Action
In case of a verified customer complaint perform the service fix procedure outlined below.SERVICE INSTRUCTION
Remove
1. Remove steering gear (see Global Technical Reference GTR Workshop Manual, section: 211-02).
Caution:
Before disconnecting or removing components, ensure the immediate area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Ensure that working surfaces are thoroughly clean, to avoid contamination of the hydraulic components.
2. Place steering gear on a suitable bench.
Warning:
A small amount of fluid loss is unavoidable; position an absorbent cloth or container to collect the fluid
Caution:
Always install clean plugs into open connections to prevent contamination.
Avoid excessive skin contact with mineral oil. Mineral oils remove the natural fats from the skin, leading to dryness, irritation and dermatitis.
3. Remove external fluid pipes securing plate bolt and plate at pinion housing, remove pipe clips and discard, remove pipes, remove and discard 0-rings.
Caution:
Ensure that working surfaces are thoroughly clean, to avoid contamination of the hydraulic components.
4. Position the steering gear in a vise equipped with soft jaws.
5. Remove and discard the boot securing clip on the pinion end of the rack body, and release boot (Illustration 2).
Caution:
Note the orientation of the rack bar to the rack bar housing, and mark the position of the rack bar in relation to the rack bar housing. This will aid reassembly of the pinion housing to the rack housing after the seal has been replaced, by ensuring that the rack bar teeth, are in the correct position to allow meshing of the pinion when the pinion housing is reinstalled.
6. Align the steering gear to measurements shown in illustration 3.
7. Note the position of the steering gear pinion shaft, and mark the position of the pinion shaft in relation to the pinion housing (Illustration 4).
Note:
Align the split in the tool to the paint mark on the pinion shaft and housing. The special tool should be installed flush to the pinion housing.
8. Attach the special tool 211-329/02 to the pinion shaft and tighten the Allen bolt (Illustration 5).
Caution:
Position lint free cloth over the hydraulic ports and position suitable container to collect fluid.
Cycle the steering gear slowly, to avoid excessive hydraulic pressure being generated.
9. Using a ratchet in the special tool, manually operate the steering gear to expel any residual fluid from the steering gear (Illustration 6).
10. Reposition the steering gear to align the painted marks on the steering gear pinion housing (Illustration 7). Check the rack travel measurement is 65 mm
Note:
Do not remove the 0-ring seal at this stage.
11. Remove the pinion pre-load nut using special tool 211-329/04, and collect the pre-load tension spring (Illustration 8).
12. Remove and discard the two pinion housing securing bolts (Illustration 9)
Caution:
Make sure the working surfaces are thoroughly clean to avoid contamination of the sensitive hydraulic components. Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
Note:
On removal the pinion shaft will rotate approximately 90 degrees counterclockwise.
13. Using a nylon mallet, carefully release the pinion housing.
14. Place the pinion housing assembly in a clean plastic bag, and seal to prevent contamination.
Caution:
It is imperative that no damage is caused to the seal register when removing the seal. Protect the seal register using lint free cloth.
15. Carefully remove the pinion shaft inner seal (Illustration 10).
16. Clean the seal register and thoroughly inspect for damage.
Installation
Caution:
A soft-faced hammer should be used to avoid damaging the special tool and creating debris.
Note:
Make sure the flat part of the seal is installed into the rack.
Note:
Apply lubricant (Castrol WB or Petroleum Jelly), to assist seal installation.
17. Lubricate and install the new steering gear pinion housing seal, using special tool 211-329/03 (Illustration 11).
18. Align the steering gear to measurements shown in illustration 12.
19. Remove the steering gear pinion housing from the plastic bag.
20. Lubricate and install the new 0-ring seal, rotate the pinion and align the painted marks on the steering gear pinion housing.
Note:
Ensure that the rack bar to rack housing orientation marks made at step 6 are aligned before attempting to install the pinion housing.
21. Align the paint marks, and then rotate the steering gear pinion counterclockwise so that the alignment paint marks are 90 degrees apart (Illustration 14).
Caution:
Care must be taken when locating the pinion housing assembly to avoid damaging the new seal (if the pinion housing has to be removed for realignment, the seal must be checked for damage and replaced if necessary).
22. Install the pinion housing to the steering gear body allowing the pinion shaft to rotate clockwise as it enters the body. Ease the rack shaft upwards against the body as this operation takes place to reduce the tension on the pinion shaft and help assembly.
23. Check that the paint marks and the 65 mm measurement are all aligned at the end of the installation.
24. Install the two new bolts securing the pinion housing and tighten to 17 Nm ( 12 lb.ft) (Illustration 15).
Caution:
Ensure any open connections are plugged to prevent contamination.
25. Using a M35 x 1.5 tap, clean the pinion pre-load nut thread, remove any debris from the steering gear and remove and discard the 0-ring seal.
26. Install the steering gear pretension spring to the steering gear body, and lubricate and install the new 0-ring seal (Illustration 16).
27. Using special tool 211-329-04, install the new pinion pre-load adjusting nut and tighten to 20 Nm (15 lb.ft). Mark a division on the smooth face of the steering gear body and then back-off four small divisions (Illustration 17).
Caution:
Make sure that the center punch operation is carried out in the middle of the material to ensure no fragmentation of the housing occurs.
28. Center punch the adjusting nut housing at three equidistant points (Illustration 18).
29. Using special tool 211-329-04, back-off the pinion pre-load adjusting nut a further four small divisions (Illustration 19).
30. Install a suitable dial test indicator to the steering gear dial gauge with an extension to the needle through special tool (211-329-05) directly onto the back of the pretensioner pad (Illustration 20).
Note:
Should the clearance not be correct, the pre-load adjusting nut must be moved by a single division at a time to achieve the correct clearance.
31. Using care so that the steering gear body does not move during the operation, check the pre-load by lifting the rack bar by hand. The clearance must be minimum 0.05mm and maximum 0.1 mm (Illustration 21).
32. Using the tool on the pinion shaft (211-329-02) rotate the steering gear lock-to-lock to ensure there is no significant resistance or rough motion felt. From the central position the turns should be equal lock-to-lock. If there is any roughness or resistance felt, the clearance must be rechecked, adjusted, and the check carried out again (Illustration 22).
33. Once the correct clearance is achieved, remove the dial test indicator gauge and special tools, and install the new sealing plug to the adjustment nut.
34. Reinstall rack boot, and install new clip.
Caution:
Ensure that working surfaces are thoroughly clean, to avoid contamination of the hydraulic components.
35. Remove steering gear from vice and place on suitable bench.
36. Check the external pipes are clean, install the new 0-rings to the pipes and install pipes to the steering gear body. Connect pipe unions to body and install new clips, at the pinion housing pipe unions, install the retaining plate and tighten to 12 Nm (9 lb.ft).
37. Install steering gear (see Global Technical Reference GTR Workshop Manual, section: 211-02).
When carrying out the road test
38. Check that the steering wheel is in the straight ahead position, self-centering ability coming off left and right-hand lock, smooth operation from lock to lock, and freedom from noise while turning lock to lock.
After the road test
39. Open hood and install fender protectors.
40. Check the power steering system fluid reservoir level (major level drop without any sign of external leakage may indicate that the replacement pinion seal lip area has been damaged during installation or the seal has been installed incorrectly-reversed).
41. Raise vehicle on "twin post" ramp.
42. Check for power steering system fluid leaks from hydraulic connections on fluid transfer pipes and pinion housing to rack housing security of rack end bellow fit to rack bar housing (components disturbed during seal replacement).
43. Check for power steering system fluid migration into the rack bellows causing them to expand/balloon/inflate (associated with major fluid loss from reservoir without external fluid loss).
44. Lower ramp.
45. Remove fender protectors and close hood.