Power Assisted Steering Box (ZF)
Power steering gear (ZF)WARNING:
Do not re-use fasteners that are worn or deformed in normal use.
Some fasteners are designed to be used only once, and are unreliable and may fall if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and coffer pins. Always replace these fasteners with new parts where indicated and any other time it is deemed necessary by inspection.
If power steering gear is malfunctioning determine cause using pressure tests and leakage tests. If a malfunction exists, then replace the steering gear.
Note:
If reservoir fluid is low check steering system for leaks.
If leaks occur at line connections, tighten connections, wipe area dry and recheck for leaks.
To check rack seals, loosen the hose clip on the boot and push boot to one side.
Always replace all self-locking nuts and bolts.
Do not attempt to weld or straighten steering components.
Use only steering gear grease, Part No. AOF 063 000 04, to grease steering rack.
Type of oil: hydraulic oil, Part No. G 002 000, or equivalent.
System oil capacity: 0.7-0.9 liter (0.74-0.95 US qt)
1. Tie rod end right
Revised Cabrio tie rod end,
2. 50 Nm (37 ft lb)
3. Hose clamp
4. Boot
Remove tie rod end before removing
Check for wear (cuts, cracks), make sure sealing surfaces and sealing lips are clean and undamaged
End diameters are larger than those of TRW power steering gear
Not interchangeable with boot for TRW steering gear
5. Clamp
Always replace
Tigtening Service and Repair
Not interchangeable with clamps for TRW steering gear
6. Tie rod, left
Removing & installing Service and Repair
Adjusting to length Service and Repair
Not interchangeable with tie rod for TRW steering gear
Seat dia. of boot -4- at tie rod
ZF: 15mm (0.59 in)
TRW: 12.7mm (0.50 in)
7. Clamp
Use pliers to remove
Tightening Service and Repair
Not interchangeable with clamps for TRW steering gear
8. Tie rod, right
Removing & installing Service and Repair
Adjusting to length Service and Repair
Not interchangeable with tie rod for TRW steering gear
Seat dia. of boot -4- at tie rod
ZF: 15mm (0.59 in)
TRW: 12.7mm (0.50 in)
9. Tie rod end left
Revised Cabrio tie rod end,
10. Self-locking hex nut
Always replace
30 Nm (22 ft lb)
11. Pressure balancing line
12. Self-locking hex nut
Always replace
30 Nm (22 ft lb)
13. Clamp
14. Rubber mounting
Inside diameter
ZF: 50mm (1.97 in)
TRW: 44mm (1.73 in)
15. Steering gear
Removing & installing Power Steering Gear, Removing & Installing
Check turning torque
Turning torque on vehicles equipped with VR6 engine is approx. 2 Nm (18 in lb) higher
Adjusting Adjustments
Steering gear with extra servo assistance only available on vehicles up to 66 kW (90 hp)
16. 30 Nm (22 ft lb)
17. Lower universal joint
18. Cover disc
19. Sealing ring
Always replace
20. Union nut
30 Nm (22 ft lb)
21. Data plate and company initials