Disassembling and assembling front axle

AR33.10-Y-0060IND

Disassembling and assembling front axle

02.01.2020

Front axle

400.746 in model 831.001/002/005

Front axle dismantling procedure

1

S- camshaft snap ring

2

S- camshaft

3

Brake chamber bracket

4

Torque plate

5

Tie rod ball joint cotter pin

6

Tie rod mounting nut

7

Tie rod

8

Tie rod arm cotter pin

9

Tie rod arm mounting nut

10

Tie rod arm

11

Kingpin grease nipple

12

Kingpin upper cap

13

Kingpin cover mounting bolt

14

Kingpin adjustment screw mounting nut

15

Special tool kingpin adjustment screw remover 090 589 29 33 00

16

Kingpin

17

Grease seal

18

Bush

19

Knuckle stopper bolt

Front axle assembly procedure

17

Grease seal

18

Bush

20

Knuckle

21

Thrust bearing

22

Thrust washer

14

Kingpin adjustment screw

16

Kingpin

19

Knuckle stopper bolt

10

Tie rod arm

11

Kingpin grease nipple

12

Kingpin upper cap

23

Lower kingpin cover

6

Tie rod mounting nut

7

Tie rod

8

Tie rod arm cotter pin

9

Tie rod arm mounting nut

3

Brake chamber unit bracket

4

Torque plate

5

Tie rod ball joint cotter pin

1

S-camshaft snap ring

2

S-camshaft

24

Slack adjuster washer

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Disassemble

1

Remove front axle.

AR33.10-Y-0100IND

2

Remove front foundation brake.

AR42.15-Y-1051B

3

Remove front wheel hub.

AR33.20-Y-0310C

4

Remove S-camshaft snap ring (1) from slack adjuster.

5

Remove S-camshaft (2) with slack adjuster washer.

6

Remove brake chamber bracket (3) by removing the mounting bolts (4 nos).

7

Remove torque plate (4) by removing the mounting bolts and nuts from knuckle.

8

Remove the mentioned tie rod components.

 Tie rod ball joint cotter pin (5).
Tie rod mounting nut (6).

9

Remove tie rod (7) using special tool puller.

 Puller

*090589373300

10

Remove the mentioned components from tie rod arm.

 Tie rod arm cotter pin (8).
Tie rod arm mounting nut (9).

11

Remove tie rod arm (10) using special tool puller.

 Puller

*090589373300

12

Remove the mentioned components from knuckle.

 Kingpin grease nipple (11).
Kingpin upper cap (12).
Lower kingpin cover mounting bolt (13).
Kingpin adjustment screw mounting nut (14).

13

Remove kingpin adjustment screw using special tool kingpin set bolt remover (15).

 Puller

*090589293300

14

Remove kingpin (16) from knuckle using special tool kingpin puller.

 Puller

*090589303300

15

Remove grease seal (17) from the knuckle.

16

Remove bush (18) from knuckle using special tool kingpin bushing remover.

 If required, remove stopper bolt (19) from knuckle.

 Puller

*090589313300

17

Clean the dismantled parts.

AR33.00-Y-0861C



Assemble

18

Install bush (18) in the knuckle using special tool kingpin bush installer.

 Puller

*090589313300

19

Install grease seal (17) on both sides of the knuckle using special tool oil seal installer.

 Apply recommended grease to lip area of grease seal and set grease seal.

 Insertion tool

*090589451500

20

Install knuckle (20) with thrust bearing (21) to the front axle beam.

21

Install thrust washer (22) in the knuckle.

 Select a suitable thrust washer to allow the specified clearance.

22

Inspect knuckle.

 1) Provisionally assemble kingpin and bearing, move knuckle 2 or 3 times to have them fit.
2) Measure clearance between front axle upper surface and knuckle downside.
3) Adjust if the measured value exceeds the limit using feeler gauge.

23

Install kingpin (16) to knuckle, hammer it until it comes to rest at knuckle.

 Match the kingpin adjustment screw groove in the front axle.

24

Install kingpin adjustment screw (14) mounting nut in the knuckle.

 If removed, install knuckle stopper bolt (19) at the knuckle unit.

 Knuckle stopper bolt

*BA33.10-Y-1008-02B

 King pin set bolt mounting nut

*BA33.10-Y-1005-02B

25

Install lower kingpin cover (23) to the knuckle and tighten the mounting bolt.

 Lower king pin cover to knuckle

*BA33.10-Y-1009-02B

26

Install kingpin upper cap (12) at the knuckle.

27

Install kingpin grease nipple (11) in the knuckle.

28

Install tie rod arm (10) in the knuckle.

29

Install and tighten tie rod arm mounting nut (9).

 Tie rod arm mounting nut

*BA33.10-Y-1010-02B

30

Install tie rod arm split pin (8).

31

Install the tie rod (7) to the tie rod arm.

32

Install and tighten the tie rod mounting nut (6).

 Tie rod mounting nut

*BA33.10-Y-1011-02B

33

Install tie rod ball joint cotter pin (5).

34

Install torque plate (4) to knuckle, tighten the mounting bolts and nuts.

35

Install brake chamber bracket (3) and tighten the mounting bolts (4 nos).

 Brake chamber bracket mounting bolts

*BA33.10-Y-1012-02B

36

Install S-camshaft (2) with slack adjuster washer (24) to the knuckle.

37

Install S-camshaft snap ring (1) to the slack adjuster.

38

Install front wheel hub.

AR33.20-Y-0310C

39

Install front foundation brake and brake drum.

AR42.15-Y-1051B

40

Install front axle.

AR33.10-Y-0100IND

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1005-02B

King pin set bolt mounting nut

Nm

29

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1008-02B

Knuckle stopper bolt

Nm

71

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1009-02B

Lower king pin cover to knuckle

Nm

74

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1010-02B

Tie rod arm mounting nut

Nm

686

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1011-02B

Tie rod mounting nut

Nm

196

 Front axle installation

Number

Designation

Front axle 400.746 in model 831.001/002/005

BA33.10-Y-1012-02B

Brake chamber bracket mounting bolts

Nm

135