Rattling/rumbling noises and/or play on control head side on rack-and-pinion steering and/or knocking noises when steering wheel is reversed quickly - AF46.20-P-9221AG

MODEL 203, 209, 211, 215, 220 

MODIFICATION NOTES

2.3.06

Operation step 6 revised, parts ordering notes updated

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category	Op. no.	Operation text
P	463400	Remove/install power steering
P	464350	Check play between thrust piece and toothed rack (Steering removed)
P	464355	Adjust play between thrust piece and toothed rack (Steering removed)

Damage code	Cause	Remedy
46 481 17	Play between toothed rack and thrust piece too high or wear to installed plastic thrust piece.	1 Remove rack-and-pinion steering.
	Rattling/rumbling noises from area of steering can be heard and, in some cases, felt on rough roads.	Model 203 (except 203.081 /084 /281 /284) Model 209.3 /4	AR46.20-P-0600P
	Knocking noise from area of steering when direction left/right is changed quickly, as a rule, only perceivable while standing with engine running.	Model 203.081 /084 /281 /284	AR46.20-P-0600PW
		Model 211.080 /082 /083 /087 /092 / 280 /282 /283 /287 /292, 220.083 /084 / 087 /183 /184 /187	AR46.20-P-0600IW
		Model 215.373 /374 /375 /376 /378 /379, 220.025 /026 /028 /063 /065 /067 /070 / 073 /074 /075 /125 /126 /128 /163 /165 / 167 /170 /173 /174 /175 /178 /875 /878	AR46.20-P-0600I
		Model 220.176/ 179	AR46.20-P-0600M
		2 Check thrust piece clearance.	AR46.20-P-0601P
		Bracket	Figure
		Dial indicator	Fig 2
		Steering gear housing support	Figure
		Torque wrench	Fig 4
		3 Check steering number to determine which thrust piece is installed.
		Only affects model 203!  If a plastic thrust piece is installed up to steering gear number: 20346011000108858549 (left-hand drive vehicle, standard steering) 20346013000026202953 (left-hand drive vehicle, parameter steering) 20646025000108800123 (right-hand drive vehicle, standard steering) 20346027000035000662 (right-hand drive vehicle speed-sensitive power steering) ↓
		4 Replace thrust piece with aluminum thrust piece and adjust clearance accordingly.	AR46.20-P-0601P
		Bracket	Figure
		Dial indicator	Fig 2
		Steering gear housing support	Figure
		Torque wrench	Fig 4
		If aluminum thrust piece is installed (i.e. as of steering gear number specified above): ↓
		5 Adjust clearance between toothed rack and thrust piece.	AR46.20-P-0601P
		Bracket	Figure
		Dial indicator	Fig 2
		Steering gear housing support	Figure
		Torque wrench Radial clearance of up to +/-0.08 mm at the thrust piece is OK and does not lead to any negative effect to the function.*	Fig 4
		6 Install rack-and-pinion steering.
		Model 203 (except 203.081 /084 /281 /284) Model 209.3 /4	AR46.20-P-0600P
		Model 203.081 /084 /281 /284	AR46.20-P-0600PW
		Model 211.080 /082 /083 /087 /092 / 280 /282 /283 /287 /292, 220.083 /084 / 087 /183 /184 /187	AR46.20-P-0600IW
		Model 215.373 /374 /375 /376 /378 /379, 220.025 /026 /028 /063 /065 /067 /070 / 073 /074 /075 /125 /126 /128 /163 /165 / 167 /170 /173 /174 /175 /178 /875 /878	AR46.20-P-0600I
		Model 220.176 /179 There are two versions of servo high pressure lines. The old version has a slotted support ring which can be exchanged separately. The new version has a support ring without slots. If the support ring in this version is damaged, the complete servo high pressure line must be replaced (see parts list).	AR46.20-P-0600M
		According to recent experience, chassis alignment is not required.
		Service Information: Omission of the complete chassis alignment after work has been done on the rack-and-pinion steering system.	SI46.20-P-0004A

Fig 1: Identifying Bracket (203 589 03 31 00)

Fig 2: Identifying Dial Gage (001 589 53 21 00)

Fig 3: Identifying Steering Gear Housing Support (203 589 04 31 00)

Fig 4: Identifying Torque Wrench (001 589 72 21 00)

PARTS ORDERING NOTES

Part no.	Designation	Quantity
A 203 460 04 23	Only affects model 203!  Rep. kit, thrust piece To be used only up to steering gear number 20346011000108858549 (left-hand drive vehicle, standard steering) 20346013000026202953 (left-hand drive vehicle, parameter steering) 20646025000108800123 (right-hand drive vehicle, standard steering) 20346027000035000662 (right-hand drive vehicle, parameter steering)	1
A 001 989 38 51 10	Special grease	1
N 910 113 014 000	Nut M14	2
N 000 000 003 281	Nut M14x1.5	2
A 005 997 76 40	High pressure line support ring	1
A 203 628 00 11	Tapping plate	1
A 140 990 09 58	Nut, steering coupling	1
A 210 463 07 17	Clip	1
A 210 988 01 28	Plug	1
A 005 997 76 40	High pressure line support ring, not valid for model 215/220. For model 171/203/209, high pressure line support ring is also required for high pressure line connection on steering gear. Model 171 up to VIN F 117 329, model 203 up to VIN A 832 192, model 203/209 up to VIN F 740 620. If the support ring is damaged on vehicles as of the above-mentioned VIN, the complete high pressure line must be replaced. The support ring can no longer be replaced separately.	1
A 015 997 22 45	Sealing ring of servo high pressure and low pressure line, Model 171/203/209/211 Support ring can be retrofitted on all servo high pressure lines with support ring (with and without slots) and on all servo low pressure lines.	2
A 028 997 32 48	Sealing ring of high pressure/low pressure line, Sealing ring of high pressure/low pressure line on steering gear, only model 203 (only with high pressure line without support ring) and model 215/220 left-hand drive vehicles	2
A 028 997 64 48	Sealing ring of high pressure/low pressure line, Sealing ring of high pressure/low pressure line on steering gear, only model 220 right-hand drive vehicles	2