FRONT AXLE

(FA90 / FA91)

MAY 2012
 FRONT AXLE FA90/ FA91
41.01
Service Manual

CONTENTS
GROUP - 41
FRONT AXLE - FA90 / FA91
Section Subject Page No.

41.0 GENERAL......................................................................................................... 41.02

41.0.0 Front Axle Type and Sl. No......................................................................... 41.02
41.0.1 Design and Operation.................................................................................. 41.02
41.0.2 Description of Leading Components............................................................ 41.02
41.0.3 Data............................................................................................................. 41.06
41.0.4 Front Axle Preliminary Checks..................................................................... 41.08

41.1 TO REMOVE AND REFIT FRONT AXLE FROM VEHICLE.............................. 41.10

41.1.0 To Remove................................................................................................... 41.10
41.1.1 To Refit........................................................................................................ 41.10
41.1.2 Dismantling and Assembling Procedure........................................................ 41.11
41.1.2.0 Dismantling............................................................................................ 41.11
41.1.2.1 Inspection............................................................................................... 41.12
41.1.2.2 Assembly................................................................................................ 41.13
41.1.3 Axle Arm End Play Checking Procedure..................................................... 41.14
41.1.4 Assembling King Pin Cotter......................................................................... 41.14
41.1.5 Assembling the hub end.............................................................................. 41.15
41.1.6 Hub End Play - Wet Setting........................................................................ 41.16
41.1.7 To Check Wheel Alignment (Toe in / Toe out)............................................ 41.16

41.2 TO PREPARE FRONT AXLE SUB- ASSEMBLIES........................................... 41.17

41.2.0 Axle Arm Sub-assembly............................................................................... 41.17
41.2.1 Hub Sub-assembly....................................................................................... 41.18

41.3 TRACK ROD..................................................................................................... 41.18

41.3.0 Features and Advantages............................................................................ 41.19
41.3.1 Fitment Procedure....................................................................................... 41.19
41.3.2 Check For Condition Of Ball Joints............................................................. 41.19
41.3.3 Lubrication................................................................................................... 41.19

41.4  TIGHTENING TORQUES................................................................................... 41.20

41.5 RECOMMENDED LUBRICANTS....................................................................... 41.20

41.6 FILLING CAPACITY.......................................................................................... 41.20

41.7 MAINTENANCE SCHEDULE............................................................................. 41.20

 FRONT AXLE FA90 / FA91
41.02
Service Manual

41.0 GENERAL Hub Oil Seal and Ring for Oil Seal Arrangement

41.0.0 Front Axle Type and Sl. No.

41.0.2 Description of Leading Components

The front axle serial number and type of front axle are Axle Arm
punched near LH side king pin boss of axle beam.

41.0.1 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 FA90/ FA91
41.03
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 FA90 / FA91
41.04
Service Manual
Wheel rim
Made of pressed steel with welded disc and loose lock
ring. Available in 10 wheel bolts/8 wheel bolts versions.
FA90 / FA91 FRONT AXLE LAYOUT
16
18
17
FA90 / FA91 FRONT AXLE - AXLE ARM END
ILL.No Description Qty
A front axle assembly comprises of 1
1 Front axlebeam 5t improved 1
2 Axle arm for abs 1
3 Kp bush 2
4 Oil seal king pin 2
5 King pin- std. 2
5A king pinkit- std. 2
6 Thrust brg-t151-texspin (std.) 2
7 Shim 1 mm tk-kingpin 1
8 Cotterpin top 2
9 Cotterpin bottom 2
10 Washer 27 od x 10.319 Id x 3.175 T 4
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.
14
1 13
12
19 20 5 11
8 3 2
7
10
9
15 4
6
ILL.No Description Qty
11 Joint for bottom cover 4
12 Bottom cover 4
13 Grease nipple 4
14 Screw m10 x 20 x 1.5 Cp plated for fixing top and
bottom cover plate 16
15 Track rod lever - lh (longer wb-176" and above) 1
16 Trackrod lever - rh (longer wb) ref.F2417411 1
17 Mtg.Bolt - 10.9 M20x1.5 For fixing track rod lever 4
18 Track rod assy (50x6-cew-lwb) alt - f8288700 1
19 Steering lever 1
20 Screw - Steering lever 2
 FRONT AXLE FA90/ FA91
41.05
Service Manual

19 15 18
17
20 16

14

10
13 11

22 8
21 6 1
5
12 4 3 2

9 7

FA90 /FA91 FRONT AXLE - HUB END

ILL.No Description Qty ILL.No Description Qty

1 Brake drum (ref:f1828622) 2 13 Front axle taper roller bearing - inner - orbit
bearings Ltd., 2
2 Screw m6 x 15 x 1 cp plated for hub cap to hub 12
14 Front brake assy rh- hlp fa90 1
3 Sc washer 6 diaplated for hub cap to hub 12
14 Front brake assy lh-6"-hlp-fa90 1
4 Front axle plastic hub cap 2
15 Front brake chamber lh - type 24 1
5 Joint for hub cap 2
15 Front brake chamber rh - type 24 1
6 Split-pin 3/16 dia x 2 1/2 inch plated 2
16 Automatic slack adjuster-mei 2
7 Nut- slotted hex 1 1/2 bsf x0.945 Long x0 2
17 Pivot pin 2
8 D washer 2
18 Nyloc nut 3/8 x pcp bsf plated 2
9 Front axle taper roller bearing - outer - orbit
bearings Ltd., 2 19 Anchor bracket 2

10 Wheel bolt 20 20 Screw m8 x 15 x 1.25 Cp plated -

anchor bracket to brake assy. 4
11 Front hub fa90 star abs 6 inch 2
21 Oil seal - hub - fenner 2
12 Distance piece-36.30mm length 2
22 Cast oil seal ring 2
 FRONT AXLE FA90 / FA91
41.06
Service Manual

41.0.3 Data

Description FA90/ FA91 Front Axle

Type Reverse Elliot
Axle Capacity 6000 kg
King Pin Inclination 6°
King Pin Centres 1752 mm
Camber 1.5°
Toe In (Unladen) 0 - 2 mm
Wheel Track 1963 mm
Track Rod Ball Pin Center Longer WB version 1665 mm
Shorter WB version 1605 mm
Wheel Lock Angle (on Axle) 45°
Spring Centres (Possible Range) 813 mm (762 mm to 965 mm)
Weight Of Axle Beam 84 Kg
Kingpin Bore In Axle Beam Standard 38.26 - 38.28 mm
1st O/S 38.56 - 38.58 mm
2nd O/S 38.86 - 38.88 mm
3rd O/S 39.16 - 39.18 mm
Kin Pin Dia Standard 38.24 - 38.25 mm
1st O/S 38.54 - 38.55 mm
2nd O/S 38.84 - 38.85 mm
3rd O/S 39.14 - 39.15 mm
King Pin Bush Inner Dia Standard 38.28 - 38.32 mm
1st O/S 38.58 - 38.62 mm
2nd O/S 38.88 - 38.92 mm
3rd O/S 39.18 - 39.22 mm
Kingpin Bore In Thrust Bearing Standard 38.35 mm
1st O/S 38.65 mm
2nd O/S 38.95 mm
3rd O/S 39.25 mm
King Pin Bush Outer Dia Top & Bottom 47.66 - 47.68 mm
Bore Dia In Axle Arm For Bushes Top & Bottom 47.619 - 47.644 mm
Interference of Bushes In Axle Arm Top & Bottom 0.016 - 0.061 mm
Thrust Taken On Thrust Bearing & Thrust Pad
Axle Arm End Play (For RH side) 0.025 - 0.10 mm
Axle Arm Preload (For LH side) 0.025 - 0.5 mm
Shims Available For Axle Arm End Play 0.076, 0.127, 0.254, 0.508, 1.016 mm
Renew Bushes When Diameter Clearance
Between King Pin and Bushes Exceeds 0.127 mm
 FRONT AXLE FA90/ FA91
41.07
Service Manual

41.0.3 Data
Description FA90/ FA91 Front Axle
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 FA90 / FA91
41.08
Service Manual

41.0.4 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 FA90/ FA91
41.09
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 FA90 / FA91
41.10
Service Manual

41.1 TO REMOVE AND REFIT FRONT AXLE 41.1.1 To Refit

FROM VEHICLE
Support the front axle assembly on a jack.
41.1.0 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. Fit the spacers if provided. Place Caster
plate thin side facing front. 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.

Unscrew ball pillar nut and disconnect the drag link from
the lower end of the drop arm by using the Special Tool 1 Bump stop
0602001 - Extractor Ball Pin. 2 Bump stop
mounting plate
3 Caster Plate
4 Leaf Spring
5 Shock Absorber
Mounting Plate

Ensure fitment of castor plates, 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.
Loosen the leaf spring I-bolts clamp nuts using Special
Tool 0901002 - Socket Spring Clamp Nut. Connect the shock absorber to the shock absorber
Disconnect brake hoses. bracket.

Fix the wheels and wheel nuts.

Torque tighten the fasteners.Lower

the wheels to the ground and tighten
NOTE
the wheel nuts uniformly to the
recommended torque.

Lift the front wheels off the ground by jacking the axle
beam (use conventional crawler cum trolley jack below
axle beam).
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 FA90/ FA91
41.11
Service Manual

41.1.2 Dismantling and Assembling Procedure

41.1.2.0 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

19 15 18
17
20 16

14

10
13 11

22 8
21 6 1
5
12 4 3 2

9 7

1 Brake Drum (Ref:f1828622) 13 Front Axle Taper Roller Bearing - Inner - Orbit Bearings Ltd
2 Screw M6 X 15 X 1 Cp Plated For Hub Cap To Hub 14 Front Brake Assy Rh- Hlp Fa90
3 Sc Washer 6 Diaplated For Hub Cap To Hub 14 Front Brake Assy Lh-6"-Hlp-Fa90
4 Front Axle Plastic Hub Cap 15 Front Brake Chamber Lh - Type 24
5 Joint For Hub Cap 15 Front Brake Chamber Rh - Type 24
6 Split-Pin 3/16 Dia X 2 1/2 Inch Plated 16 Automatic Slack Adjuster-Mei
7 Nut- Slotted Hex 1 1/2 Bsf X0.945 Long X0 17 Pivot Pin
8 D Washer 18 Nyloc Nut 3/8 X Pcp Bsf Plated
9 Front Axle Taper Roller Bearing - Outer - Orbit Bearings Ltd 19 Anchor Bracket
10 Wheel Bolt 20 Screw M8 X 15 X 1.25 Cp Plated
11 Front Hub Fa90 Star Abs 6 Inch 21 Oil Seal - Hub - Fenner
12 Distance Piece-36.02Mm Length 22 Cast Oil Seal Ring
 FRONT AXLE FA90 / FA91
41.12
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 split pin, castle nut and thrust 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.

41.1.2.1 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 FA90/ FA91
41.13
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.

41.1.2.2 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 FA90 / FA91
41.14
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
41.1.3 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.
41.1.4 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 FA90/ FA91
41.15
Service Manual

Assembling king pin cover plate 41.1.5 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.

Fix the outer bearing, washer and hub nut in the sequence.

Tighten the castle hub nut to the torque - 21-22 kgm.

 FRONT AXLE FA90 / FA91
41.16
Service Manual

Hub end play - Dry setting The slotted nut has twelve position and the axle arms
has four position for inserting split pin. This facilitates
the correct positioning of the slotted nut for inserting
and locking the split pin. On no account nut must be
slackened back to insert the split pin.

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 Pack the grease in the cup 1/3rd of full.
ranging from 35.6, 35.64, 35.68, 35.72, 35.76,
NOTE
35.8, 35.84, 35.88, 35.92, 35.96, 36, 36.04, Fix up hub cap along with the gasket and tighten the bolts.
36.08, 36.12, 36.16, 36.2 mm can be used.
Maintain the recommended hub end play Mount the brake drum and reverse the removal procedure
0.025 to 0.100mm to refit front axle to the vehicle. Tighten wheel nuts to the
specified torque.
No shims to be used.
41.1.7 To Check Wheel Alignment (Toe in / Toe
41.1.6 Hub End Play - Wet Setting
out)
Using recommended grade of grease for each hub, knead
the grease into the inner races of the bearings and smear Preliminary checks
the grease in the hub cavity between bearing cups.
Park the unladen vehicle on level ground.
Fix the inner bearing onto the axle arm.
Ensure all tyres are of same size and tread wear is
Fix a suitable distance piece and place the hub assembly uniform.
on the axle arm.
Ensure tyres are inflated to recommended pressure.
Fix the outer bearing, washer and hub nut in the sequence.
Check spring pin bush for excess wear .
Tighten the castle hub nut to the torque - 21 - 22 kgm.

Counter check the hub end play with dial gauge and
ensure end play 0.025 - 0.100 mm.
Locking Arrangement
Ensure the spring cambers are equal on both sides.
Spring I-bolts are tightened to correct torque value.
Ensure steering play is within limit.

Hub end play is within limit.

 FRONT AXLE FA90/ FA91
41.17
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.
41.2 TO PREPARE FRONT AXLE SUB-
ASSEMBLIES

41.2.0 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
NOTE
TOP face indicating service size i.e. OS1,
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 FA90 / FA91
41.18
Service Manual

41.2.1 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.

41.3 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
 FRONT AXLE FA90/ FA91
41.19
Service Manual

41.3.0 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.

41.3.1 Fitment Procedure 41.3.2 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.
- Ensure that the pinch bolt / nut tightening torque (6
to 7 kgm).
- 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.
41.3.3 Lubrication
- Make sure the GREASE NIPPLES are intact.
- Replace immediately if they are found missing.
- 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 FA90 / FA91
41.20
Service Manual

41.4  TIGHTENING TORQUES Kgm lb.ft. Nm

Steering lever mounting bolt 35 - 36 253 - 260 343 - 353
Hub nut 21 - 22 152 - 159 206 - 216
Brake carrier mounting 10 - 11 72 - 80 98 - 108
Cotter pin nut 4-5 29 - 36 39 - 49
King pin top & bottom cover bolts 4-5 29 - 36 39 - 49
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 - 57 398 - 412 539 - 559
Track rod pinch bolt 6-7 43 - 51 59 - 69

41.5 RECOMMENDED LUBRICANTS

Co-branded Lubricant Approved Lubricant

Aggregate Ambient Temp. °C
Gulf Oil India Indian Oil Corporation
Wheel Bearing -20 Gulf Crown Max RR3 Servo Gem ALT
King pin -20 Gulf MP Grease Max NLGI 2 Servo Grease ALT
NOTE: Do not mix lubricants of different brands/grades.

41.6 FILLING CAPACITY

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

41.7 MAINTENANCE SCHEDULE

Every km x 1000

Remarks

MAINTENANCE ACTIVITY
Weekly
Daily
PDI

A Lubrication
1 Lubricate track rod / drag link ball joints
For Tippers 3 3
For all other applications 3 Monthly
Repack the hubs with recommended grease. Also check the condition of hub bearings
2 48
and change if necessary - For all applications other than Tippers.
Repack the hubs with recommended grease. Also check the condition of hub bearings 500
3
and change if necessary - For Tippers hrs
4 Check and adjust pole wheel sensor (ABS) air gap 3 48
5 Lubricate king pins
For Tippers 3 3
For all other applications 3 Monthly
B Maintenance
1 Check wheel alignment and adjust if necessary 3 8
2 Check & adjust hub end play. Check the condition of hub bearing, change if necessary 3 48
3 Check and tighten thrust cover bolts 8
4 Check king pin vertical play & adjust if necessary 16
5 Check king pin lateral play. Replace bush if necessary 16