Clutch Steering System: Repair Manual Repair Manual

Repair
Repair Manual
Manual MAN-00103
BOLERO MAXI TRUCK CNG – BSIV NOV 2010/Rev 1
STEERING SYSTEM
CLUTCH
The repair
The repair methodsmethods
givengiven
by thebymanufacturer
the manufacturer
in thisin document
this document are based
are based on theontechnical
the technical specifications,
specifications, current
current at theattime
the time of release.
of release. The methods
The methods may may be modified
be modified as a as a result
result of changes
of changes introduced
introduced by the
by the
manufacturer
manufacturer in theinproduction
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
whichwhich the vehicles
the vehicles are manufactured.
are manufactured. The rThe r eproduction,
eproduction, translation,
translation, transmission,
transmission, in of
in part part
or of or whole
whole of theofpresent
the present document,
document, 133
283
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. Ltd. The of
The use use ofdocument
this this document byperson
by any any person
otherother
than than the trained
the trained personnel,
personnel, at theatAuthorized
the Authorized Service
Service CentreCentre of Mahindra
of Mahindra & Mahindra
& Mahindra
Ltd., Ltd., will amount
will amount to unauthorized
to unauthorized use shall
use and and shall be liable
be liable for penalty/prosecution©
for penalty/prosecution© 20102011 Mahindra
Mahindra & Mahindra
& Mahindra Ltd. Ltd.
Repair
Repair Manual
Manual MAN-00103
CLUTCH
Contents…
� Description……………………………………………………………………………. 285
� Trouble Shooting………………………………………………..................... 286
� Care of the System………………………………………………………………… 290
� In Car Repairs………………………………………………………………………… 291
� Dismantling…………………………………………………………………………… 294
� Specification………………………………………………………………………….. 301
� Tightening Torques………………………………………………………………… 302
� Lubricants & Sealants…………………………………………………………….. 302
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
284
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Description -
The steering system of a vehicle is not only important for safety reasons but also enhances the
comfort level of the vehicle. The steering system enables the driver to negotiate bends and
maneuver the vehicle at his will.
There are two basic types of steering system, mechanical steering and rack & pinion steering.
The standard mechanical steering can be either power assisted or non-power. Rack & pinion is
always power assisted type.
The mechanical steering system consists of steering gear, steering knuckles, steering connecting
rod. Master tie rod and steering damper. The steering connecting rod transmits the movement
of drop arm to the steering knuckle through the master tie rod, which has the ball and socket
type joints at the ends.
Mechanical steering uses a series of links and arms to insure both wheels turn in the same
direction at the same time. The steering wheel is connected to the steering box through the
steering column. The steering box turns the rotation of the steering wheel.
Another toe rod connects the steering drop arm with the single master tie rod. The vehicle is
equipped with different kinds of connecting rods having ball and socket type sealed joints at
both ends. The ball and socket tie rod should be replaced if any end play is noticed.
Steering Gear Mounting –
� The steering gear is rigidly mounted on the right side chassis member ahead of the front
axle with four M12 bolts.
� The steering column is bolted to the dash unit with the brackets provided on the column
and is further supported in the floor board with brackets and clamp.
� A floating intermediate shaft which passes through the cross member connects the
steering column and gear housing with two universal joints on its ends.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
285
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Trouble shooting –
The problems in steering, suspension, wheels & tyres engross several systems, all to be considered when
diagnosing a complaint. It is recommended to test drive the vehicle for better understanding on the
customer complaint.
Ensure followings before vehicle test drive –
1. Inspect tyres for correct air pressure/ uneven wear if any.

2. Lift vehicle on a hoist and inspect front and rear suspension.
3. Spin front wheels. Inspect for wheel jam, unbalance tyres, bent or damaged rims, loosen and/or
rough wheel bearings.
SYMPTOM CAUSES REMEDIAL ACTION

Vehicle Pulling 1. Mismatched or uneven tyres. � Replace tyre.
2. Uneven tyre pressure. � Adjust tyre pressure.
3. Disturbed front wheel alignment. � Check and do front wheel
alignment.
4. Brake dragging in wheel. � Check and adjust brakes.
5. Loose, bent front or rear � Tighten or replace suspension
suspension components. components.
Abnormal/ Excessive 1. Sagging or broken spring. � Replace spring.

Tyre Wear 2. Unbalance tyres. � Adjust balance or replace
tyre.
3. Disturbed front wheel alignment. � Check and adjust front wheel
alignment.
4. Faulty shock absorber. � Replace shock absorber.
5. Tyre rotation not done. � Rotate tyres.
6. Worn or loose wheel bearing. � Replace wheel bearing.
7. Tyres not adequately inflated. � Adjust tyre pressure.
Wheel Tramp 1. Blister or bump on tyre. � Replace tyre.

2. Improper shock absorber action. � Replace shock absorber.
Hard Steering 1. Tyre not adequately inflated. � Adjust correct tyre pressure.
� Replace tie rod end or lower
2. Bend in tie rod end or lower ball ball joint.
joints. � Check and adjust front wheel
3. Disturbed front wheel alignment. alignment.
� Repair or replace.
4. Bind in steering column.
Steering Wheel Play 1. Wheel bearings worn. � Replace.
2. Worn steering shaft joints. � Replace joint.
3. Worn tie rod ends or ball joints. � Replace tie rod end or tie rod.
Steering Return ability 1. Bind in tie rod end ball studs. � Replace tie rod end.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
286
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
Poor 2. Bind in ball joints. � Replace.
3. Bind in steering column. � Repair or replace.
4. Lack of lubrication in rack and � Check, repair or lubricate rack
pinion. & pinion.
alignment.
6. Tyres not adequately inflated. � Adjust proper tyre pressure.
Steering Stability Poor 1. Mismatched/ uneven tyres. � Replace tyres.

2. Loosen ball joints and tie rod ends. � Replace ball joints or tie rod
end.
3. Faulty shock absorber. � Replace shock absorber.
4. Loose stabilizer bar/ bush worn out. � Tighten or replace stabilizer
bar or bush.
5. Broken or sagging springs. � Replace spring.
alignment.
Erratic Steering 1. Worn wheel bearings. � Replace.

on Braking 2. Broken or sagging springs. � Replace coil spring.
3. Tyres are inflated unequally. � Inflate tyres to correct
pressure.
alignment.
5. Brakes not working in unity. � Check and adjust brakes.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
287
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
TIE RODS
The tie rods are of three piece constructions of the rod and two ball and socket end assemblies.
Ball & socket end assemblies are threaded into each rod and locked with clamps around each
end of rod. Right and left hand threads on tie rod assemblies provide toe-in adjustments
without removing the tie rod ends from the steering arms.
STEERING GEAR
Refer below sketch for steering gear exploded view -
This is anti- friction re-circulating ball variable ratio sector type steering gear of high efficiency.
A hardened and precision ground single start worm shaft is supported in the steering box by
angular contact bearing assembly at each end. Adjustment of bearing pre load on these
bearings is achieved by shills between the bottom end plate and steering housing.
The worm shaft is provided with splines for attachment to a separate intermediate shaft by
means of a universal joint which is provided with splines on both sides. The other end of the
intermediate shaft is connected to the wheel end of the steering column through another
universal joint.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
288
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
As the steering wheel is turned, the worm
rotates and moves the main nut in the axial
direction of the worm shaft.
The main nut employs two independent ball

circuits. The transfer tubes guides the ball at
end of circuit for re-entering them to start
of the respective helical path and are
positioned that the balls leave and re-enter
on a line tangential to the pitch circle. The
transfer tubes are clamped in place by the
retainer.
The rack on one side of the main nut

meshes tooth gear of the sector shaft so
that the sector shaft rotates during the axial
movement of the main nut.
The sector shaft teeth are conical and are

designed specially to provide true rack and
sector action when main nut is positioned at
a slight angle. This construction permits
backlash adjustments by shifting sector
slightly along its axis by means of an Steering Gear Sectional View
adjuster screw.
The sector shaft is supported by bushes fitted in the cover plate side and in the housing. There
is a tapered spline at the shaft end to which drop arm is fitted and is retained in position by a
nut and tab washer.
The steering column consists of a wheel end housed in outer tube and is supported at the two
ends of the tube by bushes held in position by rubber bushes. Two external circlips are provided
on the wheel end to prevent it from coming out and to restrict its movement within the outer
tube.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
289
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Care of the System –
STEERING GEAR
Oil Capacity : 0.6 liters

Oil specification : SAE 80W90 Gear Oil confirming to API GL4 SAE 140.
MAXIMILE GO 80W90
Check Oil level : At every 20,000 KMs.
Change Oil : Whenever steering gear is dismantled.
STEERING FLUID (MANUAL) – LEVEL / LEAK – CHECK
Schematic -Steering Gear Box
Oil Filler Plug
POWER STEERING FLUID – LEVEL/ LEAK – CHECK (Refer illustration shown above)
1. Open the plug on the steering gear box and check the oil level – it should be just below the
plug bottom edge. If found below that, top it up with recommended oil.
2. Check steering gear box oil leakage/ seepage at –
� In put shaft oil seal area.
� Drop arm shaft area.
� Gear box joint areas.
� If required do steering wheel Check & adjust play at 20,000 KMs.

� If the play of steering wheel exceeds 50mm carry out the adjustments.
� At regular intervals check and tighten all steering gear mounting bolts,
drop arm retaining nut.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
290
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� In Car Repairs –
Lubrication –
� Oil level to be maintained up to the level plug. (Check once in a month).

� Use the recommended grade of oil (Do not use mixture of oil & grease).
� If oil leak found in the steering gear, it should be arrested immediately & oil to be topped up.
STEERING FREE PLAY ADJUSTMENTS -
Provision is made in the design to adjust so that there is no backlash in the straight ahead
position, but backlash will be apparent away from SAP and will be increasing towards the
steering locks.
If there is excessive free play on the steering wheel at SAP, check and adjust the backlash as per
the procedure given below:
1 Rock the steering wheel and check for the visual lift in the ball joints. If the lift is in excess
the ball joint requires replacement.
2 Keep the vehicle in SAP. It is important to ensure this, since the sector shaft is machined to
give more back lash at the extremities of each lock. Therefore if the backlash adjustment is
carried out at any other position other than at SAP severe binding would occur at SAP.
3 Disconnect the connecting link from the drop arm.
4 Check at the drop arm small end for any lash by rocking in the direction of movement.
5 Loosen the adjuster screw lock nut and screw in the adjuster screw until the play in the
drop arm just stops.
6 Tighten the adjuster screw lock nut.
7 Re-fit the connecting link.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
291
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
DISMANTLING OF STEERING GEAR
Remove the drop arm lock & spring washer.

Remove the dust seal.
Mark the position of drop arm and rocker shaft and remove the drop arm using a suitable extractor.
Remove oil plug and drain oil by inverting the steering

gear assembly.
Rotate the worm shaft and keep in mid gear position.
Loosen the adjuster screw lock nut. Remove the bolts

which retain the side cover. Withdraw the cover plate
with rocker shaft By gently tapping the end of the shaft
with a mallet.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
292
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
Remove the adjuster lock nut and screw out the sector shaft from the cover plate.
Loosen the screw plug lock nut and remove the

screw plug along with the bottom bearing cage
assembly.
Take out the worm & nut assembly along with the
top bearing cage assembly.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
293
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
Remove the bearing races from the inner column, screw plug and housing with suitable extractor.
Remove the transfer tube retainer bolts from the

main nut and remove the retainer. Remove the
transfer tube carefully and dislodge main nut balls
by rotating the main nut on either direction.
Collect the main nut balls (74 Nos.)
Note - This procedure is only for the purpose of

servicing the steering gear. At the time of
replacement; the worm & main nut assembly is
supplied as a kit.
After dislodging all the main nut balls, remove the main nut from the inner column.
Remove both the oil seals from the housing by

carefully levering at diametrically opposite points.
Cleaning & Inspection of dismantled parts –
� In the interest of safety and reliability, all steering gear components must be in good condition
and if there is any damage to the components it should not be rectified, rather to be replaced
� Wash all parts prior to inspection. Inspection, repair and assembly of steering parts must not be
attempted in dirty surroundings Parts must be kept absolutely clean.
� Examine the steel balls, bearing tracks of main nut and worm for undue wear and pitting. If
damage to any one of the component in the form of pitting or grooving is evident, the worm &
main nut assembly must be renewed as a set.
� Check for wear on the rack teeth position of the main nut.
� Check for the damages on the serrations / threads of the worm, Intermediate shaft and outer
column. If any damages observed check serrations of the corresponding mating serrations of the
steering wheel / universal joints also for damages
� Check sector shaft for wear & damages at gear teeth, spline and threads.
� Check adjuster screw visually for any bend and threads for damage and replace if necessary.
� Check for axial play of the adjuster screw in the sector shaft. In case of excess play remove
circlip and adjust the play using shims.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
294
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Examine the bearing and races for wear, pitting and cracked/deformed cages. If evidence of the
above are found, the bearing must be renewed It is advisable to replace both worm bearings
together when renewal is required.
� Check fit of the sector shaft in the housing bush. If a slack fit is apparent replace both the bushes
in the housing.
� Check the wheel end for smooth rotation and for excess play in the top and bottom bearing In
case of excess play replace the outer column assembly.
� Check the transfer tube for any damages / wear especially at the tip and ball entry points.
ASSEMBLY PROCEDURE –
Clean all components before assembly. Care must be taken to clean the cover plate.
Insert the main nut in to the inner column and

align the nut and worm tracks. Ensure that the
circuit with shorter pitch is towards top.
Fit the top and bottom inner races on the inner column.
Count 74nos. of 9/32” dia steel balls and insert

20 nos. in the shorter pitch circuit and 34 nos.
in the longer pitch circuit. The remaining 20
nos. are to be placed in the two sets of transfer
tube (10 nos. in each set) with sufficient grease
to keep them in position.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
295
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH Ensure that the balls are assembled properly in the right track. The track from the end of the top
circuit to the beginning of the bottom circuit is called as “no ball zone” and care should be taken to
see that the balls do not slip into this zone Any balls present in this zone will damage the transfer
tube leading to failure of the steering mechanism.
Insert the transfer tubes in to position in the

main nut. Keep the transfer tube retainer in
position over the transfer tubes and secure
with screw and washers. Check for free
movement of the main nut on the worm shaft.
Press the top bearing outer race in to position

in the housing and Place bearing cage over it.
Press the bottom bearing outer race in to

position in the screw plug.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
296
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH Insert the worm & nut assembly in to the box and place the bottom bearing cage over the inner
race.
Assemble the screw plug with a thin coating of

hold tite and screw in gently to achieve the
specified worm shaft pre load. Ensure proper
seating of both the bearing.
Fit the lock nut and tighten to the specified torque.
Ensure smooth rotation of inner column without axial movement.
Check for axial play of the adjuster screw. If play exists remove circlip and adjuster (End float of
0.05 mm maximum is permissible) Adjuster screw should not get jammed due to excess shimming
and should be free to rotate by hand.
Set the steering in mid gear position.
Insert the sector shaft in the correct position so that centre teeth of the sector shaft engage with
the middle portion of the main- nut rack.
Apply a thin coating of shellac on the housing and place a new gasket on the housing cover plate.
Assemble the cover plate in to the housing by engaging adjuster screw thread in to the thread
provided in the cover plate.
Draw out the sector shaft adjuster screw fully.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
297
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH Provide a thin coating of holdite on bolts and

tighten the cover plate bolts to specified
torque.
Fix the drop arm and adjuster the rocker shaft to NIL backlash condition between main nut rack
teeth and sector shaft gear teeth by suitably adjusting the adjuster screw and tighten the lock nut.
Ensure that the adjustments is done in mid gear position only.
Drive new oil seals in position into the sector

shaft side and worm shaft of the housing.
Fit the dust sleeve and fix the drop arm by

matching the mark already made.
Place spring washer and tighten the lock nut to

the specified torque.
Fill the steering gear assembly with SAE 90 / SAE 140 grade of oil and check for smooth operation.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
298
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Backlash Adjustment –
If there is excess free play on the steering wheel (beyond 2.5”/65mm on the periphery), check and
adjust the Backlash as per the procedure given below.
Before adjusting the backlash, check the steering column lift. If lift is found, inner column pre load
should be adjusted by way of reducing the shims in between the outer column tube housing and the box
facing.
1. Rock the steering wheel and look for visual lift in the (Tie-rod/connecting tie rod) ball joints. If lift is
in excess the ball joints requires replacements.
2. Keep the vehicle in SAP.
3. Disconnect the connecting tie rod assembly form the drop arm.
4. Check backlash by rocking at the small end of the drop arm in the direction of movement.
5. Loosen the adjuster screw lock nut and screw in the adjuster screw until the play in the drop arm
just stops.
6. Tighten the adjuster screw lock nut
7. Re-fit the connecting tie rod assembly.
Fitment –
At regular intervals, check and tighten all steering gear mounting bolts, drop arm retaining nuts.
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
299
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Following are the Steering system components checks –
Tie Rod Boot –

Inspect each boot for tear. If even a small tear is noted,
replace with new one.
Steering intermediate Shaft Joints –

Check shaft joint for wear, breakage and other damage and
replace if any defect exists.
TIE ROD END –

- Check ball joints for play.
- Check play in tie rod end ball joint.
In either case, if found defective, replace it.
STEERING RACK –
Inspect rack for deflection, teeth wear or damage.
Limit of rack deflection: 0.40 mm
If deflection exceeds limit, replace the rack.
STEERING WHEEL -
Check steering wheel for play and rattle, holding car in straight forward condition on the ground.
Steering wheel play: 0 – 30 mm.
If steering wheel play is not within specification, inspect as follows and replace if found defective.
� Tie-rod end ball stud for wear.
� Lower ball joint for wear
� Steering shaft joint for wear
� Steering rack gear for wear/ breakage
� Each part for looseness
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
300
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Specification –
Steering system :
Type (Manual / Power assisted –Hydraulic / Power
assisted – Electric/Other) Manual
Steering wheel
Position (center/offset) Offset
Outside dia. (mm) 406 mm
Number of spokes 3
Total number of revolution 5.4 turns
No. of balls in circuits 74 Nos.( Ø 9/32”)
Steering column
Make Rane/ Talbros
Maximum No. of rotation of steering wheel from
lock to lock 5.4
Offset of the steering column with respect to the
seat 50.0 mm to left of seat centre line
Steering Gear
Type of steering gear Re-circulating ball type
Make Rane
Steering gear ratio 20.5: 1 to 23.5: 1 variable ratio
Wheel lock angle (deg.) Inner Outer Inner Outer
Left Left 35 33
Right Right 33 29
Power Assistance NA
Min turning circle diameter (mm) (Left & Right) 12800
Min. turning circle clearance diameter (mm) (Left &
Right) 13300
Total rotation of Drop arm (Permissible) ± 44°
Oil to be used for steering gear SAE 80W90/140 Oil
Oil Quantity 600 ml approx.
Steering worm shaft bearing Angular Contact bearings
Worm shaft bearing pre-load 2 – 4 Inch Lbs.
Steering gear final load at SAP 8 to 12 Inch Lbs. (Max)
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
301
by any any person
otherother
& Mahindra
Mahindra & Mahindra
Repair
Repair Manual
Manual MAN-00103
CLUTCH
� Tightening torques –
Description Torque Values

Cover Plate bolts 19.5 ± 4.5 Nm (14 ± 3 lbf-ft)
Adjuster screw lock nut 28 ± 4 Nm (21 ± 3 lbf-ft)
Drop arm nut 204 Nm (150 lbf-ft)
Oil filler plug 22.5 ± 2.5 N m (17 ± 2 lbf-ft)
� Sealants -
Cover Plate Housing Gasket : Shellac

Cover Plate Bolts : Holdtite adhesive
� Lubricants –
Recommended Oils -
OIL COMPANY SPECIFICATION

SAE 80W90 SAE 140
Indian Oil Corporation Servo Super Multigrade Servo Gear Super 140
20 W 40
Bharat Petroleum Bharat Actuma Multigrade 20W40 Bharat Spirol
HD-40
Hindustan petroleum HP Gear Oil EP-90 HP Gear Oil HD- 140
Tide Water Oil Co. Veedol Miltigrade 90 Veedol
Multigrade HD- 140
Castrol India Ltd. Castrol Hypoy C80W-90W Hypoy B140
The repair
givengiven
the manufacturer
in thisin document
result of changes
introduced by the
by the
manufacturer
are prohibited
the production
without
of theofvarious
the prior
the various
written
component
component
consent
units units
of Mahindra
and accessories
and accessories
& Mahindra
from from
transmission, in of
in part part
or of or whole
document, 133
302
by any any person
otherother
& Mahindra
Mahindra & Mahindra

Clutch Steering System: Repair Manual Repair Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Clutch Steering System: Repair Manual Repair Manual

Uploaded by

Copyright:

Available Formats

Repair

Steering Gear Mounting –

Ensure followings before vehicle test drive –

1. Inspect tyres for correct air pressure/ uneven wear if any.

SYMPTOM CAUSES REMEDIAL ACTION

Abnormal/ Excessive 1. Sagging or broken spring. � Replace spring.

Wheel Tramp 1. Blister or bump on tyre. � Replace tyre.

Steering Stability Poor 1. Mismatched/ uneven tyres. � Replace tyres.

Erratic Steering 1. Worn wheel bearings. � Replace.

Refer below sketch for steering gear exploded view -

The main nut employs two independent ball

The rack on one side of the main nut

The sector shaft teeth are conical and are

Oil Capacity : 0.6 liters

STEERING FLUID (MANUAL) – LEVEL / LEAK – CHECK

Schematic -Steering Gear Box

Oil Filler Plug

� If required do steering wheel Check & adjust play at 20,000 KMs.

� Oil level to be maintained up to the level plug. (Check once in a month).

STEERING FREE PLAY ADJUSTMENTS -

Remove the drop arm lock & spring washer.

Remove oil plug and drain oil by inverting the steering

Rotate the worm shaft and keep in mid gear position.

Loosen the adjuster screw lock nut. Remove the bolts

Loosen the screw plug lock nut and remove the

Remove the transfer tube retainer bolts from the

Note - This procedure is only for the purpose of

Remove both the oil seals from the housing by

Cleaning & Inspection of dismantled parts –

Insert the main nut in to the inner column and

Count 74nos. of 9/32” dia steel balls and insert

Insert the transfer tubes in to position in the

Press the top bearing outer race in to position

Press the bottom bearing outer race in to

Assemble the screw plug with a thin coating of

Fit the lock nut and tighten to the specified torque.

Ensure smooth rotation of inner column without axial movement.

Set the steering in mid gear position.

CLUTCH Provide a thin coating of holdite on bolts and

Drive new oil seals in position into the sector

Fit the dust sleeve and fix the drop arm by

Place spring washer and tighten the lock nut to

Tie Rod Boot –

Steering intermediate Shaft Joints –

TIE ROD END –

Description Torque Values

Cover Plate Housing Gasket : Shellac

OIL COMPANY SPECIFICATION

You might also like