Rack and Pinion Steering Gear, ThyssenKrupp

46.04
General Information

Principles of Operation
The rack and pinion steering system is mounted to the front axle with two brackets, and connected by outer tie rods to the tie rod arms that pivot the wheels. See Fig. 1. When the steering wheel is turned, the intermediate steering shaft turns the input shaft, rotating the torsion bar and pinion gear within the rack housing. When the torsion bar twists, power steering uid provides power assist, via a rackmounted piston, to the pinion gear, moving the rack. The rack, with a tie rod at each end, then moves the tie rod arms.

Cascadia Workshop Manual, Supplement 5, September 2009

050/1

46.04
General Information

Rack and Pinion Steering Gear, ThyssenKrupp

11 12 15 10 8 9 13 14

16

7 6

17 3 4 5 2

19 9 18 1 3
07/24/2009

21 8 20 22 23 5 4
f462151

1. 2. 3. 4. 5. 6. 7. 8. 9.

Steering Tie Rod Arm Power Steering Fluid Lines Large Bellows Clamp Bellows Small Bellows Clamp Driver-Side Outer Tie Rod Tie Rod Jam Nut Inner Tie Rod Flat Inner Tie Rod Ball Joint

10. 11. 12. 13. 14. 15. 16.

Input Shaft Seal Cover I-Shaft Upper Yoke I-Shaft Lower Yoke Boot Clamp I-Shaft Lower Yoke Boot I-Shaft Lower End Yoke Transfer Line Tube Fittings Power Steering Fluid Line Fittings

17. 18. 19. 20. 21. 22. 23.

I-Shaft Slip Joint Transfer Lines Rack and Pinion Gear Pinch Bolt Tie Rod Clamp Tie Rod Clamp Nut Passenger-Side Outer Tie Rod

Fig. 1, Rack and Pinion Steering System

050/2

Cascadia Workshop Manual, Supplement 5, September 2009

Rack and Pinion Steering Gear, ThyssenKrupp

46.04
Rack and Pinion Alignment

Alignment
Rack and pinion steering gears require a different alignment procedure from integral (recirculating ball) steering gears, and can only be aligned using a calibrated, computerized, multiwheel alignment tool, operated by a certied service technician. 1. Complete the setup needed for the computerized alignment tool (identical to the setup for integral steering gears). 2. With the wheels on turnplates, center the rack travel by aligning the timing pointers on the input shaft seal cover and the input shaft housing. (Fig. 1). 4.2

in place with a backup wrench on the inner tie rod at (Fig. 2, Item 3). With the gear on-center, place a wrench on the driver-side inner tie rod at and align the left tire by rotating the inner tie rod. Total left side toe-in should be between 0 and 0.085 degrees. 4.3 4.4 4.5 Tighten the tie rod jam nut 285 to 305 lbfft (386 to 413 Nm). Loosen the passenger-side tie rod clamp nut, see Fig. 2. With the gear on-center, place a wrench on the passenger-side inner tie rod at and align the right tire by rotating the inner tie rod. Total right side toe-in should be between 0 and 0.085 degrees.

1 A 2

4.6

Tighten the tie rod clamp nut 30 to 36 lbfft (41 to 48 Nm).

IMPORTANT: Total toe-in for both sides should be as close to 0 degrees as possible, and no greater than 0.17 degrees.

NOTICE
05/31/2007 f462071

Maximum wheel cut should not exceed 46 degrees. Excessive wheel cut may damage the inner tie rod. 5. Turn the wheels as far right and left as possible to check for interference between the wheels/ tires and other components. There must be at least 1/2 inch (13 mm) clearance from any xed object, and 3/4 inch (19 mm) from any moving object.

A. Align the pointers. 1. Input Shaft Seal Cover 2. Input Shaft Housing Fig. 1, Rack and Pinion Pointer Alignment

3. Whenever the computerized alignment program requires that the steering wheel be pointed straight ahead, the steering rack on-center pointers should be aligned.

NOTE: Do not clock the steering wheel; it is clocked at the end of the procedure.
4. Adjust each tie rod length to obtain the specied toe-in dimension, as follows. 4.1 Loosen the driver-side tie rod jam nut, see Fig. 2. If necessary, hold the inner tie rod

IMPORTANT: The spline/pinch bolt connections between the steering gear and the last U-joint in the column t in only one position, so reclocking the splined connections after alignment is not possible.
6. Make sure that the steering wheel is within 10 degrees of center as shown in Fig. 3. If not, remove and center the wheel, as follows. 6.1

If the vehicle has an airbag, deactivate and remove the airbag module according

Cascadia Workshop Manual, Supplement 6, March 2010

100/1

46.04
Rack and Pinion Alignment

Rack and Pinion Steering Gear, ThyssenKrupp

1 4 3 3 5 A B

3 A 2 1
07/24/2009

f462166

A. Counterclockwise rotation increases the toe-in angle B. Clockwise rotation decreases the toe-in angle 1. Outer Tie Rod 2. Tie Rod Jam Nut 3. Inner Tie Rod Flat 4. Tie Rod Clamp Fig. 2, Rack and Pinion Gear Assembly 5. Tie Rod Clamp Nut

to the instructions in Section 46.07. If the vehicle does not have an airbag, remove the horn button by prying it out around the edge.
6.2 Loosen the nut that holds the steering wheel on the steering column, but leave it on the shaft until the wheel has been released from the tapered t. Remove the wheel from the tapered t by striking it upward from below, at the rim/ spoke intersections, with both hands. Remove and discard the steering wheel nut, and install and center the steering wheel.

6.5 6.6

Install a new steering wheel nut and tighten it 33 to 41 lbfft (45 to 55 Nm).

If the vehicle has an airbag, install and reactivate the airbag according to the instructions in Section 46.07. If the vehicle does not have an airbag, install the horn button.

6.3

6.4

100/2

Cascadia Workshop Manual, Supplement 6, March 2010

Rack and Pinion Steering Gear, ThyssenKrupp

46.04
Rack and Pinion Alignment

10 1

10 2

10

10

06/13/2007

f462080

1. 9 oclock

2. 3 oclock

Fig. 3, Steering Wheel Centered

Cascadia Workshop Manual, Supplement 6, March 2010

100/3

Rack and Pinion Steering Gear, ThyssenKrupp

46.04

Rack and Pinion Removal and Installation

Removal
1. Place the front tires in the straight-ahead position. If possible, drive the vehicle in a straight line for a short distance, stopping at the spot where the work is to be done. 2. Turn off the engine, apply the parking brakes, chock the tires, and open the hood. 3. Clean all ttings and hose connections on the steering gear until they are free of dirt. 4. While holding the power steering uid line ttings in place with a backup wrench, disconnect the uid lines from the steering gear. Plug the lines and the ttings to keep out dirt and prevent uid leakage. 5. Remove and discard the cotter pins and castellated nuts from the outer tie rods. Disconnect the outer tie rods from the tie rod arms. 6. Disconnect the end yoke of the steering I-shaft from the rack and pinion input shaft. Discard the pinch bolt and nut. 7. Remove and discard the steering gear mounting bolts and nuts that connect the rack and pinion to the axle steering gear brackets, then remove the gear.
A 2

05/31/2007

f462071

A. Align the pointers. 1. Input Shaft Seal Cover 2. Input Shaft Housing Fig. 1, Rack and Pinion Pointer Alignment

5. Apply torque seal, OGP F900WHITE, to the exposed pinch bolt threads and nut. 6. If needed, install power steering uid line ttings (Fig. 2, Item 5) on the steering gear and tighten 30 to 35 lbfft (41 to 47 Nm). 7. Connect the power steering uid lines to the ttings, ensuring that the hoses do not touch the axle or each other. While holding the ttings in place with a backup wrench, tighten the pressure hose 43 to 47 lbfft (58 to 64 Nm) and the return hose 55 to 61 lbfft (75 to 83 Nm).

Installation
1. Install the steering gear on the axle steering gear brackets, using new mounting bolts and nuts. Tighten the fasteners 202 to 256 lbfft (274 to 347 Nm). 2. Attach the outer tie rods of the rack and pinion gear to the tie rod arms, using new castellated nuts. Tighten the castellated nuts 240 lbfft (325 Nm). Continue to tighten until the the next castellated nut slot aligns with the hole in the ball stud and insert the new cotter pin. 3. Center the rack travel and align the timing pointers on the input shaft seal cover and the input shaft housing. See Fig. 1. 4. Using a new pinch bolt and nut, attach the steering I-shaft to the steering gear input shaft. Tighten the nut 30 to 35 lbfft (41 to 47 Nm).

NOTICE
Do not loosen or tighten the hard transfer line tube ttings. Tightening the tube ttings can cause the O-ring seal to leak. 8. Fill and bleed the power steering system. 8.1 8.2 Raise the front wheels off the ground and support the vehicle with jack stands. Fill the power steering reservoir with automatic transmission uid that meets Dexron III or TES-389 specications.

Cascadia Workshop Manual, Supplement 6, March 2010

110/1

46.04

Rack and Pinion Steering Gear, ThyssenKrupp

Rack and Pinion Removal and Installation

2 6 1 1 4 5 6 3

7 1 2 7 1
07/27/2009

3
4. Power Steering Fluid Lines 5. Power Steering Fluid Line Fittings

f462167

1. Steering Tie Rod Arm 2. Castellated Nut 3. Outer Tie Rod

6. Steering Gear Mounting Bolts 7. Steering Gear Mounting Nuts

Fig. 2, Rack and Pinion Steering Gear Assembly

8.3

With the engine off, turn the wheel fully left and right ve times to bleed the air from the rack. Start the engine and turn the steering wheel fully left and right several times to bleed the remaining air from the system. If the steering system needs additional bleeding, repeat the previous substep after the uid in the reservoir has had time to release any air. Remove the jack stands and lower the vehicle.

8.4

8.5

8.6

9. Set the toe-in using the instructions in Subject 100.

110/2

Cascadia Workshop Manual, Supplement 6, March 2010

Rack and Pinion Steering Gear, ThyssenKrupp

46.04

Input Shaft Seal Replacement

Replacement
1. Place the front tires in the straight-ahead position. If possible, drive the vehicle in a straight line for a short distance, stopping at the spot where the work is to be done. 2. Turn off the engine, apply the parking brakes, chock the tires, and open the hood. 3. Clean all ttings and connections until they are free of dirt and debris. 4. While holding the ttings in place with a backup wrench, disconnect the power steering uid lines from the steering gear. Plug the lines and the ttings to keep out dirt and prevent uid leakage. 5. Remove and discard the pinch bolt and nut from the I-shaft end yoke, and disconnect the end yoke from the input shaft. 6. Clean the valve and input shaft seal cover until they are free of dirt and debris. 7. Work the input shaft seal cover off with a screwdriver. 8. Remove the dust cover. 9. Remove the retaining ring with retaining ring pliers. 10. Clean the area thoroughly to prevent any contaminants from entering the gear after the seal is removed. 11. Wrap the input shaft and seal area with a clean cloth to prevent uid spray when removing the seal, then remove the input shaft seal by blowing compressed air into the outlet port. See Fig. 1. 12. Install the protective cap on the input shaft. 13. Apply grease, Renolit JP1619N (Mercedes-Benz DBL 6804.70), on the input shaft seal lip, then install the new seal on the input shaft. 14. Position the depth tool over the input shaft and press the seal into the housing by lightly tapping on the tool with a rubber mallet until the tool hits the upper edge of the housing. Check the position of the seal after each tap to make sure it stays level. The seal is correctly installed when it is fully under the retaining ring groove. 15. Install the retaining ring with retaining ring pliers. The ring must be seated fully in the retaining ring groove.
3
07/24/2009

1 1

B 2

f462114

A. Apply air to the outlet port to remove the input shaft seal. B. Seal the inlet port while applying air. 1. Power Steering Fluid Line Fittings 2. Transfer Line Tube Fittings Fig. 1, Removal of the Input Shaft Seal

16. Apply grease to the top of the seal, completely covering the seal. See Fig. 2.

2 1 4 A

10/11/2007

f462113

A. Cover top of seal with grease. 1. Retaining Ring 2. Protective Cap 3. Dust Cover 4. Input Shaft Seal

Fig. 2, Dust Cover Installation

IMPORTANT: The dust cover must be installed with the outer lip upward to properly protect the shaft components.

Cascadia Workshop Manual, Supplement 6, March 2010

120/1

46.04

Rack and Pinion Steering Gear, ThyssenKrupp

Input Shaft Seal Replacement

17. Install the dust cover, making sure the outer lip of the cover curves upward. Wipe away any excess grease. 18. Remove the protective cap from the input shaft. 19. Install the input shaft seal cover on the input shaft. 20. Using a new pinch bolt and nut, attach the steering I-shaft to the steering gear input shaft. Tighten the nut 30 to 35 lbfft (41 to 47 Nm). 21. Apply torque seal, OGP F900WHITE, to the exposed pinch bolt threads and nut. 22. Check the power steering uid line ttings for a torque value of 30 to 35 lbfft (41 to 47 Nm). Tighten them if needed. 23. Connect the power steering uid lines to the ttings, ensuring that the hoses do not touch the axle or each other. While holding the ttings in place with a backup wrench, tighten the pressure hose 43 to 47 lbfft (58 to 64 Nm) and the return hose 55 to 61 lbfft (75 to 83 Nm).

NOTICE
Do not loosen or tighten the hard transfer line tube ttings (Fig. 1, Item 2). Tightening the tube ttings can cause the O-ring seal to leak. 24. Fill and bleed the power steering system. 24.1 24.2 Raise the front wheels off the ground and support the vehicle with jack stands. Fill the power steering reservoir with automatic transmission uid that meets Dexron III or TES-389 specications. With the engine off, turn the wheel fully left and right ve times to bleed the air from the rack. Start the engine and turn the steering wheel fully left and right several times to bleed the remaining air from the system. If the steering system needs additional bleeding, repeat the previous substep after the uid in the reservoir has had time to release any air. Remove the jack stands and lower the vehicle.

24.3

24.4

24.5

24.6

120/2

Cascadia Workshop Manual, Supplement 6, March 2010

Rack and Pinion Steering Gear, ThyssenKrupp

46.04
Outer Tie Rod Replacement

Replacement
1. Place the front tires in the straight-ahead position. If possible, drive the vehicle in a straight line for a short distance, stopping at the spot where the work is to be done. 2. Turn off the engine, apply the parking brakes, chock the tires, and open the hood. 3. For driver-side outer tie rod replacement, proceed as follows. See Fig. 1. 3.1 3.2 Remove and discard the cotter pin and castellated nut. Loosen the jam nut. Note the number of exposed threads and the position of the outer tie rod to ease installation. Remove the outer tie rod from the tie rod arm. Unthread the outer tie rod from the inner tie rod. If necessary, hold the inner tie rod in place with a backup wrench on the inner tie rod at. Discard the outer tie rod. 3.5 3.6 3.7 Remove and discard the jam nut. Install the new jam nut. Install the new outer tie rod on the inner tie rod. Ensure that the outer tie rod position and number of exposed threads is the same as noted during step 3.2. Tighten the jam nut.

4.5

Install the new outer tie rod on the inner tie rod. Ensure that the outer tie rod position and number of exposed threads is the same as noted during step 4.2. Tighten the tie rod clamp.

4.6

5. Attach the outer tie rod of the rack and pinion to the tie rod arm with a new castellated nut. Tighten the castellated nut 240 lbfft (325 Nm). Continue to tighten until the the next castle nut slot aligns with the hole in the ball stud and insert the new cotter pin. 6. Align the rack and pinion gear using the instructions in Subject 100. 7. On the driver side, tighten the jam nut 285 to 305 lbfft (386 to 413 Nm). On the passenger side, tighten the clamp nut 30 to 36 lbfft (41 to 48 Nm).

3.3 3.4

3.8

4. For passenger-side outer tie rod replacement, proceed as follows. See Fig. 1. 4.1 4.2 4.3 Remove and discard the cotter pin and castellated nut. Remove the outer tie rod from the tie rod arm. Loosen the tie rod clamp. Note the number of exposed threads and the position of the outer tie rod to ease installation. Unthread the outer tie rod from the inner tie rod. If necessary, hold the inner tie rod in place with a backup wrench on the inner tie rod at. Discard the outer tie rod.

4.4

Cascadia Workshop Manual, Supplement 5, September 2009

130/1

46.04
Outer Tie Rod Replacement

Rack and Pinion Steering Gear, ThyssenKrupp

3 7 6

2 4
07/27/2009

3
4. Tie Rod Jam Nut 5. Inner Tie Rod Flat 6. Tie Rod Clamp Nut 7. Tie Rod Clamp

f462168

1. Castellated Nut and Cotter Pin 2. Steering Tie Rod Arm 3. Outer Tie Rod

Fig. 1, Rack and Pinion Outer Tie Rod Assembly

130/2

Cascadia Workshop Manual, Supplement 5, September 2009

Rack and Pinion Steering Gear, ThyssenKrupp

46.04
Bellows Replacement

Replacement
1. Park the vehicle on a level surface. Shut down the engine, set the parking brake, and chock the tires. Open the hood. 2. Loosen the jam nut on the driver side, or the tie rod clamp on the passenger side. Note the number of exposed threads, and the position of the outer tie rod, to ease installation. 3. Unthread the inner tie rod from the outer tie rod until the inner tie rod and bellows assembly is free from the outer tie rod. If necessary, use a backup wrench on the inner tie rod at (Fig. 1, Item 6) to turn the inner tie rod.

5. Remove and discard the bellows clamps and bellows. 6. Inspect the gear for corrosion or evidence of hydraulic uid. If either is found, replace the rack and pinion gear. 7. Loosely install new small and large Oetiker bellows clamps onto the bellows. 8. Ensure the bellows seats on the gear housing and on the inner tie rods are free of dirt and debris. 9. Install the bellows onto the gear. 10. Ensure the bellows are seated properly on the housing and tie rod. 11. Ensure the Oetiker clamps are properly seated in the clamp grooves on the bellows. Using an Oetiker clamp tool (Fig. 2), crimp the small and large Oetiker bellows clamp ears until the ear width is 0.08 to 0.16 in (2 to 4 mm).

6 5 4 2 1 3

12 10 9 3 4 5 6 7 8
07/24/2009 f580473

11

Fig. 2, Oetiker Clamp Tool

07/24/2009 f462112

12. Install the jam nut on the driver side, or the tie rod clamp on the passenger side. 13. Thread the inner tie rod into the outer tie rod. 14. Tighten the jam nut on the driver side, or tie rod clamp nut on the passenger side. 15. Align the rack and pinion using the instructions in Subject 100. 16. Tighten the jam nut 285 to 305 lbfft (386 to 413 Nm), or tighten the tie rod clamp nut 30 to 36 lbfft (41 to 48 Nm).

1. Driver-Side Outer Tie Rod 2. Tie Rod Jam Nut 3. Small Oetiker Clamp 4. Bellows 5. Large Oetiker Clamp 6. Inner Tie Rod Flat 7. Inner Tie Rod Ball Joint

8. 9. 10. 11. 12.

Bellows Seat Pinch Bolt Tie Rod Clamp Tie Rod Clamp Nut Passenger-Side Outer Tie Rod

Fig. 1, Tie Rod and Bellows Assembly

4. Remove both Oetiker bellows clamps.

Cascadia Workshop Manual, Supplement 5, September 2009

140/1

46.04
Bellows Replacement

Rack and Pinion Steering Gear, ThyssenKrupp

17. Inspect the bellows to ensure that they have not been torn, punctured, or otherwise damaged during installation.

140/2

Cascadia Workshop Manual, Supplement 5, September 2009