Student Book

UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS TABLE OF CONTENTS
LESSON ONE - STEERING LINKAGE INSPECTION PROCEDURES ..........................................2 INTRODUCTION...................................................................................................................3 Idler Arms ........................................................................................................................3 Pitman Arm Inspection......................................................................................................4 Pitman Arm Removal ........................................................................................................4 Pitman Arm Installation .....................................................................................................5 Pitman Shaft, Seals, and Bearings .....................................................................................5 Steering Damper............................................................................................................. 10 Tie Rod Ends ................................................................................................................. 11 Stabalizer Linkage .......................................................................................................... 17 Rack and Pinion ............................................................................................................. 20 WHEEL ALIGNMENT......................................................................................................... 22

Student Book

UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

LESSON ONE STEERING LINKAGE INSPECTION PROCEDURES

TERMINAL OBJECTIVE
Successful completion of this Units enabling objectives (technical competencies) will allow you to meet the Integrated Curriculum Standards (ICS) listed in the right margin.
ICS 155 Steering and Suspensions Systems 166 Inspection

ENABLING OBJECTIVES
Upon completion of Lesson One, you should be able to: Inspect and replace pitman arm, relay (centerlink/intermediate) rod, idler arm and mountings, and steering linkage damper. Inspect, replace, and adjust tie rod ends (Sockets), tie rod sleeves, and clamps. Inspect and replace manual or power rack-and-pinion steering gear inner tie rod ends (sockets) and bellows boots. Inspect and adjust (where applicable) front and rear steering linkage geometry including parallelism and vehicle ride height.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS INTRODUCTION

The following descriptions are for general information only. Always refer to the appropriate service information for specific procedures. During inspection of the steering linkage and related components, you should carefully inspect all pivot points for looseness. Any looseness in the steering linkage can cause toe change which is the most serious of the tire wearing angles.

Idler Arms
Idler arms are sometimes overlooked and considered relatively unimportant. However, only slight looseness in an idler arm may cause an excessive amount of toe-change while driving, particularly on rough pavement. To check idler arms, grasp the center link as close to the idler arm as possible and vigorously move it up and down. Excessive vertical looseness indicates the idler arm is worn and should be replaced. Some vehicles have an idler arm inspection procedure with measurable tolerances. When removal is necessary, the following steps are usually required: Separate the idler arm from the center link, using a taper breaking tool if needed. Unbolt the frame bracket and remove the arm Before installing the new arm, check tapers and stud condition. Reconnect and torque to specifications. Also, you should perform an alignment check.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Pitman Arm Inspection
Pitman arms are checked in a manner similar to idler arms. An additional important check is to rotate the steering column. If there is movement between the stud and the housing bowl it can be detected at this time. Movement here is often misinterpreted as looseness in the steering gear box.

Pitman Arm Removal

The following steps are typical for pitman arm removal: 1. 2. 3. 4. 5. Place the front wheels in a straight-ahead position. Disconnect and cap the fluid hoses from the steering gear. Remove coupler pinch bolt at the steering gear and slide shaft off the gear. Mark the pitman shaft and pitman arm for installation reference. Remove the steering gear retaining bolts and nuts. Remove the steering gear from the vehicle.

3-001

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Pitman Arm Installation
1. 2. 3. 4. 5. Position the steering gear on the frame rail and install the bolts. Tighten the bolts to specification. Align the steering coupler on the gear shaft. Install and tighten the pinch bolt. Align and install the pitman arm. Install the washer and retaining nut on the pitman shaft. Connect the fluid hoses to the steering gear, tighten to specification. Add fluid.

Pitman Shaft, Seals, and Bearings

Disassembly 1. Clean the exposed end of the pitman shaft and housing with a wire brush. 2. Remove the preload adjuster nut. 3. Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns. 4. Center the stub shaft by rotating it from the stop of the total amount of turns. 5. Remove the side cover bolts and remove the side cover, gasket and pitman shaft as an assembly. The pitman shaft will not clear the housing if it is not centered. 6. Remove the pitman shaft from the side cover.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

3-002

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

7. Remove the dust seal from the housing with a seal pick.

3-003

8. 9. 10.

Remove the retaining ring with snap ring pliers. Remove the washer from the housing. Remove the oil seal from the housing with a seal pick.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

11. Remove the pitman shaft bearing from the housing with a bearing driver and handle.

3-004

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install the pitman shaft bearing into the housing with a bearing driver and handle. Coat the oil seal and washer with the special grease supplied with the new seal. Install the oil seal with a driver and handle. Install the backup washer. Install the retainer ring with snap ring pliers. Coat the dust seal with the special grease supplied with the new seal. Install the dust seal with a driver and handle. Install the pitman shaft to side cover by crewing the shaft until it fully seats to the side cover. Install the preload adjuster nut. Do not tighten the nut until after the Over-Center Rotation Torque adjustment has been made. Install the gasket to the side cover and bend the tabs around the edges of the side cover. Install the pitman shaft assembly and side cover to the housing. Install the side cover bolts and tighten to specification. Perform the over-center rotation torque adjustment.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Steering Damper
The steering damper is a very important component in the steering system. It must dampen road shock and tire shimmy. If the vehicle is equipped with a steering damper, check for leakage, cylinder damage and the condition of the mounting points. When replacing steering dampers, torque mounting points and then turn the wheels to extreme right and left to ensure proper operation. Removal 1. 2. 3. Raise the vehicle. Scribe a location mark on the tie rod for the bracket at each end of the bracket. Remove the u-bolt nuts from the tie rod bracket.

Installation 1. 2. 3. Position the bracket on the tie rod. Align the location marks with the bracket. Install the u-bolts and nuts finger tight. Measure with a tape from the right grease fitting of the tie rod to the left side of the bracket. The measurement specification should be in the service manual. Tighten the u-bolt nuts to specification. Install the damper to the bracket and tighten the nut to specification. Remove the support and lower the vehicle.

4. 5. 6.

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Tie Rod Ends
Checking tie rods requires the hand force test. Looseness will usually be caused by weak take up springs or other worn internal parts. Some manufacturers require the use of a dial indicator as part of the inspection. Removal 1. 2. Remove the front wheel and tire. Remove the nuts attaching both the outer tie rod ends to the steering knuckles. The nuts should be removed by holding the tie rod end stud with a socket while loosening and removing the nut with a wrench.

3-005

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3. Remove both tie rod ends from the steering knuckles.

3-006

4.

Loosen the inner to outer tie rod jam nut. Remove the outer tie rod from the inner tie rod.

3-007

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5. 6. Remove the jam nut from the inner tie rod. Using pliers, expand the tie rod boot clamp and remove the clamp from the steering gear clamp.

3-008

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7. Remove the inner tie rod boot to steering gear clamp.

3-009

After removing the inner boot clamps, use a very small screwdriver to lift the boot from its retaining groove in the steering gear.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Assembly 1. 2. Install the tie rod boot to steering gear clamp on the tie rod boot. Then install the tie rod boot on the inner tie rod. Crimp the inner tie rod boot to steering gear clamp on the tie rod boot.

3-010

3.

4. 5.

Lubricate the inner tie rod boot groove with a silicone-type lubricant, then install the tie rod boot to the inner tie rod clamp. The clamp will have to be loosened for toe adjustment. Install the inner to outer tie rod jam nut on the inner tie rod. Install outer the outer tie rod on the inner tie rod. Do not tighten the jam nut yet.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

6. 7. 8. Install the steering gear assembly back in the vehicle. Install the tie rod end seal boot heat shield on the tie rod end. Install the tie rod end into the steering knuckle. Start the tie rod end to the steering knuckle attaching nut onto the stud of the tie rod end. While holding the stud of the tie rod end stationary, tighten the tie rod end to the steering knuckle attaching nut. Then using a crowfoot and socket wrench, torque the tie rod end attaching nut to specification.

3-011

9. 10.

Make the toe adjustment by turning the inner tie rod. Tighten the inner to outer tie rod jam nut to specification. Lubricate the tie rod boot groove with silicone type lubricant, before installing the outer boot clamp, making sure the boot is not twisted.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Stabilizer Linkage
Stabilizer links connect the lower control arms to the sway bar. The sway bar attempts to keep the two lower control arms in the same plane during cornering. Worn bushings and sleeves must be replaced since they, too, affect handling. To replace these bushings, first the stabilizer, bushings and washers must be removed. When removing the stabilizer link, note the direction the bolt is facing, up or down, so that you can install the new bolt in the same position. Removal 1. 2. 3. Raise the vehicle. Remove both rear wheel and tire assemblies from the vehicle. Remove the nuts attaching the stabilizer links/isolator bushings to the stabilizer bar.

3-012

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4. Remove the bolts attaching the stabilizer bar bushing clamps to the rear suspension crossmember.

3-013

Installation 1. 2. Install the stabilizer bar back in the vehicle with the bushings removed, using the reverse sequence of removal. When the stabilizer bar is installed in the vehicle, it must be installed with the bend in the end of the stabilizer bar positioned up in the vehicle when viewed from the side.

3-014

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

3. Install the stabilizer bar onto the stabilizer bar to forward lateral link attaching links. Install the stabilizer bar to attaching link bushings on attaching links. Tighten the bushing retaining nuts to the specified torque. Loosely install the stabilizer bar bushing clamps on the rear suspension crossmember. Position the stabilizer bar so it is centered in the vehicle and does not contact other suspension components or the vehicle body. Tighten the bolts attaching the stabilizer bar bushing clamps to the rear crossmember to specified torque. Install the wheel and tire assembly on the vehicle. Tighten the wheel mounting studs in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque. Lower the vehicle.

4. 5.

6. 7.

8.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS

Rack and Pinion
When inspecting the rack and pinion system you should start on one side of the vehicle and work across to the opposite side. Perform the inspection as follows: Check the tire for scalloping, a break in the belt, runout or a bent rim. Check the ball joint for looseness. Any play may be a reason to recommend replacement. Check the outer tie rod ends for looseness by pushing up and down with hand force. Any vertical looseness can be a reason for suggesting replacement. The bellows boot protects the rack from contamination. It may also contain fluid that helps keep the rack lubricated. If any cracks, splits or leaks exist, the boot should be replaced. On power steering, if the boot has power steering fluid in it or is leaking, this may mean a rack seal needs service. To check the inner tie rod socket, squeeze the bellows boot until the inner socket can be felt. Push and pull on the tire. If looseness is found in the tie rod end, it should be replaced. Rack mounting bushings must be inspected closely. Look for wear or deterioration in bushings or excessive movement.

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With the wheels on the ground, rock the steering wheel and
check for motion in the outer tie rods. Look for excessive housing movement in case the bushings need replacement. Inspect the flex-type steering coupling or universal coupling or universal joint for wear or looseness. If play is found, you should recommend replacement. Grab the pinion gear shaft at the flex coupling and try to move it in and out of the gear box. If theres movement, the pinion bearing preload may need to be adjusted. By turning the left tire outwards, you should be able to grab the rack and try to move it up and down. If movement is found, theres a procedure in the manufacturers service manual for increasing the rack-to-pinion gear preload.

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UNIT THREE INSPECTING AND REPLACING STEERING LINKAGE COMPONENTS WHEEL ALIGNMENT
Proper vehicle wheel alignment is the adjustment of all interrelated front and rear suspension angles. These angles are what affects the handling and steering of the vehicle when it is in motion. The method of checking a vehicles front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions provided by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment. Do not attempt to modify any suspension or steering components by heating or bending of the component.

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Wheel alignment adjustments should always be made in the following sequence to ensure that an accurate alignment is performed: 1. 2. 3. 4. Adjust the rear camber to be at the preferred setting specification. Adjust the rear wheel toe to be at the preferred setting specification. Adjust front wheel toe to be at the preferred setting specification for individual wheel toe and for total toe. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. Thrust angle is defined as the average of the toe settings on each rear wheel. If this measurement is out of specification, re-adjust the rear wheel toe so that each wheel has of the total toe measurement. When re-adjusting, do not exceed the total toe specification.

5.

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