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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.