Service Manual Trucks · Service Manual Trucks Group 640–500 Steering System VN/VHD...

Service ManualTrucks

Group 640–500

Steering System

VN/VHD

PV776-TSP153872

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to March 2001.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP153872

© 2001 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral ........................................................................ 3Steering System ........................................................... 3

Specifications ............................................................. 5Power Steering System ................................................ 5

Power Steering Gear .................................................. 5Power Steering Pump ................................................ 5System ....................................................................... 5Tightening Torques ..................................................... 6

Tools ............................................................................ 7Standard Tools ........................................................... 7Special Tools .............................................................. 7Special Equipment ..................................................... 9

Design and Function ................................................ 10Power Steering System .............................................. 10

System Description .................................................. 10Additional Maintenance Information ......................... 11Basic Operation ........................................................ 12Power Steering Pump .............................................. 12Power Steering Gear ................................................ 16Oil Reservoir and Filter ............................................ 20Steering Shaft .......................................................... 22Steering Column ...................................................... 23Steering Wheel ......................................................... 25Supplemental Restraint System (SRS) .................... 26

Troubleshooting ........................................................ 29Steering System Troubleshooting ............................ 29

................................................................................. 30

Service Procedures .................................................. 31Steering Wheel, Replacement ................................. 31Steering Wheel, Replacement ................................. 32Steering Column, Replacement ............................... 36Steering Column, Overhaul ...................................... 39Steering Column Adjustment Cable, Replacement . 41Steering Shaft, Replacement ................................... 44Upper Steering Shaft, Replacement ........................ 47Lower Steering Shaft, Replacement ........................ 47Steering Shaft Carrier Bearing, Replacement ......... 48Intermediate Steering Shaft, Replacement .............. 49Steering Shaft Boot, Replacement .......................... 49Steering Shaft Carrier Bearing Bracket, Replace-ment ......................................................................... 50Power Steering Pump, Replacement ....................... 50Power Steering Pump, Overhaul .............................. 52Steering Gear Relief Valve, Adjustment .................. 54Steering Gear, Replacement .................................... 54Power Steering Fluid Filter, Replacement ............... 57Power Steering Hydraulic Fluid, Changing .............. 58Power Steering Hydraulic System, Bleeding ........... 59Power Steering System, Checking ........................... 60Tilt Steering Column Cable, Adjustment .................. 62Input Shaft Seal, Replacement ................................ 63Sector Shaft Seal, Replacement .............................. 66

Feedback

Operation Numbers

1

Group 64 Steering System General

General

Steering SystemThis information covers the design, function, operation, and service procedures of thesteering system hydraulic components used on the VN/VHD series vehicles.

W6000623

3

Group 64 Steering System Specifications

Specifications

Power Steering SystemPower Steering Gear

Model ........................................................................................ TRW TAS-65 Sheppard M100 ZF 8098

Type .......................................................................................... Ball nut Ball nut Ball nut

Ratio ......................................................................................... 20.4:1 18.9:1 18.3:1

Steering wheel travel ................................................................. 4.5 turns 4.75 turns 5.1 turns

Maximum output torque (@ 2175 psi) ...................................... 42,900 in-lb 43,050 in-lb 54,450 in-lb

Power Steering Pump

Engine VolvoD12

CumminsM11

CumminsN14

DetroitDieselSeries 60

Caterpillar3406E

Part No. 8071732 8081009 8081010 8081011 8081010

Rotation cw cw ccw cw ccw

Drive type gear spline spline spline gear

Displacement /rev(cm3)

21 21 17 21 17

For all engines:

Oil type ........................................................................................................................................ Dexron II or Dexron III

Pressure output (max) ................................................................................................................... 15.0 MPa (2175 psi)

Pressure output (min) .................................................................................................................... 12.5 MPa (1800 psi)

Regulated Flow ........................................................................................................................... 16 liters/min (4.2 gpm)

System

Oil capacity ........................................................................................................................................ 4.7 liters (1.25 gal)

5

Group 64 Steering System Specifications

Tightening Torques

Steering Wheel

Steering wheel center bolt ................................................................................................... 85 ± 15 Nm (63 ± 11 ft-lb)

Note: Steering wheel center bolt is not to be reused

Steering Column

Upper steering column attachment bolts .......................................................................... 15 ± 3.5 Nm (135 ± 30 in-lb)

Gas spring bolts ................................................................................................................... 17 ± 3 Nm (150 ± 25 in-lb)

Steering Shaft

Steering shaft U-joint pinch bolts ............................................................................................ 60 ± 10 Nm (45 ± 7 ft-lb)

Steering Gear

Pitman arm retainer (Sheppard) ................................................................................................. as marked on retainer

Pitman arm pinch bolt (TAS) ............................................................................................. 400 ± 60 Nm (295 ± 45 ft-lb)

Pitman arm jam nut (ZF) .................................................................................................. 600 ± 50 Nm (445 ± 37 ft-lb)

Mounting bolts, steering gear .......................................................................................... 540 ± 90 Nm (400 ± 67 ft-lb)

Pitman arm/drag link ........................................................................................................ 200 ± 30 Nm (148 ± 22 ft-lb)

Power Steering Pump

Housing bolts ........................................................................................................................... 45 ± 5 Nm (33 ± 4 ft-lb)

Lock nut, gear wheel (D12 only) ........................................................................................... 100 ± 10 Nm (75 ± 7 ft-lb)

Mounting bolts .......................................................................................................................... 46 ± 1 Nm (34 ± 1 ft-lb)

6

Group 64 Steering System Tools

ToolsStandard Tools

Steering system maintenance requires the use of many tools that are part of a techni-cian’s normal tool set. In addition, the following tools are required to performmaintenance procedures on the steering system.

W0001220

Torque Wrench

W0001232

Thermometer

Special ToolsThe following special tools are required for work on the steering system. The tools canbe ordered from Volvo Truck.

W0001253

9985433 Puller

W0001257

9985434 Puller

W0001239

9992327 Pry Bar

W0001254

9992619 Spindle

W0001255

9992658 Puller

W0001258

9992670 Hydraulic Hand Pump

W0001247

9992671 Hydraulic Cylinder

W0001256

9992672 Handle

7


W0001260

9992681 Pitman Arm Puller

W0001240

9996201 Ball Joint Puller

W0001249

9996222 Foot Pump

W0001259

9996519 Steering Wheel Puller

8


Special EquipmentThe following special equipment is required for troubleshooting and repair of the steer-ing system. This equipment can be ordered from Volvo Truck or from other tool andequipment distributors.

W0001236

Flowmeter with Pressure Gauge

9

Group 64 Steering System Design and Function

Design and Function

Power Steering SystemSystem DescriptionThe steering system is a hydraulically operated controlsystem comprised of a pump, steering gear, fluid reser-voir, steering column, steering shaft, steering wheel, andinterconnecting hoses.

The power steering pump is mounted to the engine andis driven by either a gear or a splined shaft. Pump rota-tion produces hydraulic pressure at approximately 17.2MPa (2500 psi) for system operation.

The pump’s high pressure output is directed through ahose to the steering gear. The steering gear uses theenergy in the fluid to position a gear, called the sectorshaft, so that a moveable arm, called the pitman arm,turns to produce changes in front wheel direction. Thesteering gear is mounted outboard the left side frame railalmost at the forward end.

Input to the steering gear comes from the steering wheelthrough the steering column and steering shaft. Thesteering column is positioned within the vehicle cab. Itserves as the mounting for the steering wheel. Thesteering shaft is the portion of the steering system thattransitions the system from inside the cab to the enginecompartment. The shaft is a two piece telescoping unitwith a universal joint welded to each end. One end isconnected to the steering column within the cab, theother is connected to the steering gear.

Power steering fluid is supplied to the pump from thefluid reservoir. The reservoir is connected to the powersteering pump and the steering gear through hoses. Thefluid is returned to the reservoir from the steering gear.The reservoir has an internally mounted filter in the fluidreturn path. The reservoir, which is made of moldedplastic, is strapped to an aluminum bracket. The bracketis bolted to the vehicle frame and serves as both amounting device and a heat exchanger for the reservoir.

10


Additional Maintenance InformationThe typical steering gear installed in the VN series wasthe Sheppard M100. That was changed to the TRWTAS65 in 1999. The only steering gear installed in theVHD series is the TRW TAS65 which is supplementedwith a helper cylinder on the right side for heavy axlepressures and a second power steering box on veryheavy axle pressures.

Specific maintenance procedures for the various steeringgears, such as changing seals, or overhaul (and pitmanarm removal and installation on the M100), are not in-cluded. Those procedures can be found in the respectivevendor’s manual for each steering gear. If routine main-tenance or troubleshooting reveals that repair of thesteering gear is necessary, refer to the appropriate ven-dor manual for maintenance instructions for that gear.

Vendor manuals for the two steering gears are availablefrom Volvo. Refer to the following list for the appropriatemanual.

TRW TAS 65 ....................................................................... TAS Steering Gear Service Manual TAS SM WA 5M 3/94

Sheppard ...................................................................................... Sheppard Power Steering Service Manual 1000400

11


Basic OperationUnder normal straight running circumstances, the steer-ing system performs little work. Fluid from the reservoirflows to the pump which increases its pressure and de-livers it to the steering gear. If the steering wheel is notpositioned for a turn, the fluid pressure is equalizedthroughout the steering gear, so there is no movement ofthe sector shaft or the pitman arm attached to it.

When the driver turns the steering wheel, the steeringgear changes the flow pattern of the incoming high pres-sure fluid so that there is a pressure difference acrossthe steering gear’s internal piston. That pressure differ-ence forces the piston to move, which in turn rotates thesector shaft and the pitman arm. The pitman arm pulls orpushes the drag link to cause the vehicle to turn. Whenthe steering wheel is returned to the straight ahead posi-tion, the fluid flow path changes to push the piston backto its straight running position, returning the sector shaft,pitman arm, and drag link to their neutral positions.

Power Steering PumpThe power steering pump converts mechanical energysupplied by the engine to hydraulic energy in the form offluid flow and pressure. Fluid is supplied to the pumpfrom the fluid reservoir and distributed at high pressureto the steering gear.

The pump is a vane type pump. Its rotor consists of awheel and ten vanes that can slide in an out of the rotor.The rotor and vanes are housed in an oval shapedchamber. As the rotor spins, centrifugal force moves thevanes toward the outer edges of the chamber. When avane is at the wide part of the chamber it scoops up hy-draulic fluid. As a vane moves toward the narrow part ofthe chamber its fluid is forced toward the lower pressureregion of the chamber outlet. Because the chamber isoval, each vane can scoop and deliver fluid twice duringeach rotation, doubling the pump capacity.

W6000631

12


Refer to the figure below. The pump also houses a con-trol valve which regulates the oil flow and acts as asafety valve. In its rest position, the control valve ispressed to the left by a spring. When pump rotationbegins, oil from the pump chamber flows through the de-livery channel through an orifice out into the delivery lineapplying delivery pressure to the valve.

Because of the orifice, the pressure in the delivery chan-nel is higher than in the space to the right of the valve.Thus pressure is pushing the valve to the right, com-pressing the spring. When pump speed is high enough,the valve moves over so that surplus pressure is relievedby oil passing the valve. That oil returns to the suctionside of the pump. This valve action regulates the flow ofoil. Since the pump typically is called on to supply lessthan its maximum capacity, the valve action is part ofnormal operation.

In the event that the fluid flow is blocked, such as whena wheel is being forced against a curb or stuck in a rut,the pressure in the delivery line increases to equalizethe pressure on both sides of the control valve. Thespring then pushes the valve to the left closing off theexcess flow return causing the pressure to rise. Thespring force on the pressure valve ball is overcome to letfluid through to the suction side through a return hole.

The pressure remains at maximum until the wheel ob-struction is removed or the steering wheel is released.While the pressure valve is open there is only a smallvolume of fluid recirculating. Due to its high pressure,the temperature of the recirculating fluid increasesrapidly. If a high temperature condition continues formore than approximately 5 seconds there is risk ofbreakdown of the fluid’s lubricating properties, whichcould cause severe pump damage.

To help prevent an over-temperature condition, steeringgear has off-loading valves to minimize excess mechani-cal loads and to allow a larger volume of fluid torecirculate, thereby minimizing the rate of temperaturebuildup.

The hydraulic pump is driven either by a gear or aneleven tooth, splined shaft depending on the engine onwhich it is installed. The splined axle drive is used on allengines except Volvo and CAT 3306.

A splined axle drive does not generate excessive axialforces, therefore the drive end bearing and housing hasa bushing in place of the ball bearing. These pumps aredesignated the LF series by LuK. Pumps designed foraxial and radial drive forces (gear attached to pump) aredesignated the VT-series pumps.

W60007951) Flange 4) Rotor 7) Orifice2) Seal 5) Housing 8) Bearings or

bushing3) Vane 6) Controlvalve

13


Power Steering Pump, Exploded View

W6000798

1 Plug 10 Dowel pin 18 Flange2 Spring 11 Flange 19 Bushing3 Control valve 12 Retaining ring 20 Shaft4 Housing 13 Bearing 21 Seal5 Wear plate 14 Shaft 22 Retaining ring6 Casing ring 15 Retaining ring 23 O-ring7 Rotor 16 Gear 24 O-ring8 Vane 17 Lock nut 25 Backup ring9 Wear plate

14


Power Steering Pump Model Number Designations

W6000866

15


Power Steering Gear

W6000867

Typical steering gear

The steering gear consists of an input shaft, a wormshaft, a torsion bar, a control valve, a piston, a sectorshaft, and plunger or poppet valves. The gear also has apitman arm attached to the sector shaft. All of the com-ponents except the pitman arm are located within thegear housing.

The input shaft and the worm shaft are connected by thetorsion bar which is pinned to both shafts. The controlvalve is fixed to the upper part of the worm shaft. Thethreaded portion of the worm shaft is inserted into thepiston. Contact between the worm shaft and piston isthrough a set of recirculating balls.

The steering gear receives high pressure hydraulic fluidfrom the pump. The input shaft rotates in the same di-rection as the steering wheel. When the input shaft isturned, the ports in the control valve line up to direct thehigh pressure fluid to the inside or outside of the pistoncausing rotation of the sector shaft and thus movementof the pitman arm.

Detailed operation of the steering gear is described laterin this chapter.

W6000800

Steering gear mounted on frame

16


Steering Gear FunctionUnder straight driving, high pressure fluid flows from thepump to the steering gear. The fluid flows through thedrilled ports in the control valve and the worm shaft andaround the piston. Since pressure is equalized through-out the gear, both poppet valves are open, allowing freemovement of fluid to the other side of the piston to thedischarge ports in the worm shaft and control valve.

W6000633

As the steering wheel is turned clockwise, the steeringgear input shaft turns. This movement cause the torsionbar and worm shaft to turn as well, since the torsion baris pinned to both the input shaft and the worm shaft. Theworm shaft attempts to move the piston, but the pistonresists because the force required to turn the sectorshaft is greater than that supplied by the worm shaft. Asa result, the torsion bar twists. This causes the ports andchannels in the control valve and worm shaft to alignand apply the high pressure fluid to the upper end of thepiston, causing the lower poppet valve to close. Nowthere is a pressure differential between the upper endand the lower end of the piston, causing it to move to-ward the rear of the housing. The rearward motion of thepiston rotates the sector shaft, which moves the pitmanarm toward the steering axle, causing a right turn.

W6000634

As the steering wheel is returned to its normal position,the lower poppet valve reopens and the steering gearpressures are equalized again. The piston is forced backto the neutral position due to hydraulic fluid flow in theopposite direction and the force from the mechanicalsteering system (if the vehicle is in motion).

W6000633

17


As the steering wheel is turned counterclockwise, theprocess is the same as for clockwise except that theports and channels in the control valve and worm shaftalign to apply the high pressure fluid to the outside ofthe piston, causing the upper poppet valve to close. Nowthere is a pressure differential between the inside andthe outside of the piston causing it to move toward thefront of the housing. The forward motion of the piston ro-tates the sector shaft, which moves the pitman arm awayfrom the steering axle, causing a left turn.

To prevent damage to other steering components whenthe steering system is at an extreme position, the poppetvalve stems extend beyond the poppet sleeves. As thepiston nears full travel the poppet valve stem will contacteither the end of the cylinder bore (upper poppet duringleft turn) or the fixed stop bolt (lower poppet during aright turn). When the poppet stem contacts the end ofthe bore (or the end of the bolt) that poppet valve opensrelieving the pressure from the high side just enough tostop the gear from trying to turn beyond its limits. Thisprotects the steering gear as well as the pump becausethe piston is prevented from contacting the end of thecylinder bore.

W6000635

18


Steering GeometryFor a vehicle to have good road characteristics and cor-rect steering without steering wheel vibrations, it isimportant that all the parts of the steering system arecorrectly adjusted in relation to one another.

The steering gear center position should always bechecked after replacement of the steering gear, frontspring, pitman arm, or drag link. It should also bechecked any time the vehicle exhibits unstable steeringor pulling.

In its center position the steering gear has a so-calledpressure point (center torque between sector shaft andpiston). The torque across the center point dampens anysmall vibrations when driving straight ahead.

The unloading valves, or relief valves, should alwaysbe checked and adjusted after the curve angles (wheelstops) have been set and before or in conjunction withchecking the hydraulic function.

19


Oil Reservoir and FilterThe fluid reservoir contains the power steering fluid forthe system. It holds approximately 0.75 liters (21 oz.) ofhydraulic fluid. The reservoir is mounted to an aluminumbracket that is bolted to the left side frame rail. Thebracket is designed to support the reservoir as well asaid in heat dissipation. Only Dexron II® or Dexron III®

steering fluid may be used.

There is a filter mounted inside the reservoir in the returnpath from the steering gear. The filter is in the return lineto avoid creating a restriction in the pump suction line.The filter is held in place by a yoke and a spring whichexert pressure on the upper cover. In the event that thefilter becomes clogged, the filter pressure relief functionwill ensure fluid flow and prevent rupture of the filter.When fluid pressure is high enough to overcome thespring force, the filter lifts off the guide at the bottom ofthe reservoir and unfiltered oil will flow into the reservoir.

The reservoir is mounted such that it is at the highestpoint in the system so that any air in the system will flowtoward it. W6000632

VN Fluid Reservoir

W6001419

VHD Fluid Reservoir

20


Fluid Reservoir, Exploded View

W6000799

1 Reservoir 4 Spring

2 Dipstick 5 Locking device

3 Filter 6 Cap

21


Steering ShaftThe steering shaft is the component that connects thesteering gear to the steering column inside the cab. Thesteering shaft consists of two tubes. The upper tube (2)fits inside the lower tube (1) , and has a circulating ballmechanism (4) at its lower end. The balls recirculatingreduces wear and isolates much of the vehicle vibrationfrom the steering column and steering wheel.

The upper end of the lower shaft and all of the uppershaft is housed in a rubber boot that keeps dirt andmoisture out of the shafts and out of the cab.

Each end of the steering shaft has a universal joint (3)that fits on the spline of the steering column and thesteering gear. The steering shaft is easily removed byloosening the pinch bolt on each universal joint and pry-ing the U-joint off the serrated end of the steering gearor steering column.

W6000628

VN and VHD (Axle Back) Steering Shaft

W6001420

VHD Steering Shaft

22


Steering ColumnThe steering column (1) is located inside the vehicle cab.It is housed in an aluminum housing (2) which is con-nected to the vehicle cab through the adjustmentmechanism. The column is supported at each end byball bearings and held in place by retaining clips. Bothends of the column are splined. The upper spline con-nects to the steering wheel. The lower end is connectedto the steering shaft.

W6000627

Column Adjusting MechanismThe steering column adjustment mechanism allows thedriver to set the steering wheel height and angle to amore comfortable position. A bearing arm (1) is con-nected to the cab, where it swivels to provide the verticalmotion. The steering column is attached to a set of fric-tion plates (2) and to the bearing arm. The friction platesslide forward and back to provide the angular adjustment.

Column motion is slowed and smoothed by a gas spring(3) which is attached to the bearing arms and the steer-ing column housing. In order to adjust the steering wheelposition, the driver presses the foot pedal (4) which pullsthe cable (5) down against a spring. The other end ofthe cable pulls two parts of a disc assembly together torelease the pressure on the friction plates, which allowsthe column to move.

W6000801

23


Steering Column Adjustment Mechanism, Exploded View

W6000796

1 Pedal 6 Friction plates

2 Gas spring 7 Bearer arm

3 Disc assembly 8 Adjuster cable

4 Friction plates 9 Support plates

5 Column housing

24


Steering WheelThe steering wheel is typical for heavy trucks, howeveron the VN/VHD series vehicles the splined upper end ofthe steering column is cylindrical, not tapered. Thismeans that a wheel puller is no longer required to re-move the steering wheel. The wheel is held firmly inplace by a bolt that is coated with adhesive.

When the vehicle is in a forward position, the steeringwheel should be straight-ahead at ± 4�. To alter thesteering wheel alignment refer to “Steering Shaft, Re-placement” page 44.

Note: Although a puller is not required for removal of thesteering wheel, puller 9996519 can be used for easiersteering wheel removal.

W6000626

25


Supplemental Restraint System (SRS)Note: The SRS is not standard on all VN/VHD series ve-hicles.

W8001291

GeneralThe Supplemental Restraint System (SRS) is a personalsafety device that works in conjunction with the driver’ssafety belt. It consists of an airbag that will automaticallydeploy and inflate in the event of a rapid vehicle deceler-ation such as would occur in a collision.

The components of the SRS include an electronic con-trol unit (ECU), a contact reel, and an airbag module.With the exception of the ECU, all of the componentsare mounted on the steering system.

Electronic Control Unit (ECU)The ECU is an electronic sensing device that monitorsthe rate of deceleration of the vehicle. It determineswhether or not the vehicle is in a collision situation bysensing if the vehicle is slowing rapidly enough and forlong enough to require deployment of the airbag to pro-tect the driver. The ECU is mounted on a special shelfthat is welded to the cab to allow it to properly sense thecab deceleration rate.

The sensing circuits are designed such that a decelera-tion that is too slow (such as locking up the brakes) orthat is too short duration (such as bumping into anothervehicle while slowly rolling forward) will not cause theairbag to be deployed. The deceleration must be rapidand must be for an extended period of time, such as in acollision at driving speed with a stopped vehicle.

T8006850

26


Contact Reel

The electrical signal from the ECU is transmitted to theairbag module through a device called the contact reel.The contact reel is mounted on top of the steering col-umn housing. It utilizes a coiled ribbon harness to allowfor multiple rotations of the steering wheel. Proper posi-tioning of the parts of the contact reel is crucial to itsoperation. Care must be used when removing the steer-ing wheel to ensure the contact reel orientation is notdisturbed.

For further information on maintenance of the contactreel and other SRS components, refer to Group 88 Sup-plemental Restraint System (SRS) service information.

T8006881

Airbag ModuleThe airbag module is mounted on the steering wheel. Itconsists of a detonator, gas generator, and the airbag.The airbag is folded up and is positioned above the gasgenerator. A fully inflated bag has a volume of approxi-mately 67 liters. The airbag is made of a strongpolyamide weave. There are two evacuation holes in thebag so that it collapses to absorb the energy from theforward movement of the driver.

T8006851

The detonator (A) causes a rapid reaction of the con-tents of the gas generator (B) to produce enough gas toinflate the airbag. The gas generator is an enclosed unit,filled with a propellant which forms a harmless gas.

T8006856

27


SRS MaintenanceAdditional care must be taken when performing mainte-nance on a steering system on a vehicle that isequipped with an airbag. Before any maintenance beginsplease refer to “Steering Wheel, Replacement” page 32.

SRS IdentificationA vehicle equipped with SRS can be identified by thepresence of the following decals.

W6001401

1) Driver’s sun visor 3) Steering shaft2) Driver’s side B-pillar or Driver’s sun visor 4) Windshield

28

Group 64 Steering System Troubleshooting

TroubleshootingSteering System Troubleshoot-ingThe troubleshooting tables are intended only as a guide to assist the technician in discovering the possible cause of avehicle steering problem. The tables are not intended to cover all the possible problems in the steering system or theirexact remedy. The tables should not be used in place of good troubleshooting technique and experience, but as atime saving tool to help locate possible causes and possible cures of steering problems.

Complaint Possible Cause Remedy

Fluid level too low and/or air in power steer-ing system.

Add oil and bleed steering system.Check for leakage.Check the pump drive shaft seal.

Incorrect oil in power steering system. Change the oil.

Steering shaft universal joints binding. Replace steering shaft.

Abnormally large resistance in wheel suspen-sion.

Check and correct tire pressure.Ensure steering knuckles do not bind.

Insufficient pressure and oil flow in powersteering pump.

Check hydraulic function.Overhaul power steering pump.

Steering heavy inboth directions

Excessive internal leakage in steering gear. Overhaul steering gear.

Unloading too early. Check and adjust unloading mechanism.Steering heavy inone direction

Incorrectly adjusted and/or faulty valves orseals in steering gear.

Overhaul steering gear.

Insufficient pressure and oil flow in powersteering pump.

Check hydraulic function.Overhaul power steering pump.

Steering heavywith rapid steeringwheel turns Air in power steering system. Check and correct leakage.

Check and/or replace pump driveshaft seal.

Abnormally large resistance in wheel suspen-sion.

Check and correct tire pressure.Ensure steering knuckles do not bind.

Too little camber. Adjust camber.

Steering wheel hasstiff return to neu-tral after steering

Excessive friction or dirt in steering shaft orsteering column components.

Clean, repair, or replace components as nec-essary.

29

Group 64 Steering System Troubleshooting

Complaint Possible Cause RemedyFluid level too low and/or air in power steer-ing system.

Add oil and bleed steering system.Check for leakage.

Incorrect tire equipment. Ensure front wheels heve same type tires onboth wheels.

Steering incorrectly adjusted. Adjust steering center position.

Pressure point incorrectly adjusted. Adjust steering gear pressure point.

Excessive play in steering shaft U-joints orsteering rod ball joints.

Replace steering shaft or steering rod balljoints.

Loose steering gear mounting bolts. Tighten bolts to correct torque.

Incorrect toe setting. Adjust toe.

Difficult to main-tain straightcourse

Stiff kingpins. Replace kingpins and their bushings.



Steering gear mounting bolts loose. Tighten bolts to the correct torque.

Steering gear pressure point setting incorrect. Adjust pressure point.

Excessive play in steering shaft U-joint(s). Replace steering shaft.

Excessive play in steering rod ball joints. Replace worn ball joints or steering rods.

Faulty shock absorbers. Replace shock absorbers.

Impact felt insteering wheel

Fault in steering gear. Repair/replace steering gear.

Vibration in steer-ing wheel

Imbalance in front wheels or front brakedrums.

Balance front wheels and front brake drums.



Incorrect fluid in power steering system. Change power steering fluid.

Fault in power steering pump. Repair/replace power steering pump.

Unusual noise inpower steeringsystem

Fault in steering gear. Repair/replace steering gear.

Steering wheelturns by itself toone stop or theother

Control valve mechanism in steering gearfaulty.

Repair/replace steering gear.

30

Group 64 Steering System Service Procedures

Service Procedures6411-03-02-01Steering Wheel, Replacement

Without SRS

Removal

Before working on a vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

1

W3000789

Remove the horn button from thesteering wheel.

2

W6000872

Remove the bolt in the center of thesteering wheel. Discard the bolt.

Note: The steering wheel center boltmust not be reused. The bolt must bereplaced with a new original equip-ment bolt when the steering wheel isinstalled.

3Pull the steering wheel off the steeringcolumn by hand. If the wheel will notcome off by hand, use puller 9996519to remove the wheel.

9996519

4Disconnect the wires for the horn.

31


InstallationNote: Ensure the steering system is aligned prior to in-stalling the steering wheel.

1Place the steering wheel on the steer-ing column.

2Connect the wires for the horn.

3

T8006876

Install a new original equipment boltand washer in the center of the steer-ing wheel and torque to 85 ± 15 Nm(63 ± 11 ft-lb).

317656485 ± 15 Nm63 ± 11 ft-lb

4Install the horn button.

6411-03-02-01Steering Wheel, Replacement

With SRS

Removal1

The battery must not be connected when the airbagmodule is being removed or installed. Failure todisconnect the battery could result in premature actu-ation of the SRS, causing serious personal injury.

CAUTION

Before beginning this procedure, disconnect anyground cables connected to the battery (such as en-gine ECU, satellite system, etc.). Disconnect thosegrounds first to avoid damaging electrical compo-nents. Then disconnect battery negative and positiveterminals disconnect the ground terminal first.

CAUTION

Possible equipment damage. The orientation of thecontact reel to the center position of the steering gearmust be maintained at all times. The steering wheelmust be held in the center position anytime the steer-ing column and the steering gear are not connectedby the steering shaft. Failure to maintain proper con-tact reel orientation could result in breakage of theribbon harness rendering the SRS inoperable.

Ensure the steering wheel is centeredand the vehicle front wheels are point-ing straight ahead.

2Secure the steering wheel in position.If steering wheel has a locking device,turn the ignition switch to off, other-wise, strap the wheel in position.

32


3

T8006862

Turn the ignition switch off and discon-nect the negative battery terminal.

4

T8006874

Remove the airbag module by remov-ing the two bolts underneath thesteering wheel. Disconnect the con-nector and lift off the airbag module.

5

W6001430

Always store a non-deployed airbag module with themetal (underneath) side down and in a place where itwill not be handled carelessly. This is to reduce thechances of the airbag being projected from its storageposition if accidentally deployed, which could causeserious personal injury or death.

Store the non-deployed airbag modulein a secure place.

6

T8006875

Loosen the bolt in the center of thesteering wheel. Do not remove thebolt at this time.

7Ensure the vehicle steer wheels arepointing straight ahead. Verify thesteering gear is centered by observingproper orientation of the timing marks.

33


8

T8006876

Remove the bolt from the center of thesteering wheel. Discard the bolt.

Note: The steering wheel center boltmust not be reused. The bolt must bereplaced with a new original equip-ment bolt when the steering wheel isinstalled.

9

T8006878

Remove the screw in the end of theplastic band and screw it firmly to thecontact reel (the screw must alwaysremain in the plastic band). The con-tact reel is now secured in its position.

Note: The steering wheel must neverbe turned when the contact reel is se-cured.

10Lift off the steering wheel without turn-ing it. If the wheel will not come off byhand, use puller 9996519 to removethe wheel. Allow the cable and plasticband to pass through the hole in thesteering wheel.

9996519

11Disconnect the wires for the horn.

InstallationNote: Ensure the steering system is aligned prior to in-stalling the steering wheel.

1

T8006862

Turn the ignition switch OFF and dis-connect the negative battery terminal.

2Place the steering wheel on the steer-ing column. Feed the cable and plasticband through the hole in the steeringwheel.

3Connect the wires for the horn.

4

T8006878

Remove the screw from the contactreel to the blind hole in the steeringwheel. Ensure the screw stays in theplastic band.

34


5

T8006876

Install a new bolt in the center of thesteering wheel and torque to 48 ± 7Nm (35 ± 5 ft-lb).

97992448 ± 7 Nm(35 ± 5 ft-lb)

6Connect the contact reel cable to theairbag module and place the moduleon the steering wheel.

7

T8006874

Install the airbag on the steeringwheel. Tighten the left hand bolt first.Torque the bolts to 10 ± 2 Nm (90 ±18 in.-lb.).

10 ± 2 Nm(90 ± 18 in.-lb)

8Close the cab windows. Turn the igni-tion switch to ON. Ensure no one is inthe cab. Close the cab doors.

9

WARNING

Personal injury hazard. It is important to be sure thatno one is in the cab during this procedure step. Theair bag could deploy causing serious injury.

CAUTION

If there are other ground cables to be connected to thebattery (such as engine ECU, satellite system, etc.),connect the battery ground cable first, then connectthose grounds. Electronic modules may be damagedwhen additional grounds are connected/disconnectedwithout the main battery ground connected. Alwaysreconnect the main battery ground first.

CAUTION

In vehicles with a Supplemental Restraint System(SRS), turn the ignition switch ON before connectingthe battery. Failure to do so may result in permanentdamage to the instrument cluster or other electroniccircuits on the vehicle. Check for fault codes after re-pairs are complete.

Connect the negative battery lead.

35


6412-03-02-04Steering Column, Replacement


Removal1Remove steering wheel in accordancewith the appropriate serviceprocedure. See “Steering Wheel, Re-placement” page 31 and “SteeringWheel, Replacement” page 32.

2

T8006351

Remove the covers from around thesteering column and above the pedalsin the order shown.

Note: Use caution when pulling centerpanel off of push lock clips.

3Pull the floor mat back.

4

W6000648

Remove the turn signal switch screws.Disconnect and remove the switch.

5

W6000647

Remove the windshield wiper switchscrews. Disconnect and remove theswitch.

6Extend the steering column as far outas possible.

7

T6006167

Disconnect the gas spring (A) from thegas spring bolt (B).

36


8

W6000650

Remove the steering column pivotscrews (2).

9Pull the column forward until bothsteering column attachment bolts areclear of the dash.

10

W6000650

Remove both upper steering columnattachment bolts (1).

11Rotate the steering column until theupper shaft points toward the cab floor.

12

W6000649

Loosen the steering shaft upper endU-joint pinch bolt. Pry the U-joint offthe steering column.

13Remove the column.

Installation1Place the steering column housing onthe adjustment mechanism.

2

W6000650

Install upper steering column bolts (1).Torque bolts to 15 ± 3.5 Nm(135 ± 30 in.-lb.).

15 ± 3.5 Nm(135 ± 30 in.-lb.).

37


3Ensure the vehicle front wheels arepointing straight ahead. Also ensurethe timing marks on the steering gearhousing are aligned.

4

W6000865

Ensure the timing mark on the steer-ing shaft is pointing toward the top ofthe column housing.

5Replace the steering shaft upper U-joint pinch bolt with a new originalequipment bolt. Apply locking fluid tothe bolt.

6782610971086

6

W6000649

Connect the steering shaft to thesteering column. Torque the pinch boltto 60 ± 10 Nm (45 ± 7 ft-lb).

60 ± 10 Nm(45 ± 7 ft-lb)

7

W6000650

Install the column pivot screws (2).

38


8Attach the gas spring to its bolt on thecolumn housing.

9Attach the turn signal switch and wipercontrol switch. Connect the wires forthe switches.

10Install the steering column covers inthe reverse order from removal. See“Steering Wheel, Replacement” page31 and “Steering Wheel, Replace-ment” page 32.

11Install the steering wheel in accor-dance with the appropriate serviceprocedure.

6412-04-04-01Steering Column, Overhaul

WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with engine debris orfluids.

Disassembly1

W6000646

Place the steering column housing ina vice.

2

W6000652

Remove the retaining ring from thelower end of the column.

3Pull the lower bearing from the hous-ing.

39


4Remove the column from the housing.

5Remove the seal.

6Remove the retaining ring from the up-per end of the housing.

7Rotate the housing in the vice so thatthe lower end points up.

8

W6000655

Using a suitable drift, drive the upperbearing out of the housing.

Assembly1

W6000654

Using a suitable drift, press a new up-per bearing into the housing.

2Install the retaining ring in the grooveat the upper end.

3From the lower end, press a new sealinto the housing.

4Install a new bearing on the column.Press it on with a drift.

40


5

W6000653

Install the column in the lower end ofthe housing. Press the column in untilthe bearing is below the groove for theretaining ring.

6Install the lower retaining ring in thehousing.

6412-03-02-03Steering Column AdjustmentCable, Replacement

Removal1

W3000655


DO NOT attempt to adjust the tilt steering column bytightening or loosening the screw joint. Adjustmentsmust be made ONLY from the cable at the foot pedal.Adjustments attempted at any other location mayaffect the safety features of the steering column, re-sulting in and accident and/or serious personal injuryor death.

Remove the push clips from the bot-tom of the front and rear uppersteering column covers.

41


2

T8006351

Remove the torx screws from thesteering wheel covers and remove thecovers in the order shown. Disconnectthe ventilation hose and the diagnos-tics connector from the left side cover.

3Pull back the floor mat.

4

T6006167

Remove gas spring (A). Remove thegas spring bolt (B) from the bracket.

5Remove the forward grab handle.

6Remove side kick panel.

7Remove the plastic clamps holding theair lines and electric cables. Label anddisconnect 4 air lines and 2 air fittingsto provide access to the pedal.

8

T6006168

Remove brackets (A and B) for thesteering wheel adjustment pedal plate.

9

T6006174

Lift the steering wheel upwards andplace a long extension between thesteering column housing and theclutch pedal spring anchorage.

10Remove the two bolts that hold thepedal in place. Remove the pedal.

11Remove the cable from the locking de-vice forks. Pull the cable out of the cab.

42


12

T6006169

Loosen nuts (A) which hold the cableto the pedal plate. Remove the cablefrom the pedal.

13Remove the spring from the cable fortransfer to the new cable.

14

T6006173

Using a caliper, verify the distance be-tween the locking device forks is59 ± 1 mm (2.32 ± 0.04 in.). If neces-sary, adjust the distance by turningadjusting bolt (A).

Installation1Run the new cable through the steer-ing column bracket. Install the newcable in the locking device forks. In-stall the pedal plate brackets.

2Attach the cable to the pedal.

3Install the pedal. Ensure the spacer isin place and install the mounting bolt.Torque the bolt to 24 ± 4 Nm(18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

4Tighten the pedal adjusting nuts.

5

T6006167

Apply locking fluid to the gas springbolt (B). Install the bolt and torque it to17 ± 3 Nm (150 ± 25 in-lb). Install thegas spring (A).

6Check that the adjustment mechanismoperates properly.

7Install fittings removed and reconnectthe air lines.

8Install the plastic clamp on the airlines and electric cables.

9Install the side kick panel.

10Install the grab handle. Torque thebolts to 24 ± 4 Nm (18 ± 3 ft-lb).

43


11Install the steering wheel covers in thereverse order of removal and tightenthe torx screws.

12

W3000655

Install the push clips on the front andrear upper steering column covers.

6412-03-02-02Steering Shaft, Replacement


Removal1Ensure the vehicle front wheels arepointing straight ahead.

2

W3000655

Remove the push clips from the bot-tom of the front and rear uppersteering column covers.

44


3

T8006351

Remove the covers from around thesteering wheel in the order shown.

4Loosen the pinch bolt on the steeringshaft upper U-joint. Pry the U-joint offthe steering column.

5Remove the bolts from the shaft bootin the engine compartment.

6

W6000659

CAUTION

Possible equipment damage. Some steering gearshave a plastic ring on the input shaft that acts as bothan timing ring and a dirt cover. Use care not to dam-age the ring when prying the U-joint off the steeringgear. Failure to use care could damage the plasticring.

Remove the pinch bolt on the steeringshaft lower U-joint. Pry the U-joint offthe steering gear.

7Pull the shaft and boot out of the cabfrom the engine compartment side.

8Cut the tie strap off the end off theshaft boot. Slide the plastic shroud outof the boot.

9Cut the tie straps off the plasticshroud.

Installation1Replace the pinch bolts on each endof the steering shaft with a new origi-nal equipment bolt.

6782610971086

2Ensure the felt strip is at the lower endof the shroud. Holding the shroudhalves together on the new shaft, in-stall a tie strap at each end of theshroud.

3Install the shaft and boot in from theengine compartment side.

4Line up the color coded alignmentmark on the steering column shaftwithe the center mark on the casting.

5Install the steering wheel.

45


6Connect the shaft upper U-joint to thesteering column. Tighten the pinch boltto 60 ± 10 Nm (45 ± 7 ft-lb). The pinchbolt is perpendicular to the steeringcolumn shaft.

7Ensure the steering wheel is centered.

8Visually align the front end tires.

9

W6000657

Connect the shaft lower U-joint to thesteering gear input shaft. Tighten thepinch bolt to 60 ± 10 Nm (45 ± 7 ft-lb).

60 ± 10 Nm(45 ± 7 ft-lb)

10Detach the lower steering shaft fromthe the steering gear by loosening orremoving the bearing bolts.

11Perform a final alignment of the lowersteering shaft.

Note: Note and correct any tightnessin the steering mechanism.

12Reattach the lower shaft to the gearand remount the bearing to the sup-port.

13Install and tighten the bolts in thesteering shaft boot.

14Install the steering column covers inthe reverse order from removal andtighten the torx screws.

15

W3000655

Install the push clips on the front andrear upper steering column covers.

46


6412-03-02-08Upper Steering Shaft, Replace-ment

Removal1

Before working on a vehicle, set the parking brakes,place the transmission in neutral and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

Park the vehicle on a level surfacewith the transmission in neutral andthe front wheels chocked.

2Remove the three torx screws form thesteering shaft boot tie-down bracket.

3Remove the three torx screws in theupper steering column panel cover,and then remove the cover.

4Roll the floor cover toward the driverseat and remove the two plastic nutssecuring the left lower dash panels tothe floor pan.

5Remove the three torx screws secur-ing the left lower dash panels to theupper dash panel.

6Push the vent through the hole in thepanel to the left to allow enough roomto remove the lower steering columnpanel and remove the panel.

7Rotate steering wheel until spline boltis accessible, mark splines and re-move the spline bolt.

8Remove the shaft from the vehicle.

Installation1Using the assistance of another tech-nician to help align the shaft, installthe replacement upper steering shaft,start and tighten bolt.

2Install the complete lower left dashpanel assembly and lower steeringcolumn panel.

3Install the upper steering column coverpanel.

4Install the six torx screws in the steer-ing shaft boot.

6412-03-02-09Lower Steering Shaft, Replace-ment

Removal1



2Remove the two carrier bearing mountbolts.

3Remove the power steering gearboxshaft spline bolt, mark spline and theyoke assembly.

4Remove the lower shaft yoke assem-bly from the gearbox splines.

47


5Remove the lower shaft spline bolt atthe intermediate shaft yoke assembly,then remove the lower shaft from thevehicle.

Installation1Align the lower replacement shaft yokesplines with the gearbox splines andstart the spline bolt.

2Align the lower replacement shaftsplines with the intermediate shaftyoke assembly and start the splinebolt.

3Start and tighten the two carrier bear-ing mount bolts.

4Tighten the gearbox spline bolt.

5Tighten the lower shaft spline bolt.

6419-03-02-08Steering Shaft Carrier Bearing,Replacement

Removal1



2Remove the two carrier bearing mountbolts

3Remove the lower shaft spline bolt atthe intermediate shaft yoke assemblyand separate the lower shaft from theintermediate shaft.

4Remove the carrier bearing stop andremove the carrier bearing.

Installation1Install the replacement carrier bearingassembly and install the bearing stop.

2Align the lower and intermediate shaftsplines and start the spline bolt.

3Start and tighten the two carrier bear-ing bolts.

4Tighten the lower shaft spline bolt.

48


6412-03-02-10Intermediate Steering Shaft,Replacement

Removal

1




3Remove the six torx screws from theshaft boot tie-down bracket.

4Mark and remove the intermediateshaft.

5Uninstall the boot from the removedintermediate shaft and reinstall theboot on the replacement shaft.

6Align the splines at the upper steeringshaft and slide upward enough to alignthe splines with the lower shaft.

7Start and tighten the spline bolt.

8Install the six torx screws in the steer-ing shaft boot.

6419-03-02-07Steering Shaft Boot, Replace-mentRemoval1




3Remove the six torx screws from thesteering shaft boot tie-down bracket.

4Mark and remove the intermediateshaft.

5Remove the boot from the old interme-diate shaft.

Installation1Install the replacement steering shaftboot.

2Align the splines at the upper steeringshaft and slide upward to align thesplines to the lower shaft.

3Start and tighten the spline bolt.

4Install the six torx screws in the re-placement steering shaft boot.

49


6419-03-02-06Steering Shaft Carrier BearingBracket, Replacement

Removal1



2Unlatch and raise the hood.

3Remove the left side inner fender.

4Remove the two steering shaft, carrierbearing and mount bolts.

5Remove the four steering shaft, carrierbearing, and mount bracket bolts.

Installation1Install the replacement steering shaft,carrier bearing and mount bracket.

2Mount the steering shaft carrier bear-ing on the replacement mount bracket.

3Install the left side inner fender.

6453-03-02-01Power Steering Pump, Replace-mentRemoval


WARNING


CAUTION

Component damage may occur if the cleanliness ofthe hydraulic system is not maintained. The areaaround any component to be disconnected should becleaned prior to disconnecting. Used hydraulic fluidshould never be put into the hydraulic system. Failureto follow these precautions could result in damage tothe steering system hydraulic components.

1Disconnect the two fluid lines from thepump.

2Drain the power steering fluid.

Note: Dispose of used power steeringfluid according to State and Local reg-ulations.

3Remove the two mounting bolts andpull the pump off the engine.

4Clean the gasket surfaces on the en-gine and on the pump.

50


Installation1If necessary, transfer the fluid fittingsfrom the pump removed or install newfittings on the pump to be installed. En-sure the fittings are properly oriented.

2

Spline driven pump1) Engine flange 4) Pump flange2) Gasket 5) Washer3) Drive coupler 6) Mounting bolt

If pump shaft is splined, ensure thereis a circlip installed in the drive couplerand the drive coupler is placed in theengine.

3

Gear driven pump1) Mounting hole 4) Pump flange2) O-ring 5) Mounting bolt3) Drive gear

For spline driven pumps, place a gas-ket on the pump. For gear drivenpumps, install an O-ring on the pump.

4Install the pump on the engine. Torquebolts to 46 ± 1 Nm (34 ± 1 ft-lb).

46 ± 1 Nm(34 ± 1 ft-lb)

5Connect the two fluid lines to thepump. Using a tie strap the fluid linestogether to prevent them from rubbingon the frame.

6Fill the reservoir with power steeringfluid and bleed the system in accor-dance with the hydraulic systembleeding service procedure. Verifythere is no leakage in the system.

51


6453-04-04-01Power Steering Pump, Over-haul

WARNING


CAUTION

Possible component damage. Strict cleanliness mustbe observed when performing power steering pumpmaintenance. Dirt in the hydraulic system can dam-age the power steering pump or steering gear.

CAUTION

Possible component damage. All power steeringpump components must be lubricated with powersteering fluid during assembly. Failure to lubricatepump components could result in pump damagewhen it is operated.

Note: Refer to “Power Steering Pump Model NumberDesignations” page 15 for additional pump componentnomenclature.

1

W6000794

Remove the plug, spring, and controlvalve from the control valve port.

2

W6000791

Remove the four housing bolts. Sepa-rate the housing from the flange.

3

W6000792

Remove the cartridge from the hous-ing.

4Remove the large snap ring from theshaft bearing and remove the shaftfrom the flange.

5Remove the small snap ring from theshaft and remove the bearing from theshaft.

6Remove the shaft seal from the flange.

52


7Separate the parts of the cartridge.

8Thoroughly clean all parts of the pump.

9Assemble the cartridge.

10Grease a new shaft seal and install itin the housing.

11Install a new bearing on the shaft andsecure it with the small snap ring.

12Install the shaft into the flange and se-cure it with the large snap ring.

13Install new O-rings on the flange.

14

W6000793

Install new O-rings and back-up ringsin the housing.

15Fit the housing and flange together. In-stall and torque the bolts to 45 ± 5 Nm(33 ± 4 ft-lb).

45 ± 5 Nm(33 ± 4 ft-lb)

16

W6000794

Install the control valve and its spring.

17Install a new O-ring and install andtighten the plug.

53


Steering Gear Relief Valve, Ad-justment1Perform adjustment of steering gearinternal plungers (Sheppard), poppets(TRW), or steering lock limiter (ZF) inaccordance with the appropriate ven-dor manual.

6421-03-02-01Steering Gear, Replacement

Removal


CAUTION


1

W6000630

Turn the steering wheel to align thetiming mark on the input shaft or onthe dirt and water seal (1) with themark on the steering gear housing (2).

2Disconnect the pressure and returnhoses from the gear. Allow fluid todrain into a drip pan. Plug the ends ofthe hoses to avoid contamination.

Note: Dispose of used hydraulic fluidaccording to State and Local regula-tions.

54


3

W6000659

Using tool 9992337 remove the pinchbolt at lower end of steering shaft andpry the shaft from the steering gear.

Note: On TAS gears, take care not todamage the plastic alignment ring.

9992337

4Remove the cotter pin and nut fromthe drag link. Discard the cotter pin.

5

W6000663

Using tool 9996201, press the ballsocket from the pitman arm.

Note: On VHD Axle Forward vehicles,because the steering gear is locatedinside the frame rail, the cooling pack-age is removed before removing thesteering gear. For removal proceduresfor the Cooling Package, see serviceliterature in Function Group 26.

9996201

6Remove the steering gear mountingnuts. Lower the steering gear to thefloor.

7Place the gear in a vise or a holdingfixture.

8

CAUTION

Potential equipment damage. Do not hammer on thepitman arm or apply any heat to aid in removal. Ham-mering on or applying heat to the pitman arm couldcause damage to the pitman arm and sector shaft.

Note: Perform this step only for theSheppard steering gear.

Remove the pitman arm in accordancewith the Sheppard Power SteeringService Manual.

55


9Note: Perform this step only for theTAS steering gear.

Loosen then remove the pitman armpinch bolt. Spread the upper end ofthe pitman arm apart by driving awedge into the slot in the end.

10Note: Perform this step only for the ZFsteering gear.

Loosen and remove the pitman armnut.

11

T6006280

Note: Perform this step only for theTAS or ZF steering gear.

Remove the pitman using puller9992681, a hydraulic cylinder, and drift9992497 or other suitable drift.

99924979992619999267199926729992681

12Remove the fluid hose fittings from thesteering gear.

Installation1Install the fluid fittings using newsealant washers.

2Set steering gear timing by turning in-put shaft to align timing marks on thesector shaft to timing mark on thesteering gear housing.

3Install pitman arm so that timingmarks on pitman arm and sector shaftare aligned.

4Note: Perform this step only for theSheppard steering gear.

Install the pitman in accordance withthe Sheppard Power Steering ServiceManual.

5Note: Perform this step only for theTAS steering gear.

Torque the pitman arm pinch bolt to400 ± 60 Nm (295 ± 45 ft-lb).

400 ± 60 Nm(295 ± 45 ft-lb)

6Note: Perform this step only for the ZFsteering gear.

Torque the pitman arm lock nut to 600± 50 Nm (445 ± 37 ft-lb). Stake thelocking edge of the lock nut.

600 ± 50 Nm(445 ± 37 ft-lb)

7Install the gear on the vehicle usingthe spacers and mounting bolts.Torque mounting bolts to 540 ± 90 Nm(400 ± 67 ft-lb).

540 ± 90 Nm(400 ± 67 ft-lb)

8Install the drag link ball joint in the pit-man arm. Torque the nut to 200 ± 30Nm (150 ± 22 ft-lb).

200 ± 30 Nm(150 ± 22 ft-lb)

9Tighten the nut until the slots in thecastellated nut line up with the cotterpin hole. Do NOT loosen the nut toalign. Install and bend a new cotterpin.

10Replace the lower steering shaft U-joint pinch bolt with a new originalequipment bolt.

6782610971086

11Ensure the timing marks on the steer-ing gear are aligned, then install thesteering shaft U-joint on the steeringgear. Ensure the U-joint cup faces up.Tighten the pinch bolt to 60 ± 10 Nm(45 ± 7 ft-lb)

60 ± 10 Nm(45 ± 7 ft-lb)

56


12Install high pressure hose and tightenthe fitting.

13Install the return hose using a newclamp. Crimp the clamp.

14

W6000669

Fill the reservoir with power steeringfluid and bleed the system in accor-dance with the hydraulic systembleeding service procedure. Verifythere is no leakage in the system.

15Set the steering gear plungers/poppetsusing the appropriate vendor manual.

16Perform road test of the vehicle steer-ing system. Refill fluid reservoir ifnecessary.

Note: For instructions on performingthe TRW Ball Socket Wear Inspectionprocedure refer to TRW Service Bul-letin #LNK-105.

6456-03-03-02Power Steering Fluid Filter, Re-placement


CAUTION

Component damage may occur if the cleanliness ofthe hydraulic system is not maintained. The areaaround the reservoir cap should be cleaned prior toremoval. Used hydraulic fluid should never be put intothe hydraulic system. Failure to follow these precau-tions could result in damage to the steering systemhydraulic components.

1Unscrew and remove the reservoircover.

2Press down and turn the filter lockingdevice to unlock it.

3Lift out the existing filter while placing afinger under the lower hole to preventdirt from falling back into the reservoir.

4Transfer the locking device and springto the new filter and place it in thereservoir.

5Secure the filter by pressing down thelocking device and turning until the itsnaps in place.

6Refill the reservoir if necessary. Installthe reservoir cover.

7Dispose of filter properly.

57


1750-03-02-11Power Steering Hydraulic Fluid,Changing


CAUTION


1Jack up the front of the vehicle andplace it on jack stands.

2Place a drain pan under the steeringgear.

3Turn the steering wheel to the full leftposition. Remove the plug from thebottom of the steering gear.

4Start the engine and let it idle for amaximum of 10 seconds, then shut itoff.

5Turn the steering wheel from full left tofull right until all fluid has run out ofthe gear.

6Install the plug in the steering gear.

7

W6000669

Fill the reservoir with Dexron II® orDexron III® fluid.

8Bleed the system in accordance withthe appropriate service procedure.See “Power Steering Hydraulic Sys-tem, Bleeding” page 59.

58


6459-05-03-02Power Steering Hydraulic Sys-tem, BleedingNote: Ensure steering gear poppets are set prior to per-forming this procedure.

1


Exhaust gases contain carbon monoxide. When test-ing a vehicle with the engine running, conduct the testoutdoors or use a properly vented exhaust hose. Pro-longed or excessive exposure may cause seriousillness or death.

CAUTION

Potential equipment damage. Do NOT turn the steer-ing wheel until required by the procedure. Turning thesteering wheel before the system has been sufficientlybled could result in damage to the steering gear.

Fill the fluid reservoir nearly full. DoNOT steer.

2Start and run the engine for 10 sec-onds, then shut it off. Check thereservoir and refill if necessary. Re-peat this step at least three times.

3

CAUTION

Equipment damage. Do NOT allow the fluid level todrop significantly or run out of the reservoir. This mayintroduce air into the system which could result indamage to the steering gear.

Start the engine and let it idle for twominutes, then shut it off. Check thereservoir and refill if necessary. DoNOT steer.

4Start the engine. Steer the vehiclefrom full left to full right several times.Add fluid as necessary to maintain itat the full line on the dipstick.

59


6459-06-02-02Power Steering System, Check-ing

W6000625

Preparation


WARNING

A faulty steering pump high pressure relief valve maynot relieve pump pressure. Closing the high pressureshut off valve may cause severe pump damage orhigh pressure hoses to rupture. Watch the pressureclosely when closing the shut off valve. If pressurerises rapidly or exceeds 17.2 MPa (2500 psi), immedi-ately open the valve. Failure to follow theseprecautions could result in severe equipment damageor personal injury.

WARNING

Never check for leaks with your hands. Oil releasedunder high pressure can penetrate the skin causingsevere injury.

1Install a steering system analyzer inthe high pressure fluid line betweenthe pump and the steering gear. Theanalyzer should include a pressuregauge, flow meter, and a shut off valve.

2Place a thermometer in the fluid reser-voir.

3Start the engine and warm the hy-draulic system by partially closing theshut off valve until the pressure gaugereads 6.9 MPa. When fluid tempera-ture reaches 50 – 55�C (125 – 135�F)open the shut off valve.

Pump Pressure Test1

CAUTION

Potential pump damage. Do NOT leave the shut offvalve fully closed for more than 5 seconds. Leavingthe shut off valve fully closed too long could result inexcessive fluid temperatures and pump damage.

Close the shut off valve and read thepressure gauge. Immediately openthe shut off valve.

2If pump pressure was below the mini-mum value listed in the Specificationssection, repair or replace the pump.

3Allow the fluid to cool to 50 – 55�C(125 – 135�F) before performing othertests or shutting off the engine.

Pump Flow Test1

CAUTION

Potential steering gear damage. The maximum flowrate for the TAS series steering gear is 27 L/min (7gpm). Excessive flow can cause damage to the steer-ing gear.

Ensure the engine is idling and fluidtemperature is between 50 – 55�C(125 – 135�F).

2Note the fluid flow rate.

60


3

CAUTION

Possible equipment damage. The substeps within thisstep must be performed in rapid succession. Leavingthe shut off valve closed for too long could result inexcessive fluid temperatures and pump damage.

Fully close the shut off valve. Whenpump relief pressure is reached, verifythe flow rate is zero. Immediately openthe shut off valve. Verify the flow raterapidly returns to the value noted inabove.

4Allow the fluid to return to 50 – 55�C(125 – 135�F).

5Set engine speed at governed rpm,then note the fluid flow rate.

6

CAUTION

Possible equipment damage. The substeps within thisstep must be performed in rapid succession. Leavingthe shut off valve closed for too long could result inexcessive fluid temperatures and pump damage.

Fully close the shut off valve. Whenpump relief pressure is reached, verifythe flow rate is zero. Immediately openthe shut off valve. Verify the flow raterapidly returns to the value noted inabove.

7Allow the fluid to return to 50� to 55�C(125� to 135�F).

8Repeat steps 6 and 7 two additionaltimes.

9If flow rate did not immediately returnto the noted flow rate, the pump ismalfunctioning and should be repairedor replaced.

Steering Gear Internal LeakageTest


1Place a socket over the left wheel stopbolt.

2Ensure fluid temperature is between50 – 55�C (125 – 135�F).

3

CAUTION

Potential pump damage. Do not hold the steeringwheel at full lock longer than 10 seconds. Pump dam-age could result.

Turn the steering wheel to the right un-til the left spindle contacts the socketon the left stop bolt. Verify the pumppressure equals the relief pressurevalue from the pump pressure test. .Read the steering gear leakage flowon the flow meter.

4Return the wheel to neutral.

5Move the socket to the right wheelstop bolt.

6Ensure fluid temperature is between50 – 55�C (125 – 135�F).

61


7

CAUTION

Potential pump damage. Do not hold the steeringwheel at full lock longer than 10 seconds. Pump dam-age could result.

Turn the steering wheel to the left untilthe right spindle contacts the socketon the right stop bolt. Verify the pumppressure equals the relief pressurevalue from the pump pressure test.Read the steering gear leakage flowon the flow meter.

8Return the wheel to neutral.

9If internal leakage is greater than 1.0gpm (3.8 L/min), overhaul or replacethe steering gear.

10Following repair or replacement ofsteering gear, repeat the leakage test.

6412-05-02-01Tilt Steering Column Cable,Adjustment


It is important that any adjustments to the tilt steeringcolumn be made only on the cable at the foot pedal.

DO NOT attempt to adjust the tilt steering column bytightening or loosening the screw joint. Adjustmentsmust be made ONLY from the cable at the foot pedal.Adjustments attempted at any other location mayaffect the safety features of the steering column, re-sulting in an accident and/or personal injury or death.

1

T6006169

Adjust the tilt steering column ONLY byincreasing or decreasing the tensionon the cable. This is done by adjustingthe position of the fasteners (A) thatconnect the cable to the foot pedal.

2

W6001307

Using a caliper, verify the distancebetween the adjustment forks. The ad-justment forks should be preset at thefactory to a distance (inside measure-ment) of 38 ± 1 mm (1.5 ± 0.04 in)

Note: Do not attempt to modify thismeasurement by adjusting the screwjoint.

62


6429-03-04-02Input Shaft Seal, Replacement

(Steering Gear Removed)


WARNING


This repair information covers the ZF Steering gear.

1Clean the steering gear.

2

T6006308

Attach fixture 9996516 to overhaulstand 9992520.Secure the steering gear to the fixture.

99925209996516

3

T6006277

Remove the input shaft dust cover andrubber seal.

4Remove the cover on the steeringgear housing.

5

T6006312

Move the pitman arm rearward whileremoving the piston at the same time.

63


6

T6006315

Remove the input shaft roller bearing,washer and sealing ring from thehousing.

7

T6006294

Install a new O-ring and teflon ring onthe piston.

8

T6006313

Install the input shaft sealing ring ondrift 9998322.The sealing lip on the sealing ringshould face away from the drift. Installthe sealing ring in the housing.

99926139998322

9

T6006314

Lubricate the input shaft washer andbearing with ATF and install them inthe housing.

64


10

T6006299

Wrap thin tape around the input shaftsplines so as not to damage the sealwhen installing the piston in the hous-ing.

11

T6006310

Insert the piston in the housing. Movethe pitman arm forward when the firsttooth on the piston is engaged withthe first tooth on the sector shaft.

12

T6006309

Screw down the input shaft (A). Installthe cover using a new O-ring. The ad-justing screw for the off-loading valvein the cover should be aligned with thevalve on the piston.If the cover does not lay flat againstthe housing, the piston may not be suf-ficiently far down in the housing due tothe teeth on the sector shaft and pis-ton not being correctly synchronized.

13Tighten the cover bolts to 190 Nm(140 ft–lb).

190 Nm(140 ft-lb)

14

T6006291

Remove the tape from the input shaftand install the rubber seal and dustcover on the input shaft.

Note: When installing the dust cover,the arrow on the cover should be inline with the marks on the pin andhousing.

15Remove the steering gear from the fix-ture.

65


6425-03-04-01Sector Shaft Seal, Replacement

(Steering Gear Removed)

WARNING


This repair information covers the ZF Steering gear.

1Clean the steering gear.

2

T6006308

Attach fixture 9996516 to overhaulstand 9992520.Secure the steering gear to the fixture.

99925209996516

3

T6006277

Remove the input shaft dust cover andrubber seal.

4Remove the cover on the steeringgear housing.

5

T6006312

Move the pitman arm rearward whileremoving the piston.

6

T6006315

Remove the input shaft roller bearing,washer and sealing ring from thehousing.

66


7

T6006307

Tap loose the nut locking arrangementon the pitman arm.Remove the nut.

Note: Check that the position of thepitman arm on the sector shaft ismarked. If not, mark the position.

8

T6006311

Remove the pitman arm with puller9992681.

999249799926199992671999267299926819996222

9

T6006281

Remove the sector shaft dust cover.Remove the bearing snap ring.

10

T6006282

Pull out the bearing using puller9998329.Remove the plastic washer on thesector shaft.

9998329

11Turn the steering gear around and re-move the dust cover on the other sideof the sector shaft.Remove the snap ring, pull out thebearing and remove the plasticwasher.

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12

T6006283

Remove the sector shaft.

13

T6006306

Remove the O-rings for the sectorshaft bearings from the housing.

14

T6006284

Remove the steering gear from the fix-ture and remove the pressure limitingvalve.

15Clean all components.Remove the sealing ring and plasticwasher in the sector shaft bearingsand clean the bearings.

16

T6006305

Install a new O-ring on the pressurelimiting valve. Install the valve in thehousing.

17

T6006294

Install a new O-ring and teflon ring onthe piston.

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18

T6006308

Install new O-rings for the sector shaftbearings in the housing.Lubricate the O-rings with ATF tomake it easier to press in the bearings.

19

T6006295

Carefully tap in the locking tab on thebearings.Grind/file the outside of the bearingsat the tab to round-off the surface.Clean the bearings.

20

T6006285

Install the plastic washer and sealingring in the bearings.

Note: The flat side of the plasticwasher should face the bearing rollers.

21

T6006283

Install the sector shaft in the housing.

Note: Make sure the sector shaft isturned the correct way.

69


22

T6006303

Install the plastic washers on the sec-tor shaft with the flat side facingoutward.

23

T6006286

Set the sector shaft bearings in posi-tion.When installing the bearings, makesure that the locking tabs are not posi-tioned in the same place in thehousing as previously.Place the bearings so that the smallholes in the bearing inner races comeopposite each other and as near therecess in the housing as possible. Tapin the bearings until they enter thehousing.

24Place the steering gear in a press withthe splined end of the sector shaft fac-ing upward.

25

T6006296

Using drift 9996090, press down thebearing far enough to be able to installthe snap ring.

9996090

26

T6006297

Install the snap ring.The ends of the snap ring should bepositioned as near the recess in thehousing as possible.

27Press in the other bearing in the samemanner and install the snap ring.

70


28

T6006308

Secure the steering gear to fixture9996516.

29

T6006298

Install setting tool 8307 with sleeves9998331 and 9998332 on the sectorshaft.The pins in the sleeves should fit intothe holes in the bearings. Lock thesleeves to the tool with the lockingscrews.

999830799983319998332

30The bearings for the shaft are eccen-tric.Adjust the sector shaft outward, i.e.from the piston center position in thesteering gear housing by altering theposition of the bearings in the housing.Remove the tool.

31

T6006287

Install the input shaft sealing ring ondrift 8322.The sealing ring should be positionedwith the sealing lip facing away fromthe drift.Install the sealing ring in the housing.

99926139998322

32

T6006314

Lubricate the input shaft washer andbearing with ATF and install them inthe housing.

71


33Install the pitman arm on the sectorshaft according to the marking.

34

T6006299

Wrap thin tape around the input shaftsplines so as not to damage the sealwhen installing the piston in the hous-ing.

35

T6006310

Insert the piston in the housing. Movethe pitman arm forward when the firsttooth on the piston is engaged withthe first tooth on the sector shaft.

36

T6006309

Screw down the input shaft A.Install the cover using a new O-ring.The adjusting screw for the off-loadingvalve in the cover should be alignedwith the valve on the piston.If the cover does not lay flat againstthe housing, the piston may not be suf-ficiently far down in the housing due tothe teeth on the sector shaft and pis-ton not being correctly synchronized.

37Tighten the cover bolts to 190 Nm(140 ft-lb).

190 Nm(140 ft-lb)

38Remove the pitman arm.

39

T6006298

Position the setting tool. 999830799983319998332

72


40

T6006289

Remove the tape from the input shaftand install sleeve 9996459.

9996459

41

T6006300

Set torque-wrench 8081 on the sleeve.Set the torque wrench pointer to zero.Turn the input shaft from end to endposition and count the number ofturns. Turn back half of the number ofthose turns, in other words, to the cen-ter position.

9998081

42Turn the input shaft one turn to the leftand then back again. Read off the in-crease in torque when the screwpasses the center position (pressurepoint).Torque increase should be approx. 0.4- 0.8 Nm (3.6 - 7.2 in-lb).

0.4 - 0.8 Nm(3.6 - 7.2 in-lb).

43Turn the input shaft one turn to theright and then back again. Repeat themeasuring procedure.

44Both measurements should give atorque increase in the center positionof approx. 0.4 - 0.8 Nm (3.6 - 7.2 in-lb).If the torque deviates from the above,the position of the sector shaft mustbe readjusted with the setting tool.

0.4 - 0.8 Nm(3.6 - 7.2 in-lb).

45

T6006291

Remove the setting tool and sleevefrom the input shaft.Install the rubber seal and dust coveron the input shaft.

Note: When installing the dust cover,the arrow on the cover should be inline with the marks on the pin andhousing.

73


46

T6006301

Install pressing tool 8306 in position.Position the tool with the rubber pin (2)opposite the recess in the housing.Screw in the screw (1) and check thatthe position of the rubber pin (2) is notaltered.Screw in the stop screw (3) to fix thetool in position.

9998306

47

T6006316

Lock the bearing by screwing in thescrew on the tool until the bearingouter ring is deformed.

48

T6006312

Remove the tool and check that thebearing race is locked in the groove,see illustration.

49Install the tool and repeat the lockingprocedure on the other bearing outerring.

50Install the bearing dust covers.

74


51

T6006307

Install the pitman arm as per the tim-ing marks.Torque tighten the nut and lock it bystaking the locking edge of the nut.

550 ± 50 Nm(405 ± 35 ft-lb)

52Remove the steering gear from the fix-ture.

75

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

Operation Numbers

1750-03-02-11 Power Steering Hydraulic Fluid, Changing . . . . . . . . . . . . . . . . . . . . 586411-03-02-01 Steering Wheel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 31, 326412-03-02-02 Steering Shaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 446412-03-02-03 Steering Column Adjustment Cable, Replacement . . . . . . . . . . . . . . . . 416412-03-02-04 Steering Column, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 366412-03-02-08 Upper Steering Shaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . 476412-03-02-09 Lower Steering Shaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . 476412-03-02-10 Intermediate Steering Shaft, Replacement . . . . . . . . . . . . . . . . . . . . 496412-04-04-01 Steering Column, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 396412-05-02-01 Tilt Steering Column Cable, Adjustment . . . . . . . . . . . . . . . . . . . . . 626419-03-02-06 Steering Shaft Carrier Bearing Bracket, Replacement . . . . . . . . . . . . . . . 506419-03-02-07 Steering Shaft Boot, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 496419-03-02-08 Steering Shaft Carrier Bearing, Replacement . . . . . . . . . . . . . . . . . . . 486421-03-02-01 Steering Gear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 546425-03-04-01 Sector Shaft Seal, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 666429-03-04-02 Input Shaft Seal, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 636453-03-02-01 Power Steering Pump, Replacement . . . . . . . . . . . . . . . . . . . . . . . 506453-04-04-01 Power Steering Pump, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 526456-03-03-02 Power Steering Fluid Filter, Replacement . . . . . . . . . . . . . . . . . . . . . 576459-05-03-02 Power Steering Hydraulic System, Bleeding . . . . . . . . . . . . . . . . . . . 596459-06-02-02 Power Steering System, Checking . . . . . . . . . . . . . . . . . . . . . . . . 60

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP153872 (1000) 03.2001 © Volvo Trucks North America, Inc., 2001

Service Manual Trucks · Service Manual Trucks Group 640–500 Steering System VN/VHD...

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