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Home >> Mercedes Benz >> 2006 >> CL500 >> Repair and Diagnosis >> Steering >> Power Steering >> Steering -- Testing & Repair -- 215 & 220 Chassis >> Testing & Repair >> Replace bottom radial shaft sealing ring on control head - AR46.20-P-0003Q

Replace bottom radial shaft sealing ring on control head - AR46.20-P-0003Q

MODEL 203, 209 except CODE (213) Speed-sensitive power steering 

MODEL 215, 220 

Shown on model 209 

Fig 1: Identifying Inner Tie Rods Axial Joint, Bellows And Clamps - Shown On Model 209
G04737126

Shown on model 209 

Fig 2: Identifying Oil Line, Adjusting Screw And Bolts - Shown On Model 209
G04737127

Shown on model 209 

Fig 3: Identifying Stop Plate, Sap, Bolts And Control Head - Shown On Model 209
G04737128

Shown on model 209 

Fig 4: Identifying Steering Gear Housing, Stud Bolt And Disk Spring - Shown On Model 209
G04737129

Shown on model 209 

Fig 5: Identifying Steering Gear Housing And Stop Ring - Shown On Model 209
G04737130
Fig 6: Locating Grease Gap And Mark On Control Head
G04737131
MODIFICATION NOTES

20.1.04 Due to tight tolerances the vehicle does not have to be measured anymore after replacing the lower radial sealing ring    
REMOVINGINSTALLING Remove/install    
DANGER 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
DANGER 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
1 Remove rack-and-pinion steering Model 203 except models 203.081/084/281/284, model 209 AR46.20-P-0600P
    Model 203.081/084/281/284 AR46.20-P-0600PW
    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 220.083/084/087/183/184/187 AR46.20-P-0600IW 
    Model 220.176/179 AR46.20-P-0600M 
2 Mount rack-and-pinion steering into steering gear housing mounting device IMPORTANT Ensure that the workplace is scrupulously clean when carrying out the work described below and while performing repairs!
Only the specified tools may be used!
Before starting repair, remove loose dirt from steering gear without using cleaning agent!		  
    SPECIAL TOOL Steering gear housing support *203589043100
3 Remove clamps (1) of both bellows (2) IMPORTANTInstallation:  Replace clamps (1).  
4 Push outer clamps together and slide bellows (2) towards the tie rod end    
5 Detach inner tie rods with axial joint (3) NOTES Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint (3) will be damaged.
IMPORTANT Secure the steering rack to prevent it from twisting and counter with a 22 mm open wrench.		  
    TORQUE SPECIFICATION Inner track rod with axial joint to rack-and-pinion steering *BA46.40-P-1003-01E 
    SPECIAL TOOL Open-end wrench Figure
    SPECIAL TOOL Torque wrench Fig 14
DISASSEMBLING Disassemble     
6 Remove bolts (4)    
7 Remove screw (5)    
8 Detach oil lines (6)    
9 Unscrew adjusting screw (7) IMPORTANT Mark the position before unscrewing the adjusting screw (7).  
10 Take out push spring IMPORTANT The thrust piece can remain in the steer jacket (14).  
11 Mount stop plates (8) at left and right to the rack-and-pinion    
12 Remove cap (9)    
13 Remove screws (10)    
14 Turn in studs (11) NOTES To remove the control head (12) the stud (11) must be screwed in in order not to damage the radial shaft sealing ring (13) and tooth flanks.
IMPORTANT The stud (11) can be shop-made (M8x50 mm).		  
15.1 Rotate input shaft clockwise Left hand drive vehicle steering
IMPORTANT Turn clockwise until the stop plate (8) abuts the steer jacket (14).		  
    SPECIAL TOOL Socket wrench Fig 8
15.2 Rotate input shaft anti-clockwise Right hand drive vehicle steering
IMPORTANT Turn counterclockwise until the stop plate (8) abuts the steer jacket (14).		  
    SPECIAL TOOL Socket wrench Fig 8
16 Continue pressing with light pressure against the stop IMPORTANT Until the control head (12) with input shaft lifts off the steer jacket (14).  
17 Remove control head (12) NOTES The control head (12) must be removed with the input shaft in order to avoid damage to the control head (12).  
18 Remove spring washer (15)    
19 Unscrew stud (11)    
20 Remove oil which has leaked into control head (12) from rack-and-pinion steering. NOTES In order to rule out contamination, do not use any cleaning agents, shop towels or cleaning cloths, as the function can be impaired if the gear rack is exposed to dirt.
IMPORTANT Turn rack-and-pinion steering with opening facing downwards and allow oil to drain out.		  
21 Remove radial shaft sealing ring (13). NOTES Do not attach the puller to the thread and not too far inside so that the thread and seat of the O-ring are not damaged.  
    SPECIAL TOOL Puller dia. 28 to 37 mm *000589283300
    SPECIAL TOOL Countersupport *000589333300
ASSEMBLING Assemble     
22 Grease outer surface of the radial shaft sealing ring (13) IMPORTANT Use a finger to coat MB-multipurpose grease. Do not use any other aid.  
    MB multipurpose grease *BR00.45-Z-1017-06A 
23 Drive in radial shaft sealing ring (13) NOTES Check drift and guide sleeve are correctly seated, as otherwise the radial shaft sealing ring (13) will be damaged.
IMPORTANT Pay attention to correct installation position of radial shaft sealing ring (13).		  
    SPECIAL TOOL Drift *210589051500
    SPECIAL TOOL Guide sleeve *210589011400
24 Grease inner lip of radial shaft sealing ring (13) IMPORTANT Use a finger to coat MB-multipurpose grease. Do not use any other aid.  
    MB multipurpose grease *BR00.45-Z-1017-06A 
25 Insert spring washer (15) IMPORTANT Insert spring washer (15) with the curvature towards the steer jacket (14).  
26 Turn in studs (11) NOTES The studs (11) must be turned in to install the control head (12), in order to avoid any damage to the radial shaft sealing ring (13) and tooth flanks.  
27 Slide in control head (12) as far as possible. NOTES Replace O-ring, in order to avoid leakage.  
28.1 Rotate input shaft anti-clockwise Left hand drive vehicle steering
NOTES Turn carefully! Teeth faces can be damaged. *
IMPORTANT Turn to the left until the bearing of the input shaft is located in the guide in the steer jacket (14).		  
    SPECIAL TOOL Socket wrench Fig 8
28.2 Rotate input shaft clockwise Right hand drive vehicle steering
NOTES Turn carefully! Teeth faces can be damaged. *
IMPORTANT Turn to right, until the input shaft bearing is positioned in the guide in the steer jacket (14).		  
    SPECIAL TOOL Socket wrench Fig 8
29 Unscrew stud (11)    
30 Screw in screws (10) IMPORTANT Turn in gradually to avoid any tilting.
MODEL 203, 209		  
    TORQUE SPECIFICATION Control head to steering housing
Model 215, 220		 *BA46.20-P-1008-01F 
    TORQUE SPECIFICATION Control head to steering housing *BA46.20-P-1012-01E 
31 Move steering rack to center position IMPORTANT Dismantle the stop plate (8) on both sides of the steering rack. Use depth gauge to determine center position. Balance out the gaps from the end of the steering rack to the stop ring (16) in the steer jacket (14) on both sides of the steering rack.  
32 Grease gap between input shaft and control head (12) (arrow) IMPORTANT Use a finger to coat MB-multipurpose grease. Do not use any other aid.  
    MB multipurpose grease *BR00.45-Z-1017-06A 
33 Slide on covering cap (9) IMPORTANT The marking on the cap (9) must match the marking on the control head (12) (arrow).  
34 Install oil lines (6) NOTES Replace O-rings in order to avoid leakage.  
35 Screw in bolt (5) Model 203, 209  
    TORQUE SPECIFICATION Oil line to control head
Model 215, 220		 *BA46.20-P-1009-01F 
    TORQUE SPECIFICATION Oil line to control head *BA46.20-P-1013-01E 
36 Screw in screws (4) NOTES Observe tightening torque, as otherwise the steer jacket (14) will be damaged.
Model 203, 209		  
    TORQUE SPECIFICATION Oil line to steering housing
Model 215, 220		 *BA46.20-P-1010-01F 
    TORQUE SPECIFICATION Oil line to steering housing *BA46.20-P-1014-01E 
37 Insert push spring IMPORTANT On model 203 up to steering gear number 203460110001088##### (LHD standard) 203460250001088##### (RHD standard) replace the thrust piece.  
38 Screw in adjusting screw (7)    
39 Setting play between thrust element and steering rack   AR46.20-P-0601P 
40 Check rack for easy motion by turning manually.    
41 Install in the reverse order    
42 Check rack-and-pinion steering for proper function. * IMPORTANT Turn steering wheel several times from lock to lock. Check oil level in steering. Check steering leaktightness. Check steering function at slow and fast cornering.  
TORQUE SPECIFICATION STEERING GEAR

Number Designation Model 215 Model 220.025/026/ 028/063/065/ 067/070/073/ 074/075/125/ 126/128/163/ 165/167/170/ 173/174/175/ 176/178/179/ 875/878 Model 220.083/084/ 087/183/ 184/187
BA46.20-P-1012-01E Control head to steer jacket Nm 18 (±2) 18 (±2) 18 (±2)
BA46.20-P-1013-01E Oil line to control head Nm 28 (±8) 28 (±8) 28 (±8)
BA46.20-P-1014-01E Oil line to steer jacket Stage 1 Nm 100 100 100
2nd stage, loosen ∠ ° -20 -20 -20
Stage 3 Nm 90 90 90
TORQUE SPECIFICATION STEERING GEAR

Number Designation Model 203 except 203.081/ 084/087/ 092/281/284/287/292 Model 203.081/ 084/087/ 092/281/ 284/287/ 292 Model 209
BA46.20-P-1008-01F Control head to steer jacket Nm 18 (±2) 18 (±2) 18 (±2)
BA46.20-P-1009-01F Oil line to control head Nm 18 (±2) 18 (±2) 18 (±2)
BA46.20-P-1010-01F Oil line to steer jacket Stage 1 Nm 100 100 100
2nd stage, loosen ∠ ° -20 -20 -20
Stage 3 Nm 90 90 90
TORQUE SPECIFICATION TIE ROD

Number Designation Model 203 except 203.081/ 084/281/ 284 Model 203.081/084/281/284 Model 209
BA46.40-P-1003-01E Inner track rod with axial joint to rack-and-pinion joint Nm 110 110 110
TORQUE SPECIFICATION TIE ROD

Number Designation Model 215 Model 220 except model 220.083/ 084/087/ 183/184/ 187 Model 220.083/ 084/087/ 183/184/ 187
BA46.40-P-1003-01E Inner track rod with axial joint to rack-and-pinion joint Nm 110 110 110
Fig 7: Identifying Steering Gear Housing Support (203 589 04 31 00)
G04737132
Fig 8: Identifying Socket Wrench (203 589 04 31 03)
G04737133
Fig 9: Identifying Open End Wrench (201 589 00 01 00)
G04737134
Fig 10: Identifying Drift (210 589 05 15 00)
G04737135
Fig 11: Identifying Guide Sleeve (210 589 01 14 00)
G04737136
Fig 12: Identifying Puller, Dia. 28-37 Mm (000 589 28 33 00)
G04737137
Fig 13: Identifying Counter Stay (000 589 33 33 00)
G04737138
Fig 14: Identifying Torque Wrench (001 589 67 21 00)
G04737139
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1017-06A MB multipurpose grease A 001 989 34 51 11
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