Removing, installing and checking bearing cover with pitman arm shaft - RA46097650232X(46-0232)

Preceding work:

Removing and installing steering gear (46-3400)

Operation No. of operation texts and operation values or standard texts and flat rates:

46-3256

1. Steering gear with adjusting screw at top, models 124 (except 124.034/036), 201, 202 
   Fig 1: Identifying Steering Gear Components With Adjusting Screw At Top Models 124 (Except 124.034/036))

   

   Steering gear (1)	mount on assembly support 140 589 00 59 00 with two screws and clamp in vise (number 1).
   Distance "a" between pitman arm (12) and pitman arm shaft/bearing cover (51)	measure and note size (number 2).
   Locking ring (16)	detach, attach, replace (number 3).
   Pitman arm (12)	pull off, by unscrewing nut (14a) and taking off bolt (14) (numbers 3 and 4). When installing pitman arm shaft and pitman arm, coat with Loctite 270 and fit on up to measured size "a" (number 2). Replace nut (14a) and attach with bolt (14), 55 Nm (numbers 17, 18).
   Pitman arm shaft (43)	turn into center position (number 5).
   Self-locking bolts (59)	unscrew, screw in, replace (numbers 6, 13) 30-35 Nm.
   Self-locking collar nut (50)	unscrew, screw on, replace (numbers 7, 15) 60-65 Nm.
   Pitman arm shaft (43)	press out of steering gear housing with pitman arm shaft/bearing cover (51) by turning adjusting screw clockwise (number 8, pay attention to center position). After installing pitman arm shaft, check friction torque of steering gear and adjust (number 14).
   O-rings (56 and 58)	replace, ensure correctly fitted (number 10).

   Special tools 

   Fig 2: Identifying Special Tools (140 589 00 59 00 46)

   
   Fig 3: Identifying Special Tools (001 589 67 21 00 00)

   
   Fig 4: Identifying Special Tools (000 589 88 33 00 00)

   
   Fig 5: Identifying Special Tools (201 589 06 21 00 40 46)

   

   

   Pay attention to "Important notes regarding repair of steering gear" (46-0230)

   Removal 

   1. Attach steering gear to the assembly support 140 589 00 59 00 with two bolts and clamp in vise.
      Fig 6: Identifying Steering Gear And Special Tool

      
   2. Measure distance "a" between pitman arm (12) and pitman arm shaft/bearing cover (51) and note size "a".
      Fig 7: Identifying Distance Between Pitman Arm (12) And Pitman Arm Shaft/Bearing Cover (51)

      
   3. Take off locking ring (16). Unscrew nut (14a) and take off bolt (14).
      Fig 8: Identifying Pitman Arm, Steering Gear And Locking Ring

      
   4. Pull pitman arm (12) off pitman arm shaft, use puller 000 589 88 33 00, if necessary.
      Fig 9: Identifying Special Tools And Pitman Arm (12)

      
   5. Turn steering gear into center position  by unscrewing bolt (62) and screwing in center position inspection bolt 201 589 06 21 00.

      

      If the steering gear is not in the center position, the steering gear housing will be damaged on the inside when pressing out the pitman arm shaft together with bearing cover/pitman arm shaft.

      Fig 10: Identifying Bolt And Snap Ring

      

      Position steering gear with external centering (as of 1/90) to mark (arrows).

      Fig 11: Identifying Steering Gear With External Centering Position Mark

      
   6. Unscrew self-locking bolts (59) for attaching pitman arm shaft/bearing cover (51).
      Fig 12: Identifying Self-Locking Bolts (59) And Pitman Arm Shaft/Bearing Cover (51)

      
   7. Unscrew collar nut from adjusting screw, holding adjusting screw tight.
      Fig 13: Identifying Adjusting Screw And Special Tool

      
   8. With steering in center position  , turn adjusting screw clockwise; this causes the pitman arm shaft (43) to be pressed out of the steering gear housing together with the bearing cover/pitman arm shaft (51).
      Fig 14: Identifying Pitman Arm Shaft (43) And Bearing Cover/Pitman Arm Shaft (51)

      

      Installation 

   9. Turn steering worm so that the center tooth gap of the power piston (arrow) is positioned in the middle of the opening in the steering gear housing.
      Fig 15: Identifying Tooth Gap Of Power Piston

      
   10. Replace O-rings. Introduce pitman arm shaft/bearing cover (51) together with pitman arm shaft into the steering gear housing so that the center tooth of the pitman arm shaft meshes into the middle tooth gap of the power piston. Ensure that the O-rings are properly seated (arrow).
   11. Turn pitman arm shaft/bearing cover (51) so that oil passage and bore are aligned with those of the steering gear.
       Fig 16: Locating Proper Position Of O-Rings

       
   12. Screw adjusting screw (45) into the steering gear housing far enough for it to make contact. Unscrew center position inspection bolt and fit screw plug with new seal (35-40 Nm).
       NOTE: Only by screwing in the adjusting screw is it ensured that the pitman arm shaft/bearing cover rests against the steering gear housing.
       Fig 17: Identifying Adjusting Screw (45)

       
   13. Tighten pitman arm shaft/bearing cover (51) with new self-locking bolts (59), (30-35 Nm).
       Fig 18: Identifying Self-Locking Bolts (59) And Pitman Arm Shaft/Bearing Cover (51)

       
   14. Check, adjust friction torque of steering gear (46-0120) .
       NOTE: A slight pressure point must be felt when turning beyond the center position. The steering gear must move freely when the steering shaft is turned from lock to lock.
       Fig 19: Identifying Special Tool And Steering Gear

       
   15. Screw collar nut onto the adjusting screw and tighten to 60-65 Nm, holding the adjusting screw tight.
   16. Re-check friction torque (46-0120) .
       Fig 20: Identifying Adjusting Screw And Special Tool

       
   17. Clean shaft spline on the pitman arm shaft and on the pitman arm (12). Both parts must be free of oil and grease.

       Coat  shaft spline of pitman arm with Loctite 270  . Then, push pitman arm shaft to size "a" measured in number 2 on to the pitman arm shaft in line with the cross nut.

   18. Insert bolt (14). Replace nut (14a), 55 Nm.
   19. Install new locking ring (16). Ensure it is correctly seated.
   20. Detach steering gear from assembly support.
       Fig 21: Identifying Locking Ring (16), Pitman Arm (12), Bolt (14) And Nut (14a)

       
2. Steering gear with adjusting screw below, models 124.034/036, 129 and 140 
   Fig 22: Identifying Steering Gear Components With Adjusting Screw Below (Models 124.034/036)

   

   Steering gear (1)	attach on assembly support 140 589 00 59 00 with two bolts and clamp in vise (number 1).
   Distance "a" between pitman arm (12) and pitman arm shaft/bearing cover (51)	measure and note size "a" (number 2).
   Locking ring (16)	detach, attach, replace (number 3).
   Pitman arm (12)	pull off, by unscrewing nut (14a) and taking off bolt (14) (numbers 3-5). When installing, coat pitman arm shaft and pitman arm with Loctite 270 and fit on to the measured size "a". Install new nut (14a) and bolt (14), 55 Nm (numbers 20, 21).
   Pitman arm shaft (43)	turn into center position (number 4).
   Self-locking bolts (59)	unscrew, screw in, replace (numbers 6, 16) 30-35 Nm.
   Self-locking collar nut (50)	unscrew, screw on, replace (numbers 7, 18) 60-65 Nm.
   Pitman arm shaft (43)	press out of the steering gear housing with the pitman arm shaft/bearing cover (51) by turning the adjusting screw (45) clockwise. (Number 9, pay attention to center position). After installing pitman arm shaft, check and adjust friction torque of steering gear (number 17).
   Needle bearing in steering gear housing	check whether any bearing needles have dropped out (32 needles); insert bearing needles with grease, if necessary (number 10).
   Shop-made assembly mandrel (090)	insert in steering gear (number 11).
   O-rings (56 and 58)	replace, ensure correctly fitted (number 13).

   Special tools 

   Fig 23: Identifying Special Tools (140 589 00 50 00 46)

   
   Fig 24: Identifying Special Tools (001 589 67 21 00 00)

   
   Fig 25: Identifying Special Tools (000 589 88 33 00 00)

   

   Shop-made tool 

   Mandrel (090).

   Fig 26: Identifying Shop-Made Tool

   

   

   Pay attention to "Important notes regarding repair of steering gear" (46-0230).

   Removal 

   1. Mount steering gear on assembly support 140 589 00 59 00 with two bolts and clamp in vise.
      Fig 27: Identifying Steering Gear And Special Tool

      
   2. Measure distance "a" between pitman arm (12) and pitman arm shaft/bearing cover (51) and note size "a".
      Fig 28: Identifying Distance Between Pitman Arm (12) And Pitman Arm Shaft/Bearing Cover (51)

      
   3. Take off locking ring (16). Unscrew nut (14a) and take off bolt (14).
   4. Turn steering into center position so that markings are aligned (arrow).

      

      If the steering gear is not in the center position, the steering gear housing will be damaged internally when pressing out the pitman arm shaft with the bearing cover/pitman arm shaft.

      Fig 29: Locating Steering Gear Center Position

      
   5. Pull pitman arm (12) off the pitman arm shaft, use puller 000 589 88 33 00, if necessary.
      Fig 30: Identifying Special Tools And Pitman Arm (12)

      
   6. Unscrew self-locking bolts (59) for attaching pitman arm shaft/bearing cover (51).
      Fig 31: Identifying Self-Locking Bolts (59) And Pitman Arm Shaft/Bearing Cover (51)

      
   7. Unscrew collar nut (50) from the adjusting screw (45), holding adjusting screw (45) tight.
      Fig 32: Identifying Collar Nut (50) And Adjusting Screw (45)

      
   8. Rotate assembly support 140 589 00 59 00 so that the pitman arm shaft is positioned vertically.
   9. With steering in center position  , turn adjusting screw (45) clockwise; this causes the pitman arm shaft (43) together with the pitman arm shaft/bearing cover (51) to be pressed out of the steering housing (1).
      Fig 33: Turning Adjusting Screw

      
   10. Examine the needle bearing (99) and the O-ring located behind it for signs of damage and wear. Ensure that none of the 32 bearing needles drops out of the needle bearing; insert bearing needles with grease if necessary.
   11. Prevent the bearing needles in the steering gear housing from dropping out by pushing the shop-made mandrel (090) over the adjusting screw and securing with the collar nut.
       NOTE: A needle bearing with cage has been installed as of approx. 6/92.
       Fig 34: Identifying Adjusting Screw (45) And Needle Bearing (99)

       
       Fig 35: Identifying Needle Bearing (99) And Shop-Made Mandrel (090)

       

       Installation 

   12. Rotate steering worm so that the middle tooth gap of the power piston (arrow) is located in the center of the opening in the steering gear housing.
       Fig 36: Identifying Tooth Gap Of Power Piston

       
       NOTE: On steering gear 765.94 (model 140), turn the steering worm until the center tooth flank (arrow) is in the center of the opening in the steering gear.
       Fig 37: Identifying Steering Gear Center Tooth Flank

       
   13. Replace O-rings. Introduce pitman arm shaft/bearing cover (51) together with pitman arm shaft into the steering gear housing so that the center tooth of the pitman arm shaft meshes into the middle tooth gap of the power piston. Ensure that the O-rings are correctly seated.
   14. Rotate pitman arm shaft/bearing cover (51) so that oil passage and bore are aligned with those of the steering gear.
       Fig 38: Locating Proper Position Of O-Rings

       
   15. Turn adjusting screw (45) in the pitman arm shaft (43) far enough to the left for the pitman arm shaft to be making contact in the steering gear housing.
       NOTE: Only by screwing in the adjusting screw (45) is it ensured that the pitman arm shaft/bearing cover is touching the steering gear housing.
       Fig 39: Turning Adjusting Screw

       
   16. Tighten pitman arm shaft/bearing cover (51) with new self-locking bolts (59)

       Tightening torque 30-35 Nm.

       Fig 40: Identifying Self-Locking Bolts (59) And Pitman Arm Shaft/Bearing Cover (51)

       
   17. Test and adjust friction torque of the steering gear (46-0120) .
       NOTE: A slight pressure point must be felt when rotating beyond the center point. The steering gear must operate easily when the steering worm is turned from lock to lock.
       Fig 41: Identifying Special Tool And Steering Gear

       
   18. Screw collar nut (50) onto the adjusting screw (45) and tighten to 60-65 Nm, holding the adjusting screw (45) tight.
   19. Re-check friction torque (46-0120) .
       Fig 42: Identifying Collar Nut (50) And Adjusting Screw (45)

       
   20. Clean shaft spline of the pitman arm shaft and pitman arm (12). Both parts must be free of oil and grease.

       Coat  shaft spline of pitman arm (12) with Loctite 270  . Then, push pitman arm onto the pitman arm shaft to the size "a" measured in number 2 in line with the cross nut.

       Fig 43: Identifying Locking Ring (16), Pitman Arm (12), Bolt (14) And Nut (14a)

       
   21. Push in bolt (14). Replace nut (14a), 55 Nm.
   22. Install new locking ring (16). Ensure it is correctly seated.
   23. Detach steering gear from assembly support.
       Fig 44: Identifying Locking Ring (16), Pitman Arm (12), Bolt (14) And Nut (14a)