Genuine Volvo V40 Rack and Pinions

Volvo V40 Rack and Pinions Parts and Q&A

• Steering Gear
  8251803
  Q: How to remove and refit the steering gear assembly using Rack And Pinions on Volvo V40?

  A:

  To remove the rack and pinions, start by peeling back the carpet from the base of the steering column to gain access to the lower joint, with the Steering Wheel in its position so that the clamp bolt is accessible, and the steering lock is engaged. Unscrew the clamp bolt, mark the joint alignment points between the joint and rack and pinions, unscrew the column. Remove the rack and pinions retaining bolts from the sealing plate and cut off any cable ties if applicable. Tighten the rear wheels, engage the handbrake, loosen the front wheel nuts, jack up the car and remove the front roadwheels. Remove the undershield under the engine/transmission, the front pipe of the exhaust system, and the bolts of the heat shield if there is one. Support the engine transmission with a hoist or jack, then remove the mounting bolts from the front and rear of the transmission and the crossmember, and recover the mounting rubbers and spacers. Unbolt the mounting of the rear engine/transmission and pull the assembly slightly forward for improved access to the rack and pinions, taking care no strain is placed on wiring or hoses. Remove the heat shield from the rack and pinions housing, secure the power steering hoses with clamps to reduce fluid loss, mark the unions, unscrew the feed and the return pipe union nuts and catch any spillage. Free power steering pipes from clips, recover sealing rings and plug the ends to prevent leakage. Extract split pins, unscrew the retaining nuts from the track rod ball joints, breaking them free of the hubs. Remove rack and pinions mounting clamps, and remove the rack and pinions. For overhaul, examine the assembly for wear or damage, make sure the rack moves freely and check for leaks. If necessary, request the advice of a specialist whether the unit should be overhauled or replaced, as there are some parts that can be renewed only by a home mechanic. For refitting, it is important to check that the mating surfaces are clean, that the rack and pinions is in place, and that the mounting rubbers and clamps are in place and tightened to specified bolt torque. Refit the sealing plate and make sure that the gaiter is correctly located. Line up the marks made during removal, engage the steering column joint and tighten the clamp bolt. Install new sealing rings in power steering pipes, reconnect power steering pipes, and make sure power steering pipes are routed and held in place before putting on union nuts. Find the track rod ball joints in the swivel hubs, screw the retaining nuts and secure with new split pins. Refit the heat shield, shift the engine back into normal position and secure the rear mounting. Make sure that mounting rubbers and spacers are properly fitted and that the crossmember is properly positioned and that all bolts are tightened to the recommended torque. Refit exhaust heat shield and front pipe, top up the fluid reservoir and bleed the hydraulic system. Finally, tighten the engine undershield, refit the roadwheels, drop the car and tighten the wheel nuts and check the alignment of the front wheels.