Noises and knocking in the steering while driving
The cause of the malfunction may be too much play in the steering bearing bush.
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In the event of a malfunction, install the steering gear repair kit.
To replace the bushing, it is necessary to prepare a mounting bracket for the steering gear.
Note. The manufacture of the mounting bracket is described in steps 1-4.
1. Cut a 40x40mm square steel pipe 500mm long.
2. Drill 2 holes with a diameter of 12.5 mm.
The distance between the centers of the holes is 400 mm.
3. Fix the steering gear on the square tube with 2 screws M12x130 (1, 2).
Use washers and nuts.
4. Tack-weld screw heads (1, 2).
5. Remove the front wheels.
6. Hang the radiator on the air baffle.
Use 2 cable ties.
7. Disconnect the intermediate steering shaft 2 from the steering gear (pic. II).
Loosen and remove bolt 1.
8. Disconnect the 2 pendulum arms 1 from the suspension strut support tube (pic. III).
Hold the two flats on the steering knuckle bolt with an open wrench.
9. Disconnect 2 tie rod ends 1 using tool KM-507-C 2 from the steering knuckles (pic. IV).
10. Remove the front exhaust pipe 1 from the catalyst (pic. V).
Loosen 3 nuts 2.
11. Remove the rear torque arm damping block.
Loosen the screw.
12. Disconnect the exhaust system.
Remove 2 rubber hangers.
Note. Attach the exhaust system to the bottom with suitable means.
13. Disconnect the oxygen sensor harness connector.
14. Disconnect the front bumper from the axle housing.
Remove 3 plastic rivets.
15. Disconnect the shift mechanism (pic. VI).
Remove retaining clip 1 from shift mechanism 2.
Detach the shift mechanism from above from the shift mechanism bracket.
16. Install a hydraulic jack under the front axle housing together with tools KM-904 and KM-6168.
Note. Make sure that the KM-6168 drive pins are inserted into the drive holes on both sides of the front axle housing.
17. Remove 4 screws on the front axle housing (pic. VII, arrows).
18. Using a hydraulic jack, lower the front axle housing until the steering gear screws are accessible.
Note. Be careful not to lift the front axle housing off the KM-6168.
19. Remove the steering gear from the front axle housing.
Loosen 2 screws.
Remove the steering gear.
20. Install the steering gear on the prepared mounting bracket (see fig. I).
21. Remove 2 anthers.
Remove 4 clamps.
22. Remove 2 tie rods (pic. VIII).
23. Set the steering gear to the middle position (pic. IX).
Note. Measure the protrusion of both ends of the steering shaft 1 relative to the housing 2 with a caliper 3.
The size must be the same on both sides.
The toothed rack protrusion can be adjusted by turning the steering shaft.
24. Mark (pic. X, arrows) on the housing with respect to the lock nut 1 and the adjusting screw 2.
25. Mark (pic. XI, arrows) on the housing relative to the steering shaft.
26. Loosen the locknut (pic. XII).
Use tool KM-280 2.
27 Loosen adjusting screw 3.
Note. It is not allowed to change the position of the locknut relative to the adjusting screw. This is necessary to ensure the correct mounting position.
28. Remove the O-ring (pic. XIII, 2).
Use a suitable tool 3 to press the O-ring into the body.
Remove the O-ring from the body using the screwdriver 1 as a lever.
29. Remove retaining ring (pic. XIV).
Remove grease.
Remove the snap ring.
30. Remove the steering shaft from the housing.
31. Remove the rack from the housing and check the surface.
Note. If the surface is damaged, such as grooves, the steering gear must be replaced.
32. Remove the old bearing bush (pic. XV).
Loosen the bearing bush 1 using a suitable tool 2.
Push the bearing bush out of the housing from the opposite side using a long tool.
33. Clean the bearing housing.
34. Install a new bearing bush (pic. XVI).
Insert the bearing sleeve until it stops.
Install retaining ring 1.
35. Lightly lubricate the bearing bush with the supplied grease.
36. Install the gear rack.
Lubricate the gear rack evenly with the supplied grease.
Insert the gear rack into the center of the housing.
37. Install the steering shaft.
Note. The toothed rack must be set to the middle position.
The marks on the steering shaft and the body must match (see fig. XI).
Measure the protrusion of both ends of the steering rack relative to the housing using a vernier caliper.
Note. The size must be the same on both sides.
If the protrusion is not the same, repeat the operation to obtain the desired result.
38. Install retaining ring.
39. Install a new O-ring (1, fig. XVII).
Put the supplied grease into the housing.
Press the O-ring in with your fingers.
40. Screw in the adjusting screw with locknut.
Note. It is not allowed to change the position of the lock nut relative to the adjusting screw.
41. Tighten the locknut to 80 Nm. The marks on the body and on the adjusting screw must match.
Note. Hold down the adjusting screw if necessary. Be sure to observe the adjustment marks.
42. Install 2 tie rods.
Apply locking mastic to the gear shaft threads.
Tighten 2 tie rod ends (tightening torque 70 Nm).
Note. Hold the flats on the rack with an open wrench.
43. Install 2 anthers.
Install 4 clamps.
44. Remove steering gear from mounting bracket.
Loosen 2 nuts.
45. Attach the steering gear to the front axle housing.
Insert 2 new bolts.
Use 2 new washers.
Tighten 2 new nuts to 45 Nm + 45°+ 15°.
46. Install the front axle housing.
Using a hydraulic jack, carefully raise the front axle housing with the KM-6394 tools on KM-6168-A and KM-904 to the underside of the vehicle, rear torque arm bracket, or front torque rod.
47. Secure the front axle housing.
Tighten 4 new screws to 90 Nm. + 45°+ 15°.
48. Attach the shift mechanism.
Insert the shifter into the shifter bracket from above.
Install the mounting clip.
49. Attach the front bumper to the front axle housing.
Insert 3 plastic rivets.
50. Connect the oxygen sensor harness connector.
51. Attach the exhaust system.
Install 2 rubber hangers.
52. Install the front torque arm damping block.
Tighten the screw with a torque of 60 Nm.
53. Attach the front exhaust pipe to the catalyst.
Tighten 3 nuts with a torque of 25 Nm.
54. Attach 2 tie rod ends to the steering knuckle.
Tighten the new nuts to 35 Nm.
55. Attach 2 pendulum arms to the suspension strut support tube.
Tighten the nuts with a torque of 65 Nm.
Hold the two flats on the steering knuckle bolt with an open wrench.
56. Attach the intermediate steering shaft to the steering gear.
Tighten the nut on the clamp bolt to 24 Nm.
57. Remove the radiator suspension to the air deflector.
Cut off 2 plastic cable ties.
58. Install the front wheels.
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