Steering - Revised Steering Box Installation
No: 57/03/05/NASFGN LT211
Ref:
Issue: 1
Date: March 16, 2005
Revised Procedure and Time for Steering Box Installation
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) All
SITUATION:
REVISED WORKSHOP MANUAL PROCESS AND TIME
This bulletin has been released to provide revised steering box removal and installation procedures.
The information will appear in the next workshop manual update.
RESOLUTION:
USE NEW PROCESS TO REPLACE STEERING BOX
Should it become necessary to remove/install a steering box, refer to the relevant procedure below relating to the vehicle model.
PARTS INFORMATION:
Refer to the appropriate Parts Catalog listings
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.
NOTE:
The published time below reflects a 0.10 hour reduction from the previous time of 1.40 Hours.
REPAIR PROCEDURE
NOTE:
The following procedure is for renewing the steering box with an exchange unit, which is supplied without a drop-arm. If a new steering box is to be installed, the drop-arm should be disconnected from the linkage rather than the steering box. GTR will be updated at the next opportunity.
REMOVE STEERING BOX
WARNING
A vehicle must always be supported by safety jack stands when work is performed under the vehicles.
1. Raise front of vehicle and support on axle stands under front axle.
2. Remove LH front road wheel.
3. Where installed, remove the undertray.
4. Remove the three screws securing the LH splash shield and remove splash shield. (Figure 1)
NOTE:
Remove the key from the steering lock and engage the column lock.
5. Centralize the steering wheel with the road wheels in the straight-ahead position.
6. Disconnect the connector from the mass air flow sensor and release the securing clip. Position harness aside.
7. Release the clamp and disconnect the air intake pipe from the throttle body. (Figure 2)
8. Release the two clips and disconnect the mass air flow sensor from the air cleaner. (Arrowed in Figure 3)
9. Remove and discard "0" ring. (Figure 3)
10. Position air intake pipe aside.
CAUTION:
Do not turn the steering wheel with the intermediate shaft or universal joint disconnected as damage to the rotary coupler and the steering wheel switches may occur.
11. Remove the two bolts and displace the steering intermediate shaft universal joint upwards from the steering box. (Figure 4)
12. Position a suitable container below the PAS box to collect fluid spillage.
CAUTION:
Always install clean plugs to open connections to prevent contamination.
13. Remove bolt securing PAS pipe bracket to PAS box, release pipes and discard four 0-rings.
14. Remove the two nuts and bolts securing the Panhard rod and remove the rod.
15. With assistance, support the steering box while removing the four securing bolts.
16. With assistance, remove the steering box.
NOTE:
Do not carry out further dismantling if component is removed for access only.
17. When installing a reconditioned steering box, use special tool, LRT-57-012, to remove the drop-arm from the steering box. (Figure 7)
INSTALL REPLACEMENT STEERING BOX
18. Clean the drop-arm and the steering box splines.
19. Install the drop-arm to the steering box output shaft.
20. Install a new lock washer and install, but do not fully tighten the new nut.
21. Install a centralizing bolt to the steering box. (Figure 8)
22. Secure the steering box drop-arm in a vise.
23. Tighten the nut securing the drop-arm to 240 Nm (177 lb-ft).
24. With assistance, position the steering box, install the securing bolts and tighten to 90 Nm (66 lb-ft).
25. Position the Panhard rod, install the nuts and bolts then tighten to 230 Nm (170 lb-ft).
WARNING:
Failure to remove the centralizing bolt will lock the steering box and prevent turning the steering wheel.
26. Remove the centralizing bolt from the steering box. (Figure 8)
27. Position the coolant rail and secure with clips.
28. Install the bolt securing the coolant rail and tighten to 20 Nm (14.75 lb-ft).
29. Install new 0-rings to the PAS pipes.
30. Install the pipes to the PAS pump and tighten the securing bolt to 22 Nm (16 lb-ft).
31. Remove the container from below PAS box.
32. Check the alignment and connect the intermediate shaft to the steering box and tighten upper securing bolt to 25 Nm (18 lb-ft) and lower securing bolt to 30 Nm (22 lb-ft).
33. Install a new "0" ring and install the mass air flow sensor to the air cleaner. Secure with clips.
34. Install the air intake pipe to throttle body and secure with clip.
35. Connect the connector to the mass air flow sensor and secure wiring harness with clip.
36. Where necessary, install the undertray.
37. Install the LH splash shield and tighten the three securing bolts to 10 Nm (7 lb-ft).
38. Install the LH front road wheel and tighten the wheel nuts to 140 Nm (103 lb-ft).
39. Remove stands and lower vehicle.
40. Refill and bleed PAS system.