14-101 R. Chambi

MACK AL AND
AL II AIR
SUSPENSION APRIL 2000
SERVICE AND REPAIR (REVISED)
14-101
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MACK AL AND AL II
AIR SUSPENSION
SERVICE AND REPAIR
APRIL 2000 © MACK TRUCKS, INC. 2000

(REVISED — SUPERSEDES ISSUE DATED SEPTEMBER 1996) 14-101
front.fm Page ii Wednesday, January 19, 2000 10:02 AM
ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including electronic, mechanical, photocopying,
recording, or otherwise without prior written permission
of Mack Trucks, Inc.
ii
front.fm Page iii Wednesday, January 19, 2000 10:02 AM
TABLE OF CONTENTS
TABLE OF CONTENTS
iii
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview of Air Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Suspension Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fifth-Wheel Mounting Angle Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspecting and Testing Height-Control Valve (HCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ride Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AL II Suspension Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AL Suspension Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Suspension Alignment — AL and AL II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SCHEMATIC & ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SCHEMATIC AND ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AL II Suspension Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AL Suspension Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
iv
14_101.bk Page 1 Wednesday, January 19, 2000 9:56 AM
INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:
Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.
Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.
Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.
A procedure, practice, or condition that is essential to emphasize.
A helpful suggestion which will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.
Page 2
INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle always be seated in the driver’s seat, place the
transmission in Neutral, be sure that parking brakes are set, and
disengage the clutch (if equipped).
2. Before working on a vehicle, place the transmission in Neutral, set the
parking brakes, and block the wheels.
3. Before towing the vehicle, place the transmission in Neutral and lift the
rear wheels off the ground, or disconnect the driveline to avoid damage to
the transmission during towing.
Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.
REMEMBER,
SAFETY ... IS NO ACCIDENT!
Page 3
INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
CODE
The organization of MACK service manuals has GROUP 500 — BRAKES, AUXILIARY
been upgraded to standardize manual content SYSTEMS
according to a reference system based on
component identification. The new reference GROUP 600 — CAB, TRUCK BODY
system will help to link the information contained
in this publication with related information GROUP 700 — ELECTRICAL
included in other MACK service-warranty
publications, such as associated service The second two digits of the three-digit code are
bulletins, warranty manuals, and MACK Service used to identify the system, assembly or
Labor Time Standards. subassembly, as appropriate, within each of the
groupings. The codes applicable to this
The system is based on a numerical code, the publication may be shown at the COMPONENT
first digit of which identifies the general HEADINGS as necessary, and may also appear
component grouping as listed here: in the TABLE OF CONTENTS, to guide you to
specific component information.
GROUP 000 — GENERAL DATA
Additionally, a two-character alpha code (i.e.,
GROUP 100 — CHASSIS [DP] SPRING, AIR) may be shown with each
operation. This alpha code, in combination with
GROUP 200 — ENGINE the three-digit Group number, identifies the
specific assembly, subassembly or part, and
GROUP 300 — CLUTCH, TRANSMISSION, directly relates to the first five positions of the
TRANSFER CASE AND PTO operation code listed in MACK Service Labor
Time Standards.
Example of Numerical Code
Page 4
INTRODUCTION
ABOUT THIS MANUAL Use only genuine MACK replacement parts for
servicing these suspensions. Genuine MACK
This publication will assist the experienced parts are available through your nearest MACK
heavy-duty truck technician in preventive dealer, service dealer or parts dealer.
maintenance and rebuild of the MACK AL family
of suspensions. In this manual, the designation
“AL” refers to the AL-23, AL-36, AL-40 and AL-46
suspensions. The “AL II” designation refers to the DO NOT modify or rework parts. DO NOT use
AL-231, AL-361, AL-401, AL-402 and AL-461 substitute parts. A modified or substitute part
suspensions. The AL-401LH has no special may result in loss of vehicle control and
designation. possible personal injury or property damage.
The AL suspension (and its various improved
versions) was used on MACK vehicles from 1989 Proper service and repair is important to safe and
through 1995. The AL II suspension was first reliable operation of the air suspension. The
used in production on 1995 MACK chassis. The service procedures recommended by Mack and
AL-401LH was used on some vehicles beginning described in this technical publication are
October 1995. effective methods of performing maintenance.
Some of these operations (e.g., removal and
This manual includes a General Information installation of bushings) may require the use of
section that applies to both MACK air tools made in the shop.
suspensions, as well as separate sections
containing procedures that apply specifically to
either the AL or AL II assembly.
A technician who decides to use a service
Several component replacement procedures are procedure or tool not recommended by Mack
so similar for both AL and AL II suspensions that Trucks, Inc. must first satisfy himself that the
they are covered together. Specifically, these selected method or tool will not jeopardize either
include replacement of: his safety or that of the vehicle.
r Frame hanger slipper pads
r Frame hangers Throughout are various Dangers, Warnings,
r Shock absorbers Cautions and Notes. Read these carefully to
minimize the risk of personal injury and to ensure
r Longitudinal torque rods using proper methods. Improper service can
r Height-control valves damage the vehicle or render it unsafe to
operate. Also understand that these Dangers,
r Dump valves Warnings, Cautions and Notes are not
exhaustive. Mack cannot evaluate and advise the
Before servicing, determine if the air suspension service trade of all conceivable ways in which
is an AL or AL II model. Then refer to either the service may be performed or of all the hazards
combined AL/AL II information section or the involved.
section which covers that particular model
suspension.
The illustrations in this manual are typical, and

may differ slightly from the vehicle being
serviced. These variations should not present any
difficulty during service, as long as attention is
paid to component arrangements during
disassembly. Maintain original relationships when
reassembling components.
Page 5
NOTES
Page 6
DESCRIPTION AND OPERATION
Page 7

DESCRIPTION AND A pressure protection valve, located on the
vehicle air storage tanks, protects the primary air
OPERATION system should a failure occur in the suspension
MACK air suspensions are ideal for operations air system.
with diminishing load, such as tankers and
grocery operations, and where ride quality both Notable design features include:
empty and loaded is important. r Constant ride height, empty and loaded
A single height-control valve controls suspension r One-piece cast modular iron-frame hangers,
stiffness and ride height. The suspension also axle seats and axle caps
incorporates a dump valve for exhausting air from r Premium rubber bushings for torque rods
the rear suspension. The dump valve is
controlled by an air switch inside the cab. r No lubrication required
r Positive axle alignment through the use of
The dump valve is used to exhaust the drop-in shims at torque rod ends, or
suspension air bags when coupling and adjustable torque rods (AL II or AL-401LH)
uncoupling a trailer, or when raising and lowering
a dump body. The air bags must be reinflated Additionally, AL II and AL-401LH models feature:
before the vehicle is operated.
r Outboard-mounted shock absorbers
r Lower-profile transverse torque rod
mounting (with MACK axles)
On trucks equipped with a dump body, always
exhaust the air from the air bags before raising r Low-profile spring hanger brackets
the body to prevent damaging the bags and to
improve chassis stability while dumping a load. The AL-402 and AL-461 models, which are also
Reinflate the air bags after lowering the dump designated as AL II suspensions, feature inboard
body. mounted shock absorbers on the rear rear axle.
These two suspension models are specifically
designed for dump truck applications. The
AL-402 model uses cast longitudinal torque rods,
whereas the AL-461 model uses heavy-duty
Do NOT uncouple a trailer without exhausting the longitudinal torque rods.
air suspension. Do NOT operate a vehicle with air
exhausted from the air suspension air bags, as
damage to the chassis driveline will result.
Always reinflate the air bags after coupling or
uncoupling a trailer, or after lowering a dump
body.
When preparing to connect a tractor to a trailer,

make sure that the height of the fifth wheel
matches the height of the underside of the trailer.
Failure to do so will result in the trailer being
improperly connected. After the trailer has been
coupled and the trailer landing gear has been
raised, make sure that the fifth wheel jaws have
properly engaged the trailer king pin. Make sure
that there is no gap between the fifth wheel plate
and the bottom of the trailer.
Page 8

GENERAL INFORMATION 2
Overview of Air Control Valves

AL and AL II suspensions incorporate a height-
control valve. The height-control valve senses
changes in frame height, and adjusts the
pressure in the air springs to maintain the proper
height.
Most suspensions also incorporate a dump

feature. This feature allows the vehicle operator
to exhaust air from the system for coupling or
uncoupling a trailer, raising a dump body, or
performing certain suspension repairs.
Figure 2 — Separate Dump Valve
Earlier model vehicles use a single-function
height-control valve (manufactured by King of the
Beginning in 1997, a combination valve
Road) in conjunction with a dump valve, as
(manufactured by Barksdale), which incorporates
shown in Figure 1 (a typical dump valve is shown
both height control and dump functions, was
in Figure 2). The single-function height-control
phased into production. The combination valve is
valve has a metallic body and features a built-in
shown in Figure 3. This valve has a plastic body,
delay feature. When the valve lever is moved
and does not have a delay feature. When the
from center, there is a 2–9 second delay before
valve lever is moved from center, the valve
the valve begins to add or exhaust air from the air
begins to add or exhaust air immediately.
springs. 3
1
Figure 1 — Single-Function Height-Control Valve

(Manufactured by King of the Road)
Figure 3 — Combination Valve (Manufactured by

Barksdale)
Page 9

Fifth-Wheel Mounting Angle
Clearance
If replacement of a single-function height-control
valve (manufactured by King of the Road) is Fifth-wheel mounting angles that extend down
necessary, it is recommended that the valve and over the side of the main frame rails must be cut
separate dump valve be replaced with a out to provide proper clearance for the frame
Barksdale combination type height control/dump hangers as shown in Figure 4.
valve. Procedures for replacing the single-
function valve and separate dump valve, with a Allow approximately 1/8-inch (3-mm) clearance
combination valve, are outlined in the “REPAIR between the fifth-wheel mounting angle and the
INSTRUCTIONS” section of this manual. frame hanger.
4
Suspension Integrity
Do not use a cutting torch to remove any of

the fasteners used on the air suspension.
Applying heat to suspension components will
adversely affect the strength of these parts.
Damaging a component in this manner may
result in the loss of vehicle control and
possible personal injury or property damage.
Figure 4 — Fifth-Wheel Mounting Angle Clearance
Exercise extreme care when handling or

performing maintenance in the area of the The AL II and AL-401LH suspension families use
main support members. Do not connect an low-profile spring hanger brackets, which in most
arc welding ground line to the main support cases, eliminates the need to cut out the fifth-
members. Do not strike an arc with the wheel mounting flanges. However, continue to
electrode on the main support members. Do allow approximately 1/8-inch (3-mm) clearance
not use heat near the main support members. between the top and sides of the hanger brackets
Do not nick or gouge the main support or any other frame-mounted component, if
members. A main support member that has longer-than-standard mounting angles are used.
been subjected to any of these conditions
must be replaced. Otherwise, it may fail,
causing loss of vehicle control and possible
personal injury or property damage.
Some MACK chassis use Huck-Fit™ fasteners to

attach suspension parts to the frame. Do not
reuse fasteners that have been removed.
Huck-Fit™ fasteners are not reuseable and can
loosen and cause frame damage. USE ONLY
NEW HUCK-FIT™ FASTENERS.
Page 10
COMPONENT LOCATOR
COMPONENT LOCATOR
Page 11
COMPONENT LOCATOR
COMPONENT LOCATOR
5
Figure 5 — AL II Suspension Components
1. Frame Hanger 5. Main Support Member

2. Transverse Torque Rod 6. Shock Absorber
3. Cross Channel 7. Longitudinal Torque Rod
4. Air Spring
Page 12
TROUBLESHOOTING
TROUBLESHOOTING
Page 13
TROUBLESHOOTING
TROUBLESHOOTING SINGLE-FUNCTION HCV (KING OF THE
ROAD)
Inspecting and Testing
Height-Control Valve (HCV)
Prior to performing the tests outlined below, build For the single-function valve (manufactured by
up the air system to normal operating pressure. King of the Road), the delay mechanism must be
Allow the suspension to inflate to its normal ride centered prior to performing the “Air Delivery” and
height. Inspection of the HCV consists of “Air Exhaust” tests. To do this, move the lever up
checking for the following: and down a few times.
r External leaks 1. Air Delivery: Check delivery as shown in

r Air delivery to the air springs Figure 7. For the single-function valve, move
the lever downward briefly, then upward
r Air exhaust from the air springs approximately two inches and
r Internal leakage with the valve centered simultaneously count seconds before air
starts to pass through the valve. There
r Valve free travel, or “dead band” should be a delay of two to nine seconds
r Clogged ports before air passes through. If so, the valve
delivery function is functioning properly.
7
A detailed description of these tests follows:
1. External Leaks: If an external air leak is
suspected, spray the valve and all nylon
tube air fittings with a soapy water solution
to detect the location of the leak. Correct
leaks at the nylon tube fittings by tightening
the fittings until only two threads show on
the fittings. Recheck with the soapy water
solution. If the valve is leaking at the pivot of
the valve lever, replace the valve.
2. Clogged Ports: Check for clogged screens
in inlet adapter ports and fittings, and
delivery ports (see Figure 6).
6
Figure 7 — Checking Air Delivery and Exhaust
2. Air Exhaust: Check exhaust as shown in

Figure 7. For the single-function valve, move
the lever upward briefly, then downward
approximately two inches and
simultaneously count seconds before air
starts to escape through the exhaust port.
There should be a delay of two to nine
seconds before air starts to exhaust. If so,
the exhaust function of the valve is working
properly.
Page 14
TROUBLESHOOTING
3. Internal Leaks: Air should not pass through COMBINATION HEIGHT-CONTROL/DUMP
the height-control valve when its lever is VALVE (BARKSDALE)
centered. To check this function, first 9
disconnect the control rod from the valve
lever. Then disconnect the delivery line
which goes from the height-control valve to
the air springs.
The single-function height-control valve has
a spring mechanism which returns the valve
lever to the center (closed) position when
the lever is released.
If no air passes when the lever is centered,
this function is operating properly.
4. Dead Band: The valve has a free-travel
range or “dead band” at the level position, as
shown in Figure 8. The lever should move
3/16 inch (about 1-1/2 degrees) in either
direction before air passes. When the lever
is positioned within the dead band, no air
should pass.
8
Figure 9 — Height-Control Valve
The height-control valve test can be done with

Barksdale Field Test Kit No. KD 2247. If the
Barksdale Inc. kit is used, follow their instructions.
If using shop tools, you will need the following for

proper testing:
r 160 psi minimum pressure gauge that has
5 psi graduation marks and has a 1/4-inch
male brass connection
r Two-inch long, 1/4-inch tubing, inserted into
brass connection of gauge
If the valves pass all of the preceding tests, they r 1/4-inch female straight adapter that mates
are functioning properly. If not, they must be to a 1/4-inch air hose
replaced.
r 1/4-inch NPT-1/4-inch PTC fitting
r 1/4-inch NPT plug
r Centering pin (1/8-inch wooden dowel rod)
Do not attempt to disassemble or repair the
height-control valve. Doing so will void the r Tool for air line removal
warranty.
Page 15
TROUBLESHOOTING
10
If valve meets all the above characteristics, the

valve is operating properly. Do not attempt to
disassemble or repair valve. Doing so will void
the warranty.
11
Figure 10 — Height-Control Valve Testing Set-up
1. Disconnect the height-control valve linkage

from the control valve arm.
2. Rotate valve arm down to exhaust air.
3. Clean around air fittings.
4. Disconnect the air lines to the air springs at
both delivery ports (C1 and C2). Refer to Figure 11 — Maximum Allowable Pressure Drop
Figure 10.
5. Plug C2 port. DUMP VALVE FUNCTION
6. Attach pressure gauge and tubing to C1 With air suspension at normal ride height, move
port, as shown in Figure 10. the dashboard air suspension control switch to
the Trailer Coupling or Uncoupling position (lower
7. Apply lubricant on tubing end to ease suspension). Air should exhaust from the valve
installation. as the air bags deflate. Move the switch to the
8. Move handle up, to FILL mode. This Normal Vehicle Operation position (raise
pressurizes the test valve/gauge. suspension). The suspension air bags should
reinflate. If the dump valve does not function in
9. Move valve arm towards center and install this manner, make sure that control pressure is
centering pin (1/8-inch wooden dowel rod) in delivered from the dashboard switch to the dump
holes on the valve arm and housing. Use valve control port.
care to prevent overshooting the center
(blocked) mode of the valve. This causes the
test volume to be exhausted.
10. Note pressure reading on gauge.
11. Observe the pressure reading for a period of
30 seconds.
12. Refer to Figure 11 for maximum allowable
pressure drop vs. inlet pressure in
30 seconds. The valve is good if pressure
drop does not exceed maximum allowable.
13. Replace valve if maximum allowable
pressure drop is exceeded.
14. Reconnect linkage and air lines to the valve.
Page 16
MAINTENANCE
MAINTENANCE
Page 17
MAINTENANCE
PREVENTIVE MAINTENANCE Torque Requirements
The MACK air suspension does not require To prevent suspension component damage and
lubrication. There are several other items, ensure operator safety, proper suspension torque
however, that should be checked periodically to is of the utmost importance. The procedures in
ensure proper operation and continued reliability. this section are essential for maintaining proper
r Normal operation of the MACK AL and AL II air suspension performance.
suspensions results in some wear between
the main support members and frame U-BOLT LOCKNUTS
hangers. Inspect these components at least
once a year as described in the Repair Vehicles equipped with a MACK air suspension
Instructions section (under Main Support require the following procedures:
Members, Frame Hangers and Frame r Spring clips MUST be retorqued at
Hanger Slipper Pads) for either the AL 1,000 miles (1 600 km).
suspension or the AL II suspension.
r Spring clips MUST be checked and
r Check air lines regularly for leaks, chafing retorqued at 25,000 miles (40 000 km).
and security of clamps. Thereafter, follow 25,000-mile (40 000-km)
r Verify suspension alignment after making inspection schedule.
any repairs to the suspension or any time
abnormal tire wear is noticed or loose After replacing spring clips (or components that
suspension fasteners are found. require spring clip removal), the following
procedure is necessary:
r Inspect torque rods at each inspection
interval, during rear suspension 1. Torque spring clips.
maintenance, chassis lubrication, or if any 2. Perform suspension alignment.
related component fails. Replace the torque
rod if rod movement exceeds 1/8 inch 3. Road test chassis to seat components.
(3 mm), the rod cross bar is bent, the 4. Retorque spring clips after road test.
bushings are cracked or loose, rubber
exposure is unequal, the pins are off-center, 5. Spring clips MUST be retorqued at
or if the mounting pin bolt holes are 1,000 miles (1 600 km) following service.
expanded. 6. Spring clips MUST be checked and
r Inspect shock absorbers. Refer to “AL retorqued at 25,000 miles (40 000 km)
Suspension Component Replacement” if following service. Thereafter, follow
ride quality has deteriorated or if shocks are 25,000-mile (40 000-km) inspection interval.
leaking.
r Thoroughly inspect all suspension
components any time the vehicle is involved Correct U-bolt torque is essential for maintaining
in an accident. proper suspension performance. Improper
tightening can cause chassis lean problems or
serious component damage.
If chassis lean is evident, check to see if the main

support members are in contact with the spring Spring clip nuts on AL II and later-model AL
hanger wear surfaces. If not, loosen and then suspensions are phosphate/oil-coated and black
retorque the spring clips (U-bolts). in color. They require 400–450 lb-ft
(540–610 N•m) of torque.
Early-production AL suspension spring-clip nuts

are cadmium/wax-coated and silver in color. They
require 270–310 lb-ft (370–420 N•m) of torque.
Page 18
MAINTENANCE
Some AL-401LH suspensions (with Eaton or OTHER SUSPENSION FEATURES
Meritor axles) use 3/4-inch diameter spring clips.
At 100,000-mile (160 000-km) intervals, check
The locknuts for these spring clips require
the torque of the following fasteners:
260–320 lb-ft (353–434 N•m) of torque.
12
r Air spring-to-frame bracket inboard
(AL only): 50–70 lb-ft (70–95 N•m)
r Air spring-to-frame bracket outboard:
20–30 lb-ft (30–40 N•m)
r Air spring-to-lower mounting bracket (or
cross channel section): 20–30 lb-ft
(30–40 N•m)
r Transverse torque rod (frame end, straddle
mount):
— M16 metric fasteners: 175–200 lb-ft
(250–275 N•m)
— 5/8-inch x 18 fasteners: 275–300 lb-ft
(375–400 N•m)
Figure 12 — U-Bolt Torque Pattern r Transverse torque rod (axle bracket end,
straddle mount):
MAIN SUPPORT MEMBER LOCKNUTS — M16 metric fasteners: 175–200 lb-ft
At the end of the initial break-in period of (250–275 N•m)
1,000 miles (1 600 km), and every 25,000 miles — 5/8-inch x 18 fasteners: 275–300 lb-ft
(40 000 km) thereafter, retorque the main support (375–400 N•m)
member locknuts to 260–320 lb-ft (353–434 N•m)
for the: r Transverse torque rod (AL axle bracket end,
stud type): 400–450 lb-ft (543–610 N•m)
r Support member to air spring lower
mounting bracket on AL suspensions r Frame-bracket rebound roller bolt:
50–70 lb-ft (70–95 N•m)
r Support member to cross channel section
on AL II and AL-401LH suspensions r Shock absorbers:
— AL (both ends): 50–70 lb-ft
(70–95 N•m)
— AL II (both ends): 90–110 lb-ft
(120–150 N•m)
— AL-401LH upper nut: 90–110 lb-ft
(120–150 N•m)
— AL-401LH lower stud nut: 50–70 lb-ft
(70–95 N•m)
Page 19
MAINTENANCE
Ride Height Adjustment Ride height must be measured on the axle to
which the height-control valve linkage is
MACK air suspensions function best when ride attached. On tandem axle suspensions, frame
height is properly adjusted. Check ride height and slope may cause the ride height to vary from the
adjust, if necessary, at each D inspection interval. 4.25-inch (108-mm) dimension on the axle that
does not have the height-control valve. Ride
height should be set when the vehicle is
unloaded and parked on a level surface. Prior to
Driveline universal-joint operating angles are checking or setting ride height, drive the vehicle
strongly affected by variations in ride height. forward and backward a few feet several times,
Failure to maintain the proper ride height setting and bring the vehicle to a stop without using the
is likely to lead to driveline vibration and brakes. Chock the wheels to prevent the vehicle
subsequent drivetrain durability problems. from moving, and do not set the parking brakes.
With the air system fully pressurized, use the air
suspension control inside the cab to exhaust,
Ride height is measured from the bottom of the then reinflate the air suspension. Wait until airflow
frame rail to the bottom of the main support to the suspension has stopped, then check ride
member. This dimension must be 4.25 ± height.
0.125 inches (108 ± 3 mm), as shown in
Figure 13. This dimension is the most important Changes to ride height are made by adjusting the
measurement when adjusting ride height. A height-control valve linkage. The following
gauge for checking this dimension is available different height-control valve and linkage
from Hendrickson Suspension (Hendrickson part configurations are used on MACK chassis:
No. 45745-050).
13 r Height-control valve linkage with rubber rod
ends
r Height-control valve linkage with threaded
rod ends
r Height-control valve with adjustable arm
Do not slot the HCV mounting bracket holes to

adjust ride height. Ride height adjustments must
be made by adjusting the valve linkage rod.
Figure 13 — Main Support Member Height
Page 20
MAINTENANCE
Ride height adjustment is different for each valve/ r On chassis equipped with a height-control
linkage configuration. Changes to ride height are valve linkage having threaded rod ends,
made by adjusting the height-control valve disconnect the linkage from the bracket on
linkage in one of the following ways: the cross channel. Loosen the jam nut. Then
turn the rod end to achieve the specified ride
r On chassis equipped with height-control
height. Reattach the linkage to the bracket
valve linkage having rubber rod ends,
on the cross channel and torque all linkage
loosen the hose clamp at the bottom rod
fasteners (jam nut and attachment
end. Slide the rod end up or down on the
hardware) to 100–150 lb-in (11–12 N•m).
linkage rod to achieve the specified ride 15
height. Retighten the hose clamp when the
adjustment is complete.
14
Figure 15 — Height-Control Valve with Threaded Rod

Ends
r On chassis equipped with a height-control

valve that has an adjustable arm, the valve
has a stud that passes through an elongated
hole in the arm. The arm is secured with a
locknut. To adjust ride height on these
chassis, loosen the control arm locknut and
reposition the arm to achieve the specified
ride height. Retorque the arm locknut to
100–150 lb-in (11–12 N•m).
16
Figure 14 — Height-Control Valve with Rubber Rod End
Figure 16 — Height-Control Valve with Adjustable Arm
Page 21
MAINTENANCE
r In addition to the adjustable height-control
valve linkages, the ride height on most
chassis can be fine-tuned by moving the
entire valve assembly. On these chassis,
one hole in the valve mounting bracket is
elongated to allow for adjustment. To fine-
tune ride height, loosen the locknuts on the
valve mounting studs slightly, then rotate the
entire valve assembly to achieve the
specified ride height. Retorque the valve
mounting locknuts to 50–100 lb-in
(5.4–10.8 N•m).
17
Figure 17 — Height-Control Valve with Adjustable Valve

Mounting
After ride height adjustments are complete,

exhaust and reinflate the suspension. Wait until
airflow to the suspension has stopped, then
recheck the ride height.
Page 22
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
Page 23
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS INSTALLING SLIPPER PADS
The vehicle must be empty of all load when

Component Replacement installing slipper pads (i.e., work on an empty
The following component replacement vehicle). Before beginning the installation
procedures cover components that are the same, procedure, take the following precautions:
or similar, on both the AL and AL II suspension r Chock the wheels of all axles.
families. For replacement procedures that are
unique to either suspension, refer to the section r Support the frame with frame stands.
covering the particular suspension being r Support the axles with jackstands.
serviced.
r Release all air from the air springs.
FRAME HANGER SLIPPER PADS Replace or install the frame hanger slipper pads,
Normal MACK air suspension operation results in using the following steps:
some wear between the main support members 1. Complete the left and right sides for each
and the frame hangers. Later production AL axle at the same time. Remove the rebound
suspension chassis and all AL II suspensions bolt locknuts, washers, bolts, spacers and
were manufactured with replaceable slipper pads rollers. The torque rods can remain in place.
that extend the service life of the main support
members and frame hangers. Using these pads 2. Apply an upward force on the cross-channel
also reduces suspension slap (noise) when section (cross tube) or the lower air spring
braking. brackets with a jack or pry bar. This causes
18 the tips of the main support members to
drop away from the cam surface of the
spring hanger.
3. Inspect the top sides of the main support
members. If wear is uneven (i.e., grooving
marks are not parallel), replace both right
and left main support members. If grooves
are parallel, or if wear is even, and wear on
main support members does not exceed
3/8 inch (10 mm) as shown in Figure 19, the
existing support members can be reused.
19
Figure 18 — Frame Hanger Slipper Pads
Installing slipper pads on an older chassis or

replacing existing pads requires 4 slipper pads,
8 retainer plates and 16 self-tapping screws
(3/8 inch). The original retainer plates and
possibly the screws may be reused. Inspect them
for damage, however, before reusing.
Figure 19 — Main Support Member Wear Area
Page 24
REPAIR INSTRUCTIONS
4. Inspect the frame hanger legs for wear (see
Figure 20). Replace the frame hanger if
wear exceeds 1/8 inch (3 mm). If slipper
pads were not previously used, or if existing Early production models used two sizes of
slipper pads have worn through, also inspect rebound rollers. On chassis with slipper pads,
the frame hanger cam area. Replace frame use the smaller-diameter rebound roller (part
hangers if cam wear is uneven or if the cam No. 10QK269M). See Figure 21 for rebound roller
area is cracked or worn through. location.
20
21
Figure 20 — Frame Hanger Wear Areas
5. Remove the worn slipper pads (if used) and

place new slipper pads on the frame
hangers (refer to Figure 18). If pads were
not previously installed, use a slipper pad as
a guide, and drill four 11/32-inch holes in
each frame hanger.
Make sure that the slipper pad is seated against

the frame hanger cam surface before drilling
holes (see frame hanger cam in Figure 20). Figure 21 — Torque Rod Bar Locknuts (AL Suspension
Improper seating results in poor slipper pad Shown)
service life.
8. Assemble the rebound rollers, spacers,
6. Position retainer plates over the slipper bolts, washers and locknuts. Torque the
pads. Apply lubricating oil to 3/8-inch self- locknuts to 50–70 lb-ft (70–95 N•m).
tapping screws. Insert and tighten screws to 9. For tandem axle suspensions, repeat this
25 lb-ft (34 N•m). Refer to Figure 18. procedure on the other axle.
7. Release the jack or pry bar on the cross tube
or lower the air spring brackets, allowing the
main support members to move up to the
new slipper pads.
Page 25
REPAIR INSTRUCTIONS
FRAME HANGERS (MAIN SUPPORT 22
MEMBERS)
MACK air suspension operation results in some
wear between the main support members and
frame hangers. With normal use, these
components function satisfactorily throughout the
life of the vehicle, even though the components
may show some wear. Premature wear can
occur, however, requiring replacement of either or
both parts.
Replace frame hangers if groove wear in the legs

exceeds 1/8 inch (3 mm), or if the cam is cracked
or worn through. See Figure 22 and refer to
“FRAME HANGER SLIPPER PADS” on page 24
Figure 22 — Frame Hanger Wear Areas
for additional information. 23
If frame hangers must be replaced, attach new

hangers to the frame, using new metric Property
Class 10.9 Huck-Fit™ fasteners or bodybound
hex bolts (Grade 8 or Metric Property Class 10.9).
For guidelines on the proper selection and
installation of bodybound bolts or Huck-Fit™
fasteners, refer to MACK Master Manual, 14-100
(Frame, Springs and Suspension).
Chock wheels and exhaust air pressure from air

springs before beginning work.
Some MACK chassis use Huck-Fit™ fasteners to

attach suspension parts to the frame. Do not
reuse fasteners that have been removed.
Huck-Fit™ fasteners are not reuseable and can
NEW FASTENERS.
Always check suspension after replacing the

frame hanger.
Figure 23 — Bodybound Bolt/Huck-Fit™ Fastener

Locations
Page 26
REPAIR INSTRUCTIONS
LONGITUDINAL TORQUE RODS
MACK AL suspensions feature fixed-length
longitudinal torque rods that require drop-in shims The bushings are not cartridge-type bushings as
for suspension alignment. AL II and AL-401LH they do not have outer metal sleeves.
suspensions use fixed- or adjustable-length
torque rods.
2. Clean and inspect the inside diameter of the
torque rod ends. Remove any nicks with
Mack recommends the following procedure for
emery cloth.
replacing torque rods or torque rod bushings.
3. Lubricate the inside diameter of the torque
REMOVAL rod ends and the new rubber bushings with
a vegetable-based oil (cooking oil or lard).
1. Chock wheels of drive axles.
DO NOT use petroleum- or soap-based
2. Remove the straddle-mount bar pin locknuts lubricants.
and washers at the axle end of the torque
rod.
3. Loosen the rebound bolt locknut.
Be sure the torque rod is squarely supported
4. Remove the straddle-mount bar pin on the press bed to prevent personal injury.
locknuts, bolts, washers and any alignment
shims at the frame hanger end of the torque
4. Press in new bushings. Support the torque
rod. Note the number of shims used. They
rod end on the receiving tool with the end
must be reinstalled in the same manner to
tube of the torque rod centered on the tool.
avoid affecting alignment.
Press directly on the straddle-mount bar pin
of the bushing. Bushings must be centered
BUSHING REPLACEMENT
within the torque rod end tubes. When
pressing in new bushings, overshoot the
desired final position by approximately
3/16 inch (5 mm). Press the bushing again
Make sure the torque rod is squarely from the opposite side to center the bushing
supported on the press bed to prevent within the torque rod end.
personal injury.
Do not use heat or a cutting torch to remove the

bushings from the torque rod. Using heat
adversely affects the strength of the torque rod.
1. Press out old bushings. Use a vertical shop

press with a minimum capacity of 10 tons.
This procedure requires a receiving tool
made of steel tubing, 5 inches (127 mm) in
length, with a 2-inch (51-mm) inside
diameter and 1/4-inch (6-mm) wall
thickness. Support the torque rod end on the
receiving tool with the end tube of the torque
rod centered on the tool. Push directly on
the bushing straddle mount bar pin until the
bushing clears the torque rod end tube.
Page 27
REPAIR INSTRUCTIONS
INSTALLATION SHOCK ABSORBERS
1. Position the new or rebushed torque rod Inspect shock absorbers before replacing them.
against the top cap and install the washers Shocks may be defective if there is noticeable
and locknuts. Hand-tighten the locknuts. ride deterioration or oil deposits on the lower
reserve tube that may come from the shock
2. Position the torque rod on the forward face
absorber.
of the frame hanger legs. Install the bolts,
alignment shims, washers and locknuts as
INSPECTION
shown in Figure 24. Torque the locknuts to
150–205 lb-ft (200–280 N•m). 1. If a shock absorber is suspected of being
defective, feel the lower reserve tube after
3. Torque the locknuts at the axle end of the
operating the vehicle for about 30 minutes. If
torque rod to 150–205 lb-ft (200–280 N•m).
the reserve tube is warm, the shock is
4. Torque the rebound bolt locknuts to functioning properly.
50–70 lb-ft (70–95 N•m).
2. If the shock absorber is not warm,
5. Check suspension alignment. disconnect it from the lower mounting
24
bracket and cycle it up and down. Little or no
resistance indicates that the shock absorber
is worn and should be replaced.
Repeat this procedure for all other shock

absorbers. Replace only those shock absorbers
that fail this inspection.

replacing a shock absorber. Although AL and
AL II suspensions have different mounting
locations and bracket arrangements, the shock
absorber replacement procedures are similar.
REMOVAL
1. Remove the locknut and washer connecting
the shock absorber to the shock absorber
lower mounting bracket. (Remove bolt on
AL II only.)
2. Remove the locknut and washer connecting
the shock absorber to the shock absorber
frame hanger (or shock stud on AL II and
AL-401LH).
3. Remove the shock absorber from the studs.
Figure 24 — Torque Rod Fasteners and Shims
Page 28
REPAIR INSTRUCTIONS
INSTALLATION HEIGHT-CONTROL VALVE (HCV)
1. Install the inner washers and shock REMOVAL
absorber onto the shock absorber studs as
shown in Figure 25 for either the AL or AL II If it is necessary to replace the height-control
suspension. valve, use the following steps:
2. Install the outer washers (if equipped) and 1. Chock wheels to prevent the truck from
locknuts onto the studs. Washers must be rolling.
installed on both sides of each shock
2. Exhaust the air pressure from the system.
bushing, a total of four washers per shock
for AL suspensions. AL II suspensions do 3. Disconnect the air lines from the height-
not require a washer on the outboard side of control valve.
the shock mounting.
4. Disconnect the height-control valve linkage
Torque values for the shock absorber locknuts by removing the locknut securing the rod to
are as follows: the valve arm.
r AL (both ends): 50–70 lb-ft (70–90 N•m) 5. Remove the locknuts, washers and bolts
r AL II (both ends): 90–110 lb-ft that connect the height-control valve to the
(120–150 N•m) frame.
r AL-401LH (upper nut): 90–110 lb-ft 6. Remove the brass air fittings from the
(120–150 N•m) height-control valve.
r AL-401LH (lower stud nut): 50–70 lb-ft
(70–95 N•m)
25
Figure 25 — AL/AL II Shock Mountings
Page 29
REPAIR INSTRUCTIONS
INSTALLATION SEPARATE DUMP VALVE
1. Install the brass air fittings on the new The dump valve (Figure 27) allows the vehicle
height-control valve. operator to exhaust air from the system to couple
a trailer or perform certain suspension repairs.
2. Mount the height-control valve onto the
Replacement procedures are as follows:
frame. Install bolts, washers and locknuts 27
that secure the valve to the frame.
3. Connect the air lines to the height-control
valve.
4. Connect height-control valve linkage by
installing the control rod into the valve arm
and securing with the locknut.
5. Pressurize the system.
6. Adjust the height-control valve to achieve
proper ride height. Refer to “Ride Height
Adjustment” on page 20.
26
Figure 27 — Dump Valve
REMOVAL
1. Chock wheels to prevent the vehicle from
rolling.
2. Exhaust the air pressure from the system.
3. Mark the air lines to facilitate reassembly.
Disconnect the air lines from the dump
valve.
4. Remove the locknuts, washers and bolts
that connect the dump valve to the frame.
5. Remove the brass air fittings from the valve.
INSTALLATION
1. Install the brass air fittings into the dump
valve.
2. Connect the air lines to the dump valve
according to the markings made during
removal.
3. Connect the dump valve to the frame by
installing the connecting bolts, washers and
locknuts.
Figure 26 — Height-Control Valve and Linkage (Rubber
Rod End) 4. Pressurize the system.
Page 30
REPAIR INSTRUCTIONS
REPLACING SINGLE-FUNCTION SINGLE-FUNCTION VALVE AND SEPARATE
HEIGHT-CONTROL VALVE WITH DUMP VALVE REMOVAL
COMBINATION VALVE
If it is necessary to replace the existing height-
If replacement of a single-function height-control
control valve and separate pilot dump valve,
valve (manufactured by King of the Road) is
perform the following steps:
necessary, it is recommended that the valve and
separate dump valve be replaced with a 1. Park the vehicle on a level surface and set
combination valve manufactured by Barksdale. the parking brakes.
The parts required are as follows:
28 2. Label the air lines as shown.
29
Figure 28 — Combination Height-Control Valve

Components Figure 29 — Height-Control Valve and Dump Valve
Quantity Description
3. Disconnect the air lines from the pilot dump
valve and the height-control valve.
1 1. Height-control valve
4. Remove the height-control valve linkage.
1 2. 45-degree elbow fitting (1/4″ pipe to
1/4″ tubing) 5. Remove the valves from the frame rail.
1 3. Height-control valve linkage
4 4. 90-degree elbow fitting (1/4″ pipe to
3/8″ tubing)
ITEMS NOT ILLUSTRATED
1 — 1/4″ tubing union fitting
1 — 3/8″ tubing union fitting
2 — 3/8-16 UNRC-2A x 1-1/4″ long bolt
2 — 3/8-16 UNRC flanged locknut
24 inches — 1/4″ plastic tubing
24 inches — 3/8″ plastic tubing
Page 31
REPAIR INSTRUCTIONS
COMBINATION VALVE INSTALLATION 3. Mount the new height-control valve onto the
frame. Install bolts and locknuts that secure
1. Install the “Z” bracket onto the height-control
the valve to the frame.
valve so the leg attached to the valve body
points to the rear of the chassis (toward the 4. Connect the 3/8-inch air line labeled “Rear
valve arm), and the leg that attaches to the Air Bag” to the fitting in the height-control
frame rail points toward the front of the valve port labeled C2.
chassis. 32
30
Figure 32 — Air Line Connections
5. Connect the 3/8-inch air line labeled “Front

Air Bag” to the fitting in the height-control
valve port labeled C1.
Figure 30 — “Z” Bracket Installation

A line union and additional tubing may be added
2. Install the air fittings into the height-control to the existing line if it is not long enough to reach
valve. the fitting.
31
6. Connect the 1/4-inch air line labeled “Dump

Control” to the fitting in the dump port of the
height-control valve.
A line union and additional tubing may be added

to the existing line if it is not long enough to reach
the fitting.
7. Connect the 3/8-inch air line labeled

“Supply” to the fitting in the height-control
valve port labeled “E/I.”
8. Install an 8-inch long piece of 3/8-inch tubing
Figure 31 — Air Fitting Installation in the height-control valve port labeled “I/E.”
This tubing is for the exhaust function of the
valve, and the end of the tube should hang
just below the bottom flange of the frame
rail.
Page 32
REPAIR INSTRUCTIONS
34
When installing the height-control valve linkage,

the chassis must be parked on a level surface.
9. With the chassis parked on a level surface,

start the engine. While holding the height-
control valve arm in the neutral position,
allow the air system to build pressure to
110–130 psi. Shut the engine off.
10. Chock the front wheels to prevent the
vehicle from moving. Then release the air
brakes.
11. Actuate the height-control valve to fill the air Figure 34 — Linkage Rod Installation
bags. Use Suspension gauge (part
No. 45745-050) to set ride height to 14. Install the bottom of the linkage rod into the
4.25 inches. If 4.25 inches is exceeded while mounting hole in the suspension bracket.
filling the air bags, exhaust the air, and refill 15. Recheck the ride height. If the ride height is
them to obtain the 4.25-inch dimension. correct (4.25 inches), tighten the lower
Using the exhaust and fill method positions linkage rod nut to 100–150 lb-in
the valve at the bottom end of the valves (11–12 N•m). If the ride height is incorrect,
“dead band” zone. leave the linkage rod lower nut loose and
33
adjust rod length until the correct height is
obtained. Tighten the rod nut to
100–150 lb-in (11–12 N•m).
35
Figure 33 — Main Support Member Height
12. Loosen the worm-type hose clamp at the

lower end of the height-control valve linkage
Figure 35 — Height-Control Valve and Linkage
rod. Adjust the length of the rod so that it is
equal to the distance between the hole in the 16. Tighten the worm-type hose clamp at the
height-control valve arm and the bracket on lower end of the linkage rod.
the suspension.
17. Cycle the suspension by using the AL
13. Install the linkage rod to the height-control suspension control switch. Then recheck
valve arm as shown. Tighten the nut to ride height.
100–150 lb-in (11–12 N•m).
Page 33
REPAIR INSTRUCTIONS
AL II Suspension Component REMOVAL
Replacement 1. Chock the wheels to prevent the vehicle
from rolling.
The service procedures in this section are unique
to and recommended for, MACK AL II and 2. Support the axle with jackstands.
AL-401LH air suspensions. 3. Exhaust the air pressure from the air
springs.
The AL II suspension was first used on 1995
production MACK vehicles. The AL-401LH was 4. Disconnect height-control valve linkage.
first installed on some vehicles in October 1995. 5. Remove the rebound bolt, locknut, washers,
spacer tube and rebound roller from the
MAIN SUPPORT MEMBERS frame hanger. See Figure 37.
37
With normal use, the main support members

function satisfactorily through the life of the
vehicle, even though the components may show
some wear. Premature wear can occur, however,
requiring replacement. Replace main support
members if wear at the frame hanger cam contact
area exceeds 3/8 inch (10 mm). See Figure 36.
36
The following procedures are recommended

when replacing any of the main support
members.
Figure 37 — Removing Rebound Roller
6. Raise the rear of the frame far enough to

Main support members for 40,000-pound AL and remove the load from the main support
AL II suspensions are not all identical. If replacing member.
only one main support member, always verify that
7. Remove the U-bolt locknuts and washers.
it is the same part number as the support
member on the opposite side of that axle.
During disassembly, note the component

arrangement. Variations exist and all parts must
be reinstalled in their original positions for proper
suspension operation.
Page 34
REPAIR INSTRUCTIONS
8. Remove U-bolts, bottom cap, top pad and
Delrin liner (see Figure 38).
9. Remove the locknuts, washers and bolts DO NOT modify or rework parts. DO NOT use
that connect the shock absorber lower substitute parts. Modified or substitute parts
mounting bracket and cross channel section may result in loss of vehicle control and
to the main support member, on both sides possible personal injury or property damage.
of the vehicle.
10. Slide the shock absorber lower mounting
INSTALLATION
bracket off the main support member.
The sole purpose of the locating pins on the axle

Both sides of the cross channel must be
housing and main support member is to provide
disconnected from the main support member.
correct spring centers during initial assembly. It is
Raise the cross channel off of the main support
possible to damage or completely shear off either
member. Use a jack in the center of the cross
of these pins. DO NOT attempt to repair or
channel to raise it.
replace the pins. Any modification weakens the
38 main support member or axle housing. As long as
there is no other obvious damage, use the main
support member and axle housing as is, carefully
centering the seats and main support members
during reassembly.
Before beginning any reassembly, thoroughly

clean (preferably with a wire wheel) all spring
seats, spacers, clamp plates and spherical
washers, and inspect for damage. The recesses
in the clamp plates must be cleaned with a wire
wheel to ensure that the spherical washers seat
properly during reassembly. Remove any ridges
on the spring seats or spacers by grinding.
Carefully grind the axle housing surface ONLY
AS NECESSARY, to remove any high spots that
may prevent the seats or clamp plates from
seating properly against the axle housing.
1. Position the replacement main support

member on the axle seat with the main
support member center dowel pin piloting
into the hole in the axle seat or spacer.
Figure 38 — Removing U-Bolts, Bottom Cap, Top Pad Position the Delrin liner on the top side of the
and Delrin Liner main support member (refer to Figure 39).
Use only genuine MACK replacement parts for
parts are available through your nearest MACK
In most instances, the Delrin liners may be
branch or parts distributor.
reused. It is normal and acceptable for the Delrin
liners to “squash” out. Replace the Delrin liner
only if cut, torn or shows other signs of severe
damage.
Page 35
REPAIR INSTRUCTIONS
40
U-bolt clamping arrangements may differ.

Reassemble components in their original
relationships.
2. Assemble the Delrin liner, top pad, U-bolts,

bottom cap, washers and locknuts as shown
in Figure 39. DO NOT tighten U-bolt
locknuts at this time.
3. Insert the bolts through the cross channel
section and the shock absorber lower
mounting bracket into the main support
member.
4. Assemble the washers and locknuts that
connect the cross channel section and
shock mounting bracket to the main support
member, on both sides of the vehicle. Only
snug the bolts at this time. Tighten the
locknuts to specified torque.
39
Figure 40 — Channel Section and Mounting Bracket
5. Lower the frame so that the frame hangers

engage the main support member. Reinstall
the height-control valve linkage. Pressurize
the system.
To ensure that all components seat properly,

always torque U-bolt locknuts in stages (e.g., 150,
300, 425 lb-ft [203, 408, 576 N•m]). Use the
torque pattern shown in Figure 41.
Figure 39 — Mounting Bracket Locknut Location
Page 36
REPAIR INSTRUCTIONS
41 42
Figure 41 — U-Bolt Torque Pattern
6. Torque the U-bolt locknuts to 400–450 lb-ft

(540–610 N•m). Rap the top of the U-bolts
with a soft mallet and retorque.
Current production U-bolt nuts are phosphate/oil-

coated, black in color and require 400–450 lb-ft
(540–610 N•m) of torque for 7/8-inch diameter
spring clips and 260–320 lb-ft (353–434 N•m) for
3/4-inch diameter spring clips.
Figure 42 — Assembling Rebound Bolt, Spacer, Roller,
r Spring clips MUST be retorqued at Washers and Locknut
1,000 miles (1 600 km).
r Spring clips MUST be checked and retorqued
at 25,000 miles (40 000 km). Thereafter,
follow 25,000-mile (40 000-km) inspection Follow similar procedures for the AL-401LH,
interval. except for lower shock mounting area.
7. Assemble the rebound bolt, spacer, roller,

washers and locknut in the frame hangers
as shown in Figure 42. Torque the locknut to
50–70 lb-ft (70–95 N•m).
8. Check suspension alignment after the new
main support members have been installed.
Page 37
REPAIR INSTRUCTIONS
CROSS CHANNEL SECTION 5. Install the washers and locknuts that
connect the air springs to the cross channel
REMOVAL
section. See Figure 43. Torque the locknuts
1. Chock the wheels to prevent the vehicle to 20–30 lb-ft (30–40 N•m).
from rolling.
6. Lower the frame of the vehicle.
2. Exhaust the air pressure from the air
7. If working on the rearmost cross channel,
springs. Raise the frame of the vehicle just
remount the height-control valve control-rod
enough to remove the load from the
bracket on the cross channel section.
suspension.
43
It is not necessary to remove the shock absorbers

to perform this procedure.
3. If removing the rearmost cross channel

section, first disconnect the height-control
valve control rod mounting bracket from the
cross channel section.
4. Remove the locknuts and washers that
connect the air spring to the cross channel
section. Refer to Figure 43.
connect the cross channel section and the
lower shock mounting brackets to the main
support members. Refer to Figure 43.
6. Slide the lower shock mounting brackets
rearward and remove the cross channel
section from the suspension.
INSTALLATION
1. Position the cross channel section across
the ends of the main support members while
guiding the lower mounting studs of the air
springs through the holes in the channel
section.
2. Slide the lower shock mounting brackets Figure 43 — Cross Channel Section
over the main support member ends and
under the cross channel section. AIR SPRING
3. Insert the bolts that go through the cross REMOVAL
channel section. Install the lower shock
mounting brackets and the main support 1. Chock the wheels to prevent the vehicle
member ends. See Figure 43. from rolling.
4. Install the washers and locknuts that 2. Exhaust the air pressure from the air
connect the cross channel section and springs.
shock absorber mounting brackets to the 3. Raise the frame of the vehicle to remove the
main support members. Torque the locknuts load from the suspension.
to 260–320 lb-ft (353–434 N•m). See
Figure 43.
Page 38
REPAIR INSTRUCTIONS
4. Remove the locknut and washer that 4. Install the washer and locknut that connects
connects the air spring to the cross channel the air spring to the air spring frame hanger.
section. Refer to Figure 44. See Figure 45. Torque the locknut to
20–30 lb-ft (30–40 N•m).
5. Disconnect the air lines from the air spring.
5. Install the brass air fitting on the air spring.
6. Remove the brass air fittings from the air
Use TFE thread seal on the threads.
spring.
6. Attach the air lines to the air springs.
7. Remove the locknut and washer that
connects the air spring to the air spring 7. Lower the frame of the vehicle.
frame hanger.
8. Remove the air spring. 45
INSTALLATION
1. Insert the stud at the top of the air spring into
the hole in the air spring frame hanger.
2. Insert the stud at the bottom of the air spring
into the hole in the cross channel section.
3. Install the washer and locknut that connects
the air spring to the channel section. See
Figure 44. Torque the locknut to 20–30 lb-ft
(30–40 N•m).
44
Figure 45 — Installing Air Spring Washer and Locknut

(AL II Suspension)
Figure 44 — Installing Air Spring to Cross Channel

Section
Page 39
REPAIR INSTRUCTIONS
AIR SPRING FRAME HANGER 4. Pressurize the system.
46
replacing an air spring hanger.
REMOVAL
1. Chock the wheels to prevent the vehicle
from rolling.
springs.
3. Raise the frame of the vehicle to remove the
load from the suspension.
connect the air spring to the air spring frame
hanger. Refer to Figure 46.
5. Remove the bolts that connect the air spring
frame hanger to the frame.
6. Remove the air spring frame hanger.
INSTALLATION
1. Attach the air spring frame hanger to the
frame, using Grade 8 or metric Property
Class 10.9 bolts. Refer to MACK Master
Manual, 14-100, “Frame, Springs and
Suspension,” for guidelines on properly
selecting and installing bolts. Make sure that
the bottom surface of the bracket is flush
with the bottom surface of the frame rail. Figure 46 — Air Spring Frame Hanger Installation
2. Install the washer and locknut that connects

the air spring to the air spring frame hanger. SHOCK ABSORBER MOUNTING STUD
Refer to Figure 46. Torque the locknut to REMOVAL
20–30 lb-ft (30–40 N•m).
1. Remove the locknut and washer that secure
3. Lower the frame of the vehicle. the shock to the shock absorber mounting
stud.
2. Remove the shock absorber from the stud.
3. Remove the stud mounting nut, and remove
the stud.
Page 40
REPAIR INSTRUCTIONS
INSTALLATION INSTALLATION
1. Install the stud and torque the mounting nut 1. Slide the replacement shock absorber lower
to 250–300 lb-ft (340–400 N•m). mounting bracket onto the main support
member and beneath the cross channel
2. Attach the shock absorber to the mounting
section. Refer to Figure 48.
stud. Torque the nut to 90–110 lb-ft
(120–150 N•m). 2. Insert the mounting bolts through the cross
47
channel, shock mounting bracket and main
support member end.
3. Install the washers and locknuts which
connect the cross channel and shock lower
mounting bracket to the main support
member. See Figure 48. Torque the locknuts
to 260–320 lb-ft (353–434 N•m).
4. Reconnect the shock absorber to its lower
mounting bracket, using the bolt and
washers as shown.
48
Figure 47 — Shock Absorber Mounting
SHOCK ABSORBER LOWER MOUNTING

BRACKET
REMOVAL
from rolling.
2. Exhaust air pressure from the air springs.
4. Disconnect the shock absorber from its
lower mounting bracket.
secure the cross channel section and the
shock absorber lower mounting bracket to
the main support member. Refer to
Figure 47.
6. Slide the shock lower mounting bracket off
the main support member end.
Figure 48 — Installing Shock Absorber Lower Mounting

Bracket
Page 41
REPAIR INSTRUCTIONS
TRANSVERSE TORQUE ROD 4. Install washers and locknuts as shown in
Figure 50 to attach the torque rod and
REMOVAL
bracket to the frame. Refer to “Torque
Requirements” on page 18.
5. Check side-to-side alignment of the
Note the arrangement and quantity of washers at suspension.
50
the straddle mount brackets. These washers
affect side-to-side alignment of the suspension.
1. Remove locknuts and washers that connect

the transverse torque rod to the frame
bracket and the frame. See Figure 49.
connect the torque rod to the axle bracket.
3. Remove the transverse torque rod.
49
Figure 49 — Transverse Torque Rod
INSTALLATION
Figure 50 — Transverse Torque Rod Frame Mounting
1. Position either straddle mount end of the
torque rod at the axle bracket as shown in
Figure 49.
2. Install the locknuts and washers that The length of a new transverse torque rod may
connect the torque rod to the axle bracket. differ slightly from that of the original component.
Refer to “Torque Requirements” on page 18 Verify side-to-side alignment after installing a new
for locknut torque value. transverse torque rod. Refer to “Suspension
3. Insert bolts through the spacer, frame rail, Alignment — AL and AL II” on page 53.
plate, bracket, washers and the other
straddle mount end of the transverse torque
rod at the frame rail as shown in Figure 50.
Arrangement and quantity of washers at the

torque rod brackets affect side-to-side alignment
of the suspension.
Page 42
REPAIR INSTRUCTIONS
AL Suspension Component REMOVAL
Replacement 1. Chock the wheels to prevent the vehicle
from rolling.
The service procedures in this section are unique
to and recommended for the MACK AL air 2. Exhaust the air pressure from the air
suspension. This suspension was used on MACK springs.
vehicles from 1989 through 1995. 3. Remove the rebound bolt, locknut, washers,
spacer tube and rebound roller from the
MAIN SUPPORT MEMBERS frame hanger. See Figure 52.
52
With normal use, the main support members will

function satisfactorily throughout the life of the
vehicle, even though the components may show
some wear. Premature wear may occur, however,
requiring replacement. Replace main support
members if wear at the frame hanger cam contact
area exceeds 3/8 inch (10 mm). See Figure 51.
51
Mack recommends the following procedures for

replacing any of the main support members.
Figure 52 — Rebound Roller
MACK AL-40 air suspensions use two types of 4. Raise the rear of the frame far enough to
support members. If replacing only one main remove the load from the main support
support member, make sure it is the same type member.
as that used on the other side of the axle.
5. Remove the U-bolt locknuts and washers.
Replace old-type main support members with
new ONLY as an axle set.
Note component arrangement during

disassembly. Variations exist and all parts must
be reinstalled in their original positions for proper
suspension operation.
Page 43
REPAIR INSTRUCTIONS
6. Remove the U-bolts, bottom cap, top pad, INSTALLATION
Delrin liner and stiffener plate. See
1. Position the replacement main support
Figure 53.
member on the axle seat (or on the spacer
7. Remove the locknuts, washers and bolts plate, if so equipped), with the main support
that connect the air spring mounting bracket member center dowel pin piloting into the
to the main support member. hole in the axle seat or spacer plate. A Delrin
liner must be positioned on the top side of
8. Lift the air spring mounting bracket off the
the main support member, and a stiffener
main support member.
plate must be used on top of the Delrin liner.
9. Remove the main support member.
53
U-bolt clamping arrangements may differ.

Reassemble components in their original
positions.
2. Assemble the Delrin liner, stiffener plate, top

pad, U-bolts, bottom cap, washers and
locknuts as shown in Figure 54. DO NOT
tighten U-bolts at this time.
In most instances, the Delrin liners may be

reused. It is normal and acceptable for the Delrin
liners to “squash” out. Replace the Delrin liner
only if cut, torn or shows other signs of severe
damage.
Figure 53 — Delrin Liner and Stiffener Plate
Use only genuine MACK replacement parts when

parts are available through your nearest MACK
distributor.
DO NOT modify or rework parts. DO NOT use

substitute parts. Modified or substitute parts
may result in loss of vehicle control and
possible personal injury or property damage.
Page 44
REPAIR INSTRUCTIONS
54 55
Figure 54 — Assembling Delrin Liner, Stiffener Plate and Figure 55 — Air Spring Mounting
Top Pad
5. Lower the frame so that the frame hangers
3. Insert air spring mounting bracket bolts into engage the main support member. Then
the main support member. pressurize the system.
4. Assemble the washers and locknuts that 6. Torque U-bolt locknuts:
connect the air spring mounting bracket to
the main support member (see Figure 55). Black phosphate/oil-coated nuts —
Tighten the locknuts to 260–320 lb-ft 400–450 lb-ft (540–610 N•m)
(353–434 N•m). Silver cadmium/wax-coated nuts —
270–310 lb-ft (370–420 N•m)
Page 45
REPAIR INSTRUCTIONS
7. Assemble the rebound bolt, spacer, roller,
washers and locknut in the frame hangers
as shown in Figure 57. Torque the locknut to
To ensure proper seating of all components, 50–70 lb-ft (70–95 N•m).
always torque U-bolt locknuts in stages (e.g., 150,
300, 425 lb-ft [203, 408, 576 N•m]). Use the 8. Check suspension alignment after installing
torque pattern shown in Figure 56. new main support members.
57
56
Figure 56 — U-Bolt Torque Pattern
Later production U-bolt nuts are phosphate/oil-

coated, black in color, and require a torque of
400–450 lb-ft (540–610 N•m). Early production
spring clip nuts are cadmium/wax-coated, silver
in color, and require a torque of 270–310 lb-ft
370–420 N•m).
r Spring clips MUST be retorqued at
1,000 miles (1 600 km). Figure 57 — Rebound Roller
r Spring clips MUST be checked and

retorqued at 25,000 miles (40 000 km).
Thereafter, follow 25,000-mile (40 000-km)
inspection interval.
Page 46
REPAIR INSTRUCTIONS
CROSS TUBE 7. Lower the frame of the vehicle.
REMOVAL 8. Pressurize the system.
58
1. Chock the wheels to prevent the truck from
rolling.
springs. Raise the frame of the vehicle to
remove the load from the suspension.
connect the air spring to the air spring
mounting bracket. Refer to Figure 58.
4. Remove the locknuts that connect the air
spring mounting bracket to the main support
member. Refer to Figure 58.
5. Remove the air spring mounting bracket
from the cross tube by sliding the bracket off
the tube.
6. Slide the cross tube out of the other air
spring mounting bracket.
INSTALLATION
1. Using MG-C, grease the bore of each air
2. Slide the cross tube into the greased bore of
the air-spring bracket attached to the
chassis.
3. Slide the unattached air spring mounting
bracket onto the other end of the cross tube. Figure 58 — Cross Tube Replacement
4. Insert the studs or bolts of the air spring
mounting bracket through the main support AIR SPRING
member.
REMOVAL
5. Install the washers and locknuts that
connect the air spring mounting bracket to 1. Chock the wheels to prevent the vehicle
the main support member. See Figure 58. from rolling.
Torque the locknuts to 260–320 lb-ft 2. Dump the air pressure from the air springs.
(353–434 N•m).
6. Install the washers and locknuts that load from the suspension.
mounting bracket (Figure 58). Torque the 4. Remove the locknuts and washers that
locknuts to 20–30 lb-ft (30–40 N•m). connect the air spring to the air spring
5. Disconnect the air lines from the air spring.
6. Remove the brass air fittings from the air
spring.
hanger.
8. Remove the air spring.
Page 47
REPAIR INSTRUCTIONS
INSTALLATION 4. Install the washers and locknuts that
1. Insert studs at the top of the air spring into
hanger. Torque the outboard locknut to
the appropriate holes in the air spring frame
20–30 lb-ft (30–40 N•m). Torque the inner
hanger.
locknut to 50–70 lb-ft (70–95 N•m). See
2. Insert studs at the bottom of the air spring Figure 60 and Figure 61 for outboard and
into the holes in the air spring mounting inboard locknut locations.
bracket. 60
3. Install the washers and locknuts that

connect the air spring to the mounting
bracket. See Figure 59. Torque locknuts to
20–30 lb-ft (30–40 N•m).
59
Figure 60 — Air Spring Attachment (Outboard Side)

61
Figure 59 — Air Spring Mounting
Figure 61 — Air Spring Attachment (Inboard Side)
Page 48
REPAIR INSTRUCTIONS
5. Install the brass air fitting on the air spring. 4. Attach the air lines to the air spring.
6. Assemble the air lines to the air springs. 62

AIR SPRING FRAME HANGER

REMOVAL
from rolling.
springs.
4. Disconnect the air lines from the air spring. Figure 62 — Air Spring Attachment (Outboard Side)
63
5. Remove the brass air fitting from the air

spring.
hanger. Refer to Figure 62.
7. Remove the Huck-Fit™ fasteners or
bodybound bolts that connect the air spring
frame hanger to the frame.
8. Remove the air spring frame hanger.
INSTALLATION
1. Attach the air spring frame hanger to the
frame, using the appropriate bodybound
bolts (Grade 8 or metric Property Class
10.9) or NEW metric Property Class
10.9 Huck-Fit™ fasteners. Consult MACK
Master Manual, 14-100, “Frame, Springs
and Suspension” for guidelines on properly
selecting and installing bodybound bolts or
Huck-Fit™ fasteners.
2. Install the washers and locknuts that attach
the air spring to the air spring frame hanger.
Torque the outboard locknut to 20–30 lb-ft
(30–40 N•m). Torque inboard locknut to
50–70 lb-ft (70–95 N•m). Refer to Figure 62 Figure 63 — Air Spring Attachment (Inboard Side)
and Figure 63 for locknut locations.
3. Install the brass air fitting on the air spring.
Page 49
REPAIR INSTRUCTIONS
SHOCK ABSORBER FRAME HANGER 64
REMOVAL
connect the shock to the shock absorber
frame hanger.
2. Remove the shock and the inside shock
washer from the shock absorber frame
hanger stud.
3. Remove the Huck-Fit™ fasteners or
bodybound bolts that connect the shock
absorber frame hanger to the frame.
4. Remove the shock absorber frame hanger.
INSTALLATION
1. Attach the new shock absorber frame
hanger to the frame, using NEW metric
Property Class 10.9 Huck-Fit™ fasteners or
the appropriate bodybound bolts (Grade 8 or
metric Property Class 10.9). Consult MACK
Master Manual 14-100, for guidelines on
properly selecting and installing bodybound
bolts and Huck-Fit™ fasteners.
2. Install the inside washer and shock absorber
on the shock absorber frame hanger stud.
Refer to Figure 64.
3. Install the outside washer and locknut that Figure 64 — Shock Absorber Frame Hanger
retain the shock absorber on the shock
absorber frame hanger. Torque the locknut AIR SPRING MOUNTING BRACKET
to 50–70 lb-ft (70–95 N•m). Refer to
Figure 64. REMOVAL
1. Chock the wheels to prevent vehicle from
rolling.
Some MACK chassis use Huck-Fit™ fasteners to 2. Exhaust the air pressure from the air
attach suspension parts to the frame. Do not springs.
reuse fasteners that have been removed. 3. Raise the frame of the vehicle to remove the
Huck-Fit™ fasteners are not reuseable and can load from the suspension.
NEW HUCK-FIT™ FASTENERS. 4. Remove the locknuts and washers that
connect the air spring mounting bracket to
the main support member. Refer to
Figure 65.
6. Slide the air spring mounting bracket off the
cross tube.
Page 50
REPAIR INSTRUCTIONS
INSTALLATION TRANSVERSE TORQUE ROD
1. Using MG-C, grease the bore of the air REMOVAL
2. Slide the air spring mounting bracket onto
the cross tube.
Note the arrangement and quantity of washers
3. Insert the studs or bolts of the air spring used at the frame bracket. These washers affect
mounting bracket through the main support side-to-side alignment of the suspension.
member.
4. Install the washers and locknuts that 1. Remove the locknuts and washers that
connect the air spring mounting bracket to connect the transverse torque rod to the
the main support member (see Figure 65). frame bracket and the frame. Refer to
Torque the locknuts to 260–320 lb-ft Figure 66.
(353–434 N•m). 2. Remove the locknut and washer that
5. Install the washers and locknuts that connect the tapered stud end of the torque
connect the air spring to the air spring rod to the axle bracket. Refer to Figure 66.
mounting bracket (see Figure 65). Torque 3. Remove the tapered stud from the axle
the locknuts to 20–30 lb-ft (30–40 N•m). bracket by hitting ONLY THE AXLE
6. Lower the frame of the vehicle. BRACKET with a hammer. See Figure 66.
66

65
Figure 66 — Transverse Torque Rod Arrangement
Figure 65 — Air Spring Mounting Bracket 1. Transverse Rod Frame 5. Tapered Stud End
Bracket 6. Transverse Rod Axle
2. Straddle Mount End Bracket
3. Washer 7. Locknut
4. Rap Here 8. Transverse Rod
Page 51
REPAIR INSTRUCTIONS
INSTALLATION 7. Install washers and locknuts as shown in
Figure 67 to attach the torque rod and
1. Make sure that the tapered hole in the axle
bracket to frame. Torque the locknuts to
bracket is free of all foreign matter.
specification (refer to “Torque
2. Insert the tapered stud into the axle bracket. Requirements” on page 18).
3. Install the washer and locknut on the torque 8. Check the side-to-side alignment of the
rod stud. Torque the locknut to 400–450 lb-ft suspension.
(543–610 N•m). 67
4. After tightening, hit ONLY THE AXLE

BRACKET with a hammer to seat the
tapered stud as shown in Figure 66.
5. Retorque the locknut to 400–450 lb-ft
(543–610 N•m).
6. Position the straddle mount end of the
torque rod at the transverse torque rod
frame bracket as shown in Figure 67.
The arrangement and quantity of washers used

at the frame bracket affects side-to-side
alignment of the suspension.
Figure 67 — Transverse Torque Rod Frame Mounting
The length of a new transverse torque rod may

differ slightly from that of the original. Always
verify side-to-side alignment after installing a new
transverse torque rod. Refer to “Suspension
Alignment — AL and AL II” on page 53.
Page 52
REPAIR INSTRUCTIONS
Suspension Alignment — AL and 68
AL II
Perform the following procedure after completing
all repairs and tightening all suspension fasteners
to specified torque. Make all alignment checks
with suspension at the proper ride height.
(See ride height adjustment in the Preventive
Maintenance section.)
1. Position vehicle on level floor area. Free and
center all suspension joints by slowly
moving vehicle back and forth several times
without using the brakes.
2. Chock front wheels and make sure that the
tractor brakes are released.
3. Verify side-to-side alignment before taking
other measurements. Side-to-side
measurements should be within 1/4 inch
(6 mm) of each other to avoid potential
interference between the frame rail and
spring clips under severe articulation. If
adjustment is necessary, washer spacers
(part No. 37AX271) can be added or
removed from between the transverse
torque rod and the torque rod frame bracket.
Refer to Figure 68.
Figure 68 — Suspension Alignment and Adjustment
4. After verifying side-to-side measurements,

securely clamp a nine-foot piece of straight
bar stock or angle iron (or straightedge)
across the frame, using C-clamps. Select a
location as far forward of the forward drive
axle as possible, where components will not
interfere. On some vehicles, the lower frame
flange may be preferred. Otherwise, use the
upper frame flange. Refer to Figure 69.
Page 53
REPAIR INSTRUCTIONS
5. Accurately square the straightedge to the
frame, using a carpenter’s square.
6. Begin alignment by first checking the rear The removal or addition of each drop-in torque
drive axle. Use a trammel bar or its rod shim changes the difference between Ll and
equivalent to measure from the straightedge Lr by about 1/8 inch (3 mm). Use no more than
to the center line of the rear axle on both four shims for a permitted total maximum
sides of the vehicle (see Figure 69, Ll thickness of 1/4 inch (6 mm).
and Lr).
7. Rear drive axle alignment is acceptable if
both sides measure within 1/8 inch (3 mm)
of each other.
AL II and AL-401LH suspensions are equipped
8. If Ll and Lr measurements differ by more with adjustable length torque rods. When working
than 1/8 inch (3 mm), adjust the rear drive on this type of suspension, simply adjust the rod
axle by adding or removing drop-in shims at length to obtain proper alignment. Using drop-in
location shown in Figure 70. shims is not necessary.
69
9. The torque rod bar pin must always be

mounted to the forward face of the frame
hanger legs. After adjusting, snug torque rod
bar pin locknuts, but do not torque to
specification.
10. With the rear drive axle properly aligned,
front drive axle alignment can be checked by
measuring forward from the rear drive axle
center, using a trammel bar as shown in
Figure 69. If the forward drive axle
measurements differ by more than 1/8 inch
(3 mm), Sl and Sr in Figure 69, make
adjustments at the forward frame hangers
by adding or removing shims. Snug torque
rod bar pin locknuts.
Figure 69 — Alignment Measurements
Page 54
REPAIR INSTRUCTIONS
11. After aligning both axles, move the vehicle
back and forth several times before
removing the straightedge from the frame.
Recheck alignment to confirm adjustments.
Tighten the torque rod bar pin locknuts at the
frame hanger end to 150–205 lb-ft
(203–278 N•m). See Figure 70.
70
Figure 70 — Torque Rod Bar Locknuts (AL Suspension

Shown)
Page 55
NOTES
Page 56
SCHEMATIC & ROUTING DIAGRAMS
Page 57

SCHEMATIC AND ROUTING 71
DIAGRAMS
AL II Suspension Air Piping
Figure 71 and Figure 72 show the air piping
diagram for AL II suspensions.
Figure 71 — AL II Suspension with Single-Function Height-Control Valve Piping Diagram
Page 58

72
Figure 72 — AL II Suspension with Combination Height-Control/Dump Valve Piping Diagram
Page 59

AL Suspension Air Piping 73
Figure 73 shows the air piping diagram for

AL suspensions.
Figure 73 — AL Suspension Air Piping Diagram
1. Double Check Valve 4. Air Spring Assembly

2. Air Switch 5. Height-Control Valve
3. Console Manifold 6. Dash Manifold
Page 60
SPECIAL TOOLS & EQUIPMENT
Page 61

SPECIAL TOOLS
Tool No. Description
45745-050 Hendrickson Suspension Ride-Height
Gauge
KD 2247 Barksdale Field Test Kit
Page 62
Index.fm Page 63 Wednesday, January 19, 2000 10:03 AM
INDEX
INDEX
Page 63
Index.fm Page 64 Wednesday, January 19, 2000 10:03 AM
INDEX
A I
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . .5 INSPECTING AND TESTING
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . .2 HEIGHT-CONTROL VALVE (HCV) . . . . . 14
AL II SUSPENSION AIR PIPING . . . . . . . . . . .58
AL II SUSPENSION COMPONENT O
REPLACEMENT . . . . . . . . . . . . . . . . . . . .34 OVERVIEW OF AIR CONTROL VALVES . . . . 9
AL SUSPENSION AIR PIPING . . . . . . . . . . . .60
AL SUSPENSION COMPONENT P
REPLACEMENT . . . . . . . . . . . . . . . . . . . .43
PREVENTIVE MAINTENANCE . . . . . . . . . . . 18
C
R
COMPONENT LOCATOR . . . . . . . . . . . . . . . .12
COMPONENT REPLACEMENT . . . . . . . . . . .24 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . 24
RIDE HEIGHT ADJUSTMENT . . . . . . . . . . . . 20
D
S
DESCRIPTION AND OPERATION . . . . . . . . . .8
SAFETY INFORMATION . . . . . . . . . . . . . . . . . 2
E SCHEMATIC AND ROUTING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 58
EXPLANATION OF NUMERICAL SERVICE PROCEDURES AND
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 TOOL USAGE . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 62
F
SUSPENSION ALIGNMENT — AL
FIFTH-WHEEL MOUNTING ANGLE AND AL II . . . . . . . . . . . . . . . . . . . . . . . . . 53
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . .10 SUSPENSION INTEGRITY . . . . . . . . . . . . . . . 10
G T
GENERAL INFORMATION . . . . . . . . . . . . . . . .9 TORQUE REQUIREMENTS . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 14
Page 64
MACK AL AND
AL II AIR
SUSPENSION
SERVICE AND REPAIR
PRINTED IN U.S.A.
14-101 © MACK TRUCKS, INC. 2000

14-101 R. Chambi

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SERVICE AND REPAIR (REVISED)

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Activities associated with Danger indicate that death or serious personal

A procedure, practice, or condition that is essential to emphasize.

Example of Numerical Code

The illustrations in this manual are typical, and

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

When preparing to connect a tractor to a trailer,

DESCRIPTION AND OPERATION

Overview of Air Control Valves

Most suspensions also incorporate a dump

Figure 1 — Single-Function Height-Control Valve

Figure 3 — Combination Valve (Manufactured by

DESCRIPTION AND OPERATION

Do not use a cutting torch to remove any of

Exercise extreme care when handling or

Some MACK chassis use Huck-Fit™ fasteners to

Figure 5 — AL II Suspension Components

1. Frame Hanger 5. Main Support Member

r External leaks 1. Air Delivery: Check delivery as shown in

Figure 7 — Checking Air Delivery and Exhaust

2. Air Exhaust: Check exhaust as shown in

Figure 6 — Checking Air Delivery and Exhaust

Figure 9 — Height-Control Valve

The height-control valve test can be done with

If using shop tools, you will need the following for

If valve meets all the above characteristics, the

Figure 10 — Height-Control Valve Testing Set-up

1. Disconnect the height-control valve linkage

If chassis lean is evident, check to see if the main

Early-production AL suspension spring-clip nuts

Do not slot the HCV mounting bracket holes to

Figure 13 — Main Support Member Height

Figure 15 — Height-Control Valve with Threaded Rod

r On chassis equipped with a height-control

Figure 14 — Height-Control Valve with Rubber Rod End

Figure 16 — Height-Control Valve with Adjustable Arm

Figure 17 — Height-Control Valve with Adjustable Valve

After ride height adjustments are complete,

The vehicle must be empty of all load when

Figure 18 — Frame Hanger Slipper Pads

Installing slipper pads on an older chassis or

Figure 19 — Main Support Member Wear Area

Figure 20 — Frame Hanger Wear Areas

5. Remove the worn slipper pads (if used) and

Make sure that the slipper pad is seated against

Replace frame hangers if groove wear in the legs

If frame hangers must be replaced, attach new

Chock wheels and exhaust air pressure from air

Some MACK chassis use Huck-Fit™ fasteners to

Always check suspension after replacing the

Figure 23 — Bodybound Bolt/Huck-Fit™ Fastener