pressure & return hoses steering component repair · pdf filepressure & return hoses steering...
TRANSCRIPT
Pressure & Return Hoses
Steering ComponentRepair Kits
Catalog Number 102Weatherly Index #174
Supersedes Catalog 101and Supplement 2003-S2
A1
Limited Warranty Information/Toll Free Number A2
Replacement O Ring Assortment A3
How to Service Power Steering A4-A5
Installation Procedure A6
Power Steering Repair Kit Contents A7-A11
Power Steering Systems A12-A13
Pump and Gear Identification A14-A15
System and Component Identification A16-A23
Alphabetical Listings
Passenger Cars 1-25
Light Trucks 26-63
Typical International and Navistar Steering 64
Medium/Heavy Duty Trucks and Buses 65-68
Numerical Listing for Hose Assemblies 69-85
Repair Kit Contents 86-87
Repair Kits Passenger Cars and Light Trucks 88-121
Repair Kits Medium/Heavy Trucks and Buses 122-125
Numerical Listing for Repair Kits 126-133
Manufacturers Part Numbers 134-143
Changeovers Power Steering Hose and Repair Kits 144-185
Pressure Hose Illustrations I1-I40
Power Steering Troubleshooting Inside Back Cover
TABLE OF CONTENTS
A2
LIMITED WARRANTY
POWER STEERING PROBLEM?
Call UsOn OurToll FreeNumbers
WARRANTY: We make a commitment that our products, at the time of sale to the customer, meet standards applicable to uses recommended by the manufacturer. Our products will offer best service wheninstalled, used and maintained according to our recommendations. If we determine that a product does notmeet these standards, the product will, at our option, be replaced, repaired, or credited. This is the exclusiveremedy, limited to the customers purchase price of the product. Damage to the product due to abuse, misuse, improper use, inadequate maintenance, or failure to follow published installation, use and servicerecommendations automatically voids this warranty. For warranty service, please contact YOUR SUPPLER,or the Customer Service Department, Plews/Edelmann Division, Route 38 East, Airport Industrial Park,Dixon, IL 61021.
THERE IS NO OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING FITNESS FOR A PARTICULARPURPOSE. ALL IMPLIED WARRANTIES ARE EXPRESSLY DISCLAIMED. LIABILITY FOR CONSEQUENTIALOR INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.
For Technical Assistance Only For Placing Orders OnlyCall 1-800-323-6294 Ask for Customer Service
1-800-770-4639
POWER STEERING HOSE
A3
Power Steering Tech-TipsPower Steering Hose Change and System Flush Remove hose using open-end wrench or screwdriver. Install new hose, hand thread fitting and tighten with open-end wrench. Disconnect return line at pump and point to drain pan. Cover pump tube with cap. Fill reservoir and start engine. Turn wheel side to side, filling reservoir as needed until fluid is clear. Stop engine. Remove cap, connect return line and re-check fluid level.
It is always recommended that you replace your return line when replacing a pressure hose. Failure to do so could result in further system damage.
Replacement O Ring AssortmentIdeal for Jobbers and Installers for replacing O Rings and seals. Replacement components are availableby ordering part numbers in content lists below.
NEW 70011 Replacement O Ring / Seal / Gasket / Plug Assortment
CONTENTS:
Part Number Size Description Quantity70001 5/16" Standard O Ring 2570002 3/8" Viton O Ring 2570003 3/8" Standard O Ring 2570004 9/16"18 Type II Teflon Seals 2570005 16mm Type III Teflon Seals 2570006 14mm Copper Washer 1270007 16mm Copper Washer 12
70008NEW 3/8"24 Switch Socket Plug 5
Restric-tion In
System
SERVICING YOUR
Guidelines for Inspection Brittleness or hardness an early sign of internal wear. The hose has lost its ability
to absorb pressure surges. Soft, spongy hose A more serious sign of wear, indicating advanced internal deterioration
and probably leakage. Leakage of power steering fluid easily detected by visual inspection of hose at fittings. External wear and abrasion caused by contact with manifold or other engine parts;
calls for replacement and realignment of hose. Thick, sludgy fluid in pump reservoir indicates internal hose wear and need for
a complete flush of system.
Identifying Power Steering Problems
Physical Problems
Probable Causes
LowTire
Pressure
HighInternal
Leak(Pump or
Gear)
PumpBelt
Loose
FlowControlValve
Sticking
LowOil In
Reservoir
AirIn
System
FrontEndMis-
aligned
Steering Linkage/Coupler
Damaged
Symptom
Hard Steering
Increased Effort
Wheel Jerks atLow Speeds
Loose Steeringor Excess WheelReturn
Vehicle Wandersfrom Side to Side
Poor Wheel Return
Split or dent road debris orrust from high salt areas
Stripped thread improper installation or worn o-rings Couplings creeping off oil contamination
Checking or flakingof external cover
Wear from rubbingagainst metal
Probable Solutions
A4
Fill Tire To
Recom-mendedPressure
ReplaceGear OrPump
TightenPumpBelt
RemoveValveBuff
Clean AndReplace
FillReservoirWith Oil
Flush And
BleedSystem
Realign ReplaceBall-StudsTie-Rods
Or Linkage
FlushSystemCheck
Hoses ForBlockage
POWER STEERING HOSE
Maintenance and Causes of Wear Inspection of power steering hose eliminates expensive repairing or replacing of the
pump or other components.
Hoses should be replaced after 20,000 24,000 miles as preventive maintenance.
High temperature pulsations cause power steering hoses to deteriorate from the inside. The constant flexing and pressure surges result in the breaking off of small particles ofhose, which are carried through the system, and can lead to system malfunction.
Audible Problems
Probable Causes
Probable Solutions
FlowControlValve
Sticking
Low OilIn
Reservoir
AirIn
System
DamperO RingOn SpoolValve Cut
Restric-tionIn
System
ScoredPumpShaft
Bushing/Bearing
ScoredPumpPlate
Wear On
CamRing
Symptom
Gear Squawk
Growling
Hissing Noise
Groan
Swish in Pump
Whine in Pump
Weeping deterioration at crimp
Exterior deterioration excessive heat or ozone
A5
RemoveValve
Buff CleanAnd
Replace
FillReservoirWith Oil
FlushAnd
BleedSystem
ReplaceO Ring
FlushSystem,Check
Hoses ForBlockage
ReplaceBushing
ReplacePump
ReplacePump
INSTALLATION PROCEDURE
Installation Procedure for Replacing Crimped or Ferruled Power Steering Return Line AssembliesNote: This is ONLY for return line assemblies and will not work for pressure assemblies.
1. Locate hose to be replaced. If possible, for easier access, remove assembly from vehicle. Locate ferrule attaching hose to the assembly.
2. If assembly is removed from vehicle, clamp itwith a vise or to a stationary object, such as atable. BE CAREFUL, do not distort assemblywhen clamping.
3. Using a hacksaw, dremmel tool or other cutting-type tool, carefully cut the ferrulelengthwise, slitting the ferrule from end toend. IMPORTANT: Cut only the ferrule. Cutting through the hose can damage thetube or nipple surface. CAUTION: ALWAYSWEAR EYE PROTECTION WHEN USING AROTOR TOOL.
4. After ferrule is split, spread it open and remove from assembly.
5. Remove ferrule and existing hose. If hose is stuck dont force or pry it off. This coulddamage the nipple. Use a sharp knifeto cut or peel it off. Dont cut too deep avoid scoring thetube/nipple surface.
6. Check nipple for damage and clean nipplewith a wire brush to assure a smooth sealing surface.
7. Install new hose and secure with new clamps.Lubricating hose with coolant makes installa-tion over nipple easier. Position new clampover hose between raised bead and exposedtube surfaces. See below. Tighten clamp torecommended specifications.
8. Reinstall assembly. With engine at operatingtemperature, check for leaks and tightenclamps as needed.
A6
POWER STEERING REPAIR KIT CONTENTS
Parts included with complete rebuilding kit: Housing O rings External reservoir O rings Pressure union O ring fittings Drive shaft bushing/bearing Drive shaft seal
Parts included with Pump Seal kit: All above excluding drive shaft bushing/bearing
Parts included with drive shaft seal kit: Drive shaft seal only
Power steering pump parts NOT available in above kits: Hard parts like vanes, rotors, shaft, cam ring, plates or slippers
(Excludes Rack & Pinion)All repair kits are supplied with detailed instruction sheets including exploded viewillustrations and step by step service procedures.(Parts may vary by type)
REPAIR KITS FOR POWER STEERING PUMPS
=
A7
POWER STEERING REPAIR KIT CONTENTS cont.
(Excludes Rack & Pinion)
REPAIR KITS FOR POWER STEERING GEARS
Parts included with complete rebuilding kit: Pitman shaft bearing (most kits) Input shaft bearing (most kits) Teflon seals (for piston and spool valve) Pitman shaft seals, snap ring, input shaft seals, dust covers O rings Housing O rings
Parts included with gear seal kit: All above excluding Pitman & input shaft bearings
Parts included with input shaft seal kit: Input shaft seal Dust cover Snap ring
Parts included with complete Pitman shaft seal kit: Housing cover O ring Pitman shaft & seals (number of seals may vary) Dust cover
Parts i