Steering System - Power Saab 900 I

DESCRIPTION

System consists of a rack and pinion steering gear with a servo valve which regulates the oil flow to a servo plunger on the rack. Hydraulic pressure is generated by an oil pump which is driven by a crankshaft driven belt. Pump and hydraulic reservoir are one unit. Pump contains a control valve which regulates oil pressure and flow.

FLUID TYPE

Use General Motors power steering fluid. DO NOT use ATF type fluid.

Scheme 1

1. Clean areas around hydraulic connections and disconnect return and pressure lines from steering gear. Plug lines and steering gear to prevent dirt from entering system and fluid from draining out.
2. Remove steering gear-to-intermediate shaft clamp bolt. Raise and support vehicle. Remove front wheel assemblies. Separate tie rods from steering knuckles.
3. Remove steering gear retaining bolts. Separate intermediate shaft joint from steering gear. Lift steering gear to the side. Remove by guiding it diagonally downward through opening in engine compartment.

Installation

To install, reverse removal procedure. Tie rod ends are to be connected after gear assembly has been fully installed. Check wheel alignment.

Scheme 2

Scheme 3

1. With steering gear removed from vehicle, remove lock nuts and tie rod ends. Remove rubber bellows and breather tube. Remove hydraulic lines from steering valve and steering housing.
2. Remove lock nut, adjusting nut, spring and piston from steering housing. Remove pinion dust cap. Using an 11/16" socket, hold pinion from rotating while removing pinion lock nut. Remove dust cover lock ring from upper pinion. (Scheme 2) (Scheme 2): Removing Pinion Lock Nut from Pinion Gear & Spool Valve Wrap tape around serrations. Courtesy of Saab-Scania of America, Inc.
3. Press pinion (with spool valve) out of steering gear. The bearing, support, seal, and dust cover seal will come out with the pinion. NOTE: Do not use a hammer to remove pinion, or damage to pinion, spool valve and/or housing could result.
4. Remove inner ball joint furthest from pinion. Clamp rack in a soft-jawed vise. Push plastic sleeve out of the way. Unscrew ball joint.
5. Remove lock-ring in end of hydraulic cylinder gear housing. Push rack into gear housing as far as it will go. Install Removal/Installer Sleeve (89 96 407 ) over rack. Tighten inner ball joint to press seal housing in.
6. Use a punch to depress wire end of lock-ring. Using 2 screwdrivers, pry out lock-ring. With ring removed, remove ball joint and special sleeve.
7. Remove ball joint nearest pinion in same manner as first ball joint. Press out rack together with seal, washer and bushing. Ensure there are no burrs on rack before removing seal and bushing.
8. Using Seal Remover/Installer (89 96 399 ) and a long punch, remove inner rack. Insert lips of tool under seal. From opposite end of housing, insert long rod and drive out seal.
9. Remove lock ring and lower pinion bearing. Remove sealing ring and bushing from top of pinion housing.

Scheme 4

Scheme 5

1. Lubricate pinion gear, rack teeth, bearings and dust cover seal with lithium grease. Lubricate all hydraulic parts with power steering fluid.
2. Install lower pinion bearing (enclosed side of bearing facing downward) and lock ring (with chamfer on lock ring facing outward). Using Remover/Installer Sleeve (90 06 407 ), install upper pinion bushing and hydraulic seal into pinion housing of gear housing.
3. Install rack inner hydraulic seal onto rack. Use a thin plastic sheath, or metal foil to cover rack teeth to protect sealing lip of seal.
4. Install rack into housing. Install inner hydraulic seal into housing using rack piston as a press. Do not use more than 500 lbs. (226.8 kg) of force.
5. Install bushing in gear housing (smaller bore facing in). Install washer against bushing. Install new "O" ring on outer hydraulic seal support. Install old seal (if not damaged).
6. Slide sealing ring support carefully onto rack to avoid damaging sealing lip. Using Sleeve (83 90 148 ), press sealing ring support into housing. Center rack.
7. Rotate rack so that rack teeth will mesh with pinion gear teeth when it is installed. Hold pinion gear (with spool valve), so that groove in end of shaft points toward the left (9 o'clock position), when pinion teeth engage rack teeth.
8. Insert pinion. Pinion should rotate so that groove in end of pinion points toward front (12 o'clock position), with rack centered. Install pinion lock nut. Tighten lock nut. Install cover.
9. Install washer, needle bearing, sealing ring, dust cover, and lock ring onto top of pinion gear (spool valve). Protect seal lips with tape or plastic sleeve over splines of pinion.
10. Install bearing piston, spring and adjusting nut in gear housing. Tighten adjusting nut until bearing piston firmly contacts rack. Back off adjusting nut 30-50 degrees. Install and tighten lock nut.
11. Install plastic sleeves (end stops) and inner ball joints, with tie rods, to rack ends. Hold rack in soft-jawed vise. Tighten ball joints. Lock inner ball joints by tapping tab on ball joint into rack. DO NOT use pinion as support when loosening or tightening ball joints.
12. Install lock ring for sealing ring support in end of gear housing. Turn pinion until inner ball joint presses against sealing ring support. Press in support and, at the same time and using a thin screwdriver, install sealing ring in groove. Install rubber bellows, breathing tube and hydraulic lines.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS