TRW TA S40 Series Service Manual Download

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GROUP 0603-V-003-0207

STEERING

DocID

TRW TAS STEERING GEAR

Page 1-1

Review Draft

0603-V-003-0207

TRW TAS STEERING GEAR

TRW Automotive

Commercial Steering Systems

TAS Steering Gear

Service Manual

T A S40,55,65, 66 AND 85 SERIES

Summary of Contents for TA S40 Series

Page 1: ...003 0207 STEERING 7 DocID TRW TAS STEERING GEAR Page 1 1 Review Draft 0603 V 003 0207 TRW TAS STEERING GEAR TRW Automotive Commercial Steering Systems TAS Steering Gear Service Manual T A S40 55 65 66 AND 85 SERIES ...

Page 2: ... read and understood before servicing If inspection or testing reveals evidence of abnormal wear or damage to the TAS steering gear or if you encounter circumstances not covered in the Manual Stop Consult the vehicle manufacturer s Service Manual and warranty Do not try to repair or service a TAS steering gear which has been damaged or includes any part that shows excessive wear unless the damaged...

Page 3: ... 3 Gear Disassembly Inspection and Assembly Disassembly Preparation 23 Disassembly Procedures 24 Inspection 31 Assembly Preparation 33 Assembly Procedures 33 Internal Component Repair Procedures Poppets 41 Valve Housing Worm Screw 43 Roller Bearing Standard Gears 50 Roller Bearing Step Bore Gears 51 Port Plugs Screws and Manual Bleed Screw Replacement 52 Final Adjustments 53 Section 4 Reinstallati...

Page 4: ...am 3 Section 1 General Information Introduction 5 Oil Flow Illustration 7 General Design 8 General Operation 9 Gear Speciﬁcation Numbers 10 Torque Chart 11 Exploded View 12 Exploded View Part Descriptions 13 Service Parts List 14 Parts Vary by Speciﬁcation 15 Service Kits General 16 Service Kits Gear Speciﬁc 16 ...

Page 5: ...GROUP 0603 V 003 0207 STEERING 7 DocID TRW TAS STEERING GEAR Page 1 5 Review Draft 4 ...

Page 6: ...INDING PROCESS THAT BETTER ALLOWS THE 3ERVICE ANUAL TO LAY mAT The three column format used in the Service Manual will also help make it easy for you to service a steering gear Column 1 illustrates the procedure with photographs column 2 gives a brief key as well as tools to be used for each procedure and column 3 explains in detail the procedure you should follow Pay special attention to the note...

Page 7: ...GROUP 0603 V 003 0207 STEERING 7 DocID TRW TAS STEERING GEAR Page 1 7 Review Draft 6 ...

Page 8: ...odified September 17 2012 10 18 am 7 Oil Flow Illustration Straightline Running No Steering Action Left Hand Turn Steering Wheel Input Counter Clockwise Rotation Supply Pressure Return Pressure Left Hand Lead Right Hand Lead Right Hand Turn Steering Wheel Input Clockwise Rotation ...

Page 9: ...is a dual steering system at the proper ﬂow rate and pressure Pressure Means Work Flow Means Speed The higher pressure a steering gear can withstand the more work it can perform The maximum operating pressure for TAS40 55 65 and 85 gears is 2 175 psi 150 bar The maximum operating pressure for a TAS66 gear is 2 320 psi 160 bar Maximum ﬂow rate for all TAS gears is 8 gal min 30 3 L min The TAS serie...

Page 10: ...ry of the steering gear causes the control valve to send high pressure ﬂuid to the correct cylinder cavity to resist the shock forces By absorbing the shock forces hydraulically the steering gear prevents objectionable kickback at the steering wheel Unloading Poppet Valves Most TAS gears are equipped with two unloading valves one at each end of the rack piston One valve or the other depending on t...

Page 11: ...ery TAS gear The number cast into the side of the housing IS NOT the part number Gear Identiﬁer Letters stenciled after the part number indicate the following A Q Step Bore Hsg T Z High Flow Poppets R Reman TRW Date Code An example date code would be 29097 this means the gear was built on the 290th day of 1997 Serial Newer gears include a serial number TAS65001A 29097S01B27 Gear Part Date Code Ser...

Page 12: ...top screw 37 38 58 lbf ft 52 79 N m Relief valve cap 5 25 35 lbf ft 34 48 N m Sector shaft adjusting screw jam nut 46 40 45 lbf ft 54 61 N m Side cover bolts TAS40 47 108 128 lbf ft 147 174 N m Side cover bolts TAS55 65 66 85 47 160 180 lbf ft 217 244 N m Valve hsg bolts TAS40 55 65 1 75 85 lbf ft 102 115 N m Valve hsg bolts TAS85 1 108 128 lbf ft 147 174 N m Torque Chart Special tools can be purc...

Page 13: ...p Bore w Hook Groove Step Bore w Retaining Ring Standard B B A A B A TAS85 Only TAS40 55 65 and 66 1 8 9 10 14 18 16 18 23 24 25 26 24 28 28 14 21 35 30 46 46 45A 44 47 43 42 42 45A 55 54 45B 45A 45A 29 32 33 34 34 33 12 5 6 7 36 37 41 38 39 36 2 3 4 11 13 15 17 19 20 23 35 23 27 31 49 53 36 53 49 43 48 36 48 50 43 49 51 48 52 43 27 40 23 24 25 26 24 29 54 56 13 22 ...

Page 14: ... 2 24 Poppet 2 25 Push Tube 26 Poppet Spring 27 Ring Rack Piston Teﬂon Seal 28 O ring Rack Piston Back up 29 Screws Torx 2 30 Strap Ball Return Guide 31 Cap Ball Return Guide 32 Seal Cap 33 Guide Halves Ball Return 34 Balls Steel 35 Piston Rack 36 Housing 37 Bolt Alt Fixed Stop 38 Bolt and Washer Fixed Stop 39 Jam Nut Poppet Sealing 40 Screw Poppet Adjusting 41 Shaft Sector 42 Gasket Side Cover 43...

Page 15: ...nd Sleeve Assy Poppet Available in Kit Available in Kit Available in Kit 24 Poppet 2 Available in Kit Available in Kit Available in Kit 25 Tube Push Available in Kit Available in Kit Available in Kit 26 Spring Poppet Available in Kit Available in Kit Available in Kit 27 Ring Rack Piston Teﬂon Seal Available in Kit Available in Kit Available in Kit 28 O ring Rack Piston Back up Available in Kit Ava...

Page 16: ...rts Vary by Speciﬁcation Item Description 5 Cap Relief Valve 7 Valve 2 Piece Relief 10 Housing Valve 19 Worm Valve Assembly Input Shaft 33 Guide Halves Ball Return 35 Piston Rack 36 Housing 41 Shaft Sector 44 Cover Assembly Side 47 Bolts Side Cover 6 or 8 49 Bearing Roller Contact TRW Technical Service for part numbers ...

Page 17: ...t Kit TAS000003 TAS85 Poppet Kit TAS850006 All TAS Poppet Adjusting Screw Nut Kit 021407X1 All TAS Relief Valve Cap and O ring 411061A1 All TAS Auxiliary Port Plug and O ring 415437A1 Gear Part Number Description Kit Part Number TAS65127A Complete Seal Kit TAS650014 TAS65129A TAS65155A TAS65156A TAS65172A TAS65094T Poppet Kit TAS000004 TAS65095T TAS65126T TAS65142T TAS65198T TAS65200T TAS65202T TA...

Page 18: ...RW TAS STEERING GEAR DocID STEERING GROUP0603 V 003 0207 File Last Modified September 17 2012 10 18 am Section 2 Installation NITIAL NSTALLATION NITIAL 0OPPET 3ETTING AINTENANCE 4IPS UTPUT 3HAFT REASE 0ACK IAGRAMS ...

Page 19: ...EW INSTALLED IN THE HOUSING OR A POPPET ADJUSTING SCREW INSTALLED SO THAT IT DUPLICATES THE lXED STOP SCREW LENGTH The axle stops and all steering linkage must be set according to vehicle manufacturer s speciﬁcations and the pitman arm must be correctly aligned on the sector shaft for poppets to be set correctly OLLOW THE SAME PROCEDURE WHILE TURNING THE STEERING WHEEL IN THE OTHER DIRECTION 4HE P...

Page 20: ...idents THAT COULD HAVE DAMAGED STEERING COMPONENTS Do not attempt to weld any broken steering component 2EPLACE THE COMPONENT WITH ORIGINAL EQUIPMENT ONLY Do not cold straighten hot straighten or bend any steering system component LWAYS clean off around the reservoir ﬁller cap BEFORE YOU REMOVE IT 0REVENT DIRT OR OTHER FOREIGN MATTER FROM ENTERING THE HYDRAULIC SYSTEM Investigate and correct any e...

Page 21: ...3EAL IGH 0RESSURE UTPUT 3EAL 7ASHER 2ETAINING 2ING IGH 0RESSURE UTPUT 3EAL UTPUT 3HAFT UTPUT 3HAFT UTPUT 3HAFT IRT AND 7ATER 3EALS EARING OUSING REASE ITTING IRT AND 7ATER 3EAL EARING OUSING REASE ITTING IRT AND 7ATER 3EAL EARING OUSING REASE ITTING 2ETAINING 2ING OOK ROOVE Output Shaft Grease Pack Diagrams Step Bore Gear Standard Gear ...

Page 22: ...ection and Assembly Disassembly Preparation 23 Disassembly Procedures 24 Inspection 31 Assembly Preparation 33 Assembly Procedures 33 Internal Component Repair Procedures Poppets 41 Valve Housing Worm Screw 43 Roller Bearing Standard Gears 50 Roller Bearing Step Bore Gears 51 Port Plugs Screws and Grease Fitting Replacement 52 Final Adjustments 53 ...

Page 23: ...GROUP 0603 V 003 0207 STEERING 7 DocID TRW TAS STEERING GEAR Page 1 23 Review Draft 22 ...

Page 24: ...with the automatic poppet adjustment feature to rotate more than 1 5 input shaft revolutions from straight ahead position when the output shaft is disconnected from the vehicle steering linkage this could disrupt the poppet setting achieved at initial installation The steering gear is in the straight ahead position when the timing marks on the end of the housing trunnion and sector shaft are align...

Page 25: ...ge or boss Input shaft should be horizontal side cover and valve housing are accessible for disassembly 2 Prepare for ﬂuid drainage and unplug hydraulic ports Do not clamp against body of housing If mounting boss or ﬂange is not accessible fabricate and attach a mounting plate to the housing mounting bosses 3 Rotate the input shaft until the timing mark on the end of the sector shaft is in line wi...

Page 26: ...errations and bolt groove of the sector shaft with one layer of masking tape The tape should not extend onto the sec tor shaft bearing diameter 7 Remove the sector shaft adjusting screw jam nut 46 8 Be prepared for more ﬂuid drainage and remove the six or eight bolts 47 from the side cover 44 Remove side cover Soft mallet 9 Be prepared for more ﬂuid drainage and remove the side cover and sector sh...

Page 27: ...g the seal 13 Clamp the side cover in a vise Place a standard 5 8 or 11 16 3 8 drive socket in the center of the side cover Pry the seal 43 out with a rolling head pry bar using the socket for support Discard the seal and remove the socket Screwdriver 3 8 Drive socket Rolling head pry bar Inspect adjusting screw and retainer 14 Inspect the sector shaft assembly for damaged adjusting screw threads ...

Page 28: ...bolts 17 Clean any paint or corrosion from the exposed area of the input shaft 18 Remove the four torx head valve housing bolts 1 Fine grade emery cloth Torx socket E 16 or E 18 Remove valve housing worm and rack subassembly 19 Be prepared for more ﬂuid drainage and remove the rack piston subassembly Place the assembly on a clean cloth For the TAS85 it may help to rotate the input shaft to move th...

Page 29: ...ball return guides are removed as damage to the ball guides will occur Remove ball return guide cap strap 21 Remove and discard the two special sealing screws 29 Remove the ball return cap 31 and seal 32 or strap 30 discard the seal 5 32 Allen wrench or T 30 Torx wrench Remove ball return guides 22 Make sure the rack piston is on a cloth so the steel balls that fall out won t roll very far Remove ...

Page 30: ...recommends the poppet seat and sleeve assemblies 23 not be removed unless replacement of poppet components is required Inspect valve housing and worm screw 27 Inspect valve housing worm screw subassembly for heat damage or bearing roughness If these conditions are present or if there wasexcessiveinternalleakage orifpreloadadjustmentisrequired go to Valve Housing Worm Screw procedures on page 43 If...

Page 31: ... damaged go to Replace Housing Ports Plugs Screws Fittings on page 52 If not proceed to the Inspection Section on page 31 Remove pres sure seal and spacer washer if equipped 30 Standard gears Insert a screwdriver into the housing bearing bore from the trunnion end and carefully push the seal 43 and spacer washer 50 out of the other end of the bearing bore without damaging the sealing area of the b...

Page 32: ... sector shaft 41 and set of balls 34 2 Inspect the rack piston ball track grooves for brinelling or spalling If either condition exists replace the input shaft valve worm assembly valve housing rack piston subassembly and balls Any of the following conditions present in the steering gear indicates impact damage Condition Area Brinelling Ball track grooves of rack piston Ball track grooves of worm ...

Page 33: ...ling areas and sector teeth contact surfaces for brinelling spalling or cracks Run your ﬁngernail edge across these areas to detect steps Remove masking tape from the shaft and inspect for twisted or otherwise damaged serrations If any of these conditions exist replace the sector shaft A service sector shaft will come assembled with the adjusting screw and retainer Inspect input shaft valve worm a...

Page 34: ...irements Replace all seals seal rings and gaskets with new ones each time you disassemble the gear TRW Commercial Steering Systems has complete seal kits available These kits can be purchased through most OEM parts distributors Contact your local dealer for availability Assembly Procedures Ratchet Screwdriver Sockets Torx sockets Vise Grease Exxon Polyrex EP2 P N 045422 Seal kit TAS400004 TAS55000...

Page 35: ...bearing and seal tool short end so the lip with the garter spring is toward the shoulder of the tool Working from the side cover side of the housing pilot the seal tool into the washer and bearing and press with a force of 100 800 lb 445 3 560 N until the seal is seated ﬁrmly Step Bore gears with Retaining Ring only Install the inside retaining ring 48 from the side cover opening Seat the ring ﬁrm...

Page 36: ...TAS66 32 TAS85 34 when using the service ball kit Position rack pis ton in housing Insert worm and valve assembly into rack piston All Thread TAS40 66 1 2 20 x 7 TAS85 9 16 14 x 7 9 Apply clean oil to housing cylinder bore Place the rack piston in the housing piston bore with ball return guide holes facing up 10 Insert the worm screw into the rack piston close to maximum depth without the valve ho...

Page 37: ...g balls The correct number of balls are required for proper gear operation Count the balls and insert each carefully as in step 11 TAS40 TAS55 TAS65 TAS66 TAS85 Original 29 30 31 32 32 34 Service 29 31 32 32 34 TAS55 gears built prior to 33889 were equipped with 30 balls Remove any ﬂuid present in the two screw holes Fluid in these holes could cause improper clamp load when torquing the cap or str...

Page 38: ...nd of rack piston enters the housing ﬁrst the seal ring will be destroyed when the rack is removed The poppet seat and sleeve assemblies 23 must not bottom against the internal poppet stops in the steering gear until the gear is installed on the vehicle and the poppet adjustment procedures are performed Rotate input shaft to check for proper installation of balls 15 Rotate the input shaft from one...

Page 39: ...over Apply a generous amount of Exxon Polyrex EP2 to the short bearing area of the sector shaft 18 If the gear is equipped with a relief valve assemble a new o ring 6 on relief valve cap 5 Assemble the small end of ta pered spring onto the pin on the relief valve cartridge and insert the assembly 7 large end of tapered spring end ﬁrst into the relief valve cap cavity Turn the relief valve cap as a...

Page 40: ...ack piston 26 There are four teeth on the rack piston Rotate input shaft to position the rack piston so the space between the second and third tooth is in the center of the sector shaft opening This will center the rack piston for assembly of sector shaft If the rack piston is not centered when sector shaft is installed gear travel will be severely limited in one direction This could result in an ...

Page 41: ...ll in positions 3 and 6 ﬁrst by hand Install the remaining side cover bolts 47 into the side cover and torque them in the sequence shown If bolts must be replaced use bolts of the same design type and length as those you removed Do not use a substitute Lubricate side cover bolts and torque TAS40 bolts to 118 ft lb 160 N m TAS55 65 66 and 85 bolts to 170 ft lb 230 N m 13 16 Socket TAS40 15 16 Socke...

Page 42: ...23 are retained by Loctite applied to the threads which makes the assemblies difﬁcult to remove Soft jawed vise J36452 A 2 lb Sledge 3 With a ratchet applied to the tool turn one adjuster seat and sleeve assembly out of the rack piston If the ratchet does not turn easily strike the adjuster removal tool again with a hammer If the engaging tangs won t stay in place while torquing it might be necess...

Page 43: ...w seat and sleeve assemblies 23 Allow to dry for ten minutes then carefully apply Loctite RC680 to same threads Apply Locquic T primer and Loctite RC680 Install one poppet seat and sleeve assembly 8 Locquic T primer Loctite RC680 Soft jawed vise Wear eye protection while assembling poppets as spring loaded poppets could eject and cause eye injury Do not allow Loctite or Locquic to get on the adjus...

Page 44: ...ts 12 point sockets Place valve hous ing and valve assembly in vise Unstake adjuster locknut 1 With worm vertical place the valve housing input shaft valve worm assembly in a vise 2 Unstake the valve housing 10 where it was upset into the adjuster locknut 22 slot Also unstake adjuster nut from adjuster 21 Roll pin punch Hammer Remove bearing adjuster locknut Remove bearing adjuster 3 Turn bearing ...

Page 45: ...ng Remove input shaft Remove seal ring and o ring Small probe or pick Remove thick washer and bearing 8 Remove thick thrust washer 17 and thrust bearing 18 from valve housing Input shaft valve worm assembly must not be disassembled further The components were a select ﬁt at assembly and are available only as part of this subassembly If disas sembled further the subassembly must be replaced 9 Remov...

Page 46: ...o detect steps Inspect for discoloration from excess heat Inspect input shaft ball track grooves for brinelling or spalling If any of these conditions exist you must replace the input shaft valve worm assembly valve housing and balls Also replace rack piston if brinelling or spalling is found 13 Inspect the thrust bearing 18 rollers for any deterioration Inspect thrust washers 17 20 for brinelling...

Page 47: ...nput shaft and against the thick thrust washer 17 to hold the bearing components in place Be sure not to butterﬂy this seal ring during installation This will deform the part and cause it to be damaged during the installation process 16 First install o ring 16 into valve housing groove Then insert seal ring 15 into groove as shown being careful not to but terﬂy the seal towards the inner diameter ...

Page 48: ...that would impede the locknut from turning freely on adjuster or the adjuster turning freely in valve housing 23 Lightly oil and assemble bearing adjuster 21 over worm and into valve housing Torque adjuster to 13 ft lb 18 N m indicated torque using a torque wrench inserted in adjuster tool J37070 This will seat the components Back off adjuster 1 4 to 1 2 of a turn Assemble bearing adjuster J37070 ...

Page 49: ...staking torque required to rotate input shaft must be between 5 10 in lb 5 1 0 N m greater than the torque noted in step 25 Torque value must not exceed 22 in lb 2 5 N m Unstake and readjust if necessary Center punch Hammer 13 16 Socket Ft lb Torque wrench The bearing adjuster locknut and valve housing ﬂange should be ﬂush If not the seal ring 14 or o ring 13 may be out of position which will resu...

Page 50: ...p the seal installer tool until the tool shoulder is squarely against the valve housing This will correctly position the seal in the housing bore just beyond the retaining ring groove Remove any seal material that may have sheared off and is in seal bore and retaining ring groove J37073 Hammer 31 Insert new retaining ring 3 into its groove in valve housing 10 Insert retaining ring 32 Pack the end ...

Page 51: ...t of trunnion end of the bearing bore Discard bearing Screwdriver J37705 J37071 or J37071 A J38779 Press Press in housing roller bearing Install retaining ring 4 Standard Gears only Press the roller bearing into the housing from the trunnion end of bearing bore until it is seated against the retaining ring DO NOT PUSH IT IN FARTHER Be sure the housing is square with the press base and the bearing ...

Page 52: ...ess it out of the side cover end of the bearing bore Discard bearing J37071 A Press Press in housing roller bearing 2 Press the roller bearing into the housing from the side cover end of the bearing bore until it is seated against the step bore Be sure the housing is square with the press base and the bearing is not cocked Use the bearing installation end of the tool short end If the bearing remov...

Page 53: ...its position to the nut and screw removed Torque sealing nut to 35 ft lb 47 N m 5 8 Socket or E 14 Torx socket Ft lb Torque wrench 7 32 Allen wrench 3 4 or 5 8 closed end wrench Ft lb Torque wrench Replace automatic bleed screw and aux port plugs Replace manual bleed screw 3 If damaged remove and replace automatic bleed plug Torque to 48 ft lb 65 N m If damaged remove and replace permanent auxilia...

Page 54: ...less than one input shaft rotation in one direction from steering gear center position if new or reset poppet adjuster seat and sleeve assemblies are assembled in the unit Worm preload adjustment was set when input shaft valve and worm were assembled into valve housing 3 4 and 11 16 Socket or box end wrench 2 With adjusting screw jam nut 46 loose turn sector shaft adjusting screw clockwise to prov...

Page 55: ...oted in step 3 by 7 in lb 8 N m Tighten jam nut 46 ﬁrmly against side cover while holding the adjusting screw in position Finally torque the jam nut to 43 ft lb 58 N m and check input shaft valve worm assembly torque again Readjust if input shaft torque exceeds 40 in lb 4 5 N m Adjust adjusting screw 3 4 Socket 11 16 Socket Ft lb Torque wrench In lb Torque wrench ...

Page 56: ...Page 1 56 TRW TAS STEERING GEAR DocID STEERING GROUP0603 V 003 0207 File Last Modified September 17 2012 10 18 am Section 4 Reinstallation 2EINSTALLATION 0ROCEDURE 0OPPET 2ESETTING 0ROCEDURE ...

Page 57: ...GROUP 0603 V 003 0207 STEERING 7 DocID TRW TAS STEERING GEAR Page 1 57 Review Draft ...

Page 58: ...UR ERgS RECOMMENDATION s ONNECT DRAG LINK TO PITMAN ARM Poppet Resetting Procedure IF 0OPPETS REMAIN UNCHANGED FROM WHEN GEAR WAS REMOVED FROM VEHICLE AND GEAR IS BEING INSTALLED ON THE SAME VEHICLE WITH NO CHANGE IN AXLE STOPS OR LINKAGE IF 0OPPETS WERE REPLACED WITH NEW COMPONENTS OR RESET DURING GEAR DISASSEMBLY AND ARE READY FOR AUTOMATIC POSITIONING IF 0OPPETS MAY HAVE BEEN MOVED DURING DISAS...

Page 59: ...ACCIDENTS OR OTHER SIMILAR EVENTS WHICH EXCEED THE HYDRAULIC CAPACITY OF THE STEERING GEAR Internal Leakage LUID LEAKING INSIDE THE GEAR Lash REE PLAY Manual Bleed Systems EARS ARE MOUNTED IN SUCH A WAY THAT AN AIR POCKET COULD FORM IN ONE END OF THE STEER ING GEAR 4HE BLEED SCREW IS POSITIONED SO TRAPPED AIR CAN BE FORCED OUT WHEN LOOSENED OLLOW PROCEDURE ON PAGE OSHA CCUPATIONAL 3AFETY AND EALTH...

Page 60: ...STEERING GROUP0603 V 003 0207 File Last Modified September 17 2012 10 18 am TRW Automotive Commercial Steering Systems 800 Heath Street Lafayette IN 47904 Tel 765 423 5377 Fax 765 429 1868 www trucksteering com TRW Inc 2007 TRW1108 Rev 2 07 ...

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