BENDIX BW1600 User's Manual
Contents
1. 1111 1 1 25 ADJUSTMENT 5 cez O l aude Aa 26 e Piston to Output Shaft Gear Backlash 26 Stroke Limiting Stem ea 27 ON VEHICLE POWER STEERING TESTS 27 PO MIM ANY wa OO O e Deba 28 e Pressure Relief Valve aa 28 e Internal Leakage uu aa 28 TECHNICAL DATA auuuaaaeuu222 29 ASSEMBLY TORQUE CHART 29 TROUBLESHOOTING 30 PISTON OVER OUTPUT SHAFT MOUNTING LEFT HAND THREAD SPINDLE PISTON UNDER OUTPUT SHAFT MOUNTING RIGHT HAND THREAD SPINDLE STEERING WHEEL INPUT SPINDLE SHAFT ASSEMBLY INPUT STEERING SHAFT SHAFT 4 WHEEL ASSEMBLY A gt p A a N PISTON VEHICLE RIGHT TURN VEHICLE LEFT TURN FIGURE 1 MECHANICAL OPERATION OPERATION GENERAL Both steering gears are composed of mechanical and hydraulic power assist components Actual steering is accomplished mechanically Effort applied at the vehicle s steering wheel results in mechanical movement within the steering gear which causes the vehicle to change its direction of travel The hydraulic power assist components function solely to reduce the mechanical effort required to turn the vehicle s steering wheel Loss of hydraulic power will in no way prevent the vehicle from being maneuvered2. are centered in the side cover opening in the housing Figure 53 OUTPUT SHAFT 8 SIDE COVER REASSEMBLY 28 29 30 Install the shim washer 34 over the adjusting screw 33 and secure both in the output shaft 25 using the retaining ring 30 The maximum end play permitted for these parts is 002 however binding should to occur If end play is excessive it may be necessary to install a different shim washer 34 The shim washer is available in eight different thicknesses to provide the proper end play Figure 39 Install the seal 29 in the side cover 31 with its pressure side toward the outer race of the side cover roller bearing 26 Note This seal prevents fluid leakage around the output shaft Do not distort this flexible seal more than is necessary for installation Install the split nylon backup ring 28 which is a separate part of the seal by winding it into the groove formed by side cover and the backside of the seal 29 Make certain the split ring is completely seated and that the diagonal split surfaces of the ring mate properly Install the O ring 27 in its groove in the side cover 31 Figure 29 amp 50 Note The two piece seal seal and nylon split ring may not be used in all steering gears A one piece seal is sometimes used instead Install the seventeen rollers of the bearing 26 in the outer race contained in the side cover 31 Use a heavy coating of lithium grease to hold the roll
3. on the valve body 7 Figure crio moga 38 tem Fi 7 Install the ball cage 6 over the input shaft end of the spindle assembly 3 Using a general purpose lithium base grease to hold them in place install the seventeen balls 9 in the ball cage Figure 43 8 Install the outer ball bearing race half 8 over the input shaft end of the spindle assembly 3 and insert the spindle assembly through Bendix tool 297676 Insert the spindle and tool into the valve body 3 until tool completely exits the other side and the seventeen balls 9 ofthe bearing assembly are resting against the outer race 8 in the valve body Figure 44 9 Position the pressure side of the seal 5 in the bore of the non pressure side of the valve nut 1 Carefully drive the seal into the bore until the retaining ring groove within the bore is visible Install the retaining ring 50 making certain it is completely seated in the groove After installing the retaining ring gently tap the seal 5 from the opposite side until it rests squarely against the snap ring 50 Note The seal 5 can be driven into the valve body bore using a piece of round brass stock with a diameter of 1 55 inches Figure 45 10 Apply Loctite 932 or 567 to the tread of the valve nut 1 Note Due to the proximity of the spindle ball bearing use extreme care in applying the Loctite to the valve nut threads and allow adequate cure time Making certain not to damage the seal 5 i
4. 73 pound feet using a 26mm socket 2 To prevent the operation of the steering limiting valves if the gear is so equipped place a steel spacer block between the axle stop and the adjusting screw The block should be a minimum of one inch thick and long enough to be inserted without danger of pinching fingers Keep fingers clear of pinch points and be sure block is square to points of contact WARNING Failure to follow these instructions can result in serious injury or damage to the equipment 3 Run the engine at idle Turn the steering wheel until the axle stop contacts the spacer block Apply a sufficient torque to the steering wheel to ensure the power steering gear control valve is completely open in the direction of the turn Observe the following A Gauge pressure should read the same as the power steering pump relief pressure B With system pressure at pump relief read the flow meter If a flow greater than 1 6 quarts per minute 0 40 GPM is noted internal leakage is excessive and the steering gear requires repair CAUTION When running this test do not hold the torque on the steering wheel for more than 5 seconds beyond the time the pressure relief setting has been reached It may damage the unit or cause the temperature of the oil to raise beyond 200 4 Repeat Step 3 turning the steering wheel in the opposite direction 5 With the engine off remove the pressure relief test plug assembly 106773 Reinst
5. C 500N power steering gear the steering limiting stem in the valve body 7 is identical to the one in the housing 19 20 21 and can be removed or adjusted externally without removal of the valve body 7 from the housing 22 See the inset in figure 4 and 11 Remove the steering limiting stem protective plug 21 from the valve body 7 and using a screw driver remove the steering limiting stem 19 and O ring 20 from the valve body 7 Separate and discard the O ring 20 from the stem 19 A A Body e 20 Remove the input shaft dust seal 4 from the valve nut ham 7 XA 1 Figure 32 With a drift punch unblock the safety point between the valve nut 1 and valve body 7 Using Spanner wrench 106234 loosen and remove the valve nut 1 from the valve body 7 Figures 33 8 34 22 Grasp the input shaft end of the spindle assembly 3 and lift the spindle assembly 3 ball cage 6 17 balls 9 and one half of the outer race 8 out of the valve body Figure 35 2 FIGURE 36 SPINDLE ASSEMBLY BALL BEARING FIGURE 34 VALVE NUT amp VALVE BODY 17 23 Separate the outer race 8 ball cage 6 and 17 balls OUTPUT SHAFT DISASSEMBLY 9 from the spindle assembly 3 Figure 36 27 Remove the retaining ring 30 the adjuster screw spacer 24 Do not remove the other half of the ball bearing outer 34 and the adjuster screw 33 from the output shaft race 8 in the valve body 25 Figu
6. The following instructions are for the externally adjustable steering limiting stem 1 Adjust the axle stops using the vehicle manufacturer s specifications Install a pressure gauge or gauge and flow meter combination in the pressure supply line between the power steering pump and steering gear Figure 56 Note If a shut off valve is part of the gauge or gauge flow meter make certain the valve is open Caution During the procedure that follows use extreme care not to operate the power steering pump at its relief valve pressure for more than a few seconds at a time Extended operation at pump relief pressure will result in excessive heat and subsequent damage to the system A thermometer installed in the pump reservoir will allow temperature checks to assure the maximum pump and gear temperatures are not exceeded Start the engine and gently turn the steering wheel to the axle stop in both directions while observing the OIL RESERVOIR POWER STEERING PUMP VALVE FLOW METER SHUTOFF FIGURE 56 FLOW METER 8 PRESSURE GAUGE INSTALLATION pressure gauge and the direction of the wheel cut right or left Read the possible reactions described below and take the appropriate action A Gauge pressure drops noticeably just prior to the steering mechanism contacting the axle stop in one turning direction only In the opposite steering direction gauge pressure increases to pump or gear relief pressure as the steering mec
7. parking brake and place the transmission gear selector in neutral 4 Perform the power steering pump performance tests specified by the vehicle manufacturer Make certain that system back pressure maximum and minimum pump flow and pump relief pressure all meet specified requirements TESTING THE POWER STEERING GEAR PRESSURE RELIEF VALVE Note Disregard this test if the steering gear is not equipped with an optional pressure relief valve 1 To prevent the operation of the steering limiting valves if the gear is so equipped place a steel spacer block between the axle stop and the adjusting screw The block should be a minimum of one inch thick and long enough to be inserted without danger of pinching fingers Keep fingers clear of pinch points and be sure block is square to points of contact WARNING Failure to follow these instructions can result in serious injury or damage to the equipment 2 Check fluid temperature in the reservoir Thermometer reading should be approximately 130 at start of the test and the shut off valve on the flow meter must be totally open Note Refer to Preliminary Instructions section of the service data 3 Turn the steering wheel until the axle stop contacts the spacer block Apply sufficient torque to the steering wheel to ensure the power steering gear control valve is completely open in the direction of the turn At this time the pressure gauge will read the gear pressure relief setting
8. return line Figures 5 amp 6 STEERING LIMITING VALVE OPERATION In steering gears equipped with steering limiting valve power assisted movement of the piston within its bore is limited by poppet valves installed in both piston faces As the piston approaches its extreme travel in either direction a stem unseats the steering limiting poppet valve Some hydraulic power assist is removed as pressurized oil passes around the poppet valve to the other side of the piston and to the return line Continued movement of the piston will result in removal of increasing amounts of power assist and cause increased steering effort Steering limiting reduces the maximum power assist that can be transmitted to the axle LIMITING STEM PRESSURIZED SIDE DURING RIGHT TURN POPPET VALVES STEERING LIMITING steering linkages and components Figure 7 When this feature is incorporated in the C 300N only one of the two steering limiting stems is externally adjustable Both steering limiting stems in the C 500N are externally adjustable Figure 4 PRESSURE RELIEF VALVE OPERATION The pressure relief valve is an option Located in the valve body the pressure relief valve limits hydraulic pressure within the power steering gear to a preset maximum While the setting of the pressure relief valve may be adjusted to various levels depending upon part number and application it is always set to a pressure lower than the relief valve on the power steer
9. single component CLEANING AND INSPECTION CLEANING Wash all parts individually in clean solvent and dry thoroughly All non metallic parts should be discarded and replaced with new INSPECTION Parts found broken cracked distorted excessively pitted or scored must be replaced Cause for the replacement of any part should be investigated and corrected to prevent reoccurrence Visually inspect all parts carefully paying particular attention to 1 Bearings and bearing surfaces should not exhibit brinelling pitting spalling or cracks If upon inspection it is determined that the outer races of the roller bearings 26 contained in the housing 22 or the side cover 31 are not serviceable the entire housing or side cover must be replaced If the outer ball bearing race 8 remaining in the valve body 7 is not serviceable the entire valve body must be replaced Inspect the bearing surfaces of both the inputs 2 Gear teeth in the output shaft and piston may show signs of polishing and slight wear however pitting spalling and cracks should not be present 3 Output and input shaft splines 4 Check the ball rolling surfaces on the exterior of spindle and interior of piston for cracks pitting spalling and brinelling 5 Exterior of piston and interior of housing bore Note Minor scuffing of the piston exterior and housing bore can be considered normal If deep scoring is detected the affected parts should be rep
10. steps Incorrect assembly of this group may result in one or more balls failing inside the piston or coming out at the top and lodging in the housing Install the remaining seven balls 9 in the recirculating tube halves 35 and use lithium base grease to retain them in the tube Seat the assembled tube halves 35 containing the seven balls in the recirculating tube holes in the piston 23 Lightly grease the sealing surfaces of the tube cover 24 and install it in the piston making certain the slot in the underside of the cover mates with the recirculating tube in the piston Install the retaining ring 36 in the piston to secure the tube cover making certain it is completely seated in its groove After assembly check for smooth rotation of the spindle assembly in both directions Figure 21 22 24 6 48 NEW STYLE BALL TUBE 21 Insert the valve body and spindle assembly 3 all the way into the piston 23 making certain that the steering limiting stem 13 is not damaged and that it mates with the valve seat 17 in the piston 23 Pull the valve and spindle assembly 3 out of the piston 23 about two inches MAKING CERTAIN THE STEERING LIMITING STEM 13 REMAINS ALIGNED WITH VALVE BALL AND SEAT 17 Make certain the spindle threads will not interfere with the ball pick up tabs on the ball tube 35 when it is inserted into the tube holes in the piston 23 The spindle s threads are visible at the bottom of the tube holes in
11. the direction clockwise or counterclockwise that threads the spindle assembly OUT OF THE PISTON FIGURE 21 TUBE COVER DISASSEMBLY ASSEMBLY 14 FIGURE 24 BALL TUBE COVER O RING Nom 33 FIGURE 25 REMOVING INSTALLING SPINDLE Separate the valve body and spindle from the piston Check the inside of the piston for any stray balls 9 that may not have been removed in the operation above A total of 26 balls 7 from the ball tube and 19 from the piston should be accounted for Figure 25 12 Remove the sealing ring 14 and O ring 15 below it from the groove in the piston 23 Figure 26 13 Ifthe steering gear is not equipped with a steering limiting valve feature disregard steps 13 15 Remove either of the steering limiting valve seats 17 and sealing washer 18 from the piston Either a Phillips or straight blade screwdriver will be required depending upon which of the two styles of body is in use Figure 27 Ding Mem 15 Sealing Ring ham Ta FIGURE 26 REMOVING INSTALLING PISTON SEALING RING amp O RING SEALING WASHER ITEM 18 SPRING ITEM 16 SEALING WASHER ITEM 18 BALL ITEM 9 VALVE SEAT ITEM 17 x N ser 5 ITEM 17 PISTON ITEM 23 FIGURE 27 REMOVING INSTALLING STEERING LIMITING COMPONENTS Note Care must be taken during this operation since damage to the screwdriver slot will make removal difficult 14 Remove one of the two balls 9 the spring
12. 16 then the remaining ball 9 Referring to the previous step remove the remaining steering limiting valve seat 17 and its sealing washer 18 from the other end of the piston Figure 27 HOUSING 8 SIDE COVER DISASSEMBLY 15 Remove the steering limiting stem protective plug 21 from the housing Using a screwdriver remove the stroke limiting valve stem 19 from the housing and separate the O ring 20 from the stem Figure 28 16 Remove the O ring 27 from the side cover 31 Remove the seal 29 and its split nylon backup ring 28 from FIGURE 28 REMOVING INSTALLING STEERING LIMITING STEM 15 W FIGURE O RING Gust Fem iiam 38 p r 1 AI j Na FIGURE 30 REMOVING INSTALLING HOUSING OUTPUT SHAFT DUST SEAL 17 18 16 the side cover bore The nylon split ring comes out separately but is part of the seal 29 Figure 29 Note The two piece seal seal and nylon split ring may not be used in all steering gears A one piece seal is sometimes used instead CAUTION Do not remove the outer race of the roller bearing from the side cover Carefully pry out and remove the dust seal 38 from the housing 22 Figure 30 Reaching through the side cover opening of the housing 22 remove the output shaft seal 29 and its split nylon backup ring 28 which comes out separately but is part of the seal 29 Figure 31 Note The two piece seal Backup Rag Side Cover Opening fa Haai
13. Cover Adjusting Screw Lock Nut Item 32 Valve Body Valve Nut Item 1 Steering Limiting Valve Seat Item 17 Pressure Relief Valve Seat Item 48 Pressure Relief Valve Plug Item 42 Drain Plug Item 54 221 257 Pound Feet C 300N 81 88 Pound Feet 81 88 Pound Feet 74 78 Pound Feet C 500N 92 99 Pound Feet 92 99 Pound Feet 74 78 Pound Feet 221 257 Pound Feet 8 11 Pound Feet 15 18 Pound Feet 66 73 Pound Feet 37 47 Pound Feet 8 11 Pound Feet 15 18 Pound Feet 66 73 Pound Feet 37 47 Pound Feet SYMPTOM Power steering does not operate or manual steering effort is excessive Steering effort greater in one direction than in the other Power steering tends to turn by itself when engine is running Excessive free play in steering wheel Power steering operates normally but is intermittently hard 6 Oil leaks N a TROUBLESHOOTING CHART CAUSE Low oil level Air in system The pressure pump does not supply an adequate flow or pressure Obstruction in the oil reservoir outlet or inlet Internal leakage in power steering gear piston Mechanical faults in vehicle steering members not belonging to power steering gear Low pressure in front tires Relief valve opens at low pressure Low or no pressure applied to one side of power steering piston Faulty operation of the rotary valve Mechanical fault in vehicle steering members not belonging to power steering units Faulty r
14. F TORSION BAR OIL IN OIL OUT SUPPLY LEFT TURN OUTER VALVE SPINDLE ASSEMBLY ELEMENT GROOVE FIGURE 5 SPINDLE ASSEMBLY WITH ROTARY VALVE COMPONENTS ROTARY CONTROL VALVE OPERATION The rotary control valve is an open center type which allows a continuous flow of oil through the longitudinal grooves in the input shaft and bore of the ball screw when held in the neutral position by the torsion bar When steering effort is applied the input shaft and ball screw tend to turn in unison however the spring action of the torsion oiL OILIN RETURNING FROM RIGHT TURN SIDE OF POWER PISTON OIL OUT LEFT TURN LEFT TURN FIGURE 8 ROTARY VALVE OPERATION 6 OIL OUT LEFT TURN NEUTRAL bar results in the input shaft rotating slightly in advance of the ball screw The six pairs of grooves that form the rotary control valve are displaced from their neutral flow position As steering effort increases so does the amount of displacement Depending on the direction steered the groove displacement of the input shaft directs hydraulic oil through the appropriate drilled passages in the ball screw to one side or the other of the piston Hydraulic pressure acting INPUT SHAFT INNER VALVE ELEMENT BALLSCREW OUTER VALVE ELEMENT OIL RETURNING FROM LEFT TURN SIDE OF POWER PISTON RIGHT TURN EXTREME LEFT TURN POSITION POPPET VALVE OPEN Q e OUTPUT SHAFT RETURN SIDE OF PISTON BALL INPU
15. Figure 49 Lightly grease the sealing surfaces of the tube cover 24 and install it in the piston making certain the slot in the underside of the cover mates with the recirculating tube in the piston Install the retaining ring 36 in the piston to secure the tube cover making certain it is completely seated in its groove After assembly check for smooth rotation of the spindle assembly in both directions Figures 21 22 24 HOUSING REASSEMBLY 23 24 25 Reaching through the side cover opening ofthe housing 22 install the seal 29 with its pressure side toward the INTERIOR of the housing Note Do not distort this flexible seal any more than is necessary for installation Install the split nylon backup ring 28 which is a separate part of the seal 29 by winding it into the groove formed by the backside non pressure side of the seal and the housing Make certain the split ring is completely seated and that the diagonal split surfaces of the ring mate properly Note This seal prevents pressurized fluid from leaking out of the housing around the output shaft Figures 50 amp 51 Note The two piece seal seal and nylon split ring may not be used in all steering gears A one piece seal is sometimes used instead Install the dust seal 38 in the housing 22 with its sealing lip toward the OUTSIDE of the housing Note This seal is intended to prevent water and dirt from entering the housing Figure 30 Instal
16. If the pressure reading is within plus or minus 60 p s i of the pressure specified in the vehicle manual the pressure relief valve is operating properly If the pressure is outside of this range the pressure relief valve should be adjusted or repaired as necessary CAUTION When running this test do not hold the torque on the steering wheel for more than 5 seconds beyond the time the pressure relief setting has been 28 reached It may damage the unit or cause the temperature of the oil to rise beyond 200 TESTING THE POWER STEERING GEAR FOR INTERNAL LEAKAGE General Note Excessive internal leakage past seals and O rings will generally be manifested by an increase in steering effort especially when steering quickly to the right or left The tests that follow can be used to confirm this symptom 1 If the power steering gear is equipped with a pressure relief valve it will be necessary to temporarily change its setting to a pressure above that of the power steering pump relief valve Only the Bendix pressure relief valve test pump assembly 106773 Figure 57 must be used To install the plug assembly A With the engine stopped remove the pressure relief valve plug 42 and its sealing washer 44 B Install approximately 030 to 060 additional shims 41 in the socket portion of the plug 42 C Reinstall the plug 42 and its seal washer 44 along with the additional shims 41 Torque the plug to between 66 and
17. LESHOOTING PRELIMINARY CHECKS Before proceeding to the troubleshooting headings it is strongly recommended that some preliminary checks be made and a test ride be taken to eliminate unnecessary work 1 Check for proper and equal tire inflation on the steering axle Note any abnormal tire wear which may be attributable to front end alignment 2 Make certain the power steering reservoir oil level is correct 3 Make certain the power steering pump belt is not slipping 4 Visually inspect the following components for obvious damage misadjustment and possible binding A steering column and universals or couplings B steering arms tie rods tie rod ends and knuckles C general looseness in the steering linkages 5 Check hoses for sharp bends kinks and proper size The most common faults may be grouped under the following headings 1 Power steering does not operate 2 The power steering is stiff in one direction and normal in the other 3 The power steering tends to turn itself when the engine is started 4 Excessive free play at the steering wheel 5 The power steering operates normally but is intermittently hard 6 Oil leaks 7 The power steering is stiff when turning the steering wheel quickly The power steering does not return correctly 9 The power steering operates but with noise turbulence or vibration oo TORQUE CHART Item Valve Body Bolts Item 40 Side Cover Bolts Item 49 Side
18. OPTIONAL PILOTED SCREWDRIVER USED TO REMOVE AND INSTALL THE PRESSURE RELIEF VALVE SEAT HOLDING FIXTURE USED TO HOLD THE PISTON AND VALVE BODY DURING ASSEMBLY AND DISASSEMBLY FIGURE 10 TOOLS FORASSEMBLY DISASSEMBLY N3LS NILINIT ONIHJ4LS ANY AQOd AN WA 40 1IV130 NO0S 9 la POWER STEERING PARTS LIST Valve Nut 28 Backup Ring External Dust Seal 29 Seal 8 Backup Ring Spindle Assembly 30 Retaining Ring Internal Dust Seal 31 Side Cover Seal 32 Nu Ball Cage 33 Adjusting ve Body 34 Adjusting Screw Spacer Race 35 Ball Tube Il 36 Retaining Ring lon Ring 37 O Ring Ring 38 Dust Seal Ring 39 Dust Boot Steering Limiting Stem 40 Bolt Seal Ring 41 Adjusting Shims O Ring 42 Pressure Relief Valve Plug Spring 43 Spring Valve Seat 44 Sealing Washer Sealing Washer 45 Spring Seat Steering Limiting Stem 46 Valve Piston O Ring 47 Seal Washer Plug 48 Valve Seat Housing 49 Bol Piston 50 Retaining Ring Tube Cover 51 Bypass Valve Spring Output Shaft 52 Bypass Ball Valve Rollers 53 Seal Washer O Ring 54 Drain Plug NO0S 9 N 00 9 YOS ALS 39NL NYNL3H TIVd 31VN4317V FIGURE 7 C 300N C 500N POWER STEERING GEAR 10 5 Remove the steering gear from the vehicle SPECIAL TOOLS Two special tools are required to disassemble assemble the C 300N and C 500N The tools listed and illustrated here are useful but not all required All special tools may be obtained from au
19. OUTPUT SD 30 4265 C 300N NAME PLATE SHAFT OIL RETURN OIL SUPPLY NAMEPLATE OUTPUT SHAFT OIL RETURN 0 r STEERING LIMITING STEM PLUG DESCRIPTION The Compact 300N and 500N C 300N C 500N Hydraulic Power Steering Gears are designed for medium and heavy duty vehicles with front axle weight ratings of 6 000 to 9 000 lbs for the C 300N and up to 15 000 Ibs for the C 500N They are integral power steering gears incorporating the mechanical and hydraulic actuation and control components in a single cast housing which serves as the power cylinder The C 300N and C 500N power steering gears are very similar in appearance with the major difference being that the C 500N is proportionately larger than the C 300N ADJUSTING SCREW PRESSURE RELIEF amp BYPASS VALVE CAP NUT POWER STEERING GEAR The vehicle s steering column is coupled to the gear at the input shaft which transmits steering effort through a recirculating ball screw spindle assembly and piston The piston is an integral part of the power assist and also acts as a steering damper The direction and degree of power assist is controlled by a rotary hydraulic valve which is integral to the input shaft and spindle assembly An engine driven hydraulic pump supplies the flow and pressure SD 30 4265 TABLE OF CONTENTS DESCRIPTION o a end 1 OPERATION jasc za LAO oO AA 1 A O 1 e Mechanical ooooocccnnnooocccccccoconancccncnonnncncnncnnnnnnncnnnc
20. STON REASSEMBLY 13 14 15 16 22 Install one of the two steering limiting valve seats 17 and its sealing washer 18 into the piston 23 Insert one of the two balls 9 then the valve spring 16 into the piston from the opposite end and install the remaining ball 9 sealing washer 18 and seat 17 in the piston Taking care not to damage the valve seats 17 torque each to between 88 and 132 pound inches Figure 27 Install the O ring 15 into its groove in the piston 23 Figure 26 Thoroughly heat the glide ring 14 to between 285 and 320 F in preparation for installation on the piston Note DO NOT USE AN OPEN FLAME to heat the glide ring A heat lamp or a similar device should be used Install the heated glide ring 14 over the O ring 15 in the piston s groove 23 OLD STYLE FIGURE 47 BALL TUBE STYLES NEW STYLE Ball Tube hemn 35 FIGURE 48 INSTALLING BALLS IN OLD STYLE BALL RETURN TUBE IMPORTANT 17 18 The glide ring should be distorted as little as possible during installation Using an automotive piston ring compression tool or a smooth piece of sheet metal and an appropriately large screw type hose clamp reshape the glide ring into the piston groove Allow approximately ten minutes cooling time before removing the compression tool from the piston Figure 46 Install the O ring 37 in its groove in the ball return opening of the piston 23 Figure 24 CAUTION Th
21. T SCREW SHAFT a PISTON al ay are MA EXTREME RIGHT TURN POSITION POPPET VALVE OPEN OUTPUT SHAFT INPUT PISTON HAPT SPINDLE ASSEMBLY LIMITING STEM POPPET VALVE PRESSURIZED SIDE PISTON SPRING OF PISTON DURING POPPET SEAT LEFT TURN ADJUSTABLE STEM RING FIGURE 7 STEERING LIMITING POPPET VALVE OPERATION upon the piston surface eliminates much of the piston s resistance to movement Spring force exerted by the torsion bar causes the ball screw to rotate as piston resistance is removed As the ball screw rotates the relative groove displacement is eliminated and the rotary valve returns toa neutral position Moderate effort at the steering wheel produces smaller valve displacements and lower power assist thus providing good steering feel At Increased displacements the pressure rises more rapidly giving increased power assistance and quicker response Maximum pressure is developed after approximately 3 displacement giving a direct feel to the steering Groove displacement is limited by the clearance of the stop spline mesh between the input shaft and ball screw The splines take up the steering movement while allowing the torsion bar to hold the groove displacement The torsion bar and stop splines form two parallel means of transmitting the steering torque When no steering torque is applied the torsion bar returns the valve grooves to a neutral position allowing the pressurized oil to flow to the
22. all the spring 43 Install a new unused sealing washer 44 on the pressure relief valve plug 42 then install the adjusting shims 41 in the plug Install the plug 42 in the valve body 7 and torque to 66 73 pound feet IMPORTANT Step 5 must be completed before placing the vehicle back in service TECHNICAL DATA C 300N C 500N Steering ratio input to output shaft 21 2 1 21 1 Steering wheel revolutions for 90 rotation of output shaft 53 5 25 Maximum output shaft rotation Note 1 95 Max Travel 90 Maximum output shaft torque with 1992 p s i 140 Kg C M2 power assist 1985 lb ft 270 mdaN 3767 510 Power steering fluid DEXRON 11 ATF Maximum working temperature 248 F 120 C Maximum peak temperature 302 F 150 C See Note 2 144 Kg C M2 Maximum allowable pressure Maximum pressure drop in the return line See Note 3 Maximum normal flow See Note 3 Note 1 Maximum rotation is specified maximum power assisted rotation is less when steering limiting optional feature is incorporated Note 2 Maximum working pressure is determined by the pressure setting of the pressure relief valve when that optional feature is incorporated Maximum allowable pressure for the C 300N is 2102 psi 145 bar and for the C 500N is the same Note 3 The pressure drop and flow rate are interrelated and application specific Consult the vehicle manufacturer s maintenance manual for this information TROUB
23. by rotating the output shaft 25 using the pitman arm It may be necessary to hold or rotate the input shaft 3 during this operation Continue to separate the valve body from the housing until both O rings 12 on the valve body can be seen Figure 15 4 Scribe a line or otherwise mark the relationship of the pitman arm to the output shaft 25 then remove the pitman arm then the dust boot 39 Figure 16 CAUTION Do not use heat or pound on the pitman arm or output shaft as damage can result These components must be replaced rather than repaired if they are damaged Remove any accumulated dirt grease grime and corrosion from the exposed portion of the output shaft to facilitate removal through its seals Ad Screw E 3 FIGURE 17 SIDE COVER REMOVAL INSTALLATION dutput Shalt Ham 23 FIGURE 18 SIDE COVER 8 ROLLER BEARINGS 5 Loosen and remove the lock nut 32 from adjusting screw 33 on the side cover 31 using a 19mm wrench 6 Scribe a line or otherwise mark the relationship of the side cover 31 to housing 22 Using a 19mm wrench remove the four bolts 49 that secure the side cover to the housing Figure 17 7 Separate the side cover from the housing by turning the adjusting screw 33 clockwise with a 7mm socket Continue turning the adjusting screw until the side cover can be removed from the housing 22 When the side cover is removed from the housing the 17 rollers in the side cover bear
24. e UTMOST care must be taken with the following steps Incorrect assembly of this group of parts can cause damage to the parts and failure of the gear to operate properly Two different style return tubes 35 have been used for the C 300N and C 500N power steering gears Before proceeding further identify the type of ball return tube that is being installed Ifthe OLD STYLE ball return tube is in use PROCEED TO STEP 19 Ifthe NEW STYLE ball return tube is in use PROCEED TO STEP 21 OLD STYLE BALL TUBE 19 20 Insert the valve body and spindle assembly 3 all the way into the piston 23 making certain that the stroke limiting stem 13 is not damaged and that it mates with the valve seat 17 in the piston 23 Insert nineteen of the balls 9 one at a time into one of the recirculating tube holes in the ball return opening in the piston Rotate the input shaft end of the spindle 3 slightly after each ball is inserted Rotate the spindle in one direction only and do not alternate from clockwise to counterclockwise Note When this operation is performed correctly the spindle and valve body should screw out of the piston and the balls inserted in one recirculating tube hole should appear at the opposite hole Before proceeding make certain the balls are at an equal depth in both holes of the piston This will assure correct installation of the return tube 35 Figure 25 CAUTION The utmost care must be taken with these
25. eering operates but with noise turbulence or vibration TROUBLESHOOTING CHART CAUSE 1 Restricted hose 2 Incorrect hose size 3 Faulty operation of hydraulic pump 4 Internal leakage in power steering gear 1 Lowtire pressure 2 Front axle assembly deformed as a result of accident or breakdown in the rotary valve unit 3 Bind in intermediate shafts 4 Lower steering gear parts deformed as a result of accident or breakdown in the rotary valve unit 1 Reservoir oil level low 2 Piping contacting part of the body work causing vibrations particularly the pressure feed line 3 Unsuitable oil 4 Oil reservoir filter blocked 5 Power steering pump a x N REMEDY Replace incorrect or unserviceable hoses Replace incorrect or unserviceable hoses Check pump to performance specifications Overhaul by authorized workshop Verify by test repair if necessary Inflate tires to correct pressure Lubricate front axle assembly Check for damaged or worn parts Determine cause and correct Replace the piston and spindle assembly Fill up to level Space pipe from bodywork if not possible insulate with a rubber spacer Drain oil and fill up with recommended grade Replace filter Repair or replace BW2600 2002 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2002 Printed in U S A 31
26. ers in place IMPORTANT The seventeen rollers that are installed must be the same rollers that were removed from this bearing during Disassembly Refer to Figure 18 25 32 33 FIGURE 55 INSTALLING ADJUSTING SCREW LOCK NUT 31 Adjusting Serew itam 33 wj skie Cowes p a Lack Nut ham 17 a T Lightly lubricate the seals 29 contained in both the housing 22 and side cover 31 with lithium grease Lubricate the sealing surface of the output shaft 25 on the adjusting screw end only Using a 7mm socket wrench install the assembled side cover 31 on the output shaft adjuster screw 33 and screw it on as far as it will go then back it off 1 8 of a turn Figure 54 Prior to inserting the assembled side cover and output shaft 25 into the housing 22 wrap a single layer of masking tape around the splines to protect the housing seal 29 Lubricate the exterior of the tape with a lithium grease and insert the shaft and side cover assembly into the housing with a twisting motion Remove the masking tape from the output shaft splines Figure 54 Secure the side cover to the housing using four bolts 49 Make certain that the side cover is positioned so that the marks made during disassembly are aligned Torque the bolts to between 81 and 88 pound feet for the C 300N and 92 99 pound feet for the C 500N using a 19mm socket and torque wrench Pack the cavity of exterior dust boot 39 with high temperature grea
27. g gear was equipped with the steering limiting feature follow the appropriate stem installation procedure C 300N POWER STEERING GEAR If it was necessary to remove the limiting stem from the valve body install the stem 13 now Using the dimension given in the vehicle manufacturer s maintenance manual apply Loctite 222 or 262 to the threads and screw the limiting stem 13 into the valve body 7 until the correct stem heightis obtained above the valve body Seal Driver 1 83 Inch Dia Taza FIGURE 45 INSTALLING PRESSURE SEAL IN VALVE NUT surface IMPORTANT Use care in applying the Loctite compound to prevent this material from coming in contact with other surfaces of the valve body Figure 4 amp 11 C 500N POWER STEERING GEAR Using lithium grease lubricate and install the O ring 20 in the groove in the steering limiting stem 19 Screw the assembled stem and O ring into the valve body 7 about 5 or 6 turns Do not install the plug 21 in the valve body at this time Figure 4 amp 11 inset 12 Install the dust seal 4 in the valve nut 1 taking care not to damage the seal Figure 32 The cavity between the external dust seal 2 the dust seal 4 and fluid seal 21 PISTON ITEM 23 STRIP OF SHEET METAL OVERLAPPING ITSELF AND ON TOP OF GLIDE RING FIGURE 46 RESHAPING THE PISTON GLIDE RING 5 should be filled with the high temperature grease provided in the Bendix maintenance kits PI
28. hanism contacts the axle stop If the steering gear being adjusted is a C 300N this is the desired reaction and indicates the turning direction controlled by the externally adjustable steering limiting stem The turning direction that registers pump relief is the one controlled by the externally adjustable steering limiting stem Proceed to Step 4 Ifthe steering gear being adjusted is a C 500N make certain that both externally adjustable steering limiting stems are adjusted out counter clockwise to within 5 turns of being removed then retest B Gauge pressure does not drop prior to axle stop contact in either turning direction and pump or gear relief pressure is noted upon axle stop contact If the steering gear being adjusted is a C 300N this reaction indicated the internally adjustable steering limiting stem is improperly adjusted or broken or the steering limiting valve 9 amp 17 is malfunctioning The C 300N must be removed and disassembled If the steering gear being adjusted is a C 500N this is the desired reaction Proceed to Step 4 C If gauge pressure drops prior to axle stop contact both directions turn the externally adjustable steering limiting stem counter clockwise and repeat the test until reaction A is obtained for C 300N or reaction B is obtained for C 500N 4 Return the steering to a neutral straight ahead position and turn the externally adjustable steering limiting stem clockwise to i
29. he closest side of the piston Figures 5 8 6 SIDE OUTPUT SHAFT RACKAND VIEW EJ AM SECTOR GEAR PISTON 4 TORSION BAR BALL SCREW SPINDLE ROTARY VALVE SPINDLE HOUSING STEERING STEERING LIMITING STEM LIMITING POPPET POPPET SEAT RECIRCULATING BALLS STEERING STEM PLUG 6 GG LIMITING STEM VIEW BACKUPRING NAMEPLATE C 500N DETAIL ROLLER BEARINGS ADJUSTING SCREW SPACER ADJUSTING SCREW E ADJUSTING I i a al SCREW LOCK C p NUT SHAFT SECTOR GEAR RECIRCULATING BALLS PISTON HOUSING SIDE COVER BALL TUBE POPPET VALVE COVER SEAT BALL TUBE FIGURE 4 POWER STEERING GEAR 5 BALL SCREW OUTER VALVE ELEMENT OIL IN TORSION BARPIN a ALL ALI OIL OUT RIGHT TURN OIL RETURN HOLES kdl HIDDEN FROM VIEW OIL SPINDLE ASSEMBLY OIL OUT OIL IN RIGHT TURN SUPPLY ROTARY VALVE ye LONGITUDINAL GROOVES 6 INSIDE HIDDEN BALL SCREW FROM VIEW ROTARY VALVE IL OUT OUTER ELEMENT ALAM LEFT TURN TORSION BAR PIN RETURN HOLE FROM PISTON CAVITY OIL RETURN HOLES TO PUMP RES INPUT SHAFT INNER OIL OUT LEFT VALVE ELEMENT TURN ROTARY STEERING GROOVES STOP 6 SPLINES PINHOLE TORSION BAR a INPUT SHAFT amp Z TORSION ASSEMBLY INPUT SHAFT OIL RETURN TO ROTARY VALVE PUMP RESERVOIR INNER ELEMENT OIL OUT RIGHT TURN E OE OIL RETURN TO PUMP RES phe 19 16 1S SLL AL ph
30. ing 26 will fall out loose These rollers MUST NOT BE INTERCHANGED with the rollers in the housing bearing which is identical Figure 17 8 18 CAUTION Do not attempt to remove the outer race of the roller bearing from the side cover 8 Install the pitman arm and use it to center the piston 23 mis and output shaft 25 gear teeth inside the side cover gt Pres Eo opening of the housing Remove the pitman arm and then remove the output shaft by tapping gently on the splined end with a soft mallet When the output shaft is removed from the housing the 17 rollers in the housing bearing 26 will fall out loose These rollers MUST NOT BE INTERCHANGED with the rollers in the side cover bearing which is identical CAUTION Do not attempt to remove the outer race of the roller bearing from the housing Figure 19 FIGURE 19 REMOVING OUTPUT SHAFT 13 PISTON REMOVAL 8 DISASSEMBLY 9 10 1 While preventing rotation of the input shaft end of the spindle assembly 3 pull the valve body 7 and piston 23 out of the housing 22 Figure 20 Remove the retaining ring 36 ball tube cover 24 the ball tube 35 and 7 of the 26 balls 9 from the piston 23 Remove the sealing ring 37 from the piston Note Bendix holding fixture 297678 which is pictured is a convenience but not a necessity for disassembly Figures 21 to 24 In order to remove the remaining 19 balls 9 from piston rotate the input shaft in
31. ing pump Figure 8 POWER INPUT STEERING OIL SHAFT GEAR RETURN HOUSING CHANNEL PRESSURE RELIEF ADJUSTING VALVE SHIMS VALVE PLUG SPRING BODY PRESSURE RELIEF VALVE amp PISTON BYPASS VALVE OIL RETURN OIL SUPPLY PORT PORT FIGURE 8 PRESSURE RELIEF VALVE OPERATION POWER INPUT STEERING OIL SHAFT GEAR RETURN HOUSING VALVE CHANNEL SPRING BYPASS j VALVE OIL RETURN OIL SUPPLY PORT PORT FIGURE 9 BYPASS VALVE OPERATION BYPASS VALVE OPERATION The optional bypass valve is located adjacent to the pressure relief valve in the valve body When it is necessary to steer the vehicle without the power steering pump in operation the bypass valve permits oil to flow from the return to the supply passages within the steering gear As the power piston moves inside the housing oil displaced from one side is transferred to the other through the bypass valve thus preventing reservoir flooding and cavitation in the pressure line Figure 9 POWER STEERING GEAR IDENTIFICATION A nameplate is attached to the exterior of the housing generally on one ofthe mounting lugs The information found on the name tag is illustrated PREVENTIVE MAINTENANCE POWER STEERING OIL It is important that an approved oil be used to ensure proper operation of the power steering unit The vehicle manufacturer s recommendations should be adhered to Once an oil type is in use it should never be mixed with any other type If it sh
32. install lock nut 33 and apply a torque of 74 to 88 pound feet with a 19mm crow foot and torque wrench while holding the adjustment screw in position with the 7mm socket and torque wrench Figure 55 36 After all the described steps have been performed check that the power steering unit runs smoothly throughout its entire motion and that the gear preload at the center position is as prescribed in Step 34 37 Install the power steering gear on the vehicle Fill gear with fluid per vehicle manufacturer s procedure Test for flow leakage and the pressure relief valve setting if applicable as well as setting the stroke limiting if applicable STEERING LIMITING STEM ADJUSTMENT GENERAL The function of the optional steering limiting feature is to relieve most of the hydraulic power assist prior to the piston 23 reaching the end of its full travel in either direction This ensures that the axle stops are not impacted with full hydraulic assist when a full wheel cut is made in either direction The C 300N has two adjustable steering limiting stems 13 amp 19 of which only one 19 is externally adjustable The internal adjustable stem 13 must be preset during assembly to meet vehicle requirements The C 500N has two externally adjustable steering limiting stems 19 one located in the housing 22 like the C 300N and one in the valve body 7 Both stems are adjusted externally after mounting the C 500N on the vehicle
33. l the O ring 20 in the groove around the steering limiting stem 19 and screw the stem 19 and screw the stem 19 into the housing 22 about five or six full turns Figure 52 put Sha i Gpdina o Ba Lubricated Acdjustng Serme ham 37 FIGURE 54 INSTALLING ASSEMBLED OUTPUT amp SIDE COVER 26 Install the seventeen rollers of the bearing 26 in the outer race contained in the housing 22 Use a heavy coating of lithium grease to hold the rollers in place IMPORTANT The seventeen rollers that are installed must be the same rollers that were removed from this bearing during Disassembly Figure 53 27 Align the steering limiting stem 13 in the valve body 7 with the steering limiting valve seat 17 in the piston 23 Insert the piston 23 into the housing 22 so that the rack teeth of the piston are visible in the side cover opening in the housing Figures 20 amp 53 Make certain that the valve body is oriented in the housing so that the marks made during disassembly align Slide the piston and valve body assembly completely into the housing taking SPECIAL CARE not to damage the piston glide ring 14 and the valve body O rings 12 Secure the valve body 7 to the housing 22 using four bolts 40 Torque the bolts to 81 88 pound feet for the C 300N and 92 99 pound feet for the C 500N using a 19mm socket and socket and torque wrench Rotate the input shaft of the spindle 3 until the rack teeth of the piston
34. laced as Spring Seat tram AT FIGURE 41 INSTALLING PRESSURE RELIEF SPRING SEAT leakage will occur and steering control and reaction will be affected Do not attempt honing or boring of these parts as leakage rates will increase 6 Pitmanarm 7 Exterior of housing and its mounting lugs 8 Valve body and porting REASSEMBLY OF THE POWER STEERING GEAR GENERAL To ensure proper operation of the power steering gear the following procedure and its sequence should be carefully followed Failure to do so may result in damage to the gear or faulty operation or both The appropriate maintenance kits should be obtained prior to reassembly VALVE BODY amp SPINDLE REASSEMBLY 1 If the power steering gear is so equipped install the bypass valve ball 52 and spring 51 in the valve body 7 Figure 40 2 Install the sealing washer 47 around the pressure relief valve seat 48 and using a large bladed screwdriver or tool piece number 298077 install both in the valve body 7 Tighten the valve seat to between 15 and 18 pound feet Figure 40 3 Install the pressure relief valve piston 46 spring seat 45 and spring 43 in the valve body Figure 41 CAUTION The spring seat 45 must be installed as illustrated in Figure 40 Incorrect installation of the spring 19 base grease The spindle assembly can be used to assist in pushing the tool through the bore Figure 42 amp 38 sh 6 Install the two O rings 12
35. mechanically however greater effort will be required to turn the steering wheel MECHANICAL OPERATION The turning effort exerted by the driver on the steering wheel is transmitted to the input shaft which is part of the spindle assembly The spindle and piston function like a screw and nut through the action of a chain of recirculating balls that serve as an interface Rotation of the spindle causes axial movement of the piston within the power cylinder Gear teeth cut directly into the piston mesh with corresponding gear teeth on the output shaft As the piston moves the output shaft and the attached pitman arm are rotated Figure 1 Spindle and piston sets are provided with either right or left hand screw threads Figure 2 The manner in which the steering gear is mounted on the vehicle determines of the thread used Figures 1 2 3 LEFT HAND THREAD RIGHT HAND THREAD FIGURE 2 SPINDLE ASSEMBLIES PITMAN A SPINDLE ASSEMBLY PISTON UNDER OUTPUT SHAFT PISTON OVER OUTPUT SHAFT FIGURE 3 POWER STEERING GEAR MOUNTING CONFIGURATION When the steering gear is mounted on the vehicle in a position similar to the piston under output shaft illustration in figure 1 the piston and spindle used will have a right hand thread A left hand thread is required when the steering gear is mounted in a position similar to the piston over output shaft illustration In either mounting position a right turn is accomplished whe
36. n the input shaft is rotated clockwise and the output shaft along with the pitman arm rotate toward the rear of the vehicle HYDRAULIC OPERATION GENERAL Functioning together the spindle and valve body assemblies serve as a means of flow and pressure control for the power assist portion of the steering gear All hydraulic fluid enters and exits the power steering gear through lines connected to the threaded ports in the valve body The valve body assembly forms a closure for the housing and provides a means of retaining the spindle assembly It contains a series of circular channels and radial passages which serve to direct the flow of hydraulic oil into and out of the rotary control valve in the spindle assembly In addition the valve body can contain an optional pressure relief and bypass valve The pressure relief valve ensures that a preset maximum pressure is not exceeded It is always set at a pressure level below that of the power steering pump relief valve and is intended to limit the power assist to a specific maximum level Figure 8 The optional bypass valve is intended to lessen the manual steering effort required in the event hydraulic pressure is lost The bypass valve permits fluid to circulate within the 4 steering gear rather than being forced to and from the power steering pump and reservoir Figure 9 The spindle assembly rotates on a ball bearing in the bore of the valve body The spindle is composed of three majo
37. ng Ham 29 FIGURE 31 REMOVING INSTALLING HOUSING OUTPUT SHAFT SEAL seal and nylon split ring may not be used in all steering gears A one piece seal is sometimes used instead CAUTION Do not remove the outer race ofthe roller bearing from the housing VALVE BODY 8 SPINDLE DISASSEMBLY 19 If the steering gear is not equipped with the steering limiting feature this STEP MAY BE DISREGARDED Follow the appropriate procedure C 300N POWER STEERING GEARS In the C 300N power steering gear the steering limiting stem is threaded into a blind hole in the valve body and is accessible only after the valve body 7 has been removed from the housing 22 Check the condition and length of the limiting stem 13 in the valve body 7 The length of the stem measured from the surface of the valve body to the tip of the stem should be specified in the vehicle service manual If the limiting stem is of the correct length and in good condition DO NOT REMOVE it The limiting stem can be removed if necessary by heating the steering limiting stem using a hot air gun to soften the Loctite compound Care must be taken to minimize the amount of heat applied to the stem DO NOT OVERHEAT The stem may be removed by turning counterclockwise After removal clean Loctite residue from the hole Use a M6X1 tap to clean the tapped hole If M6X1 tap is not available hole should be cleaned with solvent and dried well C 500N POWER STEERING GEAR In the
38. ng brakes and always block the wheels 2 Stop the engine when working around the vehicle 3 Ifthe vehicle is equipped with air brakes make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle 4 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that removes all electrical power from the vehicle 5 When working in the engine compartment the engine should be shut off Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components with strip
39. nns 3 Hydra UliC oe wez ti zad AE EA td 4 e Rotary Control Valve eeeuuaeeee aaa aaa eree 4 Steering Limiting Valve ea aa 7 e Pressure Relief Valve oria eaea n a n a 8 Bypass Valve s eoa E S ES fw 8 POWER STEERING IDENTIFICATION 8 PREVENTIVE MAINTENANCE 8 Power Steering Ollessaan ree 8 e Draining and Filling the System 8 Oil Change Intervals sanea p ae a 8 e Output Shaft Sector Teeth Adjustment 8 e Output Shaft Boot amp Dust Seals 9 CAUTION NOTE euuu eau aaa cecaaa 9 REMOVAL see wo ao ites do aca ade e lens 9 SPECIAL TOOLS cios 9 DISASSEMBLY iecere ii 11 Generale A A Ma 11 e Output Shaft Removal uueeeee aaa aaa aaa ae 11 8 PISION asc OE O Oda Miz A 13 e Main Housing 8 Side Cover 1 111 15 e Valve Body 8 Spindle su uaaaeaaaaaa aaa 16 ASS O 18 e Pressure Relief amp Bypass Valve 18 A a NA AKA Seats Mies elena en sees edie 18 CLEANING 8 INSPECTION 19 REASSEMBLY 522 sti dad ciones ace tt e mese huido saca 19 A dzo Aa EE OE pra 19 e Valve Body 8 Spindle aasarin 19 PISTONS a ad ANA WEOL EAC OCL 21 e FIOUSINJ szo Ao EE dd oO ZK 24 e Output Shaft 8 Side Cover
40. nstall the valve nut 1 over the input shaft end of the spindle assembly 3 and into the valve body 7 Using Bendix tool 106234 FIGURE 42 FORMING VALVE BODY TEFLON RING amp O RING seat will result in malfunction of the relief valve and damage to the valve piston and seat 4 Install the pressure adjusting shims 41 and the seal washer 44 on the plug 42 Install the plug in the valve body and torque to between 66 and 73 pound feet i minii any using a 26mm socket Note When installing the st _ E pressure adjusting shims 41 use the shims that were er removed during disassembly However if a complete rebuild of the power steering gear is underway it may be necessary to add or subtract shims in order to properly set the pressure relief valve Figure 40 E 5 Install the three O rings 11 and three Teflon rings 10 in the appropriate grooves in the valve body 7 Form expand the Teflon rings into their grooves by pushing Bendix tool 297676 through the bore of the valve body Note Prelubricate the tool with a light film or lithium FIGURE 43 INSTALLING SPINDLE ASSY BALL BEARINGS Y 4 Ph ee 20 Spindle Assy 4 M ve 3 ii FIGURE 44 INSTALLING SPINDLE ASSEMBLY 11 torque the valve nut to between 221 and 257 pound feet Figure 34 Reset the safety point between the valve nut and valve body using a drift punch or similarly appropriate tool Figure 33 If the steerin
41. otary valve Power steering housing or housing support loose Excessive play between output shaft sector teeth and piston Loose or worn ball studs in steering linkage Loose or worn intermediate steering shafts Dirty oil Low oil level Faulty operation pressure pump specification Overhaul by authorized workshop if required Hose or hose connections Faulty or incorrectly installed seal rings REMEDY Check oil level Check that there are no leaks bleed and top up with oil Check pump performance to specification Remove lines and clean Verify by test and repair as necessary Overhaul and test in accordance with vehicle service manual Inflate tires to correct pressure Verify by test amp repair as necessary Verify be test and repair as necessary Replace piston and spindle assembly Overhaul and check in accordance with vehicle service manual Replace piston amp spindle assembly Retighten mounting bolts Adjust gear lash If all adjustment has been used replace output shaft and spindle assembly Mechanical faults in vehicle steering members See vehicle manual Change oil Check oil level Check pump to performance Tighten or replace Clean amp dry the outside of the power steering body and take the vehicle out on test to locate the leak SYMPTOM Power steering stiff when turning steering wheel quickly Power steering does not return correctly Power st
42. ould become necessary to change types of oil the entire system must be drained following the procedure below DRAINING AND FILLING THE SYSTEM 1 Lift the front axle sufficiently to raise the wheels clear of the ground BENDIXASSEMBLY PART NUMBER MONTH ASSEMBLED A JAN ETC SERIALNUMBER YEARASSEMBLED LOCATION OF LAST DIGIT MANUFACTURE POWER STEERING GEAR NAMEPLATE INFORMATION 2 Remove the drain plug 54 and seal washer 53 or disconnect the return line at the valve body outlet port The outlet port is identified by the arrow which flows out of the gear Turn the steering wheel to the left as far as it will go Run the engine for 10 seconds at the most until the oil is drained from the reservoir and pump Switch off the engine and turn the steering wheel backwards and forwards from full lock to full lock until all the oil is drained out 3 Clean the outside of the reservoir Remove and replace the old filter element Fill reservoir full of oil 5 Turn the engine over with the starter motor Must be done in a manner that the engine does not start Add oil as the level drops to avoid air being drawn into the system 6 When the oil level reaches the full mark on the dipstick start the engine and turn the steering wheel slowly from side to side until air bubbles cease to appear in the reservoir Refill reservoir to full mark on the dipstick 7 The oil level should be checked every 2 000 miles The co
43. ped threads or damaged parts should be replaced rather than repaired Repairs requiring machining or welding should not be attempted unless specifically approved and stated by the vehicle or component manufacturer 11 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition REMOVING THE POWER STEERING GEAR 1 Mark or identify the inlet and return lines at the valve body ports 2 Drain the system following the instructions presented under Preventive Maintenance Remove both inlet and return lines 3 Disconnect the steering column at the input shaft following the vehicle manufacturer s instructions 4 Disconnect the pitman arm from the vehicle s steering linkage using the vehicle manfacturer s instructions CAUTION If it is necessary to remove the pitman arm before the steering gear is removed from the vehicle DO NOT USE HEAT OR POUND ON THE PITMAN ARM OR OUTPUT SHAFT as damage can result Do not attempt repairs to these components They must be replaced if damaged Use a large gear puller to remove the pitman arm such as Snap On puller CG 283 or Ford part number T64P 3590 F PART NUMBER 106234 REQUIRED SPANNER WRENCH REQUIRED FOR REMOVAL AND INSTALLATION OF THE VALVE NUT PART NUMBER 297676 REQUIRED SEATING TOOL REQUIRED TO FORM TEFLON GLIDE RINGS AND TO INSTALL SPINDLE ASSEMBLY IN VALVE BODY PART NUMBER 298077
44. r parts the input shaft torsion bar and ball screw One end of the input shaft is finely splined for connection to the steering column while the other end has a coarse spline which mates loosely with a similar spline inside the ball screw The coarse splines form mechanical stops which limit the amount of relative rotation between the ball screw and input shaft Six evenly distributed longitudinal grooves are machined into the outer surface of the input shaft and correspond to six grooves machined into the bore of the ball screw The torsion bar is pinned to the ball screw and input shaft and forms a spring connection between the two With the input shaft inserted into the ball screw the six grooves of each of these components alternate with each other and form the hydraulic rotary control valve Holes on the outside surface of the ball screw extend into the six grooves within its bore Figure 5 These holes allow pressurized oil to enter and exit the two parts of the rotary control valve There are three groups of holes in the ball screw Each group is made up of three different size holes which form a diagonal line across the surface of the ball screw The largest hole in each group conducts pressurized oil into the grooves of the rotary control valve The second largest hole in each group conducts oil out of the rotary control valve to the side ofthe power piston furthest from the rotary control valve while the smallest hole conducts oil to t
45. re 39 25 Remove the retaining ring 50 and then the seal 5 from the valve nut 1 Figure 37 26 Remove the two outside O rings 12 from the valve Adjusting Screw body then remove the three Teflon rings 10 and the go 2 corresponding three O rings 11 from the spindle bore Figure 38 Rimming Atag ieam 30 Output Shatr tem 25 1 lo Oe Retaining Fing itam z i lem 5 Teflon Aiag T e j Valre B A pri m y ham 7 A z i i SEAL ITEM 47 SHIMS O rings 3 r la SPRING SPRING SEAT ITEM 41 i 7 ITEM 45 at CD Sa ALE soupemper ITEM 46 SPRING si ITEM 43 PLUG ITEM 44 FIGURE 40 PRESSURE RELIEF 8 BYPASS VALVE FIGURE 38 VALVE BODY SEALS amp O RINGS COMPONENTS 18 PRESSURE RELIEF 8 BYPASS VALVE DISASSEMBLY 28 If the steering gear is equipped with a pressure relief valve begin disassembly by removing the plug 42 and its sealing washer 44 from the valve body 7 Figure 40 29 Remove the spring 43 spring seat 45 adjusting shims 41 and the valve piston 46 Figure 40 30 Using a wide bladed screwdriver or tool 298077 remove the valve seat 48 and its sealing washer 47 If the gear is so equipped remove the bypass valve spring 51 and the ball 52 SPINDLE DISASSEMBLY CAUTION Do not attempt disassembly of the spindle assembly which contains the rotary valve Individual replacement parts are NOT available It must be treated as a
46. rrect level is between the minimum and maximum level marks on the dipstick with the engine stopped OIL CHANGE INTERVALS It is recommended that the oil be changed at 40 000 mile intervals and at the time of rebuild Beyond its function as the media for transmitting power the oil also serves to lubricate and dissipate heat Carefully clean inspect and replace if necessary all filter elements in the pump system including vents and breathers OUTPUT SHAFT SECTOR TEETH ADJUSTMENT The gear lash or preload between the piston teeth and sector gear should not require attention in normal service however a provision for adjustment is provided Adjustment requires that the steering gear be drained and the pitman arm and input shaft be disconnected from the vehicle The adjustment procedure is described at the end of the assembly section of this manual EXTERIOR BOOTS AND DUST SEALS Inspect the integrity of the output and input shaft boot and dust seal These components prevent contamination from entering the housing around the shaft If deterioration is noted these components should be replaced The cavities between the boots and seals should be filled with special high temperature grease IMPORTANT PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parki
47. se provided in the Bendix maintenance kit then install the exterior dust boot 39 on the output shaft Refer to Figures 13 amp 16 PRELOAD ADJUSTMENT ADJUSTING THE PISTON TO OUTPUT SHAFT GEAR PRELOAD 34 26 The piston and output shaft gear preload is correct when a 4 to 18 pound inch increase in torque is noted at the input shaft as it is rotated and the piston passes through the midpoint of its total travel in the housing The torque increase at the input shaft will occur only as the piston travels through the mid point of its travel and should disappear as the piston moves past the midpoint To obtain the adjustment stated above make certain the adjusting screw 33 is turned counterclockwise as far as it will go Rotate the input shaft as far as possible in both directions Count the total revolutions in either direction and at the same time measure the average torque to rotate the shaft To obtain the proper preload adjustment rotate the input shaft 180 in both directions past the midpoint of piston travel The midpoint of piston travel is approximately one half the number of input shaft revolutions possible in a single direction Each time the direction of input shaft rotation is changed turn the output shaft adjustment screw 33 clockwise 1 8 to 1 4 turn Continue this procedure until a 4 to 18 pound inch increase is noted in the torque required to rotate the input shaft 35 When the adjustment is correct
48. the piston Figure 49 Insert the ball return tube halves 35 all the way into the holes in the piston If the ball return tube is properly installed the Morro Install Baill Tube lam 35 Install 26 Hala item f FIGURE 49 INSTALLING NEW STYLE BALL RETURN TUBE 8 BALLS 23 U BACKUP RING INSTALLED SEAL IN NON PRESSURE SIDE rem 29 TEM 28 OF SEAL PRESSURE SEALINGLIP FOR D PRESSURE SIDE OF SEAL NON PRESSURH SIDE OF SEAL PRESSURE SEALING LIP FOR O D FIGURE 50 DETAIL OF SEAL amp BACKUP RINGASSY m m 3 Avion Backup Ring sad Fart Of Seal fiom 28 f Side Cover Opening in Housing iam 22 4 ham 25 PA o a Pi FIGURE 51 INSTALLING HOUSING OUTPUT SHAFT SEAL 24 Side Cover Opening ir Housing z iom 37 Y FIGURE 53 INSTALLING OUTPUT SHAFT ROLLERS IN HOUSING spindle should rotate freely and will begin to thread into or out of the piston depending upon the direction of spindle rotation Note Hold the ball return tube firmly in place when rotating the spindle 22 While FIRMLY HOLDING THE BALL TUBE 35 IN PLACE insert as many of the balls 9 through the opening in the ball tube as possible Rotate the input shaft 3 slightly to make room for each ball that is inserted Note As the spindle is rotated the ball tube may tend to rise out of the holes in the piston Continue to insert balls until ALL TWENTY SIX HAVE BEEN INSTALLED
49. thorized Bendix part outlets DISASSEMBLY GENERAL A high level of cleanliness should be observed at all times when working on the power steering gear Clean the exterior of all parts prior to disassembly Dust Bost lem 2 FIGURE 13 REMOVING INSTALLING INPUT SHAFT DUST BOOT The following disassembly and assembly procedure is presented for reference purposes and presupposes that a major rebuild of the power steering gear is being undertaken Several replacement parts and maintenance kits are available which do not require full disassembly The instructions provided with these parts and kits should be followed in lieu of the instructions presented here After removing the power steering gear from the vehicle and cleaning the outside secure the power steering gear to the work bench for disassembly A large vise with jaw protectors may be used Clamp across the mounting bolt bosses Do not overtighten Figure 12 OUTPUT SHAFT REMOVAL 1 Remove the external dust boot 2 from the spindle assembly s input shaft spline Figure 13 Pious ig fimm Ki LIE w i d A st i F A 4 i yo 4 A E pa e El Valve Sady iam r FIGURE 14 VALVE BODY BOLT REMOVAL 11 2 Scribe a line or otherwise mark the relationship of the valve body to the housing Using a 19mm wrench remove the four bolts 40 that secure the valve body 7 to the housing 22 Figure 14 3 Separate the valve body 7 from the housing 22
50. ts full travel Gently turn the steering wheel in the direction effected by the externally adjustable steering limiting stem until the axle stop is contacted Pressure registered on the gauge should be relatively low With the steering wheel held to maintain axle stop contact turn the stroke limiting stem counterclockwise until the gauge pressure JUST begins to rise or until the gauge pressure specified by the vehicle manufacturer is obtained Note A rise in pressure on the gauge while turning the stroke limiting stem counterclockwise indicates that the stroke limiting valve is beginning to close Continued turning of the stem will cause the valve to close and the pressure to rise until the valve is PART NUMBER 106773 PRESSURE RELIEF VALVE TEST PLUG ASSEMBLY FIGURE 57 PRESSURE RELIEF VALVE TEST PLUG ASSEMBLY completely closed and the pressure rises to the gear or pump relief setting 6 After adjustment of the stroke limiting is complete install the plug s 21 in the stem bore s 27 ON VEHICLE POWER STEERING TESTS PRELIMINARY 1 Install a flow meter pressure gauge 3 000 p s i minimum and a shut off valve in the pressure line between the power steering pump and gears illustrated in the figure MAKE CERTAIN THE SHUTOFF VALVE IS OPEN 2 Install a thermometer capable of reading 300 F in the power steering pump reservoir 3 Turn the vehicle s front wheels to the straight ahead position engage the
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