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9. If the vehicle is equipped with the shock absorbers attached to the top axle wrap, it will be
necessary to remove the lower shock absorber mounting locknuts and washers. Remove the
shock absorbers from the lower mounting bolts and push clear of spring assembly.
THE REPAIR OR RECONDITIONING OF SUSPENSION OR AXLE COMPONENTS IS NOT ALLOWED.
HENDRICKSON ADVISES REPLACING ALL COMPONENTS FOUND TO BE DAMAGED OR OUT OF
SPECIFICATIONS. ALL MAJOR HENDRICKSON COMPONENTS ARE HEAT TREATED AND TEMPERED.
SOFTEK COMPONENTS CANNOT BE BENT, WELDED, HEATED, OR REPAIRED WITHOUT REDUCING THE
STRENGTH OR LIFE OF THE COMPONENT. FAILURE TO FOLLOW THESE GUIDELINES CAN CAUSE LOSS
OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR DEATH OR PROPERTY DAMAGE AND WILL
VOID APPLICABLE WARRANTIES.

SERVICE HINT

If a clamp group nut fails to come off bolt, cut half way through the bolt with an abrasive cut off
wheel, taking care not to contact axle beam or other components. Using an impact wrench, spin
the locknut to fracture the bolt and remove.
10. Remove the ¾" clamp group U-bolts / hex bolts, washers, and locknuts. Discard fasteners.
11. Lower the axle and remove from the vehicle.
FIGURE 9-13

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STEERTEK AXLE (REMOVED FROM CHASSIS)

FIGURE 9-14

CLAMP GROUP DISASSEMBLY
1. Remove the bottom axle wrap and liner from the axle.
2. Strike the top axle wrap with a dead blow mallet at the
front and rear on the underside of the axle wrap to dislodge it from the axle, see Figure 9-14.
3. After removal of the top axle wrap from the axle inspect
for cracks or fretting.
4. Remove the tie rod assembly, see Tie Rod Disassembly in this section.
REMOVAL OF THE CAP SCREWS WILL ALLOW THE STEERING KNUCKLE TO SEPARATE FROM THE AXLE. THE
BACKBONE MUST BE SUPPORTED BEFORE REMOVAL OF THESE TWO (2) CAP SCREWS. FAILURE TO DO SO
CAN CAUSE COMPONENT DAMAGE OR PERSONAL INJURY.

5. Remove the two (2) 5⁄8" socket head cap screws from the steering knuckle assembly.
6. Remove the steering knuckle, thrust bearing, and shims (if equipped).
7. After complete removal of the one side, repeat Steps 1-6 for the opposite side of the axle.
8. Inspect the steering kingpin bushings for excessive wear. If worn, replace the kingpin bushings
and seals. See the Kingpin Bushing replacement instructions in this section.
FIGURE 9-15

CLAMP GROUP ASSEMBLY
1. Install the new top axle wrap liner on the axle.
Index the liner with the axle’s guide pin, see
Figure 9-15.
DO NOT STRIKE THE TOP AXLE WRAP WITH A HAMMER.
DAMAGE TO THE ALUMINUM AXLE WRAP WILL OCCUR.
USE A PLASTIC DEAD BLOW MALLET WITH CARE
WHEN INSTALLING THE AXLE WRAP.
SECURELY INSTALL THE TOP WRAP TO THE AXLE. FAILURE
TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL,
PERSONAL INJURY OR PROPERTY DAMAGE.

SERVICE HINT

Apply a lubricant (such as an aerosol silicone)
to the outer surface of the plastic liner to aid in
assembly of the top axle wrap.
2. Install the top axle wrap, see Axle Wrap
Assembly instructions located in this section.
The axle wrap must be aligned with the guide
pin on the axle.
3. At this point in the assembly, DO NOT install anything further on the axle.

AXLE INSTALLATION
1. Place the new axle on the floor jack and position the axle under the vehicle.
2. Install the axle spacer on the top axle wrap prior to raising the axle into position.
3. Raise the axle into position, see Figure 9-16. Care must be taken at this point to ensure that
the front leaf spring assemblies’ center bolt is aligned correctly in the top axle wrap.
4. Verify that the galvanized liner is between the leaf springs and the top pad.
5. Install the new bottom axle wrap liners on the bottom axle wraps.

Component Replacement

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SOFTEK® for Lion Bus
FIGURE 9-16

6. Install the bottom axle wraps on the axle.
7. Install the top pad with the directional identification facing correctly on the vehicle, see
Figure 9-17.
8. Install the new ¾" clamp group U-bolts / hex
bolts, washers and locknuts. Snug the bolts,
DO NOT tighten to the specified torque at
this time.
9. Ensure that the clamp groups are properly
aligned and the bolts are seated in the top
pad, and the bottom axle wraps are centered
on the top axle wraps, see Figure 9-18.
10. Install the lower shock absorber connection
(if removed) from the inboard side to the
outboard side. Install the lower shock absorber fasteners and tighten to
pounds torque.

130 ± 5 foot

FIGURE 9-17

11. Install the steering knuckles as per the Steering Knuckle replacement instructions in this section.
12. Install the tie rod assembly as per the Tie Rod replacement instructions in this section.
13. Install the 7⁄8" hardened washers on the lower steering knuckles
(Ackermann arms) and the castle nuts. Tighten the castle nuts to
185 foot pounds, then rotate until the first castle slot lines up with
the cotter pin bore in the tie rod end. DO NOT back off the nut for cotter pin installation.
FIGURE 9-18

14. Install the tie rod end cotter pins.
15. Connect the drag link. Install the castle nut. Tighten the castle nut
to 185 foot pounds, then rotate until the first castle slot lines up
with the cotter pin bore in the drag link. DO NOT back off the nut for
cotter pin installation.
16. Install the drag link cotter pin.
17. Install the brake backing plate assemblies.
18. Install the brakes, hubs, and wheels as per manufacturer’s
guidelines.
19. Fill the hubs with the proper lubricant (see manufacturer’s guidelines for recommended lubrication specifications).
20. Raise the vehicle and remove the frame stands.
21. Lower the vehicle.
FIGURE 9-19

22. Tighten the ¾" clamp group locknuts evenly in 50 foot pounds increments to 293 ± 12 foot pounds torque in the proper sequence to
achieve uniform bolt tension, see Figure 9-19.
23. Grease the front steering components as per lubrication guidelines in
the Preventive Maintenance Section of this publication.
24. Remove the wheel chocks.

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STEERING KNUCKLE
STEERING KNUCKLE DISASSEMBLY
NOTE

See tools needed to remove and install kingpin bushing under Special Tools Section of this
publication.
The steering knuckle disassembly and assembly includes the Kingpin Preparation and
Measurement and Kingpin Bushing Removal process.
1. Place the vehicle on level floor.
2. Chock the wheels.
3. Support the vehicle with jack stands on the axle.
4. Remove the wheel and hub assembly.
5. Remove the brake components from steering knuckle.
6. Remove the tie rod assembly.
7. Remove the drag link from the knuckle if necessary.
FIGURE 9-20

SERVICE HINT

Lightly tap the side of the lower steering knuckle
(Ackermann arm) with a mallet to separate the tie
rod end from the Ackermann arm, see Figure 9-20.
REMOVAL OF THE CAP SCREWS WILL ALLOW THE
STEERING KNUCKLE TO SEPARATE FROM THE AXLE.THE
STEERING KNUCKLE MUST BE SUPPORTED BEFORE
REMOVAL OF THESE TWO (2) CAP SCREWS. FAILURE
TO DO SO CAN CAUSE COMPONENT DAMAGE OR
PERSONAL INJURY.

FIGURE 9-21

8. Remove the two (2) socket head cap screws
that connect upper kingpin connection to the
steering knuckle, see Figure 9-21.
9. Remove the lower steering knuckle from the
kingpin by sliding it down the kingpin.
10. Remove the upper steering knuckle by sliding
it up off the kingpin.

KINGPIN PREPARATION AND MEASUREMENT
TO HELP PREVENT SERIOUS EYE INJURY, ALWAYS WEAR PROPER EYE PROTECTION WHEN YOU
PERFORM VEHICLE MAINTENANCE OR SERVICE.
SOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS AND CAUSE BURNS. TO HELP AVOID SERIOUS
PERSONAL INJURY, CAREFULLY FOLLOW THE MANUFACTURER’S PRODUCT INSTRUCTIONS AND
GUIDELINES AND THE FOLLOWING PROCEDURES:
■■
■■
■■
■■

■■

Component Replacement

WEAR PROPER EYE PROTECTION.
WEAR CLOTHING THAT PROTECTS YOUR SKIN.
WORK IN A WELL VENTILATED AREA.
DO NOT USE GASOLINE, SOLVENTS OR OTHER MATERIALS THAT CONTAIN GASOLINE THAT CAN
EXPLODE.
HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY. FOLLOW THE
MANUFACTURER’S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY TO HELP
PREVENT PERSONAL ACCIDENT OR INJURY.
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SOFTEK® for Lion Bus
DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR
POLISHED PARTS. DAMAGE TO THE PARTS WILL RESULT.
■■

Cleaning Ground and Polished Parts
●●

●●

Use a cleaning solvent to clean ground or polished parts and surfaces. DO NOT USE
GASOLINE.
DO NOT clean ground or polished parts in a hot solution tank or with water, steam, or
alkaline solutions. These solutions will cause corrosion of the parts.

DRYING THE CLEANED PARTS
■■

Parts must be dried immediately after cleaning. Dry the parts with clean paper towels, clean
rags, or compressed air. DO NOT dry bearings by spinning with compressed air. Damage to
the bearings will result.

PREVENTING CORROSION ON CLEANED PARTS
■■

Apply a light coating of oil to all cleaned and dried parts that are going to be reused. DO NOT
apply oil to the brake lining or the brake drums. If parts are to be stored, apply an effective rust
inhibitor to all surfaces.

STEERTEK IS A UNIQUE AXLE, IN THAT THE KINGPIN IS CRYOGENICALLY INSTALLED IN THE AXLE. THE
KINGPIN IS A NON-REPLACEABLE COMPONENT OF THE AXLE ASSEMBLY. DO NOT TRY TO REMOVE THE
KINGPIN. IF THE KINGPIN SHOWS SIGNS OF MOVEMENT, CONTACT THE HENDRICKSON TECHNICAL
SERVICES DEPARTMENT.

1. Prepare and polish the kingpin by removing all grease and excess debris using a fine grit (220
grit or higher) emery cloth and parts solvent, see Figures 9-22 through 9-25.
FIGURE 9-22

FIGURE 9-23

FIGURE 9-24

FIGURE 9-25

2. Inspect the kingpin for wear or damage. Use a micrometer and measure the upper and lower kingpin in two locations. Positions must be 90º opposed from each other. If the kingpin has less than
1.802" diameter, replacement of the axle is necessary, see Figures 9-26 through 9-29.
Kingpin minimum dimension is 1.802"

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FIGURE 9-26

FIGURE 9-27

FIGURE 9-28

FIGURE 9-29

KINGPIN BUSHING
You will need:
■■

A hydraulic shop press with a minimum forcing capacity of 2.5 tons (or an arbor press) or
optional method - use hand tools.

■■

Adjustable Straight Flute Reamer with a cutting diameter must facilitate a range of
1.802" - 1.812"

Refer to the Special Tools Section of this publication for the following shop made tools:

FIGURE 9-30

Component Replacement

■■

Kingpin Bushing Driver Tool

■■

Kingpin Bushing Receiving Tool (for shop press method)

■■

Kingpin Handle, Bushing Driver Installer / Remover and Seal Driver Installer Tool
FIGURE 9-31

FIGURE 9-32

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SOFTEK® for Lion Bus
REMOVAL
1. Remove the retaining ring for the grease cap.
NOTE

If a shop press is not available to remove and install the kingpin bushings, an acceptable optional
method is to use a hammer along with the shop made tools (Kingpin Bushing Drivers and Seal
Driver Tools) on a work bench.
BEFORE APPLYING HYDRAULIC PRESSURE TO ANY TOOLING SET-UP, ALWAYS CHECK TO ENSURE THE
PRESS PLATE, ADAPTERS, AND COMPONENTS BEING WORKED ON ARE POSITIONED PROPERLY, I.E.
“IN LINE” WITH THE RAM OF THE PRESS. IMPROPER POSITIONING CAN CAUSE PERSONAL INJURY OR
COMPONENT DAMAGE.

2. Ensure that each part of the steering knuckle assembly is squarely supported on the Receiving
Tool before applying hydraulic pressure to press out the kingpin bushings (see Special Tools
Section of this publication), see Figures 9-31 and 9-32.
3. Remove the grease zerk in the grease cap.
4. Place the upper steering knuckle in the press with the grease cap side (non machined side)
facing up. Use the Kingpin Bushing Installer / Remover Tool and Kingpin Handle to press out
the grease cap, kingpin bushing and seal, see Figure 9-31.
BEFORE APPLYING HYDRAULIC PRESSURE TO REMOVE OR INSTALL THE KINGPIN BUSHING, SUPPORT
THE LOWER STEERING KNUCKLE AS SHOWN IN FIGURE 9-32. IMPROPER SUPPORT TO THE STEERING
KNUCKLES CAN CAUSE COMPONENT DAMAGE.

5. Use the same procedure to remove the kingpin bushing in the the lower steering knuckle.
Place the lower steering knuckle upside down in press. Be sure to support the lower steering
knuckle assembly so that it sits in-line with the press, see Figure 9-32.
FIGURE 9-33

6. Clean the parts and inspect for reassembly,
see Figure 9-33.

STEERING KNUCKLE BORE MEASUREMENT
Complete the following steering knuckle bore
inspection and the measurement instructions
prior to installing the kingpin bushing.
1. Measure the upper knuckle bore inside diameter at two locations. Always use a an inside
micrometer or a telescoping gauge when taking a knuckle bore measurement. Some out-of-roundness at the top and bottom of the bore
edges is acceptable. Steering knuckle bore diameter is 1.938" ± 0.003".
2. Measure the upper and lower bore in two positions and at two locations.The two positions must be
90º opposed from each other, see Figures 9-34 through 9-36. If the average measurement is more
than the knuckle bore maximum diameter specification, replace the knuckle.
FIGURE 9-34

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FIGURE 9-35

49

FIGURE 9-36

Component Replacement

SOFTEK® for Lion Bus
INSTALLATION
BEFORE APPLYING HYDRAULIC PRESSURE TO ANY TOOLING SET-UP, ALWAYS CHECK TO ENSURE THE
PRESS PLATE, ADAPTERS, AND COMPONENTS BEING WORKED ON ARE POSITIONED PROPERLY, I.E.
“IN LINE” WITH THE RAM OF THE PRESS. IMPROPER POSITIONING CAN CAUSE PERSONAL INJURY OR
COMPONENT DAMAGE.

1. Install the lower or upper steering knuckle in the press. Ensure that each part of the steering
knuckle assembly is squarely supported on the Receiving Tool before applying hydraulic pressure to press in the kingpin bushings.
2. Always install the kingpin bushing from the machined side (axle side) of the lower steering
knuckle using the Kingpin Bushing Driver to install kingpin bushing (see tool specifications in
the Special Tools Section of this publication), see Figures 9-37 and 9-39.
3. Press in the kingpin bushing using the Kingpin Bushing Installer / Remover Tool and Kingpin
Handle, (see Special Tools Section of this publication), to a depth of no less than 15⁄64" (0.236")
or 6 millimeters and no more than 5⁄16" (0.32") or 8 millimeters past the kingpin bore.
4. Following this procedure it is necessary to ream the kingpin bushings to fit the kingpins, see
Kingpin Bushing Reaming in this section.
FIGURE 9-37

FIGURE 9-38

FIGURE 9-39

KINGPIN BUSHING REAMING
REAM THE KINGPIN BUSHINGS WITH AN ADJUSTABLE STRAIGHT FLUTE REAMER, SEE SPECIAL TOOLS
SECTION OF THIS PUBLICATION. DO NOT HONE OR BURNISH THE KINGPIN BUSHINGS. HONING OR
BURNISHING WILL DAMAGE THE BUSHINGS AND VOID WARRANTY.
WHEN INSTALLING STEERING KNUCKLE COMPONENTS IN A VISE IT IS NECESSARY TO PROTECT THE
MACHINED SURFACES FROM GOUGES OR MARRING BY USING BRASS JAWS. FAILURE TO DO SO CAN
CAUSE PREMATURE PART DAMAGE, DAMAGE TO THE STEERING KNUCKLE COMPONENTS, LOSS OF
WARRANTY, LOSS OF VEHICLE CONTROL, CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

1. Install the lower steering knuckle assembly in a vise with brass jaws.
SERVICE HINT

It is acceptable to mount the knuckle components in a vise either vertically or horizontally when
performing the reaming procedure.
FIGURE 9-40

2. Install the reamer into the lower steering knuckle until the blades touch the
kingpin bushing.
3. Rotate the reamer with light downward pressure. Rotate the reamer
smoothly. DO NOT apply too much
pressure, see Figures 9-41 and 9-42.
4. Slide the reamer out of the bottom of
the steering knuckle assembly. If it is
necessary to remove the reamer from
the top, rotate the reamer opposite of
cutting rotation, see Figure 9-40.

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5. Clean and remove all kingpin bushing material from the steering knuckle assembly. Take special attention to remove material from the grease channels and dimples.
6. Clean the 5⁄8" brake spider / torque plate bolts with a wire wheel and run a tap through the
threads of the lower steering knuckle assembly and then flush out with brake cleaner and dry
with compressed air.
PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL LOCTITE® MATERIAL IS REMOVED FROM THE
MOUNTING BOLTS AND THE THREAD BORES IN THE UPPER STEERING KNUCKLES, AND NEW LOCTITE
277 OR EQUIVALENT IS APPLIED TO HELP ENSURE THAT THE BOLTS SUSTAIN THE PROPER TORQUE
REQUIREMENT. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL
INJURY OR PROPERTY DAMAGE.
FIGURE 9-41

NOTE

FIGURE 9-42

The Hendrickson Genuine part, socket head cap screw comes with a pre-applied loctite compound.
7. Install the upper and lower steering knuckle on the kingpin.
8. Check for the proper fit by rotating the knuckle assembly back and forth to verify there is no
binding on the kingpin, see Figure 9-42.
9. If the bushing is too tight repeat Steps 1 through 8 until the proper clearance is achieved.

NOTE

Bushing size is to be 0.001" larger than the kingpin size.

KINGPIN SEAL INSTALLATION
FIGURE 9-43

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FIGURE 9-44

51

Component Replacement

SOFTEK® for Lion Bus
1. Place the steering knuckle assembly in a vise with brass jaws or place on a suitable workbench.
The steering knuckle will have the machined surface facing up (axle side up).
2. Lay the kingpin seal into the bore of the steering knuckle. The seal lip should face outward or
toward the axle.
3. Use a Kingpin Bushing Driver Tool and press seal firmly into the steering knuckle assembly.
4. Install the kingpin seal until it makes contact with the kingpin bushing, see Figures 9-43 and
9-44.

STEERING KNUCKLE ASSEMBLY
After replacement of the kingpin bushings it is necessary to re‑assemble the steering knuckle
assemblies. The STEERTEK axle is equipped with two (2) different thrust bearings installed. DO
NOT substitute aftermarket components when servicing.
FIGURE 9-45

1. Install the thrust bearing on the
lower kingpin with the seal facing
up toward axle (the black seal will
designate the top side, see Figure
9-45).The composite thrust bearing
is installed on the left side of the
axle. The roller bearing is installed
on the right side of the axle.
2. Install the shim on the upper
kingpin.

Black Seal

Top View of Thrust Bearings

COMPOSITE THRUST BEARING
Left Side

Seal

ROLLER THRUST BEARING
Right Side

3. Pack the bushing dimples on the upper and lower steering knuckles with multi purpose
Lithium based grease (NLGI Grade 2) before installation.
4. Install the upper steering knuckle on the upper arm kingpin.
5. Install the lower steering knuckle on the lower kingpin and install the old socket head cap
screws loose into the top two threaded holes.

SERVICE HINT

The easiest way to achieve this is with the grease caps not installed in the knuckle assemblies.
This eliminates back pressure. The assembly can then freely slide up and down on the kingpin.
If the grease caps are still installed, remove the grease zerks to avoid creating back pressure.
Grease zerks will be re-installed at the end of the procedure.
6. Install a bottle jack under the lower knuckle and slightly raise the knuckle until it is ­possible to
thread in the three (3) brake backing plate bolts by hand. These are for guide ­purposes only.
7. Snug the two (2) socket head cap screws.
8. Lower the bottle jack so that all the vertical clearance is on the underside of the axle.
FIGURE 9-46

9. Affix a magnetic base dial indicator on the axle
and place the tip of the dial indicator on top of
the knuckle assembly, see Figure 9-46.
10. Zero the dial indicator.
11. Raise the bottle jack until there is NO CLEARANCE between the knuckle assembly and the
bottom of the axle, slightly lifting the axle.
12. Check the reading on the dial indicator. The
specification for vertical travel on the steering
knuckle during assembly is 0.008" to 0.011".

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SOFTEK® for Lion Bus
13. If the clearance is above 0.011", loosen the socket head cap screws and push down on the
knuckle assembly until the proper vertical clearance is achieved. Add (0.005") shim if necessary.
14. If the clearance is below the 0.008", loosen the two (2) socket head cap screws and pull up
on the knuckle assembly until the proper vertical clearance is achieved. If the 0.008" minimum clearance is unattainable it may be necessary to remove a 0.005" shim.
PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL LOCTITE MATERIAL IS REMOVED FROM THE
MOUNTING BOLTS AND THE THREAD BORES IN THE UPPER STEERING KNUCKLE, AND NEW LOCTITE
277 OR EQUIVALENT IS APPLIED TO HELP ENSURE THAT THE BOLTS SUSTAIN THE PROPER TORQUE
REQUIREMENT. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL
INJURY OR PROPERTY DAMAGE.

NOTE

The steering knuckle socket head cap screws come with a pre-applied loctite compound.
15. Remove one (1) old socket head cap screw and replace with a new socket head cap screw.
16. Remove second socket head cap screw and replace with new socket head cap screw. Tighten
both socket head cap screws to 188 ± 12 foot pounds torque.
17. Recheck the vertical clearance with the dial indicator or a 0.010" feeler gauge, see Figure 9-46.
18. Remove the brake spider bolts, they should thread out freely.
19. Remove the bottle jack and continue assembling the wheel ends.

IMPORTANT NOTE

Loctite applied to the three (3) brake spider bolts is a critical procedure to ensure that these bolts
sustain the torque requirement of Steering knuckle assembly.
20. Apply loctite to the three (3) brake spider bolts prior to installation into the brake spider.
Tighten bolts to 188 ± 12 foot pounds torque.
DO NOT GREASE KNUCKLES WITHOUT THE BRAKE SPIDER INSTALLED AND TIGHTENED TO PROPER
TORQUE. FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE RESULTING IN FAILURE AND LOSS OF
VEHICLE CONTROL, POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

21. Install the tie rod ends into the lower steering knuckles (Ackermann arms).
22. Tighten the castle nuts to 185 foot pounds torque then rotate the castle nut to the next
castle slot and install cotter pin.
23. Install the drag link into the steering arm and tighten to the vehicle manufacturer’s s­ pecifications.
24. Install new O-rings on the grease caps and lubricate O-rings with grease.
25. Install grease caps and new retaining rings.
26. Install brakes, drums, wheels and tires.
27. Remove jack and safety stands.
28. Grease steering knuckles with the vehicle on the floor.
29. Remove wheel chocks.

TIE ROD END AND CROSS TUBE
DISASSEMBLY
1. Chock the wheels.