Remove/install protective cap for input shaft on steering gear

AR46.20-P-0004P

Remove/install protective cap for input shaft on steering gear

23.4.12



Removing

1

Mount rack-and-pinion steering on the steering gear housing support

 Make sure that the workplace is clean when carrying out the work described below and while performing repairs.

Only the specified tools may be used.

Before starting the repair work, remove any loose dirt from the steering gear without using cleaning agents.

 Steering gear housing support

*221589013100

2

Detach clamps (1) of both boots (2)

3

Slide boot (2) toward tie rod end

 To do so, squeeze the clamps on the inner tie rods with axial joints (3) together.

4

Remove inner track rod with axial joint (3)

 Do not use force (hammer blows, excessive leverage). Otherwise the inner tie rod with axial joint (3) may be damaged.

 Dismantle at left and right sides.

Models 171, 172, 203, 204 (except 204.9), 207, 209, 211, 230

 Open-end wrench

*201589000100

Models 204.9, 212

 Plug in open-end wrench

*221589020900

Models 169, 245

 Open-end wrench bit

*169589000100

5

Move steering rack to center position

 Use depth gauge to determine when the assembly is centered. Balance out the gaps from the end of the steering rack to the stop ring (16) in the steer jacket (14) on both sides of the steering rack.

6

Detach protective cap (4)



Install

7

Grease gap between input shaft and control head (arrow)

Except model 169, 245

 Apply grease using fingers. Do not use any other aid.

Renolit JP1619 special grease

*BR00.45-Z-1067-06A

8

Fit protective cap (4)

 Marking (5) must line up exactly with marking (6). Otherwise the Electronic Stability Program (ESP®) may malfunction.

Models 169, 245

 There are various versions of the protective cap (4). The version fitted must always be reinstalled.



Modified rack-and-pinion steering

Model 169 as of 31.3.05

BT46.20-P-0600-01AK



Checking

9

Check center steering position on steering gear

AR46.20-P-3015P

10

Attach inner tie rod with axial joint (3)

 Do not use force (hammer blows, excessive leverage). Otherwise the inner tie rod with axial joint (3) may be damaged.

 Mount on left and right sides.

Models 171, 172, 203, 209, 211, 230

 Inner track rod with axial joint to rack-and-pinion steering

*BA46.40-P-1003-01E

Models 169, 245

 Inner tie rod to rack-and-pinion steering

*BA46.40-P-1003-01J

Models 204, 207, 212

 Inner tie rod to rack-and-pinion steering

*BA46.40-P-1003-01N

Models 171, 172, 203, 204 (except 204.9), 207, 209, 211, 230

 Open-end wrench

*201589000100

Models 204.9, 212

 Plug in open-end wrench

*221589020900

Models 169, 245

 Open-end wrench bit

*169589000100

11

Mount bellows (2)

12

Mount clamps (1) of both bellows (2)

 Replace clamps (1).

Models 169, 171, 203, 209, 211, 230, 245

Models 172, 204, 207, 212

AR46.40-P-7200-01EW

 Installation: Make sure that the clamps (1) are attached at the correct position.

13

Detach rack-and-pinion steering from steering gear housing support

Number

Designation

Model 171

Model
172

BA46.40-P-1003-01E

Inner track rod with axial joint to rack-and-pinion joint

Nm

110

110

Number

Designation

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

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

BA46.40-P-1003-01E

Inner track rod with axial joint to rack-and-pinion joint

Nm

110

110

Number

Designation

Model 209

Model
211 except 211.08/09/ 28/29

Model
211.08/09/ 28/29

Model
230

BA46.40-P-1003-01E

Inner track rod with axial joint to rack-and-pinion joint

Nm

110

110

110

110

Number

Designation

Model
169

Model
245

BA46.40-P-1003-01J

Inner tie rod to rack-and-pinion steering

Nm

80

80

Number

Designation

Model
204

Model
207

Model
212

BA46.40-P-1003-01N

Inner tie rod to rack-and-pinion steering

Nm

110

110

110

Number

Designation

Order number

BR00.45-Z-1067-06A

Renolit JP1619 special grease

A 001 989 38 51 10