TRW Automotive otive
Co m m e r c i a l S t e e r i n g S y s t e m s
TAS Steering Gear Ser ervv ice M anu anual al TAS40,55,65, AND 85 SERIES
HazardWarningDefin efinition tions A warning describe escribes hazards or unsafe practices ctices whic which h could result in in severe personal injury or death. A caution descri scribes bes hazards or unsafe practices ctices whic which h could result iin n personal injury njury or product or property damage. A no te gives ke key y inf nfor orm m at ati ion to m ake follow ing a p pr roce du re e as asi ie r o r q u ick cke e r.
Disclaimer This S er ervi vice M anualhas be en pr prep ep ared by TR W C om m erci ercialS teer eeri ing S ystem s for for ref efer eren en ce and use by m ech an ani ics w ho hav have e b ee n tr traine d to to rep rep air and se ser rvice st stee ee ring com po ne nt nts s and and system s on heavy com m er erci cialvehicles. TR W C om m erci ercialS tee ring S yst yste e m s has h as e xe xer rcise sed dr re e aso n ab abl le c car are e an and d d ilig en ce to p res ese e n t accu rate, ate, cle ar an and d com plet ete e inf nfor orm m at ati ion and inst nstr ruct ucti ion s reg ar ardi ding the TR W C om m er erci cialS tee ring TA S S e rie s In te g ral P o w e r S te e rin g G e ar ars. s. S in ce this is a ge n e ralS e rvice M anu an u al, th e p h o to g raph ap h s a an n d illu st str rat ati io n s m ay n o t lo o k e xac xact tly like th e ste ste e rin g g e ar bei be in g se rviced ce d . T h e p ro ce ced d u re s, the refor efore e , m u st b e c car are e fu lly re re ad an a n d u n de rst stoo oo d b e fo re se rvicin g . If ins nspe pe ct cti ion or tes est ting reve als e vide nc nce e of abnor abn orm m alw ea ear r or dam age to the TA S ste ste erin g g e ar o r if yo you u e n co cou u n te r circu cum m st stan ance ces sn no o t co cove ver re d in the the M anu an u al, Stop-
Consult the vehicle manufacturer' facturer's s Servic Service Manual andwarranty. Do not try to repair air or servic service a TAS steering steeringgear which which has beendamagedor incl includ udes any part that shows excesexcessive sive wear unless the damagedandworn parts are replaced replaced with with original riginal TRWreplacem replacement andservice service parts andtheunit is restored restored to TRW's W's specifi specific cations ations for theTAS steering steeringgear. It is the re sp spo o n sib ility o f th e m e ch chan ani ic p e rfo rm in g th e m ain te n ance an ce , re p airs o r se rvice o n a p art articu lar T A S st ste e e rin g g e ar to ( (a) a) in sp spe e ct th e s st te e rin g g e ar fo r abn ab n o rm al w e ar and an d d am ag age e , (b ) ch cho o o se a r re e p air p ro ce cedu du re w h ich w illn ot enda en dan n g er his/h e r saf safe e ty, th e sa saf fe ty o f o th e rs, th e ve h icle , o r th e sa saf fe o p e ratio n o f th e ve h icle , an d (c) fu lly in sp e ct and an d test th e T A S st ste e e ring g e ar an and dt th he v ve e hicle s st te erin g syst s yste e m to e n sur su re th th at th e re p air or servi service of the st stee ee rin g ge ar ha has s b e en prop prope e rly p erfo rm e d an and d th at th e ste ste e rin g g e ar an and d sys syst te m w illfu n ct cti io n p ro p e rly.
Patents TR W C om m er erci cialS tee ring D ivision TA S po w er st stee ee ring ge ar ars s are cover co vered ed by sever se veral al U n ite d S tate ate s a an n d fo re ig n p at ate e n ts, e ith er issu ed o r p en d in g .
© TR W Inc., 2002 1
Contents Section ion1
General Information ion In nt tro d u ctio on n ................................................................................... .4 4 O ilF lo w Illu stra at tio on n .......................................................................5 .5 G e n e ra al lD e sig n .............................................................................6 .6 G e n e ra ral lO p e ra rati tio n ......................................................................... 7 A p p ro rov ve d H yd ra rau u lic F lu id s ............................................................8 ..8 G e ar S p e cificatio n N u m b e rs ......................................................... 8 T o rq qu u e C h art ................................................................................. .9 9
StandardGear E xp lo d e d V ie w ............................................................................1 ..1 0 S e rv vi ice P arts Li L ist ........................................................................1 .1 1
Step Bore Gear E xp lo d e d V ie w ............................................................................1 ..1 2 S e rv vi ice P arts Li L ist ........................................................................1 .1 3
Section ion2
Initia itiall In Installat llation ion In ns sta al llatio on n ................................................................................... .1 15 P o p p e t S e tting ng ............................................................................1 .1 5 M ain te ten n an ce T ip s ........................................................................1 ..1 6
Section ion3
On-VehicleService F illin g an d A ir B le e d in g th the e S ystem tem ............................................ 1 7 In p u t S h aft S e alR e p lace m e n t ....................................................1 ..1 8 S e cto tor r S h aft A d ju stm e n t............................................................. 2 2 Po ppe t R eadjust ustm m ent S in g le G e ars ....................................................................... 2 4 D u alG e ars .......................................................................... .2 27
Section ion4
Reseal & Repair D isasse m b ly ................................................................................3 .3 3 In ns sp e ctio on n ................................................................................... .4 41 A sse m b ly ....................................................................................4 .4 3 Int nter erna nal lD am ag age e R ep air (by ref efer eren en ce ce) ) P o p p e t C o m p o n e n t R e p lace m e n t ...................................... 5 1 V alve H o u sin g W o rm S cre crew w D isa sass sse e m b ly ......................... 5 3 R o lle r B e arin g o r R e tain in g R in g R e p lac ace e m e n t .................. 6 0 R o lle r B e arin g R e p lac ace e m e n t (S te p B o re G e ar). ar).. .................. 6 1 R e p lac ace e H o u sin g P o rts, Pl P lu g s, Scre S crew w s, Fi Fittin g s ................ 6 2 F in alA d ju stm e n ts ....................................................................... 6 3
Section ion5
Reinstallat llation ion R e in ns sta al lla at tio on n ............................................................................... .6 65 P o p p e t R e se ttin g ........................................................................6 ..6 5 G lo ssary ......................................................................................6 .66
All All steeringmechanisms are safetycritic critical al item items. As such,it is imperative thattheinstructions nstructions in this bookl booklet et be foll followed totheletter. Failure Failuretoobservetheprocedu roceduressetforth forthinthis thispamphletmayresult resultin inaloss lossofsteeri steering ng.
2
Section1
General Information
Intro duction .........................................................................4 O il Flow Illustration .............................................................5 G eneralD esign ...................................................................6 G eneralO peration ...............................................................7 A pproved H ydraulic Fluids ..................................................8 G ear S pecification N um bers ...............................................8 Torque C hart.......................................................................9
StandardGear E xploded V iew ..................................................................10 S ervice P arts List..............................................................11
StepBoreGear E xploded V iew ..................................................................12 S ervice P arts List..............................................................13
Introduction Th is ne w TA S S ervice M anu alrep laces allpreviou s ed ition s of TR W 's TA S 40 , 55 , 65 and 85 S ervice M anuals. C han ge s in the layout of this S ervice M anual reflect TR W 's com m itm en t to p rovide easily usab le m aterialand high ly recognizable hazard notices. S om e of the m ajor chan ge s are: • R evised torque, force, pressu re and flow notation s that conform to international standards. • S ervice M anualdivided into sections for easier reference. • U ninterrupted resealing instruction s. R eference to dam age section allow s you to repair or replace dam aged parts an d return to the resealing procedures easily. • B inding proce ss that better allow s the S ervice M an ualto lay flat. Th e three -colum n form at used in the S ervice M anual w illalso he lp m ake it easy for you to service a steering g ear. C olum n 1 illustrates the p rocedu re w ith ph otographs, colum n 2 gives a brief key as w ellas too ls to b e u sed for each p roced ure, and co lum n 3 explains in detailthe procedure yo u should follow . Pay special attention to the notes,
cautions and warnings. Item nu m bers on the e xplode d view correspo nd w ith item nu m be rs used throug ho ut the S ervice M anu al. A s you gain expe rien ce in servicing TA S stee ring ge ars, you m ay find that som e inform ation in this S ervice M anualcould be clearer and m ore com plete. If so, let us know abo ut it. D on 't try to secon d-gu ess the S ervice M anual; if you do no t un de rstand a procedure, or are stuck, contact our Field S ervice D epartm ent at 765.423 .5377. S ervicing TA S series steering gears sho uld be safe and prod uctive.
4
Oil Flow Illustration LeftHandLead
RightHandLead
RightHandTurn Steering Wheel Input: Clockw ise Rotation
StraightlineRunning No Steering Action
LeftHandTurn Steering Wheel Input: Counter-Clockw ise Rotation
SupplyPressure Return Pressure
5
General Design Integral PowerSteering TA S pow er stee ring g ears are the latest de sign in the TR W C om m ercialS tee ring D ivision fam ily o f integ ral hyd rau lic po w er steering gears. Integral hyd rau lic po w er stee ring m eans that the g ear contains a m anualsteering m ech anism , a hydraulic co ntrolvalve, and a hyd rau lic pow er cylinder, allin a single, co m pact packag e.
Rotary Control Valve The rotary controlvalve com bines sim plicity o f co nstruction w ith desirable perform an ce characteristics. The spe ed at w hich the driver can turn the stee ring w he el w ith p ow er assist is de pe nd en t up on the pu m p flow (m easu red in gallon s p er m inute or liters pe r m inu te) directed to a cylinder cavity. The co ntrolvalve co ntrols flow through the steering gear. Th e pressu re (m easu red in po un ds pe r squ are inch , or bar)required for the gear to stee r the ve hicle is created by the po w er stee ring pu m p to overcom e resistance at the stee red w he els. T he con trol valve se nse s the se requirem ents and directs fluid to the ap propriate cylinder cavity in the steering gear (an d in the auxiliary cylinder if it is a d ual steering system ) at the proper flow rate and pressure.
Pressure Means Work, Flow Means Speed Th e higher pressu re a steering gear can w ithstand, the m ore w ork it can perform . Th e m axim um ope rating pressure for allTA S gears is 2 ,175 psi(150 bar), m axim um flow rate for allTA S gears is 8 gal/m in (30.3 L/m in). The TA S series gears can steer a ve hicle w ithin its fronten d w eigh t rating throu gh a turn at low spee d and en gine idle. A s the d rive r turns the steering w heelfaster or slow er, m ore or less fluid w illbe required by the gear. TA S se ries vehicle front-end w eight ratings are as follow s:
6
Gear
FrontAxle Rating
TA S 40
9,000 lb (4,100 kg)
TA S 55
12,000 lb (5,400 kg)
TA S 65
14,300 lb (6,500 kg)
TA S 85
18,000 lb (8,200 kg)
The recom m ended m inim um flow at 1 1 ⁄2 stee ring w he el turns p er second is as follow s:
Gear
MinimumFlow Rate
TA S 40
2.2 gal/m in (8.3 L/m in)
TA S 55
2.6 gal/m in (9.8 L/m in)
TA S65
3.0 gal/m in (11.4 L/m in)
TA S85
3.6 gal/m in (13.6 L/m in)
If the steering gear valve is controlling an auxiliary cylinder, increase d m inim um flow is req uired (gen erally at least 75% ) base d on the size of the auxiliary cylinder and the vehicle's steering geom etry. M axim um internalleakag e for allTA S ge ars is 1 gal/m in.
General Operation What Happens Duringa SteeringManeuver
Relief Valve
W hen the d river turns the steering w he el, he transm its force from the stee ring w hee lto the steering gear input shaft. A torsion bar, pinned at its one end to the input shaft and at its other end to the w orm shaft, turns w ith the input sh aft and exerts a rotationalforce on the w orm sh aft. In resp onse to this rotational force , the w orm shaft, acting through the recircu lating ballm ech anism , tries to m ove the rack piston axially through the gear housing cylinder bore.
S om e TA S ge ars, (w ith or w itho ut pop pe ts), are supp lied w ith a relief valve . The relief valve lim its m axim um supply p ressu re to protect the po w er steering gear, but it do es n ot red uce pressu re as the stee red w he els approach the axle stops.
The rack piston's axialm ovem ent is resisted b y its en gage m en t to the sector shaft, w hich is con ne cted by linkag e to the steered w heels. B ecau se of this resistan ce , the torsion bar is tw isted by the input sh aft, thereby actuating the co ntrolvalve . P ressurized fluid, directed by the controlvalve, assists in m oving the rack piston axially through the cylinder bore. T he rack p iston then turns the sector shaft to steer the ve hicle.
BleedSystems S om e TA S g ears w hich are m ounted w ith the ou tput shaft above the rack p iston b ore are e quipp ed w ith e ither an autom atic blee d system or a m anu alblee d screw . Th e proced ure for air blee ding the system is on pag e 17 of this m anu al. R ep lacem en t of dam age d autom atic blee d p lug s, and m anu alblee d screw s is de scribe d o n page 62.
ShockLoadstotheGear If the steered w heels receive a sh ock load, the sho ck force s are transm itted through the se ctor sh aft to the rack piston , and o n to the w orm shaft. T he internal ge om etry of the stee ring gear cau ses the control valve to se nd high-pressure fluid to the co rrect cylinder cavity to resist the shock forces. B y absorbing the sh ock forces hyd rau lically, the steering gear prevents objectionab le kickb ack at the steering w heel.
Unloading(Poppet) Valves M ost TA S ge ars are e qu ipp ed w ith tw o u nload ing valves, on e at each e nd of the rack piston . O ne valve o r the other, depending on the direction of turn, w illtrip as the stee red w he els app roach the axle stop s (w hich m ust be se t acco rding to m an ufacturer's specification). The trippe d valve reduces pressu re in the gear and helps to red uce he at ge nerated b y the p um p. A t the sam e tim e, the valves also reduce forces on the steering linkage. These valve s are au tom atically se t to axle stops after installation in vehicle at first fullright an d left turn.
7
ApprovedHydraulic Fluids A utom aticapproved T ransm ission and Fluid Drecommended exron II lA TF 210 Fluids for use Minobi TRW steering systems include: atic T ransm ission Fluid Type "E " or "F" M obilS uper 10W -40 M otor O il •AC utom Automatic Transmission Fluid Dextron II, III, Mercon hevron 10W -40 Prem ium B lue 2000 - SA E 15W -40 •C hevr Automatic on C ustom Transmission 10W -40 M otor O il Fluid ATF +4 Texaco 10W -40 C he vron To rqu e 5 Fluid Te xaco TL -18 33 P ow er S tee ring Fluid E xxon N uto H 32 H ydraulic Fluid nion 10W -40 NOTE Use of fluids other than Uapproved NOTE and recommended may Flee trite P S F (C an # 99 06 25 C 2) U nion 15W -40 void the steering system warranty. Ford Spec.M 2C 138C J U nocalG uardol 15W -40 M otor O il M ack EO -K2 E ngine O il The steering system should be kept filled w ith one of the above fluids.
Completelyflushthesteeringsystemwithoneoftherecommended fluids above only. Do not mix oil types. Any mixture or any unapproved oil couldleadtoseal deterioration and leaks. A leak could ultimately causethe loss of fluid, which could result in a loss of power steering assist.
SpecificationNumbers
Th e stee ring ge ar specification n um ber and date code are stam ped on a m achine d su rface o pp osite the inp ut shaft of every T A S ge ar. N ew er ge ars includ e a serialnu m ber.
Spec. No
StepBore Identifier TAS65001A 29097S01B27
DateCode
Serial Number
A n exam ple date code w ou ld be 2 909 7; this m eans the g ear w as b uilt on the 29 0th d ay of 199 7. A n "A " includ ed at the en d of the sp ecification n um be r indicates a step bore ho using .
8
TorqueChart PartName
Item# Torque Range Dry
Torque Range Lubricated
A uxiliary cylinder plug
54
25-35 lbf ft (34-48 N m )
B allreturn guide cap/strap bolts
31
14-22 lbf ft (19-29 N m )
B earing adjuster
17
11-15 lbf ft (15-20 N m )*
Locknut
18
101-122 lbf ft (137-165 N m )**
M anualbleed screw
50
40-50 lbf in. (3.1-3.7 N m )
P lug, auto bleed
51
38-58 lbf ft (52-79 N m )
P oppet sleeve assem bly
22
16-20 lbf ft (22-27 N m )
P oppet sealing nut, service
60
33-37 lbf ft (45-50 N m )
P oppet fixed stop screw
52
38-42 lbf ft (52-57 N m )
P oppet fixed stop screw
52A
38-58 lbf ft (52-79 N m )
R elief valve cap
56
25-35 lbf ft (34-48 N m )
S e cto r sh aft ad ju stin g scre w jam n ut
47
4 0-4 5 lb f ft (54-61 N m )
S ide cover bolts (TA S 40)
48
108-128 lbf ft (147-174 N m )
S ide cover bolts (TA S 55, 65, 85)
48
160-180 lbf ft (217-244 N m )
V alve housing bolts (TA S 40, 55, 65)
1
75-85 lbf ft (102-115 N m )
V alve housing bolts (TA S 85)
1
108-128 lbf ft (147-174 N m )
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Item nu m bers reference d are sho w n o n the e xplode d view s,page s 10 and 12. * A fter tightening to this torque value, the adjuster m ust be backe d off 1 ⁄4 to 1 ⁄2 of a turn as describe d in step 22 on page 57.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
S pe cialtoo ls can be pu rchased throu gh : S P X C orpo ration K en t-M oore To ol G rou p 28635 M ound Road W arren, M I 48092 1-80 0-32 8-66 57
** To rqu e value ind icated is u sing reco m m en de d too ls.
9
TAS Series ExplodedView -- Standard 48 49
47
46 41
TA S 85 C on struction
45
48 59/60
49
42
46
52/53 41
52A
47
41
40
45
34 23 22
36
25
23A
37
23
24
38
26
36
23A
39
22
27 30
29
28 19 21
31
20 18 17
9
8 16 15 13 56 15
13A
12
58 11
34
S hort "V " C onstruction
14
32
9
2C 8 7
16 31
10
15
2B 6
12 5
28
54 /55
27
20
Item Description B olts (4-Valve H ousing) D irt and W ater Se al13/16" S err. D irt and W ater S eal 7/8" S err. D irt and W ater S eal 1" S err. R etaining Ring Seal (Input Shaft) V alve H o usin g Seal R ing (Valve H ousing) Seal R ing (Valve H ousing) S e alR in g (2 ) O -rin g (2 ) S ealR in g O -ring (Valve H ousing) Thrust W asher (Thick) Input Shaft, Valve,W orm A ssy. Inp ut S h., V alve, W orm A ssy. (A lt.) Spacer Sleeve (A lt.) Thrust B earing (1 or 2)
16 17 *18 19 *20 *21 22 23 24 25 26 27 28 * 29 30 *31 *32 34 35
Thrust W asher (Thin) B earing Adjuster Adjuster Locknut R a ck P isto n Teflon SealR ing O -ring (B ack up; R ack Piston) Poppet Seat and Sleeve Assy. (2) P oppet (2) P o pp et S p rin g S pacer R od P ush Tube B alls B allR eturn G uide H alves (2) S e al(C a p) B allR eturn G uide C ap Torx Screw s (2-C ap/Strap) B allR eturn G uide S trap H ousing G rease Fitting
36 37 * 38 *39 40 *41 42 43 44 *45 46 47 48 *49 50 51 52 52A 53 54 *55 56 *5 7 58 59 60
3
2
R etaining R ing (2) R oller B earing D irt S eal D irt and W ater Se al(Trunnion) W ash er (S p ace r) Seal(2-O utput) S e cto r S h aft A djusting S crew (Se ctor Sh aft) R etainer (A djusting Screw ) G asket (Side Cover) S id e C o ve r A s se m b ly Jam N ut S pecialB olts (6 or 8-S ide C over) Vent Plug (Side Cover) B le ed S cre w (M an ual) Plug (Auto B leed) Fixed Stop Screw (Poppet) Fixed Stop Screw (P oppe t-A lt) W ash er (S to p S cre w ) A uxiliary P ort P lug (2) O -ring (2-A ux. P ort Plug) R elief Valve Cap O -ring (R elief V alve) R elief Valve (2 piece) Service P oppet A djusting Screw Service Sealing Jam N ut
*T hese item s are includ ed in com plete seal kits alon g w ith 04 5422 lubrican t and a se rvice bulletin.
10
4
1
21 19
1 *2 *2 B *2 C *3 *4 5 *6 *7 *8 *9 * 10 *11 12 13 13 A 14 15
57
Service Parts List - Standard CommonParts
Parts VarybySpecification*
ItemDescription
PartNumber
ItemDescription
1 2 2B 2C 3 4 7 8 9 10 11 12 15 16 17 18 27 29 30 31 32 35 43 44 47 49 50 51 52A 54 55 57 59 60
020251 4 78 04 4 478060 478050 401637 478076 032823 029123 032200-158 029116 032200-152 400143 070027 400144 400149 027007 213684-X 1 478042 400161 020228 400167 037032 0 212 00 062005 025150 036201 213705 021397 021426 415437-A 1 032229 032200-153 0 214 07 025119
5 13 13 A 14 19 34 42 46 56 58
B olts (4-V alve H ousing) D irt an d W ate r S e al1 3/1 6" S e rr. D irt and W ater S eal7/8" S err. D irt and W ater S eal1" S er R etaining R ing S eal(Input S haft) (H igh Tem p) S ealR ing (V alve H ousing) S ealR ing (2) O -ring (2) (H igh Tem p ) S ealR ing O -ring (Valve H ousing)(H igh Tem p) Thrust W asher (Thick) Thrust B earing (2) Thrust W asher (Thin) B earing A djuster A djuster Locknut B alls S eal(C ap) B allR eturn G uide C ap Torx S crew s (2-C ap/S trap) B allR eturn G uide S trap G rease Fitting A d justing S crew (S ecto r S haft) R etainer (A djusting S crew ) Jam N ut V ent P lug (S ide C over) B leed S crew (M anual) P lug (A uto B leed) Fixed stop screw A uxiliary P ort P lug (2) O -ring (2-A ux. P ort P lug) O -ring (R elief V alve) S ervice P opp et A d ju sting S crew S ervice S ealing Jam N ut
V alve H o usin g Input Shaft, Valve, W orm A ssy. Inp ut Sh aft, V alve, W orm A ssy. (A lt.)** S pacer Sleeve (A lt.)** R a ck P isto n H ousing S e cto r S h aft S id e C o ve r A s se m b ly R elief Valve Cap R elief Valve (2 piece) *C on tact Se rvice/S ales for part nu m be rs ** A pp licab le to T A S 65 ge ars on ly
Kits Items
Description
PartNumber
54 & 55 5 6 & 57 59 & 60 2 ,2 B , 2 C , 3 , 4
P ort P lug & O -ring R e lie f V alve C ap & O -ring A dj. S crew & Jam N ut In pu t S h aft S e alK it TA S 40 S ealK it TA S 55 S ealK it TA S 65 S ealK it TA S 85 S ealK it
415437-A 1 41 106 1-A 1 021407-X 1 T A S 0 0 00 01 TA S 400004 TA S 550004 TA S 650012 TA S 850003
Parts Vary byGear Size ItemDescription
TAS40
TAS55
TAS65
TAS85
6 20 21 22 23 23A 24 25 26 28
032829 032828 032827 409118-A 2 040210 040248 401662 040209 080154 400158 400159 401674 070030 478052 478053 028527 478051 H FB 529000 021277
032829 032830 032831 409118-A 2 040210 040248 401662 040209 080154 400160 400165 401650 071032 478041 478045 028519 478040 H FB 649000 021434
032616 032590 032615 409118-A 2 040210 040248 401662 040209 080154 400156 400157 401650 071033 478041 478045 028519 478040 H FB 649000 021434
032834 032547 032556 409118-A 6 040217 040249 401684 040218 080158 400162 400163 401685 072004 478057 478059 028534 478084 TA S 859000 021434
36 37 38 39 40 41 45 48
S ealR ing (V alve H ousing) Teflon S ealR ing O -ring (B ack up; R ack P iston) P oppet S eat and S leeve A ssy. (2) P oppet (2-old design) P oppet (2-new design) P oppet S pring S pacer R od P ush Tube B allR eturn G uide H alves (2) R .H . L.H . R etaining R ing (2) R oller B earing D irt S eal D irt and W ater S eal(Trunnion) W asher (S pacer) S eal(2-O utput) G asket (S ide C over) S pecialB olts (6 or 8-S ide C over)
11
TAS Series ExplodedView -- StepBore 48 49
47
46 41 45
42
59/60 52/53
63
52A
41 37 34 23A 24
22
61
23A
25 26
24
23A 26
22 23A
27 30
29
22
28 19 21
31
20 18 17
9
8 16 15 13 56 15
34
12
58 11
S hort "V " C onstruction
10
9
31
57
2C
8 7
2B 6
32 28
5
27
20
54 /55
21
1 *2 *2B *2C *3 *4 5 *6 *7 *8 *9 *1 0 *11 12 13 15 16
B olts (4-Valve H ousing) D irt and W ater Se al13/16" S err. D irt and W ater S eal 7/8" S err. D irt and W ater S eal 1" S err. R etaining Ring Seal (Input Shaft) V alve H o usin g Seal R ing (Valve H ousing) Seal R ing (Valve H ousing) SealRing (2) O -rin g (2 ) S ealR in g O -ring (Valve H ousing) Thrust W asher (Thick) Input Shaft, Valve,W orm A ssy. Thrust B earing (1 or 2) Thrust W asher (Thin)
17 *18 19 *20 *21 22 23 24 26 27 28 * 29 30 *31 *32 34 35 37
B earing Adjuster Adjuster Locknut R a ck P isto n Teflon SealR ing O -ring (B ack up; R ack Piston) Poppet Seat and Sleeve Assy. (2) P op pe t (2) P o pp et S p rin g P ush Tube B alls B allR eturn G uide H alves (2) S e al(C a p) B allR eturn G uide C ap Torx Screw s (2-C ap/Strap) B allR eturn G uide S trap H ousing G rease Fitting R oller B earing
*41 42 43 44 *45 46 47 48 *49 50 51 52 52A 53 54 *55 56 *57 58 59 60 *61 63
2
Seal(2-O utput) S e cto r S h aft A djusting S crew (Se ctor Sh aft) R etainer (A djusting Screw ) G asket (Side Cover) S id e C o ve r A s se m b ly Jam N ut S pecialB olts (6 or 8-S ide C over) Vent Plug (Side Cover) B le ed S cre w (M an ual) Plug (Auto B leed) Fixed Stop Screw (Poppet) Fixed Stop Screw (P oppe t-A lt) W ash er (S to p S cre w ) A uxiliary P ort P lug (2) O -ring (2-A ux. P ort Plug) R elief Valve Cap O -ring (R elief V alve) R elief Valve (2 piece) Se rvice Popp et A djusting Screw Service Sealing Jam N ut D irt & W ater Seal (Trunnion) R etaining Ring
*The se item s are included in com plete se al kits along w ith 0454 22 lubrican t and a se rvice bu lletin.
12
3
1
19
Item Description
4
Service Parts List - StepBore CommonParts
Parts VarybySpecification*
ItemDescription
PartNumber
ItemDescription
1 2 2B 2C 3 4 7 8 9 10 11 12 15 16 17 18 27 29 30 31 32 35 43 44 47 49 50 51 52A 54 55 57 59 60
020251 4 78 04 4 478060 478050 401637 478076 032823 029123 032200-158 029116 032200-152 400143 070027 400144 400149 027007 213684-X 1 478042 400161 020228 400167 037032 02 120 0 062005 G 9419666 036201 213705 021397 021426 G 9410358 032229 032200-153 02 140 7 025119
5 13 19 34 42 46 56 58
B olts (4-V alve H ousing) D irt an d W ate r S e al1 3/1 6" S e rr. D irt and W ater S eal7/8" S err. D irt and W ater S eal1" S er R etaining R ing S eal(Input S haft) (H igh Tem p) S ealR ing (V alve H ousing) S ealR ing (2) O -ring (2) (H igh Tem p) S ealR ing O -ring (Valve H ousing)(H igh Tem p) Thrust W asher (Thick) Thrust B earing (2) Thrust W asher (Thin) B earing A djuster A djuster Locknut B alls S eal(C ap) B allR eturn G uide C ap Torx S crew s (2-C ap/S trap) B allR eturn G uide S trap G rease Fitting A d ju stin g S cre w (S ecto r S haft) R etainer (A djusting S crew ) Jam N ut V ent P lug (S ide C over) B leed S crew (M anual) P lug (A uto B leed) Fixed stop screw A uxiliary P ort P lug (2) O -ring (2-A ux. P ort P lug) O -ring (R elief V alve) S ervice P op pet A d justin g S cre w S ervice S ealing Jam N ut
V alve H o usin g Input Shaft, Valve,W orm A ssy. R a ck P isto n H ousing S e cto r S h aft S id e C o ve r A s se m b ly R elief Valve Cap R elief Valve (2 piece) *C on tact Se rvice/S ales for part nu m be rs
Kits Items
Description
PartNumber
54 & 55 5 6 & 57 59 & 60 2 ,2 B , 2 C , 3 , 4
P ort P lug & O -ring R e lief V alve C ap & O -rin g A dj. S crew & Jam N ut In pu t S h aft S e alK it TA S 40 S ealK it TA S 55 S ealK it TA S 65 S ealK it TA S 85 S ealK it
415437-A 1 4 11 061 -A 1 021407-X 1 T A S 0 00 00 1 TA S 400004 TA S 550004 TA S 650012 TA S 850003
Parts Vary by Gear Size ItemDescription
TAS40
TAS55
TAS65
TAS85
6 20 21 22 23 23A 24 26 28
032829 032828 032827 409118-A 2 040210 040248 401662 080154 400158 400159 070030 478051 H FB 529000 021277 K 301963 401674
032829 032830 032831 409118-A 2 040210 040248 401662 080154 400160 400165 071032 478040 H FB 649000 G 223734 478095 401650
032616 032590 032615 409118-A 2 040210 040248 401662 080154 400156 400157 071033 478040 H FB 649000 G 223734 478095 401650
032834 032547 032556 409118-A 6 040217 040249 401684 080158 400162 400163 072004 478084 TA S 859000 G 223734 478096 401685
37 41 45 48 61 63
S ealR ing (V alve H ousing) Teflon S ealR ing O -ring (B ack up; R ack P iston) P oppet S eat and S leeve A ssy. (2) P oppet (2-old design) P oppet (2-new design) P oppet S pring P ush Tube B allR eturn G uide H alves (2) R .H . L.H . R oller B earing S eal(2-O utput) G asket (S ide C over) S pecialB olts (6 or 8-S ide C over) D irt & W ater S eal(Trunnion) R etaining R ing
13
14
Section2
Initial Installation
Installation .........................................................................15 P oppet S etting ..................................................................15 M aintenance Tips .............................................................16
Initial TAS Installation • B olt ge ar to fram e, torqu e to vehicle m anu facturer's reco m m en dation . • C onne ct return line to TA S return p ort. • C on ne ct hyd raulic line from pu m p to pressure po rt in TA S un it. • C onne ct stee ring colum n to input shaft, torqu e pinch bolt to vehicle m anufacturer's recom m endation. • Installpitm an arm on output shaft, torqu e bolt to vehicle m anufacturer's recom m en dation.
Initial PoppetSetting Fo r this proce du re to w ork correctly, you m ust have: A ne w ge ar rece ived from TR W or you r veh icle m anufacturer's afterm arket system , or a u sed ge ar on w hich po pp et seats have b ee n rep laced or rese t du ring ge ar disassem bly procedures. ALSO: A fixed stop screw installed in the housing, or a p oppet ad justing screw installed so that it duplicates the fixed stop screw length.
Theaxlestopsandall steering linkage must be set according to vehicle manufacturer's specifications,andthepitman armmust be correctly aligned onthesector shaft for poppetstobesetcorrectly. Full turnin one direction
1.
W ith the eng ine at idle an d the vehicle u nloade d, turn the stee ring w heelto fulltravelin one direction un tilaxle stop contact is m ade. M axim um inp ut torque to be ap plied during this procedure is 4 0 lb rim pu ll(17 8 N ) on a 20 in. (50 8m m ) diam eter stee ring w he el. If you en cou nter excess rim pu ll effort, allow the ve hicle to roll forw ard or jack up the ve hicle at the front axle.
Full turnin other direction
2.
Follow the sam e procedure w hile turning the stee ring w hee lin the other direction . The popp ets are n ow positione d to trip and reduce p ressu re as the steered w hee ls approach the axle stops in e ither direction.
15
Maintenance Tips Never high-pressure washor steamcleana power steering gear while on or off the vehicle. Doingso could force contaminantsinsidethegearandcauseittomalfunction.
M ake sure vehicle w he el cut or clearance s m ee t m anufacturer's sp ecifications, and m ake sure pitm an arm tim ing m arks are aligned p roperly to preventinternal bottoming of the steering gear.
Donotattempttoweldanybrokensteeringcomponent. R ep lace the com po ne nt w ith o riginal eq uipm en t on ly.
Donotcoldstraighten,hotstraighten,or bendanysteering systemcomponent.
A lw ays cleanoff aroundthe reservoir filler cap be fore yo u rem ove it. P reve nt dirt or other foreign m atter from entering the hydraulic system .
Regularly check the fluid and the fluid levelin the pow er steering reservo ir.
Investigateandcorrect anyexternal leaks, no m atter ho w m ino r.
Keep tires inflated to correct pressure.
Replace reservoir filters according to requirem ents. Never usea torchtoremovepitmanarm.
Investigate and im m ediately correct the cause of anyplay, rattle, or shimmy in any p art of the steering system .
If yo u feelthe ve hicle is deve loping excessive ly high hydraulic fluid temperatures, co nsu lt w ith yo ur ve hicle m anu facturer for reco m m en dation s.
Make sure the steeringcolumn is aligned properly.
Maintaingreasepack behind the output sh aft dirt and
Encourage drivers to report anymalfunctions or accidents that could have dam aged steering com pon ents.
StepBoreGear
Dirtand WaterSeal
16
w ater sealas a g en eralm ainten ance proce du re at least tw ice a year,in the S pring an d Fall. G rease fitting is provide d in h ou sing trun nion . U se on ly N LG I grade 2 or 3 m ultipu rpo se chassis lub e, and use on ly a han d op erated grease g un o n fitting. A dd g rease u ntilit begins to extrude past the sector shaft dirt and w ater seal.
Standard Gear
CorrosionInhibiting GreaseBarrier
Corrosion Inhibiting GreaseBarrier
Bearing High-Pressure OutputSeal
Dirt and WaterSeals
Bearing
High-Pressure OutputSeal
Section3
On-Vehicle Service
Filling and A ir B leeding the S ystem ..................................17 Input S haft S ealR eplacem ent ..........................................18 S ector Shaft A djustm ent ..................................................22 P oppe t R eadjustm ent S ingle G ears ...........................................................24 D ualG ears .............................................................27
FillingandAir Bleedingthe System Tools Required
Materials Required
⁄ So cket Lb f in. To rqu e w ren ch
H yd rau lic fluid
5 16
"
•
Make sure poppets are set correctlybeforebeginningthis procedure. Runenginefor10 seconds, turnoff and fill reservoir
1.
Fillthe reservoir nearly full. D o n ot steer. S tart an d run the engine for 10 seconds, the n shut it off. C heck an d refillthe rese rvo ir. R epeat at least three tim es, checking the reservoir each tim e.
H yd rau lic fluid
Do not allow the fluid level to drop significantly or run outof the reservoir. This may induce air intothesystem.
Runenginefor2 minutes,turnoff and fill reservoir
2.
S tart the en gine and let it idle for 2 m inu tes. D o not steer. S hut off the e ngine and check the fluid leve l in the reservoir. R efillas required.
3.
S tart the en gine again. S tee r the vehicle from full left to fullright se ve ral tim es. A dd fluid, as nece ssary, to the fullline on the dip stick.
H yd rau lic fluid
Steer vehicle
A utom atic blee d system s should n ow be free from trap ped air. Manual bleedsystemscontinuewithstep4.
Auto Bleed Plug Do Not Remove
M anual Bleed Screw
Allow air tobleed outfrombleed screw Lb f in. Torque w rench 5⁄ 16 So cket •
"
4.
W ith e ngine idling, steer from fullleft turn to full right turn several tim es. S top steering and loosen the m anu alblee d screw abo ut on e turn. A llow air and aerated fluid to "bleed out" untilonly clear fluid is se en. C lose the bleed screw , refillthe rese rvo ir if required. R epeat step 4 three to four tim es u ntilallthe air is discharge d. To rqu e m anu alblee d screw to 45lbf in. •
Do not turn steeringwheel with bleedscrew loosened. 17
Input Shaft Seal Replacement Tools Required
Materials Required
H am m er J37073 S crew driver
C lean cloth D rip p an H igh p ressure fitting H ydraulic fluid P lug Shop tow el
Th is proce du re u ses the vehicle's po w er stee ring pu m p to force out the input shaft seal. T o u se this proce dure, the p ow er steering p um p should have a m inim um of 1,500 psi availab le.
1.
D iscon ne ct return line from the stee ring ge ar and plug the line. A lso cap the return p ort of the gear w ith a h igh pressure fitting.
Disconnect column
2.
R em ove the steering colum n from the gear input shaft.
Removedirt& water seal
3.
R em ove the dirt and w ater sealfrom the steering gear. S ave this sealto m atch the new sealto the co rrect size.
Removeretaining ring
4.
W ipe out the grease and then rem ove the spiral retaining ring. U se a screw drive r inse rted into the notch form ed in the e nd of the ring. B e carefulnot to scratch the bore w ith the screw driver.
Disconnect return line H igh pressure fitting P lug
C lean cloth S crew driver
18
Replace column
5.
S lip the stee ring colum n back onto the inp ut shaft w ith the pinch bolt installed, but not tightened.
Wrap exposed area
6.
Tie o r w rap a shop tow el aroun d the inp ut shaft area and place a d rip pan unde r the vehicle to catch the oil.
7.
A dd fluid as n ece ssary, to the fullline on the dipstick. D o n ot m ix fluid type s.
D rip p an Shop tow el
Fill reservoir H ydraulic fluid
Anymixtureoffluidtypes,oruseof anyunapprovedfluidcouldleadto seal deteriorationandleaks. A leak couldultimately cause the loss of fluid, which could result in aloss of powersteeringassist.
Force out the seal
8.
W ith the veh icle in ne utral, m om en tarily turn the starter (quickly turn off the engine if it starts).
Removeinputshaft seal
9.
R em ove the shop tow el. D isconnect the steering colum n, and rem ove the inp ut shaft seal.
19
Inspect seal area
10 . C he ck the seal area o f the valve h ou sing for any se al fragm en ts. R em ove any that are fou nd .
Inspectoldseal
11 . C he ck the sealfor he at dam age. If the sealis stiff an d brittle, an d not pliab le like the new se al, it is prob ably heat dam aged . D eterm ine an d fix the cau se of exce ssive heat in the vehicle.
Install new seal
12 . P ut clean grease 04 54 22 on the inside dia. of the new input shaft seal, an d place it over the input sh aft. W ith the sm alldia. of toolJ37073 against the se al, tap the tooluntilthe toolsh oulder is square against the valve h ou sing . R em ove any sealm aterialthat m ay have sheared off in the sealbore o r retaining ring groove .
New Seal
HeatDamagedSeal
H am m er J37073
Donotuse asocket toinstall this seal because you will not be able to control seal installation depth, possibly causinga leak.
20
Install retaining ring
13 . Inse rt ne w retaining ring into the groo ve.
Install dirt &water seal
14 . P ack the end of the valve h ousing bo re arou nd the inp ut shaft w ith grease 045 42 2. C ho ose the correct size d irt & w ater sealby co m paring the choices to the old seal, or by m easuring the m ajor diam eter of the input sh aft se rrations (see ch art next pag e). A pp ly m ore grease 04 542 2 to the n ew dirt & w ater sealand installit over the input shaft. S eat it in the groo ve beh ind the serrations and against the valve ho using .
Reconnectcolumn
15 . R eco nn ect the stee ring colum n to the inp ut shaft an d tighten the pinch bolt to torque leve lsp ecified.
Reconnectreturn line
16 . R eco nn ect the return line to the stee ring ge ar return port.
Air bleed system
17 . A ir bleed the system using the p roced ure on page 17 .
Seal PartNo.
SerrationSize
Major SerrationDia.
478044
13/16" x 36
0.807 / 0.799
478060
7/8 x 36
0.866 / 0.857
478050
1" x 36
0.987 / 0.977
478050
1" x 79
1.008 / 1.000
21
Sector Shaft Adjustment Tools Required
Materials Required
S crew driver 3⁄ 4 So cket 3⁄ 4 O pen end w rench
Th is adjustm en t can on ly be com pleted on the veh icle if the adjusting screw jam nut is acce ssible. T his nut is located on the side cover. P ho tos in this se ction w ere taken on a m ock fram e railfor clarity.
"
"
Centerthesector shaft
1.
W ith the en gine on , rotate the stee ring w he el (inp ut sh aft) untilthe tim ing m ark on the se ctor sh aft lines up w ith the m ark on the ho using . The line on the sector shaft should be at a 90 angle from the inp ut shaft. T he sector shaft is now on its "ce nter of travel". Turn the ve hicle off. °
Removethedrag link
2.
R em ove the drag link from the pitm an arm .
To avoid resettingthe poppets, do notrotatetheinputshaftmorethan 1 1 ⁄ 2 turns fromthe"center of travel" positionwhile the draglink is disconnected.
Check forsector shaftlash
3.
From the "center of travel" po sition , grasp the pitm an arm an d gently try to rotate it back an d forth. If loose ness or lash is felt at this p oint, the se ctor shaft is out of ad justm ent.
Loosenjamnut
4.
L oo se n th e jam n ut.
⁄ S ocket
3 4
22
"
If the ge ar is rem ove d from the ve hicle to ad just the lash: •Le ave the pitm an arm con ne cted to the ge ar. •B est option is to follow the FinalA djustm en t proced ure on p age 63 . •A lternate option is to continue w ith step 5 of this procedure.
Positionadjusting screw
5.
If no lash w as detected in step 3, turn the shaft adjusting screw counterclockw ise untilyou feellash at the output shaft.
6.
S low ly turn the shaft adjusting screw clockw ise un til you feelno lash at the output shaft w ithout using m ore than 1 0 lbf ft (14 N m ) of torque. From this position, turn the screw clockw ise 1⁄8 to 3⁄16 of a turn m ore. H old the adjusting screw in place , and tighten the jam nut. Final jamnut torque 43lbf ft (58 N m ).
S crew driver
Adjust shaft
•
S crew driver 3⁄ 4 O p en e nd w rench "
•
•
•
Recheck for lash
7.
Turn the steering w heel 1 ⁄4 turn each side of center, the n back to cen ter and rech eck the pitm an arm for lash. Y ou sh ould feelno lash; if there is lash, repeat step s 4, 6 an d 7 .
Connect draglink
8.
R econ nect the d rag link to the p itm an arm according to m an ufacturer's specifications.
Maintain grease in the sector shaft bearingthroughthegreasefitting in the housingusingonly a hand operated grease gun. Addgreaseuntil itbeginstoextrudepastthedirtand water seal. Do not use a power grease gunbecause it will supply grease too fast; this could adversely affect thehighpressureseal andcontaminatethehydraulic fluid.
23
Poppet Readjustment- Single Gears Tools Required
Materials Required
⁄ A llen w ren ch ⁄ O pen end w rench 3⁄ 4 O pen end w rench 3⁄ 4 Socket Lb f lb T orqu e w rench
H ydrau lic fluid Jack
7 32 58
"
"
"
"
This resetting p rocedure w illw ork in m ost case s w ith at least 1 3 ⁄4 hand-w heel-turns from each side of center. If you're m aking a large redu ction in w heelcut and this proce du re doe s not w ork, you m ay have to rep lace or internally reset the pop pets u sing the procedure describe d in the P op pe t C om po ne nt section of this S ervice M anual.
•
Setaxlestops, warm-upsystem
1.
S et the axle stop s to ve hicle m anu facturer's w heelcu t or clearance sp ecifications. S tart the engine and allow the vehicle to idle for 510 m inutes to w arm the h ydraulic fluid. S hut off the en gine .
Assemble adjustingscrewintonut
2.
If a new popp et adjusting screw and nu t are be ing used, turn the screw into the non-sealing en d of the jam nut untilthe drive end of screw is flush w ith the nut. Y our steering gear w illhave either a fixed stop bolt or an adjusting screw . If the adjusting screw is already p art of the steering gear, back the nut off of the ad justing screw untilit is flush w ith the end of the adjusting screw .
Remove poppet stop bolt
3.
⁄ O p en e nd w rench 58
M ake sure the en gine is off and the road w hee ls are in straight ahead position. R em ove and d iscard the poppet fixed stop bolt (if equipped) and w ash er (if eq uipp ed ) from the low er en d of the ho using .
"
Turnadjusting screwassembly intohousing
If the unit has a popp et adjusting screw and sealing nu t that ne ed to be rep laced, rem ove and discard them .
4.
Turn the adjusting screw and sealing n ut assem bly, w ithout rotating the nut on the screw , into the housing untilthe nut is firm ly against the housing using a 7 ⁄32 A llen w rench. Tighten the se aling nut against the housing . "
⁄ A llen w rench 7 32
24
"
If thedriveendofthescrewis below the face of the nut, the popet seat flange will break duringstep 7d.
Refill reservoir
5.
R efillthe system reservoir w ith ap prove d h ydraulic fluid.
H yd rau lic fluid
Donotmix fluid types. Mixingof transmissionfluid,motoroil,or other hydraulic fluids will cause seals todeteriorate faster.
J ack upvehicle
6.
P lace a jack un de r the cen ter of the fron t axle and jack up the front end of the ve hicle so the steer axle tires are off the ground.
7.
a) S tart the engine an d let it run at idle sp eed.
Jack
Pushupperpoppet outtoprepareitfor setting
b) N ote w hich ou tpu t shaft tim ing m ark is nearest the ho using piston bo re.
c) Turn the steering w heelin the direction that m akes this tim ing m ark m ove tow ard the adjusting screw just installed. Turn in this d irection untilaxle stop co ntact is m ade.
d) P ullhard on the stee ring w hee l(put up to 40 lb rim pullon a 2 0" dia. stee ring w heel) after the axle stop is co ntacted.
Set upper poppet
8.
a) Turn the steering w heelin the opposite direction (en d of tim ing m ark aw ay from adjusting screw ) untilthe other axle stop is contacted.
b) P ullhard on the stee ring w he el(put up to 40 lb rim pullon a 2 0" dia. steering w heel).
c) R elease the stee ring w he el and shu t off the en gine .
Back outadjusting screw ⁄ A llen w rench 3⁄ 4 O pen end w rench 7 32
9.
Lo osen the sealing nu t and back ou t the adjusting screw until1" is past the n ut. T ighten the se aling nut against the h ou sing.
"
"
Donotholdthesteeringwheel at full turn for more than 10seconds at a time; the heat build-up at pump relief pressure may damage components.
25
Setlowerpoppet
10 . a) S tart the engine an d let it idle.
b) Turn the stee ring w heelin the original direction (end of tim ing m ark tow ard adjusting screw ), until axle stop contact is m ade.
c) H old the steering w heelin this p osition (w ith up to 40 lb rim pull) for 10 se conds, then release. R ep eat this ho ld and release proce ss as m any tim es as nece ssary w hile com pleting step 11 .
Positionadjusting screw ⁄ A llen w rench 3⁄ 4 O pen end w rench 3⁄ 4 So cket Lb f ft Torque w rench 7 32
"
"
"
•
The procedure is complete
11 . a) W ith steering w heelheld tightly at fullturn loose n the jam nu t and ho ld it in place w ith a w ren ch.
b) Turn the adjusting screw in (clockw ise) using finger-pressure only (don't use a ratchet), untilthe A llen w rench stops. D o n ot attem pt to turn it in further. P au se the turning-in process each tim e the drive r release s the steering w heel; continue turning only w hile the w heelis h eld at fullturn.
c) B ack o ff the adjusting screw 3 1⁄4 turns and tighten the sealing n ut. T orque sealing n ut to 35lbf ft. •
12. The p oppets have now been com pletely reset. Low er the vehicle. C heck the rese rvo ir an d fillif required.
Thelengthoftheadjustingscrew beyondthe nutmustbe nomore 1 than1 ⁄ 16 for proper thread engagement. "
The length o f adjusting screw be yon d the sealing nu t m ay be different for each ve hicle.
26
PoppetReadjustment- Dual Gears MirrorImageSystems andReversedImageSystems B efore se tting po pp ets on a du alge ar system , you m ust de term ine w he the r the system has m irror im age g ears or reversed im age g ears. T he procedures are slightly different for each type of system . 1.
P ark the vehicle w ith the w hee ls turned allthe w ay to the axle stop in e ither direction. T urn the ve hicle off.
2.
Loo k at the output shaft tim ing m ark ne arest the ho using p iston b ore o n the m aster gear. Is this m ark pointing tow ard the po pp et screw or aw ay from it?
3.
N ow check the sam e tim ing m ark on the rotary cylinder. D oes it point tow ard the poppet screw or aw ay from it? If they point to opp osite ends of the ge ars yo u have a m irror im age system . If the y both po int tow ard the po pp et screw s or bo th po int tow ard the en d o pp osite the po pp et screw s, you have a reversed im age system .
Lower Poppet Upper Poppets Lower Poppet
27
Poppet Readjustment - Dual Gears - Mirror Image Tools Required
Materials Required
⁄ A llen w ren ch ⁄ O pen end w rench 3⁄ 4 O pen end w rench 3⁄ 4 So cket Lb f lb Torque w rench
H yd rau lic fluid Jack
7 32 58
"
"
"
"
This resetting procedure w illw ork in m ost case s w ith at least 1 3⁄4 hand-w heel-turns from each side o f center. If you're m aking a large red uction in w hee lcut and this proce du re doe s not w ork, you m ay have to rep lace or internally reset the po ppets using the procedure describe d in the P op pe t C om po ne nt section of this S ervice M anual.
•
1.
S et the axle stops to veh icle m anufacturer ’ s w heelcut or clearan ce specifications.
7.
a) S tart the engine an d let it run at idle sp eed. b) Turn the steering w heelin the direction that
S tart the engine, an d allow the ve hicle to idle for 510 m inutes to w arm the h ydraulic fluid. S hut off the en gine . 2.
m akes the tim ing m ark on the m aster gear m ove tow ard the adjusting screw just installed. T urn in this d irection untilaxle stop co ntact is m ad e.
If ne w po ppe t adjusting screw s and nuts w illbe used , turn each screw into the no n-sealing en d of the jam nut untilthe drive end of screw is flush w ith the nut.
c) P ullhard on the steering w heel(put 40 lbs. rim pullon a 2 0" dia. steering w heel) after the axle stop is contacted. 8.
Y our steering gear an d rotary cylinder w illboth have either fixe d stop bolts o r ad justing screw s. If the ad justing screw is alread y part of the gear or cylinder, back the nut off of the ad justing screw untilit is flush w ith the en d of the adjusting screw .
a) Turn the steering w heelin the opposite direction (en d o f tim ing m ark on the m aster ge ar aw ay from ad justing screw ) untilthe other axle stop is contacted.
b) P ullhard on the steering w heel(put 40 lbs. rim pullon a 2 0" dia. stee ring w heel).
3.
M ake sure the e ngine is off and the road w heels are in straight ahead p osition. R em ove and d iscard the poppet fixe d stop bolt (if equipped) an d w ash er (if eq uipp ed ) from the low er en d o f ho using on bo th the gear and the cylinder. If either unit has a poppet adjusting screw an d sealing nu t that ne ed to be rep laced, rem ove and discard the m .
4.
5.
O n b oth the m aster ge ar and the rotary cylinde r, turn the ad justing screw and se aling n ut asse m bly, w ithout rotating the nut on the screw , into the housing untilthe nut is firm ly against the housing using a 7 ⁄32 " allen w rench . Tighten the sealing nut against the hou sing. R efillsystem reservoir w ith ap proved h ydraulic fluid.
Donotmix fluid types. Mixingof transmissionfluid,motoroil,or other hydraulic fluids will cause seals to deteriorate faster. 6.
28
P lace a jack un de r the cen ter of the fron t axle an d jack u p the front end of the vehicle so the steer axle tires are off the ground.
c) R elease the stee ring w he el and shut off the en gine . 9.
Lo osen the sealing nu t and back ou t the adjusting screw on the m aster gear until1" is past the nut. Tighten the sealing nut against the housing.
Donotholdthesteeringwheel at full turn for more than 10seconds at a time; the heat build-up at pump relief pressure may damage components. 10 . a) S tart the engine an d let it idle.
b) Turn the stee ring w heelin the original direction (en d o f tim ing m ark on the ge ars tow ard adjusting screw ), untilaxle stop contact is m ade.
c) H old the steering w heelin this position (w ith 40 lbs. rim pull) for 10 se co nds, then release. R ep eat this hold and release proce ss as m any tim es as n ece ssary w hile com pleting step s 1 1 & 12 .
11 . a) W ith steering w heelheld at fullturn, loose n the jam nut on the m aster ge ar and h old it in place w ith a w ren ch.
b) Turn the ad justing screw in (clockw ise) using finger- pressure only (don't use a ratch et), until the A llen w ren ch com es to a stop. D o no t attem pt to turn it in farther. P au se the turning-in process e ach tim e the driver releases the steering w heel; C ontinu e turning only w hile the w heelis h eld at fullturn.
15. The p oppets have now been com pletely reset. Low er the vehicle . C heck the rese rvo ir an d fillif required.
The lengthof the adjusting screw beyondthe nutmustbe nomore 1 than1 ⁄ 16 for proper thread engagement. "
The length o f adjusting screw be yon d the sealing nu t m ay be different for each ve hicle.
c) B ack o ff the adjusting screw 3 1 ⁄4 turns and tighten the sealing n ut. T orque the sealing n ut to 33-37 lbf ft. •
d) R elease the stee ring w he el and shut off the en gine . 12 . Lo ose n the sealing nu t and back out the adjusting screw on the rotary cylinder until1" is past the nut. Tighten the sealing nu t against the hou sing. 13 . a) S tart the engine an d let it idle.
b) Turn the steering w heelin the opposite direction (en d o f tim ing m ark on m aster ge ar aw ay from adjusting screw ), untilaxle stop contact is m ad e.
c) H old the steering w heelin this p osition (put up to 40 lb. rim pullon a 2 0" dia. stee ring w heel) for 10 seconds, then release . R epeat this ho ld an d release proce ss as m any tim es as n ece ssary w hile com pleting step 14 14 . a) W ith steering w heelheld at fullturn, loose n the jam nut on the rotary cylinder an d hold it in place w ith a w ren ch.
b) Turn the ad justing screw in (clockw ise) using finger- pressure only (don't use a ratch et), until the A llen w ren ch com es to a stop. D o no t attem pt to turn it in farther. P au se the turning-in process e ach tim e the driver releases the steering w heel; C ontinu e turning only w hile the w heelis h eld at fullturn.
c) B ack o ff the adjusting screw 3 1 ⁄4 turns and tighten the sealing n ut. T orque the sealing n ut to 33-37 lbf ft. •
d) R elease the stee ring w he el and shut off the en gine .
29
PoppetReadjustment- Dual Gears - ReversedImage Tools Required
Materials Required
⁄ A llen w ren ch ⁄ O pen end w rench 3⁄ 4 O pen end w rench 3⁄ 4 So cket Lb f lb T orqu e w ren ch
H yd rau lic fluid Jack
7 32 58
"
"
"
"
Th is resetting p rocedure w illw ork in m ost case s w ith at least 1 3⁄4 hand-w hee l-turns from each side o f center. If you're m aking a large reduction in w heelcut and this proce du re doe s not w ork, you m ay have to rep lace or internally reset the popp ets u sing the procedu re describe d in the P op pe t C om po ne nt section of this S ervice M anual.
•
1.
S et the axle stop s to veh icle m anufacturer ’ s w heelcu t or clearance sp ecifications.
7.
a) S tart the engine an d let it run at idle sp eed. b) N ote w hich ou tpu t shaft tim ing m ark is nearest
S tart the engine, an d allow the ve hicle to idle for 510 m inutes to w arm the h ydraulic fluid. S hut off the en gine . 2.
the housing p iston b ore.
c) Turn the steering w heelin the direction that m akes this tim ing m ark m ove tow ard the ad justing screw s just installed on both the gear an d the cylinder. Turn in this d irection untilaxle stop con tact is m ade .
If n ew popp et adjusting screw s and nuts are being used, turn the screw s into the n on -sealing e nd o f the jam nuts u ntilthe drive end of screw is flush w ith the n ut.
d) P ullhard on the steering w heel(put 40 lbs. rim Y our steering gear and rotary cylinder w illhave either fixe d stop bolts o r ad justing screw s. If the adjusting screw is already p art of the steering gear or cylinder, back the nut off of the ad justing screw untilit is flush w ith the end of the ad justing screw . 3.
pullon a 2 0" dia. stee ring w heel) after the axle stop is contacted. 8.
a) Turn the steering w heelin the opposite direction (en d of tim ing m ark aw ay from adjusting screw ) untilthe other axle stop is contacted.
M ake sure the en gine is off and the road w hee ls are in straigh t ahead position. R em ove and discard the poppet fixed stop bolts (if equipped) and w ashers (if eq uipp ed ) from the low er en d o f ho using on bo th the m aster ge ar and the rotary cylinde r.
b) P ullhard on the steering w heel(put 40 lbs. rim pullon a 20" dia. steering w heel).
c) R elease the stee ring w he el and shu t off the en gine .
If the unit has poppe t adjusting screw s and sealing nu ts that ne ed to be rep laced, rem ove and discard them . 4.
5.
6.
30
Turn the adjusting screw s and sealing nut assem blies, w ithout rotating the nut on the screw , into the housing untilthe nut is firm ly against the housing, on bo th the m aster gear and the rotary cylind er, using a 7⁄32 " allen w rench. Tighten the se aling nut against the ho using. R efillsystem reservoir w ith ap proved hydraulic fluid.
9.
Lo osen the sealing nu t and back ou t the adjusting screw until1" is past the n ut on bo th the m aster gear an d the rotary cylinder. T ighten the se aling nuts against both ho usings.
Donotholdthesteeringwheel at full turn for more than 10 seconds at a time; the heat build-up at pump relief pressure may damage components. 10 . a) S tart the engine an d let it idle.
Donotmix fluid types. Mixingof transmissionfluid,motoroil,or other hydraulic fluids will cause seals todeteriorate faster.
b) Turn the stee ring w heelin the original direction
P lace a jack un de r the cen ter of the fron t axle an d jack up the front end of the ve hicle so the steer axle tires are o ff the ground.
c) H old the steering w heelin this p osition (w ith 40
(en d of tim ing m ark tow ard adjusting screw ), until axle stop con tact is m ade.
lbs. rim pull) for 10 se co nds, then release. R ep eat this hold and release proce ss as m any tim es as n ecessary w hile co m pleting step s 11 and 12, first on the m aster ge ar, then on the rotary cylinder.
11 . a) W ith steering w heelheld at fullturn, loosen the jam nut on the m aster gear, and hold it in place w ith a w ren ch.
b) Turn the adjusting screw in (clockw ise ) using finger- pressure only (don't use a ratch et), until the A llen w rench co m es to a stop . D o no t attem pt to turn it in farther. P au se the turning-in process e ach tim e the driver releases the steering w heel; C ontinue turning on ly w hile the w heelis h eld at fullturn.
c) B ack o ff the adjusting screw 3 1⁄4 turns and tighten the se aling nut. Torque nut to 33-37lbf ft. •
12 . a) W ith steering w heelheld at fullturn, loosen the jam nut on the rotary cylinder an d hold it in place w ith a w rench.
b) Turn the adjusting screw in (clockw ise ) using finger- pressure only (don't use a ratch et), until the A llen w rench co m es to a stop . D o no t attem pt to turn it in farther. P au se the turning-in process e ach tim e the driver releases the steering w heel; C ontinue turning on ly w hile the w heelis h eld at fullturn.
c) B ack o ff the adjusting screw 3 1⁄4 turns and tighten the se aling nut. Torque nut to 33-37lbf ft. •
13 . Th e po ppe ts on bo th the m aster ge ar and rotary cylind er have n ow be en co m pletely rese t. Lo w er the ve hicle . C heck the rese rvo ir an d fillif required.
The lengthof the adjusting screw beyondthe nutmustbe nomore 1 than1 ⁄ 16 for proper thread engagement. "
The length o f adjusting screw be yon d the se aling nu t m ay be different for each ve hicle.
31
32
Section4
Reseal &Repair
D isassem bly .....................................................................33 Inspection .........................................................................41 A ssem bly ..........................................................................43 InternalD am age R epair (by reference) P oppet C om ponent R eplacem ent ...........................5 1 V alve H ousing W orm S crew D isassem bly ..............53 R oller B earing or R etaining R ing R eplacem ent........60 R oller B earing R eplacem ent - S tep B ore G ear.........61 R eplace H ousing P orts, P lugs, S crew s, Fittings ......62 Final A djustm ents .............................................................63
DisassemblyPreparation S top the veh icle w ith w he els pointed straight ahead. C lean off alloutside dirt from around fittings an d ho se connections be fore you rem ove the ge ar. R em ove input and o utput shaft conne ction s per vehicle m anufacturer's instructions.
Whenusingachisel tospreadapinchbolt-typepitmanarmboss forassemblyor removal fromthe shaft, maintain a firmgrip on the chisel at all times. Failure to dothis may result in the chisel flying loose which could cause an injury. Never leave the chisel wedgedin thepitmanarmboss. If youcannotremovethepitmanarmfromtheshaftwithachisel andyourhands,removethechisel fromthearm bossanduseapulleronlytoremovepitmanarm. Donotuseahammeronthepitmanarmtoremoveitfromsectorshaftas internal damageto steeringgear could result. Be sure there is no spreadingwedgeleft in the pitman armboss beforetighteningpitmanarmclampboltafterassemblyonsectorshaft. Donotpoundtheuniversal jointorinput shaftcouplingonorofftheinputshaftasinternal damagetothesteeringgearcanresult. Unless the poppet adjuster seat and sleeve assemblies (22) are to be removed and replaced or reset for automatic poppet adjustment, or a manual adjustment with aservice poppet adjusterscrew(59)andnut(60)is anticipated,donotallowtheinputshaftonasteeringgearwiththeautomatic poppet adjustment feature to rotate more than 1.5 input shaft revolutions from"straightahead position" when the output shaftis disconnected fromthevehicle steeringlinkage; this could disruptthepoppetsettingachieved at initial installation. The steering gear is in the "straight ahead position"when the timingmarks on the endof the housingtrunnionandsectorshaftarealigned. R em ove the supp ly an d return line s from the ge ar, and im m ediately p lug allpo rt holes an d fluid lines.
TAS steeringgears can weighupto 110pounds dry. Exercise caution whenyouremove, lift, carry, or fix in a bench vise. R em ove the stee ring ge ar from the veh icle and take it to a clean w ork su rface. C lean and dry the gear before you start to disassem ble it. A s yo u disassem ble the gear, clean allparts in clean, O S H A approved solvent, and air blow -dry them only.
Becausetheyareflammable, beextremelycareful whenusinganysolvents. Evenasmall explosionor fire could cause injuryor death. Weareyeprotectionandbesureto comply withOSHAorothermaximumairpressure requirements. Never steamcleanor high-pressure wash hydraulic steeringcomponents. Donotforce or abuse closely fittedparts. Use care that bearing andsealingsurfaces are not damagedby theassembly anddisassembly procedures. K eep e ach part separate to avoid n icks an d b urrs. D iscard allseals, o-ring s, and gaskets rem oved from the ge ar. R ep lace the m w ith ne w parts only. Th e stee ring ge ar shou ld be ide ntified to the vehicle from w hich it w as rem oved . Th e po pp et adjuster seat and sleeve assem blies are se t for that particular veh icle only. 33
Disassembly ToolsRequired
Materials Required
A llen w ren che s P ocket kn ife R atchet R olling head pry bar R ub be r m allet
E m ery cloth M asking tape
S crew driver Sockets: S tandard Torx V ise • •
Positiongear in vise
1.
P ut the stee ring ge ar in a vise, clam ping firm ly against the housing m ou nting flange or boss. Input sh aft should be horizon tal; side co ver and valve housing are acce ssible for disassem bly.
Donotclampagainstbodyof housing. If mountingboss or flange is notaccessible, fabricate andattach amountingplate tothehousingmountingbosses.
2.
P rep are for fluid d rainage and un plug hyd raulic ports.
Positionsector shaft
3.
R otate the inp ut shaft un tilthe tim ing m ark on the end of the se ctor sh aft is in line w ith the tim ing m ark on the end of the ho using . This w illpo sition the sector shaft for rem oval.
Removedirt& water seal
4.
Standard gears only - R em ove and discard dirt &
Unplugports A ppropriate size socke t or op en end w rench
Sm all screw driver
34
w ater seal (39) from the housing trunnion .
Cleansectorshaft
5.
R em ove any paint or corrosion from the exposed area of the se ctor sh aft (42).
6.
Tape the serration s and bo lt groo ve o f the sector shaft w ith one laye r of m asking tape. Th e tape should not extend onto the sector shaft bearing diam eter.
7.
R em ove the sector shaft adjusting screw jam nut (47).
8.
B e p repared for m ore fluid d rainage and rem ove the six o r eight specialbolts (48) from the side co ver (46).
9.
B e p repared for m ore fluid d rainage and rem ove the side cover and sector shaft assem bly from the ge ar. Y ou m ay start the shaft and cove r assem bly rem oval by tap ping the end of the sh aft lightly w ith a soft m allet or w ood en ham m er handle.
Fine g rade em ery cloth
Tape sector shaft M asking tape
Removejamnut ⁄ So cket
34
"
Remove side cover bolts ⁄ S ocket or ⁄ So cket
15 16
"
13 16
"
Remove side cover S oft m allet
35
Discardgasket
10 . R em ove an d d iscard the side cover gasket (45 ).
Removeventplug
11. R em ove and discard the vent plug (49).
Removesector shaftfromcover
12 . S crew sector shaft adjusting screw (43 ) clockw ise through the side cover and pullthe sector shaft out of the side cover.
S crew driver
Remove side cover seal ⁄ D rive so cket R olling head pry b ar 38
13 .
Don't damage the bore or DU bushing when removingthe seal. TAS85gears arenotequippedwiththeDUbushing.
"
C lam p the side co ver in a vise. P lace a standard 5⁄8 or 11 ⁄16 - 3 ⁄8 drive so cke t in the ce nter of the side co ve r. p ry the seal (41) out w ith a rolling h ead pry bar, using the socket for su pport. D iscard the seal and rem ove the socke t.
"
"
Inspectadjusting screw andretainer
36
14 . Inspe ct the sector shaft assem bly for dam aged adjusting screw threads. Th e retainer (44 ) m ust be securely staked in p lace. T he adjusting screw m ust rotate by hand w ith no perce ptible end play (lash).
Removerelief valvecomponents
15. If eq uipped , rem ove relief valve cap (56), o-ring (57) an d tw o-piece relief valve (58) from the valve housing. D iscard the o-ring.
⁄ So cket
78
"
Removedirt& water seal
16 . R em ove an d d iscard the dirt & w ater seal(2, 2B or 2C ) from the inp ut shaft (13 o r 13A ). S ave this seal for com parison w ith the ne w seal.
Clean inputshaft
17 . C lean any paint or corrosion from the exp ose d area of the input sh aft.
Fine g rade em ery cloth
Remove valve housingbolts
18 . R em ove the fou r torx head valve hou sing bo lts (1).
To rx socket E -16 o r E -18
Remove valve housing, wormand racksubassembly
19 . B e p repared for m ore fluid d rainage and rem ove the rack piston sub assem bly. P lace the assem bly on a clean cloth. For the TA S 85 it m ay h elp to rotate the inp ut shaft to m ove the rack p iston tow ard the low er end o f the h ousing. T his w illforce the valve housing to e xit the m ain h ousing.
Thesetpositionofpoppetseatand sleeve assemblies (22) must not be disturbedifthepoppetsarenotgoingtobereplacedor resetduringdisassembly.
37
P ocke t knife
Remove seals
19A.
If yo ur gear is short "V " co nstruction, the rack p iston se alis on the end of the rack piston farthest from the inp ut shaft. R em ove the sealbe fore rem oving the valve ho using assem bly to preve nt the Te flon rack piston sealring (20) from "han ging u p" w hen it exits the h ou sing. E xpose the se althrough the sector shaft cavity, then cut and rem ove the seal ring from the rack piston.
20 . R em ove and discard the valve hou sing seal ring s (6 & 7).
Donotremovetheinputshaft, valvewormassemblyorballsfrom the rack piston until the ball returnguides are removed as damageto the ball guides will occur.
Remove ball return guidecap/strap
21. R em ove and d iscard the tw o spe cialsealing screw s (31). R em ove the b allreturn cap (30) and seal(29), or strap (32), discard the se al.
⁄ A llen w ren ch or T-30 Torx w ren ch 5 32
"
OR Remove ball return guide clip
21 A . B en d do w n the tw o tabs (tang s) that are against the he x head bo lts. R em ove tw o bo lts and the clip. D iscard the clip.
1/2" S ocket
Remove ball return guides S crew driver
22 . M ake sure the rack piston is on a cloth so the stee l balls that fallout w on't rollve ry far. R em ove ball return guide halve s (28) by carefully inse rting a screw driver be tw ee n the rack piston and g uide s. Left han d ballreturn guide halves are co pper plated for identification an d right han d guides are n ot plated . Retaintheguidesforreassembly.
38
Remove steel balls
23 . R em ove the stee lballs (27 ) from the rack piston (19 ) by rotating the input shaft, valve w orm asse m bly untilthe balls fallout. P lace the balls and return guides in a cup o r other container. C ount the b alls, and m ake sure allhave bee n rem oved.
The steel balls are a matched set. If any are lost, the set must be replacedbyservice balls. Number of factoryballs installed: TAS40-29,TAS55-31(30if datecodeis337-89 orearlier),TAS65-32,TAS85-34. Separaterack pistonfromworm subassembly
24 . R em ove the inp ut shaft, valve/w orm , valve ho using sub assem bly from the rack piston .
Removeseal ring ando-ring
25 . C ut and rem ove the Te flon sealring (20 ) and o -ring (21) from the rack piston if not rem oved during disassem bly step 19A .
P ocke t kn ife
Inspect poppet assemblies
26. P ush po ppe t stem s,they shou ld spring back. P ush po pp et seat, it sho uld n ot m ove by h and . If com po ne nts are be nt or broke n, po pp et stem s d on 't spring back, or po pp et seat m ove s by hand , go to Poppet Component Replacement section o n pag e 51 . O the rw ise, proce ed to step 27 . TRW recom m ends the poppet adjuster seat and slee ve assem blies (22 ) no t be rem ove d u nless rep lacem en t of po pp et com po ne nts is req uired .
Inspectvalve housingand worm screw
27. Inspect valve ho using/w orm screw subassem bly for he at dam age or be aring rou gh ne ss. If the se co nd itions are prese nt, or if there w as excessive internal leakag e, or if preload ad justm ent is required, go to ValveHousing/WormScrew Disassembly proce du res on pag e 5 3. If no t, procee d to step 28 .
39
Removeretaining ring(if equipped)
28 . Standardgearsonly - R em ove the retaining ring (36 ) that is close st to the output end of the housing trunnion.
Removedirtseal
29 . Standardgears - R em ove and discard d irt seal(38).
S crew driver
Remove pressure seal (andspacer washerif equipped)
Stepboregears - R em ove and discard the dirt and w ater se al(61).
30 . Standardgears - Inse rt a screw drive r into the housing bearing b ore from the trunnion e nd, an d carefully pu sh the seal(41) and space r w ash er (40 ) out of the other end o f the be aring b ore withoutdamagingthe sealingarea of the bore . D iscard the seal.
S crew driver
StepBoregears - R em ove the retaining ring (63) through the side co ver opening. Then insert a screw driver through the trunnion op ening, and carefully p ush the se al (41) out withoutdamagingthe sealingarea of the bore . D iscard the seal.
Inspect roller bearing
31 . Standardgears - Inspect roller bearing (37) in the housing for brinelling or sp alling. Insp ect retaining ring for dam age. If replacem ent of either part is required, go to RollerBearingorRetainingRing Replacement on page 60 . If no t, procee d to step 32 .
StepBoregears - Insp ect the roller bearing (37) for brinelling or sp alling. If replacem ent is req uired, go to Roller BearingReplacement- Step Bore on page 61. If not,proceed to step 32.
Inspect housing screws, and plugs
32 . Inspe ct the follow ing for dam age: Pop pe t fixed stop screw (52 or 52 A ) and w ashe r (53) if equipped. P oppet adjusting screw (59) and sealing nut (60) A uto-blee d plug (51 ) M anualblee d screw (50 ) A uxiliary port plugs (54) an d o-rings (55)
•
• • • •
If any are d am age d, go to Replace HousingPorts, Plugs andScrews on page 6 2. If not, proceed to the Inspection S ection. 40
Inspection M ake sure allsealing surface s an d sealcavities are free from nicks and corrosion. A ny nicke d or corroded surface req uires part replace m en t to ensure proper sealing . W ash allparts in clean , O S H A app rove d so lven t. A ir blow the m dry on ly.
Becausetheyareflammable, beextremelycareful whenusinganysolvents. Evenasmall explosion or fire could cause injuryor death. Weareyeprotectionandbesure tocomply withOSHAorothermaximumairpressure requirements. Any of the followingconditions present in the steeringgear indicates impact damage.
Condition
Area
Brinelling
•Ball trackgrooves of rack piston • Ball track grooves of wormscrew • Bearingarea of sector shaft •Thrustwashersandbearingsinvalvehousing
Cracks or Breaks
•Bearingareaof sectorshaft •Sector shaftteeth •Rackpistonteeth • Housing •Thrustwashersandbearingsinvalvehousing • Wormscrew
Twistedserrations
•Outputshaftserrations
If one of these conditions is found in one component, be sure to inspect all components carefully for signs of impact damage. Replace components notedin individual inspection steps below if yoususpect impact damage. Failure to replace all damagedcomponentscouldresult in aserious vehicle accident.
Inspect rack piston 1. teeth
Insp ect the rack piston (19 ) tee th for cracks or ob viou s dam age. If tee th are dam aged , rep lace the rack piston , se ctor shaft (42) an d se t of balls (27).
Inspect rack piston 2. andwormball track grooves
Insp ect the rack p iston (19 ) balltrack g roo ves for brinelling or spalling. If either condition exists, replace the inpu t shaft, valve/w orm asse m bly, valve ho using, rack p iston sub asse m bly and b alls.
41
Inspect input shaft, valve/worm assembly sealing areas
3.
Inspe ct the sealing area o f inp ut shaft and valve (13 or 13A ) for nicks, and d am age. Insp ect for disco loration from excess h eat. Insp ect input sh aft ball-track groove s for brinelling or sp alling. If an y of these co nditions e xist,replace the input sh aft, valve w orm assem bly, valve h ousing an d balls. A lso replace rack piston if brinelling or spalling is found.
Inspect housing cylinder bore
4.
Inspe ct the ho using (34) cylinde r bo re. som e sco ring m arks are n orm al. If the re w as internal leakag e g reater than 1 gal/m in, m ake sure there are no dam age d se als be fore rep lacing the ho using .
Inspect housing faces
5.
Insp ect the ho using faces for nicks that w ou ld prevent proper sealing. R eplace the g ear hou sing if these nicks are present and can not be easily rem oved w ith a fine-tooth flat file w ithout changing the d im ensional ch aracteristics.
Inspect side cover bushing/bearing
6.
TAS40,55,65: Insp ect side cover (46 ) D U bu shing for dam age . A lso check side cove r bu shing to sector sh aft clearance . If dam ag e e xists, or if clearance excee ds .00 8" (0.20 m m ) rep lace side cover/bu shing assem bly.
TAS85: Insp ect roller bearing in side cover assem bly (46) for brinelling or spalling. If either condition exists, rep lace the side cover and bearing asse m bly.
Inspectsector shaft assembly
7.
Inspe ct the sector shaft (42 ) be aring and sealing areas and sector tee th contact surface s for brinelling, sp alling or cracks. R un yo ur fingernail ed ge across the se areas to detect step s. R em ove m asking tape from the shaft and inspect for tw isted or otherw ise d am aged se rrations. If any of these co nditions e xist,replace the se ctor shaft. A service se ctor sh aft w ill com e assem bled w ith the ad justing screw (43) an d retainer (44).
42
AssemblyPreparation W ash allparts in clean, O S H A approve d solven t. A ir blow -dry the m on ly.
Becausetheyareflammable, beextremelycareful whenusinganysolvents. Evenasmall explosionor fire could cause injury or death. Weareyeprotectionandbesureto comply withOSHAorothermaximumairpressure requirements. R ep lace allseals, sealring s, and gaskets w ith ne w on es each tim e you disassem ble the ge ar. TR W C om m ercialS tee ring D ivision m akes com plete se alkits available. Th ese parts can be purchased through m ost O E M parts distributors. C ontact yo ur localdealer for availab ility.
Assembly ToolsRequired ⁄ A llen w rench Lb f ft Torque w rench H am m er J37705 (TA S40 ) 5 32
"
•
J37071 (TAS55/65) J38779 (TA S85 ) P ress Punch R atchet S crew driver
Materials Required Sockets To rx sockets V ise
A TF oil S eal kit: R oss G rease (E xxon U nirex* R S 460 M asking tape 7⁄ lThread 16 "-14 x 7 1 ⁄ 4" A l
Install dirt seal
1.
TA S 40 00 04 TAS550004 TAS650012 TAS850005
StandardGears - Installnew dirt seal(38) into the trun nion e nd o f the h ou sing sector shaft bore and ag ainst the bearing, w ith the se al lip out.
Install retaining ring
2.
Standardgearsonly - Installthe outside retaining ring (36), seating it firm ly in the housing retaining ring groove.
*T rade m ark of E xxon O ilC orp. 43
Install washer
3.
Standardgearsonly - Installw asher (40) into the side cover side of the ho using sealbo re w ith the sm all diam eter piloted into the retaining ring.
If you are w orking w ith a ho using w ith an u nm achine d trun nion face, you m ay ne ed to sq uare the ho using to the p ress w ith shim s for step 4.
Press seal into housing
4.
All gears - A ssem ble ne w seal (41 ) on to be aring and se al tool(sh ort end) so the lip w ith the garter sp ring is tow ard the sh oulder of the tool. W orking from the side cover side of the housing, pilot the sealtool into the w asher and be aring and press w ith a force of 100-800 lb (445-3,560 N ) untilthe sealis seated firm ly.
J37705 (TA S4 0) J370 71 o r J370 71-A
(TA S 55 /65 ) J38779 (TA S8 5) P ress
Step Bore gears only - Installthe inside retaining ring (63) from the side cover open ing. S eat the ring firm ly in the retaining ring groove .
Greasethebearing andseal area
5.
se al (38) an d pressure se al (41) including roller bearing w ith clean, high tem perature industrial grease,045 422 E xxon U nirex* R S 460.
G rease
Install dirt &water seal
Standardgears - Liberally p ack the area betw een dirt
6.
StepBoregears - Installthe dirt & w ater se al (61) w ith the bearing and seal tool(long e nd), m aking su re it is n ot co cked. P ress the se al only u ntilit se ats ag ainst the bearing, don't push it in farther.
J370 71 o r J370 71-A
P ress Liberally pack the roller bearing an d new seals w ith clean , high tem perature industrial grease , E xxo n U nirex* R S 460.
Assemble seal rings
7.
Ligh tly oilne w sealring (7) and assem ble in valve ho using m ou nting face groo ve.
TAS40,55,65: O ilnew sealring (6) and asse m ble in valve ho using m ou nting face groo ve.
TAS85: O ilnew sealring (6) and asse m ble in valve housing p ilot groove .
*T rade m ark of E xxon O ilC orp. 44
Install rack piston o-ringandseal ring
8.
Installa ne w backup o-ring (21 ) and then a ne w Teflon sealring (20) on rack piston (19). D o not ove r-stretch these rings as you installthem . D o not allow the Teflon se alring to be tw isted.
Positionrack pistonin housing
9.
A pp ly clean oilto hou sing cylind er bo re. P lace the rack piston (19) in the housing piston bore w ith ball return g uide h oles up.
Insertwormand valveassembly into rack piston
10 . Inse rt the w orm screw into the rack piston close to m axim um dep th, w ithou t the valve h ou sing m aking contact w ith the po pp et stem . Insert tw o 7⁄16 -14 A ll threads through valve ho using bo lt holes and tighten into h ou sing to su pp ort the w orm screw . L ine up rack piston ballguide holes w ith the w orm balltrack groove s by rotating the input shaft.
⁄ -14 x 7 1 ⁄4" A ll Thread 7 16
"
Assemble ball return guide halves
"
11 . A ssem ble the ballreturn gu ide halves (28 ) into the rack p iston untilse ated , rotate the input sh aft slightly if nece ssary.
Donotseatguideswithahammer. Damagetoguidescanresultin subsequent lockup or loss of steering. If a new rack piston (19) or a new inputshaft,valve,wormsubassembly (13or 13A) is beingassembled, the balls (27) removedfromtheunitmustbediscardedandaservice ball kit utilized. The balls in a service ball kit are sized to function in the ball track guide pathas altered by componentreplacement. When usingthe service ball kit, use the correct quantityof service balls: TAS40-29, TAS55-31, TAS65-32, TAS85-34.
45
Assemble balls
12 . Hold the ball returnguides (28) firmly in place duringthis entire procedure. Insert as m an y of the steelballs as yo u can through the hole in the top of the ballreturn guides. R otate the input sh aft to p ullthe b alls dow n an d around the balltrack g uide p ath. C ontinue u ntil the co rrect num ber of balls are in the balltrack guide path.
Holddowntheball returnguides until capor clipis reinstalled. Failure to hold the guides will result in a trapped ball or balls, which could cause a vehicle accident. If the ball guides become unseated (raise up) at anytime, repeat the procedure starting atstep 9. The correct number of balls are requiredforpropergearoperation. Count the balls andinsert each carefully as in step11. TAS40 TAS55 TAS65 TAS85 29 30/31* 32 34 29 31 32 34
Original Service
*TAS55gearsbuiltpriorto338-89wereequippedwith 30balls. Do not allow valve housingto contactthepoppetstemor move 12 inches (69 more than2 ⁄ .1mm)fromupperendofrack piston during these procedures. This could incorrectly resetthepoppet,orback outwormbeyondclosedball loop,trappingballs. Remove anyfluid present in the twoscrew holes. Fluid inthese holes could cause improper clamp load when torquing thecap or strap screws.
Assemble ball returnguidecap ⁄ A llen or T30 Torx socket Lb f in. Torque w rench G rease 5 32
"
•
46
13 . P lace a new ballreturn gu ide cap seal(29 ) in the sealgroo ve o f the cap (30 ). M ake su re the seal m akes fullcontact w ith the rack piston surface . Installtw o ne w A llen or Torx h ead screw s (31 ) and torque each screw alternately untila final torque of 18 lbf ft (24.5 N m ) is ach ieved . •
•
Ball capseal is greasedtohold seal ingroovewhileassembling. Besurenottotraptheseal outsideofthegrooveduring reassembly.
Assemble ball returnguidestrap ⁄ A llen or T30 Torx socket Lb f in. Torque w rench G rease 5 32
"
•
Rotate input shaft to check for proper installationof balls
14 . If your ge ar w as equ ipp ed w ith the ballreturn g uide strap (32), or if it w as equipped w ith the clip, install the n ew ballreturn g uide strap . P osition it on the rack piston, installtw o new A llen or Torx head screw s (31) and torqu e each screw alternately until a final torque of 18 lbf ft (24.5 N m ) is ach ieve d. •
•
15 . R otate the inp ut shaft from on e e nd of travelto the othe r w itho ut contacting the po pp et stem to the valve h ou sing , and w itho ut m oving the valve h ou sing face m ore than 2 1⁄2 (69 .1 m m ) from inp ut en d (upper end) of rack piston. If you can not rotate the inp ut shaft, rem ove the balls and reassem ble the m . "
If you install a gear ona vehicle with the wormshaft unable to rotate, the gear will not function correctly. Steering and gear failure may result. Install rackpiston, worm,valve assembly O il
16 . A pply clean oilto Te flon sealring (20) on rack piston. M ake su re the re is a space of 3⁄8 - 1⁄2 (10.0-13.0 m m ) be tw ee n valve h ou sing (5) and po pp et stem to preven t po pp et con tact at eithe r en d. R em ove the A llThreads, and push the rack p iston asse m bly into the ho using w ith the rack p iston teeth tow ard the se ctor sh aft cavity. Line u p the valve housing cylinder fee d hole w ith the gear housing feed ho le. M ake sure bo th o-ring s in the valve ho using rem ain in position. "
Donotdamagetheseal ring(19) whileinstallingtherackpiston intohousing. If theseal ringendof rack pistonenters thehousingfirst,theseal ringwill bedestroyedwhen therack isremoved. Thepoppetseatandsleeve assemblies (22)mustnotbottom againsttheinternal poppetstopsinthesteeringgear until thegear is installed onthevehicle andthepoppet adjustmentprocedures areperformed.
Install valve housingbolts
17 . Lubricate and installthe four valve hou sing bolts (1) into the housing. Torque the TAS40,55and65bolts alternately to 80 lbf ft (108.5 N m ). To rqu e TAS85bolts to118lbf ft (16 0 N m ). •
E -16 To rx socket (TA S 40 , 55 , 65 ) E -18 To rx socket (TA S 85 Lb f ft Torque w rench
•
•
•
•
47
Install reliefvalve parts ⁄ So cket Lb f ft Torque w rench 78
"
•
18. If the g ear is equippe d w ith a relief valve, asse m ble a new o-ring (57) on relief valve cap (56). A ssem ble the sm allend o f tapered spring o nto the pin o n the relief valve cartridge an d inse rt the asse m bly (58), (large end of tap ered sp ring end first)into the relief valve cap cavity. Turn the relief valve cap as assem bled into the valve ho using and torqu e to 30 lbf ft (41 N m ). •
Lubricate side coverbushing/ bearing
•
19 . TAS40,55,65: Lightly oilD U bushing. Donotgrease.
TAS85 only: A pp ly a ge nerous am ou nt of E xxon U nirex* R S 46 0 (do no t substitute ano the r type of grease) to the caged b earing assem bly inside the side cover.
This bearingis sealed and will receive no lubrication fromthe hydraulic fluid inthegear. Failure to use the proper grease could result in premature bearingwear.
Press seal in side cover J37705 (TA S40 ) J370 71 o r J370 71-A
(TA S 55 /65 ) J38779 (TA S85 ) Press
Lubricatesector shaft
20 . G rease and assem ble ne w seal(41 ) on to installation toolso the side w ith the garter sp ring is against the sh oulder of the tool. P ilot the toolinto the side cover (46) w ith a force of 10 0-800 lb (445 -3560 N ) untilit is seated ag ainst the bearing or bush ing.
Make sure the OD of the seal, and theIDoftheborearefreefrom greaseanddust,forproper engagementoftheseal.
21 . TAS40,55,65: Lightly oilsh ort bearing area o f se ctor shaft. Donotgrease.
TAS85 only: A pp ly a ge nerous am ou nt of E xxon U nirex* R S 46 0 to the sho rt be aring area of the se ctor sh aft.
Install sectorshaft into side cover S crew driver
22. Insert the sector shaft (42) into the side cover subassem bly (46 ), and screw the sector shaft ad justing screw (43) counterclockw ise into the side co ver untilthe screw reaches so lid height. R otate the adjusting screw clockw ise one half turn so the side co ver w illrotate freely o n the sector sh aft.
*T rade m ark of E xxon O ilC orp. 48
Install jamnut
23. Installthe se ctor shaft adjusting screw jam nut (47) onto the sector shaft ad justing screw (43) a few threads. F inalad justm ent w illbe m ade later.
Assemble vent plug
24 . P ress the ne w ven t plug (49 ) into the ho le p rovide d in the side co ver untilthe plug is bottom ed.
Do not weld or otherwise plugthis hole in anypermanentmanner. This is a safety ventwhich functions only if the side cover seal fails. If theseal fails andthe plugcannot vent,thesteeringgearmaylock-uporotherwise malfunction.
Install side cover gasket
25 . A pp ly clean g rease to the n ew side co ver gasket (45) to hold it in place and assem ble it onto the side cover (46).
Centerrack piston
26 . Th ere are fou r tee th on the rack piston . R otate inp ut shaft to position the rack piston so the space be tw ee n the secon d and third too th is in the center of the se ctor shaft opening. This w illcenter the rack piston for assem bly of sector sh aft.
If therack pistonis notcentered whensectorshaftis installed,gear travel will beseverelylimitedinone direction. This could result in anaccident. Install sectorshaft andside cover into housing M asking tape
27 . C lean off any old tape on the serration s. R eap ply one laye r of m asking tape. Installthe sector sh aft asse m bly into the housing . The ce nter too th of the sector shaft m ust en gag e the cen ter space (be tw een the second and third tooth) of the rack piston, w ith side cover gaske t in place .
If the serrations are not properly taped,theywill damagetheoutput seal (38)in housing, causingtheseal to leak.
49
6
Install side cover bolts
1 TAS85
3
4 2
8
5
⁄ S ocket (TA S4 0) 15 ⁄ 16 S ocket (TA S 55 , 65 , 85 ) Lb f ft Torque w rench 13 16
1
"
"
TAS40, 55,65
6
3 5
4 2
7
•
Remove tape
28 . InstallTA S 40 , 55 and 65 bo lts in p osition s 3 and 4 first,by h an d. For TA S 85, Installin positions 3 an d 6 first,by h an d. Installthe rem aining sp ecial side cover bolts (48) into the side cove r and torque them in the sequ en ce show n. If bo lts m ust be rep laced, use bo lts of the sam e d esign , type and len gth as tho se you rem ove d. D o not use a su bstitute. Lu bricate side cover bolts an d torque TA S 40 bolts to 118 lbf ft (16 0 N m ), TA S 55 , 65 and 85 bo lts to 170 lbf ft (23 0 N m ). •
•
•
•
29 . Standardgears - R em ove tape from sector shaft and pack the e nd of the housing trunnion area at the sector shaft w ith clean , high tem perature industrial grease , E xxon U nirex* R S 46 0. A pp ly m ore of the grease to the inside of the new trunnion dirt seal (39) an d assem ble it over the sector sh aft and into the trun nion bore.
Stepboregears - rem ove tape from the sector shaft.
Install dirt &water seal G rease
30 . P ack the en d o f the valve h ousing bo re arou nd the input shaft w ith clean, high tem perature industrial grease , E xxon U nirex* R S 46 0. A pp ly m ore of the grease to the inside of a ne w dirt and w ater seal(2, 2B or 2C ) an d installit ove r the input sh aft. S eat the sealin the groove behind the serrations and against the valve housing. Th is step m ay have alread y bee n com pleted if you disassem bled the valve h ou sing and w orm screw for repair.
Proceed to Final Adjustments on page 63.
*T rade m ark of E xxon O ilC orp. 50
PoppetComponentReplacement ToolsRequired
Materials Required
2 lb S led ge Lb f ft Torque w rench J36 45 2-A P ress 3⁄ llrod 8 x 6" dri
Locquic "T" prim er Lo ctite R C 68 0
•
R atchet S oft-jaw ed vise
"
Place rack piston in vise
1.
If the po ppet assem blies are to be rem oved for replacem ent, place rack piston in a soft-jaw ed vise .
2.
S lide specialtoo l#J36 45 2-A over the seat of pop pe t adjuster seat and slee ve assem bly (22 ) and e ng age toolin the slots in the thread ed sleeve . H it the e nd of the toolfirm ly fou r or five tim es w ith a 2 lb sledge ham m er to loo sen Lo ctite.
S oft-jaw ed vise
Loosen poppet adjuster seat J36 45 2-A 2 Lb S ledg e
Poppetadjusterseatandsleeve assemblies(22)areretainedby Loctiteappliedtothethreadswhichmakestheassemblies difficult toremove. Remove poppet adjuster seat
3.
W ith a ratche t app lied to the too l, turn o ne adjuster seat and slee ve asse m bly out of the rack p iston. If the ratchet does n ot turn easily, strike the ad juster rem ovaltoo lagain w ith a ham m er. If the en gaging tangs w on't stay in place w hile torquing, it m ight be necessary to hold in place w ith an arbo r press w hile applying loosening torque. D iscard p oppe t seat and slee ve assem bly.
4.
R em ove the tw o pop pets (23 or 23A ), spring (24), and p ush tub e (26 ). S om e g ears w illalso h ave a space r rod (25 ) to be rem ove d.
J36 45 2-A
Remove poppet components
Old Design
New Design
Spring Poppet
Poppet PoppetSeat Poppet Sleeve
Spacer Rod
PushTube
Spring Poppet
Poppet Poppet Seat
Poppet Seat and SleeveAssembly
Poppet Sleeve
PushTube
PoppetSeatand Sleeve Assembly
51
Remove other seat & sleeve if necessary
5.
R em ove and discard rem aining poppet seat and sleeve assem bly only if required. It is p ossible to rese t one pop pet adjuster seat and sleeve assem bly for autom atic pop pe t adjustm en t w hile it is in the rack piston if one ad juster se at an d sleeve assem bly and the po pp ets, spring , spacer rod and push tube are rem oved.
Resetremaining poppetseatand sleeveassembly
6.
"
P ress 3⁄ llrod 8 X 6" D ri "
ApplyLocquic "T" primerandLoctite RC680
7.
Locquic "T" prim er Lo ctite R C 68 0
Install onepoppet seat andsleeve assembly
J36 45 2-A Lb f ft Torque w rench
C arefully apply Locqu ic "T" prim er to the thread s in po pp et ho les, and thread s on the ne w seat and sleeve asse m blies (22). A llow to dry for ten m inutes; then carefully apply L octite ® R C 680 to sam e threads.
Do not allow Loctite or Locquic to getontheadjuster seatcomponent of theadjuster seat andsleeve assembly. The poppets will not function properly. 8.
S oft-jaw ed vise
Install remaining poppetcomponents
If on e p op pe t seat and slee ve assy. (22 ) w as left in rack piston, it can be rese t for au tom atic poppet adjustm ent by inserting a 3⁄8 (9.52 m m ) diam eter X 6" (15 2.4 m m ) drillrod do w n throu gh the po pp et seat hole at the oppo site en d of the rack piston and ag ainst the ad juster seat to press the se at in untilit bo ttom s ag ainst the adjuster slee ve.
Weareyeprotectionwhile assemblingpoppets,as spring loaded poppets could eject and cause eye injury. P lace rack piston (19) in a so ft-jaw ed vise an d turn on e new po pp et adjuster seat and slee ve assem bly (22), (slotted end out) into the poppet hole in one en d of rack piston.
Do notuse the spacer with the new poppet design. You must install the spacer withtheoldpoppetdesign. 9.
From the other end of the pop pet hole in the rack piston, install: o ne p oppet (23A ), poppet sp ring (24), pu sh tube (26), other po ppet (23 A ), and the o ther ne w po pp et adjuster seat and slee ve asse m bly (22 ). The n ew com pone nts w illstack up as show n below .
•
To rqu e bo th po pp et seat and slee ve assem blies to 18 lbf ft (25 N m ). •
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Returntostep27,page39. 52
Valve Housing/WormScrew Disassembly ToolsRequired H am m er Lb f ft Torque w rench P un ch, cen ter P unch , rollpin •
Materials Required
Lb f in. Torque w rench J37464 J37070 J37073 S crew driver •
S m allprob e o r pick Sockets 12-point sockets
Place valve housingandvalve assemblyinvise
1.
W ith w orm vertical, place the valve hou sing , inp ut shaft, valve/w orm asse m bly in a vise.
Unstakeadjuster locknut
2.
U nstake the valve housing (5) w here it w as upset into the ad juster locknut (18) slot. A lso unstake adjuster nut from ad juster (17).
3.
Tu rn b earing adjuster locknu t (18 ) ou t of the valve ho using .
4.
Tu rn be aring adjuster (17 ) ou t of the valve ho using .
R ollpin punch H am m er
Removebearing adjusterlocknut J37464
Removebearing adjuster J37070
53
5.
R em ove and d iscard se alring (8) and o -ring (9) from bearing ad juster.
Remove inputshaft
6.
R em ove the input shaft, valve/w orm assem bly (13 or 13 A ) from the valve h ou sing .
Remove thin washerand bearing
7.
R em ove thin thrust w asher (16) and thrust be aring (15) from input sh aft.
Removethick washerand bearing
8.
R em ove thick thrust w asher (12 ) and thrust be aring (15) from valve housing.
Removeseal ring ando-ring S m allprob e o r pick
Input shaft, valve wormassembly mustnotbedisassembledfurther. Thecomponentswereaselect fitatassemblyandare available only as part of this subassembly. If disassembled further, the subassembly must be replaced. OR Removebearing components
8A . Fo r alternate construction TA S 65 ge ars, rem ove sp acer sleeve (14), thin w asher (16), thrust bearing (15) and thick w asher (12).
If the TAS65 gear has a ball bearing andball race in the valve housing, removethemandcall TRWfor disposition. Donot rebuild the gear.
54
Removeseal rings ando-rings
9.
R em ove and discard sealring s (10 ) and (8) and o rings (11) an d (9) from valve housing (5).
S m allprob e o r pick
Remove retaining ring
10 . Tu rn o ver valve h ou sing and rem ove retaining ring (3).
S crew driver
Removeseal 1 1 ⁄8 So cket H am m er "
11 .
Exercise special care when removingseal (4)toprevent damagingthe valve housingseal bore. Tap input sh aft seal(4) out of valve housing. D iscard se al. The valve housing also utilizes a ballplug for m an ufacturing purpose s that m ust not be rem oved .
Inspect input shaft, valveworm assemblysealing areas
12. Inspect the sealing areas of input shaft and valve (13 or 13A ) for nicks and run yo ur fingernailedge across the sealing surfaces to d etect steps. Inspect for discoloration from exce ss heat. Inspect input shaft ball-track g roove s for brinelling or spalling. If any o f these cond itions e xist, you m ust rep lace the input shaft, valve/w orm assem bly, valve ho using and balls. A lso replace rack piston if brinelling or sp alling is found.
Inspect thrust washersand bearings
13. Inspect the thrust bearing (15) rollers for any deterioration. Inspect thrust w ash ers (12 & 16) for brinelling, sp alling, or cracks. R eplace an y part w ith these conditions.
AlternateConstructionTAS65: If sp acer sleeve (14) is dam aged, replace the input shaft/valve/worm subassembly and u se thick w ash er and roller bearing o nly du ring reasse m bly.
55
Place valve housinginvise
14. P lace valve housing (5) firm ly in a vise so the input shaft, valve/w orm assem bly (13 or 13 A ) can b e assem bled vertically w ith the w orm en d up .
Donotclampagainstthreadedport hole or relief valve hole sealing faceswhenplacingvalvehousinginvise.
Assembleo-ring
15 . O iland assem ble a n ew o-ring (9) into its counterbore in valve hou sing.
Assemble other oringand seal ring
16 . Ligh tly oiland assem ble n ew o-ring (11 ) and ne w se al ring (10) into the large diam eter se al ring groove in valve h ou sing , be nd ing and w orking the m in an d sm oo thing the m out as necessary.
Install roller thrust bearingand washer
17. Installroller thrust be aring (15) and then the thick w ash er (12) (square side out) onto input shaft en d of inp ut shaft, valve, w orm subasse m bly, seating the m ag ainst the input sh aft thrust face.
OR Install bearing components
17A. Alternate construction TAS65: A ssem ble spacer sleeve (14) onto input shaft w ith rad iused side tow ard valve. M ake sure slee ve is square. A sse m ble thin w ash er (16), thrust bearing (15) and thick w ash er (12 ) onto input shaft be hind space r sleeve.
If youare replacingthe input shaft/ valve/wormassembly, discard spacer sleeve and thin washer.
56
Install seal ring
18 . Ligh tly oiland assem ble n ew sealring (8) on to inp ut shaft and ag ainst the thick thrust w asher (12) to hold the be aring com po ne nts in p lace.
Assemble input shaft, valve worm & bearingassembly
19 . D ip the inp ut en d o f the inp ut shaft, valve, w orm assem bly (13 or 13 A ) into o ilup to the w orm lead . A ssem ble the inp ut shaft en d o f the assem bly into the valve housing (5) untilit is firm ly seated .
Assemble bearing andthrustwasher
20 . A pp ly oiland assem ble the othe r thrust be aring (15 ) then the thin thrust w asher (16) ove r the ballgroove en d o f w orm , and seat the m against the sho ulde r of inp ut shaft, valve, w orm assem bly.
Assemble seals in bearing adjuster
21 . Ligh tly o ila n ew o-ring (9) and assem ble into the sealgroove in b earing adjuster (17). O iland w ork a ne w sealring (8) into the sam e g roo ve an d sm oo th it out. B e su re the valve h ou sing , ad juster locknut and bearing ad juster threads are clean and free of any staking bu rrs that w ou ld im pe de the locknu t from turning freely o n ad juster or the ad juster turning freely in valve h ousing.
Assemble bearing adjuster
22 . Ligh tly o iland assem ble be aring adjuster (17 ) ove r w orm and into valve h ou sing . T orqu e ad juster to 13 lbf ft (18N m ) indicated torque using a torqu e w rench inse rted in ad juster tool#J3 7070. This w ill seat the com po ne nts. B ack off adjuster 1 ⁄4 to 1 ⁄2 of a turn. •
J37070 Lb f ft Torque w rench •
•
57
Assemble new locknut J37464
Adjust to required inputtorque ⁄ or 11 ⁄16 12 po int socket Lb f in. Torque w rench 34
"
"
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Torquelocknut J37070 J37464 Lb f ft Torque w rench •
23 . Ligh tly oiland assem ble ne w lockn ut (18 ) on to bearing ad juster (17) w ith rad ius (slightly rou nded) side dow n. Tighten slightly to ke ep the bearing ad juster in place.
24. R everse assem bly in vise so the w orm end is dow n. W ith an inch pou nd torqu e w rench on the inp ut shaft, note torque required to rotate the input shaft 36 0 in each direction. Tighten the bearing adjuster to increase the m axim um torqu e at the inp ut shaft 5-10 lbf in. (.5-1.0 N m ) ove r that w hich w as previou sly noted . °
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25 . A gain reve rse the asse m bly in vise. T orqu e lockn ut w hile holding bearing adjuster in position estab lish ed in step 24 w ith ap propriate ad juster tool. W he n u sing a torqu e w ren ch in lockn ut too lJ37 46 4, the torqu e w ren ch read ing sho uld be 112 lbf ft (152 N m ). •
•
The b earing adjuster, lockn ut and valve h ousing flange should be flush . If not, the se al ring (8) or o-ring (9) m ay be out of position; w hich w illresu lt in axial lash.
Checkinputshaft torque
26 . R ech eck inp ut shaft torqu e. It sho uld m atch torqu e m easu red in step 2 4. R ep eat step s 24 and 25 if necessary.
Stake valve housingand locknut
27 . S take valve ho using into the clockw ise m ost corne r of tw o o pposing slots in lockn ut (18). S take the lockn ut into the ad juster (17) in tw o place s (180 apart) at threaded area. C hoose areas that have n ot bee n previously stake d.
C en ter pu nch H am m er 13 ⁄ 16 So cket Lb f in. Torque w rench "
•
°
A fter staking, torque required to rotate input sh aft m ust be betw een 5-10 lbf in. (.5-1.0 N m ) greater than the torque noted in step 24 . Torque value m ust not exceed 22 lbf in. (2.5 N m ). U nstake and read just if nece ssary. •
•
58
•
•
Reposition subassembly in vise
28. R eposition w orm screw /valve ho using subassem bly in so ft-jaw ed vise , clam ping tightly ag ainst valve ho using , so the w orm screw is pointing do w n.
Install inputshaft seal
29. A pp ly clean g rease (E xxon U nirex* R S 460 ) to the outside and inside diam eters (fillcavity betw een the lips) of the new input shaft se al(4) and assem ble it, garter sp ring side first over the input sh aft. A lign se alin the valve housing se albore.
J37073 H am m er
A sse m ble sealinstaller tool#J3707 3, sm alldiam eter end first,ove r the input sh aft an d ag ainst the se al. Tap the se al installer tooluntilthe toolsh oulder is sq uarely ag ainst the valve housing. T his w illco rrectly position the se al in the housing bore just beyond the retaining ring groo ve. R em ove any seal m aterialthat m ay have sh eared off an d is in se albore an d retaining ring groove.
The input shaft seal must be square in the seal bore andinstalled to the correctdepth.
Insert retaining ring
30. Inse rt new retaining ring (3) into its g roove in valve ho using .
Install dirt & water seal
31. P ack the end of the valve ho using bore aroun d the input sh aft w ith clean , high tem perature industrial grease , E xxon U nirex* R S 46 0. A pp ly m ore of the grease to the inside of a n ew dirt and w ater seal(2, 2B or 2C ) an d installit ove r the input sh aft. S eat the sealin the groove behind the serrations and against the valve ho using.
G rease
Returntostep28,page40. *T rade m ark of E xxon O ilC orp.
59
Roller Bearingor Ret. RingRepl. - Standard ToolsRequired P ress J37071 (TA S 55 , 65 ) or J370 71 -A (TA S 55 , 65 ) J37705 (TA S4 0) J38779 (TA S8 5)
Materials Required S crew driver
Removeroller bearingif required
1.
ne ed s to be rep laced, place the be aring rem ovalen d (long end) of the bearing and seal toolag ainst the side cover end of the be aring and press it ou t of trunnion e nd of the b earing b ore. D iscard be aring .
J37705 J37071 or J37 07 1-A J38779 Press
Removeretaining ring
2.
3.
J37705 J37071 or J37 07 1-A J38779 Press
Standard Gears Only: Insert retaining ring (36), if it w as rem ove d, into the ho using bo re from the trunnion e nd (to protect se aling area). M ake su re it is seated in the retaining ring groove close st to side cover end of the be aring bore. Lubricate the bearing bore.
G rease
Pressinhousing rollerbearing
Standard Gears Only: If the retaining ring (36) that is stillin the housing bearing bore needs to be replace d, rem ove it through the trunnion end of the be aring bore to protect the pressu re sealbore area from being dam aged.
S crew driver
Install retaining ring
Standard Gears Only: If roller bearing (37) in housing
4.
Standard Gears Only: P ress the roller bearing (37) into the ho using from the trun nion en d of bearing bo re untilit is seated against the retaining ring. Don't push itfarther. B e su re the ho using is squ are w ith the press base and the be aring is not cocked .
Use the bearing installation end of thetool (short end). If the bearing removalendofthebearing&seal toolisusedtopress in bearing, the cage on the new bearingmay be damaged. Returntostep32,page40.
60
Roller BearingReplacement- StepBore ToolsRequired
Materials Required
Press J370 71-A (TA S 65 S tep B ore ge ar)
Removeroller bearingif required
1.
If roller be aring (37 ) in ho using ne ed s to be rep laced, place the be aring rem ovalend (long end) of the bearing and seal toolag ainst the trunnion end of the be aring and press it out of the side cover en d of the bearing bo re. D iscard be aring.
2.
P ress the roller bearing (37 ) into the ho using from the side co ve r end of the bearing bore untilit is seated against the step bo re. B e sure the ho using is sq uare w ith the press base and the be aring is n ot cocked.
J37 07 1-A P ress
Pressinhousing rollerbearing J37 07 1-A P ress
Use the bearing installation endof thetool (short end). If thebearing removal endofthebearing&seal tool isusedtopress in bearing, the cage onthe new bearingmay be damaged. If the un m ach ine d trunnion face is not square, use shim s to square it before pressing in the bearing.
Returntostep32,page40.
61
Replace HousingPorts, Plugs, Screws, Fittings ToolsRequired
Materials Required
A llen w ren ch To rx so ckets Sockets Lb f in. Torqu e w ren ch Lb f ft To rqu e w ren ch • •
Replace poppet fixed stop screw
1.
•
⁄ S ocket or E -14 To rx socket lbf ft Torque w rench 58
If dam aged, rem ove and replace the p oppe t fixed stop screw (52 or 52 A ) and w asher (53 ) if eq uipp ed . R eplace w ith p opp et fixed stop screw (52A ), discard the w ashe r. Torqu e to 48 lbf ft (65 N m ). •
"
•
Replace poppet adjustingscrew
2.
⁄ A llen w rench ⁄ or 5⁄8 closed-end w rench Lb f ft Torque w rench 7 32 34
A ssem ble the new nut on to the ne w adjusting screw , m atching its p osition to the nut and screw rem oved . To rqu e sealing n ut to 35 lbf ft (47 N m ).
"
"
If dam aged, rem ove popp et adjusting screw (59) and sealing nut (60) w ithout allow ing the nut to change its position on the screw .
"
•
•
•
Replace automatic bleedscrew, and aux. port plugs
3.
If dam aged, rem ove and replace autom atic bleed plug (51). Torque to 48 lbf ft (65 N m ). •
•
If dam age d, rem ove and rep lace pe rm ane nt auxiliary port plugs (54 ) and o-rings (55). A sse m ble new orings (55) on port plugs and torque to their respective ports in the housing or valve housing to 30 lbf ft (41 N m ).
E -14 To rx
socket Lb f ft Torque w rench •
•
•
Replacemanual bleed screw
4.
If dam aged,rem ove and replace m anualbleed screw (50). To rque to 45 lbf in. (3.4 N m ). •
⁄ H ex socket Lb f in. Torque w rench 5 16
"
•
Returntoinspectionsection,page41. 62
•
Final Adjustments ToolsRequired B ox-en d w rench Lb f ft Torque w rench Lb f in. Torque w rench
Materials Required
S crew driver Sockets
•
•
Center steering gear
1.
⁄ and 11 ⁄16 S ocke t or bo x end w rench
34
"
To center the stee ring g ear, rotate input shaft, valve w orm assem bly (13 or 13 A ) un tilthe tim ing m ark on the end of the se ctor sh aft(42) is in line w ith the tim ing m ark on the en d o f ho using trun nion .
"
Donotrotatetheinputshaft more than1.5revolutionsfromcenter position until the steering gear is installed, during poppet settingprocedure. Doingso couldmake the automatic poppets inoperative, which would require disassemblyofsteeringgeartorepositionpoppetseat andsleeveassemblies. Initial poppet co ntact w illoccur at less than one input shaft rotation in one direction from steering gear ce nter position, if new or reset poppet adjuster seat and slee ve assem blies are assem bled in the un it. W orm preload adjustm ent w as set w hen input shaft, valve and w orm w ere assem bled into valve ho using.
Tightenadjusting screw
2
W ith adjusting screw jam nut (47 ) loose , turn sector shaft adjusting screw (43 ) clockw ise to provide 4550 lbf in. (5-5.5 N m ) of torque required to rotate the inp ut shaft, valve/w orm assem bly (13 or 13 A ) through one half turn (180 ) each side of ce nter. •
Lb f in. Torque w rench S crew driver 11 ⁄ 16 or 3 ⁄ 4 Socket •
"
°
This proce dure w illproperly m esh an d se at the rack piston and se ctor sh aft teeth for finaladjustm ents.
"
Loosenadjusting screw andnote torque
•
3.
Tu rn sector shaft adjusting screw (43 ) cou nterclockw ise on e half turn and note maximumtorque required to rotate the input shaft, valve/w orm asse m bly through one half turn (18 0 ) each side of ce nter. °
Lb f in. Torque w rench S crew driver 11 ⁄ 16 So cket •
"
63
Adjustadjusting screw
4.
A djust sector sector shaft shaft adjusti usting screw screw (43 ) clockw ise orque noted noted in step step 3 by to increa increase se m axim um torque 7 lbf in. in. (.8 N m ). T ig h te n jam n u t (4 7 ) firm ly ag ain st sid e cove co ver r w h ile h o ld in g th e adj ad ju sti stin g screw in p o sitio n . Final torque jam nut to 43 lbf ft (58 N m ) and che ck inp ut shaft shaft, valve/w orm orm assem bly to rq u e ag a g ain . R e ad ju st if in p u t shaf sh aft t to rq u e e xce e d s 4 0 lb f in . (4 .5 N m ). •
⁄ So cket cket ⁄ S ocket ocket Lb f ft T o rq u e w rench Lb f in . T o rq u e w rench
34
"
11 16
"
•
•
64
•
•
•
•
•
Section5
Reinstallation
R e in stal tallatio n ....................................................................6 ..6 5 P o p p e t R e se ttin g ..............................................................6 ..6 5 G lo ssary ............................................................................6 6
Reinstallation • V erify that axle stops are set to m anufacturer's w heelcut or clearance sp ecifications. • B olt ge ar to fram e, torqu e to ve hicle m anufacturer's recom m en dation . • C onnect return line to rese rvo ir in TA S return port. • C on ne ct hydraulic line from pu m p to pressure po rt in T A S un it. • C onnect steering colum n to input shaft, torque pinch bolt to vehicle m anufacturer's recom m en dation . • Installpitm an arm on output shaft, w ith tim ing m arks aligned. Torque bolt to veh icle m anu facturer's reco m m en dation . • C on ne ct drag link to p itm an arm .
Poppet Resetting
IF
Po ppets rem ain unchanged from w hen gear w as rem oved from vehicle, and gear is being installed on the sam e vehicle w ith no change in axle stop s o r linkage .
A fter installation, ch eck to m ake sure poppets relieve in both turns just before axle stop contact is m ad e. If not, use resetting proced ure b eg inn ing on page 24 .
IF
P opp ets w ere replaced w ith new com pon ents or reset during gear disassem bly, and are ready for autom atic positioning.
U se p op pe t setting proced ure o n p age 15 .
IF
U se p op pe t rese tting proce du re b eg inn ing on pag e 2 4.
P opp ets m ay have bee n m oved during disassem bly or reassem bly p rocedures, or gear is b eing installed on a different vehicle.
65
Glossary AeratedFluid Fluid w ith air bubbles
Automatic Bleed Systems G ears are m oun ted in such a w ay that trapped air can be forced out of the system "autom atically" w ithout loosening bleed screw . Follow procedure o n p age 1 3.
Integral Power Steering S tee ring ge ar has m anualstee ring m echanism , hydraulic co ntrolvalve, an d h yd rau lic pow er cylinder all w ithin g ear housing.
Lim its m axim um supp ly pressure
Return Line Line that connects steering g ear to reservoir to recirculate hydraulic fluid
Impact The application of torques and forces to stee ring ge ar com po ne nts du ring accidents o r other sim ilar eve nts w hich exce ed the h ydraulic cap acity of the steering gear
Axial In-ou t m ove m en t alon g an axis (im ag inary straight line on w hich an ob ject m oves)
Relief Valve
RotaryControl Valve C ontrols flow in internal cavities
Scoring Internal Leakage
S cratch
Fluid leaking inside the gear
Brinelling D ents
Shock Load Lash
S hake or jar
Free p lay
DateCode D ate the steering g ear w as built (Ju lian date)
Discoloration
Spalling Manual Bleed Systems
Flaking or ch ipping
G ears are m oun ted in such a w ay that an air pocke t could form in one end of the steering gear. The bleed screw is p ositioned so trappe d air can be forced o ut w he n loo sene d. Fo llow proced ure o n p age 1 3.
Subassembly
OSHA
Supply Line
O ccupation alS afety an d H ealth A dm inistration
Line that conn ects pum p to stee ring gear
Poppets
TwistedSerrations
U nloading valves, reduce pressu re in fullturns.
O utpu t shaft serration s d am age d by im pact overload. S errations can be tw isted at the area be tw ee n the large diam eter of the shaft and the en d o f the se rrations.
A n asse m bled unit that fits into a larger unit
C han ge in co lor
External Leakage Fluid L eaking ou t of the system or steering gear
Full Turn H ub con tacts axle stop
66
