Action
In case of a verified customer complaint perform the service fix procedure outlined below.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. Position the steering gear in a vise equipped with soft jaws (Illustration 1).
Warning:
Avoid excessive skin contact with mineral oil. Mineral oils remove the natural fats from the skin, leading to dryness, irritation and dermatitis.
3. Remove and discard the pinion shaft dust cap/centralization device (Illustration 2).
Warning:
A small amount of fluid loss is unavoidable; position an absorbent cloth or container to collect the fluid.
Caution:
Always install clean plugs to open connections to prevent contamination.
4. Remove external fluid pipes securing plate bolt and plate at pinion housing, and undo pipe union connections to rack body and remove pipes. Remove and discard the four 0-ring seals (Illustration 3).
5. Remove and discard the boot securing clip on the pinion end of the rack body, and release boot (Illustration 4).
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 5.
7. Note the position of the steering gear pinion shaft, mark the position of the pinion shaft in relation to the pinion housing Illustration 6.
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 211-329-01 to the pinion shaft and tighten the Allen bolt (Illustration 7).
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 8).
10. Reposition the steering gear to align the painted marks on the steering gear pinion housing (Illustration 9). Check that 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 10).
12. Remove and discard the two pinion housing securing bolts (Illustration 11).
Caution:
Make sure the working surfaces are thoroughly clean to avoid contamination of the sensitive hydraulic components. Before the disconnecting or removing any components, ensure that the area around the joint faces and connections is clean. Plug any open connections to prevent contamination.
NOTE:
On removal the pinion shaft will rotate approximately 90 degrees
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 12).
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. 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 13).
18. Align the steering rack to measurements shown in illustration 14.
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 (Illustration 15).
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 16).*
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 (Illustration 16) and tighten to 17 Nm (12 lb.ft) (Illustration 17).
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 18).
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 to the smooth face of the steering gear body and then back-off four small divisions (Illustration 19).
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 20).
29. Using special tool 211-329-04, back-off the pinion pre-load adjusting nut a further four small divisions (Illustration 21).
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 pre-tensioner pad (Illustration 22).
Note:
Should the clearance not be correct, move the pre-load adjusting nut by a single division at a time to achieve the correct clearance.
31. With 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 0.05 mm and maximum 0.1 mm (Illustration 23).
32. Using the tool on the pinion shaft (211-329-01) 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 24).
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. Lubricate the 0-ring on the end of the steering gear body and reinstall the boot with the new clip.
35. Check the external pipes are clean, install the new 0-rings to the pipes and install pipes to the steering gear body. Tighten pipe unions to body to 10 Nm (7 lb.ft) and the pinion pipe retaining plate to 12 Nm (9 lb.ft).
Caution:
Use care when installing the seal dust cover, as it is tight on the splines.
36. Recheck the paint marks on the pinion shaft to housing, and then install the new pinion shaft seal dust cover, ensuring the centralizing pin on the cover locates in the pinion housing recess (Illustration 25).
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 lift.
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 lift.
45. Remove fender protectors and close hood.