SteeringSteering gear, overhaul (manual steering gear)
Steering Gear, Overhaul (Manual Steering Gear) Remove steering gear - see operation " Steering gear Remove and Install (Vehicles with Left-hand Drive)" or " Steering Gear Remove and Install (Vehicles with Right-hand Drive)".
 Disassemble Remove the rubber bearing ring with grip (arrows) and bulkhead sealing rubber. Remove both clamp wires from the bellows. Withdraw both bellows from the housing pipe. Release the steel plate - hexagon nut for the adjustment screw with KM-472 (1). Screw out the adjustment bolt (2). Take out the compression spring from the adjustment bolt opening. Remove the locking ring plate (3) and the pinion fixing bolt (replace the bolt sealing ring). | 
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Disassemble Remove the guide segment from the adjustment screw. Guide segment is held in place through suction in the housing opening (replace seal ring). | 
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Remove the sheet closing cap (arrow) from the steering housing.
 Important! Further disassembly of the steering gear housing, and also removal of the steering racks bearing bushings and of the pinion needle bearings, is not envisaged.
 Clean Clean all components. | 
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 Inspect Check all parts for wear and damage, if necessary replace. In the event of damage to the steering racks or pinion needle bearings always replace the whole steering housing assembly.
Important! In the event of replacement: follow the whole steering changeover - see "Technical Data - Manual Steering Gear".
 Assemble Lubricate the rack and pinion with steering grease. Fill the inside of the steering housing evenly between the bearing areas of the steering rack with approx. 20 g of grease. Install the rack and pinion in the steering housing.
 Measure Rack position - dimension "I" = 61 mm - between long steering housing and rack front face. Long gap (arrow) on the pinion show towards the left (steering in the 'straight on' position)
Assemble Tighten rack fastening bolts to housing - tightening torque 40 Nm/ 29.5 lbf. ft. Secure with sheet snap rings. Previously, fill the cavity between the screw and the pinion with roller bearing grease. Drive in new locking ring with KM-473 (1). | 
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 Adjust Steering gear: Screw on sliding and guiding pieces in conjunction with two spacer sleeves (1) with both tie rod fastening bolts to steering rack. Spacer sleeve = 30 mm (1.2 in.) high, 25/12.5 mm (0.98/0.49 in.) diameter
(own construction). | 
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Install guide segment and pressure spring in the adjustment screw opening. Tighten the adjustment screw until resistance is detected. (Prescribed value
= 5 Nm/4 lbf. ft.) (steering gear in straight ahead position). Turn back adjustment screw 20 ° to 40 ° .
Inspect Check the free play of the steering rack over the complete contact range of the pinion. | 
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Assemble Tighten counter nut for adjusting bolt with KM-472 (1) - tightening torque 60 Nm. Secure adjustment bolt. Fit new sheet closing cap in short steering housing end. Push the housing pipe and both bellows on to the steering housing. Previously screw out the two rack fixing bolts from the rack. Fix the two bellows with clamping wire (arrows). Pull both wire ends, in the steering gear - install position, upwards.
Important! Bellows must not be twisted when in position. | 
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Assemble Install rubber bushing rings with retaining clamp and bulkhead rubber seal on the steering gear. The retaining flange inner chamfer points downwards.
 Install, Connect Install steering gear - see operation "Steering Gear Remove and Install (Vehicles with Left-hand Drive)" or "Steering Gear Remove and Install (Vehicles with Right-hand Drive)".
Important! After installation of steering gears, establish during test drive whether steering returns automatically to straight ahead position. | 
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12 Steering & suspension
