lock NISSAN PULSAR 1987 Repair Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 132 of 238
132 Manual Transaxle and Drive Shafts
Check the mainshaft for pitting.
(6) Inspect the striking rod, lever and interlock
for wear and damage paying particular attention to
the detent grooves in the end of the striking rod.
Renew parts as necessary. (7) Inspect the shift check and reverse check
balls and springs for wear, cracks and loss of tension
in the springs. Renew parts as necessary.
Check clearance A between the synchro ring and the
gear synchro teeth and compare with Specifications.
(8) Inspect the reverse and fifth gear check
assembly for wear, damage and loss of spring tension.
Renew the assembly as necessary. (9) Inspect all the bearings for pitting, wear and
damage. Renew the bearings as necessary.
NOTE: If the transaxle has seen consider-
able service, it is advisable to renew all the
bearings, oil seals, O rings and snap rings
during the overhaul.
(10) Inspect the various synchro components for
wear and damage paying par ticular attention to the
shift plates and springs and the internal teeth of the
synchro sleeves. Renew parts as necessary. (11) Compare the various gear end floats mea- sured during dismantling with the Specifications and
if the end floats are excessive, check the contact
surfaces of the ge
ars, shaft and synchro hubs. Renew
worn parts as necessary.
TO ASSEMBLE
(1) Lubricate all the components with the spec-
ified gear oil prior to assembly. (2) Install new input shaft and striking rod
oil
seals to the clutch housing in the direction noted on
removal. Lubricate the oil seal lips with multipurpose
grease prior to installation. (3) Assemble the components of the fifth gear
synchro assembly aligning the marks made on dis-
mantling. Ensure that the ends of the shift plate
springs are not aligned.
(4) Install the split bearing to the rear of the
input shaft and install the fifth gear.
(5) Install the fifth gear sy nchro assembly and the
shift retainer to the rear of the input shaft. Ensure that
the slots in the synchro ring are aligned with the shift
plates.
Check the friction surfaces of the input shaft for pitting. Dismantled view of the fifth gear synchro assembly.
Illustration showing the correct positioning of the shift plates and springs.
Page 134 of 238
134 Manual Transaxle and Drive Shafts
(32) Install and tighten the retaining bolts to
the specified torque.
(33) Repeat operation (29). The total turning
torque should be 5.9-13.7 Nm if new bearings have
been installed or slightly l ess if the original bearings
have been installed. If the turning torque is no t as specified, adjust the
mainshaft turning torque as follows:
(a) Remove the transaxle case rear cover, O ring,
spacer and adjusting shim from the transaxle case.
(b) Ensure that the mainsh aft rear bearing outer
race is fully seated on the bearing cone. (c) Using micrometer depth gauge, measure the
distance from the transaxle case to the bearing outer
race and note the reading. (d) Referring to the following table, select the
appropriate shim, according to the reading noted in
operation (c), required to correct the mainshaft turn-
ing torque.
READING SHIM
2.35-2.40 mm............................................... 0.10 mm
2.40-2.45 mm............................................... 0.15 mm
2.45-2.50 mm...............................................0.20 mm
2.50-2.55 mm...............................................0.25 mm
2.55-2.60 mm...............................................0.30 mm
2.60-2.65 mm............................................... 0.35 mm
2.65-2.70 mm............................................... 0.40 mm
2.70-2.75 mm............................................... 0.45 mm
2.75-2.80 mm............................................... 0.50 mm
2.80-2.85 mm............................................... 0.55 mm
2.85-2.90 mm............................................... 0.60 mm
2.90-2.95 mm............................................... 0.65 mm
2.95-3.00 mm............................................... 0.70 mm
3.00-3.05 mm............................................... 0.75 mm
3.05-3.10 mm............................................... 0.80 mm
3.10-3.15 mm............................................... 0.85 mm
3.15-3.20 mm............................................... 0.90 mm
3.20-3.25 mm............................................... 0.95 mm
3.25-3.30 mm...............................................1.00 mm.
(e) Install the spacer, shim, O ring and rear
cover to the transaxle case. Tighten the retaining
bolts securely.
(34) Measure the total turning torque as previ-
ously described. (35) Install the striking interlock and striking lever
to the clutch housing. (36) Install the striking ro d to the clutch housing
sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal. (37) Install a new retaining pin to the striking rod
using a pin punch. (38) Install the reverse and fifth gear check
assembly to the clutch housing. Tighten the retaining
screws securely. (39) Install the balls, spring and reverse check
plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the
reverse and fifth gear check assembly body. Apply locking com-
pound and tighten the reverse check plug securely.
(40) Using a bar clamped to the end of the
striking rod, check that a force of 4.9-7.4 Nm is
required to overcome the spring loading of the reverse
and fifth gear check assembly. If necessary, renew the
springs to achieve this correct spring loading.
NOTE: Ensure that the reverse check plug is
coated with locking compound when finally
installed.
(41) Install the shift check ball, spring and plug to
the clutch housing. Ensure that the ball is centrally
located in the plug.
(42) If removed, install the oil reservoir to the
clutch housing.
(43) Install the input shaft assembly and the
reverse idler gear to the clutch housing taking care not
to damage the seal.
(44) Apply locking compound to the bearing
retainer bolts and tighten the bolts to the specified
torque.
(45) Install the spacer to the reverse idler shaft.
(46) Install the differential assembly to the clutch
housing.
(47) Install the mainshaft to the clutch housing
ensuring that the resin oil ch annel is located centrally
in the end of the mainshaft. (48) Install the shift cap to the slot in the first/
second shift fork and install the shift fork and control
bracket to the clutch housing. Use grease to hold the
shift cap in the shift fork slot. Ensure that the reverse
idler shift fork is correctly located over the gear.
(49) Apply locking compound to the threads of
the control bracket retaining bolts and tighten the
bolts to the specified torque. (50) Install the shift cap in the slot in the third/
fourth shift fork and install the fork to the transaxle
assembly. Use grease to hold the shift cap in the shift
fork slot. (51) Install the fifth gear shift fork to the transaxle
ensuring that the shift fork slot engages the control
finger.
(52) Install the fork shaft an d spring to the clutch
housing sliding the shaft through the shift forks. Use
grease to hold the spring in the end of the shaft. (53) Apply a continuous bead of sealant to the
mating face of the clutch housing so that the bead is
located inside the row of bolt holes.
NOTE: Sealant is available from Nissan
spare parts using the part number KP
610-00250.
(54) Install the transaxle case to the clutch hous-
ing. Install and tighten the retaining bolts to the
specified torque. (55) Select each gear in turn and check that the
transaxle turns freely in each gear. Ensure that it is not
Page 136 of 238
136 Manual Transaxle and Drive Shafts
right hand side gear and the adjacent spacer in an area
where there is no oil groove in the differential case.
(d) Insert another 0.03 mm feeler gauge diago-
nally opposite the first feeler gauge to avoid tilting the
side gear.
(e) Insert a splined adaptor into the right hand
side gear and attempt to rotate the gear by hand.
(f) If the gear cannot be rotated, change the
thickness of the left hand side gear spacer, repeating
the test until the gear can be rotated.
NOTE: Spacers are available in thicknesses
from 0.8 mm to 1.5 mm in increments of
0.1 mm.
(g) Remove the 0.03 mm feel er gauges and insert
0.09 mm feeler gauges to the same position. The gear
should lock.
(h) The spacer selection is correct when the right
hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges
are inserted.
(18) Install the ring gear to the differential case
with the chamfered edge of the ring gear inwards. (19) Install and tighten the retaining bolts in
a
diagonal sequence to the specified torque.
(20) Install a new speedometer drive gear to
the
differential case. Install the stopper adjacent to the
drive gear.
(21) Install the differentia] carrier bearing
cones
and roller assemblies to the differential case.
(22) Remove the adjusting shim from behind the
carrier bearing outer race in the transaxle case and
replace the outer race in the transaxle case.
(23) Install the differential assembly to the clutch
housing. (24) Install the transaxle case to the clutch housing
and tighten the retaining bolts to the specified torque.
(25) Mount a dial gauge to the clutch housing so
that the contact point is resting on the differential
case. (26) Insert a bar through the opposite side gear
and, contacting the pinion shaft, raise and lower the
differential case and measure the end float in the
carrier bearings. (27) Using the following table, select a shim to
correspond to the relevant end float.
END FLOAT SHIM THICKNESS
0.30-0.34 mm....................................................0.64 mm
0.34-0.38 mm................................................... 0.68 mm
0.38-0.42 mm................................................... 0.72 mm
0.42-0.46 mm................................................... 0.76 mm
0.46-0.50 mm................................................... 0.80 mm
0.50-0.54 mm................................................... 0.84 mm
0.54-0.58 mm................................................... 0.88 mm
0.58-0.62 mm................................................... 0.92 mm
0.62-0.66 mm................................................... 0.96 mm
0.66-0.70 mm................................................... 1.00 mm
0.70-0.74 mm................................................... 1.04 mm
0.74-0.78 mm ................................................... 1.08 mm
0.78-0.82 mm ................................................... 1.12 mm
0.82-0.86 mm ................................................... 1.16 mm
0.86-0.90 mm ................................................... 1.20 mm
0.90-0.94 mm ................................................... 1.24 mm
0.94-0.98 mm ................................................... 1.28 mm
0.98-1.02 mm ................................................... 1.32 mm
1.02-1.06 mm ................................................... 1.36 mm
1.06-1.10 mm ................................................... 1.40 mm
1.10-1.14 mm ................................................... 1.44 mm
1.14-1.18 mm ................................................... 1.48 mm
1.18-1.22 mm ................................................... 1.52 mm
1.22-1.26 mm ................................................... 1.56 mm
1.26-1.30 mm ................................................... 1.60 mm
1.30-1.34 mm ................................................... 1.64 mm
1.34-1.38 mm ................................................... 1.68 mm
1.38-1.42 mm ................................................... 1.72 mm
1.42-1.46 mm ................................................... 1.76 mm
The thickest shim available is 0.88 mm. Multiple
shims are required above this thickness.
(28) Install the shim behind the carrier
bearing
outer race in the transaxle case and assemble the unit
once more. (29) Using a suitable slotted adaptor engage the
pinion shaft and using a to rque gauge, measure the
differential turning torque. The turning torque when new carrier bearings
have been installed should be 3.9-7.8 Nm or slightly
lower if the original carrier bearings have been
replaced.
(30) Assemble the transaxle and measure the total
turning torque of the diff erential assembly and the
mainshaft. The total turning torque should be 5.9 to
13.7 Nm with new bearings or slightly lower if the
original bearings have been replaced.
5. GEAR LEVER ASSEMBLY
TO DISMANTLE AND ASSEMBLE
(1) Remove the gear lever knob and remove the
centre console as described in the Body section. If not
previously removed, remove the rubber boot sur-
rounding the gear lever. (2) Raise the front of the vehicle and support it
on chassis stands. Remove the catalytic converter and
heat shield as described in the Engine section.
(3) Remove the bolt and disconnect the control
rod from the bottom of the gear lever, noting the
position of the return spring and bracket.
(4) Remove the nuts retaining the gear lever
socket to the support rod. (5) Working inside the vehicle, lift the gear lever
out of the floor bracket. (6) Separate the lower rubber boot, socket,
spring seat, spring, upper ball seat and lower ball seat
from the gear lever, noting the location of each
component to aid assembly.
Page 139 of 238
Manual Transaxle and Drive Shafts 139
SNAP RING
Assembled view of the inner C.V. joint.
(10) Slide the large end of the inner C.V. joint
boot over the inner C.V. joint housing and locate the
boot in the groove in the housing.
(11) Pull the C.V. joint until the boot is the
normal length. Deformation of the boot could occur if
this operation is neglected. (12) With no vacuum or pressure present in the
C.V. joint boot, install the two C.V. joint boot
retaining clips.
Install the C.V. joint retain ing ring into the C.V. joint
housing. Ensure that the retaining ring is correctly
seated.
NOTE: Ensure that the retaining dips are
securely installed preven ting the entry of
damaging dust or water and that the lock
tabs on the retaining clips are correctly bent
over.
(13) Install the remaining snap ring onto the inner
C.V. joint housing shaft and install the drive shaft to
the vehicle as previously described.
Page 140 of 238
140
AUTOMATIC TRANSAXLE
SPECIFICATIONS
Make .............................................. JATCO RL3F01A
Type .....................3 speed and reverse epicyclic gear
train with lock up torque converter
Operation .................................... Automatic hydraulic
Lubricant:
Type....................................................... Dexron IT
Capacity................................................. 6.3 liters
TORQUE WRENCH SETTINGS
Drive plate to crankshaft bolls ........................60 Nm
Drive plate to torque converter bolts ..............49 Nm
Convener housing to engine ...........................22 Nm
Converter housing to transaxle ........................23 Nm
Transaxle sump to transaxle ............................. 7 Nm
Oil cooler pipe to transaxle .............................49 Nm
Selector shaft locknut .......................................42 Nm
Transaxle filter bolts.........................................12 Nm
1. AUTOMATIC TRANSAXLE TROUBLE SHOOTING
NO DRIVE IN D RANGE
{1) Low fluid level in transaxle: Check the fluid
level in the transaxle and top up if required.
(2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed. (3) Incorrect or contaminated transaxle fluid:
Drain and refill with the recommend type and quan-
tity of transaxle fluid.
NOTE: Check the possible causes in the
order given.
NO REVERSE IN R RANGE
(1) Low fluid level in transaxle: Check the fluid
level and top up if required. (2) Incorrectly adjusted selector linkage: Check
the condition of the selector cable, selector quadrant
and selector arm for wear and damage. Adjust as
required.
Check the drive shaft oil seals as a likely leak source.
SLIPPING OR ROUGH UPSHIFT
(1) Incorrectly adjusted selector linkage: Check
and adjust the selector linkage. (2) Low fluid level in transaxle: Check the fluid
level and top up if required.
NO TRANSAXLE KICKDOWN
(1) Incorrectly adjusted throttle cable: Check
and adjust the cable as detailed in the Fuel and Engine
Management section.
Check the oil cooler hose connections for leaks if the
fluid level is low.
Page 142 of 238
142 Automatic Transaxle
(8) Install the dipstick and start the engine and
recheck the fluid level.
NOTE; Do not overfill the transaxle or
foaming and unsatisfactory operation of the
transaxle will result.
TO DRAIN AND REFILL
This is not a normal maintenance and lubrication
procedure. It is only necessary to drain the complete
system, including the torq ue converter and the oil
cooler, when the transaxle assembly is removed for
overhaul or the renewal of transaxle components such
as bearings, clutches or as semblies. When this condi-
tion arises, the torque converter and the cooler should
be cleaned and flushed to remove any dirt or sludge.
After transaxle overhaul, install approximately 6
liters of new transaxle fluid, and top up as previously
described.
4. BRAKE BAND
Band adjustment is not a normal maintenance
procedure.
The adjustment entails removal of the valve body
and for this reason the vehicle should be taken to an
authorized dealer.
5. KICKDOWN CABLE
TO ADJUST
(1) On models with a 1.6 liter engine, remove
the air cleaner assembly. (2) With the aid of an assistant, ensure that the
throttle valve is fully open when the throttle pedal is
fully depressed. (3) Push the clip on the outer kickdown cable
and pull the cable away from the throttle linkage.
View of the kickdown cable adjustment point. 1.6 liter
engine.
(4) Slowly depress the throttle pedal to the full
throttle position.
The outer kickdown cable will automatically ad-
just and emit a clicking noise.
6. TRANSAXLE SELECTOR LINKAGE
TO ADJUST CONTROL CABLE
(1) Place the selector lever in the Park position.
(2) Loosen the control cable locknuts and ensure
that the transaxle selector lever is in the Park position.
View of the transaxle selector linkage control cable
adjustment.
(3) Hold the selector rod horizontal and adjust
the outer locknut until it touches the selector rod.
(4) Tighten the inner locknut securely.
7. NEUTRAL SAFETY SWITCH
The neutral safety switch, incorporating the re-
verse lamp switch is located on the transaxle case
View of the kickdown cable adjustment point. The
arrow indicates the direction in which the outer kick-
down cable must be pulled to initiate the automatic adjustment. 1.8 liter engine.
Page 147 of 238
147
PART 2. MANUAL STEERING
SPECIFICATIONS
Steering gear type ............................ Rack and pinion
Steering column type ...................... Energy absorbing
collapsible and tilt adjustable
Steering wheel free play
(maximum ) ...................................................... 35 mm
Linkage........................... Direct from rack ends to t i e
rods and steering knuckles
Turns lock to lock ................................................. 3.6
Steering column length .................. 534.7-537.3 mm
Steering gear lubricant.............. Castrol EPL 1 grease
TORQUE WRENCH SETTINGS
Steering wheel retaining nut ............................ 39 Nm
Steering gear to bulkhead
mounting bolts .............................................. 108 Nm
Tie rod to steering knuckle nut...................... 98 Nm
Tie rod to tie rod end locknut ....................... 98 Nm
Tie rod ball housing to rack............................ 88 Nm
Steering column to mounting
bracket bolt ...................................................... 14 Nm
Steering column universal
coupling joint pinch bolts ............................... 29 Nm
2. STEERING WHEEL
Special Equipment Required:
To Remove Steering Wheel - Steering wheel
puller
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Using a small screwdriver, carefully prise the
centre ornament from the steering wheel.
View of the steering wheel removed from the vehicle.
Steering wheels may vary between models.
1. DESCRIPTION
The steering gear is a rack and p i n i o n type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.
The design of this assembly requires a range of
special tools to dismantle and assemble the steering
gear. If the steering gear is found to have a fault which
requires overhaul of the rack and pinion, it is recom-
mended that this be performed by an authorized work-
shop or steering specialist.
However, the procedures for the removal and
installation of the steering gear and the renewal of the
tie rods, the tie rod ends and the rubber boots are fully
covered in this section.
The rack and pinion assembly requires no lubri-
cation during service.
The steering column is of the energy absorbing
type designed to compress in the event of a severe
front end collision. The energy absorbing units are the
outer steering column, the tilt bracket and the steering
shaft. All these units shoul d be handled with extreme
care if service operations are performed on the
steering column assembly.
(3) Remove the steering wh eel retaining nut and
mark the steering shaft and steering wheel hub in
relation to each other as an aid to assembly.
(4) Remove the steering wheel from the steering
shaft.
NOTE: If the steering wheel will not sepa-
rate from the steering shaft, loosen the horn
pad retaining screws at the rear of the
steering wheel and withdraw the horn pad
after disconnecting the wire. A puller can
now be used to pull the steering wheel from
the steering shaft. Do not strike the end of
the steering shaft as sharp blows can cause
irreparable damage to the collapsible steer-
ing shaft.
(5) If necessary the steering wheel can be dis-
mantled as shown in the illustration.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Apply a light coat of multipurpose grease to
the horn slip ring and the turn signal canceling pins.
(2) Ensure that the marks on the steering wheel
and steering shaf t are aligned.
(3) Tighten the steering wheel retaining nut to
the specified torque.
Page 148 of 238
148 Steering — Part 2
3. STEERING COLUMN
Special Equipment Required:
To Remove Steering Wheel — Steering wheel
puller
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working in the engine compartment, mark
the relationship between the steering shaft universal
coupling joint and the steering gear pinion shaft. (3) Remove the pinch bolts from the universal
joint. (4) Working inside the vehi cle, remove the steer-
ing wheel as previously described. (5) Remove the steering column shroud screws,
unclip the lower and upper covers and remove them
from the steering column. (6) Disconnect all the steering column wiring
connectors. (7) Remove the lower trim from underneath the
steering column.
(8) Fold back the insulator and remove the nuts
from the steering colu mn floor bracket.
(9) Remove the nuts from the lower steering
column bracket. (10) Remove the bolts from the tilt bracket
assembly. (11) Maneuver the steering column from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Measure the dimension between the lower
bracket pin and the upper edge of the steering shaft as
shown in the illustration.
If the dimension is not as specified, the steering
shaft has collapsed and the steering column should be
renewed.
(2) Rotate the steering shaft in the column and
check the shaft bearing for roughness and damage.
Renew as necessary. (3) Inspect the steering shaft universal coupling
joints for wear and damage and renew as necessary. (4) Position the steering column assembly under
the dashboard ensuring that the floor bracket is
located correctly and that the steering shaft universal
joint is aligned with the steering gear pinion shaft
marks.
(5) Install all the steering bracket nuts and bolts
finger tight. (6) Install the universal coupling joint pinch bolts
and tighten securely.
(7) Tighten all the stee ring column nuts and
bolts securely. (8) Test the operation of all the steering column
controls when installation is complete.
TO DISMANTLE
(1) Remove the steering column assembly from
the vehicle as previously described. (2) Suitably mark the position of the universal
coupling joint and remove it from the steering shaft. (3) Mark the position of the rubber boot in
relation to the floor bracket and steering column.
Loosen the retaining bands and remove the boot and
floor bracket from th e steering column.
(4) Using snap ring pliers, remove the snap ring,
plain washer and wave washer from the upper end of
the steering shaft. (5) Loosen the combination switch retaining
screw, push the combination switch in, turn the switch
and remove it from the steering column. (6) Turn the ignition switch to the On position
and slide the steering shaft from the column assembly. (7) If necessary dismantle the tilt bracket com-
ponents after removing the through bolts. Note the
position of the components to aid assembly. (8) To remove and install the steering lock pro-
ceed as follows: (a) Remove the ignition switch retaining screw
and carefully withdraw the switch from the steering
lock bracket.
View of the steering column assembly removed from
the vehicle. Steering column length is shown as dimen- sion A. A - 534.7-537.3 mm. Dismantled view of the steering lock and ignition
switch assembly.
Page 149 of 238
Steering — Part 2 149
Dismantled view of the steering column and tilt bracket assembly.
(b) Using a suitable drill, carefully remove the
heads of the steering lock br acket shear type retaining
bolt heads. Remove the steering lock bracket from the
column.
(c) Install the steering lock to the column
using
new shear bolts. Ensure that the steering lock is
operating correctly and tigh ten the shear bolts until
the heads snap off.
(d) Install the ignition switch and tighten
the
retaining screw securely.
TO CHECK AND INSPECT
(1) Thoroughly clean and dry the components
using a suitable solvent.
(2) Inspect the steering shaft for bends, damage
and wear. Pay particular attention to the steering shaft
universal coupling joint and the internal and external
splines. Renew as necessary. (3) Inspect the steering column upper bearing
for ease of operation and if necessary, renew the
column assembly.
TO ASSEMBLE
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Install the steering shaft to the column.
Ensure that the steering shaft is correctly located in
the upper bearing and insta ll the wave washer and the
plain washer. Install the snap ring using a ring
spanner
which has minimum clearan ce over the steering shaft.
(2) Install the rubber boot and floor bracket
to
the steering column aligning the marks made during
removal. If no marks were made, align the cutouts of
the rubber boots with the protrusions on the steering
column and the floor bracket. (3) Before installing the tilt bracket assembly to
the column, measure the steering column length as
shown on the illustration.
If the length is not as specified, the steering
column and the steering shaft must be renewed as an
assembly.
(4) Install the tilt bracket, lever, through bolt,
washers and adjusting nu t to the t i l t bracket.
(5) Before installing the column assembly to the
vehicle adjust the column tilt lever as follows:
(a) Position the tilt lever in its locked position,
the end of the lever should contact the flanged portion
of the tilt bracket.
(b) Tighten the adjusting bolt to 11 Nm.
(c) Unlock the tilt lever fully and ensure that the
column moves smoothly up and down the tilt bracket. (d) Return the tilt lever to the locked position
and ensure that the column is locked securely. Adjust
the tilt bracket thro ugh bolt if necessary.
(6) Install the universal coupling joint to the
lower steering shaft and tighten the pinch bolt se-
curely.
(7) Install the steering column assembly to
the
vehicle as previously described.
4. STEERING GEAR ASSEMBLY
Special Equipment Required:
To Renew Tie Rod Ball Housings — Large Still-
sons.
TO REMOVE AND INSTAL
( 1 ) Working in the engine compartment and
with the wheels in the straight ahead position, suitably
Page 150 of 238
150 Steering — Part 2
View of the steering gear and associated components removed from the vehicle.
mark the universal coupling joint in relation to the
steering gear pinion as an aid to installation.
(2) Remove the bolt retaining the universal
coupling joint to the steering gear pinion. (3) Raise the front of the vehicle, support it on
chassis stands at the jack ing points and remove the
front wheels. Refer to the Wheel and Tires section.
(4) Remove the split pins and castellated nuts
from the tie rod end studs and disconnect the tie rod
ends from the steering arms.
NOTE: Disconnect each tie rod end by
placing a suitable dolly or hammer against
one side of the steer ing arm eye and striking
the opposite side with a hammer.
(5) Remove the bolts from the steering gear
mounting brackets. (6) Separate the steering gear pinion from the
universal coupling joint and maneuver the steering
gear from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that the steering gear mounting
bracket rubbers are in good condition. Renew if
necessary.
(2) Renew the split pins on the tie rod castel-
lated nuts.
(3) Check and if necessary adjust the front wheel
toe in. Refer to the Front Suspension section for the
correct procedure.
TO OVERHAUL
To overhaul the steering gear a range of special
tools is required. If the steering gear has a fault
which requires the removal of the rack or pinion it
is recommended that the necessary repairs be car-
ried out by an authorized dealer.
TO RENEW TIE ROD BALL HOUSINGS
(1) Remove the steering gear from the vehicle as
previously described.
(2) Note or mark the installed position of the
mounting rubbers as an aid to assembly and remove
the rubbers from the steering gear.
(3) Thoroughly clean the exterior of the steering
gear in a suitable cleaning solvent.
(4) Secure the steering gear in a soft jawed vice
and centralize the rack in the steering gear. (5) Loosen both the ti e rod end locknuts and
unscrew the tie rod ends from the tie rods, noting the
number of turns required to do so. Remove the
locknuts from the tie rods. (6) Remove the tie rod rubber boot retaining
clamps, detach the boot s from the steering gear
housing and slide them from the tie rods. Take care to
position a container to catch the oil contained in the
steering gear assembly. (7) Where the tie rod ball housing is retained by
staking, drill the staking away from the rack and t i e
rod using a 4.0 mm drill. Do not drill into the rack
more than is necessary to drill out the staking.
Where the tie rod ball housing is retained by a
lock pin, drill out the lock pin from the ball housing
and tie rod using a 4.0 mm drill. Do not exceed a
drilling depth of 10.0 mm.
Using a 4.0 mm drill to remove the staking from the tie
rod ball housing.