Remove/install protective cap for input shaft on steering gear - AR46.20-P-0004P

MODEL 169, 171, 203, 204, 209, 211, 230, 245 

Shown on model 203, left-hand drive vehicle 

Fig 1: Identifying Inner Tie Rods Axial Joint, Bellows And Clamps - Shown On Model 203, Left-Hand Drive Vehicle

Fig 2: Identifying Steering Gear Housing And Stop Ring

Fig 3: Identifying Protective Caps And Markings

(Left illustration) Model 169 up to 30.3.05, left-hand drive vehicle 

(Middle illustration) Model 169, 245, right-hand drive vehicle 

(Right illustration) Model 169 as of 31.3.05, model 245, left-hand drive vehicle 

Shown on model 203, left-hand drive vehicle 

Fig 4: Identifying Protective Cap And Marking (Shown On Model 203, Left-Hand Drive Vehicle)

Shown on model 203, right-hand drive vehicle 

Fig 5: Identifying Protective Cap And Marking (Shown On Model 203, Right-Hand Drive Vehicle)

Shown on model 211, left-hand drive vehicle 

Fig 6: Identifying Protective Cap And Marking (Shown On Model 211, Left-Hand Drive Vehicle)

Shown on model 211, right-hand drive vehicle 

Fig 7: Identifying Protective Cap And Marking (Shown On Model 211, Right-Hand Drive Vehicle)

Shown on model 230, left-hand drive vehicle 

Fig 8: Identifying Protective Cap And Marking (Shown On Model 230, Left-Hand Drive Vehicle)

Shown on model 230, right-hand drive vehicle 

Fig 9: Identifying Protective Cap And Marking (Shown On Model 230, Right-Hand Drive Vehicle)

	Removing
1	Mount rack-and-pinion steering onto steering gear housing mounting device	Ensure that the workplace is clean when carrying out the work described below and while performing repairs! Only the specified tool may be used! Before starting repair, remove loose dirt from steering gear without using cleaning agent!
			Figure
2	Detach inner clamps (1) of both bellows (2)
3	Slide bellows (2) towards tie rod end	To do so push outer clamps together.
4	Remove inner track rod with axial joint (3)	Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint (3) will be damaged. Dismantle at left and right sides.
			Figure
5	Move steering rack to center position	Use depth gauge to determine when the assembly is centered. 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.
6	Detach protective cap (4)
	Install
7	Grease gap between input shaft and control head (arrow)	Except model 169, 245 Apply grease using fingers. Do not use any other aid.
		Renolit JP1619 special grease	*BR00.45-Z-1067-06A
8	Fit protective cap (4)	Marking (5) must line up exactly with marking (6) as otherwise the Electronic Stability Program (ESP) may malfunction. Model 169, 245: There are various versions of the protective cap (4). The version fitted must always be reinstalled.
	Modified rack-and-pinion steering	Model 169 as of 31.3.05	BT46.20-P-0600-01AK
	Checking
9	Check center steering position on steering gear		AR46.20-P-3015P
10	Mount the inner tie rod with axial joint (3)	Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint (3) will be damaged. Mount on left and right sides.
			*BA46.40-P-1003-01E
			*BA46.40-P-1003-01J
			*BA46.40-P-1003-01N
			Figure
11	Mount bellows (2)
12	Mount inner clamps (1) of both bellows (2)	Replace clamps (1).
13	Detach rack-and-pinion steering from steering gear housing mounting device

TIE ROD

TIE ROD

TIE ROD

TIE ROD

Fig 10: Identifying Steering Gear Housing Support (203 589 04 31 00)

Fig 11: Identifying Open End Wrench (201 589 00 01 00)