Remove/install steering gear

AR46.20-G-0500A

Remove/install steering gear

09.03.2020

Model

427

with steering ZF 8095

Model

435

with steering ZF 8095

Model

437.000/110/111/112/113/120/130/131/141

with steering ZF 8095

1

Steering gear

2

Drag link

3

Pitman arm

4

Return flow pipe

5

Fitting

6

Pressure line

7

Fitting

8

Bolts

2

Drag link

3

Pitman arm

1

Steering gear

3

Pitman arm

12

Primary shaft

13

Cover

A

Mark

B

Mark

C

Mark

 Danger

Risk of death caused by vehicle slipping or toppling off during lifting

Only lift vehicle at the lift support points specified by the vehicle manufacturer.

AS00.00-Z-0032-01A

 Warning

Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.

Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Assessment of steering after accidents

AH46.00-N-1000-01A



Remove

1

Perform a test drive and mark position of steering wheel when driving straight ahead



Clean

2

Clean steering gear (1)


The utmost cleanliness must be ensured when performing assembly operations on the steering.
Otherwise the ingress of dirt particles may result in malfunctions or failure of the steering gear (1).

 Only lint-free cloths or paper hand towels may be used for cleaning work.

3

Lift up front axle and move front wheels to straight-ahead position

 Observe the marking made on the steering wheel.

4

Lower front axle and lower front wheels onto turn plates



Check

5

Check straight-ahead position of front wheels using marking made on steering wheel

If this is not the case



Move front wheels to straight-ahead position.

6

Set scales on turn plates to zero

7

Remove underride guard

8

Detach drag link (2) from pitman arm (3)

 Puller

*625589003500

9

Remove engine hood

10

Remove steering shaft

AR46.10-G-7310A

11

Remove return line (4) from steering gear (1) and collect escaping oil

12

Remove pressure line (6) from steering gear (1) and collect escaping oil

13

Remove fitting (5) from steering gear (1)

14

Seal all openings on steering gear (1) using suitable stop plugs

 Record plug

*129589009100

15

Prop up steering gear (1) using floor jack or pit hoist

16

Remove bolts (8) and remove steering gear (1)

 The bolts (8) located between the steering gear (1) and the frame have washers that are convex on one side.

17

Detach steering gear pitman arm (3) from the steering gear (1)

Only if the steering gear (1) is replaced.

AR46.40-G-2000-01A

 The pitman arm (3) detaches suddenly when it is pulled off.

 Spindle

*655589003502

 Bell-type puller

*437589033300

18

Remove cover (13)

Only if the steering gear (1) is not being replaced.



Check

19.1

Check cover (13) for damage

Only if the steering gear (1) is not being replaced.

If damage is present



Replace cover (13).

19.2

Check installation position of cover (13) on steering gear (1)

Only if the steering gear (1) is replaced.

 Marking (B) must line up with marking (A).

If this is not the case



Correct installation position of cover (13).



Clean

20

Rinse grease out of blind tapped holes in steering gear (1) and out of holes in frame using universal cleaner

CRC Quickleen, universal cleaner aerosol (500 ml)

*BR00.45-Z-1055-04A

21

Remove any remaining grease using cloth from the blind tapped holes on the steering gear (1) and the holes on the frame



Install

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

22

Apply coating of lubrication to gearing of primary shaft (12) in area of radial shaft sealing ring

Only if the steering gear (1) was not replaced.

Long-life grease

*BR00.45-Z-1001-06A

23

Install cover(13)

Only if the steering gear (1) was not replaced.

 Marking (B) must line up with marking (A).

24

Remove setting screws for hydraulic steering limiter and seal openings on steering gear (1) using suitable stop plugs

AR46.25-G-3120A

 Record plug

*129589009100

25

Attach pitman arm (3) to steering gear (1)

Only if the steering gear (1) was replaced.

AR46.40-G-2000-01A

 Pitman arm to steering gear

*BA46.20-N-1001-01P

26

Fit new bolts (8) into frame

27

Slide shims onto bolts (8)


The flat sides of the shims must face towards the steering gear (1) and the convex sides to the frame.
Otherwise, the steering gear (1) or frame may be damaged.

28

Move the steering gear (1) using floor jack or pit hoist into installation position and uniformly fit all bolts (8) into place

29

Tighten bolts (8)

 Steering gear to frame

*BA46.20-N-1005-01P

30

Remove all stop plugs from openings for return line (4) and pressure line (6) on steering gear (1)

31

Mount fitting (7) onto steering gear (1)

Only if the steering gear (1) was replaced.

 Fitting, pressure line to steering gear

*BA46.20-N-1008-01P

32

Mount fitting (5) onto steering gear (1)

 Fitting, return line to steering gear

*BA46.20-N-1009-01P

33

Counterhold fitting (5) and mount return line (4) onto steering gear (1)

 Return line to steering gear

*BA46.20-N-1004-01P

34

Counterhold fitting (7) and mount pressure line (6) onto steering gear (1)

 Pressure line to steering gear

*BA46.20-N-1003-01P

35

Move steering gear (1) to center position

AR46.20-G-0500-01A

36

Place front wheels in straight-ahead position

 Observe the zero position of the scales on the turntables.

37

Position drag link (2) on pitman arm (3)


When positioning the drag link (2) the pitman arm (3) and the front wheels must not be moved.
Otherwise, the setting of the steering gear center position may be faulty.

 The drag link (2) must be inserted free of any tension.

If a problem arises



Release clamp on drag link (2), correct length of drag link (2) and tighten clamp on drag link (2) again.

 Nut, clamp to drag link

*BA46.40-N-1001-06O

38

Tighten nut of drag link (2) on pitman arm (3)

 Nut, drag link to pitman arm/steering knuckle arm

*BA46.40-N-1002-06O

39

Install adjustment screws of hydraulic steering limiter

AR46.25-G-3120A

 Only perform the operation steps for installing the setting screws.

40

Grease gearing of primary shaft (12) in area of cover (13) with lubricant

Long-life grease

*BR00.45-Z-1001-06A

41

Install steering shaft

AR46.10-G-7310A

42

Lift up front axle and remove turn plates

43

Add oil to oil container up to Max. marking



Steering gear oils (ATF) (specification 236.3)

BB00.40-P-0236-03A

 See operator's manual.

44

Start engine and run at idling speed

45

By alternately turning the steering wheel all the way to the end stop at the right and left, bleed the steering until air bubbles are no longer visible in the oil container

 When bleeding, check the oil level in the oil container continuously and add oil if necessary.

46

Turn off engine

47

Lower front axle

48

Apply coating of top coat to steering gear (1) and bolts (8)

Only if the steering gear (1) was replaced.

 A top coat that correspond with standard MB 9124 is to be used.

49

Apply coating of anticorrosion wax and underbody protection to steering gear (1) and bolts (8)

Only if the steering gear (1) was replaced.

 Before applying the underfloor protection, observe the flash-off time. Refer to the directions for use of the anticorrosion wax.

Anti-corrosion wax, Dinitrol 3650, 1 liter

*BR00.45-Z-1004-05A

Underbody protection, Dinitrol 4941 (black), 1 liter

*BR00.45-Z-1005-05A

50

Install underride guard

51

Install engine hood

52

Conduct a road test

 Check the overall steering ability of the vehicle and the maximum left and right steering stop.



Check

53

Check leak tightness at steering gear (1)

 Visual inspection.

54

Check oil level in oil container for power steering system

 See operator's manual.

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1001-01P

Pitman arm to steering gear

Nm

520

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1003-01P

Pressure line to steering gear

Nm

90

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1004-01P

Return line to steering gear

Nm

50

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1005-01P

Steering gear to frame

Nm

420

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1008-01P

Fitting, pressure line to steering gear

Nm

55

 Steering gear

Number

Designation

Model 427, 435, 437.0/1
with steering gear ZF 8095

BA46.20-N-1009-01P

Fitting, return line to steering gear

Nm

80

 Steering linkage

Number

Designation

Model 437.0/1

Model 427

BA46.40-N-1001-06O

Nut, clamp to drag link

M10x1

Nm

55

55

M12x1.5

Nm

80

80

 Steering linkage

Number

Designation

Model 435

BA46.40-N-1001-06O

Nut, clamp to drag link

M10x1

Nm

55

M12x1.5

Nm

80

 Steering linkage

Number

Designation

Model 437.0/1

Model 427

BA46.40-N-1002-06O

Nut, drag link to pitman arm/steering knuckle arm

M20x1.5

Nm

225

225

M24x1.5

Nm

280

280

M27x1.5

Nm

350

350

 Steering linkage

Number

Designation

Model 435

BA46.40-N-1002-06O

Nut, drag link to pitman arm/steering knuckle arm

M20x1.5

Nm

225

M24x1.5

Nm

280

M27x1.5

Nm

350

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1004-05A

Anti-corrosion wax, Dinitrol 3650, 1 liter

A 000 986 59 70 10

BR00.45-Z-1005-05A

Underbody protection, Dinitrol 4941 (black), 1 liter

A 000 986 60 70 10

BR00.45-Z-1055-04A

CRC Quickleen, universal cleaner aerosol (500 ml)

CRC Industries Europe
http://www.crcind.com