IMPACT 4.03.

01 7/5/2017

Chassis ID Path
M050 85475 611/Description, Design and Function//Front Axle

Model Identity
CXU 132775610

Publish date ID/Operation

3/27/2014

Front Axle

1. Steering Knuckle (left)

2. Steering Lever (left)
3. Axle Center
4. Steering Lever (right)
5. Steering Knuckle (right) [Not used on all models]
6. Cross Steering Lever (right)
7. Cross Steering Tube Assembly
8. Cross Steering Lever (left)

The information in this manual covers Specifications, Design and Function, Troubleshooting, Service Repair
Procedures, and Preventive Maintenance for the MACK FXL Front Axles.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

Steering is accomplished by mounting a steering knuckle on the front axle with a steering knuckle (king) pin so
that each steering knuckle is free to pivot. Steering input to the steering knuckle (and subsequently the front
wheels) is achieved through a drag link that is attached between the steering gear lever (pitman arm) and the
steering lever that is rigidly mounted to the steering knuckle.

While most vehicles have the steering lever attached to the left knuckle, some vehicles are built to provide for
right-hand
steering. In this case, the linkage and steering lever are mounted on the right-hand knuckle. In special cases,
vehicles are provided with steering levers on both the right- and left-hand steering knuckles. On these vehicles,
the steering linkage from the steering gear is connected to the left-hand steering knuckle with a power assist
slave gear connected to the right-hand knuckle. The gear and power assist slave gear are interconnected
hydraulically to provide easier steering.

On all axles, the steering knuckles are connected by the cross steering levers and cross steering tube to
maintain alignment.

On the FXL front axles assemblies, the steering knuckles use nylon lower bushings and tapered roller upper
bearings to provide a bearing surface for the kingpin. Seals are used to exclude dirt and retain lubrication inside
the knuckle assembly. The front axles are positioned on the vehicle by the springs that are attached to the
frame with support brackets.

Stable steering and normal tire life depend upon maintaining balanced forces in the front end and steering
system. To prevent undesirable effects from the various forces acting upon the front end, it is essential that
wheel and tire assemblies be properly aligned and balanced. Additionally, all components of the front axle,
suspension and steering system must be maintained in good mechanical condition and proper adjustment.

The information covered in this manual deals with front axle and steering specifications, maintenance,
troubleshooting, repair
instructions, adjustments (which is contained within the repair instructions section) and special tools.

It must be noted that the steering characteristics of the vehicle are also dependent upon rear wheel alignment
and frame
geometry, as well as wheels and tires. For additional information, refer to the MACK Service Manuals that
cover these items. All
information about vehicle alignment can be found in Axle Alignment, Specifications Function Group 6.

The technician performing front axle service should have sufficient knowledge of the basic factors that affect
the steering system, to allow logical system diagnosis and correction of trouble.

All equipment and instruments used for checking or repairing the vehicle must be inspected and adjusted at
regular intervals to ensure accuracy. Inaccurate and unsatisfactory work results when even these instruments
are carelessly maintained or handled.

Front Axle Maintenance

General maintenance procedures for MACK components are detailed in Function Group 1. For periodic maintenance
instructions and intervals, refer to Function Group 1. Axle alignment specifications are given in Function Group 6.

Kingpin Upper Bearing

With the vehicle weight on the ground, apply the recommended chassis lubricant to the upper bearing grease fitting
until grease purges from the joint between the upper steering knuckle and the upper portion of the axle eyelet. Ensure
kingpin upper
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

bearing is lubricated with vehicle weight on the ground.

Kingpin Lower Bearing

With the vehicle raised off the ground and supported on jack stands, lubricate the kingpin lower bushing. Raising the
vehicle off the ground ensures that grease will fill the areas around the kingpin and bushing. Apply the recommended
chassis lubricant to the lower bushing grease fitting until grease purges from the joint between the lower steering
knuckle and the lower portion of the axle eyelet. Ensure kingpin lower bushing is lubricated with the front of the vehicle
raised off the ground and supported on jack stands of adequate capacity.

Danger
Do not work under a vehicle that is supported only on a hydraulic jack. The hydraulic jack could fail suddenly
and unexpectedly, resulting in severe personal injury or death. Always use jack stands of adequate capacity to
support the weight of the vehicle.

Steering Maintenance
At each inspection interval, inspect steering linkages, including steering shaft U-joints and yokes, drag link and cross
steering tubes for damage or looseness. Also, check ball sockets for boot damage, looseness or wear. Also, at the
same intervals, check the condition of the steering gear mounting brackets and check all fasteners for looseness.
Inspect the steering gear,
hoses, pump and reservoir for leaks. Check the oil level in the power steering reservoir and add the recommended oil if
necessary. (Refer to the Function Group 1 for recommended power steering oil.)

At each inspection interval, check that the steering shaft pinch bolts are tightened to specification (See Steering Shaft
Universal Joint Pinch Bolts). Replace any pinch bolts that are corroded or damaged.

Lubrication Intervals
See Function Group 1 for service intervals.

Front Axle Components

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

1. Steering Lever
2. Steering Lever Ball Stud
3. Kingpin Nut
4. Upper Seal
5. Knuckle Upper Cover
6. Kingpin Bearing
7. Hub Nut
8. Snap Ring
9. Lock Plate
10. ”D” Washer
11. O-ring
12. Lower seal
13. Nylon Bushing
14. Kingpin
15. Lower Cover
16. Cross Steering Lever Ball Socket
17. Cross Steering Tube Assembly
18. Cross Steering Lever
19. Axle Center
20. Stop Bolt Nut
21. Stop Bolt

Ball Socket (Tie Rod End) Assembly

This assembly is installed on each end of the cross steering tube. The ball sockets (tie rod ends) are attached to the
cross steering levers on the steering knuckles.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

Cross Steering Lever

These two arms are attached to the bottom of the tie rod arm right-and left-hand steering knuckles, and are linked
together by the cross steering tube.

Cross Steering Tube (Tie Rod) Assembly

This tube connects the two cross steering levers and includes the two cross steering ball socket assemblies. These ball
socket assemblies are screwed into the cross steering tube ends, which allow the steering tube to be adjusted for
length.

Drag Link
This is the mechanical link between the steering lever and the steering gear lever (pitman arm).

Knuckle Pins (Kingpins)

These pins (one on each side) are used to attach the steering knuckles to the axle center.

Pivot Center
This is the theoretical point on the knuckle pin axis where it is intersected by the axis of the steering knuckle spindle.

Steering Knuckle
This is the movable portion of the axle that pivots on the knuckle pins (kingpins).

Steering Knuckle Spindle

This is the steering knuckle that supports the hub assembly, wheel and tire.

Steering Lever
This lever is attached to the top of the steering knuckle and is used to transmit force from the drag link to the steering
knuckle, in order to turn the wheels

Front Axle Identification

FXL series axle model designations reflect the axle rating (in thousands of pounds) in the designations. The complete
letter designations equal the following:

F= Front Axle
XL= Extra heavy-duty unitized maintenance free Long-life hub

Pivot Centers

The dimension between the right-hand and left-hand pivot center depends of the design of the specific axle. The FXL
series of axles have a pivot center of 1776 mm (69.92 in.).

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

Part Number Location

The part number is found on the center front of the axle beam.

1. Part number location — FXL 12 and 14.6 axles

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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1. Part number location — FXL 18 and 20 axles

Warning
Do not grind or bend the front axle. If grinding has been performed on axle, or the axle has been bent, either
intentionally or by accident, it must be replaced

Steering (Turning) Angle and Turning Radius

Correct setting of the turning angle is important. A steering angle that is too large can cause interference between the
tires and the chassis or steering linkage. In some cases, excessive steering
angle can cause a dangerous steering linkage toggle condition that can lock the steering and cause a loss of vehicle
control. If the steering angle is too small, the maneuverability of the vehicle is reduced and the turning radius increases.

Note: On all vehicles, the front axle wheel stops must be

adjusted to provide a minimum of one-inch clearance between the tires and chassis components, and a minimum of
one-half inch between any moving steering component (pitman arm, drag link, steering lever, etc.) and any other
steering component.

Check the turning angle whenever the wheels are aligned or if new springs or front axle have been installed, or if tire
size has been changed. The turning angle must be adjusted for both right- and left-hand turns. The angle for a
right-hand turn may not be the same as for a left-hand turn. See function Function Group 6 for wheel alignment
specifications and steering pressure and flow checks.

Springs and U-Bolts

Vehicle stability suffers if the springs do not keep the front and rear axles in alignment. Check for broken or sagging
springs, loose spring U-bolts or rebound U-bolts, loose axle clamping plates, and front spring center bolt wear
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

(indicated by the loose fit of the bolt).

Checking for Broken or Sagging Springs

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

Torquing Springs U-bolts

Torque the U-Bolts according the sequence showed.

Sequence U-Bolts torque

Note: U-Bolts should be re-tightened at 1600 Km (1,000 miles) after replacement.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.03.01 7/5/2017

Checking Axle Clamp Plates

Excessive side clearance on the shackle end of the spring may result in shimmy. Be sure that the pin and bushing at
the fixed end of the spring are a good fit. Clearance should not
exceed 0.8 mm (0.030 in). Looseness in this area contributes to increased tire wear and tramp.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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