ZF Rack and Pinion Power Steering Gears ZF Recirculating ... · PDF fileService 7830/8051 W 07/01 e Maintenance Troubleshooting Oil Change Filter Change Disassembly Assembly ZF Rack

Service

7830/8051 W 07/01 e

Maintenance

Troubleshooting

Oil Change

Filter Change

Disassembly

Assembly

ZF Rack and Pinion Power Steering Gears

ZF Recirculating Ball Power Steering Gears(Passenger Cars)

ZF Lenksysteme GmbH

D-73522 Schwäbisch Gmünd

Telephone (07171) 31-0 Telefax (07171) 31-4396

Table of Contents

1Maintenance, Troubleshooting, Oil-/Filter Change, Disassembly, Assembly

Page

I. Maintenance 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Maintenance Intervals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Maintenance Work 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Checking for External Leakproofness 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Visual Inspection 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Fitting the ZF Servotest Tester 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Checking the Oil Level 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Bleeding the Steering System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Checking the Hydraulic Functioning of the Steering System 8. . . . . . . . .

III. Oil Change 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Draining the Oil 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Oil Fill 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV. Filter Change 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V. Disassembly of the Steering Box 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VI. Assembly of the Steering Box 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Filling the Steering System with Oil and Bleeding 13. . . . . . . . . . . . . . . . .

3 Checking the Front Axle Geometry 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VII. Special Tools 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIII. Inspection Report 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attention:

The descriptions below are generally binding and apply to work to be carried out on ZF units.

In addition, the vehicle manufacturers’ instructions must be complied with.

Maintenance

2 Maintenance, Troubleshooting, Oil-/Filter Change, Disassembly, Assembly

I. Maintenance

1 Maintenance Intervals

To increase road safety, we recommend to proceed to a maintenance of the steering systemevery 50,000 kms.

2 Maintenance Work

2.1 Checking the Fit of the Mounting Bolts

Check whether the bolts on the steering gear (steering box, transmission parts, steering col-umn) are fitting closely.

If required retighten the bolts in accordance with the vehicle manufacturer’s instructions.

2.2 Checking the Straight Ahead Position of the Steering Gear and the Vehicle

Place the front wheels on swivel plates.

Determine the total number of steering wheel turns.

From the lock stop, rotate the steering gear back by half the number of total steering wheelturns.

Then continue to rotate until the marks on the steering input shaft/protecting cap coincide withthe marks on the valve housing.

Check whether the steered wheels are in the straight ahead driving position.

A correction can be made by turning the ball joint at the tie rod further in or out.

Attention:

If a correction of the setting turns out to be necessary, it may well be that this necessity origi-nates in a preceding accident-like event.

Therefore:

S check whether the steering gear is installed in a twisted position

S check all further transmission parts for bending, cracks or torsion.

Deformed parts may not be re-bent but must be replaced.

Maintenance


2.3 Checking the Play of the Steering Column

By moving (shaking) the steering wheel sideward to and fro, check whether there is any play.If so, check the steering column bearing arrangement or replace the bearing.

2.4 Checking the Universal Joint and the Universal Joint Disc between UpperSteering Input Shaft and Steering Box for Angular Play and Stiff Operation

If play or stiff operation are found, repair or replace the defective component.

2.5 Checking the High Spot Adjustment (Increase in Frictional Torque) (Can be donefor ZF Recirculating Ball Power Steering Gears only)

S Rotate the steering gear to straight ahead. To be able to do so, determine the totalnumber of steering wheel turns.

S From the lock stop, rotate the steering gear back by half the total number of steeringwheel turns.

S Check whether the straight ahead driving marks coincide.

S Remove the drag link/tie rod from the drop arm.

S Fit the torque meter to the steering wheel - cf. Chapter VII..

S Rotate the steering gear to one end position and, while doing so, measure the frictionaltorque required to rotate the steering gear outside the straight ahead driving range(approx. 1/2 turn before reaching the lock stop). The value determined corresponds tothe basic frictional torque (without frictional torque increase).

S Then, from the straight ahead driving position, rotate the steering gear 1/2 turn to theleft and to the right and measure the increase in frictional torque.

Specified values for increase in frictional torque (ADP: Automatic High Spot Re-Adjust-ment):

without ADP with ADP

Type 8051 10...60 Ncm -

Type 8052 5...30 Ncm 10...55 Ncm

Type 8053/54 5...30 Ncm 10...45 Ncm

Type 8055/8076 5...40 Ncm -

Type 8073 - 10...65 Ncm

Type 8074/8075 5...30 Ncm 10...35 Ncm

Type 8074 with Servotronic 5...30 Ncm 10...35 Ncm

Type 8075 with Servotronic 5...30 Ncm 10...35 Ncm

If the specified value is not reached, a new adjustment is required.

Maintenance

62

27


2.6 New Adjustment of High Spot (Increase in Frictional Torque) for Types8051...8076

Rotate the steering gear to the straight ahead position. Loosen the sealing nut (27) and turnthe adjusting screw (62) back until there is no more increase in frictional torque (high spot) tobe found. Then measure the existing basic frictional torque by slowly rotating the steering geararound mid-position within the straight ahead driving range.Next, adjust the frictional torque increase (high spot) of the steering gear around mid-position.To do so, turn the adjusting screw (62) clockwise until an increase in frictional torque (see tablebelow) as compared with the basic frictional torque is reached.

Specified values for frictional torque increase:

Type 8051 60...80 NcmType 8052 30...40 NcmType 8053/54 40...50 NcmType 8055/8076 30...50 NcmType 8073 20...40 NcmType 8074/8075 20...35 NcmType 8074 with Servotronic 20...35 NcmType 8075 with Servotronic 20...35 Ncm

During this adjustment, permanently rotate the steering wheel 1/2 turn to the left and to theright from the straight ahead driving position.

Tighten the sealing nut (27) and hold the adjusting screw (62) fast while doing so.

Tightening torque: 30 Nm

Check again the increase in frictional torque (high spot) thus adjusted.

3 Checking for External Leakproofness

S Start the engine.S Check whether all screwed connections and lines of the steering system and the sealing

elements on the steering gear and on the pump are leakproof. Repair leakages, if any.S Stop the engine.

4 Visual Inspection

Check all hoses and lines for possible chafe marks and check the bellows and collars for cracks,damages, twisting and firm fit.

Troubleshooting

return line

pressure line

Troubleshooting


II. Troubleshooting

1 Fitting the ZF Servotest Tester

Fit the ZF Servotest Tester to the pressure line between the ZF oil pump and the ZF steeringgear (see illustration below) at a place enabling a perfect monitoring of the indicating instru-ments from the driver’s seat.

Note:The illustration shows a ZF Rack and Pinion Power Steering Gear. However, the installation ofthe tester is analogous for the ZF Recirculating Ball Power Steering Gear.

For the fitment and operation of the ZF Servotest Tester, please refer to the ZF Servotest Operat-ing Instructions.

2 Checking the Oil Level

Note:

S Prior to removing the oil tank cover, thoroughly clean the oil tank and its immediatesurroundings to prevent impurities from getting into the steering system.

S When the steering system is filled with hydraulic fluid, there is a risk of impurities gettinginto to steering system. Therefore, to avoid malfunctions caused by foreign bodies in thesystem, maximum cleanliness is an absolute must during initial fill and during all furthertopping-ups.

Oil grade required: please refer to the lubricants list TE-ML 09 or to the vehicle manufacturer’soil specification.

S with the engine off:

The oil in the oil tank should reach the “max.” mark.

S with the engine running:

The oil level in the oil tank should be between the “min.” and “max.” marks.

After the engine was turned off, the oil level may rise by 5 mm maximum. If it rises by morethan 5 mm, bleed the steering system.

Troubleshooting

33


3 Bleeding the Steering System

Steering gear versions with bleeding screw (33)- ZF Recirculating Ball Power SteeringGears only:

Fill the oil tank with the specified oil (see vehicle manufacturer’s instructions or list of lubricantsTE-ML 09) to the ”max.” mark.

Relieve the front axle by jacking it up.

With the engine off, slowly rotate the steering gear twice from lock to lock.

Top up with oil to the ”max.” mark.

Remove the closing cap at the bleeder screw (33) and start the engine.

Make sure the oil tank is permanently filled with oil.

Then open the bleeder screw by 1/2...1 turn to enable the air to escape.

As soon as oil only is escaping from the bore of the bleeder screw (33), tighten the bleederscrew with a torque of 5 Nm.

Slowly rotate the steering gear several times from lock to lock, making sure not to build uptoo high a force at the lock stops to prevent the oil from foaming.

Note:

On vehicles with poor bleeding owing to unfavourable positions of the cylinder line ports,bleeding may take place prior to mounting the tie rods (to the wheel suspension system)/thedrop arm. As a larger stroke is now possible, the bleeding operation can be sped up.

Check the oil level.

If required, top up with oil.

Again open the bleeder screw (33) by 1/2...1 turn to enable any further air to escape.

Put on the bleeder screw (33) closing cap.

Stop the engine and check by how much the oil level rises in the oil tank.

If it rises by more than approx. 5 mm, the bleeding operation described above has to berepeated.

Troubleshooting


Steering Versions with Automatic Bleeding:

Steering versions with automatic bleeding do not have any bleeder screws.

Fill the oil tank with the specified oil (see vehicle manufacturer’s instructions or list of lubricantsTE-ML 09) to the ”max.” mark.


With the engine off, slowly rotate the steering gear twice from lock to lock.


Start the engine.

Make sure the oil tank is permanently filled with oil.

Slowly rotate the steering gear several times from lock to lock, making sure not to build uptoo high a force at the lock stops to prevent the oil from foaming.

Note:On vehicles with poor bleeding owing to unfavourable positions of the cylinder line ports,bleeding may take place prior to mounting the tie rods (to the wheel suspension system)/thedrop arm. As a larger stroke is now possible, the bleeding operation can be sped up.

Check the oil level.

If required, top up with oil.


If it rises by more than approx. 5 mm, the bleeding operation described above has to berepeated.

Troubleshooting


4 Checking the Hydraulic Functioning of the Steering System

4.1 Checking the Tension of the Drive Belt

Check the drive belt tension.

Even at maximum pressure within the steering system, the drive belt must transmit the powerwithout any slip.

4.2 Checking the Maximum Pressure/Pressure Relief of the ZF Pump

For the maximum pressure indication, refer to the pump nameplate.

Start the engine.

At engine idling speed, close the shut-off valve of the ZF Servotest tester and read the maxi-mum pressure.

Attention:

Allow the maximum pressure to act for a short time only, maximum 5 seconds, for otherwisethe inner pump components would be heated excessively thus entailing a possible early wear.

Turn the shut-off valve back to its initial position.

Specified value: Nominal value indicated on the nameplate � 10%

If the specified value is not attained, repair or replace the pump.

4.3 Checking the Pump Flow Rate

At engine idling speed, close the shut-off valve to an extent enabling the generation of thetest pressure (see technical data sheet) required for the pump type in question.

Read the flow rate (specified values see technical data sheet).

If the specified value is not reached, repair or replace the pump.

4.4 Checking the Maximum Pressure and the Leakage Rate of the Power Steering

S For versions without hydraulic steering limitation

Build up the maximum pressure in the steering system.To do so, rotate the steering gear to the lock stop or lock it by means of a convenient device.

S For versions with hydraulic steering limitation

Using an appropriate tool, lock the steering gear outside the range in which the hydraulicsteering limitation operates (for instance, mid-position).

Troubleshooting


S For versions with/without hydraulic steering limitation

Actuate the steering valve to maximum extent and, thereby, build up maximum pressure.

Have the engine run at idling speed.

Read the maximum pressure at the ZF Servotest tester.

Carry our the same measurement as above, but steer to the left.

If the pump maximum pressure previously measured is not attained, repair or replace the powersteering gear.

Read the flow rate (corresponding to the leakage oil rate) at the ZF Servotest tester.

Specified value: max.1 dm3/min

4.5 Measuring the Steering Wheel Play

Note:

This check can only be carried out for a ZF Recirculating Ball Power Steering Gear.

S Jack the steered axle up.

S By fitting a locking device, lock the drop arm in the straight ahead driving position ofthe steering gear.

S Fit a scale (cf. Chapter VII.) to the steering wheel and fasten the index hand at thedashboard or at the windscreen.

S Start the engine.

S Watch the pressure gauge and slowly rotate the steering wheel to the left.

S When a pressure rise of 1 bar as compared with idle pressure is reached, hold the steeringwheel fast and mark the scale value on the scale.

S Then turn the steering wheel to the right until again a pressure rise of 1 bar is attained.

S Measure the total travel covered at the steering wheel circumference.

S Specified value: max. 25 mm

S If the travel is more than 25 mm, there is mechanical play in the steering box. The steer-ing box must in this case be removed from the vehicle and repaired.

S Stop the engine, remove the ZF Servotest tester, top up the oil, put the drag link intoplace and fasten and secure it.

S Lower the steered axle down to the ground.

Oil Change/Filter Change


III. Oil Change

Note:

An oil change will only become necessary after replacing the power steering gear or the pump.

1 Draining the Oil

Jack the steered axle up.

Screw off the pressure and return lines.

Have the engine run for approx. 10 seconds and collect the oil that is draining off.

Rotate the power steering gear from lock to lock.

Screw on the pressure and return lines again and close them in a way to make them oil-tight.

2 Oil Filling

Required oil grade: see the list of lubricants TE-ML 09

Through the oil tank opening, fill in the oil until the oil level is approx. 1 cm above the “max.”mark.

Next, start the engine and top up with oil to the “max.” mark.

Bleeding: refer to Chapter II.

IV. Filter Change

A filter change is only required if

S the oil was changed

S the power steering gear was replaced

S the pump was replaced.

Remove the filter cartridge from the oil tank and replace it or replace the complete plastic oiltank.

Then fill the steering system with oil and bleed it as described in Chapter VI.

Disassembly of the Steering Box


V. Disassembly of the Steering Box

Attention:

The descriptions given below are generally binding and apply to work to be carried out on ZFunits.

In addition, the vehicle manufacturers’ instructions must be complied with.

S Rotate the steering box to the straight ahead driving position.

S Thoroughly clean the steering gear and its immediate surroundings, in particular the lineconnections.

S Jack up the steered axle.

S Screw off the pressure and return lines.

S Have the engine run for approx. 10 seconds and collect the oil that is draining off.

S Rotate the steering gear from lock to lock.

S Close all oil lines (risk of impurities).

S Loosen the universal joint or the elastic coupling arranged between the steering box andthe steering column.

S Using a suitable tool, remove the tie rods from the wheel suspension system.

S Screw out the mounting bolts and remove the steering gear.

Assembly of the Steering Box


VI. Assembly of the Steering Box

1 Assembly

Attention:

The descriptions given below aregenerally applicable and refer towork to be carried outon ZFunits.In addition, the vehicle manufacturers’ instructions must be complied with.Self-locking nuts, screws, sealing elements and securing elements must be replaced.If the steering gears is replaced following a road accident, also the remaining parts of the steeringsystem, such as tyres, wheel rims, axles, axle suspensions and mechanical connecting parts mustbe checked for damages (even if there is no visible damage).

If required, repair or replace such parts.

Interrupt the electric circuit (switch off the ignition and disconnect the negative pole of the battery).

Turn the front axle of the vehicle to the straight ahead driving position (the wheels of the front andrear axles must now be in perfect alignment).

Check whether the steering box, too, is in the straight ahead driving position (if so, the marks onthe steering input shaft/protection cap (if there is any) will coincide with those on the valve housing.

Rotate the steering wheel to the straight ahead driving position.

Put the steering column on the input shaft of the power steering gear and fasten it (for tighteningtorques, refer to the vehicle manufacturer’s instructions).

Install the power steering gear in exactly the same position as in the initial installation and fastenit bymeans of bolts, nuts, washers etc... (for tightening torques, refer to the vehiclemanufacturer’sinstructions).

Fit the drop arm and the tie rods to the steering gear (for tightening torques, refer to the vehiclemanufacturer’s instructions).

Attention:(for ZF Rack and Pinion Power Steering Gears only)

When tightening the tie rods, the rackmust be supported at the spanner flat (do not use any pliers!)for otherwise the inner parts of the steering might be damaged.If there is no spanner flat, no supporting will be required.

Connect the hydraulic lines (pressure and return lines). For the tightening torques, refer to the ve-hicle manufacturer’s instructions.

Assembly of the Steering BoxAssembly of the Steering Box


For versions with Servotronic additionally:

Insert the converter cable into the converter connection.

2 Filling the Steering System and Bleeding

Fill the oil tank with the specified oil (see vehicle manufacturer’s instructions or list of lubricants TE-ML 09) to the ”max.” mark.


With the engine stopped, slowly rotate the steering gear twice from lock to lock.


Start the engine and make sure the oil tank is permanently filled with oil to prevent a sucking inof air.

Slowly rotate the steering gear several times from lock to lock and take care not to build up highforces at the lock stop to prevent the oil from foaming.

Note:On vehicles with poor bleeding owing to unfavourable positions of the cylinder line ports, bleedingmay take place prior to fastening the tie rods (to the wheel suspension system)/the drop arm. Asthe stroke available is now larger, the bleeding operation can be sped up.

Check the oil level, if required top up with oil.

By visual inspection, check the steering system (steering gear, cylinder lines and connections, oilpump) for leakproofness.


If it rises by more than approx. 5 mm, the bleeding operation described above has to be repeated.

3 Checking the Front Axle Geometry

Check and adjust the front axle geometry in accordance with the vehicle manufacturer’s instruc-tions.

Special Tools


VII. Special Tools

Ordering Reference

ZF-Servotest 570 tester 7418 798 570

Scale with index hand 7418 798 452

Additional tool for ZF Recirculating Ball Power Steering Gear

Types 8051...55 and 8073...8076

Torque meter 7418 798 706

Clamping range:

350...500 mm

Inspection ReportZF Rack and Pinion Power Steering Gears andZF Recirculating Ball Power Steering Gears

Orig

inalfordu

plicating


Order No.: Date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version ref.: Mfg. ref.: Mfg. date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Work

1 Maintenance intervals: after 50,000 km, each

2 Checking the Mechanical Functioning of the Power Steering Gear

Fit of the mounting bolts checked: j yes

Straight ahead driving position checked: j yes

Play of the steering column checked: j yes

Angular play and stiff operation betweenupper input shaft and steering box checked: j yes

High spot adjustment checked (ZF Recirculating Ball Power Steering Gears only):j yes

3 Checked for External Leakage: j yes

4 Visual Inspection: j yes

5 Fitting the ZF Servotest Tester:

6 Oil Level Checked: j yes

7 Steering System Bled: j yes

8 Checking the Hydraulic Functioning of the Steering System

Drive belt tension checked: j yes

Maximum pressure/pressure relief of ZF pump: bar. . . . . . . .

Flow rate of ZF pump:

Speed r.p.m. Pressure bar Flow rate dm3/min. . . . . . . . . . . . . . . . . . . .

Maximum pressure of power steering gear: bar. . . . . . . . .

Leakage rate of power steering gear: dm3/min. . . . . . . .

Steering wheel play: mm. . . . . . . .

Test drive carried out: j yes

Examined by: Date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notes


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Documents

ZF Rack and Pinion Power Steering Gears ZF Recirculating ... · PDF fileService 7830/8051 W 07/01 e Maintenance Troubleshooting Oil Change Filter Change Disassembly Assembly ZF Rack