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