Assemble
Tool Required
^ 999 1801 Handle
^ 999 5277 Drift
^ 999 5388 Drift
^ 999 5393 Drift
^ 999 5179 Socket
^ 999 5519 Drift
^ 999 5182 Protective Sleeve
^ 999 5333 Pin Spanner
^ 999 2706 Drift
^ 999 8081 Torque Wrench
^ 951 2050 Angle Gauge
1. Replace piston seal only if damaged or if car has covered more than 40,000 km (25,000 miles). Fit O-ring, then teflon ring on piston. Warm teflon ring to 40-50°C (104-122°F) if difficult to fit.
2. Install new pinion bushing in steering gear housing.
a. Use handle and drift.
NOTE: Take care when installing bushing. Pinion may freeze (seize) if bushing is deformed.
b. Check that bushing is seated against shoulder in housing by visual observation through preload assembly opening.
3. Install new seal in steering gear housing Use handle and drift.
NOTE: Tap in seal carefully.
4. Install pinion ball bearing Use handle and drift. Install snap ring (circlip).
5. Install seal and backing ring on rack:
a. Protect teeth with wide strip of tape. Oil tape with fluid.
b. Mount seal carefully on rack with lip facing piston seal.
c. Ensure that plastic ring of seal is in position.
d. Install backing ring.
e. Remove tape, ensuring that no remnants of tape or adhesive remain.
6. Pack rack teeth with steering gear grease. Use Volvo grease, P/N 1161001-1, or equivalent.
7. Install rack with seal and backing ring. Guide rack into position, taking care to avoid damage to internal surfaces of housing. When rack is fully inserted, press to ensure that seal and backing ring are firmly seated. Tap end of rack gently with plastic mallet.
8. Check position of seal. Inspect through pressure line connection. Seal should be past center of opening when rack is fully home.
9. Press rack backward.
NOTE: Press rack backward until end barely projects beyond housing opening. Do not press further or seal will be damaged by teeth.
10. Install:
a. Seal and bushing on rack.
b. O-ring on bushing.
c. Seal on rack. Take care when fitting seal and ensure that plastic ring is in position.
d. Bushing on rack. Press seal into position against bushing.
11. Install bushing and seal in steering gear housing:
a. Align bushing so that locking wire hole is opposite hole in housing.
b. Press home bushing.
NOTE: Take care to ensure that O-ring is not damaged by edges of hole in housing.
12. Install locking wire. Insert locking wire hook in hole in bushing. Turn bushing with hook spanner until wire is in position. Seal hole with sealant, P/N 1161277-7.
NOTE: Use new locking wire.
13. Install pinion assembly:
a. Pack pinion teeth with grease, P/N1161001-1.
b. Install assembly in housing with flat on pinion shaft for universal joint clamping bolt aligned as shown. Take care to avoid damage to valve sleeve when installing pinion assembly. Check that pinion and rack are engaged correctly with each other. Flat on pinion shaft, earlier version (A), must be positioned as illustrated when rack is projecting by 82 mm (3.23 inch). On later version of pinion (B), mark must be aligned with dashed line in illustration. However, the pinion position is subject to a tolerance of + 10°.
14. Install pinion locknut. Use new nut. Tighten to 37 Nm (27 ft. lbs.). Use socket and handle as counterhold. Remove socket.
15. Check rack: To check that rack is not freezing (seizing): Turn pinion a few times from left to right end limits. Freezing indicates that pinion is deformed or rack is skew.
16. Install pinion shaft bearing:
a. Lubricate bearing with grease, P/N 1161001-1.
b. Install bearing. Use drift. Tap bearing gently into position in housing.
17. Mount upper seal on pinion shaft:
a. Grease seal. Mount seal on protective sleeve. Install seal with spring facing downward.
b. Remove protective sleeve. Counterhold seal and withdraw tool.
NOTE: Seal cannot be finally installed with this tool.
18. Tap seal into position:
a. Use drift to tap seal gently into position.
b. Install snap ring (circlip). Pack space between seal and dust seal with grease.
19. Install pinion dust seal. Use protective sleeve. Tap dust seal into position with drift.
20. Install new pinion cover.
a. Fill cover with grease, P/N 1161001-1.
b. Install cover using drift.
21. Install:
a. Preload assembly components. Apply locking fluid to threads of new cover.
b. Piston (greased).
c. Spring.
d. Cover.
22. Tighten cover. Adjust rack to mid-position: Tighten preload bolt to 5.0-5.6 Nm (3.7-4.1 ft. lbs.). Use pin spanner and torque wrench. Then slacken bolt 50°- 55°. Use angle gauge.
23. Check steering gear torque. Attach torque wrench and socket to pinion shaft. Move rack back and forth to end limits. If torque is too high at any point on rack, set rack to this position and repeat torquing of preload device cover. If torque is still too high, replace steering gear. If torque is correct, secure preload device cover by punching housing at three points.
24. Install spacers (If equipt.).
a. Install spacers on rack (at each end).
b. Install spacers with flat side facing housing.
NOTE: Inside radius on spacer should be seated age tie rod [track rod).
25. Install tie rod (track rod):
a. When re-using tie rods (track rods), the right and left rods may be interchanged to alter the locking edge positions. However, a rod with a defective locking edge must not be re-used.
b. Tighten with an adjustable pliers and counterhold with an adjustable wrench as illustrated.
NOTE: A counterhold is essential to prevent damage to the rack and pinion.
26. Lock tie rod (track rod) to rack. Press ball joint edges into recesses in rack. Do not turn rack more than necessary to gain access. Use thin drift to lock rod. Press spacers (If equipt.) against tie rod (track rod).
27. Fit boots (gaiters). Pack each boot with 20 g of grease, P/N 1161001-1. Fit boots and secure at each end.
28. Install ball joints.
29. Remove steering gear from fixture and connect pressure lines.
a. Install new O-rings (If equipt.). Tighten to 7.5 Nm (5.5 ft. lbs.).
b. (lines with tapered seals): Tighten to 16.5 Nm (12.2 ft. lbs.).
c. Fill steering gear with fluid on completion of installation.
30. Install steering gear.