Genuine Volvo 244 Rack and Pinions

Volvo 244 Rack and Pinions Parts and Q&A

• Pinion Shaft
  1206952
  Q: What steps should be taken to clean and inspect the Rack And Pinions components before reassembly on Volvo 244?

  A:

  Clean all external dirt and inspect the inner ball joints for wear before dismantling. Undo the left side bellows clip, ease off the bellows and empty the oil. Bend up the peening lock on the inner ball joint then remove the left side trackrod and then the right side trackrod. Remove the cover on the pre-loading device and pull out the spring ring and piston. Remove the pinion cover, remove the pinion, top bearing, and spacer sleeve, along with the shims. Pull out rack to pinion side of rack and pinions. Clean all in white spirit, examine rack bush for wear, renew if necessary, examining lower bearing of pinion by using puller if required to renew. Inspect the rack and pinions for wear and damage and replace all seals and gaskets accordingly.
• Steering Gear
  1229322
  Q: How should the rack and pinions be prepared and assembled for the steering gear on Volvo 244?

  A:

  Oil all the parts before they are assembled using engine oil. Fit the oil seal, bearing, and 'O' ring on the valve housing cover with the plastic ring and 'O' ring on the rack bearing sleeve. Install the circlip on the inner tube, and place the 'O' ring and plastic ring onto the rack piston, making sure the 'O' ring is under the plastic ring. Fit the spacer sleeve, oil seal, and plastic ring on the rack from the teeth side, covering the teeth with wide tape to protect the oil seal fitting. After removing the tape, fit the spacer sleeve. In the left side housing, install the oil seal (with the lip facing outwards), the bushing (with an appropriate drift), and the two 'O' rings. Fit the spacer washer and two 'O' rings in the right side housing. On the left side housing, install the inner tube and its spacer washer, and finally fit the rack fitted with seal and spacer rings into the inner tube, pressing in the seal and spacer rings in advance of fitting the retaining circlip. Fit the lock bolt to the outer tube to the left side housing, aligning the hole for the lock bolt with the hole in the housing. Insert the bearing sleeve in the outer tube and make sure the holes for the lock bolt are in line. Fit the seal and plastic ring in the bearing sleeve using tape on the sharp edge of the rack to protect the seal. Connect the pipe with rubber seal in the right side housing, fit the right side housing, corresponding holes of the lock bolt and connecting pipe, and fit the lock bolt and connect the pipe. Install the outer race for the pinion lower bearing and then fit the pinion carefully so as not to damage the valve, followed by the inner race and ball retainer on the pinion, fixed on the lock ring and nut without locking the nut. Fit the outer race and spacer sleeve and press down the spacer sleeve until it bottoms on the bearing and measure the distance between the spacer ring and housing to know the gasket thickness required. Fit the chosen gasket(s) and Volvo tool 5054, which represents the cover with the center removed for nut accessibility when adjusting the rack and pinions in the car. Install the 'O' ring in the valve housing, install the housing, and fit the coil spring in the valve housing big end first, then fit the valve housing cover, making sure the spring does not get caught. The pinion shaft shoulder should be 0.06 in (1.5 mm) above the face of the cover, adjusting it if required by moving the lower bearing inner race. Fit the pre-loading piston without 'O' ring fitted in the housing and measure the distance between the housing and piston face with a feeler gauge and steel ruler, selecting shims equal to the distance measured plus 0.002-0.006 in (0.05-0.15 mm) for correct end clearance. Install the 'O' ring and spring for the pre-loading piston, install the chosen shims and cover. Connect the torque gauge to the pinion shaft and move the rack back and forth for its entire travel, checking to make sure the torque registers between 5-15 lb fin (0.09-0.17 kg f m). If too much, stop the rack and recalibrate the pre-loading piston. If the rack gets jammed with the piston removed, it needs to be renewed. Finally, fit the oil pipes and steering rods; the valve adjustment, filling power steering oil, and lubricating oil are carried out after the rack and pinions are refitted in the car.