Reliant Kitten Estate, Руководство по ремонту

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Page 27
Operation 9 Steering rack pinion preload adjustment
1. Carefully mount the steering rack into a vice so that the
pinion cover plate is uppermost.
2. Remove the two bolts securing the pinion bearing preload
cover to the casing.
3. Lift off the cover plate, shim pack and gasket.
4. Refit the pinion cover plate and loosely assemble the
retaining bolts. Do not fit the shim pack and gasket.
5. Tighten the cover plate evenly until the cover plate is just
contacting the pinion bearing.
6. Using feeler gauges, measure the gap between the cover
plate and the steering gear casing. Note this dimension. (to confirm
that the cover plate has been pulled down evenly, take feeler gauge
measurements adjacent to each bolt).
7. assemble a shim pack (including a gasket which must be
next to the cover plate when assembled) which is 0.0. to 0.10 mm
(0.002 to 0.004 in) smaller than the gap measured with the feeler
gauges. There must be this amount of preload on the pinion bearings
when correctly shimmed. Details of available shim thicknesses and
part numbers are given at the end of this section.
8. Remove the pinion cover plate, assemble the shim pack and
refit the cover plate. Fit the securing bolts using sealer on the threads
and tighten to a torque of 0.85 to 1.1 kg/cm (6 to 8 lb/ft).
Checking the above measurements
Determine the torque required to start the pinion rotating using a
rotary torque gauge. This should be 5.77 to 9.21 kg/cm (5 to 8 lb/in). If
the actual torque is not within the prescribed limits, the adjustment is
incorrect (re-check the shimming) or there is a malfunction within the
assembly (tight bearings/bushes, damaged gear teeth, lack of
lubricant etc) which is increasing the friction in the unit.
Operation 10 Steering gear overhaul, including inner ball joint
removal and gaiter removal
To dismantle ( Figure 3 )
1. Remove the steering rack assembly as described in
operation 7.
2. Remove the ball joint and lock nut from one track rod
noting the number of turns to remove them.
3. Slacken the clips securing the gaiter to the track rod and the
steering rack casing
. Note:
In production, the inner end of the gaiter
may be secured with soft iron wire, not a screw clip. The soft iron wire
must never be re-used. a screw clip should be used on re-assembly.
4. Pull off the gaiter, keeping the steering rack body below the
level of the gaiter to avoid oil spillage.
5. Drain the oil into a suitable waste container. To do this, the
rack must be held vertically and traversed from lock to lock several
times until all the oil is expelled.
6. Remove the remaining track rod ball joint and locknut,
again noting the number of turns necessary to unscrew these.
7. Slacken the clips securing the remaining gaiter to the
assembly and remove the gaiter.
Track rod inner ball joint removal
To dismantle
( Figure 3 )
1. Drill out the retaining pin that locks the locknut and the ball
housing in position. Take great care not to drill too deeply.
2. Screw the ball housing off the end of the rack shaft.
3. Remove the spring and ball seat from the recess in the end
of the rack and discard.
4.
Examine the ball housing and the ball formed on the end of
the track rod and discard if wear or damage is evident.
To overhaul
( Figure 3 )
1.
Remove the pinion cover plate complete with shim pack
and gasket.
2. Withdraw the pinion and one of the pinion bearing
assemblies.
3. Withdraw the rack from inside the casing. It is better to
withdraw the rack from the pinion end of the unit. This avoids passing
the rack teeth through the bearing/bush in the opposite end of the
casing.
4. Remove the remaining pinion bearing assembly from the
casing.
5.
Inspect all parts for wear or damage. If the rack or the
pinion teeth are damaged, a complete new steering gear must be
fitted. Examine the rack support bush and replace if necessary.
6. Remove the pinion oil seal from the casing.
To re-assemble
1.
Fit a new pinion oil seal in to the casing.
2. Fit a new pinion bearing assembly and thrust washer to the
recess in the casing. Use grease to retain the bearings and thrust
washer.
3. Assemble the rack in to the casing and locate it so the teeth
are adjacent to the pinion location. Position the rack shaft in the
centre of its travel (i.e. the straight ahead position) by measuring the
rack protrusion at each end.
4. Assemble the other pinion bearing and thrust washer to the
pinion and fit the pinion in to the casing.
5. Replace the shim pack, gasket and cover plate securing with
two bolts, using sealer on the bolt threads. Tighten the bolts to a
torque of 0.85 to 1.1 kg/m (6 to 8 lb/ft). Check damper and preload
adjustments. See operations 8 and 9.
6. Fit a new spring and ball seat into the recess in the end of
the rack shaft.
7. Smear SAE 90 EP oil on to the ball, ball housing and seat.
8. Assemble the ball housing to the track rod. Screw the ball
housing on to the rack shaft until the track rod articulation becomes
stiff.
9. Fit a piece of wire to a pull spring balance and hook the wire
round the threaded end of the track rod approximately 13 mm (½ in)
from the end.
10. With the track rod in mid position - parallel to the rack
shaft, adjust the position of the ball housing on the rack until the
effort required to move the track rod, measured on the balance scale
is 2.8kg (5lbs).
11. Tighten the locknut against the ball housing.
12.
Drill a 3.18 mm (1/8") hole 9.5 mm (3/8") deep on the line
of contact of the locknut and the ball housing. Half the drilled hole
will be in the locknut and half in the ball housing.
Note: A new hole must be drilled even if the halves of the previous
hole align.
13. Insert a new retaining pin and tap it in to position. Peen the
end of the pin to secure it.
14. Repeat the sequence 6 to 13 to re-assemble the opposite
track rod end.
Replacing the steering gear gaiters ( Figure 3 )
1. Slide the new gaiter along the track rod in to position on
the rack.
2. With the rack centralised, fit the inner clip to the gaiter and
rack housing.
3. Position the outer end of the gaiter on to the track rod so it
is capable of accommodating the full movement of the rack from lock
to lock.