Contents: Manual steering. ⬇ Power steering. ⬇
Manual steering.
1. Remove the steering from the vehicle as described earlier.
2. Clean off external dirt.
3. Remove the bellows and the case cuff.
4. Remove the slider and guide with the toothed
5. Release the compressed steel lock nut from the rack adjusting screw.
6. Loosen and remove the adjusting screw and pull out the coil spring, oil seal and shock absorber slider.
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7. Pull the locking ring off the gear nut, unscrew the nut and remove the seal.
Figure 8.7 Section of the pinion and shock absorber of the toothed rack
8. Remove the rack and pinion.
Figure 8.8 Removing the steering gear locking ring - left side
9. Push the cap out of the end of the case using a long rod (Figure 8.9).
Figure 8.9 Removing the rack housing cap - indicated by the arrow (left side)
10. Further disassembly is not possible. If the rack bushings or needle bearing are worn, replace the entire housing. The gear can only be replaced together with the ball bearing.
Figure 8.10 Notch on pinion shaft located at greatest distance from longer tubular portion of rack housing - left side
11. Clean off old grease and lubricate internal components with specified grease. Grease with 50 grams (1 3/4 oz) lubrication between the rack bushings on the inside of the housing.
Figure 8.11 Dimensions of temporary fixture (Dimensions are in mm).
12. Insert the rack into the case and position it so that its end farthest from the pinion is in the position shown in Figure 8.10.
Figure 8.12 Adjusters (A) bolted to steering rack - left side
13. Now insert the pinion so that when its toothed wheel finally engages the teeth of the rack, the slot in the pinion shaft is at right angles to the rack and to distance A as shown in Figure 8.10.
14. Lubricate the pinion ball bearing with the specified grease and tighten the pinion nut to the specified torque. Install the new nut retaining ring, pushing it into place using a piece of pipe.
15. Now it is necessary to adjust the steering. To do this, make two fixtures following the dimensions shown in Figure 8.11. Screw the slider, guide and manufactured fixtures to the rack using the rod eye mounting bolts (Figure 8.12).
16. Insert the rack shock absorber slider and coil spring into their hole and tighten the adjusting screw until you feel some resistance.
17. Loosen the adjusting screw 1/8 to 1/4 turn and check that the rack moves freely along its entire feed length.
18. Without disturbing the position of the adjusting screw, install the compressed steel lock nut and tighten it to the specified torque value.
19. Hammer a new end cap into the case, install the bellows and remove the temporary fixtures and rod eye bolts from the rack.
20. Install the fasteners and gear cap seal as described in Section 5, paragraphs 5 and 6.
21. Check steering alignment as specified in Section 4, paragraphs 12 - 16. If the pinion-to-rack engagement is incorrect, the pinion must be removed and moved to correct the alignment.
22. After installing the steering control on the vehicle, perform a test drive along a route with corners and turns. The steering should exhibit a distinct self-centering action after the steering unit has been applied. If this is not the case, then this means that the rack shock absorber has been overtightened and needs to be adjusted.
Power steering.
23. Inspection of power steering is not recommended. Any malfunction or wear means that the entire unit must be replaced.
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