A) Steering drop arm
Open the tab washer.
When installing: The longer of the two metal tabs should be on
the right of the steering drop arm looking forwards.
Unscrew the nut.
Pull off the steering drop arm with Kukko 204-2 extractor.

When installing: The arrows on the steering drop arm and the
marking on the segment shaft must be aligned.

B) Cover - pressure point
Unscrew nut (1).
Remove the cover attachment screws.

Raise the cover by turning the adjusting screw clockwise.
When installing:Check condition of O-ring in cover and replace if
necessary.
Before tightening the cover screws, turn the adjusting screw until the cover
is firmly seated.

When installing: Determine the mid-point of worm shaft movement by
halving the total number of turns.
Turn back the worm shaft 1 complete turn to the left.
Using attachment 7015 and a friction meter, turn the shaft clockwise over the
pressure point and read off the friction value¹).
To adjust the friction value, first turn back the worm shaft 1 turn to the left.
Turn the adjusting screw (1) until the prescribed friction value¹) obtained as the
pressure point is crossed.



See technical data

C) Segment shaft
Pull out the segment shaft while in the central position.
When installing: Pack the splines with high temperature bearing grease.
Insert the segment shaft carefully to avoid damaging ring seals.

Check axial play¹) of adjusting screw and if necessary correct by installing
a thicker washer (1).
The adjusting screw must turn freely without sticking.


See technical data

Lift out the Seeger circlip (1) and ring seal (2).
Extract the needle roller bearing (3) .
Drive out needle roller bearing (4) with thrust washer (5) and ring seal (6).
When installing: The sealing lips on ring seals (2) and (6) must face the interior
of the steering box.

D) Valve housing
Pull off the protecting cap.
Remove the valve housing.
When installing: To prevent damage to the ring seal, cover the
splines with scotch tape.

Remove the ball bearing.
When installing: Check condition of ring seals (1 to 4) and replace
if necessary.

If the needle rollter bearing is replaced:
Press off the bearing race (1).
Slide off the double needle roller cage (2).
Pull bearing race out of the valve housing with a Kukko extractor.
When installing: Fit bearing (1) and needle roller cage (2) without
play. For this purpose the needle roller cages (2) are available in 4 different sizes.
Warning: Adjust friction value with bearing disc. See Fig. 32-13/6-4
(worm head adjusting).

E) Intermediate cover
Extract the worm with the intermediate cover and piston from the steering
box housing.
When installing:Check condition of sealing rings (1 to 4) and
replace if necessary.

Unscrew the worm from the piston.
Warning: Do not allow balls to escape.
Remove intermediate cover.
Take off the recirculating tube.

Check condition of needle roller cage (1), bearing washer (2), slotted ring
(3), O-ring (4) and sealing ring (5).
The shim washer (6) is needed for adjusting the position of the slotted ring (3)¹).


See technical data

When installing:Attach the valve housing without ring seal, the
worm head without the Teflon sealing rings, the intermediate cover without the
O-ring and the slotted ring with ball bearing, needle roller cage (1) and bearing
washer (2) to the valve housing.

Tighten the screws evenly to 3.4 mkp (25 lb. ft.) forque.
Adjust friction value of worm bearing with bearing washer (2)¹).


See technical data

Check prestressing of Teflon ring in inermediate cap.
Place bearing disc and retainer ring in intermediate cap.
Insert O-ring (7) and Teflon ring (8) into the groove.
(A = 1.7 mm/0.0669".)

Fit on worm shaft.
Measure frictional value¹) with shaft in vertical position by means of special too
No. 7015.
If frictional value is too low use a thicker Teflon ring.


See technical data

F) Teflon rings, worm gear, piston
Push Teflon rings (1 ÷ 4) out of worm gear and piston by means of
blade-type gauge.
Take out O-ring (5).
Note when assembling: Replace the rings that have been
removed.

G) Checking and adjusting overall frictional value of the worm gear
With the Teflon rings inserted in the worm gear and the radial sealing
ring inserted in the valve casing.
Teflon ring (8) inserted in the intermediate cap; frictional value of Teflon ring
determined.
Insert O-ring (4) and groove packing ring (3) - with sealing tab facing towards piston -
together with the spacers removed beforehand. Build worm gear into piston casing.
Fasten intermediate cap on valve casing with a tightening torque of 3.4 mkp
(24.58 ft./lb.).
Determine frictional value¹)
By means of spacers (6), set prestress of groove packing ring (3) 1 cm/kp higher
than the frictional value in the inermediate cap as determined beforehand.


See technical data

H) Pistons and worm.
Important: Do not remove the valve pistons (1).
After removing these pistons the hydraulic centre adjusted accurately through
the steering wheel shaft and the torsion bar would not be correct anymore.
Check standard dimension of wheel locking valve A = 107 - 0.2 mm
(4.2125 - 0.0079").

The wheel locking valve using only one ball has been replaced by
double ball valve (15) so as to avoid noise.

The wheel locking valve must open shortly before the maximum wheel lock
is reached.
Adjust set bolt (2) in such a way that the wheel locking valve opens 2 mm
(0.0787") before the track rod arm reaches its stop.

Insert worm into piston - A = approx. 4 cm / 1.5748".
Put in 16 balls through the front hole. While putting in balls turn in worm.

Place 7 balls in the circulation tube.
Secure the two outer balls by applying grease.

Fasten circulation tube on piston.
Secure bolts by bending over the ends of the clamp.

Turn out worm approx. 3½ turns.
Measure frictional value¹) over a range of at least 90° by means of special tool
No. 7015 (with worm in horizontal position).
The frictional value is dependent on the dia. of the balls.
Important: Use only balls with the same diameter - tolerance groups.
Remove worm after having adjusting the frictional value.
Take off intermediate cap and connect worm to piston.
Important: Never turn out worm more than 3½ turns, as balls might
otherwise fall into the piston bore.


See technical data

Hydraulic power steering in neutral
(1) Steering housing
(2) Piston
(3) Circulation tube
(4) Balls
(5) Worm
(6) Steering worm sector shaft
(7) Torsion bar
(8) Steering wheel shaft
(9) Valve piston
(10) Curved ring
(11) Impeller
(12) Pressure-relief valve
(13) Pressure check valve
(14) Throttle element
(15) Wheel locking valve