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Drive Axle Suspension, 12C 1

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Drive Axle Suspension, 12C 1 102D SERIES MAINTENANCE MANUAL 12-SUSPENSION August 2000 Date 12CĆ1 Page SECTION 12C DRIVE AXLE SUSPENSION CONTENTS OF THIS SECTION SUBJECT PAGE General Description. 12CĆ1 Components. 12CĆ1 Maintenance. 12CĆ1 Torque Specifications. 12CĆ8 Specifications. 12CĆ9 Service Tools . 12C-10 GENERAL DESCRIPTION needs for the rear suspension system, therefore, only procedures for disassembly and removal of serviceable The D series rear axle suspension system is typical components will be discussed. with basic or optional drive axle configurations. There are All serviceable suspension components are some minor differences in the attachment of the radius mechanically fastened to the coach chassis and axle rods between the specific models, but otherwise, the assembly. A periodic inspection of these fasteners the installations are similar. The 102DL3's radius rods attach condition of torque seals and lock straps on 102D3 to the front of the chassis, whereas the 102D3's radius coaches, with special attention to their specific torque, rods attach at the rear. should be undertaken. COMPONENTS WARNING The typical rear suspension systems (Figure 1 & 2) are composed of the following: Left and right suspension supports assemblies, structure on 102D3 models having Avoid accessing suspension components from provisions for attaching the shock absorbers with outside coach wheel well areas. Unintentional studĆdesign upper mounts and structure on 102DL3 Actuation of the height control valves with fully models having provisions for attaching shock absorbers inflated air springs could result in serious injury. with eyering upper mounts. One set each of upper Always block the coach body adequately during (diagonally mounted) and lower (longitudinally mounted) any inspections and/or repairs in these areas. radius rods stabilize the rear axle assembly. Four heavy duty shock absorbers, along with four rollingĆlobe type air RADIUS RODS springs, (of one piece design), support the rear The lower radius rods maintain the axle longitudinally. suspension. Two left and right height control valves The two upper radius rods are offset, forming a wishĆ regulate pressure in the rear axle air springs. bone, and maintain the axle both longitudinally and laterally. The upper radius rods also act to limit vehicle roll MAINTENANCE while turning and are subject to higher loads. The following instructions apply to radius rods used on This section will address the specific maintenance the rear drive axle suspension. Radius rod ends are requirements of the rear suspension system and its mounted via mounting tabs on the rubberized saddle components. There are no specific periodic maintenance pins that act as rod bushings. 102D SERIES MAINTENANCE MANUAL 12-SUSPENSION August 2000 Date 12CĆ2 Page RH SUPPORT AIR SPRING ASSEMBLY MOUNTING PLATE SHOCK UPPER DRIVE AXLE RADIUS RODS AIR SPRING BUMPER L&R SUPPORT ASSEMBLY TIE RODS LH SUPPORT ASSEMBLY 8085 Figure 1. Rear Suspension 102DL3 Inspection NOTE:ă If worn bushings are not replaced, excessive wear to other suspension components and tires will NOTE: Do not rely on visual inspection for determining result. the serviceability of radius rod and their bushings. MCI recommends checking radius rod bushings at Radius Rod Removal 50,000 mile (80,450 km) intervals to determine if the ă1.ăElevate and block the coach body. Elevate and bushings require replacing due to wear. The Magnaflux block the rear axle at the correct ride height as outlined in process is recommended for detecting cracks in the Section 3G of this manual. radius rods. ă2.ăRemove the drive axle wheels. Due to the mounting configuration of the radius rods to the rear suspension supports and rear bogie assembly, ă3.ăUnfasten and remove the upper radius rods from special attention should be placed on the inspection of the axle's top mounting bracket shown in Figures 1 and 2. these rods and their saddle pin bushings. ă4.ăUnfasten and remove the remaining radius rods. 102D SERIES MAINTENANCE MANUAL 12-SUSPENSION August 2000 Date 12CĆ3 Page SHOCK RH SUPPORT ASSEMBLY AIR SPRING AIR SPRING MOUNTING PLATE UPPER DRIVE AXLE RADIUS RODS BUMPER L&R SUPPORT ASSEMBLY TIE RODS LH SUPPORT ASSEMBLY 9290 Figure 2. Rear Suspension 102D3 Bushing Removal ă1.ăPlace radius rod eye with saddle pin bushing on Radius rod bushing removal and installation tools are top of spacer pipe in press (Figure 3). shown on the SERVICE TOOLS" page at the end of this ă2.ăPlace the round bar on top of radius rod saddle subĆsection. pin's mounting tab. Rear axle radius rod bushings require the use of a ă3.ăApply pressure with the press until the bushing special sleeve installation tool 20Ć389. The replacement drops out of the eye and into the pipe. The round bar will saddle pin bushings have metal outer sleeves. drop out also. Additionally, a 2Ćinch diameter round bar, (for removing ă4.ăRemove the radius rod, bushing and round rod pins), and a 7Ćinch long piece of 3Ćinch nominal size from press. (schedule 80) pipe will be needed as a press spacer. ă5.ăClean the remainder of the bonded rubber residue NOTE:ăAll tools are to be used in conjunction with a from inside diameter of the rod eye. hydraulic press in the removal and installation procedures that follow. Bushing Installation ă1.ăCoat exterior of new saddle pin bushing with NeverĆSeize compound or equivalent antiĆseize CAUTION compound. Support or block components in accordance NOTE:ăAntiĆseize compounds are applied only to the with good hydraulic press operating procedures. bushing's outer metal sleeve. 102D SERIES MAINTENANCE MANUAL 12-SUSPENSION August 2000 Date 12CĆ4 Page ă4.ăRemove tool, radius rod and pipe from press. BUSHING REMOVAL TOOL Radius Rod Installation ă1.ăSet coach at the correct ride height (Figure 7). ă2.ăApply a thin coating of antiĆseize on all mounting surfaces of the radius rod saddle pins and reinstall. RADIUS ROD W/BUSHING NOTE: AntiĆseize is applied only to saddle pin bushing's tabĆtoĆchassis mating points and fasteners. PIPE STAND PRESS ă3.ăInstall fasteners with hex nuts out and torque to 220 ftĆlbs (300 N.m). 8068 SHOCK ABSORBERS Figure 3. Bushing Removal The main function of the shock absorber is to regulate ă2.ăPlace radius rod, bushing and appropriate sleeve the vehicle axle travel by dampening the rebound motion. installation tool in press, centered on top of spacer pipe Fluid contained within the shock absorber is forced through a restricted opening by a piston when the (Figure 4). suspension air springs are flexed. The shock absorbers are heavyĆduty doubleĆacting BUSHING INSTALLATION type. They are of welded construction and cannot be TOOL repaired. Defective shock absorbers must be replaced PRESS with new units. Some early models 102DL3 shock absorbers have stud type mountings at both shock ends. All other models RADIUS ROD are fitted with shocks that have a stud type mount at the bottom and an eyeĆring type mount at the top for RADIUS ROD BUSHING horizontal attachment to bogie assembly. Follow the applicable procedures for removing shock absorbers. PIPE STAND Shock Inspection 8069 A visual inspection of the shock absorbers should be Figure 4. Bushing Installation included with the suspension inspection. A road test may also determine if the shock absorbers need service NOTE:ăCorrect Orientation of the saddle pin tabs in (Figure 5). relationship to their mounting must be made before Points to inspect include: pressing pin into rod eye. ă1.ăshock absorber body for physical damage of evidence of oil leakage ă3.ăApply pressure to top of tool until bushing is seated inside the radius rod eye. ă2.ăshock absorber rod for bending, nicks and scratches, or evidence of oil leakage (a light film of oil on NOTE:ăCutĆouts are provided in the sleeve installation the rod is normal) tool for determining correct seating. ă3.ărubber bushings for deterioration. 102D SERIES MAINTENANCE MANUAL 12-SUSPENSION August 2000 Date 12CĆ5 Page Figure 6. Misting vs Leaking Heat Test Shock absorbers function at temperatures ranging from ambient to 350'F. A shock's role is to dampen the oscillation of the coach's springs. It does this by transforming the energy produced by the spring to heat Figure 5. Visual Shock Check and dissipating it. As a result the shock should be slightly warm to hot to the touch after normal use. If ride deterioration is experienced and there is suspicion that a shock has failed internally, which is visually undetectable, perform the following "SHOCK HEAT TEST" within a few minutes of operating the equipment: Leaking and Misting ă1.ăDrive the vehicle at moderate speeds for at least Misting shocks are often misĆdiagnosed as failures. 15 minutes. Misting is the process whereby very small amounts of ă2.ăWithin a few minutes of driving the vehicle, touch shock fluid evaporate at high operating temperatures each shock absorber carefully on its body below the dust through the upper seal of the shock. When the mist" cover or tube, after first touching a nearby part of the reaches the cooler outside air, it condenses and forms a chassis to establish a reference ambient temperature of film on the outside of the shock body. When mixed with the metal. road debris and dust, a grime will often coat the entire ă3.ăAll shock absorbers should be warmer than the body of the shock. Misting is a perfectly normal and chassis. Suspect a failure in any shock absorber that is necessary function of the shock. The fluid which noticeably cooler than it's mate on the other end of the evaporates through the seal area helps to lubricate axle. Different temperatures from axle to axle do not prolong the life of the seal.( Figure 6) indicate failures, but cooler temperatures on any one axle Many technicians find it difficult to differentiate does warrant removal and examination of the cooler between a misting shock and true leaker which needs to shock absorber.
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