Land Rover Range Rover 1987 Power Steering Box Rover Manual

							POWER STEERING BOX
Remove and refit
Service tools:
Drop arm extractor-MS252A
NOTE: It is important that whenever any part of
the system,including the flexible piping, is
removed or disconnected, that the utmost
cleanliness is observed.
All ports and hose connections should be
suitably sealed off to prevent ingress of dirt, etc.
If metallic sediment is found in any part of the
system, the complete system should be checked,
the cause rectified and the system thoroughly
cleaned.
Under no circumstances must the engine be
started until the reservoir has been filled. Failure
to observe this rule will result in damage to thepump.Metric pipe fittings are used with 
‘0’ ring pipe
ends on the fittings to the steering box.
Follow normal 
‘0’ ring replacement procedure
;.: ;:.whenever pipes are disconnected.. . .Ensure that compatible metric components are
used when fitting replacement pipes.
CAUTION: PRIOR TO REMOVING ANY OF THE
COMPONENTSINCORPORATED INTHE
STEERING LINKAGE, IT IS IMPERATIVE THAT THE
ROAD WHEELS ARE IN A STRAIGHT AHEAD
POSITION AND THAT THE STEERING WHEEL IS
THEN REMOVED TO PREVENT THE CRUISE
CONTROL SPIRAL CASSETTE BEING WOUND UP
OR DAMAGED IF THE STEERING LINKAGE IS
INADVERTENTLY MOVED OR ROTATED.
AFTER
REFllTlNGSTEERING
LINKAGE
COMPONENTS, THE ROAD WHEELS MUST BE
RE-POSITIONEDSTRAIGHT AHEADBEFORE
FllTlNG THE STEERING WHEEL, DO NOT
RECONNECT THE MULTI-PLUG TO THE CASSETTE
OR FIT THE TRIM PAD AT THIS STAGE. IF, AFTER
THE VEHICLE HAS BEEN DRIVEN, IT IS FOUND
THATTHESTEERINGWHEELREQUIRES
RE-POSITIONING,REMOVETHEWHEEL.
RE-ALIGN THE DRIVE PEGS ON THE CRUISE
CONTROL 
CASSElTE BY SLIGHTLY ROTATING
THE UPPER PART OF THE 
CASSE’ITE IN THE
APPROPRIATE DIRECTION UNTIL THE PEGS LIE
HORIZONTAL TO THE STEERING COLUMN.FIT THE STEERING WHEEL ENSURING THAT THE
DRIVE PEGS LOCATE IN THEIR RESPECTIVE
HOLES ON THE REAR OF THE STEERING WHEEL.
AFTER FINAL ALIGNMENT RECONNECT THE
MULTI-PLUG TO THE CASSETTE, TIGHTEN THE
STEERING WHEEL SECURING NUT AND FIT THE
TRIM PAD.
Removing
1.
2.
3.
4.
5.Park the vehicle on a level surface.
Prop open the hood.
Remove the filler cap from the power steering
fluid reservoir.
Disconnect the fluid pipes from the pump.
Drain and discard the fluid. Replace the filler
cap.Disconnect the fluid feed and return pipes
from the steering box.
6. Seal all disconnected hose connections to
prevent ingress of foreign matter.
7 lack up and support the chassis front end withaxle stands. Alternatively, raise the vehicle on a
hoist.
WARNING: Whichever method is adopted, it is
essential that the wheels are chocked, the
parking brake is applied, and low range selected
with differential lock engaged.
Continued-’ 
						

							,ga, r(HI*uCROVER
8.
9.
10.
11.
12.
13.
14.Disconnect the drag fink from the drop arm
using a suitable extractor.
Remove the drop arm, using drop arm
extractor 
MS252A.Remove the pinch bolt attaching the universal
joint to the power steering box.
Loosen the nut securing the tie bar to the
chassis.
Remove the bolts securing the tie bar to the
steering box and move the tie bar aside.
Remove the fixings attaching the power
steering box to the 
chassrs side member.
Withdraw the power steering box.
8,19
RR2196ERefitting9;18
15. Refit the steering box to the chassis side
member and tighten the four 
Nyloc nuts to
the correct torque (see section 06-Torque
values).
16. Refit the tie bar to the steering box, and
tighten the tie bar securing nut to the correct
torque (see section 06-Torque values).
17. Reconnect the pinch bolt, attaching the
universal joint to the power steering box, and
tighten to the correct torque (see section
OC-Torque values).18. Refit the drop arm.
19. Refit the drag link and secure.
20. Lower the vehicle to ground level.
21. Remove the sealing. plugs and reconnect the
flexible hoses to the steering box.
22.
23.
25.
26.
27.Remove the sealing plug and refit the flexible
hose to the power steering pump.
Ensurethat the steering wheel is correctly
alignedwhenthe wheels arein the
straight-ahead position.
NOTE: 
II may be necessary to remove the
steeringwheel and reposition on the
splines to obtain this condition. See
steering wheel- remove and refit.
Remove the filler cap from the power steering
fluid reservoir. Fill the reservoir to the oil level
mark 
on the dipstick attached to the filler cap
with the recommended fluid 
(see Section 09)and bleed the power steering system. See
power steering system-bleed.
Check the 
liuid level and replace the filler cap.
Check, and if necessary, adjust the steering
box.
Test the steering system for leaks. with the
engine running, by holding the steering hard
on full lock in both directions.. 
\.,CAUTION: Do not maintain this pressure for
more than 
30 seconds in any one minute, to
avoid causing the oil to overheat and possible
damage to the seals.
28. Close the hood.
29. Road test the vehicle.
2
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							. ..POWER STEERING BOX OVERHAUL
Service tools:
LSTl20-‘C’ Wrench
LSTll9 -Worm adjusting wrench
MS252A -Drop arm extractor
606602 -Ring expander
606603 -Ring compressor
606604 -Seal saver, sector shaft
R01015 -Seal saver, valve and worm
R01016 -Torque setting tool
Dismantle
I. Remove the steering box from the vehicle,
and withdraw the drop arm.
; .,. :
‘,.
:.. .:,Rotate the retainer ring, as necessary, until one
end is approximately 12 mm (0.500 in) from
the extractor hole.
Lift the cover retaining ring from the groove in
the cylinder bore, using a suitable pointed drift
applied through the hole provided in the
cylinder wall.
Complete the removal of the retainer ring,
using a screwdriver.
Turn on left lock until the piston pushes out
the end cover.
6.
7.
8.
9.
10.
11.Loosen the set screw retaining the rack pad
adjuster.
Remove the rack pad adjuster.
Remove the sector shaft adjuster locknut.
Remove the sector shaft cover fixings.
Screw in the sector shaft adjuster until the
cover is removed.
Slide out the sector shaft.
12. Withdraw the piston. using a suitable bolt
screwed 
Into the tapped hole in the piston.
Continued
_’,.:.REVISED: DEC. 873 
.’
.:. 
						

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RANGt
“*’ ROVER
.
13. Remove the worm adjuster locknut using ‘C’Wrench, 
LSTI 20.
14. Remove the worm adjuster using wrench
LSTll9.
IS.
16.
17.
18.
19.Tap the splined end of the shaft to free the
bearing.
Withdraw the bearing cup and caged ball
bearing assembly.
Withdraw the valve and worm assembly.
Withdraw the inner bearing ball race and
shims.
Retain the shims for reassembly
Steering box seals20. Remove the circlip and seals from the sector
shaft housing bore.
NOTE: Do not remove the sector bushes
from the casing, Replacement parts are not
available.
I
21. Remove the circlip and seals from the input
shaft housing bore...-
‘.1
RR234SE
Inspecting22. Discard
allrubbersealsand provide
replacements.
NOTE: A rubber seal is fitted behind the
plastic ring on the rack piston. Discard the
seal and also the plastic ring and provide
replacements.
lj. 
.’
4REVISED: DEC. 87
AR23!5OEfs ’
‘ ‘. ‘.-
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							STEERING 157 1
‘.
,_-
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.:Steering box casing
23. Examine the piston bore for traces of scoring
and wear.24. Examine the inlet tube thread for damage. If
repair is necessary this can be undertaken by
using a suitable tap.
25. Examine the feed tube for signs of cracking.
23Sector shaft assembly
26. Check that there is no side play on the rollers.
27. If excessive side play on the roller does exist
fit a new sector shaft.
28. Check the condition of the adjuster screw
threads.
29. Examine the bearing areas on the shaft for
excessive wear.
30. Examine the gear teeth for uneven or
excessive wear.Sector shaft cover assembly
31. The cover, bush and seat are supplied as a
complete assembly for replacement purposes.
Sector shaft adjuster locknut
32. The locknut functions also as a fluid seal, a
new nut be fitted at overhaul.
Valve and worm assembly
33. Examine the valve rings which must be free
from cuts, scratches and grooves. The valve
rings should be a loose fit in the valve
grooves.
34. Remove the damaged rings ensuring that no
damage is done to the seal grooves.
35. If required, fit replacement rings, using the
ring expander 606602. Warm the rings and
expander tool to aid assembly, using hot water
for this purpose. Fit the rings to the expander,
slide the expander over the valve and worm
assembly,in turn fit the rings to their
respective grooves. Remove the expander,
slide the valve and worm assembly into the
ring compressor 606603 and allow the rings to
NOTE: The expander will not pass over rings
already fitted. The rings must be discarded
to allow access and then new rings must be
fitted.
Continued 
*’REVISED: DEC. 87
5 
						

							I:
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:‘. .‘,
l-l57 STEERING.\, .# .VL
“*’ ROVER
36. Examine the bearing areas for wear. The areas
must be smooth and not indented.
37. Examine the worm track which must be
smooth and not indented.
38. Check for wear on the torsion bar assembly
pins; no free movement should exist between
the input shaft and the worm.
NOTE: Any sign of wear makes it essential
that a new valve and worm assembly is
fitted.
RR932MBall bearing and cage assemblies
39. Examine the ball races and cups for wear and
general condition.
40. If the ball cage has worn against the bearing
cup, fit replacements.
41. Bearing balls must be retained by the cage.
42. Bearings and cage repair are carried out by the
complete replacement of the bearings and
cage assembly.
6REVISED: DEC. 8743. To remove the inner bearing cup and shim
washers, jar the steering box on the work
bench, or use a suitable extractor.
i “INOTE: Should difficulty be experienced at
this stage, warm the casing and the bearing
assembly. Cool the bearing cup using a
suitable mandrel and jar the steering box
on the bench.
Rack thrust pad and adjuster
44. Examine the thrust pad for scores.
45. Examine the 
adfuster for wear in the pad seat.
46. Examine the nylon pad for distortion and
adjuster set screw assembly for wear.
46
/‘PRack and piston
47.
48.
49.
50.Examine for excessive wear on the rack teeth.
Ensure the thrust pad bearing surface is free
from scores and wear.
Ensure that the piston outer diameters are free
from burrs and damage.
Examine the seal and ring groove for scoresand damage. 
						

							51. Fit a new rubber ring to the piston. Warm theSector shaft sealwhite nylon seal and fit this to the piston.
52. Slide the piston assembly into the cylinder
with the rack tube outwards. Allow to cool.
ReassembleNOTE: When fitting replacement oil seals, these
must be lubricated with recommended fluid.
Also ensure that absolute cleanliness is observed
during assembly.Input shaft oil seal
53. Fit the seal, lipped side first, into the housing.
When correctly seated, the seal backing will lie
flat on the bore shoulder.
54. Fit the extrusion washer and secure with the
circlip.
,53
RR2362Ex’ I55. Fit the oil seal, lipped side first.
56. Fit the extrusion washer.
57. Fit the dust seal, lipped side last.
58. Fit the circlip.
RRQ38MFitting the valve and worm assembly
59. 
If removed, refit the original shim washer(s)and the inner bearing cap. Only Petroleum
Jelly may be used as an aid to assembling the
bearings.
NOTE: If the original shims are not
available, fit 
shim(s) of 0.76 mm (0.030 in)
nominal thickness.
Continued
REVISED: DEC. 87
7
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							1987 RANGEROVER
60. Fit the inner cage and bearings assembly.
61. Fit the valve and worm assembly, using seal
saver 
RQ1015 to protect the input shaft seal.
62. Fit the outer cage and bearings assembly.
63. Fit the outer bearing cup.
6364. Fit a new worm adjuster sealing ring and
loosely screw the adjuster into the casing. Fit
the locknut, but do not tighten.
65. Turn in the worm adjuster until the end-float
at the input is almost eliminated.
66. Measure and record the maximum rolling
distance of the valve and worm assembly,
using a spring balance and cord coiled around
the torque setting tool 
~01016.67. Turn in the worm adjuster to increase the
figure recorded in instruction 66 by 1.8 to 2.2
kg (4 to 5 lb) at 1.250 in (31.7 mm) radius to
settle the bearings, then back off the worm
adjuster until the figure recorded in instruction
66 is increased by 0.9 to 1.3 kg (2 to 3 lb)
only, with locknut tight. Use worm adjusting
wrench 
LSTl19 and ‘C’ wrench LSTI 20.Fitting the rack and piston
68.
69.
70.Screw a slave bolt into the piston head for use
as an assembly tool.
Fit the piston and rack assembly so that the
piston is 63.5 mm (2.5 in) approximately from
the outer end of the bore.
Feed in the sector shaft using seal saver
606604 aligning the centre gear pitch on the
rack with the centre gear tooth on the sector
shaft. Push in the sector shaft, and, at the
same time rotate the input shaft about a small
arc to allow the sector roller to engage the
worm.
RRS41H
aREVISED: DEC. 87 
						

							74.
75.
76.
77.Fitting the rack adjuster
71. Fit the sealing ring to the rack adjuster.
72. Fit the rack adjuster and thrust pad to engage
the rack. Back off a half turn on the adjuster.
73. Loosely fit the nylon pad and adjuster set
screw assembly to engage the rack adjuster.NOTE: Before tightening the fixings, rotate
the input shaft about a small arc to ensure
that the sector roller is free to move in the
valve worm.
78. Fit the cover fixings and tighten to the correct
torque 
(see section 06-Torque values).
Fitting the cylinder cover
79. Fit the square section seal to the cover.
80. Remove the slave bolt fitted at operation 68
and press the cover into the cylinder just
sufficient to clear the retainer ring groove.
81. Fit the retainer ring to the groove with one
end of the ring positioned 
I2 mm (0.5 in)
approximately from the extractor hole.
RR942MFitting the sector shaft cover
Fit the sealing ring to the cover.
Screw the cover assembly fully on to the
sector shaft adjuster screw.
Position the cover on to the casing.
Tap the cover in place. It necessary back off
on the sector shaft adjuster screw to allow the
cover to joint fully with the casing.
RR944MIII
Continued
9.i:,;. 
						

							RANGElg8’ ROVER
. . . ..  .I
Adjusting the sector shaftTorque peak check
82.
83.
84.
as.
86.
87.
,Set the worm on centre by rotating the input
shaft half the total number of turns from either
lock.
Rotate the sector shaft adjusting screw
counter-clockwise to obtain backlash between
the input shaft and the sector shaft.
Rotate the sector shaft adjusting screw
clockwise until the backlash is just eliminated.
Measure and record the maximum rolling
resistance at the input shaft, using a spring
balance, cord and torque tool 
ROlOl6.Hold the sector shatt adjuster screw and
loosely tit a new locknut.
Turn in the sector shaft adjuster screw until
the figure recorded in instruction 85 is
increased by 0.9 to 1.3 kg (2 to 3 
lb) with the
locknut tightened.
Adjusting the rack adjuster
aa. Turn in the rack adjuster to increase the figure
recorded in instruction 87 by 0.9 to 1.3 kg 
(2to 3 lb). The final figure may be 
less than
7.25 kg (16 lb) but must not exceed this
figure.
89. Lock the rack adjuster in position with the set
screw.With the input shaft rotated from lock-to-lock, the
.‘.. ’”roliing resisiance torque figures should be greatest
across the centre position (1.5 turns approximately
from full lock) and equally disposed about the
centre position.
The condition depends on the value of shimming
fitted between the valve and worm assembly inner
bearing cup and the casing. The original shim
washer value will
give the correct torque peak
position unless major components have been
replaced.
Procedure90. With the input coupling shaft toward the
operator,turn
theshaftfully -‘>counter-clockwise.
91. Check the torque figures obtained from
lock-to-lock using a spring balance cord and
torque tool R01016.
Y‘5‘. ., ,:
Adjustments92. Note where the greatest figures are recorded
relative to the steering position. If the greatest
figures are not recorded across the centre of
travel (i.e. steering straight-ahead position),
adjust as follows:
.,,:. .‘.