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64: Reconditioning, steering gear Page 1 of 16
64: Reconditioning, steering gear
850, 1994
15/1/2023 PRINT
64: Reconditioning, steering gear
Reconditioning,
steering gear
Special tools:
951 2050
999 1801
999 2250
999 2706
999 5046
999 5154
999 5179
999 5182
999 5277
999 5333
999 5388
999 5389
999 5393
999 5519
999 8081
Steering gear,
dismantling
Hint:
For removing steering
gear, see Steering gear,
replacement:Attach
support rails 999 5033,
mounting bracket
999 5006 and lifting
hook 999 5460. Jack up
the engine slightly to
relieve load on engine
mountings . For
installing, see: Steering
gear, replacement .
Clean the outside of
the steering gear
Remove the delivery lines and O-
rings from the pipes.
Note! Delivery lines of later

version have tapered seals.
http://192.168.0.143/Vida/jsp/information/xml/xmlDocPrintPreview.jsp 2023-01-15
Set up the steering

gear in fixture 999
5046 and stand 999
2250 or 999 5154
For attaching, use U-bolt 1272597-4
and intermediate piece 1272679-0.
Drain the oil from the

steering gear
Place a collection container under
the pipe outlets. Turn the pinion
back and forth until the oil has been
pumped out. Use socket 999 5179
and a ratchet handle. Then set the
rack in approx. middle position.
Check any wear in

the outer and inner
ball joints
Remove:
 the outer ball joints
 the clamps and gaiters
 the seal rings for the gaiters
on the steering gear housing.
Note! On steering gears for
right-hand drive cars there is

only a seal ring on the right side.
On left-hand drive cars:

Remove the left tie rod and
loosen the right a few revolutions
On right-hand drive cars:

Remove the right tie rod and
loosen the left a few revolutions
Use an adjustable wrench and
polygrip pliers. Place an adjustable
wrench as counterhold as far out as
possible on the rack. Remove/loosen
the tie rods.
Note! On certain versions there

are spacer rings on the tie rods.
Caution! Use counterhold,

otherwise there is a risk of
damage to the rack and pinion.
Caution! Right/left tie rod shall

be left in place. This is to prevent
that the end sleeve from shooting
off. See further under
Reconditioning, steering
gear:Blow out the rack's bushing
and seal .
Remove:
 the sealing compound that
covers the hole for the lock
wire
 the lock wire for the rack's
bushing.
Turn the end sleeve with a hook

wrench (C-wrench) so that the lock
wire can be seen and can be
removed.
Note! A screwdriver may have to

be used to pry up the end of the
lock wire.
Blow out the rack's

bushing and seal
Counterhold on the pinion with
socket 999 5179 and a ratchet
handle.
Blow with compressed air in the
outer pipe connection so that the
bushing with seal comes out. Now
the tie rod functions like a stop so
that the bushing does not shoot
away.
Warning! The compressed air

may cause a loud booming
noise. Use hearing protection.
Remove:
 the tie rod
 the bushing with seal.
Remove the rack's

preloading device
Use tap tool 999 5333 for the cover.
Remove the cover, spring and
preloading piston.
Remove the dust

cover and lock ring
for the pinion
Use a screwdriver for the dust
cover. Be careful so that the pinion
or steering gear housing is not
damaged.
Remove the pinion's

cover
Use a chisel. Tap loose the cover.
Remove the lock nut

for the pinion
Counterhold the pinion, with socket
999 5179 and a ratchet handle,
when the nut is removed.
Remove the pinion

Tap with a brass drift and a
hammer on the pinion's lower part.
Remove the rack

Pull out the rack carefully so that
the surfaces on the rack and
housing are not damaged.
Tap out the pinion's

ball bearing from
above
Remove the lock ring and tap out
the bearing with a drift.
Tap out the pinion's

lower seal and
bushing from below
Use a long extension and a socket
with 24 mm outside diameter.
Tap out the rack's

seal and back-up ring
from the steering
gear housing
Use two extensions and a socket
with 25 mm outside diameter.
Insert the extensions and socket
through the steering gear housing.
Make sure that the socket grips the
edge of the back-up ring. Tap out

the seal and the back-up ring.
Caution! Be careful so that the

surfaces in the housing are not
damaged.
Piston seal
Replace the piston seal only if it is

damaged or if the car has been
driven more than 40 000 km.
From the pinion,

remove:
 the sleeve 999 5179 (1)
 the dust cover (2)
 the snap ring (3)
 the seal ring (4)
 the roller bearing (5).
Caution! The four seal rings

made of teflon on the valve
spool may not be removed.
Clean and check all

parts
Check:
 the gaiters, replace when
needed
 the gaiters' seals, replace
when needed
 all parts for wear, corrosion,
cracks and pressure damage
 the pinion with valve spool. In
case these parts are damaged,
the whole steering gear must
be replaced.
Caution! Carefully clean the

threads in the steering gear
housing. Use cleaning tap 999
5389 for the preloading device's
cover.
Steering gear,
assembling
Piston seal
Replace the piston seal only if it

is damaged or if the car has
been driven more than 40 000
km
First install the O-ring and then the
teflon ring. Warm the teflon ring to
40-50°C if it is difficult to install on
the piston.
Install a new bushing

for the pinion in the
steering gear housing
Use handle 999 1801 and drift 999

5277 .
Caution! Be careful when

installing the bushing. If it is
deformed the pinion will bind.
Check through the hole for the

preloading device that the bushing
is positioned against its shoulder in
the housing.
Install a new seal

ring in the steering
gear housing

5393 .
Note! Tap in the seal ring

carefully.
Install the ball

bearing for the pinion

5388 . Install the lock ring.
Install the seal ring

and the back-up ring
on the rack
Lay a wide strip of tape over the

teeth as protection. Lubricate the
tape with oil.
Install the seal ring carefully, with
the lip facing the piston seal. Check
that the seal's plastic ring is in
place.
Install the back-up ring.
Remove the tape. Check that there
is no remaining tape or glue.
Fill the teeth on the

rack with steering
gear grease
Use Volvo grease, part number

1161001-1
Install the rack with

seal and back-up ring
Guide in the rack so that it does

not damage the surfaces in the
housing. When the rack is all the
way in, press so that the seal and
back-up ring are secured in its seat.
Tap carefully with a plastic mallet
on the end of the rack.
Check the seal ring's

position
Inspect inside the delivery line's

connection. When the rack is
pressed in against the seal, the
piston's seal shall have passed the
center of the hole.
Press back the rack
Caution! The rack may not be

pressed back too far, the rack's
end must protrude outside the
steering gear housing,
otherwise the seal is damaged
by the teeth.
Install:
 the seal and the bushing on
the rack
 the O-ring on the bushing
 the seal ring on the rack. Be
careful, check that the seal's
plastic ring is in place
 the bushing on the rack. Press
the seal ring for the bushing
into place.
Install the bushing
with seal in the

steering gear housing
Align the bushing so that the hole

for the lock wire lines up directly
opposite the hole in the steering
gear housing.
Press in the bushing.
Caution! Be careful so that the

O-ring is not damaged by the
hole's edges in the steering
gear housing.
Install the lock wire
Caution! Use new lock wire.
Insert the lock wire's hook in the

hole on the bushing. Turn the
bushing with a hook wrench (C-
wrench) until the wire is in place.
Seal the hole with sealant, part
number 1161277-7.
Install the pinion
Fill the teeth on the pinion with

grease, part number 1161001-1.
Install the pinion in the housing
with the face for the clamping screw
as shown in the figure. Be careful
when installing the pinion so that
you do not damage the valve spool.
Check that the pinion and rack are
in correct mesh with each other.
The pinion's face, earlier version
( A), for the clamping screw shall
be in the position as shown in the
figure when the rack protrudes 82
mm. On the pinion of later version
( B) the marking shall be aimed
against the dashed line. However,
there is a certain tolerance of ± 10°
for the pinion's position.
Install the lock nut

for the pinion
Use a new nut. Tighten with 37

Nm. Counterhold with socket 999
5179 and a ratchet handle.
Check the rack

To check that the rack
does not bind; turn the
pinion a few times
between right and left
end-position.
If the rack binds, then
either the guide sleeve
for the pinion is
deformed or the rack is
not straight.
Install the pinion's
bearing
Grease the bearing with grease,

part number 1161001-1.
Install the bearing. Use drift 999
5519 . Carefully tap the bearing into
place in the steering gear housing.

upper seal ring
Lubricate the seal. Slide the seal on

protective sleeve 999 5182 . Install
the seal on the steering gear with
the spring on the seal facing down.
Remove protective sleeve 999
5182 . Counterhold on the seal and
pull off the tool.
Caution! The seal ring cannot be

installed for good with this tool.
Tap in the seal ring
Use drift 999 5519 . Carefully tap

the seal ring into place.
Install the lock ring. Put grease
between the seal ring and the dust
cover.

dust cover
Use protective sleeve
999 5182 according to
Reconditioning, steering
gear:Install the pinion's
upper seal ring . Tap in
the dust cover. Use drift
999 5519 .
Install a new sealing
plug for the lower
pinion bearing
Fill the plug with grease, part

number 1161001-1 . Install the
plug. Use drift 999 2706 .
Install:
 the preloading device's parts.
Apply lock fluid on the new
cover's threads
 the piston greased
 the spring
 the cover.
Tighten the cover
Set the rack in middle position.

Tighten the preloading screw with
5.0-5.6 Nm. Use tap tool 999 5333
and torque wrench 999 5519 . Then
loosen the screw 50°- 55°. Use a
protractor 951 2050 .
Check the steering

gear's torque
Connect torque wrench 999 5519

with socket 999 5179 to the pinion's
shaft. Turn the rack back and forth
against its end-positions.
If the torque is too high at any
point on the rack, set the rack in
this position and repeat torquing of
the preloading cover.
If the torque still is too high,
replace the steering gear. If the
torque is correct, secure the
preloading cover with three punch
marks in the steering gear
housing.
On certain versions:
Install spacer
washers.
Also see Steering gear spacers,
installation .
Install spacer washers on the rack

(both sides). Slide on the spacer
washers with the smooth side facing
in against the steering gear
housing.
Note! The washers' inner radius

shall be positioned up against
the tie rods.
Install the tie rods
When a used tie rod is to be used

again, then right and left tie rods
can change place so that another
position on the lock edge becomes
available. Rods with defective lock
edge shall not be used again.
Tighten with polygrip pliers and
counterhold with an adjustable
wrench, see figure.
Caution! Counterhold must be

used, otherwise the rack and
pinion will be damaged.
Lock the tie rod to
the rack
Fold down the ball joints' edges in

the slots on the rack. Do not turn
out the rack farther than to enable
access.
Use a narrow drift to lock the tie
rod.
On certain versions: Press the
spacer washers against the tie
rods.
Install the gaiters
Fill each gaiter with 20 grams of

grease, part number 1161001-1.
Install the gaiters and clamp them
at both ends.
Install the ball joints
Remove the steering

gear from the fixture
and install the
delivery lines
On early version: Install new O-

rings. Tighten with 7.5 Nm.
Late version (pipes with tapered
seals) : Tighten with 16.5 Nm.
Fill oil in the steering gear when it
is in place in the car.
For installing steering gear, see:
Steering gear, replacement .
15/1/2023 PRINT

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64: Reconditioning, steering gear Page 1 of 16

64: Reconditioning, steering gear

Note! Delivery lines of later

Set up the steering

Drain the oil from the

Check any wear in

Note! On steering gears for

right-hand drive cars there is

On left-hand drive cars:

On right-hand drive cars:

Note! On certain versions there

Caution! Use counterhold,

Caution! Right/left tie rod shall

Turn the end sleeve with a hook

Note! A screwdriver may have to

Blow out the rack's

Warning! The compressed air

Remove the rack's

Remove the dust

Remove the pinion's

Remove the lock nut

Remove the pinion

Remove the rack

Tap out the pinion's

Tap out the pinion's

Tap out the rack's

edge of the back-up ring. Tap out

Caution! Be careful so that the

Replace the piston seal only if it is

From the pinion,

Caution! The four seal rings

Clean and check all

Caution! Carefully clean the

Replace the piston seal only if it

Install a new bushing

Use handle 999 1801 and drift 999

Caution! Be careful when

Check through the hole for the

Install a new seal

Use handle 999 1801 and drift 999

Note! Tap in the seal ring

Install the ball

Use handle 999 1801 and drift 999

Install the seal ring

Lay a wide strip of tape over the

Fill the teeth on the

Use Volvo grease, part number

Install the rack with

Guide in the rack so that it does

Check the seal ring's

Inspect inside the delivery line's

Press back the rack

Caution! The rack may not be

Install the bushing

with seal in the

Align the bushing so that the hole

Caution! Be careful so that the

Install the lock wire

Caution! Use new lock wire.

Insert the lock wire's hook in the

Install the pinion

Fill the teeth on the pinion with

Install the lock nut