Steering - Steering Rack Replacement
No: 57/07/05/NASFGN 211-02
Ref:
Issue: 1
Date: 26 September 2005
Revised Procedure for Steering Rack Replacement
AFFECTED VEHICLE RANGE:
Freelander (LN)
All
SITUATION:
NEW PROCEDURE DERIVED FROM TIME STUDY
This Technical Bulletin has been issued to inform Retailers of a change in the workshop procedure to remove/install the power steering rack as the result of a time study review. On KV6 vehicles the time study eliminated the removal of the top engine mounting and changed the procedure for system bleed.
RESOLUTION:
REPLACE STEERING RACK FOLLOWING NEW PROCEDURES
Remove and install the power steering rack following the new workshop method present in the Repair Procedure section of this bulletin below. Following this procedure permit reduction from the old labor time for "Steering Rack Removal and Refit" 57.10.01 from 2.4 hours to 1.7 hours
PARTS INFORMATION:
Refer to Microcat for parts required for the repair.
DDW WARRANTY CLAIMS:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time. Repairs associated with this procedure that require the new workshop process for steering rack replacement will also have revised times.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
REMOVE POWER STEERING RACK
NOTE:
Some of the illustrations are right-hand drive vehicles. Left-hand drive would be mirrored.
CAUTION:
Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
1. Raise the vehicle on a twin-post lift.
2. Rotate the steering wheel to the straight-ahead position, align the pinion marks and remove the ignition key.
3. Remove pinch bolt securing steering column to power steering rack pinion. (Figure 1)
4. Remove front road wheels.
5. Remove the underbelly panel.
6. Install an M12 nut to each ball pin, flush with the end of each pin.
7. Using special tool 57-043, separate ball pins from right-hand and left-hand steering arms. (Figure 2)
8. Remove M12 nuts and release ball pins from steering arms.
9. Remove two nuts securing steering rack heat shield and remove heat shield. (Figure 3)
10. Remove two bolts securing the camshaft cover heatshield and remove the heatshield.
11. Remove bolt securing coolant rail to cylinder head.
12. Remove and discard two bolts securing power steering rack mounting to bulkhead.
13. Remove power steering rack clamp. (Figure 4)
14. Remove rubber mount.
15. Remove and discard the two bolts securing the power steering rack to the bulkhead. Save the washer. (Figure 5)
16. Release power steering rack pinion from steering column.
17. Position container to collect power steering fluid spillage.
18. Remove bolt securing pipe bracket to power steering rack.
CAUTION:
To prevent contamination clean plugs should be installed to open connections.
19. Release pipe unions and disconnect fluid pipes from power steering rack. (Figure 6)
20. Remove and discard O-rings.
21. Remove bolt securing power steering pipes to clamp, and loosen clamp bolt.
22. With assistance remove power steering rack from passenger side of vehicle.
23. Remove dust shield from pinion housing. (Figure 7)
24. Remove and discard the two bolts securing the track rods to steering rack.
25. Remove the track rods from the steering rack. Collect the three spacers.
INSTALL STEERING RACK
CAUTION:
Care must be taken to ensure that the following conditions are achieved:
^ Each track rod is installed to the correct side of the steering rack.
^ Spacers are aligned and installed correctly.
1. Install the track rods to the steering rack. Install the spacers.
2. Hold track rods parallel with power steering rack and tighten new bolts to 100 Nm (73 lbf.ft).
3. Install power steering rack to vehicle from passenger side.
4. Install dust shield to pinion housing.
5. Ensure pipe unions are clean.
6. Install new O-rings to fluid pipes.
7. Install fluid pipes to power steering rack but do not tighten at this stage.
8. Align fluid pipe bracket to power steering rack, install bolt but do not tighten at this stage.
9. With assistance install power steering rack pinion to steering column, ensuring column coupling is aligned with gear input flag.
10. Install washer and new bolts securing steering rack mounting to bulkhead, but do not tighten at this stage.
Ensure large washer is installed to the lower bolt.
11. Install rubber mount and clamp to power steering rack.
12. Install bolts securing clamp to bulkhead but do not tightened at this stage.
13. Tighten power steering rack mounting bolts to 45 Nm (33 lbf.ft).
14. Tighten power steering rack clamp bolts to 45 Nm (33 lbf.ft).
15. Tighten power steering rack fluid feed pipe union to 18 Nm (13 lbf.ft).
16. Tighten power steering rack fluid return pipe union to 22 Nm (16 lbf.ft).
17. Tighten fluid pipe bracket to 8 Nm (6 lbf.ft).
18. Align PAS rack clamp and tighten bolt.
19. Align pipes to clamp fit bolt and tighten to 10 Nm (7 lbf.ft).
20. Install pinch bolt to steering column and tighten to 32 Nm (24 lbf.ft).
21. Ensure tapers in track rod end and steering arm are clean, and rubber boot is not damaged.
22. Install ball joints to steering arms. Install new nuts and tighten to 55 Nm (40 lbf.ft).
23. Align coolant rail to cylinder block, install bolts and tighten to 9 Nm (6 lbf.ft).
24. Install the camshaft cover heat shield, and tighten the two securing bolts to 25 Nm (18 lbf.ft).
25. Position heat shield, install nuts and tighten to 25 Nm (18 lbf.ft)
26. Install road wheels and tighten nuts to 115 Nm (85 lbf.ft).
27. Lower the vehicle.
28. Install pinch bolt to steering column and tighten to 32 Nm (24 lbf.ft).
29. Top-up power steering reservoir and bleed system.
30. Visually check power steering system for leaks.
31. Install underbelly panel.
32. Check and if necessary adjust wheel alignment.
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