1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specification
2、s (MPAPS) NUMBER: MPAPS P-9540 Former Designation: TMS-9540 TITLE: Quality Requirements for Front Axle and Rear Axle Assemblies CURRENT REV No.: 1508 DATE: August 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: 1402 Feb. 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CU
3、RRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability
4、 of regulatory limits prior to use. Change Notice: Added specific coating requirements for steel axle flanges; Editorial changes Reference: File:02 Keywords: Front axles, rear axles, axle assemblies. 1.0 APPLICATION This specification covers quality control requirements for purchased front and rear
5、axle assemblies which are purchased from a supplier, provided by a licensee of a NAVISTAR axle design, or provided to NAVISTAR plants as completed units ready for delivery directly to the truck assembly line. 2.0 SCOPE This specification covers paint requirements, quality requirements, quality contr
6、ol plan, source approval, and shipping and identification requirements. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless other
7、wise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS G-9009 NAVISTAR MPAPS B-50 CFR Title 49, Part 571 NAVISTAR TMS-9543 NAVI
8、STAR Engineering Design Std. A-16 CFR Title 29, Part 1910 NAVISTAR Manufacturing Standard MS-D-13 CFR Title 49, Part 571.121 NAVISTAR TMS-9526 MPAPS G-5, Grade -32 4.0 GENERAL REQUIREMENTS Product supplied shall be suitable for its intended application. 4.1 Purchased Axle Housings For axle housings
9、purchased separately for production or service part usage or as part of a purchased axle assembly, the axle housing supplier must provide and warrant the housing free of defects and fully capable of performing to an axle housing capacity rating as established by the manufacturer. Considerations for
10、the supplier include choice of material, actual mechanical properties of the material, NUMBER: MPAPS P-9540 TITLE: Quality Requirements for Front Axle and Rear Axle Assemblies REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from
11、Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 2 of 6 heat treatment, quality of manufacture including welding, cleanliness, and protective coatings. These considerations are to be the responsibility of the axle housing s
12、upplier. Refer to TMS-9526 for axle housing weld requirements. 4.1.1 Cleanliness All housings shall be clean and free of any material detrimental to the function of the part. 4.2 Protective Coatings 4.2.1 All unmachined surfaces shall be protected by paint (black) which meets the requirements of MPA
13、PS G-9009, Class IIB. Also, this paint shall be compatible for re-coating with chassis paint, Grade -32, per MPAPS G-5, used as a finish coating in NAVISTAR Assembly Plants. 4.2.2 All steel axle flanges and hub ends shall be prepared to one of the following prior to chassis paint: Primer meeting MPA
14、PS G-9009 Class IIP. Color specified as NAV-0001. If parts are received from supplier in primed condition, a suitable Rust Preventative or Rust inhibiting oil should also be applied. Clean surface prepared per MPAPS G-1 Type Z1. If parts are received from supplier in prepared condition a suitable Ru
15、st Preventative or Rust inhibiting oil should also be applied. 100% of assemblies must be cleaned of contamination and any RP/Rust inhibiting oil removed fully prior to chassis paint; this shall not be an optional process step based on visual inspection. Cleaning and RP/rust inhibiting oil removal p
16、rocess to be defined by Navistar Manufacturing site and trialed / verified effective. Recommended RP removal wipe product: Bonderite Parcosol 263 RP removal wipe from Henkel. 4.3 Lubricants for Spindles All spindles must be coated with a corrosion resistant lubricant using the approved products list
17、ed in Section 9.0. Use of coatings not on this list must be approved by NAVISTAR Drivetrain Engineering prior to use. 5.0 QUALITY All front and rear axle assemblies supplied must be delivered in a clean and dry condition. All axle assembly/test fluids/greases which may remain or leave a residue in o
18、r on the axle must be compatible with NAVISTAR factory fill oils/greases. Spindles shall be free of rust, pits, burrs, gouges, nicks, and scratches, and must be coated with a temporary protective coating. Preservative oils and compounds must provide protection from rust and corrosion for a minimum p
19、eriod of 1 month outdoor storage for production parts and for a minimum period of 1 year unheated inside storage for service parts. Threaded ends shall be free from paint, dirt, or damage which could affect the torque-tension relationship. Kingpin and tie rod joints are to be lubed. 5.1 Compliance t
20、o FMVSS 121 All axles supplied with hubs, brakes, and steering arms must comply with the applicable requirements of FMVSS 121. A Compliance Report in accordance with TMS-9543 will be provided. 5.2 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement be
21、tween NAVISTAR and the supplier. The following items, where applicable,* shall be included in the control plan as features for management by statistical process control.* NUMBER: MPAPS P-9540 TITLE: Quality Requirements for Front Axle and Rear Axle Assemblies REVISION: 1508 This document is restrict
22、ed and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 3 of 6 5.2.1 Front Non-Drive Axles Supplied Less Hubs, Brakes, and Steering Arm 5.2.1.1 St
23、eering Knuckle Brake/Arm/Wheel Bearing Mounting Surfaces 1. Steering arm female taper gage diameter 2. Cotter key hole - location 3. Inner wheel bearing diameter 4. Outer wheel bearing diameter 5. Wheel seal diameter 6. Wheel seal surface finish 7. Brake pilot diameter 8. Brake mounting bolt holes,
24、true location 9. ABS hole diameter 5.2.2 Front Non-Drive Axles Supplied Less Hubs and Brakes and With Steering Arm 5.2.2.1 Steering Knuckle Brake/Arm/Wheel Bearing Mounting Surfaces 1. Cotter key hole - location 2. Inner wheel bearing diameter 3. Outer wheel bearing diameter 4. Wheel seal diameter 5
25、. Wheel seal surface finish 6. Brake pilot diameter 7. Brake mounting bolt holes, true location 8. ABS hole diameter 5.2.2.2 Steering Arm 1. Female taper gage diameter 2. Hardness of induction hardened zone (when specified on the engineering drawing) 3. Steering Arm Attachment Torque 5.2.2.3 I-Beam
26、Assembly 1. Spring pad parallelism (pads perpendicular to king pin) 2. Tie rod end nut torque 3. Tie rod arm nut torque 4. Tie rod clamp nut torque 5. Tie rod clamp orientation to clear beam (clearance to the I-beam must be checked at maximum turn angle) 6. U-bolt hole diameter 7. U-bolt lateral spa
27、cing 8. Toe-in setting NUMBER: MPAPS P-9540 TITLE: Quality Requirements for Front Axle and Rear Axle Assemblies REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume
28、all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 4 of 6 5.2.3 Front Non-Drive Axles Supplied With Unitized Hub, Drums And Brakes 5.2.3.1 Steering Arm 1. Female taper gage diameter 2. Hardness of induction hardened zone (when specified on the engineering drawing) 3. Steering Arm Attachme
29、nt Torque 5.2.3.2 I-Beam Assembly 1. Spring pad parallelism (pads perpendicular to king pin) 2. Tie rod end nut torque 3. Tie rod arm nut torque 4. Tie rod clamp nut torque 5. Tie rod clamp orientation to clear beam (clearance to the I-beam must be checked at maximum turn angle) 6. U-bolt hole diame
30、ter 7. U-bolt lateral spacing 8. Toe-in setting 5.2.3.3 Hub Assembly 1. Lateral Run-out Wheel mounting Surface 2. Hub Diameter of Hub Piloted Wheels 5.2.4 Front Drive Axles Supplied With Hubs, Brakes, And Steering Arm 5.2.4.1 Complete Axles with Hubs, Brakes, and Steering Arms 1. Steering arm female
31、 taper gage diameter 2. Steering arm attachment torque 3. Input spline OD (measurement over teeth) 4. Toe-in setting 5. Camber setting 6. Lateral run-out of the wheel mounting surface 7. Hub diameter of hub piloted wheels. NUMBER: MPAPS P-9540 TITLE: Quality Requirements for Front Axle and Rear Axle
32、 Assemblies REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 5 of 6 5.2.5 Rear Axle Assemblies 1. D
33、iameter of Axle Shaft Flange Mounting Holes 2. Distance from the Suspension Locating Pin to the Center of the Axle 3. Inner Wheel Bearing Diameter 4. Outer Wheel Bearing Diameter 5. Inner Wheel Seal Diameter 6. Spindle Thread Pitch Diameter: Measure with Johnson variable thread gages or equivalent.
34、* Additional characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9
35、001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnis
36、h copies of registration certificates to the Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing pra
37、ctices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Te
38、st data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall both perform a
39、nd report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality co
40、ntrol manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING, AND IDENTIFICATION Identification, packing and shipping shall be in accordance with Manufacturing Standard MS-D-13. NUMBER: MPAPS P-9540 TITLE: Quality Requirements
41、 for Front Axle and Rear Axle Assemblies REVISION: 1508 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. AUGUST 2015 Page 6 of 6 8.
42、0 DESIGNATION ON DRAWINGS The drawing will utilize the KCC symbol or include a note on the drawing stating: “Completed assemblies will comply with the requirements of MPAPS P-9540.” 9.0 APPROVED PRODUCTS FOR SPINDLE COATINGS* 1) ANTICORIT 6120/42 Corrosion Protection Oil (Fuchs Lubricants Co., Harve
43、y, IL) 2) Castrol Tarp BFX Barium-Free Thixotropic Rust Preventive (Castrol Industrial North America, Naperville, IL) 3) Chevron Multifak EP Chevron Product Co., San Ramon, CA 4) Ferrocote 5856 BF (Quaker Chemical Corp., Conshohocken, PA) 5) Rust Veto 853 *Other products may be used upon prior appro
44、val by Drivetrain Engineering. Supplier must provide NAVISTAR with product datasheets verifying effectiveness. 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Ave. Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/
