FRONT AXLE

TYPE: 30 & 50

MAY 2012
 FRONT AXLE TYPE: 30 & 50
07.02
Service Manual
 FRONT AXLE TYPE: 30 & 50
07.03
Service Manual

CONTENTS

Group - 07

FRONT AXLE TYPE: 30 & 50

Section Subject Page No.

07.0 general......................................................................................................... 07.04

07.0.1 Data............................................................................................................. 07.05

07.1 special tools.............................................................................................. 07.06

07.2 PRINCIPLE OF OPERATION - STEERING GEOMETRY.................................. 07.07

07.2.0 Castor Angle................................................................................................ 07.07
07.2.1 Toe-in........................................................................................................... 07.07
07.2.2 Front to Rear Axle Alignment...................................................................... 07.08
07.2.3 Steering Geometry Checking Procedure...................................................... 07.08

07.3 FRONT AXLE ASSEMBLY - REMOVAL AND INSTALLATION........................ 07.09

07.4 FRONT AXLE ASSEMBLY OVERHAUL........................................................... 07.10

07.4.0 Drum Removal and Refitment...................................................................... 07.10
07.4.1 Hub Assembly Removal............................................................................... 07.10
07.4.2 Wheel Bearing Cup Removal....................................................................... 07.11
07.4.3 Wheel Bearing Cup Installation................................................................... 07.11
07.4.4 Stub Axle Removal...................................................................................... 07.12
07.4.5 Stub Axle Bush Renewal............................................................................. 07.12
07.4.6 Reaming the Bushes................................................................................... 07.13
07.4.7 Stub Axle Installation................................................................................... 07.13
07.4.8 Hub and Drum Assembly Installation:.......................................................... 07.15
07.4.9 Hub Setting and End Float Adjustment....................................................... 07.15

07.5 TROUBLE SHOOTING...................................................................................... 07.16

07.6.1 Hub Overhaul............................................................................................... 07.17
07.6.2 Stub Axle Overhaul...................................................................................... 07.17
07.6.3 Renewal of Stub Axle Bushes..................................................................... 07.18

07.7 Tightening Torques................................................................................... 07.20

07.8 Maintenance schedule........................................................................... 07.21

07.9 Recommended Lubricants....................................................................... 07.21

 FRONT AXLE TYPE: 30 & 50
07.04
Service Manual

07.0 general Design and Description

Front Axle Type and Sl. No. The front axle & suspension system is conventional
in design, and consists of an ‘I’ section axle beam, to
which is connected at each end a stub axle. The stub
axles carry wheel hub and drum assemblies as fitted.
The axle beam is suspended on road springs which are
attached to the vehicle chassis frame. Shock absorbers
are fitted to dampen the effect of the road springs.

Axle Beam

The axle beam is an ‘I’ section steel forging, with two

locating flanges on the top surface for mounting the
road springs, and an inclined eye at each end to locate
& support the king pins.

Two sizes of axle beams are available, and are

designated as types 30 and 50 and have nominal
carrying capacities of 3000 kg and 5000 kg respectively.

Stub Axles

Type 30 Front Axle - Representative Diagram

The forged steel stub axles have two bosses which are
bored and fitted with steel backed bronze bushes to
accommodate the king pins. The vertical load on the
stub axle is transferred to the axle beam via a thrust
bearing. The upper and lower steering arms are fitted
to the stub axles, the method of fitment being dependent
on the type of axle. The stub axle also incorporates a
flange to provide a mounting for the brake backplate.

The steering arms bolted to the stub axles and in

addition the brake backplate is retained by the steering
arm bolts. On these axles it is necessary to gain access
to the brake backplate to remove the steering arms.

Type 50 Front Axle - Representative Diagram King Pins

The stub axles are connected to the axle beam by

hardened steel king pins. Each pin is located and
The front axle serial number and type of front axle are
secured in the axle beam eye by either one or two heat
punched near LH side king pin boss of axle beam.
treated cotter pins (depending upon axle type). On type
30 axles, one taper cotter pin with lock nut arrangement
is used. Whereas on type 50 axles, two selective fit
tapered cotter pins are used with each king pin.
 FRONT AXLE TYPE: 30 & 50
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Service Manual

Front Hubs

The SG Iron hubs are mounted on the stub axle spindles by two opposed taper roller bearings. On type 30 & 50
front axles, correct wheel bearing adjustment is achieved by means of a distance piece and shims arrangement.
The wheel bearings are to be packed by kneading the grease into the bearings. The front axle grease cup has to
be packed fully with grease.

Hub - Exploded View

07.0.1 Data
Type 30 50
Axle Capacity (kg) 3000 5000
Camber Angle 0° to 1°15' 0° to 1°15'
Caster Angle 1°20' - 4°40' 1°20'-4°40'
Toe In (mm) 1.28 - 3.84 1.70 - 5.11
Outer Wheel Turning Angle at full lock 41° - 43° 40° - 42°
Inner Wheel Turning Angle at full lock 34°30' - 35°48' 33°24' - 34°26'
King Pin Inclination 7°55' - 8°55' 7°55' - 8°55'
Bore Dia For King Pin In Axle Beam (mm) 31.7 - 31.32 36.41 - 36.46
King Pin Diameter - Standard Size mm) 31.24 - 31.27 36.38 - 36.41
King Pin Bush Inner Dia (Assembled and Reamed) (mm) 31.29 - 31.31 36.43 - 36.46
Bore Dia In Axle Arm For Bushes (mm) 34.92 - 34.97 39.62 - 39.67
Thrust Taken On Thrust Bearing Thrust Bearing
End Play of Axle Arm (mm) 0.053 0.0 - 0.10
Thrust Bearing Shim Size (mm) 3.0 - 4.1 2.7 - 4.2
Hub End Play mm 0.025 - 0.076 0.025 - 0.076
 FRONT AXLE TYPE: 30 & 50
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Service Manual

07.1 special tools

SPECIAL
APPLICATION DESCRIPTION
MAINTENANCE TOOLS
0605001 (3001) - SPANNER GREASE CUP TYPE 30 CARGO 709/759

TO REMOVE GREASE CUP

0605002 (3003) - DRIFT KING BUSH TYPE 30 CARGO 709/759

TO INSTALL KING PIN TOP

AND BOTTOM BUSHES

0606002 (5003) - SPANNER HUB NUT TYPE 50 CARGO 909

TO LOOSEN OR TIGHTEN
HUB NUT SPANNER - 909

0801002 (3941) - REMOVER SHOE RETURN SPRING (SAW BRAKES)

TO REMOVE & REFIT

BRAKE SHOE RETURN
SPRINGS

0605006 (3002) - INSTALLER & REMOVER ‘E’CLIP CARGO

TO REMOVE ‘E’ CLIP ON

WEDGE SHAFT

0605007 (3006) - DRIFT CIRCLIP EXPANDER ASSY CARGO

TO INSTALL CIRCLIP ON
EXPANDER ASSY.

0605008 (3004) - INSTALLER & EXTRACTOR SPRING CAGE CARGO

TO REMOVE AND REFIT

CAGE ON HOUSING

0605009 (3005) - DRIFT EXCLUDER ASSY FITMENT CARGO

TO INSTALL EXCLUDER
ASSY.

07.2 PRINCIPLE OF OPERATION - STEERING
GEOMETRY
In order for a vehicle to exhibit satisfactory steering ride
and handling characteristics, especially when operating
in a laden condition, it is important to ensure that the
steering geometry is accurately set. The term ‘steering
geometry’ is normally used to cover the following specific
items; caster angle, camber angle, king pin inclination,
toe-in and toe-out on turn, front to rear axle alignment
and steering wheel alignment.
Camber angle and king pin inclination. The illustration
below shows a theoretical steering system where both
the camber angle and king pin inclination are zero.
The front wheels are pushed along by a force ‘F’ acting
through the centre line of the king pin. This force is
opposed by an equal and opposite force ‘R’ (the
resistance of the tyre on the road). These two forces
combine to produce a couple (two equal and opposite
parallel acting forces) of magnitude ‘F’ x ‘X’. The couple
causes a large splaying- out effect at the wheels, this
effect increasing greatly as the brakes are applied. In
addition, this theoretical steering system causes heavy
steering due to the distance ‘X’ between the king pin
and wheel centre line, the wheel having to move around
the king pin in an arc radius ‘X’. In order to reduce the
above conditions, the wheel and king pin are arranged
to make the dimension ‘X’ considerably smaller. This is
achieved by incorporating camber angle and king pin.
The following illustration shows a practical steering
system incorporating both camber angle and king pin
inclination.
FRONT AXLE TYPE: 30 & 50
07.07
Service Manual
The angle between the vertical and a line passing
through the rolling axis of the wheel is termed ‘camber
angle’ and is achieved by producing the stub axle at a
downward angle to the king pin bore. The angle between
the vertical and the centre line of the king pin is termed
‘king pin inclination’ and is achieved by producing the
king pin bores in the axle beam at the required angle to
the vertical. It can be seen that the camber angle and
king pin inclination are not adjustable, there is however
a need to ensure that these remain within product
specification.
07.2.0 Castor Angle
It is important for a driver to feel the straight ahead
position of his vehicle and also to rely on the steering
system self-centering after the steering manoeuvre has
been completed. The above two conditions are achieved
by angling the bottom of the king pin towards the front of
the vehicle, as shown in the illustration below.
In this system, a theoretical line drawn through the king
pin centre contracts the road in front of the centre line
of the road wheel. The angle between the two centre
lines is termed ‘castor angle’ and results in the vehicle
effectively pulling the front wheel along the road, thereby
giving steering self-centering and feel.
The castor angle which ‘is built’ into the vehicle is non-
adjustable. There is however a need to ensure that this
angle remains within production specification.
07.2.1 Toe-in
When a vehicle is travelling in the straight ahead
 FRONT AXLE TYPE: 30 & 50
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Service Manual
direction, the front road wheels should be parallel. In
order to achieve this, an allowance must be made for
free play in the steering ball joints which is taken up by
the splaying out of the wheels.
On rear wheel drive vehicles the front wheels normally
splay out. Therefore to counteract this a toe-in figure is
specified. The illustration below the toe-in on the front
wheels of a vehicle.
Toe-in is measured at the rim of the wheels. Two
measurements being taken at the same point, the
vehicle having moved half the circumference of the
wheel between measurements. Toe-in adjusted by
altering the effective length of the track rod.
Toe-out on turns
With reference to the illustration it can be seen that as
a vehicle is driven around a curve, the outer front wheel
travels a greater distance than the inner wheel.
It can also be seen that the angular movement of the
outer wheel (frontlock angle) is less than that of the
inner wheel (backlock angle).
This difference in wheel angle which increases as
the wheels are turned is termed ‘toe-out on turns’ For
geometry checking, this is measured with the steering
turned at an angle of 20° from the straight ahead
position.
The front-lock angle for one wheels is directly related to
and controlled by the back lock angle for the opposite
wheel and is not in itself adjustable. If, toe-out on turns
is not as per specification it is possible that the backlock
angles are incorrect, or that toe-in is incorrect or that
damage has occurred to a steering arm or to the track
rod.
It is important to ensure that back lock and front-lock
angles are maintained within specification, Failure
to do so may result in the vehicle turning circle being
adversely affected or mechanical damage may occur to
the power steering gear (where fitted) on to the steering
linkages.
07.2.2 Front to Rear Axle Alignment
The thrust axis of the vehicle (rear axle) must be-correctly
aligned with the front axle. Otherwise an adverse effect
on the rest of the steering geometry will result.
Vehicle with a misaligned thrust axis will have to be
steered to counteract the uneven thrust.
This will result in difficulty in steering and a potentially
dangerous handling. The wear on the front tyres will be
uneven and severe.
Where axle misalignment is detected, the rear axle
suspension and locating assemblies should be
thoroughly checked for wear and damage.
07.2.3 Steering Geometry Checking Procedure
To Check Wheel Alignment
- Park the unladen vehicle on level ground.
- Ensure all tyres are of same size and tread wear is
uniform.
- Ensure tyres are inflated to recommended
pressure.
- Check spring pin bush wear is within limit.
- Ensure the spring cambers are equal on both
sides.
- Spring I-bolts are tightened to correct torque value.
- Ensure steering centre point play is nil.
- Hub end play is nil.
To Set Toe-in/Toe-out
- Set the wheels in the straight ahead position.
- Place the toe in gauge in front of the front wheels
and adjust the height of the pointers to the centre
of the wheel on both sides. Note the reading.
- Mark both the wheel drums with chalk at the points
where the pointers have touched. Remove toe-in
gauge.
- Now roll the vehicle forward one half revolution
until the chalk marks turn by 180° towards the rear,
i.e., the chalk marks are at the rear.
- Place toe-in gauge behind the front axle and let
the pointers touch the chalk mark. Note down the
reading. It should be 0-3 mm toe in.
- In case the readings do not correspond to the
recommended value, adjust the length of the track
rod. Repeat the check and ensure that the wheels
are set parallel. Then tighten the clamp bolts of the
sockets fully.
Any run out of the wheel rims will not affect
the toe in measurement, if the wheel is
NOTE moved forward by 180° between the two
measurements as explained above.

Camber
Camber is the tilt of the wheel away from a true vertical
position. A wheel tilted outwards at the top has positive
camber. A wheel tilted inward at the top has negative
camber. The reading gives the camber in degrees. The
amount of camber is controlled by machining of the axle
beam and axle arm. The effect of too much positive
camber is irregular tyre wear of the outside shoulders.
Tyre wear on the inside shoulders, hard steering and
wandering are the indications of reverse or negative
camber.
Castor
It is in the forward or backward tilt of the axle. If the axle
is tilted to the rear is positive castor and if it is tilted to
the front it is negative castor. The MDV front axles are
designed to have positive castor angle.
Procedure
Turn the wheel to a specified angle (say 20°) to one side
from the straight ahead position.
Adjust the castor scale to zero on the gauge by using
adjusting screw provided at the bottom.
Turn the wheel in the opposite direction to make 20°
from the centre line or totally 40° from the measured
position.
The reading in the scale in relation to the position of the
bubble will indicate the castor angle.
Repeat the procedure for the other wheel.
Use standard steering geometry measuring equipment
to measure the camber / castor as well as Toe out on
turns.
07.3 FRONT AXLE ASSEMBLY - REMOVAL
AND INSTALLATION
This operation explains the removal and installation of
the front axle assembly (axle beam, stub axles, hubs
drums, etc) as a complete unit. Should be necessary to
remove the axle beam separately, reference should be
made to front Axle Assembly Overhaul.
Front Axle Assembly Removal
Shock Absorber and Anti-roll Bar Mounting
FRONT AXLE TYPE: 30 & 50
07.09
Service Manual
- Position the unladen vehicle on a firm, flat surface,
apply the parking brake, chock the rear wheels
and tilt the vehicle cab.
- Slacken the wheel nuts on the front wheels.
- Raise the front of the vehicle until the wheels are
clear of the ground, and position chassis stands.
The chassis stands should be positioned to the rear
of the axle beam to allow access to the axle beam
from the front of the vehicle. Remove the Jack.
- Remove the wheel nuts and remove the road
wheels.
- Drain the air reservoirs and disconnect the hoses
to brake actuators by loosening the union nuts at
the chassis end of the pipe.
- Remove the split pin and castellated nut from the
drag link to steering arm ball joint, and separate
the ball joint taper. Support the drag link clear of
the axle beam.
- Position a suitable jack centrally under the front
axle. Raise the jack to support the axle and install
safety chain the axle to the jack.
- Remove the spring U-bolt nuts and remove the
U-bolts from the axle beam.
- Slowly and carefully lower the jack with the front
axle assembly securely attached, until the spring
locating dowels are free from the axle beam.
Carefully pull the jack and axle assembly out from
the front of the vehicle. Collect and retain any
spacers fitted between the axle beam and springs.
- On reassembly, it is important to ensure that
spacers are refitted in the same position from
which they were removed, otherwise the vehicle
altitude may be adversely affected.
Front Axle Assembly Installation
 FRONT AXLE TYPE: 30 & 50
07.10
Service Manual

The type of cab attitude spacer fitted is 4

mm or 25 mm thick. The 25 mm spacer
NOTE is a steel casting with an integral dowel
on its lower face for locating in the axle
beam. The top face is drilled to accept the
spring locating dowel. The 4 mm spacer is
manufactured from steel plate and drilled
centrally to enable the spring locating dowel
to protrude through the hole and locate in
the axle beam.

- Raise the axle assembly and securely mount it

with safety chains on the jack. Ensure that the
spring axle beam, bump stop mating surface are
clean. Ensure that U-bolt threads are clean and
undamaged.

- Carefully position the jack and axle underneath

the vehicle. If any spacers were removed, these
should be refitted to the axle beam in the same
position from which they were removed.

- Slowly raise the axle on the jack and align the road
spring locating dowels with the recesses on the 07.4 FRONT AXLE ASSEMBLY OVERHAUL
axle beam spring seats. Carefully raise the jack
until the dowels are fully into the spring recesses This procedure explains the overhaul of the complete
and the springs sit fully on the axle beam. front axle assembly. If it is required to carry out part of this
procedure (eg: Renewal of wheel bearings) the relevant
- Position the bump stop spacers on the spring and part should be extracted from the main procedure.
fit the two ‘U’ blots. fit the anti-roll bar rear mounting
bracket to the front ‘U’ bolt. Fit and tighten the ‘U’ 07.4.0 Drum Removal and Refitment
bolt nuts progressively and evenly to the specified
Type 30 & 50 Axles :
torque.
- Remove the wheel nuts previously slackened, and
- Remove the safety chain from the axle beam &
remove the road wheel, Position the roadwheel on
slowly lower the jack and remove.
the ground, mounting flange uppermost.
- Ensure that the draglink ball joint taper is clean
- Remove drum mounting bolts and washers.
& refit the draglink to the steering arm. Fit the
castellated nut and torque to specification. If the - Lift the brake drum from the hub. If necessary a
split pin holes do not align, advance to the next mallet may be used to release the hub to drum
hole to align. Do not slacken the nut. Fit a new seal.
split pin.
- Remove hub along with bearings from stub axle.
- Reconnect the hoses from each brake actuator
and tighten the union nuts. - For refitting reverse the above procedure.

- Fit the wheels & Wheelnuts and tighten. 07.4.1 Hub Assembly Removal

- Position a jack under the axle beam and raise the
vehicle to clear off the chassis stands. Remove
the stands and lower the vehicle to the ground.
Remove the jack Lower the vehicle cab.
- Torque the wheel nuts to the specification.
- Position the vehicle on a flat surface apply the
parking brake and chock the rear wheels. Tilt the
vehicle cab.
- If the hub is to be separated from the brake drum,
all wheel nuts should be slackened.

- Remove the wheel chocks. - Raise the front wheels clear off the ground, and
position chassis stands, Lower the vehicle on to
the stands.
 FRONT AXLE TYPE: 30 & 50
07.11
Service Manual

- Slacken the brake adjusters on each front wheel. locate the drift or puller if drifting out, ensure the
cup remains secure within the hub bore by drifting
Type 30 Axles: it alternatively on each side, Ensure that the drift
does not damage the bearing cup bores in the
Remove the hub grease cap using special tool no
hub. Discard the bearing cups.
0605001. Remove the split pin, castle nut, thrust
washer and outer bearing cone. - Thoroughly wash and de-grease the hub and
grease cap.
Type 50 Axles :
07.4.3 Wheel Bearing Cup Installation
Remove the 4 bolts securing the hub grease cap and
remove the cap. Bend back the lock tabs from the
wheel bearing adjusting lock nut & remove the locknut.
Remove the lock tab washer. Remove the locking ring,
bearing adjusting nut, and the outer bearing cone.

- Carefully remove the wheel hub and drum

separately from the stub axle.

- Carefully remove all the asbestos brake lining dust

from the drum, drake shoes and brake back plate.
Ensure that dust does not enter the wheel hub and
contaminate the grease.

Asbestos dust is Injurious to health and must

not be inhaled. Do not blow the dust with
WARNING
an air line. Use a suitable vacuum cleaner.
If a vacuum cleaner is not available, use
personal protective breathing equipment
or a suitable facemark and remove the
dust carefully with a brush. Collect the dust
CAUTION
for disposal. Do not use petrol, paraffin,
trichloride ethylene or any petroleum based
fluid as damage will occur to the rubber
components, resulting in brake failure.
Use only clear Methylated spirits Isopropyl
alcohol.

- Remove the remaining front hub and drum

assembly as previously described.

07.4.2 Wheel Bearing Cup Removal

Bearing cone & bearing cup assemblies

are supplied in matched sets and should
NOTE be used as sets. It is not permissible to
assemble a bearing cup & bearing cone
from different manufacture.

- Check the degree of fit of the new bearing cones

on the appropriate stub axle. The cone should be a
push fit without tight spots and without perceptible
clearance. If there is excessive clearance, even
with a new bearing cone fitted, the stub axle should
be renewed.

If a bearing assembly has seized and

- Carefully remove the grease seal from the inner
face of the hub and withdraw the inner bearing
cone. Discard the seal & bearing.
- Using a soft metal drift or a suitable puller, remove
the inner and outer bearing cups from the hub.
Cut-outs are provided behind the bearing cups to
rotated on the stub axles, with subsequent
damage to the stub axle, the new stub axles
CAUTION
and bearing assembly must be fitted. On
no account should a stub axle be cleaned
up after bearing failure since further
bearing failure with possible dangerous
consequences may result.
 FRONT AXLE TYPE: 30 & 50
07.12
Service Manual
- Ensure the hub bearing cones are not damaged.
Install the new inner and outer bearing cups in the
hub. the cups should be installed with a soft metal
drift to avoid damaging the cups and hub. Lightly
tap the cups at diametrically opposite points to
ensure that the cups are correctly fitted when they
contact the bottoms of the hub bores.
- Fully pack a new inner bearing cone with lithium
based grease to the correct specification. Fit the
inner bearing cone into the hub, and carefully tap a
new grease seal into place.
- Renew the inner bearing, cups & grease seal,
as previously described, for the other side of the
vehicle.
07.4.4 Stub Axle Removal
Type 30 Axle
Note: On these axles, the bolts retraining
the steering arm to the stub axle, also retain
the brake backplate to the stub axle.
- Remove the split pins, when fitted from the upper
and lower steering arm to stub axle bolts and
remove the nuts. remove the bolts.
- Swing the drag link and tack rod, steering arm
and carefully remove the brake backplate from the
stub axle. Support the brake backplate to avoid
damage.
Type 50 Axles:
- Remove the bolts securing the upper/lower steering
arms to the stub axle and swing the steering arms
clear.
- Remove the steering arms from the stub axles.
- Remove the eight bolts, washers & locking nuts,
Securing the brake backplate to the stub axles.
- Carefully remove the brake back plate from the stub
axle and support it with wire to avoid damaging.
All Axles (Type 30 & 50)
- Remove the king pin upper and lower grease caps
from the stub axle.
- Carefully drift the cotterpins from the axle beam
axles have two selective fit tapered cotterpins that
are peened into position in the axle beam.
- Carefully drive the king pin out of the stub axle
beam bores. If a seized king pin is found, it may be
necessary to press it out using a hydraulic press.
As the king pin clears the stub axle lower bore, it is
important to ensure that it is not allowed to fall on
to the ground, otherwise damage may occur.
- Carefully remove the stub axle from the axle beam,
ensuring that the upper thrust washer and the
lower roller thrust bearing are retained. Remove
the seal from the upper king pin bush bore.
- Similarly remove the stub axle from the other side
of the vehicle.
07.4.5 Stub Axle Bush Renewal
- Position the stub axle on the bed of a press position
the bush remover/installer in the lower bush bore
(see below for special tool)
Type 30 Axle : Special tool no. 0605002
Type 50 Axle : Special tool no. 0606001
* Place a suitable mandrel through the upper bush
bore to locate centrally on the shaft of the tool.
Slowly press the bush from the bore.

* Remove the mandrel and bush remover/installer.
Turn the stub axle so that the remaining bush bore
is positioned on the bed of the press. Similarly
press the remaining bush from the stub axle bore.
The bore from which the bush is to be
removed, should always be seated firmly
NOTE on the bed of the press. Never attempt to
remove the bush from the upper unsupported
bore, otherwise the forces required may
permanently distort the stub axle assembly.
- Remove the stub axle from the press.
- Thoroughly clean and de-grease the stub axle.
Carefully check the bush bores in the stub axle
bosses and the boss thrust faces for burrs and
deep scratches. These should be removed with a
fine file and emery cloth.
- Ensure that the new bushes are absolutely free
from scratches and burrs, and that they are
absolutely clean.
Correct Upper Bush Installation
- Position the stub axle on the bed of the press
(i.e. same relative position as when installed in
vehicle). Place a new upper bush on the stub axle
in taper in the upper bush bore. Position the bush
remover/Installer in the new bush and carefully
press the bush into the bore. Care must be taken
FRONT AXLE TYPE: 30 & 50
07.13
Service Manual
to ensure that the bush enters the bore squarely,
otherwise the bush may get damaged.
- Continue to press the bush into the upper bore
until the dimension shown is achieved.
- Remove the bush remover/Installer from the stub
axle and remove the stub axle from the press. Turn
the stub axle over and re-position in the press.
- Similarly press a new bush into the lower bore until
the dimension shown below is achieved.
* Remove the stub axle from the press and remove
the special tool. Examine the bushes if they have
been installed correctly. They should be free from
any burrs.
07.4.6 Reaming the Bushes
New stub axle bushes should always be reamed after
fitment to ensure the correct fit between kingpin &
bushes. While selecting the type of reamer to be used,
it is important that it is either capable of reaming the
upper and lower bushes in one operation, or that it is
supported and guided one bush, while the remaining
bush will the remaining bush is being reamed. This is to
ensure that both bores are reamed concentrically.
- Refer data to establish the stub axle bush internal
diameter after reaming. Carefully adjust and lock
the reamer to the specified dimension.
- Carefully ream upper & lower bushes.
- Thoroughly clean the stub axle ensuring that all
traces of burr are removed. Pay Attention to the
bearing surfaces and the lubrication grooves of the
bushes and also the grease cap threads. Clean
the reamer.
07.4.7 Stub Axle Installation
- Clean the steering arm to stub axle mating
surfaces.
- Inspect the thrust bearing situated between the
undersize of the axle beam and the stub axle lower
boss.
 FRONT AXLE TYPE: 30 & 50
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Service Manual
Friction Thrust Bearings
Checking Stub Axle to Axle Beam Clearance
- Fit a new seal to the upper king pin bush bore.
- Establish the thickness of stub axle thrust washers
required as follows
- Place the stub axle in position on the axle beam,
and fit the thrust bearing between the beam and
stub axle lower boss.
- Temporarily fit the king pin to align the assembly.
- Place a small hydraulic jack under the stub axle
king pin bore and apply a light load to remove any
free play between the lower boss of the stub axle
and the axle beam and to compress the moulded
scaling rings on the top and bottom of the thrust
bearing.
- Measure the clearance at several point between
the axle beam and the stub axle upper boss. Note
the minimum clearance.
- Select the thrust bearing shims necessary to give
a clearance of 0 to 0.1 mm with free movement of
the stub axle from lock to lock.
- Remove the hydraulic jack and remove the king
pin.
- Coat the king pin and shims with specified grease,
insert the shim into position between the axle
beam and the stub upper boss and Install the king
pin. The king pin is marked ‘T’ (top ) and should be
fitted so that cut-out (s) for the cotter pin (s) align
with the hole (s) in the beam.
Type 30 Axle
One tapered cotter pin is fitted to each king pin.
- Drive the pin in from the front of the vehicle and
peen it in position at both ends.
Type 50 Axle
Two nos tapered selective fit pins are fitted to each king
pin.
- Fit the two cotter pins into the axle beam. The rear
of the axle beam, the longer pin is fitted into the
lower hole from the front.
Do not drift fully home at this stage.
NOTE
- Check that the stub axle swivels smoothly from
lock to lock with no tightness or excessive free
play. Recheck and adjust the shim thickness if
necessary.
- Drift the cotter pins firmly into the axle beam. When
correctly installed, the heads of the pins should
be 1.5 mm inside the axle beam holes (select the
cotter pins suitably). A shorter taper cotter pin will
reduce the depth of the cotter pin in the axle beam.
- When the cotter pins are correctly fitted, using a
centre punch, peen the axle beam around each
cotter pin hole in three places to secure the pins in
place, so that they will not loose in service.
- Install the upper and lower grease caps and tighten
to the specified torque. Refit or fit new grease
nipples into grease caps, tighten securely.
- Type 30 Axle:
Secure the brake backplate to the stub axle with
the bolts. Fit the upper and lower steering arms, to
the through bolts, fit locking nuts and tighten them
to specified torque.
 FRONT AXLE TYPE: 30 & 50
07.15
Service Manual

- Type 50 Axle - Place inner bearing cone and oil seal.

- Fit the eight bolts and washers securing the back
plate to the stub axle. Fit the lock nuts and tighten
to specified torque. Position the upper and lower
steering arms against the stub axle and fit retaining
bolts and tighten to torque.
- Fit the stub axle as previously described on the
other side of the vehicle.
- Position the hub on the spindle bearing diameter.
- Ensure no damage caused to inner bearing and oil
seal of the hub.
- Place the shims and outer bearing (pre-greased)
on the spindle journal using drift for aligning outer
bearing inner race.

07.4.8 Hub and Drum Assembly Installation: - Fit the adjusting nut and tighten torque to 108 Nm.

- Ensure that the stub axle wheel spindle and bearing
adjusting nut threads are clean and undamaged.
Securely fit the hub, drum and wheel assembly to
the wheel trolley.
- Ensure that the wheel trolley is adjusted to the
correct height and carefully fit the assembly to the
stub axle wheel spindle. Never use undue force to
fit the assembly to the spindle, otherwise damage
may occur to the grease seal or bearing cups.
If force is necessary, it indicates that the wheel
trolley height is incorrectly adjusted.
07.4.9 Hub Setting and End Float Adjustment
Type 30
- Pack inner, outer bearings and hub cavity with
grease.
- Position the distance piece in the hub.
- Place inner bearing cone and oil seal.
- Position the hub on the spindle bearing diameter.
- Rotate hub in both direction.
- Fit washer bearing retainer engaging with hole
in ring bearing lock and fasten with nut over peg.
(Reverse or back off, to align).
- Ensure the end float 0.025 to 0.076 mm, if the
end float is not within limits, adjust the shims for
required end float.
- Fit tab washer and lock nut on spindle, tightening
torque to 95 Nm. Fold the tab washer over the lock
nut.
- Fit pre-greased front hub cup with screws,
tightening torque to 17.5 - 22 Nm.
Lubricate the stub axle king pin bushes by applying
specified grade of grease through the grease nipples.
In the king pin grease caps. Adjust the brakes lower
the vehicle to the ground. Torque the wheel nut to
specification. Check and adjust the wheel. toe in & front
& back lock angles. Lower the vehicle cab & remove
the rear wheel chocks.

- Ensure no damage caused to inner bearing and oil

seal of the hub.

- Place the shims and outer bearing (pre-greased)

on the spindle journal using drift for aligning outer
bearing inner race.

- Place the thrust washer and castle nut.

- Rotate the hub in both direction, tighten the nut to

torque of 95 Nm.

- Check the end float of the hub, ensure end float

within 0.025 to 0.076 mm limits.

- If the end float is not within limits, adjust the shims

for required end float.

- Assemble the split pin and fold.

- Fit pre-greased front hub cap on the hub, tighten

torque to 40 - 60 Nm.

Type 50

- Pack inner, outer bearings and hub with grease.

- Position the distance piece in the hub.

 FRONT AXLE TYPE: 30 & 50
07.16
Service Manual

07.5 TROUBLE SHOOTING

Fault Possible Causes Remedy

in the straight ahead
in the straight ahead to Grease king pins with front wheels
Insufficient grease in king pin
lock off ground and operating steering
bushes
from lock position

Low tyre pressure Inflate tyres as specified

High steering effort in

King pin/bushes require lubrication Lubricate as necessary
one or both directions

King pin thrust-bearing severely Fit new bearing as described in

worn the Manual

Wheel bearings incorrectly adjusted

Adjust or renew bearings
or worn
Steering ‘shimmy’
Vehicle front end chassis alignment Check alignment and if necessary
not to specification rectify

Low or unequal tyre pressure Inflate tyres as specified

Steering wanders from Wheel bearings incorrectly adjusted

Adjust or renew wheel bearings
straight ahead position or worn

Steering geometry incorrect Check and if necessary adjust

Tyre pressure low Inflate tyres as specified

Vehicle front end chassis alignment Check alignment and if necessary

Steering does not not to specification rectify
return to straight ahead
position after manoeure. King pins tight in stub axle bores Check and if necessary, rectify

Castor angle not to specification Check castor angle


07.6.1 Hub Overhaul
To dismantle
1. Isolate batteries.
2. Chock rear road wheel and move hand control to
value to 'PARK' position.
3. Slacken front road wheel retaining nuts.
4. Jack and suitable support front axle, remove nuts
and wheel.
5. Release break shoes, then withdraw brake drum.
6. Remove hub cap.
7. Extract split pin and remove hub nut and keyed
washer.
8. Remove hub assembly.
9. Remove outer roller bearing, leaving bearing race
in place in hub.
10. Remove oil seal and hub inner bearing, leave
bearing inner race in place in hub.
To inspect
1. Thoroughly clean all components.
2. Inspect bearing for evidence of pitting, wear,
overheating or cage distortion.
3. Examine hub for wear or damage, renew as
necessary.
4. Examine wheel bolts for worn or damage, if
necessary replace.
5. When fitting new hub bearing outer races should
be press fit in hub, if this condition is not apparent
wear of outer race location in hub has occurred
and hub must be renewed.
To Reassemble and adjust end float
1. Pack inner, outer bearing and hub cavity with
grease.
FRONT AXLE TYPE: 30 & 50
07.17
Service Manual
2. Place inner bearing and withdrawal plate before
pressing oil seal.
3. Press the oil seal with using suitable bunk and
hammer.
4. Position the hub on the stub axle spindle bearing
diameter.
5. Ensure no damage caused to inner bearing and oil
seal of the hub.
6. Place the outer bearing (pre-greased) on the
spindle diameter and using drift for aligning outer
bearing.
7. Place the keyed washer and hub nut.
8. Tighten the hub nut until recommended end float is
obtained.
9. Insert the split pin and fold.
10. Fit the hub cap with packed grease.
11. Fit brake drum road wheel and nuts.
12. Lower the vehicle to the ground and tighten wheel
nuts to recommended torque values.
13. Adjust the brakes.
07.6.2 Stub Axle Overhaul
Stub Axle (Steering Knuckle)
To dismantle
1. Remove appropriate hub, refer page 07.23 for
front hub overhaul.
2. Remove bolts and lockwashers securing steering
lever to top of stub axle.
On stub axle not connected to drag link with
NOTE
a steering lever a cover plate is fitted.
3. Remove four bolts, nuts securing back plate to
stub axle, remove backplate complete with brake
assemble then extract O-ring from top of swivel
pin.
4. Remove bolts securing track rod arm to stub
axle. Remove tract-rod with assembled arm and
bearing, O-ring and V-seal.
To inspect
1. Thoroughly clean all components prior to inspection
and reassembly.
2. Examine stub axle bushes for wear and scoring, if
necessary replace.
 FRONT AXLE TYPE: 30 & 50
07.18
Service Manual
3. Examine swivel pin for wear and scoring, if
necessary replace.
4. Check diametral clearance of swivel pin in stub
axle bushes, if necessary replace.
To reassemble
Stub Axle - Representative Diagram
1. Fit O-ring to stub axle upper jaw.
2. Fit ‘V’ ring oil seal to lower jaw of the stub axle.
3. Ensure lib of the oil seal rests against stub axle on
the axle beam with ‘O’ rings.
4. Then using a suitable jack press swivel pin up into
stub axle until tapered shank is in hard contact
with tapered hole in axle beam. Remove jack.
5. Fit original shim pack to pack trackrod arm, then
fit thrust bearing (without O-ring) at this stage. Fit
trackrod arm and tighten bolts fully.
6. Using a dial test indicator and a suitable lever as
shown check stub axle end float, for recommended
values. Adjust the shims to obtain the end float
within limits.
Fig. 4 Checking Stub Axle Lift
7. When end float is correct disconnect track-rod arm
and fit new O-ring, fit track rod arm and tighten bolt
to recommended torque value.
8. Fit O-ring on upper jaw top on RH/LH, then fit
steering lever and tighten bolts to recommended
torque value. Fit back plate complete with brake
assembly and secure in place with nuts and bolts.
Tighten bolts to torque.
9. Re-connect the brake hoses.
10. Carryout procedure for reassembling hub, refer
page no. 07.23.
11. Lubricate swivel pin and swivel pin bushes with
recommend grease.
07.6.3 Renewal of Stub Axle Bushes
The stub axle must be in a vertical centralised position
while pressing bushes in or out. The stub axle on
driver’s side or vehicle is dowelled on upper and lower
faces, and on lower face only on opposite side.
Special Tools:
SMT 3847: Drift for king pin bush-Upper in
axle arm.
SMT 3848: Drift for king pin bush-Lower in
axle arm.
To Renew
1. Dismantle stub axle, Refer page 07.25.
2. Clean all paint and remove all burns from outer
surface of stub axle.
3. Manufacture a suitable plate of sufficient thickness
to ensure that locating dowels do not contact base
of press when fitting or removing upper or lower
bushes.
4. Invert stub axle, then position special Tool 1
through lower bushes and insert spigot end into
upper bush. Position plate previously described
in operation 3 between outer face of stub axle and
base of press. Operate press and remove upper
bush.
Removing Small (Upper) Stub Axle Bush
 FRONT AXLE TYPE: 30 & 50
07.19
Service Manual

5. Invert stub axle and insert special tool 2 into bottom 13. Fit plate as described in operation 10, operate
bush tool 1 through upper bore of stub axle. Spigot press and fit upper bush.
end first and into the recess of tool 2.

6. Position plate previously used to remove top bush,

between lower face of stub axle and base of press
Operate press and remove bottom bush 3.

Fitting Small (Upper) Stub Axle Bush

14. Check depth of upper bush correct dimension
should be 1.3 to 1.5 mm.
Removal of Bottom Bush
7. Thoroughly clean all components remove all burns
of scores and lubricate the bushes and stub axle
bores prior to reassembly.

8. Invert stub axle and position bottom bush over

mating bore with split positioned as shown in
illustration insert spigot end of tool 2 into bush.

9. Position Tool 1 through upper bore and insert into

tool 2 end first.

Fitting Bottom Bush

10. Position plate previously used to remove bushes,

between outer face of stub axle and base of press.
Operate press and fit bottom bush with split in
bush positioned as shown.

11. Assemble upper bush on tool 1 and secure in

position with tool 3.

12. Invert stub axle position into lower bush pass tool
1 through tool 2 and into upper bore.
 FRONT AXLE TYPE: 30 & 50
07.20
Service Manual

07.7 Tightening Torques

Kgm lb.ft Nm
Type 30
Steering arm/track lever mounting nut 53.5 387 525
Brake shoe Assembly Mounting Nuts 14 - 16 103 - 118 140 - 160
Brake shoe acuator mounting bolts 5-7 38 - 52 51 - 71
King pin grease cap covers 9 - 11 66 - 81 90 - 110
Lubricator 0.86 6 8.5
Max. cut setting nut 8.9 - 12.5 65 - 90 88 - 123
Track rod mounting nut 14 100 135
Track rod pinch bolt 4.5 33 45
Hub nut 9.6 70 95
Hub grease cup 4 29 40 - 60
Brake drum mounting bolts 5-7 38 - 52 51 - 71
Wheel nuts 50 361 490

Type 50
Steering arm/track lever mounting nut 45 328 445
King pin grease cap covers 9 - 11 66 - 81 90 - 110
Lubricator 0.86 6 8.5
Max. cut setting nut 8.9 - 12.5 65 - 90 88 - 123
Track rod mounting nut 17 125 170
Track rod pinch bolt 4.5 33 45
Brake shoe Assembly Mounting Nuts 9.6 - 10.7 70 - 77 95 - 105
Brake shoe acuator mounting bolts 5-7 38 - 52 51 - 71
Hub adjusting nut 11 80 108
Hub lock nut 9.6 70 95
Hub grease cup 11 80 17.5 -22
Brake drum mounting bolts 5-7 38 - 52 51 - 71
Wheel nuts 50 361 490
 FRONT AXLE TYPE: 30 & 50
07.21
Service Manual

07.8 Maintenance schedule

Every km x 1000
MAINTENANCE ACTIVITY Remarks

Weekly
Daily
PDI
1 Lubricate track rod / drag link ball joints - For all other applications 3 Monthly
2 Lubricate track rod / drag link ball joints - For Tippers 3 3
Repack the hubs with recommended grease. Check the condition of hub bearings
3 and change if necessary. Adjust hub end play. Also check and reset Pole 48
wheel sensor air gap - For all applications other than Tippers
Repack the hubs with recommended grease. Check the condition of hub
4 bearings and change if necessary. Adjust hub end play. Also check and 500 Hrs
reset Pole wheel sensor air gap - For Tippers
5 Lubricate king pins - For all applications other than Tippers 3 Monthly
6 Lubricate king pins - For Tippers 3 3

7 Check wheel alignment and adjust if necessary 3 8

8 Check and tighten thrust cover bolts 8
9 Check king pin vertical play & adjust if necessary 16
10 Check king pin lateral play. Replace bush if necessary 16

07.9 Recommended Lubricants

Co-branded Lubricant Approved Lubricant

Indian Oil
Aggregate Ambient Temp. °C Gulf Oil India
Corporation

Drag link, track rod and Servo

-20 MP Grease Max NLGI 2
King pin Grease ALT

Gulf Crown
Wheel Bearing -20 Servo Gem ALT
Max RR3

# : Specification and change period applicable for special, arduous duty & army applications refer service manual.
NOTE : Do not mix lubricants of different brands/grades.