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.