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1. 60 Replace Housing Port Plugs Screws and Fittings 61 IVa PROVO due 62 Reinstallation FAC IS ellie LOM yau uywas uuu um EE 65 Popp t ResettiNg EE 65 er 66 AN WANT fem All steering mechanisms are safety critical items As such it is imperative that the instructions in this booklet be followed to the letter Failure to observe the procedures set forth in this pamphlet may result in a loss of steering Section 1 General Information Langer rege 2 OF Wie 3 General Designs 4 General Operatori 5 ch Approved Me ele tege E e EE 6 Approved EE 6 Gear Specification Number 6 or l L uz A x ss 7 Exploded Ve 8 Service Parts List EE 9 Introduction This THP PCF Service Manual applies to all TRW THP45 PCF45 THP60 and PCF60 steering gears This service manual reflects TRW s commitment to provide easily usable material and highly recognizable hazard notices Some of the updates are e Caution and warning definitions e Torque force pressure and flow notations that provide metric equivalents e Service manual divided into sections for easier reference e Uninterrupted resealing instructions Reference to damage section allows you to repair or replace damaged parts and return to the resealing procedures easily The three column format used in the service manual will also help make it easy for you to service a steering gear Column 1 illustrat
2. If the unit has poppet adjusting screws and sealing nuts that need to be replaced remove and discard them 4 Turn the adjusting screws and sealing nut assem blies without rotating the nut on the screw into the housing until the nut is firmly against the housing on both the master gear and the rotary cylinder using a6mm THP PCF45 or 782 THP PCF60 allen wrench Tighten the sealing nut against the housing 5 Refill system reservoir with approved hydraulic fluid Do not mix fluid types Mixing of transmission fluid motor oil or other hydraulic fluids will cause seals to deteriorate faster CAUTION 6 Place a jack under the center of the front axle and jack up the front end of the vehicle so the steer axle tires are off the ground This resetting procedure will work in most cases with at least 1 hand wheel turns from each side of center If you re making a large reduction in wheelcut and this procedure does not work you may have to replace or internally reset the poppets using the procedure de scribed in the Poppet Component section of this Service Manual 7 a Start the engine and let it run at idle speed b Note which output shaft timing mark is nearest the housing piston bore c Turn the steering wheel in the direction that makes this timing mark move toward the adjusting screws just installed on both the gear and the cylinder Turn in this direction until axle stop contact Is made d Pull har
3. Remove the ball return cap 32 and seal 31 discard the seal T 30 Torx wrench Remove ball return 21 Make sure the rack piston is on a cloth so the steel guides balls that fall out won t roll very far Remove ball return guide 30 by carefully inserting a screwdriver between the rack piston and guides Lett hand ball return guide halves are plated with copper or zinc chromate for identification Right hand guides are not plated Retain the guides for reassembly Remove steel balls 22 Remove the steel balls 29 from the rack piston 28 by rotating the input shaft valve worm assembly until the balls fall out Place the balls and return guides in a cup or other container Count the balls and make sure all have been removed AN VII I AN The steel balls are a matched set If any are lost the set must be replaced by service balls Number of factory balls installed THP PCF45 29 balls THP PCF60 31 balls Separate rack 23 Remove the input worm and valve housing subas piston from worm sembly from the rack piston subassembly Remove seal ring 24 Cutand remove the Teflon seal ring 23 and o ring and o ring 22 trom the rack piston Pocket knife 39 Inspect poppet 25 Push poppet stems they should spring back Push assemblies poppet seat It should not move by hand If compo nents are bent or broken poppet stems don t spring back or poppet seat moves by hand go to Poppet Component Replacemen
4. tw RW Automoti Commercial Steering un THP PCF Steering Gear Service M anual THP PCF 45 AND 60 SERIES Hazard Warning Definitions AN NTT fem A warning describes hazards or unsafe practices which could result in severe personal injury or death AN AIIIN A caution describes hazards or unsafe practices which could result in personal injury or product or property damage NOTE A note gives key information to make following a procedure easier or quicker Disclaimer This Service Manual has been prepared by RW Commercial Steering Systems for reference and use by mechanics who have been trained to repair and service steering components and systems on heavy commercial vehicles TRVV Commercial Steering systems has exercised reasonable care and diligence to present accurate clear and complete information and instructions regarding the TRW Commercial Steering THP PCF Series Integral Power Steering Gears Since this is a general service manual the photographs and illustrations may not look exactly like the steering gear being ser viced The procedures therefore must be carefully read and understood before Servicing If inspection or testing reveals evidence of abnormal wear or damage to the THP PCF steering gear or if you encounter circum stances not covered In the Manual STOP Consult the vehicle manufacturer s Service Manual and warranty Do not try to repair or service a THP PCF steering gear which has been
5. Dirt and Water Seal 7 8 Serr Dirt and Water Seal 1 Serr Retaining Ring Seal Input Shaft Valve Housing Assembly Auxilliary Port O ring 2 Auxilliary Port Plugs 2 Relief Valve 2 Piece O ring Relief Valve Cap O ring Valve Housing Bearing Assembly O ring Seal Ring Worm and Valve Assembly Thrust Bearing 34 Thrust Washer Seal Ring O ring Bearing Adjuster Lock Nut O ring Seal Ring Push Tube Poppet Spring Poppet 2 Poppet Seat amp Sleeve Assy 2 Rack Piston Balls Ball Return Guide Seal Cap Ball Return Guide Cap Torx Screw 2 Housing S fe Dirt and Water Seal Trunnion Grease Fitting Plug Auto Bleed Fixed Stop Screw Poppet Poppet Adjusting Screw Nut Poppet Adjusting Screw Bearing Roller Seal 2 Output Sector Shaft Assembly Sector Shaft Adjusting Screw Washer Bearing Roller Side Cover O ring Side Cover Assembly Jam Nut Vent Plug Side Cover Bolts Side Cover 6 These items are included in complete seal kits along with 045422 lubricant and a service bulletin 8 THP PCF Service Parts List Common Parts Parts Vary by Specification Item Description Part Number Item Description 1 Bolts 4 Valve Housing 023037 5 Valve Housing 2 Dirt and Water Seal 13 16 Serr 478044 8 Relief Valve 2B Dirt and Water Seal 7 8 Serr 478060 15 Input Shaft Valve Worm Assy 2C Dirt and Water Seal 1 Ser 478050 28 Rack Piston 3 Retaining Ring 401637 34 Hou
6. and improved position feedback control less hysterisis e Allows separation of parking efforts from on highway efforts e Premium performance steering gear designed for line haul vehicles Design THP PCF gear is based on the TAS model s proven steering gear technology plus e mproved side cover design that reduces weight package size more robust seal and a roller bearing to reduce friction and wear e Material and design changes made to operate at the higher pressure Contents Section 1 Section 2 Section 3 Section 4 Section 5 General Information INUOGUCHIO EE 2 BIR Gelee e EE 3 General DESIO WEE 4 General Ree EE 5 Approved Rly Ol UIC FIS EE 6 Approved Grease EE 6 Gear SO SCINCA ion NUIT OSI S sai 6 He se Ua Ee 7 EXDIOGEUNIEW Gases aasan au atas am uu ude 8 Dee lg t etic cat rt RI 9 Initial Installation SECO EE 13 F019 5 L SG l uu nasqa amun nT hamu khatata kakunqa 13 NIIMICHARCe PS EE 14 On Vehicle Service Filling and Air Bleeding the System 16 Input Shaft Seal Replacement asas neces eeeeeeeeneeeneees 17 Sector Ssnaft AJUSTEN EE 21 Poppet Readjustment SASE O EE 23 Dual Gres espace Me 26 Milt eigent Le 27 Neverse lmMage panira E a 29 Reseal amp Repair Bie e E 34 INSPEGHON fata 42 Seriana 44 Internal Damage Repair by reference Poppet Component Replacement 51 Valve Housing Worm Screw Disassembly 53 Roller Bearing Replacement
7. 3 4 or 116 12 point socket inelb Torque wrench Torque locknut J37070 J37464 ftelb Torque wrench Check input shaft torque 20 21 22 23 24 Lightly oil and assemble bearing adjuster 20 over worm and Into valve housing Torque adjuster to 13 ftelb 18 Nem indicated torque using a torque wrench inserted in adjuster tool J37070 This will seat the components Back off adjuster to 1 2 of a turn Lightly oil and assemble new locknut 21 onto bearing adjuster 20 with radius slightly rounded side down Tighten slightly to keep the bearing adjuster in place Reverse assembly in vise so the worm end is down With an inch pound torque wrench on the input shaft note torque required to rotate the input shaft 360 in each direction Tighten the bearing adjuster to Increase the maximum torque at the input shaft 5 10 inelb 5 1 0 Nem over that which was previously noted Again reverse the assembly in vise Torque locknut while holding bearing adjuster in position estab lished in step 22 with appropriate adjuster tool When using a torque wrench in locknut tool 437464 the torque wrench reading should be 112 ftelb 152 Nem Recheck input shaft torque It should match torque measured in step 22 Repeat steps 22 and 23 if necessary 57 Stake valve 25 housing and locknut Center punch Hammer 1346 Socket inelb Torque wrench Reposition 26 subassembly in v
8. Torque wrench 14mm X 2 0mm Ratchet All Thread Press seal into 4 AII gears Assemble new seal 40 onto bearing and housing seal tool short end so the lip with the garter spring is toward the shoulder of the tool Working from J37705 the side cover side of the housing pilot the seal tool THP PCF45 into the washer and bearing and press with a force J27071 of 100 800 Ib 445 3 560 N until the seal is seated THP PCF60 firmly Install dirt amp water 6 Install the dirt amp water seal 35 with the bearing and seal seal tool long end making sure it is not cocked Press the seal only until it seats against the bearing don t push it in farther Press Liberally pack the roller bearing and new seals with clean high temperature industrial grease Exxon Polyrex EP P N 045422 44 Assemble seal rings Install rack piston o ring and seal ring Position rack piston in housing Insert worm and valve assembly into rack piston 14mm X 2 0mm All Thread 4 6 Lightly oil new seal ring 11 and assemble in valve housing mounting face groove Then oil new seal ring 10 and assemble in valve housing 5 mounting face groove Install a new backup o ring 22 and then a new Teflon seal ring 23 on rack piston 19 Do not over stretch these rings as you Install them Do not allow the Teflon seal ring to be twisted Apply clean oil to housing cylinder bore Place the rack piston 28 In the housing piston bore w
9. Unstake the valve housing 5 where it was upset locknut into the adjuster locknut 21 slot Also unstake adjuster nut from adjuster 20 Roll pin punch Hammer Remove bearing 3 Turn bearing adjuster locknut 21 out of the valve adjuster locknut housing J37464 Remove bearing 4 Turn bearing adjuster 20 out of the valve housing adjuster J37070 53 Remove seal ring 5 Remove and discard seal ring 18 and o ring 19 and o ring from bearing adjuster Small probe or pick Remove input shaft 6 Remove the input shaft valve worm assembly 15 trom the valve housing 5 Remove thin 7 Remove thin thrust washer 17 and thrust bearing washer and 16 from input shaft 15 bearing AN AVIDAN Input shaft valve worm assembly must not be disassembled further The components were a select fit at assembly and are available only as part of this subassembly If disas sembled further the subassembly must be replaced Remove ball 8 Remove bearing 12 trom valve housing bearing AN IPT YIL IS Do not remove the ball cup that the bearing 12 rides on Do not remove the special spacer seal behind the ball cup Remove seal ring 9 Remove and discard seal ring 14 trom valve housing 5 Small probe or pick 54 Remove retaining ring Screwdriver Remove seal 1 Socket Hammer Inspect input shaft valve worm assembly sealing areas Inspect thrust washer and bearings Place val
10. face Is not square use shims to square it before pressing in the bearing Return to step 29 page 40 Replace Housing Port Plugs Screws and Fittings Tools Required Materials Required Allen wrench Torx sockets SAE Metric sockets Open end wrench inelb Torque wrench ftelb Torque wrench Replace poppet fixed stop screw THP PCF45 18mm Socket THP PCF60 DE Socket ftelb Torque wrench Replace poppet adjusting screw THP PCF45 6mm Allen wrench 18mm Socket 19mm Wrench THP PCF60 7 32 Allen wrench 58 Socket 3 4 Wrench 1 2 ftelb Torque wrench Replace automatic bleed screw and aux port plugs E 14 Torx socket ftelb Torque wrench Replace manual bleed screw Sie Hex socket inelb Torque wrench 3 4 If damaged remove and replace the poppet fixed stop screw 38 and washer Not shown if equipped Replace with poppet fixed stop screw 38 discard the washer Torque to 48 ftelb 65 Nem If damaged remove poppet adjusting screw 38A and sealing nut 38B without allowing the nut to change Its position on the screw Assemble the new nut onto the new adjusting screw matching Its position to the nut and screw removed Torque sealing nut to 35 ftelb 47 Nem If damaged remove and replace automatic bleed plug 38 Torque to 48 ftelb 65 Nem If damaged remove and replace permanent auxiliary port plugs 7 and o rings 6 Assemble new o rings
11. inside dia of the new input shaft seal and place it over the Input shaft With the small dia of tool J37073 against the seal tap the tool until the tool shoulder is square against the valve housing Remove any seal mate rial that may have sheared off in the seal bore or retaining ring groove AN CAUTION Do not use a socket to install this seal because you will not be able to control seal installation depth possibly causing a leak Insert new retaining ring into the groove Pack the end of the valve housing bore around the Input shaft with grease 045422 Choose the correct size dirt amp water seal by comparing the choices to the old seal or by measuring the major diameter of the input shaft serrations see chart next page Apply more grease 045422 to the new dirt amp water seal and install it over the input shaft Seat it in the groove behind the serrations and against the valve housing 19 20 Reconnectcolumn 15 Reconnect the steering column to the input shaft and tighten the pinch bolt to torque level specified Reconnect return 16 Reconnect the return line to the steering gear return line port Air bleed system 17 Air bleed the system using the procedure on pg 16 Seal PartNo Saerration Size Major Serration Dia 478044 13 16 x 36 0 807 0 799 478060 7 8 x 36 0 866 0 857 478050 1 x 36 0 987 0 977 478050 1 x 79 1 008 1 000 Sector Shaft Adjustment This adjustment can only be compl
12. must be set according to vehicle manufacturer s specifications and the pitman arm must be correctly aligned on the sector shaft for poppets to be set correctly Full turn in one 1 With the engine at idle and the vehicle unloaded direction turn the steering wheel to full travel in one direction until axle stop contact is made Maximum input torque to be applied during this procedure is 40 Ib rim pull 178 N on a 20 In 508mm diameter steering wheel If you encounter excess rim pull effort allow the vehicle to roll forward or jack up the vehicle at the front axle Full turn in other 2 Follow the same procedure while turning the direction steering wheel in the other direction The poppets are now positioned to trio and reduce pressure as the steered wheels approach the axle stops in either direction 13 Maintenance Tips Never high pressure wash or steam clean a power steering gear while on or off the vehicle Doing so could force contami nants inside the gear and cause it to malfunction Make sure vehicle wheel cut or clearances meet manufacturer s specifications and make sure pitman arm timing marks are aligned properly to prevent internal bottoming of the steering gear Regularly check the fluid and the fluid level in the power steering reservoir Keep tires inflated to correct pressure Never use a torch to remove pitman arm Investigate and immediately correct the cause of any play rattle or shimm
13. rack piston 1 Inspect the rack piston 28 teeth for cracks or teeth obvious damage If teeth are damaged replace the rack piston sector shaft 41 and set of balls 29 Inspect rack piston 2 Inspect the rack piston 28 ball track grooves for and worm ball brinelling or spalling If either condition exists track grooves replace the input shaft valve worm assembly 15 valve housing 5 rack piston subassembly 28 and balls 29 42 Inspect input shaft valve worm assembly sealing areas Inspect housing cylinder bore Inspect valve housing surface Inspect side cover bearing Inspect sector shaft assembly 3 4 6 7 Inspect the sealing area of input shaft and valve 15 for nicks and damage Inspect for discoloration from excess heat Inspect input shaft ball track grooves for brinelling or spalling If any of these conditions exist replace the input shaft valve worm assembly valve housing and balls Also replace rack piston if brinelling or spalling is found Inspect the housing 34 cylinder bore some scoring marks are normal If there was internal leakage greater than 1 2 gom 4 5 lom make sure there are no damaged seals before replacing the housing Inspect the valve housing mating surface for nicks that would prevent proper sealing Replace the gear housing if these nicks are present and cannot be easily removed with a fine tooth flat file without changing the dimensional chara
14. t stay In place while torquing It might be necessary to hold in place with an arbor press while applying loosening torque Discard poppet seat and sleeve assembly Remove poppet 4 Remove the two poppets 26 spring 25 and push components tube 24 Poppet Components Re DOE Poppet w CH Push Tube Sleeve Assembly Poppet Seat and DI 52 Remove other seat amp sleeve if necessary Reset remaining poppet seat and sleeve assembly Press 3 2 X 6 Drill rod Apply Locquic T primer and Loctite RC680 Locquic T primer Loctite RC680 Install one poppet seat and sleeve assembly Soft jawed vise Install remaining poppet compo nents J36452 A ftelb Torque wrench Di Remove and discard remaining poppet seat and sleeve assembly only if required It is possible to reset one poppet adjuster seat and sleeve assembly for automatic poppet adjustment while it is in the rack piston if one adjuster seat and sleeve assembly and the poppets spring spacer rod and push tube are removed If one poppet seat and sleeve assy 27 was left in rack piston it can be reset for automatic poppet adjustment by inserting a 3 2 9 52 mm diameter X 6 152 4 mm drill rod down through the poppet seat hole at the opposite end of the rack piston and against the adjuster seat to press the seat in until it bottoms against the adjuster sleeve
15. 3 Rack Piston O ring 032827 032831 30 Ball Return Guide Halves 2 R H 400158 400172 IHR 400159 400173 35 Dirt and Water Seal Trunnion 478098 478095 39 Holler Bearing Trunnion 070030 071033 40 Output Seal 2 478105 478104 42 Washer 028561 028557 43 Side Cover Roller Bearing 070031 071035 38 Fixed Stop Screw 023044 021426 38A Poppet Adjusting Screw 023045 021407 38B Poppet Adjusting Screw Nut 027018 025119 Section 2 Initial Installation EF Gs SU Atl OWN u u u l uuu unupa 13 Hee Seting u u u ee EE 13 Klenger Le EE 14 E G i amh D ct Initial THP PCF Installation e Bolt steering gear to frame torque bolts to vehicle manufacturer s recommendation e Connect return line to THP PCF gear return port e Connect hydraulic line from pump to pressure port on THP PCF unit e Connect steering column to input shaft torque pinch bolt to vehicle manufacturer s recommendation e Install pitman arm on output shaft torque bolt to vehicle manufacturer s recommenda tion Initial Poppet Setting For this procedure to work correctly you must have A new gear received from TRW or your vehicle manufacturer s aftermarket system or a used gear on which poppet seats have been replaced or reset during gear disassembly procedures ALSO A fixed stop screw installed in the housing or a poppet adjusting screw installed so that it dupli cates the fixed stop screw length AN Wifi The axle stops and all steering linkage
16. 45 50 inelb 5 5 5 Nem of torque required to rotate the input shaft valve worm assembly 15 through one half turn 180 each side of center inelb Torque wrench Screwdriver 1 16 or 3 Socket This procedure will properly mesh and seat the rack piston and sector shaft teeth for final adjustments Loosen adjusting 3 Turn sector shaft adjusting screw 41A counter screw and note clockwise one half turn and note maximum torque torque required to rotate the input shaft valve worm assembly through one half turn 180 each side of inelb Torque ale wrench Screwdriver 11 6 Socket Adjust adjusting screw Zu Socket 116 Socket ftelb Torque wrench inelb Torque wrench 4 Adjust sector shaft adjusting screw 41A clockwise to increase maximum torque noted in step 3 by 7 inelb 8 Nem Tighten jam nut 47 firmly against side cover while holding the adjusting screw in position Finally torque jam nut to 43 ftelb 58 Nem and check input shaft valve worm assembly torque again Readjust if input shaft torque exceeds 40 inelb 4 5 Nem 63 Section 5 Reinstallation KE VE E 65 Weieen e e EE 65 Eer 66 ad d A amh D Reinstallation e Verify that axle stops are set to manufacturer s wheelcut or clearance specifications e Bolt gear to frame torque to vehicle manufacturer s recommendation e Connect return line to reservoir in THP PCF return port e Connect hydraul
17. Carefully apply Locquic T primer to the threads in poppet holes and threads on the new seat and sleeve assemblies 27 Allow to dry for ten min utes then carefully apply Loctite RC680 to same threads AN AINI MN Do not allow Loctite or Locquic to get on the adjuster seat component of the adjuster seat and sleeve assembly The poppets will not function properly AN IPT AIT IS Wear eye protection while assembling poppets as spring loaded poppets could eject and cause eye injury Place rack piston 28 in a soft jawed vise and turn one new poppet adjuster seat and sleeve assembly 27 Slotted end out into the poppet hole in one end of rack piston From the other end of the poppet hole in the rack piston Install one poppet 26 poppet spring 25 push tube 24 other poppet 26 and the other new poppet adjuster seat and sleeve assembly 27 The new components will stack up as shown below Torque both poppet seat and sleeve assemblies to 18 ftelb 25 Nem Return to step 25 page 40 Valve Housing Worm Screw Disassembly Tools Required Materials Required Hammer inelb Torque ftelb Torque wrench wrench J37464 Punch center J37070 Punch roll pin 357073 Screwdriver Small probe or pick Sockets 12 point sockets Place valve 1 With worm vertical place the valve housing 5 housing and valve input shaft valve worm assembly 15 in a vise assembly in vise Unstake adjuster 2
18. Port Plugs and Screws on page 61 If not proceed to the Inspection Section 41 Inspection Make sure all sealing surfaces and seal cavities are free from nicks and corrosion Any nicked or corroded surface requires part replacement to ensure proper sealing Wash all parts in clean OSHA approved solvent Air blow them dry only AN WAPATA Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death AN ITA IO Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements AN P II Any of the following conditions present in the steering gear indicates impact damage Condition Area Brinelling e Ball track grooves of rack piston e Ball track grooves of worm screw e Bearing area of sector shaft e Thrust washer and bearing in valve housing e Ball cup and bearing in valve housing Cracks or Breaks e Bearing area of sector shaft e Sector shaft teeth e Rack piston teeth e Housing e Thrust washer and bearing in valve housing e Worm screw e Ball cup and bearing in valve housing Twisted serrations Output shaft serrations If one of these conditions is found in one component be sure to inspect all components carefully for signs of impact damage Replace components noted in individual inspection steps below if you suspect impact damage Failure to replace all damaged components could result in a serious vehicle accident Inspect
19. ainer adjusting screw threads The retainer 41B not shown must be securely staked in place The adjusting screw must rotate by hand with no perceptible end play lash Remove relief 14 If equipped remove relief valve cap 10 o ring 9 valve components and two piece relief valve 8 from the valve hous ing Discard the o ring 37 Remove dirt amp 15 Remove and discard the dirt amp water seal 2 2B or water seal 2C from the input shaft worm and valve assembly Save this seal for comparison with the new seal wee Clean input shaft 16 Clean any paint or corrosion from the exposed area of the input shaft Fine grade emery cloth Remove valve 17 Remove the four torx head valve housing bolts 1 housing bolts E 18 Torx socket Remove valve 18 Be prepared for more fluid drainage and remove the housing worm and rack piston subassembly Place the assembly on a rack subassembly clean cloth N CAUTION The set position of poppet seat and sleeve assemblies 27 must not be disturbed if the poppets are not going to be replaced or reset during disassembly Remove seals 19 Remove and discard the valve housing seal rinos 11 amp 13 AN NIR Do not remove the input shaft valve worm assembly or balls from the rack piston until the ball return guides are removed as damage to the ball guides will occur 38 Remove ball return 20 Remove and discard the two special sealing screws guide cap 33
20. ars which are mounted with the output shaft above the rack piston bore are equipped with either an automatic bleed system or a manual bleed screw The procedure for air bleeding the system is on page 16 of this manual Replacement of damaged automatic bleed plugs and manual bleed screws is described on page 61 Approved Hydraulic Fluids Automatic Transmission Fluid Dexron ll Mobil ATF 210 Automatic Transmission Fluid Type E or F Mobil Super 10W 40 Motor Oil Chevron 10W 40 Premium Blue 2000 SAE 15VW 40 Chevron Custom 10VV 40 Motor Oil Texaco 10VW 40 Chevron Torque 5 Fluid Texaco TL 1833 Power Steering Fluid Exxon Nuto H32 Hydraulic Fluid Union 10VV 40 Fleetrite PSF Can 990625C2 Union 15W 40 Ford Spec M2C138CJ Unocal Guardol 15VV 40 Motor Oil Mack EO K2 Engine Oil The steering system should be kept filled with one of the above fluids AN WANT OT Completely flush the steering system with one of the recommended fluids above only Do 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 Approved Grease Exxon Polyrex EP2 P N 045422 Gear Specification Numbers The steering gear specification number and date code are stamped ona machined surface opposite the input shaft of every THP PCF gear An example date code would be 29001 this means THPxxxxx the gear wa
21. ate and install the four valve housing bolts 1 into the housing Torque the bolts to 118 138 ftelb 160 187 Nem 47 48 Install relief valve 13 parts 7g Socket ftelb Torque wrench Lubricate side 14 cover bearing Press seal In side 15 cover J37705 THP PCF45 J37071 THP PCF60 Press Lubricate sector 16 shaft Install sector shaft 17 into side cover Screwdriver If the gear is equipped with a relief valve assemble a new o ring 9 on relief valve cap 10 Assemble the small end of tapered spring onto the pin on the relief valve cartridge and insert the assembly 8 large end of tapered spring end first into the relief valve cap cavity Turn the relief valve cap as as sembled into the valve housing and torque to 30 ftelb 41 Nem Apply a generous amount of Exxon Polyrex EP2 TRW P N 045422 do not substitute another type of grease to the caged bearing assembly inside the side cover Next install washer 42 on top of bearing before inserting the seal 40 N III OBB This bearing is sealed and will receive no lubrication from the hydraulic fluid in the gear Failure to use the proper grease could result in premature bearing wear Grease and assemble new seal 40 onto installation tool so the side with the garter spring is against the shoulder of the tool Pilot the tool into the side cover 45 with a force of 100 800 Ib 445 3560 N until it is seated against
22. chet until the Allen wrench stops Do not attempt to turn It In further Pause the turning in process each time the driver releases the steering wheel continue turning only while the wheel is held at full turn c Back off the adjusting screw 3 turns and tighten the sealing nut Torque sealing nut to 35 ftelb 48 Nem The poppets have now been completely reset Lower the vehicle Check the reservoir and fill if required AN VAPAINA The length of the adjusting screw beyond the nut must be no more than 11 6 for proper thread engagement The length of adjusting screw beyond the sealing nut may be different for each vehicle 25 Poppet Readjustment Dual Gears Mirror Image Systems and Reversed Image Systems Before setting poppets on a dual gear system you must determine whether the system has mirror image gears or reversed image gears The procedures are slightly different for each type of system 26 Park the vehicle with the wheels turned all the way to the axle stop In either direction Turn the vehicle off Look at the output shaft timing mark nearest the housing piston bore on the master gear Is this mark pointing toward the poppet screw or away from it Now check the same timing mark on the rotary cylinder Does it point toward the poppet screw or away from it If they point to opposite ends of the gears you have a mirror image system see pg 27 If they both point toward the poppet screws or b
23. cteristics Inspect roller bearing in side cover assembly 45 for brinelling or spalling If either condition exists replace the side cover and bearing assembly Inspect the sector shaft 41 bearing and sealing areas and sector teeth contact surfaces for brinelling spalling or cracks Run your fingernail edge across these areas to detect steps Remove masking tape from the shaft and inspect for twisted or otherwise damaged serrations If any of these conditions exist replace the sector shaft A service sector shaft will come assembled with the adjusting screw 41A and retainer Not shown 43 Assembly Preparation Wash all parts in clean OSHA approved solvent Air blow dry them only OTTO Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death OTTO Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements Replace all seals seal rings and gaskets with new ones each time you disassemble the gear TRW Commercial Steering Division makes complete seal kits available These parts can be purchased through most OEM parts distributors Contact your local dealer for availability Assembly Tools Required Materials Required Hammer Screwdriver ATF oll seal kit THP450001 J37705 THP PCF45 Sockets Grease Exxon THP600001 J37071 THP PCF60 Torx sockets Polyrex EP2 Press Vise Masking tape Punch
24. d on the steering wheel put 40 lbs rim pull on a 20 dia steering wheel after the axle stop Is contacted 8 a Turn the steering wheel in the opposite direction end of timing mark away from adjusting screw until the other axle stop Is contacted b Pull hard on the steering wheel put 40 Ibs rim pull on a 20 dia steering wheel c Release the steering wheel and shut off the engine 9 Loosen the sealing nut and back out the adjusting screw until 1 Is past the nut on both the master gear and the rotary cylinder Tighten the sealing nuts against both housings Do not hold the steering wheel at full turn for more than 10 seconds AN CAUTION at a time the heat build up at pump relief pressure may damage components 10 a Start the engine and let it idle b Turn the steering wheel in the original direction end of timing mark toward adjusting screw until axle stop contact Is made c Hold the steering wheel in this position with 40 los rim pull for 10 seconds then release Repeat this hold and release process as many times as necessary while completing steps 11 and 12 first on the master gear then on the rotary cylinder 29 11 12 13 30 a With steering wheel held at full turn loosen the jam nut on the master gear and hold it in place with a wrench b Turn the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to a sto
25. damaged or includes any part that shows excessive wear unless the damaged and worn parts are replaced with original TRW replacement and service parts and the unit Is restored to TRW s specifications for the THP PCF steering gear It is the responsibility of the mechanic performing the maintenance repairs or service on a particular THP PCF steering gear to a inspect the steering gear for abnormal wear and damage b choose a repair procedure which will not endanger his her safety the safety of others the vehicle or the sate operation of the vehicle and c fully inspect and test the THP PCF steering gear and the vehicle steering system to ensure that the repair or service of the steering gear has been properly performed and that the steering gear and system will function properly Patents TRW Commercial Steering Systems THP PCF power steering gears are covered by several United States and foreign patents either issued or pending TRW Inc 2001 Design Features Size Reduced package size for increased wheelcut Weight Reduced weight for improved vehicle efficiency Improved Steering Performance e Faster steering ratio for improved handling and lower lock to lock turns e Low internal friction for better return to center High Pressure Capability Provides for the smallest and lightest package Positive Center Feel Optional e Provides steering precision through improved straight ahead torque feedback more stiffness
26. e Check the reservoir and fill if required AN dd It The length of the adjusting screw beyond the nut must be no more than 11 6 for proper thread engagement The length of adjusting screw beyond the sealing nut may be different for each vehicle Poppet Readjustment Dual Gears Reversed Image Tools Required THP PCF45 6mm Allen wrench 19mm Open end wrench Open end wrench 3 4 Socket Open end wrench ftelb Torque wrench Materials Required Hydraulic fluid Jack 19mm Socket 18mm Open end wrench THP PCF60 732 Allen wrench 1 Set the axle stops to vehicle manufacturer s wheelcut or clearance specifications Start the engine and allow the vehicle to idle for 5 10 minutes to warm the hydraulic fluid Shut off the engine 2 If new poppet adjusting screws and nuts are being used turn the screws into the non sealing end of the jam nuts until the drive end of screw is flush with the nut Your steering gear and rotary cylinder will have either fixed stop bolts or adjusting screws If the adjusting screw is already part of the steering gear or cylinder back the nut off of the adjusting screw until it is flush with the end of the adjusting screw 3 Make sure the engine is off and the road wheels are in straight ahead position Remove and discard the poppet fixed stop bolts if equipped and washers it equipped from the lower end of housing on both the master gear and the rotary cylinder
27. ears Integral hydraulic power steering means that the gear contains a manual steering mechanism a hydraulic control valve and a hydraulic power cylinder all in a single compact package Rotary Control Valve The rotary control valve combines simplicity of construc tion with desirable performance characteristics The Speed at which the driver can turn the steering wheel with power assist is dependent upon the pump flow measured in gallons per minute or liters per minute directed to a cylinder cavity The control valve controls flow through the steering gear The pressure measured in pounds per square inch or bar required for the gear to steer the vehicle is created by the power steering pump to overcome resistance at the steered wheels The control valve senses these requirements and directs fluid to the appropriate cylinder cavity in the steering gear and in the auxiliary cylinder if it is a dual steering system at the proper flow rate and pressure Pressure Means Work Flow Means Speed The higher pressure a steering gear can withstand the more work it can perform The maximum operating pressure for all THP PCF gears is 2685 psi 185 bar maximum flow rate for all THP PCF gears is 6 gom 22 7 lom The THP PCF series gears can steer a vehicle within its front end weight rating through a turn at low speed and engine idle As the driver turns the steering wheel faster or slower more or less fluid will be required by the gea
28. eat build up at pump relief pressure may turn the adjusting screw and sealing nut assembly damage components without rotating the nut on the screw into the housing until the nut is firmly against the housing io a Saris tama ana tasha using a 6mm THP PCF45 or 782 THP PCF60 allen wrench Tighten the sealing nut against the housing Refill system reservoir with approved hydraulic fluid N CAUTION Do not mix fluid types Mixing of transmission fluid motor oil or other hydraulic fluids will cause seals to deteriorate faster Place a jack under the center of the front axle and jack up the front end of the vehicle so the steer axle tires are off the ground b Turn the steering wheel in the original direction end of timing mark on the gears toward adjusting screw until axle stop contact Is made c Hold the steering wheel in this position with 40 los rim pull for 10 seconds then release Repeat this hold and release process as many times as necessary while completing steps 11 amp 12 2 11 12 13 14 28 a With steering wheel held at full turn loosen the I5 jam nut on the master gear and hold it in place with a wrench b Turn the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to a stop Do not attempt to turn it in farther Pause the turning in process each time the driver releases the steering wheel Continue turning
29. eck for lash ke Connect drag link Di dh 8 If no lash was detected in step 3 turn the shaft adjusting screw counterclockwise until you feel lash at the output shaft Slowly turn the shaft adjusting screw clockwise until you feel no lash at the output shaft without using more than 10 ftelb 14 Nem of torque From this position turn the screw clockwise to 6 of a turn more Hold the adjusting screw in place and tighten the jam nut Final jam nut torque 43 ftelb 58 Nem Turn the steering wheel Wa turn each side of center then back to center and recheck the pitman arm for lash You should feel no lash if there is lash repeat steps 4 6 and 7 Reconnect the drag link to the pitman arm according to manufacturer s specifications N CAUTION Maintain grease in the sector shaft bearing through the grease fitting in the housing using only a hand operated grease gun Add grease until it begins to extrude past the dirt and water seal Do not use a power grease gun because it will supply grease too fast this could adversely affect the high pressure seal and contaminate the hydraulic fluid Poppet Readjustment Single Gears This resetting procedure will work in most cases with at least 1 hand wheel turns from each side of center If you re making a large reduction in wheelcut and this procedure does not work you may have to replace or internally reset the poppets using the procedure de scribed in the Poppe
30. es the procedure with photographs column 2 gives a brief key as well as tools to be used for each procedure and column 3 explains in detail the procedure you should follow Pay special attention to the notes cautions and warnings Item numbers on the exploded view correspond with item numbers in that are used throughout the service manual As you gain experience in servicing THP PCF series steering gears you may find that some information in this service manual could be clearer and more complete If so let us know about it Don t try to second guess the service manual if you do not understand a procedure or are stuck contact our Field Service Department at 317 423 5377 servicing THP PCF series steering gears should be safe and productive Oil Flow Illustration Left Hand Lead AY Right Hand Turn steering Wheel Input Clockwise Rotation WWW CR A S O zB Straightline Running No Steering Action ANI Left Hand Turn Steering Wheel Input Counter Clockwise Rotation Supply Pressure Return Pressure Right Hand Lead AN AY AY S i So A eee General Design Integral Power Steering THP PCF power steering gears are the latest design in the TRW Commercial Steering Systems family of integral hydraulic power steering g
31. eted on the vehicle if the adjusting screw Jam nut is accessible This nut is located on the side cover Tools Required Materials Required Screwdriver 3 4 Socket i Photos in this section were taken on a mock frame rail for 3 Open end wrench clarity Center the sector 1 With the engine on rotate the steering wheel input shaft shaft until the timing mark on the sector shaft lines up with the mark on the housing The line on the sector shaft should be at a 90 angle from the input shaft The sector shaft is now on its center of travel Turn the vehicle off Remove the drag 2 Remove the drag link from the pitman arm link AN CAUTION To avoid resetting the poppets do not rotate the input shaft more than Is turns from the center of travel position while the drag link is disconnected Check for sector 3 From the center of travel position grasp the shaft lash pitman arm and gently try to rotate it back and forth If looseness or lash is felt at this point the sector shaft is out of adjustment Loosen jam nut 4 Loosen the jam nut If the gear is removed from the vehicle to adjust the lash e Leave the pitman arm connected to the gear e Best option Is to follow the Final Adjustment procedure on page 62 e Alternate option is to continue with step 5 of this procedure 21 22 Position adjusting screw Screwdriver Adjust shaft Screwdriver Open end wrench Rech
32. f 18 ftelb 24 5 Nem Is achieved AN CAUTION Ball cap seal is greased to hold seal in groove while assembling Be sure not to trap the seal outside of the groove during reassembly Rotate the input shaft from one end of travel to the other without contacting the poppet stem to the valve housing and without moving the valve hous ing face more than 2 69 1 mm from input end upper end of rack piston If you cannot rotate the input shaft remove the balls and reassemble them AN WAPEANA If you install a gear on a vehicle with the worm shaft unable to rotate the gear will not function correctly Steering and gear failure may result Apply clean oil to Teflon seal ring 23 on rack piston Make sure there is a space of 1 2 10 0 13 0 mm between valve housing 5 and poppet stem to prevent poppet contact at either end Remove the All Threads and push the rack piston assembly into the housing with the rack piston teeth toward the sector shaft cavity Line up the valve housing cylinder feed hole with the gear housing feed hole Make sure both o rings in the valve housing remain In position ANEH LOLE Do not damage the seal ring 23 while installing the rack piston into housing AN CAUTION The poppet seat and sleeve assemblies 27 must not bottom against the internal poppet stops in the steering gear until the gear is installed on the vehicle and the poppet adjustment procedures are performed Lubric
33. g 3 Into its groove in valve ring housing 5 58 Install dirt amp water seal Grease 29 Pack the end of the valve housing bore around the Input shaft with clean high temperature industrial grease Exxon Polyrex EP2 P N 045422 Apply more of the grease to the inside of a new dirt and water seal 2 2B or 2C and install it over the input shaft Seat the seal in the groove behind the serrations and against the valve housing Return to step 26 page 40 DO Roller Bearing Replacement Tools Required Materials Required Press J37705 THP PCF45 J37071 A THP PCF60 60 Remove roller bearing if required J37705 THP PCF60 Press Press in housing roller bearing J37705 THP PCF60 Press 1 2 If roller bearing 39 in housing needs to be replaced place the bearing removal end long end of the bearing and seal tool against the trunnion end of the bearing and press it out of the side cover end of the bearing bore Discard bearing Press the new roller bearing 39 into the housing from the side cover end of the bearing bore until it Is seated against the step bore Be sure the housing Is square with the press base and the bearing Is not cocked ANEP I EN Use the bearing installation end of the tool short end If the bearing removal end of the bearing amp seal tool is used to press in bearing the cage on the new bearing may be damaged If the unmachined trunnion
34. ic line from pump to pressure port in THP PCF unit e Connect steering column to input shaft torque pinch bolt to vehicle manufacturer s recommendation e Install pitman arm on output shaft with timing marks aligned Torque bolt to vehicle manufacturer s recommendation e Connect drag link to pitman arm Poppet Resetting IF Poppets remain unchanged from when gear was After installation check to make sure poppets relieve in removed trom vehicle and gear is being installed on the both turns just before axle stop contact Is made If not same vehicle with no change in axle stops or linkage use resetting procedure beginning on page 23 2 gt IF Poppets were replaced with new components or Use poppet setting procedure on page 13 reset during gear disassembly and are ready for auto matic positioning 2 gt IF Poppets may have been moved during disassembly Use poppet resetting procedure beginning on page 23 or reassembly procedures or gear is being installed on a different vehicle 2 gt 65 Glossary Aerated Fluid Fluid with air bubbles Automatic Bleed Systems Gears are mounted in such a way that trapped air can be forced out of the system automatically without loosening bleed screw Axial In out movement along an axis imaginary straight line on which an object moves Brinelling Dents Date Code Date the steering gear was built Julian date Discoloration Change in co
35. ise Install input shaft 27 seal Je Hammer Stake valve housing into the clockwise most corner of two opposing slots in lock nut 21 Stake the locknut into the adjuster 20 in two places 180 apart at threaded area Choose areas that have not been previously staked After staking torque required to rotate input shaft must be between 5 10 inelb 5 1 0 Nem greater than the torque noted in step 22 Torque value must not exceed 22 inelb 2 5 Nem Unstake and readjust If necessary Reposition worm screw valve housing subassembly in soft awed vise clamping tightly against valve housing so the worm screw Is pointing down Apply clean grease Exxon Polyrex EP2 P N 045422 to the outside and inside diameters fill cavity between the lips of the new input shaft seal 4 and assemble it garter spring side first over the input shaft Align seal in the valve housing seal bore Place seal installer tool J37073 small diameter end first over the Input shaft and against the seal Tap the seal installer tool until the tool shoulder is squarely against the valve housing This will cor rectly position the seal in the housing bore Just beyond the retaining ring groove AN Nid Remove any seal material that may have sheared off and is in seal bore and retaining ring groove AN N id The input shaft seal must be square in the seal bore and installed to the correct depth Insert retaining 28 Insert new retaining rin
36. ith ball return guide holes up Insert the worm screw into the rack piston close to maximum depth without the valve housing making contact with the poppet stem Insert two 14 mm x 2 0 mm All Threads through valve housing bolt holes and tighten into housing to support the worm screw Line up rack piston ball guide holes with the worm ball track grooves by rotating the input shaft 45 46 Assemble ball return guide halves Assemble balls 8 Assemble the ball return guide 30 into the rack piston until seated rotate the input shaft slightly if necessary AN AV IM Do not seat guides with a hammer Damage to guides can result in subsequent lockup or loss of steering AN CAUTION If a new rack piston 28 or a new input shaft valve worm subassem bly 15 is being assembled the balls 29 removed from the unit must be discarded and a service ball kit utilized The balls in a service ball kit are sized to function in the ball track guide path as altered by component replacement AN CAUTION When using the service ball kit use the correct quantity of service balls THP PCF45 29 balls THP PCF60 31 balls Hold the ball return guide 30 firmly in place during this entire procedure Insert as many of the steel balls as you can through the hole in the top of the ball return guides Rotate the input shaft to pull the balls down and around the ball track guide path Continue until the correct number of ball
37. lor External Leakage Fluid Leaking out of the system or steering gear Full Turn Hub contacts axle stop Integral Power Steering steering gear has manual steering mechanism hydraulic control valve and hydraulic power cylinder all within gear housing 66 Impact The application of torques and forces to steering gear components during accidents or other similar events which exceed the hydraulic capacity of the steering gear Internal Leakage Fluid leaking Inside the gear Lash Free play Manual Bleed Systems Gears are mounted in such a way that an air pocket could form in one end of the steering gear The bleed screw Is positioned so trapped air can be forced out when loosened OSHA Occupational Safety and Health Administration PCF Positive Center Feel option available on THP series steering gears Poppets Unloading valves reduce pressure In full turns Relief Valve Limits maximum supply pressure Return Line Line that connects steering gear to reservoir to recirculate hydraulic fluid Rotary Control Valve Controls flow in internal cavities Scoring Scratch Shock Load Shake or jar Spalling Flaking or chipping Subassembly An assembled unit that fits into a larger unit Supply Line Line that connects pump to steering gear Twisted Serrations Output shaft serrations damaged by impact overload Serrations can be twisted at the area between the large diame
38. lve assists In moving the rack piston axially through the cylinder bore The rack piston then turns the sector shaft to steer the vehicle Shock Loads to the Gear If the steered wheels receive a shock load the shock forces are transmitted through the sector shaft to the rack piston and on to the worm shaft The internal geometry of the steering gear causes the control valve to send high pressure fluid to the correct cylinder cavity to resist the shock forces By absorbing the shock forces hydraulically the steering gear prevents objectionable kickback at the steering wheel Unloading Poppet Valves Most THP PCF gears are equipped with two unloading valves one at each end of the rack piston One valve or the other depending on the direction of turn will trip as the steered wheels approach the axle stops which must be set according to manufacturer s specification The tripped valve reduces pressure in the gear and helps to reduce heat generated by the pump At the same time the valves also reduce forces on the steering linkage These valves are automatically set to axle stops after installation in vehicle at first full right and left turn Relief Valve some THP PCF gears with or without poppets are supplied with a relief valve The relief valve limits maxi mum supply pressure to protect the power steering gear but It does not reduce pressure as the steered wheels approach the axle stops Bleed Systems some THP PCF ge
39. n the second and third tooth Is in the center of the sector shaft opening This will center the rack piston for assembly of sector shaft AN WANT fem Ifthe 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 Clean off any old tape on the serrations Reapply one layer of masking tape Install the sector shaft assembly into the housing The center tooth of the sector shaft must engage the center space be tween the second and third tooth of the rack piston Lightly tap on sidecover with a rubber hammer to seat cover against housing face AN CAUTION If the serrations are not properly taped they will damage the output seal 41 in housing causing the seal to leak 49 50 Install side cover bolts 19 6 Socket Torque wrench Remove tape Install dirt amp water seal Grease 23 24 25 Install bolts in positions 3 and 4 first by hand Then install the remaining side cover bolts 48 into the side cover and torque them in the sequence shown If bolts must be replaced use bolts of the same design type and length as those you removed Do not use a substitute Lubricate side cover bolts and torque bolts to 180 220 ftelb 244 298 Nem Remove tape from the sector shaft 41 Pack the end of the valve housing bore around the input shaft with clean high temperature industrial grease Exxon Poly
40. ng Replacement 60 Replace Housing Port Plugs Screws and Fittings 61 ial e WEE LE 63 ad CD GI CD D Qo ahd CD EZ D wm Disassembly Preparation Stop the vehicle with wheels pointed straight ahead Clean off all outside dirt from around fittings and hose connections before you remove the gear Remove input and output shaft connections per vehicle manufacturer s instructions AN WA ANA When using a chisel to spread a pinch bolt type pitman arm boss for assembly or removal from the shaft maintain a firm grip on the chisel at all times Failure to do 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 arm boss and use a puller only to remove pitman arm N CAUTION Do not use a hammer on the pitman arm to remove it from sector shaft as internal damage to steering gear could result Be sure there is no spreading wedge left in the pitman arm boss before tightening pitman arm clamp bolt after assembly on sector shaft Do not pound the universal joint or input shaft coupling on or off the input shaft as internal damage to the steering gear can result N VIII BB Unless the poppet adjuster seat and sleeve assemblies 27 are to be removed and replaced or reset for automatic poppet adjustment or a manual adjustment with a service poppet adju
41. on port plugs and torque to their respective ports In the housing or valve housing to 30 ftelb 41 Nem If damaged remove and replace manual bleed screw Not shown Torque to 45 inelb 3 4 Nem Possible manual bleed screw locations Return to inspection section page 42 61 Final Adjustments Tools Required Materials Required Box end Screwdriver wrench Sockets ftelb Torque wrench inelb Torque wrench Center steering 1 To center the steering gear rotate input shaft valve gear worm assembly 15 until the timing mark on the end of the sector shaft 41 Is in line with the timing Yn and ch mark on the end of housing trunnion Socket or box AN N id Do not rotate the input shaft more than 1 5 revolutions from center position until the steering gear is installed during poppet setting procedure Doing so could make the automatic poppets inoperative which would require disassembly of steering gear to reposition poppet seat and sleeve assemblies end wrench Initial poppet contact will occur at less than one Input shaft rotation in one direction from steering gear center position if new or reset poppet adjuster seat and sleeve assemblies are assembled in the unit Worm preload adjustment was set when input shaft valve and worm were assembled into valve housing Tighten adjusting 2 With adjusting screw Jam nut 46 loose turn sector screw shaft adjusting screw 41A clockwise to provide
42. only while the wheel is held at full turn c Back off the adjusting screw 3 turns and tighten the sealing nut Torque the sealing nut to 33 37 ftelb 45 50 Nem d Release the steering wheel and shut off the engine Loosen the sealing nut and back out the adjusting screw on the rotary cylinder until 1 is past the nut Tighten the sealing nut against the housing a Start the engine and let it idle b Turn the steering wheel in the opposite direction end of timing mark on master gear away from adjusting screw until axle stop contact Is made c Hold the steering wheel in this position put up to 40 b rim pull on a 20 dia steering wheel for 10 seconds then release Repeat this hold and release process as many times as necessary while completing step 14 a With steering wheel held at full turn loosen the jam nut on the rotary cylinder and hold it in place with a wrench b Turn the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to a stop Do not attempt to turn it in farther Pause the turning in process each time the driver releases the steering wheel Continue turning only while the wheel is held at full turn c Back off the adjusting screw 3 turns and tighten the sealing nut Torque the sealing nut to 33 37 ftelb 45 50 Nem d Release the steering wheel and shut off the engine The poppets have now been completely reset Lower the vehicl
43. ot to scratch the bore with the screwdriver Clean cloth Screwdriver 17 Replace column 5 Slip the steering column back onto the input shaft with the pinch bolt installed but not tightened Wrap exposed 6 Tie or wrap a shop towel around the input shaft area area and place a drip pan under the vehicle to catch the oll Drip pan Shop towel Fill reservoir 7 Add fluid as necessary to the full line on the dip stick Do not mix fluid types Hydraulic fluid AN ITA OT Any mixture of fluid types or use of any unapproved fluid 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 Force out the seal 8 With the vehicle in neutral momentarily turn the Starter quickly turn off the engine If it starts Remove input shaft 9 Remove the shop towel Disconnect the steering seal column and remove the input shaft seal 18 Inspect seal area Inspect old seal Install new seal Hammer J37073 Seal Driver Install retaining ring Install dirt amp water seal 10 11 12 13 14 Check the seal area of the valve housing for any seal fragments Remove any that are found Check the seal for heat damage If the seal is stiff and brittle and not pliable like the new seal It IS probably heat damaged Determine and fix the cause of excessive heat in the vehicle Put clean grease 045422 on the
44. oth point toward the end opposite the poppet screws you have a reversed image system see pg 29 Poppet Screw Lower Poppet SS e Upper Poppets m Lower Poppet w Poppet Screw Poppet Readjustment Dual Gears Mirror Image This resetting procedure will work in most cases with at least 1 hand wheel turns from each side of center If you re making a large reduction in wheelcut and this procedure does not work you may have to replace or internally reset the poppets using the procedure de scribed in the Poppet Component section of this Service Manual Tools Required THP PCF45 6mm Allen wrench 19mm Open end wrench Open end wrench 3 4 Socket Open end wrench ftelb Torque wrench Materials Required Hydraulic fluid Jack 19mm Socket 18mm Open end wrench THP PCF60 732 Allen wrench 1 Set the axle stops to vehicle manufacturer s 7 a Start the engine and let it run at idle speed wheelcut or clearance specifications b Turn the steering wheel in the direction that makes the timing mark on the master gear move toward the adjusting screw just installed Turn in this direction until axle stop contact Is made Start the engine and allow the vehicle to idle for 5 10 minutes to warm the hydraulic fluid Shut off the engine c Pull hard on the steering wheel p
45. p Do not attempt to turn it in farther Pause the turning in process each time the driver releases the steering wheel Continue turning only while the wheel is held at full turn c Back off the adjusting screw 3 turns and tighten the sealing nut Torque nut to 33 37 ftelb 45 50 Nem a With steering wheel held at full turn loosen the jam nut on the rotary cylinder and hold it in place with a wrench b Turn the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to a stop Do not attempt to turn it in farther Pause the turning in process each time the driver releases the steering wheel Continue turning only while the wheel is held at full turn c Back off the adjusting screw 3 turns and tighten the sealing nut Torque nut to 33 37 ftelb 45 50 Nem The poppets on both the master gear and rotary cylinder have now been completely reset Lower the vehicle Check the reservoir and fill if required AN dd VI The length of the adjusting screw beyond the nut must be no more than 1 6 for proper thread engagement The length of adjusting screw beyond the sealing nut may be different for each vehicle Section 4 Reseal amp Repair IS ASS NOI E 34 Hl SIC le EEN 42 ASSEMPI iter ek 44 Internal Damage Repair by reference Poppet Component Replacement ee 51 Valve Housing Worm Screw Disassembly 53 Roller Bearing or Retaining Ri
46. placement 17 Sector Shaft e E E RE EN Poppet Readjustment SNIE SC E 23 BIS KEE 26 Kill ergin Ce E 27 Reversed Image 29 T lt N lt O Filling and Air Bleeding the System Tools Required Materials Required 16 Socket Hydraulic fluid inelb Torque wrench Run engine for 10 seconds turn off and fill reservoir Hydraulic fluid Run engine for 2 minutes turn off and fill reservoir Hydraulic fluid Steer vehicle I Auto Bleed Plug Do Not Remove Manual Bleed Screw Screw inelb Torque wrench Ye Socket 16 Allow air to bleed out from bleed Make sure poppets are set correctly before beginning this AN CAUTION Fill the reservoir nearly full Do not steer Start and run the engine for 10 seconds then shut it off Check and refill the reservoir Repeat at least three times checking the reservoir each time N III II BN Do not allow the fluid level to drop significantly or run out of the reservoir This may induce air into the system Start the engine and let it idle for 2 minutes Do not steer Shut off the engine and check the fluid level in the reservoir Refill as required Start the engine again Steer the vehicle from full left to full right several times Add fluid as neces sary to the full line on the dip stick Automatic bleed systems should now be free from trapped air Man
47. poppet adjusting screw and sealing nut that need to be replaced remove and discard them Turn the adjusting screw and sealing nut assembly without rotating the nut on the screw into the housing until the nut is firmly against the housing using a 6mm THP PCF45 or 2 THP PCF60 Allen wrench Tighten the sealing nut against the housing If the drive end of the screw is below the face of the nut the poppet seat flange will break during step 7d CAUTION 23 24 Refill reservoir b Hydraulic fluid Jack up vehicle 6 Push upper poppet 7 out to prepare it for setting Set upper poppet 8 Back out adjusting 9 Screw THP PCF45 6mm Allen wrench 19mm Wrench THP PCF60 732 Allen wrench Wrench Refill the system reservoir with approved hydraulic fluid AN VITVl Do not mix fluid types Mixing of transmission fluid motor oil or other hydraulic fluids will cause seals to deteriorate faster Place a jack under the center of the front axle and jack up the front end of the vehicle so the steer axle tires are off the ground a Start the engine and let it run at idle speed b Note which output shaft timing mark is nearest the housing piston bore c Turn the steering wheel in the direction that makes this timing mark move toward the adjust ing screw just installed Turn in this direction until axle stop contact Is made d Pull hard on the steering wheel put up to 40 Ib rim p
48. procedures Keep each part separate to avoid nicks and burrs Discard all seals o rings and gaskets removed from the gear Replace them with new parts only The steering gear should be identified to the vehicle from which it was removed The poppet adjuster seat and sleeve assemblies are set for that particular vehicle only 34 Disassembly Tools Required Materials Required Screwdriver Sockets eStandard e orx Vise Allen wrenches Pocket knife Ratchet Rolling head pry bar Rubber mallet Position gear in vise Unplug ports Appropriate size socket or open end wrench Position sector shaft Clean sector shaft Fine grade emery cloth Emery cloth Masking tape 3 4 Put the steering gear in a vise clamping firmly against the housing mounting flange or boss Input shaft should be horizontal side cover and valve housing are accessible for disassembly Do not clamp against body of housing If mounting boss or flange CAUTION is not accessible fabricate and attach a mounting plate to the housing mounting bosses Prepare for fluid drainage and unplug hydraulic ports Rotate the input shaft until the timing mark on the end of the sector shaft is in line with the timing mark on the end of the housing This will position the sector shaft for removal Remove any paint or corrosion trom the exposed area of the sector shaft 41 30 36 Tape sec
49. r THP PCF series vehicle front end weight ratings are as follows Gear Front Axle Rating THP PCF45 THP PCF60 9 000 Ib 4 100 kg 14 300 Ib 6 500 kg The recommended minimum flow at 11 2 steering wheel turns per second is as follows Gear Minimum Flow Rate THP PCF45 THP PCF60 2 2 gal min 8 3 L min 2 6 gal min 9 8 L min If the steering gear valve is controlling an auxiliary cylin der increased minimum flow is required generally at least 75 based on the size of the auxiliary cylinder and the vehicle s steering geometry Maximum internal leakage for all THP PCF gears is 1 2 gpm 4 5 Ipm General Operation What Happens During a Steering Maneuver VVhen the driver turns the steering wheel he transmits force trom the steering wheel to the steering gear input shaft A torsion bar pinned at its one end to the input shaft and at its other end to the worm shaft turns with the Input shaft and exerts a rotational force on the worm shaft In response to this rotational force the worm shaft acting through the recirculating ball mechanism tries to move the rack piston axially through the gear housing cylinder bore The rack piston s axial movement Is resisted by its engagement to the sector shaft which is connected by linkage to the steered wheels Because of this resis tance the torsion bar is twisted by the input shaft thereby actuating the control valve Pressurized fluid directed by the control va
50. rex EP2 P N 045422 Apply more of the grease to the inside of a new dirt and water seal 2 2B or 2C and install it over the input shaft Seat the seal in the groove behind the serrations and against the valve housing This step may have already been completed if you disassembled the valve housing and worm screw for repair Proceed to Final Adjustments on page 62 Poppet Component Replacement Tools Required Materials Required 2 lb Sledge Ratchet Locquic T primer ftelb Torque Soft jawed vise Loctite RC680 wrench J36452 A Press 3 2 x 6 drill rod Place rack piston 1 Ifthe poppet assemblies are to be removed for in vise replacement place rack piston in a soft jawed vise Soft jawed vise Loosen poppet 2 Slide special tool J36452 A over the seat of poppet adjuster seat adjuster seat and sleeve assembly 27 and engage tool in the slots in the threaded sleeve Hit the end of the tool firmly four or five times with a 2 Ib sledge J36452 A hammer to loosen Loctite 2 Lb Sledge AN CAUTION Poppet adjuster seat and sleeve assemblies 27 are retained by Loctite applied to the threads which makes the assem blies difficult to remove Remove poppet 3 With a ratchet applied to the tool turn one adjuster adjuster seat seat and sleeve assembly out of the rack piston If the ratchet does not turn easily strike the adjuster removal tool again with a hammer If the engaging J36452 A tangs won
51. ring 18 and thrust washer Assemble seals in 19 bearing adjuster Lightly oil and assemble new seal ring 14 into the large diameter seal ring groove in valve housing bending and working It in and smoothing it out as necessary The seal ring must be smoothed out or It may be damaged when the worm Is installed Install ball bearing 12 into valve housing 5 Incorrect installation Correct installation _ Dip the input end of the input shaft valve worm assembly 15 into oil up to the worm lead As semble the input shaft end of the assembly into the valve housing 5 until it is firmly seated Apply oil and assemble the other thrust bearing 16 then the thin thrust washer 17 over the ball groove end of worm and seat them against the shoulder of input shaft valve worm assembly 15 Lightly oil a new o ring 19 and assemble into the seal groove in bearing adjuster 20 Oil and work a new seal ring 18 into the same groove and smooth It out Be sure the valve housing adjuster locknut and bearing adjuster threads are clean and free of any staking burrs that would impede the locknut from turning freely on adjuster or the adjuster turning freely in valve housing Assemble bearing adjuster J37070 ftelb Torque wrench Assemble new locknut J37464 Adjust to required input torque
52. s are in the ball track guide path N AVI AT Hold down the ball return guides until cap is reinstalled Failure to hold the guides will result in a trapped ball or balls which could cause a vehicle accident If the ball guide becomes unseated raises at any time repeat the procedure starting at step 7 N EVI Te The correct number of balls are required for proper gear operation Count the balls and insert each carefully as in step 7 Number required THP PCF45 29 balls THP PCF60 31 balls AN Vill 8 Do not allow valve housing to contact the poppet stem or move more than 21 inches 69 1 mm from upper end of rack piston during these procedures This could incorrectly reset the poppet or back out worm beyond closed ball loop trapping balls AN CAUTION Remove any fluid present in the two screw holes Fluid in these holes could cause improper clamp load when torquing the cap Assemble ball 9 return guide cap T 30 Torx socket inelb Torque wrench Grease Rotate input shaft 10 to check for proper installation of balls Install rack piston 11 worm valve assembly Install valve 12 housing bolts E 18 Torx socket ftelb Torque wrench Place a new ball return guide cap seal 31 in the seal groove of the cap 32 Make sure the seal makes full contact with the rack piston surface Install two new Torx head screws 33 and torque each screw alternately until a final torque o
53. s built on the 29001S00B00 290th day of 2001 Serial A letter suffix at the end of the specification number indicates a design level for the gear Number Trademark of Exxon Oil Corporation Torque Chart pente pas Torque Range Dry Torque Range Lubricated Valve housing bolts 118 138 ftelb 160 187 Nem Auxiliary port plug 25 35 ftelb 34 48 Nem Relief valve cap 25 35 ftelb 34 48 Nem Bearing adjuster 11 15 ftelb 15 20 Nem Locknut 101 122 ftelb 137 165 Nem Poppet sleeve assembly 16 20 ftelb 22 27 Nem Torx screw 14 22 ftelb 19 29 Nem Plug auto bleed 38 58 ftelb 52 79 Nem Poppet fixed stop screw 38 42 ftelb 52 57 Nem sector shaft adjusting screw jam nut 40 45 ftelb 54 61 Nem Side cover bolts 180 220 ftelb 244 298 Nem Poppet sealing nut service 33 37 ftelb 45 50 Nem Manual bleed screw 40 50 inelb 3 1 3 7 Nem Item numbers referenced are shown on the exploded Special tools can be purchased through view located on page 8 SPX Corporation Kent Moore Tool Group After tightening to this torque value the adjuster must 28635 Mound Road be backed off 1 4 to 1 2 of a turn as described in step 20 Warren MI 48092 on page 5 1 800 328 6657 Torque value indicated is using recommended tools THP PCF Exploded View Item 1 9 2B 2C 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Description Valve Housing Bolts 4 Dirt and Water Seal 13 16 Serr
54. sing 4 Seal Input Shaft 478076 41 Sector Shaft Includes 41A 6 O ring 2 Aux Port Plug 032229 45 Side Cover Assembly Includes 40 42 43 7 Auxiliary Port Plug 2 415437 A1 9 O ring Relief Valve 032200 153 Contact Service Sales for part numbers 10 Cap Relief Valve 411061 11 Seal Ring 032829 12 Ball Bearing Assy 400152 A1 13 Seal Ring Valve Housing 032823 14 Seal Ring Valve Housing 029128 16 Thrust Bearing 070027 17 Thrust Washer 400144 18 Seal Ring 029123 19 O ring 032200 158 20 Bearing Adjuster 400149 21 Adjuster Locknut 027007 24 Push Tube 080154 25 Poppet Spring 401662 Kits 26 Poppet 2 040248 Da 27 Poppet Seat and Sleeve Assy 2 409118 A2 Items Description Part Number 29 Balls 213684 X1 6 amp 7 Port Plug amp O ring 415437 A1 31 Cap Seal 478042 9 amp 10 Relief Valve Cap amp O ring 411061 A1 32 Ball Return Guide Cap 400177 38A amp 38B Adj Screw amp Jam Nut 33 Torx Screws 2 020228 THP PCF45 Kit 023045 X1 36 Grease Fitting 037032 THP PCF60 Kit 021407 X1 37 Plug Auto Bleed 021397 2 2B 2C 3 4 Input Shaft Seal Kit THPOOOOO1 37A Screw Manual Bleed 213705 THP PCF45 Seal Kit THP450001 38 Screw Fixed Stop 021426 THP PCF60 Seal Kit THP600001 38A Screw Poppet Adjusting 38B Nut Poppet Adjusting Screw 44 O ring Sidecover 032856 46 Nut Jam 025150 47 Plug Vent Side Cover 036201 48 Bolts Side Cover 021434 Parts Vary by Gear Size Item Description THP PCF45 THP PCF60 22 Rack Piston Seal Ring 032828 032830 2
55. ster screw 38A and nut 38B is anticipated do not allow the input shaft on a steering gear with the automatic poppet adjustment feature to rotate more than 1 5 input shaft revolutions from straight ahead posi tion when the output shaft is disconnected from the vehicle steering linkage this could disrupt the poppet setting achieved at initial installation The steering gear is in the straight ahead position when the timing marks on the end of the housing trunnion and sector shaft are aligned Remove the supply and return lines from the gear and immediately plug all port holes and fluid lines AN WAV Tem THP PCF steering gears can weigh up to 70 pounds dry Exercise caution when you remove lift carry or fix in a bench vise Remove the steering gear from the vehicle and take it to a clean work surface Clean and dry the gear before you start to disassemble It As you disassemble the gear clean all parts in clean OSHA approved solvent and air blow dry them only AN eV TNT Te Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death AN WAENI Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements AN N id Never steam clean or high pressure wash hydraulic steering components Do not force or abuse closely fitted parts Use care that bearing and sealing surfaces are not damaged by the assembly and disassembly
56. t Component section of this Service Manual Tools Required WIFI CIF 6mm Allen wrench 19mm Open end wrench 3 Open end wrench 3 4 Socket Dei Open end wrench ftelb Torque wrench Materials Required Hydraulic fluid 19mm Socket 18mm Open end wrench THP PCF60 7 30 Allen wrench Jack Set axle stops Is warm up system Assemble adjust 2 ing screw into nut Remove poppet di stop bolt Ree 18mm Open end wrench THP PCF60 Open end wrench Turn adjusting 4 screw assembly into housing THP PCF45 6mm Allen wrench 19mm Wrench THP PCF60 732 Allen wrench Wrench Set the axle stops to vehicle manufacturer s wheelcut or clearance specifications Start the engine and allow the vehicle to idle for 5 10 minutes to warm the hydraulic fluid Shut off the engine If a new poppet adjusting screw and nut are being used turn the screw into the non sealing end of the jam nut until the drive end of screw is flush with the nut Your steering gear will have either a fixed stop bolt or an adjusting screw If the adjusting screw is already part of the steering gear back the nut off of the adjusting screw until it is flush with the end of the adjusting screw Make sure the engine is off and the road wheels are In straight ahead position Remove and discard the poppet fixed stop bolt if equipped and washer if equipped from the lower end of the housing If the unit has a
57. t section on page 51 Other wise proceed to step 26 TRW recommends the poppet adjuster seat and sleeve assem blies 27 not be removed unless replacement of poppet components Is required Inspect valve 26 Inspect valve housing worm screw subassembly for housing and worm heat damage or bearing roughness If these condi screw tions are present or if there was excessive internal leakage or if preload adjustment is required go to Valve Housing Worm Screw Disassembly procedures on page 53 If not proceed to step 27 Remove dirt seal 27 Remove and discard the dirt and water seal 40 Screwdriver Remove pressure 28 Insert a screwdriver through the trunnion opening seal and carefully push the seal 40 out without damaging the sealing area of the bore Discard the seal A special hook groove has been machined into the bore to hold the seal in position Clean out rubber from groove prior to installing new seal Inspect roller 29 Inspect the roller bearing 39 for brinelling or bearing spalling If replacement is required go to Roller Bearing Replacement on page 60 If not proceed to step 30 40 Inspect housing screws and plugs 30 Inspect the following for damage ePoppet fixed stop screw 38 ePoppet adjusting screw 38A and sealing nut 38B eAuto bleed plug 37 eManual bleed screw Not shown eAuxiliary port plugs 7 and o rings 6 If any are damaged go to Replace Housing
58. ter of the shaft and the end of the serrations
59. the bearing or bushing AN VII I AN Make sure the OD of the seal and the ID of the bore are free from grease and dust for proper engagement of the seal Apply a generous amount of Exxon Polyrex EP2 P N 045422 to the short bearing area of the sector shaft Insert the sector shaft 41 into the side cover subassembly 45 and turn the sector shaft adjust Ing screw 41A counterclockwise Into the side cover until the screw reaches solid height Rotate the adjusting screw clockwise one half turn so the side cover will rotate freely on the sector shaft Install jam nut 18 Assemble vent 19 plug Install side cover 20 o ring Center rack piston 21 Install sector shaft 22 and side cover into housing Masking tape Install the sector shaft adjusting screw jam nut 46 onto the sector shaft adjusting screw 41A a few threads Final adjustment will be made later Press the new vent plug 47 into the hole provided In the side cover until the plug is bottomed AN UO AT Do 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 Apply clean oil to the new side cover o ring 44 and assemble it onto the side cover 45 There are four teeth on the rack piston Rotate input shaft to position the rack piston so the space betwee
60. tor shaft Masking tape Remove jam nut Remove side cover bolts Remove side cover Soft mallet Discard O ring Di 6 dh 8 9 Tape the serrations and bolt groove of the sector shaft with one layer of masking tape The tape should not extend onto the sector shaft bearing diameter Remove the sector shaft adjusting screw jam nut 46 Be prepared for more fluid drainage and remove the six bolts 48 from the side cover 45 Be prepared for more fluid drainage and remove the side cover and sector shaft assembly from the gear You may start the shaft and cover assembly removal by tapping the end of the shaft lightly with a soft mallet or wooden hammer handle Remove and discard the side cover o ring 44 Remove vent plug 10 Remove and discard the vent plug 47 Remove sector 11 Turn sector shaft adjusting screw 41A clockwise shaft from cover through the side cover and pull the sector shaft out of the side cover Remove side cover 12 AN VIII BN Don t damage the bore or bearing seal and washer when removing the seal 8 Drive socket Rolling head pry Clamp the side cover in a vise Place a standard Sei or 16 drive socket in the center of the side cover Pry the seal 40 out with a rolling head pry bar using the socket for support Discard the seal and remove the socket Remove washer 42 bar Inspect adjusting 13 Inspect the sector shaft assembly for damaged screw and ret
61. ual bleed systems continue with step 4 With engine idling steer from full left turn to full right turn several times Stop steering and loosen the manual bleed screw about one turn Allow air and aerated fluid to bleed out until only clear fluid is seen Close the bleed screw refill the reservoir if required Repeat step 4 three to four times until all the air is discharged Torque manual bleed screw to 45 inelb AN Wii BE Do not turn steering wheel with bleed screw loosened Input Shaft Seal Replacement This procedure uses the vehicle s power steering pump to force out the input shaft seal To use this procedure the power steering pump should have a minimum of 1 500 psi available Tools Required Materials Required Hammer Clean cloth J37073 Seal Driver Drip pan Screwdriver High pressure fitting Hydraulic fluid Plug Shop towel Disconnect return 1 Disconnect return line from the steering gear and line plug the line Also cap the return port of the gear with a high pressure fitting High pressure fitting Plug Disconnect 2 Remove the steering column from the gear input column shaft Remove dirt amp 3 Remove the dirt and water seal from the steering water seal gear Save this seal to match the new seal to the correct size Remove retaining 4 Wipe out the grease and then remove the spiral ring retaining ring Use a screwdriver inserted Into the notch formed in the end of the ring Be careful n
62. ull on a 20 dia steering wheel after the axle stop Is contacted a Turn the steering wheel in the opposite direction end of timing mark away from adjusting screw until the other axle stop Is contacted b Pull hard on the steering wheel put up to 40 Ib rim pull on a 20 dia steering wheel c Release the steering wheel and shut off the engine Loosen the sealing nut and back out the adjusting screw until 1 Is past the nut Tighten the sealing nut against the housing AN CAUTION Do not hold the steering wheel at full turn for more than 10 seconds at a time the heat build up at pump relief pressure may damage components Set lower poppet cl Position adjusting screw TAHP PCF45 Gmm Allen wrench 19mm Wrench 19mm Socket THP PCF60 732 Allen wrench 3 4 Wrench Socket ftelb Torque wrench The procedure is complete 10 dl 12 a Start the engine and let it idle b Turn the steering wheel in the original direction end of timing mark toward adjusting screw until axle stop contact Is made c Hold the steering wheel in this position with up to 40 Ib rim pull for 10 seconds then release Repeat this hold and release process as many times as necessary while completing step 11 a With steering wheel held tightly at full turn loosen the jam nut and hold it in place with a wrench b Turn the adjusting screw in clockwise using finger pressure only don t use a rat
63. ut 40 lbs rim pull on a 20 dia steering wheel after the axle stop Is contacted 2 If new poppet adjusting screws and nuts will be used turn each screw into the non sealing end of the jam nut until the drive end of screw is flush with the nut 8 a Turn the steering wheel in the opposite direction Your steering gear and rotary cylinder will both have either fixed stop bolts or adjusting screws If the adjusting screw Is already part of the gear or cylin der back the nut off of the adjusting screw until It is flush with the end of the adjusting screw Make sure the engine is off and the road wheels are in straight ahead position Remove and discard the poppet fixed stop bolt if equipped and washer if equipped from the lower end of housing on both end of timing mark on the master gear away from adjusting screw until the other axle stop is contacted b Pull hard on the steering wheel put 40 Ibs rim pull on a 20 dia steering wheel c Release the steering wheel and shut off the engine the gear and the cylinder 9 Loosen the sealing nut and back out the adjusting screw on the master gear until 1 Is past the nut If either unit has a poppet adjusting screw and Tighten the sealing nut against the housing sealing nut that need to be replaced remove and discard them AN VIII Do not hold the steering wheel at full turn for more than 10 seconds On both the master gear and the rotary cylinder at a time the h
64. ve housing in vise 10 11 12 13 Turn over valve housing and remove retaining ring 3 AN Wifi Exercise special care when removing seal 4 to prevent damaging the valve housing seal bore Tap input shaft seal 4 out of valve housing Dis card seal The valve housing also utilizes a ball plug for manufacturing purposes that must not be removed Inspect the sealing areas of input shaft and valve 15 for nicks and run your fingernail edge across the sealing surfaces to detect steps Inspect for discol oration from excess heat Inspect input shaft ball track grooves for brinelling or spalling If any of these conditions exist you must replace the input shaft valve worm assembly valve housing and balls Also replace rack piston if brinelling or spalling is found Inspect the thrust bearing 16 rollers and ball bearing 12 for any deterioration Inspect thrust washer 17 and ball bearing race in the valve housing for brinelling spalling or cracks Replace any part with these conditions Place valve housing 5 firmly in a vise so the input shaft valve worm assembly 15 can be assembled vertically with the worm end up Do not clamp against threaded port hole or relief valve hole sealing faces when placing valve housing in vise N CAUTION DO 56 Assemble sealring 15 Install ballbearing 16 into valve housing Assemble input 17 shaft valve worm Assemble bea
65. y in any part of the steering system Make sure the steering column is aligned properly Encourage drivers to report any malfunctions or accidents that could have damaged steering components THP PCF Gear Do not attempt to weld any broken steering component Replace the component with original equipment only Do not cold straighten hot straighten or bend any steering system component Always clean off around the reservoir filler cap before you remove it Prevent dirt or other foreign matter from entering the hydraulic system Investigate and correct any external leaks no matter how minor Replace reservoir filters according to requirements If you feel the vehicle is developing excessively high hydraulic fluid temperatures consult with your vehicle manufacturer for recommendations Maintain grease pack behind the output shaft dirt and water seal as a general maintenance procedure at least twice a year in the Spring and Fall Grease fitting is provided in housing trunnion Use Exxon Polyrex EP2 P N 045422 or NLGI grade 2 or 3 multipurpose chassis lube and use only a hand operated grease gun on fitting Add grease until it begins to extrude past the sector shaft dirt and water seal Corrosion Inhibiting Grease Barrier UE E WA Dirt and Water Seal 14 High Pressure Output Seal Section 3 On Vehicle Service Filling and Air Bleeding the System 16 Input Shaft Seal Re

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