Steering - Difficulty Making Tight Turns/Noise/Tire Rub
No: 57/05/03/NASRef:
Issue: 1
Date: 10/31/03
Steering Lock Stop Adjustment
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) up to 4A828723
[1A725326 to 4A828723 Turning circle complaint]
[up to 1A253325 orXA900000 to XA907214 Tire rub if steering box replaced]
SITUATION:
STEERING STOP ADJUSTMENT AFFECTS MANEUVERABILITY
NOTE:
All vehicles from VIN 1A725326 were fitted with increased length lock stops to prevent potential tire rub at full steering lock.
The customer may experience difficulty in maneuvering into tight spaces. A noise complaint from the front of the vehicle may occur when turning at full lock if the steering box has been replaced. In both cases the cause may be an incorrectly adjusted or incorrectly sized steering lock stop.
^ The large turning circle condition can result from too great a steering stop dimension. The correct turning radius as specified in the Owners Handbook is 39ft 1 inch.
^ A tire rub condition may be experienced between the tire and the radius arm if the stop adjustment dimension is too little.
^ A tire rub condition may be experienced if the latest specification steering box without pressure relief valves has been fitted into a vehicle built before VIN 1A725326.
RESOLUTION:
VERIFY TIRE CLEARANCE AND ADJUST STEERING STOPS
If either the tire rub complaint or the large turning circle complaint have been made, inspect and if necessary adjust the steering stop dimensions following the procedure outline in this bulletin.
PARTS INFORMATION:
FTC5151 23 mm Lock Stop Qty 2 per vehicle
WD112081L Washer As required
AS400 WARRANTY CLAIMS:
57.65.89/28 Time 0.10 hrs.
Check lock stop dimensions only
57.65.89/27 Time 0.60 hrs.
Measure lock stop dimensions and replace with correct stop/washer combination
FAULT CODE: A
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
VERIFY CORRECT STEERING LOCK STOP DIMENSION
CAUTION:
If a PAS box has been replaced, verify the clearance between the front tires and suspension radius arms at the extremes of both full left hand and right hand steering lock.
NOTE:
If a 29 mm lock stop is installed on the vehicle there is a potential adjustment to reduce the turning circle. Reducing the lock stop by 1 mm (0.040 in.) may reduce the turning circle by up to 25cm (9.8in).
1. Turn the steering wheel to full left hand lock and check the size of RH lock stop. (Figure 1)
2. Turn the steering wheel to full right hand lock and check the size of LH lock stop.
3. If the lock stops measure 23mm (7/8 inch) then the vehicle has the short lock stop already installed.
^ If the complaint is for turning circle improvement, no further adjustment is possible.
^ If the complaint is for tire rub, perform the adjustment process to gain proper tolerances.
4. If the lock stops measure 29mm (11/8 inch), perform adjustment to improve the turning circle.
ADJUST LOCK STOP DIMENSION
1. Raise the front of the vehicle.
2. Turn and hold the steering wheel to full left lock.
3. Measure and note in millimeters (mm) the clearance between the tire and the radius arm at their closest point on right side of the vehicle. (Figure 2).
4. Turn and hold the steering wheel to full right lock.
5. Measure and note in millimeters (mm) the clearance between the tire and the radius arm at their closest point on left side of the vehicle. (Figure 2).
6. Perform the following calculation for each side:
^ Subtract 10 from the measurement obtained from step 3.
^ Divide the answer by 4.6.
^ Subtract that answer from 29 to obtain the required lock stop length.
7. If the calculated required lock stop length figure is less than 23mm, then lock stop FTC5151 can be fitted without any washers.
NOTE:
The installation location of the of washers will depend on which side has been measured and calculated:
^ If the steering wheel was on full left lock when the measurement was taken in step 3, fit the new lock stop and any washers to the right hand steering knuckle.
^ If the steering wheel was on full right lock when the measurement was taken in step 3, fit the new lock stop and any washers to the left hand steering knuckle.
8. If the calculated required lock stop length figure is more than 23mm, then lock stop FTC5151 can be installed together with the required number of washers from the chart.
9. Install lock stop FTC5151 and washers as required by calculations.
10. Tighten lock stop to 24Nm (18 lbf.ft.).
11. Verify the correct clearance has been achieved.
NOTE:
If the lock stop does not contact the axle, the steering box is preventing any further travel.
12. If the lock stop does not contact the axle, refer to RAVE Workshop Manual section 57.35.05 and center the steering linkage.
CAUTION:
Re-adjustments are required to the lock stops to adjust to new wheel and tire combination conditions. Measurement and adjustments if indicated should be performed:
^ If the wheels or tires are replaced
^ If the vehicle is to be used with snow chains