Remove/install rack-and-pinion steering

AR46.20-P-0600P

Remove/install rack-and-pinion steering

6.12.10



Removing

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Evaluating steering rack when repairing accident vehicles

AH46.20-P-9409-01A

1

Remove front wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

2

Extract fluid out of the power steering pump's fluid reservoir

 Hand pump

*210589007100

3

Extend or pull out adjustable steering column fully

 Needed for separating the steering coupling (25).

4

Deactivate easy entry/exit function

Vehicles with memory package (driver seat, steering column, mirrors) code 275

 Otherwise the driver seat and steering wheel move to a different position, e.g. when the driver door is opened/closed. The upper frame may be damaged when the holding device is installed.

 It is switched off using the buttons on the steering wheel in the "Comfort" menu on the multifunction display, see vehicle owner's manual.

5

Turn steering wheel to central position (front wheels in straight ahead position) and secure with the retaining device

 On a disengaged steering coupling (25) the steering wheel should not be turned because the spiral contact coil will be destroyed.

 Holding device

*129589012100

6.1

Remove lower engine compartment paneling

Model 203, 209 with gasoline engine

AR61.20-P-1105P

6.2

Remove bottom sections of soundproofing

Model 203, 209 with diesel engine

AR94.30-P-5300P

7

Remove diagonal strut at left and right front

Model 209.4

 Installation: The diagonal struts may only be fitted when the vehicle is standing with the wheels on the ground.



*BA61.10-P-1011-01C

8

Press tie rod joints (10a) off steering knuckles

AR46.40-P-0200-02I

 Thrust piece

*140589006300

 Puller

*124589033300

9

Remove exhaust shielding plate (105d) to front plate over steering coupling (25)

10

Remove the bolt of the steering coupling to steering shaft (25a)

11

Pull the lower steering shaft (80a) upward to extract it from the steering coupling (25.)

Do not apply excessive force (hammer blows, excessive lever action) because the lower steering shaft (80a) is sensitive to lateral loads and could be damaged.

12

Detach oil lines to rack-and-pinion steering (23)

13

Remove support bracket (1g) to front axle carrier (1)

 Remove bolts of retaining plate on front axle carrier (23a, 23b) to do this.

14

Detach electrical connector to rack-and-pinion steering (23)

Vehicles with speed-sensitive power steering, code 213

15

Remove bolts of rack-and-pinion steering at front axle carrier (23g)

16

Detach oil line retaining plate (23q) from rack-and-pinion steering (23) and pull out oil lines

 Seal off line connections with plugs.

 Set of stop plugs

*129589009100

17

Remove threaded hole plate (23n) of rack-and-pinion steering (23)

18

Remove rack-and-pinion steering (23)

19

Check rubber mount (21) of rack-and-pinion steering mounting for signs of damage

 Damaged rubber mounts (21) must be replaced:



Remove/install rubber mount of rack-and-pinion mounting.

AR46.20-P-0600-02I

Lubricant paste

*BR00.45-Z-1002-06A

20

Check protective cap on input shaft of rack-and-pinion steering (23) for damage

 Replace if necessary:



Remove/install protective cap for input shaft on steering gear.

AR46.20-P-0004P



Install

21

Insert threaded hole plate (23n) of rack-and-pinion steering (23)

 Replace threaded hole plate (23n).

22

Insert rack-and-pinion steering (23) and fasten to front axle carrier (1) using bolts for rack-and-pinion steering to front axle carrier (23g)

 The bolts for the rack-and-pinion steering to the front axle carrier (23g), threaded hole plate (23n) and the area around the bolted connections must be free of oil and grease. Under exposure to heat the lubricants can liquify, allowing bolts and nuts to loosen.



*BA46.20-P-1002-01F

23

Mount support bracket (1g) using bolts for support bracket to front axle carrier (23a)

 The bolts for the support bracket to the front axle carrier (23a), threaded hole plate (23n) and the area around the bolted connections must be free of oil and grease. Under exposure to heat the lubricants can liquify, allowing bolts and nuts to loosen.



*BA46.20-P-1004-01F

24

Mount support bracket (1g) using bolts for support bracket to front axle carrier (23b)



*BA46.20-P-1004-01F

25

Insert oil lines and mount retaining plate for oil lines (23q) to rack-and-pinion steering (23)

 Replace O-rings to prevent any escape of oil.



*BA46.20-P-1001-01F

26

Mount oil lines onto rack-and-pinion steering (23)

 Front left and right side.

27

Fit steering coupling (25)

 To do so turn rack-and-pinion steering (23) to center position.

AR46.20-P-0600-01P

28

Push on the locking plate (25f) until the lug in the steering coupling (25) latches.

 The locking plate (25f) is not available as a replacement part.

 Insert a new self-locking nut into the existing locking plate (25f).

29

Insert lower steering shaft (80a) as far as the end stop in the steering coupling (25)

Do not apply excessive force (hammer blows, excessive lever action) because the lower steering shaft (80a) is sensitive to lateral loads and could be damaged.

 When doing so observe the steering coupling (25) journal and the groove of the lower steering shaft (80a) (arrows).

30

Turn in bolt for steering coupling to steering shaft (25a)



*BA46.10-P-1001-01E

31

Mount exhaust shielding plate (105d) to front plate under steering coupling (25)

32

Mount tie rod joints (10a) onto steering knuckles

AR46.40-P-0200-02I



*BA46.40-P-1001-01E

33

Fill power steering pump and bleed

Except model 203.2 with rear axle level control system code 480

AR46.30-P-0010P

34

Check steering for function and leaks

 There is a grease cushion under the cover cap. A slight escape of grease is to be regarded as normal and should not be confused with leakage.

35

Mount front wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

36

Check front axle toe and adjust if necessary

 When installing new parts.

See: 

Perform wheel alignment check

AR40.20-P-0200P

37.1

Install lower engine compartment paneling

Model 203, 209 with gasoline engine

AR61.20-P-1105P

37.2

Install bottom section of soundproofing

Model 203, 209 with diesel engine

AR94.30-P-5300P

Number

Designation

Model
209 except 209.4

Model
209 .4

BA61.10-P-1011-01C

Self-locking bolt, front diagonal strut to frame floor/front axle carrier

Nm

80

80

Number

Designation

Model
203 except
203.081/
084/087/
092/281/
284/287/
292

Model
209

BA46.10-P-1001-01E

Bolt, steering coupling to steering shaft

Stage 1

Nm

30

30

Stage 2

°

-

-

Number

Designation

Model
203

Model
209

BA46.20-P-1001-01F

Bolt, oil line retaining plate to rack-and-pinion steering

Nm

18

18

BA46.20-P-1002-01F

Bolted connection, rack-and-pinion steering to front axle carrier

Stage 1

Nm

50

50

Stage 2

°

90

90

BA46.20-P-1004-01F

Bolted connection, supporting plate to front axle carrier

Stage 1

Nm

50

50

Stage 2

°

60

60

Number

Designation

Model 203
except model 203.081/084/
087/092/281/
284/287/292

Model 209

BA46.40-P-1001-01E

Self-locking nut, tie rod to steering knuckle

Stage 1

Nm

50

50

Stage 2

°

60

60

Number

Designation

Order number

BR00.45-Z-1002-06A

Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00

A 000 989 01 60