EQUALIZING BEAM END BUSHINGS
■■

Bar Pin Style

You will need:
■■ A shop press with a capacity of at least 100 tons
■■ End bushing service kit, refer to the Parts List Section of this publication.
■■ End bushing tools – Receiving Tool No. 66086-111, Installation Tool No. 66086‑106 and

Removal Tool No. 66086-109, see Special Tools Section of this publication.

DISASSEMBLY
WHEN REMOVING AND INSTALLING BUSHINGS IN THE EQUALIZING BEAMS, FOLLOW THE PROCEDURES
OUTLINED IN THIS PUBLICATION. DO NOT USE A CUTTING TORCH TO REMOVE THE BUSHING OUTER
METALS PRESSED IN THE BEAM BORES OR FASTENERS. WELDING, TORCHING OR ATTACHING MATERIAL
TO THE EQUALIZING BEAM MUST NEVER BE PERFORMED. THE USE OF HEAT CAN ADVERSELY AFFECT
THE STRENGTH OF THE EQUALIZING BEAMS AND CAN CAUSE DAMAGE TO THE EQUALIZING BEAM
ASSEMBLY, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.
DISCARD USED FASTENERS. ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR. FAILURE TO DO SO
COULD RESULT IN FAILURE OF THE PART OR MATING PARTS, ADVERSE VEHICLE HANDLING, PERSONAL
INJURY, OR PROPERTY DAMAGE.

NOTE

Hendrickson recommends the use of Grade 8 bolts, hardened washers, and Class C locknuts.
Hardened washers are not necessary when flange head fasteners are used.

NOTE

Whenever an equalizing beam is removed for repair or inspection of the equalizing beam end
connection reveals movement, measure the distance between the axle bracket legs for correct
width. Refer to Axle Bracket in Preventive Maintenance Section of this publication for measurement
location and dimensions. An axle bracket outside of the measurement range must be repaired or
replaced. Consult the vehicle manufacturer for inspection, component repair and replacement
instructions.
1. Remove equalizing beam assembly from vehicle as detailed in the equalizing beam disassembly instructions in this section.
FIGURE 8-29

2. Place the equalizing beam in the shop press with the
beam end hub squarely supported on the receiving
tool (Part No. 66086-111) or press bed.
3. Prior to removal, mark the orientation of the bar pin
flats on the equalizing beam with a paint stick, see
Figure 8-29.

Bar Pin
Flat
Inner
Metal

4. Support the beam end hub with it centered on the
receiving tool. Be sure the equalizing beam is squarely
supported on the press bed for safe­ty.
5. Press on the end bushing inner metal, see Figure 8-29,
of the end bushing until the inner metal is flush with
the top of the equalizing beam end hub.This will move
the bushing rubber away from the outer metal of the
bushing so the removal tool (Part No. 66086-109)
can be installed.

Mark the location of the bar pin flats
with a paint stick on the equalizing
beam end hub

6. Center the bushing removal tool directly on the bushing’s outer metal and press the bushing out of the equalizing beam end hub.

Component Replacement

44

17730-299

ULTIMAAX® for Fire and Rescue Vehicles
INSPECTION
After removing the bar pin end bushings, thoroughly inspect the beam bores. If the equalizing
beam is damaged from end bushing removal, replacement of the equalizing beam is required,
replace with a new equalizing beam. DO NOT attempt re-bush or use an equalizing beam that
has been damaged.
FAILURE TO REPLACE AN EQUALIZING BEAM THAT HAS BEEN DAMAGED FROM BUSHING REMOVAL
CAN RESULT IN THE FAILURE OF THAT BEAM, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL
INJURY OR PROPERTY DAMAGE.

1. Clean the bores of the equalizing beams with emery cloth or ball hone, removing any nicks or
metal buildup from bushing removal.
2. Measure the equalizing beam end hub bore inner
diameter.The Hendrickson specification for the equalizing beam end hub bore diameter is 4.621" ± 0.004"
(117.38 mm ± 0.10 mm), and is taken as the mean
of any two readings 90° apart in the same plane, see
Figure 8-30. If it is NOT within the specified range,
replacement is required.

ASSEMBLY
NOTE

FIGURE 8-30
Equalizing Beam
End Hub Bore Diameter

Equalizing
Beam

4.617" / 4.625"
(117.28 mm / 117.48 mm)

Always use the bushing outer metal for pressing operations. Pressing on the bushings inner metal
may damage the bushing and require bushing replacement.
FIGURE 8-31

1. The equalizing beam bore may
have a more substantial lead in
chamfer at one end of the bore
than the other. Take advantage of
the larger chamfer by pressing in
the new end bushing from this end.
2. Lubricate the equalizing beam
end hub inside bore and the bar
pin end bushing outer sleeve with
a NLGI #2 – EP (Extreme Pressure)
grease.

End Bushing
Installation Tool
Part No.
66086-106

3. Place the equalizing beam in
a shop press with the end hub,
End Bushing
squarely supported on the receivReceiving
Tool
ing tool, see Figure 8-31.
4. Position and align the end bushing to the mark made before
removal as shown in Figure 8-29.
NOTE

Part No.
66086-111

Equalizing
Beam

The end bushing must be square with
the equalizing beam end hub before pressing the end bushing into the beam. End bushings
pressed in at an angle will damage the end bushing and the equalizing beam.
CARE MUST BE TAKEN DURING THE INSTALLATION OF THE BUSHING. DO NOT PUSH ON THE INNER
METAL OF THE BUSHING, DOING SO WILL CAUSE DAMAGE TO THE BUSHING AND VOID WARRANTY.

NOTE

Always use the bushing outer metal for pressing operations. Pressing on the bushings inner metal
may damage the bushing and require bushing replacement.
5. Place the end bushing installation tool on the end hub.

17730-299

45

Component Replacement

ULTIMAAX® for Fire and Rescue Vehicles
6. The through hole in the tool can help align the bar pin flats due to lack of visibility. Place a bolt
with enough length to go through the tool and the bar pin hole, see Figure 8-32.
7. With the tools align, press in the end bushing, see Figure 8-31.
8. The end bushing must be centered within the hub of the equalizing beam, see Figure 8-33.
9. Install the equalizing beam assembly into vehicle as detailed in equalizing beam assembly
in this section.
FIGURE 8-32

FIGURE 8-33
Bar Pin

66086-106
End Bushing Installation Tool

Equalizing Beam
End Hub
Outer metal is
centered in the
equalizing beam
end hub

Through hole can be used to
help align the bar pin ats due
to lack of visibility.
Place a bolt through the tool
and bar pin hole.

FIGURE 8-34
■■

Adapter Style

YOU WILL NEED:
■■ A shop press with a capacity of at least 100

tons

■■ Air hammer / chisel / Bent chisel, see

Figure 8-34

■■ Hendrickson Tool No. 66086-101 (OTC Part

No. 1763), see Special Tools Section of this publication

DISASSEMBLY
NOTE

It is recommended that a penetrating oil be applied to all beam end connections.
1. Remove the cotter pins, slotted nuts and end bushing adapter tube, see Figure 8-35.
2. The beam end adapters have two chisel recesses located in their flanges as shown in
Figure 8-36.
3. Locate the recess for the chisel, rotate the adapter if necessary. Place the air hammer/chisel
in the recess.
4. If the adapter does not turn, use a hammer to rap the outside of the axle bracket legs around
the adapter area and repeat with the air hammer chisel.
5. Support the end of the equalizing beam as it may drop when the other adapter is removed.
6. Remove remaining adapters.
FIGURE 8-35

FIGURE 8-36
Beam End
Adapter

Chisel
Recess

Adapter
Flat Side
Vertical

Chisel Recess

Component Replacement

46

17730-299

ULTIMAAX® for Fire and Rescue Vehicles
7. When the adapter has enough clearance between the axle bracket and the adapter flange,
use a bent chisel as shown in Figure 8-34 to wedge and force the adapter out.
THE ADAPTER REMOVAL PROCESS CAN CAUSE DAMAGE. REUSE OF DAMAGED OR WORN ADAPTERS
COULD RESULT IN A COMPONENT FAILURE LEADING TO ADVERSE VEHICLE HANDLING AND POSSIBLE
PERSONAL INJURY.

NOTE

Due to the process necessary to remove the adapters, the adapter can be subjected to damage.
DO NOT reuse worn or damaged adapters. Replace as necessary.
8. Remove the equalizing beam assembly from vehicle as detailed in the Equalizing Beam
Disassembly instructions in this section.
9. Position the equalizing beam in the shop press and align the End Bushing Removal /
Replacement Adapter with the tapered end facing the bushing to be removed, see Figure 8-37.
CHECK TO INSURE PROPER ALIGNMENT OF TOOLING ADAPTERS WITH EQUALIZING BEAM
COMPONENTS BEFORE APPLYING FULL HYDRAULIC PRESSURE WITH A SHOP PRESS.

10. Apply hydraulic force and push out the old bushing.
FIGURE 8-37

FIGURE 8-38

END BUSHING INSTALLATION

END BUSHING REMOVAL
End Bushing
Removal / Replacement
Adapter Tool
Part No. 66086-101

End Bushing
Removal / Replacement
Adapter Tool
Part No. 66086-101

End
Bushing

Clamp

End
Bushing
Equalizing Beam

Equalizing Beam

Receiver

ASSEMBLY

FIGURE 8-39

1. Clean the end bushing bore with a cylinder
ball hone or emery paper. Clean any debris.
2. Lubricate the equalizing beam bore and
the equalizing beam center bushing outer
metal sleeve with an NLGI#2 – EP (Extreme
Pressure) grease, see Figure 8-39.
3. Position the end bushing removal / replacement adapter, with the tapered end facing
away from the new bushing, onto the clamp,
see Figure 8-38.
4. Wrench tighten the clamp onto the bushing
and the adapter as shown in Figure 8-38.

Adapter Style
End Bushing

Equalizing Beam
End Hub

Outer Metal

Equalizing
Beam

NOTE
Lubricate the inside diameter of END HUB and
the end bushing OUTER METAL with NLGI#2-EP
(Extreme Pressure) lithium base grease

ENSURE PROPER ALIGNMENT OF TOOLING ADAPTERS WITH EQUALIZING BEAM COMPONENTS BEFORE
APPLYING FULL HYDRAULIC PRESSURE WITH A SHOP PRESS.

17730-299

47

Component Replacement

ULTIMAAX® for Fire and Rescue Vehicles
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. Install one adapter through the axle bracket leg at the wheel side, into the beam end bushing,
see Figure 8-40.
FIGURE 8-40

FIGURE 8-41

7. 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.

Axle Bracket

8. Insert adapter connections, see Figure 8-41.
9. Rotate the adapters so the adapter cut off flats
are vertical as shown in Figure 8-41.
NOTE

Axles must be in operational position before fasteners are tightened to prevent pre-loading of the rubber
bushing.

Adapter
Equalizing
Beam

Chisel Reliefs

Adapter
Flat Side
Vertical

10. Assemble one slotted nut to the shaft and install the cotter pin. Place a suitable wrench on the
nut and ensure the wrench is locked in place (braced) to prevent movement. Tighten using
one of the following torque procedure.

TORQUE PROCEDURE
IF THE RECOMMENDED TORQUE VALUE IS 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.

A simple torque wrench will not be sufficient to obtain the proper torque requirement. The proper
torque requirement can be obtained with the use of a torque multiplier. If one is not available the
use of a slug wrench is recommended.

METHOD A: TORQUE MULTIPLIER
You will need:
■■ Torque Multiplier

a. Assemble the opposite nut and use a torque wrench with multiplier.
b. Tighten the nut to torque multiplier value 700 ± 50 Foot Pounds torque, see Table 1.
DO NOT BACK OFF NUT TO INSTALL COTTER PIN, DOING SO MAY REDUCE THE TIGHTENING TORQUE
BELOW THE REQUIRED SPECIFICATION.

c. Install cotter pin. The nut may be advanced to the next nut slot. DO NOT back off nut.

Component Replacement

48

17730-299

ULTIMAAX® for Fire and Rescue Vehicles
METHOD B: SLUG WRENCH
You will need:
■■ Two slug wrenches (see Figure 8-42)
■■ 4 pound hammer
FIGURE 8-42
¾"

TABLE 1

TORQUE SPECIFICATIONS

14¾"

SLUG WRENCH METHOD
1

/16" R

1

/8" R

5"

TORQUE
MULTIPLIER

⁄4 or
90º turn 700 ± 50 Foot
on castle
Pounds
nut
1

2"

125 Foot
Pounds

2½"
13

2 /16"
Min. Hex 12 Point

a. Assemble the opposite nut and
using a torque wrench, tighten
the nut to the initial torque
value shown in Table 1.
b. Remove torque wrench and
replace with the Slug Wrench.
Using a four pound hammer,
tighten the assembly by hitting the slug wrench near the
handle as shown in Figure 8-43
until the nut has been turned to
the degrees specified in Table 1.

FIGURE 8-43
Axle

Axle Bracket Legs

Equalizing Beam
End Hub

Slug Wrench
4 lb. Hammer

Locked in Place
(Braced)

DO NOT BACK OFF NUT TO INSTALL COTTER PIN, DOING SO MAY REDUCE THE TIGHTENING TORQUE
BELOW THE REQUIRED SPECIFICATION.
REPEATED HAMMERING BEYOND THE DEGREE SPECIFIED CAN CAUSE COMPONENT DAMAGE.

c. Install cotter pin. The nut may be advanced to the next nut slot, DO NOT back off nut.
INSUFFICIENT TIGHTENING TORQUES CAN CAUSE PREMATURE WEAR AND DAMAGE TO THE AXLE
BRACKET LEGS, HOLES AND/OR BEAM END CONNECTION COMPONENTS, THIS CAN FURTHER CAUSE
FAILURE AND SEPARATION OF COMPONENTS, AND RESULT IN ADVERSE VEHICLE HANDLING, SEVERE
PERSONAL INJURY OR DEATH. MAINTAIN PROPER TIGHTENING TORQUES AT ALL TIMES.

17730-299

49

Component Replacement

ULTIMAAX® for Fire and Rescue Vehicles
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 A Equalizing Beam Removal Method - Follow the steps in the Equalizing Beam
Component Replacement 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 B Center Bushing End Plug Removal

You will need:
■■
■■
■■
■■

Cross Tube Service Kit 60961-759 (see Parts Lists Section)
Cutting Torch
Welding Equipment
Hole Saw

DISASSEMBLY
1. Use a work bay with a level on a flat surface.
2. Chock the front steer axle wheels.
FOLLOW THE SAFETY GUIDELINES FOR OPERATING THE TORCH. USE CAUTION AS PARTS MAY BE HOT.

3. Using a cutting torch, make two cuts in the cross tube, see Figure 8-44.
4. Remove the cut section of the cross tube, slide each remaining section of the cross tube and
discard.
5. Use a 2" hole saw and remove only one center bushing end plug from the suspension.
FIGURE 8-44

ASSEMBLY
1. Clean the open end of the center bushing bore to approximately 1" 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 or both equalizing beams to align the cross
tube.

Component Replacement

50

17730-299

ULTIMAAX® for Fire and Rescue Vehicles
FIGURE 8-45

4. Position the end plug ¼" recessed in the center bushings and tack weld, see Figure 8-45.
5. Check end plug position, final weld shall be a ¼" fillet, see Figure 8-45.

TORQUE RODS
THE ULTIMAAX SUSPENSION INCORPORATES BOTH LONGINTUDINAL AND TRANSVERSE 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
AND POSSIBLE TIRE CONTACT WITH THE FRAME OR THE SUSPENSION.
FIGURE 8-46

■■

LONGITUDINAL TORQUE RODS

DISASSEMBLY
1. Chock the front wheels of the vehicle.
SERVICE HINT

To remove all the load from the longitudinal torque rod, raise or lower the pinion as needed. This
will ease the removal of the longitudinal torque rod.
2. Support the pinion on the axle being serviced.

NOTE

Prior to disassembly of the longitudinal torque rod, 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, see Figure 8-46.
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 rod, see Figure 8-46.

17730-299

51

Component Replacement

ULTIMAAX® for Fire and Rescue Vehicles
ASSEMBLY
1. Install longitudinal torque rod.
2. Install the fasteners and any shims that were removed to the cross member and 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 axle bracket depending on the direction of adjustment needed. Contact
the vehicle manufacturer for proper pinion angle specifications.
5. Remove wheel chocks.
■■

TRANSVERSE TORQUE RODS

DISASSEMBLY
1. Chock the front 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 the torque rod mounting fasteners.
3. Remove the transverse torque rod, see Figure 8-46.
4. Inspect the mounting surfaces for any wear or damage. Repair or replace as necessary.

ASSEMBLY