All former steering gear versions are to be replaced with the current version 92834701027

The elastic steering stop, 928.347.329.03, for left and right sides is replaces by a solid steering stop, 928.347.329.04, for improvement in quality. At the same time it was necessary to replace the dust cover, 928.347.191.02, with a new version dust cover having a supporting lip, Part No. 928.347.191.03.

Instructions for Repair Sector:

Only the new steering stop 928.347.329.04 and the new bellows 928.347.191.03 are supplied for steering gear 928.347.010.24. The bellows 928.347.191.03 and the steering stop 928.347.329.04 are also applicable to steering gears 928.347.010.26 / 928.347.010.27 (as of MY 91 or 928 GTS).

The new steering stop may only be installed together with the new dust cover.

When installing a solid stop for the first time, stops and dust covers must be replaced on both sides.

The new version dust cover can also be installed together with the old version elastic stop.

See cross reference survey on page 48 - 6d.

INSTALLATION OVERVIEW 1

928,347.329
928.347. !. :

928.347.329.03 et

48 - 6d Steering Stops, Installation XIII, 1986 - Printed in Germany , Overview

REMOVING AND INSTALLING POWER STEERING PUMP

Rem o v ing

1. Detach intake hose to air cleaner on left side. Draw hydraulic fluid out of reservoir.

2, Remove splash shield.

7. Detach pressure hose.

4. Remove rear bolt from power steering pump.

Rem o v ing

1. Detach intake hose to air cleaner on left side. Draw hydraulic fluid out of reservoir.

2, Remove splash shield.

3. Loosen front bolts on power steering pump a little.

4. Remove rear bolt from power steering pump.

5. Remove v-belt.

6. Take off left upper section of drive belt cover to facilitate procedures.

7. Detach pressure hose.

If hose is routed too close to exhaust manifold, the hose could come loose from its holder and cause failure of the power steering.

Asbestos protected hoses are no longer available for replacements.

3. Install upper section of drive belt cover.

4. Install suction hose.

8. Remove suction hose after loosening clamp.

9. Remove bolts on front holder of power steering pump.

3. Install upper section of drive belt cover.

Install this pressure hose leaving not mope than 25 mm between inner wheel well and hose.

If hose is routed too close to exhaust manifold, the hose could come loose from its holder and cause failure of the power steering.

Asbestos protected hoses are no longer available for replacements.

4. Install suction hose.

Installing

1. Tighten two bolts on front holder; only insert rear one (belt tightness).

2. Install pressure hose so that in installed position the protective ring (arrow) rests on spring strut mount. (Installed position: install drive belt, do not finish installation yet because of point 3.)

Pressure hoses in initially manufactured cars had an asbestos sleeve.

5. Install belt and adjust to remove tension. Also check tightness of alternator belt (slight corrections could be made).

6. Bolt on splash shield. Add hydraulic fluid. Bleed steering system. Check for leaks and operation.

Note:

Make sure that no hydraulic fluid is spilled on alternator belt while disassembling and assembling.

REPLACING SEALS FOR ALUMINUM POWER STEERING PUMP

Note:

Body of power steering pump is made of aluminum as of 1981 models to reduce weight. Worn seals can be replaced on these aluminum power steering pumps, but pump has to be disassembled.

No.

Description

Qty.

Note When : Removing Installing

Special I Instructions

1

Self-locking nut M 14 x 1.5

1

Hold on pulley with open-end wrench

Replace if necessary. Torque :

50 Nm (36 ftlb)

2

Pulley

1

Use standard puller, e.g. Kukko 20/1

3

Woodruff key

1

Replace if necessary

4

Hook snap ring

1

Pull out of radial groove with pliers, while holding down cap no. 5 to prevent it from popping up and causing injury

5

Cap

1

Bevel faces inside of pump. Only press on far enough that hook snap ring can be installed

Don't cant cap when removing and installing

5

Spring

1

Position correctly; large diameter end faces cap

7

Drive shaft with drive end face plate and rotor

1

Knock out with a plastic hammer

Install face plate in correct position

8

Cap end face plate

1

Position correctly

see assembly instructions

9

Cam ring

1

Position correctly

10

Pump impeller

10

Position correctly, must move easily in rotor

11

Dowel pin

2

Insert in power steering pump body

No.

Description

Qty.

Note When : TRemoving Installing

Special Instructions

O-ring, large dia.

1

Remove with plastic needle or air pressure

Replace — watching out for different diameters and installed positions

p. 48-8g, point 5

14

O-ring, small dia.

1

15

Support ring, small dia.

1

.

16

Shaft seal

1

Lift out being careful not to damage bearing surface

Pack space between both sealing lips with multi-purpose grease. Don't damage sealing lips on groove in drive shaft (cover up}

17

Aluminum body

1

See disassembling power steering pump, point 2 p. 48-8g, point 5

REPLACING SEALS FOR ALUMINUM POWER STEERING PUMP

Disassembling Power Steering Pump

1, Use a standard puller (e. g. Kukko 20/1) to take pulley and woodruff key off removed pump.

3. Pull hook snap ring out of radial groove with pliers. Press down on cover during this step to prevent snap ring from popping up and causing injury. Do not cant cover while removing, to prevent damage to the sealing surface.

2. Remove front bracket on power pump.

Note

Note:

Pump may only be clamped in a vise on the marked surfaces (arrows) when replacing seals. Always use soft jaws in vise and keep clamping force as low as possible.

Loosen a canted cover by removing deposits in cylinder opening and tapp lightly with a plastic hammer. If necessary, remove cover together with rotor set and face plates (step 4).

4. Drive out drive shaft with face plates and rotor Inspecting Components set by tapping with plastic hammer.

Clean parts with a cleaning fluid and check visually.

Checking Points:

— Drive shaft: bearing surface of shaft seal and bearing sleeve (for wear). Threads, taper and groove for woodruff key.

5. Lift out shaft seal, being careful not to damage bearing surface and bearing sleeve. Remove support ring and O-ring in radial grooves of body (use plastic needle or air pressure).

— Bearing surfaces and radial grooves of seals. Bores in body.

— Sealing surface of cover.

— Connection threads for pressure line.

Cam ring (cam surface — seizure marks, wear) and rotor (guide slots — wear). Pump impellers (seizure marks and wear especially on round bearing surface and guiding surfaces on sides).

— Face plates (seizure marks and wear on face surfaces}.

1. Insert dowel pins in body.

2. Install ten impellers in slots of rotor so that their polished and round outer surfaces face the cam ring.

Make sure impellers move easily.

3. Install drive shaft, face plate and rotor assembly in body. Slide face plate on dowel pins with wide element opposite valve bore.

1. Insert dowel pins in body.

2. Install ten impellers in slots of rotor so that their polished and round outer surfaces face the cam ring.

Make sure impellers move easily.

Note:

Lubricate all parts lightly with ATF before installing.

A = Valve bore

B = Wide side of face plates opposite valve bore

C = Slots in both face plates and cam ring aligned

4, Install cam ring. Cast arrow in cam ring circumference indicates pump driving direction. Since the pump turns clockwise, arrow must be on cover end.

There are elongated holes for the dowel pins in the cam ring and face plate. Elongated hole in cam ring must be aligned with elongated hole in face plate.

5. Place support and O-rings with small diameter in lower radial groove.

Place support and O-rings with large diameter in center radial groove. Lubricate O-rings with ATF.

Note:

Check order of support and O-rings.

Since March, 1983 or Pump Number 866201 the cover end support ring has been omitted (modified radial groove in case).

6. Press face plate on to rotor set. Dowel pins must engage in bores provided for this purpose. Slot must be aligned with slots in cam ring and face plate (wide section opposite valve bore).

7. Install spring with small diameter end facing face plate.

Press cover (with bevel facing inside of pump) into body without canting far enough, that hook snap ring can be installed (second mechanic required).

8. Pack mufti-purpose grease in shaft seal between both sealing lips and install seal on drive shaft.

Use a suitable sleeve or cover woodruff key groove with a narrow strip of tape to avoid damaging shaft seal on groove.

10. Install front bracket. Install woodruff key and pulley. Tighten self-locking hexagon nut to 50 Nm (36 ftlb).

11. Install power pump Fill and bleed steering system.

Check pump operation and for leaks.

9. Press on shaft seal against stop with a suitable mandrel.

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Responses

  • Kati
    Did steering gears used to have asbestos?
    6 years ago

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