2. Introduction
Participant Name
Dealership Name
Location
Experience in Tata Motors (In years & months)
Specialization in which Models / Aggregates
Hobbies
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3. Program Objectives
At the end of this module the participants will be able to:
Understand the commonly used steering systems
Overhaul the three types of suspension systems used in Tata Motors LCV vehicles (ZF Type,
Rack & Pinion Type, and Mechanical Type)
Know construction, removal and installation, and diagnosis of Propeller Shaft-709 Type
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4. Program Agenda
Power & Mechanical steering Systems
– Introduction to ZF Ball & Nut type Power steering system
– Introduction to Rack & Pinion Power Steering
– Introduction to Mechanical Type Steering System
Steering System Overhauling: ZF Type, Rack & Pinion Type & Mechanical Type
– Removal of Steering System from Vehicle
– Steering Gear Overhauling/Adjustments
– Troubleshooting
Propeller Shaft-709 Type
– Technical Specification & Special Tools
– Construction of Propeller Shaft
– Removal & Installation of Propeller shaft from the vehicle
– Troubleshooting
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5. Recirculating Ball Type/ Worm & Roller, Rack & Pinion
Power & Mechanical Steering Systems
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7. Classification of Steering System
Steering System can be classified mainly in to two types:
Mechanical steering system
Power assisted steering system
Mechanical steering system
Mechanical steering system solely relies on driver to provide steering force.
Commonly used Mechanical steering systems are
– Rack & Pinion
– Worm & Roller / Recirculating Ball Type
Power assisted steering system
Hydraulic or electric power assist the driver to apply steering force.
Power assisted steering system can be two types:
– Hydraulic assisted
Rack & Pinion type, Worm & Roller type, Recirculating Ball & Nut type and Hydrostatic (Gerotor)
– Electrical / Electro-hydraulic assisted
Rack & Pinion
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8. Types of Steering System..
Tata motors uses both Mechanical & Power Assisted Steering Systems mainly in LCV range of
vehicles. The types in these two systems are:
– Recirculating Ball & Nut type (mechanical and power)
– Rack & Pinion type (mechanical and power)
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Recirculating Ball & Nut Type Rack & Pinion Type
Power Mechanical Power
Mechanical
10. Recirculating Ball & Nut Type Steering- Layout
Power Steering
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Mechanical Steering
11. General Information - Recirculating Ball & Nut type
(Mechanical)
Construction:
The recirculating ball steering mechanism
contains a worm gear inside a block with a
threaded hole in it
This block has gear teeth cut into the
outside to engage the sector shaft (also
called a sector gear) which moves
the pitman arm
The steering wheel connects to a shaft,
which rotates the worm gear inside of the
block
Instead of twisting further into the block,
the worm gear is fixed so that when it
spins, it moves the block, which transmits
the motion through the gear to the pitman
arm, causing the road wheels to turn
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12. Model Matrix of Steering Gears
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Rane Steering Model Matrix
Model GB Model Pump
207 T 54 (RH) Aluminum 70 bar
Xenon T 54 (LH) Aluminum 70 bar
LCV (712 / 912) RT 250 Aluminum 100 bar
1109 HFB 64 AVP 20
2518 HFB 64 AVP 20
Winger Rack & Pinion Type Aluminum 80 bar
ZF Pump Model Matrix
ZF Model Veh Model
7672955274 LCV (Cast Iron)
7613955138
LCV (LPK & BS IV models,
Alluminium)
7673955380 HCV (697 engine)
7673955800 HCV (Cummins)
7613955137 Xenon RX
ZF Gearbox Model Matrix
GB Model Veh Model
8046 RH HCV
8043 RH MCV
8033 Regular LCV
M033 Xenon
13. Working of Recirculating Ball & Nut type Steering
(Mechanical)
With rotation, the balls are rolled along the
grooves, partly in the worm and partly in the nut,
and they circulate by passing through ball-return-
guides at each end of the nut.
External teeth on one side of the nut mesh with
the teeth of the sector gear formed on the sector
shaft, or Pitman shaft, and this transfers the
motion through the Pitman arm to the steering
linkage.
The sector gear and nut teeth are designed so that
when the teeth are in the straight-ahead position,
they have minimum clearance. This reduces free
play in that position.
The Pitman shaft is supported by 2 caged, needle
roller-bearings, in the steering box housing.
The sector teeth are angled, and an adjustment
screw on the steering housing cover provides
proper engagement of the sector gear and nut
teeth
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14. Layout - Recirculating Ball & Nut type Steering – 407
Type
A Steering Wheel
B Steering Column
C Non Driver side Tie rod Arm
D Tie Rod
E Spindles
F Universal Joints
G Pitman Arm
H Steering Gear Box Assembly
I Driver Side tie rod Arm
J Drag Link
K Steering Arm
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17. Technical Specification - Recirculating Ball & Nut type
Steering – 407 Type
Type Manual Steering
Steering Wheel Diameter 420 mm
Wheel Lock Angle(Inner Wheel) 41±1°
Turning Circle Diameter 113 m (W.B 3100 mm), 11.9 m (W.B 2750 mm)
Pitman Arm Length ( hole to hole) 185 mm
Total rotation of pit arm 90°
Free play steering wheel 20-30 mm
Steering Gear Box Anti-friction, Recirculating Ball Type
Steering Gear Box Ratio 25-28:1
Number of Steel Balls in Circulation 66
Total Number of Turns of steering worm 6.8
Total Steering Wheel turns 5.7
Oil Capacity of Steering Gear Box 0.5 Lt.
Recommended Oils
B.P – MAK TATA Motors Spirol S 80W-90
Castrol – Castrol Long Life Gear Oil – 80W-90
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18. General Information - Recirculating Ball & Nut type
Steering (Power – Hydraulic)
Construction & Working:
Power steering for the recirculating ball
type steering system consists of a
pump, fluid reservoir, pressure and
return hoses and steering gear. The
pump, which is driven by an accessory
drive belt, consists of an impeller,
pressure valve, and fluid reservoir.
Pump pressure builds only when the
engine is running. The pump impeller
turns, picking up hydraulic fluid from
the reservoir and feeding it to the
steering gear under pressure through
the pressure line. The fluid is then
returned to the fluid reservoir through
the non-pressurized return line.
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22. Components of Recirculating Ball Type Steering
System – Hydraulic (Rane)
Steering Gear:
Worm
Both radial and axial roller bearings are
mounted in intermediate cover. Worm Shaft
with grooved channel for ball circulation is
mounted in this cover.
Piston
Valve bush which accommodates the valve
spool is pressed into cross bore hole.
Underside of the piston is machined as a gear
rack, which engages in the toothed segment
of sector shaft. Steering nut and finger
passes into longitudinal bore hole of the
piston. Thus establishing the connection with
valve spool through worm.
Depending on the version, valve is centered
by means of centering springs, or bending
bar.
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23. Components of Recirculating Ball Type Steering Gear
– Hydraulic(Rane)
Steering nut
Longitudinal bore hole for worm engagement with grooves for ball circulation are provided.
Groove on the external diameter is milled and ground for accepting the finger, which engages
in cross bore hole of valve spool. This establishes the connection to worm by means of ball
chain. In steering nut worm, depends on the selection of the corresponding type of ball.
Steering nut is mounted in piston, play-free, between two roller bearings. Adjustment is
carried out by turning threaded ring which is secured on the open side of the piston.
Housing
Housing has integrated passages for pressure and return lines and, a built-in pressure limiting
valve. Oil passages which are required within the steering system are arranged as bore holes
in housing, housing cover / plate or in piston. No external connecting lines are required due
to this design. Housing has mounting holes and machined surfaces for securing steering gear
box on mounting bracket of the vehicle.
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24. Components of Recirculating Ball Type Steering Gear
– Hydraulic (Rane)
Sector shaft
Sector gearing is cut with a flat angle to the shaft axis in order to facilitate, service adjustment
in axial direction. Center tooth is shaped more convex, so that re-adjustment can be carried
out in straight ahead position (SAP), since this is the area where greatest amount of wear
occurs, without the following gear teeth, both left and right, becoming jammed.
Forces in axial direction are taken up by means of an adjustment screw ; screw is held into the
bore hole of sector shaft, play-free and passes through threading in housing cover.
Adjustment in axial direction is carried out by utilizing this thread pitch and locking is done by
means of a lock nut.
Housing cover
It houses the adjustment screw for supporting sector shaft also.
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25. Components of Recirculating Ball Type Steering -
Hydraulic
Power Steering Pump:
Power Steering Pumps used in LCV
Recirculating Ball Type are ZF type vane
pumps.
Pumps are supplied with the Power
Steering Oil. Pumps get the drive from the
Engine and pump the oil with pressure to
the steering gear
Vane type pumps have minimum rotating
parts to give maximum pressure at low
rpm
Vane Type Pumps
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26. Components of Recirculating Ball Type Steering -
Hydraulic
Pressure Relief Valves:
Used in a power steering system to control
maximum oil pressure
Prevents system damage by limiting
pressure
Valve opens when the steering wheel is
turned to the full-left or full-right position
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27. Components of Recirculating Ball Type Steering -
Hydraulic
Power Steering Hoses:
High-pressure, hydraulic, rubber hoses that
connect the power steering pump and the
gearbox or power cylinder
One line serves as the pressure feed line
One line serves as a return line to the
reservoir
Steel line may be used where movement is
not necessary
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28. Components of Recirculating Ball Type Steering -
Hydraulic
Power Steering Oil Reservoir Tank:
Stores the Power Steering Oil required for the operation.
Two types may be seen, metal type or plastic containers.
Some models have replaceable filter inside the reservoir.
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Power Steering Reservoir Matrix
Sr. No. Make Model Type
1 ZF All LCV Plastic
2 ZF 1109 / LCV Export Metal
3 ZF All HCV Plastic
4 ZF 207 RX / Xenon RX Plastic
5 ZF LHD Ex 207 Metal
6 ZF Xenon Plastic
7 Rane 207 DI / Xenon Plastic
8 Rane HCV SE / SK / LP RHD Plastic
9 Rane Winger Plastic
29. Operation of Recirculating Ball & Nut Type Steering
Gear - Hydraulic
When the driver turns the steering wheel, he activates the steering gear input shaft. A torsion
bar pinned at its one end to the input shaft and the other end to the worm shaft, turns with
the input shaft and exerts a rotational force on the worm shaft. In response to this rotational
force the worm shaft acting through the re-circulating ball mechanism, tries to move the rack
piston axially through the gear housing cylinder bore.
The rack piston’s axial movement is resisted by its engagement to the sector shaft, which is
connected by linkage to the steered wheels. Because of this resistance, the torsion bar is
twisted by the input shaft, thereby actuating the control valve. Pressurised fluid directed by
the control valve assists in moving the rack piston axially through the cylinder bore. The rack
piston then turns the sector shaft to steer the vehicle.
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31. Operation of Power Steering (Rane)
Control Valve in Neutral Position:
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1 Housing 13 Return oil control edge
2 Piston 14 Return oil chamber
3 Valve slide 15 Radial groove ZR
4 Worm 16 Radial groove ZL
5 Torsion bar 17 Hydraulic steering limiter
6 Sector shaft 18 Pressure relief valve
7 Ball chain 19 Replenishing valve
8 Fed oil radial groove 20 Flow limiting valve
9 Feed oil control groove 21 Steering pump
10 Feed oil control groove 22 Oil reservoir
11 Axial groove ZL Power cylinder left (front)
12 Return oil control groove ZR Power cylinder right / behind
32. Operation of Power Steering (Rane)
Control Valve in Working Position. Steering wheel turned clockwise:
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1 Housing 13 Return oil control edge
2 Piston 14 Return oil chamber
3 Valve slide 15 Radial groove ZR
4 Worm 16 Radial groove ZL
5 Torsion bar 17 Hydraulic steering limiter
6 Sector shaft 18 Pressure relief valve
7 Ball chain 19 Replenishing valve
8 Fed oil radial groove 20 Flow limiting valve
9 Feed oil control groove 21 Steering pump
10 Feed oil control groove 22 Oil reservoir
11 Axial groove ZL Power cylinder left (front)
12 Return oil control groove ZR Power cylinder right (behind)
33. Oil flow in steering gear - Neutral position (ZF)
It goes through respective bores to a recess on the piston top, from here back to the oil tank.
Oil Flow: After flowing through supply and return flow control edges to the middle of the valve
spool and through bores to the right and left cylinder chamber.
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No. Parts
1 Housing
2 Piston
3 Worm
4 Bending bar
5 Sector shaft
6 Balls
7 Steering nut
8 Threaded ring
9 Threaded ring
10 Angular ball bearing
11 Cover
12 Pressure limiting valve
13 Vane pump with flow limiting valve
14 Oil reservoir
15 Feedback piston (Hydraulic Reaction)
16 Valve piston
17 Driver
34. Oil flow in steering gear - Right turn (CW)
When steering turned right side (Clockwise), valve spool moved to the right, pressure oil gets
into the cylinder chamber, left cylinder chamber connected to return flow.
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35. Oil flow in steering gear - Left turn (ACW)
When steering wheel turn left side (Anticlockwise), valve spool moved to the left, pressure oil
gets into the cylinder chamber, right cylinder chamber connected return flow.
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36. Lubrication and maintenance
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Long distance travelling
Long and short distance
travelling
Travelling on building sites
and cross - country
I. Inspection 100000 km 100000 km 80000 km
II. Inspection 200000 km 175000 km 150000 km
III. Inspection 300000 km 250000 km 200000 km
38. General Information- Rack & Pinion Type Steering
( Mechanical)
Construction:
A typical rack and pinion steering gear
assembly consists of a pinion shaft and
bearing assembly, rack gear, gear housing,
two tie rod assemblies, an adjuster
assembly, dust boots and boot clamps, and
grommet mountings and bolts. When the
steering wheel is turned, this manual
movement is relayed to the steering shaft
and shaft joint, and then to the pinion
shaft. Since the pinion teeth mesh with the
teeth on the rack gear, the rotary motion is
changed to transverse movement of the
rack gear. The tie rods and tie rod ends
then transmit this movement to the
steering knuckles and wheels.
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39. Working of Rack & Pinion Type Steering
( Mechanical)
Rack and pinion steering gear uses a rotating
toothed pinion to generate the sliding
movement to rack. The teethed pinion are in
the constant mesh on the rack and any
movement of the steering column will
transversely displace the steering rack. The
rack movement is directly transferred to tie
rods fitted to both end of the rack .Ball and
socket joints between the rack and tie rods
allow for independent vertical movement of
the tie rods.
The rack is retained in mesh with the pinion
by a spring loaded pressure pad which
automatically adjusts any free play between
the teeth
Rack & Pinion Mechanical Type is not used in Tata
Motors LCV range of Vehicles.
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40. General Information- Rack & Pinion Type Steering
( Hydraulic)
Construction:
Construction of the Rack & Pinion Power
Type is same as the Mechanical one but
with some additional Components
The steering gear assembly is different
with hydraulic control valves & seals
A power steering pump driven by engine
power is additional
Power Steering Reservoir to store the
Power steering Oil
Suction and Return hoses for the delivery
of Power Steering Oil to the Gear Assembly
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41. Working of Rack & Pinion Type Steering
( Hydraulic)
Atypical hydraulic power assisted steering
system uses a fluid pressure pump to
supply fluid under pressure to a hydraulic
circuit . The fluid pump operated and
driven by the engine.
Fluid under pump pressure flows to a spool
control valve in the steering gear with the
steering shaft in the straight ahead
position the fluid flows through the spool
control valve and returns to the reservoir.
When the driver turns the steering wheel
the spool control valve directs the fluid to
the appropriate side of a piston which is
placed within a cylinder at the end of the
rack and pinion steering gear.
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42. Working of Rack & Pinion Type Steering
( Hydraulic)
A rod attached to the piston is connected
to the rack and any fluid pressure applied
to the piston assists the movement of the
rack
Fluid on the opposite side of the piston
returns to the reservoir via the spool
control valve .if the driver turns the
steering in the other direction the whole
process is reversed.
In event of power assistance failure the
steering gear would still operate
mechanically but considerable more effort
would be required from the driver
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43. Functions of Rotary Valves in the Steering Gear
during Turns
When driver turns the steering wheel, force transmits to steering gear input shaft through steering
wheel.
Input shaft rotation is transmitted to the Pinion through Torsion bar which is pinned at one end to
the Input shaft and pressed firmly into the Pinion at the other end.
The Pinion tends to push the Rack linearly through the Rack tube bore.
But the linear movement of the Rack which is connected to the steered road wheels through link
mechanism is resisted by the load on the steered wheels.
The is resistance offered by the steered wheels on the Pinion, leads to a definite twist on the
Torsion bar depending on the input torque level.
The Torsion bar twist disturbs the neutral position of the Rotary Control Valve (input shaft and
valve sleeve).
The disturbed Rotary Control Valve directs the oil flow from pump to the appropriate side of the
cylinder.
The Piston rack pressurized by the oil, moves in the required direction overcoming the resistance
offered by the steered wheels and produces the steering action.
The resistance in the rotation direction of Pinion is reveled by movement of Piston Rack by
hydraulic force and the action of torsion bar returns the rotary valve ti its neutral position.
The oil flow diagram in neutral, right turn and left turn positions of the steering gear.
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47. Application of Rack & Pinion Type Steering -
(Hydraulic)
Rack & Pinion Hydraulic Type Steering Tata Winger
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48. Technical specification- Rack & Pinion Type Power
Steering - Winger
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Power Steering Gear
Type End take Off-Rack & Pinion Steering Gear
Rack travel 157.6 mm
No. of steering wheel turns Lock to lock 3.58 turns
Power Steering Pump
Type Vane Type
Cartridge capacity 9.6 cc/rev.
Controlled Flow Drooping Flow
Relief pressure 70 bar
Operating speed 500 to 8000 rpm
Power Steering Reservoir
Type Transparent plastic reservoir with replaceable filter cartridge
Capacity
At Max. level - 375 ml
At Min. level - 300 ml
Hydraulic fluid Automatic transmission fluid
49. Components of Rack & Pinion Type Power Steering
Steering wheel
Steering wheel is basic part of steering system, which is rotate by driver.
There are many type of steering wheels such as: Tilt wheel, Telescope wheel,
Adjustable wheel, Swing-away wheel etc.
Steering column assembly
Steering column assembly is connected between Steering wheel and universal
joint.
Intermediate shaft
Intermediate shafts and universal joints connect the steering column to the
steering gear and transmit the torque.
Universal joint
Coupled between steering column and intermediate shaft that allows
intermediate shaft to bend in any direction and also transmit rotary motion to
steering gear.
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50. Components of Rack & Pinion Type Power Steering
Pinion
Pinion is a circular gear engaged with rack transmit rotational motion to
rack.
Rack
Rack is a linear gear bar, rotational motion of pinion gear is cause rack to
move.
Power steering fluid reservoir
Installed in vehicles provided power assisted (hydraulic) steering system.
Hydraulic oil for the Power Steering system is stored in the reservoir.
The reservoir generally is located at a higher level above pump to ensure
feed by gravitational flow.
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51. Components of Rack & Pinion Type Power Steering
Power steering pump
The power steering pump provides the hydraulic assistance for the power steering gear to
operate.
Pump provides sufficient pressure for steering assist at all engine speeds.
The need for assist is greatest during periods of low-speed maneuvering, which may occur at
idle or low engine speeds, and less when cruising at high speed.
When the pump is turning fast and steering demands are low, most of the fluid is diverted
back to the inlet side of the pump through a pressure relief valve.
Pump is driven by engine by any one of the following drive arrangement:
– Belt Drive
– Gear Drive
– Direct Drive
Belt drive is commonly used arrangement for passenger cars.
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52. Power Steering Vane Pumps
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ZF Make
RANE TRW Make
Pump Inlet
Pump Outlet
53. Components of Rack & Pinion Type Power Steering
Power steering pump..
Sliding vane type
– This describes the type of pumping element. The pumping consists of three components.
1. The rotor that holds the vanes and is driven by engine with the pump input shaft.
2. The vanes that slide back and forth in slots in the rotor while following the internal contour of the cam
ring as the rotor is being turned, thus a sliding vane.
3. The cam ring that contains the internal contour that defines the amount of fluid that is output with each
revolution of the rotor.
Two line
– The pump requires an inlet line to supply oil to the pump and an outlet line to take the oil
supplied by the pump to the steering gear. All excess, (bypass) oil is diverted internally in the
pump housing back to the inlet of the pumping element.
Internal flow control valve
– The pump has a pilot operated valve built in to the pump housing that will control the amount of
oil that is output to the steering gear. This allows the output flow to remain within specification
for almost any input speed variation.
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54. Pump Parts
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1 Shaft 6 Cartridge assembly
2 Ball bearing (Double row angular contact) 7 Pressure plate
3 Single lip seal 8 End cover
4 Double lip seal 9 Flow cum pressure relief valve assembly
5 Side plate 10 Flow control spring
55. Components of Rack & Pinion Type Power Steering..
Power steering pump..
Relief valve
– The pump has a operated relief valve built into the flow control valve spool which will limit the
maximum pressure the pump can produce. When the pressure limit has been reached, the relief
section will cause the flow control to bypass more oil internal to the pump, limiting the outlet
pressure.
Specifications
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Pump capacity 9.6 cc/rev
Flow at 800 rpm, 50 bar load & 55 0
C 6.5 LPM/min
Regulated pressure (30220062)
Regulated pressure (30220082)
70 + 5 /-2 bar
80 + 5 /-2 bar
Pump speed 500 ~ 8000 rpm
Direction of rotation Right hand (CW)
Oil temperature 300 - 1200C
Oil type Castrol TQ (or) Equivalent
Drive Belt
56. Exploded View – Rack & Pinion Type Power Steering
Pump
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No. Description Quantity per assembly
1
Housing assembly (for 30220062)
Housing assembly (for 30220082)
1
1
2 Shaft sub assembly 1
3 Cartridge assembly 1
4 Seal kit 1
5 End cover 1
6 Bolt for end cover 4
7 Pressure port connector 1
8 O ring - pre port connector 1
9 Retaining ring 1
10 Suction connector (for 30220062) 1
Suction connector (for 30220082) 1
11 O ring - suction port 1
12 Bolt - suction port 2
13 Spring washer 2
14 Retaining ring 1
Power steering pump..
57. Recirculating Ball & Nut, Rack & Pinion type Power Steering System
Steering System Overhauling:
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58. Removal of Steering System from Vehicle
Recirculating Ball & Nut type
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59. Special Service Tools - Recirculating Ball & Nut type
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Description Part no. Picture
Servo Tester
Test gauge
7418 798 530
Tongue for Piston Assembly M02851
Assembly vice for steering gear M02903
Torque measuring device (without insert) 7470 798 703
60. Special Service Tools - Recirculating Ball & Nut type..
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Description Part no. Picture
Insert for torque measuring device 8052 798 552
Entry bush for shaft seal 7832 798 001
61. Tightening Torques - Recirculating Ball & Nut type
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Description Values
Friction movement outside “SAP”, measured at input shaft of steering gear box 4.0 - 6.0 cmkg
Friction movement at “SAP”, measured at input shaft of steering gear box
Add 7.0 - 15.0 cmkg
Higher to 1.
Hex. Bolts (132) / Cover (128)
M10 = 6.2 mkg
M12 X 1.5 = 11.5 mkg
M14 X 1.5 = 19.0 mkg
Hex. Bolts (46) Cover (40)
M10 = 6.2 mkg
M12 X 1.5 = 11.5 mkg
M14 X 1.5 = 19.0 mkg
M16 X 1.5 = 28.5 mkg
Sealing nut (50) 7.0 mkg
62. Removal & Installation of Gear Box Assembly from the Vehicle -
709/909 type
Removal & Installation of Gear Box Assembly from
the Vehicle
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Removal & Re-fitting of
Steering Gear Box from
Vehicle
(Recirculating Ball & Nut
type – Hydraulic -
709/909)
64. Overhauling of Manual Steering
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Step - 1 Step - 2 Step - 3
Take out steering gear box from vehicle and
remove sector shaft
Remove top cover and take out warm shaft Check and replace re-circulating balls
Step - 4 Step - 5 Step - 6
Set the warm shaft and adjust the shims on
to cover such that pre load on bearing will
be 0.05 mm
Tight the bolt with screw driver by holding the
nut, till there will be 0 play between sector
shaft and worm nut,
Match the sector shat missing splines with
steering arm
65. Overhauling of HFB 64 Steering Gear (Rane)
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Install Gearbox on work fixture Remove seal protector boot from Trunnion
cover.
Loose sector shaft adjusting jam nut.
Remove Trunnion cover bolts.
Remove the seal ring, two piece
sector shaft seal & Teflon back up
washer from Trunnion cover .
Remove sector shaft side cover bolts & take
out side cover along with sector shaft
assembly
Remove sector shaft side cover gasket
66. Overhauling of HFB 64 Steering Gear (Rane)
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Remove Sector shaft by removing bolt Remove Sector shaft by removing bolt &
separate the sector shaft from side cover
Remove side cover retaining ring
Remove two piece side cover seal, Teflon
back up washer & Steel back up washer
Loosen the worm shaft Pre load adjusting
locking nut & screw
Loosen Poppet adjusting screw sealing nut
& screw by 2 turns
67. Overhauling of HFB 64 Steering Gear (Rane)
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Remove seal protector from worm shaft Loosen the other poppet adjusting screw by 2
turns
Remove 4 valve housing bolts
Remove Valve sleeve from the valve
housing
Remove 1st thrust washer, thrust bearing &
2nd thrust washer from housing
Remove 2 Teflon seal rings from valve sleeve
groove
68. Overhauling of HFB 64 Steering Gear (Rane)
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Remove seal ring from valve housing Remove retaining ring from valve housing Remove steel back up washer, input shaft
seal, input shaft O ring from valve housing
Remove Rack piston & worm shaft from
housing.
Rack piston with ball return guide clip bend
the 2 locking tabs
Remove the 2 hex head bolts & clip
69. Overhauling of HFB 64 Steering Gear (Rane)
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Remove the 2 halves of the ball return guide Remove the worm shaft from the rack piston Remove Teflon rack piston seal ring back up
O ring
Remove Teflon worm shaft seal ring & O
ring
If required then remove 2 poppet retaining
spring, 2 poppet seats, 2 poppets, nylon
spacer rod & poppet spring by holding in soft
jawed vice
To remove needle bearing apply pressure
from side cover side to turnnion cover side.
Dismantling Process completed.
70. Assembling of HFB 64 Steering Gear (Rane)
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Slide compression tool smaller dia. First on worm end of
worm shaft beyond the seal ring groove
Compress the sealing ring by pulling compressor tool back
over the sealing. keep seal in compressed condition for 10
minutes. *If your do not allow for this time, the seal may
tear or be cut when you place the worm into the rack
Install the new bearing assembly into the housing, first
install the retaining ring into the groove on the
bearing’s outside diameter. press the bearing into the
housing from the turnnion side using bearing mandrel
Torque both
poppet seats
to 27 - 34 Nm
Install the new rack piston backup O-ring and then
the new Teflon rack piston seal ring
Slip on compression tool and allow 10 minutes to
ensure proper seating
Install into the rack piston one poppet seat. From the
other end of the rack piston install one poppet , the
spring, the nylon spacer rod
71. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 71
Install the worm shaft assembly into the rack piston end
that will position the worm seal ring in the rack bore.
Position the worm ball track grooves to accept the set
of balls through the rack piston ball guide holes
Assemble the ball return guide halves into the rack piston Insert 27 steel balls into the ball return guide through
the hole provided in the top of the guide & rotate the
worm shaft to pull the balls down into ball track grooves
Install two new lock tabs and the two hex head bolts.
Torque the bolts to 19-30 Nm. Finish by bending the
locking tabs up against the bolt head flats.
Apply ATF oil to the Teflon rack piston seal ring and to the
housing cylinder bore & insert piston as shown
Rotate the rack piston and worm shaft assembly so rack
teeth are exposed in the sector shaft cavity of the
housing.
72. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 72
Install the worm shaft preload adjusting screw and
sealing nut into the closed end of the gear housing
a few turns
Assemble poppet adjusting screw and seal nut into
end of housing a few turns. Final adjustments will be
made later.
Using seal installation tool assemble the backup O-
rings and then the seal rings onto the valve sleeve.
(apply grease while installation)
Use compression tool to compress the Teflon seal
rings. Keep for 10 minutes
Install a new seal ring into the valve housing groove. Place the thrust washer into the valve housing
(apply grease to washer before installation)
73. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 73
Install the greased thrust bearing into the valve
housing and onto the first thrust washer
Remove valve sleeve from compressor. Place 2nd thrust
washer on the face (greased)
Locate the timing mark on the valve sleeve, R or L
punched on the inlet groove. Make a
corresponding mark on the front face with a felt
marker.
Insert assembled valve sleeve inside the housing &
measure approximately 10.2 mm bellow
the face of the valve housing.
Position the rack piston so that it is flush with the valve
housing end of the gear housing & comes out of
housing completely.
Locate the scribed timing marks on the worm shaft
assembly and valve sleeve
74. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 74
Align the valve sleeve R (or) L mark and scripe timing
marks and place the valve housing and valve sleeve as
an assembly onto the input shaft end of the worm shaft
until the drive ring lugs on assembly are fully engaged in
valve sleeve lug slots. (“R or L”: stamped between the
seal lands)
If paint mark marked during is mantling on both housing
then it is easy during fitment
Install the valve housing by 4 bolts into the valve
housing. Torque them to 142-156 Nm
Assemble the seal onto the end of the sector shaft with
help of special tool. The words “oil side” on the seal
must face toward the sector shaft. Assemble the
Teflon washer and then the steel backup washer.
Insert side cover on the sector shaft assembly. Unscrew the
sector shaft adjusting screw until to the side cover butts
against the split collar special tool.
Remove the split collar special tools (big & small). Fix
the retaining ring in to the groove provided in the
side cover.
75. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 75
Install the sector shaft adjusting screw jam nut onto
the sector shaft adjusting screw a few threads
Press the new vent plug into the hole provided in the
side cover until the plug is flush.
Apply clean grease to the new side cover gasket
and assemble it into the side cover.
Position the rack piston to centre position the third
teeth, is in the center of the sector shaft opening.
Attach a Special tool to adjust the steering box
preload
Adjust the pre load to 20 – 30 Nm. Torque.
76. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 76
Install the sector shaft and side cover into the gear
housing as an assembly. Make sure that the center
tooth of the sector shaft engages the centre space
(between the second and third teeth) of the rack
piston.
Install the six bolts of side cover into the side cover &
torque them to 298-325 Nm
Install new Teflon backup washer inside turnnion
cover. Install the new two-piece sector shaft seal so
that the words “oil side” are visible after the seal is
in place.
Grease the new turnnion cover seal ring and install
it into the turnnion cover seal ring groove & install
the turnnion cover.
Fix 4 bolts of trunnion cover & torque them to 20-30
Nm
Assemble a new dirt & water seal using special tool.
Assemble protector boot over sector shaft &
trunnion cover
77. Assembling of HFB 64 Steering Gear (Rane)
7/27/2022 TML 77
Apply clean grease to the input shaft seal assembly
and to the input shaft. Install the new two-piece
input shaft seal, flat side out.
Assemble the steel pack up washer. Assemble the input shaft seal using special tool.
Install the retaining ring Install the new dirt and water seal, with part number
facing out
Apply grease. Assembly process completed.
78. Overhauling ZF Steering Gear
7/27/2022 TML 78
Dismantling Steering Box
Remove bolts of housing cover & remove the cover by
turning adjustment screw in anticlockwise direction
Remove the sector shaft in centre position (teeth upwards)
Remove bolts of end cover Remove the piston with teeth upwards to avoid the burrs of
the teeth (if any) scratching cylinder surface.
79. Overhauling ZF Steering Gear
7/27/2022 TML 79
Assembly Precautions
Fit the piston assembly in final position (teeth parallel to sector shaft
bore) to avoid damage to the seals.
Fit the end cover.
Fit the housing cover Locate mid position of steering wheel by turning left & right.
Adjusting screw to be screwed out till frictional torque increases by
40-60 Nm compared to torque at far LH / RH positions.
80. RANE T 54 Gearbox Dismantling Process
7/27/2022 TML 80
Remove Pitman arm nut with the help
of special tool
Remove Pitman arm with the help
of special tool
Rotate Cylinder Cover with the help
of special tool
Lock ring visible after rotation.
Dislodge with the help of screw driver
Rotation Cylinder cover to remove
lock ring
Rotation clockwise Worm shaft so
cylinder Cover projects out
81. RANE T 54 Gearbox Dismantling Process
7/27/2022 TML 81
Remove Cylinder cover & O ring Fix gearbox on work fixture Remove with allen key drop screw of
rack pad adjuster
Remove drop screw Remove Rack pad adjuster with the
help of special tool
Remove Rack pad adjuster & O ring
82. RANE T 54 Gearbox Dismantling Process
7/27/2022 TML 82
Loosen the sector shaft screw with
screw driver by holding nut
Remove sector shaft cover bolts Loosen sector shaft cover by rotating
bolt in clockwise direction
Remove sector shaft cover Remove Worm shaft by turning with
the special tool
Remove Rack piston, Rack adjuster
thrust Pad & Locking pin
83. RANE T 54 Gearbox Dismantling Process
7/27/2022 TML 83
Remove locking pin of worm shaft
with the help of screw driver
With the help of special tool remove
adjuster cover of worm shaft housing
Remove adjuster cover of worm shaft
housing & O ring
Remove Worm Shaft from housing
with the help of plastic hammer
Remove wire circlip from sector shaft
housing
Remove seal & inner seal.
Dismantling process completed.
84. RANE T 54 Gearbox Assembly Process
7/27/2022 TML 84
Install needle cage bearing with the
help of mandrill in sector shaft
housing
Needle cage bearing mark side should be
outside
With the help of mandrill insert inner
needle bearing & seal in sector shaft
housing
Install Steel washer in sector shaft
housing
Install circlip in sector shaft housing Install rubber seal with the help
of mandrill in sector shaft housing
85. RANE T 54 Gearbox Assembly Process
7/27/2022 TML 85
Install oil seal of worm shaft with the help of
mandrill in the housing
Insert Worm gear inside housing & tap
for correct installation.
Fit O ring & adjuster cover of worm gear.
Fix the pre loading tool & set the pre load
0.069 mkg by tightening adjuster cover
Match Lock pin hole of adjuster cover
with housing
Insert Lock pin Insert Sector gear inside housing
partially
86. RANE T 54 Gearbox Assembly Process
7/27/2022 TML 86
Insert Rack pad. From outer face
depth should be 37 mm
Install sector gear side cover with the
help help of screw driver
Tight the side cover bolts with the
torque of 2.5 to 3 mkg
Insert O ring & cylinder cover Tight the cylinder cover with the help of
special tool till locking pin groove visible
Tight the cylinder cover along with the
locking ring
87. RANE T 54 Gearbox Assembly Process
7/27/2022 TML 87
Fit Rack pad, spring, O ring & adjuster Tight the trust pad with the help of
special tool till head remains out by 4
mm
Fit drop screw with the help of 3 mm
allen key to lock trust pad
Loose the sector shaft screw & tight
lock nut
After tightening of sector shaft nut 4
threads should remain outside of lock
nut
Install rubber washer on sector shaft.
Install Pitman arm & Assembly process
completed.
89. Vane Pump Overhauling
7/27/2022 TML 89
ZF Make Steering Pump:
Used in LCV: Green colour
Used in HCV : Black Colour
Never Interchange the pump
Used in Y 1 / LCV :
Aluminum alloy
Pump kit change procedure :
Take out the pump cover by
opening circlip at back
Clean and change kit
Assy. sequence to assemble
parts:
1.Pressure plate R side down
2.Cam ring groove side
down
3.Front plate R side up
First assemble shaft and
keep shaft towards
downwards, then follow
assy sequence
1 3
2
90. RANE Aluminum Pump & T 54 Overhaul Process
7/27/2022 TML 90
Mount pump of rig. Remove High
pressure port connector
Remove ring, Valve & spring Remove suction port
Remove end cover bolts Remove end cover & Gasket from
housing
Remove 2 Dowel Pins from cartridge
sub assembly cam
91. RANE Aluminum Pump & T 54 Overhaul Process
7/27/2022 TML 91
Remove retainer circlip from cam
plate
Remove rotor & Vanes Remove Pressure Plate & O ring
Remove Shaft Sub Assembly Remove Retainer Ring By the Remove Shaft seal by Screw
driver dismantling process completed
92. Critical Steps of RANE Aluminum Pump Assembly
Process
7/27/2022 TML 92
Install Pump shaft seal with the help of
drift & insert the shaft
During assembly of cam ring hole
matches with housing slot
During assembly of rotor vanes. Vanes
rounded corners should face outward
Install Retainer ring with the help of
special tool
Install 2 Dowel Pins Install end cover & tight bolts
3 to 3.9 mkg torque
93. Critical Steps of RANE Aluminum Pump Assembly
Process
7/27/2022 TML 93
Install Valve Spring, valve, seal &
adapter
Torque high pressure port connector by
4 to 5.5 mkg torque
Torque Suction port by 1.5 to 2.5 mkg
torque
94. Maintenance of Steering Gear Box & Trouble shooting
Recirculating Ball & Nut type
7/27/2022 TML 94
95. Steering Gear Box Oil Seal Replacement
ZF Steering gear Box : Process to change oil seals, O rings
RANE TRW Power Steering Seal Change process
7/27/2022 TML 95
Open top cover (sector shaft side) By moving steering shaft, take out assy
for inspection
Change the oil seals and O rings as per
kit. Do not disturb other parts
96. Steering gear box with Steering wheel Adjustment
Process
7/27/2022 TML 96
• While fitting the Drop Arm on sector shaft, match the
both SAP marks as shown in figure.
• In case of mismatch of the SAP mark, drop arm travel
movement will less on one side causing the less turns
on one side.
Marks to adjust steering box and sector shaft
97. Belt replacement & belt tension adjustment process
7/27/2022 TML 97
Loose Lock Nut Loose Lock Nut of tensioner
rod
Tight Main Nut to loose belt
in arrow shown direction
Remove old belt & install
new belt
Loosen Main Nut to tight
belt in arrow shown
direction
Check the belt tension in
range of 5 mm to 10 mm
Check the belt tension in range of 5 mm to 10 mm
98. Power Steering Limiting Valve Adjustment
Purpose:
In driving condition of the vehicle, when a
Driver takes extreme turns, to the right or
left, the vehicle is considerably slow and
the System pressure shoots up to its
maximum, as soon as the Axle stops are
reached.
Higher pressure in the steering system,
loads the Engine, causing extra power
consumption, load on the Pulley/Belt and
higher torques on the Steering linkages.
To avoid this kind of failures, the “hydraulic
limiters’ are provided in the steering gear
box, which responds when the Axle Stops
are reached.
7/27/2022 TML 98
99. Power Steering Limiting Valve Adjustment
Pre Inspection process for Steering Limiter Valve Setting:
1. Ensure that the wheel lock angles are set as per the Vehicle Specifications by putting vehicle
on turn table, If required re-set the Axle Stopper bolts.
2. Set the vehicle (Wheels / Tyres) in Straight Ahead Condition (SAC), while on the ‘Turn Shaft’.
3. Ensure that the Steering Gear’s “In put Shaft” is in Straight Ahead Condition. Refer to the
“SAP” marking provided on the Input Shaft (4. If the Marking is away from the SAP, remove
the “Ball Joint’ from the small end of the drop-arm and increase or Decrease the length of
the Drag Link to achieve the SAP of the Steering Gear, without disturbing the wheels / Tyres).
7/27/2022 TML 99
100. Power Steering Limiting Valve Adjustment
Preparation for Adjustment:
1. A pressure gauge (Pressure range from 0 to 250 bar) is installed in the pressure line between
the Pump and the Steering Gear and the steering axle is jacked up if rigid axle.
Setting Process:
1. Turn the steering wheel without using much force up to the wheel stop when the engine is
running. Hold a distance piece with a thickness of 2-3 mm between the parts of the wheel
stops so that a small reserve is maintained.
2. Turn to the left or right extreme turn with the normal force (as required to turn for the
power steering vehicle) the pressure will start to increase (max. 5 seconds) if pressure drops
too early or too late then adjustment required in limiter screw.
3. If a pressure higher than 35 bar is measured, the corresponding steering limiter valve (55)
must be turned further in towards the cover (In clockwise direction). If a pressure lower than
30 bar is measured, the corresponding steering limiter valve (55) must be turned further out
(anti-clockwise).
7/27/2022 TML 100
101. Power Steering Limiting Valve Adjustment
Reconfirmation of the Hydraulic setting without Pressure Gauge.
1. Normally loaded and traveling slowly, steering the wheel so far until the hydraulic assistance
is switched off. In this position, a gap of approximately 1-3 mm should exist between the
wheel stop.
2. If gap is less or more when hydraulic assistance ends then need to adjust the limiting valve.
7/27/2022 TML 101
102. Oil Filling and Air Bleeding
Note: Thoroughly clean oil reservoir oil and the area around it before removing oil reservoir cover
or dip-stick so that dirt does not get into oil.
Type of oil: AFT oil with specifications dexron IID/III or mercon.
Oil quantity: 1.6 ltrs.
Oil filling:
Note: Special care must be taken during the procedure given below, to ensure that oil
reservoir is not allowed to run empty since this would cause air bubbles in the steering
system.
In addition to this, special care must also be taken during oil filling and air bleeding to ensure
that steering pump only turns at lowest possible speed (idling).
If the inlet flow is too great, small air bubbles would enter the pump and be split up into
extremely small air bubbles during its passage through the pump this situation may lead to
foam formation thus greatly extending the bleeding process.
7/27/2022 TML 102
103. Oil Filling and Air Bleeding..
Oil filling..
Due to various types of installation possibilities of gear box bleeding process may take longer
time. In such a case. Drop arm should be removed so that the entire piston stroke from stop
to stop can be utilized for bleeding process.
In this way air remaining in the cylinder is reduced to a minimum. This is an insignificant
amount which will be bleed automatically during operation.
Steering system should be filled through the opening on reservoir. For the first filling and for
oil changes, it is recommended to remove the cover of container and fill with oil up to the
edge of container.
Engine should then be cranked briefly a number of times with starter, in order to fill entire
system with oil. Since this causes oil level in the container to fall rapidly, oil must be
continually topped up during this process. Under all circumstances, the pump must be
prevented from taking in air.
Ensure that oil level does not fall below upper marking on dipstick when engine is switched
off.
7/27/2022 TML 103
104. Oil Filling and Air Bleeding..
Bleeding
Jack-up steering axle. Start engine and run at idling speed.
Allow engine to run for some time at idling speed, thus allowing most of the air to escape
from cylinder. Oil level must be topped up immediately if the level still sinks.
When the above instructions have been observed, oil level in container must not rise higher
than 1 to 2 cm when engine is switched off.
Note: Steering gear 8043 / 8033 / M033 are system with automatic bleeding and do not have
a bleeding screw. These steering systems automatically bleed remaining air in the system
after the bleeding process has been carried out as described above.
Switch off engine.
Checking oil level:
Oil level should be checked at operating temperature at specified intervals.
7/27/2022 TML 104
105. Oil Filling and Air Bleeding..
Oil check on stationary engine
In order to establish that no air is sucked in, when engine is started, it must first be establish
whether oil loss has occurred when engine is stationery. Therefore, the container should be
filled approximately 1 to 2 cm above the upper marking on dip-stick
Oil check on running engine
Oil level falls slightly when engine is running since the oil requires a pressure of 2 to 4 bar to
flow through the steering gear box as a result of the resistance to flow.
Oil should therefore once again be topped up so that oil level lies constantly at the upper
marking. Engine can then be switched off again. If this level is exceeded. Then this is a sign
that there is still air in the system.
7/27/2022 TML 105
106. Oil Filling and Air Bleeding..
Changing oil and Filter
Filter has to be replaced at specified intervals.
Oil & filter has to be changed when steering gear box or pump are repaired or replaced. Oil
pipes/hoses also have to be cleaned.
When soiled filter cartridge is removed, bottom opening of the filter must be closed
immediately while removing from the filter from its support to prevent dirty oil in filter
cartridge flowing back into reservoir and entering oil circuit.
Inspection Recommended
Steering system should be inspected in installed condition, corresponding to the intervals laid
down in the following table depending on vehicle applications.
7/27/2022 TML 106
Long distance travelling Long and short distance travelling Travelling on building sites and cross-country
I. Inspection 1,00,000 km 1,00,000 km 80,000 km
II. Inspection 2,00,000 km 1,75,000 km 1,50,000 km
III. Inspection 3,00,000 km 2,50,000 km 2,00,000 km
107. Troubleshooting of Steering System – Recirculating Ball & Nut
Type - Hydraulic
Troubleshooting – Steering System – Recirculating
Ball & Nut Type - Hydraulic
7/27/2022 TML 107
Troubleshooting of
Steering System
(Recirculating Ball & Nut
type – Hydraulic -
709/909)
108. Minors Repairs on Power Rack & Pinion Steering Gear
Rack & Pinion Steering - Hydraulic
7/27/2022 TML 108
109. Special Service Tools - Rack & Pinion type
7/27/2022 TML 109
Description Part no. Purpose
Rack holding tool 2845 5890 46 01 To hold the rack while loosening & tightening inner ball joint.
Bellow support protector Dolly 2845 5890 46 02 To assemble new Bellows support into the inner ball joint.
Special spanner 36 mm 2845 5890 46 03
Torque Wrenches (Standard) To loosen / tighten the feed pipe and inner ball joint.
Plier (Standard) To remove and fix the Bellow Straps.
110. Minor Repairs & Dismantling of Power Steering
Rack & Pinion Steering- Hydraulic
7/27/2022 TML 110
111. Dismantling, Assembly & Minor Repairs on Rack & Pinion
Steering Gear
Minor Repairs on Rack & Pinion Gear
7/27/2022 TML 111
Dismantling, Assembly
& Minor Repairs on Rack
& Pinion Steering Gear
112. Overhaul Process of Rack and Pinion
7/27/2022 TML 112
Step - 1 Step - 2
Remove the Bellow small & big end Metal Strap using pliers. Remove Bellow support from
the IBJ.
Step - 3 Step - 4
Removal of IBJ:
• Hold the rack using rack holding tool at housing side.
• Loosen the housing side IBJ from the rack using 36 mm spanner.
• Remove the IBJ from the rack
Removal of feed pipe :
• Carefully unscrew the flare nuts at the ends of the long feed
pipes connected to housing and rack tube ends using 11mm
open end spanner.
113. Plug the ports in the steering pump immediately after
disconnecting the hydraulic connections and draining the oil out.
Use only special tools and not hammer to remove any of the
steering pump parts.
Take care to avoid damage to suction port & discharge port
when drawing out the steering pump assembly from the vehicle.
Dismantling & Assembly of Power Steering Pump
7/27/2022 TML 113
Dismantling & Assembly
of Power Steering Pump
– Rack & Pinion Type -
Hydraulic
115. Power Steering System - Hydraulic Test Using
Diagnostic Gauge
Using diagnostic gauge (pressure gauge, flow meter, shut off valve and hose), we can check
the following and compare to specification of the system.
1. Pump performance check
a. Flow
b. Relief pressure
c. Pump response
2. Steering gear - Internal leakage
7/27/2022 TML 115
116. Power Steering System - Hydraulic Test Using
Diagnostic Gauge..
Preparation of hydraulic System
Install diagnostic gauge in the pressure line (fluid supply line from pump to steering gear).
Check and top-up oil in reservoir. Bleed the system as per procedure.
Place a thermometer in the reservoir to record temperature. With the shut off valve of
diagnostic gauge fully open, warm up the hydraulic system by partially closing the shut off
valve until the pressure gauge reads 7 bar (100 PSI). When the temperature reads 51.70 C
(1250 F) and 57.20 C (1350 F) open the valve.
The system is now warmed up and ready for conducting the hydraulic test.
7/27/2022 TML 116
117. Power Steering System - Hydraulic Test Using
Diagnostic Gauge..
Test no. 1
Pump performance
Keep and eye on the pressure gauge and slowly close the shut off valve of diagnostic gauge.
System pressure not to exceed the relief pressure specified.
Caution
Do not keep the shut off valve closed for more than 5 seconds at a time to avoid damage to
the pump.
Measure and record in table bellow the flow, pressure and temperature at idling and
governed speed with shut off valve in fully opened and closed condition.
7/27/2022 TML 117
Engine speed Shut off valve condition Pressure Flow Temperature
Idling Speed
Open A
Closed B
Governed Speed
Open A
Closed B
118. Power Steering System - Hydraulic Test Using
Diagnostic Gauge..
Caution..
Compare minimum / maximum flow and maximum pressure (relief pressure) recorded with
specification and refer appropriate comments bellow for corrective action. If it specification,
proceed to Test no. 2.
Comments
Steady state fluid pressure (with hands off steering wheel) should be equal to or less than
that specified for the system.
– If it reads higher than the specification, check the feed and return line circuit and hoses between
pump and gear box for clogging / deformation. Check the filter for any clogging.
If the measured flow is less than the specification the pump needs to be repaired (or) replace.
If maximum system pressure (relief pressure) recorded is lower than the specification, it may
not be developing enough pressure to assist steering. The pump needs to be repaired or
replace.
7/27/2022 TML 118
119. Power Steering System - Hydraulic Test Using
Diagnostic Gauge..
7/27/2022 TML 119
Caution
With shut off closed, the flow drops to zero and should not be closed be more than five
seconds.
Test no. 2
Pump response test
Keeping any eye on the flow meter, look for instant return of flow rate to recommended flow
range from zero when shut off valve is opened from the closed position both at idling and
governed speed. Conduct the above test once at idling speed and three times at engine
governed speed.
If the flow rate does not return immediately the pump is malfunctioning and can result in
momentary loose of power assist. The pump needs to be repaired or replaced.
120. Power Steering System - Hydraulic Test Using
Diagnostic Gauge..
Test no. 3
Steering gear internal leakage test
First conduct pump performance test and confirm that the pump is working satisfactorily.
With shut off valve open and at steady idling speed of engine, turn the steering wheel to any
wheel lock end and apply force at the rim of the steering wheel to be sure that the control valve is
fully closed.
The pressure gauge should now read maximum pressure (relief pressure) specified for the pump.
If it reads appreciably less than the relief pressure, it indicates reduction in power assistance
because excessive internal leakage. Repair or replace the steering gear.
Repeat this test at the opposite wheel lock.
Caution
Don’t hold the steering wheel in the full turn position (lock end) for more than 5 sec. to avoid
damaging the pump.
Note
When hydraulic tests are completed and fluid lines are reconnected check fluid level and bleed the
system.
7/27/2022 TML 120
121. Filling and Air bleeding procedure
Procedure for filling and air bleeding the hydraulic system
Apply parking brake and set the gear shift lever in neutral.
Raise the front wheel clear off the ground and support with safety stand.
Check for proper connection and tightness of end fitting / hose clips in hydraulic lines.
Fill the reservoir nearly full with recommended power steering fluid.
Crank the engine for 10 seconds without, if possible allowing it to start. If the engine does
start, shut off immediately. Check and refill reservoir. Repeat atleast 3 times each time
checking and refilling till the level in the reservoir is stabilized.
7/27/2022 TML 121
122. Lubrication and Maintenance
Specification of power steering oil
Automatic transmission fluid
Maintenance
Regularly check the fluid and the level in the power steering reservoir.
Encourage drives to report any malfunctions or accidents, which could have damaged
steering components.
Do not attempt to weld any broken steering component. Replace the component with
original equipment only.
Do not cold - straighten, hot straighten, or any steering system component.
Always clean off around the reservoir filler cap before you remove it. Prevent dirt or other
foreign matter from entering hydraulic system.
Investigate and correct any external leaks, no matter how minor.
Replace reservoir filters according to requirements.
7/27/2022 TML 122
123. Lubrication and Maintenance..
Oil and filter change schedule
80,000 kms or 2 years whichever is earlier.
Oil specification: Automatic transmission fluid type A.
Brands of oil recommended: Castrol TQ, Bharat ATF
Caution: Do not mix different brands of oil.
Oil replacement schedule
7/27/2022 TML 123
125. Propeller shaft
Function:
To transmit the motion from gear box to rear axle which are at two continuously varying
planes
Where there is prop-shaft with more than 1 piece , The propeller shaft is supported by Center
Bearing Bracket.
When there are two rear axles, Rear rearward & Front forward, inter-axles is used
7/27/2022 TML 125
126. Construction of Propeller Shaft
Universal Joint:
Universal joints are used to transmit power
from one shaft to other when they are
inclined with each other.
Merits :
– Cheap & Easy to maintain
Demerits :
– Causes a lot of vibrations because Input
shaft & Output shaft don’t rotate at same
speed at all times.
7/27/2022 TML 126
127. Construction of Propeller Shaft
Slip Joint:
The purpose of slip joint is to avoid thrust load on Propeller Shaft & Centre Bearing Support.
Due to flexing of leaf springs the length of Propeller Shaft varies. To accommodate this
variation slip joints are provided.
7/27/2022 TML 127
128. Construction of Propeller Shaft
Glide Coating:
The center shaft of Slip Joint has anti
friction coating known as Glide coating.
It smoothens the to & fro motion of shaft
over slip yoke.
7/27/2022 TML 128
Glide Coating
129. Construction of Propeller Shaft
Needle Roller Bearing:
Needle Roller Bearing are used because
they have the capacity to carry large load
in limited space
Rubber Seal:
Synthetic Rubber Seal on UJ cross prevents
the entry of dust & water in needle roller
bearings.
7/27/2022 TML 129
130. Construction of Propeller Shaft
Couplings:
Two types of couplings may be found
– Plain
– Serrated
7/27/2022 TML 130
Plane flange Serrated flange
131. General Lay out of Propeller Shaft
7/27/2022 TML 131
Propeller shaft Rear axle
Gear box
133. Layout of Two Piece Prop-shaft
7/27/2022 TML 133
Centre bearing mounting
with frame cross member
Drive shaft
Prop- shaft Guard
Front shaft
134. Layout of Three Piece Prop-shaft
7/27/2022 TML 134
Centre bearing mounting
with frame cross member
Centre bearing mounting
with frame cross member
Drive shaft
Front shaft
135. Layout of Prop-shaft with Inter-Axle
7/27/2022 TML 135
Inter-axle shaft
Drive shaft
Rear Rearward rear-axle
Front Forward rear axle
137. Propeller Shaft – Application Matrix
7/27/2022 TML 137
Type
Y1 9.6T,
8.5T, 7.5T
XENON/
207
407/
410
709 /
712
909
/912
1109/
1112
1613 2518
Complete LFL (Lube for Life, Non
Greasable)
Partially LFL ( Lube for Life, Only Slip joint
is greasable)
Greasable
138. Propeller Shaft – Application Matrix
7/27/2022 TML 138
Type Supplier
Y1 9.6T,
8.5T, 7.5T
XENON 407 709 1112 1109 909 2518 1613
Complete LFL (Non
Greasable)
Spicer a
Partially LFL(Only Slip
joint is greasable)
Spicer a
1 piece Untized
Greasable prop shaft
MSL a a
Spicer a
2 piece prop shaft (1
piece unitized + 1
single piece)
MSL a
Spicer a
2 piece prop shaft Spicer a a
140. Parts of Propeller Shaft
7/27/2022 TML 140
Center Bearing
Support bracket
Center
Bearing
Center Bearing
Support Rubber
Center Bearing
Inner Seal
Center Bearing
Outer Seal
Slip Yoke
Dust cover
Dust cover
Seal
Slip Yoke Splined shaft or Center Shaft
Center Bearing bracket :
The bracket supports propeller shaft at
cross member and firmly attached to
the cross member.
It contains bearing covered with rubber
housing and seal at both ends.
141. Drive shaft
When there is single piece shaft, it is by
default drive shaft with sliding joint.
Sliding joint is provided to avoid any thrust
load on propeller shaft or Centre bearing
support due to flexing of leaf springs.
For this shaft guard should be provided,
because at maximum length of shaft there
is possibility of open of full slide length , to
protect shaft from falling down at full slide
,one bracket called guard is provided with
it.
7/27/2022 TML 141
142. Drive shaft
When shaft is of more than one piece,
front shaft with centre bearing comes with
drive shaft.
Centre bearing is mounted to frame cross
member by using centre bearing bracket
at required height.
7/27/2022 TML 142
144. Technical Specifications
7/27/2022 TML 144
Adjustment Data
Max permissible displacement in lateral and axial direction under 3.3 kgm load 0.15 mm
Max permissible axial and radial looseness in slip yoke and tube shaft 0.18 mm
Max permissible imbalance 18 gm cm @ 3200 rpm
Total ovality 0.25 mm
Total runout 0.76 mm
148. Technical Specifications
7/27/2022 TML 148
Diameter of bearing cup mounting bores in propeller shaft
yokes
Colour code
Bearing cup outer
diameter
30.021/30.00 mm White 30.045/30.030 mm
30.041/30.020 mm Yellow 30.065/30.045 mm
30.061/30.040 mm Blue 30.080/30.065 mm
Bearing cup inner diameter 24.953/24.920 mm
Needle roller diameter
Set 1 2.500/2.497 mm
Set 2 2.498/2.495 mm
Set3 2.496/2.493 mm
Number of needless per cup 28 nos.
Diameter of cross spigots 19.880/19.871 mm
Max. permissible imbalance of propeller shaft 50 cm. gm.
Straightness of propeller shaft (total indicator reading over entire length) 0.3 mm
150. Special Tools
7/27/2022 TML 150
Description Part No.
Puller for centre bearing 2505 5890 01 02
Drift for installing center bearing 2640 5890 35 15
152. Technical Specifications
7/27/2022 TML 152
Diameter of bearing cup mounting bores in propeller shaft
yokes
Colour code
Bearing cup outer
diameter
38.025/38.00 mm White 38.055/38.035 mm
38.050/38.025 mm Yellow 38.080/38.055 mm
38.075/38.050 mm Blue 38.100/38.080 mm
Bearing cup inner diameter 28.913/28.880 mm
Needle roller diameter
Set 1 2.500/2.497 mm
Set 2 2.498/2.495 mm
Set3 2.496/2.493 mm
Number of needless per cup 33 nos.
Diameter of cross spigots 23.840/23.831 mm
Max. permissible assembly imbalance of propeller shaft 25 gm cm
Straightness of propeller shaft (total indicator reading over entire length) 0.3 mm
Axial play of universal joint assembly 0.02 to 0.04 mm
154. Special Tools
7/27/2022 TML 154
Description Part No.
Puller for centre bearing 312 589 25 33
Holder for coupling flange 321 589 01 31
Puller for removal of Coupling flange 2574 5890 35 07
Drift for installing coupling flange 312 589 14 39
155. Removal & Installation of Propeller Shaft Form the Vehicle
Propeller Shaft-709 Type
7/27/2022 TML 155
156. 1. Unlock and unscrew coupling flange fastening screws/nuts to
disconnect rear propeller shaft from front propeller shaft.
Carefully place front end of rear propeller shaft on ground.
2. Unlock and unscrew coupling flange fastening screws to
disconnect rear propeller shaft from tail pinion. Remove rear
propeller shaft.
3. Unscrew nuts to remove centre bearing bracket from cross
member. Carefully place rear end of front propeller shaft on
ground.
4. Unlock and unscrew coupling flange fastening screws to
disconnect front propeller shaft from gearbox. Remove front
propeller shaft.
Exercise
7/27/2022 TML 156
Removal of Propeller
Shaft from Vehicle
Removal of centre
bearing bracket
157. For installation proceed in reverse order of removal.
Note:
1. Assemble in such a way that all the three yokes of propeller
shafts are in one plane.
2. Use new lock plates for coupling flange fastening screws /
nuts.
3. Tighten coupling flange screws / nuts to specified torque and
lock them with lock plates.
4. Tighten centre bearing bracket fastening screws/ nuts to
specified torque.
Exercise
7/27/2022 TML 157
Installation of Propeller
Shaft on Vehicle
Locking
coupling
flange nuts
Tighten
centre
bearing
bracket
fastening
nuts
158. Removal of centre bearing from front propeller shaft
Unstake coupling flange nut from groove
on front propeller shaft.
Mount holder 321 589 01 31 on coupling
flange. Grip the holder in vice. Unscrew
and remove coupling flange nut with 50
mm socket. Remove holder.
7/27/2022 TML 158
Centre bearing
mounting
arrangement
159. Removal of centre bearing from front propeller shaft..
Mount puller 2574 5890 35 07, and pull
out coupling flange.
Unstake clamping strap and remove centre
bearing bracket.
Displace rubber housing from its seating
with a screw driver if necessary. Slide off
rubber housing from centre bearing
assembly.
Remove rear spacer ring.
With puller 3112 589 25 33 pull out centre
bearing assembly from front propeller
shaft.
Remove front spacer ring.
7/27/2022 TML 159
Removal of
coupling
flange with
puller
Removal of
centre bearing
160. Inspection of centre bearing
1. Clean all components thoroughly.
2. Check condition of splines and threads on front propeller shaft.
3. Check condition of splines and holes on coupling flange.
4. Check condition of bore and mounting holes of centre bearing bracket.
5. Check condition of rubber housing. Replace with new one.
6. Check centre bearing assembly for:
a) Condition of both rubber seals.
b) For checking of centre bearing proceed as follows:
i. Clean centre bearing assembly with diesel only.
ii. Do not use kerosene or petrol for cleaning.
iii. Bearing should not bind when rotated manually.
iv. For judging silent running of bearing, apply few drops of engine oil to cleaned bearing and rotate it
v. The bearing should have negligible radial play.
7. Check both spacer rings for wear / score marks. If found defective, replace with new one.
7/27/2022 TML 160
161. Installation of centre bearing on front propeller shaft
1. Unscrew and remove grease nipple for
centre bearing from front propeller shaft.
2. Clean lubrication passage for centre bearing
in the front propeller shaft rear end.
3. Screw back grease nipple (if found
defective, use new grease nipple).
4. Check condition of protective caps on front
propeller shaft and coupling flange. If found
damaged, replace with new ones. These are
tack welded to respective components.
5. Install one centre bearing spacer ring in
such a manner on front propeller shaft rear
end that its chamfered surface with notches
comes in contact with inner race of centre
bearing.
6. Apply grease to centre bearing assembly
(centre bearing and seats).
7. Install centre bearing assembly on front
propeller shaft rear end.
7/27/2022 TML 161
Installation of centre bearing
162. Installation of centre bearing on front propeller shaft..
8. Install other spacer ring for centre bearing
on front propeller shaft rear end, in such a
manner that its chamfered surface with
notches will come in contact with inner race
of centre bearing.
9. Apply glycerine on inner periphery of
rubber housing and slide it onto centre
bearing assembly, so that recess on rubber
housing is matched with lugs on centre
bearing.
10. Apply grease on splines of front propeller
shaft and coupling flange.
11. Insert coupling flange on front propeller
shaft using drift 312 589 14 39 such that it
rests fully against spacer ring of centre
bearing.
12. Screw in new coupling flange nut on front
propeller shaft.
7/27/2022 TML 162
163. Installation of centre bearing on front propeller
shaft..
13. Mount holder 321 589 01 31 on coupling
flange. Clamp holder in vice arid tighten
coupling flange nut.
14. Stake collar on coupling flange nut in the
slot provided on front propeller shaft such
that coupling flange is locked against
loosening.
15. Assemble centre bearing bracket and
clamping strap on rubber housing. Crimp
clamping strap on to bracket at both ends.
Ensure that there are no cracks at crimping.
Also check for proper crimping of rubber
housing retainer.
7/27/2022 TML 163
165. Disassembly of Universal Joint
1. Clean paint and dust from snap rings and
top of bearing cups.
2. Remove all snap rings by pressing with a
screw driver. If necessary, tap bearing
cups lightly with mallet.
3. Rest yoke on suitable support and press
out bearing cup using suitable spacer on a
hand press.
4. Rest opposite side of yoke on support and
press out other bearing cup using suitable
spacer.
5. With same procedure press out the
remaining two bearing cups.
6. Unstake sheet metal retainer from
bearing cup and remove rubber seal.
7. Remove the cross and dust caps.
7/27/2022 TML 165
Pressing out bearing cup
166. Inspection of Universal Joint
Clean all metal parts thoroughly in a
cleaning solvent, but wipe rubber parts
only with a dry cloth.
Measure the diameters of bearing cup
mounting bores in propeller shaft yokes.
Measure inner bores of bearing cups.
Check for wear, damage, over tightening.,
etc.
7/27/2022 TML 166
167. Inspection of Universal Joint..
Measure outer diameter of bearing cups and check for required fit in corresponding
mounting bores in propeller shaft yokes. Both should have same colour code mark for correct
fit.
Check needle rollers for pitting, damage, wear, overheating, etc.
Note: All needle rollers in four bearing cups of a cross assembly should be from same set.
Check cross for damage, wear, overheating, etc. measure diameters of cross spigots.
Check rubber seal and sheet metal retainer for damage. Replace these, if necessary.
Check lubrication passage in cross.
Note: If any of the above defect is observed replace complete cross assembly.
7/27/2022 TML 167
168. Assembly of Universal Joint
Clean thoroughly needle rollers and
bearing cups.
Smear grease on the needle rollers and
bearing cups.
Assemble needle rollers in the bearing
cups.
Note: Ensure that each cup is assembled with
33 needle rollers. All four bearing cups of an
universal joint should have same colour code
mark and should be assembled with needle
rollers from same set.
Fit the rubber seal with the sheet metal
retainer. Stake the retainer in the groove
provided on the body of the bearing cup.
7/27/2022 TML 168
169. Assembly of Universal Joint..
Fit grease nipple on the cross and install the
cross in the propeller shaft yokes.
Note: Grease nipple on the cross should face
propeller shaft and not coupling flange.
Press new dust caps on the cross using
suitable tubes.
Press the needle roller bearing cup assembly
in the yokes using suitable spacer on a hand
press. Ensure that colour code on yoke and
bearing cup are same or correct fit.
After pressing in the bearing cups, secure
them in position with appropriate thickness
of snap rings.
The universal joint should be assembled with
0.02 to 0.04 mm axial play. After assembly,
slightly tap the yokes with a mallet to ensure
proper assembly.
Grease the universal joint.
7/27/2022 TML 169
170. Inspection of Propeller Shaft
Rear propeller shaft
Unscrew and loosen hose clips from both
ends of rubber boot.
Slide off yoke from shaft.
Remove rubber boot and check its condition.
Clean and apply grease to splines on shaft
and yoke.
Install rubber boot on splined shaft.
Slide yoke onto shaft ensuring alignment of
mating arrows.
7/27/2022 TML 170
171. Inspection of Propeller Shaft..
Check for free sliding of yoke on shaft.
Tighten hose clip at both ends of rubber boot such that screws on hose clip strap are
diametrically opposite to each other.
Check rear propeller shaft for bend by suitably clamping coupling flanges at both ends. If
necessary straighten.
Note: All straighten operations are to be done with complete shaft assembly.
Check rear propeller shaft for dynamic imbalance.
Pack grease in sliding joint with grease gun through grease nipple.
Caution: Avoid over greasing. Since this may burst the rubber boot.
7/27/2022 TML 171
172. Inspection of Propeller Shaft..
Front propeller shaft
Remove coupling flange and centre bearing with bracket from front propeller shaft.
Check front propeller shaft for bend. If necessary straighten.
Check front propeller shaft for dynamic imbalance.
Install centre bearing with bracket and coupling flange on front propeller shaft.
Checking Straightness of prop shaft : 0.3 mm
7/27/2022 TML 172
174. Example of Crossed parallel phasing (plus –plus –
minus).
7/27/2022 TML 174
Plus joint
Plus joint
Minus joint
175. Fitment of sliding yoke to propeller shaft
Phasing of Propeller Shaft:
Align the paint/arrow marking on shaft and
yoke in one line. The shaft is balanced in
this condition. Changing the position will
create imbalance and vibrations.
Care while dismantle:
While disconnecting ensure that the paint
marks are made on the rear propeller shaft
& sliding yoke are marked clearly so that
they can be aligned while reassembly
7/27/2022 TML 175
Pinion: The pinion is connected to the steering column. As the driver turns the steering wheel, the forces are transferred to the pinion and it then causes the rack to move in either direction. This is achieved by having the pinion in constant mesh with the rack.
Rack: The rack slides in the housing and is moved by the action of the meshed pinion into the teeth of the rack. It normally has an adjustable bush opposite the pinion to control their meshing, and a nylon bush at the other end.
