Front axle fa99

43.01
Service Manual

Contents
Group - 43
front axle - FA99
Section Subject Page No.

43.0 General......................................................................................................... 43.02

43.0.0 Front Axle Type and Sl. No......................................................................... 43.02
43.0.1 Design and Operation.................................................................................. 43.02
43.0.2 Description of Leading Components............................................................ 43.02
43.0.3 Data............................................................................................................. 43.06
43.0.3 Data............................................................................................................. 43.07
43.0.4 Front Axle Preliminary Checks..................................................................... 43.08

43.1 To Remove and Refit Front axle from vehicle.............................. 43.10

43.1.0 To Remove................................................................................................... 43.10
43.1.1 To Refit........................................................................................................ 43.10
43.1.2 Dismantling and Assembling Procedure........................................................ 43.11
43.1.2.0 Dismantling............................................................................................ 43.11
43.1.2.1 Inspection............................................................................................... 43.12
43.1.2.2 Assembly................................................................................................ 43.13
43.1.3 Axle Arm End Play Checking Procedure..................................................... 43.14
43.1.4 Assembling King Pin Cotter......................................................................... 43.14
43.1.5 Assembling the hub end.............................................................................. 43.15
43.1.6 Hub End Play - Wet Setting........................................................................ 43.16
43.1.7 To Check Wheel Alignment (Toe in / Toe out)............................................ 43.16

43.2 To Prepare Front Axle Sub- Assemblies........................................... 43.17

43.2.0 Axle Arm Sub-assembly............................................................................... 43.17
43.2.1 Hub Sub-assembly....................................................................................... 43.18

43.3 track rod..................................................................................................... 43.18

43.3.0 Features and Advantages............................................................................ 43.19
43.3.1 Fitment Procedure....................................................................................... 43.19
43.3.2 Check For Condition Of Ball Joints............................................................. 43.19
43.3.3 Lubrication................................................................................................... 43.19

43.4  Tightening Torques................................................................................... 43.20

43.5 Recommended lubricants....................................................................... 43.20

43.6 Filling capacity.......................................................................................... 43.20

43.7 Maintenance schedule............................................................................. 43.20

 Front axle fa99
43.02
Service Manual

43.0 General Hub Oil Seal and Ring for Oil Seal Arrangement

43.0.0 Front Axle Type and Sl. No.

ALFA99 XE518376Z

43.0.2 Description of Leading Components

The front axle serial number and type of front axle are Axle Arm
punched at the centre of axle beam.

43.0.1 Design and Operation

The front axle beam is a heavy “I” section alloy-steel

forging, carrying the axle arms which pivot about the
kingpins. The axle arms carry the brake assembly and the
wheel hubs which run on opposed tapered roller bearings.

The kingpins are mounted in the axle beam and are

located by double cotter pins, on each side. The axle
arm swivel on plain bushes pressed into the axle arms top
and bottom and the thrust is taken on taper roller thrust
bearing. Axle arm end play between the axle arms and
beam is set by shims.

The assembly is made leak proof by providing oil seals Also called as stub axle, made of forged steel machined
on upper and lower boss of the axle arm. Also bottom with inbuilt camber and king pin inclination angles,
oil seal retains the grease in the thrust bearing. reverse elliot type.
Lubrication of the king pins and bushes is done by grease. Track rod assy
Grease nipples are provided for greasing top and bottom
bushes on each side. The brake assembly is spigotted
on the axle arm for mounting. Brake carrier uses serrated
bolts for better locking.

The hubs are carried on two tapered roller bearings, and

distance pieces.

Leakage of hub grease to the brake drums is prevented

by the oil seal fitted inside the hub.

Wheel disc and brake drums are located on ‘Spigot’ on

the hub. This prevents radial shock loads from being
transmitted directly on the wheel bolts.

Wheel bolts have ‘D’ heads (apart from serrations) to

ensure better locking of the bolts on hub. Both LH and Keeps the LH/RH wheels connected through ball joints
RH have RH threads. for steering purpose. Made of steel tube with LH/RH
threads at either ends. Wheel alignment is set using
track rod assembly.

Track rod lever
Fitted on both side of axle arm by 2 nos. of bolt, made
of forged steel. Axle arms are connected to track rod,
through these levers.
Steering lever
Fitted to RH stub axle by 2 nos. bolt and wire locked.
Made of forged steel fully polished to have smooth finish.
This lever is connected to steering box through drag link/
drop arm arrangement.
Axle beam
Heavy I-section alloy steel forging. King pin bores are
precision machined.
Front axle fa99
43.03
Service Manual
Wheel hubs
Made of steel forging/casting with spigotted arrangement
and D-headed wheel bolts. The wheel rim and brake
drum are located and fastened on Hubs.
Brake drums
Made of high grade cast-iron. The brake drum standard
diameter can be machined to suit two over size brake
linings during its service.
King pins
Made of specially heat treated steel and available in
standard and three over sizes. The king pin is locked to
axle beam by double cotter pins.
 Front axle fa99
43.04
Service Manual
Wheel rim
Made of pressed steel with welded disc and loose lock
ring. Available in 10 wheel bolts/8 wheel bolts versions.
FA99 FRONT AXLE LAYOUT
FA 99 FRONT AXLE - HUB END
S.No Description Qty
1 Brake drum 2
2 Screw M6 x 15 x 1 CP plated 12
3 SC washer 6 dia plated 18
4 Hub cap 2
5 Joint for hub cap 2
6 Screw M6 x 20 x 1 cp plated 6
7 Tongue washer with holes 2
8 Locking nut 2
9 Tongue washer 2
10 Taper roller bearing - outer 2
11 Distance piece 2
12 Front hub - 6 inch 2
13 Wheel bolt 20
14 Pole wheel front 2
15 Taper roller bearing - inner 2
16 Ring for oil seal 2
Brake carrier assembly
The brake is operated by a "S" form cam which is an integral
part of the camshaft. The expanding force at the S cam is
applied to the shoes through roller followers. The brake
shoe clearance is adjusted by 'S' cam shaft in combination
with slack adjuster.
S.No Description Qty
17 Hub Oil seal 2
18 Sub assembly of hub 2
19 Front brake chamber LH - Type 24 1
20 Front brake assembly - LH 1
21 Pivot pin 2
22 Manual slack adjuster - LH 1
23 Nyloc nut 3/8 x pcp bsf plated 2
24 Washer 27 od x 10.319 Id x 3.175 T 4
25 Nyloc nut m10 x pc 8 x 1 fp plated 4
26 Cotter pin bottom 2
27 Axle beam for 100 mm drop 1
28 Manual slack adjuster - RH 1
29 Front brake assembly - RH 1
30 Front brake chamber RH - Type 24 1
31 Cotter pin top 2
32 Track rod assembly 1
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43.05
Service Manual

FA99 FRONT AXLE - AXLE END

S.No Description Qty S.No Description Qty

33 Sub assembly of axle arm RH 1 47 M20 bolt for fa 99 track rod lever mounting 6

34 Sub assembly of axle arm LH 1 48 Track rod lever - RH 1

35 Grease nipple (M8 x 1) 4 49 Track rod lever - LH 1

36 Bolt M8 x 1.25 X 20 12 50 Sensor - ABS 2

37 SC washer 8 dia plated 12 51 Sensor bush - ABS 2

38 Cover plate for king pin 4 52 Screw M12 x 20 x 1.5 Fp plated 2

39 Joint cover plate 4 53 Axle arm 1

40 SC washer 12 dia plated 14 54 King pin bush 4

41 Cleveloc nut plated 12 55 Oil seal for king pin 4

42 Grommet 2 56 Thrust bearing 2

43 Abs sensor bush - front 2 57 King pin - fa99 2

44 Lock - nut M12 x pc 8 x 1.5 Fp plated 2 58 Clamp 2

45 Max cut screw 2 59 Shim - kingpin ar

46 Steering lever (bent) 1 60 Axle arm 1

 Front axle fa99
43.06
Service Manual

43.0.3 Data

Description FA99 Front Axle

Type Reverse Elliot
Axle Capacity 6000 kg
King Pin Inclination 6.5°
King Pin Centres 1810 mm
Camber 0.7°
Toe In (Unladen) 0 - 2 mm
Wheel Track for 10 X 20 tyres 2054 mm
Wheel Track for 11 X 20 tyres 2044 mm
Track Rod Ball Pin Center
   Longer WB version 1725 mm
   Shorter WB version 1705 mm
Wheel Lock Angle (on Axle) 54° (inner angle)
Spring Centres (Possible Range) 863.6 mm (32" to 36" )
Weight Of Axle Beam 84 Kg
Kingpin Bore In Axle Beam
   Standard 44.158 - 44.184 mm
   1st O/S 44.458 - 44.484 mm
   2nd O/S 44.758 - 44.784 mm
   3rd O/S 45.058 - 45.084 mm
Kin Pin Dia
   Standard 44.138 - 44.148 mm
   1st O/S 44.438 - 44.448 mm
   2nd O/S 44.738 - 44.748 mm
   3rd O/S 45.038 - 45.048 mm
King pin bush inner dia before pressing
   Standard 44.23 - 44.26 mm
   OS 1 44.53 - 44.56 mm
   OS 2 44.83 - 44.86 mm
   OS 3 45.13 - 45.16 mm
King pin bush inner dia after pressing
   Standard 44.18 - 44.22 mm
   OS 1 44.48 - 44.52 mm
   OS 2 44.78 - 44.82 mm
   OS 3 45.08 - 45.12 mm
Kingpin Bore In Thrust Bearing
   Standard 44.577 - 44.831 mm
   1st O/S 44.877 - 45.131 mm
   2nd O/S 45.177 - 45.431 mm
   3rd O/S 45.477 - 45.731 mm
 Front axle fa99
43.07
Service Manual

43.0.3 Data

King Pin Bush Outer Dia

   Top & Bottom 53.56 - 53.58 mm
Bore Dia In Axle Arm For Bushes
   Top & Bottom 53.517 - 53.542 mm
Interference of Bushes In Axle Arm
   Top & Bottom 0.018 - 0.063 mm
Thrust Taken On Thrust Bearing
Axle Arm End Play 0.025 - 0.10 mm
Shims Available For Axle Arm End Play 0.076, 0.127, 0.254, 0.508, 1.016 mm
Renew Bushes When Diameter Clearance
0.127 mm
Between King Pin and Bushes Exceeds
axle drop 100 mm
Wheel Bearing
 Inner Bearing
   Inner Dia 65.088 - 65.101 mm
   Outer Dia 135.755 - 135.780 mm
 Outer Bearing
   Inner Dia 44.45 - 44.46 mm
   Outer Dia 111.12 - 111.15 mm
Hub
   Inner Bearing Seating Dia 135.65 - 135.68 mm
   Fit of Inner Race 0.001 - 0.031 mm
   Fit of Outer Race 0.075 - 0.130 mm
   Outer Bearing Seating Dia 111.05 - 111.02 mm
   Fit of Inner Race 0.005 - 0.031 mm
   Fit of Outer Race 0.075 - 0.130 mm
   Hub End Play 0.025 - 0.100 mm
Brake Drum Sizes
   Standard 393.70 - 394.00 mm
   1st O/S 395.30 - 395.60 mm
   2nd O/S 396.90 - 397.20 mm
 Front axle fa99
43.08
Service Manual

43.0.4 Front Axle Preliminary Checks

It is mandatory to carry out few preliminary check on front axle before dismounting from the vehicle. The following
cause and effects diagram can lead to overhauling decision.

King pin Low Tyre Inflation

Lubrication
Play

Bush binding
Steering
hard

Beam Ball Joint Track rod

Bend Tight lubrication

Cause and Effect Diagram - Steering Hard

Improper Scoring of drums. Due

Excess wheel Excess wear on
tightening of to non refitment of dust
bearing play king pin
cotter pins covers

Wavy tyre
wear

Failed wheel Improper Excess

bearings assembly of imbalance of
king pins brake drums

Cause and Effect Diagram - Wavy Tyre Wear

 Front axle fa99
43.09
Service Manual

Improper Improper wheel

lubrication of alignment
track rod/drag link setting
sockets

Feathery or
saw tooth
tyre wear

Track rod & Improper

Loose
drag link seating of
'I' bolts
sockets loose spring on seat

Cause and Effect Diagram - Feathery or Saw Tooth Tyre Wear

Edge Centre
wear wear

Under
Over inflation of
inflation
tyres
of tyres
Over
loading

Tyre wears

King pin
bush worn
Stub Axle Bend
Brake
Binding Axle Beam
Bend
Tyre rotation
Sudden brake
neglected
application

Patchy Camber
Wear Wear

Cause and Effect Diagram - Tyre wears

 Front axle fa99
43.10
Service Manual

43.1 To Remove and Refit Front axle 43.1.1 To Refit

from vehicle
Support the front axle assembly on a jack.
43.1.0 To Remove
Park the vehicle on level ground. Position the front axle assembly under the springs. Place
Disconnect battery terminals, chock the wheels. the shock absorber plate on the axle beam and check
that it registers with the location in the mounting pad of
the axle beam. Lift the jack and ensure that the front axle
assembly, is located correctly.

Fix the clamp plate with rubber buffer over the spring,
install the fixing bolts and tighten with Special Tool
0901002 - Socket Spring Clamp Nut.

5 6
4
2
Unscrew ball pillar nut and disconnect the drag link from
the lower end of the drop arm by using the Special Tool
0602001 - Extractor Ball Pin. 1

3
8

1. Front Spring Multi-Leaf

2. Top Clamp
3. Shock Absorber Mounting Bracket
4. Bump Stop
5. Screw
6. SC washer
7. U-Bolt Front Spring
Loosen the leaf spring I-bolts clamp nuts using Special
8. U-Bolt Nut
Tool 0901002 - Socket Spring Clamp Nut.
Disconnect brake hoses. Ensure fitment of shock absorber plate and clamp plate.

Connect the brake hoses to the brake chambers and

ensure that they do not come in contact with the wheels
when the wheels are turned either to left or to the right.

Connect the drag link to the steering lever, tighten the

castle nut and fix the split pin.

Connect the shock absorber to the shock absorber

bracket.

Fix the wheels and wheel nuts.

Lift the front wheels off the ground by jacking the axle Torque tighten the fasteners.Lower
beam (use conventional crawler cum trolley jack below the wheels to the ground and tighten
axle beam). NOTE the wheel nuts uniformly to the
recommended torque.
Unscrew shock absorber fasteners and remove shock
absorber assemblies.
Remove both side tyres, place suitable chassis support
props below chassis frame.
Remove the axle assembly along with the hub ends.
 Front axle fa99
43.11
Service Manual

43.1.2 Dismantling and Assembling Procedure

43.1.2.0 Dismantling

Remove split pins and castle nuts from the track rod
Clean front axle assembly externally. joints. Remove ball pins out using special tool extractor.

Mount the front axle on the repair stand.

Dismantling the hub ends

1 BRAKE DRUM 10 OUTER BEARING[535/532A]

2 SCREW M6 X 15 X 1 CP PLATED - HUB CAP WITH HUB 11 FRONT HUB - 6INCH
MOUNTING SCREW
12 WHEEL BOLT
3 SC WASHER 6 DIA PLATED - FOR HUB CAP MOUNTING
13 DISTANCE PIECE - LENGTH 47.77 MM
SCREW
14 INNER BEARING ASSY
4 HUB CAP
15 RING FOR OIL SEAL
5 JOINT FOR HUB CAP
16 OIL SEAL - HUB - FENNER
6 SCREW M6 X 20 X 1 CP PLATED
17 POLE WHEEL FRONT
7 TONGUE WASHER WITH HOLES FOR LOCK NUT
18 AXLE ARM
8 LOCKING NUT
9 TONGUE WASHER FOR OUTER BEARING
 Front axle fa99
43.12
Service Manual

Remove brake drums.

Jack out the drum by using the two suitable bolts.
Loosen the six set screws of the hub cap and remove
the hub cap.
Remove the tongue washer with holes, locking nut and
tongue washer. Pull out hub with outer bearing.
Remove the inner bearing, ring for oil seal and distance
piece from the hub.
Remove the pivot pin connecting the slack adjusters and
the brake chambers.
Remove the brake chambers from RH and LH side.
Remove circlip from the end of the ‘S’ camshaft along Remove the three setscrews (M8) on top and bottom of
with the shims. Identify the shims for refitting in the each side and take off the king pin top and bottom cover.
same manner.
Remove the slack adjuster and sleeve from the splined
end of the camshaft.
Remove the brake assembly.

Use Special Tool 0602002 - Hook Brake

Shoe Assembly for removing brake shoes.
NOTE

Cut off the wire lock on both LH and RH sides, remove

the setscrews and take off both the track rod levers and
steering lever.

Drive out the kingpins using a brass punch and hammer

from the top.

Remove the axle arms from the axle beam with thrust
bearings and shims.

43.1.2.1 Inspection

Clean all parts and dry thoroughly.

Check the axle arm bushes for wear and renew if worn.
Check that the lubricating inner grooves are clear.

Remove the wheel lock adjustment screws. Renew the kingpin if the surfaces are worn or damaged.

Inspect wheel bearing, oil seal and replace, if worn.

Measure kingpin bore in axle beam if bore is worn out/

damage, ream it to next repair size.

If bend/twist of the axle beam is suspected following an

accident or collision, the beam should be checked using
Special Tool 0602007 - Gauge Beam Bend Checking.

It is impractical to straighten a beam

satisfactorily and yet retain the properties
NOTE of heat-treated alloy. It is therefore
advisable to reject a misaligned beam and
use a new axle beam.

Renew king pin thrust bearing if excessive wear/play is

Drive out the cotter pins after removing the securing nuts
evident.
from front and rear side on each side.
 Front axle fa99
43.13
Service Manual

Similarly, the axle arms should be cleaned and inspected

carefully for cracks.

Examine the brake linings for wear and replace if

necessary, for next over size.

Examine the surface of the brake drums and machine

the surface if necessary for next oversize.

W
E2/3559
Examine the ‘S’ camshaft bushes/needle roller bearings
in brake assembly and replace if necessary.

Examine the wheel bolts and renew if necessary.

43.1.2.2 Assembly Insert the special tool from bottom and align the bottom
cotter pin groove. Fit the special tool in the bottom cotter
pin hole.
Tighten the special tool bottom nut to hand tight.

Mount the axle arm on the axle beam and insert the
aligning tool into the king pin bore.
Remove the axle arm adjusting tool.

Measure the clearance at several points between axle

Fit the taper roller thrust bearing at R.H side and L.H side arm upper boss and axle beam as shown in figure by
between axle beam and axle arm at lower boss. Align using a feeler gauge. Note the minimum clearance.
the thrust bearing and axle arm assembly.

Ensure that the thrust bearing 'TOP' mark is on the top side. Select the shims and insert the shims into the position
between axle arm upper boss and axle beam.
 Front axle fa99
43.14
Service Manual
Ensure end play 0.025 to 0.100 mm of the axle arm
with the free movement of the axle arm from lock to lock
position.
Insert the king pin into the king pin bore and align cotter
pin slots with the holes in the axle beam.
Ensure TOP/T marked ends of the king pin
is in top. While inserting king pin in its
NOTE position, remove special tools accordingly.
Coat the king pins and shims with
specified grease. Fit the shorter cotter pin
NOTE
into axle beam top hole from the rear and
longer cotter pin into the axle beam lower
hole from the front.
Don't drift fully home at this stage before
ensuring the end play of the axle arm.
NOTE
43.1.3 Axle Arm End Play Checking Procedure
Hit the boss of the axle arm with brass/rubber mallet to
properly seat the parts in position.
Turn the axle arm to the straight ahead position.
Attach a magnetic stand with dial gauge. Fix the tip on
the centre of the king pin. Set the dial gauge indicating
to zero.
Put a pry bar between axle arm and the top of the axle
beam. Push the axle arm up and measure the end play,
repeat the above with axle in the fully right and full left
position.
Ensure the end play must be 0.025 to 0.100 mm in all
position.
If the axle arm binds or zero end play measured - remove
shims.
If more than 0.10 mm end play is measured - add shims.
43.1.4 Assembling King Pin Cotter
Drift the cotter pin in the axle beam firmly using a brass
hammer. When correctly installed, the heads of the pins
should project out from the axle beam by 2 to 8 mm.
Three sizes of cotter pins are available to
NOTE
achieve the correct fit.
Fit the washer and nut in the cotter pins and torque tighten
to 4 - 5 kgm. Tap cotter pin head sharply with a hammer
and retorque nut to 4 - 5 kgm.
 Front axle fa99
43.15
Service Manual

Assembling king pin cover plate 43.1.5 Assembling the hub end

Fit the gasket, top & bottom cover plate and grease
nipples.

Top and bottom cover bolt torque tighten to 4 to 5 kgm.

Lubricate with multipurpose grease under

pressure through top and bottom grease
NOTE
nipples till grease is seen coming out
from axle beam top and thrust bearing at
bottom.

Fix the oil seal ring and inner bearing onto the axle arm.

Fix the track rod levers LH and RH and tighten the special
set screws to 55 - 57 kgm. Wire lock the bolts fit & torque
steering lever mounting special set screws to 55 - 57 kgm. Fix distance piece.

Fit the brake shoe assembly on the axle arm and tighten
the 6 nuts.

Fit the slack adjuster on to the splined end of the ‘S’

camshaft.

Install the removed shims at the nose of the ‘S’ camshaft.

Fix the circlip.

Fix the brake chamber on RH side and LH side. Connect

the slack adjuster and brake chamber with the pivot pin.

Fit the hub and outer bearing on to the axle arm. Place
the tongue washer and tighten the locking nut on the axle
arm to torque of 30 - 32 kgm.
 Front axle fa99
43.16
Service Manual

Hub end play - Dry setting After outer bearing, lug washer and lock nut to be
assembled.
Lock nut to be tightened to torque 30 -32 kgm.

Assemble the perforated lug washer, tighten the nut

further to match hole in washer.

If the hole in perforated lug washer is misaligned more

than 10°, reverse the washer and tighten the nut to match
holes.

Assemble the three screws.

Counter check the hub end play with dial gauge and
ensure end play 0.025 - 0.100 mm

Check the hub end play with dial gauge.

Fit a suitable distance piece and check the hub end play
until recommended end play is achieved (0.025 - 0.100
mm).
Distance pieces of variable thickness
ranging from 47.53, 47.59, 47.65, 47.71,
NOTE 47.77, 47.83, 47.89, 47.95 mm can be used.
Maintain the recommended hub end play
0.025 to 0.100mm
No shims to be used.

43.1.6 Hub End Play - Wet Setting

Using recommended grade of grease for each hub, knead

the grease into the inner races of the bearings and smear Pack the grease in the cup 1/3rd of full.
the grease in the hub cavity between bearing cups.
Fix up hub cap along with the gasket and tighten the bolts.
Fix the inner bearing onto the axle arm.
Mount the brake drum and reverse the removal procedure
Fix distance piece and place the hub assembly on the
to refit front axle to the vehicle. Tighten wheel nuts to the
axle arm.
specified torque.
Locking Arrangement
43.1.7 To Check Wheel Alignment (Toe in / Toe
out)

Preliminary checks
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 for excess wear .

Ensure the spring cambers are equal on both sides.

Spring I-bolts are tightened to correct torque value.

1 SCREW - HUB CAP WITH HUB
MOUNTING SCREW
2 SC WASHER - FOR HUB CAP
MOUNTING SCREW
3 HUB CAP
4 JOINT FOR HUB CAP
6 TONGUE WASHER WITH
HOLES FOR LOCK NUT
Ensure steering play is within limit.
7 LOCKING NUT
8 TONGUE WASHER FOR
OUTER BEARING
Hub end play is within limit.
9 OUTER BEARING

5 SCREW 11 wheel bolt

12 front hub - 6 inch

 Front axle fa99
43.17
Service Manual

To Set Toe-in/Toe-out To assemble press new bushes using special tool

referred above.

Set the wheels in the straight ahead position.

Place the toe-in gauge in machined area of the brake Press both the bushes to achieve the dimension as
drum in front of the front wheels and adjust the height shown in figure.
of the pointers to the centre of the wheel on both sides.
Note the reading.

Mark both the brakes drums by using 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.
The difference should be 0 - 2 mm more than front.
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 toe in is 0 - 2 mm.
Fit the king pin oil seal as shown in figure.
Then tighten the clamp pinch bolts torque to 43 - 50 lb. ft.
Any run out of the wheel rims will not
affect the toe in measurement, if the wheel
NOTE is moved forward by 180° between the two
measurements as explained above.
43.2 To Prepare Front Axle Sub-
Assemblies

43.2.0 Axle Arm Sub-assembly

Ensure free rotation of king pin on bushes.

The king pin is available in 3 over sizes.

A punch mark is provided on king pin's
TOP face indicating service size i.e. OS1,
NOTE
OS2 and OS3.

Using 10 Ton hydraulic press and Special Tool 0602005

- Drift King Pin Bush Bottom, drift out king pin bushes
top and bottom.
 Front axle fa99
43.18
Service Manual

43.2.1 Hub Sub-assembly All wheel bolts irrespective of LH/RH hub position are
RH threaded.
To Fit Wheel Bolts
Press in the inner and outer bearing outer races fully
using Special Tool.

Position and clamp the hub assy and hammer the

D-headed wheel bolts.
Fit the hub inner oil seal using special tool.

43.3 track rod

1 HOUSING RH 11 TUBE
2 BALL PIN 12 CLAMP
3 BOTTOM CUP 13 HEX BOLT
4 TOP CUP 14 HEX NUT
5 SPRING 15 SPRING WASHER
6 LOCKING RING 16 HOUSING LH
7 DUST COVER 17 PROTECTION CAP
8 SLOTTED NUT 18 PROTECTION CAP (GREASE NIPPLE)
9 GREASE NIPPLE 19 SPLIT PIN
10 SEALING CAP
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Service Manual

43.3.0 Features and Advantages

Features Advantages

Cups and spring are axial to the ball pin Steering freeplay will be comparatively lesser since the radial
movement of cups are almost negligible.

Case Hardened material Extended life

Ball Joint Assembly Cup pressing and screw plug assembly is easy.

Ball Joint internals replacement Centre distance resetting is not required as the ball joint
internals can be replaced without dismantling the tube from
the ball joint.

Ball joint torque adjustment after few kms run. Ball joint torque can be increased by adjusting the screw
plug without removing the tube. Hence no centre distanced
resetting is required.

43.3.1 Fitment Procedure 43.3.2 Check For Condition Of Ball Joints

Correct Method

Wrong Method
- Mount the threaded part of Tie rod end on the tie
rod tube.
- Adjust the tie rod end assembly roughly to the
required track, then insert the tapered surface into
the lever hole.
- Tighten the ball pin nut securely.
- Adjust the track correctly and lock the end with the
nut/clamp provided.
- Ensure that the dis-position of ball joints are correct.
- Turn the steering wheel alternatively to the left and
to the right (with axle in loaded condition).
- The relative motion between the ball pin and the
socket as shown in the figure either in Horizontal
or Vertical direction should not exceed 2mm.
- This displacement can be checked in limit cause
by using a slide gauge.
- In case of non-conformity the joints should be
recommended for replacement.
43.3.3 Lubrication
- Make sure the GREASE NIPPLES are intact.
- Replace immediately if they are found missing.

- Ensure that the pinch bolt / nut tightening torque (6
to 7 kgm).
- Make sure that always good quality & quantity of
grease is used.
- Grease should be pumped through nipple and
ensure that old grease from inside comes through
the opening of the dust cover side.
- Grease the ball joints as recommended.
 Front axle fa99
43.20
Service Manual

43.4 STEERING LINKAGE ASSEMBLY & 43.3 SET STEERING BOX TO CENTRALIZED
WHEEL ALIGNMENT PROCEDURE POSITION
3118-current truck

43.4.1 CHECK & CORRECT HUB, KINGPIN PLAY

Hub End Play

Spec : 0.001" - 0.004"
(0.025-0.1mm)

King Pin Play

Spec : 0.001" - 0.004"
(0.025-0.1mm)

Steering wheel to be turned so that Steering

box is centralized and it is at straight ahead
position. This can be confirmed by drop arm at
vertcal position and SAP marks on input shaft
If excess play / preload found, the same to be
coinciding with that on the box casing.
rectified to achieve play as per spec.
43.4 RELAY DROP ARM ASSEMBLY
43.4.2 CHECK DROP ARM FITMENT ON PROCEDURE
STEERING BOX

Sl no Description Qty
1 Pivot Pin 1
Check Drop arm fitment to steering box with 2 Bracket relay drop arm mounting 1
SAP marks on Sector shaft and drop arm face
3 Relay drop arm 1
coinciding. This ensures that the drop arm is
aligned correctly at steering box centralized 4 Tapper Roller Bearing 2
position. 5 Bonded Seal 2
6 Lock Nut 2
If SAP marks not found coinciding, remove 7 Castle Nut 1
drop arm and re-fit the same with SAP marks 8 Split pin 1
coinciding (Drop arm nut torque – 700Nm). 9 Grease Nipple 1
10 Spacer 1
11 Shim 0.08 mm thick AR
12 Shim 0.13 mm thick AR
13 Shim 0.25 mm thick AR
14 Shim 0.508 mm thick AR
15 Shim 1.2 mm thick AR
Add shims between spacer and bearing inner
face to get the axial play of 0.001" to 0.004".
 Front axle fa99
43.21
Service Manual

43.5 Draglink setting length

- Relay drag link to be set to 1760 ± 1.5 mm length between ball centers and assembled between main
drop arm and relay drop arm. If relay draglink length not found as per spec, set relay draglink length to
spec and re-fit the same.

- Steering box to be centralized so that it is at straight ahead position. This can be confirmed by SAP
marks on input shaft coinciding with that on the box casing.

- Keep the first front axle and 2nd front axle in SAP condition and assemble the draglinks. Approximate
length of first draglink is 880 mm mm and 2nd draglink is 926 mm.

- Subject to minor change while doing wheel alignment

43.6 Wheel lock setting procedure

43.6.1 Max cut Bolt Setting:

- Adjust max cut screw on 1st front axle to achieve 100 mm Gap between inner tyre rear and spring on
both LH & RH turns.

- In the above condition, adjust max cut screw on 2nd axle so that there is a gap of 2 mm between max
cut screw head and axle beam.
43.6.2 Pressure cut off setting :

- Set max cut pressure relief on first axle by adjusting the limiter screws on the steering box with a 3- 4
mm spacer between max cut screw head and axle beam on 1st axle (As normally done on other models)
for both LH & RH turns.

43.6.3 Lock Steering Wheel

Steering wheel to be rigidly held in Straight ahead position to arrest movement till completion of the wheel
alignment procedure (Step 8- Step 11)
 Front axle fa99
43.22
Service Manual

43.7 Set 1st Front Axle to SAP

RHS
A1 A2

C.L of vehicle

FA1 FA2 RA1 RA2

LHS

Check dimension A1 & A2 as shown in sketch for 1st front axle RHS wheel brake drum

Spec: A2 – A1 = 0 to 1mm

If A2 – A1 is not found as per spec, the same needs to be achieved by adjusting 1st FA draglink length.

Record Dimension ‘A1’ & ‘A2’

43.8 Check & Correct 1st FA Toe - in

RHS
A1 A2

C.L of vehicle

B1 B2
LHS

Check dimension B1 & B2 as shown in sketch for 1st front axle LHS wheel brake drum

Spec: B2 – B1 = 0 to 1mm

If B2 – B1 is not found as per spec, the same needs to be achieved by adjusting 1st FA track rod.

Record Dimension ‘B1’ & ‘B2’

 Front axle fa99
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Service Manual

43.9 CHECK & CORRECT 2ND FA PARALLELISM

A1 A2
RHS
C1 C2

C.L of vehicle

B1 B2 D1 D2
LHS

Check dimension C1 & C2 as shown in sketch for 2nd front axle RHS wheel brake drum

Spec: C2 – C1 = 0 to 1mm

If C2 – C1 is not found as per spec, the same needs to be achieved by adjusting length of 2nd FA draglink.

Record Dimension ‘C1’ & ‘C2’

Check dimension D1 & D2 as shown in sketch for 2nd front axle LHS wheel brake drum

Spec: D2 – D1 = 0 to 1mm

If D2 – D1 is not found as per spec, the same needs to be achieved by adjusting 2nd FA track rod.

Record Dimension ‘D1’ & ‘D2’

43.10 Calculate Front Axle Track offset:

RHS
A1 A2 C1 C2

C.L of 1st axle C.L of 2nd axle

C.L of vehicle

E F
B1 B2 D1 D2

LHS

E = (A1+A2)/2 – (B1+B2)/2

F = (C1+C2)/2 – (D1+D2)/2

FA Track Offset = |E – F| < 4mm

If Front axle offset is more than 4mm, loosen the I-Bolts and shift the axle suitably.
 Front axle fa99
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Service Manual

43.11 Thrust Angle & Scrub Angle (applicable only for NRS suspension)

RHS

C.L of vehicle M

LHS
N

- Check Thrust angle (M ) & Scrub angle (N) as shown in sketch for Rear Axles

Spec : Thrust angle M(in deg) : ± 5 min

Scrub angle N(in deg) : ± 5 min

- If M & N are not found as per spec, the same needs to be achieved by loosening the rear axle U-bolts
and adjusting the rear axles suitably. -

- Record Dimension ‘M & N


1. STEERING LINKAGE ASSEMBLY &
WHEEL ALIGNMENT PROCEDURE - 3118
lift axle
1.0 Check & Correct Hub, Kingpin play
Hub End Play
Spec : 0.001" - 0.004"
(0.025-0.1mm)
King Pin Play
Spec : 0.001" - 0.004"
(0.025-0.1mm)
If excess play / preload found, the same to be
rectified to achieve play as per spec.
1.1 Check Drop arm fitment on steering box
Check Drop arm fitment to steering box with
SAP marks on Sector shaft and drop arm face
coinciding. This ensures that the drop arm is
aligned correctly at steering box centralized
position.
If SAP marks not found coinciding, remove
drop arm and re-fit the same with SAP marks
coinciding (Drop arm nut torque – 700Nm).
Front axle fa99
43.25
Service Manual
2. SET STEERING BOX TO CENTRALIZED
POSITION
Steering wheel to be turned so that Steering
box is centralized and it is at straight ahead
position. This can be confirmed by drop arm
at 10 deg towards rearward position and SAP
marks on input shaft coinciding with that on the
box casing.
3. Draglink setting length
- Steering box to be centralized so that it is at
straight ahead position. This can be confirmed
by SAP marks on input shaft coinciding with that
on the box casing.
- Keep the first front axle in SAP condition and
assemble the draglinks. Approximate length of
draglink is 951 mm .
- Subject to minor change while doing wheel
alignment
4. Wheel lock setting procedure
4.1 Max cut Bolt Setting:
- Adjust max cut screw on 1st front axle to
achieve 85 mm Gap between inner tyre rear
and spring on both LH & RH turns.
4.2 Pressure cut off setting :
- Set max cut pressure relief on first axle by
adjusting the limiter screws on the steering
box with a 3- 4 mm spacer between max cut
screw head and axle beam on 1st axle (As
normally done on other models) for both LH
& RH turns.
4.3 Lock Steering Wheel
Steering wheel to be rigidly held in Straight ahead
position to arrest movement till completion of the
wheel alignment procedure (Step 7- Step 8)
 Front axle fa99
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Service Manual

5. Set 1st Front Axle to SAP

RHS
A1 A2

C.L of vehicle

FA1 LA RA1 RA2

LHS

Check dimension A1 & A2 as shown in sketch for 1st front axle RHS wheel brake drum

Spec: A2 – A1 = 0 to 1mm

If A2 – A1 is not found as per spec, the same needs to be achieved by adjusting 1st FA draglink length.

Record Dimension ‘A1’ & ‘A2’

6. Check & Correct 1st FA Toe - in

RHS
A1 A2

C.L of vehicle

B1 B2

LHS

Check dimension B1 & B2 as shown in sketch for 1st front axle LHS wheel brake drum

Spec: B2 – B1 = 0 to 1mm

If B2 – B1 is not found as per spec, the same needs to be achieved by adjusting 1st FA track rod.

Record Dimension ‘B1’ & ‘B2’

 Front axle fa99
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Service Manual

7. Lift Axle Toe - in

RHS
A1 A2

C.L of vehicle

L1 L2

B1 B2

LHS

Check dimension L1 & L2 as shown in sketch for Lift Axle

Spec: L2 – L1 = 0 to 2 mm

If L2 – L1 is not found as per spec, the same needs to be achieved by adjusting length of Lift axle track rod.

Record Dimension ‘L1’ & ‘L2’

8. Thrust Angle & Scrub Angle (applicable only for NRS suspension)

RHS

C.L of vehicle M

LHS
N

- Check Thrust angle (M ) & Scrub angle (N) as shown in sketch for Rear Axles

Spec : Thrust angle M (in deg) : ± 5 min

Scrub angle N (in deg) : ± 5 min
- If M & N are not found as per spec, the same needs to be achieved by loosening the rear axle U-bolts
and adjusting the rear axles suitably. Record Dimension ‘M & N
 Front axle fa99
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Service Manual

1. STEERING LINKAGE ASSEMBLY & 2. SET STEERING BOX TO CENTRALIZED

WHEEL ALIGNMENT PROCEDURE - 3718 POSITION
lift axle

1.0 Check & Correct Hub, Kingpin play

Hub End Play

Spec : 0.001" - 0.004"
(0.025-0.1mm)

King Pin Play

Spec : 0.001" - 0.004" Steering wheel to be turned so that Steering
(0.025-0.1mm) box is centralized and it is at straight ahead
position. This can be confirmed by drop arm
at 9 deg towards rearward position and SAP
marks on input shaft coinciding with that on the
If excess play / preload found, the same to be box casing.
rectified to achieve play as per spec.
3. RELAY DROP ARM ASSEMBLY
PROCEDURE
1.1 Check Drop arm fitment on steering box

Sl no Description Qty
1 Pivot Pin 1
Check Drop arm fitment to steering box with 2 Bracket relay drop arm mounting 1
SAP marks on Sector shaft and drop arm face 3 Relay drop arm 1
coinciding. This ensures that the drop arm is 4 Tapper Roller Bearing 2
aligned correctly at steering box centralized 5 Bonded Seal 2
position. 6 Lock Nut 2
7 Castle Nut 1
If SAP marks not found coinciding, remove
drop arm and re-fit the same with SAP marks 8 Split pin 1
coinciding (Drop arm nut torque – 700Nm). 9 Grease Nipple 1
10 Spacer 1
11 Shim 0.08 mm thick AR
12 Shim 0.13 mm thick AR
13 Shim 0.25 mm thick AR
14 Shim 0.508 mm thick AR
15 Shim 1.2 mm thick AR
Add shims between spacer and bearing inner
face to get the axial play of 0.001" to 0.004".
 Front axle fa99
43.29
Service Manual

4. DRAGLINK SETTING LENGTH

- Relay drag link to be set to 1760 ± 1.5 mm length between ball centers and assembled between main
drop arm and relay drop arm.

- If relay draglink length not found as per spec, set relay draglink length to spec and re-fit the same.

- Steering box to be centralized so that it is at straight ahead position. This can be confirmed by SAP marks
on input shaft coinciding with that on the box casing.

- Keep the first front axle and 2nd front axle in SAP condition and assemble the draglinks. Approximate
length of first draglink is 951 mm and 2nd draglink is 1110 mm.

- Subject to minor change while doing wheel alignment.

5. WHEEL LOCK SETTING PROCEDURE

5.1 Max cut Bolt Setting:

- Adjust max cut screw on 1st front axle to achieve 85 mm Gap between inner tyre rear and spring on both
LH & RH turns.

- In the above condition, adjust max cut screw on 2nd axle so that there is a gap of 2 mm between max
cut screw head and axle beam.

5.2 Pressure cut off setting :

- Set max cut pressure relief on first axle by adjusting the limiter screws on the steering box with a 3- 4 mm
spacer between max cut screw head and axle beam on 1st axle (As normally done on other models) for
both LH & RH turns.

5.3 Lock Steering Wheel

Steering wheel to be rigidly held in Straight ahead position to arrest movement till completion of the wheel
alignment procedure (Step 8- Step 11)
 Front axle fa99
43.30
Service Manual

6. SET 1ST FRONT AXLE TO SAP

RHS
A1 A2

C.L of vehicle

FA1 FA2 LA RA1 RA2

LHS

Check dimension A1 & A2 as shown in sketch for 1st front axle RHS wheel brake drum

Spec: A2 – A1 = 0 to 1mm

If A2 – A1 is not found as per spec, the same needs to be achieved by adjusting 1st FA draglink length.

Record Dimension ‘A1’ & ‘A2’

7. CHECK & CORRECT 1ST FA TOE -IN

RHS
A1 A2

C.L of vehicle

B1 B2

LHS

Check dimension B1 & B2 as shown in sketch for 1st front axle LHS wheel brake drum

Spec: B2 – B1 = 0 to 1mm

If B2 – B1 is not found as per spec, the same needs to be achieved by adjusting 1st FA track rod.

Record Dimension ‘B1’ & ‘B2’

 Front axle fa99
43.31
Service Manual

8. CHECK & CORRECT 2ND FA PARALLELISM

RHS
A1 A2
C1 C2

C.L of vehicle

B1 B2 D1 D2

LHS

Check dimension C1 & C2 as shown in sketch for 2nd front axle RHS wheel brake drum

Spec: C2 – C1 = 0 to 1mm

If C2 – C1 is not found as per spec, the same needs to be achieved by adjusting length of 2nd FA draglink.

Record Dimension ‘C1’ & ‘C2’

Check dimension D1 & D2 as shown in sketch for 2nd front axle LHS wheel brake drum

Spec: D2 – D1 = 0 to 1mm

If D2 – D1 is not found as per spec, the same needs to be achieved by adjusting 2nd FA track rod.

Record Dimension ‘D1’ & ‘D2’

9. Calculate Front Axle Track offset:

RHS
A1 A2 C1 C2

C.L of 1st axle C.L of 2nd axle

C.L of vehicle

E F
B1 B2 D1 D2

LHS

E = (A1+A2)/2 – (B1+B2)/2

F = (C1+C2)/2 – (D1+D2)/2

FA Track Offset = |E – F| < 4mm

If Front axle offset is more than 4mm, loosen the I-Bolts and shift the axle suitably.
 Front axle fa99
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Service Manual

10. Lift Axle Toe - in

RHS
A1 A2
C1 C2

C.L of vehicle

L1 L2

B1 B2 D1 D2

LHS
Check dimension L1 & L2 as shown in sketch for Lift Axle

Spec: L2 – L1 = 0 to 2 mm, If L2 – L1 is not found as per spec, the same needs to be achieved by adjusting length
of Lift axle track rod.Record Dimension ‘L1’ & ‘L2’

11.Thrust Angle & Scrub Angle (applicable only for NRS suspension)

RHS

C.L of vehicle M

LHS
N

- Check Thrust angle (M ) & Scrub angle (N) as shown in sketch for Rear Axles

Spec: Thrust angle M(in deg) : ± 5 min

Scrub angle N(in deg) : ± 5 min

- If M & N are not found as per spec, the same needs to be achieved by loosening the rear axle U-bolts
and adjusting the rear axles suitably. Record Dimension ‘M & N
Torque Specification for Suspension & steering

sl no component Description Specification

1 U- Bolt Torque 475 - 508 N.m
2 I Bolt Tightness 244-298 N.m
3 Kingpin Play 0.001” -0.004”
4 Hub Play 0.001” -0.004”
5 Draglink Pinch bolt Torque 60 - 70 N.m
6 Track rod pinch bolt Torque 60 - 70 N.m
7 Relay draglink Dimension 1760 +/- 1.5 mm
8 Power Cylinder Pinch bolt 60 - 70 N.m
9 Ball Pillar Slotted nut 180 - 200 N.m
10 Main Drop arm Nut 700 N.m
11 Relay drop arm Nut 300 N.m
 Front axle fa99
43.33
Service Manual

43.4 Tightening Torques Kgm lb.ft. Nm

Steering lever mounting bolt 55 - 57 400 - 410 542 - 556
Hub nut 30 - 32 220 - 235 298 - 319
Brake carrier mounting 10 - 11 75 - 80 102 - 108
Cotter pin nut 4 - 5 30 - 35 41 - 47
King pin top & bottom cover bolts 4 - 5 30 - 35 41 - 47
Track rod ball pillar nuts 18 - 20 130 - 145 177 - 196
Wheel Nuts 66 - 72 475 - 525 644 - 712
Brake chamber mounting nuts 14 - 18 101 - 130 137 - 177
Hub cap mounting screws 3 - 4 22 - 29 29 - 39
Track rod lever mounting bolts 55 - 57 400 - 410 542 - 556
Track rod pinch bolt 6 - 7 43 - 51 59 - 68

43.5 Recommended lubricants

Minimum Co-branded Lubricant Approved Lubricant
Aggregate Ambient
Temp. °C Gulf Oil India Indian Oil Corporation
Wheel Bearing (Hub greasing) - for U-Truck Gulf Crown Dura Max NLGI3 Servo Grease Super 3
Wheel Bearing (Hub greasing) - for non U-Truck models -20 Gulf Crown Max RR3 Servo Gem ALT
All other greasing points Gulf MP Grease Max NLGI 2 Servo Grease ALT
Note : Do not mix lubricants of different brands/grades.

43.6 Filling capacity

Aggregates Filling Capacity
1. Front Hub 450 g approx.
2. King pin per side 120 g approx.

43.7 Maintenance schedule

km x 1000

Sl.
Monthly

Description Remarks
No.
Every
Pdi

For all applications other than Tippers:

i. Repack the hubs with recommended grease
1 ii. Check the condition of hub bearings and change if necessary. 48 For non - U Truck models.
iii. Adjust hub end play.
iv. Check and reset pole wheel sensor air gap.
For all applications other than Tippers:
For U Truck models.
i. Repack the hubs with recommended grease.
Also check hub end play
2 ii. Check the condition of hub bearings and change if necessary. 80
at every 40,000kms and
iii. Adjust hub end play.
adjust if required.
iv. Check and reset pole wheel sensor air gap.
For Tippers: For U Truck models.
i. Repack the hubs with recommended grease. 1500 Also check hub end play
3
ii. Check the condition of hub bearings and change if necessary. Hrs at every 1000 Hrs. and
iii. Adjust hub end play. adjust if required.
For Tippers:
i. Repack the hubs with recommended grease. 500
4 For non - U Truck models.
ii. Check the condition of hub bearings and change if necessary. Hrs
iii. Adjust hub end play.
5 Check wheel alignment and adjust if necessary. 3 40
6 Check and tighten thrust cover bolts 40
7 Check king pin vertical play & adjust if necessary 40
8 Check kingpin lateral play & adjust if necessary 40
9 Lubricate track rod/ drag link ball joints 3 3
10 Lubricate kingpins 3 3
 Front axle fa99
43.34
Service Manual

Front axle
(fa99)

June 2011
 Foreword

This Service Training Handout contains specifications, data and instructions on the
correct methods of carrying out dismantling, assembling and repair work on Front Axle
FA90 / FA91 and FA99 models.

By using this Handbook and the appropriate special tools, it is possible to execute repairs
within the specified time. Adhering to the safety instructions will protect operators from
accidents. Before starting any repair work, ensure the availability of safety measures
in good order. Check and wear prescribed safety-wear required by safety regulations,
i.e., goggles, helmet, hand gloves and safety shoes. Check all tools, material handling
equipments before using them.

In accordance with Ashok Leyland Limited (the Company’s) policy of continuous product
improvements, the company reserves the right to change the procedures, material,
specifications, dimensions or design referred to in this Booklet, at any time and without
prior notice. Relevant changes would be updated through our service circulars, if found
necessary.

Care has been taken to include as much useful information as possible. Every reasonable
effort has been made to ensure that this booklet is accurate. The Information, Data and
Procedures given in this manual are indicative in nature and not binding.

Participants of the Service Training Course are requested to contact AL Regional

Offices \ Area Offices to obtain necessary guidance or communicate to -

Service Training Institute

Ashok Leyland Limited
Plot No. SP 26, Block II,
Thiru-Vi-Ka Industrial Estate,
Ekkattuthangal, Guindy,
Chennai - 600 032

stc-cni-FA:500:0811:21
 We
are just
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¾ ¾ TatkaAL - Assured emergency response ¾ ¾ Restoration in 48 Hours.

Comprehensive Motor Insurance Package

from Ashok Leyland

Special features of the AllCover Insurance package

Policy benefits
'' Comprehensive motor policy comprising own damage and third party insurances
at the dealer’s doorstep
'' Attractive rates on OD Premium
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delivery
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