Remove/install rack-and-pinion steering - AR46.20-P-0600P

MODEL 203 (except 203.081 /084 /087 /092 /281 /284 /287 /292) 

MODEL 209 

Fig 1: Identifying Rack-And-Pinion Steering Remove/Install Components - Model 203 (Except 203.081 /084 /087 /092 /281 /284 /287 /292)

	Removing
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Evaluating steering rack when repairing accident vehicles		AH46.20-P-9409-01A
1	Remove front wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
2	Extract fluid out of the power steering pump's fluid reservoir	Hand pump	Fig 2
3	Extend or pull out adjustable steering column fully	Needed for separating the steering coupling (25).
4	Deactivate easy entry/exit function	Vehicles with memory package (driver's seat, steering column, mirrors) code 275 Otherwise the driver's seat and steering wheel move to a different position, e.g. when the driver door is opened/closed. The upper frame may be damaged when the holding device is installed. It is switched off using the buttons on the steering wheel in the "Comfort" menu on the multifunction display, see vehicle owner's manual.
5	Turn steering wheel to central position (front wheels in straight ahead position) and secure with the retaining device	On a disengaged steering coupling (25) the steering wheel should not be turned because the spiral contact coil will be destroyed.
		Retainer	Figure
6.1	Remove lower engine compartment paneling	Model 203 with engine 111, 112, 113, 271, 272, 612.990 Model 209 with engine 112, 113, 156, 271, 272, 273	AR61.20-P-1105P
6.2	Remove bottom sections of soundproofing capsule	Model 203 with engine 611, 612, 642, 646 except 612.990 Model 209 with engine 612, 642, 646	AR94.30-P-5300P
7	Remove diagonal strut at left and right front	Model 209.4 Installation:  The diagonal struts may only be fitted when the vehicle is standing with the wheels on the ground.
			*BA62.30-P-1004-01A
8	Press tie rod joints (10a) off steering knuckles		AR46.40-P-0200-02I
		Thrust piece	Fig 5
		Puller	Fig 6
9	Remove exhaust shielding plate (105d) to front plate over steering coupling (25)
10	Undo bolt for steering coupling to steering shaft (25a)
11	Pull the lower steering shaft (80a) upward to extract it from the steering coupling (25)	Do not use force (hammer blows, strong lever action) because the lower steering shaft (80a) is sensitive to lateral dynamic force and can be damaged.
12	Detach oil lines to rack-and-pinion steering (23)
13	Remove support bracket (1g) to front axle carrier (1)	To do so undo bolts for support bracket to front axle carrier (23a, 23b).
14	Detach electrical connector to rack-and-pinion steering (23)	Vehicles with speed-sensitive power steering, code 213
15	Undo bolts for rack-and-pinion steering to front axle carrier (23g)
16	Detach oil line retaining plate (23q) from rack-and-pinion steering (23) and pull out oil lines.	Seal off line connections with plugs.
		Set of stop plugs	Fig 3
17	Remove threaded hole plate (23n) of rack-and-pinion steering (23)
18	Remove rack-and-pinion steering (23)
19	Check rubber mount (21) of rack-and-pinion steering mounting for signs of damage.	Damaged rubber mounts (21) must be replaced: ↓
		Remove/install rubber mount of rack-and-pinion mounting.	AR46.20-P-0600-02I
		Lubricant	*BR00.45-Z-1002-06A
20	Check protective cap on input shaft of rack-and-pinion steering (23) for damage	Replace if necessary: ↓
		Remove/install protective cap for input shaft on steering gear.	AR46.20-P-0004P
	Install
21	Insert threaded hole plate (23n) of rack-and-pinion steering (23)	Replace threaded hole plate (23n).
22	Insert rack-and-pinion steering (23) and fasten to front axle carrier (1) using bolts for rack-and-pinion steering to front axle carrier (23g)	The bolts for the rack-and-pinion steering to the front axle carrier (23g), threaded hole plate (23n) and the area around the bolted connections must be free of oil and grease. Under exposure to heat the lubricants can liquefy, allowing bolts and nuts to loosen.
			*BA46.20-P-1002-01F
23	Mount support bracket (1g) using bolts for support bracket to front axle carrier (23a)	The bolts for the support bracket to the front axle carrier (23a), threaded hole plate (23n) and the area around the bolted connections must be free of oil and grease. Under exposure to heat the lubricants can liquefy, allowing bolts and nuts to loosen.
			*BA46.20-P-1003-01F
24	Mount support bracket (1g) using bolts for support bracket to front axle carrier (23b)
25	Insert oil lines and mount retaining plate for oil lines (23q) to rack-and-pinion steering (23)	Replace O-rings to prevent any escape of oil.
			*BA46.20-P-1001-01F
26	Mount oil lines onto rack-and-pinion steering (23)	Front left and right side
27	Mount steering coupling (25)	To do so turn rack-and-pinion steering (23) to center position.	AR46.20-P-0600-01P
28	Push on new locking plate (25f)	Until the lug latches into the steering coupling (25).
29	Push lower steering shaft (80a) as far as possible into steering coupling (25)	Do not use force (hammer blows, strong lever action) because the lower steering shaft (80a) is sensitive to lateral dynamic force and can be damaged. When doing so observe the steering coupling (25) journal and the groove of the lower steering shaft (80a) (arrows).
30	Turn in bolt for steering coupling to steering shaft (25a)		*BA46.10-P-1001-01E
31	Mount exhaust shielding plate (105d) to front plate under steering coupling (25)
32	Mount tie rod joints (10a) onto steering knuckles		AR46.40-P-0200-02I
			*BA46.40-P-1001-01E
33	Fill power steering pump and bleed	Except model 203.2 with rear axle level control system, code 480	AR46.30-P-0010P
34	Check steering for function and leaks	There is a grease cushion under the cover cap. A slight escape of grease is to be regarded as normal and should not be confused with leakage.
35	Mount front wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
36	Check front axle toe and adjust if necessary	When installing new parts. see: ↓
		Perform chassis alignment	AR40.20-P-0200P
37.1	Install lower engine compartment paneling	Model 203 with engine 111, 112, 113, 271, 272, 612.990 Model 209 with engine 112, 113, 156, 271, 272, 273	AR61.20-P-1105P
37.2	Install bottom section of soundproofing	Model 203 with engine 611, 612, 642, 646 except 612.990 Model 209 with engine 612, 642, 646	AR94.30-P-5300P

CROSSMEMBER AND FRONT REINFORCEMENT

STEERING SHAFT

STEERING GEAR

TIE ROD

Fig 2: Identifying Hand Pump (210 589 00 71 00)

Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)

Fig 4: Identifying Retainer (129 589 01 21 00)

Fig 5: Identifying Thrust Piece (140 589 00 63 00)

Fig 6: Identifying Puller (124 589 03 33 00)