centered starting position).
After the toe-in has been set, and the pitman arms
have been centered, the front wheels should be in
line with the rear wheels.
Toe-in adjustments should only be performed by
experienced alignment technicians.
NOTE: Ideally, the right and left toe links should be less
than 1/4 inch (6 mm) difference in length.

5. When the adjustment is complete:


a. Tighten jam nuts (2) on both ends of each toe link to
110 lb-ft (149 Nm).

I MPORTANT
Double check the toe-in after tightening the jam
nuts. Occasionally, the toe-in may change. Readjust the toe-in as needed.

Page 1-52

TAK-4 INDEPENDENT FRONT SUSPENSION

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GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

b. Setting Steering Hard Stops

! CAUTION

NOTE:

Fold lockwasher tab on hex flat farthest from the


groove in tube.

Toe-in must be set before setting steering hard


stops.

b. Bend lockwasher tab (4) over farthest jam nut flat


from the groove in the tube (5) on each of the four jam
nuts.

Angle adjustment of the rotary tables is not


necessary nor do they require calibration. Their
use is only for allowing the wheels to turn with no
resistance on a shop floor.

1. Jack up the wheel assemblies and place rotary tables


under the wheels.
9

2. Lower the vehicle onto the rotary tables with the wheels
pointing straight ahead. Note initial angle setting.

3. Turn the wheel left until a 0.5 inch (13 mm) clearance
is obtained between the tire sidewall and the upper
control arm, or the angles indicated in the following
table, whichever occurs first.
Table 1-2: Initial Steering Angle Settings

! CAUTION

Tire Size

Steer Angle

315 / 80 / 22.5
395 / 65 R 22.5
425 / 65 R 22.5
445 / 65 R 22.5

42 +0 / -2
42 +0 / -2
40 +0 / -2
40 +0 / -2
1

Do not disconnect the bottom of the steering


column shaft at the miter box. The steering
column may be damaged if it is allowed to turn
freely when disconnected from the miter box.

6. If necessary, center the steering wheel:


a. Remove locknut (6) and screw (7) from U-joint (8)
and remove U-joint from primary steering gear (9).
b. Center the steering wheel and connect the U-joint to
the primary steering gear shaft.
c. Connect the steering shaft U-joint (8) to the primary
steering gear (9). Secure the U-joint using a screw
(7) and locknut (6).
7. Set steering hard stops and adjust relief plungers. (See
Setting Steering Hard Stops on page 1-53 and
Setting Primary Steering Gear Hydraulic Reliefs
on page 1-53)

4. Loosen the jam nut (1) on the steering stop set screw
(2).
5. Adjust the steering stop set screw (2) until it contacts
the side of the pitman arm (3).
6. Hold steering stop set screw (2) and tighten the jam nut
(1) to 150 lb-ft (204 Nm).
7. Repeat steps 3 through 6 for a right turn.
8. Adjust relief plungers. (See Setting Primary
Steering Gear Hydraulic Reliefs on page 1-53)

c. Setting Primary Steering Gear Hydraulic


Reliefs
DocID

1. Set toe-in. (See Setting Wheel Toe-In on


page 1-51)

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-53

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

2. Set steering hard stops. (See Setting Steering Hard


Stops on page 1-53)
3. Park vehicle on a clean, dry, solid surface, preferably
concrete. Set parking brake and block the rear wheels.
4. Place transmission in neutral and start engine. Allow
the engine to operate at idle speed.

! WARNING
Keep hands clear of the pitman arm when
adjusting the steering gear reliefs. Severe injury
to your hands could occur if they become pinched
between the steering hard stop and the pitman
arm.

! CAUTION
Do not adjust the plunger with pressure on the
steering wheel, as seal damage can occur.
1

6. Turn the steering wheel fully to the left and check


clearance between the pitman arm (3) and steering
hard stop (4). Clearance must be at least 0.120 inch (3
mm), but not more than 0.180 inch (4.5 mm). If
clearance is not within specifications adjust as follows:

Primary Steering GearFront Poppet Screw (Left Turn)

a. Return the front tires to straight-ahead position and


release the steering wheel.
b. Using a flat blade screwdriver adjust the front poppet
(1) (left turn) or rear poppet (2) (right turn). Turning
the plunger in will increase the clearance between
the steering hard stop and the pitman arm. Turning
the plunger out will decrease the clearance.
c. Turn the wheel fully left and measure clearance
again. If adjustment is still needed, repeat procedure
until clearance is within specifications.

7. Repeat step 6 for a right turn.


8. Re-check all clearances to ensure that a 1/2 inch
(13 mm) gap is still available between the tire sidewall
and any other component.
Primary Steering GearRear Poppet Screw (Right Turn)

5. Locate plungers on primary steering gear box. Front


poppet screw (1) is for left turn, rear poppet screw (2)
is for right turn.
4
3

NOTE: The steering gear will make a hissing sound


when it goes into relief. Also, the use of a hydraulic
pressure gauge will verify that the steering gear is
going into relief.
9. Ensure that the steering pressure relieves when fully
turning in both directions.
10. Perform steering gear bleed procedure. (See
Steering Gear Bleed Procedure on page 1-54)

d. Steering Gear Bleed Procedure


1. Ensure primary steering gear hydraulic reliefs have
been set. (See Setting Primary Steering Gear
Hydraulic Reliefs on page 1-53)

! CAUTION
DO NOT allow the reservoir to empty during this
procedure, since pump damage or further
aeration could result.
2. Verify that the hydraulic fluid level in the reservoir is at
the full mark.
Page 1-54

TAK-4 INDEPENDENT FRONT SUSPENSION

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FRONT AXLE & SUSPENSION

3. Park truck on any dry shop floor surface or other dry


pavement. Run engine at low idle.
4. Steer the vehicle from full right to full left several times.
5. Steer to full left and shut off the engine.
6. Remove plastic plug from bleed screw port.
3

11. Using an Allen wrench, take out the bleed screw (4) and
ball (5) in the front of the secondary steering gear (3).
Allow the oil to drain out. The air in the front cylinder is
gone when a constant stream of oil comes out of the
bleed port. Install the ball and bleed screw back into the
port and tighten. Install plastic plug.
12. Verify that the hydraulic fluid level in the reservoir is at
the full mark. Add oil as needed.

13. Remove DO NOT START tag from truck ignition


switch.

23. STEERING GEAR TRAY REPLACEMENT


a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assemblies. (See Front Wheel and
Tire Service, Group 0705-P-001.)

Secondary Steering GearRear Bleed Screw

3. Remove both steering gears from the steering gear


tray. (See Steering Gear Replacement on
page 1-41)
1

7. Using an Allen wrench, remove the bleed screw (1) and


the ball (2) from the rear of the secondary steering gear
(3). Gravity will draw the oil into the gear and, therefore,
push the air out (this could take from 5 seconds to a
minute). The air in the rear cylinder bore is gone when
a constant stream of oil comes out of the bleed port.
Install the ball and bleed screw back into the port and
tighten. Install plastic plug.

4
~

8. Verify that the hydraulic fluid level in the reservoir is at


the full mark. Add oil as needed.
9. Start the engine and steer to a full right turn, then shut
off the engine.
10. Remove plastic plug from bleed screw port.
4

Front CrossmemberViewed from Top

4. Remove six locknuts (1), screws (2), and support (3)


from the steering gear tray (4) and front crossmember
(5).

Secondary Steering GearFront Bleed Screw

DocID

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-55

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

Front of
Vehicle

! WARNING

13

8
10

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
NOTE:

10
12
7

Install all fasteners hand tight until all fasteners


have been installed and steering gear tray has
been centered.
Always use new locknuts for installation.

11

5. Remove three locknuts (6) and screws (7) from each


side of the steering gear tray (4).
NOTE: Support bracket and steering gear tray before
removing screws and nuts.
6. Remove the front two locknuts (8) and screws (9) from
each side of the steering gear tray (4) and side plate
(10).

1. Apply Loctite 242 (Pierce P/N 1198896) to all screw


threads (7, 9, and 13).
2. Install steering gear tray (4) between side plates, and
install two screws (13) and locknuts (12) on each side
of the steering gear tray and side plate (10). Do not
tighten screws and locknuts at this time.

7. Remove bracket (11).

3. Install bracket (11) to steering gear tray (4) using three


locknuts (6) and screws (7) on each side of the steering
gear tray.

8. Remove the rear two locknuts (12) and screws (13)


from each side of the steering gear tray (4) and side
plate (10), and remove steering gear tray.

4. Install two screws (9) and locknuts (8) on each side of


the steering gear tray (4) and side plate (10). Do not
tighten screws and locknuts at this time.
1

b. Installation
6

Front of
Vehicle

4
~

13

4
~

8
10

10

5
12
7

11

Front CrossmemberViewed from Top

NOTE: Always use new locknuts for installation.


5. Install the support (3) on the steering gear tray (4) and
front crossmember (5) using six screws (2) and
locknuts (1).
6. Install the steering gears. (See Steering Gear
Replacement on page 1-41)

Page 1-56

TAK-4 INDEPENDENT FRONT SUSPENSION

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FRONT AXLE & SUSPENSION


6. Remove five locknuts (9) and screws (10) from each
side of the rear crossmember (4) and remove the rear
crossmember.

7. Tighten all 5/8-inch nuts to 210 lb-ft (285 Nm).


8. Tighten all 3/4-inch nuts to 375 lb-ft (508 Nm).
9. Apply Sentry Seal (Pierce P/N 95-1356) to screws (2,
7, 9, and 13) and locknuts (1, 6, 8, and 12).

b. Installation

10. Remove DO NOT START tag from truck ignition


switch.

24. REAR CROSSMEMBER REPLACEMENT

5
6

a. Removal
1. Attach a DO NOT START tag to truck ignition switch.

2. Remove wheel/tire assemblies. (See Front Wheel and


Tire Service, Group 0705-P-001.)
3. Remove any oil cooler lines or air lines. Label them to
ensure correct installation.
~

6
~

10

8 NOT SHOWN

4. Remove two screws (1) and locknuts (2) from the


rearmost pivot pin blocks on the lower control arm (3)
on each side of the rear crossmember (4).
5. Remove locknut (5) and screw (6) from each side of the
rear crossmember (4) and side plates (7 and 8).

DocID

8 NOT SHOWN

! WARNING

10

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
NOTE:
Install all fasteners hand tight until all fasteners
have been installed.
Always use new locknuts for installation.
1. Apply Loctite 242 (Pierce P/N 1198896) to all screw
threads (1, 6, and 10).

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-57

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

2. Position the rear crossmember (4) between both of the


side plates (7 and 8) and loosely install a screw (6) and
locknut (5) on each side of the rear crossmember (4).

3. Loosely install five locknuts (9) and screws (10) on


each side of the rear crossmember (4).
4. Loosely install two screws (1) and locknuts (2) in the
rear-most pivot pin blocks on the lower control arm (3)
on each side of the rear crossmember (4).

5. Tighten locknuts (5) and screws (6) to 375 lb-ft


(508 Nm).
6. Tighten locknuts (2) and screws (1) to 375 lb-ft
(508 Nm).

7. Tighten locknuts (9) and screws (10) to 210 lb-ft (285


Nm).
8. Install oil filter lines and any other air lines or hoses that
were removed.
9. Install wheel/tire assemblies. (See Front Wheel and
Tire Service, Group 0705-P-001.)
10. Remove DO NOT START tag from truck ignition
switch.

Front CrossmemberViewed from Top

4. Remove cushion clamps (5) as needed.


5. Remove three locknuts (6) and screws (7) from support
(8) and front crossmember (9).

25. FRONT CROSSMEMBER


REPLACEMENTSTANDARD
a. Removal
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assemblies. (See Front Wheel and
Tire Service, Group 0705-P-001.)

NOTE: Matchmark U-joint and steering gear input shaft


before removing steering shaft.
3. Remove locknut (1) and screw (2) from U-joint (3), and
remove U-joint from primary steering gear (4).

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b. Installation

15
16

15
16
17
17

~
~

13
13

17
18

17
18

9
9
12

10 11

13

14 NOT SHOWN

6. Remove four locknuts (10) and screws (11) that attach


the lower control arm (12) to the side plates (13 and 14)
and the front crossmember (9).
7. Remove locknut (15) and screw (16) from each side of
the front crossmember (9) and side plates (13 and 14).
8. Remove five locknuts (17) and screws (18) from each
side of the front crossmember (9) and remove the front
crossmember.

10 11

12

NOTE: Support the front crossmember before


removing screws and locknuts.

13

14 NOT SHOWN

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.
NOTE:
Install all fasteners hand tight until all fasteners
have been installed.
Always use new locknuts for installation.

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TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-59

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

1. Apply Loctite 242 (Pierce P/N 1198896) to all screw


threads (11, 16, and 18).

2. Position the front crossmember (9) between both side


plates (13 and 14), and loosely install five screws (18)
and locknuts (17).

3. Loosely install a screw (16) and locknut (15) on each


side of the front crossmember (9).
4. Loosely install four screws (11) and locknuts (10) on
each side of the lower control arm (12).

5. Tighten locknuts (17) and screws (18) to 210 lb-ft (285


Nm).
6. Tighten locknuts (15) and screws (16) to 375 lb-ft
(508 Nm).

7. Tighten locknuts (10) and screws (11) to 375 lb-ft


(508 Nm).
8. Apply Sentry Seal (Pierce P/N 95-1356) to screws (11,
16, and 18) and locknuts (10, 15, and 17).
6

NOTE: Always use new locknuts for installation.


11. Connect the steering shaft U-joint (3) to the primary
steering gear (4), aligning the match marks. Secure the
U-joint using a screw (2) and locknut (1).

12. Install wheel/tire assemblies. (See Front Wheel and


Tire Service, Group 0705-P-001.)
13. Remove DO NOT START tag from truck ignition
switch.

26. FRONT CROSSMEMBER


REPLACEMENTLIFT AND TOW OPTION

a. Removal

1. Attach a DO NOT START tag to truck ignition switch.


8

2. Remove wheel/tire assemblies. (See Front Wheel and


Tire Service, Group 0705-P-001.)

Front CrossmemberViewed from Top.


1

NOTE: Always use new locknuts for installation.


9. Install three screws (7) and locknuts (6) in front
crossmember (9) and support (8).

10. Install cushion clamps (5) as needed.

NOTE: Matchmark U-joint and steering gear input shaft


before removing steering shaft.

Page 1-60

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3. Remove locknut (1) and screw (2) from U-joint (3), and
remove U-joint from primary steering gear (4).
6

13

17 18

10
11

14 15

Front CrossmemberViewed from Top.

16

4. Remove cushion clamps (5) as needed.


12

5. Remove three locknuts (6) and screws (7) from support


(8) and front crossmember (9).

19
20

NOTE: Support the front crossmember before


removing screws and locknuts.
6. Remove two locknuts (10) and screws (11) from each
side of the front crossmember (9) and side plates (12
and 13).

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FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

7. Remove four locknuts (14) and screws (15) that attach


the front of the lower control arm (16) to the side plates
(12 and 13) and the front crossmember (9).

b. Installation
13

8. Remove locknut (17) and screw (18) from each side of


the front crossmember (9) and side plates.

17 18

10

9. Remove five locknuts (19) and screws (20) from each


side of the front crossmember (9), and remove the front
crossmember.

11

14 15

16

12

19
20

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27. SIDE PLATE REPLACEMENT

NOTE:
Install all fasteners hand tight until all fasteners
have been installed.
Always use new locknuts for installation.
1. Apply Loctite 242 (Pierce P/N 1198896) to all screw
threads (11, 15, 18, and 20).
2. Position the front crossmember (9) between both side
plates, and loosely install two locknuts (10) and screws
(11) on each side of the front crossmember (9) and side
plates (12 and 13).
3. Loosely install four locknuts (14) and screws (15) that
attach the lower control arm (16) to the side plates (12
and 13) and the front crossmember (9).

a. Removal
NOTE: Both of the side plates are removed the same
way.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove shock absorber. (See Shock Absorber
Replacement on page 1-11)
3. Remove jounce stop. (See Jounce Stop
Replacement on page 1-12)
4. Remove upper control arm, (See Upper Control Arm
Repair on page 1-25)

4. Loosely install five screws (20) and locknuts (19) on


each side of the front crossmember (9).

5. Remove lower control arm. (See Lower Control Arm


Repair on page 1-31)

5. Loosely install locknut (17) and screw (18) on each side


of the front crossmember (9) and side plates.

6. Remove front crossmember. (See Front


Crossmember ReplacementStandard on
page 1-58 or Front Crossmember Replacement
Lift and Tow Option on page 1-60)

6. Tighten locknut (17) and screw (18) to 375 lb-ft


(508 Nm).
7. Tighten locknuts (14) and screws (15) to 210 lb-ft (285
Nm).

7. Remove rear crossmember. (See Rear


Crossmember Replacement on page 1-57)
8. Remove steering gear tray. (See Steering Gear Tray
Replacement on page 1-55)

8. Tighten locknuts (10) and screws (11) to 375 lb-ft


(508 Nm).

9. Tighten locknuts (19) and screws (20) to 210 lb-ft (285


Nm).

10. Apply Sentry Seal (Pierce P/N 95-1356) to all screws


and locknuts.
1
3
4

! WARNING
3

The side plate assembly weighs an estimated 130


lb (59 kg). Have an assistant help during removal
or use a suitable lifting device. Failure to comply
could result in injury to personnel.

NOTE: Always use new locknuts for installation.


11. Connect the steering shaft U-joint (3) to the primary
steering gear (4), aligning the match marks. Secure the
U-joint using a screw (2) and locknut (1).
12. Remove DO NOT START tag from truck ignition
switch.

DocID

NOTE:
Note positions of the attaching hardware during
removal to ensure correct installation.
Quantum and Velocity chassis will have nine
screws and nuts securing the side plate to the
frame.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-63

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

9. Remove locknuts (1) and screws (2) and remove side


plate (3) from frame (4).

9. Install jounce stop. (See Jounce Stop


Replacement on page 1-12)

b. Installation
NOTE: Both of the side plates are installed the same
way.
4

8. Install shock absorber. (See Shock Absorber


Replacement on page 1-11)

10. Remove DO NOT START tag from truck ignition


switch.

28. STEERING HARD STOP SET SCREW


REPLACEMENT
a. Removal
NOTE: Both of the steering hard stop set screws are
removed the same way.

1. Attach a DO NOT START tag to truck ignition switch.


2. Center the steering wheel with the truck on a dry level
surface.
3. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)
3

! WARNING

Adhesives, solvents, and sealing compounds can


burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

NOTE: Install all fasteners hand tight until all fasteners


have been installed.
1. Apply Loctite 242 (Pierce P/N 1198896) to all screw
threads (2).
2. Position side plate (3) on frame (4) and install screws
(2) and locknuts (1) in the positions as noted during
removal. Tighten all hardware to 210 lb-ft (285 Nm).
3. Install steering gear tray. (See Steering Gear Tray
Replacement on page 1-55)
4. Install rear crossmember. (See Rear Crossmember
Replacement on page 1-57)
5. Install front crossmember. (See Front Crossmember
ReplacementStandard on page 1-58 or Front
Crossmember ReplacementLift and Tow Option
on page 1-60)

4. Remove rubber sleeve (1).


5. Loosen the jam nut (2) on the steering stop set screw
(3).
6. Remove the steering stop set screw (3) from the side
plate (4).

b. Installation
NOTE: Both of the steering hard stop set screws are
installed the same way.

6. Install upper control arm. (See Upper Control Arm


Repair on page 1-25)
7. Install lower control arm. (See Lower Control Arm
Repair on page 1-31)

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2
3
1

1. Install the steering stop set screw (3) with jam nut (2) in
the side plate (4).
2. Tighten the jam nut (2) on the steering stop set screw
(3) to 150 lb-ft (204 Nm).
3. Install rubber sleeve (1) over the end of the steering
stop set screw (3).

3. Remove cable ties (1) securing ABS sensor wire


harness (2) to the air brake line (3).
4

4. Perform steering system adjustments. (See Torsion


Bar Replacement on page 1-45)
5. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)

5
~

6. Remove DO NOT START tag from truck ignition


switch.

29. ABS SENSOR REPLACEMENT


a. Removal
NOTE: Both ABS sensors are removed the same way.
1. Attach a DO NOT START tag to truck ignition switch.
2. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

! CAUTION
Use caution when removing the ABS sensor. Do
not pull on the wire harness to remove it. Possible
damage to the sensor could occur if sensor is
removed by pulling on the wire harness.
4. Grasp the ABS sensor body (4) and pull out of the
bushing in the steering knuckle (5).

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GROUP 0152-P-002-0114

2
3
1

6
8
7

5. Remove cable ties (6) securing ABS sensor wire


harness (2) to the truck harness (7).
2

NOTE: Note the routing of the ABS harness to ensure


correct installation.

6. Unplug the wire harness connector (8) and remove the


ABS sensor wire harness (2).

b. Installation
NOTE: Both ABS sensors are installed the same way.
6
4

8
7

2. Route ABS wire harness (2) as noted during removal.


3. Connect the ABS sensor wire harness connector (8) to
truck harness.
4. Secure the ABS sensor wire harness (2) to the truck
harness (7) using cable ties (6) as needed.
5. Secure the ABS sensor wire harness (2) to the air brake
line (3) using cable ties (1 and 6).
6. Install wheel/tire assembly. (See Front Wheel and Tire
Service, Group 0705-P-001.)
NOTE: Grease must be mineral oil-based and contain
molydisulfide. It should have excellent anticorrosion and adhesion characteristics, and be
capable of continuous function within a
temperature range of 40 to 300F
(40 to 150C).

7. Adjust ABS sensor gap. (See Adjustment on


page 1-66)

c. Adjustment
NOTE: Both front ABS sensors are adjusted the same
way.

1. Apply Meritor WABCO-approved grease (Pierce P/N


1971740) to ABS sensor body (4) and install ABS
sensor body into bushing in steering knuckle (5).

Page 1-66

TAK-4 INDEPENDENT FRONT SUSPENSION

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a. Scheduled Inspections

! WARNING
DO NOT get under the truck in any way after it is
raised unless the truck is supported with safety
stands or blocks. The hydraulic jack is used for
lifting the vehicle only, and not for supporting the
vehicle in the raised position. Failure to correctly
support the truck could let the truck fall, causing
serious injury or death.

! WARNING
Place blocks under the rear wheels to keep the
vehicle from moving, which may cause personal
injury.
1. Raise wheel off of the ground high enough to be able
to spin the wheel.
2. Push the ABS sensor fully into the bushing until it
bottoms out against the ABS exciter ring.
3. Spin the wheel a few complete revolutions to set the
ABS sensor air gap.
4. Lower wheel to the ground.
NOTE: Ensure that the ABS cable routing is correct by
steering the wheel end through the full range of
motion. Monitor the ABS cable to ensure that it
does not go tight or become pinched. Reposition
as needed.
5. Check operation of the ABS system.

30. MAINTENANCE INSPECTION INTERVALS


This section provides instruction for periodic inspection
intervals of the independent suspension system. All
servicing and maintenance must be performed at specified
intervals for optimum vehicle performance and maximum
uptime.

NOTE:
The safety inspection should be performed on
vehicles in case of a major assembly failure or if
major brake repairs are required within 60 days or
2,000 miles of a scheduled safety inspection.
Worn parts or components visually determined to
be in doubtful condition should be considered
justification for complete disassembly/repair and/
or replacement.
Inspection intervals to be observed on this vehicle are
categorized as follows:
Daily (or after each use).
PeriodicMonthly, 50 hours, or 1,000 miles, whichever
comes first.
Periodic4 months, 100 hours, or 2,000 miles,
whichever comes first.
Periodic36 months, or 50,000 miles, whichever
comes first.
SafetyAnnually, 300 hours, or 6,000 miles,
whichever comes first.
The vehicle Operator's Manual contains the daily
inspections which should be performed by the vehicle
operators. Periodic inspections in this section should be
conducted by maintenance personnel. Periodic inspection
of the independent suspension system consists of
performance, condition checks, and visual inspection of
components. It is intended that these inspections and
services, listed in the table, be accomplished by the visual
and feel method during the course of lubrication, and
should not be cause for extensive test or corrective action
unless such actions are obviously required.
Safety inspections should be performed at intervals
specified in the table. This inspection includes items which
may affect safety of personnel and equipment.

The Scheduled Inspections table in this section lists the


inspections to be conducted and specifies the intervals at
which such inspection should be performed. Intervals are
nominal periods, based on normal operating conditions.
Intervals should be adjusted accordingly for extremes of
temperature or other adverse operating conditions existing
in the area of vehicle operation.

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GROUP 0152-P-002-0114

Table 1-3: Scheduled Inspections


System/Components to Be Checked

Inspection Interval
Daily

Periodic

Safety

Or after
Monthly 4 Months 36 Months
each use 50 Hours 100 Hours 50,000
Miles
2000
1000
Whicheve
Miles
Miles
r Comes
Whicheve
Whicheve
First
r Comes r Comes
First
First

Annually
300 Hours
6000
Miles
Whicheve
r Comes
First

Front and Rear Suspension


Re-torque the steering gear mounting bolts to 460 ft-lb.
Inspect for broken or damaged torsion bars.a
Check clamps, hangers, and hardware for damage, wear, or
corrosion.

X
X
X

Wheels and Tires


Check for proper tire air pressure.
Inspect tires for uneven wear or damage.
Inspect wheel bearings for wear or damage.
Check tightness of wheel mounting bolts.
Inspect rims for damage.
Check alignment of the front wheels.

X
X
X
X
X
X

Service Brakes
Check operation of brakes for uneven action, dragging, slow,
or spongy action, and squealing or chatter.
Inspect all brake lines and hoses for air leaks or damage.
Check brake pads for wear and general condition.
Replace as necessary.
Check wheel chambers for leaks and proper operation.

X
X
X
X

Steering System
Check operation.
Check steering pump for external leaks.
Check level of fluid in hydraulic system reservoir.
Inspect filter cartridge for deposits. Replace if necessary.
Check pump mounting hardware for security.
Check all lines and hoses for leaks or damage.
Inspect steering stops for proper setting.
Inspect steering gears for oil leaks.
Inspect linkages for wear or damage.
Inspect upper and lower ball joints for wear.

X
X
X
X
X
X
X
X
X
X

a. Inspect tape on torsion bars for cuts or tears. Repair cuts or tears by applying RTV to the area or by retaping. Allowing a
tear or cut to remain in the tape could allow water/salt entry which could cause rust to form on the torsion bars. Rust and
subsequent pitting will weaken the torsion bar and the torsion bar could fail.

Page 1-68

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31. BALL JOINT INSPECTION

! CAUTION
The upper and lower control arm ball joints are
designed to be lubed-for-life. They do not require
periodic maintenance. DO NOT ATTEMPT TO
LUBRICATE OR FILL WITH GREASE. Attempting
to lubricate can result in damage to equipment.
Both the upper and lower ball joints on the TAK-4
Independent Suspension should be inspected at 50,000
mile intervals or every three years.
Inspect one side of the truck at a time.

8
4

Inspection of the ball joints requires approximately


45 minutes per side and requires the following tools:

Floor jack
Jack stand
Bottle jack
3/4 inch drive impact wrench and sockets for wheel
removal

3- to 4-foot (0.9- to 1.2-meter) long pry bar


1-5/8 inch open end wrench (qty. 2)
Dial indicator with magnetic base
2 x 4 x 6 inch wood block

a. Upper Ball Joint Procedure


4. Verify that the torsion bar (3) is completely unloaded. If
there is space between the pin (4) and torsion bar
anchor (5) and/or a space between the inner jam nut (6)
and pin (4), the torsion bar is unloaded. If the torsion bar
is unloaded, proceed to step 7.

5. Unload torsion bar. Match mark (7) inner jam nut (6)
with pin (4) as shown.
2

! CAUTION
Do NOT disconnect the shock absorber in an
attempt to get increased downward suspension
travel, as equipment damage will occur.

1. Using a side plate (1) as a jacking point, raise one side


of truck until tire is off the ground.
2. Install a jack stand (2) as a safety stand at the rear of
the side plate (1) as shown. Supporting the side plate
allows full suspension rebound (downward travel).
3. Remove wheel/tire assembly. (See Front Wheel and
Tire Service, Group 0705-P-001.)

DocID

NOTE: Failure to correctly count inner jam nut turns will


result in changed vehicle ride height if the inner jam
nut is reinstalled in a different position.
6. Loosen outer jam nut (8) and spin back approximately
10 turns. Loosen inner jam nut and count the number
of rotations it takes to loosen until nut can be spun by
hand.

TAK-4 INDEPENDENT FRONT SUSPENSION

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FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
10. Push down on the pry bar (15) with approximately
100 pounds of force to seat the ball joint. Set the dial
indicator (11) to zero.

10

11

14

13

15

7. Install the bottle jack (9) under the lower control arm
jacking point. Raise the jack up until the jack just
contacts the control arm (10). Raise the lower control
arm approximately 0.25 inches (6.35 mm). Verify that
the torsion bar is still unloaded. If torsion bar is loaded,
loosen the inner jam nut further.
11

17

11. Remove the wood block (13) from the upper control
arm (14) and set on top of steering arm (17) as shown.
Place pry bar (15) on top of wood block and position the
pry bar under the upper control arm.
12. Push down on the pry bar (15) with approximately
100 pounds of force and record the measurement on
the dial indicator (11):
a. If the measurement at 50,000 miles or after first three
years is 0.015 inches (0.381 mm) or greater, replace
the upper ball joint.

12

b. If less than 0.015 inches (0.381 mm), refer to the


following table. It will indicate when the next
inspection should be, based on actual free play
measurement.
Table 1-4: Upper Ball Joint Inspection Schedule

8. Install the magnetic-based dial indicator (11) on top of


the knuckle (12) as shown. Indicate the plunger on the
top of the upper control arm, perpendicular to the top
surface.
13

16
11

If free play measurement


at 50,000 miles is:

Next inspection interval


should be at:

0.014 inch
0.013 inch
0.012 inch
0.011 inch
0.010 inch
0.009 inch
0.008 inch

5,000 miles
8,000 miles
11,000 miles
15,000 miles
18,000 miles
21,000 miles
25,000 miles

15

b. Lower Ball Joint Procedure


1. Perform steps 1 through 7 of the upper ball joint
inspection procedure.
14

9. Place the 2 x 4 x 6 inch wood block (13) on top of the


upper control arm (14). Insert the pry bar (15) into the
jounce bumper pocket (16).

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Table 1-5: Lower Ball Joint Inspection Schedule

If free play measurement


at 50,000 miles is:

Next inspection interval


should be at:

0.022 inch
0.021 inch
0.020 inch
0.019 inch
0.018 inch

11,000 miles
15,000 miles
18,000 miles
21,000 miles
25,000 miles

2
3

6. Remove the dial indicator, pry bar, wood block, and


bottle jack from the truck.
6

2. Place the magnetic-based dial indicator (1) on the


bottom of the knuckle (2) as shown. Indicate plunger on
bottom of lower control arm (3), perpendicular to
bottom surface. Set dial indicator to zero.
3. Place the 2 x 4 x 6 inch wood block (4) on the lower
control arm between the knuckle (2) and lower shock
mount (5).
8
4

7. If the torsion bar was unloaded when the truck was


disassembled, tighten the inner jam nut back to its
original position. With the inner jam nut rotated the
original number of turns, align the match marks. Install
the outer jam nut and torque to 180 lb-ft (244 Nm).

8. Install wheel/tire assembly. (See Front Wheel and Tire


Service, Group 0705-P-001.)
1

4. Place pry bar (6) on top of wood block (4) with tip of pry
bar under ball joint stud on steering arm as shown.
5. Press down on the pry bar (6) with approximately 110
pounds of force and record the measurement on the
dial indicator (1):
If the measurement at 50,000 miles or after first three
years is 0.025 inches (0.635 mm) or greater, replace
the lower ball joint.
If less than 0.025 inches (0.635 mm), refer to the
following table. It will indicate when the next inspection
should be, based on actual free play measurement.
Table 1-5: Lower Ball Joint Inspection Schedule
If free play measurement
at 50,000 miles is:

Next inspection interval


should be at:

0.024 inch
0.023 inch

5,000 miles
8,000 miles

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9. Repeat the ball joint check on the opposite side of the


truck.

32. TOE CONTROL LINK INSPECTION

! CAUTION
The tie rod ball joints are designed to be lubedfor-life. They do not require periodic
maintenance. DO NOT ATTEMPT TO LUBRICATE
OR FILL WITH GREASE. Attempting to lubricate
can result in damage to equipment.
The toe control link steering joints on the TAK-4
Independent Suspension should be inspected annually.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-71

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

a. Visual Inspection

NOTE:
The following procedure requires two people.
Some end lift movement is part of the design of
the steering joint and should be considered normal.
As the joint is articulated it will kick out. This is part
of the design of the joint which increases its life
span. This feature should not be mistaken for
excessive wear or replacement need. After the
visual check, perform the end lift measurement
tests to determine if the joint is within
specifications.

1. Park the vehicle on a flat surface.


2. Rock the steering wheel firmly in each direction, with a
force great enough to load the steering components
and joints.
3. As the steering wheel is being rocked, have a helper
visually inspect the ball joints for excessive end lift play.
Some movement is normal.
4. Visually inspect the steering joint boot(s). If any
damage to the boot is present which could allow
moisture or foreign matter to enter, the steering joint
must be replaced.

b. End Lift Measurement


And end lift measurement should be performed to
determine the condition of the steering joint. This is
performed by applying a load through the axis of the pin and
measuring its movement relative to the socket body. If the
measurement exceeds the maximum allowable tolerance,
the steering joint should be replaced.

4. Place a magnetic-based dial indicator (1) on a flat


surface which will not move, such as the steering arm
(2). Indicate the plunger in the top of the steering joint,
ideally in the center of the rivet (3) and perpendicular to
the to surface.

! CAUTION
The load applied should never exceed 1622 ft. lbs
(2200 Nm) or damage to the joint may result,
making the joint unfit for service.
Load
Point
End Lift
Measurement

This procedure requires the following tools:


2-foot (0.6-meter) long pry bar or wide jaw pliers
Dial indicator with magnetic base
1. Attach a DO NOT START tag to truck ignition switch.

! WARNING
Cab stay arm must be in the support position
before working under the cab or on cab lift
components. Failure to comply may result in
serious injury or death to personnel.
2. Raise cab for Quantum, Saber, Arrow XT,
Velocity, Impel and Dash CF (Refer to Operation
& Maintenance Manual.)
3. Turn battery switch OFF (if equipped).

5. Using a pry bar, apply a downward force of 737 ft. lbs


(1000 Nm) at the load point.
6. Measure the end lift of the ball joint. Refer to Table 16 for tolerances.
Table 1-6: Steering Joint Inspection
Testing Load

Wear Out End Lift

737 ft lbs (1000 Nm)

.079 in (2mm) MAX

7. If the end lift measurement is greater than the


maximum allowable, replace the steering joint.

Page 1-72

TAK-4 INDEPENDENT FRONT SUSPENSION

DocID

GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

33. LUBRICATION
a. Steering Gear Lubrication (Primary
Steering Gear)
One grease fitting is
located at the input shaft.

Two grease fittings are located under


the upper control arm pivot points.

Two grease fittings are located on the


top of the lower control arm pivot points.
The rear fitting is not shown.

Maintain grease pack behind the input shaft dirt and water
seal as a general maintenance procedure at least twice a
year, in the spring and fall. Use GAA grease and only a
hand-operated grease gun. Add grease until it begins to
extrude past the input shaft dirt and water seal.

b. Independent Suspension Components

! CAUTION
The upper and lower control arm ball joints are
designed to be lubed for life. They do not require
periodic maintenance. DO NOT ATTEMPT TO
LUBRICATE OR FILL WITH GREASE. Attempting
to lubricate can result in damage to equipment.

NOTE: If the truck is equipped with a Vogel Lube or


Robert Shaw Lube automatic lubrication system,
refill the reservoir using only the following
approved greases:
NLGI grade #00 (Mobil Mobilith SHC 007, Shell
Alvania EP 00, Chevron Dura-Lith 00, Conoco EP
Conolith 00, Castrol Dryden Drydene Lithium EP
00)
NLGI grade #000 (Mobil Mobilux EP 023, Shell
Alvania EP 000, Exxon Lidok 000, Conoco EP
Conolith 000, Castrol Dryden Drydene Lithium EP
000)

1. UPPER AND LOWER CONTROL ARM PIVOT


POINTS
Apply grease to fittings until the bushings purge. Grease as
a general maintenance procedure at least twice a year, in
the spring and fall.
Only the following NLGI Grade #2 greases are approved for
use on the TAK-4 suspensions.
GAA

DocID

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-73

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
Table 1-7: Wheel Bearing Lubricants

Shell Alvania EP2


Mobil Mobilith SHC220

Oil

Exxon/Mobil Ronex MP

Timken Approved

SAE 80W90 GL5 Gear Oil

Mobil Mobilux EP2

Grease

Castrol HD Lithium EP

Timken Preferred

2. TIE AND TOE CONTROL LINKS

34. RIDE HEIGHT ADJUSTMENT

These components are lubricated for life. No maintenance


is required.

The torsion bar anchor system on the TAK-4 suspension


is designed so that a Pierce Manufacturing authorized
service facility can easily adjust the vehicle ride height to
factory specifications or eliminate side-to-side lean.

c. Disc Brakes
Lubricate slide pins with Bendix approved grease. Grease
as a general maintenance procedure every 10,000 miles
(16 090 km).

! CAUTION
Failure to maintain the ride height within the
specified range, either too low or too high, could
cause 1) the suspension components to break or
malfunction, 2) the ride height to sag over time, or
3) the steering to wander.

d. Wheel Bearings
Table 1-7: Wheel Bearing Lubricants
Oil
Timken Preferred

Tables 1-8, 1-9, and 1-10 show the ride height specification
that is required for each axle weight rating. Setting the
vehicle ride height at the target height will maximize the
durability and performance of the suspension.

SAE 75W90 GL5


Synthetic Gear Oil
SAE 85W140 GL5 Gear Oil

Timken Approved

Lithium NLGI Grade EP2 Grease

Measured front
axle weight

Table 1-8: Frame Heights for Arrow XT, Impel and Velocity (Standard 4-Inch Jounce)

24000
23500
23000
22800
22500
22000
21500
21000
20500
20000
19500
19000
18500
18000
17500
17000
16500
16000
15500
15000
14500

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

27.90
28.02
28.13
28.18
28.25
28.36
28.48
28.60
28.71
28.83
28.95
29.07
29.19
29.31
29.43
29.55
29.67
29.79
29.91
30.03
30.15

27.80
27.92
28.03
28.08
28.15
28.26
28.36
28.50
28.61
28.73
28.85
28.97
29.09
29.21
29.33
29.45
29.57
29.69
29.81
29.93
30.05

27.60
27.72
27.83
27.88
27.95
28.06
28.18
28.30
28.41
28.53
28.65
28.77
28.89
29.01
29.13
29.25
29.37
29.49
29.61
29.73
29.85

27.40
27.47
27.59
27.70
27.82
27.94
28.06
28.17
28.29
28.41
28.53
28.65
28.77
28.89
29.01
29.13
29.25
29.37

27.40
27.47
27.59
27.70
27.82
27.94
28.06
28.17
28.29
28.41
28.53
28.65
28.77
28.89
29.01
29.13
29.25
29.37

27.10
27.17
27.29
27.40
27.52
27.64
27.76
27.87
27.99
28.11
28.23
28.35
28.47
28.59
28.71
28.83
28.95
29.07

26.40
26.47
26.59
26.70
26.82
26.94
27.06
27.17
27.29
27.41
27.53
27.65
27.77
27.89
28.01
28.13
28.25
28.37

26.40
26.55
26.71
26.86
27.02
27.18
27.33
27.49
27.65
27.81
27.97

26.40
26.55
26.71
26.86
27.02
27.18
27.33
27.49
27.65
27.81
27.97

26.30
26.45
26.61
26.76
26.92
27.08
27.23
27.39
27.55
27.71
27.87

26.80
26.76
26.91
27.07
27.23
27.39
27.55
27.71

26.40
28.56
26.71
26.87
27.03
27.19
27.35
27.51

26.50
26.66
26.81
26.97
27.13
27.29
27.45
27.61

26.60
26.76
26.91
27.07
27.23
29.39
27.55
27.71

REF: 1751760 (B)

Page 1-74

TAK-4 INDEPENDENT FRONT SUSPENSION

DocID

GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

Measured front
axle weight

Table 1-8: Frame Heights for Arrow XT, Impel and Velocity (Standard 4-Inch Jounce)

14000
13500
13000
12500
12000
11500
11000
10500
10000

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

30.27
30.39
30.52
30.64
30.76
30.88
31.01
31.13
31.25

30.17
30.29
30.42
30.54
30.66
30.78
30.91
31.03
31.15

29.97
30.09
30.22
30.34
30.46
30.58
30.71
30.83
30.95

29.49
29.62
29.74
29.86
29.98
30.11
30.23
30.35
30.47

29.49
29.62
29.74
29.86
29.98
30.11
30.23
30.35
30.47

29.19
29.32
29.44
29.56
29.68
29.81
29.93
30.05
30.17

28.49
28.62
28.74
28.68
28.98
29.11
29.23
29.35
29.47

28.13
28.29
28.45
28.62
28.78
28.94
29.11
29.27
29.44

28.13
28.29
28.45
28.62
28.78
28.94
29.11
29.27
29.44

28.03
28.19
28.35
28.52
28.68
28.84
29.01
29.17
29.34

27.87
28.03
28.19
28.35
28.52
28.68
28.85
29.01
29.18

27.67
27.83
27.99
28.15
28.32
28.48
28.65
28.81
28.98

27.77
27.93
28.09
28.25
28.42
28.58
28.75
28.91
29.08

27.87
28.03
28.19
28.35
28.52
28.68
28.85
29.01
29.18

REF: 1751760 (B)

NOTE:
The frame height is the distance from the ground
to the bottom of the frame rail.
The permitted tolerance is 0.13 in.
If the measured weight falls between the weights
given in the table, round up to the higher weight
value.

Measured front
axle weight

Table 1-9: Frame Heights for Arrow XT, Impel and Velocity (3-Inch Jounce)

24000
23500
23000
22800
22500
22000
21500
21000
20500
20000
19500
19000
18500
18000
17500
17000
16500
16000
15500
15000
14500

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

26.90
26.99
27.08
27.11
27.17
27.25
27.34
27.43
27.52
27.61
27.70
27.79
27.88
27.97
28.06
28.15
28.24
28.33
28.42
28.51
28.61

26.80
26.89
26.98
27.01
27.07
27.15
27.24
27.33
27.42
27.51
27.60
27.69
27.78
27.87
27.96
28.05
28.14
28.23
28.32
28.41
28.51

26.60
26.69
26.78
26.81
26.87
26.95
27.04
27.13
27.22
27.31
27.40
27.49
27.58
27.67
27.76
27.85
27.94
28.03
28.12
28.21
28.31

26.40
26.45
26.54
26.63
26.72
26.81
26.90
26.99
27.08
27.17
27.26
27.35
27.44
27.53
27.62
27.71
27.80
27.89

26.40
26.45
26.54
26.63
26.72
26.81
26.90
26.99
27.08
27.17
27.26
27.35
27.44
27.53
27.62
27.71
27.80
27.89

26.10
26.15
26.24
26.33
26.42
26.51
26.60
26.69
26.78
26.87
26.96
27.05
27.14
27.23
27.32
27.41
27.50
27.59

25.40
25.45
25.54
25.63
25.72
25.81
25.90
25.99
26.08
26.17
26.26
26.35
26.44
26.53
26.62
26.71
26.80
26.89

25.40
25.52
25.64
25.76
25.88
26.00
26.12
26.24
26.36
26.48
26.60

25.40
25.52
25.64
25.76
25.88
26.00
26.12
26.24
26.36
26.48
26.60

25.30
25.42
25.54
25.66
25.78
25.90
26.02
26.14
26.26
26.38
26.50

25.60
25.72
25.84
25.96
26.08
26.20
26.32
26.44

25.40
25.52
25.64
25.76
25.88
26.00
26.12
26.24

25.50
25.62
25.74
25.86
25.98
26.10
26.22
26.34

25.60
25.72
25.84
25.96
26.08
26.20
26.32
26.44

REF: 1751760 (B)

DocID

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-75

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114

Measured front
axle weight

Table 1-9: Frame Heights for Arrow XT, Impel and Velocity (3-Inch Jounce)

14000
13500
13000
12500
12000
11500
11000
10500
10000

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

28.70
28.79
28.88
28.97
29.06
29.15
29.24
29.34
29.43

28.60
28.69
28.78
28.87
28.96
29.05
29.14
29.24
29.33

28.40
28.49
26.58
28.67
28.76
28.85
28.94
29.04
29.13

27.98
28.07
28.17
28.26
28.35
28.44
28.53
28.62
28.72

27.98
28.07
28.17
28.26
28.35
28.44
28.53
28.62
28.72

27.68
27.77
27.87
27.96
28.05
28.14
28.23
28.32
28.42

26.98
27.07
27.17
27.26
27.35
27.44
27.53
27.62
27.72

26.72
26.84
26.96
27.09
27.21
27.33
27.45
27.58
27.70

26.72
26.84
26.96
27.09
27.21
27.33
27.45
27.58
27.70

26.62
26.74
26.86
26.99
27.11
27.23
27.35
27.48
27.60

26.56
26.69
26.81
26.93
27.05
27.17
27.30
27.42
27.54

26.36
26.49
26.61
26.73
26.85
26.97
27.10
27.22
27.34

26.46
26.59
26.71
26.83
26.95
27.07
27.20
27.32
27.44

26.56
26.69
26.81
26.93
27.05
27.17
27.30
27.42
27.54

REF: 1751760 (B)

NOTE:
The frame height is the distance from the ground
to the bottom of the frame rail.
The permitted tolerance is 0.13 in.
If the measured weight falls between the weights
given in the table, round up to the higher weight
value.

Measured front
axle weight

Table 1-10: Frame Heights for Quantum (Standard 4-Inch Jounce)

24000
23500
23000
22800
22500
22000
21500
21000
20500
20000
19500
19000
18500
18000
17500
17000
16500
16000
15500
15000
14500

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

28.90
29.02
29.13
29.18
29.25
29.36
29.48
29.60
29.71
29.83
29.95
30.07
30.19
30.31
30.43
30.55
30.67
30.79
30.91
31.03
31.15

28.80
28.92
29.03
29.08
29.15
29.26
29.38
29.50
29.61
29.73
29.85
29.97
30.09
30.21
30.33
30.45
30.57
30.69
30.81
30.93
31.05

28.60
28.72
28.83
28.88
28.95
29.06
29.18
29.30
29.41
29.53
29.65
29.77
29.89
30.01
30.13
30.25
30.37
30.49
30.61
30.73
30.85

28.40
28.47
28.59
28.70
28.82
28.94
29.06
29.17
29.29
29.41
29.53
29.65
29.77
29.89
30.01
30.13
30.25
30.37

28.40
28.47
28.59
28.70
28.82
28.94
29.06
29.17
29.29
29.41
29.53
29.65
29.77
29.89
30.01
30.13
30.25
30.37

28.10
28.17
28.29
28.40
28.52
28.64
28.78
28.87
28.99
29.11
29.23
29.35
29.47
29.59
29.71
29.83
29.95
30.07

27.40
27.47
27.59
27.70
27.82
27.94
28.06
28.17
28.29
28.41
28.53
28.65
28.77
28.89
29.01
29.13
29.25
29.37

27.40
27.55
27.71
27.86
28.02
28.18
28.33
28.49
28.65
28.81
28.97

27.40
27.55
27.71
27.86
28.02
28.18
28.33
28.49
28.65
28.81
28.97

27.30
27.45
27.61
27.76
27.92
28.08
28.23
28.39
28.55
28.71
28.87

27.60
27.76
27.91
28.07
28.23
28.39
28.55
28.71

27.40
27.56
27.71
27.87
28.03
28.19
28.35
28.51

27.50
27.66
27.81
27.97
28.13
28.29
28.45
26.61

26.40
27.76
27.91
28.07
28.23
28.39
28.55
28.71

REF: 1751760 (B)

Page 1-76

TAK-4 INDEPENDENT FRONT SUSPENSION

DocID

GROUP 0152-P-002-0114

FRONT AXLE & SUSPENSION

Measured front
axle weight

Table 1-10: Frame Heights for Quantum (Standard 4-Inch Jounce)

14000
13500
13000
12500
12000
11500
11000
10500
10000

24000

22800

445/65R22.5
Michelin

365/
70R22.5

425/65R22.5

Goodyear

Michelin

19500

18000

385/65R22.5

315/80R22.5

Goodyear

Michelin

XZY-3

XFE2

G286

XZY-3

XFE2

G286

XZA

XZY-3

Michelin
XFE2

Goodyear
G286

XZY-3

Michelin
XZA-1

G291

Goodyear
G287
MSA

31.27
31.39
31.52
31.64
31.76
31.88
32.01
32.13
32.25

31.17
31.29
31.42
31.54
31.66
31.78
31.91
32.03
32.15

30.97
31.09
31.22
31.34
31.46
31.58
31.71
31.83
31.95

30.49
30.62
30.74
30.86
30.98
31.11
31.23
31.35
31.47

30.49
30.62
30.74
30.86
30.98
31.11
31.23
31.35
31.47

30.19
30.32
30.44
30.56
30.68
30.81
30.93
31.05
31.17

29.49
29.62
29.74
29.86
29.98
30.11
30.23
30.35
30.47

29.13
29.29
29.45
29.62
29.78
29.94
30.11
30.27
30.44

29.13
29.29
29.45
29.62
29.78
29.94
30.11
30.27
30.44

29.03
29.19
29.35
29.52
29.68
29.84
30.01
30.17
30.34

28.87
29.03
29.19
29.35
29.52
29.68
29.85
30.01
30.18

28.67
28.83
28.99
29.15
29.32
29.48
29.65
29.81
29.98

28.77
28.93
29.09
29.25
29.42
29.58
29.75
29.91
30.08

28.87
29.03
29.19
29.35
29.52
29.68
29.85
30.01
30.18

REF: 1751760 (B)

NOTE:
The frame height is the distance from the ground
to the bottom of the frame rail.
The permitted tolerance is 0.13 in.
If the measured weight falls between the weights
given in the table, round up to the higher weight
value.

10

11

NOTE:
Current ride height charts provide measurements
from the bottom of the frame rail to the floor, not
from the top of the frame rail.
For all adjustments, see Table 1-8, Table 1-9, or
Table 1-10 to determine the correct ride height for
your suspension rating.

4
5
2

1. Measure the vehicle ride height as follows:


a. Measure the weight on the front axle of the vehicle at
its in-service weight (loaded with all equipment and
water).

2. Unbend locking tabs (1) at threaded rod (2).

b. Roll the vehicle forward or backward to verify that the


suspension has leveled out.

3. Place suspension in rebound by jacking up the frame


and allowing the control arms to hang down.

c. Park the vehicle on a level surface, while at its inservice weight (loaded with all equipment and
water).
d. Measure from the bottom of the frame rail to the floor,
at the front axle.

NOTE: The jam nut, screw and locknut referenced in


Steps 4 & 5 must be loose during the ride height
adjustment.
4. Loosen jam nut (3).
5. Loosen screw (4) and locknut (5).
6. Remove outer jam nut (6) and lockwasher (7) from
threaded rod (2).
7. Adjust the inner jam nut (8) until the desired ride height
is obtained:
a. Turning the jam nut clockwise raises the vehicle ride
height.

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GROUP 0152-P-002-0114

b. Turning the jam nut counter-clockwise lowers the


vehicle ride height.
c. One complete turn of the jam nut equals
approximately 0.22 in. change in ride height for that
side of the vehicle.
8. Using a jack underneath the lower control arm, raise
each wheel high enough to seat the pin (9) in the torsion
bar anchor (10) pocket and seat the torsion bar anchor
(10) against the anchor pivot block (11).
9. Tighten screw (4) and locknut (5) hand tight.

11. Lower the vehicle to the ground. Verify that the pin (9)
is fully seated in the torsion bar anchor (10) pocket
before fully loading the vehicle suspension.

10. Tighten jam nut (3) to 350 lb-ft (475 Nm).

12. Re-measure the ride height of vehicle following the


instructions in Step 1.
a. If the ride height is correct per Table 1-8, Table 1-9,
or Table 1-10, proceed to Step 13.
b. If the ride height is still incorrect, repeat Step 3 thru
Step 12 until the proper ride height is attained.
13. Loosen screw (4) and locknut (5).

! WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. Keep away from
open fire and use in well-ventilated area. If
adhesives, solvents, or sealing compounds get
on skin or clothing, wash immediately with soap
and water. Failure to comply could result in
serious injury or death to personnel.

18. When the ride height adjustment is completed, the final


jam nut location (dimension A plus B) must be 5.25
in. (13.34 cm) .75 in (1.90 cm).

14. Apply Loctite 242 (Pierce P/N 1198896) to screw


threads.
15. Torque screw (4) and locknut (5) to 210 lb-ft (285 Nm).
16. Install lockwasher (7) and outer jam nut (6), then torque
outer jam nut (6) to 180 lb-ft (244 Nm).
17. Bend over locking tabs (1) to engage flats on tube and
secure jam nut (3).

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35. TORSION BAR SURFACE REPAIR


If the torsion bars protective surface coating becomes
damaged, it must be repaired. Nicks or pitting from rusting
can be sources of future torsion bar failures. An exposed
surface subjects a torsion bar to corrosion and impact
damage that could lead to bar failure.
If there are no nicks and only light, sandable rusting, a
repair to the surface can be possible. If nicks or pitting is
apparent, the torsion bar should be replaced.
NOTE: In October 2013, a new type of torsion bar for
the TAK-4 suspension was phased into production.
These new torsion bars are identical in fit, form,
and function to the original type, but have a new
polyurethane coating. The Rhino Linings Rhino
Extreme polyurethane coating offers enhanced
durability, more complete coverage, and prevents
water infiltration behind the coating.

Clean Area

3. Clean the prepared area with isopropyl alcohol and


wipe clean with a lint-free cloth. If the area will not clean
completely with alcohol, use a slightly abrasive pad and
wipe clean with a lint-free cloth.

If your vehicle is equipped with the original type


torsion bar with the tape coating, proceed here. If
your vehicle is equipped with the polyurethanecoated torsion bar, refer to Torsion Bar
Polyurethane Repair on page 1-80.

a. Torsion Bar Tape Repair


1. REPAIR PROCEDURE

! CAUTION
Do not use a knife to cut off loose or torn tape
pieces, as the sharp edge of a knife could nick a
torsion bar. Nicks in the bar could lead to stress
cracks and potential failures.
1. Tear off any loose pieces of tape.
NOTE: Do not use paint stripper to remove loose paint
from a torsion bar.

Prepare Area

4. Apply a thin uniform coating of Dow Corning 1204


primer with a clean cloth and immediately wipe off any
excess with a second clean cloth.
Apply primer to the area of the bar that is exposed, to
the area of tape that is damaged, and to a generous
portion of the surrounding tape.
5. Allow 15 minutes for the primer to cure.

Apply RTV Coating

2. If necessary, remove any loose paint with a wire brush.


A correctly prepared area should appear like the
example.

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Apply Primer

6. Using a brush, putty knife, or dispenser, apply Dow


Corning 3145, a non-flowable RTV coating, on the
damaged area, adequately overlapping on the
surrounding area to guarantee full encapsulation.

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b. Torsion Bar Polyurethane Repair


If the torsion bars protective surface coating becomes
damaged, it must be repaired. Nicks or pitting from rusting
can be sources of future torsion bar failures. An exposed
surface subjects a torsion bar to corrosion and impact
damage that could lead to bar failure.
If there are no nicks and only light, easily sandable rusting,
a repair to the surface can be possible. If nicks or pitting is
apparent, the torsion bar should be replaced.

Blend RTV Compound

7. Wipe off or blend in excess RTV to maintain an even


thickness and avoid large drips.

NOTE: In October 2013, a new type of torsion bar for


the TAK-4 suspension was phased into production.
These new torsion bars are identical in fit, form,
and function to the original type, but have a new
polyurethane coating. The Rhino Linings Rhino
Extreme polyurethane coating offers enhanced
durability, more complete coverage, and prevents
water infiltration behind the coating.
If your vehicle is equipped with the new type
polyurethane-coated torsion proceed here. If your
vehicle is equipped with the original taped torsion
bar, refer to Torsion Bar Tape Repair on
page 1-79.

1. REPAIR PROCEDURE
NOTE: A local Rhino Linings dealer may be able to
clean and repair the item. For self-repair, follow this
procedure.

Completed Repair

8. Allow 20 minutes for the coating to skin over. Limited


handling or use is allowed after 90 minutes.

The torsion bar may be able to be repaired on or


off the vehicle.

9. If the torsion bar was removed from the vehicle, refer to


Torsion Bar Replacement on page 1-45 and
reinstall on the vehicle using black silicone to keep out
containments.

A urethane product can be used to repair the damaged


area. A quality urethane will adhere well, if a primer is used.
The urethane has similar properties of the Rhino coating in
terms of oil resistance and elasticity.

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Pierce recommends a good-quality urethane and its


compatible primer, such as 3M Window-Weld P/N 08609,
and 3M Single-Step Primer P/N 08681. These should be
available at most body shop supply stores.

4. Apply the necessary amount of fresh urethane on the


damaged area, and just outside the damaged area, to
insure sufficient protection.

1. Clean off the damaged area with a solvent such as


acetone.
2. Inspect the steel for nicks and rust pitting. If any surface
rust can be eliminated by light sanding, it is unlikely that
pitting has started. If there are any nicks, pitting, or
moderate rusting, the torsion rod should be replaced.

5. Allow the coating to dry per the directions.


6. If the torsion bar was removed from the vehicle, refer to
Torsion Bar Replacement on page 1-45 and
reinstall on the vehicle using black silicone to keep out
containments.
3. Prime the surface with the primer product using a clean
swab or rag. Wipe the damaged area on the torsion rod
as well as just outside the damaged area. DO NOT rewipe the area with a dirty rag or swipe as this will
contaminate the surface.

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36. TROUBLESHOOTING GUIDE

1. The dual steer application can be tested with the


pressure and flow meter hooked to the primary gear.
2. Put a 1-inch block between the axle stop and axle.

! WARNING
When setting the vehicle ride height, measure the
frame height to verify that it is within the
specification as defined in Ride Height
Adjustment on page 1-74 A frame height that is
either too high or too low could cause:
A. The suspension components to break or
malfunction.
B. The suspension to sag over time.
C. The steering to wander.

3. Turn steering wheel all the way to the block.


4. At the stops, the flow should drop off below 1 gpm
(gallon per minute). If the flow stays above 1 gpm, there
is a flow problem with one of the gears.
5. Perform steps 2 through 4 in both directions.
NOTE:
Use a drain pan for the fluid spilling from the fitting
on the secondary box during this procedure.
Do not cap off fitting on the secondary box unless
the drag link is disconnected. This will cause the
secondary box to be in hydraulic lock.

NOTE:
It is recommended that the steering gear NOT be
disassembled before going through the following
troubleshooting steps. The table shows that many
factors outside the steering system, such as
misaligned wheel toe-in, worn suspension
components or incorrectly sized tires can affect
steering performance.
All TAK-4 systems use a hydraulic pump that is
rated at 2150 psi at 7 gpm.

6. Disconnect the lines to the secondary gear and plug


them.
7. Repeat steps 2 through 5. If the flow drops and
pressure goes toward pump relief, the secondary gear
is bad and primary gear is OK. If flow stays up and
doesn't build pressure, the primary gear is bad.

When troubleshooting a Sheppard dual steering


system for a flow problem, the proper way to check
to see which steering gear box may be giving you
problems is as follows:
Table 1-11: Troubleshooting Guide
Symptom

Possible Cause

Remedy

Steering hydraulic oil leaking


at output shaft of steering
gear.
Steering hydraulic oil leaking
at input shaft of steering gear.
Steering hydraulic oil milky or
white in appearance.
Steering hydraulic oil
foaming or forced out of
reservoir.

Damaged sector shaft seal.

Replace sector shaft seal and sector shaft if


necessary.

Page 1-82

TAK-4 INDEPENDENT FRONT SUSPENSION

Worn or damaged oil seal.

Replace input shaft seal and input shaft if


necessary.
Water entry through reservoir venting Clean vent system or replace cap assembly
system.
and flush system.
Clogged oil filter.
Change oil and oil filter.
Air in system.
Bleed air from system or check for air leak on
suction side of supply pump. (See Steering
Gear Bleed Procedure on page 1-54)
Air leak in suction side of supply pump.
Refer to pump service instructions.
Pump cavitating.
Check for restriction in steering gear supply.
Oil overheating.
Check for restriction in steering gear return.
Engine oil in power steering
Faulty seal at pump drive shaft.
Replace pump seals.
reservoir (gear driven pump).
Steering hydraulic oil
Operating temperatures too high.
Check and correct cause of overheating.
discolored.
Change intervals too long or incorrect oil
Change oil. Drain, flush and refill with
used.
recommended fluid.

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Table 1-11: Troubleshooting Guide

Symptom

Possible Cause

Steering system operating at


high temperature.

Relief plunger of steering gear not


adjusted properly.

Remedy

Adjust relief plungers. (See Setting Primary


Steering Gear Hydraulic Reliefs on
page 1-53)
Steering hydraulic oil flow restriction.
Check back pressure.
Steering hydraulic oil flow too high.
Check maximum oil flow setting.
No power steering on cold Vanes not extending on hydraulic supply Briefly increase engine speed to extend vanes
starts.
pump.
so that pumping starts. (Usually intermittent
and not a cause for pump repair or
replacement).
Excessive back pressure
Pinched oil return line.
Relocate or replace if necessary.
with steering gear in neutral Binding steering column, universal joint Repair or replace components as needed.
position.
or miter box.
Erratic steering or
Insufficient flow rate of steering hydraulic.
Refer to pump servicing instructions.
mechanical steering only.
Hard steering.
Faulty supply pump.
Check pump flow and refer to pump servicing
instructions.
High operating temperature.
Determine and correct cause of overheating.
Damaged, worn or incorrect size tires.
Replace tires.
Incorrect tire pressure.
Set all tires to correct pressure.
Input shaft, universal joint or steering
Repair or replace defective component.
column binding.
Low steering hydraulic oil level.
Fill to correct level with recommended fluid
type.
Wheel turns hard in one or
Bind in steering column.
Check column for damage or misadjustment,
both directions.
replace or adjust correctly.
Worn or damaged ball joints.
Repair or replace ball joints, tie linkage or toe
linkage as required. (See Upper Ball Joint
Replacement on page 1-13 or Lower Ball
Joint Replacement on page 1-19)
Worn or damaged tie rods.
Repair or replace tie linkage or toe linkage as
required. (See Tie Control Link
Replacement on page 1-38 or Toe Control
Link Replacement on page 1-38)
Axle overloaded
Lighten load.
Hydraulic steering hydraulic oil level low.
Fill reservoir to correct level with
recommended fluid type.
Air in system.
Bleed system and correct cause of air
intrusion. (See Steering Gear Bleed
Procedure on page 1-54)
Wheel turns hard in one Metal or foreign material in relief ball seat
Remove and clean relief valve seats or
direction.
in piston of steering gear.
replace damaged parts.

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GROUP 0152-P-002-0114
Table 1-11: Troubleshooting Guide

Symptom

Possible Cause

Remedy

Steering effort not smooth.


Handwheel torque varies
more than 15 lb-in. while
steering lock to lock.

Binding or seized universal joint.


Inadequate lubrication at miter box,
primary gear extension or universal
joints.
Universal joints not phased properly.
Hydraulic steering fluid flow rate
inadequate.
Pump cavitating.

Replace or rebuild universal joint.


Lubricate all components and verify free
operation.

Re-phase or replace input shafts.


Idle speed too low or supply pump not to
specification. Replace pump if necessary.
Make certain pump is receiving adequate
amount of fluid; correct any source of air
leakage.
Steering system overheating.
If fluid level is correct and pump flow is within
specs, check for external heat sources
contacting components or lines.
No return to straight ahead
Linkage rod ends seized or binding.
Repair or replace as necessary.
from turns (Steering does not
Ball joints worn or binding.
Check end play and replace as needed. (See
self-center).
Ball Joint Inspection on page 1-69)
Steering hydraulic fluid flow rate
Check pump gpm setting. Re-set flow rate or
incorrect.
replace pump.
Truck darts or wanders
Steering hydraulic oil flow too high.
Reset pump flow; refer to pump service
(oversteers).
instructions.
Air trapped in steering gear.
Bleed system and correct cause of air
intrusion. (See Steering Gear Bleed
Procedure on page 1-54)
Worn ball joints or steering linkage rod
Repair or replace rod ends and joints as
ends causing looseness in steering.
necessary. (See Upper Ball Joint
Replacement on page 1-13 or Lower Ball
Joint Replacement on page 1-19)
Front wheel toe-in incorrect.
Reset toe-in to specifications. (See Setting
Wheel Toe-In on page 1-51)
Truck overloaded or load improperly
Reduce or redistribute truck load.
distributed.
Rear tandem axles not parallel.
Check and repair as required.
Tie rod ends or toe link sockets are tight.
Check rotational torque and replace as
necessary.
Vehicle leans excessively.
Adjust torsion bar anchors to correct.
Loose steering arm.
Replace pitman arm and sector shaft.
Incorrect tire pressure.
Set to specified pressure.
Loose wheel nuts.
Inspect wheel and hub pilot. Inspect and
replace studs and nuts if threads are
damaged. Torque nuts to specification.

Page 1-84

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Table 1-11: Troubleshooting Guide

Symptom

Possible Cause

Excessive backlash
(freeplay).

Universal joint yoke loose on input shaft.

Vehicle has unequal turning


cut right versus left.

Accelerated tire wear or


uneven tire wear.

Excessive vehicle roll or


vehicle ride is too soft.

DocID

Remedy

Replace universal joint and input shaft if


needed.
Worn universal joint.
Repair or replace damaged joint.
Loose steering gear on tray.
Inspect steering gear tray for oval-shaped
holes. Replace tray if necessary. Replace
hardware. Inspect bend radii of tray to verify
that the hardware is bearing on flat surfaces.
Torque to specifications. (See Steering
Gear Tray Replacement on page 1-55)
Loose miter box mounting.
Inspect box and bracket for damage and
replace if needed. Replace fasteners and
torque to specification.
Rack or piston damaged.
Replace steering gear. (See Steering Gear
Replacement on page 1-41)
Damaged sector shaft or splines.
Replace steering gear. (See Steering Gear
Replacement on page 1-41)
Worn or damaged pitman arm splines. Replace pitman arm and sector shaft. (See
Pitman Arm Replacement on page 1-39
or Steering Gear Replacement on
page 1-41)
Worn miter box gears or bearings.
Replace miter box.
Pitman arms not centered.
Inspect and adjust as required. (See Pitman
Arm Replacement on page 1-39)
Steering gear relief plungers set
Set plunger(s) to maintain 1/8-inch gap
incorrectly.
between pitman arm and steering hard stop.
Do not adjust hard stop; maintain the original
factory setting. (See Setting Primary
Steering Gear Hydraulic Reliefs on
page 1-53)
Incorrect tire pressure.
Set to specified pressure.
Unbalanced tires.
Balance or replace tires.
Incorrect toe-in alignment.
Set toe-in to specifications. (See Setting
Wheel Toe-In on page 1-51)
Incorrect ride height.
Check frame height and adjust ride height to
specification. (See Ride Height
Adjustment on page 1-74)
Incorrect rear axle alignment.
Align rear axle.
Shock absorber leaking or worn.
Replace shock(s). (See Shock Absorber
Replacement on page 1-11)
Shock absorber bushings worn.
Replace bushings. (See Shock Absorber
Replacement on page 1-11)
Jounce bumper worn or damaged.
Replace jounce bumper. (See Jounce Stop
Replacement on page 1-12)
Incorrect ride height.
Adjust ride height to correct specifications.
(See Ride Height Adjustment on
page 1-74)

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-85

FRONT AXLE & SUSPENSION

GROUP 0152-P-002-0114
Table 1-11: Troubleshooting Guide

Symptom

Possible Cause

Vehicle ride is harsh


or suspension making
clunking noises.

Shock absorber(s) leaking or binding.

Suspension sags.

Vehicle pulls to one side.

Page 1-86

Remedy

Replace shock(s). (See Shock Absorber


Replacement on page 1-11)
Shock absorber bushings worn.
Replace shock. (See Shock Absorber
Replacement on page 1-11)
Control arm pivots worn.
Inspect and replace as required. (See Upper
Control Arm Repair on page 1-25 or
Lower Control Arm Repair on page 1-31)
Ball joints worn.
Check end-play and replace as required. (See
Ball Joint Inspection on page 1-69)
Jounce bumpers worn or missing.
Replace bumpers. (See Jounce Stop
Replacement on page 1-12)
Incorrect ride height.
Adjust ride height to correct specification.
(See Ride Height Adjustment on
page 1-74)
Overloaded axle.
Lighten load.
Jam nuts on torsion bar anchor loose or Inspect and tighten to torque specification.
adjusted incorrectly.
(See Installation on page 1-47)
Torsion bar, upper control arm, or anchor Replace torsion bar and the effected splined
splines stripped.
mating part. (See Torsion Bar
Replacement on page 1-45)
Torsion bar yielded.
Replace torsion bar, and reset ride height.
(See Torsion Bar Replacement on
page 1-45 and Ride Height Adjustment
on page 1-74)
Torsion bar broken.
Replace torsion bar and reset ride height.
(See Torsion Bar Replacement on
page 1-45 and Ride Height Adjustment
on page 1-74)
Incorrect tire pressure.
Set to specified pressure.
Improper brake adjustment.
Inspect and correct as required.
Vehicle leans side to side.
Measure frame height and set to specification.
(See Ride Height Adjustment on
page 1-74)
Incorrect toe-in.
Adjust toe-in to specified settings. (See
Setting Wheel Toe-In on page 1-51)
Wheel bearings out of adjustment.
Inspect bearings, check wheel bearing endplay and adjust as required. (See Wheel
Bearing Adjustment on page 1-4)
Damaged wheel bearing (clunking and
Clean, replace cup and cone, and torque
grinding noise audible).
spindle nut using specified procedure. (See
Wheel Hub Assembly Repair on
page 1-5)

TAK-4 INDEPENDENT FRONT SUSPENSION

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Table 1-11: Troubleshooting Guide

Symptom

Possible Cause

Vehicle pulls to one side


when braking.

Improper running clearance-brake pads


to rotor.
Uneven brake pad wear (greater than
0.08 in. [2 mm] side to side).
Brake pads worn.

DocID

Remedy

Check adjuster on caliper. If the adjuster is


damaged, replace caliper.
Lubricate or replace caliper guide pins as
necessary (check minimum pad thickness).
Replace all four brake pads as an axle set.
Inspect and replace rotor if damaged or worn
out of specification.
Scored, cracked or damaged brake rotor. Resurface or replace as necessary. Rotor
thickness must be within specification. Refer
to rotor inspection criteria to determine
acceptability of heat checking or small cracks.
Contaminated or glazed brake pad
Replace all four brake pads as an axle set.
friction material.
Brake supply air line leak or obstruction.
Repair or replace air line.
Air pressure uneven side to side.
Check side-to-side air pressure and correct as
needed.
Rear axle brakes out of adjustment.
Check and adjust as required.
Brake chamber air leak or diaphragm
Replace brake chamber.
damaged.

TAK-4 INDEPENDENT FRONT SUSPENSION

Page 1-87