Usage:
D20D (9MG),
D25D (1HK),
D30D (3AJ, 1PK),
D250D (6NG),
D250E (5TN),
D300E (7FN),
D40D (2JJ),
D350D (9RF),
D350E (9LR),
D400D (8TF, 4EJ),
D400E (2YR) Articulated Trucks
NOTE: The information in this article supersedes the information given in the January 17, 1994 Service Magazine, Page 8, "Knocking Noise In Front Suspension Frame Group Can Be Eliminated With Shims" and December 30, 1996 Service Magazine, Page 14, "Procedure for Aligning Front Suspension Frame Group With Output Transfer Gearbox".
It may sometimes be necessary to align the front suspension frame group with the output transfer gearbox. The front axle differential input shaft must be aligned with the transfer gearbox output shaft.
Illustration 1.
Front Suspension Frame Group Components. (1) Axle Housing. (2) 3.0 mm (.12 in) Shims. (3) 1.0 mm (.04 in) Shims. (4) Cap. (5) Seal.
The differential input shaft the for front axle (1) must be aligned with the transfer gearbox output shaft. The adjustment is done using shims (2 and 3) installed under the bearing caps (4). The objective of the adjustment procedure that follows is to achieve adequate shaft alignment while making sure there is minimum sideways movement of the suspension frame group. There should also be no side load imposed on the bearings.
1. Raise the front of the machine by the mainframe until the tires are off the ground. Place suitable supports under the mainframe.
2. Remove the front wheels to improve access to the front suspension frame group.
3. With the suspension frame group in position and the suspension arm bearings in place, use a suitable pry bar to move the suspension frame group right and left as needed until the universal joints are aligned. Use a straight edge to measure across the driveshaft universal joints for correct alignment. Take two measurements 180° apart.
4. Use a soft mallet to impact both the right and left side bearings to make sure they are fully seated.
Location of Dimension (A) and Dimension (B).
5. Use finger pressure to press on the bearing to remove any seal deflection that may be present. Use a vernier scale, or similar tool, to obtain Dimension A and Dimension B by measuring the distance from the bottom of the counterbore to the top face of the bearing outer shells on the right and left side of the machine. Add Dimensions A and B together.
6. For D20D, D250D, D250E and D300E Articulated Trucks, use 3.0 mm (.12 in) thick, 7U-6608 Shims (2) and 1.0 mm (.04 in) thick 6U-1345 Shims (3) to make a shim pack that exceeds the sum of Dimensions A and B by the minimum amount possible.
For D25D, D30D, D350D, D40D, D400D, D350E and D400E Articulated Trucks, use 3.0 mm (.12 in) thick, 4U-8849 Shims (2) and 1.0 mm (.04 in) thick 4U-8769 Shims (3) to make a shim pack that exceeds the sum of Dimensions A and B by the minimum amount possible.
7. Divide the shim pack in the best proportions with respect to Dimensions A and B to maintain drive shaft alignment.
8. Install the shim pack and install cap (4). Install the bolts and washers that hold cap (4) in position.
9. Measure the total amount of sideways movement of the suspension frame group by using the prybar to move it fully left then fully right. Total side movement should not exceed 1.0 mm (.04 in).
10. Check universal joint alignment. Maximum allowable misalignment is 5.0 mm (.20 in). but actual misalignment when using this procedure should be less.
Example
1. Measure and record Dimension (A). Dimension (A) is 6.3 mm (.25 in).
2. Measure and record Dimension (B). Dimension (B) is 4.1 mm (.16 in).
3. Add Dimension (A) 6.3 mm (.25 in) to Dimension (B) 4.1 mm (.16 in). The sum is equal to 10.4 mm (.41 in).
4. Make a shim pack whith a thickness that exceeds 10.4 mm (.41 in) by the minimum amount possible, 11.0 mm (.43 in).
5. Divide the shim pack and install 5.0 mm (.20 in) in the side where Dimension A was measured, and 6.0 mm (.24 in) in the side where Dimension B was measured.