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Kingpin Bushing Service Kit Kingpin Bushing Service Kit
SUBJECT: Kit No. 60961-009, 60961-039
and Axle Service Kit 60691-040
LIT NO: 59310-011
DATE: December 2007 REVISION: C
INTRODUCTION
This kit was developed to service vehicles that have a STEERTEK front steer axle. Proper
maintenance, service, and repair is important to the reliable operation of the suspension
and axle. For complete service instructions on the AIRTEK
®
and SOFTEK
®
suspensions with
the STEERTEK axle see the Hendrickson website www.hendrickson-intl.com. Follow the pro-
cedure below for proper installation of the king pin bushing service kit.
KINGPIN BUSHING INSTALLATION
A MECHANIC USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED
BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE
VEHICLES SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED. INDIVIDUALS
DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED ASSUME ALL RISKS OF
CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED.
1.
A hydraulic shop press with a minimum forcing capacity of 10 tons will be required
and a kingpin bushing driver, see Figure 1.
FIGURE 1
Driver for Kingpin Bushing Installation
BEFORE APPLYING HYDRAULIC PRESSURE TO ANY TOOLING SET-UP, ALWAYS CHECK TO BE
SURE THE PRESS PLATE, ADAPTERS, AND COMPONENTS BEING WORKED ON ARE
POSITIONED PROPERLY, I.E. IN LINE WITH THE RAM. IMPROPER POSITIONING CAN CAUSE
PERSONAL INJURY OR COMPONENT DAMAGE.
2.
Install the lower or upper steering knuckle in the press.
1.13"
0.76"
1.79"
1.90"
5.83"
1.94"
KINGPIN BUSHING
KIT CONTENTS
QTY.
DESCRIPTION
1
Thrust Bearing
2
Grease Cap Assy.
2
Retaining Ring
2
King Pin Bushing
2
King Pin Seal
2
5
/
8
" Socket Head
Cap Screw
4
King Pin Shim .005"
1
King Pin Shim .047"
1
Loctite
®
(Red)
1
LIT# 59310-011 3.
Install the kingpin bushing from the machined side (axle side) of the lower or upper
steering knuckle using a bushing driver, see Figure 1. Press in the bushing to a depth
of no less than
15
/
64
" (0.236") or 6 millimeters and no more than
5
/
16
" (0.32") or 8
millimeters, see Figures 2 and 3.
4.
Following the installation of the kingpin bushing, it is necessary to ream the kingpin
bushings to fit the kingpins.
FIGURE 2
FIGURE 3
FIGURE 4
KINGPIN BUSHING REAMING
REAM THE KINGPIN BUSHINGS WITH AN
ADJUSTABLE STRAIGHT FLUTE REAMER, SEE
FIGURE 5. DO NOT HONE OR BURNISH THE
KINGPIN BUSHINGS, IT WILL DAMAGE THE
BUSHINGS AND VOID WARRANTY.
WHEN INSTALLING STEERING KNUCKLE
COMPONENTS IN A VISE IT IS NECESSARY TO
PROTECT THE MACHINED SURFACES FROM
GOUGES OR MARRING BY USING BRASS JAWS.
FAILURE TO DO SO CAN CAUSE PREMATURE
PART DAMAGE, DAMAGE TO THE STEERING
KNUCKLE COMPONENTS, LOSS OF WARRANTY, LOSS OF VEHICLE CONTROL, CAUSING
PERSONAL INJURY OR PROPERTY DAMAGE.
FIGURE 5
Adjustable Straight Flute Reamer
1.
Install the steering
knuckle assembly
in a vise with brass
jaws.
SERVICE HINT
It is acceptable to mount
the knuckle components
in a vise either vertically or horizontally when performing the reaming procedure.
2.
Install the reamer into the steering knuckle until the blades touch the kingpin bushing.
3.
Rotate the reamer with light downward pressure. Rotate the reamer smoothly. DO NOT
apply too much pressure, see Figures 6 and 7.
4.
Slide the reamer out of the bottom of the steering knuckle assembly. If it is necessary
to remove the reamer from the top, rotate the reamer opposite of cutting rotation.
KINGPIN BUSHING SERVICE KIT
2
59310-011 FIGURE 6
Lower Steering Knuckle in Vise
FIGURE 7
Upper Steering Knuckle in Vise
5.
Clean and remove all kingpin bushing material from the steering knuckle assembly.
Take special attention to remove material from the grease channels and dimples.
6.
Clean the
5
/
8
" brake backing plate bolts with a wire wheel and run a tap through the
threads of the lower steering knuckle assembly and then flush out with brake clean-
er and dry with compressed air.
PRIOR TO INSTALLATION, ENSURE THAT ALL RESIDUAL LOCTITE
®
MATERIAL IS REMOVED
FROM THE MOUNTING BOLTS AND THE THREAD BORES IN THE UPPER STEERING KNUCKLES,
AND NEW LOCTITE 277 (INCLUDED IN KIT) OR EQUIVALENT IS APPLIED TO HELP ENSURE
THAT THE BOLTS SUSTAIN THE PROPER TORQUE REQUIREMENT. FAILURE TO DO SO CAN
CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.
NOTE
The
Hendrickson Genuine part, socket head cap screw comes with a pre-applied Loctite
compound.
7.
Install the upper and lower steering knuckle on the kingpin.
8.
Check for the proper fit by rotating the knuckle assembly back and forth to verify there
is no binding on the kingpin, see Figures 8 and 9.
9.
If the bushing is too tight repeat steps 1 through 8 until the proper clearance is
achieved.
NOTE
Bushing size is to be 0.001" larger than the kingpin size.
FIGURE 8
FIGURE 9
KINGPIN BUSHING SERVICE KIT
3
59310-011 www.hendrickson-intl.com
Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected.
© 2006 Hendrickson USA, L.L.C. (U.S. Rights) Hendrickson International Corporation (Rights Outside U.S.) All Rights Reserved
59310-011 Rev C 12-07
Truck Suspension Systems
800 South Frontage Road
Woodridge, IL 60517-4904 USA
630.910.2800
Fax 630.910.2899
Printed in United States of America
KINGPIN SEAL INSTALLATION
1.
Place the steering knuckle assembly in a vise with brass jaws or place on a suitable
workbench. The steering knuckle will have the machined surface facing up (axle
side up).
2.
Lay the kingpin seal into the bore of the knuckle. The lip seal should face outward, or
toward the axle.
3.
Using a bushing driver tool, press seal firmly into the knuckle assembly.
4.
Install the kingpin seal until it makes contact with the kingpin bushing, see Figures 10
and 11.
FIGURES 10 AND 11
KINGPIN BUSHING SERVICE KIT