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Mercedes-Benz Sprinter / Dodge Sprinter. Service manual - part 425

LINKAGE

TABLE OF CONTENTS

page

LINKAGE

DIAGNOSIS AND TESTING - OUTER TIE ROD

END

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS - TORQUE CHART

. . . . . . . . . 9

SPECIAL TOOLS

FRONT SUSPENSION

. . . . . . . . . . . . . . . . . . 10

TIE ROD END

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 10

LINKAGE

DIAGNOSIS AND TESTING - OUTER TIE ROD
END

NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.

(1) Raise the front of the vehicle. Place safety floor

stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.

(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle

steering knuckle and then zero the dial indicator.

(4) Position indicator plunger on the topside of the

outer tie rod end.

NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the outer tie rod
end.

(5) Position a pry bar in order to pry downwards

on the outer tie rod end.

(6) If the travel exceeds 0.5 mm (0.020 in.), replace

the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).

(7) If the outer tie rod end is within specs reinstall

the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Outer Tie Rod End Nut

130

—

Outer Tie Rod End Lock-

ing Nut

—

Steering Gear Boot

Clamp

—

LINKAGE

19 - 9

SPECIAL TOOLS

FRONT SUSPENSION

TIE ROD END

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Loosen the lock nut (Fig. 1).
(4) Remove the tie rod end retaining nut (Fig. 1).
(5) Separate the tie rod end from the steering

knuckle (Fig. 1) using special tool C-3894–A.

(6) Remove the outer tie rod end from the inner tie

rod end by unscrewing (Fig. 1).

INSTALLATION

(1) Install the outer tie rod end by screwing it onto

thew inner tie rod end (Fig. 1).

(2) Install the outer tie rod end into the steering

knuckle (Fig. 1).

(3) Tighten the outer tie rod end nut

(Fig. 1).

Tighten to 130 N·m (96 ft. lbs.).

(4) Install the front wheels.
(5) Lower the vehicle.
(6) Perform toe adjustment.

(7) Tighten the lock nut after toe adjustment (Fig.

1). Tighten to 50 N·m (37 ft. lbs.).

Puller Tie Rod C-3894-A

Fig. 1 OUTER TIE ROD END

1 - OUTER TIE ROD END RETAINING NUT
2 - TIE ROD SEPERATOR TOOL
3 - OUTER TIE ROD END
4 - LOCKING NUT
5 - INNER TIE ROD END

19 - 10

LINKAGE

PUMP

TABLE OF CONTENTS

page

PUMP

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 11

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DIAGNOSIS AND TESTING - PUMP LEAKAGE

. 11

STANDARD PROCEDURE

STANDARD PROCEDURE - POWER

STEERING PUMP - INITIAL OPERATION . . . . 11

STANDARD PROCEDURE - FLUSHING

POWER STEERING SYSTEM . . . . . . . . . . . . 12

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIFICATIONS - TORQUE CHART

. . . . . . . . 13

FLUID

STANDARD PROCEDURE

POWER STEERING PUMP FILL AND BLEED

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 13

FLUID COOLER TUBE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 13

HOSES

REMOVAL

REMOVAL - PRESSURE HOSE

. . . . . . . . . . . 14

REMOVAL - RETURN LINE FROM PUMP TO

COOLER TUBE . . . . . . . . . . . . . . . . . . . . . . . 14

REMOVAL - RETURN HOSE FROM GEAR

TO COOLER TUBE . . . . . . . . . . . . . . . . . . . . 14

INSTALLATION

INSTALLATION - PRESSURE HOSE

. . . . . . . 14

INSTALLATION - RETURN LINE FROM

PUMP TO COOLER TUBE . . . . . . . . . . . . . . . 14

INSTALLATION - RETURN HOSE FROM

GEAR TO COOLER TUBE . . . . . . . . . . . . . . . 14

PUMP

DESCRIPTION

CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.

The pump is connected to the steering gear via the

pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.

All vehicles are equipped with a power steering

fluid cooler.

NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.

OPERATION

Hydraulic pressure is provided for the power steer-

ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.

DIAGNOSIS AND TESTING - PUMP LEAKAGE

The pump is serviced as an assembly and should

not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.

Check for leaks in the following areas:
• Pump shaft seal behind the pulley

• Pump to reservoir O-ring

• Reservoir cap

• Pressure and return lines

• Flow control valve fitting

STANDARD PROCEDURE

STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION

WARNING:

THE

FLUID

LEVEL

SHOULD

CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.

Wipe filler cap clean, then check the fluid level.

The dipstick should indicate COLD when the fluid is
at normal temperature.

(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level

and let the fluid settle for at least two (2) minutes.

(3) Raise the front wheels off the ground.

PUMP

19 - 11

(4) Slowly turn the steering wheel lock-to-lock 20

times with the engine off while checking the fluid
level.

NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.

(5) Start the engine. With the engine idling main-

tain the fluid level.

(6) Lower the front wheels and let the engine idle

for two minutes.

(7) Turn the steering wheel in both direction and

verify power assist and quiet operation of the pump.

If the fluid is extremely foamy or milky looking,

allow the vehicle to stand a few minutes and repeat
the procedure.

CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.

STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM

Flushing is required when the power steering/hy-

draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.

(1) Raise the front end of the vehicle off the

ground until the wheels are free to turn.

(2) Remove the return line from the pump.

NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.

(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-

tainer to catch the fluid.

(5) While an assistant is filling the pump reservoir

start the engine.

(6) With the engine running at idle turn the wheel

back and forth.

NOTE: Do not contact or hold the wheel against the
steering stops.

(7) Run a quart of fluid through the system then

stop the engine and install the return line/lines.

(8) Fill the system with fluid and perform Steering

Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).

(9) Start the engine and run it for fifteen minutes

then stop the engine.

(10) Remove the return line/lines from the pump

and plug the pump port/ports.

(11) Pour fresh fluid into the reservoir and check

the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.

(12) Install the return line/lines and perform

Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).

REMOVAL

(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-

ble out of the reservoir.

(3) Remove the high pressure power steering hose

at the pump (Fig. 1).

(4) Remove the return hose from the pump (Fig.

1).

(5) Remove the bolts securing the power steering

pump to the engine (Fig. 1).

INSTALLATION

(1) Install the power steering pump to the engine

and tighten the bolts (Fig. 1). Tighten to 21 N·m (15
ft. lbs.).

(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten

the clamp (Fig. 1).

(4) Install the high pressure hose to the pump

(Fig. 1). Tighten to 38 N·m (28 ft. lbs.).

(5) Fill the power steering fluid (Refer to 19 -

STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).

Fig. 1 POWER STEERING PUMP

1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT

19 - 12

PUMP

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