Replacement
GENERAL PRECAUTIONS1. Whenever any part of system, is removed or disconnected, utmost cleanliness must be observed.
2. Disconnected ports and hoses must be plugged to prevent ingress of dirt.
- If metal sediment is found in system, establish cause rectify and flush system.
3. Do not start engine until reservoir is full as pump will be damaged.
4. Metric pipe installings are used with 'O' ring pipe ends on installings to steering box.
5. Follow normal 'O' ring replacement procedure whenever pipes are disconnected.
6. Ensure compatible metric components when installing replacement pipes.
CAUTION:
^ Before removing any parts of steering linkage, it is imperative that road wheels are positioned straight ahead. Then steering wheel removed to prevent rotary coupler being wound up or damaged.
^ After reinstalling steering linkage parts follow correct procedure to ensure that road wheels, steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition. If steering wheel requires repositioning, ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced.
^ This ensures drive pegs locate in their holes in rear of steering wheel.
^ After final alignment connect rotary coupler muitiplug, tighten steering wheel securing nut and install air bag.
NOTE: When drag link is disconnected from steering box, travel available at steering wheel to each full lock is not equal.
REMOVAL
1. Site vehicle on level surface.
2. Open bonnet[hood].
3. Remove filler cap from power steering fluid reservoir.
4. Clean steering box.
5. Disconnect feed and return pipes (5) from steering box.
6. Plug open pipes and steering box ports to prevent ingress of dirt.
7. Support chassis front on axle stands, or raise vehicle on a suitable hoist.
NOTE: Ensure wheels are chocked, parking brake is applied, and low range selected as required.
8. Remove undertray.
9. Disconnect drag link (9) from drop arm using a suitable extractor.
10. Remove pinch bolt (10) securing lower shaft universal joint to power steering box.
11. Loosen but do not remove nut (11) securing tie bar to mounting.
12. Remove bolts (12) securing tie bar, move tie bar aside.
13. Remove bolts (134) securing power steering box to chassis side member.
14. Withdraw power steering box.
INSTALLATION
1. Position steering box to chassis side member, ensuring locating peg is engaged, then insert bolts and tighten to 81 Nm.
2. Install pinch bolt and nut securing universal joint to power steering box, then tighten to 25 Nm.
3. Position tie bar, tighten bolts and nut to 81 Nm, starting with tie bar to mounting nut, then loosen nut and bolts by one complete turn.
4. Check steering box, adjust if necessary. See Adjustment
5. Install drag link to drop arm, then tighten nut to 40 Nm.
6. Install undertray.
7. Lower vehicle to ground.
8. Remove plugs and reinstall pipes to steering box.
- Tighten as follows:
- 16mm thread to 20 Nm.
- 14mm thread to 15 Nm.
9. Remove reservoir filler cap, then using recommended fluid, fill reservoir to oil level mark on dipstick.
10. Bleed power steering system, then recheck fluid level and replace cap. Service and Repair
11. With engine running, test steering system for leaks by holding steering in both full lock directions.
CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute, to avoid oil overheating and possible seal damage.
12. Test drive vehicle: using both full lock directions, to settle steering components. If possible, drive vehicle over speed bumps and include harsh braking.
WARNING: Do not test drive vehicle on public highway.
13. Drive vehicle in a straight line on level ground and stop.
14. Tighten tie bar to mounting nut to 110 Nm.
15. Tighten bolts securing tie bar to 81 Nm.
16. Ensure steering wheel is correctly aligned when wheels are positioned straight ahead.
17. If necessary reposition steering wheel. Refer to Steering Wheel
18. Road test vehicle.