This is the LoneStar front air suspension manual, publication S03015, for the MaxxPower front air suspension on International ProStar and LoneStar trucks. It covers the air system, height control valves, air springs, shock absorbers, torque rods and ride-height adjustment.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | ProStar and LoneStar (Unit Code 03AZD, 03AZG) |
| System / Group | LoneStar / Front Air Suspension |
| Publication no. | S03015 |
| Year / Revision | 10/12/2009 |
| Pages | 48 |
| File size | 0.9 MB |
| Format | |
| Language | English |
Inside the LoneStar front air suspension
- Description: air system and height control valves
- Air springs, shock absorbers and sway bar
- Torque rods and transverse torque rod
- Height control valve removal and installation
- Air spring and shock absorber service
- Ride height checks and front axle caster
Copyrighted by Navistar in October 2009, the manual describes the air system, height control valves, air springs, shock absorbers, torque rods, sway bar and transverse torque rod that make up the system for feature codes 03AZD and 03AZG. It notes one shock absorber per side to control body sway and reduce tire wear, dual torque rods that minimise axle movement during braking, and a sway bar mounted to the lower torsion bars to reduce lean in corners. Remove-and-install procedures cover the height control valves, air springs, shocks, sway bar and both torque rods, with a caution to tighten torque-rod bolts only at proper ride height. Ride height must always be set by filling with air, never by exhausting, and the closing chart lists torque values from 60 lbf-in on valve mounts up to 300 to 370 lbf-ft on upper torque-rod bolts.
Applicable truck models
The MaxxPower system (feature codes 03AZD and 03AZG) uses one shock per side, dual torque rods and a sway bar. Ride height must be set by filling with air, not exhausting. Torque values include 195 to 240 lbf-ft on lower torque rod front mounts. Verify coverage against your VIN and build sheet on the International Trucks website.
Who needs the LoneStar front air suspension
Suspension and alignment technicians use this manual to replace air springs and shocks, service torque rods and the sway bar, and set correct ride height and caster on ProStar and LoneStar chassis.
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