ZF Gearbox

NOTE:
- It is not intended that repair work be carried out on the power steering gear.
- If complaints are received determine cause with the help of pressure tests, leakage test and troubleshooting programs.
- If a malfunction exists replace the power steering gear.
- Always replace self-locking nuts and bolts.
- Welding and straightening work on steering components Is not permitted.
- To grease the rack use only steering gear grease, Part No. AOF 063 000 04, or equivalent.
- Type of oil: Hydraulic oil part No. G 002 000, or equivalent
- Oil system capacity: 0.7-0.9 liter. (0.74-0.95 qt)
- Supply and pressure line routing.

1 Power Steering Gear
- Removing and installing.
- Adjusting.
- Checking steering moment

2 Hose Clip
- Always replace
- Use pliers to open
- Tensioning, refer to Servicing.

3 Boot
- Remove ball joint before removing
- Check for wear (cuts cracks), ensure sealing surfaces and sealing lips are clean and undamaged
- The end diameters are larger than the boot for TRW power steering gears
- Must not be installed on TRW power steering gear

4 Hose Clip
- Always replace
- Use pliers to open
- Tensioning, refer to Servicing.
- Must not be installed on a TRW power steering gear

5 Right-Hand Tie Rod
- Removing and installing.
- Vehicle alignment.
- Tie rod boot seat diameter
- ZF: 15 mm
- TRW: 12.7 mm
- Must not be installed on a TRW power steering gear

6 Left-Hand Tie Rod
- Removing and installing.
- Tie rod boot seat diameter
- ZF: 15 mm
- TRW: 12.7 mm
- Must not be installed on a TRW power steering gear
- Adjusting length.

7 Lock Nut
- tighten to: 50 Nm (37 ft. lbs.)

8 Tie rod ball joint

9 Pressure Balance Pipe

10 Mounting Bracket Nuts
- Tighten to: 30 Nm 122 ft. lbs.)

11 Clamp

12 Rubber Mounting
- Internal diameter
- ZF: 50 mm
- TRW: 44 mm

13 Data Plate And Company Initials