DAF CF65, CF75, CF85 Series . Manual — part 964
©
200423
4-1
Removal and installation
STEERING BOX
ΧΦ65/75/85 series
7
3
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION, ENTIRE STEERING BOX
If the vehicle has been involved in a
collision in which the steering box or
other components of the steering
gear have (possibly) been damaged,
the steering box should always be
sent to DAF for inspection or be
replaced. This instruction even
applies if no external damage is
visible. In the collision, the steering
box may have sustained internal
damage, causing it to be unreliable.
Removing the entire steering box
1.
Clean the steering box and the surrounding
area.
2.
Place the steering gear in the central
position. This can be checked using the
markings on the steering box.
3.
With an EMAS-controlled trailing axle,
remove the connector from the angle sensor.
4.
Remove the steering oil pipes from the
steering box. Collect the steering oil flowing
out and plug the openings of the pipes and at
the steering box, to prevent dirt entering.
Note:
If the pipe connections might accidentally be
switched, they should be marked.
5.
Remove the steering rod from the pitman
arm.
Note:
When a steering rod has been removed, the
input shaft must not be rotated more than
1.5 turns (counting from the central position)
because otherwise the setting of the wheel
deflection limiting valves will be changed.
6.
If present, detach the wiring harness and/or
other pipes from the steering bracket.
7.
Remove the steering shaft from the steering
box input shaft.
Note: The steering box weighs
approx. 35 kg. The steering box
should be supported securely and
responsibly, or safely suspended in
a hoist.
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STEERING BOX
4-2
©
200423
Removal and installation
3
ΧΦ65/75/85 series
7
8.
Remove the attachment bolts from the
steering box to the steering bracket and
remove the steering box from the vehicle.
Keep the removed bolts to check the length
of the new bolts.
9.
With an EMAS-controlled trailing axle,
remove the angle sensor from the steering
box, if necessary.
Installing the entire steering box
1.
Carefully clean and inspect the threaded
holes of the steering box.
2.
Remove all paint, dirt, grease, etc. from the
contact surfaces of both the steering box and
the steering bracket (a thin, factory-applied
layer of paint is allowed). The contact
surfaces should be absolutely free from dirt
and grease.
3.
In the case of the new or revised steering
box, fit the pipe connections. For the
connection points, see 'Technical data'.
4.
With an EMAS-controlled trailing axle, fit the
angle sensor to the steering box, if
necessary.
5.
Replace the attachment bolts. Because the
yield stress is exceeded while tightening the
bolts, they may not be re-used.
Check that the new bolts are exactly the
same length as the removed bolts.
Grease the new bolt sparingly. On no
account should you over apply the lubricant.
This could result in the connection coming
loose.
Carefully check the length of the new
bolts. If the bolts used to fit the
steering box are too long, they can
lock in the steering box thus
resulting in insufficient pre-load.
6.
Fit the steering box equipped with a pitman
arm to the steering bracket. Make sure that
the locating bolt is fitted into the middle
threaded hole under the steering box.
7.
Tighten the attachment bolts evenly.
Tighten the bolts to the specified tightening
torque. See 'Technical data'.
8.
Fit the pipes to the steering box.
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©
200423
4-3
Removal and installation
STEERING BOX
ΧΦ65/75/85 series
7
3
9.
Fit the new, original locating bolt and nut in
the universal joint.
Tighten the bolt to the specified torque, see
'Technical data'.
10. Fit the steering shaft to the steering box input
shaft. The groove (A) in the coupling must be
aligned with the mark (B) on the input shaft of
the steering box.
Check that the steering shaft is
correctly fitted to the input shaft, so
that the bolt can be fitted in the
recess (C).
11. Install the steering rod.
12. Fit the cable harness and/or other pipes back
in their original position.
13. With an EMAS-controlled trailing axle, fit the
connector to the angle sensor.
14. Fill and bleed the steering gear, see 'Filling
and bleeding'.
15. If the steering box input shaft may have been
rotated more than 1.5 turns (as seen from the
central position) while the steering rod was
removed, the final limiting pressures should
be checked. See 'Inspection and
adjustment'.
16. With an EMAS-controlled trailing axle,
calibrate the EMAS system.
17. Make a test drive. During the test drive, the
proper functioning of the steering gear
should be checked. After the test drive, the
system should be checked for leaks.
K1 01 353
A
C
B
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STEERING BOX
4-4
©
200423
Removal and installation
3
ΧΦ65/75/85 series
7
4.2 REMOVAL AND INSTALLATION, STEERING BRACKET
Be careful when tilting the cab or
when working under the tilted cab if
the steering bracket is to be
inspected or replaced because of a
collision. Vital parts of the cab
suspension may have been
damaged. Take the necessary
precautions.
Removing the steering bracket
1.
Remove the steering box.
2.
Support the steering bracket. Remove the
attachment bolts and take the steering
bracket off the chassis.
After a collision, the steering bracket
should be inspected very carefully
for deformation and cracks. This is
important for vehicle safety. If
possible, the steering bracket
should be magnaflux tested. If in
doubt, always replace the steering
bracket.
Re-using attachment bolts
As bolts are tightened to breaking point, every
bolt should be inspected before it is re-used.
1.
Clean the bolt thread thoroughly.
2.
Check the thread for damage. To do so,
manually screw a new nut onto the thread to
be checked. If the new nut cannot be fully
hand-screwed onto the entire thread of the
bolt to be checked, it is not allowed to re-use
the bolt.
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