where the bushing tube’s radius edge has been
worn away is considered abnormal. If this type of
wear is present, determine how much wear has
occurred according to specifications in Table 2.

1. Using the jack, carefully lower the suspension
beam assembly out of the frame bracket to expose
the bushings. Bushing tube spacers should fall out
as the beam is lowered.
2. Inspect bushing tube spacers. If worn through,
check for possible damage to frame bracket
according to procedures in L750 Bushing Tube
Spacer Inspection/Replacement Procedure.

The amount of bushing tube wear can be
determined by measuring the width of the worn
bushing tube (Figure 9) and subtracting this
measured dimension from the new tube width.

3. Discard the bushing tube spacers.
IMPORTANT: If within the warranty time period, The
following is recommended at this time
as defined in Hendrickson literature
number L583 Comprehensive Warranty
Statement:
• CONTACTING HENDRICKSON prior to service.
• SEND photos to [email protected]
for evaluation.
NOTE: If within warranty, the original bushings must
be returned to Hendrickson for further warranty
consideration.

L427 H

7

Bushing Replacement Procedure 
Example A: WIDE BUSHING tube measurement:
Suppose the inspection reveals extensive bushing tube wear and the bushing tube measures 515/16
inches. Subtracting 515/16 from 6 reveals the amount of bushing tube material that has worn away, in
this case 1/16 of an inch.
6" - 515/16" = 1/16"
IF THE BUSHING TUBE MEASURES:
Wide Bushing
Narrow Bushing
57/8 to 6"

(No wear on the
bushing tube)

31/8 ±1/32"
(No wear on the
bushing tube) 1

5¾" TO 57/8"
(Wear of 1/8" to ¼" on
the bushing tube)
Less than 5¾"

2

Continue with bushing replacement.

N/A

Less than 33/32"
(More than ¼" wear
(Worn into the
on the bushing tube,
weld 1)
Worn into the weld 1)
Uneven wall thickness 2
(parent material loss)
1

THEN:

A.

(Optional) Refer to CONTACTING HENDRICKSON on page 2 to verify
conclusion and next steps.

B.

Replace the HALFTRAAX™ or the beam assembly. Refer to Hendrickson literature
number L533 HALFTRAAX™ Axle and Beam Removal/Replacement Procedure.

C.

Realign the axle per L579 Alignment Procedure.

Any bushing tube wear into the weld is not acceptable. In this case, the axle/beam weldment (HALFTRAAX) will need to be replaced.
Wall thickness should be checked after BUSHING REMOVAL and prior to EVALUATING BUSHING TUBE EDGE WEAR on page 13. Any component that
contains an area where corrosion removal or material wear has reduced the material thickness should be replaced. Components, where the accumulated
material removal may be compromising the aggregate material thickness, should be replaced. However, cleaning of bushing tube edge, within
specifications, is allowed as defined in page 14.

Table 2: Bushing tube measurement evaluation

Bushing tube

Radius intact

Radius worn away

Normal tube edge

Abnormal (worn) tube edge
Figure 8: Bushing tube edge wear (wide bushing)

BUSHING TYPE

NEW TUBE
WIDTH

Wide

A=6"

Narrow

A=31/8"

A

See Table 2 for specifications

Figure 9: Bushing tube width

8

L427 H

Bushing Replacement Procedure

BUSHING REMOVAL

If the index mark is not visible on the bushing tube,
use the bushing position locator as a reference for
drawing the bushing orientation line.

With the bushing tube and bushing exposed, the
bushing can now be removed with the applicable
bushing tool.

Bushing
tube mark

Bushing
tube
Bushing voids

Bushing
index mark

Bushing position
indicator

Beam
assembly

Bushing
position locator

Figure 10: Bushing orientation within the bushing tube

1. With the beam assembly lowered, locate
the bushing index mark on the bushing tube
(Figure 10).

Figure 12: Properly marked bushing orientation

The bushing index mark is a small dimple or
indent in the side of the bushing tube and is used
along with the bushing position locator to properly
align the bushing within the bushing tube. When
installed, the bushing voids must be vertically
centered when the suspension is at ride height.
By aligning the bushing position locator with the
bushing index mark, proper bushing orientation is
achieved.
Figure 13: Applying lube to the hex head bolt

3. Apply extreme‑pressure lube (provided with tool) to
the threads of the hex head bolt (Figure 13).

Figure 11: Marking bushing orientation on the bushing tube

2. Using a square and the bushing index mark as
a reference point, scribe or draw a line on the
outside of the bushing tube (Figure 11). This line
marks the orientation of the existing bushing within
the bushing tube and will be used to properly
orient the replacement bushing during installation
(Figure 12).

L427 H

9

Bushing Replacement Procedure 
NOTICE

Do not use extreme-pressure lube on
the bushing. It is intended only for use
on the hex head bolt, thrust bearing and
thrust washers.

5. With the transition tube empty, assemble the
bushing replacement tool as shown in Figure 15.
IMPORTANT: For bushing removal, ensure the tool
is assembled so that the end of the
transition tube with the bearing cup
(wide tool) or taper (narrow tool) can
be placed against the bushing tube as
shown in Figure 15.
There must be two lubricated thrust
washers on each side of the thrust
bearing as shown in Figure 15 and
Figure 16.

Figure 14: Applying lube to the thrust bearing

4. Apply extreme-pressure lube to the internal parts of
the thrust bearing (Figure 13).

Front
plate
Hex Thrust
head bearing
bolt

Transition
tube

Removal
spacer

Rear
drive
plate

Bearing cup end

Thrust
washers
Wide bushing tool
Bushing tube
Front
plate

Transition
tube

Hex Thrust
head bearing
bolt

Removal
spacer

Rear
drive
plate

Tapered end

Thrust
washers
Narrow bushing tool
Figure 15: Assembling bushing tool for removal

10

L427 H

Bushing Replacement Procedure

Bushing
position locator
Figure 19: TF II wide bushing
Either here

or here

Figure 16: Applying lube to thrust washers

6. Apply extreme-pressure lube to external surfaces of
the thrust washers (Figure 16).

Figure 20: Set screw installation for TF II wide bushing drive plate

NOTE: Diagonal placement of the set screws is to
prevent drive plate rotation during bushing
removal as shown in Figure 26 on page 13.
Figure 17: Mounting tool on bushing tube

7. Insert the hex head bolt of the partially assembled
tool through the bushing until the transition tube
rests squarely on the bushing tube (Figure 17).

Flat side toward
bushing in
bushing tube

NOTE: Set screws enter bushing void to
prevent rear drive plate rotation

Removal spacer
Figure 18: Installing removal spacer

Figure 21: Checking set screw depth

A. Thread the two 4‑inch long set screws into
diagonally opposite holes in rear drive plate
(shown in Figure 20,“HVY” holes only). At least
two inches of each set screw must be left
exposed on the flat side of the rear drive plate

8. Slide the removal spacer over the exposed hex
head bolt threads on the opposite side of the
bushing tube (Figure 18).
9. (Wide bushing tool ONLY) Configure set screws in
the rear drive plate as shown in Figure 20.
L427 H

11

Bushing Replacement Procedure 
as shown in Figure 21. If necessary, use 1/4-inch
Alllen wrench to turn screws.
B. If present, ensure the two 2‑inch long set
screws (used during installation) are screwed
into unused HVY holes in the rear drive plate
until they are flush with or below the flat (nonconcaved) surface of the rear drive plate. These
will be used later for wide bushing installation.

Figure 24: Ensure thrust bearing is free to turn

NOTICE
Figure 22: Narrow bushing rear drive plate alignment pins

NOTE: Narrow bushing tool alignment pins in the rear
drive plate (Figure 22) are fixed. No other rear
drive plate preparation is necessary with this
tool.

The thrust bearing needs to be free to
turn to prevent binding or damage to the
threads of the hex head bolt during the
removal process (Figure 24).

13. Using a 3/4‑inch impact wrench and a 111/16‑inch
heavy-duty (six‑point) impact socket, remove the
bushing by turning the hex head bolt clockwise
(Figure 25). Normal removal time should be four
minutes or less.

10. Thread the rear drive plate (flat side first, Figure 21)
onto the hex head bolt (Figure 23). If using the wide
bushing tool, the two set screws must enter the
bushing voids (open areas) to prevent the rear drive
plate from turning.

IMPORTANT: Ensure the transition tube remains
seated against the bushing tube during
the entire bushing removal procedure. If
the hex head bolt stops turning during
the removal process:

11. Hand tighten the hex head bolt until snug.

A. Reverse the impact wrench and loosen the tool
assembly.
B. Check the tool for damage.
C. Reset the rear drive plate and try again.

Ensure the tool is
squarely seated
on bushing tube

Bushing tube

As a last resort, a small amount of heat may be
required to break the bushing loose (Figure 26).
DO NOT OVERHEAT THE BUSHING TUBE. Allow
the bushing tube to cool before installing the new
bushing.

Set screws
must enter
bushing voids

Figure 23: Ensure tool is square to bushing tube

NOTICE

12. Ensure tool rests squarely on the bushing tube
(Figure 23).

12

The use of a one-inch impact wrench
is not recommended. Damage to the
threads of the hex head bolt could result.

L427 H

Bushing Replacement Procedure

EVALUATING BUSHING TUBE EDGE
WEAR

With the beam assembly lowered and the bushing
removed from the previous procedure, inspect the
edges of the bushing tube.
NOTE: If not already done so, refer to Table 2 on
page 8 to measure and check bushing
tube length.
As described in Table 2 on page 8, it is acceptable
to reuse the bushing tube if within the specifications
listed in the table.
When the bushing tube wears, a slight “hook” or “tooth”
of metal may develop on both inside and outside
diameters of the tube (Figure 27). As the vehicle turns,
the unique design of the TRI‑FUNCTIONAL® Bushing
allows it to elongate sightly to absorb the forces
associated with road surface, load, etc. When the turn
is complete and those particular forces are no longer
present, the TRI‑FUNCTIONAL Bushing returns to its
original position. If the “hook” or “tooth” on the bushing
tube is not removed, it can “bite” into the rubber
TRI‑FUNCTIONAL Bushing when elongated and hold or
prevent it from returning to its original position, which is
unacceptable. As this is repeated, the TRI‑FUNCTIONAL
Bushing can eventually be pulled out of the bushing
tube. The rubber TRI‑FUNCTIONAL Bushing may also
become damaged by these irregular edges.

Figure 25: Typical bushing removal progression as hex head bolt is
turned clockwise

Also, if not repaired:
• The new bushing could bind and/or be damaged
during installation.
• New bushing tube spacers will wear more rapidly
than normal.
Before attempting to install a new bushing, the worn
bushing tube edge must be dressed. Use a grinder to
re‑establish a radius on the edge of the bushing tube as
shown in Figure 27 and using the following procedure.
NOTE: For HT™ Series Y-beam suspensions, the
bushing tube is part of the bushing assembly
(Figure 48 on page 24) and is replaced with
a new bushing.

Figure 26: As a last resort, apply heat to the bushing tube

14. After bushing removal, reverse the impact wrench
to disassemble the tool.

L427 H

13

Bushing Replacement Procedure 
Section AA before grinding edges

Section AA after grinding
/8" minimum, 3/16" maximum ID radius

1

Tube edge
“Hook” develops
due to wear

1

/16" minimum, 1/8" maximum OD radius

NOTE: ID radius must be smooth for
bushing installation, ID & OD radius
must be smooth for bushing tube
spacer.
Normal tube edge

Abnormal (worn) tube edge
Figure 27: Bushing tube edge dressing

1. Clean the bushing tube on the trailer suspension
beam. All rust, rubber, scale and other buildup
must be removed from the inside surface of the
bushing tube before the replacement bushing can
be installed. The bushing tube must also be cool to
the touch.

2. Check the edges of the bushing tube for burrs or
sharp edges. If OK, skip next step.
3. Remove any burrs or sharp edges with a grinding
tool (Figure 27).
4. Refer to Table 2 on page 8 to re-measure and
check bushing tube length.

IMPORTANT: Any component that contains an area
where corrosion removal or material
wear has reduced the material thickness
should be replaced. Components, where
the accumulated material removal
may be compromising the aggregate
material thickness, should be replaced.
Refer to CONTACTING HENDRICKSON on
page 2 for guidance. Refer to Table 2
on page 8.