Home

TAS Steering Gear Service Manual

1. Grease Fitting Adjusting Screw Sector Shaft Retainer Adjusting Screw J am Nut Vent Plug Side Cover Bleed Screw Manual Plug Auto Bleed Fixed stop screw Auxiliary Port Plug 2 O ring 2 Aux Port Plug O ring Relief Valve Service Poppet Adjusting Screw Service Sealing J am Nut Item Description 6 Seal Ring Valve Housing Teflon Seal Ring O ring Back up Rack Piston Poppet Seat and Sleeve Assy 2 Poppet 2 old design Poppet 2 new design Poppet Spring Push Tube Ball Retum Guide Halves 2 R H Roller Bearing Seal 2 Output Gasket Side Cover L H Special Bolts 6 or 8 Side Cover Dirt amp Water Seal Trunnion Retaining Ring Part Number 020251 478044 478060 478050 401637 478076 032823 029123 032200 158 029116 032200 152 400143 070027 400144 400149 027007 213684 X1 478042 400161 020228 400167 037032 021200 062005 G9419666 036201 213705 021397 021426 G9410358 032229 032200 153 021407 025119 TAS40 032829 032828 032827 409118 A2 040210 040248 401662 080154 400158 400159 070030 478051 HFB529000 021277 K301963 401674 Parts Vary by Specification Item Description 5 Valve Housing 13 Input Shaft Valve Worm Assy 19 Rack Piston 34 Housing 42 Sector Shaft 46 Side Cover Assembly 56 Relief Valve Cap 58 Relief Valve 2 piece Contact Service Sales for part numbers Kits Items 54 amp 55 56 amp 57 59 amp 60 2
2. RW Automotive Commercial Steering Systems TAS Steering Gear Service M anual TAS40 55 65 AND 85 SERIES Hazard Warning Definitions A WAV tem A warning describes hazards or unsafe practices which could result in severe personal injury or death A mans 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 TRW 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 TRW Commercial Steering Systems has exercised reasonable care and diligence to present accurate clear and complete information and instructions regarding the TRW Commercial Steering TAS Series Integral Power Steering Gears Since this is a general Service M anual 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 TAS steering gear or if you encounter circumstances not covered in the M anual Stop Consult the vehicle manufacturer s Service Manual and warranty Do not try to repair or service a TAS steering gear which has been damaged or includes any part
3. 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 Manual bleed systems continue with step 4 With engine idling steer from full left tum to full right turn several times Stop steering and loosen the manual bleed screw about one tum 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 lbfsin A CAUTION Do not turn steering wheel with bleed screw loosened 17 Input Shaft Seal Replacement Materials Required Tools Required Clean cloth Drip pan High pressure fitting Hydraulic fluid Plug Shop towel Hammer J 37073 Screwdriver line High pressure fitting Plug ring Clean cloth Screwdriver Disconnect return 1 Disconnect 2 column Remove dirt amp 3 water Seal Remove retaining 4 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 Disconnect retum line from the steering gear and plug the line Also cap the retum port of the gear with a high pressure fitting Remove the steering column from the gear input Shaft Remov
4. 2B 2C 3 4 Description Part Number Port Plug amp O ring 415437 A1 Relief Valve Cap amp O ring 411061 A1 Adj Screw amp JamNut 021407 X1 TAS55 032829 032830 032831 409118 A2 040210 040248 401662 080154 400160 400165 071032 478040 HFB649000 G223734 478095 401650 Input Shaft Seal Kit TAS000001 TAS40 Seal Kit TAS400004 TAS55 Seal Kit TAS550004 TAS65 Seal Kit TAS650012 TAS85 Seal Kit TAS850003 TAS65 TAS85 032616 032834 032590 032547 032615 032556 409118 A2 409118 A6 040210 040217 040248 040249 401662 401684 080154 080158 400156 400162 400157 400163 071033 072004 478040 478084 HFB649000 TAS859000 G223734 G223734 478095 478096 401650 401685 13 14 Section 2 Initial Installation NS tal As alt nn PODDOCES SEEING sasssa a sn Maintenance TIPS EE Initial TAS Installation Bolt gear to frame torque to vehicle manufacturer s recommendation e Connect retum line to TAS retum port e Connect hydraulic line from pump to pressure port in TAS 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 recom mendation 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 proc
5. Also unstake adjuster nut from adjuster 17 Roll pin punch Hammer Remove bearing 3 Tum bearing adjuster locknut 18 out of the valve adjuster locknut housing 37464 Remove bearing 4 Tum bearing adjuster 17 out of the valve housing adjuster J 37070 53 54 Remove seal ring 5 Remove and discard seal ring 8 and o ring 9 from and o ring bearing adjuster Small probe or pick Remove inputshaft 6 Remove the input shaft valve worm assembly 13 or 13A from the valve housing Remove thin 7 Remove thin thrust washer 16 and thrust bearing washer and 15 from input shaft bearing Remove thick 8 Remove thick thrust washer 12 and thrust bearing washer and 15 from valve housing bearing UH TT 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 OR Remove bearing 8A For alternate construction TAS65 gears remove components Spacer sleeve 14 thin washer 16 thrust bearing 15 and thick washer 12 NETTO ifthe TAS65 gear has a ball bearing and ball race in the valve housing remove them and call TRW for disposition Do not rebuild the gear rs Tai n D e Ki k EES M men N 2 E Remove seal rings 9 and o rings Small probe or pick Remove retaining 10
6. Line up rack piston ball guide holes with the worm ball track grooves by rotating the input shaft Assemble the ball retum guide halves 28 into the rack piston until seated rotate the input shaft slightly if necessary FWA IT Do not seat guides with a hammer Damage to guides can resultin subsequent lockup or loss of steering A Tail fa new rack piston 19 or a new input shaft valve worm subassem bly 13 or 13A is being assembled the balls 27 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 A Vith When using the service ball kit use the correct quantity of service balls TAS40 29 TAS55 31 TAS 65 32 TAS 85 34 45 Assemble balls 12 Hold the ball return guides 28 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 retum guides Rotate the input shaft to pull the balls down and around the ball track guide path Continue until the correct number of balls are in the ball track guide path A e Hold down the ball return guides until cap or clip is reinstalled Failure to hold the guides will result in a trapped ball or balls which could cause a vehicle accident If the ball guides become unseated raise up at any time repeat the procedure starting at step 9 AULIA The correct number
7. in the side cover until the plug is bottomed A WAV tem 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 grease to the new side cover gasket 45 to hold it in place and assemble it onto the side cover 46 There are four teeth on the rack piston Rotate input Shaft to position the rack piston so the space between 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 PORTO ITT Ifthe rack piston is not centered when sector shaft is installed gear travel will be severely limited in one direction This could resultin 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 with side cover gasket in place VIMEO NUE Mm ifthe serrations are not properly taped they will damage the output seal 38 in housing causing the seal to leak 49 50 Install side cover bolts 13 6 Socket TAS40 1 16 Socket TAS55 65 85 Lbfeft Torque wrench Remove tape Install dirt amp water seal Grease 28 29 3
8. 134 hand wheel tums from each side of center If 732 Allen wrench Avdradlic fluid you re making a large reduction in wheelcut and this Ja Open end ene J G procedure does not work you may have to replace or SS p internally reset the poppets using the procedure de Ya Open end wrench i i 34 Socket scribed in the Poppet Component section of this Service Lbfelb Torque wrench Manual Setaxle stops 1 Set the axle stops to vehicle manufacturer s warm up system 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 Assemble adjust 2 lf anew poppet adjusting screw and nut are being ing screw into nut 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 Remove poppet 3 Make sure the engine is off and the road wheels are stop bolt in straight ahead position Remove and discard the poppet fixed stop bolt if equipped and washer if 5 Open end equipped from the lower end of the housing veer If the unit has a poppet adjusting screw and sealing nut that need to be replaced remove and discard them Turn adjusting 4 Tum the adjusting screw and seali
9. 5 10 Ibfein 5 1 0 Nem greater than the torque noted in step 24 Torque value must not exceed 22 lbfein 2 5 Nem Unstake and readjust if necessary Reposition 28 subassembly in vise Install inputshaft 29 seal J37073 Hammer Insert retaining 30 ring Install dirt amp water 31 seal Grease Reposition worm screw valve housing subassembly in soft jawed vise clamping tightly against valve housing so the worm screw is pointing down Apply clean grease Exxon Unirex RS460 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 Assemble seal installer tool 4 37073 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 Remove any seal material that may have sheared off and is in seal bore and retaining ring groove UJ TE The input shaft seal must be square in the seal bore and installed to the correct depth Insert new retaining ring 3 into its groove in valve housing Pack the end of the valve housing bore around the input shaft with clean high temperature industrial grease Exxon Unirex RS460 Apply more of the grease to the inside of a ne
10. 85 34 Remove the input shaft valve worm valve housing subassembly from the rack piston Cut and remove the Teflon seal ring 20 and o ring 21 from the rack piston if not removed during disassembly step 19A Push poppet stems they should spring back Push 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 Replacement section on page 51 Other wise proceed to step 27 TRW recommends the poppet adjuster seat and sleeve assem blies 22 not be removed unless replacement of poppet components is required Inspect valve housing worm screw subassembly for heat damage or bearing roughness If these condi tions are present or if there was excessive intemal leakage or if preload adjustment is required go to Valve Housing Worm Screw Disassembly procedures on page 53 If not proceed to step 28 39 Remove retaining 28 Standard gears only Remove the retaining ring 36 ring if equipped that is closest to the output end of the housing trunnion Remove dirt seal 29 Standard gears Remove and discard dirt seal 38 Step bore gears Remove and discard the dirt and water seal 61 Remove pressure 30 Standard gears Insert a screwdriver into the housing seal and spacer bearing bore from the trunnion end and carefully washer if push the seal 41 and spacer washer 40 out of the equipped other en
11. Do not clamp against body of housing If mounting boss or flange is notaccessible fabricate and attach a mounting plate to the housing mounting bosses Unplug ports 2 Prepare for fluid drainage and unplug hydraulic ports Appropriate size socket or open end wrench Position sector 3 Rotate the input shaft until the timing mark on the shaft 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 dirt amp 4 Standard gears only Remove and discard dirt amp water seal water seal 39 from the housing trunnion Small screwdriver Clean sector shaft 5 Fine grade emery cloth Se Tape sector shaft 6 N M asking tape Remove jam nut 7 Remove sidecover 8 J bolts it d 1916 Socket or mere 1716 Socket Remove side cover 9 Soft mallet Remove any paint or corrosion from the exposed area of the sector shaft 42 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 47 Be prepared for more fluid drainage and remove the six or eight special bolts 48 from the side cover 46 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
12. Ratchet Locquic T primer Lbfeft Torque Soft jawed vise Loctite RC680 wrench 36452 A Press Sg x 6 drill rod Place rack piston 1 If the 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 4 36452 A over the seat of poppet adjuster seat adjuster seat and sleeve assembly 22 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 36452 A hammer to loosen Loctite 2 Lb Sledge A CAUTION Poppet adjuster seat and sleeve assemblies 22 are retained by Loctite applied to the threads which makes the assem ac blies difficult to remove Remove poppet 3 With a ratchet applied to the tool tum one adjuster adjuster seat seat and sleeve assembly out of the rack piston If the ratchet does not tum easily strike the adjuster removal tool again with ahammer If the engaging tangs won 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 23 or 23A spring 24 components and push tube 26 Some gears will also have a Spacer rod 25 to be removed ns ian Old Design New Design Poppet Poppet ro Spacer Rod O Poppet Seat aa O O Poppet Seat O Poppet Seat and i Poppe
13. all within gear housing 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 Follow procedure on page 13 OSHA Occupational Safety and Health Administration 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 Tw isted Serrations Output shaft serrations damaged by impact overload Serrations can be twisted at the area between the large diameter of the shaft and the end of the serrations AAN did TRW Automotive Commercial Steering Systems 800 Heath Street Lafayette IN 47904 Tel 765 423 5377 Fax 765 429 1868 http trucksteering trw com http www trucksteering com TRW Inc 2006 TRW1108 Rev 3 06
14. and allow the vehicle to idle for 5 10 minutes to warm the hydraulic fluid Shut off the engine If new poppet adjusting screws and nuts are being used tum 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 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 if equipped from the lower end of housing on both the master gear and the rotary cylinder If the unit has poppet adjusting screws and sealing nuts that need to be replaced remove and discard them Tum 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 a 732 allen wrench Tighten the sealing nut against the housing 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 A CAUTION Place a jack under the center of the front axle and jack up the front end of the vehicle so th
15. 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 A Te Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death A WAPAA Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements A d VI il 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 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 33 Disassembly Tools Required Materials Required Allen wrenches Screwdriver Emery cloth Pocket knife Sockets Masking tape Ratchet eStandard Rolling head eTorx pry bar Vise Rubber mallet Position gear in 1 Put the steering gear in a vise clamping firmly vise against the housing mounting flange or boss Input Shaft should be horizontal side cover and valve housing are accessible for disassembly UH TY
16. 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 Install valve 17 Lubricate and install the four valve housing bolts 1 housing bolts into the housing Torque the TAS40 55 and 65 bolts alternately to 80 lbfeft 108 5 Nem Torque TAS85 bolts E 16 Torx to 118 Ibfeft 160 Nem socket TAS4O 55 65 E 18 Torx socket TAS85 Lbfeft Torque wrench 47 48 Install relief valve 18 parts Ver Socket Lbfeft Torque wrench Lubricate side 19 cover bushing bearing Press Seal in side 20 cover J 37705 TAS40 37071 or J 37071 A TAS55 65 J 38779 TAS85 Press Lubricate sector 21 shaft Install sector shaft 22 into side cover enge If the gear is equipped with a relief valve assemble a new o ring 57 on relief valve cap 56 Assemble the small end of tapered spring onto the pin on the relief valve cartridge and insert the assembly 58 large end of tapered spring end first into the relief valve cap cavity Tum the relief valve cap as as sembled into the valve housing and torque to 30 Ibfeft 41 Nem TAS40 55 65 Lightly oil DU bushing Do not grease TAS85 only Apply a generous amount of Exxon Unirex RS460 do not substitute another type of grease to the caged bearing assembly inside the Side cover HT TE This bearing is sealed and wi
17. productive Oil Flow Illustration Left Hand Lead y O Right Hand Turn Steering W heel Input Clockwise Rotation Straightline Running No Steering Action Left Hand Turn Steering W heel Input Counter Clockwise Rotation Supply Pressure L Return Pressure Right Hand Lead g D i We n le Pal ge Vr I oi mi General Design Integral Power Steering TAS power steering gears are the latest design in the TRW Commercial Steering Division family of integral hydraulic power steering gears 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 tum 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 measure
18. them dry only Condition Brinelling Cracks or Breaks Twisted serrations FOI IT Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death A ITT Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements A WARNING Any of the following conditions presentin the steering gear indicates impact damage Area Ball track grooves of rack piston Ball track grooves of worm screw Bearing area of sector shaft Thrust washers and bearings in valve housing Bearing area of sector shaft Sector shaft teeth Rack piston teeth Housing Thrust washers and bearings in valve housing Worm screw 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 suspectimpact damage Failure to replace all damaged components could resultin a serious vehicle accident Inspect rack piston teeth Inspect rack piston and worm ball track grooves 1 Inspect the rack piston 19 teeth for cracks or obvious damage If teeth are damaged replace the rack piston sector shaft 42 and set of balls 27 2 Inspect the rack piston 19 ball track grooves for brinelling or spalling If either condition exists replace the input shaft va
19. through one half turn 180 each side of center This procedure will properly mesh and seat the rack piston and sector shaft teeth for final adjustments Tum sector shaft adjusting screw 43 counterclock wise one half tum and note maximum torque required to rotate the input shaft valve worm assembly through one half turn 180 each side of center 63 64 Adjust adjusting screw Ya Socket 11 16 Socket Lbfeft Torque wrench Lbfein Torque wrench 4 Adjust sector shaft adjusting screw 43 clockwise to increase maximum torque noted in step 3 by 7 Ibfein 8 Nem Tighten jam nut 47 firmly against side cover while holding the adjusting screw in position Final torque jam nut to 43 Ibf ft 58 Nem and check input shaft valve worm assembly torque again Readjust if input shaft torque exceeds 40 Ibfein 4 5 Nem Section 5 Reinstallation Reinstallation sa PoppetReaseltnd ss oi IR eo N Ee GEE GOSS ay EE 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 retum line to reservoir in TAS return port e Connect hydraulic line from pump to pressure port in TAS 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 manufac
20. 0 Install TAS40 55 and 65 bolts in positions 3 and 4 first by hand For TAS85 Install in positions 3 and 6 first by hand Install the remaining special 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 TAS40 bolts to 118 Ibf ft 160 Nem TAS55 65 and 85 bolts to 170 Ibfeft 230 Nem Standard gears Remove tape from sector shaft and pack the end of the housing trunnion area at the sector shaft with clean high temperature industrial grease Exxon Unirex RS460 Apply more of the grease to the inside of the new trunnion dirt seal 39 and assemble it over the sector shaft and into the trunnion bore Step bore gears remove tape from the sector shaft Pack the end of the valve housing bore around the input shaft with clean high temperature industrial grease Exxon Unirex RS460 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 63 Trademark of Exxon Oil Corp Poppet Component Replacement Tools Required Materials Required 2 Ib Sledge
21. 10 seconds A CAUTION ata time the heat build up at pump relief pressure may damage components a Start the engine and let it idle b Tum 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 lbs rim pull for 10 seconds then release Repeat this hold and release process as many times as necessary while completing steps 11 amp 12 11 12 13 14 a With steering wheel held at full turn loosen the 15 jam nut on the master gear and hold it in place with a wrench b Tum the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to astop Do not attempt to tum it in farther Pause the tuming in process each time the driver releases the steering wheel Continue tuming only while the wheel is held at full tum c Back off the adjusting screw 3 tums and tighten the sealing nut Torque the sealing nut to 33 37 Ibfeft 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 L is past the nut Tighten the sealing nut against the housing a Start the engine and let it idle b Tum 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 t
22. 3 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 21 Sector Shaft Adjustment Tools Required Materials Required This adjustment can only be completed on the vehicle if the adjusting screw jam nut is accessible This nut is located on the side cover Screwdriver Y Socket 34 Open end wrench Photos in this section were taken on a mock frame rail for clarity Center the sector L 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 A TT EA To avoid resetting the poppets do not rotate the input shaft more than 142 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 Leave the pitman arm connected to the gear Best option is to follow the Final Adjustment procedure on page 63 e Alternate op
23. 50 Bleed Screw Manual 51 Plug Auto Bleed 52A Fixed stop screw 54 Auxiliary Port Plug 2 55 O ring 2 Aux Port Plug 57 O ring Relief Valve 59 Service Poppet Adjusting Screw 60 Service Sealing J am Nut Parts Vary by Gear Size Item Description Seal Ring Valve Housing Teflon Seal Ring O ring Back up Rack Piston Poppet Seat and Sleeve Assy 2 Poppet 2 old design Poppet 2 new design Poppet Spring Spacer Rod Push Tube Ball Return Guide Halves 2 R H L H Retaining Ring 2 Roller Bearing Dirt Seal Dirt and Water Seal Trunnion Washer Spacer Seal 2 Output Gasket Side Cover Special Bolts 6 or 8 Side Cover Part Number 020251 478044 478060 478050 401637 478076 032823 029123 032200 158 029116 032200 152 400143 070027 400144 400149 027007 213684 X1 478042 400161 020228 400167 037032 021200 062005 025150 036201 213705 021397 021426 415437 Al 032229 032200 153 021407 025119 TAS40 032829 032828 032827 409118 A2 040210 040248 401662 040209 080154 400158 400159 401674 070030 478052 478053 028527 478051 HFB529000 021277 Parts Vary by Specification Item Description 5 Valve Housing 13 Input Shaft Valve Worm Assy 13A Input Shaft Valve Worm Assy Alt 14 Spacer Sleeve Alt 19 Rack Piston 34 Housing 42 Sector Shaft 46 Side Cover Assembly 56 Relief Valve Cap 58 Relief Valve 2 piece Contact Servi
24. 8 Housing 59 Grease Fitting 60 TAS85 Construction Retaining Ring 2 Roller Bearing Dirt Seal Dirt and Water Seal Trunnion Washer Spacer Seal 2 Output Sector Shaft Adjusting Screw Sector Shaft Retainer Adjusting Screw Gasket Side Cover Side Cover Assembly J am Nut Special Bolts 6 or 8 Side Cover Vent Plug Side Cover Bleed Screw Manual Plug Auto Bleed Fixed Stop Screw Poppet Fixed Stop Screw Poppet Alt Washer Stop Screw Auxiliary Port Plug 2 O ring 2 Aux Port Plug Relief Valve Cap O ring Relief Valve Relief Valve 2 piece Service Poppet Adjusting Screw Service Sealing J am Nut These items are included in complete seal kits along with 045422 lubricant and a service bulletin 10 Service Parts List Standard Common Parts Item Description 1 Bolts 4 Valve Housing 2 Dirt and Water Seal 13 16 Sem 2B Dirt and Water Seal 7 8 Serr 2C Dirt and Water Seal 1 Ser 3 Retaining Ring 4 Seal Input Shaft High Temp 7 Seal Ring Valve Housing 8 Seal Ring 2 9 O ring 2 High Temp 10 Seal Ring 11 O ring Valve Housing High Temp 12 Thrust Washer Thick 15 Thrust Bearing 2 16 Thrust Washer Thin 17 Bearing Adjuster 18 Adjuster Locknut 21 Balls 29 Seal Cap 30 Ball Return Guide Cap 31 Torx Screws 2 Cap Strap 32 Ball Return Guide Strap 35 Grease Fitting 43 Adjusting Screw Sector Shaft 44 Retainer Adjusting Screw 47 jam Nut 49 Vent Plug Side Cover
25. Step Bore gears Install the dirt amp water seal 61 seal with the bearing and seal tool long end making Sure it is not cocked Press the seal only until it SIR or 37071 A seats against the bearing don t push it in farther ress Liberally pack the roller bearing and new seals with clean high temperature industrial grease Exxon Unirex RS460 Assemble seal 7 Lightly oil new seal ring 7 and assemble in valve n rings housing mounting face groove TAS40 55 65 Oil new seal ring 6 and assemble in valve housing mounting face groove TAS85 Oil new seal ring 6 and assemble in valve housing pilot groove Trademark of Exxon Oil Corp 44 Install rack piston 8 o ring and seal ring Position rack 9 piston in housing Insert worm and 10 valve assembly into rack piston Zoe LA x 7 All Thread Assemble ball 11 return guide halves Install anew backup o ring 21 and then a new Teflon seal ring 20 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 19 in the housing piston bore with ball retum 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 7is 14 All threads through valve housing bolt holes and tighten into housing to support the worm screw
26. TAS40 108 128 Ibfeft 147 174 Nem Side cover bolts TAS55 65 85 160 180 Ibfeft 217 244 Nem Valve housing bolts TAS40 55 65 75 85 lbfeft 102 115 Nem Valve housing bolts TAS85 108 128 Ibfeft 147 174 Nem tem numbers referenced are shown on the exploded Special tools can be purchased through views pages 10 and 12 SPX Corporation Kent M oore Tool Group After tightening to this torque value the adjuster must 28635 Mound Road be backed off Y to 2 of a tum as described in step 22 Warren MI 48092 on page 57 1 800 328 6657 Torque value indicated is using recommended tools TAS Series Exploded View Standard Description Bolts 4 Valve Housing Dirt and Water Seal 13 16 Serr Dirt and Water Seal 7 8 Serr Dirt and Water Seal 1 Serr Retaining Ring Seal Input Shaft Valve Housing Seal Ring Valve Housing Seal Ring Valve Housing Seal Ring 2 O ring 2 Seal Ring O ring Valve Housing Thrust Washer Thick Input Shaft Valve Worm Assy Input Sh Valve Worm Assy Alt Spacer Sleeve Alt Thrust Bearing 1 or 2 Thrust Washer Thin 43 Bearing Adjuster AA Adjuster Locknut 45 Rack Piston 46 Teflon Seal Ring 47 O ring Back up Rack Piston 48 Poppet Seat and Sleeve Assy 2 49 Poppet 2 50 Poppet Spring 51 Spacer Rod 52 Push Tube 52A Balls 53 Ball Return Guide Halves 2 54 Seal Cap 55 Ball Return Guide Cap 56 Torx Screws 2 Cap Strap 57 Ball Return Guide Strap 5
27. Torx socket screws 31 and torque each screw alternately until Lbfein Torque a final torque of 18 Ibf ft 24 5 Nem is achieved wrench Grease Rotate inputshaft 15 Rotate the input shaft from one end of travel to the to check for proper other without contacting the poppet stem to the installation of valve housing and without moving the valve hous balls ing face more than 2 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 PORTO ITU fyouinstall a gear on a vehicle with the worm shaft unable to rotate the gear will not function correctly Steering and gear failure may result Install rack piston 16 Apply clean oil to Teflon seal ring 20 on rack piston worm valve Make sure there is a space of 3 2 10 0 13 0 mm assembly 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 M ake sure both o rings in the valve housing remain in position OTTO Do not damage the seal ring 19 while installing the rack piston into housing If the seal ring end of rack piston enters the housing first the seal ring will be destroyed when the rack is removed UH TT The poppet seat and sleeve assemblies 22
28. UH TIEN Do notallow Loctite or Locquic to get on the adjuster seat component of the adjuster seat and sleeve assembly The poppets will not function properly OUT Wear eye protection while assembling poppets as spring loaded poppets could eject and cause eye injury Place rack piston 19 in a soft jawed vise and tum one new poppet adjuster seat and sleeve assembly 22 slotted end out into the poppet hole in one end of rack piston TIl Do not use the spacer with the new poppet design You must install the spacer with the old poppet design From the other end of the poppet hole in the rack piston install one poppet 23A poppet spring 24 push tube 26 other poppet 23A and the other new poppet adjuster seat and sleeve assembly 22 The new components will stack up as shown below Torque both poppet seat and sleeve assemblies to 18 Ibfeft 25 Nem Return to step 27 page 39 Valve Housing Worm Screw Disassembly Tools Required Materials Required Hammer Lbfeft Torque wrench Punch center Punch roll pin Lbfein Torque wrench 37464 J 37070 J 37073 Screwdriver Small probe or pick Sockets 12 point sockets Place valve L With worm vertical place the valve housing input housing and valve Shaft valve worm assembly in a vise assembly in vise Unstake adjuster 2 Unstake the valve housing 5 where it was upset locknut into the adjuster locknut 18 slot
29. W s TAS40 55 65 and 85 Service M anuals Changes in the layout of this Service M anual reflect TRW s commitment to provide easily usable material and highly recognizable hazard notices Some of the major changes are e Revised torque force pressure and flow notations that conform to intema tional standards 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 retum to the resealing proce dures easily e Binding process that better allows the Service M anual to lay flat The three column format used in the Service M anual will also help make it easy for you to service a steering gear Column 1 illustrates 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 tem numbers on the exploded view correspond with item numbers used throughout the Service Manual As you gain experience in servicing TAS 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 M anual if you do not under stand a procedure or are stuck contact our Field Service Department at 765 423 5377 Servicing TAS series steering gears should be safe and
30. ast the sector shaft dirt and water seal Standard Gear Corrosion Inhibiting Grease Barrier T WEE Ke ck ia Bearing High Pressure Output Seal ater Seals Section 3 On Vehicle Service Filling and Air Bleeding the SySteM ee ee ee EE Ee 17 Input Shaft Seal Replacement ee 18 Sector Shaft Adjustment AA 22 Poppet Readjustment elle 24 Dial GANS Ee Ee ER TTT ee od 27 Filling and Air Bleeding the System Tools Required Materials Required Vis Socket Hydraulic fluid Lbfein Torque wrench Run engine for 10 1 seconds turn off and fill reservoir Hydraulic fluid Run engine for 2 2 minutes turn off and fill reservoir Hydraulic fluid Auto Bleed Plug Do Not Remove Allow air to bleed 4 M anual Bleed Screw out from bleed screw Lbfein Torque wrench s Socket Steer vehicle 3 JU TT Make sure poppets are set correctly before beginning this procedure 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 UH TEN 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
31. ce Sales for part numbers Applicable to TAS65 gears only Kits Items Description Part Number 54 amp 55 Port Plug amp O ring A15437 A1 56 amp 57 Relief Valve Cap amp O ring 411061 A1 59 amp 60 Adj Screw amp JamNut 021407 X1 2 2B 2C 3 4 Input Shaft Seal Kit TAS000001 TAS40 Seal Kit TAS400004 TAS55 Seal Kit TAS550004 TAS65 Seal Kit TAS650012 TAS85 Seal Kit TAS850003 TAS55 TAS65 TAS85 032829 032616 032834 032830 032590 032547 032831 032615 032556 409118 A2 409118 A2 409118 A6 040210 040210 040217 040248 040248 040249 401662 401662 401684 040209 040209 040218 080154 080154 080158 400160 400156 400162 400165 400157 400163 401650 401650 401685 071032 071033 072004 478041 478041 478057 478045 478045 478059 028519 028519 028534 478040 478040 478084 HFB649000 HFB649000 TAS859000 021434 021434 021434 TAS Series Exploded View Step Bore Description 1 Bolts 4 Valve Housing 2 Dirt and Water Seal 13 16 Serr 2B Dirt and Water Seal 7 8 Serr 2C Dirt and Water Seal 1 Serr 3 Retaining Ring 4 Seal Input Shaft 5 Valve Housing 6 Seal Ring Valve Housing 7 Seal Ring Valve Housing 8 Seal Ring 2 Q O ring 2 10 Seal Ring 11 O ring Valve Housing 12 Thrust Washer Thick 13 Input Shaft Valve Worm Assy 15 Thrust Bearing 1 or 2 16 Thrust Washer Thin Bearing Adjuster Adjuster Locknut Rack Piston Teflon Seal Ring O ring Back up Rack Piston Poppet Seat and Sleeve Assy 2 Popp
32. d 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 TAS gears is 2 175 psi 150 bar maxi mum flow rate for all TAS gears is 8 gal min 30 3 L min The TAS series gears can steer a vehicle within its front end weight rating through a tum at low speed and engine idle As the driver tums the steering wheel faster or Slower more or less fluid will be required by the gear TAS series vehicle front end weight ratings are as fol lows Gear Front Axle Rating 9 000 Ib 4 100 kg 12 000 Ib 5 400 kg 14 300 ID 6 500 kg 18 000 Ib 8 200 kg The recommended minimum flow at 1 steering wheel tums per second is as follows Gear Minimum Flow Rate 2 2 gal min 8 3 L min 2 6 gal min 9 8 L min 3 0 gal min 11 4 L min 3 6 gal min 13 6 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 geo
33. d of the bearing bore without damaging the sealing area of the bore Discard the seal Step Bore gears Remove the retaining ring 63 through the side cover opening Then insert a screwdriver through the trunnion opening and carefully push the seal 41 out without damaging the sealing area of the bore Discard the seal Inspect roller 31 Standard gears Inspect roller bearing 37 in the bearing housing for brinelling or spalling Inspect retaining ring for damage If replacement of either part is required go to Roller Bearing or Retaining Ring Replacement on page 60 If not proceed to step 32 Step Bore gears Inspect the roller bearing 37 for brinelling or spalling If replacement is required go to Roller Bearing Replacement Step Bore on page 61 If not proceed to step 32 Inspect housing 32 Inspect the following for damage screws and plugs e Poppet fixed stop screw 52 or 52A and washer 53 if equipped e Poppet adjusting screw 59 and sealing nut 60 Auto bleed plug 51 e Manual bleed screw 50 e Auxiliary port plugs 54 and o rings 55 If any are damaged go to Replace Housing Ports Plugs and Screws on page 62 If not proceed to the Inspection Section 40 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
34. dure is 12 The poppets have now been completely reset complete Lower the vehicle Check the reservoir and fill if required TI eg The length of the adjusting screw beyond the nut must be no more than 1 for proper thread engagement The length of adjusting screw beyond the sealing nut may be different for each vehicle 26 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 1 Park the vehicle with the wheels turned all the way to the axle stop in either direction Turn the vehicle off 2 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 3 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 If they both point toward the poppet screws or both point toward the end opposite the poppet screws you have a reversed image system Low er Poppet ENE 5 LZ Upper Poppets Low er Poppet 27 Poppet Readjustment Dual Gears Mirror Image Tools Required Materials Required 732 All
35. e sealing nut Torque nut to 33 37 lbfeft 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 FOI OUT The length of the adjusting screw beyond the nut must be no more than 1c for proper thread engagement NOTE The length of adjusting screw beyond the sealing nut may be different for each vehicle 31 ES Section 4 Reseal amp Repair NIE e EE 33 Jace e gel WEE 41 ASSEINDIY ariana 43 Intemal Damage Repair by reference Poppet Component Replacement 51 Valve Housing Worm Screw Disassembly 53 Roller Bearing or Retaining Ring Replacement 60 Roller Bearing Replacement Step Bore Gear 61 Replace Housing Ports Plugs Screws Fittings 62 Final Adjustments sas ia 63 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 A GR 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 th
36. e shaft with a chisel and your hands remove the chisel from the arm boss and use a puller only to remove pitman arm UH TIEN Do notuse 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 w edge 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 A Hd VI il EN Unless the poppet adjuster seat and sleeve assemblies 22 are to be removed and replaced or reset for automatic poppet adjustment or a manual adjustment with a service poppet adjuster screw 59 and nut 60 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 position 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 FOI em TAS steering gears can weigh up to 110 pounds dry Exercise caution when you remove lift carry or fix in a bench vise Remove the steering
37. e steer axle tires are off the ground This resetting procedure will work in most cases with at least 134 hand wheel tums 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 M anual 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 Tum 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 hard on the steering wheel put 40 Ibs rim pull on a 20 dia steering wheel after the axle stop is contacted 8 a Tum 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 A dT Do not hold the steering wheel at full turn for more than 10 seconds ata time the heat build up at pump relief pressure may damage compone
38. e the dirt and water seal from the steering gear Save this seal to match the new seal to the correct size Wipe out the grease and then remove the spiral retaining ring Use a screwdriver inserted into the notch formed in the end of the ring Be careful not to scratch the bore with the screwdriver 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 oil Drip pan Shop towel eu Fill reservoir 7 Add fluid as necessary to the full line on the dip EE mn stick Do not mix fluid types Ka eet Hydraulic fluid PORTO 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 resultin a loss of power steering assist Force outthe seal 8 With the vehicle in neutral momentarily tum the starter quickly tum off the engine if it starts Remove inputshaft 9 Remove the shop towel Disconnect the steering seal column and remove the input shaft seal 19 Inspect seal area 10 Check the seal area of the valve housing for any seal fragments Remove any that are found Inspect old seal 11 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 Determi
39. e valve housing and locknut Center punch Hammer 13 6 Socket Lbfein Torque wrench 23 24 25 26 21 Lightly oil and assemble new locknut 18 onto bearing adjuster 17 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 Ibfein 5 1 0 Nem over that which was previ ously noted Again reverse the assembly in vise Torque locknut while holding bearing adjuster in position estab lished in step 24 with appropriate adjuster tool When using a torque wrench in locknut tool J 37464 the torque wrench reading should be 112 Ibf ft 152 Nem The bearing adjuster locknut and valve housing flange should be flush If not the seal ring 8 or o ring 9 may be out of position which will result in axial lash Recheck input shaft torque It should match torque measured in step 24 Repeat steps 24 and 25 if necessary Stake valve housing into the clockwise most comer of two opposing slots in locknut 18 Stake the locknut into the adjuster 17 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
40. edures 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 Odd The axle stops and all steering linkage 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 tum 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 tuming the direction steering wheel in the other direction The poppets are now positioned to trip and reduce pressure as the steered wheels approach the axle stops in either direction 15 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
41. en wrench Open end wrench Hydraulic fluid J ack 4 Open end wrench Ya Socket Lbfelb Torque wrench 28 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 new poppet adjusting screws and nuts will be used tum each screw into the non sealing end of the jam nut until the drive end of screw is flush with the nut 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 M ake 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 the gear and the cylinder If either unit has a poppet adjusting screw and sealing nut that need to be replaced remove and discard them On both the master gear and the rotary cylinder tum 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 732 allen wrench Tighten the sealing nut against the housing Refill system reservoir with approved hydraulic fluid Do not mix fluid types Mixing of transm
42. et 2 Poppet Spring Push Tube Balls Ball Return Guide Halves 2 Seal Cap Ball Return Guide Cap Torx Screws 2 Cap Strap Ball Return Guide Strap Housing Grease Fitting Roller Bearing 63 Seal 2 Output Sector Shaft Adjusting Screw Sector Shaft Retainer Adjusting Screw Gasket Side Cover Side Cover Assembly J am Nut Special Bolts 6 or 8 Side Cover Vent Plug Side Cover Bleed Screw M anual Plug Auto Bleed Fixed Stop Screw Poppet Fixed Stop Screw Poppet Alt Washer Stop Screw Auxiliary Port Plug 2 O ring 2 Aux Port Plug Relief Valve Cap O ring Relief Valve Relief Valve 2 piece Service Poppet Adjusting Screw Service Sealing J am Nut Dirt amp Water Seal Trunnion Retaining Ring These items are included in complete seal kits along with 045422 lubricant and a service bulletin 12 Service Parts List Step Bore Common Parts Item Description 1 2 2B 2C Parts Vary by Gear Size Bolts 4 Valve Housing Dirt and Water Seal 13 16 Serr Dirt and Water Seal 7 8 Serr Dirt and Water Seal 1 Ser Retaining Ring Seal Input Shaft High Temp Seal Ring Valve Housing Seal Ring 2 O ring 2 High Temp Seal Ring O ring Valve Housing High Temp Thrust Washer Thick Thrust Bearing 2 Thrust Washer Thin Bearing Adjuster Adjuster Locknut Balls Seal Cap Ball Return Guide Cap Torx Screws 2 Cap Strap Ball Return Guide Strap
43. gainst the retaining ring Don t push it farther Be sure the housing is square with the press base and the bearing is not cocked EA TE 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 Return to step 32 page 40 60 Roller Bearing Replacement Step Bore Tools Required Materials Required Press J 37071 A TAS65 Step Bore gear Remove roller bearing if required J 37071 A Press Press in housing roller bearing J 37071 A Press 1 2 If roller bearing 37 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 roller bearing 37 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 f TT 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 face is not square use shims to Square it before pressing in the bearing Return to step 32 page 40 61 Replace Housing Ports Plu
44. gs Screws Fittings Tools Required Materials Required Allen wrench Torx sockets Sockets Lbfein Torque wrench Lbfeft Torque wrench Replace poppet fixed stop screw ys Socket or E 14 Torx socket Ibfeft Torque wrench Replace poppet adjusting screw 732 Allen wrench Va or Ve closed end wrench Lbfeft Torque wrench Replace automatic bleed screw and aux port plugs E 14 Torx socket Lbf sft Torque wrench Replace manual bleed screw Vie Hex socket Lbfein Torque wrench If damaged remove and replace the poppet fixed stop screw 52 or 52A and washer 53 if equipped Replace with poppet fixed stop screw 52A discard the washer Torque to 48 Ibf ft 65 Nem If damaged remove poppet adjusting screw 59 and sealing nut 60 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 Ibf ft 47 Nem If damaged remove and replace automatic bleed plug 51 Torque to 48 Ibfeft 65 N em If damaged remove and replace permanent auxiliary port plugs 54 and o rings 55 Assemble new o rings 55 on port plugs and torque to their respec tive ports in the housing or valve housing to 30 Ibf ft 41 Nem If damaged remove and replace manual bleed screw 50 Torque to 45 Ibfein 3 4 Nem Return to inspection section page 41 F
45. he input housing in vise Shaft valve worm assembly 13 or 13A can be assembled vertically with the worm end up Vili Do not clamp against threaded port hole or relief valve hole sealing faces when placing valve housing in vise Assemble o ring 15 Oil and assemble a new o ring 9 into its counterbore in valve housing Assemble othero 16 Lightly oil and assemble new o ring 11 and new ring and seal ring Seal ring 10 into the large diameter seal ring groove in valve housing bending and working them in and smoothing them out as necessary Install roller thrust 17 Install roller thrust bearing 15 and then the thick bearing and washer 12 Square side out onto input shaft end of washer input shaft valve worm subassembly seating them against the input shaft thrust face OR Install bearing 17A Alternate construction TAS65 Assemble spacer components Sleeve 14 onto input shaft with radiused side toward valve Make sure sleeve is square As semble thin washer 16 thrust bearing 15 and thick washer 12 onto input shaft behind spacer Sleeve A CAUTION If you are replacing the input shaft valve w orm assembly discard spacer sleeve and thin washer 56 Install seal ring 18 Lightly oil and assemble new seal ring 8 onto input Shaft and against the thick thrust washer 12 to hold the bearing components in place Assemble input 19 Dip the input end of the input shaft valve worm Shaft valve wo
46. he steering wheel in this position put up to 40 Ib 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 tum loosen the jam nut on the rotary cylinder and hold it in place with a wrench b Tum the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to astop Do not attempt to tum it in farther Pause the tuming in process each time the driver releases the steering wheel Continue tuming only while the wheel is held at full tum c Back off the adjusting screw 3 tums and tighten the sealing nut Torque the sealing nut to 33 37 Ibfeft d Release the steering wheel and shut off the engine The poppets have now been completely reset Lower the vehicle Check the reservoir and fill if required FOI III The length of the adjusting screw beyond the nut must be no more than 1c for proper thread engagement NOTE The length of adjusting screw beyond the sealing nut may be different for each vehicle 29 Poppet Readjustment Dual Gears Reversed Image Tools Required Materials Required 732 Allen wrench ys Open end wrench Hydraulic fluid J ack y4 Open end wrench Ya Socket Lbfelb Torque wrench 30 Set the axle stops to vehicle manufacturer s wheelcut or clearance specifications Start the engine
47. ice Filling and Air Bleeding the System iii 17 Input Shaft Seal Replacement EE EE EE ee ee 18 Sector Shaft Acdhustrment EEN 22 Poppet Readjustment nel EE AR a 3 afi kalla A a 24 DOES a A AG Ee 21 Reseal Repair DisassemnD ecer 33 als 6 Lea E 41 nal 43 Internal Damage Repair by reference Poppet Component Replacement iese rr 51 Valve Housing Worm Screw Disassembly 53 Roller Bearing or Retaining Ring Replacement ie 60 Roller Bearing Replacement Step Bore Gear 61 Replace Housing Ports Plugs Screws Fittings 62 Final Adjustments steli 63 Reinstallation REISA AG OWA EE 65 Poppet Resetting sisi a EE SG Ge ee dee 65 Ela Ge EE 66 A ITT All steering mechanisms are safety critical items As such itis imperative that the instructions in this booklet be follow ed to the letter Failure to observe the procedures set forth in this pamphlet may result in a loss of steering Section 1 General Information Jet e ale Ten 4 OI let NMS UAL OM EE 9 General DESIO nisi a 6 General Operation 7 Approved Hydraulic FIUIOS i 8 Gear Specification NUMDEFS AAA 8 TOQUE e EEN 9 Standard Gear Exploded View EI RE ER 10 Seivice Parts LISE ED Ee ee ee 11 Step Bore Gear EXDIOGEO VIEW alli 12 S rvI CE Parts IC RE a RA 13 Introduction This new TAS Service Manual replaces all previous editions of TR
48. 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 shimmy 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 Step Bore Gear Corrosion Inhibiting Grease Barrier NEE IN de 74 EER od Dirtand Water Seal High Pressure Output Seal Do not attempt to weld any broken steering component Replace the component with onginal 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 only 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 p
49. inal Adjustments Tools Required Materials Required Box end wrench Lbfeft Torque wrench Lbfein Torque wrench Screwdriver Sockets Center steering gear Ya and Ye Socket or box end wrench Tighten adjusting screw Lbfein Torque wrench Screwdriver 1 6 or 7a Socket Loosen adjusting screw and note tordue Lbfein Torque wrench Screwdriver 1 16 Socket To center the steering gear rotate input shaft valve worm assembly 13 or 13A until the timing mark on the end of the sector shaft 42 is in line with the timing mark on the end of housing trunnion 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 A CAUTION 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 With adjusting screw jam nut 47 loose turn sector Shaft adjusting screw 43 clockwise to provide 45 50 Ibfein 5 5 5 Nem of torque required to rotate the input shaft valve worm assembly 13 or 13A
50. ission 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 CAUTION This resetting procedure will work in most cases with at least 134 hand wheel tums 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 M anual a Start the engine and let it run at idle speed 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 c Pull hard on the steering wheel put 40 Ibs rim pull on a 20 dia steering wheel after the axle stop is contacted a Tum the steering wheel in the opposite direction 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 Loosen the sealing nut and back out the adjusting screw on the master gear until 1 is past the nut Tighten the sealing nut against the housing Do not hold the steering w heel at full turn for more than
51. le 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 L is past the nut Tighten the sealing nut against the housing A Alal Do not hold the steering wheel at full turn for more than 10 seconds ata time the heat build up at pump relief pressure may damage components 25 Set lower poppet 10 a Start the engine and let it idle b Tum 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 lb rim pull for 10 seconds then release Repeat this hold and release process as many times as necessary while completing step 11 Position adjusting 11 a With steering wheel held tightly at full turn loosen screw the jam nut and hold it in place with a wrench b Turn the adjusting screw in clockwise using 732 Allen finger pressure only don t use a ratchet until the wrench Allen wrench stops Do not attempt to turn it in 74 Open end further Pause the tuming in process each time wrench the driver releases the steering wheel continue 34 Socket tuming only while the wheel is held at full tum Lbfeft Torque c Back off the adjusting screw 3 tums and tighten wrench the sealing nut Torque sealing nut to 35 Ibfeft The proce
52. ll 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 41 onto installation tool so the side with the garter spring is against the Shoulder of the tool Pilot the tool into the side cover 46 with a force of 100 800 Ib 445 3560 N until it is seated against the bearing or bushing A CAUTION M ake sure the OD of the seal and the ID of the bore are free from grease and dust for proper engagement of the seal TAS 40 55 65 Lightly oil short bearing area of sector Shaft Do not grease TAS85 only Apply a generous amount of Exxon Unirex RS460 to the short bearing area of the sector shaft Insert the sector shaft 42 into the side cover subassembly 46 and screw the sector shaft adjusting screw 43 counterclockwise into the side cover until the screw reaches solid height Rotate the adjusting screw clockwise one half tum so the side cover will rotate freely on the sector Shaft Trademark of Exxon Oil Corp Install jam nut Assemble vent plug Install side cover gasket Center rack piston Install sector shaft and side cover into housing Masking tape 23 24 25 26 21 Install the sector shaft adjusting screw jam nut 47 onto the sector shaft adjusting screw 43 a few threads Final adjustment will be made later Press the new vent plug 49 into the hole provided
53. ll dirt seal 1 Standard Gears Install new dirt seal 38 into the trunnion end of the housing sector shaft bore and against the bearing with the seal lip out Install retaining 2 Standard gears only Install the outside retaining ring ring 36 seating it firmly in the housing retaining ring groove Trademark of Exxon Oil Corp 43 Install washer 3 Standard gears only Install washer 40 into the side cover side of the housing seal bore with the small diameter piloted into the retaining ring If you are working with a housing with an unmachined trunnion face you may need to square the hous ing to the press with shims for step 4 Press seal into 4 All gears Assemble new seal 41 onto bearing and housing Seal tool short end so the lip with the garter spring is toward the shoulder of the tool Working from the side cover side of the housing pilot the seal tool EE into the washer and bearing and press with a force TAS55 65 of 100 800 Ib 445 3 560 N until the seal is seated J 38779 TAS85 firmly Press Step Bore gears only Install the inside retaining ring 63 from the side cover opening Seat the ring firmly in the retaining ring groove Grease the bearing 5 Standard gears Liberally pack the area between dirt and seal area seal 38 and pressure seal 41 including roller bearing with clean high temperature industrial grease 045422 Exxon Unirex RS460 Install dirt amp water 6
54. lve housing Discard the o ring Remove and discard the dirt amp water seal 2 2B or 2C from the input shaft 13 or 13A Save this seal for comparison with the new seal Clean any paint or corrosion from the exposed area of the input shaft Remove the four torx head valve housing bolts 1 Be prepared for more fluid drainage and remove the rack piston subassembly Place the assembly on a clean cloth For the TAS85 it may help to rotate the input shaft to move the rack piston toward the lower end of the housing This will force the valve housing to exit the main housing A TR The set position of poppet seat and sleeve assemblies 22 must not be disturbed if the poppets are not going to be replaced or reset during disassembly 37 19A If your gear is short V construction the rack piston seal is on the end of the rack piston farthest from the input shaft Remove the seal before removing the valve housing assembly to prevent the Teflon rack piston seal ring 20 from hanging up when it exits the housing Expose the seal through the sector shaft cavity then cut and remove the seal ring from the rack piston Remove seals 20 Remove and discard the valve housing seal rings 6 amp 7 A CAUTION 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 Remove ball return 21 Remove and discard
55. lve worm assembly valve housing rack piston subassembly and balls 41 Inspectinput shaft 3 Inspect the sealing area of input shaft and valve 13 valve worm or 13A for nicks and damage Inspect for discolora assembly sealing tion from excess heat Inspect input shaft ball track areas 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 housing 4 Inspect the housing 34 cylinder bore some cylinder bore scoring marks are normal If there was internal leakage greater than 1 gal min make sure there are no damaged seals before replacing the housing Inspect housing 5 Inspect the housing faces for nicks that would faces prevent proper sealing Replace the gear housing if these nicks are present and cannot be easily re moved with a fine tooth flat file without changing the dimensional characteristics Inspectside cover 6 TAS40 55 65 Inspect side cover 46 DU bushing for bushing bearing damage Also check side cover bushing to sector Shaft clearance If damage exists or if clearance exceeds 008 0 20 mm replace side cover bushing ina F n assembly am 7 Ps e be we i CAN 4 A TAS85 Inspect roller bearing in side cover assembly ag 46 for brinelling or spalling If either condition exists replace the side cover and bearing assembly Inspect
56. metry Maximum internal leakage for all TAS gears is 1 gal min General Operation What Happens During a Steering Maneuver When the driver tums the steering wheel he transmits force from 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 tums 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 valve assists in moving the rack piston axially through the cylinder bore The rack piston then tums 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 intemal 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 stee
57. ne and fix the cause of excessive heat in the vehicle Install new seal 12 Put clean grease 045422 on the inside dia of the new input shaft seal and place it over the input GC Shaft With the small dia of tool J 37073 against the Seal tap the tool until the tool shoulder is square J 37073 l against the valve housing Remove any seal mate rial that may have sheared off in the seal bore or retaining ring groove NEST TEN Do not use a socket to install this seal because you will not be able to control seal installation depth possibly causing a leak Install retaining 13 Insert new retaining ring into the groove ring Install dirt amp water 14 Pack the end of the valve housing bore around the seal 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 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 retum line port Air bleed system 17 Air bleed the system using the procedure on page 17 Seal PartNo Serration Size M ajor Serration Dia 478044 1
58. ng nut assembly screw assembly without rotating the nut on the screw into the into housing housing until the nut is firmly against the housing using a 732 Allen wrench Tighten the sealing nut F 72 Allen against the housing wrench Paie WHITE ifthe drive end of the screw is below the face of the nut the popet seat flange will break during step 7d 24 Jack up vehicle Push upper poppet out to prepare it for setting Set upper poppet Back out adjusting screw 742 Allen wrench Ys Open end wrench Refill the system reservoir with approved hydraulic fluid A TR 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 Tum in this direction until axle stop contact is made d Pull hard on the steering wheel put up to 40 Ib rim pull on a 20 dia steering wheel after the axle stop is contacted a Tum the steering wheel in the opposite direction end of timing mark away from adjusting screw until the other ax
59. nts 10 a Start the engine and let it idle b Tum 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 lbs 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 11 12 13 a With steering wheel held at full tum loosen the jam nut on the master gear and hold it in place with a wrench b Tum the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to astop Do not attempt to tum it in farther Pause the tuming in process each time the driver releases the steering wheel Continue tuming only while the wheel is held at full tum c Back off the adjusting screw 3 tums and tighten the sealing nut Torque nut to 33 37 lbfeft a With steering wheel held at full tum loosen the jam nut on the rotary cylinder and hold it in place with a wrench b Tum the adjusting screw in clockwise using finger pressure only don t use a ratchet until the Allen wrench comes to astop Do not attempt to tum it in farther Pause the tuming in process each time the driver releases the steering wheel Continue tuming only while the wheel is held at full tum c Back off the adjusting screw 3 tums and tighten th
60. of balls are required for proper gear operation Count the balls and insert each carefully as in step 11 TAS55 Original 30 31 Service 31 TAS55 gears built prior to 338 89 were equipped with 30 balls UH TIEN Do notallow valve housing to contact the poppet stem or move more than 2 2 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 Pdf Remove any fluid present in the two screw holes Fluid in these holes could cause improper clamp load when torquing the cap or strap screws Assemble ball 13 Place anew ball retum guide cap seal 29 in the return guide cap seal groove of the cap 30 Make sure the seal makes full contact with the rack piston surface 5 9 Allen or T Install two new Allen or Torx head screws 31 and 30 Torx socket torque each screw altemately until a final torque of Lbfein Torque 18 Ibf ft 24 5 Nem is achieved wrench Grease A 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 f Assemble ball 14 If your gear was equipped with the ball return guide i d return guide strap Strap 32 or if it was equipped with the clip install the new ball retum guide strap Position it on the 532 Allen or T rack piston install two new Allen or Torx head 30
61. ring Screwdriver Remove seal 11 1 Socket Hammer Inspectinputshaft 12 valve worm assembly sealing areas Inspect thrust 13 washers and bearings Remove and discard seal rings 10 and 8 and o rings 11 and 9 from valve housing 5 Tum over valve housing and remove retaining ring 3 A CAUTION 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 13 or 13A for nicks and run your fingernail edge across the sealing surfaces to detect steps Inspect for discoloration 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 15 rollers for any deterio ration Inspect thrust washers 12 amp 16 for brinelling spalling or cracks Replace any part with these conditions Alternate Construction TAS65 If spacer sleeve 14 is damaged replace the input shaft valve worm subassembly and use thick washer and roller bearing only during reassembly 55 Place valve 14 Place valve housing 5 firmly in a vise so t
62. ring wheel Unloading Poppet Valves Most TAS 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 TAS gears with or without poppets are supplied with a relief valve The relief valve limits maximum Supply pressure to protect the power steering gear but it does not reduce pressure as the steered wheels ap proach the axle stops Bleed Systems Some TAS gears 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 17 of this manual Replacement of damaged automatic bleed plugs and manual bleed screws is described on page 62 Approved Hydraulic Fluids Fluids approved and recommended for use in TRW steering systems include e Automatic Transmission Fluid Dextron Il III Mercon e Automatic Transmission Fluid ATF 4 Use of fluids other than approved and recommended may void the steering sy
63. rm assembly 13 or 13A into oil up to the worm lead amp bearing assem Assemble the input shaft end of the assembly into bly the valve housing 5 until it is firmly seated Assemble bearing 20 Apply oil and assemble the other thrust bearing 15 and thrust washer then the thin thrust washer 16 over the ball groove end of worm and seat them against the shoulder of input shaft valve worm assembly Assemble seals in 21 Lightly oil anew o ring 9 and assemble into the i bearing adjuster seal groove in bearing adjuster 17 Oil and work a y 7 new seal ring 8 into the same groove and smooth it out Be sure the valve housing Cp adjuster locknut and bearing V adjuster threads are clean and free of any staking burrs that would impede the locknut from turing freely on adjuster or the adjuster tuming freely in gt Sila valve housing Assemble bearing 22 Lightly oil and assemble bearing adjuster 17 over sj adjuster wom and into valve housing Torque adjuster to 13 z Ibf ft 18Nem indicated torque using a torque wrench inserted in adjuster tool 4 37070 This will seat the components Back off adjuster Va to 2 of a tum 1 37070 EE Lbfeft Torque wrench 5 7 Assemble new locknut J 37464 Adjust to required input torque Ya or Mis 12 point socket Lbfein Torque wrench Torque locknut J 37070 37464 Lbfeft Torque wrench Check input shaft torque Stak
64. sector 7 Inspect the sector shaft 42 bearing and sealing shaft assembly areas and sector teeth contact surfaces for brinelling spalling or cracks Run your fingemail i edge across these areas to detect steps Remove WH masking tape from the shaft and inspect for twisted or otherwise damaged serrations If any of these conditions exist replace the sector shaft NOTE A service sector shaft will come assembled with the adjusting screw 43 and retainer 44 42 Assembly Preparation Wash all parts in clean OSHA approved solvent Air blow dry them only A 1 em Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death A TE 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 7 32 Allen J 37071 TAS55 65 Sockets ATF oil Seal kit Ross TAS400004 wrench J 38779 TAS85 Torx sockets Grease Exxon TAS550004 Lbfeft Torque Press Vise Unirex RS460 TAS650012 wrench Punch Masking tape TAS850005 Hammer Ratchet Tie 14 x 7 4 All Thread J 37705 TAS40 Screwdriver Insta
65. stem warranty A Te 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 resultin a loss of power steering assist Specification Numbers Step Bore Identifier TAS65001A 29097901827 Date Code Serial Number The steering gear specification number and date code are stamped on a machined surface opposite the input shaft of every TAS gear Newer gears include a serial number An example date code would be 29097 this means the gear was built on the 290th day of 1997 An A included at the end of the specification number indicates a step bore housing Torque Chart _ Torque Range Dry Torque Range Lubricated Auxiliary cylinder plug 25 35 Ibfeft 34 48 Nem Ball return guide cap strap bolts 14 22 Ibfeft 19 29 Nem Bearing adjuster 11 15 Ibfeft 15 20 Nem Locknut 101 122 Ibfeft 137 165 Nem Manual bleed screw 40 50 Ibfein 3 1 3 7 Nem Plug auto bleed 38 58 Ibfeft 52 79 Nem Poppet sleeve assembly 16 20 Ibfeft 22 27 Nem Poppet sealing nut service 33 37 Ibfeft 45 50 Nem Poppet fixed stop screw 38 42 Ibfeft 52 57 Nem Poppet fixed stop screw 38 58 Ibfeft 52 79 Nem Relief valve cap 25 35 Ibfeft 34 48 Nem Sector shaft adjusting screw jam nut 40 45 Ibfeft 54 61 Nem Side cover bolts
66. t Seat and dEr Push Tube Sleeve Assembly ES Push Tube Sleeve Assembly 51 52 Remove other seat amp sleeve if necessary Reset remaining poppet seat and sleeve assembly Press Ys 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 J 36452 A Lbfeft Torque wrench 5 6 7 8 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 22 was left in rack piston it can be reset for automatic poppet adjustment by inserting a 36 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 Carefully apply Locquic T primer to the threads in poppet holes and threads on the new seat and sleeve assemblies 22 Allow to dry for ten min utes then carefully apply Loctite RC680 to same threads
67. tapping the end of the shaft lightly with a soft mallet or wooden hammer handle 35 Discard gasket 10 shaft from cover Screwdriver seal 3 Drive socket Rolling head pry bar Inspect adjusting 14 screw and retainer 36 Remove vent plug 11 Remove sector 12 Remove side cover 13 Remove and discard the side cover gasket 45 Remove and discard the vent plug 49 Screw sector shaft adjusting screw 43 clockwise through the side cover and pull the sector shaft out of the side cover Don t damage the bore or DU bushing when removing the seal TAS85 gears are not equipped with the DU bushing A CAUTION Clamp the side cover in a vise Place a standard 38 or dei 3 drive socket in the center of the side cover pry the seal 41 out with a rolling head pry bar using the socket for support Discard the seal and remove the socket Inspect the sector shaft assembly for damaged adjusting screw threads The retainer 44 must be securely staked in place The adjusting screw must rotate by hand with no perceptible end play lash Remove relief valve components Remove dirt amp water seal Clean input shaft Fine grade emery cloth Remove valve housing bolts Torx socket E 16 or E 18 Remove valve housing worm and rack subassembly 15 16 17 18 19 If equipped remove relief valve cap 56 o ring 57 and two piece relief valve 58 from the va
68. that shows exces sive wear unless the damaged and worn parts are replaced with original TRW replacement and service parts and the unitis restored to TRW s specifications for the TAS steering gear It is the responsibility of the mechanic performing the maintenance repairs or service on a particular TAS 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 safe operation of the vehicle and c fully inspect and test the TAS 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 Division TAS power steering gears are covered by several United States and foreign patents either issued or pending TRW Inc 2002 Contents Section 1 Section 2 Section 3 Section 4 Section 5 General Information INTOdUCION sica rallo 4 OI Flow UI ele RTE 5 General DESIGN gita iraniana 6 Gene A OPEN rasa a EE 1 Approved Hydraulic Fluids rns 8 Gear Specification Numbers AAA 8 Torque Char ale lella 9 Standard Gear Exploded RTE 10 Service Parts Eege enee e 11 Step Bore Gear E DIOdEd RE 12 Service Parts EE 13 Initial Installation installation BE 15 P DDet Seting D 15 Maintenance TIPS ss ES SE e E E 16 On Vehicle Serv
69. the two special sealing screws ar guide cap strap 31 Remove the ball retum cap 30 and seal 29 Mech or strap 32 discard the seal 5 32 Allen wrench or T 30 Torx wrench OR Remove ball return 21A Bend down the two tabs tangs that are against the guide clip hex head bolts Remove two bolts and the clip Discard the clip 1 2 Socket Remove ball return 22 Make sure the rack piston is on a cloth so the steel guides balls that fall out won t roll very far Remove ball retum guide halves 28 by carefully inserting a screwdriver between the rack piston and guides Left hand ball retum guide halves are copper plated for identification and right hand guides are not plated Retain the guides for reassembly 38 wf ge Remove steel balls 23 Separate rack 24 piston from worm subassembly Remove seal ring 25 and o ring E I EF L Ze Inspect poppet 26 assemblies Inspect valve 21 housing and worm screw Remove the steel balls 27 from the rack piston 19 by rotating the input shaft valve worm assembly until the balls fall out Place the balls and retum guides in a cup or other container Count the balls and make sure all have been removed A Til TYE The steel balls are a matched set If any are lost the set must be replaced by service balls Number of factory balls installed TAS 40 29 TAS55 31 30 if date code is 337 89 or earlier TAS65 32 TAS
70. tion is to continue with step 5 of this procedure 22 lag i Screw Pi Senge i f Screwdriver Ys Open end wrench Position adjusting 5 Adjust shaft 6 Recheck for lash 7 Connect drag link 8 If no lash was detected in step 3 tum the shaft adjusting screw counterclockwise until you feel lash at the output shaft Slowly tum the shaft adjusting screw clockwise until you feel no lash at the output shaft without using more than 10 Ibfeft 14 Nem of torque From this position tum the screw clockwise Ve to ie of a tum more Hold the adjusting screw in place and tighten the jam nut Final jam nut torque 43 lbfeft 58 Nem Tum the steering wheel tum 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 NEST IE 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 23 Poppet Readjustment Single Gears This resetting procedure will work in most cases with at Tools Required Materials Required least
71. turer 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 from vehicle and gear is being installed on the Poth si se SS stop contact Is Get If not same vehicle with no change in axle stops or linkage USO ean Proe dus AAN OR PAJE aa gt IF Poppets were replaced with new components or Use poppet setting procedure on page 15 reset during gear disassembly and are ready for auto matic positioning gt IF Poppets may have been moved during disassembly Use poppet resetting procedure beginning on page 24 or reassembly procedures or gear is being installed on a different vehicle 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 Follow procedure on page 13 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 J ulian date Discoloration Change in color External Leakage Fluid Leaking out of the system or steering gear Full Turn Hub contacts axle stop 66 Integral Power Steering Steering gear has manual steering mechanism hydraulic control valve and hydraulic power cylinder
72. w 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 28 page 40 Trademark of Exxon Oil Corp 59 Roller Bearing or Ret Ring Repl Standard Tools Required Materials Required Press Screwdriver J 37071 TAS55 65 or J 37071 A TAS55 65 J 37705 TAS40 J 38779 TAS85 Remove roller 1 Standard Gears Only If roller bearing 37 in housing bearing if required needs to be replaced place the bearing removal end long end of the bearing and seal tool against the Side cover end of the bearing and press it out of trunnion end of the bearing bore Discard bearing Remove retaining 2 Standard Gears Only If the retaining ring 36 that is ring still in the housing bearing bore needs to be re placed remove it through the trunnion end of the bearing bore to protect the pressure seal bore area Screwdriver l from being damaged Install retaining 3 Standard Gears Only Insert retaining ring 36 if it ring was removed into the housing bore from the trunnion end to protect sealing area Make sure it bw VC 3 is seated in the retaining ring groove closest to side VW cover end of the bearing bore Lubricate the bearing bore Press in housing 4 Standard Gears Only Press the roller bearing 37 into roller bearing the housing from the trunnion end of bearing bore until it is seated a

TAS Steering Gear Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents