Publisher The Goodheart-Willcox Co., Inc. Tinley Park, Illinois

1. PublisherThe Goodheart-Willcox Co., Inc.Tinley Park, Illinois PowerPoint for Modern Automotive Technology by Russell Krick

2. Chapter 70 Steering System Diagnosis and Repair

3. Contents • Steering system problem diagnosis • Steering system maintenance • Steering column service • Manual steering gearbox service (recirculating-ball type) • Steering linkage service • Manual rack-and-pinion service • Power steering system service

4. Steering System Problem Diagnosis • Symptoms of steering problems include play in the steering wheel, hard steering, and abnormal noises when turning • Inspect and test the steering system to find the source of the trouble

5. Steering System Problems

6. Steering Wheel Play • Amount you can turn the steering wheel without front-wheel movement • Caused by worn ball sockets, a worn idler arm, or too much clearance in the steering gearbox • Compare the play to service manual specifications • 1 1/2" (33 mm) of play is typically the max

7. Dry Park Test With the vehicle on the ground, rotate the steering wheel back and forth while someone watches for part wear

8. Steering Inspection After raising the vehicle on a lift, wiggle the tires back and forth while watchingfor steering play

9. Hard Steering • Caused by problems with the steering gearbox, power steering components, ball sockets, or the suspension system • Check the condition and tension of the power steering pump belt • If the belt is slipping, hard steering could result • Check for cracks and glazing and compare the tension to specs

10. Steering System Noise • Noise can be a sign of worn parts, dry bearings or ball sockets, loose parts, slipping belts, or a low power steering fluid level • Belt squeal and power steering pump noise both occur when the steering wheel is turned • Pump noise can result from a low fluid level or aerated fluid

11. Steering System Maintenance • Maintenance involves checking for low fluid level, incorrect belt adjustment, system leaks, and other problems • Ball socket lubrication may be necessary

12. Checking the Fluid Check most systems at operating temperature, with the engine off

13. Servicing the Belt When changing a belt, pry on a recommended point and adjust the tension to specs

14. Steering Column Service • Service is needed after a collision or when internal parts of the column fail • Most repairs can be done without column removal

15. Steering Column

16. Steering Wheel Removal • Remove the horn button and steering shaft nut • Scribe alignment marks on the steering wheel and the steering shaft • Mount a wheel puller over the steering wheel • Screw the bolts into the threaded holes in the steering wheel

17. Steering Wheel Removal Tighten the puller against the steering shaft to remove the wheel

18. Steering Wheel Installation • When installing the steering wheel, match any alignment marks • Many steering shafts use a master spline so the wheel only installs in one position

19. Steering Column Joint Replacement • The rubber couplings can deteriorate after prolonged service or from exposure to oil leakage • The U-joints can wear and develop play

20. Manual Steering Gearbox Service (Recirculating-Ball Type) • Service involves the adjustment or the replacement of worn parts (bearings, seals, and bushings) • When adjustment will not provide proper operation, gearbox repair or overhaul may be necessary

21. Gearbox Adjustment • Two basic adjustments are performed on manual recirculating-ball gearboxes: • Worm bearing preload • preloads the bearings to ensure that the worm shaft is held snugly in the housing • Over-center clearance • controls the amount of lash between the pitman shaft gear and the teeth on the ball nut

22. Gearbox Adjustment

23. Worm Bearing Preload Adjustment • Disconnect the pitman arm • Loosen the pitman shaft over-center locknut and adjusting screw • Using a torque wrench or spring scale, turn the steering wheel slowly from side to side

24. Worm Bearing Preload Adjustment Compare the required force to specs If needed, tighten or loosen the adjustment nut

25. Over-Center Clearance Adjustment • Center the steering gear in its travel • A preload is produced in the center of travel to avoid steering wheel play during straight-ahead driving

26. Over-Center Clearance Adjustment Loosen the locknut and bottom the adjustment screw lightly

27. Over-Center Clearance Adjustment • Use a torque wrench or spring scale to measure the amount of force needed to move the shaft back and forth through the center • Tighten or loosen the adjustment screw until the amount of force needed to move the shaft is within specs • Tighten the locknut after adjustment and recheck the required force

28. Over-Center Clearance Adjustment

29. Steering Gearbox Overhaul • Follow the service manual procedures • Disassemble the gearbox • Clean and inspect all the parts • All worn parts and used rubber seals must be replaced • Reassemble and install the gearbox • Fill the housing with the specified lubricant • most gearboxes use SAE 90 gear oil

30. Steering Gear Components

31. Steering Linkage Service When your inspection finds worn steering linkage parts, new parts must be installed

32. Steering System Inspection

33. Idler Arm Service • Idler arm wear will cause play in the steering wheel • To check an idler arm, force it up and down by hand • Note the amount of movement at the end of the arm and compare it to specifications • typically, an idler arm should not wiggle more than 1/4" (6.5 mm)

34. Idler Arm Service • To replace the idler arm, remove the cotter pin and castle nut • Use a fork tool or puller to force the ball stud out of the hole in the center link • Unbolt the idler arm from the frame • Install the new idler arm • Torque the idler arm fasteners to specifications • Install a new cotter pin

35. Tie-Rod End Service • Tie-rod end wear will cause steering play • To remove a tie-rod end, separate the tie-rod end from the steering knuckle or center link

36. Tie-Rod End Service Use a fork or puller to separate the tie-rod end from the steering knuckle

37. Tie-Rod End Service Loosen the adjusting sleeve, and count the number of turns required to remove the tie-rod from the sleeve

38. Tie-Rod End Service • Install the new part the exact same number of turns • Install the tie-rod ball stud into the center link or steering knuckle • Tighten all the fasteners to specs and install a new cotter pin • Check toe adjustment with an alignment machine

39. Inner Tie-Rod End Service (Rack-and-Pinion) Cut off the strapsand slide the bootout of the way Remove the part using two wrenches or special tools

40. Inner Tie-Rod End Service (Rack-and-Pinion) • Install the new part • Install all flat and lock washers in their original locations • Torque the tie-rod nut to specs • Replace the boot straps

41. Manual Rack-and-Pinion Service

42. Lubrication • Some gears require periodic lubrication • Remove the boot to inspectthe tie-rod socket

43. Adjustment When there is play in the steering, adjust the steering gear

44. Adjustment • Loosen the locknut • Turn the rack guide screw in until it bottoms lightly • Back off the screw the amount recommended in the service manual • Tighten the locknut • Recheck steering and measure steering effort

45. Removal • Separate the outer tie-rod ends from the steering knuckles • Unbolt the steering gear mounting brackets from the frame or crossmember • Disconnect the steering shaft U-joint

46. Removal Rotate the steering gear and slideit out of the chassis

47. Overhaul • Follow the service manual procedures • Disassemble the unit and inspect each part • Replace any part that shows signs of wear • Special procedures may be required for ball socket removal • Replace all seals and rubber parts • Assemble the unit

48. Rack-and-Pinion Components

49. Special Procedures Drilling out the pin in a tie-rod ball socket

50. Power Steering System Service • Many parts of a power steering system are the same as those used in a manual steering system • Hoses, a pump, a power piston, and a control valve are added • these parts can require repair or replacement