Remove/install steering knuckle

AR33.25-Y-0400A

Remove/install steering knuckle

31.10.2019

Front axle

400.760 in model 400.204/207/212/216/241/243/262/281

Front axle

400.767 in model 831.247

Removal of steering knuckle

31

Puller 090 589 14 33 00

65

Front wheel nuts

66

Hydraulic jack

67

Jack stand

73

Drag link cotter pin

83

Drag link ball joint

28

Steering arm

29

Tie rod ball joint cotter pin

30

Tie rod ball joint nut

31

Puller 090 589 14 33 00

32

Tie rod arms

33

Steering knuckle

34

Top and bottom snap rings

35

Dust caps

36

O-rings

37

Lock wedge nut

38

King pin

39

Drift front axle 090 589 28 15 00

41

Thrust bearing

42

Shim

87

Kingpin puller

Installation of steering knuckle

38

King pin

39

Drift front axle 090 589 28 15 00

40

Hydraulic press

41

Thrust bearing

42

Shim

48

Front axle assembly centering pin (centralizer) 090 589 27 15 00

49

Stopper plate 090 589 07 32 00

29

Tie rod ball joint cotter pin

30

Tie rod ball joint nut

32

Tie rod arms

34

Top and bottom snap rings

35

Dust caps

36

O-rings

37

Lock wedge nut

50

Tie rod

28

Steering arm

51

Grease gun



Remove

1

Loosen the front axle wheel nuts (65).

 Jack up the front axle using a trolley jack (66) and support the front axle using jack stand (67).

2

Remove front wheel.

Front axle 400.760 in model 400.204/207/212/216/241/243/262/281

AR40.10-Y-1100B

Front axle 400.767 in model 831.247

AR40.10-Y-1100A

3

Remove wheel hub (front).

AR33.10-Y-0020A

4

Remove front wheel brake units.

Front axle 400.760 in model 400.204/207/212/216/241/243/262/281

AR42.10-Y-0166A

Front axle 400.767 in model 831.247

AR42.15-Y-1051A

5

Remove cotter pin (73) of the drag link ball joint from steering arm.

6

Remove the drag link ball joint nut and drag link ball joint (83) from the steering arm using special tool puller (31).

 Support the drag link suitably.

 Puller

*625589003500

7

Remove steering arm (28) from the steering knuckle on the steering gear box side.

 Only for steering side of front axle.

8

Remove tie rod ball joint cotter pin (29) and nut (30).

9

Remove the tie rod by removing tie rod ball joint from the tie rod arm using special tool puller (31).

 Support the tie rod suitably.

 Puller

*625589003500

10

Remove tie rod arm (32) from the steering knuckle (33).

11

Remove top and bottom snap rings(34), dust caps (35) and O-rings (36) from the steering knuckle.

12

Remove the lock wedge bolt by removing the nut (37) and lock washer.

 Use drift and hammer to remove the lock wedge bolt.

13

Set up kingpin puller (87) on top of kingpin.

 Press out the kingpin (38) from the axle using special tool drift front axle (39).

 Drift

*090589281500

14

Remove steering knuckle (33), thrust bearing (41) and shim (42) from the axle.



Install

15

Install the steering knuckle, thrust bearing (41) and shim (42) on the axle beam.

 Use special tool front axle assembly centering pin (centralizer) (48).

 Ensure that the height of the bush maintain proper seating of the oil seal during installation of bush to the steering knuckle.
Ensure proper positioning of thrust bearing. (top and bottom side of the bearing).

 Guide pin

*389589006100

16

Check the clearance between the steering knuckle and axle beam.

 Check at the top side of kingpin bore (opposite to the bearing side) using dial indicator.

 Play must be within the limit value (0.05 mm- 0.01 mm).
Available thrust plate thickness are 0.7 mm to 2.3 mm of 0.1 mm in steps.

If the clearance is more,



Add shim as required.

17

Install special tool front axle assembly centering pin (centralizer) (48) in position.

 Fix the special tool stopper plate (49) at the bottom of the steering knuckle. Adjust the height of the stopper plate bolt for ensuring the height of the kingpin.

 Guide pin

*389589006100

 Locating plate

*090589073200

18

Insert the wedge bolt by adjusting the position of special tool front axle assembly centering pin (centralizer).

 Adjust the stopper plate bolt to firm touch the kingpin. Don't disturb the stopper plate adjustment till the kingpin is installed completely.

 Guide pin

*389589006100

19

Remove the wedge bolt and special tool front axle assembly centering pin (centralizer).

 Guide pin

*389589006100

20

Support the front axle housing suitably on the hydraulic press (40) with top end of the kingpin facing upwards.


Exercise care while handled the liquid nitrogen. Use necessary protective wear.
This can lead to injuries.

 Soak the kingpin (38) in liquid nitrogen and prepare the kingpin for installation. Immerse the kingpin in liquid nitrogen to cool until -20°C temperature is reached.

21

Place the kingpin (38) over the bore and press down the kingpin using special tool drift (39) and hydraulic press (40).

 Press till the kingpin firmly contacts with special tool stopper plate.

 Locating plate

*090589073200

 Drift

*090589281500

22

Install wedge bolt by tightening wedge nut (37) and remove the axle from kingpin puller.

 Wedge bolt head must face the vehicle front side and nut to be tightened from the rear side.
Check that at least two threads of the wedge bolt are past the nut.

 Wedge bolt tighten

*BA33.20-Y-1001-02A

23

Remove the snap ring and special tool stopper plate.

24

Install top and bottom O-rings (36), dust caps (35) and snap ring (34) to the steering knuckle.

 Ensure the lubricating grease nipples are properly positioned and cleaned before fitment.

 Locating plate

*090589073200

25

Install tie rod arms (32) to the steering knuckle assembly and tighten the bolts.

AR40.20-Y-0100A

 Ensure equal number of threads of ball joint are projecting outside the tie rod on both sides.

 Tie rod arm to steering knuckle tighten

*BA33.20-Y-1004-02A

If tie rod length is disturbed,



Locate the tie rod (50) ends to the steering knuckle by setting the distance between the tie rod ball joints center to center as 1693.5 mm.

26

Tighten the ball joint nut (30) and insert the cotter pin (29) and lock the nut.

 Ball joint nut tighten

*BA33.20-Y-1002-02A

27

Install steering arm (28) to the steering knuckle by tightening the bolts.



BB00.40-P-0267-00A

 Apply the recommended lubricating grease to the kingpin lubricating grease nipple using grease gun (51).

 Greasing on upper and lower lubricating grease nipple to be done until fresh lubricating grease starts to flow out of the thrust bearing and thrust plate.

 Steering arm to steering knuckle tighten

*BA33.20-Y-1003-02A

28

Install foundation brake units to the steering knuckle assembly.

Front axle 400.767 in model 831.247

AR42.15-Y-1051A

29

Install wheel hub (front) assemblies to the front axle.

AR33.10-Y-0020A

30

Install brake drum.

Front axle 400.767 in model 831.247

AR42.15-Y-1051A

31

Install front wheel.

Front axle 400.760 in model 400.204/207/212/216/241/243/262/281

AR40.10-Y-1100B

Front axle 400.767 in model 831.247

AR40.10-Y-1100A

Front axle 400.767 in model 831.247

AR40.20-Y-0345A

 Ensure max cut angle is correct and steering wheel is straight ahead position, if necessary readjust.

32

Road test the vehicle.

 Steering knuckle bearing remove/install

Number

Designation

Front axle 400.760 in model 400.204/207/212/216/231/241/243/262/281
Front axle 400.767 in model 831.247

BA33.20-Y-1001-02A

Wedge bolt tighten

Nm

30

 Steering knuckle bearing remove/install

Number

Designation

Front axle 400.760 in model 400.204/207/212/216/231/241/243/262/281
Front axle 400.767 in model 831.247

BA33.20-Y-1002-02A

Ball joint nut tighten

Nm

295

 Steering knuckle bearing remove/install

Number

Designation

Front axle 400.760 in model 400.204/207/212/216/231/241/243/262/281
Front axle 400.767 in model 831.247

BA33.20-Y-1003-02A

Steering arm to steering knuckle tighten

Torque

Nm

300

Angular torque

°

90

 Steering knuckle bearing remove/install

Number

Designation

Front axle 400.760 in model 400.204/207/212/216/231/241/243/262/281
Front axle 400.767 in model 831.247

BA33.20-Y-1004-02A

Tie rod arm to steering knuckle tighten

Torque

Nm

300

Angular torque

°

90