module 1–steering wheel and column

Transcription

®
Textbook
Steering And Suspension
Program 3
IMPORTANT NOTICE
This material provides general directions for collision damage repair using tested, effective procedures. Following them will help assure the reliability of the repair.
I-CAR cannot accept responsibility for any individual repair, nor can it warrant to the quality of such repair.
Anyone who departs from the instructions in this program must first establish that neither personal safety nor
the integrity of the repair of the vehicle is compromised by the choice of methods, tools, or supplies.
I-CAR does not endorse or recommend any brands or makes of vehicles, repair equipment and supplies or
other products. The appearance of various makes and brand names in any I-CAR material is purely coincidental
and is based on the availability of those products at the time of production.
All recommendations presented in this program are based upon research programs or upon tests conducted
by laboratories, manufacturers, or selected collision repair facilities. If performed as outlined, these recommendations will provide the basis for a thorough, professional repair.
© 2003
by the Inter-Industry Conference On Auto Collision Repair (I-CAR) All Rights Reserved
Steering And Suspension Program 3 v.5.1
© 2003 Inter-Industry Conference On Auto Collision Repair
2
CONTENTS
Module 1–Steering Wheel And Column.......................................................................................................... 4
A. Steering Column Parts ............................................................................................................................... 4
B. Steering Column Safety Features ............................................................................................................. 7
C. Steering Wheel Removal And Installation............................................................................................13
D. Review.........................................................................................................................................................16
Module 2-Parallelogram Steering Systems.......................................................................................... 17
A. System And Operation ............................................................................................................................17
B. Steering Gear..............................................................................................................................................17
C. Sector Shaft ................................................................................................................................................21
D. Pitman Arm ................................................................................................................................................22
E. Idler Arm ......................................................................................................................................................24
F. Center Link ..................................................................................................................................................26
G. Tie Rods ......................................................................................................................................................28
H. Steering Damper.......................................................................................................................................29
I. Parallelogram Steering Inspection ...........................................................................................................30
J. Review...........................................................................................................................................................30
Module 3-Rack And Pinion Steering Systems ..................................................................................... 31
A. Rack And Pinion Overview.....................................................................................................................31
B. Rack And Pinion Parts ..............................................................................................................................32
C. Rack And Pinion Inspection....................................................................................................................36
D. Review.........................................................................................................................................................39
Module 4-Power Steering ..................................................................................................................... 40
A. Power Steering Overview........................................................................................................................40
B. Power Steering Pump ...............................................................................................................................41
C. Power Steering Hoses ..............................................................................................................................44
D. Power Steering Belt ..................................................................................................................................47
E. Power Steering Fluid..................................................................................................................................50
F. Four-Wheel Steering Systems ..................................................................................................................56
G. Review.........................................................................................................................................................57
Steering And Suspension Program 3 v.5.1
3
MODULE 1–STEERING WHEEL AND COLUMN
Topic A. Steering Column Parts
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I-CAR RECOMMENDED TRAINING PATHS
Select the Demonstration Icon found on screen
A-1 of your CD-ROM for a demonstration of
training paths.
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A-3 Parts on a steering column include the steering wheel, shafts, and
U-joints.
Steering column parts include but are not limited
to:
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the steering wheel.
steering shafts.
the steering column jacket.
universal joints (U-joints).
brackets.
A-2 Steering columns are used to transfer driver input to the steering gear.
Steering columns are designed to:
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receive input from the steering wheel.
transfer the steering action from the column to
the rack and pinion or parallelogram steering
gear.
collapse upon impact with the driver.
house accessory controls such as a turn signal
switch or high beam switch.
Steering And Suspension Program 3 v.5.1–Module 1
4
A-4 This steering shaft connects the upper steering shaft to the steering gear.
A-6 The U-joint allows the shaft to rotate at an angle.
Steering column shafts transfer the action of the steering wheel to the steering gear. The steering shaft may
be comprised of the lower, intermediate, and upper
steering shafts or just upper and intermediate shafts
depending on steering system design.
Universal joints (U-joints):
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allow the steering column to rotate at angles.
attach to or are part of the flexible coupling used
for steering gear input.
may be used in two or more locations on the
upper and lower steering column.
A-5 The steering column jacket houses the steering shaft.
The steering column jacket:
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houses the steering shaft and related parts.
attaches to the vehicle body.
may be one or two piece.
5
A-7 Tamper-resistant fasteners may be used to help deter theft.
Upper steering column parts may include the:
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steering column shaft.
turn signal switch.
ignition lock cylinder. Some lock cylinders have
tamper-resistant fasteners. The tamper-resistant
fasteners typically have heads that twist off during
installation. To remove the fasteners, a slot may
have to be cut into the bolt head.
high beam switch.
windshield washer switch.
The 2002 Mazda 626 has tamper-resistant fasteners that are used to install the lock cylinder. During
installation, the fastener heads are designed to shear
off to help prevent removal. To remove the existing
fasteners, a screwdriver and hammer are used to
create a slot in the top of the fastener. The slot is
used with a screwdriver for removal.
A-8 The clock spring and steering wheel are part of the upper column
assembly.
Additional steering column parts include:
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springs, seals, bearings, and mounting brackets.
the upper and lower shroud or trim cover.
the clock spring. The clock spring provides a continuous electrical connection between the driver
airbag system wiring and the airbag module. It
may also provide an electrical connection for the
horn and other vehicle accessories. Other names
for the clock spring include the spiral cable or
SIR coil.
the steering wheel.
STEERING COLUMN
A-8 of your CD-ROM for a demonstration on
the different parts of a steering column.
TAMPER-RESISTANT FASTENERS
A-7 of your CD-ROM for a demonstration of
tamper-resistant fasteners.
6
Topic B. Steering Column Safety
Features
Collapse
B-2 Some column designs allow one shaft to compress inside another
upon impact.
B-1 Steering columns are designed to collapse at either the U-joint or
convoluted area.
Upper column may use:
Steering columns have safety features built into the
steering column that absorb the driver impact by
collapsing at a specific point. By collapsing upon
impact, injury to the driver may be reduced. Collapsing the steering column also prevents the steering
wheel and column from being pushed up toward
the driver during a frontal collision.
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Steering column collapse is managed in two parts,
upper and lower. Some steering systems control
column collapse by linking the lower section to two
or more offset universal joints. The universal joints
allow the section to fold upon impact.
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two shafts, where one compresses inside the other
upon impact. The shaft has plastic inserts that
lock the outer shaft to the inner. Upon impact,
the plastic inserts sheer, allowing one shaft to
telescope inside the other. Other types of steering
columns may use steel balls in a plastic retainer
that allow the shaft to roll forward inside the tube
upon impact.
a steel mesh or convoluted area that compresses
upon impact. Steering columns may have one
or two convoluted areas on the steering shaft
depending on the design.
7
B-3 Inspect the capsules to ensure they have not been damaged.
B-6 The wheel is rotated to check for noise, wobble, or runout.
Some systems have capsules on the steering column
bracket assembly. These are designed to break away
during an airbag deployment or driver impact on the
steering wheel. During inspection, the capsules must
be securely seated in the bracket slots and checked
for looseness when pushed or pulled by hand.
When inspecting the steering wheel, check for:
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Some vehicles have a safety feature in the steering
column that prevents the steering wheel from being
locked when the transmission is in gear and the
vehicle may be moving. The column ignition lock
system consists of a:
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loose mountings.
steering wheel wobble or runout. This can be an
indication of a bent steering shaft.
noise while turning the steering wheel.
abnormal steering effort.
a damaged airbag module or cover.
damaged wiring or connectors.
steering column electric park lock.
park position switch.
The steering column electric park lock contains a
spring-loaded pin that mechanically prevents the ignition key cylinder from being turned to the LOCK
position when the transmission is not in the PARK
position. If vehicle power is lost or the transmission
is not in the PARK position, the driver will not be
able to turn the ignition key to the LOCK position
and will not be able to remove the ignition key from
the column.
Common collision-related damage to the steering
wheel includes:
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a cracked or bent steering wheel.
damage resulting from airbag deployment.
8
B-7 The column shift lever should be checked for abnormal shifting effort.
Additional steering column inspection items include
checking the:
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ignition lock cylinder for proper operation and
turning effort.
column shift lever for abnormal shifting effort,
loose mounting, or a misaligned shift select indicator.
vehicle movement while it is in PARK. This helps
determine if the shift column is functioning properly.
When checking for proper shifting, note that some
late model vehicles can be shifted without applying
the brake first.
B-8 A dial indicator or straightedge may be used to check for steering
shaft runout.
When inspecting a steering column off the vehicle,
check:
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shaft runout. Specifications may be available.
length dimensions of the steering column.
General Motors recommends that any frame damage
that could cause a bent steering shaft must have the
steering shaft runout checked. Using a dial indicator at
the lower end of the steering shaft, rotate the steering
wheel. Runout should not exceed 1.6 mm.
GM recommends testing for straightness of the
column by placing a straightedge against various
locations on the intermediate shaft.
9
Listed below are possible conditions, causes, and
corrections that may occur from a damaged steering column:
Condition: Rubbing sound when turning wheel
Possible Cause: Column rubbing on shroud
Correction: Realign shaft or shroud
B-9 The injected plastic in the steering column will sheer upon airbag
deployment.
If the steering column has injected plastic to hold the
column in place, visually inspect the column to make
sure the plastic has not sheared from the force of an
impact. If the injected plastic on the steering shaft has
sheared, a new steering shaft must be installed.
Some vehicle makers require the entire steering
column assembly and lower steering column coupler
be replaced following an airbag deployment. Some
require replacing just the steering wheel.
Condition: Steering wheel catches or sticks in certain
positions or is difficult to turn
Possible Cause: Excessive friction in the steering
column or intermediate shaft/coupler
Correction: Isolate and correct condition
Condition: Excessive steering wheel play
Possible Cause: Column bearing wear, loose steering
gear bolts, damaged or worn steering gear, loose or
worn damaged steering column bearings
Correction: Correct condition
Some vehicle makers may have mandatory replacement procedures following an airbag deployment.
Vehicles that require replacing the steering wheel
following deployment include the:
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2002 BMW 7 series.
2002 Dodge Caravan/Town and Country.
2002 Mercedes SLK.
2002 Volvo S40, S60, S80, V40, V70.
Steering column and lower coupling replacement
following deployment is recommended for the 2002
Chrysler 300M, Concord, and Dodge Intrepid, Neon,
and Stratus.
B-12 The steering column should be measured and compared to the vehicle
maker’s specification to determine if it has compressed upon impact.
When repairing a steering column:
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replace any damaged steering column parts.
if the steering column does not measure to
specification, it may require replacement of the
complete column. Do not pull the steering column
back to specification.
do NOT straighten steering column shafts.
10
INSPECTING A STEERING COLUMN
Refer to screen B-13v for a video on how to
inspect a steering column for damage.
B-15 The tilt lever is typically connected to a spring-loaded locking
mechanism that holds the steering wheel in place.
B-14 The lock and unlock lever releases the tilt steering for driver adjustment.
Tilt steering columns:
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tilt the steering wheel up or down according to
the driver’s preference.
have the other end of the upper shaft connected
to the lower or intermediate shaft using a universal
joint.
When the steering wheel tilt lever is released, the
spring-loaded locking mechanism is released. The
locking mechanism has teeth that fit into a splined
collar on the steel column jacket. This type of design
is common for vehicles that tilt just behind the steering wheel.
Power tilt steering column systems may have a power
tilt mechanism with a memory function built into the
tilt operation. If equipped with a memory function,
the computer uses a position sensor to determine
the location of the column.
Some systems tilt at a joint just behind the steering wheel. Others tilt at the U-joint just before the
cowl.
11
B-17 To check for damage to the tilt steering column, the tilt lever is
released and the column is moved up and down. Damage may be indicated by noise, binding, or a loose pivot.
When inspecting a tilt steering column, check for:
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noise in the column while tilting it.
binding or slipping.
loose mountings.
a loose pivot.
the locking mechanism malfunctioning so that it
does not lock in any position.
Also, make sure the steering column returns to the
top tilt position when the tilt lever is released. If the
column does not return to the top tilt position, check
the springs.
B-18 A broken spring mechanism may cause the steering wheel to fall
when the release lever is pulled.
Possible tilt steering column problems include:
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binding pivot pins.
a weak or broken lock spring.
a tilt lever that is too loose or too tight.
On one type of vehicle, to make tilt lever adjustments, move the tilt lever from the loose position to
the lock position 3 to 5 times; then measure the tilt
lever preload 10 mm from the end of the tilt lever
using a spring scale.
If the measurement is out of specification, adjust the
preload using the following procedures:
1. Loosen the tilt lever and set the steering column
in the neutral position.
2. Remove the 6 mm lock bolt, then remove the
stop.
3. Adjust the preload by turning the tilt lock bolt
left or right.
4. Pull up the tilt lever to the uppermost position and
install the stop. Check the preload again. If the
measurement is still out of specification, repeat
the procedure.
12
Topic C. Steering Wheel Removal And
Installation
B-19 Telescoping steering columns are designed to automatically move
the steering wheel inward or outward.
Telescoping steering columns:
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are used to adjust the position of the steering
wheel inward or outward.
can be adjusted as much as 50 mm (2") depending on the type of system.
may have one-touch release for both tilt and
telescopic adjustments.
Telescoping systems may also have automatic adjustments. These are sometimes combined with the autotilt mechanism.
C-1 The steering wheel is press-fit onto a spindle at the end of the steering shaft.
Steering wheels are:
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attached to the upper steering shaft.
press-fit onto the tapered portion of the steering
shaft.
secured with a lock nut in the center of the steering wheel and torqued to specification.
Diagnosing automatic telescoping steering columns
generally requires the use of a vehicle-specific scan
tool. Problems indicated may include a damaged
actuator, bad switch, poor connections, and damaged wiring.
13
Not all vehicles have column locks. Many late model
automatic transmission General Motors trucks and
sport utilities do not have the steering column or
steering wheel locking feature.
2002 vehicles that do not have column locks include
the Chevrolet and GMC C/K pickups (Silverado,
Sierra), C/K sport utility vehicles (Tahoe, Suburban,
Yukon, Denali, and Yukon XL), and the Cadillac
Escalade.
C-2 Almost all steering wheel removal procedures begin by disabling the
airbag system and removing the airbag.
When removing the steering wheel:
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disconnect the battery, first the negative, then
the positive battery cable.
disable the airbag. Disabling airbag systems
should be done following the vehicle maker’s
recommendations. The following is a common
airbag system disabling procedure:
1. Turn the ignition OFF.
2. Disconnect and isolate the battery cables.
Taping will prevent accidental grounding.
3. Remove one or more fuses.
4. Wait a specific amount of time before working on the system to allow the capacitors to
discharge.
5. Disconnect the backup power supply.
6. Disconnect the wire connectors for the driver
and passenger airbag modules. Shorting clips
may automatically short pins when the connector is disconnected.
make sure the front wheels are pointed straight
ahead, then lock the column.
remove the airbag module. The following is a
common airbag removal procedure:
1. Remove the airbag module retaining bolts.
2 Locate the airbag connector.
3. Disconnect the connector between the airbag
and cable reel.
4. Disconnect the horn switch, if equipped.
5. Remove the airbag module.
remove any accessory switches.
C-3 A steering wheel puller is used to detach the steering wheel from
the steering shaft.
When removing the steering wheel:
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disconnect any remaining electrical connectors.
Some connectors have caps or plugs that attach
to the ends when disconnected to protect them
from static electricity.
remove the steering wheel using recommended
tools, such as a steering wheel puller.
remove the clock spring. When removing a clock
spring, check the alignment of the coil to the
steering wheel. Adjustment of the coil may be
required. Follow the vehicle maker’s recommendations for centering the coil during installation.
If the coil is not properly centered, it may break
when the steering wheel is turned.
14
With the wheel removed, remove or disconnect the:
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Be careful not to bump or hammer on a collapsible steering column. The column is very
susceptible to impact damage.
shrouds or trim panel.
knee bolster.
lower U-joint.
shift linkage.
electrical and mechanical attachments.
C-7 The clock spring should be properly centered during installation to
prevent possible damage when rotating the steering wheel.
C-5 Unbolt the upper shaft from the lower shaft at the U-joint to remove
the steering column.
To remove the column:
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loosen or remove the toe plates at the cowl. A
toe plate may also be called a column seal or
steering joint cover.
loosen or remove support attachments to the
instrument panel.
remove the steering column assembly.
When installing a steering wheel, make sure the clock
spring is centered. Follow the vehicle maker’s procedure for aligning the clock spring. This prevents damaging the clock spring when the wheel is rotated.
When installing a replacement clock spring:
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Do not lay an airbag face down. Do not stand
a steering column on the airbag cover.
STEERING SHAFT OUT-OF-VEHICLE
INSPECTION
Refer to screen C-6v of your CD-ROM for a
video on inspecting a steering shaft out of
the vehicle.
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make sure the front wheels are still facing straight
ahead.
make sure the replacement clock spring is
centered. Some replacement clock springs are
shipped with a retainer to hold the clock spring
centered until it is installed. If the clock spring
does not have a centering retainer, carefully rotate
the clock spring clockwise until it stops. Then
rotate it counterclockwise until it stops. Count
the number of turns from stop to stop. Rotate
it back clockwise half the total number of turns
and apply tape to hold it in position.
install the replacement clock spring using the
new fasteners.
reconnect the clock spring electrical connector
at the base of the steering column.
15
Chrysler’s procedure for centering a clock spring:
1. Depress the two plastic locking pins to disengage
the locking mechanism.
2. Rotate the clock spring rotor clockwise until the
rotor stops.
3. From the end of the travel, rotate the rotor three
turns counterclockwise.
4. Make sure the wires are at the top.
5. Engage the locking pins.
6. From the center-locked position, rotate the clock spring
1⁄2 additional turn counterclockwise. The clock spring
wiring should now be at the bottom and properly
positioned for installation of the steering wheel.
C-10 Recycled parts must be inspected for damage before installation.
If using recycled steering columns:
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note that vehicle makers may not recommend
using recycled steering columns.
compare recycled parts to original parts to make
sure they are the same.
do NOT install recycled bushings or fasteners.
Do NOT install parts with:
C-8 When installing a steering wheel, it must be properly torqued to
ensure it does not loosen over time.
When installing a replacement steering wheel:
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make sure the replacement steering wheel is
centered.
note that the steering wheel may have master
splines or flat spots on the steering shaft that
align with the steering wheel splines. This ensures
proper steering wheel orientation.
torque the steering wheel lock nut. A steering
wheel that is not properly torqued may cause
the steering wheel to loosen over time.
When reinstalling the steering wheel:
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flood or water damage.
incorrect column length.
evidence of being heated, welded, or straightened.
After installing a recycled steering column, any
undamaged parts such as the original ignition lock
cylinder, airbag module, steering wheel, etc. may be
transferred to the new steering column.
Topic D. Review
TOPIC D. REVIEW
Refer to screens D-1 through D-3 of your
CD-ROM for review questions on steering
column repair.
reinstall accessory switches.
reinstall the airbag.
reactivate the airbag system.
road-test the vehicle for proper operation.
align the steering wheel as required.
16

module 1–steering wheel and column

Transcription

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