6.3. Replacing the Steering Shaft

6.3. Replacing the Steering Shaft

The steering shaft can be replaced without removing the complete steering. First disconnect the steering shaft universal joint (see Fig. 6.3) by removing the clamp bolt and pulling the steering wheel upwards until the joint has disengaged.

Disconnect the lower universal joint from the steering pinion. To do this, remove the cover underneath the pedal assembly to gain access to the clamp bolt. Withdraw the shaft upwards to disengage it.

The installation is a reversal of the removal procedure. To set the steering rack to the centre position, remove the steering gaiter (rubber boot) on the L.H. side and pull it back. Turn the steering pinion until the rack protrudes by exactly 76.0 mm (dimension "X" in Fig. 6.6). Refit the gaiter and secure it.

Tighten the two clamp bolts at top and bottom to 2.5 kgm (18 ft.lb.). Make sure the rubber seal is fitted correctly under the floor panel cover.

6.4. Replacing a Track Rod

It is possible to replace a track rod when the steering is fitted, but it may be far easier to carry out the work when the steering is removed. This concerns mainly the locking of the new ball joint housing to the steering rack, as the access is rather difficult.

If the complete track rod is to be replaced replace it together with the ball joint housing as the old housing may have been damaged by peening the housing to the steering rack.

• Remove the rubber gaiter from the track rod and the side of the rack housing. Cut the old clamp band. On the other side roll back the two rubber rings securing the gaiter to the track rod. Move the gaiter towards the outside of the track rod.
• Clamp the steering box into a vice (soft-metal jaws) and unscrew the ball joint housing. Workshops use a special wrench, but a pair of pliers or grips can be used. The round-shaped ball joint housing is fairly tight and more than one attempt may be required. Definitely replace the ball joint housing if removed in the described manner.
• Unscrew the track rod and clamp it into a vice. Slacken the track rod and unscrew the track rod end piece, counting the numbers of turns required to remove it.
• Screw the new track rod with the new ball joint housing to the rack and tighten it as much as possible with the grips.
• Secure the ball joint housing to the steering rack. The rack housing is clamped into a vice and the lug on the ball joint housing is peened into the groove of the

Fig. 6.7. — The track rod ball joint housing is secured as shown.