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Only one adjustment procedure for the rack-and-pinion steering is permissible. Should several caulkings (center punch marks) be visible on the adjustment screw (2), it is assumed that an adjustment procedure has already been performed, in this case the rack-and-pinion steering should be replaced. |
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| 1 |
Remove rack-and-pinion steering |
Model 203 with 4-MATIC |
AR46.20-P-0600PW |
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Model 203 without 4-MATIC, 209 |
AR46.20-P-0600P |
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Model 211 without 4-MATIC |
AR46.20-P-0600T |
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Model 211 and model 220 with 4-MATIC |
AR46.20-P-0600IW |
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Model 215, 220 without 4-MATIC except model 220.176/ 179 |
AR46.20-P-0600I |
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Model 220.176/ 179 |
AR46.20-P-0600M |
| 2 |
Mount the rack-and-pinion steering on the steering gear housing support |
Ensure that the workplace is scrupulously clean when carrying out the work described below and while performing repairs!
Only the specified tool may be used! Before the start of repair remove loose contamination without using cleaning agent on the steering gear housing (14) |
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*203589043100 |
| 3 |
Remove inner clamps from both bellows |
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| 4 |
Press together the outer clamps of the two bellows and move bellows outwards towards the tie rod ends |
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| 5 |
Detach both inner tie rods with axial joints |
Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint will be damaged.
Secure the gear rack (4) with an open wrench to prevent twisting. |
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Figure |
| 6 |
Screw the stop plates (1) on the left and right into the gear rack (4) |
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| 7 |
Grease steering rack (4) |
Renolit JP1619 special grease |
*BR00.45-Z-1067-06A |
| 8 |
Crank gear rack (4) several times using socket wrench |
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Figure |
| 9 |
Move steering rack (4) to center position |
The gear rack must be exactly in the center position, to avoid falsifying the test result.
Detach the stop plates (1) on both sides of the gear rack. Find the middle position using a depth gauge. 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. |
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| 10 |
Pull rubber plug carefully out of the adjusting screw (2) |
Do not damage rubber plug when pulling out. |
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Checking |
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| 11 |
Mount bracket and dial indicator on the steering gear housing (14) over the adjustment screw (2) |
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*203589033100 |
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*001589532100 |
| 12 |
Using the dial indicator, check the play between the gear rack (4) and thrust piece (3) |
To do this, crank the gear rack in the direction of the arrow. In the process the specified test torque of the toothed rack must not be exceeded, otherwise the inner compression spring will be damaged.
Test torque: |
*BE46.20-P-1001-01C |
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Model 203, 209, 211 |
*BA46.20-P-1006-01F |
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Model 215, 220
The gear rack must be exactly in the center position, to avoid falsifying the test result.
Further procedure after determining an unacceptable play between the toothed rack and thrust piece on model 211, 215, 220:
- Play less than 0.04 mm: Adjust play.
- Play 0.09 to 0.6 mm: Adjust Play.
- Play greater than 0.6 mm: Replace rack-and-pinion steering.
Further procedure after determining an unacceptable play between the toothed rack and thrust piece on model 203, 209, :
- Play less than 0.04 mm: Adjust play.
- Play 0.09 to 0.3 mm: Adjust Play.
- Play 0.3 to 0.6 mm: Replace thrust piece.
- Play greater than 0.6 mm: Replace rack-and-pinion steering.
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*BA46.20-P-1010-01E |
| 13 |
Detach bracket and dial indicator from steering gear housing (14) |
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Adjust play between rack-and-pinion steering and thrust piece (3) |
Perform work steps 14 to 21 only if necessary. |
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| 14 |
Move steering rack (4) to center position |
The gear rack must be exactly in the center position, to avoid falsifying the test results and any associated incorrect adjustment.
Detach the stop plates (1) on both sides of the gear rack. Find the middle position using a depth gauge. 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. |
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| 15 |
Tighten adjusting screw (2) on block |
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| 16 |
Slacken adjusting screw (2) approx. 1/8 turn |
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| 17 |
Mount bracket and dial indicator on the steering gear housing (14) over the adjustment screw (2) |
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| 18 |
Using the dial indicator, check the play between the gear rack (4) and thrust piece (3) |
To do this, crank the gear rack in the direction of the arrow. In the process the specified test torque of the toothed rack must not be exceeded, otherwise the inner compression spring will be damaged.
Test torque: |
*BE46.20-P-1001-01C |
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Model 203, 209, 211 |
*BA46.20-P-1006-01F |
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Model 215, 220
- If the play is smaller than the specified tolerance, loosen the adjustment screw (2) again slightly (in order to prevent the thrust piece digging into the toothed rack) and check play again.
- If the play is then still within the tolerance, then the play is OK.
- If the play is then outside the permissible tolerance, the adjustment must be repeated. Should the play still be outside the specified tolerance after being adjusted again, the rack-and-pinion steering (model 211, 215, 220) or thrust piece (model 203, 209) must be replaced.
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*BA46.20-P-1010-01E |
| 19 |
Detach bracket and dial indicator from steering gear housing (14) |
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| 20 |
Secure the adjusting screw (2) with three center punch marks |
Center punch marks see items, second picture. |
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| 21 |
Press rubber plug carefully into the adjusting screw (2) |
Check rubber plug for damage and replace if necessary. |
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Replace thrust piece (3) |
Only models 203, 209
Perform work steps 22 to 31 only if necessary. |
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| 22 |
Unscrew adjusting screw (2) |
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| 23 |
Remove inner compression spring |
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| 24 |
Take out thrust piece (3) carefully using pliers |
The slide blocks can stick in the gear rack (4) and damage it |
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| 25 |
Insert new thrust piece (3) |
Grease slide blocks and outer edge of thrust piece |
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Renolit JP1619 special grease |
*BR00.45-Z-1067-06A |
| 26 |
Grease inner compression spring |
Renolit JP1619 special grease |
*BR00.45-Z-1067-06A |
| 27 |
Insert inner compression spring |
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| 28 |
Grease thread of adjusting screw (2) |
Renolit JP1619 special grease |
*BR00.45-Z-1067-06A |
| 29 |
Screw in adjusting screw (2) |
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| 30 |
Crank gear rack (4) several times using socket wrench |
It must be possible to crank the gear rack easily. |
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Figure |
| 31 |
Adjust play between rack-and-pinion steering and thrust piece (3) |
See work steps 14 to 21 |
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Install |
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| 32 |
Mount both inner tie rods with axial joints on gear rack (4) |
Secure steering rack to prevent it from twisting with open end wrench. |
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*BA46.40-P-1003-01E |
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Figure |
| 33 |
Mount the bellows |
Check bellows for leaktightness and damage, replace bellows if necessary
Perfect bellows sealing is required for the function of the rack-and-pinion steering. By turning the rack-and-pinion steering onto left or right lock stretch the boots and in the process check for damage (cracks, chafe marks etc.) and replace if necessary. |
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| 34 |
Mount bellows clamps |
Replace clamps. |
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| 35 |
Detach rack-and-pinion steering from steering gear housing support |
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| 36 |
Install rack-and-pinion steering |
Model 203 with 4-MATIC |
AR46.20-P-0600PW |
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Model 203 without 4-MATIC, 209 |
AR46.20-P-0600P |
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Model 211 without 4-MATIC |
AR46.20-P-0600T |
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Model 211 and 220 with 4-MATIC |
AR46.20-P-0600IW |
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Model 215, 220 without 4-MATIC, except model 220.176/ 179 |
AR46.20-P-0600I |
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Model 220.176/ 179 |
AR46.20-P-0600M |