Replace steering gear (ZF)
Spezialwerkzeugliste: |
- CH-47658
- KM-161-2
- KM-161-B
- KM-6004-2
- KM-J-22610
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Note: Only front axle
body is released. The guide joints remain attached to the steering
knuckle.
Remove
1. |
Turn steering wheel as far as the stop
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Turn steering wheel and front wheels to the straight-ahead
position.
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Allow steering lock to engage
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2. |
Remove intermediate shaft from steering gear.
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Remove clamp bolt (1) of intermediate shaft.
Note: Bolt is
accessible from the passenger compartment.
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Detach intermediate shaft from steering wheel.
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3. |
Remove rubber sleeve from steering gear (2).
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4. |
Detach 2x front wheels
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Remove 10x wheel bolts
Note: Mark position
relative to the wheel hub.
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5. |
Release 2x tie rod ends (6) from steering knuckle (5)
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Attach CH-47658 (1)
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Place CH-47658 (1) in position with a
suitable sleeve (4)
Note: To centre CH-47658 , CH-47658
must be inserted with a suitable socket (3).
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Fasten CH-47658 (1) to hex (2)
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Unscrew tie rod end nut
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6. |
Detach 2x tie rod ends from steering knuckle
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Press tie rod end out of steering knuckle using KM-161-B (1) combined with KM-161-2
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7. |
Detach lower engine compartment cover
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8. |
Remove front exhaust pipe.
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Remove 3 nuts for connecting the front pipe to the particle
filter / rear catalytic converter (1).
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Remove 3 nuts for connecting the pipe to the front catalytic
converter (2).
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Remove the bracket from the oil pan (3).
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Remove the exhaust pipe.
Note: The flexible part
of the pipe must not be bent by more than 5°.
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9. |
Remove rear engine damping block from transmission.
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10. |
Place vehicle jack in position under the front axle
housing.
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11. |
Remove triangular plate.
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Unscrew 6 bolts (1) (2).
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12. |
Remove centre bolts from axle housing (1) 2x.
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13. |
On LHD vehicles: Remove engine damping block bracket (1) at the
rear of engine damping block.
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14. |
Detach rear engine damping block (2)
Note: Illustration
shows front axle body removed.
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Unscrew bolt connection
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15. |
Remove supply line (3) and return line (4) from steering
gear
Note: Oil runs out -
use catchment tray
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16. |
Remove electro-hydraulic supply unit from front axle body
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Release 2x wiring harness plug (1) and (2) and remove from
electro-hydraulic supply unit
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Remove 3x nuts (3) and (4) from steering gear and front axle
body
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Remove electro-hydraulic supply unit with supply and return
line from steering gear and front axle body
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17. |
Remove tie rods on both sides of steering gear
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Detach 2x retaining strap (1) and (2)
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Remove 2x boot from steering gear
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Detach 2x tie rod (4) from steering gear with KM-6004-2
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counterhold with an open-ended wrench on the toothed rack flat
on the steering shaft side
Note: Counterholding is
no longer necessary in vehicles as of model year 2006.
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18. |
Remove steering gear from front axle body
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Remove 2x nut (2) from front axle body
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Install
19. |
Attach steering gear to front axle body
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Tighten 2x new nuts 45 Nm + 45° +
15°
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20. |
Attach 2x tie rod to steering gear with KM-6004-2 90 Nm
Note: Clean thread on
rack and coat with locking compound.
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counterhold with an open-ended wrench on the toothed rack flat
on the steering shaft side
Note: Counterholding is
no longer necessary in vehicles as of model year 2006.
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21. |
Attach 2x boot to steering gear
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Place 2x boot on steering gear
Note: Ensure that the
boot sits in the grooves of the tie rod and steering gear
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Attach 2x new retaining clamp to steering gear with KM-J-22610
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Fit 2x boot to tie rod using new retaining strap
Note: Ensure that the
boots sit in the grooves of the tie rod.
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22. |
Attach electro-hydraulic supply unit with bracket to front axle
body 22 Nm
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Place electro-hydraulic supply unit with holder on steering
gear and front axle body
Note: Note steering
wiring harness
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23. |
Connect 2x wiring harness plug to electro-hydraulic supply
unit
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24. |
Attach supply and return line to steering gear 16 Nm
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25. |
Attach supply and return line holder to steering gear
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26. |
Attach rear engine damping block bracket to engine damping
block 55 Nm
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27. |
Fit bolts for front axle housing.
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Fit triangular plates, insert the following new bolts and leave
slack.
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Tighten 2x bolts (2) for front axle housing to 90 Nm +45° +15° .
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Tighten 4x bolts (1) for triangular plates to vehicle underbody
65 Nm
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28. |
Insert centre bolts for front axle body and leave slack
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Tighten 2x bolts for front axle housing (1) to 90 Nm +45° +15° .
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30. |
Place engine support underneath, at the back on the
transmission.
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Tighten bolt to 80 nm .
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31. |
Attach front exhaust pipe.
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Lubricate the bolts with bolt paste and fit the pipe between
the front and rear catalytic converter.
Note: Use new gaskets
and new nuts. Tighten to 25 nm .
Note: The flexible part
of the pipe must not be bent by more than 5°.
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Fit bracket to oil pan and tighten the bolts to 25 Nm .
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32. |
Attach lower engine compartment cover.
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Tighten 8x bolts to 5 Nm .
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33. |
Charge and bleed hydraulic system
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34. |
Check straight-ahead position, adjust if necessary
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35. |
Check toe-in, adjust if necessary
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36. |
Attach front wheels
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Tighten 10x wheel bolts 110 Nm
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