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Assembly Sequence Chart, Including Possible Problem Areas

Fig 1: Exploded View Of Steering Gear
G00498381Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  1. Assemble new ball bearings into steering gear wheel (pinion shaft).
    2. Fig 2: Installing Ball Bearing
    G00498390Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  2. Assemble the gear ring into steering gear wheel (pinion shaft) with snap ring pliers.
    3. Fig 3: Installing Bearing Retaining Ring
    G00498391Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  3. Assemble the steering gear wheel onto the steering gear housing with a rubber hammer.
    4. Fig 4: Installing Pinion Shaft
    G00498392Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD

    Attention:  Always knock gently when mounting the steering gear wheel.

  4. Assemble new retainer ring with a snap ring pliers.
    5. Fig 5: Installing Retainer Ring
    G00498393Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  5. Assemble the oil seal onto the steering gear housing.

    6. Attention:  Make sure the interface between the oil seal and steering gear housing is free of grease lubricant.

    Fig 6: Installing Oil Seal
    G00498394Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  6. Assemble the steering rack into the steering gear housing.

    7. Attention:  Apply grease lubricant on the whole outer surface and teeth surface of grease steering rack. Do not damage steering rack bushing when assembling.

    Fig 7: Inserting Steering Rack Into Housing
    G00498395Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  7. Assemble the adjusting plug block.
    8. Fig 8: Installing Adjusting Plug Block
    G00498396Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  8. Assemble the adjusting spring.
  9. Starting torque adjusting system.
    1. Screw down the steering rack with a spanner wrench to adjust the plug. Tightening torque is 11-15 Nm.
    2. After step a), return the plug back to a position of 45°-55°. Measure the starting torque with a torque wrench. Repeat step a) to step c) if measurement doesn't meet specified starting torque of 1.5-1.6 Nm.
    3. Screw down the adjustable plug to a specified torque of 35-45 Nm
    4. Remeasure starting torque of 1.5-1.6Nm.
    10. Fig 9: Turning Adjusting Plug
    G00498397Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
    Fig 10: Tightening Lock Nut
    G00498398Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  10. Assemble the tie rod ball joint assembly.
    1. Screw the lock nut down to bottom thread of tie rod ball joint assembly (The big end of lock nut faces towards the tie rod ball joint assembly)
    2. Assemble the tie rod ball joint on the steering rack under status 1.
    3. Tighten the steering rack and lock nut to the specified torque. Specified torque: 50-60 Nm.
    11. Fig 11: Identifying Inner Tie Rod Ball Joint
    G00498399Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
  11. Assemble the expansion sleeve (bellows boot).
  12. Assemble a new clamp tightening tape.
  13. Assemble a new spring hoop.
  14. Assemble a new plinth assembly. Specified torque: 32-48 Nm.

    15. Attention:  Connect the tie rod end to the steering rack as per the alignment mark.

    Fig 12: Identifying Tie Rod End Alignment Mark
    G00498382Courtesy of LIUZHOU WULING SPECIAL PURPOSE VEHICLE MANUFACTURING CO. ,LTD
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