Power Steering Gears
Steering gear, repairing
Disassembling
NOTE: If upper valve housing oil seal is leaking, replace the steering gear assembly.
- clamp steering gear assembly in vise (use jaw covers) at end housing
- remove hydraulic lines from steering gear assembly
- remove clamps and slide boot off
- using a drift inserted in steering gear mounting hole, drive end tube out of housing as far as possible
- pull end tube completely out of housing
- loosen two mounting bolts for cover plate to release some tension on gear
- remove self-locking nut on end of steering rack piston rod
- remove valve housing from end housing by removing bolts and tapping valve housing with plastic hammer
- remove cover plate, spring and spacer from end housing (thrust washer and sleeve can be removed also)
- remove bolts holding steering gear housing to end housing and take off end housing
- tilt steering gear housing and remove piston, piston seal and shims
- remove rack from housing by pulling firmly on toothed portion
Fig. 1 Supporting ring, removing:
- insert longer end of a punch a (part of tool 3086) into end of tool
- stand housing on end on a block of wood, insert tool 3086 and tap lightly on end of tool with a hammer to remove supporting ring and piston rod seal
NOTE: The end tube, steering gear housing, steering rack and end housing must all be thoroughly cleaned before reassembly.
Assembling
- lightly grease the steering rack, the steering rack bushing and the inner portion of steering gear housing in area of rack bushing
- grease, Part No. AOF 063 000 04
- lightly oil the end tube 0-rings
Fig. 2 Piston rod seal, installing:
- attach shorter end of punch into tool 3086
NOTE: Install the piston rod seal together with the 0-ring and supporting ring.
- push supporting ring 1 with large diameter toward steering housing, over tool
- slide 0-ring 2 onto piston rod seal
- push piston rod seal 3 with metal cage toward steering housing, over tool
- using a hammer, drive piston rod seal and supporting ring into steering housing 4 until seated
CAUTION: Due to production tolerances, the inside diameter of the steering housing may deviate from the specification such that special tool 3086 cannot be inserted. If this occurs, special tool 3086 should be unscrewed by approximately 0.5 mm in the diameter.
NOTE: Check piston rod for damage before installing rack.
Fig. 3 End tube, Installing to hold piston rod seal while installing rack:
- install end tube without 0-rings so holes line up with holes in steering housing
- hold end tube in housing with a bolt or rod through holes
Fig. 4 End housing, assembling:
- install thrust ring 1 (with slits) and center 0-ring 2 on end housing 3
Fig. 5 Steering rack, installing:
- attach mounting sleeve, tool 3086/2A to steering rack and lubricate with hydraulic oil
Fig. 6 Steering Rack, Installing:
- guide steering rack with mounting sleeve into housing
- tap end of rack with plastic hammer to install
- remove end tube and mounting sleeve 3086/2A
Fig. 7 End housing oil seal/O-ring, removing:
- use an extractor such as Kuko no.21/4 (arrow) or pry out end housing oil seal and 0-ring
Fig. 8 End housing oil seal, installing:
- replace end housing 0-ring and drive in seal until seated
- install end housing onto steering gear housing but do not torque bolts
- slide piston, piston seal and shims onto piston rod and install but do not tighten nut
- install valve housing and ensure that teeth of gears mesh. Torque bolts to 20 Nm (15 ft lb)
- torque piston rod nut to 20 Nm (15 ft lb)
- install 0-rings on end tube and install with holes lined up with holes on steering gear housing
- slide boot onto steering gear assembly but do not clamp
- install hydraulic lines and leave bolts loose (turn steering gear housing to line up holes)
- tighten housing to end housing bolts evenly and torque to 8 Nm (71 In. lb)
- torque bolts for hydraulic lines (see page 48.6 for torque specifications)
- install spacer, spring and cover plate (install sleeve and thrust washer if removed)
Fig. 9 Steering boot clamp, installing:
- a=210 mm (8-1/4 in.)
- install clamps for boot
- adjust steering gear after installing in vehicle
Fig. 10 Steering gear, Adjusting:
- turn wheels to straight-ahead position
- turn adjusting bolt (arrow) clockwise approx 20°
- road test vehicle
- if steering too heavy
- turn adjusting bolt slightly counter-clockwise
- if steering too loose
- turn adjusting bolt slightly further clockwise
- road test vehicle