16 16-Steering KM816009 01/12/05

Department Customer Service

Category Service Manual
Section Steering
Title Mechanical Steering System

Number KM816009

Service Date
Model
01/12/05
All

Manual Page 1 of 15

Mechanical Steering System

 Page 2 of 15

Steering: Mechanical Steering System Number KM816009

Description
The steering system consists of the:
• steering wheel and column assembly.
• slip joint.
• U-joints.
• gearbox.
• pitman arm.
• drag link.

The steering gear is of the worm and roller type. The

worm gear is held in position by a pair of tapered roller
bearings and meshes with a three-tooth roller which is
supported by bearings on the cross shaft. All bearings
are replaceable and precise steering gear adjustments
can be made to eliminate excessive backlash.

Since most of the steering action is performed near the

straight-ahead position, maximum wear occurs at the
center of the gearbox worm. In order to give a long ser-
vice life to the steering gear assembly, the wear is com-
pensated for by creating backlash in the off-center
position. This backlash permits readjustment for lost
motion in the center position without causing a bind when
the wheel is turned off-center. The built-in backlash
occurs approximately a half turn each way from the cen-
ter position and gradually increases to develop the larg-
est amount of backlash at the end of gear travel.
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Steering: Mechanical Steering System Number KM816009

Specifications

Torque

N.m Lb.-Ft. Lb.-In.

Gear Box:
• Mounting Bolts 203-237 150-175 ---

• Worm Cover Cap Screws 61-74 45-55 ---

• Cross Shaft Cover Cap Screws 61-74 45-55 ---

• Cross Shaft Adj. Screw Locknut 27-33 20-25 ---

• Worm Bearing Preload 1-1.8 --- 9-16

• Cross Shaft or Total Preload 2.6-3.8 --- 23-34

(Worm Bearing Plus Cross Shaft Preload)

Draglink Clamp Bolt 74-88 55-65

Draglink End Stud Nut* 224-244 165-180

Pitman Arm Pinchbolt & Nut (COE models) 203-237 150-175

Pitman Arm Retaining Nut (Conventionals) 474 350

Steering Driveline Yoke Pinchbolt 74-81 55-60

Steering Wheel Retaining Nut 48-61 35-45

NOTE: The torque values given are for threads lubricated with SAE 20 or 30 oil.

*Torque nut to specified value, then tighten nut as necessary to line up the next cotter pin hole. Do not back off.

Lubrication

Lubricant Interval

Gearbox SAE 90 gear lubricant with EP additives, Check:

API-GL-5 10 000 km (6,000 mi)
Drain & Refill: Annually

Draglink EP Chassis Grease 10,000 km (6,000 mi)

Steering Slip Joint EP Chassis Grease 10,000 km (6,000 mi)


Steering: Mechanical Steering System
Maintenance
Lubrication
Lubricate the following every 10,000 km (6,000 miles):
• Tie Rod.
• Draglink.
• Steering Slip Joint.
• Steering U-Joint.
• Gearbox-Check level. Change oil annually.
Torque
Every 20,000 km (12,000 miles) check the following
torque values (threads lubricated with SAE 20 or 30 oil):
• Gearbox Mounting Bolts: 203-237 N.m (150-175 Ib.
ft.).
• Draglink Clamp Bolt: 74-88 N.m (55-65 Ib. ft.).
• Pitman Arm Pinch Bolt (COE): 203-237 N.m
(150-175 lb. ft.).
• Pitman Arm Retaining Nut (Conv.): 474 N.m (350 lb.
ft.).
• Steering Driveline Yoke Pinchbolt: 74-81 N.m (55-60
lb. ft.).
• Steering Wheel Retaining Nut: 48-61 N.m (35-45 lb.
ft.).
NOTE: If centering the steering wheel is necessary, refer
to Steering Wheel Removal And Replacement.
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Number KM816009
Inspection
Every 10,000 km (6,000 miles) and when lubricating the
vehicle:
• Inspect the tie rod to be certain that it is straight and
the ends are not loose.
• Verify tightness of the draglink ball and stud sockets
and tube clamp bolt.
• Verify clearance between draglink tube clamps and
steering linkage.
Steering System Maintenance Tips
• Check for wear in steering linkage before making
adjustments to the steering gear assembly.
• Verify proper adjustment of axle stops to prevent
internal bottoming of the steering gear.
• Periodically check front end alignment.
• Maintain correctly inflated tires.
• Always remove steering arms with a puller-never with
a torch or hammer.
• Examine all parts that have been subject to impact.
Replace any that are questionable.
• Immediately investigate and correct the cause of any
play, rattle or shimmy in the steering mechanism.
• Maintain proper steering column alignment.
• Do not weld, cold or hot straighten any steering sys-
tem component.
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Steering: Mechanical Steering System Number KM816009

Troubleshooting
When investigating a steering problem, begin with the simplest, most obvious probability, then progress to the more
complex situations. General steering problems and their causes are listed below.

Problem Possible Cause

Hard Steering 1. Underinflated front tires.

2. Overloaded front axle.

3. Lack of lubricant.

4. Binding universal joint or slip joint.

5. Steering column misaligned, boot binding.

6. Excessive caster.

7. Worm bearing or pitman arm shaft adjusted too tight.

8. Worn steering gear bearings.

9. Worn or damaged worm gear or roller.

Wandering 1. Tire pressure incorrect or unequal left to right.

2. Incorrect load distribution.

3. Dry fifth wheel.

4. Loose steering gear mounting bolts.

5. Worn U-joints or slip joint splines.

6. Excessive pitman arm backlash.

7. Components in steering linkage or knuckle pins worn.

8. Wheel bearings improperly adjusted or worn.

9. Steering gear not properly centered.

10. Front end out of alignment.

11. Sagging or broken spring.

12. Rear axle shifted.

Excessive Free Play at Steering Wheel 1. Worn draglink or tie rod ends.

2. Worn steering shaft U-joints or slip joint.

3. Steering gear mounting bolts lose.

4. Pitman arm loose on output shaft.

5. Wheel bearings worn or out of adjustment.

6. Steering wheel loose on shaft.

7. Steering gear worn or needs adjustment.

8. Knuckle bushings worn.

Shimmy 1. Incorrect or uneven tire pressure.

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Steering: Mechanical Steering System Number KM816009

Problem Possible Cause

2. Tire size not uniform.

3. Badly worn or unevenly worn tires.

4. Steering linkage loose.

5. Wheel bearings worn or out of adjustment.

6. Wheels out of balance or not true.

7. Steering gear mounting bolts loose.

8. Caster or toe-in incorrect.

9. Steering gear out of adjustment.

No Recovery 1. Tire pressure low.

2. Fifth wheel dry.

3. Front-end components binding.

4. Front-end caster incorrect.

5. Front-end caster incorrect.

6. Steering column misaligned and binding.

Pulling To One Side 1. Tire pressure low or unequal.

2. Tires not of uniform size.

3. Brake dragging on one side.

4. Caster unequal or incorrect.

5. Toe-in incorrect.

6. Wheel bearings tight or not properly lubricated.

7. Sagging or broken spring.

8. Steering knuckle spindle bent.

9. Rear axle shifted.

10. Frame out of alignment.

Uneven or Excessive Tire Wear 1. Incorrect tire pressure.

2. Overloading.
3. Uneven tire wear.

4. Wheel alignment incorrect.

5. Steering linkage loose.

6. Tire and wheel assembly out of balance.

7. Steering knuckles worn.

8. Severe or unequal brake action.

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Steering: Mechanical Steering System Number KM816009

Adjustment
If any bearing play exists in the steering gear, make
adjustments in the following sequence.
1. Adjust worm bearing preload.
2. Adjust cross shaft preload.
3. Center worm gear before reinstalling the steering
gearbox.

Checking Worm Bearing Preload

1. Disconnect the draglink from the pitman arm and the
universal joint from the worm shaft.
2. Remove the steering gearbox from the vehicle. The torque required to turn the worm shaft should be
1 to 1.8 N.m (9 to 16 lb. in.) or you must adjust the
3. Verify that the worm bearing cover capscrews are
worm bearing preload.
torqued to 61-74 N.m (45-55 Ib. ft.).
NOTE: Erratic torque readings generally indicate
NOTE: Make a special adapter for turning the worm
damaged bearings. See Disassembly Procedure in
shaft with a torque wrench Cut the yoke from a steer-
this publication for bearing replacement
ing driveline universal joint and weld a steel disc and
hex nut to the yoke as shown below.
Adjusting Worm Bearing Preload
1. Drain the oil from the gearbox.
2. Remove the worm cover and the shim pack.

3. Add shims to the pack to reduce the preload.

Remove shims to increase the preload.
4. Turn the worm shaft in either direction to the end of
travel. IMPORTANT: Add or remove only one shim at a time.

5. From the end of travel, turn the worm shaft 1/4 turn 4. After removing or adding a shim, replace the worm
with an inch-pound torque wrench. To get an accu- cover and tighten the capscrews lunger-tight only.
rate reading, the worm shaft must be vertical and the
torque wrench horizontal.
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Steering: Mechanical Steering System Number KM816009

5. Gradually tighten the capscrews in small increments,

moving from screw to screw in the sequence shown.
Torque the capscrews to 40 N.m, (30 lb. ft.), turning
the worm shaft by hand while tightening to prevent
damage if the amount of shims is wrong.

The torque required to turn the wormshaft through

the center point should be 2.6-3.8 N.m (23-34 lb. in.).
Incorrect torque requires readjustment of preload.

NOTE: Erratic torque readings usually indicate dam-

6. If a light preload is on the wormshaft, torque the cap-
aged bearings.
screws to 61-74 N.m (45-55 lb.ft.), and fill the gear
housing to the proper level with SAE 90 steering gear
lubricant. Adjusting Cross Shaft Preload
Again check the preload on the worm shaft to verify 1. The cross shaft preload is made by loosening the
correct adjustment. locknut on the cross shaft cover . . .

IMPORTANT: After adjusting the worm bearing pre-

load, the cross shaft {sometimes called sector shaft)
preload must also be checked and then adjusted if
necessary.

Checking Cross Shaft Preload

1. Center the steering gear by counting the number of
turns the worm shaft makes from extreme right to
left, then turn back half that number of turns.
2. To measure the preload, rotate the worm shaft 180
through the center point with an inch-pound torque
wrench.
. . . and turning the adjusting screw clockwise to
increase the preload, or counter-clockwise to
decrease the preload.
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Steering: Mechanical Steering System Number KM816009

5. Install the pitman arm, verifying that the timing marks

on the pitman arm align exactly with the timing mark
on the output of the steering gearbox.

2. Tighten the locknut and check the preload. If the pre-

load is between 2.6-3.8 N.m (23-34 lb. in.), torque the
locknut first to 27 N.m and then to 33 N.m (20 to 25
lb. ft.) to prevent O ring damage.

IMPORTANT: After checking and adjusting the worm

bearing and output shaft preload, center the worm
gear as outlined in the following procedure.

NOTE: (K100 only) Do not move the pitman arm set-

Centering The Steering (Worm Gear)
When checking, adjusting repairing or replacing the gear-
box, the worm gear must be recentered. this procedure
minimizes steering play in the straight-ahead position to
help prevent vehicle wander.
ting when reinstalling gearbox.
6. Connect the draglink to the pitman arm without mov-
ing either the front wheels or the pitman arm. If the
end of the draglink will not mate exactly with the pit-
man arm, loosen the draglink clamp . . .

NOTE: On COE models, the steering gear must be

removed from the truck to center the steering.
1. Turn the front wheels until they point straight ahead.
2. Disconnect the pitman arm from the draglink.

NOTE: (K100 Only) Disconnect the steering drive-

line at the U-joint and remove the gearbox.
3. Remove the pitman arm from the gearbox with a suit-
able puller.
4. Rotate the gearbox input shaft (worm gear) to a
locked position. Counting the number of turns, rotate
the input shaft in the opposite direction until full lock
is reached again. Divide the number of turns from
. . . and adjust the length of the draglink by screwing
lock-to-lock by two, and rotate the input shaft from
it in or out until the tapered end mates with the pit-
lock that number of turns. This will put the gearbox in
man arm.
exact center.
If the draglink must be lengthened, verify that there
are at least 50 mm (2 in.) of thread contact in the
adjustable coupling.

Steering: Mechanical Steering System
Connect the draglink end nut and torque it to 224-244
N.m (165-180 lb. ft.). Tighten the nut as necessary to
line up the next cotter pin hole. Do not back off.
Torque the draglink clamp and nut to 74-88 N.m
(55-65 lb. ft.).
7. Reconnect the steering driveline universal joint to the
input shaft of the gear. With the front wheels parallel
to the frame, instruments should be easily visible
through the spokes of the steering wheel. Torque the
steering driveline yoke pinchbolt to 74-81 N.m (55-60
lb. ft.) and the steering wheel retaining nut to 48-61
N.m (35-45 lbs. ft.).
Axle Stops
Internal stops within the steering gear housing limit travel
of the steering output shaft. However, these internal
stops are not intended to act as wheel stops.
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Number KM816009
Wheel Stop Adjustment
1. Park the vehicle on a hard, level surface.
2. Set the parking brakes
3. Place chocks under the rear wheels to prevent acci-
dental movement.
4. Jack both front wheels off the ground. Use two jack
stands—one under each spring perch.
5. Insert 25.4 mm (1 in.) spacer blocks.
6. Loosen the locknut on the axle stop bolt and adjust
the axle stop to provide a minimum of 13 mm (1/2 in.)
clearance between the tire (bias ply 1 in. radial) and
the draglink.
7. Tighten both locknuts.
8. Before lowering the wheels, swing them slowly and
gently from stop-to-stop as a final check on steering
angle and clearances.
Disassembly
If bearing preload torque readings are erratic, the bear-
ings are probably damaged. The gear will have to be dis-
assembled to replace the bearings. Complete the
following procedure.
1. Drain the oil from the housing. Check the end of the
cross shaft for the alignment mark. The pitman arm
may have a punch mark opposite the cross shaft
mark. If no mark is visible, make one so that the pit-
man arm may be installed correctly.
2. Remove the pitman arm from the cross shaft.

Steering: Mechanical Steering System
3. Remove the two dowels from the cover so that the
cross shaft and shaft cover may be removed from the
housing. Turn the worm shaft to put the worm and
roller into the straight-ahead position.
4. Loosen the adjusting screw locknut and remove the
shaft cover screws.
5. Remove the output shaft and shaft cover assembly.
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Number KM816009
NOTE: Tap the output shaft with a small mallet to break
the shaft cover loose.
6. Separate the shaft and the cover by removing the
adjusting screw locknut and turning the adjusting
screw clockwise until the shaft may be removed from
the cover.
7. Remove the input shaft and worm assembly from the
gear housing by removing the cover screw and the
cover.
8. Remove the shim pack and the worm bearing cup by
pressing on the worm shaft.
If the cup cocks as you press on the shaft, tap it back into
position and press on the shaft again.
9. Remove the upper roller bearing assembly.

Steering: Mechanical Steering System
10. Remove the worm shaft assembly.
Now the lower roller bearing assembly and the worm
bearing cup may be removed. The bearing cup is
pressed in and must be driven out. This is recommended
only if the bearing cup shows signs of wear or pitting and
must be replaced.
The gear is now completely disassembled.
Inspection and Repair
When the steering gear is fully disassembled, inspect the
bearing races, tapered rollers and cups on each end of
the worm for pitting or brinnelling.
NOTE: If replacement is necessary, replace in complete
sets.
Page 12 of 15
Number KM816009
Rollershaft Assembly
See Figure 16-1 on page 13, No. 11.
Check the cross shaft and worm gear for excessive wear
or pitting. Check the roller for excessive sideplay by
inserting a feeler gauge between the roller and the shoul-
der. The clearance must not exceed 0.1 mm (.004 in.)
Rollershaft Adjusting Screws
See Figure 16-1 on page 13, No. 12, 13, and 14.
If end play of the assembled rollershaft adjusting screw
exceeds 0.2 mm (.008 in), replace it with a new threaded
adjusting crews retainer and thrust washer. Adjust to
0.254-0.072 mm (.001-.003 in.) end play. Carefully stake
(two places) the outer flange of the threaded adjusting
screw retainer into slots on the end of the rollershaft.
NOTE: Excess end play of the adjusting screw will be
noticeable when making total preload adjustment as the
turning torque will be uneven (left to right/right to left)
when turning gear across center or straight ahead posi-
tion.
Housing Bearings
See Figure 16-1 on page 13, No. 10.
If the roller shaft (11) to bushing clearance exceeds .25
mm (.010 in), replace the bushings as follows:
1. Press out old bushings with piloted mandrel.
2. Install new bushings with piloted mandrel. Press
bushing into bore from outer end of trunnion until the
outer face of the bushing is flush with the inner face
of seal counter bore.
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Steering: Mechanical Steering System Number KM816009

3. Size the bushing to 44.45-44.47 mm (1.750 in.-1.751

in.).

Figure 16-1

Shaft Cover Dowl Pins
See Figure 16-1 on page 13, No. l8
Shaft cover dowel pins must be a drive fit through the
shaft cover and into the housing cowl holes. Oversize
service dowels are available.
Rollershaft and Worm Shaft Seals
1. Assemble lubricated seals in counter bore with long-
est lip facing into gear.
2. Use a mandrel of a size to contact all around the seal
case. Drive lubricated seals to firmly contact bottom
of counter bore.
NOTE: The seal surface on the worm shaft may be
lightly polished with fine abrasive e cloth to provide good
sealing.

See Figure 16-1 on page 13, No. 7 and 9.

Reassembly
Replace seals if the gear is completely disassembled.
Clean and lubricate all components before reassembling
the gear.

Steering: Mechanical Steering System
1. Replace the lower worm bearing cup, if removed, and
replace the lower bearing assembly in the housing.
2. Insert the worm shaft assembly into the housing.
3. Replace the upper roller bearing assembly.
4. Replace the upper bearing cup.
Page 14 of 15
Number KM816009
5. Replace the shim pack and the worm cover.
6. Finger tighten the worm cover screws.
7. Slowly tighten the cover screws, moving from screw
to screw in the sequence shown. As you tighten the
cover screws, turn the input shaft to prevent damag-
ing the bearing surfaces.
As soon as a light preload on the worm bearing may be
measured, torque the cover screws first to 61 N.m then to
74 N.m (45 to 55 Ib. ft.).
8. Check the worm bearing preload.
9. When installing the cross shaft and cover, put the
adjusting screw into the shaft cover first. If a new
cross shaft is installed, the roller may not move freely
on the shaft. To free the roller, insert the cross shaft
in the gear housing without the shaft cover.

Steering: Mechanical Steering System
10. Mesh the roller teeth with the worm screw, and hold
the cross shaft in place with your thumb. Now turn
the worm shaft. This will free the roller on the cross
shaft.
11. Draw the cross shaft into the shaft cover bearing with
the adjusting screw.
12. When the shaft touches the bottom of the bearing,
back off the adjusting screw one full revolution.
13. Position a new gasket on the cross shaft cover and
insert the shaft and cover assembly into the housing.
14. Drive the dowels back into their holes.
Page 15 of 15
Number KM816009
The dowels must be a tight, drive-fit to prevent the side
cover from moving under load. If either dowel is loose,
ream the dowel holes and drive in bigger dowels.
15. Finger-tighten the cross shaft cover screws and
check for a light preload on the cross shaft.
16. If the preload is light and there's no binding, torque
the cover screws first to 61 N.m then to 74 N.m
(45-55 Ib. ft.).
17. Press in new shaft oil seals and fill the housing to the
proper level with SAE 90 EP gear oil. Replace the
drain plug.
18. Check the cross shaft preload and adjust it to 2.6-3.8
N.m (23-34 Ib. in.) with the adjusting screw.
19. Torque the adjusting screw locknut first to 27 N.m
then to 33 N.m (20-25 lb. ft.) to prevent any damage
to the O ring.
20. Center the reassembled gear (see Adjustment in this
publication) and install gear in vehicle.