Genuine Volvo 242 Rack and Pinions

Volvo 242 Rack and Pinions Parts and Q&A

• Steering Gear
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  Q: How to install the ball bearing onto the pinion shaft in rack and pinions and complete the assembly process on Volvo 242?

  A:

  Press the ball bearing onto the pinion shaft and fit the circlip and thrust washer. Install new 'O' rings on the rack bushing and press it into the housing, ensuring the locking tabs for the bearing fit correctly into the recesses. Grease the rack with Calypso! D4024-OK grease and insert it into the pinion side of the housing, taking care not to damage the bushing with the rack teeth. Grease and insert the pinion, pack the bearing with grease, fit a new 'O' ring on the pinion nut, and secure the nut with the locking circlip. Fill the cavity on top of the nut with grease and fit the pinion dust seal. Install a new 'O' ring on the pre-loading piston, grease the pinion, and fit the piston and spring, then place the cover without final tightening. Connect a torque gauge to the pinion and check the torque, cranking back and forth to each end of travel; the torque should be 5-15 lb fin (0.06-0.17 kg f m). To increase the torque, screw in the preload, and once the correct torque is achieved, fit the split pin to lock the cover and attach the dust cover. Extend the rack fully and fill the tooth spaces with grease, then crank the rack in and out again, applying more grease as needed, with a total grease charge of approximately 1 oz (25 grams). Finally, fit the steering rods.