Steering Column Volvo 240 I

DESCRIPTION

Steering column upper and lower sections are joined by a flange. On frontal impact, flange breaks from upper column. Upper column is carried in 2 ball bearings in jacket tube. Lower end of steering column connects to steering shaft with a flange.

REMOVAL & INSTALLATION

Removal

1. Disconnect battery ground cable. Remove clamp bolts and snap rings from upper and lower steering shaft joints. Push steering shaft toward cowl and remove.
2. Remove steering wheel, column covers and switches. Remove trim panels and heater duct under dash. Punch and drill out column lock shear bolts. Remove lower bearing plate attaching bolts and column support bolts.
3. Turn ignition key to "II" position and remove column lock retaining screw. Press inward on tab underneath lock to remove lock. Remove key and wiring connector. Remove column guide from bracket. Remove column.

Installation

To install, reverse removal procedure. After installing column lock bracket and lower bearing plate, tighten new shear bolts until heads break off.

1. Disconnect battery ground cable. Disconnect upper joint from upper and lower steering shafts. Remove steering wheel, column covers and switches. Refer to STEERING WHEEL & COLUMN SWITCHES in this section.
2. From underneath instrument panel, remove trim panel and console side panel. Disconnect connector at steering lock. Drill lock retaining screws and remove with screw extractor. Remove defroster duct.
3. Remove column lower bracket. Pull column toward seat and remove firewall seal. Remove column and lock as an assembly.

1. Install lock so upper edge is 3.8" (97 mm) from upper edge of column. (Scheme 1) Ensure both plastic guides and spacers are in place. Washers must face downward.
2. Insert column through firewall. Install shear bolts and column clamp, but do not tighten them.
3. Adjust column position so lock protrudes.53-.65" 13.5-16.5 mm) from dash, measured at lock position "II". Column must not contact upper attachment plastic guides. Adjust dash beam if needed.
4. Tighten column clamp and bracket bolts. Install defroster duct and firewall seal. Loosely install upper joint on steering shaft. Install lower steering shaft flange to upper joint.
5. Check distance between lower steering shaft shoulder and upper joint. Distance should be.40-.75" (10-19 mm). If distance is incorrect, pull up lower joint cover, loosen joints and move lower shaft up or down.
6. Check distance between steering wheel and upper column cover. If clearance is not.04-.08" (1-2 mm), pull up lower joint cover, loosen lower joint and move lower shaft up or down.
7. To complete installation, reverse removal procedure. Tighten shear bolts until heads break off. If necessary, place 1 or 2 flat washers between steering wheel and upper bearing spring to eliminate rattling.

Disassembly

1. Remove shaft from column. Clamp steering shaft in soft-jawed vise and remove bearing race with a hammer and open end wrench. Grease inside of race, and install so that flats align with shaft flats.
2. Race should be 1.98" (50.3 mm) from shaft flat end. Upper column length must be 28.59-28.67" (726.2-728.2 mm). If length is incorrect, replace shaft.
3. To replace upper bearing, press bearing housing toward shaft. Remove snap ring, plastic cone, bearing housing, metal cone, washer, spring and washer.
4. Using a punch, tap out inner race first, then outer race.

Inspection

Check all bearing surfaces for excessive wear or scoring. Check universal joints for excessive play. Replace worn or damaged parts as necessary.

Reassembly

1. Install new bearing with Drift (2724) and Handle (1801). Install washer, spring, washer and metal cone. Temporarily place 2 flat washers between upper washer and metal cone, on each side of shaft.
2. Install bearing housing and plastic cone (facing housing). Install snap ring. Remove 2 flat washers.

Scheme 1

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS