a shop press.

Equalizing Beam

5. Apply hydraulic force and press the new bushing into place. The bushing will be completely seated when the clamp makes contact with the
beam face.
6. Using the floor jacks, slowly raise both equalizing beams and cross tube as an assembly
into the axle brackets. Ensure that each equalizing beam end bushing correctly engages
the axle bracket.
7. Install one (1) adapter through the axle bracket leg at the wheel side, into the beam
end bushing.
8. Install the other adapter through the axle bracket leg at the axle side, taking advantage of the cutoff flange on the adapter to clear the axle.
Figure 8-32

Figure 8-33

9. Rotate the adapters so that the adapter cut-off flats are vertical as shown in Figure 8-32.
10. Install the end shaft and slotted nuts.
11. Place the axles in their normal operating positions before the slotted nuts are torqued to
specifications.
If the tightening torques recommended below are not properly maintained, the metal
surfaces of the axle bracket legs, holes, adapters and rubber bushing inner metals can
experience excessive wear and / or failure. This can cause separation of components
and Adverse Vehicle Handling, property damage or personal injury.

12. Tighten the locknuts until final torque value is achieved, DO NOT EXCEED specified
torque value.
■■ 40K —

225 ± 15 foot pounds torque

■■ 46K —

470 ± 25 foot pounds torque

13. Remove the frame supports and lower the saddle onto the center bushings.
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14. Install the saddle caps, refer to Saddle Cap Assembly in this section.
15. Install the tires.
16. Remove the supports from the drive axles and lower the vehicle onto the ground.
17. Remove the wheel chocks.

Longitudinal Torque Rods
AR2 SUSPENSIONS INCORPORATE torque RODS FOR VEHICLE STABILITY. IF THESE COMPONENTS
ARE DISCONNECTED OR ARE NON-FUNCTIONAL, THE VEHICLE SHOULD NOT BE OPERATED. FAILURE
TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING, Adverse Vehicle Handling, POSSIBLE TIRE
CONTACT WITH THE FRAME, PREMATURE COMPONENT DAMAGE, OR SEVERE PERSONAL INJURY.

Disassembly
Figure 8-34

1. Chock the front wheels
of the vehicle.
2. Support the pinion on
the axle being serviced.
SERVICE HINT

To remove all the load from
the longitudinal torque rods,
raise or lower the pinion as
needed. This will ease the
removal of the longitudinal
torque rod.

NOTE

Prior to disassembly of the longitudinal torque rods, note the quantity and orientation of the longitudinal torque rod shims. It is required that the longitudinal torque rod shims are installed in the
same orientation and location as removed to preserve the existing alignment.
3. Remove the torque rod mounting fasteners and shims (if equipped).
4. Remove the fasteners that connect the longitudinal torque rod to the cross member and
axle brackets.
5. Remove longitudinal torque rods, see Figure 8-34.

Assembly
1. Install longitudinal torque rods.
2. Install new fasteners and any shims (that were equipped) to the cross member and torque
rod axle brackets.
NOTE

Hendrickson recommends the use of grade 8 bolts and grade C locknuts. If flange head bolts
and locknuts are not used then hardened structural washers must be used under bolt heads
and locknuts.
3. Tighten all fasteners to vehicle manufacturer’s torque specifications.
4. Verify proper pinion angle, and correct with drop in shims between the torque rod bar pin
and the cross member or torque rod axle bracket depending on the direction of adjustment
needed. Contact the vehicle manufacturer for proper pinion angle specifications.
5. Remove wheel chocks.

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Transverse Torque Rods
AR2 SUSPENSIONS INCORPORATE TRANSVERSE RODS FOR VEHICLE STABILITY. IF THESE COMPONENTS
ARE DISCONNECTED OR ARE NON-FUNCTIONAL, THE VEHICLE SHOULD NOT BE OPERATED. FAILURE
TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING, Adverse Vehicle Handling, POSSIBLE TIRE
CONTACT WITH THE FRAME, PREMATURE COMPONENT DAMAGE, OR SEVERE PERSONAL INJURY.

DISASSEMBLY
Figure 8-35

1. Chock the wheels of the vehicle.
SERVICE HINT

Note the quantity and location of shims removed to maintain the lateral alignment of the axle
during assembly. See Alignment & Adjustments section of this publication.
2. Remove and discard the torque rod mounting fasteners, see Figure 8-35.
3. Remove and discard the two (2) torque rod-to-frame mounting fasteners.
4. Remove the transverse torque rod.
5. If servicing the inner spacer plates or outer backup plates, remove the 5⁄8" fasteners from the
frame rails, see Figure 8-35.

INSPECTION
1. Inspect the torque rod mating surfaces and rubber bushings for any wear or damage. Repair
as necessary.
2. Inspect the torque rod for straightness, wear, or cracks. Replace as necessary.
3. Inspect the inner spacer plate, outer backup plates and frame rail for wear or damage.
Replace as necessary.

ASSEMBLY
1. If the inner spacer plates or outer backup plates are being serviced, install the 5⁄8" fasteners
through the inner spacer plates, frame rail, and outer backup plate, see Figure 8-35.
2. Prior to installing the transverse torque rod to the axle bracket, apply red Loctite to the taper
pin 5⁄8" bolt thread, see Figure 8-35.
3. Install the 11⁄4" taper pin through the torque rod axle bracket. Install fasteners, DO NOT tighten
at this time.
4. Install the transverse torque rod to the frame bracket, see Figure 8-35.
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5. Install the two (2) 5⁄8" fasteners through the torque rod bar pin and shims as per prior to
removal.
6. Install transverse torque rod frame bracket, spacer plate, and backup plate as per prior to
removal.
NOTE

Hendrickson recommends the using Grade 8 bolts and Grade C locknuts for all torque rod
attachments.
7. Prior to tightening torque rod fasteners ensure the vehicle is at the proper ride height, refer to
Ride Height in the Alignment & Adjustment section of this publication.
8. Tighten the taper pin to axle bracket at the 11⁄4" locknut to
9. Tighten the

5⁄8"

bolt head to torque rod to

200 ± 25 foot pounds torque.

75 ± 15 foot pounds torque.

5⁄8"

torque rod-to-frame mounting fasteners to 185 ± 25 foot pounds
10. Tighten the two (2)
torque and at the 5⁄8" bolt head to 200 ± 25 foot pounds torque, see Figure 8-35.
11. Check the lateral alignment, if not within the vehicle manufacturer’s specified range, a lateral alignment is necessary. Refer to the Lateral Alignment in the Alignment & Adjustments
section of this publication.
12. Remove the wheel chocks.

ULTRA ROD • ULTRA ROD PLUS
Torque Rod Bushings

Figure 8-36
Taper Pin Bushing

You will need
■■ A vertical press with a capacity of at least

10 tons

■■ Shop made receiving tool and installation /

removal tool, refer to the Special Tools section of
this publication for more information

Straddle Pin Bushing

■■ Funnel Tools, refer to the Special Tools section of this publication for more information
■■ ULTRA ROD, Tool Part No. 66086-001L
■■ ULTRA ROD PLUS, Tool Part No. 66086-000L

Disassembly
1. Remove torque rods as detailed in Torque Rod Disassembly instructions in this section.
DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE THE BUSHINGS FROM THE TORQUE ROD. THE
USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE ROD, HEAT CAN CHANGE THE
MATERIAL PROPERTIES. A component damaged in this manner can result in Adverse Vehicle
Handling and possible personal injury or property damage.

2. Support the torque rod end tube centered on the receiving tool. Be sure the torque rod is
squarely supported on the press bed for safe­ty.
3. Push directly on the straddle mount bar pin, until the top of the pin is level with the top of
torque rod end tube. Place the push out tool directly on top of the bar pin and press until the
bushing clears the torque rod end tube.
4. Remove the fasteners from the tapered bar pin bushing, and support the torque rod end on
the receiving tool with the tapered stud pointing up and the end tube centered on the tool. Be
sure the torque rod is squarely supported on the press bed for safety.
5. Push directly on the tapered stud until the bushing clears the torque rod end tube.

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Figure 8-37

Assembly
1. Clean and inspect the inner diameter of the
torque rod end tubes.
NOTE

DO NOT use paraffinic oil, or soap base lubricant.
Such lubricants can cause adverse reactions with
the bushing, such as deterioration of the rubber, causing premature failure. Use only a light
Naphthenic base oil, such as 60 SUS at 100°F.
2. Lubricate the inner diameter of the torque rod
end tubes and the new rubber bushings with a light Naphthenic base oil, such as 60 SUS at
100°F, see Figure 8-37.
3. Support the torque rod end tube centered on the receiving tool. Be sure the torque rod is
squarely supported on the press bed for safety. The straddle mount bar pin bushings must
have the mounting flats positioned at zero degrees to the shank of the torque rod, see
Figure 8-38.
Figure 8-38

4. Push directly on the straddle mount bar pin, or the tapered stud. The bushing must be centered within the end hubs of the torque rod.
■■ When pushing in the new rubber bushings, overshoot the desired final position by approx-

imately 3/16" (4.76 mm), see Figure 8-39

■■ Push the rubber bushing again from the opposite side to center the rubber bushing within

the end hub, see Figure 8-40

If the torque rod assembly is not allowed the allotted time for the lubricant to dissipate,
the bushing may slide from the torque rod end hub causing The bushing to be removed
and a new bushing re-installed.
Figure 8-39

Figure 8-40

5. Wipe off the excess lubricant. Allow the lubricant four hours to dissipate prior to operating
the vehicle.
6. Install the torque rod as detailed in the Torque Rod Assembly instructions in this section.

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Figure 8-41

XTRB Torque Rod Bushings
You Will Need
■■ A vertical press with a capacity of at least 10 tons
■■ Shop made receiving tool and installation / removal

tool, see the Special Tools section of this publication
for more information

DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE
THE BUSHINGS FROM THE TORQUE ROD. THE USE OF HEAT
WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE
ROD, HEAT CAN CHANGE THE MATERIAL PROPERTIES. A component damaged in this manner can
result in Adverse Vehicle Handling and possible personal injury or property damage.

Disassembly
1. Remove the torque rod(s) as detailed in Torque Rod
Disassembly instructions in this section.
Service hint

Figure 8-42
Mark the clocking position of the
bar pin flats with a paint stick
on the torque rod end hub

When servicing a straddle mount bar pin bushing assembly, mark the clocking position of the straddle mount bar
pin flats with a paint stick on the torque rod end hub prior
to disassembly, see Figure 8-42. This marking will serve as
a guide when installing the new bushing assembly so the
original clocking position can be retained.
2. Mark the clocking position of the straddle mount bar
pin flats with a paint stick on the torque rod end hub
prior to disassembly, see Figure 8-42.
3. Support the torque rod end hub centered on the receiving tool. Be sure the torque rod is squarely supported on
the press bed for safe­ty.
4. Push directly on the straddle mount bar pin, until the top of the bar pin is level with the top of
torque rod end hub, see Figure 8-43.
Figure 8-43

Figure 8-44

5. P l a c e t h e s h o p m a d e
removal tool on the bar pin
and press until the bushing
clears the torque rod hub,
see Figure 8-44.
6. Remove the fastener from
the tapered bar pin bushing, and support the torque
rod hub on the receiving
tool with the tapered stud
pointing down and the end
hub centered on the tool.
Be sure the torque rod is
squarely supported on the
press bed for safety.

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Assembly
1. Clean and inspect the inner diameter of the torque rod end hubs, see Figure 8-45.
Service Hint

DO NOT use a paraffinic oil, or soap base lubricant. Such lubricants can cause adverse reactions
with the bushing, causing premature failure.
2. Lubricate the inner diameter of the torque rod end hubs and the new bushings with NLGI#2 –
EP (Extreme Pressure) lithium base grease, see Figure 8-46.
3. Support the torque rod end hub centered on the receiving tool. Be sure the torque rod is
squarely supported on the press bed for safety.
4. Re-align the bar pin bushings to the mark made before removal as shown in Figure 8-42.
5. Using the shop made tool, place the installer tool on the bushing and press in. The bushing
must be centered within the hub of the torque rod.
Figure 8-45

Figure 8-46

Inspect and clean the inner
diameter of torque rod
end hubs

Apply NLGI #2-EP (Extreme Pressure)
lubricant to the inner diameter of torque
rod end hub and bushings

6. Wipe off the excess lubricant.
7. Install the torque rod as detailed in the Torque Rod Assembly instructions in this section.

Cross Tube
A cross tube seldom requires replacement, usually only when it has been bent, possibly due to
hitting an object. A bent cross tube may cause misalignment of the axles, and must be replaced
immediately to eliminate abnormal tire wear.
■■ Method 1 — Equalizing Beam Removal - Follow the Equalizing Beam component replace-

ment procedure in this section. Within the procedure, after removal of the equalizing beams
when the equalizing beams are separated, remove and replace cross tube.

■■ Method 2 — Center Bushing End Plug Removal

You will need
■■ Center Bushing End Plug (see Parts Lists section)
■■ Cutting Torch
■■ Welding Equipment
■■ Hole Saw

Disassembly
1. Use a work bay with a level surface.
2. Chock the front steer axle wheels.
3. Use a cutting torch to make two cuts in the cross tube, see Figure 8-47.
4. Remove the cut section of the cross tube and slide the remaining sections out of the center
bushings and discard.
5. Use a 2½" hole saw and remove only one (1) center bushing end plug from the suspension.
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Figure 8-47

Follow the safety guidelines for operating the torch. Use caution as parts may
be hot.
Figure 8-48

Assembly
1. Clean the open end of the
center bushing bore to
approximately 1" (25.4 mm)
depth of weld and debris.
2. From the open center bushing slide the new cross tube
into both center bushings.
3. It may be necessary to use
a floor jack under one (1)
or both equalizing beams to
align the cross tube.
4. Position the end plug ¼" (6.35 mm) recessed in the center bushings and tack weld, see
Figure 8-48.
5. Check end plug position, final weld shall be a ¼" (6.35 mm) fillet.

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SECTION 9

AR2 Conversion from RT•RTE
This section is only for the conversion from a Hendrickson RT•RTE rear suspension [52" or 54"
(1,321 mm or 1,372 mm) axle spacing, with a 9½" or 10½" (241 mm or 267 mm) ride height] to
AR2. All other conversions to AR2 will require approval from Hendrickson Engineering.
Prior to removal of the existing RT•RTE suspension, all the following inspection and measurements need to be checked and recorded. The truck must be on a level surface prior to making
any measurements:
■■ Check and record rear suspension ride height (Bottom of frame to axle centerline)
■■ Check and record drive axle pinion angles
■■ Mark existing suspension centerline on frame
■■ Verify the total vehicle alignment is within specification
■■ Verify the lateral alignment is within specification
■■ Check for irregular tire wear
■■ Road test (Note any unusual noise or vibration)

Peripheral Components
A complete inspection of the equalizing beams, torque rods, and frame rails and peripheral components should be performed prior to suspension removal. If any of these components are found
to be worn it will be necessary to replace them. Check for any driveline or axle interference on the
vehicle chassis prior to suspension removal. Verify that the axle stops are installed by the vehicle
manufacturer and in good condition. If the vehicle is not equipped with axle stops contact the
vehicle manufacturer for the correct amount of articulation allowed for the rear suspension. After AR2
installation is complete, check for proper clearance with all suspension and chassis components.

FASTENERS
Hendrickson recommends when servicing the vehicle, replace all removed fasteners with new
equivalent fasteners. Maintain correct torque values as specified. See Hendrickson’s Torque
Specifications section of this publication. If non-Hendrickson fasteners are used, follow torque
specifications listed in the vehicle manufacturer’s service manual.

Equalizing Beams
If the equalizing beams are equipped with bronze center bushings it will be necessary to replace
them with rubber center bushings.
If the equalizing beam inspection requires the replacement of the bar pin style end bushings
equipped with alignment shims it is recommended that replacement bar pin alignment shims be
installed in the neutral position prior to the equalizing beam installation. This should position the
axles square to the centerline of the vehicle prior to alignment.
All pre-existing components that are to be re-used for the AR2 installation must be replaced if
they are not in serviceable condition. An installation drawing of the AR2 suspension is normally
supplied with a AR2 suspension kit. Installers should ensure that they have the correct assembly
drawing for the vehicle to which the AR2 is to be installed, questions can be addressed by contacting Hendrickson Engineering at 630-910-2800.

Cross member
Hendrickson requires an RT•RTE cross member (not supplied by Hendrickson) be used on all AR2
installations. To obtain the correct cross member, contact the vehicle manufacturer.
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Longitudinal and TRANSVERSE TORQUE RODS
Refer to Preventive Maintenance section in this publication for complete longitudinal and transverse torque rod inspection.

Vehicle Preparation and Suspension Removal
Disassembly
1. Chock the front wheels.
2. Lift and support the frame.
3. Lift and support the axles.
4. Remove the tires.
SERVICE HINT

It is recommended that the suspension is at full rebound before installing the jack stands. This will
provide maximum clearance for removal and installation of suspension components.

Service hint

If the is equipped with a fifth wheel, to ease in AR2 installation it may be necessary to remove the
fifth wheel and re-install after AR2 suspension installation is completed.
5. Mark the centerline of the old suspension on both sides of the frame.
6. Disconnect and remove the old suspension. Leave the walking beams installed, unless being
re-bushed.

Preparation and inspection of Suspension
1. Clean the frame rail from rust and debris.
2. Inspect the frame rail for any cracks or damage. Repair or replace as necessary.
3. Reference the schematic and lay out holes on the frame. Typically all holes are referenced
from the centerline of the front hanger, see Figure 9-1. If equipped with a non RT•RTE suspensions, the holes will be referenced from the centerline of the cross member.
Note

Prior to drilling any holes in the frame or cross member gusset it is recommended that the height
control valve and linkage be fitted for proper location within the confines of the chassis.

Figure 9-1

AR2 Conversion from RT•RTE

64

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Figure 9-2

Note

Figure 9-3

Hendrickson requires an RT•RTE cross member be used on all AR2 installations.
4. Replace the cross member with the RT•RTE cross member and if needed, install spacers
(not supplied by Hendrickson) between the frame flange and the bottom of the hanger, see
Figure 9-3.
5. Recheck measurements.
6. Center punch and drill holes in the frame.
7. Remove any burrs or shavings on the new holes.
8. Hendrickson recommends to paint the frame rails to inhibit rust prior to installation of the AR2
suspension components.
Figure 9-4

Height Control Valve
and Linkage
SERVICE HINT

Prior to drilling any holes in the
frame or cross member gusset, it
is recommended that the height
control valve and linkage be fitted for
proper location within the confines
of the chassis.

Assembly
NOTE

It may be necessary to modify the
height control valve mounting
bracket to mount on the cross member gusset.
1. The bracket can be modified by
straightening one of the bent
legs on the bracket to form an
“L” shaped bracket rather than a “Z” shaped bracket.
2. The chosen height control bracket location on the chassis requires that the leveling valve arm
face the rear of the truck.

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