Steering Gear, Replacing

Replacing the steering gear

Special tools:
999 5259 SEPARATOR 999 5259 Separator
999 5460 Lifting hook 999 5460 Lifting Hook
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5972 FIXTURE 999 5972 Fixture
999 7018 Lifting lug 999 7018 Lifting Lug

Removal

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Installing lifting tools




Remove the engine cover (applies only to diesels).
Ensure that the front wheels are pointing straight ahead
Lock the steering wheel by removing the ignition key
Do not turn the front wheels so that the position of the steering gear changes. This could damage the contact reel for the SRS-system.
Install lifting lug 999 7018 Lifting lug 999 7018 Lifting Lug (applies only to 6 cylinder engines).




Position the lifting device 999 5716 Reading off tool 999 5716 Reading Off Tool and lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook.
Lift up the engine slightly to offload the engine pads.

Disconnecting the connector





Note! Only applies to cars with speed related power steering.

Left-hand drive:
Disconnect the connector at the brake servo.

Right-hand drive:
Disconnect the connector at the right suspension turret.

Left and right-hand drive:
Disconnect the connector cable from the clips along the ABS cable.
Push down the connector and cable to the steering gear.

Removing track rod ends




Raise the car.

Note! Ensure that the front wheels are pointing straight ahead.

Remove:
- the front wheels
- the track rod ends from the steering arms.

Note! If the car has steel wheel spindles, use puller 999 5259 SEPARATOR 999 5259 Separator.

Measuring the position of the track rod in the steering gear




On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.

Removing the splash guard




Remove the splash guard under the engine.

Removing the bracket for the exhaust pipe





Remove:
- the mounting for the exhaust pipe on the bracket
- the screws holding the exhaust pipe bracket.
Disconnect the brake pipe from the snap fasteners on the bracket.
Remove the bracket.

Removing the collision protection system over the steering gear





Right-hand drive:
- Remove the collision protection system over the steering gear (2 screws)
- Position a container under the steering gear to collect the oil.
- Disconnect the oil pipes from the steering gear.

Removing the nuts and screw for the steering gear




Remove the four nuts and the screw holding the steering gear to the sub-frame.

Right-hand drive:
Remove the nut (A) holding the lower half of the collision protection.

Lowering the sub-frame at the rear edge




Place a mobile jack with a universal fixture 999 5972 FIXTURE 999 5972 Fixture at the rear of the subframe.
Remove the screws holding the sub-frame brackets to the bodywork on both sides.
Remove the rear screws on the subframe together with the brackets and washers.
Unscrew the front screws in the sub-frame by 10-15 mm.




Remove the bracket for the heated oxygen sensor (HO2S) from its mounting (6 cylinder engines only).
Lower the rear edge of the sub-frame approximately 90 mm. Ensure that the steering gear screws are released from the sub-frame.
Remove the mobile jack.

Removing steering gear




Remove the screw for the rear engine mount.
Position a container under the steering gear to collect the oil.
Remove the oil pipes from the steering gear and holders along the steering gear.




Remove the screw for the joint between the steering gear and the steering shaft.
Press up the joint from the steering gear.
Lift the steering gear out to the left (left-hand drive cars only).
Lift the steering gear out to the right (right-hand drive cars only).

Installation

Installing steering gear




Transfer the heat shield.

When replacing steering gear:
Replace the oil pipe holder (only left-hand drive).

Checking the position of the track rod in the steering gear




Check that track rod is in the same position as when it was removed.




Lift in the steering gear in from the left (left-hand drive cars).
Lift in the steering gear in from the right (right-hand drive cars).
Allow the steering gear to rest on the sub-frame.
Install the oil pipes on the steering gear. Use new O-rings. Tighten to 25 Nm.
Secure the oil pipes in the holders on the power steering (left-hand drive).

Applies to cars with speed related power steering:
Slide the connector to the terminal at the brake servo.
Install the cabling in the clip along the ABS cable.

Applies to all models:





Note! Always check carefully that the ball joint's screw hole aligns with the cut-out in the steering gear shaft.

Align the steering shaft joint.
Lift up the rear edge of the sub-frame slightly using a mobile jack and universal fixture 999 5972 FIXTURE 999 5972 Fixture.
Locate the steering shaft joint on the steering gear.
Install a new steering shaft screw. Tighten to 20 Nm.




Install the rear engine mounting screw.
Align the steering gear so that it is positioned straight relative to the sub-frame. Tighten the screw. Tighten to 50 Nm.

Installing the sub-frame at the rear edge




- Lift the sub-frame. At the same time locate the steering gear mounting screws in the frame and, on right-hand drive cars, the collision protection system screw
- Loosely install the sub-frame brackets together with the washers
- Install the rear screws in the sub-frame. Use new screws. Do not tighten yet
- Move the mobile jack to the front edge of the subframe.
- Replace the front sub-frame screws
- First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm. Angle tighten 120°.
- Then tighten the right-hand side to the same values as the left side
- Finally tighten the screws for the brackets on both sides. Tighten to 50 Nm.




Install the four nuts and the screw holding the steering gear. Use new nuts and a new screw. Tighten to 50 Nm.

Right-hand drive:
Install nut (A) holding the lower half of the collision protection system. Tighten to 50 Nm.
Install the oil pipes. Use new O-rings.




Install the collision protection system over the steering gear (2 screws).
Tighten to 80Nm.

Installing the cable harness for the heated oxygen sensors (HO2S)





Applies only to 6 cylinder engines:
Install the bracket for the heated oxygen sensor (H02S) in its mounting. Connect the connectors.
Install the wiring on the sub-frame. Connect the connectors.

Installing the bracket for the exhaust pipe





Install:
- the mounting for the exhaust pipe on the bracket. Tighten to 10 Nm
- the brake pipe on the exhaust pipe bracket
- the exhaust pipe bracket. Tighten the bracket screws to 25 Nm.

Installing the track rod ends on the steering arms




Install the track rod ends on the steering arms. Use new nuts.
Tighten the steering arm on the wheel spindle. Refer to: Tightening torque [1][2]Mechanical Specifications

Install:
- the protective cover under the engine
- the wheels. See Installing wheels Service and Repair.

Removing the lifting tools




Lower the car.
Remove the lifting tools.
Install the engine cover (diesel engines only).

Applies to cars with speed related power steering:
Connect the connector at the brake servo (left-hand drive cars).
Connect the connector at the right-hand suspension turret (right-hand drive cars).




Top up the oil level in the servo reservoir. Bleed the system.
For the correct oil quality, see specifications.

Warning! Avoid skin contact with the oil.

Repeatedly turn the steering wheel to full lock.
Top up the oil if necessary.
Lower the car.
Apply the handbrake.
Start the engine.
A: Turn the steering wheel slowly to the right. Hold on full lock for 2 seconds.
B: Turn the steering wheel slowly to the left. Hold on full lock for 2 seconds.
Repeat operations A and B approximately 10 times.

Finishing
Check the toe-in. See Wheel alignment, checking / adjusting Service and Repair.