INSTALLATION INSTRUCTIONS

Transcription

1 VOLVO THREADED FRONT LEAF SPRING BUSHING IMPORTANT INFORMATION AND SAFETY PRECAUTIONS This product will provide excellent service life when it has been properly installed and maintained. 1 OF 6 Read the instructions carefully. Pay particular attention to the NOTE sections which contain helpful information to make the installation as easy as possible. Also pay close attention to the sections with the following warning symbol next to them: These are provided to help avoid personal injury, property damage or to prevent future safety problems with the vehicle. In addition, we recommend that you strictly adhere to all federal and state approved shop safety practices and procedures. Carefully inspect the vehicle suspension that is being repaired. Correct or replace all defective components. REQUIRED TOOLS The PT91500 drive handle and PT91118 alignment nose are required when installing the Atro threaded leaf spring bushings. In addition, the PT threaded pin drive tool, or a spanner wrench, will be needed to install the threaded stainless steel pin into the Atro threaded leaf spring bushings. NOTE: Be sure to use the proper Atro leaf spring bushing installation tool. Use of the wrong tool may damage the bushing assembly and void your warranty. REMOVAL OF OLD COMPONENTS - FRONT OF FRONT SPRING EYE Always wear safety glasses and any other necessary safety gear while performing this procedure to protect against bodily injury. Overheating the spring eye could weaken the spring resulting in a premature failure. 1. Securely support the vehicle to remove the weight off of the front leaf springs 2. Remove the old front of front spring pin and spring eye bushing. NOTE: It is not necessary to completely remove the leaf spring from the axle. ATRO LEAF SPRING BUSHING INSTALLATION - FRONT OF FRONT SPRING EYE Always wear safety glasses and any other necessary safety gear while performing this procedure to protect against bodily injury. If the leaf spring eye was heated during bushing removal, allow it to cool before installing the Atro leaf spring bushing. This will prevent overheating of the bushing/polyurethane material. Overheating of the material could lead to premature failure. Inspect the leaf spring eye for cracks, out-of-round or worn out bore conditions. If any of these conditions exist, replace the damaged components. Failure of any of these components could result in an accident, serious property damage and severe injury or death.

2 VOLVO THREADED FRONT LEAF SPRING BUSHING 2 OF 6 1. Remove all burrs and corrosion from the spring eye with a file, hone or wire brush and wipe clean. 2. Measure spring eye ID. Recommended basic ID should be between and If ID is too large, replace spring. If ID is too small, make sure all corrosion and contamination are removed from spring eye. 3. Remove one of the plastic plugs from one end of the Atro leaf spring bushing. Do not remove plastic plug in opposite end of bushing until bushing is installed. This will help prevent contamination from getting inside the bushing during the installation process. 4. Insert the bushing drive tool into the Atro leaf spring bushing. (Refer to Figure 1) 5. Align Atro leaf spring bushing with bore of spring eye. Using a press (preferred), draw bolt, or impact hammer, install the bushing in the spring eye. 6. Remove second plastic plug. NOTE: The Atro leaf spring bushings come pre-lubricated with special break-in grease. It is NOT necessary to re-lubricate these bushings during their service life. FIGURE 1 FRONT SPRING BRACKET SPRING EYE BUSHING BUSHING DRIVE TOOL ATRO THREADED SPRING PIN INSTALLATION - FRONT OF FRONT SPRING EYE 1. Check bracket/spring alignment. If spring and bracket are out of alignment, correct alignment before continuing. 2. Remove any contaminants, such as rust or dirt, which may have been deposited in the inner diameter of the bushing during installation. NOTE: Do NOT remove grease from spring eye bushing. 3. Align bore of spring eye bushing with the spring pin holes in hanger bracket. (Refer to Figure 2)

3 VOLVO THREADED FRONT LEAF SPRING BUSHING 3 OF 6 FIGURE 2 SPRING PIN LOCK BOLT THREADED SPRING PIN 4. Insert threaded spring pin through hanger bracket into spring eye bushing. 5. Using the Atro PT threaded pin drive tool, or a spanner wrench, thread the pin into the bushing and hanger bracket until grooves in threaded pin line up with spring pin lock bolt holes in bracket. Note: Do NOT use air tools to tighten locking nuts. A torque wrench must be used to attain the required torque and precent over tightening. 6. Insure there is an equal amount of space between edge of spring and hanger bracket on both sides of the spring (center spring in bracket). Thread spring pin in or out to adjust spacing. Doing this will prevent the spring from rubbing against the hanger bracket during use. 7. Insert NEW spring pin lock bolts and nuts, torque to ft-lbs. NEVER reuse old bolts and nuts. REMOVAL OF OLD COMPONENTS - REAR OF FRONT SPRING EYE Always wear safety glasses and any other necessary safety gear while performing this procedure to protect against bodily injury. Overheating the spring eye could weaken the spring resulting in premature failure. 1. Securely support the vehicle to remove the weight off of the front leaf springs. 2. Remove the old shackle assembly. NOTE: It is not necessary to competely remove the leaf spring from the axle.

4 VOLVO THREADED FRONT LEAF SPRING BUSHING ATRO LEAF SPRING BUSHING INSTALLATION - REAR OF FRONT SPRING EYE & BRACKET Always wear safety glasses and any other safety gear while performing this procedure to protect against bodily injury. If the leaf spring eye or bracket were heated during bushing removal, allow them to cool before installation of Atro leaf spring bushings. This will prevent overheating of the bushing/polyurethane material. Overheating of material could lead to premature failure. Inspect the frame hanger bracket and the leaf spring eye for cracks, out-of-round or worn out bore conditions. If any of these conditions exist, replace the damaged components. Failure of any of these components could result in an accident, serious property damage and severe injury or death. 1. Remove all burrs and corrosion from the spring eye and bracket with a file, hone or wire brush and wipe clean. 2. Measure spring eye ID. Recommended basic ID should be between and If ID is too large, replace spring. If ID is too small, make sure all corrosion and contamination are removed from spring eye. 3. Remove one of the plastic plugs from the end of the Atro leaf spring bushing. Do not remove plastic plug in opposite end of bushing until bushing is installed. This will help prevent contamination getting inside the bushing during the installation process. 4. Insert the bushing drive tool into the Atro leaf spring bushing. (Refer to Figure 3) 5. Align Atro leaf spring eye bushing with bore of rear spring eye. 6. Using a press (preferred), draw bolt or impact hammer, install the bushing into the rear spring eye. 7. Remove second plastic plug. 8. Repeat steps 3-6 to install an Atro leaf spring bushing into the frame hanger bracket. 9. If the hanger has been removed, reinstall following the manufacturers instructions. NOTE: The Atro leaf spring bushings come pre-lubricated with a special break-in grease. It is NOT necessary to re-lubricate these bushings during their service life. FIGURE 3 4 OF 6 FRAME HANGER BRACKET BUSHING DRIVE REAR SPRING EYE SPRING EYE BUSHING Do not weld the Atro leaf spring bushing into the leaf spring eye. Welding the Atro leaf spring bushing will damage it and VOID warranty.

5 VOLVO THREADED FRONT LEAF SPRING BUSHING 5 OF 6 ATRO THREADED SPRING PIN INSTALLATION - REAR OF FRONT 1. Remove any contaminants, such as rust or dirt, which may have been deposited in the inner diameter of the bushing during installation. NOTE: Do NOT remove grease from spring eye bushing. 2. Using the Atro PT threaded pin drive tool, or a spanner wrench, thread a spring pin into both the hanger bracket and rear spring eye bushings until it is centered. NOTE: Do NOT use an impact tool to thread spring pin into bushing. NOTE: The spring pin in the hanger bracket and the rear spring eye must be threaded in from the oppoite directions in order for the side bars to fit properly. (Refer to figure 4) SIDE BAR INSTALLATION 1. Make sure the grooves in the small end of the spring pins are aligned horizontally so the side bar lock bolts will slide through them. Install the side bars on the ends of the pins protruding from the spring eye bushings. (Refer to Figure 4) FIGURE 4 SIDE BAR LOCK BOLTS SIDE BAR Inspect side bars for excessive wear. If necessary, replace side bars with Volvo side bar #: Failure to do so could result in an accident, serious property damage and severe injury or death. 2. Install NEW side bar lock bolts and locking nuts. Do not tighten yet! (Refer to Figure 4) 3. Insure there is an equal amount of space between edge of spring and side bars on both sides of the spring. Also insure there is an equal amount of space between edge of hanger bracket and side bars on both side of the hanger bracket. Thread spring pins in or out to adjust spacing (two side barlock bolts on the small end of the pins will have to be removed in order to rotate spring pin). Doing this will prevent the sidebars from rubbing against the hanger bracket or spring during use. 4. Torque side bar lock bolts to ft-lbs. NEVER reuse old bolts and nuts.

6 VOLVO THREADED FRONT LEAF SPRING BUSHING FRONT END ALIGNMENT After installing the Atro leaf spring bushing, it may be necessary to perform a front end alignment check for caster, camber and toe-in. Use the manufacturers guidelines and specifications for performing this task. MAINTENANCE The Atro leaf spring bushings are self-lubricating and virtually maintenance free. The spring, hanger bracket, side bars, and Atro leaf spring bushings should be visually inspected during every oil change. Also, the lock bolts should be re-torqued periodically to insure the integrity of the leaf spring bushings. WARRANTY NOTICE Follow the guidelines below to take full advantage of your Atro spring eye bushing warranty. Failure to do so could void your warranty and may lead to premature failure, damages and/or injuries. DO NOT use alternate components and/or hardwar in conjunction with Atro spring eye bushings Always use matching Atro components on both sides of the vehicle DO NOT exceed the 20,000lb GAWR Use proper installation tools and installation methods (see installation instructions) DO NOT expsose Atro spring eye bushings to excessive heat (i.e. welding or torch use) Atro Engineered Systems, Inc. can not be held responsible for any failure, damages or injuries that may result from not adhering to these guidelines. 6 OF 6 POLYURETHANE PARTS SOLUTIONS FOR HEAVY TRUCKS Atrobushing.com 2017 Atro Engineered Systems, Inc. 6 Bolte Lane St. Clair, Missouri U.S.A. (800) Fax (866)