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Power Steering Box: Reassembly

NOTE: When fitting replacement oil seals lubricate with recommended fluid and ensure absolute cleanliness.
NOTE: Changes to input oil seal. Up to steering box number GBE 51000 00 (see Adwest identity plate), the input shaft oil seal was as shown in Fig 1 . This type of seal MUST be fitted at this stage.
NOTE: A dirt excluder was added at steering box serial number GBE 51000 00. This is fitted at step  36 . A revised seal without backing washer was introduced at serial number GBE 51400 00. This seal MUST be fitted at step  35 .
  1. Install input shaft oil seal. See OIL SEALS  under REMOVAL & INSTALLATION. Install oil seal, lip side first, into housing. Seal backing to lie flat on bore shoulder. See Fig 1 . Install circlip. Install backing washer.
    Fig 1: Reassembling Input Shaft Oil Seal
    G00096828Courtesy of LAND ROVER NORTH AMERICA, INC.
  2. To install sector shaft oil seal, install oil seal, lip side first. See OIL SEALS  under REMOVAL & INSTALLATION. See Fig 2 .
    Fig 2: Reassembling Sector Shaft Oil Seal
    G00096832Courtesy of LAND ROVER NORTH AMERICA, INC.
  3. Install extrusion washer. See Fig 2 .
  4. Install dust seal, lipped side last. See Fig 2 .Install circlip.
    5. NOTE: If original shims are not used, install shims of 0.76 mm (0.029") thickness.
    Fig 3: Installing Valve & Worm Assembly
    G00096836Courtesy of LAND ROVER NORTH AMERICA, INC.
  5. To install valve and worm assembly, refit original shims and inner bearing cup. Use Petroleum Jelly to aid assembly. See Fig 3 . Install inner cage and bearings assembly.
  6. Install valve and worm assembly. See Fig 3 . Install outer cage and bearings assembly. Install outer bearing cup.
  7. Install new worm adjuster sealing ring.
  8. Loosely screw adjuster into casing. See Fig 4 .
  9. Install locknut, do not tighten. See Fig 4 .
  10. Turn in worm adjuster until end float is almost eliminated. Ensure bearing cages are seated correctly.
  11. Measure maximum rolling torque of valve and worm assembly, using a torque wrench and spline socket. See Fig 4 .
    Fig 4: Installing Adjuster & Locknut
    G00096840Courtesy of LAND ROVER NORTH AMERICA, INC.
  12. Turn in worm adjuster while rotating shaft to increase figure measured in step  11 to 5 INCH lbs. (0.56 N.m).
  13. Back off worm adjuster 1/4 turn. Turn in worm adjuster to increase reading at step  11 by 2-3 INCH lbs. (0.21-0.34 N.m). With locknut tight, 74 ft. lbs. (100 N.m). Use worm adjusting wrench (LRT-57-006) and lockout wrench. See SPECIAL TOOLS  .
  14. To install rack and piston, screw slave bolt into piston to aid assembly. See Fig 5 .
    Fig 5: Installing Sector Shaft & Input Shaft
    G00096844Courtesy of LAND ROVER NORTH AMERICA, INC.
  15. Install piston and rack so piston is 70 mm (2.76") from outer end of bore. See Fig 5 . To install sector shaft, install sector shaft using a seal saver (LRT-57-021). Align roller with cut out in casing. Push in sector shaft while rotating input shaft to allow sector roller to engage worm.
  16. To install rack adjuster, install rack adjuster and thrust pad to engage rack. Back off half turn on adjuster. See Fig 6 . Loosely install new nylon pad and adjuster set screw assembly.
    Fig 6: Installing Rack Adjuster
    G00096848Courtesy of LAND ROVER NORTH AMERICA, INC.
    17. NOTE: Before tightening fixings, rotate input shaft to ensure sector shaft roller is free to move in valve worm. If initial resistance is left, turn adjuster screw approximately 2 turns in a clockwise direction.
  17. To install sector shaft cover, install new sealing ring to cover. Align cover with casing.
  18. Screw cover assembly fully on to sector shaft adjuster screw. See Fig 7 . If necessary back off sector shaft adjuster screw. Tap cover in place to allow cover to joint fully with casing.
    Fig 7: Installing Sector Shaft Cover
    G00096852Courtesy of LAND ROVER NORTH AMERICA, INC.
  19. Install cover bolts and tighten to 37 ft. lbs. (50 N.m). From steering box serial number 1J001, tighten bolts to 55 ft. lbs. (74.6 N.m). See Fig 7 .
  20. To install cylinder cover, install new square section seal to cover. See Fig 8 .
    Fig 8: Installing Cylinder Cover
    G00096856Courtesy of LAND ROVER NORTH AMERICA, INC.
  21. Remove slave bolt fitted at step  14 . Press cover into cylinder just to clear retainer ring groove. See Fig 8 .
  22. Install retaining ring to groove with one end of ring positioned 12 mm (0.47") from extractor hole. See Fig 8 .
    23. NOTE: Refit drop arm and tighten nut sufficiently to ensure that no backlash exists between drop arm and sector shaft.
    Fig 9: Adjusting Sector Shaft
    G00096860Courtesy of LAND ROVER NORTH AMERICA, INC.
  23. To adjust sector shaft, rotate input shaft to full right inner lock. Rotate input shaft back towards center 2 full turns. See Fig 9 . The box is now on center and can be adjusted.
  24. Hold input shaft and rock drop arm to establish backlash is present. Continue rocking and slowly turn sector shaft adjusting screw clockwise. Continue rotating adjuster screw until backlash has almost been eliminated. See Fig 9 . Refit locknut and tighten.
    25. NOTE: It is important steering box is centralized before any adjustments are made. See CENTRALIZE STEERING BOX  .
  25. Check maximum rolling torque one and a quarter turns either side of center position, using a torque wrench and spline socket (LRT-57-025). See SPECIAL TOOLS  . Rotate adjuster screw to obtain across center torque of 3 INCH lbs. (0.34 N.m) plus torque figure at one and a quarter turns. Tighten adjuster locknut to 44 ft. lbs. (60 N.m). See Fig 9 .
  26. To adjust rack adjuster, turn in rack adjuster to increase torque value measured in adjustment procedure step  25 by 2-3 INCH lbs. (0.23-0.34 N.m).
    NOTE: The final torque value may be less, but must not exceed 12 INCH lbs. (1.4 N.m).
  27. Lock rack adjuster in position with grub screw, tighten to 44 INCH lbs. (5 N.m). See TORQUE SPECIFICATIONS  .
  28. To check torque peak, make sure input shaft has been rotated from lock to lock. Rolling torque values should be greatest across center position and equally disposed about center position.
  29. The condition depends on value of shimming fitted between valve and worm assembly inner bearing cup and casing. The original shim washer value will give correct torque peak position unless major components have been replaced.
  30. With input coupling shaft toward the operator, turn shaft fully counterclockwise.
  31. Check torque figures obtained from lock to lock using torque wrench and spline socket (LPT-57-025). See SPECIAL TOOLS  . See Fig 10 . Check also for equal engagement either side of center.
    Fig 10: Checking Torque Peak
    G00096864Courtesy of LAND ROVER NORTH AMERICA, INC.
    32. CAUTION: When reshimming valve and worm, extreme caution must be exercised to prevent seal damage during reassembly.
    NOTE: Adjustment of 0.07 mm (0.003") to shim value will move torque peak area by 1/4 turn on the shaft.
  32. To adjust torque peak, note where greatest figures are recorded relative to steering position. If greatest figures are not recorded across center of travel (steering straight-ahead), adjust in the following way.
  33. If torque peak occurs before center position, add to shim washer value, if torque peak occurs after center position, subtract from shim washer value. See steps  5 - 13 .
  34. Shim washers are available as follows: 0.03 mm (0.0012"), 0.07 mm (0.0028"), 0.12 mm (0.0047") and 0.24 mm (0.0094").
    35. NOTE: Installation steps  35 and  36 refer to power steering boxes produced after GBE 51400 00
  35. To install input shaft oil seal, install seal, lip side first into housing. Use seal saver (LRT 57-016) and seal installer. See SPECIAL TOOLS  . Note that seal is fitted to a depth of 4.75-5.00 mm (0.187-0.197") from face of box. See Fig 11 . Secure seal with circlip.
    36. NOTE: Installation step refers to power steering boxes produced after GBE 51000 00.
    Fig 11: Installing Input Shaft Seal
    G00096868Courtesy of LAND ROVER NORTH AMERICA, INC.
  36. Smear inner lip of dirt excluder with PTFE grease. Install dirt excluder using tool No. LRT-57-027. When fitted correctly, outer shoulder of excluder should be 4.00-4.50 mm (0.157-0.1771") from face of box. See Fig 11 .
  37. Remove drop arm. See DROP ARM  under REMOVAL & INSTALLATION. Smear inner lip of dirt excluder with PTFE grease and refit, ensuring outer lip is flush with casing.
  38. With input shaft on center, line up centralizing holes (if fitted) in drop arm and steering box. See Fig 12 . Install drop arm. See DROP ARM  under REMOVAL & INSTALLATION. Install drop arm to steering box using a new tab washer. Tighten to 130 ft. lbs. (176 N.m) and bend over tabs.
    Fig 12: Lining Up Centralizing Holes
    G00096872Courtesy of LAND ROVER NORTH AMERICA, INC.
    39. NOTE: If steering box is earlier type without centralizing holes, install drop arm in position shown in Fig 12 with input shaft on center.
  39. Refit steering box to vehicle. Tighten chassis fixings to 60 ft. lbs. (81 N.m).
  40. Fill system with power steering fluid. See CAPACITY  and FLUID TYPE  under LUBRICATION.
  41. Bleed power steering system. See POWER STEERING SYSTEM  under BLEEDING.
    42. CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals.
  42. Test system for leaks, with engine running hold steering on full lock in both directions. When testing vehicle, do not test drive vehicle on public highway. Road test vehicle.
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