Power Steering - Lack of Power Assistance

9233jaguar01

57-14


PAS - Lack of Power Assistance - Repair Procedure

MODEL Sedan Range
DATE 4/92


SUPERSEDES: TECHNICAL BULLETIN 57-13

ISSUE:
Lack of power steering from a cold start caused by oil leaking past the PTFE sealing rings of the PAS valve assembly.

New energized sealing rings have been introduced on PAS racks from date code 1K 1368 (CCC 5651/N).

ACTION:
PAS racks from date code 9G 1673 (CBC 9053/N) must be rebuilt using seal kit JLM 10839.


NOTE:
The following special tools are required for this procedure:
^ JD 184 Pinion valve extraction tool
^ JD 185 Pinion valve seal and energizer loading tool (3 pieces)
^ JD 186 Pinion valve seal sizing tool
^ JD 187 Pinion seal protector
^ JD 120 Rack centralizing tool

Inspect all tools for damage. Replace tools which are scored or burred. Use PAS fluid to lubricate the tools and seals.





Check the date code on the PAS rack, (Fig. 1). If the date code is earlier than 9G 1673, replace the rack. If the date falls within 9G 1673 to 1K 1367 (CBC 9053/N), rebuild the rack.

Date Code Format:
9 G 1672
1989 July Unit built in month


STEERING RACK VALVE ASSEMBLY REBUILDING PROCEDURE:

^ Remove and clean the steering rack. Refer to Repair Operation 57.10.01 in the Sedan Range Repair manual.

^ Remove dirt deflector from the pinion shaft.





^ Install JD 184 (Fig. 2). Rotate pinion lock to lock, to remove any excess fluid.





^ Remove the tapered plug from the steering rack centering pin hole and install tool JD 120. Center steering rack. For realignment, mark pinion housing and cover plate in-line with the center of the pinion pinch bolt cut out, (Fig. 3). Remove JD 120.





^ Loosen the two 8 mm bolts securing the damper assembly approximately 3/8", but do not remove bolts. (Fig. 4).








^ Remove tool JD 184, the pinion cover plate and the shims, (Fig. 5).

^ Install tool JD 184 to the pinion, (Fig. 2).





^ Remove the pinion from the housing by gently pulling, (Fig. 6). The pinion will rotate 90~ counter clockwise. Remove JD 184.

^ Remove thrust washer assembly from the top of the pinion. Clean the thrust washer and save for re-assembly.

^ Remove and discard the pinion quad seal from the lower pinion housing. Clean and check the pinion housing for damage.


NOTE:
Service Tool JD 185 is a three piece tool comprised of the following:

- Tapered mandrel
- Zinc plated sleeve
- Black machine finish sleeve





^ Cut and remove the original pinion valve seals, being careful not do damage the pinion (Fig. 7).

^ Clean the valve assembly.





^ Install the zinc plated sleeve onto the mandrel of tool JD 185. Place tool on a soft surface and load 4 energizing rings on the sleeve (Fig. 8) and remove sleeve from mandrel.





^ Install sleeve on pinion valve and align with the groove that is closest to the pinion gear. Slip ring into first groove and continue until all rings are fitted, (Fig. 9).





^ Install black finish sleeve onto mandrel. Place tool on a soft surface and load 4 PTFE seals on the sleeve, (Fig. 10).

^ Remove sleeve from mandrel and install the black sleeve on the pinion valve and align with the groove that is closest to the pinion gear.


NOTE:
The PTFE sealing rings should NOT remain on the black finish sleeve for more than 5 minutes.





^ Slip each PTFE seal from the black sleeve into each ring groove. Remove sleeve, (Fig. 11).





^ Rotate the pinion valve between the palms of hands to compress the valve seals, (Fig. 12).


^ Lubricate and install quad seal to the pinion housing. Lubricate the pinion housing bore.

^ Secure tool JD 186 in the round jaw section of a vise and install JD 184 to the pinion. Lubricate and install pinion into tapered side of tool JD 186. Pass the pinion through the tool 5 times to size the seals.

^ Install tool JD 186 to the pinion housing using the 3 cap screws (but do not tighten) to allow tool to self center with the housing.

^ Check rack alignment using tool JD 120.





^ Check alignment marks and allowing 90~ for pinion rotation install pinion in rack (Fig. 13). Remove tool JD 186 and JD 184, making sure that the pinion pinch bolt cut-out aligns with the mark on the housing. Remove tool JD 120 and install the tapered plug.

^ Tighten the two 8 mm support plate bolts (Torque to 17 ft. lbs.).

^ Install tool JD 186 to the pinion housing.





^ Install square cut "O" ring to the bottom of the thrust washer. Install small "O" ring in recess of the thrust washer. Place thrust washer ("O" ring side up) into bevel edge of tool JD 186 and lubricate. Use the handle end of tool JD 184 to push the thrust washer assembly into the housing. Remove tools JD 186 and JD 184, (Fig. 14).

^ Install seal protector tool JD 187 over pinion splines. Lubricate and install small PTFE seal (step side down) onto tool JD 187.


^ Slide the seal into the thrust washer and remove tool JD 187. Position the handle end of tool JD 184 over the pinion and lightly push the PTFE seal into place, (Fig. 14).





^ Install pinion shims and top plate. Align the top plate with marks on the housing, (Fig. 3). Tighten the three 6 mm bolts. (Torque 7 ft.lbs.).








^ Install a new dirt deflector using a soft face mallet and tool JD 184, (Fig. 15). Set the top of the dirt deflector 4 to 4.5 mm from the top of the plate, (Fig. 16).

^ Install rack in vehicle and road test.


NOTE:
Any steering friction that is felt will wear off after 100-200 miles of driving.


TORQUE SPECIFICATIONS:

6 mm bolts: 7 ft.lbs. (10 N-m)
8 mm bolts: 17 ft.lbs. (23 N-m)


SERVICE ADVISOR NOTE:

The customer MUST be informed that for the first 100-200 miles, the steering may not self center completely after turning.


PARTS INFORMATION:

Part Number Description

JLM 10839 Seal Kit


WARRANTY INFORMATION

Fault Code:
5AAN
Repair Operation Number:
57.10.09 (Steering rack pinion valve assembly seals - renew)
Time Allowance:
2.40