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• Lea Lea

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Steering Repairs and! maintenanc:e

Section

Group

6

64

Steering 1975-

240/260

Contents Op.

Page

Specification ...... . . . .. . . . ................. .. ................... 2 Special tool . ....... . .... . . .. .... ... ... .. . .. ....... . . .. ... . ... . . . . 5

•

Service procedures Replacing steering column or steering lock M anual steering gear, removal

A l - A43 Bl -B6

9 16

Steering gear typa Cam Gear:

Disassembly ...... . . . . . . . . . . . . .. .... . ...... . .... . •....•. . ..... Illustration ......... . . . . . . ............ . ......... . Assembly ............................................. • ...... Staering gear typa ZF: Disassembly ................... . ..... . .... . .... . ............. . Ulustration ...... . ...... . . . ............ . ... .. .. . ... .. .... , .. . Assembly .............. . . . . . . . ............ . ...•.. . . . . .... . ..

Cl -C 13 01 -02 1 El -E12

17 21 22

F l -F20

27 30 31

Manual st eering gear, installatton ........ . .... . ......... . ... .

Gl -G8

36

Power steering gear. removal ............ . .... . ............ . .. .

Hl -HB

38

Power steering gear type Cam Gear: Oisassembly ......... . . . Illustration .............. . . . Assembly ...... . .. . . Installation ............... . Adjusting balance . . . . . In stallation continued ........ .

40 47 Jl -J52 49 Kl -K6 61 Kl -K27 63 K2B-K39 68

Pow er steering gear type ZF: Checking balance .... . . .

L1 -L6

71

Ml - M ll

73 76 77

•

11 -125

Power steering pump Saginaw: Disassembly ............. . ...... . Illustration ..................... . Assembly ........ . ... ....

Nl -N12

Power steering pump ZF: Disassembly .................. . . • .. . . • . .. . ..• . .. . .. . . . . • . . . . Illustration ........... . .... . .... . . ... . . ...... .. ... .. ... . .... . Assembly ....... . . . . • . . .. • . .. . • . .. . .• . .... . •... . •. . . . . • . . . .

TP 30001 /3 4500 .8.84

[ ____p_';n_t~ __;_n _u_.s_.A_.__~ We reserve the right to make alterations

Cl 1984, VOl VO OF AMERICA CORPORATION

0 1-09 P l -P 14

BO 83 84

• • • •

Group 64

Steering 1975-

power steertog pump steenog co4umn

al(1e member

steem"lg gear

VOLVO PARTS l 060 19748 1107,n

Group 64 Steering

1

Specifications

Specifications Front end alignrnent

Vehicles unloaded

",,,,,

Toe-in The toe-in should be set as follows: angle 2 8

A-a

B-b

4.5 ± 1.6 mm 3.5 ± 1 mm

Manual steering

C-c

2.5 ± 1 mm

24' ± S' 3/1S·':t1 / 1S" 9 / S4"± 1 132" 3 / 32"± 1 132"

3.0 ± 1.5 mm 2.0 ± 1 mm

Power steering

1S'

+

1.5 ± 1 mm

S' 1 I S"± 11 1S"

5 / 64"± 1 132" 1/ 1S±1 / 32"

Vehicle should not be loaded. Measuremcnts must be made at center (hub) height. 8 is an angle, read on certain instruments. A, B. and C refer t o tire outer diameter, tire inner shoulder and rim, respectively.

Caster (not to exceed 1/~ difference between sides) ........... . with power steering ............................................. . Camber

2

(difference not to exceed 1/2° between left and right side)

Group 64 Steering

+~ to

+JO +JO to +4°

Specifications

Manual steering gear, Cam Gear Type ..... ,."".".""., ................•••...•....

Rack and plmon

No of turns from lock to lock ..............•.•.. • . ... Ratio ..............................•.•.••.•.•....... Pinion: pre-tension ................•....••....•....... shims available ..................•....•.......

4.34 21.4:1 0,1 mm 0.004" 0 .1 27 mm 0.191 mm 0.254 mm 0.002-0.15 mm 0.0008-0.006" 0.127 mm 0.254 mm 0.381 mm 0.508 mm 0.6- 1.7 nm 0.44- 1.25 ft.lb. Volvo P/ N 1161001 75 grams 2.5 oz.

Clearance between pre-tensioning pislon and cover ... . Shims available ..................................... .

Pre-tension pinion to rack ..............•....•........ Lubricant (grease) .....................••...• • ...••. Ouantity .............................•••..•.•..••...

Manual steering gear, ZF Type ............................................... . No. of turns from lock to lock .......• . . . . • . ..•. . •... Ratio ............................ • ..•....•....•..... Pre-tension pinion to rack ............•....•....•..... Lubricant ............................•....•....•..... Ouantity ......................•..•..•...............

Rack and pinian

4.34 21 .4:1 0.6- 1. 7 Nm

0.44-1.25 tt.lb.

Volvo P/ N 1161001 75 grams 2.5 oz.

Power steering gear, Cam Gea" (Early typa) Type ............................................... . No. of turns from lock to lock ...................... . Ratio ............................. . Pinion: gaskats for pinian pre-tension ............ . Clearance between pre-tensioning piston and cover ... . Shims available ..................................... .

Pre-tension pinian to rack .....•.......••...• • ....•... Checking balance: - Power pump pressure .........................•... - at torque reading .. , ............................. . Difference between sides must not exceed .....••..... Lubricanr I"Lubricant for steering gea(') ........•...... Ouantity Power pump oil ...............................•..... Ouantity. integrated oil reservair ............. . •..... separate oil reservair ........•.........•.

Rack and pinien

3.5 17.2: 1 P/N 1206931, 1206934 0.05-0.15 mm 0.002-0.006" 0.051 mm 0.089 mm 0.127 mm 0.254 mm 0.9-1.7 Nm 8-15 in.lbs. 1.2 MPa

3.5- 5.0 Nm 1.0 Nm

170 psi 30-40 in.lbs. 0.73 tt.lb.

Volvo P/ N 1161001-1 0.2 liter 0.2 qt. ATF 0.7 liter 0.65 qt. 1.2 liter 1.1 qt.

Group 64

Steering

3

Specifications

Power steering gear, ZF (Fixed Valve Houslng) Checking balance: - Power pump pressure ............................ . - at torque reading ................................. . Difference between sides must not exceed ......•.....

2.0 MP. 4-5.5 Nm 0.5 Nm

285 psi 35-40 in.lb. 4.4 in.lb.

Power steering pump, ZF Type ................................•. • •............ Max. pressure, early proc!. . ..........• • • • • . ...•....... late proc!. . ............•..•....•. .. .... Theoretical capacity at 500 rpm ...... • ..•....•....... Drive .................................. • ....•....... Drive ratio, engine to pump .................. . .•.....

Vane pump

7.5 MP.

1070 psi

5.8 MPa 6.65 liter / min Belt drive

820 p~ 6.24 Qt / min

1: 1

Power steering pump, Saginaw Type ..........................................•..... Max. pressure .............................•..•••.•.. Theoretical capacity at 500 rpm ...........•....•..... Drive ............................................. .. Drive ratio, engine to pump ............ . ..•....•.....

Vane pump

5.5-7 MP. 5 liter / min

780-995

p~

5.3 Qt / min

Beh drive

1:0.9

Torques Stearing Steering wheel center nut .................•....•..... Screws, steering column attachment ...... . •.... • ..... Screws, steering shaft rubber coupling ................ . Screws, steering shaft joint .............., . ............ . Screws and nuts, steering gear to front a:de ......... . Nut, tie roc! to ball joint ............................. .

Nm 60±15 20±5 20±5 23±5 20±5 70±10

44± 11 14±4 14±4 17±4 14±4 51±7

24±2

17±1.5

ft.lb.

Manual steering g88r, ZF Pinien nut . . .......................•.....•....•......

Manual steering gear, Cam Gear Screws, pin ian. cover .......................... . ...... . Screws, pre-tensiening davice cover .....•............

19±2 19±2

14± 1.5 14± 1.5

Power steering gear, Cam Gear Screws, pre-tensioning davice cover ........•.. ... .... Screws. upper pinion cover ......... . Screws. lower pinion cover .................•....•.... Lock screws, outer tube to housing .................. . Lock nut, pinian ................ . ........... . Fittings. pressure hoses and return hoses .......•.•...

4

Group 64 Steering

19±2 19±2 19±2 19±2 14± 1 42±7

14±1.5 14±1.5 14±1.5 14±1.5 1O±0.75 30±5

•

Special tools

Special tools When ordering toots, put 999 in front of 4-' Group 54 Steering

73

Power steen"ng pump, Saginaw

Disassembly M4

Remove O-rings and magnet.

M5 Remove end plate and spring. Use a narrow screwdriver to press in the lock ring through the side hale. Use another screwdriver to bend out the lock ring. Lift out pressure plate and spring.

" . . . Il

M6

Remove the dowel pins. Use plieTs.

M7

Remove pressure plate. Use pliers.

74

Group 64 Steen"ng

Power steering pump, S8ginaw Disassembly M8

Remove the O-rings.

M9

Remove the shaft. Hold the shaf t. Use two screwdrivers to remove the snap ring. Aemove the shaft.

M IO

Remove rotor, pump ring, thrust plate

and flow controi valve. Turn the housing upside down to remove the parts.

Mil

Remove shaft seal. Usa pullars 5051 and 5047.

". ,,, Group 64 S teering

75

Power stee· Saginaw ring pump

"

CJCDC' o

76

Group 64

Steedng

Power steering pump, Saginaw Assembly

Assembling power steering pump Saginaw NI

Press in the shaft seal. Use drift 2863.

N2

Install thrust plate and dowel pins.

I

N3 Install rotor. In5ta1l the rotor without vanes. Then install shims to equal the play noted in operation M 1 minus

0.10 mm. Shims available:

P/N 1272 1272 1272 1272

Thickness

634 635 636 637

0.05 mm

0.10 mm 0.20 mm 0.30 mm

Install the snap ring, rounded edge IN.

N4 Install rotor ring. The ring marking UP and toward the boss on the housing.

Group 64 Steering

77

Power steering pump. Saginaw A ssembly N5

Install the rotor vanes. The rounded edges of the vanes should face OUT.

N6

Install the two O-rings _

N7 Install pressure plate and spring. Position the pressure plate so the dowel pins fit in the recesses.

N8

Install end cover. Position the pump housing in a vise. Use a clamp to press in the cover while installing the retaining ring.

78

Group 64 Steering

Power steering pump. Saginaw Assembly

N9 Check end play. Use dial gauge. Correct end play;

0.05-0.10 mm = 0.002-0.004".

NIO

Install flow controi valve and spring .

Nl1

Install O-rings and magnet. The magnet will collect ferric particles which may be suspended in the oil.

N 12

Install the oil reservoir. Oil the O-rings (ATFl Install the oil reservDir, with a new O-ring.

Group 64 Stee';ng

79

Power steenng pump, ZF Disassembly

Power steering pump ZF Disassembly

01

Remove front seal.

u, I" 02

Remove snap ring and rear cover.

03

Remove spring and pressure plate. Use pliers to remove the pressure plate.

80

Group 64

Steering

Power steenng pump, ZF Oisassembly

04

Remove rotor and cam ring. Turn pump over, tap lightlyan end until parts fall frea. If the cam ring does not come loose, let it remain until later on.

05 Remove ball bearing retaining ring.

06

Press out the shaft.

07

Push out thrust ring. Also push out cam ring, if remaining.

Group 64

Steenng

81

Power steering pump, ZF Disassembly

08 Remove plug. controi valve and spring. Hex 27 mm.

,

. 09 Remove O-rings. Check all parts for wear and scratches. Replace worn or damaged parts. Replace all O-rings. If the pump housing bushing is defective, replace housing assembly. Rotor. vanes and cam ring are al50 replaced as an assembly.

82

Group 64 Steering

t

Power stee· ring pump ZF

[D

20

19

•• •

12 2

•• ••

• • I I I

I

I

I

9

••• •

4

----- ~ ~

11 10

I

I

21 22 ,

23

Group 54

Steering

83

Power steering pump, ZF Assembly

Assembling power steering pump ZF PI

Install bearing on shaft . (if replacedl The bearing is retained by snap rings on both sides.

P2

Press the shaft into the housing .

P3

Install bearing retaining ring .

.. ...... P4

Install thrust plate. Locate the thrust plate with the dowel pin in one of the holes.

",u,

84

Group 64

Steering

Power steering pump. ZF

Assembly

P5 Install the cam ring. Install on dowel. arrow UP.

"'W P6

'nstall inner O-ring. One of the O-rings is smaller.

'" UJ

P7

Install rotor assembly. Install with recessed round shaft hole DOWN. toward drive side. Vanes with rounded ends toward cam ring .

....... P8

Install pressure plate. The dowel pin should align in one of the outer hales.

111 .'"

Group 64

Steedng

85

J

Power steering pump, ZF

Assembly

P9

Install outer O.ring. Install spring.

Pro Install cover. Clamp cover when insta11ing retaining ring.

PTT

Install controi valvs.

PT2

Install spring.

86

Group 64 Steedng

Power steedng pump, ZF Assembly P13

Install the plug Use a new COPpel' seal.

Hex 27 mm.

•

"... . P14

Install the shaft seal Tap lightly until the sea1 is properly seate,t

•

Group 64 Steering

87

•

•

AS: CERTIFIED

I

'VOLVO SUPPORTS VOLUNTARY

MECHANIC CEATlFICATlOH BY THE N.I.A .S.E. (U S A on ly)

• • •

Service literatuTe Your nIDst linportant

specialtooI

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