Dongfeng DFA1101GZ5AD6J-907. Manual - part 44

Front Axle

FA-1

Front Axle

Structure

Front axle, steering knuckle

1.Upper cover--steering knuckle
2.Spacer--steering knuckle upper 
cover
3.Steering knuckle pin
4.Upper bushing
5.Left steering knuckle
6.Knuckle pin plug assy
7.Bolt--knuckle pin plug

8.Grease elbow
9.Adjusting spacer--steering 
knuckle
10.Left Steering knuckle arm
11.Double head bolt--upper steer-
ing arm
12.Upper steering arm--left steer-
ing knuckle

13.Wedge cotter pin--steering 
knuckle pin
14.Front axle
15.Thrust bearing
16.Right steering knuckle
17.Right steering knuckle arm
18.Steering limiting bolt

Front Axle

FA-2

Disassembly of the Front Brake

1.Front dustproof shield 
2.Rubber plug 
3.Column pin--air chamber push-
rod
4.Front brake bracket assy 
5.Front brake air chamber assy
6.O-ring
7.Front brake cam

8.Bush--air chamber bracket
9.O-ring
10.Adjusting spacer
11.Front brake adjusting arm assy
12.Washer--brake cam
13.Adjusting washer
14.Front brake bottom plate assy
15.Shaft--brake shoe

16.Bush
17.Screw
18.Pin
19.Rivet
20.Brake friction plate
21.Front brake shoe
22.Return spring

Front Axle

FA-3

Maintenance

Before using new axle, apply enough 2# lithium grease into every grease fitting.

First maintain

To assure the safe running of your vehicle and obtain a long service life, you have to do the first maintain

after the first 1,500~2,500kmafter leaving factory. Please note the following items:

1.Dismantle and check the wheel hub for any abnormal wear (please go to the Assembly and Adjustment to see

the reference)

2.Check the fastening piece.

Periodical maintain

Do the periodical maintain for the vehicle is a good way to prolong the service life and assure the safe run-

ning of the vehicle. If you follow the maintenance schedule to do the maintain, your vehicle may obtain the best
economic benefit.

The items of the periodical maintain are as following:

1.Add some grease to the grease nipple

2.Avoid important nut loosed

3.Adjust wheel hub bearing pretightening force and toe-in

4.Adjust the brake clearance

Periodical Maintain Schedule

Item

Maintenance Interval Mileage ( × 1000km)

First maintain 4

8 12 16 20 24 28 32 36 40 44 48 80

Clean the axle assy

● ● ● ● ● ● ● ● ● ● ● ●

Check the important nut for its tightness

●

● ● ● ● ● ● ● ●

Clean and adjust wheel hub bearing

●

●

●

●

Check service brake and park brake 
efficiency

●

● ● ● ● ● ● ● ● ● ● ● ●

Check the brake bottom plate for tightness

●

●

●

●

●

Clean the brake air chamber

●

Check brake pipeline for leakage

●

● ● ● ● ● ● ● ● ● ● ● ●

Front Axle

FA-4

Assembly and Adjustment

Disassemble and asseble of the assembly

Front wheel hub brake drum assembly

1.Fixed the front axle and remove the wheel hub end cover;

2.Take off the cotter pin, adjusting nut and spacer;

3.Turn the wheel hub brake drum a little and pull it, gently knock at the brake drum at the same time to loose the

inner ring of the outer bearing, then take down the wheel hub brake drum, but you need to pay attention that the
assembly is so heavy that may be fallen down or hurt someone, and the inner ring of the outer bearing need to
care at the same time, don't fall it.

The assembling sequence of the front wheel hub brake drum assembly is opposite to the above sequence, and

you must to pay attention to the tightening torque of the thread connecting parts and the adjustment of the bearing
pretightening force.

Adjustment of axle

Ajustment of axial clearance between front axle and steering knuckle

1.Installl the steering knuckle and thrust bearing on teh front axle, select the proper adjusting spacer(Note:only

use one) to adjust the clearance and assure the clearance is ≤ 0.1mm;

2.Apply a layer of grease on the surface of the kingpin, align the lock pin slot of the kingpin to the lock pin hole of

the front axle, then insert the kingpin and tighten the lock pin;

3.Before add the grease, measure both left and right of the starting force at cotter pin of steering knuckle journal,

and the starting force should be ≤ 10N.

Adjustment of front wheel hub pretightening force

1.Apply some 2# lithium grease on the thread of the steering knuckle shaft end and the wearproof spacer;

2.Tighten the locking nut by a torque of 120~150N.m;

3.Turn the wheel hub for 2~3 circles to correct the alignment of the bearing;

4.Tighten the locking nut by a torque of 120~150N.m;

5.Unscrew the locking nut for 1/3 circle, install the locking washer and limit spacer, and make the limit spacer

align to the steering knuckle key slot and the adjusting nut limit pin;

6.Install the outer nut, tighten it with a torque of 120~150N.m;

7.Make sure if the pretightening force is correct. First, turn the wheel hub for 2~3 circles, then confirm the tangen-

tial force of the wheel hub bolt;

The tangential force of the wheel hub is 20~50N.

Adjustment of the toe-in

1.First, loose the locking bolt of the tie rod;

2.Turn the tie rod and make the toe-in is 0~4mm at the external diameter of the tire;

3.Tighten the fixed nut of the tie rod, and make the angle between left and right joint is no t larger than 4°, and

the angle of oscillation of the tie rod joint during the largest turning angle must have some over measure.

Adjustment of the steering angle

1.Adjust the limit screw of the turning angle, and make the max.turning anggle of the the inner wheel is 40°;

2.After adjusting the limit screw, tighten the locking nut.

Adjustment of the brake clearance

Turn the worm shaft and shoe shaft of the brake adjusting arm, made the surface of the brake shoe totally

connected with the inner face of the brake drum, then loose 3~4 circles of the worm shaft, and adjust the clearance
between brake drum inner face and brake shoe: