Remove/install steering gear

AR46.20-W-0500HE

07.02.2020

Model

964.03/23/33

Modification notes

05.02.2020

Work procedure completely revised.

W46.20-1104-09

Shown on model 964.23 with code C6H (Steering, Servotwin, 4-axle model)

1	Steering gear	4	Oil pressure line	7	Electrical connector (only on vehicles with code C6H (Steering, Servotwin, 4-axle model))
2	Lower steering shaft	5	Bracket	8	Oil return hose
3	Bracket	6	Electrical connectors (only on vehicles with code C6H (Steering, Servotwin, 4-axle model))	9	Oil return line

W46.20-1105-09

1	Steering gear	12	Drag link (between steering gear (1) and steering arm of 1st front axle)	15	Oil pressure line (to steering cylinder)
10	Steering bracket	13	Pitman arm	16	Oil pressure line (to steering cylinder)
11	Drag link (between steering gear (1) and 1st steering idler arm)	14	Oil return hose

 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
 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 from being trapped in the swivel range of steered axles	Ensure that no persons or objects are in the swivel range of all steered axles when turning the steering wheel. Do not stand in the swivel range of the additional steering axle when the engine is running.	AS46.00-Z-0002-01A
 Warning	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.	AS60.80-Z-0001-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
Topical note	Special instructions for lifting and supporting vehicle		AH00.60-N-0100-01B
Topical note	Notes on maintenance and repair work		AH46.20-N-0001-01H
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Topical note	Notes on tilting the cab		AH60.80-N-0003-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Assessment of steering after accidents		AH46.00-N-1000-01A
	Remove
1	Thoroughly clean wider area around electromechanical controller unit.	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model)
		 No dirt particles or moisture must be allowed to enter the electromechanical controller unit. The electromechanical controller unit can be damaged by moisture and dirt, which in turn can alter the steering behavior.
2	Fix holding device for loosening and tightening pitman arm (13) in place under a rear wheel on driver's side.	Only when replacing steering gear (1) or pitman arm (13).
		 To fix the vehicle in place, drive the corresponding rear wheel onto the holding device.
		 Holding device	*964589004000
3	Remove drag link (12) between steering gear (1) and steering arm of 1st front axle.		AR46.40-W-0101HE
4	Remove drag link (11) between steering gear (1) and 1st steering idler arm.		AR46.40-W-0102HE
5	Move steering gear (1) to center position.	Vehicles without code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.20-W-0500-01H
		Vehicles with code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.20-W-0500-01HE
6	Open window on driver's door.
7	Switch off ignition.
8	Connect diagnostic system, start XENTRY and perform quick test.	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model) Only when replacing the steering gear (1) together with the electromechanical controller unit.
9	Select "Control unit replacement" and follow the instructions.	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model) Only when replacing the steering gear (1) together with the electromechanical controller unit.
		 Control unit replacement is completely menu-assisted under: APS - Electrohydraulic power steering (A73)  Adaptations  Initial startup  Control unit replacement
10	Tilt cab.
11	Secure steering wheel against turning.	 Fix the steering wheel in place on the support rod using e.g. cable ties. Before securing, make sure that the steering gear (1) is still at the center position.
12	Remove side noise encapsulations.	 Remove the front noise encapsulation, together with holder (3) if necessary.
13	Remove lower steering shaft (2).		AR46.10-W-7310H
14	Expose and disconnect electrical connectors (6, 7).	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model)
15	Remove electromechanical controller unit.	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model) Only if steering gear (1) without electromechanical controller unit is being replaced.
			AR46.25-W-3130-01H
16	Remove noise encapsulation under steering gear (1).
17	Remove entrance on driver's side.		AR88.30-W-2305H
18	Remove oil pressure lines (15, 16) to hydraulic cylinder of 2nd front axle.	 Counterhold the elbow fitting on the steering gear (1). Collect escaping oil in a suitable container and seal the openings.
		 Plug	*963589019100
19	Remove oil pressure line (4).	 Counterhold the elbow fitting on the steering gear (1). Collect escaping oil in a suitable container and seal the openings.
		 Plug	*963589019100
20	Detach all cable ties from oil return hose (8).
21	Detach oil return hose (8) from oil return feed line (9) and fasten at the side.	 Collect escaping oil in a suitable container and seal the openings.
		 Plug	*963589019100
22	Detach oil return hose (14) from steering gear (1) and fasten at the side.	 Counterhold the elbow fitting on the steering gear (1). Collect escaping oil in a suitable container and seal the openings.
		 Plug	*963589019100
23	Detach both holders (5) together with the lines from steering gear (1).
24	Detach both holders (5) from the lines.
25.1	Remove left charge air pipe.	On left-hand drive vehicles
		Engine 470.9, 471.9, 473.9	AR09.41-W-1327H
		Engine 936.9	AR09.41-W-1327M
		 So that the screws for fastening the steering bracket (10) are accessible.
25.2	Remove right charge air pipe.	On right-hand drive vehicles
		Engine 470.9, 471.9, 473.9	AR09.41-W-1326H
		Engine 936.9	AR09.41-W-1326M
		 So that the screws for fastening the steering bracket (10) are accessible.
26	Remove air filter housing.	On right-hand drive vehicles only
27	Attach lifting belt to steering gear (1).	 The lifting belt must be suitable for a load of at least 1000 kg and it must not make contact with sharp-edged objects. Otherwise the lifting belt can tear and the steering gear (1) can be damaged.
28	Using suitable lifting gear, detach steering gear (1) together with steering bracket (10) from frame and place on floor or suitable tool cart.	 Remove all fittings before setting down the steering gear (1). So that the fittings and their threaded holes in the steering gear (1) are not damaged.
		 Seal off all openings.
		 Box wrench bit	*964589000300
		 Plug	*963589019100
29	Detach pitman arm (13) from steering gear (1).	Only when replacing the pitman arm (13) or the steering gear (1).
		Vehicles without code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.40-W-2000-01HE
		Vehicles with code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.40-W-2000-01HEB
		 The pitman arm (13) detaches suddenly when it is pulled off.
		 Fahrzeuge ohne Code C6H (Lenkung, Servotwin, 4-Achser) Lifting device	*964589025900
		 Fahrzeuge mit Code C6H (Lenkung, Servotwin, 4-Achser), Aufnahme an der elektromechanischen Steuereinheit Lifting device	*964589035900
		 Fahrzeuge mit Code C6H (Lenkung, Servotwin, 4-Achser), Aufnahme am Lenkgetriebe Lifting device	*964589005900
		 Holding device	*964589004000
		 Bell-type puller	*964589003300
		 Spindle	*655589003502
	Install
30	Attach electromechanical controller unit to steering gear (1).	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model) Only when replacing the steering gear (1) without the electromechanical controller unit.
			AR46.25-W-3130-02H
		 Use  lifting device for all lifting operations of steering gear (1). Using  lifting device prevents the lifting belt from slipping off when pitman arm (13) has been removed.
		 The steering gear (1) must be in the center position before attaching the electromechanical controller unit. This is generally ensured by transport protection. If there is no transport protection or it cannot be assessed whether steering gear (1) is in the center position, move steering gear (1) to the center position by manually counting the number of turns on the primary shaft.
		 Bolt, electromechanical controller unit to steering gear	*BA46.25-N-1002-03A
		Renolit CX-FO 20	*BR00.45-Z-1100-06A
		 Lifting device	*964589005900
31	Attach pitman arm (13) to steering gear (1).	Only if pitman arm (13) or steering gear (1) was replaced.
		Vehicles without code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.40-W-2000-01HE
		Vehicles with code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.40-W-2000-01HEB
		 Nut, steering gear pitman arm to steering gear	*BA46.20-N-1003-01K
		 Bolt/nut, steering gear to steering bracket	*BA46.20-N-1001-01K
		 Fahrzeuge ohne Code C6H (Lenkung, Servotwin, 4-Achser) Lifting device	*964589025900
		 Fahrzeuge mit Code C6H (Lenkung, Servotwin, 4-Achser), Aufnahme an der elektromechanischen Steuereinheit Lifting device	*964589035900
		 Holding device	*964589004000
32	Attach steering gear (1) with steering bracket (10) to frame.	 Bolt/nut, steering bracket to frame	*BA46.20-N-1002-01K
		 Box wrench bit	*964589000300
33	Detach lifting belt from steering gear (1).
34	Move steering gear (1) to center position.	Vehicles without code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.20-W-0500-01H
		Vehicles with code C6H (Steering, Servotwin, 4-axle vehicle)	AR46.20-W-0500-01HE
		 Adapter kit	*964589000900
35	Attach both holders (5) to steering gear (1).
36	Fasten lines to holders (5) with new cable ties.
37	Connect electrical connectors (6, 7) and fasten their electrical lines to steering gear (1) using new cable ties.	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model)
38	Install lower steering shaft (2).		AR46.10-W-7310H
39	Detach anti-twist lock from steering wheel.
40	Remove all stop plugs.
41	Attach new fittings to steering gear (1).	 Vehicles without code C6H (Steering, Servotwin, 4-axle model), with an elbow fitting on the oil pressure line Install an elbow fitting with test connection so that the hydraulic steering limiter can be adjusted later on if required. The elbow fitting can be ordered under part number A 004 997 20 71 (line Ø 15 mm) or A 006 997 20 71 (line Ø 12 mm).
		 Oil pressure line fitting to steering gear	*BA46.20-N-1013-01K
		 Fitting, oil return feed line/hose to steering gear	*BA46.20-N-1012-01K
42	Attach oil return hose (14) to steering gear (1).	 Counterhold the elbow fitting on the steering gear (1).
		 Union nut, steering gear oil line/hose	*BA46.25-N-1001-04B
43	Attach oil return hose (8) to oil return feed line (9) and secure using new cable ties.	 Union nut, steering gear oil line/hose	*BA46.25-N-1001-04B
44	Install oil pressure line (4).	 Counterhold the elbow fitting on the steering gear (1).
		 Union nut, steering gear oil line/hose	*BA46.25-N-1001-04B
45	Install oil pressure lines (15, 16) to hydraulic cylinder of 2nd front axle.	 Counterhold the elbow fitting on the steering gear (1).
		 Union nut, steering gear oil line/hose	*BA46.25-N-1001-04B
46	Install air filter housing.	On right-hand drive vehicles only
47.1	Install left charge air pipe.	On left-hand drive vehicles
		Engine 470.9, 471.9, 473.9	AR09.41-W-1327H
		Engine 936.9	AR09.41-W-1327M
47.2	Install right charge air pipe.	On right-hand drive vehicles
		Engine 470.9, 471.9, 473.9	AR09.41-W-1326H
		Engine 936.9	AR09.41-W-1326M
48	Install side noise encapsulations.	 Remove the front noise encapsulation, together with holder (3) if necessary.
49.1	Turn steering full lock to the left using lower steering shaft (2).	On left-hand drive vehicles
		 So that the drag link (11) can be installed.
49.2	Turn steering full lock to the right using lower steering shaft (2).	On right-hand drive vehicles
		 So that the drag link (11) can be installed.
50	Install drag link (11) between steering gear (1) and 1st steering idler arm.		AR46.40-W-0102HE
		 Leave the 2nd front axle jacked up and the cover on the entryway steps removed.
51.1	Turn steering full lock to the left using lower steering shaft (2).	On left-hand drive vehicles
		 So that the drag link (12) can be installed.
51.2	Turn steering full lock to the right using lower steering shaft (2).	On right-hand drive vehicles
		 So that the drag link (12) can be installed.
52	Install drag link (12) between steering gear (1) and steering arm of 1st front axle.		AR46.40-W-0101HE
		 Do not yet teach in the straight-ahead position and the electrical steering limiter. Leave the wheels of the 1st front axle on the turntable and leave the 2nd front axle jacked up.
53	Install entrance on driver's side.		AR88.30-W-2305H
54	Follow instructions for "Control unit replacement".	Only on vehicles with code C6H (Steering, Servotwin, 4-axle model) Only when the steering gear (1) was replaced together with the electromechanical controller unit.
		 Do not yet teach in the straight-ahead position and the electrical steering limiter.
55	Fill and bleed steering gear oil.		AR46.25-W-3001H
		 If steering gear (1) was replaced, leave the vehicle jacked up.
56.1	Check steering stops on both sides.	Vehicles without code C6H (Steering, Servotwin, 4-axle vehicle) Only if steering gear (1) was replaced.
		Model 964.23 with front axle 730.150/151	AR33.25-W-0150A
		Model 964.03/23/33 with front axle 739.5	AR33.25-W-0150C
		If the steering stops have been changed,
		
		Check hydraulic steering limiter, adjust if necessary.
			AR46.20-W-1100H
		 The hydraulic steering limiter is preset and may only be adjusted if the steering stops have been changed.
56.2	Teach in straight-ahead position and electric steering limitation.	Vehicles with code C6H (Steering, Servotwin, 4-axle vehicle) Only if steering gear (1), with or without the electromechanical controller unit, was replaced.
			AR46.25-W-3091HE
57	Install noise encapsulation under steering gear (1).
58	Conduct a road test.	 When moving out of the workshop, pay attention to the holding device on the rear axle. Otherwise the vehicle or the special tool may be damaged.
		 During the road test check the overall steering behavior of the vehicle.
59	Checking power steering for leaks.	 Visual inspection.

 Steering gear

Number	Designation				Model 964.00/01/02/04/20/21/22/24/31/32/34/40/41/42 without code C6F, model 964.03/23/33 without code C6H	Model 964.03/23/33 with code C6H
BA46.20-N-1001-01K	Bolt/nut, steering gear to steering bracket	M201.5	Stage 1	Nm	150	150
			Stage 2	°	60	60

 Steering gear

Number	Designation			Model 964.00/01/02/04/20/21/22/24/31/32/34/40/41/42 without code C6F, model 964.03/23/33 without code C6H	Model 964.03/23/33 with code C6H
BA46.20-N-1002-01K	Bolt/nut, steering bracket to frame	Stage 1	Nm	250	250
		Stage 2	°	90	90

 Steering gear

Number	Designation		Model 964.00/01/02/04/20/21/22/24/31/32/34/40/41/42 without code C6F, model 964.03/23/33 without code C6H	Model 964.03/23/33 with code C6H
BA46.20-N-1003-01K	Nut, steering gear pitman arm to steering gear	Nm	750	750

 Steering gear

Number	Designation		Model 964.00/01/02/04/20/21/22/24/31/32/34/40/41/42 without code C6F, model 964.03/23/33 without code C6H	Model 964.03/23/33 with code C6H
BA46.20-N-1012-01K	Fitting, oil return feed line/hose to steering gear	Nm	60	60

 Steering gear

Number	Designation		Model 964.00/01/02/04/20/21/22/24/31/32/34/40/41/42 without code C6F, model 964.03/23/33 without code C6H	Model 964.03/23/33 with code C6H
BA46.20-N-1013-01K	Oil pressure line fitting to steering gear	Nm	60	60

 Hydraulic power steering

Number	Designation			Model 963, 964
BA46.25-N-1001-04B	Union nut, steering gear oil line/hose	Line Ø 12 mm	Nm	50
		Line Ø 15 mm	Nm	60

 Electrohydraulic power steering

Number	Designation			Model 964.03/23/33 with code C6H
BA46.25-N-1002-03A	Bolt, electromechanical controller unit to steering gear	When installing a new electromechanical controller unit	Nm	120
		When installing the older electromechanical controller unit (when replacing steering gear)	Nm	175