eT aan art Hydrapower”™ Integral Power Steering Gear HF54 Service Manual Ross Gear Division Price $3.00HF54 Integral Hydraulic Power Steering Gear This steering gear was specifically designed far mator trucks. Our design experience with previous models of hydraulic power steering gears have been incorporwied into this product, Design Features 1. Preloaded Linear Spool Valve—This device provides responsive steering control 2. Precision Roller Bearings—Allow the steeting gear 10 operate with high effiieney and reversibility 3, Unloading Valves—Furnish paver sigering pum Drotectin and redce pressure to unload steering linkage at the ends of steering gear travel 4. Recirculating Balls—Cambines high mechanical efficiency with smooth operation High Temperature Seals—These specially developed seals may be operated intermittently at 260°F (121.1 °C) Manual String Capabiity—Provdes far steering contol in the event of hydraulic failure Ausiliary Porting Available—For auxiliary cylinder canto! Seal Protectors—Pravide protection tram harsh erviranmantDefinitions NOTE: ——ANOTE gives key information to make a procedure easier or quicker 10 follow. CAUTION: A CAUTION refers to those procedures that must be followed to avoid damage to a steering component or the gear. WARNING: A WARNING REFERS TO THOSE PROCEDURES THAT MUST BE FOLLOWED FOR THE SAFETY OF THE ORIVER AND THE PERSON INSPECTING OR REPAIRING THE GEAR. The product represented herein is protected by United States patent No. 3, 047, OBF mR eC, 1588Table of Contents |HS4 Design Features and Phantom View: Definitions and Patents . Introduction . . . HPS4 Hydraulic Fluid Flow Mustration . Valve Hydraulic Fluid Flow Illustration. HFS4: General Design and Operation Troubleshoating Information Troubleshoating Guide Repairs and Adjustments on Vehicle —The Sector Shaft and Trunnion Cover Seal —The Wom Shaft Seal . —Worm Shaft, Valve, Thrust Bearing Preload Adjustment —Poppet Valve Adjustment —Cross Shaft or Sactor Shaft Adjustment. Torque Chart . ‘Tools and Materials Required for Servicing HF54 Exploded Assembly View Typical Disassembly Inspection Assembly Final Adjustments Hydraulic Fluid Filling and Air Bleeding the System WARNINGS for Proper Steering Gear Operation . . Steering System Maintenance Tips Page Inside Front Cover ein a neo a 2 8 v 9 a a 2 21h and 218 2 2 38 ag 50) 50 51 52 WARNING: ALL STEERING MECHANISMS ARE LIFE AND LIME ITEMS. AS SUCH, IT 1S IMPERATIVE THAT THE INSTRUCTIONS IN THIS BOOKLET ARE FOLLOWED TO THE LETTER, FAILURE TO OBSERVE THE PROCEDURES SET OUT IN THIS PAMPHLET MAY RESULT IN LOSS OF STEERING.Introduction Service Manual for Model HF54 ‘This service manual has one purpose: 'o guide you in maimaining, waubleshooting and serving the HFE4 Hydrapower™ imegral power staerng gear. ‘Material in this manual is organized so you can work on the HFS4 and get results withaut ‘wasting time or being confused, To get thase results, you should review the contents of this ‘manual before you begin any wark on the HFBS, The section of this manual on General Design nd Operation, teats the major pars of tha HHF51 and explains how they function together. The knowledge you acquire fram reviewing this section should assist you in solving your steering problem, This manual alsa contains trovbleshoating information and checklists. With them, you can sdagnase a steering problem without removing the HFS from the vehicle. If you must ‘service the HFS4, the checklists will help you to determine where the problems may be, The tieecolumn format of the Repairs, Adjustments, Disessemy, Inspection and Assembly sections will make it easier for you to servize the HSA. Column 1 gives a brief key for each procedure Column 2 explains in dati the procedure you should fol, Column 3 istotes this procedure with photogrophs, Pay special attention 1 the notes, cautions and warnings ‘A foldout page with the same typical HF54 exploded assembly view on bath sides is provided in this manual. The camponent part names and item numbers assigned on this ‘exploded assembly view correspond with names and item numbers (in parentheses) used in ‘the disassembly, assembly and other aracedures set forth in this manual. When this exploded assembly view page is folded out, yau can easly identity components and locate their relative position an the exploded assembly view as you follow the disassembly, exsembly and other procedures, As you goin experince in servicing the HF54 you may find that some informatian in tis manval could be clearer and more complete, If so, et us knaw about it. Don't try to second ‘guess the manual; i! you afe stuck, cantact us. Servicing the HFE4 should be a safe and Dbraductive procedureHF54 OIL FLOW ILLUSTRATION ree HE sree prsssune ww Left Hand Turn HB erurn on rowValve Hydraulic Fluid Flow Illustration => Flid from Pump - ++ Displaced Fluid From Cylinder Fig. B Valve Position and Fluid Flow For Right Turning Shatt and Spool Centered Preloaded Springs Inlet Port (Fram Hydraulic Pump) Na f-- a Neutral Valve Position and Fluid Flow ‘Shatt and Spook Moved Fig. C Valve Position and Fluid Flow For Left TurningHF54:; General Design and Operation Design Integral Power Steering The HFSS power stwering guar is ane of the Ross family of imogral hydraulic power steering gears. Integral hydrualic power steering means that the gear bax tontains @ manual steering mechanism, @ hydraulic control valve, and a hydraulic power cylinder, all in single, eampact package. Linear Control Vaive The linear contol valve combines ‘Simplicity of construction with desirable performance characteristics. The speed at ‘which the driver cen turn the steering ‘whee! with pawer assists dependent ‘upon the pump flow imeesured in gallans per minute—gom or LitersiMin.) directed to 8 cylinder cavity, ‘The pressure (measured in pounds per ‘square ineh—psi or biel required for the (gear to steer the vehicle i created by the pawer steering pump to overcame resistance at the steered wheels, The ‘cont valve sanses these requirements and diets fuid 10 the cylinder cavity at the proper flow rate and pressure, Pressure Means Work, low Means Speed ‘The higher pressure a geae can ‘withstand, the more wark it can perform, The HFS4 can staer a vehicle with a ‘ront-end weight rating of about 7,000 pounds (3175 Kgl through @ turn at low vehicle speed and engine idle. As abe ‘iver twins the steering wheel faster ar slower, more or less fluid will be requited by the gear in one minute. For the HFS4, maximum operating pressure is 100 psi (103.4 bet, The absolute maximum flaw fate is 6 GPM (23 litersinin.). The wehicle manufacturer's specifications must be relerred to for the maximum flow rate (GPM ot ltesimin.) 3s it willbe lower on particular HF5 steering gear ‘applications. NOTE: The recommended minimum flow at 1% hand wheel turnsisecond must be na less than 2.5 gpm (8.6 Liters/Min.). Ifthe HF54 staering gear is controlling an axiary cylinder, increased minimum flow is required based on the size of the auxiliary cylinder and the vehicle's steering geometry. Operation What Happens Ouring @ Steering Maneuver ‘When the driver turns the steering wheel, he: transmits rotational farce fram the steering wheel ta the steering gear worm finput shaft, In response 10 this rotational fore, the worm shaft, acting through the recrelating mechanism, tres to-move the rack piston axilly through the gear housing cylinder bore, The rack piston’s axial movement is resisted by its engagement to the sector Shalt, which ig connected by linkage to the steered wheal. Because of this resistance, an axial movement is then transmitted 10 the worm shat & valve spool, overcoming the hydraulic & spring forces that center tha contol valve, thereby actuating the contral valve Pressurized fd, dicted by the control Valve, assists in maving the rack piston aially tough the oylinder bore. The rack piston than turns the sector shalt 10 sear the vehicle Shock Loads to the Gear If the steered wheels receive a shock lsd, the shack forces are transmitted ‘Wwough the sector shaft, to the rack piston, and anto the worm shaft. The internal geometry of the steering gear causes the contol valve 19 send high Pressure fhid to the carreet cylinder cavity to resist the shock forces. By absorbing the shock forces hydraulically, the steoring gear prevants objectionable Fickbock at the steering whe! Unloading (Poppet) Valves The HF54 gears are equipped with twa unloading valves, ane at each end ofthe rack piston wavel, One valve oF the other, depending an the crection of turn, wil tip as the steered wheels approach the ane stops (which must be set according to manufacture’s specification). The tripped valve reduces pressure in the gear and helps to reduce heat ganerated by the pump. At the same time, the valves also reduce forcas an the steering linkage Bleed System Some HF54 gears which ate moueted with the output shaft shove the rack piston bore are equipped with # manual bled screw. The procedure far servicing the manual bleed screw is deserted under “Filing and Air Bleeding” Ipage 50) in this manualTroubleshooting Information Preliminary Checks ‘When a customer comes 10 you with a problem related to his two's steering, you can save o lat af time and work it you frst verity the prablem. Make sure you're both taking the same language about the same problem. If he says the truck's hard to steer, find out exactly what he means. Is it hard steering ita-@ night or left turn? Only wen turing the steering wel while the truck is siting sill? Is there only intermittent power steering? Or & there no power assist at all? If ot all posible, and if it’s safe to do so, test chive the iruck H you're not familiar with the rig, let the custamer dive it while you sit beside him, Take hold of the wheel while he ‘Grives to get a feel for the problem he's talking about. Since ast of his ckiving wil be wih his truck hauling 2 load, arrange for a Inad if one is required to reproduce the steering problem, Once you've determined the problem and its symptoms, don’t jump right into tear the string gear or pump apart. in mast cases, in fact, the gear shauld be the last tomponent you check, There are mary other tompanents in the steering system that could be causing the problem (see FIG, 1). These you should check first, ‘TYPICAL STEERING SYSTEM Figure 1 Begin, then, by checking the steered whaels: make sute that the tires are at corect pressure and equal all around, that they are properly sized, end that they are not warn ar damaged. Next, have the frontend alignment checked and look far abnormal looseness or tightness in the steering linkage, bel jos, and ng pis, A service replacement hose or fd Hine may be misrouted or may be too small in diameter, or it may be restricted in some other way, Reroute any hose that is kinked or bent sharply. Replace any hoses that ae not the seme as original equgment Continue by checking the power steering fluid reservcir to make sure that oil is up 10 the correct level, Aso, check the pump chive belt, if one i used, ta see it itis sipping, The belt may be tight, but it may alo be glazed, and a slipping belt doesn't ainays: squeal. If yau adjust the belt, check the specifications These ate just some of the checks you should make before you turn to the steering gear or pura. The Troubleshaoting Guide (on pages 9 thru 11 explains what to diagnose for a particular steering problem. Match the trouble symptom against the chart ‘and tolow the recommended troubleshooting sequence. Doing 50 will most likely save you time and may prevent unnecessary repairs and costs Hydraulic Tests Ht the checks described above all prove satisfactory, it i possible ‘that the cause of the steering prablem can be traced 1a a lack cf preseure or insufficient low. In this case, you may have 10 ‘do more detaled troubleshooting thet involves conducting Iydrouk tests. Preparation for Hydraulic Tests To conduct the fallowing hycroulic tests, first install @ flow meter, pressure gage and load [shut off) valve in the fluid supply ine to tbe steering gear, as indicated by the instructions that come wath the flaw meter. Steering sysiam analyzers are ‘avaiable with the 3 units integral, Place @ thermometer in the reservoir (FIG, 2), You must use a flow meter, and i is recommended that you use @ thermometer, if you ara to Troubleshoot the hydraulic system accurately sveemnis Gea Figure 2Start the engine and wim the hydraulic system up by partially lasing the load valve until the pressure gage reads 1000 pi 168.0 Bar|. When the fui temperature, as indicated on the thermometer, reeches between 125°F (61.7°C) and 135% 157.2°C), open the laed vale. The system is warmed up, and ‘you can conduct the tests, CAUTION: Do nat close the load valve completely and leave closed, or you may damage the pump. At no time allow ‘fluid temperature to exceed 180°F (82.2°C). Run all the tests at the prescribed temperature range of 125° (51.7°%C}135°F (57.2°C) Power Steering Pump Pressure Test With the engine ing, close the load vole end read the pressure goge. Ifthe pressure reads below the minimum specified by the pump manufacturer, repair or replace the pump. CAUTION: Do not keep the load valve closed for longer then 5 seconds to avoid damaging the pump. Closing the load valve causes the pump to operate at relief pressure and the fluid temperature to increase rapidly, Allow fluid to cool ta between 125°F (51.7°0) and 135°F (57.2°C) before you resume with the other tests. Power Steering Pump Flaw Test WARNING: MAXIMUM FLOW RATE FOR THE PARTICULAR HF54 STEERING GEAR SYSTEM AS SPECIFIED BY THE VEHICLE MANUFACTURER MUST NOT BE EXCEEDED. EXCESSIVE FLOW CAN CAUSE DAMAGE TO INTERNAL PARTS OF THE STEERING GEAR, WHICH COULD RESULT IN A LOSS OF POWER STEERING, NOTE: If methods of checking flow rate are provided by the vehicle manufacturer, you should follow those instructions ‘rather than the procedure described below. With the engine idling and the fluid temperature between 125% {51.7°C) and 135°F (67.2°CI, check the pump manufacturer's specifications for flow rate. Compare these specications with ‘the flow rote on the flow metar Naw, fully close the load valve until the pressure gage registors the pressure at which the gump i relieving. When pump rie is reached, flow rate must be zero, IMMEQIATELY OPEN THE UDAD VALVE. The flow rate must instontly retum to the original reading. I this rete does not retum immediately, the pump is malfunctioning, which can resuit in intermittent power asia. Now, set the engine at governed rprn, and fully close the lad valve again until pump reli is reeched. At pump ref, the flow rate must be zera, IMMEDIATELY OPEN THE LOAD. VALVE. The flow rate must instantly return to the original racing. If this rate does nat return immecitely, the pump is mmaltuncioning, which can result in imermittant power assist, NOTE: Conduct the pump flow test once at idle rpm and three times at governed rpm, CAUTION: Do not allow the fluid temperature to exceed 180°F (82.2°C). Run each phase of this test between 125°F (61.7 °C) and 135°F (57.2°C), Steering Gear Internal Leakage Test To test the steering gear for internat leakage, you must fst Prevent operation of the gears internal unloading (poppet valves. This will alow full pump relief pressure to develop. To prevert operation of the poppets, place an unhardened steel spacer block, about 1 inch thick and fang enough to keep ‘your fingers tear, berween the aie and stop at one whee! (see FIG 3h Faure 3 With the fluid temperature between 125°F (61.7°%C1 and 135° 157.2°C), turn the stesring whee! until the axle stops bottom on the spacer block (FIG. 4. CAUTION: When running this test, da not hold the steering ‘wheel in the full turn position for longer than § 10.10 seconds at 2 time to avoid damaging the pump. WARNING: KEEP YOUR FINGERS CLEAR OF THE AXLE STOPS AND SPACER BLOCK DURING THIS TEST. MAKE SURE THAT THE SPACER BLOCK CONTACTS THE AXLE STOP SQUARELY. CONTACT THAT IS NOT SQUARE COULD BREAK THE AXLE STOPS OR DANGEROUSLY THROW OR EJECT THE SPACER BLOCK. Apply 20 is. (8.1 KG) 10 the rim of the steering wheel during this test to be sure that the steering gear contral valve is fly closed. The pressure gage should now read pump rebet Pressure, as noted during the pump gressure test, You can naw feed steering geer internal leakage on the fhhw meter. ‘Acceptable internal leakage can range from O 10 1.5 gom (6.7 Litersihin) Repeat this test for the opposite direction of turn, If internal leakage is graatar than 1.5 gpm (5.7 LitersiMin.t and there is no ausilary hydraulic cylinder inthe systar, repair the (gear. If the internal leekage is greater than 1.5 gam (5.7LtersiMin.t and there isan ausiary hydraulic ovine in the osconnected lines to prevent drainage. Repeat the intemal system, controlled by the HF54 gear, solate the auxiliary Veakage test. If the intemal leakage is greater than 1.5 gom cylinder trom the system by disconnecting the auxitary cylinder (5.7 LitersMin,) vepair the HFBA gear, I itis less than 1.5 gor hydraulic tines at the HFE4 unis ausliary parts. Plug those (8.7 Lifers(Min.) repair the auxiliary cylinder, ports writ suitable pressure plugs or caps and plug the Troubleshooting Guide 1. Normal Noises © You of the diver may hear @ hissing noise fram the cantrol vale when it i eetueted during a steering maneuver © You or the driver may hear a noise as fluid bypasses through the poppets at full tur, You or the driver may hear a noise from the system ralief valve when it i required to actuate © You or the diver may hear pump growl from some types of nawer steering pumps, UL Abnormal Noises © If the power steering pura is belt criven, 8 squealing noise may indicate that the belts ‘Should be tightened or replaced © A clicking noise heard during @ turn, ar when changing directions, may indicate that some ‘eompanent is loose and shifting under load A change in the normal noise of the pump may indiete that air hes been induced into the system of that fiid level is low. Il, Possible Steering Problems and Causes Road Wander © Tie pressure incarect or unequal left ta righ. * Components in steering linkage laose or worn (Steering wheel to road wheel * Wheel bearings improperly adjusted ar worn. * Front end alignment out of specification Dry fifth wheel or paor finish an fifth whee! or teller plate Steering gear mounting bolts loose on frame Steering gear improperly adjusted * Loaseness in var axle assembles or trailer bogies.No Recovery «© Tire pressure low Frant end components binding © Frant end alignment incorrect Tight front axe king pins © Dry Fh wheel o poor finish on ‘ith whee or trailer plate * Steering column binding Pump flow insufiiont ‘Storing gear improperly adjusted Stoering gear contol vale spool sticking Shimmy Badly worn or unevenly worn tres: Improperly mounted tire or wheel Wheel bearings improperly adjustad or warn Companents in steering linkage foose or won Wheels or brake drums out of balance ‘© Front end alignment incorrect © ic in the hydraulic system . * External Oil Leakage * Finding the location of @ leak may ba dieu, since oil may run away’ from the leak sourea, the fittings, hoses, pump, or gear to a low point on the gear ar chasss. © A leak: from the vent plup atthe side cover indicates faiure of the sector shat ail seal insida the sida cover. Oversteering or Darting - Dry fifth wheal or poor finish on fith whee! or trailer plate * Front end components binding or loose + Steering column binding © Sweering gear impraperly adjusted * Steering peer eantol valve snoo!sicking Rear axe mous (ear staer) High Steering Effort in One Direction * Unequal tre pressure © Vetile overloaded «© Inadequate hydraulic system pressure © Excessive imternal leakage in one direction of tin only Werty with imernal leakage test 10High Steering Effort in Both Directions © Low tire pressure * Vehicle averlvadod Low haute fd level * Low pressure or flow from purip * Componants of steering system binding 4 Restitin in return fine, o fine toa small in diameter ‘Excessive imermal leakage (verity with internal leakage test “ Oversize ties (check manufacture’ specifications] Lost Motion (Lash) at the Steering Wheel + Steering wheel loose on the shat ‘© Lonse connection between the steering gear, intermediate eolumn, and steering column + Steering gear loose on treme ‘ Fiman arm loose an output shat “© Components in steering linkage loose or worn ‘ Stooring goar improperly adjusted Extessive Heat [150 °F (65.6°C) Over Ambient] + Excessive pump flaw Wehicleoveriaaded “* Undersized replacement hose or fine ‘Restricted hose or ine that is kinked at severaly Bent of internally blocked ‘ Restricted recentering af gear valve caused by column bind or side load on the input shaft * Poppet not adjusted properly * Prolonged stationary veticle operation WARNING: IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED, IT CAN CAUSE THE SEALS IN THE STEERING GEAR ANO PUMP TQ SHRINK. HARDEN, OR CRACK AND LOSE THEIR SEALING ABILITY. "Repairs and Adjustments on Vehicle When you have conducted the checks and tests deserted in the troubleshooting sections, you may find it necessary to repoir oc adjust the steering gear. Smice removing the gear from the vehicle és usualy dificult and time-consuming, you wil probably find it easier to perform the folowing repairs and adjustments with the gear on the vehicle, The photographs in this section show a gear mounted an a mock-up frame: for clearer austration, WARNING CAUTION Temave protector seal clean sector shaft 2 12 13 The Sector Shaft And Trunnion Cover Seal Wa eak is detected in the trunnion cover are you can remove the trunnion cover on many installations, 1a gain access to the sector shaft sool package, while the steering goor fs an the Vehicle, First check the radial postion of the pitman acm 10 the sector shaft ($11 and add timing marks to the pitman arrn and shaft if necessary to insure corect alignmant at reassembly. Remove the sector shaft nut (65) and lockwsher (64) o¢ the pitman arm pinch bolt and ™ assembly. SEE FIGURES 4 OR $. Remove the wan arm from the sactor shaft using @ suitable oir as required. SEE FIGURES 6 OR 7. NOTE: A chisel will help you loosen the pinch bolt type pitman arm. Use only a puller if you cannot remove the pitman arm with your hands, WARNING: WHEN USING A CHISEL TO SPREAD THE PITMAN ARM BOSS IN ORDER TQ LOOSEN THE PITMAN ARM FOR REMOVAL FROM THE SHAFT, MAINTAIN A FIRM GRIP ON THE CHISEL AT ALL TIMES. FAILURE TO 00 THIS MAY RESULT IN THE CHISEL FLYING LOOSE WHICH COULD CAUSE ‘AN INJURY. NEVER LEAVE THE CHISEL WEDGED IN THE PITMAN ARM BOSS. IF YOU CANNOT REMOVE THE PITMAN ARM FROM THE SHAFT WITH A CHISEL AND YOUR HANDS, REMOVE THE CHISEL FROM THE PITMAN ARM AND USE A PULLER ONLY TO REMOVE THE PITMAN ARM. CAUTION: Do nat use a hammer on the pitman. arm to remove it from sector shaft as intemal damage to steering gear could result. lemove protector seal (61) from sector shaft (51) ‘and trunnian cover (69) if included, Clean the sector shaft 151) with a fine grade of ‘emery paper. Be sure to ramave any paint, SEE FIGURE 8remove trunnion 1.4 Naxt, remove the four trunnion cover screws (60), ower and seal and trunnion caver (5). SEE FIGURE 9. A S16" package 12 paint thin wall socket required, Be prepared for fluid loss, Then remove and discard the sector ‘shaft seal package consisting of the two-piece ‘sector shaft seal 148), the “Teflon backup washer (47), and the trunnion cover seal ring 158). SEE FIGURE 10, Figura 6 clean and inspect 1.5 Caan the srunnion cover (89) with petroleum ‘trunnion caver besed solvent and inspect the seal cavity and sealing face for nicks or cormsion. Replace the trunnion cover with a new one if these conditions it WARNING WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. install a new 1.8 Install @ new teflon washer (47) and then 2 new teflon washer 2 piece seal 148) into trunnion caver (581 so that and seal package the surface marked “ol side" is facing out of the unter bore, WARNING WARNING: THE WORDS “DIL SIDE” MUST BE VISIBLE ON THE SEAL AFTER IT IS IN PLACE IN TRUNNION COVER. THE SEAL WILL NOT FUNCTION IF THE SEAL IS REVERSED AND A LOSS OF POWER STEERING ASSIST MAY OCCUR install new 1.] Grease the now trunnion cover sea ring (68) and seal ring install it into the cover ring groove, SEE FIGURE 11, ‘tape sector 1.8 Cover the serrations of the sactor shaft (51) with shaft tape if necessary to avoid damaging the seal curing instalation. SEE FIGURE 12. NOTE NOTE: Use only one fayer of tape. “Tollon 9 rgisreé waderar af OuFunCaporation Figure 12install trunnion ‘cover and screws assemble protectar seal install pitman atm WARNING install sector shaft fut and lockwasher or pitman arm bolt and aut CAUTION fill and bleed system 4 19 1.10 i 12 113 Apply clean high temperature industrial grease per Foss specification 045231, Mobil Ter. 1 or 2, ‘of equivalent to sector shaft seal area and install the trunnion cover (89) and four truntion screws (80), Torque scraws to 13-23 ft. ts. [18-31 Nm) if dry oF 11-16 ft. lbs. 118-22 Nm) if bubricated. SEE AGURES 13-14. Remove tape fram saztor shaft Pack clean high temperature industrial grease per Foss specification 045231, Mobil Temp. 1 or 2 or equivalent ta new protector seal (61) cup and install pratectoc seal to sector shaft (61) and trunnion cover 159), SEE FIGURE 16, Reconnect the pitman arm, making sure the ‘timing mark on the pitman arm aligns with the ‘timing mark on the sector shaft, SEE FIGURE 16. WARNING: WHEN USING A CHISEL TO ‘SPREAD THE PINCHBOLT TYPE PITMAN ARM BOSS FOR ASSEMBLY ONTO THE SECTOR ‘SHAFT (51), MAINTAIN A FIRM GRIP ON THE (CHISEL AT ALL TIMES. FAILURE TO 00 THIS MAY RESULT IN THE CHISEL FLYING LOOSE ‘WHICH COULD CAUSE AN INJURY. NEVER LEAVE THE CHISEL WEDGED IN THE PITMAN ‘ARM BOSS. Hf required assemble the sector shaft nu (65) and lockwasher (64) and torque put 19 300-315 ft. Ibs. [407-427 N m), 1-13/16" sacket required, SEE FIGURE 17 Hf requited ossemble the pitman arm clamp nut and bolt and torque to 220-240 ft. bs. (298-226 N mb if ory and unplsted or torque to 180-160 ft ibs. (217-284 N mal if bolt is Wbricated or slated CAUTION: Be sure there is no spreading wedge left in the pitman arm boss before torquing pitman arm clamp bolt. Before operating the steering gear, fil the system with the recomended fid and bleed ait from the system by following the Filing end Ait Bleeding instructions on page $0, Faure 13 Figure 14 Figure 172 remove input a coupling: clean input shaft WARNING remove and 22 plug the return fine remove 23 retaining ring apply air 2a Pressure to port The Worm (Input) Shaft Seal IF there i a leak in the shaft seal, you can usually replace the input shaft seal assembly (4) with the gear on the vehicle, Start by removing the input coupling per the vehicle manufacturers instructions. SEE FIGURE 1B. Remove seal protector M1 and clean the area around the worm shaft (231 with a fine grade of emery paper. SEE ROURE 19, WARNING: DO NOT DRIVE OR PRY COUPLING: FROM SHAFT. INTERNAL DAMAGE TO THE STEERING GEAR CAN RESULT. IF COUPLING 1S TIGHT, INSERT SCREWDRIVER INTO SLOT TO RELEASE. Remove and plug the return line in tha upper cover (7), SEE FIGURE 20. Remave the seal retaing ring (2) from the upper cawer (7, SEE FIGURE 21, Hold @ shop rag aver the worm shaft (231 and apply shop air pressure to the retwm port in upper cover (7. SEE FIGURE 22 WARNING: WEAR EYE PROTECTION AND BE ‘SURE TO COMPLY WITH OSHA OR OTHER ‘MAXIMUM AIR PRESSURE REQUIREMENTS. Figure 18 Figure 18 Figure 22 6remove seal and wash install seal grease worm shaft and protector seal assemble Protector seat reconnect line reconnect input ‘coupling ‘WARNING fill and bleed system 6 25 28 21 28 29 210 an The ai pressure will farce the input shalt seal (4) and the steel backup washer (3} 10 pop out of the gear, and some fluid will leek from the gear. Ciscard the seal, Disconnect the shop air as soon a the saol assembly is aut. SEE FIGURE 23, Tape the worm shatt serrations if necessary to protect seal and assembly mew seal |4) onto worm shaft 23) and into upper caver (7) with seal lip facing the uoper cover bearing IS), SEE FIGURE 24. Apply the special high temperature industrial grease per Ross specification 045231, “Mobil Temp. 1 or 2 or equivalent to back up washer (31 and instal it agsinst saa Assemble retaining ring (2). SEE FIGURE 25. ‘Apply more of the special grease in the seal ares cof warn shaft (23) and to the new protector seal (). SEE FIGURE 26. Assemble new seal protector (1) ante warm shaft (28) and upper cover (7). SEE FIGURE 27, Alemove the plug and recoanect the return lin Remove tape fram worm shaft (23) and reconnect ‘the input coupling. tthe ingut coupling male assembly slides frae of the female end during assembly, realign the timing marks to ensure Beoper phasing of the Uints. Refer to vehicle manufacturer for recammended torque WARNING: MMISTIMED U-JOINTS CAN RESULT IN A BUMPY SENSATION AT THE STEERING ‘WHEEL AND POSSIBLY AFFECT STEERING CONTROL, Before operating the steering gear, fill the system wath the recommended fui and bleed ait fram the system by following the Filing and Air Blooting instructions on page 50) Figure 27Adjustments You can make three adjustments to the gear while it is mounted an the vehicle; the worm shaft and valve thnust bearing preload adjustment, the poppet valve ‘adjustment, and the sector shaft adjustment, 3 Worm Shaft, Valve Thrust Bearing Preload Adjustment (With Vehicle Engine Off} 3.1 Remove input coupling and protector (1) and clean worm (input) shaft (231 by folowing worm (input) shaft procedure 2.1 and its succeeding warning remove and plug .?-‘omove and plug the retwin fine. SEE FIGURE 20, return line. Tape page 16. Tape serrations ith one layer of tape if serrations Inecessary to pratect seal (4). ‘remove upper cover 3.3 Remove four upper caver bolts (6) and washers bolts and washer |GAI, SEE FIGURE 28. 9/16 inch socket required ‘remove upper 14 Carehuly remove upper caver (7) assembly trom ‘cover assembly ‘worm shaft (23) while maintaining the valve assembly [151 position. SEE FIGURE 29, reassemble one 3.5 Reassamble ona bolt (6) with a spacer or spacars bolt about the width of the upper cover (7) to flange and torque bait enough to hold assembled ‘components in position, SEE FIGURE 30. unstake bearing 318 Unstake the bearing lockwasher (10) tang that és lockwasher stoked into a slot in bearing lock nut (9), SEE FIGURE 31. Remove tape from worm shaft serrations temave beating =. Place a 3/4 or 11/16 inch 12 point socket as lockwasher and nut required on worm shaft seratians and a hook ‘ype spanner wrench or self gripging (groave join! pliers on bearing lock rut 199 and turn rut aff of worm shaft (231, Remove and decerd bearing lackwashor /10), SEE FIGURE 32 NOTE NOTE: The 12 point socket must have sharp points to effectively fit the serrations and rotate the worm shaft. vassemble new bearing lockwasher, then nut ‘torque bearing Jock rut remove bolt and spacers NOTE assemble upper cover assemble and Torque bolts complete the gear reassembly 18 38 3g 3.10 an 32 ERE) ‘Assemble a new bearing lockwasher (10) onto worm shaft (23) with the imemal washer tang in ‘the worm shaft slot and the external tangs facing cut. Reassemble beering lock nut (8), lrge chamfer side in, onto threaded diameter of worm shaft until eampanents are at said height (snug SEE FIGURE 33, Torque the bearing lock nut (9) to 30 ft. Ibs. 141 NN mito ensure components are seated. Back the rut ff and torque put to 15-20 hs. (20-27 W mi, SEE FIGURE 34. Beck rut off approximately 20 deprees end bend one tang of bearing lockwasher 1101 fry ito @ mating slot i lock int, SEE FIGURE 35, Remove the one bolt (6) and spacers used 10 ccantain companents during adjustment. Tape worn shatt serrations. NOTE: It is recommended that seal (4) in the removed upper cover (7) be replaced per the Gisassembly and assembly procedure in this marwal before upper cover is reassembled, Grease and install 2 new seal ring (8) in per caver (7) and assernble upper cover assembly ‘onto the worm shaft (23). SEE FIGURE 36. ‘Assemble the four bolts (6) and washers (6A) ina upper caver (71. Carefully tarque the bolts while checking that the adaptor (1B), valve assembly (161 and uppar caver 17) are properly piloted and positioned with all sal rings in place. Torque bolts to 25°35 ft. tbs. 4-47 N mi if dry, or 21.27 ft. ts. (26-37 Nm! if lubricated. SEE FIGURE 37. Complete the steering gear reassembly by following procedures 2-7 thraugh 2.11 Figure 37sot axle stops NOTE rotate sector shaft to ition rack piston CAUTION NOTE loosen sealing nut and adjusting screw ‘set adjusting screw & tighten sealing nut 4 42 4a aa 45 Poppet Valve Adjustment (With vehicle engine on) Before you adjust the poppet, set the axle stops according to the manufacturers specifications NOTE: Not all HF54 steering gears have an adjustable poppet screw. Only the poppet on ‘the lower end (clased end) of the housing may be adjustable Install a pressure gage oF a flaw meterpressure gage package into the suapy ine ftom the pup to the gear. Make sare that the flow meter can be pressurized. Bring the fluid temperature to between 125°F and 138°F (51.7% and 57.2°C), vusing the method to warm the system up deserved in the troubleshooting section, page 8 Ta position the rack pistan for poppet adjustment ‘observe the end of sector shaft (61) for direction ‘of travel with the engine at idle. Have the steering wheel ratte inthe direction that vail rotate the sector shaft 10 the end of its travel ode against axe stop) clockwise (CW) or ‘counter-clackwise (OCW) as indicated by the shat Totabion array placed as shown in FIGURE 38 or 39 and pointing toward tha adjustable popaet and tlosed end of housing 155) CAUTION: If relief pressure is reached wile the steering wheel is at full lack (axle against ale stop, release the stecring wheel fram this Position, At no time should relief pressure be maintained for longer than 5 seconds as damage to the pump may result. NOTE: You must maintain enough force on the steering wheel to assure that the steering gear control valve is completely closed when reading pressure gage. Once you have the steering wheel in full lock faxle against axe stop) in the carrect direction, loosen the poppet adusting screw nut (541 or (4AI and the poppet adusting screw (531 oe (538), until the pressure goge reeds maximum pump relief pressure. SEE FIGURE @0. 11/16 inch box end and slot screw driver or 3/4 inch box ‘end and 5/16 inch hex socket required. Sorew in the poppet adjusting screw (531 or (9B) until the pressure gage shaws less than ‘500 PSI with the steering wheel in full lock. ighten the poppet adjusting nut (64) 10 17-22 ft Ibs, 123-30 Nm, Tighten poppet adjusting nut (SAA) 10 25:90 ft. Is. 19481 Nm). Figure 38 Figure 39 Figure a0 9locate 51 adjusting out NOTE remove the 52 drag link CAUTION NOTE center the 53 sector shaft check for lash 54 position adjusting = 5.6 screw cheek far lash 5a eliminate lash BT Cross-shaft or Sector-shaft Adjustment (With vehicle engine off} Ifthe sector shaft adjusting screw jam nut (40) located on the side cover (43, is not accessible, ‘the steering gear must be removed prior to adjustment. NOTE: Hf there is nota timing mark on the end of sector shaft 151) a timing mark must be seribed acrass the end of the sector shaft petpendicuiar to the warm shaft (23) while the vohicle’s steered wheels are in the straight ahead position and the drag link isin place. The timing mark will indicate the sector shaft “center of travel” position If the sector shaft adjusting serew (501 is ‘accessible, remave the drag link from the pitman arm CAUTION: This adjustment must be performed with the sactor shaft on its center of travel, NOTE: Because of pitman arm or internal stops of poppet adjustment the “center of travel” for this adjustment may not be the center of sector shaft or handwhee! rotatian. To position the sector shaft (51 an “center of travel" for this adjustment rotate steering wheel (warm sheft| until the timing mark across the end at the sector shaft is perpendicular to the wor shaft (23), SEE FIGURE 41 With the sector shaft (51) in the center postion, nrasp the pitman aim and gently try 10 move this aim back and forth in the direction of travel Frnge-tp force és adequate to detect lash of loose sector shaft, There must be ni movement af the input fwarm) shaft or sector shaft, no losh is detected, a not adjust. SEE FIGURE 42. Figure 42 1 lash is detected, loosen jam nur (40) with & 3/4 inch socket and move the adjusting scree (60) clockwise until the sectar shaft (51) and rack piston (39) are in contact. (Use no more than 10, ft. tbs. (14.N m) of torque), Then tum the ‘ajusting screw counterclock-wise one tum. ‘At this point, there should be lash fett through the pitman arm, Ta adjust, slowly turn the adjusting sow (60) docs’ until no lash is felt at the picman arm, Hald the adjusting screw in lace, and tighten the jam rut (40), Final nut torque & 40-45 t,t. (64-51 N mbrecheck for lash connect drag link 58 Recheck theaugh the pitman arm for lash, Turn the steering whee! 1/4 tuen wach side of center. No lash should be felt. If lash erists, repeat adjustments 6.36.8. 5.9 Reconnect drag link 10 pitman arm. Torque Chart Part Name Upper Cover Bolts Upper Cover Bolts Poppet Seat ‘Adaptor Bolt ‘Adaptor Bolt ‘Side Cover Bolts Side Cover Balt Truntion Cover Strews Truntion Cover Screws ‘Serew-Rewin Guide Poppet Serew Poppet Adj. Nut Poppet A. Nut ‘Adj, Nut (Sector Shaft} ‘Sector Shaft Nut Pitman Arm Bolt & Nut Assy Pitman Arm Bolt & Nut Ass'y Bleed Screw: Locknut Item Number Torque 6 28-36 fs. | 34 47 Nm) 6 if Lubricated 21-27 ft ths. | 28 37 Nm) 0 20-25 ft. ths. 1 27. 94N ml v 45-55 ft. ibs. | 61-75 N ml 17 if Lubricated: 42. 2 ft. ths. | 67 71N m) 2 45-59 fl. ibs, | 61- 75 Nm) 42 if Lubricated 33-40 ft ibs. | 45. 54 m) oO 13-29 ft. bs. 18 91N m} 680 if Lubricated Ve 16 ft. bs. | 15+ 22 Nm) 8 810 f. fos. ( 11- 14m) 534 ‘15-20 ft. ths. | 20- 27. N mi a VD 22 ft. hs. (23-30 N ml aa 25- 30 ft. bs. | 34 41 Nm) 0 40. 45 fi. bs, | 54 BT Nm) iy 300-315 ft. ths, (407-427 Nm) 220-240 ft. ths, (298-325 N m) Lubricated/Plated 160-180 fi. bs. (217-244 N m} 558 27-33 in. ths. (3.1-3.7 Nm) 8 18-20 fh bs. ( 20-27 Nm) Universal joint botis—torque to vehicle manufacturer's specifications. ‘All torques specified in this marusal are for dryfunplated parts unless otherwise specified. Tools and Materials Required for Servicing Service Manual Masking Tape or Special Clip Grease—"Mobil Temp 1 oF 2 oF equivalent Wheel Bearing Grease ‘Adjustable Wrench Pocket Knife Torque Wrench in ts. (8! m) Torque wrenet—ft. tbs. N/m) Soft Punch Pubber Mallet Vise 1 ar 25 mm Micrometer Emery Paper Retaining Ring Piess Breoker Bar Ratchet Sockets: 1/2, 9/16, 5/8, 1-136 inch Alen Sockets: 1/4, 3/8 inch T2Point Sockets: 3/4, 11/16, 5/16, ING inch Torr Socket T-60 Pitman Arm Puller Screw Driver Siot Type Screwdriver Sacket Chisel 14" 2" Adjustable Hook Spanner Weench Small Needle Nose Pris Loguic Grade “T" Primer "Stud Lock” Loctite Hydrauic: Sealant a‘yews 1085-1 59 (091 periey).s0y eon yo myn poor 0YS0. 922) ‘2000 yw 1 By Ue s2seeeegenesgge eg uopenig (4 Brat (yl ang 2101 f 4d 7 e. eae! ig 188 — fmm 10 " ce f Enlarged View of Valve ‘Assy. (Rotated 190°) '52A. Poppet Sow (Alernte) ‘508. Adjusting Screw, Poppet Alternate) 58. Adjusting Screw, Poppet al 8} (7/96-14 17), BA. Wesber Ia} 152 PSG Exploded Assombiy View—Typicsl _{Ideatcal ta pape 21)Disassembly Preparation ‘+ THOROUGHLY CLEAN OFF ALL OUTSIDE DIRT, ESPECIALLY FROM AROUND FITTINGS AND HOSE CONNECTIONS, BEFORE YOU REMOVE THE GEAR © Drain the steering gear assembly, © Remove input and output shaft connections per 1.1 and 2.1, Page 12 and 15. © Remove the supply end return lines from the gear, and immediately plug all port holes and fui lines, WARNING: THIS STEERING GEAR WEIGHS APPROXIMATELY 80 POUNDS, 36 KG, DRY. EXERCISE CAUTION WHEN YOU REMOVE, LIFT, OR CARRY IT. 0D NOT POUND THE UNIVERSAL JOINT OR INPUT SHAFT COUPLING ON OR OFF THE INPUT SHAFT. INTERNAL DAMAGE TO THE STEERING GEAR CAN RESULT. ‘© Remove the steering gear from the vehicle and take it ta a clean surfaoe (a piece of wrepning paper makes an excellent dispassble top. "© Clean and dry the gear before you start to disassemble it "© As you disassemble the gear, clean all parts in clean, petroleum-based solvent, ‘and blow them dry only WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULO CAUSE INJURY OR DEATH. WARNING: WEAR EVE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION: Never steam clean or high-pressure wash hydraulic steering components. Do not force or abuse clasely fitted parts. ©” Keop each part separate to avoid nicks and burs Discard all seals, Ovings, and gaskets remaved from the geor. Replace them with now parts ani. Disassembly position gear 1 Pasition the steering gear firmly in a vise, and sector shaft ariping ageinst the housing (S61 mavnting flange or boss, with the worm shaft (231 in a horizontal direction and components accessible fur disassembly, SEE FIGURE 43. CAUTION CAUTION: Do not clamp against body of the housing as this cauld damage hausing and cause disassembly, assembly difficulties. I housing mounting boss ar flange is not accessible for clamping in vise, fabricate and attach @ mounting plate to the hausing ‘mounting bosses for this purpose drain goar and 2. Pregare for Tid drainage and unplug hydraulic position parts. Using apprapriane 2/4 or 11/16 inch 12 sector shaft point socket on the worm shaft serrations, rotate worm shaft (23) through gear travel & few times, to purge hydraulic fluid from gear. Then sorate Figure 44 nremove protectar seal clean sector shaft remove trunnion ‘cover bolts: remove trunnion cover and seal package loosen sector shaft adjusting screw jam nut the worm shaft until the ting merk oa the end of the sector shaft (51) is vertical to the worm shaft. This wil position the gear for sotor shah removal. SEE FIGURE 44 NOTE: If the steering gear does not have @ ‘sector shaft timing mark, position sector shaft for ramaval by rotating worm shaft from end of travel one half of the total warm shaft rotations, counted when rotating worm shaft fram ane end of travel tothe ther. 4. Remove pratector seal (61) from trunnion cover (59), SEE FIGURE 45, 4, Remove any paint ar corrosion from the exposed area of sactor shaft (81) with emery cloth, SEE FIGURE 46. 5. Remove the four tunnion cover screws (600. A 5/16 inch 12 point thin wall socket required. SEE FIGURE 47. 6. Remove the trunnion caver (59). Remove and cdscard the seal ring (SBI, the two piece sector shaft seal 148) and the “Teflon backup washer (47) from the trunnion cover. SEE FIGURE 48. 7. Loosen sector shaft adjusting screw jam rut (40), SEE FIGURE 49, 9/4 inch socket required, “Tela i a registered vademark of DuPont Corporation, aremove side 4 cover bolts NOTE NOTE remove side a cover and sector shaft assembly NOTE Temave sector 10, shaft fram side cover 1. Pregare for fluid to drain and remove the four ‘spacial bolts (42) and lockwashers (424) from the side cover (83). A 6/8 inch socket required. SEE FIGURE 50. Tap ity with @ soft hammer on the end of sectar shat (51) 10 disengage seal and let drain, NOTE: These bolts are special because they are equipped with either a ring or washer design on the underside of the head, SEE FIGURE 51. If you replace one or mare belts, ‘you must use bolts of either design and of the ‘SAME SPECIAL TYPE AND LENGTH AS THOSE YOU REMOVED. Do not use a ‘substitute, You can get these botts through your OEM parts distributor. NOTE: Some units have a flat head Torx drive bolt (428) without a lockwasher as one or two of the side cover bolts. A T-50 Torx socket required. Remove side caver (43) and shaft assembly (51) 15 2 unit from goar assembly. SEE FIGURE 62, Romove and discard saa ring (434). NOTE: If sactor shaft hangs up on housing face during remavel rotate worm shaft until sector shaft is positioned for removal Remove jam nut (40) and screw sector shatt adjusting screw (60) out of side cover (43) and lft sector shaft (51) out of side cover. SEE FIGURE 53. Remove the side cover retaining ring (62) if there is one in the unit. SEE FIGURE 54 Figure $0 Figure 51 \ Figure 52 Figure §3 Figure 64remove seal 12. NOTE remove retainer 13, and adjusting screw remove seat 4 and clean worm shaft. NOTE: loosen upper 15 cover bolts and adjusting rut remove adaptor 18. bolts. Remove the two pieve seal (48), the Teflon backup washer (47) and steel backup washer (46) from side cover (431. Discard the two piece seal and Tetlon washer. SEE FIGURE 55. Remove and siscard vent plug (411 : sining ring (45) from side cover (43) unless it must be replaced, ‘Only if replacement of retainer (49) and oF adjusting screw (50! is required, fsa inspection procedure #9, page 34.) place the sector shaft (61) firmly in a soft jawed vise and unstake reteiner using a suitable chisel, Tum retainer out of sector shaft pocket and remove adjusting szrew. Discard retsner, SEE FIGURE 56, ‘Remove protector seal (1) from worm shatt (23). ‘Geen exposed area ofthe worm shaft with a fine grade of emery paper. SEE FIGURE 57 NOTE: Scribing or marking a line across the Ihausing (55) adaptor (18) valve body (1A) -and upper cover (7) before disassembly wil facilitate correct alignment of these ‘components when reassembled Loosen the four upper cover bolts (8) far later removal. A 8/76 inch socket required. SEE FIGURE 58. Flemove four adaptor bolts (17). A 716 inch 12 point socket required. SEE FIGURE 59. Figure $6 Figure 69 5rotate worm V. shaft to loosen ataptor remove worm 18. shaft subassembly remove ball 19. return guide clip remove guides 20. and balls NOTE CAUTION WARNING B Rotate worm shaft (23) until edaptor (18) maves ‘sway from housing (551, about 344 inch [19 mm} and let drain. SEE FIGURE 60. Remave worm shaft (23), upner cover (7] adaptor 118) rack pion (39) subessembly as a unit from Fowsing (65) and place on a cloth covered work. surface, with the ball return guides (351 up. SEE FIGURE 61. Remove and wiscard seal ring (181 and seal ring (161 Bend the tangs down on the two locking tabs (87), SEE FIGURE B2. Remove the two hex bolts 136), locking tabs and ball retin guide clip (36) 76 ineh socket required. SEE FIGURE 63, Discard loc tabs ‘Remave the ball return guide halves (36) from the rack piston (391. With the rack piston ball guide holes titing daven, rotate woe shaft (23) 10 ‘allow all balls (344, 34B} 10 fall out, SEE FIGURE 4, NOTE: The ball return guide is closely fitted ‘with the rack piston, and you may have to remove the halves by carefully insarting @ ‘screw driver between the rack and the guide. CAUTION: The 22 steel balls are a matched set. Take care not to lose any of them, If you lose any of the balls, you must replace them with a complete, new set. WARNING: INCORRECT MATCHING OF BALLS, WORMSCREW AND RACK PISTON CAN RESULT IN LOSS OF STEERING, WHICH COULD RESULT IN AN ACCIDENT. Figure 61 Figure 63remove rack 2. piston from subassembly NOTE WARNING remave poppets 22. cut and a Femove worm shaft seal remave retainers: 24. and washers Remove rack piston 199) fram worm shaft (23) subassembly. SEE FIGURE 65. NOTE: Do not remove rack piston ring (39A) ‘or poppet (31) components from the rack piston unless replacement is necessary. WARNING: DURING STEP 22 YOU SHOULD WEAR EYE PROTECTION. AS THE SPRING LOADED POPPETS COULD EJECT, AND CAUSE EYE INJURY, To remave pappets, place rack piston (391 in @ soft jawed vise and turn poppet seats (30) out of ‘both ends of rack piston, Ramave two poppets (31), the nylon spscer rod (33) and spring (221. A ‘9/6 inch sacket required. SEE FIGURES 66 and 67. Hold the seal cup (26) and seal (25) in place with piirs and cut, remove, and discard the seal cup and seal from end of worm shaft (23), SEE FIGURE 6 Remove retaining ring (291 using needle nose pliers, then remave retaining washer (28) bronze backup washer 127) and steal washer (24) trom vend of worm shaft (23), SEE FIGURE 68. Figure 6 Figure 67 Figure 68remove upper B cover, bolts, and washers remove upper 6 ‘ower retaining package remove adaptor = 27. from worm shaft remove retsining 28, ring, seal and backup washer a Remove the four loosened upper cover bolts (6), Washers (6A) end the upper caver 17) assembly. SEE FIGURE 70. Discard seal ring (8). Remove retaining ring (21 from upper cover [7] with the appropriate retsining ring pliers or small serew driver, SEE FIGURE 71. Remove backup washer (31 and saal (41, SEE FIGURE 72, Discard seal Remove adaptor (181 from worm shaft (231. SEE FIGURE 73. Remave and discard seal ring (8) and ‘wo sea rings: (16). Remove retaining ring (22) from adaptor (18), SEE FIGURE 74. Remove end discard seal (21) and backup washer (201, SEE FIGURE 75, Figure 70 Figure 71 Figure 73 Figure 74nstake locking 29. washer from nut remove bearing 0. lock nut NOTE remave washer 31 and thrust bearing package remave valve R. assembly CAUTION Unstake the tang an bearing lockwasher (10) thet is staked in 8 slot of bearing (spanner! lock rut (} on the worm shaft, vale subgssembly. SEE FIGURE 76: Use @ breaker bar and the appropriate 34 or 11/16 inch 12 point socket on the serrations to Fold worm shaft (23) from rotating or lamp ‘worm shaft carefully in a sol jawed vise, Turn ‘off the bearing lack rut (2 frm the werm shaft with & hook type spanner wrench oF self griping \groowe joint) pers. SEE FIGURE 77. NOTE: The 12 point socket must have sharp points to effectively fit the serrations and hold fr rotate the worm shaft. Remove and discard bearing lock washer [10) and remove washer (11), dwust washer (12), trust bearing 113) and thrust washer (141. SEE FIGURE 78 Carefuly remove valve assembly 116) intact fram ‘worm shaft (23) and set aside for inspection and assembly procedures, SEE FIGURE 79, CAUTION: The valve assembly (15) is the control canter af the hydraulic system, The ‘major parts, which are the body and spool, are machined to very close tolerances and with precision machined edges. The valve spool and valve body are selectively fitted at the factory and tharefare these two parts are not soparately replaceable. If either is damaged or ‘excessively worn, the whole valve assembly should be replaced » good performance of power steering is not assured if “mismatched” valve spool and valve body are used. Care should be exercised in the hanling of these parts to prevent damage. Sealing edges of the valve body bore and the valve spool should not be broken, This will result in excessive leakage and reduce hydraulic power. Should valve spool (158) or other waive components become disassembled follow the assembly procedures with care, Figure 75 Figure 77 oococwe? Figue 74 Figure 79 aremove second 3, thrust bearing package NOTE remove and 3M, disassemble oppet screw assembly remove retaining 25, ng 30 Remove the second thrust washer (14) and vrust bearing (15) from warm shaft (231. SEE FIGURE 80 NOTE: HF54 steering gears may be equipped with one of three alternate types of poppet Screws as shown on the expladed assembly view on pages 214 and 218. flerove poppet screw assembly or poppet sew and nut assembly from housng (86) as follows: Remove fut (54i, poppet adjusting screw (63) and ering 182), Discard p-ring, 11/16 inch socket required. SEE FIGURE 81 Or remove sealing nut (S44) and adjusting screw 1831, Discard seeing nut. 3/8 and S16 inch socket required. SEE FIGURE 82. Or remove non adjusting hex head pogpet screw (S3A) and ong (S24). Discard o-ing. 12 or QV16 ineh sueket required, SEE FIGURE 63 Remove spacer rng (SSA from bottam af hausing {55} rack piston bore ifthe housing is so equipped. SEE FIGURE 64. Figue 80 Figure 82 Figure 83 Figure 64remove bleed 36. Remove bleed screw (S58) if the housing is sa screw equipped, §/16 inch socket required, SEE FIGURE 88. ‘remove housing ‘37. The housing bearing assembly (67) should only be bearing if removed if you determine that only the bearing necessary musi be replaced efter following housing inspection procedures 8, 7, end B, Pace 2 suitable bearing mandrel that will clear the retaining ring (58) inside iameter vo apply pressure from the side cover opening and press ‘the bearing assembly out through the trunnion cover opening, SEE FIGURE BE, Maintsin » good ‘Square contact between housing and press bese to avoid damaging the housing besring bore, Discard bearing. Do not remove retaining ring (56) unless it must be replaced CAUTION (CAUTION: If the hearing is cocked while you [press it out, it will burnish the bore, causing it ‘10 become oversized. You will then have to replace the gear housing. press aut 3B, Press bearing (5! out of upper cover 17) with 2 ‘upper cover baring mare ogeist seal end of baarng and bearing only if itis to be replaced, Discard bearing, SEE FIGURE 87 Figure 8? ‘This completes the cisassembly of HFS steering gear. aInspection ‘Check to make sure that all sealing surfaces and seal cavtias are fee fromm ricks and corrosion, Hf any partis nicked or coroded where sealing occurs, you must replace the part to insure proper sealing. ‘© Wash all parts in clean petroleum-based solvent. Blow them dry with air only, WARNING WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. ‘WARNING WARNING: WEAR EYE PROTECTION AND BE ‘SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS, inspect rack 1. Inspect rack piston (38) teeth for cracks and piston teeth weer. If you can detect a sten by running your fingernail horizontally acrass the teeth surface, you must replace the rack piston, sector shaft (61) and ser of 22 bas (34), SEE FIGURE 6B. inspect ball 2, Inspect the rack piston internal ballsreck groves twack grooves {or brineling (dents) or spaling {Naking), SEE ‘on rack piston FIGURE B9. If either condition exists, you must and worm shaft replace the rack piston (38), worm shaft 123) and use @ set of service balls (34) NOTE NOTE: If @ ball (34A) (348) is lost during service procedures all 22 balls must be replaced with a service ball kit Damaged balls Would require & matched worm shaft, rack piston and ball set replacement. inspect worm ‘3. Inspect the worm shaft (23) ball tack grooves for shaft brineling or spaling. SEE FIGURE $0. If either condition exists, you must replace the worm shaft, rack piston (38), and the set of serie balls (341. Visually inspect the sealing surface on the worm shaft for nicks, and run your fingernail ledge across tha saaing surfaco 19 detect stops These conditions would raqure worm stft replacement and 8 service ball kit. If discoloration from excess heat is detected replace wocm shaft, vole rack piston, adaptor and upper cover assembly, SEE FIGURE 91, 2 Figure 68 Figure £9 Figue 81‘inspect valve ‘assembly CAUTION inspect thrust washers and bearing inspect hausing cylinder bore NOTE 5. 6 Inspect valve spool (158) and valve body (154) bore for broken sealing edges. SEE FIGURE 92 CAUTION: The valve assembly (15) is the control center of the hydraulic system. The major parts, which are the body and spool, are machined to vary clase tolerance and with precision machined edges. The valve spool and valve body are selectively fitted at the factory and therefare these two parts are not ‘separately replaceable. If either is damaged or excessively worn, the whole valve assembly should be replaced - good performance of power steering is not assured if “mismatched” valve spool and valve body are used, Gare should be exercised in the handling of these parts ta prevent damage. Sealing edges af the velve body bore and the valve spool should not be broken. This will result in excessive leakage and reduce hydrauic power. Should valve spool (158) or other valve components become disassembled, follow the assembly procedures with care, Figure 92 Inspect the thrust bearing 119) alles for any deterioration, spect the thrust washers (121 and (14) for einen, spaling, or cracks. SEE FIGURE $3. Reploce the part if you detect these conditions Inspect the hausing (5 cylinder bore, SEE FIGURE $4. You wil probably natice normal scaring marks running lengthwise through the bore, Since this scoring normel, you should nat compar it 10 the storing considered detrimental inthe cylinder ores of an internal combustion engine, Replace the housing only if youve tested it for internal leskage (as described in the Uwoubleshooting section on page 7) end you've determined that the scoring, and not damaged saa, is responsible for the excassve intrnal Weokage, greater than 1.6 GPM (6.7 tein.) NOTE: In running the internal leakage test after reassombly of the unit, make sure that ermal exceeding 1.5 GPM (6.7 fitersimin.) ean only be attributed to the housing and not to the improper assembly of the new seals in the worm shaft, rack piston, and valve assembly, before you replace the housing, Figure 94 ainspect housing faces inspect housing and side cover bearings inspect sector shaft assembly inspect adjusting screw and retainer NOTE Inspect the housing (55 faces for nicks thet ‘would prevent proper sealing. Replace the gear housing if these nicks are present and cannot be easly removed with a fine-toothed flat fie without changing the dimensional characteris ‘SEE FIGURE 86. Inspect the housing bearing ($71 and the side caver bearing for brneling or speling, SEE FIGURES 96 & 97. If either eondition exists, roplce the damaged housing bearing [57), For ‘the housing bearing, follow disassembly step 37 ‘and assembly step 1, pages 31 and 36. If the ‘de cover bearing & demagee, replace side cover sembly (43). Inspet the sector shaft (51} bearing and sealing areas and sector teeth contact surfaces for ‘wineling or spaling, SEE FIGURE 98. Run your fingernail edge across these areas to detect steps. Inspect also for cracks. Remave any masking tape irom the shaft serrations end inspect for twisted of otherwise damaged serrations. If any of these conditions exist, replace the sector shaft, Inspect the sector shalt assembly for damaged adusing screw (60) threads. The staked retainer (49) must be locked in place, and have no cracks. The adjusting screw must rotate by hand with no perceptible end play (lash. eptace adjusting sorew, if damaged. Replace the retainer, if damaged, or if the adjusting screw requires replacement or adjustment NOTE: A service shaft assembly veil have the adjusting screw (50) and retainer (49) assembled int it. The screw (50) and retainer 149) can be serviced separately if required. This completes inspection of HFEA steering goar ‘Figure 96 Figure 97Assembly Preparation ‘© Wash all parts in clean petroleum-based solvent, Blow them dry only. WARNING: WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY ‘SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. ‘© Roplace all seals and seal rings with mew anes each time you disassemble ‘the gear ‘© Rass Gear does provide individual seals, seal rings, as well as complete and partial seal kits, SEE FIGURE 99, These parts should be available through most OEM parts distutors. Contact your local dealer for avatiy. Assembly install housing 1. If you are installing a new housing bearing (57, bearing and first install the retaining ring (5B) into the groove retaining ring in the housing bearing (85) bore if it was removed. Place the housing, side caver face down on @ woaden block if necessary to pratect the cover face, Carefully press the bearing inta the housing from the trunrion gover sie until the bearing contacts the retaining ring, SEE FIGURE 100. During this procedure be sure the hausng is suare with tha press base and the bearing is nat ‘cocked. Lubricate bearing and set housing aside, 2, you ae insaling @ mew needle bearing (5) nto ‘into upper the uppar cover (7), @ suitable pressing mandrel caver must be fabricated which will pilat on the inner diameter of the needle bearing and have earance in the bearing tore, Place the mandrel ‘against the lenered end af bearing and press bearing ita upper cover bearing bore from the valve face side until the bearing i positioned 1.13 inch (28 mm) trom upper cover valve fae, Alter the beering assembly is pressed in upper caver ‘the bearing rollers must orbit and rotate freely in bearing shel. Lubricate bearing. SEE FIGURE 101 clamp valve body 3. Assemble @ hydraulic fitting securely in walve body ar assembled valve (15A) hydrauic por. Clamp vale body assembled body in vise cr disassembled securely in a vise, clamping ‘against the hydraulic fitting or port bosses. Position vale bay in the vise so thet worm shalt, adaptor and upper cover can be assembled SEE FIGURE 102. Figure 102 6CAUTION CAUTION CAUTION NOTE cossembly of valve spool plungers and spring sets. NOTE NOTE 36 CAUTION: Use only the correct size standard ‘344-16 or Q/16-18 JIC-SAE bydrauiic fitting in the valve ports. The use of # wrong fitting ‘such 8 pipe fitting will damage the valve port and require replacement of the complete valve assembly. CAUTION: Clamp valve body only as directed and use care not to clamp against machined valve faces or sides of valve body. This could damage sealing surfaces or distort valve bore. When clamping against valve port bosses do ‘ot tighten vise with extreme force as this ‘ould distort valve ports. he valve assembly is unique to the HF54 steering gear flaw rate ‘application. Use only the spacifiod valve ‘assembly replacement to ensure proper operation. NOTE: If valve assembly components are not tisossembled go to assembly procedure 47. Ht vahe assembly 15) is disassombled, seer the enlarged exploded view, on pages 214 & 218, Assembla vale spool (158) into valve bady (SAL The and of the vale spool with identification grooves in the bare arin the undercut ar reliet on the autside diameter must be towerd the adaptor side or face of valve boty after sssemiiy. The adeptor sie or fae of the valve body has two Ibid) cylinder feed hoes that do nat extend through to the opposite side or face. On some vale bodies the cast identification # boss is pointed on the end toward the adaptor side or face. SEE FIGURE 103. Assemble o plunger 115C1 » spring (15D) and ‘anther plunger {18C) in that order in six thraugh Holas in the valve body (1A) as shown in the enlarged exploded view on fold out pages. SEE FIGURE 104. NOTE: The twa oil transfer holes designated in the enlarged view are too small to accept lungers. NOTE: Some valve assemblies (15) may have one inactive (long) plunger instead of the set of twa active plungers (15D) and a spring (15D) in four of the plunger holes in the valve body (15). Assemble these inactive Gong) plungers evenly as possible among the active plungers (15D) sets in the circle of plunger holes if their original positioning was not noted during disassembly. Figure 104 Figure 105 Figure 106‘assemble check = 6, assemble first r thurst bearing package on worm shaft ‘essemble worm ‘subassembly into valve assembly assemble thrust 4. bearing package lockwasher and nut ‘torque bearing MN. lock nut ‘Assemble » ball (15F¥ and conical spring (156), small end first, inta the two check valve plungers ((18E! if they became disassembled. Assemble one check valve plunger assembly, 8 spring (16D) and ‘hen the other check valve plunger assembly into the remeining vale body plunger hole as shown in the exploded view. The spring end of the check valve jungers must face each other when ‘essembled in valve body. SEE FIGURE 105. Assemble thurst bering (13) and thrust washer 114) on the input Iserrated! end af worm shaft (23) and against worm shaft shoulder. SEE FIGURE 106. Assemble the input (serrated) end of the worm shit (23) with bearing package into the adaptor ‘end af the valve spac! 1188) bore as described in ‘procedure #4, until shaft and beeing assembly ‘tops against the spool. SEE FIGURE 107. ‘Assemble the other thrust washer (14), thrust beating (131 and thrust washer (12) anto the imput (serrated) end of worm shakt (23) and ‘against the valve spool (158), SEE FIGURE 108. Assemble washer 111) then @ new bearing lack- washer (101 onto worm shaft (23), The internal washer tangs must enter slot in worm shaft and the external tangs of bearing lock washer must face out. SEE FIGURE 108. Assemble bearing lock rut 9), large chamfer side in, onto threaded ciamater of worm shaft until components are at Solid height and snug against valve spoot (158) Torque the bearing rut 19) 10 30 ft. Ios. 41 N inl ta seat the components. Back the nut off and then torque ta 15-20 ft, Ibs. (20-27 N mi. SEE FIGURE 110, Back the nut off approximately 20 degrees ond bend one tang af lock-washer (101 inta @ matching nut slot. SEE FIGURE 117, & hook tyne spanner wrench, 2 3/4 or 11/16 inch 1 point socket and a ft. Ib. (N ma) torque wrench required, Figure 109 Figure 110 Figure 111check warm 12 shaft rotation NOTE assemble 13 washer seal and retainer into adaptor assemble seal 14, ings assemble 15. adaptor on ‘worm assembly 8 Check for free rotation of worm shaft (23) in vale assembly (161 and for perceptible end play. ‘SEE FIGURE 112, NOTE: The worm shaft in the above assembly should rotate at 3 to 5 inch Ibs. 94 to 57 N m). No end play should be evident. Assarble beck yp washer (20! and then mew seal (21) inta adaptor (18) so that sea! lig is facing ‘out of seal cavity. SEE FIGURE 173. Assemble retaining ring (21. SEE FIGURE 114. Coat each new seat ring liberally with clean reese {or retention and assemble new seal rng (81, thee new seal rings (1B), new seal rng (18) in the appropriate recesses provided in adaptor (18), SEE FIGURE 115 Assemble the edoptar (1B) onto the rack piston tend of worm shaft (23) assembly with the side with four threaded holes against the face af the vvolve assembly end the cylinder feed holes in ‘adaptor and valve body FTBA) aligned, SEE FIGURE 116. Figue 119 Figure 174 Figure 115 Figure 116assemble ‘16. On a clean work surtate, assemble new seal (4) upper cover into upper cover (7) wth the seal ip facing the seal, spacer, Upper cave: bearing. Grease and assemble new retaining spacer (3). SEE FIGURE 117. Install retaining ring ring and (2) securely inta the upper cover retaining ring seal ring groove, SEE FIGURE 118, Retaining ring pias or small sere driver required, Apply clean graase liberally to new seal ring (B) ond assemble it inta the upper cover recess provided. Figuee 117 ee Fue 118 ‘tape worm: 17, Tape the warm shaft (23) serrations and lightly shaft coat the remaining portion of the worm shaft serrations with ol, SEE FIGURE 119 install upper cover (7) assembly carefully over worm shaft (24) serrations, aligning the upper ‘cover, wale body (164) and adaptor (18) in their ccignal positions. SEE FIGURE 120, NOTE INOTE: If a line was scribed acres these ‘components before disassembly you can now utilize the fine to align these components. assemble 18. Assemble four upper coves bolts 16) and washers ‘upper cover (BA), Carefully tighten the bolts while checking bolts: and that the adaptor (18) valve assembly (151 and washer upper caver (7| faces are property piloted and positioned with all seal rings in place. Torque bolts to 25-36 ft. Its. 194-47 Nm) if dry, oF 21-27 ft. tbs. [28-37 Nm) if lubricated. 8116 inch socket required. SEE FIGURE 121 Figure 121 8assemble seal a ‘components on warm shaft ring on ‘worm shaft ‘install 2 piston ring deen and 2 apply locquic to rack piston ‘and poppet seats ‘opply studlock = 24, and assemble poppet seat Assemble onto the rack end of warm sheft 123) stool washer (24), news seal (25), with sharp comer side towerd steel washer, new seal cup (26) with counter bore toward seal, bronze back ‘up washer (27) and retaining washer (28) with counter bore out. SEE FIGURE 122 Compress the seal components just assembled on ‘worm shaft [23] and assemble retaining ring (28). Be sure the retsining rng is prapetly seated in its groove in the worm shaft and in the retaining washer (26) counter bore, SEE FIGURE 123 Remove subessembty from visa Place rack pistan 139) in a soft jawed vise in @ horiontel pasion. Carefuly expand piston ring (BAI over end of rack piston and install in the ring groove. SEE FIGURE 124 Hf ponpets ware removed, clean the two threaded poppet seat holes in the end of the rack piston (91 with cleanfclear solvent and blow dry. Aoply Locquit grade “T” primer to the threaded holes ‘and 10 the two poppet seat (30) threads and allow 10 dry for ten minutes. SEE FIGURE 126, When the Locquic primer has dryed for 10 minutes, aply Std Lock to poppet seat (30) Urns and threaded poppet hole at one end af rack pston (38), Assemble the poppet seat inta that end of the rack piston and torque to 20-25 ft Ios. (27-34 N m). 9/16 inch socket required. SEE FIGURE 126 AND 127. Figure 124 Figura 125 Figure 126assemble 2, boppet components assemble worm B. shaft assembly into rack piston NOTE 2m. WARNING Insert @ poppet (31), spring (32), cod (38) and another popaet (31) at the opposite end of rack piston poppet hole. Apply Stud! Lock to the sacond papnet seat (30) threads and its’ theeded hole in the rack piston. Assemble the second foppet seat (30) and torque to 20425 ft. ths (27-34 N ml. SEE FIGURE 128, Alow Stud Lock 10 dry 20 minutes before adcing hyrauic id Remove the rack pistan fram vise and place on a Clean cloth covered work surface with the ball return guide holes up. Lubricate the rack piston (381 warm bore and worm shaft seal (25) with ceen grease. And assemble worm shaft (23) as assembied into rack piston bore sa that the rack piston ball guide holes are aligned over the worm shaft ball track groaves and the warm seal is positioned in the rack piston worm bore. SEE FIGURE 123 NOTE: IF the original set of 22 balls are being reassembled, they must be segregated by micrometer measurement into a group of 11 large balls (344) and a group of 11 small ‘spacer balls (34B). Tha small spacer balls ‘were originally colored black for identification 485 are the spacer balls in a service ball kit ‘The set of original large (working) balls vill ‘measure .0005 inch (.01270 mm) larger than ‘the spacer balls. SEE FIGURE 130. Insert the eraser end of @ pencil into one ball return guide hole in the rack piston (39) as far as ‘it will go. Alternately insert one large ball (34Al ‘then ona small (spacer) ball (348) into the other tall return guide hole while slowly tuning the vworm shaft ¢23) 10 work each ball own the same ball grogve path an one side of the worm shaft and up and around toward the other ball return guide hole. When 16 balls are inserted, remove pencil. A ball should be visible at each bball return guide hole. SEE FIGURE 131, WARNING: BE SURE EACH BALL INSERTED STARTS DOWN THE BALL GROOVE ON THE CORRECT SIDE OF THE WORM SHAFT. 00 NOT ALLOW THE WORM SHAFT OR RACK PISTON TO ROTATE AFTER THE PENCIL IS REMOVED UNTIL THE BALL RETURN GUIDES ‘ARE RETAINED IN THE RACK PISTON. SUCH ROTATION COULD MOVE A BALL OR BALLS. INTO THE DEAD TRACK BEYOND THE BALL RETURN GUIDE LOOP (PASSAGE) RESULTING IN A STEERING LOCKUP WHICH COULD CAUSE AN ACCIDENT, Figure 128 Figure 128 ane, Figure 131 41instal ball 2 return guide halves and balls CAUTION WARNING: ‘assemble ball a return uide clip WARNING WARNING position ww. housing in vise a Coat @ ball return guide al (35) iecelly with grease and insert the remaining 6 balls atterately large (344) and small (348) (black) into the Qreased guide half, SEE FIGURE 132. Join the (ides halves together and firmly seat tis subessembly inta the réck peston (39) ball return wide holes. CAUTION: The grease must hold the balls in the return guides unt the guides are seated in the rack piston, WARNING: DO NOT SEAT THE BALL RETURN GUIDES WITH A HAMMER. DAMAGE TO THE GUIDES GAN RESULT IN SUBSEQUENT LOCK: UP OR LOSS OF STEERING. Install the ball return guide clip 136] so that the holt hole faces are in full contact with the rack piston (39) surface. Install the two new lock tabs (37) and the two hex head sorows (36). SEE FIGURE 133. Torque sorews to 8-10 ft Ibs. (17-14 NN m), Bend up lock tabs apainst the screw heads. 7/16 inch socket remuired. SEE FIGURE 134, WARNING: ROTATE THE WORM SHAFT WHILE HOLDING THE RACK PISTON, FROM END OF TRAVEL TO ENO OF TRAVEL, TO MAKE CERTAIN THAT YOU HAVE INSTALLED ‘THE BALLS PROPERLY. IF YOU CANNOT ROTATE THE WORM SHAFT, YOU WILL HAVE ‘TO REMOVE THE BALLS AND REASSEMBLE ‘THEM. IF YOU INSTALL THE GEAR ON A VEHICLE WITH THE SHAFT UNABLE TO ROTATE, THE GEAR WILL NOT FUNCTION. SEE FIGURE 135. WARNING: DO NOT ALLOW RACK PISTON TO ROTATE TO THE EXTREME LOWER END OF WORM TRAVEL BY IT'S OWN WEIGHT WHILE ‘THIS SUBASSEMBLY IS NOT CONTAINED IN ‘THE GEAR HOUSING. THIS COULD DESTROY ‘THE SEAL PACKAGE AT THE LOWER END OF WORM, CAUSING LOSS OF POWER STEERING IN QNE DIRECTION. Position housing (551 firmly in vise positioned as it was for the disassembly procedures. SEE FIGURE 136. Figure 132 Figure 133 Figure 134 Figure 138 Fue 136grease piston ring and housing bore insert the assembled rack piston assembly position adaptor _ageinst housing NOTE a. 2. 33 3. | a spacer ring (GSA) wes removed from the housing (86) assemble and seat the spacer ring in the bottom wf the housing retk piston bore. SEE FIGURE 137. Ht you removed a non adjustable hex heed poppet screw [53A) end o-ing (S2Al from the housing, assemble a new oving (S2A) an the poppet screw. Install the poppet screw assembly in housing (65) and torque screw to 15-20 ft. hs. (20-27 N ml, SEE FIGURE 198. 1/2 or 816 inch hex socket required. Hf you removed nut (541, poppet adjusting screw (53) and o-ring ($21, assemble a new o-ing (521 ‘and the rit an the adjusting serew and tum the screw assembly into the housing 155) until 7/B inch (22 mm of screw thread protrudes from the housing, Uf you removed sealing nut (6441 and poopet adjusting strew 1598), turn the threaded end of the adjusting screw inta the end of a naw sealing fut 154A) away from its seal sa that the seal wil face the housing, Tum the screw assembly a few turns ito the housing. The final ausiment of ither type of adjustable poppet screw must be ‘made after the assembled gear is instaled on the vehicle Agply # generous amount of clean grease 0 the piston ring (384) on assembled rack piston and to ‘he housing (65) rack pistan bore, SEE FIGURE 129, Insert the assembled vack piston (3) into housing (55) and position rack teeth to be visible through the side cover opening and the pogpet (31) in ling with poppet scraw in the housing. AS tha rack piston enters the Wbriceted hausing bore compress piston ring (GBA and wark the rack piston into assembled position. SEE FIGURE 140 Move tbe adaptor (18) against housing (86) with ‘their bolt holes aligned and their cylinder feed (ail transfer hole aligned. Tha poppet recess in the ‘adaptor must ign with poppet (31) and seal ring (19) and seal rng (16) must be in place. SEE FIGURE 141 NOTE: The fines stribed before disassembly can again be used to insure correct assembly ‘alignment. Figure 141 aadaptor bolts and washers adjusting screw and retainer WARNING grease side 38. cover bearing CAUTION assemble #8 retaining ring assemble side 40. cover seal pack WARNING 48 ‘Assemble four bolts (17) through adaptor (18) into hhousing (56). Torque bolts to 48-55 ft. Ibs. (61-75 Nom) if dry or 42-62 ft Ibs, (57-71 N mid if lubricated, A 7/16 inet 12-point socket required, ‘SEE FIGURE 142, IW the adiusting screw (801 has been removed from the sector shaft (G1, clamp the sector shaft into a sol-faced vise by gripping the serrated end. Cost the expanded end of the mew adjusting screw with a suitable grade of whee! bearing (tease and insert into recess in end of sector Shalt. Thread @ new sector shaft screw reiziner (49) into the sector shaft and adjust 10 permit free corating of sector shaft adjusting screw by hand without perceptible end play, 000 to .002 in. 05 mm! Noose. Stake the new retainer into the two slots provided using a suitable punch and ‘again check freedam of adjusting screw mmavement and end play. SEE FIGURE 143, WARNING: USE CARE IN SECURELY STAKING THE RETAINER (49) INTO THE SECTOR SHAFT SLOTS. A RETAINER THAT IS BROKEN OR CRACKED DURING THE STAKING PROCEDURE MUST BE REPLACED AS IT COULD RESULT IN THE SECTOR SHAFT NOT BEING RETAINED AND THE LOSS OF MANUAL ANO POWER STEERING CONTROL. Apply a generous amount of clean wheel bearing grease (do not substitute another type of grease) to the bearing in side cover (431, SEE FIGURE 144, CAUTION: Use only wheel bearing grease. This bearing is sealed and will receive no lubrication ‘rom the hydraulic fuid in the gear. Without ‘Wheel bearing grease, the bering could wear prematurely. Assemble retaining ring (46) into side cover [43] fing groove closest to the beer, ifthe retaining ring wes removed. Assemble the steel backup washer {46} into side caver (43), Assemble 8 new Teflon washer [47] then 8 new two piece seal [48) into the side Cover, such that the words "Diside” are visible after the seal is assembled. SEE FIGURE 146, Grease and assamble naw seal ring [43A) into side cover. SEE FIGURE 148, WARNING: THE WORDS “OIL SIDE” MUST BE VISIBLE ONCE THE SEAL IS IN PLACE. OTHERWISE, THE SEAL WILL NOT FUNCTION, WHICH COULD RESULT IN A LOSS OF POWER ‘STEERING ASSIST. Figure 142 Figure 143 Figure 144 Figure 145 Figure 146assemble 4 NOTE install 42, sector shaft into side CAUTION NOTE assemble seal 43. ring and steel ‘and Teflon washers into side cover assemble 4, ‘Assemble retaining ring (621 into its’ ring groove inside caver [43), SEE FIGURE 147 NOTE: Retaining ring (62) is not included in all HF54 steering gears. Apply @ generous amount of clean grease to the short bearing area of the sector shaft (61), Insart the sector shaft carefully into the side cover 143). Screw in the sector shaft adjusting screw (501 counter-locowiseinta the sde caver until the screw reaches solid height, Then, rotate the agjusting serew clockwise one turn, 30 that the sida cover will rotate frealy on the sectar shat SEE GUE 148. CAUTION: Be sure the two piece seal remains correctly assembled and that the vent plug (41) has been removed during these procedures, NOTE: If the side cover two piece seal (48) cannot be maintained in postion when the shaft (51) is assembied into the shaft side cover (43) using procedures 440, #41, and a go to alternate procedures #43, #44, and Grease and assemble seal ring (434). Assemble the steel backup washer (46) aad thei the new Tefian washer (47) into the side cover 143} bearing bore. SEE FIGURE 148 Slide retaining ring (62! if required onto the cover end of sector shaft (51). Assamble the new twa- piece seal (48| onto the end of the sector shaft about 1 inch (25.4 mm). The words “Oil Side" on the seal must face toward the sector shaft. SEE FIGURE 150, Figure 147 —— Figure 148 Figure 149 Figure 150install 46, sector shaft ima side cover CAUTION instal jam 16. ut assemble vent 47. plug WARNING: center rack 48. piston 45 Be sure the side caver bearing, the sector shaft beating diameter and seal are well greased, then insert sector shaft (61) assembly ino the side cover (43) bearing and tum the adjusting screw {50} into the side cover about 8 turns. Slowly and carefully work the two piece seal (48) down the ‘sector shaft and squarely inta the side cover until it is past the retaining ring groove. Then wark the reteining ring (62) if inched inta the reteining ring groove. Use an appropiate blunt fend punch ar punches, SEE FIGURE 151, Carefully turn the adjusting screw (50) trough sie caver ‘until it reaches solid height then beck screw one ‘turn, so that the sida cover ratates freely on sector shaft CAUTION: Be sure the two piece seal remains ‘corectiy assembled and that the vent plug (41) has been removed during these procedures. Install the sector shaft adjusting serewy jam nut (40) onto the sector shaft adjusting screw (80) a few threads. Final adjustment vail be made later. SEE FIGURE 152, Prass a new went plug (41) ita tha hole prawided in the sido cover (23) until the plug is Mush, SEE FIGURE 163. WARNING: 00 NOT WELD OR OTHERWISE PLUG THIS HOLE IN ANY PERMANENT MANNER. THIS IS A SAFETY VENT WHICH FUNCTIONS ONLY IF THE SIDE COVER SEAL FAILS. IF THE SEAL FAILS AND THE PLUG CANNOT VENT, THE STEERING GEAR MAY LOCK UP OR OTHERWISE MALFUNCTION. Theee are five full teeth on the rack piston (38) ‘SEE FIGURE 154. Rowte the worm shaft (231 to position the center rack piston tooth (third tooth from large end) in line vat the center of the housing sector shaft bore, SEE FIGURE 155, Figure 151 Figure 183WARNING: add timing 4a mark to sector shaft install sector 50. shaft and side cover assembly CAUTION install side St ‘cover bolts NOTE install trunnion 52, cover washer ‘and seal WARNING WARNING: IF THE RACK PISTON IS NOT CENTERED WHEN SECTOR SHAFT IS INSTALLED, GEAR TRAVEL WILL BE ‘SEVERELY LIMITED IN ONE DIRECTION. THIS COULD RESULT IN AN ACCIDENT. It there is not @ timing mark on the end af sectar shaft (61) add a timing mark ith chalk or marking pencil on the and of the sector shaft in line with the center of the canter tooth space. SEE FIGURE 156. Remove any old tape fram sector shaft (51) serrations and apply ane layer of naw tape to shalt serrations and batt groove if nacessary to protect seal. Install sect shaft and side caver assembly into housing (5S, The sector shaft center tooth space as indicated by the timing ‘mark an the end of sectar shaft must engape the rack piston (39) center tooth, SEE FIGURE 157, CAUTION: Be sure seal ring (43A) is in place. Install the four spacial side cover bolts (421 and \washers (424) inta the side cover and torque them to 45-55 ft, lbs. 167-75 Nm) if dry or 33-40 ft, Ibs, (45-54 N nb if lubocated. 6/8 inch or T-50 Torx socket aquired. SEE FIGURE 158, NOTE: One or more of the side cover bolts may be flat head TORX bolts (428) for clearance purposes. Place the trunnion caver (591 exterior face down ‘on a bench and install the new Teflon backup washer (47) and then the new two piece seal (481, The words: “Oil Side” on the seal must be visible after assembly. SEE FIGURE 158. WARNING: THE WORDS “OIL SIDE” MUST BE VISIBLE ON THE SEAL AFTER IT IS IN PLACE. IF NOT, THE SEAL WILL NOT FUNCTION, AND A LOSS OF POWER STEERING ASSIST MAY OCCUR. Figure 185 Figure 156 Figure 156 Figure 168 alinstall seal install ‘trunnion caver ‘and bolts assemble sector shaft protectar seal ‘assemble worm ‘shaft protector seal assemble bleed screw ‘This completes assembly of the HFB4 steering gear. Before you install the gear onto th vehicle, make final adjustments described on page 42, Al ports should be plugged until unit is installed in vehicle 4a 53, 54 56, 58. 51 Grease the mew trunnion cover seal ring (58) and install tint the trunion cover (59) sea ring qoove Figure 160 Pack seal area of sector shaft (51) with clean high temperature industrial grease per Rass specication 045231, Mobil Temp 1 or 2 oF cequivalant, Carefully install the trunnion caver (65), SEE FIGURE 160. install the four tunnion cover screws (60) and torque them 1a 1328 ft. ths. (1891 N mf if dey or 11-16 ft. Ibs. 15-22 N inh if lbricated. A 6/16 inch 12 point thin wll socket required. SEE FIGURE 161 Figue 161 ‘Add mare of the special grease to the cupped ‘Side of protector seal (61) and assemble aver sector shaft (61) and trunnion cover 158). SEE FIGURE 162. ‘Add the special grease 10 cupped side of protector seal |1) and assemble seal over worm shaft (23) and upper cover (7), SEE FIGURE 163 Faure 163 If bleed screw (558) was removed fram housing (85) reassemble and torque to 27-33 in. tbs. (8.1.3.7 N ml, SEE FIGURE 164.Final Adjustments center steering 1 To center the steering gear, rotate worm shaft ‘ear (2) unt the timing mark: on the ed of sector shaft [51) is perpendiculr to the worm shaft ‘SEE FIGURE 165. A 12 point 11/16 or 3/4 inch ‘box end or socket required. NOTE NOTE: Worm, valve thrust bearing preload adjustment was accomplished i procedure 11, page 37. ‘tighten 2. Tighten sector shaft adjusting screw (60) 10 adjusting screw provide 20-26 inch ths. (2.3-2.8 N m! of torque Tequired to rotate the worm shaft (23) through 930 degrees each side of center. SEE FIGURE 166. NOTE NOTE: This procedure will properly mesh and ‘seat th piston teeth and sector shaft ‘teath for final adjustments. loosen 3, Lonsen sector shaft adjusting screw (60) one turn adjusting screw ‘and nate maximum torque required to rotate: the and note torque worm shaft (231 through 90 degrees each side af center. adjust 4, Adjust sector sheft adjusting serew (501 10 adjusting increase maximum torque noted in procedure #3 seiew by 2 ta 4 inch Ibs. 1.28 to .45 N mi. Torque jam ‘nut (40) using 2 3/4 inch socket, to 40-45 fh, fs. (84.61 Nm} and check warm shait torque agai, Readfust if worm shaft torque exceeds 15 inch bbs. 11.7 Nm), This completes the final adjustments of the HFS4 gear to be made before it is installed into the vehicle's steering system. Install the gear by folowing instructions in the vehicle shop manual. Then follow the succeeding sections of this service: manual HFS4 on "HYDRAULIC FLUID” and “FILLING AND AIR BLEEDING THE SYSTEM” which also includes instructions for adjustment of the adjustable poppet valve. Figure 165 uA ua Figure 165 950 Hydraulic Fluid Keeg the stearing system filled with one of the following fluids: AUTOMATIC TRANSMISSION FLUID TYPE “E” or “F ‘ORD SPEC. M2C13BC) AUTOMATIC TRANSMISSION FLUID DEXRON It ‘SHELL ROTELLA T SAE a0 MOBIL cece cee e etter eter eer eeeeee eee SAE TOWED ASHLAND SAE 10W40 UNION eee cece eee weer ee SAE TOWED TexACO ‘SAE 1040 MOBIL eee eee ee cree essere SAE TOWED WARNING: COMPLETELY FLUSH THE STEERING SYSTEM WITH ONE OF THE RECOMMENDED FLUIDS ABOVE ONLY. D0 NOT MIX OIL TYPES. ANY MIXTURE OR ANY UNAPPROVED OIL COULD LEAD TO SEAL DETERIORATION AND LEAKS. A LEAK COULD ULTIMATELY CAUSE THE LOSS OF FLUID, WHICH COULD RESULT IN A LOSS OF POWER STEERING ASSIST. Filling and Air Bleeding the System CAUTION: For steps 1 and 2, do not tun the steering wheel. Otherwise, ar may be induced into the system. 1. Fil the resarvoir nearly full. Crank the engine for 10 seconds without, if possible, allowing it to stort. Ifthe engine does start, shut it down immediately. Check and refill the reservoir. Repeat at lesst three times, each time checking and refiling the reservoir, CAUTION: Da not allow the fiid to drop significantly or run out of the reservair. This may induce air into the system 2. Start the engine and let it idle for 2 minutes, Shut the engine off and check the fluid level in the reserva 3. Stat the engine agen. Steer the veicle from full lft to full ight turn several times: ‘Add fluid, as necessary, to the fil line on the dipstick. NOTE: Poppets, equipped on the gpar, must be adjusted so that they relieve pressure at full left and right turns to sid in the removing of air from the system. At this time, make sure any poppets are properly adjusted. If they are not, adjust them in accordance with section 4 Ipage 19) and repeat step 3, The above procedures should remove all the air from the steering system, unless the gear is mounied in an inverted position end is equipped with the manual bleed screw (858) (See FIG. 164, Page 4B). If this i so, refer to step 4,4. Remove the air from a gear mounted in an inverted position and equipped with a ‘manyal bleed screw (558) by fallowing steps 1, 2 and 3 above. Then, with the engine ‘idling, steer the gear from full left turn to full right tum several times. Loosen the rmanval bleed screw shout one tur, with the steering gear in neutral (na steering ‘ction, allowing ar and aerated fiuid to “bled out” around tha blaed screw until only dear {non aerated) fd is bleeding out then close the bleed screw. 5/16 inch socket required. Check and refill reservoir. Repeat this provedure 3 ar 4 times starting with the steering maneuver with bleed screw closed, un only clear (non sereted) fuid is discharged whan blead screw x loasaned, Torque the manual bleed sszew to 27-39 in, Ibs. (3.13.7 Nm), Check and vrafill reservoir, CAUTION: Do not tum steering wheel with bleed screw loosened as this could induce air into the system. Warnings for Proper Steering Gear Operation WARNING: DO NOT WELD, BRAZE OR SOLDER ANY STEERING GEAR OR SYSTEM ARM COMPONENTS, WARNING: MAXIMUM FLOW UNDER ANY CONDITIONS MUST NOT EXCEED VEHICLE MANUFACTURER'S SPECIFICATIONS. WARNING: MAXIMUM OPERATING PRESSURE MUST NOT EXCEED 1500 PS! (103.4 bar WARNING: ALWAYS CAREFULLY INSPECT ANY STEERING COMPONENT WHICH HAS BEEN (OR 1S SUSPECTED TO HAVE BEEN) SUBJECTED TO IMPACT. REPLACE ANY DAMAGED OR QUESTIONABLE COMPONENT. 5Steering System Maintenance Tips 52 —Prevent internal bottoming of the steering gear. Careuly check axe stops to be ‘sure that they meet the manufacturer's specifications. —fiegularly check the tid and the fluid level in the power steering reservoir. Keep tires inflated to conrect pressure, —Always use 2 puller, never a hammer ar torch, to remove pitman arms Investigate and immediately corect the cause of any play, rattle, or shimmy in any part of the steering linkage or steering mechanism, —Remave the cause of steering column misalignment. Encourage al drivers to report any malfunctions ar accidents: that could have damaged steering components, —Da not attempt to weld any broken steering companent. Replace the component with orginal equipment ony —Da not cold straighten, hot straighten, or bend any steering system companant Always clean off around the reservoir filer cap before you remave it. Prevent dirt or ‘ther foreign matter fram entering the hydraulic systems, Investigate and correct any externa leaks, no matter how minor. Replace fiters and pumps in campiance with specification, —Hf extended stationary use of vehicle is devoloning excessive hydraulic fhid Temperatures consult vehicle manwlacturer for auclary cooling method. —Meimain grease pack applied behind the ingut end output shaf's pratector seal as @ general maintenance procedure,HF54 Series Service Procedure aw WRITE Om CALL FOR BWFORWATION AND ADDED DETAR ‘CONCERWNG YOUR INSTAILATION AND APPLICATIONS, Pune 3174735077 Tap: Bia WRITE; TW ROSS GEAR DIVISION ‘0 ear STREET LAFAYETTE, olan 4792 vest