Steering Gear: Service and Repair
POWER STEERING GEAR BOX ASSEMBLY
REMOVAL AND INSTALLATION
WARNING: Before removing the steering gear box, Center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render the SRS system inoperative risking serious injury.
Removal Service Points
<> Tie Rod End Disconnection
CAUTION:
- Use special tool MB991113 or MB990635 to loosen the nut from the ball joint instead of removing it.
- Hang special tool MB991113 or MB990635 with ropes to prevent it from falling.
Use special tool MB991113 or MB990635 to disconnect the ball joint.
<> Gear Box Assembly Removal
CAUTION: Be sure not to damage the bellows and the tie rod end dust cover when removing the gear box assembly.
Installation Service Points
>>A<< Pressure Tube Assembly Installation
Align the marks on the pressure tube assembly and steering gear box, and install the pressure tube assembly.
>>B<< Return Hose Assembly Installation
Align the marks on the return hose assembly and steering gear box, and install the return hose assembly.
POWER STEERING GEAR BOX ASSEMBLY INSPECTION
GEAR BOX TOTAL PINION TORQUE CHECK
CAUTION: When holding the steering gear box assembly in a vice, secure its mounting positions. If it is secured in any other places the gear housing may become deformed or damaged.
Using special tool MB990228 or MB991006, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque.
Standard value: 0.8 - 1.9 Nm (6.9 - 16.5 inch lbs.)
[Change in torque: 0.7 Nm (6.1 inch lbs.) or less]
NOTE: When measuring, remove file bellows from the rack housing.
Measure the pinion torque through the whole stroke of the rack.
If the measured value is not within the standard range, first adjust the rack support cover, and then check the total pinion torque again.
If the total pinion torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary.
TIE ROD SWING RESISTANCE CHECK
1. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance with a spring balance. Standard value: 4.0 - 18.6 N (17.8 - 82.7 lb) [1.0 - 4.9 Nm (8.7 - 43.4 inch lbs.)]
3. If the measured value exceeds the standard value, replace tie rod.
4. If the measured value is below the standard value, the tie rod can be re-used if it swings smoothly without excessive play.
TIE ROD END BALL JOINT DUST COVER CHECK
1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the tie rod end.
NOTE: Cracks or damage of the dust cover may damage the ball joint. If it is damaged during service work, replace the dust cover.
DISASSEMBLY AND ASSEMBLY
LUBRICATION AND SEALING POINTS
Disassembly Service Points
<> Tie Rod/Tab Washer Removal
Unstake the tab washer which secures the tie rod and rack with a chisel.
<> Rack Support Cover Removal
Using special tool MB991204, remove the rack support cover from the gear box.
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Using a plastic hammer, gently tap the pinion to remove it.
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CAUTION: When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.
Cut the seal ring and remove it from the pinion and valve assembly and the rack.
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Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
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If the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.
1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
2. Turn the rack stopper counterclockwise to remove the circlip.
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Pull out the rack slowly. At this time also take out the rack stopper and the rack bushing simultaneously.
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CAUTION: Do not damage oil seal press fitting surface.
Partially bend oil seal and remove from rack bushing.
<> Ball Bearing Removal
Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.
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CAUTION: Do not open special tool MB991120 excessively to prevent damaging housing interior.
Use special tool MB991120 to remove the needle roller bearing from the rack housing.
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CAUTION: Be careful not to damage the inner surface of the rack cylinder of the gear housing.
Use a piece of pipe or similar tool to remove the oil seal from the gear housing.
Assembly Service Point
>>A<< Oil Seal Installation
1. Apply a coating of the Automatic transmission Fluid "DEXRON-II" to the both sides of the oil seal.
2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing.
>>B<< Needle Roller Bearing/Ball Bearing Installation
CAUTION: Press-fit straight. Valve housing is aluminum, and may become deformed if Press-fit on an angle.
1. Apply Automatic transmission Fluid "DEXRON-II~" to housing, bearing and oil seal press fitting surface.
2. Press fit needle roller bearing with special tools MB990938 and MB991202.
>>C<< Oil Seal/D-Ring Installation
1. Apply a coating of the Automatic transmission Fluid "DEXRON-II~" to the outside of the oil seal and O-ring.
2. Use special tool MB990927 to press fit oil seal until it touches rack bush end.
>>D<< Rack Installation
CAUTION: Do not close the vent hole in the rack with grease.
1. Apply a coating of Mopar(R) Multi-mileage Lubrication Part No. 2525035 or equivalent to the rack teeth face.
2. Cover rack serrations with special tool MB991213.
3. Apply Automatic transmission Fluid "DEXRON-II~" to special tool MB991213.
4. Align center of oil seal with rack to prevent retainer spring from slipping. Slowly insert rack from power cylinder side.
>>E<< Rack Bushing Installation
CAUTION: Do not allow oil seal retainer spring to slip out.
Wrap the rack end with vinyl tape, apply a coating of the Automatic transmission Fluid "DEXRON-II@", and then install the rack bushing and rack stopper.
>>F<< Circlip Installation
CAUTION: Insert circlip to rack stopper hole whilst turning rack stopper clockwise.
Insert circlip to rack stopper hole through cylinder hole. Turn rack stopper clockwise and insert circlip firmly.
>>G<< Oil Seal/Ball Bearing Installation
Apply a coating of the Automatic transmission Fluid "DEXRON II" to the outside of the oil seal. Using special tools MB990938 and MB991203, press the oil seal into the valve housing.
>>H<< Seal Ring Installation
Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the rings, or press down by hand.
>>I<< Oil Seal Installation
CAUTION: To eliminate a seal malfunction at the valve housing alignment surface, the upper stir/ace of the oil seal should project outward approximately 1 mm (0.04 inch) from the housing edge surface. Using special tool MB991152, press the oil seal into the valve housing.
>>J<< End Plug Installation
1. Apply the 3M AAD Part number 8663 or equivalent to the threaded part of the end plug.
2. Secure the threaded portion of the end plug at two places by using a punch.
>>K<< Rack Support Cover/Jam Nut Installation
1. Position rack at its center.
2. Apply the 3MTM AAD Part number 8663 or equivalent to the threaded part of the rack support cover.
3. Use special tool MB991204 to tighten rack support cover to 13 ± 2 Nm (109 ± 21 inch lbs.).
4. Turn the rack support cover by 10 degree counterclockwise.
5. Use special tool MB991204 to hold the rack support cover, and then tighten the jam nut to 59 ± 10 Nm (44 ± 7 ft. lbs.).
>>L<< Total Pinion Torque Adjustment
CAUTION:
- When adjusting, set at the highest value of the standard value range.
- Be sure there is no ratcheting or catching when operating the rack towards the shaft.
- Measure the total pinion torque through the whole stroke of the rack.
NOTE: If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.
1. Using special tool MB990228 or MB991006, rotate the pinion shaft at the rate of one rotation in four to six seconds to check the total pinion torque and the change in torque.
Standard value:
Total pinion torque: 0.8 - 1.9 mm (6.9 - 16.5 inch lbs.)
[Change in torque: 0.7 Nm (6.1 inch lbs.) or less]
2. If the total pinion torque or the change in torque is outside the standard value, return the rack support cover within 0° angle to 30° angle, and adjust again.
>>M<< Tab Washer/Tie Rod Installation
After installing tie rod to rack, fold tab washer end (two locations) to tie rod notch.
>>N<< Bellows Band Installation
1. Turn the adjusting bolt of special tool MB991561 to adjust the opening dimension (W) to the standard value.
NOTE: The dimension (W) is adjusted by approximately 0.7 mm per one turn.
NOTE: Do not turn the adjusting bolt more than one turn.
Standard value (W): 1.9 mm (0.07 inch)
When more than 1.9 mm (0.07 inch),: Screw in the adjusting bolt.
When less than 1.9 mm (0.07 inch): Loosen the adjusting bolt.
CAUTION:
- Hold the rack housing, and use special tool MB991561 to crimp the bellows band securely.
- Crimp the bellows band until special tool MB991561 touches the stopper.
2. Use special tool MB991561 to crimp the bellows band.
3. Check that crimped width (A) is within the standard value.
Standard value (A): 1.4 -1.8 mm (0.06 - 0.07 inch)
When more than 1.8 mm (0.07 inch): Readjust the dimension (W) of step 1 to the value calculated by the following equation, and repeat step (2). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 1.9 mm (0.07 inch), (W) is 3.6 mm (0.14 inch).]
When less than 1.4 mm (0.06 inch): Remove the bellows band, readjust the dimension (W) of step 1 to the value calculated by the following equation, and use a new bellows band to repeat steps 2 to 3. W = 5.5 mm (0.22 inch) - A [Example: if (A) is 1.3 mm (0.05 inch), (W) is 4.2 mm (0.17 inch).]
>>O<< Tie Rod End/Tie Rod End Jam Nut Installation
Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut.
INSPECTION
RACK
- Check the rack tooth surfaces for damage or wear.
- Check the oil seal contact surfaces for uneven wear.
- Check the rack for bends.
PINION AND VALVE ASSEMBLY
- Check the pinion gear tooth surfaces for damage or wear.
- Check for worn or defective seal ring.
BEARING
- Check for roughness or abnormal noise during bearing operation.
- Check the bearing for play.
- Check the needle roller bearings for roller slip-off.
OTHERS
- Check the cylinder inner surface of the rack housing for damage.
- Check the boots for damage, cracking or deterioration.
- Check the rack support for uneven wear or dents.
- Check the rack bushing for uneven wear or damage.
TIE ROD END, BALL JOINT DUST COVER REPLACEMENT
If the dust cover is damaged accidentally during service work, replace the dust cover as follows:
1. Apply MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent to the lip and inside of the dust cover.
2. Drive in the dust cover with special tool MB990776 until it is fully seated.
3. Check the dust cover for cracks or damage by pushing it with your finger.