CHAPTER 30 • STEERING-SYSTEM SERVICE 341

g linkage
• Servicing steerin
S te e r in g -c o lu m n service
•
o w e r- s te e r in g m a in tenance
• P
-a n d -p in io n s te e r in g service
• Rack
-p in io n p o w e r- s te e ring service
• Rack-and
s in g p o w e r- s te e r in g problems
• Analy
g a r e c ir c u la ti n g -b all steering box
• Servicin
-t y p e s te e r in g b o x adjustments
• Wor m
ti n g -b a ll b o x w it h p ower steering
• Recircula
• Steering faults
• Technical terms
s
• Review question

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 342 PART 4 • RUNNING GEAR

Steering systems on passenger cars generally require Hint: Free play must be checked in the straight-
no periodic lubrication, although worm-type steering ahead position. If checked in any other position, normal
boxes require a check of the lubricant. Most ball clearance between the gears will allow more steering
joints are lubricated and sealed during manufacture wheel movement.
and normally do not have to be lubricated in service.
Some light commercial vehicles with ball joint
suspension have grease nipples on the tie-rod ball
joints; others have plugs that can be removed so that Checking ball joints
grease nipples can be fitted and the ball joints lubri- The ball joints can be checked for looseness by
cated with a grease gun. rocking the steering wheel with quick movements so
Vehicles with power steering require a check of that it moves further than the normal free play.
the oil level at normal service periods. This check requires one person to rock the
steering wheel while another person checks each
ball joint in turn for unwanted movement. The idler
arm should also be checked for wear and looseness
Servicing steering (Figure 30.2).
linkage
The linkage on all steering systems can be checked
for looseness, wear, loss of oil from the steering
box or power steering, and for general condition.
Where tyre wear is excessive or irregular, or steering
difficulties are encountered, then a wheel and
steering alignment check and adjustment should be
carried out. These are discussed in Chapter 31.

Checking steering for looseness

With the wheels of the vehicle on the ground, and
the steering wheel in the straight-ahead position,
rock the steering wheel lightly to the left and right
to check the free play. The rim of the steering wheel
should have a maximum free movement of 30 mm Figure 30.2 Steering-wheel free play and linkage checks –
check points are indicated by arrows
(Figure 30.1).
If there is excessive free play, it could be in the
steering box or in the linkage. Steering-box free play Rack-and-pinion linkage
can normally be corrected by adjustment, unless the As well as the ball joints on the outer ends of the tie
internal parts are excessively worn or damaged. rods, rack-and-pinion steering boxes have a ball joint
at each end of the rack, referred to as the rack balls,
or inner ball joints (Figure 30.3). These connect the
tie rods to the rack and are covered by the bellows.

Figure 30.3 Rack-and-pinion ball joints – inspection for

Figure 30.1 Checking steering-wheel free play FORD looseness and wear

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 343

The outer ball joints can be checked visually by the steering arm. A forcing screw is tightened with a
rocking the steering wheel as indicated above. How- spanner to spread the tool and apply force to the end
ever, if looseness of the inner ball joints is suspected, of the ball stud. Tapping the steering arm can assist
the bellows will have to be removed from the end with removal.
of the housing. This will allow the ball joint to be Sealed ball joints cannot be dismantled, but
properly checked. damaged boots can be renewed once the ball joint
The bellows should also be checked at the same has been removed. Figure 30.5 shows a ball joint of
time as the ball joints. Torn or damaged bellows will this type. After cleaning, grease can be applied to the
allow the steering box lubricant to escape and dirt to exposed part of the joint and to the interior of the
enter. new boot before it is fitted. An application of sealer
could be required on the edge of the boot, or it might
Removing ball joints have a spring retaining clip.
A ball joint has a tapered stud that fits into a tapered
hole in the steering arm or in some other part of the Worm-type steering linkage
steering linkage. Special tools are used for removal. Figure 30.6 shows the dismantled parts of a steering
One type of tool is shown in Figure 30.4. This has linkage for a recirculating-ball steering box. To achieve
a forked end which fits between the ball joint and this, ball joints have to be removed so that the parts
can be separated as shown.

Figure 30.4 Tool for removing steering-linkage ball joints

MITSUBISHI Figure 30.5 Steering-linkage ball joint MITSUBISHI

sub-frame
steering box

pitman arm idler arm sub-frame

idler arm mounting

track rod

clamps

R. H. tie rod front of vehicle

L. H. tie rod steering arm

adjusting sleeve

Figure 30.6 Parts of a steering linkage for a recirculating-ball steering box FORD

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 344 PART 4 • RUNNING GEAR

The steering box is bolted to the subframe on the Removal of idler arms
right side, and the idler arm is bolted to the subframe The idler arm mounting is bolted to the subframe.
on the left side. Movement of the pitman arm is It can be removed after disconnecting the track rod.
transferred through the track rod and tie rods to the The idler arm in this system is mounted on rubber
steering arms. bushes. The idler arm can be separated from its
The sleeves join the parts of the tie rods with a mounting by removing a retaining nut. This enables
left-hand thread at one end and a right-hand thread at worn bushes to be replaced.
the other. This enables the tie rods to be adjusted for
length. Turning the sleeve one way lengthens the rod
and turning it the other way shortens the tie rod.
Steering-column service
A steering-column assembly is shown in Figure 30.8.
Information: Both tie rods must be adjusted to the The illustration should be used to identify the follow-
same length. ing parts:
1 The steering wheel.
2 The horn pad on the steering wheel.
3 The combination switch for the headlamps,
Removal of pitman arms windscreen wiper and turn signals.
The pitman arm on a worm-type steering box is fitted 4 The ignition switch and steering lock.
to the sector shaft on tapered splines and retained by 5 The arrangement for tilting the steering wheel.
a large nut. It usually requires a puller for removal. 6 The steering column.
The end of the sector shaft, and the pitman arm, 7 The intermediate shaft and universal joints.
are often marked to identify their relative positions
(Figure 30.7). A check for marks should be made The assembly is mounted to the body with two
before the pitman arm is removed. If no marks are mountings. Plastic covers have to be removed to
evident, the parts should be marked, although some gain access to the upper mounting, the switches and
pitman arms have master splines which allows them other parts. (Also see Figure 30.11.)
to be fitted only in one position.
Steering-wheel removal
In most systems, the steering wheel is fitted to the
mainshaft on tapered splines and requires a puller
for removal (Figure 30.9).
Threaded holes are often provided in the hub of
the wheel so that puller bolts can be attached. Where
there are no threaded holes, a puller with legs that fit
under the steering wheel is used.
The shaft should not be struck with a hammer
when attempting to remove a steering wheel as this
can damage bearings. It can also cause damage by
bending or shortening a collapsible steering shaft and
column. Generally, any force on the steering column
should be avoided.

Information: While many steering wheels and

Figure 30.7 Alignment marks on the pitman arm and the
end of the sector shaft MITSUBISHI shafts have tapered splines that require some form
of puller for removal, there are steering wheels with
parallel splines which are easier to remove.

Information: The pitman arm must be reinstalled

in its original position, otherwise the spokes of the
steering wheel will be misaligned and the steering box Steering-wheel position
will be off-centre. Before removing the steering wheel, it should be
checked for marks so that it can be replaced in its

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 345

Figure 30.8 Parts of a steering-column assembly and associated components HYUNDAI

The steering wheel should be centred when the

vehicle is being driven straight ahead. The position
of the spokes will show whether it is in the correct
position. If the position is not correct, it will be due
to incorrectly adjusted tie rods (uneven length) or
to the steering wheel having been badly installed. It
could also be caused by a bent steering arm, or an
incorrectly fitted pitman arm.
If no marks are available, the steering box should
be centred, the steering wheel fitted temporarily, and
the number of turns from centre to lock on each side
checked. The steering wheel can be repositioned, if
necessary, before being secured.

Figure 30.9 Puller fitted to the steering wheel MITUBISHI Steering wheel with air bag
Where an air bag is fitted, the air bag has to be
removed and the clockspring electrical connections
original position. If no marks are apparent, then disconnected before the steering wheel nut is access-
the wheel and shaft should be carefully marked. ible (Figure 30.10).
This is necessary so that the steering wheel, when A steering wheel with an air bag requires special
reinstalled, will have its spokes correctly positioned. safety precautions to prevent the air bag from being

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 346 PART 4 • RUNNING GEAR

Figure 30.10 Steering wheel with air bag removed FORD

accidentally deployed. Should this occur, the air bag 1 Checking the oil level in the reservoir.
will be suddenly inflated. This will be accompanied 2 Checking the drive belt for condition and
by a loud bang and some white powder. Injury is correct adjustment.
possible if this occurs when the air bag has been 3 Checking the system for leaks.
removed from the steering wheel. 4 Bleeding the system.
5 Changing the oil in the system.

Safety: An understanding of air bags is essential Checking the oil level, the drive belt and leaks are
before working on the parts of a vehicle that have air routine maintenance items. Bleeding and changing
bag equipment. (Air bags are covered in Chapter 35: the oil are only done if this becomes necessary.
Supplemental restraint systems (SRS) and occupant
safety in Volume 2.) Checking the oil level
The oil level is checked by means of a dipstick
attached to the reservoir filler cap. If the level is low,
the reservoir should be topped up with automatic-
Steering column transmission fluid and the various parts of the system
A steering-column assembly with provision for checked to determine where the oil has been lost.
a driver’s air bag is shown in Figure 30.11. This has a
clockspring assembly at the top of the steering column Bleeding the system
which provides a flexible electrical connection. If the oil has been drained from the system, or the
As its name suggests, this device is like a large oil in the reservoir has been lost due to leaks, air
coiled clockspring with connections for the air bag. will enter the system. After filling the reservoir to
Being a spring allows the steering wheel to be turned the correct level, the system must then be bled to
while still connected electrically to the wiring in the remove trapped air.
steering column. A general procedure for bleeding a power steering
Other features of this steering column that can be system is as follows:
identified are: its mounting to the dash; its electrical 1 Top up the reservoir to the correct level.
switches, its telescopic column and its coupling to 2 Raise the front wheels of the vehicle.
the rotary valve of a rack-and-pinion power-steering 3 Turn the steering from lock to lock several times.
assembly. 4 Check the oil level and top up.
5 Start the engine and again turn the steering
from lock to lock several times.
6 Stop the engine, and check and top up the oil
Power-steering to the correct level. The oil level will drop as air
maintenance 7
is removed.
Repeat steps 5 and 6 until the oil level no longer
Maintenance of power-steering systems includes the drops. This indicates that all the air has been
following items: removed from the system.

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 347

upper cover

steering column
bracket

clockspring turn signal

switch

ignition
wiper switch
switch

tilt
lever

lower
cover
dash panel

universal
joint
telescopic
column

intermediate
shaft

coupling

input
shaft
control valve
assembly

Figure 30.11 Steering-column assembly for a steering wheel with an air bag HOLDEN LTD

Constant checks of the oil level should be made to 1 Clean away any oil from the area of the
ensure that the oil level does not drop to the extent suspected leak. This could be at the pump, the
that air is drawn into the system. pipe connections or the steering box.
2 Start the engine and move the steering from
lock to lock several times.
Information: During the bleeding operations, the 3 Stop the engine and check the various parts
steering should not be held on full lock for more than of the system for oil that has leaked out. Leaks
a few seconds at a time. may be easier to locate when the oil is hot.

Leaks at external connections can be corrected

with the steering box in the vehicle, but for more
Checking for oil leaks serious problems, the steering box will have to be
When checking for leaks, proceed as follows: removed and dismantled.

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 348 PART 4 • RUNNING GEAR

Changing the power-steering oil

It is not usual to change the oil in the power-steering
system, but this could be necessary if the oil becomes
contaminated in some way. The system can be drained
by disconnecting the return hose and proceeding as
shown in Figure 30.12.
The oil is changed and the system flushed by
running the engine and directing the oil from the
return hose into a container instead of returning it
to the reservoir. The steering is moved from lock to
lock so that oil circulates on both sides of the power
cylinder.

Hint: Flushing is recommended whenever

components are replaced.

Before starting the engine, the return pipe at the

reservoir must be plugged so that the reservoir can be
filled with clean oil. This must be kept at a reasonable
level so that air is not drawn into the system.
The operation is continued until only clean oil is
being discharged from the return hose.

Rack-and-pinion steering
service
Figure 30.13 shows some service operations on the
external parts of a rack-and-pinion steering box.
These apply to both manual and power steering
boxes. They can be carried out with the steering box
in the vehicle, or as part of steering box dismantling:

1 Keeping tie rods the same length. If a ball joint is

to be removed, the parts should be marked so
that the ball joint can be replaced in its original
position (Figure 30.13(a)).
Both tie rods must be the same length so that
the pinion is meshed with the centre of the rack
when it is in the straight-ahead steering position.
2 Removing ball joints. The ball joint should be
held while the locknut is loosened so that load
is not applied to the rack (Figure 30.13(b)).
After loosening, leave the locknut in its
original position and count the number of turns
required to unscrew the ball joint from the tie
rod. This enables either the ball joint that has
been removed or a replacement ball joint to be
installed in the original position.
Figure 30.12 Changing the power-steering oil and
3 Servicing ball joints. The dust cover can be bleeding the system TOYOTA
removed from many ball joints by carefully

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 349

tie rod

machined
groove lock nut

(a) Measured length of tie rod (b) Removing ball joint from tie rod

tie rod
dust cover

grease
spring clip

(c) Removing dust cover from ball joint (d) Lubrication of ball joint

bellows

housi
tie rod

ball joint
(e) Removing clip from bellows (f) Fitting bellows to tie rod and housing

Figure 30.13 Servicing the external parts of a rack-and-pinion steering box HYUNDAI

prising it free with a screwdriver (Figure 6 Fitting the bellows. When being replaced, the
30.13(c)). A spring retainer clip is used in some bellows should be correctly aligned so that the
cases to hold the dust cover in place. folds are straight (Figure 30.13(f)). One end of
4 Lubricating ball joints. With the dust cover the bellows fits into a groove machined in the
removed, old grease can be removed and new tie rod, and the other end fits over the end of
grease applied in the recess and inside the dust the housing.
cover (Figure 30.13(d)).
5 Removing or replacing a bellows. The bellows Reference: The steering angles will need to be
are retained by clips at each end (Figure checked if the tie rod length has been altered by
30.13(e)). The tab end of the clips shown can changing the position of its outer ball joint.
be raised with a screwdriver to loosen the clip.
Other types of clips and clamps are also used.

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 350 PART 4 • RUNNING GEAR

Rack-and-pinion dismantling
Dismantled rack-and-pinion steering boxes can be Hint: For power steering, automatic transmission fluid
seen in Figures 30.14 and 30.15. These are typical is used to coat all seals and related parts.
manual boxes. Power steering boxes have similar
mechanical components and similar dismantling
procedures. Power steering components are covered Pinion adjustment
later. In some steering boxes, the pinion shaft bearings are
An outline of the dismantling procedure for a fitted with a light preload, and a screw adjustment is
rack-and-pinion steering is as follows: provided for this purpose.
The preload can be checked by means of a pull
1 Support the steering box in a vice with suitable scale and a lever attached to the pinion shaft. Only a
soft jaws, or in a holding fixture. light preload is used.
2 Mark the position of the ball joints on the tie
rods. Unscrew the ball joints from the tie rods Rack-support yoke adjustment
and remove the locknuts. The rack-support yoke is used to support the rack
3 Remove both bellows after loosening the and hold its teeth in mesh with the pinion. The yoke
clips that secure them to the tie rods and the has a screw adjustment which enables it to be set
housing. with minimum clearance against the back of the rack.
4 Remove the tie rods from the rack by The adjusting screw is tightened to a light torque
disconnecting the inner ball joints. The rack and then backed off a few degrees to provide a small
must be supported when the ball joints are clearance. The compressed spring provides a thrust
being unscrewed. against the yoke.
5 Loosen the locknut on the yoke plug, unscrew
the plug from the housing and remove the
yoke.
6 Pry the pinion shaft oil seal from the top of the Rack-and-pinion
7
pinion housing.
Remove the snap ring from the pinion housing
power-steering service
and withdraw the pinion and bearings. Figure 30.16 shows a dismantled rack-and-pinion
8 Remove the rack from the steering-box housing. power steering box. There are mechanical parts
and hydraulic parts that can be identified. The main
The above points relate generally to all manual hydraulic parts are the rotary control valve assembly
rack-and-pinion steering boxes, but there are a and the power cylinder. Apart from these, the con-
number of variations in design. struction and servicing procedures are similar to
those for a manual steering box.
Inspection of parts To provide a better understanding of the
When dismantled, the parts should be inspected as construction of a power-steering box assembly, some
shown in Figure 30.15. Generally: general points which relate to dismantling the power
1 Check all parts for wear and damage. components are noted below:
2 Check the condition of the bearings.
3 Ensure that the bellows do not have tears or Control valve assembly
deterioration. 1 Before dismantling, the hydraulic pipes and
4 Inspect the rack and teeth for wear. hoses, which connect the pump to the control
5 Check for excessive wear between the rack and valve, have to be disconnected. Also the pipes
the bush in the housing. between the control valve and the power
cylinder have to be removed.
Reassembly 2 To remove the rotary control valve, the valve
Reassembly is generally the reverse of dismantling. housing is removed from the top of the box and
During reassembly, the rack and other moving parts this exposes the rotary valve.
are coated with specified lubricant (Figure 30.15). 3 The rack yoke, which holds the rack against the
Lithium-based grease is used for the mechanical pinion, has to be removed from the housing.
parts. 4 The rack yoke is retained in the housing by
a threaded plug and locknut. There is also a
spring which acts against the yoke.

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 351

Figure 30.14 Rack-and-pinion steering-box assembly – inspection of parts DAIHATSU

Figure 30.15 Lubrication of steering-box parts during reassembly – arrows show parts that are packed with grease TOYOTA

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 352 PART 4 • RUNNING GEAR




 


 




 
 





 



 
   


 








Figure 30.16 Parts of a rack-and-pinion power steering system

1 dust cover, 2 valve housing, 3 O-ring, 4 oil seal, 5 bearing, 6 O-ring, 7 rotary valve, 8 seal, 9 bearing, 10 bearing,
11 nut, 12 plug, 13 lock nut, 14 adjuster, 15 spring, 16 washer, 17 rack yoke, 18 insert, 19 tie rod, 20 oil pipes, 21 housing, 22 mounting
bracket, 23 rack and piston, 24 circlip, 25 rack bush, 26 rack seal, 27 O-ring, 28 piston seal, 29 rack seal, 30 spacer, 31 bellows clip,
32 bellows, 33 clip, 34 tie rod, 35 clip, 36 bellows, 37 clip, 38 nut, 39 ball HOLDEN LTD

5 The plug in the bottom of the box is removed. valve assembly, can be withdrawn from the top
This gives access to the nut on the end of the of the box.
pinion shaft. 7 The rotary valve is fitted with Telfer sealing
6 When the nut on the end of the pinion shaft is rings that can be replaced, but the valve is not
removed, the pinion, complete with the rotary dismantled any further.

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 353

Power cylinder components Pressure testing

1 Before the rack and piston assembly can be The system can be pressure tested by connecting a
removed from the housing, the rack bush in the pressure gauge into the system between the pump
outer end of the housing has to be removed. and the valve, as shown in Figure 30.17. This is
2 In the steering box shown, the bush is retained used to check the pump pressure under different
by a spring wire circlip. Other boxes might have conditions.
a snap ring or a threaded bush.
3 With the bush removed, the rack and piston
thermometer
assembly can be withdrawn from the end of the
housing. oil gauge
pump
4 The piston is fixed to the rack, but there is a valve
seal on the piston as well as seals at each end of
the rack to seal off the cylinder.
5 The power cylinder is part of the housing and
so does not dismantle further.
control
valve

Reference: Before any major servicing is

attempted the appropriate workshop manual,
with details of the complete procedure, should be
consulted.
rack-and-pinion
assembly

Figure 30.17 Arrangement for checking the pressure of a power

Analysing power-steering steering system FORD

problems
Heavy steering is the most likely general problem The pressure gauge is fitted with a valve which
with power steering and there are three possible enables the pressure line to be closed off. A thermo-
sources. These are: meter in the reservoir is used to check the oil
1 The pump. If the pump is not producing temperature, and a tachometer is used for engine
pressure, or only low pressure, the steering will rpm.
be heavy when turned both left and right. After connecting the gauge, the system has to be
2 The control valve. If the valve is at fault, due bled to remove air that has entered. Gauge readings
to leaks across the seals, there could be a are made after cycling the steering wheel from lock
difference in power assistance between a left to lock and with the engine running at fast idle.
and a right turn. The steering would be heavy The general methods of checking the pressure
when turned in one direction and normal when are:
turned in the other direction. 1 Pump pressure. With the gauge valve closed,
If the control valve was to fail completely the pressure line is blocked off at the pump and
there would be no power assistance, but this is pressure should build up to specifications. The
less likely. valve should only be closed for a few seconds. If
3 The power cylinder. If the piston seal is worn, it the gauge reading is low, suspect the pump.
would allow pressure oil to leak past the piston 2 Power cylinder pressure. With the gauge valve
to the non-pressure side of the power cylinder. open, the pump is connected to the control
There would be reduced power assistance and valve and the power cylinder. The pressure
the steering would be heavier than normal. It should also be at pump pressure. If the gauge
would feel the same on both left and right turns. reading is low, suspect the piston seals.
3 Flow meter. Many power system analysers
include a flow meter. Sufficient oil flow is just as
Hint: If the steering is heavy, do not overlook the type important as pressure. Reduced flow will cause
of tyres, tyre pressures and other steering components slow operation and can be a result of damaged
as a contributing cause. hoses or pipes.

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 354 PART 4 • RUNNING GEAR

that the sector will be in a position where it will

not foul the housing when it is being removed.
Servicing a recirculating 2 Remove the top cover bolts. The cover bolts
ball steering box 3
secure the cover (1) to the housing (10).
Remove the cover from the housing. The sector
Following are general points which relate to servicing shaft and cover are connected by the adjusting
a recirculating-ball steering box. As with all mechani- screw (2). All these parts will be removed from
cal assemblies, a logical sequence must be followed the housing together.
when dismantling; parts have to be checked for 4 Screw the adjusting screw inwards. Screwing
serviceability after dismantling; adjustments are the adjusting screw out of the cover will allow
made during reassembly; and checks or tests carried the sector shaft (4) to be separated from the
out after reassembly has been completed. cover. The end of the sector shaft is slotted to
take the head of the adjusting screw.
Dismantling 5 Loosen the input shaft locknut. Loosen the
The dismantled parts of a steering box are shown in locknut (22) and unscrew the bearing adjuster
Figure 30.18. To reach the dismantled state shown, (20) from the housing (10). This enables the
the procedure would be as follows: parts of the upper bearing (18 and 19) to be
1 Centre the steering box. This is necessary so removed.

Figure 30.18 Exploded view of a recirculating-ball steering box

1 cover, 2 adjusting screw, 3 gasket, 4 sector shaft, 5 bearing, 6 plug, 7 plug, 8 seal, 9 bearing, 10 housing, 11 bearing cup, 12 balls and
cage, 13 ball nut, 14 ball-return guides, 15 retainer, 16 balls, 17 input or mainshaft, 18 balls and cage, 19 bearing cup, 20 input shaft
bearing adjuster, 21 seal, 22 locknut FORD

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 355

6 Withdraw the input shaft. Carefully withdraw play and no binding in the bearings, although a light
the input shaft (17) with the ball nut (13) from preload is applied in some boxes. The mainshaft
the housing as an assembly. Make sure that the adjustment should always be done first, with the
ball nut does not run down to either end of mesh adjustment released.
the worm, as this could damage the ball-return The locknut is first loosened, usually with a special
guides. spanner, and adjustment is then made by tightening
or loosening the bearing adjuster to bring the preload
to within the specified limits. Only a light preload is
Information: The terms mainshaft and input shaft required.
are both used for the shaft that carries the worm.

Additional dismantling
Figure 30.19 illustrates the two main dismantling
points:
1 Figure 30.19(a) shows how the sector shaft,
cover and adjuster are all removed together.
2 Figure 30.19(b) shows how the worm, complete
with the nut, is removed from the housing.

Other items relating to dismantling are:

1 Checking the ball nut. The ball nut is checked
on the worm as shown in Figure 30.19(c). The
nut need not be removed from the worm unless
roughness is evident in the balls or worm.
2 Removing the nut from the worm. Removing
the screws that hold the ball-return guides to
the ball nut allow the guides to be removed.
The balls can then be rolled out of the nut and
the nut removed from the worm.
3 Renewing ballraces and bearings. Bearings
should be checked, but removed from shafts
only if they need to be renewed. Removing
bearings unnecessarily could cause damaged
during removal.

General reassembly
Reassembly is carried out in the reverse order to
dismantling. The input shaft is installed first and its
bearings adjusted. The sector shaft is then installed
and the mesh adjustment carried out.
The final step is to fill the steering box with
lubricant to the correct level. This can be SAE 90
transmission oil or a special semiliquid grease
(Figure 30.20). During assembly, the threads of all
the bolts and adjusters are coated with a suitable oil-
resistance sealer to prevent oil leaks.

Input-shaft bearing adjustment

The purpose of the input-shaft bearing adjustment is
to ensure that the mainshaft is securely supported in Figure 30.19 Dismantling points for a recirculating-ball
its bearings. steering box MITSUBISHI
For correct adjustment there should be no end-

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 356 PART 4 • RUNNING GEAR

and it must always be done with the steering box in

the straight-ahead position.
To centre the steering box, turn the steering wheel
from lock to lock, counting the number of turns.
This can then be halved to locate the centre position.
Steering boxes are designed to have least clearance
at the centre. If adjustments are made at any other
location, binding will occur at the centre position.
The mesh adjuster (Figure 30.22) is fitted to the
cover. It accepts road shocks which are transmitted
through the steering linkage to the sector shaft. It
also positions the sector shaft for correct mesh
clearance between the gear teeth.

Figure 30.20 Checking the level of lubricant in a steering box

– a piece of wire can be formed into a dipstick MAZDA

Checking preload
Preload can be checked by means of a spring scale
attached to the outer end of a steering wheel spoke as
shown in Figure 30.21. The scale is pulled in a direction
at right angles to the radius of the wheel, and the reading
taken as the wheel is in motion. A typical specification
for the steering box illustrated is 0.4 to 0.6 Nm.
Figure 30.22 Adjusting the sector shaft (mesh adjustment)
MITSUBISHI

Figure 30.23 shows how the head of the sector

shaft adjusting screw fits into a T-shaped slot. Shim
washers under the head of the adjusting screw limit
the clearance at this point.

Figure 30.21 Checking steering-box preload with a pull

scale FORD

Information: The input shaft bearing preload only is

checked at this time. This is done as soon as the input
shaft is installed, and before the sector shaft is fitted.

Mesh adjustments Figure 30.23 Checking the clearance of the adjusting bolt
During steering-box overhaul, the mesh adjustment is in the T-slot of the sector shaft MITSUBISHI
always done after the mainshaft bearing adjustment,

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 357

Clearance between the sector gear teeth and If adjustments are being performed in the vehicle,
the teeth on the ball nut is altered by adjustment of the ball joint should be removed from the pitman arm
this screw. This is possible because the teeth on the so that the steering box is isolated from the linkage.
sector gear have a slight bevel, making it somewhat Unless this is done, accurate adjustments will not be
wedge-shaped, so that as the adjusting screw is obtained.
screwed inwards, the teeth of the sector and the nut The recirculating-ball steering box shown in
are brought closer together to reduce the clearance. Figure 30.24 has a screw-type adjuster for the input
The mesh of the teeth is adjusted until a specified shaft bearings, and another screw-type adjuster in
pull on the steering wheel is necessary to rotate the the cover for mesh adjustment. Other steering boxes
worm past its centre. This is now the total preload have a shim-type adjustment for the input shaft
which includes the input shaft bearing preload and bearings, with shims used between the end cover
any load from the meshed teeth. and the housing.

Worm-type steering box Recirculating-ball box

adjustments with power steering
There are two separate adjustments that are common Figure 30.25 shows the parts of a dismantled power
to all worm-type steering boxes, although the method steering box. The dismantling procedure is similar to
of adjustment varies with different boxes. The adjust- that for a steering box without power steering.
ments are: The sector shaft and end cover are similar to
1 the input shaft bearings those of the recirculating-ball steering box previously
2 the mesh of the worm and sector teeth (or described, but the worm and nut of that steering box
similar meshing parts in boxes of other design). is replaced by the piston and valve assembly shown
in the illustration. The piston and valve assembly are
Some steering boxes have screw adjustments, not usually dismantled.
which are accessible with the steering box in the
vehicle, although adjustment in the vehicle is mainly
confined to adjustment for mesh.

Figure 30.24 External parts of a steering box – adjustments are shown with asterisks (*) FORD

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 358 PART 4 • RUNNING GEAR

Table 30.1 Diagnosis of steering faults

end cover
Symptom Possible cause

Loose steering Incorrect front-wheel bearing

adjustment
Loose linkage ball joints
piston and valve
assembly Loose steering-box mounting
adjuster Wear or maladjustment of
O-ring steering box
Worn or loose idler arm

Heavy steering Power steering inoperative

Incorrect tyre pressure
Incorrect front-wheel alignment
input shaft
Lack of lubrication
Tight steering-box adjustment

housing Steering and Loose linkage connections

suspension rattles Loose mountings
Loose suspension joints
sector shaft
Broken spring

Steering shimmy Out-of-balance wheels

Figure 30.25 Dismantled recirculating-ball type of power
Incorrect front-end alignment
steering box TOYOTA
Loose linkage connections

Vehicle pulls to Tyre pressures uneven

one side Front-wheel alignment incorrect
Steering faults Sagging or broken spring
Table 30.1 lists some general steering faults and their Mismatched tyres
possible causes. Symptom Possible cause
Tyre squeals on Low tyre pressure
turns Incorrect wheel alignment
Bent steering arm

Wander from side Incorrect wheel alignment

to side of road Loose steering connections
Loose steering-box adjustments
Sagging spring
Incorrect tyre pressure
Uneven tyres

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 CHAPTER 30 • STEERING-SYSTEM SERVICE 359

9. Why should the position of a tie rod be marked

Technical terms before it is removed?
Grease nipples, grease gun, wheel alignment, steering free 10. What external parts can be checked on a rack-and-
play, bellows, forcing screw, pitman arm, idler arm, tapered pinion steering box?
spline, horn pad, collapsible steering shaft, power steering, 11. What external parts can be replaced on a rack-
steering lock, full lock, mainshaft, input shaft, steering column, and-pinion steering-box assembly?
lithium-based grease, rack yoke, rotary control valve, ball nut, 12. What type of maintenance is power steering likely
preload, screw-type adjuster, mesh adjuster. to need?
13. How is the oil checked in a power-steering system?
14. How can the oil be changed in a power-steering
Review questions system?
1. How would a steering system be checked for looseness? 15. What adjustments are provided on a rack-and-
2. What type of tool is used to remove a tie rod ball joint pinion steering box?
from a steering arm? 16. Where are the adjustments located on a worm-type
3. What precaution would be taken before removing a steering box?
pitman arm? 17. What parts of a steering box are likely to have
4. How is an idler arm removed? preload?
5. How are steering wheels attached to their shafts? 18. How is a pressure gauge connected to a power
6. What precautions should be taken when removing a steering system?
steering wheel? 19. What are the possible causes of looseness in a
7. What particular precautions would be taken if the steering steering system?
wheel has an air bag? 20. What are likely causes of hard steering?
8. What could cause a steering wheel to be off-centre?

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30 May - Automotive 8e.indd 360 30/3/09 3:05:33 PM