Vauxhall Workshop Service and Repair Manuals

Disassemble

Remove both rubber rings (left and right), as well as the bulkhead rubber seal, from the steering gear housing.

Unbolt left and right tie rod end from respective tie rod. To do this, loosen lock nut.

Remove retaining strap and clamp for left and right bellows, remove respective bellows.

Unbolt tie rod with flexible coupling from rack.

The steering gear must be free on the workbench - it is not to to be clamped in the vise.

Counterhold rack with open end spanner.

If necessary, replace plastic ring for tie rod stop.

Using KM - 285 loosen steel plate hex nut for set screw.

Unscrew set bolt (3) and then remove pressure spring through set screw opening.

Prise seal ring (1) out of steering gear housing, use Pliers KM - J - 4245 to remove snap ring (2) in front ball bearing.

Pull pinion and rack out of housing.

The pinion is to be replaced only as an assembly, including the ball bearing.

Prise out guide segment through the set bolt opening.

Because of its rubber seal ring, the guide segment is seated under suction in the housing opening.

Replace rubber seal ring.

Use KM - J - 26269 to press pinion needle bearing out of steering gear housing from outside to inside.

Guide rack and pinion into steering gear housing.

The rack ends (1) must extend uniformly over both sides of the housing, at the same time, the longitudinal recess on the pinion shaft points to the right (viewed from rear to front of vehicle).

Secure pinion ball bearing in steering gear housing with snap ring (2).

The side of the snap ring chamfered outward points away from the ball bearing (see illus. D 8589).

The snap ring must be properly seated in the groove.

Always use new snap ring (2) and new seal ring (1).

Use KM - 549 to drive new seal ring into steering gear housing.

Fill hollow space between ring and ball bearing with Grease 19 46 254 (90 001 820).

Insert the guide segment and the pressure spring into the set screw opening and turn set bolt into steering gear housing until re sistance is felt - standard value is 5 Nm/4 lbf. ft. (steering gear in straight ahead driving position).

Then turn set bolt back 30 ° to 60 ° and check whether the rack moves freely over the complete range where the pinion meshes with the rack.

Subsequently tighten lock nut with KM - 285 - 60 Nm/44 lbf. ft.

Counterhold set bolt while doing so.

After installing the steering gear in the vehicle later, a test drive (with cornering) is to be made to determine whether the steering returns to the straight ahead driving position of its own accord.

Tighten bolts of each tie rod with flexible coupling to rack 60 Nm/44 lbf. ft.

Use commercially available open jawed spanner insert (crow-foot) with spanner size of 32.

Counterhold rack with open end spanner.

The steering gear must be free on the workbench - it is not to be clamped in the vise.

Secure flexible coupling opposite the rack anew.

Rivet coupling collar, offset at a minimum of 90° opposed to the previous securing point.

A rack that has been removed, may on principle be reinstalled only one time.

A rack that has been removed twice is recognized by the fact that .there is no possibility of riveting the coupling collar again.

Press plastic ring for tie rod stop onto flexible coupling.

Mount bellows.

Tighten with new retaining strap and clamp.

Ensure proper seating of bellows in the housing and in the tie rod groove.

Use special clamping pliers to tighten retaining strap.

Clamping Pliers KM - J - 22610, or commercially available clamping pliers.

Bolt on left and right lie rod end and lock nut to respective tie rod.

Push both rubber bearing rings (left and right), as well as the bulk head rubber seal, onto steering gear housing.

The marking slot of the rubber seal must be seated in the steering gear housing catch.

Install steering gear.

After installation, check straight ahead driving position of steering (see operation "Steering, Position Straight Ahead").

Adjust toe-out (see operation in group E).