NANO

584

STEERING SYSTEM

Assembly :

1. Clean all components before use.

2. Assemble the Rack bush (02) with proper

lubrication on the bush inner diameter. (Refer

lubrication details in Technical Specifications)

3. Slide the steering rack tube and pinion in to case

steering gear.

4. Assemble the inner ball joint secured against rack

to specified torque. (8 - 9 Kg-m)

NOTE :

While tightening, NO scratches or damages are

allowed over the rack surface. Apply shell sterak/

servo gem EP2 grease (14 to 20 gms) on rack on

outer diameter and on all tooth root and surfaces.

5. Insert the rack tube with inner ball joint in to the

steering gear housing.

6. Fix pinion bearing retainer ring.

7. Apply few drops of loctite 542 on pinion cover

and assemble pinion cover.

8. Apply grease on oil seal and press fit in to the

groove of pinion cover.

9. Turn the housing in such a way that the yoke

bore is upright. Insert yoke and yoke spring.

10. Apply 2 to 3 drops of lock tight to the yoke cover

threads and tighten yoke cover.

11. Assemble the bellow on the housing side and

secure the bellow with bellow strap and bellow

clip.

NOTE :

Apply silicon grease on the grooves of inner ball joint

prior to the bellow assembly to enable the bellow to

rotate freely relative to inner ball joint.

12. Assemble outer ball joint and tighten lock nut.

Inspection of dismantled parts :

1. Examine the steering gear housing (01) which

consists of case steering gear, steering gear bush

(02) and pinion bush (03). If any damage to the

above component is found, replace the complete

steering gear housing assembly.

2. Check Free Pinion Torque (FPT) of the gear

assembly. If FPT is less than 8 kg-cm or greater

than 12 Kg-cm, replace the steering gear housing

assembly.

3. Examine the bellows (18) for crack and torn

condition. If any of the above is observed, replace

the bellows.

4. Examine inner ball joints (13) and outer ball joints

(14 &15) for excessive play. If axial play is more

than the specified value or anymechanical damage

is found, replace the respective ball joint assembly.

(a) Axial play for inner ball joint = 0.06 mm @ 40 kg

(b) Axial play for outer ball joint = 0.1 mm @ 200 kg

5. Examine the rack and pinion assembly individually.

If any damage to rack or pinion assembly (which

consists of pinion, retainer ring and pinion bearing)

is found, replace the respective component as per

their specified kit.

6. Examine the yoke (08) for excessive wear and

damage. If any damage is evident, replace the

yoke.Also if fit between yoke bore on case steering

gear and yoke is slack, replace the yoke by new

one.

7. Examine the yoke spring (09). If found damaged

or solid (compressed set) replace the spring.

8. In case of any mechanical damage due to accident

or also during regular overhauling process, the

rack, pinion and housing set should be checked

for visual cracks, breakage and bends. If any

damage is evident, replace the respective

component.