Overhaul

Reconditioning, steering gear

Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 1801 STANDARD SHAFT 999 1801 Standard Shaft
999 2250 SEPARATOR 999 2250 Separator
999 2706 PUNCH 999 2706 Punch
999 5046 FIXTURE 999 5046 Fixture
999 5154 FIXTURE GEARBOX 999 5154 Fixture Gearbox
999 5179 SOCKET 999 5179 Socket
999 5182 SOCKET 999 5182 Socket
999 5277 PUNCH 999 5277 Punch
999 5333 PIN KEY 999 5333 Pin Key
999 5388 PUNCH 999 5388 Punch
999 5389 CLEARER PIN 999 5389 Clearer Pin
999 5393 PUNCH 999 5393 Punch
999 5519 Drift 999 5519 Drift
999 8081 TORQUE GAUGE 0-6 Nm 999 8081 Torque Gauge 0-6 Nm

Steering gear, dismantling

Hint: For removing steering gear, see Steering gear, replacement Steering Gear, Replacement. For installing, see: Steering gear, replacement Steering Gear, Replacement.

Clean the outside of the steering gear




Remove the delivery lines and O-rings from the pipes.

Note! Delivery lines of later version have tapered seals.

Set up the steering gear in fixture 999 5046 and stand 999 2250 or 999 5154




For attaching, use U-bolt 1272597-4 and intermediate piece 1272679-0.

Drain the oil from the steering gear




Place a collection container under the pipe outlets. Turn the pinion back and forth until the oil has been pumped out. Use socket 999 5179 SOCKET 999 5179 Socket and a ratchet handle. Then set the rack in approx. middle position.

Check any wear in the outer and inner ball joints





Remove:
- the outer ball joints
- the clamps and gaiters
- the seal rings for the gaiters on the steering gear housing.

Note! On steering gears for right-hand drive cars there is only a seal ring on the right side.





On left-hand drive cars:
Remove the left tie rod and loosen the right a few revolutions

On right-hand drive cars:
Remove the right tie rod and loosen the left a few revolutions
Use an adjustable wrench and polygrip pliers. Place an adjustable wrench as counterhold as far out as possible on the rack. Remove/loosen the tie rods.

Note! On certain versions there are spacer rings on the tie rods.

Caution! Use counterhold, otherwise there is a risk of damage to the rack and pinion.

Caution! Right/left tie rod shall be left in place. This is to prevent that the end sleeve from shooting off. See further under Blow out the rack's bushing and seal.

Remove:




- the sealing compound that covers the hole for the lock wire
- the lock wire for the rack's bushing.
Turn the end sleeve with a hook wrench (C-wrench) so that the lock wire can be seen and can be removed.

Note! A screwdriver may have to be used to pry up the end of the lock wire.

Blow out the rack's bushing and seal




Counterhold on the pinion with socket 999 5179 SOCKET 999 5179 Socket and a ratchet handle.

Blow with compressed air in the outer pipe connection so that the bushing with seal comes out. Now the tie rod functions like a stop so that the bushing does not shoot away.

Warning! The compressed air may cause a loud booming noise. Use hearing protection.

Remove:




- the tie rod
- the bushing with seal.

Remove the rack's preloading device




Use tap tool 999 5333 PIN KEY 999 5333 Pin Key for the cover. Remove the cover, spring and preloading piston.

Remove the dust cover and lock ring for the pinion




Use a screwdriver for the dust cover. Be careful so that the pinion or steering gear housing is not damaged.

Remove the pinion's cover




Use a chisel. Tap loose the cover.

Remove the lock nut for the pinion




Counterhold the pinion, with socket 999 5179 SOCKET 999 5179 Socket and a ratchet handle, when the nut is removed.

Remove the pinion




Tap with a brass drift and a hammer on the pinion's lower part.

Remove the rack




Pull out the rack carefully so that the surfaces on the rack and housing are not damaged.

Tap out the pinion's ball bearing from above




Remove the lock ring and tap out the bearing with a drift.

Tap out the pinion's lower seal and bushing from below




Use a long extension and a socket with 24 mm outside diameter.

Tap out the rack's seal and back-up ring from the steering gear housing




Use two extensions and a socket with 25 mm outside diameter.

Insert the extensions and socket through the steering gear housing. Make sure that the socket grips the edge of the back-up ring. Tap out the seal and the back-up ring.

Caution! Be careful so that the surfaces in the housing are not damaged.

Piston seal




Replace the piston seal only if it is damaged or if the car has been driven more than 40 000 km.

From the pinion, remove:




- the sleeve 999 5179 SOCKET 999 5179 Socket (1)
- the dust cover (2)
- the snap ring (3)
- the seal ring (4)
- the roller bearing (5).

Caution! The four seal rings made of teflon on the valve spool may not be removed.

Clean and check all parts





Check:
- the gaiters, replace when needed
- the gaiters' seals, replace when needed
- all parts for wear, corrosion, cracks and pressure damage
- the pinion with valve spool. In case these parts are damaged, the whole steering gear must be replaced.

Caution! Carefully clean the threads in the steering gear housing. Use cleaning tap 999 5389 CLEARER PIN 999 5389 Clearer Pin for the preloading device's cover.

Steering gear, assembling

Piston seal





Replace the piston seal only if it is damaged or if the car has been driven more than 40 000 km
First install the O-ring and then the teflon ring. Warm the teflon ring to 40-50°C if it is difficult to install on the piston.

Install a new bushing for the pinion in the steering gear housing




Use handle 999 1801 STANDARD SHAFT 999 1801 Standard Shaft and drift 999 5277 PUNCH 999 5277 Punch.

Caution! Be careful when installing the bushing. If it is deformed the pinion will bind.

Check through the hole for the preloading device that the bushing is positioned against its shoulder in the housing.

Install a new seal ring in the steering gear housing




Use handle 999 1801 STANDARD SHAFT 999 1801 Standard Shaft and drift 999 5393 PUNCH 999 5393 Punch.

Note! Tap in the seal ring carefully.

Install the ball bearing for the pinion




Use handle 999 1801 STANDARD SHAFT 999 1801 Standard Shaft and drift 999 5388 PUNCH 999 5388 Punch. Install the lock ring.

Install the seal ring and the back-up ring on the rack




Lay a wide strip of tape over the teeth as protection. Lubricate the tape with oil.

Install the seal ring carefully, with the lip facing the piston seal. Check that the seal's plastic ring is in place.

Install the back-up ring.

Remove the tape. Check that there is no remaining tape or glue.

Fill the teeth on the rack with steering gear grease




Use Volvo grease, part number 1161001-1

Install the rack with seal and back-up ring




Guide in the rack so that it does not damage the surfaces in the housing. When the rack is all the way in, press so that the seal and back-up ring are secured in its seat. Tap carefully with a plastic mallet on the end of the rack.

Check the seal ring's position




Inspect inside the delivery line's connection. When the rack is pressed in against the seal, the piston's seal shall have passed the center of the hole.

Press back the rack





Caution! The rack may not be pressed back too far, the rack's end must protrude outside the steering gear housing, otherwise the seal is damaged by the teeth.

Install:




- the seal and the bushing on the rack
- the O-ring on the bushing
- the seal ring on the rack. Be careful, check that the seal's plastic ring is in place
- the bushing on the rack. Press the seal ring for the bushing into place.

Install the bushing with seal in the steering gear housing




Align the bushing so that the hole for the lock wire lines up directly opposite the hole in the steering gear housing.

Press in the bushing.

Caution! Be careful so that the O-ring is not damaged by the hole's edges in the steering gear housing.

Install the lock wire





Caution! Use new lock wire.

Insert the lock wire's hook in the hole on the bushing. Turn the bushing with a hook wrench (C-wrench) until the wire is in place. Seal the hole with sealant, part number 1161277-7 .

Install the pinion




Fill the teeth on the pinion with grease, part number 1161001-1 .

Install the pinion in the housing with the face for the clamping screw as shown in the figure. Be careful when installing the pinion so that you do not damage the valve spool. Check that the pinion and rack are in correct mesh with each other. The pinion's face, earlier version ( A ), for the clamping screw shall be in the position as shown in the figure when the rack protrudes 82 mm . On the pinion of later version ( B ) the marking shall be aimed against the dashed line. However, there is a certain tolerance of ± 10° for the pinion's position.






Install the lock nut for the pinion




Use a new nut. Tighten with 37 Nm . Counterhold with socket 999 5179 SOCKET 999 5179 Socket and a ratchet handle.

Check the rack
To check that the rack does not bind; turn the pinion a few times between right and left end-position.
If the rack binds, then either the guide sleeve for the pinion is deformed or the rack is not straight.

Install the pinion's bearing




Grease the bearing with grease, part number 1161001-1 .

Install the bearing. Use drift 999 5519 Drift 999 5519 Drift. Carefully tap the bearing into place in the steering gear housing.

Install the pinion's upper seal ring




Lubricate the seal. Slide the seal on protective sleeve 999 5182 SOCKET 999 5182 Socket. Install the seal on the steering gear with the spring on the seal facing down.

Remove protective sleeve 999 5182 SOCKET 999 5182 Socket. Counterhold on the seal and pull off the tool.

Caution! The seal ring cannot be installed for good with this tool.

Tap in the seal ring




Use drift 999 5519 Drift 999 5519 Drift. Carefully tap the seal ring into place.
Install the lock ring. Put grease between the seal ring and the dust cover.

Install the pinion's dust cover
Use protective sleeve 999 5182 SOCKET 999 5182 Socket according to Install the pinion's upper seal ring. Tap in the dust cover. Use drift 999 5519 Drift 999 5519 Drift.

Install a new sealing plug for the lower pinion bearing




Fill the plug with grease, part number 1161001-1 . Install the plug. Use drift 999 2706 PUNCH 999 2706 Punch.

Install:




- the preloading device's parts. Apply lock fluid on the new cover's threads
- the piston greased
- the spring
- the cover.

Tighten the cover




Set the rack in middle position. Tighten the preloading screw with 5.0-5.6 Nm . Use tap tool 999 5333 PIN KEY 999 5333 Pin Key and torque wrench 999 5519 Drift 999 5519 Drift. Then loosen the screw 50°- 55° . Use a protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.

Check the steering gear's torque




Connect torque wrench 999 5519 Drift 999 5519 Drift with socket 999 5179 SOCKET 999 5179 Socket to the pinion's shaft. Turn the rack back and forth against its end-positions.

If the torque is too high at any point on the rack, set the rack in this position and repeat torquing of the preloading cover.

If the torque still is too high, replace the steering gear. If the torque is correct, secure the preloading cover with three punch marks in the steering gear housing.

On certain versions: Install spacer washers.




Also see Steering gear spacers, installation Steering Gear Spacers, Installation.

Install spacer washers on the rack (both sides). Slide on the spacer washers with the smooth side facing in against the steering gear housing.

Note! The washers' inner radius shall be positioned up against the tie rods.

Install the tie rods




When a used tie rod is to be used again, then right and left tie rods can change place so that another position on the lock edge becomes available. Rods with defective lock edge shall not be used again.

Tighten with polygrip pliers and counterhold with an adjustable wrench, see figure.

Caution! Counterhold must be used, otherwise the rack and pinion will be damaged.

Lock the tie rod to the rack




Fold down the ball joints' edges in the slots on the rack. Do not turn out the rack farther than to enable access.

Use a narrow drift to lock the tie rod.

On certain versions: Press the spacer washers against the tie rods.

Install the gaiters




Fill each gaiter with 20 grams of grease, part number 1161001-1 . Install the gaiters and clamp them at both ends.

Install the ball joints

Remove the steering gear from the fixture and install the delivery lines




On early version: Install new O-rings. Tighten with 7.5 Nm .
Late version (pipes with tapered seals) : Tighten with 16.5 Nm .
Fill oil in the steering gear when it is in place in the car.
For installing steering gear, see: Steering gear, replacement Steering Gear, Replacement.