Power Steering Gear
Disassembly/AssemblyFig. 1 Steering Gear Cross-sectional View (Part 1 Of 2):
Fig. 1 Steering Gear Cross-sectional View (Part 2 Of 2):
Fig. 2 Steering Gear Exploded View (Part 1 Of 2):
Fig. 2 Steering Gear Exploded View (Part 2 Of 2):
Refer to Figs. 1 and 2, for steering gear service.
DISASSEMBLY
1. Position steering gear in suitable soft jawed vise.
2. Remove locking ring and attaching screw, then using tool No. 000 589 88 33 00 or equivalent, remove pitman arm from shaft.
3. On 1st version steering gear, remove hex nut (85) and dowel sleeve (83).
4. On all steering gears, loosen closing screw (62), then turn steering worm until nearly at right or lefthand lock.
5. Remove locking ring (75) and thrust ring (74).
6. Remove locking ring (73).
7. Remove cover (71), spring (70), spring bolt (69) and bushing (68).
8. Position steering to center position.
9. Remove steering case cover attaching screws (51).
10. Apply counter pressure to adjusting screws, then remove self-locking hex nut.
11. Turn adjusting screw to right in steering center position.
12. Remove pitman shaft from steering case cover.
13. Remove bearing cap attaching screws.
14. Turn steering worm to left until bearing cap pulls slightly from case. Do not turn to far as balls may fall from ball circuit.
15. Remove bearing cap with steering worm.
16. Using measuring tool No. 116 589 03 21 00 or 201 589 59 00 or equivalent, measure friction torque of ball circuit. Steering nut friction torque should be 5-50 Ncm, if not as indicated, replace.
17. Remove steering case cover from pitman shaft.
18. Remove locking ring (55) from steering case cover.
19. Using suitable screwdriver, remove radial steering ring (54) from case cover.
20. Remove O-rings (53 and 56) from case cover.
21. Remove adjusting screw locking ring (49), then remove thrust ring (48).
22. Remove pitman shaft locking ring (47).
23. Remove adjusting screw (45) with thrust washer (46).
24. Position bearing cap with steering worm in suitable work tray.
25. Unbend locking plate (38), then remove screws (39), locking plate clamp (37) and ball guide halves (36).
26. Remove steering worm (13) from steering nut (25), ensure no balls are lost (23 each).
27. Remove bearing cap O-ring, then position bearing cap in suitable soft jawed vise.
28. Using tool Nos. 201 589 02 09 00 and 126 589 00 16 00 or equivalent, remove bearing insert nut.
29. Remove bearing insert (17) from bearing cap (12).
30. Remove teflon ring (21) and O-ring (20) from bearing cap.
31. Remove steering worm (13) from bearing cap, then remove axial bearing (82) and washer (22) from steering worm.
32. Remove bearing cap locking ring (15).
33. Remove bearing cap seal.
34. Install piston and secure with plug.
35. Using slot wrench tool No. 201 589 01 07 00 or equivalent, remove slot nut and screw cover.
36. Remove outer race (31) from screw cover.
37. Remove ball cage (32) from steering cage.
38. Remove steering nut (25) from piston.
39. Remove inner race (30) and bearing ring (26) from steering nut.
40. Remove axial needle cage (28) and axial washer (27) from working piston.
41. Remove locking nut (9) from steering case.
42. Pull closing cap (8) from steering case.
43. Remove O-ring (10) from closing cap (8).
44. Remove control valve (4) from steering case, ensuring reaction piston springs do not fall out.
45. Remove ring (81) and O-ring (80) from steering case.
INSPECTION
1. Inspect steering worm and steering nut, as follows:
a. Check ball paths on steering worm (13) and steering nut. If traces of wear are shown, replace steering.
2. Check bearing insert as follows:
a. Check needle sleeve (18) for wear.
b. If wear is indicated, replace bearing insert (17).
3, Inspect pitman shaft, as follows:
a. Check pitman shaft for wear at bearing points and for distortion or other damage. Replace pitman shaft, if required.
4. Inspect steering case, as follows:
a. Check needle sleeve (2) in steering case for wear. If required, replace.
5. Inspect housing cover, as follows:
a. Check needle sleeve (52) for wear. Completely replace housing cover, if the needle bushing is damaged.
6. Check control valve, as follows:
a. Check reaction piston (5) in control valve for smooth operation. If required, remove reaction piston after removing locking ring and clean. Do not interchange springs (6) and compensating washers of both reaction pistons.
ASSEMBLY
1. Using tool No. 201 589 05 31 05 or equivalent, press sealing ring (14) in bearing cap to a depth of .193 inch (4.9 mm).
2. Install locking ring (15) to bearing cap.
3. Install tool No. 201 589 05 31 00 or equivalent, to bearing cap, then position in suitable soft jawed vise.
4. Install O-ring and teflon ring (21) to bearing insert.
5. Install bearing insert (17) to bearing cap (12) and tighten slightly, then install nut (23) with chamfer toward bearing cap on bearing insert.
6. Measure friction torque of steering worm in bearing cap (sealing point only), by positioning measuring tool on steering worm splines. Friction torque should be less than or equal to 12 Ncm. Then tighten bearing insert (17) to with pin spanner until an additional 4-7 Nm friction torque are measured. Then tighten slot nut to 162-177 ft. lbs. and check friction torque once again.
7. Friction torque can also be measured with torque wrench in combination with insert.
8. Remove bearing cap from fixture, install O-rings (16).
9. Install working bearing into fixture and secure with plug.
10. Install axial washer and needle cage to working piston.
11. Install bearing ring (26) and inner race (30) to steering nut.
12. Install steering knuckle (25) into working piston in such a manner that bearing ring rests on axial needle cage.
13. Install ball cage (32) on steering nut.
14. Push outer race (31) up to screw cover stop.
15. Install screw cover (33) to working piston.
16. Install slot nut (34) on screw cover and tighten slightly.
17. Clamp piston in fixture and adjust friction torque of steering nut in piston, while placing measuring device on straightedge of steering nut. Friction torque is 6-10 Ncm. Then tighten screw cover until weight on measuring device will just turn steering nut. Secure screw cover with slot nut, tightening torque 148-176 ft. lbs.
18. Remove working piston from device and place into assembly tray.
19. Install steering worm into steering nut until one ball circuit is completely shown through bore (for balls) in steering nut.
20. Install 16 balls into ball circuit while slowly turning steering worm to the right.
21. Fill one ball guide half (36) with grease and insert remaining 6 balls into this guide half. Then attach the other ball guide halves into steering nut. Mount fastening clip and install hex screws (39) with serrated washers and torque to 8-11 ft. lbs.
22. Position measuring fixture on splines of steering worm and measure friction torque of ball circuit. The friction torque of steering nut/steering worm should be 5-50 Ncm. If the friction torque is not within this tolerance, replace complete ball circuit together with steering nut, steering worm and balls.
23. The friction torque can also be measured with torque wrench.
24. Replace O-ring (3) in steering case.
25. Install bearing cap O-ring (40) to case.
26. Install O-ring (10) on control valve.
27. Install reaction pin spring (6).
28. Install control valve (4) to case, ensuring springs do not fall out.
29. Replace closing cover (8), then knock closing cover into steering case by means of a plastic hammer.
30. Install locking ring (9) into steering case in such a manner that the lugs of the ring are exerting pressure on closing cover. If required, knock-in locking ring slightly by means of a mandrel until correctly fitted in groove of steering case.
31. Carefully install working piston complete with steering worm, steering nut and bearing cap into steering case, while installing straightedge of steering nut into groove of control valve. Do not use force.
32. Turn bearing cap in such a manner, that the oil duct on steering case is in alignment with the oil bore on bearing cap. Watch out for correct seat of O-rings. Then install hex bolts without snap rings and washers and torque to 51-55 ft. lbs.
33. Turn steering worm with the center tooth gap resting against piston in center of steering case.
34. Insert O-rings (53 and 56) into housing cover.
35. Insert adjusting screw (45), including thrust washer (46) and locking ring into pitman shaft, ensure of perfect seating of locking ring. Install adjusting screw into pitman shaft with as little play as possible. For this purpose, thrust washers .104, .106, .108, .110, .112, .114, .116, .118, .120 & .122 inch (2.65, 2.70, 2.75, 2.80, 2.85, 2.90, 2.95, 3.00, 3.05 and 3.10mm) thick are available.
36. Position thrust ring (48) on adjusting screw and insert locking ring (49).
37. Place housing cover (51) on pitman shaft, then insert pitman shaft into steering housing. Ensure the center tooth of the pitman shaft enters the center tooth gap of the working piston and that the O-rings are correctly seated.
38. Install adjusting screw (45) into steering case until it is hard to move.
39. Turn housing cover so that both oil ducts are one above the other. Then install hex bolts with new high-tension snap rings and tighten to 22-26 ft. lbs. The housing cover is now attached to steering housing by means of 4 hex screws.
40. Loosen adjusting screw (45) until the steering worm is easy to turn, then measure friction torque of steering worm and measure friction value.
41. Adjust pressure mechanism of pitman shaft by turning adjusting screw to the right until the friction torque has increased by 40-60 Ncm.
42. The friction torque can be measured with torque wrench.
43. Install seal/lock collar nut on adjusting screw (47) and tighten to 44-48 ft. lbs., while applying counterhold to adjusting screw.
44. Check total friction torque once again (refer to steps 36 and 37).
45. Slightly turn steering worm until working piston is no longer in steering center.
46. Install bushing (68) and spring bolt (69) to steering case.
47. Install compression spring (70) to cap, then install cap and spring to case.
48. Install cap locking ring.
49. Push thrust ring (74) on cap and install locking ring (75).
50. Install dowel sleeve (83) onto steering worm so that two surfaces are parallel with fastening points of steering and milled cut pointing toward pitman arm.
51. Install supporting ring (84) and torque to 37 ft. lbs.
52. Install pitman arm.