Power Steering Gear: Section 6C
Power Steering Gear: Section 6C
Power Steering Gear: Section 6C
Diagnostic Information and Procedures .............. 6C-4 Unit Repair .......................................................... 6C-13
Power Steering Rack and Pinion Gear ................... 6C-4 Rack and Pinion ................................................ 6C-13
Power Steering Rack and Pinion Gear Bench Valve and Pinion Assembly ................................ 6C-14
Testing ............................................................. 6C-6 Rack Bearing .................................................... 6C-15
Straight-Ahead Check .......................................... 6C-6 Rack Bearing Preload Adjustment ...................... 6C-16
Repair Instructions ................................................ 6C-8 Specifications ..................................................... 6C-17
On-Vehicle Service ................................................. 6C-8 Fastener Tightening Specifications ..................... 6C-17
Rack and Pinion Assembly .................................. 6C-8 Special Tools and Equipment ............................ 6C-18
Outer Tie Rod ...................................................... 6C-9 Special Tools Table ............................................ 6C-18
6C-2 POWER STEERING GEAR
SSANGYONG MY2002
POWER STEERING GEAR 6C-3
COMPONENT LOCATOR
KAA6C010
SSANGYONG MY2002
6C-4 POWER STEERING GEAR
Loss of Coolant
Checks Action
Check the power steering hose for contact with the Be sure the power steering hose is correctly fitted into
body. the hose clips.
Check the steering gear for insufficient lubrication. Lubricate the steering gear.
Check the steering gear mounting for improper Tighten the steering gear mounting bracket nuts and
installation. bolts.
Check the outer tie rods for improper installation. Tighten the outer tie rod joints. Replace the outer tie rods.
Loss of Coolant
Checks Action
Check the steering wheel for contact with the turn Adjust the turn signal housing.
signal housing.
Check the intermediate shaft joints for binding or Replace the intermediate shaft.
looseness.
Check the power steering pump flow control valve for Replace the power steering pump.
sticking and improper alignment.
Check the wheel alignment. Align the wheels.
Check the wheel bearings for wear or damage. Replace the wheel bearings.
Check the intermediate shaft joints for improper Adjust the intermediate shaft between the steering gear
installation. and the steering column. Replace the intermediate shaft.
Check the outer tie rods and the ball joints for binding Tighten the tie rods and the ball joints. Replace the tie
or looseness. rods and the ball joints.
Check the steering gear adjustments. Perform a straight-ahead check.
Check the steering column shaft seal for rubbing on Replace the dash seal.
the shaft.
Check the steering shaft bearings for binding. Replace the stub shaft bearings.
SSANGYONG MY2002
POWER STEERING GEAR 6C-5
Checks Action
Check the power steering pump for insufficient pres- Replace the power steering pump.
sure.
Check the power steering pump flow control valve for Replace the power steering pump.
sticking and improper operation.
Check the power steering pump serpentine belt for Tighten the power steering serpentine belt.
slippage.
Check for air contamination in the power steering Bleed the power steering system
system.
Checks Action
Check for air contamination in the power steering Bleed the power steering system.
system.
Check the power steering pump serpentine belt for Tighten the power steering serpentine belt.
looseness.
Checks Action
Check for air contamination in the power steering Bleed the power steering system.
system.
Check the wheel bearings for wear or damage. Replace the wheel bearings.
Check the steering gear mounting for improper instal- Tighten the steering gear mounting bracket nuts and
lation. bolts.
Check the intermediate shaft joints for improper Adjust the intermediate shaft between the steering
Installation. gear and the steering column. Replace the intermedi-
ate shaft.
Check the outer tie rods and the ball joints for Tighten the tie rods and the ball joints. Replace the tie
looseness. rods and the ball joints.
Checks Action
Check the intermediate shaft joints for improper Adjust the intermediate shaft between the steering gear
installation. and the steering column. Replace the coupling flange.
Check the power steering pump flow control valve for Replace the power steering pump.
sticking and improper installation.
Check the power steering pump for insufficient pressure. Replace the power steering pump.
Check the power steering pump for internal leaks. Replace the power steering pump.
Check for a loose or a worn intermediate shaft. Tighten the intermediate shaft. Replace the intermedi-
ate shaft, as needed.
Check the power steering pump serpentine belt tension. Tighten the power steering serpentine belt.
SSANGYONG MY2002
6C-6 POWER STEERING GEAR
POWER STEERING RACK AND 3. Remove the extensions and reconnect the pressure
and return lines.
PINION GEAR BENCH TESTING 4. Install and connect the power steering gear. Refer
Removal and Installation Procedure to “Rack and Pinion Assembly” in this section.
Notice: Pressure checks or pressure and flow checks 5. Start the engine and allow it to idle for 10 seconds.
may also be conducted using this setup. 6. Check the power steering fluid level. Refer to
Section 6A, Power Steering System.
1. Disconnect and remove the power steering gear.
Refer to “Rack and Pinion Assembly” in this
section.
STRAIGHT-AHEAD CHECK
2. Place the power steering gear on a bench next to After all the necessary operations on the steering gear
the vehicle. are completed (removing and installing, disassembling
and assembling), check the exact straight-ahead posi-
3. Disconnect the pressure line at the point where the tion of the steering in each case.
hose connects to the pipe. Extend this line to reach
the power steering gear on the bench. With the vehicle on the floor, place the steering wheel
in the straight-ahead position. Mark the centerline of
4. Disconnect the return line from the power steering both tires on the floor. Turn the steering wheel all the
fluid reservoir. Extend this line to reach the power way to the right and mark the new centerline of both
steering gear on the bench. tires on the floor.
5. Connect the power steering pipes to the power
steering gear.
6. Start the engine and allow it to idle for 10 seconds.
7. Check the power steering fluid level. Refer to
Section 6A, Power Steering System.
8. Start the engine and turn the rack and pinion stub
shaft a full turn in each direction. Hold the shaft
against each stop for 5 seconds.
9. Inspect for possible leak points. Refer to Section
6A, Power Steering System.
Installation Procedure
1. Stop the engine.
KAA6C020
2. Disconnect the power steering pipes from the power
steering gear.
SSANGYONG MY2002
POWER STEERING GEAR 6C-7
SSANGYONG MY2002
6C-8 POWER STEERING GEAR
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
RACK AND PINION ASSEMBLY
Tools Required
661 589 13 33 00 Ball Joint Remover
KAA6C040
SSANGYONG MY2002
POWER STEERING GEAR 6C-9
KAA6C050
KAA6C140
SSANGYONG MY2002
6C-10 POWER STEERING GEAR
KAA6C080
DUST BOOT
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
wheels.
3. Remove the outer tie rod. Refer to “Outer Tie Rod”
in this section.
4. Remove the dust boot retaining clamps.
KAA6C090
KAA6C100
INTERMEDIATE SHAFT
Removal and Installation Procedure
1. Turn the steering wheel until it is horizontal. This
is the straight-ahead position. Make a mark on
the stub shaft housing that lines up with a mark
on the intermediate shaft lower universal joint.
Installation Notice:
• When attaching the lower universal joint, the
marks on the intermediate shaft and on the stub
shaft should line up
KAA6C110
SSANGYONG MY2002
POWER STEERING GEAR 6C-11
KAA6C130
SSANGYONG MY2002
6C-12 POWER STEERING GEAR
SSANGYONG MY2002
POWER STEERING GEAR 6C-13
UNIT REPAIR
RACK AND PINION
Disassembly and Assembly Procedure
1. Remove the rack and pinion assembly from the
vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the valve and pinion assembly from the
rack and pinion steering assembly. Refer to “Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
KAA6C150
and pinion steering assembly. Refer to “Rack
Bearing” in this section.
4. Mark the threads on the inner tie rod to aid in
repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
Installation Notice:
• When installing the outer tie rod nut, the mark
on the inner tie rod and adjusting nut should
line up.
• After installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
KAA6C160
KAA6C170
SSANGYONG MY2002
6C-14 POWER STEERING GEAR
KAA6C180
KAA6C190
KAA6C200
SSANGYONG MY2002
POWER STEERING GEAR 6C-15
KAA6C220
KAA6C230
RACK BEARING
Disassembly and Assembly Procedure
Tools Required
DW310-040 Power Steering Rack Guide Spring Cap
Wrench
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to “Rack and Pinion
Assembly” in this section.
2. Remove the adjuster plug locknut from the
adjuster plug, and remove the adjuster plug from
KAA6C240 the housing with the power steering rack guide
spring cap wrench DW310-040.
Installation Notice
Tightening Torque 59 N•m (43 lb-ft)
SSANGYONG MY2002
6C-16 POWER STEERING GEAR
KAA6C250
SSANGYONG MY2002
POWER STEERING GEAR 6C-17
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N•m Lb-Ft Lb-In
Adjust Plug Locknut 59 43 -
Hydraulic Cylinder Line Fitting At The Valve End 14 10 -
Hydraulic Cylinder Line Fitting At The Cylinder End 14 10 -
Intermediate Shaft Lower Pinch Bolt 27 20 -
Intermediate Shaft Upper Pinch Bolt 27 20 -
Outlet Tie Rod Nut 39 29 -
Power Steering Gear Inlet Pipe Fitting 17 13 -
Power Steering Gear Outlet Pipe Fitting 17 13 -
Rack And Pinion Assembly Mounting Bolts 78 58 -
SSANGYONG MY2002
6C-18 POWER STEERING GEAR
DW 310 - 040
Power Steering Rack
Guide Spring Cap
Wrench
KAA6C270
SSANGYONG MY2002