The method of replacing the oil seal of the bipod shaft UAZ 31512. Steering
The steering of UAZ-469 and UAZ-469B vehicles consists of a steering mechanism with a steering column, a steering wheel and a steering gear. The working pair of the steering mechanism is a globoidal worm and a double-ridged roller mounted on an axis in the head of the bipod shaft.
Steering UAZ-469 and UAZ-469B, general arrangement and differences.
The engagement of the worm with the roller is regulated by a screw located in the side cover of the crankcase. The steering bipod is planted on small splines cut on the cone of the bipod shaft. The correct angular installation of the bipod on the shaft is ensured by the presence of four double splines in it and the corresponding double hollows on the shaft, and the tightness of the fit is achieved by tightening the nut.
The position of the bipod corresponding to driving in a straight line must coincide with the middle position of the bipod shaft roller engaged with the worm. Permissible deviation - 25 degrees of steering wheel rotation in one direction or another. The average position of the roller is determined by the minimum clearance in engagement with the worm.
Steering column UAZ-469 and UAZ-469B.
The steering column, with the help of a stepladder and a bushing that compensates for the movement of the body while the car is moving, is attached to the bracket for the strut of the front panel and instruments. To compensate for the displacement of the steering column when installing the steering, adjusting shims are installed between the bracket and the rubber bushing, and the holes in the bracket for mounting the ladder are oval.
The steering column must be fixed in the position obtained when attaching the crankcase to the frame. It is not allowed to tighten the steering column to the spacer bracket when it is fastened, as this will lead to bending of the steering column shaft and its inevitable breakage.
The rods are tubular, and the levers are cast integrally with the pivot pins. All hinges are self-locking and do not require adjustment in operation. The steering rod joints of the UAZ-469 vehicle are hermetically sealed and the stock of grease put into them during assembly ensures the operation of the joints for a long time.
The steering rod joints of the UAZ-469B car differ in their design from the joints of the UAZ-469 car and are not interchangeable with them. A design feature of the UAZ-469B steering linkage linkage joint is the presence of protrusions on the support foot, which are located perpendicular to the linkage axis and rest against the end of the pin through spring washers and thereby limit the linkage overturning resulting from the linkage bending in the horizontal plane.
From turning, the support heel is fixed with a mustache, which enters the hole for the grease fitting. There are no protrusions on the heel in the hinges of the bipod thrust, and there are no spring washers. The hinges are sealed with two spherical washers with a rubber ring and a spring cap.
The presence of a bend in the horizontal plane on the UAZ-469B trapezoid rod does not allow adjusting the toe-in by rotating the rod itself. Therefore, the left tip is welded to the rod, and between the right tip and the rod there is an adjusting fitting with an internal right and external left thread, the rotation of which adjusts the toe-in. On the UAZ-469 car, the trapezoid rod is straight with tips screwed into it with right and left threads, which allows you to adjust the wheels by rotating the rod itself.
Possible malfunctions of the steering UAZ-469 and UAZ-469B.
Increased transmission to the steering wheel shocks from the road and vibration of the steering wheel.
- Increased movement of the body relative to the steering column when driving on rough roads.
Increased steering wheel free play, over 40 mm when measured at the rim.
- Increased clearances in the swivel joints of the steering rods.
— Loose fastening of the pivot arm.
— The ball pin cones are not tightened.
- Wear or misalignment of the worm and roller.
- Wear or misadjustment of the tightening of the worm bearings.
- Loosening the bipod mounting nut.
The axial movement of the worm is felt on the steering wheel.
- Violation of the adjustment of the tightening of the worm bearings.
- Worn bearings or worm cones.
Axial movement of the steering wheel on the shaft.
- Weak tightening of the steering wheel nut.
The radial movement of the steering shaft is felt on the steering wheel.
- Destruction or wear of the bearing in the steering column.
— Loose fastening of the steering column ladder.
Seizures in the steering mechanism.
- Incorrectly adjusted side clearance in the engagement of the worm with the roller or the tightening of the worm bearings.
- Large wear of the roller or worm
Squeaking or clicks in engagement.
- Lack of lubrication.
- Destruction of the working surfaces of the roller or worm.
Creak at the top of the steering column.
- Lack of lubrication in the steering column bearing.
Hard rotation of the steering wheel.
— Skewed steering column.
Leakage of grease from the steering gear.
— Defective steering arm shaft seal.
- Violation of the tightness of the flaring of the tube in the bottom cover.
Steering UAZ car
Device
The steering of automobiles consists of a steering mechanism, a shaft with a steering wheel, a bipod and steering rods. The design of the steering mechanism is shown in fig. 103.
The working pair of the steering mechanism is a globoidal worm and a double roller. Gear ratio of the steering mechanism (average) -20.3.
The worm pressed onto the shaft is installed in the steering gear housing on two roller tapered bearings. The bearing preload is adjusted with thin paper shims placed under the lower crankcase cover.
On the steering arm shaft, one end of which rests on a bronze bushing, and the other on a cylindrical roller bearing (in the side cover of the crankcase), a double roller is fixed.
The gap in the engagement of the roller with the worm is regulated by the axial movement of the bipod shaft with a screw installed in the side cover of the crankcase. When the shaft moves, the distance between the axes of the roller and the worm changes and the gap in the engagement changes.
On the splined conical end of the bipod shaft, a steering bipod is installed, tightly tightened with a nut.
The steering shaft in the upper part rests on a ball angular contact bearing located in the steering column tube.
A steering wheel 20 with a diameter of 425 mm is attached to the end of the shaft.
To seal the bipod shaft and the worm shaft, oil seals are pressed into the crankcase.
If malfunctions are found in the steering, it is necessary to check not only the steering, but also the components that affect its operation: wheel hubs, brakes, front springs; you should also check the correct installation of the front wheels and the air pressure in the tires.
Steering traction. On a UAZ-451 car, the steering trapezoid thrust is located behind the front axle, and on a UAZ-452 car, it is in front.
Both rods are equipped with tips in which pins 2 with ball heads are installed. The tips do not regulate, since the springs 6 in them automatically eliminate the gaps that appear during wear.
Rice. 1. Steering mechanism: 1- steering bipod; 2 - steering gear housing; 3- lower crankcase cover; 4 - adjusting shims of worm bearings; 5 - double roller; 6 - worm; 7 and 8 - worm bearings; 9-filler plug; 10 - roller bearing; 11 - lock washer of the adjusting screw; 12 - locknut; 13 - adjusting screw; 14 - side cover of the crankcase; 15 - drain plug; 16 - bushing; 17 - bipod shaft; 18 - stuffing box; 19 - column pipe; 20 - steering wheel; 21 - steering shaft bearing; 22 - steering shaft; 23 - clamping clamp; 24 - roller axis
Longitudinal steering rods of UAZ-451M and UAZ-452 cars are identical in design and differ only in length. These rods have adjustable ball joints. On fig. 2 shows the longitudinal rod and the parts included in it. In case of wear of the hinge parts, it is necessary to adjust the tightening of the ball pins as follows: unpin the plug at the end of the rod, screw it in until it stops, and then unscrew it by U12-‘L of a turn and cotter it. In the same way, adjust the ball pin at the other end of the rod.
Rice. 2. Longitudinal steering rod: 1 - clip of the protective lining; 2- protective pad; 3 - a finger with a ball head; 4 - cork; 5 - finger cracker; 6 - spring; 7 - spring limiter; 8 - grease fitting; 9 - longitudinal steering rod; 10 - tie rod lever
Maintenance
At T0-1:
- check the fastening of the steering levers, steering rods and bipod;
- lubricate the steering rod joints through four grease fittings. It is necessary to force the lubricant to come out to make sure that it has passed into the joint. If the grease does not come out, it is necessary to check the serviceability of the grease fittings and replace the faulty ones.
If, even with a working grease fitting, the grease does not pass, then the hinge should be unloaded or the connection should be disassembled and the cause of the grease not passing should be eliminated.
Through TO-1, perform the work specified for TO-1, and additionally:
- check and, if necessary, tighten the mount of the steering gear housing; check the condition of the swivel joints of the steering rods;
- Check steering wheel play.
At T0-2:
- Tighten the nut for fastening the steering arm and the nuts for fastening the crankcase of the steering mechanism to the longitudinal beam of the frame. Before tightening the crankcase nuts, loosen the nuts of the steering column mounting ladder;
- check the condition of the tie rod heads, the serviceability of their seals. If necessary, unpin and tighten the nuts of the tie rod pins;
- check the fastening of the steering rod levers; check and adjust steering. Through TO-2, perform the work indicated for TO-2 and change the lubricant in the steering gear housing.
To drain the oil from the crankcase, unscrew the drain plug from the bottom of the crankcase.
Removal and disassembly of the steering mechanism
To repair the steering mechanism, it is necessary to remove it from the car and disassemble it.
After disassembling and washing the parts, you need to check their condition (wear) and determine suitability for further work.
If the working pair of the steering - the worm and the mouth, in addition to significant wear on the working surface of the thread, has shells, dents or delamination, it is replaced with a new one; with a noticeable shift of the splines in the connection of the shaft with the bipod, as well as in the event of a collapse of the conical surface at the ball pin and bipod, they are also replaced with new ones.
The steering mechanism is removed in the following sequence.
Loosen the rudder bipod mounting nut and remove the bipod with a puller.
Remove the turn signal switch clamp on the steering column, remove the instrument panel and turn signal switch together with the wire bundle and lower the switch to the floor of the body.
Disconnect the signal wire from the connector.
Remove the signal button, remove the contact cup of the button, the spring and the seat of the button spring.
Loosen the screws securing the contact plate of the signal button, remove the contact plate together with the insulator and wire, and remove the spring.
Loosen the steering wheel nut by 2-3 threads. Using a puller, slide the steering wheel off the shaft cone, and then remove it.
Remove the steering column mounting stepladder, shims and stepladder rubber bushing.
Remove the floor mat, floor seal and steering column seal retainer ring.
Loosen the bolts securing the crankcase to the frame bracket and remove the steering gear (down under the frame).
Disassembly of the steering mechanism is performed in the following sequence.
Unscrew the crankcase drain plug and drain the oil.
Loosen the clamp bolt and remove the dispenser tube and clamp.
Loosen the bipod shaft adjusting screw lock nut and remove the lock washer.
Remove the crankcase side cover along with the bipod shaft and gasket.
Unscrew the adjusting screw from the side cover and remove the ssshka shaft.
Carefully (without damaging the shims) remove the cover with O-ring, spring and spring washer, gaskets, lower bearing outer race and cage with rollers. Remove from the crankcase the steering shaft with the worm assembly 'and the separator with the rollers of the upper bearing.
Press the upper bearing outer race and the bipod shaft oil seal out of the crankcase if replacement is required.
If there is a lot of wear, press the bipod shaft bushing out of the crankcase.
If it is necessary to replace the bipod shaft roller, drill out the axle head and press the axle out. After installing the new roller in place, insert the removed axle and weld it on the shaft by electric arc welding.
Remove the spring, expansion ring from the upper end of the steering column tube and press out the bearing.
Assembly and installation of the steering mechanism
The assembly of the steering mechanism is performed in the reverse order of disassembly. In doing so, the following must be taken into account.
After installing a new worm on the shaft, the end of the shaft must coincide with the end of the undercut in the worm; deviation should not exceed 0.25 mm.
Adjust the worm bearings with paper spacers (thick and thin) installed under the steering gear housing cover.
When installing the steering arm shaft into the crankcase, lubricate the cylindrical part of the shaft and the roller with gear oil.
In the assembled steering mechanism, the runout of the steering wheel shaft on the neck for the ball bearing should be no more than 2 mm.
Install the steering column on the car in the reverse order of removal. In this case, first of all, the bolts of the steering gear housing to the frame bracket are tightened, and then the nuts of the stepladder of the steering column to the bracket. If, after tightening the bolts, a gap appears between the rubber cushion put on the column tube and the column mounting bracket, then it is eliminated by installing shims.
It is impossible to eliminate the gap by pulling the pipe with a ladder. This will cause the tube and steering shaft to bend and the bearings to malfunction.
When the column is shifted to the side, the oblong holes in the column mounting bracket allow you to fix it in a new position.
If necessary, allow sawing holes.
Steering gear adjustment
With the correct adjustment of the engagement of the working pair of the steering mechanism, there should be no play in the steering wheel when driving in a straight line. When the steering wheel is turned in any direction by 45 ° or more, a gap appears in the engagement of the worm with the shaft roller. With further rotation of the steering wheel, the gap in engagement, gradually increasing, reaches in the extreme positions of the roller up to 30° of the steering wheel rotation.
During the operation of the car, the working pair of the steering mechanism, worm bearings and other steering parts wear out.
First, there is an increased clearance in the engagement of the worm and roller, and later, an increased axial movement of the worm.
The appearance of increased clearances in the steering mechanism causes a violation of its adjustment and leads to a loss of vehicle traffic safety.
Therefore, you should periodically check the gap in the engagement of the working pair of the steering mechanism and the axial movement of the worm and eliminate them by adjustment.
The condition of the steering mechanism is considered normal and does not require adjustment if the free play on the steering wheel rim in the straight ahead position does not exceed 40 mm.
If the steering wheel play is more than specified, then before proceeding with the steering adjustment, it is necessary to make sure that the steering gear housing mounting bolts are tight, the hinge joints are in good condition, and the bipod is firmly seated on the shaft.
Adjustment begins with checking the axial clearance in the worm bearings.
For this you need:
- put the wheels in the position of driving in a straight line;
- putting a finger to the lower end of the steering wheel hub and the column pipe, turn the steering wheel in both directions at a certain angle. If there is wear on the worm bearings, the axial movement of the steering wheel hub relative to the pipe will be felt with a finger.
If there is no axial movement, then only the engagement of the working pair of the steering mechanism is regulated.
Adjustment of the engagement of the working pair of the steering mechanism. When a gap appears in the engagement of the working pair, it is adjusted by moving the bipod shaft along the axis (without removing the steering from the vehicle).
The adjustment procedure is as follows.
Place the front wheels of the vehicle in the straight ahead position.
Detach the tie rod from the steering arm.
Loosen the adjusting screw locknut and remove the lock washer.
Turn the adjusting screw clockwise with a key until the gap in the engagement of the worm with the roller is eliminated.
Put on the lock washer. If the washer hole does not line up with the pin, turn the adjusting screw until the washer hole lines up with the pin.
Screw the locknut onto the screw. Check, by shaking the bipod with your hand, the correctness of the adjustment made. The movement of the end of the steering arm must not exceed 0.3 mm.
Install the ball pin in the bipod hole, screw on the nut and cotter pin.
Worm bearing adjustment. After long-term operation of the car in the steering mechanism, gaps appear in the bearings of the worm.
To eliminate the axial movement of the worm, you need to remove the steering gear from the car and adjust the bearings. The removal of the steering mechanism is necessary to check the correctness of the adjustment made and to measure the amount of effort to turn the shaft with the worm.
Adjustment is performed by reducing the number of paper pads installed under the lower crankcase cover in the following sequence.
Remove the steering gear from the vehicle as described above.
Drain the oil from the crankcase of the steering mechanism, disassemble the mechanism and wash its parts.
Install the steering shaft with the worm and bearings into the crankcase.
Install the lower crankcase cover, after removing the thin adjusting shim. Tighten the cover bolts and secure the steering wheel to the shaft. Turning the steering wheel so that the bearing rollers are in the correct position, check the worm for the absence of axial movement.
If the play is not eliminated, remove the thick gasket of the crankcase cover, and install the thin one in place.
After eliminating the backlash, use the tool to check that the bearings are properly tightened. The force required to rotate the shaft with the worm, applied at a radius of 212.5 mm, should be in the range of 0.22-0.45 kg (without the bipod shaft installed).
In this case, the axial play of the shaft in the bearings should be absent.
The force required to rotate the shaft with the worm engaged with the bipod shaft roller (when the steering bipod is in a straight line position), applied at a radius of 212.5 mm, should be in the range of 0.9-1.4 kg when checking without glands.
In the middle position of the roller (within 45 ° of rotation of the worm in one direction or another), there should be no gap in the engagement.
After adjusting the worm bearings, install the bipod shaft and side cover into the crankcase and adjust the engagement of the worm with the roller.
With properly adjusted gearing, the free play on the steering wheel rim (with stationary wheels) should be within 10-15 mm.
To Category: - UAZ
The steering of the UAZ-3151, UAZ-31512, UAZ-31514 and UAZ-31519 cars is safety, consists of a steering wheel, a non-adjustable steering column with one or two cardan joints, a steering mechanism and a steering gear.
Steering UAZ-3151, 31512, 31514, 31519 without power steering.
The steering gear consists of a bipod, a bipod tie rod, a knuckle arm, a tie rod, and trapezoid arms. The rods are located in front of the front axle and are connected to the bipod and levers by spherical self-clamping collapsible hinges with tapered shanks.
The transverse link of the trapezoid of the UAZ-31512, UAZ-31514 and UAZ-31519 cars has a deflection in the horizontal plane, therefore, between the right steering tip and the rod there is an adjusting fitting with an internal right and external left thread, the rotation of which changes the length of the rod, which allows you to adjust the amount of convergence front wheels.
Types of steering gears UAZ-3151, 31512, 31514, 31519 without power steering.
On UAZ-3151 and UAZ-31512 cars, steering with two types of steering mechanisms could be installed: a globoidal worm with a double-ridged roller, it is also a worm-roller or a screw-ball nut-sector type, it is also a screw-ball nut-rail-sector. Steering UAZ-31512 with the second type of steering mechanism could be additionally equipped with a steering wheel. On cars UAZ-31514 and UAZ-31519, a steering mechanism of the type screw - ball nut - sector with or without power steering was installed.
Worm-roller type steering mechanism.
It consists of a crankcase in which a globoidal worm is mounted on tapered roller bearings, which engages with a double-ridged roller. The roller rotates on angular contact ball bearings mounted on an axle pressed into the bipod shaft head.
When the steering shaft is turned, the worm rotates, and the roller, rolling along it, turns the bipod shaft mounted in the crankcase on a radial roller bearing and a bronze bushing. The mechanism is adjusted with a screw at the end of the bipod shaft. Steering gear catalog number: 469-3400014-11.
Steering gear type screw-ball nut-sector.
It consists of an aluminum crankcase in which a screw is mounted on angular contact bearings. The screw encloses a ball nut-rail, which has a helical groove inside and rack teeth on the outside. Balls are placed between the nut and the screw. When the screw rotates, the balls roll along the helical groove and the nut moves along the screw. The rack teeth turn the sector shaft mounted in the crankcase on two cylindrical roller bearings without a separator. A steering arm is fixed on the conical splines of the sector shaft.
The adjustment of the engagement of the rail with the sector shaft is made by turning the eccentric cages of the sector shaft bearings. The screw with ball nut and balls are matched to each other and, if necessary, can only be replaced as an assembly. Catalog number of the steering gear, for UAZ-3151 and UAZ-31512: 3151-3400013, for UAZ-31514 and UAZ-31519: 3151-3400014.
Checking the condition of the steering UAZ-3151, 31512, 31514, 31519 without power steering.
For steering gear type globoidal worm with double ridged roller.
The condition of the steering mechanism is considered normal and does not require adjustment if the free play of the steering wheel in the straight ahead position does not exceed 10 degrees with a force on the dynamometer of 7.35 N (0.75 kgf), which corresponds to 40 millimeters when measured on the wheel rim.
For steering mechanism type screw-ball nut-sector.
The condition of the steering mechanism is considered normal and does not require adjustment if the free play of the steering wheel in the straight ahead position, the middle position of the rack nut, does not exceed 10 degrees, which corresponds to 40 millimeters when measured on the wheel rim.
If the free play of the steering wheel is more than 40 millimeters.
First of all, you need to make sure that the increase in free play is not caused by wear of the steering rod joints and cardan joints, play of the front wheel bearings, as well as loosening of the bipod nut, nuts of the hinge pins, wedges of the cardan shaft and other fasteners. To do this, check the tightness of the nuts and bolts of the steering, and, if necessary, tighten them. The nuts of the ball joints of the steering rods and the cardan shaft of the steering must be cottered.
When turning the steering wheel, there should be no play in the ball joints of the rods. The backlashes in the universal joints of the steering shaft are checked in the same way. If, after eliminating the above backlashes, the free wheeling of the steering wheel still exceeds the permissible limits, then the steering mechanism itself must be adjusted.
Oils and lubricants for steering UAZ without power steering.
Steering mechanisms without power steering are lubricated with SAE 75W90 oil according to API GL-4, GL-5, poured into their crankcase. For the steering gear type worm-roller 0.25 liters, for the screw-ball nut-sector: 0.5 liters. Steering rod joints, steering tips are lubricated with Litol-24 grease until fresh grease comes out from under the seals.
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UAZ-469 steering gear adjustment
Adjust the UAZ-469 steering gear to eliminate the gaps that appear when the working pair of the worm-roller is run in and worn out during the operation of the vehicle.
Adjust the tightening of the bearings of the UAZ-469 worm using gaskets 13 (Fig. 90) installed between the crankcase and the lower cover of the steering gear housing, in the following sequence:
2. Drain the oil from the crankcase.
kah shaft. The appearance of a knock in the column is also affected by the weakening of the fastening of the body to the frame.
If a radial play appears in the hinge (axial movement of the cross in the bearings), perform an additional centering of the bearings in the fork ears. Carry out the punching in such a way as to prevent the bearing cup from collapsing.
The bearings of the cross are filled with Litol-24 grease during assembly at the factory and it is not required to add it in operation.
Adjust the steering gear to eliminate the gaps that appear during the running-in of the working pair of worm-roller and its wear during the operation of the vehicle.
The working pair of the steering mechanism is designed in such a way that when the roller is in the position corresponding to the movement of the vehicle in a straight line, the engagement gap is practically zero. As the wheel turns in one direction or another, the gap in the engagement gradually increases, reaching its maximum value in the extreme positions of the roller. The condition of the steering mechanism is considered normal and does not require adjustment if the free play of the steering wheel in the straight ahead position does not exceed 10 °, which corresponds to 40 mm when measured at the wheel rim.
If the steering wheel play is more than specified, then, before proceeding with the adjustment of the steering mechanism, make sure that the crankcase mounting bolts are tight and the drive swivel joints are in good condition.
Adjust the tightening of the worm bearings using gaskets 13 (Fig. 90) installed between the crankcase and the lower cover of the steering gear housing, in the following sequence:
1. Remove the steering gear from the vehicle.
2. Drain the oil from the crankcase.
3. Clamp the steering mechanism in a vise.
4. Loosen cap nut 33 and remove lock washer 34 from adjusting screw 32.
5. Turn away bolts of fastening of a lateral cover 37 crankcases.
6. Remove the shaft 17 of the bipod together with the cover with light blows of a copper or aluminum drift on the end of the shaft and carefully remove the gasket 38.
7. Turn away bolts of fastening of the bottom cover of a crankcase and remove the bottom cover 12.
8. Carefully peel off and remove the thin paper spacer 13.
9. Replace the bottom cover, tighten the bolts and check the axial movement of the worm.
10. If axial movement remains, then remove the bottom cover again, remove the thick gasket, and install the previously removed thin one in its place. Do not remove more than one gasket.
Rice. 93. Checking the tightness of the worm bearings with a dynamometer.
Rice. 5.1. The steering mechanism of cars of the UAZ-31512 family:
1 - crankcase; 2.39 - bushings; 3 - cuff; 4 - bipod; 5 - washer; 6.33 - nuts; 7 - stuffing box; 8.14 - bearings; 9 - plug; 10 – a shaft of the steering mechanism; 11 - worm; 12 - bottom cover; 13 - shims; 15 – roller axis; 16 - bipod shaft roller; 17 - bipod shaft; 18 - crankcase mounting bolts; 19 - hinge; 20 - retaining ring; 21 - protective washer; 22 - spring; 23 - expanding ring; 24 - bearings; 25 – a wire of a sound signal; 26 - contact sleeve; 27 - screw; 28.29 - plastic bushings; 30 - steering wheel; 31 – steering shaft; 32 - adjusting screw; 34 - lock washer; 35 - pin; 36 - bearing; 37 - side cover of the crankcase; 38 - gasket
Rice. 5.3. Steering drive for cars of the UAZ-31512 family:
1 – steering linkage levers; 2 - transverse steering rod; 3 – bipod of the steering mechanism; 4 - bipod thrust; 5 – lever of a rotary fist
Rice. 5.4. Steering gear for cars of the UAZ-3741 family:
1 – longitudinal steering rod; 2 – lever of longitudinal steering draft; 3, 6 – steering linkage levers; 4, 7 – tie rod ends; 5 – transverse steering rod
The steering of the car consists of a worm-roller type steering mechanism with a steering wheel (Fig. 5.1, 5.2) and a steering gear (Fig. 5.3, 5.4).
Rice. 5.5. Steering mechanism type screw-ball nut-sector:
1 - steering housing; 2 - shaft-sector; 3 - nut-rail; 4 - balls; 5,21,24 - retaining rings; 6,9,20,25 - protective covers; 7 - universal joint; 8 - bushing; 10 - cuff; 11 - screw bearings; 12 – bolts of fastening of the steering mechanism to a frame; 13 - shims; 14 - screw; 15 - bipod; 16 - lower crankcase cover; 17, 23, 26 - sealing rings; 18 - nut; 19 - washer; 22 - rollers; 27 - protective ring; 28 - ring of the shaft-sector support; 29 - filler plug; 30 – ball guide chute; 31 - pad of the ball guide; 32 - drain plug; 33 - plug
Rice. 5.6. Steering gear with hydraulic booster:
1 - nut; 2, 5, 6, 19, 21, 22, 35, 39 - sealing rings; 3 - glass; 4, 10 - thrust bearings; 7 - piston-rail; 8 - screw; 9 - crankcase; 11 - fitting of the discharge hose; 12 - drain hose fitting; 13 - sleeve; 14 - cuff; 15 - torsion bar; 16, 38 - pins; 17 - ball guide; 18 - balls; 20 - channel in the crankcase; 23 - bipod; 24 - bipod nut; 25 – protective bottom cover; 26 - retaining rings; 27 - adjusting washers; 28 - bipod shaft supports; 29 - rollers; 30 - bipod shaft; 31 - top protective cover; 32 - rotor; 33 - protective cap; 34 - distributor housing; 36 - channel in the distributor housing; 37 - bolts for fastening the distributor housing to the crankcase
On individual vehicles of the UAZ-31512 family, a steering gear of the screw-ball nut-sector type is installed without hydraulic booster (Fig. 5.5) or with hydraulic booster (Fig. 5.6).
Maintenance steering differs only in the adjustment of the steering gears.
Timely tighten the bolts securing the steering gear housing to the frame side member, check the fastening of the steering rod pins, bipod and steering knuckle lever. Check the free play of the steering wheel, adjust the steering gear, lubricate the tie rod joints and add oil to the steering gear housing or oil reservoir (in the case of a power steering gear) according to the lubrication table.
Rice. 5.7. Tie rod joint:
1 - plug; 2 - spring; 3 - heel; 4 - lower spherical washer; 5 – top spherical washer; 6 - protective ring; 7 - spring cap; 8 - cotter pin; 9, 13 - nuts; 10 - ball pin; 11 - cracker; 12 - tip; 14 - thrust
If a gap appears in the steering rod joints, screw the plug 1 up to the stop (Fig. 5.7), and then unscrew it 1/2 turn and tighten it in this position.
Periodically check the tightness of the tie rod nuts.
Do not allow gaps in the tapered joints of the levers and pins.
To eliminate them, unpin the nut and tighten it until it stops.
Untimely tightening of these connections causes wear of the conical holes in the levers, which will require replacement of parts.
When servicing vehicles of the UAZ-31512 family, pay attention to the condition of the mounting of the bearings in the forks of the steering joint.
If a radial clearance appears in the hinge (axial movement of the cross in the bearings), perform an additional reaming of the bearings in the lugs of the forks. Carry out the punching in such a way as to prevent the bearing cup from collapsing.
The bearings of the cross are filled with Litol-24 grease during assembly at the factory and it is not required to add it in operation.
Maintenance of the power steering system consists in checking the tension of the pump drive belt, checking the tightness of the hoses and their connections, checking for leaks in the pump and steering gear seals, checking the level and changing the oil in the oil reservoir.
Steering wheel free play check
The condition of the steering mechanism is considered normal and does not require adjustment if the free play of the steering wheel in the straight ahead position does not exceed 10 degrees, which corresponds to 40 mm when measured on the steering wheel rim.
In the presence of a power steering, check the free play of the steering wheel when the engine is idling, shaking the steering wheel in both directions until the front wheels start turning.
In the case of a steering mechanism without hydraulic booster, check the free play with a force of 7.5 N (0.75 kgf) on the steering wheel rim in both directions. If the free play is more than specified, then, before proceeding with the adjustment of the steering mechanism, check the mounting of the steering mechanism, the condition of the steering rod joints, the condition of the steering column hinge, the tightening of the bolts for fastening the forks of the hinges and the absence of play in the spline connection of the cardan shaft, the tightening of the bipod fastening nuts and lever, steering wheel mount.
Power steering pump drive belt tension
With normal belt tension, its deflection in the middle between the crankshaft and pump pulleys, when the belt is pressed with a force of 39 N (4 kgf), should be 12–17 mm. If necessary, tension the belt by moving the pump along the bracket for its attachment to the engine. To do this, loosen the bolts securing the pump to the bracket, move the pump with the adjusting screw until the belt tension is normal and tighten the pump mounting bolts. Replace the belt if it is damaged or overstretched.
Checking the level and changing the power steering oil
The front wheels must be straight when checking the oil level in the oil tank.
Add oil to the level of the grid of the oil tank filler filter or above it by no more than 5 mm. The oil must be pre-filtered through a filter with a filtration fineness of not more than 40 microns.
All-weather grade "P" oil is used as a working fluid.
The volume of the filled oil is 1.1 l.
Change the oil and filter in the oil tank every 100,000 km or 2 years of operation.
Change the oil also when repairing or adjusting the steering mechanism.
Filling system
1. Remove the oil tank cap, fill in oil until it appears above the filter mesh (no more than 5 mm).
2. Without starting the engine, turn the steering wheel or the input shaft of the mechanism from lock to lock until air bubbles come out of the oil in the tank. Add oil to the tank. When pumping, disconnect the bipod link from the bipod or hang the front wheels.
3. Start the engine while adding oil to the tank.
Note In case of abundant foaming of the oil in the tank, which indicates the ingress of air into the system, turn off the engine and let the oil settle for at least 20 minutes (until air bubbles come out of the oil). Inspect the places where the hoses are connected to the units of the hydraulic booster system and, if necessary, eliminate leaks.
4. Let the engine run for 15–20 seconds and bleed the hydraulic booster system to remove residual air from the steering mechanism by turning the steering wheel from lock to lock, without stopping in extreme positions, three times in each direction.
5. Add oil to the tank if necessary.
6. Close the tank with a lid and tighten the lid nut by hand.
7. Attach the bipod link, tighten and cotter the ball stud nut.
Servicing the flow and relief valves of the pump
If the flow and safety valves are dirty, flush them.
For this:
1. Unscrew the plug located above the pump outlet.
2. Remove the spring and spool of the flow valve, and reinstall the plug to prevent oil from escaping.
3. Flush the spool and the safety valve that is installed inside the spool.
4. Reassemble in reverse order.
Worm-roller steering adjustment
The steering mechanism must be adjusted to eliminate the gaps that appear between the worm and the roller.
Rice. 5.8. Checking the axial clearance in the worm bearings
Start the adjustment by checking the axial clearance in the worm bearings.
To do this, grasp the column with your palm so that your thumb touches the end of the steering wheel hub and turn the steering wheel in both directions at a certain angle (Fig. 5.8). When the worm bearings are worn, the finger will feel the axial movement of the steering wheel hub relative to the column tube. If there is no axial movement of the worm, then adjust only the engagement of the roller with the worm.
Worm bearing adjustment ) use gaskets 13 (see Fig. 5.1) installed between the crankcase and the bottom cover of the steering gear housing in the following order:
1. Remove the steering gear from the vehicle.
2. Drain the oil from the crankcase.
3. Fix the steering mechanism in a vise.
4. Loosen nut 33 and remove lock washer 34 from adjusting screw 32.
5. Turn away bolts of fastening of a lateral cover 37 crankcases.
6. Lightly hitting the end of the bipod shaft 17 with a copper or aluminum drift, remove the bipod shaft together with the roller and cover and carefully remove the gasket 38.
7. Turn away bolts of fastening of the bottom cover 12 crankcase and remove a cover.
8. Carefully peel off and remove the thin paper spacer 13.
9. Replace the bottom cover, tighten the bolts and check the axial movement of the worm.
10. If axial movement remains, remove the bottom cover again, remove the thick gasket, and install the previously removed thin one in its place. Do not remove more than one pad
11. By rotating the worm 11, finally check the tightening of bearings 8 and 14. With the correct tightening of the worm roller bearings, the force required to turn the steering wheel should be 2.2–4.5 N (0.22–0.45 kgf) (without installed bipod shaft).
Check the tightening of the bearings using a dynamometer (Fig. 5.9).
Rice. 5.9. Checking the tightness of the worm bearings with a dynamometer
Adjustment of the engagement of the roller with the worm cars of the UAZ-31512 family ( Adjustment on cars of the UAZ-3741 family is carried out similarly) in the following order:
1. Set the steering wheel to the position corresponding to the movement of the car in a straight line.
2. Disconnect the tie rod from the bipod.
3. Unscrew nut 33 (see Fig. 5.1) and remove lock washer 34 from adjusting screw 32.
4. Turning the adjusting screw 32 clockwise, eliminate the gap in the engagement.
5. Put on the lock washer. If the hole in the washer does not line up with the pin, turn the adjusting screw until the hole in the washer lines up with the pin.
6. Screw the nut 33 onto the adjusting screw and, shaking the steering arm by hand, check that there is no gap in the engagement.
7. Check the effort needed to turn the steering wheel. The steering wheel should turn freely from the middle position, corresponding to the movement in a straight line, with a force of 9–16 N (0.9–1.6 kgf) applied to the steering wheel. In the absence of a special device to check the force required to turn the steering wheel, use a dynamometer.
8. Connect the link to the bipod
Adjustment of the steering gear type screw-ball nut-sector
To adjust the steering mechanism, remove it together with the bipod from the vehicle.
Fasten the steering gear with the splined end of the screw 14 (see Fig. 5.5) up, the axis of the screw 14 should take a vertical position.
1. Using a dynamometer, measure the moment of turning the screw 14 in the middle and in the extreme positions of the sector shaft
2. The middle position of the shaft-sector is found by turning the screw 2.5 turns from any extreme. To measure the moment of turning the screw in the extreme position of the shaft-sector, it is necessary to turn the screw by 1/2 turn to remove the shaft-sector from the stop in the extreme position and measure the value of the moment by turning the screw for one turn. With the correct tightening of the bearings and the absence of a gap in the engagement of the rack nut and the sector shaft, the moment of turning the shaft in the middle position of the sector shaft should be 1.6–2.5 N m (0.16–0.25 kgf m), in the extreme position of the shaft-sector, the moment should decrease to 0.8–1.2 N m (0.08–0.12 kgf m).
3. If the moment of turning the screw in the extreme positions is less than the specified one, it is necessary to adjust the tightening of the bearings 11 of the screw.
Screw bearing tightening adjustment
1. Install the steering mechanism with the bottom cover 16 (see Fig. 5.5) up and secure in this position.
2. Turn away bolts of fastening of a cover and remove a cover 16.
3. Remove one of the thin spacers 13 (0.05 mm thick).
4. Replace the cover, tighten the bolts, turn the steering mechanism over with the splined end of the screw 14 up and again measure the torque of the screw in the extreme positions.
5. If the required torque value is not reached, remove the 0.1 mm or 0.15 mm thick gasket in the same sequence, and reinstall the previously removed gasket. At least three 0.05 mm thick shims are installed in the steering mechanism, and 0.1 mm, 0.15 mm and 0.5 mm thick shims can also be installed, the number of which is determined by the assembly needs. It is not recommended to remove more than one gasket with a thickness of 0.05 mm if thicker gaskets are available.
6. Finally check the moment of turning the screw in the extreme positions of the sector shaft.
If, when checking the moment of turning the screw, it turns out that the moment in the extreme positions of the sector shaft corresponds to the recommended value, and the moment in the middle position of the sector shaft is lower than recommended, the engagement of the nut-rack 3 and the sector shaft 2 should be adjusted.
An additional sign of the need to adjust the engagement can be a gap, which is noticeable when the sector shaft swings by the bipod in the middle position of the sector shaft.
Gearing adjustment do it in the following order:
1. If on the ring mechanism 28 (see Fig. 5.5) the sector shaft supports are locked by punching the shoulder into the crankcase hole, remove the plugs 33 of the holes and straighten the shoulder with a barb and a hammer, without applying excessively strong blows. If these rings are locked with screws, loosen them.
2. Remove protective covers 20 and 25. When locking the rings with a punch, the bipod must also be removed.
3. Eliminate the gap in the engagement by turning the rings 28 of the sector shaft supports counterclockwise, as viewed from the side of the sector shaft splines. In this case, the rings of the shaft-sector supports must rotate at the same angle.
4. Check the moment of turning the screw in the middle position of the sector shaft.
5. When the torque of turning the screw in the middle position of the recommended value is reached, lock the rings of the sector shaft supports by punching the collar into the crankcase holes or by tightening the lock screws and lock nuts.
6. Install protective covers 20 and 25, plugs 33, bipod. Pre-tighten the bipod mounting nut. Make the final tightening of the bipod nut after installing the steering mechanism on the vehicle and attaching the bipod rod to the bipod.
Power steering adjustment
The steering gear must be removed from the vehicle in order to be adjusted.
For this:
1. Disconnect the pressure and drain hoses from the steering gear and secure the hoses in such a way as to prevent the complete leakage of oil from the hydraulic system.
2. Loosen the nut and remove the wedge screw from the yoke, remove the yoke from the mechanism.
3. Disconnect the bipod link from the bipod.
4. Turn away bolts of fastening and remove the steering mechanism.
Steering gear adjustment perform in the following sequence:
1. Fix the steering mechanism in a vise so that the discharge and drain holes are at the bottom. While manually turning the input shaft of the steering mechanism, drain the oil from the mechanism.
2. Lightly pressing the input shaft along its axis with your hand, shake the bipod. If axial movement of the input shaft is felt, adjust the screw bearing preload.
For this:
- using a beard and a hammer, carefully, without applying excessively strong blows, straighten the bead of the glass 3 (see Fig. 5.6), fixed in the grooves of the crankcase wall 9;
– by turning glass 3 clockwise, eliminate the backlash;
– check the moment of rotation of the input shaft, which should be no more than 3 Nm (0.3 kgfm). Measure the moment for no more than one revolution of the input shaft from any extreme position;
- screw the edge of the glass into the grooves of the crankcase wall
3. If the axial movement of the rotor is not felt or eliminated, and in the middle position of the bipod shaft when swinging the bipod, there is a gap, adjust the gearing.
For this:
– unscrew nut 24 and remove bipod 23;
– remove top 31 and bottom 25 protective covers;
– remove retaining rings 26 and adjusting washers 27;
- straighten the adjusting washers;
- simultaneously turning the supports 28 of the bipod shaft counterclockwise (when viewed from the side of the splined end of the bipod shaft), eliminate the gap in the engagement. Make adjustments in the position of the bipod shaft corresponding to the middle position of the gear sector;
- check the moment of turning the bipod shaft, which should be within 35–45 N m (3.5–4.5 kgf m) when the bipod shaft passes through the middle position. If the backlash cannot be eliminated after adjusting the bearing preload and the gear gap, then the backlash is caused by wear on the ball screw. In this case, the steering mechanism must be repaired;
- install the adjusting washers, bend one of the mustaches in both adjusting washers into the groove of the bipod shaft support and install the retaining rings.
4. Install the steering gear on the vehicle, install the bipod and hand-tighten the bipod nut.
5. Connect the cardan shaft yoke, the discharge and drain hoses, avoiding their twisting and sharp bends, fill the hydraulic system with oil (see above).
6. Attach the bipod link, tighten and cotter the ball stud nut, tighten the bipod nut.
Repair
When repairing the steering, use the data in Table. 5.1.
Removal and disassembly of the tie rod do it in the following order:
1. Loosen the steering link pin nuts.
2. Turn away nuts and press out adaptation fingers from levers.
3. Remove spring caps 7, rubber protective rings 6 and spherical washers 4 and 5 from fingers 10 (see Fig. 5.7).
4. Fix the rod in a vice, unscrew the lock nuts 1 (Fig. 5.10) and 3 and unscrew the tips 4 and the adjusting fitting 2.
5. Unscrew the threaded plug (Fig. 5.7) of the tip and remove the spring 2, the heel 3, the pin 10 and the cracker 11.
Rice. 5.10. Tie Rod End:
1 – nut with left thread; 2 - adjusting fitting; 3 – nut with right-hand thread; 4 - tip
Thrust Assembly do it in reverse order.
Replace the finger complete with cracker. It is not recommended to replace only the finger, since the rusk sphere wears out unevenly and when replacing one finger, it is not possible to achieve good mating between the finger and rusk spheres.
Before assembly, lubricate the hinge parts according to the lubrication table. When installing the screw plug, screw it in until it stops, and then unscrew it 1/2 turn and tighten it in this position.
Removal, disassembly and assembly of bipod traction produced in a similar way.
Tightening torques for main steering connections, N m (kgf m):
Steering wheel nut ..... 64–78 (6.5–8.0)
Bracket stud nuts (column mounting stepladders) ..... 18–25 (1.8–2.5)
Nut of fastening of forks of the hinge of a steering shaft..... 20–25 (2,0–2,5)
Bolts for fastening the crankcase to the frame of cars of the family:
UAZ-31512.....55-78 (5.6-8.0)
UAZ-3741.....55-61 (5.6-6.2)
Bipod nut ..... 196–275 (20–28)
Tie rod lock nuts ..... 103–128 (10.5–13.0)
Nut of fastening of a spherical finger..... 49–69 (5–7)
Steering gear without hydraulic booster
Removal and disassembly of the steering column make cars of the UAZ-31512 family in the following order:
4. Loosen the steering wheel mounting nut by 2–3 turns and, using a puller (Fig. 5.11), loosen the steering wheel mounting on the steering shaft cone. Loosen the steering wheel nut and remove the steering wheel.
5. Turn away nuts and remove a ladder of fastening of a steering column and a rubber plug.
6. Turn away a nut and take the top coupling bolt of the hinge of a steering column.
7. Remove the steering column.
8. Remove screw 27 (see Fig. 5.1) and take out bushings 26 and 28.
9. Remove the lower retaining ring 20, the protective washer 21, the spring 22 and the expansion ring 23.
10. Remove the steering shaft 31, press out the bearings.
Disassemble the steering column only to replace worn bearings.
Assemble and install the steering column in the reverse order
Rice. 5.11. Removing the steering wheel
Removing the steering gear from cars of the UAZ-31512 family perform without removing the steering column in the following order:
1. Turn away a coupling bolt of the hinge of a steering column.
2. Turn away a nut of fastening of a bipod of the steering mechanism and remove a bipod (fig. 5.12) by means of a puller.
3. Turn away bolts of fastening of a case of the steering mechanism to a side member of a frame.
4. Remove the steering gear and drain the oil
Removing the steering gear from cars of the UAZ-3741 family do it in the following order:
1. Remove the turn signal switch.
2. Disconnect the signal wire.
3. Remove the signal button and contact parts.
4. Loosen the steering wheel mounting nut by 2–3 turns and, using a puller (see Fig. 5.11), loosen the steering wheel mounting on the steering shaft cone. Loosen the steering wheel nut and remove the steering wheel.
5. Turn away nuts and remove a ladder of fastening of a steering column and a rubber plug.
6. Disconnect the bipod link from the bipod.
7. Turn away bolts of fastening of a case of the steering mechanism.
8. Remove the steering gear together with the steering column.
On vehicles with a steering column with a universal joint (see Fig. 5.2, a), the removal of the steering mechanism is possible without removing the steering column (similar to the removal of the steering mechanism of cars of the UAZ-31512 family).
Rice. 5.2. The steering gear of cars of the UAZ-3741 family:
a - variant design - steering column with cardan joint; 1 - bipod; 2 – crankcase; 3 – bottom cover; 4 - shims of worm bearings; 5 - roller; 6 - worm; 7, 8, 29 - bearings; 9 - cork seal; 10 - filler plug; 11 - gasket; 12 - side cover of the crankcase; 13 - pin; 14 - lock washer; 15, 35 - bushings; 16 - bipod shaft; 17 - cuff; 18 - washer; 19 - nut; 20 – steering wheel; 21 - column; 22 - steering shaft; 23 - bipod shaft bearing; 24 - adjusting screw of the gap in engagement; 25 - cap nut; 26 - roller axis; 27 - stuffing box; 28 – a wire of a sound signal; 30, 39 - plastic bushings; 31 - screw; 32 - spacer sleeve; 33 - protective washer; 34 - hinge; 36 - retaining ring; 37 - springs; 38 - contact sleeve
Disassembly of the steering gear type worm-roller do it in the following order:
1. Disconnect the universal joint from the worm shaft (on vehicles of the UAZ-31512 family).
2. Loosen the nut and remove the lock washer from the adjusting screw.
3. Turn away bolts of fastening of a lateral cover of a crankcase.
4. With light blows of a copper or aluminum drift on the end of the bipod shaft, remove the bipod shaft together with the roller and cover and carefully remove the gasket.
5. By screwing the adjusting screw into the crankcase side cover, remove the side cover and the adjusting screw from the bipod shaft.
6. Turn away bolts of fastening of the bottom cover of a crankcase and remove a cover together with linings, an outer ring of the lower bearing and a cage with rollers.
7. Remove the shaft with the worm assembly and the separator with the rollers of the upper bearing from the crankcase. The outer ring of the upper bearing, the cuff of the steering gear shaft, the cuff of the bipod shaft and the bipod shaft bushing should be pressed out of the steering gear housing only if they are replaced.
Disassembly of the steering gear type screw-ball nut-sector do it in the following order:
1. Remove the protective covers and retaining rings of the sector shaft support rings on both sides.
2. Remove the plugs in the holes Г 7 mm of the crankcase above the sector shaft supports and straighten the support flanges or loosen the locking screws, as indicated in the “Engagement adjustment” subsection.
3. With light blows of a copper or aluminum drift on the end of the sector shaft, first from the side of the upper support, and then from the side of the capstan end, remove the support rings and the sector shaft.
4. Turn away bolts of fastening of the bottom cover of a crankcase and remove it together with adjusting linings, an outer ring of the bottom bearing of the screw and a cage with balls.
5. Remove from the crankcase the screw assembly with the nut-rail, the inner races of the bearings and the separator with the balls of the upper bearing. The outer ring of the upper bearing of the propeller, the collar of the propeller shaft, the sealing rings in the body and cover, the sealing and protective rings in the bearings of the sector shaft, remove only if it is necessary to replace them. Press out the inner races of the bearings and remove the rack nut with screws also only if it is necessary to replace the bearings and parts of the ball screw pair of the steering mechanism. Do not unnecessarily disassemble the rollers in the rings of the sector shaft supports.
Assessment of the technical condition of parts.
After disassembly, thoroughly rinse and inspect each part.
If a hardened layer in the form of shells appears on the surface of the worm, screw, nut-rack or shaft-sector of the steering mechanism, as well as if they are significantly worn, replace the parts.
Replace the worm (screw) bearings with new ones if all shims must be removed to eliminate axial play or if the working surfaces of the rings and rollers (balls) are damaged.
If there are shells, cracks, dents on the working surfaces of the bipod shaft roller, or play has formed in the ball bearings or in the fit on the axle, then drill out the axle head, knock out the axle, remove the roller. Insert a new roller and axle into the groove of the shaft.
It is allowed to mount by electric welding on the bipod shaft of the old axle - from the side of the drilled head, and the new axle - from both sides. At the same time, do not allow the roller to overheat.
Replace the sector shaft support rings if there are pits, dents, or significant wear on the surfaces under the rollers.
Replace the bronze crankcase bushing if there is significant wear on one side. After pressing a new bushing into the crankcase, iron it with a brooch to a diameter of 35 + 0.027 mm.
Assembly of the steering gear type worm-roller proceed in reverse order, taking into account the following:
1. In the case of replacing the worm, when pressing it onto the shaft, it is necessary that the high spline of the worm coincides with the keyway of the shaft. The discrepancy between the end of the shaft and the end of the undercut on the worm should not exceed 0.25 mm.
2. The bipod shaft roller should turn freely by hand. Lubricate the cylindrical part of the bipod shaft and the roller when installed in the crankcase with liquid lubricant. Lubricate cylindrical and tapered bearings, the outer surfaces of the worm and oil seals with Litol-24 grease.
3. Tighten the worm bearings and adjust the engagement of the roller with the worm, as indicated in the section “Adjusting the worm-roller steering mechanism”.
4. The runout of the shaft neck under the steering column ball bearing on the assembled steering should not be more than 3 mm. When checking, the shaft assembly with the worm should easily turn in the worm bearings (for cars of the UAZ-3741 family).
5. When installing the steering mechanism on cars of the UAZ-3741 family, first tighten the bolts securing the crankcase to the frame side member, and then fix the column. At the same time, pre-select the required number of shims installed between the rubber bushing and the column mounting bracket to prevent the shaft from bending.
Assembling the steering gear type screw-ball nut-sector proceed in the reverse order of disassembly, bearing in mind the following:
1. Assemble the screw and the rail nut mating with it with balls 7.144–40 GOST 8722–81 of only one group and from one batch.
2. The bolts fixing the gutter cover must be tightened to a torque of 8–10 N m (0.8–1.0 kgf m). One of the petals of the lining, coinciding with the edge of each bolt, after tightening, should be bent to the edge of the bolt.
3. The rotation of the screw in the nut-rail should be smooth without jamming and jerking. The torque required to turn the screw should be 0.3–0.5 N m (0.03–0.05 kgf m). Check the torque after turning the rack nut twice along the entire length of the screw.
4. Adjust the preload of the screw bearings with shims before installing the sector shaft, while the number of 0.05 mm thick shims must be at least three. Axial and radial movement of the screw is not allowed. Control its absence with a force of 49–78 N m (5–8 kgf m).
5. When installing the sector shaft, the middle tooth of the sector must enter the middle cavity of the rack nut.
6. Install the sector shaft supports by smoothly, without distortions, pressing into the crankcase holes, while the support rollers must be of the same group, and one plastic insert must be installed between them to prevent them from falling out. When installing the supports of the shaft-sector, the grooves on the outer ends of the rings of the supports should be opposite the holes in the crankcase Zh 7 (for plugs), while the risk on the ring should be as far as possible from the gearing.
7. After installing the retaining rings, check the axial movement of the sector shaft, which should be within 0.02–0.1 mm with a force of 15–20 N (1.5–2.0 kgf).
8. Adjust the engagement of the rack nut and the sector shaft by simultaneously turning the rings of the sector shaft supports in the crankcase holes clockwise, as viewed from the side of the splined end of the sector shaft. In this case, the grooves on the outer ends of the rings, intended for their rotation, should be located in the same plane.
9. After finishing the adjustment of the engagement, fix the position of each support of the shaft-sector, as indicated in the subsection “Adjustment of the engagement”.
10. Before installing protective plastic covers, grease the surfaces of parts covered by them with Litol-24 grease.
Removing the steering gear do it in the following order:
1. Disconnect the hoses from the steering mechanism by unscrewing the bolt fittings and fix the hoses so as to prevent the complete leakage of oil from the hydraulic system or drain the oil into a clean bowl.
2. Turn away a nut of a bolt of fastening of a plug of the universal joint, take a bolt, remove a plug from an output shaft of the mechanism.
3. Loosen and unscrew the nut that secures the bipod link pin to the bipod, remove the pin from the bipod hole.
4. Turn away bolts of fastening of the steering mechanism and remove the steering mechanism.
Power steering disassembly
1. Drain the oil from the mechanism by turning the input shaft from stop to stop.
2. Using a puller, remove the bipod from the bipod shaft.
3. Remove the top and bottom protective covers of the bipod shaft supports.
4. Remove the bipod shaft support circlips and lock washers.
5. By gently pressing the press, press out the bipod shaft together with the upper support, without completely removing the bipod shaft from the lower support.
6. Remove the top support with rollers from the bipod shaft without spilling the rollers.
7. By gently pressing the press on the upper end of the bipod shaft, press out the lower support of the bipod shaft.
8. Remove the lower support with rollers from the bipod shaft, remove the bipod shaft.
9. Remove the o-rings of the bipod shaft supports from the crankcase grooves.
10. Turn away bolts of fastening of the case of the distributor.
11. Carefully, without distortions, remove the distributor housing.
12. Remove the screw with the hydraulic distributor and piston rack from the crankcase.
13. Remove the bearing cup with bearing and nut from the crankcase.
Ball Screw Disassembly
1. Bend the petals of the ball guide lining away from the edges of the bolts.
2. Turn away bolts of fastening of an overlay of a spherical guide.
3. Remove the ball guide from the piston rack.
4. Turn the piston rail upside down with the holes for the ball guide and, turning the screw by hand, pour out the balls.
5. Remove the screw from the piston rack.
Dismantling of the hydrodistributor
1. Carefully press out the sleeve pin and torsion bar pin.
2. Using a special tool, remove the rotor with sleeve and torsion bar from the propeller.
3. Carefully remove the sleeve from the rotor.
4. Remove the torsion bar from the rotor. O-rings and cuff installed in the distributor housing and in the piston rack, take out only if they are replaced.
Assessment of the technical condition of parts
After disassembly, rinse thoroughly, dry with compressed air and inspect the parts.
If the working surface of the screw, piston rail, bipod shaft, bipod shaft supports or rolling elements of the bearings has peeling of the hardened layer in the form of shells, as well as if they are significantly worn, replace the parts.
Replace the bipod shaft if its splines are twisted.
Replace rubber o-rings if damage is found or the cross-sectional shape changes (rings must be round) visible to the naked eye.
When replacing a screw or piston rack, parts should only be replaced with parts of the same group. The group number is marked on the end face of the screw and piston rack.
Hydraulic booster parts (rotor, sleeve and torsion bar) are selected individually at the factory, and therefore can only be replaced as a set. In this case, it is necessary to adjust the hydraulic center on a special stand. The shaft bearings must be replaced together with the rollers.
The assembly of the power steering mechanism is carried out in the reverse order of disassembly, taking into account the following:
Assembling the Ball Screw.
To assemble the ball screw, balls Ø 7.144 ± 0.014 mm are used, sorted into seven groups by diameter at intervals of 0.004 mm. To assemble, all balls must be of the same group. To facilitate assembly, use a dosing tube (tube 10x1 mm, length 275 mm).
1. Insert the screw into the hole in the piston rack and align the first turn of the helical groove with the ball guide hole in the piston rack closest to the screw flange.
2. Insert the dosing tube filled with balls into the opening of the ball guide so that the balls begin to fill the screw channel.
3. To fill the screw channel, slowly turn the screw counterclockwise until the first ball appears in the second hole for the ball guide.
4. Fill the groove of the ball guide with the remaining balls. To prevent the balls from scattering, thickly lubricate the chute with Litol-24 grease.
5. Insert the groove filled with balls together with the second groove into the hole for the ball guide in the piston rack.
6. While holding the ball guide from falling out, check the screw turning torque, which should be 0.5–0.8 N m (0.05–0.08 kgf m). Rotation should be smooth, without jerks and jamming. If the torque is greater or less than required, replace the entire set of balls with a set of a smaller or larger diameter, respectively. Mixing balls of different size groups is not allowed.
7. Install the ball guide overlay, wrap the bolts of its fastening and lock them by bending the overlay petal onto the edge of each bolt.
Installation of fluoroplastic sealing rings
Fluoroplastic sealing rings are used to seal moving joints: sleeve-distributor housing, rail-piston-crankcase, screw-rail-piston. In the bipod shaft supports, a protective fluoroplastic ring is used together with a rubber one. Re-installation of PTFE rings is not allowed. The inner rings are installed with their preliminary deflection inward, the outer ring - with preliminary stretching on a conical mandrel to a size sufficient for installation. After installing the rings, it is necessary to calibrate (settle) with special mandrels with exposure on the mandrel for 30 minutes (Table 5.2).
Assembling the steering mechanism from sub-assembled nodes
1. In cup 3 (see Fig. 5.6), install bearing disc 4, separator with rollers and ring.
2. Install rubber sealing ring 2 and nut 1 into the crankcase so that the protrusion of the nut coincides with the groove on the bottom of the crankcase.
3. Screw the cup into the nut 2-3 turns.
4. Install the piston rail assembly with the screw, rotor and sleeve into the crankcase so that the screw protrusion enters the bearing ring hole, and the piston rail teeth are parallel to the bipod shaft axis.
5. Install the roller bearing 10 on the screw.
6. Install the distributor body 34, fix it with bolts 37.
7. Adjust the tightness in the screw bearings (see subsection “Adjusting the power steering mechanism”).
8. Turning the input shaft and holding the piston rail from turning, install the piston rail so that the middle cavity of the rail is opposite the center of the hole for the bipod shaft. Install rubber rings 21.
9. Install support 28 with rollers 29 and sealing rings 22 on the shaft 30 of the bipod so that the mark on the support is opposite the middle tooth of the sector of the bipod shaft.
10. Insert the bipod shaft with the support into the crankcase so that the middle tooth of the sector enters the middle cavity of the rack and press the support.
11. Carefully, not allowing the rollers to spill, press in the second support of the bipod shaft.
12. Adjust the engagement of the sector of the teeth of the bipod shaft and the rack (see paragraph 3 of the subsection “Adjusting the power steering mechanism”).
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