Hendrickson AR2 series Operating instructions
AR2™ Air Over Walking Beam
Suspension
SUBJECT: Service Instructions
LIT NO: 17730-241
DATE: July 2018 REVISION: A
TABLE OF CONTENTS
Section 1 Introduction...........................2
Section 2 Product Description ...................3
Section 3 Important Safety Notice ...............5
Section 4 Special Tools .........................10
Section 5 Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AR2 Plumbing Diagram................14
Section 6 Preventive Maintenance
Hendrickson Recommended
Inspection Intervals ................15
Component Inspection ................15
Beam End Axle Brackets ...............16
Equalizing Beam End Connection ........18
Bar Pin End Bushing ..................21
Bar Pin Shims .......................21
Rubber Center Bushing ................21
Frame Hanger to Trailing Arm Connection ..22
Longitudinal and Transverse Torque Rods ..22
Saddle Connection ...................23
Cross Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shock Absorber ......................25
Air Fittings..........................26
Axle Stops ..........................26
Section 7 Alignment & Adjustments
Ride Height .........................27
Axle Pinion Angle ....................29
Drive Axle Alignment ..................30
Lateral Alignment ....................31
Bar Pin with shims Alignment ...........32
Section 8 Component Replacement
Fasteners ..........................35
Frame Hanger .......................35
Trailing Arm.........................36
Trailing Arm Bushing ..................38
Air Spring ..........................40
Shock Absorber ......................42
Height Control Valve ..................42
Equalizing Beam.....................44
Center Bushing .....................49
Bar Pin End Bushings .................51
Adapter Style End Bushing. . . . . . . . . . . . . . 54
Longitudinal Torque Rods. . . . . . . . . . . . . . . 56
Transverse Torque Rods ................57
ULTRA ROD • ULTRA ROD PLUS
Torque Rod Bushings ...............58
XTRB Torque Rod Bushings..............61
Cross Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 62
Section 9 .........64
Section 10 Torque Specications.................71
Section 11 Troubleshooting Guide. . . . . . . . . . . . . . . . . .
Introduction 2 17730-241
AR2™
Introduction
This publication is intended to acquaint and assist maintenance personnel in the preventive main-
tenance, service, repair and rebuild of the Hendrickson AR2™rear air suspension system.
Use only Hendrickson Genuine Parts for servicing this suspension system.
It is important to read and understand the entireTechnical Procedure publication prior to perform-
ing any maintenance, service,repair, or rebuild of this product.The information in this publication
contains parts lists, safety information, product specifications, features, proper maintenance, ser-
vice,repair and rebuild instructions for the AR2 suspension.
Hendrickson reserves the right to make changes and improvements to its products and
publications at any time. Contact Hendrickson Tech Services for information on the latest version
of this manual at 1-866-755-5968 (toll-free U.S.and Canada),1-630-910-2800 (outside U.S.and
The latest revision of this publication is also available online at
www.hendrickson-intl.com.
17730-241 3 Product Description
AR2™
Product Description
The Hendrickson AR2 offers a better ride and improved suspension performance by converting
your Hendrickson RT™•RTE™suspension into a highly engineered and lighter weight walking
beam air suspension.The air spring system in AR2 absorbs the load and road inputs — delivering
the preferred combination of empty-ride and loaded stability for vocational applications.
AR2 provides versatility for demanding job-sites or off-road conditions.When loaded,AR2 delivers
up to 14" (356 mm) of diagonal wheel articulation to keep load on all drive wheels.
Unloaded articulation varies with vehicle configuration and empty body weight.Available in con-
version or complete kit form with 40,000 and 46,000 pound (18,144 and 20,865 kilograms)
capacities,AR2 can be installed by service centers and OEM dealerships who want to give their
customers a new suspension solution.
■Trailing arm / Saddle assembly — Replaces spring / saddle assembly of existing RT•RTE
suspensions.The heavy-duty trailing arm / saddle assembly provides lighter weight, good
articulation and optimal ground clearance
■Large volume air springs — Rolling lobe design provides variable spring rates to deliver
superior ride quality
■ AR2 is compatible with 40K • 46K capacity Hendrickson RT•RTE walking
beams. If required, rigid forged beams or robust lightweight fabricated beams are available
separately
■Heavy-duty shock absorbers — Standard for optimal ride and cargo / body protection
■Bar pin rubber end bushings — Provide longer bushing life and adds axle alignment capabil-
ity.Three-piece adapter-beam end connection also available
■Cross tube — Made from rigid steel to deliver lateral suspension support and enhanced stability.
■Longitudinal torque rods — Engineered to optimize resistance to axle wind-up during accel-
eration and braking
■Transverse torque rods — Heavy-duty transverse rods ensure maximum lateral axle control
and straight line suspension stability
■Lightweight frame hanger — Controls acceleration, braking, and vertical forces for longer
hanger and trailing arm life
■Height control valve — Maintains proper ride height
Product Description 4 17730-241
AR2™
1
40K 46K
Suspension Rating 40,000 lbs. 46,000 lbs.
Gross Vehicle Weight (GVW) Approval273,000 lbs. 80,000 lbs.
Gross Combination Weight (GCW) Approval 160,000 lbs. 190,000 lbs.
Site Travel Rating3See Below560,000 lbs.
Diagonal Articulation414"
Ride Heights 9.5", 10.5"
Axle Spacing 52", 54"
Lift Axle See Below5See Below6
AR2 is approved for vocational truck applications such as dump under 18 feet, crane / boom and platform
applications.Contact Hendrickson for approval of additional applications.
1. Conversion kit — if existing RT • RTE suspension includes bronze center bushings, they must be replaced
with rubber center bushings. Bronze center bushings are not compatible with transverse torque rods.
Any comparison to other suspensions should consider all of these components, including axle
brackets.
2 Contact Hendrickson for applications that may exceed GVW approval ratings.
3 Site Travel Rating — Ratings are limited to no more than 5% of vehicle operation at speed not to
exceed 5 mph.Site travel ratings are consistent with published axle manufacturer’s limitations.Axle and
suspension site travel specications must not be exceeded.
4 Suspension articulation may exceed vehicle’s capability and may be limited by vehicle manufacturer;
vehicle manufacturer installed axle stops may restrict suspension’s articulation.
5 No add-on lift axles approved for 40,000 lbs. applications.
6 One or more lift axles. Maximum 60,000 lbs.load suspension for site travel.
17730-241 5 Important Safety Notice
AR2™
Important Safety Notice
Proper maintenance, service, and repair is important for the reliable operation of the suspension.
The procedures recommended by Hendrickson and described in this technical publication are
methods of performing such maintenance,service and repair.
This technical publication should be read carefully to help prevent personal injury and to assure
that proper methods are used.Improper maintenance, service or repair may damage the vehicle,
cause personal injury, render the vehicle unsafe in operation, or void manufacturer’s warranty.
Failure to follow the safety precautions in this manual can result in personal injury and / or prop-
erty damage. Carefully read and understand all safety related information within this publication,
on all decals and in all such materials provided by the vehicle manufacturer before conducting
any maintenance, service or repair.
■
Hazard “Signal Words” (Danger-Warning-Caution) appear in various locations throughout this
publication. Information accented by one of these signal words must be observed to help mini-
mize the risk of personal injury to service personnel, or possibility of improper service methods
which may damage the vehicle or render it unsafe.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
Additional Notes or Service Hints are utilized to emphasize areas of procedural importance and
provide suggestions for ease of repair.The following definitions indicate the use of these signal
words as they appear throughout the publication.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH,IF NOT AVOIDED WILL RESULT IN SERIOUS
INJURY OR DEATH.
INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH,IF NOT AVOIDED COULD RESULT IN DEATH OR
SERIOUS INJURY.
INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH,IF NOT AVOIDED MAY RESULT IN MINOR OR
MODERATE INJURY.
An operating procedure, practice condition, etc.which is essential to emphasize.
A helpful suggestion that will make the servicing being performed a little easier and / or faster.
Also note that particular service operations may require the use of special tools designed for
specific purposes.These special tools can be found in the Special Tools section of this publication.
The torque symbol alerts you to tighten fasteners to a specified torque value. Refer to Torque
Specifications section of this publication.
Important Safety Notice 6 17730-241
AR2™
■
DISCARD USED FASTENERS.ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR. FAILURE TO DO
SO COULD RESULT IN FAILURE OF THE PART,OR MATING COMPONENTS,ADVERSE VEHICLE HANDLING,
PERSONAL INJURY,OR PROPERTY DAMAGE.
LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, ADVERSE VEHICLE
HANDLING, PROPERTY DAMAGE,OR SEVERE PERSONAL INJURY. MAINTAIN CORRECT TORQUE VALUE
AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED, USING A REGULARLY
CALIBRATED TORQUE WRENCH.TORQUE VALUES SPECIFIED IN THIS TECHNICAL PUBLICATION ARE FOR
HENDRICKSON SUPPLIED FASTENERS ONLY. IF NON HENDRICKSON FASTENERS ARE USED, FOLLOW
TORQUE SPECIFICATION LISTED IN THE VEHICLE MANUFACTURER’S SERVICE MANUAL.
DO NOT ASSEMBLE BEAM END CONNECTION WITHOUT PROPER FASTENERS. HENDRICKSON
RECOMMENDS THE USE OF HENDRICKSON FASTENERS TO SUSTAIN PROPER CLAMP FORCE. FAILURE
TO DO SO CAN CAUSE ADVERSE VEHICLE HANDLING, PROPERTY DAMAGE OR PERSONAL INJURY.
ENSURE THAT BEAM END CONNECTION AND SADDLE CAP FASTENERS TORQUE VALUE ARE SUSTAINED
AS RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION. FAILURE TO SO
CAN CAUSE ADVERSE VEHICLE HANDLING RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.
IF BEAM END BUSHING MOVEMENT OR LOOSENESS IS NOTED IN THE EQUALIZING BEAM END HUB,DO
NOT OPERATE THE VEHICLE. REPLACE THE END BUSHINGS AND ALL CONNECTING PARTS.THE ABOVE
CONDITION CAN RESULT IN COSTLY REPAIR, DOWNTIME, POSSIBLE SEPARATION OF COMPONENTS,
ADVERSE VEHICLE HANDLING,PROPERTY DAMAGE,OR PERSONAL INJURY.
THE TRAILING ARM ASSEMBLIES ARE ATTACHED TO THE CENTER BUSHINGS OF EACH EQUALIZING BEAM
WITHTWO (2) SADDLE CAPS.EACH SADDLE CAP USESTWO (2) STUDSTO CLAMP THE CENTER BUSHING
INNER METAL TO THE SADDLE.THE SADDLE CAPS MUST BE INSTALLED AND TIGHTEN SO THAT THERE IS
AN EVEN GAP BETWEENTHE SADDLE CAPS AND THE BASE OF THE TRAILING ARM ASSEMBLY AS SHOWN
IN FIGURE 3-1.IF THEY ARE NOT INSTALLED PROPERLY,THE TRAILING ARM ASSEMBLIES COULD BECOME
DEFORMED,RESULTING IN BENT BOLTS OR ASSEMBLY DAMAGED.
AR2 SUSPENSION INCORPORATES LONGITUDINAL 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,
ADVERSE VEHICLE HANDLING,POSSIBLE TIRE CONTACT WITH THE FRAME, PREMATURE COMPONENT
DAMAGE,OR SEVERE PERSONAL INJURY.
17730-241 7 Important Safety Notice
AR2™
ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION.ADD-ON AXLE ATTACHMENTS
AND OTHER LOAD TRANSFERRING DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED
AND APPROVED CAPACITIES,WHICH CAN RESULT IN COMPONENT DAMAGE AND ADVERSE VEHICLE
HANDLING,POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.
ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT
TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTENANCE,REPAIR OR SERVICE.
PRIOR TO DISASSEMBLY OF THE SUSPENSION, AIR SPRING ASSEMBLIES MUST BE DEFLATED.
UNRESTRICTED AIR SPRING ASSEMBLIES CAN VIOLENTLY SHIFT. DO NOT INFLATE AIR SPRING
ASSEMBLIES WHEN THEY ARE UNRESTRICTED.AIR SPRING ASSEMBLIES MUST BE RESTRICTED
BY SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE BEYOND PRESSURES
RECOMMENDED BY AIR SPRING MANUFACTURER, CONTACT HENDRICKSON TECHNICAL SERVICES
FOR DETAILS. IMPROPER USE OR OVER INFLATION MAY CAUSE AIR SPRING ASSEMBLIES TO BURST,
CAUSING PROPERTY DAMAGE AND / OR SEVERE PERSONAL INJURY.
PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM, ENSURE ALL
PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND AROUND THE SERVICE
AREA, FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.
INFLATE THE SUSPENSION SLOWLY AND MAKE SURE THE RUBBER BLADDER OF THE AIR SPRING
INFLATES UNIFORMLY AND IS NOT BINDING. FAILURE TO DO SO CAN CAUSE DAMAGE TO THE AIR
SPRING AND / OR MOUNTING BRACKETS AND VOID WARRANTY.
IF THE AIR SPRING IS BEING REMOVED FOR AN ALTERNATE REPAIR,IT IS MANDATORY TO LUBRICATE THE
LOWER AIR SPRING FASTENERS WITH PENETRATING OIL AND REMOVE WITH HAND TOOLS TO PREVENT
DAMAGE TO THE LOWER AIR SPRING MOUNTING STUD. FAILURE TO DO SO CAN CAUSE COMPONENT
DAMAGE AND VOID WARRANTY.
WHEN THE TRUCK / TRAILER BODY / BOOM / AND OR ATTACHMENT IS LIFTED IT IS MANDATORY TO
COMPLETELY EXHAUST THE AIR FROM THE SUSPENSION SYSTEM TO HELP PROVIDE STABILITY WHEN
LIFTED. FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING, ROLL-OVER, OR VEHICLE
INSTABILITY, POSSIBLY CAUSING SEVERE PERSONAL INJURY, PROPERTY DAMAGE, OR DEATH. FIRST
RAISE ANY AUXILIARY AXLES AND THEN EXHAUST ALL PRESSURE FROM REAR TRACTOR / TRAILER AND
TRUCK AIR SUSPENSION SYSTEMS PRIOR TO RAISING THE BODY / BOOM OR ATTACHMENTS. FOLLOW
THE VEHICLE MANUFACTURER’S OPERATING INSTRUCTIONS FOR MAINTAINING PROPER STABILITY.
IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE, AND RESULT IN ADVERSE
VEHICLE HANDLING, PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH AND WILL VOID
HENDRICKSON’S WARRANTY.
■DO NOT USE THE SUSPENSION CROSS TUBE AS A JACKING POINT TO RAISE THE VEHICLE
■REFER TO THE VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS
PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO PREVENT THE VEHICLE FROM
MOVING OR ROLLING. DO NOT WORK AROUND OR UNDER A RAISED VEHICLE SUPPORTED BY ONLY
A FLOOR JACK OR OTHER LIFTING DEVICE.ALWAYS SUPPORT A RAISED VEHICLE WITH RIGID SAFETY
STANDS.FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY OR DAMAGE TO EQUIPMENT.
Important Safety Notice 8 17730-241
AR2™
THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SUSPENSION. ANYTIME THE AXLE
ON AN AR2 SUSPENSION IS SUSPENDED, IT IS MANDATORY THAT THE SHOCK ABSORBERS REMAIN
CONNECTED. FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO SEPARATE FROM THE PISTON AND
RESULT IN PREMATURE AIR SPRING FAILURE AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.
REPLACEMENT OF SHOCK ABSORBERS WITH NON-HENDRICKSON PARTS CAN ALTER THE REBOUND
TRAVEL AND THE RIDE QUALITY OF THE SUSPENSION.
DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON. DO NOT
SUBSTITUTE REPLACEMENT COMPONENTS NOT AUTHORIZED BY HENDRICKSON. USE OF MODIFIED,
REWORKED, SUBSTITUTE OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY NOT
MEET HENDRICKSON’S SPECIFICATIONS,AND CAN RESULT IN FAILURE OF THE PART,ADVERSE VEHICLE
HANDLING, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE,AND WILL VOID ANY APPLICABLE
WARRANTIES. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.
A TECHNICIAN USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED BY
HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE VEHICLE’S SAFETY
WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED.INDIVIDUALS DEVIATING IN ANY MANNER
FROM THE INSTRUCTIONS PROVIDED ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR
DAMAGE TO EQUIPMENT INVOLVED.
IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE WHICH CAN CAUSE ADVERSE
VEHICLE HANDLING, PROPERTY DAMAGE OR SEVERE PERSONAL INJURY AND WILL VOID
HENDRICKSON’S WARRANTY.
■DO NOT USE THE SUSPENSION CROSS TUBE AS A JACKING POINT,REFER TO VEHICLE MANUFAC-
TURER FOR PROPER JACKING INSTRUCTIONS
■ACCEPTABLE LIFTING POINTS FOR A VEHICLE AT THE RATED LOAD INCLUDE BUT NOT LIMITED
TO:THE AXLE, EQUALIZING BEAM, AND THE VEHICLE FRAME RAIL. REFER TO THE VEHICLE
MANUFACTURER FOR PROPER JACKING INSTRUCTIONS
17730-241 9 Important Safety Notice
AR2™
DO NOT USE A CUTTING TORCH TO REMOVE ANY FASTENERS.THE USE OF HEAT ON SUSPENSION
COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS.A COMPONENT DAMAGED
IN THIS MANNER CAN RESULT IN THE ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY
OR PROPERTY DAMAGE.
EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF THE
EQUALIZING BEAM. DO NOT CONNECT ARC WELDING GROUND LINE TO THE EQUALIZING BEAM. DO
NOT STRIKE AN ARC WITH THE ELECTRODE ON THE EQUALIZING BEAM AND AXLE. DO NOT USE HEAT
NEAR THE EQUALIZING BEAM ASSEMBLY. DO NOT NICK OR GOUGE THE EQUALIZING BEAM. SUCH
IMPROPER ACTIONS CAN DAMAGE THE EQUALIZING BEAM ASSEMBLY, AND CAN CAUSE ADVERSE
VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.
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:
1. WEAR PROPER EYE PROTECTION.
2. WEAR CLOTHING THAT PROTECTS YOUR SKIN.
3. WORK IN A WELL-VENTILATED AREA.
4. DO NOT USE GASOLINE OR FLAMMABLE SOLVENTS THAT CAN EXPLODE.
5. 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.
DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR
POLISHED PARTS. DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY.
Special Tools 10 17730-241
AR2™
Special Tools
Hendrickson Part No. 66086-103
Visit otctools.com
Use with the equalizing beam removed from the
truck, and in conjunction with OTC No. 51100
press plate and a 100 ton hydraulic shop press.
Hendrickson Part No. 66086-104
Visit otctools.com
This shop made tool is made from cold rolled
steel or equivalent.The drawings are for refer-
ence only, Hendrickson does not supply this tool.
Hendrickson Part No. 66086-105
Visit otctools.com
28K-52K lb. Rubber Bushings
Hendrickson Part No. 66086-102
Visit otctools.com
40K lb. Rubber Bushings
Hendrickson Part No. 66086-100
Visit otctools.com
1. Remover 310248
2. Installer 310249
12
6
3,4,5
1. Installer 520493
2. Cap 219554
3. Cap Screw 520563
4.Washer 11253
5. Hex Nut 10221
6. Shims 302401
12
3
9
8
5
7
4
6
1. Installer 206457
2. Remover 302027
3. Press Plate 51100
4. Installer 302031
5. Remover 302032
6. Press 206457
7. Remover 302030
8. Installer Clamp 42052
9. Clamp Plate 206459
12
17730-241 11 Special Tools
AR2™
Hendrickson Part No. 66086-001L
Hendrickson Part No. 66086-000L
These shop made tools are designed for the torque rod bushings. Bushing tools are to be made from cold rolled steel or
equivalent. Drawing is for reference only. Hendrickson does not supply these tools.
BUSHING
Parts Lists 12 17730-241
AR2™
Parts Lists
17730-241 13 Parts Lists
VEHICLE
KEY NO. PART NO. DESCRIPTION QTY.
VEHICLE
KEY NO. PART NO. DESCRIPTION QTY.
AR2™
1 Equalizing Beam Assembly 2
See Selection Guide 45745-147
2 44643-009L Cross Tube 447⁄8", (If converted from RT•RTE 1
suspension, refer to Lit.No.SP-168 Parts List)
Use Center Bushing End Plug 22281-000 for
Cross Tube Replacement
3 Rubber Center Bushing 2
49400-000L 40K Welded End Plug
49600-000L 40K w/Loose End Plug
29483-005L 46K Welded End Plug
34013-097L 46K w/Loose End Plug
4 34013-087L Non-Shim Type, Includes Key No. 7a, 8
5 34013-088L Shim Type, Includes Key Nos. 6a, 7b, 8
34013-188L Rotating Bar Pin (Not Shown), Shim Type,
Includes Key Nos. 6a, 7c, 8
6 Bar Pin Shim 8
a 50130-000 0.19" / 0.19" Standard
b 50131-000 0.25" / 0.12" Optional
c 57026-000 0.375" Optional at shim
7 *Bar Pin End Bushing 4
a Non-Shim Type
b Shim Type
c Rotating Bar Pin,Shim Type (Not Shown)
8 34013-104
Includes Key Nos.9-11
9 *1"-8 UNC x 6" Hex Bolt 8
10 *1" Hardened Washer 16
11 *1"-8 UNC Locknut 8
12
34013-049L 40K, Includes Key Nos. 13a, 14
34013-073L 46K, Includes Key Nos. 13b, 14
13
a 45000-007L 40K
b 21140-034L 46K
14 45900-000L Rubber End Bushing 4
15 LH Frame Hanger Assembly - Blank 1
65461-001 33.94-34.19" Frame Width
65461-003 34.25-34.50" Frame Width
65461-005 34.56-34.81" Frame Width
RH Frame Hanger Assembly - Blank (Not Shown) 1
65461-002 33.94-34.19" Frame Width
65461-004 34.25-34.50" Frame Width
65461-006 34.56-34.81" Frame Width
16 Trailing Arm Assembly,
Includes Key Nos. 17, 24-27
• Left Hand 1
65655-001 40K - 9½"
65655-003 40K - 10½"
65655-005 46K - 9½"
65655-007 46K - 10½"
• Right Hand 1
65655-002 40K - 9½"
65655-004 40K - 10½"
65655-006 46K - 9½"
65655-008 46K - 10½"
Includes Key Nos. 17-18
34013-111L 40K
34013-112L 46K
17 Trailing Arm Bushing 2
45900-000L 40K
29878-001L 46K
18 21140-053L Adapter Assembly, Includes Key Nos. 19-23 2
19 45289-003 Adapter Tube 2
20 45871-000 Trailing Arm Adapter 4
21 30550-005 1"-14 UNS x 9¾" Bolt 2
22 22962-008 1" Hardened Washer 4
23 08017-000 1"-14 UNS Locknut 2
24 58795-000 Saddle Cap 4
25 06696-000 7⁄8"-14 UNF Saddle Cap Stud 8
26 22962-002 7⁄8" Hardened Washer 8
27 04842-000 7⁄8"-14 UNF Locknut 8
28 Air Spring Assembly
65455-002L Forward 2
65652-002L Rear 2
29 Air Spring Bracket
65426-000 Forward 2
65680-000 Rear 2
49177-017
Includes Key Nos. 30-34
30 22962-001 ¾" Hardened Washer 4
31 17700-031 ¾"-16 UNF Nylocknut 4
32 65999-000 ½"-13 UNC x 2¼" Stud, Replaces 65454-000 8
33 22962-011 ½" Hardened Washer 8
34 17700-010 ½"-13 UNC Nylocknut 8
35 60665-012L Shock Absorber 2
50754-013 Single Upper Shock Bracket and Fastener 2
Service Kit, Includes Key Nos. 36-39
36 67463-001 Shock Bracket, Replaces 65000-001 2
37 50764-010 ¾"-10 UNC x 4¾" Bolt 2
38 22962-001 ¾" Hardened Washer 2
39 49842-000 ¾"-10 UNC Locknut 2
50754-018
Includes Key Nos. 40-42
40 50764-013 ¾"-10 UNC x 7½" Bolt 2
41 22962-001 ¾" Hardened Washer 4
42 49842-000 ¾"-10 UNC Locknut 2
43 65427-000 Lower HCV Bracket 2
57977-000 Height Control Valve Assembly, Includes 2
Key Nos. 44-47
44 60501-000 Height Control Valve 2
45 *¼" Hardened Washer 4
46 *¼"-20 UNC Locknut
47 *Height Control Valve Bracket 1
57430-004
Includes Key Nos.48-50
48 58035-004 3⁄8"-16 UNC x 1¼" Bolt 4
49 22962-015 3⁄8" Hardened Washer 4
50 17700-006 3⁄8"-16 UNC Nylocknut 4
51 58994-001 Height Control Valve Linkage Assembly 2
Includes Key Nos. 52-58
52 *Linkage Extension Rod 2
53 *Adj.Valve Arm Joint 2
54 *Valve Arm Clamp 2
55 *5⁄16"-18 UNC Stud 4
56 *5⁄16"-18 UNC Jam Nut 4
57 *5⁄16" Hardened Washer 4
58 *5⁄16"-18 UNC Locknut 4
59 **One-piece ULTRA ROD®PLUS™ Longitudinal
Torque Rod Assembly Straddle/Straddle,
Specify Length in mm, Includes Key No.61a
72000-XXX Front 1
72001-XXX Rear 1
60 ***One-piece Transverse Torque Rod Assembly 2
Straddle/Taper,Specify Length in mm
72350-XXX ULTRA ROD PLUS,Includes Key Nos.61a-62a
92350-XXX XTRB, Includes Key Nos. 61b-62b
61 Straddle Bushing 6
a 64400-002L ULTRA ROD PLUS
b 66649-002L XTRB
62 Taper Bushing 2
a 64400-004L ULTRA ROD PLUS
b 66649-004L XTRB
Parts Lists 14 17730-241
AR2™
**Two-Piece Torque Rod Assembly
with Bushings Service Kit
65781-000 ULTRA ROD PLUS Straddle/Taper
65781-001 XTRB Straddle/Straddle
65781-002 XTRB Straddle/Taper
63 22186-000 Torque Rod Bracket 4
64 Torque Rod Axle Bracket 2
46868-000 For Meritor Axle
48042-000 For Dana Axle
65 49689-000L Torque Rod Shim (As Required)
66 Torque Rod Back-up Plate As Req.
45045-001
1⁄8" Thickness
45045-002 ¼" Thickness
45045-003
3⁄8" Thickness
67 32043-019 5⁄8"-11 UNC x 5½" Bolt 4
68 22962-004 5⁄8" Hardened Flat Washer 8
69 47764-000 5⁄8"-11 UNC Locknut 4
70867-001 P-80 Lubricant - 10 ml (Not Shown) Per Bushing 1
70 65202-001 Pressure Protection Valve, See plumbing diagram 1
71 66029-000 In Cab Air Dump Switch, See plumbing diagram 1
72 48940-000 In Cab Air Switch Plate (Not Shown) 1
* Item included in assembly / kit only, part not sold separately.
** Hendrickson’s part number is stamped on the torque rod for identication.Be sure to include the sufx number when ordering,this number
indicates torque rod length.Hendrickson’s two-piece ULTRA ROD PLUS can be used to create the desired length,see literature number
45745-148.
*** Transverse torque rods are mandatory with the AR2 Suspension regardless of axle spacing and require rubber center bushings.
AR2 PLUMBING DIAGRAM
Port 3:
Vent to
atmosphere
Port 2:
Supply
to Height
Control Valve
Port 1:Input
from pressure
protection valve
Key No. 71
17730-241 15 Preventive Maintenance
AR2™
Preventive Maintenance
Following appropriate inspection procedures is important to help ensure the proper maintenance
and operation of the AR2 heavy-duty suspension system and component parts function to their
highest efficiency. Look and replace any bent, cracked, worn or damaged parts. Hendrickson rec-
ommends the AR2 heavy-duty rear suspension is inspected at pre-delivery, the first 1,000 miles
(1,600 kilometers) of service and at the regular preventive maintenance intervals. Off-highway
and severe service operating conditions require more frequent inspections than on-highway ser-
vice operation. Inspection must include the following items and other components referenced in
this section.
Torque values shown in this publication apply only if Hendrickson supplied fasteners are used. If
non Hendrickson fasteners are used,follow the torque specification listed in the vehicle manufac-
turer’s service manual.
FIRST
Visual Inspection for proper assembly and function.
Check for all of the following and replace components as
necessary:
• Signs of unusual movement, loose or missing
components
• Signs of abrasive or adverse contact with other
components
• Damaged, or cracked parts
100 Miles
100 Hours
comes first
Inspection of fasteners for proper torque as
recommended in the Torque Specication section of
this publication with special attention to the following
suspension connections:
• Frame hanger to trailing arm connection
• Equalizing beam end connection
•Torque rods
• Saddle cap to trailing arm connection
Verication of the alignment of axles are within the
vehicle manufacturer’s tolerances
Verify proper ride height,refer to the Ride Height in the
Alignment & Adjustments section of this publication
Hendrickson recommends the use of Grade 8 bolts, Grade C locknuts and hardened washers for
all suspension component attachments.
■Air spring — Look for chafing or any signs of spring or component damage.Ensure that the upper
bead plate is tight against the underside of the frame.Replace all worn or damaged parts.
■Cross tube — Clean the cross tube and inspect it for cracks or excessive wear 8" to 10" from
each end where it enters into the equalizing beam center bushings. Use a straight edge to
check the straightness of the cross tube. If there is a doubt as to fracture, wear or straight-
ness,replacement is necessary.
■Shock absorbers — Look for any signs of dents or leakage.Misting is not considered a leak.
See Shock Absorber Inspection in this section.
Preventive Maintenance 16 17730-241
AR2™
■ — Check the overall
condition of the equalizing beam for dents, dings, or other damage. Inspect the equalizing
beam end connection and saddle cap fasteners for proper torque.The beam end connec-
tion must sustain proper clamp force of the axle bracket legs to the bushing inner casting
prevent any movement of the beam end connection. See Equalizing Beam End Connection
in this section. See Torque Specifications section of this publication for recommended
torque requirements.
■Fasteners — Look for any loose or damaged fasteners on the entire suspension.Make sure
all fasteners are tightened to a torque value within the specified torque range. See Torque
Specifications section of this publication for recommended torque requirements. Use a cali-
brated torque wrench to check torque in a tightening direction.As soon as the fastener starts
to move, record the torque. Correct the torque if necessary. Replace any worn or damaged
fasteners with genuine specified fasteners. For fasteners not supplied by Hendrickson, see
vehicle manufacturer.
■Torque rods — All torque rods must be inspected every six months for looseness, torn or
shredded rubber, bushing walk-out, and for proper fastener torque. If there is metal-to-metal
contact in the bushing joint, this is a sign of excessive bushing wear and the bushing needs
to be replaced.
■ — Inspect all parts of the suspension for wear and damage.Look for bent
or cracked parts.Replace all worn or damaged parts.
■Frame hanger bracket — Check for any signs of loosening or damage at the pivot connec-
tions.Check for cracks,damage,or any signs of looseness at the mounting fasteners.Replace
all worn or damaged parts.
■Height control valve and air lines — Check the suspension air system for air leaks. Check
all air lines for proper routing.Check for chafing or pinched air lines.Check the height control
valve linkage for damage or interference with peripheral components. Replace all worn or
damaged parts.
■Trailing arm assembly — Check the overall condition of the trailing arm for cracks, dents,
dings,or other damage on the trailing arm assembly.Check the trailing arm bushings for tear-
ing or extreme bulging. Check for any metal to metal contact in the bushed joints.Replace all
worn or damaged parts.
■Tire wear — Inspect the tires for wear patterns that may indicate suspension damage or
misalignment. Replace all worn or damaged parts.
See vehicle manufacturer’s applicable publications for other preventive maintenance
requirements.
The axle brackets are furnished and welded into position by the vehicle manufacturer or axle
manufacturer.
When an equalizing beam is removed for repair or inspected, check for signs of movement.Also
inspect the axle brackets:
■For damage and / or cracks,see Figures 6-1 and 6-2
■Measure the two dimensions on the axle bracket legs,see Figure 6-2
An axle bracket outside of the measurement range, damaged or cracked must be repaired
or replaced. Consult the vehicle manufacturer for inspection, component repair and replace-
ment instructions.
17730-241 17 Preventive Maintenance
AR2™
■
1. Inspect the axle brackets for damage or cracks in the locations shown in Figures6-1 and 6-2.
Any axle bracket that is found damaged or cracked must be repaired or replaced.
2. Measure the distance between the axle bracket legs for correct width,refer to Figures6-1 and
6-2 for measurement location and dimensions.An axle bracket outside of the measurement
range must be repaired or replaced.
3. Consult the vehicle manufacturer for inspection, component repair and replacement
instructions.
■Adapter Style
1. Inspect the 2½" (64 mm) diameter holes in each of the axle bracket legs as shown in Figure6-3.
2. Remove any burrs or material left there by the
old adapters.
3. Use a new adapter as a gauge for fit, being
sure it enters the holes from the outside of
each bracket leg.
The Adimension between the inside sur-
faces of the axle bracket legs for beam
end adapter style, as shown in Figure 6-3
as dimension, must be as in determined in
Table 6-1.
A
40K • 46K 5¾" 5.765"± 0.005"
Preventive Maintenance 18 17730-241
AR2™
An inspection of the beam end connections are necessary when a vehicle is in the shop for major
repair work or every six months,whichever comes first.Periodic visual inspection by the driver and
service personnel is also recommended. Off-highway and severe service operating conditions
require more frequent inspections than on-highway service operation.
The equalizing beam end connection requires that the fasteners are tightened to torque specifi-
cations to maintain the clamp load of the axle bracket legs to the bar pin.All bushing motion is
accommodated by rubber deflection.
■
1. Chock the wheels.
2. Visually inspect suspension components for signs of movement or excessive wear.
■Inspect alignment shims in equalizing beam end for looseness. Lightly tap on the align-
ment shims to see if they can be moved. If movement is detected, tighten fasteners to the
proper torque value, see Figure 6-6
■Inspect equalizing beam end connection for signs of excessive wear or looseness
An equalizing beam end connection, which is visibly cleaner than the other connections, may
indicate a loose connection.
■Look for worn, frayed or distorted rubber in the bar
pin beam end bushing,see Figure 6-4
■Look for the equalizing beam to be lower in the
beam hanger, see Figure 6-4
■If the bar pin beam end bushing is visually offset
a floor jack test should be performed. See Jack
Test in this section
1. Place a jack under each beam end as shown. Raise
the jack to check for movement in the connection or
rubber components,see Figure 6-5.
17730-241 19 Preventive Maintenance
AR2™
The gap at each side of the visible rubber on the lower part of the bar pin end bushing is normal,
see Figure6-5, and is not an indication to replace the bushing. Because all rubber end bushings
are in compression, with the load bearing on the top side,the lower side of the rubber is slightly
relieved, allowing the rubber to move inward,and a gap appears.
■
IF BAR PIN MOVEMENT OR LOOSENESS IS NOTED IN THE EQUALIZING BEAM END HUB, DO NOT
OPERATE THE VEHICLE. REPLACE THE RUBBER END BUSHINGS AND ALL CONNECTING PARTS.
THE ABOVE CONDITION CAN RESULT IN COSTLY REPAIR, DOWNTIME, POSSIBLE SEPARATION OF
COMPONENTS,ADVERSE VEHICLE HANDLING, PROPERTY DAMAGE,OR PERSONAL INJURY.
An equalizing beam end connection that is visibly cleaner than the other connections may indi-
cate a loose connection.
2. If bar pin end bushing movement or looseness is detected in the equalizing beam end hub,
replace the end bushings and all connecting parts. Refer to the Component Replacement
section of this publication.
3. Check and record torque values for each 1" bar pin fastener,see Figure 6-6.Ensure all fasten-
ers are tightened to the following:
■At the locknuts tighten to 525 ± 75 foot pounds torque
■At the bolt head tighten to 575 ± 75 foot pounds torque
4. Recheck equalizing beam end connections for signs of looseness.
■Inspect alignment shims in equalizing beam end for looseness. Lightly tap on the align-
ment shims to see if they can be moved. If movement is detected, tighten fasteners to the
proper torque value, see Figure 6-6
■Inspect equalizing beam end connection for signs of excessive wear or looseness
5. If bar pin looseness is still detected in the equalizing beam end hub, operate the
vehicle. One or more components will require replacement, see Component Replacement
section of this publication.
Preventive Maintenance 20 17730-241
AR2™
■
1. Chock the wheels.
2. Visually inspect suspension components for signs of movement or excessive wear.
■Inspect equalizing beam end connection for signs of excessive wear or looseness
■Look for worn, frayed or distorted rubber in the beam, see Figure 6-4
■Look for the equalizing beam to be lower in the axle bracket,see Figure 6-4
■If it is visually offset a jack test should be performed. Place a jack under each beam end
as shown.Raise the jack to check for movement in the connection or rubber components,
see Figure 6-5
3. The beam end adapter style connections have
an adapter flange with a flat side for assembly
clearance with the axle housing bowl.
■The flat must be positioned vertically as
shown in Figure 6-7.If the flat of the adapter
position is incorrect, removal of the fasten-
ers will be necessary to correct position,
refer to the Adapter Style End bushings in the
Component Replacement section
■
IF BUSHING MOVEMENT OR LOOSENESS IS NOTED IN THE EQUALIZING BEAM END HUB, DO NOT
OPERATE THE VEHICLE. REPLACE THE RUBBER END BUSHINGS AND ALL CONNECTING PARTS.
THE ABOVE CONDITION CAN RESULT IN COSTLY REPAIR, DOWNTIME, POSSIBLE SEPARATION OF
COMPONENTS,ADVERSE VEHICLE HANDLING, PROPERTY DAMAGE,OR PERSONAL INJURY.
An equalizing beam end connection that is visibly cleaner than the other connections may indi-
cate a loose connection.
1. If bushing movement or looseness is detected in the equalizing beam end hub, oper-
ate vehicle. Replace the equalizing beam end bushings and all connecting parts.Refer to the
Component Replacement section of this publication.
2. Check and record torque values, see Figure 6-8. Ensure all fasteners are tightened to the
following:
■40K — 225 ± 15 foot pounds torque
■46K — 470 ± 25 foot pounds torque
3. Recheck equalizing beam end connections for signs of looseness.
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